Shop Manual D155A-6
Shop Manual D155A-6
Shop Manual D155A-6
BULLDOZER D155A -6
SERIAL NUMBERS 85001 and up
SEN02856-24
D155A-6
D155A-6 1
SEN02856-24 00 Index and foreword
01 Specification SEN02858-03
Specification and technical data SEN02859-03
40 Troubleshooting SEN02871-10
Failure code table and fuse locations SEN03204-05
General information on troubleshooting SEN03205-05
Troubleshooting by failure and error codes, Part 1 SEN03206-05
Troubleshooting by failure and error codes, Part 2 SEN03207-05
Troubleshooting by failure and error codes, Part 3 SEN03208-07
Troubleshooting by failure and error codes, Part 4 SEN03209-03
Troubleshooting of electrical system (E-mode) SEN03210-03
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03211-03
Troubleshooting of engine (S-mode) SEN03212-01
2 D155A-6
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D155A-6 3
SEN02856-24 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN02856-24
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
01 Specification
Specification and technical data SEN02859-03
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 9
Table of fuel, coolant and lubricants ............................................................................................ 12
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D155A-6 5
SEN02856-24 00 Index and foreword
40 Troubleshooting
Failure code table and fuse locations SEN03204-05
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 8
General information on troubleshooting SEN03205-05
Points to remember when troubleshooting .................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Check before troubleshooting ..................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Information in troubleshooting table ............................................................................................ 8
Connection table for connector pin numbers............................................................................... 10
T- branch box and T- branch adapter table ................................................................................. 46
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D155A-6 7
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D155A-6 9
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E-1 When starting switch turned ON, machine monitor displays nothing.................................... 8
E-2 When starting switch turned ON (before starting engine), basic check item lights up .......... 10
E-3 Engine does not start (Engine does not turn) ...................................................................... 12
E-4 Preheater does not operate ................................................................................................. 15
E-5 Precaution item lights up while engine is running ................................................................. 18
E-6 Emergency stop item lights up while engine is running ....................................................... 20
E-7 Engine coolant temperature gauge does not indicate normally............................................ 22
E-8 Fuel level gauge does not indicate normally......................................................................... 23
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally....................... 25
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ........................... 26
E-11 Contents of display by machine monitor are different from applicable machine ................ 28
E-12 Machine monitor does not display some items................................................................... 28
E-13 Function switch does not work............................................................................................ 28
E-14 Operation mode does not change ..................................................................................... 29
E-15 Gearshift mode does not change........................................................................................ 29
E-16 Customize function does not operate normally................................................................... 30
E-17 Customize memory function does not normally.................................................................. 30
E-18 Alarm buzzer cannot be stopped ........................................................................................ 31
E-19 Air conditioner does not operate normally (including air conditioner fault history).............. 32
E-20 When starting switch is turned OFF, service meter is not displayed................................... 46
E-21 Machine monitor cannot be set in service mode ............................................................... 46
E-22 Ripper pin puller cylinder does not operate ....................................................................... 48
E-23 Backup alarm does not sound or does not stop ................................................................ 50
E-24 Headlamp, rear lamp, and ripper point lamp do not light up............................................... 52
E-25 Windshield wiper and window washer do not operate........................................................ 57
E-26 KOMTRAX terminal does not operate normally.................................................................. 73
E-27 Fan does not reverse.......................................................................................................... 74
E-28 Gear cannot be shifted ...................................................................................................... 76
E-29 Electric priming pump does not operate or does not stop automatically ........................... 78
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03211-03
Information in troubleshooting table ........................................................................................... 3
H-1 Power is low (Drawbar pull is low)........................................................................................ 4
H-2 Machine does not travel (at 2nd or 3rd gear speed)............................................................. 5
H-3 Machine does not start at any gear speed .......................................................................... 6
H-4 Machine can travel only forward or in reverse...................................................................... 7
H-5 When gear speed or travel direction is changed, time lag is large ...................................... 8
H-6 Steering is not possible......................................................................................................... 9
H-7 Steering is possible only on one side .................................................................................. 10
H-8 Steering overrun occurs........................................................................................................ 11
H-9 Brake does not work............................................................................................................. 12
H-10 Power train oil is overheated ............................................................................................. 13
H-11 Speed of all work equipment is low..................................................................................... 14
H-12 No work equipment moves ................................................................................................ 15
H-13 Blade lift speed or power is low ......................................................................................... 16
H-14 Blade tilt speed or power is low ......................................................................................... 17
H-15 Ripper lift speed or power is low......................................................................................... 18
H-16 Ripper tilt speed or power is low......................................................................................... 19
H-17 Hydraulic drift of blade lift is large....................................................................................... 19
H-18 Hydraulic drift of blade tilt is large....................................................................................... 20
H-19 Hydraulic drift of ripper lift is large ..................................................................................... 20
H-20 Ripper pin puller cylinder does not operate ....................................................................... 21
H-21 Abnormal sound comes out from around work equipment pump ....................................... 22
H-22 Fan speed is abnormal
(Sound and/or vibration are abnormally large or engine over heats) ..................................... 23
Troubleshooting of engine (S-mode) SEN03212-01
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance of engine is poor................................................................................. 6
S-2 Engine does not start............................................................................................................ 7
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D155A-6 11
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60 Air conditioner
Structure, function, testing, adjusting, and troubleshooting SEN04442-03
Structure and function ................................................................................................................. 3
Air conditioner component ....................................................................................................... 3
Configuration and function of refrigerating cycle ..................................................................... 4
Outline of refrigerating cycle .................................................................................................... 5
Air conditioner unit ................................................................................................................... 7
Functions of major components in the air conditioner unit ...................................................... 9
Control plate ............................................................................................................................ 11
Compressor ............................................................................................................................. 13
Condenser ............................................................................................................................... 14
Receiver drier .......................................................................................................................... 15
Testing, adjusting and troubleshooting ........................................................................................ 17
Caution about refrigerant ......................................................................................................... 17
Troubleshooting procedure ...................................................................................................... 18
Block diagram .......................................................................................................................... 19
Circuit diagram and arrangement of connector pins................................................................ 20
Detail of air conditioner unit ..................................................................................................... 22
Part and connector locations ................................................................................................... 24
Testing air leakage (duct)......................................................................................................... 31
Testing with self-diagnosis function ......................................................................................... 33
Testing temperature control ..................................................................................................... 36
Testing vent (mode) changeover ............................................................................................. 39
Testing Recirc/Fresh changeover ............................................................................................ 42
Testing inner sensor................................................................................................................. 44
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D155A-6 13
SEN02856-24 00 Index and foreword
D155A-6 Bulldozer
Form No. SEN02856-24
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 12-22 (01)
14 D155A-6
SEN02857-04
D155A-6
D155A-6 1
SEN02857-04 00 Index and foreword
Safety notice 1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
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D155A-6 3
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q If the load is unstable or the wire rope 13) Remember the position of the main switch
or chains are twisted, lower the load so that you can turn off the power immedi-
and lift it up again. ately in an emergency.
q Do not lift up the load slantingly. 14) If the hoist stops because of a power fail-
13) When lifting down a load, observe the fol- ure, turn the power switch OFF. When
lowing. turning on a switch which was turned OFF
q When lifting down a load, stop it tem- by the electric shock prevention earth
porarily at 30 cm above the floor, and leakage breaker, check that the devices
then lower it slowly. related to that switch are not in operation
q Check that the load is stable, and state.
then remove the sling. 15) If you find an obstacle around the hoist,
q Remove kinks and dirt from the wire stop the operation.
ropes and chains used for the sling 16) After finishing the work, stop the hoist at
work, and put them in the specified the specified position and raise the hook
place. to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5. Precautions for using mobile crane
a Read the Operation and Maintenance 7. Selecting wire ropes
Manual of the crane carefully in advance 1) Select adequate ropes depending on the
and operate the crane safely. weight of parts to be hoisted, referring to
the table below.
6. Precautions for using overhead hoist crane
k When raising a heavy part (heavier Wire ropes
than 25 kg), use a hoist, etc. In Disas- (Standard “Z” twist ropes without galvanizing)
sembly and assembly, the weight of a (JIS G3525, No. 6, Type 6X37-A)
part heavier than 25 kg is indicated Nominal
Allowable load
after the mark of 4. diameter of rope
1) Before starting work, inspect the wire mm kN ton
ropes, brake, clutch, controller, rails, over 10 8.8 0.9
wind stop device, electric shock preven- 12 12.7 1.3
tion earth leakage breaker, crane collision 14 17.3 1.7
prevention device, and power application 16 22.6 2.3
warning lamp, and check safety. 18 28.6 2.9
2) Be sure not to touch the lifting tool and 20 35.3 3.6
lifted load directly. Use push-pull sticks or
25 55.3 5.6
tagline ropes.
30 79.6 8.1
3) Observe the signs for sling work.
40 141.6 14.4
4) Operate the hoist at a safe place.
5) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
6) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
7) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
8) Do not drag a sling.
9) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
10) Consider the travel route in advance and
lift up a load to a safe height.
11) Place the control switch on a position
where it will not be an obstacle to work
and passage.
12) After operating the hoist, do not swing the
control switch.
D155A-6 5
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8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
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q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
D155A-6 7
SEN02857-04 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 D155A-6
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Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 D155A-6
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D155A-6 13
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2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 D155A-6
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3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D155A-6 15
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16 D155A-6
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
D155A-6 17
SEN02857-04 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 D155A-6
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6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D155A-6 19
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20 D155A-6
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q 114 engine
q 107 engine
D155A-6 21
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q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
D155A-6 23
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2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 D155A-6
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(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
D155A-6 25
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3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 D155A-6
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a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D155A-6 29
SEN02857-04 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 D155A-6
00 Index and foreword SEN02857-04
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
D155A-6 31
SEN02857-04 00 Index and foreword
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 D155A-6
00 Index and foreword SEN02857-04
D155A-6 33
SEN02857-04 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 D155A-6
00 Index and foreword SEN02857-04
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
D155A-6 35
SEN02857-04 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 D155A-6
00 Index and foreword SEN02857-04
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D155A-6 37
SEN02857-04 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 D155A-6
00 Index and foreword SEN02857-04
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D155A-6 39
SEN02857-04 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 D155A-6
00 Index and foreword SEN02857-04
D155A-6 41
SEN02857-04 00 Index and foreword
D155A-6 BULLDOZER
Form No. SEN02857-04
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 12-22 (01)
42 D155A-6
SEN02859-03
D155A-6
01 Specification 1
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 9
Table of fuel, coolant and lubricants.............................................................................................................. 12
D155A-6 1
SEN02859-03 01 Specification
2 D155A-6
01 Specification SEN02859-03
Specifications
Machine model D155A-6
Forward
2nd 5.7
km/h
3rd (low speed) 7.5
Performance
3rd 11.4
1st 4.7
Reverse
2nd 6.8
km/h
3rd (low speed) 9.2
3rd 13.7
• Bare tractor 86.73 {0.88}
Overall height Overall width Overall length Ground pressure
D155A-6 3
SEN02859-03 01 Specification
4 D155A-6
01 Specification SEN02859-03
D155A-6 5
SEN02859-03 01 Specification
6 D155A-6
01 Specification SEN02859-03
Performance
D155A-6 7
SEN02859-03 01 Specification
8 D155A-6
01 Specification SEN02859-03
Weight table
k This weight table is for reference in handling or transporting components.
Unit: kg
Machine model D155A-6
D155A-6 9
SEN02859-03 01 Specification
Unit: kg
Machine model D155A-6
10 D155A-6
01 Specification SEN02859-03
Unit: kg
Machine model D155A-6
D155A-6 11
SEN02859-03 01 Specification
12 D155A-6
01 Specification SEN02859-03
Unit: l
Hydraulic system
Engine oil Power train Damper Fainal drive Cooling
(with blade, without Fuel tank
pan case case case system
ripper)
(each left
Specified capacity (l) 45 105 1.5 and right) 240 625 82
31
(each left
Refill capacity (l) 37 70 1.5 and right) 85 — —
31
D155A-6 13
SEN02859-03 01 Specification
D155A-6 Bulldozer
Form No. SEN02859-03
© 2018 KOMATSU
All Rights Reserved
Printed in Japan 04-18 (01)
14 D155A-6
SEN02861-02
D155A-6
D155A-6 1
SEN02861-02 10 Structure, function and maintenance standard
2 D155A-6
10 Structure, function and maintenance standard SEN02861-02
1. Overflow hose
2. Air bleed hose
3. Inlet hose
4. Coolant filler cap
5. Radiator core assembly
6. Reservoir tank
7. Inlet hose (for circulating at low coolant
temperature)
8. Outlet hose
9. Lower tank (power train oil cooler built-in)
10. Fan
11. Drain plug
12. Cushion
13. Breather cap
14. Pressure valve
a: Aftercooler
b: Aftercooler outlet hose
c: Aftercooler inlet hose
Outline
q The reservoir tank is provided for radiator.
q The power train oil cooler is built in the lower
tank of the radiator.
D155A-6 3
SEN02861-02 10 Structure, function and maintenance standard
Oil cooler
Outline
q The power train oil cooler is built in the lower
tank of the radiator.
4 D155A-6
10 Structure, function and maintenance standard SEN02861-02
D155A-6 5
SEN02861-02 10 Structure, function and maintenance standard
6 D155A-6
10 Structure, function and maintenance standard SEN02861-02
1. Overflow hose
2. Air bleed hose
3. Inlet hose
4. Coolant filler cap
5. Radiator core assembly
6. Reservoir tank
7. Inlet hose (for circulating at low coolant
temperature)
8. Outlet hose
9. Lower tank (power train oil cooler built-in)
10. Fan
11. Drain plug
12. Cushion
13. Breather cap
14. Pressure valve
a: Aftercooler
b: Aftercooler outlet hose
c: Aftercooler inlet hose
Outline
q The reservoir tank is provided for radiator.
q The power train oil cooler is built in the lower
tank of the radiator.
D155A-6 7
SEN02861-02 10 Structure, function and maintenance standard
Outline
q The power train oil cooler is built in the lower
tank of the radiator.
8 D155A-6
10 Structure, function and maintenance standard SEN02861-02
Engine mount 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bracket size Shaft Hole clearance limit
1
and cushion
–0.1 +0.046 0.1 –
60 — Replace
–0.3 +0.046 0.346
Standard clearance Clearance limit
2 Free height of mount rubber
86 84
D155A-6 9
SEN02861-02 10 Structure, function and maintenance standard
10 D155A-6
10 Structure, function and maintenance standard SEN02861-02
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D155A-6 11
SEN02861-02 10 Structure, function and maintenance standard
12 D155A-6
10 Structure, function and maintenance standard SEN02861-02
(
[
D
$ )
*
D155A-6 13
SEN02861-02 10 Structure, function and maintenance standard
(
[
[
D
)
*
)
q Swash plate angle (a) is in proportion to the
pump delivery.
*
14 D155A-6
10 Structure, function and maintenance standard SEN02861-02
D155A-6 15
SEN02861-02 10 Structure, function and maintenance standard
Servo valve
16 D155A-6
10 Structure, function and maintenance standard SEN02861-02
s1P
^sNJP`
1P 1P
^NJP` 3+ ^NJP`
$$
3( 1P
^NJP`
(3&RXWSXW
SUHVVXUH
3
%%
*
D155A-6 17
SEN02861-02 10 Structure, function and maintenance standard
18 D155A-6
10 Structure, function and maintenance standard SEN02861-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installation Free Installation
13 Spool return spring outer diameter length load length load Replace spring
146 N 117 N if damaged or
62.66 x 19.8 53.5 —
{14.9 kg} {11.9 kg} deformed.
13.7 N 11.0 N
14 Check valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}
D155A-6 19
SEN02861-02 10 Structure, function and maintenance standard
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) [4 or 5 pieces], and gener-
ates force (F1)[F1 = P x xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°)
degrees to the output shaft(1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] against the (Y-Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = (F3 x ri)] rotates
cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
20 D155A-6
10 Structure, function and maintenance standard SEN02861-02
2. Suction valve
3XPS
0$ 0%
3
7
*
0$ 0%
*
D155A-6 21
SEN02861-02 10 Structure, function and maintenance standard
1) When the ON-OFF solenoid is de-energized. 2) When the ON-OFF solenoid is energized.
q If ON-OFF solenoid (1) is “de-energized“, the q If ON-OFF solenoid (1) is “energized“, ON-
pressurized oil from the pump is blocked by OFF selector valve (2) changes to let the pres-
ON-OFF selector valve (2), and port (C) opens surized oil from the pump flow through port (C)
for the tank circuit. into spool chamber (D).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) pushes
q Motor port (MA) opens and pressurized oil valve spool (3) to the left against spring (4).
flows in to revolve the motor in forward (clock- q Motor port (MB) opens and pressurized oil
wise). flows in to revolve the motor in reverse (coun-
terclockwise).
3XPS
3XPS
2))
3 21
3
0$ 0%
0$ 0%
&
' &
7
7
*
*
22 D155A-6
10 Structure, function and maintenance standard SEN02861-02
4. Safety valve
3XPS
*
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
D155A-6 23
SEN02861-02 10 Structure, function and maintenance standard
D155A-6 Bulldozer
Form No. SEN02861-02
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 03-19 (01)
24 D155A-6
SEN02862-03
D155A-6
D155A-6 1
SEN02862-03 10 Structure, function and maintenance standard
Outline
q The power generated by engine (1) has its tor- q The power transmitted to the bevel gear shaft
sional vibration dampened by damper (2), and is transmitted to divided at right angles to the
then passes through universal joint (3), and is left and right and transmitted to the respective
transmitted to torque converter (8). steering clutches (11).
q The power from the engine is transmitted The power transmitted from the bevel gear
through the oil by torque converter (8) to the shaft to the final drive is used to steer the
transmission input shaft (turbine shaft) in machine by engaging or disengaging steering
accordance with the change in load. (with L/U) clutch (11).
q Transmission (9) uses a combination of a plan- The steering lever is operated to disengage
etary gear system and hydraulic clutches to the steering clutch on the side to which the
reduce the speed and shift the gears (3 for- machine is to be steered in order to change the
ward gears and 3 reverse gears). It connects direction of travel. The side of the turning
2 sets of clutches selected according to the radius id controlled by steering brake (12)
change in load, and transmits the power to installed to the outside of the steering clutch.
bevel gear (10) from the bevel pinion at the Steering brake (12) uses the same disc system
rear end of the transmission. that is used for the steering clutch.
The power sent from steering brake (12) is
transmitted to final drive (13).
q Final drive (13) consists of a single-stage spur
gear and a single-stage planetary gear system.
It reduces the speed and rotates sprocket (14)
to drive track shoe (15) and move the machine.
It also rotates cooling fan motor (17) with the
oil discharged from cooling fan pump (16)
driven with PTO (6).
2 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 3
SEN02862-03 10 Structure, function and maintenance standard
4 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 5
SEN02862-03 10 Structure, function and maintenance standard
6 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 7
SEN02862-03 10 Structure, function and maintenance standard
8 D155A-6
10 Structure, function and maintenance standard SEN02862-03
1. Breather
2. Dipstick
3. Drain plug
4. Output shaft
5. Flywheel
6. Outer body
7. Coupling
8. Universal joint
9. Cover
10. Rubber coupling
11. Inner body
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between flywheel size Shaft Hole clearance limit
12
housing and cover
–0.022 +0.070 0.022 –
511.18 0.2
–0.092 +0.070 0.162
Clearance between flywheel –0.020 +0.063 0.020 – Replace
13 466.72 0.2
and damper –0.083 +0.070 0.146
Standard size Tolerance Repair limit
Outside diameter of coupling
14 –0.087
oil seal contact surface 90 89.8
–0.087
Outline
q The damper, dampens the torsional vibration
caused by the change in engine torque and
the impact torque generated when accelerat-
ing suddenly or when carrying out heavy-duty
digging. In this way, it acts to protect the torque
converter, transmission, and other parts of the
power train.
q The damper has few component parts: it uses
a rubber coupling, so the vibration is absorbed
by the damping effect of the rubber material.
Operation
q The motive force from the engine passes
through flywheel (5) and is transmitted to outer
body (6).
The torsional vibration of the engine is absorbed
by rubber coupling (10), and the power is trans-
mitted to inner body (11). It passes through uni-
versal joint (8), and is then transmitted to the
torque converter and transmission.
D155A-6 9
SEN02862-03 10 Structure, function and maintenance standard
10 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 11
SEN02862-03 10 Structure, function and maintenance standard
12 D155A-6
10 Structure, function and maintenance standard SEN02862-03
General
q 3-element, 1-stage and 1-phase type is
employed for the torque converter. It is inte-
grated with the transmission.
q Pump (14) is integrated with coupling (6), input
shaft (7) and drive case (11), and rotated by
the power from the engine.
q Turbine (10) is integrated with turbine boss
(18) and transmission input shaft (17), and
rotates using the oil from pump (14) as the
medium.
q Stator (13) is integrated with stator shaft (16),
and fixed to torque converter case (5).
q The PTO system is consisted of input shaft (7),
PTO idler gear (8), PTO gear A (19), PTO gear
B and scavenging pump drive gear (21).
D155A-6 13
SEN02862-03 10 Structure, function and maintenance standard
14 D155A-6
10 Structure, function and maintenance standard SEN02862-03
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Outside diameter of coupling oil
1 -0.054 Repair by hard
seal contact surface 100 99.8
-0.054 chromium-plat-
ing or replace
Inside diameter of stator shaft +0.030
65 65.1
seal ring contact surfac +0.025
-0.01
2 Wear on seal ring Width 3 2.7
-0.03
of the transmission Replace
input shaft Thickness 2.7 ±0.1 2.55
Repair by hard
Inside diameter of retainer seal +0.040
3 150 150.5 chromium-plat-
ring contact surface +0.040 ing or replace
Backlash between input shaft
4 0.198 – 0.484
and PTO idler gear
Backlash between PTO idler
5 0.198 – 0.484
gear and PTO gear A
Backlash between PTO idler
6 0.198 – 0.484
gear and PTO gear B
Backlash between input shaft
7 and scavenging pump drive 0.198 – 0.484
gear
D155A-6 15
SEN02862-03 10 Structure, function and maintenance standard
%
$
*
16 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 17
SEN02862-03 10 Structure, function and maintenance standard
Transmission 1
18 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 19
SEN02862-03 10 Structure, function and maintenance standard
20 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 21
SEN02862-03 10 Structure, function and maintenance standard
22 D155A-6
10 Structure, function and maintenance standard SEN02862-03
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
1 R clutch spring (12 springs) length load load
59.8 N 51.0 N
81.7 72.4 76.8
{6.1 kg} {5.2 kg}
34.3 N 29.4 N
2 F clutch spring (12 springs) 81.7 76.4 76.8
{3.5 kg} {3.0 kg}
97.1 N 82.4 N
3 3rd clutch spring (12 springs) 70.0 50.2 65.8
{9.9 kg} {8.4 kg}
90.2 N 76.5 N
4 2nd clutch spring (12 springs) 70.0 51.6 65.8
{9.2 kg} {7.8 kg}
66.7 N 56.9 N
5 1st clutch spring (12 springs) 66.0 51.8 62.0
{6.8 kg} {5.8 kg}
Standard size Tolerance Repair limit
Total assembled thickness of 6
6
disks and 6 plates for R clutch 51.6 ±0.35 48.4
-0.01
Width 3.0 2.70
Wear of input shaft -0.03
13
seal ring
Thickness 2.7 ±0.1 2.55
-0.01
Width 4.0 3.60
Wear of seal ring -0.04
15
(large) on 2nd carrier
Thickness 4.0 ±0.15 3.85
-0.01
Width 4.0 3.60
Wear of seal ring -0.04
16
(small) on 2nd carrier
Thickness 4.0 ±0.15 3.85
-0.01
Width 4.0 3.60
Wear of seal ring -0.04
17
(large) on 1st carrier
Thickness 4.0 ±0.15 3.85
D155A-6 23
SEN02862-03 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
-0.01
Wear of seal ring Width 4.0 3.60
18 -0.04
(small) on 1st carrier
Thickness 5.0 ±0.15 4.85
R, F,
Backlash between 0.14 – 0.35
3rd, 1st
19 sun gear and plane-
Replace
tary pinion 2nd 0.13 – 0.32
R 0.15 – 0.39
Backlash between
F, 2nd,
20 planetary pinion and 0.15 – 0.38
1st
ring gear
3rd 0.16 – 0.42
Disc clutch
Structure Operation
When clutch is "engaged" (fixed)
*
24 D155A-6
10 Structure, function and maintenance standard SEN02862-03
*
VWFOXWFKSLVWRQ
q As the oil from ECMV is stopped, piston (2) is *
pushed back rightward by return spring (6).
q The friction force between plates (3) and discs q When the steering/directional/gear shift lever is
(4) is released and ring gear (1) is released. set in the "neutral" position, the 1st, 2nd, or 3rd
speed is selected.
q The piston chamber of the clutch correspond-
ing to the selected gear speed is filled with oil
by electronically controlling the hydraulic circuit
of each clutch.
q When the steering/directional/gear shift lever is
shifted from the "neutral" position to the"for-
ward" or "reverse" position, the pump is
required to supply oil of quantity to fill the pis-
ton chamber of the F clutch or R clutch.
q When the gear speed is changed from "for-
ward 1st" to "forward 2nd", the pump is
required to supply oil of only quantity to fit the
plate and disc of the 2nd clutch together since
the F clutch has been filled with the oil.
q The time lag in the gear shifting operation is
reduced by controlling the oil in the clutch cir-
cuit as explained above.
D155A-6 25
SEN02862-03 10 Structure, function and maintenance standard
26 D155A-6
10 Structure, function and maintenance standard SEN02862-03
F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed with oil pressure.
D155A-6 27
SEN02862-03 10 Structure, function and maintenance standard
28 D155A-6
10 Structure, function and maintenance standard SEN02862-03
F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed with oil pressure.
D155A-6 29
SEN02862-03 10 Structure, function and maintenance standard
30 D155A-6
10 Structure, function and maintenance standard SEN02862-03
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed with oil pressure.
D155A-6 31
SEN02862-03 10 Structure, function and maintenance standard
32 D155A-6
10 Structure, function and maintenance standard SEN02862-03
R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are fixed with oil pressure.
D155A-6 33
SEN02862-03 10 Structure, function and maintenance standard
Transmission ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
34 D155A-6
10 Structure, function and maintenance standard SEN02862-03
1. 3rd clutch proportional solenoid a When the directional lever is in (neutral) posi-
2. 1st clutch proportional solenoid tion, the speed clutch of the speed selected by
3. R clutch proportional solenoid gear shift lever activates.
4. F clutch proportional solenoid
5. 2nd clutch proportional solenoid
6. 3rd clutch fill switch
7. 2nd clutch fill switch
8. 1st clutch fill switch
9. R clutch fill switch
10. F clutch fill switch
11. Transmission oil filter
12. Connector for 1st clutch proportional solenoid
13. Connector for 3rd clutch fill switch
14. Connector for 3rd clutch proportional solenoid
15. Connector for R clutch proportional solenoid
16. Connector for 2nd clutch fill switch
17. Connector for 2nd clutch proportional solenoid
18. Connector for F clutch proportional solenoid
19. Connector for 1st clutch fill switch
20. Connector for R clutch fill switch
21. Connector for F clutch fill switch
D155A-6 35
SEN02862-03 10 Structure, function and maintenance standard
1. Fill switch
2. Pressure control valve
3. Body (upper)
4. Body (lower)
5. Proportional solenoid
6. Filter
7. Pressure detection valve
8. Sleeve
36 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 37
SEN02862-03 10 Structure, function and maintenance standard
7 $
*
38 D155A-6
10 Structure, function and maintenance standard SEN02862-03
% $ 3
* *
q If current is supplied to proportional solenoid q If current flows in proportional solenoid (1), the
(1) with no oil in the clutch, the oil pressure solenoid generates thrust in proportion to the
force balanced with the solenoid force is current. This thrust of the solenoid is balanced
applied to chamber (B) and pushes pressure with the sum of the thrust generated by the oil
control valve (3) to the right. As a result, pump pressure in clutch port and the repulsion of
port (P) and clutch port (A) are opened and oil pressure control valve spring (2) to regulate
starts filling the clutch. If the clutch is filled with the pressure.
oil, fill switch (5) is turned "on".
D155A-6 39
SEN02862-03 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between main relief size Shaft Hole clearance limit
1
valve and body
-0.035 +0.013 0.035 –
28 0.078
-0.045 +0.013 0.058
Clearance between the torque con- -0.035 +0.013 0.035 –
2 22 0.078
verter relief valve and the body -0.045 +0.013 0.058
Standard size Repair limit
Replace
Installation Installation Installation
Main relief valve spring Free length Free length
3 length load load
(outside)
481 N 457 N
122 78.0 118.3
{49 kg} {46.6 kg}
Main relief valve spring 368 N 349 N
4 108 78.0 104.8
(inside) {37.5 kg} {35.6 kg}
Torque converter relief valve 182 N 174 N
5 50 40.5 48.5
spring {18.6 kg} {17.7 kg}
40 D155A-6
10 Structure, function and maintenance standard SEN02862-03
Main relief valve q The oil from the hydraulic pump flows to cham-
q The main relief valve is keeping each hydraulic ber (F) through the filter, port (C) of the relief
circuit of the transmission and the parking valve and orifice (a) of main relief valve (1).
brake at set pressure.
Set pressure: (
3.18 ± 0.1 MPa {32.4 ± 1.0 kg/cm2}
(Engine at rated speed)
)
Operation
Operation of torque converter relief valve
( & *
$
q As the oil pressure in the circuit goes beyond
the set pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting reaction
force pushes main relief valve (1) leftward,
opening ports (C) and (E).
*
Above operation conducts the oil from port (E)
to the torque converter.
E *
D155A-6 41
SEN02862-03 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installation Installation Installation
Free length Free length
1 Lubrication relief valve spring length load load Replace
12.5 N 11.9 N
26 23.6 25.2
{1.27 kg} {1.21 kg}
42 D155A-6
10 Structure, function and maintenance standard SEN02862-03
D155A-6 43
SEN02862-03 10 Structure, function and maintenance standard
Scavenging pump 1
Type: SAR(4)125
Serial No.: 85001 – 85024
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
1 Side clearance
0.11 – 0.16 0.19
Clearance between plain bear-
2 ing inner diameter and gear 0.06 – 0.14 0.20
shaft outer diameter Replace
General
q The scavenging pump is installed to the torque
converter case and is driven with the power
from the engine. It returns the oil collected in
the bottom of the transmission case to the
steering case.
44 D155A-6
10 Structure, function and maintenance standard SEN02862-03
Type: SAR(3)125
Serial No.: 85025 and up
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
1 Side clearance
0.10 – 0.15 0.19
Clearance between plain bear-
2 ing inner diameter and gear 0.078 – 0.149 0.20
shaft outer diameter Replace
General
q The scavenging pump is installed to the torque
converter case and is driven with the power
from the engine. It returns the oil collected in
the bottom of the transmission case to the
steering case.
D155A-6 45
SEN02862-03 10 Structure, function and maintenance standard
46 D155A-6
10 Structure, function and maintenance standard SEN02862-03
Unit: mm
No. Check item Criteria Remedy
Type Standard clearance Clearance limit
3 Side clearance SAR(3)100
0.10 – 0.15 0.19
SAR(3)40
Clearance between plain bear- SAR(3)100
4 ing inner diameter and gear 0.06 – 0.15 0.20 Replace
shaft outer diameter SAR(3)40
Type Standard size Tolerance Repair limit
5 Pin driving depth SAR(3)100 -0.5
14 —
SAR(3)40 -0.5
6 Rotating torque of spline shaft 13.7 – 23.5 Nm {1.4 – 2.4 kgm}
Delivery Standard Discharge
Rotation
pressure discharge amount
Type speed
Delivery amount (MPa{kg/ amount limit —
(rpm)
– Oil: SAE10WCD cm2}) (l/min) (l/min)
Oil temperature: 45 – 55°C
SAR(3)100 2,500 2.94{30} 241 96
SAR(3)40 2,500 2.94{30} 239 85
D155A-6 47
SEN02862-03 10 Structure, function and maintenance standard
D155A-6 Bulldozer
Form No. SEN02862-03
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 03-19 (01)
48 D155A-6
SEN02863-01
D155A-6
D155A-6 1
SEN02863-01 10 Structure, function and maintenance standard
2 D155A-6
10 Structure, function and maintenance standard SEN02863-01
Outline
q The pump unit is composed of the variable
capacity swash plate type piston pump and LS
valve.
1. Main pump
2. LS valve
D155A-6 3
SEN02863-01 10 Structure, function and maintenance standard
1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7 Cylinder block
8. Valve plate
9. End cap
10. Servo piston
4 D155A-6
10 Structure, function and maintenance standard SEN02863-01
D155A-6 5
SEN02863-01 10 Structure, function and maintenance standard
&
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6 D155A-6
10 Structure, function and maintenance standard SEN02863-01
Control of delivery
q If swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
becomes larger and pump delivery (Q)
increases.
q Servo piston (10) is used for changing swash
plate angle (a).
q Servo piston (10) carries out linear reciprocal
movement according to the signal pressure
from the LS valve.
q This linear movement is transmitted to rocker
cam (4) through slider (14).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (10) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (10).
D155A-6 7
SEN02863-01 10 Structure, function and maintenance standard
LS valve
Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls pump delivery (Q) accord-
ing to differential pressure (dPLS)
[ = (PP) – (PLS)] (called LS differential pres-
sure) between pump discharge pressure (PP)
and control valve outlet port pressure (PLS).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output enter this valve.
8 D155A-6
10 Structure, function and maintenance standard SEN02863-01
D155A-6 9
SEN02863-01 10 Structure, function and maintenance standard
Operation
37
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10 D155A-6
10 Structure, function and maintenance standard SEN02863-01
D155A-6 11
SEN02863-01 10 Structure, function and maintenance standard
37
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q When the difference between pump discharge q When spool (3) moves, port (D) and port (E)
pressure (PP) and LS pressure (PLS), in other are interconnected and connected to the drain
w o r d s , L S d i ffe r e n t i a l p r e s s u r e ( dP L S) port.
becomes smaller [for example, when the area q The pressure at the large diameter end of
of opening of the control valve becomes larger servo piston (10) becomes drain pressure
and pump discharge pressure (PP) drops], (PT), and pump pressure (PP) enters port (J)
spool (3) is pushed to the left by the combined at the small diameter end, so servo piston (10)
force of LS pressure (PLS) and the force of is pushed to the left side. Therefore, servo pis-
spring (4). ton (10) is moved in the direction to make the
delivery larger.
12 D155A-6
10 Structure, function and maintenance standard SEN02863-01
37
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q If LS differential pressure (dPLS) becomes q While main pump pressure (PP) is present in
larger (for example, when the area of control port (J) of the smaller diameter side of the pis-
valve opening becomes smaller and the pump ton, servo piston (10) is pressed to the right by
pressure (PP) increases), spool (3) is pressed its area difference between the larger and the
to the right by the force of pump pressure (PP). smaller diameter sides. As the result, servo
q As a result of the movement of spool (3), pump piston (10) moves in the direction to minimize
discharge pressure (PP) flows from port (C) to the swash plate angle.
port (D), then from port (K) to the large diame-
ter side of the piston.
D155A-6 13
SEN02863-01 10 Structure, function and maintenance standard
37
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q Let us take the area receiving the pressure at q And the swash plate of the pump will be held in
the large diameter end of the piston as (A1), an intermediate position. [Spool (3) will be
the area receiving the pressure at the small stopped at a position where the distance of the
diameter end as (A0), and the pressure flowing opening from port (D) to port (E) and the dis-
into the large diameter end of the piston as tance from port (C) to port (D) is almost the
(PEN). same.]
q If the main pump pressure (PP) of the LS valve q The formula (A0) : (A1) C 3 : 5 represents the
and the combined force of spring (4) and LS relation of pressure receiving areas across the
pressure (PLS) are balanced, and the relation- end of servo piston (10). And (PP) : (PEN) C 5 :
ship is (A0) × (PP) = (A1) × (PEN), servo pis- 3 represents the pressure applied across the
ton (10) will stop in that position. piston when balanced.
q The force of spring (4) is adjusted to determine
the balanced stop position of this spool (3) at
the center of the standard when (PP) – (PLS) =
2.0 MPa {20 kg/cm2}.
14 D155A-6
10 Structure, function and maintenance standard SEN02863-01
1. Body Outline
2. Valve q This valve is installed in the oil cooler inlet cir-
3. Spring cuit. If any abnormal pressure is generated in
the oil flowing to the oil cooler, this valve acts
A: Hydraulic oil cooler inlet to return the oil directly to the hydraulic tank.
B: To hydraulic tank
Set pressure
Cracking pressure ( MPa {kg/cm })
2 0.5 {5.1}
D155A-6 15
SEN02863-01 10 Structure, function and maintenance standard
16 D155A-6
10 Structure, function and maintenance standard SEN02863-01
1. Potentiometer Outline
2. Lock lever q PCCS lever (3) sends electric signals to power
3. PCCS lever (Steering) train controller (5). Upon receiving those sig-
4. Limit switch nals, power train controller (5) sends signals to
5. Power train controller the EPC valve of the control valve.
6. Rod (From brake pedal) q Brake pedal (7) receives signals from potenti-
7. Brake pedal ometer (1) through rod (6). Then, power train
controller (5) sends signals to the brake valve
Positions of levers and pedals to operate the brake.
A: Neutral q Lock lever (2) is connected to limit switch (4)
B: Forward straight and used as the parking brake lever, too.
C: Reverse straight When it is in lock position "J", power train con-
D: Left turn troller (5) does not send turning signals to the
E: Right turn EPC valve of the control valve.
F: Brake OFF
G: Brake ON
H: Free
J: Lock
D155A-6 17
SEN02863-01 10 Structure, function and maintenance standard
Steering unit 1
(Bevel gear shaft, steering clutch and steering brake)
18 D155A-6
10 Structure, function and maintenance standard SEN02863-01
A: To transmission case
B: From scavenging pump and steering lubrication pump
C: R.H. brake oil pressure pickup port (RB)
D: L.H. brake oil pressure pickup port (LB)
E: From pin puller solenoid valve (drain)
F: R.H. steering clutch oil pressure pickup port (RC)
G: L.H. steering clutch oil pressure pickup port (LC)
D155A-6 19
SEN02863-01 10 Structure, function and maintenance standard
20 D155A-6
10 Structure, function and maintenance standard SEN02863-01
D155A-6 21
SEN02863-01 10 Structure, function and maintenance standard
22 D155A-6
10 Structure, function and maintenance standard SEN02863-01
General
D155A-6 23
SEN02863-01 10 Structure, function and maintenance standard
24 D155A-6
10 Structure, function and maintenance standard SEN02863-01
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Replace
Thickness 4.5 ±0.1 4.0
1 Steering brake disk
Repair or
Strain — 0.05 0.14
replace
Large
+0.081
Inside diameter of diamete 280 280.1
+0.081
contact surface of portion
8
seal ring on steering Small
brake piston +0.072
diameter 220 220.1
+0.081
portion
Large
+0.081
Inside diameter of diamete 280 280.1 Replace
+0.081
contact surface of portion
9
seal ring on steering Small
clutch piston +0.072
diameter 220 220.1
+0.081
portion
Standard size Repair limit
Installation Installation Installation
Steering brake spring (2 springs Free length Free length
10 length load load
make up a set)
35.7 kN 33.9 kN
33 19.6 32.0
{3,640 kg} {3,460 kg}
Steering clutch spring (2 springs 35.7 kN 33.9 kN
11 33 19.6 32.0
make up a set) {3,640 kg} {3,460 kg}
Standard Tolerance Standard Clearance
Clearance between bevel gear size Shaft Hole clearance limit
12
and reamer bolt
+0.019 +0.027 -0.019 –
16 0.026
+0.001 +0.027 0.026
D155A-6 25
SEN02863-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Backlash between brake hub
13 0.23 – 0.42
and disk
Backlash between brake drum
14 0.23 – 0.42
and plate
Replace
Backlash between clutch hub
15 0.23 – 0.42
and disk
Backlash between clutch drum
16 0.23 – 0.42
and plate
Standard shim thickness of
17 2.0
retainer A Adjustment of
Standard shim thickness of shims
18 2.0
retainer B
Rotary torque: 4.2 – 5.1 Nm {0.43 – 0.52 kgm}
Preload of bevel gear shaft
19 (22.6 – 26.5 Nm {2.3 – 2.7 kgm} at the bevel gear addendum Adjusting
bearings A and B
when the bevel pinion gear is not meshed)
26 D155A-6
10 Structure, function and maintenance standard SEN02863-01
Unit: mm
No. Check item Criteria Remedy
Backlash between bevel gear Adjust or
1 0.25 – 0.33
and bevel pinion replace
Standard shim thickness of Adjustment of
2 2.0
cage shims
D155A-6 27
SEN02863-01 10 Structure, function and maintenance standard
When the steering clutch is turned "on" When the steering clutch is turned "off"
* *
Oil pressure to the back side of clutch piston (19) is Oil being pressure-fed to the back side of clutch
stopped, and the repulsion of clutch spring (20) is piston (19) releases clutch hub (16).
used for fixing clutch hub (16).
Power from transmission
Power from transmission O
O Bevel pinion
Bevel pinion O
O Bevel gear
Bevel gear O
O Bevel gear shaft (14)
Bevel gear shaft (14) O
O Clutch hub (16)
Clutch hub (16)
O
Clutch drum (22)
O
Brake hub (12)
O
Output shaft
O
Final drive
28 D155A-6
10 Structure, function and maintenance standard SEN02863-01
When the steering brake is "released" When the steering brake is "actuated"
(When PCCS lever is in "operation")
*
*
q When the PCCS lever is set to the "neutral"
position and the brake pedal is not pressure, q As the PCCS lever is operated in the right or
the brake pressure alone is set to the maxi- left, the steering clutch is "disengaged" by the
mum pressure by the steering control valve. steering control valve and, at the same time,
Thus, oil pressure works on the back side of draining of oil to the back side of brake piston
brake piston (8) as soon as the steering clutch (8) is started.
is "engaged". q At this point, brake piston (8) is pushed back
q At this point, brake piston (8) compresses and rightward by the tension of brake spring (7),
moves brake spring (7) leftward with the pressure-bonding disk (10) and plate (9)
increased oil pressure, relieving the pressure- against brake drum (11).
bonding force of disk (10) and plate (9). q Brake piston (8) and brake drum (11) are fixed
q The power being transmitted from bevel gear to the steering case.
shaft (14) to brake hub (12) through the steer- q Pressure-bonding disk (10) and plate (9) stops
ing clutch is then transmitted to the final drive the inertia-based rotation of brake hub (12)
through the output shaft. and output shaft even if the steering clutch is
"disengaged".
q Adjustment of the turn radius and swing
becomes available by adjusting the braking
force through controlling the oil pressure to the
back side of brake piston (8) corresponding to
the rightward and leftward stroke of the PCCS
lever.
D155A-6 29
SEN02863-01 10 Structure, function and maintenance standard
*
30 D155A-6
10 Structure, function and maintenance standard SEN02863-01
D155A-6 31
SEN02863-01 10 Structure, function and maintenance standard
32 D155A-6
10 Structure, function and maintenance standard SEN02863-01
D155A-6 33
SEN02863-01 10 Structure, function and maintenance standard
*1:
The clutch used Name plate stamp
Steering clutch,
R*******
Steering brake
34 D155A-6
10 Structure, function and maintenance standard SEN02863-01
Outline of ECMV
q The ECMV consists of 1 pressure control valve
and 1 fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the controller and this valve
converts it to an oil pressure.
q Fill switch
This is a switch to detect that a clutch or brake
is filled with oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the signal
(fill signal) to the controller to notify the finish-
ing of filling.
2. While the oil pressure is applied to the clutch
or brake, the fill switch outputs the signal (fill
signal) to the controller to notify the presence
of the oil pressure.
Operation of ECMV
q The ECMV is controlled by the command
current from the controller to the propor-
tional solenoid and the fill switch output
signal.
D155A-6 35
SEN02863-01 10 Structure, function and maintenance standard
When the PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in
"free" position: Straight travel
(L.H. and R.H. brake are "released", parking brake is "released")
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q When the PCCS lever is in "neutral" position q Proportional solenoid (5) of the brake ECMV is
and the brake pedal is "released", proportional energized and pushes ball (6) to the left and
solenoid (1) of the clutch ECMV is demagne- closes the sealing part.
tized and the sealing part of ball (2) is opened. q The oil in port (Pb) of the brake ECMV flows in
q The oil from the power train pump flows port (E) and pushes valve (7) to the left to con-
through port (Pc) of the clutch ECMV to orifice nect port (Pb) with port (B) and disconnect port
(a), then it is drained through the sealing part (B) from port (Dr). At this time, the oil flows in
of ball (2). the back pressure port of the brake piston. As
q Valve (3) is moved to the right by the tension of the oil pressure rises, the brake piston is
spring (4) to disconnect port (Pc) from port (C), pushed to the left to compress the brake
and connect port (C) with port (Dr). At this spring, then the brake is "released".
time, the oil from the back pressure port of the q When the parking brake lever is set in the
clutch piston is drained through port (C) and "free" position, the pilot pressure of brake
the clutch is turned "on" by the tension of the ECMV port (S) remains, because the parking
clutch spring. brake solenoid valve is de-energized.
q The oil pressure in the brake circuit, etc. is
secured by orifice (a).
36 D155A-6
10 Structure, function and maintenance standard SEN02863-01
When the PCCS lever is "operated to the left halfway", brake pedal is "released", and parking brake
lever is in "free" position: Gradual left turn
(L.H. brake is "half released", R.H. brake is "released", parking brake is "released")
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q When the PCCS lever is "operated to left half- solenoid (5) according to the stroke of the
way" and the brake pedal is "released", propor- PCCS lever.
tional solenoid (1) of the L.H. clutch ECMV is q Proportional solenoid (5) generates the propul-
energized and the sealing part of ball (2) is sion force in proportion to the command cur-
closed. rent. This propulsion force is balanced with the
q The oil from the power train pump flows sum of the propulsion force generated by the
through port (C) of the clutch EMCV and orifice oil pressure in the back pressure port of the
(a) to port (F) and pushes valve (3) to the left to brake piston and the tension of spring (8), then
connect port (Pc) with port (C) and disconnect the brake pressure is set up to adjust the brake
port (C) from port (Dr). At this time, the oil flows force.
in the back pressure port of the clutch piston. q Accordingly, if the stroke of the PCCS lever is
As the oil pressure rises, the clutch piston is short, the oil pressure after port (B) is set high
pushed to the left to compress the clutch and the brake is turned from "released" to "half
spring, then the clutch is turned "off". released". If the stroke of the PCCS lever is
q Proportional solenoid (5) of the brake ECMV is long, the oil pressure after port (B) is set low
energized and pushes ball (6) to the left and and the brake is turned from "half released" to
closes the sealing part. "applied".
q The oil in port (Pb) of the brake ECMV flows in q When the parking brake lever is set in the
port (E) and pushes valve (7) to the left. As for "free" position, the pilot pressure of brake
the oil pressure after port (B), the controller ECMV port (S) remains, because the parking
outputs the command current to proportional brake solenoid valve is de-energized.
D155A-6 37
SEN02863-01 10 Structure, function and maintenance standard
When the PCCS lever is "operated fully to the left", brake pedal is "released", and parking brake lever
is in "free" position: Sharp left turn
(L.H. clutch is turned "off", L.H. brake is "applied", R.H. clutch is turned "on", R.H. brake is "released", and
parking brake is "released".)
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q When the PCCS lever is shifted from "operated q The oil pressure in the clutch circuit, etc. is
to left halfway" to "operated to left fully", pro- secured by orifice (b).
portional solenoid (5) of the L.H. brake ECMV q When the parking brake lever is set in the
is demagnetized and the sealing part of ball (6) "free" position, the pilot pressure of brake
is fully opened. ECMV port (S) remains, because the parking
q Since the oil in port (E) is drained through the brake solenoid valve is de-energized.
sealing part, valve (7) is moved to the right by
the tension of spring (8) to disconnect port (Pb)
from (B) and connect port (B) with port (Dr). At
this time, the oil from the back pressure port of
the brake piston is drained through port (B)
and the brake is turned "applied" by the ten-
sion of the brake spring.
q The oil from the power train pump flows
through port (Pb) of the brake ECMV and ori-
fice (b), then it is drained through sealing part
of ball (6).
38 D155A-6
10 Structure, function and maintenance standard SEN02863-01
When the PCCS lever is in "neutral", brake pedal is "depressed", and parking brake lever is in "free"
position: Stop
(L.H. and R.H. brake are "operated", parking brake is "released")
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q When the brake pedal is depressed fully, pro- q Since the PCCS lever is in "neutral" position,
portional solenoids (5) of L.H. and R.H. brake proportional solenoids (1) of L.H. and R.H.
ECMV are demagnetized to open the sealing clutch ECMV are demagnetized and L.H. and
part of ball (6). R.H. clutch are turned "on".
q The controller outputs the command current to q When the brake pedal is depressed fully, the
proportional solenoids (5) according to the brake pedal switch is turned "ON", and the
brake pedal stroke. parking brake solenoid valve is energized to
q Proportional solenoid (5) generates the propul- drain the pilot pressure of the brake ECMV port
sion force in proportion to the command cur- (S).This carries out the same function as when
rent. This propulsion force is balanced with the the parking brake lever is set at the "lock" posi-
sum of the propulsion force generated by the tion.
oil pressure in the back pressure port of the
brake piston and the tension of spring (8), then
the brake pressure is set up to adjust the brake
force.
D155A-6 39
SEN02863-01 10 Structure, function and maintenance standard
Solenoid valve
5. Coil (ON-OFF type)
6. Push pin
7. Spring
8. Spool
9. Body
40 D155A-6
10 Structure, function and maintenance standard SEN02863-01
When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in
"lock" position: Parking
(L.H. and R.H. brake are "operated", parking brake is "operated")
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q When the parking brake lever is in the "lock" q When the parking brake lever is in the "free"
position, the parking brake lever switch is position, the parking brake lever switch is
turned "ON" and coil (1) of the parking brake "OFF" and coil (1) of the parking brake sole-
solenoid valve is energized. noid valve is de-energized.
q Spool (3) is pushed to the right direction by q Spool (3) is returned to the left, and close port
push pin (2), then port (P) and (T) are opened (P) and (T) to remain the pilot pressure of the
to drain the pilot pressure of the L.H. and R.H. L.H. and R.H. brake ECMV.
brake ECMV. q The oil pressure from the brake ECMV is
q The oil which had flown into the brake piston applied to the back pressure port of the brake
back pressure port is drained through the piston, and brake is "released".
brake ECMV.
q The oil pressure in the back pressure port of
the brake piston continues to decrease, then
the brake is fully "applied" and that situation is
kept.
q When the engine is started again, as port (P)
and (T) are still opened, the brake is continu-
ously "applied".
D155A-6 41
SEN02863-01 10 Structure, function and maintenance standard
EPC valve
2. Coil (proportional type)
3. Push pin
4. Valve
5. Ball
6. Spool
7. Body
42 D155A-6
10 Structure, function and maintenance standard SEN02863-01
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General
q The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electric
system.
q Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) and con-
sequently the sudden brake can be avoided
when coil (2) of brake ECMV is de-energized.
q If an abnormality takes place in the electric
system, also coil (3) of the sudden stop pre-
vention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
D155A-6 43
SEN02863-01 10 Structure, function and maintenance standard
44 D155A-6
10 Structure, function and maintenance standard SEN02863-01
Final drive 1
Outline
q The final drive is a single stage spur gear, sin-
gle stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears. The final drive can be removed
and installed as a single unit.
q Floating seal (1) is installed to the rotating slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
D155A-6 45
SEN02863-01 10 Structure, function and maintenance standard
46 D155A-6
10 Structure, function and maintenance standard SEN02863-01
Unit: mm
No. Check item Criteria Remedy
Backlash between No.1 pinion Standard clearance Clearance limit
18
and No.1 gear 0.25 – 0.77 0.77
Backlash between sun gear Replace
19 0.20 – 0.55 0.55
and planetary gear
Backlash between planetary
20 0.22 – 0.71 0.71
gear and ring gear
Standard size Tolerance Repair limit
Outside diameter of No.1 pin- Repair or
21 –0.087
ion oil seal contact surface 95 94.913 replace
–0.087
Thickness of thrust collar of
22 23 22.95
inner body roller bearing
Standard Tolerance Standard Clearance
Clearance between outer size clearance limit
Shaft Hole
diameter of planet gear shaft
23
and inner diameter of carrier (Max.
–0.015 –0.009 - 0.024 – Replace
hole. (Small diameter) 68.262 clearance)
–0.034 –0.039 + 0.025
+ 0.025
Clearance between outer
diameter of planet gear shaft –0.036 –0.066 - 0.065 –
24 90 – 0.008
and inner diameter of carrier –0.058 –0.101 - 0.008
hole.(Large diameter)
Standard shim thickness for
25 2 Adjust
No.1 pinion bearing cage
Standard size Repair limit Repair or
26 Wear of wear guard
67 21 replace
D155A-6 47
SEN02863-01 10 Structure, function and maintenance standard
q The power from the bevel gear shaft and steer- Then, the rotating force of sun gear (2) forms
ing clutch is transmitted to 1st pinion (10) to the rotating force of carrier (3), which supports
rotate 1st gear (13) meshed with the 1st pinion the planetary gear (7), via shaft (15), and is
and sun gear (2) meshed with the 1st gear. transmitted to sprocket boss (4).
The rotation of sun gear (2) is transmitted to The rotating direction of carrier (3) is the same
planetary gear (7). Since ring gear (8) meshed with sun gear (2).
with the planetary gear is fixed to cover (6), the The rotational force transmitted to sprocket
planetary gear (7) rotates along the ring gear boss (4) is further transmitted to sprocket teeth
(8) and revolves around the sun gear (2). (5).
48 D155A-6
10 Structure, function and maintenance standard SEN02863-01
D155A-6 49
SEN02863-01 10 Structure, function and maintenance standard
Sprocket 1
Unit: mm
No. Check item Criteria Remedy
Standard clearance Repair limit
1 Wear of sprocket tooth tip
351 339
2 Wear of sprocket tooth root 21.7 15.5
Rebuid or
Wear of width of sprocket replace
3 83 75
tooth tip
Wear of width of sprocket
4 105 95
tooth root
50 D155A-6
10 Structure, function and maintenance standard SEN02863-01
D155A-6 51
SEN02863-01 10 Structure, function and maintenance standard
D155A-6 Bulldozer
Form No. SEN02863-01
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 03-19 (01)
52 D155A-6
SEN02864-00
D155A-6
D155A-6 1
SEN02864-00 10 Structure, function and maintenance standard
Track frame 1
2 D155A-6
10 Structure, function and maintenance standard SEN02864-00
Unit: mm
No. Check item Criteria Remedy
Item Repair limit
Curvature 7 (over length of 3,000) Correct or
4 Deformation of track frame
Twisting 3 (over length of 300) replace
Dents (pipe portion) 12
D155A-6 3
SEN02864-00 10 Structure, function and maintenance standard
Recoil spring 1
1. Yoke Outline
2. Dust seal q Recoil spring (4) is used to adjust the track ten-
3. Rod sion by pumping in or releasing grease from
4. Recoil spring lubricator (6) to move rod (3) forward or back-
5. Wear ring ward. The recoil spring also acts to dampen
any sudden shock brought to bear on the idler.
6. Lubricator
7. Nut
8. Housing
9. Cylinder
10. Holder
11. Bushing
4 D155A-6
10 Structure, function and maintenance standard SEN02864-00
Unit: mm
No. Check item Criteria Remedy
Press-fitting force for
1 392 kN {40 ton} Adjust
idler yoke
Standard Tolerance Standard Clearance
Clearance between rod size Shaft Hole clearance limit
11
and bushing
–0.036 +0.277 0.098 –
110 1.0
–0.090 +0.062 0.367
Standard size Repair limit Replace
Installed Installed Installed
Free length Free length
4 Recoil spring length load load
298 kN 274 kN
734 597 687
{30,388 kg} {27,900 kg}
D155A-6 5
SEN02864-00 10 Structure, function and maintenance standard
Idler 1
6 D155A-6
10 Structure, function and maintenance standard SEN02864-00
Unit: mm
No. C heck item Criteria Remedy
Standard size Repair limit
1 Outer diameter of protrusion
850 —
2 Outer diameter of tread 800 781
Rebuild or
3 Depth of tread 25 34.5
replace
4 Thickness of tread 21 11.5
5 Overall width 245 —
6 Width of tread 62 —
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
7
and bushing
–0.210 +0.255 0.430 –
85 —
–0.260 +0.220 0.515 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler size Shaft Hole interference limit
8
and bushing
+0.130 +0.100 0.02 –
135 —
+0.080 –0.050 0.18
Standard size Repair limit
9 Shaft flange width
20
–0
–0.05
— Replace
10 Play of shaft in axial direction 0.49 – 0.72
D155A-6 7
SEN02864-00 10 Structure, function and maintenance standard
Track roller 1
8 D155A-6
10 Structure, function and maintenance standard SEN02864-00
Unit: mm
No. C heck item Criteria Remedy
Outer diameter of flange Standard size Repair limit
1
(outside flange) 298 —
Outer diameter of flange
2 282 —
(inside flange)
3 Outer diameter of tread 255 230
4 Thickness of tread 60 47.5
5 Overall width 294 —
Rebuild or
Width of tread
6 64 — replace
(single flange)
Width of tread
7 62 —
(double flange)
Flange width
8 25 —
(outside of double flange)
Flange width
9 22 —
(inside of double flange)
10 Shaft flange width 20 —
D155A-6 9
SEN02864-00 10 Structure, function and maintenance standard
Carrier roller 1
10 D155A-6
10 Structure, function and maintenance standard SEN02864-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outer diameter of flange
220 —
2 Outer diameter of tread 190 167 Rebuild or
3 Width of tread 63 — replace
4 Thickness of tread 37.5 26
5 Width of flange 21 —
Tolerance Standard
Standard size
Interference between Shaft Hole interference
6
shaft and ring
+0.166 +0.030
70 0.090 – 0.166
+0.120 +0.030
Tolerance Standard
Standard size Replace
Clearance between Shaft Hole clearance
7
shaft and support
–0.2 +0.300
68 0 – 0.5
–0.2 +0.030
Standard clearance
8 Play of roller in axial direction
0.010 – 0.230
D155A-6 11
SEN02864-00 10 Structure, function and maintenance standard
Track shoe 1
Dry type
12 D155A-6
10 Structure, function and maintenance standard SEN02864-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch 231.9 (Heavy-duty areas)
228.9
233.9 (Standard areas)
When turned Reverse or
Standard size replace
2 Bushing outside diameter Normal load Impact load
81 75.0 77.0
3 Thickness of bushing metal 15.8 9.8 11.8
Standard size Repair limit
4 Link height
144 128 Repair or
replace
Thickness of link metal
5 45.5 29.5
(bushing press-fitting portion)
Tightening torque Additional tightening
6 Shoe bolt (Nm {kgm}) angle (deg.) Retighten
590 ± 60 {60 ± 6} 120 ± 10
Tolerance Standard
Standard size
Interference between Shaft Hole interference
7
bushing and link
+0.404 +0.074
77.0 0.230 – 0.404
+0.304 +0.074
Interference between +0.484 –0.038
8a 48.5 0.372 – 0.584 Adjust or
regular pin and link +0.334 –0.100
replace
Interference between +0.230 –0.038
8b 48.5 0.238 – 0.330
master pin and link +0.200 –0.100
Standard clearance
9 Clearance between links One side Both side
1.4 2.8
D155A-6 13
SEN02864-00 10 Structure, function and maintenance standard
14 D155A-6
10 Structure, function and maintenance standard SEN02864-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch
228.9 231.9
When turned Reverse or
Standard size
2 Bushing outside diameter Normal load Impact load replace
81 72.5 75.0
3 Thickness of bushing metal 15.8 7.3 9.8
Standard size Repair limit
4 Link height
144 128 Repair or
replace
Thickness of link metal
5 45.5 29.5
(bushing press-fitting portion)
Tightening torque Additional tightening
a. Regular link (Nm {kgm}) angle (deg.)
6 Shoe bolt Retighten
590 ± 60 {60 ± 6} 120 ± 10
b. Master link 590 ± 60 {60 ± 6} 180 ± 10
Standard Tolerance Standard
Interference between size Shaft Hole interference
7
bushing and link
+0.404 +0.074
77.0 0.230 – 0.404
+0.304 +0.074
Adjust or
Interference between +0.484 –0.038
8 48.5 0.372 – 0.584 replace
regular pin and link +0.334 –0.100
Standard clearance
9 Clearance between links One side Both side
1.4 2.8
D155A-6 15
SEN02864-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Height of
1 single 80 30
grouser
Repair or
heavy duty 80 30
replace
Overall height single 97 47
2
of shoe heavy duty 99 49
16 D155A-6
10 Structure, function and maintenance standard SEN02864-00
D155A-6 17
SEN02864-00 10 Structure, function and maintenance standard
Main frame 1
18 D155A-6
10 Structure, function and maintenance standard SEN02864-00
1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Coupling
7. Cap
8. Plate
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between size clearance limit
Shaft Hole
9 equalizer bar shaft Replace
and bushing –0.036 +0.213 0.165 –
95 1.0
–0.090 +0.129 0.303
Press-fitting force for
10 equalizer bar shaft 29.42 – 68.65 kN {3 – 7 ton} Adjust
mounting bushing
D155A-6 19
SEN02864-00 10 Structure, function and maintenance standard
Suspension 1
20 D155A-6
10 Structure, function and maintenance standard SEN02864-00
Unit: mm
No. Check item Criteria Remedy
Press-fitting force for side
9 pin bushing 27.46 – 64.7 kN {2.8 – 6.6 ton}
—
Press-fitting force for center
12 pin bushing 47.07 – 131.41 kN {4.8 – 13.4 ton}
Outline
q The front of the track frame rocks up and down
using the rear pivot shafts (6) as a fulcrum.
Equalizer bar (1) rocks using center pin (11) as
a fulcrum. The left and right track frames are
connected by side pin (10).
D155A-6 21
SEN02864-00 10 Structure, function and maintenance standard
D155A-6 Bulldozer
Form No. SEN02864-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (02)
22 D155A-6
SEN02865-05
D155A-6
D155A-6 1
SEN02865-05 10 Structure, function and maintenance standard
2 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Multi-shank ripper
1. Control valve
2. Divider block
3. Ripper lift cylinder
4. Ripper tilt cylinder
D155A-6 3
SEN02865-05 10 Structure, function and maintenance standard
Giant ripper
1. Control valve
2. Divider block
3. Ripper lift cylinder
4. Pin puller cylinder
5. Ripper tilt cylinder
6. Pin puller solenoid valve
4 D155A-6
10 Structure, function and maintenance standard SEN02865-05
D155A-6 5
SEN02865-05 10 Structure, function and maintenance standard
6 D155A-6
10 Structure, function and maintenance standard SEN02865-05
D155A-6 7
SEN02865-05 10 Structure, function and maintenance standard
3
4
2
1
AJG00278
8 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Lever positions
A : Blade HOLD
B : Blade LOWER
B + C :Blade FLOAT
D : Blade RAISE
E : Blade LEFT TILT
F : Blade RIGHT TILT
G : Ripper HOLD
H : Ripper RAISE
J : Ripper LOWER
K : Ripper DECREASE TIP ANGLE
(with variable ripper)
L : Ripper INCREASE TIP ANGLE
(with variable ripper)
M : FREE
N : LOCK
Outline
q The work equipment control employs a PPC
system which uses a PPC valve to move the
spools of the control valve.
D155A-6 9
SEN02865-05 10 Structure, function and maintenance standard
10 D155A-6
10 Structure, function and maintenance standard SEN02865-05
D155A-6 11
SEN02865-05 10 Structure, function and maintenance standard
Specified
value
Tank capacity (l) 125
Hydraulic Hi (l) 95
Level
tank inside Center (l) 85
tank
Low (l) 75
Cracking pressure 16.7 ± 2.5
(kPa {kg/cm2}) {0.17±0.025}
Breather
Vacuum valve actuating 2 ± 0.3
pressure (kPa {kg/cm2}) {0.02±0.003}
Cracking pressure 147 ± 29.4
(kPa {kg/cm2}) {1.5±0.31}
Hydraulic Mesh size (µ m) 20/10/5
filter
Filtering area (cm2) 13,600
Filtering oil flow (l/min) 550
Mesh size (µ m) 105
Strainer
Filtering area (cm2) 1,850
12 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Accumulator 1 Function
q The accumulator is installed between the
For EPC valve redusing valve and the EPC valve. Even if the
engine is started with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the control valve to actuate it and
enable the work equipment to move down
under its own weight.
Operation
q After the engine is stopped, when the EPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
q When the EPC valve is operated, the oil pres-
sure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas
in chamber (A) expands the bladder, so the oil
in chamber (B) acts as the pilot pressure and
actuates the main control valve.
%HIRUHDFWXDWLRQ $IWHUDFWXDWLRQ
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1. Gas plug *
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.14 MPa {32 kg/cm2}
Min. actuation pressure: 1.18 MPa {12 kg/cm2}
D155A-6 13
SEN02865-05 10 Structure, function and maintenance standard
PPC valve 1
Blade PPC valve
P: From self pressure reducing valve P3: To blade tilt valve (LEFT TILT)
P1: To blade lift valve (LOWER, FLOAT) P4: To blade tilt valve (RIGHT TILT)
P2: To blade lift valve (RAISE) T: To tank
14 D155A-6
10 Structure, function and maintenance standard SEN02865-05
1. Spool 6. Plate
2. Piston 7. Retainer
3. Disc 8. Body
4. Nut (For connecting lever) 9. Filter
5. Joint
D155A-6 15
SEN02865-05 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installed
Installed Installed
Metering spring x Outside Free length
10 length load load
(For ports P3 and P4) diameter
16.7 N 13.3 N
26.53 x 8.15 24.9 —
{1.7 kg} {1.36 kg}
Centering spring 107.9 N 86.3 N Replace
11 48.57 x 15.5 32.5 —
(For ports P3 and P4) {11 kg} {8.8 kg} spring If
Metering spring 16.7 N 13.3 N damaged or
12 26.3 x 8.15 24.1 —
(For port P2) {1.7 kg} {1.36 kg} deformed.
Centering spring 78.5 N 62.8 N
13 43.2 x 15.5 34 —
(For port P2) {8 kg} {6.4 kg}
Centering spring 94 N 75.3 N
14 34.0 x 15.5 31.9 —
(For port P1) {9.6 kg} {7.68 kg}
Metering spring 16.7 N 13.3 N
15 29.27 x 8.15 25.4 —
(For port P1) {1.7 kg} {1.36 kg}
16 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Operation
1. When in neutral
1) For lifting blade 2) For tilting blade
q Ports (A) and (B) of the blade lift valve of the- q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P1) and (P2) of the control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D). hole (f) of spool (1) to drain chamber (D).
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D155A-6 17
SEN02865-05 10 Structure, function and maintenance standard
18 D155A-6
10 Structure, function and maintenance standard SEN02865-05
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SEN02865-05 10 Structure, function and maintenance standard
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10 Structure, function and maintenance standard SEN02865-05
D155A-6 21
SEN02865-05 10 Structure, function and maintenance standard
22 D155A-6
10 Structure, function and maintenance standard SEN02865-05
1. Spool
2. Piston
3. Disc
4. Nut (for connecting lever)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
Centering spring × Outside Free length
10 length load load
(For ports P3 and P4) diameter
Replace spring
55.9 N 44.7 N
50.35 × 15.5 34 — if damaged or
{5.7 kg} {4.56 kg}
deformed.
Centering spring 71.4 N 57.1 N
11 50.05 × 15.5 34 —
(For ports P1 and P2) {7.28 kg} {5.8 kg}
16.7 N 13.3 N
12 Metering spring 26.53 × 8.15 24.9 —
{1.7 kg} {1.36 kg}
D155A-6 23
SEN02865-05 10 Structure, function and maintenance standard
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10 Structure, function and maintenance standard SEN02865-05
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D155A-6 25
SEN02865-05 10 Structure, function and maintenance standard
1. Solenoid
2. Body
3. Spool
Outline
q The work equipment lock valve is installed
between the basic pressure valve and control
valve in the work equipment control circuit. If
the work equipment lock lever is set in the
FREE position, the work equipment lock switch
operates and the work equipment lock valve
opens the work equipment control circuit so
that the operator can operate the work equip-
ment.
Operation
q The solenoid is operated by the electric signal
to move the spool. As a result, the circuit
between port (A) connected to the basic pres-
sure valve and port (B) connected to the con-
trol valve is opened.
26 D155A-6
10 Structure, function and maintenance standard SEN02865-05
D155A-6 27
SEN02865-05 10 Structure, function and maintenance standard
Control valve 1
General view
28 D155A-6
10 Structure, function and maintenance standard SEN02865-05
D155A-6 29
SEN02865-05 10 Structure, function and maintenance standard
Sectional view
(1/3)
30 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
x Outside Free length
9 Spool return spring length load load
diameter
224N 178N
76.3 x 30 68.5 —
{22.8kg} {18.2kg}
If damaged or
140N 112N
10 Spool return spring 51.7 x 31.3 50 — deformed,
{14.3kg} {11.4kg}
replace spring
217N 174N
11 Spool return spring 54.7 x 36.5 33.5 —
{22.1kg} {17.7kg}
12.7N 9.8N
12 Load check valve spring 20.8 x 12.2 13.5 —
{1.3kg} {1.0kg}
193N 154N
13 Unload valve spring 86.7 x 30 66 —
{19.63kg} {15.7kg}
D155A-6 31
SEN02865-05 10 Structure, function and maintenance standard
(2/3)
32 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
x Outside Free length
7 Suction valve spring length load load deformed,
diameter
replace spring
6.37N 5.1N
64.9 x 12.5 56 —
{0.65kg} {0.52kg}
D155A-6 33
SEN02865-05 10 Structure, function and maintenance standard
(3/3)
34 D155A-6
10 Structure, function and maintenance standard SEN02865-05
1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
x Outside Free length
4 Suction valve spring length load load deformed,
diameter
replace spring
5.49N 4.41N
46.8 x 7.5 40.6 —
{0.56kg} {0.45kg}
D155A-6 35
SEN02865-05 10 Structure, function and maintenance standard
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10 Structure, function and maintenance standard SEN02865-05
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Operation
q When the spool is at the HOLD position, the ing on the left end of spool (3) of the pressure
pump pressure is sent from chamber (A) compensation valve, so it pushes against the
through the notch in spool (3) of the pressure load of spring (4) and moves to the right to the
compensation valve, and passes through maximum stroke position. In this condition, the
chamber (B) to chamber (C). Chamber (G) is area of the opening to spool (1) of the blade tilt
drained through chamber (H) to chamber (F). valve is at its minimum.
When this happens, the pump pressure is act-
D155A-6 37
SEN02865-05 10 Structure, function and maintenance standard
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Operation
q When the tilt lever is operated to right tilt, pilot q PLS = differential pressure between ports
pressure (PB1) acts on the right end of spool (K) and (J) = 1.96 MPa {20kg/cm2}
(1) through the PPC valve, and when the pres- q PLS' = differential pressure between ports
sure becomes greater than the set load of (I) and (D)
spring (2), the spool starts to move to the left. It q PLS C PLS'
is balanced at a position corresponding to PPC
output pressure (PB1).
38 D155A-6
10 Structure, function and maintenance standard SEN02865-05
q Chamber (C) and chamber (D) are connected, q In addition, pump servo valve (7) is controlled
and the oil from the pump flows through ports so that the differential pressure between pump
(A), (B), (C), and (D) to tilt cylinder (6). At the pressure (P) and LS pressure (LS) (LS differ-
same time, the load pressure in chamber (D) ential pressure: ( PLS) remains constant, so
passes through LS orifice (5) and chamber (H), a suitable amount of oil flows to ensure that the
and is sent to chamber (G). It is also sent from loss of pressure at the control valve ( PLS') is
the LS circuit (O) to pump servo valve (7). equal to ( PLS). The loss of pressure in the
q The condition of the pressure of spool (3) is control valve is determined by the area of the
chamber (B) pressure C chamber (C) pressure, opening of the main spool, so the oil flow
and chamber (G) pressure C chamber (D) matches the opening of the spool.
pressure, so spool (3) is controlled by the dif- q The return oil flow from the tilt cylinder passes
ferential pressure of spool (1) (chamber (C) through chamber (E) and chamber (F), and is
pressure – Chamber (D) pressure), and bal- drained.
ances with spring (4).
In other words, if the oil flow is too large, the
differential pressure of spool (1) becomes
larger, so spool (3) moves in the direction to
throttle the oil flow; on the other hand, if the oil
flow is too small, spool (3) moves in the direc-
tion to increase the oil flow.
D155A-6 39
SEN02865-05 10 Structure, function and maintenance standard
3. Meter-out control when blade moves down under its own weight
(work equipment lever at LOWER)
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10 Structure, function and maintenance standard SEN02865-05
Operation
q In the case where the blade falls owing to the
weight of the blade, the return flow from a cyl-
inder is controlled according to the opening
area of main spool (1).
D155A-6 41
SEN02865-05 10 Structure, function and maintenance standard
4. Meter-out control when blade moves down under its own weight
(work equipment lever at FLOAT)
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42 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Operation
q When the lift valve is at FLOAT, the cylinder
port and drain port are connected to put the cir-
cuit in a no-load condition.
q When the lift valve is in the FLOAT condition,
the pump passage and cylinder ports (A3) and
(B3) are separated so that the other control
valves can be operated.
q When the work equipment control lever is at
t h e F L O AT p o s i t i o n , i f p r e s s u r e ( PA 3 )
becomes 3.4 MPa (35 kg/cm 2 ) or more, lift
spool (1) is moved to the maximum stroke
position.
q In this condition, ports (A3) and (B3) and the
LS passage (O) are all connected to the drain
circuit, so there is no load on the lift cylinder.
q If the cylinder is driven by the weight of the
blade, the oil entering from (A3) flows to ports
(A), (B), (B1) and (A1), while the rest of the oil
flows through port (D), and is drained. The oil
from suction valve (9) flows to port (B3). When
this happens, the oil flow is throttled by the
area of opening between ports (A) and (B) of
spool (1), and the cylinder speed is controlled.
q The pump circuit chamber (E) and ports (A3)
and (B3) are separated, and pump pressure
(P) is formed, so it is possible to carry out com-
pound operations with other control valves.
D155A-6 43
SEN02865-05 10 Structure, function and maintenance standard
5. At relief
(Blade lift, blade tilt, ripper lift, ripper tilt)
a The diagram shows the condition at relief for work equipment LS relief valve (5) with blade tilt stroke
end.
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10 Structure, function and maintenance standard SEN02865-05
Operation
q If blade tilt valve (1) is moved, and the pres-
sure of tilt cylinder (8) becomes higher, work
equipment LS relief valve (5) will crack and oil
will be drained from LS circuit (O). (Ports (P),
(F), (G), (J), and (K)). As a result, there will be
a drop in pressure in LS passage (O) starting
from LS sensing hole (F), and ( P2) will
become larger.
q For the same reason, if the pressure in cham-
ber (I) and (H) drops, spool (2) will push
against spring (3) and move to the right, and
will make the opening between chambers (B)
and (C) smaller, so the flow between chambers
(B) and (C) will be throttled and ( P4) will
become larger.
q Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by
the flow at work equipment LS relief valve (5)
( P1) + ( P2) equal to LS differential pres-
sure ( LS). When this happens, pump LS
valve (6) detects the differential pressure gen-
erated by LS relief valve (5), and moves the
pump swash plate from the maximum to the
minimum position where the LS differential
pressure is 1.96 MPa {20 kg/cm2}.
q When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil
flow is greater than the LS relief oil flow + leak-
age at any part, the pressure is confined in the
pump circuit (the pump and chambers (A) and
chamber (B) through pressure compensation
valve (7)), so the LS differential pressure rises.
If this differential pressure goes above the set
pressure for unload valve (4), the unload valve
is actuated to relieve the excess oil flow and
balance the circuit.
D155A-6 45
SEN02865-05 10 Structure, function and maintenance standard
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D155A-6 47
SEN02865-05 10 Structure, function and maintenance standard
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10 Structure, function and maintenance standard SEN02865-05
D155A-6 49
SEN02865-05 10 Structure, function and maintenance standard
Ripper cylinder
a The piping of the lift cylinder and tilt cylinder of the variable multi-shank ripper is different from the
above.
50 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
size Shaft Hole clearance limit
Blade -0.030 +0.279 0.095 –
75 0.666
LIFT -0.076 +0.065 0.355
Clearance between
1 piston rod and bush- Blade 90
-0.036 +0.270 0.097 –
0.695
ing TILT -0.090 +0.061 0.330
Ripper -0.036 +0.257 0.105 –
100 0.675
LIFT -0.090 +0.047 0.375
Ripper -0.036 +0.261 0.105 –
110 0.675
TILT -0.090 +0.047 0.375
Clearance between
piston rod support Blade +0.3
2 85 — — 1.0
shaft and blade LIFT +0.3
ball portion
Clearance between Replace
Blade -0.100 0.100 –
3 cylinder support 85 — 0.5
LIFT -0.174 0.228
shaft and bushing
Clearance between
Blade -0.200
4 piston rod spherical 115 — — —
TILT -0.300
surface and cap
Blade -0.030 +0.174 0.130 –
60 1.0
TILT -0.050 +0.100 0.224
Clearance between
cylinder bottom sup- Ripper -0.036 +0.207 0.156 –
5 90 1.0
port shaft and bush- LIFT -0.090 +0.120 0.297
ing
Ripper -0.036 +0.201 0.156 –
100 1.0
TILT -0.090 +0.119 0.291
Clearance between Ripper -0.036 +0.207 0.156 –
90 1.0
cylinder rod sup- LIFT -0.090 +0.120 0.297
6
port shaft and bush- Ripper -0.036 +0.201 0.156 –
ing 100 1.0
TILT -0.090 +0.119 0.291
D155A-6 51
SEN02865-05 10 Structure, function and maintenance standard
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction
of the arrow until piston valve seat (4) comes
into snug contact with the tapered section,
thereby, this causing the pressure in the cylin-
der to rise and moving piston (2) in the direc-
tion of the arrow.
*
52 D155A-6
10 Structure, function and maintenance standard SEN02865-05
D155A-6 53
SEN02865-05 10 Structure, function and maintenance standard
Structure
The quick drop valve consists of valve body (1),
spool (2), check valve (3), and spring (4).
The quick drop valve serves to increase the blade % $
lowering speed and to reduce the occurrence of
vacuum when the blade is lowering, thereby short-
ening the time lag before digging is started.
The blade lowering speed, which is generally deter-
mined by the pump discharge, can be made faster
with the quick drop valve.
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2. While lowering
Pressurized oil from the cylinder head flows
into port (C) through port (B).
At this time, the oil flow is restricted by an ori-
fice (a) provided along the way, causing a dif-
ferential pressure before and after the orifice.
When the differential pressure becomes
greater than the force of spring (4), it com-
presses the spring and moves spool (2) and
check valve (3) to the right.
When the spool and the check valve have
moved, part of the oil flowing from the cylinder
1. Valve body head to tank enters the passage to the cylinder
2. Spool bottom together with the oil from the control
3. Check valve valve.
4. Spring Thus, the blade lowering speed increases in
accordance with the amount of oil that flows to
Operation the bottom of the cylinder and reduces the for-
1. Start of lowering mation of vacuum at the bottom of the cylinder.
When the blade lever is operated to LOWER,
the oil from the control valve enters the cylin-
der bottom through port (A) and pushes the
piston. In the meantime, the oil in the cylinder
head is pushed out into the piston, enters valve
port (B), and flows into the tank from port (C).
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54 D155A-6
10 Structure, function and maintenance standard SEN02865-05
T: To hydraulic tank
P1: From cooling fan pump
P2: To cooling fan motor
PR: Supply to PPC valve and EPC valve
D155A-6 55
SEN02865-05 10 Structure, function and maintenance standard
56 D155A-6
10 Structure, function and maintenance standard SEN02865-05
Operation
At engine stop (total low pressure)
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q The self pressure reducing valves reduce the
discharge pressure of the fan pump and sup-
plies it to the PPC valve, the EPC valve, etc. as
the control pressure.
D155A-6 57
SEN02865-05 10 Structure, function and maintenance standard
2. When the load pressure P2 is lower than the output pressure PR of the self pressure reducing
valve.
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q The spring (3) and the (PR) pressure (0 MPa q Therefore, there will occur a differential pres-
{0 kg/cm2} at the time of engine stop) pushes sure around the hold a in the spool (8) and the
the valve (2) in the direction to close the circuit spool will move in the direction to close the
between the ports (P1) and (P2). When the port (P1) and the (PR) opening. Then, the (P1)
hydraulic oil enters the (P1) port, the expres- pressure is reduced and adjusted to a certain
sion ((P1) pressure Spring (7) force + (ø(d) pressure (set pressure) with the opening and is
area x (PR) pressure)) holds, and the self pres- supplied as the (PR) pressure.
sure reducing valve will adjust the openings of
the ports (P1) and (P2) so that the (P1) pres-
sure can be maintained higher than the (PR)
pressure.
q When the (PR) pressure rises above the set
pressure, the poppet (5) will open and the
hydraulic oil flows through the route from the
(PR) port, the hole a in the spool (8), the pop-
pet (5) opening to the tank port (T).
58 D155A-6
10 Structure, function and maintenance standard SEN02865-05
33&YDOYH
)DQSXPS
6HUYR (3&YDOYH
3 3 35 7
)DQPRWRU
D
*
q When the load pressure (P2) rises due to dig- q When the (PR) pressure rises above the set
ging or other operations, the pump delivery will pressure, the poppet (5) will open and the
increase and the (P1) pressure will rise. hydraulic oil will flow through the route from the
Then, the expression ((P1) pressure > Spring (PR) port, the hole (a) in the spool (8), the pop-
(7) force + ( (d) area x (PR) pressure)) will pet (5) opening to the tank port (T).
hold, and the valve (2) will move to the right q Therefore, there will occur a differential pres-
side till the stroke end. As a result, the open- sure around the hold (a) in the spool (8) and
ing between the ports (P1) and (P2) will the spool will move in the direction to close the
increase, the passage resistance will become port (P1) and the (PR) opening. Then, the (P1)
smaller to reduce engine loss horsepower. pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.
D155A-6 59
SEN02865-05 10 Structure, function and maintenance standard
33&YDOYH
35 7
*
60 D155A-6
10 Structure, function and maintenance standard SEN02865-05
D155A-6 61
SEN02865-05 10 Structure, function and maintenance standard
D155A-6 Bulldozer
Form No. SEN02865-05
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 03-19 (01)
62 D155A-6
SEN02866-02
D155A-6
D155A-6 1
SEN02866-02 10 Structure, function and maintenance standard
Cylinder stay 1
1. Yoke
2. Dust seal
3. Bushing
4. Bushing
5. Grease nipple
2 D155A-6
10 Structure, function and maintenance standard SEN02866-02
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between cylinder size Shaft Hole clearance limit
6
yoke and bushing
–0.172 +0.063 0.172 –
125 —
–0.235 +0.046 0.298
Replace
Clearance between cylinder –0.170 +0.054 0.170 –
7 100 —
yoke and bushing –0.224 +0.046 0.278
Clearance between bushing
–0.172 +0.054 0–
8 of cylinder support shaft and 110 0.5
–0.035 +0.046 0.089
yoke
D155A-6 3
SEN02866-02 10 Structure, function and maintenance standard
Blade 1
Sigma-tilt dozer, semi-U blade
4 D155A-6
10 Structure, function and maintenance standard SEN02866-02
D155A-6 5
SEN02866-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height of outside of end bit
315 235
Replace
2 Width of end bit 540 440
3 Height of inside of end bit 254 215
Turn
4 Height of cutting edge 254 215 (175 to turning)
or replace
6 D155A-6
10 Structure, function and maintenance standard SEN02866-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit Turn
1 Height of cutting edge
330 260 (215 to turning) or replace
2 Height of outside of end bit 300 235
3 Height of inside of end bit 330 260 Replace
4 Width of end bit 640 500
D155A-6 7
SEN02866-02 10 Structure, function and maintenance standard
Ripper 1
Variable multi-shank ripper
8 D155A-6
10 Structure, function and maintenance standard SEN02866-02
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between arm size clearance limit
Shaft Hole
1,7 mounting pin and mounting
bracket or beam bracket –0.036 +0.207 0.156 –
110 1.5
–0.090 +0.120 0.297
Clearance between arm –0.036 +0.529 0.499 –
2,8 110 1.5
mounting pin and bushing –0.090 +0.463 0.619
Clearance between tilt cylin-
–0.036 +0.207 0.156 –
3,9 der mounting pin and mount- 100 1.5
–0.090 +0.120 0.297
ing bracket or beam bracket
Clearance between tilt cylin- –0.036 +0.201 0.155 –
4,10 100 1.5
der mounting pin and bushing –0.090 +0.119 0.291
Clearance between lift cylinder
–0.036 +0.207 0.156 –
5,11 mounting pin and mounting 90 1.5 Replace
–0.090 +0.120 0.297
bracket or beam bracket
Clearance between lift cylinder
–0.036 +0.207 0.156 –
6,12 mounting pin and shank bush- 90 1.5
–0.090 +0.120 0.297
ing
Clearance between shank
Shaft 80 +0.300 +0.300 1.400 –
13 mounting pin and shank 10.0
Hole 82 –0.300 –0.300 2.600
holder
Clearance between shank Shaft 80 +0.300 +1.000 3.700 –
14 15.0
mounting pin and shank hole Hole 88 –0.300 –1.000 6.300
Standard size Repair limit
15 Wear of point
335 225
16 Wear of protector 75 50
D155A-6 9
SEN02866-02 10 Structure, function and maintenance standard
Unit: mm
10 D155A-6
10 Structure, function and maintenance standard SEN02866-02
D155A-6 11
SEN02866-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between arm size clearance limit
Shaft Hole
1,7 mounting pin and mounting
bracket or beam bracket –0.036 +0.207 0.156 –
110 1.5
–0.090 +0.120 0.297
Clearance between arm –0.036 +0.529 0.499 –
2,8 110 1.5
mounting pin and bushing –0.090 +0.463 0.619
Clearance between tilt cylin-
–0.036 +0.207 0.156 –
3,9 der mounting pin and mount- 100 1.5
–0.090 +0.120 0.297
ing bracket or beam bracket
Clearance between tilt cylin- –0.036 +0.201 0.155 –
4,10 100 1.5
der mounting pin and bushing –0.090 +0.119 0.291
Clearance between lift cylinder
–0.036 +0.207 0.156 –
5,11 mounting pin and mounting 90 1.5 Replace
–0.090 +0.120 0.297
bracket or beam bracket
Clearance between lift cylinder
–0.036 +0.207 0.156 –
6,12 mounting pin and shank bush- 90 1.5
–0.090 +0.120 0.297
ing
Clearance between shank
Shaft 75 +0.300 +0.300 1.400 –
13 mounting pin and shank 10.0
Hole 77 –0.300 –0.300 2.600
holder
Clearance between shank Shaft 75 +0.300 +1.000 3.700 –
14 15.0
mounting pin and shank hole Hole 80 –0.300 –1.000 6.300
Standard size Repair limit
15 Wear of point
335 225
16 Wear of protector 75 50
12 D155A-6
10 Structure, function and maintenance standard SEN02866-02
Unit: mm
D155A-6 13
SEN02866-02 10 Structure, function and maintenance standard
D155A-6 Bulldozer
Form No. SEN02866-02
© 2018 KOMATSU
All Rights Reserved
Printed in Japan 02-18 (01)
14 D155A-6
SEN02867-00
D155A-6
D155A-6 1
SEN02867-00 10 Structure, function and maintenance standard
1. Support Outline
2. Damper mount (front) q Viscous mounts are installed at two places at
3. Damper mount (rear) the front and two places at the rear to secure
4. ROPS pin (front) the floor frame and cab.
5. ROPS pin (rear) q An oil-filled damper mount is used to absorb
the vibration.
q The ROPS pins are installed to 2 places each
at the front and rear sections to fix the ROPS
(built in the cab) when the machine rolls over.
2 D155A-6
10 Structure, function and maintenance standard SEN02867-00
ROPS cab 1
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
5. ROPS sub (built in CAB)
D155A-6 3
SEN02867-00 10 Structure, function and maintenance standard
ROPS floor 1
Cab less spec.
1. ROPS floor
4 D155A-6
10 Structure, function and maintenance standard SEN02867-00
Air conditioner 1
Air conditioner piping
D155A-6 5
SEN02867-00 10 Structure, function and maintenance standard
D155A-6 Bulldozer
Form No. SEN02867-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (02)
6 D155A-6
SEN02868-02
D155A-6
D155A-6 1
SEN02868-02 10 Structure, function and maintenance standard
Engine control 1
2 D155A-6
10 Structure, function and maintenance standard SEN02868-02
D155A-6 3
SEN02868-02 10 Structure, function and maintenance standard
Deceleration potentiometer 1
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the inside of the dashboard and connected to
4. Potentiometer the decelerator pedal by linkage.
5. Cuppling q If the decelerator pedal is pressed, it rotates
6. Shaft the throttle potentiometer shaft through the
7. Stopper linkage and the potentiometer resistance
changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and a voltage sig-
nal is sent through pin (B) to the engine con-
troller according to the position of the
decelerator pedal.
4 D155A-6
10 Structure, function and maintenance standard SEN02868-02
D155A-6 5
SEN02868-02 10 Structure, function and maintenance standard
Monitor system 1
q The monitor system monitors the machine con- q The CPU (Central Processing Unit) in the mon-
dition with the sensors installed to various itor panel displays and outputs various infor-
parts of the machine and processes and dis- mation items processed by the power train
plays the obtained information on the panel controller. The display unit is LCD (Liquid Crys-
quickly to notify the operator of the machine tal Display)
condition.
The main display sections and functions of the
panel are as follows.
1) Monitor unit which turns on the alarm
when the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids,
6 D155A-6
10 Structure, function and maintenance standard SEN02868-02
Other items
Contents and conditions of processing Method Flow of signals
01 Monitoring
02 Trouble history
03 Maintenance history
04 Maintenance mode change
05 Telephone number set
06 Default
07 Adjustment
08 PM clinic
09 Reduced cylinders mode operation – –
10 No injection cranking
11 Fuel consumption display
12 —
13 Service message display
88 Screen adjustment a
89 —
a See testing and adjusting, special functions of machine monitor.
D155A-6 7
SEN02868-02 10 Structure, function and maintenance standard
Machine monitor
8 D155A-6
10 Structure, function and maintenance standard SEN02868-02
CN-CM02 CN-CM04
Input/ Input/
Pin No. Signal name output Pin No. Signal name output
1 NC(*) — 1 NC(*) —
2 NC(*) — 2 NC(*) —
3 Coolant level sensor Input 3 NC(*) —
4 NC(*) — 4 NC(*) —
5 NC(*) — 5 NC(*) —
6 NC(*) — 6 NC(*) —
7 Chassis signal GND — 7 NC(*) —
8 CAN terminating resistance — 8 NC(*) —
9 CAN_H Input/ 9 NC(*) —
Output
10 NC(*) —
10 CAN_L Input/
Output 11 NC(*) —
11 NC(*) — 12 NC(*) —
12 NC(*) — *: Never connect to NC or malfunctions or failures will
occur.
*: Never connect to NC or malfunctions or failures will
occur.
CN-CM05
Input/
Pin No. Signal name
output
1 Electric power supply for camera Output
2 Camera NTSC signal input 1 Input
3 Camera NTSC signal input 2 Input
4 Camera NTSC signal input 3 Input
5 Electric power supply GND for camera —
6 Camera signal GND1 —
7 Camera signal GND2 —
8 Camera signal GND3 —
D155A-6 9
SEN02868-02 10 Structure, function and maintenance standard
10 D155A-6
10 Structure, function and maintenance standard SEN02868-02
D155A-6 11
SEN02868-02 10 Structure, function and maintenance standard
Below 49.0kPa
Engine oil pressure
{0.5kg/cm2}
Above 105°C:
Symbol ON + buzzer Display when normal: OFF
When at highest level on Display when abnormal: ON
engine coolant Alarm buzzer sounds
temperature gauge
Torque converter oil tem-
Above 120°C:
perature
Symbol ON
Above 130°C:
Symbol ON + buzzer
Above 100°C:
Symbol ON
Hydraulic oil temperature
Above 110°C:
Symbol ON + buzzer
12 D155A-6
10 Structure, function and maintenance standard SEN02868-02
Display
Symbol Display item Display range Display method
category
Engine coolant
temperature
Service meter
From 0 to 99999 Actuated when the engine is rotating
(Hours meter)
D155A-6 13
SEN02868-02 10 Structure, function and maintenance standard
Gauge
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Temperature or vol-
Gauge Range ume Indicator Buzzer sound
A1 105 Red Q
A2 102 Red
Engine coolant A3 100 Off
temperature
(°C) A4 85 Off
A5 60 Off
A6 30 White
B1 130 Red Q
B2 120 Red
Power train oil B3 118 Off
temperature
(°C) B4 90 Off
B5 50 Off
B6 0 White
C1 110 Red Q
C2 100 Red
Hydraulic oil C3 98 Off
temperature
(°C) C4 70 Off
C5 20 Off
C6 0 White
D1 565 Off
D2 425 Off
D3 310 Off
Fuel level (l)
D4 220 Off
D5 150 Off
D6 75 Red
14 D155A-6
10 Structure, function and maintenance standard SEN02868-02
1. 0 km/h 3. 10 km/h 1. 0 V 4. 25 V
2. 5 km/h 4. 15 km/h 2. 17 V 5. 30 V
3. 20 V 6. 31 V
D155A-6 15
SEN02868-02 10 Structure, function and maintenance standard
Selects item on left side (Selects right end item after left
F3 Select item
end item).
Selects item on right side (Selects left end item after right
F4 Select item
end item).
16 D155A-6
10 Structure, function and maintenance standard SEN02868-02
D155A-6 17
SEN02868-02 10 Structure, function and maintenance standard
Maintenance function
q Pressing F5 on the normal screen switches to
the maintenance screen.
Replacement interval
No. Item
(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
F1 : Displays the next page. 41 Fuel pre filter 500
Displays the top page when the last page is 04 Hydraulic filter 2000
displayed.
06 Corrosion resistor 1000(*)
F2 : Displays the previous page.
07 Damper case oil 2000
Displays the last page when the top page is
08 Final drive case oil 1000
displayed.
10 Hydraulic oil 2000
F3 : Selects (highlights) an item one down.
19 P/L oil 1000
F4 : Selects (highlights) an item one up.
F5 : Returns to the normal screen. 20 P/L oil filter 500
F6 : Switches to the maintenance time reset screen. *: If equipped (To be determined)
P/L: Power train
No operation at least 30 sec. : Returns to the nor-
mal screen.
q The content of the caution display differs
according to the remaining time. The relation-
q If the remaining time on the maintenance table
ship is as shown in the table below.
screen is less than 30 hours, the relevant items
are highlighted in yellow, and if 0 hours, they Display Condition
are done in red. Remaining time for mainte-
q On the maintenance time reset screen, reset None nance for all items is more
the remaining time for the selected item to than 30 hours.
return to the default. There is one or more items
Notice display (black sym-
with less than 30-hour
bol displayed on yellow
remaining time for mainte-
background)
nance.
There is one or more items
Warning display (white
with less than 0-hour
symbol displayed on red
remaining time for mainte-
background)
nance.
18 D155A-6
10 Structure, function and maintenance standard SEN02868-02
D155A-6 19
SEN02868-02 10 Structure, function and maintenance standard
Standard display
q The normal screen is selected.
Load display
q The horizontal axis indicates the time and the
vertical axis indicates the traction force. The
operation should be carried out in the green q The following items can be selected.
range.
No. Selected item Remarks
q The graph on the screen is updated and
scrolled to the left at intervals of several sec- 1 Power train oil Temperature With caution
onds. 2 HYD oil temperature With caution
3 Vehicle Speed —
4 HYD Pressure —
5 ENG Oil Pressure With caution
6 Battery Voltage —
7 Engine Speed —
8 Traction Force —
9 Clock —
10 ENG coolant temperature For Utility Screen Select
11 Fuel For Utility Screen Select
20 D155A-6
10 Structure, function and maintenance standard SEN02868-02
1) Time setting
Set the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
D155A-6 21
SEN02868-02 10 Structure, function and maintenance standard
Language setting
q Selecting the Language from the user menu
screen and pressing F6 switches to the lan-
guage setting screen.
q From this menu, you can change the language
to be displayed on the monitor. Available lan-
guages are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, and
Turkish
22 D155A-6
10 Structure, function and maintenance standard SEN02868-02
q Press F6 to enter user mode and select “Mes- Fan reverse mode
sage display” and you can view (open) the q In this mode, the fan is driven in reverse to
messages. clean the radiator core.
q While the starting switch is OFF, select an item
with switch F3 or F4 and confirm that item with
switch F6.
q While screen (A) is displayed, press switch F6,
and the fan is ready to run in reverse.
q While screen (B) is displayed, start the engine.
D155A-6 23
SEN02868-02 10 Structure, function and maintenance standard
24 D155A-6
10 Structure, function and maintenance standard SEN02868-02
Sensors 1
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine coolant temperature Resistance — —
Torque converter oil temperature Resistance — —
Hydraulic oil temperature Resistance — —
Coolant level Contact ON OFF
Fuel level Resistance — —
Engine speed sensor Resistance — —
Bevel gear speed sensor Resistance — —
Pitch angle sensor Resistance — —
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
D155A-6 25
SEN02868-02 10 Structure, function and maintenance standard
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
1. Connector Function
2. Float q The fuel sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down
4. Body according go the fuel level. This movement of
5. Spring the float is transmitted by the arm and actuates
6. Contact a variable resistance. This sends a signal to
7. Spacer the monitor panel to indicate the remaining fuel
level.
26 D155A-6
10 Structure, function and maintenance standard SEN02868-02
1. Magnet 4. Boots
2. Terminal 5. Connector
3. Case
1. Body 3. Wire
2. Tube 4. Connector
D155A-6 27
SEN02868-02 10 Structure, function and maintenance standard
28 D155A-6
10 Structure, function and maintenance standard SEN02868-02
Display of screen
The gearshift mode is displayed in the gearshift
mode display section of the monitor panel as
shown below.
A: Auto gearshift mode
1. Gear speed used currently
2. Preset (gear speed at start) and maximum
gear speed during travel
3. Mark of AUTO (which indicates auto gear-
shift mode)
4. Mark of Dozing (which indicates auto
gearshift mode)
B: Manual gearshift mode
5. Gear speed used currently
6. Preset (gear speed at start)
7. Mark of Ripping (which indicates manual
gearshift mode)
D155A-6 29
SEN02868-02 10 Structure, function and maintenance standard
Setting preset with shift switches in neutral Changing gear speed with gearshift switches
q Set the preset (gear speed at start) and the during travel
maximum gear speed during travel (for only q The maximum gear speed during travel (in the
the auto gearshift mode) with the gearshift auto gearshift mode) or the gear speed used
switches in neutral. during travel (in the manual gearshift mode)
A: Auto gearshift mode can be changed with the gearshift switches
2. Setting preset (gear speed at start) and while the machine is traveling.
maximum gear speed during travel) A: Auto gearshift mode
2. Changing maximum speed during travel
During forward travel: The maximum gear
speed can be set to F1 – F3.
During reverse travel: The maximum gear
speed can be set to R1 – R3.
30 D155A-6
10 Structure, function and maintenance standard SEN02868-02
KOMTRAX system 1
D155A-6 31
SEN02868-02 10 Structure, function and maintenance standard
KOMTRAX terminal 1
TH300
Connector B
Input/
Pin No. Signal name
output
B-1 Serial signal DCD Output
B-2 Serial signal RXD Output
B-3 Serial signal TXD Input
B-4 Serial signal DTR Input
B-5 Serial signal SGND —
B-6 Serial signal DSR Output
B-7 NC(*1) —
B-8 NC(*1) —
B-9 NC(*1) —
B-10 NC(*1) —
*1: Never connect to NC or malfunctions or failures
will occur.
32 D155A-6
10 Structure, function and maintenance standard SEN02868-02
D155A-6 33
SEN02868-02 10 Structure, function and maintenance standard
D155A-6 Bulldozer
Form No. SEN02868-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (02)
34 D155A-6
SEN03199-01
D155A-6
D155A-6 1
SEN03199-01 20 Standard value table
Engine SAA6D140E-5
Oil temperature • Whole speed range (In oil pan) °C 90 – 110 120
2 D155A-6
20 Standard value table SEN03199-01
temperature: Within
operating range
Fan motor speed Max. speed rpm 1,100 (0/+50) 1,100 (0/+50)
• Fan: Set in 100%
mode
• Engine: High idle
No
mm 30 ± 5 30 ± 5
Forward/ Forward
Reverse travel No
PCCS lever
Stroke of control lever/pedal
mm 30 ± 5 30 ± 5
• Stop engine Reverse
• Center of lever grip
N o Left mm 40 ± 5 40 ± 5
Steering
N o Right mm 40 ± 5 40 ± 5
• Stop engine
Decelerator pedal mm 50 ± 10 50 ± 10
• Center of pedal
All stroke mm 79 ± 10 79 ± 10
• Engine: Low idle
Brake pedal
• Center of pedal Stroke to 0 of
mm 54 ± 4 54 ± 4
oil pressure
D155A-6 3
SEN03199-01 20 Standard value table
N o Raise mm 60 ± 10 72 ± 10
N o Lower mm 60 ± 10 72 ± 10
• Stop engine
Stroke of control lever/pedal
No
mm 53 ± 10 53 ± 10
Right tilt
N o Raise mm 77 ± 10 75 ± 10
N o Lower mm 77 ± 10 75 ± 10
• Stop engine
Ripper control lever
• Center of lever knob
N o In mm 79 ± 10 80 ± 10
N o Out mm 79 ± 10 80 ± 10
4 D155A-6
20 Standard value table SEN03199-01
clutch pressure ature: Within operating {kg/cm2} {28.7 – 31.7} {Min. 26.7}
(When operating range MPa 3.04 – 3.33 Min. 2.84
N1 o F1) High idle
• PCCS lever: Neutral {kg/cm2} {31.0 – 34.0} {Min. 29.0}
(Main relief pressure) MPa 2.55 – 2.94 Min. 2.35
Transmission 2nd Low idle
• Brake pedal: Press {kg/cm2} {26.0 – 30.0} {Min. 24.0}
clutch pressure
(Other than above)
(When operating MPa 2.70 – 3.09 Min. 2.50
N1 o F2) High idle
{kg/cm2} {27.5 – 31.5} {Min. 25.5}
Transmission 3rd MPa 2.81 – 3.11 Min. 2.62
Low idle
clutch pressure {kg/cm2} {28.7 – 31.7} {Min. 26.7}
(When operating MPa 3.04 – 3.33 Min. 2.84
F2 o F3) High idle
{kg/cm2} {31.0 – 34.0} {Min. 29.0}
Transmission lubri-
MPa 0.098 – 0.25 0.098 – 0.25
cating oil pressure High idle
{kg/cm2} {1.0 – 2.5} {1.0 – 2.5}
(Reference)
MPa 3.04 – 3.33 3.04 – 3.33
Low idle
Steering right brake {kg/cm2} {31.0 – 34.0} {31.0 – 34.0}
pressure • Power train oil MPa 3.04 – 3.33 3.04 – 3.33
temperature: Within High idle
{kg/cm2} {31.0 – 34.0} {31.0 – 34.0}
operating range
• PCCS lever: Neutral MPa 3.04 – 3.33 3.04 – 3.33
Low idle
Steering left brake • Brake pedal: Release {kg/cm2} {31.0 – 34.0} {31.0 – 34.0}
pressure MPa 3.04 – 3.33 3.04 – 3.33
High idle
{kg/cm2} {31.0 – 34.0} {31.0 – 34.0}
MPa 2.3 – 2.6 2.3 – 2.6
• Power train oil Low idle
Steering right {kg/cm2} {23.5 – 26.5} {23.5 – 26.5}
temperature: Within
clutch pressure operating range MPa 2.3 – 2.6 2.3 – 2.6
High idle
• Gear speed: N {kg/cm2} {23.5 – 26.5} {23.5 – 26.5}
• PCCS lever: Right MPa 2.3 – 2.6 2.3 – 2.6
stroke end Low idle
Steering left clutch {kg/cm2} {23.6 – 26.5} {23.6 – 26.5}
pressure • PCCS lever: Left
MPa 2.3 – 2.6 2.3 – 2.6
stroke end High idle
{kg/cm2} {23.6 – 26.5} {23.6 – 26.5}
D155A-6 5
SEN03199-01 20 Standard value table
operating range
• Power train oil F3L km/h 7.5 ± 0.4 7.5 ± 0.4
temperature: Within
operating range F3 km/h 11.6 ± 0.6 11.6 ± 0.6
Travel speed • Select manual
gearshift mode R1 km/h 4.6 ± 0.2 4.6 ± 0.2
• Engine: High idle
• Approach run: R2 km/h 6.8 ± 0.4 6.8 ± 0.4
10 – 30 m
• Measuring distance: R3L km/h 9.2 ± 0.5 9.2 ± 0.5
20 m
(Converted into km/h) R3 km/h 14.0 ± 0.7 14.0 ± 0.7
• Hydraulic oil tempera- MPa
Low idle — —
ture: Within operating {kg/cm2}
Unload pressure range
MPa 2.45 (+1.37/0) 2.45 (+1.37/0)
• All levers: High idle
Set in neutral {kg/cm2} {25 (+14/0)} {25 (+14/0)}
Blade lift relief MPa 27.5 ± 1.5 27.5 ± 1.5
pressure {kg/cm2} {280 ± 15} {280 ± 15}
Blade tilt relief MPa 27.5 ± 1.5 27.5 ± 1.5
Work equipment oil pressure
pressure • Hydraulic oil temperature: Within {kg/cm2} {280 ± 15} {280 ± 15}
operating range
Ripper lift relief MPa 27.5 ± 1.5 27.5 ± 1.5
• Engine: High idle
pressure {kg/cm2} {280 ± 15} {280 ± 15}
• Cylinder of measured circuit:
Ripper tilt relief Stroke end MPa 27.5 ± 1.5 27.5 ± 1.5
pressure {kg/cm2} {280 ± 15} {280 ± 15}
Work equipment LS MPa 25.0 ± 0.98 25.0 ± 0.98
relief pressure {kg/cm2} {255 ± 10} {255 ± 10}
• Hydraulic oil temperature: Within
Control circuit basic operating range MPa 3.97 (+0.49/0) 3.78 – 4.46
pressure • Engine: High idle {kg/cm2} {40.5 (+5/0)} {38.5 – 45.5}
• All levers: Set in neutral
• Hydraulic oil temperature: Within
Control valve PPC operating range
MPa 3.82 – 4.12 3.53
valve output • Engine: High idle
{kg/cm2} {39 – 42} {36}
pressure • Lever of measured circuit: Stroke
end
• Hydraulic oil tempera-
ture: Within operating
Work equipment speed
6 D155A-6
20 Standard value table SEN03199-01
D155A-6 7
SEN03199-01 20 Standard value table
Hydraulic drift
• Stop engine
of machine mm Max. 50/5 minutes 70/5 minutes
• Measure reduction of track shoe
tilted by blade
bottom height h in 5 minutes
• For measuring posture, see Fig. 7
• Hydraulic oil temperature: Within
operating range
Hydraulic drift
• Stop engine
of machine mm Max. 50/5 minutes 70/5 minutes
• Measure reduction of sprocket center
lifted by ripper
height h in 5 minutes
• For measuring posture, see Fig. 8
Leakage from cylinder
Blade lift
cc/min Max. 3.0 12
cylinder
• Hydraulic oil temperature: Within
operating range
Ripper lift
• Engine: High idle cc/min Max. 2.7 11
cylinder
• Measure leakage from relieved
cylinder in 1 minute
Ripper tilt
cc/min Max. 2.7 11
cylinder
8 D155A-6
20 Standard value table SEN03199-01
Fig. 3: Ripper lift speed Fig. 6: Hydraulic drift of machine lifted by blade
D155A-6 9
SEN03199-01 20 Standard value table
10 D155A-6
20 Standard value table SEN03199-01
D155A-6 11
SEN03199-01 20 Standard value table
D155A-6 Bulldozer
Form No. SEN03199-01
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
12 D155A-6
SEN03200-05
D155A-6
D155A-6 1
SEN03200-05 30 Testing and adjusting
2 D155A-6
30 Testing and adjusting SEN03200-05
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
– 101 – 200 kPa
Measuring intake air pres- 799-201-2202 Boost gauge kit 1
A {– 760 – 1,500 mmHg}
sure (boost pressure)
799-401-2220 Hose 1 Straight type quick coupler
Measuring exhaust
B 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
temperature
1 799-201-9001 Handy smoke checker 1
Measuring exhaust gas
C Commercially Bosch index: 0 – 9
color 2 Smoke meter 1
available
Commercially Air intake: 0.35 mm,
Adjusting valve clearance D Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 7.0 MPa {0 – 70 kg/cm2}
Measuring compression
E 795-471-1330 Adapter 1
pressure 2 For 140E-5 engine
6261-71-6150 Gasket 1
Measuring blow-by
F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil Pressure gauge: 60 MPa
G
pressure 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Pressure gauge: 1.0 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
Measuring fuel pressure H {600 kg/cm2}
Pressure gauge: 1.0 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
795T-471-2010 Adapter 1
3 8 × 1.25 mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ø5 mm × 2 – 3 m
available
Measuring fuel return rate Commercially
J 4 Hose 1 ø15 mm × 2 – 3 m
and fuel leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring fan speed K 799-205-1101 Tachometer kit 1 6.0 – 99999.9 rpm
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
D155A-6 3
SEN03200-05 30 Testing and adjusting
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
Measuring power train oil {25, 60, 400, 600 kg/cm2}
M
pressure
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Adjusting brake pedal N 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
4 D155A-6
30 Testing and adjusting SEN03200-05
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
Measuring internal leak-
Commercially
age of work equipment V Measuring cylinder 1
available
cylinder
Measuring coolant
temperature and oil — 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Ruler 1
hydraulic drift available
Measuring work equip- Commercially
— Stopwatch 1
ment speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
799-601-4101
or T-adapter assembly
799-601-4201
For DRC60 • ECONO*² (Max 60P)
799-601-4350 • T-box 1 (Does not include in assembly
No.799-601-4201)
For engine (CRI-T3) coolant temper-
ature sensor (PACKARD 2P)
For engine (CRI-T3) fuel temperature
795-799-5530 • Socket 1
sensor (PACKARD 2P)
For engine (CRI-T3) oil temperature
sensor (PACKARD 2P)
For engine (CRI-T3) boost tempera-
795-799-5540 • Socket 1
ture sensor (PACKARD 2P)
For engine (CRI-T3) ambient pres-
799-601-4240 • Socket 1
sure sensor (AMP 3P)
For engine (CRI-T3) boost pressure
799-601-4110 • Socket 1
sensor (SUMITOMO 3P)
For engine (CRI-T3) G (Bkup) sensor
799-601-4330 • Socket 1
(SUMITOMO 3P)
For engine (CRI-T3) supply pump
Engine related controller, 799-601-9430 • Socket 1 PCV1 • supply pump PCV sensor
sensor and actuator diag- — (SUMITOMO 3P)
nosis
For engine (CRI-T3) NE sensor
799-601-4130 • T-adapter 1
(FRAMATOME 3P)
For engine (CRI-T3) oil pressure sen-
799-601-4150 • T-adapter 1
sor (FRAMATOME 3P)
For engine (CRI-T3) common rail
799-601-9420 • T-adapter 1
pressure sensor (AMP 3P)
For engine controller (DRC26-50P)
799-601-4211 • T-adapter 1 (Does not include in assembly No.
799-601-4201)
For engine controller DRC26-60P
799-601-4220 • T-adapter 1 (Does not include in assembly No.
799-601-4201)
For engine controller (DTP-4P)
799-601-4260 • T-adapter 1 (Include in assembly No. 799-601-
9000 and 799-601-9100, too)
For DT 4P
799-601-9040 • T-adapter 1 (Include in assembly No. 799-601-
9000 and 799-601-9200, too)
For DT 2P
799-601-9020 • T-adapter 1 (Include in assembly No. 799-601-
9000 and 799-601-9200, too)
D155A-6 5
SEN03200-05 30 Testing and adjusting
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
799-601-9000
or
799-601-9100 T-adapter assembly
or
799-601-9300
799-601-9200 • T-box 1 For ECONO*¹ (Max 24P)
799-601-4101 T-adapter assembly
799-601-4350 • T-box 1 For DRC60 • ECONO*² (Max 60P)
799-601-7000
or
799-601-7100
or T-adapter assembly
799-601-7400
or
799-601-8000
For ECONO*³ (Max 21P)
799-601-2600 • T-box 1 (Does not include in assembly No.
799-601-7000.)
799-601-7210 • T-adapter 1 For AMP040 16P
799-601-7220 • T-adapter 1 For AMP040 20P
799-601-7110 • T-adapter 1 For M 3P
For SWP 6P (Does not include in
799-601-7050 • T-adapter 1
assembly No. 799-601-8000.)
799-601-7500 T-adapter assembly
799-601-7510 • T-adapter 1 For AMP070 10P
799-601-7520 • T-adapter 1 For AMP070 12P
Mashine related controller 799-601-7530 • T-adapter 1 For AMP070 14P
and sensors/wiring har- —
799-601-7540 • T-adapter 1 For AMP070 18P
nesses diagnosis
799-601-7550 • T-adapter 1 For AMP070 20P
799-601-9000
or T-adapter assembly
799-601-9200
For DT 4P
799-601-9040 • T-adapter 1 (Include in assembly No. 799-601-
4101 and 799-601-4201, too.)
799-601-9020 • T-adapter 1 For DT 2P
799-601-9030 • T-adapter 1 For DT 3P
799-601-9050 • T-adapter 1 For DT 6P
799-601-9060 • T-adapter 1 For DT 8P
799-601-9070 • T-adapter 1 For DT 8P
799-601-9110 • T-adapter 1 For DT 12P (Gray)
799-601-9120 • T-adapter 1 For DT 12P (Black)
799-601-9130 • T-adapter 1 For DT 12P (Green)
799-601-9140 • T-adapter 1 For DT 12P (Brown)
799-601-9280 • T-adapter 1 For HD36 24-24P
799-601-9290 • T-adapter 1 For HD36 24-31P
(Does not include in assembly
No.799-601-9200.)
(Include in assembly No. 799-601-
9100, too.)
799-601-9300 T-adapter assembly
799-601-9360 • T-adapter 1 For pump controller (DRC26-24P)
799-601-9350 • T-adapter 1 For pump controller (DRC26-40P)
6 D155A-6
30 Testing and adjusting SEN03200-05
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
1 791T-165-1020 Rod holding tool (cutting) 2
Select one of them, and do the pro-
W
2 791T-165-1030 Rod holding tool (sheet 2 cessing.
metal processing)
D155A-6 7
SEN03200-05 30 Testing and adjusting
H3 Adapter
S2 Elbow
8 D155A-6
30 Testing and adjusting SEN03200-05
Plate
G0124870
1225001400 SS400
PLATE
791T-165-1020
Plate
G0126871
1225001400 SPCCT
PLATE
791T-165-1030
D155A-6 9
SEN03200-05 30 Testing and adjusting
Collar
G0124578
----------------- STKM13A
COLLAR
791T-165-1040
10 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 11
SEN03200-05 30 Testing and adjusting
a The parking brake lever and work a The preset mode display section (at
equipment lock lever may be kept in the right bottom of the screen) can be
the LOCK position. set to [F3-R3] only while the Adjust-
ment function is selected.
6. Measuring torque converter stall speed 3) Set the work equipment lock lever in the
1) Start the engine and set the fuel control free position and operate the ripper control
dial in the low idle (MIN) position. lever to set the ripper lift cylinder to the
2) Operate the shiftup (UP) switch of the raise stroke end.
PCCS lever and set the preset mode dis- 4) While pressing the brake pedal securely,
play section to [F3-R3]. set the parking brake lever in the free
a The preset mode display section (at position and set the direction of PCCS
the right bottom of the screen) can be lever in the forward position.
set to [F3-R3] only while the Adjust- a Before going to the next step, check
ment function is selected. that [F3] is displayed in the gear
3) While pressing the brake pedal securely, speed display section (at the right
set the parking brake lever in the free bottom of the screen).
position and set the direction of PCCS a Keep the steering system in neutral.
lever in the forward position. 5) Press the decelerator pedal and set the
a Before going to the next step, check fuel control dial in the high idle (MAX)
that [F3] is displayed in the gear position.
speed display section (at the right 6) Return the decelerator pedal slowly to stall
bottom of the screen). the torque converter with the engine at
a Keep the steering system in neutral. high idle.
4) Press the decelerator pedal and set the k Keep pressing the brake pedal se-
fuel control dial in the high idle (MAX) curely and keep your right foot on the
position. decelerator pedal for safety until the
5) Return the decelerator pedal slowly to stall work is finished.
the torque converter with the engine at 7) Just after the power train oil temperature
high idle. gauge (T/C TEMPERATURE) indicates
k Keep pressing the brake pedal se- 118 – 120 °C, return the direction of PCCS
curely and keep your right foot on the lever to neutral.
decelerator pedal for safety until the a The top of the green range of the
work is finished. power train oil temperature gauge
6) Just after the power train oil temperature indicates about 118 – 120 °C.
gauge (T/C TEMPERATURE) indicates 8) Repeat above steps 4) – 7) 3 times.
118 – 120 °C, return the direction of PCCS 9) Perform steps 4) – 6) again, operate the
lever to neutral. ripper control lever to relieve the ripper
a The top of the green range of the raise system, and measure the engine
power train oil temperature gauge speed about 5 seconds after the power
indicates about 118 – 120 °C. train oil temperature gauge (T/C TEM-
7) Repeat above steps 3) – 6) 3 times. PERATURE) indicates 118 – 120 °C.
8) Perform steps 3) – 5) again and measure a Immediately after finishing measure-
the engine speed about 5 seconds after ment, return the direction of PCCS
the power train oil temperature gauge (T/C lever to neutral and lower the power
TEMPERATURE) indicates 118 – 120 °C. train oil temperature with the engine
a Immediately after finishing measure- at high idle.
ment, return the direction of PCCS
lever to neutral and lower the power
train oil temperature with the engine
at high idle.
12 D155A-6
30 Testing and adjusting SEN03200-05
Measuring intake air pressure 4. Run the engine at a medium or higher speed
(boost pressure) 1 and drain the oil from the test hose.
a Insert the connecting parts of the gauge
a Measuring instruments for intake air pressure and hose about a half and open the self-
(boost pressure) seal on the hose side repeatedly, and the
Symbol Part No. Part name oil will be drained.
a If Pm kit (A) is available, you may drain
799-201-2202 Boost gauge kit
A the oil by using the oil draining coupling
799-401-2220 Hose
(790-261-1130) in that kit.
k Stop the machine on level ground, lower a If oil is left in the hose, the gauge does not
the work equipment to the ground, stop the work. Accordingly, be sure to drain the oil.
engine, and set the parking brake lever and
5. Turn the starting switch ON and set the
work equipment lock lever in the lock posi-
machine monitor to Adjustment function of the
tion.
service mode.
k Be careful not to touch any hot part of the
q Adjustment code: 0530 (Stall mode)
engine when removing or installing the
a For the operating method, see Special
measuring tools.
functions of machine monitor (EMMS).
a Measure the intake air pressure (boost pres-
sure) under the following conditions.
q Engine coolant temperature: Within oper-
ating range
q Power train oil temperature: Within operat-
ing range
q Hydraulic oil temperature: Within operat-
ing range
1. Open the engine left side cover.
2. Remove intake air pressure pickup plug (1)
from the rear of the air intake connector.
D155A-6 13
SEN03200-05 30 Testing and adjusting
14 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 15
SEN03200-05 30 Testing and adjusting
2) Start the engine and set the fuel control 8) Under the condition of step 7), stop reliev-
dial in the low idle (MIN) position. ing the ripper raise system and lower the
3) Operate the shiftup (UP) switch of the exhaust temperature by only stalling the
PCCS lever and set the preset mode dis- torque converter (Condition (b) in the fig-
play section to [F3-R3]. ure).
a The preset mode display section (at a If the exhaust temperature does not
the right bottom of the screen) can be lower but rises, set the temperature
set to [F3-R3] only while the Adjust- high in step 7).
ment function is selected. 9) After the exhaust temperature is lowered
4) Set the work equipment lock lever in the and stabilized, measure the exhaust tem-
free position and operate the ripper control perature (Condition (c) in the figure).
lever to set the ripper lift cylinder to the
raise stroke end. k Just after the power train oil tem-
5) While pressing the brake pedal securely, perature (T/C TEMPERATURE)
set the parking brake lever in the free reaches about 120 °C, return the
position and set the direction of PCCS direction of PCCS lever to neutral
lever in the forward position. and lower the power train oil tem-
a Before going to the next step, check perature with the engine at high
that [F3] is displayed in the gear idle.
speed display section (at the right a The border between the green range
bottom of the screen). and red range of the power train oil
a Keep the steering system in neutral. temperature gauge indicates about
6) Press the decelerator pedal and set the 120 °C.
fuel control dial in the high idle (MAX)
position.
7) Return the decelerator pedal slowly to stall
the torque converter and relieve the ripper
raise system to raise the exhaust temper-
ature to about 650 °C (Condition (a) in the
figure) with the engine at high idle.
k Keep pressing the brake pedal
securely and keep your right foot
on the decelerator pedal for safety
until the work is finished.
16 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 17
SEN03200-05 30 Testing and adjusting
18 D155A-6
30 Testing and adjusting SEN03200-05
1. Remove the engine hood assembly and air 5. Install adapter E2 to the mounting hole on the
cleaner together. injector and connect compression gauge E1.
4 Engine hood assembly: 170 kg a Be sure to fit the gasket to the injector
end.
2. Remove cylinder head cover (1) of the cylinder a Fix the adapter with the injector holder.
to measure the compression pressure. 3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
D155A-6 19
SEN03200-05 30 Testing and adjusting
7. Set the engine in the no-injection cranking 2) Tighten bolt (13) and washer (14) tempo-
mode with the machine monitor. rarily.
a See Testing and adjusting (Part 3), "No- 2 Spherical part of washer:
injection cranking". Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
20 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 21
SEN03200-05 30 Testing and adjusting
Measuring engine oil pressure 1 4. Run the engine at low idle and high idle and
measure the engine oil pressure.
a Measuring instruments for engine oil pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
22 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 23
SEN03200-05 30 Testing and adjusting
Measuring fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Measuring instruments for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
H 2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm²}
795T-471-2010 Adapter
3
07005-00812 Gasket
24 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 25
SEN03200-05 30 Testing and adjusting
26 D155A-6
30 Testing and adjusting SEN03200-05
3) Run the engine at high idle and stall the 2) Lay test hose J4 so that it will not slacken
torque converter. After the engine speed and put its end in the oil pan.
is stabilized, measure the leakage in 1
minute with measuring cylinder J5.
a For the procedure for stalling the
torque converter, see Measuring
torque converter stall speed.
a You may measure the leakage for 20
seconds and judge by multiplying the
result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Leakage
Engine speed
(cc/min)
Torque converter
Max. 10
stall
D155A-6 27
SEN03200-05 30 Testing and adjusting
28 D155A-6
30 Testing and adjusting SEN03200-05
Bleeding air from fuel circuit 1 a The electric priming pump stops while the
lamp is blinking. This phenomenon is not
a Bleed air from the fuel circuit in the following abnormal, however.
cases according to this procedure. a If the switch is turned "OFF" position while
q When the fuel filter is replaced the lamp is blinking, the lamp goes off and
q When fuel is used up the electric priming pump stops.
k
q When the engine is started for the first While the electric priming pump is in
time after the fuel piping or supply pump is operation, pressure is applied to the
replaced fuel circuit. Do not loosen the air
a If the fuel filter was replaced, do not fill the bleeding plug at this time, since the
main filter and prefilter with the fuel. fuel may spout out.
D155A-6 29
SEN03200-05 30 Testing and adjusting
30 D155A-6
30 Testing and adjusting SEN03200-05
Measuring fuel circuit for leakage1 9. Check the fuel piping and devices for fuel leak-
age.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
a After testing the fuel system or removing and and inspect again from step 1.
installing its parts, test it for fuel leakage a If no fuel leakage is detected, inspection is
according to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
D155A-6 31
SEN03200-05 30 Testing and adjusting
Testing and adjusting alternator 6. Install belt cover (1) with the 2 mounting bolts.
belt tension 1 a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and V-
k Stop the machine on level ground, lower grooves, and contact of the belt covers
the work equipment to the ground, stop the and rotating parts.
engine, and set the parking brake lever and a If the belt is lengthened to the adjustment
work equipment lock lever in the lock posi- limit, cut, or cracked, replace it with new
tion. one.
a If the V-belt is replaced, adjust its tension
Testing again after 1 operating hour.
1. Open the engine right side cover and remove a After tightening the bolts, check that the
the inspection plate on the right of the radiator belt tension is normal according to the
guard. above procedure.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
32 D155A-6
30 Testing and adjusting SEN03200-05
Testing and adjusting air a After tightening the bolts, check that the
conditioner compressor belt belt tension is normal according to the
above procedure.
tension 1
k Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock posi-
tion.
Testing
1. Open the engine left side cover and left mud-
guard.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
D155A-6 33
SEN03200-05 30 Testing and adjusting
34 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 35
SEN03200-05 30 Testing and adjusting
36 D155A-6
30 Testing and adjusting SEN03200-05
7. While running the engine at high idle, measure Bleeding air from fan pump 1
the fan circuit oil pressure.
a If the fan pump is removed and installed or its
piping is disconnected and connected, bleed
air from the fan pump case according to the
following procedure.
a Before starting the following work, check that
the hydraulic oil level is normal.
D155A-6 37
SEN03200-05 30 Testing and adjusting
38 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 39
SEN03200-05 30 Testing and adjusting
40 D155A-6
30 Testing and adjusting SEN03200-05
D155A-6 41
SEN03200-05 30 Testing and adjusting
D155A-6 Bulldozer
Form No. SEN03200-05
© 2021 KOMATSU
All Rights Reserved
Printed in Japan 07-21 (01)
42 D155A-6
SEN03201-04
D155A-6
D155A-6 1
SEN03201-04 30 Testing and adjusting
2 D155A-6
30 Testing and adjusting SEN03201-04
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SEN03201-04 30 Testing and adjusting
1. Measuring transmission main relief pres- 2. Measuring right steering clutch pressure
sure (TM) (RC)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester M to oil pressure pickup plug (1). lic tester M to oil pressure measurement
a When using an analog oil pressure nipple (2).
gauge, use one of 6.0 MPa {60 kg/ a Use a 6.0 MPa {60 kg/cm²} oil pres-
cm²}. sure gauge.
2) Start the engine and set the PCCS lever in 2) Start the engine and set the parking lever
the fully neutral position. to the FREE position.
a The parking brake lever may be set in 3) Operate the PCCS lever steering fully to
the LOCK position. the right.
3) While running the engine at low idle and a Set the direction to the neutral posi-
high idle, measure the main relief pres- tion.
sure. 4) Measure the oil pressure with the engine
at low idle and high idle.
a Check that the oil pressure becomes
0 when the PCCS lever steering is
returned to neutral.
4 D155A-6
30 Testing and adjusting SEN03201-04
3. Measuring left steering clutch pressure (LC) 4. Measuring transmission forward clutch
1) Connect oil pressure gauge [1] of hydrau- pressure (F)
lic tester M to oil pressure measurement 1) Connect oil pressure gauge [1] of hydrau-
nipple (3). lic tester M to oil pressure pickup plug (4).
a Use a 6.0 MPa {60 kg/cm²} oil pres- a When using an analog oil pressure
sure gauge. gauge, use one of 6.0 MPa {60 kg/
cm²}.
D155A-6 5
SEN03201-04 30 Testing and adjusting
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D155A-6 7
SEN03201-04 30 Testing and adjusting
5) While running the engine at low idle, mea- 4) While pressing the brake pedal, set the
sure the 2nd clutch pressure. direction of PCCS lever in the forward
k Since the torque converter is position and shift up the gear to the 3rd
stalled, keep pressing the brake gear speed with the shiftup switch.
pedal securely and keep your right a Keep the steering system in neutral.
foot on the decelerator pedal for a Check that [F3] is displayed in the
safety until the work is finished. gear speed display section.
k Do not increase the engine speed 5) While running the engine at low idle, mea-
to high idle during measurement. sure the 3rd clutch pressure.
k Since the torque converter is
stalled, keep pressing the brake
pedal securely and keep your right
foot on the decelerator pedal for
safety until the work is finished.
k Do not increase the engine speed
to high idle during measurement.
8 D155A-6
30 Testing and adjusting SEN03201-04
9. Measuring steering right brake pressure 10. Measuring steering left brake pressure (LB)
(RB) 1) Connect oil pressure gauge [1] of hydrau-
1) Connect oil pressure gauge [1] of hydrau- lic tester M to oil pressure pickup plug
lic tester M to oil pressure pickup plug (9). (10).
a When using an analog oil pressure a When using an analog oil pressure
gauge, use one of 6.0 MPa {60 kg/ gauge, use one of 6.0 MPa {60 kg/
cm²}. cm²}.
2) Start the engine and set the parking brake 2) Start the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) While running the engine at low idle and 3) While running the engine at low idle and
high idle, measure the right brake pres- high idle, measure the left brake pressure.
sure. a During measurement, check that the
a During measurement, check that the oil pressure lowers to 0 when the
oil pressure lowers to 0 when the brake pedal is pressed or the parking
brake pedal is pressed or the parking brake lever is set in the LOCK posi-
brake lever is set in the LOCK posi- tion.
tion.
D155A-6 9
SEN03201-04 30 Testing and adjusting
11. Measuring torque converter inlet pressure 12. Measuring torque converter outlet pressure
1) Connect oil pressure gauge [1] of hydrau- 1) Connect hydraulic tester M to oil pressure
lic tester M to oil pressure measurement measurement nipple (12).
nipple (11). a Use a 2.5 MPa {25 kg/cm²} oil pres-
a Use a 2.5 MPa {25 kg/cm²} oil pres- sure gauge.
sure gauge.
10 D155A-6
30 Testing and adjusting SEN03201-04
k Stop the machine on level ground, lower 6. Start the engine, set the machine monitor to
the work equipment to the ground, stop the Monitoring function of the service mode, and
engine, and set the parking brake lever and check that the transmission speed is indicated
work equipment lock lever in the LOCK normally.
position. a Monitoring code: 31400 T/M Out Speed
a For the operating method, see Special
1. Remove the fuel tank and transmission output functions of machine monitor (EMMS).
shaft speed sensor (1). a To rotate the transmission output shaft,
4 Fuel tank: 950 kg (when full) drive the machine actually or run the track
idle.
a Before adjusting the transmission output
shaft speed sensor, remove it and check
that its tip is free from steel chips and
flaws, and then reinstall it.
D155A-6 11
SEN03201-04 30 Testing and adjusting
Simple test procedure for brake 6. Return the decelerator pedal slowly and check
performance 1 that the machine does not start when the
engine speed reaches the high idle speed.
k
k
Stop the machine on level ground, lower
Since the torque converter is stalled,
the work equipment to the ground, stop the
keep pressing the brake pedal securely
engine, and set the parking brake lever and
and keep your right foot on the deceler-
work equipment lock lever in the LOCK
ator pedal for safety until the work is
position.
finished.
a Carry out the simple performance test of the
brake under the following condition.
q Power train oil temperature:
Within operating range
12 D155A-6
30 Testing and adjusting SEN03201-04
D155A-6 13
SEN03201-04 30 Testing and adjusting
14 D155A-6
30 Testing and adjusting SEN03201-04
k Stop the machine on level ground, lower q Brake oil pressure (At high idle)
the work equipment to the ground, stop the
Parking brake lever Oil pressure
engine, and set the parking brake lever and
work equipment lock lever in the LOCK 2.75 ± 0.29 MPa
FREE position
position. {28.0 ± 3.0 kg/cm²}
a Tighten the locknut of the rod securely and LOCK position 0 MPa {0 kg/cm²}
bend the cotter pin securely.
a Remove the lever cover in the cab.
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SEN03201-04 30 Testing and adjusting
16 D155A-6
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D155A-6 17
SEN03201-04 30 Testing and adjusting
4) Start the engine and set the parking brake 2) Install volume pump [3] of pump assembly
lever in the FREE position. P2 to the outside of the operator's cab.
5) Operate switch assembly [1] and move
the machine to a safe place.
a The gear speed switch is so made
that the switch on the lower gear
speed will be operated first.
18 D155A-6
30 Testing and adjusting SEN03201-04
D155A-6 19
SEN03201-04 30 Testing and adjusting
20 D155A-6
30 Testing and adjusting SEN03201-04
Adjustment procedure
1] To grasp the adjustment quantity,
measure clearance (B) and let it be x.
Adjusting quantity: x – 2 mm
D155A-6 21
SEN03201-04 30 Testing and adjusting
Testing
1. Drive the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler 4. After finishing adjustment, return the removed
and front carrier roller and measure maximum parts.
clearance (a) between the bottom of the steel
bar and shoe grouser.
a For the above measurement, use an L-
shaped steel which will be deflected less.
q Standard max. clearance (a): 20 – 30 mm
Adjusting
a If the track shoe tension is abnormal, adjust it
according to the following procedure.
22 D155A-6
30 Testing and adjusting SEN03201-04
D155A-6 23
SEN03201-04 30 Testing and adjusting
2) Install nipples Q2 and connect them to oil 3. Measuring with machine monitor
pressure gauges [1] of hydraulic tester 1) Turn the starting switch ON and set the
Q1. machine monitor to Monitoring function of
a When using analog oil pressure the service mode.
gauges, use ones of 40 MPa {400 kg/ q Monitoring code:
cm²}. 70700 Hydraulic Pump Pressure 1
a For the operating method, see Spe-
cial functions of machine monitor
(EMMS).
24 D155A-6
30 Testing and adjusting SEN03201-04
D155A-6 25
SEN03201-04 30 Testing and adjusting
26 D155A-6
30 Testing and adjusting SEN03201-04
k Stop the machine on level ground, lower 4. Run the engine at high idle, set the work equip-
the work equipment to the ground, stop the ment lock lever in the LOCK position and
engine, and set the parking brake lever and FREE position, and measure the solenoid
work equipment lock lever in the LOCK valve output.
position. a If the output pressure is as follows, the
a Measure the work equipment lock solenoid operation of the work equipment lock sole-
valve output pressure under the following con- noid valve is normal.
dition.
Work equipment
q Hydraulic oil temperature: Within operat- Output pressure
lock lever
ing range
LOCK position 0 MPa {0 kg/cm²}
1. Remove the control valve cover. Same as control circuit
FREE position basic pressure (See stan-
4 Control valve cover: 25 kg dard value table)
D155A-6 27
SEN03201-04 30 Testing and adjusting
Measuring PPC valve output 5. Run the engine at high idle, operate the control
pressure 1 lever of the circuit to be measured, and mea-
sure the oil pressure.
a Measuring tools for PPC valve output pressure a Measure the oil pressure with the control
lever at the stroke end.
Symbol Part No. Part name
a Measure the oil pressure on the blade
799-101-5002 Hydraulic tester lowering side with the control lever at the
1
790-261-1204 Digital hydraulic tester float position.
799-401-3100 Adapter (02)
T 2
02896-11008 O-ring
799-401-3200 Adapter (03)
3
02896-11009 O-ring
28 D155A-6
30 Testing and adjusting SEN03201-04
D155A-6 29
SEN03201-04 30 Testing and adjusting
k Stop the machine on level ground, lower 1. Measuring play in directions of ports P3
the work equipment to the ground, stop the and P4
engine, and set the parking brake lever and Measure play (x) in the neutral position of the
work equipment lock lever in the lock posi- lever at 240 mm from the turn center of the
tions. lever.
a If the blade lever end play is large, adjust the (x): Max. 24 mm
PPC valve according to the following proce- a If the play is out of the above range, joint
dure. (1) may be worn. In this case, replace joint
a The ripper valve cannot be adjusted. (1).
30 D155A-6
30 Testing and adjusting SEN03201-04
3. Applying grease
1) Apply grease to the sliding part of joint (1)
and contact parts of disc (4) and piston
(5).
2 Grease (G2-LI)
2) Quantity of grease to be applied
1] Sliding part of joint (1):
7 – 10 ml/periphery
2] Contact parts of disc (4) and piston
(5) (4 places): 0.3 – 0.8 ml/place
D155A-6 31
SEN03201-04 30 Testing and adjusting
32 D155A-6
30 Testing and adjusting SEN03201-04
[Reference]
Reason why the lowering speed is increased when
the cylinder packing is the cause of the hydraulic
drift:
2) Blade tilt cylinder 1. If the machine is set in the above position
Extract the tilt cylinder to the stroke end (where the holding pressure is applied to the
and brace the blade to push up the left bottom side), the oil leaks from the bottom side
side of the machine body. to the head side. Since the volume on the
head side is less than that on the bottom side
by the volume of the rod, the pressure in the
head side is increased by the oil flowing in
from the bottom side.
2. As the pressure in the head side is increased,
it is balanced at a certain level (which depends
on the leakage), then the lowering speed is
lowered.
3. If the circuit on the head side is opened to the
drain circuit by the above operation of the lever
(the bottom side is closed by the check valve
at this time), the oil on the head side flows in
the drain circuit. As a result, the pressure is
3) Ripper lift cylinder unbalanced and the lowering speed is
Brace the ripper to push up the rear side increased.
of the machine body.
D155A-6 33
SEN03201-04 30 Testing and adjusting
34 D155A-6
30 Testing and adjusting SEN03201-04
1. Loosen hydraulic tank cap (1) gradually to 3. While running the engine at high idle, carry out
release the remaining pressure in the tank. the operation in step 2.
D155A-6 35
SEN03201-04 30 Testing and adjusting
k Stop the machine on level ground, lower a Monitoring code: 70300 Blade Sw Input
the work equipment to the ground, stop the a For the operating method, see Special
engine, and set the parking brake lever and functions of machine monitor (EMMS).
work equipment lock lever in the LOCK
position.
a Tighten the locknut of the rod securely and
bend the cotter pin securely.
a When adjusting the work equipment lock lever,
remove the control valve cover.
4 Control valve cover: 25 kg
36 D155A-6
30 Testing and adjusting SEN03201-04
Adjusting blade 1
D155A-6 37
SEN03201-04 30 Testing and adjusting
2) Adjust the shim of center section (2) (2 2. Adjusting blade tilt distance (Single tilt
places). specification)
a After reassembling the center section, 1) Adjust installed dimension (d) of brace (4)
supply grease to it. with the handle.
2 Center section: Grease (G2-LI)
Dimen-
blade Semi-U blade Full-U blade
Adjusted Adjusted Standard Standard shim sion
point clearance clearance thickness d 1,292 mm 1,372 mm 1,372 mm
2 b See note. 4 mm
2) Measure right and left tilt distances (e1)
a Adjust the shim so that the play of the and (e2).
ball in the axial direction will be less
Dimen-
than 1 mm and the ball can rotate blade Semi-U blade Full-U blade
sion
smoothly.
e1 565 mm 570 mm 583 mm
e2 565 mm 570 mm 583 mm
38 D155A-6
30 Testing and adjusting SEN03201-04
D155A-6 39
SEN03201-04 30 Testing and adjusting
1
C A 2 1
B B
4 3
C
A
2
A-A
4 3
B-B
C-C
G0124521
40 D155A-6
30 Testing and adjusting SEN03201-04
Testing play of blade electric lever 7. Tighten the nut (5) at the part (b) (width across
If there is too much play in the lever end, test the le- flats: 22mm).
ver as follows. a When the nut (5) is tightened, the torque
Test the play in the 1-2 direction and 3-4 direction as increases suddenly.
follows. a Make sure that there is no play on the
Test the play of the lever at neutral (x) while the le- lever at this time.
ver is 200 mm away from the rotation center. a If there is a play when the torque is
Play of lever at neutral (x): 3 mm or below increased, replace the universal joint. For
details, see “Replacing universal joint”.
Adjusting play of blade electric lever 8. Tighten the nut (5) by 60° (1/6 turn).
If there is too much play in the lever end, adjust the 9. Tighten the nut (3) by hand.
lever as follows.
1. Remove the exterior parts around the lever.
2. Lift the machine body boot around the lever.
3. Remove the clamp (1a), and remove the knob
switch connector (1b).
4. Remove the bolt (1c), and remove the knob
(1d).
a Fully clean the area around the lever with
detergent liquid.
5. Remove the boot (2).
D155A-6 41
SEN03201-04 30 Testing and adjusting
42 D155A-6
30 Testing and adjusting SEN03201-04
9. Rotate the disc (4) clockwise by 45°, rotate the 12. Put the crowfoot wrench (AA) on the part (c)
part (b) (width across flats: 22mm) of the nut (width across flats: 17mm) of the universal joint
(5) counterclockwise, and remove it. (1), and remove it.
a You can do the work easily with the deep k Set the machine in a stable posture
socket (Y) or crowfoot wrench (Z). before you tighten the universal joint
(1). The machine can fall over by the
reaction force when it is loosened.
a When the universal joint (1) is loosened,
the tool can hit the machine body. Protect
the area around it with clothes.
a Loctite is applied on the universal joint (1),
and large torque is required to loosen it.
a If the tool hits the rod (6), it can be dam-
aged. Be careful not to hit.
a If the tool is not engaged to the universal
joint (1) fully, the part (c) (width across
flats: 17mm) of the universal joint can be
10. Remove the 2 bolts (10), remove the grease deformed. Handle it carefully.
pocket (11), and clean it. a You can do the work easily with the crow-
a Be very careful not to let sand or dirt foot wrench (AA).
attach. a You can apply the torque to loosen it eas-
ily with the universal joint bending preven-
tion tool (X). It also prevents the damage
to the rod (6).
D155A-6 43
SEN03201-04 30 Testing and adjusting
44 D155A-6
30 Testing and adjusting SEN03201-04
20. Apply grease (G2-LI) of 0.3 ml to 0.8 ml on 23. Tighten the nut (5) at the part (b) (width across
the part (g) of the rod (6) and disc (4). flats: 22mm), and loosen the nut (5) by 60° (1/6
21. Apply grease (G2-LI) of 0.1 ml to 0.3 ml on turn).
the part (h) of the disc (4) and plate (9). 24. Tighten the nut (3) by hand.
a When you tighten it by hand, be careful
not to let the disc (4) rotate together.
D155A-6 45
SEN03201-04 30 Testing and adjusting
26. Tighten the nut (3). q ADJUSTMENT MENU “Blade Tilt Lever
3 Nut (3): 68.6 to 88.2 Nm {7 to 9 kgfm} LH Pos Adjust”
a Put the wrench (AB) at the part (k) (width q ADJUSTMENT MENU “Blade Tilt Lever
across flats: 60mm) of the disc (4), and fix RH Pos Adjust”
the disc (4) not to rotate together when
you tighten it.
a After you tighten the nut (3), make sure
that the identification mark (i) on the upper
surface of the disc aligns with the shaft of
the stopper (j) on the plate (9).
46 D155A-6
30 Testing and adjusting SEN03201-04
D155A-6 47
SEN03201-04 30 Testing and adjusting
4) Check around the dashboard carefully for 4) Loosen the mounting bolts of damper rub-
water leakage. ber (6).
a If water leaks, caulk the leaking part a You can remove and install the shims
and check again. without removing the mounting bolts.
5) Increase or decrease shims (7) under
damper rubber (6) to adjust the height of
damper rubber (6) properly.
48 D155A-6
30 Testing and adjusting SEN03201-04
5) Open and close door (5) and check that it 2) Check that striker (10) is not leaning
is locked and unlocked smoothly. against or from center (g) of latch (11).
a If the door is not locked or unlocked 3) Check that striker (10) is aligned with cen-
smoothly (the operating effort of the ter (h) of latch (11).
knob is large), repeat adjustment q Normal: Quantity of misalignment is
from the first. 0.5 mm or less.
a Operating effort of door knob:
49 ± 19.6 N {5 ± 2 kg}
6) Apply grease to latch (8).
a If the latch dries up, the operating
e ff o r t o f t h e k n o b i s i n c r e a s e d .
Accordingly, apply sufficient grease to
the latch.
2 Latch: Grease (G2-LI)
D155A-6 49
SEN03201-04 30 Testing and adjusting
50 D155A-6
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D155A-6 51
SEN03201-04 30 Testing and adjusting
D155A-6 Bulldozer
Form No. SEN03201-04
© 2021 KOMATSU
All Rights Reserved
Printed in Japan 07-21 (01)
52 D155A-6
SEN03202-04
D155A-6
D155A-6 1
SEN03202-04 30 Testing and adjusting
2 D155A-6
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D155A-6 3
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Display of screen to input password Display of warning after check before starting
After the KOMATSU logo is displayed, the screen If any abnormality is detected by the check before
to input the engine start lock password is displayed. starting, the warning monitor is displayed on the
a This screen is displayed only when the engine screen.
start lock function is set effective. a The following figure shows that the radiator
a If the password is input normally, the screen coolant level monitor (a) is warning of low radi-
changes to "Display of check before starting". ator coolant level.
a The machine monitor has some password
functions other than the engine start lock.
Those functions are independent from one
another.
6 D155A-6
30 Testing and adjusting SEN03202-04
D155A-6 7
SEN03202-04 30 Testing and adjusting
a Heater specification
8 D155A-6
30 Testing and adjusting SEN03202-04
Operation to display camera mode (if camera is Operation to display clock and service meter
installed) While the ordinary screen is displayed, press [F4],
When a camera is installed, if [F3] is pressed, the and section (a) changes to the service meter and
multi-display changes to the camera image. clock alternately.
a Set the connection of the camera in the service a When the clock is selected, adjust the time, set
mode. 12-hour or 24-hour display, and set the sum-
mer time with the user mode function.
a Display of service meter
D155A-6 9
SEN03202-04 30 Testing and adjusting
a To reset the time left after finishing mainte- a There are following items in the user menu.
nance, more operations are necessary.
Utility Screen Select
Multi Gage Select
Screen Adjustment
Clock Adjustment
Language
Message display
Hydraulic fan reversing
[KOMTRAX message]
q There are 2 types of KOMTRAX message; one
is for the user and the other is for the service.
q For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the ordinary
screen. To see the contents of the message,
operate "Message display" in the above user
menu.
10 D155A-6
30 Testing and adjusting SEN03202-04
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SEN03202-04 30 Testing and adjusting
a Remedies given by displayed action codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
Action
Method of indicating trouble Examples of trouble Remedy given to operator to take
code
• Although all or a part of automatic
function stops, machine can be
• Action code and failure code are • Backup alarm does not sound.
E01 operated.
displayed. • Fan speed is kept at maximum.
• Ask your Komatsu distributor for
repair.
• If operator stops and restarts
• Gear is not shifted up or down. engine, machine can be operated
• Action code and failure code are • Engine boost pressure is abnor- without limiting any function.
E02 displayed. mal. Operator must take care, how-
• Alarm buzzer sounds. • Exhaust gas color is bad when ever.
temperature is low. • Ask your Komatsu distributor for
repair.
• Engine coolant temperature sen-
sor is abnormal.
• Action code and failure code are
• Usable gear speeds are limited.
displayed. • Move machine to safe place.
• Engine speed does not rise to
E03 • Telephone No. is displayed (if • Ask your Komatsu distributor for
maximum.
set). repair.
• Gearshift shock is increased.
• Alarm buzzer sounds.
• Steering performance lowers.
• Braking shock is increased.
• Action code and failure code are
displayed. • Engine cannot be controlled. • Stop machine immediately.
E04 • Telephone No. is displayed (if • Machine cannot travel. • Ask your Komatsu distributor for
set). • Machine stops. repair.
• Alarm buzzer sounds.
12 D155A-6
30 Testing and adjusting SEN03202-04
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SEN03202-04 30 Testing and adjusting
14 D155A-6
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SEN03202-04 30 Testing and adjusting
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select "01 Monitoring" on the "Service Menu"
screen.
16 D155A-6
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18 D155A-6
30 Testing and adjusting SEN03202-04
SDNO
ON • OFF P/T
(Gear shift down sw)
PNC
40905 T/M Sw Input 1 ON • OFF P/T
(Parking brake lever sw)
PNO
ON • OFF P/T
(Parking brake lever sw)
F (F clutch fill sw) ON • OFF P/T
R (R clutch fill sw) ON • OFF P/T
T/M Fill Sw
40906 1st (1st clutch fill sw) ON • OFF P/T
Input 1
2nd (2nd clutch fill sw) ON • OFF P/T
3rd (3rd clutch fill sw) ON • OFF P/T
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20 D155A-6
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SEN03202-04 30 Testing and adjusting
E03 15SEL1 Speed 1st clutch: Fill high P/T Electrical system
E03 15SELH Speed 1st clutch: Fill Low P/T Electrical system
E03 15SFL1 Speed 2nd clutch: Fill high P/T Electrical system
E03 15SFLH Speed 2nd clutch: Fill Low P/T Electrical system
E03 15SGL1 Speed 3rd clutch: Fill high P/T Electrical system
E03 15SGLH Speed 3rd clutch: Fill Low P/T Electrical system
E04 2201L1 Right clutch: See the list P/T Electrical system
E04 2201LH Right clutch: See the list P/T Electrical system
E04 2202L1 Left clutch: See the list P/T Electrical system
E04 2202LH Left clutch: See the list P/T Electrical system
E04 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E03 CA122 Chg (boost) Air Press Sensor High Error ENG Electrical system
E03 CA123 Chg (boost) Air Press Sensor Low Error ENG Electrical system
E02 CA135 Eng Oil Press Sensor High Error ENG Electrical system
E02 CA141 Eng Oil Press Sensor Low Error ENG Electrical system
24 D155A-6
30 Testing and adjusting SEN03202-04
E02 CA144 Coolant Temp Sens High Error ENG Electrical system
E02 CA145 Coolant Temp Sens Low Error ENG Electrical system
E01 CA153 Chg (boost) Air Temp Sensor High Error ENG Electrical system
E01 CA154 Chg (boost) Air Temp Sensor Low Error ENG Electrical system
E03 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E03 CA221 Ambient Press Sens High Error ENG Electrical system
E03 CA222 Ambient Press Sens Low Error ENG Electrical system
E03 CA227 Sens Supply 2 Volt High Error ENG Electrical system
E03 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E01 CA263 Fuel Temp Sensor High Error ENG Electrical system
E01 CA265 Fuel Temp Sensor Low Error ENG Electrical system
E03 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E03 CA386 Sens Supply 1 Volt High Error ENG Electrical system
E03 CA449 Rail Press Very High Error ENG Electrical system
E03 CA451 Rail Press Sensor High Error ENG Electrical system
E03 CA452 Rail Press Sensor Low Error ENG Electrical system
E03 CA554 Rail Press Sensor In Range Error ENG Electrical system
E03 CA731 Eng Bkup Speed Sens Phase Error ENG Electrical system
E04 CA757 All Continuous Data Lost Error ENG Electrical system
D155A-6 25
SEN03202-04 30 Testing and adjusting
E03 CA778 Eng Bkup Speed Sensor Error ENG Electrical system
E03 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E03 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E03 CA2249 Rail Press Very Low Error ENG Electrical system
E01 CA2555 Grid Htr Relay Volt Low Error ENG Electrical system
E01 CA2256 Grid Htr Relay Volt High Error ENG Electrical system
E01 D161KB Back-up alarm relay: Short circuit P/T Electrical system
E03 D5ZKKX Throttle Dial: Out of normal range P/T Electrical system
E02 DD13KB Shift down Sw: Short circuit P/T Electrical system
E03 DD14KB Parking lever Sw: Short circuit P/T Electrical system
E02 DDDDKB Back up brake Sw: Short circuit P/T Electrical system
E02 DDDDKX Back up brake Sw: Signal mismatch P/T Electrical system
E01 DGT1KA T/C oil temp sensor: Abnormal P/T Electrical system
E01 DGT1KX T/C oil temp sensor abnormal P/T Electrical system
26 D155A-6
30 Testing and adjusting SEN03202-04
E03 DK10KX Fuel control Dial: Out of normal range P/T Electrical system
E03 DKH1KB Pitch angle sensor: Short circuit P/T Electrical system
E01 DW7BKB Fan rev EPC: Short circuit P/T Electrical system
E01 DWN5KB Fan pump solenoid: Short circuit P/T Electrical system
E03 DXH4KB 1st clutch ECMV: Short circuit P/T Electrical system
E03 DXH4KY 1st clutch ECMV: Short circuit P/T Electrical system
E03 DXH5KB 2nd clutch ECMV: Short circuit P/T Electrical system
E03 DXH5KY 2nd clutch ECMV: Short circuit P/T Electrical system
E03 DXH6KB 3rd clutch ECMV: Short circuit P/T Electrical system
E03 DXH6KY 3rd clutch ECMV: Short circuit P/T Electrical system
D155A-6 27
SEN03202-04 30 Testing and adjusting
E03 DXH9KB Right clutch ECMV: Short circuit P/T Electrical system
E04 DXH9KY Right clutch ECMV: Hot short P/T Electrical system
E03 DXHAKB Left clutch ECMV: Short circuit P/T Electrical system
E04 DXHAKY Left clutch ECMV: Hot short P/T Electrical system
E04 DXHBKB Right brake ECMV: Short circuit P/T Electrical system
E04 DXHBKY Right brake ECMV: Short circuit P/T Electrical system
E04 DXHCKB Left brake ECMV: Short circuit P/T Electrical system
E04 DXHCKY Left brake ECMV: Short circuit P/T Electrical system
E03 DXJ4KB Weq lock Sol.: Short circuit P/T Electrical system
28 D155A-6
30 Testing and adjusting SEN03202-04
D155A-6 29
SEN03202-04 30 Testing and adjusting
30 D155A-6
30 Testing and adjusting SEN03202-04
D155A-6 31
SEN03202-04 30 Testing and adjusting
q Default: Maintenance interval set in machine a If this operation is executed, the set val-
monitor (Recommended by manufacturer ues of all the maintenance items are set to
and not changeable). default values.
q Set: Maintenance interval which can be q [F5]: Return to Maintenance Mode Change
set freely. Maintenance functions in oper- screen
ator mode operate on basis of this set time q [F6]: Execute default setting
(which is increased or decreased by 50 a A while after [F6] is pressed, the default
hours). setting completion screen is displayed.
q ON: Maintenance function of this item is Then, if the "Maintenance Mode Change"
set effective in operator mode. screen is displayed, default setting is com-
q OFF: Maintenance function of this item is pleted.
set ineffective in operator mode. a The default setting of the corrosion resis-
q [F3]: Select Reduce set value (Upper) or tor is "OFF".
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to Maintenance Mode
Change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower
lines is confirmed with [F6] and the screen
changes to the Maintenance Mode
Change screen with [F5], the setting is
effective.
32 D155A-6
30 Testing and adjusting SEN03202-04
1. Selecting menu
Select "05 Phone Number Entry" on the "Ser-
vice Menu" screen.
D155A-6 33
SEN03202-04 30 Testing and adjusting
34 D155A-6
30 Testing and adjusting SEN03202-04
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.
3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set with the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to default
screen
q [F6]: Confirm selection and return to default
screen
a When the machine is delivered, the SI unit
system is set.
D155A-6 35
SEN03202-04 30 Testing and adjusting
Default setting (Setting of maintenance pass- q [F6]: Confirm selection and return to default
word) screen
Check or change various settings related to the
machine monitor and machine by default setting.
The function of setting maintenance password is
used to set the display of the password screen
when the functions related to the maintenance are
used in the operator mode.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.
3. Selecting Enable/Disable
After the "Maintenance Password" screen is
displayed, select the setting with the function
switches.
q Disable: Password screen is not displayed
q Enable: Password screen is displayed
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Initial-
ization screen
36 D155A-6
30 Testing and adjusting SEN03202-04
D155A-6 37
SEN03202-04 30 Testing and adjusting
Default setting (Setting of ECO display) a If ECO display is turned ON, ECO is dis-
Check or change various settings related to the played when the screen changes to the
machine monitor and machine by initialization. ordinary screen.
The ECO display setting function is used to set the
display of the ECO gauge.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.
38 D155A-6
30 Testing and adjusting SEN03202-04
Adjustment
The operator can adjust various items related to the
machine with the machine monitor.
When using an adjustment item, select it according
to the following procedure.
1. Selecting menu
Select "07 Adjustment" on the "Service Menu"
screen.
D155A-6 39
SEN03202-04 30 Testing and adjusting
40 D155A-6
30 Testing and adjusting SEN03202-04
Adjustment ID: 0002 (Power train controller initial- Adjustment ID: 0005 (Brake pedal potentiometer
ization) initial correction)
q This adjustment code is used to initialize the q This adjustment code is used to make the
specification code recognized by the power power train controller recognize the zero point
train controller and the set values of the mem- of the brake pedal potentiometer.
ory in the controller. a After the power train controller or brake pedal
a After the power train controller is replaced, be potentiometer is replaced or the brake pedal
sure to carry out this adjustment once. linkage is disconnected and connected, be
sure to carry out this adjustment once.
q Functions of function switches
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]: Unused
[F5]: Return to adjustment item selecting [F4]: Unused
screen (ID inputting screen) [F5]: Return to adjustment item selecting
[F6]: Save setting screen (ID inputting screen)
[F6]: Save corrected value
q Operating method:
1) Press [F6] and check that the alarm q Operating method:
buzzer sounds. 1) Check that the brake pedal is in the neu-
2) Check that the displayed specification tral position (it is not pressed at all) and
code [CODE] has changed from [5x5] to keep it in that position.
[999]. 2) Press [F6] and check that the alarm buzz-
a If specification code [999] is not displayed, er sounds.
the controller wiring harness or the con- a Even if the adjustment is carried out, the
troller unit may be defective. displayed value does not change.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the setting is effective. the correction is effective.
a This adjustment code is used to make the
controller recognize the zero point of the
potentiometer. It is not used to adjust the
braking force.
D155A-6 41
SEN03202-04 30 Testing and adjusting
Adjustment ID: 0007 Adjustment ID: 0009 (Pitch angle sensor initial cor-
(Engine decelerator cutting) rection)
q This adjustment code is used to stop the auto- q This adjustment code is used to make the
deceleration function of the engine and check power train controller recognize the zero point
the high idle speed of the engine unit. of the pitch angle sensor and to correct the
a The engine can be driven and tested with the installation error.
auto-deceleration reset only while this adjust- a After the power train controller is replaced or
ment code is selected. the pitch angle sensor is removed and installed
a Use this adjustment code for testing, adjusting, or replaced, be sure to carry out this adjust-
or troubleshooting when necessary. ment once.
42 D155A-6
30 Testing and adjusting SEN03202-04
q This adjustment code is used to set the cooling q This adjustment code is used to set the fan
fan speed to about 70% forcibly. speed in the 100% mode automatically and
a Use this adjustment code for testing, adjusting, make it possible to set the preset (gear speed
or troubleshooting when necessary. at start) to [F3-R3] to stall the torque converter.
a The preset (gear speed at start) can be
q Functions of function switches set to [F3-R3] only while this adjustment
[F3]: Increase adjustment value [FAN 70% code is selected.
SPEED MODE] a Use this adjustment code for testing,
[F4]: Decrease adjustment value [FAN 70% adjusting, or troubleshooting when neces-
SPEED MODE] sary.
[F5]: Return to adjustment item selecting
screen (ID inputting screen) q Functions of function switches
[F6]: Unused [F3]: Unused
[F4]: Unused
q Operating method: [F5]: Return to adjustment item selecting
When this adjustment code is displayed, its screen (ID inputting screen)
function is effective and the cooling fan speed [F6]: Unused
is controlled to about 70% of the maximum
speed. q Mode setting information within screen
a After this adjustment code is turned OFF, [P-AUTO SFT MODE]:
its function is ineffective. Automatic gearshift in P mode
[E-AUTO SFT MODE]:
Automatic gearshift in E mode
[P-MANUAL SFT MODE]:
Manual gearshift in P mode
[E-MANUAL SFT MODE]:
Manual gearshift in E mode
q Operating method:
When this adjustment code is displayed, its
function is effective and the preset (gear speed
at start) is set to [F3-R3].
k This adjustment code does not stall the
t o r q u e c o n v e r t e r a u t o m a t i c a l l y.
Accordingly, operate the levers and
pedals securely when stalling the
torque converter (For the procedure for
stalling the torque converter, see Mea-
suring engine speed).
a After this adjustment code is turned OFF,
its function is ineffective.
D155A-6 43
SEN03202-04 30 Testing and adjusting
Adjustment ID: 0910 (Load record check mode) Adjustment ID: 1005 (Fan 100% mode)
q This adjustment code is used to check the load q This adjustment code is used to set the cooling
on the machine, odometer, and reverse odom- fan speed to about 100% forcibly. It is also
eter. used to set the adjustment value of the maxi-
a Use this adjustment code for testing, adjusting, mum speed.
or troubleshooting when necessary. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
q Functions of function switches
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]: Increase adjustment value [FAN 100%
[F5]: Return to adjustment item selecting SPEED MODE]
screen (ID inputting screen) [F4]: Decrease adjustment value [FAN 100%
[F6]: Unused SPEED MODE]
[F5]: Return to adjustment item selecting
q Mode setting information within screen screen (ID inputting screen)
[1000 rpm SMR]: Time displayed by service [F6]: Save adjustment value
meter in which engine speed
was above 1,000 rpm q Operating method:
[ODO METER FORWARD]: a When this adjustment code is displayed,
Total forward travel distance its function is effective and the cooling fan
[ODO METER REVERSE]: speed is controlled to about 100% of the
Total reverse travel distance maximum speed.
1) Increase or decrease the adjustment
q Operating method: value by pressing [F3] or [F4].
When this adjustment code is displayed, its 2) When confirming the adjustment value,
function is effective and the load on the press [F6] and check that the alarm
machine, odometer, and reverse odometer are buzzer sounds.
displayed simultaneously. a After this adjustment code is turned OFF,
a The data cannot be reset. its function is ineffective but the set adjust-
a After this adjustment code is turned OFF, ment value is effective.
its function is ineffective.
44 D155A-6
30 Testing and adjusting SEN03202-04
Adjustment ID: 1012 (Steering lever neutral posi- Adjustment ID: 1013 (Steering lever leftmost posi-
tion adjustment) tion adjustment)
q This adjustment code is used to make the q This adjustment code is used to make the
power train controller recognize the neutral power train controller recognize the leftmost
position of the steering potentiometer of the position of the steering potentiometer of the
PCCS lever. PCCS lever.
a After the power train controller or PCCS lever a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- is replaced, be sure to carry out this adjust-
ment once. ment once.
D155A-6 45
SEN03202-04 30 Testing and adjusting
Adjustment ID: 1014 (Steering lever rightmost posi- Adjustment ID: 1015 (Right brake oil pressure off-
tion adjustment) set)
q This adjustment code is used to make the q This adjustment code is used to adjust the right
power train controller recognize the rightmost brake oil pressure manually.
position of the steering potentiometer of the a Use this adjustment code for work when nec-
PCCS lever. essary.
a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- q Functions of function switches
ment once. [F3]: Increase adjustment value
[F4]: Decrease adjustment value
q Functions of function switches [F5]: Return to adjustment item selecting
[F3]: Unused screen (ID inputting screen)
[F4]: Unused [F6]: Save adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen) q Information displayed on screen
[F6]: Save adjustment value The offset oil pressure is displayed and the
adjustment value is increased or decreased by
q Operating method: 0.1 kg/cm² (The value displayed on the screen
1) Operate the PCCS lever to the right stroke is multiplied by 100).
end of the steering direction and keep it in a The default adjustment value is 0 kg/cm².
that position. a The adjustment range is -3 – 3 kg/cm².
2) Press [F6] and check that the alarm
buzzer sounds. q Operating method:
a Even if the adjustment is carried out, the 1) Increase or decrease the adjustment val-
displayed value does not change. ue by pressing [F3] or [F4].
a Even if this adjustment code is turned off, 2) Press [F6] and check that the alarm buzz-
the adjustment is effective. er sounds.
a This adjustment code is used to make the a If the oil pressure has been adjusted, it is
controller recognize the rightmost position displayed. It can be adjusted again within
of the potentiometer. It is not used to the adjustment range, however.
adjust the steering force. a It is not necessary to operate the brake
during adjustment. After finishing adjust-
ment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
a Even if this adjustment code is turned off,
the adjustment is effective.
46 D155A-6
30 Testing and adjusting SEN03202-04
Adjustment ID: 1016 Adjustment ID: 2021 (Power train controller voltage
(Left brake oil pressure offset) check mode)
q This adjustment code is used to adjust the left q This adjustment code is used to check the con-
brake oil pressure manually. stant power supply voltage and switch power
a Use this adjustment code for work when nec- supply voltage applied to the power train con-
essary. troller.
a Use this adjustment code for testing, adjusting,
q Functions of function switches or troubleshooting when necessary.
[F3]: Increase adjustment value
[F4]: Decrease adjustment value q Functions of function switches
[F5]: Return to adjustment item selecting [F3]: Unused
screen (ID inputting screen) [F4]: Unused
[F6]: Save adjustment value [F5]: Return to adjustment item selecting
screen (ID inputting screen)
q Information displayed on screen [F6]: Unused
The offset oil pressure is displayed and the
adjustment value is increased or decreased by q Information displayed on screen
0.1 kg/cm² (The value displayed on the screen [PT CONTROLLER UNSWITCH POWER]:
is multiplied by 100). Constant power supply voltage
a The default adjustment value is 0 kg/cm². [PT CONTROLLER ACC POWER]:
a The adjustment range is -3 – 3 kg/cm². Switch power supply voltage
D155A-6 47
SEN03202-04 30 Testing and adjusting
Adjustment ID: 6001 (R1 reverse slow set speed) Adjustment ID: 6002 (R2 reverse slow set speed)
q This adjustment code is used to adjust the q This adjustment code is used to adjust the
engine speed applied to travel at gear speed engine speed applied to travel at gear speed
R1 with the reverse slow mode ON. R2 with the reverse slow mode ON.
a Use this adjustment code for work when nec- a Use this adjustment code for work when nec-
essary. essary.
48 D155A-6
30 Testing and adjusting SEN03202-04
Adjustment ID: 6003 (R3 reverse slow set speed) Adjustment ID: 7842 (Transmission clutch IP auto-
matic initial correction)
D155A-6 49
SEN03202-04 30 Testing and adjusting
Adjustment ID: 7843 (Transmission clutch IP man- Adjustment ID: 7845 (Transmission clutch IP learn-
ual initial correction) ing display)
q This adjustment code is used to carry out cor- q This adjustment code is used to check the
rection manually when the correction is not information of correction made by the opera-
carried out normally by the operation of IP tion of IP automatic correction (Adjustment ID:
automatic correction (Adjustment ID: 7842). 7842) or IP manual correction (Adjustment ID:
a Use this adjustment code after the IP correc- 7843).
tion work, if necessary. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
q Functions of function switches
[F3]: Increase adjustment value q Functions of function switches
[F4]: Decrease adjustment value [F3]: Change display
[F5]: Return to adjustment item selecting [F4]: Change display
screen (ID inputting screen) [F5]: Return to adjustment item selecting
[F6]: Save adjustment value screen (ID inputting screen)
a If [F2] is pressed while [F1] is pressed, all [F6]: Unused
the correction values are set to 0.
q Operating method
q Functions of shift-up and shift-down switches When this adjustment code is displayed, its
You can select a clutch to be corrected manu- function is effective and the correction informa-
ally with the shift-up and shift-down switches. tion is displayed.
a After this adjustment code is turned OFF,
q Conditions for correction work its function is ineffective.
Same as the conditions for IP automatic cor-
rection (Adjustment ID: 7842).
q Operating method:
1) Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2) Select a clutch to be corrected manually
with the shift-up or shift-down switches.
3) Increase or decrease the adjustment
value by pressing [F3] or [F4].
4) Press [F6] and check that the alarm
buzzer sounds.
a The machine does not move during the
correction work.
a Even if this adjustment code is turned off,
the correction is effective.
50 D155A-6
30 Testing and adjusting SEN03202-04
Adjustment ID: 9995 Adjustment ID: 9996 (Sudden stop prevent valve
(Control brake release mode) operation mode)
q This adjustment code is used to release the q This adjustment code is used to stop the sud-
control brake (right and left brake ECMV) to den stop prevent solenoid valve and right and
check the operation of the backup brake left brake ECMV to check the operation of the
(brake pedal solenoid valve). sudden stop prevent valve.
a Use this adjustment code for testing, adjusting, a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary. or troubleshooting when necessary.
D155A-6 51
SEN03202-04 30 Testing and adjusting
Adjustment ID: 9997 Adjustment ID: 9998 (Max. gear speed setting mode)
(High idle cut mode)
52 D155A-6
30 Testing and adjusting SEN03202-04
1. Selecting menu
Select "08 PM CLINIC" on the Service menu
screen.
D155A-6 53
SEN03202-04 30 Testing and adjusting
54 D155A-6
30 Testing and adjusting SEN03202-04
D155A-6 55
SEN03202-04 30 Testing and adjusting
2. Starting measurement
After the screen of "Fuel Consumption" is dis-
played, start measurement with the function
switches. 4. Finishing measurement
q [F1]: Start Press [F1], and measurement is finished and
q [F2]: Clear the data are displayed on the finishing date
q [F5]: Return to Service menu screen and time side.
a When the screen of "Fuel Consumption" is
displayed, if a data is indicated, it is the 5. Displaying fuel consumption
data of the previous measurement. This If the measurement is finished, the hourly fuel
data is not an obstacle to new measure- consumption calculated from the fuel con-
ment and can be deleted by pressing [F2]. sumption calculated by the engine controller
a If [F1] is pressed, the data is displayed on and the elapsed time are displayed.
the starting date and time side and mea-
surement starts.
a The display unit of the fuel changes
according to the unit set with the initializa-
tion (unit setting) function.
SI and meter: l/h,
inch: gal/h
56 D155A-6
30 Testing and adjusting SEN03202-04
Display of KOMTRAX Settings (Terminal Status) q [F5]: Return to KOMTRAX Settings screen
The setting condition and operating condition of
KOMTRAX can be checked with "KOMTRAX Set-
tings".
Terminal Status is used to check the setting condi-
tion of the KOMTRAX terminal.
1. Selecting menu
Select "12 KOMTRAX Settings" on the "Ser-
vice Menu" screen.
D155A-6 57
SEN03202-04 30 Testing and adjusting
Display of KOMTRAX Settings (GPS & Commu- 3. Contents of display of condition of positioning
nication Status) and communication
The setting condition and operating condition of On the screen of "GPS & Communication Sta-
KOMTRAX can be checked with KOMTRAX Set- tus", the following items are displayed.
tings. q Positioning: Positioning condition of GPS
Condition of positioning and communication is used q Communication: Communication environ-
to check the condition of positioning and communi- ment of communication MODEM and con-
cation of the KOMTRAX terminal. necting condi tion of c ommunication
MODEM
1. Selecting menu q Number of message not yet sent: Number
Select "12 KOMTRAX Settings" on the "Ser- of mails in machine monitor not yet sent
vice Menu" screen. q [F5]: Return to KOMTRAX Settings screen
58 D155A-6
30 Testing and adjusting SEN03202-04
1. Selecting menu
Select "12 KOMTRAX Settings" on the "Ser-
vice Menu" screen.
D155A-6 59
SEN03202-04 30 Testing and adjusting
60 D155A-6
30 Testing and adjusting SEN03202-04
D155A-6 61
SEN03202-04 30 Testing and adjusting
D155A-6 Bulldozer
Form No. SEN03202-04
© 2018 KOMATSU
All Rights Reserved
Printed in Japan 02-18 (01)
62 D155A-6
SEN03203-00
D155A-6
D155A-6 1
SEN03203-00 30 Testing and adjusting
2 D155A-6
30 Testing and adjusting SEN03203-00
1. Machine monitor
1) Remove the 4 mounting bolts each from
covers (1) and (2) and remove those cov-
ers.
2) Remove the 4 mounting bolts each from
covers (3) and (4) and remove those cov-
ers together with the foot rest.
a The 2 bolts on the front window side of the
3) Insert or connect troubleshooting T-adapt-
foot rest are used as the cover mounting
ers in or to connectors EGC1, EGC2, and
bolts, too.
EGC3 of engine controller (7).
3) Remove the 4 mounting bolts of machine
a Since connectors EGC1 and EGC2
monitor (5) and pull out machine monitor
are fixed with screws, loosen those
(5) and switch cover together toward the
screws before disconnecting.
operator's seat.
a When returning connectors EGC1
and EGC2, tighten the screws to the
specified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
D155A-6 3
SEN03203-00 30 Testing and adjusting
4 D155A-6
30 Testing and adjusting SEN03203-00
Pm Clinic 1
Machine model Serial No. Service meter
D155A-6 h
/ /
Specifications
Blade Rear attachment Shoe width
T blade T Multi-shank ripper T 560 mm T
T Semi-U blade T Variable giant ripper T 610 mm
T Full-U blade T Counterweight ( kg) T 660 mm
T T T 710 mm
Working condition
Quarry/Mining Construction Type of soil (Specific gravity: ) Contents of work
T Coal T Construction/Civil engineering T Rock T Dozing %
T Gold T Road T Gravel T Side cutting %
T Limestone T Tunnel T Sand T Ripping %
T T T Clay T Travel %
Check of oil and coolant levels
T Engine coolant level When necessary
T Engine oil level T Damper case oil level T Final drive oil level
T Hydraulic oil level T Power train oil level T
Engine coolant temperature Power train oil temperature Ambient temperature Altitude
Max. range: Max. range: Max. °C/Min. °C m
Following figure (Left) Following figure (Right)
Operator's opinion Result of visual inspection
D155A-6 5
SEN03203-00 30 Testing and adjusting
Check positions/Method 1
6 D155A-6
30 Testing and adjusting SEN03203-00
Check positions/Method 2
D155A-6 7
SEN03203-00 30 Testing and adjusting
Check positions/Method 3
8 D155A-6
30 Testing and adjusting SEN03203-00
Machine model Serial No. Service meter User's name Date of execution Inspector
D155A-6
1. Engine
Accepted
Standard
Rejected
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Low idling 740 – 780 740 – 780
Without deceleration
2,050 – 2,100 2,050 – 2,100
High (Adjustment: 0007)
Engine speed idle Normal (Deceleration) rpm 1,825 – 1,925 1,825 – 1,925
Decelerator pedal 850 – 900 850 – 900
F3 stall 1,615 – 1,715 1,450
F3 stall + Ripper raise relieve 1,580 – 1,680 1,395
Boost kPa Min. 85 72
Engine
F3 stall
pressure {mmHg} {Min. 640} {540}
Exhaust Ambient temperature — — — —
°C
temperature F3 stall 670 720
Blow-by pres- kPa Max. 2.94 3.92
F3 stall
sure {mmH2O} {Max. 300} {400}
Min. 034 0.21
High idle
Engine oil MPa {Min. 3.5} {2.1}
pressure {kg/cm²} Min. 010 0.08
Low idle
{Min. 1.0} {0.8}
2. Cooling fan
Accepted
Standard
Rejected
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Low idle — — — —
Speed Adjust- rpm
Fan
D155A-6 9
SEN03203-00 30 Testing and adjusting
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Monitoring: 32601
pressure Max. 1.0 Max. 1.0
High idle
MPa {Max. 10.0} {Max. 10.0}
{kg/cm²} 0.05 – 0.29 0.05 – 0.29
Low idle
Outlet {0.5 – 3.0} {0.5 – 3.0}
Monitoring: 32603
pressure 0.29 – 0.69 0.29 – 0.69
High idle
{3.0 – 7.0} {3.0 – 7.0}
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Standard
Service limit Measure- Rejected
Item Measurement condition Unit value for new
value ment result
machine
Low idle
Left brake Gear speed: N {25.0 – 31.0} {22.0}
pressure Brake: Released 2.46 – 3.04 2.16
High idle
{25.0 – 31.0} {22.0}
Brake MPa
F2 stall, high idle Machine must not move.
performance {kg/cm²}
2.3 – 2.6 2.3 – 2.6
Gear speed: N Low idle
Right clutch {23.5 – 26.5} {23.5 – 26.5}
PCCS lever: Right
pressure 2.3 – 2.6 2.3 – 2.6
stroke end High idle
{23.5 – 26.5} {23.5 – 26.5}
Clutch
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30 Testing and adjusting SEN03203-00
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Work equipment
Work equipment/HSS oil pressure
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
sec
Ripper lower High idle 2.5 – 3.5 4.0
Ripper tilt in High idle 4.5 – 5.5 6.2
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Hydraulic oil
°C — — — —
temperature
Hydraulic
7. Final drive
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
D155A-6 11
SEN03203-00 30 Testing and adjusting
Date Service meter Repair record Date Service meter Repair record
/ / h / / h
/ / h / / h
/ / h / / h
/ / h / / h
/ / h / / h
12 D155A-6
30 Testing and adjusting SEN03203-00
Machine model Serial No. Service meter User's name Date of execution Inspector
D155A-6
1. Bushing temperature
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SEN03203-00 30 Testing and adjusting
Accepted
Rejected
Clearance Measure-
Item Measurement condition Unit Pin No.
limit ment result
Opening of Measure
mm
track link dimension (a).
14 D155A-6
30 Testing and adjusting SEN03203-00
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SEN03203-00 30 Testing and adjusting
D155A-6 Bulldozer
Form No. SEN03203-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (02)
16 D155A-6
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D155A-6
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 8
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SEN03204-05 40 Troubleshooting
Fuse locations 1
Connection table of circuit breakers and fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
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Locations of circuit breakers CB30, CB105, and CB105H (In battery room)
Locations of circuit breakers CB1 – CB9 and fuse boxes FS1 and FS2 (In battery room)
10 D155A-6
40 Troubleshooting SEN03204-05
Fuse box
Power circuit fuse Fuel
Fuse No. Destination of power
(Type of power supply) capacity
FS1-1 Radio
(Unswitched power 1 10A 12V accessory connector (Via DC converter)
supply) 12V accessory socket (Via DC converter)
Additional light relay, additional light
FS1-3 2 20A
Rotary lamp
(Accessory power
supply) 12V accessory connector (Via DC converter)
3 20A
12V accessory socket (Via DC converter)
Radio
Room lamp
FS1-4 4 20A
Cigarette lighter
(Accessory power
supply) Windshield wiper (Via intermittent relay)
5 10A Front wiper, rear wiper
6 10A Left wiper, right wiper
D155A-6 11
SEN03204-05 40 Troubleshooting
D155A-6 Bulldozer
Form No. SEN03204-05
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 08-19 (01)
12 D155A-6
SEN03205-05
D155A-6
40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Check before troubleshooting ......................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Information in troubleshooting table ................................................................................................................ 8
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table ................................................................................................... 46
D155A-6 1
SEN03205-05 40 Troubleshooting
1. When carrying out troubleshooting, do not 4) Check the stroke of the control valve
hurry to disassemble the components. spool.
If components are disassembled immediately 5) Other maintenance items can be checked
any failure occurs: externally, so check any item that is con-
q Parts that have no connection with the fail- sidered to be necessary.
ure or other unnecessary parts will be dis-
4. Confirming failure
assembled.
q Confirm the extent of the failure yourself,
q It will become impossible to find the cause
and judge whether to handle it as a real
of the failure.
failure or as a problem with the method of
It will also cause a waste of manhours, parts,
operation, etc.
or oil or grease, and at the same time, will also
a When operating the machine to reen-
lose the confidence of the user or operator.
act the troubleshooting symptoms, do
For this reason, when carrying out trouble-
not carry out any investigation or
shooting, it is necessary to carry out thorough
measurement that may make the
prior investigation and to carry out trouble-
problem worse.
shooting in accordance with the fixed proce-
dure. 5. Troubleshooting
q Use the results of the investigation and
2. Points to ask user or operator
inspection in Items 2 – 4 to narrow down
1) Have any other problems occurred apart
the causes of failure, then use the trouble-
from the problem that has been reported?
shooting flowchart to locate the position of
2) Was there anything strange about the
the failure exactly.
machine before the failure occurred?
a The basic procedure for troubleshoot-
3) Did the failure occur suddenly, or were
ing is as follows.
there problems with the machine condition
1) Start from the simple points.
before this?
2) Start from the most likely points.
4) Under what conditions did the failure
3) Investigate other related parts or
occur?
information.
5) Had any repairs been carried out before
the failure? 6. Measures to remove root cause of failure
When were these repairs carried out? q Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the
before? same failure will occur again.
To prevent this, always investigate why
3. Check before troubleshooting
the problem occurred. Then, remove the
1) Check the oil level
root cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
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40 Troubleshooting SEN03205-05
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40 Troubleshooting SEN03205-05
1. Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in fault his-
tory:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" accord-
ing to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".
3. When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D155A-6 5
SEN03205-05 40 Troubleshooting
Troubleshooting
No. Phenomena looking like troubles Display
E mode H mode S mode
of code
Phenomena related to action code/failure code
1 Action code and failure code are displayed on machine monitor
Accord-
When fault history is checked, failure code is displayed in mechanical
2 ing to dis-
system fault history
played
When fault history is checked, failure code is displayed in electrical code
3
system fault history
When fault history is checked, failure code is displayed in air conditioner
4
or heater fault history
Phenomena related to engine
5 Starting performance of engine is poor S-1
6 Engine does not start E-3 S-2
7 Engine does not pick up smoothly S-3
8 Engine stops during operation S-4
9 Engine does not rotate smoothly S-5
10 Engine lack output (or lacks power) S-6
11 Exhaust gas is black (incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust gas is blue) S-8
13 Oil becomes dirty quickly S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant or fuel) S-13
18 Coolant temperature becomes too high (Overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Air cannot be bled from fuel circuit S-17
22 Preheater does not operate E-4
Phenomena related to power train
23 Power is low (Drawbar pull is low) H-1
24 Machine does not travel (at 2nd or 3rd gear speed) H-2
25 Machine does not start at any gear speed H-3
26 Machine can travel only forward or in reverse H-4
27 When gear speed or travel direction is changed, time lag is large H-5
28 Steering is not possible H-6
29 Steering is possible only on one side H-7
30 Steering overrun occurs H-8
31 Brake does not work H-9
32 Power train oil is overheated H-10
Phenomena related to work equipment
33 Speed of all work equipment is low H-11
34 No work equipment moves H-12
35 Blade lift speed or power is low H-13
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40 Troubleshooting SEN03205-05
Troubleshooting
No. Phenomena looking like troubles Display
E mode H mode S mode
of code
36 Blade tilt speed or power is low H-14
37 Ripper lift speed or power is low H-15
38 Ripper tilt speed or power is low H-16
39 Hydraulic drift of blade lift is large H-17
40 Hydraulic drift of blade tilt is large H-18
41 Hydraulic drift of ripper lift is large H-19
42 Ripper pin puller cylinder does not operate E-22 H-20
43 Abnormal sound comes out from around work equipment pump H-21
Fan speed is abnormal (Sound and/or vibration are abnormally large or
44 H-22
engine over heats)
Phenomena related to machine monitor
45 When starting switch turned ON, machine monitor displays nothing E-1
When starting switch turned ON (before startingengine), basic check
46 E-2
item lights up
47 Precaution item lights up while engine is running E-5
48 Emergency stop item lights up while engine is running E-6
49 Engine coolant temperature gauge does not indicate normally E-7
50 Fuel level gauge does not indicate normally E-8
Power train oil temperature gauge (multi-gauge) does not indicate
51 E-9
normally
52 Hydraulic temperature gauge (multi-gauge) does not indicate normally E-10
Contents of display by machine monitor are different from applicable
53 E-11
machine
54 Machine monitor does not display some items E-12
55 Function switch does not work E-13
56 Operation mode does not change E-14
57 Gearshift mode does not change E-15
58 Customize function does not operate normally E-16
59 Customize memory function does not normally E-17
60 Alarm buzzer cannot be stopped E-18
Air conditioner does not operate normally (including air conditioner fault
61 E-19
history)
62 When starting switch is turned OFF, service meter is not displayed E-20
63 Machine monitor cannot be set in service mode E-21
64 Ripper pin puller cylinder does not operate E-22
65 Backup alarm does not sound or does not stop E-23
66 Headlamp, rear lamp, and ripper point lamp do not light up E-24
67 Windshield wiper and window washer do not operate E-25
68 Fan does not reverse E-27
69 Gear cannot be shifted E-28
Other phenomena
70 KOMTRAX terminal does not operate normally E-26
71 Electric priming pump does not operate or does not stop automatically E-29
D155A-6 7
SEN03205-05 40 Troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
1 • Remarks on judgment
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40 Troubleshooting SEN03205-05
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SEN03205-05 40 Troubleshooting
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
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D155A-6 45
SEN03205-05 40 Troubleshooting
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
46 D155A-6
40 Troubleshooting SEN03205-05
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
D155A-6 47
SEN03205-05 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
795-799-5470 Cable for engine (HPI-T2) 3 — q
795-799-5480 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
48 D155A-6
40 Troubleshooting SEN03205-05
D155A-6 49
SEN03205-05 40 Troubleshooting
D155A-6 Bulldozer
Form No. SEN03205-05
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 08-20 (01)
50 D155A-6
SEN03206-05
D155A-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 1
Failure code [1500L0] ..................................................................................................................................... 3
Failure code [15SAL1] .................................................................................................................................... 4
Failure code [15SALH].................................................................................................................................... 6
Failure code [15SBL1] .................................................................................................................................... 8
Failure code [15SBLH].................................................................................................................................. 10
Failure code [15SEL1] .................................................................................................................................. 12
Failure code [15SELH].................................................................................................................................. 14
Failure code [15SFL1]................................................................................................................................... 16
Failure code [15SFLH] .................................................................................................................................. 18
Failure code [15SGL1] .................................................................................................................................. 20
Failure code [15SGLH] ................................................................................................................................. 22
Failure code [2201L1] ................................................................................................................................... 24
Failure code [2201LH]................................................................................................................................... 26
Failure code [2202L1] ................................................................................................................................... 28
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68 D155A-6
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70 D155A-6
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D155A-6 71
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72 D155A-6
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D155A-6 73
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74 D155A-6
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D155A-6 75
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76 D155A-6
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78 D155A-6
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SEN03206-05 40 Troubleshooting
D155A-6 Bulldozer
Form No. SEN03206-05
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 08-20 (01)
80 D155A-6
SEN03207-05
D155A-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 2
Failure code [CA234] ...................................................................................................................................... 3
Failure code [CA238] ...................................................................................................................................... 4
Failure code [CA263] ...................................................................................................................................... 6
Failure code [CA265] ...................................................................................................................................... 8
Failure code [CA271] ...................................................................................................................................... 9
Failure code [CA272] .....................................................................................................................................11
Failure code [CA273] .................................................................................................................................... 13
Failure code [CA274] .................................................................................................................................... 15
Failure code [CA322] .................................................................................................................................... 17
Failure code [CA323] .................................................................................................................................... 19
Failure code [CA324] .................................................................................................................................... 21
Failure code [CA325] .................................................................................................................................... 23
Failure code [CA331] .................................................................................................................................... 25
Failure code [CA332] .................................................................................................................................... 27
D155A-6 1
SEN03207-05 40 Troubleshooting
2 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 3
SEN03207-05 40 Troubleshooting
Ne speed Disconnect
1 If the engine Ne speed
sensor devices at right in
sensor is damaged or
order. If "E" of fail-
connected defectively,
ure code disap- Engine Ne speed
NE connector NO • Re-install or replace
pears when a sensor
the Ne speed sensor.
device is discon-
• Proceed to "Confirma-
nected, that device
tion of repair".
has trouble in it.
• No open circuit occurs
a Prepare with starting switch OFF, then carry out trouble-
in the wiring harness.
shooting without turning starting switch ON. YES
• Proceed to the next
Does the troubleshooting result match the judgment criteria?
check item.
Open circuit
Wiring harness between ENG (female) Resis- • An open circuit occurs
2 in wiring har- Max. 1 z
ness (16) – NE (female) (1) tance in the wiring harness.
• Repair or replace the
NO
Wiring harness between ENG (female) Resis- wiring harness.
Max. 1 z • Proceed to "Confirma-
(48) – NE (female) (2) tance
tion of repair".
• No ground fault occurs
a Prepare with starting switch OFF, then carry out trouble-
in the wiring harness.
shooting without turning starting switch ON. YES
• Proceed to the next
Does the troubleshooting result match the judgment criteria?
check item.
Ground fault
Wiring harness between ENG (female) • Ground fault occurs in
3 in wiring har- Resis-
(16) – NE (female) (1) and chassis Min. 1 Mz the wiring harness.
ness tance
ground • Repair or replace the
NO
Wiring harness between ENG (female) wiring harness.
Resis- • Proceed to "Confirma-
(48) – NE (female) (2) and chassis Min. 1 Mz
tance tion of repair".
ground
• No short circuit occurs
a Prepare with starting switch OFF, then carry out trouble-
in the wiring harness.
shooting without turning starting switch ON. YES
• Proceed to the next
Does the troubleshooting result match the judgment criteria?
check item.
Short circuit in
4 wiring har- • A short circuit occurs
ness in the wiring harness.
Wiring harness between ENG (female)
Resis- • Repair or replace the
(16) – NE (female) (1) and between Min. 1 Mz NO
tance wiring harness.
ENG (female) (48) – NE (female) (2)
• Proceed to "Confirma-
tion of repair".
4 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 5
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6 D155A-6
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D155A-6 7
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8 D155A-6
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D155A-6 9
SEN03207-05 40 Troubleshooting
10 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 11
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12 D155A-6
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D155A-6 13
SEN03207-05 40 Troubleshooting
14 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 15
SEN03207-05 40 Troubleshooting
16 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 17
SEN03207-05 40 Troubleshooting
18 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 19
SEN03207-05 40 Troubleshooting
20 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 21
SEN03207-05 40 Troubleshooting
22 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 23
SEN03207-05 40 Troubleshooting
24 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 25
SEN03207-05 40 Troubleshooting
26 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 27
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28 D155A-6
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D155A-6 29
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30 D155A-6
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D155A-6 31
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32 D155A-6
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D155A-6 33
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34 D155A-6
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D155A-6 35
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36 D155A-6
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D155A-6 37
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38 D155A-6
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40 D155A-6
40 Troubleshooting SEN03207-05
Check fuel used (for high viscosity). • The fuel is not appropri-
2 Fuel used ate.
Is the fuel appropriate?
• Replace the fuel with the
NO
appropriate type.
• Proceed to "Confirma-
tion of repair".
• The state of the electri-
cal system of common
rail pressure sensor is
YES
normal.
Electrical sys- • Proceed to the next
Common rail pressure sensor may have electric trouble.
tem of com- check item.
Carry out troubleshooting for failure code [CA451].
3 mon rail
Is the electrical system of common rail pressure sensor nor- • The electrical system of
pressure sen-
mal? common rail pressure
sor
sensor is defective.
NO
• Repair the defective part.
• Proceed to "Confirma-
tion of repair".
• The state of the mechani-
cal system of common
rail pressure sensor is
YES
normal.
Mechanical • Proceed to the next
system of Check mechanical system of common rail pressure sensor. check item.
4 common rail Is the mechanical system of common rail pressure sensor
pressure sen- normal? • The mechanical system
sor of common rail pressure
sensor is defective.
NO
• Repair the defective part.
• Proceed to "Confirma-
tion of repair".
D155A-6 41
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42 D155A-6
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D155A-6 43
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44 D155A-6
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D155A-6 45
SEN03207-05 40 Troubleshooting
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
46 D155A-6
40 Troubleshooting SEN03207-05
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q Fuel filter: Replace. (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it. (See Fig. 2.)
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
Fig. 2
D155A-6 47
SEN03207-05 40 Troubleshooting
B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value Measured
Code Displayed item Checking condition ISO unit Good NG
(Reference value) value
Low idle r/min 715 – 765
01002 Engine speed High idle r/min 1,825 – 1,925
Torque converter stall r/min 1,560 – 1,660
Final accelerator Low idle % 0
31706
position High idle % 100
Final fuel injection
18600 rate command Torque converter stall mg/st — — —
(by weight)
4 Final common rail
36200 Torque converter stall MPa — — —
pressure command
Common rail pres-
36400 Torque converter stall MPa — — —
sure
Low idle CA — — —
Final injection tim-
36300 High idle CA — — —
ing command
Torque converter stall CA — — —
Chg (boost) pres-
36500 Torque converter stall kPa — — —
sure
Engine coolant tem-
04107 Low idle °C — — —
perature
14200 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value Measured
Setting Reduced cylinder Checking condition ISO unit Good NG
(Reference value) value
No. 1 cylinder r/min — — —
5 No. 2 cylinder r/min — — —
Reduce No. 3 cylinder r/min — — —
each
cylinder No. 4 cylinder r/min — — —
No. 5 cylinder r/min — — —
No. 6 cylinder r/min — — —
48 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 49
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50 D155A-6
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D155A-6 51
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52 D155A-6
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D155A-6 53
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54 D155A-6
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D155A-6 55
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56 D155A-6
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D155A-6 57
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58 D155A-6
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D155A-6 59
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60 D155A-6
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D155A-6 61
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62 D155A-6
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D155A-6 63
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64 D155A-6
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D155A-6 65
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66 D155A-6
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D155A-6 67
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68 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 69
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70 D155A-6
40 Troubleshooting SEN03207-05
D155A-6 71
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72 D155A-6
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D155A-6 73
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74 D155A-6
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D155A-6 75
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76 D155A-6
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D155A-6 77
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78 D155A-6
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D155A-6 79
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80 D155A-6
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D155A-6 81
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D155A-6 Bulldozer
Form No. SEN03207-05
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 08-20 (01)
82 D155A-6
SEN03208-07
D155A-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 3
Failure code [D5ZKKX] ................................................................................................................................... 3
Failure code [DAFRKR] .................................................................................................................................. 6
Failure code [DAFRMC].................................................................................................................................. 8
Failure code [DB2RKR]................................................................................................................................. 15
Failure code [DB90KR] ................................................................................................................................. 18
Failure code [DBE0KK] ................................................................................................................................. 20
Failure code [DBE0KT] ................................................................................................................................. 23
Failure code [DBE6KK] ................................................................................................................................. 24
Failure code [DBE7KK] ................................................................................................................................. 26
Failure code [DBE9KQ]................................................................................................................................. 29
Failure code [DD12KA] ................................................................................................................................. 31
Failure code [DD12KB] ................................................................................................................................. 33
Failure code [DD13KA] ................................................................................................................................. 35
Failure code [DD13KB] ................................................................................................................................. 37
D155A-6 1
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2 D155A-6
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D155A-6 3
SEN03208-07 40 Troubleshooting
4 D155A-6
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D155A-6 5
SEN03208-07 40 Troubleshooting
6 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 7
SEN03208-07 40 Troubleshooting
8 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 9
SEN03208-07 40 Troubleshooting
10 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 11
SEN03208-07 40 Troubleshooting
12 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 13
SEN03208-07 40 Troubleshooting
WEC2 (DRC26-40A)
JNXA
JNX9
G0191528
14 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 15
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16 D155A-6
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D155A-6 17
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18 D155A-6
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D155A-6 19
SEN03208-07 40 Troubleshooting
20 D155A-6
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D155A-6 21
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22 D155A-6
40 Troubleshooting SEN03208-07
Related
-
information
D155A-6 23
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24 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 25
SEN03208-07 40 Troubleshooting
26 D155A-6
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D155A-6 27
SEN03208-07 40 Troubleshooting
28 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 29
SEN03208-07 40 Troubleshooting
30 D155A-6
40 Troubleshooting SEN03208-07
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related
information • State of shift-up switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
D155A-6 31
SEN03208-07 40 Troubleshooting
32 D155A-6
40 Troubleshooting SEN03208-07
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related
information • State of shift-up switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
D155A-6 33
SEN03208-07 40 Troubleshooting
34 D155A-6
40 Troubleshooting SEN03208-07
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related
information • State of shift-down switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
D155A-6 35
SEN03208-07 40 Troubleshooting
36 D155A-6
40 Troubleshooting SEN03208-07
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related
information • State of shift-down switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
D155A-6 37
SEN03208-07 40 Troubleshooting
38 D155A-6
40 Troubleshooting SEN03208-07
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related
information • State of parking brake lever switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
D155A-6 39
SEN03208-07 40 Troubleshooting
40 D155A-6
40 Troubleshooting SEN03208-07
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related
information • State of parking brake lever switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
D155A-6 41
SEN03208-07 40 Troubleshooting
42 D155A-6
40 Troubleshooting SEN03208-07
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related
information • State of brake pedal switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input1)
D155A-6 43
SEN03208-07 40 Troubleshooting
44 D155A-6
40 Troubleshooting SEN03208-07
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related
information • State of brake pedal switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
D155A-6 45
SEN03208-07 40 Troubleshooting
46 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 47
SEN03208-07 40 Troubleshooting
48 D155A-6
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D155A-6 49
SEN03208-07 40 Troubleshooting
50 D155A-6
40 Troubleshooting SEN03208-07
D155A-6 51
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52 D155A-6
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D155A-6 53
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54 D155A-6
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D155A-6 55
SEN03208-07 40 Troubleshooting
56 D155A-6
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D155A-6 57
SEN03208-07 40 Troubleshooting
58 D155A-6
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D155A-6 59
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60 D155A-6
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D155A-6 61
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62 D155A-6
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D155A-6 63
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64 D155A-6
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D155A-6 65
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66 D155A-6
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D155A-6 67
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68 D155A-6
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D155A-6 69
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70 D155A-6
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D155A-6 71
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72 D155A-6
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D155A-6 73
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74 D155A-6
40 Troubleshooting SEN03208-07
PCCS lever TLV1 (male) PCCS lever Resistance • The PCCS lever F-R
2 F-R potenti- Between (4) – (1) 3.2 kz ± 20% potentiometer 1 is
ometer 1 defective.
Between (4) – (3) 6 – 1 kz
• Replace the PCCS
During steering NO lever F-R potentiome-
operation ter 1.
Between (3) – (1) 1 – 6 kz • Proceed to
"Confirmation of
repair".
• No open circuit occurs
a Prepare with starting switch OFF, then carry out trouble-
in the wiring harness.
shooting without turning starting switch ON. YES
Does the troubleshooting result match the judgment criteria? • Proceed to the next
check item.
Open circuit Wiring harness between STC1 Resis- • An open circuit occurs
3 in wiring har- Max. 1 z
(female) (22) – TLV1 (female) (4) tance in the wiring harness.
ness • Repair or replace the
NO wiring harness.
Wiring harness between STC1 Resis-
Max. 1 z • Proceed to
(female) (13) – TLV1 (female) (3) tance
"Confirmation of
repair".
D155A-6 75
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76 D155A-6
40 Troubleshooting SEN03208-07
PCCS lever TLV1 (male) PCCS lever Resistance • The PCCS lever F-R
2 F-R potenti- Between (4) – (1) 3.2 kz ± 20% potentiometer 1 is
ometer 1 defective.
Between (4) – (3) 6 – 1 kz
• Replace the PCCS
During steering NO lever F-R potentiome-
operation ter 1.
Between (3) – (1) 1 – 6 kz • Proceed to
"Confirmation of
repair".
• No hot short circuit
a Prepare with starting switch OFF, then turn starting switch occurs in the wiring
ON and carry out troubleshooting. YES harness.
Does the troubleshooting result match the judgment criteria? • Proceed to the next
check item.
Hot short in • A hot short circuit
3 wiring har- occurs in the wiring
ness harness.
Wiring harness between STC1
• Repair or replace the
(female) (13) – TLV1 (female) (3) and Voltage Max. 1 V NO
wiring harness.
chassis ground
• Proceed to
"Confirmation of
repair".
D155A-6 77
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78 D155A-6
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D155A-6 79
SEN03208-06 40 Troubleshooting
D155A-6 Bulldozer
Form No. SEN03208-07
© 2023 KOMATSU
All Rights Reserved
Printed in Japan 10-23 (01)
80 D155A-6
SEN03209-03
D155A-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 4
Failure code [DK57KA] ................................................................................................................................... 4
Failure code [DK57KB] ................................................................................................................................... 6
Failure code [DKH1KA]................................................................................................................................... 8
Failure code [DKH1KB]................................................................................................................................. 10
Failure code [DLT3KA] .................................................................................................................................. 12
Failure code [DLT3KB] .................................................................................................................................. 14
Failure code [DW7BKA] ................................................................................................................................ 16
Failure code [DW7BKB] ................................................................................................................................ 18
Failure code [DWN3KA]................................................................................................................................ 20
Failure code [DWN3KB]................................................................................................................................ 22
Failure code [DWN3KY]................................................................................................................................ 24
Failure code [DWN5KA]................................................................................................................................ 26
Failure code [DWN5KB]................................................................................................................................ 28
Failure code [DXH4KA]................................................................................................................................. 30
D155A-6 1
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2 D155A-6
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D155A-6 3
SEN03209-03 40 Troubleshooting
4 D155A-6
40 Troubleshooting SEN03209-03
D155A-6 5
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6 D155A-6
40 Troubleshooting SEN03209-03
D155A-6 7
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8 D155A-6
40 Troubleshooting SEN03209-03
D155A-6 9
SEN03209-03 40 Troubleshooting
10 D155A-6
40 Troubleshooting SEN03209-03
D155A-6 11
SEN03209-03 40 Troubleshooting
12 D155A-6
40 Troubleshooting SEN03209-03
D155A-6 13
SEN03209-03 40 Troubleshooting
14 D155A-6
40 Troubleshooting SEN03209-03
D155A-6 15
SEN03209-03 40 Troubleshooting
16 D155A-6
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D155A-6 17
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D155A-6 19
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D155A-6 21
SEN03209-03 40 Troubleshooting
22 D155A-6
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D155A-6 23
SEN03209-03 40 Troubleshooting
24 D155A-6
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D155A-6 25
SEN03209-03 40 Troubleshooting
26 D155A-6
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D155A-6 27
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D155A-6 Bulldozer
Form No. SEN03209-03
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 08-20 (01)
88 D155A-6
SEN03210-03
D155A-6
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting for electrical system ............................................................................... 3
Information in troubleshooting table ................................................................................................................ 7
E-1 When starting switch turned ON, machine monitor displays nothing ....................................................... 8
E-2 When starting switch turned ON (before starting engine), basic check item lights up............................ 10
E-3 Engine does not start (Engine does not turn) ......................................................................................... 12
E-4 Preheater does not operate.................................................................................................................... 15
E-5 Precaution item lights up while engine is running .................................................................................. 18
E-6 Emergency stop item lights up while engine is running.......................................................................... 20
E-7 Engine coolant temperature gauge does not indicate normally ............................................................. 22
E-8 Fuel level gauge does not indicate normally .......................................................................................... 23
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 25
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 26
E-11 Contents of display by machine monitor are different from applicable machine................................... 28
E-12 Machine monitor does not display some items .................................................................................... 28
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Locations of circuit breakers CB30, CB105, and CB105H (In battery room)
Locations of circuit breakers CB1 – CB9 and fuse boxes FS1 and FS2 (In battery room)
D155A-6 5
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Fuse box
Power circuit fuse Fuel
Fuse No. Destination of power
(Type of power supply) capacity
FS1-1 Radio
(Unswitched power 1 10A 12V accessory connector (Via DC converter)
supply) 12V accessory socket (Via DC converter)
Additional light relay, additional light
FS1-3 2 20A
Rotary lamp
(Accessory power
supply) 12V accessory connector (Via DC converter)
3 20A
12V accessory socket (Via DC converter)
Radio
Room lamp
FS1-4 4 20A
Cigarette lighter
(Accessory power
supply) Windshield wiper (Via intermittent relay)
5 10A Front wiper, rear wiper
6 10A Left wiper, right wiper
6 D155A-6
40 Troubleshooting SEN03210-03
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do
(1) Method of indicating connector No. and handling of T-
not indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
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E-1 When starting switch turned ON, machine monitor displays nothing 1
Trouble • When starting switch turned ON, machine monitor displays nothing.
• When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen of check before starting, screen to check setting of preset, and ordinary screen
Related in order.
information • When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery. In this case, the machine monitor goes off for a moment.
This phenomenon is not a failure, however.
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(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
Trouble
warm.
Related • Check that engine can be turned with starting motor (If engine cannot be turned, carry out trouble-
information shooting for E-3 Engine does not start (Engine does not turn)).
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(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble (4) Display of engine coolant temperature gauge is different from display of engine coolant tempera-
ture monitor.
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.
information • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Coolant Temperature)
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(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related • Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel Level Sensor Volt)
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40 Troubleshooting SEN03210-03
E-9 Power train oil temperature gauge (multi-gauge) does not indicate
normally 1
(1) While power train oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H).
• Signals of power train oil temperature sensor are input to power train controller and then transmitted
Related to machine monitor through communication system.
information • Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
(3) Display of power train temperature gauge is different from actual power train oil temperature.
Trouble (4) Display of power train oil temperature gauge is different from display of power train oil temperature
monitor.
• Signals of power train oil temperature sensor are input to power train controller and then transmitted
Related to machine monitor through communication system.
information • Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
Power train oil temperature gauge and power train oil temperature monitor
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(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
Related • Hydraulic oil temperature can be checked with monitoring function.
information (Code: 04401 Hyd Oil Temperature)
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Trouble (2) When operation mode is changed, engine output is not changed.
Related • Engine output mode recognized by engine controller can be checked with monitoring function.
information (Code: 17500 Engine Power Mode)
Trouble (2) When gearshift mode is changed, gearshift setting of power train is not changed.
Related
information
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Trouble (2) When setting is changed on customize screen, setting of machine is not changed.
Related
information
Trouble (2) When selection is changed on customize memory screen, setting of machine is not changed.
Related
information
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Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information
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Trouble (3) Air does not come out (Air flow is insufficient).
Related
information
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(5) Air conditioner fault history: Communication condition "CAN disconnection", Communication condi-
Trouble
tion "Abnormal"
• While abnormality in communication is being detected, "CAN disconnection" is displayed.
• If abnormality in communication has been detected and reset, "Abnormality" is displayed.
Related
• If "CAN disconnection" is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, condition of other items is not displayed.
• Method of reproducing fault history: Turn starting switch ON.
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Trouble (7) Air conditioner fault history: Internal air sensor "Abnormality"
• If "CAN disconnection" is displayed as communication condition, communication cannot be carried
Related
out normally. Accordingly, this condition is not displayed.
information
• Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
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Trouble (8) Air conditioner fault history: External air sensor "Unused"
• External air sensor is not used in air conditioner system of this machine.
Related
• If "CAN disconnection" is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, this condition is not displayed.
Trouble (9) Air conditioner fault history: Air flow sensor "Abnormality"
• If "CAN disconnection" is displayed as communication condition, communication cannot be carried
Related
out normally. Accordingly, this condition is not displayed.
information
• Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
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Trouble (11) Air conditioner fault history: Air outlet damper 1 "Abnormality"
• If "CAN disconnection" is displayed as communication condition, communication cannot be carried
Related
out normally. Accordingly, this condition is not displayed.
information
• Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
40 D155A-6
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Trouble (12) Air conditioner fault history: Air outlet damper 2 "Abnormality"
• If "CAN disconnection" is displayed as communication condition, communication cannot be carried
Related
out normally. Accordingly, this condition is not displayed.
information
• Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
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E-24 Headlamp, rear lamp, and ripper point lamp do not light up 1
Trouble (1) Headlamp does not light up.
Related • Only when headlamp switch is set in "Moon" mark position, screen brightness of machine monitor is
information changed for night.
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Trouble (2) Rear lamp and ripper point lamp do not light up.
Related
information
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Trouble (2) Front windshield wiper does not operate (Continuous operation is defective).
• If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become
Related defective.
information • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
• Carry out troubleshooting with front wiper switch ON and intermittent switch OFF.
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Trouble (4) Rear windshield wiper does not operate (Continuous operation is defective).
• If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become
Related infor- defective.
mation • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
• Carry out troubleshooting with rear wiper switch ON and intermittent switch OFF.
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Trouble (6) Right door wiper does not operate (Continuous operation is defective).
• If fuse ( -6) is broken, operations of both right door wiper and left door wiper become defective.
Related
information • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
• Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF.
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Trouble (8) Left door wiper does not operate (Continuous operation is defective).
• If fuse ( -6) is broken, operations of both right door wiper and left door wiper become defective.
Related
information • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
• Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF.
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Trouble (10) Water does not come out from front window washer.
• Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
information • If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.
Disconnection in wiring har- Wiring harness between fuse (5) – CN14 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
or defective contact in con- Wiring harness between CN14 (female) (6) Resis-
nector) Max. 1 z
– WSH1 (female) (3) tance
Wiring harness between WSH1 (female) (4) Resis-
Max. 1 z
– chassis ground (GND06) tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between fuse (5) – CN14 Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between CN14 (female) (6) Resis-
Min. 1 Mz
– WSH1 (female) (3) and chassis ground tance
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Trouble (11) Water does not come out from rear window washer.
• Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
information • If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.
Disconnection in wiring har- Wiring harness between fuse (5) – CN12 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
or defective contact in con- Wiring harness between CN12 (female) (6) Resis-
nector) Max. 1 z
– WSH2 (female) (3) tance
Wiring harness between WSH2 (female) (4) Resis-
Max. 1 z
– chassis ground (GND06) tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between fuse (5) – CN12 Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between CN12 (female) (6) Resis-
Min. 1 Mz
– WSH2 (female) (3) and chassis ground tance
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Trouble (12) Water does not come out from right door washer.
• Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
information • If fuse ( -6) is broken, operations of both right door washer and left door washer become defec-
tive.
Disconnection in wiring har- Wiring harness between fuse (6) – CN13 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
or defective contact in con- Wiring harness between CN13 (female) (6) Resis-
nector) Max. 1 z
– WSH2 (female) (1) tance
Wiring harness between WSH2 (female) (2) Resis-
Max. 1 z
– chassis ground (GND06) tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between fuse (6) – CN13 Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between CN13 (female) (6) Resis-
Min. 1 Mz
– WSH2 (female) (1) and chassis ground tance
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Trouble (13) Water does not come out from left door washer.
• Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
• If fuse ( -6) is broken, operations of both right door washer and left door washer become defec-
information
tive.
Disconnection in wiring har- Wiring harness between fuse (6) – CN15 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
or defective contact in con- Wiring harness between CN15 (female) (6) Resis-
nector) Max. 1 z
– WSH1 (female) (1) tance
Wiring harness between WSH1 (female) (2) Resis-
Max. 1 z
– chassis ground (GND06) tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between fuse (6) – CN15 Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between CN15 (female) (6) Resis-
Min. 1 Mz
– WSH1 (female) (1) and chassis ground tance
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a Select "Setting condition of terminal" from "12 Display a Select "Condition of positioning and communication"
of KOMTRAX setting" in the service menu of the from "12 Display of KOMTRAX setting" in the service
machine monitor. menu of the machine monitor.
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E-29 Electric priming pump does not operate or does not stop
automatically 1
Trouble • Electric priming pump does not operate or does not stop automatically
Relative
information
78 D155A-6
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D155A-6 79
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D155A-6 Bulldozer
Form No. SEN03210-03
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 08-19 (01)
80 D155A-6
SEN03211-03
D155A-6
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Information in troubleshooting table ................................................................................................................ 3
H-1 Power is low (Drawbar pull is low) ........................................................................................................... 4
H-2 Machine does not travel (at 2nd or 3rd gear speed) ................................................................................ 5
H-3 Machine does not start at any gear speed ............................................................................................... 6
H-4 Machine can travel only forward or in reverse ......................................................................................... 7
H-5 When gear speed or travel direction is changed, time lag is large........................................................... 8
H-6 Steering is not possible ............................................................................................................................ 9
H-7 Steering is possible only on one side ..................................................................................................... 10
H-8 Steering overrun occurs ..........................................................................................................................11
H-9 Brake does not work .............................................................................................................................. 12
H-10 Power train oil is overheated................................................................................................................ 13
H-11 Speed of all work equipment is low ...................................................................................................... 14
H-12 No work equipment moves................................................................................................................... 15
H-13 Blade lift speed or power is low............................................................................................................ 16
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Possible causes 2
and standard Possible causes of trouble
<Contents of description>
value in normal (Given numbers are refer-
• Standard value in normal state to judge possible causes
state ence numbers, which do
• Remarks on judgment
not indicate priority)
3
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H-2 Machine does not travel (at 2nd or 3rd gear speed) 1
Trouble • Machine does not travel (at 2nd or 3rd gear speed).
Related • Before carrying out troubleshooting, check that power train oil level is normal.
information • Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).
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H-5 When gear speed or travel direction is changed, time lag is large 1
Trouble • When gear speed or travel direction is changed, time lag is large.
Related
• Before carrying out troubleshooting, check that power train oil level is normal.
information
8 D155A-6
40 Troubleshooting SEN03211-03
1 Defective operation of brake Raise machine with blade and ripper, drive it in F3 (or R3), and steer
it in direction in which machine cannot turn. If track shoe stops at
this time, brake is defective. (Carry out troubleshooting for "H-9
Brake does not work".)
a Prepare with starting switch OFF, then drive the engine in high
idle mode for troubleshooting.
PCCS lever Left stroke end Right stroke end
D155A-6 9
SEN03211-03 40 Troubleshooting
1 Defective operation of brake Raise machine with blade and ripper, drive it in F3 (or R3), and steer
it in direction in which machine cannot turn. If track shoe stops at
this time, brake is defective. (Carry out troubleshooting for "H-9
Brake does not work".)
a Prepare with starting switch OFF, then drive the engine in high
idle mode for troubleshooting.
PCCS lever Left stroke end Right stroke end
10 D155A-6
40 Troubleshooting SEN03211-03
D155A-6 11
SEN03211-03 40 Troubleshooting
1 Degradation of brake Step on the brake pedal, shift the gear to F2 and drive the engine in
high idle mode. When the machine moves, the brake performance
is degraded.
Defective operation of brake The brake pedal and the brake valve are supposed not to work nor-
2
pedal mally. Check them directly.
a Prepare with starting switch OFF, then drive the engine in high
idle mode for troubleshooting.
PCCS lever Left stroke end Right stroke end
Possible causes
2.3 – 2.6 MPa 0 MPa
and standard Left clutch pressure
{23.5 – 26.5 kg/cm2} {0 kg/cm2}
value in normal Defective operation of steer-
state 3 0 MPa 2.3 – 2.6 MPa
ing brake valve (ECMV) Right clutch pressure
{0 kg/cm2} {23.5 – 26.5 kg/cm2}
0 MPa 3.04 – 3.33 MPa
Left brake pressure
{0 kg/cm2} {31.0 – 34.0 kg/cm2}
3.04 – 3.33 MPa 0 MPa
Right brake pressure
{31.0 – 34.0 kg/cm2} {0 kg/cm2}
When the brake seal is not normal in the troubleshooting of the
4 Defective brake seal cause 3, the brake seal is supposed to be defective. Check it
directly.
The inside of the brake is supposed to be defective. Check it
5 Internal defect of brake
directly.
12 D155A-6
40 Troubleshooting SEN03211-03
Malfunction of brake (Drag- 1. Float machine above ground with blade and ripper.
5 2. Run engine at low idle and set transmission gear in F3 or R3.
ging)
3. If track shoe does not turn, brake is dragging.
(Carry out troubleshooting for "H-9 Brake does not work".)
a Start engine and check.
6 Malfunction of brake (Slip) Stall machine at F3. If machine does not stop perfectly, brake is
slipping.
D155A-6 13
SEN03211-03 40 Troubleshooting
Possible causes a Prepare with starting switch ON, then run engine at high idle
and standard Improper set pressure or and carry out troubleshooting.
value in normal 4 malfunction of main relief Blade control lever Main relief pressure
state valve 27.5 ± 1.5 MPa
Raise relief
{280 ± 15 kg/cm2}
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Improper set pressure or PCCS lever
5 malfunction of self-acting Blade control lever Control circuit basic pressure
pressure reducing valve Ripper control lever
3.78 – 4.46 MPa
Neutral
{38.5 – 45.5 kg/cm2}
If check result of cause 5 is abnormal, fan pump may have trouble
6 Trouble in fan pump
in it. Check it directly.
If cause 5 is detected, oil may be leaking in PPC valve. Check
7 Internal leak of PPC valve
PPC valve directly.
14 D155A-6
40 Troubleshooting SEN03211-03
D155A-6 15
SEN03211-03 40 Troubleshooting
16 D155A-6
40 Troubleshooting SEN03211-03
D155A-6 17
SEN03211-03 40 Troubleshooting
18 D155A-6
40 Troubleshooting SEN03211-03
D155A-6 19
SEN03211-03 40 Troubleshooting
20 D155A-6
40 Troubleshooting SEN03211-03
D155A-6 21
SEN03211-03 40 Troubleshooting
H-21 Abnormal sound comes out from around work equipment pump 1
Trouble • Abnormal sound comes out from around work equipment pump.
Related
• Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
information
22 D155A-6
40 Troubleshooting SEN03211-03
D155A-6 23
SEN03211-03 40 Troubleshooting
D155A-6 Bulldozer
Form No. SEN03211-03
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 08-19 (01)
24 D155A-6
SEN03212-01
D155A-6
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance of engine is poor .................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operation.................................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lack output (or lacks power) ....................................................................................................... 13
S-7 Exhaust gas is black (incomplete combustion) ...................................................................................... 14
S-8 Oil consumption is excessive (or exhaust gas is blue) ........................................................................... 15
S-9 Oil becomes dirty quickly........................................................................................................................ 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (Overheating) ........................................................................ 21
S-15 Abnormal noise is made....................................................................................................................... 22
D155A-6 1
SEN03212-01 40 Troubleshooting
2 D155A-6
40 Troubleshooting SEN03212-01
Questions
Items to be drawn from the user or operator. 2
They correspond to A and B in the chart on the A
3
right. The items in A are basic ones. The
4
items in B can be drawn from the user or oper-
ator, depending on their level. 5
[Check items] B 6
Simple check items used by the serviceman to 7
narrow the causes. They correspond to C in C 8
the chart on the right.
Check items
9
[Causes]
10
Items to be narrowed from the questions and
check items. The serviceman narrows down 11
the probable causes from A, B, and C. Troubleshooting a
[Troubleshooting]
b
Items used to find out the true cause by verify-
ing the narrowed causes finally in order from c
the most probable one by applying trouble- d
shooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
D155A-6 3
SEN03212-01 40 Troubleshooting
4 D155A-6
40 Troubleshooting SEN03212-01
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 — Step 3 shown below.
D155A-6 5
SEN03212-01 40 Troubleshooting
Defective injector
may not start until the crankshaft revolves 2 turns at
maximum. This phenomenon does not indicate a trou-
ble, however
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage of 20 – 30 V generated between alternator terminals B and E Yes q
while engine is running at low idle? No q
Specific gravity of electrolyte and battery voltage are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 D155A-6
40 Troubleshooting SEN03212-01
Replace
Replace
Replace
Replace
Correct
Remedy
—
D155A-6 7
SEN03212-01 40 Troubleshooting
Degree of use of
Operated for long period E E E
machine
Exhaust gas suddenly stopped coming out (when starting again) w Q w w w E E
Filters have not been replaced according to Operation and Maintenance Manual w w E Q
Fuel tank is empty w
Air breather hole of fuel tank cap is clogged Q w
There are rust and water in fuel drained from fuel tank Q Q Q Q Q
There is not fuel in removed fuel filter w w
Fuel is leaking from fuel piping w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
8 D155A-6
40 Troubleshooting SEN03212-01
When air bleeding plug of fuel filter is removed, fuel does not
While engine is rotated flow out Q w w
with starting motor,
When spill hose from injector is disconnected, little fuel spills w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
D155A-6 9
SEN03212-01 40 Troubleshooting
When engine is rotated, abnormal sound comes out from around cylinder head w
When engine is rotated, interference sound comes out from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
Engine hunts (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
10 D155A-6
40 Troubleshooting SEN03212-01
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
D155A-6 11
SEN03212-01 40 Troubleshooting
There are rust and water in fuel drained from fuel tank Q Q
Fuel is leaking from fuel piping w
Priming pump is too light or too heavy to operate w Q Q
Correct
Correct
Correct
Correct
Clean
Remedy
Add
12 D155A-6
40 Troubleshooting SEN03212-01
turbocharger
When engine is rotated, abnormal sound comes out from around cylinder head w
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load
is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
Engine hunts (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Remedy
*2: Displayed failure code [CA122] and [CA123]
*3: Displayed failure code [CA263] and [CA265]
D155A-6 13
SEN03212-01 40 Troubleshooting
When engine is rotated, abnormal sound comes out from around cylinder head w
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Blow-by gas is excessive w
When spill hose from injector is disconnected, abnormally much fuel spills w
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
14 D155A-6
40 Troubleshooting SEN03212-01
Turbocharger
Worn or damaged valve (stem, guide, or seal)
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
D155A-6 15
SEN03212-01 40 Troubleshooting
Exhaust gas is
Black w
Comes out excessively Q Q w Q
Blow-by gas
Does not come out at all w
See S-7
Check breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
16 D155A-6
40 Troubleshooting SEN03212-01
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
When spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
q
code
Confirm with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
D155A-6 17
SEN03212-01 40 Troubleshooting
When hydraulic oil or power train oil is drained, water flows out w
Remedy
—
18 D155A-6
40 Troubleshooting SEN03212-01
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
—
Add
D155A-6 19
SEN03212-01 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20 D155A-6
40 Troubleshooting SEN03212-01
Malfunction of thermostat
Malfunction of fan
Low coolant level
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Questions
Occurred suddenly Q w Q
Overheating
Has continued at low level Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates low (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Milky oil is floating on coolant w
There are many bubbles in radiator and coolant spurts back w
When light applied to radiator core, no light passes through w
Check items
Dirt and mud are accumulated in radiator shroud and undercover on applicable
machine side w w
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
D155A-6 21
SEN03212-01 40 Troubleshooting
Gradually increased Q Q
Abnormal noise
Suddenly increased Q Q Q
Non-specified fuel is used Q
Oil must be added more frequently w
There are metal particles in oil drained from oil filter w w
Air leaks between turbocharger and cylinder head w
When engine is rotated, interference sound comes out from around turbocharger w
When engine is rotated, abnormal sound comes out from around cylinder head w w
When engine is rotated, beat noise comes out from around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
22 D155A-6
40 Troubleshooting SEN03212-01
Replace
Replace
Replace
Adjust
Adjust
Remedy
D155A-6 23
SEN03212-01 40 Troubleshooting
Degree of use of
machine
Operated for long period EE
Non-specified fuel is used Q Q
Fuel tank is empty w
Fuel tank cap breather hole is clogged Q w
Fuel is leaking from fuel piping w
Switch lamp does not blink w w Q
Check items
Replace
Charge
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
24 D155A-6
40 Troubleshooting SEN03212-01
• Remove joint bolt (1) and blow clean compressed air into hole [b] of the orifice to check for clogging.
D155A-6 25
SEN03212-01 40 Troubleshooting
D155A-6 Bulldozer
Form No. SEN03212-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (02)
26 D155A-6
SEN03366-07
D155A-6
D155A-6 1
SEN03366-07 50 Disassembly and assembly
2 D155A-6
50 Disassembly and assembly SEN03366-07
D155A-6 3
SEN03366-07 50 Disassembly and assembly
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
Gasket sealant
4 D155A-6
50 Disassembly and assembly SEN03366-07
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
D155A-6 5
SEN03366-07 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
6 D155A-6
50 Disassembly and assembly SEN03366-07
New/Remodel
Sym- Nature of work and
Necessity
Work item Part No. Part name
bol remarks
Sketch
Q'ty
Removal and installation 1 795-630-5500 Standard puller t 1
of fuel supply pump 2 01010-81090 Bolt t 2 Separation of drive gear
assembly A 3 01643-31032 Washer t 2
Removal and installation Tightening of cylinder head
4 790-331-1110 Wrench q 1
of cylinder head assembly bolt
795T-521-1111 Push tool t 1 R Q
Installation of Engine front
2 01050-31655 Bolt t 3
seal
01050-31635 Bolt t 3
3 795-931-1100 Seal puller t 1
795T-421-1270 Push tool t 1 Q Installation of Engine rear
4 01050-31645 Bolt t 4 seal
D155A-6 7
SEN03366-07 50 Disassembly and assembly
New/Remodel
Sym- Nature of work and
Necessity
Work item Part No. Part name
bol remarks
Sketch
Q'ty
790-337-1032 Lifting tool t 1
Removal and installation 791-627-1320 Shackle t 2 Removal and installation of
J
of final drive assembly 791T-627-1910 Plate t 1 N Q final drive assembly
01010-82080 Bolt t 2
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
1 Pulling out of pinion shaft
790-101-2480 Adapter t 2
791T-627-1920 Plate t 1 N Q
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
790-431-1031 Block t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
01643-32460 Washer t 2 Pulling out and press fitting
2 of sprocket and hub
791T-627-1930 Plate t 1 N Q assembly
791T-627-1940 Push tool t 1 N Q
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
3 791-627-1280 Installer t 1 Installation of floating seal
Disassembly and assem- 790-101-5401 Push tool kit t 1
K
bly of final drive assembly 790-101-5441 • Plate 1
4 Press fitting of oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5401 Push tool kit t 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
5 Press fitting of bearing
01010-51240 • Bolt 1
791T-627-1950 Plate t 1 N Q
791T-627-1960 Plate t 1 N Q
790-201-1500 Push tool kit t 1
790-201-1680 • Plate 1
6 Press fitting of bearing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
7 791-112-1180 Nut t 1 Press fitting of bearing
01643-22460 Washer t 1
792-785-1120 Plate t 1
8 D155A-6
50 Disassembly and assembly SEN03366-07
New/Remodel
Sym- Nature of work and
Necessity
Work item Part No. Part name
bol remarks
Sketch
Q'ty
791-830-1410 Push tool t 1
Disassembly and assem-
K 7 790-101-2102 Puller t 1 Press fitting of bearing
bly of final drive assembly
790-101-1102 Hydraulic pump t 1
791-630-1220 Rod t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
Press fitting of idler bush-
1 01580-01411 Nut t 2
Disassembly and assem- ing
01643-31445 Washer t 2
bly of idler assembly
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Hydraulic pump t 1
2 791-651-1510 Installer t 1 Installation of floating seal
3 791-601-1000 Oil pump t 1 Refilling with oil
791T-130-1010 Bracket t 2 N Q
14 01010-63060 Bolt t 4 Locking of bogie
01643-33080 Washer t 4
791-630-1360 Spacer t 1
790-101-2310 Block t 1
790-101-2360 Plate t 2
15 790-445-4130 Screw t 2 Removal of shaft and ring
791-112-1180 Nut t 2
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
L 790-201-2760 Spacer t 1
791-630-1370 Adapter t 1
790-434-1060 Screw t 2
16 01580-13024 Nut t 2 Removal of floating seal
Removal and installation 01643-33080 Washer t 1
of 1st bogie assembly 790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
17 796-230-1120 Installer t 1 Installation of floating seal
19 791T-630-1390 Guide t 1 Q Installation of cartridge pin
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
20 790-101-2360 Plate t 2 Press fit of pin
791-112-1180 Nut t 2
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
Check of floating seal tight-
21 791-601-1000 Oil pump (seal checker) t 1
ness and charging of oil
790-401-1700 Lifting tool t 1
22 Removal of track roller
790-401-1761 Adapter t 1
D155A-6 9
SEN03366-07 50 Disassembly and assembly
New/Remodel
Sym- Nature of work and
Necessity
Work item Part No. Part name
bol remarks
Sketch
Q'ty
791T-130-1010 Bracket t 2 N Q
14 01010-63060 Bolt t 4 Fixing of boggy
01643-33080 Washer t 4
791-630-1360 Spacer t 1
790-101-2310 Block t 1
790-101-2360 Plate t 2
15 790-445-4130 Screw t 2 Pulling out of shaft and ring
791-112-1180 Nut t 2
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
790-201-2760 Spacer t 1
791-630-1370 Adapter t 1
790-434-1060 Screw t 2
Removal and installation 16 01580-13024 Nut t 2 Removal of floating seal
of 2nd, 3rd, and 4th bogie L 01643-33080 Washer t 1
assemblies
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
17 796-230-1120 Installer t 1 Installation of floating seal
19 791T-630-1390 Guide t 1 Q Press fitting of cartridge pin
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
20 790-101-2360 Plate t 2 Press fitting of cartridge pin
790-112-1180 Nut t 2
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
Check of airtightness of
21 791-601-1000 Oil pump (seal checker) t 1 floating seal, and refilling
with oil
791-685-8006 Compressor t 1
10 D155A-6
50 Disassembly and assembly SEN03366-07
New/Remodel
Sym- Nature of work and
Necessity
Work item Part No. Part name
bol remarks
Sketch
Q'ty
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
Disassembly and assem- 20 790-101-2360 Plate t 2 Pulling out and press fitting
Q
bly of bogie assembly 791-112-1180 Nut t 2 of pin assembly and shaft
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
21 791-601-1000 Oil pump t 1
Removal and installation of
1 790-102-1891 Nut wrench t 1
nut
Disassembly and assem-
bly of carrier roller assem- R 2 791-651-1510 Installer t 1 Installation of floating seal
bly 3 791T-630-1350 Spacer t 1 Q Press fitting of ring
4 791-601-1000 Oil pump t 1 Refilling with oil
791-675-9701 Remover and installer t 1
791-101-4300 Cylinder (196 kN {20 ton}) t 1 Disassembly and assembly
1
791-101-4200 Puller (294 kN {30 ton}) t 1 of track shoe assembly
791-101-1102 Hydraulic pump t 1
General disassembly and 2 791-932-1110 Plug push tool t 1 Driving of plug (small)
general assembly of track S 3 791-660-7460 Pin brush t 1 Cleaning of pin
shoe assembly
4 791-432-1110 Plug push tool t 1 Driving of plug (large)
5 791-632-1052 Installer t 1 Insertion of link seal
Check of oil supply and air-
6 790-701-3000 Seal checker t 1
tightness
7 791-601-1000 Oil pump t 1 Refilling with oil
791-675-9581 Adapter t 1
Field disassembly and 791-675-9590 Guide t 1 Disassembly and assembly
T 1
assembly of 1 link 01010-52460 Bolt t 2 of track shoe assembly
01010-51440 Bolt t 2
D155A-6 11
SEN03366-07 50 Disassembly and assembly
New/Remodel
Sym- Nature of work and
Necessity
Work item Part No. Part name
bol remarks
Sketch
Q'ty
790-101-1102 Pump t 1
2 Cylinder Disassembly of 1 link
790-101-4300 t 1
(1,470 kN {150 ton})
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 1
791-685-9560 Bolt t 1
3 Disassembly of 1 link
791-675-9570 Adapter t 1
04530-12030 Eyebolt t 1
790-101-1102 Pump t 1
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
791-685-9540 Rod t 1
4 Disassembly of 1 link
791-685-9550 Nut t 3
791-675-5520 Guide t 1
791-675-5530 Pusher t 1
5 Disassembly of 1 link
01010-51030 Bolt t 1
791-685-9620 Extension t 1
790-101-1102 Pump t 1
6 Disassembly of 1 link
790-101-4200 Puller (294 kN {30 ton}) t 1
Field disassembly and
T 791-675-5542 Adapter t 1
assembly of 1 link
791-675-5571 Adapter t 1
7 790-101-1102 Pump t 1 Assembly of 1 link
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
8 791-675-5580 Guide t 1 Assembly of 1 link
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
9 Assembly of 1 link
01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-675-5542 Adapter t 1
791-675-5560 Guide t 1
790-101-1102 Pump t 1
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
791-675-5560 Guide t 1
10 Assembly of 1 link
791-675-5542 Adapter t 1
12 D155A-6
50 Disassembly and assembly SEN03366-07
New/Remodel
Sym- Nature of work and
Necessity
Work item Part No. Part name
bol remarks
Sketch
Q'ty
790-101-1102 Pump t 1
11 Assembly of 1 link
790-101-4200 Puller (294 kN {30 ton}) t 1
12 791-670-3270 Guide t 1 Assembly of 1 link
Field disassembly and
T 791-126-0150 Adapter t 1
assembly of 1 link
791-675-5560 Guide t 1
13 Assembly of 1 link
791-675-9570 Adapter t 1
01010-51030 Bolt t 1
790-101-1102 Pump t 1
1 Expansion of link
790-101-4200 Puller (294 kN {30 ton}) t 1
791-675-9701 Remover and installer t 1
790-101-1102 Pump t 1
2 790-101-4200 Puller (294 kN {30 ton}) t 1
Disassembly and assem- Disassembly and assembly
U Cylinder
bly of master link 790-101-4300 t 1 of track shoe assembly
(1,470 kN {150 ton})
3 791-432-1110 Plug push tool t 1 Driving of plug (large)
Check of oil supply and air-
4 790-701-3000 Seal checker t 1
tightness
5 791-932-1110 Plug push tool t 1 Driving of plug (small)
791T-650-2110 Sleeve t 1 Q
790-201-2770 Spacer t 1
791T-650-2120 Plate t 1 Q
792-104-3940 Bolt t 2
Removal and installation 790-101-2510 Block t 1
V Press fitting of ring
of pivot shaft assembly 790-101-2570 Washer t 2
01580-01613 Nut t 1
Jack assembly
790-105-2300 t 1
(196 kN {20 ton})
790-101-1102 Hydraulic pump t 1
791T-650-2130 Sleeve t 1 Q
790-101-2420 Adapter t 1
791-520-4140 Screw t 1
Removal and installation
W 790-101-2540 Washer t 2 Pulling out of center pin
of equalizer bar assembly
790-112-1180 Nut t 2
790-101-4000 Puller (294 kN {50 ton}) t 1
790-101-1102 Hydraulic pump t 1
Removal and installation
of operator's cab X 1 793-498-1210 Lifter (Suction cup) t 2 Installation of window glass
(stuck glass)
Disassembly and assembly
790-502-1003 Cylinder repair stand t 1
Disassembly and assem- 1 of hydraulic cylinder
bly of hydraulic cylinder Y 790-101-1102 Hydraulic pump t 1
assembly Installation of round head
2 790-102-3802 Multi-wrench t 1
(Blade lift)
D155A-6 13
SEN03366-07 50 Disassembly and assembly
New/Remodel
Sym- Nature of work and
Necessity
Work item Part No. Part name
bol remarks
Sketch
Q'ty
790-201-1702 Push tool kit t 1 Press fitting of bushing
790-201-1721 • Push tool 1
790-201-1821 • Push tool 1 Blade lift
790-201-1841 • Push tool 1 Blade tilt
3
790-201-1851 • Push tool 1 Ripper lift
790-201-1861 • Push tool 1 Ripper tilt
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit t 1 Press fitting of dust seal
790-201-1630 • Plate 1 Blade lift
790-201-1650 • Plate 1 Blade tilt
Disassembly and assem- 4 790-201-1660 • Plate 1 Ripper lift
bly of hydraulic cylinder Y
assembly 790-201-1670 • Plate 1 Ripper tilt
790-101-5021 • Grip 1
Press fitting of dust seal
01010-50816 • Bolt 1
790-720-1000 Expander t 1 Installation of piston ring
796-720-1670 Ring t 1
Blade lift
07281-01279 Clamp t 1
5 796-720-1690 Ring t 1 Blade tilt
07281-01919 Clamp t 1 Ripper lift
796-720-1720 Ring t 1
Ripper tilt
07281-02429 Clamp t 1
790-102-4300 Wrench t 1 Removal and installation
6
790-102-4310 Pin t 2 of screw-type piston
Commercially
A Webbing sling 4 Width 25 mm × length 3 m
available
Commercially
B Lever block 1
available
Commercially
C Wire 3
Removal and installation available
of blade lift cylinder Commercially
assembly D Oil pan 1
available
1 07376-70628 Plug (#06) 4
Removal and installation of
E 2 02789-00628 Cap (#06) 4
blade lift cylinder assembly
3 02896-11008 O-ring (#06) 4
F 1 198-61-55130 Cylinder fixing tool 1 Machine accessory
14 D155A-6
50 Disassembly and assembly SEN03366-07
D155A-6 15
SEN03366-07 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
C5: Push tool
16 D155A-6
50 Disassembly and assembly SEN03366-07
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
C9: Push tool
D155A-6 17
SEN03366-07 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
Component of J: Plate (791T-627-1910)
18 D155A-6
50 Disassembly and assembly SEN03366-07
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
Component of K2: Plate (791T-627-1930)
D155A-6 19
SEN03366-07 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
Component of K5: Plate (791T-627-1950)
20 D155A-6
50 Disassembly and assembly SEN03366-07
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
L14: Bracket
L19: Guide
D155A-6 21
SEN03366-07 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
L20: Plate
22 D155A-6
50 Disassembly and assembly SEN03366-07
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
Component of V: Sleeve (791T-650-2110)
D155A-6 23
SEN03366-07 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
Component of W: Sleeve (791T-650-2130)
24 D155A-6
50 Disassembly and assembly SEN03366-07
D155A-6 25
SEN03366-07 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03366-07
© 2021 KOMATSU
All Rights Reserved
Printed in Japan 11-21 (01)
26 D155A-6
SEN03367-06
D155A-6
D155A-6 1
SEN03367-06 50 Disassembly and assembly
Removal and installation of fuel 3. Remove the fuel filter and filter head assembly
supply pump assembly 1 according to the following procedure.
1) Loosen joint (5) at the top of the fuel air
Special tools bleeding tube. [*1]
2) Disconnect joint (6) at the bottom of the
New/Remodel
fuel air bleeding tube. [*2]
Necessity
Sym- 3) Disconnect fuel filter inlet tube (7) and fuel
Part No. Part name
Sketch
bol filter outlet tube (8) from the filter. [*3]
Q'ty
4) Remove clamp (9) of the engine oil level
gauge guide.
1 795-630-5500 Standard puller t 1
5) Remove fuel filter and filter head assem-
A 2 01010-81090 Bolt t 2 bly (10).
3 01643-31032 Washer t 2
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
2 D155A-6
50 Disassembly and assembly SEN03367-06
5. Disconnect the following wiring connectors. 7. Remove the high-pressure pipes according to
1) Wiring fixing bracket mounting bolts (12) the following procedure.
and (13). 1) Remove the clamp and stay (28).
2) Wiring connectors PCV1 (14), CPV2 (15) 2) Remove the clamp and stay (29).
and backup sensor (16). 3) Remove the clamp and stay (30).
4) Remove 4 boots (31) (2 pieces each on
the supply pump side and common rail
side). [*11]
D155A-6 3
SEN03367-06 50 Disassembly and assembly
8. Rotate crank shaft forward so that the middle 12. Remove bracket (40), and loosen four mount-
position (a) of "2.5 TOP" stamp line of damper ing bolts (41).
(36) and "3.4 TOP" stamp line aligns to the
pointer (37). 13. Set tools A1, A2 and A3 on drive gear (42),
a Crank the crankshaft at hexagonal part (b) and tighten the center bolt of tool A1 to remove
of water pump drive shaft tip. drive gear (42) from the shaft (43).
10. Check that the mounting bolt hole (c) at the top
of cover align to the forcing tap of drive gear.
a If they are not aligned, rotate crankshaft
one more turn.
4 D155A-6
50 Disassembly and assembly SEN03367-06
1. Set fuel supply pump assembly (44). 5. Tighten bracket (40) permanently.
a Before setting, check that key (d) of shaft Mounting bolt: Width across flats 17 mm
aligns to the key slot (e) of drive gear.
3 Mounting bolt:
2. Temporarily tighten four mounting bolts (41) 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
and bracket (40) with fingers.
2 Mounting bolt: Liquid adhesive (LT-2)
D155A-6 5
SEN03367-06 50 Disassembly and assembly
Assembly [*9]
Fuel return tube joint bolt:
[*1], [*2] Between supply pump and priming pump (25)
3 Fuel air bleeding tube joint bolt:
Width across flats 14 mm
(Air vent side and fuel filter head side) (5), Between supply pump and common rail (26)
(6): Width across flats 14 mm
7.8 – 9.8 Nm {0.8 – 1.0 kgm} 3 Fuel return tube joint bolt:
Between supply pump and priming pump
[*3], [*5] (25)
3 Fuel tube joint bolt:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
Between fuel filter and supply pump (18): (Supply pump side)
24.5 – 34.3 Nm {2.5 – 3.5 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
(Fuel filter side) (Priming pump side of (25))
14.8 – 19.6 Nm {1.5 – 2.0 kgm} Between supply pump and common rail (26)
(Supply pump side) 17.7 – 22.6 Nm {1.8 – 2.3 kgm}
Between fuel filter and supply pump (17): (Common rail side)
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
(Fuel filter side) [*10]
3 Lubrication tube joint bolt:
[*4] 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
3 Gauge guide mounting nut: (Supply pump side)
19.6 – 34.3 Nm {2 – 3.5 kgm} 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(Block side)
[*6]
3 Tube joint bolt between feed pump and prim- [*11]
ing pump: a Install covers (32) and (33) with the notch in
14.8 – 19.6 Nm {1.5 – 2.0 kgm} the following direction.
(Feed pump side) q Cover (32): Common rail side
43 – 47 Nm {4.4 – 4.8 kgm} q Cover (33): Supply pump side
(Priming pump side)
[*12]
[*7] Nut (39): Width across flats 27 mm
3 Tube joint bolt between feed pump and cool- 3 Nut (39): 176 – 196 Nm {18 – 20 kgm}
ing plate:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Feed pump side)
43 – 47 Nm {4.4 – 4.8 kgm}
(Cooling plate side)
[*8]
3 Fuel return tube clamp bolt:
9.8 ± 1 Nm {1.0 – 0.1 kgm}
6 D155A-6
50 Disassembly and assembly SEN03367-06
D155A-6 7
SEN03367-06 50 Disassembly and assembly
8 D155A-6
50 Disassembly and assembly SEN03367-06
D155A-6 9
SEN03367-06 50 Disassembly and assembly
10 D155A-6
50 Disassembly and assembly SEN03367-06
2. Install high pressure pipe clamp and stay. 3. Install the subsequent procedure in the reverse
1) Temporarily tighten high pressure pipe order of removal.
clamp, stay (23), clamping bolts (45) through
(49), and stay mounting bolt, with fingers. [*1]
2) Tighten permanently high pressure pipe Corrosion resistor tube joint bolt:
clamping bolt. Width across flats 19 mm
Clamping bolt: Width across flats 10 mm 3 Corrosion resistor tube joint bolt:
3 Clamping bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
9.8 ± 1 Nm {1 ± 0.1 kgm} (Inlet and outlet)
3) Tighten permanently stay mounting bolt.
4) Temporarily tighten high pressure pipe [*2]
clamp, stay (22), clamping bolts (50) through 3 Fuel air bleeding tube joint bolt
(54), and stay mounting bolt, with fingers. (Upper and lower):
5) Install boot (18). 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
a Install with the notch toward cylinder
block side. [*3]
6) Install high pressure pipe clamp (17) and Fuel filter tube joint bolt: Width across flats 19 mm
gate type frame (14) temporarily. 3 Fuel filter tube joint bolt:
7) Tighten clamping bolt for high pressure 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
pipe clamp (17) permanently. (Inlet and outlet)
Clamping bolt: Width across flats 10 mm
3 Clamping bolt: [*4]
9.8 ± 1 Nm {1 ± 0.1 kgm} 3 Prefilter inlet hose sleeve nut (7):
8) Tighten gate type frame (14) permanently. 84 – 132 Nm {8.5 – 13.5 kgm}
9) Tighten high pressure pipe clamp, stay Prefilter outlet tube sleeve nut (8):
(22) and clamping bolts (50) through (54), (Bracket side)
permanently. 84 – 132 Nm {8.5 – 13.5 kgm}
Clamping bolt: Width across flats 10 mm (Tube side)
3 Clamping bolt: 43 – 47 Nm {4.4 – 4.7 kgm}
9.8 ± 1 Nm {1 ± 0.1 kgm}
10) Tighten permanently stay mounting bolt. [*5]
Installation procedure for oil filter tube
1. Install tubes (55) and (56) temporarily to
bracket (58) with clip (57).
2. Install flange (59) and tubes (55) and (56) tem-
porarily.
3. Install the oil filter end of tubes (55) and (56) in
the hole of the oil filter bracket and tighten
bolts (60) temporarily.
4. Install flange (59) to the cylinder block tempo-
rarily with bolts (61).
5. Tighten bolts (60) on the oil filter side perma-
nently.
6. Tighten bolts (61) of flange (59) permanently.
D155A-6 11
SEN03367-06 50 Disassembly and assembly
12 D155A-6
50 Disassembly and assembly SEN03367-06
D155A-6 13
SEN03367-06 50 Disassembly and assembly
4. Disconnect wiring clips (19) and (20) and 8. Remove breather tube (40).
remove heater wiring connector RHT (21).
9. Remove aftercooler outlet hose (41) and air
5. Remove wiring clips (22) – (34) and move the intake connector (42) together. [*8]
wiring aside.
14 D155A-6
50 Disassembly and assembly SEN03367-06
14. Remove clamp (47). 18. Remove 2 wiring harness clamps (54), upper
and lower, at the rear of the air intake manifold.
15. Remove mounting bolts of bracket (48) and
move bracket (48) breather (49) together.
D155A-6 15
SEN03367-06 50 Disassembly and assembly
21. Remove high-pressure pipe clamp stays (59), 2) Remove bracket (66).
(60), (61), (62) and (63). [*11]
23. Remove the muffler according to the following 24. Remove the turbocharger assembly according
procedure. to the following procedure.
1) Remove heat insulation plate (65). 1) Remove air connector (69). [*13]
2) Remove heat insulation plates (70), (71)
and (72).
3) Remove bracket (73).
4) Remove muffler drain tube (74).
5) Remove water tube (75).
6) Remove the turbocharger-end mounting
bolt of oil tube (76).
16 D155A-6
50 Disassembly and assembly SEN03367-06
7) Remove bracket (77). 25. Disconnect connectors CN1 (79), CN2 (80),
CN3 (81), CN4 (82), CN5 (83) and CN6 (84),
and move wiring harnesses (85) and (86).
a To disconnect the connector, push in the
(X) direction with a flat-head screwdriver
[1] placed at the stepped portion (a) while
pressing stopper (b).
D155A-6 17
SEN03367-06 50 Disassembly and assembly
29. Remove water tube (92). [*20] 32. Remove three mounting bolts (95) through
(97), and remove rocker arm and rocker shaft
30. Remove cylinder head cover (93). [*21] assembly (98).
a Loosen lock nut (100), and loosen adjust-
ment screw (101) two or three turns to
prevent excessive force applied to push
rod (99), when installing rocker arm and
rocker shaft assembly. [*22]
18 D155A-6
50 Disassembly and assembly SEN03367-06
34. Remove two push rods (99). 2) Check cylinder head mounting bolts for
the following items, and if out of standard,
replace mounting bolt without reusing it.
q Bolt tightening should be 5 times or
less.
(The number of punch mark at the
head of bolt should be 5 or less.)
q Bolt under head length service limit
(a)
Short bolt:Less than 170.8 mm
Long bolt: Less than 205.8 mm
D155A-6 19
SEN03367-06 50 Disassembly and assembly
20 D155A-6
50 Disassembly and assembly SEN03367-06
[*5]
Installation procedure for oil filter tube
Install the oil filter tube according to [*5] in
"Removal and installation of fuel injector assem-
bly".
D155A-6 21
SEN03367-06 50 Disassembly and assembly
[*9] [*15]
a Tighten exhaust manifold mounting bolts in the
Joint bolt (53a): Width across flats 17 mm
numerical order shown below.
Joint bolt (53b): Width across flats 17 mm
2 Threads of mounting bolt:
3 Joint bolt (53a):
Lubricant with molybdenum disulfide
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(LM-P)
3 Joint bolt (53b):
Mounting bolt: Width across flats 17 mm
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
[*21]
Cylinder head cover mounting bolt:
Width across flats 12 mm
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
[*14]
Oil tube cylinder block side joint bolt:
Width across flats 24 mm
3 Oil tube cylinder block side joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
22 D155A-6
50 Disassembly and assembly SEN03367-06
[*26] [*27]
a Install the fuel injector assembly referring to
the section, "Removal and installation of fuel
injector assembly".
a Eliminate the slack of the injector wiring har-
ness and press it against the injector body so
that it will not interfere with the rocker arm.
Tighten the nuts alternately.
D155A-6 23
SEN03367-06 50 Disassembly and assembly
24 D155A-6
50 Disassembly and assembly SEN03367-06
Installation
q Carry out installation in the reverse order of
removal.
[*1]
a Install hoses (5) and (7) with the red circle
paint upward.
2 Tube flange: gasket sealant
Hose clamp: Width across flats 8 mm
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
a Tighten two parallel clamps for hose (6) with its
bolt location rotated 180° each other.
2 Tube flange: gasket sealant
Hose clamp: Width across flats 8 mm
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
a Install radiator mounting brackets (9 – 11) and
cushion (19) according to the following proce-
dure.
1) Set plate (18), cushion (19) and brackets
(9 – 11) on the mounting boss of radiator
(12). At this time, fit brackets (9 – 11) to
the mounting seat of upper tank (17).
(You may tighten bracket mounting bolts
(22) temporarily.)
2) Install collar (20) upside down (with the
small diameter side up) and tighten
mounting bolt (21).
Compress cushion (19). (L1 o L2)
3) With mounting bolt (21) tightened, tighten
mounting bolts (22) of brackets (9 – 11).
4) Once remove mounting bolt (21).
5) Install collar (20) again in the normal (with
the small diameter side down).
6) Tighten mounting bolt (21).
7) Check clearance (L3) (approx. 7 mm).
D155A-6 25
SEN03367-06 50 Disassembly and assembly
[*3]
a Set radiator assembly according to the follow-
ing procedure.
1) Set rubber (13) with its stepped portion (a)
downward.
a Apply appropriate amount of grease
to prevent drop down when lifted up.
2) Install O-ring (14).
2 O-ring periphery: Grease (G2-LI)
26 D155A-6
50 Disassembly and assembly SEN03367-06
Removal and installation of 4. Remove four mounting bolts for tube (4). [*2]
aftercooler assembly 1
5. Remove brackets, (5), (6) and (7).
Removal
k Disconnect the negative terminal (–) of the
battery.
D155A-6 27
SEN03367-06 50 Disassembly and assembly
28 D155A-6
50 Disassembly and assembly SEN03367-06
[*1] [*2]
a When loosened hose clamp, replace clamp
with new one.
a Install each MIKALOR clamp according to the
following procedure.
1) Set the hose to its original position.
2) Set the bridge (BR) under the bolt (BC)
and reduce lapping area (b) over the band
(BD) to a minimum of 5 mm.
3) Tighten bolt (BC).
a Do not use an impact wrench.
2 Threaded part of bolt: Lubricating
oil (THREEBOND, PANDO 18B)
q When reusing the hose, install it to the
clamp mark on it.
Bolt (BC): Width across flats 13 mm
3 Bolt (BC):
25 ± 5 Nm {2.55 ± 0.5 kgm}
q When using a new hose, tighten until
dimension BDG is as follows.
a Dimension BDG: 8 – 10 mm
D155A-6 29
SEN03367-06 50 Disassembly and assembly
Removal and installation of 5. Remove air intake connector and air hose
engine assembly 1 assembly (2). [*2]
30 D155A-6
50 Disassembly and assembly SEN03367-06
3) Remove 4 muffler mounting bolts (6) and 12. Disconnect fuel hose (11) between the fuel
lift off muffler (7). tank and prefilter. [*3]
4 Muffler: 55 kg
D155A-6 31
SEN03367-06 50 Disassembly and assembly
15. Remove heater hose (15). 22. Disconnect connectors AC05 (24), EG2 (25)
and EG1 (26).
16. Lift off water tube (16).
23. Remove and move receiver tank (27).
32 D155A-6
50 Disassembly and assembly SEN03367-06
[*1]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70)).
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt.
Threaded part of hose (M16 x 1.5):
28. Sling engine assembly (32) and remove it. Width across flats 24 mm
a Check all wires and pipes are removed. Threaded part of hose (M22 x 1.5):
a Remove carefully to avoid any interfer- Width across flats 32 mm
ence with the machine body. Threaded part of hose (M24 x 1.5):
Width across flats 36 mm
3 Threaded part of hose (M16 x 1.5):
12 – 15 Nm {1.2 – 1.5 kgm}
3 Threaded part of hose (M22 x 1.5):
20 – 25 Nm {2.0 – 2.5 kgm}
3 Threaded part of hose (M24 x 1.5):
30 – 35 Nm {3.0 – 3.5 kgm}
[*2] [*4]
(MIKALOR clamp)
a Use a new MIKALOR clamp.
a Installation procedure of hose
1) Set the hose to the original position.
2) Set the bridge (BR) under the clamp bolt
(BC) and lap it over band (BD) at least (b)
reaches 5 mm.
D155A-6 33
SEN03367-06 50 Disassembly and assembly
[*3]
3 Hose mounting sleeve nut:
84 – 132 Nm {8.5 – 13.5 kgm}
[*5]
Hose clamp: Width across flats 8 mm
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*6]
Universal joint mounting bolt:
Width across flats 19 mm
3 Universal joint mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*7]
Engine mounting bolt: Width across flats 36 mm
3 Engine mounting bolt:
823.8 – 1,029 Nm {84 – 105 kgm}
34 D155A-6
50 Disassembly and assembly SEN03367-06
Removal and installation of 4. Remove the 4 front hood mounting bolts and lift
engine hood assembly 1 off front hood (7).
4 Front hood: 55 kg
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
D155A-6 35
SEN03367-06 50 Disassembly and assembly
[*1]
Hose clamp: Width across flats 8 mm
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
36 D155A-6
50 Disassembly and assembly SEN03367-06
New/Remodel
a Before removing, slightly drive the front seal in
Necessity
Sym- once to free it from fixation.
Part No. Part name
Sketch
bol a When front seal (3) is fixed too hard to the front
Q'ty
cover (4), carry out the following procedure.
1) Drill through a hole of approx. 3 mm dia.
795T-521-1111 Push tool t 1 R Q
on front seal (3).
2 01050-31655 Bolt t 3 2) Replace the tip of tool C3 with the drill
01050-31635 Bolt t 3 type one.
C 3) Insert the top end of tool C3 into the drilled
3 795-931-1100 Seal puller t 1
hole, and remove the front seal by the
795T-521-1150 Push tool t 1 Q impact of slide hammer (SH). (Apply the
8
01050-31635 Bolt t 4 slide hammer evenly not to tilt the front
seal.)
a Remove the metal powders completely.
Removal a When the sleeve is attached, cut sleeve (6)
1. Remove the radiator and oil cooler guard using a gad and hammer to remove it.
assembly. a Take care not to damage crankshaft (5).
q Tool C3
D155A-6 37
SEN03367-06 50 Disassembly and assembly
38 D155A-6
50 Disassembly and assembly SEN03367-06
2) Push in the metal ring of seal (3) evenly as 2. Procedure for installing sleeved seal
if you are passing over the large diameter a When installing the front seal, do not apply
side of plastic inside cylinder (7). oil or grease to the shaft, inside cylinder
3) After pushing in the seal to a depth where surface of sleeve (6) and seal lip.
it does not come off the front cover, 1) Set sleeve and front seal assembly (8) to
remove plastic inside cylinder (7). tool C8 (for fitting the sleeved seal).
a When removing the inside cylinder, 2 Sleeve inside cylinder surface (6):
take care not to damage the seal lip. Gasket sealant (LG-7)
4) Tighten tool C2 until the bolts (55 mm)
reach the end.
D155A-6 39
SEN03367-06 50 Disassembly and assembly
40 D155A-6
50 Disassembly and assembly SEN03367-06
Removal and installation of 3. Install eyebolt [1] to flywheel (2), sling flywheel
engine rear seal 1 (2), and remove bolts (3).
Special tools 4. While moving flywheel (2) toward this side, lift
it off.
New/Remodel
k Since the socket part of the flywheel is
Necessity
Sym- shallow, it may fall suddenly. Take care
Part No. Part name
Sketch
bol not to catch your fingers in the fly-
Q'ty
wheel.
3 795-931-1100 Seal puller t 1 4 Flywheel: 60 kg
795T-421-1270 Push tool t 1 Q
4 01050-31645 Bolt t 4
01643-31645 Washer t 8
795T-421-1240 Push tool t 1 Q
C
5 01050-31645 Bolt t 4
01643-31645 Washer t 4
795T-421-1250 Push tool t 1 Q
9 01050-31645 Bolt t 4
01643-31645 Washer t 8
Removal
5. Remove rear seal (4) according to the follow-
1. Remove the engine assembly. For details, see ing procedure.
"Removal and installation of engine assembly". a Measure the distance from the end of the
housing.
2. Remove damper assembly (1). For details, 1) Before pulling out rear seal (4), drive it in a
see "Removal and installation of damper little to separate it from housing (FWH).
assembly".
D155A-6 41
SEN03367-06 50 Disassembly and assembly
42 D155A-6
50 Disassembly and assembly SEN03367-06
1. Procedure for installing standard seal 4) Tighten the 3 bolts evenly to press fit rear
a When installing rear seal (4), do not apply seal (4) until the end of tool C4 (for press
oil or grease to the shaft and seal lip. fitting the seal) reaches the end of crank-
1) Set large inside diameter side (b) of plas- shaft (6).
tic inside cylinder (7) of rear seal (4) to the a Tighten tool C4 (for press fitting the
end of crankshaft (6). se a l) f ir st w ith o u t in s er t in g a n y
a Take care not to mistake the direction washer until the bolts reach the end
of the plastic inside cylinder. and then tighten with 2 washers
inserted (in each bolt).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
D155A-6 43
SEN03367-06 50 Disassembly and assembly
3) Remove tool C5 (for press fitting the a Tighten the mounting bolts according to
sleeved seal) and install tool C9 (for press the following procedure.
fitting the seal). Flywheel mounting bolts:
4) Tighten the 3 bolts evenly to press fit Width across flats (hexalobular internal)
sleeve and rear seal assembly (8) until the 22 mm
end of tool C9 reaches the end of crank- 3 Flywheel mounting bolts
shaft (6). 1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm}
a Tighten the bolt of tool C9 (for press 2nd time:1)When using tool A4
fitting the seal) without washer until it (See the tools list) Retighten
reaches, and then tighten the bolt each bolt by 90 (+30°/0) in
using 2 washers (for each bolt). the order of [1] – [8].
a After press fitting the seal, remove the 2) When not using tool A4
red sealant layer from its periphery. Make marks on each bolt
a Rear seal driving depth: and flywheel withpaint,then
13.2 ± 0.2 mm from end of crankshaft retighten each bolt by 90
(+30°/0) in the order of [1] –
[8].
44 D155A-6
50 Disassembly and assembly SEN03367-06
D155A-6 45
SEN03367-06 50 Disassembly and assembly
46 D155A-6
50 Disassembly and assembly SEN03367-06
D155A-6 47
SEN03367-06 50 Disassembly and assembly
Removal and installation of fan 4. Disconnect wiring harness connector FAR (5)
drive assembly 1 and remove wiring harness clamp.
Installation
q Carry out installation in the reverse order to
removal.
48 D155A-6
50 Disassembly and assembly SEN03367-06
[*3]
a Clean and degrease the fitting areas of the fan
motor and fan.
D155A-6 49
SEN03367-06 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03367-06
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 04-22
50 D155A-6
SEN03368-05
D155A-6
D155A-6 1
SEN03368-05 50 Disassembly and assembly
2 D155A-6
50 Disassembly and assembly SEN03368-05
[*2]
a Apply gasket sealant to damper cover, and
tighten mounting bolts 2 to 3 minutes after
application.
Damper cover mounting bolt:
Width across flats 19 mm
3 Damper cover mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*3]
a Install damper cover assembly according to
the following procedure.
1) Degrease the spline portion "a" of shaft (7),
apply dry lubricant A, and leave it 2 to 3 min-
utes.
2) Fill "b" portion of inner body (8) with about 80 g
of lithium base extreme pressure grease with
molybdenum disulphide B.
Dry lubricant with Sumiko lubricant Rocol
A
molybdenum disulphide Dry Splay or equivalent
• Kyodo yushi
Molylex No.2 or an
equivalent
Lithium base extreme
• Showa Shell Sekiyu
B pressure grease with
Retinax AM or an equiv-
molybdenum disulphide
alent
• Nippon Oil Corporation
Molytex or an equivalent
D155A-6 3
SEN03368-05 50 Disassembly and assembly
[*4] [*5]
Damper mounting bolt: Width across flats 19 mm
3 Damper mounting bolt:
98 – 122.6 Nm {10 – 12.5 kgm}
4 D155A-6
50 Disassembly and assembly SEN03368-05
Special tools
New/Remodel
Necessity
Sym-
Part number Part name
Sketch
bol
Q'ty
791-612-1100 Installer t 1
Puller
F 790-101-4200 t 1
(294 kN {30 ton})
790-101-1102 Hydraulic pump t 1
D155A-6 5
SEN03368-05 50 Disassembly and assembly
1. Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
2. Shaft
1) Set damper cover assembly (1) to block
[1], and remove shaft (6) by tapping it from
output side with plastic hammer, etc.
a Shaft (6) will be pulled out with inner
race (7-1) of bearing (7) and oil seal
(8).
6 D155A-6
50 Disassembly and assembly SEN03368-05
D155A-6 7
SEN03368-05 50 Disassembly and assembly
Assembly
Assembly of damper assembly (10)
8 D155A-6
50 Disassembly and assembly SEN03368-05
D155A-6 9
SEN03368-05 50 Disassembly and assembly
3. Install collar (7-2) and O-ring to shaft (6). 6. Install coupling (5) and holder (4), and tighten
bolt (3).
Mounting bolt: Width across flats 24 mm
3 Mounting bolt:
245.2 – 308.9 Nm {25 – 31.5 kgm}
10 D155A-6
50 Disassembly and assembly SEN03368-05
Removal and installation of power 12. Remove clamps (14) and (15) and hoses (16)
train unit assembly 1 and (17).
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
D155A-6 11
SEN03368-05 50 Disassembly and assembly
12 D155A-6
50 Disassembly and assembly SEN03368-05
23. Remove 4 mounting bolts (32) on the engine 27. Remove covers (38) on both sides of the steer-
side and disconnect universal joint (33). [*1] ing case.
a After disconnecting the universal joint,
push the yoke into the torque converter
side to disconnect the universal joint com-
pletely.
D155A-6 13
SEN03368-05 50 Disassembly and assembly
31. Using eyebolt [1] (M10 x 1.5), pull out drive 33. Lift off power train assembly (45). [*5]
shaft (43). a Check that all the wiring and piping are
a Pull out the drive shaft until it comes off disconnected.
the spline on the steering case side. a When lifting up the assembly, take care
a If the drive shaft cannot be pulled out eas- that it will not interfere with the machine.
ily, raise the shoe grouser with a jack to a
4 Power train assembly: 2,500 kg
position where the drive shaft can be
pulled out easily.
a Pull out the drive shaft on the opposite
side similarly.
14 D155A-6
50 Disassembly and assembly SEN03368-05
[*2]
3 Cap mounting bolt:
245.8 – 309 Nm {25 – 31.5 kgm}
[*3]
a When installing the power train unit assembly,
direct the seal stamp (UP) up.
a Securely clamp the seal ridge of coupling with
clamp (27). At this time, set the clamp bolt in
parallel with the cap mounting seat.
[*4]
3 Mount mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*5]
a When installing the power train unit assembly,
take care not to damage seal (40).
D155A-6 15
SEN03368-05 50 Disassembly and assembly
16 D155A-6
50 Disassembly and assembly SEN03368-05
10. Remove hoses (21) and (22). 16. Disconnect suction tube (30) from the fan
pump.
11. Remove tube (23).
17. Remove work equipment pump suction tube
mounting bolt (31) and lift off work equipment
pump suction tube (28) and fan pump suction
tube (30) together.
D155A-6 17
SEN03368-05 50 Disassembly and assembly
19. Remove power train and lubricating oil pump 22. Remove coupling (36).
assembly (33).
4 Power train and lubricating oil pump
assembly: 25 kg
18 D155A-6
50 Disassembly and assembly SEN03368-05
D155A-6 19
SEN03368-05 50 Disassembly and assembly
20 D155A-6
50 Disassembly and assembly SEN03368-05
Connection
q Carry out connection in the reverse order to
disconnection.
[*1]
a The oil pressure pickup hoses have color
bands on their adapters. Referring to the
table, connect those hoses to the power train
unit.
Sym-
Pressure pick up point Band color
bol
a 1st transmission clutch pressure Red
Yellow/
b 3rd transmission clutch pressure
Black
Reverse transmission clutch pres-
c Red/Blue
sure
White/
d 2nd transmission clutch pressure
Yellow
Forward transmission clutch pres-
e White/Blue
sure
f Transmission main relief pressure No band
g Torque converter inlet pressure Blue/Black
Yellow/
h Torque converter outlet pressure
Black
i Left brake pressure White
White/
j Right clutch pressure
Black [*2]
k Left clutch pressure Black Steering case mounting bolt:
Width across flats 19 mm
l Right brake pressure Yellow
3 Steering case mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
PTO assembly mounting bolt:
Width across flats 19 mm
3 PTO assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*4]
Torque converter mounting bolt:
Width across flats 19 mm
3 Torque converter mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
D155A-6 21
SEN03368-05 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03368-05
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 04-22
22 D155A-6
SEN03369-05
D155A-6
D155A-6 1
SEN03369-05 50 Disassembly and assembly
2 D155A-6
50 Disassembly and assembly SEN03369-05
6) Remove bearing (40) from case (17). 4) Remove inner race (41) from gear (13).
3. Cooling fan pump drive gear and cover 5) Remove snap ring (14) and remove bear-
assembly ing (15) from cover (12).
1) Remove 6 mounting bolts (10) and set a
guide bolt.
2) Tighten forcing screws into hole (c) to
remove gear and cover assembly (11).
D155A-6 3
SEN03369-05 50 Disassembly and assembly
4. Scavenging pump drive gear assembly 2) Remove the mounting bolts and set guide
1) Remove snap ring (18). bolt [2].
2) Remove gear (19) by pushing it into the 3) Using forcing screws [3], remove shaft
case. (23).
a Keep holding the gear in the case.
4 D155A-6
50 Disassembly and assembly SEN03369-05
D155A-6 5
SEN03369-05 50 Disassembly and assembly
5) Install gear (24). 2) While holding the inner race side of the
6) Install bearing (25) and tighten plate (22) bearing with push tool [5], install drive
with the bolt to press fit the bearing to the gear (19).
shaft.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245.0 – 308.7 Nm {25.0 – 31.5 kgm}
6 D155A-6
50 Disassembly and assembly SEN03369-05
2) Press fit bearing (15) to cover (12) and 5) Install gear and cover assembly (11),
install snap ring (14). meshing it with the idler gear.
2 O-ring: Grease (G2-LI)
2 Mounting bolt; Adhesive (LT-2)
3 Mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
D155A-6 7
SEN03369-05 50 Disassembly and assembly
3) Press fit inner race (7) to gear (6). 6) Install gear and cover assembly (4) to the
case.
2 O-ring: Grease (G2-LI)
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
6. Lubrication tube
1) Install lubrication tube (2).
3 Joint bolt:
34.3 – 44.2 Nm {3.5 – 4.5 kgm}
8 D155A-6
50 Disassembly and assembly SEN03369-05
D155A-6 9
SEN03369-05 50 Disassembly and assembly
10 D155A-6
50 Disassembly and assembly SEN03369-05
1. Pump
1) Press fit bearing (26) to retainer (23) and
install snap ring (25).
2) Install retainer (23) to pump (24).
2 Mounting bolt: Adhesive (LT-2)
2. Stator and race assembly
Mounting bolt: Width across flats 17 mm 1) Install race (15) to stator (16) and install 2
3 Mounting bolt:
snap rings (14).
58.8 – 73.6 Nm {6.0 – 7.5 kgm}
D155A-6 11
SEN03369-05 50 Disassembly and assembly
12 D155A-6
50 Disassembly and assembly SEN03369-05
D155A-6 13
SEN03369-05 50 Disassembly and assembly
Disassembly and assembly of 3) Remove sleeve (3) and flanges (4) and
transmission assembly 1 (5).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-615-1300 Puller assembly t 1 N
1 791T-615-1310 • Plate 1 N Q
G 01010-82040 • Bolt 1
Oil leak tester kit
2 799-301-1600 t 1
(A)
3. Snap ring
Remove snap ring (123) from output shaft
(124).
a Remove the snap ring at this time.
14 D155A-6
50 Disassembly and assembly SEN03369-05
3) Using eyebolts [2], sling transmission case 2) Disassemble the input shaft-front cover-
(8), remove 13 tie bolts (9) (used to clamp No. 1 carrier assembly according to the
the transmission case, too), and remove following procedure.
case (8). 1] Remove snap ring (12), No. 2 sun
gear (13) and snap ring (14).
2] Remove snap ring (15), No. 1 sun
gear (16) and collar (17).
5. Tie bolts
Remove 4 remaining tie bolts (9).
D155A-6 15
SEN03369-05 50 Disassembly and assembly
5] Remove snap ring (20) and drive out 8. No. 1 housing assembly
input shaft (21) toward the torque 1) Using eyebolts [4], remove No. 1 housing
converter. assembly (33).
2) Remove No. 1 piston (34) from the hous-
ing.
16 D155A-6
50 Disassembly and assembly SEN03369-05
D155A-6 17
SEN03369-05 50 Disassembly and assembly
14. No. 3 disc, plate and spring 16. Output shaft and No. 4 sun gear
1) Remove springs (60). 1) Pull out output shaft (73).
2) Remove springs (61), discs (62) and 2) Remove snap ring (74) from the output
plates (63). shaft.
3) Remove No. 4 sun gear (75).
18 D155A-6
50 Disassembly and assembly SEN03369-05
2) Disassemble the No. 4 carrier and No. 3 19. No. 4 disc, plate, spring and guide pin
ring gear assembly according to the fol- 1) Remove spring (89).
lowing procedure. 2) Remove springs (90), No. 4 discs (91) and
1] Remove snap ring (77) and ring gear plates (92).
(127). 3) Remove guide pin (93).
a Push the snap ring inward with a
pin (Diameter: Max. 3 mm) from
outside to warp and remove it.
2] Remove seal rings (78) and (79).
3] Drive in roll pin (80) to pull out shaft
(80A).
4] Remove thrust washer (81), planetary
gear (82) and bearing (83).
5] Remove snap ring (84) to remove
bearing (85) and spacer (86) as an
assembly.
6] Remove bearing (85) from spacer
(86).
D155A-6 19
SEN03369-05 50 Disassembly and assembly
2] Remove snap ring (101) and remove 23. No. 5 disc, plate and spring
No. 4 ring gear (102) from carrier 1) Remove springs (107).
(103). 2) Remove discs (108), plates (109) and
springs (110).
20 D155A-6
50 Disassembly and assembly SEN03369-05
1. Output housing
1) Using the push tool, press fit bearing (121)
to spacer (122).
D155A-6 21
SEN03369-05 50 Disassembly and assembly
2) Using the push tool, press fit spacer (122) 3. No. 5 piston
and bearing assembly (121) to output Install No. 5 piston (112) to the output housing.
housing (123).
3) Install snap ring (120). 4. No. 5 ring gear
Install No. 5 ring gear (111).
2. Cover assembly
1) Using the push tool, press fit bearing (119) 5. Guide pin
to cover (118). Install guide pin (93).
2) Install seal rings (117) and (116) to cover
(118). 6. No. 5 disc, plate and spring
1) Install discs (108), plates (109) and
springs (110).
a Install the 3 discs and 2 plates.
2) 2) Install springs (107).
a Free length of spring: 66 mm
22 D155A-6
50 Disassembly and assembly SEN03369-05
7. No. 4 housing assembly 2) Using guide bolts, set No. 5 carrier and
1) Fit the seal ring and install No. 4 piston No. 4 ring gear assembly (95) and tighten
(106). mounting bolts (94).
2) Install No. 4 housing assembly (105). 2 Threaded part of mounting bolt:
a Check that the springs are fitted to Adhesive (LT-2)
the grooves. Mounting bolt:
Inside hexagonal width across flats 8 mm
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
D155A-6 23
SEN03369-05 50 Disassembly and assembly
24 D155A-6
50 Disassembly and assembly SEN03369-05
15. No. 3 carrier assembly 16. No. 3 discs, plates and springs
1) Assemble the No. 3 carrier assembly 1) Install discs (62), plates (63) and springs
according to the following procedure. (61).
1] Using the push tool, press fit bearing a Install the 4 discs and 3 plates.
(72) to the carrier and install snap ring 2) Install springs (60).
(71). a Free length of spring: 70 mm
2] Install bearing (69) to planetary gear
(68). While fitting thrust washers (67)
to both sides of them, set them to the
carrier.
3] Fit ball (70) and install shaft (66).
4] Install seal ring (65).
D155A-6 25
SEN03369-05 50 Disassembly and assembly
4] Install bearing (53) to gear (52). 2) Using eyebolts [5], install No. 2 housing
While fitting thrust washers (51) to and No. 2 carrier assembly (42).
both sides of them, set them to the a Check that the springs are fitted to
carrier. the grooves.
5] Fit ball (54) and install shaft (50). 3) Fit the seal ring and install No. 2 piston
(43).
8] Install No. 2 housing (46) to No. 2 car- 18. Install through bolt guide (40), spring (130) and
rier assembly (45). lubricating oil relief valve (41).
a Press fit the inner race side of
the housing bearing.
9] Install snap ring (44).
26 D155A-6
50 Disassembly and assembly SEN03369-05
19. Guide pin 3] Set No. 1 ring gear (23) to No. 1 car-
Install guide pins (35). rier and install snap ring (22).
D155A-6 27
SEN03369-05 50 Disassembly and assembly
9] Install No. 2 sun gear (13) and snap 24. Front cover
ring (12). 1) Install seal ring (121) to front cover (122).
2) Sling input shaft and No. 1 carrier assem- 2) Using eyebolts [6], install front cover
bly (119) and install it, while meshing the (122), while aligning it with the guide pins
No. 2 sun gear with No. 2 planetary gear. and springs. Press fit the inner race side
of bearing (123) and install snap ring (24).
a Check that the springs are fitted to
the cover.
28 D155A-6
50 Disassembly and assembly SEN03369-05
D155A-6 29
SEN03369-05 50 Disassembly and assembly
30 D155A-6
50 Disassembly and assembly SEN03369-05
New/Remodel
H1, remove clutch and brake assembly
Necessity
Sym- (2).
Part No. Part name
a Do not remove the hexagon socket
Sketch
bol
Q'ty
head bolt.
a Remove the clutch and brake assembly
791-662-1110 Bracket t 1
on the other side in the same way.
1 01010-31685 Bolt t 1
H 01017-31620 Bolt t 1
790-302-1500 Spanner kit t 1
2
09003-09200 • Spanner 1
Disassembly
1. Steering valve assembly, reducing valve
Remove steering valve assembly (1).
D155A-6 31
SEN03369-05 50 Disassembly and assembly
iii)Loosen 4 hexagon socket head bolts ix) Using eyebolts, remove drum (12)
uniformly and remove, then using together with disc and plate.
eyebolts [1], remove cover (6). x) Remove 6 discs (13), 5 plates (14),
a The inner race of the bearing will and 6 springs (15) from drum (12).
come out.
iv) Remove bearing (7) from cover (6).
32 D155A-6
50 Disassembly and assembly SEN03369-05
iii)Remove snap ring (19), then remove ix) Remove clutch spring (25).
inner drum (20). x) Remove clutch outer drum (26) from
a Remove the snap ring from the brake hub (27).
ring groove, then fit it in the inner
drum groove.
iv) Remove snap ring (21).
3. Pipes
Remove 6 pipes (31).
a When removing the pipes, be careful not
vii) Remove mounting bolts, then remove to damage the O-rings.
cage (23).
viii) Remove clutch piston (24).
D155A-6 33
SEN03369-05 50 Disassembly and assembly
5. Case cover
Remove cover (33).
7. Lubrication tubes
Remove left and right lubrication tubes (36).
34 D155A-6
50 Disassembly and assembly SEN03369-05
v) Remove bearing (45) from bevel pin- 3) Lift off bevel gear shaft, bevel gear assem-
ion (40). bly (49).
9. Bevel gear shaft, bevel gear assembly 4) Disassembly of bevel gear shaft, bevel
1) Turn over steering case so that right cage gear assembly
is at top, then remove cage (46) and shim i) Using puller [7], remove bearing (51)
(47). from bevel gear shaft (50).
a Check the number and thickness of ii) Remove reamer bolt (52), then
the shims, and keep in a safe place. remove bevel gear (53) from bevel
gear shaft (50).
D155A-6 35
SEN03369-05 50 Disassembly and assembly
10. Nipple
Remove nipple (58). 2. Bevel gear shaft, bevel gear assembly
1) Using push tool [9], press fit outer race
(57) to cage (55).
36 D155A-6
50 Disassembly and assembly SEN03369-05
2) Assemble shim (56) and install cage (55). 4) Turn over steering case so that right side
a There are four types of shim: 0.05, is at top, then install bevel gear shaft and
0.1, 0.2, 0.5 mm bevel gear assembly (49).
3 Cage mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
D155A-6 37
SEN03369-05 50 Disassembly and assembly
3. Adjusting preload of bevel gear shaft iv) Press fit bearing (42) to cage (41)
1) Adjust thickness of shims at cage to adjust with press.
turning torque of bevel gear shaft. v) Hold in press so that pinion does not
a Turning torque move, then use tool H2 and tighten
(bevel pinion not meshed): locknut (39).
4.2 – 5.1 Nm {0.43 – 0.52 kgm} 2 Locknut:
(At tip of bevel gear teeth: Thread tightener (LT-2)
22.6 – 26.5 N {2.3 – 2.7 kg}) 3 Locknut:
a Rotate the bevel gear 2 – 3 times 779.6 ± 83.4 Nm {79.5 ± 8.5 kgm}
when measuring the turning torque. a Rotate the cage when tightening.
38 D155A-6
50 Disassembly and assembly SEN03369-05
D155A-6 39
SEN03369-05 50 Disassembly and assembly
40 D155A-6
50 Disassembly and assembly SEN03369-05
D155A-6 41
SEN03369-05 50 Disassembly and assembly
10. Pipes
Install 6 pipes (31).
6. Lubrication tubes
Install left and right lubrication tubes (36).
8. Case cover
Install cover (33).
42 D155A-6
50 Disassembly and assembly SEN03369-05
iii)Install clutch outer drum (26) to brake ix) Press fit inner drum (20) to cage (23),
hub (27). then install snap ring (19) assembled
3 Mounting bolt: to inner drum.
110.3 ± 12.3 Nm{11.25 ± 1.25 kgm} a The outer race of bearing (22)
iv) Set clutch outer drum facing up, then (installed in Step 1) -viii)) is press
assemble clutch spring (25). fitted.
v) Assemble clutch piston (24). x) Assemble plate (18) and disc (17).
vi) Fit seal ring and install cage (23). a Assemble the plate to the piston
3 Mounting bolt: end.
110.3 ± 12.3 Nm{11.25 ± 1.25 kgm} a Pistons: 5, Plates: 5
xi) Install cover (16).
a The cover is being pushed by the
clutch spring, so tighten the bolts
uniformly.
3 Mounting bolt:
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
D155A-6 43
SEN03369-05 50 Disassembly and assembly
2) Assembly of brake assembly vii) Using push tool, press fit bearing (7)
i) Install 3 seal rings (11) to brake hub to cover (6).
(27).
ii) Install cage (10) to brake hub (27).
a The outer race of the bearing is
press fitted.
44 D155A-6
50 Disassembly and assembly SEN03369-05
xi) Remove guide bolts and install plate 12. Steering valve, reducing valve
(5). Install steering valve (1).
xii) Install seal ring (4) and flange (3). 3 Mounting bolt:
a Assemble the clutch and brake 49.0 ± 4.9 Nm {5 ± 0.5 kgm}
assembly on the opposite side in
the same way.
3 Flange mounting bolt:
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
D155A-6 45
SEN03369-05 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03369-05
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 04-22
46 D155A-6
SEN03370-03
D155A-6
D155A-6 1
SEN03370-03 50 Disassembly and assembly
New/Remodel
under the steering case.
Necessity
Sym- 2) Set right and left support stands [3]
Part No. Part name
Sketch
bol under the main frame on the front
Q'ty
side of the machine.
a After setting support stands [1] and [3], set
790-337-1032 Lifting tool t 1
the hydraulic jack and ripper as auxiliary
791-627-1320 Shackle t 2 supports.
J
791T-627-1910 Plate t 1 N Q
01010-82080 Bolt t 2
Removal
1. Spread the track assembly. For details, see
"Spreading and installation of track assembly".
2 D155A-6
50 Disassembly and assembly SEN03370-03
5. Remove drive shaft cover (5). 8. Using tool J, sling final drive assembly (1) and
remove the remaining bolts.
k First, loosen 1 bolt on each of both
sides of the final drive so that the final
drive will not jump out. Then, loosen
all the bolts gradually to pull out the
final drive assembly.
Installation
q Carry out installation in the reverse order to
removal.
[*1], [*2]
Final drive mounting bolt:
Width across flats 41 mm
3 Final drive mounting bolt:
1,150 – 1,440 Nm {118 – 147 kgm}
D155A-6 3
SEN03370-03 50 Disassembly and assembly
New/Remodel
6
Necessity
Sym- 2. Drive shaft
Part No. Part name
Sketch
bol
Remove drive shaft (1).
Q'ty
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
1
790-101-2480 Adapter t 2
791T-627-1920 Plate t 1 N Q
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
790-431-1031 Block t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
3. Shaft
01643-32460 Washer t 2
2 1) Set the final drive assembly to the block.
791T-627-1930 Plate t 1 N Q 2) Remove mounting bolts (2).
791T-627-1940 Push tool t 1 N Q
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
3 791-627-1280 Installer t 1
790-101-5401 Push tool kit t 1
790-101-5441 • Plate 1
4
K 790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5401 Push tool kit t 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
5
01010-51240 • Bolt 1
791T-627-1950 Plate t 1 N Q
791T-627-1960 Plate t 1 N Q
790-201-1500 Push tool kit t 1
790-201-1680 • Plate 1
6
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
791-112-1180 Nut t 1
01643-22460 Washer t 1
7
792-785-1120 Plate t 1
791-830-1410 Push tool t 1
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
4 D155A-6
50 Disassembly and assembly SEN03370-03
3) Using eyebolts [1], remove shaft (3). 4) Remove floating seal (8) and bearing
outer races (9) and (10).
a Keep the floating seal in a safe place
so that it will not be damaged.
D155A-6 5
SEN03370-03 50 Disassembly and assembly
7. Carrier assembly
1) Using 3 eyebolts [5], remove carrier
assembly (21).
4) Using eyebolts [3], sling cover assembly
(16). Using 3 forcing screws [4], remove
the cover assembly.
6 D155A-6
50 Disassembly and assembly SEN03370-03
10. Gear
4] Remove bearing outer races (29) and 1) Remove the gear according to the follow-
(30) from the planetary gear. ing procedure.
1] Sling case-hub-case assembly (35) a
little.
2] Push the shaft of case (36) to make a
clearance between bearing (37) and
case shaft.
a Take care not to damage the
bearing holding area on the pin-
ion side.
8. Sun gear
Remove thrust washer (31) and sun gear (32).
D155A-6 7
SEN03370-03 50 Disassembly and assembly
11. Hub and case assembly 4) Remove collar (43) and remove bearing
1) Using tool K2, remove hub assembly (40) (44) from case (36).
and bearing (37).
8 D155A-6
50 Disassembly and assembly SEN03370-03
2) Remove outer race (48) and oil seal (49) 14. Outer race and oil seal
from cage (47). Remove outer race (55) and oil seal (56) from
case (36).
D155A-6 9
SEN03370-03 50 Disassembly and assembly
3. Cage assembly
1) Using tool K4, press fit oil seal (49) to
cage (47).
a When press fitting the oil seal, take
care of its direction.
a Apply gasket sealant thinly to the
inside wall of the housing and wipe off
projected part.
2 Oil seal lip: Grease (G2-LI)
2 Oil seal press fitting area:
Gasket sealant (LG-5)
2) Using tool K5, press fit outer race (55) to
case (36).
q Outer race press fitting force:
1 – 13 kN {0.1 – 1.4 ton}
10 D155A-6
50 Disassembly and assembly SEN03370-03
2) Using tool K5, press fit bearing outer race 4] Install determined shim (50) to the
(48) to cage (47). cage and tighten the 6 mounting bolts
q Bearing press fitting force: of cage (47) evenly.
1 – 13 kN {0.1 – 1.4 ton} Mounting bolt:
Width across flats 19 mm
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
4) Adjustment of shim
q Adjust the pinion bearing clearance
according to the following procedure.
1] Tighten mounting bolts (D), (E), (G)
and (H) of cage (40) evenly.
Mounting bolt:
Width across flats 19 mm
3 Mounting bolt: 20 Nm {2 kgm}
2] Using a thickness gauge, measure
clearances (a) and (b) between cage
(47) and case (36).
3] Referring to Table 1, determine quan-
tity (c) of the shim from the total of
clearances (a) and (b).
D155A-6 11
SEN03370-03 50 Disassembly and assembly
12 D155A-6
50 Disassembly and assembly SEN03370-03
4) Using tool K5, press fit 2 bearing outer 2) Tighten gear mounting bolts (38).
races (42) to hub (41). 2 Mounting bolt: Adhesive (LT-2)
q Bearing press fitting force: Mounting bolt: Width across flats 24 mm
3 – 18 kN {0.3 – 1.8 ton} 3 Mounting bolt:
230 – 289 Nm {23.5 – 29.5 kgm}
5. Gear
1) Using eyebolts [6], sling gear (39). While
slanting the hub, set the gear to the hub.
6. Holder
Install holder (34) and tighten mounting bolt
(35).
2 Mounting bolt: Adhesive (LT-2)
Mounting bolt: Width across flats 24 mm
3 Mounting bolt:
230 – 289 Nm {23.5 – 29.5 kgm}
D155A-6 13
SEN03370-03 50 Disassembly and assembly
8. Carrier assembly
a Since each planetary gear bearing is an
assembly, assemble it from the inner race,
outer race and spacer of the same identifi- 4) Install holders (23) and tighten bolts (22).
cation mark. 2 Mounting bolt: Adhesive (LT-2)
1) Using tool K6, press fit bearing outer Mounting bolt: Width across flats 24 mm
races (29) and (30) to the planetary gear. 3 Mounting bolt:
q Bearing press fitting force: 230 – 289 Nm {23.5 – 29.5 kgm}
10 – 35 kN {1.0 – 3.6 ton}
14 D155A-6
50 Disassembly and assembly SEN03370-03
D155A-6 15
SEN03370-03 50 Disassembly and assembly
10. Wear guard 3) Using tool K3, press fit floating seal (8).
Install wear guard (12). a Degrease and dry the O-ring and O-
Mounting bolt: Width across flats 36 mm ring contact surface before installing
3 Mounting bolt: the floating seal.
824 – 1,030 Nm {84 – 105 kgm} a After installing the floating seal, check
that its tilt is 1 mm or less.
16 D155A-6
50 Disassembly and assembly SEN03370-03
5) Using tool [10], press fit bearing (7). 2) Tighten mounting bolts (2).
a While rotating the sprocket hub Mounting bolt: Width across flats 41 mm
assembly, press fit the bearing. 3 Mounting bolt:
q Bearing press fitting force: 1,225 – 1,470 Nm {125 – 150 kgm}
15 – 43 kN {1.5 – 4.4 ton}
D155A-6 17
SEN03370-03 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03370-03
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 04-22
18 D155A-6
SEN03371-05
D155A-6
D155A-6 1
SEN03371-05 50 Disassembly and assembly
2 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 3
SEN03371-05 50 Disassembly and assembly
4) Remove 2 mounting bolts (8) and remove 6. Lift off track frame assembly (14). [*2]
washer (9). a When lifting off the track frame assembly,
take care extremely not to damage the
seal surface.
4 Track frame assembly: 3,960 kg
4 D155A-6
50 Disassembly and assembly SEN03371-05
Installation [*3]
a Install seal (15) according to the following pro-
q Carry out installation in the reverse order to
cedure.
removal.
1) Reverse seal (15) so that the molded let-
ter (c) face will be on the inside.
[*1]
2) With the seal reversed, insert seal (15) in
a Install seal (10) according to the following pro-
pivot shaft (16).
cedure.
3) Apply oil (EO-30) to face (d) of track frame
1) Reverse seal (10) so that the molded let-
assembly (14).
ter (a) face will be on the inside.
4) Install track frame assembly to the pivot
2) With the seal reversed, insert the seal in
shaft.
washer (12).
3) Apply oil (EO-30) to face (b) of washer (9)
at the shaft end.
4) Install washer (9) to the shaft end.
[*2]
a When inserting the track frame assembly, take
care extremely not to damage the seal surface.
D155A-6 5
SEN03371-05 50 Disassembly and assembly
3. Remove seat support bolt (1), and remove 662 – 829 Nm {67.5 – 84.5kgm}
plate (2) and shim (3). [*1] a Set clearance (Tc): 2.0 – 3.4 mm
(Including endplay)
4. Loosen support mounting bolts (4), and a Endplay (Ep): 0.49 – 0.72 mm
remove shim (5). [*2] (Total of both side)
6 D155A-6
50 Disassembly and assembly SEN03371-05
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791-630-1220 Rod t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
01580-01411 Nut t 2
1
01643-31445 Washer t 2
L
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Hydraulic pump t 1
2 791-651-1510 Installer t 1
3 791-601-1000 Oil pump t 1
Disassembly
1. Remove the oil drain plug to drain the oil.
6 Idler: Approx. 390 – 450 cc
D155A-6 7
SEN03371-05 50 Disassembly and assembly
8. Reverse the idler assembly (1) and set it to 14. Using tool L1, remove shaft (14) and bushing
blocks [1]. (12).
4 Idler assembly: 400kg
15. Remove bushing (12) from shaft (14).
a Do not remove inner bushing from outer
9. Remove nut (8) and pull out bolt (9).
bushing. [*1]
10. Lift off support assembly (10).
4 Support assembly: 100kg
17. Using push tool [2] and tool L1, remove bush-
ing (6).
a Do not remove inner bushing from outer
bushing. [*2]
8 D155A-6
50 Disassembly and assembly SEN03371-05
a Clean all the parts thoroughly and check them 7. Using tool L2, install floating seal (5a) to bush-
for dirt or damage. ing (6).
D155A-6 9
SEN03371-05 50 Disassembly and assembly
13. Using tool L3, add oil to the specified level and
tighten the plug.
6 Idler: 390 – 450 cc (GO140B)
10 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 11
SEN03371-05 50 Disassembly and assembly
Disassembly and assembly of 3) Using push tool [1], pull out piston (9) from
recoil spring assembly 1 yoke (8) with a press.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
M 2 791T-630-2610 Spacer t 1 Q
790-101-1300 Cylinder t 1
790-101-1102 Hydraulic pump t 1
2. Disassembly of yoke and piston assembly 3. Remove holder (13) from recoil spring case
1) Remove snap ring (3), packing (4) and (12).
k Never stand in front of or at the rear of
ring (5).
2) Remove bolt (6) and plate (7). the recoil spring assembly to avoid
danger.
12 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 13
SEN03371-05 50 Disassembly and assembly
14 D155A-6
50 Disassembly and assembly SEN03371-05
4. Install nut (11) and spacer (19). 6. Install lubricator (18) to cylinder (10) and install
a Eliminate the clearance between the nut the lock plate.
and spacer. a Install the grease fitting at 45° ± 5° out.
(Reference) If there is any clearance, the
spring load is applied to the
threaded part of the nut. The nut
may be damaged and may not be
able to be disassembled next
time.
7. Assembly of holder
1) Using the push tool, press fit bushing (17)
to holder (14) and install seal (16).
2 Bushing and oil seal:
Grease (G2-LI)
2) Install cover (15) to holder (14).
5. Release the hydraulic pressure gradually to
release the spring tension completely and then
remove recoil spring assembly (1) from tool
M2.
D155A-6 15
SEN03371-05 50 Disassembly and assembly
16 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 17
SEN03371-05 50 Disassembly and assembly
Disassembly and assembly of 7. Reverse track roller assembly (8) and set to
track roller assembly 1 press.
New/Remodel
9. Using press, push out shaft (10) and bushing
Necessity
Sym- (4).
Part No. Part name
Sketch
bol
Q'ty
10. Remove bushing (11) from shaft (10).
a Do not separate inner bushing and outer
L 2 791-651-1510 Installer t 1
bushing. [*1]
Disassembly
1. Remove plug and drain oil.
18 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 19
SEN03371-05 50 Disassembly and assembly
k Park the machine on level ground, and set the parking brake lever to the LOCK position.
k Lower the work equipment to the ground, and set the work equipment lock lever to LOCK posi-
tion.
k Turn the starting switch to OFF position, and stop the engine.
k Disconnect the cable from the negative (-) terminal of the battery.
20 D155A-6
50 Disassembly and assembly SEN03371-05
Removal
1. Sling engine undercover (17), and remove bolts (17a) (12
pieces). At this time, be sure to remove engine undercover
(17) gradually while supporting it from below using the lifting
and lowering device.
4 Engine undercover (17): 220 kg
Bolt (17a): Width across flats of 36 mm
D155A-6 21
SEN03371-05 50 Disassembly and assembly
7. Use tool L22 (lifting tool) to sling track roller assembly (5).
4 Track roller assembly (5): 95 kg
Tool: Special tool L22
8. With track roller assembly (5) slung, remove roller cap bolts
(16) (4 pieces) and cap (3) (2 pieces), and then pull track
roller assembly (5) outward to remove with tool L22
installed.
a Pull out the track roller assembly outward while balanc-
ing it.
22 D155A-6
50 Disassembly and assembly SEN03371-05
5) Set puller tool L16 (puller jig) to remove rings (10) and
(11).
Tool: Special tool L16
q Pushing force (reference): 216 to 402 kN {22 to 41
tons}
D155A-6 23
SEN03371-05 50 Disassembly and assembly
24 D155A-6
50 Disassembly and assembly SEN03371-05
Installation
1. Assembly of pin
1) Press-fit shaft (7) to ring (8).
q Press fit force of shaft (7): 1.96 to 15.68 kN {0.2 to
1.6 ton}
2 Between shaft (7) and ring (8):
Molybdenum disulfide lubricant (LM-P)
D155A-6 25
SEN03371-05 50 Disassembly and assembly
26 D155A-6
50 Disassembly and assembly SEN03371-05
3. Align the mounting hole for the pin in the track frame with
that in the bogie, and then set guide tool L19 (guide).
Tool: Special tool L19
k When aligning the mounting holes for the pin,
never insert your fingers in the holes.
4. Install the cartridge pin assembly to the mounting hole for
the pin with arrow mark (b) on its end face up.
5. Set tool L20 (press-fitting jig) to the track frame.
Tool: Special tool L20
6. Install cover (6) to cartridge pin assembly (15), and use
hydraulic puller of tool L20 to press-fit cartridge pin assem-
bly (15) to the track frame.
a Be sure to press-fit the cartridge pin assembly until it
reaches to machined surface (c) on the track frame.
2 Outer circumference of pin:
Molybdenum disulfide lubricant (LM-P)
q Press fit force of cartridge pin assembly:
216 to 402 kN {22 to 41 ton}
9. Use tool L22 (lifting tool) to sling and set track roller assem-
bly (5).
a Be sure to set it with its oil filler plug facing the outside
of the machine.
a Be sure to set the track roller assembly while balancing
it.
Tool: Special tool L22
4 Track roller assembly: 95 kg
10. Install roller cap (3) and use bolts (16) (4 pieces) to install it
lightly.
a Take care not to damage the dowel pin installed in it.
Bolt (16): Width across flats of 32 mm
D155A-6 27
SEN03371-05 50 Disassembly and assembly
11. Align dowel pin (17) with the dowel hole, and then tighten
bolts (16).
2 Roller cap mounting bolt: Adhesive (LT-2)
Bolt (16): Width across flats of 32 mm
3 Roller cap mounting bolt:
662 to 829 Nm {67.5 to 84.5 kgm}
12. Remove tool L14 that has been installed to the 2nd bogie.
13. Install the track shoe assembly. For details, see "Separation
and connection of track shoe assembly".
14. Sling engine undercover (17) and set it to its installed posi-
tion.
4 Engine undercover: 220 kg
15. Use bolts (17a) (12 pieces) to install engine undercover
(17).
Bolt (17a): Width across flats of 36 mm
3 Bolt (17a): 785 to 980 Nm {80 to 100 kgm}
16. Adjust the track tension. For details, see Testing and ,
adjusting, "Testing and adjusting track tension".
28 D155A-6
50 Disassembly and assembly SEN03371-05
k Park the machine on level ground, and set the parking brake lever to the LOCK position.
k Lower the work equipment to the ground, and set the work equipment lock lever to LOCK posi-
tion.
k Turn the starting switch to OFF position, and stop the engine.
k Disconnect the cable from the negative (-) terminal of the battery.
D155A-6 29
SEN03371-05 50 Disassembly and assembly
Removal
1. Separate the track shoe assembly. For details, see "Sepa-
ration and connection of track shoe assembly".
2. Sling engine undercover (17), and remove bolts (17a) (12
pieces). At this time, be sure to remove engine undercover
(17) gradually while supporting it from below using the lifting
and lowering device.
a The engine undercover needs to be removed because
it can hinder the work to remove the bogie assembly.
4 Engine undercover (17): 220 kg
Bolt (17a): Width across flats of 36 mm
3. Sling power train undercover (18), and remove bolts (18a)
(10 pieces). At this time, be sure to use a lever block to
remove power train undercover (18) gradually while sup-
porting it from below using the lifting and lowering device.
a The power train undercover needs to be removed
because it can hinder the work to remove the bogie
assembly.
4 Power train undercover (18): 270 kg
Bolt (18a): Width across flats of 36 mm
30 D155A-6
50 Disassembly and assembly SEN03371-05
2) Push out shaft (3) using tool L15 (pushing tool) to press
out shaft (3) and ring (4) to the opposite side.
q Pushing force (reference): 216 to 402 kN {22 to 41
tons}
5) Set tool L16 (puller jig) to pull out and remove rings (6)
and (7) from the track frame using hydraulic puller of
tool L16.
Tool: Special tool L16
q Pushing force (reference): 216 to 402 kN {22 to 41
tons}
D155A-6 31
SEN03371-05 50 Disassembly and assembly
10. Operate the blade and ripper slowly to raise the machine off
the ground to a height where track roller assembly (1) can
be pulled out.
k Be sure to set blocks on track rollers that are not
removed and track links to prevent the machine
from lowering.
a When operating the blade and ripper, be sure to reduce
the engine speed and operate them slowly.
11. Sling bogie assembly (1), and slide the assembly on steel
plate [2] to pull out and remove it outside.
4 Bogie assembly: 525 kg
32 D155A-6
50 Disassembly and assembly SEN03371-05
Installation
1. Assembly of pin
1) Press-fit shaft (3) to ring (4).
q Press fit force of shaft (3): 1.96 to 15.68 kN {0.2 to
1.6 ton}
2 Between shaft (3) and ring (4):
Molybdenum disulfide lubricant (LM-P)
D155A-6 33
SEN03371-05 50 Disassembly and assembly
4) Install spacer (9) to ring (6), and use tool [3] to press-fit
ring (7).
q Press fit force for ring (7): 3.9 to 48 kN {0.4 to 4.9
ton}
2 Between shaft (3) and ring (7):
Molybdenum disulfide lubricant (LM-P)
2. Use L21 (oil pump) to fill the cartridge pin assembly with
specified amount of oil.
Tool: Special tool L21
5 Cartridge pin assembly (81 to 95 % full amount):
50 to 60 cc (GO140)
3. Sling bogie assembly (1) and lower the assembly onto block
[1] and steel plate decking [2].
Tool: Blocks [1], steel plate decking [2]
4. Install lever block [4] to the bogie of the track frame on the
opposite side of that of bogie assembly (1) to be installed.
Tool: Lever block [4]
5. Use lever block [4] to pull bogie assembly (1), and slide the
assembly on steel plate decking [2] to set it to its installed
position.
34 D155A-6
50 Disassembly and assembly SEN03371-05
3) Set blocking tool [7] and hydraulic jack [8] at the front
(e) (each side) of the machine
a Be sure to set the hydraulic jack extended fully.
Tool: Blocking tool [7], hydraulic jack [8]
4) Use front and rear hydraulic jacks [6] and [8] to lower
the machine, and install locking tool L14 (bracket) to
bogie assembly (1).
Tool: Hydraulic jack [6] and [8], special tool L14
5) Use front and rear hydraulic jacks [6] and [8] to adjust
the height, and align mounting hole for the pin in the
track frame with that in bogie assembly (1).
k When aligning the mounting holes for the pin,
never insert your fingers in the holes.
a When the mounting holes for the pin cannot be
aligned with each other by the adjustment of front
and rear hydraulic jacks, sling the track on the
opposite side at its front part and adjust the mount-
ing hole position for the pin, or apply a hydraulic
jack to the bogie assembly and adjust the mount-
ing hole position for the pin.
6) Put tool L19 (guide) into the hole for the pin.
Tool: Special tool L19
D155A-6 35
SEN03371-05 50 Disassembly and assembly
7. Put cartridge pin assembly (11) in the hole for the pin.
a Be sure to put in cartridge pin assembly (11) with arrow
mark (b) on its end face up.
8. Set tool L20 (press-fitting jig) to the track frame.
9. Set cover (6) to cartridge assembly (11), and use tool L20 to
press-fit the assembly.
Tool: Special tool L2020
a Be sure to press-fit the cartridge pin assembly (11) until
it reaches to machined surface (c) on the track frame.
2 Outer circumference of pin:
Molybdenum disulfide lubricant (LM-P)
q Press fit force of cartridge pin assembly:
216 to 402 kN {22 to 41 ton}
10. Follow steps 6- 6) to 9. to press-fit cartridge pin (11) on the
opposite side.
11. Use bolts (2a) (3 pieces) to install covers (2) on the inside
and outside.
a 2 locations of inside and outside
12. Remove tool (L14).
13. Install the track shoe assembly. For details, see "Separation
and connection of track shoe assembly".
14. Sling power train undercover (18) and set it to its installed
position.
a Follow this step when it has been removed.
4 Power train undercover: 270 kg
15. Use bolts (18a) (10 pieces) to install power train undercover
(18).
3 Bolt (18a): 785 to 980 Nm {80 to 100 kgm}
16. Sling engine undercover (17) and set it to its installed posi-
tion.
a Follow this step when it has been removed.
4 Engine undercover: 220 kg
17. Use bolts (17a) (12 pieces) to install engine undercover
(17).
18. Adjust the track tension. For details, see Testing and
adjusting, "Testing and adjusting track tension".
36 D155A-6
50 Disassembly and assembly SEN03371-05
Disassembly
1. Track roller assembly
1) Reverse bogie assembly (1).
2) Remove the roller cap and lift off 2 track roller assem-
blies (2).
a Take care not to damage the installed dowel pin.
4 Track roller assembly
(single flange): 95 kg
4 Track roller assembly
(double flange): 105 kg
2. Cover
Remove cover (3).
3. Cartridge pin assembly
Remove cartridge pin assembly (4) according to the proce-
dure in "Removal and installation of bogie assembly".
4. Bogies
Disconnect inner bogie (5) and outer bogie (6).
D155A-6 37
SEN03371-05 50 Disassembly and assembly
Assembly
1. Assembly of cartridge pin assembly
Assemble cartridge pin assembly (4) according to the pro-
cedure in "Removal and installation of bogie assembly".
2. Bogies
Set outer bogie (6) and inner bogie (5).
3. Cartridge pin assembly
1) Set tool Q20.
38 D155A-6
50 Disassembly and assembly SEN03371-05
8. Roller guide
Set the roller guide (20) to the bogie assembly when remov-
ing and installing the roller guide, so that no clearance is left
on the face (g).
D155A-6 39
SEN03371-05 50 Disassembly and assembly
Removal and installation of 4. Pass rope [2] through the link hole and wind it
carrier roller assembly 1 onto carrier roller (3) and stretch it. Loosen the
rope gradually to pull out carrier roller (3) from
Removal support (4). [*1]
1. Remove the track frame top cover and loosen 4 Carrier roller: 45 kg
lubricator (1) to lower the track tension.
k Since the internal pressure of the recoil
spring cylinder is very high, do not
loosen the lubricator more than 1 turn.
If the grease does not come out suffi-
ciently after the lubricator is loosened,
move the machine forward and in
reverse.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
When installing the carrier roller to the support,
make clearance (a) shown in the figure.
2. Using hydraulic jacks [1], raise the track shoe. q Clearance (a): 1.2 mm
2 Support mounting bolt: Adhesive (LT-2)
3. Remove mounting bolts (2).
q Adjust the track shoe assembly tension. For
details, see Testing and adjusting, "Testing and
adjusting track shoe assembly tension".
40 D155A-6
50 Disassembly and assembly SEN03371-05
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-102-1891 Nut wrench t 1
2 791-651-1510 Installer t 1
R
3 791T-630-1350 Spacer t 1 Q
4 791-601-1000 Oil pump t 1
Disassembly
1. Remove the plug to drain the oil.
a While rotating the shaft, drain the oil.
7. Remove outer race (7) from the roller.
6 Carrier roller: 570 – 680 cc
8. Using puller [3], remove ring (8) and the inner
2. Set carrier roller assembly (1) to block [1]. race of bearing (9) together.
D155A-6 41
SEN03371-05 50 Disassembly and assembly
42 D155A-6
50 Disassembly and assembly SEN03371-05
5. Using tool R1, tighten nut (4) to "58.8 Nm {6 9. Using tool R2, install floating seal (10) to ring
kgm}". (8).
a After tightening the nut, if the nut hole is
not aligned with the shaft hole, align it by 10. Fit the O-ring and install ring (8) while setting it
loosening it. to the dowel pin.
D155A-6 43
SEN03371-05 50 Disassembly and assembly
12. Using tool R3, press fit ring (11). 14. After checking for air leakage, check again that
a Press fit the ring so that dimension (a) the oil supplied in step 8 is still at a proper
from the shaft end to the ring top will be level.
131.95 ± 0.2 mm. a Check of oil level
Remove the oil filler plug, slant the carrier
roller approx. 10°, and check the oil level.
44 D155A-6
50 Disassembly and assembly SEN03371-05
Removal and installation of pivot 3. Sling pivot shaft assembly (3) and remove the
shaft assembly 1 mounting bolts. Using eyebolts [1], lift off pivot
shaft assembly (3). [*2]
Special tools 4 Pivot shaft assembly: 135 kg
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-650-2110 Sleeve t 1 Q
790-201-2770 Spacer t 1
791T-650-2120 Plate t 1 Q
792-104-3940 Bolt t 2
790-101-2510 Block t 1
V
790-101-2570 Washer t 2
01580-01613 Nut t 1
Jack assembly
790-105-2300 t 1
(196 kN {20 ton})
790-101-1102 Hydraulic pump t 1
Removal
1. Remove the track frame assembly. For details,
see "Removal and installation of track frame
assembly".
D155A-6 45
SEN03371-05 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Install seal (1) according to the following pro-
cedure.
1) Reverse seal (1) so that the molded letter
(a) face will be on the inside.
2) With seal (1) reversed, insert it in pivot
shaft (3).
[*2]
2 Pivot shaft mounting bolt: Adhesive (LT-2)
Pivot shaft mounting bolt:
Width across flats 41 mm
3 Pivot shaft mounting bolt:
784 – 981 Nm {80 – 100 kgm}
46 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 47
SEN03371-05 50 Disassembly and assembly
48 D155A-6
50 Disassembly and assembly SEN03371-05
Installation
q Carry out installation in the reverse order to
expansion (ordinary).
[*1]
a Adjust the track shoe tension. For details, see
Testing and adjusting, "Testing and adjusting
track shoe tension".
[*2]
a Tighten the shoe mounting bolts for the master
link in the following order.
2 Shoe mounting bolt:
Molybdenum disulfide grease (LM-P)
Shoe mounting bolt: Width across flats 36 mm
3 Shoe mounting bolt:
1st time: 590 ± 60 Nm {60 ± 6 kgm}
2nd time: Retighten by 180° ± 10°
a Tighten all the 4 bolts with fingers until the
master link mating faces are fitted.
a If the bolts are tightened forcibly before the
master link mating faces are fitted, their
threads and master link may be damaged.
D155A-6 49
SEN03371-05 50 Disassembly and assembly
New/Remodel
among the links.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Remover and
791-675-9701 t 1
installer
Cylinder
791-101-4300 t 1
1 (196 kN {20 ton})
Puller
791-101-4200 t 1
(294 kN {30 ton})
791-101-1102 Hydraulic pump t 1
S
2 791-932-1110 Plug push tool t 1
3 791-660-7460 Pin brush t 1
4 791-432-1110 Plug push tool t 1
2. Disassembly of link
5 791-632-1052 Installer t 1 1) Set the link assembly on a link press and
6 790-701-3000 Seal checker t 1 hit it with a hammer so that the bushing
7 791-601-1000 Oil pump t 1 will be fitted to the jaw.
a If the link tread, outside of the bush-
a For the general disassembly of the track shoe, ing, etc. are worn, adjust the height of
see "Parts judgment guide, Undercarriage, Oil jaw [1] or guide plate and align disas-
lubricated track" and "Parts judgment guide, sembly jigs [2] and [3] with the pin
Undercarriage, Reversing procedure for oil and bushing so that the link hole will
lubricated track". not be damaged during disassembly
work.
a If the disassembly jigs are not aligned
General disassembly well, the link hole may be damaged
1. Removal of shoe and the pin and bushing may be bro-
Sling the shoe assembly and set it with the ken during disassembly work.
shoe up on the floor and remove the shoe by
using a shoe bolt impact wrench.
a If a shoe bolt is not loosened after it is
unscrewed by 1 turn (If its torque is not
reduced to 0), loosen the other bolts first,
and it will be removed smoothly.
a If a shoe bolt is turned forcibly while its
torque is not 0, it and link will adhere to
each other and they will need to be
repaired.
a When moving the shoe assembly, take
care not to damage the master link.
50 D155A-6
50 Disassembly and assembly SEN03371-05
a Using tool S2, drive the small plug of 4) Return the right cylinder and take out the
the pin inward after the disassembly links, pins, bushings, and spacers on the
work so that the workplace will not right and left sides and feed the next 1 set
become dirty. of the link assembly to the jaw.
a If the bushing ends and sealing sur-
faces are damaged, oil will leak.
Accordingly, handle them carefully.
D155A-6 51
SEN03371-05 50 Disassembly and assembly
52 D155A-6
50 Disassembly and assembly SEN03371-05
3) If the link, pin, bushing and spacer are 5) Installation of seal assembly
dirty, clean them. Remove the nodules Clean the counterbore portion (d) of the
sticking to the link and bushing with the link carefully and push in the seal to the
grinder. bottom by using tool S5.
a Since these parts rust easily, clean a If oil sticks to the counterbore portion
them just before assembling. of the link or seal assembly, the seal
a Do not polish the bushing ends. If will turn and its sealing performance
they are polished, oil may leak. will lower. Accordingly, do not apply
4) If the large plug was pulled out, drive it in any oil. When inserting the seal in the
by using tool S4. counterbore portion, take care that oil
a Clean the pin hole in advance by not stick to the seal.
using tool S3.
D155A-6 53
SEN03371-05 50 Disassembly and assembly
54 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 55
SEN03371-05 50 Disassembly and assembly
11) Set the left jig on the receiving side and 13) Using a shoe bolt hole pitch gauge, mea-
the right one on the pushing side and sure the distance between the shoe bolt
press fit the left link. holes and check that the result is within
a When press fitting, take care that both the standard range.
seals and spacers will not come off. a If the distance between the shoe bolt
a Link press fitting force: holes is longer than the standard
343 – 490 kN {35 – 50 ton} range, disassemble and check for
abnormality, then press fit again.
a If the distance between the shoe bolt
holes is shorter than the standard
range and the shoe cannot be
installed, the spacer or bushing end
may be worn more than repair limit.
In this case, disassemble and replace
the parts.
56 D155A-6
50 Disassembly and assembly SEN03371-05
15) Using tool S7, supply oil (G090) until the 16) After supplying oil, drive in the small plug
oil supply pressure rises to 196 – 294 kPa into the specified position, using tool S2.
{2 – 3 kg/cm2}. a Apply G090 around the small plug.
a In a cold or very cold district, supply a Drive in the small plug to the following
KOM AT SU ge nuin e oil ( 15 0-0 9- depth.
19270 for cold district or 195-32- Driving depth from end: 7.5 ± 1 mm
61990 for very cold district) having
better low-temperature characteristics
instead of G090.
a If the oil pressure is heightened too
much, it has bad effects on the seal.
Take care.
D155A-6 57
SEN03371-05 50 Disassembly and assembly
2) When installing a 2-piece shoe, place the When recycling for grease lubricated track
assembled 2-piece shoes on a level place 1. Preparation work
in 1 line with the shoe side up. 1) Cleaning of seal assembly
3) Pull pin-side master link (1) and bushing- Remove the seal assembly from the link
side master link (2) together and set them and divide it into the seal ring (1) and load
to each other by the mating faces. ring (2), and then clean them.
4) Place shoe (3) and fit the mating surfaces a Since the seal ring and load ring are
of the links. deteriorated easily by the cleaning liq-
5) Check that master bolts (4) can be tight- uid, clean them quickly. After clean-
ened easily with the fingers, then connect ing them, wipe off the cleaning liquid
the links with the master bolts. from them.
2 Master bolt:
Molybdenum disulfide grease
(LM-P)
Master bolt (Master link):
Width across flats 36 mm
3 Master bolt (Master link)
Initial torque:
590 ± 60 Nm {60 ± 6 kgm}
Retightening angle: 180° ± 10°
58 D155A-6
50 Disassembly and assembly SEN03371-05
3) Using tools S2 and S4, drive the large and 6) Installation of seal assembly
small plugs (3) into the pin (4). Clean the counterbore portion (d) of the
1] Insert each plug through the plug link carefully. Using tool S5, push in the
insertion window into the guide hole. seal to the bottom.
a Apply oil to the plug. a If grease sticks to the counterbore
2] Push the bar with the hand until the portion of the link or seal assembly,
plug stops. the seal will turn and its sealing per-
3] Push the plug with the bar to press formance will lower. Accordingly, do
the guide against the pin. not apply any grease.
4] Drive in the bar with a hammer.
a Driving distance (a) from pin end:
Small plug: 7.5 ± 1 mm
Large plug: 6.0 ± 2 mm
a If the plugs were not pulled out of
the pin when the shoe was disas-
sembled, reuse them as they
are.
D155A-6 59
SEN03371-05 50 Disassembly and assembly
60 D155A-6
50 Disassembly and assembly SEN03371-05
6) Send the master links and set the next pin 8) Using a shoe bolt hole pitch gauge, mea-
and bushing. sure the distance between the shoe bolt
a When reusing a pin, install it so that holes. When the distance is in the stan-
its side hole will be on the link tread dard range, stop press fitting.
side similarly to a new one. If it is not
installed so, its strength may be low-
ered. Accordingly, indicate the direc-
tion of the side hole on the end face
to prevent a mistake.
a If the outside of the pin is worn, install
it so that the un-worn surface will be
on the traction side. In this case,
install the pin so that its side hole will
be on the link tread side.
3. Installation of shoe
1) Set the link assembly on the bed and
install the shoe with a shoe bolt impact
wrench and a torque wrench.
7) Set the right and left links and operate a When reusing (reversing) the bush-
both pushing jigs to press fit the pin and ing, set the worn outside surface of
bushing simultaneously. the bushing on the shoe fitting side of
a If the pin and bushing have play when the link (set the bushing with the worn
they are press fitted, the seal may outside surface up on the link press).
come off the link. To prevent this, 2 Shoe bolt:
press fit smoothly. If the seal comes Molybdenum disulfide grease
off the link, stop press fitting and set (LM-P)
the seal to the link correctly, then start Shoe bolt (Regular link):
press fitting again. Width across flats 36 mm
a Final pressing force for pin and bush- 3 Shoe bolt (Regular link):
ing: 343 – 490 Nm {35 – 50 ton} Initial torque:
Final pressing force C 1.8 x Average 590 ± 60 Nm {60 ± 6 kgm}
press fitting force Retightening angle: 120° ± 10°
(Adjust the relief pressure of the link
press to set the final pressing force.)
D155A-6 61
SEN03371-05 50 Disassembly and assembly
62 D155A-6
50 Disassembly and assembly SEN03371-05
Adjustment Precaution
Adjust the dimensions of the press fitting jig of the 1. The link receiving faces of jaw (5) must be ver-
link press to keep the projection of the pin and tical.
bushing constant and keep the installed dimen- 2. Wear plate (6) should be replaceable.
sions of the seal within the standard range.
a If the pin end (part P) or the sides of the link
(parts Q and R) are worn, add the dimensions
of the worn parts when adjusting the standard
dimensions so that the projections of the pins
and bushings on the right and left sides will be
even.
Unit: mm
Dimensions of jig
a b c
4.5 3.25 50.6
D155A-6 63
SEN03371-05 50 Disassembly and assembly
New/Remodel
New/Remodel
Necessity
Necessity
Sym- Sym-
Part No. Part name Part No. Part name
Sketch
Sketch
bol bol
Q'ty
Q'ty
791-675-9581 Adapter t 1 8 791-675-5580 Guide t 1
791-675-9590 Guide t 1 791-685-9510 Frame t 1
1
01010-52460 Bolt t 2 791-685-9520 Frame t 1
01010-51440 Bolt t 2 791-685-9530 Rod t 1
790-101-1102 Pump t 1 791-685-9540 Rod t 1
2 Cylinder 791-685-9550 Nut t 3
790-101-4300 t 1
(1,470 kN {150 ton}) 791-685-9560 Bolt t 4
791-685-9510 Frame t 1 791-126-0150 Adapter t 1
9
791-685-9520 Frame t 1 01010-51030 Bolt t 1
791-685-9530 Rod t 1 791-685-9620 Extension t 1
791-685-9550 Nut t 1 791-675-5542 Adapter t 1
791-685-9560 Bolt t 1 t 1
3 791-675-5560 Guide
791-675-9570 Adapter t 1 T 790-101-1102 Pump t 1
04530-12030 Eyebolt t 1 Cylinder
790-101-4300 t 1
790-101-1102 Pump t 1 (1,470 kN {150 ton})
T Cylinder 791-675-5560 Guide t 1
790-101-4300 t 1 10
(1,470 kN {150 ton}) 791-675-5542 Adapter t 1
791-685-9540 Rod t 1 790-101-1102 Pump t 1
4
791-685-9550 Nut t 3 11 Puller
790-101-4200 t 1
791-675-5520 Guide t 1 (294 kN {30 ton})
791-675-5530 Pusher t 1 12 791-670-3270 Guide t 1
5
01010-51030 Bolt t 1 791-126-0150 Adapter t 1
791-685-9620 Extension t 1 791-675-5560 Guide t 1
13
790-101-1102 Pump t 1 791-675-9570 Adapter t 1
6 Puller 01010-51030 Bolt t 1
790-101-4200 t 1
(294 kN {30 ton})
791-675-5542 Adapter t 1
791-675-5571 Adapter t 1
7 790-101-1102 Pump t 1
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
64 D155A-6
50 Disassembly and assembly SEN03371-05
Disassembly of 1 link in field 3. Insert the rod of tool T4 from the cylinder side
k Only how to use the tools is explained below. and install it with the nuts (2 pieces).
For details of disassembly and assembly, Pass the rod through the hole of link (1) and
see "General disassembly (or assembly) of install it.
track shoe".
D155A-6 65
SEN03371-05 50 Disassembly and assembly
Assembly of 1 link in field 3. Set link (4) on the opposite side and support it
1. Assemble the link sub-assembly. with tool T8 (guide).
1) Set tool T7 the link end face and press fit
bushing (1).
a Busing press fitting force:
88 – 304 kN {9 – 31 ton}
2. Set the link to be connected to link sub-assem- 5. Using tool T11 (294 kN {30 ton} puller) as in
bly (3). the disassembly procedure, push open link (5)
on the bushing side.
66 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 67
SEN03371-05 50 Disassembly and assembly
New/Remodel
(6) by moving them up and down. Then,
Necessity
Sym- remove pins (8) and (9) from regular link
Part No. Part name
Sketch
bol (7) by pressing them up and down with the
Q'ty
press.
Special tool : 1. Gas cutting machine
790-101-1102 Pump t 1
: 2. Tool U2
1 Puller
790-101-4200 t 1
(294 kN {30 ton})
Remover and
791-675-9701 t 1
installer
790-101-1102 Pump t 1
U 2 Puller
790-101-4200 t 1
(294 kN {30 ton})
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
3 791-432-1110 Plug push tool t 1
4 790-701-3000 Seal checker t 1
5 791-932-1110 Plug push tool t 1
68 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 69
SEN03371-05 50 Disassembly and assembly
5) Install the shoe to the link at the connect- 2) Insert pin (9) in bushing (8), set master
ing section. links (10) on the pin side from the right
6) Drive in large plug (6) with tool U3, add oil and left sides, and press fit them with tool
with tool U4, and drive in small plug (7) U2.
with U5. 3) Drive in large plug (11) with tool U3, add
a When press fitting the right and left oil with tool U4, and drive in small plug
master links, take care extremely that (12) with U5.
they will be in parallel (on the bushing
side and pin side).
a Do not damage the mating faces of
the master links and end of the bush-
ing.
a Take care extremely that dirt or sand
will not stick to the seal, spacer, ends
of bushing and tap mating faces of
the master link.
70 D155A-6
50 Disassembly and assembly SEN03371-05
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-650-2130 Sleeve t 1 Q
790-101-2420 Adapter t 1
791-520 -4140 Screw t 1
790-101-2540 Washer t 2
W 790-112-1180 Nut t 2
Puller
790-101-4000 t 1
(294 kN {50 ton})
Hydraulic pump
790-101-1102 t 1
5. Operate hydraulic jacks [2] slowly to lower the
machine until the equalizer bar reaches the
Removal right and left track frames.
1. Remove the engine undercover and power 6 Disconnect grease hose (5).
train undercover.
4 Engine undercover: 220 kg
4 Power train undercover: 270 kg
D155A-6 71
SEN03371-05 50 Disassembly and assembly
[*1]
2 Threaded part of cover mounting bolt:
Adhesive (LT-2)
Cover mounting bolt: Width across flats 36 mm
3 Cover mounting bolt:
784 – 981 Nm {80 – 100 kgm}
[*2]
kWhen aligning the pin holes, never insert
your fingers in them.
a Before installing the side pin, adjust the height
of the main frame with the hydraulic jacks to
9. Using tool W, pull out center pin (8). [*3] align the equalizer bar hole with the track
k Do not operate the hydraulic device in
frame hole.
front of or under the puller, but operate 2 Seal lip: Grease (G2-LI)
as far from the puller as possible.
[*3]
kWhen aligning the pin holes, never insert
your fingers in them.
a Before installing the center pin, sling the equal-
izer bar to align the equalizer bar hole with the
main frame hole.
2 Equalizer bar center bushing:
Grease (G2-LI)
[*4]
Install the equalizer bar with the grease fitting side
forward.
72 D155A-6
50 Disassembly and assembly SEN03371-05
2. Side bushing
1) Install ring (2) to one side of equalizer bar
(4).
3) Using tool [1], remove spherical bushing 2) Using the press, press fit spherical bush-
(3) from equalizer bar (4). ing (3) to equalizer bar (4).
a Press fitting force for spherical bush-
ing: 27.4 – 64.7 kN {2.8 – 6.6 ton}
2 Periphery of spherical bushing:
Molybdenum disulfide grease
(LM-P)
3. Center bushing
Remove center bushing (5) from equalizer bar
(4).
D155A-6 73
SEN03371-05 50 Disassembly and assembly
74 D155A-6
50 Disassembly and assembly SEN03371-05
D155A-6 75
SEN03371-05 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03371-05
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 04-22
76 D155A-6
SEN03372-05
D155A-6
D155A-6 1
SEN03372-05 50 Disassembly and assembly
2 D155A-6
50 Disassembly and assembly SEN03372-05
Installation
q Carry out installation in the reverse order to
removal.
q Bleeding air
Bleed air from each part. For details, see Test-
ing and adjusting, "Bleeding air from each
part".
D155A-6 3
SEN03372-05 50 Disassembly and assembly
Removal and installation of 2) Disconnect hoses (3), (4), (5) and (6).
hydraulic pump assembly 1 3) Disconnect accumulator (7) and hose
together.
Removal
k Lower the work equipment to the ground
and release the residual pressure in the
piping, referring to Testing and adjusting,
"Releasing residual pressure in hydraulic
circuit". Then, loosen the hydraulic tank
cap gradually to release the internal pres-
sure of the hydraulic tank.
k Disconnect the cable from the negative (–)
terminal of the battery.
4 D155A-6
50 Disassembly and assembly SEN03372-05
8) Disconnect suction tube (16). q Removal of power train and steering lubri-
a Remove the suction tube mounting cating oil pump assembly
bolts on the fuel pump side, too. 1) Disconnect tubes (1), (2) and (3).
2) Sling power train and steering lubricating
oil pump assembly (4), remove 2 mount-
ing bolts (5), and lift off pump assembly
(4).
4 Power train and steering lubricating
oil pump assembly: 30 kg
D155A-6 5
SEN03372-05 50 Disassembly and assembly
q Bleeding air
Bleed air from each part. For details, see Test-
ing and adjusting, "Bleeding air from each
part".
6 D155A-6
50 Disassembly and assembly SEN03372-05
New/Remodel
q Blade lift cylinder
Necessity
Sym-
Part No. Part name 1) Set cylinder assembly (1) to tool Y1.
Sketch
bol
2) Using the hydraulic pump or the
Q'ty
power wrench and tool Y2, remove
Cylinder repair head assembly (2).
790-502-1003 t 1
1 stand 3) Pull piston rod assembly (3).
790-101-1102 Hydraulic pump t 1 a Put an oil pan under the cylinder
2 790-102-3802 Multi-wrench t 1 to receive the oil.
790-201-1702 Push tool kit t 1
790-201-1721 • Push tool 1
790-201-1821 • Push tool 1
790-201-1841 • Push tool 1
3
790-201-1851 • Push tool 1
790-201-1861 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit t 1
790-201-1630 • Plate 1
Y
790-201-1650 • Plate 1
4 790-201-1660 • Plate 1 q Blade tilt cylinder, ripper lift cylinder, and
790-201-1670 • Plate 1 ripper tilt cylinder
1) Remove the mounting bolt assembly
790-101-5021 • Grip 1
and disconnect head assembly (4).
01010-50816 • Bolt 1 q Width across flats of blade tilt cyl-
790-720-1000 Expander t 1 inder: 16 mm
796-720-1670 Ring t 1 q Width across flats of ripper lift
and tilt cylinders: 18 mm
07281-01279 Clamp t 1
2) Pull piston rod assembly (5).
5 796-720-1690 Ring t 1 a Put an oil pan under the cylinder
07281-01919 Clamp t 1 to receive the oil.
796-720-1720 Ring t 1
07281-02429 Clamp t 1
790-102-4300 Wrench t 1
6
790-102-4310 Pin t 2
D155A-6 7
SEN03372-05 50 Disassembly and assembly
8 D155A-6
50 Disassembly and assembly SEN03372-05
4. Head assembly
1) Remove head assembly (2) or (4).
D155A-6 9
SEN03372-05 50 Disassembly and assembly
q Only blade tilt cylinder 1] Using tool Y3, press-fit bushing (35).
1] Remove bolts (36), and remove plate
(37).
2] Remove O-ring (28) and backup ring 2] Install snap ring (34).
(29).
3] Remove dust seals (38) and (33).
4] Remove packing (30).
5] Remove snap ring (31).
6] Remove snap ring (34), and remove
bushing (35).
Assembly
q Apply engine oil to the sliding surfaces of each
part and install the rod packings, dust seals,
and O-rings, taking care not to damage them.
1. Head assembly
1) Assembly of head assembly
q Blade lift cylinder, ripper lift cylinder,
and ripper tilt cylinder
10 D155A-6
50 Disassembly and assembly SEN03372-05
D155A-6 11
SEN03372-05 50 Disassembly and assembly
3] Install snap ring (31). 8] Install plate (37) with bolts (36).
4] Install packing (30).
5] Install backup ring (29) and O-ring
(28).
2. Piston assembly
7] Using plate (37), install dust seal (38). q Ripper lift cylinder and ripper tilt cylinder
1) Assembly of piston assembly
1] Using tool Y5, expand piston ring
(26).
a Set the piston ring to tool Y5
and turn the handle of the
tool by 8 – 10 turns to
expand the piston ring.
2] Remove piston ring (26) from
tool Y5 and install it to the piston.
3] Using tool Y5, compress piston
ring (26).
12 D155A-6
50 Disassembly and assembly SEN03372-05
4] Install wear ring (25). 3) When reusing piston rod (23) and pis-
5] Install backup ring and O-ring t o n a s s e m b ly ( 1 7 ) , i n s ta l l t h e m
(24). according to the following procedure.
a Before installing the backup a Remove burrs and fins from the
ring, warm it in water at 50 – threaded part with a file.
60 °C. a Clean the parts thoroughly and
a Apply grease to the O-ring remove metal chips and dirt.
and backup ring so that the 1] Using tool Y6, tighten piston
backup ring will not open. assembly (17) into piston rod
(23) until the screw holes are
aligned.
D155A-6 13
SEN03372-05 50 Disassembly and assembly
14 D155A-6
50 Disassembly and assembly SEN03372-05
D155A-6 15
SEN03372-05 50 Disassembly and assembly
16 D155A-6
50 Disassembly and assembly SEN03372-05
D155A-6 17
SEN03372-05 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03372-05
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 04-22
18 D155A-6
SEN03373-04
D155A-6
D155A-6 1
SEN03373-04 50 Disassembly and assembly
2 D155A-6
50 Disassembly and assembly SEN03373-04
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Adjust clearance (a) at the cap mating sur-
faces to the following range with the shim and
check that the cylinder turns smoothly.
q Standard clearance (a): 0.2 – 0.5 mm
q Standard shim thickness: 4 mm
a After installing the blade, adjust the blade tilting
distance. For details, see Testing and adjust-
ing, "Adjusting blade".
q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
[*2]
a Adjust height (b) and width (c) of the right and
left straight frames to the following values with
blocks [1] etc.
q Height (b) of trunnion: Approx. 636 mm
q Width (c) of frame: Approx. 3,053 mm
D155A-6 3
SEN03373-04 50 Disassembly and assembly
Obey the items that follow when you make the machine stable.
k Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable
posture.
k Set the parking brake switch to the LOCK position.
k Set the work equipment lock switch to the LOCK position.
Obey the items that follow when you stop the engine.
k Turn the starting switch to the OFF position to stop the engine.
k Disconnect the cable from the negative (-) terminal of the battery.
Obey the items that follow before you start the work.
k Immediately after the engine stops, the temperature of the coolant, oil, and parts around the
engine are very hot and they can cause burn injury. Wait until the temperature decreases, and
then start the work.
REMARK
Special caution is necessary as the temperature of the aftertreatment devices and area around them are
400? or above.
k The remaining pressure in the hydraulic tank can cause an accident. Release the remaining
pressure carefully.
REMARK
For details, see TESTING AND ADJUSTING, “RELEASE REMAINING PRESSURE IN HYDRAULIC
SYSTEM”.
k Check for flammable materials such as dry leaves and twigs stuck to the aftertreatment devices.
If dirt or flammable materials are found, remove them.
k The aftertreatment devices can be damaged by the shock if they fall. Handle them carefully. Do
not use the damaged parts again.
Obey the items that follow when you handle the wirings and hoses.
k Check the connector numbers and installation positions before you disconnect the wirings,
hoses, and clamps, and write them down.
k If the wirings and hoses can be deformed or damaged, remove the clips and clamps before the
work.
k Prepare a container to receive oil before you disconnect the hoses.
k Install a plug or flange to the parts where a hydraulic hose is disconnected not to let oil flow out.
k Replace the O-ring, seal washer, and gasket with new ones.
4 D155A-6
50 Disassembly and assembly SEN03373-04
D155A-6 5
SEN03373-04 50 Disassembly and assembly
3. Start the engine, release the work equipment lock lever, and
fully retract the piston rod of the blade lift cylinder assembly
(1).
NOTICE
q When you retract the piston rod, the position of the
center of gravity of the blade lift cylinder assembly
(1) changes, and there is a danger that it rotates
around the yoke.
q Keep a sufficient distance to the blade lift cylinder
assembly (1) when you retract the piston rod.
q After the piston rod is retracted, adjust the tension
of the webbing sling with the lever block (B) as
much as it is loosened, and hold the blade lift cylin-
der assembly (1) while it is lifted.
q After the piston rod is retracted, fix the piston rod
with the wire (C) not to let it move off.
4. Set the blade lift cylinder assembly (1) to the position shown
in the figure, install the fixing tool (F), and fix it to the radia-
tor guard.
NOTICE
q Do not rotate the blade lift cylinder assembly (1) to
th e angle above the horizontal. If the angle
becomes (a) shown in the figure, there is a danger
that the yoke is removed from the radiator guard.
q Angle (a): 25 ± 5°
q (b) and (c) in the figure show the parts with the key
structure.
q (b): Line of yoke
q (c): Line of radiator guard
6 D155A-6
50 Disassembly and assembly SEN03373-04
9. Lift the blade lift cylinder assembly (1), hold it, and remove
the 4 bolts (15).
NOTICE
Before you remove the bolt (15), make sure that the
blade lift cylinder assembly (1) is lifted directly above.
If you remove the bolt (15) while the blade lift cylinder
assembly (1) is not lifted correctly, it can swing. It is
very dangerous.
10. Remove the blade lift cylinder assembly (1), and set it on
the stable position (where it does not rotate).
D155A-6 7
SEN03373-04 50 Disassembly and assembly
11. Cut the wire (C) that fixes the cap (16), and remove the cap
(16).
4 Cap (16): 5 kg
12. Remove the dowel pin (13).
13. Remove the bushing (14).
REMARK
Do the same work on the opposite side.
8 D155A-6
50 Disassembly and assembly SEN03373-04
6. Lift the blade lift cylinder assembly (1), and set it to the
installation position.
NOTICE
q Lift it at the lifting points (a). (a)= Approx. 300 mm
q Set the lever block (B) at the one side of the web-
bing sling (A) to adjust the angle.
4 Blade lift cylinder assembly (1): 190 kg
D155A-6 9
SEN03373-04 50 Disassembly and assembly
7. Install the blade lift cylinder assembly (1) with the 4 bolts
(15).
NOTICE
q Do not rotate the blade lift cylinder assembly (1) to
th e angle above the horizontal. If the angle
becomes (a) shown in the figure, there is a danger
that the yoke is removed from the radiator guard.
q Angle (a): 25 ± 5°
q (b) and (c) in the figure show the parts with the key
structure.
q (b): Line of yoke
q (c): Line of radiator guard
8. Set the blade lift cylinder assembly (1) as shown in the fig-
ure, and install the fixing tool (F).
9. Install the grip (13) with the 2 bolts (12).
10 D155A-6
50 Disassembly and assembly SEN03373-04
Bleed air
1. Bleed air from the work equipment cylinder. For the procedure to bleed air, see TESTING AND
ADJUSTING, “BLEED AIR IN WORK EQUIPMENT CYLINDERS”.
REMARK
Do the same work on the opposite side.
D155A-6 11
SEN03373-04 50 Disassembly and assembly
12 D155A-6
50 Disassembly and assembly SEN03373-04
10. Sling arm (12), remove the lock plates, pull out
right and left pins (13), and lift off arm (12).
4 Arm: 650 kg
D155A-6 13
SEN03373-04 50 Disassembly and assembly
3. Sling tilt cylinder assembly (5) and install pin 7. Sling lift cylinder assembly (3), run the engine,
(9). extend the piston rod, align the pin holes,
install pin (4), and fix it with the lock plate.
4 Tilt cylinder assembly: 260 kg
a After installing, lower the rod side to the
arm.
14 D155A-6
50 Disassembly and assembly SEN03373-04
10. Greasing
After assembling, supply sufficient amount of
grease to each pin.
2 Pin: Grease (G2-LI)
D155A-6 15
SEN03373-04 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03373-04
© 2021 KOMATSU
All Rights Reserved
Printed in Japan 11-21 (01)
16 D155A-6
SEN03375-03
D155A-6
D155A-6 1
SEN03375-03 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
2 D155A-6
50 Disassembly and assembly SEN03375-03
[*1]
a Connect the window washer hoses according
to their band colors.
Window washer hoses
Red ................... Right door
Blue................... Left door
Black ................. Rear window
No color band ... Front window
[*2]
a Before installing, check that seal rubber parts
(brown, 2 pieces) are installed to the connector
and they are not broken.
Connector mounting bolt:
Inside hexagonal width across flats 4 mm
3 Connector mounting bolt:
2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
[*3], [*4]
1) Tighten bolts (1) – (23) in the numeric order
shown in the attached drawing.
D155A-6 3
SEN03375-03 50 Disassembly and assembly
* Among the panes of window glass of the opera- (1): Front window glass
tor's cab, the 3 panes of (1) and (2) on both (2): Left door window glass
sides are stuck. In this section, the procedure : Right door window glass
for replacing the stuck glass is explained. (3): Both-sided adhesive tape
(4): Trim seal
(5): Door handle
4 D155A-6
50 Disassembly and assembly SEN03375-03
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Lifter
X 1 793-498-1210 t 2
(Suction cup)
Removal
* Remove the window glass to be replaced
according to the following procedure.
D155A-6 5
SEN03375-03 50 Disassembly and assembly
6 D155A-6
50 Disassembly and assembly SEN03375-03
4. Install trim seals (4) to both door window 5. Position the new window glass.
glasses (2). 1) Using tool X1, set the window glass to the
sticking position. Check the clearance
between the window glass and the opera-
tor's cab on the right, left, upper, and lower
sides, and then adjust it evenly.
a Position front window glass (1) from
inside of operator's cab (7). Adjust it
so that the difference between black
coated part and the metal sheet of
operator's cab (7) will be even on the
right, left, upper, and lower sides.
a When positioning each door window
glass (2), align handle holes (d) of
door (9) (on the glass side and door
metal sheet side) first. Then, adjust
a Install each trim seal (4) so that its finish- the door window glass so that the
ing end and starting end will be jointed at positional relationship between it and
position (c) and dimension (b) between door metal sheet will be even all
the corner and position (c) will be 90 mm. around the window.
D155A-6 7
SEN03375-03 50 Disassembly and assembly
6. Apply adhesive.
2 Adhesive:Sikaflex 256HV
manufactured by Sika Japan
a Do not use primer. 2) Cut the tip of the adhesive nozzle (12) so
a The using limit of the adhesive is 6 months that dimensions (f) and (g) will be as fol-
after the date of manufacture. Do not use lows.
the adhesive after this limit. q Dimension (f) : 10 mm
a Keep the adhesive in a dark place where q Dimension (g): 15 mm
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
8 D155A-6
50 Disassembly and assembly SEN03375-03
4) Remove release tape of the both-sided a Apply adhesive (13) to dimensions (h)
adhesive tape (3a) on the glass side. and (j) of both-sided adhesive tape
(3) of operator's cab (7).
q Dimension (h): 10 mm
q Dimension (j) : 15 mm
a Apply adhesive (13) higher than both-
sided adhesive tape (3).
a Apply the adhesive evenly.
D155A-6 9
SEN03375-03 50 Disassembly and assembly
10 D155A-6
50 Disassembly and assembly SEN03375-03
D155A-6 11
SEN03375-03 50 Disassembly and assembly
12 D155A-6
50 Disassembly and assembly SEN03375-03
D155A-6 13
SEN03375-03 50 Disassembly and assembly
6. Disconnect air conditioner hoses (17) and (18). 10. Lift off battery top cover (23).
4 Cover: 75 kg
14 D155A-6
50 Disassembly and assembly SEN03375-03
13. Disconnect 4 window washer hoses (27). 17. Remove mounting bolts (34) at the rear right
and left of the floor frame. [*3]
14. Disconnect wiring harness (28).
18. Remove cover (35).
D155A-6 15
SEN03375-03 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Before installing, check that seal rubber parts
(brown, 2 pieces) are installed to the connector
and they are not broken.
Connector mounting bolt:
Inside hexagonal width across flats 4 mm
3 Connector mounting bolt:
2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
[*2], [*3]
Floor frame mounting bolts (19) and (20):
Width across flats 24 mm
3 Floor frame mounting bolts (19) and (20):
824 – 1,030 Nm {84 – 105 kgm}
[*2]
3 Bracket mounting bolt (33):
153 – 190 Nm {15.5 – 19.5 kgm}
[*3]
3 Floor frame mounting bolt (34):
984 – 980 Nm {80 – 100 kgm}
16 D155A-6
50 Disassembly and assembly SEN03375-03
D155A-6 17
SEN03375-03 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03375-03
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 04-22
18 D155A-6
SEN03376-05
D155A-6
D155A-6 1
SEN03376-05 50 Disassembly and assembly
Removal and installation of air 3. Remove the cover at the right lower part of the
conditioner unit assembly 1 operator's seat.
2 D155A-6
50 Disassembly and assembly SEN03376-05
8. Remove the 4 mounting bolts of work equip- 11. Disconnect wiring harness connectors AC01
ment controller assembly (7) and disconnect (10) and AC02 (11).
the assembly.
12. Disconnect wiring harness clamp (12) and
move wiring harness (13) aside.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a When installing the air conditioner hoses, take
care that dirt, dust, water, etc. will not enter
them.
a When installing each air conditioner pipe,
check that the O-ring is fitted to it.
a Check that the O-ring is not damaged or deteri-
orated.
2 O-ring: ND-OIL8
q Filling air conditioner with refrigerant
Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 870 ± 50 g
D155A-6 3
SEN03376-05 50 Disassembly and assembly
1. Open the left engine side cover and lift off side
cover assembly (1).
4 Side cover assembly: 40 kg
Installation
q Carry out installation in the reverse order to
removal.
[*1]
Connector mounting screw:
Inside hexagonal width across flats 4 mm
2. Remove 2 oil filters (2). 3 Connector mounting screw:
2.82 Nm {0.288 kgm}
4 D155A-6
50 Disassembly and assembly SEN03376-05
1. Remove the left lower cover of the operator's 1. Remove 4 mounting bolts (1), cover (2).
seat.
Installation
q Carry out installation in the reverse order to
Installation
removal.
q Carry out installation in the reverse order to
removal.
[*1]
Connector mounting screw:
Inside hexagonal width across flats 4 mm
3 Connector mounting screw:
2.82 Nm {0.288 kgm}
D155A-6 5
SEN03376-05 50 Disassembly and assembly
D155A-6 Bulldozer
Form No. SEN03376-05
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 04-22
6 D155A-6
SEN04442-03
D155A-6
60 Air conditioner 1
Structure, function, testing, adjusting,
and troubleshooting
Structure and function ..................................................................................................................................... 3
Air conditioner component ....................................................................................................................... 3
Configuration and function of refrigerating cycle ..................................................................................... 4
Outline of refrigerating cycle .................................................................................................................... 5
Air conditioner unit ................................................................................................................................... 7
Functions of major components in the air conditioner unit ...................................................................... 9
Control plate ...........................................................................................................................................11
Compressor ........................................................................................................................................... 13
Condenser ............................................................................................................................................. 14
Receiver drier ........................................................................................................................................ 15
Testing, adjusting and troubleshooting.......................................................................................................... 17
Caution about refrigerant ....................................................................................................................... 17
Troubleshooting procedure .................................................................................................................... 18
Block diagram ........................................................................................................................................ 19
D155A-6 1
SEN04442-03 60 Air conditioner
2 D155A-6
60 Air conditioner SEN04442-03
Specifications
Refrigerant R134a
Refrigerant refilling level (g) 870 ± 50
D155A-6 3
SEN04442-03 60 Air conditioner
4 D155A-6
60 Air conditioner SEN04442-03
D155A-6 5
SEN04442-03 60 Air conditioner
5. Evaporation (Evaporator)
The refrigerant changes from liquid to gas
(superheated vapor) in the evaporator.
The refrigerant mist in the evaporator evapo-
rates actively.
At this time, the refrigerant evaporates quickly,
absorbing heat necessary for evaporation
(latent heat of vaporization) from the air around
the cooling fins (air in the operator’s cab). The
cooled air is spread in the operator’s cab by
the fan to lower the temperature in the opera-
tor’s cab.
The refrigerant mist sent through the expansion
valve and the evaporated refrigerant are mixed
together in the evaporator. While the refrigerant
liquid changes to the refrigerant gas, the rela-
tionship between the pressure (evaporation
pressure) and temperature (evaporation tem-
perature) is kept constant. If the pressure is set,
the temperature is decided automatically.
That is, the relationship between the above
pressure and temperature is equal to the rela-
tionship between saturation pressure and satu-
ration temperature.
To evaporate the refrigerant at lower tempera-
ture, the pressure in the evaporator must be
kept lower.
Accordingly, the evaporated refrigerant is
sucked into the compressor.
The refrigerant circulates in the refrigerating
cycle, repeating the above four actions, to
move the heat from the operator’s cab where
the temperature is low to the outside where the
temperature is high.
If the amount of the refrigerant is insufficient,
all of the refrigerant is evaporated while it is
passing through the evaporator and the evapo-
rator capacity decreases. It can cause a cool-
ing trouble.
To the contrary, if the amount of the refrigerant
is too much, a part of it is not evaporated in the
evaporator and is absorbed in the compressor.
As a result, the compressor compresses the
liquid and may be broken.
6 D155A-6
60 Air conditioner SEN04442-03
D155A-6 7
SEN04442-03 60 Air conditioner
Outline
q The air conditioner unit consists of the evapo-
rator, heater core and fan (blower) and gener-
ates cool air and hot air.
q Temperature control
The machine monitor sends temperature set-
ting data to the control amplifier (See “Control
plate”) according to the temperature control
switch operation.
The control amplifier controls the air mix servo-
motor to adjust the angle of the cool door, hot
door and sub hot door for temperature control.
8 D155A-6
60 Air conditioner SEN04442-03
D155A-6 9
SEN04442-03 60 Air conditioner
10 D155A-6
60 Air conditioner SEN04442-03
D155A-6 11
SEN04442-03 60 Air conditioner
7 BLOW F/B Blower feedback signal Input 21 A/M A A/M servo terminal A Output
8 PTR B Power transistor control signal Output 22 A/M B A/M servo terminal B Output
Blowing out (mode) servo 23 MODE A Blowing out (mode) servo terminal A Output
9 MODE P Input
potentiometer voltage 24 MODE B Blowing out (mode) servo terminal B Output
10 — — — 25 — — —
11 THI Inner air temperature sensor Input 26 — — —
12 THEVA Evaporator temperature sensor Input 27 GND S Sensor GND Input
13 — — — 28 — — —
14 — — — 29 — — —
15 SS Sunlight sensor Input 30 — — —
16 GND GND Input 31 — — —
32 — — —
33 — — —
34 — — —
35 CCRL Compressor clutch relay Output
36 BLOW RL Blower main relay Output
12 D155A-6
60 Air conditioner SEN04442-03
Compressor 1
Specifications
Piston capacity (cc/rev) 157.3
Allowable maximum speed
6,000
(rpm)
Denso: ND-OIL8
Refrigerant oil used
(For R134a)
Refrigerant oil refilling volume
180
(cc)
D155A-6 13
SEN04442-03 60 Air conditioner
Condenser
1. Condenser
Function
Condenser (1)
q Condenser cools and liquefies the high-pres-
sure, high-temperature misty refrigerant from
the compressor.
Specifications
Fin pitch (mm) 4.0
Height × Width × Thickness 357 × 540 × 16
Max. pressure used
3.6 {36}
(MPa {kg/cm2})
14 D155A-6
60 Air conditioner SEN04442-03
Receiver drier 1
Specifications
Weight of desiccating agent (g) 370
D155A-6 15
SEN04442-03 60 Air conditioner
16 D155A-6
60 Air conditioner SEN04442-03
D155A-6 17
SEN04442-03 60 Air conditioner
The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function,
you can inspect the operation of sensors and servomotors in the system.
If a troubled section is detected, every part of that section must be inspected.
Troubleshooting procedure 1
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Find the troubled section with the self-diagnosis function (See “Inspection with self-diagnosis”).
If the air conditioner unit does not operate at all, check that the power supplied to the control amplifier is
normal and that CAN communication between machine monitor and the control amplifier is normal.
If any part of the air conditioner unit operates, the power supply and CAN communication do not need to
be checked.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Occurrence of trouble:
Examination,
confirmation of failure
1. Battery voltage (24 V)
2. Tension of compressor belt
Basic check 3. Oil stain at air conditioner hose joints (*2)
4. Abnormal sound check (*3)
Compressor, blower motor and air conditioner
hose (clamp)
Troubleshooting with
Troubleshooting with E mode
troubleshooting chart 1
Inspection with
troubleshooting chart 2
*1: By error display or abnormal display on “Abnormality Record” screen on machine monitor.
*2: If refrigerant leaks, recirculating compressor oil in the air conditioner circuit always leaks, too.
*3: Start engine and then air conditioner switch ON.
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Block diagram 1
a This air conditioner unit is auto temperature control type.
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a INSIDE TEMP. SENSOR means “Inner sensor” on “Abnormality Record” screen: “03 Air-conditioning
System”.
a BLOWING OUT (MODE) SERVOMOTOR means BLOWING OUT (MODE) CHANGEOVER SERVO-
MOTOR.
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9. Pressure switch
Open engine left cover (6) and remove covers
(7) – (9).
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11. Sunlight sensor connector SLS and machine 5) Float dashboard (14) and pull it out
monitor connector CM02 (CAN communication toward you.
connector) a Since the wiring harness is con-
a If the machine monitor connector CM02 is nected, pull out the dashboard
disconnected, the engine controller and slowly.
other controller(s) can not perform the q DSH: Intermediate connector of
CAN communication. Accordingly, failure machine monitor
code: [DAFRMC] is displayed. a Connector DSH is DRC-70.
If the screen changes to the air condi- Take care in handling it. See the
tioner operation screen at this time, “A/C next page.
Controller error” is displayed red. If the
above error is not displayed, no check is
necessary.
Note: “A/C Controller error” on the air con-
ditioner operation screen is also displayed
when the vent cannot be changed, when
the temperature control is abnormal or
when the refrigerant pressure switch is
turned OFF. (“A/C Controller error” display
for “the refrigerant pressure switch is
turned OFF” will be abolished in the
future.)
1) Remove dashboard cover (10).
2) Disconnect sunlight sensor (S) con-
nector (SLS). 6) Disconnect the following connectors.
q (15): KEY
q (16): BKSW --- Red band
q (17): DCL --- Blue band
q (18): BRK --- Yellow band
q (19): FLSW
q (20): RLSW
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1. Remove recirculated air filter (1) from the rear 4. Remove cover (4).
of the operator seat.
5. Ensure that the following are not removed.
1) Duct (5)
2) Front duct (FD)
3) Defroster duct (DD)
q A/C U: Air conditioner unit
q A1 and A2: Front blowingout route
q C1, C2 and C3: Defroster blowingout
route
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Normal screen
O While pressing [4], press [1], [2] and [3] in
order.
Service menu (Mode)
O Press [F3] once. Press [F6].
02 Abnormality Record
O Press [F3] twice. Press [F6].
03 Air-conditioning system “Abnormality Record”
screen
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Caution
Inner Sensor means inside temperature sensor on
“block diagram” or “circuit diagram”.
“Ventilating Sensor is abnormal” means that evapo-
rator temperature sensor is short circuit or discon-
nected.
“Sunlight Sensor is abnormal” means that Sunlight
Sensor is short circuit only.
“Ventilation is abnormal” means servomotor for
blowing out changeover (mode) damper does not
rotate judging from the servomotor potentiometer
q Information displayed on Abnormality voltage.
Record screen: “03 Air-conditioning Sys- a Damper is the same as door.
tem” screen “Air Mix is abnormal” means servomotor
(a): System/Component name for Air Mix (temperature adjustment)
(b): Number of occurrence time damper does not rotate judging from the
(c): Condition (Normal or abnormal) servomotor potentiometer voltage.
(d): If CAN status is abnormal in condition, “Refrigerant” means refrigerant pressure
CAN communication cannot be carried out from (dual) pressure switch. Namely,
normally but air conditioner unit is discon- “refrigerant is abnormal” means that (dual)
nected. Accordingly, the conditions (d) of pressure switch of refrigerant is OFF.
other items are not displayed.
(e): If [E] is displayed on the left of a condition, 1. CAN Status (communication) is abnormal
the abnormality is still occurring or clear- The CAN communication between the
ing of it has not been confirmed. machine monitor and air conditioner control
q [F2]: Clear “Abnormality Record” amplifier (CNTAMP) is not carried out normally.
q [F5]: Return to “Abnormality Record” a If failure code [DAFRMC] (Error of CAN
screen communication with engine controller) is
displayed, all the communication circuit is
abnormal. In this case, see failure code
[DAFRMC] in Chapter 40. If [DAFRMC] is
not displayed, only the communication
between control amplifier (CNTAMP) and
machine monitor is abnormal.
(Check connectors CN-N10, CN-AC01, [1]
and [2] for disconnection. See “Part and
connector locations” 2., 3., and 6. or see
E-1.)
2. Setting abnormal
The software of the air conditioner amplifier
does not match that of the monitor. Check the
part numbers of those components.
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Outline
q Temperature is controlled by mixing ratio of the
hot air from the heater and cooled air from the
evaporator by changing the angles of the four
doors (dampers) in the air mix section. The
angle of each door (damper) is set changed by
the air mix servomotor through plate (P1),
lever 1 (L1) – lever 6 (L6) and rod (RODAM).
Only rod (RODAM), lever 5 (L5) and lever 6
(L6) are seen from outside. (For the figure, see
item 5.)
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5. Check the rod (RODAM) for disconnection. a Plate (P1), lever 1 (L1) – lever 4 (L4) are
not seen from outside.
6. Start the engine and turn the air conditioner
power ON.
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5) Rotate plate (P2) with the hand to see a F. Face door position will change from “OPEN”
where lever 7 (L7) – lever 12 (L12) are to “Half” gradually when raising the setting
hitched and then repair. temperature from 18°C to 32°C gradually.
a If the levers do not move smoothly,
clean them and apply grease to the
links.
2 Link: Molykote ® MH-62 Grease
(Dow Corning Toray Co. Ltd.)
6) When plate (P2) is rotated with the hand, if
lever 7 (L7) – lever 12 (L12) move
smoothly, the servomotor may have trou-
ble. In this case, exchange servomotors
(5) and (6) and operate them.
a The figures of the foot mode and
defroster mode are shown before.
a For electrical problem, see “E-5 Vent (mode)
cannot be changed over”.
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Testing inner sensor 1 8. Check that the resistance between female con-
nector [8] (2) (PB) (on the wiring harness side)
a Inner Sensor is the same as inside tempera- and connector [1] (11) (PB) (on the wiring har-
ture sensor on “block diagram” or “circuit dia- ness side) is 1 z or below. (If not, the wiring
gram”. harness is defective.)
q If “Inner Sensor abnormal” is displayed by the
self-diagnosis (“Abnormality Record” screen 9. Check that the resistance between female con-
on machine monitor: “03 Air-conditioning Sys- nector [8] (1) (BrR) (on the wiring harness side)
tem”), test the inner sensor. and connector [2] (27) (BrR) (on the wiring har-
q To reset the self-diagnosis system (detection of ness side) is 1 z or below. (If not, the wiring
abnormality), the starting switch must be harness is defective.)
turned OFF.
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Installation
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Testing (dual) pressure switch for 3. Ensure that the terminals on the switch side of
refrigerant 1 connector AC05 are shorted to each other
(ON). (When they are not shorted (OFF), the
q If “Refrigerant abnormal” is displayed by the pressure switch detects abnormal refrigerant
self-diagnosis (“Abnormality Record” screen pressure.)
on machine monitor: “03 Air-conditioning Sys- a When the pressure switch is OFF, connect
tem”), test pressure switch connector AC05. a pressure gauge to the high pressure
q To reset the self-diagnosis system (detection of side of the air conditioner compressor and
abnormality), the starting switch must be check the refrigerant pressure.
turned OFF. See “Connection of service tool” and
q The pressure switch unit is turned ON when “Troubleshooting with gauge pressure.”
the refrigerant pressure is normal and OFF a If refrigerant pressure is normal, the pres-
when the refrigerant pressure is abnormal. sure switch is defective.
a The pressure switch unit may be OFF when
ambient temperature below 0°C because the q (Dual) pressure switch
refrigerant pressure becomes down. The pres-
sure switch unit is not defective but normal.
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Troubleshooting chart 1 1
a The numbers in the boxes are the item numbers in the troubleshooting table.
a E-2, E-3 means Troubleshooting for electrical system (E mode).
1. Cooling trouble
2. Heating trouble
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Troubleshooting chart 2 1
1. Blower fan motor does not revolve or its speed is different from set value.
a See troubleshooting "E-3 Blower motor system (No air comes out or air flow is abnormal)" for trou-
bleshooting for the electrical system.
3. Low/high pressure
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8. Other items
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• If failure code [DAFRMC] is displayed on machine monitor, see Chapter 40 Troubleshooting first and
repair so that [DAFRMC] will not be displayed.
a CAN communication is connected to machine monitor, engine controller, pump controller and air
conditioner controller.
• “A/C Controller Error” is displayed on air conditioner operation screen of machine monitor in follow-
ing cases. In E-1, 1), 2) and 3) of following cases are explained.
1) Power is not supplied to control amplifier.
2) Control amplifier is broken.
3) Control amplifier (CNTAMP) cannot communicate with machine monitor.
4) Blowing out door (damper) servomotor does not rotate.
5) Temperature control (AIRMIX) door (damper) servomotor does not rotate.
6) Refrigerant pressure is abnormal.
Related • Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine
information monitor: “03 Air-conditioning System” and check to see if “CAN Status” is abnormal. Abnormality of
“CAN Status” indicates that control amplifier at rear of air conditioner unit cannot communicate with
machine monitor.
“CAN Status” is indicated as abnormal in any case of 1), 2) and 3) above.
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E-3 Blower motor system (No air comes out or air flow is abnormal)
Problem No air comes out or air flow is abnormal due to blower motor system failure.
Indication of • LCD of machine monitor on air conditioner operation screen lights normally but air does not come
problem on out.
machine • Air flow does not match fan switch setting on air conditioner operation screen.
• This trouble is not checked with self-diagnosis function.
• If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. Possible
causes for this trouble are as follows.
1) Compressor clutch relay is defective (Stuck closed). (See E-2, 5, A.)
2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air
conditioner unit.)
Related 3) Expansion valve is adjusted improperly. (Remove air conditioner unit and replace expansion
information valve.)
• If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
• If air comes out but its flow is abnormal in heating mode, replace power transistor first.
• For each connector, relay, and power transistor, see “Part and connector locations”.
• T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.
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• Referring to “Testing vent (mode) changeover”, check that there is not contact of connector [5] or
mechanical trouble (removal or interference of link, etc.)
Related • Air mix servomotor and blowing out (mode) servomotor are same. Operating angle of temperature
information control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connect-
ing connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and blow-
ing out (mode) servomotor to see if they are normal.
• Blowing out servomotor can be checked for trouble by connecting new servomotor to connector [5]
and see if it operates normally.
• For each connector, see “Part and connector locations”.
• T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a Since T-adapter is not prepared for other connectors, check signals with control amplifier during
operation.
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*1 If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are
stained with oil. Increase tightening of the joints or replace parts.
*2. k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After replacing it, fill
up the air conditioner system with refrigerant again.
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a Use the service tool kit for R134a. Connect the gauge manifold, hoses and other ser-
vice tools according to the following procedure.
Service tool kit
1. Gauge manifold 1. Close the high-pressure valve (HI) and low-
2. High pressure charging hose (red) pressure valve (LO) of gauge manifold (1).
3. Low pressure charging hose (blue) 2. Connect red charging hose (2) to the (HI) side
4. Quick joint (Hi) (Large diameter) and blue charging hose (3) to the (LO) side.
5. Quick joint (Lo) (Small diameter) 3. Connect quick joints (4) and (5) to each hose.
a. The thread is rough. So be careful not to loosen. 4. Connect the quick joints to the service valves
of the high and low-pressure pipings.
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D155A-6 Bulldozer
Form No. SEN04442-03
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 08-19 (01)
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Power train hydraulic circuit diagram Power train hydraulic circuit diagram
D155A-6
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Hydraulic circuit diagram Hydraulic circuit diagram 1
Serial No.: 85001 – 85024 D155A-6
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Serial No.: 85025 and up D155A-6
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D155A-6 Bulldozer
Form No. SEN02875-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (02)
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2 GND06 - 1.25B
Window washer tank
WSH2 I1 C409 DT 6
(Rear, right) 3 FD4(Male) 7 1.25V
4 GND06 - 1.25B
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Connectors table and arrangement drawing D155A-6 Connectors table and arrangement drawing
D155A-6
Connector Type of Number Connector Type of Number
Location Address No. connector of pin Location Address
No. connector of pin
250 Terminal 1 Starting switch (Terminal B) R-9 GND03 Terminal 6 Ground (ROPS) M-5
255 Terminal 1 Starting switch (Terminal R1) R-8 GND06 Terminal 4 Ground (Fender) J-1
256 Terminal 1 Starting switch (Terminal R2) R-8 GND07 Terminal 1 Ground (Bulkhead) G-1
260 Terminal 1 Starting switch (Terminal BR) R-8 GND08 Terminal 4 Ground (Guard) [Additional headlamp specification] —
270 Terminal 1 Starting switch (Terminal ACC) R-9 GND09 Terminal 1 Ground (Engine) AE-2
280 Terminal 1 Starting switch (Terminal C) R-9 GND11 Terminal 6 Ground (Floor) AB-6
A/C DT 2 Air conditioner compressor AE-1 GND12 Terminal 6 Ground (Floor) AB-6
A/C1 DT 2 Intermediate conncector F-7, AG-8 GND20 Terminal 2 Ground (Engine) AF-2
AC01 YAZAKI 8 Intermediate conncector K-8, AB-8 GND21 Terminal 1 Ground (electric air bleeding pump switch) M-4
AC02 SUMITOMO4 4 Intermediate conncector K-9, AB-7 HDT DT 2 Hydraulic oil temperature sensor AI-2
AC03 Relay 5 Air conditioner blower relay AB-5 HHP DT 3 Work equipment and HSS pump pressure sensor AI-4
AC04 Relay 4 Air conditioner compressor relay AB-4 HNSW DT 2 Horn switch V-9
AC05 S090 2 Air conditioner gas pressure sensor I-1 HRN — 1 Horn C-2
ACCN 040 36 Air conditioner controller L-8 HT Terminal 2 Heater relay (Terminal C) A-5
ACD1 DT 2 Diode AB-2 HT/A Terminal 1 Heater relay (Terminal A) B-5
ACD2 DT 2 Diode AB-2 HT/B Terminal 1 Heater relay (Terminal B) A-4
ACS DT 2 Diode AE-2 HTD DT 2 Diode H-1
ACT Relay 5 Engine ACC signal cut relay D-8 INJ DT 12 Intermediate connector (injector) AG-3
AF1 DT 2 Air cleaner clogging switch (If equipped) E-7 J1939 DT 3 Service connector AF-8
AL/B Terminal 1 Alternator terminal B AC-4 JM01 — 5 Junction wiring harness AH-4
AL/R Terminal 1 Alternator terminal R AC-5 JM02 — 6 Junction wiring harness AH-3
AT11 — 1 Machine monitor F-8 JM03 — 4 Junction wiring harness AH-3
AT12 — 1 GPS antenna I-9 JM04 — 4 Junction wiring harness AG-2
AT21 — 1 KOMTRAX communication module H-8 JM05 — 3 Junction wiring harness AH-5
AT22 — 1 ORBCOMM antenna I-9 JM08 — 6 Junction wiring harness AG-8
AUX0 — 1 Service connector K-2 KEY DT 6 Starting switch R-6
B30L Terminal 1 Circuit breaker (30A) L-2 LHD DT 2 Intermediate connector C-3
B30S Terminal 1 Circuit breaker (30A) L-2 LHDL DT 2 Left headlamp C-3
B105HL Terminal 1 Circuit breaker (105A) M-3 LHDL1 DT 2 Additional left headlamp [Additional headlamp specification] —
B105HS Terminal 1 Circuit breaker (105A) M-3 LHDL2 DT 2 Additional left headlamp [Additional headlamp specification] —
B105L Terminal 1 Circuit breaker (105A) L-2 LHDR DT 2 Right headlamp C-4
B105S Terminal 1 Circuit breaker (105A) L-2 LHDR1 DT 2 Additional right headlamp [Additional headlamp specification] —
BKA Relay 5 Backup alarm relay A-8 LHDR2 DT 2 Additional right headlamp [Additional headlamp specification] —
BKAL DT 2 Backup alarm M-5 LMD1 DT 2 Diode Q-8
BKSW DT 3 Brake pedal switch P-6 LMD2 DT 2 Diode Q-8
BRB Terminal 1 Battery relay (Contact input terminal) N-3 LMFL Relay 5 Left headlamp relay C-9
BRC Terminal 3 Battery relay (Contact output terminal) M-3 LMFR Relay 5 Right headlamp relay C-9
BRE Terminal 1 Battery relay (Coil ground terminal) N-1 LMRE Relay 5 Rear lamp relay A-9
BRK DT 3 Brake pedal potentiometer P-5 LMRP Relay 5 Ripper lamp relay D-7
BVRV DT 2 Transmission bevel speed sensor AK-6 LREL DT 2 Left rear lamp M-7
CA1 DT 3 CAN terminal resistance AH-3 LRER DT 2 Right rear lamp I-9
CB1 — 1 Circuit breaker (20A) C-6 LRP2 DT 3 Ripper lamp M-6
CB2 — 1 Circuit breaker (20A) C-6 NE FRAMATONE 3 Engine Ne speed sensor AH-4
CB3 — 1 Circuit breaker (20A) C-6 NSF Relay 5 Neutral safety relay C-9
CB4 — 1 Circuit breaker (20A) B-6 OPPW DT 2 Intermediate connector Z-9
CB5 — 1 Circuit breaker (20A) B-6 PAMB FRAMATONE 4 Ambient pressure sensor AH-3
CB6 — 1 Circuit breaker (20A) B-6 PBD DT 2 Diode AB-6
CB7 — 1 Circuit breaker (20A) B-6 PBS DT 2 Pedal brake solenoid AL-7
CB8 — 1 Circuit breaker (30A) A-6 PCV1 SUMITOMO 2 Supply pump #1 AD-2
CB9 — 1 Circuit breaker (20A) D-6 PCV2 SUMITOMO 2 Supply pump #2 AD-2
CB30 — 2 Circuit breaker (30A) L-2 PFUEL AMP 3 Common rail pressure sensor AF-2
CB105 — 2 Circuit breaker (105A) L-3 PHR Relay 5 Preheat relay B-9
CB105H — 2 Circuit breaker (105A) M-3 PIM CANNON 4 Charge pressure sensor AH-6
CBPW DTP 4 Intermediate connector X-9 PKD DT 2 Diode AB-6
CK01 070 14 KOMTRAX communication module Y-9 PKS DT 2 Parking brake solenoid AL-6
CK02 070 10 KOMTRAX communication module Y-9 PKSW DT 3 Parking brake lever switch L-8, AB-5
CM01 070 18 Machine monitor R-6 PL1 DRC-70A 70 Intermediate connector AB-4, AN-7
CM02 070 12 Machine monitor R-5 PLSW DT 2 Pin puller switch W-9
CM03 070 18 Machine monitor R-5 POIL CANNON 4 Engine oil pressure sensor AG-2
CM04 070 12 Machine monitor — PPL DT 2 Pin puller solenoid valve M-4
CM05 070 8 Machine monitor — PRT DT-A 12 Intermediate connector E-7
CN1 DT 2 Injecter #1 AC-4 PT1 DT 3 Pitch angle sensor D-6
CN2 DT 2 Injecter #2 AC-5 RDG DT-A 12 Intermediate connector C-5
CN3 DT 2 Injecter #3 AD-7 RES DT 2 Service connector AG-7
CN4 DT 2 Injecter #4 AE-7 RHT Terminal 1 Intake air heater (Ribbon heater) AC-6
CN5 DT 2 Injecter #5 AE-7 RLSW SWP 6 Rear lamp switch P-4
CN6 DT 2 Injecter #6 AH-7 RSD DT 2 Diode AB-1
DCL DT 3 Decelerator pedal potentiometer P-6 S1T DT 2 Transmission 1st clutch ECMV (Solenoid) AI-8
DIAL M 3 Fuel control dial AB-8 S2T DT 2 Transmission 2nd clutch ECMV (Solenoid) AJ-7
DSH DRC-70A 70 Intermediate connector P-2, V-1 S3T DT 2 Transmission 3rd clutch ECMV (Solenoid) AI-8
Intermediate connector (used when work equipment controller is SBRL DT 2 Left brake ECMV (Solenoid) AM-7
DTS DT 12 Z-9
installed)
SBRR DT 2 Right brake ECMV (Solenoid) AM-7
E22 DT 6 Intermediate connector AG-2
SCLL DT 2 Left steering clutch ECMV (Solenoid) AN-6
EFP DT 2 Electric air bleeding pump AF-2
SCLR DT 2 Right steering clutch ECMV (Solenoid) AN-7
EG1 DTP 2 Intermediate connector H-1, AH-5
SFT DT 2 Transmission F clutch ECMV (Solenoid) AJ-7
EG2 DT-B 12 Intermediate connector H-1, AH-5
SFTD — 3 Shift-down switch X-1
EGC1 DRC-60 60 Engine controller AH-4
SFTU — 3 Shift-up switch Y-1
EGC2 DRC-50 50 Engine controller AH-4
SLS 050 2 Daylight sensor P-7
EGC3 DTP 4 Engine controller AG-3
SRT DT 2 Transmission R clutch ECMV (Solenoid) AI-8
EGPW DTP 2 Intermediate connector L-3
SRV DT-A 12 Service connector (for CAN communication) W-9
EHL Relay 5 Engine hold relay D-9
SSP DT 2 Sudden stop prevent valve AK-6
EPP DT 6 Electric air bleeding pump switch F-7
ST DT 2 Starting motor (Terminal R, S) AC-3
ESD DT 3 Service connector (for engine option) Z-9
ST/B Terminal 1 Starting motor (Terminal B) AD-7
F105 DTHD 1 Intermediate connector K-2
STC1 DRC26-24 24 Power train controller Z-1
F1T DT 2 Transmission 1st clutch ECMV (Fill switch) AJ-9
STC2 DRC26-40A 40 Power train controller Z-1
F2T DT 2 Transmission 2nd clutch ECMV (Fill switch) AJ-7
STC3 DRC26-40B 40 Power train controller AA-1
F3T DT 2 Transmission 3rd clutch ECMV (Fill switch) AI-8
SW Terminal 1 Battery relay (Coil signal terminal) N-1
F30 DTHD 1 Intermediate connector L-3
TCT DT 2 Torque converter oil temperature sensor AM-2
FAC DT 2 Fan pump control valve AI-3
TFUEL PACKARD 2 Fuel temperature sensor AH-7
FAR DT 2 Fan reverse solenoid valve C-1
TIM PACKARD 2 Charge temperature sensor AH-6
FBRL DT 2 Left brake ECMV (Fill switch) AL-7
TLV1 DT-B 8 Steering/directional/gearshift lever (Potentiometer) Y-1
FBRR DT 2 Right brake ECMV (Fill switch) AM-7
TLV2 DT 6 Steering/directional/gearshift lever (Shift switch) Y-1
FCLL DT 2 Left steering clutch ECMV (Fill switch) AN-6
TMV 24-23 23 Intermediate connector AN-3
FCLR DT 2 Right steering clutch ECMV (Fill switch) AN-7
TWTR PACKARD 2 Engine coolant temperature sensor AF-8
FD1 24-31 31 Intermediate connector K-2, AB-4
WELK DT 3 Work equipment lock lever switch W-9
FD2 DT-C 12 Intermediate connector L-3
WLK DT 2 Work equipment lock solenoid valve AJ-6
FD3 DT 6 Intermediate connector M-3
WLV DT 2 Radiator coolant level sensor C-2
FD4 24-31 31 Intermediate connector J-2, AB-3
WSH DT 4 Intermediate connector X-9
FFT DT 2 Transmission F clutch ECMV (Fill switch) AK-9
WSH1 DT 6 Window washer tank (Front, left) J-2
FLSW SWP 6 Headlamp switch P-5
WSH2 DT 6 Window washer tank (Rear, right) I-1
FLV DT 2 Fuel level sensor M-4
FRT DT 2 Transmission R clutch ECMV (Fill switch) AK-9
FS11 — 5 Fuse box A-8
FS12 — 5 Fuse box A-7
FS21 — 5 Fuse box A-7
FS22 — 5 Fuse box A-7
FSB 24-21 21 Intermediate connector B-9, AB-4
FTK DT 6 Intermediate connector M-7
G SUMITOMO 3 Engine Bkup speed sensor AD-2
GND Terminal 1 Ground (ROPS) M-3
SEN02874-04
D155A-6 97
Wiring harness diagram (1/19) Wiring harness diagram (1/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
CAB SPEC(1/3)
1 15 29 43 57
JPR2 FD1_M-23 JPK1 AC01_F-8 FSB_M-C
0.85Gy 0.85Y 1.25Br 0.85O 1.25R
. . . . .
C . . . . .
D
(TO 8/19)
GND11 JGM4 FSB_M-U . STC1-3
1.25B 0.85B 1.25L GRO 0.85W
. . . . . JPK1,JPK2
GND11 . . JPK1 JJP1
䝎䝑䝅䝳䝪䞊䝗䝝䞊䝛䝇䜈 1.25B
.
GRO
.
GRO
.
0.85Br
.
0.85P
.
JGM4,JPK4
TO DASH BOARD HARNESS 28
CN-DSH_F 䈜
E (DRC16-70SAE-P066) CK01-1
0.85Y
FD1_M-6
0.85L
CK01-8
0.85B
.
GRO
FD1_M-13
0.85P JNX5
. . . . .
I
JGP3
J JGP3
STC1-4
0.85B
TLV2_F-5
0.85B
TLV2_F-2
0.85B
. . .
JNG1 DSH_F-12
䈜 JNX5 BRAID 0.85B
L . .
4 1
M STC3-9 STC1-24
JJP1
0.85P
STC1-13
0.85W
STC1-7
0.85Br
JGP1
0.85B 3
JGP1
0.85B
STC1-1
0.85V 2
1 0.85L
.
0.85Br
.
6 . . . . . .
STC1-12 STC1-18 5 8
3 0.85Y 0.85G 4
. .
CN-TLV1 DIAL
N (DT-B) (M)
CN-TLV2_F ㉮⾜䝺䝞䞊䜈 ⇞ᩱ䝎䜲䜰䝹䜈
(DT) TO TRAVEL LEVER TO FUEL DIAL
䝅䝣䝖SW䜈
(TO 2/19) TO SIFT SW
200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222
SEN02874-04
D155A-6 99
Wiring harness diagram (2/19) Wiring harness diagram (2/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
CAB SPEC(2/3) TO P/T CONTROLLER
PL1_M-8 PKD-1 JS15
P/T䝁䞁䝖䝻䞊䝷䜈 JCE6 0.85G
.
0.85G
.
0.85G
.
PL1_M-67 PL1_M-70 STC3-10 JOP2
JOP1
(FROM 1/19)
0.85O 1.25B 0.85B 1.25B
CN-STC3
PL1_M-10 PBD-1 JS19
19
TLV1-6 PL1_M-30 JGP1 JJP1 PKSW-B TLV2_F-6
24 31
. JNH . PTF-4 PL1_M-43 . . PL1_M-21 . .
40 10
JOP1 TLV2_F-1 PL1_M-54 PL1_M-22 PL1_M-58 PL1_M-16 JPK3 JRP1 JPP1 JUP1
JGP1 0.85B 0.85B 0.85B 0.85B 0.85B 0.85B . . . . . .
0.85Br
.
0.85Y
.
0.85B
.
0.85P
.
0.85W
.
0.85Br
.
GRO
.
0.75W
.
GRO
.
0.85B
.
0.85G
.
GRO
.
GRO
.
0.85P
.
GRO
.
GRO
.
0.85B
.
0.85L
.
0.85Br
.
0.85L
.
0.85Br
.
0.85Y
.
0.85V
.
0.85B
.
0.85Br
.
0.85R
.
1 . . . . . .
JOP4 PL1_M-60 PL1_M-42 PL1_M-46 PL1_M-53
B TLV1-3 . JPR2 FD1_M-22 JS15 TLV2_F-4 . JNL . JNH3 PL1_M-49 . ESD-C . PL1_M-56 PL1_M-55 . PL1_M-57 FD1_M-4 . PL1_M-61 PL1_M-19 JPKE JRP2 JPP1 JUP1 JGP1 FD1_M-20 PL1_M-29 PL1_M-40 JOP3 1.25B 0.85B 0.85B 0.85B 0.85B
13 0.85W GRO 0.85Gy 0.85P 0.85G 0.85G 18 21 GRO 0.75B GRO 0.85V 0.85Gy GRO 0.85P GRO 0.85B 0.85Br 30 20 GRO 0.85L 0.85W GRO 0.85G 0.85L 0.85Br 0.85B 0.85Br 0.85R 11 JGP2 0.85B
.
0.85B
.
0.85B
.
0.85B
.
. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
PL1_M-18 GND12 PL1_M-4 JOP3 PL1_M-38
TLV1-2 FD1_M-21 PL1_M-39 WELK-A DSH_F-58 TLV2_F-3
11
. JNX8 PL1_M-1 PTF-1 WELK-C . ESD-A FD1_M-28 FSB_M-W .
20
DTS_F-9 PL1_M-63 . PL1_M-44 PL1_M-51 PL1_M-2 JPKE JRP3 JPP1 JOP2 FD1_M-14 FD1_M-24 FD4_F-16 DSH_F-17 JGM4 JOP4 0.85B 0.85B 0.85B 1.25B 0.85B
7 0.85Br
.
0.85W
.
0.85O
.
0.85B
.
0.85W
.
0.85Y
.
12 GRO
.
0.85B
.
0.85O
.
0.85P
.
0.85O
.
GRO
.
0.85G
.
0.85O
.
0.85V
.
GRO
.
30 0.85B
.
0.85P
.
GRO
.
0.85L
.
0.85Y
.
0.85W
.
0.85Br
.
0.85B
.
0.85Br
.
0.85B
.
21 䝎䜲䜸䞊䝗 JGM5 1.25B 0.85B 0.85B 0.85B 0.85B . . . . .
. . . . .
DIODE
DIAL-2 TLV1-7 DSH_F-62 JGP3 JS19 . . PL1_M-15 PL1_M-7 PTF-2 WELK-B . DSH_F-13 FSB_M-N FSB_M-X . PL1_M-65 PL1_M-50 . PL1_M-47 PL1_M-36 PL1_M-5 PL1_M-31 JOP2 JOP2 JOP2 AC02_F-4 FSB_M-L AC03-4 AC04-4
1 0.85V 0.85Y 0.85W 0.85B 0.85Y GRO 6 1 GRO 0.85Gy 0.85L 0.85L 0.85Gy GRO 0.85L 1.25P 0.85Gy GRO 10 40 0.85O 0.85Br GRO 0.85O 0.85Sb 0.85Gy 0.85P 0.85B 0.85B 0.85B 31 CN-PKD CN-PBD JPAA 0.85G
.
2G
.
2G
.
1.25G
.
. . . . . . . . . . . . . . . . . . . . . . . . . .
(DT) (DT)
C JJP1,JPR2 TLV1-4 STC1-22 TLV1-5 DSH_F-63 DIAL-1 JPAC
AC03-1 AC01_F-4
0.85P 0.85P
AC04-1
0.85P
ACD1-1
0.85P
ACD2-1
0.85P
JJP1 0.85P 0.85P 0.85P 0.85P 0.85P . . . . .
JGP1,JGP2 . . . . .
JRP1,JRP2,JRP3 JPAE
ACD1-2 AC01_F-1 AC03-3
JS15,JS19 JNX8 JNXG JNG2 GND12 JNX5 JNX6 0.85V 0.85V 0.85V
(TO 3/19)
G
JPAA,JPAC
PL1_M-6 PL1_M-20 PL1_M-17 PL1_M-3 PL1_M-64 STC3-3
H JRP1 0.85B
.
0.85B
.
0.85B
.
0.85B
.
0.85B
.
0.85B
.
JPAE,JPAF
2 1 1 1
PL1_M-48 PL1_M-45 FD1_M-5 STC3-13
JRP2 0.85B 0.85B 0.85B 0.85B FD4_F-14 JPAC JPAC 䝎䜲䜸䞊䝗
JCE6,JCE7
. . . .
CN-AC04 1.25W
.
0.85P
.
0.85P
.
DIODE
JRP3
PL1_M-59
0.85B
JRP4
0.85B
PL1_M-62 PL1_M-52
0.85B 0.85B
STC3-23
0.85B
䝁䞁䝥䝺䝑䝃䝸䝺䞊䜈 JPAF JPAA JPAE CN-ACD1 JRP5,JRP6
TO COMPRESSOR RELAY 0.85Br 1.25G 0.85V
. . . . . . . . (DT) JOP3,JOP4
I JRP4
PL1_M-23
0.85B
JRP6
0.85B
PL1_M-37
0.85B
JRP5
0.85B
JRP3
0.85B STC2-34 .
3 4 2 2
. . . . . 4 0.85B GRO 3
. .
1 1
PL1_M-9 PKD-2 JRP4
JRP5 0.85B
.
0.85B
.
0.85B
. 2
STC2-4
0.85L
STC2-14
0.85P 1 1 4
JPAC
0.85P
. . .
PL1_M-11 PBD-2 JRP4
JPAC
0.85P
JPAA
2G JPAF
CN-ACD2
JRP6 0.85B 0.85B 0.85B . . 0.85Br
(DT)
CN-AC03
. . . . . .
2 GRO GRO 1 .
䈜
J PKSW-C STC1-17 JCE6 . .
䝤䝻䜰䝸䝺䞊䜈
.
JNX6 2 2
JS15 0.85G
.
0.85G
.
0.85G
. . .
.
TO BLOWER RELAY
4 GRO GRO 3 JPAE AC01_F-3
1 1
. . 0.85V 2O
DSH_F-59 JCE7 STC1-5 . . JOL2
JS19 0.85Y 0.85Y 0.85Y JPK3
0.85V
. . .
3 5 JGM5,JPK3 .
N 1.25R
.
JPKC 1.25G
.
. .
0.85B
. .
0.85W
. JGM5 . . HNSW-1
0.85L
. JRP2
0.85W
. DSH_F-66 . 1 0.85O
.
0.85W
.
0.85B
.
0.85B
.
0.85Gy
.
0.85B
.
0.85L
.
0.85G
.
0.85B
.
0.85Y
.
0.85B
.
GRO
.
GRO
.
GRO
.
14
1.25Br GRO GRO 0.85B 0.85P 0.85B 0.85B
. . . . . . .
13 15 15 13
. DSH_F-16 HNSW-2 DSH_F-64
24 14 0.85Gy
27 27 14 24
GRO 0.85Br 0.85P
. . AC04-2 . . JPK3 . JGM5 . JGM5
GRO 1.25W GRO 1.25V 1.25B 0.85B
. . . . . . 䝟䝽䞊䝷䜲䞁䝝䞊䝛䝇䜈
(TO 13/19)
25 26 26 25
. . . . TO P/L HARNESS
CN-PL1_M
GRO GRO GRO GRO
. . . .
O (DRC12-70PAE)
(TO 14,18/19)
ᕥ䝣䜵䞁䝎䞊䝝䞊䝛䝇䜈
TO LEFT FENDER HARNESS
P (TO 10/19)
223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245
SEN02874-04
D155A-6 101
Wiring harness diagram (3/19) Wiring harness diagram (3/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
CAB SPEC(3/3)
TO A/C UNIT
B A/C䝴䝙䝑䝖䜈
STC1-23 FSB_M-A
7 0.75B
.
0.85B
.
0.85B
.
0.85Gy
.
GRO
.
GRO
.
C 0.85P
.
.
(DT)
D CN-GND12 B 0.85W
.
1.25O
.
A JNH JNH3 GND11 JPKC JUF2 FSB_M-J FSB_M-M JOL2 FSB_M-V STC2-17
C
JOP4 JNG1 AC01_F-5 FD4_F-4 6 0.75W 0.85V 2B 0.85Br 2R 2O
1 1 2W 2B 2 B 1.25Br 0.85G
A FD1_M-17 FD1_M-18
0.85B 2B 0.85B 0.85B
䈜
. . . . . . . . . . 1 0.85Y
.
0.85V
.
2
. . . .
JNXE
CN-GND11
SRV-9 SRV-12 DTS_F-4 JOP2 DSH_F-6 DSH_F-7
E 0.85B
.
1.25B
.
2B
.
2B
.
1.25B
.
1.25B
.
䈜
(TO 15/19)
JNXG 䝩䞊䞁䝇䜲䝑䝏䜈
TO HORN SWITCH
CN-HNSW
F
(DT)
(FROM 2/19) 1
FD1_M-16
0.85P
.
28 28 15 7 FD1_M-15
0.85Br
.
G
2
䈜
JNXC
䝃䞊䝡䝇䝁䝛䜽䝍
H SERVICE CONNECTOR
CN-SRV
(DT-A)
6 7
JNH3 .
0.85V GRO
. .
I . .
GRO GRO
. .
. GND11
GRO 0.85B
. .
JNH JNL
0.75W 0.75B
. .
. DSH_F-41 DSH_F-40 DSH_F-39 DSH_F-38 DSH_F-37 DSH_F-36 DSH_F-9 . DSH_F-69 DSH_F-68 DSH_F-67 DSH_F-56 DSH_F-55
14 . 0.85L 0.85O 0.85V 0.85Y 0.85G 0.85B 0.85B 7 10 . 0.85Y 0.85Gy 0.85Br 0.85O 0.85L 5
J . . . . . . . . . . . . . .
JPKC
0.85Br
JNXC
0.85B
. .
. . DSH_F-70 . . DSH_F-8 DSH_F-54 DSH_F-53 DSH_F-52 DSH_F-51
6 . . 0.85P . . 0.85Y 1 4 0.85W 0.85G 0.85Br 0.85V 1 JUF2 GND11
. . . . . . . . . . 1.25R 1.25B
. .
1 12
CN-CK01 CN-CK02 FD4_F-9 FD4_F-6 FSB_M-B .
4 1 1 3L GRO 4
KOMTRAX
0.85G 0.85W
K KOMTRAX . . . .
FSB_M-D FSB_M-E
3
FD4_F-8
0.85L
FD4_F-7
0.85V 2 2 3Y 3R 3
. . . .
㻷㻻㻹㼀㻾㻭㼄㻌䝰䝕䝮䜈
TO KOMTRAX MODEM
CN-WSH CN-CBPW
(DT) (DTP)
L
䜻䝱䝤䝝䞊䝛䝇䜈
TO CAB HARNESS
STC1-10 STC2-5
A 0.85B
.
0.85Gy
.
B
STC2-15
0.85O C
M .
CN-WELK
(DT)
సᴗᶵ䝻䝑䜽䝇䜲䝑䝏䜈
TO WORK EQUIPMENT LOCK SWITCH
SRV-11 JNG2
䈜JNXC 0.85B
.
BRAID
.
AC02_F-3 JNG2
䈜JNXE 0.85B BRAID
O . .
DTS_F-8 JNG1
䈜JNXG 0.85B
.
BRAID
.
246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268
SEN02874-04
D155A-6 103
Wiring harness diagram (4/19) Wiring harness diagram (4/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
CAB-less SPEC(1/3)
䝎䝑䝅䝳䝪䞊䝗䝝䞊䝛䝇䜈
(TO 9/19)
TO DASH BOARD HARNESS
CN-DSH_F
(DRC16-70SAE-P066) JGP3
STC1-4
0.85B
TLV2_F-5
0.85B
TLV2_F-2
0.85B JPK2
FSB_M-P DSH_F-31 DSH_F-2
1.25G 1.25G 0.85G
. . . . . .
JNH3 STC2-7 JNX5 JNL JNH . . GND11 GND11 JUF2 JUF2 JPK1 JPK2 JPR2
B 14 0.85V
.
0.85L
.
0.85B
.
0.75B
.
0.75W
.
GRO
.
GRO
.
1.25B
.
1.25B
.
1.25R
.
1.25R
.
0.85Br
.
0.85G
.
0.85Gy
.
1 JGM5 DSH_F-20 DSH_F-47 FSB_M-T DSH_F-19 DSH_F-30
䈜
JNX5
D
F
JPK1,JPK2
JPK4,JGM4
1 2 2 1
G ቑタ䝷䜲䝖䜈 GND12 FD1_M-26
(TO 19/19)
TO ADDITIONAL LIGHT GRO GRO 1.25B 1.25G
. .
CN-LBP_F FD1_M-25 GND12
(DT)
GRO GRO 1.25L 1.25B
. .
4 3 3 4
I
3 1
䝅䝣䝖SW䜈 STC1-12
0.85Y
JGP3
0.85B
STC3-9
0.85L
TO SIFT SW . . .
J 4 6
K
B
STC2-5 CN-WELK
JGP3 0.85Gy
. STC2-15 (DT)
0.85O
STC1-10 . సᴗᶵ䝻䝑䜽䝇䜲䝑䝏䜈
5 4
0.85B
. C TO WORK EQUIPMENT
LOCK SWITCH
JJP1 JJP1
L 0.85P 0.85P A
. .
O B
FD1_M-15 FD1_M-16
⇞ᩱ䝎䜲䜰䝹䜈 STC1-1
0.85V
2 0.85Br
.
0.85P
.
1
(TO 5/19)
TO FUEL DIAL . JGP1
CN-DIAL JJP1
0.85B
.
(DT)
0.85P
. C CN-HNSW
A
(DT)
䝩䞊䞁䝇䜲䝑䝏䜈
P TO HORN SWITCH
(TO 15/19)
269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291
SEN02874-04
D155A-6 105
Wiring harness diagram (5/19) Wiring harness diagram (5/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
CAB-less SPEC(2/3)
TO P/T CONTROLLER
P/T䝁䞁䝖䝻䞊䝷䜈
B
(FROM 4/19) CN-STC1 CN-STC2
CN-STC3
TLV1-6 PL1_M-30 JGP1 JJP1 PKSW-B TLV2_F-6 . JNH . PTF-4 PL1_M-43 . . PL1_M-21 . . JOP1 TLV2_F-1 PL1_M-54 PL1_M-22 PL1_M-58 PL1_M-16 JPK3 JRP1 JPP1 JUP1
19 0.85Br
.
0.85Y
.
0.85B
.
0.85P
.
0.85W
.
0.85Br
.
24 31 GRO 0.75W GRO 0.85B 0.85G GRO GRO 0.85P GRO GRO 40 10 0.85B 0.85L 0.85Br 0.85L 0.85Br 0.85Y 0.85V 0.85B 0.85Br 0.85R 1
. . . . . . . . . . . . . . . . . . . .
TLV1-3 . JPR2 FD1_M-22 JS15 TLV2_F-4 . JNL . JNH3 PL1_M-49 . ESD-C . PL1_M-56 PL1_M-55 . PL1_M-57 FD1_M-4 CBR-1 PL1_M-61 PL1_M-19 JPKE JRP2 JPP1 JUP1
13 0.85W
.
GRO
.
0.85Gy
.
0.85P
.
0.85G
.
0.85G
.
18 21 GRO 0.75B GRO 0.85V 0.85Gy GRO 0.85P GRO 0.85B 0.85Br 30 20 GRO 0.85L 0.85W 0.85Y 0.85G 0.85L 0.85Br 0.85B 0.85Br 0.85R 11
. . . . . . . . . . . . . . . . . . . .
TLV1-2 FD1_M-21 PL1_M-39 WELK-A DSH_F-58 TLV2_F-3 . JNX8 PL1_M-1 PTF-1 WELK-C . ESD-A FD1_M-28 FSB_M-W . . PL1_M-63 . PL1_M-44 PL1_M-51 PL1_M-2 JPKE JRP3 JPP1 JOP2
C 7 0.85Br
.
0.85W
.
0.85O
.
0.85B
.
0.85W
.
0.85Y
.
12 11 GRO 0.85B 0.85O 0.85P 0.85O GRO 0.85G 0.85O 0.85V GRO 20 30 GRO 0.85P GRO 0.85L 0.85Y 0.85W 0.85Br 0.85B 0.85Br 0.85B 21
. . . . . . . . . . . . . . . . . . . .
DIAL-B TLV1-7 DSH_F-62 JGP3 JS19 . . PL1_M-15 PL1_M-7 PTF-2 WELK-B . DSH_F-13 FSB_M-N FSB_M-X . PL1_M-65 PL1_M-50 . PL1_M-47 PL1_M-36 PL1_M-5 PL1_M-31 JOP2 JOP2 JOP2
1 0.85V
.
0.85Y
.
0.85W
.
0.85B
.
0.85Y
.
GRO
.
6 1 GRO 0.85Gy 0.85L 0.85L 0.85Gy GRO 0.85L 1.25P 0.85Gy GRO 10 40 0.85O 0.85Br GRO 0.85O 0.85Sb 0.85Gy 0.85P 0.85B 0.85B 0.85B 31
. . . . . . . . . . . . . . . . . . . .
JGP1,JGP2
JJP1,JPR2
JRP1,JRP2
D JS19,JS15
JRP3,JRP4
JPKE
E
䈜
JNX8
F JNH,JNL,JNH3
JOP1,JOP2
JPKC,JPP1 JNG1
JUF2,JUP1
G
(TO 6/19)
JCE7
PL1_M-10 PBD-1 JS19
JPKE
JPKC STC3-14 STC3-24 䈜 JOP3,JOP4
1.25Y
.
0.85Y
.
0.85Y
.
0.85R
.
0.85Br
.
0.85Br
. JNX6
TLV1-8 JGP2 DIAL-C TLV1-1 DSH_F-61 STC1-21 STC3-12 STC3-22 FSB_M-H PL1_M-68 STC3-2 JGM5,JOL2
J JGP1 0.85B
.
0.85B
.
0.85B
.
0.85B
.
0.85B
.
0.85B
.
JPP1 0.85Br
.
0.85Br
.
2Br
.
1.25Br
.
0.85Br
.
JPK3
JGP1 FD1_M-20 PL1_M-29 PL1_M-40 STC1-15 DSH_F-1 FD1_M-2 RSD-2
JGP2 0.85B
.
0.85B
.
1.25B
.
1.25B
.
JPR2 0.85Gy
.
0.85Gy 1.25Gy 0.85Gy
. . .
TLV1-4 DSH_F-63 DIAL-A STC1-22 TLV1-5 PL1_M-45 FD1_M-5 STC3-13 CBR-2 PL1_M-48
JJP1 0.85P
.
0.85P
.
0.85P
.
0.85P
.
0.85P
.
JRP2 0.85B
.
0.85B
.
0.85B
.
0.85B
.
0.85B
.
TO FUSE HARNESS
JNX8 JNX5 JNX6 GND12 JNXC PL1_M-59 PL1_M-52 STC3-23 JRP4 PL1_M-62
JNG1 BRAID
.
BRAID
.
BRAID
.
0.85B
.
BRAID
.
JRP3 0.85B
.
0.85B
.
0.85B
.
0.85B
.
0.85B
.
䝠䝳䞊䝈䝝䞊䝛䝇䜈
L CN-FSB_M
SRV-6 DSH_F-14 STC2-24 PL1_M-23 JRP5 JRP3 JRP6 PL1_M-37 (24-21)
JNH3 0.85V
.
0.85V
.
0.85V
.
JRP4 1.25B
.
0.85B
.
0.85B
.
0.85B
.
0.85B
.
TO LEFT FENDER HARNESS
H ᕥ䝣䜵䞁䝎䞊䝝䞊䝛䝇䜈
SRV-3 STC2-32 DSH_F-10 FD1_M-8 PL1_M-9 PKD-2 JRP4
X JPP1
2Br
J
CN-FD1_M
JNH 0.75W 0.75W 0.75W 0.75W JRP5 1.25B 0.85B 0.85B STC2-9 .
(24-31)
0.85Gy . GRO
. . . . . . .
W . . K
M STC2-19
0.85V G B
JUF2
2R
SRV-10 STC2-22 DSH_F-11 FD1_M-9 PL1_M-11 PBD-2 JRP4 . . . .
JNL 0.75B 0.75B 0.75B 0.75B JRP6 1.25B 0.85B 0.85B GRO GRO STC3-19 STC3-6 JRP3 JOP3 STC3-16 JRP3 STC3-29 JRP1 STC3-40 . JOP1 JPP1 FD1_M-3 JOP1
. . . . . . . V
ESD-B
. . L
CBR-3
57 0.85L
.
0.85Br
.
0.85B
.
0.85B
.
0.85G
.
0.85B
.
0.85P
.
1.25B
.
0.85O
.
GRO
.
0.85O
.
1.25Br
.
1.25W
.
1.25B
.
70
31 20
1.25Br 1.25G
F A C DSH_F-46 JGP2
. . 30 8 21 STC2-35 STC3-27 JRP2 JOP3 STC3-37 JRP2 STC2-25 STC3-39 STC3-26 JRP3 JOP3 STC3-8 STC2-30 STC2-29
JOL2
OPPW-2 FD1_M-19 FD1_M-29
2B 1.25B 1.25B JS15
PKSW-C STC1-17
0.85G 0.85G
JCE6
0.85G
FD1_M-1
1.25W
PKSW-A
1.25O
DSH_F-57
1.25R DSH_F-45
1.25L
. JNH
0.85B
. STC1-8 43 0.85G
.
0.85L
.
0.85B
.
0.85B
.
0.85O
.
0.85B
.
0.85Gy
.
0.85Br
.
0.85Y
.
0.85B
.
0.85B
.
0.85Br
.
0.85Br
.
0.85B
.
56
U M 1.25V 0.75W 0.85W
. . . . . . . . .
DSH_F-34 OPPW-1 . . .
19 9 JGP2 STC1-20 STC3-34 . . . . STC3-36 JRP4 JOP4 STC1-9 JGP2 . JOP3
1.25L
. E D
2W
. JOL2 JNL 29 1.25B 0.85Y 0.85P GRO GRO GRO GRO 0.85Sb 0.85B 0.85B 0.85O 1.25B GRO 0.85B 42
N PL1_M-67 PL1_M-70 STC3-10 JOP2 DSH_F-59 JCE7 STC1-5 T
. .
N
18
PLSW-2
1.25B
JPR2
2
0.75B
10
JNX6
. . . . . . . . . . . . . .
JOP1 0.85O 1.25B 0.85B 1.25B JS19 0.85Y 0.85Y 0.85Y GRO
.
GRO
. 29 0.85V
.
1.25Gy
.
0.85B 22 STC2-2 STC3-5 JRP1 JOP4 STC3-15 JRP1 STC2-38 STC3-7 JRP4 DSH_F-24 DSH_F-25 . . .
. . . . . . . JPK4
1.25W
STC2-8
1.25P JOL2 .
7
.
3
. STC1-16 15 0.85Gy
.
0.85Y
.
1.25B
.
0.85B
.
0.85L
.
1.25B
.
0.85P
.
0.85L
.
1.25B
.
1.25G
.
1.25B
.
GRO
.
GRO
.
GRO
.
28
. S P . 1.25B 0.85P
DSH_F-23 PL1_M-69
DSH_F-33 R JPK2
. 17 1 11 .
STC2-13 STC3-25 JRP1 JOP4 STC3-35 JRP1 STC2-3 JCE6 JRP5 JCE7 JRP6 . . .
0.85B 1.25W
JOP2
STC3-21 STC3-32
0.85B 0.85B
STC3-33
0.85B
STC3-31
0.85B
JOP1
1.25B
GND11
2B JUF2
FSB_M-K
2R
JUP1
2R
DSH_F-5
1.25R
SRV-1
1.25R
DSH_F-4
1.25R
1.25R
.
JPKC 1.25G
.
PLSW-1
0.85Y
. FSB_M-F
1.25W
. DSH_F-65
0.85Y
1 0.85O
.
0.85W
.
1.25B
.
0.85B
.
0.85Gy
.
0.85B
.
0.85L
.
1.25G
.
1.25B
.
1.25Y
.
1.25B
.
GRO
.
GRO
.
GRO
.
14
1.25Br
. . . . . . . . . . . . 28 . . . 23
6 4
STC2-18 DSH_F-15
DSH_F-22 STC3-18
0.85O 16 5 12 0.85Y
. 0.85L 0.85W .
HNSW-1 JRP2 DSH_F-66
O JOP3
JOP4 PL1_M-60 PL1_M-53 PL1_M-42 PL1_M-46
JUP1
JUF2 STC3-11 STC3-1
0.85P
.
0.85B
.
0.85B
(TO 13/19)
1.25B 0.85B 0.85B 0.85B 0.85B 2R 0.85R 0.85R
. . . . . . . . .
15
.
13
. TO P/L HARNESS
HNSW-2 DSH_F-64
27
0.85Br
14
0.85P
24 䝟䝽䞊䝷䜲䞁䝝䞊䝛䝇䜈
JPK3 JGM5 DSH_F-16
JOP4
PL1_M-18
0.85B
JOP3
1.25B
PL1_M-38
0.85B
GND12 PL1_M-4
0.85B 0.85B 䈜JNX6
JNG1
BRAID
FD1_M-10
0.85B
1.25V
.
.
1.25B
.
.
0.85Gr
.
CN-PL1_M
(DRC12-70PAE)
. . . . . . . 26 25
LBP_F-1 LBP_F-3
(TO 14,18/19)
1.25G 1.25L
. .
STC3-4 DSH_F-32 FD1_M-27 RSD-1 JNG1 STC2-12
P JPK3 0.85V
.
1.25V
.
1.25V
.
0.85V
.
䈜JNX8 BRAID
.
0.85B
.
(TO 11/19)
292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314
SEN02874-04
D155A-6 107
Wiring harness diagram (6/19) Wiring harness diagram (6/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
CAB-less SPEC(3/3)
C
TO PARKING BRAKE SWITCH SRV-11 JNG1
CN-PKSW
(DT)
D
JS15
C 0.85G
.
STC1-23 FSB_M-A
B 0.85W
.
1.25O
.
A
CN-GND12
JOP4 JNG1 LBP_F-2 CBZ-1 LBP_F-4 1 1
0.85B 0.85B 1.25B 1.25B 1.25B
. . . . . FSB_M-M
2W GRO CN-OPPW
.
F CN-GND11 JOL2
(DT)
2B GRO
䜸䝥䝅䝵䞁㟁※⏝䝁䝛䜽䝍
CN-CBZ
SRV-9 SRV-12 JOP2 DSH_F-6 DSH_F-7 .
0.85B 1.25B 2B 1.25B 1.25B OPTION POWER CONNECTOR
. . . . .
(DT) 2 2
㆙ሗ䝤䝄䞊
CAUTION BUZZER
B
G GND12 CBR-5
FSB_M-V
1.25Br
1 1.25B 1.25O 2 . STC2-27
. .
STC2-17
0.85P
. CN-ESD
0.85G
. C A (DT)
2
JRP2 A GRO
䝻䞊䜹䝹䜸䝥䝅䝵䞁䝁䝛䜽䝍
LOCAL OPTION CONNECTOR
0.85B
CN-CBR 3 5 . GRO
H ㆙ሗ䝤䝄䞊䝸䝺䞊
FSB_M-L
1.25G
CBZ-2
1.25O
.
.
GRO
1 䈜
CN-RSD JNXC
I CN-PKD,CN-PBD
(FROM 5/19) 6 7 7 6
JNH3 .
0.85V GRO GRO GRO
. .
.
GRO
.
GRO GRO GRO CN-SRV
J . .
(DT-A)
. GND11
GRO
.
0.85B
.
GRO GRO 䝃䞊䝡䝇䝁䝛䜽䝍
SERVICE CONNECTOR
JNH JNL
0.75W 0.75B GRO GRO
. .
JPKC JNXC
0.85Br 0.85B GRO GRO
. .
K JUF2 GND11
1.25R 1.25B GRO GRO
. .
1 12 12 1
L 3 1 CN-PTF
1 3
. STC2-14 . . (X)
JPR2 JPK3 JRP6 JCE7 JRP5 JCE6 GRO
.
0.85P
.
GRO
.
GRO
. P/T䝁䞁䝖䝻䞊䝷
2 0.85Gy
.
0.85V
.
1 2 0.85B
.
0.85Y
.
1 2 0.85B
.
0.85G
.
1
STC2-34
0.85B
STC2-4
0.85L
.
GRO
.
GRO
᭩㎸䜏䝁䝛䜽䝍
. . . . P/T CONTOROLLER
FLASH CONNECTOR
2 1 2 1 2 1 4 2 2 4
M
315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337
SEN02874-04
D155A-6 109
Wiring harness diagram (7/19) Wiring harness diagram (7/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
02
2
1
01
6 14 10 16 8 12
B
PCV1 12 11 10 9 8 7
ఫ䝝䜴䝆䞁䜾 : 6189-0039(⅊) INJ
SUMITOMO HOUSING : (GRAY) 1 2 3 4 5 6
䝍䞊䝭䝘䝹:1500-0110
(TO 7/19)
TERMINAL
C 䝽䜲䝲䝅䞊䝹:7161-9785(Ⲕ) 2 PCV2
1 5 13 9 15 7 11
WIRE SEAL : (BROWN) ఫ䝝䜴䝆䞁䜾:6189-0074(⃰䛔⅊Ⰽ)
SUMITOMO TERMINAL : (DARK GRAY)
04 䝍䞊䝭䝘䝹:1500-0110
TERMINAL
03 䝽䜲䝲䞊䝅䞊䝹:7161-9785(Ⲕ)
WIRE SEALHOUSING : (BROWN)
D
INJ
(FROM 7/19)
10 06 13 09 15 11 16 12
CN INJ
F 2 1 CN1 2 1 CN2 2 1 CN3 14 37 05 07 62 57 08
61
02 01 04 03 06 05 24
PFUEL
AMP 51 52 53 54 55 56 57 58 59 60
G ENG 41 42 43 44 45
A 46 47 48 49 50 64
䝝䜴䝆䞁䜾:174357-2(㯮)
HOUSING :(BLACK) 31 32 33 34 35 36 37 38 39 40
䝍䞊䝭䝘䝹:171662-1 21 22 23 24 25 26 27 28 29 30 49
TERMINAL
G 45 11 12 13 14 15 16 17 18 19 20
H 䝍䞊䝭䝘䝹:1500-0110 䝣䝻䞁䝖䝩䝹䝎䞊:174358-7
FRONT HOLDER
TERMINAL
JM08 35 47 26 79 58 78
䝽䜲䝲䝅-䝹:7160-8234(㯮)
WIRE SEAL : (BLACK) 35
08 07 10 09 12 11 34 22 01 02 65 56 03
55
33 04
24
321
54
3 2
I 1 26
POIL 1 25
53 FRAMATOME 2
3
䝝䜴䝆䞁䜾:54200308
HOUSING(KEY A,BLACK)
56 57 58
䝍䞊䝭䝘䝹:54001803
(GOLD COATING,FEMALE)TERMINAL
J
RES
78 1 2 3 21 22 23
68
A
2
NE 1 2 3
C
K B FRAMATOME
1
RES 67
䝝䜴䝆䞁䜾:54200311 PAMB 12 10 08 06 04 02
HOUSING(KEY D,WHITE)
J1939 AMP
79
䝍䞊䝭䝘䝹:54001803
TERMINAL(GOLD COATING,FEMALE) 䝝䜴䝆䞁䜾:1318670-2(㯮)
HOUSING : (BLACK) 7 8 9 10 11 12
䝍䞊䝭䝘䝹:1318329-1(FEMALE) INJ
6 5 4 3 2 1
TERMINAL
L JM05
11 09 07 05 03 01
M PIM
䝝䜴䝆䞁䜾:ఫ 6098-0141(⅊)
HOUSING : SUMITOMO : (GRAY)
䝸䝔䞊䝘:ఫ 6920-0080(㯤)
RETAINER:SUMITOMO : (YELLOW)
TFUEL
䝍䞊䝭䝘䝹:ఫ(▮ᓮ)
PACKARD
N 1410-0096(7116-1530) JM01 JM02 JM03 JM04
䝝䜴䝆䞁䜾:12162193(㯮) TERMINAL:SUMITOMO(YAZAKI)
HOUSING : (BLACK)
䝽䜲䝲䝅䞊䝹:ఫ(▮ᓮ)
䝍䞊䝭䝘䝹:12124075
TERMINAL 7165-0159(7157-3881-70)(㯤)
1 WIRE SEAL:SUMITOMO(YAZAKI) : (YELLOW)
50 B
3
2 TWTR
A 36
B A PACKARD
O 37 䝝䜴䝆䞁䜾:12162193(㯮)
TIM 38 B A HOUSING : (BLACK)
49
46 45 PACKARD 䝍䞊䝭䝘䝹:12124075
TERMINAL
䝝䜴䝆䞁䜾:12162197(⅊) 48 47
HOUSING : (GRAY)
䝍䞊䝭䝘䝹:12124075
TERMINAL
P
338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360
SEN02874-04
D155A-6 111
Wiring harness diagram (8/19) Wiring harness diagram (8/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
CAB SPEC
CN-LMD1 CN-LMD2
DSH-12 .
(DT) (DT) 䈜N1 0.85B BRAID
. .
B 䝎䜲䜸䞊䝗 䝎䜲䜸䞊䝗
DIODE DIODE DSH-10 CM02-8 CM02-9
NA 0.75W 0.85W 0.85W
. . .
DSH-4 DSH-5 DSH-6 DSH-7 DSH-14 DSH-13 DSH-20 DSH-24 . . DSH-15 DSH-16 . RLSW-1 RLSW-6 DSH-46
DSH-43 DSH-44 1 1.25R 1.25R 1.25B 1.25B 0.85V 0.85L 0.85B 0.85G 8 1 . . 0.85Y 0.85Gy . 5 F 1.25L 1.25L 1.25L
1 0.85O 0.85L 2 . . . . . . . . . . . . . . . .
. .
D 9
DSH-22
0.85L .
. DSH-1
0.85Gy
X E DSH-3
0.85B 0.85G 0.85Br
DSH-2 DSH-19
0.85G 0.85W .
.
.
.
18 6 .
. DSH-17 NA NA DSH-11
0.85B 0.85W 0.85W 0.75B
.
. .
.
12 RLSW-5 FLSW-5 DSH-49
CN-BKSW . . . . . . . . . . . . . . . . . G 1.25Br 1.25Br 1.25Br
. . .
(DT)
RLSW-2 FLSW-2 DSH-47
䝤䝺䞊䜻䝨䝎䝹䝸䝭䝑䝖䝇䜲䝑䝏 H 1.25B 1.25B 1.25B
BRAKE PEDAL SWITCH . . .
A
DSH-23 DSH-25 CM01-12
DSH-57 X 0.85B 0.85B 0.85B
E DSH-59
0.85R . . .
.
C 0.85Y
DSH-58
.
MONITOR 0.85W
.
䝰䝙䝍䞊
CN-CM03 B
57 43 29 15 1
(070) BKSW-A SLS-1 KEY-1 CM02-3 CM01-11
0.85R 0.85O 1.25Br 0.85Y 0.85Gy
F . . . . .
DSH-51 DSH-52 DSH-55 DSH-36 DSH-70 DSH-67 DSH-53 DSH-54 BKSW-B SLS-2 KEY-2 CM02-4 CM01-15
1 0.85V 0.85Br 0.85L 0.85B 0.85P 0.85Br 0.85G 0.85W 8 0.85W 0.85L 1.25W 0.85Gy 0.85G
. . . . . . . . NA,X . . . . .
DSH-56 DSH-68 DSH-69 DSH-9 DSH-40 DSH-37 DSH-38 DSH-39 DSH-41 DSH-8 BKSW-C C KEY-3 CM02-7 CM01-14
9 0.85O 0.85Gy 0.85Y 0.85B 0.85O 0.85G 0.85Y 0.85V 0.85L 0.85Y 18 0.85Y 1.25V 1.25G 0.85B 0.85Br
. . . . . . . . . . . . . . .
. F KEY-4 . CM01-1
GRO 1.25L 1.25V GRO 1.25R
. . . . .
G BRK-A H KEY-5 CM01-16 CM01-2
0.85B 1.25B 1.25R 0.85W 1.25R
. . . . .
BRK-B . KEY-6 CM01-7 CM01-3
A
0.85W
.
BRK-C G
GRO
.
1.25L 0.85B 1.25B
.
.
.
.
.
CM01-4
(FROM 1/19)
0.85P 1.25Br GRO GRO 1.25B TO FLOOR HARNESS
CN-BRK DSH-61
0.85B 䈜 . . . . .
H 䝣䝻䜰䝝䞊䝛䝇䜈
(DT) C
DSH-63 . N1
A
0.85P
. DSH-62 CN-DSH
䝤䝺䞊䜻䝨䝎䝹䝫䝔䞁䝅䝵 0.85W
BREAKE PEDAL POTENTIO . DCL-B
0.85P
. CM03-4 CM01-9 CM03-18
GRO 0.85B 0.85L 0.85Y (DRC12-70PAE)
. . . . .
B
DCL-A CM03-1 CM03-14 X CM03-12
0.85Y 0.85V 0.85G 0.85B 0.85B
. . . . .
DCL-C CM03-2 CM03-15 CM01-8 NA
I 0.85B 0.85Br
. .
0.85Y 0.85G 0.75W
. . .
CM03-6 CM03-7 CM03-16 X CM02-10
0.85Br 0.85G 0.85V 0.85B 0.75B
. . . . .
A CM03-10 CM03-8 CM03-13 . N1
0.85Gy 0.85W 0.85O GRO 0.85B
CN-DCL DSH-65
0.85Y . . . . .
(DT) C
DSH-66
0.85B
. CM03-11 CM03-3
0.85Y 0.85L
CM03-17
0.85L
. CM01-6
GRO 0.85L
. DSH-64
J 䝕䝉䝹䝫䝔䞁䝅䝵 0.85P . . . . .
DECEL PEDAL POTENTIO . CM03-5 CM03-9 . . CM01-5
0.85P 0.85O GRO GRO 0.85V
B . . . . .
70 56 42 28 14
A,C,E,F,G,H
K
M
DSH-29 DSH-34
1 1.25Br 1.25L 6
. .
6 4 DSH-30 DSH-33
1.25W 1.25R
F G . . .
1.25L 1.25Br .
. . . DSH-31 DSH-32
N 3 1.25G 1.25V 4
. H F . .
6 4 . 1.25B 1.25L
. . .
E G A
1.25G 1.25Br 1.25Y
. . .
3 1 CN-KEY
A H E CN-RLSW (DT)
1.25Y 1.25B 1.25G
. . . (SWP) 䜻䞊䝇䜲䝑䝏䜈
TO KEY SWITCH
O 3 1 ᚋ↷ⅉ䝇䜲䝑䝏
CN-FLSW
REAR LAMP SWITCH
(TO 15/19)
(SWP)
๓↷ⅉ䝇䜲䝑䝏
FRONT LAMP SWITCH
361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383
SEN02874-04
D155A-6 113
Wiring harness diagram (9/19) Wiring harness diagram (9/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
A
CAB-less SPEC
䈜 DSH_M-12 .
JNX4 0.85B BRAID
B . .
1 1 2
2
JPL2 JPLE
57 43 29 15 1
2 1 2
JPL2 JPLF 1.25V 1.25Y
1 1.25V
.
1.25G
.
. .
BKSW-A . KEY-1 CM02-3 CM01-11
F 1.25R
.
GRO
.
1.25Br
.
0.85Y
.
0.85Gy
.
DCL-A . . JGM1 .
0.85Y GRO GRO 0.85B GRO
A . . . . .
I CN-BRK DSH_M-61
0.85B
DCL-C . . CM01-8 JNMH
0.85B GRO GRO 0.85G 0.75W
(DT) DSH_M-63
0.85P
. . . . . .
. DSH_M-62 . . . JGM1 CM02-10
䝤䝺䞊䜻䝨䝎䝹䝫䝔䞁䝅䝵 0.85W GRO GRO GRO 0.85B 0.75B
BREAKE PEDAL POTENTIO . . . . . .
C B . . . . JNX4
GRO GRO GRO GRO 0.85B
. . . . .
. . . . CM01-6
J GRO
.
GRO
.
GRO
.
GRO
.
0.85L
.
. . . . CM01-5
GRO GRO GRO GRO 0.85V
A . . . . .
CN-DCL DSH_M-65
0.85Y 70 56 42 28 14
(DT) DSH_M-66
0.85B
.
JPL2,JPLE,JPLF
. DSH_M-64
䝕䝉䝹䝫䝔䞁䝅䝵 0.85P
K
.
DECEL PEDAL POTENTIO JGM3,JPKA,JPL8
C B
DSH_M-29 DSH_M-34
1 1.25Br
.
1.25L
.
6
DSH_M-30 DSH_M-33
JPL8 JPKA . 1.25W 1.25R
6 1.25L 1.25Br . 4 . .
N
. . .
DSH_M-31 DSH_M-32
. JGM3 JPL8 3 1.25G 1.25V 4
3 .
.
1.25B
.
1.25L
.
1 . .
CN-FLSW
(SWP) (TO 15/19)
๓↷ⅉ䝇䜲䝑䝏
FRONT LAMP SWITCH
384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406
SEN02874-04
D155A-6 115
Wiring harness diagram (10/19) Wiring harness diagram (10/19)
D155A-6
D155A-6
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
★ Wiring harness diagram may differ from some sales vehicles.
CN-FD1_F
1.25W
.
9
0.75W
.
19
1.25V
.
GRO
.
1.25L
.
GRO
. CN-FD4_M
19 9
(24-31) 10 EG2_F-2
0.75B
2 GND03
1.25B
18 18 .
2 WSH2-1
10 (24-31)
JNXJ EG2_F-7 PPL-1 GRO 1.25G
. . . . . . .
22 0.85B 1.25Gy 1.25V 29 29 GRO GRO GRO 22 FD3_M-5 FD1_F-14 GND03 PPL-2 FD2_M-1
PT1-C .
3
.
7
. GND03 . .
7
.
3
. . JOL1 1.25B
.
1.25B
.
2B
.
1.25B
.
1.25B
.
1.25P 1.25B GRO GRO
JPZ6 FTK_F-4 WSH2-3 AC05-1
. 11 1 17 . . 17 1 11 .
B
1.25W 1.25B 1.25V 1.25G
EG2_F-11
1.25Y
. EG2_F-8
1.25W
. FD2_M-12
1.25Y
.
GRO
. .
GRO
. .
GRO JPZ6
BKAL-1 FD1_F-3
1.25W 1.25W
FD2_M-10
1.25W
CN-GND03
23 . . . 28 28 . . . 23 . . .
4 6
PRT_F-4
PRT_F-6 FTK_F-3
FD2_M-9 .
6
WSH1-3
4
AC05-2
. ಙྕ䜰䞊䝇
1.25Y 12 5 16 1.25O GRO 16 5 12 GRO SIGNAL EARTH
. 1.25W 1.25L . 1.25W 1.25B JNXJ EG2_F-3
. .
EG2_F-12
1.25B
. PRT_F-7
1.25B
. PRT_F-3
1.25P