SEN02854-16
BULLDOZER
D155A -6 SERIAL NUMBERS
85001
and up
SEN02856-16
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
00 Index and foreword
1
Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
D155A-6
1
SEN02856-16
00 Index and foreword
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN02854-16
00 Index and foreword Index Foreword and general information
SEN02855-16 SEN02856-16 q SEN02857-03
01 Specification Specification and technical data
SEN02858-03 SEN02859-03
10 Structure, function and maintenance standard Engine and cooling system Power train, Part 1 Power train, Part 2 Undercarriage and frame Hydraulic system Work equipment Cab and its attachments Electrical system
SEN02860-09 SEN02861-02 q SEN02862-03 q SEN02863-01 q SEN02864-00 SEN02865-05 q SEN02866-02 SEN02867-00 SEN02868-02
20 Standard value table Standard service value table
SEN02869-01 SEN03199-01
30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3 Testing and adjusting, Part 4
SEN02870-08 SEN03200-04 SEN03201-03 SEN03202-04 SEN03203-00
40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure and error codes, Part 1 Troubleshooting by failure and error codes, Part 2 Troubleshooting by failure and error codes, Part 3 Troubleshooting by failure and error codes, Part 4 Troubleshooting of electrical system (E-mode)
SEN02871-07 SEN03204-03 q SEN03205-03 q SEN03206-03 q SEN03207-03 q SEN03208-03 q SEN03209-01 q SEN03210-02 q
2
D155A-6
00 Index and foreword
Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode)
SEN02856-16 SEN03211-02 q SEN03212-01
50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Power train, Part 1 Power train, Part 2 Power train, Part 3 Undercarriage and frame Hydraulic system Work equipment Cab and its attachments Electrical system
SEN02872-07 SEN03366-05 q SEN03367-04 q SEN03368-03 q SEN03369-03 q SEN03370-01 q SEN03371-03 q SEN03372-03 q SEN03373-02 q SEN03375-01 q SEN03376-03 q
60 Air conditioner Structure, function, testing, adjusting, and troubleshooting
SEN04441-02 SEN04442-02 q
90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings
SEN02873-05 SEN02875-01 SEN02874-04 q
D155A-6
3
SEN02856-16
00 Index and foreword
Table of contents
1
00 Index and foreword Index SEN02856-16 2 Composition of shop manual....................................................................................................... 4 Table of contents ......................................................................................................................... Foreword and general information SEN02857-03 Safety notice................................................................................................................................ 2 7 How to read the shop manual ..................................................................................................... 9 Explanation of terms for maintenance standard.......................................................................... Handling of electric equipment and hydraulic component........................................................... 11 Handling of connectors newly used for engines.......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN02859-03 2 Specification dimension drawings ............................................................................................... 3 Specifications .............................................................................................................................. 9 Weight table ................................................................................................................................ Table of fuel, coolant and lubricants ............................................................................................ 12 10 Structure, function and maintenance standard Engine and cooling system SEN02861-02 2 Radiator, oil cooler....................................................................................................................... 9 Engine mount .............................................................................................................................. Cooling fan pump ........................................................................................................................ 10 Cooling fan motor ........................................................................................................................ 18 Power train, Part 1 SEN02862-03 2 Power train skeleton.................................................................................................................... 4 Overall drawing of power train unit.............................................................................................. 6 Power train hydraulic piping drawing........................................................................................... 8 Damper, universal joint................................................................................................................ Torque converter, PTO ................................................................................................................ 10 Transmission ............................................................................................................................... 18 Transmission ECMV.................................................................................................................... 34 Main relief valve and torque converter relief valve ...................................................................... 40 Lubricating oil relief valve ............................................................................................................ 42 Scavenging pump........................................................................................................................ 44 Power train and steering lubrication pump .................................................................................. 46 Power train, Part 2 SEN02863-01 2 Work equipment pump ................................................................................................................ Work equipment cooler bypass valve.......................................................................................... 15 Steering, brake control ................................................................................................................ 16 Steering unit ................................................................................................................................ 18 Steering control valve .................................................................................................................. 32 Steering clutch ECMV, steering brake ECMV ............................................................................. 34 Parking brake solenoid valve ...................................................................................................... 40 Sudden stop prevention valve ..................................................................................................... 42 Final drive.................................................................................................................................... 45 Sprocket ...................................................................................................................................... 50
4
D155A-6
00 Index and foreword
SEN02856-16
Undercarriage and frame SEN02864-00 2 Track frame ................................................................................................................................. 4 Recoil spring ............................................................................................................................... 6 Idler ............................................................................................................................................. 8 Track roller .................................................................................................................................. Carrier roller ................................................................................................................................ 10 Track shoe................................................................................................................................... 12 Main frame .................................................................................................................................. 18 Suspension ................................................................................................................................. 20 Hydraulic system SEN02865-05 2 Work equipment hydraulic piping diagram .................................................................................. 6 Work equipment control piping diagram...................................................................................... 8 Work equipment control .............................................................................................................. Hydraulic tank and filter............................................................................................................... 10 Accumulator ................................................................................................................................ 13 PPC valve ................................................................................................................................... 14 Work equipment lock valve ......................................................................................................... 26 Control valve ............................................................................................................................... 28 Work equipment cylinder............................................................................................................. 50 Piston valve................................................................................................................................. 52 Quick drop valve ......................................................................................................................... 54 Self pressure reducing valve....................................................................................................... 55 Work equipment SEN02866-02 2 Cylinder stay ............................................................................................................................... 4 Blade ........................................................................................................................................... 6 Cutting edge, end bit ................................................................................................................... 8 Ripper.......................................................................................................................................... Cab and its attachments SEN02867-00 2 Cab mount + ROPS pin............................................................................................................... 3 ROPS cab ................................................................................................................................... 4 ROPS floor .................................................................................................................................. 5 Air conditioner ............................................................................................................................. Electrical system SEN02868-02 2 Engine control ............................................................................................................................. 3 Engine control system................................................................................................................. 4 Deceleration potentiometer ......................................................................................................... 6 Monitor system............................................................................................................................ Sensors ....................................................................................................................................... 25 Palm command control system ................................................................................................... 28 KOMTRAX system ...................................................................................................................... 31 20 Standard value table Standard service value table SEN03199-01 2 Standard value table for engine .................................................................................................. 3 Standard value table for machine................................................................................................ 30 Testing and adjusting Testing and adjusting, Part 1 SEN03200-04 3 Tools for testing, adjusting, and troubleshooting ......................................................................... 7 Sketches of special tools............................................................................................................. 8 Measuring engine speed............................................................................................................. Measuring intake air pressure (boost pressure).......................................................................... 10 Measuring exhaust temperature ................................................................................................. 12 Measuring exhaust gas color ...................................................................................................... 14 Adjusting valve clearance ........................................................................................................... 15 Measuring compression pressure ............................................................................................... 16 D155A-6
5
SEN02856-16
00 Index and foreword
Measuring blow-by pressure ....................................................................................................... 18 Measuring engine oil pressure .................................................................................................... 19 Handling fuel system parts .......................................................................................................... 20 Releasing residual pressure from fuel system ............................................................................ 20 Measuring fuel pressure.............................................................................................................. 21 Measuring fuel return rate and fuel leakage................................................................................ 22 Bleeding air from fuel circuit ........................................................................................................ 26 Measuring fuel circuit for leakage................................................................................................ 28 Testing and adjusting alternator belt tension ............................................................................... 29 Testing and adjusting air conditioner compressor belt tension.................................................... 30 Measuring fan speed................................................................................................................... 31 Measuring fan circuit oil pressure................................................................................................ 33 Bleeding air from fan pump ......................................................................................................... 34 Bleeding air from work equipment pump..................................................................................... 35 Adjusting fuel control dial and decelerator pedal......................................................................... 36 Testing and adjusting, Part 2 SEN03201-03 3 Measuring power train oil pressure ............................................................................................. Adjusting transmission output shaft speed sensor ...................................................................... 11 Simple test procedure for brake performance ............................................................................. 12 Adjusting brake pedal.................................................................................................................. 13 Adjusting parking brake lever ...................................................................................................... 15 Emergency escape method when power train has trouble ......................................................... 17 Adjusting idler clearance ............................................................................................................. 20 Testing and adjusting track shoe tension .................................................................................... 22 Measuring and adjusting work equipment oil pressure ............................................................... 23 Measuring control circuit basic pressure ..................................................................................... 26 Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure) ... 27 Measuring PPC valve output pressure........................................................................................ 28 Adjusting work equipment PPC valve play.................................................................................. 30 Measuring ripper pin puller solenoid valve output pressure ........................................................ 32 Testing parts which cause hydraulic drift of blade and ripper ...................................................... 33 Measuring internal leakage of work equipment cylinder ............................................................. 34 Releasing residual pressure from work equipment cylinder........................................................ 35 Bleeding air from work equipment cylinder ................................................................................. 35 Adjusting work equipment lock lever ........................................................................................... 36 Adjusting blade............................................................................................................................ 37 Adjusting operator's cab .............................................................................................................. 39 Testing and adjusting, Part 3 SEN03202-04 2 Special functions of machine monitor (EMMS)............................................................................ Testing and adjusting, Part 4 SEN03203-00 2 Handling of power supply circuit of engine controller .................................................................. 3 Preparation work for troubleshooting of electrical system ........................................................... 5 Pm Clinic ..................................................................................................................................... 40 Troubleshooting Failure code table and fuse locations SEN03204-03 2 Failure codes table ...................................................................................................................... 8 Fuse locations ............................................................................................................................. SEN03205-03 General information on troubleshooting 2 Points to remember when troubleshooting .................................................................................. 3 Sequence of events in troubleshooting ....................................................................................... 4 Check before troubleshooting ..................................................................................................... 5 Classification and procedures for troubleshooting ...................................................................... 8 Information in troubleshooting table ............................................................................................ Connection table for connector pin numbers............................................................................... 10 T- branch box and T- branch adapter table ................................................................................. 46
6
D155A-6
00 Index and foreword
SEN02856-16
Troubleshooting by failure and error codes, Part 1 SEN03206-03 3 Failure code [1500L0] ................................................................................................................. 4 Failure code [15SAL1]................................................................................................................. 6 Failure code [15SALH] ................................................................................................................ 8 Failure code [15SBL1]................................................................................................................. 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 Failure code [2202LH]................................................................................................................. 30 Failure code [2300KM] ................................................................................................................ 32 Failure code [2301L1] ................................................................................................................. 33 Failure code [2301LH]................................................................................................................. 35 Failure code [2302L1] ................................................................................................................. 37 Failure code [2302LH]................................................................................................................. 39 Failure code [7RFAKA]................................................................................................................ 41 Failure code [AA10NX]................................................................................................................ 43 Failure code [AB00MA] ............................................................................................................... 45 Failure code [B@BAZG].............................................................................................................. 47 Failure code [B@BCNS] ............................................................................................................. 48 Failure code [B@BCZK].............................................................................................................. 49 Failure code [B@CENS] ............................................................................................................. 50 Failure code [B@HANS] ............................................................................................................. 51 Failure code [CA111] ................................................................................................................... 52 Failure code [CA115]................................................................................................................... 54 Failure code [CA122] .................................................................................................................. 56 Failure code [CA123] .................................................................................................................. 59 Failure code [CA131] .................................................................................................................. 60 Failure code [CA132] .................................................................................................................. 62 Failure code [CA135] .................................................................................................................. 63 Failure code [CA141] .................................................................................................................. 66 Failure code [CA144] .................................................................................................................. 67 Failure code [CA145] .................................................................................................................. 69 Failure code [CA153] .................................................................................................................. 70 Failure code [CA154] .................................................................................................................. 72 Failure code [CA187] .................................................................................................................. 72 Failure code [CA221] .................................................................................................................. 73 Failure code [CA222] .................................................................................................................. 76 Failure code [CA227] .................................................................................................................. 77 Troubleshooting by failure and error codes, Part 2 SEN03207-03 3 Failure code [CA234] .................................................................................................................. 4 Failure code [CA238] .................................................................................................................. 6 Failure code [CA263] .................................................................................................................. 8 Failure code [CA265] .................................................................................................................. 9 Failure code [CA271] .................................................................................................................. 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 D155A-6
7
SEN02856-16
00 Index and foreword
Failure code [CA331]................................................................................................................... 25 Failure code [CA332]................................................................................................................... 27 Failure code [CA342]................................................................................................................... 29 Failure code [CA351]................................................................................................................... 30 Failure code [CA352]................................................................................................................... 33 Failure code [CA386]................................................................................................................... 34 Failure code [CA441]................................................................................................................... 36 Failure code [CA442]................................................................................................................... 36 Failure code [CA449]................................................................................................................... 37 Failure code [CA451]................................................................................................................... 38 Failure code [CA452]................................................................................................................... 41 Failure code [CA553]................................................................................................................... 42 Failure code [CA554]................................................................................................................... 44 Failure code [CA559]................................................................................................................... 45 Failure code [CA689]................................................................................................................... 51 Failure code [CA731]................................................................................................................... 53 Failure code [CA757]................................................................................................................... 54 Failure code [CA778]................................................................................................................... 55 Failure code [CA1633]................................................................................................................. 58 Failure code [CA2185]................................................................................................................. 60 Failure code [CA2186]................................................................................................................. 62 Failure code [CA2249]................................................................................................................. 62 Failure code [CA2555]................................................................................................................. 63 Failure code [CA2556]................................................................................................................. 64 Failure code [D110KA] ................................................................................................................ 66 Failure code [D110KB] ................................................................................................................ 68 Failure code [D130KA] ................................................................................................................ 70 Failure code [D130KB] ................................................................................................................ 73 Failure code [D161KA] ................................................................................................................ 75 Failure code [D161KB] ................................................................................................................ 77 Failure code [D190KA] ................................................................................................................ 79 Failure code [D190KB] ................................................................................................................ 81 Troubleshooting by failure and error codes, Part 3 SEN03208-03 3 Failure code [D5ZKKX]................................................................................................................ 6 Failure code [DAFRKR]............................................................................................................... 8 Failure code [DB2RKR] ............................................................................................................... Failure code [DB90KR]................................................................................................................ 11 Failure code [DBE0KK] ............................................................................................................... 13 Failure code [DBE0KT]................................................................................................................ 16 Failure code [DBE6KK] ............................................................................................................... 17 Failure code [DBE7KK] ............................................................................................................... 19 Failure code [DBE9KQ] ............................................................................................................... 22 Failure code [DD12KA]................................................................................................................ 24 Failure code [DD12KB]................................................................................................................ 26 Failure code [DD13KA]................................................................................................................ 28 Failure code [DD13KB]................................................................................................................ 30 Failure code [DD14KA]................................................................................................................ 32 Failure code [DD14KB]................................................................................................................ 34 Failure code [DDDDKA] .............................................................................................................. 36 Failure code [DDDDKB] .............................................................................................................. 38 Failure code [DDDDKX] .............................................................................................................. 40 Failure code [DGT1KA] ............................................................................................................... 41 Failure code [DGT1KX] ............................................................................................................... 43 Failure code [DH21KA]................................................................................................................ 45 Failure code [DH21KB]................................................................................................................ 47 Failure code [DK10KX]................................................................................................................ 49 Failure code [DK30KA]................................................................................................................ 52 Failure code [DK30KB]................................................................................................................ 54
8
D155A-6
00 Index and foreword
SEN02856-16
Failure code [DK30KX]................................................................................................................ 56 Failure code [DK30KZ]................................................................................................................ 56 Failure code [DK30L8] ................................................................................................................ 57 Failure code [DK31KA]................................................................................................................ 58 Failure code [DK31KB]................................................................................................................ 60 Failure code [DK40KA]................................................................................................................ 62 Failure code [DK40KB]................................................................................................................ 64 Failure code [DK55KX]................................................................................................................ 66 Failure code [DK55KZ]................................................................................................................ 66 Failure code [DK55L8] ................................................................................................................ 67 Failure code [DK56KA]................................................................................................................ 68 Failure code [DK56KB]................................................................................................................ 70 Troubleshooting by failure and error codes, Part 4 SEN03209-01 4 Failure code [DK57KA]................................................................................................................ 6 Failure code [DK57KB]................................................................................................................ 8 Failure code [DKH1KA] ............................................................................................................... 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 Failure code [DXH4KB] ............................................................................................................... 32 Failure code [DXH4KY] ............................................................................................................... 34 Failure code [DXH5KA] ............................................................................................................... 36 Failure code [DXH5KB] ............................................................................................................... 38 Failure code [DXH5KY] ............................................................................................................... 40 Failure code [DXH6KA] ............................................................................................................... 42 Failure code [DXH6KB] ............................................................................................................... 44 Failure code [DXH6KY] ............................................................................................................... 46 Failure code [DXH7KA] ............................................................................................................... 48 Failure code [DXH7KB] ............................................................................................................... 50 Failure code [DXH7KY] ............................................................................................................... 52 Failure code [DXH8KA] ............................................................................................................... 54 Failure code [DXH8KB] ............................................................................................................... 56 Failure code [DXH8KY] ............................................................................................................... 58 Failure code [DXH9KA] ............................................................................................................... 60 Failure code [DXH9KB] ............................................................................................................... 62 Failure code [DXH9KY] ............................................................................................................... 64 Failure code [DXHAKA]............................................................................................................... 66 Failure code [DXHAKB]............................................................................................................... 68 Failure code [DXHAKY]............................................................................................................... 70 Failure code [DXHBKA]............................................................................................................... 72 Failure code [DXHBKB]............................................................................................................... 74 Failure code [DXHBKY]............................................................................................................... 76 Failure code [DXHCKA] .............................................................................................................. 78 Failure code [DXHCKB] .............................................................................................................. 80 Failure code [DXHCKY] .............................................................................................................. 82 Failure code [DXJ4KA]................................................................................................................ 84 Failure code [DXJ4KB]................................................................................................................ 86 Troubleshooting of electrical system (E-mode) SEN03210-02 Before carrying out troubleshooting for electrical system ........................................................... 3 7 Information in troubleshooting table ............................................................................................ 9 E-1 When starting switch turned ON, machine monitor displays nothing ...................................
D155A-6
9
SEN02856-16
00 Index and foreword
E-2 When starting switch turned ON (before starting engine), basic check item lights up .......... 12 E-3 Engine does not start (Engine does not turn) ....................................................................... 14 E-4 Preheater does not operate .................................................................................................. 17 E-5 Precaution item lights up while engine is running ................................................................. 21 E-6 Emergency stop item lights up while engine is running ........................................................ 23 E-7 Engine coolant temperature gauge does not indicate normally............................................ 27 E-8 Fuel level gauge does not indicate normally......................................................................... 29 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally....................... 32 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ............................ 34 E-11 Contents of display by machine monitor are different from applicable machine ................. 37 E-12 Machine monitor does not display some items................................................................... 37 E-13 Function switch does not work............................................................................................ 38 E-14 Operation mode does not change ...................................................................................... 39 E-15 Gearshift mode does not change........................................................................................ 40 E-16 Customize function does not operate normally................................................................... 41 E-17 Customize memory function does not operate normally..................................................... 42 E-18 Alarm buzzer cannot be stopped ........................................................................................ 43 E-19 Air conditioner does not operate normally (including air conditioner fault history).............. 44 E-20 When starting switch is turned OFF, service meter is not displayed................................... 68 E-21 Machine monitor cannot be set in service mode ................................................................ 68 E-22 Ripper pin puller cylinder does not operate ........................................................................ 69 E-23 Backup alarm does not sound or does not stop ................................................................. 71 E-24 Headlamp, rear lamp, and ripper point lamp do not light up............................................... 73 E-25 Windshield wiper and window washer do not operate........................................................ 79 E-26 KOMTRAX terminal does not operate normally.................................................................. 107 E-27 Fan does not reverse.......................................................................................................... 109 E-28 Gear cannot be shifted ....................................................................................................... 111 E-29 Electric priming pump does not operate or does not stop automatically ............................ 112 SEN03211-02 Troubleshooting of hydraulic and mechanical system (H-mode) 3 Information in troubleshooting table ............................................................................................ H-1 Power is low (Drawbar pull is low)........................................................................................ 4 6 H-2 Machine does not travel (at 2nd or 3rd gear speed)............................................................. 8 H-3 Machine does not start at any gear speed ........................................................................... H-4 Machine can travel only forward or in reverse...................................................................... 10 H-5 When gear speed or travel direction is changed, time lag is large ....................................... 12 H-6 Steering is not possible......................................................................................................... 14 H-7 Steering is possible only on one side ................................................................................... 16 H-8 Steering overrun occurs........................................................................................................ 18 H-9 Brake does not work............................................................................................................. 19 H-10 Power train oil is overheated .............................................................................................. 21 H-11 Speed of all work equipment is low..................................................................................... 23 H-12 No work equipment moves ................................................................................................. 25 H-13 Blade lift speed or power is low .......................................................................................... 27 H-14 Blade tilt speed or power is low .......................................................................................... 29 H-15 Ripper lift speed or power is low......................................................................................... 31 H-16 Ripper tilt speed or power is low......................................................................................... 33 H-17 Hydraulic drift of blade lift is large....................................................................................... 35 H-18 Hydraulic drift of blade tilt is large....................................................................................... 36 H-19 Hydraulic drift of ripper lift is large ...................................................................................... 37 H-20 Ripper pin puller cylinder does not operate ........................................................................ 38 H-21 Abnormal sound comes out from around work equipment pump ....................................... 39 H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine overheats)........................................ 40 Troubleshooting of engine (S-mode) SEN03212-01 3 Method of using troubleshooting chart ........................................................................................ 6 S-1 Starting performance of engine is poor................................................................................. 7 S-2 Engine does not start............................................................................................................ S-3 Engine does not pick up smoothly ........................................................................................ 10
10
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00 Index and foreword
SEN02856-16
S-4 Engine stops during operation .............................................................................................. S-5 Engine does not rotate smoothly .......................................................................................... S-6 Engine lack output (or lacks power) ..................................................................................... S-7 Exhaust gas is black (incomplete combustion)..................................................................... S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... S-9 Oil becomes dirty quickly...................................................................................................... S-10 Fuel consumption is excessive........................................................................................... S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. S-12 Oil pressure drops .............................................................................................................. S-13 Oil level rises (Entry of coolant or fuel)............................................................................... S-14 Coolant temperature becomes too high (Overheating) ...................................................... S-15 Abnormal noise is made ..................................................................................................... S-16 Vibration is excessive ......................................................................................................... S-17 Air cannot be bled from fuel circuit .....................................................................................
11 12 13 14 15 16 17 18 19 20 21 22 23 24
50 Disassembly and assembly SEN03366-05 General information on disassembly and assembly 2 How to read this manual ............................................................................................................. 4 Coating materials list................................................................................................................... 7 Special tool list ............................................................................................................................ Sketches of special tools............................................................................................................. 15 Engine and cooling system SEN03367-04 2 Removal and installation of fuel supply pump assembly............................................................. Removal and installation of fuel injector assembly ..................................................................... 11 Removal and installation of cylinder head assembly .................................................................. 20 Removal and installation of radiator assembly............................................................................ 38 Removal and installation of aftercooler assembly ....................................................................... 44 Removal and installation of engine assembly ............................................................................. 51 Removal and installation of engine hood assembly .................................................................... 60 Removal and installation of engine front seal ............................................................................. 64 Removal and installation of engine rear seal .............................................................................. 68 Removal and installation of fuel tank assembly .......................................................................... 74 Removal and installation of cooling fan drive assembly.............................................................. 79 Removal and installation of fan motor assembly......................................................................... 83 Power train, Part 1 SEN03368-03 2 Removal and installation of damper assembly............................................................................ 7 Disassembly and assembly of damper assembly ....................................................................... Removal and installation of power train unit assembly ............................................................... 13 Disconnection and connection of power train unit assembly ...................................................... 25 Power train, Part 2 SEN03369-03 2 Disassembly and assembly of PTO assembly ............................................................................ Disassembly and assembly of torque converter assembly ......................................................... 11 Disassembly and assembly of transmission assembly ............................................................... 17 Disassembly and assembly of steering case assembly .............................................................. 36 Power train, Part 3 SEN03370-01 2 Removal and installation of final drive assembly ........................................................................ 9 Disassembly and assembly of final drive assembly .................................................................... Undercarriage and frame SEN03371-03 3 Removal and installation of track frame assembly ...................................................................... Removal and installation of idler assembly ................................................................................. 10 Disassembly and assembly of idler assembly............................................................................. 18 Removal and installation of recoil spring assembly .................................................................... 22 Disassembly and assembly of recoil spring assembly ................................................................ 25 Removal and installation of track roller assembly ....................................................................... 30 Disassembly and assembly of track roller assembly................................................................... 37 Removal and installation of 1st bogie assembly ......................................................................... 39 D155A-6
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SEN02856-16
00 Index and foreword
Removal and installation of 2nd, 3rd, and 4th bogie assemblies ................................................ 49 Disassembly and assembly of bogie assembly........................................................................... 58 Removal and installation of carrier roller assembly ..................................................................... 61 Disassembly and assembly of carrier roller assembly ................................................................ 64 Removal and installation of pivot shaft assembly........................................................................ 69 Separation and connection of track shoe assembly.................................................................... 72 General disassembly and assembly of track shoe ...................................................................... 77 Disassembly and assembly of 1 link in field ................................................................................ 90 Disassembly and assembly of master link .................................................................................. 95 Removal and installation of equalizer bar assembly ................................................................... 99 Disassembly and assembly of equalizer bar assembly............................................................... 104 Removal and installation of segment teeth ................................................................................. 106 Hydraulic system SEN03372-03 2 Removal and installation of hydraulic tank assembly .................................................................. 8 Removal and installation of hydraulic pump assembly................................................................ Disassembly and assembly of hydraulic cylinder assembly........................................................ 19 Work equipment SEN03373-02 2 Removal and installation of blade assembly ............................................................................... 6 Disassembly and assembly of multi-shank ripper ....................................................................... Cab and its attachments SEN03375-01 2 Removal and installation of operator's cab assembly ................................................................. 7 Removal and installation of operator's cab glass (adhered window glass) ................................. Removal and installation of operator's cab and floor frame assembly ........................................ 17 Electrical system SEN03376-03 2 Removal and installation of air conditioner unit assembly........................................................... 9 Removal and installation of engine controller assembly ............................................................. Removal and installation of power train controller....................................................................... 12 Removal and installation of KOMTRAX assembly ...................................................................... 15 60 Air conditioner Structure, function, testing, adjusting, and troubleshooting SEN04442-02 3 Structure and function ................................................................................................................. 3 Air conditioner component ....................................................................................................... 4 Configuration and function of refrigerating cycle ..................................................................... 5 Outline of refrigerating cycle .................................................................................................... 7 Air conditioner unit ................................................................................................................... 9 Functions of major components in the air conditioner unit ...................................................... Control plate ............................................................................................................................ 11 Compressor ............................................................................................................................. 13 Condenser ............................................................................................................................... 14 Receiver drier .......................................................................................................................... 15 Testing, adjusting and troubleshooting ........................................................................................ 17 Caution about refrigerant ......................................................................................................... 17 Troubleshooting procedure ...................................................................................................... 18 Block diagram .......................................................................................................................... 19 Circuit diagram and arrangement of connector pins................................................................ 20 Detail of air conditioner unit ..................................................................................................... 22 Part and connector locations ................................................................................................... 24 Testing air leakage (duct)......................................................................................................... 31 Testing with self-diagnosis function ......................................................................................... 33 Testing temperature control ..................................................................................................... 36 Testing vent (mode) changeover ............................................................................................. 39 Testing Recirc/Fresh changeover ............................................................................................ 42 Testing inner sensor................................................................................................................. 44 Testing evaporator temperature sensor ................................................................................... 45 Testing sunlight sensor ............................................................................................................ 48
12
D155A-6
00 Index and foreword
SEN02856-16
Testing (dual) pressure switch for refrigerant .......................................................................... Testing relays and diodes ........................................................................................................ Troubleshooting chart 1 ........................................................................................................... Troubleshooting chart 2 ........................................................................................................... Troubleshooting for electrical system (E mode) ...................................................................... E-1 Power supply system (Air conditioner does not operate) .............................................. E-2 Compressor system (Air is not cooled) ......................................................................... E-3 Blower motor system (No air comes out or air flow is abnormal) .................................. E-4 Temperature cannot be controlled................................................................................. E-5 Vent (mode) cannot be changed over ........................................................................... E-6 Recirc/Fresh air cannot be changed over ..................................................................... Troubleshooting with gauge pressure...................................................................................... Connection of service tool ....................................................................................................... Precautions for connecting air conditioner piping.................................................................... Handling of compressor oil ...................................................................................................... 1 Control of compressor oil .................................................................................................. 2 Adding of compressor oil .................................................................................................. 3 Compressor replacement.................................................................................................. 4 Applying compressor oil for O-ring....................................................................................
49 51 53 54 57 58 62 66 72 75 78 81 83 84 85 85 85 86 86
90 Diagrams and drawings Hydraulic diagrams and drawings SEN02875-01 3 Power train hydraulic circuit diagram .......................................................................................... 5 Hydraulic circuit diagram Serial No.: 85001 - 85024 ................................................................... 7 Hydraulic circuit diagram Serial No.: 85025 and up .................................................................... Electrical diagrams and drawings SEN02874-04 3 Electrical circuit diagram ............................................................................................................. Electrical circuit diagram for inside cab ....................................................................................... 31 Connector/electrical wiring connection table ............................................................................... 33 Connectors table and arrangement drawing ............................................................................... 97 Wiring harness diagram .............................................................................................................. 99
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00 Index and foreword
D155A-6 Bulldozer Form No. SEN02856-16
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
14
D155A-6
SEN02857-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
00 Index and foreword
1
Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
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00 Index and foreword
Safety notice
(Rev. 2008/08) 1
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.
2
General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7)
8) 9)
If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
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00 Index and foreword
2.
Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
3.
Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
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6)
When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11) When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
3
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4.
4
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
00 Index and foreword
8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
SEN02857-03
13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
q
5.
6.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
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7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
5
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8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)
6
00 Index and foreword a
Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.
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00 Index and foreword
How to read the shop manual q q q
1.
SEN02857-03
1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
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3.
4.
00 Index and foreword
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
Special safety precautions are necessary when performing work.
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
Places that require special attention for tightening torque during assembly.
2
Coat
5
Oil, coolant
6
Drain
Remarks
Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
5.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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SEN02857-03
Explanation of terms for maintenance standard
1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.
Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q
Example: Standard size 120
Tolerance –0.022 –0.126
a
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
q
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
Example: Standard size 60
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Tolerance Shaft Hole –0.030 +0.046 –0.076 +0
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2.
Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
00 Index and foreword
5.
q
3.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
4.
Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
10
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q
6.
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q
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Handling of electric equipment and hydraulic component
SEN02857-03
1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.
Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
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Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
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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 soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
5)
Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
00 Index and foreword
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00 Index and foreword
3.
SEN02857-03
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q
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When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
13
SEN02857-03
2)
14
00 Index and foreword
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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3)
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Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
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q
Disconnection
q
Connection (Example of incomplete setting of (a))
15
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4)
16
00 Index and foreword
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
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00 Index and foreword
4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
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17
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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1.
Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3.
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4.
Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
18
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5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6.
Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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19
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Handling of connectors newly used for engines a
1.
Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
2.
1
Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
q
Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
20
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3.
SEN02857-03
Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q
q
114 engine
q
107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
107 engine
a
2)
D155A-6
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
21
SEN02857-03
q
4)
95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
00 Index and foreword
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
q
1)
Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
22
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SEN02857-03
How to read electric wire code a
1
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile
Symbol AV
AVS
Heat-resistant low-voltAEX age wire for automobile
D155A-6
Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
23
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2.
00 Index and foreword
Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
108/0.80 127/0.80 169/0.80 217/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
“f” of nominal No. denotes flexible”.
24
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3.
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Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White. 4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others
D155A-6
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
–
R B R D Y G L
–
–
WG
–
–
–
–
–
–
–
–
–
– –
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– –
Gr Br – –
25
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Precautions when carrying out operation
1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q
a
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
26
Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30
27
07049-02734
27
22.5
34
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2. q q q q q q q q q q q q q
a
a 3.
SEN02857-03
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
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27
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4)
5)
28
00 Index and foreword
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
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SEN02857-03
Method of disassembling and connecting push-pull type coupler
1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container. Type 1 1.
Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
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29
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Type 2 1.
2.
Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
q
30
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SEN02857-03
Type 3 1.
2.
Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
q
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31
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Standard tightening torque table 1.
1
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
The following table applies to the bolts in Fig. B.
Thread diameter of bolt mm 6 8 10 12 a Fig. A
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Width across flats mm 10 12 14 17
Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
32
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2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt mm 10 12 16
3.
Width across flats mm 14 17 22
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No. 02 03,04 05,06 10,12 14
4.
SEN02857-03
Thread diameter mm 14 20 24 33 42
Width across flats mm
Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
D155A-6
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
33
SEN02857-03
5.
00 Index and foreword
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}
Nominal No. of hose
Width across flats
02
19
03 04 05 06 (10) (12) (14)
6.
22 24 27 32 36 41 46 55
Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).
Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Tightening torque Nm {kgm} Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification. 7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
34
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
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00 Index and foreword
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
9.
SEN02857-03
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
D155A-6
Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
35
SEN02857-03
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 1.
Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
36
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
D155A-6
00 Index and foreword
SEN02857-03
Millimeters to inches
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
D155A-6
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
37
SEN02857-03
00 Index and foreword
Liters to U.K. Gallons
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
38
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
419.5 491.8 564.2 636.5 708.8
1142.8 1215.1 1287.5 1359.8 1432.1
426.8 499.1 571.4 643.7 716.1
1150.0 1222.4 1294.7 1367.0 1439.4
D155A-6
00 Index and foreword
SEN02857-03
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
D155A-6
39
SEN02857-03
00 Index and foreword
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
177.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
40
D155A-6
00 Index and foreword
D155A-6
SEN02857-03
41
SEN02857-03
00 Index and foreword
D155A-6 BULLDOZER Form No. SEN02857-03
© 2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (02)
42
D155A-6
SEN02859-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
01 Specification
1
Specification and technical data Specification dimension drawings ................................................................................................................... 2 Specifications .................................................................................................................................................. 3 Weight table .................................................................................................................................................... 9 Table of fuel, coolant and lubricants.............................................................................................................. 12
D155A-6
1
SEN02859-03
01 Specification
Specification dimension drawings
Item
2
Unit
Semi U-tilt dozer + Variable multiple shank ripper
Sigma-tilt dozer + Variable multiple shank ripper
A
Overall length
mm
8,325
8,275
B
Overall height (with ROPS)
mm
3,510
3,510
C
Overall width
mm
4,130
4,060
Item
Unit
Semi U-tilt dozer + Variable giant ripper
Sigma-tilt dozer + Variable giant ripper
A
Overall length
mm
8,680
8,630
B
Overall height (with ROPS)
mm
3,510
3,510
C
Overall width
mm
4,130
4,060
D155A-6
01 Specification
SEN02859-03
Specifications Machine model
D155A-6
Serial number
85001 and up
Weight
• Bare tractor • With semi U-tilt dozer + variable giant ripper + ROPS cab + air conditioner + 560mm HD shoe + side cover
31,200 kg
• With multi ripper
42,080
Minimum turning radius (F1, center of machine)
mm
2.1
Gradeability
deg.
30
Stability (front, rear, left, right)
deg.
35
D155A-6
Forward Reverse
Transmission speed ranges Overall height Overall width Overall length Ground pressure
Performance
1st
Dimensions
41,700
3.9
2nd
5.7 km/h
3rd (low speed)
7.5
3rd
11.4
1st
4.7
2nd
6.8 km/h
3rd (low speed)
9.2
3rd
13.7
• Bare tractor
86.73 {0.88}
• With semi U-tilt dozer + variable giant ripper + ROPS cab + air conditioner + 560mm HD shoe + side cover
kPa {kg/cm2}
• With multi ripper
115.13 {1.17}
Bare tractor With semi U-tilt dozer + tractor
113.97 {1.16}
4,875 mm
6,225
With semi U-tilt dozer + variable giant ripper
8,680
Bare tractor
2,765
With semi U-dozer + tractor
mm
4,130
With Sigma-tilt dozer + variable multi-shank ripper
4,060
To blade lift cylinder
3,510
To top of cab With ROPS cab installed
mm
2,210 3,395
3
Dimensions
SEN02859-03
01 Specification
Machine model
D155A-6
Serial number
85001 and up
Track gauge
2,140
Length of track on ground
3,150
Track shoe width (Standard)
mm
Minimum ground clearance (To bottom surface of undercover)
500
Name
SAA6D140E-5 4-cycle, water-cooled, in-line, vertical type, direct injection, with turbocharger, aftercooler
No. of cylinders - Bore x Stroke
mm
6 – 140 x 165
Piston displacement
l {cc}
15.24 {15,240}
Flywheel horsepower
kW {HP}/rpm
239 {320}/1,900
Max. torque
Nm {kgm}/rpm
1,834 {187}/1,300
Max. speed at no load
rpm
2,100
Min. speed at no load
rpm
740
g/kWh {g/HPh}
193 {142}
Performance
Engine
Type of engine
Power train system
Min. fuel consumption ratio
4
560
Starting motor
24V, 11kW
Alternator
24V, 50A
Battery
12V, 136Ah x 2
Radiator core type
Rectangle wave fin
Torque converter
3-element, 1-stage, 1-phase
Transmission
Planetary gear, multiple disc clutch, hydraulically actuated, (electrically type) force-feed lubrication gear pump, forward 3-speed, reverse 3-speed, electrically actuated type
Bevel gear shaft
Spiral bevel gear, force-feed lubrication gear pump
Steering clutch
Wet type, multiple disc clutch type, springboosted type, hydraulic actuation type (manual type), brake linkage type
Steering brake
Wet type, multiple disc clutch type, springboosted type, hydraulic actuation type (foot operation, manual type), clutch linkage type
Final drive
Spur gear 1-stage, planetary gear 1-stage, splash type lubrication
D155A-6
Undercarriage
01 Specification
SEN02859-03
Machine model
D155A-6
Serial number
85001 and up
Suspension
Rigid, balancing beam type
Carrier roller
2 each side
Track roller
7 each side
Track shoe (shoe width: 560 mm)
Assembly type, single grouser, 41 each side, pitch: 228.6 mm
Lubrication pump + power train (tandem)
Gear type (SAR(3)100 + (2)40) 85001 – 85024 Gear type (SAR(4) + 125) 85025 and up Gear type (SAR(3) + 125)
Scavenging pump (tandem)
Hydraulic pump
MPa {kg/cm2}
Variable swash plate type (HPV112) Max. delivery pressure: 27.5 {280}
l/min/rpm
Theoretical delivery: 216/2,250 1+1+2 tandem spool type, hydraulically assisted type
Control valve
Variable multi-shark ripper type • For ripper tilt
+ Ripper tilt
• For ripper lift
+ Ripper lift
• For blade lift + (Blade lift + blade tilt) • For blade tilt
D155A-6
Dimensions of blade tilt Dimensions of blade tilt Dimensions of blade lift (For semi U-dozer) (For sigma-tilt dozer)
Hydraulic cylinder
Work equipment hydraulic system
Type
Reciprocal, piston type
Cylinder bore
mm
110
Piston rod outer diameter
mm
75
Max. piston stroke
mm
1,404
Max. distance between pins
mm
2,093
Min. distance between pins
mm
687.5
Cylinder bore
mm
160
Piston rod outer diameter
mm
90
Max. piston stroke
mm
205
Max. distance between pins
mm
1,395
Min. distance between pins
mm
1,190
Cylinder bore
mm
160
Piston rod outer diameter
mm
90
Max. piston stroke
mm
210
Max. distance between pins
mm
1,475
Min. distance between pins
mm
1,265
5
Dimensions of variable Dimensions of variable Dimensions of blade giant ripper tilt cylinder multi ripper lift cylinder (For sigma-tilt dozer tilt and pitch) Dimensions of ripper tilt
Hydraulic cylinder
Work equipment hydraulic system
SEN02859-03
01 Specification
Machine model
D155A-6
Serial number
85001 and up
Cylinder bore
mm
160
Piston rod outer diameter
mm
90
Max. piston stroke
mm
165
Max. distance between pins
mm
1,430
Min. distance between pins
mm
1,265
Cylinder bore
mm
180
Piston rod outer diameter
mm
100
Max. piston stroke
mm
565
Max. distance between pins
mm
1,730
Min. distance between pins
mm
1,165
Cylinder bore
mm
180
Piston rod outer diameter
mm
100
Max. piston stroke
mm
630
Max. distance between pins
mm
1,795
Min. distance between pins
mm
1,165
Cylinder bore
mm
200
Piston rod outer diameter
mm
110
Max. piston stroke
mm
605
Max. distance between pins
mm
1,815
Min. distance between pins
mm
1,210
Fan drive system
Hydraulic tank
6
Box type (control valve externally installed)
Cooling fan pump
MPa {kg/cm2} l/min
Variable swash plate (LPV45) Max. delivery pressure: 31.9 {325} Theoretical delivery pressure: 103/2,296
Cooling fan motor
MPa {kg/cm2}
Fixed swash plate (LMF65) Max. delivery pressure: 31.9 {325}
D155A-6
01 Specification
Machine model
D155A-6
Serial number
85001 and up
Blade support method
Brace type (right tilt cylinder)
Dimensions Performance Dimensions Performance Dimensions
Semi U-tilt dozer
D155A-6
Performance
Hydraulic sigma-tilt dozer Hydraulic semi U-tilt dozer Hydraulic U-tilt dozer
Sigma tilt dozer
Type
Full U-dozer
Work equipment
SEN02859-03
Blade lifting height (from ground level)
mm
1,311
Blade lowering depth (from ground level)
mm
627
Max. blade tilt
mm
1,000
Blade cutting angle variation
deg.
±5
Blade capacity (SAE)
m3
9.4
Blade width
mm
4,060
Blade height
mm
1,850
Blade cutting angle
deg.
46
Blade lifting height (from ground level)
mm
1,250
Blade lowering depth (from ground level)
mm
590
Max. blade tilt
mm
935
Blade cutting angle variation
deg.
±6
Blade capacity (SAE)
m3
9.4
Blade width
mm
4,130
Blade height
mm
1,790
Blade cutting angle
deg.
52
Blade lifting height (from ground level)
mm
1,250
Blade lowering depth (from ground level)
mm
590
Max. blade tilt
mm
970
Blade cutting angle variation
deg.
±6
Blade capacity (SAE)
m3
11.9
Blade width
mm
4,225
Blade height
mm
1,790
Blade cutting angle
deg.
52
7
8
Dimensions Performance Dimensions Performance
Variable multi-shank ripper Variable giant ripper
Work equipment
SEN02859-03
01 Specification
Machine model
D155A-6
Serial number
85001 and up
Max. digging depth
mm
835
Max. lifting height
mm
890
Ripping angle of point
deg.
30 – 70
Max. beam width
mm
2,320
Shank positions
No. of holes
2
Max. digging depth
mm
1,370
Max. lifting height
mm
900
Ripping angle of point
deg.
30 – 70
Max. beam width
mm
1,520
Shank positions
No. of holes
4
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
Serial number
85001 and up
Engine, damper assembly
1,900
• Engine assembly
1,725
• Damper assembly
120
• Universal joint
18
• Engine mount parts (wiring)
3
Radiator assembly (including built-in oil cooler hydraulic cooler and codenser)
333
Air flow control grid
81
Fuel tank assembly (when empty)
383
Fuel tank assembly (when full)
913
Power train unit assembly
2,412
• Torque converter, PTO assembly
410
• Transmission assembly
634
• C & B assembly
1,038
• Brake valve assembly
63
• Power train filter assembly
16.5
• Scavenging pump
20
• Power train, lubrication pump
28
• Hydraulic pump
145
Final drive assembly
1,395 x 2
Sprocket teeth
(12 x 9) x 2
Hull frame assembly
4,440
Track group assembly (each side)
3,900
• Track frame
1,607
• Idler assembly
458
• Recoil spring assembly
449
• Track roller assembly (single flange x1) (double flange x1)
112 x 2 124 x 5
• Carrier roller assembly
48 x 2
D155A-6
9
SEN02859-03
01 Specification
Unit: kg Machine model
D155A-6
Serial number
85001 and up
Track shoe assembly (560 mm, wet type)
2,280 x 2
Pivot shaft assembly (Left)
126
Pivot shaft assembly (Right)
142
Equalizer bar
231
Hydraulic tank assembly (including hydraulic filter)
99
Control valve (Blade lift + blade tilt + ripper lift + ripper tilt + steering)
104
Engine underguard
248
Transmission underguard
285
Operator seat
68
Sigma tilt dozer assembly
5,364 (Standard 4,937)
• Blade
3,200 (Standard 2,929)
• Straight frame
1,687 (Standard 1,531)
• Tilt brace
97 x 1
• Center brace
250 x 1
• Tilt cylinder assembly
130
Semi U-tilt dozer assembly
5,623 (Standard 4,962)
• Blade
3,459 (Standard 2,954)
• Straight frame
1,687 (Standard 1,531)
• Tilt brace
97 x 1
• Center brace
250 x 1
• Tilt cylinder assembly
130
Blade lift cylinder assembly
187 x 2
Multi-shank ripper assembly
4,330
• Bracket, beam, arm
2,300
• Shank
266 x 3
• Lift cylinder assembly
184 x 1
• Tilt cylinder assembly
252 x 1
10
D155A-6
01 Specification
SEN02859-03
Unit: kg Machine model
D155A-6
Serial number
85001 and up
Giant ripper assembly
3,950
• Bracket, beam, arm
2,975
• Shank
446 x 1
• Lift cylinder assembly
188 x 1
• Tilt cylinder assembly
252 x 1
• Pin puller cylinder assembly
7
Cab assembly
410
Dashboard
54
Floor frame (including air conditioner unit)
611
Side cover
20
Air conditioner unit assembly
10
D155A-6
11
SEN02859-03
01 Specification
Table of fuel, coolant and lubricants a
12
For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D155A-6
01 Specification
SEN02859-03
Unit: l Engine oil Power train case pan
Damper case
Hydraulic system Fainal drive (with blade, without case ripper)
Fuel tank
Cooling system
Specified capacity (l)
45
105
1.5
(each left and right) 31
240
625
82
Refill capacity (l)
37
70
1.5
(each left and right) 31
85
—
—
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
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
10 Structure, function and maintenance standard
1
Engine and cooling system Radiator, oil cooler .......................................................................................................................................... 2 Engine mount.................................................................................................................................................. 9 Cooling fan pump.......................................................................................................................................... 10 Cooling fan motor.......................................................................................................................................... 18
D155A-6
1
SEN02861-02
Radiator, oil cooler
10 Structure, function and maintenance standard
1
Radiator (without sand protection grill)
2
D155A-6
10 Structure, function and maintenance standard
SEN02861-02
1. 2. 3. 4. 5. 6. 7.
Overflow hose Air bleed hose Inlet hose Coolant filler cap Radiator core assembly Reservoir tank 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: b: c:
Aftercooler Aftercooler outlet hose 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
1. 2.
Hydraulic cooler Power train oil cooler
A: B:
Power train oil cooler inlet port Power train oil cooler outlet port
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
D155A-6
SEN02861-02
5
SEN02861-02
10 Structure, function and maintenance standard
Radiator (with sand protection grill)
6
D155A-6
10 Structure, function and maintenance standard
SEN02861-02
1. 2. 3. 4. 5. 6. 7.
Overflow hose Air bleed hose Inlet hose Coolant filler cap Radiator core assembly Reservoir tank 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: b: c:
Aftercooler Aftercooler outlet hose 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
Oil cooler (sand protection grill)
1. 2. 3.
Hydraulic cooler Power train oil cooler Sand protection grill
A: B:
Power train oil cooler inlet port Power train oil cooler outlet port
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
1
Clearance between bracket and cushion
Criteria Standard size 60
2
Free height of mount rubber
D155A-6
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
–0.1 –0.3
+0.046 +0.046
0.1 – 0.346
—
Standard clearance
Clearance limit
86
84
Replace
9
SEN02861-02
10 Structure, function and maintenance standard
Cooling fan pump
1
Type: LPV45
P1: Pump discharge port PAEPC: EPC output pressure pickup plug PEPC: EPC valve basic pressure input port PS: Pump suction port TO: Drain port
10
1. 2.
Servo valve Air bleeder
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
Function q The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.
10 Structure, function and maintenance standard
q q q
Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).
Structure Cylinder block (7) is supported to shaft by spline (11). q Shaft (1) is supported with front and bearings (12). q The end of piston (6) has a spherical hollow and is combined with shoe (5). q Piston (6) and shoe (5) form a spherical bearing. q Shoe (5) is kept pressed against plane (A) of rocker cam (4) and slid circularly. q Rocker cam (4) slides around ball (13). q Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). q
12
D155A-6
10 Structure, function and maintenance standard
Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q At this time, rocker cam (4) slants around ball (13). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. q Angle (a) is called the swash plate angle.
SEN02861-02
q
q
q q
q
With the condition of center line (X) of rocker cam (4) has swash plate angle (a) to axial direction of cylinder block (7), flat surface (A) functions as cam against shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) sucks and discharges the oil by the amount (F) - (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.
(
[ D
$
)
*
D155A-6
13
SEN02861-02
q
q
10 Structure, function and maintenance standard
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) [swash plate angle (a) = 0], the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
(
Control of delivery q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases. q Swash plate angle (a) is changed with servo piston (10). q Servo piston (10) reciprocates straight according to the signal pressure of the servo valve. q This straight motion is transmitted to rocker cam (4). q Rocker cam (4) supported with ball (13) slides around ball (13).
(
[ [ D
)
*
q
)
Swash plate angle (a) is in proportion to the pump delivery. *
14
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02861-02
15
SEN02861-02
10 Structure, function and maintenance standard
Servo valve
P: EPC valve basic pressure PE: Control piston pressure PH: Pump discharge pressure T: Drain port
16
1. 2. 3. 4. 5. 6. 7. 8.
Plug Lever Retainer Seat Spool Piston Sleeve Spring
D155A-6
10 Structure, function and maintenance standard
SEN02861-02
s 1P ^ s NJP` 1P ^ NJP`
3+
1P ^ NJP`
$ $
3(
1P ^ NJP` (3& RXWSXW SUHVVXUH
3 % %
*
Function q The servo valve controls the current input to the EPC valve and the pump delivery (Q) so that they will be related as shown in the diagram.
q q
q
q
q
q
q q
The output pressure of the EPC valve flows in the piston chamber to push piston (6).
D155A-6
Piston (6) pushes spool (5) until it is balanced with the spring. Then, the land of the servo piston pressure passage is connected to the pump discharge passage by the notch of spool (5) and the discharge pressure is led to the servo piston. When the rocker cam is pushed up by the servo piston, a position feedback is applied and lever (2) moves to compress spring (8). When spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are cut off. Pressure in the servo piston chamber drops and the rocker cam returns in the direction of a maximum swash plate angle. These processes are repeated until the swash plate is fixed to a position where the EPC output pressure is balanced with spring (8) force. The greater the EPC output pressure, the smaller the swash plate angle. Conversely, the smaller the EPC output pressure, the greater the swash plate angle.
17
SEN02861-02
Cooling fan motor
10 Structure, function and maintenance standard
1
Type: LMF75(65)
P: From fan pump T: From cooler to tank TC: To tank
18
Specifications Type: LMF75(65) Capacity: 65.1 cc/rev Rated speed: 1,250 rpm Rated flow: 81.4 l/mm Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6.
Output shaft Case Thrust plate Piston assembly Cylinder block Valve plate
SEN02861-02
7. End cover 8. Center spring 9. Check valve 10. Pilot valve 11. Spool for reversible valve 12. Safety valve Unit: mm
No.
Check item
Criteria
Remedy
Standard size 13 Spool return spring
14 Check valve spring
D155A-6
Repair limit
Free length x Installation outer diameter length
Installation load
Free length
62.66 x 19.8
53.5
146 N {14.9 kg}
—
16.4 x 8.9
11.5
13.7 N {1.4 kg}
—
Installation load Replace spring if damaged or 117 N {11.9 kg} deformed. 11.0 N {1.12 kg}
19
SEN02861-02
10 Structure, function and maintenance standard
1. Hydraulic motor Function q This hydraulic motor is called a swash platetype axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation q The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5). This oil can flow on only one side of the (Y-Y) line connecting the top dead center and bottom dead center of the stroke of piston (4). q The oil sent to one side of cylinder block (5) presses piston (4) [4 or 5 pieces], and generates force (F1)[F1 = P x xD2/4]. q This force is applied to thrust plate (2). Since thrust plate (2) is fixed to the angle of (a°) degrees to the output shaft(1), the force is divided into components (F2) and (F3). q The radial component (F3) generates torque [T = F3 x ri] against the (Y-Y) line connecting the top dead center and bottom dead center. q The result of this torque [T = (F3 x ri)] rotates cylinder block (5) through the piston. q Since this cylinder block (5) is splined to the output shaft, the output shaft revolves to transmit the torque.
20
D155A-6
10 Structure, function and maintenance standard
SEN02861-02
2. Suction valve Function q If the fan pump stops, the pressurized oil does not flow into the motor. Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. q When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and supplies it to port (MA) where there is not sufficient oil to prevent cavitation. Operation 1) q
2) q
q
When the pump is stopped If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm, the pressurized oil from the pump is not supplied to port (P) any more. As the pressurized oil is not supplied to the (MA) side of the motor, the motor speed lowers gradually to stop. If the motor shaft is revolved by the force of inertia while the oil flow in the port (P) is reducing, the oil in port (T) on the outlet side is sent by the suction valve (1) to the (MA) side to prevent cavitation.
When pump is started If the pressurized oil from the pump is supplied to port (P) and the pressure on (MA) side rises and starting torque is generated in the motor, the motor starts revolution.The pressurized oil on the motor outlet (MB) side of the motor returns through port (T) to the tank.
3XPS
3XPS
3
0$
0%
3 7
*
0$
0%
7
*
D155A-6
21
SEN02861-02
10 Structure, function and maintenance standard
3. Operation of reversible valve 1) q
q q
When the ON-OFF solenoid is de-energized. If ON-OFF solenoid (1) is “de-energized“, the pressurized oil from the pump is blocked by ON-OFF selector valve (2), and port (C) opens for the tank circuit. Spool (3) is pushed to the right by spring (4). Motor port (MA) opens and pressurized oil flows in to revolve the motor in forward (clockwise).
2) q
q q
When the ON-OFF solenoid is energized. If ON-OFF solenoid (1) is “energized“, ONOFF selector valve (2) changes to let the pressurized oil from the pump flow through port (C) into spool chamber (D). The pressurized oil in chamber (D) pushes valve spool (3) to the left against spring (4). Motor port (MB) opens and pressurized oil flows in to revolve the motor in reverse (counterclockwise).
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
3
*
Function q When the engine is started, the pressure in port (P) of the fan motor is heightened in some cases. q Safety valve (1) is installed to protect the fan system circuit. Operation q If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1) opens to release the pressurized oil into port (T). q By this operation, generation of abnormal pressure in port (P) is prevented.
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 04-19(01)
24
D155A-6
SEN02862-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
10 Structure, function and maintenance standard
1
Power train, Part 1 Power train skeleton ....................................................................................................................................... 2 Overall drawing of power train unit ................................................................................................................. 4 Power train hydraulic piping drawing .............................................................................................................. 6 Damper, universal joint ................................................................................................................................... 8 Torque converter, PTO .................................................................................................................................. 10 Transmission................................................................................................................................................. 18 Transmission ECMV ..................................................................................................................................... 34 Main relief valve and torque converter relief valve........................................................................................ 40 Lubricating oil relief valve.............................................................................................................................. 42 Scavenging pump ......................................................................................................................................... 44 Power train and steering lubrication pump.................................................................................................... 46
D155A-6
1
SEN02862-03
10 Structure, function and maintenance standard
Power train skeleton
Outline q The power generated by engine (1) has its torsional vibration dampened by damper (2), and then passes through universal joint (3), and is transmitted to torque converter (8). q The power from the engine is transmitted through the oil by torque converter (8) to the transmission input shaft (turbine shaft) in accordance with the change in load. (with L/U) q Transmission (9) uses a combination of a planetary gear system and hydraulic clutches to reduce the speed and shift the gears (3 forward gears and 3 reverse gears). It connects 2 sets of clutches selected according to the change in load, and transmits the power to bevel gear (10) from the bevel pinion at the rear end of the transmission.
1
q
q
2
The power transmitted to the bevel gear shaft is transmitted to divided at right angles to the left and right and transmitted to the respective steering clutches (11). The power transmitted from the bevel gear shaft to the final drive is used to steer the machine by engaging or disengaging steering clutch (11). The steering lever is operated to disengage the steering clutch on the side to which the machine is to be steered in order to change the direction of travel. The side of the turning radius id controlled by steering brake (12) installed to the outside of the steering clutch. Steering brake (12) uses the same disc system that is used for the steering clutch. The power sent from steering brake (12) is transmitted to final drive (13). 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).
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9.
Engine (SAA6D140E-5) Damper Universal joint Scavenging pump (SAR(4)125) Hydraulic pump (HPV112) PTO Power train, lubricating pump (SAR(3)100+40) Torque converter Transmission
D155A-6
SEN02862-03
10. Bevel gear 11. Steering clutch 12. Steering brake 13. Final drive 14. Sprocket 15. Track shoe 16. Cooling fan pump (LPV45) 17. Cooling fan motor (LMF65)
3
SEN02862-03
Overall drawing of power train unit
4
10 Structure, function and maintenance standard
1
D155A-6
10 Structure, function and maintenance standard
1. Steering brake 2. Transmission 3. Power train, lubricating pump (SAR(3)100+40) 4. Power train oil strainer 5. Main relief, torque converter relief valve 6. Torque converter, PTO 7. Scavenging pump (SAR(4)125) 8. Cooling fan pump (LPV45) 9. Hydraulic pump (HPV112) 10. Brake control valve
D155A-6
SEN02862-03
Outline q The power train unit can be broadly divided into torque converter, PTO (7), transmission (2), and steering brake (1). So, after th e p ower tra in unit ha s bee n removed, it can be disassembled into the torque converter, PTO (7), transmission (2), and steering brake (1). q Steering clutch consists of the bevel pinion unit, bevel gear shaft, and steering brake.
5
SEN02862-03
10 Structure, function and maintenance standard
Power train hydraulic piping drawing
6
1
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8.
SEN02862-03
Hydraulic pump (HPV112) Centralized pressure detection port Power train, lubrication pump (SAR(3)100+(3)40) Brake control valve Main relief, torque converter relief valve Power train oil filter Scavenging pump (SAR(4)125) Power train oil cooler (built in radiator lower tank)
A: B: C:
Left brake oil pressure pickup port (LB) Right brake oil pressure pickup port (RB) 3rd transmission clutch oil pressure pickup port (3RD) D: 2nd transmission clutch oil pressure pickup port (2ND) E: 1st transmission clutch oil pressure pickup port (1ST) F: Reverse transmission clutch oil pressure pickup port (R) G: Forward transmission clutch oil pressure pickup port (F) H: Transmission main relief oil pressure pickup port (TM) J: Left clutch oil pressure pickup port (LC) K: Right clutch oil pressure pickup port (RC) L: Torque converter oil pressure pickup port (IN) M: Torque converter oil pressure pickup port (OUT)
D155A-6
7
SEN02862-03
Damper, universal joint
8
10 Structure, function and maintenance standard
1
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.
12
Check item Clearance between flywheel housing and cover
13
Clearance between flywheel and damper
14
Outside diameter of coupling oil seal contact surface
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
511.18
–0.022 –0.092
+0.070 +0.070
0.022 – 0.162
0.2
466.72
–0.020 –0.083
+0.063 +0.070
0.020 – 0.146
0.2
Standard size
Clearance limit
Standard size
Tolerance
Repair limit
90
–0.087 –0.087
89.8
Replace
Outline q The damper, dampens the torsional vibration caused by the change in engine torque and the impact torque generated when accelerating suddenly or when carrying out heavy-duty digging. In this way, it acts to protect the torque converter, transmission, and other parts of the power train. q The damper has few component parts: it uses a rubber coupling, so the vibration is absorbed by the damping effect of the rubber material. Operation q The motive force from the engine passes through flywheel (5) and is transmitted to outer body (6). The torsional vibration of the engine is absorbed by rubber coupling (10), and the power is transmitted to inner body (11). It passes through universal joint (8), and is then transmitted to the torque converter and transmission.
D155A-6
9
SEN02862-03
10 Structure, function and maintenance standard
Torque converter, PTO a
PTO: Abbreviation for Power Take Off
A: B: C:
To power train oil cooler From main relief valve From transmission case
10
1
D: E:
To transmission case From power train oil cooler
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02862-03
11
SEN02862-03
10 Structure, function and maintenance standard
1. 2. 3. 4.
Work equipment pump mounting port Cooling fan pump mounting port Scavenging pump mounting port Power train and steering lubrication pump mounting port 5. Torque converter case 6. Coupling 7. Input transfer drive gear (Number of teeth: 58) 8. PTO idler gear (Number of teeth: 66) 9. PTO idler gear shaft 10. Turbine 11. Drive case 12. Rase 13. Stator 14. Pump 15. Retainer 16. Stator shaft 17. Transmission input shaft 18. Turbine boss 19. PTO gear A (Number of teeth: 49) 20. PTO gear B (Number of teeth: 48) 21. Scavenging pump drive gear (Number of teeth: 56) 22. Power train oil strainer 23. Sleeve
12
D155A-6
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 integrated 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
14
10 Structure, function and maintenance standard
D155A-6
10 Structure, function and maintenance standard
SEN02862-03
Unit: mm No.
Check item
Criteria
1
Outside diameter of coupling oil seal contact surface
Remedy
Standard size
Tolerance
Repair limit
100
-0.054 -0.054
99.8
Inside diameter of stator shaft seal ring contact surfac
65
+0.030 +0.025
65.1
Width
3
-0.01 -0.03
2.7
Thickness
2.7
±0.1
2.55
3
Inside diameter of retainer seal ring contact surface
150
+0.040 +0.040
150.5
4
Backlash between input shaft and PTO idler gear
0.198 – 0.484
5
Backlash between PTO idler gear and PTO gear A
0.198 – 0.484
6
Backlash between PTO idler gear and PTO gear B
0.198 – 0.484
7
Backlash between input shaft and scavenging pump drive gear
0.198 – 0.484
2
8
9
Wear on seal ring of the transmission input shaft
Tolerance for fitness of PTO idler gear bearing
Tolerance for fitof scaveng11 ness ing pump drive gear bearing
D155A-6
Replace
Repair by hard chromium-plating or replace
Standard size
Shaft
Hole
Standard clearance
Clearance limit
Outside diameter
140
-0.018 -0.018
-0.008 -0.033
0.033 – 0.010
—
Inside diameter
80
-0.019 -0.019
-0.015 -0.015
0.015 – 0.019
—
Outside diameter (Cover side)
140
-0.018 -0.018
+0.026 -0.014
0.014 – 0.044
—
120
-0.015 -0.015
+0.022 -0.013
0.013 – 0.037
—
65
+0.030 +0.011
-0.015 -0.015
0.045 – 0.011
—
Inside diameter (Case side)
65
+0.030 +0.011
-0.015 -0.015
0.045 – 0.011
—
Outside diameter (Cover side)
120
-0.015 -0.015
+0.022 -0.013
0.013 – 0.037
—
Outside diameter (Case side)
120
-0.015 -0.015
+0.022 -0.013
0.013 – 0.037
—
Inside diameter (Cover side)
55
+0.030 +0.011
-0.015 -0.015
0.045 – 0.011
—
Inside diameter (Case side)
65
+0.030 +0.011
-0.015 -0.015
0.045 – 0.011
—
Outside diameter
85
-0.015 -0.015
+0.010 -0.025
0.025 – 0.025
—
Inside diameter
45
+0.018 +0.002
-0.012 -0.012
0.030 – 0.002
—
Outside Tolerance for fitdiameter ness of drive gear (Case side) bearing on work equipment, power Inside train and steering diameter lubrication pump (Cover side)
Tolerance for fit10 ness of fan pump drive gear bearing
Tolerance
Repair by hard chromium-plating or replace
Replace
15
SEN02862-03
10 Structure, function and maintenance standard
Power transmitting route
Oil flow
%
$
*
q
Power generated from engine O Damper O Universal joint O Input coupling (1) O Input shaft (2) O Drive case (3) and pump (4) rotate integral to each other O Oil is used as medium O Turbine (5) O Transmission input shaft (6)
16
q
q
The oil flows through the main relief valve and its pressure is reduced to less than the set pressure by the torque converter relief valve, then it flows through inlet port (A) and oil passage of torque converter case (1), stator shaft (2), retainer (3), to pump (4). The oil is given a centrifugal force by pump (4), and then it enters turbine (5) to transmit its energy to turbine (5). The oil from turbine (5) is sent to stator (6), and then returned to pump (4). Part of this oil is sent to the power train oil cooler through stator (6) and outlet port (B).
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02862-03
17
SEN02862-03
Transmission
18
10 Structure, function and maintenance standard
1
D155A-6
10 Structure, function and maintenance standard
A: B: C: D: E: F: G: H: J:
1st clutch pressure pickup port (1ST) 3rd clutch pressure pickup port (3RD) R clutch oil pressure pickup port (R) 2nd clutch pressure pickup port (2ND) F clutch oil pressure pickup port (F) From power train pump To brake control valve From steering case From power train oil cooler
D155A-6
SEN02862-03
K: L: M: N: P: R: S: T: U:
To torque converter To scavenging pump To torque converter case From torque converter case To R clutch To 3rd clutch To 1st clutch To 2nd clutch To F clutch
19
SEN02862-03
20
10 Structure, function and maintenance standard
D155A-6
10 Structure, function and maintenance standard
1. 2.
Transmission ECMV Main relief valve and torque converter relief valve 3. Transmission case 4. Sleeve 5. Transmission input shaft 6. Tie bolt 7. R ring gear (hub) 8. R planetary pinion (number of teeth: 26) 9. R ring gear (number of internal teeth: 86) 10. F planetary pinion (number of teeth: 24) 11. F ring gear (number of internal teeth: 91) 12. 3rd planetary pinion (number of teeth: 35) 13. 3rd ring gear (number of internal teeth: 89) 14. 2nd planetary pinion (number of teeth: 31) 15. 2nd ring gear (number of internal teeth: 91) 16. 1st ring gear (number of internal teeth: 91) 17. 1st planetary pinion (number of teeth: 27) 18. Transmission output shaft (3rd sun gear)(number of teeth: 19) 19. 1st clutch housing 20. 1st clutch piston 21. 1st sun gear (number of teeth: 37) 22. 1st carrier 23. 2nd clutch housing 24. 2nd clutch piston 25. 2nd sun gear (number of teeth: 29) 26. 2nd carrier 27. 3rd clutch housing 28. 3rd clutch piston 29. 3rd carrier 30. F clutch housing 31. F clutch piston 32. F carrier 33. R clutch housing 34. F sun gear (number of teeth: 44) 35. R clutch piston 36. Washer spring 37. Clutch plate 38. Clutch disc 39. Piston return spring 40. R carrier 41. Front housing 42. R sun gear (number of teeth: 34)
D155A-6
SEN02862-03
General q The transmission consists of planetary gear systems and disc clutches and has "3 forward gear speeds and 3 reverse gear speeds". q Among the 5 sets of planetary gear system and disc clutches of the transmission, 2 clutches are fixed hydraulically with the ECMV to select 1 rotating direction and gear speed. q The transmission transfers the power received by the transmission input shaft to the output shaft while changing the gear speed (forward 1st-3rd or reverse 1st-3rd) by any combination of the F, R clutches and 3 speed clutches. Number of plates and discs used Clutch No.
Number of plates
Number of discs
R clutch
6
6
F clutch
6
7
3rd clutch
3
4
2nd clutch
3
4
1st clutch
2
3
Combinations of clutches at respective gear speeds and reduction ratio Gear speed
Operated clutches
Reduction ratio
Forward 1st
F x 1st
1.705
Forward 2nd
F x 2nd
1.151
Forward 3rd
F x 3rd
0.540
Neutral
*
—
Reverse 1st
R x 1st
1.406
Reverse 2nd
R x 2nd
0.949
Reverse 3rd
R x 3rd
0.445
*: The 1st, 2nd, or 3rd clutch is filled with low-pressure oil.
21
SEN02862-03
22
10 Structure, function and maintenance standard
D155A-6
10 Structure, function and maintenance standard
SEN02862-03
Unit: mm No.
Check item
Criteria Standard size
1
R clutch spring (12 springs)
Remedy Repair limit
Free length
Installed length
Installed load
Free length
Installed load
81.7
72.4
59.8 N {6.1 kg}
76.8
51.0 N {5.2 kg}
2
F clutch spring (12 springs)
81.7
76.4
34.3 N {3.5 kg}
76.8
29.4 N {3.0 kg}
3
3rd clutch spring (12 springs)
70.0
50.2
97.1 N {9.9 kg}
65.8
82.4 N {8.4 kg}
4
2nd clutch spring (12 springs)
70.0
51.6
90.2 N {9.2 kg}
65.8
76.5 N {7.8 kg}
5
1st clutch spring (12 springs)
66.0
51.8
66.7 N {6.8 kg}
62.0
56.9 N {5.8 kg}
6
Total assembled thickness of 6 disks and 6 plates for R clutch
7
Standard size
Tolerance
Repair limit
51.6
±0.35
48.4
Total assembled thickness of 7 disks and 6 plates for F clutch
57.0
±0.36
53.3
8
Total assembled thickness of 4 disks and 3 plates for 3rd clutch
31.2
±0.26
29.1
9
Total assembled thickness of 4 disks and 3 plates for 2nd clutch
31.2
±0.26
29.1
10
Total assembled thickness of 3 disks and 2 plates for 1st clutch
22.6
±0.22
21.0
11 Thickness of clutch disk
5.4
±0.1
4.9
12 Thickness of clutch plate
3.2
±0.1
2.9
Width
3.0
-0.01 -0.03
2.70
Thickness
2.7
±0.1
2.55
Width
4.0
-0.01 -0.04
3.60
Thickness
5.0
±0.15
4.85
Width
4.0
-0.01 -0.04
3.60
Thickness
4.0
±0.15
3.85
Width
4.0
-0.01 -0.04
3.60
Thickness
4.0
±0.15
3.85
Width
4.0
-0.01 -0.04
3.60
Thickness
4.0
±0.15
3.85
Wear of input shaft 13 seal ring Wear of seal ring on the front housing, F 14 clutch housing and 3rd carrier Wear of seal ring 15 (large) on 2nd carrier
Wear of seal ring 16 (small) on 2nd carrier
Wear of seal ring 17 (large) on 1st carrier
D155A-6
Replace
23
SEN02862-03
10 Structure, function and maintenance standard
Unit: mm No.
18
Check item
Wear of seal ring (small) on 1st carrier
Backlash between 19 sun gear and planetary pinion
Backlash between 20 planetary pinion and ring gear
Criteria
Remedy
Standard size
Tolerance
Repair limit
Width
4.0
-0.01 -0.04
3.60
Thickness
5.0
±0.15
4.85
R, F, 3rd, 1st
0.14 – 0.35
2nd
0.13 – 0.32
R
0.15 – 0.39
F, 2nd, 1st
0.15 – 0.38
3rd
0.16 – 0.42
Disc clutch Structure
Replace
Operation When clutch is "engaged" (fixed)
* q q
q q
24
The disc clutch consists of piston (2), plates (3), discs (4), pin (5), return spring (6) etc. to fix ring gear (1). Inside teeth of disc (4) are engaged with outside teeth of ring gear (1). Plate (3) is assembled to clutch housing (7) with pin (5).
q
q
The oil sent from the ECMV flows through the oil passage in clutch housing (7), is pressurefed to the back side of piston (2), and pushes piston (2) to the left. Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by use of the friction force generated between them. Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), move of ring gear (1) is stopped.
D155A-6
10 Structure, function and maintenance standard
When clutch is "disengaged" (released)
SEN02862-03
Oil passage in speed clutch a The figure shows the case in which "1st" gear speed is selected. )URP WUDQVPLVVLRQ (&09
* q q
As the oil from ECMV is stopped, piston (2) is pushed back rightward by return spring (6). The friction force between plates (3) and discs (4) is released and ring gear (1) is released.
VW FOXWFK SLVWRQ
q
q
q
q
q
D155A-6
*
When the steering/directional/gear shift lever is set in the "neutral" position, the 1st, 2nd, or 3rd speed is selected. The piston chamber of the clutch corresponding to the selected gear speed is filled with oil by electronically controlling the hydraulic circuit of each clutch. When the steering/directional/gear shift lever is shifted from the "neutral" position to the"forward" or "reverse" position, the pump is required to supply oil of quantity to fill the piston chamber of the F clutch or R clutch. When the gear speed is changed from "forward 1st" to "forward 2nd", the pump is required to supply oil of only quantity to fit the plate and disc of the 2nd clutch together since the F clutch has been filled with the oil. The time lag in the gear shifting operation is reduced by controlling the oil in the clutch circuit as explained above.
25
SEN02862-03
10 Structure, function and maintenance standard
Power transmitting route Forward 1st speed
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. Power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd ring gear (16) O 1st carrier (17) O 1st planetary pinion (18) O 1st sun gear (20) O Output shaft (22)
D155A-6
2nd sun gear (21)
27
SEN02862-03
10 Structure, function and maintenance standard
Forward 2nd speed
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. Power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd sun gear (21) O Output shaft (22)
D155A-6
29
SEN02862-03
10 Structure, function and maintenance standard
Forward 3rd speed
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. Power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O Output shaft (22)
D155A-6
31
SEN02862-03
10 Structure, function and maintenance standard
Reverse 1st speed
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. Power from torque converter O Input shaft (1) O R sun gear (5) O R planetary pinion (6) O R ring gear (9) (R carrier (8) is fixed with R ring gear = R ring gear (9) rotates in reverse with regard to input shaft (1) Not translated O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd ring gear (16) O 1st carrier (17) O 1st planetary pinion (18) O 1st sun gear (20) O Output shaft (22)
D155A-6
2nd sun gear (21)
33
SEN02862-03
10 Structure, function and maintenance standard
Transmission ECMV a a
34
1
ECMV: Abbreviation for Electronic Control Modulation Valve Don't try to disassemble it since adjustment for maintaining the performance will be needed.
D155A-6
10 Structure, function and maintenance standard
SEN02862-03
AF: To F clutch AR: To R clutch A1: To 1st clutch A2: To 2nd clutch A3: To 3rd clutch P: From power train pump T: Drain Dr: Drain PF: F clutch oil pressure pickup port PR: R clutch oil pressure pickup port P1: 1st clutch oil pressure pickup port P2: 2nd clutch oil pressure pickup port P3: 3rd clutch oil pressure pickup port
Operation table of ECMV
1. 3rd clutch proportional solenoid 2. 1st clutch proportional solenoid 3. R clutch proportional solenoid 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
a
D155A-6
ECMV Gear speed
F
R
N F1
Q
F2
Q
F3
Q
1st
2nd
3rd
Q
Q
Q
Q Q Q
R1
Q
R2
Q
R3
Q
Q Q Q
When the directional lever is in (neutral) position, the speed clutch of the speed selected by gear shift lever activates.
35
SEN02862-03
1. 2. 3. 4. 5. 6. 7. 8.
36
10 Structure, function and maintenance standard
Fill switch Pressure control valve Body (upper) Body (lower) Proportional solenoid Filter Pressure detection valve Sleeve
D155A-6
10 Structure, function and maintenance standard
SEN02862-03
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 switch detects that the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2. Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch.
ECMV and proportional solenoid q For each ECMV, 1 proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. Current - propulsion force characteristics of proportional solenoid
Propulsion force - Hydraulic pressure characteristics of proportional solenoid
Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned "ON" during triggering (Range D).
D155A-6
ECMV and fill switch For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. The oil pressure is built up according to this signal.
q
37
SEN02862-03
10 Structure, function and maintenance standard
Operation of ECMV q ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal. The relationship between the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown below.
Before shifting gear (when draining) (Range A in chart)
7
$
*
q
Under the condition where any current is not sent to the proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T). Also at this time, fill switch (5) is turned "OFF" because oil pressure is not applied to pressure detection valve (4).
Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned "ON" during triggering (Range D). q When gear is shifted with gear shift switch, the clutch is compressed by piston. If high pressure is suddenly applied, the piston suddenly engages clutch, causing sudden start of machine and excessive shock. ECMV reduces a shock at the start of the machine by increasing the oil pressure applied to the piston gradually to set pressure, and puts clutch smoothly "engaged". It aims to increase durability of power transmitting route and enhances an operator comfort.
38
D155A-6
10 Structure, function and maintenance standard
During filling (Range B in chart)
%
SEN02862-03
Pressure adjustment (Range C in chart)
$
3
* q
If current is supplied to proportional solenoid (1) with no oil in the clutch, the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the right. As a result, pump port (P) and clutch port (A) are opened and oil starts filling the clutch. If the clutch is filled with oil, fill switch (5) is turned "on".
D155A-6
* q
If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the repulsion of pressure control valve spring (2) to regulate the pressure.
39
SEN02862-03
10 Structure, function and maintenance standard
Main relief valve and torque converter relief valve
1
Unit: mm No.
1
2
Check item Clearance between main relief valve and body Clearance between the torque converter relief valve and the body
Criteria Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
28
-0.035 -0.045
+0.013 +0.013
0.035 – 0.058
0.078
22
-0.035 -0.045
+0.013 +0.013
0.035 – 0.058
0.078
Standard size 3
Main relief valve spring (outside)
Remedy
Free length
Repair limit
Installation Installation Installation Free length length load load
122
78.0
481 N {49 kg}
118.3
457 N {46.6 kg}
4
Main relief valve spring (inside)
108
78.0
368 N {37.5 kg}
104.8
349 N {35.6 kg}
5
Torque converter relief valve spring
50
40.5
182 N {18.6 kg}
48.5
174 N {17.7 kg}
6. Body 7. Piston 8. Torque converter relief valve 9. Piston 10. Main relief valve
40
Replace
A: Drain (Torque converter relief) B: Drain C: From pump D: Drain E: To torque converter P1: Main relief oil pressure pickup port P8a: Torque converter relief oil pressure pickup port P8b: Torque converter inlet oil pressure pickup port D155A-6
10 Structure, function and maintenance standard
General
SEN02862-03
Operation of main relief valve
Torque converter relief valve q The torque converter relief valve maintains the oil pressure in the torque converter inlet circuit always below the set pressure in order to protect the torque converter from abnormally high pressure. Set pressure: 1.06 ± 0.05 MPa {10.8 ± 0.5 kg/cm2} (Cracking pressure) Main relief valve q The main relief valve is keeping each hydraulic circuit of the transmission and the parking brake at set pressure. Set pressure: 3.18 ± 0.1 MPa {32.4 ± 1.0 kg/cm2} (Engine at rated speed)
)
& q
D
*
The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief valve and orifice (a) of main relief valve (1).
( )
Operation
Operation of torque converter relief valve
&
(
$
* E q
q
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.
*
The oil from the main relief valve is conducted to the torque converter through port (E) and, at the same time, also conducted to chamber (G) through orifice (b) of torque converter relief valve (3). As the oil pressure to the torque converter rises beyond the set pressure, the oil conducted to chamber (G) pushes piston (4) and the resulting reaction force pushes torque converter relief valve (3) rightward, opening ports (E) and (A). As a result, the oil in port (E) is drained through port (A).
D155A-6
41
SEN02862-03
10 Structure, function and maintenance standard
Lubricating oil relief valve
1
Unit: mm No.
Check item
Criteria
Remedy
Standard size 1
Lubrication relief valve spring
Free length 26
2. 3. 4.
F clutch housing R clutch housing Piston
A: B: C:
From oil cooler Drain Drain
42
Repair limit
Installation Installation Installation Free length length load load Replace 23.6
12.5 N {1.27 kg}
25.2
11.9 N {1.21 kg}
General q The oil leaving the torque converter passes through the power train oil cooler built in the radiator lower tank. It then goes through the lubrication relief valve and lubricates the transmission and PTO. q The lubrication relief valve is installed to the right side face of the F clutch housing. It keeps the lubricating oil pressure below the set pressure. s
Specified value
Normal pressure (MPa{kg/cm2})
0.14 ± 0.05 {1.4 ± 0.5}
Cracking pressure (MPa{kg/cm2})
0.30 ± 0.03 {3.0 ± 0.3}
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02862-03
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
1
Side clearance
2
Clearance between plain bearing inner diameter and gear shaft outer diameter
3
Pin driving depth
4
Spline shaft rotating torque
–
Delivery amount Oil: SAE10WCD Oil temperature: 45 – 55°C
Criteria
Remedy
Standard clearance
Clearance limit
0.11 – 0.16
0.19
0.06 – 0.14
0.20
Replace
Standard size
Tolerance
Repair limit
21
-0.5 -0.5
—
9.8 - 14.7 Nm {1.0 - 1.5 kgm} Rotation speed (rpm)
Delivery pressure MPa{kg/cm2}
Standard discharge amount (l/min)
Discharge amount limit (l/min)
2,200
2.94{30}
264
234
—
General q The scavenging pump is installed to the torque converter case and is driven with the power from the engine. It returns the oil collected in the bottom of the transmission case to the steering case.
44
D155A-6
10 Structure, function and maintenance standard
SEN02862-03
Type: SAR(3)125 Serial No.: 85025 and up
Unit: mm No.
Check item
1
Side clearance
2
Clearance between plain bearing inner diameter and gear shaft outer diameter
3
Pin driving depth
4
Spline shaft rotating torque
–
Delivery amount Oil: SAE10WCD Oil temperature: 45 – 55°C
Criteria
Remedy
Standard clearance
Clearance limit
0.10 – 0.15
0.19
0.078 – 0.149
0.20
Replace
Standard size
Tolerance
Repair limit
14
-0.5 -0.5
—
6.9 - 11.8 Nm {0.7 - 1.2 kgm} Rotation speed (rpm)
Delivery pressure MPa{kg/cm2}
Standard discharge amount (l/min)
Discharge amount limit (l/min)
2,000
2.94{30}
240.7
213.1
—
General q The scavenging pump is installed to the torque converter case and is driven with the power from the engine. It returns the oil collected in the bottom of the transmission case to the steering case.
D155A-6
45
SEN02862-03
10 Structure, function and maintenance standard
Power train and steering lubrication pump
1
Type: SAR (3) 100 + (3) 40
1. 2.
46
Power train pump Steering lubrication pump
General q The power train pump and the steering lubrication pump are installed to the torque converter case. They are driven by the power from the engine to supply the oil pressure to the torque converter, the transmission and the steering unit.
D155A-6
10 Structure, function and maintenance standard
SEN02862-03
Unit: mm No.
Check item
Criteria Type
3
Side clearance
SAR(3)100 SAR(3)40
4
Clearance between plain bearing inner diameter and gear shaft outer diameter Pin driving depth
SAR(3)40
SAR(3)100 SAR(3)40
6
–
Rotating torque of spline shaft
Delivery amount Oil: SAE10WCD Oil temperature: 45 – 55°C
D155A-6
Clearance limit
0.10 – 0.15
0.19
0.06 – 0.15
0.20
SAR(3)100
Type 5
Remedy
Standard clearance
Replace
Standard size
Tolerance
Repair limit
14
-0.5 -0.5
—
13.7 – 23.5 Nm {1.4 – 2.4 kgm} Type
Rotation speed (rpm)
Delivery pressure (MPa{kg/ cm2})
Standard discharge amount (l/min)
Discharge amount limit (l/min)
SAR(3)100
2,500
2.94{30}
241
96
SAR(3)40
2,500
2.94{30}
239
85
—
47
SEN02862-03
10 Structure, function and maintenance standard
D155A-6 Bulldozer Form No. SEN02862-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
48
D155A-6
SEN02863-01
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
10 Structure, function and maintenance standard
1
Power train, Part 2 Work equipment pump .................................................................................................................................... 2 Work equipment cooler bypass valve ........................................................................................................... 15 Steering, brake control .................................................................................................................................. 16 Steering unit .................................................................................................................................................. 18 Steering control valve.................................................................................................................................... 32 Steering clutch ECMV, steering brake ECMV ............................................................................................... 34 Parking brake solenoid valve ........................................................................................................................ 40 Sudden stop prevention valve....................................................................................................................... 42 Final drive ..................................................................................................................................................... 45 Sprocket ........................................................................................................................................................ 50
D155A-6
1
SEN02863-01
Work equipment pump
10 Structure, function and maintenance standard
1
Type: HPV95 (112)
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. PA: Pump discharge port PB: Pump pressure input port PC: Pump discharge pressure pickup port PD1: Case drain port PD2: Drain plug PEN: Control pressure pickup port PLS: Load pressure input port PLSC: Load pressure pickup port PS: Pump suction port 1. 2.
Main pump 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
Function q The pump converts the engine and torque rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.
SEN02863-01
q
q q q
Structure q Cylinder block (7) is supported to shaft (1) by spline (12). q Shaft (1) is supported with bearings (13). q The end of piston (6) has a spherical hollow and is combined with shoe (5). q Piston (6) and shoe (5) form a spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement. q Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides.
D155A-6
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).
5
SEN02863-01
10 Structure, function and maintenance standard
Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the axial direction of cylinder block (7) changes. q Angle (a) is called the swash plate angle.
q
q
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
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With center line (X) of rocker cam (4) at swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) sucks and discharges the oil by the amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.
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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 pressure 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 pressure 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
PA: Pump port PDP: Drain port PLP: LS control pressure output port PLS: LS pressure input port PP: Pump port PSIG: Drain port
1. 2. 3. 4. 5. 6. 7. 8.
Sleeve Piston Spool Spring Seat Sleeve Plug Locknut
Function q The LS (load sensing) valve detects the load and controls the delivery. q This valve controls pump delivery (Q) according to differential pressure (dPLS) [ = (PP) – (PLS)] (called LS differential pressure) 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 control valve output enter this valve.
8
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02863-01
9
SEN02863-01
10 Structure, function and maintenance standard
Operation 1)
When the control valve is situated at neutral
37 3/6
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D155A-6
10 Structure, function and maintenance standard
q
q
q
q
q q q q
SEN02863-01
The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the inlet port of the control valve brought to spring chamber (B), and pump discharge pressure (PP) brought to port (H) of sleeve (1). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge pressure (self pressure) (PP) determine the position of spool (3). Before starting engine, servo piston (10) is pressed to the right. (See the figure to the right) If the control lever is in neutral at start of the engine, LS pressure (PLS) is set to 0 MPa {0 kg/cm2}. (It is connected with the drain circuit through the control valve spool.) Spool (3) is pushed to the right, and port (C) and port (D) will be connected. Pump discharge pressure (PP) enters the large diameter side of the piston from port (K). Pump pressure (PP) is present in port (J) on the small diameter side of the piston. According to the difference in the areas on servo piston (10), servo piston (10) moves in to the direction of minimizing the swash plate angle.
D155A-6
11
SEN02863-01
2)
10 Structure, function and maintenance standard
Action for the direction of maximizing the pump delivery
37 3/6
33
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12
When the difference between pump discharge pressure (PP) and LS pressure (PLS), in other 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) becomes smaller [for example, when the area of opening of the control valve becomes larger and pump discharge pressure (PP) drops], spool (3) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4).
q
q
When spool (3) moves, port (D) and port (E) are interconnected and connected to the drain port. The pressure at the large diameter end of servo piston (10) becomes drain pressure (PT), and pump pressure (PP) enters port (J) at the small diameter end, so servo piston (10) is pushed to the left side. Therefore, servo piston (10) is moved in the direction to make the delivery larger.
D155A-6
10 Structure, function and maintenance standard
3)
SEN02863-01
Action for the direction of minimizing the pump delivery
37 3/6
33
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If LS differential pressure (dPLS) becomes larger (for example, when the area of control valve opening becomes smaller and the pump pressure (PP) increases), spool (3) is pressed to the right by the force of pump pressure (PP). As a result of the movement of spool (3), pump discharge pressure (PP) flows from port (C) to port (D), then from port (K) to the large diameter side of the piston.
D155A-6
q
While main pump pressure (PP) is present in port (J) of the smaller diameter side of the piston, servo piston (10) is pressed to the right by its area difference between the larger and the smaller diameter sides. As the result, servo piston (10) moves in the direction to minimize the swash plate angle.
13
SEN02863-01
4)
10 Structure, function and maintenance standard
When servo piston is balanced
37 3/6
33
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Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced, and the relationship is (A0) × (PP) = (A1) × (PEN), servo piston (10) will stop in that position.
q
q
q
14
And the swash plate of the pump will be held in an intermediate position. [Spool (3) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] The formula (A0) : (A1) C 3 : 5 represents the relation of pressure receiving areas across the end of servo piston (10). And (PP) : (PEN) C 5 : 3 represents the pressure applied across the piston when balanced. 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}. D155A-6
10 Structure, function and maintenance standard
SEN02863-01
Work equipment cooler bypass valve
1. 2. 3.
Body Valve Spring
A: B:
Hydraulic oil cooler inlet To hydraulic tank
1
Outline q This valve is installed in the oil cooler inlet circuit. If any abnormal pressure is generated in the oil flowing to the oil cooler, this valve acts to return the oil directly to the hydraulic tank. Set pressure Cracking pressure ( MPa {kg/cm }) 2
D155A-6
0.5 {5.1}
15
SEN02863-01
Steering, brake control a
10 Structure, function and maintenance standard
1
a
Regarding the transmission-related description of the operation of the PCCS lever, see Transmission control. PCCS: Palm Command Control System
16
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7.
Potentiometer Lock lever PCCS lever (Steering) Limit switch Power train controller Rod (From brake pedal) Brake pedal
Positions of levers and pedals A: Neutral B: Forward straight C: Reverse straight D: Left turn E: Right turn F: Brake OFF G: Brake ON H: Free J: Lock
D155A-6
SEN02863-01
Outline q PCCS lever (3) sends electric signals to power train controller (5). Upon receiving those signals, power train controller (5) sends signals to the EPC valve of the control valve. q Brake pedal (7) receives signals from potentiometer (1) through rod (6). Then, power train controller (5) sends signals to the brake valve to operate the brake. q Lock lever (2) is connected to limit switch (4) and used as the parking brake lever, too. When it is in lock position "J", power train controller (5) does not send turning signals to the EPC valve of the control valve.
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
A: B: C: D: E: F: G:
SEN02863-01
To transmission case From scavenging pump and steering lubrication pump R.H. brake oil pressure pickup port (RB) L.H. brake oil pressure pickup port (LB) From pin puller solenoid valve (drain) R.H. steering clutch oil pressure pickup port (RC) L.H. steering clutch oil pressure pickup port (LC)
D155A-6
19
SEN02863-01
20
10 Structure, function and maintenance standard
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02863-01
21
SEN02863-01
10 Structure, function and maintenance standard
1. Bevel gear rotation sensor 2. Drain plug 3. Drain valve 4. Steering clutch and brake control valve 5. Case 6. Brake cylinder 7. Brake spring 8. Brake piston 9. Brake plate 10. Brake disk 11. Brake drum 12. Brake hub 13. Tube 14. Bevel gear shaft 15. Bevel gear (Number of teeth: 32) 16. Clutch hub 17. Clutch plate 18. Clutch disk 19. Clutch piston 20. Clutch spring 21. Clutch cylinder 22. Clutch drum 23. Clutch stopper 24. Shim B (For bevel gear adjustment) 25. Bevel gear shaft bearing B 26. Bevel gear shaft bearing A 27. Shim A (For bevel gear adjustment) 28. Retainer 29. Spacer 30. Shim C (For bevel pinion adjustment) 31. Gauge 32. Bevel pinion bearing 33. Nut (For bevel pinion) 34. Bevel pinion (Number of teeth: 17)
22
D155A-6
10 Structure, function and maintenance standard
SEN02863-01
General Bevel gear shaft q Using the meshing of bevel pinion (34) and bevel gear (15), the bevel gear shaft system directs the power being transmitted through the engine, torque converter and transmission orthogonally in the right and left directions and, at the same time, reduces the revolution. q A spiral bevel gear is employed for bevel pinion (34) and bevel gear (15) on the bevel gear shaft system. And as for the lubrication, spattering by use of the oil from the steering lubrication pump and scavenging pump is employed. q The bevel gear shaft system is consisted of bevel pinion (34), bearing (32) and cage (31) supporting the bevel pinion, bevel gear (15) to be meshed with the bevel pinion, bevel gear shaft (14) and bearings (25) and (26) and retainer (28) supporting the bevel gear shaft. Steering clutch The steering clutch is connected to both ends of bevel gear shaft (14) through the spline. It changes the machine turn direction by connecting or disconnecting the power from bevel gear shaft (14) to the final drive. q The wet type multi-disk clutch and springboosted type are employed for the steering clutch. It is hydraulically actuated, in conjunction with the brake, by the pressurized oil from the steering clutch valve. q The lubrication system employed the forced lubrication approach by use of the oil from the steering lubrication pump and scavenging pump. q The steering clutch is consisted of clutch hub (16) (connected to the bevel gear shaft), clutch disk (18), clutch plate (17), clutch drum (22), clutch piston (19), cluch spring (20), and clutch cylinder (21) supporting above components. Clutch drum (22) and the clutch cylinder being connected to the brake hub transmit the power from the bevel gear shaft to the output shaft through brake hub (12). q
D155A-6
Steering brake q The steering brake being connected to the R.H. and L.H. steering clutches damps the machine by damping the power from the steering clutch to the final drive. q The wet type multi-disk clutch and springboosted type are employed for the steering clutch. It hydraulically actuates steering brake control valve (4) through the operation of its brake pedal. q The forced lubrication approach employed for the lubrication conducts the oil from the steering lubrication pump and scavenging pump to brake disk (10) and brake plate (9) through passage in the steering case, case (5) and brake drum (11). q When the engine is stopped, back pressure of brake piston (8) drops without pressing the brake piston, setting the steering brake to "actuated" state. However, if the engine is restarted and oil pressure in the circuit increases, the brake is "released". Thus, the parking brake must be set to the "lock" position. q The steering brake is consisted of clutch cylinder (21), clutch drum (22) (connected to brake hub (12)), brake disk (10), brake plate (9), brake drum (11), brake piston (8), brake spring (21) and brake cylinder (6) supporting above components. Brake drum (11) is fixed to the steering case.
23
SEN02863-01
24
10 Structure, function and maintenance standard
D155A-6
10 Structure, function and maintenance standard
SEN02863-01
Unit: mm No.
1
2
3
4
5
6
7
8
9
Check item
Criteria Tolerance
Repair limit
Thickness
4.5
±0.1
4.0
Strain
—
0.05
0.14
Repair or replace
Thickness
2.9
±0.1
2.6
Replace
Strain
—
0.05
0.15
Repair or replace
Total assembled thickness of 6 disks and 5 plates for steering brake
41.5
±0.33
38.3
Thickness
4.5
±0.1
4.1
Strain
—
0.05
0.14
Repair or replace
Thickness
2.9
±0.1
2.6
Replace
Strain
—
0.05
0.15
Repair or replace
Total assembled thickness of 5 disks and 5 plates for steering clutch
37.0
±0.32
34.3
Inside diameter of brake cylinder seal ring contact surface
125
+0.040 +0.035
125.5
Width
5
–0.08 –0.13
4.2
Thickness
4.5
±0.15
4.05
280
+0.081 +0.081
280.1
220
+0.072 +0.081
220.1
280
+0.081 +0.081
280.1
220
+0.072 +0.081
220.1
Steering brake disk
11
Replace
Steering brake plate
Replace
Steering clutch disk
Steering clutch plate
Wear of brake hub seal ring
Large diamete Inside diameter of portion contact surface of seal ring on steering Small brake piston diameter portion Large diamete Inside diameter of portion contact surface of seal ring on steering Small clutch piston diameter portion
Standard size 10
Remedy
Standard size
Steering brake spring (2 springs Free length make up a set)
Steering clutch spring (2 springs make up a set)
Clearance between bevel gear 12 and reamer bolt
Repair limit
Installation Installation Installation Free length length load load
33
19.6
35.7 kN {3,640 kg}
32.0
33.9 kN {3,460 kg}
33
19.6
35.7 kN {3,640 kg}
32.0
33.9 kN {3,460 kg}
Standard size
Shaft
Hole
Standard clearance
Clearance limit
+0.019 +0.001
+0.027 +0.027
-0.019 – 0.026
0.026
16
D155A-6
Replace
Tolerance
25
SEN02863-01
10 Structure, function and maintenance standard
Unit: mm No.
Check item
Criteria
Backlash between brake hub 13 and disk
0.23 – 0.42
14
Backlash between brake drum and plate
0.23 – 0.42
15
Backlash between clutch hub and disk
0.23 – 0.42
16
Backlash between clutch drum and plate
0.23 – 0.42
17
Standard shim thickness of retainer A
2.0
18
Standard shim thickness of retainer B
2.0
19
Preload of bevel gear shaft bearings A and B
26
Remedy
Replace
Adjustment of shims
Rotary torque: 4.2 – 5.1 Nm {0.43 – 0.52 kgm} (22.6 – 26.5 Nm {2.3 – 2.7 kgm} at the bevel gear addendum Adjusting when the bevel pinion gear is not meshed)
D155A-6
10 Structure, function and maintenance standard
SEN02863-01
Unit: mm No.
Check item
Criteria
1
Backlash between bevel gear and bevel pinion
0.25 – 0.33
2
Standard shim thickness of cage
2.0
D155A-6
Remedy Adjust or replace Adjustment of shims
27
SEN02863-01
10 Structure, function and maintenance standard
Operation of the steering clutch When the steering clutch is turned "on"
When the steering clutch is turned "off"
*
Oil pressure to the back side of clutch piston (19) is stopped, and the repulsion of clutch spring (20) is used for fixing clutch hub (16). Power from transmission O Bevel pinion O Bevel gear O Bevel gear shaft (14) O Clutch hub (16) O Clutch drum (22) O Brake hub (12) O Output shaft O Final drive
28
*
Oil being pressure-fed to the back side of clutch piston (19) releases clutch hub (16). Power from transmission O Bevel pinion O Bevel gear O Bevel gear shaft (14) O Clutch hub (16)
D155A-6
10 Structure, function and maintenance standard
SEN02863-01
Operation of steering brake When the steering brake is "actuated" (When PCCS lever is in "operation")
When the steering brake is "released"
* * q
q
q
When the PCCS lever is set to the "neutral" position and the brake pedal is not pressure, the brake pressure alone is set to the maximum pressure by the steering control valve. Thus, oil pressure works on the back side of brake piston (8) as soon as the steering clutch is "engaged". At this point, brake piston (8) compresses and moves brake spring (7) leftward with the increased oil pressure, relieving the pressurebonding force of disk (10) and plate (9). The power being transmitted from bevel gear shaft (14) to brake hub (12) through the steering clutch is then transmitted to the final drive through the output shaft.
q
q
q q
q
D155A-6
As the PCCS lever is operated in the right or left, the steering clutch is "disengaged" by the steering control valve and, at the same time, draining of oil to the back side of brake piston (8) is started. At this point, brake piston (8) is pushed back rightward by the tension of brake spring (7), pressure-bonding disk (10) and plate (9) against brake drum (11). Brake piston (8) and brake drum (11) are fixed to the steering case. Pressure-bonding disk (10) and plate (9) stops the inertia-based rotation of brake hub (12) and output shaft even if the steering clutch is "disengaged". 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.
29
SEN02863-01
10 Structure, function and maintenance standard
When the steering brake is "applied" (When the PCCS lever is in "neutral" and brake pedal is "depressed")
* q
q
30
If the brake pedal is pressed while the PCCS lever is at "neutral", the steering control valve starts draining the oil on the back side of brake piston (8), "engaging" the steering clutch and actuating the steering brake. Thus, rotation of the output shaft is stopped. Adjusting the braking force becomes available by controlling the oil pressure to the back side of brake piston (8) corresponding to the stroke of the brake pedal.
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02863-01
31
SEN02863-01
Steering control valve
32
10 Structure, function and maintenance standard
1
D155A-6
10 Structure, function and maintenance standard
P: L:
From power train pump Scavenging pump From steering lubrication pump PS: To pin puller solenoid valve LB: To L.H. steering brake LL: To L.H. steering brake lubrication LC: To L.H. steering clutch RB: To R.H. brake RL: To R.H. brake lubrication RC: To R.H. steering clutch BSL: To bevel gear shaft and bearing lubrication BGL: To bevel gear lubrication DLB: Drain (L.H. steering brake) DRB: Drain (R.H. steering brake) DLC: Drain (L.H. steering clutch) DRC: Drain (R.H. steering clutch) DB: Drain (Sudden stop prevention valve) DPB: Drain (Parking brake) PLB: L.H. steering brake oil pressure pickup port PRB: R.H. steering brake oil pressure pickup port PLC: L.H. steering clutch oil pressure pickup port PRC: R.H. steering clutch oil pressure pickup port 1. 2. 3. 4. 5. 6. 7. 8. 9.
L.H. steering brake ECMV R.H. steering brake ECMV L.H. steering clutch ECMV R.H. steering clutch ECMV Steering oil filter Valve seat Parking brake solenoid valve Sudden stop prevention valve Check valve
D155A-6
SEN02863-01
General q The steering control valve controls the steering clutch and steering brake by use of 4 ECMVs, parking brake solenoid valve and sudden stop prevention valve installed on the valve seat. q The steering control valve is provided in the circuit across the power train pump, steering clutch and steering brake piston. It is consisted of the steering clutch ECMV (R.H. and L.H.) and steering brake ECMV (R.H. and L.H.). q The steering control valve conducts the oil from the power train pump to the steering clutch and steering brake to control the R.H. and L.H. disk clutches and the disk brake. q If the PCCS lever is leaned to the right or left, the steering clutch is disengaged. The steering brake will operate by further leaning the PCCS lever. q The controller sends signals to each ECMV according to the right or left stroke of the PCCS lever and adjusts the gradual or sharp turns. q As the brake pedal is pressed, the controller sends the command, corresponding to the pedal stroke, to the steering brake ECMV to actuate the R.H. and L.H. brakes and, thus, to apply braking to the machine. q The controller, which is electrically connected to the PCCS lever and brake pedal, operates the steering clutch and steering brake by controlling each ECMV and solenoid valve. q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly, when an abnormality takes place in the electric system. q As the parking brake lever is set to the "lock" position, the controller sends the signal to the parking brake solenoid valve to drain the oil between the R.H. and L.H. steering brake ECMVs and brake piston in order for actuating the brake. The parking brake solenoid valve is electrically connected to the brake pedal, too.
33
SEN02863-01
10 Structure, function and maintenance standard
Steering clutch ECMV, steering brake ECMV a a
ECMV: Abbreviation for Electronic Control Modulation Valve Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch or brake P: From pump S: To parking brake solenoid valve T: Drain DR: Drain P1: Brake oil pressure pickup port 1. 2. 3. 4. 5. 6. 7.
1
General q Each ECMV keeps the steering clutch oil pressure and steering brake oil pressure to the set pressure and furthermore changes the circuit to the piston chamber of the steering clutch and steering brake.
Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve Name plate (*1)
*1:
34
The clutch used
Name plate stamp
Steering clutch, Steering brake
R*******
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 finishing of filling. 2. While the oil pressure is applied to the clutch or brake, the fill switch outputs the signal (fill signal) to the controller to notify the presence of the oil pressure. ECMV and proportional solenoid q One proportional solenoid is mounted for each ECMV. The propulsion force is generated according to the command current from the controller. The propulsion force generated by the proportional solenoid is actuated on the spool of the pressure control valve and generates the oil pressure. Accordingly, by controlling the amount of the command current, the propulsion force changes and the pressure control valve is actuated, then the oil flow and oil pressure is controlled. ECMV and fill switch For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. The oil pressure is built up according to this signal.
q
Operation of ECMV The ECMV is controlled by the command current from the controller to the proportional solenoid and the fill switch output signal.
q
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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When the PCCS lever is in "neutral" position and the brake pedal is "released", proportional solenoid (1) of the clutch ECMV is demagnetized and the sealing part of ball (2) is opened. The oil from the power train pump flows through port (Pc) of the clutch ECMV to orifice (a), then it is drained through the sealing part of ball (2). Valve (3) is moved to the right by the tension of spring (4) to disconnect port (Pc) from port (C), and connect port (C) with port (Dr). At this time, the oil from the back pressure port of the clutch piston is drained through port (C) and the clutch is turned "on" by the tension of the clutch spring. The oil pressure in the brake circuit, etc. is secured by orifice (a).
q
q
q
Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left and closes the sealing part. The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left to connect port (Pb) with port (B) and disconnect port (B) from port (Dr). At this time, the oil flows in the back pressure port of the brake piston. As the oil pressure rises, the brake piston is pushed to the left to compress the brake spring, then the brake is "released". When the parking brake lever is set in the "free" position, the pilot pressure of brake ECMV port (S) remains, because the parking brake solenoid valve is de-energized.
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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When the PCCS lever is "operated to left halfway" and the brake pedal is "released", proportional solenoid (1) of the L.H. clutch ECMV is energized and the sealing part of ball (2) is closed. The oil from the power train pump flows through port (C) of the clutch EMCV and orifice (a) to port (F) and pushes valve (3) to the left to connect port (Pc) with port (C) and disconnect port (C) from port (Dr). At this time, the oil flows in the back pressure port of the clutch piston. As the oil pressure rises, the clutch piston is pushed to the left to compress the clutch spring, then the clutch is turned "off". Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left and closes the sealing part. The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left. As for the oil pressure after port (B), the controller outputs the command current to proportional
D155A-6
q
q
q
solenoid (5) according to the stroke of the PCCS lever. Proportional solenoid (5) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pressure port of the brake piston and the tension of spring (8), then the brake pressure is set up to adjust the brake force. Accordingly, if the stroke of the PCCS lever is short, the oil pressure after port (B) is set high and the brake is turned from "released" to "half released". If the stroke of the PCCS lever is long, the oil pressure after port (B) is set low and the brake is turned from "half released" to "applied". When the parking brake lever is set in the "free" position, the pilot pressure of brake ECMV port (S) remains, because the parking brake solenoid valve is de-energized.
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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38
When the PCCS lever is shifted from "operated to left halfway" to "operated to left fully", proportional solenoid (5) of the L.H. brake ECMV is demagnetized and the sealing part of ball (6) is fully opened. Since the oil in port (E) is drained through the sealing part, valve (7) is moved to the right by the tension of spring (8) to disconnect port (Pb) from (B) and connect port (B) with port (Dr). At this time, the oil from the back pressure port of the brake piston is drained through port (B) and the brake is turned "applied" by the tension of the brake spring. The oil from the power train pump flows through port (Pb) of the brake ECMV and orifice (b), then it is drained through sealing part of ball (6).
q q
The oil pressure in the clutch circuit, etc. is secured by orifice (b). When the parking brake lever is set in the "free" position, the pilot pressure of brake ECMV port (S) remains, because the parking brake solenoid valve is de-energized.
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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When the brake pedal is depressed fully, proportional solenoids (5) of L.H. and R.H. brake ECMV are demagnetized to open the sealing part of ball (6). The controller outputs the command current to proportional solenoids (5) according to the brake pedal stroke. Proportional solenoid (5) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pressure port of the brake piston and the tension of spring (8), then the brake pressure is set up to adjust the brake force.
D155A-6
q
q
Since the PCCS lever is in "neutral" position, proportional solenoids (1) of L.H. and R.H. clutch ECMV are demagnetized and L.H. and R.H. clutch are turned "on". When the brake pedal is depressed fully, the brake pedal switch is turned "ON", and the parking brake solenoid valve is energized to drain the pilot pressure of the brake ECMV port (S).This carries out the same function as when the parking brake lever is set at the "lock" position.
39
SEN02863-01
Parking brake solenoid valve
10 Structure, function and maintenance standard
1
P: From brake ECMV T: Drain Dr: Drain 1. 2. 3. 4.
Parking brake lever solenoid valve Brake pedal solenoid valve Connector for parking brake lever solenoid valve Connector for brake pedal solenoid valve
Solenoid valve 5. Coil (ON-OFF type) 6. Push pin 7. Spring 8. Spool 9. Body
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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When the parking brake lever is in the "lock" position, the parking brake lever switch is turned "ON" and coil (1) of the parking brake solenoid valve is energized. Spool (3) is pushed to the right direction by push pin (2), then port (P) and (T) are opened to drain the pilot pressure of the L.H. and R.H. brake ECMV. The oil which had flown into the brake piston back pressure port is drained through the brake ECMV. The oil pressure in the back pressure port of the brake piston continues to decrease, then the brake is fully "applied" and that situation is kept. When the engine is started again, as port (P) and (T) are still opened, the brake is continuously "applied".
D155A-6
q
q
q
When the parking brake lever is in the "free" position, the parking brake lever switch is "OFF" and coil (1) of the parking brake solenoid valve is de-energized. Spool (3) is returned to the left, and close port (P) and (T) to remain the pilot pressure of the L.H. and R.H. brake ECMV. The oil pressure from the brake ECMV is applied to the back pressure port of the brake piston, and brake is "released".
41
SEN02863-01
Sudden stop prevention valve
10 Structure, function and maintenance standard
1
A: From power train pump B: From brake ECMV dr1: Drain dr2: Drain 1.
Sudden stop prevention valve
EPC valve 2. Coil (proportional type) 3. Push pin 4. Valve 5. Ball 6. Spool 7. Body
42
D155A-6
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 consequently the sudden brake can be avoided when coil (2) of brake ECMV is de-energized. q If an abnormality takes place in the electric system, also coil (3) of the sudden stop prevention valve (1) is de-energized. Then, the oil of port (DR) is drained through orifice (a) so that the brake is applied gradually.
D155A-6
43
SEN02863-01
44
10 Structure, function and maintenance standard
D155A-6
10 Structure, function and maintenance standard
Final drive
SEN02863-01
1
Outline q The final drive is a single stage spur gear, single stage planetary gear reduction type. The lubrication is of splash type using the rotation of the gears. The final drive can be removed and installed as a single unit. q Floating seal (1) is installed to the rotating sliding portion of the sprocket to prevent the entry of dirt or sand and to prevent leakage of lubricating oil.
D155A-6
45
SEN02863-01
46
10 Structure, function and maintenance standard
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9.
SEN02863-01
Floating seal Sun gear Carrier Sprocket boss Sprocket teeth Cover Planetary gear Ring gear Cover
10. No.1 pinion 11. Final drive case 12. Bearing cage 13. No.1 gear 14. No.1 gear hub 15. Shaft 16. Wear guard 17. Pivot shaft
Unit: mm No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.25 – 0.77
0.77
18
Backlash between No.1 pinion and No.1 gear
19
Backlash between sun gear and planetary gear
0.20 – 0.55
0.55
20
Backlash between planetary gear and ring gear
0.22 – 0.71
0.71
21
Outside diameter of No.1 pinion oil seal contact surface
22
Thickness of thrust collar of inner body roller bearing
23
Clearance between outer diameter of planet gear shaft and inner diameter of carrier hole. (Small diameter)
24
Clearance between outer diameter of planet gear shaft and inner diameter of carrier hole.(Large diameter)
25
Standard shim thickness for No.1 pinion bearing cage
26
Wear of wear guard
D155A-6
Replace
Standard size
Tolerance
Repair limit
95
–0.087 –0.087
94.913
23 Standard size
Repair or replace
22.95 Tolerance
Shaft
Hole
Standard clearance
Clearance limit
68.262
–0.015 –0.034
–0.009 –0.039
- 0.024 – + 0.025
(Max. Replace clearance) + 0.025
90
–0.036 –0.058
–0.066 –0.101
- 0.065 – - 0.008
2
– 0.008
Adjust
Standard size
Repair limit
67
21
Repair or replace
47
SEN02863-01
10 Structure, function and maintenance standard
Path of power transmission
q
48
The power from the bevel gear shaft and steering clutch is transmitted to 1st pinion (10) to rotate 1st gear (13) meshed with the 1st pinion and sun gear (2) meshed with the 1st gear. The rotation of sun gear (2) is transmitted to planetary gear (7). Since ring gear (8) meshed with the planetary gear is fixed to cover (6), the planetary gear (7) rotates along the ring gear (8) and revolves around the sun gear (2).
Then, the rotating force of sun gear (2) forms the rotating force of carrier (3), which supports the planetary gear (7), via shaft (15), and is transmitted to sprocket boss (4). The rotating direction of carrier (3) is the same with sun gear (2). The rotational force transmitted to sprocket boss (4) is further transmitted to sprocket teeth (5).
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02863-01
49
SEN02863-01
10 Structure, function and maintenance standard
Sprocket
1
Unit: mm No.
Check item
Criteria Standard clearance
Remedy Repair limit
1
Wear of sprocket tooth tip
351
339
2
Wear of sprocket tooth root
21.7
15.5
3
Wear of width of sprocket tooth tip
83
75
4
Wear of width of sprocket tooth root
105
95
50
Rebuid or replace
D155A-6
10 Structure, function and maintenance standard
SEN02863-01
Sprocket tooth shape of full scale
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 04-19(01)
52
D155A-6
SEN02864-00
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
10 Structure, function and maintenance standard
1
Undercarriage and frame Track frame ..................................................................................................................................................... 2 Recoil spring ................................................................................................................................................... 4 Idler ................................................................................................................................................................. 6 Track roller ...................................................................................................................................................... 8 Carrier roller .................................................................................................................................................. 10 Track shoe .................................................................................................................................................... 12 Main frame .................................................................................................................................................... 18 Suspension ................................................................................................................................................... 20
D155A-6
1
SEN02864-00
10 Structure, function and maintenance standard
Track frame
1. 2. 3. 4. 5. 6. 7. 8.
Equalizer bar Pivot shaft Idler Track frame Carrier roller Sprocket Sprocket cover guard Track roller
1
Outline q The track rollers are mounted on an K-shaped bogie. This increases the actual ground contact area between the track shoes and the ground on rough surfaces, and helps increase the drawbar pull. q The K-shaped bogies are equipped with rubber pads to absorb the shock from the ground surface. Track roller, bogie Track roller flange type arrangement 1st
2nd
3rd
4th
5th
6th
7th
S
D
D
D
D
D
S
D: Double S: Single
2
D155A-6
10 Structure, function and maintenance standard
SEN02864-00
Unit: mm No.
4
Check item
Deformation of track frame
D155A-6
Criteria
Remedy
Item
Repair limit
Curvature
7 (over length of 3,000)
Twisting
3 (over length of 300)
Dents (pipe portion)
12
Correct or replace
3
SEN02864-00
Recoil spring
1. Yoke 2. Dust seal 3. Rod 4. Recoil spring 5. Wear ring 6. Lubricator 7. Nut 8. Housing 9. Cylinder 10. Holder 11. Bushing
4
10 Structure, function and maintenance standard
1
Outline q Recoil spring (4) is used to adjust the track tension by pumping in or releasing grease from lubricator (6) to move rod (3) forward or backward. The recoil spring also acts to dampen any sudden shock brought to bear on the idler.
D155A-6
10 Structure, function and maintenance standard
SEN02864-00
Unit: mm No.
Check item
1
Press-fitting force for idler yoke
11
Clearance between rod and bushing
Criteria 392 kN {40 ton} Standard size 110
Tolerance
Recoil spring
D155A-6
Adjust
Shaft
Hole
Standard clearance
Clearance limit
–0.036 –0.090
+0.277 +0.062
0.098 – 0.367
1.0
Standard size 4
Remedy
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
734
597
298 kN {30,388 kg}
687
274 kN {27,900 kg}
Replace
5
SEN02864-00
Idler
6
10 Structure, function and maintenance standard
1
D155A-6
10 Structure, function and maintenance standard
SEN02864-00
Unit: mm No.
C
heck item
Criteria Standard size
Remedy Repair limit
1
Outer diameter of protrusion
850
—
2
Outer diameter of tread
800
781
3
Depth of tread
25
34.5
4
Thickness of tread
21
11.5
5
Overall width
245
—
6
Width of tread
62
—
7
Clearance between shaft and bushing
Standard size 85
8
Interference between idler and bushing
Standard size 135
9
Shaft flange width
10
Play of shaft in axial direction
D155A-6
Tolerance
Rebuild or replace
Shaft
Hole
Standard clearance
Clearance limit
–0.210 –0.260
+0.255 +0.220
0.430 – 0.515
—
Tolerance Shaft
Hole
+0.130 +0.080
+0.100 –0.050
Standard Interference interference limit 0.02 – 0.18
Standard size
Repair limit
–0 20 –0.05
—
Replace bushing
—
Replace
0.49 – 0.72
7
SEN02864-00
Track roller
8
10 Structure, function and maintenance standard
1
D155A-6
10 Structure, function and maintenance standard
SEN02864-00
Unit: mm No.
C
heck item
Criteria
Remedy
Standard size
Repair limit
298
—
282
—
1
Outer diameter of flange (outside flange)
2
Outer diameter of flange (inside flange)
3
Outer diameter of tread
255
230
4
Thickness of tread
60
47.5
5
Overall width
294
—
6
Width of tread (single flange)
64
—
7
Width of tread (double flange)
62
—
8
Flange width (outside of double flange)
25
—
9
Flange width (inside of double flange)
22
—
10
Shaft flange width
20
—
11
Clearance between shaft and bushing
Standard size 85
12
Interference between bushing and roller
Standard size 135
13
End play
D155A-6
Tolerance Shaft
Hole
Standard clearance
–0.210 –0.260
+0.255 +0.220
0.430 – 0.515
Tolerance Shaft
Hole
+0.130 +0.080
+0.063 –0.020
Rebuild or replace
Clearance limit —
Standard Interference interference limit 0.017 – 0.150
Standard size
Clearance limit
0.5 – 0.75
—
Replace bushing
Replace
— Adjust or replace
9
SEN02864-00
Carrier roller
10
10 Structure, function and maintenance standard
1
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
3
Width of tread
63
—
4
Thickness of tread
37.5
26
5
Width of flange
21
6
7
Interference between shaft and ring
Clearance between shaft and support
Standard size 70 Standard size 68
8
Play of roller in axial direction
D155A-6
Rebuild or replace
— Tolerance Shaft
Hole
+0.166 +0.120
+0.030 +0.030
Tolerance Shaft
Hole
–0.2 –0.2
+0.300 +0.030
Standard interference 0.090 – 0.166 Standard clearance
Replace
0 – 0.5
Standard clearance 0.010 – 0.230
11
SEN02864-00
10 Structure, function and maintenance standard
Track shoe
1
Dry type
a
12
P portion shows the link of bushing press fitting end. D155A-6
10 Structure, function and maintenance standard
SEN02864-00
Unit: mm No. 1
2
Check item
Bushing outside diameter Thickness of bushing metal
4
Link height
5
Thickness of link metal (bushing press-fitting portion)
6
Shoe bolt
Interference between bushing and link
Remedy
Standard size
Repair limit
228.9
231.9 (Heavy-duty areas) 233.9 (Standard areas)
Link pitch
3
7
Criteria
When turned
Standard size
Normal load
Impact load
81
75.0
77.0
15.8
9.8
11.8
Standard size
Repair limit
144
128
45.5
29.5
Tightening torque (Nm {kgm})
Additional tightening angle (deg.)
590 ± 60 {60 ± 6}
120 ± 10
Standard size
Tolerance
Reverse or replace
Repair or replace
Retighten
Standard interference
Shaft
Hole
77.0
+0.404 +0.304
+0.074 +0.074
0.230 – 0.404
8a
Interference between regular pin and link
48.5
+0.484 +0.334
–0.038 –0.100
0.372 – 0.584
8b
Interference between master pin and link
48.5
+0.230 +0.200
–0.038 –0.100
0.238 – 0.330
Adjust or replace
Standard clearance 9
Clearance between links
D155A-6
One side
Both side
1.4
2.8
13
SEN02864-00
10 Structure, function and maintenance standard
Sealed and lubricated track
a
14
P portion shows the link of bushing press fitting end.
D155A-6
10 Structure, function and maintenance standard
SEN02864-00
Unit: mm No. 1
2 3
Check item
Thickness of bushing metal Link height
5
Thickness of link metal (bushing press-fitting portion) a. Regular link b. Master link
7
8
Repair limit
228.9
Bushing outside diameter
Shoe bolt
Remedy
Standard size
Link pitch
4
6
Criteria
Interference between bushing and link Interference between regular pin and link
231.9 When turned
Standard size
Normal load
Impact load
81
72.5
75.0
15.8
7.3
9.8
Standard size
Repair limit
144
128
45.5
29.5
Tightening torque (Nm {kgm})
Additional tightening angle (deg.)
590 ± 60 {60 ± 6}
120 ± 10
590 ± 60 {60 ± 6}
180 ± 10 Tolerance
Standard size
Reverse or replace
Repair or replace
Retighten
Standard interference
Shaft
Hole
77.0
+0.404 +0.304
+0.074 +0.074
0.230 – 0.404
48.5
+0.484 +0.334
–0.038 –0.100
0.372 – 0.584
Adjust or replace
Standard clearance 9
Clearance between links
D155A-6
One side
Both side
1.4
2.8
15
SEN02864-00
10 Structure, function and maintenance standard
Single shoe, heavy duty shoe
Unit: mm No. 1
2
16
Check item
Criteria
Remedy
Standard size
Repair limit
single
80
30
heavy duty
80
30
Overall height single of shoe heavy duty
97
47
99
49
Height of grouser
Repair or replace
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02864-00
17
SEN02864-00
Main frame
18
10 Structure, function and maintenance standard
1
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8.
SEN02864-00
Main frame Cage Clamp Cover Seal Coupling Cap Plate Unit: mm
No.
Check item
9
Clearance between equalizer bar shaft and bushing
10
Press-fitting force for equalizer bar shaft mounting bushing
D155A-6
Criteria Standard size 95
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
–0.036 –0.090
+0.213 +0.129
0.165 – 0.303
1.0
29.42 – 68.65 kN {3 – 7 ton}
Replace
Adjust
19
SEN02864-00
Suspension
20
10 Structure, function and maintenance standard
1
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5.
SEN02864-00
Equalizer bar Pivot shaft assembly Cover Thrust plate Thrust plate
6. Pivot shaft 7. Seal cage 8. Seal 10. Side pin 11. Center pin Unit: mm
No.
Check item
Criteria
Remedy
9
Press-fitting force for side pin bushing
27.46 – 64.7 kN {2.8 – 6.6 ton}
12
Press-fitting force for center pin bushing
47.07 – 131.41 kN {4.8 – 13.4 ton}
13
Clearance between center pin and bushing
14
Clearance between side pin and bushing
15
Interference between side pin boss and bushing
16
17
18
Interference between pivot shaft and seal stopper ring Clearance between pivot shaft and bushing (outer) Clearance between pivot shaft and bushing (inner)
— Tolerance
Standard size
Shaft
Hole
Standard clearance
Clearance limit
95
–0.036 –0.090
+0.279 +0.213
0.249 – 0.369
1.0
70
–0.030 –0.060
+0.046 +0.046
0.030 – 0.106
1.0
Standard size
Tolerance
Standard Interference interference limit
Shaft
Hole
130
+0.033 +0.015
–0.028 –0.068
0.043 – 0.101
—
179
+0.083 +0.043
–0.053 –0.093
0.096 – 0.176
—
Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
148
–0.145 –0.208
+0.099 +0.035
0.180 – 0.307
1.0
175
–0.145 –0.208
+0.095 +0.025
0.170 – 0.303
1.0
Replace bushing
Outline q The front of the track frame rocks up and down using the rear pivot shafts (6) as a fulcrum. Equalizer bar (1) rocks using center pin (11) as a fulcrum. The left and right track frames are connected by side pin (10). 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
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
10 Structure, function and maintenance standard
1
Hydraulic system Work equipment hydraulic piping diagram ...................................................................................................... 2 Work equipment control piping diagram ......................................................................................................... 6 Work equipment control .................................................................................................................................. 8 Hydraulic tank and filter ................................................................................................................................ 10 Accumulator .................................................................................................................................................. 13 PPC valve ..................................................................................................................................................... 14 Work equipment lock valve ........................................................................................................................... 26 Control valve ................................................................................................................................................. 28 Work equipment cylinder .............................................................................................................................. 50 Piston valve................................................................................................................................................... 52 Quick drop valve ........................................................................................................................................... 54 Self pressure reducing valve......................................................................................................................... 55
D155A-6
1
SEN02865-05
10 Structure, function and maintenance standard
Work equipment hydraulic piping diagram
1
Semi U-dozer
1. 2. 3. 4.
2
Blade tilt cylinder R.H. blade lift cylinder Accumulator Control valve
5. 6. 7. 8.
Hydraulic tank Hydraulic pump L.H. blade lift cylinder Oil cooler
D155A-6
10 Structure, function and maintenance standard
SEN02865-05
Multi-shank ripper
1. 2. 3. 4.
Control valve Divider block Ripper lift cylinder Ripper tilt cylinder
D155A-6
3
SEN02865-05
10 Structure, function and maintenance standard
Giant ripper
1. 2. 3. 4. 5. 6.
4
Control valve Divider block Ripper lift cylinder Pin puller cylinder Ripper tilt cylinder Pin puller solenoid valve
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02865-05
5
SEN02865-05
10 Structure, function and maintenance standard
Work equipment control piping diagram
1
Blade, ripper control Serial No.: 85001 – 85024
1. 2.
6
Accumulator Control valve
3. 4.
Work equipment lock valve Self pressure reducing valve
D155A-6
10 Structure, function and maintenance standard
SEN02865-05
Serial No.: 85025 and up
1. 2. 3.
Accumulator Control valve Work equipment lock valve
D155A-6
4. 5.
Self pressure reducing valve Filter
7
SEN02865-05
10 Structure, function and maintenance standard
Work equipment control
1
3 4 2 1 5
M
N
AJG00278
8
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5.
SEN02865-05
Work equipment lock lever Blade PPC valve Ripper PPC valve Work equipment lock switch Control valve
Lever positions A : Blade HOLD B : Blade LOWER B + C :Blade FLOAT D : Blade RAISE E : Blade LEFT TILT F : Blade RIGHT TILT G : Ripper HOLD H : Ripper RAISE J : Ripper LOWER K : Ripper DECREASE TIP ANGLE (with variable ripper) L : Ripper INCREASE TIP ANGLE (with variable ripper) M : FREE N : LOCK Outline q The work equipment control employs a PPC system which uses a PPC valve to move the spools of the control valve.
D155A-6
9
SEN02865-05
10 Structure, function and maintenance standard
Hydraulic tank and filter
1
Serial No.: 85001 to 87478
1. 2. 3. 4. 5. 6.
10
Pressure valve Drain valve Drain plug Cover Cover Hydraulic tank
7. Strainer 8. Suction valve 9. Spring 10. Hydraulic filter element 11. Oil filler cap 12. Sight gauge
D155A-6
10 Structure, function and maintenance standard
SEN02865-05
Serial No.: 87479 and up
1. 2. 3. 4. 5. 6.
Pressure valve Drain valve Drain plug Cover Cover Hydraulic tank
D155A-6
7. Strainer 8. Suction valve 9. Spring 10. Hydraulic filter element 11. Oil filler cap 12. Sight gauge
11
SEN02865-05
10 Structure, function and maintenance standard
Specified value Tank capacity Hydraulic tank
Breather
Level inside tank
(l)
125
Hi
(l)
95
Center
(l)
85
Low
(l)
75
Cracking pressure 16.7 ± 2.5 (kPa {kg/cm2}) {0.17±0.025} 2 ± 0.3 Vacuum valve actuating pressure (kPa {kg/cm2}) {0.02±0.003} Cracking pressure (kPa {kg/cm2})
Hydraulic filter
Strainer
12
147 ± 29.4 {1.5±0.31}
Mesh size
(µ m)
20/10/5
Filtering area
(cm2)
13,600
Filtering oil flow
(l/min)
550
Mesh size
(µ m)
105
Filtering area
(cm2)
1,850
D155A-6
10 Structure, function and maintenance standard
Accumulator For EPC valve
1
SEN02865-05
Function q The accumulator is installed between the redusing valve and the EPC valve. Even if the engine is started with the work equipment still raised, the pressure of the nitrogen gas compressed inside the accumulator sends the pilot pressure to the control valve to actuate it and enable the work equipment to move down under its own weight. Operation After the engine is stopped, when the EPC valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B). q When the EPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30 kg/cm2}, and the pressure of the nitrogen gas in chamber (A) expands the bladder, so the oil in chamber (B) acts as the pilot pressure and actuates the main control valve. q
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Gas plug Shell Poppet Holder Bladder Oil port
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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
PPC valve
10 Structure, function and maintenance standard
1
Blade PPC valve
P: From self pressure reducing valve P1: To blade lift valve (LOWER, FLOAT) P2: To blade lift valve (RAISE)
14
P3: To blade tilt valve (LEFT TILT) P4: To blade tilt valve (RIGHT TILT) T: To tank
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5.
Spool Piston Disc Nut (For connecting lever) Joint
D155A-6
SEN02865-05
6. 7. 8. 9.
Plate Retainer Body Filter
15
SEN02865-05
10 Structure, function and maintenance standard
Unit: mm No.
Check item
Criteria Standard size
10
Metering spring (For ports P3 and P4)
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
26.53 x 8.15
24.9
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
11
Centering spring (For ports P3 and P4)
48.57 x 15.5
32.5
107.9 N {11 kg}
—
86.3 N {8.8 kg}
12
Metering spring (For port P2)
26.3 x 8.15
24.1
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
13
Centering spring (For port P2)
43.2 x 15.5
34
78.5 N {8 kg}
—
62.8 N {6.4 kg}
14
Centering spring (For port P1)
34.0 x 15.5
31.9
94 N {9.6 kg}
—
75.3 N {7.68 kg}
15
Metering spring (For port P1)
29.27 x 8.15
25.4
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
16
Replace spring If damaged or deformed.
D155A-6
10 Structure, function and maintenance standard
Operation 1. When in neutral 1) For lifting blade q Ports (A) and (B) of the blade lift valve of thecontrol valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
'
q
For tilting blade Ports (C) and (D) of the blade tilt valve of the control valve and ports (P3) and (P4) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
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SEN02865-05
*
17
SEN02865-05
2. q
q
q
q
q
q
q
18
When in fine control (Neutral o Fine control) If piston (2) is pushed by disc (3), retainer (7) is pushed and spool (1) is also pushed down through metering spring (15). Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port (P1) through fine control hole (f) to port (B). If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously to release the pressure in port (P1). As a result, spool (1) moves up and down to balance the force of metering spring (15) with the pressure in port (P1). The positional relationship between spool (1) and body (8) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (7) comes in contact with spool (1). Since metering spring (15) is compressed in proportion to the stroke of the control lever, the pressure in port (P1) rises in proportion to the stroke of the control lever. Accordingly, the control valve spool moves to a position at which the pressure in port (B) [equal to the pressure in port (P1)] is balanced with the force of the control valve spool return spring.
10 Structure, function and maintenance standard
'
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D155A-6
10 Structure, function and maintenance standard
3. q
q
q
q
When in fine control (When control lever is returned) If disc (3) begins to return, the force of centering spring (14) and the pressure in port (P1) push up spool (1). As a result, fine control hole (f) is connected to drain chamber (D) and the oil in port (P1) is released. If the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (15) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f’) of the valve which is not in operation and then flows through port (P2) into port (A).
SEN02865-05
4. q
q
q
When lever is operated to stroke end If disc (3) pushes down piston (2) and retainer (7) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and pushes the control valve spool. The oil returning from port (A) flows through port (P2) and fine control (f’) into drain chamber (D).
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D155A-6
19
SEN02865-05
10 Structure, function and maintenance standard
5.
6.
q
q
q q
q
q q
When blade is “floated” If piston (2) on the “LOWER” side of port (P1) is pushed down by disc (3), ball (18) touches projection (a) of the piston in the middle of the stroke (The detent starts to operate). If piston (2) is pushed in further, ball (18) pushes up collar (17) supported on detent spring (16) and escapes out to go over projection (a) of the piston. At this time, piston (2') on the opposite side is pushed up by spring (19). As a result, the oil in chamber (F) flows through (b) and (c) to chamber (E) and piston (2') follows disc (3). Since passage (d) is connected to port (P1), almost the same pressure is applied to passage (d) and port (P1). Chamber (E) is normally connected to drain chamber (D). If ball (18) goes over projection (a) of the piston, passage (d) and chamber (E) are connected and the oil starts flowing. At this time, the control valve moves to the “FLOAT” position and the blade is floated. Since piston (2') is pushed up by the pressure in chamber (E), the “FLOAT” state is kept even if the lever is released.
q
When “FLOAT” state of blade is reset Disc (3) is pushed down with a force larger than the oil pressure in chamber (E) to return from the “FLOAT” position. As a result, chamber (E) is disconnected from passage (d) and connected to the drain chamber. Accordingly, the oil pressure in chamber (E) is lost and the “FLOAT” state is reset.
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D155A-6
10 Structure, function and maintenance standard
SEN02865-05
Ripper PPC valve
P P1 P2 P3 P4 T
: From self pressure reducing valve : To ripper tilt valve (OUT) : To ripper tilt valve (IN) : To ripper lift valve (LOWER) : To ripper lift valve (RAISE) : To tank
D155A-6
21
SEN02865-05
22
10 Structure, function and maintenance standard
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9.
SEN02865-05
Spool Piston Disc Nut (for connecting lever) Joint Plate Retainer Body Filter
Unit: mm No.
Check item
Criteria
Remedy
Standard size Centering spring 10 (For ports P3 and P4)
11
Centering spring (For ports P1 and P2)
12 Metering spring
D155A-6
Repair limit
Free length × Outside diameter
Installed length
Installed load
Free length
Installed load
50.35 × 15.5
34
55.9 N {5.7 kg}
—
44.7 N {4.56 kg}
50.05 × 15.5
34
71.4 N {7.28 kg}
—
57.1 N {5.8 kg}
26.53 × 8.15
24.9
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
Replace spring if damaged or deformed.
23
SEN02865-05
10 Structure, function and maintenance standard
Operation 1. When in neutral q Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
q
Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the pressure in port (P1)] is balanced with the force of the control valve spool return spring.
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2. q
q
q
q
q
24
When in fine control (Neutral o Fine control) If piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed down through metering spring (2). Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port (P1) through fine control hole (f) to port (A). If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously to release the pressure in port (P1). As a result, spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1). The positional relationship between spool (1) and body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact with spool (1). Since metering spring (2) is compressed in proportion to the stroke of the control lever, the pressure in port (P1) rises in proportion to the stroke of the control lever.
D155A-6
10 Structure, function and maintenance standard
3. q
q
q
q
When in fine control (When control lever is returned) If disc (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). As a result, fine control hole (f) is connected to drain chamber (D) and the oil in port (P1) is released. If the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (2) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f') of the valve which is not in operation and then flows through port (P2) into chamber (B).
SEN02865-05
4. q
q
q
When lever is operated to stroke end If disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into chamber (A) and pushes the control valve spool. The oil returning from chamber (B) flows through port (P2) and fine control (f') into drain chamber (D).
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D155A-6
25
SEN02865-05
Work equipment lock valve
1. 2. 3.
10 Structure, function and maintenance standard
1
Solenoid Body Spool
Outline q The work equipment lock valve is installed between the basic pressure valve and control valve in the work equipment control circuit. If the work equipment lock lever is set in the FREE position, the work equipment lock switch operates and the work equipment lock valve opens the work equipment control circuit so that the operator can operate the work equipment. Operation q The solenoid is operated by the electric signal to move the spool. As a result, the circuit between port (A) connected to the basic pressure valve and port (B) connected to the control valve is opened.
26
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02865-05
27
SEN02865-05
Control valve
10 Structure, function and maintenance standard
1
General view
28
D155A-6
10 Structure, function and maintenance standard
SEN02865-05
A: Pump pressure pick-up port A1: To blade tilt cylinder head A2: To blade lift cylinder head A3: To ripper lift cylinder head A4: To ripper tilt cylinder bottom B: LS pressure pick-up port B1: To blade tilt cylinder bottom B2: To blade lift cylinder bottom B3: To ripper lift cylinder bottom B4: To ripper tilt cylinder head C: PPC main pressure port LS: To pump LS valve P: From pump PA1: From blade PPC valve PA2: From blade PPC valve PA3: From ripper PPC valve PA4: From ripper PPC valve PB1: From blade PPC valve PB2: From blade PPC valve PB3: From ripper PPC valve PB4: From ripper PPC valve T: To tank
D155A-6
29
SEN02865-05
10 Structure, function and maintenance standard
Sectional view (1/3)
30
D155A-6
10 Structure, function and maintenance standard
1. 2. 3. 4.
Valve block Ripper tilt spool Ripper lift spool Blade lift spool
SEN02865-05
5. 6. 7. 8.
Blade tilt spool Valve body Load check valve Pressure compensation valve Unit: mm
No.
Check item
Criteria Standard size
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
76.3 x 30
68.5
224N {22.8kg}
—
178N {18.2kg}
10 Spool return spring
51.7 x 31.3
50
140N {14.3kg}
—
112N {11.4kg}
11 Spool return spring
54.7 x 36.5
33.5
217N {22.1kg}
—
174N {17.7kg}
12 Load check valve spring
20.8 x 12.2
13.5
12.7N {1.3kg}
—
9.8N {1.0kg}
13 Unload valve spring
86.7 x 30
66
193N {19.63kg}
—
154N {15.7kg}
9
Spool return spring
D155A-6
If damaged or deformed, replace spring
31
SEN02865-05
10 Structure, function and maintenance standard
(2/3)
32
D155A-6
10 Structure, function and maintenance standard
1. 2. 3.
LS check valve Main relief valve LS relief valve
SEN02865-05
4. 5. 6.
Unload valve Suction valve Check valve (built in spool) Unit: mm
No.
Check item
Criteria Standard size
7
Suction valve spring
D155A-6
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
64.9 x 12.5
56
6.37N {0.65kg}
—
5.1N {0.52kg}
If damaged or deformed, replace spring
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 Standard size
4
Suction valve spring
D155A-6
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
46.8 x 7.5
40.6
5.49N {0.56kg}
—
4.41N {0.45kg}
If damaged or deformed, replace spring
35
SEN02865-05
10 Structure, function and maintenance standard
Operation of control valve
$
%
)6
&
'
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)2
*
Function q When the main spool is at the HOLD position, it drains the excess oil discharged by the pump, and prevents the pressure from being formed in the circuit from rising. q Use of the CLSS circuit (Closed Center Load Sensing System) makes it possible to control the oil flow by adjusting the area of opening of the spool driven by the PPC valve, regardless of the load.
q
When (FO) becomes larger than set load (FS) of spring (2), the spool moves to the right and connects the passage between chamber (A) and chamber (B), so the oil from the pump is drained. Therefore, spool (1) is balanced at a position that matches the supply of oil from the pump. Actually, the amount of oil supplied from the pump is small, so the pressure in the circuit is almost the same as the set load of spring (2).
Operation of unload valve q When the main spool is at the HOLD position, the pump pressure passes from chamber (A) through oriffice (4) to chamber (D). Chambers (C) and (C') are connected to the drain circuit. q When oil is supplied from the pump, the pressure in chamber (D) rises, and spool (1) is pushed to the right by pressure (FO) which is determined by the cross-sectional area of piston (3) receiving the pressure.
36
D155A-6
10 Structure, function and maintenance standard
SEN02865-05
Control of oil flow 1. a
At HOLD The diagram shows blade right tilt cylinder circut
7LOW F\OLQGHU 5 +
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Operation q When the spool is at the HOLD position, the pump pressure is sent from chamber (A) through the notch in spool (3) of the pressure compensation valve, and passes through chamber (B) to chamber (C). Chamber (G) is drained through chamber (H) to chamber (F). When this happens, the pump pressure is act-
D155A-6
ing on the left end of spool (3) of the pressure compensation valve, so it pushes against the load of spring (4) and moves to the right to the maximum stroke position. In this condition, the area of the opening to spool (1) of the blade tilt valve is at its minimum.
37
SEN02865-05
2.
10 Structure, function and maintenance standard
At blade right tilt
(
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Operation q When the tilt lever is operated to right tilt, pilot pressure (PB1) acts on the right end of spool (1) through the PPC valve, and when the pressure becomes greater than the set load of spring (2), the spool starts to move to the left. It is balanced at a position corresponding to PPC output pressure (PB1).
38
q q q
PLS = differential pressure between ports (K) and (J) = 1.96 MPa {20kg/cm2} PLS' = differential pressure between ports (I) and (D) PLS C PLS'
D155A-6
10 Structure, function and maintenance standard
q
q
Chamber (C) and chamber (D) are connected, and the oil from the pump flows through ports (A), (B), (C), and (D) to tilt cylinder (6). At the same time, the load pressure in chamber (D) passes through LS orifice (5) and chamber (H), and is sent to chamber (G). It is also sent from the LS circuit (O) to pump servo valve (7). The condition of the pressure of spool (3) is chamber (B) pressure C chamber (C) pressure, and chamber (G) pressure C chamber (D) pressure, so spool (3) is controlled by the differential pressure of spool (1) (chamber (C) pressure – Chamber (D) pressure), and balances 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 direction to increase the oil flow.
D155A-6
SEN02865-05
q
q
In addition, pump servo valve (7) is controlled so that the differential pressure between pump pressure (P) and LS pressure (LS) (LS differential pressure: ( PLS) remains constant, so a suitable amount of oil flows to ensure that the loss of pressure at the control valve ( PLS') is equal to ( PLS). The loss of pressure in the control valve is determined by the area of the opening of the main spool, so the oil flow matches the opening of the spool. The return oil flow from the tilt cylinder passes through chamber (E) and chamber (F), and is drained.
39
SEN02865-05
3.
10 Structure, function and maintenance standard
Meter-out control when blade moves down under its own weight (work equipment lever at LOWER)
/2:(5
( '
%ODGH WLOW 33& YDOYH
3$
$
%
%
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3XPS
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'
/6
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40
D155A-6
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 cylinder is controlled according to the opening area of main spool (1). q
Oil flows from the suction valve (2) to a cylinder so that it prevents the circuit from being evacuated.
q
When a spool port opens with PPC output pressure at (PA2), oil on the cylinder head side passes through ports (A), (B) and (D) and then drains into the tank owing to the weight of the blade. At this time, the opening area between ports (A) and (B) squeezes the return flow from a lift cylinder in order to control the drop speed. In the case where the blade falls owing to the weight of the blade, oil on the cylinder head side passes through a drain circuit and the suction valve (2) and then it is supplied to the cylinder bottom side. At the same time, the output flow from the pump passes through ports (A1), (B1), (C1), (D1) and (E1) and then it is supplied to the cylinder bottom side.
q
D155A-6
41
SEN02865-05
4.
10 Structure, function and maintenance standard
Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)
$
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)/2$7
$ %ODGH WLOW 33& YDOYH
3$
( $
%
%
6HOI SUHVVXUH UHGXFLQJ YDOYH
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3
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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 circuit 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 compound operations with other control valves.
D155A-6
43
SEN02865-05
5. a
10 Structure, function and maintenance standard
At relief (Blade lift, blade tilt, ripper lift, ripper tilt) The diagram shows the condition at relief for work equipment LS relief valve (5) with blade tilt stroke end. /()7 7,/7
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44
P1 = P3 + P4 = Differential pressure between ports (M) and (P) P2 = Differential pressure between ports (P) and (N) P3 = Differential pressure between ports (M) and (B)
q q
P4 = Differential pressure between ports (B) and (P) LS = P1 + P2 = Differential pressure between ports (M) and (N) = 1.96 MPa {20 kg/ cm2}
D155A-6
10 Structure, function and maintenance standard
SEN02865-05
Operation q If blade tilt valve (1) is moved, and the pressure 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 chamber (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 pressure ( LS). When this happens, pump LS valve (6) detects the differential pressure generated 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 + leakage 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
6. a
10 Structure, function and maintenance standard
Compound operation of work equipment valve The diagram shows the condition when the blade lift and tilt valves are operated at the same time.
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46
D155A-6
10 Structure, function and maintenance standard
q
It consists of a parallel circuit, so when compound operations are carried out, the oil flow is divided according to the size of each spool opening.
q
Tilt spool (1) and lift spool (2) are actuated by PPC valve output pressure (PA1) and (PB2), and each is balanced at a position that matches its own pilot pressure.
1) q
SEN02865-05
When pump pressure (P2) Z (P3) Lift valve load pressure (P3) is sent to pump LS valve (4) through LS passage (O). (1) When pump swash plate does not reach maximum angle q When the maximum flow of oil from the pump is greater than the total of the oil flow demanded by the tilt valve and lift valve, an oil flow that matches the opening of the spool flows to both the tilt valve and lift valve. (2) When pump swash plate is at maximum angle q When the maximum flow of oil from the pump is smaller than the total of the oil flow demanded by the tilt valve and lift valve, the flow of oil to the tilt valve and lift valve is divided according to differential pressure (PO) – (P2) and differential pressure (PO) – (P3). In other words, more oil flows to (P2) where the load is small. q
2) q
In cases where the blade is raised in the air and the tilt valve and lift valve (for raise) are operated at the same time, the tilt valve load pressure is smaller than the lift valve load pressure, so the flow of oil to the tilt valve is given priority. In addition, the oil flow demanded by the tilt valve is smaller, so the condition is just as if priority was given to the oil flow for the tilt valve.
When pump pressure (P2) = pump pressure (P3) (P) – (P2) C (P) – (P3), so an oil flow proportional to the size of the spool opening is distributed to each spool.
D155A-6
47
SEN02865-05
7. a
10 Structure, function and maintenance standard
Unload valve preset system The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is operated.
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48
D155A-6
10 Structure, function and maintenance standard
q
This improves the response of the system including the pump swash plate and pressure compensation valve by sending the pilot pressure (basic pressure of PPC valve) to the LS circuit, and compensating the rise of the LS circuit pressure.
q
When lift spool (1) is at the HOLD position, pilot pressure (P1) (basic pressure of PPC valve) is sent through preset check valve (3) to the chamber (F) of the pressure compensation valve. This pressure is called preset pressure (P2). At the same time, unload pressure (P) is being sent to chamber (B), but (P1) + (FO) > (P) ((FO): load of spring (4)), so pressure compensation spool (2) moves to the left and the size of the opening between (A) and (B) becomes the maximum.
q
When spool (1) is switched, unload pressure (P) flows immediately through chamber (A), (B), (C), (D), and (E) to lift cylinder (8), so the pressure at the port starts to rise and the time lag becomes smaller.
q
At the same time, preset pressure (P2) is supplied to LS circuit (O) by the timing of the spool, and the pressure in the LS circuit rises. Because of this, unload valve (7) closes, and oil is sent further to pump LS valve (6) to improve the response of the pump swash plate angle. This makes it possible to reduce the response time for giving the necessary oil flow. Check valve (5) is built in the spool to prevent preset pressure (P2) from venting in force from the cylinder port.
q
When cylinder port pressure (P3) rises and becomes greater than preset pressure (P2), it pushed up check valve (5), and oil is sent to chamber (F) of the pressure compensation valve and pump LS valve (6) to give the basic ( PLS) control. When this happens, pressure (P3) at the cylinder port is prevented from entering the PPC pump circuit by preset check valve (3).
D155A-6
SEN02865-05
49
SEN02865-05
Work equipment cylinder
10 Structure, function and maintenance standard
1
Blade lift cylinder
Blade tilt cylinder
Ripper cylinder
a
The piping of the lift cylinder and tilt cylinder of the variable multi-shank ripper is different from the above.
50
D155A-6
10 Structure, function and maintenance standard
SEN02865-05
Unit: mm No.
Check item
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
75
-0.030 -0.076
+0.279 +0.065
0.095 – 0.355
0.666
90
-0.036 -0.090
+0.270 +0.061
0.097 – 0.330
0.695
100
-0.036 -0.090
+0.257 +0.047
0.105 – 0.375
0.675
Ripper TILT
110
-0.036 -0.090
+0.261 +0.047
0.105 – 0.375
0.675
2
Clearance between piston rod support shaft and blade ball portion
Blade LIFT
85
—
+0.3 +0.3
—
1.0
3
Clearance between cylinder support shaft and bushing
Blade LIFT
85
-0.100 -0.174
—
0.100 – 0.228
0.5
4
Clearance between piston rod spherical surface and cap
Blade TILT
115
-0.200 -0.300
—
—
—
60
-0.030 -0.050
+0.174 +0.100
0.130 – 0.224
1.0
5
Blade TILT Clearance between cylinder bottom sup- Ripper port shaft and bush- LIFT ing Ripper TILT
90
-0.036 -0.090
+0.207 +0.120
0.156 – 0.297
1.0
100
-0.036 -0.090
+0.201 +0.119
0.156 – 0.291
1.0
Ripper LIFT
90
-0.036 -0.090
+0.207 +0.120
0.156 – 0.297
1.0
Ripper TILT
100
-0.036 -0.090
+0.201 +0.119
0.156 – 0.291
1.0
Blade LIFT
1
6
Clearance between piston rod and bush- Blade TILT ing Ripper LIFT
Clearance between cylinder rod support shaft and bushing
D155A-6
Replace
51
SEN02865-05
10 Structure, function and maintenance standard
Piston valve
1
For blade lift cylinder Outline q The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches its stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston. When the blade is tilted, the blade is subject to a tortional force owing to the uneven position of the pistons in the two cylinders; that is the piston on one side is still moving while the piston on the other side has reached its stroke end. The piston valves are installed to prevent the tortional force from occurring. When one of the pistons reaches its stroke end, its piston valve opens to relieve the oil pressure. In addition the piston valve relieves the shock which occurs when the piston comes into contact with the cylinder head or the bottom and serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape from the cylinder before the piston reaches its stroke end.
2.
Piston valve OPEN Just before piston rod (1) reaches the end of its stroke, the tip of valve (6) contacts the cylinder bottom, so valve (6) and piston valve (3) stop at that position and do not move further. Only piston (2) moves further. When this happens, the oil at the cylinder head, which was sealed by piston valve (3), escapes from piston valve seats (4) and (5), and the pressure inside the cylinder stops rising.
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*
Operation 1. Piston valve CLOSED Pressurized oil from the hydraulic pump acts on piston (2) and piston valve (3). The piston valve (3) is pushed in the direction of the arrow until piston valve seat (4) comes into snug contact with the tapered section, thereby, this causing the pressure in the cylinder to rise and moving piston (2) in the direction of the arrow.
52
*
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02865-05
53
SEN02865-05
Quick drop valve
10 Structure, function and maintenance standard
1
(Blade lift cylinder) Structure The quick drop valve consists of valve body (1), spool (2), check valve (3), and spring (4). The quick drop valve serves to increase the blade lowering speed and to reduce the occurrence of vacuum when the blade is lowering, thereby shortening the time lag before digging is started. The blade lowering speed, which is generally determined by the pump discharge, can be made faster with the quick drop valve.
%
$
2.
1. 2. 3. 4.
Valve body Spool Check valve Spring
Operation 1. Start of lowering When the blade lever is operated to LOWER, the oil from the control valve enters the cylinder 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).
&
*
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 orifice (a) provided along the way, causing a differential pressure before and after the orifice. When the differential pressure becomes greater than the force of spring (4), it compresses 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 head to tank enters the passage to the cylinder bottom together with the oil from the control valve. Thus, the blade lowering speed increases in accordance with the amount of oil that flows to the bottom of the cylinder and reduces the formation of vacuum at the bottom of the cylinder.
% D
$
&
*
54
D155A-6
10 Structure, function and maintenance standard
Self pressure reducing valve
SEN02865-05
1
T: To hydraulic tank P1: From cooling fan pump P2: To cooling fan motor PR: Supply to PPC valve and EPC valve
D155A-6
55
SEN02865-05
10 Structure, function and maintenance standard
1. 2. 3. 4.
5. 6.
Sequence valve Valve Filter Screw
Poppet Ball
Unit: mm No.
Check item
Criteria
Remedy
Standard size 7
Valve return spring
Repair limit
Free length Installation x outer length diameter
Installation load
Free length
Installation load
70.9 x 18
56
250 N {25.5 kg}
—
200 N {20.4 kg}
8
Ball return spring
16.1 x 7.8
13.4
61.8 N {6.3 kg}
—
49.0 N {5.0 kg}
9
Valve return spring
19.2 x 7.2
16.1
19.6 N {2.0 kg}
—
15.7 N {1.6 kg}
56
If damaged or deformed, replace spring
D155A-6
10 Structure, function and maintenance standard
SEN02865-05
Operation At engine stop (total low pressure)
33& YDOYH
)DQ SXPS 6HUYR
(3& YDOYH
3
)DQ PRWRU
3
35
7
*
q
q
q
Spring (6) pushes the poppet (5) to the seat, and the circuit between ports (PR) and (T) is closed. Spring (7) pushes valve (8) to the left side, and the circuit between port (P1) and port (PR) is open. Spring (3) pushes the valve (2) to the upper side, and the circuit between ports (P1) and (P2) is closed.
Function q The self pressure reducing valves reduce the discharge pressure of the fan pump and supplies it to the PPC valve, the EPC valve, etc. as the control pressure.
D155A-6
57
SEN02865-05
2.
10 Structure, function and maintenance standard
When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve.
33& YDOYH
)DQ SXPS 6HUYR
(3& YDOYH
3
35
3
7
G
)DQ PRWRU
D
*
q
q
58
The spring (3) and the (PR) pressure (0 MPa {0 kg/cm2} at the time of engine stop) pushes the valve (2) in the direction to close the circuit between the ports (P1) and (P2). When the hydraulic oil enters the (P1) port, the expression ((P1) pressure Spring (7) force + (ø(d) area x (PR) pressure)) holds, and the self pressure reducing valve will adjust the openings of the ports (P1) and (P2) so that the (P1) pressure can be maintained higher than the (PR) pressure. 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 poppet (5) opening to the tank port (T).
q
Therefore, there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port (P1) and the (PR) opening. Then, the (P1) pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the (PR) pressure.
D155A-6
10 Structure, function and maintenance standard
3.
SEN02865-05
At raise of load pressure P2
33& YDOYH
)DQ SXPS 6HUYR
(3& YDOYH
3
35
3
7
G
)DQ PRWRU
D
* q
When the load pressure (P2) rises due to digging or other operations, the pump delivery will increase and the (P1) pressure will rise. Then, the expression ((P1) pressure > Spring (7) force + ( (d) area x (PR) pressure)) will hold, and the valve (2) will move to the right side till the stroke end. As a result, the opening between the ports (P1) and (P2) will increase, the passage resistance will become smaller to reduce engine loss horsepower.
D155A-6
q
q
When the (PR) pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil will flow through the route from the (PR) port, the hole (a) in the spool (8), the poppet (5) opening to the tank port (T). Therefore, there will occur a differential pressure around the hold (a) in the spool (8) and the spool will move in the direction to close the port (P1) and the (PR) opening. Then, the (P1) pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the (PR) pressure.
59
SEN02865-05
4.
10 Structure, function and maintenance standard
At occurrence of abnormal high pressure
33& YDOYH
35
7
* q
60
When the (PR) pressure of the self pressure reducing valve rises abnormally high, the ball (10) will separate from the seat against the spring (9) force to flow the hydraulic oil to the output ports (PR) (T) so as to reduce the (PR) pressure. Then, the equipment (PPC valve, etc.), to which the oil pressure is supplied, is protected from the abnormal high pressure.
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02865-05
61
SEN02865-05
10 Structure, function and maintenance standard
D155A-6 Bulldozer Form No. SEN02865-05
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
62
D155A-6
SEN02866-02
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
10 Structure, function and maintenance standard
1
Work equipment Cylinder stay ................................................................................................................................................... 2 Blade............................................................................................................................................................... 4 Cutting edge, end bit....................................................................................................................................... 6 Ripper ............................................................................................................................................................. 8
D155A-6
1
SEN02866-02
Cylinder stay
1. 2. 3. 4. 5.
2
10 Structure, function and maintenance standard
1
Yoke Dust seal Bushing Bushing Grease nipple
D155A-6
10 Structure, function and maintenance standard
SEN02866-02
Unit: mm No.
6
Check item Clearance between cylinder yoke and bushing
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
125
–0.172 –0.235
+0.063 +0.046
0.172 – 0.298
— Replace
7
Clearance between cylinder yoke and bushing
100
–0.170 –0.224
+0.054 +0.046
0.170 – 0.278
—
8
Clearance between bushing of cylinder support shaft and yoke
110
–0.172 –0.035
+0.054 +0.046
0– 0.089
0.5
D155A-6
3
SEN02866-02
Blade
10 Structure, function and maintenance standard
1
Sigma-tilt dozer, semi-U blade
4
D155A-6
10 Structure, function and maintenance standard
SEN02866-02
Sigma-tilt, semi-U blade common parts mark Unit: mm No.
1
Check item Clearance between brace and pin
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
60
–0.3 –0.5
+0.174 +0.100
0.4 – 0.674
2
2
Clearance between brace pin and bracket
60
–0.3 –0.5
+0.5 +0.2
0.5 – 1.0
2
3
Clearance between brace spherical surface and cap
115
–0.2 –0.3
+0.3 +0.6
0.2 – 0.6
1
4
Clearance between brace pin and bracket
90
–0.3 –0.5
+0.3 +0.1
0.4 – 0.8
2
5
Clearance between brace pin and brace
90
–0.3 –0.5
+0.5 +0.3
0.6 – 1.0
2
6
Clearance between joint and blade bracket
140
–0.2 –0.7
+0.5 +0.3
0.5 – 1.2
2
7
Clearance between frame pin and joint
70
–0.5 –0.6
+0.3 +0.6
0.5 – 0.9
3
8
Clearance between blade bracket pin and blade bracket
70
–0.5 –0.6
+0.3 +0.6
0.5 – 0.9
3
9
Clearance between blade bracket pin and joint
70
–0.5 –0.6
+0.3 +0.6
0.5 – 0.9
3
10
Clearance between center brace spherical surface and cap
165
–0.2 –0.3
+0.3 +0.6
0.2 – 0.6
1
11
Clearance between trunnion spherical surface and cap (Left)
160
–0.5 –1.0
+0.5 +0.0
0.5 – 1.5
8
12
Clearance between trunnion spherical surface and cap (Right)
195
–0.5 –1.0
+0.5 +0.0
D155A-6
Replace
Adjust shims or replace
Replace
Adjust shims or replace
Replace 0.5 – 1.5
8
5
SEN02866-02
10 Structure, function and maintenance standard
Cutting edge, end bit
1
For semi-U blade
Unit: mm No.
Check item
1
Height of outside of end bit
2
Width of end bit
3 4
6
Criteria
Remedy
Standard size
Repair limit
315
235
540
440
Height of inside of end bit
254
215
Height of cutting edge
254
215 (175 to turning)
Replace
Turn or replace
D155A-6
10 Structure, function and maintenance standard
SEN02866-02
For sigma-tilt blade
Unit: mm No.
Check item
1
Height of cutting edge
2
Height of outside of end bit
3 4
Criteria
Remedy
Standard size
Repair limit
330
260 (215 to turning)
300
235
Height of inside of end bit
330
260
Width of end bit
640
500
D155A-6
Turn or replace
Replace
7
SEN02866-02
Ripper
10 Structure, function and maintenance standard
1
Variable multi-shank ripper
8
D155A-6
10 Structure, function and maintenance standard
SEN02866-02
Unit: mm No.
Check item
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
110
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.5
Clearance between arm mounting pin and bushing
110
–0.036 –0.090
+0.529 +0.463
0.499 – 0.619
1.5
Clearance between tilt cylin3,9 der mounting pin and mounting bracket or beam bracket
100
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.5
Clearance between tilt cylinder mounting pin and bushing
100
–0.036 –0.090
+0.201 +0.119
0.155 – 0.291
1.5
Clearance between lift cylinder 5,11 mounting pin and mounting bracket or beam bracket
90
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.5
Clearance between lift cylinder 6,12 mounting pin and shank bushing
90
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.5
13
Clearance between shank mounting pin and shank holder
Shaft 80 Hole 82
+0.300 –0.300
+0.300 –0.300
1.400 – 2.600
10.0
14
Clearance between shank mounting pin and shank hole
Shaft 80 Hole 88
+0.300 –0.300
+1.000 –1.000
3.700 – 6.300
15.0
15
Wear of point
16
Wear of protector
Clearance between arm 1,7 mounting pin and mounting bracket or beam bracket 2,8
4,10
D155A-6
Standard size
Standard size
Repair limit
335
225
75
50
Replace
9
SEN02866-02
10 Structure, function and maintenance standard
Unit: mm No.
Item
Criteria Standard dimension
a
Wear of ripper shank L = 2.6
10
Repair limit
L>0
Judging method
Remedy
With ripper shank lowered to ground, and without backlash between point and shank, measure minimum clearance (L) between ripper point and point fixing pin. If minimum clearance (L) is 0 [mm] and ripper point is in contact with fixing pin, modify according to remedy at right.
Replace ripper shank or repair ripper shank end
D155A-6
10 Structure, function and maintenance standard
SEN02866-02
Variable giant ripper
D155A-6
11
SEN02866-02
10 Structure, function and maintenance standard
Unit: mm No.
Check item
Criteria
Remedy
Shaft
Hole
Standard clearance
Clearance limit
110
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.5
Clearance between arm mounting pin and bushing
110
–0.036 –0.090
+0.529 +0.463
0.499 – 0.619
1.5
Clearance between tilt cylin3,9 der mounting pin and mounting bracket or beam bracket
100
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.5
Clearance between tilt cylinder mounting pin and bushing
100
–0.036 –0.090
+0.201 +0.119
0.155 – 0.291
1.5
Clearance between lift cylinder 5,11 mounting pin and mounting bracket or beam bracket
90
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.5
Clearance between lift cylinder 6,12 mounting pin and shank bushing
90
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.5
13
Clearance between shank mounting pin and shank holder
Shaft 75 Hole 77
+0.300 –0.300
+0.300 –0.300
1.400 – 2.600
10.0
14
Clearance between shank mounting pin and shank hole
Shaft 75 Hole 80
+0.300 –0.300
+1.000 –1.000
3.700 – 6.300
15.0
15
Wear of point
16
Wear of protector
Clearance between arm 1,7 mounting pin and mounting bracket or beam bracket 2,8
4,10
12
Standard size
Tolerance
Standard size
Repair limit
335
225
75
50
Replace
D155A-6
10 Structure, function and maintenance standard
SEN02866-02
Unit: mm No.
Item
Criteria Standard dimension
a
Repair limit
Wear of ripper shank L = 2.6
D155A-6
L>0
Judging method
Remedy
With ripper shank lowered to ground, and without backlash between point and shank, measure minimum clearance (L) between ripper point and point fixing pin. If minimum clearance (L) is 0 [mm] and ripper point is in contact with fixing pin, modify according to remedy at right.
Replace ripper shank or repair ripper shank end
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
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
10 Structure, function and maintenance standard
1
Cab and its attachments Cab mount + ROPS pin .................................................................................................................................. 2 ROPS cab ....................................................................................................................................................... 3 ROPS floor...................................................................................................................................................... 4 Air conditioner ................................................................................................................................................. 5
D155A-6
1
SEN02867-00
Cab mount + ROPS pin
10 Structure, function and maintenance standard
1
Cab spec.
1. 2. 3. 4. 5.
2
Support Damper mount (front) Damper mount (rear) ROPS pin (front) ROPS pin (rear)
Outline q Viscous mounts are installed at two places at the front and two places at the rear to secure the floor frame and cab. q An oil-filled damper mount is used to absorb the vibration. q The ROPS pins are installed to 2 places each at the front and rear sections to fix the ROPS (built in the cab) when the machine rolls over.
D155A-6
10 Structure, function and maintenance standard
ROPS cab
SEN02867-00
1
Cab assembly
1. 2. 3. 4. 5.
Front wiper Front glass Rear wiper Door ROPS sub (built in CAB)
D155A-6
3
SEN02867-00
ROPS floor
10 Structure, function and maintenance standard
1
Cab less spec.
1.
4
ROPS floor
D155A-6
10 Structure, function and maintenance standard
SEN02867-00
Air conditioner
1
Air conditioner piping
1. 2. 3. 4. 5. 6. 7. 8. 9.
Condenser Hot water return piping Hot water pick-up piping Front window defroster Side window defroster Air outlet for face Air outlet for center Air outlet for rear Air conditioner unit
D155A-6
10. Air outlet for foot 11. Receiver tank 12. Refrigerant piping 13. Valve (hot water outlet) 14. Air conditioner compressor 15. Valve (hot water inlet) A: B:
Fresh air Recirculated air
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
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
10 Structure, function and maintenance standard
1
Electrical system Engine control ................................................................................................................................................. 2 Engine control system..................................................................................................................................... 3 Deceleration potentiometer............................................................................................................................. 4 Monitor system................................................................................................................................................ 6 Sensors......................................................................................................................................................... 25 Palm command control system..................................................................................................................... 28 KOMTRAX system........................................................................................................................................ 31
D155A-6
1
SEN02868-02
Engine control
1. 2. 3. 4. 5. 6. 7. 8. 9.
2
Decelerator pedal Decelerator potentiometer Starter switch Fuel control dial Battery relay Battery Power train controller Starter Fuel supply pump
10 Structure, function and maintenance standard
1
Outline q The throttle signals of the fuel control dial are sent to the power train controller and processed together with the 3rd throttle signal, and then sent as the throttle commands together with the throttle signals of the decelerator pedal to the engine throttle controller. The engine throttle controller controls the engine according to the commands.
D155A-6
10 Structure, function and maintenance standard
SEN02868-02
Engine control system
Outline q The engine throttle controller receives the fuel control dial signal of the 1st throttle, decelerator pedal signal of the 2nd throttle, and 3rd throttle signal which is the control signal from the power train controller, and then controls the fuel supply pump according to the command signal having the lowest engine speed. The control signals of the 3rd throttle are as follows. (1) Auto deceleration (F3, R3, F2, R2) (2) Neutral deceleration q The power train controller calculates a proper engine speed from information items (1), (2), etc. and sends it as the 3rd throttle signal to the engine throttle controller.
D155A-6
1
q
q
q
The information of the engine throttle controller is possessed jointly by the other controllers through the network and used for the optimum control of the engine and machine body. The auto deceleration is a function of setting the engine speed low temporarily when the travel direction is changed from F3, R3, F2, and R2 (to protect the transmission clutch). The neutral deceleration is a function of limiting the high idle speed when the transmission is set in neutral.
3
SEN02868-02
Deceleration potentiometer
1. 2. 3. 4. 5. 6. 7.
4
Connector Lever Body Potentiometer Cuppling Shaft Stopper
10 Structure, function and maintenance standard
1
Outline q The deceleration potentiometer is installed to the inside of the dashboard and connected to the decelerator pedal by linkage. q If the decelerator pedal is pressed, it rotates the throttle potentiometer shaft through the linkage and the potentiometer resistance changes. Constant voltage is applied between pins (A) and (C) of the potentiometer and a voltage signal is sent through pin (B) to the engine controller according to the position of the decelerator pedal.
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02868-02
5
SEN02868-02
10 Structure, function and maintenance standard
Monitor system
q
6
The monitor system monitors the machine condition with the sensors installed to various parts of the machine and processes and displays the obtained information on the panel quickly to notify the operator of the machine condition. The main display sections and functions of the panel are as follows. 1) Monitor unit which turns on the alarm when the machine has a trouble. 2) Gauge unit which constantly displays the machine condition (coolant temperature, torque converter oil temperature, fuel level, etc.) 3) Function of displaying error codes. 4) Function of monitoring the current and voltage of the sensors and solenoids,
1
q
The CPU (Central Processing Unit) in the monitor panel displays and outputs various information items processed by the power train controller. The display unit is LCD (Liquid Crystal Display)
D155A-6
10 Structure, function and maintenance standard
SEN02868-02
Processing in machine monitor (Common to all specifications) Display of machine monitor Contents and conditions of processing 1. Display of travel direction and gear speed. • F1, R3, etc. are notified by CAN according to information of power train controller.
Method
Flow of signals
CAN
2. Display of gauges of fuel level, engine coolant temperature, etc. • Controller converts the sensor signals into gauge CAN numbers and sends them to the machine monitor by CAN. 3. Display of trouble • When the machine has a trouble, the corresponding failure code is notified to the machine monitor by CAN. • Which one should be turned on, the buzzer or the caution lamp, is notified, too. 1) In normal state User code, service code CAN 2) In trouble history display mode The service code (6-digit code) and the following items are displayed • Time after first occurrence • Time after latest occurrence • Number of past occurrences The machine monitor displays the code.
Each sensor/solenoid-controllermachine monitor
Display of monitoring condition Contents and conditions of processing
Method
1. The communication conditions of each sensor, each solenoid, and CAN are displayed. • The item Nos. and device conditions are notified to CAN the machine monitor by CAN. • The machine monitor displays the items and each value.
Flow of signals
Each sensor-controller-machine monitor
2. Each items is selected by using the cursor switches and CAN confirmation switch.
Other items 01 02 03 04 05 06 07 08 09 10 11 12 13 88 89
a
Contents and conditions of processing Monitoring Trouble history Maintenance history Maintenance mode change Telephone number set Default Adjustment PM clinic Reduced cylinders mode operation No injection cranking Fuel consumption display — Service message display Screen adjustment a —
Method
Flow of signals
–
–
See testing and adjusting, special functions of machine monitor.
D155A-6
7
SEN02868-02
10 Structure, function and maintenance standard
Machine monitor
Outline q The machine monitor has the functions to display various items and the functions to select modes and electric parts. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The monitor display employs an LCD (Liquid Crystal Display). The switches are flat sheet switches.
8
Precautions on the machine monitor display q The liquid crystal display panel may have black spots (which do not light up) or bright spots (which stay on). Products having 10 or less black or bright spots conform the product specification; such the condition is quite normal. q Battery voltage may suddenly drop at enginestart due to ambient temperature or the condition of the battery. The machine monitor display may temporarily disappear if it happens; it is quite normal. q Continuous operation of the machine monitor may display blue bright spots on the screen having a black background; it is quite normal. The screen normally displayed on the monitor has a blue or white background. For this reason, blue spots will not cause any problem (since the liquid crystal lights up red, blue, and green spots when displaying white).
D155A-6
10 Structure, function and maintenance standard
Input and output signals
Input/ output 1 Battery power (+24V constantly) Input 2 Battery power (+24V constantly) Input 3 Battery power GND — 4 Battery power GND — Input/ 5 Wake-up Output 6 Relay output Output 7 Chassis signal GND — 8 Hydraulic oil pressure — 9 Fuel level Input 10 NC(*) — 11 Charge amount Input 12 Chassis analog signal GND — 13 Light switch Input 14 Key switch (ACC) Input 15 Key switch (C) Input 16 Preheating Input 17 NC(*) — 18 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Signal name
CN-CM02 Input/ output 1 NC(*) — 2 NC(*) — 3 Coolant level sensor Input 4 NC(*) — 5 NC(*) — 6 NC(*) — 7 Chassis signal GND — 8 CAN terminating resistance — Input/ 9 CAN_H Output Input/ 10 CAN_L Output 11 NC(*) — 12 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.
CN-CM03 Pin No.
CN-CM01 Pin No.
SEN02868-02
Signal name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Input/ output RS232C CD for communication terminal Input RS232C RXD for communication terminal Input RS232C SG for communication terminal — Signal name
Signal GND for communication terminal — control Communication terminal selection signal Input RS232C RTS for communication terminal Output RS232C TXD for communication terminal Output RS232C DTR for communication terminal Output RS232C DTR for communication terminal Input RS232C CTS for communication terminal RS232C RI for communication terminal Power GND for communication terminal Input CH1 for communication terminal status Output for communication terminal power control Output CH1 for communication terminal control Output CH2 for communication terminal control Input CH2 for communication terminal status Electric power supply for communication terminal
Input Input — Input Output Output Output Input Output
CN-CM04 Input/ output 1 NC(*) — 2 NC(*) — 3 NC(*) — 4 NC(*) — 5 NC(*) — 6 NC(*) — 7 NC(*) — 8 NC(*) — 9 NC(*) — 10 NC(*) — 11 NC(*) — 12 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
CN-CM05 Pin No. 1 2 3 4 5 6 7 8
D155A-6
Input/ output Electric power supply for camera Output Camera NTSC signal input 1 Input Camera NTSC signal input 2 Input Camera NTSC signal input 3 Input Electric power supply GND for camera — Camera signal GND1 — Camera signal GND2 — Camera signal GND3 — Signal name
9
SEN02868-02
10 Structure, function and maintenance standard
Monitor control, display portion
1. 2. 3. 4. 5. 6. 7. 8.
10
Gear shift mode selector switch Buzzer cancel switch Working mode selector switch Engine coolant temperature Multi gauge Pilot display Service meter, clock Hydraulic mode display
9. Fuel level 10. Travel gear speed gear shift mode preset 11. Guidance icon 12. Function switch 13. Custom switch 14. Custom memory switch 15. Air conditioner switch
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02868-02
11
SEN02868-02
10 Structure, function and maintenance standard
Machine monitor display
Check
Display category
Symbol
Display item
Displays when engine is stopped and starting switch is ON Display when normal: OFF Display when abnormal: ON
Below low level
Engine oil pressure
When sensor is abnormal Display when normal: OFF or when wiring harness is Display when abnormal: ON disconnected
Battery charge
Displays when starting switch is ON and engine is running When charge is defective Display when normal: OFF Display when abnormal: ON CAUTION lamp flashes
Engine oil pressure
Below 49.0kPa {0.5kg/cm2}
Radiator coolant level
Below low level
Caution
Torque converter oil temperature
Pilot
Display method
Radiator coolant level
Engine coolant temperature
12
Display range
When at highest level on engine coolant temperature gauge Above 102°C: Symbol ON Above 105°C: Symbol ON + buzzer When at highest level on engine coolant temperature gauge Above 120°C: Symbol ON Above 130°C: Symbol ON + buzzer
Hydraulic oil temperature
Above 100°C: Symbol ON Above 110°C: Symbol ON + buzzer
Maintenance
When replacement time of filter or oil has been passed
Preheating
When preheating
Displays when starting switch is ON and engine is running Display when normal: OFF Display when abnormal: ON Alarm buzzer sounds
Lights according to required time determined by engine controller based. It also lights at the time of manual preheat by setting starting switch at preheat position (turning it counterclockwise).
D155A-6
10 Structure, function and maintenance standard
Display category
Symbol
Display item
SEN02868-02
Display range
Display method
Engine coolant temperature
Gauges
Torque converter oil temperature
Indicative applicable temperature
Hydraulic oil temperature
Fuel level
Service meter (Hours meter)
D155A-6
Indicative applicable level
From 0 to 99999
Actuated when the engine is rotating
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. Gauge
Engine coolant temperature (°C)
Power train oil temperature (°C)
Hydraulic oil temperature (°C)
Fuel level (l)
14
Range A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 C1 C2 C3 C4 C5 C6 D1 D2 D3 D4 D5 D6
Temperature or volume 105 102 100 85 60 30 130 120 118 90 50 0 110 100 98 70 20 0 565 425 310 220 150 75
Indicator
Buzzer sound
Red Red Off Off Off White Red Red Off Off Off White Red Red Off Off Off White Off Off Off Off Off Red
Q
Q
Q
D155A-6
10 Structure, function and maintenance standard
Machine speed
1. 0 km/h 2. 5 km/h
Battery voltage
3. 10 km/h 4. 15 km/h
Hydraulic oil pressure
1. 0 MPa 2. 10 MPa 3. 20 MPa
D155A-6
1. 0 V 2. 17 V 3. 20 V
4. 25 V 5. 30 V 6. 31 V
Engine speed
4. 30 MPa 5. 40 MPa 6. 50 MPa
Engine oil pressure
1. 0.0 MPa 2. 0.2 MPa 3. 0.3 MPa
SEN02868-02
1. 500 rpm 2. 1,000 rpm 3. 1,500 rpm
4. 2,000 rpm 5. 2,500 rpm 6. 3,000 rpm
Drawbar pull
4. 0.4 MPa 5. 0.5 MPa 6. 0.7 MPa
1. 0 W 2. 0.2 W 3. 0.4 W
4. 0.6 W 5. 0.8 W 6. 1.0 W
15
SEN02868-02
10 Structure, function and maintenance standard
Guidance icon and function switch The function switches differ depending on the screen display. Each guidance icon shows the function of the switch below it. Switches with no guidance icon are disabled. The functions shown by the guidance icons are as shown in the table below. Symbol
16
Switch
Item
Function
F6
Enter
Enters selected/set item.
F5
Return
Returns to previous screen.
F4
Select service meter/clock
Selects service meter and clock alternately.
F5
Select maintenance screen
Selects maintenance screen.
F6
Select user mode screen
Selects user mode screen.
F3
Select item
Selects item on left side (Selects right end item after left end item).
F4
Select item
Selects item on right side (Selects left end item after right end item).
F3
Select item
Selects item on lower side (Selects top item after bottom item)/Resets holding of monitoring.
F4
Select item
Selects item on upper side (Selects bottom item after top item)/Holds monitoring.
F1
Select item
Selects page on lower side (Selects top page after bottom page).
F2
Select item
Selects page on upper side (Selects bottom page after top page).
F2
Return to default setting
Returns selected item to default setting. (Used for adjustment of screen.)
F1
Start
Starts operation. (Used to start measurement of split fuel consumption on fuel consumption display screen.)
F1
Stop
Stops operation. (Used to stop measurement of split fuel consumption on fuel consumption display screen.)
F1/F2
Clear
Clears selected/displayed item
F1
Set
Executes setting.
F2
Change multi gauge
Change of multi gauge items
D155A-6
10 Structure, function and maintenance standard
SEN02868-02
Air conditioner control switch To operate the air conditioner, use the air conditioner control switches.
Service meter/time selector function 9a : Specifies airflow 9b : Specifies temperature 9c : AUTO 9d : A/C 9e : Switches among air blowing modes 9f : Switches between inside air and outside air 9g : OFF 9a to 9c : Enables entered information simultaneously with switching to the air conditioner control screen below. 9d to 9f : Switches to the air conditioner control screen below. Another pressing switches among modes. 9g : Turns OFF the air conditioner function without switching to the air conditioner screen.
q
Pressing F4 on the normal screen when the service meter is displayed in the top center of the screen switches the display to the time, and doing so when the time is displayed switches the display to the service meter.
If you do no operation at least 5 sec. with the air conditioner control screen displayed, the window returns to the normal window. a When communication with the air conditioner is disconnected, or “spurting-out damper”, “A/M damper”, or “refrigerant” has a problem, the following screen appears.
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.
F5 : Cancels the reset to return to the maintenance table screen. F6 : Resets the remaining time to return to the normal screen. No operation at least 30 sec. : Returns to the normal screen. q
No.
F1 : Displays the next page. Displays the top page when the last page is displayed. F2 : Displays the previous page. Displays the last page when the top page is displayed. F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Returns to the normal screen. F6 : Switches to the maintenance time reset screen. No operation at least 30 sec. : Returns to the normal screen. q
q
18
If the remaining time on the maintenance table screen is less than 30 hours, the relevant items are highlighted in yellow, and if 0 hours, they are done in red. On the maintenance time reset screen, reset the remaining time for the selected item to return to the default.
The table below shows the maintenance items and replacement intervals. The time remaining to maintenance is reduced as the machine is operated. Item
01 Engine oil 02 Engine oil filter 03 Fuel main filter 41 Fuel pre filter 04 Hydraulic filter 06 Corrosion resistor 07 Damper case oil 08 Final drive case oil 10 Hydraulic oil 19 P/L oil 20 P/L oil filter *: If equipped (To be determined) P/L: Power train q
Replacement interval (Hours) 500 500 1000 500 2000 1000(*) 2000 1000 2000 1000 500
The content of the caution display differs according to the remaining time. The relationship is as shown in the table below. Display
Condition Remaining time for mainteNone nance for all items is more than 30 hours. There is one or more items Notice display (black symwith less than 30-hour bol displayed on yellow remaining time for maintebackground) nance. There is one or more items Warning display (white with less than 0-hour symbol displayed on red remaining time for maintebackground) nance.
D155A-6
10 Structure, function and maintenance standard
q
To reset the maintenance time carelessly, it is locked by the password.
SEN02868-02
User mode q q
q q
a
1
Pressing F6 on the normal screen enters the user mode, switching to the user menu screen. In user mode, you can specify items relating to the machine monitor and machine shown below. Utility screen select Multi gauge select Screen adjustment Clock adjustment Language setting Message display Fan reverse mode
The default password is “000000”. Enabling the password lock on an attachmentequipped machine locks the attachment setting screen at the same time. For information on changing the maintenance password, see “Maintenance password change function” in the Testing and adjusting section.
F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Returns to the normal screen. F6 : Switches to the setting screen for the selected item. No operation at least 30 sec. : Returns to the normal screen. (In user mode, no switch operation at least 30 sec. returns to the previous screen.)
Utility screen select q
q
D155A-6
If utility screen select is selected with switch F6, (1) Standard Display, (2) Load Display, or (3) Body Pitch Display can be selected. Select an item with switch F3 or F4 and confirm that item with switch F6.
19
SEN02868-02
10 Structure, function and maintenance standard
Multi gauge select On this screen, the gauges displayed at the center can be selected. Select an item with switch F3 or F4 and confirm that item with switch F6.
q q
Standard display The normal screen is selected.
q
Load display q The horizontal axis indicates the time and the vertical axis indicates the traction force. The operation should be carried out in the green range. q The graph on the screen is updated and scrolled to the left at intervals of several seconds.
The following items can be selected.
q
No.
Selected item
Remarks
1
Power train oil Temperature
With caution
2
HYD oil temperature
With caution
3
Vehicle Speed
4
HYD Pressure
5
ENG Oil Pressure
With caution
6
Battery Voltage
—
7
Engine Speed
—
8
Traction Force
—
9
Clock
—
— —
10 ENG coolant temperature For Utility Screen Select 11 Fuel
For Utility Screen Select
Body Pitch Display q The horizontal axis indicates the time and the vertical axis indicates the pitch angle of the body. q The graph on the screen is updated and scrolled to the left at intervals of several seconds.
20
D155A-6
10 Structure, function and maintenance standard
Screen adjustment q
q
q q
Selecting the Screen adjustment from the user menu and pressing F6 switches to the screen adjustment screen. From this menu, you can adjust the brightness, contrast, and luminance of the machine monitor screen. When the light switch is in Night mode ON, the night mode screen is adjustable. When the light switch is in Daytime mode ON or OFF, the daytime mode screen is adjustable.
F2 : Returns all adjusted values to the defaults. F3 : Decreases the value indicated by the indicator one graduation left. F4 : Increases the value indicated by the indicator one graduation right. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. F6 : Confirms the changes and moves to the next item. q
q
SEN02868-02
F6 : Moves to the setup items of the selected (highlighted) item. q q
The adjustment methods for the camera screen and normal screen are the same. The background when adjusting the camera screen is the No. 1 camera image.
F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. F6 : Moves to the setup items of the selected (highlighted) item.
Clock adjustment q
q
Selecting the Clock adjustment from the user menu and pressing F6 switches to the clock adjustment screen. On this screen, you can change the setting of the time displayed on the normal screen.
For a camera-equipped machine, the brightness, contrast, and illuminance of the camera screen are also adjustable. For a camera-equipped machine, selecting Sc reen adjus tment fro m the us er menu switches to the screen for selecting a screen you want to adjust.
1)
F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. D155A-6
Time setting Set the clock time. If the time setting item is not highlighted, press F6 to highlight it. The time display part is highlighted. F3 : Advances the clock one hour. F4 : Sets the clock back one hour. F5 : Cancels changes you made before confirming them with F6 to return to the user menu. F6 : Confirms the changes and moves to minute setting.
21
SEN02868-02
10 Structure, function and maintenance standard
The minute display part is highlighted. F3 : Advances the clock one min. F4 : Set the clock back one min. F5 : Cancels changes you made before confirming them with F6 to return to the use menu. F6 : Confirms the changes and moves to the 12/24 display mode. 2)
3)
12/24 display mode Specify time display to 12-hour display (AM/PM) or 24-hour display. If the item of 12/24 display mode is not highlighted, press F6 to highlight it. F3 : Moves to the item one right. F4 : Moves to the item one left. F5 : Cancels the changes to return to the user menu. F6 : Confirms the changes and moves to summer time. Summer time Selecting ON for this sets the time forward one hour. Setting OFF returns to the ordinary time. F3 : Moves to the item one right. F4 : Moves to the item one left. F5 : Cancels changes you made before confirming them with F6 to return to the user menu screen. F6 : Confirms the changes and moves to the time setting. a
F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Cancels the changes to return to the user menu. F6 : Cancels the changes to return to the user menu.
Message display q
q q
For a KOMTRAX-equipped machine, you can view notification from the sales representative. When there is a message, the message monitor appears on the upper left of the normal screen. The lighting green monitor indicates that there are messages to be read. The lighting blue monitor appears when you have not sent replies yet after opening messages which accept replies.
Summer time (daylight saving time) is a system to lead a life according to the one-hour advanced time in order to make efficient use of daylight time.
Language setting q
q
22
Selecting the Language from the user menu screen and pressing F6 switches to the language setting screen. From this menu, you can change the language to be displayed on the monitor. Available languages are as follows. English, Japanese, Chinese, French, Spanish, Portuguese, Italian, German, Russian, and Turkish
D155A-6
10 Structure, function and maintenance standard
q
Press F6 to enter user mode and select “Message display” and you can view (open) the messages.
SEN02868-02
Fan reverse mode q q
q q
In this mode, the fan is driven in reverse to clean the radiator core. While the starting switch is OFF, select an item with switch F3 or F4 and confirm that item with switch F6. While screen (A) is displayed, press switch F6, and the fan is ready to run in reverse. While screen (B) is displayed, start the engine.
F6 : Returns to the user mode screen. q
q
q q
q
Under messages that accept replies, “Value to be entered with 10-key: [ ]” appears.If it appears, enter the selected item number provided in the message using the switches of the machine monitor, and press F6. “Do you want to transmit the entered value?” appears under the message. Press F6 and the entered value will be sent.
Messages will be deleted when their validity expire or a new message is received. When no message has not been received, “No message” appears at the blue part of the top of the screen. Separately from the message display for users above, the service menu is provided with message display for service.
D155A-6
Precautions for using fan reverse mode a q In this mode, the fan cannot be reversed while the engine is running. q When running the fan in reverse, set the travel lock in the LOCK position. q While the fan is running in reverse, the machine cannot travel. q When resetting the reverse running, turn the starting switch OFF to stop the engine. q When using this mode, warm up the engine sufficiently. If the engine is not warmed up, air may not be supplied sufficiently.
23
SEN02868-02
10 Structure, function and maintenance standard
Service meter check function
Display LCD check function
q
If you continuously pressing auto-deceleration switch (1) and buzzer cancel switch (2) at the same time when setting the starting switch to the OFF position, the service meter will appear on the screen in 3 to 5 sec.
q
When these switches are released, the LCD goes out. Continuous operation of the machine monitor may display blue bright spots on this screen; it is quite normal.
a
24
q
Continuously pressing the buzzer cancel switch (1) and F2 at the same time on the password input screen or normal screen causes the entire LCD to light in white. Release F2 and buzzer cancel switch in order. If any part of the display is black, the LCD is broken.
q
Pressing any function switch returns to the previous screen.
D155A-6
10 Structure, function and maintenance standard
SEN02868-02
Sensors Type of sensor
1 Sensor method
When normal
When abnormal
Contact
OFF
ON
Resistance
—
—
Torque converter oil temperature
Resistance
—
—
Hydraulic oil temperature
Resistance
—
—
Contact
ON
OFF
Fuel level
Resistance
—
—
Engine oil pressure Engine coolant temperature
Coolant level Engine speed sensor
Resistance
—
—
Bevel gear speed sensor
Resistance
—
—
Pitch angle sensor
Resistance
—
—
Engine oil pressure sensor
1. 2. 3.
Plug Contact ring Contact
4. 5. 6.
Diaphragm Spring Terminal
4. 5. 6.
Tube Wire Connector
Engine coolant temperature sensor Torque converter oil temperature sensor Hydraulic oil temperature sensor
1. 2. 3.
Thermistor Body Tube
D155A-6
25
SEN02868-02
10 Structure, function and maintenance standard
Coolant level sensor
1. 2. 3.
Float Sensor Tube
4. 5.
Wire Connector
Fuel level sensor
1. 2. 3. 4. 5. 6. 7.
26
Connector Float Arm Body Spring Contact Spacer
Function q The fuel sensor is installed to the side face of the fuel tank. The float moves up and down according go the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level.
D155A-6
10 Structure, function and maintenance standard
SEN02868-02
Engine speed sensor Bevel gear speed sensor
1. 2. 3.
Magnet Terminal Case
4. 5.
Boots Connector
3. 4.
Wire Connector
Pitch angle sensor
1. 2.
Body Tube
D155A-6
27
SEN02868-02
Palm command control system
1. 2. 3. 4. 5. 6. 7. 8.
28
10 Structure, function and maintenance standard
1
Machine monitor (Multi-information) Preset mode switch Engine throttle controller Power train controller Engine speed sensor Transmission control valve Steering control valve Transmission output shaft speed sensor
D155A-6
10 Structure, function and maintenance standard
SEN02868-02
Gearshift mode function Outline There are the auto gearshift mode and manual gearshift mode in the gearshift mode. These modes are changed to each other each time gearshift mode switch (1) is pressed. 1. Auto gearshift mode (Dozing mode) q If a load is applied, the gear is shifted down automatically. When the load is removed, the gear is shifted up to the set maximum gear speed automatically. q The torque converter lockup operates according to loads and the maximum gear speed is selected automatically. In this mode, less fuel is consumed and more production is obtained. 2. Manual gearshift mode (Ripping mode) q If a load is applied, the gear is shifted down automatically. When the load is removed, however, the gear is not shifted up automatically.
Gear shift operation q Set a gear by pressing (a) or (b) of the steering/directional/gearshift lever. (a) Shift-up switch (b) Shift-down switch Display of screen The gearshift mode is displayed in the gearshift mode display section of the monitor panel as shown below. A: Auto gearshift mode 1. Gear speed used currently 2. Preset (gear speed at start) and maximum gear speed during travel 3. Mark of AUTO (which indicates auto gearshift mode) 4. Mark of Dozing (which indicates auto gearshift mode) B: Manual gearshift mode 5. Gear speed used currently 6. Preset (gear speed at start) 7. Mark of Ripping (which indicates manual gearshift mode)
D155A-6
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SEN02868-02
10 Structure, function and maintenance standard
Setting preset with shift switches in neutral q Set the preset (gear speed at start) and the maximum gear speed during travel (for only the auto gearshift mode) with the gearshift switches in neutral. A: Auto gearshift mode 2. Setting preset (gear speed at start) and maximum gear speed during travel)
Changing gear speed with gearshift switches during travel q The maximum gear speed during travel (in the auto gearshift mode) or the gear speed used during travel (in the manual gearshift mode) can be changed with the gearshift switches while the machine is traveling. A: Auto gearshift mode 2. Changing maximum speed during travel During forward travel: The maximum gear speed can be set to F1 – F3. During reverse travel: The maximum gear speed can be set to R1 – R3. Shift-up switch: Each time this switch is pressed, the maximum gear speed is heightened to the next range. Shift-down switch: Each time this switch is pressed, the maximum gear speed is lowered to the next range.
B: Manual gearshift mode 6. Setting preset (gear speed at start)
B: Manual gearshift mode 5. Changing maximum speed during travel During forward travel: The maximum gear speed can be set to F1 – F3. During reverse travel: The maximum gear speed can be set to R1 – R3. Shift-up switch: Each time this switch is pressed, the maximum gear speed is heightened to the next range. Shift-down switch: Each time this switch is pressed, the maximum gear speed is lowered to the next range.
a
30
When the starting switch is turned ON, the auto gearshift mode ([F1 – R1]) is set. When the gearshift mode is changed, [F1 – R1] is selected initially.
D155A-6
10 Structure, function and maintenance standard
KOMTRAX system
q
q
q
a
SEN02868-02
1
The KOMTRAX system consists of a KOMTRAX terminal, communication antenna, machine monitor, and GPS antenna. This system transmits various kinds of machine information wirelessly. Persons to operate the KOMTRAX can refer to the information at office to provide various kinds of services for customers. Information transmittable from the KOMTRAX system includes the following. 1. Operation map 2. Service meter 3. Position information 4. Error history and others. To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
D155A-6
31
SEN02868-02
KOMTRAX terminal
10 Structure, function and maintenance standard
1
TH300
q
For japan / For other countries Using satellite wave
1. 2. 3.
Communication antenna connection Connector A (14 poles) Connector B (10 poles)
q
Outline q The KOMTRAX terminal is a wireless communication device to transmit various kinds of machine information or GPS position information the monitor obtains from network signals or input signals in the machine. The terminal can transmit information via the communication antenna. q Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed. q When using TH300 in Japan or in other countries, the satellite communication company to contract is different. So, part numbers of TH300 are different in Japan or in other countries. Also, when using TH300 in countries other than Japan, you must notify the name of the country.
Input and output signals Connector A Pin No. A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 A-11 A-12 A-13 A-14
Signal name Power (12V) NC(*1) NC(*1) Electric power supply switching NC(*1) NC(*1) GND GND NC(*1) NC(*1) NC(*1) NC(*1) NC(*1) NC(*1)
Input/ output Input — — Output — — — — — — — — — —
Connector B Input/ output B-1 Serial signal DCD Output B-2 Serial signal RXD Output B-3 Serial signal TXD Input B-4 Serial signal DTR Input B-5 Serial signal SGND — B-6 Serial signal DSR Output B-7 NC(*1) — B-8 NC(*1) — B-9 NC(*1) — B-10 NC(*1) — *1: Never connect to NC or malfunctions or failures will occur. Pin No.
32
Signal name
D155A-6
10 Structure, function and maintenance standard
D155A-6
SEN02868-02
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
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
20 Standard value table
1
Standard service value table Standard value table for engine ...................................................................................................................... 2 Standard value table for machine ................................................................................................................... 3
D155A-6
1
SEN03199-01
20 Standard value table
Standard value table for engine
Category
Item
Speed
1
Machine model
D155A-6
Engine
SAA6D140E-5 Unit
Standard value for new machine
Service limit value
High idle
rpm
2,100 (0/-50)
2,100 (0/-50)
Low idle
rpm
740 (+40/0)
740 (+40/0)
Rated speed
rpm
1,900
1,900
Min. 85 {Min. 640}
72 {540}
670
720
Max. 30 (Max. 3.0)
40 {4.0}
Max. 1.0
2.0
Measurement condition
• Engine coolant temperature: Within operating range
• Engine coolant temperature: Within operating range Intake air pressure kPa • Power train oil temperature: Within (Boost pressure) {mmHg} operating range • Torque converter: Stalled Exhaust • Whole speed range °C temperature (Outside temperature: 20°C) At sharp % acceleration (Bosch • Engine coolant (Low idle o index) Exhaust gas color temperature: Within High idle) operating range (Bosch High idle index)
Engine
Valve clearance
Compression pressure
Blow-by pressure
Intake valve
mm
0.35
—
Exhaust valve
mm
0.57
—
Min. 4.1 {Min. 42}
2.8 {29}
rpm
200 – 250
200 – 250
kPa {mmH2O}
Max. 2.94 {Max. 300}
3.92 {400}
MPa {kg/cm2}
Min. 0.34 {Min. 3.5}
0.21 {2.1}
MPa {kg/cm2}
Min. 0.10 {Min. 1.0}
0.08 {0.8}
°C
90 – 110
120
mm
13 – 16
13 – 16
mm
Approx. 10
Approx. 10
• Normal temperature
• Engine oil temperature: 40 – 60°C
Compression MPa pressure {kg/cm2}
Engine speed • Engine coolant temperature: Within operating range • Power train oil temperature: Within operating range • Torque converter: Stalled
• SAE0W30EOS, SAE5W40EOS, High idle SAE10W30DH, Engine oil pressure SAE15W40DH SAE30DH Oil • Engine oil temperature: Low idle Min. 80 °C Oil temperature
• Whole speed range (In oil pan)
• Between water pump pulley – alternator pulley • Deflection under finger pressure of 98 N {10 kg} • Between compressor pulley – fan Air compressor belt pulley tension • Deflection under finger pressure of 59 N {6 kg} Alternator belt tension
2
D155A-6
20 Standard value table
SEN03199-01
Standard value table for machine
1
Machine model Category
Item
Cooling fan
Engine speed
Decelerator pedal speed
Auto deceleration speed
D155A-6 Unit
Standard value for new machine
Service limit value
rpm
875 ± 25
875 ± 25
rpm
1,875 ± 50
1,875 ± 50
rpm
1,665 ± 50
1,450
rpm
1,630 ± 50
1,395
rpm
1,100 (0/+50)
1,100 (0/+50)
mm
30 ± 5
30 ± 5
mm
30 ± 5
30 ± 5
N o Left
mm
40 ± 5
40 ± 5
N o Right
mm
40 ± 5
40 ± 5
mm
50 ± 10
50 ± 10
All stroke
mm
79 ± 10
79 ± 10
Stroke to 0 of oil pressure
mm
54 ± 4
54 ± 4
Measurement condition • Engine coolant temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine: High idle • Decelerator pedal speed: Press pedal • Auto deceleration speed: Set all levers in neutral
• Engine coolant temperature: Within operating range Torque converter • Power train oil temperature: Within stall speed operating range • Hydraulic oil temperature: Within operating range • Engine: High idle Torque converter • Select P mode stall speed + Work • Torque converter stall speed: F3 equipment relief • Torque converter stall speed + Work speed equipment relief speed: F3 + Ripper raise
Fan motor speed
• Hydraulic oil temperature: Within operating range • Fan: Set in 100% mode • Engine: High idle
Max. speed
PCCS lever
Stroke of control lever/pedal
No Forward
Forward/ Reverse travel
No • Stop engine • Center of lever grip
Steering
Decelerator pedal
• Stop engine • Center of pedal
Brake pedal
• Engine: Low idle • Center of pedal
D155A-6
Reverse
3
SEN03199-01
20 Standard value table
Machine model Item
Blade control lever
Unit
Standard value for new machine
Service limit value
N o Raise
mm
60 ± 10
72 ± 10
N o Lower
mm
60 ± 10
72 ± 10
N o Left tilt
mm
53 ± 10
53 ± 10
mm
53 ± 10
53 ± 10
N o Raise
mm
77 ± 10
75 ± 10
N o Lower
mm
77 ± 10
75 ± 10
N o In
mm
79 ± 10
80 ± 10
N o Out
mm
79 ± 10
80 ± 10
No
N {kg} N {kg} N {kg} N {kg} N {kg} N {kg} N {kg} N {kg} N {kg} N {kg}
56.9 ± 6.9 {5.8 ± 0.7} 50.1 ± 6.9 {5.2 ± 0.7} 24.5 ± 4.9 {2.5 ± 0.5} 27.5 ± 4.9 {2.8 ± 0.5} 49.0 ± 9.8 {5.0 ± 1.0} 411.6 ± 78.4 {42.0 ± 8.0} 39.2 ± 5.9 {4.0 ± 0.6} 39.2 ± 9.8 {4.0 ± 1.0} 82 ± 9.8 {8.4 ± 1.0} 28.4 ± 5.9 {2.9 ± 0.6}
56.9 ± 6.9 {5.8 ± 0.7} 50.1 ± 6.9 {5.2 ± 0.7} 24.5 ± 4.9 {2.5 ± 0.5} 27.5 ± 4.9 {2.8 ± 0.5} 49.0 ± 9.8 {5.0 ± 1.0} 411.6 ± 78.4 {42.0 ± 8.0} 39.2 ± 5.9 {4.0 ± 0.6} 39.2 ± 9.8 {4.0 ± 1.0} 82 ± 9.8 {8.4 ± 1.0} 28.4 ± 5.9 {2.9 ± 0.6}
N {kg}
28.4 ± 5.9 {2.9 ± 0.6}
28.4 ± 5.9 {2.9 ± 0.6}
N {kg} N {kg} N {kg} N {kg}
19.6 ± 4.9 {2.0 ± 0.5} 19.6 ± 4.9 {2.0 ± 0.5} 24.5 ± 4.9 {2.5 ± 0.5} 24.5 ± 4.9 {2.5 ± 0.5}
19.6 ± 4.9 {2.0 ± 0.5} 19.6 ± 4.9 {2.0 ± 0.5} 24.5 ± 4.9 {2.5 ± 0.5} 24.5 ± 4.9 {2.5 ± 0.5}
Measurement condition
• Stop engine • Center of lever knob
No Right tilt
Ripper control lever
PCCS lever
Stroke of control lever/pedal
Category
D155A-6
• Stop engine • Center of lever knob
Forward
Forward/ Reverse travel
No • Stop engine • Center of lever grip
Reverse N o Left
Steering
Operating effort of control lever/pedal
N o Right Decelerator pedal Brake pedal
• • • •
Stop engine Center of pedal Engine: Low idle Center of pedal N o Raise N o Lower
• Stop engine Blade control lever • Center of lever knob • Lower o Float
Lower o Float N o Left tilt No Right tilt N o Raise
Ripper control lever
• Stop engine • Center of lever knob
N o Lower N o In N o Out
4
D155A-6
20 Standard value table
SEN03199-01
Machine model Category
Item Torque converter inlet pressure
Torque converter outlet pressure
D155A-6
Measurement condition Low idle • Power train oil temperature: Within operating High idle range • PCCS lever: Neutral Low idle • Display by monitoring High idle
Power train oil pressure
• Power train oil temperature: Within operating Low idle range Transmission main • PCCS lever: Neutral relief pressure (Main relief pressure) High idle • Brake pedal: Press (Other than above)
Standard value for new machine
Service limit value
0.05 – 0.49 {0.5 – 5.0} Max. 1.0 {Max. 10.0}
0.05 – 0.49 {0.5 – 5.0} Max. 1.0 {Max. 10.0}
0.05 – 0.29 {0.5 – 3.0}
0.05 – 0.29 {0.5 – 3.0}
0.29 – 0.69 {3.0 – 7.0}
0.29 – 0.69 {3.0 – 7.0}
MPa {kg/cm2}
2.81 – 3.11 {28.7 – 31.7}
Min. 2.62 {Min. 26.7}
MPa {kg/cm2}
3.04 – 3.33 {31.0 – 34.0}
Min. 2.84 {Min. 29.0}
Unit MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2}
Transmission F clutch pressure (When operating N1 o F1)
Low idle
MPa {kg/cm2}
2.55 – 2.94 {26.0 – 30.0}
Min. 2.35 {Min. 24.0}
High idle
MPa {kg/cm2}
Transmission R clutch pressure (When operating N1 o R1)
Low idle
2.65 – 3.04 {27.0 – 31.0} 2.60 – 2.99 {26.5 – 30.5}
Min. 2.45 {Min. 25.0} Min. 2.40 {Min. 24.5}
2.74 – 3.14 {28.0 – 32.0}
Min. 2.55 {Min. 26.0}
Transmission 1st clutch pressure (When operating N1 o F1)
• Power train oil temper- Low idle ature: Within operating range High idle • PCCS lever: Neutral (Main relief pressure) Low idle • Brake pedal: Press (Other than above) High idle
2.81 – 3.11 {28.7 – 31.7} 3.04 – 3.33 {31.0 – 34.0}
Min. 2.62 {Min. 26.7} Min. 2.84 {Min. 29.0}
2.55 – 2.94 {26.0 – 30.0}
Min. 2.35 {Min. 24.0}
2.70 – 3.09 {27.5 – 31.5} 2.81 – 3.11 {28.7 – 31.7}
Min. 2.50 {Min. 25.5} Min. 2.62 {Min. 26.7}
3.04 – 3.33 {31.0 – 34.0}
Min. 2.84 {Min. 29.0}
Transmission 2nd clutch pressure (When operating N1 o F2)
High idle
Transmission 3rd clutch pressure (When operating F2 o F3) Transmission lubricating oil pressure (Reference) Steering right brake • Power train oil pressure temperature: Within operating range • PCCS lever: Neutral Steering left brake • Brake pedal: Release pressure • Power train oil temperature: Within operating range • Gear speed: N • PCCS lever: Right stroke end Steering left clutch • PCCS lever: Left pressure stroke end Steering right clutch pressure
D155A-6
Low idle High idle
MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2}
High idle
MPa {kg/cm2}
0.098 – 0.25 {1.0 – 2.5}
0.098 – 0.25 {1.0 – 2.5}
Low idle
MPa {kg/cm2}
3.04 – 3.33 {31.0 – 34.0}
3.04 – 3.33 {31.0 – 34.0}
High idle
MPa {kg/cm2}
3.04 – 3.33 {31.0 – 34.0} 3.04 – 3.33 {31.0 – 34.0}
3.04 – 3.33 {31.0 – 34.0} 3.04 – 3.33 {31.0 – 34.0}
3.04 – 3.33 {31.0 – 34.0}
3.04 – 3.33 {31.0 – 34.0}
2.3 – 2.6 {23.5 – 26.5} 2.3 – 2.6 {23.5 – 26.5}
2.3 – 2.6 {23.5 – 26.5} 2.3 – 2.6 {23.5 – 26.5}
2.3 – 2.6 {23.6 – 26.5}
2.3 – 2.6 {23.6 – 26.5}
2.3 – 2.6 {23.6 – 26.5}
2.3 – 2.6 {23.6 – 26.5}
Low idle High idle Low idle High idle Low idle High idle
MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2}
5
SEN03199-01
20 Standard value table
Machine model
Power train performance
Category
Item
Travel speed
Work equipment oil pressure
Unload pressure
Blade lift relief pressure Blade tilt relief pressure Ripper lift relief pressure
D155A-6 Unit
Standard value for new machine
Service limit value
F1
km/h
3.8 ± 0.2
3.8 ± 0.2
F2
km/h
7.5 ± 0.4
7.5 ± 0.4
F3L
km/h
7.5 ± 0.4
7.5 ± 0.4
F3
km/h
11.6 ± 0.6
11.6 ± 0.6
R1
km/h
4.6 ± 0.2
4.6 ± 0.2
R2
km/h
6.8 ± 0.4
6.8 ± 0.4
R3L
km/h
9.2 ± 0.5
9.2 ± 0.5
R3
km/h
14.0 ± 0.7
14.0 ± 0.7
MPa {kg/cm2}
—
—
2.45 (+1.37/0)
2.45 (+1.37/0)
{25 (+14/0)}
{25 (+14/0)}
27.5 ± 1.5 {280 ± 15}
27.5 ± 1.5 {280 ± 15}
27.5 ± 1.5 {280 ± 15}
27.5 ± 1.5 {280 ± 15}
27.5 ± 1.5 {280 ± 15} 27.5 ± 1.5 {280 ± 15}
27.5 ± 1.5 {280 ± 15} 27.5 ± 1.5 {280 ± 15}
25.0 ± 0.98 {255 ± 10}
25.0 ± 0.98 {255 ± 10}
Measurement condition • Flat ground • Engine coolant temperature: Within operating range • Power train oil temperature: Within operating range • Select manual gearshift mode • Engine: High idle • Approach run: 10 – 30 m • Measuring distance: 20 m (Converted into km/h)
• Hydraulic oil temperaLow idle ture: Within operating range • All levers: High idle Set in neutral
• • •
Ripper tilt relief pressure Work equipment LS relief pressure • Control circuit basic • pressure •
MPa {kg/cm2} MPa Hydraulic oil temperature: Within {kg/cm2} operating range MPa Engine: High idle {kg/cm2} Cylinder of measured circuit: MPa Stroke end {kg/cm2} MPa {kg/cm2} Hydraulic oil temperature: Within operating range MPa Engine: High idle {kg/cm2} All levers: Set in neutral
6
Work equipment speed
Work equipment
• Hydraulic oil temperature: Within Control valve PPC operating range valve output • Engine: High idle pressure • Lever of measured circuit: Stroke end
Blade lift
MPa {kg/cm2}
• Hydraulic oil temperature: Within operating range Raise • Engine: High idle • Select P mode • Apply no load to blade. • Measure time required to move blade from ground level to raise Lower stroke end • For measuring posture, see Fig. 1
3.97 (+0.49/0)
3.78 – 4.46
{40.5 (+5/0)}
{38.5 – 45.5}
MPa {kg/cm2}
3.82 – 4.12 {39 – 42}
3.53 {36}
sec
3.0 – 4.0
3.0 – 4.0
sec
1.0 – 1.7
1.0 – 1.7
D155A-6
20 Standard value table
SEN03199-01
Machine model Category
Item
Work equipment
Work equipment speed
Blade tilt
Ripper lift
Ripper tilt
Time lag
Blade
Ripper
D155A-6
Measurement condition • Hydraulic oil temperature: Within Left tilt operating range • Engine: High idle • Select P mode • Apply no load to blade • Measure time required to move blade from left tilt end to right tilt end Right tilt • For measuring posture, see Fig. 2 • Hydraulic oil temperature: Within operating range Raise • Engine: High idle • Select P mode • Apply no load to ripper (Shank hole: Lowest) • Measure time required to move ripper from ground level to raise Lower end • For measuring posture, see Fig. 3 • Hydraulic oil temperature: Within operating range Tilt in • Engine: High idle • Select P mode • Apply no load to ripper • Measure time required to move ripper from tilt in end to tilt back end Tilt back • For measuring posture, see Fig. 4 • Hydraulic oil temperature: Within operating range • Engine: Low idle • Select P mode. • Blade control lever: Set to stroke end • Lower blade from max. rising position and measure time after blade comes in contact with ground until idler is lifted • Hydraulic oil temperature: Within operating range • Engine: Low idle • Select P mode • Ripper control lever: Set to stroke end • Lower ripper from max. rising position and measure time after ripper comes in contact with ground until sprocket is lifted
D155A-6 Unit
Standard value for new machine
Service limit value
sec
1.8 – 2.8
3.1
sec
1.8 – 2.8
3.1
sec
2.5 – 3.5
4.0
sec
2.5 – 3.5
4.0
sec
4.5 – 5.5
6.2
sec
3.3 – 4.3
5.7
sec
Max. 1.7
2.5
sec
Max. 1.5
1.5
7
SEN03199-01
20 Standard value table
Machine model Category
Unit
Standard value for new machine
Service limit value
mm
Max. 150/15 minutes
200/15 minutes
mm
Max. 50/5 minutes
70/5 minutes
mm
Max. 50/5 minutes
70/5 minutes
• Hydraulic oil temperature: Within operating range Hydraulic drift • Stop engine of machine • Measure reduction of sprocket center lifted by ripper height h in 5 minutes • For measuring posture, see Fig. 8
mm
Max. 50/5 minutes
70/5 minutes
Blade lift cylinder
cc/min
Max. 3.0
12
cc/min
Max. 2.7
11
cc/min
Max. 2.7
11
Item
Hydraulic drift of work equipment Leakage from cylinder
Work equipment
Hydraulic drift of lifted blade
8
D155A-6
Hydraulic drift of machine lifted by blade
Hydraulic drift of machine tilted by blade
Ripper lift cylinder Ripper tilt cylinder
Measurement condition • Hydraulic oil temperature: Within operating range • Stop engine • Measure reduction of blade bottom height h in 15 minutes • For measuring posture, see Fig. 5 • Hydraulic oil temperature: Within operating range • Stop engine • Measure reduction of idler center height h in 5 minutes • For measuring posture, see Fig. 6 • Hydraulic oil temperature: Within operating range • Stop engine • Measure reduction of track shoe bottom height h in 5 minutes • For measuring posture, see Fig. 7
• Hydraulic oil temperature: Within operating range • Engine: High idle • Measure leakage from relieved cylinder in 1 minute
D155A-6
20 Standard value table
SEN03199-01
Postures and procedures for measuring performance Fig. 1: Blade lift speed
Fig. 4: Ripper tilt speed
Fig. 2: Blade tilt speed
Fig. 5: Hydraulic drift of lifted blade
Fig. 3: Ripper lift speed
Fig. 6: Hydraulic drift of machine lifted by blade
D155A-6
9
SEN03199-01
20 Standard value table
Fig. 7: Hydraulic drift of machine tilted by blade
Fig. 8: Hydraulic drift of machine lifted by ripper
10
D155A-6
20 Standard value table
D155A-6
SEN03199-01
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
SEN03200-04
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
30 Testing and adjusting
1
Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting............................................................................................. 3 Sketches of special tools ................................................................................................................................ 7 Measuring engine speed................................................................................................................................. 8 Measuring intake air pressure (boost pressure) ........................................................................................... 10 Measuring exhaust temperature ................................................................................................................... 12 Measuring exhaust gas color ........................................................................................................................ 14 Adjusting valve clearance ............................................................................................................................. 15 Measuring compression pressure................................................................................................................. 16 Measuring blow-by pressure......................................................................................................................... 18 Measuring engine oil pressure...................................................................................................................... 19 Handling fuel system parts............................................................................................................................ 20 Releasing residual pressure from fuel system .............................................................................................. 20 Measuring fuel pressure ............................................................................................................................... 21 Measuring fuel return rate and fuel leakage ................................................................................................. 22 Bleeding air from fuel circuit.......................................................................................................................... 26 Measuring fuel circuit for leakage ................................................................................................................. 28
D155A-6
1
SEN03200-04
30 Testing and adjusting
Testing and adjusting alternator belt tension................................................................................................. 29 Testing and adjusting air conditioner compressor belt tension...................................................................... 30 Measuring fan speed..................................................................................................................................... 31 Measuring fan circuit oil pressure ................................................................................................................. 33 Bleeding air from fan pump ........................................................................................................................... 34 Bleeding air from work equipment pump....................................................................................................... 35 Adjusting fuel control dial and decelerator pedal .......................................................................................... 36
2
D155A-6
30 Testing and adjusting
SEN03200-04
Testing and adjusting item
Symbol
Measuring intake air pressure (boost pressure)
A
Measuring exhaust temperature
B
Measuring exhaust gas color
Remarks
799-201-2202 Boost gauge kit
1
– 101 – 200 kPa {– 760 – 1,500 mmHg}
799-401-2220 Hose
1 Straight type quick coupler
799-101-1502 Digital thermometer
1 – 99.9 – 1,299°C
Part No.
Part name
1 799-201-9001 Handy smoke checker C
Adjusting valve clearance
2
D
E
1
Commercially Thickness gauge available
1
Measuring engine oil pressure
Air intake: 0.35 mm, Exhaust: 0.57 mm
1 0 – 7.0 MPa {0 – 70 kg/cm2} 1
6261-71-6150 Gasket
1
799-201-1504 Blow-by checker
1 0 – 5 kPa {0 – 500 mmH2O}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester
1
Pressure gauge: 1.0 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
1
Pressure gauge: 1.0 MPa {10 kg/cm2}
F
1 G
1 Measuring fuel pressure
Bosch index: 0 – 9
795-471-1330 Adapter
2
Measuring blow-by pressure
1
Commercially Smoke meter available
1 795-502-1590 Compression gauge Measuring compression pressure
1
Q'ty
Tools for testing, adjusting, and troubleshooting
H 2 799-401-2320 Hydraulic tester 3
795T-471-2010 Adapter
1
07005-00812 Gasket
1
For 140E-5 engine
8 × 1.25 mm o R1/8
1 6151-51-8490 Spacer
1 Inside diameter: 14 mm
2 6206-71-1770 Joint
1 Inside diameter of joint: 10 mm
3
Commercially Hose available
1 ø5 mm × 2 – 3 m
Measuring fuel return rate J 4 and fuel leakage
Commercially Hose available
1 ø15 mm × 2 – 3 m
5
Commercially Measuring cylinder available
1
6
Commercially Stopwatch available
1
799-205-1101 Tachometer kit
1 6.0 – 99999.9 rpm
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
Measuring fan speed
K
1 Measuring fan circuit pressure
L
2 799-401-3400 Adapter 3
D155A-6
799-101-5220 Nipple 07002-11023 O-ring
1 Size: 05 1 Size: 10 × 1.25 mm
3
Testing and adjusting item
Measuring power train oil pressure
30 Testing and adjusting
Symbol
Measuring and adjusting work equipment oil pressure
Remarks
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
Part No.
Part name
M
Adjusting brake pedal Emergency escape method when power train has trouble
Q'ty
SEN03200-04
N 1
P
79A-264-0091 Push-pull scale
1 0 – 490 N {0 – 50 kg}
19M-06-32820 Switch assembly
1
17A-06-41410 Wiring harness
1
2 790-190-1601 Pump assembly
1
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
799-101-5220 Nipple
2
07002-11023 O-ring
2
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
799-401-3200 Adapter
1
02896-11009 O-ring
1
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600 kg/cm2}
1 Q 2
1 Measuring control circuit basic pressure
R 2
1 Testing work equipment lock solenoid valve output S 790-261-1204 Digital hydraulic tester pressure 791T-643-1010 Elbow 2 07002-11423 O-ring
1
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
799-401-3100 Adapter
1
02896-11008 O-ring
1
799-401-3200 Adapter
1
02896-11009 O-ring
1
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
799-401-3200 Adapter
1
02896-11009 O-ring
1
–
Commercially Socket available
21mm deep socket 1 (MITOLOY 4ML 21 or equivalent) Applied engine: 530056 – 534132
–
795T-981-1010 Socket
1
T 2 3
1 Measuring ripper pin puller solenoid valve output U pressure 2
Removal and installation of engine coolant temperature sensor
4
Size: 03
1
1 PPC valve output pressure
Size: 10 × 1.25 mm
Size: 02 Size: 03
Size: 03
19 mm deep socket Applied engine: 534133 –
D155A-6
30 Testing and adjusting
SEN03200-04
Symbol
Measuring internal leakage of work equipment cylinder
Part name
Q'ty
Testing and adjusting item
V
Commercially Measuring cylinder available
1
Measuring coolant temperature and oil temperature
—
799-101-1502 Digital thermometer
1 – 99.9 – 1,299°C
Testing operating effort and pressing force
—
79A-264-0021 Push-pull scale
1 0 – 294 N {0 – 30 kg}
79A-264-0091 Push-pull scale
1 0 – 490 N {0 – 50 kg}
Measuring stroke and hydraulic drift
—
Commercially Ruler available
1
Measuring work equipment speed
—
Commercially Stopwatch available
1
Measuring voltage and resistance
—
Commercially Circuit tester available
1
Part No.
Remarks
799-601-4101 or T-adapter assembly 799-601-4201
Engine related controller, sensor and actuator diagnosis
D155A-6
—
799-601-4350 • T-box
For DRC60 • ECONO*² (Max 60P) 1 (Does not include in assembly No.799-601-4201)
795-799-5530 • Socket
For engine (CRI-T3) coolant temperature sensor (PACKARD 2P) For engine (CRI-T3) fuel temperature 1 sensor (PACKARD 2P) For engine (CRI-T3) oil temperature sensor (PACKARD 2P)
795-799-5540 • Socket
1
For engine (CRI-T3) boost temperature sensor (PACKARD 2P)
799-601-4240 • Socket
1
For engine (CRI-T3) ambient pressure sensor (AMP 3P)
799-601-4110 • Socket
1
For engine (CRI-T3) boost pressure sensor (SUMITOMO 3P)
799-601-4330 • Socket
1
For engine (CRI-T3) G (Bkup) sensor (SUMITOMO 3P)
799-601-9430 • Socket
For engine (CRI-T3) supply pump 1 PCV1 • supply pump PCV sensor (SUMITOMO 3P)
799-601-4130 • T-adapter
1
For engine (CRI-T3) NE sensor (FRAMATOME 3P)
799-601-4150 • T-adapter
1
For engine (CRI-T3) oil pressure sensor (FRAMATOME 3P)
799-601-9420 • T-adapter
1
For engine (CRI-T3) common rail pressure sensor (AMP 3P)
799-601-4211 • T-adapter
For engine controller (DRC26-50P) 1 (Does not include in assembly No. 799-601-4201)
799-601-4220 • T-adapter
For engine controller DRC26-60P 1 (Does not include in assembly No. 799-601-4201)
799-601-4260 • T-adapter
For engine controller (DTP-4P) 1 (Include in assembly No. 799-6019000 and 799-601-9100, too)
799-601-9040 • T-adapter
For DT 4P 1 (Include in assembly No. 799-6019000 and 799-601-9200, too)
799-601-9020 • T-adapter
For DT 2P 1 (Include in assembly No. 799-6019000 and 799-601-9200, too)
5
Testing and adjusting item
30 Testing and adjusting
Symbol
Part No.
Part name
Q'ty
SEN03200-04
Remarks
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 799-601-2600 • T-box
For ECONO*³ (Max 21P) 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
799-601-7050 • T-adapter
1
For SWP 6P (Does not include in assembly No. 799-601-8000.)
799-601-7500 T-adapter assembly
Mashine related controller and sensors/wiring harnesses diagnosis
—
799-601-7510 • T-adapter
1 For AMP070 10P
799-601-7520 • T-adapter
1 For AMP070 12P
799-601-7530 • T-adapter
1 For AMP070 14P
799-601-7540 • T-adapter
1 For AMP070 18P
799-601-7550 • T-adapter
1 For AMP070 20P
799-601-9000 or T-adapter assembly 799-601-9200 799-601-9040 • T-adapter
For DT 4P 1 (Include in assembly No. 799-6014101 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 799-601-9290 • T-adapter
1 For HD36 24-24P 1 For HD36 24-31P (Does not include in assembly No.799-601-9200.) (Include in assembly No. 799-6019100, too.)
799-601-9300 T-adapter assembly
6
799-601-9360 • T-adapter
1 For pump controller (DRC26-24P)
799-601-9350 • T-adapter
1 For pump controller (DRC26-40P)
D155A-6
30 Testing and adjusting
Sketches of special tools
SEN03200-04
1
Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. H3 Adapter
S2 Elbow
D155A-6
7
SEN03200-04
Measuring engine speed k Stop
a
1.
1
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the engine speed under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range q Working mode: P mode q Gearshift mode: Either Auto or Manual
Preparation work Measure the engine speed with the Adjustment function in the service mode of the machine monitor. a For the operating method of the machine monitor, see Special functions of machine monitor (EMMS). 1) Measuring low idle speed, decelerator pedal speed, auto-deceleration speed, torque converter stall speed, and torque converter stall speed + work equipment relief speed (full stall speed): q Adjustment code: 0530 (Stall mode) a When stalling the torque converter for a purpose other than measuring the engine speed, be sure to use this adjustment code, too.
2)
8
30 Testing and adjusting
Measuring high idle speed: q Adjustment code: 0007 (Reset engine deceleration) a Only when this code is selected, the engine can be operated and tested with the auto-decelerator reset.
2.
Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position.
3.
Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position. a When measuring the high idle speed, be sure to select adjustment code [0007] (If adjustment code [0530] is selected, the auto-deceleration speed is measured).
4.
Measuring decelerator pedal speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral, press the decelerator pedal to the stroke end, and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position.
5.
Measuring auto-deceleration speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed.
D155A-6
30 Testing and adjusting a
The parking brake lever and work equipment lock lever may be kept in the LOCK position.
6.
Measuring torque converter stall speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. 3) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering system in neutral. 4) Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. 5) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 6) Just after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120 °C, return the direction of PCCS lever to neutral. a The top of the green range of the power train oil temperature gauge indicates about 118 – 120 °C. 7) Repeat above steps 3) – 6) 3 times. 8) Perform steps 3) – 5) again and measure the engine speed about 5 seconds after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120 °C. a Immediately after finishing measurement, return the direction of PCCS lever to neutral and lower the power train oil temperature with the engine at high idle.
7.
Measuring torque converter stall + work equipment relief speed (Full stall speed) 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3].
D155A-6
SEN03200-04 a
The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. 3) Set the work equipment lock lever in the free position and operate the ripper control lever to set the ripper lift cylinder to the raise stroke end. 4) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering system in neutral. 5) Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. 6) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 7) Just after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120 °C, return the direction of PCCS lever to neutral. a The top of the green range of the power train oil temperature gauge indicates about 118 – 120 °C. 8) Repeat above steps 4) – 7) 3 times. 9) Perform steps 4) – 6) again, operate the ripper control lever to relieve the ripper raise system, and measure the engine speed about 5 seconds after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120 °C. a Immediately after finishing measurement, return the direction of PCCS lever to neutral and lower the power train oil temperature with the engine at high idle.
9
SEN03200-04
30 Testing and adjusting
Measuring intake air pressure (boost pressure) a
4.
Run the engine at a medium or higher speed and drain the oil from the test hose. a Insert the connecting parts of the gauge and hose about a half and open the selfseal on the hose side repeatedly, and the oil will be drained. a If Pm kit (A) is available, you may drain the oil by using the oil draining coupling (790-261-1130) in that kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil.
5.
Turn the starting switch ON and set the machine monitor to Adjustment function of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see Special functions of machine monitor (EMMS).
6.
While running the engine at high idle, stall the torque converter and measure the intake air pressure (boost pressure). a For the procedure for stalling the torque converter, see Measuring engine speed. a Normally, the intake air pressure (boost pressure) should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter.
1
Measuring instruments for intake air pressure (boost pressure)
Symbol A
Part No. 799-201-2202 799-401-2220
Part name Boost gauge kit Hose
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 position. k Be careful not to touch any hot part of the engine when removing or installing the measuring tools. a Measure the intake air pressure (boost pressure) under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range 1.
Open the engine left side cover.
2.
Remove intake air pressure pickup plug (1) from the rear of the air intake connector.
3.
10
Install nipple [1] of boost gauge kit A and connect gauge [2].
D155A-6
30 Testing and adjusting
7.
SEN03200-04
After finishing measurement, remove the measuring instruments and return the removed parts. q Remove the gasket sealant sticking to the threaded part of the removed plug with a wire brush, apply adhesive or gasket sealant to it, and install it. 2 Plug: LT-2 or LG-5 3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm} (Air intake connector made of FC) 6.9 – 14.7 Nm {0.7 – 1.5 kgm} (Air intake connector made of Al)
D155A-6
11
SEN03200-04
30 Testing and adjusting
Measuring exhaust temperature 1 a
Measuring instruments for exhaust temperature
Symbol
Part No.
B
799-101-1502
Part name Digital thermometer
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 position. k Install and remove the measuring instruments after the exhaust manifold is cooled. a Measure the exhaust temperature under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range 1.
Open the engine right side cover and right mudguard.
2.
Remove 1 exhaust temperature pickup plug (1) from the exhaust manifold. a You may measure the exhaust temperature at either front or rear plug.
3.
12
Install sensor [1] of digital thermometer B and connect them to meter [2]. a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part during measurement.
4.
When measuring maximum exhaust temperature for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. a Use the PEAK mode of the thermometer. a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. q Corrected value [°C] = Measured value + 2 × (20 – Outside air temperature)
5.
Procedure for measuring exhaust temperature periodically for preventive maintenance (Pm clinic) a If the torque converter is stalled simply, the torque converter oil is overheated before the exhaust temperature is stabilized. Accordingly, measure according to the following procedure. 1) Turn the starting switch ON and set the machine monitor to Adjustment function of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see Special functions of machine monitor (EMMS).
D155A-6
30 Testing and adjusting
2) 3)
4)
5)
6)
7)
SEN03200-04
Start the engine and set the fuel control dial in the low idle (MIN) position. Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. Set the work equipment lock lever in the free position and operate the ripper control lever to set the ripper lift cylinder to the raise stroke end. While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering system in neutral. Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. Return the decelerator pedal slowly to stall the torque converter and relieve the ripper raise system to raise the exhaust temperature to about 650 °C (Condition (a) in the figure) with the engine at high idle.
8)
9)
Under the condition of step 7), stop relieving the ripper raise system and lower the exhaust temperature by only stalling the torque converter (Condition (b) in the figure). a If the exhaust temperature does not lower but rises, set the temperature high in step 7). After the exhaust temperature is lowered and stabilized, measure the exhaust temperature (Condition (c) in the figure). k Just after the power train oil tem-
a
perature (T/C TEMPERATURE) reaches about 120 °C, return the direction of PCCS lever to neutral and lower the power train oil temperature with the engine at high idle. The border between the green range and red range of the power train oil temperature gauge indicates about 120 °C.
k Keep
pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
6.
D155A-6
After finishing measurement, remove the measuring instruments and return the removed parts. q Clean the threaded part of the removed plug, apply anti-seizure compound to it, and tighten it. 2 Plug: Anti-seizure compound (LC-G) 3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
13
SEN03200-04
30 Testing and adjusting
Measuring exhaust gas color a
Measuring instruments for exhaust gas color
Symbol C
1
Part No.
Part name
1
799-201-9001
Handy smoke checker
2
Commercially available
Smoke meter
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 position. k Be careful not to touch any hot part of the engine when removing or installing the measuring tools. a If an air source and an electric power source are not available in the field, use handy smoke checker C1. When recording official data, use smoke meter C2. a Measure the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range 1.
Measuring with handy smoke checker C1 1) Stick a sheet of filter paper to smoke checker C1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Start the engine. 4) Accelerate the engine suddenly or run it at high idle and operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas.
2)
3)
4)
5)
6) 7)
5) 6)
2.
14
Remove the filter paper and compare it with the attached scale. After finishing measurement, remove the measuring instrument and return the removed parts.
Measuring with smoke meter C2 1) Insert probe [1] of smoke meter C2 in the outlet of exhaust pipe (1) and fix it to the exhaust pipe with a clip.
8)
9)
Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter C2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm²}. Connect the power cable to a receptacle of AC 100 V. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn power switch of smoke meter C2 ON.
Start the engine. Accelerate the engine suddenly or run it at high idle and press the pedal of smoke meter C2 and collect the exhaust gas into the filter paper. Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing measurement, remove the measuring instrument and return the removed parts.
D155A-6
30 Testing and adjusting
SEN03200-04
Adjusting valve clearance a
1
Measuring instruments for valve clearance
Symbol
Part No.
D
Commercially available
Part name Thickness gauge
k Stop
a
1.
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Adjust the valve clearance under the following condition. q Engine coolant temperature: Normal temperature
Remove the engine hood assembly and air cleaner together. 4
2.
5.
6.
Engine hood assembly: 170 kg
Remove all cylinder head covers (1).
7.
3.
Remove the inspection plate on the right of the radiator guard.
4.
Rotate the crankshaft forward to bring the stamped "1.6TOP" line (a) of the damper to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Rotate the crankshaft with the hexagonal part at the end of the water pump drive shaft. a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn. a Eliminate the slack of the injector wiring harness and press it against the injector body so that it will not interfere with the rocker arm. Tighten the nuts alternately.
D155A-6
8.
9.
While fixing adjustment screw (3), loosen locknut (4). a After setting the No. 1 cylinder to the compression top dead center, adjust the valve clearance of the No. 1 cylinder. Insert thickness gauge D in the clearance between rocker arm (5) and cross head (6) and adjust the valve clearance with adjustment screw (3). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the thickness gauge lightly. a Valve clearance Intake valve : 0.35 mm Exhaust valve: 0.57 mm While fixing adjustment screw (3), tighten locknut (4). 3 Locknut: 45.1 – 51.0 Nm {4.6 – 5.2 kgm} a After tightening the locknut, check the valve clearance again.
After adjusting the No. 1 cylinder, rotate the crankshaft forward by 120 ° to set the stamped TOP line of each cylinder to pointer (2) according to the firing order and adjust the valve clearance. q Firing order: 1–5–3–6–2–4 After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
15
SEN03200-04
30 Testing and adjusting a
Measuring compression pressure1 a
Measuring tools for compression pressure
Symbol 1 E
2
Part No.
Part name
795-502-1590
Compression gauge
795-471-1330
Adapter
6261-71-6150
Gasket
a
Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and remove the injector wiring harness (Loosen the 2 terminal nuts alternately). Pass a wire under the fuel path projected sideways and pull up the injector (Do not pry the injector top up).
k Stop
a
a
1.
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure under the following conditions. q Engine oil temperature: 40 – 60 °C
Remove the engine hood assembly and air cleaner together. 4
2.
Install adapter E2 to the mounting hole on the injector and connect compression gauge E1. a Be sure to fit the gasket to the injector end. a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily.
6.
Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a See Adjusting valve clearance.
Engine hood assembly: 170 kg
Remove cylinder head cover (1) of the cylinder to measure the compression pressure.
3.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a For the procedure for bringing each cylinder to the compression top dead center, see Adjusting valve clearance.
4.
Disconnect fuel high-pressure tube (3) and injector wiring harness (4) and remove injector (5) and wiring harness.
16
5.
D155A-6
30 Testing and adjusting
7.
Set the engine in the no-injection cranking mode with the machine monitor. a See Testing and adjusting (Part 3), "Noinjection cranking".
8.
Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. q Monitoring code: 01002 Engine Speed a For the operating method, see Special functions of machine monitor (EMMS). a Be sure to replace the copper gasket and O-ring with new ones before installing the injector.
SEN03200-04
2)
Tighten bolt (13) and washer (14) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure 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}
a 1)
2) 3) 4)
a
9.
Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized. a When measuring the compression pressure, check that the engine speed is in the range of the measurement condition.
Install the injector wiring harness according to the following procedure. Install the injector wiring harness to the rocker arm housing and fix the connector side with the plate. Fix the intermediate clamp with the clip. Tighten the nut on the injector side. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} Secure the clamp and spacer with the bolt. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} Adjust the valve clearance. For details, see Adjusting valve clearance. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 kgm {3.0 – 3.5 kgm}
10. After finishing measurement, remove the measuring instruments and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. a Before installing the injector, replace the copper gasket and O-ring with new ones. 1) Push in injector (11) with the hand to assemble holder (12) temporarily.
D155A-6
17
SEN03200-04
30 Testing and adjusting
Measuring blow-by pressure a
1
value is judged abnormal, check for increase of oil consumption, bad exhaust gas color, deterioration of oil, high deterioration speed of oil, etc. which are related to the abnormal blow-by pressure.
Measuring instrument for blow-by pressure
Symbol
Part No.
F
799-201-1504
Part name Blow-by checker
k Stop
a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the blow-by pressure under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range
1.
Open the engine left side cover and left mudguard.
2.
Install nozzle [1] and hose [2] of blow-by checker F to the end of breather hose (1) and connect them to gauge [3].
3.
While running the engine at high idle, stall the torque converter and measure the blow-by pressure. a For the procedure for stalling the torque converter, see Measuring engine speed. a Normally, the blow-by pressure should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter. a If it is impossible to run the engine at the rated output or stall the torque converter, measure while the engine is running at high idle. The value obtained in this case is about 80% of the blow-by pressure at the rated output. a The blow-by pressure may vary largely with the engine condition. If the measured
18
4.
After finishing measurement, remove the measuring instruments and return the removed parts.
D155A-6
30 Testing and adjusting
SEN03200-04
Measuring engine oil pressure a
4.
Run the engine at low idle and high idle and measure the engine oil pressure.
5.
After finishing measurement, remove the measuring instruments and return the removed parts. q Remove the gasket sealant sticking to the threaded part of the removed plug with a wire brush, apply adhesive or gasket sealant to it, and install it. 2 Plug: LT-2 or LG-5 3 Plug: 16.7 – 37.2 Nm {1.7 – 3.8 kgm}
Measuring instruments for engine oil pressure
Symbol G
1
1 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
k Stop
a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range
1.
Open the engine left side cover and left mudguard.
2.
Remove engine oil pressure pickup plug (1) from the cylinder block.
3.
Install nipples [1] and [2] of hydraulic tester G1 and connect them to hydraulic tester G2. a Since the size of the plug hole is R1/4, quick nipples (799-101-5210) may be used instead of nipples [1] and [2].
D155A-6
19
SEN03200-04
Handling fuel system parts a
a
a
20
30 Testing and adjusting
1
Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter. Precaution for connecting fuel spill circuit hose The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If the engine is started while the spill circuit hose is blocked, the spill circuit pressure increases abnormally and the injector may be damaged.
Releasing residual pressure from fuel system 1 a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. k Before testing the fuel system or removing its parts, wait at for least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
D155A-6
30 Testing and adjusting
SEN03200-04
Measuring fuel pressure a
3.
Measuring instruments for fuel pressure
Symbol
Part No.
1 H
1
2 3
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal. Engine speed
Fuel pressure
High idle
0.15 – 0.3 MPa {1.5 – 3 kg/cm²}
795T-471-2010 Adapter 07005-00812
Gasket
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 position. a Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel filter to the supply pump. k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured. 1.
Open the engine left side cover and remove fuel pressure pickup plug (1) from the top of the fuel filter.
2.
Install adapter H3 and elbow [1] and nipple [2] of hydraulic tester H1 and connect them to hydraulic tester H2.
D155A-6
4.
After finishing measurement, remove the measuring instruments and return the removed parts. 3 Plug: 7.84 – 9.8 Nm {0.8 – 1.0 kgm}
21
SEN03200-04
30 Testing and adjusting
Measuring fuel return rate and fuel leakage
a
Measuring instruments for return rate and fuel leakage
Symbol
J
1
Part No.
Part name
1
6151-51-8490
Spacer
2
6206-71-1770
Joint
3
Commercially available Hose
4
Commercially available Hose
5
Commercially available Measuring cylinder
6
Commercially available Stopwatch
a
Prepare an oil pan of about 20 l to receive the fuel flowing out during the test. 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 position.
22
D155A-6
30 Testing and adjusting
1.
SEN03200-04
Preparation work 1) Open the engine left side cover and left mudguard. 2) Remove tube (3) between supply pump (1) and common rail (2). a In the figure, 1 oil filter is removed temporarily from the common rail side. a Disconnect both ends of the tube, loosen the clamp, and move the tube to the opposite side of the cylinder block.
5)
2.
3)
Insert spacer J1 on supply pump (1) side and tighten the removed joint bolt again. a Connect the return pipe to the fuel tank again, too. a Be sure to fit the gaskets to both ends of the spacer.
4)
Insert joint J2 on common rail (2) side and tighten the removed joint bolt again. a In the figure, 1 oil filter is removed temporarily from the common rail side. a Be sure to fit the gaskets to both ends of the joint.
D155A-6
Connect test hose J3 to the end of joint J2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for measuring the leakage from the pressure limiter.
Testing leakage from pressure limiter 1) Lay test hose J3 so that it will not slacken and put its end in the oil pan. 2) Turn the starting switch ON and make the machine monitor display the "Adjustment" function in the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".
23
SEN03200-04
3)
4)
3.
24
30 Testing and adjusting
Run the engine at high idle and stall the torque converter. After the engine speed is stabilized, measure the leakage in 1 minute with measuring cylinder J5. a For the procedure for stalling the torque converter, see Measuring torque converter stall speed. a You may measure the leakage for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following range, it is normal. Engine speed
Leakage (cc/min)
Torque converter stall
Max. 10
After finishing measurement, stop the engine.
Testing return rate from injector a Keep the hose on the pressure limiter side connected and keep its end in the oil pan while measuring the return rate from the injector. 1) Disconnect return hose (5) of return block (4) and connect test hose J4. a Stop the return hose with a plug, etc. and fix it to the fuel tank. Plug: 07376-70315 a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off.
2)
Lay test hose J4 so that it will not slacken and put its end in the oil pan.
3)
Turn the starting switch ON set the machine monitor to Adjusting function of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".
D155A-6
30 Testing and adjusting
4)
5)
4.
SEN03200-04
Run the engine at high idle and stall the torque converter. After the engine speed is stabilized, measure the return rate in 1 minute with measuring cylinder J5. a For the procedure for stalling the torque converter, see Measuring engine speed. a You may measure the return rate for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the measurement. a If the return rate (spill) from the injector is in the following range, it is normal. Torque converter stall speed (rpm)
Limit of return rate (spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1.200
After finishing measurement, stop the engine.
Work after finishing measurement After finishing all measurement, remove the measuring instruments and return the removed parts. 3 Common rail pressure limiter joint bolt: 17.7 – 22.6 Nm {1.8 – 2.3 kgm} 3 Supply pump overflow joint bolt: 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
D155A-6
25
SEN03200-04
Bleeding air from fuel circuit a
a
30 Testing and adjusting
Turn the starting switch to the "OFF" position.
2.
Check that the fuel valve on the fuel tank side is open.
3.
Open the left side cover of the engine and set air bleeding piping lever (1) in the vertical position to open the valve of the circuit.
Turn "ON" switch (3) of electric priming pump timer (2) installed to the side of the air cleaner. a The electric priming pump operates and lamp (4) blinks.
a
26
The electric priming pump stops while the lamp is blinking. This phenomenon is not abnormal, however. a If the switch is turned "OFF" position while the lamp is blinking, the lamp goes off and the electric priming pump stops. k While the electric priming pump is in operation, pressure is applied to the fuel circuit. Do not loosen the air bleeding plug at this time, since the fuel may spout out.
Bleed air from the fuel circuit in the following cases according to this procedure. q When the fuel filter is replaced q When fuel is used up q When the engine is started for the first time after the fuel piping or supply pump is replaced If the fuel filter was replaced, do not fill the main filter and prefilter with the fuel.
1.
4.
a
1
5.
After the specified time (approx. 7 minutes), lamp (4) goes off and the electric priming pump stops automatically. a If only the fuel filter was replaced, the air bleeding work is completed now.
6.
If the fuel was used up or the fuel piping or supply pump was replaced and there is not fuel in the fuel circuit, turn switch (3) "ON" again after the electric priming pump stops automatically.
7.
When lamp (4) goes off, the air bleeding work is completed.
8.
Set air bleeding piping lever (1) in the horizontal position to stop the valve of the circuit.
The electric priming pump has a timer in it to start and stop itself automatically (See the following figure).
D155A-6
30 Testing and adjusting
9.
SEN03200-04
Start the engine with the starting motor. a Do not operate the starting motor continuously for more than 20 seconds. q Run the engine at low idle for about 5 minutes to bleed all air from the fuel circuit. q After stopping the engine, check that the air bleeding valve is closed.
10. If the engine does not start, start it according to the following procedure. k When starting the engine, check that there is no person around the engine. a Perform the following procedure with the air bleeding valve closed. (Do not open the air bleeding valve after step 7.) a If the engine does not start, wait for at least 2 minutes before trying to start again. 1) Turn the electric priming pump switch "ON". 2) While the electric priming pump is operating, start the engine. q If the engine does not start, repeat the above operation. a Do not operate the starting motor continuously for more than 20 seconds. a If the engine does not start, wait for at least 2 minutes before trying to start again. 3) After the engine starts, keep it running for at least 5 minutes to bleed all air from the fuel circuit. 4) Stop the engine and check that the air bleeding valve is closed. 5) From now on, start the engine as usual.
D155A-6
27
SEN03200-04
Measuring fuel circuit for leakage1
k Very high pressure is generated in the high-
a a
pressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing and installing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.
1.
Spray color checker (developer) over the joints of the fuel supply pump, common rail, fuel injector, and high-pressure piping.
2.
Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
3.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
4.
Run the engine at low idle.
5.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
6.
Run the engine at high idle.
7.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
8.
Run the engine at high idle and load it. a Relieve the ripper circuit by raising the ripper.
28
30 Testing and adjusting
9.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. a If no fuel leakage is detected, inspection is completed.
D155A-6
30 Testing and adjusting
Testing and adjusting alternator belt tension 1
SEN03200-04
6.
Install belt cover (1) with the 2 mounting bolts. a Check for breakage of the pulleys, wear of the V-grooves, contact of the belts and Vgrooves, and contact of the belt covers and rotating parts. a If the belt is lengthened to the adjustment limit, cut, or cracked, replace it with new one. a If the V-belt is replaced, adjust its tension again after 1 operating hour. a After tightening the bolts, check that the belt tension is normal according to the above procedure.
7.
After testing and adjusting, return the removed parts.
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 position.
Testing 1. Open the engine right side cover and remove the inspection plate on the right of the radiator guard. 2.
Press the intermediate point of the belt between alternator pulley and water pump pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 98 N {Approx. 10 kg} a Deflection (a): 13 – 16 mm
Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.
Remove the 2 mounting bolts and belt cover (1). a Remove the belt cover only when replacing the belt.
2.
Loosen 2 mounting bolts (3) of alternator (2), and then loosen lock bolt (4) of the adjustment rod.
3.
Loosen locknut (5) of the adjustment rod and move alternator (2) with adjustment nut (6) to adjust the tension of the belt.
4.
While fixing adjustment nut (6), tighten locknut (5).
5.
Tighten locknut (4) of the adjustment rod and 2 mounting bolts (3) of alternator (2).
D155A-6
29
SEN03200-04
Testing and adjusting air conditioner compressor belt tension k Stop
30 Testing and adjusting a
1
After tightening the bolts, check that the belt tension is normal according to the above procedure.
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
Testing 1. Open the engine left side cover and left mudguard. 2.
Press the intermediate point of the belt between the supply pump pulley and compressor pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 59 N {Approx. 6 kg} a Deflection (a): 10 mm
5.
After testing and adjusting, return the removed parts.
Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.
Loosen 4 bracket mounting bolts (1).
2.
Loosen locknut (2) and move compressor (4) and bracket as a unit with adjustment bolt (3) to adjust the belt tension.
3.
While fixing adjustment nut (3), tighten locknut (2).
4.
Tighten 4 bracket mounting bolts (1). a Check for breakage of the pulleys, wear of the V-grooves, contact of the belts and Vgrooves, and contact of the belt covers and rotating parts. a If the belt is lengthened to the adjustment limit, cut, or cracked, replace it with new one. a If the V-belt is replaced, adjust its tension again after 1 operating hour.
30
D155A-6
30 Testing and adjusting
SEN03200-04
Measuring fan speed a
1
Measuring instrument for fan speed
Symbol
Part No.
K
799-205-1101
Part name Tachometer kit
k Stop
a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the fan motor speed under the following condition. q Hydraulic oil temperature: Within operating range
1.
Open the radiator mask and remove the fan net.
2.
Stick 1 reflection tape [1] of tachometer kit K to fan (1)
3.
Set probe [2] to the reflection tape with stand [3] and connect it to tachometer [4]. k Take care that the probe will not inter-
a
4.
Hydraulic oil temperature [ºC]
fere with the fan. Rotate the fan with the hand and check that the probe can sense the rotation of the reflection tape.
57 ± 2 ºC or 77 ± 2 ºC
Engine speed [rpm]
Standard fan seed [rpm]
Low idle
500 ± 50
High idle
1100 – 1150
1675 ± 25
1100 – 1150
Test and adjust the fan 100% speed according to the following procedures. 1) Set the fuel control dial to the high idle position and then check the engine speed in the monitoring mode (ID: 01000) and press and hole the decelerator pedal so that the engine speed will be 1675 ± 25 [rpm]. 2) Set the fan in the fan 100% mode (ID: 1005) of the adjustment mode and test the fan 100% speed. If the fan 100% speed is out of the standard range, adjust it. 3) If the fan 100% speed is lower or higher than the standard range, see Troubleshooting, H mode, "H-23: Fan speed is abnormal". 4) Test the fan 100% speed in the high idle and low idle modes.
Close the radiator mask.
k Before starting the engine, be sure to
close the radiator mask. Do not start the engine while the radiator mask is open. 5.
Test the fan speed at each engine speed in the fan 100% speed mode (ID: 1005) according to the following procedure. a For the operating method in the adjustment mode, see "Special functions of monitor panel (EMMS)".
D155A-6
31
SEN03200-04
6.
32
30 Testing and adjusting
After finishing measurement, remove the measuring instruments and return the removed parts.
D155A-6
30 Testing and adjusting
SEN03200-04
Measuring fan circuit oil pressure1 a
Measuring instruments for fan circuit oil pressure
Symbol 1 L
2 3
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3400
Adapter (05)
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring
k Stop
a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the fan circuit oil pressure under the following condition. q Hydraulic oil temperature: Within operating range
1.
Open the radiator mask and remove the fan net.
2.
Disconnect supply hose (1) of the fan motor.
3.
Install adapter L2 and connect the disconnected hose again.
4.
Install nipple L3 and connect it to oil pressure gauge [2]. a When using an analog oil pressure gauge, use one of 39.2 MPa {400 kg/cm²}.
D155A-6
5.
Close the radiator mask.
k Before starting the engine, be sure to
close the radiator mask. Do not start the engine while the radiator mask is open. 6.
Start the engine and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 1005 (Fan 100% mode) a For the operating method, see "Special functions of machine monitor (EMMS)". a If this adjustment code is displayed, the fan speed is kept at 100% speed in accordance with the engine speed, regardless of the state of the machine.
33
SEN03200-04
7.
While running the engine at high idle, measure the fan circuit oil pressure.
30 Testing and adjusting
Bleeding air from fan pump a
a
8.
34
1
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. Before starting the following work, check that the hydraulic oil level is normal.
1.
Remove the left step cover.
2.
Loosen air bleeder (1) and leave it for 15 minutes.
3.
After 15 minutes, start the engine and run it at low idle.
4.
After oil flows out of air bleeder (1), tighten air bleeder (1) and stop the engine. 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
After finishing measurement, remove the measuring instruments and return the removed parts.
D155A-6
30 Testing and adjusting
SEN03200-04
Bleeding air from work equipment pump 1 a
a
If the work equipment pump is removed and installed or its piping is disconnected and connected, bleed air from the work equipment pump case according to the following procedure. Before starting the following work, check that the hydraulic oil level is normal.
1.
Remove the right step cover.
2.
Loosen air bleeder (1) and leave it for 15 minutes.
3.
After 15 minutes, start the engine and run it at low idle.
4.
After oil flows out of air bleeder (1), tighten air bleeder (1) and stop the engine. 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
D155A-6
35
SEN03200-04
30 Testing and adjusting
Adjusting fuel control dial and decelerator pedal
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 position.
1.
36
Outline of fuel control system q The following signals are input as rotation command signals to the engine controller. 1) Fuel control dial potentiometer signal 2) Decelerator pedal potentiometer signal 3) 3rd throttle signal (Power train controller) q The engine controller controls the fuel control system of the engine (CRI system) according to the one of the above input signals which indicates the lowest engine speed. q Adjust the decelerator pedal speed and high idle speed with the decelerator pedal linkage.
DIAL: Fuel control dial PEDAL: Decelerator pedal ROD: Decelerator pedal rod POTENTIO: Decelerator pedal potentiometer ENG-ECU: Engine controller P/T-ECU: Power train controller ENGINE: Engine unit (CRI devices) [KOMNET]: KOMNET communication circuit (3rd throttle signal)
D155A-6
30 Testing and adjusting
2.
Preparation work 1) Remove the right cover of the dashboard and the right foot rest as a unit. 2) Start the engine and set the machine monitor to Adjusting function of the service mode. q Adjustment code: 0007 (Engine decelerator cut) a For the operating method, see "Special functions of machine monitor (EMMS)".
3.
Adjusting decelerator pedal speed With the fuel control dial in the high idle position (MAX), press decelerator pedal (1) to stopper bolt (2) and check that the decelerator pedal speed is normal. q Decelerator pedal speed: 875 ± 50 rpm a If the decelerator pedal speed is abnormal, adjust installed dimension (a) of stopper bolt (2). q Standard installed dimension a) of stopper bolt: 35.0 mm
4.
Adjusting high idle speed With the fuel control dial in the high idle position (MAX), release decelerator pedal (1) and check that the high idle speed is normal. q High idle speed: 2,050 ± 50 rpm a If the high idle speed is abnormal, adjust it according to the following procedure. q When the engine speed is above 1,950 rpm: Lower the engine speed below 1,900 rpm temporarily with stopper bolt (3) to eliminate the play of the decelerator pedal, and then adjust the engine speed to the high idle. q When the engine speed is below 1,950 rpm: Adjust the engine speed to the high idle speed with stopper bolt (3). q Standard installed dimension (b) of stopper bolt: 34.8 mm
D155A-6
SEN03200-04
5.
Work after adjustment After finishing all adjustment, return the removed parts.
37
SEN03200-04
30 Testing and adjusting
D155A-6 Bulldozer Form No. SEN03200-04
© 2011 KOMATSU All Rights Reserved Printed in Japan 11-11
38
D155A-6
SEN03201-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
30 Testing and adjusting
1
Testing and adjusting, Part 2 Measuring power train oil pressure................................................................................................................. 3 Adjusting transmission output shaft speed sensor.........................................................................................11 Simple test procedure for brake performance............................................................................................... 12 Adjusting brake pedal ................................................................................................................................... 13 Adjusting parking brake lever........................................................................................................................ 15 Emergency escape method when power train has trouble ........................................................................... 17 Adjusting idler clearance............................................................................................................................... 20 Testing and adjusting track shoe tension ...................................................................................................... 22 Measuring and adjusting work equipment oil pressure................................................................................. 23 Measuring control circuit basic pressure....................................................................................................... 26 Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure) ..................... 27 Measuring PPC valve output pressure ......................................................................................................... 28 Adjusting work equipment PPC valve play ................................................................................................... 30 Measuring ripper pin puller solenoid valve output pressure.......................................................................... 32 Testing parts which cause hydraulic drift of blade and ripper........................................................................ 33 Measuring internal leakage of work equipment cylinder ............................................................................... 34
D155A-6
1
SEN03201-03
30 Testing and adjusting
Releasing residual pressure from work equipment cylinder.......................................................................... 35 Bleeding air from work equipment cylinder ................................................................................................... 35 Adjusting work equipment lock lever............................................................................................................. 36 Adjusting blade.............................................................................................................................................. 37 Adjusting operator's cab................................................................................................................................ 39
2
D155A-6
30 Testing and adjusting
SEN03201-03
Measuring power train oil pressure a
1
Measuring instruments for power train oil pressure
Symbol M
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
k Stop
a
a
a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the power train oil pressure under the following condition. q Power train oil temperature: Within operating range Since the power trail oil pressure pickup plugs (centralized pressure pickup section) are installed inside the right step cover, remove that cover when measuring the power train oil pressure. Pressure pickup plugs and gauges to be used
No. Stamp 1
TM
2
RC
3
LC
4
F
5
R
6
1ST
7
2ND
8
3RD
9
RB
10
LB
11
IN
12
OUT
D155A-6
Oil pressure to be measured
Transmission main relief pressure Steering right clutch pressure Steering left clutch pressure Transmission forward clutch pressure Transmission reverse clutch pressure Transmission 1st clutch pressure Transmission 2nd clutch pressure Transmission 3rd clutch pressure Steering right brake pressure Steering left brake pressure Torque converter inlet pressure Torque converter outlet pressure
Oil pressure gauge (MPa {kg/cm²}) 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 2.5 {25} 2.5 {25}
3
SEN03201-03
1.
Measuring transmission main relief pressure (TM) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (1). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
2)
3)
4)
Start the engine and set the PCCS lever in the fully neutral position. a The parking brake lever may be set in the LOCK position. While running the engine at low idle and high idle, measure the main relief pressure.
30 Testing and adjusting
2.
Measuring right steering clutch pressure (RC) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure measurement nipple (2). a Use a 6.0 MPa {60 kg/cm²} oil pressure gauge.
2) 3)
4)
After finishing measurement, remove the measuring instruments and return the removed parts. 5)
4
Start the engine and set the parking lever to the FREE position. Operate the PCCS lever steering fully to the right. a Set the direction to the neutral position. 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.
After completing the measurement, remove the measuring equipment and set to the original condition.
D155A-6
30 Testing and adjusting
3.
Measuring left steering clutch pressure (LC) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure measurement nipple (3). a Use a 6.0 MPa {60 kg/cm²} oil pressure gauge.
2) 3)
4)
Start the engine and set the parking lever to the FREE position. Operate the PCCS lever steering fully to the left. a Set the direction to the neutral position. 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.
SEN03201-03
4.
Measuring transmission forward clutch pressure (F) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (4). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
2) 3)
4)
5)
Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2 While pressing the brake pedal, set the direction of PCCS lever in the forward position and shift up the gear to the 3rd gear speed with the shiftup switch. a Keep the steering system in neutral. a Check that [F3] is displayed in the gear speed display section. While running the engine at high idle, measure the forward clutch pressure. k Since
the torque converter is stalled, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
5)
D155A-6
After completing the measurement, remove the measuring equipment and set to the original condition.
5
SEN03201-03
6)
5.
30 Testing and adjusting
After finishing measurement, remove the measuring instruments and return the removed parts.
Measuring transmission reverse clutch pressure (R) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (5). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
6)
2) 3)
4)
5)
After finishing measurement, remove the measuring instruments and return the removed parts.
Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2 While pressing the brake pedal, set the direction of PCCS lever in the reverse position and shift up the gear to the 3rd gear speed with the shiftup switch. q Keep the steering system in neutral. q Check that [R3] is displayed in the gear speed display section. While running the engine at high idle, measure the reverse clutch pressure. k Since
the torque converter is stalled, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
6
D155A-6
30 Testing and adjusting
6.
SEN03201-03
Measuring transmission 1st clutch pressure (1ST) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (6). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
6)
7. 2) 3)
4)
5)
Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F1-R1 While pressing the brake pedal, set the direction of PCCS lever in the forward position. a Keep the steering system in neutral. a Check that [F1] is displayed in the gear speed display section. While running the engine at low idle, measure the 1st clutch pressure.
After finishing measurement, remove the measuring instruments and return the removed parts.
Measuring transmission 2nd clutch pressure (2ND) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (7). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
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.
2) 3)
4)
D155A-6
Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2 While pressing the brake pedal, set the direction of PCCS lever in the forward position. a Keep the steering system in neutral. a Check that [F2] is displayed in the gear speed display section.
7
SEN03201-03
5)
While running the engine at low idle, measure the 2nd clutch pressure.
30 Testing and adjusting
4)
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.
5)
While pressing the brake pedal, set the direction of PCCS lever in the forward position and shift up the gear to the 3rd gear speed with the shiftup switch. a Keep the steering system in neutral. a Check that [F3] is displayed in the gear speed display section. While running the engine at low idle, measure 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.
6)
8.
Measuring transmission 3rd clutch pressure (3RD) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (8). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
2) 3)
8
After finishing measurement, remove the measuring instruments and return the removed parts.
6)
After finishing measurement, remove the measuring instruments and return the removed parts.
Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2
D155A-6
30 Testing and adjusting
9.
Measuring steering right brake pressure (RB) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (9). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
2) 3)
Start the engine and set the parking brake lever in the FREE position. While running the engine at low idle and high idle, measure the right brake pressure. a During measurement, check that the oil pressure lowers to 0 when the brake pedal is pressed or the parking brake lever is set in the LOCK position.
SEN03201-03
10. Measuring steering left brake pressure (LB) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (10). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
2) 3)
4) 4)
D155A-6
After finishing measurement, remove the measuring instruments and return the removed parts.
Start the engine and set the parking brake lever in the FREE position. While running the engine at low idle and high idle, measure the left brake pressure. a During measurement, check that the oil pressure lowers to 0 when the brake pedal is pressed or the parking brake lever is set in the LOCK position.
After finishing measurement, remove the measuring instruments and return the removed parts.
9
SEN03201-03
11. Measuring torque converter inlet pressure 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure measurement nipple (11). a Use a 2.5 MPa {25 kg/cm²} oil pressure gauge.
30 Testing and adjusting
12. Measuring torque converter outlet pressure 1) Connect hydraulic tester M to oil pressure measurement nipple (12). a Use a 2.5 MPa {25 kg/cm²} oil pressure gauge.
2) 2) 3)
Start the engine and set all the functions of the PCCS lever to neutral. Measure the oil pressure with the engine at low idle and high idle.
3)
4) 4)
10
After completing the measurement, remove the measuring equipment and set to the original condition.
Start the engine and set all the functions of the PCCS lever to neutral. Measure the oil pressure with the engine at low idle and high idle.
After completing the measurement, remove the measuring equipment and set to the original condition.
D155A-6
30 Testing and adjusting
Adjusting transmission output shaft speed sensor k Stop
SEN03201-03
Remove the fuel tank and transmission output shaft speed sensor (1). 4
a
Fuel tank: 950 kg (when full)
Before adjusting the transmission output shaft speed sensor, remove it and check that its tip is free from steel chips and flaws, and then reinstall it.
2.
Screw in sensor (1) until its tip touches the tooth tip of bevel gear (2). 2 Threads: Gasket sealant (LG-5)
3.
Return sensor (1) by the specified angle. a Returning angle of sensor: 1/2 – 1 turn a Adjust clearance (a) between the sensor tip and gear tooth tip to 0.75 – 1.5 mm.
4.
While fixing sensor (1), tighten nut (3). 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
D155A-6
After finishing adjustment, return the removed parts.
6.
Start the engine, set the machine monitor to Monitoring function of the service mode, and check that the transmission speed is indicated normally. a Monitoring code: 31400 T/M Out Speed a For the operating method, see Special functions of machine monitor (EMMS). a To rotate the transmission output shaft, drive the machine actually or run the track idle.
1
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position.
1.
5.
11
SEN03201-03
Simple test procedure for brake performance 1 k Stop
a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Carry out the simple performance test of the brake under the following condition. q Power train oil temperature: Within operating range
1.
Set the blade and ripper in the travel position on a level place.
2.
Run the engine and set the parking brake lever in the FREE position.
3.
Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2
4.
While pressing the brake pedal, set the direction of PCCS lever in the forward position.
30 Testing and adjusting
6.
Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idle speed. k Since
the torque converter is stalled, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
k If this test is carried out in the 1st gear
a a 5.
12
position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd gear speed. Check that [F2] is displayed in the gear speed display section. Keep the steering system in neutral.
Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position.
D155A-6
30 Testing and adjusting
SEN03201-03
Adjusting brake pedal
a
1
Adjusting tool for brake pedal
Symbol N
Part No.
Part name
79A-264-0091 Push-pull scale
k Stop
a a
1.
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Tighten the locknut of the rod securely and bend the cotter pin securely. When adjusting the brake pedal, remove the left cover of the dashboard and left foot rest as a unit. Adjusting brake potentiometer 1) Turn the starting switch ON and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 0005 (Brake pedal potentiometer initial correction) a For the operating method, see "Special functions of machine monitor (EMMS)".
D155A-6
2)
3)
4)
Adjust installed dimension (b) of stopper (2) so that dimension (a) will be 80 mm. q Dimension (b) = 35.5 mm (Reference value) Adjust installed dimension (b) of stopper (2) so that the brake pedal potentiometer voltage will be the specified voltage when brake pedal (1) is released. q Brake pedal voltage: 2,500 ± 50 mV Referring to "Special functions of machine monitor (EMMS), Service mode 07, Adjustment (Adjustment ID: 0005)", perform initial correction of the brake pedal potentiometer.
13
SEN03201-03
2.
Adjusting brake pedal pressing effort a While brake pedal (1) is released, adjust installed dimension (d) of return spring (5). 1) Loosen nut (8). 2) Turn double nut (7) to adjust the brake pedal pressing effort. a Turn the 2 nuts together. Do not loosen them from each other. q Adjustment dimension (d) of rod (Installed dimension of return spring): 92 ± 0.5 mm q Assembly dimension (e) of rod: 127 mm
3.
Adjusting brake limit switch 1) Press brake pedal (1). When the brake pedal potentiometer voltage is in the following range, fix the brake pedal. q Brake pedal voltage: 3,940 – 4,150 mV 2) Adjust the installed position of brake limit switch (6) so that it will be turned ON at this position. q Backup brake active Sw ON 3) After adjusting, return the brake pedal slowly and check that brake limit switch (6) is turned OFF in the voltage range shown in 1). q Backup brake active Sw OFF
4.
Measuring brake pedal pressing force 1) Operate the brake pedal with the foot and check that it moves smoothly. 2) Using push-pull scale N, measure the pressing force to start operation of the brake. q Pressing force to start operation: 49 N {5 kg} 3) Using push-pull scale N, measure the pressing force at the stroke end of the brake pedal. q Pressing force at stroke end: 461 N {47 kg}
5.
Work after finishing adjustment After finishing adjustment, return the removed parts.
14
30 Testing and adjusting
D155A-6
30 Testing and adjusting
SEN03201-03
Adjusting parking brake lever
k Stop
a a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Tighten the locknut of the rod securely and bend the cotter pin securely. Remove the lever cover in the cab.
1.
Assembly and installation of lever assembly 1) Assemble lever assembly (1) and adjust the operation of limit switch (2). q Lever raising position: OFF, lowering position: ON q Limit switch operation stroke: 2.8 mm 2) Install lever assembly (1).
2.
Checking brake oil pressure Run the engine and check that the brake oil pressure is as follows when parking brake lever (3) is set in the FREE position and LOCK position. a For the method of measuring the brake oil pressure, see Measuring power train oil pressure.
D155A-6
1
q
Brake oil pressure (At high idle) Parking brake lever
Oil pressure
FREE position
2.75 ± 0.29 MPa {28.0 ± 3.0 kg/cm²}
LOCK position
0 MPa {0 kg/cm²}
15
SEN03201-03
3.
Checking limit switch 1) Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. a Monitoring code: 40905 T/M Sw Input 1 a For the operating method, see "Special functions of machine monitor (EMMS)".
2)
16
30 Testing and adjusting
Check that the limit switch signal is input normally when parking brake lever (3) is set in the FREE position and LOCK position. q FREE position: Travel lock NC OFF, Travel lock NO ON q LOCK position: Travel lock NC ON, Travel lock NO OFF
D155A-6
30 Testing and adjusting
SEN03201-03
Emergency escape method when power train has trouble 1 a
Tools for emergency escape
Symbol P
1 2
1.
Part No.
Part name
19M-06-32820 Switch assembly 17A-06-41410 Wiring harness 790-190-1601
Pump assembly
Emergency escape method with switch box (Using P1) a If the machine cannot be moved because of a trouble in the electric system of the power train control unit (travel direction, gear speed, steering), escape according to the following procedure. a The engine must be startable for the following procedure. a If the engine cannot be started, see Emergency escape method with brake releasing device (Using P2). k Do not turn the starting switch ON or start the engine before preparing the switch assembly and wiring harness P1 completely. 1) Connect wiring harness [2] to switch assembly [1] of emergency escape device P1. k Set the all gear speed switches of
switch assembly [1] in the OFF position and set the directional switch in the P position to prevent the machine from starting suddenly.
2)
D155A-6
3)
Disconnect neutral safety relay NSF (2) and connect pins No. 3 and No. 5 of the connector on the wiring harness side. a Direct coupling circuit: NSF (female) No. 3 io No. 5 a If connector PL1 is disconnected, a model selection error is made and neutral safety relay NSF is not driven. The above operation is performed to prevent this. k If the engine is started by this method, the neutral safety function d o e s n o t w o r k . A c c o r d i n g l y, before starting the engine, set the parking brake lever in the LOCK position and set the PCCS lever in the fully neutral position. k Start the engine by this method only in an emergency. If the engine does not start in another case, be sure to carry out troubleshooting and repair the trouble.
Open the left fender inspection cover and connect wiring harness [2] to connector PL1 (1). a The male housing and female housing of connector PL1 are fixed with screws. a Connect the wiring harness to both male side and female side of connector PL1.
17
SEN03201-03
4) 5)
6)
2.
18
Start the engine and set the parking brake lever in the FREE position. 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.
30 Testing and adjusting
2)
Install volume pump [3] of pump assembly P2 to the outside of the operator's cab.
3)
Remove the fuel tank under rear cover and disconnect supply hose (3) of the pin puller solenoid valve.
4)
Connect end hose [4] of pump assembly P2 to the hose side. a Since the hose on the machine side is face seal type, use a nipple of face seal type on the pump assembly P2 side. a Stop the solenoid valve side with a cap nut, etc. Cap nut: 02789-00315
5)
Turn the starting switch ON and set the parking brake lever in the FREE position.
After moving the machine, remove the instruments used and return the removed parts. a Check that the seal at the joint of connector PL1 is not projected or removed and then tighten the screws to the specified torque. 3 Screw of connector PL1: 2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
Escape method with brake releasing device (Using P2) a If the engine cannot be started and the parking brake cannot be released, escape according to the following procedure. 1) Assemble pump assembly P2.
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30 Testing and adjusting
6)
7)
D155A-6
SEN03201-03
Operate the volume pump to raise the brake releasing oil pressure to the initial pressure. q Initial pressure: Approx. 2.74 MPa {Approx. 28 kg/cm²} a Since the accumulator is installed in the circuit, the handle must be operated 30 – 50 times to raise the oil pressure. a If the oil pressure does not rise above a certain level, the relief valve may be set to low pressure. In this case, adjust the set pressure of the relief valve. Tow the machine to a safe place. a The brake releasing oil pressure lowers gradually because of internal leakage and the brake is applied again in about 1 minute. Accordingly, work quickly. a If the brake releasing pressure lowers to about 1.57 MPa {about 16 kg/cm²}, the brake is applied. In this case, operate the volume pump again to raise the brake releasing pressure to the initial pressure.
19
SEN03201-03
Adjusting idler clearance
a
If the lateral guide, vertical guide, or guide plate of the idler is worn and the idler runs out sideways or slants, adjust the idler clearance according to the following procedure.
1.
Adjusting in lateral directions 1) Travel the machine on a flat ground 1 – 2 m and measure clearance (A) (at 4 places on the right and left sides, inside, and out side). 2) If clearance (A) is 4 mm or wider, loosen bolts (1) and adjust the clearance with shim (2) to the following range. Clearance on each side: 0.5 – 1.0 mm a Types of shim: 0.5 mm, 1.0 mm a Do not loosen bolts (1) more than 3 turns.
20
30 Testing and adjusting
1
D155A-6
30 Testing and adjusting
2.
Adjusting in vertical directions 1) Measure clearance (B) between support (3) and guide plate (4) and clearance (C) between vertical guide (5) and wear plate (6). 2) If the total of clearances (B) + (C) is 5 mm or wider, pull out shim (7) and add it to shim (8) to adjust the clearance to the following range. Clearances (B) + (C): 2 mm a When normal, clearance (C) = 0 mm.
SEN03201-03
(7) Tighten bolts (1). 3 Bolt: 662 – 829 Nm {67.5 – 84.5 kgm} a This part can be adjusted to 6 mm.
Adjustment procedure 1] To grasp the adjustment quantity, measure clearance (B) and let it be x. Adjusting quantity: x – 2 mm a
2]
3] a
4]
5] a
6]
D155A-6
Vertical guide (5) must be set free to move shim (7) to shim (8). For this purpose, perform following steps 2] and 3]. Loosen bolts (9) (4 each on the inside and outside). a Loosen until the spring reaction is lost. Loosen bolts (1). Do not loosen the bolts more than 3 turns.
Pull up vertical guide (5) with a bar etc. to reduce clearance (C) to 0 and pull out shim (7) for the adjusting quantity measure in step 1]. Add shim (7) pulled out to shim (8). (Right, left, inside, and outside, 8 places in total) Check that the total number of shims (7) and (8) in each place is the same as the total number before the adjustment. If the number of the shims is changed, the internal spring does not function normally. After adjusting, tighten spring holding bolts (9).
21
SEN03201-03
30 Testing and adjusting
Testing and adjusting track shoe 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 position.
Testing 1. Drive the machine slowly on a level place, then stop it. a Do not apply the brake when stopping. 2.
Place straight steel bar (1) between the idler and front carrier roller and measure maximum clearance (a) between the bottom of the steel bar and shoe grouser. a For the above measurement, use an Lshaped steel which will be deflected less. q Standard max. clearance (a): 20 – 30 mm
4.
After finishing adjustment, return the removed parts.
Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. 1.
Remove cover (2).
2.
When the tension is too high Loosen plug (3) to discharge the grease. k Since
the high-pressure grease may spout out, do not loosen the plug more than 1 turn. 3 Plug: 59 – 88 Nm {6 – 9 kgm}
3.
22
When tension is low Add grease through grease fitting (4). a If the track shoe is not tensed well, drive the machine forward and in reverse slowly.
D155A-6
30 Testing and adjusting
SEN03201-03
Measuring and adjusting work equipment oil pressure a
1
Measuring and adjusting instruments for work equipment oil pressure
Symbol
Part No.
1 Q 2
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring
k Stop
a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. When measuring and adjusting the work equipment oil pressure, remove the control valve cover. 4
3)
Run the engine at high idle and set the blade control lever and ripper control lever in neutral and measure the unload pressure. a The work equipment lock lever may be set in the LOCK position. k Do not operate the work equipment or steer the machine with the oil pressure gauge of 6.0 MPa {60 kg/ cm²} installed. If you do so, the oil pressure gauge will be broken.
4)
After finishing measurement, remove the measuring instrument and return the removed parts.
Control valve cover: 25 kg
Measuring a Measure the work equipment under the following condition. q Hydraulic oil temperature: Within operating range a The unload pressure, work equipment oil pressure can be checked with the monitoring function of the service mode of the machine monitor (See 4). 1.
Measuring unload pressure 1) Remove P oil pressure pickup plug (1) from the control valve.
2.
2)
D155A-6
Measuring work equipment oil pressure 1) Remove P oil pressure pickup plug (1) and LS oil pressure pickup plug (2) from the control valve.
Install nipple Q2 and connect it to oil pressure gauge [1] of hydraulic tester Q1. a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.
23
SEN03201-03
2)
Install nipples Q2 and connect them to oil pressure gauges [1] of hydraulic tester Q1. a When using analog oil pressure gauges, use ones of 40 MPa {400 kg/ cm²}.
3)
Start the engine and set the work equipment lock lever in the FREE position. Run the engine at high idle, operate the blade control lever and ripper control lever to relieve each cylinder at a stroke end, and measure the work equipment relief pressure and work equipment LS relief pressure. a The work equipment relief pressure is measured on the P-stamp side and the work equipment LS relief pressure is measured on the LS-stamp side. k Do not steer the machine with the oil pressure gauge of 40 MPa {400 kg/cm²} installed. If you do so, the oil pressure gauge will be broken.
4)
5)
24
30 Testing and adjusting
3.
Measuring with machine monitor 1) Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. q Monitoring code: 70700 Hydraulic Pump Pressure 1 a For the operating method, see Special functions of machine monitor (EMMS).
2)
Start the engine and measure each oil pressure. a The measuring condition of each oil pressure is the same with 1 – 3 above. a Only the oil pressures on the P-stamp side (unload pr essure and work equipment relief pressure) can be measured with the monitoring function. The oil pressures on the LSstamp side (work equipment and LS relief pressure) cannot be measured.
After finishing measurement, remove the measuring instrument and return the removed parts.
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30 Testing and adjusting
Adjusting 1. Adjusting unload pressure a The unload pressure cannot be adjusted. 2.
SEN03201-03
3)
While fixing adjustment nut (4), tighten locknut (5). 3 Locknut: 39 – 49 Nm {4 – 5 kgm}
4)
After finishing measurement, check the work equipment oil pressure according to the above measuring method.
Adjusting work equipment oil pressure a If the work equipment oil pressure is abnormal, adjust it with work equipment LS relief valve (3) according to the following procedure.
1) 2)
D155A-6
While fixing adjustment nut (4), loosen locknut (5). Adjust the pressure by rotating adjustment nut (4). a If the adjustment nut is q rotated to the right, the pressure is heightened. q rotated to the left, the pressure is lowered. a Quantity of adjustment per turn of adjustment nut: Approx. 19.6 MPa {Approx. 200 kg/cm²}
25
SEN03201-03
30 Testing and adjusting
Measuring control circuit basic pressure 1 a
Measuring instruments for control circuit basic pressure
Symbol 1 R 2
Part No.
Part name
799-101-5002
Hydraulic tester
709-261-1204
Digital hydraulic tester
799-401-3200
Adapter (03)
02896-11009
O-ring
a
The control circuit basic pressure is the pressure lowered by the self-pressure reducing valve of the fan circuit. It is used commonly for the fan pump control and PPC valve. 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 position. a Measure the control circuit basic pressure under the following condition. q Hydraulic oil temperature: Within operating range 1.
Run the engine at high idle, set the blade control lever and ripper control lever in neutral, and measure the control circuit basic pressure. a The work equipment lock lever may be set in the LOCK position.
5.
After finishing measurement, remove the measuring instrument and return the removed parts.
a
The control circuit basic pressure cannot be adjusted.
Remove the centralized pressure pickup block top cover of the right fender of the machine.
2.
Install adapter R2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester R1 and connect it to oil pressure gauge [2]. a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/cm²}.
26
4.
D155A-6
30 Testing and adjusting
SEN03201-03
Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure) 1 a
Measuring instruments for work equipment lock solenoid valve output pressure
Symbol
Part No.
1 S 2
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
791T-643-1010 Elbow 07002-11423
O-ring
k Stop
a
1.
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the work equipment lock solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range
4.
Run the engine at high idle, set the work equipment lock lever in the LOCK position and FREE position, and measure the solenoid valve output. a If the output pressure is as follows, the operation of the work equipment lock solenoid valve is normal. Work equipment lock lever
Output pressure
LOCK position
0 MPa {0 kg/cm²}
FREE position
Same as control circuit basic pressure (See standard value table)
Remove the control valve cover. 4
Control valve cover: 25 kg
2.
Disconnect hose (1), replace elbow (2) with adapter S2, and connect hose (1) again.
3.
Install nipple [1] of hydraulic tester S1 to tool S2 and connect oil pressure gauge [2] of 6.0 MPa {60 kg/cm2}.
5.
D155A-6
After finishing measurement, remove the measuring instrument and return the removed parts.
27
SEN03201-03
30 Testing and adjusting
Measuring PPC valve output pressure a
Run the engine at high idle, operate the control lever of the circuit to be measured, and measure the oil pressure. a Measure the oil pressure with the control lever at the stroke end. a Measure the oil pressure on the blade lowering side with the control lever at the float position.
6.
After finishing measurement, remove the measuring tools and return the removed parts.
1
Measuring tools for PPC valve output pressure
Symbol 1 T
5.
2 3
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3100
Adapter (02)
02896-11008
O-ring
799-401-3200
Adapter (03)
02896-11009
O-ring
k Stop the machine on a flat ground, lower
a a
the work equipment to the ground, and set the parking brake lever and safety lock lever in the lock position. Before measuring the PPC valve output pressure, check that the basic pressure of the control circuit is normal. Measure the PPC valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range
1.
Remove the main control valve cover.
2.
Disconnect PPC valve output pressure hose (1) and install pressure pickup adapter (T2, T3). a For the circuit to be measured, see the figure on the next page.
3.
Install nipple [1] of hydraulic tester T1 and connect oil pressure gauge [2].
4.
Start the engine and set the safety lock lever in the free position.
28
D155A-6
30 Testing and adjusting
1. 2. 3. 4. 5.
Main valve Self-pressure reducing valve PPC lock valve Blade PPC valve Ripper PPC valve
D155A-6
SEN03201-03
A. B. C. D. E. F. G. H.
Blade right tilt Blade lower Ripper lower Ripper tilt back Ripper tilt in Ripper tilt raise Blade raise Blade left tilt
29
SEN03201-03
30 Testing and adjusting
Adjusting work equipment PPC valve play
1
a Part R in hatched area must not be disassembled
k Stop
a a
30
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 positions. If the blade lever end play is large, adjust the PPC valve according to the following procedure. The ripper valve cannot be adjusted.
1.
Measuring play in directions of ports P3 and P4 Measure play (x) in the neutral position of the lever at 240 mm from the turn center of the lever. (x): Max. 24 mm a If the play is out of the above range, joint (1) may be worn. In this case, replace joint (1).
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30 Testing and adjusting
SEN03201-03
Replacement procedure for joint (1) 1) Remove boot (2), nut (3) and disc (4). 2) Replace joint (1). 3 Joint (1): 39 – 49 Nm {4 – 5 kgm} 3) Install disc (4). 4) Install nut (3). 2.
Adjusting lever end play 1) Remove boot (2) and nut (3). 2) Tighten disc (4) and tighten nut (3) temporarily. 3) Measure the lever end play. q Measuring play in directions of ports P3 and P4 Measure play (x) in the neutral position of the lever at 240 mm from the turn center of the lever. (x): 0.6 – 3.6 mm q Measuring play in direction of port P1 (Full stroke) (y): 0.03 – 0.3 mm 4) Tighten nut (3). a Fix disc (4) and tighten nut (3). 3 Nut (3): 93.1 – 112.7 Nm {9.49 – 11.49 kgm}
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
4.
Install boot (2).
D155A-6
31
SEN03201-03
30 Testing and adjusting
Measuring ripper pin puller solenoid valve output pressure 1 a
Measuring instruments for ripper pin puller solenoid valve output pressure
Symbol 1 U 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3200
Adapter (03)
02896-11009
O-ring
k Stop
a
1.
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the ripper pin puller solenoid valve output pressure under the following condition. q Power train oil temperature: Within operating range
4.
Run the engine at high idle, set the pin puller switch in the pull-out position and push-in position, and measure the solenoid valve output pressure at each position. a If the output pressure is as follows, the operation of the ripper pin puller solenoid valve is normal. Tested Pin puller hose switch
Remove the undercover of the fuel tank and disconnect ripper pin puller solenoid valve hose (1) or (2). q Hose (1): Pin puller cylinder head side q Hose (2): Pin puller cylinder bottom side
(1)
(2)
2.
Install adapter U2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester U1 and connect oil pressure gauge [2]. a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/cm²}.
32
5.
Output pressure
Pull-out
Same as transmission main relief pressure (See standard value table)
Push-in
0 MPa {0 kg/cm²}
Pull-out
0 MPa {0 kg/cm²}
Push-in
Same as transmission main relief pressure (See standard value table)
After finishing measurement, remove the measuring instrument and return the removed parts.
D155A-6
30 Testing and adjusting
SEN03201-03
Testing parts which cause hydraulic drift of blade and ripper1 a
If the blade or ripper drifts hydraulically, check to see if the cause is on the cylinder packing side or control valve side according to the following procedure.
1.
Set the cylinders to be tested in the following positions and stop the engine. 1) Blade lift cylinder Brace the blade to raise the front side of the machine body. a Since the blade lift cylinder is equipped with a piston valve, do not extend it to the stroke end.
2)
Blade tilt cylinder Extract the tilt cylinder to the stroke end and brace the blade to push up the left side of the machine body.
3)
Ripper lift cylinder Brace the ripper to push up the rear side of the machine body.
D155A-6
2.
Turn the starting switch ON and set the work equipment lock lever in the FREE position.
3.
Extend the cylinder to be tested with the corresponding lever and check its movement. q If the lowering speed is increased, the cylinder packing is defective. q If the lowering speed does not change, the control valve is defective. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator.
[Reference] Reason why the lowering speed is increased when the cylinder packing is the cause of the hydraulic drift: 1. If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. 2. As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), then the lowering speed is lowered. 3. If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.
33
SEN03201-03
30 Testing and adjusting
Measuring internal leakage of work equipment cylinder a
q
1
q
Measuring instruments for internal leakage of work equipment cylinder
Symbol
Part No.
V
Commercially available
k Stop
a a
1.
2.
34
Hose (2): Ripper lift cylinder Hose (3): Ripper tilt cylinder Head: 07378-11000 (Size #10) O-ring: 07000-13032 (Size #10)
Part name Measuring cylinder
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Since the blade lift cylinder is equipped with a piston valve, its internal leakage cannot be measured. Measure the internal leakage of work equipment cylinder under the following condition. q Hydraulic oil temperature: Within operating range Extend the cylinder to be measured to the stroke end and set the machine in the measuring position. 1) Blade tilt cylinder Tilt the blade to the left end. 2) Ripper lift cylinder Pull out the shank pin and lower the ripper to the end. 3) Ripper tilt cylinder Tilt the ripper forward (in) to the end. k Release the residual pressure from the cylinder circuit. For details, see Releasing residual pressure from work equipment cylinder. Disconnect hoses (1), (2), and (3) on the head side of the tested cylinder and stop the hose side with a plug or a flange. a When working on the blade tilt cylinder hoses, remove the hose cover of the frame. k Take care not to disconnect the hoses on the bottom side. q Hose (1): Blade tilt cylinder Plug: 07376-70422 (Size #04) O-ring: 02896-11012 (Size #04)
3.
Run the engine at high idle and apply the relief pressure to the cylinder bottom side. q Blade tilt cylinder: Operate to tilt blade to left. q Ripper lift cylinder: Operate to lower ripper. q Ripper Tilt cylinder: Operate to tilt ripper forward (in).
4.
After 30 second, measure leakage in 1 minute with measuring cylinder V.
5.
After finishing measurement, return the removed parts. a Bleed air from the cylinder circuit. For details, see Bleeding air from work equipment cylinder.
D155A-6
30 Testing and adjusting
SEN03201-03
Releasing residual pressure from work equipment cylinder 1
Bleeding air from work equipment cylinder 1
a
When disconnecting the piping between the control valve and work equipment cylinder, release the residual pressure from the circuit according to the following procedure. 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 position. k When lowering the work equipment to the ground, pitch back the blade to the stroke end for dual tilt specification, and set the blade at the flat position for single tilt specification.
a
1.
Loosen hydraulic tank cap (1) gradually to release the remaining pressure in the tank.
2.
Turn the starting switch to ON position and set the work equipment lock lever in FREE position.
3.
Operate the blade control lever and ripper control lever in all directions. The remaining pressure in the accumulator is all released with several times of lever operation.
4.
Set the work equipment lock lever to LOCK position, set the fuel control dial to MIN (Low idle) position, and start the engine.
5.
Run the engine for approximately 10 seconds with the fuel control dial set to MIN (Low idle) position to charge the accumulator, and then stop the engine.
6.
Repeat the steps 2 to 5 described above for 2 to 3 times, and then finish the operation with the step 3.
a
If the work equipment cylinder is removed and installed or its piping is disconnected and connected, bleed air from its circuit according to the following procedure. Before performing the following operation, check that the hydraulic oil level is normal.
1.
Run the engine at low idle for about 5 minutes.
2.
While running the engine at low idle, extend and retract the cylinder to be bled 4 – 5 times. a Move the piston rod to about 100 mm before the stroke end and never relieve the oil.
3.
While running the engine at high idle, carry out the operation in step 2.
4.
While running the engine at low idle, move the cylinder to the stroke end to relieve the oil.
7. Tighten the oil filler cap of the hydraulic tank. Remaining pressure will be completely released from the piping.
D155A-6
35
SEN03201-03
30 Testing and adjusting
Adjusting work equipment lock lever
1
k Stop
a a
4
Monitoring code: 70300 Blade Sw Input For the operating method, see Special functions of machine monitor (EMMS).
Control valve cover: 25 kg
1.
Set work equipment lock lever (1) in the LOCK position.
2.
Set and install limit switch (2) to sliding surface (a) of lever (1). a Just set the roller of the limit switch to the sliding surface. Do not move it.
3.
Set work equipment lock lever (1) in the FREE position and check that limit switch (2) operates normally. q Stroke of limit switch: 2.5 – 3 mm
4.
Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode.
36
a a
the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Tighten the locknut of the rod securely and bend the cotter pin securely. When adjusting the work equipment lock lever, remove the control valve cover.
5.
Check that the limit switch signal is input normally when work equipment lock lever (1) is set in the FREE position and LOCK position. q FREE position: Work equipment lock NC OFF, Work equipment lock NO ON q LOCK position: Work equipment lock NC ON, Work equipment lock NO OFF
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30 Testing and adjusting
SEN03201-03
Adjusting blade
a a 1.
1
If the blade is removed and installed or disassembled and reassemble, adjust it according to the following procedure. The above figure shows the blade of the dual tilt specification. Adjusting shims for assembly 1) Adjust the shim of tilting section (1) (1 place). a After reassembling the tilting section, supply grease to it. 2 Tilting section: Grease (G2-LI)
Adjusted point
Adjusted clearance
Standard clearance
Standard shim thickness
1
a
See note.
4 mm
a
D155A-6
Adjust the shim so that the play of the ball in the axial direction will be less than 1 mm and the ball can rotate smoothly.
37
SEN03201-03
2)
30 Testing and adjusting
Adjust the shim of center section (2) (2 places). a After reassembling the center section, supply grease to it. 2 Center section: Grease (G2-LI)
Adjusted point
Adjusted clearance
Standard clearance
Standard shim thickness
2
b
See note.
4 mm
a
3)
Adjusting blade tilt distance (Single tilt specification) 1) Adjust installed dimension (d) of brace (4) with the handle.
Dimension
blade
Semi-U blade
Full-U blade
d
1,292 mm
1,372 mm
1,372 mm
2) Adjust the shim so that the play of the ball in the axial direction will be less than 1 mm and the ball can rotate smoothly.
Measure right and left tilt distances (e1) and (e2).
Dimension
blade
Semi-U blade
Full-U blade
e1
565 mm
570 mm
583 mm
e2
565 mm
570 mm
583 mm
Adjust the shim of lifting section (3) (2 places).
Adjusted point
Adjusted clearance
Standard clearance
Standard shim thickness
3
c
Max. 1 mm
4 mm
38
2.
3)
If both tilt distances are not the same, adjust installed dimension (d) of brace (4) according to the following procedure. q e1 > e2: Increase installed dimension (d) slightly. q e1 < e2: Decrease installed dimension (d) slightly.
D155A-6
30 Testing and adjusting
Adjusting operator's cab
SEN03201-03
1
a
If the operator's cab is removed and installed or disassembled and transported and assembled in the field, test and adjust it according to the following procedure.
1.
Measuring internal pressure of cab a Criterion Criterion: Measured value X 88.2 Pa {9 mmH2O} a Measurement condition q Engine speed: High idle q Fan speed: Fan 100% mode q EXTERNAL/INTERNAL air changeover switch: EXTERNAL position q Air conditioner fan switch: High (FULL) 1) Prepare a transparent vinyl hose. q Outside diameter: 6 mm, Length: 3,000 mm 2) Secure the inside end of the hose to the top of the seatback with a tape. 3) Remove 1 bolt (1) under the left console box. Pass the other end of the hose through the bolt hole and take it out of the top of battery cover (2) on the left side of the cab.
4) 5) 6)
D155A-6
Seal the clearance between the hole of bolt (1) and hose [1] with tape (3). Pour water in the hose up to about half and bend the hose in a U-shape. Secure hose [1] to the outside of the cab and set the water level in the vinyl hose out of the cab to that in the cab.
2.
7)
Start the engine and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 1005 (Fan 100% mode) a For the operating method, see Special functions of machine monitor (EMMS).
8)
Run the engine at high idle and measure water level difference (c) in hose [1]. q (a): Inside of cab (Pressurized) q (b): Out of cab (Ambient pressure) q (c): Measured value (Internal pressure of cab) a If the measured value (internal pressure of the cab) is lower than the standard value, check the seals of the h o l e s fo r w i r i n g h a r n e s s e s a n d optional parts in the cab.
Checking searing performance 1) Close all the openings (doors and windows) of the cab. 2) Splash water around the hatched part of the cab at the rate of about 19 l/min for 10 minutes. a At this time, it is not necessary to splash pressurized water. 3) Splash water horizontally from a hose over the contact portions of seal (4) between the cab and floor frame.
39
SEN03201-03
4)
30 Testing and adjusting
Check around the dashboard carefully for water leakage. a If water leaks, caulk the leaking part and check again.
4)
5)
3.
Testing and adjusting door lock (damper rubber) a Close the door and check the relationship between the operator's cab and door (damper rubber portions). If there is any abnormality, adjust it. 1) Stick adhesive tape [2] to the contact face of damper rubber (6) of door (5). a Check both sides, 2 places on each side. 2) Open and close door (5) 2 – 3 times. 3) Check the contact portions of adhesive tape [2] and operator's cab. q Normal: When the door is closed, the damper rubber comes in contact lightly (No adjustment is required). q Abnormal: When the door is closed, the damper rubber does not come in contact or comes in contact so strongly that the adhesive tape is removed (Adjustment is required).
4.
Testing and adjusting door lock (latch and striker) a Close the door and check the relationship between the operator's cab and door (latch and striker). If there is any abnormality, adjust it. 1) Move door (5) in the closing direction and check the engaging condition of latch (8) and striker (9). a Check quantity of misalignment (f) between center of latch (d) and center of striker (e) from the direction of (A). q Normal: Quantity of misalignment (f) is 0.5 mm or less.
2)
3) 4)
40
Loosen the mounting bolts of damper rubber (6). a You can remove and install the shims without removing the mounting bolts. Increase or decrease shims (7) under damper rubber (6) to adjust the height of damper rubber (6) properly.
Tighten the mounting bolts of striker (9) temporarily. Then, open and close door (5) 2 – 3 times to align latch (8) with striker (9). Check the engagement of latch (8) and striker (9). Tighten the mounting bolts of striker (9) securely.
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30 Testing and adjusting
5)
6)
Open and close door (5) and check that it is locked and unlocked smoothly. a If the door is not locked or unlocked smoothly (the operating effort of the knob is large), repeat adjustment from the first. a Operating effort of door knob: 49 ± 19.6 N {5 ± 2 kg} Apply grease to latch (8). a If the latch dries up, the operating e ff o r t o f t h e k n ob i s i n c r ea s e d . Accordingly, apply sufficient grease to the latch. 2 Latch: Grease (G2-LI)
SEN03201-03
2) 3)
4) 5)
5.
Check that striker (10) is not leaning against or from center (g) of latch (11). Check that striker (10) is aligned with center (h) of latch (11). q Normal: Quantity of misalignment is 0.5 mm or less.
Loosen the mounting bolts of striker (10). While setting striker (10) upright, tighten the mounting bolts.
Testing and adjusting open lock (latch and striker) a Check the relationship between the operator's cab and door (latch and striker) while the door is locked open. If there is any fault, adjust the open lock. 1) Check the relationship between the open lock latch and striker from the direction of (B). a Move the door in the opening direction and check the engagement of the latch and striker.
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6.
Testing and adjusting open lock (stopper rubber) a Check the relationship between the operator's cab and door (stopper rubber) while the door is locked open. If there is any fault, adjust the open lock. 1) Lock the door open and move it in the forward and reverse directions to check that it does not have play. a Check both sides, 2 places on each side. 2) Check that the operating effort of the unlock lever is not large. 3) Loosen the locknut of stopper rubber (12) (upper one).
4)
Loosen the locknut of stopper rubber (13) (lower one).
5)
Adjust the height of stopper rubbers (12) and (13) according to the trouble. a If there is play, project (heighten) the stopper rubber until the play is eliminated. a If the door is not locked easily or the unlock lever is heavy, return (lower) the stopper rubber in the range that the door does not have play. While fixing stopper rubbers (12) and (13), tighten the locknuts.
6)
42
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D155A-6 Bulldozer Form No. SEN03201-03
© 2017 KOMATSU All Rights Reserved Printed in Japan 04-17 (01)
44
D155A-6
SEN03202-04
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
30 Testing and adjusting
1
Testing and adjusting, Part 3 Special functions of machine monitor (EMMS) ............................................................................................... 2
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SEN03202-04
Special functions of machine monitor (EMMS)
30 Testing and adjusting
1
Air conditioner specification
2
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30 Testing and adjusting
Heater specification
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Upper section of machine monitor (Display section) (a): Multi-display a The figure shows an example of display of symbols and gauges in the ordinary display mode (The contents of display depend on the condition of the machine and operating method). a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper section of machine monitor (Switch section) [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower section of machine monitor (Switch section) [1]: Numeral 1 input switch/Operation mode selector switch [2]: Numeral 2 input switch/Gearshift mode selector switch [3]: Numeral 3 input switch/Customize switch [4]: Numeral 4 input switch/Buzzer cancel switch [5]: Numeral 5 input switch [6]: Numeral 6 input switch/Customize memory switch [7]: Numeral 7 input switch/Air conditioner or heater switch [8]: Numeral 8 input switch/Air conditioner or heater switch [9]: Numeral 9 input switch/Air conditioner or heater switch [0]: Numeral 0 input switch/Air conditioner or heater switch Switch having no numerals: Air conditioner or heater switch a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multidisplay (a). a The difference between the air conditioner specification and heater specification is only the functions of the switches in this section.
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t Ordinary functions and special functions of machine monitor The machine monitor has the ordinary functions and special functions and displays information of various types on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special functions: Service mode The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting. Operator mode (Outline) A Display of KOMATSU logo
Page 5p
A Display of screen to input password
6p
A Display of check before starting
6p
A Display of warning after check before starting
6p
Page
Service mode
5p
15 p
01 Monitoring
16 p Mechanical system "Abnormality Record"
02 Abnormal- Electrical system "Abnormality ity Record Record"
21 p 22 p
Air conditioner "Abnormality Record"/ 29 p Heater "Abnormality Record"
6p
03 Maintenance Record
30 p
7p
04 Maintenance Mode Change
31 p
A Display of ordinary screen
7p
05 Phone Number Entry
33 p
A Display of end screen
7p
Key-on Mode
34 p
B Selection of operation mode
7p
Setting of unit
35 p
B Selection of gearshift mode
8p
o 06 Default
Setting of maintenance password
36 p
B Customizing operation
8p
B Operation of customize memory
8p
B Operation of air conditioner/heater
8p
Operation to display camera mode (if camera is installed)
9p
Special operations
A Display of ending of maintenance interval A Display of check of preset
B
Setting of camera
37 p
Setting of ECO display
38 p
07 Adjustment
39 p
08 Pm Clinic
53 p
B Operation to display clock and service meter
9p
09 Cylinder Cut-Out
54 p
B Check of maintenance information
10 p
10 No Injection
55 p
10 p
11 Fuel Consumption
56 p
C Display of caution monitor
11 p
C Display of action code and failure code
11 p
Terminal Status 12 KOMTRAX GPS & Communication Status Settings Modem S/N
58 p 59 p
13 Service Message
60 p
B
Setting and display of user mode (including KOMTRAX messages for user)
O (Special operations) Function of checking display of LCD D (Liquid Crystal Display)
13 p
D Function of checking service meter
13 p
D Function of changing maintenance password
14 p
57 p
a
Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch
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30 Testing and adjusting t a
a
SEN03202-04
Operator mode (Outline) Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see "the Structure, function and maintenance standard, or Operation and Maintenance Manual". The following are the displays or functions of the operator mode explained in this section (including some items which need special operations). Display pattern
Display of KOMATSU logo
a
b
c
d
1
1
1
1
Display of screen to input password
2
–
–
–
Display of check before starting
3
2
2
2
Display of warning after check before starting
–
–
3
–
Display of ending of maintenance inter– val
–
–
3
Display of check of preset
4
4
4
4
Display of ordinary screen
5
4
5
5
a
Display pattern of operator mode The contents of display from the time when starting switch is turned ON to the time when screen changes to ordinary screen depends on the setting and condition of the machine. a: When engine start lock is set effective b: When engine start lock is set ineffective c: When there is abnormal item in checkbefore-starting items d: When there is maintenance item which is not maintained after specified interval
Display of KOMATSU logo When the s tarting switch is turned ON, the KOMATSU logo is displayed for 2 seconds. After the KOMATSU logo is displayed for 2 seconds, the screen changes to "Display of screen to input password" or "Display of check before starting".
Display of end screen Selection of operation mode Selection of gearshift mode Customizing operation Operation of customize memory Operation to cancel alarm buzzer Operation of air conditioner/heater Operation to display camera mode (if camera is installed) Operation to display clock and service meter Check of maintenance information Setting and display of user mode (including KOMTRAX messages for user)
a a
The following screen may be displayed instead of the above "Display of screen to input password screen". If this screen is displayed, call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy.
Display of caution monitor Display of action code and failure code O (Special operations) Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing maintenance password
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Display of screen to input password After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is set effective. a If the password is input normally, the screen changes to "Display of check before starting". a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another.
Display of check before starting When the screen changes to the check-beforestarting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to "Display of warning after check before starting" or "Display of ending of maintenance interval". a If no abnormality is detected by the check before starting, the screen changes to "Display of check of preset". a The monitors (3 pieces) displayed on the screen are the items under the check before starting.
6
30 Testing and adjusting
Display of warning after check before starting If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the radiator coolant level monitor (a) is warning of low radiator coolant level.
Display of ending of maintenance interval When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is effective. The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval. a Set or change the maintenance function in the service mode.
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30 Testing and adjusting
Display of check of preset If the check before starting is finished normally, the screen to check the preset (gear speed at start) is displayed for 2 seconds. a After display of check of preset is finished, the sc re en ch anges to "Di spl ay of ordi nary screen".
Display of ordinary screen If the machine monitor starts normally, the ordinary screen is displayed. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]). a Power train oil temperature gauge (b) is displayed on the multi-gauge section (It is turned ON and OFF with the user mode function or [F2]). a ECO gauge (c) is displayed at the right end of the screen (It is turned ON and OFF in the service mode).
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Display of end screen When the starting switch is turned OFF, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen, depending on the message display function of KOMTRAX.
Selection of operation mode While the ordinary screen is displayed, press the operation mode selector switch, and the operation mode monitor (a) changes. a Each time the switch is pressed, the operation mode changes between [P (Power)] and [E (Economy)].
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Selection of gearshift mode While the ordinary screen is displayed, press the gearshift mode selector switch, and the gearshift mode monitor (a) in the gear speed display section changes. a Each time the switch is pressed, the gearshift mode changes between [Dozing (Automatic gearshift)] and [Ripping (Manual gearshift)]. a If dozing (automatic gearshift) is selected, AUTO symbol (b) is displayed in the gear speed display section.
Customizing operation While the ordinary screen is displayed, press the customize switch, and you can change the setting of the machine. a If the customize memory switch is operated while the above screen is displayed, up to 5 settings can be saved.
30 Testing and adjusting
Operation of customize memory While the ordinary screen is displayed, press the customize memory switch, and you can select the recorded setting of customization.
Operation of air conditioner/heater While the ordinary screen is displayed, press the air conditioner switch or heater switch, and the Airconditioner Adjustment screen or Heater Adjustment screen is displayed. a While the Air-conditioner Adjustment screen or Heater Adjustment screen is displayed, if you do not touch any switch for 5 seconds, the screen changes to the ordinary screen. a Air conditioner specification
a
8
Heater specification
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30 Testing and adjusting
Operation to display camera mode (if camera is installed) When a camera is installed, if [F3] is pressed, the multi-display changes to the camera image. a Set the connection of the camera in the service mode.
a
a a
a a
a
Up to 3 cameras can be connected. If the camera mode is selected, however, only the image of camera 1 is always displayed.
SEN03202-04
Operation to display clock and service meter While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and clock alternately. a When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the summer time with the user mode function. a Display of service meter
a
Display of clock
If a caution is generated in the camera mode, the caution monitor is displayed at the left upper of the screen. When an error that there is a user code occurs in the camera mode, if the machine stops for 10 seconds, the screen changes to the ordinary screen and displays the error information. When 2 or more cameras are connected, the image of one of them or the images of 2 of them can be displayed. If 2-camera image display [F4] is selected, the image of camera 1 is displayed on the left side of the screen and the image of camera 2 is displayed on the right side. The image of camera 3 is displayed only singly. If the images of 2 cameras are displayed simultaneously, images are displayed at intervals of 1 second on the right and left screen.
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Check of maintenance information While the maintenance monitor or ordinary screen is displayed, press [F5], and the maintenance table screen is displayed.
Setting and display of user mode (including KOMTRAX messages for user) While the ordinary screen is displayed, press [F6], and the user menu screen is displayed.
a
a
To reset the time left after finishing maintenance, more operations are necessary.
There are following items in the user menu. Utility Screen Select Multi Gage Select Screen Adjustment Clock Adjustment Language Message display Hydraulic fan reversing
[KOMTRAX message] q There are 2 types of KOMTRAX message; one is for the user and the other is for the service. q For user: A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is displayed on the ordinary screen. To see the contents of the message, operate "Message display" in the above user menu.
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30 Testing and adjusting
q
For service: A message transmitted from the KOMTRAX base station for the service. Even if it is received, nothing is displayed on the ordinary screen. To see the contents of the message, operate "KOMTRAX message display" in the service menu.
Display of caution monitor If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen, the caution monitor is displayed large for a moment and then displayed at (a) in the screen. a On the camera mode screen, the caution monitor blinks at the left upper of the screen when the caution is generated.
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Display of action code and failure code If an abnormality which displays an action code and a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed. (a) : Action code (3 digits) (b) : Failure code (5 or 6 digits) (c) : Telephone mark (d) : Telephone No. a This screen is displayed only when an abnormality (failure code) for which an action code is set occurs. a The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the fault history in the service mode, check the details in the service mode.
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30 Testing and adjusting
Remedies given by displayed action codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual)
Action code
Method of indicating trouble
Examples of trouble
Remedy given to operator to take
E01
• Action code and failure code are • Backup alarm does not sound. • Fan speed is kept at maximum. displayed.
• Although all or a part of automatic function stops, machine can be operated. • Ask your Komatsu distributor for repair.
E02
• Gear is not shifted up or down. • Action code and failure code are • Engine boost pressure is abnordisplayed. mal. • Alarm buzzer sounds. • Exhaust gas color is bad when temperature is low.
• If operator stops and restarts engine, machine can be operated without limiting any function. Operator must take care, however. • Ask your Komatsu distributor for repair.
E03
• Engine coolant temperature sensor is abnormal. • Action code and failure code are • Usable gear speeds are limited. • Move machine to safe place. displayed. • Engine speed does not rise to • 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.
E04
• Action code and failure code are • Engine cannot be controlled. displayed. • Machine cannot travel. • Telephone No. is displayed (if • Machine stops. set). • Alarm buzzer sounds.
12
• Stop machine immediately. • Ask your Komatsu distributor for repair.
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30 Testing and adjusting
Function of checking display of LCD (Liquid Crystal Display) While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. a The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the function switch.
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Function of checking service meter To check the service meter while the starting switch is turned OFF, operate the numeral input switches as follows. At this time, only the service meter section displays. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD, hold down the switches until the LCD displays normally. a After the machine monitor is used continuously, blue points (points which do not go off) may be seen on this screen. This phenomenon does not indicate a failure or a defect.
13
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30 Testing and adjusting a
Function of changing maintenance password When changing the maintenance password used for the maintenance setting function, follow these procedures. 1.
2.
3.
14
q
While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [5] o [5] o [5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned on.
q
Set a new password of 4 – 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). [F5]: Delete input numeral/Return to ordinary screen [F6]: Confirm input numeral
4.
After the "New Password" screen is displayed again, input a new password again with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.
5.
If the screen to notify completion of setting is displayed and then the ordinary screen is displayed, the password is changed successfully.
After the "Password" screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to input the password again is displayed.
After the "New Password" screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. D155A-6
30 Testing and adjusting
SEN03202-04
t Service mode To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1.
a
You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].
a
The items which can be selected in the service menu are as follows.
Check of display of screen and operation of switches While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3]
01 Monitoring Mechanical system "Abnormality Record" 02 Abnormality Record
Electrical system "Abnormality Record" Air conditioner "Abnormality Record"/ Heater "Abnormality Record"
a
This operation of the switches is accepted only while the ordinary screen is displayed.
03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-OFF Mode Setting of unit 06 Default
Setting of maintenance password Setting of camera Setting of ECO display
07 Adjustment 08 PM CLINIC 09 Cylinder Cut-Out 10 No Injection 11 Fuel Consumption
2.
Selection of service menu When the "Service Menu" screen is displayed, the service mode is selected. Select a service menu you use with the function switches or numeral input switches. q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary screen (operator mode) q [F6]: Confirm selection
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Terminal Status GPS & Communication Status Modem S/N
13 Service Message
a
Items with 2-digit codes are the menus displayed on the Service menu screen. The items on their right are the menus on the next hierarchy.
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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.
3.
2.
16
Selecting monitoring items After the "Monitoring" screen is displayed, select items to be monitored with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Delete input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items.
Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and confirm with [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.
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30 Testing and adjusting
4.
Executing monitoring After the "Monitoring" screen is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be set to SI unit, metric unit, or inch unit with the Default function in the service mode.
5.
Holding monitoring information The monitoring information can be held and holding is reset with the function switches. q [F3]: Reset holding q [F4]: Hold information (displayed data) q [F5]: Return to monitoring selection menu screen
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6.
Changing machine setting mode To change the setting of the "P/E Mode", "Fan Rev." mode, or "Working" mode during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to return to the monitoring information screen. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the ordinary screen after monitoring is finished.
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Monitoring items list Code No.
Monitoring item (Display on screen)
Unit (Initial setting: ISO) ISO
meter
inch
Component in charge
50300 S/T Lever 1 Potentio
mV
mV
mV
P/T
50301 S/T Lever 2 Potentio
mV
mV
mV
P/T
50400 Brake Pedal Potentio
mV
mV
mV
P/T
31619 Brake LH ECMV(F/B)
mA
mA
mA
P/T
31618 Brake RH ECMV(F/B)
mA
mA
mA
P/T
90600 S/T Clutch LH ECMV(F/B)
mA
mA
mA
P/T
90601 S/T Clutch RH ECMV(F/B)
mA
mA
mA
P/T
31628 S.S.P Solenoid
mA
mA
mA
P/T
32900 Pitch Angle
°
°
°
P/T
60100 Pitch Angle Sensor
mV
mV
mV
P/T
60500 ENG Hold Relay
mV
mV
mV
P/T
60600 BR Hold Relay
mV
mV
mV
P/T
50000 Fuel Dial Throttle
%
%
%
P/T
03000 Fuel Dial Sensor
mV
mV
mV
P/T
31521 S/T Fill Sw Input
BL (Left brake fill sw)
ON • OFF
P/T
CL (Left clutch fill sw)
ON • OFF
P/T
CR (Right clutch fill sw)
ON • OFF
P/T
BR (Right brake fill sw)
ON • OFF
P/T
50200 T/M Lever 1 Potentio
mV
mV
mV
P/T
50201 T/M Lever 2 Potentio
mV
mV
mV
P/T
31622 T/M Clutch F ECMV(F/B)
mA
mA
mA
P/T
31616 T/M Clutch R ECMV(F/B)
mA
mA
mA
P/T
31602 T/M Clutch 1st ECMV(F/B)
mA
mA
mA
P/T
31603 T/M Clutch 2nd ECMV(F/B)
mA
mA
mA
P/T
31604 T/M Clutch 3rd ECMV(F/B)
mA
mA
mA
P/T
30100 T/C Oil Temperature
C
C
F
P/T
31400 T/M Out Speed
r/min
rpm
rpm
P/T
50900 T/M Lock Relay
mV
mV
mV
P/T
40001 Vehicle Speed
km/h
km/h
MP/h
P/T
60000 Traction
W
W
W
P/T
70200 T/M Out Speed Sensor
mV
mV
mV
P/T
70400 Back Alarm Relay
mV
mV
mV
P/T
31624 Fan Pump Solenoid(F/B)
mA
mA
mA
P/T
10000 Fan Speed
r/min
rpm
rpm
P/T
40905 T/M Sw Input 1
18
SUNC (Gear shift up sw)
ON • OFF
P/T
SUNO (Gear shift up sw)
ON • OFF
P/T
SDNC (Gear shift down sw)
ON • OFF
P/T
Remarks
D155A-6
30 Testing and adjusting
Code No.
Monitoring item (Display on screen)
40905 T/M Sw Input 1
T/M Fill Sw 40906 Input 1
31520
T/M Fill Sw Input 2
40909 T/M Output 1
SEN03202-04
Unit (Initial setting: ISO) ISO
meter
inch
Component in charge
SDNO (Gear shift down sw)
ON • OFF
P/T
PNC (Parking brake lever sw)
ON • OFF
P/T
PNO (Parking brake lever sw)
ON • OFF
P/T
F (F clutch fill sw)
ON • OFF
P/T
R (R clutch fill sw)
ON • OFF
P/T
1st (1st clutch fill sw)
ON • OFF
P/T
2nd (2nd clutch fill sw)
ON • OFF
P/T
3rd (3rd clutch fill sw)
ON • OFF
P/T
L/U( Lock-up clutch fill sw)
ON • OFF
P/T
S/C (Stator clutch fill sw)
ON • OFF
P/T
Brly (Back Alarm relay)
ON • OFF
P/T
Prly (Parking lock relay)
ON • OFF
P/T
Fres (Fan reverse solenoid)
ON • OFF
P/T
70700 Hydraulic Pump Pressure 1
MPa
kg/cm²
psi
P/T
70701 Hydraulic Pressure Sensor 1
mV
mV
mV
P/T
20227 Monitor Ass’y P/N
—
MON
20402 Monitor Serial No
—
MON
20228 Monitor Prog P/N
—
MON
20242 P/T Con Ass’y P/N
—
P/T
20404 P/T Con Serial No
—
P/T
20243 P/T Con Prog P/N
—
P/T
04200 Fuel Level Sensor Volt
V
V
V
MON
04300 Battery Charge Volt
V
V
V
MON
04401 Hyd Oil Temperature
C
C
F
MON
04002 Hyd Temp Sens Volt
V
V
V
MON
18900 ECM Internal Temp
C
C
F
ENG
37200 Engine Oil Pressure
kPa
kg/cm²
psi
ENG
00201 Machine ID
—
ENG
20216 ECM Build Version
—
ENG
20217 ECM Calibration Data Ver
—
ENG
20400 ECM Serial No
—
ENG
01002 Engine Speed
r/min
rpm
rpm
ENG
36700 Engine Torque Ratio
%
%
%
ENG
31701 Throttle Position
%
%
%
ENG
03001 Throttle Pos Sens Volt
mV
mV
mV
ENG
17500 Engine Power Mode
D155A-6
—
Remarks
ENG
19
SEN03202-04
30 Testing and adjusting
Unit (Initial setting: ISO) ISO
meter
inch
Component in charge
36400 Rail Pressure
MPa
kg/cm²
psi
ENG
36401 Rail Pressure Sens Volt
V
V
V
ENG
36200 Rail Press Command
MPa
kg/cm²
psi
ENG
36300 Injection Timing Command
CA
CA
CA
ENG
04107 Coolant Temperature
C
C
F
ENG
01405 Coolant Temp Sens Volt
V
V
V
ENG
37400 Ambient Pressure
kPa
kg/cm²
psi
ENG
37401 Ambient Press Sens Volt
V
V
V
ENG
36500 Charge Pressure-Abs
kPa
kg/cm²
psi
ENG
36501 Charge Press Sens Volt
V
V
V
ENG
03203 Battery Power Supply
V
V
V
ENG
37300 Fuel Rate
l/h
l/h
gal/h
ENG
31706 Final Throttle Position
%
%
%
ENG
18500 Charge Temperature
C
C
F
ENG
18501 Charge Temp Sens Volt
V
V
V
ENG
18600 Inject Fueling Command
mg/st
mg/st
mg/st
ENG
17201 PCV Close Timing
CA
CA
CA
ENG
18700 Engine Output Torque
Nm
kgm
lhft
ENG
37201 Eng Oil Press Sens Volt
V
V
V
ENG
14200 Fuel Temperature
C
C
F
ENG
14201 Fuel Temp Sens Volt
V
V
V
ENG
Code No.
Monitoring item (Display on screen)
40912 P/T Sw Input
40910 P/T Sw Input 2
40915 P/T Output
a a
a
20
R-sig
ON • OFF
P/T
Acc
ON • OFF
P/T
Eng S
ON • OFF
P/T
Eng L
ON • OFF
P/T
Eng Sd
ON • OFF
P/T
WL-NO (Work equipment lock Sw)
ON • OFF
P/T
WL-NC (Work equipment lock Sw)
ON • OFF
P/T
W-LOK (Work equipment lock SOL)
ON • OFF
P/T
Remarks
Indication by absolute value (including ambient pressure)
Entry order of items in table The items are entered in the order of display on the monitoring selection menu screen. Unit The display unit can be set to ISO, meter, or inch freely (Set it with Unit in "Default" of the service menu). "CA" in the display unit is an abbreviation for crankshaft angle. "mg/st" in the display unit is an abbreviation for milligram/stroke. Components in charge MON : The machine monitor is in charge of detection of monitoring information. ENG : The engine controller is in charge of detection of monitoring information. P/T : The power train controller is in charge of detection of monitoring information. D155A-6
30 Testing and adjusting
"Abnormality Record" (Mechanical system "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the mechanical system "Abnormality Record", perform the following procedures. 1.
Selecting menu Select "02 Abnormality Record" on the "Service Menu" screen.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "01 Mechanical Systems" with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. If the heater specification is selected, "03 Heater Abnormality Record" is displayed.
D155A-6
SEN03202-04
3.
Information displayed on "Abnormality Record" screen On the "Mechanical Systems" screen, the following information is displayed. (a): Occurrence order of abnormality from latest one/Total number of records (b): Failure code (c): Contents of trouble (d): Number of occurrence time (e): Service meter reading at first occurrence (f): Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to "Abnormality Record" screen a If no "Abnormality Record" is recorded, "No Abnormality Record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table in "Abnormality Record (Electrical system Abnormality Record)".
4.
Deleting "Abnormality Record" The contents of the mechanical system "Abnormality Record" cannot be deleted.
21
SEN03202-04
"Abnormality Record" (Electrical system "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the electrical system "Abnormality Record", perform the following procedures. 1.
Selecting menu Select "02 Abnormality Record" on the "Service Menu" screen.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "02 Electrical Systems" with the function switches or numeral input switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. If the heater specification is selected, "03 Heater Abnormality Record" is displayed.
22
30 Testing and adjusting
3.
Information displayed on "Abnormality Record" screen On the "Electrical Systems" screen, the following information is displayed. (a):Occurrence order of abnormality from latest one/Total number of records (b):Failure code (c): Contents of trouble (d):Number of occurrence time (e):Service meter reading at first occurrence (f): Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to "Abnormality Record" screen a If no "Abnormality Record" is recorded, "No Abnormality Record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table.
4.
Deleting "Abnormality Record" 1) While the "Electrical Systems" screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3] a Operate the switches similarly to the procedure for changing the ordinary display to the service mode.
D155A-6
30 Testing and adjusting
SEN03202-04 a
2)
3)
D155A-6
Check that the screen is set in the delete mode, and then delete the items one by one or together with the function switches. a If the screen is set in the delete mode, [CLEAR] graphic mark is indicated at [F2]. q [F2]: Delete all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to "Abnormality Record" screen q [F6]: Delete selected item a To delete items one by one: Select the item to be deleted with [F3] or [F4] and press [F6]. a To delete all items together: Press [F2], and all the items are deleted, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the deleting operation is accepted but the information is not deleted.
4)
The following figure shows the screen displayed when the items are deleted one by one (which is a little different from the screen displayed when all the items are deleted together).
If the screen to notify completion of deletion is displayed and then the "Electrical Sys. Error Reset" (delete mode) screen is displayed, the deletion of the "Abnormality Record" is completed. a After a while, the screen returns to the "Electrical Sys. Error Reset" screen.
After the "Electrical Sys. Error Reset" screen is displayed, operate the function switches. q [F5]: Return to "Electrical Sys. Error Reset" screen (Delete mode) q [F6]: Execute deletion
23
SEN03202-04
30 Testing and adjusting
Failure codes table Action code
Failure code
E03
1500L0
E03
Component in charge
Category of history
Transmission clutch: Abnormal
P/T
Electrical system
15SAL1
Forward clutch: Fill high
P/T
Electrical system
E03
15SALH
Forward clutch: Fill Low
P/T
Electrical system
E03
15SBL1
Reverse clutch: Fill high
P/T
Electrical system
E03
15SBLH
Reverse clutch: Fill Low
P/T
Electrical system
E03
15SEL1
Speed 1st clutch: Fill high
P/T
Electrical system
E03
15SELH
Speed 1st clutch: Fill Low
P/T
Electrical system
E03
15SFL1
Speed 2nd clutch: Fill high
P/T
Electrical system
E03
15SFLH
Speed 2nd clutch: Fill Low
P/T
Electrical system
E03
15SGL1
Speed 3rd clutch: Fill high
P/T
Electrical system
E03
15SGLH
Speed 3rd clutch: Fill Low
P/T
Electrical system
E04
2201L1
Right clutch: See the list
P/T
Electrical system
E04
2201LH
Right clutch: See the list
P/T
Electrical system
E04
2202L1
Left clutch: See the list
P/T
Electrical system
E04
2202LH
Left clutch: See the list
P/T
Electrical system
—
2300KM
Stall in 1st gear speed
P/T
Electrical system
E04
2301L1
Right brake: Fill high
P/T
Electrical system
E04
2301LH
Right brake: Fill low
P/T
Electrical system
E04
2302L1
Left brake: Fill high
P/T
Electrical system
E04
2302LH
Left brake: Fill low
P/T
Electrical system
—
7RFAKA
ECM HOLD RELAY: Disconnection
P/T
Electrical system
—
AA10NX
Air Cleaner Clogging
MON
Mechanical system
—
AB00MA
Battery Charge Abnormal
MON
Mechanical system
—
B@BAZG
Eng Oil Press Low
ENG
Mechanical system
—
B@BCNS
Eng Water Overheat
ENG
Mechanical system
—
B@BCZK
Eng Water Level Low
MON
Mechanical system
—
B@CENS
T/C Oil Overheat
P/T
Mechanical system
—
B@HANS
Hyd Oil Overheat
MON
Mechanical system
E04
CA111
EMC Critical Internal Failure
ENG
Electrical system
E04
CA115
Eng Ne and Bkup Speed Sens Error
ENG
Electrical system
E03
CA122
Chg (boost) Air Press Sensor High Error
ENG
Electrical system
E03
CA123
Chg (boost) Air Press Sensor Low Error
ENG
Electrical system
E03
CA131
Throttle Sensor High Error
ENG
Electrical system
E03
CA132
Throttle Sensor Low Error
ENG
Electrical system
E02
CA135
Eng Oil Press Sensor High Error
ENG
Electrical system
E02
CA141
Eng Oil Press Sensor Low Error
ENG
Electrical system
24
Trouble (Displayed on screen)
D155A-6
30 Testing and adjusting
Action code
Failure code
E02
CA144
E02
SEN03202-04
Component in charge
Category of history
Coolant Temp Sens High Error
ENG
Electrical system
CA145
Coolant Temp Sens Low Error
ENG
Electrical system
E01
CA153
Chg (boost) Air Temp Sensor High Error
ENG
Electrical system
E01
CA154
Chg (boost) Air Temp Sensor Low Error
ENG
Electrical system
E03
CA187
Sens Supply 2 Volt Low Error
ENG
Electrical system
E03
CA221
Ambient Press Sens High Error
ENG
Electrical system
E03
CA222
Ambient Press Sens Low Error
ENG
Electrical system
E03
CA227
Sens Supply 2 Volt High Error
ENG
Electrical system
—
CA234
Eng Overspeed
ENG
Electrical system
E03
CA238
Ne Speed Sens Supply Volt Error
ENG
Electrical system
E01
CA263
Fuel Temp Sensor High Error
ENG
Electrical system
E01
CA265
Fuel Temp Sensor Low Error
ENG
Electrical system
E03
CA271
PCV1 Short Error
ENG
Electrical system
E03
CA272
PCV1 Open Error
ENG
Electrical system
E03
CA273
PCV2 Short Error
ENG
Electrical system
E03
CA274
PCV2 Open Error
ENG
Electrical system
E03
CA322
Inj #1 Open/Short Error
ENG
Electrical system
E03
CA323
Inj #5 Open/Short Error
ENG
Electrical system
E03
CA324
Inj #3 Open/Short Error
ENG
Electrical system
E03
CA325
Inj #6 Open/Short Error
ENG
Electrical system
E03
CA331
Inj #2 Open/Short Error
ENG
Electrical system
E03
CA332
Inj #4 Open/Short Error
ENG
Electrical system
E04
CA342
Calibration Code Incompatibility
ENG
Electrical system
E03
CA351
Injectors Drive Circuit Error
ENG
Electrical system
E03
CA352
Sens Supply 1 Volt Low Error
ENG
Electrical system
E03
CA386
Sens Supply 1 Volt High Error
ENG
Electrical system
E04
CA441
Battery Voltage Low Error
ENG
Electrical system
E04
CA442
Battery Voltage High Error
ENG
Electrical system
E03
CA449
Rail Press Very High Error
ENG
Electrical system
E03
CA451
Rail Press Sensor High Error
ENG
Electrical system
E03
CA452
Rail Press Sensor Low Error
ENG
Electrical system
E02
CA553
Rail Press High Error
ENG
Electrical system
E03
CA554
Rail Press Sensor In Range Error
ENG
Electrical system
E02
CA559
Rail Press Low Error
ENG
Electrical system
E03
CA689
Eng Ne Speed Sensor Error
ENG
Electrical system
E03
CA731
Eng Bkup Speed Sens Phase Error
ENG
Electrical system
E04
CA757
All Continuous Data Lost Error
ENG
Electrical system
D155A-6
Trouble (Displayed on screen)
25
SEN03202-04
Action code
Failure code
E03
CA778
E03
30 Testing and adjusting
Component in charge
Category of history
Eng Bkup Speed Sensor Error
ENG
Electrical system
CA1633
KOMNET Datalink Timeout Error
ENG
Electrical system
E03
CA2185
Throt Sens Sup Volt High Error
ENG
Electrical system
E03
CA2186
Throt Sens Sup Volt Low Error
ENG
Electrical system
E03
CA2249
Rail Press Very Low Error
ENG
Electrical system
E01
CA2555
Grid Htr Relay Volt Low Error
ENG
Electrical system
E01
CA2256
Grid Htr Relay Volt High Error
ENG
Electrical system
—
D110KA
Battery relay: Disconnection
P/T
Electrical system
—
D110KB
Battery Relay: Drive Short Circuit
P/T
Electrical system
E02
D130KA
Neutral relay: Disconnection
P/T
Electrical system
E02
D130KB
Neutral relay: Short circuit
P/T
Electrical system
E01
D161KA
Back-up alarm relay: Disconnection
P/T
Electrical system
E01
D161KB
Back-up alarm relay: Short circuit
P/T
Electrical system
—
D190KA
ACC signal relay: Disconnection
P/T
Electrical system
—
D190KB
ACC signal relay: Short circuit
P/T
Electrical system
E03
D5ZKKX
Throttle Dial: Out of normal range
P/T
Electrical system
E03
DAFRKR
CAN Disconnection (Monitor)
MON
Electrical system
E03
DB2RKR
CAN Disconnection (Engine controller)
ENG
Electrical system
E03
DB90KR
PT controller: Can communication lost
P/T
Electrical system
E03
DBE0KK
PT controller: Source voltage reduction
P/T
Electrical system
E01
DBE0KT
PT controller: Abnormality in controller
P/T
Electrical system
E02
DBE6KK
PT controller: Source voltage reduction
P/T
Electrical system
E02
DBE7KK
PT controller: Source voltage reduction
P/T
Electrical system
E04
DBE9KQ
PT controller: Type select signal
P/T
Electrical system
E02
DD12KA
Shift up Sw: Disconnection
P/T
Electrical system
E02
DD12KB
Shift up Sw: Short circuit
P/T
Electrical system
E02
DD13KA
Shift down Sw: Disconnection
P/T
Electrical system
E02
DD13KB
Shift down Sw: Short circuit
P/T
Electrical system
E03
DD14KA
Parking lever Sw: Disconnection
P/T
Electrical system
E03
DD14KB
Parking lever Sw: Short circuit
P/T
Electrical system
E02
DDDDKA
Back up brake Sw: Disconnection
P/T
Electrical system
E02
DDDDKB
Back up brake Sw: Short circuit
P/T
Electrical system
E02
DDDDKX
Back up brake Sw: Signal mismatch
P/T
Electrical system
E01
DGT1KA
T/C oil temp sensor: Abnormal
P/T
Electrical system
E01
DGT1KX
T/C oil temp sensor abnormal
P/T
Electrical system
—
DH21KA
Weq pressure sensor: Disconnection
P/T
Electrical system
—
DH21KB
Weq pressure sensor: Short circuit
P/T
Electrical system
26
Trouble (Displayed on screen)
D155A-6
30 Testing and adjusting
Action code
Failure code
E03
DK10KX
E03
SEN03202-04
Component in charge
Category of history
Fuel control Dial: Out of normal range
P/T
Electrical system
DK30KA
ST lever 1: Disconnection
P/T
Electrical system
E03
DK30KB
ST lever 1: Short circuit
P/T
Electrical system
E04
DK30KX
ST lever 1: Out of normal range
P/T
Electrical system
E04
DK30KZ
ST lever: Disconnection or short circuit
P/T
Electrical system
E03
DK30L8
ST lever: Signal mismatch
P/T
Electrical system
E03
DK31KA
ST lever 2: Disconnection
P/T
Electrical system
E03
DK31KB
ST lever 2: Short circuit
P/T
Electrical system
E03
DK40KA
Brake potentiometer: Disconnection
P/T
Electrical system
E03
DK40KB
Brake potentiometer: Short circuit
P/T
Electrical system
E04
DK55KX
FR lever: Out of normal range
P/T
Electrical system
E04
DK55KZ
FR lever: Disconnection or short circuit
P/T
Electrical system
E03
DK55L8
FR lever: Signal mismatch
P/T
Electrical system
E03
DK56KA
FR lever 1: Disconnection
P/T
Electrical system
E03
DK56KB
FR lever 1: Short circuit
P/T
Electrical system
E03
DK57KA
FR lever 2: Disconnection
P/T
Electrical system
E03
DK57KB
FR lever 2: Short circuit
P/T
Electrical system
E03
DKH1KA
Pitch angle sensor: Disconnection
P/T
Electrical system
E03
DKH1KB
Pitch angle sensor: Short circuit
P/T
Electrical system
E01
DLT3KA
T/M out-speed sensor: Disconnection
P/T
Electrical system
E01
DLT3KB
T/M out-speed sensor: Abnormal
P/T
Electrical system
E01
DW7BKA
Fan rev EPC: Disconnection
P/T
Electrical system
E01
DW7BKB
Fan rev EPC: Short circuit
P/T
Electrical system
E04
DWN3KA
Ssp solenoid: Disconnection
P/T
Electrical system
E04
DWN3KB
Ssp solenoid: Short circuit
P/T
Electrical system
E04
DWN3KY
Ssp solenoid: Short circuit
P/T
Electrical system
E01
DWN5KA
Fan pump solenoid: Disconnection
P/T
Electrical system
E01
DWN5KB
Fan pump solenoid: Short circuit
P/T
Electrical system
E03
DXH4KA
1st clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH4KB
1st clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH4KY
1st clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH5KA
2nd clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH5KB
2nd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH5KY
2nd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH6KA
3rd clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH6KB
3rd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH6KY
3rd clutch ECMV: Short circuit
P/T
Electrical system
D155A-6
Trouble (Displayed on screen)
27
SEN03202-04
Action code
Failure code
E03
DXH7KA
E03
30 Testing and adjusting
Component in charge
Category of history
R clutch ECMV: Disconnection
P/T
Electrical system
DXH7KB
R clutch ECMV: Short circuit
P/T
Electrical system
E04
DXH7KY
R clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH8KA
F clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH8KB
F clutch ECMV: Short circuit
P/T
Electrical system
E04
DXH8KY
F clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH9KA
Right clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH9KB
Right clutch ECMV: Short circuit
P/T
Electrical system
E04
DXH9KY
Right clutch ECMV: Hot short
P/T
Electrical system
E03
DXHAKA
Left clutch ECMV: Disconnection
P/T
Electrical system
E03
DXHAKB
Left clutch ECMV: Short circuit
P/T
Electrical system
E04
DXHAKY
Left clutch ECMV: Hot short
P/T
Electrical system
E04
DXHBKA
Right brake ECMV: Disconnection
P/T
Electrical system
E04
DXHBKB
Right brake ECMV: Short circuit
P/T
Electrical system
E04
DXHBKY
Right brake ECMV: Short circuit
P/T
Electrical system
E04
DXHCKA
Left brake ECMV: Disconnection
P/T
Electrical system
E04
DXHCKB
Left brake ECMV: Short circuit
P/T
Electrical system
E04
DXHCKY
Left brake ECMV: Short circuit
P/T
Electrical system
E03
DXJ4KA
Weq lock Sol.: Disconnection
P/T
Electrical system
E03
DXJ4KB
Weq lock Sol.: Short circuit
P/T
Electrical system
a a
a
a
28
Trouble (Displayed on screen)
Entry order of items in table The items are entered in the order of their failure codes (incremental order). Action code If the failure code is detected, the action code, failure code, and telephone No. (if regisAttached: tered) are displayed on the ordinary screen to notify the operator of the fault. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the fault. Component in charge MON: The machine monitor is in charge of detection of fault. ENG: The engine controller is in charge of detection of fault. P/T: The power train controller is in charge of detection of fault. Category of record Mechanical equipment system: Fault information is recorded in the "Mechanical Systems". Electrical equipment system: Fault information is recorded in the "Electrical Systems" .
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30 Testing and adjusting
"Abnormality Record" (Air conditioner "Abnormality Record"/Heater "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the air conditioner "Abnormality Record" or heater "Abnormality Record", perform the following procedures. a All the following figures show the air conditioner specification. 1.
Selecting menu Select "02 Abnormality Record" on the Service menu screen.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "03 Air-conditioning System" or "03 Heater Abnormality Record" with the function switches or numeral input switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].
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3.
Information displayed on "Abnormality Record" screen On the air conditioner "Abnormality Record" or heater "Abnormality Record" screen, the following information is displayed. (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) q [F2]: Delete "Abnormality Record" q [F5]: Return to "Abnormality Record" screen a If [E] is displayed on the left of a condition, the abnormality is still occurring or resetting of it has not been confirmed. a If "CAN Status" is displayed in Communication condition, communication cannot be carried out normally. Accordingly, the conditions of other items are turned OFF.
4.
Deleting "Abnormality Record" While the "Abnormality Record" screen is displayed, press [F2], and the number of occurrence time of fault is deleted. If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.
a
Heater specification In the heater specification, the display of "Air conditioner" is replaced with "Heater" and the items which are not related to the heater are not displayed.
29
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30 Testing and adjusting
Maintenance Record The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section.
01 Engine Oil Change
1.
07 Check and addition of damper case oil
02 Eng Oil Filter Change 03 Fuel Main Filter Change 41 Fuel Pre Filter Change 04 Hyd Oil Filter Change 06 Corrosion Resistor Change
Selecting menu Select "03 Maintenance Record" on the "Service Menu" screen.
08 Replacement interval of final drive case oil 10 Replacement of hydraulic oil 19 Replacement of power train oil 20 Replacement of power train oil filter
3.
2.
Selecting maintenance record item After the "Maintenance Record" screen is displayed, select an item to be checked with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.
a
30
Items displayed on Maintenance Record screen The following items are displayed. (a): Maintenance items (b): Number of times of change up to now (c): Service meter reading (SMR) at previous change
The following items can be selected in the maintenance record.
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Maintenance Mode Change The operating condition for maintenance function in the operation mode can be set and changed with this menu. q Set function effective or ineffective q Change set change interval (by items) q Initialize all set change intervals
00 Maintenance Mode On/Off
1.
06 Replacement interval of corrosion resistor
Selecting menu Select "04 Maintenance Mode Change" on the Service menu screen.
01 Engine Oil Change Int 02 Eng Oil Filter Change Int 03 Fuel Main Filter Change Int 41 Fuel Pre Filter Change Int 04 Hyd Oil Filter Change Int 07 Check and replacement interval of damper case oil 08 Replacement interval of final drive case oil 10 Replacement interval of hydraulic oil 19 Replacement interval of power train oil 20 Replacement interval of power train oil filter 99 Use Default Value
3.
2.
Selecting sub menu After the "Maintenance Mode On/Off" screen is displayed, select an item to be monitored with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].
a
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Contents of setting of ON/OFF of maintenance mode After selecting "00 Maintenance Mode On/Off", if the screen is displayed, set ON or OFF with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance mode screen q [F6]: Confirm selection and return to Maintenance mode screen a Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.
The following items can be selected on the "Maintenance Mode On/Off" screen.
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4.
Contents of setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches.
q
q
q q q q q
q
a
32
Default: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). Set: Maintenance interval which can be set freely. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 50 hours). ON: Maintenance function of this item is set effective in operator mode. OFF: Maintenance function of this item is set ineffective in operator mode. [F3]: Select Reduce set value (Upper) or OFF (Lower). [F4]: Select Increase set value (Upper) or ON (Lower). [F5]: Cancel setting before confirmation and return to Maintenance Mode Change screen. [F6]: Confirm setting of upper or lower line. After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance Mode Change screen with [F5], the setting is effective.
30 Testing and adjusting
5.
Function of All Default Value After selecting "99 Use Default Value", if the screen is displayed, set with the function switches.
a
q q
a
a
If this operation is executed, the set values of all the maintenance items are set to default values. [F5]: Return to Maintenance Mode Change screen [F6]: Execute default setting A while after [F6] is pressed, the default setting completion screen is displayed. Then, if the "Maintenance Mode Change" screen is displayed, default setting is completed. The default setting of the corrosion resistor is "OFF".
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30 Testing and adjusting
Phone Number Entry The phone No. displayed when the action code/failure code is displayed in the operator mode can be input and changed according to the following procedure. If a phone No. is not input with this function, no phone No. is displayed in the operator mode. 1.
Selecting menu Select "05 Phone Number Entry" on the "Service Menu" screen.
2.
Registering and changing telephone No. After the "Phone Number Entry" screen is displayed, register or change the phone No. q [F2]: Delete all input No. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Delete input digit/Return to service menu q [F6]: Confirm input
a a
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If [F6] is pressed without inputting a digit, there is not information of phone No. Accordingly, no phone No. is displayed in the operator mode.
Up to 14 digits can be input from the left. Input nothing in the surplus positions. If one of the input digits is wrong, move to that digit (and its background changes to orange) and overwrite it with the correct digit.
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Default setting (Key-on Mode) Check or change various settings related to the machine monitor and machine by default setting. The function of Key-on Mode is used to set the initial mode displayed on the machine monitor when the starting switch is turned ON. 1.
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "01 Key-on Mode" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen. a This function sets the following 4 mode items (which are the items set with the customize switch in the operator mode). q Power: P/E q Reverse slow mode: ON/OFF q Work equipment fine control: ON/OFF q Blade slow down: ON/OFF
34
30 Testing and adjusting
3.
Selecting mode After the "Key-on Mode" screen is displayed, select the mode to be set with the function switches. q Mode at previous key-OFF: Final mode in previous operation is displayed when starting switch is turned ON q Default Value (ALL OFF): Default setting of all mode items (Power: E, other 3 items: OFF) is displayed when starting switch is turned ON q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to default screen q [F6]: Confirm selection and return to default screen a When the machine is delivered, Default Value (All OFF).
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30 Testing and adjusting
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Default setting (Setting of unit) Check or change various settings related to the machine monitor and machine by default setting. The unit selecting function is used to select the unit of the data displayed for monitoring, etc. 1.
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "02 Unit" with the function switches or numeral input switches. a Select this item similarly to an item 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.
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30 Testing and adjusting
Default setting (Setting of maintenance password) 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.
[F6]: Confirm selection and return to default screen
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "03 Maintenance Password" with the function switches or numeral input switches. a Select this item similarly to an item 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 Initialization screen
36
q
4.
Displaying maintenance password screen When the following operation is performed, the password screen is displayed in the operator mode. q The ordinary screen is changed to the maintenance mode (with [F5]) and then the "Maintenance table" screen is changed to the "Maintenance interval reset" screen.
5.
Changing maintenance password The password can be changed by operating the switches specially in the operator mode. a See "Function of changing maintenance password" in the operator mode. a Default password: [000000] a If the password setting is changed from "Enable" to "Disable", the password is reset to the default. a When "Enable" is set again, be sure to set a new password. a The maintenance password is different from the engine start lock password.
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30 Testing and adjusting
Default setting (Setting of camera) Check or change various settings related to the machine monitor and machine by default setting. The camera setting function is used to set default setting and removal of a camera. 1.
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q q q q
a
Selecting menu Select "06 Default" on the "Service Menu" screen. a a
a a 2.
Selecting sub menu After the "Default" screen is displayed, select "04 Camera" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting camera setting After the "Camera" screen is displayed, select the setting with the function switches. q OFF: Camera is not connected q Original image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor)
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a
[F3]: Move to left item [F4]: Move to right item [F5]: Cancel setting before confirmation and return to Default screen [F6]: Confirm selection in each line After "Camera" screen is displayed, camera 1 can be always set. When 2 or more cameras are connected, if camera 1 is set, the screen changes to setting of camera 2 automatically. After confirming the setting of each line with [F6], return to the Default screen with [F5], and the setting is effective. If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. If 2 or more cameras are connected, be sure to set the use of them from camera 1 in order. The function of displaying 2 images simultaneously is effective when use of camera 1 and camera 2 is set. When a camera is installed, check that the displayed image is not inverted horizontally in the operator mode.
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Default setting (Setting of ECO display) Check or change various settings related to the machine monitor and machine by initialization. The ECO display setting function is used to set the display of the ECO gauge. 1.
a
If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen.
a
Display of ECO gauge (a)
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "05 ECO Display" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting display setting After the "ECO Display" screen is displayed, select the setting with the function switches. q ON: Display ECO q OFF: Do not display ECO q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel selection and return to default screen q [F6]: Confirm selection and return to default screen
38
30 Testing and adjusting
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30 Testing and adjusting
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Adjustment The operator can adjust various items related to the machine with the machine monitor. When using an adjustment item, select it according to the following procedure. 1.
Selecting menu Select "07 Adjustment" on the "Service Menu" screen.
3.
2.
Selecting adjustment item After the "Adjustment" screen is displayed, input the 4-digit adjustment ID of the adjustment item to be used with the numeral input switches. q [F5]: Cancel adjustment and return to Service menu screen q [F6]: Confirm input adjustment ID and go to Adjustment screen a For the adjustment ID's and their adjustment items, see the adjustment items table.
a
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Displaying adjustment screen After the "Adjustment" screen for the adjustment ID is displayed, you can start adjustment. a In the figure, adjustment ID [0002] is selected and displayed as an example. a "000", "00", and "0" on the left of the adjustment ID must be filled but they are not displayed on the adjustment screen. a The functions given to function switches [F3] – [F6] depend on the adjustment item. a For the method of operating each adjustment item, see the explanation of its adjustment ID.
If the input adjustment ID is incorrect, the message of "No ready Adjustment" is displayed and the ID input screen does not change (Another ID can be input again with the numeral input switches while this screen is displayed).
39
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30 Testing and adjusting
Adjustment items table Adjustment ID
40
Adjustment item
0002
Power train controller initialization
0005
Brake pedal potentiometer initial correction
0007
Engine decelerator cutting
0009
Pitch angle sensor initial correction
0010
Fan 70% mode
0530
Stall mode
0910
Load record check mode
1005
Fan 100% mode
1012
Steering lever neutral position adjustment
1013
Steering lever leftmost position adjustment
1014
Steering lever rightmost position adjustment
1015
Right brake oil pressure offset
1016
Left brake oil pressure offset
2021
Power train controller voltage check mode
Remarks
Resetting auto-decelerating function
Recommended mode of torque converter stall
6001
R1 reverse slow set speed
Fine adjustment of reverse slow mode
6002
R2 reverse slow set speed
Fine adjustment of reverse slow mode
6003
R3 reverse slow set speed
Fine adjustment of reverse slow mode
7842
Transmission clutch IP automatic initial correction
7843
Transmission clutch IP manual initial correction
7845
Transmission clutch IP learning display
9995
Control brake release mode
9996
Sudden stop prevent valve operation mode
9997
High idle cut mode
9998
Max. gear speed setting mode
Control brake: Brake ECMV (Right and left)
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30 Testing and adjusting
Adjustment ID: 0002 (Power train controller initialization)
q
a
q
q
This adjustment code is used to initialize the specification code recognized by the power train controller and the set values of the memory in the controller. After the power train controller is replaced, be sure to carry out this adjustment once. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save setting Operating method: 1) Press [F6] and check that the alarm buzzer sounds. 2) Check that the displayed specification code [CODE] has changed from [5x5] to [999]. a If specification code [999] is not displayed, the controller wiring harness or the controller unit may be defective. a Even if this adjustment code is turned off, the setting is effective.
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Adjustment ID: 0005 (Brake pedal potentiometer initial correction)
q
a
This adjustment code is used to make the power train controller recognize the zero point of the brake pedal potentiometer. After the power train controller or brake pedal potentiometer is replaced or the brake pedal linkage is disconnected and connected, be sure to carry out this adjustment once.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save corrected value
q
Operating method: 1) Check that the brake pedal is in the neutral position (it is not pressed at all) and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, 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.
41
SEN03202-04 Adjustment ID: 0007 (Engine decelerator cutting)
30 Testing and adjusting
Adjustment ID: 0009 (Pitch angle sensor initial correction)
This adjustment code is used to stop the autodeceleration function of the engine and check the high idle speed of the engine unit. The engine can be driven and tested with the auto-deceleration reset only while this adjustment code is selected. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save corrected value
q
Operating method: When this adjustment code is displayed, its function is effective and the auto-deceleration function is stopped. a After this adjustment code is turned OFF, its function is ineffective.
q
Operating method: 1) Check that the machine is level. 2) Press [F6] and check that the alarm buzzer sounds. a If adjustment is carried out, displayed item [BODY PITCH ANGLE] changes to [0.0 °] (The other displayed items do not change). a Even if this adjustment code is turned off, the correction is effective.
q
a a
42
a
This adjustment code is used to make the power train controller recognize the zero point of the pitch angle sensor and to correct the installation error. After the power train controller is replaced or the pitch angle sensor is removed and installed or replaced, be sure to carry out this adjustment once.
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30 Testing and adjusting Adjustment ID: 0010 (Fan 70% mode)
q
a
q
q
This adjustment code is used to set the cooling fan speed to about 70% forcibly. Use this adjustment code for testing, adjusting, or troubleshooting when necessary. Functions of function switches [F3]: Increase adjustment value [FAN 70% SPEED MODE] [F4]: Decrease adjustment value [FAN 70% SPEED MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused Operating method: When this adjustment code is displayed, its function is effective and the cooling fan speed is controlled to about 70% of the maximum speed. a After this adjustment code is turned OFF, its function is ineffective.
SEN03202-04 Adjustment ID: 0530 (Stall mode)
q
This adjustment code is used to set the fan speed in the 100% mode automatically and make it possible to set the preset (gear speed at start) to [F3-R3] to stall the torque converter. a The preset (gear speed at start) can be set to [F3-R3] only while this adjustment code is selected. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Mode setting information within screen [P-AUTO SFT MODE]: Automatic gearshift in P mode [E-AUTO SFT MODE]: Automatic gearshift in E mode [P-MANUAL SFT MODE]: Manual gearshift in P mode [E-MANUAL SFT MODE]: Manual gearshift in E mode
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
a
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t o r q u e c o n v e r t e r a u t o m a t i c a l l y. Accordingly, operate the levers and pedals securely when stalling the torque converter (For the procedure for stalling the torque converter, see Measuring engine speed). After this adjustment code is turned OFF, its function is ineffective.
43
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Adjustment ID: 0910 (Load record check mode)
q
a
q
q
q
44
This adjustment code is used to check the load on the machine, odometer, and reverse odometer. Use this adjustment code for testing, adjusting, or troubleshooting when necessary. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused Mode setting information within screen [1000 rpm SMR]: Time displayed by service meter in which engine speed was above 1,000 rpm [ODO METER FORWARD]: Total forward travel distance [ODO METER REVERSE]: Total reverse travel distance Operating method: When this adjustment code is displayed, its function is effective and the load on the machine, odometer, and reverse odometer are displayed simultaneously. a The data cannot be reset. a After this adjustment code is turned OFF, its function is ineffective.
30 Testing and adjusting
Adjustment ID: 1005 (Fan 100% mode)
q
a
This adjustment code is used to set the cooling fan speed to about 100% forcibly. It is also used to set the adjustment value of the maximum speed. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Increase adjustment value [FAN 100% SPEED MODE] [F4]: Decrease adjustment value [FAN 100% SPEED MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method: a When this adjustment code is displayed, its function is effective and the cooling fan speed is controlled to about 100% of the maximum speed. 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) When confirming the adjustment value, press [F6] and check that the alarm buzzer sounds. a After this adjustment code is turned OFF, its function is ineffective but the set adjustment value is effective.
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30 Testing and adjusting
Adjustment ID: 1012 (Steering lever neutral position adjustment)
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Adjustment ID: 1013 (Steering lever leftmost position adjustment)
This adjustment code is used to make the power train controller recognize the neutral position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method: 1) Check that the PCCS lever is in the neutral position of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the neutral position of the potentiometer. It is not used to adjust the steering force.
q
Operating method: 1) Operate the PCCS lever to the left stroke end of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the leftmost position of the potentiometer. It is not used to adjust the steering force.
q
a
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a
This adjustment code is used to make the power train controller recognize the leftmost position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.
45
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Adjustment ID: 1014 (Steering lever rightmost position adjustment)
q
a
q
q
46
This adjustment code is used to make the power train controller recognize the rightmost position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Operating method: 1) Operate the PCCS lever to the right stroke end of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the rightmost position of the potentiometer. It is not used to adjust the steering force.
30 Testing and adjusting
Adjustment ID: 1015 (Right brake oil pressure offset)
q
a
This adjustment code is used to adjust the right brake oil pressure manually. Use this adjustment code for work when necessary.
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Information displayed on screen The offset oil pressure is displayed and the adjustment value is increased or decreased by 0.1 kg/cm² (The value displayed on the screen is multiplied by 100). a The default adjustment value is 0 kg/cm². a The adjustment range is -3 – 3 kg/cm².
q
Operating method: 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a If the oil pressure has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to operate the brake during adjustment. After finishing adjustment, however, operate the brake and check that there is not a problem in the actual brake performance. a Even if this adjustment code is turned off, the adjustment is effective.
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30 Testing and adjusting Adjustment ID: 1016 (Left brake oil pressure offset)
q
a
q
q
q
This adjustment code is used to adjust the left brake oil pressure manually. Use this adjustment code for work when necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Information displayed on screen The offset oil pressure is displayed and the adjustment value is increased or decreased by 0.1 kg/cm² (The value displayed on the screen is multiplied by 100). a The default adjustment value is 0 kg/cm². a The adjustment range is -3 – 3 kg/cm². Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a It is not necessary to operate the brake during adjustment. After finishing adjustment, however, operate the brake and check that there is not a problem in the actual brake performance. a If the oil pressure has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a Even if this adjustment code is turned off, the adjustment is effective.
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Adjustment ID: 2021 (Power train controller voltage check mode)
q
a
This adjustment code is used to check the constant power supply voltage and switch power supply voltage applied to the power train controller. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Information displayed on screen [PT CONTROLLER UNSWITCH POWER]: Constant power supply voltage [PT CONTROLLER ACC POWER]: Switch power supply voltage
q
Operating method: When this adjustment code is displayed, its function is effective and the constant power supply voltage and switch power supply voltage are displayed simultaneously. a After this adjustment code is turned OFF, its function is ineffective.
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Adjustment ID: 6001 (R1 reverse slow set speed)
30 Testing and adjusting
Adjustment ID: 6002 (R2 reverse slow set speed)
This adjustment code is used to adjust the engine speed applied to travel at gear speed R1 with the reverse slow mode ON. Use this adjustment code for work when necessary.
q
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Information displayed on screen The speed reduced from the high idle speed (2,050 rpm) is displayed and the adjustment value is increased or decreased by 50 rpm (The value displayed on the screen is multiplied by 1/10). a The default adjustment value is 300 rpm (Displayed value: 30). (Default setting: 2,050 – 300 = 1,850 rpm)
q
Information displayed on screen The speed reduced from the high idle speed (2,050 rpm) is displayed and the adjustment value is increased or decreased by 50 rpm (The value displayed on the screen is multiplied by 1/10). a The default adjustment value is 300 rpm (Displayed value: 30). (Default setting: 2,050 – 300 = 1,850 rpm)
q
Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a If the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R1 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
q
Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a If the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R2 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
q
a
48
a
This adjustment code is used to adjust the engine speed applied to travel at gear speed R2 with the reverse slow mode ON. Use this adjustment code for work when necessary.
D155A-6
30 Testing and adjusting
Adjustment ID: 6003 (R3 reverse slow set speed)
q
a
q
q
q
This adjustment code is used to adjust the engine speed applied to travel at gear speed R3 with the reverse slow mode ON. Use this adjustment code for work when necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Information displayed on screen The speed reduced from the high idle speed (2,050 rpm) is displayed and the adjustment value is increased or decreased by 50 rpm (The value displayed on the screen is multiplied by 1/10). a The default adjustment value is 300 rpm (Displayed value: 30). (Default setting: 2,050 – 300 = 1,850 rpm) Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a If the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R3 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
D155A-6
SEN03202-04
Adjustment ID: 7842 (Transmission clutch IP automatic initial correction)
q
a
This adjustment code is used to make the power train controller recognize the mechanical condition of the transmission. After the power train controller or transmission is replaced, be sure to carry out this adjustment once.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Conditions for correction work 1) [ENGINE SPEED]: 1,700 – 1,950 rpm 2) [T/C TEMPERATURE]: 65 – 85 °C 3) Parking brake lever: LOCK position a When using this adjustment code, keep t he abo ve c ond iti ons ( In pa rti c ula r, increase the power train oil temperature sufficiently before starting adjustment).
q
Operating method: 1) Start the engine and keep its speed in the specified range of condition with the fuel control dial. 2) Press [F6] and start the correction work and check that [1ST CLUTCH] is displayed newly on the screen. 3) If [END OF TEACHING] is displayed on the screen, press [F6]. If the alarm buzzer sounds at this time, correction work is completed. a The machine does not move during the correction work. a Even if this adjustment code is turned off, the correction is effective.
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SEN03202-04
Adjustment ID: 7843 (Transmission clutch IP manual initial correction)
q
a
q
This adjustment code is used to carry out correction manually when the correction is not carried out normally by the operation of IP automatic correction (Adjustment ID: 7842). Use this adjustment code after the IP correction work, if necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value a If [F2] is pressed while [F1] is pressed, all the correction values are set to 0.
q
Functions of shift-up and shift-down switches You can select a clutch to be corrected manually with the shift-up and shift-down switches.
q
Conditions for correction work Same as the conditions for IP automatic correction (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
30 Testing and adjusting
Adjustment ID: 7845 (Transmission clutch IP learning display)
q
a
This adjustment code is used to check the information of correction made by the operation of IP automatic correction (Adjustment ID: 7842) or IP manual correction (Adjustment ID: 7843). Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Change display [F4]: Change display [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method When this adjustment code is displayed, its function is effective and the correction information is displayed. a After this adjustment code is turned OFF, its function is ineffective.
D155A-6
30 Testing and adjusting Adjustment ID: 9995 (Control brake release mode)
SEN03202-04
Adjustment ID: 9996 (Sudden stop prevent valve operation mode)
This adjustment code is used to release the control brake (right and left brake ECMV) to check the operation of the backup brake (brake pedal solenoid valve). Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method When this adjustment code is displayed, its function is effective and the control brake (right and left brake ECMV) is kept released. a After this adjustment code is turned OFF, its function is ineffective.
q
Operating method When this adjustment code is displayed, its function is effective and the sudden stop prevent solenoid valve and right and left brake ECMV are kept stopped. a After this adjustment code is turned OFF, its function is ineffective.
q
a
D155A-6
a
This adjustment code is used to stop the sudden stop prevent solenoid valve and right and left brake ECMV to check the operation of the sudden stop prevent valve. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
51
SEN03202-04 Adjustment ID: 9997 (High idle cut mode)
30 Testing and adjusting
Adjustment ID: 9998 (Max. gear speed setting mode)
q q
a
q
q
52
This adjustment code is used to limit the high idle speed. Use this adjustment code for work when necessary. Functions of function switches [F3]: Increase adjustment value [HIGH IDLE RPM SET MODE] [F4]: Decrease adjustment value [HIGH IDLE RPM SET MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a When resetting the limitation of the high idle speed, set the adjustment value to the original high idle speed (2,050 rpm). a Even if this adjustment code is turned off, the adjustment is effective.
q
a
This adjustment code is used to limit the maximum transmission gear speed. The limited gear speed is applied in both automatic gearshift mode and manual gearshift mode. Use this adjustment code for work when necessary.
q
Functions of function switches [F3]: Increase adjustment value [MAX SHIFT] [F4]: Decrease adjustment value [MAX SHIFT] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a When resetting the limitation of the maximum gear speed, set the adjustment value to the maximum gear speed (3RD). a Even if this adjustment code is turned off, the adjustment is effective.
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30 Testing and adjusting
SEN03202-04
Pm Clinic The machine monitor can check the condition of the machine without connecting testing tools to assist the Pm Clinic and other periodic inspections. 1.
q
2nd screen
q
[F1]: Change screen [F2]: Change screen [F3]: Reset holding [F4]: Hold (displayed data) [F5]: Return to service menu screen
Selecting menu Select "08 PM CLINIC" on the Service menu screen.
q q q q
3. 2.
Information displayed on Pm Clinic screen The Pm Clinic function displays the following information on 2 pages. q 1st screen
D155A-6
Holding displayed information The displayed information can be held and released with [F3] and [F4].
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SEN03202-04
Cylinder Cut-Out operation The operator can perform Cylinder Cut-Out operation with the machine monitor. Reduced cylinder mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1.
2.
30 Testing and adjusting
3.
Resetting disabled cylinder When changing a cylinder to be disabled or when reduced cylinder mode operation is finished, select a disabled cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes light blue, the cylinder is reset. a If the machine monitor rests a disabled cylinder but the engine controller cannot reset that disabled cylinder, the background of the cylinder No. becomes red. a The reduced cylinder mode operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to perform the resetting operation after the reduced cylinder mode operation is finished.
4.
Function of holding displayed information If [F4] is pressed during the reduced cylinder mode operation, the displayed information is newly held (c) (The real-time information is kept displayed on the left side). a While the information is held, if [F3] is pressed, the holding function is reset. a The holding function is effective, regardless of setting of the reduced cylinder mode operation.
Selecting menu Select "09 Cylinder Cut-Out" on the "Service Menu" screen.
Selecting cylinder to be disabled After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be disabled with the function switches. q [F1]: Move selection mark (R) to left q [F2]: Move selection mark (R) to right q [F3]: Reset holding q [F4]: Hold q [F5]: Return to service menu screen q [F6]: Confirm selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is disabled. a If the machine monitor disables a cylinder but the engine controller cannot disable that cylinder, the background of the cylinder No. becomes yellow. a One or more cylinders can be disabled.
[Reference] If a normally operating cylinder is disabled, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) q If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command. q
54
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30 Testing and adjusting
SEN03202-04 a
Display of No Injection If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set the No Injection while the engine is stopped. 1.
2.
3.
Limit the cranking time to 20 seconds to protect the starting motor.
Selecting menu Select "10 No Injection" on the "Service Menu" screen.
Displaying check screen If the "No Injection" screen is displayed, the machine monitor asks the operator if no-injection cranking should be performed. Answer with the function switch. q [F5]: Do not perform (Return to Service menu screen) q [F6]: Perform a While the screen is changing to the following screen, the screen of "Communication between controllers is being checked" is displayed.
4.
Finishing no-injection cranking After completing the no-injection cranking operation, press [F6], and finish of no-injection cranking is displayed and the screen returns to the "Service Menu" screen automatically.
5.
Prohibiting no-injection cranking If the operator tries to perform the no-injection cranking while the engine is running, the message that the engine is running is displayed and the no-injection cranking is not set effective. a This function can be selected even while the engine is running. If the no-injection cranking is performed, however, the message of "Engine is running" is displayed on the screen.
Starting no-injection cranking If no-injection cranking (Fuel injection in no cylinders) becomes effective, that is displayed on the screen. Under this condition, crank the engine with the starting motor. a While the screen is changing to the following screen, the screen of "Setting is being prepared" is displayed.
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SEN03202-04
Display of Fuel Consumption This function calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicates it. 1.
Selecting menu Select "11 Fuel Consumption" on the "Service Menu" screen.
2.
Starting measurement After the screen of "Fuel Consumption" is displayed, start measurement with the function switches. q [F1]: Start q [F2]: Clear q [F5]: Return to Service menu screen a When the screen of "Fuel Consumption" is displayed, if a data is indicated, it is the data of the previous measurement. This data is not an obstacle to new measurement and can be deleted by pressing [F2]. a If [F1] is pressed, the data is displayed on the starting date and time side and measurement starts. a The display unit of the fuel changes according to the unit set with the initialization (unit setting) function. SI and meter: l/h, inch: gal/h
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30 Testing and adjusting
3.
Display and function during measurement Clock mark (a) flashes during measurement. a While the fuel consumption is being measured, the operator can work with the operator mode and other functions. Measurement is not finished until this screen is displayed again and [F1] is pressed (Even if the starting switch is turned OFF, this function is kept effective, although fuel consumption is measured only while the engine is running).
4.
Finishing measurement Press [F1], and measurement is finished and the data are displayed on the finishing date and time side.
5.
Displaying fuel consumption If the measurement is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.
D155A-6
30 Testing and adjusting
Display of KOMTRAX Settings (Terminal Status) The setting condition and operating condition of KOMTRAX can be checked with "KOMTRAX Settings". Terminal Status is used to check the setting condition of the KOMTRAX terminal. 1.
Selecting menu Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "01 Terminal Status" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Contents of Terminal Status On the "Terminal Status" screen, the following items are displayed. q Terminal Type: Model name of KOMTRAX communication MODEM q KOMTRAX communication: Executing condition of KOMTRAX communication q GMT time: Greenwich Meant Time (+ 9 hours in Japan)
D155A-6
SEN03202-04
q
[F5]: Return to KOMTRAX Settings screen
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SEN03202-04
Display of KOMTRAX Settings (GPS & Communication Status) The setting condition and operating condition of KOMTRAX can be checked with KOMTRAX Settings. Condition of positioning and communication is used to check the condition of positioning and communication of the KOMTRAX terminal. 1.
Selecting menu Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the Display of "KOMTRAX Settings" screen is displayed, select "02 GPS & Communication Status" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
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30 Testing and adjusting
3.
Contents of display of condition of positioning and communication On the screen of "GPS & Communication Status", the following items are displayed. q Positioning: Positioning condition of GPS q Communication: Communication environment of communication MODEM and connecting condi tion of c ommunication MODEM q Number of message not yet sent: Number of mails in machine monitor not yet sent q [F5]: Return to KOMTRAX Settings screen
D155A-6
30 Testing and adjusting
SEN03202-04
Display of KOMTRAX Settings The setting condition and operating condition of KOMTRAX can be checked with KOMTRAX Settings. MODEM S/N is used to check the serial No. of the KOMTRAX communication MODEM. 1.
Selecting menu Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the Display of "KOMTRAX Settings" screen is displayed, select "03 Modem S/N" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Contents of display of MODEM S/N The serial No. of KOMTRAX communication MODEM is displayed. q [F5]: Return to KOMTRAX Settings screen
D155A-6
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SEN03202-04
Display of Service Message Special messages for the serviceman sent from the KOMTRAX base station (a distributor, etc.) can be checked with this function. If there is setting in a message, a return mail can be sent by using numeral input switches. 1.
Operation to display menu Select "13 Service Message" on the "Service Menu" screen.
2.
Display of message (Read-only) If there is a message, its contents are displayed. If there is not a message, "No message" is displayed. q [F5]: Return to service menu screen a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.
3.
Display of message (with return mail function) If a box to enter a value with the numeral keys is displayed under the message, enter a proper number with the numeral input switches and function switches and confirm it, and the information is returned to the KOMTRAX base station. q [F5]: Return to service menu screen
60
30 Testing and adjusting
q
a a
[F6]: Confirm and return input value This message is different from a message transmitted to the operator in the operator mode. Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.
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30 Testing and adjusting
D155A-6
SEN03202-04
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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
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
30 Testing and adjusting
1
Testing and adjusting, Part 4 Handling of power supply circuit of engine controller...................................................................................... 2 Preparation work for troubleshooting of electrical system .............................................................................. 3 Pm Clinic......................................................................................................................................................... 5
D155A-6
1
SEN03203-00
30 Testing and adjusting
Handling of power supply circuit of engine controller 1 1.
Before disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF.
2.
If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
2
D155A-6
30 Testing and adjusting
Preparation work for troubleshooting of electrical system
SEN03203-00
2.
1
a
When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller, power train controller, or work equipment controller, expose the related connectors according to the following procedure.
1.
Machine monitor 1) Remove the 4 mounting bolts each from covers (1) and (2) and remove those covers. 2) Remove the 4 mounting bolts each from covers (3) and (4) and remove those covers together with the foot rest. a The 2 bolts on the front window side of the foot rest are used as the cover mounting bolts, too. 3) Remove the 4 mounting bolts of machine monitor (5) and pull out machine monitor (5) and switch cover together toward the operator's seat.
4)
D155A-6
Engine controller 1) Open the left engine side cover and left mudguard. 2) Remove the mounting bolts and cover (6).
3)
Insert or connect troubleshooting T-adapters in or to connectors EGC1, EGC2, and EGC3 of engine controller (7). a Since connectors EGC1 and EGC2 are fixed with screws, loosen those screws before disconnecting. a When returning connectors EGC1 and EGC2, tighten the screws to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and CM03 of machine monitor (5). a AT11 is for the GPS antenna. a If a camera is installed, CM05 is also wired.
3
SEN03203-00
3.
4
30 Testing and adjusting
Power train controller 1) Remove the inside lower cover of the left console. 2) Insert or connect troubleshooting T-adapters in or to connectors STC1, STC2, and STC3 of power train controller (8). a Since the connectors are fixed with screws, loosen those screws before disconnecting. a When returning the connectors, tighten the screws to the specified torque. 3 Screw: 2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
D155A-6
30 Testing and adjusting
SEN03203-00
Pm Clinic
1
Machine model
Serial No.
Service meter
D155A-6
h
User's name
Date of execution /
Inspector
/
Specifications Blade
Rear attachment
T blade T Semi-U blade T Full-U blade T
T Multi-shank ripper T Variable giant ripper T Counterweight ( T
Shoe width
T 560 mm T 610 mm T 660 mm T 710 mm
kg)
T
Working condition Construction
Quarry/Mining T Coal T Gold T Limestone
) Contents of work T Dozing T Side cutting T Ripping T Travel
Type of soil (Specific gravity:
T Construction/Civil engineering T Rock T Road T Gravel T Tunnel T Sand T T Clay
T
% % % %
Check of oil and coolant levels
T Engine coolant level T Engine oil level T Hydraulic oil level
When necessary T Damper case oil level T Power train oil level
Engine coolant temperature
Power train oil temperature
Max. range: Max. range: Following figure (Left) Following figure (Right) Operator's opinion
T Final drive oil level T
Ambient temperature Max.
°C/Min.
Altitude
°C
m
Result of visual inspection
Fault history of mechanical system
Fault history of electrical system
AA10NX
times/1st time
h/last
h
times/1st time
h/last
h
AB00MA
times/1st time
h/last
h
times/1st time
h/last
h
B@BAZG
times/1st time
h/last
h
times/1st time
h/last
h
B@BCNS
times/1st time
h/last
h
times/1st time
h/last
h
B@BCZK
times/1st time
h/last
h
times/1st time
h/last
h
B@CENS
times/1st time
h/last
h
times/1st time
h/last
h
B@HANS
times/1st time
h/last
h
times/1st time
h/last
h
CA234
times/1st time
h/last
h
times/1st time
h/last
h
D155A-6
5
SEN03203-00
30 Testing and adjusting
Check positions/Method 1
6
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30 Testing and adjusting
SEN03203-00
Check positions/Method 2
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7
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30 Testing and adjusting
Check positions/Method 3
8
D155A-6
30 Testing and adjusting
SEN03203-00
Pm Clinic check sheet Machine model
Serial No.
Service meter
User's name
Date of execution
Standard value for new machine
Service limit value
740 – 780
740 – 780
Inspector
D155A-6
Unit
Low idling Without deceleration High (Adjustment: 0007) Engine speed idle Normal (Deceleration)
rpm
Engine
Exhaust temperature
850 – 900
F3 stall
1,615 – 1,715
1,450
F3 stall + Ripper raise relieve
1,580 – 1,680
1,395
Min. 85 {Min. 640}
72 {540}
—
—
670
720
Max. 2.94 {Max. 300}
3.92 {400}
Min. 034 {Min. 3.5}
0.21 {2.1}
Min. 010 {Min. 1.0}
0.08 {0.8}
Standard value for new machine
Service limit value
—
—
kPa {mmHg}
Ambient temperature F3 stall
Blow-by presF3 stall sure Engine oil pressure
2.
°C kPa {mmH2O}
High idle Low idle
—
—
—
1,825 – 1,925 1,825 – 1,925 850 – 900
F3 stall
—
2,050 – 2,100 2,050 – 2,100
Decelerator pedal
Boost pressure
Measurement result
Rejected
Measurement condition
Rejected
Item
Accepted
Engine
Accepted
1.
MPa {kg/cm²}
Cooling fan Item
Measurement condition
Unit
Low idle Fan
Speed
Circuit pressure
D155A-6
Adjustment: High idle 1005 High idle
Measurement result
rpm 1,045 – 1,155 1,045 – 1,155 MPa {kg/cm²}
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SEN03203-00
Transmission
Item
Max. 1.0 {Max. 10.0}
Max. 1.0 {Max. 10.0}
0.05 – 0.29 {0.5 – 3.0}
0.05 – 0.29 {0.5 – 3.0}
0.29 – 0.69 {3.0 – 7.0}
0.29 – 0.69 {3.0 – 7.0}
Standard value for new machine
Service limit value
Low idle
2.81 – 3.11 {28.7 – 31.7}
Min. 2.62 {Min. 26.7}
High idle
3.04 – 3.33 {31.0 – 34.0}
Min. 2.84 {Min. 29.0}
2.55 – 2.94 {26.0 – 30.0}
Min. 2.35 {Min. 24.0}
2.60 – 2.99 {26.5 – 30.5}
Min. 2.40 {Min. 24.5}
Monitoring: 32601 High idle Low idle Monitoring: 32603 High idle
Measurement condition
Unit
Gear speed: P/N
F clutch pressure
Gear speed: F3 Brake: Applied
Low idle
R clutch pressure
Gear speed: R3 Brake: Applied
Low idle
1st clutch pressure
Gear speed: F1 Brake: Applied
Low idle
2.81 – 3.11 {28.7 – 31.7}
Min. 2.62 {Min. 26.7}
2nd clutch pressure
Gear speed: F2 Brake: Applied
Low idle
2.60 – 2.89 {26.5 – 29.5}
Min. 2.40 {Min. 24.5}
3rd clutch pressure
Gear speed: F3 Brake: Applied
Low idle
2.81 – 3.11 {28.7 – 31.7}
Min. 2.62 {Min. 26.7}
Standard value for new machine
Service limit value
Low idle
2.46 – 3.04 {25.0 – 31.0}
2.16 {22.0}
High idle
2.46 – 3.04 {25.0 – 31.0}
2.16 {22.0}
Low idle
2.46 – 3.04 {25.0 – 31.0}
2.16 {22.0}
High idle
2.46 – 3.04 {25.0 – 31.0}
2.16 {22.0}
Measurement condition
Right brake pressure
Gear speed: N Brake: Released
Left brake pressure
Gear speed: N Brake: Released
Brake F2 stall, high idle performance
MPa {kg/cm²}
Unit
MPa {kg/cm²}
2.3 – 2.6 {23.5 – 26.5}
2.3 – 2.6 {23.5 – 26.5}
2.3 – 2.6 {23.5 – 26.5}
Low idle
2.3 – 2.6 {23.5 – 26.5}
2.3 – 2.6 {23.5 – 26.5}
High idle
2.3 – 2.6 {23.5 – 26.5}
2.3 – 2.6 {23.5 – 26.5}
Low idle Gear speed: N PCCS lever: Right stroke end High idle
Left clutch pressure
Gear speed: N PCCS lever: Left stroke end
Measurement result
Measurement result
Machine must not move. 2.3 – 2.6 {23.5 – 26.5}
Right clutch pressure Clutch
10
MPa {kg/cm²}
Rejected
0.05 – 0.49 {0.5 – 5.0}
Main relief pressure
Item
Brake
0.05 – 0.49 {0.5 – 5.0}
Low idle
Measurement result
Rejected
Outlet pressure
Service limit value
Unit
Rejected
Inlet pressure
Standard value for new machine
Measurement condition
Accepted
Torque converter
Item
Accepted
Power train oil pressure k Measure each transmission clutch pressure only while the engine is running at low speed for safety.
Accepted
3.
30 Testing and adjusting
D155A-6
30 Testing and adjusting
Work equipment/HSS oil pressure
Item
Work equipment relief pressure
Work equipment control lever: All levers in neutral
2.45 – 3.82 {25 – 39}
2.45 – 3.82 {25 – 39}
High idle
26.0 – 29.0 {265 – 295}
26.0 – 29.0 {265 – 295}
Cylinder stroke
MPa {kg/cm²} High idle
24.0 – 26.0 {245 – 265}
24.0 – 26.0 {245 – 265}
Control circuit basic pressure
High idle
3.97 – 4.46 {40.5 – 45.5}
3.78 – 4.46 {38.5 – 45.5}
Standard value for new machine
Service limit value
3.0 – 4.0
3.0 – 4.0
1.8 – 2.8
3.1
2.5 – 3.5
4.0
4.5 – 5.5
6.2
Unit
Standard value for new machine
Service limit value
°C
—
—
mm
Max. 150
200
mm
Max. 50
70
Service limit value
Work equipment control lever: All levers in neutral
High idle
Blade left tilt
High idle
Ripper lower
High idle
Ripper tilt in
High idle
sec
Measurement result
Rejected
Blade raise
Unit
Measurement result
Rejected
Measurement condition
Accepted
Item
Accepted
Work equipment speed
—
—
Hydraulic drift of work equipment
Hydraulic drift
Item
Measurement condition
Hydraulic oil temperature Hydraulic drift of blade lift
Engine: Stopped Blade lift: 15 minutes Ripper lift: 5 minutes
Hydraulic drift of ripper lift
Final drive
FD
Item
Measurement condition
Unit
Standard value for new machine
Final drive
Engine: Stopped
—
There must not abnormally much metal dust.
D155A-6
Measurement result
Rejected
7.
High idle
Measurement result
Accepted
6.
Service limit value
Unit
Work equip- end relief ment LS relief pressure
Work equipment speed
5.
Unload pressure
Standard value for new machine
Measurement condition
Rejected
Work equipment oil pressure Accepted
4.
SEN03203-00
11
SEN03203-00
8.
Repair record (Must be filled in) Date
12
30 Testing and adjusting
Service meter
Repair record
Date
Service meter
/
/
h
/
/
h
/
/
h
/
/
h
/
/
h
/
/
h
/
/
h
/
/
h
/
/
h
/
/
h
Repair record
D155A-6
30 Testing and adjusting
SEN03203-00
Pm Clinic undercarriage check sheet Machine model
Serial No.
Service meter
User's name
Date of execution
Inspector
D155A-6
1.
Bushing temperature Item
Measurement condition
Measurement result
Accepted Rejected
Under- Bushing Measure just Left side of machine carriage temperature after work. Right side of machine
Left side of machine
a
Symbols to be entered in check drawing H : Hot (You cannot keep touching, Very hot, Min. 50 °C) W : Warm (Lukewarm, warmer than link, Approx. 35 °C) C : Normal temperature: Same as link temperature
Right side of machine
a
Symbols to be entered in check drawing H : Hot (You cannot keep touching, Very hot, Min. 50 °C) W : Warm (Lukewarm, warmer than link, Approx. 35 °C) C : Normal temperature: Same as link temperature
D155A-6
13
Item
Measurement condition
Unit
Undercarriage
Left side of machine
Opening of track link
Measure dimension (a).
Clearance limit
Pin No.
Measurement result
Rejected
30 Testing and adjusting
Accepted
SEN03203-00
1.4 (Each side)
mm
Right side of machine
1.4 (Each side)
Opening of track link (a)
14
D155A-6
30 Testing and adjusting
D155A-6
SEN03203-00
15
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
SEN03204-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
40 Troubleshooting
1
Failure code table and fuse locations Failure codes table.......................................................................................................................................... 2 Fuse locations................................................................................................................................................. 8
D155A-6
1
SEN03204-03
40 Troubleshooting
Failure codes table
1
Action code
Failure code
E03
1500L0
Transmission clutch: Abnormal
E03
15SAL1
Forward clutch: Fill high
E03
15SALH
Forward clutch: Fill Low
E03
15SBL1
Reverse clutch: Fill high
E03
15SBLH
Reverse clutch: Fill Low
E03
15SEL1
Speed 1st clutch: Fill high
E03
15SELH
Speed 1st clutch: Fill Low
E03
15SFL1
Speed 2nd clutch: Fill high
E03
15SFLH
Speed 2nd clutch: Fill Low
E03
15SGL1
Speed 3rd clutch: Fill high
E03
15SGLH
Speed 3rd clutch: Fill Low
E04
2201L1
Right clutch: See the list
E04
2201LH
Right clutch: See the list
E04
2202L1
Left clutch: See the list
E04
2202LH
Left clutch: See the list
–
2300KM
Stall in 1st gear speed
E04
2301L1
Right brake: Fill high
E04
2301LH
Right brake: Fill low
E04
2302L1
Left brake: Fill high
E04
2302LH
Left brake: Fill low
–
7RFAKA
ECM HOLD RELAY: Disconnection
–
AA10NX
Air Cleaner Clogging
–
AB00MA
Battery Charge Abnormal
–
B@BAZG Eng Oil Press Low
–
B@BCNS Eng Water Overheat
–
B@BCZK Eng Water Level Low
–
B@CENS T/C Oil Overheat
–
B@HANS Hyd Oil Overheat
Trouble (Displayed on screen)
E04
CA111
EMC Critical Internal Failure
E04
CA115
Eng Ne and Bkup Speed Sens Error
2
Component Category of in charge history Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Mechanical MON system Mechanical MON system Mechanical ENG system Mechanical ENG system Mechanical MON system Mechanical P/T system Mechanical MON system Electrical ENG system Electrical ENG system
Reference manual
Troubleshooting by failure code, Part 1 SEN03206-**
D155A-6
40 Troubleshooting
SEN03204-03
Action code
Failure code
Trouble (Displayed on screen)
E03
CA122
Chg (boost) Air Press Sensor High Error
E03
CA123
Chg (boost) Air Press Sensor Low Error
E03
CA131
Throttle Sensor High Error
E03
CA132
Throttle Sensor Low Error
E02
CA135
Eng Oil Press Sensor High Error
E02
CA141
Eng Oil Press Sensor Low Error
E02
CA144
Coolant Temp Sens High Error
E02
CA145
Coolant Temp Sens Low Error
E01
CA153
Chg (boost) Air Temp Sensor High Error
E01
CA154
Chg (boost) Air Temp Sensor Low Error
E03
CA187
Sens Supply 2 Volt Low Error
E03
CA221
Ambient Press Sens High Error
E03
CA222
Ambient Press Sens Low Error
E03
CA227
Sens Supply 2 Volt High Error
–
CA234
Eng Overspeed
E03
CA238
Ne Speed Sens Supply Volt Error
E01
CA263
Fuel Temp Sensor High Error
E01
CA265
Fuel Temp Sensor Low Error
E03
CA271
PCV1 Short Error
E03
CA272
PCV1 Open Error
E03
CA273
PCV2 Short Error
E03
CA274
PCV2 Open Error
E03
CA322
Inj #1 Open/Short Error
E03
CA323
Inj #5 Open/Short Error
E03
CA324
Inj #3 Open/Short Error
E03
CA325
Inj #6 Open/Short Error
E03
CA331
Inj #2 Open/Short Error
E03
CA332
Inj #4 Open/Short Error
E04
CA342
Calibration Code Incompatibility
E03
CA351
Injectors Drive Circuit Error
E03
CA352
Sens Supply 1 Volt Low Error
D155A-6
Component Category of in charge history Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system
Reference manual
Troubleshooting by failure code, Part 1 SEN03206-**
Troubleshooting by failure code, Part 2 SEN03207-**
3
SEN03204-03
40 Troubleshooting
Action code
Failure code
E03
CA386
Sens Supply 1 Volt High Error
E04
CA441
Battery Voltage Low Error
E04
CA442
Battery Voltage High Error
E03
CA449
Rail Press Very High Error
E03
CA451
Rail Press Sensor High Error
E03
CA452
Rail Press Sensor Low Error
E02
CA553
Rail Press High Error
E03
CA554
Rail Press Sensor In Range Error
E02
CA559
Rail Press Low Error
E03
CA689
Eng Ne Speed Sensor Error
E03
CA731
Eng Bkup Speed Sens Phase Error
E04
CA757
All Continuous Data Lost Error
E03
CA778
Eng Bkup Speed Sensor Error
E03
CA1633
KOMNET Datalink Timeout Error
E03
CA2185
Throt Sens Sup Volt High Error
E03
CA2186
Throt Sens Sup Volt Low Error
E03
CA2249
Rail Press Very Low Error
E01
CA2555
Grid Htr Relay Volt Low Error
E01
CA2256
Grid Htr Relay Volt High Error
–
D110KA
Battery relay: Disconnection
–
D110KB
Battery Relay: Drive Short Circuit
E02
D130KA
Neutral relay: Disconnection
E02
D130KB
Neutral relay: Short circuit
E01
D161KA
Back-up alarm relay: Disconnection
E01
D161KB
Back-up alarm relay: Short circuit
–
D190KA
ACC signal relay: Disconnection
–
D190KB
ACC signal relay: Short circuit
E03
D5ZKKX
Throttle Dial: Out of normal range
E03
DAFRKR CAN Disconnection (Monitor)
E03
DB2RKR
CAN Disconnection (Engine controller)
E03
DB90KR
PT controller: Can communication lost
4
Trouble (Displayed on screen)
Component Category of in charge history Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical MON system Electrical ENG system Electrical P/T system
Reference manual
Troubleshooting by failure code, Part 2 SEN03207-**
Troubleshooting by failure code, Part 3 SEN03208-**
D155A-6
40 Troubleshooting
SEN03204-03
Action code
Failure code
E03
DBE0KK
PT controller: Source voltage reduction
E01
DBE0KT
PT controller: Abnormality in controller
E02
DBE6KK
PT controller: Source voltage reduction
E02
DBE7KK
PT controller: Source voltage reduction
E04
DBE9KQ
PT controller: Type select signal
E02
DD12KA
Shift up Sw: Disconnection
E02
DD12KB
Shift up Sw: Short circuit
E02
DD13KA
Shift down Sw: Disconnection
E02
DD13KB
Shift down Sw: Short circuit
E03
DD14KA
Parking lever Sw: Disconnection
E03
DD14KB
Parking lever Sw: Short circuit
E02
DDDDKA Back up brake Sw: Disconnection
E02
DDDDKB Back up brake Sw: Short circuit
E02
DDDDKX Back up brake Sw: Signal mismatch
E01
DGT1KA
T/C oil temp sensor: Abnormal
E01
DGT1KX
T/C oil temp sensor abnormal
–
DH21KA
Weq pressure sensor: Disconnection
–
DH21KB
Weq pressure sensor: Short circuit
E03
DK10KX
Fuel control Dial: Out of normal range
E03
DK30KA
ST lever 1: Disconnection
E03
DK30KB
ST lever 1: Short circuit
E04
DK30KX
ST lever 1: Out of normal range
E04
DK30KZ
ST lever: Disconnection or short circuit
E03
DK30L8
ST lever: Signal mismatch
E03
DK31KA
ST lever 2: Disconnection
E03
DK31KB
ST lever 2: Short circuit
E03
DK40KA
Brake potentiometer: Disconnection
E03
DK40KB
Brake potentiometer: Short circuit
E04
DK55KX
FR lever: Out of normal range
E04
DK55KZ
FR lever: Disconnection or short circuit
E03
DK55L8
FR lever: Signal mismatch
D155A-6
Trouble (Displayed on screen)
Component Category of in charge history Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system
Reference manual
Troubleshooting by failure code, Part 3 SEN03208-**
5
SEN03204-03
40 Troubleshooting
Action code
Failure code
E03
DK56KA
FR lever 1: Disconnection
E03
DK56KB
FR lever 1: Short circuit
E03
DK57KA
FR lever 2: Disconnection
E03
DK57KB
FR lever 2: Short circuit
E03
DKH1KA
Pitch angle sensor: Disconnection
E03
DKH1KB
Pitch angle sensor: Short circuit
E01
DLT3KA
T/M out-speed sensor: Disconnection
E01
DLT3KB
T/M out-speed sensor: Abnormal
E01
DW7BKA Fan rev EPC: Disconnection
E01
DW7BKB Fan rev EPC: Short circuit
E04
DWN3KA Ssp solenoid: Disconnection
E04
DWN3KB Ssp solenoid: Short circuit
E04
DWN3KY Ssp solenoid: Short circuit
E01
DWN5KA Fan pump solenoid: Disconnection
E01
DWN5KB Fan pump solenoid: Short circuit
E03
DXH4KA
1st clutch ECMV: Disconnection
E03
DXH4KB
1st clutch ECMV: Short circuit
E03
DXH4KY
1st clutch ECMV: Short circuit
E03
DXH5KA
2nd clutch ECMV: Disconnection
E03
DXH5KB
2nd clutch ECMV: Short circuit
E03
DXH5KY
2nd clutch ECMV: Short circuit
E03
DXH6KA
3rd clutch ECMV: Disconnection
E03
DXH6KB
3rd clutch ECMV: Short circuit
E03
DXH6KY
3rd clutch ECMV: Short circuit
E03
DXH7KA
R clutch ECMV: Disconnection
E03
DXH7KB
R clutch ECMV: Short circuit
E04
DXH7KY
R clutch ECMV: Short circuit
E03
DXH8KA
F clutch ECMV: Disconnection
E03
DXH8KB
F clutch ECMV: Short circuit
E04
DXH8KY
F clutch ECMV: Short circuit
E03
DXH9KA
Right clutch ECMV: Disconnection
6
Trouble (Displayed on screen)
Component Category of in charge history Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical W/E system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system
Reference manual Troubleshooting by failure code, Part 3 SEN03208-**
Troubleshooting by failure code, Part 4 SEN03209-**
D155A-6
40 Troubleshooting
SEN03204-03
Action code
Failure code
E03
DXH9KB
Right clutch ECMV: Short circuit
E04
DXH9KY
Right clutch ECMV: Hot short
E03
DXHAKA Left clutch ECMV: Disconnection
E03
DXHAKB Left clutch ECMV: Short circuit
E04
DXHAKY Left clutch ECMV: Hot short
E04
DXHBKA Right brake ECMV: Disconnection
E04
DXHBKB Right brake ECMV: Short circuit
E04
DXHBKY Right brake ECMV: Short circuit
E04
DXHCKA Left brake ECMV: Disconnection
E04
DXHCKB Left brake ECMV: Short circuit
E04
DXHCKY Left brake ECMV: Short circuit
E03
DXJ4KA
Weq lock Sol.: Disconnection
E03
DXJ4KB
Weq lock Sol.: Short circuit
a a
a
a
Trouble (Displayed on screen)
Component Category of in charge history Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system
Reference manual
Troubleshooting by failure code, Part 4 SEN03209-**
Entry order of items in table The items are entered in the order of their failure codes (incremental order). Action code Attached: If the failure code is detected, the action code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the fault. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the fault. Component in charge MON: The machine monitor is in charge of detection of fault. ENG: The engine controller is in charge of detection of fault. P/T: The power train controller is in charge of detection of fault. Category of record Mechanical equipment system: Fault information is recorded in the "Mechanical Systems". Electrical equipment system: Fault information is recorded in the "Electrical Systems" .
D155A-6
7
SEN03204-03
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. Circuit breakers CB1 – CB9 Power circuit breaker Circuit (Type of power supply) breaker No.
CB105 (Accessory power supply)
CB30 (Unswitched power supply)
Circuit breaker capacity
Destination of power
CB9
20A
Optional power supply
CB1
20A
CB2
20A
CB3
20A
Air conditioner unit, blower motor, and compressor electromagnetic clutch
CB4
20A
Headlamp, additional headlamp
CB5
20A
Rear lamp, additional rear lamp, ripper point lamp
CB6
20A
CB7
20A
Power train controller Emergency power supply (For power train switch box) Work equipment controller Emergency power supply (For work equipment switch box)
Starting switch Engine hold relay Machine monitor Power train controller Work equipment controller
CB8
30A
Engine controller, Electric priming pump
—
—
Engine electrical intake air heater
Power circuit breaker (Type of power supply)
Fuse No.
Fuse capacity
CB30 (Unswitched power supply)
1
20A
Operator's cab power supply (To connection table of fuse box
2
5A
Backup alarm, backup alarm relay
3
20A
Operator's cab power supply (To connection table of fuse box
)
4
20A
Operator's cab power supply (To connection table of fuse box
)
5
5A
Engine controller (Signal ACC)
CB105H (Unswitched power supply)
Fuse box FS1
CB105 (Accessory power supply) Starting switch (ACC)
8
Destination of power
)
D155A-6
40 Troubleshooting
SEN03204-03
Fuse box FS2 Power circuit breaker (Type of power supply)
Fuse No.
Fuse capacity
CB30 (Unswitched power supply)
1
5A
Pedal brake solenoid valve
2
5A
Parking brake solenoid valve
CB105 (Accessory power supply)
Starting switch (ACC)
D155A-6
Destination of power
Engine electrical intake air heater 3
20A
Ripper pin puller solenoid valve
4
5A
Horn
5
20A
Optional power supply
Pneumatic suspension seat
9
SEN03204-03
40 Troubleshooting
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
SEN03204-03
Fuse box Power circuit fuse (Type of power supply) FS1-1 (Unswitched power supply) FS1-3 (Accessory power supply)
Fuse No.
Fuse capacity
Destination of power Radio
1
10A
12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter)
2
20A
3
20A
Additional light relay, additional light Rotary lamp 12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter) Radio
FS1-4 (Accessory power supply)
Location of fuse box
D155A-6
Room lamp
4
20A
5
10A
Front wiper, rear wiper
6
10A
Left wiper, right wiper
Cigarette lighter Windshield wiper (Via intermittent relay)
(In operator's cab)
11
SEN03204-03
40 Troubleshooting
D155A-6 Bulldozer Form No. SEN03204-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
12
D155A-6
SEN03205-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
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
SEN03205-03
40 Troubleshooting
Points to remember when troubleshooting
1
k Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
2.
3.
2
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.
4) 5)
4.
Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.
q
5.
Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information.
q
6.
Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
q
D155A-6
40 Troubleshooting
SEN03205-03
Sequence of events in troubleshooting
1
D155A-6
3
SEN03205-03
40 Troubleshooting
Check before troubleshooting Item 1. Check of level and type of fuel 2. Check of fuel for foreign matter
Lubricating oil/Coolant
4
Remedy
—
Add fuel
—
Clean and drain
Between H – L
Add oil
4. Check of damper case oil level
Between H – L
Add oil
5. Check of power train oil level
Between H – L
Add oil
Between H – L
Add oil
7. Check of coolant level (in sub tank)
Between FULL - LOW
Add coolant
8. Check of dust indicator for clogging
Out of red range
Clean or replace
9. Check of brake pedal stroke
—
Adjust
1. Check for abnormal noise/smell
—
Repair
2. Check for oil leakage
—
Repair
3. Bleeding air
—
Bleed air
1. Check of battery terminals and wiring for looseness and corrosion
—
Retighten or replace
2. Check of alternator terminals and wiring for looseness and corrosion
—
Retighten or replace
3. Check of starting motor terminals and wiring for looseness and corrosion
—
Retighten or replace
4. Check of battery voltage (with engine stopped)
20 – 30 V
Charge or replace
Between H – L
Add or replace
6. Check of wires for discoloration, burn, and removal of cover
—
Repair or replace
7. Check for released wire clamp and drooping wire
—
Repair
8. Check of wires for wetness (Check connectors and terminals for wetness, in particular)
—
Dry
9. Check circuit breaker for turning OFF and fuse for disconnection and corrosion
—
Replace
10. Check of alternator voltage (while engine speed is at middle or higher)
After operating for several minutes: 27.5 – 29.5 V
Replace
11. Check of battery relay for operating sound (when starting switch is turned ON or OFF)
—
Replace
5. Check of electrolyte level Electrical equipment
Criterion
3. Check of hydraulic oil level
6. Check of level and type of engine oil (in oil pan)
Hydraulic/ Mechanical equipment
1
D155A-6
40 Troubleshooting
SEN03205-03
Classification and procedures for troubleshooting
1
Classification for troubleshooting Type Display of code
Contents Troubleshooting by failure code
E mode
Troubleshooting for electrical system
H mode
Troubleshooting for hydraulic and mechanical system
S mode
Troubleshooting for engine
Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1.
Procedure for troubleshooting to be taken when action code and failure code are displayed on machine monitor: If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting for the corresponding "Display of code" according to the displayed failure code.
2.
When electrical system failure code or mechanical system failure code is recorded in fault history: If a action code and a failure code are not displayed on the machine monitor, check for a mechanical system failure code and an electrical system failure code with the fault history function of the machine monitor. If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" according to that code. a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is still detected. a A failure code of the mechanical system cannot be deleted. a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history function, carry out the corresponding troubleshooting in "E mode".
3.
When action code or failure code is not displayed and no failure code is recorded in fault history: If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D155A-6
5
SEN03205-03
40 Troubleshooting
Phenomena looking like troubles and troubleshooting Nos. Troubleshooting No.
Phenomena looking like troubles
Display of code
E mode
H mode
S mode
Phenomena related to action code/failure code 1 Action code and failure code are displayed on machine monitor 2
When fault history is checked, failure code is displayed in mechanical system fault history
3
When fault history is checked, failure code is displayed in electrical system fault history
4
When fault history is checked, failure code is displayed in air conditioner or heater fault history
According to displayed code
Phenomena related to engine 5 Starting performance of engine is poor 6 Engine does not start
S-1 E-3
S-2
7 Engine does not pick up smoothly
S-3
8 Engine stops during operation
S-4
9 Engine does not rotate smoothly
S-5
10 Engine lack output (or lacks power)
S-6
11 Exhaust gas is black (incomplete combustion)
S-7
12 Oil consumption is excessive (or exhaust gas is blue)
S-8
13 Oil becomes dirty quickly
S-9
14 Fuel consumption is excessive
S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11
16 Oil pressure drops
S-12
17 Oil level rises (Entry of coolant or fuel)
S-13
18 Coolant temperature becomes too high (Overheating)
S-14
19 Abnormal noise is made
S-15
20 Vibration is excessive
S-16
21 Air cannot be bled from fuel circuit
S-17
22 Preheater does not operate
E-4 Phenomena related to power train
23 Power is low (Drawbar pull is low)
H-1
24 Machine does not travel (at 2nd or 3rd gear speed)
H-2
25 Machine does not start at any gear speed
H-3
26 Machine can travel only forward or in reverse
H-4
27 When gear speed or travel direction is changed, time lag is large
H-5
28 Steering is not possible
H-6
29 Steering is possible only on one side
H-7
30 Steering overrun occurs
H-8
31 Brake does not work
H-9
32 Power train oil is overheated
H-10 Phenomena related to work equipment
33 Speed of all work equipment is low
H-11
34 No work equipment moves
H-12
35 Blade lift speed or power is low
H-13
6
D155A-6
40 Troubleshooting
SEN03205-03
Troubleshooting No.
Phenomena looking like troubles
Display of code
E mode
H mode
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
43 Abnormal sound comes out from around work equipment pump 44
S mode
H-20 H-21
Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats)
H-22
Phenomena related to machine monitor 45 When starting switch turned ON, machine monitor displays nothing 46
When starting switch turned ON (before startingengine), basic check item lights up
E-1 E-2
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 normally
E-9
52 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-10
Contents of display by machine monitor are different from applicable machine
E-11
51
53
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
61
Air conditioner does not operate normally (including air conditioner fault history)
E-19
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
SEN03205-03
40 Troubleshooting
Information in troubleshooting table
1
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Contents of trouble
Contents of trouble detected by machine monitor or controller
Action code
Display on machine monitor
Action of Action taken by machine monitor or controller to protect system or devices when they detect machine monitrouble tor or controller Problem that appears on machine
Problem that appears on machine as result of action taken by machine monitor or controller (shown above)
Related information
Information related to detected trouble or troubleshooting
No.
Check item
3
<Troubles in wiring harness> • Disconnection Connector is connected defectively or wiring harness is Possible broken. check items • Ground fault for troubleWiring harness which is not connected to chassis shooting ground circuit is in contact with chassis ground circuit. (Given num- • Hot short bers are referWiring harness which is not connected to power source ence (24 V) circuit is in contact with power source (24 V) cirnumbers, cuit. which do not • Short circuit indicate priorIndependent wiring harnesses are in contact with each ity) other abnormally.
4
8
Judgment and remedy
<Contents of description> • Standard value in normal state to judge possible causes • Remarks on judgment
1
2
Procedure of troubleshooting
5
Reconfirmation of check item
6
Confirmation of repair
<Precautions for troubleshooting> (1) Method of indicating connector No. and handling of Tadapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. • 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.
YES
Remedy when criterion is judged to be "YES"
NO
Remedy when criterion is judged to be "NO"
D155A-6
40 Troubleshooting
SEN03205-03
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (i o): Roughly shows the location on the machine.
D155A-6
9
SEN03205-03
Connection table for connector pin numbers
40 Troubleshooting
(Rev. 2009.04)
a
The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
10
D155A-6
40 Troubleshooting
D155A-6
SEN03205-03
11
SEN03205-03
12
40 Troubleshooting
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40 Troubleshooting
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SEN03205-03
13
SEN03205-03
14
40 Troubleshooting
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40 Troubleshooting
D155A-6
SEN03205-03
15
SEN03205-03
16
40 Troubleshooting
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40 Troubleshooting
D155A-6
SEN03205-03
17
SEN03205-03
18
40 Troubleshooting
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40 Troubleshooting
D155A-6
SEN03205-03
19
SEN03205-03
20
40 Troubleshooting
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40 Troubleshooting
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SEN03205-03
21
SEN03205-03
22
40 Troubleshooting
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40 Troubleshooting
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SEN03205-03
23
SEN03205-03
24
40 Troubleshooting
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40 Troubleshooting
D155A-6
SEN03205-03
25
SEN03205-03
26
40 Troubleshooting
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40 Troubleshooting
D155A-6
SEN03205-03
27
SEN03205-03
28
40 Troubleshooting
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40 Troubleshooting
D155A-6
SEN03205-03
29
SEN03205-03
30
40 Troubleshooting
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40 Troubleshooting
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SEN03205-03
31
SEN03205-03
32
40 Troubleshooting
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40 Troubleshooting
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SEN03205-03
33
SEN03205-03
34
40 Troubleshooting
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40 Troubleshooting
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35
SEN03205-03
36
40 Troubleshooting
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40 Troubleshooting
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37
SEN03205-03
38
40 Troubleshooting
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40 Troubleshooting
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39
SEN03205-03
40
40 Troubleshooting
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40 Troubleshooting
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41
SEN03205-03
42
40 Troubleshooting
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40 Troubleshooting
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43
SEN03205-03
44
40 Troubleshooting
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40 Troubleshooting
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SEN03205-03
45
SEN03205-03
40 Troubleshooting
T- branch box and T- branch adapter table a
(Rev. 2009.03) 1
q
q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
q
799-601-3200 T-box (for MS)
37
q q
799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
q
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
q
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
q q
799-601-3470 Case 799-601-2710 Adapter for MIC
5
MIC-5P
q q
799-601-2720 Adapter for MIC
13
MIC-13P
q q
799-601-2730 Adapter for MIC
17
MIC-17P
q q q
799-601-2740 Adapter for MIC
21
MIC-21P
q q q
799-601-2950 Adapter for MIC
9
MIC-9P
799-601-2750 Adapter for ECONO
2
ECONO2P
q q
799-601-2760 Adapter for ECONO
3
ECONO3P
q q
799-601-2770 Adapter for ECONO
4
ECONO4P
q q
799-601-2780 Adapter for ECONO
8
ECONO8P
q q
799-601-2790 Adapter for ECONO
12 ECONO12P q q
799-601-2810 Adapter for DLI
8
DLI-8P
q q
799-601-2820 Adapter for DLI
12
DLI-12P
q q
799-601-2830 Adapter for DLI
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
q q q
q
q q
q
q q q
q
q
q
799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO)
q
q
60
q
799-601-4360 Case 799-601-7010 Adapter for X (T-adapter)
1
q
q
799-601-7020 Adapter for X
2
X2P
q q q
q
799-601-7030 Adapter for X
3
X3P
q q q
q q
799-601-7040 Adapter for X
4
X4P
q q q
799-601-7050 Adapter for SWP
6
SW6P
q q q q q q
799-601-7060 Adapter for SWP
8
SW8P
799-601-7310 Adapter for SWP
12
SW12P q
q
q
q
M2P
q q q
q
M3P
q q q
q
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-adapter)
1
799-601-7090 Adapter for M
2
799-601-7110 Adapter for M
3
46
q q
D155A-6
40 Troubleshooting
SEN03205-03
q
Out of kit
q
799-601-4201
q q q
799-601-4101
S8P
799-601-9300
8
799-601-9200
799-601-7140 Adapter for S
799-601-9100
M8P
799-601-9000
8
799-601-8000 q
799-601-7340 Adapter for M
799-601-7500
q
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
6
799-601-7000
4
799-601-7130 Adapter for M
799-601-2800
799-601-7120 Adapter for M
Part name
799-601-2700
Identification symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
799-601-7150 Adapter for S (White)
10
S10P
q q q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
799-601-7170 Adapter for S (Blue)
16
S16P
q q q
799-601-7330 Adapter for S (White)
16
S16PW
799-601-7350 Adapter for S (White)
12
S12PW
799-601-7180 Adapter for AMP040
8
A8P
q
799-601-7190 Adapter for AMP040
12
A12P
q
q q q q
799-601-7210 Adapter for AMP040
16
A16P
q q q
q
799-601-7220 Adapter for AMP040
20
A20P
q q q
q
799-601-7230 Short connector for X
2
—
q q q
q
q q
799-601-7240 Case
q
799-601-7270 Case 799-601-7510 Adapter for 070
10
07-10
q
799-601-7520 Adapter for 070
12
07-12
q
799-601-7530 Adapter for 070
14
07-14
q
799-601-7540 Adapter for 070
18
07-18
q
799-601-7550 Adapter for 070
20
07-20
q
799-601-7360 Adapter for relay
5
REL-5P
q
799-601-7370 Adapter for relay
6
REL-6P
q
799-601-7380 Adapter for JFC
2
—
799-601-9010 Adapter for DTM
2
DTM2
q
q
799-601-9020 Adapter for DT
2
DT2
q
q
799-601-9030 Adapter for DT
3
DT3
q
q
799-601-9040 Adapter for DT
4
DT4
q
q
799-601-9050 Adapter for DT
6
DT6
q
q
799-601-9060 Adapter for DT (Gray)
8
DT8GR
q
q
q
799-601-9070 Adapter for DT (Black)
8
DT8B
q
q
799-601-9080 Adapter for DT (Green)
8
DT8G
q
q
799-601-9090 Adapter for DT (Brown)
8
DT8BR
q
q
799-601-9110 Adapter for DT (Gray)
12
DT12GR
q
q
799-601-9120 Adapter for DT (Black)
12
DT12B
q
q
799-601-9130 Adapter for DT (Green)
12
DT12G
q
q
799-601-9140 Adapter for DT (Brown)
12
DT12BR
q
q
799-601-9210 Adapter for HD30-18
8
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
9
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)
D155A-6
24
q q q q
q q
q
q q
q
47
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
40 Troubleshooting
Number of pins
SEN03205-03
q
799-601-9330 Case
q
799-601-9340 Case 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
Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor
3
A3
q q
2
P
q q
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) Temperature sensor
2
C
q q
2
A
q q
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
—
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
3
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
3
FCIB
q q
Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch
2
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
3
4180
q q
Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure
3
1,2,3L
q q
4
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
3
1,2,3A
q q
799-601-9430*
795-799-5540*
799-601-4140
799-601-4230*
Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
Adapter for engine (CRI-T3) Atomosphere pressure
Socket for engine (CRI-T3) Air intake pressure/temperature
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* Pump actuator
2
2,PA
q q
4
1,2,3,4T
799-601-4260 Adapter for controller (ENG)
4
DTP4
q q
799-601-4380*
Socket for engine (CRI-T3)(95) Air intake pressure/temperature
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, 3, 4,
—
q
799-601-9890
Multi-adapter for DT2 – 4 and DTM2
“ * ” Shows not T-adapter but socket.
48
D155A-6
40 Troubleshooting
D155A-6
SEN03205-03
49
SEN03205-03
40 Troubleshooting
D155A-6 Bulldozer Form No. SEN03205-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
50
D155A-6
SEN03206-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
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
D155A-6
1
SEN03206-03
40 Troubleshooting
Failure code [2202LH]................................................................................................................................... 30 Failure code [2300KM] .................................................................................................................................. 32 Failure code [2301L1] ................................................................................................................................... 33 Failure code [2301LH]................................................................................................................................... 35 Failure code [2302L1] ................................................................................................................................... 37 Failure code [2302LH]................................................................................................................................... 39 Failure code [7RFAKA].................................................................................................................................. 41 Failure code [AA10NX].................................................................................................................................. 43 Failure code [AB00MA] ................................................................................................................................. 45 Failure code [B@BAZG]................................................................................................................................ 47 Failure code [B@BCNS] ............................................................................................................................... 48 Failure code [B@BCZK]................................................................................................................................ 49 Failure code [B@CENS] ............................................................................................................................... 50 Failure code [B@HANS] ............................................................................................................................... 51 Failure code [CA111] ..................................................................................................................................... 52 Failure code [CA115]..................................................................................................................................... 54 Failure code [CA122] .................................................................................................................................... 56 Failure code [CA123] .................................................................................................................................... 59 Failure code [CA131] .................................................................................................................................... 60 Failure code [CA132] .................................................................................................................................... 62 Failure code [CA135] .................................................................................................................................... 63 Failure code [CA141] .................................................................................................................................... 66 Failure code [CA144] .................................................................................................................................... 67 Failure code [CA145] .................................................................................................................................... 69 Failure code [CA153] .................................................................................................................................... 70 Failure code [CA154] .................................................................................................................................... 72 Failure code [CA187] .................................................................................................................................... 72 Failure code [CA221] .................................................................................................................................... 73 Failure code [CA222] .................................................................................................................................... 76 Failure code [CA227] .................................................................................................................................... 77
2
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [1500L0]
1
Contents of trouble
• Among failure codes related to transmission clutch, 2 or more of following failure codes occurred similarly. 1) Either [DXH4KA] or [DXH4KB] 2) Either [DXH5KA] or [DXH5KB] 3) Either [DXH6KA] or [DXH6KB] • Among failure codes related to transmission clutch, following combinations of failure codes occurred similarly. 1) [15SAL1] and [15SBL1] 2) [15SALH] and [15SBLH] 3) 2 or all of [15SEL1], [15SFL1], and [15SGL1] 4) 2 or all of [15SELH], [15SFLH], and [15SGLH]
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Auto-shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to specific gear speed.
Related information
-
No.
1
2
Check item
Procedure of troubleshooting
Related failure code(s)
If other failure codes are displayed, carry out troubleshooting for them. [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH], [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB]
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Drive the machine. Is this failure code displayed?
Judgment and remedy
-
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
3
SEN03206-03
40 Troubleshooting
Failure code [15SAL1]
1
Contents of trouble
When output to transmission F clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
Action code
E03
Action of controller
• Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement). • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1.
Related information
State of F clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
F clutch ECMV fill switch
Procedure of troubleshooting
• The state of the F clutch ECMV fill switch a Prepare with starting switch OFF, then start engine and carry YES is normal. out troubleshooting. • Proceed to the next check item. FFT (male) Between (1) – chassis ground
2
3
Ground fault in wiring harness
Power train controller
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
N
Min. 1 Mz
F1, F2, F3
Max. 1 z
NO
• The F clutch ECMV fill switch is defective. • Replace the F clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (35) – FFT (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine and carry mal. YES out troubleshooting. • Proceed to the next check item. STC2 Between (35) – chassis ground
PCCS lever (Travel gear speed)
Voltage
N
5 – 11 V
F1, F2, F3
Max. 1 V
NO
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in neutral. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
5
SEN03206-03
40 Troubleshooting
Failure code [15SALH]
1
Contents of trouble
When output to transmission F clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.
Action code
E03
Action of controller
• Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement). • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1.
Related information
State of F clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
F clutch ECMV fill switch
Procedure of troubleshooting
• The state of the F clutch ECMV fill switch a Prepare with starting switch OFF, then start engine and carry YES is normal. out troubleshooting. • Proceed to the next check item. FFT (male) Between (1) – chassis ground
2
3
Open circuit in wiring harness
Power train controller
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
N
Min. 1 Mz
F1, F2, F3
Max. 1 z
NO
• The F clutch ECMV fill switch is defective. • Replace the F clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (35) – FFT (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine and carry mal. YES out troubleshooting. • Proceed to the next check item. STC2 Between (35) – chassis ground
PCCS lever (Travel gear speed)
Voltage
N
5 – 11 V
F1, F2, F3
Max. 1 V
NO
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in forward position. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
7
SEN03206-03
40 Troubleshooting
Failure code [15SBL1]
1
Contents of trouble
When output to transmission R clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
Action code
E03
Action of controller
• Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement). • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1.
Related information
State of R clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
R clutch ECMV fill switch
Procedure of troubleshooting
• The state of the R clutch ECMV fill switch a Prepare with starting switch OFF, then start engine and carry YES is normal. out troubleshooting. • Proceed to the next check item. FRT (male) Between (1) – chassis ground
2
3
Ground fault in wiring harness
Power train controller
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
N
Min. 1 Mz
R1, R2, R3
Max. 1 z
NO
• The R clutch ECMV fill switch is defective. • Replace the R clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (25) – FRT (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine and carry mal. YES out troubleshooting. • Proceed to the next check item. STC2 Between (25) – chassis ground
PCCS lever (Travel gear speed)
Voltage
N
5 – 11 V
R1, R2, R3
Max. 1 V
NO
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
8
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in neutral. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
9
SEN03206-03
40 Troubleshooting
Failure code [15SBLH]
1
Contents of trouble
When output to transmission R clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.
Action code
E03
Action of controller
• Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement). • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1.
Related information
State of R clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
R clutch ECMV fill switch
Procedure of troubleshooting
• The state of the R clutch ECMV fill switch a Prepare with starting switch OFF, then start engine and carry YES is normal. out troubleshooting. • Proceed to the next check item. FRT (male) Between (1) – chassis ground
2
3
Open circuit in wiring harness
Power train controller
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
N
Min. 1 Mz
R1, R2, R3
Max. 1 z
NO
• The R clutch ECMV fill switch is defective. • Replace the R clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (25) – FRT (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine and carry mal. YES out troubleshooting. • Proceed to the next check item. STC2 Between (25) – chassis ground
PCCS lever (Travel gear speed)
Voltage
N
5 – 11 V
R1, R2, R3
Max. 1 V
NO
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
10
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in reverse position. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
11
SEN03206-03
40 Troubleshooting
Failure code [15SEL1]
1
Contents of trouble
When output to transmission 1st clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of 1st clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
1st clutch ECMV fill switch
Procedure of troubleshooting
• The state of the 1st clutch ECMV fill switch a Prepare with starting switch OFF, then start engine, select YES is normal. manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. F1T (male)
Between (1) – chassis ground
2
Ground fault in wiring harness
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
Other than F1, N, or R1
Min. 1 Mz
F1, R1
Max. 1 z
No
• The 1st clutch ECMV fill switch is defective. • Replace the 1st clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (19) – F1T (female) (1) and chassis ground
Resistance
Min. 1 Mz
No
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine, select mal. YES manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. 3
Power train controller
STC3
Between (19) – chassis ground
PCCS lever (Travel gear speed)
Voltage
Other than F1, N, or R1
5 – 11 V
F1, R1
Max. 1 V
No
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
12
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in neutral. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
13
SEN03206-03
40 Troubleshooting
Failure code [15SELH]
1
Contents of trouble
When output to transmission 1st clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Auto-shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2.
Related information
State of 1st clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
1st clutch ECMV fill switch
Procedure of troubleshooting
• The state of the 1st clutch ECMV fill switch a Prepare with starting switch OFF, then start engine, select YES is normal. manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. F1T (male)
Between (1) – chassis ground
2
Open circuit in wiring harness
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
Other than F1, N, or R1
Min. 1 Mz
F1, R1
Max. 1 z
No
• The 1st clutch ECMV fill switch is defective. • Replace the 1st clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (19) – F1T (female) (1)
Resistance
Max. 1 z
No
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine, select mal. YES manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. 3
Power train controller
STC3
Between (19) – chassis ground
PCCS lever (Travel gear speed)
Voltage
Other than F1, N, or R1
5 – 11 V
F1, R1
Max. 1 V
No
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
14
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
Check item
Confirmation of repair
SEN03206-03
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in F1 or R1 position (in manual gearshift mode). 5. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
15
SEN03206-03
40 Troubleshooting
Failure code [15SFL1]
1
Contents of trouble
When output to transmission 2nd clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Auto-shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2.
Related information
State of 2nd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
2nd clutch ECMV fill switch
Procedure of troubleshooting
• The state of the 2nd clutch ECMV fill switch a Prepare with starting switch OFF, then start engine, select YES is normal. manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. F2T (male)
Between (1) – chassis ground
2
Ground fault in wiring harness
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
Other than F2, N, or R2
Min. 1 Mz
F2, R2
Max. 1 z
NO
• The 2nd clutch ECMV fill switch is defective. • Replace the 2nd clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (29) – F2T (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine, select mal. YES manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. 3
Power train controller
STC3
Between (29) – chassis ground
PCCS lever (Travel gear speed)
Voltage
Other than F2, N, or R2
5 – 11 V
F2, R2
Max. 1 V
NO
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
16
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in neutral. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
17
SEN03206-03
40 Troubleshooting
Failure code [15SFLH]
1
Contents of trouble
When output to transmission 2nd clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of 2nd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
2nd clutch ECMV fill switch
Procedure of troubleshooting
• The state of the 2nd clutch ECMV fill switch a Prepare with starting switch OFF, then start engine, select YES is normal. manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. F2T (male)
Between (1) – chassis ground
2
Open circuit in wiring harness
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
Other than F2, N, or R2
Min. 1 Mz
F2, R2
Max. 1 z
NO
• The 2nd clutch ECMV fill switch is defective. • Replace the 2nd clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. •
Wiring harness between STC3 (female) (29) – F2T (female) (1)
Resistance
Max. 1 z
NO
An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine, select mal. YES manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. 3
Power train controller
STC3
Between (29) – chassis ground
PCCS lever (Travel gear speed)
Voltage
Other than F2, N, or R2
5 – 11 V
F2, R2
Max. 1 V
NO
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
18
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
Check item
Confirmation of repair
SEN03206-03
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in F2 or R2 position (in manual gearshift mode). 5. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
19
SEN03206-03
40 Troubleshooting
Failure code [15SGL1]
1
Contents of trouble
When output to transmission 3rd clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Auto-shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F3 and R3.
Related information
State of 3rd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
3rd clutch ECMV fill switch
Procedure of troubleshooting
• The state of the 3rd clutch ECMV fill switch a Prepare with starting switch OFF, then start engine, select YES is normal. manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. F3T (male)
Between (1) – chassis ground
2
Ground fault in wiring hamess
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
Other than F3, N, or R3
Min. 1 Mz
F3, R3
Max. 1 z
NO
• The 3rd clutch ECMV fill switch is defective. • Replace the 3rd clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (39) – F3T (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine, select mal. YES manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. 3
Power train controller
STC3
Between (39) – chassis ground
PCCS lever (Travel gear speed)
Voltage
Other than F3, N, or R3
5 – 11 V
F3, R3
Max. 1 V
NO
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
20
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in neutral. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
21
SEN03206-03
40 Troubleshooting
Failure code [15SGLH]
1
Contents of trouble
When output to transmission 3rd clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of 3rd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1)
No.
1
Check item
3rd clutch ECMV fill switch
Procedure of troubleshooting
• The state of the 3rd clutch ECMV fill switch a Prepare with starting switch OFF, then start engine, select YES is normal. manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. F3T (male)
Between (1) – chassis ground
2
Open circuit in wiring harness
Judgment and remedy
PCCS lever (Travel gear speed)
Resistance
Other than F3, N, or R3
Min. 1 Mz
F3, R3
Max. 1 z
NO
• The 3rd clutch ECMV fill switch is defective. • Replace the 3rd clutch ECMV fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (39) – F3T (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF, then start engine, select YES mal. manual gearshift mode, and carry out troubleshooting. • Proceed to the next check item. 3
Power train controller
STC3
Between (39) – chassis ground
PCCS lever (Travel gear speed)
Voltage
Other than F3, N, or R3
5 – 11 V
F3, R3
Max. 1 V
NO
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
22
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
Check item
Confirmation of repair
SEN03206-03
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set transmission in F3 or R3 position (in manual gearshift mode). 5. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
23
SEN03206-03
40 Troubleshooting
Failure code [2201L1]
1
Contents of trouble
The fill switch signal is set on at output stop of the right steering clutch solenoid circuit.
Action code
E04
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • Auto-shift down function does not work.
Related information
The input state (ON/OFF) from the right steering clutch fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the right steering clutch fill a Prepare with starting switch OFF. Engine start for troubleYES switch is normal. shooting. • Proceed to the next check item. 1
Right steering clutch fill switch
FCLR (male)
Between (1) – chassis ground
2
3
Ground fault in wiring harness
Power train controller
PCCS lever
Resistance
N (Neutral)
Min. 1 Mz No
Right max. steering
Max. 1 z
• The right steering clutch fill switch is defective. • Replace the right steering clutch fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (3) – FCLR (female) (1) with chassis ground
Resistance
Min. 1Mz
No
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF. Engine start for troublemal. YES shooting. • Proceed to the next check item. STC2 Between (3) – chassis ground
PCCS lever
Voltage
N (Neutral)
5 – 11 V No
Right max. steering
Max. 1 V
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
24
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic pressure system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
5
Confirmation of repair
SEN03206-03
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
25
SEN03206-03
40 Troubleshooting
Failure code [2201LH]
1
Contents of trouble
The fill switch signal is set off at output stop to the right steering clutch solenoid circuit.
Action code
E04
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • Auto-shift down function does not work.
Related information
The input state (ON/OFF) from the right steering clutch fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the right steering clutch fill a Prepare with starting switch OFF. Engine start for troubleYES switch is normal. shooting. • Proceed to the next check item. 1
Right steering clutch fill switch
FCLR (male)
Between (1) – chassis ground
2
3
Open circuit in wiring harness
Power train controller
PCCS lever
Resistance
N (Neutral)
Min. 1 Mz No
Right max. steering
Max. 1 z
• The right steering clutch fill switch is defective. • Replace the right steering clutch fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (3) – FCLR (female) (1)
Resistance
Max. 1 z
No
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF. Engine start for troublemal. YES shooting. • Proceed to the next check item. STC2 Between (3) – chassis ground
PCCS lever
Voltage
N (Neutral)
5 – 11 V No
Right max. steering
Max. 1 V
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
26
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic pressure system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Release the parking brake lever. Operate the PCCS lever (right steering). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
27
SEN03206-03
40 Troubleshooting
Failure code [2202L1]
1
Contents of trouble
The fill switch signal is set on at output stop of the left steering clutch solenoid circuit.
Action code
E04
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • Auto-shift down function does not work.
Related information
The input state (ON/OFF) from the left steering clutch fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
No.
1
Check item
Left steering clutch fill switch
Procedure of troubleshooting
• The state of the left steering clutch fill a Prepare with starting switch OFF. Engine start for troubleswitch is normal. YES shooting. • Proceed to the next check item. FCLL (male) Between (1) – chassis ground
2
3
Ground fault in wiring harness
Power train controller
Judgment and remedy
PCCS lever
Resistance
N (Neutral)
Min. 1 Mz
Left max. steering
Max. 1 z
NO
• The left steering clutch fill switch is defective. • Replace the left steering clutch fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (13) – FCLL (female) (1) with chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF. Engine start for troublemal. YES shooting. • Proceed to the next check item. STC2 Between (13) – chassis ground
PCCS lever
Voltage
N (Neutral)
5 – 11 V NO
Left max. steering
Max. 1 V
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
28
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The hydraulic pressure system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Related circuit diagram
D155A-6
29
SEN03206-03
40 Troubleshooting
Failure code [2202LH]
1
Contents of trouble
The fill switch signal is set off at output stop to the left steering clutch solenoid circuit.
Action code
E04
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • Auto-shift down function does not work.
Related information
The input state (ON/OFF) from the left steering clutch fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
No.
1
Check item
Left steering clutch fill switch
Procedure of troubleshooting
• The state of the left steering clutch fill a Prepare with starting switch OFF. Engine start for troubleYES switch is normal. shooting. • Proceed to the next check item. FCLL (male) Between (1) – chassis ground
2
3
Open circuit in wiring harness
Power train controller
Judgment and remedy
PCCS lever
Resistance
N (Neutral)
Min. 1 Mz
Left max. steering
Max. 1 z
NO
• The left steering clutch fill switch is defective. • Replace the left steering clutch fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. •
Wiring harness between STC2 (female) (13) – FCLL (female) (1)
Resistance
Max. 1 z
NO
An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the power train controller is nora Prepare with starting switch OFF. Engine start for troubleYES mal. shooting. • Proceed to the next check item. STC2 Between (13) – chassis ground
PCCS lever
Voltage
N (Neutral)
5 – 11 V NO
Left max. steering
Max. 1 V
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
30
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic pressure system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03206-03
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Release the parking brake lever. Operate the PCCS lever (left steering). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
31
SEN03206-03
40 Troubleshooting
Failure code [2300KM] Contents of trouble
-
Action code
-
Action of controller
Saves only history.
Problem that appears on machine
-
Related information
-
No.
1
32
Check item
1
Procedure of troubleshooting
Work by operWork prohibited by operator ator
Judgment and remedy
-
• Work done by the operator is prohibited. • There is no troubleshooting for this failure code.
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [2301L1]
1
Contents of trouble
When output to steering case right brake ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
Action code
E04
Action of controller
Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Applies brake lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, machine cannot travel at all.
Related information
State of right brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 S/T Fill Sw Input)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshoot- YES ing. • 1
Right brake ECMV fill switch
FBRR (male) Between (1) – chassis ground
2
Ground fault in wiring harness
Brake pedal
Resistance
Released
Max. 1 z NO
Pressed
Min. 1 Mz
• The right brake ECMV fill switch is defective. • Replace the right brake ECMV fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (38) – FBRR (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshoot- YES ing. • 3
Power train controller
The state of the right brake ECMV fill switch is normal. Proceed to the next check item.
STC2 Between (38) – chassis ground
Brake pedal
Voltage
Released
Max. 1 V NO
Pressed
5 – 11V
The state of the power train controller is normal. Proceed to the next check item.
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
33
SEN03206-03
No.
5
40 Troubleshooting
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the parking brake lever (Free). Operate the brake pedal (Press). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
34
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [2301LH]
1
Contents of trouble
When output to steering case right brake ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.
Action code
E04
Action of controller
Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Applies brake lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, machine cannot travel at all.
Related information
State of right brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 S/T Fill Sw Input)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshoot- YES ing. • 1
Right brake ECMV fill switch
FBRR (male) Between (1) – chassis ground
2
Open circuit in wiring harness
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
NO
• The right brake ECMV fill switch is defective. • Replace the right brake ECMV fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (38) – FBRR (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshoot- YES • ing. 3
Power train controller
The state of the right brake ECMV fill switch is normal. Proceed to the next check item.
STC2 Between (38) – chassis ground
Brake pedal
Voltage
Released
Max. 1 V NO
Pressed
5 – 11 V
The state of the power train controller is normal. Proceed to the next check item.
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
35
SEN03206-03
No.
5
40 Troubleshooting
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the parking brake lever (Free). Operate the brake pedal (Press). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
36
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [2302L1]
1
Contents of trouble
When output to steering case left brake ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
Action code
E04
Action of controller
Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Applies brake lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, machine cannot travel at all.
Related information
State of left brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 S/T Fill Sw Input)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshoot- YES ing. • 1
Left brake ECMV fill switch
FBRL (male) Between (1) – chassis ground
2
Ground fault in wiring harness
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
NO
• The left brake ECMV fill switch is defective. • Replace the left brake ECMV fill switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (2) – FBRL (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshoot- YES • ing. 3
Power train controller
The state of the left brake ECMV fill switch is normal. Proceed to the next check item.
STC2 Between (2) – chassis ground
Brake pedal
Voltage
Released
Max. 1 V NO
Pressed
5 – 11 V
The state of the power train controller is normal. Proceed to the next check item.
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
37
SEN03206-03
No.
5
40 Troubleshooting
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the parking brake lever (Free). Operate the brake pedal (Press). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
38
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [2302LH]
1
Contents of trouble
When output to steering case left brake ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.
Action code
E04
Action of controller
Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Applies brake lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, machine cannot travel at all.
Related information
State of left brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 S/T Fill Sw Input)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshoot- YES ing. • 1
Left brake ECMV fill switch
FBRL (male) Between (1) – chassis ground
2
Open circuit in wiring harness
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
NO
• The left brake ECMV fill switch is defective. • Replace the left brake ECMV fill switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (2) – FBRL (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshoot- YES • ing. 3
Power train controller
The state of the left brake ECMV fill switch is normal. Proceed to the next check item.
STC2 Between (2) – chassis ground
Brake pedal
Voltage
Released
Max. 1 V NO
Pressed
5 – 11 V
The state of the power train controller is normal. Proceed to the next check item.
• The power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The hydraulic system may be defective. • Perform related troubleshooting (H mode). • Proceed to "Confirmation of repair".
39
SEN03206-03
No.
5
40 Troubleshooting
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the parking brake lever (Free). Operate the brake pedal (Press). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
40
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [7RFAKA]
1
Contents of trouble
When ground circuit of engine cut relay circuit is disconnected to turn output ON, no current flows.
Action code
-
Action of controller
None in particular.
Problem that appears on machine
When engine cut mechanism is installed, engine cannot be cut (stopped).
Related information
• State of engine cut relay circuit signal can be checked with monitoring function. (Code: 40912 P/T Sw Input) • This failure code detects abnormality on primary side (coil side) of engine cut relay but does not detect abnormality on secondary side (contact side).
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the engine a Prepare with starting switch OFF, then carry out troublecut relay is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
2
Engine cut relay
Open circuit in wiring harness
ACT (male)
Resistance
Between (1) – (2)
200 – 400 z
NO
• The engine cut relay is defective. • Replace the engine cut relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC2 (female) (19) – ACT (female) (2)
Resistance
Max. 1 z
Wiring harness between ACT (female) (1) – terminal 270
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
Short circuit in Wiring harness between STC2 wiring har(female) (19) – ACT (female) (2) and ness chassis ground Wiring harness between ACT (female) (1), (3) – terminal 270, circuit branch end and chassis ground
Resistance
Min. 1 Mz NO
Resistance
Min. 1 Mz
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
41
SEN03206-03
No.
Check item
5
Confirmation of repair
40 Troubleshooting
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
42
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [AA10NX]
1
Contents of trouble
While engine was running, air cleaner clogging switch signal circuit detected clogging of air cleaner (opening of sensor contact).
Action code
-
Action of None in particular. machine monitor Problem that appears on machine
If machine is used as it is, engine may be damaged.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The air cleaner is not clogged. YES • Proceed to the next check item.
1
Clogged air cleaner
a Air cleaner may be clogged. Check and clean or replace it. NO
2
Air cleaner clogging switch
• The state of the air cleaner clogging a Prepare with starting switch OFF, then start engine and carry YES switch is normal. out troubleshooting. • Proceed to the next check item. AF1 (male)
Between (1) – (2)
3
Open circuit in wiring harness
• The air cleaner is clogged. • Clean or replace the air cleaner. • Proceed to "Confirmation of repair".
Air cleaner
Resistance
Normal (Intake air resistance: *1)
Max. 1 z
Clogged (Intake air resistance: *2)
Min. 1 Mz
NO
• The air cleaner clogging switch is defective. • Replace the air cleaner clogging switch. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CM02 (female) (4) – AF1 (female) (1)
Resistance
Wiring harness between CM01 (female) (7), CM02 (female) (7) – AF1 (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
43
SEN03206-03
40 Troubleshooting
*1: Max. -3,430 Pa {-350 mmH2O} *2: -7,470 ± 490Pa {-762 ± 50 mmH2O} Related circuit diagram
44
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [AB00MA]
1
Contents of trouble
While engine was running, alternator signal circuit detected that battery charge voltage was low.
Action code
-
Action of Displays charge level monitor red on machine monitor. machine monitor Problem that appears on machine
If machine is used as it is, battery may not be charged.
Related information
Battery voltage can be checked with monitoring function. (Code: 03203 Battery Power Supply)
No.
1
Check item
Charge by alternator
Procedure of troubleshooting
Judgment and remedy
• The state of charge by a Prepare with starting switch OFF, then start engine and carry alternator is normal. YES out troubleshooting. • Proceed to the next check item. CM01 Between (11) – chassis ground
Engine
Voltage
Above medium speed
27.5 – 29.5 V
NO
• Charge by alternator is defective. • Replace the alternator. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The charge level monitor system may be defective. • Perform troubleshooting for E mode "E-5 Caution item lights up while engine is running". • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
45
SEN03206-03
40 Troubleshooting
Related circuit diagram
46
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [B@BAZG]
1
Contents of trouble
While engine was running, engine oil pressure sensor signal circuit detected that engine oil pressure was abnormally low.
Action code
-
Action of controller
• Displays engine oil pressure monitor red on machine monitor. • Continues operation with limited output (Limits injection rate and engine speed).
Problem that appears on machine
If machine is used as it is, engine may be seized.
Related information
• Engine oil pressure sensor signal is input to engine controller and then transmitted to machine monitor through communication system. • Engine oil pressure can be checked with monitoring function. (Code: 37200 Engine Oil Pressure)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the engine oil pressure is normal. YES • Proceed to the next check item.
1
Engine oil pressure
Check engine oil pressure. If it is low, remove cause. NO
• The engine oil pressure is abnormal (low). • Remove the cause of low pressure. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine oil pressure sensor system may be defective. • Perform troubleshooting for the failure codes [CA135] and [CA141]. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
47
SEN03206-03
40 Troubleshooting
Failure code [B@BCNS]
1
Contents of trouble
While engine was running, engine coolant temperature sensor signal circuit detected that engine coolant was overheated.
Action code
-
Action of controller
Displays engine coolant temperature monitor red on machine monitor.
Problem that appears on machine
If machine is used as it is, engine may be seized.
Related information
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature)
No.
1
Check item
Engine coolant temperature
Procedure of troubleshooting
Check engine coolant for overheating. If it is overheated, remove cause.
Judgment and remedy • The state of the engine coolant temperature is YES normal. • Proceed to the next check item.
NO
• The engine coolant is overheated. • Remove the cause of overheat. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
48
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine coolant temperature sensor system may be defective. • Perform troubleshooting for the failure codes [CA144] and [CA145]. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [B@BCZK]
1
Contents of trouble
While starting switch was ON (and engine was stopped) or engine was running, radiator coolant level switch signal circuit detected that radiator coolant level was low (sensor contact was open).
Action code
-
• Displays radiator coolant level monitor red on machine monitor. Action of machine monitor • Continues operation with limited output (Limits injection rate and engine speed). Problem that appears on machine
If machine is used as it is, engine may be overheated.
Related information
-
No.
1
Check item
Coolant level
Procedure of troubleshooting
Check radiator sub tank for lowering of coolant level. If coolant level is low, add coolant.
Judgment and remedy • The coolant level is normal. YES • Proceed to the next check item.
NO
2
Radiator coolSince the float may be stuck by clogging of dirt, check the coolant level senant level sensor. sor
• The coolant level is not appropriate. • Replenish the coolant. • Proceed to "Confirmation of repair".
• The state of the radiator coolant level sensor is normal. YES • Proceed to the next check item.
NO
• The radiator coolant level sensor is defective. • Replace the radiator coolant level sensor. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
4
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The radiator coolant level monitor system may be defective. • Perform troubleshooting for E mode "E-2 Caution item lights up while starting switch is ON (and engine is stopped)". • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
49
SEN03206-03
40 Troubleshooting
Failure code [B@CENS]
1
Contents of trouble
While engine was running, torque converter oil temperature sensor signal circuit detected that power train oil was overheated.
Action code
-
Action of controller
Displays torque converter oil temperature monitor red on machine monitor.
Problem that appears on machine
If machine is used as it is, power train components may be damaged.
Related information
• Torque converter oil temperature sensor signal is input to power train controller and then transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The power train oil temperature is normal. YES • Proceed to the next check item.
1
Power train oil
Check power train oil for overheating. If it is overheated, remove cause. NO
• The power train oil is overheated. • Remove the cause of overheat. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
50
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The torque converter oil temperature sensor system may be defective. • Perform troubleshooting for the failure code [DGT1KA] or [DGT1KX]. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [B@HANS]
1
Contents of trouble
While engine was running, hydraulic oil temperature sensor signal circuit detected that hydraulic oil was overheated.
Action code
-
Action of controller
Displays hydraulic oil temperature monitor red on machine monitor.
Problem that appears on machine
If machine is used as it is, work equipment and HSS circuit components may be damaged.
Related information
Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The hydraulic oil temperature is normal. YES • Proceed to the next check item.
1
Hydraulic oil
Check hydraulic oil for overheating. If it is overheated, remove cause. NO
• The hydraulic oil is overheated. • Remove the cause of overheat. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The hydraulic oil temperature gauge system may be defective. • Perform troubleshooting for E mode "E-10 Hydraulic oil temperature gauge (Multigauge) does not indicated normally". • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
51
SEN03206-03
40 Troubleshooting
Failure code [CA111]
1
Contents of trouble
Trouble occurred in engine controller.
Action code
E04
Action of controller
None in particular.
Problem that appears on machine
Engine runs normally but may stop during operation or may not be able to start.
Related information
Source voltage of engine controller can be checked with monitoring function. (Code: 03203 Battery Power Supply)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the circuit breaker is normal. YES • Proceed to the next check item.
1
Circuit breaker
If circuit breaker (CB30 or CB8) is turned OFF, circuit probably has ground fault. (See check item 3.) NO
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Open circuit in wiring harness
Wiring harness between EGC3 (female) (3), (4) – CB8 (2)
Resistance
Max. 1 z
Wiring harness between CB8 (1) – CB30 (B30S)
Resistance
Max. 1 z
Wiring harness between CB30 (B30L) – terminal BRB
Resistance
Max. 1 z
Wiring harness between EGC3 (female) (1), (2) – chassis ground (GND20)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
52
Ground fault in wiring harness
Wiring harness between EGC3 (female) (3), (4) – CB8 (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB8 (1) – CB30 (B30S), circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB30 (B30L) – terminal BRB and chassis ground
Resistance
Min. 1 Mz
Wiring harness between EGC3 (female) (1), (2) – chassis ground (GND20) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03206-03
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
53
SEN03206-03
40 Troubleshooting
Failure code [CA115]
1
Contents of trouble
Trouble occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
Action code
E04
Action of controller
None in particular.
Problem that appears on machine
• Engine cannot be started (if engine has been stopped). • Engine stops (if engine has been running).
Related information No.
1
Check item
Ne speed sensor system
Procedure of troubleshooting
Ne speed sensor system may be defective. Carry out troubleshooting for code [CA689].
Judgment and remedy • The state of the Ne speed sensor system is normal. YES • Proceed to the next check item.
NO
2
Bkup speed sensor system
• The Ne speed sensor system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the Bkup speed sensor system YES is normal. • Proceed to the next check item. Bkup speed sensor system may be defective. Carry out troubleshooting for code [CA778]. NO
• The Bkup speed sensor system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the mount of Ne speed sensor is normal. YES • Proceed to the next check item. 3
Ne speed sensor
Check mount of Ne speed sensor for defect (defective installation of sensor, internal trouble of flywheel, etc.) NO
54
• The mount of Ne speed sensor is defective. • Reinstall the Ne speed sensor. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03206-03
Procedure of troubleshooting
Judgment and remedy • The state of the mount of Bkup speed sensor YES is normal. • Proceed to the next check item.
4
Bkup speed sensor
Check mount of Bkup speed sensor for defect (defective installation of sensor, internal trouble of supply pump, etc.) NO
• The mount of Bkup speed sensor is defective. • Reinstall the Bkup speed sensor. • Proceed to "Confirmation of repair".
• The sensor is connected correctly. YES • Proceed to the next check item. 5
Connection of Check Ne speed sensor and Bkup speed sensor for defective sensor connection (wrong connection). NO
• The sensor is not connected correctly. • Reconnect or replace the sensor. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
55
SEN03206-03
40 Troubleshooting
Failure code [CA122]
1
Contents of trouble
Signal voltage in charge pressure sensor circuit is abnormally high.
Action code
E03
Action of controller
Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that appears on machine
Acceleration performance of engine lowers or black smoke is produced more during acceleration.
Related information
State of charge pressure sensor can be checked with monitoring function. (Code: 36500 Charge Pressure-Abs)
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor power If code [CA187] or [CA227] is indicated, carry out troubleshootsupply sysing for it first. tem
• The state of the sensor power supply system YES is normal. • Proceed to the next check item.
NO
• The sensor power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the charge pressure sensor is nora Prepare with starting switch OFF, then turn starting switch YES mal. ON or start engine and carry out troubleshooting. • Proceed to the next check item. 2
Charge pressure sensor
PIM Between (1) – (3)
Voltage Power supply
4.75 – 5.25 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
NO
• The charge pressure sensor is defective. • Replace the charge pressure sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
56
Open circuit in wiring harness
Wiring harness between ENG (female) (37) – PIM (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – PIM (female) (3)
Resistance
Max. 1 z
Wiring harness between ENG (female) (44) – PIM (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03206-03
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
4
Ground fault in wiring harness
Wiring harness between ENG (female) (37) – PIM (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – PIM (female) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (44) – PIM (female) (2) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
5
Wiring harness between ENG (female) Short circuit in (37) – PIM (female) (1) and between ENG (female) (47) – PIM (female) (3) wiring harness Wiring harness between ENG (female) (37) – PIM (female) (1) and between ENG (female) (44) – PIM (female) (2) Wiring harness between ENG (female) (47) – PIM (female) (3) and between ENG (female) (44) – PIM (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
57
SEN03206-03
40 Troubleshooting
Related circuit diagram
58
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [CA123]
1
Contents of trouble
Signal voltage in charge pressure sensor circuit is abnormally low.
Action code
E03
Action of controller
Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that appears on machine
Acceleration performance of engine lowers or black smoke is produced more during acceleration.
Related information
State of charge pressure sensor can be checked with monitoring function. (Code: 36500 Charge Pressure-Abs)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA122].
2
Confirmation of repair
1. 2. 3. 4.
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy
-
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
59
SEN03206-03
40 Troubleshooting
Failure code [CA131]
1
Contents of trouble
Signal voltage in decelerator pedal potentiometer circuit is abnormally high.
Action code
E03
Action of controller
Sets throttle position with fuel control dial signal and continues operation.
Problem that appears on machine Related information No.
1
State of decelerator pedal optimum operation range signal can be checked with monitoring function. (Code: 03001 Throttle Pos Sens Volt)
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor power If code [CA2185] or [CA2186] is indicated, carry out troublesupply sysshooting for it first. tem
• The state of the sensor power supply system YES is normal. • Proceed to the next check item.
NO
• The sensor power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the fuel a Prepare with starting switch OFF, then carry out troublecontrol dial is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Fuel control dial
DCL (male)
Resistance
Between (B) – (C)
1.5 – 2.5 kz
Between (A) – (B)
0 – 3 kz
Between (A) – (C)
0 – 3 kz
NO
• The fuel control dial is defective. • Replace the fuel control dial. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
60
Open circuit in wiring harness
Wiring harness between EGC2 (female) (9) – DCL (female) (A)
Resistance
Max. 1 z
Wiring harness between EGC2 (female) (22) – DCL (female) (B)
Resistance
Max. 1 z
Wiring harness between EGC2 (female) (23) – DCL (female) (C)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03206-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Ground fault in wiring harness
Wiring harness between EGC2 (female) (9) – DCL (female) (A) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between EGC2 (female) (22) – DCL (female) (B) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between EGC2 (female) (23) – DCL (female) (C) and chassis ground
Resistance
Min. 1 Mz
No
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
61
SEN03206-03
40 Troubleshooting
Failure code [CA132]
1
Contents of trouble
Signal voltage in decelerator pedal potentiometer circuit is abnormally low.
Action code
E03
Action of controller
Sets throttle position with fuel control dial signal and continues operation.
Problem that appears on machine Related information
State of decelerator pedal optimum operation range signal can be checked with monitoring function. (Code: 03001 Throttle Pos Sens Volt)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA131].
2
Confirmation of repair
1. 2. 3. 4.
62
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy
-
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [CA135]
1
Contents of trouble
Signal voltage in engine oil pressure sensor circuit is abnormally high.
Action code
E02
Action of controller
Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that appears on machine Related information No.
1
State of engine oil pressure sensor can be checked with monitoring function. (Code: 37201 Eng Oil Press Sens Volt)
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor power If code [CA187] or [CA227] is indicated, carry out troubleshootsupply sysing for it first. tem
• The state of the sensor power supply system YES is normal. • Proceed to the next check item.
NO
• The sensor power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the engine oil pressure sensor is a Prepare with starting switch OFF, then turn starting switch YES normal. ON or start engine and carry out troubleshooting. • Proceed to the next check item.
2
Engine oil POIL pressure sensor Between (1) – (2) Power supply
Voltage 4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
NO
• The engine oil pressure sensor is defective. • Replace the engine oil pressure sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
Open circuit in wiring harness
D155A-6
Wiring harness between ENG (female) (37) – POIL (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – POIL (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (13) – POIL (female) (3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
63
SEN03206-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
4
Ground fault in wiring harness
Wiring harness between ENG (female) (37) – POIL (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – POIL (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (13) – POIL (female) (3) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
5
Wiring harness between ENG (female) Short circuit in (37) – POIL (female) (1) and between ENG (female) (47) – POIL (female) (2) wiring harness Wiring harness between ENG (female) (37) – POIL (female) (1) and between ENG (female) (13) – POIL (female) (3) Wiring harness between ENG (female) (47) – POIL (female) (2) and between ENG (female) (13) – POIL (female) (3)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
64
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Related circuit diagram
D155A-6
65
SEN03206-03
40 Troubleshooting
Failure code [CA141]
1
Contents of trouble
Signal voltage in engine oil pressure sensor circuit is abnormally low.
Action code
E02
Action of controller
Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that appears on machine Related information
State of engine oil pressure sensor can be checked with monitoring function. (Code: 37201 Eng Oil Press Sens Volt)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA135].
2
Confirmation of repair
1. 2. 3. 4.
66
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy
-
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [CA144]
1
Contents of trouble
Signal voltage in engine coolant temperature sensor circuit is abnormally high.
Action code
E02
Action of controller
Fixes engine coolant temperature (90°C) and continues operation.
Problem that appears on machine
Startability of engine lowers at low temperature.
Related information
State of engine coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant Temp Sens Volt)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the engine coolant temperature a Prepare with starting switch OFF, then carry out troubleYES sensor is normal. shooting without turning starting switch ON. • Proceed to the next check item. 1
Engine coolant temperature sensor
TWTR (male)
Between (A) – (B)
2
3
Open circuit in wiring harness
Ground fault in wiring harness
Coolant temperature
Resistance
0°C
30 – 37 kz
25°C
9.3 – 10.7 kz
50°C
3.2 – 3.8 kz
80°C
1.0 – 1.3 kz
95°C
700 – 800 z
NO
• The engine coolant temperature sensor is defective. • Replace the engine coolant temperature sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (15) – TWTR (female) (A)
Resistance
Max. 1 z
Wiring harness between ENG (female) (38) – TWTR (female) (B)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between ENG (female) (15) – TWTR (female) (A) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
67
SEN03206-03
No.
Check item
5
Confirmation of repair
40 Troubleshooting
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
68
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [CA145]
1
Contents of trouble
Signal voltage in engine coolant temperature sensor circuit is abnormally low.
Action code
E02
Action of controller
Fixes engine coolant temperature (90°C) and continues operation.
Problem that appears on machine
Startability of engine lowers at low temperature.
Related information
State of engine coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant Temp Sens Volt)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA144].
2
Confirmation of repair
1. 2. 3. 4.
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy
-
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
69
SEN03206-03
40 Troubleshooting
Failure code [CA153]
1
Contents of trouble
Signal voltage in charge temperature sensor circuit is abnormally high.
Action code
E01
Action of controller
Fixes charge temperature (intake air temperature) (70°C) and continues operation.
Problem that appears on machine
Startability of engine lowers at low temperature.
Related information
State of charge temperature sensor signal can be checked with monitoring function. (Code: 18501 Charge Temp Sens Volt)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the charge temperature sensor is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item.
1
Charge temperature sensor
TIM (male)
Between (A) – (B)
Between (A) – chassis ground
2
3
Open circuit in wiring harness
Ground fault in wiring harness
Intake air temperature
Resistance
0°C
29 – 36 kz
25°C
9 – 11 kz
40°C
4.9 – 5.8 kz
100°C
600 – 700 kz
All range
Min. 1 Mz
NO
• The charge temperature sensor is defective. • Replace the charge temperature sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (23) – TIM (female) (A)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – TIM (female) (B)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES • Proceed to the next shooting without turning starting switch ON. check item.
Wiring harness between ENG (female) (23) – TIM (female) (A) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
70
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
5
Confirmation of repair
SEN03206-03
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
71
SEN03206-03
40 Troubleshooting
Failure code [CA154]
1
Contents of trouble
Signal voltage in charge temperature sensor circuit is abnormally low.
Action code
E01
Action of controller
Fixes charge temperature (intake air temperature) (70°C) and continues operation.
Problem that appears on machine
Startability of engine lowers at low temperature.
Related information
State of charge temperature sensor signal can be checked with monitoring function. (Code: 18501 Charge Temp Sens Volt)
No.
Check item
Procedure of troubleshooting
1
Related failure code(s)
Carry out troubleshooting for failure code [CA153].
2
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy
-
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Failure code [CA187] Contents of trouble
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
Action code
E03
Action of controller
• • • •
Problem that appears on machine
1
Operates Bkup speed sensor with signals of Ne speed sensor. Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation. Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
Engine output drops.
Related information No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA227].
2
Confirmation of repair
1. 2. 3. 4.
72
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy
-
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [CA221]
1
Contents of trouble
Signal voltage in ambient pressure sensor circuit is abnormally high.
Action code
E03
Action of controller
Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that appears on machine
Engine output drops.
Related information
State of ambient pressure sensor signal can be checked with monitoring function. (Code: 37401 Ambient Press Sens Volt)
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor power If code [CA187] or [CA227] is indicated, carry out troubleshootsupply sysing for it first. tem
• The state of the sensor power supply system YES is normal. • Proceed to the next check item.
NO
• The sensor power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the ambient pressure sensor is a Prepare with starting switch OFF, then turn starting switch YES normal. ON and carry out troubleshooting. • Proceed to the next check item. 2
Ambient pressure sensor
PAMB
Voltage
Between (1) – (3)
Power supply
4.75 – 5.25 V
Between (2) – (3)
Signal
0.3 – 4.7 V
NO
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
• The ambient pressure sensor is defective. • Replace the ambient pressure sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
Open circuit in wiring harness
D155A-6
Wiring harness between ENG (female) (37) – PAMB (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (38) – PAMB (female) (3)
Resistance
Max. 1 z
Wiring harness between ENG (female) (3) – PAMB (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
73
SEN03206-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
4
Ground fault in wiring harness
Wiring harness between ENG (female) (37) – PAMB (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (38) – PAMB (female) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (3) – PAMB (female) (2) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
5
Wiring harness between ENG (female) Short circuit in (37) – PAMB (female) (1) and between wiring harENG (female) (38) – PAMB (female) (3) ness Wiring harness between ENG (female) (37) – PAMB (female) (1) and between ENG (female) (3) – PAMB (female) (2) Wiring harness between ENG (female) (38) – PAMB (female) (3) and between ENG (female) (3) – PAMB (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
74
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Related circuit diagram
D155A-6
75
SEN03206-03
40 Troubleshooting
Failure code [CA222]
1
Contents of trouble
Signal voltage in ambient pressure sensor circuit is abnormally low.
Action code
E03
Action of controller
Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that appears on machine
Engine output drops.
Related information
State of ambient pressure sensor signal can be checked with monitoring function. (Code: 37401 Ambient Press Sens Volt)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA221].
2
Confirmation of repair
1. 2. 3. 4.
76
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy
-
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03206-03
Failure code [CA227]
1
Contents of trouble
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
Action code
E03
Action of controller
• • • •
Problem that appears on machine
Operates Bkup speed sensor with signals of Ne speed sensor. Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation. Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Fixes charge (boost) pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
Engine output drops.
Related information No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the related system is normal. YES • Proceed to the next check item.
1
Related system
If another failure code is indicated, carry out troubleshooting for it. NO
• The related system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the sensor a Prepare with starting switch OFF, then turn starting switch is normal. YES ON and carry out troubleshooting. • Proceed to the next check item.
2
3
Sensor
Open circuit in wiring harness
Bkup speed senDisconnect sor devices at right in Oil pressure senorder. If "E" of failsor ure code disappears when a Ambient pressure device is disconsensor nected, that device Charge pressure has trouble in it. sensor
G connector POIL connector NO PAMB connector
• The sensor is defective. • Replace the sensor. • Proceed to "Confirmation of repair".
PIM connector
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item. Wiring harness between ENG (female) (37) – each sensor (female)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – each sensor (female)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
D155A-6
Wiring harness between ENG (female) (37) – each sensor (female) and chassis ground
Resistance
Wiring harness between ENG (female) (47) – each sensor (female) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
77
SEN03206-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
5
Short circuit in wiring harWiring harness between ENG (female) ness (37) – each sensor (female) and between ENG (female) (47) – each sensor (female)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
78
D155A-6
40 Troubleshooting
D155A-6
SEN03206-03
79
SEN03206-03
40 Troubleshooting
D155A-6 Bulldozer Form No. SEN03206-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
80
D155A-6
SEN03207-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
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
SEN03207-03
40 Troubleshooting
Failure code [CA342] .................................................................................................................................... 29 Failure code [CA351] .................................................................................................................................... 30 Failure code [CA352] .................................................................................................................................... 33 Failure code [CA386] .................................................................................................................................... 34 Failure code [CA441] .................................................................................................................................... 36 Failure code [CA442] .................................................................................................................................... 36 Failure code [CA449] .................................................................................................................................... 37 Failure code [CA451] .................................................................................................................................... 38 Failure code [CA452] .................................................................................................................................... 41 Failure code [CA553] .................................................................................................................................... 42 Failure code [CA554] .................................................................................................................................... 44 Failure code [CA559] .................................................................................................................................... 45 Failure code [CA689] .................................................................................................................................... 51 Failure code [CA731] .................................................................................................................................... 54 Failure code [CA757] .................................................................................................................................... 55 Failure code [CA778] .................................................................................................................................... 56 Failure code [CA1633] .................................................................................................................................. 59 Failure code [CA2185] .................................................................................................................................. 61 Failure code [CA2186] .................................................................................................................................. 63 Failure code [CA2249] .................................................................................................................................. 63 Failure code [CA2555] .................................................................................................................................. 64 Failure code [CA2556] .................................................................................................................................. 65 Failure code [D110KA] .................................................................................................................................. 67 Failure code [D110KB] .................................................................................................................................. 69 Failure code [D130KA] .................................................................................................................................. 71 Failure code [D130KB] .................................................................................................................................. 74 Failure code [D161KA] .................................................................................................................................. 76 Failure code [D161KB] .................................................................................................................................. 78 Failure code [D190KA] .................................................................................................................................. 80 Failure code [D190KB] .................................................................................................................................. 82
2
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA234]
1
Contents of trouble
Engine speed is above operating range.
Action code
-
Action of controller
Limits fuel injection rate until engine speed lowers to operating range.
Problem that appears on machine
Engine speed fluctuates.
Related information
Engine speed can be checked with monitoring function. (Code: 01002 Engine Speed)
No.
1
Check item
Related system
Procedure of troubleshooting
If another failure code is indicated, carry out troubleshooting for it.
Judgment and remedy • The state of the related system is normal. YES • Proceed to the next check item.
NO
• The related system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The machine usage is appropriate. YES • Proceed to the next check item. 2
Machine usage
Way of use of machine may be improper. Teach proper way of use to operator. NO
• The machine usage is not appropriate. • Provide direction to properly use the machine. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Run the engine at high idle. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
3
SEN03207-03
40 Troubleshooting
Failure code [CA238]
1
Contents of trouble
Trouble occurred in Ne speed sensor power supply (5 V) circuit.
Action code
E03
Action of controller
Controls Ne speed sensor with signals of Bkup speed sensor.
Problem that appears on machine
• Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the Ne speed sensor is nora Prepare with starting switch OFF, then turn starting switch YES mal. ON and carry out troubleshooting. • Proceed to the next check item. 1
2
Ne speed sensor
Open circuit in wiring harness
Disconnect devices at right in order. If "E" of failEngine Ne speed ure code disapsensor pears when a device is disconnected, that device has trouble in it.
NE connector
NO
• The Ne speed sensor is defective. • Replace the Ne speed sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (16) – NE (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (48) – NE (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
Ground fault in wiring harness
Wiring harness between ENG (female) (16) – NE (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (48) – NE (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
4
Short circuit in wiring harness Wiring harness between ENG (female) (16) – NE (female) (1) and between ENG (female) (48) – NE (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03207-03
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
5
SEN03207-03
40 Troubleshooting
Failure code [CA263]
1
Contents of trouble
Signal voltage in fuel temperature sensor circuit is abnormally high.
Action code
E01
Action of controller
Fixes fuel temperature (90 °C) and continues operation.
Problem that appears on machine
-
Related information
State of fuel temperature sensor signal can be checked with monitoring function. (Code: 14201 Fuel Temp Sens Volt)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the fuel temperature sensor is a Prepare with starting switch OFF, then carry out troublenormal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
TFUEL (male)
Fuel temperature sensor
Between (A) – (B)
2
3
Open circuit in wiring harness
Ground fault in wiring harness
Fuel temperature
Resistance
0°C
30 – 37 kz
25°C
9.3 – 10.7 kz
50°C
3.2 – 3.8 kz
80°C
1.0 – 1.3 kz
95°C
700 – 800 z
NO
• The fuel temperature sensor is defective. • Replace the fuel temperature sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (30) – TFUEL (female) (A)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – TFUEL (female) (B)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between ENG (female) (30) – TFUEL (female) (A) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Related circuit diagram
D155A-6
7
SEN03207-03
40 Troubleshooting
Failure code [CA265]
1
Contents of trouble
Signal voltage in fuel temperature sensor circuit is abnormally low.
Action code
E01
Action of controller
Fixes fuel temperature (90°C) and continues operation.
Problem that appears on machine
-
Related information
-
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA263].
2
Confirmation of repair
1. 2. 3. 4.
8
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA271]
1
Contents of trouble
There is short circuit in PCV1 circuit of supply pump.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
-
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the supply a Prepare with starting switch OFF, then carry out troublepump PCV1 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Supply pump PCV1
PCV1 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z NO
Between (1), (2) – chassis ground
Min. 1 Mz
• The supply pump PCV1 is defective. • Replace the supply pump PCV1. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 2
3
Ground fault in wiring harness
Hot short in wiring harness
Wiring harness between ENG (female) (4) – PCV1 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (5) – PCV1 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. Wiring harness between ENG (female) (4) – PCV1 (female) (1) and chassis ground Wiring harness between ENG (female) (5) – PCV1 (female) (2) and chassis ground
Voltage
Max. 1 V NO
Voltage
Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
9
SEN03207-03
40 Troubleshooting
Related circuit diagram
10
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA272]
1
Contents of trouble
There is disconnection in PCV1 circuit of supply pump.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
-
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the supply a Prepare with starting switch OFF, then carry out troublepump PCV1 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Supply pump PCV1
PCV1 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z NO
Between (1), (2) – chassis ground
2
Open circuit in wiring harness
Min. 1 Mz
• The supply pump PCV1 is defective. • Replace the supply pump PCV1. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (4) – PCV1 (female) (1)
Resistance
Wiring harness between ENG (female) (5) – PCV1 (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item. 3
Ground fault in wiring harness
Wiring harness between ENG (female) (4) – PCV1 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (5) – PCV1 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
11
SEN03207-03
40 Troubleshooting
Related circuit diagram
12
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA273]
1
Contents of trouble
There is short circuit in PCV2 circuit of supply pump.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
-
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the supply a Prepare with starting switch OFF, then carry out troublepump PCV2 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Supply pump PCV2
PCV2 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z NO
Between (1), (2) – chassis ground
Min. 1 Mz
• The supply pump PCV2 is defective. • Replace the supply pump PCV2. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 2
3
Ground fault in wiring harness
Hot short in wiring harness
Wiring harness between ENG (female) (9) – PCV2 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (10) – PCV2 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. Wiring harness between ENG (female) (9) – PCV2 (female) (1) and chassis ground Wiring harness between ENG (female) (10) – PCV2 (female) (2) and chassis ground
Voltage
Max. 1 V NO
Voltage
Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
13
SEN03207-03
40 Troubleshooting
Related circuit diagram
14
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA274]
1
Contents of trouble
There is disconnection in PCV2 circuit of supply pump.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
-
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the supply a Prepare with starting switch OFF, then carry out troublepump PCV2 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Supply pump PCV2
PCV2 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z NO
Between (1), (2) – chassis ground
2
Open circuit in wiring harness
Min. 1 Mz
• The supply pump PCV2 is defective. • Replace the supply pump PCV2. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (9) – PCV2 (female) (1)
Resistance
Wiring harness between ENG (female) (10) – PCV2 (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item. 3
Ground fault in wiring harness
Wiring harness between ENG (female) (9) – PCV2 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (10) – PCV2 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
15
SEN03207-03
40 Troubleshooting
Related circuit diagram
16
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA322]
1
Contents of trouble
There is disconnection or short circuit in injector #1 circuit.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the injeca Prepare with starting switch OFF, then carry out troubletor #1 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Injector #1
CN1 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z NO
Between (1), (2) – chassis ground
2
Open circuit in wiring harness
Min. 1 Mz
• The injector #1 is defective. • Replace the injector #1. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (45) – CN1 (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (53) – CN1 (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
4
Ground fault in wiring harness
Wiring harness between ENG (female) (45) – CN1 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (53) – CN1 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
Another cylinIf a failure code of troubles in multiple injectors is displayed, der injector or carry out troubleshooting for it. Carry out troubleshooting for a wiring harshort circuit in circuit #2 or #3. ness
• The state of the another cylinder injector or wiring harness is YES normal. • Proceed to the next check item.
NO
D155A-6
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• Another cylinder injector or wiring harness is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
17
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
18
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA323]
1
Contents of trouble
There is disconnection or short circuit in injector #5 circuit.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the injeca Prepare with starting switch OFF, then carry out troubletor #5 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Injector #5
CN5 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z NO
Between (1), (2) – chassis ground
2
Open circuit in wiring harness
Min. 1 Mz
• The injector #5 is defective. • Replace the injector #5. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (46) – CN5 (female) (1)
Resistance
Wiring harness between ENG (female) (60) – CN5 (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
4
Ground fault in wiring harness
Wiring harness between ENG (female) (46) – CN5 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (60) – CN5 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
Another cylinIf a failure code of troubles in multiple injectors is displayed, der injector or carry out troubleshooting for it. Carry out troubleshooting for a wiring harshort circuit in circuit #4 or #6. ness
• The state of the another cylinder injector or wiring harness is YES normal. • Proceed to the next check item.
NO
D155A-6
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• Another cylinder injector or wiring harness is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
19
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
20
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA324]
1
Contents of trouble
There is disconnection or short circuit in injector #3 circuit.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the injeca Prepare with starting switch OFF, then carry out troubletor #3 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Injector #3
CN3 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z NO
Between (1), (2) – chassis ground
2
Open circuit in wiring harness
Min. 1 Mz
• The injector #3 is defective. • Replace the injector #3. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (55) – CN3 (female) (1)
Resistance
Wiring harness between ENG (female) (52) – CN3 (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
4
Ground fault in wiring harness
Wiring harness between ENG (female) (55) – CN3 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (52) – CN3 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
Another cylinIf a failure code of troubles in multiple injectors is displayed, der injector or carry out troubleshooting for it. Carry out troubleshooting for a wiring harshort circuit in circuit #1 or #2. ness
• The state of the another cylinder injector or wiring harness is YES normal. • Proceed to the next check item.
NO
D155A-6
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• Another cylinder injector or wiring harness is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
21
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
22
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA325]
1
Contents of trouble
There is disconnection or short circuit in injector #6 circuit.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the injeca Prepare with starting switch OFF, then carry out troubletor #6 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Injector #6
CN6 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z NO
Between (1), (2) – chassis ground
2
Open circuit in wiring harness
Min. 1 Mz
• The injector #6 is defective. • Replace the injector #6. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (57) – CN6 (female) (1)
Resistance
Wiring harness between ENG (female) (59) – CN6 (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
4
Ground fault in wiring harness
Wiring harness between ENG (female) (57) – CN6 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (59) – CN6 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
Another cylinIf a failure code of troubles in multiple injectors is displayed, der injector or carry out troubleshooting for it. Carry out troubleshooting for a wiring harshort circuit in circuit #4 or #5. ness
• The state of the another cylinder injector or wiring harness is YES normal. • Proceed to the next check item.
NO
D155A-6
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• Another cylinder injector or wiring harness is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
23
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
24
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA331]
1
Contents of trouble
There is disconnection or short circuit in injector #2 circuit.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the injeca Prepare with starting switch OFF, then carry out troubletor #2 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Injector #2
CN2 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z NO
Between (1), (2) – chassis ground
2
Open circuit in wiring harness
Min. 1 Mz
• The injector #2 is defective. • Replace the injector #2. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (54) – CN2 (female) (1)
Resistance
Wiring harness between ENG (female) (51) – CN2 (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
4
Ground fault in wiring harness
Wiring harness between ENG (female) (54) – CN2 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (51) – CN2 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
Another cylinIf a failure code of troubles in multiple injectors is displayed, der injector or carry out troubleshooting for it. Carry out troubleshooting for a wiring harshort circuit in circuit #1 or #3. ness
• The state of the another cylinder injector or wiring harness is YES normal. • Proceed to the next check item.
NO
D155A-6
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• Another cylinder injector or wiring harness is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
25
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
26
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA332]
1
Contents of trouble
There is disconnection or short circuit in injector #4 circuit.
Action code
E03
Action of controller
None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the injeca Prepare with starting switch OFF, then carry out troubletor #4 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Injector #4
CN4 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z NO
Between (1), (2) – chassis ground
2
Open circuit in wiring harness
Min. 1 Mz
• The injector #4 is defective. • Replace the injector #4. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (56) – CN4 (female) (1)
Resistance
Wiring harness between ENG (female) (58) – CN4 (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
4
Ground fault in wiring harness
Wiring harness between ENG (female) (56) – CN4 (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (58) – CN4 (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
Another cylinIf a failure code of troubles in multiple injectors is displayed, der injector or carry out troubleshooting for it. Carry out troubleshooting for a wiring harshort circuit in circuit #5 or #6. ness
• The state of the another cylinder injector or wiring harness is YES normal. • Proceed to the next check item.
NO
D155A-6
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• Another cylinder injector or wiring harness is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
27
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
28
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA342]
1
Contents of trouble
Incompatibility occurred in engine controller data.
Action code
E04
Action of controller
None in particular.
Problem that appears on machine
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information
-
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA111].
2
Confirmation of repair
1. 2. 3. 4.
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
29
SEN03207-03
40 Troubleshooting
Failure code [CA351]
1
Contents of trouble
Trouble occurred in injector drive circuit.
Action code
E03
Action of controller
Limits engine output and continues operation (Limits common rail pressure).
Problem that appears on machine
Engine output drops.
Related information
Source voltage of engine controller can be checked with monitoring function. (Code: 03203 Battery Power Supply)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the related system is normal. YES • Proceed to the next check item.
1
Related system
If another failure code (failure code of trouble in injector system) is indicated, carry out troubleshooting for it. NO
• The related system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the circuit breaker is normal. YES • Proceed to the next check item. 2
Circuit breaker
If circuit breaker (CB30 or CB8) is turned OFF, circuit probably has ground fault (See check item 4). NO
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
30
Open circuit in wiring harness
Wiring harness between EGC3 (female) (3), (4) – CB8 (2)
Resistance
Max. 1 z
Wiring harness between CB8 (1) – CB30 (B30S)
Resistance
Max. 1 z
Wiring harness between CB30 (B30L) – terminal BRB
Resistance
Max. 1 z
Wiring harness between EGC3 (female) (1), (2) – chassis ground (GND20)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03207-03
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Ground fault in wiring harness
Wiring harness between EGC3 (female) (3), (4) – CB8 (2) and chassis ground
Resistance
Wiring harness between CB8 (1) – CB30 (B30S) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB30 (B30L) – terminal BRB and chassis ground
Resistance
Min. 1 Mz
Wiring harness between EGC3 (female) (1), (2) – chassis ground (GND20) and chassis ground
Resistance
Min. 1 Mz
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
31
SEN03207-03
40 Troubleshooting
Related circuit diagram
32
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA352]
1
Contents of trouble
Signal voltage in sensor power supply 1 (5 V) circuit of engine controller is abnormally low.
Action code
E03
Action of controller
Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
Problem that appears on machine
Engine output drops.
Related information
-
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA386].
2
Confirmation of repair
1. 2. 3. 4.
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
33
SEN03207-03
40 Troubleshooting
Failure code [CA386]
1
Contents of trouble
Signal voltage in sensor power supply (5 V) circuit is abnormally high.
Action code
E03
Action of controller
Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
Problem that appears on machine
Engine output drops.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the related system is normal. YES • Proceed to the next check item.
1
Related system
If another failure code is indicated, carry out troubleshooting for it. NO
• The related system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the sensor a Prepare with starting switch OFF, then turn starting switch is normal. YES ON and carry out troubleshooting. • Proceed to the next check item. 2
3
Sensor
Open circuit in wiring harness
Disconnect devices at right in order. If “E” of failCommon rail presure code disapPFUEL connector sure sensor pears when a device is disconnected, that device has trouble in it.
NO
• The sensor is defective. • Replace the sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ENG (female) (33) – PFUEL (female) (1)
Resistance
Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES • Proceed to the next shooting without turning starting switch ON. check item. 4
34
Ground fault in wiring harness
Wiring harness between ENG (female) (33) – PFUEL (female) (1) and chassis ground
Resistance
Wiring harness between ENG (female) (47) – PFUEL (female) (3) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03207-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
5
Short circuit in wiring harWiring harness between ENG (female) ness (33) – PFUEL (female) (1) and between ENG (female) (47) – PFUEL (female) (3)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
35
SEN03207-03
40 Troubleshooting
Failure code [CA441]
1
Contents of trouble
Power supply circuit voltage of engine controller is abnormally low.
Action code
E04
Action of controller
None in particular.
Problem that appears on machine
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information
Source voltage of engine controller can be checked with monitoring function. (Code: 03203 Battery Power Supply)
No.
Check item
Procedure of troubleshooting
1
Related failure code(s)
Carry out troubleshooting for failure code [CA111].
2
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Failure code [CA442]
1
Contents of trouble
Power supply circuit voltage of engine controller is abnormally high.
Action code
E04
Action of controller
None in particular.
Problem that appears on machine
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information
Source voltage of engine controller can be checked with monitoring function. (Code: 03203 Battery Power Supply)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA111].
2
Confirmation of repair
1. 2. 3. 4.
36
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA449]
1
Contents of trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 2).
Action code
E03
Action of controller
Limits engine output and continues operation (Limits common rail pressure).
Problem that appears on machine
Engine output drops.
Related information
Common rail pressure can be checked with monitoring function. (Code: 36400 Rail Pressure)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA553].
2
Confirmation of repair
1. 2. 3. 4.
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
37
SEN03207-03
40 Troubleshooting
Failure code [CA451]
1
Contents of trouble
Signal voltage in common rail pressure sensor circuit is abnormally high.
Action code
E03
Action of controller
Limits engine output and continues operation (Limits common rail pressure).
Problem that appears on machine
Engine output drops.
Related information
State of common rail pressure sensor signal can be checked with monitoring function. (Code: 36401 Rail Pressure Sense Volt)
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor power If code [CA352] or [CA386] is indicated, carry out troubleshootsupply sysing for it first. tem
• The state of the sensor power supply system YES is normal. • Proceed to the next check item.
NO
• The sensor power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the common rail pressure sena Prepare with starting switch OFF, then turn starting switch sor is normal. YES ON or start engine and carry out troubleshooting. • Proceed to the next check item.
2
Common rail PFUEL pressure sensor Between (1) – (3) Power supply
4.75 – 5.25 V
Between (2) – (3)
0.26 – 4.6 V
Signal
Voltage
NO
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
• The common rail pressure sensor is defective. • Replace the common rail pressure sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
38
Open circuit in wiring harness
Wiring harness between ENG (female) (33) – PFUEL (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (25) – PFUEL (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03207-03
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Ground fault in wiring harness
Wiring harness between ENG (female) (33) – PFUEL (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (25) – PFUEL (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – PFUEL (female) (3) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES • Proceed to the next shooting without turning starting switch ON. check item.
5
Wiring harness between ENG (female) (33) – PFUEL (female) (1) and between ENG (female) (25) – PFUEL Short circuit in (female) (2) wiring harWiring harness between ENG (female) ness (33) – PFUEL (female) (1) and between ENG (female) (47) – PFUEL (female) (3) Wiring harness between ENG (female) (25) – PFUEL (female) (2) and between ENG (female) (47) – PFUEL (female) (3)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
39
SEN03207-03
40 Troubleshooting
Related circuit diagram
40
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA452]
1
Contents of trouble
Signal voltage in common rail pressure sensor circuit is abnormally low.
Action code
E03
Action of controller
Limits engine output and continues operation (Limits common rail pressure).
Problem that appears on machine
Engine output drops.
Related information
State of common rail pressure sensor signal can be checked with monitoring function. (Code: 36401 Rail Pressure Sense Volt)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA451].
2
Confirmation of repair
1. 2. 3. 4.
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
41
SEN03207-03
40 Troubleshooting
Failure code [CA553]
1
Contents of trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
Action code
E02
Action of controller
None in particular.
Problem that appears on machine
Engine output drops.
Related information
Common rail pressure can be checked with monitoring function. (Code: 36400 Rail Pressure)
No.
1
Check item
Related system
Procedure of troubleshooting
If another failure code is indicated, carry out troubleshooting for it.
Judgment and remedy • The state of the related system is normal. YES • Proceed to the next check item.
NO
• The related system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The fuel is appropriate. YES • Proceed to the next check item. 2
Fuel used
Check fuel used (for high viscosity). NO
3
Electrical system of comCommon rail pressure sensor may have electric trouble. mon rail Carry out troubleshooting for failure code [CA451]. pressure sensor
• The state of the electrical system of common rail pressure sensor is norYES mal. • Proceed to the next check item.
NO
4
Mechanical system of common rail Check mechanical system of common rail pressure sensor. pressure sensor
• The electrical system of common rail pressure sensor is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the mechanical system of common rail pressure sensor is YES normal. • Proceed to the next check item.
NO
42
• The fuel is not appropriate. • Replace the fuel with the appropriate type. • Proceed to "Confirmation of repair".
• The mechanical system of common rail pressure sensor is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03207-03
Judgment and remedy
Procedure of troubleshooting
• The state of the overflow valve is normal. YES • Proceed to the next check item. 5
Overflow valve
Check overflow valve for broken spring, worn seat, and stuck ball. NO
• The overflow valve is defective. • Replace the overflow valve. • Proceed to "Confirmation of repair".
• The overflow piping is not clogged. YES • Proceed to the next check item. 6
Overflow pipCheck overflow piping for clogging. ing NO
• The overflow piping is clogged. • Clean or replace the overflow piping. • Proceed to "Confirmation of repair".
YES The repair is completed.
7
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
8
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The pressure limiter may be defective. • Replace the pressure limiter. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
43
SEN03207-03
40 Troubleshooting
Failure code [CA554]
1
Contents of trouble
In-range error occurred in common rail pressure sensor circuit.
Action code
E03
Action of controller
Limits engine output and continues operation (Limits common rail pressure).
Problem that appears on machine
Engine output drops.
Related information
State of common rail pressure sensor signal can be checked with monitoring function. (Code: 36401 Rail Pressure Sense Volt)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for Failure code [CA451].
2
Confirmation of repair
1. 2. 3. 4.
44
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA559]
1
Contents of trouble
Supply pump does not feed fuel (level 1).
Action code
E02
Action of controller
Limits common rail pressure.
Problem that appears on machine
Engine output drops.
Related information
Common rail pressure can be checked with monitoring function. (Code: 36400 Rail Pressure)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the related system is normal. YES • Proceed to the next check item.
1
Related system
If another failure code is indicated, carry out troubleshooting for it. NO
• The related system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The fuel is appropriate. YES • Proceed to the next check item. 2
Fuel used
Check fuel used for improper quality. NO
• The fuel is not appropriate. • Replace the fuel with the appropriate type. • Proceed to "Confirmation of repair".
• a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjust- YES ing, Testing fuel pressure. • 3
Low-pressure circuit device Pressure in fuel low-pressure circuit (high idle)
0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}
NO
The state of the lowpressure circuit device is normal. Proceed to the next check item.
• The low-pressure circuit device is defective. • Replace the low-pressure circuit device. • Proceed to "Confirmation of repair".
• The filter/strainer is not clogged. YES • Proceed to the next check item. 4
Clogged filter/ a For contents of troubleshooting, see Note 2. strainer NO
D155A-6
• The filter/strainer is clogged. • Clean or replace the filter/strainer. • Proceed to "Confirmation of repair".
45
SEN03207-03
No.
5
40 Troubleshooting
Check item
Procedure of troubleshooting
Electrical sys- Supply pump PCV may have electric trouble. Carry out troubletem of supply shooting for following codes; [CA271], [CA272], [CA273] and pump PCV [CA274].
Judgment and remedy • The state of the electrical system of supply YES pump PCV is normal. • Proceed to the next check item.
NO
6
Common rail Common rail pressure sensor may be defective. Check wiring pressure senharness for damage. sor
• The electrical system of supply pump PCV is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the common rail pressure senYES sor is normal. • Proceed to the next check item.
NO
• The common rail pressure sensor is defective. • Replace the common rail pressure sensor. • Proceed to "Confirmation of repair".
• The state of the presa For testing of leakage from pressure limiter, see Testing and sure limiter is normal. YES adjusting, Measuring fuel return rate and fuel leakage. • Proceed to the next check item. 7
Pressure limiter Leakage from pressure limiter (Operation equivalent to rated operation (under stall load))
Max. 10 cc/min.
NO
• The pressure limiter is defective. • Replace the pressure limiter. • Proceed to "Confirmation of repair".
• The state of the injector is normal. a For measuring of return (spill) limit from injector, see Testing YES and adjusting, Measuring fuel return rate and fuel leakage. • Proceed to the next check item.
8
Injector
Speed in rated operation (stall load)
Return (Spill) limit from injector
1,600 rpm
960 cc/min.
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
NO
• The injector is defective. • Replace the injector. • Proceed to "Confirmation of repair".
YES The repair is completed.
9
Reconfirmation of check item
Confirmation 10 of repair
46
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The supply pump may be defective. • Replace the supply pump. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
<How to use check sheet> Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for rail pressure low error". Note 1: When low-pressure circuit is defective, check the following: q Fuel level q Clogged fuel tank breather q Water separator/Prefilter filled with water q Clogged fuel filter q Clogged screen in water separator q Stuck or worn feed pump, clogged filter q Leaked or clogged low-pressure fuel pipe q Bypass valve malfunction, defective assembly of other parts (See Fig.1.) q Clogged fuel filter q Fuel in oil pan (fuel leakage in head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2): Spring is seen through hole on nut side. q Fuel inlet joint (3): Gauze filter is seen through both holes.
D155A-6
47
SEN03207-03
40 Troubleshooting
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
48
D155A-6
40 Troubleshooting
SEN03207-03
Check sheet for rail pressure low error Model Machine serial No.
D155A-6 #
Date of check
Engine Engine serial No.
Work No.
SAA6D140E-5
/
/
Service meter
#
h
Worker's name
Good NG
A. Visual check 1 Fuel leakage to outside 2 Clogging of fuel tank breather
B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG 3 Check of failure code
/
/
/
/
Check of monitoring information Code
Displayed item
01002 Engine speed
Standard value (Reference value)
Low idle
r/min
715 – 765
High idle
r/min
1,825 – 1,925
Torque converter stall
r/min
1,560 – 1,660
Measured value
Good NG
Low idle
%
0
High idle
%
100
Torque converter stall
mg/st
—
—
—
36200
Final common rail Torque converter stall pressure command
MPa
—
—
—
36400
Common rail pressure
Torque converter stall
MPa
—
—
—
Low idle
CA
—
—
—
High idle
CA
—
—
—
Torque converter stall
CA
—
—
—
Torque converter stall
kPa
—
—
—
°C
—
—
—
°C
—
—
—
ISO unit
Standard value (Reference value)
No. 1 cylinder
r/min
—
—
—
No. 2 cylinder
r/min
—
—
—
Reduce No. 3 cylinder each cylinder No. 4 cylinder No. 5 cylinder
r/min
—
—
—
r/min
—
—
—
r/min
—
—
—
No. 6 cylinder
r/min
—
—
—
31706
Final accelerator position
Final fuel injection 18600 rate command (by weight) 4
ISO unit
Checking condition
Final injection tim36300 ing command 36500
Chg (boost) pressure
04107
Engine coolant temLow idle perature
14200 Fuel temperature
Low idle
Check of reduced cylinder mode operation (Engine speed) Setting
5
D155A-6
Reduced cylinder
Checking condition
Measured value
Good NG
49
SEN03207-03
C. Check of fuel circuit pressure 6
Fuel low-pressure circuit pressure
40 Troubleshooting
Checking condition High idle
Unit
Standard value (Reference value)
MPa {kg/cm2}
0.15 – 0.3 {1.5 – 3.0}
Measured value
D. Check of strainers and filters
Good NG
Good NG
7 Visual check of strainers 8 Visual check of gauze filter 9 Visual check of fuel filter 10 Visual check of bypass valve
E. Check of leakage and return rate 11
Leakage through pressure limiter
12 Return rate from injector
50
Checking condition
Unit
Standard value (Reference value)
Torque converter stall
cc/min
Max. 10
Torque converter stall 1,600 rpm
cc/min
960
Torque converter stall 1,700 rpm
cc/min
1,020
Torque converter stall 1,800 rpm
cc/min
1,080
Torque converter stall 1,900 rpm
cc/min
1,140
Torque converter stall 2,000 rpm
cc/min
1,200
Measured value
Good NG
Speed: Leakage
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA689]
1
Contents of trouble
Trouble occurred in engine Ne speed sensor circuit.
Action code
E03
Action of controller
Operates with signals of Bkup speed sensor.
Problem that appears on machine
• Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related information
-
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor power supply sysIf code [CA238] is indicated, carry out troubleshooting for it first. tem
• The state of the sensor power supply system YES is normal. • Proceed to the next check item.
NO
• The sensor power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Open circuit in wiring harness
Wiring harness between ENG (female) (16) – NE (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (48) – NE (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (27) – NE (female) (3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Ground fault in wiring harness
D155A-6
Wiring harness between ENG (female) (16) – NE (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (48) – NE (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (27) – NE (female) (3) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
51
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Wiring harness between ENG (female) Short circuit in (16) – NE (female) (1) and between ENG (female) (48) – NE (female) (2) wiring harness Wiring harness between ENG (female) (16) – NE (female) (1) and between ENG (female) (48) – NE (female) (3) Wiring hamess between ENG (female) (48) – NE (female) (2) and between ENG (female) (27) – NE (female) (3)
5
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Sensor or Check Ne speed sensor for defective mount (defective clearrotation sensance) or check rotation sensing part (flywheel) for defect. ing part
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the mount of sensor or rotation sensing part is normal. YES • Proceed to the next check item.
NO
• The mount of sensor or rotation sensing part is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
52
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller or engine Ne speed sensor may be defective. • Replace the engine controller or engine Ne speed sensor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Related circuit diagram
D155A-6
53
40 Troubleshooting
SEN03207-03
Failure code [CA731]
1
Contents of trouble
Engine Bkup sensor circuit detected phase error.
Action code
E03
Action of controller
Controls with signals of engine Ne speed sensor.
Problem that appears on machine
• Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information
-
No.
1
Check item
Procedure of troubleshooting
Engine Ne Engine Ne speed sensor may be defective. Carry out troublespeed sensor shooting for failure code [CA689]. system
Judgment and remedy • The state of the engine Ne speed sensor system is normal. YES • Proceed to the next check item.
NO
• The engine Ne speed sensor system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine Bkup speed sensor system may be defective. • Perform troubleshooting for the failure code [CA778]. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
53
40 Troubleshooting
SEN03207-03
Failure code [CA757]
1
Contents of trouble
All data in engine controller are lost.
Action code
E04
Action of controller
None in particular.
Problem that appears on machine
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information
-
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA111].
2
Confirmation of repair
1. 2. 3. 4.
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
55
SEN03207-03
40 Troubleshooting
Failure code [CA778]
1
Contents of trouble
Trouble occurred in engine Bkup speed sensor circuit.
Action code
E03
Action of controller
Operates with signals of Ne speed sensor.
Problem that appears on machine
• Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information
-
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor power If code [CA187] or [CA227] is indicated, carry out troubleshootsupply sysing for it first. tem
• The state of the sensor power supply system YES is normal. • Proceed to the next check item.
NO
• The sensor power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Open circuit in wiring harness
Wiring harness between ENG (female) (37) – G (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (47) – G (female) (2)
Resistance
Max. 1 z
Wiring harness between ENG (female) (26) – G (female) (3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
56
Ground fault in wiring harness
Wiring harness between ENG (female) (37) – G (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (47) – G (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ENG (female) (26) – G (female) (3) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03207-03
Procedure of troubleshooting
Judgment and remedy
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Wiring harness between ENG (female) Short circuit in (37) – G (female) (1) and between ENG (female) (47) – G (female) (2) wiring harness Wiring harness between ENG (female) (37) – G (female) (1) and between ENG (female) (26) – G (female) (3) Chassis ground between ENG (female) (47) – G (female) (2) and between ENG (female) (26) – G (female) (3)
5
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Sensor or Check Bkup speed sensor for defective mount (defective clearrotation sensance) or check rotation sensing part (in supply pump) for defect. ing part
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the mount of sensor or rotation sensing part is normal. YES • Proceed to the next check item.
NO
• The mount of sensor or rotation sensing part is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
NO
• The engine controller or engine Bkup speed sensor may be defective. • Replace the engine controller or engine Bkup speed sensor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
57
SEN03207-03
40 Troubleshooting
Related circuit diagram
58
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA1633]
1
Contents of trouble
Trouble occurred in KOMNET (CAN) communication circuit between engine controller and machine monitor, power train controller, and work equipment controller.
Action code
E03
Action of controller
Operates in default mode or maintains condition when abnormality occurs.
Problem that appears on machine
-
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Open circuit in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32)
Resistance
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Ground fault in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32), ACCN (female) (17), SRV (male) (3) or CA1 (female) (A) and chassis ground
Resistance
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
3
Hot short in wiring harness
D155A-6
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32), ACCN (female) (17), SRV (male) (3) or CA1 (female) (A) and chassis ground
Voltage
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground
Voltage
Max. 1 V NO Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
59
SEN03207-03
No.
4
40 Troubleshooting
Check item
CAN terminal resistance
Procedure of troubleshooting
Judgment and remedy
• The state of the CAN terminal resistance is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. CA1 (male)
Resistance
Between (A) – (B)
Approx. 120 z
NO
• The CAN terminal resistance is defective. • Replace the CAN terminal resistance. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
60
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA2185]
1
Contents of trouble
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
Action code
E03
Action of controller
Sets throttle position with signal of fuel control dial and continues operation.
Problem that appears on machine
-
Related information
State of decelerator pedal optimum operation range signal can be checked with monitoring function. (Code: 03001 Throttle Pos Sens Volt)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the fuel a Prepare with starting switch OFF, then turn starting switch control dial is normal. YES ON and carry out troubleshooting. • Proceed to the next check item. 1
2
Fuel control dial
Open circuit in wiring harness
Disconnect devices at right in order. If "E" of failure code disapDecelerator pedal pears when a potentiometer device is disconnected, that device has trouble in it.
DCL connector
NO
• The fuel control dial is defective. • Replace the fuel control dial. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between EGC2 (female) (22) – DCL (female) (B)
Resistance
Max. 1 z
Wiring harness between EGC2 (female) (23) – DCL (female) (C)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
Ground fault in wiring harness
Wiring harness between EGC2 (female) (22) – DCL (female) (B) and chassis ground
Resistance
Wiring harness between EGC2 (female) (23) – DCL (female) (C) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Short circuit in wiring harWiring harness between EGC2 ness (female) (22) – DCL (female) (B) and between EGC2 (female) (23) – DCL (female) (C)
D155A-6
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
61
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
62
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA2186]
1
Contents of trouble
Signal voltage in throttle sensor power supply (5 V) circuit of engine controller is abnormally low.
Action code
E03
Action of controller
Sets throttle position with signal of fuel control dial and continues operation.
Problem that appears on machine
-
Related information
State of decelerator pedal optimum operation range signal can be checked with monitoring function. (Code: 03001 Throttle Pos Sens Volt)
No.
Check item
Procedure of troubleshooting
1
Related failure code(s)
Carry out troubleshooting for failure code [CA2185].
2
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Failure code [CA2249]
1
Contents of trouble
Very low pressure error (level 2) occurred in supply pump.
Action code
E03
Action of controller
Limits common rail pressure.
Problem that appears on machine
Engine output drops.
Related information
-
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA559].
2
Confirmation of repair
1. 2. 3. 4.
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
63
SEN03207-03
40 Troubleshooting
Failure code [CA2555]
1
Contents of trouble
There is disconnection in intake air heater relay circuit.
Action code
E01
Action of controller
None in particular.
Problem that appears on machine
Engine does not start easily at low temperature.
Related information
Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure code [CA2556].
2
Confirmation of repair
1. 2. 3. 4.
64
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [CA2556]
1
Contents of trouble
There is short circuit in intake air heater relay.
Action code
E01
Action of controller
None in particular.
Problem that appears on machine
Engine does not start easily at low temperature.
Related information
• Engine controller has automatic preheating function, which is turned ON when engine coolant temperature is below -5 °C (for up to 30 seconds). • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature)
No.
1
2
3
Check item
Intake air heater relay
Open circuit in wiring harness
Ground fault in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the intake air heater relay is nora Prepare with starting switch OFF, then carry out troublemal. YES shooting without turning starting switch ON. • Proceed to the next check item. PHR (male)
Resistance
Between (1) – (2)
200 – 400 z
NO
• The intake air heater relay is defective. • Replace the intake air heater relay. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between EGC2 (female) (40) – PHR (female) (1)
Resistance
Max. 1 z
Wiring harness between PHR (female) (2) – chassis ground (GND03)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
Wiring harness between EGC2 (female) (40) – PHR (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
65
SEN03207-03
40 Troubleshooting
Related circuit diagram
66
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [D110KA]
1
Contents of trouble
Turns signal to battery relay holding circuit, no current flows.
Action code
-
Action of controller
Turns signal to battery relay holding circuit OFF.
Problem that appears on machine
Problem may occur in writing data into ROM (non-volatile memory) of each controller.
Related information
State of battery relay holding circuit signal can be checked with monitoring function. (Code: 60600 BR Hold Relay)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the battery a Prepare with starting switch OFF, then carry out troublerelay is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
2
3
Battery relay
Open circuit in wiring harness
Hot short in wiring harness
Battery relay
Continuity
Between terminals SW – BRE
There is continuity
NO
• The battery relay is defective. • Replace the battery relay. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (4) – terminal SW
Resistance
Wiring harness between terminal BRE and chassis ground
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (4) – terminal SW, terminal 260, terminal AL/R or circuit branch end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON, and then OFF. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
67
SEN03207-03
40 Troubleshooting
Related circuit diagram
68
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [D110KB]
1
Contents of trouble
When signal was output to battery relay circuit, abnormal current flowed.
Action code
-
Action of controller
Turns signal to battery relay holding circuit OFF.
Problem that appears on machine
Problem may occur in writing data into ROM (non-volatile memory) of each controller.
Related information
State of battery relay holding circuit signal can be checked with monitoring function. (Code: 60600 BR Hold Relay)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the battery a Prepare with starting switch OFF, then carry out troublerelay is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
2
Battery relay
Ground fault in wiring harness
Battery relay
Continuity/Resistance
Between terminals SW – BRE
There is continuity
Between terminal SW – chassis ground
Min. 1 Mz
NO
• The battery relay is defective. • Replace the battery relay. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (4) – terminal SW, terminal 260 or RSD (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
4
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON, and then OFF. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
69
SEN03207-03
40 Troubleshooting
Related circuit diagram
70
D155A-6
40 Troubleshooting
SEN03207-03
Failure code [D130KA]
1
Contents of trouble
When ground circuit of neutral safety relay circuit is disconnected, no current flows.
Action code
E02
Action of controller
Turns output of neutral safety relay circuit OFF.
Problem that appears on machine
Engine cannot be started.
Related information
• State of neutral safety relay circuit signal can be checked with monitoring function. (Code: 59099 T/M Lock Relay) • This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not detect abnormality on secondary side (contact side).
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse (FS2-5) is blown out, circuit probably has ground fault (See check item 4). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the neutral safety relay is normal. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item. 2
3
Neutral safety relay
Open circuit in wiring harness
D155A-6
NSF (male)
Resistance
Between (1) – (2)
300 – 600 z
NO
• The neutral safety relay is defective. • Replace the neutral safety relay. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item. Wiring harness between STC2 (female) (8) – NSF (female) (2)
Resistance
Wiring harness between NSF (female) (1) – FS21 (5)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
71
SEN03207-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC2 (female) (8) – NSF (female) (2) and chassis ground
Resistance
Wiring harness between NSF (female) (1) – FS21 (5) or circuit branch end and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
72
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever (Free). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Related circuit diagram
D155A-6
73
SEN03207-03
40 Troubleshooting
Failure code [D130KB]
1
Contents of trouble
When ground circuit of neutral safety relay was disconnected, abnormal current flowed.
Action code
E02
Action of controller
Turns output of neutral safety relay circuit OFF.
Problem that appears on machine
Engine cannot be started.
Related information
• State of neutral safety relay circuit signal can be checked with monitoring function. (Code: 59099 T/M Lock Relay) • This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not detect abnormality on secondary side (contact side).
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the neutral safety relay is normal. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 1
2
Neutral safety relay
Hot short in wiring harness
NSF (male)
Resistance
Between (1) – (2)
300 – 600 z
NO
• The neutral safety relay is defective. • Replace the neutral safety relay. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC2 (female) (8) – NSF (female) (2) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
74
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever (Free). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Related circuit diagram
D155A-6
75
SEN03207-03
40 Troubleshooting
Failure code [D161KA]
1
Contents of trouble
When ground circuit of back-up alarm relay circuit is disconnected, no current flows.
Action code
E01
Action of controller
Turns output of back-up alarm relay circuit OFF.
Problem that appears on machine
Back-up alarm does not sound.
Related information
• State of back-up alarm relay circuit signal can be checked with monitoring function. (Code: 70400 Back Alarm Relay) • This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not detect abnormality on secondary side (contact side).
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse (FS1-2) is blown out, circuit probably has ground fault (See check item 4). NO
2
3
76
Backup alarm relay
Open circuit in wiring harness
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the backup alarm relay is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. BKA (male)
Resistance
Between (1) – (2)
300 – 600 z
NO
• The backup alarm relay is defective. • Replace the backup alarm relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES • Proceed to the next shooting without turning starting switch ON. check item. Wiring harness between STC2 (female) (18) – BKA (female) (2)
Resistance
Max. 1 z
Wiring harness between BKA (female) (1) – FS12 (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03207-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC2 (female) (18) – BKA (female) (2) or circuit branch end and chassis ground
Resistance
Wiring harness between BKA (female) (1), (3) – FS12 (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (Reverse). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
77
SEN03207-03
40 Troubleshooting
Failure code [D161KB]
1
Contents of trouble
When ground circuit of back-up alarm relay was disconnected, abnormal current flowed.
Action code
E01
Action of controller
Turns output of back-up alarm relay circuit OFF.
Problem that appears on machine
Back-up alarm does not sound.
Related information
• State of back-up alarm relay circuit signal can be checked with monitoring function. (Code: 70400 Back Alarm Relay) • This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not detect abnormality on secondary side (contact side).
No.
1
2
Check item
Backup alarm relay
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the backup alarm relay is a Prepare with starting switch OFF, then carry out troublenormal. YES shooting without turning starting switch ON. • Proceed to the next check item. BKA (male)
Resistance
Between (1) – (2)
300 – 600 z
NO
• The Backup alarm relay is defective. • Replace the backup alarm relay. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC2 (female) (18) – BKA (female) (2) or circuit branch end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
78
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (Reverse). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Related circuit diagram
D155A-6
79
SEN03207-03
40 Troubleshooting
Failure code [D190KA]
1
Contents of trouble
When ground circuit of ACC signal drive relay circuit is disconnected, no current flows.
Action code
-
Action of controller
Turns signal to ACC signal drive relay circuit OFF.
Problem that appears on machine
• Turbo-timer function does not operate (if turbo-timer is installed). • Machine is not affected particularly (if turbo-timer is not installed).
Related information
• State of ACC signal drive relay circuit signal can be checked with monitoring function. (Code: 60500 ENG Hold Relay) • This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does not detect abnormality on secondary side (contact side).
No.
1
2
3
Check item
ACC signal drive relay
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the ACC signal drive relay is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. EHL (male)
Resistance
Between (1) – (2)
200 – 400 z
NO
• The ACC signal drive relay is defective. • Replace the ACC signal drive relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC2 (female) (9) – EHL (female) (2)
Resistance
Max. 1 z
Wiring harness between EHL (female) (1) – branch point (J)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC2 (female) (9) – EHL (female) (2) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
80
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03207-03
Check item
Procedure of troubleshooting
Confirmation of repair
1. Turn the starting switch OFF. 2. Connect all the composed equipment. 3. Turn the starting switch ON, and then OFF (if turbo-timer is installed). 4. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
81
SEN03207-03
40 Troubleshooting
Failure code [D190KB]
1
Contents of trouble
When ground circuit of ACC signal drive relay was disconnected, abnormal current flowed.
Action code
-
Action of controller
Turns output of ACC signal drive relay circuit OFF.
Problem that appears on machine
• Turbo-timer function does not operate (if turbo-timer is installed). • Machine is not affected particularly (if turbo-timer is not installed).
Related information
• State of ACC signal drive relay circuit signal can be checked with monitoring function. (Code: 60500 ENG Hold Relay) • This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does not detect abnormality on secondary side (contact side).
No.
1
2
Check item
ACC signal drive relay
Ground fault in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the ACC signal drive relay is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. EHL (male)
Resistance
Between (1) – (2)
200 – 400 z
NO
• The ACC signal drive relay is defective. • Replace the ACC signal drive relay. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (9) – EHL (female) (2) and chassis ground
Resistance
1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
82
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. Turn the starting switch OFF. 2. Connect all the composed equipment. 3. Turn the starting switch ON, and then OFF (if turbo-timer is installed). 4. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03207-03
Related circuit diagram
D155A-6
83
SEN03207-03
40 Troubleshooting
D155A-6 Bulldozer Form No. SEN03207-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
84
D155A-6
SEN03208-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
40 Troubleshooting
1
Troubleshooting by failure and error codes, Part 3 Failure code [D5ZKKX] ................................................................................................................................... 3 Failure code [DAFRKR] .................................................................................................................................. 6 Failure code [DB2RKR]................................................................................................................................... 8 Failure code [DB90KR] ..................................................................................................................................11 Failure code [DBE0KK] ................................................................................................................................. 13 Failure code [DBE0KT] ................................................................................................................................. 16 Failure code [DBE6KK] ................................................................................................................................. 17 Failure code [DBE7KK] ................................................................................................................................. 19 Failure code [DBE9KQ]................................................................................................................................. 22 Failure code [DD12KA] ................................................................................................................................. 24 Failure code [DD12KB] ................................................................................................................................. 26 Failure code [DD13KA] ................................................................................................................................. 28 Failure code [DD13KB] ................................................................................................................................. 30 Failure code [DD14KA] ................................................................................................................................. 32
D155A-6
1
SEN03208-03
40 Troubleshooting
Failure code [DD14KB] ................................................................................................................................. 34 Failure code [DDDDKA] ................................................................................................................................ 36 Failure code [DDDDKB] ................................................................................................................................ 38 Failure code [DDDDKX] ................................................................................................................................ 40 Failure code [DGT1KA] ................................................................................................................................. 41 Failure code [DGT1KX] ................................................................................................................................. 43 Failure code [DH21KA] ................................................................................................................................. 45 Failure code [DH21KB] ................................................................................................................................. 47 Failure code [DK10KX].................................................................................................................................. 49 Failure code [DK30KA].................................................................................................................................. 52 Failure code [DK30KB].................................................................................................................................. 54 Failure code [DK30KX].................................................................................................................................. 56 Failure code [DK30KZ].................................................................................................................................. 56 Failure code [DK30L8] .................................................................................................................................. 57 Failure code [DK31KA].................................................................................................................................. 58 Failure code [DK31KB].................................................................................................................................. 60 Failure code [DK40KA].................................................................................................................................. 62 Failure code [DK40KB].................................................................................................................................. 64 Failure code [DK55KX].................................................................................................................................. 66 Failure code [DK55KZ].................................................................................................................................. 66 Failure code [DK55L8] .................................................................................................................................. 67 Failure code [DK56KA].................................................................................................................................. 68 Failure code [DK56KB].................................................................................................................................. 70
1 1
2
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [D5ZKKX]
1
Contents of trouble
Signal voltage of fuel control dial is below 0.30 V or above 4.55 V.
Action code
E03
Action of controller
• Continues control with decelerator pedal potentiometer signal. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel Dial Sensor)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the fuel control dial is normal. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 2
Fuel control dial
DIAL (male)
Resistance
Between (1) – (3)
4.0 – 6.0 kz
Between (1) – (2)
0.25 – 7.0 kz
Between (2) – (3)
0.25 – 7.0 kz
NO
• The fuel control dial is defective. • Replace the fuel control dial. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
Open circuit in wiring harness
D155A-6
Wiring harness between STC1 (female) (22) – DIAL (female) (1)
Resistance
Wiring harness between STC1 (female) (1) – DIAL (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
3
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC1 (female) (1) – DIAL (female) (2) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch harness. YES ON and carry out troubleshooting. • Proceed to the next check item. 5
Hot short in wiring harness Wiring harness between STC1 (female) (1) – DIAL (female) (2) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
D155A-6
5
SEN03208-03
40 Troubleshooting
Failure code [DAFRKR]
1
Contents of trouble
Machine monitor cannot recognize engine controller, power train controller, or work equipment controller in CAN communication circuit.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Open circuit in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32) Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22)
Resistance
Max. 1 z NO
Resistance
Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Ground fault in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32), ACCN (female) (17), SRV (male) (3) or CA1 (female) (A) and chassis ground
Resistance
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
3
6
Hot short in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32), ACCN (female) (17), SRV (male) (3) or CA1 (female) (A) and chassis ground
Voltage
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground
Voltage
Max. 1 V NO Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the CAN terminal resistance is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. 4
CAN terminal resistance
CA1 (male)
Resistance
Between (A) – (B)
Approx. 120 z
NO
• The CAN terminal resistance is defective. • Replace the CAN terminal resistance. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The machine monitor, engine controller or power train controller may be defective. • Replace the machine monitor, engine controller or power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
7
SEN03208-03
40 Troubleshooting
Failure code [DB2RKR]
1
Contents of trouble
Power train controller cannot recognize engine controller in CAN communication circuit.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Open circuit in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32) Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22)
Resistance
Max. 1 z NO
Resistance
Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Ground fault in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32), ACCN (female) (17), SRV (male) (3) or CA1 (female) (A) and chassis ground
Resistance
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
3
8
Hot short in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32), ACCN (female) (17), SRV (male) (3) or CA1 (female) (A) and chassis ground
Voltage
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground
Voltage
Max. 1 V NO Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03208-03
Procedure of troubleshooting
Judgment and remedy
• The state of the CAN terminal resistance is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. 4
5
CAN terminal resistance
Engine controller or power train controller
CA1 (male)
Resistance
Between (A) – (B)
Approx. 120 z
NO
• The CAN terminal resistance is defective. • Replace the CAN terminal resistance. • Proceed to "Confirmation of repair".
• The state of the engine controller or power train controller is norYES mal. • Proceed to the next check item. If check items 1 – 4 are not detected, engine controller or power train controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) NO
• The engine controller or power train controller is defective. • Replace the engine controller or power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The engine controller power supply may be defective. • Perform troubleshooting for the failure code [CA111]. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
9
SEN03208-03
40 Troubleshooting
Related circuit diagram
1
10
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DB90KR]
1
Contents of trouble
Power train controller cannot recognize machine monitor, engine controller or work equipment controller in CAN communication circuit.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Open circuit in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32) Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22)
Resistance
Max. 1 z NO
Resistance
Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Ground fault in wiring harness
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32), ACCN (female) (17), SRV (male) (3) or CA1 (female) (A) and chassis ground
Resistance
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
3
Hot short in wiring harness
D155A-6
Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32), ACCN (female) (17), SRV (male) (3) or CA1 (female) (A) and chassis ground
Voltage
Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground
Voltage
Max. 1 V NO Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
11
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the CAN terminal resistance is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. 4
CAN terminal resistance
CA1 (male)
Resistance
Between (A) – (B)
Approx. 120 z
NO
• The CAN terminal resistance is defective. • Replace the CAN terminal resistance. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The machine monitor, engine controller or power train controller may be defective. • Replace the machine monitor, engine controller or power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
12
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DBE0KK]
1
Contents of trouble
Source voltage of work equipment controller is below 17 V.
Action code
E03
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• • • •
Related information
Source voltage of power train controller can be checked with adjusting function. (Code: 2121)
No.
Check item
Machine monitor may not display normally. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all.
Procedure of troubleshooting
Judgment and remedy • The state of the circuit breaker is normal. YES • Proceed to the next check item.
1
Circuit breaker
If circuit breaker (CB1, CB7, CB30 or CB105) is turned OFF, circuit probably has ground fault (See check item 3). NO
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
2
Open circuit in wiring harness
D155A-6
Wiring harness between STC3 (female) (1), (11) – CB7 (2)
Resistance
Max. 1 z
Wiring harness between CB7 (1) – CB30 (B30S)
Resistance
Max. 1 z
Wiring harness between CB30 (B30L) – terminal BRB
Resistance
Max. 1 z
Wiring harness between STC3 (female) (2), (12), (22) – CB1 (2)
Resistance
Max. 1 z
Wiring harness between CB1 (1) – CB105 (B105S)
Resistance
Max. 1 z
Wiring harness between CB105 (B105L) – terminal BRC
Resistance
Max. 1 z
Wiring harness between STC3 (female) (21), (31), (32), (33) – chassis ground (GND11)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
13
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Ground fault in wiring harness
Wiring harness between STC3 (female) (1), (11) – CB7 (2) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB7 (1) – CB30 (B30S) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB30 (B30L) – terminal BRB and chassis ground
Resistance
Min. 1 Mz
Wiring harness between STC3 (female) (2), (12), (22) – CB1 (2) or PL1 (female) (68) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB1 (1) – CB105 (B105S) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB105 (B105L) – terminal BRC and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
14
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
D155A-6
15
SEN03208-03
40 Troubleshooting
Failure code [DBE0KT]
1
Contents of trouble
Information in ROM (non-volatile memory) of power train controller is abnormal.
Action code
E01
Action of controller
Sets internal adjustment values to default values.
Problem that appears on machine
• Shifting feel of transmission may become bad. • Adjusting function may not operate normally.
Related information
-
No.
1
Check item
Procedure of troubleshooting
Turn Adjustment function in service mode ON and perform Adjustment of operation of reproducing trouble. If "E" of failure code disappears at this time, system is normal. power train controller • Adjustment code: 0002 (Initialization of power train controller)
Judgment and remedy • The state of the adjustment of power train controller is normal. YES • Proceed to the next check item.
NO
• The adjustment of power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
16
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DBE6KK]
1
Contents of trouble
• Voltage of 24V power supply circuit for power train controller sensors is below 17 V or above 30 V. • Abnormal current flowed in 24V power supply circuit for power train controller sensors.
Action code
E02
Action of controller
• Turns output of 24V power supply circuit OFF, if abnormal current flows. • Limits operation of engine and transmission.
Problem that appears on machine
• System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the pitch angle sensor or torque a Prepare with starting switch OFF, then carry out troubleconverter pressure YES shooting without turning starting switch ON. sensor is normal. • Proceed to the next check item.
1
Pitch angle sensor or torque converter pressure sensor Disconnect devices in order. If "E" of failure code disappears when a device is disconnected, that device has trouble in it.
NO
• The pitch angle sensor or torque converter pressure sensor is defective. • Replace the pitch angle sensor or torque converter pressure sensor. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 2
Ground fault in wiring harness Wiring harness between STC1 (female) (16) – PT1 (female) (C)
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
4
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
17
SEN03208-03
40 Troubleshooting
Related circuit diagram
18
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DBE7KK]
1
Contents of trouble
• Voltage of 5V power supply circuit for power train controller sensors is below 4.5 V or above 5.5 V. • Abnormal current flowed in 5V power supply circuit for power train controller sensors.
Action code
E02
Action of controller
• Turns output of 5V power supply circuit OFF, if abnormal current flows. • Limits operation of engine and transmission.
Problem that appears on machine
• System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the brake pedal potentiometer, fuel control dial and a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. PCCS lever is normal. • Proceed to the next check item.
1
Brake pedal potentiometer, fuel control dial or PCCS lever
Disconnect devices at right in order. If "E" of failure code disappears when a device is disconnected, that device has trouble in it.
Brake pedal potentiometer
Connector BRK
Fuel control dial
Connector DIAL NO
PCCS lever
Connector TLV1
• The brake pedal potentiometer, fuel control dial or PCCS lever is defective. • Replace the brake pedal potentiometer, fuel control dial or PCCS lever. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Ground fault in wiring harness
D155A-6
Wiring harness between STC1 (female) (22) – BRK (female) (C) and chassis ground [Brake pedal potentiometer system]
Resistance
Wiring harness between STC1 (female) (22) – DIAL (female) (1) and chassis ground [Fuel control dial system]
Resistance
Min. 1 Mz
Wiring harness between STC1 (female) (22) – TLV1 (female) (4), (5) and chassis ground [PCCS lever system]
Resistance
Min. 1 Mz
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
19
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
3
Hot short in wiring harness
Wiring harness between STC1 (female) (22) – BRK (female) (C) and chassis ground [Brake pedal potentiometer system]
Voltage
Wiring harness between STC1 (female) (22) – DIAL (female) (1) and chassis ground [Fuel control dial system]
Voltage
Max. 1 V
Wiring harness between STC1 (female) (22) – TLV1 (female) (4), (5) and chassis ground [PCCS lever system]
Voltage
Max. 1 V
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
20
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
D155A-6
21
SEN03208-03
40 Troubleshooting
Failure code [DBE9KQ]
1
Contents of trouble
Specification setting in power train controller does not match to specification setting signal (Power train controller cannot be recognized).
Action code
E04
Action of controller
• Turns all outputs of power train controller OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Machine does not move at all. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
-
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Turn Adjustment function in service mode ON and perform operAdjustment of ation of reproducing trouble. If "E" of failure code disappears at power train this time, system is normal. controller • Adjustment code: 0002 (Initialization of power train controller)
• The state of the adjustment of power train controller is normal. YES • Proceed to the next check item.
NO
• The adjustment of power train controller is defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 2
Open circuit in wiring harness
Wiring harness between STC3 (female) (40) – chassis ground (GND11)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
4
Confirmation of repair
1. 2. 3. 4.
22
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
D155A-6
23
SEN03208-03
40 Troubleshooting
Failure code [DD12KA]
1
Contents of trouble
Signals of 2 systems of shift-up switch circuit are turned OFF (opened) simultaneously.
Action code
E02
Action of controller
Recognizes that shift-up switch is not pressed.
Problem that appears on machine
• Transmission gear cannot be shifted up. • Auto shift-up function does not operate.
Related information
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of shift-up switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the shifta Prepare with starting switch OFF, then carry out troubleup switch is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Shift-up switch
SFTU (male)
Shift-up switch OFF (Released)
ON (Pressed)
Resistance between (3) – (2)
Max. 1 z
Min. 1 Mz
Resistance between (1) – (2)
Min. 1 Mz
Max. 1 z
NO
• The shift-up switch is defective. • Replace the shift-up switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Open circuit in wiring harness
Wiring harness between STC3 (female) (9) – SFTU (female) (1)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (4) – SFTU (female) (2)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (12) – SFTU (female) (3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 3
Hot short in wiring harness
Wiring harness between STC3 (female) (9) – SFTU (female) (1) and chassis ground Wiring harness between STC1 (female) (12) – SFTU (female) (3) and chassis ground
24
Voltage
Max. 1 V NO
Voltage
Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the shift-up switch. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
25
SEN03208-03
40 Troubleshooting
Failure code [DD12KB]
1
Contents of trouble
Signals of 2 systems of shift-up switch circuit are turned ON (closed) simultaneously.
Action code
E02
Action of controller
Recognizes that shift-up switch is not pressed.
Problem that appears on machine
• Transmission gear cannot be shifted up. • Auto shift-up function does not operate.
Related information
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of shift-up switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the shifta Prepare with starting switch OFF, then carry out troubleup switch is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Shift-up switch
SFTU (male)
Shift-up switch OFF (Released)
ON (Pressed)
Resistance between (3) – (2)
Max. 1 z
Min. 1 Mz
Resistance between (1) – (2)
Min. 1 Mz
Max. 1 z
NO
• The shift-up switch is defective. • Replace the shift-up switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Ground fault in wiring harness
Wiring harness between STC3 (female) (9) – SFTU (female) (1) and chassis ground Wiring harness between STC1 (female) (12) – SFTU (female) (3) and chassis ground
Resistance
Min. 1 Mz NO
Resistance
Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
26
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the shift-up switch. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
D155A-6
27
SEN03208-03
40 Troubleshooting
Failure code [DD13KA]
1
Contents of trouble
Signals of 2 systems of shift-down switch circuit are turned OFF (opened) simultaneously.
Action code
E02
Action of controller
Recognizes that shift-down switch is not pressed.
Problem that appears on machine
• Transmission gear cannot be shifted down. • Auto shift-down function does not operate.
Related information
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of shift-down switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the shifta Prepare with starting switch OFF, then carry out troubledown switch is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Shift-down switch
SFTD (female)
Shift-down switch OFF (Released)
ON (Pressed)
Resistance between (3) – (2)
Max. 1 z
Min. 1 Mz
Resistance between (1) – (2)
Min. 1 Mz
Max. 1 z
NO
• The shift-down switch is defective. • Replace the shift-down switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Open circuit in wiring harness
Wiring harness between STC1 (female) (18) – SFTD (female) (1)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (4) – SFTD (female) (2)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (24) – SFTD (female) (3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 3
Hot short in wiring harness
Wiring harness between STC1 (female) (18) – SFTD (female) (1) and chassis ground Wiring harness between STC1 (female) (24) – SFTD (female) (3) and chassis ground
28
Voltage
Max. 1 V NO
Voltage
Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the shift-down switch. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
29
SEN03208-03
40 Troubleshooting
Failure code [DD13KB]
1
Contents of trouble
Signals of 2 systems of shift-down switch circuit are turned ON (closed) simultaneously.
Action code
E02
Action of controller
Recognizes that shift-down switch is not pressed.
Problem that appears on machine
• Transmission gear cannot be shifted down. • Auto shift-down function does not operate.
Related information
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of shift-down switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the shifta Prepare with starting switch OFF, then carry out troubledown switch is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Shift-down switch
SFTD (female)
Shift-down switch OFF (Released)
ON (Pressed)
Resistance between (3) – (2)
Max. 1 z
Min. 1 Mz
Resistance between (1) – (2)
Min. 1 Mz
Max. 1 z
NO
• The shift-down switch is defective. • Replace the shift-down switch. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Ground fault in wiring harness
Wiring harness between STC1 (female) (18) – SFTD (female) (1) and chassis ground Wiring harness between STC1 (female) (24) – SFTD (female) (3) and chassis ground
Resistance
Min. 1 Mz NO
Resistance
Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
30
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the shift-down switch. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
1
D155A-6
31
SEN03208-03
40 Troubleshooting
Failure code [DD14KA]
1
Contents of trouble
Signals of 2 systems of parking brake lever switch circuit are turned OFF (opened) simultaneously.
Action code
E03
Action of controller
• Recognizes that parking brake lever is in FREE position. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of parking brake lever switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse (FS2-5) is blown out, circuit probably has ground fault (See check item 4). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the parking brake lever switch a Prepare with starting switch OFF, then carry out troubleis normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Parking brake lever switch
PKSW (male)
Parking brake lever FREE position
LOCK position
Resistance between (A) – (B)
Max. 1 z
Min. 1 Mz
Resistance between (A) – (C)
Min. 1 Mz
Max. 1 z
NO
• The parking brake lever switch is defective. • Replace the parking brake lever switch. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
32
Open circuit in wiring harness
Wiring harness between FS22 (2) – PKSW (female) (A)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (23) – PKSW (female) (B)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (17) – PKSW (female) (C)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Ground fault in wiring harness
Wiring harness between FS22 (2) – PKSW (female) (A) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between STC1 (female) (23) – PKSW (female) (B) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between STC1 (female) (17) – PKSW (female) (C), PKS (female) (1) or PKD (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
33
SEN03208-03
40 Troubleshooting
Failure code [DD14KB]
1
Contents of trouble
Signals of 2 systems of parking brake lever switch circuit are turned ON (closed) simultaneously.
Action code
E03
Action of controller
• Recognizes that parking brake lever is in FREE position. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of parking brake lever switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the parking brake lever switch a Prepare with starting switch OFF, then carry out troubleis normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Parking brake lever switch
PKSW (male)
Parking brake lever FREE position
LOCK position
Resistance between (A) – (B)
Max. 1 z
Min. 1 Mz
Resistance between (A) – (C)
Min. 1 Mz
Max. 1 z
NO
• The parking brake lever switch is defective. • Replace the parking brake lever switch. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 2
Hot short in wiring harness
Wiring harness between STC1 (female) (23) – PKSW (female) (B) and chassis ground Wiring harness between STC1 (female) (17) – PKSW (female) (C), PKS (female) (1) or PKD (female) (1) and chassis ground
Voltage
Max. 1 V NO
Voltage
Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
34
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
D155A-6
35
SEN03208-03
40 Troubleshooting
Failure code [DDDDKA]
1
Contents of trouble
Signals of 2 systems of brake pedal switch circuit are turned OFF (opened) simultaneously.
Action code
E02
Action of controller
• Recognizes that brake pedal is not pressed. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of brake pedal switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse (FS2-1) is blown out, circuit probably has ground fault (See check item 4). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the brake a Prepare with starting switch OFF, then carry out troublepedal switch is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Brake pedal switch
BKSW (male)
Brake pedal Released
Pressed
Resistance between (A) – (B)
Max. 1 z
Min. 1 Mz
Resistance between (A) – (C)
Min. 1 Mz
Max. 1 z
NO
• The brake pedal switch is defective. • Replace the brake pedal switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
36
Open circuit in wiring harness
Wiring harness between FS22 (1) – BKSW (female) (A)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (11) – BKSW (female) (B)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (5) – BKSW (female) (C)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Ground fault in wiring harness
Wiring harness between FS22 (1) – BKSW (female) (A) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between STC1 (female) (11) – BKSW (female) (B) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between STC1 (female) (5) – BKSW (female) (C), PBS (female) (1) or PBD (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the brake pedal. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
37
SEN03208-03
40 Troubleshooting
Failure code [DDDDKB]
1
Contents of trouble
Signals of 2 systems of brake pedal switch circuit are turned ON (closed) simultaneously.
Action code
E02
Action of controller
• Recognizes that brake pedal is not pressed. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of brake pedal switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the brake a Prepare with starting switch OFF, then carry out troublepedal switch is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Brake pedal switch
BKSW (male)
Brake pedal Released
Pressed
Resistance between (A) – (B)
Max. 1 z
Min. 1 Mz
Resistance between (A) – (C)
Min. 1 Mz
Max. 1 z
NO
• The brake pedal switch is defective. • Replace the brake pedal switch. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 2
Hot short in wiring harness
Wiring harness between STC1 (female) (11) – BKSW (female) (B) and chassis ground Wiring harness between STC1 (female) (5) – BKSW (female) (C), PBS (female) (1), or PBD (female) (1) and chassis ground
Voltage
Max. 1 V NO
Voltage
Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
38
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the brake pedal. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
D155A-6
39
SEN03208-03
40 Troubleshooting
Failure code [DDDDKX]
1
Contents of trouble
Brake pedal potentiometer signal does not match to brake pedal switch signal.
Action code
E02
Action of controller
None in particular.
Problem that appears on machine
Backup brake may not operate.
Related information
State of brake pedal potentiometer signal can be checked with monitoring function. (Code: 50400 Brake Pedal Potentio)
No.
1
Check item
Procedure of troubleshooting
Brake pedal If failure code [DDDDKA] or [DDDDKB] is also displayed, switch system carry out troubleshooting for it first.
Judgment and remedy • The state of the brake pedal switch system is YES normal. • Proceed to the next check item.
NO
2
Brake pedal switch
Adjust brake pedal and perform operation of reproducing trouble. If "E" of failure code disappears at this time, system is normal. • Testing and adjusting item: Adjusting brake pedal
• The brake pedal switch system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the brake pedal switch is normal. YES • Proceed to the next check item.
NO
• The brake pedal switch is defective. • Replace the brake pedal switch. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
40
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the brake pedal. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DGT1KA]
1
Contents of trouble
Torque converter oil temperature sensor signal is out of normal range.
Action code
E01
Action of controller
None in particular.
Problem that appears on machine
Power train oil temperature gauge may not indicate normally.
Related information
Torque converter oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the torque converter oil temperaa Prepare with starting switch OFF, then carry out troubleYES ture sensor is normal. shooting without turning starting switch ON. • Proceed to the next check item. 1
Torque converter oil temperature sensor
TCT (male)
Resistance
Between (1) – (2)
1 – 50 kz
NO Between (1) – chassis ground
Min. 1 Mz
• The torque converter oil temperature sensor is defective. • Replace the torque converter oil temperature sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Open circuit in wiring harness
Wiring harness between STC1 (female) (9) – TCT (female) (1)
Resistance
Wiring harness between STC1 (female) (21) – TCT (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
Ground fault in wiring harness
D155A-6
Wiring harness between STC1 (female) (9) – TCT (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
41
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 4
Hot short in wiring harness Wiring harness between STC1 (female) (9) – TCT (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
1
42
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DGT1KX]
1
Contents of trouble
Torque converter oil temperature sensor signal is out of normal range.
Action code
E01
Action of controller
None in particular.
Problem that appears on machine
Power train oil temperature gauge may not indicate normally.
Related information
Torque converter oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the torque converter oil temperaa Prepare with starting switch OFF, then carry out troubleYES ture sensor is normal. shooting without turning starting switch ON. • Proceed to the next check item. 1
Torque converter oil temperature sensor
TCT (male)
Resistance
Between (1) – (2)
1 – 50 kz
NO Between (1) – chassis ground
Min. 1 Mz
• The torque converter oil temperature sensor is defective. • Replace the torque converter oil temperature sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Open circuit in wiring harness
Wiring harness between STC1 (female) (9) – TCT (female) (1)
Resistance
Wiring harness between STC1 (female) (21) – TCT (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
Ground fault in wiring harness
D155A-6
Wiring harness between STC1 (female) (9) – TCT (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
43
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 4
Hot short in wiring harness Wiring harness between STC1 (female) (9) – TCT (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
44
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DH21KA]
1
Contents of trouble
Signal voltage of work equipment pump oil pressure sensor is below 0.5 V.
Action code
-
Action of controller
None in particular.
Problem that appears on machine
Oil pressure of work equipment pump cannot be monitored.
Related information
State of work equipment pump oil pressure sensor can be checked with monitoring function. (Code: 70701 Hydraulic Pressure Sensor 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DB95KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each YES case. •
2
HHP Work equipPower supply ment oil pres- Between (B) – (A) sure sensor Between (C) – (A) Signal
Voltage 4.5 – 5.5 V 0.5 – 6.0 V NO
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
The state of the work equipment oil pressure sensor is normal. Proceed to the next check item.
• The work equipment oil pressure sensor is defective. • Replace the work equipment oil pressure sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
Open circuit in wiring harness
D155A-6
Wiring harness between STC1 (female) (21) – HHP (female) (A)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (34) – HHP (female) (B)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (20) – HHP (female) (C)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
45
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC1 (female) (20) – HHP (female) (C) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
46
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DH21KB]
1
Contents of trouble
Signal voltage of work equipment pump oil pressure sensor is above 6.0 V.
Action code
-
Action of controller
None in particular.
Problem that appears on machine
Oil pressure of work equipment pump cannot be monitored.
Related information
State of work equipment pump oil pressure sensor can be checked with monitoring function. (Code: 70701 Hydraulic Pressure Sensor 1)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DB95KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each YES case. •
2
HHP Work equipPower supply ment oil pres- Between (B) – (A) sure sensor Between (C) – (A) Signal
Voltage 4.5 – 5.5 V 0.5 – 6.0 V NO
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
The state of the work equipment oil pressure sensor is normal. Proceed to the next check item.
• The work equipment oil pressure sensor is defective. • Replace the work equipment oil pressure sensor. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 3
Hot short in wiring harness Wiring harness between STC1 (female) (20) – HHP (female) (C) and chassis ground
D155A-6
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
47
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
48
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DK10KX]
1
Contents of trouble
Signal voltage of fuel control dial is out of normal range.
Action code
E03
Action of controller
• Continues control with signal of decelerator pedal potentiometer. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of fuel control dial signal can be checked with monitoring function. (Code: 03000 Fuel Dial Sensor)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply sysYES tem is normal. • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the fuel a Prepare with starting switch OFF, then carry out troublecontrol dial is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Fuel control dial
DIAL (male)
Resistance
Between (1) – (3)
4.0 – 6.0 kz
Between (1) – (2)
0.25 – 7.0 kz
Between (2) – (3)
0.25 – 7.0 kz
NO
• The fuel control dial is defective. • Replace the fuel control dial. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
Open circuit in wiring harness
D155A-6
Wiring harness between STC1 (female) (22) – DIAL (female) (1)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (1) – DIAL (female) (2)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (21) – DIAL (female) (3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
49
SEN03208-03
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC1 (female) (22) – DIAL (female) (1) or circuit branch end and chassis ground
Resistance
Wiring harness between STC1 (female) (1) – DIAL (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch harness. YES ON and carry out troubleshooting. • Proceed to the next check item.
5
Hot short in wiring harness
Wiring harness between STC1 (female) (22) – DIAL (female) (1) or cir- Voltage cuit branch end and chassis ground
Max. 1 V
Wiring harness between STC1 (female) (1) – DIAL (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between STC1 (female) (21) – DIAL (female) (3) or cir- Voltage cuit branch end and chassis ground
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
50
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Related circuit diagram
D155A-6
51
SEN03208-03
40 Troubleshooting
Failure code [DK30KA]
1
Contents of trouble
Signal voltage of PCCS lever steering potentiometer 1 system is below 0.5 V.
Action code
E03
Action of controller
• Continues control with signal of PCCS lever steering potentiometer 2 system. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever steering potentiometer 1 signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the PCCS lever steering potentia Prepare with starting switch OFF, then carry out troubleometer 1 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
PCCS lever steering potentiometer 1
TLV1 (male)
PCCS lever
Resistance
Between (5) – (8)
3.2 kz ± 20%
Between (5) – (7)
6 – 1 kz NO
During steering operation Between (7) – (8)
1 – 6 kz
• The PCCS lever steering potentiometer 1 is defective. • Replace the PCCS lever steering potentiometer 1. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
52
Open circuit in wiring harness
Wiring harness between STC1 (female) (22) – TLV1 (female) (5)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (2) – TLV1 (female) (7)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC1 (female) (2) – TLV1 (female) (7) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in steering direction). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
53
SEN03208-03
40 Troubleshooting
Failure code [DK30KB]
1
Contents of trouble
Signal voltage of PCCS lever steering potentiometer 1 system is above 4.5 V.
Action code
E03
Action of controller
• Continues control with signal of PCCS lever steering potentiometer 2 system. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever steering potentiometer 1 signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the PCCS lever steering potentia Prepare with starting switch OFF, then carry out troubleometer 1 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
PCCS lever steering potentiometer 1
TLV1 (male)
PCCS lever
Resistance
Between (5) – (8)
3.2 kz ± 20%
Between (5) – (7)
6 – 1 kz NO
During steering operation Between (7) – (8)
1 – 6 kz
• The PCCS lever steering potentiometer 1 is defective. • Replace the PCCS lever steering potentiometer 1. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 3
Hot short in wiring harness Wiring harness between STC1 (female) (2) – TLV1 (female) (7) and chassis ground
54
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in steering direction). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
55
SEN03208-03
40 Troubleshooting
Failure code [DK30KX]
1
Contents of trouble
In PCCS lever steering potentiometer 1 and 2 systems, either of failure codes [DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
Action code
E04
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever steering potentiometer signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Confirmation of repair
1. 2. 3. 4. 5.
2
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in steering direction). Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Failure code [DK30KZ]
1
Contents of trouble
In PCCS lever steering potentiometer 1 and 2 systems, when starting switch is turned ON, only either side is abnormal and then either of failure codes [DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
Action code
E04
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
State of PCCS lever steering potentiometer signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Confirmation of repair
1. 2. 3. 4. 5.
2
56
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in steering direction). Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DK30L8]
1
Contents of trouble
In PCCS lever steering potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V or above 5.59 V.
Action code
E03
Action of controller
• Continues control with signal of normal one of PCCS lever steering potentiometer 1 and 2 systems. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever steering potentiometer signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Confirmation of repair
1. 2. 3. 4. 5.
2
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in steering direction). Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
57
SEN03208-03
40 Troubleshooting
Failure code [DK31KA]
1
Contents of trouble
Signal voltage of PCCS lever steering potentiometer 2 system is below 0.5 V.
Action code
E03
Action of controller
• Continues control with signal of PCCS lever steering potentiometer 1 system. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever steering potentiometer 2 signal can be checked with monitoring function. (Code: 50301 S/T Lever 2 Potentio)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the PCCS lever steering potentia Prepare with starting switch OFF, then carry out troubleometer 2 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
PCCS lever steering potentiometer 2
TLV1 (male)
PCCS lever
Resistance
Between (5) – (8)
3.2 kz ± 20%
Between (5) – (6)
6 – 1 kz NO
During steering operation Between (6) – (8)
1 – 6 kz
• The PCCS lever steering potentiometer 2 is defective. • Replace the PCCS lever steering potentiometer 2. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
58
Open circuit in wiring harness
Wiring harness between STC1 (female) (22) – TLV1 (female) (5)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (19) – TLV1 (female) (6)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC1 (female) (19) – TLV1 (female) (6) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in steering direction). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
59
SEN03208-03
40 Troubleshooting
Failure code [DK31KB]
1
Contents of trouble
Signal voltage of PCCS lever steering potentiometer 2 system is above 4.5 V.
Action code
E03
Action of controller
• Continues control with signal of PCCS lever steering potentiometer 1 system. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever steering potentiometer 2 signal can be checked with monitoring function. (Code: 50301 S/T Lever 2 Potentio)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the PCCS lever steering potentia Prepare with starting switch OFF, then carry out troubleometer 2 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
PCCS lever steering potentiometer 2
TLV1 (male)
PCCS lever
Resistance
Between (5) – (8)
3.2 kz ± 20%
Between (5) – (6)
6 – 1 kz NO
During steering operation Between (6) – (8)
1 – 6 kz
• The PCCS lever steering potentiometer 2 is defective. • Replace the PCCS lever steering potentiometer 2. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 3
Hot short in wiring harness Wiring harness between STC1 (female) (19) – TLV1 (female) (6) and chassis ground
60
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in steering direction). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
61
SEN03208-03
40 Troubleshooting
Failure code [DK40KA]
1
Contents of trouble
Signal voltage of brake pedal potentiometer is below 0.5 V.
Action code
E03
Action of controller
Cannot recognize brake pedal position.
Problem that appears on machine
Auto shift-down function may not operate normally.
Related information
State of brake pedal potentiometer signal can be checked with monitoring function. (Code: 50400 Brake Pedal Potentio)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the brake pedal potentiometer is a Prepare with starting switch OFF, then carry out troublenormal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Brake pedal potentiometer
BRK (male)
Resistance
Between (C) – (A)
4.0 – 6.0 kz
Between (B) – (A)
0.25 – 7.0 kz NO
Between (B) – (C)
0.25 – 7.0 kz
• The brake pedal potentiometer is defective. • Replace the brake pedal potentiometer. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
62
Open circuit in wiring harness
Wiring harness between STC1 (female) (21) – BRK (female) (A)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (3) – BRK (female) (B)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (22) – BRK (female) (C)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC1 (female) (3) – BRK (female) (B) and chassis ground
Resistance
Wiring harness between STC1 (female) (22) – BRK (female) (C) or circuit branch end and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the brake pedal. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
63
SEN03208-03
40 Troubleshooting
Failure code [DK40KB]
1
Contents of trouble
Signal voltage of brake pedal potentiometer is above 4.5 V.
Action code
E03
Action of controller
Cannot recognize brake pedal position.
Problem that appears on machine
Auto shift-down function may not operate normally.
Related information
State of brake pedal potentiometer signal can be checked with monitoring function. (Code: 50400 Brake Pedal Potentio)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the brake pedal potentiometer is a Prepare with starting switch OFF, then carry out troublenormal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
Brake pedal potentiometer
BRK (male)
Resistance
Between (C) – (A)
4.0 – 6.0 kz
Between (B) – (A)
0.25 – 7.0 kz NO
Between (B) – (C)
0.25 – 7.0 kz
• The brake pedal potentiometer is defective. • Replace the brake pedal potentiometer. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 3
Hot short in wiring harness
Wiring harness between STC1 (female) (3) – BRK (female) (B) and chassis ground
Voltage
Wiring harness between STC1 (female) (22) – BRK (female) (C) or cir- Voltage cuit branch end and chassis ground
64
Max. 1 V NO Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the brake pedal. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
65
SEN03208-03
40 Troubleshooting
Failure code [DK55KX]
1
Contents of trouble
In PCCS lever F-R potentiometer 1 and 2 systems, either of failure codes [DK56KA] and [DK56KB] and either of failure codes [DK57KA] and [DK57KB] occurred simultaneously.
Action code
E04
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
State of PCCS lever F-R potentiometer signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
Confirmation of repair
1. 2. 3. 4. 5.
2
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in F-R direction). Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Failure code [DK55KZ]
1
Contents of trouble
In PCCS lever F-R potentiometer 1 and 2 systems, when starting switch is turned ON, only either side is abnormal and then either of failure codes [DK56KA] and [DK56KB] and either of failure codes [DK57KA] and [DK57KB] occurred simultaneously.
Action code
E04
Action of controller
Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
State of PCCS lever F-R potentiometer signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
Confirmation of repair
1. 2. 3. 4. 5.
2
66
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in F-R direction). Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03208-03
Failure code [DK55L8]
1
Contents of trouble
In PCCS lever F-R potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V or above 5.59 V.
Action code
E03
Action of controller
• Continues control with signal of normal one of PCCS lever F-R potentiometer 1 and 2 systems. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever F-R potentiometer signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio)
No.
Check item
1
Related failure code(s)
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
Confirmation of repair
1. 2. 3. 4. 5.
2
D155A-6
Procedure of troubleshooting
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in F-R direction). Is this failure code displayed?
Judgment and remedy -
• The repair is completed. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
67
SEN03208-03
40 Troubleshooting
Failure code [DK56KA]
1
Contents of trouble
Signal voltage of PCCS lever F-R potentiometer 1 system is below 0.5 V.
Action code
E03
Action of controller
• Continues control with signal of PCCS lever F-R potentiometer 2 system. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever F-R potentiometer 1 signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the PCCS lever F-R potentiomea Prepare with starting switch OFF, then carry out troubleter 1 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
PCCS lever F-R potentiometer 1
TLV1 (male)
PCCS lever
Resistance
Between (4) – (1)
3.2 kz ± 20%
Between (4) – (3)
6 – 1 kz NO
During steering operation Between (3) – (1)
1 – 6 kz
• The PCCS lever F-R potentiometer 1 is defective. • Replace the PCCS lever F-R potentiometer 1. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
68
Open circuit in wiring harness
Wiring harness between STC1 (female) (22) – TLV1 (female) (4)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (13) – TLV1 (female) (3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
Wiring harness between STC1 (female) (13) – TLV1 (female) (3) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in F-R direction). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
69
SEN03208-03
40 Troubleshooting
Failure code [DK56KB]
1
Contents of trouble
Signal voltage of PCCS lever F-R potentiometer 1 system is above 4.5 V.
Action code
E03
Action of controller
• Continues control with signal of PCCS lever F-R potentiometer 2 system. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever F-R potentiometer 1 signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the sensor 5 V power supply system is normal. YES • Proceed to the next check item.
1
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the PCCS lever F-R potentiomea Prepare with starting switch OFF, then carry out troubleter 1 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
PCCS lever F-R potentiometer 1
TLV1 (male)
PCCS lever
Resistance
Between (4) – (1)
3.2 kz ± 20%
Between (4) – (3)
6 – 1 kz NO
During steering operation Between (3) – (1)
1 – 6 kz
• The PCCS lever F-R potentiometer 1 is defective. • Replace the PCCS lever F-R potentiometer 1. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. 3
Hot short in wiring harness Wiring harness between STC1 (female) (13) – TLV1 (female) (3) and chassis ground
70
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03208-03
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in F-R direction). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
71
SEN03208-03
40 Troubleshooting
D155A-6 Bulldozer Form No. SEN03208-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
72
D155A-6
SEN03209-01
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
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
SEN03209-01
40 Troubleshooting
Failure code [DXH4KB] ................................................................................................................................. 32 Failure code [DXH4KY] ................................................................................................................................. 34 Failure code [DXH5KA] ................................................................................................................................. 36 Failure code [DXH5KB] ................................................................................................................................. 38 Failure code [DXH5KY] ................................................................................................................................. 40 Failure code [DXH6KA] ................................................................................................................................. 42 Failure code [DXH6KB] ................................................................................................................................. 44 Failure code [DXH6KY] ................................................................................................................................. 46 Failure code [DXH7KA] ................................................................................................................................. 48 Failure code [DXH7KB] ................................................................................................................................. 50 Failure code [DXH7KY] ................................................................................................................................. 52 Failure code [DXH8KA] ................................................................................................................................. 54 Failure code [DXH8KB] ................................................................................................................................. 56 Failure code [DXH8KY] ................................................................................................................................. 58 Failure code [DXH9KA] ................................................................................................................................. 60 Failure code [DXH9KB] ................................................................................................................................. 62 Failure code [DXH9KY] ................................................................................................................................. 64 Failure code [DXHAKA]................................................................................................................................. 66 Failure code [DXHAKB]................................................................................................................................. 68 Failure code [DXHAKY]................................................................................................................................. 70 Failure code [DXHBKA]................................................................................................................................. 72 Failure code [DXHBKB]................................................................................................................................. 74 Failure code [DXHBKY]................................................................................................................................. 76 Failure code [DXHCKA] ................................................................................................................................ 78 Failure code [DXHCKB] ................................................................................................................................ 80 Failure code [DXHCKY] ................................................................................................................................ 82 Failure code [DXJ4KA].................................................................................................................................. 84 Failure code [DXJ4KB].................................................................................................................................. 86
2
D155A-6
40 Troubleshooting
SEN03209-01
1
D155A-6
3
SEN03209-01
40 Troubleshooting
Failure code [DK57KA]
1
Contents of trouble
Signal voltage of PCCS lever F-R potentiometer 2 system is below 0.5 V.
Action code
E03
Action of controller
• Continues control with signal of PCCS lever F-R potentiometer 1 system. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever F-R potentiometer 2 signal can be checked with monitoring function. (Code: 50201 T/M Lever 2 Potentio)
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system
• The state of the sensor 5 V power supply sysYES tem is normal. • Proceed to the next check item.
NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the PCCS lever F-R potentiomea Prepare with starting switch OFF, then carry out troubleter 2 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
PCCS lever F-R potentiometer 2
TLV1 (male)
PCCS lever
Resistance
Between (4) – (1)
3.2 kz ± 20%
Between (4) – (2)
3.2 kz ± 20% NO
Neutral Between (2) – (1)
3
4
Open circuit in wiring harness
3.2 kz ± 20%
• The PCCS lever F-R potentiometer 2 is defective. • Replace the PCCS lever F-R potentiometer 2. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC1 (female) (22) – TLV1 (female) (4)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (7) – TLV1 (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
4
SEN03209-01
Check item
Ground fault in wiring harness
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC1 (female) (7) – TLV1 (female) (2) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in F-R direction). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
5
SEN03209-01
40 Troubleshooting
Failure code [DK57KB]
1
Contents of trouble
Signal voltage of PCCS lever F-R potentiometer 2 system is above 4.5 V.
Action code
E03
Action of controller
• Continues control with signal of PCCS lever F-R potentiometer 1 system. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of PCCS lever F-R potentiometer 2 signal can be checked with monitoring function. (Code: 50201 T/M Lever 2 Potentio)
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor 5 V If failure code [DBE7KK] is also displayed, carry out troublepower supply shooting for it first. system
• The state of the sensor 5 V power supply sysYES tem is normal. • Proceed to the next check item.
NO
• The sensor 5 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the PCCS lever F-R potentiomea Prepare with starting switch OFF, then carry out troubleter 2 is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
PCCS lever F-R potentiometer 2
TLV1 (male)
PCCS lever
Resistance
Between (4) – (1)
3.2 kz ± 20%
Between (4) – (2)
3.2 kz ± 20% NO
Neutral Between (2) – (1)
3
6
Hot short in wiring harness
3.2 kz ± 20%
• The PCCS lever F-R potentiometer 2 is defective. • Replace the PCCS lever F-R potentiometer 2. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC1 (female) (7) – TLV1 (female) (2) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03209-01
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
4
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the PCCS lever (in F-R direction). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
7
SEN03209-01
40 Troubleshooting
Failure code [DKH1KA]
1
Contents of trouble
Signal voltage of pitch angle sensor is below 0.5 V.
Action code
E03
Action of controller
• Cannot sense pitch angle of machine. • Limits operation of engine and transmission.
Problem that appears on machine
• Gearshift shock is made on slope or steering shock is made on level ground. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of pitch angle sensor signal can be checked with monitoring function. (Code: 60100 Pitch Angle Sensor)
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor 24 V If failure code [DBE6KK] is also displayed, carry out troublepower supply shooting for it first. system
• The state of the sensor 24 V power supply system is normal. YES • Proceed to the next check item.
NO
• The sensor 24 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the pitch angle sensor is nora Prepare with starting switch OFF, then turn starting switch mal. YES ON and carry out troubleshooting. • Proceed to the next check item. 2
Pitch angle sensor
PT1
Voltage
Between (C) – (A)
Power supply
20 – 30 V
Between (B) – (A)
Signal
0.15 – 4.85 V
NO
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
• The pitch angle sensor is defective. • Replace the pitch angle sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item. 3
8
Open circuit in wiring harness
Wiring harness between STC1 (female) (21) – PT1 (female) (A)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (8) – PT1 (female) (B)
Resistance
Max. 1 z
Wiring harness between STC1 (female) (16) – PT1 (female) (C)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
4
SEN03209-01
Check item
Ground fault in wiring harness
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC1 (female) (8) – PT1 (female) (B) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
9
SEN03209-01
40 Troubleshooting
Failure code [DKH1KB]
1
Contents of trouble
Signal voltage of pitch angle sensor is above 4.85 V.
Action code
E03
Action of controller
• Cannot sense pitch angle of machine. • Limits operation of engine and transmission.
Problem that appears on machine
• Gearshift shock is made on slope or steering shock is made on level ground. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
State of pitch angle sensor signal can be checked with monitoring function. (Code: 60100 Pitch Angle Sensor)
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
Sensor 24 V If failure code [DBE6KK] is also displayed, carry out troublepower supply shooting for it first. system
• The state of the sensor 24 V power supply system is normal. YES • Proceed to the next check item.
NO
• The sensor 24 V power supply system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the pitch angle sensor is nora Prepare with starting switch OFF, then turn starting switch mal. YES ON and carry out troubleshooting. • Proceed to the next check item. 2
Pitch angle sensor
PT1
Voltage
Between (C) – (A)
Power supply
20 – 30 V
Between (B) – (A)
Signal
0.15 – 4.85 V
NO
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
3
Hot short in wiring harness
• The pitch angle sensor is defective. • Replace the pitch angle sensor. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC1 (female) (8) – PT1 (female) (B) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
10
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
5
Confirmation of repair
SEN03209-01
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
11
SEN03209-01
40 Troubleshooting
Failure code [DLT3KA]
1
Contents of trouble
No signal is input from transmission bevel speed sensor.
Action code
E01
Action of controller
Recognizes that transmission bevel speed is 0 rpm.
Problem that appears on machine
• Transmission bevel speed cannot be monitored. • Traction force cannot be calculated.
Related information
Transmission bevel speed can be checked with monitoring function. (Code: 31400 T/M Out Speed)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the transmission bevel speed a Prepare with starting switch OFF, then carry out troubleYES sensor is normal. shooting without turning starting switch ON. • Proceed to the next check item. 1
Transmission bevel speed sensor
BVRV (male)
Resistance
Between (1) – (2)
500 – 1,000 z NO
Between (1) – chassis ground
2
3
Open circuit in wiring harness
Ground fault in wiring harness
Min. 1 Mz
• The transmission bevel speed sensor is defective. • Replace the transmission bevel speed sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC2 (female) (30) – BVRV (female) (1)
Resistance
Max. 1 z
Wiring harness between STC2 (female) (29) – BVRV (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (30) – BVRV (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
12
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Drive the machine (drive machine actually or with no load). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
13
SEN03209-01
40 Troubleshooting
Failure code [DLT3KB]
1
Contents of trouble
No signal is input from transmission bevel speed sensor.
Action code
E01
Action of controller
Recognizes that transmission bevel speed is 0 rpm.
Problem that appears on machine
• Transmission bevel speed cannot be monitored. • Traction force cannot be calculated.
Related information
Transmission bevel speed can be checked with monitoring function. (Code: 31400 T/M Out Speed)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the transmission bevel speed a Prepare with starting switch OFF, then carry out troubleYES sensor is normal. shooting without turning starting switch ON. • Proceed to the next check item. 1
Transmission bevel speed sensor
BVRV (male)
Resistance
Between (1) – (2)
500 – 1,000 z NO
Between (1) – chassis ground
2
3
Open circuit in wiring harness
Ground fault in wiring harness
Min. 1 Mz
• The transmission bevel speed sensor is defective. • Replace the transmission bevel speed sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC2 (female) (30) – BVRV (female) (1)
Resistance
Max. 1 z
Wiring harness between STC2 (female) (29) – BVRV (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC2 (female) (30) – BVRV (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
14
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Drive the machine (drive machine actually or with no load). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
15
SEN03209-01
40 Troubleshooting
Failure code [DW7BKA]
1
Contents of trouble
When signal is output to fan reverse solenoid circuit, no current flows.
Action code
E01
Action of controller
Turns signal to fan reverse solenoid circuit OFF.
Problem that appears on machine
Fan reverse function cannot be used.
Related information
Operating condition of fan reverse solenoid can be checked with monitoring function. (Code: 40909 T/M Output 1)
No.
1
2
3
Check item
Fan reverse solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the fan reverse solenoid is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. FAR (male)
Resistance
Between (1) – (2)
34 – 44 z
NO
• The fan reverse solenoid is defective. • Replace the fan reverse solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (18) – FAR (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (13) – FAR (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (18) – FAR (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
16
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Select fan reverse mode. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
17
SEN03209-01
40 Troubleshooting
Failure code [DW7BKB]
1
Contents of trouble
When signal was output to fan reverse solenoid circuit, abnormal current flowed.
Action code
E01
Action of controller
Turns signal to fan reverse solenoid circuit OFF.
Problem that appears on machine
Fan reverse function cannot be used.
Related information
Operating condition of fan reverse solenoid can be checked with monitoring function. (Code: 40909 T/M Output 1)
No.
1
Check item
Fan reverse solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the fan reverse solenoid is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. FAR (male)
Resistance
Between (1) – (2)
34 – 44 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Ground fault in wiring harness
• The fan reverse solenoid is defective. • Replace the fan reverse solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (18) – FAR (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (18) – FAR (female) (1) and between STC3 (female) (13) – FAR (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
18
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Select fan reverse mode. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
19
SEN03209-01
40 Troubleshooting
Failure code [DWN3KA]
1
Contents of trouble
When signal is output to sudden stop prevent solenoid circuit, no current flows.
Action code
E04
Action of controller
Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to sudden stop prevent solenoid can be checked with monitoring function. (Code: 31628 SSP Solenoid)
No.
1
2
3
Check item
Sudden stop prevent solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the sudden stop prevent solea Prepare with starting switch OFF, then carry out troubleYES noid is normal. shooting without turning starting switch ON. • Proceed to the next check item. SSP (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
NO
• The sudden stop prevent solenoid is defective. • Replace the sudden stop prevent solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (7) – SSP (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (23) – SSP (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (7) – SSP (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
20
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
5
Confirmation of repair
SEN03209-01
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
21
SEN03209-01
40 Troubleshooting
Failure code [DWN3KB]
1
Contents of trouble
When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
Action code
E04
Action of controller
Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to sudden stop prevent solenoid can be checked with monitoring function. (Code: 31628 SSP Solenoid)
No.
1
Check item
Sudden stop prevent solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the sudden stop prevent solea Prepare with starting switch OFF, then carry out troubleYES noid is normal. shooting without turning starting switch ON. • Proceed to the next check item. SSP (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z NO
Between (1) – chassis ground
2
Ground fault in wiring harness
Min. 1 Mz
• The sudden stop prevent solenoid is defective. • Replace the sudden stop prevent solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
Wiring harness between STC3 (female) (7) – SSP (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (7) – SSP (female) (1) and between STC3 (female) (23) – SSP (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
22
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
23
SEN03209-01
40 Troubleshooting
Failure code [DWN3KY]
1
Contents of trouble
When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
Action code
E04
Action of controller
Limits operation of engine, transmission, and brake.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to sudden stop prevent solenoid can be checked with monitoring function. (Code: 31628 SSP Solenoid)
No.
1
Check item
Sudden stop prevent solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the sudden stop prevent solea Prepare with starting switch OFF, then carry out troubleYES noid is normal. shooting without turning starting switch ON. • Proceed to the next check item. SSP (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z NO
Between (1) – chassis ground
2
Hot short in wiring harness
Min. 1 Mz
• The sudden stop prevent solenoid is defective. • Replace the sudden stop prevent solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (7) – SSP (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (7) – SSP (female) (1) and between STC3 (female) (23) – SSP (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
24
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
5
Confirmation of repair
SEN03209-01
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
25
SEN03209-01
40 Troubleshooting
Failure code [DWN5KA]
1
Contents of trouble
When signal is output to fan pump EPC solenoid circuit, no current flows.
Action code
E01
Action of controller
Turns signal to fan pump EPC solenoid circuit OFF.
Problem that appears on machine
Fan speed is kept at maximum.
Related information
• If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed. • Output to fan pump EPC solenoid can be checked with monitoring function. (Code: 31624 Fan pump Solenoid (F/B))
No.
1
2
3
Check item
Fan pump EPC solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the fan pump EPC solenoid is a Prepare with starting switch OFF, then carry out troublenormal. YES shooting without turning starting switch ON. • Proceed to the next check item. FAC (male)
Resistance
Between (1) – (2)
2 – 12 z
NO
• The fan pump EPC solenoid is defective. • Replace the fan pump EPC solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (36) – FAC (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (23) – FAC (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (36) – FAC (female) (1) end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
26
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
5
Confirmation of repair
SEN03209-01
Procedure of troubleshooting 1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
27
SEN03209-01
40 Troubleshooting
Failure code [DWN5KB]
1
Contents of trouble
When signal was output to fan pump EPC solenoid circuit, abnormal current flowed.
Action code
E01
Action of controller
Turns signal to fan pump EPC solenoid circuit OFF.
Problem that appears on machine
Fan speed is kept at maximum.
Related information
• If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed. • Output to fan pump EPC solenoid can be checked with monitoring function. (Code: 31624 Fan pump Solenoid (F/B))
No.
1
Check item
Fan pump EPC solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the fan pump EPC solenoid is a Prepare with starting switch OFF, then carry out troublenormal. YES shooting without turning starting switch ON. • Proceed to the next check item. FAC (male)
Resistance
Between (1) – (2)
2 – 12 z NO
Between (1) – chassis ground
2
Ground fault in wiring harness
Min. 1 Mz
• The fan pump EPC solenoid is defective. • Replace the fan pump EPC solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
Wiring harness between STC3 (female) (36) – FAC (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (36) – FAC (female) (1) and between STC3 (female) (23) – FAC (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
28
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
29
SEN03209-01
40 Troubleshooting
Failure code [DXH4KA]
1
Contents of trouble
When signal is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
Action code
E03
Action of controller
• Turns signal to transmission 1st clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Auto shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2.
Related information
Output to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602 T/M Clutch 1st ECMV (F/B))
No.
1
2
3
Check item
1st clutch ECMV solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the 1st clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. S1T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
NO
• The 1st clutch ECMV solenoid is defective. • Replace the 1st clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (6) – S1T (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (23) – S1T (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (23) – S1T (female) (2) or circuit branch end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
30
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F1 or R1. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
31
SEN03209-01
40 Troubleshooting
Failure code [DXH4KB]
1
Contents of trouble
When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Turns signal to transmission 1st clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Auto shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2.
Related information
Output to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602 T/M Clutch 1st ECMV (F/B))
No.
1
Check item
1st clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the 1st clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleis normal. YES shooting without turning starting switch ON. • Proceed to the next check item. S1T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Ground fault in wiring harness
• The 1st clutch ECMV solenoid is defective. • Replace the 1st clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (6) – S1T (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (6) – S1T (female) (1) and between STC3 (female) (23) – S1T (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
32
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F1 or R1. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
33
SEN03209-01
40 Troubleshooting
Failure code [DXH4KY]
1
Contents of trouble
When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Turns signal to transmission 1st clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Auto shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2.
Related information
Output to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602 T/M Clutch 1st ECMV (F/B))
No.
1
Check item
1st clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the 1st clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. S1T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Hot short in wiring harness
• The 1st clutch ECMV solenoid is defective. • Replace the 1st clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (6) – S1T (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (6) – S1T (female) (1) and between STC3 (female) (23) – S1T (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
34
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F1 or R1. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
35
SEN03209-01
40 Troubleshooting
Failure code [DXH5KA]
1
Contents of trouble
When signal is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
Action code
E03
Action of controller
• Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Auto shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Output to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603 T/M Clutch 2nd ECMV (F/B))
No.
1
2
3
Check item
2nd clutch ECMV solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the 2nd clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. S2T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
NO
• The 2nd clutch ECMV solenoid is defective. • Replace the 2nd clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (16) – S2T (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (23) – S2T (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (23) – S2T (female) (2) or circuit branch end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
36
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F2 or R2. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
37
SEN03209-01
40 Troubleshooting
Failure code [DXH5KB]
1
Contents of trouble
When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Auto shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Output to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603 T/M Clutch 2nd ECMV (F/B))
No.
1
Check item
2nd clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the 2nd clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. S2T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Ground fault in wiring harness
• The 2nd clutch ECMV solenoid is defective. • Replace the 2nd clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (16) – S2T (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (16) – S2T (female) (1) and between STC3 (female) (23) – S2T (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
38
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F2 or R2. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
39
SEN03209-01
40 Troubleshooting
Failure code [DXH5KY]
1
Contents of trouble
When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Auto shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Output to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603 T/M Clutch 2nd ECMV (F/B))
No.
1
Check item
2nd clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the 2nd clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. S2T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Hot short in wiring harness
• The 2nd clutch ECMV solenoid is defective. • Replace the 2nd clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (16) – S2T (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (16) – S2T (female) (1) and between STC3 (female) (23) – S2T (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
40
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F2 or R2. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
41
SEN03209-01
40 Troubleshooting
Failure code [DXH6KA]
1
Contents of trouble
When signal is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
Action code
E03
Action of controller
• Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Output to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604 T/M Clutch 3rd ECMV (F/B))
No.
1
Check item
3rd clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the 3rd clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. S3T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
3
Open circuit in wiring harness
Hot short in wiring harness
• The 3rd clutch ECMV solenoid is defective. • Replace the 3rd clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (26) – S3T (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (23) – S3T (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (23) – S3T (female) (2) or circuit branch end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
42
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F3 or R3. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
43
SEN03209-01
40 Troubleshooting
Failure code [DXH6KB]
1
Contents of trouble
When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Output to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604 T/M Clutch 3rd ECMV (F/B))
No.
1
Check item
3rd clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the 3rd clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. S3T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Ground fault in wiring harness
• The 3rd clutch ECMV solenoid is defective. • Replace the 3rd clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (26) – S3T (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (26) – S3T (female) (1) and between STC3 (female) (23) – S3T (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
44
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F3 or R3. Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
45
SEN03209-01
40 Troubleshooting
Failure code [DXH6KY]
1
Contents of trouble
When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Output to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604 T/M Clutch 3rd ECMV (F/B))
No.
1
Check item
3rd clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the 3rd clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. S3T (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Hot short in wiring harness
• The 3rd clutch ECMV solenoid is defective. • Replace the 3rd clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (26) – S3T (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (26) – S3T (female) (1) and between STC3 (female) (23) – S3T (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
46
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F3 or R3. Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
47
SEN03209-01
40 Troubleshooting
Failure code [DXH7KA]
1
Contents of trouble
When signal is output to transmission R clutch ECMV solenoid circuit, no current flows.
Action code
E03
Action of controller
• Turns signal to transmission R clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1.
Related information
Output to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B))
No.
1
2
3
Check item
R clutch ECMV solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the R clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SRT (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
NO
• The R clutch ECMV solenoid is defective. • Replace the R clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (37) – SRT (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (13) – SRT (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (13) – SRT (female) (2) or circuit branch end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
48
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to R (Reverse). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
49
SEN03209-01
40 Troubleshooting
Failure code [DXH7KB]
1
Contents of trouble
When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Turns signal to transmission R clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1.
Related information
Output to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B))
No.
1
Check item
R clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the R clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SRT (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Ground fault in wiring harness
• The R clutch ECMV solenoid is defective. • Replace the R clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (37) – SRT (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (37) – SRT (female) (1) and between STC3 (female) (13) – SRT (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
50
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to R (Reverse). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
51
SEN03209-01
40 Troubleshooting
Failure code [DXH7KY]
1
Contents of trouble
When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E04
Action of controller
• Turns signal to transmission R clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1.
Related information
Output to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B))
No.
1
Check item
R clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the R clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SRT (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Hot short in wiring harness
• The R clutch ECMV solenoid is defective. • Replace the R clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (37) – SRT (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (37) – SRT (female) (1) and between STC3 (female) (13) – SRT (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
52
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to R (Reverse). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
53
SEN03209-01
40 Troubleshooting
Failure code [DXH8KA]
1
Contents of trouble
When signal is output to transmission F clutch ECMV solenoid circuit, no current flows.
Action code
E03
Action of controller
• Turns signal to transmission F clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1.
Related information
Output to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B))
No.
1
2
3
Check item
F clutch ECMV solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the F clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SFT (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
NO
• The F clutch ECMV solenoid is defective. • Replace the F clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (27) – SFT (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (13) – SFT (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (13) – SFT (female) (2) or circuit branch end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
54
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F (Forward). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
55
SEN03209-01
40 Troubleshooting
Failure code [DXH8KB]
1
Contents of trouble
When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Turns signal to transmission F clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1.
Related information
Output to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B))
No.
1
Check item
F clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the F clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SFT (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Ground fault in wiring harness
• The F clutch ECMV solenoid is defective. • Replace the F clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (27) – SFT (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (27) – SFT (female) (1) and between STC3 (female) (13) – SFT (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
56
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F (Forward). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
57
SEN03209-01
40 Troubleshooting
Failure code [DXH8KY]
1
Contents of trouble
When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
Action code
E04
Action of controller
• Turns signal to transmission F clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1.
Related information
Output to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B))
No.
1
Check item
F clutch ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the F clutch ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SFT (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Hot short in wiring harness
• The F clutch ECMV solenoid is defective. • Replace the F clutch ECMV solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (27) – SFT (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (27) – SFT (female) (1) and between STC3 (female) (13) – SFT (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
58
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Set gear to F (Forward). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
59
SEN03209-01
40 Troubleshooting
Failure code [DXH9KA]
1
Contents of trouble
When signal is output to right steering clutch solenoid circuit, current does not flow.
Action code
E03
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission.
Problem that appears on machine
• Machine cannot be steered to right. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Outputting to right steering clutch solenoid (Current) can be checked in real-time monitoring mode. (Code 90601: Right steering clutch ECMV (E-POCV) command current, output current)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the right steering clutch solea Prepare with starting switch OFF, then carry out troublenoid is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
2
Right steering clutch solenoid
Open circuit in wiring harness
SCLR (male)
Resistance
Between (1) – (2)
5 – 15 z
NO
• The right steering clutch solenoid is defective. • Replace the right steering clutch solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (35) – SCLR (female) (1)
Resistance
Wiring harness between STC3 (female) (3) – SCLR (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
60
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Release the parking brake lever. Operate PCCS lever (to steer to right). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
61
SEN03209-01
40 Troubleshooting
Failure code [DXH9KB]
1
Contents of trouble
When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission.
Problem that appears on machine
• Machine cannot be steered to right. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Outputting to right steering clutch solenoid (Current) can be checked in real-time monitoring mode. (Code 90601: Right steering clutch ECMV (E-POCV) command current, output current)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the right steering clutch solea Prepare with starting switch OFF, then carry out troubleYES noid is normal. shooting without turning starting switch ON. • Proceed to the next check item. 1
Right steering clutch solenoid
SCLR (male)
Resistance
Between (1) – (2)
5 – 15 z NO
Between (1) – chassis ground
Min. 1 Mz
• The right steering clutch solenoid is defective. • Replace the right steering clutch solenoid. • Proceed to "Confirmation of repair".
• No short circuit with chassis ground occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STC3 (female) (35) – SCLR (female) (1) with chassis ground
Resistance
Min. 1 Mz
NO
• A short circuit with chassis ground occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harShort circuit of wiring harness between ness STC3 (female) (35) – SCLR (female) (1) with wiring harness between STC3 (female) (3) – SCLR (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
62
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Release the parking brake lever. Operate PCCS lever (to steer to right). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
63
SEN03209-01
40 Troubleshooting
Failure code [DXH9KY]
1
Contents of trouble
Some current always flows into right steering clutch solenoid circuit.
Action code
E04
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission.
Problem that appears on machine
• Machine cannot be steered to right. (R clutch cannot be disengaged.) • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more.
Related information
Outputting to right steering clutch solenoid (Current) can be checked in real-time monitoring mode. (Code 90601: Right steering clutch ECMV (E-POCV) command current, output current)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the right steering clutch solea Prepare with starting switch OFF, then carry out troublenoid is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Right steering clutch solenoid
SCLR (male)
Resistance
Between (1) – (2)
5 – 15 z NO
Between (1) – chassis ground
2
Hot short in wiring harness
Min. 1 Mz
• The right steering clutch solenoid is defective. • Replace the right steering clutch solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. Short circuit of wiring harness between STC3 (female) (35) – SCLR (female) (1) with chassis ground Short circuit of wiring harness between STC3 (female) (3) – SCLR (female) (2) with chassis ground
Voltage
Max. 1 V NO
Voltage
Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
64
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Release the parking brake lever. Operate PCCS lever (to steer to right). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
65
SEN03209-01
40 Troubleshooting
Failure code [DXHAKA]
1
Contents of trouble
When signal is output to left steering clutch solenoid circuit, current does not flow.
Action code
E03
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission.
Problem that appears on machine
• Machine cannot be steered to left. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Outputting to left steering clutch solenoid (Current) can be checked in real-time monitoring mode. (Code 90600: Left steering clutch ECMV (E-POCV) command current, output current)
No.
1
2
Check item
Left steering clutch solenoid
Open circuit in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the left steering clutch solea Prepare with starting switch OFF, then carry out troublenoid is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. SCLL (male)
Resistance
Between (1) – (2)
5 – 15 z
NO
• The left steering clutch solenoid is defective. • Replace the left steering clutch solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item. Wiring harness between STC3 (female) (25) – SCLL (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (3) – SCLL (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
66
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Release the parking brake lever. Operate PCCS lever (to steer to left). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
67
SEN03209-01
40 Troubleshooting
Failure code [DXHAKB]
1
Contents of trouble
When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission.
Problem that appears on machine
• Machine cannot be steered to left. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
Outputting to left steering clutch solenoid (Current) can be checked in real-time monitoring mode. (Code 90600: Left steering clutch ECMV (E-POCV) command current, output current)
No.
1
Check item
Left steering clutch solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the left steering clutch solea Prepare with starting switch OFF, then carry out troubleYES noid is normal. shooting without turning starting switch ON. • Proceed to the next check item. SCLL (male)
Resistance
Between (1) – (2)
5 – 15 z NO
Between (1) – chassis ground
Min. 1 Mz
• The left steering clutch solenoid is defective. • Replace the left steering clutch solenoid. • Proceed to "Confirmation of repair".
• No short circuit with chassis ground occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STC3 (female) (25) – SCLL (female) (1) with chassis ground
Resistance
Min. 1 Mz
NO
• A short circuit with chassis ground occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harShort circuit of wiring harness between ness STC3 (female) (25) – SCLL (female) (1) with wiring harness between STC3 (female) (3) – SCLL (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
68
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Release the parking brake lever. Operate PCCS lever (to steer to left). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
69
SEN03209-01
40 Troubleshooting
Failure code [DXHAKY]
1
Contents of trouble
Some current always flows into left steering clutch solenoid circuit.
Action code
E04
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission.
Problem that appears on machine
• Machine cannot be steered to left. (L clutch cannot be disengaged.) • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more.
Related information
Outputting to left steering clutch solenoid (Current) can be checked in real-time monitoring mode. (Code 90600: Left steering clutch ECMV (E-POCV) command current, output current)
No.
1
Check item
Left steering clutch solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the left steering clutch solea Prepare with starting switch OFF, then carry out troublenoid is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. SCLL (male)
Resistance
Between (1) – (2)
5 – 15 z NO
Between (1) – chassis ground
2
Hot short in wiring harness
Min. 1 Mz
• The left steering clutch solenoid is defective. • Replace the left steering clutch solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. Short circuit of wiring harness between STC3 (female) (25) – SCLL (female) (1) Voltage with chassis ground Short circuit of wiring harness between STC3 (female) (3) – SCLL (female) (2) with chassis ground
Max. 1 V NO
Voltage
Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
70
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Release the parking brake lever. Operate PCCS lever (to steer to left). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
71
SEN03209-01
40 Troubleshooting
Failure code [DXHBKA]
1
Contents of trouble
When signal is output to steering case right brake ECMV solenoid circuit, no current flows.
Action code
E04
Action of controller
• Turns signal to steering case right brake ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to right brake ECMV solenoid can be checked with monitoring function. (Code: 31618 Brake RH ECMV (F/B))
No.
1
2
3
Check item
Right brake ECMV solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the right brake ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SBRR (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
NO
• The right brake ECMV solenoid is defective. • Replace the right brake ECMV solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (15) – SBRR (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (3) – SBRR (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (15) – SBRR (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
72
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever (Free). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
73
SEN03209-01
40 Troubleshooting
Failure code [DXHBKB]
1
Contents of trouble
When signal was output to steering case right brake ECMV solenoid circuit, abnormal current flowed.
Action code
E04
Action of controller
• Turns signal to steering case right brake ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to right brake ECMV solenoid can be checked with monitoring function. (Code: 31618 Brake RH ECMV (F/B))
No.
1
Check item
Right brake ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the right brake ECMV solenoid a Prepare with starting switch OFF, then carry out troubleis normal. YES shooting without turning starting switch ON. • Proceed to the next check item. SBRR (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Ground fault in wiring harness
• The right brake ECMV solenoid is defective. • Replace the right brake ECMV solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (15) – SBRR (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (15) – SBRR (female) (1) and between STC3 (female) (3) – SBRR (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
74
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever (Free). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
75
SEN03209-01
40 Troubleshooting
Failure code [DXHBKY]
1
Contents of trouble
When signal was output to steering case right brake ECMV solenoid circuit, abnormal current flowed.
Action code
E04
Action of controller
• Turns signal to steering case right brake ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to right brake ECMV solenoid can be checked with monitoring function. (Code: 31618 Brake RH ECMV (F/B))
No.
1
Check item
Right brake ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the right brake ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SBRR (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Hot short in wiring harness
• The right brake ECMV solenoid is defective. • Replace the right brake ECMV solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (15) – SBRR (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (15) – SBRR (female) (1) and between STC3 (female) (3) – SBRR (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
76
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever (Free). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
77
SEN03209-01
40 Troubleshooting
Failure code [DXHCKA]
1
Contents of trouble
When signal is output to steering case left brake ECMV solenoid circuit, no current flows.
Action code
E04
Action of controller
• Turns signal to steering case left brake ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to left brake ECMV solenoid can be checked with monitoring function. (Code: 31619 Brake LH ECMV (F/B))
No.
1
2
3
Check item
Left brake ECMV solenoid
Open circuit in wiring harness
Hot short in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the left brake ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SBRL (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
NO
• The left brake ECMV solenoid is defective. • Replace the left brake ECMV solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (5) – SBRL (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (3) – SBRL (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (5) – SBRL (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
78
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever (Free). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
79
SEN03209-01
40 Troubleshooting
Failure code [DXHCKB]
1
Contents of trouble
When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
Action code
E04
Action of controller
• Turns signal to steering case left brake ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to left brake ECMV solenoid can be checked with monitoring function. (Code: 31619 Brake LH ECMV (F/B))
No.
1
Check item
Left brake ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the left brake ECMV solenoid a Prepare with starting switch OFF, then carry out troubleis normal. YES shooting without turning starting switch ON. • Proceed to the next check item. SBRL (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Ground fault in wiring harness
• The left brake ECMV solenoid is defective. • Replace the left brake ECMV solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (5) – SBRL (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES • Proceed to the next shooting without turning starting switch ON. check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (5) – SBRL (female) (1) and between STC3 (female) (3) – SBRL (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
80
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever (Free). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
81
SEN03209-01
40 Troubleshooting
Failure code [DXHCKY]
1
Contents of trouble
When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
Action code
E04
Action of controller
• Turns signal to steering case left brake ECMV solenoid circuit OFF. • Limits operation of engine and transmission.
Problem that appears on machine
• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.
Related information
Output to left brake ECMV solenoid can be checked with monitoring function. (Code: 31619 Brake LH ECMV (F/B))
No.
1
Check item
Left brake ECMV solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the left brake ECMV solenoid a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. SBRL (male)
Resistance
Between (1) – (2)
3.5 – 12.5 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
Hot short in wiring harness
• The left brake ECMV solenoid is defective. • Replace the left brake ECMV solenoid. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (5) – SBRL (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harWiring harness between STC3 ness (female) (5) – SBRL (female) (1) and between STC3 (female) (3) – SBRL (female) (2)
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
82
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate the parking brake lever (Free). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
83
SEN03209-01
40 Troubleshooting
Failure code [DXJ4KA]
1
Contents of trouble
When signal is output to work equipment lock solenoid circuit, no current flows.
Action code
E03
Action of controller
Turns signal to work equipment lock solenoid circuit OFF.
Problem that appears on machine
Blade and ripper cannot be operated.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the work equipment lock solea Prepare with starting switch OFF, then carry out troubleYES noid is normal. shooting without turning starting switch ON. • Proceed to the next check item. 1
2
Work equipment lock solenoid
Open circuit in wiring harness
WLK (male)
Resistance
Between (1) – (2)
20 – 60 z
NO
• The work equipment lock solenoid is defective. • Replace the work equipment lock solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between STC3 (female) (8) – WLK (female) (1)
Resistance
Max. 1 z
Wiring harness between STC3 (female) (3) – WLK (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
84
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate work equipment lock lever (Free). Is this failure code displayed?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03209-01
Related circuit diagram
D155A-6
85
SEN03209-01
40 Troubleshooting
Failure code [DXJ4KB]
1
Contents of trouble
When signal was output to work equipment lock solenoid circuit, abnormal current flowed.
Action code
E03
Action of controller
Turns signal to work equipment lock solenoid circuit OFF.
Problem that appears on machine
Blade and ripper cannot be operated.
Related information
-
No.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the work equipment lock solea Prepare with starting switch OFF, then carry out troubleYES noid is normal. shooting without turning starting switch ON. • Proceed to the next check item. 1
Work equipment lock solenoid
WLK (male)
Resistance
Between (1) – (2)
20 – 60 z
Between (1) – chassis ground
Min. 1 Mz
NO
2
3
Ground fault in wiring harness
Hot short in wiring harness
• The work equipment lock solenoid is defective. • Replace the work equipment lock solenoid. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between STC3 (female) (8) – WLK (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between STC3 (female) (8) – WLK (female) (1) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
86
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
SEN03209-01
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Operate work equipment lock lever (Free). Is this failure code displayed?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
87
SEN03209-01
40 Troubleshooting
D155A-6 Bulldozer Form No. SEN03209-01
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
88
D155A-6
SEN03210-02
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
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 ....................................................... 9 E-2 When starting switch turned ON (before starting engine), basic check item lights up............................ 12 E-3 Engine does not start (Engine does not turn) ......................................................................................... 14 E-4 Preheater does not operate.................................................................................................................... 17 E-5 Precaution item lights up while engine is running .................................................................................. 21 E-6 Emergency stop item lights up while engine is running.......................................................................... 23 E-7 Engine coolant temperature gauge does not indicate normally ............................................................. 27 E-8 Fuel level gauge does not indicate normally .......................................................................................... 29 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 32 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 34 E-11 Contents of display by machine monitor are different from applicable machine................................... 37 E-12 Machine monitor does not display some items .................................................................................... 37
D155A-6
1
SEN03210-02
40 Troubleshooting
E-13 Function switch does not work ............................................................................................................. 38 E-14 Operation mode does not change ........................................................................................................ 39 E-15 Gearshift mode does not change ......................................................................................................... 40 E-16 Customize function does not operate normally .................................................................................... 41 E-17 Customize memory function does not operate normally ...................................................................... 42 E-18 Alarm buzzer cannot be stopped.......................................................................................................... 43 E-19 Air conditioner does not operate normally (including air conditioner fault history) ............................... 44 E-20 When starting switch is turned OFF, service meter is not displayed .................................................... 68 E-21 Machine monitor cannot be set in service mode .................................................................................. 68 E-22 Ripper pin puller cylinder does not operate .......................................................................................... 69 E-23 Backup alarm does not sound or does not stop ................................................................................... 71 E-24 Headlamp, rear lamp, and ripper point lamp do not light up................................................................. 73 E-25 Windshield wiper and window washer do not operate.......................................................................... 79 E-26 KOMTRAX terminal does not operate normally ................................................................................. 107 E-27 Fan does not reverse.......................................................................................................................... 109 E-28 Gear cannot be shifted ........................................................................................................................111 E-29 Electric priming pump does not operate or does not stop automatically .............................................112
2
D155A-6
40 Troubleshooting
SEN03210-02
Before carrying out troubleshooting for electrical system
1
Connection table of circuit breakers and fuse boxes a This connection table shows the devices to which each power supply of the fuse box supplies power (An accessory power supply is a device which supplies power while the starting switch is in the ON position and an unswitched power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers and fuses to see if the power is supplied normally. Circuit breakers CB1 – CB9 Power circuit breaker Circuit (Type of power supply) breaker No.
CB105 (Accessory power supply)
CB30 (Unswitched power supply)
Circuit breaker capacity
Destination of power
CB9
20A
Optional power supply
CB1
20A
CB2
20A
CB3
20A
Air conditioner unit, blower motor, and compressor electromagnetic clutch
CB4
20A
Headlamp, additional headlamp
CB5
20A
Rear lamp, additional rear lamp, ripper point lamp
CB6
20A
CB7
20A
Power train controller Emergency power supply (For power train switch box) Work equipment controller Emergency power supply (For work equipment switch box)
Starting switch Engine hold relay Machine monitor Power train controller Work equipment controller
CB8
30A
Engine controller, electric priming pump
—
—
Engine electrical intake air heater
Power circuit breaker (Type of power supply)
Fuse No.
Fuse capacity
CB30 (Unswitched power supply)
1
20A
Operator's cab power supply (To connection table of fuse box
2
5A
Backup alarm, backup alarm relay
3
20A
Operator's cab power supply (To connection table of fuse box
)
4
20A
Operator's cab power supply (To connection table of fuse box
)
5
5A
Engine controller (Signal ACC)
CB105H (Unswitched power supply)
Fuse box FS1
CB105 (Accessory power supply) Starting switch (ACC)
D155A-6
Destination of power
)
3
SEN03210-02
40 Troubleshooting
Fuse box FS2 Power circuit breaker (Type of power supply)
Fuse No.
Fuse capacity
CB30 (Unswitched power supply)
1
5A
Pedal brake solenoid valve
2
5A
Parking brake solenoid valve
CB105 (Accessory power supply)
Starting switch (ACC)
4
Destination of power
Engine electrical intake air heater 3
20A
Ripper pin puller solenoid valve
4
5A
Horn
5
20A
Optional power supply
Pneumatic suspension seat
D155A-6
40 Troubleshooting
SEN03210-02
Locations of circuit breakers CB30, CB105, and CB105H (In battery room)
Locations of circuit breakers CB1 – CB9 and fuse boxes FS1 and FS2 (In battery room)
D155A-6
5
SEN03210-02
40 Troubleshooting
Fuse box Power circuit fuse (Type of power supply) FS1-1 (Unswitched power supply) FS1-3 (Accessory power supply)
Fuse No.
Fuse capacity
Destination of power Radio
1
10A
12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter)
2
20A
3
20A
Additional light relay, additional light Rotary lamp 12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter) Radio
FS1-4 (Accessory power supply)
Location of fuse box
6
Room lamp
4
20A
5
10A
Front wiper, rear wiper
6
10A
Left wiper, right wiper
Cigarette lighter Windshield wiper (Via intermittent relay)
(In operator's cab)
D155A-6
40 Troubleshooting
SEN03210-02
Information in troubleshooting table
1
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information No.
Trouble which occurred in the machine Information related to detected trouble or troubleshooting
Check item
3
Judgment and remedy
<Contents of description> • Standard value in normal state to judge possible causes • Remarks on judgment
1
2
Procedure of troubleshooting
<Troubles in wiring harness> • Disconnection Connector is connected defectively or wiring harness is broken. Possible check items • Ground fault for troubleWiring harness which is not connected to chassis shooting ground circuit is in contact with chassis ground circuit. (Given num- • Hot short bers are refWiring harness which is not connected to power source erence (24 V) circuit is in contact with power source (24 V) cirnumbers, cuit. which do not • Short circuit indicate priIndependent wiring harnesses are in contact with each ority) other abnormally.
4
5
Reconfirmation of check item
6
Confirmation of repair
D155A-6
<Precautions for troubleshooting> (1) Method of indicating connector No. and handling of Tadapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. • 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.
YES
Remedy when criterion is judged to be "YES"
NO
Remedy when criterion is judged to be "NO"
7
SEN03210-02
40 Troubleshooting
Related circuit diagram This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (i o): Roughly shows the location on the machine.
8
D155A-6
40 Troubleshooting
SEN03210-02
E-1 When starting switch turned ON, machine monitor displays nothing 1 Trouble
Related information
No.
1
When starting switch turned ON, machine monitor displays nothing. • When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input password (if set), screen of check before starting, screen to check setting of preset, and ordinary screen in order. • When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however.
Check item
Charge level of battery
Procedure of troubleshooting
Judgment and remedy
• The state of the charge level of battery is nora Prepare with starting switch OFF, then carry out troubleYES mal. shooting without turning starting switch ON. • Proceed to the next check item. Battery voltage (2 pieces)
Electrolyte specific gravity (1 piece)
Min. 24 V
Min. 1.26
NO
• The charge level of battery is low. • Charge the battery. • Proceed to "Confirmation of repair".
• The state of the circuit breaker is normal. YES • Proceed to the next check item. 2
Circuit breaker
If circuit breaker (CB30, CB6, or CB7) is turned OFF, circuit probably has ground fault. (See check item 6). NO
3
Connector connection
Machine monitor connector may be connected wrongly. Check it (Connection between connectors CM01 and CM02 and between connectors CM03 and CM04).
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• The state of the connector connection is YES normal. • Proceed to the next check item.
NO
• The connector connection is defective. • Reconnect or replace the connector. • Proceed to "Confirmation of repair".
• The state of the starting switch is normal. a Prepare with starting switch OFF, then turn starting switch YES ON and carry out troubleshooting. • Proceed to the next check item. 4
Starting switch
Starting switch
Between 250 – 270
D155A-6
Resistance
ON
Max. 1 z
NO
• The starting switch is defective. • Replace the starting switch. • Proceed to "Confirmation of repair".
9
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
5
Open circuit in wiring harness
Wiring harness between battery (–) – chassis ground
Resistance
Max. 1 z
Wiring harness between battery (+) – terminal BRB – CB30 (B30L)
Resistance
Max. 1 z
Wiring harness between CB30 (B30S) – CB7 (1)
Resistance
Max. 1 z
Wiring harness between CB7 (2) – CM01 (female) (1), (2)
Resistance
Max. 1 z
Wiring harness between CM01 (female) (3), (4) – chassis ground (GND11)
Resistance
Max. 1 z
Wiring harness between CB30 (B30S) – CB6 (1)
Resistance
Max. 1 z
Wiring harness between CB6 (2) – terminal 250
Resistance
Max. 1 z
Wiring harness between terminal 270 – CM01 (female) (14)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
6
Ground fault in wiring harness
Wiring harness between battery (+) – terminal BRB – CB30 (B30L) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB30 (B30S) – CB7 (1) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB7 (2) – CM01 (female) (1), (2) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB30 (B30S) – CB6 (1) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB6 (2) – terminal 250 or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between terminal 270 – CM01 (female) (14) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
7
8
10
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
Related circuit diagram
D155A-6
11
SEN03210-02
40 Troubleshooting
E-2 When starting switch turned ON (before starting engine), basic check item lights up Trouble
When starting switch turned ON (before starting engine), basic check item lights up.
Related information
Basic check item is only lowering of radiator coolant level.
No.
Check item
Procedure of troubleshooting
1
Judgment and remedy • The state of the radiator coolant level is norYES mal. • Proceed to the next check item.
1
Radiator cool- Coolant level in radiator sub tank may be low. Check it and add ant level coolant if necessary. NO
2
Radiator coolant level switch
• The state of the radiator coolant level switch a Prepare with starting switch OFF, then carry out troubleYES is normal. shooting without turning starting switch ON. • Proceed to the next check item. WLV (male)
Sub tank coolant level
Resistance
Between FULL – LOW
Max. 1 z
Below LOW
Min. 1 Mz
NO
Between (1) – (2)
3
Open circuit in wiring harness
• The radiator coolant level is not appropriate. • Replenish the radiator coolant. • Proceed to "Confirmation of repair".
• The radiator coolant level switch is defective. • Replace the radiator coolant level switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CM02 (female) (3) – WLV (female) (1)
Resistance
Wiring harness between CM01 (female) (7), CM02 (female) (7) – WLV (female) (2)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
12
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
Related circuit diagram
D155A-6
13
SEN03210-02
40 Troubleshooting
E-3 Engine does not start (Engine does not turn) Trouble Related information
No.
1
1
Engine does not start (Engine does not turn). Engine starting circuit has following 2 start lock mechanisms. 1) Start lock with password of machine monitor 2) Start lock with parking brake lever and work equipment lock lever
Check item
Charge level of battery
Procedure of troubleshooting
Judgment and remedy
• The state of the charge level of battery is nora Prepare with starting switch OFF, then carry out troubleYES mal. shooting without turning starting switch ON. • Proceed to the next check item. Battery voltage (2 pieces)
Electrolyte specific gravity (1 piece)
Min. 24 V
Min. 1.26
NO
• The charge level of battery is low. • Charge the battery. • Proceed to "Confirmation of repair".
• The state of the starta Prepare with starting switch OFF, then keep starting switch ing switch is normal. OFF and turn it to START and carry out troubleshooting in YES • Proceed to the next each case. check item. 2
Starting switch
Starting switch
Resistance OFF
Between 250 – 280
Min. 1 Mz NO
START
Max. 1 z
• The starting switch is defective. • Replace the starting switch. • Proceed to "Confirmation of repair".
• The state of the neutral safety relay is normal. a Prepare with starting switch OFF, then turn starting switch to YES START and carry out troubleshooting. • Proceed to the next check item. 3
Neutral safety relay Replace neutral safety relay (Right No.) with another relay. If engine starts at this time, neutral safety relay is defective.
NSF
NO
• The neutral safety relay is defective. • Replace the neutral safety relay. • Proceed to "Confirmation of repair".
• The state of the starting motor is normal. a Prepare with starting switch OFF, then turn starting switch to YES START and carry out troubleshooting. • Proceed to the next check item. Starting motor 4
Starting motor
Voltage
Between B – chassis ground
Battery power supply
20 – 30 V
Between ST (2) – chassis ground
Starting signal
20 – 30 V
Between ST (2) – chassis ground
Generation signal
NO Max. 13 V
If battery power supply, starting signal, and generation signal are normal but starting motor does not turn, starting motor is defective.
14
• The starting motor is defective. • Replace the starting motor. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03210-02
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the alternator is normal. a Prepare with starting switch OFF, then turn starting switch YES ON and carry out troubleshooting. • Proceed to the next check item. 5
Alternator
Alternator Between R – chassis ground
6
7
8
Open circuit in wiring harness
Ground fault in wiring harness
Hot short in wiring harness
Voltage
Generation signal
Max. 13 V
NO
• The Alternator is defective. • Replace the alternator. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between terminal 280 – NSF (female) (3)
Resistance
Max. 1 z
Wiring harness between NSF (female) (5) – EG2 (8) – ST (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between terminal 280 – NSF (female) (3) or circuit branch end and chassis ground
Resistance
Wiring harness between NSF (female) (5) – EG2 (8) – ST (female) (1) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between terminal R – ST (female) (2) or circuit branch end and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
9
Reconfirmation of check item
Confirmation 10 of repair
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The engine controller power supply may be defective. • Perform troubleshooting for the failure code [CA111]. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
15
SEN03210-02
40 Troubleshooting
Related circuit diagram
16
D155A-6
40 Troubleshooting
SEN03210-02
E-4 Preheater does not operate Trouble Related information
No.
1
(1) When starting switch is turned to HEAT position, preheating monitor does not light up. • Preheater monitor lights up when starting switch is turned to HEAT. • If engine coolant temperature is below -5 °C, automatic warm-up system operates and preheating monitor lights up for up to 40 seconds.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the starta Prepare with starting switch OFF, then keep starting switch ing switch is normal. OFF and turn it to HEAT and carry out troubleshooting in YES • Proceed to the next each case. check item. 1
Starting switch
Starting switch OFF Between 250 – 255
2
Open circuit in wiring harness
Resistance Min. 1 Mz NO Max. 1 z
HEAT
• The starting switch is defective. • Replace the starting switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between CM01 (female) (16) – terminal 255
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch to HEAT position. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
17
SEN03210-02
40 Troubleshooting
Trouble
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become warm.
Related information
Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting for E-3 Engine does not start (Engine does not turn)).
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the circuit breaker is normal. YES • Proceed to the next check item.
1
Circuit breaker
If circuit breaker (CB105H) is turned OFF, circuit probably has ground fault (See check item 5). NO
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• The state of the heater a Prepare with starting switch OFF (with wiring harness conrelay is normal. nected), then turn starting switch to HEAT and carry out trou- YES • Proceed to the next bleshooting. check item. 2
Heater relay
Heater relay
Starting switch
Between HT – chassis ground Between HT/B – chassis ground
Voltage 20 – 30 V NO
HEAT 20 – 30 V
• The heater relay is defective. • Replace the heater relay. • Proceed to "Confirmation of repair".
• The state of the intake a Prepare with starting switch OFF (with wiring harness conair heater is normal. nected), then turn starting switch to HEAT and carry out trou- YES • Proceed to the next bleshooting in each case. check item. 3
Intake air heater
RHT
Starting switch
Voltage
Between terminal – chassis ground
HEAT
20 – 30 V NO
If voltage is normal but heater mounting part does not become warm, intake air heater is defective.
• The intake air heater is defective. • Replace the intake air heater. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
18
Open circuit in wiring harness
Wiring harness between terminal 255 – terminal HT
Resistance
Max. 1 z
Wiring harness between terminal BRC – CB105H (B105HS)
Resistance
Max. 1 z
Wiring harness between CB105H (B105HL) – terminal HT/A
Resistance
Max. 1 z
Wiring harness between terminal HT/B – terminal RHT
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
5
6
Ground fault in wiring harness
Confirmation of repair
D155A-6
Wiring harness between terminal 255 – terminal HT or CM01 (female) (16) or circuit branch end and chassis ground
Resistance
Wiring harness between terminal BRC – CB105H (B105HS) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB105H (B105HL) – terminal HT/A and chassis ground
Resistance
Min. 1 Mz
Wiring harness between terminal HT/B – terminal RHT and chassis ground
Resistance
Min. 1 Mz
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch to HEAT position. Does this failure recur?
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
19
SEN03210-02
40 Troubleshooting
Related circuit diagram
20
D155A-6
40 Troubleshooting
SEN03210-02
E-5 Precaution item lights up while engine is running Trouble Related information
No.
1
Precaution item lights up while engine is running. • Check item is only charge level monitor. • State of generation signal of alternator can be checked with monitoring function. (Code: 04300 Battery Charge Volt)
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the altera Prepare with starting switch OFF, then start engine and carry nator is normal. YES out troubleshooting. • Proceed to the next check item. 1
2
Alternator
Open circuit in wiring harness
Alternator
Engine speed
Voltage
Between R – chassis ground
Medium or higher
20 – 30 V
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between CM01 (female) (11) – terminal R
3
Ground fault in wiring harness
NO
• The alternator is defective. • Replace the alternator. • Proceed to "Confirmation of repair".
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between CM01 (female) (11) – terminal R or circuit branch end and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
21
SEN03210-02
40 Troubleshooting
Related circuit diagram
22
D155A-6
40 Troubleshooting
SEN03210-02
E-6 Emergency stop item lights up while engine is running Trouble Related information
No.
1
1
(1) Engine coolant temperature monitor lights up. • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature)
Check item
Engine coolant temperature
Procedure of troubleshooting
Engine coolant may be overheated. If it is overheated, remove cause.
Judgment and remedy • The state of the engine coolant temperature is YES normal. • Proceed to the next check item.
NO
• The engine coolant is overheated. • Remove the cause of overheat. • Proceed to "Confirmation of repair".
• The state of the engine coolant temperature sensor system is norYES mal. • Proceed to the next check item. 2
Engine coolant temperature sensor system
If check item 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145]. NO
• The engine coolant temperature sensor system may be defective. • Perform troubleshooting for the failure codes [CA144] and [CA145]. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
23
SEN03210-02
Trouble Related information
No.
40 Troubleshooting
(2) Engine oil pressure monitor lights up. • Signals of engine oil pressure sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine oil pressure can be checked with monitoring function. (Code: 37200 Engine Oil Pressure)
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the engine oil pressure is normal. YES • Proceed to the next check item.
1
Engine oil pressure
Engine oil pressure may be low. If it is low, remove cause. NO
2
Engine oil If check item 1 is not detected, engine oil pressure sensor syspressure sen- tem may be defective. Carry out troubleshooting for failure codes [CA135] and [CA141]. sor system
• The engine oil pressure is abnormal (low). • Remove the cause of low pressure. • Proceed to "Confirmation of repair".
• The state of the engine oil pressure sensor system is normal. YES • Proceed to the next check item.
NO
• The engine oil pressure sensor system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
4
Confirmation of repair
1. 2. 3. 4.
24
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information
No.
1
SEN03210-02
(3) Power train oil temperature monitor lights up. • Signals of torque converter oil temperature sensor are input to power train controller and then transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature)
Check item
Procedure of troubleshooting
Power train oil Power train oil may be overheated. If it is overheated, remove temperature cause.
Judgment and remedy • The state of the power train oil temperature is YES normal. • Proceed to the next check item.
NO
2
Power train oil If check item 1 is not detected, power train oil temperature sentemperature sor system may be defective. Carry out troubleshooting for failsensor sysure codes [DGT1KA] and [DGT1KX]. tem
• The power train oil is overheated. • Remove the cause of overheat. • Proceed to "Confirmation of repair".
• The state of the power train oil temperature sensor system is norYES mal. • Proceed to the next check item.
NO
• The power train oil temperature sensor system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
4
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
25
SEN03210-02
Trouble Related information No.
1
40 Troubleshooting
(4) Hydraulic oil temperature monitor lights up. Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature)
Check item
Hydraulic oil temperature
Procedure of troubleshooting
Hydraulic oil may be overheated. If it is overheated, remove cause.
Judgment and remedy • The state of the hydraulic oil temperaYES ture is normal. • Proceed to the next check item.
NO
• The hydraulic oil is overheated. • Remove the cause of overheat. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
26
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The hydraulic oil temperature gauge system may be defective. • Perform troubleshooting for E mode "E-10 Hydraulic oil temperature gauge (Multigauge) does not indicate normally". • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
E-7 Engine coolant temperature gauge does not indicate normally
1
Trouble
(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C). (2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
Related information
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature)
No.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the engine coolant temperature sensor system is norYES mal. • Proceed to the next check item.
1
Engine coolant temperature sensor system
Engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145]. NO
• The engine coolant temperature sensor system may be defective. • Perform troubleshooting for the failure codes [CA144] and [CA145]. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
27
SEN03210-02
40 Troubleshooting
Trouble
(3) Display of coolant temperature gauge is different from actual engine coolant temperature. (4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor.
Related information
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
a Turn starting switch ON or start engine and carry out troubleshooting. Engine coolant temperature Coolant temperature gauge level
1
2
Machine monitor
Confirmation of repair
105 °C
6
102 °C
5
100 °C
4
85 °C
3
60 °C
2
30 °C
1
1. Turn the starting switch OFF. 2. Connect all the composed equipment. 3. Turn the starting switch ON or start the engine to raise the temperature of the engine coolant. 4. Does this failure recur?
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Engine coolant temperature gauge and coolant temperature monitor
28
D155A-6
40 Troubleshooting
SEN03210-02
E-8 Fuel level gauge does not indicate normally Trouble Related information No.
1
(1) While fuel is added, fuel level gauge does not rise from red range (E). (2) While fuel level is low, fuel level gauge does not lower from green range top (F). Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel Level Sensor Volt)
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the fuel a Prepare with starting switch OFF, then carry out troublelevel sensor is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
Fuel level sensor
FLV (male)
Between (1) – (2)
2
3
4
Open circuit in wiring harness
Ground fault in wiring harness
Hot short in wiring harness
Fuel level
Resistance
FULL
Approx. 4 z
EMPTY
Approx. 85 z
NO
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CM01 (female) (9) – FLV (female) (1)
Resistance
Max. 1 z
Wiring harness between CM01 (female) (12) – FLV (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between CM01 (female) (9) – FLV (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between CM01 (female) (9) – FLV (female) (1) and chassis ground
D155A-6
• The fuel level sensor is defective. • Replace the fuel level sensor . • Proceed to "Confirmation of repair".
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
29
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
30
D155A-6
40 Troubleshooting
SEN03210-02
Trouble
(3) Display of fuel level gauge is different from actual fuel level. (4) Display of fuel level gauge is different from display of fuel level monitor.
Related information
Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel Level Sensor Volt)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
a Turn starting switch ON or start engine and carry out troubleshooting.
1
2
Machine monitor
Confirmation of repair
1. 2. 3. 4.
Quantity of fuel
Reading of fuel level gauge
565 l
6
425 l
5
310 l
4
220 l
3
150 l
2
75 l
1
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Does this failure recur?
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Fuel level gauge and fuel level monitor
D155A-6
31
SEN03210-02
40 Troubleshooting
E-9 Power train oil temperature gauge (multi-gauge) does not indicate 1 normally Trouble
(1) While power train oil temperature is rising normally, temperature gauge does not rise from white range (C). (2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related information
• Signals of power train oil temperature sensor are input to power train controller and then transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature)
No.
1
Check item
Procedure of troubleshooting
Power train oil Power train oil temperature sensor system may be defective. temperature Carry out troubleshooting for failure codes [DGT1KA] and sensor sys[DGT1KX]. tem
Judgment and remedy • The state of the power train oil temperature sensor system is norYES mal. • Proceed to the next check item.
NO
• The power train oil temperature sensor system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
3
32
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
Trouble
(3) Display of power train temperature gauge is different from actual power train oil temperature. (4) Display of power train oil temperature gauge is different from display of power train oil temperature monitor.
Related information
• Signals of power train oil temperature sensor are input to power train controller and then transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature)
No.
Check item
Procedure of troubleshooting
Judgment and remedy
a Turn starting switch ON or start engine and carry out troubleshooting.
1
2
Power train oil temperature
Power train oil temperature gauge level
130 °C
6
120 °C
5
118 °C
4
80 °C
3
50 °C
2
0 °C
1
Machine monitor
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Does this failure recur?
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Power train oil temperature gauge and power train oil temperature monitor
D155A-6
33
SEN03210-02
40 Troubleshooting
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally Trouble Related information No.
1
(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C). (2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H). Hydraulic temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature)
Check item
Hydraulic oil temperature sensor system
Procedure of troubleshooting
Judgment and remedy
• The state of the hydraulic oil temperaa Prepare with starting switch OFF, then carry out troubleture sensor system is YES shooting without turning starting switch ON. normal. • Proceed to the next check item. HDT (male)
Resistance
Between (1) – (2)
3.5 – 90 kz
Between (2) – chassis ground
Min. 1 Mz
NO
2
3
4
Open circuit in wiring harness
Ground fault in wiring harness
Hot short in wiring harness
• The hydraulic oil temperature sensor system is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CM01 (female) (8) – HDT (female) (1)
Resistance
Max. 1 z
Wiring harness between CM01 (female) (12) – HDT (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between CM01 (female) (8) – HDT (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between CM01 (female) (8) – HDT (female) (1) and chassis ground
34
1
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
SEN03210-02
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
35
SEN03210-02
Trouble Related information No.
40 Troubleshooting
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor. Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature)
Check item
Procedure of troubleshooting
Judgment and remedy
a Turn starting switch ON or start engine and carry out troubleshooting.
1
2
Hydraulic oil temperature
Reading of hydraulic oil temperature gauge
110 °C
6
100 °C
5
98 °C
4
70 °C
3
20 °C
2
0 °C
1
Machine monitor
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON or start the engine. Does this failure recur?
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
36
D155A-6
40 Troubleshooting
SEN03210-02
E-11 Contents of display by machine monitor are different from applicable machine Trouble Related information No.
1
Contents of display by machine monitor are different from applicable machine. -
Check item
Procedure of troubleshooting
1
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
2
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
E-12 Machine monitor does not display some items Trouble Related information
No.
Machine monitor does not display some items. The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect.
Check item
Procedure of troubleshooting
a Turn starting switch ON and carry out troubleshooting.
1
1
Machine monitor (LCD panel)
When following switches are operated, if all LCD panel is lighted up (all surface becomes white), LCD panel is normal. • Operation of switches: [4] + [F2] (Press simultaneously)
Judgment and remedy • The state of the machine monitor (LCD YES panel) is normal. • Proceed to the next check item.
NO
• The machine monitor (LCD panel) is defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
3
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
37
SEN03210-02
40 Troubleshooting
E-13 Function switch does not work Trouble Related information No.
1
2
38
1
Function switch does not work. -
Check item
Procedure of troubleshooting
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair"
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
E-14 Operation mode does not change Trouble Related information No.
1
2
1
-
Procedure of troubleshooting
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Confirmation of repair
1. 2. 3. 4.
Related information No.
(1) When operation mode switch is operated, display of operation mode monitor does not change.
Check item
Trouble
1
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
(2) When operation mode is changed, engine output is not changed. Engine output mode recognized by engine controller can be checked with monitoring function. (Code: 17500 Engine Power Mode)
Check item
Machine monitor
Procedure of troubleshooting
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Judgment and remedy • The state of the machine monitor is YES normal. • Proceed to the next check item.
NO
• The machine monitor is defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
3
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The engine controller may be defective. • Replace the engine controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
39
SEN03210-02
40 Troubleshooting
E-15 Gearshift mode does not change Trouble Related information No.
1
2
1
-
Procedure of troubleshooting
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Confirmation of repair
1. 2. 3. 4.
Related information No.
(1) When gearshift mode switch is operated, display of speed mode section does not change.
Check item
Trouble
1
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
(2) When gearshift mode is changed, gearshift setting of power train is not changed. -
Check item
Machine monitor
Procedure of troubleshooting
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out).
Judgment and remedy • The state of the machine monitor is YES normal. • Proceed to the next check item.
NO
• The machine monitor is defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
40
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The power train controller may be defective. • Replace the power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
E-16 Customize function does not operate normally Trouble Related information No.
1
2
1
-
Procedure of troubleshooting
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Confirmation of repair
1. 2. 3. 4.
Related information No.
(1) When customize switch is operated, customize screen is not displayed.
Check item
Trouble
1
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
(2) When setting is changed on customize screen, setting of machine is not changed. -
Check item
Machine monitor
Procedure of troubleshooting
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out).
Judgment and remedy • The state of the machine monitor is YES normal. • Proceed to the next check item.
NO
• The machine monitor is defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
NO
• The engine controller or power train controller may be defective. • Replace the engine controller or power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
41
SEN03210-02
40 Troubleshooting
E-17 Customize memory function does not operate normally Trouble Related information No.
1
2
1
-
Procedure of troubleshooting
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Confirmation of repair
1. 2. 3. 4.
Related information No.
(1) When customize memory switch is operated, customize memory screen is not displayed.
Check item
Trouble
1
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
(2) When selection is changed on customize memory screen, setting of machine is not changed. -
Check item
Machine monitor
Procedure of troubleshooting
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out).
Judgment and remedy • The state of the machine monitor is YES normal. • Proceed to the next check item.
NO
• The machine monitor is defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
42
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
NO
• The engine controller or power train controller may be defective. • Replace the engine controller or power train controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
E-18 Alarm buzzer cannot be stopped Trouble Related information No.
1
2
Alarm buzzer cannot be stopped. -
Check item
Procedure of troubleshooting
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Confirmation of repair
1. 2. 3. 4.
D155A-6
1
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
43
SEN03210-02
40 Troubleshooting
E-19 Air conditioner does not operate normally (including air conditioner fault history) Trouble Related information No.
1
2
44
1
(1) When air conditioner switch is operated, air conditioner control screen is not displayed. -
Check item
Procedure of troubleshooting
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Turn the air conditioner switch ON. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
SEN03210-02
(2) When air conditioner switch is operated, air conditioner does not operate at all. -
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the circuit breaker is normal. YES • Proceed to the next check item.
1
Circuit breaker
If circuit breaker (CB3) is turned OFF, circuit probably has ground fault (See check item 4). NO
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• The state of the fuse is normal. YES • Proceed to the next check item.
2
Fuse
If fuse in unit is broken, circuit in unit probably has ground fault (See check item 4). NO
3
Open circuit in wiring harness
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CB3 (2) – fuse in unit – ACCN (wiring side) (6)
Resistance
Wiring harness between ACCN (wiring side) (16) – chassis ground (GND12)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Ground fault in wiring harness
D155A-6
Wiring harness between CB3 (2) – fuse in unit – ACCN (wiring side) (6) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
45
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
6
46
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Turn the air conditioner switch ON. Does this failure recur?
NO
• The air conditioner controller or machine monitor may be defective. • Replace the air conditioner controller or machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
SEN03210-02
(3) Air does not come out (Air flow is insufficient). -
Check item
Procedure of troubleshooting
Judgment and remedy
a Prepare with starting switch OFF, then carry out trouble• The state of the blower shooting without turning starting switch ON (coil side). YES relay is normal. AC03 (male) Resistance • Proceed to the next check item. Between (1) – (3) 140 – 340 z 1
Blower relay
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (contact side). AC03
Air conditioner switch
Voltage
Between (4) – chassis ground
Air blow position
20 – 30 V
NO
• The blower relay is defective. • Replace the blower relay. • Proceed to "Confirmation of repair".
• The state of the power transistor is normal. a Prepare with starting switch OFF, then turn starting switch YES ON and carry out troubleshooting. • Proceed to the next check item. 2
Power transistor
Fan switch
Operate between Low and Medium and High.
If air flow changes according to operation of fan switch, power transistor (ACPT) is normal.
NO
• The power transistor is defective. • Replace the power transistor. • Proceed to "Confirmation of repair".
• The state of the blower a Prepare with starting switch OFF, then turn starting switch motor is normal. YES ON and carry out troubleshooting. • Proceed to the next check item. 3
Blower motor
ACBM (wiring side)
Air conditioner switch
Voltage
Between (1) – (2)
Air blow position
20 – 30 V
If above voltage is normal and blower motor does not revolve, blower motor (ACBM) is defective.
D155A-6
NO
• The blower motor is defective. • Replace the blower motor. • Proceed to "Confirmation of repair".
47
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
4
Open circuit in wiring harness
Wiring harness between CB3 (2) – fuse in unit - AC03 (female) (1)
Resistance
Max. 1 z
Wiring harness between AC03 (female) (3) – ACCN (wiring side) (36)
Resistance
Max. 1 z
Wiring harness between CB3 (2) – AC03 (female) (4)
Resistance
Max. 1 z
Wiring harness between AC03 (female) (5) – ACBM (wiring side) (1)
Resistance
Max. 1 z
Wiring harness between ACBM (wiring side) (2) – ACPT (wiring side) (3)
Resistance
Max. 1 z
Wiring harness between ACPT (wiring side) (1) – chassis ground (GND12)
Resistance
Max. 1 z
Wiring harness between ACPT (wiring side) (2) – ACCN (wiring side) (8)
Resistance
Max. 1 z
Wiring harness between ACPT (wiring side) (4) – ACCN (wiring side) (7)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
5
Ground fault in wiring harness
Wiring harness between AC03 (female) (3) – ACCN (wiring side) (36) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between AC03 (female) (5) – ACBM (wiring side) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACBM (wiring side) (2) – ACPT (wiring side) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACPT (wiring side) (2) – ACCN (wiring side) (8) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
7
48
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Turn the air conditioner switch ON. Does this failure recur?
NO
• The air conditioner controller or air conditioner system may be defective. • Repair or replace the defective part. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
1
2
SEN03210-02
(4) Air is not cooled (Cooling performance is insufficient). -
Check item
Compressor relay
Internal air sensor
Procedure of troubleshooting
Judgment and remedy
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side).
• The state of the compressor relay is norYES mal. • Proceed to the next check item.
AC04 (male)
Resistance
Between (1) – (3)
140 – 340 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (contact side). AC04
Air conditioner switch
Voltage
Between (2) – chassis ground
Cooling position
20 – 30 V
Internal air sensor may be defective. Carry out troubleshooting for "Abnormality in internal air sensor".
NO
• The state of the internal air sensor is norYES mal. • Proceed to the next check item.
NO
3
High and low High and low pressure switches may be defective. Carry out pressure troubleshooting for "Abnormality in refrigerant". switches
Compressor clutch
• The high and low pressure switches are defective. • Replace the high and low pressure switches. • Proceed to "Confirmation of repair".
• The state of the compressor clutch is norYES mal. • Proceed to the next check item. Compressor clutch may be defective. Check it. NO
D155A-6
• The internal air sensor is defective. • Replace the internal air sensor. • Proceed to "Confirmation of repair".
• The state of the high and low pressure switches are normal. YES • Proceed to the next check item.
NO
4
• The compressor relay is defective. • Replace the compressor relay. • Proceed to "Confirmation of repair".
• The compressor clutch is defective. • Replace the compressor clutch. • Proceed to "Confirmation of repair".
49
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the compressor is normal. YES • Proceed to the next check item.
5
Compressor
Compressor may be defective. Check it. NO
• The compressor is defective. • Replace the compressor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
6
7
Open circuit in wiring harness
Ground fault in wiring harness
Wiring harness between CB3 (2) – fuse in unit – AC04 (female) (1)
Resistance
Max. 1 z
Wiring harness between AC04 (female) (3) – ACCN (wiring side) (35)
Resistance
Max. 1 z
Wiring harness between CB3 (2) – AC04 (female) (4)
Resistance
Max. 1 z
Wiring harness between AC04 (female) (2) – A/C (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between AC04 (female) (3) – ACCN (wiring side) (35) and chassis ground
Resistance
Wiring harness between AC04 (female) (2) – A/C (female) (1) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
8
9
50
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Turn the air conditioner switch ON. Does this failure recur?
NO
• The air conditioner controller or air conditioner system may be defective. • Repair or replace the defective part. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
Trouble
(5) Air conditioner fault history: Communication condition "CAN disconnection", Communication condition "Abnormal"
Related information
• While abnormality in communication is being detected, "CAN disconnection" is displayed. • If abnormality in communication has been detected and reset, "Abnormality" is displayed. • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, condition of other items is not displayed.
No.
1
Check item
Open circuit in wiring harness
Procedure of troubleshooting
Judgment and remedy
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between AC02 (female) (1) – CM02 (female) (8), (9)
Resistance
Max. 1 z
Wiring harness between AC02 (female) (2) – CM02 (female) (10)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Ground fault in wiring harness
Wiring harness between AC02 (female) (1) – CM02 (female) (8), (9), EGC2 (female) (46), STC2 (female) (32), CA1 (female) (A), or SRV (female) (3) and chassis ground
Resistance
Wiring harness between AC02 (female) (2) – CM02 (female) (10), EGC2 (female) (47), STC2 (female) (22), CA1 (female) (B), or SRV (female) (10) and chassis ground
Resistance
Max. 1 z NO Max. 1 z
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
3
Hot short in wiring harness
D155A-6
Wiring harness between AC02 (female) (1) – CM02 (female) (8), (9), EGC2 (female) (46), STC2 (female) (32), CA1 (female) (A), or SRV (female) (3) and chassis ground
Resistance
Wiring harness between AC02 (female) (2) – CM02 (female) (10), EGC2 (female) (47), STC2 (female) (22), CA1 (female) (B), or SRV (female) (10) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
51
SEN03210-02
No.
4
40 Troubleshooting
Check item
CAN terminal resistance
Procedure of troubleshooting
Judgment and remedy
• The state of the CAN terminal resistance is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. CA1 (male)
Resistance
Between (A) – (B)
Approx. 120 z
• The CAN terminal resistance is defective. • Replace the CAN terminal resistance. • Proceed to "Confirmation of repair".
NO
YES The repair is completed.
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
6
Confirmation of repair
1. 2. 3. 4.
Trouble Related information
No.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
YES
Return to the first check item.
NO
The repair is completed.
(6) Air conditioner fault history: Setting condition "Abnormality" • If setting of air conditioner controller model is different from setting of machine monitor model, "Abnormality" is displayed. • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
Check item
Procedure of troubleshooting
1
Air condiAir conditioner controller or machine monitor may be defective. tioner control(Since trouble is in system, troubleshooting cannot be carried ler or machine out.) monitor
2
Confirmation of repair
52
NO
• The air conditioner controller or machine monitor may be defective. • Replace the air conditioner controller or machine monitor. • Proceed to "Confirmation of repair".
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
Judgment and remedy
-
• The air conditioner controller or machine monitor may be defective. • Replace the air conditioner controller or machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
1
2
SEN03210-02
(7) Air conditioner fault history: Internal air sensor "Abnormality" If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
Check item
Internal air sensor
Open circuit in wiring harness
Procedure of troubleshooting
Judgment and remedy
• The state of the internal air sensor is nora Prepare with starting switch OFF, then carry out troubleYES mal. shooting without turning starting switch ON. • Proceed to the next check item. ACPS (device side)
Resistance
Between (1) – (2)
300 z – 430 kz
NO
• The internal air sensor is defective. • Replace the internal air sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ACCN (wiring side) (11) – ACPS (wiring side) (2)
Resistance
Max. 1 z
Wiring harness between ACCN (wiring side) (27) – ACPS (wiring side) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harness Wiring harness between ACCN (wiring
side) (11) – ACPS (wiring side) (2) and chassis ground
4
Hot short in wiring harness
Min. 1 Mz
NO
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between ACCN (wiring side) (11) – ACPS (wiring side) (2) and chassis ground
D155A-6
Resistance
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
53
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Trouble Related information
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn air conditioner (A/C) switch ON. Does this failure recur?
YES
Return to the first check item.
NO
The repair is completed.
(8) Air conditioner fault history: External air sensor "Unused" • External air sensor is not used in air conditioner system of this machine. • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
No.
Check item
Procedure of troubleshooting
1
Fault history display
Since external air sensor is not used in air conditioner system of this machine, above display is normal.
54
NO
• The air conditioner controller may be defective. • Replace the air conditioner controller. • Proceed to "Confirmation of repair".
Judgment and remedy -
• The state of the fault history display is normal.
D155A-6
40 Troubleshooting
Trouble Related information No.
SEN03210-02
(9) Air conditioner fault history: Air flow sensor "Abnormality" If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the air a Prepare with starting switch OFF, then carry out troubleflow sensor is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 1
2
Air flow sensor
Open circuit in wiring harness
ACFS (device side)
Resistance
Between (1) – (2)
100 z – 115 kz
NO
• The air flow sensor is defective. • Replace the air flow sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ACCN (wiring side) (12) – ACFS (wiring side) (2)
Resistance
Max. 1 z
Wiring harness between ACCN (wiring side) (27) – ACFS (wiring side) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Short circuit in wiring harness Wiring harness between ACCN (wiring
side) (12) – ACFS (wiring side) (2) and chassis ground
4
Hot short in wiring harness
Resistance
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between ACCN (wiring side) (12) – ACFS (wiring side) (2) and chassis ground
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The air conditioner controller may be defective. • Replace the air conditioner controller. • Proceed to "Confirmation of repair".
55
SEN03210-02
No.
6
56
40 Troubleshooting
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn air conditioner (A/C) switch ON. Does this failure recur?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
SEN03210-02
(10) Air conditioner fault history: Daylight sensor "Abnormality" If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the daylight sensor is normal. YES • Proceed to the next check item.
1
Daylight senDaylight sensor may be defective. sor NO
2
Open circuit in wiring harness
• The daylight sensor is defective. • Replace the daylight sensor. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ACCN (wiring side) (3) – SLS (female) (1)
Resistance
Max. 1 z
Wiring harness between ACCN (wiring side) (15) – SLS (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
4
Ground fault in wiring harness
Hot short in wiring harness
Wiring harness between ACCN (wiring side) (3) – SLS (female) (1) or circuit branch end and chassis ground
Resistance
Wiring harness between ACCN (wiring side) (15) – SLS (female) (2) and chassis ground
Resistance
Min. 1 Mz NO Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. Wiring harness between ACCN (wiring side) (3) – SLS (female) (1) or circuit branch end and chassis ground
Voltage
Wiring harness between ACCN (wiring side) (15) – SLS (female) (2) and chas- Voltage sis ground
Max. 1 V NO Max. 1 V
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• The air conditioner controller may be defective. • Replace the air conditioner controller. • Proceed to "Confirmation of repair".
57
SEN03210-02
No.
6
58
40 Troubleshooting
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn air conditioner (A/C) switch ON. Does this failure recur?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
1
SEN03210-02
(11) Air conditioner fault history: Air outlet damper 1 "Abnormality" If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the air outlet servomotor 1 is norYES mal. • Proceed to the next check item.
Air outlet serAir outlet servomotor may be defective. vomotor 1
NO
• The air outlet servomotor 1 is defective. • Replace the air outlet servomotor 1. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Open circuit in wiring harness
Wiring harness between ACB1 (wiring side) (1) – ACCN (wiring side) (3)
Resistance
Max. 1 z
Wiring harness between ACB1 (wiring side) (3) – ACCN (wiring side) (27)
Resistance
Max. 1 z
Wiring harness between ACB1 (wiring side) (5) – ACCN (wiring side) (9)
Resistance
Max. 1 z
Wiring harness between ACB1 (wiring side) (6) – ACCN (wiring side) (24)
Resistance
Max. 1 z
Wiring harness between ACB1 (wiring side) (7) – ACCN (wiring side) (23)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
3
Ground fault in wiring harness
D155A-6
Wiring harness between ACB1 (wiring side) (1) – ACCN (wiring side) (3) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACB1 (wiring side) (5) – ACCN (wiring side) (9) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACB1 (wiring side) (6) - ACCN (wiring side) (24) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACB1 (wiring side) (7) – ACCN (wiring side) (23) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
59
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
4
Hot short in wiring harness
Wiring harness between ACB1 (wiring side) (1) – ACCN (wiring side) (3) or circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between ACB1 (wiring side) (5) – ACCN (wiring side) (9) and chassis ground
Voltage
Wiring harness between ACB1 (wiring side) (6) – ACCN (wiring side) (24) and chassis ground
Voltage
Max. 1 V
Wiring harness between ACB1 (wiring side) (7) – ACCN (wiring side) (23) and chassis ground
Voltage
Max. 1 V
Max. 1 V NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
60
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn air conditioner (A/C) switch ON. Does this failure recur?
NO
• The air conditioner controller may be defective. • Replace the air conditioner controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
1
SEN03210-02
(12) Air conditioner fault history: Air outlet damper 2 "Abnormality" If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the air outlet servomotor 2 is norYES mal. • Proceed to the next check item.
Air outlet serAir outlet servomotor may be defective. vomotor 2
NO
• The air outlet servomotor 2 is defective. • Replace the air outlet servomotor 2. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
2
Open circuit in wiring harness
Wiring harness between ACB2 (wiring side) (1) – ACCN (wiring side) (3)
Resistance
Max. 1 z
Wiring harness between ACB2 (wiring side) (3) – ACCN (wiring side) (27)
Resistance
Max. 1 z
Wiring harness between ACB2 (wiring side) (5) – ACCN (wiring side) (9)
Resistance
Max. 1 z
Wiring harness between ACB2 (wiring side) (6) – ACCN (wiring side) (24)
Resistance
Max. 1 z
Wiring harness between ACB2 (wiring side) (7) – ACCN (wiring side) (23)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
3
Ground fault in wiring harness
D155A-6
Wiring harness between ACB2 (wiring side) (1) – ACCN (wiring side) (3) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACB2 (wiring side) (5) – ACCN (wiring side) (9) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACB2 (wiring side) (6) - ACCN (wiring side) (24) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACB2 (wiring side) (7) – ACCN (wiring side) (23) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
61
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
4
Hot short in wiring harness
Wiring harness between ACB2 (wiring side) (1) – ACCN (wiring side) (3) or circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between ACB2 (wiring side) (5) – ACCN (wiring side) (9) and chassis ground
Voltage
Wiring harness between ACB2 (wiring side) (6) – ACCN (wiring side) (24) and chassis ground
Voltage
Max. 1 V
Wiring harness between ACB2 (wiring side) (7) – ACCN (wiring side) (23) and chassis ground
Voltage
Max. 1 V
Max. 1 V NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
62
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn air conditioner (A/C) switch ON. Does this failure recur?
NO
• The air conditioner controller may be defective. • Replace the air conditioner controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
SEN03210-02
(13) Air conditioner fault history: A/M damper "Abnormality" If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the air mix servomotor is normal. YES • Proceed to the next check item.
1
Air mix servoAir mix servomotor may be defective. motor NO
• The air mix servomotor is defective. • Replace the air mix servomotor. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item.
2
Open circuit in wiring harness
Wiring harness between ACSM (wiring side) (1) – ACCN (wiring side) (27)
Resistance
Max. 1 z
Wiring harness between ACSM (wiring side) (3) – ACCN (wiring side) (3)
Resistance
Max. 1 z
Wiring harness between ACSM (wiring side) (5) – ACCN(wiring side) (2)
Resistance
Max. 1 z
Wiring harness between ACSM (wiring side) (6) – ACCN (wiring side) (21)
Resistance
Max. 1 z
Wiring harness between ACSM (wiring side) (7) – ACCN (wiring side) (22)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
3
Ground fault in wiring harness
D155A-6
Wiring harness between ACSM (wiring side) (3) – ACCN (wiring side) (3) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACSM (wiring side) (5) – ACCN (wiring side) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACSM (wiring side) (6) – ACCN (wiring side) (21) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACSM (wiring side) (7) – ACCN (wiring side) (22) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
63
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
4
Hot short in wiring harness
Wiring harness between ACSM (wiring side) (3) – ACCN (wiring side) (3) or circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between ACSM (wiring side) (5) – ACCN (wiring side) (2) and chassis ground
Voltage
Wiring harness between ACSM (wiring side) (6) – ACCN (wiring side) (21) and chassis ground
Voltage
Max. 1 V
Wiring harness between ACSM (wiring side) (7) – ACCN (wiring side) (22) and chassis ground
Voltage
Max. 1 V
Max. 1 V NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
64
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn air conditioner (A/C) switch ON. Does this failure recur?
NO
• The air conditioner controller may be defective. • Replace the air conditioner controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble Related information No.
SEN03210-02
(14) Air conditioner fault history: Refrigerant "Abnormality" If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the refrigerant (gas) is normal. YES • Proceed to the next check item.
1
Refrigerant (gas)
Refrigerant (gas) may be insufficient. Check it. NO
2
3
High and low pressure switches
Open circuit in wiring harness
• The refrigerant (gas) is insufficient. • Replenish the refrigerant (gas). • Proceed to "Confirmation of repair".
• The state of the high and low pressure a Prepare with starting switch OFF, then carry out troubleYES switches are normal. shooting without turning starting switch ON. • Proceed to the next check item. AC05 (male)
Resistance
Between (1) – (2)
Max. 1 z
NO
• The high and low pressure switches are defective. • Replace the high and low pressure switches. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between ACCN (wiring side) (4) – AC05 (female) (1)
Resistance
Wiring harness between AC05 (female) (2) – chassis ground (GND12)
Resistance
Max. 1 z NO Max. 1 z
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
5
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn air conditioner (A/C) switch ON. Does this failure recur?
NO
• The air conditioner controller may be defective. • Replace the air conditioner controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
65
SEN03210-02
40 Troubleshooting
Related circuit diagram
66
D155A-6
40 Troubleshooting
D155A-6
SEN03210-02
67
SEN03210-02
40 Troubleshooting
E-20 When starting switch is turned OFF, service meter is not displayed Trouble Related information
No.
1
When starting switch is turned OFF, service meter is not displayed. While starting switch is at OFF position, if following switches are operated, service meter is displayed at top center of screen. Operation of switches: [4] + [1] (Press simultaneously)
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the backup power supply YES system is normal. • Proceed to the next check item.
1
• The Backup power supply system is defective. • Perform troubleshooting for "E-1 When starting switch turned ON, machine monitor displays nothing". • Proceed to "Confirmation of repair".
When starting switch is turned ON, if machine monitor displays Backup nothing, backup power supply system may be defective. In this power supply case, carry out troubleshooting for "E-1 When starting switch system turned ON, machine monitor displays nothing". NO
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Press the switches [4] and [1] simultaneously. Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
E-21 Machine monitor cannot be set in service mode Trouble Related information No.
1
2
68
1
Machine monitor cannot be set in service mode. If following switches are operated, machine monitor is set in service mode. Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order)
Check item
Procedure of troubleshooting
Machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Confirmation of repair
1. Turn the starting switch OFF. 2. Connect all the composed equipment. 3. Press the switches [4] and [1] o [2] o [3]. (While pressing [4], press [1], [2], and [3] in order.) 4. Does this failure recur?
Judgment and remedy
-
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03210-02
E-22 Ripper pin puller cylinder does not operate Trouble Related information No.
1
(1) When pin puller switch is pulled out, cylinder is not retracted. (2) When pin puller switch is pushed in, cylinder is not extended. -
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse (FS2-3) is broken, circuit probably has ground fault (See check item 5). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the pin puller switch is normal. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 2
Pin puller switch
PLSW (male)
Pin puller switch
Resistance
Pulled out
Max. 1 z
Pushed in
Min. 1 Mz
Between (1) – (2)
3
Pin puller solenoid
NO
• The pin puller switch is defective. • Replace the pin puller switch. • Proceed to "Confirmation of repair".
• The state of the pin puller solenoid is nora Prepare with starting switch OFF, then carry out troubleYES mal. shooting without turning starting switch ON. • Proceed to the next check item. PPL (male)
Resistance
Between (1) – (2)
10 – 80 z NO
Between (1) – chassis ground
Min. 1 Mz
• The pin puller solenoid is defective. • Replace the pin puller solenoid. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Open circuit in wiring harness
D155A-6
Wiring harness between FS22 (3) – PLSW (female) (1)
Resistance
Max. 1 z
Wiring harness between PLSW (female) (2) – PPL (female) (1)
Resistance
Max. 1 z
Wiring harness between PLSW (female) (2) – chassis ground (GND03)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
69
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 5
Ground fault in wiring harness
Wiring harness between FS22 (3) – PLSW (female) (1) or circuit branch end and chassis ground Wiring harness between PLSW (female) (2) – PPL (female) (1) and chassis ground
6
Hot short in wiring harness
Confirmation of repair
Min. 1 Mz NO
Resistance
Min. 1 Mz
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item. Wiring harness between FS22 (3) – PLSW (female) (1) or circuit branch end and chassis ground Wiring harness between PLSW (female) (2) – PPL (female) (1) and chassis ground
7
Resistance
1. 2. 3. 4. 5.
Voltage
Voltage
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the pin puller switch. Does this failure recur?
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Max. 1 V
Max. 1 V
Related circuit diagram
70
D155A-6
40 Troubleshooting
SEN03210-02
E-23 Backup alarm does not sound or does not stop Trouble Related information No.
1
1
Backup alarm does not sound or does not stop. -
Check item
Backup alarm relay
Procedure of troubleshooting
Judgment and remedy
• The state of the backup alarm relay is a Prepare with starting switch OFF, then turn starting switch YES normal. ON and carry out troubleshooting. • Proceed to the next check item. Replace backup alarm relay (Right No.) with another relay. If backup alarm operates normally at this time, backup alarm relay is defective.
BKA
NO
• The backup alarm relay is defective. • Replace the backup alarm relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 2
3
4
Open circuit in wiring harness
Ground fault in wiring harness
Hot short in wiring harness
Wiring harness between BKA (female) (3) – branch point (F)
Resistance
Max. 1 z
Wiring harness between BKA (female) (5) – BKAL (female) (1)
Resistance
Max. 1 z
Wiring harness between BKAL (female) (2) – chassis ground (GND03)
Resistance
Max. 1 z
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
Wiring harness between BKA (female) (5) – BKAL (female) (1) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No hot short circuit occurs in the wiring a Prepare with starting switch OFF, then turn starting switch YES harness. ON and carry out troubleshooting. • Proceed to the next check item.
Wiring harness between BKA (female) (5) – BKAL (female) (1) or circuit branch end and chassis ground
D155A-6
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
Voltage
Max. 1 V
NO
• A hot short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
71
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the travel lever to REVERSE (put in a little). Does this failure recur?
NO
• The backup alarm may be defective. • Replace the backup alarm. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
72
D155A-6
40 Troubleshooting
SEN03210-02
E-24 Headlamp, rear lamp, and ripper point lamp do not light up Trouble Related information No.
1
(1) Headlamp does not light up. Only when headlamp switch is set in "Moon" mark position, screen brightness of machine monitor is changed for night.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the circuit breaker is normal. YES • Proceed to the next check item.
1
Circuit breaker
If circuit breaker (CB4) is turned OFF, circuit probably has ground fault (See check item 8). NO
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• The state of the headlamp is normal. YES • Proceed to the next check item. 2
Headlamp
Headlamp bulb and ground wire may be defective. Check them. NO
• The headlamp is defective. • Replace the headlamp. • Proceed to "Confirmation of repair".
• The state of the headlamp switch is normal. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
4
Headlamp switch
Left headlamp relay
FLSW (male)
Headlamp switch
Resistance
Between (5) – (4)
Moon mark
Max. 1 z
Between (5) – (4) Between (5) – (6)
Neutral
Min. 1 Mz
Between (5) – (6)
Sun mark
Max. 1 z
• The state of the left headlamp relay is nora Prepare with starting switch OFF, then turn starting switch YES mal. ON and carry out troubleshooting. • Proceed to the next check item. Replace left headlamp relay (Right No.) with another relay. If left headlamp becomes normal at this time, left headlamp relay is defective.
D155A-6
NO
• The headlamp switch is defective. • Replace the headlamp switch. • Proceed to "Confirmation of repair".
LMFL
NO
• The left headlamp relay is defective. • Replace the left headlamp relay. • Proceed to "Confirmation of repair".
73
SEN03210-02
No.
5
Check item
Right headlamp relay
40 Troubleshooting
Procedure of troubleshooting
• The state of the right headlamp relay is nora Prepare with starting switch OFF, then turn starting switch YES mal. ON and carry out troubleshooting. • Proceed to the next check item. Replace right headlamp relay (Right No.) with another relay. If right headlamp becomes normal at this time, right headlamp relay is defective.
6
Diode
Judgment and remedy
LMFR
NO
• The right headlamp relay is defective. • Replace the right headlamp relay. • Proceed to "Confirmation of repair".
• The state of the diode a Prepare with starting switch OFF, then carry out troubleis normal. YES shooting without turning starting switch ON. • Proceed to the next check item. LMD1 (male), LMD2 (male)
Continuity
Between (2) – (1)
There is continuity
NO
• The diode is defective. • Replace the diode. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
7
74
Open circuit in wiring harness
Wiring harness between terminal 270 – FLSW (female) (5)
Resistance
Max. 1 z
Wiring harness between FLSW (female) (4) – LMD1 (female) (2)
Resistance
Max. 1 z
Wiring harness between LMD1 (female) (1), LMD2 (female) (1) – LMFL (female) (1), LMFR (female) (1)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (2), LMFR (female) (2) – chassis ground (GND03)
Resistance
Max. 1 z
Wiring harness between CB4 (2) – LMFL (female) (3), LMFR (female) (3)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (5) – LHDL (female) (1)
Resistance
Max. 1 z
Wiring harness between LMFR (female) (5) – LHDR (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
8
9
Ground fault in wiring harness
Confirmation of repair
D155A-6
Wiring harness between terminal 270 – FLSW (female) (5) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between FLSW (female) (4), (3) – LMD1 (female) (2) or CM01 (female) (13) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between LMD1 (female) (1), LMD2 (female) (1) – LMFL (female) (1), LMFR (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB4 (2) – LMFL (female) (3), LMFR (female) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between LMFL (female) (5) – LHDL (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between LMFR (female) (5) – LHDR (female) (1) and chassis ground
Resistance
Min. 1 Mz
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn ON the headlamp switch. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
75
SEN03210-02
Trouble Related information No.
40 Troubleshooting
(2) Rear lamp and ripper point lamp do not light up. -
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the circuit breaker is normal. YES • Proceed to the next check item.
1
Circuit breaker
If circuit breaker (CB5) is turned OFF, circuit probably has ground fault (See check item 8). NO
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• The state of the rear lamp is normal. YES • Proceed to the next check item. 2
Rear lamp
Rear lamp bulb and ground wire may be defective. Check them. NO
• The rear lamp is defective. • Replace the rear lamp. • Proceed to "Confirmation of repair".
• The state of the ripper point lamp is normal. YES • Proceed to the next check item. 3
Ripper point lamp
Ripper point lamp bulb and ground wire may be defective. Check them. NO
• The ripper point lamp is defective. • Replace the ripper point lamp. • Proceed to "Confirmation of repair".
• The state of the rear a Prepare with starting switch OFF, then carry out troublelamp switch is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Rear lamp switch
RLSW (male)
Between (5) – (6)
Rear lamp switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
NO
• The rear lamp switch is defective. • Replace the rear lamp switch. • Proceed to "Confirmation of repair".
• The state of the rear lamp relay is normal. a Prepare with starting switch OFF, then turn starting switch YES ON and carry out troubleshooting. • Proceed to the next check item. 5
76
Rear lamp relay
Replace rear lamp relay (Right No.) with another relay. If rear lamp becomes normal at this time, rear lamp relay is defective.
LMRE
NO
• The rear lamp relay is defective. • Replace the rear lamp relay. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
6
Check item
Ripper point lamp relay
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• The state of the ripper point lamp relay is nora Prepare with starting switch OFF, then turn starting switch YES mal. ON and carry out troubleshooting. • Proceed to the next check item. Replace ripper point lamp relay (Right No.) with another relay. If ripper point lamp becomes normal at this time, ripper point lamp relay is defective.
LMRP
NO
• The ripper point lamp relay is defective. • Replace the ripper point lamp relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
7
Open circuit in wiring harness
Wiring harness between terminal 270 – RLSW (female) (5)
Resistance
Max. 1 z
Wiring harness between RLSW (female) (6) – LMRE (female) (1), LMRP (female) (1)
Resistance
Max. 1 z
Wiring harness between LMRE (female) (2), LMRP (female) (2) – chassis ground (GND03)
Resistance
Max. 1 z
Wiring harness between CB5 (2) – LMRE (female) (3), LMRP (female) (3)
Resistance
Max. 1 z
Wiring harness between LMRE (female) (5) – LREL (female) (1), LRER (female) (1)
Resistance
Max. 1 z
Wiring harness between LREL (female) (2) – chassis ground (GND03)
Resistance
Max. 1 z
Wiring harness between LRER (female) (2) – chassis ground (GND03)
Resistance
Max. 1 z
Wiring harness between LMRP (female) (5) – LRP1 (female) (1)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
8
Ground fault in wiring harness
D155A-6
Wiring harness between terminal 270 – RLSW (female) (5) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between RLSW (female) (6), (1) – LMRE (female) (1), LMRP (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB5 (2) – LMRE (female) (3), LMRP (female) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between LMRE (female) (5) – LREL (female) (1), LRER (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between LMRP (female) (5) – LRP1 (female) (1) and chassis ground
Resistance
Min. 1 Mz
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
77
SEN03210-02
No.
9
40 Troubleshooting
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn ON the rear lamp switch. Does this failure recur?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
78
D155A-6
40 Troubleshooting
SEN03210-02
E-25 Windshield wiper and window washer do not operate Trouble Related information No.
1
(1) No windshield wipers and window washers do not operate. -
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
-4) is broken, circuit probably has ground If fuse (FS12 – 4 or fault (See check item 3). NO
2
Open circuit in wiring harness
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between FS12 (4) – fuse
(B3)
Resistance
Max. 1 z
Resistance
Max. 1 z
NO Wiring harness between fuse CN11 (female) (5)
(4) –
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
Ground fault in wiring harness
Wiring harness between FS12 (4) – fuse
(B3) and chassis ground
Wiring harness between fuse (4) – CN11 (female) (5) and chassis ground
4
Confirmation of repair
D155A-6
1. 2. 3. 4.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn ON the windshield wiper switches and window washer switches. 5. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
79
SEN03210-02
Trouble Related information
No.
40 Troubleshooting
(2) Front windshield wiper does not operate (Continuous operation is defective). • If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become defective. • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with front wiper switch ON and intermittent switch OFF.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse ( -5) is broken, circuit probably has ground fault (See check item 7). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the front a Prepare with starting switch OFF, then turn starting switch wiper motor is normal. YES ON and carry out troubleshooting. • Proceed to the next check item. 2
Front wiper motor
CN23
Front wiper switch
Voltage
Between (6) – (1)
ON
20 – 30 V
a If voltage is normal but wiper does not operate, motor is defective.
NO
• The front wiper motor is defective. • Replace the front wiper motor. • Proceed to "Confirmation of repair".
• The state of the front wiper switch is normal. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
Front wiper switch
CN14 (male)
Between (2) – (3)
Front wiper switch
Resistance
OFF
Min. 1 Mz NO
ON
Max. 1 z
• The front wiper switch is defective. • Replace the front wiper switch. • Proceed to "Confirmation of repair".
• The state of the front wiper intermittent a Prepare with starting switch OFF, then turn starting switch selector relay is norYES ON and carry out troubleshooting. mal. • Proceed to the next check item.
4
80
Front wiper intermittent selector relay Replace front wiper intermittent selector relay (Right No.) with another relay. If front wiper becomes normal at this time, intermittent selector relay is defective.
CN29
NO
• The front wiper intermittent selector relay is defective. • Replace the front wiper intermittent selector relay. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
Check item
Front wiper intermittent relay
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• The state of the front wiper intermittent relay a Prepare with starting switch OFF, then turn starting switch YES is normal. ON and carry out troubleshooting. • Proceed to the next check item.
Replace front wiper intermittent relay (Right No.) with another relay. If front wiper becomes normal at this time, intermittent relay is defective.
CN28
NO
• The front wiper intermittent relay is defective. • Replace the front wiper intermittent relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
6
Open circuit in wiring harness
(5) – Wiring harness between fuse CN14 (female) (3), (5), CN28 (female) (3), or CN23 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN14 (female) (2) – CN29 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN29 (female) (4) – CN28 (female) (4)
Resistance
Max. 1 z
Wiring harness between CN28 (female) (5) – CN23 (female) (6)
Resistance
Max. 1 z
Wiring harness between CN28 (female) (6) – chassis ground (GND3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
7
8
Ground fault in wiring harness
Confirmation of repair
D155A-6
(5) – Wiring harness between fuse CN14 (female) (3), (5), CN28 (female) (3), CN23 (female) (3), or circuit branch end and chassis ground
Resistance
Wiring harness between CN14 (female) (2) – CN29 (female) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN29 (female) (4) – CN28 (female) (4) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN28 (female) (5) – CN23 (female) (6) and chassis ground
Resistance
Min. 1 Mz
1. 2. 3. 4.
Min. 1 Mz
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the front windshield wiper switch ON and intermittent switch OFF. 5. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
81
SEN03210-02
Trouble
40 Troubleshooting
(3) Front windshield wiper does not operate intermittently. • Before carrying out troubleshooting, check that continuous operation is normal.
Related information
No.
1
• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with front wiper switch and intermittent switch ON. • During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
Check item
Intermittent switch
Procedure of troubleshooting
Judgment and remedy
• The state of the intermittent switch is nora Prepare with starting switch OFF, then carry out troublemal. YES shooting without turning starting switch ON. • Proceed to the next check item. CN11 (male)
Between (5) – (6)
Intermittent switch
Resistance
OFF
Min. 1 Mz NO
ON
Max. 1 z
• The intermittent switch is defective. • Replace the intermittent switch. • Proceed to "Confirmation of repair".
• The state of the front wiper intermittent a Prepare with starting switch OFF, then turn starting switch selector relay is norYES ON and carry out troubleshooting. mal. • Proceed to the next check item.
2
3
Front wiper intermittent selector relay Replace front wiper intermittent selector relay (Right No.) with another relay. If front wiper becomes normal at this time, intermittent selector relay is defective.
Front wiper intermittent relay
CN29
NO
• The front wiper intermittent selector relay is defective. • Replace the front wiper intermittent selector relay. • Proceed to "Confirmation of repair".
• The state of the front wiper intermittent relay a Prepare with starting switch OFF, then turn starting switch YES is normal. ON and carry out troubleshooting. • Proceed to the next check item.
Replace front wiper intermittent relay (Right No.) with another relay. If front wiper becomes normal at this time, intermittent relay is defective.
CN28
NO
• The front wiper intermittent relay is defective. • Replace the front wiper intermittent relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
82
Open circuit in wiring harness
Wiring harness between CN11 (female) (6) – CN29 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN29 (female) (5) – CN28 (female) (2)
Resistance
Max. 1 z
Wiring harness between CN29 (female) (2) – chassis ground (GND3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
6
Check item
Ground fault in wiring harness
Confirmation of repair
D155A-6
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CN11 (female) (6) – CN29 (female) (1) or circuit branch end and chassis ground
Resistance
Wiring harness between CN29 (female) (5) – CN28 (female) (2) and chassis ground
Resistance
1. 2. 3. 4.
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Min. 1 Mz
Min. 1 Mz
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the front windshield wiper switch and intermittent switch ON. 5. Does this failure recur?
83
SEN03210-02
Trouble Related information
No.
40 Troubleshooting
(4) Rear windshield wiper does not operate (Continuous operation is defective). • If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become defective. • 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.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse ( -5) is broken, circuit probably has ground fault (See check item 7). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the rear a Prepare with starting switch OFF, then turn starting switch wiper motor is normal. YES ON and carry out troubleshooting. • Proceed to the next check item. 2
Rear wiper motor
CN37
Rear wiper switch
Voltage
Between (6) – (1)
ON
20 – 30 V NO
If voltage is normal but wiper does not operate, motor is defective.
• The rear wiper motor is defective. • Replace the rear wiper motor. • Proceed to "Confirmation of repair".
• The state of the rear a Prepare with starting switch OFF, then carry out troublewiper switch is normal. YES shooting without turning starting switch ON. • Proceed to the next check item. 3
Rear wiper switch
CN12 (male)
Between (2) – (3)
4
Rear wiper intermittent selector relay
Rear wiper switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
NO
• The state of the rear wiper intermittent a Prepare with starting switch OFF, then turn starting switch selector relay is norYES ON and carry out troubleshooting. mal. • Proceed to the next check item.
Replace rear wiper intermittent selector relay (Right No.) with another relay. If rear wiper becomes normal at this time, intermittent selector relay is defective.
84
• The rear wiper switch is defective. • Replace the rear wiper switch. • Proceed to "Confirmation of repair".
CN33
NO
• The rear wiper intermittent selector relay is defective. • Replace the rear wiper intermittent selector relay. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
Check item
Rear wiper intermittent relay
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• The state of the rear wiper intermittent relay a Prepare with starting switch OFF, then turn starting switch YES is normal. ON and carry out troubleshooting. • Proceed to the next check item.
Replace rear wiper intermittent relay (Right No.) with another relay. If rear wiper becomes normal at this time, intermittent relay is defective.
CN32
NO
• The rear wiper intermittent relay is defective. • Replace the rear wiper intermittent relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
6
Open circuit in wiring harness
(5) – Wiring harness between fuse CN12 (female) (3), (5), CN32 (female) (3), or CN37 (female) (6)
Resistance
Max. 1 z
Wiring harness between CN12 (female) (2) – CN33 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN33 (female) (4) – CN32 (female) (4)
Resistance
Max. 1 z
Wiring harness between CN32 (female) (5) – CN37 (female) (4)
Resistance
Max. 1 z
Wiring harness between CN32 (female) (6) – chassis ground (GND3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
7
8
Ground fault in wiring harness
Confirmation of repair
D155A-6
(5) – Wiring harness between fuse CN12 (female) (3), (5), CN32 (female) (3), CN37 (female) (6), or circuit branch end and chassis ground
Resistance
Wiring harness between CN12 (female) (2) – CN33 (female) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN33 (female) (4) –- CN32 (female) (4) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN32 (female) (5) – CN37 (female) (4) and chassis ground
Resistance
Min. 1 Mz
1. 2. 3. 4.
Min. 1 Mz
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the rear windshield wiper switch ON and intermittent switch OFF. 5. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
85
SEN03210-02
Trouble
40 Troubleshooting
(5) Rear windshield wiper does not operate intermittently. • Before carrying out troubleshooting, check that continuous operation is normal.
Related information
No.
1
• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with rear wiper switch and intermittent switch ON. • During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
Check item
Intermittent switch
Procedure of troubleshooting
• The state of the intermittent switch is nora Prepare with starting switch OFF, then carry out troubleYES mal. shooting without turning starting switch ON. • Proceed to the next check item. CN11 (male)
Between (5) – (6)
2
Rear wiper intermittent selector relay
Judgment and remedy
Intermittent switch
Resistance
OFF
Min. 1 Mz NO
ON
Max. 1 z
• The state of the rear wiper intermittent a Prepare with starting switch OFF, then turn starting switch selector relay is norYES ON and carry out troubleshooting. mal. • Proceed to the next check item.
Replace rear wiper intermittent selector relay (Right No.) with another relay. If rear wiper becomes normal at this time, intermittent selector relay is defective.
3
Rear wiper intermittent relay
• The intermittent switch is defective. • Replace the intermittent switch. • Proceed to "Confirmation of repair".
CN33
NO
• The rear wiper intermittent selector relay is defective. • Replace the rear wiper intermittent selector relay. • Proceed to "Confirmation of repair".
• The state of the rear wiper intermittent relay a Prepare with starting switch OFF, then turn starting switch YES is normal. ON and carry out troubleshooting. • Proceed to the next check item.
Replace rear wiper intermittent relay (Right No.) with another relay. If rear wiper becomes normal at this time, intermittent relay is defective.
CN32
NO
• The rear wiper intermittent relay is defective. • Replace the rear wiper intermittent relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
86
Open circuit in wiring harness
Wiring harness between CN11 (female) (6) – CN33 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN33 (female) (5) – CN32 (female) (2)
Resistance
Max. 1 z
Wiring harness between CN33 (female) (2) – chassis ground (GND3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
6
Check item
Ground fault in wiring harness
Confirmation of repair
D155A-6
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CN11 (female) (6) – CN33 (female) (1) or circuit branch end and chassis ground
Resistance
Wiring harness between CN33 (female) (5) – CN32 (female) (2) and chassis ground
Resistance
1. 2. 3. 4.
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Min. 1 Mz
Min. 1 Mz
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the rear windshield wiper switch and intermittent switch ON. 5. Does this failure recur?
87
SEN03210-02
Trouble Related information
No.
40 Troubleshooting
(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. • 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.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse ( -6) is broken, circuit probably has ground fault (See check item 7). NO
2
Right door wiper motor
• The state of the right door wiper motor is a Prepare with starting switch OFF, then turn starting switch YES normal. ON and carry out troubleshooting. • Proceed to the next check item. CN17
Right door wiper switch
Voltage
Between (3) – (1)
ON
20 – 30 V
NO
If voltage is normal but wiper does not operate, motor is defective.
3
Right door wiper switch
• The right door wiper motor is defective. • Replace the right door wiper motor. • Proceed to "Confirmation of repair".
• The state of the right door wiper switch is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. CN13 (male)
Between (2) – (3)
88
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
Right door wiper switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
NO
• The right door wiper switch is defective. • Replace the right door wiper switch. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• The state of the right door wiper intermittent a Prepare with starting switch OFF, then turn starting switch selector relay is norYES ON and carry out troubleshooting. mal. • Proceed to the next check item.
4
Right door wiper intermittent selector Replace right door wiper intermittent relay selector relay (Right No.) with another relay. If right door wiper becomes normal at this time, intermittent selector relay is defective.
CN31
NO
• The right door wiper intermittent selector relay is defective. • Replace the right door wiper intermittent selector relay. • Proceed to "Confirmation of repair".
• The state of the right door wiper intermittent a Prepare with starting switch OFF, then turn starting switch YES relay is normal. ON and carry out troubleshooting. • Proceed to the next check item.
5
Right door wiper intermittent relay Replace right door wiper intermittent
relay (Right No.) with another relay. If right door wiper becomes normal at this time, intermittent relay is defective.
CN30
NO
• The right door wiper intermittent relay is defective. • Replace the right door wiper intermittent relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
6
Open circuit in wiring harness
D155A-6
(6) – Wiring harness between fuse CN13 (female) (3), (5) or CN17 (female) (4)
Resistance
Max. 1 z
Wiring harness between fuse CN30 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN13 (female) (2) – CN31 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN31 (female) (4) – CN30 (female) (4)
Resistance
Max. 1 z
Wiring harness between CN30 (female) (5) – CN17 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN30 (female) (6) – chassis ground (GND3)
Resistance
Max. 1 z
Wiring harness between CN17 (female) (1) – chassis ground (GND1)
Resistance
Max. 1 z
(6) –
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
89
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
7
8
90
Ground fault in wiring harness
Confirmation of repair
(6) – Wiring harness between fuse CN13 (female) (3), (5), CN17 (female) (4), or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between fuse (6) – CN30 (female) (3) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN13 (female) (2) – CN31 (female) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN31 (female) (4) – CN30 (female) (4) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN30 (female) (5) – CN17 (female) (3) and chassis ground
Resistance
Min. 1 Mz
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the right door wiper switch ON and intermittent switch OFF. 5. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
Trouble
SEN03210-02
(7) Right door wiper does not operate intermittently. • Before carrying out troubleshooting, check that continuous operation is normal.
Related information
No.
1
• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with right door wiper switch and intermittent switch ON. • During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
Check item
Intermittent switch
Procedure of troubleshooting
Judgment and remedy
• The state of the intermittent switch is nora Prepare with starting switch OFF, then carry out troubleYES mal. shooting without turning starting switch ON. • Proceed to the next check item. CN11 (male)
Between (5) – (6)
Intermittent switch
Resistance
OFF
Min. 1 Mz NO
ON
Max. 1 z
• The intermittent switch is defective. • Replace the intermittent switch. • Proceed to "Confirmation of repair".
• The state of the right door wiper intermittent a Prepare with starting switch OFF, then turn starting switch selector relay is norYES ON and carry out troubleshooting. mal. • Proceed to the next check item.
2
Right door wiper intermittent selector Replace right door wiper intermittent relay selector relay (Right No.) with another relay. If right door wiper becomes normal at this time, intermittent selector relay is defective.
CN31
NO
• The right door wiper intermittent selector relay is defective. • Replace the right door wiper intermittent selector relay. • Proceed to "Confirmation of repair".
• The state of the right door wiper intermittent a Prepare with starting switch OFF, then turn starting switch YES relay is normal. ON and carry out troubleshooting. • Proceed to the next check item.
3
Right door wiper intermittent relay Replace right door wiper intermittent
relay (Right No.) with another relay. If right door wiper becomes normal at this time, intermittent relay is defective.
CN30
NO
• The right door wiper intermittent relay is defective. • Replace the right door wiper intermittent relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Open circuit in wiring harness
D155A-6
Wiring harness between CN11 (female) (6) – CN31 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN31 (female) (5) – CN30 (female) (2)
Resistance
Max. 1 z
Wiring harness between CN31 (female) (2) – chassis ground (GND3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
91
SEN03210-02
No.
5
6
92
40 Troubleshooting
Check item
Ground fault in wiring harness
Confirmation of repair
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CN11 (female) (6) – CN31 (female) (1) or circuit branch end and chassis ground
Resistance
Wiring harness between CN31 (female) (5) – CN30 (female) (2) and chassis ground
Resistance
1. 2. 3. 4. 5.
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Min. 1 Mz
Min. 1 Mz
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the right door wiper switch and intermittent switch ON. Does this failure recur?
D155A-6
40 Troubleshooting
Trouble Related information
No.
SEN03210-02
(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.
• 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.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse ( -6) is broken, circuit probably has ground fault (See check item 7). NO
2
Left door wiper motor
• The state of the left door wiper motor is a Prepare with starting switch OFF, then turn starting switch YES normal. ON and carry out troubleshooting. • Proceed to the next check item. CN24
Left door wiper switch
Voltage
Between (3) – (1)
ON
20 – 30 V
NO
If voltage is normal but wiper does not operate, motor is defective.
3
Left door wiper switch
• The left door wiper motor is defective. • Replace the left door wiper motor. • Proceed to "Confirmation of repair".
• The state of the left door wiper switch is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. CN15 (male)
Between (2) – (3)
D155A-6
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
Left door wiper switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
NO
• The left door wiper switch is defective. • Replace the left door wiper switch. • Proceed to "Confirmation of repair".
93
SEN03210-02
No.
Check item
40 Troubleshooting
Procedure of troubleshooting
Judgment and remedy
• The state of the left door wiper intermittent a Prepare with starting switch OFF, then turn starting switch selector relay is norYES ON and carry out troubleshooting. mal. • Proceed to the next check item.
4
Left door wiper intermittent selector Replace left door wiper intermittent relay selector relay (Right No.) with another relay. If left door wiper becomes normal at this time, intermittent selector relay is defective.
CN27
NO
• The left door wiper intermittent selector relay is defective. • Replace the left door wiper intermittent selector relay. • Proceed to "Confirmation of repair".
• The state of the left door wiper intermittent a Prepare with starting switch OFF, then turn starting switch YES relay is normal. ON and carry out troubleshooting. • Proceed to the next check item.
5
Left door wiper intermittent relay Replace left door wiper intermittent
relay (Right No.) with another relay. If left door wiper becomes normal at this time, intermittent relay is defective.
CN26
NO
• The left door wiper intermittent relay is defective. • Replace the left door wiper intermittent relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Resistance
Max. 1 z
(6) – Wiring harness between fuse CN26 (female) (3) or CN24 (female) (4)
Resistance
Max. 1 z
Wiring harness between CN15 (female) (2) – CN27 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN27 (female) (4) – CN26 (female) (4)
Resistance
Max. 1 z
Wiring harness between CN26 (female) (5) – CN24 (female) (3)
Resistance
Max. 1 z
Wiring harness between CN26 (female) (6) – chassis ground (GND3)
Resistance
Max. 1 z
Wiring harness between CN24 (female) (1) – chassis ground (GND3)
Resistance
Max. 1 z
Wiring harness between fuse CN15 (female) (3), (5)
6
94
Open circuit in wiring harness
(6) –
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item.
7
8
Ground fault in wiring harness
Confirmation of repair
D155A-6
(6) – Wiring harness between fuse CN15 (female) (3), (5) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between fuse (6) – CN26 (female) (3), CN24 (female) (4) or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN15 (female) (2) – CN27 (female) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN27 (female) (4) – CN26 (female) (4) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CN26 (female) (5) – CN24 (female) (3) and chassis ground
Resistance
Min. 1 Mz
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the left door wiper switch ON and intermittent switch OFF. 5. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
95
SEN03210-02
Trouble
40 Troubleshooting
(9) Left door wiper does not operate intermittently. • Before carrying out troubleshooting, check that continuous operation is normal.
Related information
No.
1
• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with left door wiper switch and intermittent switch ON. • During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
Check item
Intermittent switch
Procedure of troubleshooting
Judgment and remedy
• The state of the intermittent switch is nora Prepare with starting switch OFF, then carry out troubleYES mal. shooting without turning starting switch ON. • Proceed to the next check item. CN11 (male)
Between (5) – (6)
Intermittent switch
Resistance
OFF
Min. 1 Mz NO
ON
Max. 1 z
• The intermittent switch is defective. • Replace the intermittent switch. • Proceed to "Confirmation of repair".
• The state of the left door wiper intermittent a Prepare with starting switch OFF, then turn starting switch selector relay is norYES ON and carry out troubleshooting. mal. • Proceed to the next check item.
2
Left door wiper intermittent selector Replace left door wiper intermittent relay selector relay (Right No.) with another relay. If left door wiper becomes normal at this time, intermittent selector relay is defective.
CN27
NO
• The left door wiper intermittent selector relay is defective. • Replace the left door wiper intermittent selector relay. • Proceed to "Confirmation of repair".
• The state of the left door wiper intermittent a Prepare with starting switch OFF, then turn starting switch YES relay is normal. ON and carry out troubleshooting. • Proceed to the next check item.
3
Left door wiper intermittent relay Replace left door wiper intermittent
relay (Right No.) with another relay. If left door wiper becomes normal at this time, intermittent relay is defective.
CN26
NO
• The left door wiper intermittent relay is defective. • Replace the left door wiper intermittent relay. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
96
Open circuit in wiring harness
Wiring harness between CN11 (female) (6) – CN27 (female) (1)
Resistance
Max. 1 z
Wiring harness between CN27 (female) (5) – CN26 (female) (2)
Resistance
Max. 1 z
Wiring harness between CN27 (female) (2) – chassis ground (GND3)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
5
6
Check item
Ground fault in wiring harness
Confirmation of repair
D155A-6
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between CN11 (female) (6) – CN27 (female) (1) or circuit branch end and chassis ground
Resistance
Wiring harness between CN27 (female) (5) – CN26 (female) (2) and chassis ground
Resistance
1. 2. 3. 4. 5.
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Min. 1 Mz
Min. 1 Mz
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the left door wiper switch and intermittent switch ON. Does this failure recur?
97
SEN03210-02
Trouble Related information
No.
40 Troubleshooting
(10) Water does not come out from front window washer. • Before carrying out troubleshooting, check that windshield wiper operates normally. • If fuse ( -5) is broken, operations of both front window washer and rear window washer become defective.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse ( -5) is broken, circuit probably has ground fault (See check item 5). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the front window washer motor a Prepare with starting switch OFF, then turn starting switch YES is normal. ON and carry out troubleshooting. • Proceed to the next check item. 2
Front window washer motor
WSH1
Front wiper switch
Voltage
Between (3) – (4)
ON (Wash position)
20 – 30 V NO
If voltage is normal but washer does not operate, motor is defective.
• The front window washer motor is defective. • Replace the front window washer motor. • Proceed to "Confirmation of repair".
• The state of the front wiper switch is normal. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
Front wiper switch
CN14 (male)
Between (5) – (6)
Front wiper switch
Resistance
OFF
Min. 1 Mz NO
ON (Wash position)
Max. 1 z
• The front wiper switch is defective. • Replace the front wiper switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
98
Open circuit in wiring harness
Resistance
Max. 1 z
Wiring harness between CN14 (female) (6) – WSH1 (female) (3)
Resistance
Max. 1 z
Wiring harness between WSH1 (female) (4) – chassis ground (GND06)
Resistance
Max. 1 z
Wiring harness between fuse CN14 (female) (3), (5)
(5) –
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 5
Ground fault in wiring harness
(5) – Wiring harness between fuse CN14 (female) (3), (5) or circuit branch end and chassis ground Wiring harness between CN14 (female) (6) – WSH1 (female) (3) and chassis ground
6
Confirmation of repair
D155A-6
1. 2. 3. 4. 5.
Resistance
Resistance
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the front window washer switch ON. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Min. 1 Mz
Min. 1 Mz
99
SEN03210-02
Trouble Related information
No.
40 Troubleshooting
(11) Water does not come out from rear window washer. • Before carrying out troubleshooting, check that windshield wiper operates normally. • If fuse ( -5) is broken, operations of both front window washer and rear window washer become defective.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse ( -5) is broken, circuit probably has ground fault (See check item 5). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the rear window washer motor a Prepare with starting switch OFF, then turn starting switch YES is normal. ON and carry out troubleshooting. • Proceed to the next check item. 2
Rear window washer motor
WSH2
Rear wiper switch
Voltage
Between (3) – (4)
ON (Wash position)
20 – 30 V NO
If voltage is normal but washer does not operate, motor is defective.
• The rear window washer motor is defective. • Replace the rear window washer motor. • Proceed to "Confirmation of repair".
• The state of the rear wiper switch is normal. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 3
Rear wiper switch
CN12 (male)
Between (5) – (6)
Rear wiper switch
Resistance
OFF
Min. 1 Mz NO
ON (Wash position)
Max. 1 z
• The rear wiper switch is defective. • Replace the rear wiper switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Open circuit in wiring harness
100
Resistance
Max. 1 z
Wiring harness between CN12 (female) (6) – WSH2 (female) (3)
Resistance
Max. 1 z
Wiring harness between WSH2 (female) (4) – chassis ground (GND06)
Resistance
Max. 1 z
Wiring harness between fuse CN12 (female) (3), (5)
(5) –
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 5
Ground fault in wiring harness
(5) – Wiring harness between fuse CN12 (female) (3), (5) or circuit branch end and chassis ground Wiring harness between CN12 (female) (6) – WSH2 (female) (3) and chassis ground
6
Confirmation of repair
D155A-6
1. 2. 3. 4. 5.
Resistance
Resistance
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the rear window washer switch ON. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Min. 1 Mz
Min. 1 Mz
101
SEN03210-02
Trouble Related information
No.
40 Troubleshooting
(12) Water does not come out from right door washer. • Before carrying out troubleshooting, check that windshield wiper operates normally. • If fuse ( tive.
-6) is broken, operations of both right door washer and left door washer become defec-
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse ( -6) is broken, circuit probably has ground fault (See check item 5). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the right door washer motor is a Prepare with starting switch OFF, then turn starting switch YES normal. ON and carry out troubleshooting • Proceed to the next check item. 2
Right door washer motor
WSH2
Right door wiper switch
Voltage
Between (1) – (2)
ON (Wash position)
20 – 30 V
NO
If voltage is normal but washer does not operate, motor is defective.
3
Right door wiper switch
• The right door washer motor is defective. • Replace the right door washer motor. • Proceed to "Confirmation of repair".
• The state of the right door wiper switch is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. CN13 (male)
Between (5) – (6)
Right door wiper switch
Resistance
OFF
Min. 1 Mz
ON (Wash position)
Max. 1 z
NO
• The right door wiper switch is defective. • Replace the right door wiper switch. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. a Prepare with starting switch OFF, then carry out troubleYES shooting without turning starting switch ON. • Proceed to the next check item. 4
Open circuit in wiring harness
102
Resistance
Max. 1 z
Wiring harness between CN13 (female) (6) – WSH2 (female) (1)
Resistance
Max. 1 z
Wiring harness between WSH2 (female) (2) – chassis ground (GND06)
Resistance
Max. 1 z
Wiring harness between fuse CN13 (female) (3), (5)
(6) –
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 5
Ground fault in wiring harness
(6) – Wiring harness between fuse CN13 (female) (3), (5) or circuit branch end and chassis ground Wiring harness between CN13 (female) (6) – WSH2 (female) (1) and chassis ground
6
Confirmation of repair
D155A-6
1. 2. 3. 4. 5.
Resistance
Resistance
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the right door washer switch ON. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Min. 1 Mz
Min. 1 Mz
103
SEN03210-02
Trouble Related information
No.
40 Troubleshooting
(13) Water does not come out from left door washer. • Before carrying out troubleshooting, check that windshield wiper operates normally. • If fuse ( -6) is broken, operations of both right door washer and left door washer become defective.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the fuse is normal. YES • Proceed to the next check item.
1
Fuse
If fuse ( -6) is broken, circuit probably has ground fault (See check item 5). NO
• If the fuse has burnt out, proceed to "Ground fault in wiring harness". • If the fuse has not burnt out but it has no continuity, replace the fuse. • Proceed to "Confirmation of repair".
• The state of the left door washer motor is a Prepare with starting switch OFF, then turn starting switch YES normal. ON and carry out troubleshooting. • Proceed to the next check item. 2
Left door washer motor
WSH1
Left door wiper switch
Voltage
Between (1) – (2)
ON (Wash position)
20 – 30 V
NO
If voltage is normal but washer does not operate, motor is defective.
3
Left door wiper switch
• The left door washer motor is defective. • Replace the left door washer motor. • Proceed to "Confirmation of repair".
• The state of the left door wiper switch is a Prepare with starting switch OFF, then carry out troubleYES normal. shooting without turning starting switch ON. • Proceed to the next check item. CN15 (male)
Between (5) – (6)
Left door wiper switch
Resistance
OFF
Min. 1 Mz
ON (Wash position)
Max. 1 z
NO
• The left door wiper switch is defective. • Replace the left door wiper switch. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 4
Open circuit in wiring harness
104
Resistance
Max. 1 z
Wiring harness between CN15 (female) (6) – WSH1 (female) (1)
Resistance
Max. 1 z
Wiring harness between WSH1 (female) (2) – chassis ground (GND06)
Resistance
Max. 1 z
Wiring harness between fuse CN15 (female) (3), (5)
(6) –
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. 5
Ground fault in wiring harness
(6) – Wiring harness between fuse CN15 (female) (3), (5) or circuit branch end and chassis ground Wiring harness between CN15 (female) (6) – WSH1 (female) (1) and chassis ground
6
Confirmation of repair
D155A-6
1. 2. 3. 4. 5.
Resistance
Resistance
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Turn the left door washer switch ON. Does this failure recur?
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Min. 1 Mz
Min. 1 Mz
105
SEN03210-02
40 Troubleshooting
Related circuit diagram
106
D155A-6
40 Troubleshooting
SEN03210-02
E-26 KOMTRAX terminal does not operate normally Trouble Related information
No.
1
KOMTRAX terminal does not operate normally. • If KOMTRAX terminal administrator makes request for checking system on machine side for trouble, carry out following troubleshooting. • Even if KOMTRAX terminal has trouble, it does not particularly appear on machine. • Carry out all troubleshooting on service menu screen of machine monitor.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the transmission 1 function of a Turn starting switch ON and check "Setting condition of terYES KOMTRAX is normal. minal" screen. • Proceed to the next check item. 1
Transmission 1
Check item
Normal display
Communication start check
Completion
NO
• The transmission 1 function of KOMTRAX is defective. • Contact the KOMTRAX service hot-line. • Proceed to "Confirmation of repair".
• The state of the GPS positioning function of a Turn starting switch ON and check "Condition of positioning YES KOMTRAX is normal. and communication" screen. • Proceed to the next check item. 2
GPS positioning
Check item
Normal display N ###,##,##(Latitude)
Positioning
E ###,##,##(Longitude)
NO
In positioning If latitude and longitude are not displayed in 5 minutes on open ground, notify KOMTRAX service hot line.
3
Communication environment
• The state of the communication environa Turn starting switch ON and check "Condition of positioning ment of KOMTRAX is YES and communication" screen. normal. • Proceed to the next check item. Check item
Normal display
Communication
Zone level 1 – Zone level 3 NO
If zone level 1 – 3 is not displayed within communication zone of ORBCOMM, notify KOMTRAX service hot line.
D155A-6
• The GPS positioning function of KOMTRAX is defective. • Contact the KOMTRAX service hot-line. • Proceed to "Confirmation of repair".
• The communication environment of KOMTRAX is defective. • Contact the KOMTRAX service hot-line. • Proceed to "Confirmation of repair".
107
SEN03210-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the transmission 2 function of a Turn starting switch ON and check "Condition of positioning YES KOMTRAX is normal. and communication" screen. • Proceed to the next check item. 4
5
Transmission 2
Confirmation of repair
Check item
Normal display
Number of items not transmitted
0 – 9 (Normally 0)
1. 2. 3. 4.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
a Select "Setting condition of terminal" from "12 Display of KOMTRAX setting" in the service menu of the machine monitor.
108
NO
• The transmission 2 function of KOMTRAX is defective. • Contact the KOMTRAX service hot-line. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
a Select "Condition of positioning and communication" from "12 Display of KOMTRAX setting" in the service menu of the machine monitor.
D155A-6
40 Troubleshooting
SEN03210-02
E-27 Fan does not reverse Trouble Related information
No.
1
2
3
1
When fan is set in fan cleaning mode or fan reverse mode (if equipped), fan does not reverse. • If any switched is operated during reverse prohibition period, orange lamp blinks. • Orange lamp lights up in cleaning mode and reverse mode.
Check item
Fan reverse solenoid
Procedure of troubleshooting
Judgment and remedy
If failure code [DW7BKA], [DW7BKB] or [DW7BKY] is displayed, carry out troubleshooting for it first.
Operation of fan cleaning switch in reverse prohi- If switch is operated after engine is started, fan does not reverse bition period and orange lamp blinks. At this time, orange lamp indicated that Operation of switch operation is ineffective but does not indicate trouble. Turn key switch OFF to stop engine and turn battery relay OFF, fan reverse and then set fan in fan cleaning or fan reverse mode again. switch (if equipped) in reverse prohibition period
Fan cleaning switch
• The state of the fan reverse solenoid is normal. YES • Proceed to the next check item.
NO
• The fan reverse solenoid is defective. • Replace the fan reverse solenoid. • Proceed to "Confirmation of repair".
-
• The state of the fan cleaning switch is normal. • Proceed to the next check item.
-
• The state of the fan reverse switch is normal. • Proceed to the next check item.
• The state of the fan cleaning switch is nora Prepare with starting switch OFF, then carry out troubleYES mal. shooting without turning starting switch ON. • Proceed to the next check item. FAN1 (male)
Between (2) and (1)
Switch
Resistance
OFF
Min. 1 Mz NO
CLN position
Max. 1 z
• The fan cleaning switch is defective. • Replace the fan cleaning switch. • Proceed to "Confirmation of repair".
• The state of the fan reverse switch (if a Prepare with starting switch OFF, then carry out troubleYES equipped) is normal. shooting without turning starting switch ON. • Proceed to the next check item.
4
Fan reverse switch (if equipped)
FAN2 (male) Between (1) and (3)
Between (4) and (3)
D155A-6
Switch
Resistance
OFF
Min. 1 Mz
CLN position
Min. 1 Mz
REV position
Max. 1 z
OFF
Min. 1 Mz
CLN position
Max. 1 z
REV position
Min. 1 Mz
NO
• The fan reverse switch (if equipped) is defective. • Replace the fan reverse switch (if equipped). • Proceed to "Confirmation of repair".
109
SEN03210-02
No.
40 Troubleshooting
Check item
[When standard cleaning switch is employed] Open circuit in wiring harness 5 [When reverse switch (if equipped) is employed] Open circuit in wiring harness
Procedure of troubleshooting
Judgment and remedy
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between FAN1 (female) (1) and GND7
Resistance
Max. 1 z
Wiring harness between FAN1 (female) (2) and STCN2 (female) (38)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No open circuit occurs a Prepare with starting switch OFF, then carry out troublein the wiring harness. YES shooting without turning starting switch ON. • Proceed to the next check item. Wiring harness between FAN2 (female) (3) and GND7
Resistance
Max. 1 z
Wiring harness between FAN2 (female) (4) and STCN2 (female) (38)
Resistance
Max. 1 z
Wiring harness between FAN2 (female) (1) and STCN2 (female) (2)
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
7
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Reverse the fan. Does this failure recur?
NO
• The steering controller may be defective. • Replace the steering controller. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
110
D155A-6
40 Troubleshooting
SEN03210-02
E-28 Gear cannot be shifted Trouble Related information No.
1
Gear cannot be shifted. -
Check item
Procedure of troubleshooting
Judgment and remedy
a When failure code related to gear shift operation switch is not displayed
1
• The state of the gear Gear shift shift operation switch Hold down shift operation switch for 10 seconds. If any of foloperation is normal. YES switch lowing failure codes is displayed at this time, carry out trouble• Proceed to the next shooting for it. • Shift-up check item. [DD12KA], [DD12KB], [DD13KA], [DD13KB] switch • Shift-down a When failure code related to gear shift operation switch is • The gear shift operaswitch displayed tion switch is defective. • Shift switch • Replace the gear shift NO (Optional operation switch. type lever) Carry out troubleshooting for displayed failure code. • Proceed to "Confirmation of repair". • The state of the gear speed is normal. YES • Proceed to the next check item.
2
Gear speed
If action code displays failure code [E03] or [E04], gear speed is limited. Carry out troubleshooting gear speed limit first. NO
• The gear speed is limited. • Perform troubleshooting for gear speed limit. • Proceed to "Confirmation of repair".
YES The repair is completed.
3
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Perform a gear shift operation. Does this failure recur?
NO
• The transmission clutch may be defective. • Repair or replace the transmission clutch. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
111
SEN03210-02
40 Troubleshooting
E-29 Electric priming pump does not operate or does not stop automatically Trouble Relative information No.
1
1
Electric priming pump does not operate or does not stop automatically -
Check item
Battery charge level
Procedure of troubleshooting
Judgment and remedy • The state of the battery charge level is normal. YES • Proceed to the next check item.
Battery charge level may be low. Check battery. NO
• The battery charge is insufficient. • Charge the battery. • Proceed to "Confirmation of repair".
• The state of the circuit breaker is normal. YES • Proceed to the next check item. 2
Circuit breaker
If circuit breaker No. 10 is turned OFF, circuit probably has ground fault. (See check item No. 5) NO
3
Open circuit in wiring harness (Power supply system)
• If the circuit breaker is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
• No open circuit occurs a Prepare with battery ground cable disconnected, then conin the wiring harness. nect it and carry out troubleshooting (since power supply is YES • Proceed to the next unswitched). check item.
Between EPP (1) – (2)
Voltage
20 – 30 V
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
a Prepare with battery ground cable disconnected, then con• No open circuit occurs nect battery and turn electric priming pump ON and carry out in the wiring harness. troubleshooting. YES • Proceed to the next • Lamp blinks but stops in about 5 seconds. check item. Between EFP (1) – (2) Voltage 20 – 30 V
4
Open circuit in wiring harness (Drive a Prepare with battery ground cable disconnected, then carry power supply out troubleshooting without reconnecting (since power supsystem) ply is unswitched). Between EPP (female) (2) – ground
112
Resistance
Max. 1 z
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03210-02
Procedure of troubleshooting
Judgment and remedy
• No ground fault occurs a Prepare with battery ground cable disconnected, then carry in the wiring harness. out troubleshooting without reconnecting (since power sup- YES • Proceed to the next ply is unswitched). check item.
5
Ground fault in wiring harness
Wiring harness between EPP (female) (1) – circuit breaker B30S and ground
Resistance
Wiring harness between EPP (female) (3) – EFP (female) (1) and ground
Resistance
Min. 1 Mz
Wiring harness between EPP (female) (4) – EFP (female) (2) and ground
Resistance
Min. 1 Mz
Between EFP (female) (1) – (2)
Resistance
1–3z
Min. 1 Mz
NO
a Prepare with battery ground cable disconnected, then connect battery and turn electric priming pump ON and carry out troubleshooting. Between EPP (3) – (4)
6
Voltage
20 – 30 V
• Lamp blinks but output voltage is improper. • Results of troubleshooting steps 1 – 4 are normal and lamp Electric primdoes not blink. ing pump switch a When electric priming pump does not stop automatically, electric priming pump switch may be defective. (Turn toggle switch OFF to stop pump and then replace switch.)
7
• Lamp blinks but stops in about 5 seconds. Electric prim- a If pump is overloaded, power supply is turned OFF automatically to protect circuit (Priming switch is reset automatiing pump cally).
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the electric priming pump YES switch is normal. • Proceed to the next check item.
NO
• The electric priming pump switch is defective. • Replace the electric priming pump switch. • Proceed to "Confirmation of repair".
• The state of the electric priming pump is YES normal. • Proceed to the next check item.
NO
• The electric priming pump is overloaded. • Replace the electric priming pump. • Proceed to "Confirmation of repair".
YES The repair is completed.
8
9
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Turn the starting switch ON. Does this failure recur?
NO
• The electric priming pump may be defective. • Replace the electric priming pump. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
113
SEN03210-02
40 Troubleshooting
Related circuit diagram
1 1 1
114
D155A-6
40 Troubleshooting
D155A-6
SEN03210-02
115
SEN03210-02
40 Troubleshooting
D155A-6 Bulldozer Form No. SEN03210-02
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
116
D155A-6
SEN03211-02
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
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) ................................................................................ 6 H-3 Machine does not start at any gear speed ............................................................................................... 8 H-4 Machine can travel only forward or in reverse ....................................................................................... 10 H-5 When gear speed or travel direction is changed, time lag is large......................................................... 12 H-6 Steering is not possible .......................................................................................................................... 14 H-7 Steering is possible only on one side ..................................................................................................... 16 H-8 Steering overrun occurs ......................................................................................................................... 18 H-9 Brake does not work .............................................................................................................................. 19 H-10 Power train oil is overheated................................................................................................................ 21 H-11 Speed of all work equipment is low ...................................................................................................... 23 H-12 No work equipment moves................................................................................................................... 25 H-13 Blade lift speed or power is low............................................................................................................ 27
D155A-6
1
SEN03211-02
40 Troubleshooting
H-14 Blade tilt speed or power is low............................................................................................................ 29 H-15 Ripper lift speed or power is low .......................................................................................................... 31 H-16 Ripper tilt speed or power is low .......................................................................................................... 33 H-17 Hydraulic drift of blade lift is large ........................................................................................................ 35 H-18 Hydraulic drift of blade tilt is large ........................................................................................................ 36 H-19 Hydraulic drift of ripper lift is large ........................................................................................................ 37 H-20 Ripper pin puller cylinder does not operate.......................................................................................... 38 H-21 Abnormal sound comes out from around work equipment pump......................................................... 39 H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine overheats)............... 40
2
D155A-6
40 Troubleshooting
SEN03211-02
Information in troubleshooting table
1
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand that information fully. Trouble Related information No.
Trouble which occurred in the machine Information related to detected trouble or troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy
1
2
3
Possible check items for troubleshooting (Given numbers are reference numbers, which do not <<Contents of description> indicate pri- • Standard value in normal state to judge possible causesRemarks on judgment ority)
YES
Remedy when criterion is judged to be "YES"
NO
Remedy when criterion is judged to be "NO"
4
5
Reconfirmation of check item
6
Confirmation of repair
D155A-6
3
SEN03211-02
40 Troubleshooting
H-1 Power is low (Drawbar pull is low) Trouble Related information No.
1
Power is low (Drawbar pull is low). Before carrying out troubleshooting, check that power train oil level is normal.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the engine is normal. a Prepare with engine stopped, then run engine at high idle YES • Proceed to the next and carry out troubleshooting. check item. 1
Engine
PCCS lever
Engine speed
F3 stall
1,450 rpm
NO
• The engine is defective. • Repair or replace the engine. • Proceed to "Confirmation of repair".
• The state of the power train pump is normal. YES • Proceed to the next check item. 2
Power train pump
Power train pump may be defective. Check it. NO
Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting. 3
Torque converter
PCCS lever
Torque converter inlet pressure
Torque converter outlet pressure
Neutral
Max. 1.0 MPa {Max. 10.0 kg/cm2}
0.29 – 0.69 MPa {3.0 – 7.0 kg/cm2}
a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
NO
• The torque converter is defective. • Repair or replace the torque converter. • Proceed to "Confirmation of repair".
Min. 2.84 MPa {Min. 29.0 kg/cm2}
Check that free length of spring and number of shims are normal and spool moves smoothly. • Free length of spring (large): 122 mm • Free length of spring (small): 108 mm • Number of shims: 6
• The transmission main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
Neutral
4
• The state of the torque converter is normal. YES • Proceed to the next check item.
• The state of the transmission main relief valve or its set presYES sure is normal. • Proceed to the next check item.
PCCS lever
4
• The power train pump is defective. • Repair or replace the power train pump. • Proceed to "Confirmation of repair".
Transmission main relief pressure TM
Transmission a Prepare with engine stopped, then keep engine stopped and main relief carry out troubleshooting. valve
NO
D155A-6
40 Troubleshooting
No.
SEN03211-02
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the transmission clutch valve a Prepare with engine stopped, then run engine at low idle YES (ECMV) is normal. and carry out troubleshooting. • Proceed to the next check item.
5
Transmission clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
F
Min. 2.35 MPa {Min. 24.0 kg/cm2}
R3 stall
R
Min. 2.40 MPa {Min. 24.5 kg/cm2}
F1 stall
1ST
Min. 2.62 MPa {Min. 26.7 kg/cm2}
F2 stall
2ND
Min. 2.35 MPa {Min. 24.0 kg/cm2}
F3 stall
3RD
Min. 2.62 MPa {Min. 26.7 kg/cm2}
Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 6
7
Brake valve
Parking brake lever
Steering brake
Brake oil pressure
Free
RB LB
2.16 MPa {22.0 kg/cm2}
Parking brake If check result of check item 6 is abnormal, parking brake lever lever or brake or brake pedal linkage is adjusted defectively. Check them. pedal linkage
NO
• The transmission clutch valve (ECMV) is defective. • Replace the transmission clutch valve (ECMV). • Proceed to "Confirmation of repair".
• The state of the brake valve is normal. YES • Proceed to the next check item.
NO
• The brake valve is defective. • Proceed to "Parking brake lever or brake pedal linkage".
• The state of the parking brake lever or brake pedal linkage is YES normal. • Proceed to the next check item.
NO
• The parking brake lever or brake pedal linkage is defective. • Replace the parking brake lever or brake pedal linkage . • Proceed to "Confirmation of repair".
YES The repair is completed.
8
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
9
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The transmission may be defective. • Repair or replace the transmission. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
5
SEN03211-02
40 Troubleshooting
H-2 Machine does not travel (at 2nd or 3rd gear speed) Trouble Related information No.
1
Machine does not travel (at 2nd or 3rd gear speed). • Before carrying out troubleshooting, check that power train oil level is normal. • Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the torque converter is normal. a Prepare with starting switch ON, then run engine at high idle YES • Proceed to the next and carry out troubleshooting. check item. 1
Torque converter
PCCS lever
Torque converter inlet pressure
Torque converter outlet pressure
Neutral
Max. 1.0 MPa {Max. 10.0 kg/cm2}
0.29 – 0.69 MPa {3.0 – 7.0 kg/cm2}
NO
• The torque converter is defective. • Repair or replace the torque converter. • Proceed to "Confirmation of repair".
• The state of the transmission clutch valve a Prepare with engine stopped, then run engine at low idle YES (ECMV) is normal. and carry out troubleshooting. • Proceed to the next check item. 2
3
Transmission clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F2 stall
2ND
Min. 2.35 MPa {Min. 24.0 kg/cm2}
F3 stall
3RD
Min. 2.62 MPa {Min. 26.7 kg/cm2}
Transmission Transmission clutch (2nd or 3rd gear speed) may have trouble clutch in it. Check it.
NO
• The transmission clutch valve (ECMV) is defective. • Replace the transmission clutch valve (ECMV). • Proceed to "Confirmation of repair".
• The state of the transmission clutch is norYES mal. • Proceed to the next check item.
NO
• The transmission clutch is defective. • Replace the transmission clutch. • Proceed to "Confirmation of repair".
• The state of the parking brake is normal. YES • Proceed to the next check item. 4
Parking brake
Parking brake may be malfunctioning (Dragging). Check linkage and valves. NO
6
• The parking brake is defective. • Check linkage and valves. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03211-02
Procedure of troubleshooting a Move to level place, start engine, and check.
5
Judgment and remedy • The state of the brake is normal. YES • Proceed to the next check item.
Brake Run engine at low idle and set transmission in F2. If machine does not move at this time, brake is dragging. Carry out troubleshooting for "H-9 Brake does not work".
NO
• The brake is defective. • Perform troubleshooting for "H-9 Brake does not work". • Proceed to "Confirmation of repair".
YES The repair is completed.
6
7
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Travel the machine and perform troubleshooting. Does this failure recur?
NO
• The transmission may be defective. • Repair or replace the transmission. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
7
SEN03211-02
40 Troubleshooting
H-3 Machine does not start at any gear speed Trouble Related information No.
1
Machine does not start at any gear speed. Before carrying out troubleshooting, check that power train oil level is normal.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the power train pump is normal. YES • Proceed to the next check item.
1
Power train pump
Power train pump may be defective. Check it. NO
a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Min. 2.84 MPa {Min. 29.0 kg/cm2}
• The state of the transmission main relief valve or its set presYES sure is normal. • Proceed to the next check item.
Check that free length of spring and number of shims are normal and spool moves smoothly. • Free length of spring (large): 122 mm • Free length of spring (small): 108 mm • Number of shims: 6
• The transmission main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
PCCS lever Neutral 2
• The power train pump is defective. • Replace the power train pump. • Proceed to "Confirmation of repair".
Transmission main relief pressure TM
Transmission a Prepare with engine stopped, then keep engine stopped and main relief carry out troubleshooting. valve
NO
• a Prepare with engine stopped, then run engine at low idle and carry out troubleshooting (after checking transmission YES main relief pressure is normal). •
3
8
Transmission clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
F
Min. 2.35 MPa {Min. 24.0 kg/cm2}
R3 stall
R
Min. 2.40 MPa {Min. 24.5 kg/cm2}
F1 stall
1ST
Min. 2.62 MPa {Min. 26.7 kg/cm2}
F2 stall
2ND
Min. 2.35 MPa {Min. 24.0 kg/cm2}
F3 stall
3RD
Min. 2.62 MPa {Min. 26.7 kg/cm2}
NO
The state of the transmission clutch valve (ECMV) is normal. Proceed to the next check item.
• The transmission clutch valve (ECMV) is defective. • Replace the transmission clutch valve (ECMV). • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
4
Check item
SEN03211-02
Procedure of troubleshooting
Transmission Transmission clutch (F or R) may have trouble in it. Check it. clutch
Judgment and remedy • The state of the transmission clutch is norYES mal. • Proceed to the next check item.
NO
• The transmission clutch is defective. • Replace the transmission clutch. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Travel the machine and perform troubleshooting. Does this failure recur?
NO
• The brake may be defective. • Perform troubleshooting for "H-9 Brake does not work". • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
9
SEN03211-02
40 Troubleshooting
H-4 Machine can travel only forward or in reverse Trouble Related information No.
1
Machine can travel only forward or in reverse. Before carrying out troubleshooting, check that power train oil level is normal.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the power train pump is normal. YES • Proceed to the next check item.
1
Power train pump
Power train pump may be defective. Check it. NO
a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Min. 2.84 MPa {Min. 29.0 kg/cm2}
• The state of the transmission main relief valve or its set presYES sure is normal. • Proceed to the next check item.
Check that free length of spring and number of shims are normal and spool moves smoothly. • Free length of spring (large): 122 mm • Free length of spring (small): 108 mm • Number of shims: 6
• The transmission main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
PCCS lever Neutral 2
• The power train pump is defective. • Replace the power train pump. • Proceed to "Confirmation of repair".
Transmission main relief pressure TM
Transmission a Prepare with engine stopped, then keep engine stopped and main relief carry out troubleshooting. valve
NO
• a Prepare with engine stopped, then run engine at low idle and carry out troubleshooting (after checking transmission YES main relief pressure is normal). • 3
4
Transmission clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
F
Min. 2.35 MPa {Min. 24.0 kg/cm2}
R3 stall
R
Min. 2.40 MPa {Min. 24.5 kg/cm2}
Transmission If check result of check item 3 is abnormal, seal of transmission clutch seal clutch (F or R) may be defective. Check it.
NO
• The transmission clutch valve (ECMV) is defective. • Proceed to "Transmission clutch seal".
• The state of the transmission clutch seal is YES normal. • Proceed to the next check item.
NO
10
The state of the transmission clutch valve (ECMV) is normal. Proceed to the next check item.
• The transmission clutch seal is defective. • Replace the transmission clutch seal. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03211-02
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Travel the machine and perform troubleshooting. Does this failure recur?
NO
• The transmission clutch may be defective. • Replace the transmission clutch. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
11
SEN03211-02
40 Troubleshooting
H-5 When gear speed or travel direction is changed, time lag is large 1 Trouble Related information No.
When gear speed or travel direction is changed, time lag is large. Before carrying out troubleshooting, check that power train oil level is normal.
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the power train pump is normal. YES • Proceed to the next check item.
1
Power train pump
Power train pump may be defective. Check it. NO
a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Min. 2.84 MPa {Min. 29.0 kg/cm2}
• The state of the transmission main relief valve or its set presYES sure is normal. • Proceed to the next check item.
Check that free length of spring and number of shims are normal and spool moves smoothly. • Free length of spring (large): 122 mm • Free length of spring (small): 108 mm • Number of shims: 6
• The transmission main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
PCCS lever Neutral 2
• The power train pump is defective. • Replace the power train pump. • Proceed to "Confirmation of repair".
Transmission main relief pressure TM
Transmission a Prepare with engine stopped, then keep engine stopped and main relief carry out troubleshooting. valve
NO
• a Prepare with engine stopped, then run engine at low idle and carry out troubleshooting (after checking transmission YES main relief pressure is normal). •
3
12
Transmission clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
F
Min. 2.35 MPa {Min. 24.0 kg/cm2}
R3 stall
R
Min. 2.40 MPa {Min. 24.5 kg/cm2}
F1 stall
1ST
Min. 2.62 MPa {Min. 26.7 kg/cm2}
F2 stall
2ND
Min. 2.35 MPa {Min. 24.0 kg/cm2}
F3 stall
3RD
Min. 2.62 MPa {Min. 26.7 kg/cm2}
NO
The state of the transmission clutch valve (ECMV) is normal. Proceed to the next check item.
• The transmission clutch valve (ECMV) is defective. • Proceed to "Transmission clutch seal".
D155A-6
40 Troubleshooting
No.
4
Check item
SEN03211-02
Procedure of troubleshooting
Transmission If check result of check item 3 is abnormal, seal of transmission clutch (F or R) may be defective. Check it. clutch seal
Judgment and remedy • The state of the transmission clutch seal is YES normal. • Proceed to the next check item.
NO
5
Transmission Transmission clutch may have trouble in it. Check it. clutch
• The transmission clutch seal is defective. • Replace the transmission clutch seal. • Proceed to "Confirmation of repair".
• The state of the transmission clutch is norYES mal. • Proceed to the next check item.
NO
• The transmission clutch is defective. • Replace the transmission clutch. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
7
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Travel the machine and perform troubleshooting. Does this failure recur?
NO
• The brake may be defective. • Perform troubleshooting for "H-9 Brake does not work". • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
13
SEN03211-02
40 Troubleshooting
H-6 Steering is not possible Trouble Related information No.
1
Steering is not possible. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the brake is normal. a Prepare with starting the engine, then drive the engine in low YES • Proceed to the next idle mode for troubleshooting. check item. 1
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".)
NO
• The brake is defective. • Perform troubleshooting for "H-9 Brake does not work". • Proceed to "Confirmation of repair".
• The state of the steering clutch valve a Prepare with starting switch OFF, then drive the engine in YES (ECMV) is normal. high idle mode for troubleshooting. • Proceed to the next check item.
2
3
Steering clutch valve (ECMV)
Steering clutch seal
PCCS lever
Left stroke end
Right stroke end
Left clutch pressure
2.3 – 2.6 MPa {23.5 – 26.5 kg/ cm2}
0 MPa {0 kg/cm2}
Right clutch pressure
0 MPa {0 kg/cm2}
2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}
Left brake pressure
0 MPa {0 kg/cm2}
3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}
Right brake pressure
3.04 – 3.33 MPa {31.0 – 34.0 kg/ cm2}
0 MPa {0 kg/cm2}
When the check item 2 is not applicable, the clutch seal is supposed to be defective. Check it.
NO
• The steering clutch valve (ECMV) is defective. • Replace the steering clutch valve (ECMV). • Proceed to "Confirmation of repair".
• The state of the steering clutch seal is norYES mal. • Proceed to the next check item.
NO
• The steering clutch seal is defective. • Replace the steering clutch seal. • Proceed to "Confirmation of repair".
• The state of the steering clutch is normal. YES • Proceed to the next check item. 4
Steering clutch
The inside of the steering clutch is supposed to be defective, check it. NO
14
• The steering clutch is defective. • Replace the steering clutch. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03211-02
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the PCCS lever and perform troubleshooting. Does this failure recur?
NO
• The steering potentiometer of travel lever may be defective. • Perform troubleshooting related to steering potentiometer. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
15
SEN03211-02
40 Troubleshooting
H-7 Steering is possible only on one side Trouble Related information No.
1
Steering is possible only on one side. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the brake is normal. a Prepare with starting the engine, then drive the engine in low YES • Proceed to the next idle mode for troubleshooting. check item. 1
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".)
NO
• The brake is defective. • Perform troubleshooting for "H-9 Brake does not work". • Proceed to "Confirmation of repair".
• The state of the steering clutch valve a Prepare with starting switch OFF, then drive the engine in YES (ECMV) is normal. high idle mode for troubleshooting. • Proceed to the next check item.
2
3
Steering clutch valve (ECMV)
Steering clutch seal
PCCS lever
Left stroke end
Right stroke end
Left clutch pressure
2.3 – 2.6 MPa {23.5 – 26.5 kg/ cm2}
0 MPa {0 kg/cm2}
Right clutch pressure
0 MPa {0 kg/cm2}
2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}
Left brake pressure
0 MPa {0 kg/cm2}
3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}
Right brake pressure
3.04 – 3.33 MPa {31.0 – 34.0 kg/ cm2}
0 MPa {0 kg/cm2}
When the check item 1 is not applicable, the clutch seal is supposed to be defective. Check it.
NO
• The steering clutch valve (ECMV) is defective. • Replace the steering clutch valve (ECMV). • Proceed to "Confirmation of repair".
• The state of the steering clutch seal is norYES mal. • Proceed to the next check item.
NO
• The steering clutch seal is defective. • Replace the steering clutch seal. • Proceed to "Confirmation of repair".
• The state of the steering clutch is normal. YES • Proceed to the next check item. 4
Steering clutch
The inside of the steering clutch is supposed to be defective, check it. NO
16
• The steering clutch is defective. • Replace the steering clutch. • Proceed to "Confirmation of repair".
D155A-6
40 Troubleshooting
No.
Check item
SEN03211-02
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the PCCS lever and perform troubleshooting. Does this failure recur?
NO
• The steering potentiometer of travel lever may be defective. • Perform troubleshooting related to steering potentiometer. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
17
SEN03211-02
40 Troubleshooting
H-8 Steering overrun occurs Trouble Related information No.
1
Steering overrun occurs. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the brake a Prepare with starting the engine, then drive the engine in low is normal. YES idle mode for troubleshooting. • Proceed to the next check item. 1
Brake
Lift the machine with the blade and the ripper and steer the wheel for F3 travel (or R3 travel). If the track shoe stops, the brake is defective. (Execute the troubleshooting of “Brake does not work.”)
NO
• The brake is defective. • Perform troubleshooting for "H-9 Brake does not work". • Proceed to "Confirmation of repair".
YES The repair is completed.
2
3
18
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the PCCS lever and perform troubleshooting. Does this failure recur?
NO
• The steering clutch may be defective. • Perform troubleshooting for "H-6 Steering is not possible". • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-9 Brake does not work Trouble Related information No.
1
Brake does not work. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the brake is normal. YES • Proceed to the next check item.
a Start the engine for troubleshooting. 1
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.
NO
• The brake is defective. • Repair or replace the brake. • Proceed to "Confirmation of repair".
• The state of the brake pedal is normal. YES • Proceed to the next check item. 2
Brake pedal
The brake pedal and the brake valve are supposed not to work normally. Check them. NO
• The brake pedal is defective. • Replace the brake pedal. • Proceed to "Confirmation of repair".
• The state of the steering brake valve a Prepare with starting switch OFF, then drive the engine in YES (ECMV) is normal. high idle mode for troubleshooting. • Proceed to the next check item.
3
4
Steering brake valve (ECMV)
Brake seal
PCCS lever
Left stroke end
Right stroke end
Left clutch pressure
2.3 – 2.6 MPa {23.5 – 26.5 kg/ cm2}
0 MPa {0 kg/cm2}
Right clutch pressure
0 MPa {0 kg/cm2}
2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}
Left brake pressure
0 MPa {0 kg/cm2}
3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}
Right brake pressure
3.04 – 3.33 MPa {31.0 – 34.0 kg/ cm2}
0 MPa {0 kg/cm2}
When the brake seal is not normal in the troubleshooting of the check item 3, the brake seal is supposed to be defective. Check it.
NO
• The state of the brake seal is normal. YES • Proceed to the next check item.
NO
D155A-6
• The steering brake valve (ECMV) is defective. • Proceed to "Brake seal".
• The brake seal is defective. • Replace the brake seal. • Proceed to "Confirmation of repair".
19
SEN03211-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
6
20
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5. 6.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Travel the machine. Operate the brake pedal and perform troubleshooting. Does this failure recur?
NO
• The brake may be defective. • Repair or replace the brake. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-10 Power train oil is overheated Trouble
Related information
No.
1
Power train oil is overheated. • Before carrying out troubleshooting, check that power train oil level is normal. • Before carrying out troubleshooting, check that power train oil temperature gauge indicates actual oil temperature (If it does not, carry out troubleshooting for "E-9 Power train oil temperature gauge (Multi-gauge) does not indicate normally". • Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).
Check item
Procedure of troubleshooting
Judgment and remedy • The state of the engine is normal. YES • Proceed to the next check item.
1
Engine
Engine cooling system may be defective or engine output may be increased. Carry out troubleshooting for engine unit (S mode). NO
• The engine is defective. • Perform the troubleshooting for engine unit (S mode). • Proceed to "Confirmation of repair".
• The state of the power train pump or suction YES circuit is normal. • Proceed to the next check item. 2
Power train Power train pump may be defective or air is in suction circuit. pump or air in Check them. suction circuit NO
• The power train pump is defective or air is in suction circuit. • Replace the power train pump, or bleed air from the suction circuit. • Proceed to "Confirmation of repair".
• The state of the torque converter is normal. a Prepare with starting switch ON, then run engine at high idle YES • Proceed to the next and carry out troubleshooting. check item. 3
4
Torque converter
PCCS lever
Torque converter inlet pressure
Torque converter outlet pressure
Neutral
Max. 1.0 MPa {Max. 10.0 kg/cm2}
0.29 – 0.69 MPa {3.0 – 7.0 kg/cm2}
Transmission Transmission clutch may be malfunctioning (slipping). Check it. clutch
NO
• The state of the transmission clutch is norYES mal. • Proceed to the next check item.
NO
D155A-6
• The torque converter is defective. • Replace the torque converter. • Proceed to "Confirmation of repair".
• The transmission clutch is defective. • Replace the transmission clutch. • Proceed to "Confirmation of repair".
21
SEN03211-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting a Start engine and check.
5
Brake
1. Float machine above ground with blade and ripper. 2. Run engine at low idle and set transmission gear in F3 or R3. 3. If track shoe does not turn, brake is dragging. (Carry out troubleshooting for "H-9 Brake does not work".)
Judgment and remedy • The state of the brake is normal. YES • Proceed to the next check item.
NO
• The brake is defective. • Perform troubleshooting for "H-9 Brake does not work". • Proceed to "Confirmation of repair".
YES The repair is completed.
6
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
7
Confirmation of repair
1. 2. 3. 4.
22
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The brake may be defective. • Repair or replace the brake. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-11 Speed of all work equipment is low Trouble Related information No.
1
1
Speed of all work equipment is low. Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
Check item
PTO (work equipment pump drive section)
Procedure of troubleshooting
Judgment and remedy • The state of the PTO (work equipment pump drive section) is norYES mal. • Proceed to the next check item.
Work equipment pump drive section of PTO may be defective. Check them. NO
2
Work equipment pump
• The PTO (work equipment pump drive section) is defective. • Replace the PTO (work equipment pump drive section). • Proceed to "Confirmation of repair".
• The state of the work equipment pump is normal. YES • Proceed to the next check item. Work equipment pump may be defective. Check them. NO
• The work equipment pump is defective. • Replace the work equipment pump. • Proceed to "Confirmation of repair".
• The state of the unload a Prepare with starting switch ON, then run engine at high idle valve is normal. YES and carry out troubleshooting. • Proceed to the next check item. 3
Unload valve
PCCS lever Blade control lever Ripper control lever
Unload pressure
Neutral
2.45 (+1.37/0) MPa {25 (+14/0) kg/cm2}
NO
• The unload valve is defective. • Replace the unload valve. • Proceed to "Confirmation of repair".
• The state of the main relief valve or its set a Prepare with starting switch ON, then run engine at high idle pressure is normal. YES and carry out troubleshooting. • Proceed to the next check item. 4
Main relief valve
D155A-6
Blade control lever
Main relief pressure
Raise relief
27.5 ± 1.5 MPa {280 ± 15 kg/cm2}
NO
• The main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
23
SEN03211-02
No.
5
6
40 Troubleshooting
Check item
Self-acting pressure reducing valve
Fan pump
Procedure of troubleshooting
Judgment and remedy
• The state of the selfacting pressure reducing valve or its set a Prepare with engine stopped, then run engine at high idle YES and carry out troubleshooting. pressure is normal. • Proceed to the next check item. PCCS lever Blade control lever Ripper control lever
Control circuit basic pressure
Neutral
3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}
NO
If check result of check item 5 is abnormal, fan pump may have trouble in it. Check it.
• The self-acting pressure reducing valve or its set pressure is defective. • Proceed to "Fan pump".
• The state of the fan pump is normal. YES • Proceed to the next check item.
NO
• The fan pump is defective. • Replace the fan pump. • Proceed to "Confirmation of repair".
YES The repair is completed.
7
8
24
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the work equipment. Does this failure recur?
NO
• The PPC valve may be defective. • Replace the PPC valve. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-12 No work equipment moves Trouble Related information No.
1
1
No work equipment moves. Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
Check item
PTO (work equipment pump drive section)
Procedure of troubleshooting
Judgment and remedy • The state of the PTO (work equipment pump drive section) is norYES mal. • Proceed to the next check item.
Work equipment pump drive section of PTO may be defective. Check them. NO
2
Work equipment pump
• The PTO (work equipment pump drive section) is defective. • Replace the PTO (work equipment pump drive section). • Proceed to "Confirmation of repair".
• The state of the work equipment pump is normal. YES • Proceed to the next check item. Work equipment pump may be defective. Check them. NO
• The work equipment pump is defective. • Replace the work equipment pump. • Proceed to "Confirmation of repair".
• The state of the unload a Prepare with starting switch ON, then run engine at high idle valve is normal. YES and carry out troubleshooting. • Proceed to the next check item. 3
Unload valve
PCCS lever Blade control lever Ripper control lever
Unload pressure
Neutral
2.45 (+1.37/0) MPa {25 (+14/0) kg/cm2}
NO
• The unload valve is defective. • Replace the unload valve. • Proceed to "Confirmation of repair".
• The state of the main relief valve or its set a Prepare with starting switch ON, then run engine at high idle pressure is normal. YES and carry out troubleshooting. • Proceed to the next check item. 4
Main relief valve
D155A-6
Blade control lever
Main relief pressure
Raise relief
27.5 ± 1.5 MPa {280 ± 15 kg/cm2}
NO
• The main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
25
SEN03211-02
No.
5
40 Troubleshooting
Check item
Self-acting pressure reducing valve
Procedure of troubleshooting
Judgment and remedy
• The state of the selfacting pressure reducing valve or its set a Prepare with engine stopped, then run engine at high idle YES and carry out troubleshooting. pressure is normal. • Proceed to the next check item. PCCS lever Blade control lever Ripper control lever
Control circuit basic pressure
Neutral
3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}
NO
• The self-acting pressure reducing valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
7
26
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the work equipment. Does this failure recur?
NO
• The work equipment lock solenoid valve may be defective. • Replace the work equipment lock solenoid valve. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-13 Blade lift speed or power is low Trouble Related information
No.
1
Blade lift speed or power is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. • Check that blade has not been modified. • If hydraulic drift of blade lift is large, carry out troubleshooting for "H-17 Hydraulic drift of blade lift is large" first.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the main relief valve or its set a Prepare with starting switch ON, then run engine at high idle pressure is normal. YES and carry out troubleshooting. • Proceed to the next check item. 1
2
Main relief valve
Self-acting pressure reducing valve
Blade control lever
Main relief pressure
Raise relief
27.5 ± 1.5 MPa {280 ± 15 kg/cm2}
NO
• The state of the selfacting pressure reducing valve or its set a Prepare with engine stopped, then run engine at high idle YES and carry out troubleshooting. pressure is normal. • Proceed to the next check item. PCCS lever Blade control lever Ripper control lever
Control circuit basic pressure NO
Neutral
3
3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}
Blade lift control valve Spool of blade lift control valve may be malfunctioning. Check it. (spool)
• The self-acting pressure reducing valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the blade lift control valve (spool) YES is normal. • Proceed to the next check item.
NO
D155A-6
• The main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The blade lift control valve (spool) is defective. • Replace the blade lift control valve (spool). • Proceed to "Confirmation of repair".
27
SEN03211-02
No.
4
40 Troubleshooting
Check item
Procedure of troubleshooting
Suction valve of blade lift control valve may be malfunctioning. Blade lift conCheck it. trol valve a This suction valve can be checked by replacing it with suc(suction tion valve of ripper lift or ripper tilt control valve and observvalve) ing change of phenomenon.
Judgment and remedy • The state of the blade lift control valve (suction valve) is normal. YES • Proceed to the next check item.
NO
• The blade lift control valve (suction valve) is defective. • Replace the blade lift control valve (suction valve). • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
28
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the work equipment. Does this failure recur?
NO
• Air may be in blade lift cylinder. • Bleed air and then judge from change of phenomenon. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-14 Blade tilt speed or power is low Trouble Related information
No.
1
Blade tilt speed or power is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. • Check that blade has not been modified. • If hydraulic drift of blade tilt is large, carry out troubleshooting for "H-18 Hydraulic drift of blade tilt is large" first.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the main relief valve or its set a Prepare with starting switch ON, then run engine at high idle pressure is normal. YES and carry out troubleshooting. • Proceed to the next check item. 1
2
Main relief valve
Self-acting pressure reducing valve
Blade control lever
Main relief pressure
Left tilt relief
27.5 ± 1.5 MPa {280 ± 15 kg/cm2}
NO
• The state of the selfacting pressure reducing valve or its set a Prepare with engine stopped, then run engine at high idle YES and carry out troubleshooting. pressure is normal. • Proceed to the next check item. PCCS lever Blade control lever Ripper control lever
Control circuit basic pressure NO
Neutral
3
• The main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}
Blade tilt control valve Spool of blade tilt control valve may be malfunctioning. Check it. (spool)
• The self-acting pressure reducing valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the blade tilt control valve (spool) YES is normal. • Proceed to the next check item.
NO
• The blade tilt control valve (spool) is defective. • Replace the blade tilt control valve (spool). • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
D155A-6
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
NO
• Air may be in blade tilt cylinder. • Bleed air and then judge from change of phenomenon. • Proceed to "Confirmation of repair".
29
SEN03211-02
No.
5
30
40 Troubleshooting
Check item
Confirmation of repair
Procedure of troubleshooting 1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the work equipment. Does this failure recur?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-15 Ripper lift speed or power is low Trouble Related information
No.
1
Ripper lift speed or power is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. • Check that ripper has not been modified. • If hydraulic drift of ripper lift is large, carry out troubleshooting for "H-19 Hydraulic drift of ripper lift is large" first.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the main relief valve or its set a Prepare with starting switch ON, then run engine at high idle pressure is normal. YES and carry out troubleshooting. • Proceed to the next check item. 1
2
Main relief valve
Self-acting pressure reducing valve
Ripper control lever
Main relief pressure
Raise relief
27.5 ± 1.5 MPa {280 ± 15 kg/cm2}
NO
• The state of the selfacting pressure reducing valve or its set a Prepare with engine stopped, then run engine at high idle YES and carry out troubleshooting. pressure is normal. • Proceed to the next check item. PCCS lever Blade control lever Ripper control lever
Control circuit basic pressure NO
Neutral
3
Ripper lift control valve (spool)
3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}
• The self-acting pressure reducing valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the ripper lift control valve (spool) is normal. YES • Proceed to the next check item. Spool of ripper lift control valve may be malfunctioning. Check it. NO
D155A-6
• The main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The ripper lift control valve (spool) is defective. • Replace the ripper lift control valve (spool). • Proceed to "Confirmation of repair".
31
SEN03211-02
No.
4
40 Troubleshooting
Check item
Ripper lift control valve (suction valve)
Procedure of troubleshooting
Suction valve of ripper lift control valve may be malfunctioning. Check it. a This suction valve can be checked by replacing suction valves on head side and bottom side with each other and observing change of phenomenon.
Judgment and remedy • The state of the ripper lift control valve (suction valve) is normal. YES • Proceed to the next check item.
NO
• The ripper lift control valve (suction valve) is defective. • Replace the ripper lift control valve (suction valve). • Proceed to "Confirmation of repair".
YES The repair is completed.
5
6
32
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the work equipment. Does this failure recur?
NO
• Air may be in ripper lift cylinder. • Bleed air and then judge from change of phenomenon. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-16 Ripper tilt speed or power is low Trouble Related information No.
1
Ripper tilt speed or power is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. • Check that ripper has not been modified.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the main relief valve or its set a Prepare with starting switch ON, then run engine at high idle pressure is normal. YES and carry out troubleshooting. • Proceed to the next check item. 1
2
Main relief valve
Self-acting pressure reducing valve
Ripper control lever
Main relief pressure
Tilt-in relief
27.5 ± 1.5 MPa {280 ± 15 kg/cm2}
NO
• The state of the selfacting pressure reducing valve or its set a Prepare with engine stopped, then run engine at high idle YES and carry out troubleshooting. pressure is normal. • Proceed to the next check item. PCCS lever Blade control lever Ripper control lever
Control circuit basic pressure
Neutral
3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}
NO
3
Ripper tilt control valve (spool)
4
D155A-6
• The self-acting pressure reducing valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
• The state of the ripper tilt control valve (spool) YES is normal. • Proceed to the next check item. Spool of ripper tilt control valve may be malfunctioning. Check it. NO
Ripper tilt control valve (suction valve)
• The main relief valve or its set pressure is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
Suction valve of ripper tilt control valve may be malfunctioning. Check it. a This suction valve can be checked by replacing suction valves on head side and bottom side with each other and observing change of phenomenon.
• The ripper tilt control valve (spool) is defective. • Replace the ripper tilt control valve (spool). • Proceed to "Confirmation of repair".
• The state of the ripper tilt control valve (sucYES tion valve) is normal. • Proceed to the next check item.
NO
• The ripper tilt control valve (suction valve) is defective. • Replace the ripper tilt control valve (suction valve). • Proceed to "Confirmation of repair".
33
SEN03211-02
No.
40 Troubleshooting
Check item
Procedure of troubleshooting
Judgment and remedy YES The repair is completed.
5
6
34
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1. 2. 3. 4. 5.
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Operate the work equipment. Does this failure recur?
NO
• Air may be in ripper tilt cylinder. • Bleed air and then judge from change of phenomenon. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-17 Hydraulic drift of blade lift is large Trouble Related information No.
1
Hydraulic drift of blade lift is large. • Check that blade has not been modified. • Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the seal of blade lift control valve a Start engine and prepare, then stop engine and carry out (spool) is normal. YES troubleshooting. • Proceed to the next check item. 1
Seal of blade Perform following procedure. If hydraulic drift is increased at lift control valve (spool) this time, seal of blade lift control valve spool is defective. 1. Brace blade against ground by lifting operation to push up front part of machine. 2. Stop engine and then turn starting switch ON. 3. Set blade control lever in "Lower" position and check phenomenon.
NO
• The seal of blade lift control valve (spool) is defective. • Replace the seal of blade lift control valve (spool). • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. Turn the starting switch OFF. 2. Connect all the composed equipment. 3. Does this failure recur?
D155A-6
NO
• The seal of blade lift cylinder may be defective. • Replace the seal of blade lift cylinder. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
35
SEN03211-02
40 Troubleshooting
H-18 Hydraulic drift of blade tilt is large Trouble Related information No.
1
Hydraulic drift of blade tilt is large. • Check that blade has not been modified. • Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the seal of blade tilt control valve a Start engine and prepare, then stop engine and carry out (spool) is normal. YES troubleshooting. • Proceed to the next check item. 1
Seal of blade Perform following procedure. If hydraulic drift is increased at tilt control valve (spool) this time, seal of blade tilt control valve spool is defective. 1. Brace blade against ground by tilting operation to push up front part of machine. 2. Stop engine and then turn starting switch ON. 3. Set blade control lever in "Tilt left" position and check phenomenon.
NO
• The seal of blade tilt control valve (spool) is defective. • Replace the seal of blade tilt control valve (spool). • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. Turn the starting switch OFF. 2. Connect all the composed equipment. 3. Does this failure recur?
36
NO
• The seal of blade tilt cylinder may be defective. • Replace the seal of blade tilt cylinder. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-19 Hydraulic drift of ripper lift is large Trouble Related information No.
1
Hydraulic drift of ripper lift is large. • Check that ripper has not been modified. • Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit.
Check item
Procedure of troubleshooting
Judgment and remedy
• The state of the seal of ripper lift control valve a Start engine and prepare, then stop engine and carry out (spool) is normal. YES troubleshooting. • Proceed to the next check item. 1
Seal of ripper Perform following procedure. If hydraulic drift is increased at lift control valve (spool) this time, seal of ripper lift control valve spool is defective. 1. Brace ripper against ground by lifting operation to push up rear part of machine. 2. Stop engine and then turn starting switch ON. 3. Set ripper control lever in "Lower" position and check phenomenon.
NO
• The seal of ripper lift control valve (spool) is defective. • Replace the seal of ripper lift control valve (spool). • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. Turn the starting switch OFF. 2. Connect all the composed equipment. 3. Does this failure recur?
D155A-6
NO
• The seal of ripper lift cylinder may be defective. • Replace the seal of ripper lift cylinder. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
37
SEN03211-02
40 Troubleshooting
H-20 Ripper pin puller cylinder does not operate
1
Giant ripper specification Trouble Related information No.
1
Ripper pin puller cylinder does not operate. Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).
Check item
Pin puller solenoid
Procedure of troubleshooting
Judgment and remedy
• The state of the pin puller solenoid is nora Prepare with engine stopped, then run engine at high idle YES mal. and carry out troubleshooting. • Proceed to the next check item. Pin puller switch
Check point
Pushed in
Cylinder bottom side
Pulled out
Cylinder head side
Solenoid output pressure Min. 2.84 MPa {Min. 29.0 kg/cm2}
NO
• The pin puller solenoid is defective. • Replace the pin puller solenoid. • Proceed to "Confirmation of repair".
YES The repair is completed.
2
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
3
Confirmation of repair
1. 2. 3. 4.
38
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The pin puller cylinder may be defective. • Replace the pin puller cylinder. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
SEN03211-02
H-21 Abnormal sound comes out from around work equipment pump 1 Trouble Related information No.
Abnormal sound comes out from around work equipment pump. Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
Check item
Procedure of troubleshooting
Judgment and remedy • The oil used is appropriate. YES • Proceed to the next check item.
1
Oil used
Oil used may be improper. Check it. NO
• The oil used is not appropriate. • Replace the oil. • Proceed to "Confirmation of repair".
• The hydraulic tank strainer is not clogged. YES • Proceed to the next check item. 2
Hydraulic tank strainer
Hydraulic tank strainer may be clogged. Check it. NO
• The hydraulic tank strainer is clogged. • Clean or replace the hydraulic tank strainer. • Proceed to "Confirmation of repair".
• No air is in the suction circuit. YES • Proceed to the next check item. 3
Air in suction Suction circuit of work equipment pump may have sucked in air. circuit Check it. NO
• The air is in the suction circuit. • Bleed air from the suction circuit again, and repair or replace it. • Proceed to "Confirmation of repair".
YES The repair is completed.
4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
D155A-6
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The work equipment pump may be defective. • Replace the work equipment pump. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
39
SEN03211-02
40 Troubleshooting
H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine overheats) Trouble Related information No.
Fan speed is abnormal (Sound and/or vibration are abnormally large or engine overheats). Before starting troubleshooting, check that oil level in hydraulic tank is normal.
Check item
Procedure of troubleshooting a Start engine and carry out troubleshooting.
1
Engine speed
Measurement conditions
Engine speed
Engine at low idle
740 rpm
Engine at high idle
2,100 rpm
Judgment and remedy • The state of the engine speed is normal. YES • Proceed to the next check item.
NO
If engine speed is not increased to specification, carry out troubleshooting for "S-5 Engine hunts".
2
PTO (fan pump drive)
Fan pump or fan motor
• The engine speed is defective. • Perform troubleshooting for "S-5 Engine hunts". • Proceed to "Confirmation of repair".
• The state of the PTO (fan pump drive) is YES normal. • Proceed to the next check item. Fan pump drive of PTO may be defective. Check it. NO
3
1
• The PTO (fan pump drive) is defective. • Replace the PTO (fan pump drive). • Proceed to "Confirmation of repair".
• The state of the fan pump and fan motor is a Prepare with starting switch OFF, then run engine at high YES normal. idle and carry out troubleshooting. • Proceed to the next check item. Measurement conditions
Fan speed
Fan 100% mode
1,100 – 1,150 rpm
NO
• The fan pump or fan motor is defective. • Replace the fan pump or fan motor. • Proceed to "Confirmation of repair".
YES The repair is completed. 4
Reconfirmation of check item
1. Reconfirm the preceding troubleshooting. 2. Can you identify the cause of failure by reconfirmation?
5
Confirmation of repair
1. 2. 3. 4.
40
Turn the starting switch OFF. Connect all the composed equipment. Start the engine. Does this failure recur?
NO
• The fan may be defective. • Replace the fan. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
40 Troubleshooting
D155A-6
SEN03211-02
41
SEN03211-02
40 Troubleshooting
D155A-6 Bulldozer Form No. SEN03211-02
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
42
D155A-6
SEN03212-01
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
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
S-16 Vibration is excessive ........................................................................................................................... 23 S-17 Air cannot be bled from fuel circuit ....................................................................................................... 24
2
D155A-6
40 Troubleshooting
SEN03212-01
Method of using troubleshooting chart Causes
A
Questions
1
2
3
4
1 2 3 4 5 6
B
C
Check items
7
Troubleshooting
The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. [Questions] Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. [Check items] Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the right. [Causes] Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. [Troubleshooting] Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable one by applying troubleshooting tools or direct inspection.
1
8 9 10 11 a b c d
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w. E: Causes to be referred to for questions and check items Q : Causes related to questions and check items w : Causes highly probable among ones marked with Q a When narrowing the "causes", apply the items marked with w before those marked with Q. When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)
D155A-6
3
SEN03212-01
40 Troubleshooting
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion) Let us assume that a trouble of “Exhaust gas color is black” occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas color slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].
4
D155A-6
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
S-1 Starting performance of engine is poor General causes why starting performance is poor q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel q Coolant in exhaust pipe a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however
1
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter
Leaking or clogged fuel piping or entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder
Defective contact of valve and vale seat
Clogged air cleaner element
Causes
Confirm recent repair history
Questions
Starting performance
Operated for long period
E
E E
Became worse gradually
Q w w
Q Q
E w
Engine starts easily when warm
w
Q Q Q Q
Non-specified fuel is used Filters have not been replaced according to Operation and Maintenance Manual
w
w w Q Q w
Engine oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)
w
During operation, charge level monitor indicates abnormal charge (if monitor is installed)
w w w
Dust indicator is red (if it is installed)
w
Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping
w
Priming pump is too light or too heavy to operate
w Q Q
Q w
Check items
Starting motor cranks engine slowly While engine is rotated with starting motor
When air bleeding plug of fuel filter is removed, fuel does not flow out
w w w
When spill hose from injector is disconnected, little fuel spills
w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low
Q Q
Engine does not pick up smoothly and combustion is irregular
w Q w Q Q
Engine hunts (rotation is irregular)
w
Blow-by gas is excessive
q
Inspect air cleaner directly
q q
Compression pressure is low
q
When air is bled from fuel system, air comes out
q
Troubleshooting
Inspect fuel filter directly
q
Inspect feed pump gauze filter directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q
When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage of 20 – 30 V generated between alternator terminals B and E while engine is running at low idle?
q
Yes
q
No
q Replace
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Replace
Correct
Remedy
Clean
Specific gravity of electrolyte and battery voltage are low
Replace
Degree of use of machine
*1: Displayed failure codes: [CA559] and [CA2249]
6
D155A-6
40 Troubleshooting
SEN03212-01
S-2 Engine does not start
1
a) Engine does not rotate General causes why engine does not rotate q Seized internal parts of engine o See "S-4 Engine stops during operation" q Water hammer caused by coolant which entered cylinder q Defective electrical system q Trouble in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine
Defective starting circuit wiring
Defective starting motor (motor section)
Defective starting motor (safety relay section)
Defective starting switch
Defective battery relay
Defective connection of battery terminal
Defective or deteriorated battery
Broken flywheel ring gear
Causes
E E
Operated for long period
Q
When starting switch is Horn does not sound turned ON Horn volume is low
w
Battery electrolyte level is low
w Q
When starting switch is turned to START, starting pinion does not move out
Q
Speed of rotation is low
w
When starting switch is turned to START, start- Makes grating noise ing pinion moves out, Soon disengages again but Makes rattling noise and does not turn
Q
w
w
w
w w
q q
Specific gravity of electrolyte and battery voltage are low
q
There is not voltage (20 – 30 V) between battery relay terminals B and E
q
When terminals B and C of starting switch are connected, engine starts
Turn starting switch OFF, connect cables, When terminals B and C at safety relay outlet are connected, engine turn starting switch ON, starts and carry out troubleshooting Even if terminals B and C at safety relay outlet are connected, engine does not start
Replace
Replace
Replace
q Replace
Remedy
q
Carry out troubleshooting on applicable machine side
Q w
—
Q
Replace
Check items
When starting switch is turned ON, no operating sound comes out from battery relay
Inspect flywheel ring gear directly Troubleshooting
w
w
Battery terminal is loose
D155A-6
Q
Replace
Degree of use of machine
Correct
Questions
Confirm recent repair history
7
SEN03212-01
40 Troubleshooting
b) Engine rotates but no exhaust gas comes out General causes why engine rotates but no exhaust gas comes out q Fuel is not supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)
Defective fuel injector
Malfunction flow damper
Malfunction of overflow valve (Does not close)
Wrong connection of supply pump PCV
Defective supply pump PCV
Stuck or seized supply pump plunger
Broken supply pump shaft or key
Clogged feed pump gauze filter Seized or abnormally worn feed pump
Clogged fuel filter
Leaking or clogged fuel piping or entry of air
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Use of improper fuel
Causes
E E E
Operated for long period
w Q w w w
Exhaust gas suddenly stopped coming out (when starting again) Filters have not been replaced according to Operation and Maintenance Manual 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 w
Check items
There is not fuel in removed fuel filter
E
Q Q Q
Q Q
Fuel is leaking from fuel piping
w
Priming pump is too light or too heavy to operate
w Q Q
When air bleeding plug of fuel filter is removed, fuel does not flow out
Q
While engine is rotated with starting When spill hose from injector is disconnected, little fuel motor spills
E E Q
w
Q
w Q
Q
w w w w
Q
q q
q
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter directly Troubleshooting
w w
q
Inspect feed pump gauze filter directly
q
Inspect feed pump directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2 Short/Open Error (*3)" indicated by code
q q q
Inspect overflow valve directly
q q Replace
Correct
Replace
Replace
Replace
Clean Replace
Replace
Correct
Correct
Add
Remedy
Replace
Engine can be started in reduced cylinder mode
Replace
Degree of use of machine
Replace
Questions
Confirm recent repair history
*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA271] and [CA272] *3: Displayed failure codes [CA273] and [CA274]
8
D155A-6
40 Troubleshooting
SEN03212-01
c) Exhaust gas comes but engine does not start (fuel is injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel
Defective intake air heater system
Defective coolant temperature sensor or wiring harness
Defective or deteriorated battery
Clogged injector or defective spray
Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter
Leaking or clogged fuel system or entry of air
Clogged air breather hole of fuel tank cap
Use of improper fuel
Worn piston ring or cylinder liner
Worn dynamic valve system (Valve, rocker lever, etc.)
Clogged air cleaner element
Causes
Confirm recent repair history
E
E E
w
Suddenly failed to start
E w
Q
Q Q
Non-specified fuel is used Filters have not been replaced according to Operation and Maintenance Manual
w
w w w
Engine oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)
w w
Dust indicator is red (if it is installed)
Q
Air breather hole of fuel tank cap is clogged
w w
There are rust and water in fuel drained from fuel tank
w
There is not fuel in removed fuel filter Fuel is leaking from fuel piping
w
Priming pump is too light or too heavy to operate
w Q Q w
Check items
Starting motor rotates engine slowly
w
When engine is rotated, abnormal sound comes out from around cylinder head While engine is rotated with starting motor,
When air bleeding plug of fuel filter is removed, fuel does not flow out
Q
w
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
q
Inspect air cleaner directly
q
Inspect dynamic valve system directly
q
Compression pressure is low Troubleshooting
w w
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter directly
q
Inspect feed pump gauze filter directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
q q
When injector unit is tested, spray condition is bad
q
Specific gravity of electrolyte and battery voltage are low
q
Coolant temperature gauge does not indicate normally (if it is installed)
q Replace
Replace
Clean
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Replace
Remedy
Clean
When starting switch is turned to HEAT, intake air heater mount does not become warm
Replace
Questions
Degree of use of machine Operated for long period
*1: Displayed failure codes [CA559] and [CA2249]
D155A-6
9
SEN03212-01
40 Troubleshooting
S-3 Engine does not pick up smoothly
1
General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel spray q Improper selection of fuel q Control by controller in derate mode (limiting injection rate (output) because of an error in electrical system)
Clogged injector or defective spray
Malfunction of flow damper (Large leakage from injector)
Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter
Leaking or clogged fuel piping or entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring or cylinder liner
Seized turbocharger or interference of turbocharger
Improper valve clearance
Defective contact of valve and valve seat
Clogged air cleaner element
Causes
E E
Operated for long period
E w
Engine pick-up suddenly became worse
E E Q Q
Q w w w
Non-specified fuel is used
w
Filters have not been replaced according to Operation and Maintenance Manual
w
Oil must be added more frequently
w
Dust indicator is red (if indicator is installed)
w
Air breather hole of fuel tank cap is clogged
w w
There are rust and water in fuel drained from fuel tank Fuel is leaking from fuel piping
w
Priming pump is too light or too heavy to operate
w Q Q Q
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low
Check items
Exhaust gas color
w
w
Blue under light load
w Q
Black
w
w
w
When engine is rotated, abnormal sound comes out from around cylinder head
w
When engine is rotated, interference sound comes out from around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied
Q
w w
Engine hunts (rotation is irregular)
Q
Q w
Q
w
Blow-by gas is excessive
q
Inspect air cleaner directly
q
Compression pressure is low Troubleshooting
w
w w
q q
Inspect valve clearance directly
q
Turbocharger is heavy to rotate with hand
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter directly
q
Inspect feed pump gauze filter directly
q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Adjust
Replace
Clean
Remedy
q q Correct
Degree of use of machine
Replace
Questions
Confirm recent repair history
*1: Displayed failure codes [CA559] and [CA2249]
10
D155A-6
40 Troubleshooting
SEN03212-01
S-4 Engine stops during operation
1
General causes why engine stops during operation q Seized parts inside engine q Insufficient supply of fuel q Overheating q Trouble in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine
Broken auxiliary equipment (pump, compressor, etc.)
Trouble in drive devices on applicable machine side
Stuck or seized supply pump plunger
w
Broken supply pump shaft or key
Q w Q w
Broken or seized feed pump
Clogged feed pump gauze filter
Clogged fuel filter
Leaking or clogged fuel piping
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Broken or seized gear train
Broken or seized crankshaft bearing
Broken or seized piston or connecting rod
Broken dynamic valve system (valve, rocker arm, etc.)
Causes
Confirm recent repair history E E
Operated for long period w w w w
Questions
Made abnormal noise stopped suddenly Engine
w Q
Overheated and stopped
Q
Stopped slowly
w
Q Q
Hunted and stopped
w Q
Q Q Q
Non-specified fuel is used
Q Q Q
Filters have not been replaced according to Operation and Maintenance Manual
w w
Fuel level monitor indicates low level (if monitor is installed)
w
Fuel tank is empty
w w
Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping
w
Priming pump is too light or too heavy to operate
w Q Q w w
Check items
There are rust and water in fuel drained from fuel tank There are metal particles in oil drained from oil pan
w w
Engine does not rotate at all
w w
When engine is rotated with hand
Q
Q Q
w
Engine rotates in opposite direction
w
Engine moves by gear backlash
w w
Supply pump shaft does not turn
w
Engine rotates, but stops when load is applied to machine
q
Inspect piston and connecting rod directly
q
Inspect crankshaft bearing directly
q
Inspect gear train directly
q
Inspect fuel filter directly
q
Inspect feed pump gauze filter directly
q
Inspect feed pump directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Replace
Replace
Replace
Clean
Clean
Correct
Clean
Add
Replace
Replace
Replace
Replace
Remedy
q Replace
Troubleshooting
Carry out troubleshooting on applicable machine
q
Inspect dynamic valve system directly
—
Degree of use of machine
*1: Displayed failure codes [CA559] and [CA2249]
D155A-6
11
SEN03212-01
40 Troubleshooting
S-5 Engine does not rotate smoothly
1
General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)
Defective Bkup speed sensor or wiring harness
Defective Ne speed sensor or wiring harness
Clogged injector or defective spray (dirt in injector)
Malfunction of flow damper (Large leakage from injector)
Clogged fuel filter
Clogged feed pump gauze filter
Leaking or clogged fuel piping or entry of air
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Low setting of low idle speed
Causes
Confirm recent repair history E E
Engine hunts
At a certain speed range
Q
Q Q
At low idle
w
Q Q Q Q Q Q Q Q
Even when speed is raised
Q Q
w
On slopes
Q Q w w
Filters have not been replaced according to Operation and Maintenance Manual w
Troubleshooting
Check items
Fuel tank is empty
w
Air breather hole of fuel tank cap is clogged
Q Q
There are rust and water in fuel drained from fuel tank Fuel is leaking from fuel piping
w
Priming pump is too light or too heavy to operate
w Q Q
When air is bled from fuel system, air comes out
q q
Inspect feed pump gauze filter directly
q
Inspect fuel filter directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q q
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*1)" indicated by code
q Correct
Correct
Replace
Replace
Replace
Correct
Clean
Add
Remedy
Correct
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*2)" indicated by code
Correct
Questions
Degree of use of machine Operated for long period
*1: Displayed failure code [CA689] *2: Displayed failure code [CA778]
12
D155A-6
40 Troubleshooting
SEN03212-01
S-6 Engine lack output (or lacks power)
D155A-6
E E
Q
Q
Q Q Q Q
Q
Q Q Q Q
Defective fuel temperature sensor or wiring harness
Defective charge pressure sensor or wiring harness
Defective installation of charge pressure sensor (air leakage)
Stuck or seized supply pump plunger
Defective drive of injector (signal or solenoid)
E
Clogged injector or defective spray (dirt in injector)
Q w
Q Q Q w w w w w w w w w w Q w w Q w
Q Q Q Q Q Q
w
w
q q q q q q q
Replace
Replace
Correct
Replace
Replace
Replace
Clean
Correct
q Clean
Replace
Adjust
Replace
Replace
Correct
Remedy
Clogged feed pump gauze filter
E Q
Inspect air cleaner directly q Inspect air intake piping directly q Boost pressure is low q q q Compression pressure is low q q Inspect valve clearance directly q Inspect fuel filter directly Inspect feed pump gauze filter directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Inspect boost pressure sensor mount directly Carry out troubleshooting according to "Chg Air Press Sensor High (Low) Error (*2)" indicated by code Carry out troubleshooting according to "Fuel Temp Sensor High (Low) Error (*3)" indicated by code
*1: Displayed failure code [CA559] and [CA2249] *2: Displayed failure code [CA122] and [CA123] *3: Displayed failure code [CA263] and [CA265]
Clogged fuel filter
Leaking or clogged fuel piping
Clogged air breather hole of fuel tank cap
Worn piston ring or cylinder liner
Improper valve clearance
Defective contact of valve and valve seat
Seized turbocharger or interference of turbocharger
E
Replace
Confirm recent repair history Degree of use of machine Operated for long period Suddenly Power was lost Gradually Non-specified fuel is used Filters have not been replaced according to Operation and Maintenance Manual Engine oil must be added more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Black Exhaust gas is Blue under light load Immediately after engine is started, temperature of exhaust manifold of a cylinder is low When engine is rotated, interference sound comes out from around turbocharger When engine is rotated, abnormal sound comes out from around cylinder head High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular Engine hunts (rotation is irregular) Blow-by gas is excessive
Air leakage from air intake piping
Clogged air cleaner element
Causes
Clean
Troubleshooting
Check items
Questions
General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheating o See "S-14 Coolant temperature becomes too high (Overheating)" q Control by controller in derate mode (limiting injection rate (output) because of an error in electrical system)
1
13
SEN03212-01
40 Troubleshooting
S-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black q Insufficient intake of air q Excessive injection of fuel q Defective condition of fuel injection q Improper selection of fuel q Overheating o See "S-14 Coolant temperature becomes too high (Overheating)" q Control by controller in derate mode (limiting injection rate (output) because of an error in electrical system)
1 Defective coolant temperature sensor or wiring harness
Improper fuel injection pressure
Improper fuel injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged or seized injector
Stuck or seized supply pump plunger
Worn piston ring or cylinder liner
Crushed or clogged muffler
Leakage of air between turbocharger and cylinder head
Improper valve clearance
Defective contact of valve and valve seat
Seized turbocharger or interference of turbocharger
Clogged air cleaner element
Causes
Confirm recent repair history
E
Operated for long period
Questions
Exhaust gas color
E
E
w
Suddenly became black
w
Gradually became black
Q w
Blue under light load
Q Q
Non-specified fuel is used
w
Oil must be added more frequently Power was lost
E Q Q Q Q
w
Suddenly
Q w
Gradually
Dust indicator is red (if indicator is installed)
Q Q
Q
Q Q Q
w
Muffler is crushed
w
Air leaks between turbocharger and cylinder head or clamp is loosened
Q Q Q
Engine is operated in low-temperature mode at normal temperature
Check items
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low
Q w 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 Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)
Q Q Q Q
Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular
w Q Q Q
Q Q w w
Blow-by gas is excessive
w
When spill hose from injector is disconnected, abnormally much fuel spills
q
Inspect air cleaner directly
q
Turbocharger is heavy to rotate with hand
q
Troubleshooting
Compression pressure is low
q q
Inspect valve clearance directly
q
When muffler is removed, exhaust gas color improves Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q q
Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by code
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Replace
Replace
Clean
Remedy
q Replace
Degree of use of machine
*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA144] and [CA145]
14
D155A-6
40 Troubleshooting
SEN03212-01
S-8 Oil consumption is excessive (or exhaust gas is blue) General causes why oil consumption is excessive q Abnormal consumption of oil q Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) q External leakage of oil q Wear of parts in lubrication system
1 Oil leakage from oil pan, cylinder head, etc.
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Worn or damaged rear oil seal
Worn piston ring or cylinder liner
Broken piston ring
Clogged breather or breather hose
Oil leakage from EGR valve stem
Turbocharger Worn seal at blower end
Worn seal at turbocharger end
Worn or damaged valve (stem, guide, or seal)
Dust sucked in from intake system
Causes
E E E E
Degree of use of machine Operated for long period
E w
Oil consumption suddenly increased Q
Oil must be added more frequently
Q w
Q
Q Q w
Oil becomes dirty quickly
w w w w w
Outside of engine is dirty with oil w
There are loose piping clamps in intake system
w Q w
Inside of turbocharger exhaust outlet pipe is dirty with oil
w
There is oil in coolant w
Oil level in damper chamber is high Q
Exhaust gas is blue under light load
w w w
None q
There is dust in intake manifold
q
Inside of intake manifold is abnormally dirty
q q
Play of turbocharger shaft is excessive
q
Exhaust port of EGR valve is dirty with oil
q
Check breather and breather hose directly
q q
Compression pressure is low
q
Inspect rear oil seal directly
q q
Leakage from oil cooler is detected by pressure test
D155A-6
Correct
Correct
Replace
Correct
Replace
Replace
Clean
Replace
Replace
Replace
Remedy
Correct
q q q q
Oil leaks out of engine Correct
Troubleshooting
w w
Q
Correct
Amount of blow-by gas
Q
Excessive
Correct
Check items
Inside of turbocharger intake outlet pipe is dirty with oil
Replace
Questions
Confirm recent repair history
15
SEN03212-01
40 Troubleshooting
S-9 Oil becomes dirty quickly
1
Exhaust gas color is bad
Q
Non-specified fuel is used Q
Engine oil must be added more frequently
w w Q
There are metal particles in oil drained from oil pan
Q Q
Inside of exhaust pipe is dirty with oil
w
w w
Q
Q w
Q w
Does not come out at all q q
Exhaust port of EGR valve is dirty with oil
q q
Compression pressure is low
See S-7
Blow-by gas
w
Black Comes out excessively
q
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 Replace
Replace
Clean
Clean
Replace
Replace
Replace
Remedy
Replace
Inspect turbocharger lubrication drain tube directly
—
Exhaust gas is
w
Blue under light load
Play of turbocharger shaft is excessive
16
Clogged turbocharger lubrication drain tube
E E E E
Degree of use of machine Operated for long period
Engine oil temperature rises quickly Check items
Defective oil filter safety valve
Confirm recent repair history
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is installed)
Troubleshooting
Clogged oil filter
Clogged oil cooler
Clogged breather or breather hose
Worn piston ring or cylinder liner
Worn valve or valve guide
Worn EGR valve guide
Defective seal at turbocharger turbine end
Causes
Clean
Questions
General causes why oil becomes dirty quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Overload operation
D155A-6
40 Troubleshooting
SEN03212-01
S-10 Fuel consumption is excessive
1
General causes why fuel consumption is excessive q Leakage of fuel q Defective condition of fuel injection (fuel pressure or injection timing) q Excessive injection of fuel
Defective coolant temperature sensor or wiring harness
Improper fuel injection timing
Malfunction of injector
Defective spray by injector
Defective common rail pressure
Defective supply pump plunger
Defective feed pump oil seal
Fuel leakage from fuel filter, piping, etc.
Fuel leakage inside head cover
Causes
E E
Degree of use of machine Operated for long period
Q
Gradually increased Q Q
Suddenly increased
w
There is external leakage of fuel from engine
w
Combustion is irregular w
w w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low
Q
Low idle speed is high
Q
Torque converter stall speed or pump relief speed is high Exhaust gas is
Q Q
Black
Q Q
Q
White
q
Remove head cover and inspect inside directly
q
Inspect feed pump oil seal directly
q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q
When spill hose from injector is disconnected, much fuel spills Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by code
q
Correct
Replace
Replace
Correct
Correct
Remedy
q Replace
q
Confirm with monitoring function on applicable machine side
Correct
Check items
Engine oil level rises and oil smells of diesel fuel
Troubleshooting
Q Q Q Q
Correct
Fuel consumption
E Q
Is large compared to other machines of same model
Replace
Questions
Confirm recent repair history
*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA144] and [CA145]
D155A-6
17
SEN03212-01
40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
1
General causes why oil is in coolant q Leakage in lubrication system q Leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler on applicable machine side
Broken oil cooler core or O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring or holes caused by pitting
Crack in cylinder block
Broken cylinder head or head gasket
Causes
E
Degree of use of machine Operated for long period Oil level
Q Q
w
There are excessive air bubbles in radiator and coolant spurts back
w w
Hydraulic oil or power train oil on applicable machine side is milky
w
When hydraulic oil or power train oil is drained, water flows out
w
q q
Inspect cylinder block and liner directly
q
Inspect cylinder liner directly
q Replace
Replace
Replace
Remedy
Replace
Leakage from oil cooler is detected by pressure test
—
q
Leakage from cylinder head is detected by pressure test
Carry out troubleshooting on applicable machine side
Check items
Q
Q Q
Oil level has risen and oil is milky
18
Q
Q Q
Gradually increased
Hard water is used as coolant
Troubleshooting
E
Q
Suddenly increased
Replace
Questions
Confirm recent repair history
D155A-6
40 Troubleshooting
SEN03212-01
S-12 Oil pressure drops
1
General causes why oil pressure drops q Leakage from, clogging, or wear of lubrication system q Defective oil pressure control q Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed. q Deterioration of oil due to overheating
Defective oil pressure sensor or wiring harness
Leaking, crushed, or clogged hydraulic piping
Clogged oil filter
Defective oil pump relief valve
Defective oil pump
Clogged or broken pipe in oil pan
Clogged strainer in oil pan
Coolant or fuel in oil
Lack of oil in oil pan
Worn journal of bearing
Causes
E
Operated for long period
E
E Q w
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q
Non-specified oil is used
Q w
Filters have not been replaced according to Operation and Maintenance Manual w
Indicates pressure drop at low idle Oil pressure monitor (if installed)
Q
Indicates pressure drop at low, high idle
Q
Indicates pressure drop on slopes
w
w w w Q w
Oil level monitor indicates oil lever drop (if monitor is installed)
w
Oil level in oil pan is low
w
Q
w
External hydraulic piping is leaking or crushed w
Oil is milky or smells of diesel oil There are metal particles in oil drained from oil pan
w
There are metal particles in oil drained from oil filter
w
There are metal particles in oil filter
q
Q
q q See S-13
Inspect oil pan strainer and pipe directly Oil pump is heavy to rotate or it has play Valve spring of oil pump relief valve is fatigued or damaged Inspect oil filter directly
q q q
Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)" indicated by code Correct
Adjust
Replace
Clean
Clean
—
Add
Remedy
q Replace
Troubleshooting
Check items
Sometimes indicates pressure drop
Replace
Degree of use of machine
Replace
Questions
Confirm recent repair history
*1: Displayed codes [CA135] and [CA141]
D155A-6
19
SEN03212-01
40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel)
1
General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant"
E
E
w
Fuel consumption has increased Coolant must be added more frequently
Q
There is oil in coolant
Q
w w Q Q
w
w
Oil is milky
Q
When engine is started, water drops from muffler
Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles come out or coolant spurts back
w
w w Q
Q
Exhaust gas is white
Q w
Water pump drain hole (breather hole) is clogged
w
When water pump drain hole (breather hole) is cleaned, coolant flows out w
Oil level in damper chamber on applicable machine side is low
w
Oil level in hydraulic tank on applicable machine is low q
Compression pressure is low
q
Troubleshooting
Remove and inspect head cover directly
q q
Inspect cylinder block and liner directly
q
Inspect rear oil seal directly
q
Leakage from oil cooler is detected by pressure test
q
Remove and inspect water pump directly
q
Remove and inspect thermostat cover directly
q
Remove and inspect supply pump directly
q Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Remedy
Replace
Inspect seal of auxiliary equipment directly
20
Defective seal of auxiliary equipment (pump and compressor)
Defects in supply pump
Defective thermostat seat
Clogged water pump drain hole (breather hole) or defective seal
Broken oil cooler core or O-ring
Worn or damaged rear oil seal
Damaged cylinder liner O-ring or holes caused by pitting
Cracks inside cylinder block
E E
Degree of use of machine Operated for long period
Oil smells of diesel fuel
Check items
Fuel leakage inside cylinder block
Confirm recent repair history
Replace
Questions
Broken cylinder head or head gasket
Causes
D155A-6
40 Troubleshooting
SEN03212-01
S-14 Coolant temperature becomes too high (Overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation or damage of fan) q Drop in heat dissipation efficiency q Trouble in coolant circulation system q Rise of oil temperature in power train o Carry out troubleshooting on applicable machine side
1 Rise of power train oil temperature on applicable machine side
Defective coolant temperature gauge
Malfunction of fan
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged or crushed radiator fins
Malfunction of thermostat
Broken water pump
Low coolant level
Clogged or broken oil cooler
Damaged cylinder liner O-ring or holes caused by pitting
Broken cylinder head or head gasket
Causes
E E
Degree of use of machine Operated for long period Overheating Coolant temperature gauge (if installed)
E E Q w
Occurred suddenly
Q
Rises quickly
Q
w w
Does not go down from red range w
Radiator coolant level monitor indicates low (if monitor is installed) w Q
Engine oil level has risen and oil is milky
w
Milky oil is floating on coolant w
There are many bubbles in radiator and coolant spurts back Check items
Q Q w w
Has continued at low level
When light applied to radiator core, no light passes through
w
Dirt and mud are accumulated in radiator shroud and undercover on applicable machine side
w
w
w
Coolant is leaking because of cracks in hose or loose clamps
w
Coolant flows out from radiator overflow hose Power train oil temperature enters red range faster than engine coolant temperature (if oil temperature gauge and coolant temperature gauge are installed)
w
q q
Inspect oil cooler directly
q
Temperature difference between upper and lower tanks of radiator is large
q
Thermostat does not open at cracking temperature
q
Temperature difference between upper and lower tanks of radiator is slight
q
Inspect radiator core directly
q
Cracking pressure of radiator cap is low
q
Inspect fan directly
q Correct
Replace
Correct
Correct
Replace
Replace
Add
Replace
Replace
Remedy
Replace
Coolant temperature is normal
Replace
Troubleshooting
Inspect cylinder liner directly
D155A-6
Carry out troubleshooting on applicable machine side
q
Compression pressure is low
—
Questions
Confirm recent repair history
21
SEN03212-01
40 Troubleshooting
S-15 Abnormal noise is made
1
General causes why abnormal noise is made q Abnormality due to defective parts q Abnormal combustion q Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 5 seconds. This does not indicate abnormality, however
Improper fuel injection timing (Defective coolant temperature sensor)
Dirt caught in injector
Clogged or seized injector
Deformed cooling fan
Removed or seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring or cylinder liner
Improper valve clearance
Defective inside of muffler (Removal of bulkhead)
Broken dynamic valve system (valve, rocker lever, etc.)
Interference of turbocharger or seized turbocharger
Leakage of air between turbocharger and cylinder head
Causes
E
Degree of use of machine Operated for long period Abnormal noise
Q
Gradually increased
Q Q
Non-specified fuel is used w
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 Check items
Q
Q Q
Suddenly increased
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low Exhaust gas is
w Q w
Blue under light load Q w
Black
Q w
Engine does not pick up smoothly and combustion is irregular Q
Abnormal noise is loud when engine is accelerated
Q Q
w
Blow-by gas is excessive q
Turbocharger is heavy to rotate with hand
q
Inspect dynamic valve system directly
q
When muffler is removed, abnormal noise disappears Troubleshooting
Q
q
Inspect valve clearance directly
q
Compression pressure is low
q q
Inspect gear train directly
q
Inspect fan directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q q
Abnormal noise comes out only at start of engine
q
22
Correct
Replace
Correct
Replace
Replace
Replace
Adjust
Replace
Correct
Replace
Remedy
Replace
Confirm with monitoring function on applicable machine side
Correct
Questions
Confirm recent repair history
D155A-6
40 Troubleshooting
SEN03212-01
S-16 Vibration is excessive
1
General causes why vibration is excessive q Defective parts (abnormal wear, breakage, etc.) q Misalignment between engine and applicable machine q Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for "S-15 Abnormal noise is made", too
Broken parts in damper on applicable machine side
Worn front support spigot joint
Misalignment between engine and devices on applicable machine side
Loose engine mounting bolts or broken cushions
Improper injection timing
Worn camshaft bushing
Improper gear train backlash
Worn main bearing or connecting rod bearing
Stuck dynamic valve system (valve, rocker lever, etc.)
Causes
E
E
E
E
Q
Q
Q
Q
Non-specified fuel is used
Q
Q
There are metal particles in oil drained from oil filter
w
w
There are metal particles in oil drained from oil pan
w
w
Oil pressure is low at low idle
Q
Q
Degree of use of machine Operated for long period Vibration
Q
Suddenly increased Gradually increased
Q
Vibration occurs at medium speed Q
Vibration follows engine speed Exhaust gas is black
w
Inspect dynamic valve system directly
q
Q
Q Q Q Q
q
Inspect main bearing and connecting rod bearing directly Troubleshooting
Q
q
Inspect gear train directly
q
Inspect camshaft bushing directly
q
Confirm with monitoring function on applicable machine side
q
Inspect engine mounting bolts and cushions directly
q
Radial runout or facial runout is detected
q
Inspect front support spigot joint directly
q
D155A-6
Replace
Adjust
Replace
Adjust
Replace
Replace
Replace
Remedy
Replace
Inspect inside of damper directly
Replace
Check items
Questions
Confirm recent repair history
23
SEN03212-01
40 Troubleshooting
S-17 Air cannot be bled from fuel circuit
1
(After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but stalls.) General causes why air cannot be bled q Electric priming pump does not operate. q Fuel is not supplied or is supplied very little. q Fuel valve or air bleeding valve is not set properly. q Air bleeding piping is clogged. q Fuel return piping is clogged.
Low battery charge level
Clogged fuel filter
Clogged water separator screen
Defective wiring harness of electric priming pump
Malfunction of electric priming pump switch
Malfunction of electric priming pump
Clogged air bleeding piping
Leaking or clogged fuel piping or air in it
Clogged fuel tank cap breather hole
Improper setting of fuel valve (Closed)
Improper setting of air bleeding valve (Closed)
Low fuel level
Causes
EE
Operated for long period
Q Q
Non-specified fuel is used
w Q
Fuel tank is empty Fuel tank cap breather hole is clogged
w w
Check items
Fuel is leaking from fuel piping
w w
Switch lamp does not blink When electric priming pump switch is operated
w
Lamp blinks but pump operation sound is not heard Pump operation sound is heard but fuel does not flow out of hose soon
Q Q
w w w
Q Q
q
Air bleeding valve is closed
Troubleshooting
Q
w
Fuel valve (supply side) is closed
q
Fuel valve (return side) is closed
q
Water drain valve and air intake plug of water separator are loosened
q
Water drain valve of fuel prefilter is loosened
q q
There is flaw or dirt on sealing face of fuel prefilter or main filter
q
Check air bleeding piping and orifice directly (See Note 1)
q
Check fuel piping (supply side and return side) directly (for clogging and breakage)
q
Check electric priming pump directly
q q
Check electric priming system directly (See E-33 in E-mode)
q
Check water separator screen directly
q
24
Clean
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
Add
Check fuel filter for clogging (Failure code CA559, Note 2)
Charge
Degree of use of machine
Replace
Questions
Confirm recent repair history
D155A-6
40 Troubleshooting
SEN03212-01
Note 1: Check of air bleeding piping for clogging •
Remove joint bolt (1) and blow clean compressed air into hole [b] of the orifice to check for clogging.
D155A-6
25
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
SEN03366-05
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 General information on disassembly and assembly How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tool list ................................................................................................................................................ 7 Sketches of special tools .............................................................................................................................. 15
D155A-6
1
SEN03366-05
50 Disassembly and assembly
How to read this manual 1.
(Rev. 2009.01) 1
Removal and installation of assemblies Special tools q Special tools which are necessary for removal or inst allation of part s ar e described as A1,•••X1 etc. and their parts numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
Removal q In "Removal" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in "Removal" section are explained and listed below. k :
Precautions related to work safety
a: Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in "Installation" section. 6:
Amount of oil or coolant to be drained
4:
Weight of part or component
Installation q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in "Removal" section. q Common tools that are necessary for installation are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the "Installation" section stand for the following. k :
Precautions related to work safety
a: Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque 5
: Amount of oil or coolant to be replenished
Sketches of special tools q Various special tools are illustrated for the local manufacture.
2
D155A-6
50 Disassembly and assembly
2.
SEN03366-05
Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1,•••X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They have a new part number respectively. R : Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
Disassembly q In "Disassembly" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Disassembly" section are as follows. k :
Precautions related to work safety
a: Guidance or precautions for the work 6: Amount of oil or coolant drained
Assembly q In "Assembly" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Assembly" section are as follows. k :
Precautions related to work safety
a: Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque 5
: Amount of oil or coolant to be replenished
Sketches of special tools q Various special tools are illustrated for the local manufacture.
D155A-6
3
SEN03366-05
50 Disassembly and assembly
Coating materials list
(Rev. 2009.02) 1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Category
Komatsu code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.
LT-3
790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond 1735
Gasket sealant
• Used to stick and seal metal, glass, and plastics.
Polyethylene • Used to seal plugs. container Tube
• Heat-resistant seal used to repair engines.
50 g
• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods.
Aron-alpha 201
790-129-9130
2g
• Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.
Loctite 648-50
79A-129-9110
50 cc
• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures.
1 kg
• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
790-129-9080
LG-6
790-129-9160
200 g
Tube
• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.
Tube
• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.
LG-8 ThreeBond 1207B LG-9 ThreeBond 1206D
4
790-129-9140
Can
419-15-18131
790-129-9310
100 g
200 g
D155A-6
50 Disassembly and assembly
Gasket sealant
CateKomatsu code gory
Part number
Q'ty
Container
LG-10 ThreeBond 1206E
790-129-9320
200 g
Tube
• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.
LG-11 ThreeBond 1121
790-129-9330
200 g
Tube
• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.
ThreeBond 1211
790-129-9090
100 g
Tube
• Gasket sealant used to repair engine.
Tube
• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.
Can
• Spray type • Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. • Applicable for the propeller shaft splines, needle bearings, pins and bolts of various links, etc.
—
Can
• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)
Various
Various
• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.
Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM
• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like 400 g x 20 container swing circle bearings, etc. and spline. • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards.
Seizure prevention compound
Molybdenum disulfide lubricant
LM-P
Grease
SEN03366-05
—
LC-G NEVER-SEEZ
09940-00040
09995-00250
—
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*) Hyper White Grease G2-T, G0-T (*)
SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*) G2-S ThreeBond 1855
G2-U-S ENS grease
D155A-6
—
427-12-11871
200 g
190 g
400 g 16 kg
400 g 16 kg
200 g
2 kg
Main features and applications
• Bellows-type container • Can
Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microorganisms, animals, and plants. Can
Tube
• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.
Can
• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.
5
SEN03366-05
Part number
SUNSTAR PAINT PRIMER 580 SUPER
6
SUNSTAR PAINT PRIMER 435-95
Container
Main features and applications
20 ml
Glass container
• Used as primer for cab side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
• Used as primer for glass side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
417-926-3910
22M-54-27230
• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)
SUNSTAR GLASS PRIMER 435-41
22M-54-27240
150 ml
Can
SUNSTAR SASH PRIMER GP-402
22M-54-27250
20 ml
Glass container
• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)
SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”
417-926-3910
320 ml
Polyethylene container
• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)
SUNSTAR PENGUINE SUPER 560
22M-54-27210
320 ml
Ecocart (Special container)
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Used to seal front window. (Using limit: 6 months after date of manufacture)
Cartridge
• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
GE TOSHIBA SILICONES TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
Primer
SUNSTAR GLASS PRIMER 580 SUPER
Q'ty
Adhesive for cab glass
CateKomatsu code gory
50 Disassembly and assembly
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)
D155A-6
50 Disassembly and assembly
SEN03366-05
Special tool list
1
a Tools with part number 79*T-***-**** cannot be supplied (they must be locally manufactured). a Necessity : t . . . . . . Cannot be substituted, should always be installed (used) : q . . . . . . Extremely useful if available, can be substituted with commercially available part a New/Remodel: N. . . . . . Tools newly developed for this model and given new part Nos.
Removal and installation of fuel supply pump assembly
A
Removal and installation of cylinder head assembly
795-630-5500
Standard puller
t 1
2
01010-81090
Bolt
t 2
3
01643-31032
Washer
t 2
4
790-331-1110
Wrench
q 1
3 4 C 5
8
9
Disassembly and assembly of damper assembly
Part name
1
2
Removal and installation of engine front seal, rear seal
Part No.
F
G
t 1 R Q
Bolt
t 3
01050-31635
Bolt
t 3
795-931-1100
Seal puller
t 1
795T-421-1270 Push tool
t 1
01050-31645
Bolt
t 4
01643-31645
Washer
t 8 t 1
01050-31645
Bolt
t 4
01643-31645
Washer
t 4
Disassembly and assembly of steering case assembly
1 H 2
D155A-6
Installation of Engine front seal
Q Installation of Engine rear seal Q
Installation of Engine rear seal (Press fit of sleeve)
795T-521-1150 Push tool
t 1
01050-31635
t 4
Q Installation of Engine front seal (Press fit of sleeve)
795T-421-1250 Push tool
t 1
Q
01050-31645
Bolt
t 4
01643-31645
Washer
t 8
791-612-1100
Installer
t 1
790-101-4200
Puller (294 kN {30 ton})
t 1
790-101-1102
Hydraulic pump
t 1
Bolt
1 791T-615-1310 • Plate 2
Tightening of cylinder head bolt
01050-31655
795T-421-1240 Push tool
Nature of work and remarks
Separation of drive gear
795T-521-1111 Push tool
791T-615-1300 Puller assembly Disassembly and assembly of transmission assembly
New/Remodel Sketch
Symbol
Q'ty
Work item
Necessity
: R. . . . . . Tools remodeled from tools already available for other models and given upgraded part Nos. : Blank . . Tools already available for other models, usable without any modification a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See Sketches of special tools).
Installation of Engine rear seal
Press fitting of bearing
t 1 N 1 N Q Operation check of clutch piston 1
01010-82040
• Bolt
799-301-1600
Oil leak tester kit (A)
t 1
791-622-1110
Bracket
t 1
01010-31685
Bolt
t 1
01017-31620
Bolt
t 1
790-302-1500
Spanner kit
t 1
09003-09200
• Spanner
1
Removal and installation of brake and carrier assembly Removal and installation of nut (bevel pinion side)
7
Removal and installation of final drive assembly
J
1
2
3 Disassembly and assembly of final drive assembly
K 4
5
6
7
8
Part No.
Part name
790-337-1032
Lifting tool
t 1
791-627-1320
Shackle
t 2
New/Remodel Sketch
Symbol
Q'ty
Work item
50 Disassembly and assembly
Necessity
SEN03366-05
Nature of work and remarks
791T-627-1910 Plate
Removal and installation t 1 N Q of 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
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 of pinion shaft
791T-627-1940 Push tool
Pulling out and press fitting of sprocket and hub t 1 N Q assembly t 1 N Q
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
791-627-1280
Installer
t 1
790-101-5401
Push tool kit
t 1
790-101-5441
• Plate
1
790-101-5421
• Grip
1
01010-51240
• Bolt
1
791T-627-1930 Plate
Installation of floating seal
Press fitting of oil seal
t 1
790-101-5401
Push tool kit
790-101-5451
• Plate
1
790-101-5421
• Grip
1
01010-51240
• Bolt
1
791T-627-1950 Plate
t 1 N Q
791T-627-1960 Plate
t 1 N Q
Press fitting of bearing
t 1
790-201-1500
Push tool kit
790-201-1680
• Plate
1
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
792-785-1120
Plate
t 1
Press fitting of bearing
Press fitting of bearing
D155A-6
Disassembly and assembly of final drive assembly Removal and installation of track frame assembly Removal and installation of track roller assembly
K
7
KK
1
Disassembly and assembly of idler assembly
Part name
791-830-1410
Push tool
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
Press fitting of bearing
791T-130-1010 Bracket
t 6 N Q
01010-63060
Bolt
t 12
01643-33080
Washer
t 12
791-630-1220
Rod
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01411
Nut
t 2
01643-31445
Washer
t 2
790-101-2102
Puller (294 kN {30 ton})
t 1
Fixing of boggy
Press fitting of idler bushing
790-101-1102
Hydraulic pump
t 1
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
15
L
16
17
20
N Q
01010-63060
Bolt
t 4
01643-33080
Washer
t 4
791-630-1360
Spacer
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
790-445-4130
Screw
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller (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
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
Puller (490 kN {50 ton})
t 1
790-101-1102
Pump
t 1
796-230-1120
Installer
t 1
Installation of floating seal
t 1
Q Installation of cartridge pin
19 791T-630-1390 Guide
D155A-6
Nature of work and remarks
2
14
Removal and installation of No. 1 boggy assembly
Part No.
New/Remodel Sketch
Symbol
Q'ty
Work item
SEN03366-05
Necessity
50 Disassembly and assembly
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller (490 kN {50 ton})
t 1
790-101-1102
Pump
t 1
Locking of bogie
Removal of shaft and ring
Removal of floating seal
Q Press fit of pin
9
Removal and installation of No. 1 boggy assembly
21
Part No.
Part name
791-601-1000
Oil pump (seal checker)
t 1
790-401-1700
Lifting tool
t 1
14
15
L
16
Removal and installation of No. 2, No. 3 and No. 4 boggy assemblies
17
t 1
791T-130-1010 Bracket
t 2 N Q
01010-63060
Bolt
t 4
01643-33080
Washer
t 4
791-630-1360
Spacer
t 1
790-101-2310
Block
t 1
Plate
t 2
790-445-4130
Screw
t 2
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
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
Puller (490 kN {50 ton})
t 1
790-101-1102
Pump
t 1
796-230-1120
Installer
t 1
19 791T-630-1390 Guide
L
20
21
Disassembly and assembly of recoil spring assem- M bly
Removal of track roller
790-401-1761 Adapter
790-101-2360
t 1
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
t 2
Plate
790-112-1180
Nut
t 2
790-101-4000
Puller (490 kN {50 ton})
t 1
790-101-1102
Pump
t 1
791-601-1000
Oil pump (seal checker)
t 1
791-685-8006
Compressor
t 1
791-635-3160
Extension
t 1
2 791T-630-2610 Spacer
t 1
790-101-1300
Cylinder
t 1
790-101-1102
Hydraulic pump
t 1
Nature of work and remarks Check of floating seal tightness and charging of oil
L 22
10
New/Remodel Sketch
Symbol
Q'ty
Work item
50 Disassembly and assembly
Necessity
SEN03366-05
Fixing of boggy
Pulling out of shaft and ring
Removal of floating seal
Installation of floating seal Q
Q
Press fitting of cartridge pin
Press fitting of cartridge pin
Check of airtightness of floating seal, and refilling with oil
Q
Compression of recoil spring
D155A-6
Disassembly and assembly of boggy assembly
Q
Disassembly and assembly of carrier roller assem- R bly
Field disassembly and assembly of 1 link
D155A-6
S
T
Part name
790-101-2310
Block
t 1
790-445-4130
Nature of work and remarks
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller (490 kN {50 ton})
t 1
790-101-1102
Pump
t 1
21
791-601-1000
Oil pump
t 1
1
790-102-1891
Nut wrench
t 1
Removal and installation of nut
2
791-651-1510
Installer
t 1
Installation of floating seal
3 791T-630-1350 Spacer
t 1
Press fitting of ring
4
Refilling with oil
20
1
General disassembly and general assembly of track shoe assembly
Part No.
New/Remodel Sketch
Symbol
Q'ty
Work item
SEN03366-05
Necessity
50 Disassembly and assembly
791-601-1000
Oil pump
t 1
791-675-9701
Remover and installer
t 1
791-101-4300
Cylinder (196 kN {20 ton})
t 1
791-101-4200
Puller (294 kN {30 ton})
t 1
Q Pulling out and press fitting of pin assembly and shaft
Disassembly and assembly of track shoe assembly
791-101-1102
Hydraulic pump
t 1
2
791-932-1110
Plug push tool
t 1
Driving of plug (small)
3
791-660-7460
Pin brush
t 1
Cleaning of pin
4
791-432-1110
Plug push tool
t 1
Driving of plug (large)
5
791-632-1052
Installer
t 1
Insertion of link seal
6
790-701-3000
Seal checker
t 1
Check of oil supply and airtightness
7
791-601-1000
Oil pump
t 1
Refilling with oil
1
791-675-9581 Adapter
t 1
791-675-9590
Guide
t 1
01010-52460
Bolt
t 2
01010-51440
Bolt
t 2
Disassembly and assembly of track shoe assembly
11
2
3
4
5
6 Field disassembly and assembly of 1 link
T 7
8
9
10
12
Part No.
Part name
790-101-1102
Pump
t 1
790-101-4300
Cylinder (1,470 kN {150 ton})
t 1
791-685-9510
Frame
t 1
791-685-9520
Frame
t 1
791-685-9530
Rod
t 1
791-685-9550
Nut
t 1
791-685-9560
Bolt
t 1
791-675-9570 Adapter
t 1
04530-12030
Eyebolt
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder (1,470 kN {150 ton})
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
t 3
791-675-5520
Guide
t 1
791-675-5530
Pusher
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller (294 kN {30 ton})
t 1
791-675-5542 Adapter
t 1
791-675-5571 Adapter
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder (1,470 kN {150 ton})
t 1
791-675-5580
Guide
t 1
791-685-9510
Frame
t 1
791-685-9520
Frame
t 1
791-685-9530
Rod
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
t 3
791-685-9560
Bolt
t 4
791-126-0150 Adapter
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
791-675-5542 Adapter
t 1
791-675-5560
Guide
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder (1,470 kN {150 ton})
t 1
791-675-5560
Guide
t 1
791-675-5542 Adapter
t 1
New/Remodel Sketch
Symbol
Q'ty
Work item
50 Disassembly and assembly
Necessity
SEN03366-05
Nature of work and remarks
Disassembly of 1 link
Disassembly of 1 link
Disassembly of 1 link
Disassembly of 1 link
Disassembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
D155A-6
11
Field disassembly and assembly of 1 link
12
T 13
Removal and installation of operator's cab (stuck glass) Disassembly and assembly of hydraulic cylinder assembly
D155A-6
t 1
790-101-4200
Puller (294 kN {30 ton})
t 1
791-670-3270
Guide
t 1
791-126-0150 Adapter
t 1
791-675-5560
t 1
Guide
Assembly of 1 link Assembly of 1 link
Assembly of 1 link
Bolt
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller (294 kN {30 ton})
t 1
791-675-9701
Remover and installer
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller (294 kN {30 ton})
t 1
790-101-4300
Cylinder (1,470 kN {150 ton})
t 1
Disassembly and assembly of track shoe assembly
3
791-432-1110
Plug push tool
t 1
Driving of plug (large)
4
790-701-3000
Seal checker
t 1
Check of oil supply and airtightness
791-932-1110
Plug push tool
t 1
2
V
W
X
Pump
01010-51030
5
Removal and installation of equalizer bar assembly
790-101-1102
Nature of work and remarks
t 1
U
Removal and installation of pivot shaft assembly
Part name
791-675-9570 Adapter
1
Disassembly and assembly of master link
Part No.
New/Remodel Sketch
Symbol
Q'ty
Work item
SEN03366-05
Necessity
50 Disassembly and assembly
1
1 Y 2
791T-650-2110 Sleeve
t 1
790-201-2770
t 1
Spacer
791T-650-2120 Plate
t 1
792-104-3940
Bolt
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01613
Nut
t 1
790-105-2300
Jack assembly (196 kN {20 ton})
t 1
790-101-1102
Hydraulic pump
t 1
Expansion of link
Driving of plug (small) Q Q
Press fitting of ring
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
790-112-1180
Nut
t 2
790-101-4000
Puller (294 kN {50 ton})
t 1
790-101-1102
Hydraulic pump
t 1
793-498-1210
Lifter (Suction cup)
t 2
Installation of window glass
790-502-1003
Cylinder repair stand
t 1
Disassembly and assembly of hydraulic cylinder
790-101-1102
Hydraulic pump
t 1
790-102-3802
Multi-wrench
t 1
Pulling out of center pin
Installation of round head (Blade lift)
13
3
Disassembly and assembly of hydraulic cylinder assembly
Y
4
5
6
14
Part No.
Part name
New/Remodel Sketch
Symbol
Q'ty
Work item
50 Disassembly and assembly
Necessity
SEN03366-05
Nature of work and remarks
790-201-1702
Push tool kit
t 1
790-201-1721
• Push tool
1
790-201-1821
• Push tool
1
Blade lift
790-201-1841
• Push tool
1
Blade tilt
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
790-201-1630
• Plate
1
Blade lift
790-201-1650
• Plate
1
Blade tilt
790-201-1660
• Plate
1
Ripper lift
790-201-1670
• Plate
1
Ripper tilt
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-720-1000
Expander
t 1
796-720-1670
Ring
t 1
07281-01279
Clamp
t 1
796-720-1690
Ring
t 1
07281-01919
Clamp
t 1
796-720-1720
Ring
t 1
07281-02429
Clamp
t 1
790-102-4300
Wrench
t 1
790-102-4310
Pin
t 2
t 1
Press fitting of bushing
Press fitting of dust seal
Press fitting of dust seal Installation of piston ring Blade lift Blade tilt Ripper lift Ripper tilt Removal and installation of screw-type piston
D155A-6
50 Disassembly and assembly
Sketches of special tools
SEN03366-05
1 Note) We will not be liable for any result of use of special tools manufactured according to the following drawings.
C2: Push tool
C4: Push tool
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15
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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
C8: Push tool
16
D155A-6
50 Disassembly and assembly
SEN03366-05
Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. C9: Push tool
G1: Plate (791T-615-1310)
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17
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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)
K1: Plate (791-627-1920)
18
D155A-6
50 Disassembly and assembly
SEN03366-05
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)
Component of K2: Push tool (791T-627-1940)
D155A-6
19
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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)
Component of K5: Plate (791T-627-1960)
20
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50 Disassembly and assembly
SEN03366-05
Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. KK, L14: Bracket
L19: Guide
D155A-6
21
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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, Q20: Plate
Component of M2: Spacer (791T-630-2610)
22
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50 Disassembly and assembly
SEN03366-05
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)
Component of V: Plate (791T-650-2120)
D155A-6
23
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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
D155A-6
SEN03366-05
25
SEN03366-05
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03366-05
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
26
D155A-6
SEN03367-04
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Engine and cooling system Removal and installation of fuel supply pump assembly ................................................................................ 2 Removal and installation of fuel injector assembly ........................................................................................11 Removal and installation of cylinder head assembly .................................................................................... 20 Removal and installation of radiator assembly ............................................................................................. 38 Removal and installation of aftercooler assembly......................................................................................... 44 Removal and installation of engine assembly ............................................................................................... 51 Removal and installation of engine hood assembly ...................................................................................... 60 Removal and installation of engine front seal ............................................................................................... 64 Removal and installation of engine rear seal ................................................................................................ 68 Removal and installation of fuel tank assembly ............................................................................................ 74 Removal and installation of cooling fan drive assembly ............................................................................... 79 Removal and installation of fan motor assembly .......................................................................................... 83
D155A-6
1
SEN03367-04
50 Disassembly and assembly
Removal and installation of fuel supply pump assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
19 mm
1
2
Socket wrench
(Commercially available)
36 mm
1
3
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 785 to 980 Nm
4
Wire
(Commercially available)
1
5
Lever block
(Commercially available)
1
6
Lifting and lowering device
(Commercially available)
1
Remarks
As needed (220 kg)
(220 kg)
Special tools list Symbol
Part name Remover
A
1 Bolt Washer
Part No.
Specifications
Q'ty
795-630-5500
1
01010-81090
2
01643-31032
2
Remarks
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 Leave the negative (-) terminal of the battery disconnected.
a When removing and installing the fuel piping, take extreme care to prevent foreign material from entering into the fuel piping. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. a Check and note the connector numbers and installed positions before disconnecting wiring harnesses and hoses. a When disconnecting wiring, hoses, etc., take care that they are not damaged or deformed by clips, clamps, or the like. When it appears that wiring and hoses may be damaged or deformed, remove clips and clamps in advance.
2
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50 Disassembly and assembly
SEN03367-04
Removal 1. 2.
Open side cover (1) on the left side of engine Remove bolts (2a) (2 pieces) and (3a) (3 pieces) to remove covers (2) and (3) respectively. q Note that bolts (2a) (2 pieces) are installed from inside. Tool: Socket wrench Bolts (2a) and (3a): M12 with width across flats of 19 mm
3.
Remove bolts (51) (6 pieces), then remove cover (52) from under the fuel tank. Tool: Socket wrench Bolt (51): M12 with width across flats of 19 mm
4.
Set lever (53) of the fuel valve to CLOSE position.
5.
Use a lifting tool to sling engine undercover (4), and remove bolts (4a) (10 pieces) (except those for the hinge). At this time, be sure to use the lifting and lowering device to support engine undercover (4) from below to allow it to open gradually. Tool: Socket wrench, lifting and lowering device, wire, lever block Bolt (4a): M24 with width across flats of 36 mm 4
6.
Engine undercover (4): 220 kg
Remove the fuel filter and filter head assembly according to the following procedure. 1) Loosen joint (5) at the top of the fuel air bleeding tube. 2) Disconnect joint (6) at the bottom of the fuel air bleeding tube. 3) Remove joints (7a) and (8a), and disconnect fuel filter inlet tube (7) and fuel filter outlet tube (8) from the filter. 4) Remove clamp (9) of the engine oil level gauge guide. 5) Remove bolts (10a) (4 pieces), and remove fuel filter and filter head assembly (10).
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3
SEN03367-04
7.
Loosen mounting nut (11) of the engine oil level gauge guide.
8.
Disconnect the following wiring connectors. 1) Wiring fixing bracket mounting bolts (12) and (13). 2) Wiring connectors PCV1 (14), CPV2 (15) and backup sensor (16).
9.
Disconnect or remove the following tubes around the supply pump. 1) Remove tube clamp (17) between the pump and fuel filter. 2) Remove tube (18) between the pump and fuel filter. (This tube was disconnected from the fuel filter in step 6 - 3). 3) Remove tube clip (19) between the feed pump and priming pump. 4) Disconnect tube (20) between the feed pump and priming pump. a Tube (21) is also clamped. 5) Remove tube (22) between the feed pump and cooling plate. a Tube (21) is removed, too. 6) Remove fuel return tube clamps (23) (2 pieces). 7) Remove fuel return tube clip (24). 8) Remove fuel return tubes (25) and (26). 9) Remove lubrication tube (27).
50 Disassembly and assembly
10. Remove the high-pressure pipes according to the following procedure. 1) Remove the clamp and stay (28). 2) Remove the clamp and stay (29). 3) Remove the clamp and stay (30). 4) Remove bolts (31) and (31a) (each 2 pieces on the supply pump side and common rail side).
4
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50 Disassembly and assembly
5)
SEN03367-04
Loosen sleeve nuts (32) (2 pieces on the common rail side) and (33) (2 pieces on the supply pump side) and remove high-pressure pipes (34) and (35).
11. Rotate crank shaft forward so that the middle position (a) of "2.5TOP" stamp line of damper (36) and "3.4TOP" stamp line aligns to the pointer (37). a Crank the crankshaft at hexagonal part (b) of water pump drive shaft tip.
12. Remove bolts (38a) (2 pieces) and remove engine front cover (38).
13. Check that the mounting bolt hole (c) at the top of cover aligns to the forcing tap of drive gear. a If they are not aligned, rotate crankshaft one more turn. 14. Remove nut (39). a Take care not to drop into the case.
15. Loosen mounting bolts (4 pieces) and remove bracket (40). 16. Set tools A1, A2 and A3 on drive gear (42), and tighten the center bolt of tool A1 to remove drive gear (42) from the shaft (43).
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5
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50 Disassembly and assembly
17. Remove mounting bolts (41) (4 pieces) and remove fuel supply pump assembly (44). a Keep tool A1, A2 and A3 set on drive gear (42) until fuel supply pump assembly is installed, for the drive gear falls off without the tools.
6
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50 Disassembly and assembly
SEN03367-04
Installation 1.
Set fuel supply pump assembly (44). a Before setting, check that key (d) of shaft aligns to the key slot (e) of drive gear.
2.
Temporarily tighten mounting bolts (41) (4 pieces) and bracket (40) with fingers. 2 Mounting bolt: Liquid adhesive (LT-2)
3.
Set high pressure pipes (34) and (35), temporarily tighten sleeve nuts (32) and (33) with fingers and tighten permanently with the following torque. 3 Common rail side sleeve nut: 39.2 to 58.8 Nm{4 to 6 kgm} 3 Supply pump side sleeve nut: 39.2 to 49 Nm{4 to 5 kgm}
4.
Temporarily tighten clamps (45), (46) and (47), and stays (28), (29) and (30), with fingers. Tighten clamps (45), (46) and (47) permanently. a Tighten clamps in the order of (45), (46) and (47). 3 Clamping bolt: 9.8±1 Nm{1±0.1 kgm}
5.
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7
SEN03367-04
6. 7.
8. 9.
50 Disassembly and assembly
Tighten stays (28), (29) and (30) permanently. a Tighten stays in the order of (28), (29) and (30). Install bolts (31) and (31a) with the notch in the following direction. q Bolt (31): Engine block side q Bolt (31a): Under side
Check that the mounting bolt hole (c) at the top of cover aligns to the forcing tap of drive gear. a If they are not aligned, rotate crankshaft one more turn. Install nut (39). 3 Nut (39): 176 to 196 Nm{18 to 20 kgm} a Take care not to drop the nut into the case.
10. Install engine front cover (38) with bolts (38a) (2 pieces).
11. Connect or install the following tubes around the supply pump. 1) Install lubrication tube (27). 3 Lubrication tube joint bolt: (Supply pump side): 7.9 to 12.7 Nm{0.8 to 1.3 kgm} (Block side): 9.8 to 12.7 Nm{1.0 to 1.3 kgm} 2) Install fuel return tubes (25) and (26). 3 Fuel return tube joint bolt: Between supply pump and priming pump (25) (Supply pump side): 14.8 to 19.6 Nm{1.5 to 2.0 kgm} (Priming pump side of (25)): 19.6 to 29.4 Nm{2.0 to 3.0 kgm} Between supply pump and common rail (26) (Common rail side): 17.7 to 22.6 Nm{1.8 to 2.3 kgm} 3) Install fuel return tube clip (24). 4) Install fuel return tube clamps (23) (2 pieces). 3 Fuel return tube clamp bolt: 9.8±1 Nm{1.0 to 0.1 kgm} 5) Install tube (22) between the feed pump and cooling plate. 3 Tube joint bolt between feed pump and cooling plate: (Feed pump side): 14.8 to 19.6 Nm{1.5 to 2.0 kgm} (Cooling plate side): 43 to 47 Nm{4.4 to 4.8 kgm} a Tube (21) is installed, too.
8
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50 Disassembly and assembly
6)
7) 8)
9)
SEN03367-04
Connect tube (20) between the feed pump and priming pump. 3 Tube joint bolt between feed pump and priming pump: (Feed pump side): 14.8 to 19.6 Nm{1.5 to 2.0 kgm} (Priming pump side): 43 to 47 Nm{4.4 to 4.8 kgm} Install tube clip (19) between the feed pump and priming pump. Connect tube (18) between the pump and fuel filter to the fuel supply pump. 3 Fuel tube joint bolt: 14.8 to 19.6 Nm{1.5 to 2.0 kgm} Install tube clamp (17) between the pump and fuel filter. a Tube (21) is also clamped.
12. Connect the following wiring connectors. 1) Wiring connectors PCV1 (14), CPV2 (15) and backup sensor (16). 2) Wiring fixing bracket mounting bolts (12) and (13).
13. Install mounting nut (11) of the engine oil level gauge guide. 3 Gauge guide mounting nut: 19.6 to 34.3 Nm{2 to 3.5 kgm}
14. Install fuel filter and filter head assembly according to the following procedure. 1) Install fuel filter and filter head assembly (10) with bolts (10a) (4 pieces). 2) Install clamp (9) of the engine oil level gauge guide. 3) Connect fuel filter inlet tube (7) and fuel filter outlet tube (8) to the filter with joint (7a) and (8a). 3 Fuel tube joint bolt (7a), (8a): 24.5 to 34.3 Nm{2.5 to 3.5 kgm} 4) Install joint (6) at the bottom of the fuel air bleeding tube. 3 Fuel air bleeding tube joint bolt (6): 7.8 to 9.8 Nm{0.8 to 1.0 kgm} 5) Install joint (5) at the top of the fuel air bleeding tube. 3 Fuel air bleeding tube joint bolt (5): 7.8 to 9.8 Nm{0.8 to 1.0 kgm}
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9
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50 Disassembly and assembly
15. Use the lifting tool to sling engine undercover (4) and set it to its installed position. Tool: Wire, lever block, lifting and lowering device 4
Engine undercover (4): 220 kg
16. Use bolts (4a) (10 pieces) (except those for the hinge) to install engine undercover (4). Tool: Torque wrench (socket) Bolt (4a): M24 with width across flats of 36 mm 3 Bolt (4a): 785 to 980 Nm {80 to 100 kgm} 17. Set lever (53) of the fuel valve to OPEN position.
18. Use bolts (51) (6 pieces) to install cover (52) under the fuel tank.
19. Use bolts (2a) (2 pieces) and (3a) (3 pieces) to install covers (2) and (3) respectively. a Be sure to install bolts (2a) (2 pieces) from inside. Tool: Socket wrench Bolts (2a) and (3a): M12 with width across flats of 19 mm 3 Bolts (2a) and (3a): 98 to 123 Nm {10 to 12.5 kgm} 20. Close cover (1) on the left side of the engine.
10
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50 Disassembly and assembly
SEN03367-04
Removal and installation of fuel injector assembly
1
Standard tools The described tool is a reference. If it has a purpose, it can be used other than the described tool. No.
Part name
Part No
Specification
Q'ty
1
Socket wrench
(Commercially available)
19 mm
1
2
Torque wrench set (socket)
(Commercially available)
98 to 123 Nm
1
Remarks
k Park the machine on a level ground, and set 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 to stop the engine. k Disconnect the negative terminal (-) of the battery.
a When removing and installing the fuel piping, take extreme care to prevent foreign material from entering into the fuel piping. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. a Check the connector numbers and installed positions before disconnecting wiring and hoses, and record them. a When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses by the clips and clamps. If the wiring and hoses may be damaged or deformed, remove the clips and clamps before disconnecting them.
D155A-6
11
SEN03367-04
50 Disassembly and assembly
Removal 1. 2.
Remove the engine hood. For details, see "Removal and installation of engine hood assembly". Remove bolts (71) (6 pieces), and remove fuel tank under cover (72). Tools: Socket wrench Bolts (71): Width across flats 19 mm, M12
3.
Close fuel valve lever (73).
4.
Remove the corrosion resistor assembly, fuel filter assembly, prefilter assembly and oil filter assembly according to the following procedure. 1) Corrosion resistor 1] Disconnect corrosion resistor inlet/outlet tubes (1) (2 pieces). 2] Remove corrosion resistor bracket assembly (2). 2) Fuel filter 1] Remove oil level gauge guide clamp (3). 2] Loosen the upper joint bolt (on the air vent assembly side) of fuel air bleeding tube (4), remove the lower joint bolt, and disconnect fuel air bleeding tube (4) from fuel filter bracket assembly (5). 3] Disconnect fuel filter inlet/outlet tubes (6) (2 pieces). 4] Remove fuel filter bracket assembly (5). 3) Prefilter 1] Remove prefilter inlet hose (7) and outlet tube (8). 2] Remove prefilter bracket assembly (9). 4) Oil filter 1] Remove tube assembly (10) between the oil filter and cylinder block. 2] Remove oil filter bracket assembly (11). a When removing the No.1 fuel injector assembly, you do not need to remove the prefilter assembly. a When removing one other than the No.1 fuel injector assembly, you do not need to remove the corrosion resistor assembly and fuel filter assembly.
12
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50 Disassembly and assembly
5. 6.
7.
SEN03367-04
Remove high-pressure pipe clamp (12) between the common rail and supply pump and then remove stay (13). Remove common rail cover (14). a The following is the removal procedure for the No.1 fuel injector assembly.
Remove stay (15). a If bracket (16) is removed, you can work easily.
8. Remove clamp (17). 9. Remove boot (18). 10. Loosen sleeve nut (19). 11. Remove stays (20) to (23).
12. Remove cylinder head cover (24).
D155A-6
13
SEN03367-04
50 Disassembly and assembly
13. Rotate crankshaft forward, align damper "1.6TOP" stamp line (c) to pointer (P), and then set the No.1 cylinder to the compression top dead center. a Crank the crankshaft at hexagonal part (d) of water pump drive shaft tip.
14. Remove cover (25). 15. Remove mounting bolts (26) through (28), and remove rocker arm and rocker shaft assembly (29). a Loosen lock nut (31), and loosen adjustment screw (32) two or three turns to prevent excessive force applied to push rod (30), when installing rocker arm and rocker shaft assembly.
16. Loosen sleeve nut (33), and remove high pressure pipe (34) from injector. 17. Remove wiring harness clamping bolt (35) and clip (36). 18. Remove two wiring harness capture nuts (37) from fuel injector assembly. a Loosen nuts alternately. 19. Remove holder mounting bolt (38).
20. Set L type bar [1] under fuel injector assembly inlet connector (a), and remove slowly fuel injector assembly (39) with holder (40) using leverage action. a Do not pull out solenoid valve portion at the top of injector by pinching with pliers, etc.
14
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50 Disassembly and assembly
SEN03367-04
Installation 1.
Install fuel injector assembly according to the followinf procedure. 1) Check that no foreign material stays inside injector sleeve. 2) Install O-rings (41) and (42), and gasket (43) to injector. a Take care not to install O-ring to groove (b).
3)
Set fuel injector assembly (39) with holder (40) to cylinder head. Attach spherical washer (44) to bolt (38), and tighten temporarily bolt (38). 2 Spherical washer: Engine oil Tighten temporarily high pressure pipe sleeve nuts (33) and (19). k Install high pressure pipe after checking the followings. If an abnormality takes place, it may cause fuel leakage, and replace high pressure pipe.
4) 5)
a
Check visually taper seal portion (a portion: within 2 mm from the tip) at the joint section for visible vertical slit scar (b) or patchy dent (c). a Check the difference at (d) portion (tip of taper seal portion: within 2 mm from the tip) for any catches on a finger nail (no fatigue). 6) Tighten bolts (38) to the specified torque. 3 Bolt (38): 58.8 to 73.5 Nm{6 to 7.5 kgm} 7) Tighten sleeve nuts (33) and (19). 3 Sleeve nuts (33) and (19): 39.2 to 49 Nm{4 to 5 kgm}
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15
SEN03367-04
2.
Install two wiring harness according to the following procedure. a Eliminate the slack of the injector wiring harness and press it against the injector body so that it will not interfere with the rocker arm. Tighten the nuts alternately. 1) Tighten two capture nuts (37). a Tighten capture nuts alternately. 3 Capture nut: 2±0.2 Nm{0.2±0.02 kgm} 2) Install clip (36). 3) Install wiring harness clamping bolt (35) and clip (36).
3.
Install rocker arm and rocker shaft assembly (29) with mounting bolts (26) to (28). a When installing rocker arm and rocker shaft assembly (29), check the ball portion of adjustment screw (32) to be inserted securely into socket of push rod (30), and tighten mounting bolts. a As 3 mounting bolts are different each other, install them referring to the followings. q Mounting bolt (26): Stem length 120 mm q Mounting bolt (27): Stem length 90 mm q Mounting bolt (28): Stem length 75.2 mm 3 Mounting bolts (26), (27) and (28): 93 to 103 Nm{9.5 to 10.5 kgm} a Adjust valve clearance referring to the section of Testing and adjusting, "Adjusting valve clearance". a Loosen locknut (31), and loosen adjustment screw (32) 2 to 3 turns so that excessive force is not applied to push rod (30) when the rocker arm and rocker shaft assembly (29) is installed. Install cover (25). a Install with the notch downward.
4. 5.
16
50 Disassembly and assembly
Install cylinder head cover (24). 3 Cylinder head cover mounting bolt: 29.4 to 34.3 Nm{3.0 to 3.5 kgm}
D155A-6
50 Disassembly and assembly
6.
Install high pressure pipe clamp and stay. 1) Temporarily tighten high pressure pipe clamp, stay (23), clamping bolts (45) through (49), and stay mounting bolt, with fingers. 2) Tighten permanently high pressure pipe clamping bolt. 3 Clamping bolt: 9.8±1 Nm{1±0.1 kgm} 3) Tighten permanently stay mounting bolt (45) to (49). 4) Temporarily tighten high pressure pipe clamp, stay (22), clamping bolts (50) to (54), and stay mounting bolt, with fingers. 5) Install boot (18). a Install with the notch toward cylinder block side. 6) Install high pressure pipe clamp (17) and gate type frame (14) temporarily. 7) Tighten clamping bolt for high pressure pipe clamp (17) permanently. 3 Clamping bolt: 9.8±1 Nm{1±0.1 kgm} 8) Tighten gate type frame (14) permanently. 9) Tighten high pressure pipe clamp, stay (22) and clamping bolts (50) through (54), permanently. 3 Clamping bolt: 9.8±1 Nm{1±0.1 kgm} 10) Install clamp (12) and stay (13). 3 Clamping bolt: 9.8±1 Nm{1±0.1 kgm}
7. 8.
Install holder mounting bolt (38). Install stay (15). a Install bracket (16), if removed it.
SEN03367-04
9. Install common rail cover (14). 10. Install high-pressure pipe clamp (12) between the common rail and supply pump and then install stay (13).
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50 Disassembly and assembly
11. Install the corrosion resistor assembly, fuel filter assembly, prefilter assembly and oil filter assembly according to the following procedure. 1) Oil filter 1] Install oil filter bracket assembly (11). a When installing one other than the No. 1 fuel injector assembly, you do not need to install the corrosion resistor assembly and fuel filter assembly. 2] Install tube assembly (10) between the oil filter and cylinder block. q Installation procedure for oil filter tube 2) Install tubes (55) and (56) temporarily to bracket (58) with clip (57). 3) Install flange (59) and tubes (55) and (56) temporarily. 4) Install the oil filter end of tubes (55) and (56) in the hole of the oil filter bracket and tighten bolts (60) temporarily. 5) Install flange (59) to the cylinder block temporarily with bolts (61). 6) Tighten bolts (60) on the oil filter side permanently. 7) Tighten bolts (61) of flange (59) permanently. 8) Prefilter 1] Install prefilter bracket assembly (9). 2] Install prefilter inlet hose (7) and outlet tube (8). 3 Prefilter inlet hose sleeve nut (7): 84 to 132 Nm{8.5 to 13.5 kgm} Prefilter outlet tube sleeve nut (8): (Bracket side) 84 to 132 Nm{8.5 to 13.5 kgm} (Tube side) 43 to 47 Nm{4.4 to 4.7 kgm} 9) Fuel filter 1] Install fuel filter bracket assembly (5). 2] Connect fuel filter inlet/outlet tubes (6) (2 pieces). 3 Fuel filter tube joint bolt: (Inlet and outlet): 24.5 to 34.3 Nm{2.5 to 3.5 kgm} 3] Tighten the upper joint bolt (on the air vent assembly side) of fuel air bleeding tube (4), install the lower joint bolt, and connect fuel air bleeding tube (4) to fuel filter bracket assembly (5). 4] Install oil level gauge guide clamp (3). 10) Corrosion resistor 1] Install corrosion resistor bracket assembly (2). 2] Connect corrosion resistor inlet/ outlet tubes (1) (2 pieces). 3 Corrosion resistor tube joint bolt: (Inlet and outlet): 24.5 to 34.3 Nm{2.5 to 3.5 kgm} 12. Open fuel valve lever (73).
18
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50 Disassembly and assembly
SEN03367-04
13. Install bolts (71) (6 pieces), and install fuel tank under cover (72). Tools: Socket wrench Bolts (71): Width across flats 19 mm, M12 3 Bolts (71): 98 to 123 Nm{10 to 12.5 kgm} 14. Install the engine hood. For details, see "Removal and installation of engine hood assembly".
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19
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50 Disassembly and assembly
Removal and installation of cylinder head assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
19 mm
1
2
Socket wrench
(Commercially available)
36 mm
1
3
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 785 to 980 Nm
As needed
Part No.
Specifications
Q'ty
Remarks
Standard tools list No. A4
Part name Wrench
790-331-1110
Remarks
1
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.
k If you drain the coolant when it is still hot, you may be scalded. Wait until the coolant tempera-
ture drops, and then drain the coolant. a When removing and installing the fuel piping, take extreme care to prevent foreign material from entering into the fuel piping. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. a Check and note the connector numbers and installed positions before disconnecting wiring harnesses and hoses. a When disconnecting wiring, hoses, etc., take care that they are not damaged or deformed by clips, clamps, or the like. When it appears that wiring and hoses may be damaged or deformed, remove clips and clamps in advance.
20
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50 Disassembly and assembly
SEN03367-04
Removal 1.
Remove the engine hood. For details, see "Removal and installation of engine hood assembly".
2.
Open drain valve (125) to drain approximately half of specified capacity of coolant (approximately 40 l as a target). 6
a
Specified capacity: 82 l
Be sure to close drain valve (125) after drain.
3.
Remove bolts (121) (6 pieces), and remove fuel tank under cover (122). Tools: Socket wrench Bolts (121): Width across flats 19 mm, M12
4.
Close fuel valve lever (123).
5.
Remove the corrosion resistor assembly, fuel filter assembly, prefilter assembly and oil filter assembly according to the following procedure. 1) Corrosion resistor 1] Disconnect corrosion resistor inlet/ outlet tubes (1) (2 pieces). 2] Remove corrosion resistor bracket assembly (2). 2) Fuel filter 1] Remove oil level gauge guide clamp (3). 2] Loosen the upper joint bolt (on the air vent assembly side) of fuel air bleeding tube (4), remove the lower joint bolt, and disconnect fuel air bleeding tube (4) from fuel filter bracket assembly (5). 3] Disconnect fuel filter inlet/outlet tubes (6) (2 pieces). 4] Remove fuel filter bracket assembly (5). 3) Prefilter 1] Remove prefilter inlet hose (7) and outlet tube (8). 2] Remove prefilter bracket assembly (9). 4) Oil filter 1] Remove tube assembly (10) between the oil filter and cylinder block. 2] Remove oil filter bracket assembly (11).
D155A-6
21
SEN03367-04
6.
Disconnect or remove the hoses according to the following procedure. 1) Remove priming pump cover (12). 2) Remove clips (13), (14) and (14a) and fuel return tube (15). 3) Remove clamps (16) and (17) and then remove fuel tube (18) between the fuel filter and supply pump.
7.
Disconnect wiring clips (19) and (20) and remove heater wiring connector RHT (21).
8.
Remove wiring clips (22) to (34) and move the wiring aside.
50 Disassembly and assembly
9.
Remove stay (35), air vent assembly (36) and bracket (37) together. 10. Remove brackets (38) and (39).
11. Remove breather tube (40). 12. Remove aftercooler outlet hose (41) and air intake connector (42) together.
22
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50 Disassembly and assembly
SEN03367-04
13. Remove water tube (corrosion resistor outlet/inlet tube) (43). 14. Remove venturi connector (44). 4
Venturi connector (44): 18 kg
15. Remove housing (45).
16. Disconnect fuel hose (46).
17. Remove clamp (47). 18. Remove mounting bolts of bracket (48) and move bracket (48) and breather (49) together.
19. Disconnect connectors TFUEL (50), TIM (51) and PIM (52).
20. Remove spill tube (53).
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23
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50 Disassembly and assembly
21. Remove wiring harness clamps (54) (2 pieces), upper and lower, at the rear of the air intake manifold.
22. Remove charge pressure sensor (55), plate (56) and bracket (57) together. a These parts must be removed to secure a space for loosening the turbocharger lubrication tube clamp.
23. Remove stays (58) (5 pieces) of the high-pressure pipe clamps.
24. Remove high-pressure pipe clamp stays (59), (60), (61), (62) and (63).
25. Remove air intake manifold (64). 4
24
Air intake manifold (64): 50 kg
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50 Disassembly and assembly
SEN03367-04
26. Remove the muffler according to the following procedure. 1) Remove heat insulation plate (65).
2)
Remove bracket (66).
3)
Remove muffler mounting bolts (67) (4 pieces) and lift off muffler (68). 4
Muffler: 55 kg
27. Remove the turbocharger assembly according to the following procedure. 1) Remove air connector (69). 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). 7) Remove bracket (77).
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25
SEN03367-04
8) 9)
50 Disassembly and assembly
Remove oil tube (78). Remove water tube (79).
10) Sling turbocharger and exhaust manifold assembly (80). 11) Remove mounting bolts (81) (24 pieces) and lift off turbocharger and exhaust manifold assembly (80). 4 Turbocharger and exhaust manifold assembly: 80 kg
28. Disconnect connectors CN1 (79), CN2 (80), CN3 (81), CN4 (82), CN5 (83) and CN6 (84), and then reposition wiring harnesses (85) and (86) out of the way so that they will not hinder the work.
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).
29. Remove gate type frame (87) and clamp (88). 30. Remove spill tube (89). 31. Remove cover (90) and high pressure pipe (91) depending on the cylinder head assembly to be removed.
26
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50 Disassembly and assembly
SEN03367-04
32. Remove water tube (92). 33. Remove cylinder head cover (93).
34. Rotate crankshaft forward, align damper "1.6TOP" stamp line (c) to pointer (P), and then set the No. 1 cylinder to the compression top dead center. a Crank the crankshaft at hexagonal part (d) of water pump drive shaft tip.
35. Remove three mounting bolts (95) through (97), and remove rocker arm and rocker shaft assembly (98). a Loosen lock nut (100), and loosen adjustment screw (101) two or three turns to prevent excessive force applied to push rod (99), when installing rocker arm and rocker shaft assembly.
36. Remove fuel injector assembly. 1) Remove wiring harness clamping bolt (102) and clip (103). 2) Remove two wiring harness capture nuts (104) from fuel injector assembly. a Loosen nuts alternately. 3) Unscrew bolt (105) to remove holder (106). 4) Push connecter (107) into rocker housing, and remove injector wiring harness (108). a O-ring is installed in connector (107). 5) Remove mounting bolt (110) of holder. 6) Set L type bar [2] under fuel injector assembly inlet connector (e), and remove slowly fuel injector assembly (111) with holder using leverage action. a Do not grip the solenoid valve at the top of the injector to pull off the injector.
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50 Disassembly and assembly
37. Remove two push rods (99).
38. Remove crosshead (113). 39. Remove mounting bolts (114) (3 pieces), bolts (115) (3 pieces) and auxiliary bolt (116), and remove cylinder head assembly (117). 4
28
Cylinder head assembly (117): 25 kg
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50 Disassembly and assembly
SEN03367-04
Installation 1.
Install cylinder head assembly. 1) Install cylinder head gasket (118). a Check that the mounting surface of cylinder head and the inside of cylinder are free from foreign material. a Check that the gasket is free from peeling or coming off of grommet.
2)
3) 4)
5)
D155A-6
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 Install cylinder head assembly. 4 Cylinder head assembly (117): 25 kg Tighten each mounting bolts (114) (3 pieces) and (115) (3 pieces) in order 1 through 6 as shown in the figure. 2 Mounting bolt: Lubricant with molybdenum disulfide (LM-P) 3 Mounting bolt 1st time: 137 to 157 Nm{14 to 16 kgm} 2nd time: 284 to 294 Nm{29.0 to 30.0 kgm} 3rd time: Retighten 90 ° (+30 °/0) with tool A4 (Wrench). a When tool A4 (Wrench) is not available, put marks (a) and (b) to bolt and cylinder head, and retighten bolt 90 ° (+30 °/0).
Tighten auxiliary bolt (116) (tightening order: 7th) with the following torque. 3 Auxiliary bolt: 66.6±7.4 Nm{6.8±0.8 kgm}
29
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2.
After installing cross head (113), make adjustment as follows. 1) Loosen lock nut (100), and loosen adjustment screw (101). 2) Lightly push cross head (113) contact surface (h) with rocker arm, and hold cross head to contact with push rod (99) side valve stem (119). 3) Screw slowly adjustment screw (101), and check the position where adjustment screw touches valve stem (120). 4) From the above condition, screw adjustment screw (101) 20 °. 5) While holding adjustment screw (101) with a flat-head screwdriver, tighten locknut (100). 3 Lock nut: 58.7±5.9 Nm{6.0±0.6 kgm}
3.
Install push rod (99). a Raise push rod slightly, and check that push rod is securely inserted in cam follower.
4.
Install fuel injector assembly. a Install the fuel injector assembly referring to the installation procedure in "Removal and installation of fuel injector assembly".
5.
Install injector wiring harness according to the following procedure. a Eliminate the slack of the injector wiring harness and press it against the injector body so that it will not interfere with the rocker arm. a Tighten the nuts alternately. 1) Install O-ring to injector wiring harness (108). 2) Install injector wiring harness (108) in rocker housing, install holder (106) and tighten bolt (105). 3) Install clip (103). 4) Tighten two capture nuts (104). a Tighten capture nuts alternately. 3 Capture nut: 2±0.2 Nm{0.2±0.02 kgm} 5) Install wiring harness clamping bolt (102).
30
50 Disassembly and assembly
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50 Disassembly and assembly
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6.
Install rocker arm and rocker shaft assembly (98), with bolts (95) to (97) (3 pieces). a When installing rocker arm and rocker shaft assembly (98), check the ball portion of adjustment screw (101) to be inserted securely into socket of push rod (99), and tighten mounting bolts. a As three mounting bolts are different each other, install them referring the followings q Mounting bolt (95): Stem length 120 mm q Mounting bolt (96): Stem length 90 mm q Mounting bolt (97): Stem length 75.2 mm 3 Mounting bolt: 93 to 103 Nm{9.5 to 10.5 kgm} a Adjust valve clearance referring to the section of Testing and adjusting, "Adjusting valve clearance". 7. Install cover (90) and high pressure pipe (91), depending on the cylinder head assembly removed. 8. Install cylinder head cover (93). 3 Cylinder head cover mounting bolt: 29.4 to 34.3 Nm{3.0 to 3.5 kgm} 9. Install water tube (92). 3 Water tube joint bolt: 9.8 to 12.7 Nm{1.0 to 1.3 kgm} 10. Install spill tube (89). 3 Spill tube joint bolt: 9.8 to 12.7 Nm{1.0 to 1.3 kgm} 11. Install gate type frame (87) and clamp (88). 3 Clamp bolt: 9.8 to 12.7 Nm{1.0 to 1.3 kgm}
12. Set wiring harnesses (85) and (86) to their installed position, and then connect connectors CN1 (79), CN2 (80), CN3 (81), CN4 (82), CN5 (83), and CN6 (84).
13. Install the turbocharger assembly according to the following procedure. 1) Sling turbocharger and exhaust manifold assembly (80), and set to the mounting position. 4
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Turbocharger and exhaust manifold assembly: 80 kg
31
SEN03367-04
a
Tighten exhaust manifold mounting bolts (81) (24 pieces) in the numerical order shown the right figure. 2 Threads of mounting bolt (81): Lubricant with molybdenum disulfide (LM-P) 3 Mounting bolt (81): 58.8 to 73.5 Nm{6 to 7.5 kgm}
2) 3)
Install water tube (79). Install oil tube (78). 3 Oil tube cylinder block side joint bolt: 24.5 to 34.3 Nm{2.5 to 3.5 kgm}
4)
Install bracket (77).
50 Disassembly and assembly
5) Install turbocharger-end mounting bolt of oil tube (76). 6) Install water tube (75). 7) Install muffler drain tube (74). 8) Install bracket (73). 9) Install heat insulation plates (70), (71) and (72). 10) Install air connector (69). a Replace the clamps with new ones. a Install each 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. 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 to 10 mm
32
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50 Disassembly and assembly
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14. Install the muffler according to the following procedure. 1) Install muffler (68) with muffler mounting bolts (67) (4 pieces). 4
Muffler: 55 kg
2)
Install bracket (66).
3)
Install heat insulation plate (65).
15. Install air intake manifold (64). a Tighten intake manifold (64) mounting bolts in the numerical order shown the right figure. 3 Mounting bolt: 58.8 to 73.5 Nm{6 to 7.5 kgm} 4 Air intake manifold: 50 kg
16. Install charge pressure sensor (55), plate (56) and bracket (57) together.
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33
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50 Disassembly and assembly
17. Install 2 wiring harness clamps (54), upper and lower, at the rear of the air intake manifold.
18. Install spill tube (53). 3 Joint bolt (53a): 9.8 to 12.7 Nm{1.0 to 1.3 kgm} 3 Joint bolt (53b): 19.6 to 29.4 Nm{2.0 to 3.0 kgm}
19. Connect connectors TFUEL (50), TIM (51) and PIM (52).
20. Install bracket (48) and breather (49) together, with mounting bolts of bracket (48). 21. Install clamp (47).
22. Connect fuel hose (46).
34
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50 Disassembly and assembly
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23. Install housing (45). 24. Install venturi connector (44). 25. Install water tube (corrosion resistor outlet/inlet tube) (43). 4
Venturi connector (44): 18 kg
26. Install aftercooler outlet hose (41) and air intake connector (42) together. a Replace the clamps with new ones. a Install each 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. 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 to 10 mm 27. Install breather tube (40). 28. Install brackets (38) and (39). 29. Install stay (35), air vent assembly (36) and bracket (37) together.
30. Install wiring clips (22) to (34) and move the wiring aside. 31. Connect wiring clips (19) and (20) and install heater wiring connector RHT (21).
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35
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50 Disassembly and assembly
32. Connect or install the hoses according to the following procedure. 1) Install clamps (16) and (17) and then install fuel tube (18) between the fuel filter and supply pump. 3 Supply pump-end joint bolt of fuel tube between fuel filter and supply pump: 14.8 to 19.6 Nm{1.5 to 2.0 kgm} 2) Install clips (13), (14) and (14a) and fuel return tube (15). 3 Fuel return tube joint bolts Upper joint bolt (15a): 7.8 to 9.8 Nm{0.8 to 1.0 kgm} Lower joint bolt (15b): 19.6 to 29.4 Nm{2.0 to 3.0 kgm} 3) Install priming pump cover (12).
33. Install the corrosion resistor assembly, fuel filter assembly, prefilter assembly and oil filter assembly according to the following procedure. 1) Oil filter 1] Install oil filter bracket assembly (11). 2] Install tube assembly (10) between the oil filter and cylinder block. q Install the oil filter tube (10) according to step 11 in "Removal and installation of fuel injector assembly". 2) Prefilter 1] Install prefilter bracket assembly (9). 2] Install prefilter inlet hose (7) and outlet tube (8). 3 Prefilter inlet hose sleeve nut (7): 84 to 132 Nm{8.5 to 13.5 kgm} 3 Prefilter outlet tube sleeve nut (8): (Bracket side) 84 to 132 Nm{8.5 to 13.5 kgm} (Tube side) 43 to 47 Nm{4.4 to 4.7 kgm} 3) Fuel filter 1] Install fuel filter bracket assembly (5). 2] Connect 2 fuel filter inlet/outlet tubes (6). 3 Fuel filter tube joint bolt (Inlet and outlet): 24.5 to 34.3 Nm{2.5 to 3.5 kgm}
36
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50 Disassembly and assembly
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3]
4)
Tighten the upper joint bolt (on the air vent assembly side) of fuel air bleeding tube (4), install the lower joint bolt, and connect fuel air bleeding tube (4) from fuel filter bracket assembly (5). 3 Fuel air bleeding tube joint bolt (Upper and lower): 7.8 to 9.8 Nm{0.8 to 1.0 kgm} 4] Install oil level gauge guide clamp (3). Corrosion resistor 1] Install corrosion resistor bracket assembly (2). 2] Connect corrosion resistor inlet/ outlet tubes (1) (2 pieces). 3 Corrosion resistor tube joint bolt: 24.5 to 34.3 Nm{2.5 to 3.5 kgm}
34. Open fuel valve lever (123).
35. Use bolts (121) (6 pieces) to install cover (122) under the fuel tank. Tool: Socket wrench Bolt (121): M12 with width across flats of 19 mm 3 Bolt (121): 98 to 123 Nm {10 to 12.5 kgm} 36. Install the engine hood. For details, see "Removal and installation of engine hood assembly". 37. Refilling with coolant Refill the radiator with the coolant. 5
Radiator: 82 l
Refill it with the coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 38. Check for fuel leakage (fuel system) a Check the fuel system for leakage. For details, see Testing and adjusting, "Testing fuel circuit for leakage". 39. Bleeding air (fuel system) a Bleed air from the fuel circuit. For details, see Testing and adjusting, "Bleeding air from fuel circuit".
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50 Disassembly and assembly
Removal and installation of radiator assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
17 mm
1
2
Socket wrench
(Commercially available)
19 mm
1
3
Socket wrench
(Commercially available)
24 mm
1
4
Torque wrench (socket)
(Commercially available)
59 to 74 Nm, 98 to 123 Nm, 235 to 285 Nm
5
Eyebolt
(Commercially available)
M10
2
6
Eyebolt
(Commercially available)
M12
2
7
Wire
(Commercially available)
1
(25 kg)
8
2-point chain
(Commercially available)
1
(50 kg)
As needed
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.
k If you drain the coolant when it is still hot, you may be scalded. Wait until the coolant tempera-
ture drops, and then drain the coolant.
38
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50 Disassembly and assembly
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Removal 1.
Open the radiator cap to release internal pressure.
2.
Open drain valve (13) to drain the coolant. 6
a
Radiator: 82 l
Be sure to close drain valve (13) after draining.
3.
Remove bolts (13a) (4 pieces), and remove cover (13). Tool: Socket wrench Bolt (13a): M12 with width across flats of 19 mm
4.
Disconnect connector LHD (1).
5.
Attach the lifting tool to lifting points (b), remove bolts (2a) (4 pieces), and sling cover (2) to remove it. Tool: Socket wrench, 2-point chain, eyebolt (M12) Bolt (2a): M12 with width across flats of 19 mm 4
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Radiator upper cover (2): 50 kg
39
SEN03367-04
6. 7.
50 Disassembly and assembly
Remove clips (3a) and (4a), and disconnect hoses (3) and (4). Remove bolts (5a), (6a), and (7a) (2 pieces each), and disconnect tubes (5), (6), and (7). Tool: Socket wrench Bolts (5a) and (7a): M10 with width across flats of 17 mm Bolt (6a): M12 with width across flats of 19 mm
8.
Remove bolts (8a), (9a), (9b), (10a), (10b), (11a), and (11b) to remove brackets (8), (9), (10), and (11) respectively. q Mounting bolt of bracket (8): (8a) (4 pieces) q Mounting bolt of bracket (9): (9a) (2 pieces) and (9b) (1 piece) q Mounting bolt of bracket (10): (10a) (4 pieces) and (10b) (2 pieces) q Mounting bolt of bracket (11): (11a) (2 pieces) and (11b) (1 piece) Tool: Socket wrench Bolt (8a): M16 with width across flats of 24 mm Bolts (9a), (9b), (10a), (10b), (11a), and (11b): M10 with width across flats of 17 mm a For removing the left radiator assembly, disconnect tube (5) and remove brackets (8), (9), and (10). a For removing the right radiator assembly, disconnect tubes (6) and (7), and remove brackets (10) and (11).
9.
Attach the lifting tool to lifting points (c), sling radiator assembly (12), and remove it. Tool: Eyebolt (M10), wire 4
Radiator assembly (12): 25 kg
10. Open the radiator mask and remove the fan net. 11. Remove cushions (15) (4 pieces) from lower tank (16).
40
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50 Disassembly and assembly
SEN03367-04
Installation 1.
Install radiator assembly (12) according to the following procedure. 1) Set rubber (13) with its stepped part (a) facing downward. 2) Fill the O-ring groove with an amount of grease enough to prevent the O-ring from dropping when the radiator assembly is raised, and then install O-ring (14). 2 Outer circumference of O-ring: Grease (G2-LI)
3)
Install cushions (15) (4 pieces) to lower tank (16).
4)
Attach the lifting tool to lifting points (c), sling radiator assembly (12), and set it to its installed position. Tool: Eyebolt (M10), wire 4 Radiator assembly (12): 25 kg Then, lower radiator assembly (12) to set it to the lower tank. a Visually check its installed condition from the front of the machine. Install the fan net and close the radiator mask.
5)
6)
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2.
Install brackets (8), (9), (10), and (11) according to the following procedure. a For installing the left radiator assembly, install brackets (8), (9), and (10). a For installing the right radiator assembly, install brackets (10) and (11). 1) Set plate (18), cushion (19), and brackets (9) to (11) on the mount boss of radiator (12). a At this time, leave bracket mounting bolts (22) {(9a), (10a), and (11a)} tightened loosely, and press brackets (9), (10), and (11) against the mounting seat of upper tank (17). 2) Install collar (20) reversely (with its small diameter end up), and tighten mounting bolts (21) {(9b), (10b), and (11b)}. a Note that collar (20) is thin and has a trapezoidal and circular shape with a small diameter end and a large diameter end. q Compress cushion (19). {L1 (Before compression)oL2 (After compression)} 3) Tighten mounting bolts (22) of brackets (9) to (11) with mounting bolt (21) tightened. Tool: Torque wrench (socket) Bolt (22): M10 with width across flats of 17 mm 3 Bolt (22): 59 to 74 Nm {6 to 7.5 kgm} 4) Remove mounting bolt (21) and set collar (20) in normal direction (with its small end down). 5) Tighten mounting bolts (21). Tool: Torque wrench (socket) Bolt (21): M12 with width across flats of 19 mm 3 Bolt (21): 98 to 123 Nm {10 to 12.5 kgm} 6) Check clearance (L3). Clearance (L3): Approximately 7 mm 7) Use bolts (8a) (2 pieces) to install bracket (8). Tool: Torque wrench (socket) Bolt (8a): M16 with width across flats of 24 mm 3 Bolt (8a): 235 to 285 Nm {23.5 to 29.5 kgm}
3.
Use bolts (5a), (6a), and (7a) (2 pieces each) to connect tubes (5), (6), and (7). a Replace gaskets between tubes (5), (6), and (7) and the upper tank with new ones. 2 Gasket contacting face: Liquid gasket (LG-7) a When the hose is removed from tubes (5) and (7), install the hose with the red circle paint up. 3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm} 2 Tube flange: Liquid gasket
42
50 Disassembly and assembly
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a
When the hose is removed from tube (6), set bolts of adjacent 2 clamps {(d) and (e)} 180° apart from each other, and then tighten the bolts. 3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm} 2 Tube flange: Liquid gasket
4.
Connect hoses (3) and (4).
5.
Attach the lifting tool to lifting points (b), and set radiator upper cover (2) to its installed position. Tool: Eyebolt (M12), wire Use bolts (2a) (4 pieces) to install radiator upper cover (2). Tool: Torque wrench (socket) Bolt (2a): M12 with width across flats of 19 mm 3 Bolt (2a): 98 to 123 Nm {10 to 12.5 kgm}
6.
4
Radiator upper cover (2): 50 kg
7.
Connect wiring harness connector LHD (1).
8.
Use bolts (13a) (4 pieces) to install cover (13). Tool: Torque wrench (socket) Bolt (13a): M12 with width across flats of 19 mm 3 Bolt (13a): 98 to 123 Nm {10 to 12.5 kgm} Refilling with coolant Refill the radiator with the coolant.
9.
5
Radiator: 82 l
Refill it with the coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again.
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50 Disassembly and assembly
Removal and installation of aftercooler assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
17 mm
1
2
Socket wrench
(Commercially available)
19 mm
1
3
Socket wrench
(Commercially available)
22 mm
1
4
Socket wrench
(Commercially available)
36 mm
1
5
Torque wrench (socket)
(Commercially available)
59 to 74 Nm, 98 to 123 As Nm, 153 to 190 Nm, 785 to needed 980 Nm
6
Eyebolt
(Commercially available)
M10
2
7
Eyebolt
(Commercially available)
M12
2
8
Wire
(Commercially available)
2
(35 kg), (220 kg)
9
Lifting and lowering device
(Commercially available)
1
(220 kg)
10
2-point chain
(Commercially available)
1
(50 kg)
11
Lever block
(Commercially available)
1
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.
44
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50 Disassembly and assembly
SEN03367-04
Removal 1.
Remove bolts (13a) (4 pieces) to remove cover (13). Tool: Socket wrench Bolt (13a): M12 with width across flats of 19 mm
2.
Disconnect connector LHD (1).
3.
Attach the lifting tool to lifting points (b), remove bolts (2a) (4 pieces), and sling and remove cover (2). Tool: Socket wrench, 2-point chain, eyebolt (M12) Bolt (2a): M12 with width across flats of 19 mm 4
4.
Radiator upper cover (2): 50 kg
Use a lifting tool to sling engine undercover (14), and remove bolts (14a) (10 pieces) (except those for the hinge). At this time, be sure to use the lifting and lowering device to support engine undercover (14) from below to allow it to open gradually. Tool: Lifting and lowering device, wire, lever block, socket wrench, Bolt (14a): M24 with width across flats of 36 mm 4
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Engine undercover (14): 220 kg
45
SEN03367-04
5.
Remove bolts (3a) (4 pieces), and disconnect tube (3). a Be sure to remove the gasket. Tool: Socket wrench Bolt (3a): M12 with width across flats of 19 mm
6.
Remove bolts (4a) (4 pieces), and disconnect tube (4). Tool: Socket wrench Bolt (4a): M12 with width across flats of 19 mm Remove bolts (5a) (2 pieces), (6a) (2 pieces), and (7a) (1 piece) to remove brackets (5), (6), and (7) respectively. Tool: Socket wrench Bolt (5a): M10 with width across flats of 17 mm Bolt (6a): M14 with width across flats of 22 mm Bolt (7a): M12 with width across flats of 19 mm
7.
8.
Attach the lifting tool to lifting points (a), sling aftercooler assembly (8), and remove it. Tool: Eyebolt (M10), wire 4
46
50 Disassembly and assembly
Aftercooler assembly (8): 35 kg
D155A-6
50 Disassembly and assembly
SEN03367-04
Installation 1.
Attach the lifting tool to lifting points (a), sling aftercooler assembly (8), and set it to its installed position. Tool: Eyebolt (M10), wire 4
2.
3.
Aftercooler assembly (8): 35 kg
Use bolts (5a) (2 pieces), (6a) (2 pieces), and (7a) (1 piece) to install brackets (5), (6), and (7) respectively. Tool: Torque wrench (socket) Bolt (5a): M10 with width across flats of 17 mm 3 Bolt (5a): 59 to 74 Nm {6 to 7.5 kgm} Bolt (6a): M14 with width across flats of 22 mm 3 Bolt (6a): 153 to 190 Nm {15.5 to 19.5 kgm} Bolt (7a): M12 with width across flats of 19 mm 3 Bolt (7a): 98 to 123 Nm {10 to 12.5 kgm} Use bolts (4a) (4 pieces) to connect tube (4). Tool: Torque wrench (socket) Bolt (4a): M12 with width across flats of 19 mm 3 Bolt (4a): 98 to 123 Nm {10 to 12.5 kgm} a a 1) 2) 3)
D155A-6
Be sure to replace a clamp that has been loosened once with a new one. Install the clamp according to the following procedure. Set the hose to the original position. Set the clamp with bridge (BR) under clamp fastening bolt (BC), and adjust overlaps (b) between bridge (BR) and band (BD) to Min. 5 mm. Tighten bolt (BC). a Impact wrench is not allowed to use. 2 Threaded part of bolt (BC): Lubricating oil (ThreeBond PANDO18B) q When reusing hose Align the clamp with the clamp mark left on the hose, and install it. 3 Bolt (BC): 25 ± 5 Nm {2.55 ± 0.5 kgm} q When hose is new Tighten it until dimension (BDG) becomes as shown below. Dimension (BDG): 8 to 10 mm
47
SEN03367-04
4.
Use bolts (3a) (4 pieces) to connect tube (3). Tool: Torque wrench (socket) Bolt (3a): M12 with width across flats of 19 mm 3 Bolt (3a): 98 to 123 Nm {10 to 12.5 kgm} a Be sure to replace a clamp that has been loosened once with a new one. a Install the clamp according to the following procedure. 1) Set the hose to the original position. 2) Set the clamp with bridge (BR) under clamp fastening bolt (BC), and adjust overlaps (b) between bridge (BR) and band (BD) to Min. 5 mm. 3) Tighten bolt (BC). a Impact wrench cannot be used. 2 Threaded part of bolt (BC): Lubricating oil (ThreeBond PANDO18B) q When reusing hose Align the clamp with the clamp mark left on the hose, and install it. 3 Bolt (BC): 25 ± 5 Nm {2.55 ± 0.5 kgm} q When hose is new Tighten it until dimension (BDG) becomes as shown below. Dimension (BDG): 8 to 10 mm
5.
Start the engine and check for air leakage according to the following procedure. a Check whether air leaks from the mounting face of the aftercooler. If air leakage is found, replace the gasket, hose clamps, and tube mounting bolts. (Apply LG-6 to the gasket contacting face.) 1) Check for air leakage from the duct and tube mounting faces (1) on the aftercooler. a For checking air leakage, check for unusual noise and spray soapy water to the faces. a Perform the air leakage check while running the engine at full speed for 3 minutes.
48
50 Disassembly and assembly
D155A-6
50 Disassembly and assembly
2) 3)
4)
5)
6)
6.
If air leakage is found, remove the engine upper hood, side covers, air cleaner, and right and left mudguards. Remove the lower duct and tube (2), and replace the gaskets. 2 Aftercooler flange and duct and tube flanges: Liquid gasket (LG-6) a When applying liquid gasket (LG-6) to narrow areas of the flange, use a spatula to spread and apply a thin film of the gasket to the inner side so that gasket material will not protrude inside. a Be sure to install the duct and tube within 30 minutes after application. Install the duct and tube to the aftercooler so that their faces coated with LG-6 adhere to both sides of a new gasket. a When installing the duct and tube, take care that no displacement results and be sure to leave them intact more than 2 hours for drying after the installation. a For the gasket and mounting bolt and washer, be sure to use new ones. 3 Mounting bolt: 98 to 123 Nm {10 to 12.5 kgm} Remove the upper duct and tube (3), and replace the gaskets. 2 Aftercooler flange and duct and tube flanges: Liquid gasket (LG-6) a When applying liquid gasket (LG-6) to narrow areas of the flange, use a spatula to spread and apply a thin film of the gasket to the inner side so that gasket material will not protrude inside. a Be sure to install the duct and tube within 30 minutes after application. Install the duct and tube to the aftercooler so that their faces coated with LG-6 adhere to both sides of a new gasket. a When installing the duct and tube, take care that no displacement results and be sure to leave them intact more than 2 hours for drying after the installation. a For the gasket and mounting bolt and washer, be sure to use new ones. 3 Mounting bolt: 98 to 123 Nm {10 to 12.5 kgm}
Use the lifting tool to sling engine undercover (14) and set it to its installed position. Tool: Wire, lever block, lifting and lowering device 4
7.
SEN03367-04
Engine undercover (14): 220 kg
Use bolts (14a) (10 pieces) (except those for the hinge) to install engine undercover (14). Tool: Torque wrench (socket) Bolt (14a): M24 with width across flats of 36 mm 3 Bolt (14a): 785 to 980 Nm {80 to 100 kgm}
D155A-6
49
SEN03367-04
8.
Use bolts (2a) (4 pieces) to install cover (2). Tool: Torque wrench (socket), 2-point chain Bolt (2a): M12 with width across flats of 19 mm 3 Bolt (2a): 98 to 123 Nm {10 to 12.5 kgm} 4
9.
50 Disassembly and assembly
Radiator upper cover (2): 50 kg
Connect connector LHD (1).
10. Use bolts (13a) (4 pieces) to install cover (13). Tool: Torque wrench (socket) Bolt (13a): M12 with width across flats of 19 mm 3 Bolt (13a): 98 to 123 Nm {10 to 12.5 kgm}
50
D155A-6
50 Disassembly and assembly
Removal and installation of engine assembly
SEN03367-04
1
Removal 1. 2.
Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit. a Quantity of refrigerant to be collected: 900 ± 50 g Drain the coolant. 6
Coolant: 82 l
3.
Remove the engine hood. For details, see "Removal and installation of engine hood assembly".
4.
Open the undercover (1). k Using a floor jack, a wire rope, etc., open the undercover carefully.
5. 6.
Remove air intake connector and air hose assembly (2). Remove stay (3).
7.
Remove the muffler according to the following procedure. 1) Remove heat insulation plate (4).
2)
D155A-6
Remove bracket (5).
51
SEN03367-04
3)
50 Disassembly and assembly
Remove muffler mounting bolts (6) and lift off muffler (7) (4 pieces). 4
Muffler: 55 kg
8.
Remove the radiator assembly. For details, see "Removal and installation of radiator assembly". 9. Remove the aftercooler assembly. For details, see "Removal and installation of aftercooler assembly". 10. Remove reservoir tank (8) and bracket (9) together.
11. Disconnect ground wire (10).
12. Disconnect fuel hose (11) between the fuel tank and prefilter.
13. Disconnect return hose (12).
52
D155A-6
50 Disassembly and assembly
SEN03367-04
14. Remove aftercooler tube (13).
15. Disconnect heater hose (15). 16. Lift off water tube (16).
17. Disconnect starting motor B-terminal ST/B (17). 18. Disconnect heater hose (18). 19. Remove clamps (19) (3 pieces) of the heater hose disconnected in step 15 and disconnect the hose from the engine.
20. Remove the hoses (2 pieces) from each of air conditioner condenser (20) and oil cooler (21) and remove frame (22). 21. Remove frame (23).
22. Disconnect connectors AC05 (24), EG2 (25) and EG1 (26). 23. Remove and move receiver tank (27).
D155A-6
53
SEN03367-04
50 Disassembly and assembly
24. Disconnect hose (28) from radiator lower tank.
25. Separate universal joint (29) at the engine side.
26. Temporarily sling engine assembly. 27. Remove mounting bolts (30) and (31), 4 pcs.each.
28. Sling engine assembly (32) and remove it. a Check all wires and pipes are removed. a Remove carefully to avoid any interference with the machine body.
54
D155A-6
50 Disassembly and assembly
SEN03367-04
Installation 1.
Sling engine assembly (32) and set it to its installed position. a Take care so that it will not interfere with the machine body when installing it. a Check that the wiring and pipe are completely connected.
2.
Use mounting bolts (30) (4 pieces) and (31) (4 pieces) to install engine assembly (32). 3 Engine mounting bolt: 823.8 to 1,029 Nm{84 to 105 kgm}
3.
Connect universal joint (29) to the engine. 3 Universal joint mounting bolt: 98 to 123 Nm{10 to 12.5 kgm}
4.
Connect hose (28) to radiator lower tank. 3 Hose clamp: 8.8±0.5 Nm{90±5 kgcm}
5. 6.
Install and move receiver tank (27). Connect connectors AC05 (24), EG2 (25) and EG1 (26).
D155A-6
55
SEN03367-04
7. 8.
50 Disassembly and assembly
Install frame (23), (22). Connect hoses (2 pieces on each sides) to each of air conditioner condenser (20) and oil cooler (21).
9. Connect heater hose (18). 10. Connect starting motor B-terminal ST/B (17).
11. Sling water tube (16) and install it. 12. Connect heater hose (15). 13. Use clamps (19) (3 pieces) to fix heater hose (15).
14. Install aftercooler tube (13). (Clamp) a Use a new clamp. a Installation procedure of hose
56
D155A-6
50 Disassembly and assembly
1) 2) 3)
SEN03367-04
Set the hose to the original position. Set the bridge (BR) under the clamp bolt (BC) and lap it over band (BD) at least (b) reaches 5 mm. Tighten the clamp. a Do not use an impact wrench. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO18B)
15. Connect return hose (12).
16. Connect fuel hose (11) between the fuel tank and prefilter.
17. Connect ground wire (10).
18. Install reservoir tank (8) and bracket (9) together. 19. Install the aftercooler assembly. For details, see "Removal and installation of aftercooler assembly". 20. Install the radiator assembly. For details, see "Removal and installation of radiator assembly".
D155A-6
57
SEN03367-04
50 Disassembly and assembly
21. Install the muffler according to the following procedure. 1) Sling muffler (7) and set it to its installed position, and use bolts (6) (4 pieces) to install it.
2)
Install bracket (5).
3)
Install heat insulation plate (4).
22. Install stay (3).
23. Install air intake connector and air hose assembly (2). (Clamp) a Use a new clamp. a Installation procedure of hose
58
D155A-6
50 Disassembly and assembly
1) 2) 3)
SEN03367-04
Set the hose to the original position. Set the bridge (BR) under the clamp bolt (BC) and lap it over band (BD) at least (b) reaches 5 mm. Tighten the clamp. a Do not use an impact wrench. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO18B)
24. Install undercove (1). k Using a floor jack, a wire rope, etc., install the undercover carefully.
25. Install the engine hood. For details, see "Removal and installation of engine hood assembly". 26. Refill the air conditioner circuit with the refrigerant (air conditioner gas: R134a). a Refill quantity of refrigerant: 900 ± 50 g a When installing the hose for the air conditioner circuit, be careful to prevent any dirt, dust or water from entering into the hose. a Check that O-ring (70) is installed to the air conditioner hose connection before installation. a Check that O-ring (70) is free from flaws and deterioration. a
When connecting the refrigerant pipes, apply compressor oil for new refrigerant (R134a) (DENSO: ND-OIL8, Zexel: ZXL100PG (PAG46 or equivalent)) 3 Threaded portion (M16 X 1.5) of hose: 12 to 15 Nm {1.2 to 1.5 kgm} 3 Threaded portion (M22 X 1.5) of hose: 20 to 25 Nm {2.0 to 2.5 kgm} 3 Threaded portion (M24 X 1.5) of hose: 30 to 35 Nm {3.0 to 3.5 kgm} 27. Refilling with coolant Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then, check coolant level again. 5
D155A-6
Total amount of coolant: Approximately 82 l (For details, see "Table of fuel, coolant and lubricants")
59
SEN03367-04
50 Disassembly and assembly
Removal and installation of engine hood assembly
1
Removal k Disconnect the cable from the negative (–) terminal of
the battery. 1. 2.
Remove cover (1). Open side cover (2) and remove covers (3) to (5). a Work on the opposite side similarly.
3.
Disconnect headlamp wiring connector CN-LHD (6).
4.
Remove the 4 front hood mounting bolts and lift off front hood (7). 4
5.
60
Front hood: 55 kg
Remove two mounting bolts (9) for tube (8).
D155A-6
50 Disassembly and assembly
6.
Remove hose (10).
7.
Disconnect connector AF1 (11).
8.
Sling engine hood (12) and remove it. 4
D155A-6
SEN03367-04
Engine hood: 170 kg
61
SEN03367-04
50 Disassembly and assembly
Installation 1.
Sling engine hood (12) and install it. 4
Engine hood: 170 kg
2.
Connect connector AF1 (11).
3.
Install hose (10). 3 Hose clamp: 8.8 ± 0.5 Nm{90 ± 5 kgcm}
4.
Install two mounting bolts (9) to tube (8).
62
D155A-6
50 Disassembly and assembly
5.
SEN03367-04
Sling front hood (7) and set it to its installed position, and use bolts (4 pieces) to install it. 4
Front hood: 55 kg
6.
Connect headlamp wiring connector CN-LHD (6).
7.
Install covers (3) to (5) and close side cover (2). a Work on the opposite side similarly.
8.
Install cover (1).
D155A-6
63
SEN03367-04
50 Disassembly and assembly
Removal and installation of engine front seal
1
Special tools No.
Part name 2
C
3 8
64
Part No.
Specification
Q'ty
Push tool
795T-521-1111
1
Bolt
01050-31655
3
Bolt
01050-31635
3
Seal puller
795-931-1100
1
Push tool
795T-521-1150
1
Bolt
01050-31635
4
Remarks
D155A-6
50 Disassembly and assembly
SEN03367-04
Removal 1. 2.
Remove the radiator and oil cooler guard assembly. Remove damper (1) and flange (2).
3.
Remove front seal (3).
Removal with tool C3 a Remove all the chips. a Take care in the removal not to damage front seal (3) installation position on front cover (4) and the seal contact face on crankshaft (5). a Before removing, slightly drive the front seal in once to free it from fixation. a When front seal (3) is fixed too hard to the front cover (4), carry out the following procedure. 1) Drill through a hole of approx. 3 mm dia. on front seal (3). 2) Replace the tip of tool C3 with the drill type one. 3) Insert the top end of tool C3 into the drilled hole, and remove the front seal by the impact of slide hammer (SH). (Apply the slide hammer evenly not to tilt the front seal.) a Remove the metal powders completely. a When the sleeve is attached, cut sleeve (6) using a gad and hammer to remove it. a Take care not to damage crankshaft (5). q
Tool C3
D155A-6
65
SEN03367-04
50 Disassembly and assembly
Installation 1.
Install the front seal according to the following procedure. a Check the seal by checking the wear of the shaft and replace it with the "standard seal" or "sleeved seal". a If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 mm) and does not have any flaw, install "standard seal A". In other cases, install "sleeved seal B". a (7): Plastic inside cylinder which is also used as installation guide. a (6): Sleeve. a Do not remove installation guide (7) from front seal (3) before installing the front seal. a Handle front seal (3) and sleeve (6) as an assembly and never separate them from each other. q A: Standard spare seal q B: Sleeved seal
2.
Procedure for installing standard seal a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the front cover. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. a Never remove installation guide (7) of the replacement seal before installing the seal.
1)
Set large inside diameter side (b) of installation guide (7) to the end of crankshaft (5). a Take care not to mistake the direction of the plastic inside cylinder.
2)
Push in the metal ring of seal (3) evenly as if you are passing over the large diameter side of plastic inside cylinder (7). After pushing in the seal to a depth where it does not come off the front cover, remove plastic inside cylinder (7). a When removing the inside cylinder, take care not to damage the seal lip.
3)
4)
66
Tighten tool C2 until the bolts (55 mm) reach the end.
D155A-6
50 Disassembly and assembly
5)
3.
SEN03367-04
Tighten tool C2 with the bolts (35 mm) again to press fit seal (3) until the end of tool C2 reaches the end of crankshaft (5). a Seal driving distance (a) from crankshaft: 9.1 to 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
Procedure for installing sleeved seal a When installing the front seal, do not apply oil or grease to the shaft, inside cylinder surface of sleeve (6) and seal lip. 1) Set sleeve and front seal assembly (8) to tool C8 (for fitting the sleeved seal). 2 Sleeve inside cylinder surface (6): Gasket sealant (LG-7)
2)
Set the sleeve of the front seal assembly (8) to the end of crankshaft (5) and tighten the 3 bolts evenly to press fit sleeve and rear seal assembly (8) until the end of tool C8 (for press fitting the sleeved seal) reaches the end of crankshaft (5).
3)
Remove tool C8 (for press fitting the sleeved seal) and install tool C2 (for press fitting the seal). Tighten the bolts (35 mm, 3 pieces) evenly to press fit sleeve and front seal assembly (8) until the end of tool C2 reaches the end of crankshaft (5) a Seal driving distance (a) from crankshaft: 9.1 to 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.
4)
4.
Install flange (2).
5.
Install damper (1).
6.
Install the radiator and oil cooler guard assembly.
3 Flange mounting bolt:
245 to 309 Nm{25 to 31.5 kgm}
D155A-6
67
SEN03367-04
50 Disassembly and assembly
Removal and installation of engine rear seal
1
Special tools No.
Part name 3 4
C
5
9
68
Part No.
Specification
Q'ty
Seal puller
795-931-1100
Push tool
795T-421-1270
1
Bolt
01050-31645
4
Washer
01643-31645
8
Push tool
795T-421-1240
1
Bolt
01050-31645
4
Washer
01643-31645
4
Push tool
795T-421-1250
1
Bolt
01050-31645
4
Washer
01643-31645
8
Remarks
1
D155A-6
50 Disassembly and assembly
SEN03367-04
Removal 1. 2.
3. 4.
Remove the engine assembly. For details, see "Removal and installation of engine assembly". Remove damper assembly (1). For details, see "Removal and installation of damper assembly".
Install eyebolt [1] to flywheel (2), sling flywheel (2), and remove bolts (3). While moving flywheel (2) toward this side, lift it off. k Since the socket part of the flywheel is shallow, it may fall suddenly. Take care not to catch your fingers in the flywheel. 4
Flywheel: 60 kg
5.
Remove rear seal (4) according to the following procedure. a Measure the distance from the end of the housing. 1) Before pulling out rear seal (4), drive it in a little to separate it from housing (FWH). 2) If the seal is sleeved, cut and remove sleeve (5) with a chisel and a hammer. a When cutting, take care extremely not to damage crankshaft (6). 3) Hitch the end of tool C3 to the metal ring of rear seal (4) and pull out the seal with impacts of slide hammer (SH). a Do not use a drill etc. since chips may enter the engine. a If chips were made, remove all of them.
q
Tool C3
D155A-6
69
SEN03367-04
a
70
50 Disassembly and assembly
Left: Standard seal, Right: Sleeved seal
D155A-6
50 Disassembly and assembly
SEN03367-04
Installation 1.
Install the rear seal according to the following procedure. a Check the wear of the shaft and select the "standard" or "sleeved" Teflon seal (Laydown lip seal) to replace the used seal. If the shaft is worn to the degree of luster (If the wear depth which you feel with your finger is less than 10 mm) and does not have any flaw, install "standard seal (A)". In other cases, install "sleeved seal (B)". A: Standard spare seal B: Sleeved seal a (7): Plastic inside cylinder which is also used as installation guide. a (5): Sleeve. a Do not remove installation guide (7) from rear seal (4) before installing the rear seal. a Handle rear seal (4) and sleeve (5) as an assembly and never separate them from each other. a a a
2.
Clean, degrease, and dry the contact surface of the seal to the flywheel housing side. Clean, degrease, and dry the seal lip surface (periphery of the crankshaft). Check that the end corners and lip sliding surface of the crankshaft and the housing are free from flaw, burr and rust.
Procedure for installing standard seal a When installing rear seal (4), do not apply oil or grease to the shaft and seal lip. 1) Set large inside diameter side (b) of plastic inside cylinder (7) of rear seal (4) to the end of crankshaft (6). a Take care not to mistake the direction of the plastic inside cylinder.
2) 3)
D155A-6
Push in the metal ring of rear seal (4) evenly as if you are passing over the large diameter side of plastic inside cylinder (7). After pushing in rear seal (4) to a depth where it does not come off the housing, remove plastic inside cylinder (7). a When removing the inside cylinder, take care not to damage the seal lip.
71
SEN03367-04
4)
3.
Tighten the 3 bolts evenly to press fit rear seal (4) until the end of tool C4 (for press fitting the seal) reaches the end of crankshaft (6). a Tighten tool C4 (for press fitting the seal) first without inserting any washer until the bolts reach the end 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.
Procedure for installing sleeved seal a When installing the rear seal, do not apply oil or grease to the shaft and inside cylinder (C) and seal lip of the sleeve. 1) Set sleeve and rear seal assembly (8) to tool C5 (for fitting the sleeved seal). 2 Sleeve inside cylinder surface (C): Gasket sealant (LG-7)
2)
Set sleeve of the rear seal to the end of crankshaft (6) and tighten the 4 bolts of tool C5 evenly to press fit sleeve and rear seal assembly (8). a Tighten tool C5 (for press fitting the sleeved seal) with 1 washer inserted in each bolt until the bolts reach the end.
3)
Remove tool C5 (for press fitting the sleeved seal) and install tool C9 (for press fitting the seal). Tighten the 3 bolts evenly to press fit sleeve and rear seal assembly (8) until the end of tool C9 reaches the end of crankshaft (6). a Tighten the bolt of tool C9 (for press fitting the seal) without washer until it reaches, and then tighten the bolt using 2 washers (for each bolt). a After press fitting the seal, remove the red sealant layer from its periphery. a Rear seal driving depth: 13.2±0.2 mm from end of crankshaft a When installing, set the dowel pin of the crankshaft to the dowel hole of the flywheel.
4)
72
50 Disassembly and assembly
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50 Disassembly and assembly
4.
SEN03367-04
Flywheel Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (2), install it to the crankshaft, and tighten bolts (3). a If there are 5 punch marks on a bolt, do not use that bolt but replace it. 2 Threaded part and seat of bolt: Engine oil SAE No. 30
a
Tighten the mounting bolts according to the following procedure. 3 Flywheel mounting bolts 1st time: 118±4.9 Nm{12±0.5 kgm} 2nd time:1)When using tool C4 (See the tools list) Retighten each bolt by 90° (+30°/0) in the order of [1] to [8]. 2) When not using tool C4 Make marks (f) on each bolt and flywheel with paint, then retighten each bolt by 90° (+30°/0) in the order of [1] to [8].
a
After tightening, make 1 punch mark (g) on each bolt head to indicate the number of tightening time.
a
After installing the flywheel, measure the facial runout and radial runout with tool [2]. a Radial runout: Max. 0.30 mm a Facial runout: Max. 0.30 mm Carry out the following installation in the reverse order to removal.
q
5. 6.
Install damper assembly (1). For details, see "Removal and installation of damper assembly". Install the engine assembly. For details, see "Removal and installation of engine assembly".
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73
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50 Disassembly and assembly
Removal and installation of fuel tank assembly
1
Standard tools The described tool is a reference. If it has a purpose, it can be used other than the described tool. No.
Part name
Part No
Specification
Q'ty
1
Socket wrench
(Commercially available)
13 mm
1
2
Socket wrench
(Commercially available)
19 mm
1
3
Socket wrench
(Commercially available)
24 mm
1
4
Spanner wrench
(Commercially available)
19 mm
1
5
Spanner wrench
(Commercially available)
22 mm
1
6
Spanner wrench
(Commercially available)
27 mm
1
7
Spanner wrench
(Commercially available)
32 mm
1
8
Torque wrench set (socket)
(Commercially available)
27 to 34 Nm, 98 to 123 Nm, 235 to 285 Nm
As needed
9
Torque wrench set (spanner)
(Commercially available)
54 to 93 Nm, 84 to 132 Nm, 128 to 186 Nm
As needed
10
Eyebolt
(Commercially available)
M12
11
Wire
(Commercially available)
1
12
2-point chain
(Commercially available)
1
Remarks
2
(450 kg), (915 kg)
Special tools No.
Part name
Q'ty
Remarks
02789-00315
#03
2
AB 2 Plug (male)
07376-70315
#03
2
3 O-ring
02896-11009
For preventing oil leakage when hose is disconnected • Fuel return hose
1 Plug (female)
02789-10422
#04
1
AC 2 Plug (female)
07376-70422
#04
1
3 O-ring
02896-11012
1 Plug (female)
02789-00522
#05
2
AD 2 Plug (male)
07376-70522
#05
2
3 O-ring
02896-11015
1 Plug (female)
Part No
Specification
2
1
2
For preventing oil leakage when hose is disconnected • Fuel return hose For preventing oil leakage when hose is disconnected • Fuel return hose
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 position. k Turn the starting switch to OFF position, and stop the engine.
k Disconnect the cable from the negative (-) terminal of the battery.
k When removing and installing the fuel piping, take extreme care to prevent foreign material from
entering into the fuel piping. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel.
74
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50 Disassembly and assembly
SEN03367-04
Removal 1.
Open the water separator inspection cover and turn the fuel drain lever (1) in the direction of (L) to drain the fuel.
2.
Remove bolts (3a) (2 pieces) and pin puller drive hose mounting bracket (3). (Machine with giant ripper) Tool: Socket wrench Bolts (3a): Width across flats 19 mm, M12
3.
Remove bolts (4a) (each 2 pieces for left and right) and covers (4). (right and left) Tools: Socket wrench Bolts (4a): Width across flats 19 mm, M12 Disconnect fuel hoses (5) and (6). Tools: Spanner wrench, Special tools AC, AD Hose (5): Width across flats 32, #05 size Hose (6): Width across flats 27, #04 size Loosen clip (7a) and disconnect hose (7).
4.
5. 6. 7.
8.
9.
Disconnect fuel hoses (7b). Tools: Spanner wrench, Special tool AD Hose (7b): Width across flats 32, #05 size Remove bolts (2a) (2 pieces) and line filter assembly (2). Tools: Socket wrench Bolt (2a): Width across flats 13 mm, M8
Sling water separator storage box (9) and remove bolts (8) (5 pieces). Tools: Socket wrench, Eyebolt, Wire Bolt (8): Width across flats 24 mm, M16 Lift off water separator storage box (9).
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75
SEN03367-04
50 Disassembly and assembly
10. Open the inspection cover and disconnect wiring harness connector (10).
11. Attach the lifting tool to lifting points (a) and sling fuel tank assembly (14) temporarily. (Reference) The lifting work can be done more easily if less fuel remains. Tool: 2-point chain 4
Fuel tank assembly (14): 410 kg (When empty), 915 kg (When full)
12. Remove fuel tank mounting bolts (11) (6 pieces) on the right and left sides. Tools: Socket wrench Bolt (11): Width across flats 24 mm, M16
13. Sling the fuel tank assembly, move it back about 100 mm, and disconnect hoses (12) and (13). Tools: Spanner wrench, Special tool AB Hose (12), (13): Width across flats 22, #03 size
14. Remove fuel tank assembly (14).
76
D155A-6
50 Disassembly and assembly
SEN03367-04
Installation 1.
Attach the lifting tool to lifting point (a), sling fuel tank assembly (14), and set it to a position 100 mm shifted rearward from its installed position. Tool: 2-point chain 4
Fuel tank assembly: 410 kg (When empty), 915 kg (When full)
2.
Connect hoses (12) and (13). Tools: Torque wrench (spanner) Hose (12), (13): Width across flats 22, #03 size 3 Hose (12), (13): 54 to 93 Nm{5.5 to 9.5 kgm}
3.
Install fuel tank mounting bolts (11) (6 pieces) on the right and left sides. Tool: Torque wrench (socket) Bolt (11): Width across flats 24 mm, M16 3 Bolts (11): 235 to 285 Nm{23.5 to 29.5 kgm}
4.
Connect wiring harness connector (10) and close the inspection cover.
5.
Sling water separator storage box (8) and set it. Tools: Eyebolt, Wire Install water separator storage box (8) with bolts (9) (5 pieces). Tools: Torque wrench (socket) Bolt (9): Width across flats 24 mm, M16 3 Bolts (9): 235 to 285 Nm{23.5 to 29.5 kgm}
6.
D155A-6
77
SEN03367-04
7.
8.
50 Disassembly and assembly
Install line filter assembly (2) with bolts (2a) (2 pieces). Tools: Torque wrench (socket) Bolt (2a): Width across flats 13 mm, M8 3 Bolts (2a): 27 to 34 Nm{2.8 to 3.5 kgm} Connect fuel hoses (7b). Tools: Torque wrench (spanner) Hose (7b): Width across flats 32, #05 size 3 Hose (7b): 128 to 186 Nm{13.0 to 19.0 kgm}
9. Connect hose (7) with clip (7a). 10. Install fuel hoses (5) and (6). Tools: Torque wrench (spanner) Hose (5): Width across flats 32, #05 size 3 Hose (5): 128 to 186 Nm{13.0 to 19.0 kgm} Hose (6): Width across flats 27, #04 size 3 Hose (6): 84 to 132 Nm{8.5 to 13.5 kgm} 11. Install covers (4) (right and left) with bolts (4a) (each 2 pieces for left and right). Tool: Torque wrench (socket) Bolts (4a): Width across flats 19 mm, M12 3 Bolts (4a): 98 to 123 Nm{10 to 12.5 kgm} 12. Install pin puller drive hose mounting bracket (3) with bolt (3a) (2 pieces). (Machine with giant ripper) Tool: Torque wrench (socket) Bolts (4a): Width across flats 19 mm, M12 3 Bolts (4a): 98 to 123 Nm {10 to 12.5 kgm}
13. Turn the fuel drain lever (1) in the direction of (R) and close the water separator inspection cover.
78
D155A-6
50 Disassembly and assembly
SEN03367-04
Removal and installation of cooling fan drive assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
19 mm
1
2
Socket wrench
(Commercially available)
24 mm
1
3
Spanner wrench
(Commercially available)
22 mm
1
4
Spanner wrench
(Commercially available)
27 mm
1
5
Spanner wrench
(Commercially available)
30 mm
1
6
Spanner wrench
(Commercially available)
32 mm
1
7
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 235 to 285 Nm
As needed
8
Torque wrench (spanner)
(Commercially available)
84 to 132 Nm, 128 to 186 Nm
As needed
9
Wire
(Commercially available)
1
Remarks
(85 kg), (125 kg)
Special tools list Symbol
Q'ty
Remarks
1 Plug (female)
02789-10422
#04
1
2 Plug (male)
07376-70422
#04
1
3 O-ring
02896-11012
For preventing oil leakage when hose is disconnected • Fan motor drain hose
1 Plug (female)
02789-00522
#05
2
AD 2 Plug (male)
07376-70522
#05
2
3 O-ring
02896-11015
AC
Part name
Part No.
Specifications
1
2
For preventing oil leakage when hose is disconnected • Fan motor hose
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.
k Loosen the cap of the hydraulic tank gradually to release the pressure remaining inside the tank. k If you drain the hydraulic oil when it is still hot, you may be scalded. Wait until the hydraulic oil
temperature drops, and then drain the oil.
D155A-6
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SEN03367-04
50 Disassembly and assembly
Removal 1.
Remove plug (11) at the bottom of the hydraulic tank, and loosen valve (12) to drain the hydraulic oil. 6
Hydraulic tank: 85 l
Tool: Socket wrench Plug (11): Width across flats of 32 mm a After draining hydraulic oil, be sure to close valve (12) and tighten plug (11). Tool: Torque wrench (socket) 3 Plug (11): 58.8 to 78.4 Nm {6.0 to 8.0 kgm} 2.
Remove bolts (1) (4 pieces) and open radiator mask (2). Tool: Socket wrench Bolt (1): M16 with width across flats of 24 mm
3.
Remove bolts (3) (4 pieces), and remove fan guard (4). Tool: Socket wrench Bolt (3): M12 with width across flats of 19 mm 4
4.
5.
6.
Disconnect wiring harness connector FAR (5), remove clamp (5a), and disconnect the wiring harness from the bracket. Tool: Socket wrench Bolt for clamp (5a): M12 with width across flats of 19 mm Disconnect hydraulic hoses (6), (7), and (8). Tool: Spanner wrench, special tool AC, AD Hose (6): Width across flats of 32 mm, #04 size Hoses (7) and (8): Width across flats of 36 mm, #05 size
Attach the lifting tool to lifting points (a) and sling cooling fan drive assembly (9). Tool: Eyebolt [1] (M12), wire 4
7.
80
Fan guard (4): 15 kg
Cooling fan drive assembly (9): 125 kg
Remove bolts (10) (2 pieces on upper side and 2 pieces on lower side), sling cooling fan drive assembly (9), and remove it. a Remove cooling fan drive assembly (9) while checking that the assembly does not interfere with surrounding parts.
D155A-6
50 Disassembly and assembly
SEN03367-04
Tool: Socket wrench, eyebolt, wire Upper mounting bolts (10) (2 pieces): M16 with width across flats of 24 mm Lower mounting bolts (10) (2 pieces): M12 with width across flats of 19 mm
D155A-6
81
SEN03367-04
50 Disassembly and assembly
Installation 1.
Attach the lifting tool to lifting points (a), sling cooling fan drive assembly (9), and set the assembly to its installed position. Tool: Eyebolt [1] (M12), wire a Set cooling fan drive assembly (9) while checking that the assembly does not interfere with surrounding parts. 4
Cooling fan drive assembly (9): 125 kg
2.
Use bolts (10) (2 pieces on upper side and 2 pieces on lower side) to install cooling fan drive assembly (9). Tool: Torque wrench (socket) Upper mounting bolts (10) (2 pieces): M16 with width across flats of 24 mm 3 Bolt (10): 235 to 285 Nm {23.5 to 29.5 kgm} Lower mounting bolts (10) (2 pieces): M12 with width across flats of 19 mm 3 Bolt (10): 98 to 123 Nm {10 to 12.5 kgm}
3.
Connect hydraulic hoses (6), (7), and (8). Tool: Torque (spanner) Hose (6): Width across flats of 32 mm, #04 size 3 Bolt (6): 84 to 132 Nm {8.5 to 13.5 kgm} Hoses (7) and (8): Width across flats of 36 mm, # 05 size 3 Bolts (7) and (8): 128 to 186 Nm {13.0 to 19.0 kgm} Connect wiring harness connector FAR (5) and use clamp (5a) to fix the wiring harness. Tool: Torque wrench (socket) Bolt for clamp (5a): M12 with width across flats of 19 mm 3 Bolt for clamp (5a): 98 to 123 Nm {10 to 12.5 kgm}
4.
5.
Use bolts (3) (4 pieces) to install fan guard (4). Tool: Torque wrench (socket) Bolt (3): M12 with width across flats of 19 mm 3 Bolt (3): 98 to 123 Nm {10 to 12.5 kgm} 4
6.
7.
Fan guard (4): 15 kg
Use bolts (1) (4 pieces) to fix radiator mask (2). Tool: Torque wrench (socket) Bolt (1): M16 with width across flats of 24 mm 3 Bolt (1): 235 to 285 Nm {23.5 to 29.5 kgm} Refilling with oil (hydraulic tank) 5
Hydraulic tank: 85 l
Refill with oil to the specified level through the oil filler port. Start the engine to circulate the oil through the system. Then, check the oil level again.
82
D155A-6
50 Disassembly and assembly
SEN03367-04
Removal and installation of fan motor assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. Symbol
Part name
Part No.
Specifications
Q'ty
1
Puller
(Commercially available)
1
2
Push tool
(Commercially available)
1
3
Plastic hammer
(Commercially available)
1
Remarks
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.
k Loosen the cap of the hydraulic tank gradually to release the pressure remaining inside the tank. k If you drain the hydraulic oil when it is still hot, you may be scalded. Wait until the hydraulic oil
temperature drops, and then drain the oil.
D155A-6
83
SEN03367-04
50 Disassembly and assembly
Removal 1. 2. 3.
Remove the cooling fan drive assembly. For details, see "Removal and installation of cooling fan drive assembly". Remove the mounting bolt and lock plate (1). Remove nut (2).
4.
Using puller [1], remove fan (3).
5.
Remove 4 bolts (4) and fan motor assembly (5). 4
84
Fan motor assembly: 40 kg
D155A-6
50 Disassembly and assembly
SEN03367-04
Installation 1.
Use bolts (4) (4 pieces) to install fan motor assembly (5). 4
Fan motor assembly: 40 kg
2.
Install fan (3) together with boss (6). a Wipe off dirt and dust from the fitting part between fan motor shaft and boss (6), and degrease the fitting portion. a Use a push puller or plastic hammer for insertion work. Tool: Push tool, plastic hammer
3.
Tighten nut (2). a Tighten nut (2) so that the hole in lock plate (1) is aligned with it. 3 Mounting nut (2): 441 to 539 Nm {45 to 55 kgm}
4.
Use the mounting bolt to install lock plate (1). a When aligning holes in lock plate (1), be sure to turn nut (2) in the tightening direction.
5.
Install the cooling fan drive assembly. For details, see "Removal and installation of cooling fan drive assembly".
D155A-6
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SEN03367-04
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03367-04
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
86
D155A-6
SEN03368-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Power train, Part 1 Removal and installation of damper assembly ............................................................................................... 2 Disassembly and assembly of damper assembly ........................................................................................... 7 Removal and installation of power train unit assembly ................................................................................. 13 Disconnection and connection of power train unit assembly ........................................................................ 25
D155A-6
1
SEN03368-03
50 Disassembly and assembly
Removal and installation of damper assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
17 mm
1
2
Socket wrench
(Commercially available)
19 mm
1
3
Spanner wrench
(Commercially available)
19 mm
1
4
Spanner wrench
(Commercially available)
22 mm
1
5
Torque wrench (socket)
(Commercially available)
59 to 74 Nm, 98 to 123 Nm
6
Torque wrench (spanner)
(Commercially available)
54 to 93 Nm
1
7
Eyebolt
(Commercially available)
M12
3
8
Wire
(Commercially available)
(20 kg)
1
9
Shackle
(Commercially available)
1
10
Chain
Commercially available
1
(60 kg)
11
Guide bolt
Commercially available
M12
2
[1]
12
Forcing screw
(Commercially available)
M12
2
[2]
13
Guide bolt
Commercially available
M12
2
[3]
14
Forcing screw
(Commercially available)
M12
2
[4]
As needed
[5]
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.
k Loosen the cap of the hydraulic tank gradually to release the pressure remaining inside the tank.
2
D155A-6
50 Disassembly and assembly
SEN03368-03
Removal 1. 2. 3. 4.
Remove the operator's cab assembly. For details, see "Removal and installation of operator's cab assembly." Remove the work equipment pump and HSS pump assembly. For details, see "Removal and installation of work equipment pump and HSS pump assembly". Remove the cooling fan pump assembly. For details, see "Removal and installation of cooling fan pump assembly". Drain oil from the damper case. 6
5. 6.
7.
Disconnect breather hose (1). Tool: Spanner wrench Breather hose (1): Width across flats of 22 mm, #03 size Remove bolts (2a) and remove dipstick pipe (2). Tool: Socket wrench Bolt (2a): M10 with width across flats of 17 mm
Remove mounting bolts (4a) (4 pieces each) at the damper side and torque converter side of universal joint assembly (4), and then sling and remove universal joint assembly (4). Tool: Socket wrench, wire Bolt (4a): M12 with width across flats of 19 mm 4
8.
Damper case: 1.5 l
Universal joint assembly: 20 kg
Remove coupling (10) on the torque converter side.
9.
Remove mounting bolts (5a) (2 pieces) of damper cover assembly (5), install guide bolts [1] (2 pieces) diagonally, and then remove remaining bolts (5a) (10 pieces). Tool: Socket wrench, guide bolt (M12) Bolt (5a): M12 with width across flats of 19 mm 10. Use forcing screws [2] (2 pieces) to pull out damper cover assembly (5) to a position where the lifting tool can be attached to the assembly. Tool: Socket wrench, forcing screw (M12) Forcing screw [2]: M12 with width across flats of 19 mm 4
Damper cover assembly (5): 60 kg
11. Attach shackle [5] to the bolt hole in damper cover assembly (5) to sling it, remove guide bolts [1] (2 pieces), and then lift up damper cover assembly (5) to remove it. Tool: Shackle, chain 4
D155A-6
Damper cover assembly (5): 60 kg
3
SEN03368-03
50 Disassembly and assembly
12. Remove damper assembly (6) according to the following procedure. 1) Remove mounting bolts (6a) (2 pieces) of damper assembly (6), and then install guide bolts [3]. Tool: Socket wrench, guide bolt (M12) Bolt (6a): M12 with width across flats of 19 mm 2) Remove remaining mounting bolts (6a) (10 pieces), and then use forcing screw [4] to pull out the assembly. Tool: Socket wrench, forcing screw (M12) Forcing screw [4]: M12 with width across flats of 19 mm 3)
4
Attach shackle [5] to damper assembly (6), and lift up and remove the assembly. Tool: Shackle, wire 4 Damper assembly: 60 kg
D155A-6
50 Disassembly and assembly
SEN03368-03
Installation 1.
Attach shackle [5] to damper assembly (6), sling the assembly, and set it to its installed position. Tool: Shackle, wire 4
2. 3.
4.
Damper assembly: 60 kg
Remove shackle [5], and install bolts (6a) (3 pieces) to damper assembly (6) at equal angle intervals to install the assembly loosely. Remove guide bolts [3] (2 pieces), and use remaining bolts (6a) (9 pieces) to install damper assembly (6). Tool: Torque wrench (socket) Bolt (6a): M12 with width across flats of 19 mm 3 Bolt (6a): 98 to 123 Nm {10.0 to 12.5 kgm} Install damper assembly (6) according to the following procedure. 1) 2)
Degrease spline portion (a) of shaft (7), apply dry lubricant agent (A) to that portion, and leave it for 2 to 3 minutes. Fill portion (b) of inner body (8) with approximately 80 g of lithium base extreme pressure grease (B) with molybdenum disulfide. Molybdenum disulfide A dry agent
• Sumiko Lubricant: Dry coat spray or equivalent • Kyodo Yushi: Molylex No. 2 or equivalent
Lithium-based molybde- • Showa Shell Sekiyu: Retinax AM or equivanum disulfide extreme B lent pressure grease • Nihon Sekiyu: Molytex or equivalent
D155A-6
5
SEN03368-03
3)
4)
5) 6)
7)
Apply the liquid gasket to the mounting face on damper cover (5). a Also, apply the liquid gasket to the mounting face on the engine. a Be sure to apply a film of it 0.1 to 0.2 mm in thickness. 2 Mounting face on damper cover: Liquid gasket (LG-6) Attach shackle [5] to damper cover assembly (5), sling the assembly, and set the assembly to its installed position. Tool: Shackle, chain 4 Damper case assembly: 60 kg Install guide bolts [1] (2 pieces) to damper cover assembly (5) to keep the assembly installed loosely in that position. Remove shackle [5], and install mounting bolts (5a) (3 pieces) at equal angle intervals to install damper case assembly (5) loosely. Tool: Socket wrench Use bolts (5a) (12 pieces) to install damper cover assembly (5). Tool: Torque wrench (socket) Bolt (5a): M12 with width across flats of 19 mm 3 Bolt (5a): 98 to 123 Nm {10.0 to 12.5 kgm}
5.
Install coupling (10) on the torque converter side.
6.
Sling universal joint assembly (4) and set it to its installed position. Tool: Torque wrench (socket) Bolt (4a): M12 with width across flats of 19 mm 2 Universal joint mounting bolt (4a): Adhesive (LT-2) 3 Bolt (4a): 98 to 123 Nm {10.0 to 12.5 kgm} 4
7.
50 Disassembly and assembly
Universal joint assembly (4): 20 kg
Use mounting bolts (3a) (4 pieces each) at the damper side and torque converter side of universal joint assembly (3) to install the assembly.
8.
Use bolt (2a) to install dipstick pipe (2). Tool: Socket wrench Bolt (2a): M10 with width across flats of 17 mm 9. Connect breather hose (1). Tool: Spanner wrench Breather hose (1): Width across flats of 22 mm, #03 size 10. Install the cooling fan pump assembly. For details, see "Removal and installation of cooling fan pump assembly". 11. Install the work equipment pump and HSS pump assembly. For details, see "Removal and installation of work equipment pump and HSS pump assembly". 12. Install the operator's cab assembly. For details, see "Removal and installation of operator's cab assembly." 13. Refill the damper case with oil. q Refilling with oil 5
Damper case: 1.5 l (For details, see "Table of fuel, coolant and lubricants".)
3 Drain plug: 58.5 to 78.5 Nm {6 to 8 kgm}
6
D155A-6
50 Disassembly and assembly
SEN03368-03
Disassembly and assembly of damper assembly
1
Special tools Symbol
Part number
Part name
Necessity
Q'ty
t
1
Puller (294 kN {30 ton})
t
1
790-101-1102 Hydraulic pump
t
1
791-612-1100 Installer F
D155A-6
790-101-4200
New/ Remodel
Sketch
7
SEN03368-03
50 Disassembly and assembly
Disassembly Disassembly of damper cover assembly (1) 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).
2)
3.
Bearing and oil seal 1) Remove oil seal (9) from cover (2), and pull out inner race (7-3) of bearing (7).
2)
8
Remove collar (7-2) and O-ring of bearing (7) from shaft (6), and pull out inner race (7-1).
Remove outer races (7-4) and (7-5) of bearing (7) from cover (2).
D155A-6
50 Disassembly and assembly
SEN03368-03
Disassembly of damper assembly (10) 1.
Unscrew bolt (11) to remove flange (12).
2.
Remove outer body (13), inner body (14) and cushion (15).
3.
Pull out plug (17) from flange (16). a This procedure applies only when replacing plug.
D155A-6
9
SEN03368-03
50 Disassembly and assembly
Assembly Assembly of damper assembly (10) 1.
10
Set flange (16) and outer body (13) to cylinder [1], matching their bolt holes, and install inner body (14). 2 Mating surface of flange and outer body: Gasket sealant (LG-6) 2 Outer body inner surface: Grease (G2-LI) 2 Cushion contact surface of inner body: Grease (G2-LI)
D155A-6
50 Disassembly and assembly
2.
Install cushion (15). a Apply grease (G2-LI) to entire surface of cushion. a After installing the cushion, fill clearances (a) (16 points) between inner body (14) and outer body (13) with grease of 30% amount of the space.
3.
Install flange (12) and tighten bolts (11). 3 Mounting bolt: 58.8 to 73.5 Nm {6 to 7.5 kgm}
4.
Fill (b) portion of inner body (14) with about 80 g of the following grease. 2 : Grease Grease
SEN03368-03
Supplier part name
• Kyodo yushi Molylex No.2 or an equivalent • Showa Shell Sekiyu Lithium base extreme Retinax AM or an pressure grease with equivalent molybdenum disulphide • Nippon Oil Corporation Molytex or an equivalent
Assembly of damper cover assembly (1) 1.
Press fit outer races (7-4) and (7-5) of bearing (7) to cover (2) using push tool [2].
D155A-6
11
SEN03368-03
2.
Press fit inner race (7-1) of bearing (7) to shaft (6) with tool F.
3.
Install collar (7-2) and O-ring to shaft (6).
4.
Set cover (2) to shaft (6), and press fit bearing inner race (73) using tool F.
5.
Install oil seals (8) and (9) to cover (2). 2 Press fitting surface of oil seal: Gasket sealant (LG-5) 2 Oil seal lip surface: Grease (G2-LI) a Apply gasket sealant at oil seal surface thinly, and wipe off extra sealant.
6.
Install coupling (5) and holder (4), and tighten bolt (3). 3 Mounting bolt: 245.2 to 308.9 Nm {25 to 31.5 kgm}
12
50 Disassembly and assembly
D155A-6
50 Disassembly and assembly
SEN03368-03
Removal and installation of power train unit assembly
1
Standard tools The described tool is a reference. If it has a purpose, it can be used other than the described tool. No.
Part name
Part No
Specification
Q'ty
Remarks
1
Socket wrench
(Commercially available)
14 mm
1
2
Socket wrench
(Commercially available)
17 mm
1
3
Socket wrench
(Commercially available)
19 mm
1
4
Socket wrench
(Commercially available)
24 mm
1
5
Socket wrench
(Commercially available)
36 mm
1
6
Spanner wrench
(Commercially available)
17 mm
1
7
Spanner wrench
(Commercially available)
19 mm
1
8
Spanner wrench
(Commercially available)
22 mm
1
9
Torque wrench (socket)
(Commercially available)
4.4±0.5 Nm, 5.9±0.49 Nm, As 59 to 74 Nm, 98 to 123 needed Nm, 785 to 980 Nm
10
Torque wrench (spanner)
(Commercially available)
54 to 93 Nm, 54 to 132 Nm
11
Eyebolt
(Commercially available)
M12
2
12
Forcing screw
(Commercially available)
M10×1.5
1
13
Wire
(Commercially available)
1
14
2-point chain
(Commercially available)
1
(20 kg)
15
3-point chain
(Commercially available)
1
(2,400 kg)
16
Lever block
(Commercially available)
1
17
Wire
(Commercially available)
1
D155A-6
As needed
[1]
13
SEN03368-03
50 Disassembly and assembly
Special tools No.
Part name
1 Plug (male)
Part No
Specification
Q'ty
Remarks For preventing oil leakage when hose is disconnected • Grease tube
02789-00210
#02
1
AA 2 Plug (female)
07376-70210
#02
1
3 O-ring
02896-11008
1 Plug (male)
02789-00315
#03
8
2 Plug (female)
07376-70315
#03
8
3 O-ring
02896-11009
1 Flange
07379-01044
#10
6
2 Head
07378-11000
#10
6
AG 3 O-ring
07000-13032
6
4 Sprit flange
07371-31049
12
5 Bolt
07375-21035
24
1
AB 8
For preventing oil leakage when hose is disconnected • Pin puller hose (2) Additional filter hoses (2) For preventing oil leakage when hose is disconnected • Control valve (4) Power train filter hose (2)
k Park the machine on a level ground, and set 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 to stop the engine. k Disconnect the negative terminal (-) of the battery.
k Loosen the cap of the hydraulic tank gradually, and release the pressure remaining inside the
hydraulic tank.
k If you drain the hydraulic oil when it is still hot, you may be scalded. Wait until the hydraulic oil
drops before draining. a Check the connector numbers and installed positions before disconnecting wiring and hoses, and record them. a When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses by the clips and clamps. If the wiring and hoses may be damaged or deformed, remove the clips and clamps before disconnecting them.
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50 Disassembly and assembly
SEN03368-03
Removal 1.
Remove drain plug (46) of the hydraulic tank, and loosen valve (47) to drain the hydraulic oil. 6
Hydraulic tank: 85 l
Tool: Socket wrench Plug (46): Width across flats of 32 mm a After draining hydraulic oil, be sure to close valve (47) and tighten plug (46). Tool: Torque wrench (socket) 3 Plug (46): 58.8 to 78.4 Nm {6.0 to 8.0 kgm} 2.
Remove plug (48) of the power train case, and loosen valve (49) to drain the power train oil. 6
3. 4.
Power train case: 90 l
Tool: Socket wrench Plug (48): Width across flats of 32 mm a After draining oil, be sure to close valve (49) and tighten plug (48). Tool: Torque wrench (socket) 3 Plug (48): 58.8 to 78.4 Nm {6.0 to 8.0 kgm} Remove the cab and floor frame assembly. For details, see "Removal and installation of cab and floor frame assembly". Remove the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly".
5.
Remove bolt (1a) and disconnect clips (1b) (2 places). Tools: Socket wrench Bolt (1a): Width across flats 19 mm, M12 6. Loosen clip (1c) and remove oil level detection pipe (1). Tools: Socket wrench Clip (1c): Width across flats 7 mm 7. Remove bolts (3a) (2 pieces). Tools: Socket wrench Bolt (3a): Width across flats 19 mm, M12 8. Loosen clamp (3b) and remove oil filler pipe (3). Tools: Socket wrench Clamp (3b): Width across flats 7 mm 9. Remove bolts (2a) (2 pieces) and disconnect return hose (2). Tools: Socket wrench Bolt (2a): Width across flats 17 mm, M10 a Cover the part from which a hose is disconnected using a plastic bag so that oil will not leak out. 10. Remove bolts (4a) and (5a) (each 2 pieces), and remove stays (4) and (5). Tools: Socket wrench Bolt (4a), (5a): Width across flats 19 mm, M12 11. Remove flange bolts (6a) and (7a) (each 4 pieces) and disconnect hoses (6) and (7) from control valve (8). Tools: Socket wrench, Special tool AG Bolt (6a), (7a): Width across flats 14 mm, M10
D155A-6
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SEN03368-03
50 Disassembly and assembly
12. Remove bolts (9a) (each 1 piece) and remove 2 clips (9) and hoses (10) and (11). Tools: Socket wrench, spanner wrench, Special tool AB Bolt (9a): Width across flats 19 mm, M12 Hose (10), (11): Width across flats 22 mm, #03 size 13. Remove bolts (12a) (2 pieces) and remove pump suction tube (12). Tools: Socket wrench Bolt (12a): Width across flats 19 mm, M12 a Cover the part from which a tube is disconnected using a plastic bag so that oil will not leak out. 14. Disconnect hose (13) from control valve. Tools: Spanner wrench, Special tool AB Hose (13): Width across flats 22 mm, #03 size 15. Remove bolts (14a) and (15a) (each 1 piece) and remove clamps (14) and (15). Tools: Spanner wrench Bolt (14a), (15a): Width across flats 19 mm, M12 16. Remove bolts (16a) and (17a) (each 4 pieces) and hoses (16) and (17). Tools: Socket wrench, Special tool AG Bolt (16a), (17a): Width across flats 14 mm, M10 17. Remove bolts (18a) (2 pieces) and remove oil pressure pickup hose mounting bracket (18). Tools: Socket wrench Bolt (18a): Width across flats 19 mm, M12
18. Remove bolts (19a) (2 pieces) and remove accumulator and bracket assembly (19). Tools: Socket wrench Bolt (19a): Width across flats 19 mm, M12 19. Disconnect hose (20). Tools: Spanner wrench, Special tool AB Hose (20): Width across flats 22 mm, #03 size
20. Disconnect hose (21). Tools: Socket wrench Bolt (21a): Width across flats 19 mm, M12 a Cover the part from which a hose is disconnected using a plastic bag so that oil will not leak out.
16
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50 Disassembly and assembly
SEN03368-03
21. Remove bolts (22a) (2 pieces) and disconnect hose (22) coming from the oil cooler. Tools: Socket wrench Bolt (22a): Width across flats 17 mm, M10 a Cover the part from which a hose is disconnected using a plastic bag so that oil will not leak out.
22. Remove grease hose (23). Tools: Spanner wrench, Special tool AA Hose (23): Width across flats 19 mm, #02 size
23. Remove clips (24) to (26). Tools: Socket wrench Bolts of clips (24) to (26): Width across flats 19 mm, M12 24. Remove bolts (27a) (2 pieces) and remove stay (27). Tools: Socket wrench Bolts (27a): Width across flats 19 mm, M12 25. Move wiring and piping (28) toward the machine. 26. Remove bolts (29a) and (30a) (each 4 pieces), and disconnect power train filter hoses (29) and (30). Tools: Spanner wrench, Special tool AG Bolts (29a): Width across flats 17 mm, M10 Bolts (30a): Width across flats 14 mm, M10 27. Attach the lifting tool to 2 bolt holes in the cover of power train oil filter (31), and sling the filter. Tool: Eyebolt (M12), 2-point chain 4
Power train oil filter assembly: 30 kg
28. Remove bracket mounting bolts (31a) (4 pieces) (at the filter bottom) and remove filter and bracket assembly (31). Tools: Socket wrench, Eyebolt, Wire Bolts (31a): Width across flats 19 mm, M12
D155A-6
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SEN03368-03
50 Disassembly and assembly
29. Use the lifting tool to sling universal joint (33). Tools: Wire 30. Remove bolts (32) (4 pieces) on the engine side and disconnect universal joint (33). Tools: Socket wrench Bolts (32): Width across flats 19 mm, M12 a After disconnecting the universal joint, push the yoke into the torque converter side to disconnect the universal joint completely.
31. Remove pin puller hoses (34) and (35). Tools: Spanner wrench, Special tool AB Hose (34), (35): Width across flats 22 mm, #03 size 32. Remove bolts (36a) (2 pieces) and remove pin puller line unit (36b). Tools: Socket wrench Bolts (36a): Width across flats 19 mm, M12
33. Disconnect additional filter hoses (36) and (37). Tools: Spanner wrench, Special tool AB Hose (36), (37): Width across flats 22, #03 size
34. Remove bolts (38a) (2 pieces) and remove covers (38) on the steering case. (right and left) Tools: Socket wrench Bolts (38a): Width across flats 19 mm, M12
35. Remove bolts (39a) (2 pieces) and remove cap (39). Tools: Socket wrench Bolts (39a): Width across flats 24 mm, M16 36. Loosen coupling clamp (40) and move seal (41) out a little. Tools: Socket wrench Coupling clamp (40): Width across flats 11 mm
18
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50 Disassembly and assembly
SEN03368-03
37. Remove bolts (42a) (3 pieces) and remove final drive shaft cover (42). Tools: Socket wrench Bolts (42a): Width across flats 19 mm, M12
38. Using eyebolt [1] (M10 x 1.5), pull out drive shaft (43). a Pull out the drive shaft until it comes off the spline on the steering case side. a If the drive shaft cannot be pulled out easily, raise the shoe grouser with a jack to a position where the drive shaft can be pulled out easily. a Pull out the drive shaft on the opposite side similarly.
39. Remove bolts (44) (2 pieces) each on the right and left sides of the power train assembly. Tools: Socket wrench Bolts (44): Width across flats 36 mm, M24
40. Attach lifting tools to lifting hooks at parts (a) (3 locations), sling power train unit assembly (45), and remove the assembly. k Because the power train unit assembly has complicated shapes and is unstable, lower the assembly on the blocks [1] (blocking tool) that has been prepared in advance.
41. Lift off power train assembly (45). Tools: Eyebolt, Chain block, 3-point chain a Check that all the wiring and piping are disconnected. a When lifting up the assembly, take care that it will not interfere with the machine. 4
D155A-6
Power train assembly (45): 2,500 kg
19
SEN03368-03
50 Disassembly and assembly
Installation 1.
2.
Temporarily set seals (41) at both ends of the steering case to the main frame. a Seals (41) need to be set to the main frame before setting power train assembly (45) to its installed position. Attach lifting tools to lifting hooks at parts (a) (3 locations), sling power train unit assembly (45), and set the assembly to its installed position. Tool: 3-point chain, lever block, wire a When setting power train unit assembly (45) to its installed position, take extreme care not to damage seals (41) that have been set to the main frame at both ends of the steering case. a Take care so that it will not interfere with the machine body when setting it to its installed position. 4
Power train assembly (45): 2,500 kg
3.
Install 2 mounting bolts (44) each on right and left sides of the power train assembly. Tools: Torque wrench (socket) Bolts (44): Width across flats 36 mm, M24 3 Bolts (44): 824 to 1030 Nm {84 to 105 kgm}
4.
Install drive shaft (43). (right and left) a Push in the drive shaft until it comes to the mounting position. a If the drive shaft cannot push in easily, raise the shoe grouser with a jack to a position where the drive shaft can push in easily. a Install the drive shaft on the opposite side similarly.
5.
Install final drive shaft cover (42) with bolts (42a) (3 pieces) (right and left). Tools: Torque wrench (socket) Bolts (42a): Width across flats 19 mm, M12 3 Bolts (42a): 98 to 123 Nm {10 to 12.5 kgm}
20
D155A-6
50 Disassembly and assembly
6.
7.
SEN03368-03
Install seal (41) and fix coupling clamp (40). a Clamp the seal ridge of the coupling securely and install the threaded part of the clamp so that it will be in parallel with the cap mounting seat. Install cap (39) with bolts (39a) (2 pieces). Tools: Torque wrench (socket) Bolts (39a): Width across flats 24 mm, M16 3 Bolts (39a): 245.8 to 309 Nm {25 to 31.5 kgm}
8.
Install covers (38) on the steering case with bolts (38a) (2 pieces), (right and left) Tools: Torque wrench (socket) Bolts (38a): Width across flats 19 mm, M12 3 Bolts (38a): 98 to 123 Nm {10 to 12.5 kgm}
9.
Connect additional filter hoses (36) and (37). Tools: Torque wrench (spanner) Hose (36), (37): Width across flats 22 mm, #03 size 3 Hose (36), (37): 54 to 93 Nm {5.5 to 9.5 kgm}
10. Install pin puller line unit (36b) with bolts (36a) (2 pieces). Tools: Torque wrench (socket) Bolts (36a): Width across flats 19 mm, M12 3 Bolts (36a): 98 to 123 Nm {10 to 12.5 kgm} 11. Install pin puller hoses (34) and (35). Tools: Torque wrench (spanner) Hose (34), (35): Width across flats 22 mm, #03 size 3 Hose (34), (35): 54 to 93 Nm {5.5 to 9.5 kgm}
12. Sling universal joint assembly (33) and set it to the installed position of the coupling. Tools: Wire 13. Install universal joint (33) with bolts (32) (4 pieces) on the engine side. Tools: Torque wrench (socket) Bolts (32): Width across flats 19 mm, M12 3 Bolts (32): 98 to 123 Nm {10 to 12.5 kgm}
D155A-6
21
SEN03368-03
50 Disassembly and assembly
14. Install filter and bracket assembly (31) with bolts (31a) (4 pieces) (at the filter bottom). Tools: Torque wrench (socket), Eyebolt, Wire Bolts (31a): Width across flats 19 mm, M12 3 Bolts (31a): 98 to 123 Nm {10 to 12.5 kgm} 4
Power train filter assembly: 30 kg
15. Connect power train filter hoses (29) and (30) with bolts (29a) and (30a) (each 4 pieces). Tools: Torque wrench (socket) Bolts (29a): Width across flats 17 mm, M10 Bolts (30a): Width across flats 14 mm, M10 3 Bolts (29a), (30a): 59 to 74 Nm {6 to 7.5 kgm}
16. Set wiring and piping (28) to the mounting position. 17. Install stay (27) with bolts (27a) (2 pieces). Tools: Torque wrench (socket) Bolts (27a): Width across flats 19 mm, M12 3 Bolts (27a): 98 to 123 Nm {10 to 12.5 kgm} 18. Install clips (24) to (26). Tools: Torque wrench (socket) Bolts of clips (24) to (26): Width across flats 19 mm, M12 3 Bolts of clips (24) to (26): 98 to 123 Nm {10 to 12.5 kgm} 19. Install grease hose (23). Tools: Torque wrench (spanner) Hose (23): Width across flats 19 mm, #02 size
20. Connect hose (22) coming from the oil cooler with bolts (22a) (2 pieces). Tools: Torque wrench (socket) Bolt (22a): Width across flats 17 mm, M10 3 Hose (22a): 59 to 74 Nm {6 to 7.5 kgm}
22
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50 Disassembly and assembly
SEN03368-03
21. Connect hose (21) with bolts (21a) (4 pieces). Tools: Torque wrench (spanner) Bolt (21a): Width across flats 19 mm, M12 3 Bolts (21a): 98 to 123 Nm {10 to 12.5 kgm}
22. Connect hose (20). Tools: Torque wrench (spanner) Hose (20): Width across flats 22 mm, #03 size 3 Hose (20): 54 to 93 Nm {5.5 to 9.5 kgm} 23. Install accumulator and bracket assembly (19) with bolts (19a) (2 pieces). Tools: Torque wrench (socket) Bolt (19a): Width across flats 19 mm, M12 3 Bolts (19a): 98 to 123 Nm {10 to 12.5 kgm}
24. Install oil pressure pickup hose mounting bracket (18) with bolts (18a) (2 pieces). Tools: Torque wrench (socket) Bolt (18a): Width across flats 19 mm, M12 3 Bolts (18a): 98 to 123 Nm {10 to 12.5 kgm}
25. Install hoses (16) and (17) with bolts (16a) and (17a) (each 4 pieces). Tools: Torque wrench (socket) Bolt (16a), (17a): Width across flats 14 mm, M10 3 Bolt (16a), (17a): 59 to 74 Nm {6 to 7.5 kgm} 26. Install clamps (14) and (15) with bolts (14a) and (15a) (each 1 piece). Tools: Torque wrench (socket) Bolts (14a), (15a): Width across flats 19 mm, M12 3 Bolts (14a), (15a): 98 to 123 Nm {10 to 12.5 kgm} 27. Connect hose (13) to control valve. Tools: Torque wrench (socket) Hose (13): Width across flats 22 mm, #03 size 3 Hose (13): 54 to 93 Nm {5.5 to 9.5 kgm} 28. Install pump suction tube (12) with bolts (12a) (2 pieces). Tools: Torque wrench (socket) Bolt (12a): Width across flats 19 mm, M12 3 Bolts (12a): 98 to 123 Nm {10 to 12.5 kgm} 29. Install 2 clips (9) with bolts (9a) (each 1 piece), and connect hoses (10) and (11). Tools: Socket wrench (spanner) Bolt (9a): Width across flats 19 mm, M12 Hose (10), (11): Width across flats 22, #03 size 3 Hose (10), (11): 54 to 93 Nm {5.5 to 9.5 kgm} D155A-6
23
SEN03368-03
50 Disassembly and assembly
30. Connect hoses (6) and (7) to control valve (8) with bolts (6a) and (7a) (each 4 pieces). Tools: Torque wrench (socket) Bolt (6a), (7a): Width across flats 14 mm, M10 3 Bolt (6a), (7a): 59 to 74 Nm {6 to 7.5 kgm} 31. Install stays (4) and (5) with bolts (4a) and (5a) (each 2 pieces). Tools: Torque wrench (socket) Bolt (4a), (5a): Width across flats 19 mm, M12 3 Bolts (4a), (5a): 59 to 74 Nm {6 to 7.5 kgm} 32. Connect return hose (2) with bolts (2a) (2 pieces). Tools: Torque wrench (socket) Bolt (2a): Width across flats 17 mm, M10 3 Bolts (2a): 59 to 74 Nm {6 to 7.5 kgm} 33. Install oil filler pipe (3) with clamp (3b). Tools: Torque wrench (socket) Clamp (3b): Width across flats 7 mm 3 Clamp (3b): 5.9±0.49 Nm {0.60±0.05 kgm} 34. Install bolts (3a) (2 pieces). Tools: Torque wrench (socket) Bolt (3a): Width across flats 19 mm, M12 3 Bolts (3a): 98 to 123 Nm {10 to 12.5 kgm} 35. Install oil level detection pipe (1) with clip (1c). Tools: Torque wrench (socket) Clip (1c): Width across flats 7 mm 3 Clip (1c): 4.4±0.49 Nm {0.45±0.05 kgm} 36. Connect clip (1b) (2 places) with bolt (1a). Tools: Torque wrench (socket) Bolt (1a): Width across flats 19 mm, M12 3 Bolts (1a): 98 to 123 Nm {10 to 12.5 kgm} 37. Install the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly". 38. Install the cab and floor frame assembly. For details, see "Removal and installation of cab and floor frame assembly". 39. Fill the oil from the hydraulic tank and power train case. 5 5
24
Hydraulic tank: 85 l Power train case: 90 l
D155A-6
50 Disassembly and assembly
Disconnection and connection of power train unit assembly
SEN03368-03
1
Disconnection 1.
Set power train unit assembly (1) on block [1]. 4
2.
3.
Power train unit assembly: 2,500 kg
Referring to circuit diagram collection "Electric circuit diagrams and connector location diagrams", disconnect all the connectors from the power train unit and remove all the wiring harnesses. Remove covers (2) and (3) and remove oil pressure pickup hose assembly (4). [*1] a Disconnect the 12 oil pressure pickup hoses from the power train unit.
4.
Remove hoses (5) to (11).
5.
Remove hoses (12) to (14).
D155A-6
25
SEN03368-03
6. 7. 8. 9.
50 Disassembly and assembly
Remove hoses (15) to (17). Remove block (18). Remove hose (19). Remove bracket (20).
10. Remove hoses (21) and (22). 11. Remove tube (23).
12. Remove hoses (24) and (25).
13. Remove hose and tube assembly (26). 14. Remove tube (27). 15. Sling work equipment pump suction tube (28) and remove clamp (29).
16. Disconnect suction tube (30) from the fan pump. 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.
26
D155A-6
50 Disassembly and assembly
SEN03368-03
18. Remove work equipment pump assembly (32). 4
Work equipment pump assembly: 100 kg
19. Remove power train and lubricating oil pump assembly (33). 4
Power train and lubricating oil pump assembly: 25 kg
20. Remove cooling fan pump assembly (34). 4
Cooling fan pump assembly: 30 kg
21. Remove scavenging pump assembly (35). 4
Scavenging pump assembly: 20 kg
22. Remove coupling (36).
D155A-6
27
SEN03368-03
50 Disassembly and assembly
23. Remove right and left front mounts (48).
24. Sling power train unit assembly (37) and set block [2]. 25. Remove the 18 mounting bolts and lift off steering case assembly. [*2] 4
Steering case assembly: 1,000 kg
26. Set PTO and torque converter and transmission assembly (38) on block [3] with the PTO side up.
27. Remove inside strainer and block (39) together.
28
D155A-6
50 Disassembly and assembly
SEN03368-03
28. Remove cover (40), spring (41) and magnet assembly (42).
29. Remove pressure sensor block (43) and 2 sleeves (44).
30. Remove the 19 mounting bolts and lift off PTO assembly (45). [*3] 4
D155A-6
PTO assembly: 300 kg
29
SEN03368-03
50 Disassembly and assembly
31. Remove 10 torque converter assembly mounting bolts (46). [*4]
32. Sling torque converter assembly (47) and pull it out by using 2 forcing screws [4] (M12 x 1.75). 33. Lift off torque converter assembly (47).
30
D155A-6
50 Disassembly and assembly
SEN03368-03
Connection Carry out connection in the reverse order to disconnection.
q
[*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.
Symbol
Pressure pick up point
Band color
a
1st transmission clutch pressure
Red
b
3rd transmission clutch pressure
Yellow/Black
c
Reverse transmission clutch pressure
d
2nd transmission clutch pressure
White/Yellow
Red/Blue
e
Forward transmission clutch pressure
White/Blue
f
Transmission main relief pressure
No band
g
Torque converter inlet pressure
Blue/Black
h
Torque converter outlet pressure
Yellow/Black
i
Left brake pressure
White
j
Right clutch pressure
White/Black
k
Left clutch pressure
Black
l
Right brake pressure
Yellow
[*2]
3 Steering case mounting bolt:
98 to 123 Nm {10 to 12.5 kgm} [*3]
3 PTO assembly mounting bolt:
98 to 123 Nm {10 to 12.5 kgm} [*4]
3 Torque converter mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
1
D155A-6
31
SEN03368-03
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03368-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
32
D155A-6
SEN03369-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Power train, Part 2 Disassembly and assembly of PTO assembly ................................................................................................ 2 Disassembly and assembly of torque converter assembly ............................................................................11 Disassembly and assembly of transmission assembly ................................................................................. 17 Disassembly and assembly of steering case assembly................................................................................ 36
D155A-6
1
SEN03369-03
Disassembly and assembly of PTO assembly
50 Disassembly and assembly
1
Disassembly 1.
Lubrication tube 1) Remove shaft lubrication tube (1).
2)
2.
Work equipment and pump drive gear and cover assembly 1) Remove 4 mounting bolts (3) and set the guide bolt. 2) Tighten forcing screws into hole (a) to remove gear and cover assembly (4).
3)
2
Remove pump drive gear lubrication tube (2).
While supporting cover (5) with block, push in gear (6) to separate it from the cover.
D155A-6
50 Disassembly and assembly
3.
4)
Remove inner race (7) from gear (6).
5)
Remove snap ring (14) and remove bearing (8) from cover (5).
6)
Remove bearing (40) from case (17).
SEN03369-03
Cooling fan pump drive gear and cover assembly 1) Remove 6 mounting bolts (10) and set a guide bolt. 2) Tighten forcing screws into hole (c) to remove gear and cover assembly (11).
3)
D155A-6
While supporting cover (12) with block [1], push in gear (13) to separate it from the cover.
3
SEN03369-03
4.
4)
Remove inner race (41) from gear (13).
5)
Remove snap ring (14) and remove bearing (15) from cover (12).
6)
Remove case (17) from bearing (16).
Scavenging pump drive gear assembly 1) Remove snap ring (18). 2) Remove gear (19) by pushing it into the case.
3)
4
50 Disassembly and assembly
Remove snap ring (20) and remove bearing (21) from the case.
D155A-6
50 Disassembly and assembly
5.
Idler gear assembly 1) Remove the mounting bolt and plate (22).
2) 3)
Remove the mounting bolts and set guide bolt [2]. Using forcing screws [3], remove shaft (23). a Keep holding the gear in the case.
1]
2]
6.
SEN03369-03
Remove bearing (25) and spacer (26) from gear (24). a When reusing the bearing and spacer, keep them so that they will be combined with the original outer race. Remove outer race (27) and snap ring (28) from gear (24).
Input shaft outer race Remove snap ring (29) and input shaft outer race (30).
D155A-6
5
SEN03369-03
50 Disassembly and assembly
Assembly a a a
Clean all the parts thoroughly and check them for dirt or damage before installing. After press fitting each bearing, drop 6 cc of TO30 or TO10 onto it and rotate it about 10 turns. Check that each snap ring is fitted to the groove.
1.
Input shaft outer race Press fit input shaft outer race (30) and install snap ring (29).
2.
Idle gear assembly a Match the serial Nos. and match marks of the bearing, outer race and spacer at places [A] – [C] and use them as an assembly.
6
1)
Install snap ring (28) to gear (24) and press fit outer race (27).
2)
Using 3 guide bolts [4], insert shaft (23) to the position shown in the figure. a If shaft (23) is inserted all the way, gear (24) cannot be installed. 2 O-ring: Grease (G2-LI)
D155A-6
50 Disassembly and assembly
3.
3) 4)
Install bearing (25) to shaft (23). Install spacer (26).
5) 6)
Install gear (24). Install bearing (25) and tighten plate (22) with the bolt to press fit the bearing to the shaft. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245.0 – 308.7 Nm {25.0 – 31.5 kgm}
7)
Fix shaft (23) with the mounting bolts.
SEN03369-03
Scavenging pump drive gear 1) Press fit bearing (21) to the case and install snap ring (20).
2)
D155A-6
While holding the inner race side of the bearing with push tool [5], install drive gear (19).
7
SEN03369-03
3)
4.
8
50 Disassembly and assembly
Install snap ring (18).
Cooling fan pump drive gear and cover assembly 1) Press fit bearing (16) to case (17).
2)
Press fit bearing (15) to cover (12) and install snap ring (14).
3)
Press fit inner race (41) to gear (13).
4)
Using the push tool, press fit gear (13) to cover (12).
D155A-6
50 Disassembly and assembly
5)
5.
SEN03369-03
Install gear and cover assembly (11), 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}
Work equipment and HST pump drive gear and cover assembly 1) Press fit bearing (40) to case (17).
2)
Press fit bearing (8) to cover (5).
3)
Press fit inner race (7) to gear (6).
4)
Press fit bearing (7) and inner race (8) to gear (9).
D155A-6
9
SEN03369-03
6.
5)
Install gear and bearing assembly (6) to cover (5).
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}
Lubrication tube 1) Install lubrication tube (2). 3 Joint bolt: 34.3 – 44.2 Nm {3.5 – 4.5 kgm}
2)
10
50 Disassembly and assembly
Install lubrication tube (1). 3 Joint bolt: 34.3 – 44.2 Nm {3.5 – 4.5 kgm}
D155A-6
50 Disassembly and assembly
Disassembly and assembly of torque converter assembly
SEN03369-03
1
Disassembly 1.
Input shaft 1) Remove 18 bolts (1) from input shaft (2). 2) Use eyebolt [1], and remove input shaft (2) from case and turbine assembly (3).
3)
Remove snap ring (4), then remove inner race (5).
2.
Case, turbine assembly Remove 30 bolts (1a) from below, then use eyebolts [4], and remove case and turbine assembly (3).
3.
Case 1) Remove snap ring (6). 2) Remove spacer (7).
D155A-6
11
SEN03369-03
4.
3)
Using puller [2] and plate [3] disconnect case assembly (8) and turbine (9).
4)
Remove bearing (11) from case (10).
Stator and race assembly 1) Remove snap ring (12) and stator and race assembly (13).
2)
5.
12
50 Disassembly and assembly
Remove 2 snap rings (14) and remove race (15) from stator (16).
Pump 1) Remove snap ring (18) and spacer (19). 2) Remove pump assembly (21) from stator shaft assembly (20).
D155A-6
50 Disassembly and assembly
3) 4)
D155A-6
SEN03369-03
Remove 12 mounting bolts (22) and remove pump (24) from retainer (23). Remove snap ring (25) and remove bearing (26) from retainer (23).
13
SEN03369-03
50 Disassembly and assembly
Assembly a a a a 1.
Clean all the parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. After press fitting each bearing, drop 10 cc of TO30 or TO10 onto it and rotate it about 10 turns. When installing a bearing by expansion fit, drop 10 cc of TO30 or TO10 onto it and rotate it about 10 turns before freezing it in dry ice etc. Check that each snap ring is fitted to the groove. 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) 3 Mounting bolt: 58.8 – 73.6 Nm {6.0 – 7.5 kgm}
3)
Install seal ring (27) to stator shaft (20).
4)
Install pump assembly (21) to stator shaft assembly (20). Install spacer (19) and snap ring (18). Install snap ring (17) to the shaft.
5) 6)
2.
14
Stator and race assembly 1) Install race (15) to stator (16) and install 2 snap rings (14).
D155A-6
50 Disassembly and assembly
2)
3.
4.
SEN03369-03
Install stator and race assembly (13) and snap ring (12).
Case 1) Install bearing (11) to case (10).
2)
Using push tool [4], push inner race end of bearing, then install case assembly (8) to boss portion of turbine (9).
3) 4)
Install spacer (7). Install snap ring (6).
Input shaft 1) Press fit inner race (5), and install snap ring (4).
D155A-6
15
SEN03369-03
2)
5.
16
50 Disassembly and assembly
Install input shaft (2) to case and turbine assembly (3). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
Case, turbine assembly 1) Using eyebolts [1], align groove of case with drain plug, and install case and turbine assembly (1). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm} 2) Install drain plug. 3 Drain plug: 7.4 ± 1.5 Nm {0.75 ± 0.15 kgm}
D155A-6
50 Disassembly and assembly
SEN03369-03
Disassembly and assembly of transmission assembly
1
Special tools Symbol
1
G
2
Part No.
Part name
Necessity
Q'ty
New/ Remodel
t
1
N N
791T-615-1300
Puller assembly
791T-615-1310
• Plate
1
01010-82040
• Bolt
1
799-301-1600
Oil leak tester kit (A)
t
Sketch
Q
1
Disassembly a
Keep the removed discs and plates on a flat place so that they will not warp.
1.
Relief valve assembly Remove relief valve assembly (1).
2.
Control valve assembly 1) Remove cover assembly (2). 2) Remove the nut of wiring harness connector (2A) and push in the connector.
3)
D155A-6
Remove sleeve (3) and flanges (4) and (5).
17
SEN03369-03
4)
Remove control valve assembly (6).
3.
Snap ring Remove snap ring (123) from output shaft (124). a Remove the snap ring at this time.
4.
Transmission case 1) Set the block with the torque converter side up. 2) Remove sleeve (7).
3)
5.
18
50 Disassembly and assembly
Using eyebolts [2], sling transmission case (8), remove 13 tie bolts (9) (used to clamp the transmission case, too), and remove case (8).
Tie bolts Remove 4 remaining tie bolts (9).
D155A-6
50 Disassembly and assembly
6.
SEN03369-03
Input shaft-front cover-No. 1 carrier assembly 1) Using sling bar [3], remove input shaft-front cover-No. 1 carrier assembly (11).
2)
D155A-6
Disassemble the input shaft-front cover-No. 1 carrier assembly according to the following procedure. 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).
3] 4]
Remove snap rings (18) and (126). Drive out input shaft toward the torque converter and remove front cover (19).
5]
Remove snap ring (20) and drive out input shaft (21) toward the torque converter.
6] 7] 8]
Remove collar (128). Remove snap ring (22) and No. 1 ring gear (23). Pull out shaft (24) and remove thrust washer (25), gear (26), bearing (27) and ball (28). a Take care not to lose the ball.
19
SEN03369-03
7.
No. 1 disc, plate and spring 1) Remove spring (29). 2) Remove springs (30), discs (31) and plates (32).
8.
No. 1 housing assembly 1) Using eyebolts [4], remove No. 1 housing assembly (33). 2) Remove No. 1 piston (34) from the housing.
9.
Guide pin Remove guide pins (35).
50 Disassembly and assembly
10. No. 2 disc, plate and spring 1) Remove spring (36). 2) Remove springs (37), discs (38) and plates (39).
11. Remove through bolt guide (40), lubricating oil relief valve (41) and spring (130).
12. Snap ring Remove snap ring (125).
20
D155A-6
50 Disassembly and assembly
SEN03369-03
13. No. 2 housing and No. 2 carrier assembly 1) Using eyebolts [5], remove No. 2 housing and No. 2 carrier assembly (42). 2) Remove No. 2 piston (43).
3)
Disassemble No. 2 housing and No. 2 carrier assembly according to the following procedure. 1] Remove snap ring [44] and pull out No. 2 carrier assembly (45) from No. 2 housing (46).
2] 3]
D155A-6
Remove spacer (47) from No. 2 carrier assembly (49). Pull out shaft (50) and remove thrust washer (51), gear (52), bearing (53) and ball (54). a Take care not to lose the ball.
4]
Remove snap ring (55) and ring gear (56). a Push the snap ring inward with a pin (Diameter: Max. 3 mm) from outside to warp and remove it.
5]
Remove seal ring (57) and snap ring (58) from No. 2 housing (46) and remove bearing (59).
21
SEN03369-03
50 Disassembly and assembly
14. No. 3 disc, plate and spring 1) Remove springs (60). 2) Remove springs (61), discs (62) and plates (63).
15. No. 3 carrier assembly 1) Remove No. 3 carrier assembly (64).
2)
Disassemble No. 3 carrier assembly according to the following procedure. 1] Remove seal ring (65). 2] Pull out shaft (66). 3] Remove thrust washer (67), planetary gear (68), bearing (69) and ball (70). a Take care not to lose the ball. 4] Remove snap ring (71) and bearing (72).
16. Output shaft and No. 4 sun gear 1) Pull out output shaft (73). 2) Remove snap ring (74) from the output shaft. 3) Remove No. 4 sun gear (75).
17. No. 4 carrier and No. 3 ring gear assembly 1) Remove No. 4 carrier and No. 3 ring gear assembly (76).
22
D155A-6
50 Disassembly and assembly
2)
SEN03369-03
Disassemble the No. 4 carrier and No. 3 ring gear assembly according to the following procedure. 1] Remove snap ring (77) and ring gear (127). a Push the snap ring inward with a pin (Diameter: Max. 3 mm) from outside to warp and remove it. 2] Remove seal rings (78) and (79). 3] Drive in roll pin (80) to pull out shaft (80A). 4] Remove thrust washer (81), planetary gear (82) and bearing (83). 5] Remove snap ring (84) to remove bearing (85) and spacer (86) as an assembly. 6] Remove bearing (85) from spacer (86).
18. No. 3 housing 1) Remove No. 3 housing (87). 2) Remove No. 3 piston (88).
19. No. 4 disc, plate, spring and guide pin 1) Remove spring (89). 2) Remove springs (90), No. 4 discs (91) and plates (92). 3) Remove guide pin (93).
20. No. 5 carrier and No. 4 ring gear assembly 1) Remove mounting bolts (94). 2) Remove No. 5 carrier and No. 4 ring gear assembly (95).
3)
D155A-6
Disassemble No. 5 carrier and No. 4 ring gear assembly according to the following procedure. 1] Drive out shaft (96) to remove thrust washer (97), gear (98), bearing (99) and ball (100). a Take care not to lose the ball.
23
SEN03369-03
2]
50 Disassembly and assembly
Remove snap ring (101) and remove No. 4 ring gear (102) from carrier (103).
21. No. 5 sun gear Remove No. 5 sun gear (104).
22. No. 4 housing assembly 1) Remove No. 4 housing assembly (105). 2) Remove No. 4 piston (106).
23. No. 5 disc, plate and spring 1) Remove springs (107). 2) Remove discs (108), plates (109) and springs (110).
24
D155A-6
50 Disassembly and assembly
SEN03369-03
24. No. 5 ring gear Remove No. 5 ring gear (111). 25. No. 5 piston Remove No. 5 piston (112).
26. Cover assembly 1) Remove snap ring (113) and remove cover assembly (114) from output housing assembly (115).
2) 3)
Remove seal rings (116) and (117) from cover (118). Remove bearing (119) from cover (118).
27. Output housing 1) Remove snap ring (120) and remove bearing (121) and spacer (122) from output housing (123). 2) Remove bearing (121) from spacer (122).
D155A-6
25
SEN03369-03
50 Disassembly and assembly
Assembly q
a a a a
1.
Precautions for assembly Clean all the parts thoroughly and check them for dirt or damage before installing. Coat the sliding surfaces of each part with engine oil before installing. When installing piston seal ring (a), direct the pressure receiving side (b) toward housing (c). When installing a metallic seal ring, apply grease (G2-LI) to it and fit it evenly.
Output housing 1) Using the push tool, press fit bearing (121) to spacer (122).
2) 3)
2.
26
Using the push tool, press fit spacer (122) and bearing assembly (121) to output housing (123). Install snap ring (120).
Cover assembly 1) Using the push tool, press fit bearing (119) to cover (118). 2) Install seal rings (117) and (116) to cover (118).
D155A-6
50 Disassembly and assembly
3)
4)
Using the push tool, install cover assembly (114) to output housing assembly (115). a Press fit the inner race side of the bearing to install. Install snap ring (113).
3.
No. 5 piston Install No. 5 piston (112) to the output housing.
4.
No. 5 ring gear Install No. 5 ring gear (111).
5.
Guide pin Install guide pin (93).
6.
No. 5 disc, plate and spring 1) Install discs (108), plates (109) and springs (110). a Install the 3 discs and 2 plates. 2) 2) Install springs (107). a Free length of spring: 66 mm
7.
No. 4 housing assembly 1) Fit the seal ring and install No. 4 piston (106). 2) Install No. 4 housing assembly (105). a Check that the springs are fitted to the grooves.
8.
No. 5 carrier and No. 4 ring gear assembly 1) Assemble the No. 5 carrier and No. 4 ring gear assembly according to the following procedure. 1] Set No. 4 ring gear (102) to carrier (103) and install snap ring (101).
D155A-6
SEN03369-03
27
SEN03369-03
2] 3]
2)
9.
50 Disassembly and assembly
Install bearing (99) to gear (98). While fitting thrust washers (97) to both sides of them, set them to the carrier. Fit ball (100) and install shaft (96).
Using guide bolts, set No. 5 carrier and No. 4 ring gear assembly (95) and tighten mounting bolts (94). 2 Threaded part of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
No. 5 sun gear Install No. 5 sun gear (104).
10. No. 4 discs, plates and springs 1) Install No. 4 discs (91), plates (92) and springs (90). a Install the 4 discs and 3 plates. 2) Install springs (89). a Free length of spring: 70 mm
11. No. 3 housing assembly 1) Fit the seal ring and install No. 3 piston (88). 2) Install No. 3 housing (87). a Check that the springs are fitted to the grooves.
28
D155A-6
50 Disassembly and assembly
SEN03369-03
12. No. 4 carrier and No. 3 ring gear assembly 1) Assemble No. 4 carrier and No. 3 ring gear assembly according to the following procedure. 1] Using the push tool, press fit bearing (85) to spacer (86).
2] 3] 4] 5] 6] 7] 8]
2)
Using the push tool, press fit spacer (86) and bearing assembly (85) to the No. 4 carrier. Install snap ring (84). Install bearing (83) to planetary gear (82). While fitting thrust washers (81) to both sides of them, set them to the carrier. While setting the shaft pin hole to the carrier pin hole, install shaft (80A). Check that the pin holes are aligned and drive roll pin (80). Install seal rings (79) and (78). Set the No. 3 ring gear to No. 4 carrier and install snap ring (77). a Check that the snap ring is fitted to the groove.
Install No. 4 carrier and No. 3 ring gear assembly (76).
13. No. 4 sun gear Install No. 4 sun gear (75). 14. Output shaft 1) Install snap ring (74) to the output shaft. 2) While setting output shaft (73) to the spline of the sun gear, push it in.
D155A-6
29
SEN03369-03
50 Disassembly and assembly
15. No. 3 carrier assembly 1) Assemble the No. 3 carrier assembly according to the following procedure. 1] Using the push tool, press fit bearing (72) to the carrier and install snap ring (71). 2] Install bearing (69) to planetary gear (68). While fitting thrust washers (67) to both sides of them, set them to the carrier. 3] Fit ball (70) and install shaft (66). 4] Install seal ring (65). 2)
Install No. 3 carrier assembly (64).
16. No. 3 discs, plates and springs 1) Install discs (62), plates (63) and springs (61). a Install the 4 discs and 3 plates. 2) Install springs (60). a Free length of spring: 70 mm
17. No. 2 housing and No. 2 carrier assembly 1) Assemble the No. 2 housing and No. 2 carrier assembly according to the following procedure. 1] Press fit bearing (59) to No. 2 housing (46) and install snap ring (58). 2] Install seal ring (57).
3]
30
Set No. 1 ring gear (56) and No. 2 carrier (45) and install snap ring (55).
D155A-6
50 Disassembly and assembly
4] 5]
2) 3)
4)
D155A-6
Install bearing (53) to gear (52). While fitting thrust washers (51) to both sides of them, set them to the carrier. Fit ball (54) and install shaft (50).
6] 7]
Install No. 2 ring gear (48). Install spacer (47). a Direct the side of the cut inside toward the carrier.
8]
Install No. 2 housing (46) to No. 2 carrier assembly (45). a Press fit the inner race side of the housing bearing. Install snap ring (44).
9]
SEN03369-03
Using eyebolts [5], install No. 2 housing and No. 2 carrier assembly (42). a Check that the springs are fitted to the grooves. Fit the seal ring and install No. 2 piston (43).
Install tool G1 to the inside groove of the No. 3 carrier, pull it up, and install snap ring (125).
31
SEN03369-03
50 Disassembly and assembly
18. Install through bolt guide (40), spring (130) and lubricating oil relief valve (41).
19. Guide pin Install guide pins (35). 20. No. 2 discs, plates and springs 1) Install No. 2 discs (38), plates (39) and springs (37). a Install the 7 discs and 6 plates. 2) Install springs (36). a Free length of spring: 81.7 mm
21. No. 1 housing assembly 1) Fit the seal ring and install No. 1 piston (34). 2) Using eyebolts [4], install No. 1 housing assembly (33), while aligning it with the No. 2 piston. a Press the housing to push in the dowel pins.
22. Input shaft and No. 1 carrier assembly 1) Assemble the input shaft and No. 1 carrier assembly according to the following procedure. 1] Install bearing (27) to gear (26). While fitting thrust washers (25) to both sides of them, set them to the carrier. 2] Fit ball (28) and install shaft (24). 3] Set No. 1 ring gear (23) to No. 1 carrier and install snap ring (22).
4] 5]
32
Press fit bearing (117) to input shaft (21). Install No. 1 carrier assembly (118) to input shaft (21) and install snap ring (18).
D155A-6
50 Disassembly and assembly
2)
6] 7] 8]
Install collar (17). Install No. 1 sun gear (16) and snap ring (15). Install snap ring (14).
9]
Install No. 2 sun gear (13) and snap ring (12).
SEN03369-03
Sling input shaft and No. 1 carrier assembly (119) and install it, while meshing the No. 2 sun gear with No. 2 planetary gear.
23. No. 1 discs, plates and springs 1) Install collar (128). 2) Install No. 1 discs (31), plates (32) and spring (30). a Install 6 discs and 5 plates. 3) Install springs (29). a Free length of spring: 81.7 mm
24. Front cover 1) Install seal ring (121) to front cover (122).
D155A-6
33
SEN03369-03
2)
50 Disassembly and assembly
Using eyebolts [6], install front cover (122), while aligning it with the guide pins 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.
25. Tie bolts Install tie bolts (9) (4 pieces). (The 4 bolts marked with * in the attached drawing). 3 166.7 ± 9.8 Nm {17 ± 1 kgm}
26. Operation check of piston Using tool G2, check the operating condition and stroke of each piston. Piston
Standard stroke (mm)
No. 1
7.2
No. 2
7
No. 3
5
No. 4
5
No. 5
6
27. Transmission case Fit the O-ring. Using eyebolts [2], install transmission case (8) and remaining 13 tie bolts (9). 3 Tie bolt: 166.7 ± 9.8 Nm {17 ± 1 kgm}
28. Sleeve Install sleeve (7).
34
D155A-6
50 Disassembly and assembly
SEN03369-03
29. Snap ring Raise the case assembly and install snap ring (123) to output shaft (124).
30. Control valve assembly 1) Install control valve assembly (6). 3 Mounting bolt: 49.1 ± 4.9 Nm {5.0 ± 0.5 kgm}
2)
Install flanges (4) and (5) and sleeve (3).
3)
Install cover assembly (2). 2 Threaded part of mounting bolt: Gasket sealant (LG-11 or LG-5)
31. Main relief valve assembly Install main relief valve assembly (1). 3 Mounting bolt: 49.1 ± 4.9 Nm {5.0 ± 0.5 kgm}
D155A-6
35
SEN03369-03
50 Disassembly and assembly
Disassembly and assembly of steering case assembly
1
Special tools Symbol
1 H 2
Part No.
Part name
Necessity
Q'ty
791-622-1110
Bracket
t
1
01010-31685
Bolt
t
1
01017-31620
Bolt
t
1
790-302-1500
Spanner kit
t
1
09003-09200
• Spanner
New/ Remodel
Sketch
1
Disassembly 1.
Steering valve assembly, reducing valve Remove steering valve assembly (1).
2.
Clutch, brake assembly 1) Angle the steering case assembly approx. 15° so that tool H1 is perpendicular to ground surface. 2) Remove mounting bolts, then using tool H1, remove clutch and brake assembly (2). a Do not remove the hexagon socket head bolt. a Remove the clutch and brake assembly on the other side in the same way.
q
EDisassembly of clutch, brake assembly 1) Disassembly of brake assembly i) Remove flange (3) and seal ring (4). ii) Remove plate (5).
36
D155A-6
50 Disassembly and assembly
SEN03369-03
iii)
Loosen 4 hexagon socket head bolts uniformly and remove, then using eyebolts [1], remove cover (6). a The inner race of the bearing will come out. iv) Remove bearing (7) from cover (6).
v) Remove 2 brake springs (8). vi) Remove brake piston (9).
vii) Using puller [2], remove cage (10). a The outer race of the bearing will come out. viii) Remove 3 seal rings (11) from hub.
ix) Using eyebolts, remove drum (12) together with disc and plate. x) Remove 6 discs (13), 5 plates (14), and 6 springs (15) from drum (12).
2)
D155A-6
Disassembly of clutch assembly i) Remove mounting bolts, then remove cover (16). a The cover is being pushed by the clutch spring, so loosen the bolts uniformly. ii) Remove 5 discs (17) and 5 plates (18).
37
SEN03369-03
50 Disassembly and assembly
iii)
Remove snap ring (19), then remove inner drum (20). a Remove the snap ring from the ring groove, then fit it in the inner drum groove. iv) Remove snap ring (21).
v)
Using puller [3], remove bearing (22) from inner drum (20). vi) Remove snap ring (19) from inner drum.
vii) Remove mounting bolts, then remove cage (23). viii) Remove clutch piston (24).
ix) Remove clutch spring (25). x) Remove clutch outer drum (26) from brake hub (27).
xi) Remove bearing (28) from brake hub (27). xii) Remove snap ring (27) from brake hub, then remove stopper (30).
38
D155A-6
50 Disassembly and assembly
3.
Pipes Remove 6 pipes (31). a When removing the pipes, be careful not to damage the O-rings.
4.
Lubrication tubes Remove 3 lubrication tubes (32).
5.
Case cover Remove cover (33).
6.
Suction tube, dipstick tube Remove suction tube (34) and dipstick tube (35).
7.
Lubrication tubes Remove left and right lubrication tubes (36).
8.
Bevel pinion assembly 1) Using guide bolts [4] and forcing screws [5], remove bevel pinion assembly (37) and shim (38). a Check the number and thickness of the shims, and keep in a safe place.
D155A-6
SEN03369-03
39
SEN03369-03
2)
50 Disassembly and assembly
Disassembly of bevel pinion assembly i) Hold with press to prevent pinion from moving, then use tool H2 to remove locknut (39). ii) Using push tool [6], remove bevel pinion (40) from cage (41).
iii) Remove bearing (42). iv) Remove outer races (43) and (44) from cage (41).
v)
9.
Bevel gear shaft, bevel gear assembly 1) Turn over steering case so that right cage is at top, then remove cage (46) and shim (47). a Check the number and thickness of the shims, and keep in a safe place.
2)
40
Remove bearing (45) from bevel pinion (40).
Lift off right cover (48).
D155A-6
50 Disassembly and assembly
3)
Lift off bevel gear shaft, bevel gear assembly (49).
4)
Disassembly of bevel gear shaft, bevel gear assembly i) Using puller [7], remove bearing (51) from bevel gear shaft (50). ii) Remove reamer bolt (52), then remove bevel gear (53) from bevel gear shaft (50).
iii)
Using puller [8], remove bearing (54) from bevel gear shaft (50).
5)
Turn over steering case, then remove left cage (55) and shim (56). a Check the number and thickness of the shims, and keep in a safe place.
6)
Remove outer race (57) from cage (55).
D155A-6
SEN03369-03
41
SEN03369-03
50 Disassembly and assembly
10. Nipple Remove nipple (58).
42
D155A-6
50 Disassembly and assembly
SEN03369-03
Assembly q
a a a a
Precautions when assembling Clean all parts, and check for dirt or damage. After press fitting the bearing, apply 6 cc of EO10CD or EO30CD in drops, then rotate 10 times. Coat the sliding surfaces of all parts with engine oil before installing. Assemble the piston seal rings with the side receiving the pressure facing the housing, coat with grease (G2-LI) and install uniformly, taking care that they do not move to one side. a Fix the rotation seal ring in position with grease (G2-LI) and be extremely careful not to get it caught when assembling. Check that the snap ring is fitted securely in the groove.
1.
Nipple Install nipple (58).
2.
Bevel gear shaft, bevel gear assembly 1) Using push tool [9], press fit outer race (57) to cage (55).
2)
Assemble shim (56) and install cage (55). a There are four types of shim: 0.05, 0.1, 0.2, 0.5 mm 3 Cage mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
3)
Assembly of bevel gear shaft, bevel gear assembly i) Set bevel gear (53) to bevel gear shaft (50), then fit reamer bolt (52) and tighten nut. 3 Nut: 245.2 ± 29.4 Nm {25 ± 3 kgm}
D155A-6
43
SEN03369-03
ii) iii)
3.
44
50 Disassembly and assembly
Using push tool [10], press fit bearing (54) to bevel gear shaft (50). Using push tool [11], press fit bearing (51) to bevel gear shaft (50).
4)
Turn over steering case so that right side is at top, then install bevel gear shaft and bevel gear assembly (49).
5)
Raise right cover (48) and install. 3 Mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
6)
Assemble shim (47) and install cage (46). a There are four types of shim: 0.05, 0.1, 0.2, 0.5 mm 3 Cage mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
Adjusting preload of bevel gear shaft 1) Adjust thickness of shims at cage to adjust turning torque of bevel gear shaft. a Turning torque (bevel pinion not meshed): 4.2 – 5.1 Nm {0.43 – 0.52 kgm} (At tip of bevel gear teeth: 22.6 – 26.5 N {2.3 – 2.7 kg}) a Rotate the bevel gear 2 – 3 times when measuring the turning torque.
D155A-6
50 Disassembly and assembly
4.
SEN03369-03
Bevel pinion assembly 1) Assemble bevel pinion as follows. i) Using push tool, press fit bearing (45) to bevel pinion (40).
ii) iii)
Using push tool, press fit outer races (44) and (43) to cage (41). Put bevel pinion (40) on press stand, and set cage (41) in position.
iv) Press fit bearing (42) to cage (41) with press. v) Hold in press so that pinion does not move, then use tool H2 and tighten locknut (39). 2 Locknut: Thread tightener (LT-2) 3 Locknut: 779.6 ± 83.4 Nm {79.5 ± 8.5 kgm} a Rotate the cage when tightening.
2)
D155A-6
Using guide bolt [12], assemble shim (38) and install bevel pinion assembly (37). a There are four types of shim: 0.05, 0.1, 0.2, 0.5 mm
45
SEN03369-03
5.
Adjustment of backlash and tooth contact 1) Adjustment of backlash Apply the probe of dial gauge [13] to the tooth tip at the end of the bevel gear perpendicularly. While fixing the bevel pinion, move the bevel gear forward and backward and read the dial gauge. a Standard backlash: 0.25 – 0.33 mm a Measure the backlash diagonally at 3 or more places. a Adjust the backlash by increasing or decreasing thickness of the right and left shims. Do not change the total thickness of both shims, however, so that the pre-load will not change. (If the thickness of the shim on one side is increased, decrease the thickness of the other side, and vice versa.) q When backlash is insufficient Decrease the thickness of the shim on the left side of the machine and increase the thickness on the right side by the same quantity. (Move the bevel gear in direction (A).) q
2)
46
50 Disassembly and assembly
When backlash is too large Decrease the thickness of the shim on the right side of the machine and increase the thickness on the left side by the same quantity. (Move the bevel gear in direction (B).)
Adjustment of tooth contact Testing 1] Select 3 pieces of teeth so that circumference of bevel gear is divided into 3 evenly. Apply red lead thinly on entire teeth surfaces on travel forward side and travel reverse side. Rotate the bevel gear more than 17 times in both direction of forward and reverse. 2] Transcribe the tooth contact mark on the bevel gear to transparent tape in order to check it by sticking it on external form of the gear shown in the following figure.
D155A-6
50 Disassembly and assembly
SEN03369-03
(v): Concave surface (w): Convex surface (x): External form of gear (y): External form of pinion a
a
D155A-6
The tooth contact is as shown below. (j): 15 to 27 mm (k): 21 to 33 mm (m): 1 to 3 mm Check that there are no marks of strong contact at tooth tip (f), dedendum (g), small end (h) and large end (i). If the adjustment is done in this way, correct tooth contact is obtained when the load is applied.
47
SEN03369-03
q
50 Disassembly and assembly
The tooth contact that meets the following conditions is not appropriate. Width (aa) of tooth contact engaged at pinion tooth tip:Max. 7 mm Distance (ab) between pinion tooth tip and tooth contact large end: Min. 3 mm
Adjustment If the tooth contact pattern is not proper, adjust the tooth contact according to the following procedure. 1) If the bevel pinion is too far from the center line of the bevel gear, the contact is at the small end of the bevel gear tooth faces curved outward and at the large end of the bevel gear tooth faces curved inward. q In this case, adjust the tooth contact according to the following procedure. Adjust the thickness of the shims on the bevel pinion side to move the bevel pinion in direction (A). Move the bevel gear in direction (B) and then check the tooth contact pattern and backlash again. 2)
q
a 3)
If the bevel pinion is too close to the center line of the bevel gear, the contact is at the large end of the bevel gear tooth faces curved outward and the small end of the bevel gear tooth faces curved inward. In this case, adjust the tooth contact according to the following procedure. Adjust the thickness of the shims on the bevel pinion side to move the bevel pinion in direction (A). Move the bevel gear in direction (B), then check the tooth contact pattern and backlash again. Do not change the total thickness of the shims on the right and left sides. When adjustment is finished, tighten the mounting bolts of the cage and bevel pinion assembly to the specified torque. 2 Mounting bolts of cage and bevel pinion assembly: 98 – 122.5 Nm {10 – 12.5 kgm}
6.
Lubrication tubes Install left and right lubrication tubes (36).
7.
Suction tube, dipstick tube Install suction tube (34) and dipstick tube (35).
48
D155A-6
50 Disassembly and assembly
8.
Case cover Install cover (33).
9.
Lubrication tubes Install 3 lubrication tubes (32).
SEN03369-03
10. Pipes Install 6 pipes (31).
11. Clutch, brake assembly Assembly of clutch, brake assembly 1) Assembly of clutch assembly i) Assemble stopper (30) to brake hub (27), and install snap ring (29). ii) Using push tool, press fit bearing (28) to brake hub.
iii)
Install clutch outer drum (26) to brake hub (27). 3 Mounting bolt: 110.3 ± 12.3 Nm{11.25 ± 1.25 kgm} iv) Set clutch outer drum facing up, then assemble clutch spring (25).
D155A-6
49
SEN03369-03
50 Disassembly and assembly
v) Assemble clutch piston (24). vi) Fit seal ring and install cage (23). 3 Mounting bolt: 110.3 ± 12.3 Nm{11.25 ± 1.25 kgm}
vii) Assemble snap ring (19) in groove of inner drum (20). viii) Press fit bearing (22) to inner drum (20), and install snap ring (21).
ix) Press fit inner drum (20) to cage (23), then install snap ring (19) assembled to inner drum. a The outer race of bearing (22) (installed in Step 1) -viii)) is press fitted.
x)
Assemble plate (18) and disc (17). a Assemble the plate to the piston end. 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}
2)
50
Assembly of brake assembly i) Install 3 seal rings (11) to brake hub (27). ii) Install cage (10) to brake hub (27). a The outer race of the bearing is press fitted.
D155A-6
50 Disassembly and assembly
SEN03369-03
iii) Set brake outer drum (12) to clutch outer drum. iv) Assemble discs (13), plates (14), and springs (15). a Discs: 6, Plates: 5, Springs: 6
v)
Fit seal ring to brake cage and install brake piston (9). vi) assemble brake spring (8).
vii) Using push tool, press fit bearing (7) to cover (6).
viii) Install guide bolts [14] and [15] to brake piston (9) and brake cage (10). a Guide bolt [14] is for releasing the brake.
ix) Using eyebolts [1], align with guide bolts, and set cover (6) in position. x) Compress spring with bolt and press fit bearing (7) at same time.
D155A-6
51
SEN03369-03
50 Disassembly and assembly
xi) Remove guide bolts and install plate (5). xii) Install seal ring (4) and flange (3). a Assemble the clutch and brake assembly on the opposite side in the same way. 3 Flange mounting bolt: 66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
3) 4)
Angle the steering case assembly approx. 15° so that tool H1 is perpendicular to ground surface. Using tool H1, install clutch and brake assembly (2). a Assemble the clutch brake assembly on the opposite side in the same way. 3 Mounting bolt: 110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
12. Steering valve, reducing valve Install steering valve (1). 3 Mounting bolt: 49.0 ± 4.9 Nm {5 ± 0.5 kgm}
a
52
When removing cover (61) of steering case (59) rear surface, install new gasket (60). 2 Gasket (apply to both sides): Gasket sealant (LG-11)
D155A-6
50 Disassembly and assembly
D155A-6
SEN03369-03
53
SEN03369-03
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03369-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
54
D155A-6
SEN03370-01
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Power train, Part 3 Removal and installation of final drive assembly ............................................................................................ 2 Disassembly and assembly of final drive assembly........................................................................................ 9
D155A-6
1
SEN03370-01
50 Disassembly and assembly
Removal and installation of final drive assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
2
Socket wrench
(Commercially available)
30 mm
1
3
Socket wrench
(Commercially available)
41 mm
1
4
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 455 to 565 Nm, 1150 to 1440 Nm
5
Hydraulic jack
(Commercially available)
30 ton
2
[3]
6
Blocking tool
(Commercially available)
30 tons of load-bearing capacity
4
[1], [2]
7
Forcing screw
(Commercially available)
M10
1
8
Lever block
(Commercially available)
19 mm
1
As needed
1
Special tools Symbol
Part name Lifting tool
J
Part No.
Specifications
Q'ty
790-337-1032
1
Shackle
791-627-1320
2
Plate
791T-627-1910
1
Bolt
01010-82080
2
Remarks
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 Leave the negative (-) terminal of the battery disconnected.
2
D155A-6
50 Disassembly and assembly
SEN03370-01
Removal
1. 2.
3.
Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly". Remove inside mounting bolts (2) (8 pieces) for final drive assembly (1). Tool: Socket wrench Bolt (2): M27 with width across flats of 41 mm When raising the machine off the ground using the front blade and rear ripper 1)
2)
4.
Start the engine and operate the blade and ripper to raise the machine slowly off the ground. a Do not perform disconnection of the (-) terminal of the battery instructed as preparation. Then, for the front of the machine, set blocking tool [2] (30 tons of load-bearing capacity) (2 pieces in total) at both the right and left (part 'a') of the equalizer bar. For the rear of the machine, set blocking tool [1] (30 tons of load-bearing capacity) (2 pieces in total) each at the right and left (part ‘b’) of the frame bottom. k The work to set the blocking tool is very dangerous. Be sure to perform the work by 2 persons. k The machine is equipped with a blade and ripper at its front and rear parts respectively. Unlike that shown in the attached photo, workability of the machine is not good. Be sure to perform the work with extreme care. Tool: Blocking tools (with load-bearing capacity of min. 30 tons) (4 pieces)
When raising the machine using an overhead traveling crane 1) You may leave the battery (-) terminal disconnected. 2) Use the crane to raise the rear of the machine off the ground, set blocking tool [1] (2 pieces in total) at both the right and left (part ‘b’) of the frame bottom, and then lower the machine onto blocking tools [1] (to make them bear the weight). 4 Weight of rear part of machine: Approximately 25 tons 3)
D155A-6
Similarly, use the crane to raise the front of the machine off the ground, set blocking tool [2] (2 pieces in total) at both the right and left of the equalizer bar, and then lower the machine onto blocking tools [2] (to make them bear the weight). a Be sure to use the drawing hook attached to the undercover when raising the machine using a crane. You may also raise the machine using hydraulic jack [3] as shown in the reference drawing. 4 Weight of front part of machine: Approximately 25 tons
3
SEN03370-01
50 Disassembly and assembly
k The work to set the blocking tool is very dan-
4)
gerous. Be sure to perform the work by 2 persons. k In each case where the machine is raised off the ground on its own and using a crane, the machine is equipped with a blade and ripper at its front and rear parts respectively. Unlike the machine without the blade and ripper shown in the explanatory drawing, workability of the machine is not good. Be sure to perform the work with extreme care. Set blocks under the front bottom of the track frame being raised, and use them as auxiliary parts for the hydraulic jacks and blocking tools to assure the safety of the work. a After setting blocking tools [1] and [2], be sure to set jacks and the ripper as auxiliary parts.
5.
Remove bolts (3a) (4 pieces) and (4a) (4 pieces) to remove guards (3) and (4) respectively. a You may leave the battery (-) terminal disconnected. Tool: Socket wrench Bolts (3a) and (4a): M20 with width across flats of 30 mm
6.
Remove bolts (5a) (3 pieces) to remove drive shaft cover (5). Tool: Socket wrench Bolt (5a): M12 with width across flats of 19 mm Remove cover mounting bolts (7) (2 pieces) for the final drive assembly. Tool: Socket wrench Bolt (7): M20 with width across flats of 30 mm
7.
8.
4
Pull out drive shaft (6). a Use forcing screws to pull it out until its spline portion comes out. a If the shaft cannot be pulled out, move the sprocket forward and backward to set the sprocket at a position where the shaft can be pulled out. Tool: Forcing screw (M10)
D155A-6
50 Disassembly and assembly
9.
SEN03370-01
Set tool J {plate (lifting tool)} to mounting bolt holes in the cover removed in step 6. Tool: Plate (lifting tool) (J), socket wrench Bolt (7): M20 with width across flats of 30 mm
10. Use tool J (lifting tool) to sling final drive assembly (1), and remove mounting bolts (2a) (14 pieces) at the outer side of final drive assembly (1). Tool: Lifting tool (J), lever block, socket wrench Bolt (2a): M27 with width across flats 41 mm k Leave the mounting bolt (1 piece at each side) of the final drive loosened slightly so that the final drive will not jump out. Loosen and remove the respective bolts (2 pieces) while pulling out the final drive assembly. 11. Sling final drive assembly (1) and remove it. 4
D155A-6
Final drive assembly: 1,400 kg
5
SEN03370-01
50 Disassembly and assembly
Installation
1.
Use tool J (lifting tool) to sling final drive assembly (1) and set the assembly to its installed position. Tool: Lifting tool, lever block a Sling the final drive assembly while using the lever block to keep the assembly horizontal. 4
Final drive assembly: 1,400 kg
2.
Use mounting bolts (2a) (14 pieces) for the outer side of final drive assembly (1) to install final drive assembly (1). Tool: Torque wrench (socket) Bolt (2a): M27 with width across flats of 41 mm 3 Bolt (2a): 1,150 to 1,440 Nm {118 to 147 kgm}
3. 4.
Remove tool J (lifting tool). Install drive shaft (6). a If it is hard to install the shaft, move the sprocket forward and backward to set the sprocket at a position where the shaft can be installed.
5.
Use bolts (5a) (3 pieces) to install drive shaft cover (5). Tool: Torque wrench (socket) Bolt (5a): M12 with width across flats of 19 mm 3 Bolt (5a): 98 to 123 Nm {10 to 12.5 kgm} Install cover mounting bolts (7) (2 pieces) for the final drive assembly. Tool: Torque wrench (socket) Bolt (7): M20 with width across flats of 30 mm 3 Bolt (7): 455 to 565 Nm {46.5 to 58 kgm}
6.
7.
6
Use bolts (3a) (4 pieces) and (4a) (4 pieces) to install guards (3) and (4), respectively. Tool: Torque wrench (socket) Bolts (3a) and (4a): M20 with width across flats of 30 mm 3 Bolts (3a) and (4a): 455 to 565 Nm {46.5 to 58 kgm}
D155A-6
50 Disassembly and assembly
8.
When raising the machine off the ground by using the front blade and rear ripper 1) Start the engine and operate the blade and ripper to raise the machine slowly off the ground while ensuring safety of surrounding area. 2) Then, for the front of the machine, remove blocking tool [2] (30 tons of load-bearing capacity) (2 pieces in total) from both the right and left (part ‘a’) of the equalizer bar. For the rear of the machine, remove blocking tool [1] (30 tons of load-bearing capacity) (2 pieces in total) from both the right and left (part ‘b’) of the frame bottom. k The work to remove the blocking tool is very dangerous. Be sure to perform the work by 2 persons. k Be sure not to operate the blade nor ripper during removal work of the blocking tool. k The machine is equipped with a blade and ripper at its front and rear parts respectively. Unlike that shown in the attached photo, workability of the machine is not good. Be sure to perform the work with extreme care.
9.
When raising the machine by using an overhead traveling crane 1) Use the crane to raise the front of the machine off the ground, remove blocking tool [2] (2 pieces in total) from both the right and left of the equalizer bar, and then lower the machine on the ground. a Be sure to use the drawing hook attached to the undercover when raising the machine by using a crane. You may also raise the machine using hydraulic jack [3] as shown in the reference drawing. 4 Weight of front part of machine: Approximately 25 tons k The work to remove the blocking tool is very dangerous. Be sure to perform the work by 2 persons. k Be sure not to operate the crane during removal work of the blocking tool. k The machine is equipped with a blade and ripper at its front and rear parts respectively. Unlike that shown in the attached photo, workability of the machine is not good. Be sure to perform the work with extreme care. 2) Similarly, use the crane to raise the rear of the machine off the ground, remove blocking tool [1] (2 pieces in total) from both the right and left (part ‘b’) of frame bottom, and then lower the machine to the ground. k The work to remove the blocking tool is very dangerous. Be sure to perform the work by 2 persons. k Be sure not to operate the crane during removal work of the blocking tool. 4 Weight of rear part of machine: Approximately 25 tons
D155A-6
SEN03370-01
7
SEN03370-01
50 Disassembly and assembly
k In each case where the machine is raised off
the ground on its own and using a crane, the machine is equipped with a blade and ripper at its front and rear parts, respectively. Unlike the machine without the blade and ripper shown in the explanatory drawing, workability of the machine is not good. Be sure to perform the work with extreme care. 10. Install mounting bolts (2) (8 pieces) for the inner side of final drive assembly (1). Tool: Torque wrench (socket) Bolt (2): M27 with width across flats of 41 mm 3 Bolt (2): 1,150 to 1,440 Nm {118 to 147 kgm} 11. Install the track shoe assembly. For details, see "Separation and connection of track shoe assembly".
8
D155A-6
50 Disassembly and assembly
SEN03370-01
Disassembly and assembly of final drive assembly
1
Special tools Symbol
1
2
3
K
4
5
6
7
D155A-6
Part No.
Part name
Necessity
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
790-101-2480
Adapter
t
2
791T-627-1920
Plate
t
1
790-101-2102
Puller
t
1
790-101-1102
Hydraulic pump
t
1
New/ Remodel
Sketch
N
Q
790-431-1031
Block
t
1
791-520-4140
Screw
t
1
791-112-1180
Nut
t
2
01643-32460
Washer
t
2
791T-627-1930
Plate
t
1
N
Q
791T-627-1940
Push tool
t
1
N
Q
790-101-2102
Puller
t
1
790-101-1102
Hydraulic pump
t
1
791-627-1280
Installer
t
1
790-101-5401
Push tool kit
t
1
790-101-5441
• Plate
1
790-101-5421
• Grip
1
01010-51240
• Bolt
790-101-5401
Push tool kit
1
790-101-5451
• Plate
1
790-101-5421
• Grip
1
t
1
01010-51240
• Bolt
791T-627-1950
Plate
t
1 1
N
Q
791T-627-1960
Plate
t
1
N
Q
790-201-1500
Push tool kit
t
1
790-201-1680
• Plate
1
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
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
9
SEN03370-01
50 Disassembly and assembly
Disassembly 1.
Draining oil Remove the drain plug to drain the oil in the final drive case. 6
Final drive case: Approx. 31 l
2.
Drive shaft Remove drive shaft (1).
3.
Shaft 1) Set the final drive assembly to the block. 2) Remove mounting bolts (2).
3)
4.
Sprocket hub assembly 1) Remove mounting bolts (4) and plate (5).
2) 3)
10
Using eyebolts [1], remove shaft (3).
Using tool K1, pull out sprocket hub assembly (6). a Bearing (7) comes off, too. Using eyebolts [2], remove sprocket hub assembly (6).
D155A-6
50 Disassembly and assembly
4)
Remove floating seal (8) and bearing outer races (9) and (10). a Keep the floating seal in a safe place so that it will not be damaged.
5)
Reverse the sprocket hub assembly and remove 9 sprockets (11).
5.
Wear guard Remove wear guard (12).
6.
Cover assembly 1) Remove spacer (13). 2) Remove floating seal (14). a Keep the floating seal in a safe place so that it will not be damaged. 3) Remove mounting bolts (15).
4)
D155A-6
SEN03370-01
Using eyebolts [3], sling cover assembly (16). Using 3 forcing screws [4], remove the cover assembly.
11
SEN03370-01
5)
Remove bearing (17) and spacer (18).
6)
Reverse the cover assembly and remove 6 lock plates (19). Remove ring gear (20).
7)
7.
Carrier assembly 1) Using 3 eyebolts [5], remove carrier assembly (21).
2)
Disassemble the carrier assembly according to the following procedure. 1] Remove bolts (22) and holders (23). 2] Pull out planetary gear shaft (24).
3]
12
50 Disassembly and assembly
Remove planetary gear (25), bearings (26) and (27) and spacer (28) from the carrier.
D155A-6
50 Disassembly and assembly
4]
SEN03370-01
Remove bearing outer races (29) and (30) from the planetary gear.
8.
Sun gear Remove thrust washer (31) and sun gear (32).
9.
Holder Remove mounting bolt (33) and holder (34).
10. Gear 1) Remove the gear according to the following procedure. 1] Sling case-hub-case assembly (35) a little. 2] Push the shaft of case (36) to make a clearance between bearing (37) and case shaft. a Take care not to damage the bearing holding area on the pinion side.
3] 4]
D155A-6
Remove mounting bolts (38). Using eyebolts [6], sling gear (39), and slant the hub to remove the gear.
13
SEN03370-01
50 Disassembly and assembly
11. Hub and case assembly 1) Using tool K2, remove hub assembly (40) and bearing (37).
14
2)
Using eyebolts [7], remove hub assembly (40).
3)
Remove 2 bearing outer races (42) from hub (41).
4)
Remove collar (43) and remove bearing (44) from case (36).
5)
Remove sump plate (45) from case (36).
D155A-6
50 Disassembly and assembly
SEN03370-01
12. Cage assembly 1) Remove the mounting bolts of cage assembly (46). Using forcing screws [8], remove the cage assembly from case (36).
2)
Remove outer race (48) and oil seal (49) from cage (47).
3)
Remove shims (50).
13. Gear assembly 1) Remove gear assembly (51). 2) Using puller [9], remove bearings (52) and (53) from gear (54).
14. Outer race and oil seal Remove outer race (55) and oil seal (56) from case (36).
D155A-6
15
SEN03370-01
50 Disassembly and assembly
Assembly a a
Clean all the parts thoroughly and check them for dirt or damage before installing. Coat the sliding surfaces of each part with engine oil before installing.
1.
Oil seal and outer race 1) Using tool K4, press fit oil seal (56) to case (36). a When press fitting the oil seal, take care of its direction. a Apply gasket sealant thinly to the inside wall of the housing and wipe off projected part. 2 Oil seal lip: Grease (G2-LI) 2 Oil seal press fitting area: 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}
2.
Gear assembly 1) Using the push tool [11], press fit bearings (52) and (53) to gear (54). q Bearing press fitting force: 6 – 17 kN {0.6 – 1.7 ton} 2) Install the drive shaft cover. 3) Install gear assembly (51).
3.
Cage assembly 1) Using tool K4, press fit oil seal (49) to cage (47). a When press fitting the oil seal, take care of its direction. a Apply gasket sealant thinly to the inside wall of the housing and wipe off projected part. 2 Oil seal lip: Grease (G2-LI) 2 Oil seal press fitting area: Gasket sealant (LG-5)
16
D155A-6
50 Disassembly and assembly
2)
Using tool K5, press fit bearing outer race (48) to cage (47). q Bearing press fitting force: 1 – 13 kN {0.1 – 1.4 ton}
3)
Fit the O-ring to cage assembly (46), install them, and adjust shim (50). a When installing the cage assembly, lower it gradually not to damage the oil seal lip.
4)
Adjustment of shim q Adjust the pinion bearing clearance according to the following procedure. 1] Tighten mounting bolts (D), (E), (G) and (H) of cage (40) evenly. 3 Mounting bolt: 20 Nm {2 kgm} 2] Using a thickness gauge, measure clearances (a) and (b) between cage (47) and case (36). 3] Referring to Table 1, determine quantity (c) of the shim from the total of clearances (a) and (b). 4] Install determined shim (50) to the cage and tighten the 6 mounting bolts of cage (47) evenly. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
D155A-6
SEN03370-01
17
SEN03370-01
50 Disassembly and assembly
Table 1 Number of shims to be used
a + b (mm) Above
Below
t = 0.15
3.05
3.15
5
t = 0.5
3.15
3.25
2
1
3.25
3.35
9
1
3.35
3.45
6
3.45
3.55
3
3.55
3.65
3.65
3.75
1
7
3.75
3.85
4
3.85
3.95
1
3.95
4.05
8
4.05
4.15
5
1
1
t = 1.0
Total shim thickness (mm)
1
1.75
1
1.80 1.85
1
1.90
1
1.95
2
2.00
1
2.05
1
2.10
2
2.15
1
2.20
1
2.25
4.15
4.25
2
2
2.30
4.25
4.35
9
1
2.35
4.35
4.45
6
4.45
4.55
3
4.55
4.65
4.65
4.75
7
1 1
2
2.50
1
2.55
2
2.60
2
2.65
4.75
4.85
4
4.95
1
1 1
4.95
5.05
8
5.15
5
2.40 2.45
1
4.85 5.05
1 2
1
2.70
2
2.75
5.15
5.25
2
1
2
2.80
5.25
5.35
9
1
1
2.85
2
2.90
1
2
2.95
5.35
5.45
6
5.45
5.55
3
5.55
5.65
5.65
5.75
7
5.75
5.85
4
5.85
5.95
1
5.95
6.05
8
6.05
6.15
5
1
1
3
3.00
2
3.05
2
3.10
3
3.15
2
3.20
2
3.25
6.15
6.25
2
3
3.30
6.25
6.35
9
2
3.35
6.35
6.45
6
6.45
6.55
3
6.55
6.65
6.65
6.75
7
1 1
3
3.50
2
3.55
3
3.60
3
3.65
6.75
6.85
4
6.95
1
1 1
6.95
7.05
8
7.15
5
3.40 3.45
1
6.85 7.05
2 3
2
3.70
3
3.75
7.15
7.25
2
1
3
3.80
7.25
7.35
9
1
2
3.85
18
D155A-6
50 Disassembly and assembly
4.
SEN03370-01
Hub and case assembly 1) Install oil sump plate (45) to case (36). a When installing the plate, press its surface against case faces (a) and (b). 2 Mounting bolt: Adhesive (LT-2)
2) 3)
Using tool K5, press fit bearing (44) to case (36). q Bearing press fitting force: 21 – 54 kN {2.1 – 5.5 ton} Install collar (43).
4)
Using tool K5, press fit 2 bearing outer races (42) to hub (41). q Bearing press fitting force: 3 – 18 kN {0.3 – 1.8 ton}
5)
Using eyebolts [7], set hub assembly (40) to the shaft.
D155A-6
19
SEN03370-01
5.
Gear 1) Using eyebolts [6], sling gear (39). While slanting the hub, set the gear to the hub.
2)
Tighten gear mounting bolts (38). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 230 – 289 Nm {23.5 – 29.5 kgm}
3)
Using tool K7, press fit bearing (37) to case (36). q Bearing press fitting force: 21 – 54 kN {2.1 – 5.5 ton}
6.
Holder Install holder (34) and tighten mounting bolt (35). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 230 – 289 Nm {23.5 – 29.5 kgm}
7.
Sun gear Install sun gear (32) and thrust washer (31).
20
50 Disassembly and assembly
D155A-6
50 Disassembly and assembly
8.
SEN03370-01
Carrier assembly a Since each planetary gear bearing is an assembly, assemble it from the inner race, outer race and spacer of the same identification mark. 1) Using tool K6, press fit bearing outer races (29) and (30) to the planetary gear. q Bearing press fitting force: 10 – 35 kN {1.0 – 3.6 ton}
2)
Install bearings (26) and (27) and spacer (28) to planetary gear (25).
3)
Set the planetary gear assembly to the carrier and press fit shaft (24). a While aligning the holes of the bearing spacer, press fit the shaft gradually.
4)
Install holders (23) and tighten bolts (22). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 230 – 289 Nm {23.5 – 29.5 kgm}
5)
Using 3 eyebolts [4], install carrier assembly (21).
D155A-6
21
SEN03370-01
9.
22
50 Disassembly and assembly
Cover assembly 1) Install ring gear (20) and 6 lock plates (19) and tighten the mounting bolts. 2 Mounting bolt: Adhesive (LT-2)
2) 3)
Install spacer (18). Using tool K3, press fit bearing (17). q Bearing press fitting force: 15 – 43 kN {1.5 – 4.4 ton}
4)
Using tool K4, press fit floating seal (14). a Degrease and dry the O-ring and O-ring contact surface before installing the floating seal. a After installing the floating seal, check that its tilt is 1 mm or less.
5)
Using eyebolts [3], fit the O-ring to cover assembly (16) and install them to the case assembly. a The mating faces of the case and cover must be free from a dent, rust, oil, dirt and water. a Apply the gasket sealant all around the mating face (1 side) of the case without breakage. 2 Mating face of case: Gasket sealant (LG-7) a Tighten the bolts within 20 minutes after applying the gasket sealant.
6)
Tighten mounting bolts (15). 3 Mounting bolt: 455 – 565 Nm {46.5 – 58 kgm}
D155A-6
50 Disassembly and assembly
SEN03370-01
10. Wear guard Install wear guard (12). 3 Mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}
11. Sprocket hub assembly 1) Using tool K5, press fit bearing outer races (9) and (10). q Bearing press fitting force: 14 – 59 kN {1.5 – 4.4 ton}
2)
Install 9 sprockets (11) to the sprocket hub. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 1,176 ± 98 Nm {120 ± 10 kgm}
3)
Using tool K3, press fit floating seal (8). a Degrease and dry the O-ring and O-ring contact surface before installing the floating seal. a After installing the floating seal, check that its tilt is 1 mm or less.
4)
Using eyebolts [2], install sprocket hub assembly (6) to the cover assembly. a Check that the sliding surface of the floating seal is free from dirt and apply engine oil thinly.
D155A-6
23
SEN03370-01
5)
Using tool [10], press fit bearing (7). a While rotating the sprocket hub assembly, press fit the bearing. q Bearing press fitting force: 15 – 43 kN {1.5 – 4.4 ton}
6)
Install plate (5) and tighten mounting bolts (4). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 2 30 – 289 Nm {23.5 – 29.5 kgm}
50 Disassembly and assembly
12. Shaft 1) Fit the O-ring to the sprocket hub assembly. Using eyebolts [1], install shaft (3).
2)
Tighten mounting bolts (2). 3 Mounting bolt: 1,225 – 1,470 Nm {125 – 150 kgm}
13. Drive shaft Install drive shaft (1).
24
D155A-6
50 Disassembly and assembly
q
a
SEN03370-01
Refilling with oil Tighten the drain plug and add oil through the oil filler. After installing the final drive assembly to the machine, check the oil level again.
5
Final drive case: Approx. 31 l
3 Oil filler/Drain plug: 127 – 176 Nm {13 – 18 kgm}
3 Oil level gauge plug: 58.8 – 76.4 Nm {6 – 8 kgm}
D155A-6
25
SEN03370-01
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03370-01
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
26
D155A-6
SEN03371-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Undercarriage and frame Removal and installation of track frame assembly.......................................................................................... 3 Removal and installation of idler assembly ................................................................................................... 10 Disassembly and assembly of idler assembly .............................................................................................. 18 Removal and installation of recoil spring assembly ...................................................................................... 22 Disassembly and assembly of recoil spring assembly.................................................................................. 25 Removal and installation of track roller assembly ......................................................................................... 30 Disassembly and assembly of track roller assembly .................................................................................... 37 Removal and installation of 1st bogie assembly ........................................................................................... 39 Removal and installation of 2nd, 3rd, and 4th bogie assemblies .................................................................. 49 Disassembly and assembly of bogie assembly ............................................................................................ 58 Removal and installation of carrier roller assembly ...................................................................................... 61 Disassembly and assembly of carrier roller assembly .................................................................................. 64 Removal and installation of pivot shaft assembly ......................................................................................... 69 Separation and connection of track shoe assembly ..................................................................................... 72 General disassembly and assembly of track shoe........................................................................................ 77 Disassembly and assembly of 1 link in field.................................................................................................. 90
D155A-6
1
SEN03371-03
50 Disassembly and assembly
Disassembly and assembly of master link .................................................................................................... 95 Removal and installation of equalizer bar assembly ..................................................................................... 99 Disassembly and assembly of equalizer bar assembly............................................................................... 104 Removal and installation of segment teeth ................................................................................................. 106
2
D155A-6
50 Disassembly and assembly
SEN03371-03
Removal and installation of track frame assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
24 mm
1
2
Socket wrench
(Commercially available)
30 mm
1
3
Socket wrench
(Commercially available)
36 mm
1
4
Spanner wrench
(Commercially available)
22 mm
1
5
Spanner wrench
(Commercially available)
27 mm
1
6
Torque wrench (socket)
(Commercially available)
235 to 285 Nm, 98 to 123 Nm, 455 to 565 Nm 785 to 980 Nm
7
Torque wrench (spanner)
(Commercially available)
84 to 132 Nm
8
Wire
(Commercially available)
1
(3,825 kg), (9.5 t)
9
3-point chain
(Commercially available)
1
(3,825 kg)
10
Lever block
(Commercially available)
1
11
Blocking tool
(Commercially available)
1
12
Block
(Commercially available)
(H) 500 mm, (W) 500 mm, (L) 900 mm
1
13
Hydraulic jack
(Commercially available)
30 tons
1
As needed 1
[1], [3]
[2]
Special tools list Symbol
Part name
Part No.
Specifications
Q'ty
Bracket
791T-130-1010
6
Bolt
01010-63060
12
Washer
01643-33080
12
1 Plug (female)
02789-10422
#04
1
AC 2 Plug (male)
07376-70422
#04
1
3 O-ring
02896-11012
KK
1
Remarks For locking bogie For preventing oil leakage when hose is disconnected • Blade hose
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
3
SEN03371-03
50 Disassembly and assembly
Removal 1. 2.
Remove the blade assembly. For details, see "Removal and installation of blade assembly". Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly".
3.
Install tool KK (bracket for locking bogie) to lock bogie (19) using a bolt hole in track frame (18) and that in bogie (19). a Because the locking tool cannot be attached to the 1st bogie, use a lever block or the like to sling the 1st bogie to lock it. Tool: Bracket (KK) for locking bogie, lever block
4.
Raise the machine off the ground according to the following procedure. 1)
2)
3)
4
Use jacks, a crane, or the ripper to raise the rear of the machine, and set blocking tool [1] under the bottom of the frame on each side to keep the rear of the machine raised off ground. k The work to set the blocking tool is very dangerous. Be sure to perform the work by 2 persons. Tool: Jack [2], blocking tool [1] a When raising the machine using a crane Tool: Wire, blocking tool [1] 4 Weight of rear part of machine: Approximately 25 tons Set hydraulic jack [2] under the equalizer bar at its center to raise the front of the machine off the ground, and set blocking tool [3] under the main frame on each side to keep the front of the machine raised off the ground. Tool: Blocking tool [3], hydraulic jack [2] k The work to set the blocking tool is very dangerous. Be sure to perform the work by 2 persons. 4 Weight of front part of machine: Approximately 25 tons Set blocks under the front bottom of the track frame being raised to assure the safety of the work. Tool: Block a After setting blocking tools [1] and [3], be sure to leave jacks and the ripper set as auxiliary safety measures.
D155A-6
50 Disassembly and assembly
5.
Sling track frame assembly (16) to be removed. 1) Attach the lifting tool to the front and rear carrier rollers to sling the track frame. 2) Use a lever block for the front carrier roller to keep the track frame level.
6.
Remove bolts (1) (2 pieces) to remove cover (2). Tool: Socket wrench Bolt (1): M24 with width across flats of 36 mm Remove bolts (3a) (2 pieces) to remove lock plate (3). Tool: Socket wrench Bolt (3a): M16 with width across flats of 24 mm
7.
8.
Pull out pin (4). a The pin is hard to remove if the hole of the equalizer bar is not aligned with that of the track frame. Be sure to remove the pin while adjusting lifting height of the track frame. When the track frame assembly on the opposite side is raised off the ground, be sure to support it using blocks or the like before removing the pin.
9.
Remove bolts (5a) (4 pieces) and (6a) (4 pieces) to remove guards (5) and (6), respectively, from the track frame. Tool: Socket wrench Bolts (5a) and (6a): M20 with width across flats of 30 mm 4
SEN03371-03
Guard (6): 25 kg
10. Remove bolts (7a) (6 pieces) to remove cover (7) from the pivot shaft. Tool: Socket wrench Bolts (7a): M16 with width across flats of 24 mm a Take care not to damage the hoses that are internally connected to the cover. 11. Disconnect hoses (8), (9), (10), and (11) that are internally connected to cover (7), and then remove cover (7). Tool: Spanner wrench, special tool AC Hoses (8), (9), (10), and (11): Width across flats of 27 mm, #04 size
D155A-6
5
SEN03371-03
50 Disassembly and assembly
12. Remove bolts (12a) (2 pieces), and remove washer (12). Tool: Socket wrench Bolt (12a): M16 with width across flats of 24 mm
13. Remove seal (13). 14. Remove bolts (14a) (6 pieces), and remove washer (14). Tool: Socket wrench Bolt (14a): M16 with width across flats of 24 mm 15. Remove spacer (15) from washer (14).
16. Sling track frame assembly (16) and move it outward until the assembly is clear of the pivot shaft. Tool: Lever block, 3-point chain, lever block, wire 4
Track frame assembly: 3,825 kg
17. Remove seal (17) from pivot shaft (18).
6
D155A-6
50 Disassembly and assembly
SEN03371-03
Installation 1.
Install seal (17) to pivot shaft (18) according to the following procedure. 1) Reverse seal (17) so that its face with molded letter (c) faces inward. 2) Install seal (17) reversed to pivot shaft (18). 3) Apply engine oil to surface (d) on track frame assembly (16). (For details, see "Table of fuel, coolant and lubricants".).
4)
Sling track frame assembly (16) and install it to pivot shaft (18). a Attach the lifting tool to the front and rear carrier rollers and sling the track frame. a Use a lever block for the front carrier roller to keep the track frame level. Tool: Lever block, 3-point chain, lever block, wire 4 Track frame assembly: 3,825 kg a Take extreme care not to damage the surface of the seal when installing the track frame assembly.
2. 3.
Install spacer (15) to washer (14). Use bolts (14a) (6 pieces) to install washer (14) to the shaft end of the pivot shaft. Tool: Torque wrench (socket) Bolt (14a): M16 with width across flats of 24 mm 3 Bolt (14a): 235 to 285 Nm {23.5 to 29.5 kgm}
4.
Install seal (13) according to the following procedure. 1) Reverse seal (13) so that its face with molded letter (a) faces inward. 2) Install seal (13) reversed to washer (14). 3) Apply engine oil to surface (b) on washer (12) at the shaft end. (For details, see "Table of fuel, coolant and lubricants".).
D155A-6
7
SEN03371-03
4)
Use bolts (12a) (2 pieces) to install washer (12) to the track frame. Tool: Torque wrench (socket) Bolt (12a): M16 with width across flats of 24 mm 3 Bolt (12a): 235 to 285 Nm {23.5 to 29.5 kgm}
5.
Connect hoses (8), (9), (10), and (11) to cover (7). a Check that there is no dirt, dust, and moisture inside the hose. Tool: Torque wrench (spanner) Hoses (8), (9), (10), and (11): Width across flats of 27 mm, #04 size 3 Hoses (8), (9), (10), and (11): 84 to 132 Nm {8.5 to 13.5 kgm}
6.
Use bolts (7a) (6 pieces) to install cover (7). Tool: Torque wrench (socket) Bolts (7a): M16 with width across flats of 24 mm 3 Bolt (7a): 235 to 285 Nm {23.5 to 29.5 kgm} Use bolts (5a) (4 pieces) and (6a) (4 pieces) to install guards (5) and (6), respectively. Tool: Torque wrench (socket)
7.
50 Disassembly and assembly
4
Guard (6): 25 kg
Bolts (5a) and (6a): M20 with width across flats of 30 mm 3 Bolts (5a) and (6a): 455 to 565 Nm {46.5 to 58 kgm} 8.
Install coupling pin (4) between the equalizer bar and track frame. a The pin is hard to install if the hole of the equalizer bar is not aligned with that of the track frame. Be sure to install the pin while adjusting lifting height of the track frame. When the track frame assembly on the opposite side is raised off the ground, be sure to support it using blocks or the like before installing the pin. 9. Use 2 bolts (3a) to install lock plate (3). Tool: Torque wrench (socket) Bolt (3a): M16 with width across flats of 24 mm 3 Bolt (3a): 235 to 285 Nm {23.5 to 29.5 kgm} 10. Use bolts (1) (2 pieces) to install cover (2). 2 Threaded part of bolt (1): Adhesive (LT-2) Tool: Torque wrench (socket) Bolt (1): M24 with width across flats of 36 mm 3 Bolt (1): 785 to 980 Nm {80 to 100 kgm} 11. Supply grease through grease nipple (20). 2 Pin: Grease (G2-LI)
8
D155A-6
50 Disassembly and assembly
SEN03371-03
12. Remove blocking tools [1] and [3] according to the following procedure. 1) Set hydraulic jack [2] under the equalizer bar at its center to raise the front of the machine off the ground, and remove blocking tools [3]. Tool: Hydraulic jack k The work to remove the blocking tool is very dangerous. Be sure to perform the work by 2 persons. a Be sure to use the drawing hook attached to the engine undercover when raising the machine using a crane. Tool: Eyebolt, wire 4 Weight of front part of machine: Approximately 25 tons 2)
Use jacks, a crane, or the ripper to raise the rear of the machine, and remove blocking tools [1]. a When raising the machine using a crane Tool: Eyebolt, wire 4 Weight of rear part of machine: Approximately 25 tons k The work to remove the blocking tool is very dangerous. Be sure to perform the work by 2 persons. k Be sure to leave jacks [2] and the ripper set as auxiliary safety measures until blocking tools [1] and [3] are removed.
13. Remove tool KK (bracket for locking bogie).
14. Refilling with oil (pivot chamber) a Add specified amount of oil to the pivot chamber through oil filler port (21). 5
Engine oil: Approximately 9 l (For details, see "Table of fuel, coolant and lubricants")
15. Install the track shoe assembly. For details, see "Separation and connection of track shoe assembly". 16. Install the blade assembly. For details, see "Removal and installation of blade assembly".
D155A-6
9
SEN03371-03
50 Disassembly and assembly
Removal and installation of idler assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially 30 mm available)
1
2
Socket wrench
(Commercially 32 mm available)
1
3
Torque wrench (socket)
(Commercially 455 to 565 Nm, available) 662 to 829 Nm
1
4
Wire
(Commercially available)
2
Remarks
(460 kg)
k Place the machine on level ground, and apply the parking brake.
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 remove the key. k Leave the negative (-) terminal of the battery disconnected. k Do not stand in front of the idler for safety reasons.
Removal 1. 2. 3.
Remove blade assembly. For details, see "Removal and installation of blade assembly". Spread track shoe assembly. For detail, see "Separation and connection of track shoe assembly". Remove seat support bolt (1), and remove plate (2) and shims (3). a Be sure to remove respective ones installed inside and outside of the machine body. Tools: Socket wrench Bolts: Width across flats 21 mm, M16
4.
Loosen support mounting bolts (4), and remove shim (5). a Be sure to remove both installed inside and outside of the machine body. Tools: Socket wrench Bolts (4): Width across flats 32 mm, M22
5.
Remove bolts (6) (4 pieces) to disconnect idler (7) from yoke (8). Tools: Socket wrench Bolts (6): Width across flats 30mm, M20 Pass the lifting tool through the through-hole in idler assembly (7) to sling the idler assembly, and pull the idler assembly forward to remove it.
6.
4
7.
10
Idler assembly: 460 kg
Remove guide plates (10) (1 piece each on the inside and outside) from the support (9).
D155A-6
50 Disassembly and assembly a
8.
SEN03371-03
Remove the guide plate on the inside of the machine body in the same way.
Remove tension springs (11) (2 pieces each on the inside and outside) and spring seats (12) (2 pieces each on the inside and outside) from the support. a These parts are installed between support and track frame.
D155A-6
11
SEN03371-03
50 Disassembly and assembly
Installation 1.
Attach the lifting tool to the through-hole to sling idler assembly (7), and set it to its installed position. Tool: Wire 4
2.
3.
4. 5.
Idler assembly: 460 kg
Install spring seats (12) (2 pieces each on the inside and outside) and tension springs (11) (2 pieces each on the inside and outside) to the support. a These parts are installed between support and track frame. Install guide plates (10) (1 piece on each side) to the support (9). a Install the guide plate on the inside of the machine body in the same way. Sling idler assembly (7), and thrust the assembly backward. a Perform the same procedure for the idler on the opposite side. Use bolts (6) (4 pieces) to connect idler (7) to yoke (8). Tools: Torque wrench (Socket) Bolts (6): Width across flats 30 mm, M20 3 Bolts (6): 455 to 565 Nm{46.5 to 58 kgm}
6.
Install shim (5), and install mounting bolt (4). a Standard thickness (Ts): 6.5 mm a Set clearance (Tc): 2.0 to 3.4 mm (Including endplay) a Endplay (Ep): 0.49 to 0.72 mm (Total of both side) a Adjust both on the inside and outside. Tools: Torque wrench (Socket) Bolts (4): Width across flats 32 mm, M22 3 Mounting bolt (4): 662 to 829 Nm {67.5 to 84.5 kgm}
7.
Install plate (2) and shims (3), and install seat support bolt (1). a Standard thickness (Upper) (Tu): 8 mm a Standard thickness (Lower) (Te): 4 mm a For both inside and outside. Install track shoe assembly. For details, see "Separation and connection of track shoe assembly". Install blade assembly. For details, see "Removal and installation of blade assembly".
8. 9.
12
D155A-6
50 Disassembly and assembly
SEN03371-03
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
19 mm
1
2
Socket wrench
(Commercially available)
24 mm
1
3
Socket wrench
(Commercially available)
36 mm
1
4
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 235 to 385 Nm, 824 to 1030 Nm
5
Wire
(Commercially available)
1
(350 kg)
6
Chain
Commercially available
1
(350 kg)
As needed
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
13
SEN03371-03
50 Disassembly and assembly
Removal 1.
Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly". k Do not stand in front of the idler for safety reasons.
2.
Remove bolts (1a) (4 pieces each) to remove side cover (1). a Be sure to remove respective ones installed on the inside and outside of the machine body. Tool: Socket wrench Bolt (1a): M16 with width across flats of 24 mm
3.
Remove bolts (2a) (8 pieces) to remove the shim pack, and remove support (2). a Be sure to note the number of shims installed by thickness. a Be sure to remove respective ones installed inside and outside of the machine body. Tool: Socket wrench Bolt (2a): M16 with width across flats of 24 mm
4.
Loosen guide tension bolts (3) (4 pieces) (2 pieces on each side). a Be sure to remove respective ones installed on the inside and outside of the machine body. Tool: Socket wrench Bolt (3): M12 with width across flats of 19 mm
5.
Remove bolts (4) (4 pieces) to disconnect idler support (9) from yoke (10) on both sides (on the inside and outside of the machine body) Tool: Socket wrench Bolt (4): M24 with width across flats of 36 mm
14
D155A-6
50 Disassembly and assembly
6.
Pass the lifting tool through the through-hole in idler assembly (5) to sling the idler assembly, and pull the idler assembly forward to remove it. Tool: Chain, wire 4
7.
SEN03371-03
Idler assembly (5): 350 kg
Remove plate assemblies (6) (1 piece each on the inside and outside), tension springs (7) (2 pieces each on the inside and outside), and spring seats (8) (2 pieces each on the inside and outside) from the track frame. a Note that the parts (6), (7), and (8) are installed between the support and track frame.
D155A-6
15
SEN03371-03
50 Disassembly and assembly
Installation 1.
Install spring seats (8) (2 pieces each on the inside and outside), tension springs (7) (2 pieces each on the inside and outside), and plate assemblies (6) (1 piece each on the inside and outside) to the track frame.
2.
Attach the lifting tool to idler assembly (5), sling the assembly, and thrust the assembly into the track frame to install. Tool: Chain, wire 4
3.
16
Idler assembly (5): 350 kg
Use bolts (4) (4 pieces) to connect idler support (9) to yoke (10) on both sides (on the inside and outside of the machine body. Tool: Torque wrench (socket) Bolt (4): M24 with width across flats of 36 mm 3 Bolt (4): 824 to 1030 Nm {84 to 105 kgm}
D155A-6
50 Disassembly and assembly
4.
Tighten guide tension bolts (3) (4 pieces) (2 pieces on each side). a Be sure to tighten 2 bolts each on the inside and outside of the machine body. Tool: Torque wrench (socket) Bolt (3): M12 with width across flats of 19 mm 3 Bolt (3): 98 to 123 Nm {10 to 12.5 kgm}
5.
Install the shim pack to each support (2) on the inside and outside of the machine body, and use bolts (2a) (8 pieces) to install the support. a Be sure to install the same number and same thickness of shims as those noted at removal. a Set the idler assembly at the center of the track frame, and perform shim adjustment of clearance (a) between the track frame and guide plate. q Standard clearance (a): 0.5 to 1.0 mm q Standard thickness of shim pack: 6 mm Tool: Torque wrench (socket) Bolt (2a): M16 with width across flats of 24 mm 3 Bolt (2a): 235 to 285 Nm {23.5 to 29.5 kgm}
6.
Use bolts (1a) (4 pieces each) to install side cover (1). a Be sure to install respective ones on the inside and outside of the machine body. Tool: Torque wrench (socket) Bolt (1a): M16 with width across flats of 24 mm 3 Bolt (1a): 235 to 285 Nm {23.5 to 29.5 kgm} Install the track shoe assembly. For details, see "Separation and connection of track shoe assembly". k Do not stand in front of the idler for safety reasons.
7.
D155A-6
SEN03371-03
17
SEN03371-03
50 Disassembly and assembly
Disassembly and assembly of idler assembly
1
Special tools Symbol
1 L
Part No.
Part name
Necessity
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
01643-31445
Washer
t
2
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Hydraulic pump
t
1
2
791-651-1510
Installer
t
1
3
791-601-1000
Oil pump
t
1
New/ Remodel
Sketch
Disassembly 1.
Remove the oil drain plug to drain the oil.
2.
6 Idler: Approx. 390 to 450 cc Set idler assembly (1) to blocks [1].
3. 4.
4 Idler assembly: 500 kg Remove nut (2) and pull out bolt (3). Lift off support assembly (4).
5. 6. 7.
4 Support assembly: 100kg Remove floating seal (5a) from bushing (6). Remove floating seal (5b) from support assembly (4). Remove 6 pieces of bolts (7) from bushing (6).
18
D155A-6
50 Disassembly and assembly
8.
SEN03371-03
Reverse the idler assembly (1) and set it to blocks [1].
4 Idler assembly: 400kg 9. Remove nut (8) and pull out bolt (9). 10. Lift off support assembly (10). 4 Support assembly: 100kg 11. Remove floating seal (11a) from bushing (12). 12. Remove floating seal (11b) from support assembly (10). 13. Remove 6 pieces of bolts (13) from bushing (12).
14. Using tool L1, remove shaft (14) and bushing (12). 15. Remove bushing (12) from shaft (14). a Do not remove inner bushing from outer bushing.
16. Reverse the idler assembly (1) and set it to blocks [1]. 17. Using push tool [2] and tool L1, remove bushing (6). a Do not remove inner bushing from outer bushing.
D155A-6
19
SEN03371-03
50 Disassembly and assembly
Assembly a
Clean all the parts thoroughly and check them for dirt or damage.
1. 2.
Set idler (1) to blocks [1]. Using plate [3] and tool L1, press fit bushing (12). a Bushing (12) is supplied with a set inner bushing and outer bushing.
3.
Tighten 6 pieces of bolts (13) to bushing (12).
4. 5.
Reverse the idler assembly (1) and set it to blocks [1]. Using tool L1, press fit shaft (14) and bushing (6).
6. 7.
Tighten 6 pieces of bolts (7) to bushing (6). Using tool L2, install floating seal (5a) to bushing (6).
8.
Using tool L2, install floating seal (5b) to support assembly (4).
20
D155A-6
50 Disassembly and assembly
SEN03371-03
9. Assemble support assembly (4) to idler assembly (1). 10. Install bolt (3) and tighten nut (2).
11. Reverse the idler assembly (1) and set it to blocks [1]. 12. Assemble floating seal (11a), (11b) and support assembly (10) to idler assembly (1) as a same procedure step 7 to step 10. 13. Using tool L3, add oil to the specified level and tighten the plug. 5
D155A-6
Idler: 390 to 450 cc (GO140B)
21
SEN03371-03
50 Disassembly and assembly
Removal and installation of recoil spring assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Eyebolt
(Commercially available)
2
Wire
(Commercially available)
1
(510 kg)
3
Chain
Commercially available
1
(510 kg)
M24
1
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.
22
D155A-6
50 Disassembly and assembly
SEN03371-03
Removal 1.
Remove the idler assembly. For details, see "Removal and installation of idler assembly".
2.
Sling recoil spring assembly (1), and pull and remove it forward. a Set an eyebolt to the bolt hole in yoke (2) to sling the assembly, and pull the assembly forward to a position where you can wrap a wire around the recoil spring case. a Wrap a wire around the spring case, and remove the assembly using 2-point lifting. Tool: Eyebolt (M24), wire, chain 4
D155A-6
Recoil spring assembly: 510 kg
23
SEN03371-03
50 Disassembly and assembly
Installation 1.
Sling recoil spring assembly (1), and thrust the assembly backward to its installed position to install the assembly. a For lifting points, set an eyebolt to the bolt hole in yoke (2) to sling the assembly. In addition, wrap a wire rope around the recoil spring case to sling the assembly while balancing the assembly. Tool: Eyebolt (M24), wire, chain 4
2.
24
Recoil spring assembly: 510 kg
Install the idler assembly. For details, see "Removal and installation of idler assembly".
D155A-6
50 Disassembly and assembly
SEN03371-03
Disassembly and assembly of recoil spring assembly
1
Special tools Symbol
M
2
Part No.
Part name
Necessity
Q'ty
791-685-8006
Compressor
t
1
791-635-3160
Extension
t
1
791T-630-2610
Spacer
t
1
790-101-1300
Cylinder
t
1
790-101-1102
Hydraulic pump
t
1
New/ Remodel
Sketch
Q
Disassembly 1.
Remove yoke and piston assembly (2) from recoil spring assembly (1).
2.
Disassembly of yoke and piston assembly 1) Remove snap ring (3), packing (4) and ring (5). 2) Remove bolt (6) and plate (7).
3)
Using push tool [1], pull out piston (9) from yoke (8) with a press.
q
D155A-6
If cylinder (10) has not been broken and shaft end nut (11) has not come off, disassemble according to the following procedure.
25
SEN03371-03
3.
Remove holder (13) from recoil spring case (12). k Never stand in front of or at the rear of the recoil spring assembly to avoid danger.
4.
Disassembly of holder 1) Remove cover (15) from holder (14). 2) Remove seal (16) and bushing (17) from holder (14).
5.
Remove the lock plate from cylinder (10) and remove lubricator (18).
6.
Set recoil spring assembly (1) to tool M2. k Set the spring securely since its installed load is heavy and dangerous. a Installed load of spring: 314 kN {32,000 kg}
7.
Apply hydraulic pressure gradually to tool M2 to compress the spring and tighten nut (11) until spacer (19) comes off and then remove the spacer. Remove nut (11) and release the hydraulic oil gradually to release the spring tension.
8.
26
50 Disassembly and assembly
D155A-6
50 Disassembly and assembly
SEN03371-03
9.
Remove recoil spring (20) and cylinder (10) from recoil spring case (12). 10. Remove bushing (21) from cylinder (10). 11. Remove seal (22) and bushing (23) from recoil spring case (12).
If cylinder (10) has been broken or shaft end nut (11) has come off and the mounting bolt of holder (13) is removed, recoil spring (20) will jump out forward. In this case, disassemble according to the following procedure. k Never stand in front of or at the rear of the recoil spring assembly to avoid danger until holder (13) and recoil spring case (12) are separated and the recoil spring is taken out and safety is confirmed.
q
1)
2)
3) 4)
D155A-6
Set recoil spring assembly (1) to tool M2. k Set the spring securely since its installed load is heavy and dangerous. a Installed load of spring: 314 kN {32,000 kg} Apply hydraulic oil gradually and fix recoil spring assembly (1).
Remove the mounting bolts of holder (13). Release the hydraulic oil gradually to release the spring tension.
27
SEN03371-03
50 Disassembly and assembly
Assembly 1. 2.
Using the push tool, press fit bushing (23) to recoil spring case (12) and install seal (22). 2 Bushing: Grease (G2-LI) Using the push tool, press fit bushing (21) to cylinder (10). 2 Bushing: Grease (G2-LI)
3.
Temporarily install recoil spring (20) and cylinder (10) to recoil spring case (12) and set them to tool M2. 2 Inside of case and parts in case: Grease (Apply G2-LI to minimum thickness of 3 mm) k Set the spring securely since its installed load is heavy and dangerous. a Installed load of spring: 314 kN {32,000 kg} a When compressing the spring, align it by using lever block [2] etc. so that the threaded part will not be damaged. a Installed length of spring: 656 mm
4.
Install nut (11) and spacer (19). a Eliminate the clearance between the nut and spacer. (Reference) If there is any clearance, the spring load is applied to the threaded part of the nut. The nut may be damaged and may not be able to be disassembled next time.
5.
Release the hydraulic pressure gradually to release the spring tension completely and then remove recoil spring assembly (1) from tool M2.
6.
Install lubricator (18) to cylinder (10) and install the lock plate. a Install the grease fitting at 45° ± 5° out.
28
D155A-6
50 Disassembly and assembly
7.
Assembly of holder 1) Using the push tool, press fit bushing (17) to holder (14) and install seal (16). 2 Bushing and oil seal: Grease (G2-LI) 2) Install cover (15) to holder (14).
8.
Install holder (13) to recoil spring case (12). 2 Mating faces of holder and case: Grease (G2-LI)
9.
Assembly of yoke and piston assembly 1) Using the push tool and press, press fit piston (9) to yoke (8). q Yoke press fitting force: 392 kN {40 ton}
2) 3)
SEN03371-03
Install plate (7) and tighten bolt (6). a Check that the plate is not on the yoke. Install ring (5), packing (4) and snap ring (3). 2 Packing and ring: Grease (G2-LI)
10. Install yoke and piston assembly (2) to recoil spring assembly (1).
D155A-6
29
SEN03371-03
50 Disassembly and assembly
Removal and installation of track roller assembly
1
Standard tools The described tool is a reference. If it has a purpose, it can be used other than the described tool. No.
Part name
Part No
Specification
Q'ty
Remarks
1
Socket wrench
(Commercially available)
30 mm
1
2
Socket wrench
(Commercially available)
36 mm
1
3
Torque wrench (socket)
(Commercially available)
455 to 565 Nm, 785 to 980 Nm
1
4
Chain
(Commercially available)
2
(3,960 kg)
5
Wire
(Commercially available)
2
(115 kg), (125 kg), (145 kg), (3960 kg)
6
Lever block
(Commercially available)
2
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.
30
D155A-6
50 Disassembly and assembly
SEN03371-03
Removal 1. 2.
Remove track frame assembly. For details, see "Removal and installation of track frame". Reverse the track frame assembly (1). Tools: Chain, wire, lever block 4
3.
4.
5.
Remove 2 mounting bolts (2) and retainer (3). Tool: Socket wrench Bolts (2): Width across flats 30 mm, M20 q Each inside and outside Remove bolts (4) (4 pieces) and guard (5). Tool: Socket wrench Bolts (4): Width across flats 30 mm, M20 q Each inside and outside Remove bolts (6) (21 pieces) and guard (7). Tool: Socket wrench, wire Bolts (6): Width across flats 36 mm, M24 4
6.
Track frame assembly: 3,960 kg
Track roller guard (7): 145 kg
Remove bolts (8) (4 pieces) and lift off track roller assembly (9). Tools: Socket wrench, wire Bolts (8): Width across flats 36 mm, M24 4
Track roller (single flange): 115 kg
4
Track roller (double flange): 125 kg
D155A-6
31
SEN03371-03
50 Disassembly and assembly
Installation 1.
2.
Install track roller assembly (9) with mounting bolts (8) (4 pieces). Tools: Torque wrench (socket), Wire Bolts (8): Width across flats 36 mm, M24 3 Bolts (8): 785 to 980 Nm {80 to 100 kgm} 2 Track roller mounting bolt: Adhesive (LT-2) 4
Track roller (single flange): 115 kg
4
Track roller (double flange): 125 kg
Install guard (7) with bolts (6) (21 pieces). Tools: Torque wrench (socket), wire Bolts (6): Width across flats 36 mm, M24 4
Track roller guard (7): 145 kg
3 Bolts (6): 785 to 980 Nm {80 to 100 kgm}
3.
4.
5.
2 Guard mounting bolt: Adhesive (LT-2) Install guard (5) with bolts (4) (4 pieces). Tool: Torque wrench (socket) Bolts (4): Width across flats 30 mm, M20 3 Bolts (4): 455 to 565 Nm {46.5 to 58 kgm} 2 Guard mounting bolt: Adhesive (LT-2) q Each inside and outside Install retainer (3) with bolts (2) (2 pieces). Tool: Torque wrench (socket) Bolts (2): Width across flat 30 mm, M20 3 Bolts (2): 455 to 565 Nm {46.5 to 58 kgm} 2 Retainer mounting bolt: Adhesive (LT-2) q Each inside and outside Reverse the track frame assembly (1). Tools: Chain, wire, lever block 4
6.
32
Track frame assembly: 3,960 kg
Install track frame assembly. For details, see "Removal and installation of track frame".
D155A-6
50 Disassembly and assembly
SEN03371-03
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
32 mm
1
2
Socket wrench
(Commercially available)
46 mm
1
3
Torque wrench (socket)
(Commercially available)
662 to 829 Nm
1
4
Wire
(Commercially available)
1
Remarks
(110 kg)
Special tools list Symbol
Part name Bracket
KK
Part No.
Specifications
Q'ty
791T-130-1010
6
Bolt
01010-63060
12
Washer
01643-33080
12
Remarks For locking bogie
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
33
SEN03371-03
50 Disassembly and assembly
Removal 1.
Release track tension. For details, see "Separation and connection of track shoe assembly". Install tool KK (bracket for locking bogie) to lock bogie (1) using a bolt hole in track frame (4) and that in bogie (1).
2.
Install tool KK (bracket) to bogie assembly (1). Tool: Bracket for locking bogie (KK), socket wrench a Referring to the table shown below, lock bogie assemblies that track roller assembly (2) to be removed is associated with. Track roller assembly to be removed
Bogie assembly to be locked using tool Bogie in which track roller is housed
Associated bogie
1st roller
(*1)
2nd bogie
2nd roller
2nd bogie
1st bogie
3rd roller
2nd bogie
3rd bogie
4th roller
3rd bogie
2nd bogie
5th roller
3rd bogie
4th bogie
6th roller
4th bogie
3rd bogie
7th roller
4th bogie
-
*1: Use a lever block or the like to sling 1st bogie assembly (1) to lock. The locking tool cannot be attached to the 1st bogie assembly. 3.
4.
5. 6.
7.
34
Operate the blade and ripper to raise the machine to a height where track roller assembly (2) detaches from track shoes. a When operating the blade and ripper, be sure to reduce the engine speed and operate them slowly. Loosen mounting bolts (3a) (4 pieces) of roller cap (3) approximately 20 mm. a Be sure to loosen those on the inside and outside of the machine. a Do not remove mounting bolts. Tool: Socket wrench Bolt (3a): M22 with width across flats of 32 mm Hit the end face of the track roller shaft with a plastic hammer to make the dowel pin of the shaft separate from the bogie. Operate the blade and ripper to lower the machine to the ground. a When operating the blade and ripper, be sure to reduce the engine speed and operate them slowly. Remove bolts (3a) (4 pieces) to remove roller cap (3). Tool: Socket wrench Bolt (3a): M22 with width across flats of 32 mm a Take care not to damage dowel pin (4) installed in it.
D155A-6
50 Disassembly and assembly
8.
9.
SEN03371-03
Operate the blade and ripper to raise the machine off the ground at a height where track roller assembly (2) detaches from the bogie. k Set respective blocking tools and blocks under the bottom of the frame at its front and rear parts so that the machine will not lower. Pull out track roller assembly (2) outward. a Tie a wire to the roller and pull it out outward. Tool: Wire 4
Track roller assembly (single flange): 95 kg
4
Track roller assembly (double flange): 110 kg
D155A-6
35
SEN03371-03
50 Disassembly and assembly
Installation 1.
2.
Operate the blade and ripper to raise the machine off the ground to a height where track roller assembly (2) detaches from the bogie. a When operating the blade and ripper, be sure to reduce the engine speed and operate them slowly. Install track roller assembly (2) according to the following procedure. 1) Sling track frame assembly (2) and set the assembly on the track link at its installed position. a Be sure to set the track roller assembly with its oil filler port facing outside of the machine. Tool: Wire 4 Track roller assembly (single flange): 95 kg 4 Track roller assembly (double flange): 110 kg Configuration of rollers to be installed by type for track roller assembly (2) (S): Track roller assembly (single flange) (D): Track roller assembly (double flange)
2)
3)
3.
4. 5.
36
Operate the blade and ripper to lower the machine to a height where roller cap bolts can be installed, and use roller cap bolts (3a) (4 pieces) to install roller cap (3) loosely. Tool: Socket wrench 2 Bolt (3a): Adhesive (LT-2) Bolt (3a): M22 with width across flats of 32 mm Align dowel pin (4) with the dowel hole in track roller (3), and then tighten roller cap bolts (3a) a Take care not to break the dowel pin. Tool: Torque wrench (socket) Bolt (3a): M22 with width across flats of 32 mm 3 Bolt (3a): 662 to 829 Nm {67.5 to 84.5 kgm}
Operate the blade and ripper to lower the machine to the ground. a When operating the blade and ripper, be sure to reduce the engine speed and operate them slowly. Remove tool KK (bracket) from bogie assembly (1). Adjust track tension. For details, see "Separation and connection of track shoe assembly".
D155A-6
50 Disassembly and assembly
SEN03371-03
Disassembly and assembly of track roller assembly
1
Special tools Symbol L
2
Part No. 791-651-1510
Part name
Necessity
Q'ty
t
1
Installer
New/ Remodel
Sketch
Disassembly 1. 2. 3. 4. 5.
Remove plug and drain oil. Remove ring (1), then remove collar (2). a Remove collar (5) same as collar (2). Remove floating seal (3a) from bushing (4). Remove floating seal (3b) from collar (2). Remove floating seal (6a), (6b) same as procedure 3 and 4.
6.
Remove 6 bolts (7) from track roller (8).
7. Reverse track roller assembly (8) and set to press. 8. Remove 6 bolts (9). 9. Using press, push out shaft (10) and bushing (4). 10. Remove bushing (11) from shaft (10). a Do not separate inner bushing and outer bushing. [*1]
11. Reverse track roller assembly (8) and set to press. 12. Using push tool [1], push out bushing (11). a Do not separate inner bushing and outer bushing. [*2]
D155A-6
37
SEN03371-03
50 Disassembly and assembly
Assembly 1. 2. 3. 4.
Set track roller assembly (8) to press. Set bushing (4) to track roller (8) with o-ring. Using plate [2], press fit bushing (4) to track roller (8). Fix bushing(4) with 6 mounting bolts. 2 Mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Mounting bolt: 1st step: 735 ± 10 Nm {74 ± 1kgm} 2nd step(angle tightning): 90 ± 5°
5. 6.
Reverse track roller assembly (8) and set to block [3]. Sling shaft (10) and install it to bushing (4). a Do not damage inside of bushing.
7. 8. 9.
Set bushing (11) to track roller assembly with o-ring. Using push tool [4], press fit bushin (11). Fix bushing (11) with 6 bolts. 2 Mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Mounting bolt: 1st step: 735 ± 10 Nm {74 ± 1kgm} 2nd step(angle tightning): 90 ± 5°
10. Using tool L2, assemble floating seal (3a) to bushing (4). a Before installing the floating seal, roughly clean, degrease and dry the O-ring and floating seal contact surface (hatched areas). Take care that dirt will not stick to the floating seal contact surface. a After inserting the floating seal, check that Its tilt is 1 mm or less and projection (a) of the seal is 7 –11 mm.
11. Using tool L2, assemble floating seal (3a) to collar (9).
38
D155A-6
50 Disassembly and assembly
SEN03371-03
Removal and installation of 1st bogie assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
17 mm
1
2
Socket wrench
(Commercially available)
32 mm
1
3
Socket wrench
(Commercially available)
36 mm
1
4
Socket
(Commercially available)
46 mm
1
5
Torque wrench (socket)
(Commercially available)
59 to 74 Nm, 662 to 829 Nm, 785 to 980 Nm
6
Spacer
(Commercially available)
1
[1]
7
Wire
(Commercially available)
2
(60 kg), (95 kg), (220 kg)
8
Lever block
(Commercially available)
1
9
Lifting and lowering device
(Commercially available)
1
D155A-6
As needed
(220 kg)
39
SEN03371-03
50 Disassembly and assembly
Special tools list Symbol
Part name Bracket
14 Bolt
Part No.
Specifications
Q'ty
791T-130-1010
2
01010-63060
4
Washer
01643-33080
4
Spacer
791-630-1360
1
Block
790-101-2310
1
Plate
790-101-2360
2
15 Screw
790-445-4130
2
Nut
791-112-1180
2
Puller (490 kN {50 ton})
790-101-4000
1
Pump
790-101-1102
1
Spacer
790-201-2760
1
Adapter
791-630-1370
1
Screw
790-434-1060
2
01580-13024
2
16 Nut
Remarks Locking of bogie
Removal of shaft and ring
Installation of floating seal
Washer
01643-33080
1
Puller (490 kN {50 ton})
790-101-4000
1
Pump
790-101-1102
1
17 Installer
796-230-1120
1
Installation of floating seal
19 Guide
791T-630-1390
1
Installation of cartridge pin
Block
790-101-2310
1
Screw
790-445-4130
2
Plate
796T-470-1130
1
20 Plate
790-101-2360
2
Nut
791-112-1180
2
Puller (490 kN {50 ton})
790-101-4000
1
Pump
790-101-1102
1
791-601-1000
1
Lifting tool
790-401-1700
1
Adapter
790-401-1761
1
L
21 Oil pump (seal checker)
22
Press fit of pin
Check of floating seal tightness and charging of oil Removal of track roller
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.
40
D155A-6
50 Disassembly and assembly
SEN03371-03
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. Tool: Socket wrench, wire, lever block, lifting and lowering device 4
Engine undercover (17): 220 kg
Bolt (17a): M24 with width across flats of 36 mm
2.
Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly".
3.
Lock the 2nd bogie assembly using tool L14 (bracket), and operate the blade and ripper to raise the machine to a height where track rollers housed in 2nd bogie assembly (1) detach from track links. a When operating the blade and ripper, be sure to reduce the engine speed and operate them slowly. k Set respective blocking tools and blocks under the bottom of the frame at its front and rear parts so that the machine will not lower. Tool: Special tool L14, socket wrench
4.
Use a wire to sling 1st bogie assembly (2) to prevent 1st bogie assembly (2) from lowering. Tool: Wire, lever block
5.
Loosen mounting bolts (16) (4 pieces) of roller cap (3) approximately 20 mm. Tool: Socket wrench Bolt (16): M22 with width across flats of 32 mm a Be sure to loosen those on the inside and outside of the machine. a When operating the blade and ripper, be sure to reduce the engine speed and operate them slowly. Hit the end face of shaft (4) with a plastic hammer to make the dowel pin of the shaft separate from the bogie.
6.
D155A-6
41
SEN03371-03
a
7.
50 Disassembly and assembly
Take care not to damage dowel pin (17) installed in it.
Use tool L22 (lifting tool) to sling track roller assembly (5). 4
Track roller assembly (5): 95 kg
Tool: Special tool L22, wire
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 balancing it.
9.
Remove bolts (6a) (3 pieces), and remove cover (6). a Be sure to remove respective covers (6) installed on the inside and outside of the machine body. Tool: Socket wrench Bolt (6a): M10 with width across flats of 17 mm
42
D155A-6
50 Disassembly and assembly
SEN03371-03
10. Removal of shaft and ring 1) Set tool L15 (forcing jig) to the track frame. Tool: Special tool L15 2) Push out shaft (7) using tool L15 (pushing tool) to press out shaft (7) and ring (8) to the opposite side. q Pushing force (reference): 216 to 402 kN {22 to 41 tons}
3)
4)
Remove respective floating seals (9) from end faces of rings (8) and (10). a When the floating seal is to be reused, carefully remove and keep it so that it will not be damaged. Remove tool L15 (push jig).
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}
6) 7)
Remove spacer (12). Remove spacer (13) and floating seal (14) installed between rings (10) and (11). a When the floating seal is to be reused, carefully remove and keep it so that it will not be damaged. Follow steps 1) to 7) to remove the shaft and rings on the opposite side.
8)
D155A-6
43
SEN03371-03
50 Disassembly and assembly
11. Sling 1st bogie (13) and pull it outward. 4
44
Bogie assembly: 60 kg
D155A-6
50 Disassembly and assembly
SEN03371-03
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)
2)
Use tool L17 (installer) to install respective floating seals (9) to rings (8) and (10), and install respective floating seals (14) to the opposite end face of ring (10) and ring (11). Tool: Special tool L17 a Before installing floating seals (9) and (14), be sure to clean, completely degrease and dry the Oring and contact surfaces (hatched area) of the floating seal. Take care that no dirt and dust stick to contact faces of floating seal (9) and (14).
a
3)
D155A-6
After inserting floating seals (9) and (14), check that the leaning of seal is less than 1 mm and protrusion (a) of seal is within the range of 3 to 5 mm.
Install spacer (12) and ring (10) to the assembly of shaft (7) and ring (8).
45
SEN03371-03
4)
Install spacer (13) to ring (10), and use spacer [1] to press-fit ring (11). Tool: Spacer [1] q Press fit force for ring (11): 3.9 to 48 kN {0.4 to 4.9 ton} 2 Between shaft (7) and ring (11): Molybdenum disulfide lubricant (LM-P)
5)
Use tool L21 (seal checker) to check airtightness of the floating seal. Tool: Special tool L21
6)
Use L21 (oil pump) to fill the cartridge pin assembly with specified amount of oil. Tool: Special tool L21 a Charging pressure: 0.49 MPa {5 kg/cm2} 5
2.
46
50 Disassembly and assembly
Cartridge pin assembly (81 to 95 % full amount): 50 to 60 cc (GO140)
Sling 1st bogie (13) and set it to its installed position. Tool: Wire a Be sure to sling 1st bogie (13) when setting it to its installed position.
D155A-6
50 Disassembly and assembly
3.
4. 5. 6.
SEN03371-03
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. Install the cartridge pin assembly to the mounting hole for the pin with arrow mark (b) on its end face up. Set tool L20 (press-fitting jig) to the track frame. Tool: Special tool L20 Install cover (6) to cartridge pin assembly (15), and use hydraulic puller of tool L20 to press-fit cartridge pin assembly (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}
7.
Follow steps 4. to 6. to press-fit the cartridge pin on the opposite side.
8.
Use bolts (6a) (3 pieces) to install covers (6) on the inside and outside. a 2 locations of inside and outside Tool: Torque wrench (socket) Bolt (6a): M10 with width across flats of 17 mm 3 Bolt (6a): 59 to 74 Nm {6 to 7.5 kgm}
9.
Use tool L22 (lifting tool) to sling and set track roller assembly (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, wire 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. Tool: Socket wrench Bolt (16): M22 with width across flats of 32 mm
D155A-6
47
SEN03371-03
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) Tool: Torque wrench (socket) Bolt (16): M22 with 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. Tool: Socket wrench 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 position. Tool: Wire, lever block, lifting and lowering device 4
Engine undercover: 220 kg
15. Use bolts (17a) (12 pieces) to install engine undercover (17). Tool: Torque wrench (socket) Bolt (17a): M24 with 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".
48
D155A-6
50 Disassembly and assembly
SEN03371-03
Removal and installation of 2nd, 3rd, and 4th bogie assemblies
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
17 mm
1
2
Socket wrench
(Commercially available)
36 mm
1
3
Socket
(Commercially available)
46 mm
1
4
Torque wrench (socket)
(Commercially available)
59 to 74 Nm, 785 to 980 Nm
5
Wire
(Commercially available)
2
(220 kg), (270 kg), (525 kg)
6
Spacer
(Commercially available)
1
[3]
7
Lever block
(Commercially available)
2
[4], [5]
8
Lifting and lowering device
(Commercially available)
1
(220 kg), (270 kg)
9
Hydraulic jack
(Commercially available)
3
[6], [8]
10
Blocking tool
(Commercially available)
2
For stand for machine body [7]
11
Block
(Commercially available)
110 mm to 160 mm (H) x 150 mm (W) x 700 mm (L)
1
[1]
12
Steel plate decking
(Commercially available)
16 mm (D) x 700 mm (W) x 700 mm (L)
1
[2]
D155A-6
30 ton
As needed
49
SEN03371-03
50 Disassembly and assembly
Special tools list Symbol
Part name Bracket
14 Bolt
Specifications
Q'ty
791T-130-1010
2
01010-63060
4
Washer
01643-33080
4
Spacer
791-630-1360
1
Block
790-101-2310
1
Plate
790-101-2360
2
15 Screw
790-445-4130
2
Nut
791-112-1180
2
Puller (490 kN {50 ton})
790-101-4000
1
Pump
790-101-1102
1
Spacer
790-201-2760
1
Adapter
791-630-1370
1
Screw
790-434-1060
2
01580-13024
2
16 Nut L
Part No.
Remarks Locking of bogie
Removal of shaft and ring
Removal of floating seal
Washer
01643-33080
1
Puller (490 kN {50 ton})
790-101-4000
1
Pump
790-101-1102
1
17 Installer
796-230-1120
1
Installation of floating seal
19 Guide
791T-630-1390
1
Installation of cartridge pin
Block
790-101-2310
Screw
790-445-4130
Plate
796T-470-1130
20 Plate
790-101-2360
Nut
791-112-1180
1
Puller (490 kN {50 ton})
790-101-4000
1
Pump
790-101-1102
1
791-601-1000
1
21 Oil pump (seal checker)
Press fit of cartridge pin
Check of floating seal tightness and charging of oil
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.
50
D155A-6
50 Disassembly and assembly
SEN03371-03
Removal 1. 2.
Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly". 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. Tool: Socket wrench, wire, lever block, lifting and lowering device 4
3.
Engine undercover (17): 220 kg
Bolt (17a): M24 with width across flats of 36 mm 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 supporting 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. Tool: Socket wrench, wire, lever block, lifting and lowering device 4
Power train undercover (18): 270 kg
Bolt (18a): M24 with width across flats of 36 mm 4. 5.
6.
7.
8.
Install tool L14 (bracket) to secure bogie assembly (1) to the track frame. Tool: Special tool L14, socket wrench Remove bolts (2a) (3 pieces), and remove cover (2). a Be sure to remove that on the opposite side. Tool: Socket wrench Bolt (2a): M10 with width across flats of 17 mm
Operate the blade and ripper to raise the machine to a height where the track roller detaches from track links. 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. Set steel plate decking [2] on the track shoes and block [1] a Set block [1] at the outside of the track shoes depending on the height of the track link so that steel plate decking [2] will not tilt. Slowly operate the blade and ripper to lower the machine until the track roller housed in bogie assembly (1) touches steel plate [2]. a When operating the blade and ripper, be sure to reduce the engine speed and operate them slowly.
D155A-6
51
SEN03371-03
9.
Removal of shaft and ring 1) Set tool L15 (forcing jig) to the track frame. Tool: Special tool L15
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}
3)
Remove respective floating seals (5) from end faces of rings (4) and (6). a When the floating seal is to be reused, carefully remove and keep it so that it will not be damaged. Remove tool L15 (push jig).
4)
52
50 Disassembly and assembly
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}
6)
Remove spacer (8).
7)
Remove spacer (9) and floating seal (10) installed between rings (6) and (7). a When the floating seal is to be reused, carefully remove and keep it so that it will not be damaged.
8)
Follow steps 1) to 6) to remove the shaft and rings on the opposite side of the bogie. D155A-6
50 Disassembly and assembly
SEN03371-03
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. Tool: Wire 4
D155A-6
Bogie assembly: 525 kg
53
SEN03371-03
50 Disassembly and assembly
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)
2)
Use tool L17 (installer) to install respective floating seals (5) to rings (4) and (6), and install respective floating seals (10) to the opposite end face of ring (6) and ring (7). Tool: Special tool L17 a Before installing floating seals (5) and (10), be sure to clean, completely degrease and dry the Oring and contact surfaces (hatched area) of floating seals (5) and (10). Take care that no dirt and dust stick to contact faces of floating seals (5) and (10).
a
3)
54
After inserting floating seals (5) and (10), check that the leaning of seal is less than 1 mm and protrusion (a) of seal is within the range of 3 to 5 mm.
Install spacer (8) and ring (6) to the assembly of shaft (3) and ring (4).
D155A-6
50 Disassembly and assembly
2.
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)
5)
Use tool L21 (seal checker) to check airtightness of the floating seal.
Use L21 (oil pump) to fill the cartridge pin assembly with specified amount of oil. Tool: Special tool L21 5
q
3. 4. 5.
6.
SEN03371-03
Cartridge pin assembly (81 to 95 % full amount): 50 to 60 cc (GO140)
Charging pressure: 0.49 MPa {5 kg/cm2}
Sling bogie assembly (1) and lower the assembly onto block [1] and steel plate decking [2]. Tool: Blocks [1], steel plate decking [2], wire 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], wire 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.
Procedure for aligning mounting holes for cartridge pin 1) Operate the blade and ripper to raise the machine off the ground. a When operating the blade and ripper, be sure to reduce the engine speed and operate them slowly. 2) Set block [5] and hydraulic jack [6] at the rear (d) (each side) of the machine. a Be sure to set the hydraulic jack extended fully. Tool: Block [5], hydraulic jack [6]
D155A-6
55
SEN03371-03
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 jacks [6] and [8], special tool L14, socket wrench
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 mounting hole position for the pin, or apply a hydraulic jack to the bogie assembly and adjust the mounting hole position for the pin. Put tool L19 (guide) into the hole for the pin. Tool: Special tool L19
6)
56
50 Disassembly and assembly
D155A-6
50 Disassembly and assembly
SEN03371-03
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 L20 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 Tool: Torque wrench (socket) Bolt (2a): M10 with width across flats of 17 mm 3 Bolt (2a): 59 to 74 Nm {6 to 7.5 kgm} 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. Tool: Wire, lever block, lifting and lowering device 4
Power train undercover: 270 kg
15. Use bolts (18a) (10 pieces) to install power train undercover (18). Tool: Torque wrench (socket) Bolt (18a): M24 with width across flats of 36 mm 3 Bolt (18a): 785 to 980 Nm {80 to 100 kgm} 16. Sling engine undercover (17) and set it to its installed position. a Follow this step when it has been removed. Tool: Wire, lever block, lifting and lowering device 4
Engine undercover: 220 kg
17. Use bolts (17a) (12 pieces) to install engine undercover (17). Tool: Torque wrench (socket) Bolt (17a): M24 with width across flats of 36 mm 3 Bolt (17a): 785 to 980 Nm {80 to 100 kgm} 18. Adjust the track tension. For details, see Testing and adjusting, "Testing and adjusting track tension". D155A-6
57
SEN03371-03
50 Disassembly and assembly
Disassembly and assembly of bogie assembly
1
Special tools Symbol
Q
Part No.
20
21
Part name
Necessity
Q'ty
790-101-2310
Block
t
1
790-445-4130
Screw
t
2
796T-470-1130
Plate
t
1
790-101-2360
Plate
t
2
791-112-1180
Nut
t
2
790-101-4000
Puller (490 kN {50 ton})
t
1
790-101-1102
Pump
t
1
791-601-1000
Oil pump
t
1
New/ Remodel
Sketch
Q
Disassembly 1.
Track roller assembly 1) Reverse bogie assembly (1). 2) Remove the roller cap and lift off 2 track roller assemblies (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. 3.
4.
58
Cover Remove cover (3). Cartridge pin assembly Remove cartridge pin assembly (4) according to the procedure in "Removal and installation of bogie assembly".
Bogies Disconnect inner bogie (5) and outer bogie (6).
D155A-6
50 Disassembly and assembly
SEN03371-03
Assembly 1.
2. 3.
Assembly of cartridge pin assembly Assemble cartridge pin assembly (4) according to the procedure in "Removal and installation of bogie assembly". Bogies Set outer bogie (6) and inner bogie (5). Cartridge pin assembly 1) Set tool Q20.
2)
4.
Press fit cartridge pin assembly (4). a Push in the cartridge pin assembly with cover (3). a Set arrow (a) at the end face of the cartridge pin a s s e m b l y u p ( i n t h e i n s ta l l e d s ta te o n t h e machine). a Push in the cartridge pin assembly to machined surface of the bogie. 2 Outside of pin: Molybdenum disulfide grease (LM-P) a Press fitting force of cartridge pin assembly: 215.8 – 402.1 kN {22 – 41 ton}
Refilling with oil Using tool Q21, add oil to the cartridge pin assembly to the specified level. a Oil charge pressure: 0.49 MPa {5 kg/cm2} 5
5.
6.
7.
Cartridge pin assembly (81 – 95% of full level): 50 – 60 cc (GO140)
Cartridge pin assembly (Opposite side) Press fit the cartridge pin assembly on the opposite side according to steps 3 – 4. a After press fitting the cartridge pin assembly, adjust the inner bogie so that it will slide lightly. Cover Install covers (3). a Install the covers to 2 places of inside and outside.
Track roller assembly 1) Sling 2 track roller assemblies (2) and set them to the bogie. a Set the track roller assemblies so that their oil fillers will be directed out of the machine when the bogie assembly is installed. 4
2)
D155A-6
Track roller assembly (single flange): 95 kg 4 Track roller assembly (double flange): 105 kg Install the roller cap to each track roller assembly and tighten the mounting bolts.
59
SEN03371-03 a
50 Disassembly and assembly
Take care not to damage the installed dowel pin.
2 Roller cap mounting bolt: Adhesive (LT-2) 3 Roller cap mounting bolt:
662 – 829 Nm {67.5 – 84.5 kgm} 8.
60
Roller guide Set the roller guide (20) to the bogie assembly when removing and installing the roller guide, so that no clearance is left on the face (g).
D155A-6
50 Disassembly and assembly
SEN03371-03
Removal and installation of carrier roller assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
19 mm
1
2
Socket wrench
(Commercially available)
30 mm
1
3
Spanner
(Commercially available)
27 mm
1
4
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 455 to 565 Nm
5
Torque wrench (spanner)
(Commercially available)
6
Hydraulic jack
(Commercially available)
7
Rope
(Commercially available)
Remarks
As needed 1
10 ton
2
[1]
1
(45 kg)
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
61
SEN03371-03
50 Disassembly and assembly
Removal 1.
2.
3.
4.
5.
Remove bolts (5a) (2 pieces) to remove upper cover (5) of the track frame. Tool: Socket wrench Bolt (5a): M12 with width across flats of 19 mm Loosen lubricator (1) of the cylinder to discharge grease and decrease the track tension. k Because internal pressure of the recoil spring is extremely high, do not loosen lubricator (1) more than 1 turn. k If the grease does not come out sufficiently, move the machine backwards and forwards. Tool: Spanner wrench Lubricator (1): Width across flats of 27mm Set hydraulic jacks [1] at 2 locations before and after the carrier roller, and use them to raise track shoes until some clearance is provided between carrier roller (3) and track shoes. Tool: Hydraulic jack [1] Remove mounting bolts (2) (2 pieces). Tool: Socket wrench Bolt (2): M20 with width across flats of 30 mm
Pass rope [2] through the hole in the link, wrap the rope around carrier roller (3), and tighten the rope to keep pulling the carrier roller. Tool: Rope 4
6.
62
Carrier roller (3): 45 kg
Open the abutment joint of support (4) with a screwdriver, and use a pry bar between carrier roller (3) and support (4) to remove the carrier roller. Or tap carrier roller (3) using a hammer or the like to remove the roller. Tool: Screwdriver, bar, hammer
D155A-6
50 Disassembly and assembly
SEN03371-03
Installation 1.
Use hydraulic jacks to raise track shoes to provide clearance so that the carrier roller can be installed. Tool: Hydraulic jack [1]
2.
Pass rope [2] through the hole in the link, wrap the rope around carrier roller (3), and tighten rope [2] to pull up the carrier roller. Install carrier roller (3) to support (4) while positioning carrier roller (3) to the carrier roller installed position of support (4). Install carrier roller (3) to support (4) while positioning carrier roller (3) to the carrier roller installed position of support (4). Tool: Rope
3. 4.
4
Carrier roller: 45 kg
a
5.
6. 7.
8.
9.
When installing carrier roller (3) to support (4), be sure to provide clearance so that dimension (a) shown in the figure will be as follows. q Dimension (a): 1.2 mm Use bolts (2) (2 pieces) to install carrier assembly (3) to support (4). Tool: Torque wrench (socket) 2 Mounting bolt (2) of support: Liquid adhesive (LT-2) Bolt (2): M20 with width across flats of 30 mm 3 Bolt (2): 455 to 565 Nm {46.5 to 58 kgm} Remove hydraulic jacks. Tighten lubricator (1) of the cylinder. Tool: Torque wrench (spanner) Lubricator (1): Width across flats of 27 mm 3 Lubricator (1): 58.8 to 88.3 Nm {6 to 9 kgm} Adjust the track tension. For details, see Testing and adjusting, "Testing and adjusting track tension".
Use bolts (5a) (2 pieces) to install upper cover (5) of the track frame. Tool: Torque wrench (socket) Bolt (5a): M12 with width across flats of 19 mm 3 Bolt (5a): 98 to 123 Nm {10 to 12.5 kgm}
D155A-6
63
SEN03371-03
50 Disassembly and assembly
Disassembly and assembly of carrier roller assembly
1
Special tools Symbol
R
Part No.
Part name
Necessity
Q'ty
1
790-102-1891
Nut wrench
t
1
2
791-651-1510
Installer
t
1
3
791T-630-1350
Spacer
t
1
4
791-601-1000
Oil pump
t
1
New/ Remodel
Sketch
Q
Disassembly 1.
Remove the plug to drain the oil. a While rotating the shaft, drain the oil. 6
Carrier roller: 570 – 680 cc
2. 3. 4.
Set carrier roller assembly (1) to block [1]. Remove the mounting bolts and cover (2). Remove ring (3).
5. 6.
Using tool R1, remove nut (4). Using puller [2], remove the ring press fitting part. Using eyebolts, remove bearing (5) and roller (6) together.
7. 8.
Remove outer race (7) from the roller. Using puller [3], remove ring (8) and the inner race of bearing (9) together.
9.
Remove floating seal (10) from ring (8).
64
D155A-6
50 Disassembly and assembly
SEN03371-03
10. Using push tool [4], remove ring (11). 11. Remove floating seal (12) from ring (11).
D155A-6
65
SEN03371-03
50 Disassembly and assembly
Assembly a
Clean all the parts thoroughly and check them for dirt or damage.
1.
Using push tool [5], press fit the inner race of bearing (9) to the shaft. Using push tool [6], press fit outer race (7) of the bearing to the roller.
2.
3. 4.
Set the inner races of roller (6) and bearing (5) to the shaft. Using push tool [7], press fit the inner race of bearing (5) to the shaft. a While rotating the roller, press fit the bearing until the roller becomes a little heavy to rotate.
5.
Using tool R1, tighten nut (4) to "58.8 Nm {6 kgm}". a After tightening the nut, if the nut hole is not aligned with the shaft hole, align it by loosening it. Install ring (3).
6.
7.
Fit the O-ring and install cover (2) and then tighten the mounting bolts. a Tighten the oil filler plug temporarily.
8.
Reverse roller (6) and add oil between the shaft and roller. 5
66
Refill capacity: 570 – 680 cc (GO140)
D155A-6
50 Disassembly and assembly
SEN03371-03
9. Using tool R2, install floating seal (10) to ring (8). 10. Fit the O-ring and install ring (8) while setting it to the dowel pin.
11. Using tool R2, install floating seal (12) to ring (11).
a a a
Before installing the floating seal, thoroughly clean, degrease and dry the O-ring and O-ring contact surface (hatched areas). After inserting the floating seal, check that its tilt is 1 mm or less and projection (a) of the seal is 7 – 11 mm. Coat the sliding surfaces of the floating seal and take care that dirt will not stick to them.
12. Using tool R3, press fit ring (11). a Press fit the ring so that dimension (a) from the shaft end to the ring top will be 131.95 ± 0.2 mm.
13. Using tool R4, apply the standard pressure to the roller oil filler to check the seal for air leakage. a Standard pressure: 0.1 MPa {1 kg/cm2} a Check method Keep the standard pressure for 10 seconds and confirm that the gauge pointer does not lower.
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14. After checking for air leakage, check again that the oil supplied in step 8 is still at a proper level. a Check of oil level Remove the oil filler plug, slant the carrier roller approx. 10°, and check the oil level. 15. Tighten the oil filler plug 3 Plug: 157.0 – 255.0 Nm {16.0 – 26.0 kgm}
68
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SEN03371-03
Removal and installation of pivot shaft assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
41 mm
1
2
Torque wrench (socket)
(Commercially available)
1150 to 1440 Nm
1
3
Belt sling
(Commercially available)
4
Forcing screw
(Commercially available)
(M24)
Remarks
1
(135 kg)
1
[1]
Special tools list Symbol
V
Part name
Part No.
Specifications
Q'ty
Sleeve
791T-650-2110
1
Spacer
790-201-2770
1
Plate
791T-650-2120
1
Bolt
792-104-3940
2
Block
790-101-2510
1
Washer
790-101-2570
2
Nut
01580-01613
1
Jack assembly
790-105-2300
Hydraulic pump
790-101-1102
196 kN {20 ton}
Remarks
For press-fitting link
1 1
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.
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Removal 1. 2. 3.
4.
Remove the track frame assembly. For details, see "Removal and installation of track frame assembly". Remove seal (1) of the pivot shaft, and remove ring (2). Sling pivot shaft assembly (3), and remove mounting bolts (3a) (17 pieces).
Sling pivot shaft assembly (3), and use forcing screws [1] (2 pieces) to remove the assembly. Tool: Socket wrench, belt sling, forcing screw [1] (M24) Bolt (3a): M27 with width across flats of 41 mm 4
70
Pivot shaft assembly: 135 kg
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50 Disassembly and assembly
SEN03371-03
Installation 1.
Sling pivot shaft assembly (3) to set it to its installed position, and use mounting bolts (3a) (17 pieces) to install the assembly. Tool: Torque wrench (socket), belt sling Bolt (3a): M27 with width across flats of 41 mm 3 Mounting bolt (3a) of pivot shaft: 1150 to 1440 Nm {118 to 147 kgm} 4
Pivot shaft assembly: 135 kg
2 Mounting bolt (3a) of pivot shaft: Adhesive (LT-2)
2.
Install seal (1) according to the following procedure. 1) Reverse seal (1) so that its face with molded letter (a) faces inward. 2) Install seal (1) reversed to pivot shaft (3).
3.
Press-fit ring (2) using tool V (jack assembly or the like). Tool: Special tool V q Press fit force for ring: 8.8 to 22.5 kN {0.9 to 2.3 ton} q Ring press fit dimension: 475.5 ± 1 mm
4.
Install the track frame assembly. For details, see "Removal and installation of track frame assembly".
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Separation and connection of track shoe assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
19 mm
1
2
Socket wrench
(Commercially available)
36 mm
1
3
Spanner wrench
(Commercially available)
27 mm
1
4
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 590±60 Nm
5
Torque wrench (spanner)
(Commercially available)
58.8 to 88.3 Nm
6
Wire
(Commercially available)
1
7
Bar
(Commercially available)
1
8
Block
(Commercially available)
2
[1]
9
Block
(Commercially available)
1
[2]
As needed 1
Check before separation of track shoe assembly k In some cases, it may be extremely dangerous to separate the track shoe assembly. To prevent
danger, perform the following checks before separation of the track shoe assembly.
k When it is necessary to loosen the lubricator, do not loosen the lubricator more than 1 turn and
do not remove the lock plate.
k If the grease does not come out sufficiently, move the machine backwards and forwards.
1. 2.
3. 4.
72
Remove bolts (1a) (2 pieces), and remove cover (1). Tool: Socket wrench Bolt (1a): M12 with width across flats of 19 mm Loosen lubricator (2) of the cylinder to discharge grease and decrease the track tension. k If the grease does not come out sufficiently, move the machine backwards and forwards. k Do not loosen the lubricator more than 1 turn. Tool: Spanner wrench Lubricator (2): Width across flats of 27 mm After the track tension is decreased, follow the procedure in "Separation of track shoe assembly (normal)". If the track tension is not decreased and is still high after the above work, follow the procedure in "Separation of track shoe assembly (when track frame has internal defect)" a A problem may have occurred inside the track frame (such as damaged recoil spring, broken recoil spring set bolt, shaft end nut coming off, etc.)
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50 Disassembly and assembly
SEN03371-03
Separation of track shoe assembly (normal) a
When no problem is found in "Check before separation of track shoe assembly" and the track tension is decreased, perform the following procedure.
1.
Remove the blade assembly. For details, see "Removal and installation of blade assembly". Run the track so that master link (3) is positioned at the front of the idler. a Place block [1] so that master link mating faces will not open before the master bolts are removed.
2.
3.
Remove track shoe bolts (4a) (4 pieces), remove track shoe (4), and split master link (3). Tool: Socket wrench Shoe bolt (4a): M24 with width across flats of 36 mm a Do not remove mounting bolts (4 pieces) one by one but loosen each of them by one or two turns. Check that they can be unscrewed smoothly, and then remove them. a If a bolt does not turn smoothly and it is unscrewed forcibly, the threaded part of the bolt and master link (3) may be damaged.
4.
Sling the track shoe assembly at the end of master link (3) and move the machine slowly in reverse to separate track shoe assembly (5). a Length of track shoe assembly: Approximately 10.5 m Tool: Wire k Do not stand in front of the idler for safety reasons.
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Separation of track shoe assembly (when track frame has internal defect) a When any problem is found in "Check before separation of track shoe assembly" and the track tension cannot be decreased, perform the following procedure. k If a problem has occurred inside the track frame, the track shoe assembly may spring back when the assembly is separated. Also, the idler may fly off when the track shoe assembly is separated. This is potentially very dangerous. Be sure to separate the track shoe assembly as follows. 1.
Remove the blade assembly. For details, see "Removal and installation of blade assembly".
2.
Keep lubricator (2) loosened 1 turn. k Do not loosen lubricator (2) more than 1 turn.
3.
Move the machine forward slowly to press track shoe assembly (4) on the idler side against large block [3] or a wall (or a blade of another large-sized bulldozer of same size as the repaired machine). When the recoil spring is compressed and track shoe assembly (4) sags, stop the machine and apply the brake. a Place blocks between carrier rollers so that master link mating faces will not open before the master link shoe bolts are removed.
4.
Remove track shoe bolts (4a) (4 pieces) for the master link, remove track shoe (4), and split master link (3). a Be sure to set the track shoe assembly so that the master link shoe bolts are positioned above the idler (at that position, the bolts and shoe can be removed). a Do not remove mounting bolts (4 pieces) one by one but loosen each of them by one or two turns. Check that they can be unscrewed smoothly, and then remove them. a If a bolt does not turn smoothly and it is unscrewed forcibly, the threaded part of the bolt and master link (3) may be damaged. Tool: Socket wrench, torque multiplier wrench (power wrench)
5.
Move the machine slowly in reverse to separate the track shoe assembly. k Do not stand in front of the idler for safety reasons.
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Connection
1. 2.
Place track shoe assembly (5) under the track frame. Sling separated track shoe assembly (5) at the top end of rear master link (3) and engage the assembly with the sprocket. Tool: Wire, bar
3.
Sling track shoe assembly (5) at the end of master link (3) and move the machine slowly forward to wind the assembly up to the top of the idler.
4.
Set tools [1] and [2] at the front of the idler and between carrier rollers. Tool: Blocks [1] and [2]
5.
Install shoe bolts (4a) for master link (3) according to the following procedure. 1) Fit master link mating faces and align their shoe bolt holes with each other. 2) Align shoe bolt holes of track shoe (4) with those of the master link. 3) Install shoe bolts (4a) (4 pieces). a Finger tighten the bolts (4 pieces) until the mating faces of the master links stick fast to each other. a If the bolts are tightened forcibly before the master link mating faces stick fast to each other, the threaded part of bolts and master link may be damaged. 2 Shoe mounting bolt (master link): Molybdenum disulfide lubricant (LM-P) 4) Tighten shoe bolts (4a) (4 pieces) to the specified torque. a Tighten shoe bolts (4a) (4 pieces) in the order shown in the figure. Tool: Torque wrench (socket) Shoe bolt (4a): M24 with width across flats of 36 mm 3 Shoe bolt (4a): 1st time: 590±60 Nm {60±6 kgm} 2nd time: 180±10° (retightening)
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6.
7. 8.
9.
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50 Disassembly and assembly
Tighten lubricator (2) of the cylinder. Tool: Torque wrench (spanner) Lubricator (2): Width across flats of 27 mm 3 Lubricator (2): 58.8 to 88.3 Nm {6 to 9 kgm} Adjust the track tension. For details, see Testing and adjusting, "Testing and adjusting track tension". Use bolts (1a) (2 pieces) to install cover (1). Tool: Torque wrench (socket) Bolt (1a): M12 with width across flats of 19 mm 3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm} Install the blade assembly. For details, see "Removal and installation of blade assembly".
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SEN03371-03
General disassembly and assembly of track shoe
1
Special tools Symbol
Part No.
a
Necessity
Q'ty
791-675-9701
Remover and installer
t
1
791-101-4300
Cylinder (196 kN {20 ton})
t
1
791-101-4200
Puller (294 kN {30 ton})
t
1
791-101-1102
Hydraulic pump
t
1
2
791-932-1110
Plug push tool
t
1
3
791-660-7460
Pin brush
t
1
1
S
Part name
4
791-432-1110
Plug push tool
t
1
5
791-632-1052
Installer
t
1
6
790-701-3000
Seal checker
t
1
7
791-601-1000
Oil pump
t
1
New/ Remodel
Sketch
For the general disassembly of the track shoe, see "Parts judgment guide, Undercarriage, Oil lubricated track" and "Parts judgment guide, Undercarriage, Reversing procedure for oil lubricated track".
General disassembly 1.
Removal of shoe Sling the shoe assembly and set it with the shoe up on the floor and remove the shoe by using a shoe bolt impact wrench. a If a shoe bolt is not loosened after it is unscrewed by 1 turn (If its torque is not reduced to 0), loosen the other bolts first, and it will be removed smoothly. a If a shoe bolt is turned forcibly while its torque is not 0, it and link will adhere to each other and they will need to be repaired. a When moving the shoe assembly, take care not to damage the master link. a If it is obliged to cut a shoe nut with gas, keep the seal temperature below 80 °C to prevent thermal deterioration of the seal and take measures to prevent the spatters from entering through the clearances among the links.
2.
Disassembly of link 1) Set the link assembly on a link press and hit it with a hammer so that the bushing will be fitted to the jaw. a If the link tread, outside of the bushing, etc. are worn, adjust the height of jaw [1] or guide plate and align disassembly jigs [2] and [3] with the pin and bushing so that the link hole will not be damaged during disassembly work. a If the disassembly jigs are not aligned well, the link hole may be damaged and the pin and bushing may be broken during disassembly work.
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a
3.
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50 Disassembly and assembly
Using tool S2, drive the small plug of the pin inward after the disassembly work so that the workplace will not become dirty.
2)
Operate the left cylinder to pull out the pin and bushing from the left link simultaneously. a Check the pulling out force of the pin and bushing to see if press fitting force for them necessary for reversed reassembly is obtained.
3)
Return the left cylinder and operate the right cylinder to pull out the pin and bushing from the right link simultaneously.
4)
Return the right cylinder and take out the links, pins, bushings, and spacers on the right and left sides and feed the next 1 set of the link assembly to the jaw. a If the bushing ends and sealing surfaces are damaged, oil will leak. Accordingly, handle them carefully.
Inspection Check the parts for the following items to see if they can be used for an oil lubricated track or a grease lubricated track, then examine them generally and determine to use them for an oil lubricated track or a grease lubricated track. a For judgment of reuse of the parts, see "Parts judgment guide, Undercarriage, Oil lubricated track". 1) Check the parts visually for damage. If a part seems to be damaged, check it by dye penetrant test or magnaflux inspection. If it has any crack, it cannot be used again. Discard it.
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50 Disassembly and assembly
2)
a
SEN03371-03
Measure the outside diameters of the press fitting parts of the pin and bushing and the inside diameters of the pin and bushing fitting parts of the link with a micrometer and a cylinder gauge to see if the interference is larger than the limit. When using the pin, bushing, and link for an oil lubricated track, however, secure the standard interference between the pin and link. a If the interference is less than the limit, replace the parts with new ones. a For the dimensional criteria, see "Maintenance Standard".
Precautions for storage 1) Store the seal without removing it from the link so that the counterbore portion will not be rusted and take care not to damage the seal lip. 2) Apply rust-preventive oil to the pin and bushing fitting parts, shoe mating surface and master link mating surface of the link. 3) When storing, apply rust-preventive oil to all the surfaces of the pin, bushing and spacer. Take care not to damage the ends of the bushing in particular.
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General assembly a
For the whole assembly of the track shoe, see "Parts judgment guide, Undercarriage, Reversing procedure for oil lubricated track".
When recycling for oil lubricated track 1.
Preparation work 1) Cleaning of seal assembly Remove the seal assembly from the link and divide it into the seal ring (1) and load ring (2), and then clean them. a Since the seal ring and load ring are deteriorated easily by the cleaning liquid (trichloroethylene etc), clean them quickly. After cleaning them, wipe off the cleaning liquid from them. 2)
When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the nodules sticking to the press fitting parts with the grinder, too. a If the ends are worn and sharpened, they may scuff the press fitting parts and cause oil leakage.
3)
If the link, pin, bushing and spacer are dirty, clean them. Remove the nodules sticking to the link and bushing with the grinder. a Since these parts rust easily, clean them just before assembling. a Do not polish the bushing ends. If they are polished, oil may leak. If the large plug was pulled out, drive it in by using tool S4. a Clean the pin hole in advance by using tool S3.
4)
1] 2] 3]
80
Insert plug (3) through the plug insertion window into the guide hole. Push the bar with the hand and insert the plug until it stops. Push the plug with the bar to press the guide against pin (4). a Driving distance (a) from pin end: 10 ± 1 mm a If the chamfered part of the pin hole has been worn, chamfer it with a small-sized grinder (grindstone tip angle: 45° – 60°) so that the plug will not be damaged. a Coat the plug with GO90 and drive it with the small diameter end ahead.
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50 Disassembly and assembly
2.
5)
Installation of seal assembly Clean the counterbore portion (d) of the link carefully and push in the seal to the bottom by using tool S5. a If oil sticks to the counterbore portion of the link or seal assembly, the seal will turn and its sealing performance will lower. Accordingly, do not apply any oil. When inserting the seal in the counterbore portion, take care that oil not stick to the seal.
6)
Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. a For the standard dimensions, see "Dimensions table of press fitting jig of link press". a If the pin end (part P) or the sides of the link (parts Q and R) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on the right and left sides will be even.
7)
Adjust the relief pressure of the link press so that the pressing force of the press will not exceed the standard value. a If the pressing force is too strong, the spacer will be pressed forcibly against the bushing. As a result, the spacer may be broken and it and bushing may be worn abnormally. a Final pressing force for pin and bushing: 862 kN {88 tons} Final pressing force C 1.8 x Average press fitting force (Adjust the relief pressure of the link press to set the final pressing force.)
SEN03371-03
Assembly of link 1) Apply oil (GO90) to the mating surfaces of the pin and bushing with a clean brush and assemble them, and then set them before the jaw of the link press. a When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press).
2)
D155A-6
Set shoe mounting faces of the right and left master links on bushing side up and press fit the bushing. a At this time, use the master links on the pin side as supports. a Bushing press fitting force: 88 to 304 kN {9 to 31 ton}
81
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3)
4)
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50 Disassembly and assembly
Using the shoe bolt hole pitch gauge, press fit the master links until the distance between the shoe bolt holes of both links is the standard value. a Blow off all the steel chips caused by press fitting of the bushing with compressed air. Reverse the master links and check that they are press fitted in parallel.
5)
Measure the projections of the bushing on the right and left sides with a depth gauge. a Adjust the press fitting jig of the link press so that the projections on the right and left sides will be even.
6)
Send the master links and set the next pin and bushing. a When reusing a pin, install it so that its side hole will be on the link tread side similarly to a new one. If it is not installed so, its strength may be lowered. Accordingly, indicate the direction of side hole (e) on the end face to prevent a mistake.
7)
Set the right link and install the spacer to the pin. a Check that the seal surface and bushing end are free from dirt and apply oil (GO90) to them with a clean cloth or brush. a When installing the spacer, wipe it with a clean cloth.
8)
Set the right jig on the receiving side and the left one on the pushing side and press fit the pin and bushing simultaneously. a If the pin and bushing have play when they are press fitted, the seal may come off the link. To prevent this, press fit smoothly. If the seal comes off the link, stop press fitting and set the seal to the link correctly, and then start press fitting again. a Press fitting force for pin and bushing: 343 to 490 kN {35 to 50 ton}
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50 Disassembly and assembly
9)
SEN03371-03
Using spacer [4] for fine adjustment, press fit the pin and bushing until the pin end is fitted to the bottom of the receiving jig. a Adjust the depth of the receiving jig hole so that the projections of the pin on the right and left sides will be even.
10) Set the left link and install the spacer to the pin. a Apply oil similarly to the right link.
11) Set the left jig on the receiving side and the right one on the pushing side and press fit the left link. a When press fitting, take care that both seals and spacers will not come off. a Link press fitting force: 343 to 490 kN {35 to 50 ton}
12) Press fit until the link, spacer and bushing are fitted together. a Actually, you cannot see from outside if the above parts are fitted. Accordingly, control the hydraulic pressure of the link press. Set the relief pressure to a proper level and heighten the hydraulic pressure to that level. For setting of the relief pressure, see Preparation work. a Check that adjacent 2 links can turn around each other. 13) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes and check that the result is within the standard range. a If the distance between the shoe bolt holes is longer than the standard range, disassemble and check for abnormality, then press fit again. a If the distance between the shoe bolt holes is shorter than the standard range and the shoe cannot be installed, the spacer or bushing end may be worn more than repair limit. In this case, disassemble and replace the parts.
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14) After each link is assembled, bleed air from the pin by using tool S6 and check the sealing performance. a Keep the degree of vacuum inside the pin at 91 to 95 kPa {680 to 710 mmHg} for 5 seconds and check that the pressure does not change. If the pressure changes, disassemble and check the seal. If the seal is free from abnormality, assemble again.
15) Using tool S7, supply oil (G090) until the oil supply pressure rises to 196 to 294 kPa {2 to 3 kg/cm2}. a In a cold or very cold district, supply KOMATSU genuine oil (150-09-19270 for cold district or 19532-61990 for very cold district) having better lowtemperature characteristics instead of G090. a If the oil pressure is heightened too much, it has bad effects on the seal. Take care.
a
Determine oil level (a) as follows; supply oil (d) so that depth (L) of the hollow of pin hole (c) will be in the following range when the link is left with small plug side (b) up (with the link assembly on its side) for 30 minutes. Dimension (L): 35 to 65 mm
16) After supplying oil, drive in the small plug into the specified position, using tool S2. a Apply G090 around the small plug. a Drive in the small plug to the following depth. Driving depth from end: 7.5 ± 1 mm
17) Assemble the master link on the pin side at last. a Check that the master links on the right and left sides are press fitted in parallel. 3.
84
Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. a When reusing (reversing) the bushing, set the worn outside face of the bushing to the shoe mounting side of the link (set the bushing with the worn outside surface up on the link press). 2 Shoe bolt: Molybdenum disulfide grease (LM-P) 3 Shoe bolt (Regular link) Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 120° ± 10° D155A-6
50 Disassembly and assembly
2) 3) 4) 5)
SEN03371-03
When installing a 2-piece shoe, place the assembled 2piece shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushing-side master link (2) together and set them to each other by the mating faces. Place shoe (3) and fit the mating surfaces of the links. Check that master bolts (4) can be tightened easily with the fingers, then connect the links with the master bolts. 2 Master bolt: Molybdenum disulfide grease (LM-P) 3 Master bolt (Master link) Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 180° ± 10° a
Tighten the bolts in the order of 1 to 4.
When recycling for grease lubricated track 1.
Preparation work 1) Cleaning of seal assembly Remove the seal assembly from the link and divide it into the seal ring (1) and load ring (2), and then clean them. a Since the seal ring and load ring are deteriorated easily by the cleaning liquid, clean them quickly. After cleaning them, wipe off the cleaning liquid from them. 2)
D155A-6
When reusing the pin, chamfer its end corners carefully with a grinder so that it will be press fitted smoothly.
85
SEN03371-03
3)
Using tools S2 and S4, drive the large and small plugs (3) into the pin (4). 1] Insert each plug through the plug insertion window into the guide hole. a Apply oil to the plug. 2] Push the bar with the hand until the plug stops. 3] Push the plug with the bar to press the guide against the pin. 4] Drive in the bar with a hammer. a Driving distance (a) from pin end: Small plug: 7.5 ± 1 mm Large plug: 6.0 ± 2 mm a If the plugs were not pulled out of the pin when the shoe was disassembled, reuse them as they are.
4)
If the outside of the pin, surfaces of the spacer, and ends and inside of the bushing are dirty, clean them. Apply grease to the outside of the pin and surfaces of the spacer. Installation of seal assembly Clean the counterbore portion (d) of the link carefully. Using tool S5, push in the seal to the bottom. a If grease sticks to the counterbore portion of the link or seal assembly, the seal will turn and its sealing performance will lower. Accordingly, do not apply any grease.
5) 6)
7)
2.
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50 Disassembly and assembly
Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. a For the standard dimensions, see "Dimensions table of press fitting jig of link press". a If the pin end (part P) or the sides of the link (parts Q and R) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on the right and left sides will be even.
Assembly of link 1) Apply lithium grease (G2-LI) to the mating surfaces of the pin and bushing and assemble them, then set them before the jaw of the link press. a When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press).
D155A-6
50 Disassembly and assembly
2)
Press fit the master links on both bushing sides to the bushing with the shoe fitting faces up. a At this time, use the master links on the pin side as supports. a Press fitting force for bushing: 88 to 304 kN {9 to 31 ton}
3)
Using the shoe bolt hole pitch gauge, press fit the master links until the distance between the shoe bolt holes of both links is the standard value. a Blow off all the steel chips caused by press fitting of the bushing with compressed air. Reverse the master links and check that they are press fitted in parallel.
4)
5)
Measure the projections of the bushing on the right and left sides with a depth gauge. a Adjust the press fitting jig of the link press so that the projections on the right and left sides will be even.
6)
Send the master links and set the next pin and bushing. a When reusing a pin, install it so that its side hole will be on the link tread side similarly to a new one. If it is not installed so, its strength may be lowered. Accordingly, indicate the direction of the side hole on the end face to prevent a mistake. a If the outside of the pin is worn, install it so that the un-worn surface will be on the traction side. In this case, install the pin so that its side hole will be on the link tread side.
7)
Set the right and left links and operate both pushing jigs to press fit the pin and bushing simultaneously. a If the pin and bushing have play when they are press fitted, the seal may come off the link. To prevent this, press fit smoothly. If the seal comes off the link, stop press fitting and set the seal to the link correctly, then start press fitting again. a Final pressing force for pin and bushing: 343 to 490 Nm {35 to 50 ton} Final pressing force C 1.8 x Average press fitting force (Adjust the relief pressure of the link press to set the final pressing force.)
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3.
8)
Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes. When the distance is in the standard range, stop press fitting.
9)
Assemble the master link on the pin side at last. a Check that the master links on the right and left sides are press fitted in parallel.
Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. a When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press). 2 Shoe bolt: Molybdenum disulfide grease (LM-P) 3 Shoe bolt (Regular link): Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 120° ± 10° 2) 3) 4) 5)
When installing the assembled 2-piece track shoes, place them on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushing-side master link (2) together and set them to each other by the mating faces. Place shoe (3) and fit the mating surfaces of the links. Check that master bolts (4) can be tightened easily with the fingers, then connect the links with the master bolts. 2 Master bolt: Molybdenum disulfide grease (LM-P) 3 Master bolt (Master link) Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 180° ± 10° a
88
50 Disassembly and assembly
Tighten the bolts in the order of 1 – 4.
D155A-6
50 Disassembly and assembly
SEN03371-03
Dimensions table of fitting jig of link press
Adjustment Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. a If the pin end (part P) or the sides of the link (parts Q and R) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on the right and left sides will be even. Unit: mm Dimensions of jig a
b
c
4.5
3.25
50.6
Precaution 1. 2.
The link receiving faces of jaw (5) must be vertical. Wear plate (6) should be replaceable.
D155A-6
89
SEN03371-03
50 Disassembly and assembly
Disassembly and assembly of 1 link in field
1
Special tools Symbol
1
2
3
T
4
5
6
7
90
Part No.
Part name
Necessity
Q'ty
791-675-9581
Adapter
t
1
791-675-9590
Guide
t
1
01010-52460
Bolt
t
2
01010-51440
Bolt
t
2
790-101-1102
Pump
t
1
790-101-4300
Cylinder (1,470 kN {150 ton})
t
1
791-685-9510
Frame
t
1
791-685-9520
Frame
t
1
791-685-9530
Rod
t
1
791-685-9550
Nut
t
1
791-685-9560
Bolt
t
1
791-675-9570
Adapter
t
1
04530-12030
Eyebolt
t
1
790-101-1102
Pump
t
1
790-101-4300
Cylinder (1,470 kN {150 ton})
t
1
791-685-9540
Rod
t
1
791-685-9550
Nut
t
3
791-675-5520
Guide
t
1
791-675-5530
Pusher
t
1
01010-51030
Bolt
t
1
791-685-9620
Extension
t
1
790-101-1102
Pump
t
1
790-101-4200
Puller (294 kN {30 ton})
t
1
791-675-5542
Adapter
t
1
791-675-5571
Adapter
t
1
790-101-1102
Pump
t
1
790-101-4300
Cylinder (1,470 kN {150 ton})
t
1
New/ Remodel
Sketch
D155A-6
50 Disassembly and assembly
Symbol 8
9
T
10
11 12
13
D155A-6
Part No.
SEN03371-03
Part name
Necessity
Q'ty
791-675-5580
Guide
t
1
791-685-9510
Frame
t
1
791-685-9520
Frame
t
1
791-685-9530
Rod
t
1
791-685-9540
Rod
t
1
791-685-9550
Nut
t
3
791-685-9560
Bolt
t
4
791-126-0150
Adapter
t
1
01010-51030
Bolt
t
1
791-685-9620
Extension
t
1
791-675-5542
Adapter
t
1
791-675-5560
Guide
t
1
790-101-1102
Pump
t
1
790-101-4300
Cylinder (1,470 kN {150 ton})
t
1
791-675-5560
Guide
t
1
791-675-5542
Adapter
t
1
790-101-1102
Pump
t
1
790-101-4200
Puller (294 kN {30 ton})
t
1
791-670-3270
Guide
t
1
791-126-0150
Adapter
t
1
791-675-5560
Guide
t
1
791-675-9570
Adapter
t
1
01010-51030
Bolt
t
1
New/ Remodel
Sketch
91
SEN03371-03
50 Disassembly and assembly
Disassembly of 1 link in field k Only how to use the tools is explained below. For details of disassembly and assembly, see "General disassembly (or assembly) of track shoe". 1.
Using 2 bolts (2), install tool T1 (adapter, guide and bolt) to link (1). a The track bolts may be used as 2 bolts (2).
2.
Assemble tool T2 (pump and cylinder of 150 ton) and tool T3 (frame, rod, adapter, 1 bolt and eyebolt) and sling them together and set them on the shoe.
3.
Insert the rod of tool T4 from the cylinder side and install it with the nuts (2 pieces). Pass the rod through the hole of link (1) and install it.
4.
Set tool T5 (adapter, guide and pusher) and apply pressure to pull out pin (3). When the cylinder reaches the stroke end, insert tool T5 (extension) between the adapter and guide and repeat the work.
5.
Set tool T6 (294 kN {30 ton}) puller) and spacer [1] to the center of the roller tread of the link to be disassembled and apply hydraulic pressure to the puller to open and disconnect the link by 5 to 6 mm.
92
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50 Disassembly and assembly
SEN03371-03
Assembly of 1 link in field 1.
Assemble the link sub-assembly. 1) Set tool T7 the link end face and press fit bushing (1). a Busing press fitting force: 88 to 304 kN {9 to 31 ton}
2)
Set tool T7 to the end face of the link (on the pin side) and press fit pin (2). a Set the pin with its side hole (a) directed toward link tread (b). a Pin pressing force: 284 to 686 kN {29 to 70 ton}
2.
Set the link to be connected to link sub-assembly (3).
3.
Set link (4) on the opposite side and support it with tool T8 (guide).
4.
Set tools T9 and T10 as in the procedure for pulling out the pin. Using tool T9 (adapter, extension, guide, adapter and bolt) for (d) on the bushing side and tool T10 (extension, guide, adapter and bolt) for (c) on the pin side, press fit (d) and (c) alternately. a Pin press fitting force: 284 to 686 kN {29 to 70 ton} a Bushing press fitting force: 88 to 304 kN {9 to 31 ton}
D155A-6
93
SEN03371-03
5.
Using tool T11 (294 kN {30 ton} puller) as in the disassembly procedure, push open link (5) on the bushing side.
6.
Set pin-side link (6) to bushing-side link (5) and connect them by tool T12 (guide), and then remove tool T11 (puller).
7.
Set tool T5 to pin (7). Using tool T13 (adapter, bolt and guide), press fit pin (7). 3 Pin press fitting hole of link: Gasket sealant (198-32-19890) Cylinder: (b), Frame side: (e) a Set the pin with its side hole directed toward the link tread. a Pin press fitting force: 284 to 686 kN {29 to 70 ton}
94
50 Disassembly and assembly
D155A-6
50 Disassembly and assembly
SEN03371-03
Disassembly and assembly of master link
1
Special tools Symbol
D155A-6
Part name
Necessity
Q'ty
790-101-1102
Pump
t
1
790-101-4200
Puller (294 kN {30 ton})
t
1
791-675-9701
Remover and installer
t
1
790-101-1102
Pump
t
1
790-101-4200
Puller (294 kN {30 ton})
t
1
790-101-4300
Cylinder (1,470 kN {150 ton})
t
1
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
1
U
Part No.
2
New/ Remodel
Sketch
95
SEN03371-03
50 Disassembly and assembly
Disassembly a 1.
For the using method of tool U2, see "Disassembly in field". Removal of track shoe assembly Remove the track shoe assembly from the track frame. For details, see "Spreading and installation of track shoe assembly".
2.
Removal of master link 1) Cutting and removal of master link on bushing side with gas Cut at (a) with gas and remove the hatched part. Pull out master links (5) and (6) by moving them up and down. Then, remove pins (8) and (9) from regular link (7) by pressing them up and down with the press. Special tool : 1. Gas cutting machine : 2. Tool U2 2)
96
Removal of master link on pin side Cut at (b) with gas and remove the hatched parts. Remove pin (10) from link (11) by pressing it down with the press, and then remove pin (10) and link (12) from bushing (13) simultaneously. Special tool : 1. Gas cutting machine : 2. Tool U2
D155A-6
50 Disassembly and assembly
SEN03371-03
Assembly a
For the using method of U2, see "Assembly of 1 link in field".
1.
Assembly of link on bushing side 1) Press fit master link (1) on the bushing side to bushing (2) with the press. a When press fitting the right and left master links, take care extremely that they will be in parallel. a Do not damage the mating faces of the master links and end of the bushing. Unit: mm L1
2.
169 ± 0.7
L2
219.8 ± 0.7
D1
27 drill hole
D2
24 x 2.0
Installation of link on bushing side 1) Push open the central part of the link tread with tool U1 as shown in the figure (Open the link tip by 10 mm). (a): 5 mm
2)
Set spacer (3) and seal assembly (4) to the counterbore of the link at the connecting section.
3)
Align the holes of the pin and bushing and connect by guide pin [2].
D155A-6
97
SEN03371-03
3.
4)
Press fit pin (5) with tool U2 and install master link (1) on the bushing side. 2 Apply gasket sealant (198-32-19890) to the pin hole of the link. a Direct the side hole of the pin toward the link tread.
5) 6)
Install the shoe to the link at the connecting section. Drive in large plug (6) with tool U3, add oil with tool U4, and drive in small plug (7) with U5. a When press fitting the right and left master links, take care extremely that they will be in parallel (on the bushing side and pin side). a Do not damage the mating faces of the master links and end of the bushing. a Take care extremely that dirt or sand will not stick to the seal, spacer, ends of bushing and tap mating faces of the master link.
Assembly of link on pin side 1) Set spacer (3) and seal assembly (4) to the counterbore of the master link.
2) 3)
4.
98
50 Disassembly and assembly
Insert pin (9) in bushing (8), set master links (10) on the pin side from the right and left sides, and press fit them with tool U2. Drive in large plug (11) with tool U3, add oil with tool U4, and drive in small plug (12) with U5.
Connection of master link 1) Place the assembled 2-piece track shoes on a level place in 1 line with the shoe side up. 2) Pull pin-side master link (13) and bushing-side master link (14) together and set them to each other by the mating faces. 3) Place the shoe and fit the mating surfaces of the links. 4) Check that the master bolts can be tightened easily with the fingers, and then connect the links with the master bolts. 2 Shoe bolt: Molybdenum disulfide grease (LM-P) 3 Shoe bolt (Master link) Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 180° ± 10° D155A-6
50 Disassembly and assembly
SEN03371-03
Removal and installation of equalizer bar assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
19 mm
1
2
Socket wrench
(Commercially available)
24 mm
1
3
Socket wrench
(Commercially available)
36 mm
1
4
Spanner wrench
(Commercially available)
17 mm
1
5
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 235 to 285 Nm, 784 to 981 Nm
6
Torque wrench (spanner)
(Commercially available)
15.7 to 23.5 Nm
7
Blocking tool
(Commercially available)
8
Hydraulic jack
(Commercially available)
9
Chain
10
Remarks
As needed 1 1
[2]
1
[1], [3]
Commercially available
1
(240 kg)
Lever block
(Commercially available)
2
(240 kg)
11
Wire
(Commercially available)
2
(270 kg), (290 kg)
12
Lifting and lowering device
(Commercially available)
1
(220 kg), (270 kg)
Q'ty
Remarks
30 ton
Special tools list Symbol
W
Part name
Part No.
Specifications
Sleeve
791T-650-2130
1
Adapter
790-101-2420
1
Screw
792-520-4140
1
Washer
790-101-2540
2
Nut
790-112-1180
2
Jack assembly (196 kN {20 ton})
790-101-4000
1
Hydraulic pump
790-101-1102
1
For removing center pin
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
99
SEN03371-03
50 Disassembly and assembly
Removal 1.
Sling engine undercover (9), and remove bolts (9a) (12 pieces). At this time, be sure to remove engine undercover (9) gradually while supporting it from below using the lifting and lowering device. Tool: Socket wrench, wire, lever block, lifting and lowering device 4
Engine undercover (9): 220 kg
Bolt (9a): M24 with width across flats of 36 mm
2.
Sling power train undercover (10), and remove bolts (10a) (10 pieces). At this time, be sure to use a lever block to remove power train undercover (10) gradually while supporting it from below using the lifting and lowering device. Tool: Socket wrench, wire, lever block, lifting and lowering device 4
Power train undercover (10): 270 kg
Bolt (10a): M24 with width across flats of 36 mm 3.
Set hydraulic jack [1] to the center (a) of the equalizer bar, raise the machine off the ground slightly, and set respective blocking tools [2] and hydraulic jacks [3] at the bottom (b) of the radiator guard (each side). Tool: Blocking tool [2], hydraulic jacks [1] and [3]
4.
Remove bolts (1) (2 pieces) to remove cover (2) installed on the equalizer bar side. Tool: Socket wrench Bolt (1): M24 with width across flats of 36 mm Remove bolts (3a) (2 pieces) to remove lock plate (3) of side pin (4), and remove side pin (4). Tool: Socket wrench Bolt (3a): M16 with width across flats of 24 mm a The pin is hard to pull out if the mounting hole in the equalizer bar is not aligned with that in the track frame. In that case, pull it out while adjusting the height using hydraulic jacks [3]. a Follow steps 4 and 5 to remove the pin on the opposite side. k When the track frame assembly on the opposite side is raised off the ground, be sure to support it using blocks or the like before removing the pin. Operate the hydraulic jacks [3] slowly to lower the machine until the equalizer bar touches both right and left track frames.
5.
6.
100
D155A-6
50 Disassembly and assembly
7.
Disconnect grease hose (5). a Be sure to disconnect clip (5a) from the equalizer bar. Tool: Spanner wrench Hose (5): Width across flats of 17 mm, #02 size Tool: Socket wrench Mounting bolt of clamp (5a): M12 with width across flats of 19 mm
8.
Remove bolts (6a) (4 pieces) to remove lock plate (6) of center pin (8). Tool: Socket wrench Bolt (6a): M16 with width across flats of 24 mm
9.
Sling equalizer bar assembly (7) using a crane and a chain block. Tool: Chain, chain block 4
SEN03371-03
Equalizer bar assembly: 240 kg
10. Use tool W (adapter and jack) to pull out center pin (8). k Do not stand in front of or under the puller when performing hydraulic operation of the tool. Perform the operation while keeping away from it as much as possible. Tool: Special tool W 4
Center pin (8): 20 kg
11. Lower equalizer bar assembly (7) under the machine body while adjusting lifting angle using a lever block. k Never lower the machine body after the equalizer bar assembly is removed. 4
D155A-6
Equalizer bar assembly: 240 kg
101
SEN03371-03
50 Disassembly and assembly
Installation 1. 2.
Set equalizer bar assembly (7) under the machine body. Install center pin (8) according to the following procedure. 1) Sling equalizer bar assembly (7) at both ends using a lever block and belt sling, and set the assembly to its installed position while adjusting the lifting angle of the lever block. a Be sure to install the equalizer bar with its greasing nipple facing forward. Tool: Chain, lever block 4 Equalizer bar assembly: 240 kg 2)
3)
3.
4.
5.
Align the center of the mounting hole for the pin in equalizer bar assembly (7) with that in the main frame, and then install center pin (8). k When aligning the mounting holes for the pin, never insert your fingers in the holes. 4 Center pin: 20 kg 2 Center bushing of equalizer bar: Grease (G2-LI) Use mounting bolt (6a) (4 pieces) to install lock plate (6). Tool: Torque wrench (socket) Bolt (6a): M16 with width across flats of 24 mm 3 Bolt (6a): 235 to 285 Nm {23.5 to 29.5 kgm}
Connect greasing hose (5). Tool: Torque wrench (spanner) Greasing hose (5): Width across flats of 17 mm, #02 size 3 Greasing hose (5): 15.7 to 23.5 Nm {1.6 to 2.4 kgm} Use clip (5a) to secure greasing hose (5) to the equalizer bar. Tool: Torque wrench (socket) Mounting bolt of clip (5a): M12 with width across flats of 19 mm 3 Mounting bolt of clip (5a): 98 to 123 Nm {10 to 12.5 kgm} Operate hydraulic jacks [3] to adjust the height of the main frame. Align the center of the mounting hole for side pin (4) in equalizer bar assembly (7) with that in the track frame, and then install side pin (4).
102
D155A-6
50 Disassembly and assembly
6. 7.
8.
9.
SEN03371-03
Use bolts (3a) (2 pieces) to install lock plate (3) for the side pin. Install side pin (4), and use bolts (3a) (2 pieces) to install lock plate (3). Tool: Torque wrench (socket) Bolt (3a): M16 with width across flats of 24 mm 3 Bolt (3a): 235 to 285 Nm {23.5 to 29.5 kgm} a The pin is hard to install if the mounting hole for the pin in the equalizer bar is not aligned with that in the track frame. Be sure to install the pin while adjusting lifting height of the track frame. k When aligning the mounting holes for the pin, never insert your fingers in the holes. 2 Seal lip portion: Grease (G2-LI) a Follow steps 5, 6, and 7 to install the pin on the opposite side. Use mounting bolts (1) (2 pieces) to install cover (2). Tool: Torque wrench (socket) Bolt (1): M24 with width across flats of 36 mm 3 Bolt (1): 784 to 981 Nm {80 to 100 kgm} 2 Threaded part of cover mounting bolt: Adhesive (LT-2) Set hydraulic jack [1] to the center (a) of the equalizer bar, raise the machine, and remove blocking tools [2] and hydraulic jacks [3].
10. Sling power train undercover (10) and set it to its installed position. Tool: Wire, lever block, lifting and lowering device 4
Power train undercover: 270 kg
11. Use bolts (10a) (10 pieces) to install undercover (10). Tool: Torque wrench (socket) Bolt (10a): M24 with width across flats of 36 mm 3 Bolt (10a): 784 to 981 Nm {80 to 100 kgm} 12. Sling engine undercover (9) and set it to its installed position. Tool: Wire, lever block, lifting and lowering device 4
Engine underguard: 220 kg
13. Use bolts (9a) (12 pieces) to install engine undercover (9). Tool: Torque wrench (socket) Bolt (9a): M24 with width across flats of 36 mm 3 Bolt (9a): 784 to 981 Nm {80 to 100 kgm}
D155A-6
103
SEN03371-03
50 Disassembly and assembly
Disassembly and assembly of equalizer bar assembly
1
Disassembly 1.
Remove the equalizer bar. For details, see "Removal and installation of equalizer bar assembly".
2.
Side bushing 1) Remove seal (1). 2) Remove ring (2).
3)
3.
Using tool [1], remove spherical bushing (3) from equalizer bar (4).
Center bushing Remove center bushing (5) from equalizer bar (4).
104
D155A-6
50 Disassembly and assembly
SEN03371-03
Assembly 1.
Center bushing Using the press, press fit center bushing (5) to equalizer bar (4). a Press fitting force for center bushing: 47.1 to 131.4 kN {4.8 to 13.4 ton} 2 Periphery of spherical bushing: Molybdenum disulfide grease (LM-P)
2.
Side bushing 1) Install ring (2) to one side of equalizer bar (4). 2) Using the press, press fit spherical bushing (3) to equalizer bar (4). a Press fitting force for spherical bushing: 27.4 to 64.7 kN {2.8 to 6.6 ton} 2 Periphery of spherical bushing: Molybdenum disulfide grease (LM-P) 3) 4)
D155A-6
Install ring (2) on the opposite side. Using the press, press fit seal (1). a Press fitting force for seal: 6.9 to 18.6 kN {0.7 to 1.9 ton} a The metallic part of the seal must not project from the equalizer bar end.
105
SEN03371-03
50 Disassembly and assembly
Removal and installation of segment teeth
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
36 mm
1
2
Torque wrench (socket)
(Commercially available)
1,176 ± 98 Nm
1
3
Torque multiplier wrench (power wrench)
(Commercially available)
Approximately 3 to 8 times
1
Remarks
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.
106
D155A-6
50 Disassembly and assembly
SEN03371-03
Removal 1. 2.
Set segment teeth (1) at a position where it can be removed easily (intermediate position between the track shoes), and stop the machine. Remove bolt and nut sets (1a) (3 pieces) to remove segment teeth (1). Tool: Socket wrench, torque multiplier wrench (power wrench) Bolt and nut set (1a): M24 with width across flats of 36 mm
D155A-6
107
SEN03371-03
50 Disassembly and assembly
Installation 1.
Use bolt and nut sets (1a) (3 pieces) to install segment teeth (1). a While pressing segment teeth (1) toward the center of sprocket hub (2), tighten nuts in the order of [1], [2], and [3] shown in the figure. Tool: Torque wrench (socket), torque multiplier wrench (power wrench) Bolt and nut set (1a): M24 with width across flats of 36 mm 3 Bolt and nut set (1a): 1,176 to 98 Nm {120 to 10 kgm} 2 Threaded part of bolt (1a): Adhesive (LT-2)
108
D155A-6
50 Disassembly and assembly
D155A-6
SEN03371-03
109
SEN03371-03
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03371-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
110
D155A-6
SEN03372-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Hydraulic system Removal and installation of hydraulic tank assembly...................................................................................... 2 Removal and installation of hydraulic pump assembly ................................................................................... 8 Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 19
D155A-6
1
SEN03372-03
50 Disassembly and assembly
Removal and installation of hydraulic tank assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
17 mm
1
2
Socket wrench
(Commercially available)
19 mm
1
3
Socket wrench
(Commercially available)
24 mm
1
4
Socket wrench
(Commercially available)
32 mm
1
5
Spanner wrench
(Commercially available)
19 mm
1
6
Spanner wrench
(Commercially available)
22 mm
1
7
Spanner wrench
(Commercially available)
27 mm
1
8
Spanner wrench
(Commercially available)
32 mm
1
9
Torque wrench (socket)
(Commercially available)
58.8 to 78.4 Nm, 59 to 74 Nm, 98 to 123 Nm, 235 to 285 Nm
As needed
10
Torque wrench (spanner)
(Commercially available)
54 to 93 Nm, 84 to 132 Nm, 128 to 186 Nm
As needed
11
Wire
(Commercially available)
1
12
2-point chain
(Commercially available)
1
Remarks
(100 kg)
Special tools list Symbol
Part name
1 Plug (female)
Part No.
Specifications
Q'ty
Remarks For preventing oil leakage when hose is disconnected
02789-00315
#03
1
AB 2 Plug (male)
07376-70315
#03
1
3 O-ring
02896-11009
1 Plug (female)
02789-10422
#04
1
AC 2 Plug (male)
07376-70422
#04
1
3 O-ring
02896-11012
1 Plug (female)
02789-00522
#05
1
AD 2 Plug (male)
07376-70522
#05
1
3 O-ring
02896-11015
1
1
1
For preventing oil leakage when hose is disconnected For preventing oil leakage when hose is disconnected
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.
k Loosen the cap of the hydraulic tank gradually to release the pressure remaining inside the tank.
2
D155A-6
50 Disassembly and assembly
SEN03372-03
k If you drain the hydraulic oil when it is still hot, you may be scalded. Wait until the hydraulic oil
temperature drops, and then drain the oil. a Check and note the connector numbers and installed positions before disconnecting wiring harnesses and hoses. a When disconnecting wiring, hoses, etc., take care that they are not damaged or deformed by clips, clamps, or the like. When it appears that wiring and hoses may be damaged or deformed, remove clips and clamps in advance.
D155A-6
3
SEN03372-03
50 Disassembly and assembly
Removal 1.
Remove plug (10) at the bottom of the hydraulic tank, and loosen valve (11) to drain the hydraulic oil. 6
2.
Hydraulic tank: 85 l
Tool: Socket wrench Plug (10): Width across flats of 32 mm a After draining hydraulic oil, be sure to close valve (11) and tighten plug (10). Tool: Torque wrench (socket) 3 Plug (10): 58.8 to 78.4 Nm {6.0 to 8.0 kgm} Remove the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly".
3.
Remove bolts (1a) (5 pieces) to remove control valve cover (1). Tool: Socket wrench, wire Bolt (1a): M12 with width across flats of 19 mm
4.
Remove bolts (2a) (4 pieces), and disconnect hose (2) between control valve and hydraulic tank from the hydraulic tank. Tool: Socket wrench Bolt (2a): M12 with width across flats of 19 mm a Cover the part from which a hose is disconnected using a plastic bag so that oil will not leak out.
5.
Remove clips (3a) (2 pieces) and remove level gauge (3). Tool: Spanner wrench Mounting bolts of clip (3a): M12 with width across flats of 19 mm Disconnect clamp (4a) of oil filler pipe (4). Tool: Socket wrench Mounting bolts of clamp (4a): M12 with width across flats of 19 mm Disconnect hoses (5), (6) and (7). Tool: Spanner wrench, special tool AB, AC, AD Hose (5): Width across flats of 27 mm, #04 size Hose (6): Width across flats of 22 mm, #03 size Hose (7): Width across flats of 32 mm, #05 size
6.
7.
4
D155A-6
50 Disassembly and assembly
8.
Remove bolts (8a) (2 pieces), and disconnect tube (8). Tool: Socket wrench Bolt (8a): M10 with width across flats of 17 mm a Cover the part from which the hose is disconnected using a plastic bag so that oil will not leak out.
9.
Remove bolts (9a) (2 pieces) and disconnect suction tube (9). Tool: Socket wrench Bolt (9a): M12 with width across flats of 19 mm a Cover the part from which the tube is disconnected using a plastic bag so that oil will not leak out.
SEN03372-03
10. Attach the lifting tool to lifting points (a) and sling hydraulic tank assembly (10). Tool: 2-point chain 4
Hydraulic tank assembly: 100 kg
11. Remove (10a) (4 pieces) at the bottom of the hydraulic tank, and sling hydraulic tank assembly (10) to remove it. Tool: Socket wrench Bolts (10a): M16 with width across flats of 24 mm
D155A-6
5
SEN03372-03
50 Disassembly and assembly
Installation 1.
Attach the lifting tool to lifting points (a) to sling hydraulic tank assembly (10), and set the assembly to its installed position. Tool: 2-point chain 4
Hydraulic tank assembly: 100 kg
2.
Use bolts (10a) (4 pieces) for the bottom of the hydraulic tank to install hydraulic tank assembly (10), at the bottom of the hydraulic tank, and sling hydraulic tank assembly (10) to remove it. Tool: Torque wrench (socket) Bolts (7) and (10a): M16 with width across flats of 24 mm 3 Bolt (10a): 235 to 285 Nm {23.5 to 29.5 kgm}
3.
Use bolts (9a) (2 pieces) to connect tube (9). Tool: Torque wrench (socket) Bolt (9a):M12 with width across flats of 19 mm 3 Bolt (9a): 98 to 123 Nm {10 to 12.5 kgm}
4.
Use bolts (8a) (2 pieces) to connect tube (8). Tool: Torque wrench (socket) Bolt (8a): M10 with width across flats of 17 mm 3 Bolt (8a): 59 to 74 Nm {6 to 7.5 kgm}
5.
Connect hose (5), (6) and (7). Tools: Torque wrench (spanner) Hose (5): Width across flats of 27 mm, #04 size Hose (6): Width across flats of 22 mm, #03 size Hose (7): Width across flats of 32 mm, #05 size 3 Hose (5): 84 to 132 Nm {8.5 to 13.5 kgm} 3 Hose (6): 54 to 93 Nm {5.5 to 9.5 kgm} 3 Hose (7): 128 to 186 Nm {13.0 to 19.0 kgm} Connect clamp (4a) of oil filler pipe (4) (2 pieces) Tool: Torque wrench (socket) Mounting bolt of clamp (4a): M12 with width across flats of 19 mm
6.
6
D155A-6
50 Disassembly and assembly
SEN03372-03
3 Mounting bolt of clamp (4a):
7.
8.
98 to 123 Nm {10 to 12.5 kgm} Install level gauge (3) and use clips (3a) (2 pieces) to fix them. Tool: Torque wrench (socket) Mounting bolt of clamp (4a): M12 with width across flats of 19 mm 3 Mounting bolt of clamp (4a): 98 to 123 Nm {10 to 12.5 kgm} Use bolts (2a) (4 pieces) to connect hose (2) between control valve and hydraulic tank to the hydraulic tank. Tool: Torque wrench (socket) Bolt (2a): M12 with width across flats of 19 mm 3 Bolt (2a): 98 to 123 Nm {10 to 12.5 kgm}
9.
Use bolts (1a) (5 pieces) to install control valve cover (1). Tool: Torque wrench (socket) Bolt (1a): M12 with width across flats of 19 mm 3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm} 10. Install the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly". 11. Refilling with oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the system. Then check the oil level again. 5
Hydraulic tank: 85 l (For details, see "Table of fuel, coolant and lubricants".)
12. Air bleeding Bleed air from each part. For details, see Testing and adjusting, "Bleeding air from each part".
D155A-6
7
SEN03372-03
50 Disassembly and assembly
Removal and installation of hydraulic pump assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
8
Part name
Part No.
Specifications
Q'ty
Remarks
1
Socket wrench
(Commercially available)
14 mm
1
2
Socket wrench
(Commercially available)
17 mm
1
3
Socket wrench
(Commercially available)
19 mm
1
4
Socket wrench
(Commercially available)
24 mm
1
5
Socket wrench
(Commercially available)
32 mm
1
6
Socket wrench
(Commercially available)
36 mm
1
7
Spanner wrench
(Commercially available)
17 mm
1
8
Spanner wrench
(Commercially available)
19 mm
1
9
Spanner wrench
(Commercially available)
22 mm
1
10
Spanner wrench
(Commercially available)
27 mm
1
11
Spanner wrench
(Commercially available)
30 mm
1
12
Spanner wrench
(Commercially available)
32 mm
1
13
Spanner wrench
(Commercially available)
36 mm
1
14
Torque wrench (socket)
(Commercially available)
58.8 to 78.4 Nm, 59 to 74 Nm, 98 to 123 Nm, 235 to 285 Nm, 785 to 980 Nm
15
Torque wrench (spanner)
(Commercially available)
34 to 54 Nm, 84 to 132 As Nm, 128 to 186 Nm, 177 to needed 245 Nm
16
Wire
(Commercially available)
2
(25 kg) (30 kg) (110 kg) (270 kg)
17
2-point chain
(Commercially available)
1
(110 kg)
18
Lever block
(Commercially available)
2
19
Lifting and lowering device
(Commercially available)
2
As needed
D155A-6
50 Disassembly and assembly
SEN03372-03
Special tools list Symbol
Q'ty
Remarks
1 Plug (female)
Part name
02789-00210
Part No. #02
Specifications
6
2 Plug (male)
07376-70210
#02
6
3 O-ring
02896-11008
For preventing oil leakage when hose is disconnected • Work equipment pump • Cooling fan pump
1 Plug (female)
02789-10422
#04
1
AC 2 Plug (male)
07376-70422
#04
1
3 O-ring
02896-11012
1 Plug (female)
02789-00522
#05
1
AD 2 Plug (male)
07376-70522
#05
1
3 O-ring
02896-11015
1 Plug (female)
02789-00628
#06
1
2 Plug (male)
07376-70628
#06
1
3 O-ring
02896-11018
AA
AE
6
1
1
1
For preventing oil leakage when hose is disconnected • Cooling fan pump For preventing oil leakage when hose is disconnected • Cooling fan pump For preventing oil leakage when hose is disconnected • Work equipment pump
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.
k Loosen the cap of the hydraulic tank gradually to release the pressure remaining inside the tank. k If you drain the hydraulic oil when it is still hot, you may be scalded. Wait until the hydraulic oil
temperature drops, and then drain the oil. the remaining pressure in the hydraulic circuit referring to Testing and adjusting, "Releasing remaining pressure in hydraulic cylinder circuit". a Note connector numbers and installed positions before disconnecting wiring harnesses and hoses. a When disconnecting wiring, hoses, etc., take care that they are not damaged or deformed by clips, clamps, or the like. When it appears that wiring and hoses may be damaged or deformed, remove clips and clamps in advance.
k Release
D155A-6
9
SEN03372-03
50 Disassembly and assembly
Removal 1.
Remove plug (21) at the bottom of the hydraulic tank, and loosen valve (22) to drain the hydraulic oil. 6
Hydraulic tank: 85 l
Tool: Socket wrench Plug (21): Width across flats of 32 mm a After draining hydraulic oil, be sure to close valve (22) and tighten plug (21). Tool: Torque wrench (socket) 3 Plug (21): 58.8 to 78.4 Nm {6.0 to 8.0 kgm} 2.
Remove plug (23) of the power train case, and loosen valve (24) to drain the power train oil. a This work is not required for the machine with the work equipment pump. 6
3.
4.
Power train case: 90 l
Tool: Socket wrench Plug (23): Width across flats of 32 mm a After draining hydraulic oil, be sure to close valve (24) and tighten plug (23). Tool: Torque wrench (socket) 3 Plug (23): 58.8 to 78.4 Nm {6.0 to 8.0 kgm} Remove the operator’s cab and floor frame assembly. For details, see "Removal and installation of operator's cab and floor frame assembly". a The work of "Removal of floor frame assembly" is required only when "work equipment pump assembly" or "power train and lubrication pump assembly" is removed. Sling power train undercover (25), and remove bolts (25a) (10 pieces). At this time, be sure to use a lever block to remove power train undercover (25) gradually while supporting it from below using the lifting and lowering device. Tool: Socket wrench, wire, lever block, lifting and lowering device 4
Power train undercover (25): 270 kg
Bolt (25a): M24 with width across flats of 36 mm a This work is not required for the work of "removal of cooling fan pump". q
When removing work equipment pump 1)
10
Remove bolts (1a) (2 pieces), and disconnect centralized pressure pickup port and block (1) as a unit. Tool: Socket wrench Bolt (1a): M12 with width across flats of 19 mm
D155A-6
50 Disassembly and assembly
2)
3)
4)
5)
6)
Disconnect hoses (3), (4), (5), and (6). Tool: Spanner wrench, special tools AA and AE Hose (3): Width across flats of 36 mm, #06 size Hoses (4), (5) and (6): Width across flats of 19 mm, #02 size Remove bolts (7a) (2 pieces) to remove accumulator (7) and hose as a unit. Tool: Socket wrench Bolt (7a): M10 with width across flats of 17 mm
Remove bolts (8a) (4 pieces), and disconnect hose (8). Tool: Socket wrench Bolt (8a): M12 with width across flats of 19 mm a Cover the part from which the hose is disconnected using a plastic bag so that oil will not leak out. Disconnect hoses (9) and (10). Tool: Spanner wrench, special tool AA Hoses (9) and (10): Width across flats of 19 mm, #02 size Remove bolts (11a) (4 pieces) to remove block (11). Tool: Socket wrench Bolt (11a): M12 with width across flats of 19 mm
7)
Disconnect wiring harness connectors TVC (12), FAC (13), and HDT (14).
8)
Remove bolts (15a) (2 pieces) to remove wiring harness bracket (15). Tool: Socket wrench Bolt (15a): M12 with width across flats of 19 mm
9)
Remove bolts (16a) (4 pieces) to remove suction tube (16). Tool: Socket wrench Bolt (16a): M12 with width across flats of 19 mm a Loosen fan pump side mounting bolts (4 pieces) of suction tube (16) and remove work equipment pump side mounting bolts (16a) (4 pieces) of suction tube (16). a Cover the part from which the hose is disconnected using a plastic bag so that oil will not leak out.
D155A-6
SEN03372-03
11
SEN03372-03
50 Disassembly and assembly
10) Attach the lifting tool to lifting points (a) and sling work equipment pump assembly (17). a Be sure to wrap a wire around the input shaft side. 4 Work equipment pump assembly (17): 110 kg Tool: 2-point chain, wire 11) Remove bolts (18) (2 pieces), and sling and remove work equipment pump assembly (17). Tool: Socket wrench Bolt (18): M24 with width across flats of 36 mm q
When removing power train and steering lubrication pump 1)
q
12
Remove bolts (1a), (2a), and (3a) (4 pieces each), and disconnect tubes (1), (2), and (3) respectively. Tool: Socket wrench Bolt (1a): M10 with width across flats of 17 mm Bolt (2a): M10 with width across flats of 17 mm Bolt (3a): M12 with width across flats of 19 mm a Cover the part from which the hose is disconnected using a plastic bag so that oil will not leak out. 2) Wrap the belt string around power train and steering lubrication pump assembly (4) and sling the assembly. Tool: Belt sling 3) Remove bolts (5) (2 pieces), and sling and remove power train and steering lubrication pump assembly (4). Tool: Socket wrench Bolt (5): M16 with width across flats of 24 mm 4 Power train and steering lubrication pump assembly (4): 30 kg When removing cooling fan pump 1) Remove the floor mat. 2)
Remove bolts (11a) (13 pieces) to remove covers (11), (11b), and (11c). Tool: Socket wrench Bolt (11a): M12 with width across flats of 19 mm
3)
Disconnect wiring harness connector FAC (1).
D155A-6
50 Disassembly and assembly
SEN03372-03
4)
q
Disconnect hoses (2), (3) and (4). Tool: Spanner wrench, special tools AA, AC and AD Hose (2): Width across flats of 19 mm, #02 size Hose (3): Width across flats of 32 mm, #05 size Hose (4): Width across flats of 27 mm, #04 size 5) Remove bolts (5a) (4 pieces) to remove suction tube (5). Tool: Socket wrench Bolt (5a): M12 with width across flats of 19 mm a Cover the part from which the hose is disconnected using a plastic bag so that oil will not leak out. 6) Use the lifting tool to sling cooling fan pump assembly (6). Tool: Wire 7) Remove bolts (7) (4 pieces) to remove cooling fan pump assembly (6). Tool: Socket wrench Bolt (7): M12 with width across flats of 19 mm 4 Cooling fan pump assembly: 25 kg When removing scavenging pump assembly 1)
2)
3)
D155A-6
Remove bolts (1a) (4 pieces) to disconnect suction tube (1). Tool: Socket wrench Bolt (1a): M12 with width across flats of 19 mm q Scavenging pump side: 4 pieces q PTO case side: 4 pieces a Cover the part from which the hose is disconnected using a plastic bag so that oil will not leak out. Remove bolts (2a) (4 pieces), and disconnect outlet tube (2). Tool: Socket wrench Bolt (2a): M12 with width across flats of 19 mm a Cover the part from which the hose is disconnected using a plastic bag so that oil will not leak out. Remove bolts (3a) (2 pieces) to remove scavenging pump assembly (3). a Because a crane cannot be used for this work, be sure to remove it by 2 persons. Tool: Socket wrench Bolts (3a): M16 with width across flats of 24 mm 4 Scavenging pump assembly: 20 kg
13
SEN03372-03
50 Disassembly and assembly
Installation q
When installing work equipment pump 1)
2)
14
Attach the lifting tool to lifting points (a) to sling work equipment pump assembly (17), and set the assembly to its installed position. a Be sure to wrap a wire around the input shaft side. Tool: 2-point chain, wire 4 Work equipment pump assembly (17): 110 kg Use bolts (18) (2 pieces) to install work equipment pump assembly (17). Tool: Torque wrench (socket) Bolt (18): M24 with width across flats of 36 mm 3 Bolt (18): 785 to 980 Nm {80 to 100 kgm}
3)
Use bolts (16a) (4 pieces) to connect suction tube (16). Tool: Torque wrench (socket) Bolt (16a): M12 with width across flats of 19 mm 3 Bolt (16a): 98 to 123 Nm {10 to 12.5 kgm} a Be sure to install fan pump side mounting bolts of suction tube (16).
4)
Use bolts (15a) (2 pieces) to install wiring harness bracket (15). Tool: Torque wrench (socket) Bolt (15a): M12 with width across flats of 19 mm 3 Bolt (15a): 98 to 123 Nm {10 to 12.5 kgm}
5)
Connect wiring harness connectors TVC (12), FAC (13), and HDT (14).
D155A-6
50 Disassembly and assembly
6)
7)
8)
SEN03372-03
Use bolts (11a) (4 pieces) to install block (11). Tool: Torque wrench (socket) Bolt (11a): M12 with width across flats of 19 mm 3 Bolt (11a): 98 to 123 Nm {10 to 12.5 kgm} Connect hoses (9) and (10). Tool: Torque wrench (spanner) Hoses (9) and (10): Width across flats of 19 mm, #02 size 3 Hoses (9) and (10): 34 to 54 Nm {3.5 to 5.5 kgm} Use bolts (8a) (4 pieces) to connect hose (8). Tool: Torque wrench (socket) Bolt (8a): M12 with width across flats of 19 mm 3 Bolt (8a): 98 to 123 Nm {10 to 12.5 kgm}
9)
Use bolts (7a) (2 pieces) to install accumulator (7) and hose as a unit. Tool: Torque wrench (socket) Bolt (7a): M10 with width across flats of 17 mm 3 Bolt (7a): 59 to 74 Nm {6 to 7.5 kgm} 10) Connect hoses (3), (4), (5), and (6). Tool: Torque wrench (spanner) Hose (3): Width across flats of 36 mm, #06 size 3 Hose (3): 177 to 245 Nm {18.0 to 25.0 kgm} Hoses (4), (5), and (6): Width across flats of 19 mm, #02 size 3 Hoses (4), (5), and (6): 34 to 54 Nm {3.5 to 5.5 kgm} 11) Use bolts (1a) (2 pieces) to install centralized pressure pickup port and block (1) as a unit. Tool: Torque wrench (socket) Bolt (1a): M12 with width across flats of 19 mm 3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
q
When installing power train and steering lubrication pump 1)
2)
3)
D155A-6
Sling power train and steering lubrication pump (4) and set the assembly to its installed position. Tool: Belt sling 4 Power train and steering lubrication pump: 30 kg Use bolts (5) (2 pieces) to install power train and steering lubrication pump assembly (4). Tool: Torque wrench (socket) Bolt (5): M16 with width across flats of 24 mm 3 Bolt (5): 235 to 285 Nm {23.5 to 29.5 kgm} Use bolts (1a), (2a), and (3a) (4 pieces each) to connect tubes (1), (2), and (3). Tool: Socket wrench Bolt (1a): M10 with width across flats of 17 mm 3 Bolt (1a): 59 to 74 Nm {6 to 7.5 kgm} Bolt (2a): M10 with width across flats of 17 mm 3 Bolt (2a): 59 to 74 Nm {6 to 7.5 kgm} Bolt (3a): M12 with width across flats of 19 mm 3 Bolt (3a): 98 to 123 Nm {10 to 12.5 kgm}
15
SEN03372-03 a
q
Cover the part from which the hose is disconnected using a plastic bag so that oil will not leak out.
When installing cooling fan pump 1)
2)
3)
4)
16
50 Disassembly and assembly
Sling cooling fan pump assembly (6), and set the assembly to its installed position. Tool: Wire 4 Cooling fan pump assembly: 25 kg Use bolts (7) (4 pieces) to install cooling fan pump assembly (6). Tool: Torque wrench (socket) Bolt (7): M12 with width across flats of 19 mm 3 Bolt (7): 98 to 123 Nm {10 to 12.5 kgm} Use bolts (5a) (4 pieces) to connect suction tube (5). Tool: Torque wrench (socket) Bolt (5a): M12 with width across flats of 19 mm 3 Bolt (5a): 98 to 123 Nm {10 to 12.5 kgm} Connect hoses (2), (3) and (4). Tool: Torque wrench (spanner) Hose (2): Width across flats of 19 mm, #02 size 3 Hose (2): 34 to 54 Nm {3.5 to 5.5 kgm} Hose (3): Width across flats of 32 mm, #05 size 3 Hose (3): 128 to 186 Nm {13.0 to 19.0 kgm} Hose (4): Width across flats of 27 mm, #04 size 3 Hose (4): 84 to 132 Nm {8.5 to 13.5 kgm}
5)
Connect wiring harness connector FAC (1).
6)
Use bolts (11a) (13 pieces) to install covers (11), (11b), and (11c), and then install the floor mat. Tool: Torque wrench (socket) Bolt (11a): M12 with width across flats of 19 mm 3 Bolt (11a): 98 to 123 Nm {10 to 12.5 kgm}
D155A-6
50 Disassembly and assembly
q
When installing scavenging pump assembly 1) Set the scavenging pump assembly to its installed position, and use bolts (3a) (2 pieces) to install scavenging pump assembly (3). a Because a crane cannot be used for this work, be sure to install it by 2 persons. Tool: Torque wrench (socket) 4 Scavenging pump assembly: 20 kg Bolt (3a): M16 with width across flats of 24 mm 3 Bolt (3a): 235 to 285 Nm {23.5 to 29.5 kgm} 2)
3)
1.
2.
Use bolts (2a) (4 pieces) to connect outlet tube (2). Tool: Torque wrench (socket) Bolt (2a): M12 with width across flats of 19 mm 3 Bolt (2a): 98 to 123 Nm {10 to 12.5 kgm} Use bolts (1a) (4 pieces) to install suction tube (1). Tool: Torque wrench (socket) Bolt (1a): M12 with width across flats of 19 mm 3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm} q Scavenging pump side: 4 pieces q PTO case side: 4 pieces
Install the operator's cab and floor frame assembly. For details, see "Removal and installation of operator's cab and floor frame assembly". a The work of "Installation of operator cab and floor frame assembly" is required only when "work equipment pump assembly" or "power train and lubrication pump assembly" is removed. Refilling with oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Start the engine to circulate the oil through the system. Then, check the oil level again. 5
3.
SEN03372-03
Hydraulic tank: 85 l
Refilling with oil (power train case) Refill with oil to the specified level through the oil filler port. Start the engine to circulate the oil through the system. Then, check the oil level again. a This work is not required for the machine with the work equipment pump assembly. 5
Power train case: 90 l
Refill the hydraulic tank and power train case with oil to respective specified levels. Run the engine to circulate the oil through the piping. Then check the oil level again. Air bleeding Bleed air from each part. For details, see Testing and adjusting, "Bleeding air from each part". q
4.
D155A-6
17
SEN03372-03
5.
6.
18
50 Disassembly and assembly
Sling power train undercover (25) and set it to its installed position. a This work is not required for the work of "removal of cooling fan". Tool: Wire, lever block, lifting and lowering device Use bolts (25a) (10 pieces) to install power train undercover (25). a This work is not required for the work of "removal of cooling fan pump". Tool: Torque wrench (socket), eyebolt, wire Bolt (25a): M24 with width across flats of 36 mm 3 Bolt (25a): 785 to 980 Nm {80 to 100 kgm}
D155A-6
50 Disassembly and assembly
SEN03372-03
Disassembly and assembly of hydraulic cylinder assembly
1
1 2
3
Y 4
5
6
D155A-6
Cylinder repair stand
t
1
790-101-1102
Hydraulic pump
t
1
790-102-3802
Multi-wrench
t
1
t
Part name
790-201-1702
Push tool kit
790-201-1721
• Push tool
1
790-201-1821
• Push tool
1
790-201-1841
• Push tool
1
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
790-201-1630
• Plate
1
790-201-1650
• Plate
1
790-201-1660
• Plate
1
790-201-1670
• Plate
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-720-1000
Expander
t
1
796-720-1670
Ring
t
1
07281-01279
Clamp
t
1
796-720-1690
Ring
t
1
07281-01919
Clamp
t
1
796-720-1720
Ring
t
1
07281-02429
Clamp
t
1
790-102-4300
Wrench
t
1
790-102-4310
Pin
t
2
t
Sketch
790-502-1003
Part No.
New/Remodel
Q'ty
Symbol
Necessity
Special tools
1
1
19
SEN03372-03
50 Disassembly and assembly
Disassembly 1.
Remove the tubes. a Blade lift cylinder and ripper cylinder
2.
Piston rod assembly q Blade lift cylinder 1) Set cylinder assembly (1) to tool Y1. 2) Using the hydraulic pump or the power wrench and tool Y2, remove head assembly (2). 3) Pull piston rod assembly (3). a Put an oil pan under the cylinder to receive the oil.
q
3.
Blade tilt cylinder, ripper lift cylinder, and ripper tilt cylinder 1) Remove the mounting bolt assembly and disconnect head assembly (4). q Width across flats of blade tilt cylinder: 16 mm q Width across flats of ripper lift and tilt cylinders: 18 mm 2) Pull piston rod assembly (5). a Put an oil pan under the cylinder to receive the oil.
Piston assembly q Blade lift cylinder 1) Remove the mounting bolts and spacer (6) and pull out valve (7). 2) Pull out piston assembly (8). 3) Remove backup rings (9) and O-ring (10). 4) Remove retainer (11).
5)
q
20
Disassembly of piston assembly 1] Remove wear rings (12). 2] Remove piston ring (13). a Do not remove seat (14) and valve (15) from the piston.
Ripper tilt cylinders 1) Remove the mounting bolts and spacer (16). 2) Pull out piston assembly (17). 3) Remove backup rings (18) and O-ring (19).
D155A-6
50 Disassembly and assembly
4)
q
SEN03372-03
Disassembly of piston assembly 1] Remove wear rings (20). 2] Remove piston ring (21).
Ripper lift cylinder and ripper tilt cylinder 1) Set piston rod assembly (5) to tool Y1.
2)
Remove lock screw (22) of piston assembly (17). Screw size: M12 x Pitch 1.75
q
a
3)
D155A-6
If screw (22) is crushed so much that it cannot be removed, tighten it and cut threads of the screw hole, and then remove it.
Using tool Y6, remove piston assembly (17) from piston rod (23).
21
SEN03372-03
4)
4.
Disassembly of piston assembly 1] Remove backup ring and O-ring (24). 2] Remove wear ring (25). 3] Remove piston ring (26).
Head assembly 1) Remove head assembly (2) or (4).
2)
Disassembly of head assembly q Blade lift cylinder, ripper lift cylinder, and ripper tilt cylinder 1] Remove O-ring (27). (Only blade lift cylinder) 2] Remove O-ring (28) and backup ring (29). 3] Remove packing (30). 4] Remove ring (31). 5] Remove snap ring (32), and remove dust seal (33). 6] Remove snap ring (34), and remove bushing (35). 1]
Only blade tilt cylinder Remove bolts (36), and remove plate (37).
2] 3] 4] 5] 6]
Remove O-ring (28) and backup ring (29). Remove dust seals (38) and (33). Remove packing (30). Remove snap ring (31). Remove snap ring (34), and remove bushing (35).
q
22
50 Disassembly and assembly
D155A-6
50 Disassembly and assembly
SEN03372-03
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
D155A-6
1]
Using tool Y3, press-fit bushing (35).
2]
Install snap ring (34).
3]
Using tool Y4, install dust seal (33).
23
SEN03372-03
4]
Install snap ring (32).
5] 6] 7] 8]
Install ring (31). Install packing (30). Install O-ring (28) and backup ring (29). Install O-ring (27). (Only blade lift cylinder)
q
Only blade tilt cylinder
q
Only blade tilt cylinder Using tool Y3, press-fit bushing (35).
1]
24
50 Disassembly and assembly
D155A-6
50 Disassembly and assembly
D155A-6
2]
Install snap ring (34).
3] 4] 5]
Install snap ring (31). Install packing (30). Install backup ring (29) and O-ring (28).
6]
Using tool (B), install dust seal (33).
7]
Using plate (37), install dust seal (38).
8]
Install plate (37) with bolts (36).
SEN03372-03
25
SEN03372-03
2)
2.
Install head assembly (2) or (4) to the piston rod.
Piston assembly q Ripper lift cylinder and ripper tilt cylinder 1) Assembly of piston assembly 1] Using tool Y5, expand piston ring (26). a Set the piston ring to tool Y5 and turn the handle of the tool by 8 – 10 turns to expand the piston ring. 2] Remove piston ring (26) from tool Y5 and install it to the piston. 3] Using tool Y5, compress piston ring (26). 4] 5]
26
50 Disassembly and assembly
Install wear ring (25). Install backup ring and O-ring (24). a Before installing the backup ring, warm it in water at 50 – 60 °C. a Apply grease to the O-ring and backup ring so that the backup ring will not open.
2)
Install piston assembly (17) to piston rod (23) and set piston rod assembly (5) to tool Y1.
3)
When reusing piston rod (23) and piston assembly (17), install them according to the following procedure. a Remove burrs and fins from the threaded part with a file. a Clean the parts thoroughly and remove metal chips and dirt. 1] Using tool Y6, tighten piston assembly (17) into piston rod (23) until the screw holes are aligned.
D155A-6
50 Disassembly and assembly
2]
4)
D155A-6
Install screw (22). a Before installing the screw, degrease and dry its threaded part thoroughly. a After installing the screw, bend 4 places around it. 2 Threaded part of screw: Adhesive (LOCTITE No. 262) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} a After installing the screw, bend 4 places around it.
When either or both of piston rod (23) and piston assembly (17) are new, install them according to the following procedure. 1] Using tool Y6, tighten piston assembly (17). 3 Piston assembly: 294 ± 29.4 Nm {30 ± 3.0 kgm} 2] Make 1 screw hole to install the screw. a Apply the drill to the groove in the threads between the piston and piston rod and cut threads horizontally. q Thread cutting dimensions (mm): Tap drill diameter: 10.3 Tap drill depth: 27 Tap size: 12 x 1.75 Tapping depth: 20 3] After making the screw hole, remove chips and dirt and clean thoroughly. 4]
q
SEN03372-03
Install screw (22). a Before installing the screw, degrease and dry it thoroughly. a After installing the screw, bend 4 places around it. 2 Threaded part: Adhesive (LOCTITE No. 262) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm}
Blade tilt cylinder 1) Using tool Y5, install piston ring (21) and wear ring (20), similarly to steps 2-1)-1] – 4] above.
27
SEN03372-03
2)
3)
q
4) 5)
Install retainer (11). Fit O-ring (10) and install backup ring (9). a Before installing the backup ring, warm it in water at 50 – 60 °C. a Apply grease to the O-ring and backup ring so that the backup ring will not open. Install piston assembly (8). Install valve (7) to spacer (6) and install them with the mounting bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98.1 – 122.6 Nm {10 –12.5 kgm}
Piston rod assembly q Blade lift cylinder 1) Set cylinder (1) to tool Y1. 2) Install piston rod assembly (3) to the cylinder. 2 Sealing part: Grease (G2-LI) a Push in the piston rod to the stroke end. 3) Using tool Y2, tighten head assembly (2). 3 Head assembly: 1373 ± 137 Nm{140 ± 14 kgm} q
28
Install O-ring (19) and backup ring (18) to the piston rod and then install piston assembly (17). a Before installing the backup ring, warm it in water at 50 – 60 °C. a Apply grease to the O-ring and backup ring so that the backup ring will not open. Fix with spacer (16) and tighten the mounting bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98.1 – 122.6 Nm {10 –12.5 kgm}
Blade lift cylinder 1) Using tool Y5, install piston ring (13) and wear ring (12), similarly to steps 2-1)-1] – 4] above.
2) 3)
3.
50 Disassembly and assembly
Blade tilt cylinder, ripper lift cylinder and ripper tilt cylinder 1) Install piston rod assembly (5) to the cylinder. 2 Sealing part: Grease (G2-LI) a Push in the piston rod to the stroke end. 2) Tighten head assembly (4) with the mounting bolts. 3 Mounting bolt: q Blade tilt (343 ± 34.3 Nm {35 ± 3.5 kgm}) q Ripper lift (343 ± 34.3 Nm {35 ± 3.5 kgm}) q Ripper tilt (490 ± 49 Nm {50 ± 5.5 kgm})
D155A-6
50 Disassembly and assembly
D155A-6
SEN03372-03
29
SEN03372-03
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03372-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
30
D155A-6
SEN03373-02
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Work equipment Removal and installation of blade assembly ................................................................................................... 2 Disassembly and assembly of multi-shank ripper........................................................................................... 6
D155A-6
1
SEN03373-02
50 Disassembly and assembly
Removal and installation of blade assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
27 mm
1
2
Socket wrench
(Commercially available)
30 mm
1
3
Socket wrench
(Commercially available)
32 mm
1
4
Spanner wrench
(Commercially available)
22 mm
1
5
Spanner wrench
(Commercially available)
27 mm
1
6
Torque wrench (socket)
(Commercially available)
320 to 400 Nm, 455 to 565 Nm, 632.5 to 828.7 Nm
7
Torque wrench (spanner)
(Commercially available)
84 to 132 Nm
8
Block
(Commercially available)
2
9
Belt sling
(Commercially available)
2
10
Lever block
(Commercially available)
1
11
Hydraulic jack
(Commercially available)
2 to 5 ton
Remarks
As needed 1 [1]
2
Special tools list Symbol
AC
Q'ty
Remarks
1 Plug (female)
Part name
02789-10422
Part No. #04
Specifications
2
2 Plug (male)
07376-70422
#04
2
3 O-ring
02896-11012
For preventing oil leakage when hose is disconnected • Work equipment hose
2
k Park the machine on level ground, and set the parking brake lever to the LOCK position.
k Lower the work equipment onto level ground, and set block [1] to each I frame on both sides.
k Loosen the cap of the hydraulic tank gradually to release the pressure remaining inside the tank. k Before disconnecting hydraulic pipes and hoses, be sure to release the remaining pressure in
the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure. For details, see Testing and adjusting, "Releasing remaining pressure in hydraulic circuit". k If you disconnect a hydraulic hose when hydraulic oil is still hot, you may be scalded. Wait until the hydraulic oil temperature drops, and then disconnect the hydraulic hose. a Check and note the connector numbers and installed positions before disconnecting wiring harnesses and hoses. a When disconnecting wiring, hoses, etc., take care that they are not damaged or deformed by clips, clamps, or the like. When it appears that wiring and hoses may be damaged or deformed, remove clips and clamps in advance.
2
D155A-6
50 Disassembly and assembly
SEN03373-02
Removal 1.
Lower the work equipment onto level ground, and set block [1] to each I frame on both sides. a Be sure to set block [1] so that there is no space between block [1] and the frame.
2.
Remove bolts (1a) (4 pieces) to remove cap (1) of the lift cylinder. a Be sure to remove bolt (1a) gradually in preparation for movement of the blade cylinder due to internal pressure. Tool: Socket wrench Bolt (1a): M18 with width across flats of 27 mm a Note the number of shims installed by thickness.
3.
Sling blade lift cylinder assembly (2), start the engine, and retract blade lift cylinder rod (2a) fully. a To prevent the angle of the blade lift cylinder from changing, wind the lifting tools around the blade lift cylinder at its head and bottom ends in a balanced manner, and sling the cylinder so that current cylinder angle will be maintained. Tool: Belt sling Use stay (7) to secure blade lift cylinder assembly (3) to the chassis. a Be sure to fix the blade lift cylinder rod using wire so that it will not come out. Follow steps 2 to 4 to disconnect the blade lift cylinder on the opposite side from the blade.
4.
5. 6. 7.
8. 9.
Bleed air from the blade cylinder cylinders and tilt cylinders. For details, see Testing and adjusting, "Bleeding air from work equipment cylinder". Remove bolts (3a) (6 pieces each on the right and left side) to remove each of right and left trunnion covers (3). Tool: Socket wrench Bolt (3a): M20 with width across flats of 30 mm Disconnect hoses (4) (2 pieces). Tool: Spanner wrench, special tool AC Hose (4): Width across flats of 27 mm, #04 size Remove bolts (5a) (2 pieces each on the right and left side) to remove each of right and left trunnion caps (5), and remove blade assembly (6). Tool: Socket wrench Bolt (5a): M22 with width across flats of 32 mm a Start the engine, and move the machine slowly in reverse to disconnect the blade assembly from the trunnions.
D155A-6
3
SEN03373-02
50 Disassembly and assembly
Installation 1.
Adjust height (b) of the right and left straight frames of the removed work equipment and width (c) between them to the following dimensions using hydraulic jacks and blocks [1]. Tool: Block [1], hydraulic jack a The following dimensions are basic ones and some margin for error exists. Height (b): Approximately 636 mm Width (c): Approximately 3,053 mm
2.
Start the engine, and move the machine slowly forward to join the trunnions with trunnion parts of the blade (6).
3.
Use bolts (5a) (4 pieces) to install right and left trunnion caps (5). Tool: Torque wrench (socket) Bolt (5a): M22 with width across flats of 32 mm 3 Bolt (5a): 632.5 to 828.7 Nm {64.5 to 84.5 kgm} Connect hoses (4) (2 pieces each). Tool: Torque wrench (spanner) Hose (4): Width across flats of 27 mm, #04 size 3 Hose (4): 84 to 132 Nm {8.5 to 13.5 kgm} a Before connecting hose (4), be sure to check that the hose is not twisted. a Hose on cylinder head side: Yellow band Hose on cylinder bottom side: Without band Use bolts (3a) (6 pieces each) to install each of covers (3) on both sides. Tool: Torque wrench (socket) Bolt (3a): M20 with width across flats of 30 mm 3 Bolt (3a): 455 to 565 Nm {46.5 to 58 kgm}
4.
5.
6.
4
Install blade lift cylinder assembly (2) to the blade according to the following procedure. 1) Remove fixing wire from blade lift cylinder assembly (2) being slung. Tool: Belt sling
D155A-6
50 Disassembly and assembly
2) 3)
4)
7. 8.
SEN03373-02
Start the engine, and extend blade lift cylinder rod (2a) to perform positioning of mounting bores for pin (8). Use bolts (1a) (4 pieces) to install cap (1) of blade lift cylinder rod (2a) lightly. Tool: Socket wrench
Tighten bolts (1a) (4 pieces) to the specified torque. a Perform shim adjustment to adjust clearance (a) between cap mating faces to the following dimension. a Perform the shim adjustment while referring to the number of shims by thickness noted at the time of removal. q Standard clearance (a): 0.2 to 1.2 mm q Standard thickness of shim pack: 4 mm a Check that cap (2) turns smoothly. Tool: Torque wrench (socket) Bolt (1a): M18 with width across flats of 27 mm 3 Bolt (1a): 320 to 400 Nm {33 to 41 kgm}
Follow the same procedure to install the blade lift cylinder on the opposite side to the blade. Refilling with oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping, and check the oil level again. 5
Hydraulic oil (For details, see "Table of fuel, coolant and lubricants".): Only necessary quantity
9.
Perform blade tilt adjustment after installing the blade. For details, see Testing and adjusting, "Adjusting blade". 10. Bleeding air from work equipment cylinder Bleed air from the piping. For details, see Testing and adjusting, "Bleeding air from work equipment cylinder". 11. Operate the work equipment to check for unusual noise or defect.
D155A-6
5
SEN03373-02
50 Disassembly and assembly
Disassembly and assembly of multi-shank ripper
1
Disassembly a
Plug the disconnected pipings and hoses so that dirt will not enter them.
1.
Run the engine and set the ripper in the maximum raising and maximum tilt-in position.
2.
Sling shank (1), remove the lock pin to remove mounting pin (2), and lower shank (1) slowly to remove. 4
Shank: 270 kg
3.
Set support stands [1] under the beam, set block [2] under the arm, and lower the ripper assembly.
4.
Sling lift cylinder assembly (3), remove the lock plate, and pull out pin (4) on the rod side. a Run the engine, retract the piston rod fully, and lower it to the arm.
5.
Sling tilt cylinder assembly (5), remove the lock plate, and pull out pin (6) on the rod side. a Run the engine, retract the piston rod fully, and lower it to the arm. a Install the pin to the beam temporarily since it is used when the beam is removed. k Release the residual pressure in the piping, referring to Testing and adjusting, "Releasing residual pressure in hydraulic circuit". Then, loosen the hydraulic tank cap gradually to release the internal pressure of the hydraulic tank.
6
D155A-6
50 Disassembly and assembly
6.
Disconnect lift cylinder hose (7) and tilt cylinder hose (8) and move them toward the fuel tank.
7.
Sling lift cylinder assembly (3), remove the lock plate, pull out pin (9), and lift off lift cylinder assembly (3).
8.
4 Lift cylinder assembly: 190 kg Sling tilt cylinder assembly (5), pull out pin (9), and lift off tilt cylinder assembly (5). 4
9.
SEN03373-02
Tilt cylinder assembly: 260 kg
Sling beam (10), remove the lock plates, pull out right and left pins (11), and lift off beam (10). 4
Beam: 1,250 kg
10. Sling arm (12), remove the lock plates, pull out right and left pins (13), and lift off arm (12). 4
D155A-6
Arm: 650 kg
7
SEN03373-02
50 Disassembly and assembly
Assembly 1.
Sling arm (12), install right and left pins (13), and fix them with the lock plates. 4
a
2.
Arm: 650 kg Set block [2] under the arm.
Sling beam (10), install right and left pins (11), and fix them with the lock plates. 4
a
3.
4.
Beam: 1,250 kg Set support stands [1] under the beam.
Sling tilt cylinder assembly (5) and install pin (9). 4 Tilt cylinder assembly: 260 kg a After installing, lower the rod side to the arm. Sling lift cylinder assembly (3), push in pin (9), and fix it with the lock plate. 4
a
Lift cylinder assembly: 190 kg After installing, lower the rod side to the arm.
5.
Connect tilt cylinder hose (8) and lift cylinder hose (7).
6.
Sling tilt cylinder assembly (5), run the engine, extend the piston rod, align the pin holes, install pin (6), and fix it with the lock plate.
8
D155A-6
50 Disassembly and assembly
7.
Sling lift cylinder assembly (3), run the engine, extend the piston rod, align the pin holes, install pin (4), and fix it with the lock plate.
8.
Run the engine and set the ripper in the maximum raising and maximum tilt-in position. Pass a wire through the shank mounting hole of the beam and sling shank (1). Install pin (2) and fix it with the lock pin.
9.
4
SEN03373-02
Shank: 270 kg
10. Greasing After assembling, supply sufficient amount of grease to each pin. 2 Pin: Grease (G2-LI) 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.
D155A-6
9
SEN03373-02
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03373-02
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
10
D155A-6
SEN03375-01
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Cab and its attachments Removal and installation of operator's cab assembly ..................................................................................... 2 Removal and installation of operator's cab glass (adhered window glass)..................................................... 7 Removal and installation of operator's cab and floor frame assembly.......................................................... 17
D155A-6
1
SEN03375-01
50 Disassembly and assembly
Removal and installation of operator's cab assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
19 mm
1
2
Socket wrench
(Commercially available)
24 mm
1
3
Socket wrench
(Commercially available)
30 mm
1
4
Socket wrench
(Commercially available)
36 mm
1
5
Hexagonal wrench
(Commercially available)
4 mm
1
6
Phillips screwdriver
Commercially available
7
Torque wrench (socket)
(Commercially available)
98 to 123 Nm, 279 ± 27.9 Nm, 294 ± 29.4 Nm
8
Torque wrench (hexagonal)
(Commercially available)
9.8 Nm
1
9
Torque wrench (Phillips screwdriver)
(Commercially available)
2.83 ± 0.28 Nm
1
10
4-point chain
(Commercially available)
1
11
Lever block
(Commercially available)
1
Remarks
1 As needed
(410 kg)
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.
a When disconnecting wiring, hoses, etc., take care that they are not damaged or deformed by clips, clamps, or the like. When it appears that wiring and hoses may be damaged or deformed, remove clips and clamps in advance.
2
D155A-6
50 Disassembly and assembly
SEN03375-01
Removal 1. 2. 3.
4. 5.
Remove screws (1a) (4 pieces) and remove cover (1). Tool: Hexagonal wrench Screw (1a): M6 with width across flats of 4 mm Reverse the cover (1) and disconnect wiring connector ACC. Remove screws (2a) (8 pieces), (3a) (2 pieces) and (4a) (32 pieces), and remove cover (2), (3) and (4). Tool: Hexagonal wrench Screws (2a), (3a), (4a): M6 with width across flats of 4 mm
Disconnect washer hoses (5) (4 pieces). a Left side of operator's cab Disconnect wiring harness connectors CBPW (6) and WST (7). a Rear left side of operator's cab
6.
Remove bolts (8a) (2 pieces), and remove cover (8). Tool: Socket wrench Bolt (8a): M12 with width across flats of 19 mm
7.
Disconnect wiring harness connector DSH (9). Tool: Phillips screwdriver
8.
Remove operator's cab front lower mounting bolts (10) (6 pieces each on right and left sides). Tool: Socket wrench Bolt (10): M16 with width across flats of 24 mm
D155A-6
3
SEN03375-01
9.
50 Disassembly and assembly
Remove operator's cab inside mounting bolts (11a) (6 pieces) and (11b) (15 pieces) . q Left side front bolt (11a): 3 pieces, left side rear bolt (11b): 4 pieces q Right side front bolt (11a): 3 pieces, right side rear bolt (11b): 4 pieces q Rear bolt (11b): 7 pieces Tool: Socket wrench Bolt (11a): M24 with width across flats of 36 mm Bolt (11b): M20 with width across flats of 30 mm (Operator’s cab inside mounting bolt) Rear bolt (11b): 7 pieces ----- [1]※ to [5]※, [8]※, [9]※ q Left side rear bolt (11b): 4 pieces ----- [6]※, [7]※, [12]※, [13]※ q Right side rear bolt (11b): 4 pieces ----- [10]※, [11]※, [14]※, [15]※ q Left side front bolt (11a): 3 pieces -----[16]a, [17]a, [18]a q Right side front bolt (11a): 3 pieces -----[19]a, [20]a, [21]a (Operator's cab front lower mounting bolt) q Left lower bolt (10): 6 pieces ----- [22] ☆ q Right lower bolt (10): 6 pieces ----- [23] ☆ q
10. Attach the lifting tool to lifting points (a) (4 places) and sling operator cab assembly (12). Tool: 4-point chain, lever block 4
Operator's cab assembly (12): 410 kg
11. Sling operator's cab assembly (12), and remove it.
4
D155A-6
50 Disassembly and assembly
SEN03375-01
Installation 1.
Attach the lifting tool to lifting points (a) (4 places), sling operator cab assembly (12), and set it to its installed position. Tool: 4-point chain, lever block 4
2.
Operator's cab assembly (12): 410 kg
Install operator's cab front lower mounting bolts (10) (8 pieces) and operator's cab inside mounting bolts (11a) (6 pieces) and (11b) (15 pieces). 1) Tighten all the bolts in the numerical order ([1] to [23]) shown in the figure. (Operator’s cab inside mounting bolt) q q q q q
Rear bolt (11b): 7 pieces ----- [1]※ to [5]※, [8]※, [9]※ Rear left side bolt (11b): 4 pieces ----- [6]※, [7]※, [12]※, [13]※ Right side rear bolt (11b): 4 pieces ----- [10]※, [11]※, [14]※, [15]※ Left side front bolt (11a): 3 pieces ----- [16]a, [17]a, [18]a Right side front bolt (11a): 3 pieces -----[19]a, [20]a, [21]a
(Operator's cab front lower mounting bolt) q q
2)
D155A-6
Left lower bolt (10): 6 pieces ----- [22] ☆ Right lower bolt (10): 6 pieces ----- [23] ☆
Tool: Torque wrench (socket) Bolt (10): M16 with width across flats of 24 mm 3 Bolt (10): 279 ± 27.9 Nm {28.5 ± 2.8 kgm} Bolt (11a): M24 with width across flats of 36 mm 3 Bolt (11a): 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Bolt (11b): M20 with width across flats of 30 mm 3 Bolt (11b): 294 to 29.4 Nm {30.0 to 3.0 kgm} Retighten bolts (1) to (21) by 60 ± 10° further.
5
SEN03375-01
3.
Connect wiring harness connector DSH (9). a Check that the connector is equipped with sealing rubbers (2 pieces, brown) and is not damaged before installation. Tool: Torque wrench (Phillips screwdriver) 3 Mounting bolt of connector (9): 2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
4.
Use bolts (8a) (2 pieces) to install cover (8). Tool: Torque wrench (socket) Bolt (8a): M12 with width across flats of 19 mm 3 Bolt (8a): 98 to 123 Nm {10 to 12.5 kgm}
5.
Connect wiring harness connectors CBPW (6) and WST (7). Connect washer hoses (5) (4 pieces). q Be sure to connect washer hoses to correct parts according to their band colors. Red: Right door Blue: Left door Black: Rear window Without color band: Front window
6.
7.
8. 9.
6
50 Disassembly and assembly
Install cover (2), (3) and (4) with screws (2a) (8 pieces), (3a) (2 pieces) and (4a) (32 pieces). Tools: Torque wrench set (hexagonal wrench) Screws (2a), (3a), (4a): M6 with width across flats of 4 mm 3 Screw (2a), (3a), (4a): 9.8 Nm {1.0 kgm} (target value) Connect wiring harness connector ACC. Connect cover (1) with screw (1a) (4 pieces). Tool: Hexagonal wrench Screw (1a): M6 with width across flats of 4 mm 3 Screw (1a): 9.8 Nm {1.0 kgm} (target value)
D155A-6
50 Disassembly and assembly
SEN03375-01
Removal and installation of operator's cab glass (adhered window glass)
1
※ Among window glass sections of the operator's cab, 3 window glass sections (1) and (3) (R.H. and L.H.) shown in the figure are of the adhesion type. This section describes replacement procedures of adhered window glass. (1): Front window glass (2): Dam rubber (3): Door window glass (R.H. and L.H.) (4): Dam rubber (R.H. and L.H.) (5): Trim seal (R.H. and L.H.) (6): Door handle (R.H. and L.H.)
D155A-6
7
SEN03375-01
50 Disassembly and assembly
Standard tools list No.
Part name
Part No.
Specifications
Q'ty
Remarks
1
Seal cutter
1
[1]
2
Extra fine wire (piano wire, etc.)
1
[2]
3
Pliers
1
[3]
4
Cutter
1
[4]
5
Scraper
1
[5]
6
Plastic tape
1
[6]
7
Caulking gun
1
[7] (motorized model is recommended.)
8
Masking tape
1
[8]
9
Rubber paddle
1
[9]
10
Expanded styrene foam
1
[10]
11
Rubber band
1
[11]
12
Dam rubber
1
[12]
1
[13]
13
Sika Japan (Sikaflex 256HV super)
Adhesive
14
White gasoline
1
15
Sealing tape
1
16
Screwdriver
1
Special tools list Symbol X
8
Part name
1 Lifter (suction cup)
Part No. 793-498-1210
Specifications
Q'ty
Remarks
2
D155A-6
50 Disassembly and assembly
SEN03375-01
Removal a 1.
Remove the glass to be replaced according to the following procedure. Cut the adhesive between broken glass (6) and operator's cab (metal sheet) (7) using seal cutter [1]. Tool: Seal cutter
a
When the seal cutter is not available, use a drill to bore a hole in the adhesive and dam rubber, and thread extra fine wire (piano wire, etc.) through the hole. Pinch both ends of the extra fine wire passed through the hole with pliers [3] (or loop it around to fix), and shuttle the wire to cut the adhesive and dam rubber. Tool: Extra fine wire, pliers, (dam rubber), (adhesive) The wire may break due to frictional heat. Apply lubricant to the wire during the work. (The figure shows the operator's cab on a wheel loader.) a
2.
If the glass is broken into small pieces, it may be removed with a cutter knife [4] and a flat-head screwdriver. a While widening the cut with a flat-head screwdriver, cut the adhesive and dam rubber with a cutter knife [4]. (The figure shows the operator's cab on a wheel loader.) Remove dirt and dust on the glass surface completely, and use the suction cup lifter to remove the glass carefully.
D155A-6
9
SEN03375-01
50 Disassembly and assembly
Installation 1.
Remove the remaining adhesive and dam rubber from the sheet metal (adhesion surfaces) of the operator's cab using a knife and scraper [5]. Tool: Cutter, scraper a Note that removal of the adhesive and dam rubber left on the sheet metal surface is sufficient if they do not affect the bonding effect of new adhesive. You must avoid damaging the coating surface by excessive scraping. (If the painted surfaces are damaged, adhesion will be reduced.) (The figure below shows the operator's cab on a wheel loader.)
2.
Remove oil, dust, dirt, etc. from the adhesion surfaces on cab (7) and glass (8) with white gasoline. Tool: White gasoline a Clean them thoroughly since insufficient cleaning induces defective adhesion. a Clean all the black areas on the back of the window glass. a After cleaning, dry them naturally for more than 5 minutes.
3.
Install dam rubber (double-sided adhesive tape) [12] on the mounting portions for the front window glass and right and left door window glass components along the inside edge. Tool: Dam rubber a Do not remove the tape on the glass-adhering side of the dam rubber until installation of the window glass is started. a When installing the dam rubber, do not touch the cleaned surface.
a a
10
Take care that the dam rubber does not float up in each sticking corner. Be careful to prevent dam rubber [12] from overlapping in the abutment joint of the starting and terminating ends. Or provide a clearance of about 5 mm in abutment joint (a).
D155A-6
50 Disassembly and assembly
4.
Install trim seal (4) to the right and left door window glasses (2).
a
5.
SEN03375-01
Install trim seal (4) so that its starting and terminating ends join at position (c) where dimension (b) from a corner is 90 mm.
Perform position alignment of window glass sections to be replaced. 1) Use tool X1 {lifter (suction cup)} to set the glass to its installed position, check the clearances to the operator's cab on the right, left, upper, and lower sides, and adjust the position of the glass so that the clearances are even. Tool: Special tool X1 {lifter (suction cup)} a For positioning of front window glass (1), perform the work from the inside of operator's cab. Adjust position of the front window glass so that the distance between the black coating (black ceramic) part of the front window glass and the sheet metal of operator's cab (7) is even on the right, left, upper, and lower sides.
D155A-6
11
SEN03375-01 a
2)
50 Disassembly and assembly
For positioning of right and left door window glass (2), align center of holes (d) for the handle of door (9) (holes in the glass and door sheet metal), and then adjust position of the door window glass so that positional relationship between the glass and door sheet metal is even around the entire circumference.
After positioning is completed, for the front glass, stick tool [6] (tape) between glass (1) and operator's cab (7) at right and left sides. For door window glass, stick tool [6] (tape) between right and left door window glass (2) and operator's cab (7) at three places of right, left, and bottom sides. Then, draw positioning line (e) on each tape. Tool: Tape
3)
6.
12
Cut the tape between window glass sections (1) and (2) and operator's cab (7) with a knife, and remove the window glasses. a Do not remove the tape left on the glass and the operator's cab until the glass is installed. Apply adhesive [13]. 2 Adhesive: Sika Japan (Sikaflex 256HV) a Do not use primer. a The use limit of adhesive is 6 months after its production. Do not use the adhesive beyond this limit. a Adhesives must be stored at 25°C or lower in a dark and cool place. a Do not heat the adhesive any higher than 30°C. a When reusing the adhesive, remove the hardened adhesive at the nozzle tip completely. 1)
Break the aluminum dehumidification film [13b] at the mouth of adhesive cartridge [13a], and attach nozzle [13c].
2)
Cut the tip of adhesive nozzle [13c] to dimensions (f) and (g) as shown in the figure. q Dimension (f): 10 mm q Dimension (g): 15 mm
D155A-6
50 Disassembly and assembly
3)
Set adhesive cartridge [13a] on caulking gun [7]. Tool: Caulking gun a A better workability is obtainable from a power caulking gun.
4)
Remove tape [12a] on the glass-bonding side of the dam rubber.
5)
Apply adhesive [13] to outside portion of dam rubber [12] on the operator's cab. Tool: Adhesive, caulking gun
D155A-6
SEN03375-01
13
SEN03375-01
a
a a
7.
Apply adhesive [13] according to dimensions (h) and (j), which are relative to dam rubber [12] on operator's cab (7), indicated in the figure. q Dimension (h): 10 mm q Dimension (j): 15 mm Thickness of applied adhesive [13] must be higher than that of dam rubber[12]. Height of applied adhesive must be even.
Install the front window glass. 1) Install front window glass (1) to operator's cab (7) using tool X1 {lifter (suction cup) while aligning lines (e) of positioning tapes [6] attached in step 5. Tool: Special tool X1 {lifter (suction cup)} a Since the glass cannot be removed and installed again, install it with utmost caution. a Glass bonding work must be finished within 5 minutes from application of adhesive.
2) 3) 4)
5)
14
50 Disassembly and assembly
After installing the glass, press entire circumferential area until it adheres firmly to the dam rubber. a Press the corners of the glass firmly. Stick masking tape [8] on front window glass (1) and operator’s cab (7) to mask them. Apply caulking agent (14) to the gap between front window glass (1) and operator’s cab (7). Caulking agent: SEKISUI Silicone Sealant a Since useful life of the caulking agent is 6 months from the date of production, be sure not to use an overdue caulking agent. After applying caulking agent (14) to front window glass (1), arrange the shape of caulking agent with your fingers.
D155A-6
50 Disassembly and assembly
a
8.
SEN03375-01
For the area such as around the handrail where it is hard to arrange the shape of caulking agent with your fingers, use rubber paddle [9].
Install the right and left door window glasses. 1)
2)
D155A-6
Install right and left door window glasses (2) to right and left doors (9) using tool X1 {lifter (suction cup)} while aligning lines (e) of positioning tape [6] attached in step 4. Tool: Special tool X1 {lifter (suction cup)} a Since the glass cannot be removed and installed again, install it with utmost caution. a Glass bonding work must be finished within 5 minutes from application of adhesive. After installing the glass, press entire circumferential area until it adheres firmly to the dam rubber. a Press the corners of the glass firmly. a If adhesive [13] protrudes from trim seal (4) on the stuck right and left door glass, use rubber paddle [9] to remove it.
15
SEN03375-01
3)
9.
50 Disassembly and assembly
Caulk the area of dimension (k) between the right and left door glass and trim seal. 1] Mask the area of dimension (k) of the right and left door glass. 2] Apply the caulking agent to gap (m) between right and left door glass (2) and trim seal (4). a Since useful life of the caulking agent is 6 months from the date of production, be sure not to use an overdue caulking agent. a Apply the caulking agent to abutment joint (c) of the trim seal. 2 Caulking agent: SEKISUI Silicone Sealant
Fix window glass (9). 1) To make the front window glass adhere tightly, fix it using expanded styrene foam [10] and rubber band [11] for curing. Tool: Expanded styrene foam a Sealing tape may be used in substitution for expanded styrene foam [10] and rubber band [11]. (The figure shows the operator's cab on a hydraulic excavator.)
2)
For the right and left door window, install door handle (5) and fix it immediately after the glass is stuck.
10. After installing the glass, remove any excess of the primer and adhesive on the operator's cab and glass. Tool: White gasoline a Wipe off adhesive before it dries up using white gasoline. a When cleaning the glass, do not apply force to it. 11. Cure the adhered glass. 1) Keep the stopper rubbers, expanded styrene foam blocks, and rubber bands installed for 10 hours. (Ambient temperature: 20?, Humidity: 65 %) 2) Before actual machine operation, let it cure for 24 hours after the adhesive is applied.
16
D155A-6
50 Disassembly and assembly
SEN03375-01
Removal and installation of operator's cab and floor frame assembly 1 Standard tools The described tool is a reference. If it has a purpose, it can be used other than the described tool. No.
Part name
Part No
Specification
Q'ty
1
Socket wrench
(Commercially available)
7 mm
1
2
Socket wrench
(Commercially available)
10 mm
1
3
Socket wrench
(Commercially available)
17 mm
1
4
Socket wrench
(Commercially available)
19 mm
1
5
Socket wrench
(Commercially available)
30 mm
1
6
Socket wrench
(Commercially available)
36 mm
1
7
Spanner wrench
(Commercially available)
19 mm
1
8
Spanner wrench
(Commercially available)
22 mm
1
9
Spanner wrench
(Commercially available)
24 mm
1
10
Hexagonal wrench
(Commercially available)
24 mm
1
11
Torque wrench (socket)
(Commercially available)
4 to 7 Nm, 6.8±0.49 Nm, 59 to 74 Nm, 98 to 123 As Nm, 455 to 565 Nm, 824 to needed 1,030 Nm
12
Torque wrench (spanner)
(Commercially available)
30 to 35 Nm, 54 to 93 Nm
13
Torque wrench (Hexagonal wrench)
(Commercially available)
2.83±0.28 Nm
14
Eyebolt
(Commercially available)
1
15
Wire
(Commercially available)
2
16
4-point chain
(Commercially available)
1
17
Lever block
(Commercially available)
1
18
Belt sling
(Commercially available)
1
D155A-6
Remarks
As needed 1
(1,000 kg)
17
SEN03375-01
50 Disassembly and assembly
Special tools No.
Part name
1 Plug (female)
Part No
Specification
Q'ty
Remarks Pin puller hose (2) Additional filter hoses (2)
02789-00315
#03
8
AB 2 Plug (male)
07376-70315
#03
8
3 O-ring
02896-11009
8
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.
k When disconnecting heater hoses or draining coolant, if the radiator coolant temperature is still
hot, you may be scalded. Wait until the coolant temperature drops, and then perform the work.
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before discon-
necting air conditioner hoses. a Ask qualified persons for handling refrigerant (air conditioner gas: R134a). (Only registered persons can perform this work.) a Never release the refrigerant (air conditioner gas: R134a) into the atmosphere. k If the refrigerant (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant. a Check and note the connector numbers and installed positions before disconnecting wiring harnesses and hoses. a When disconnecting wiring, hoses, etc., take care that they are not damaged or deformed by clips, clamps, or the like. When it appears that wiring and hoses may be damaged or deformed, remove clips and clamps in advance.
18
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50 Disassembly and assembly
SEN03375-01
Removal 1. 2.
Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. a Refrigerant to be collected: 900±50 g Remove fuel tank assembly. For details see "Removal and installation of fuel tank assembly".
3.
Remove bolts (1a) (5 pieces) and remove control valve cover (1). Tools: Socket wrench Bolt (1a): Width across flats 19 mm, M12
4.
Disconnect 8 PPC hoses (2) to (9). Tools: Spanner wrench, Special tool AB Hose (2) to (9): Width across flats 22, #03 size a (Color code of each hoses) (2) Red (6) Black-red (3) Yellow (7) Black-yellow (4) Green (8) Black-green (5) Brown (9) Black-brown
5.
Remove bolts (10a) to (13a) (each 1 piece) and disconnect 4 clamps (10) to (13). Tools: Lever block Bolts (10a) to (13a): Width across flats 19 mm, M12
6. 7.
Open side cover (14), both side of right and left. Rmove bolts (15a) (3 pieces) and remove cover (15). Tools: Socket wrench Bolts (15a): Width across flats 19 mm, M12 a Both side of left and right. Remove bolts (16a) (4 pieces) and remove cover (16). Tools: Socket wrench Bolts (16a): Width across flats 19 mm, M12 a Both side of left and right.
8.
9.
Remove bolts (2 pieces) of clamp. Bolt of clamp: Width across flats 19 mm, M12
D155A-6
19
SEN03375-01
50 Disassembly and assembly
10. Disconnect air conditioner hoses (17) and (18). Tools: Spanner wrench Hose (17): Width across flats 27 mm, M24 Connection bolt of hose (18): Width across flats 10 mm, M6 a Cover the part from which a hose is disconnected using a plastic bag so that oil will not leak out.
11. Disconnect heater hoses (19) and (20). a Cover the part from which a hose is disconnected using a plastic bag so that oil will not leak out. 12. Disconnect battery cable (21).
13. Remove bolts (22) (2 pieces) and disconnect duct hose and flange (24). Tools: Socket wrench Bolts (22): Width across flats 17 mm, M10
14. Attach the lifting tool to parts (a) and temporarily sling battery top cover (23). Tool: Belt sling 4
Cover (23): 75 kg
15. Remove bolts (23a) (5 pieces) and lift off battery top cover (23). Tools: Socket wrench, Belt sling Bolts (23a): Width across flats 19 mm, M12
20
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50 Disassembly and assembly
SEN03375-01
16. Loosen clamp (24a) and remove duct hose and flange (24) from flange (25). Tools: Socket wrench Mounting bolts of clamp (24a): Width across flats 7 mm
17. Remove bolt (26a) and disconnect ground wire (26). Tools: Socket wrench Bolts (26a): Width across flats 19 mm, M12
18. Disconnect 4 window washer hoses (27). 19. Disconnect wiring harness (28).
20. Disconnect wiring harness connectors FSB (29), PL1 (30), FD1 (31) and FD4 (32). Tool: Hexagonal wrench Mounting bolt of connector (30): Width across flats 4 mm
21. Remove bracket mounting bolts (33) (each 4 pieces) in front of the floor frame. (right and left). Tools: Socket wrench Bolts (33): Width across flats 30 mm, M20
D155A-6
21
SEN03375-01
50 Disassembly and assembly
22. Remove mounting bolts (34) (1 piece on each side) at the rear right and left of the floor frame. Tools: Socket wrench Bolts (34): Width across flats 36 mm, M24 23. Remove pins (36) according to the following procedure. a Use the same procedures shown in steps 22.-1) to 3) for removal of front, rear, right and left pins (36) (4 pieces). 1) Remove bolts (35a) (2 pieces) and remove cover (35). Tools: Socket wrench Bolts (35a): Width across flats 19 mm, M12 2)
3)
Temporarily sling pin (36), and screw in bolt (37a). a The pin needs to be slung so that the pin (9) will not drop. Tools: Socket wrench, Eyebolt(M8), Wire Bolts (37a): Width across flats 19 mm, M12 Remove pin (37), and sling and remove pin (36).
24. Lift off operator's cab and floor frame assembly (38). Tools: Eyebolt, 4-point chain, Lever block 4
a
22
Floor frame assembly: 1,000 kg
When removing, take care extremely that the floor frame assembly will not interfere with another part.
D155A-6
50 Disassembly and assembly
SEN03375-01
Installation 1.
Sling operator's cab and floor frame assembly (38) and set it. Tools: 4-point chain, Lever block, Wire 4
2.
Install pins (36) according to the following procedure. a Use the same procedures shown in steps 2.-1) to 2) for installation of front, rear, right and left pins (36) (4 pieces).
1)
2)
3.
4. 5.
6.
Floor frame assembly: 1,000 kg
Pass the lifting tool (wire) through the pin mounting hole, and sling pin (36). Tools: Socket wrench (M8), Eyebolt, Wire a When slinging pin (36), be sure to sling the pin with its mounting hole facing pin (37). Insert pin (37) into the mounting hole in pin (36), and fix pin (36). 2 Pin (37): Grease (G2-LI)
Install cover (35) with bolts (35a) (2 pieces). Tools: Torque wrench (socket) Bolts (35a): Width across flats 19 mm, M12 3 Bolts (35a): 98 to 123 Nm {10 to 12.5 kgm} Install the pin on the other side at the rear and the 2 pins at the front according to steps 2 and 3. Install mounting bolts (34) at the rear right and left of the floor frame. Tools: Torque wrench (socket) Bolts (34): Width across flats 36 mm, M24 3 Bolts (34): 824 to 1,030 Nm {84 to 105 kgm} Install bracket mounting bolts (33) (each 4 pieces) in front of the floor frame (right and left). Tools: Torque wrench (socket) Bolts (33): Width across flats 30 mm, M20 3 Bolts (33): 455 to 565 Nm {46.5 to 58 kgm}
D155A-6
23
SEN03375-01
7.
Connect wiring harness connectors FSB (29), PL1 (30), FD1 (31) and FD4 (32). Tools: Torque wrench (hexagonal wrench) Mounting bolt of connector (30): Width across flats 4 mm 3 Bolt (30): 2.83±0.28 Nm {0.288±0.028 kgm}
8. 9.
Connect wiring harness (28). Connect 4 window washer hoses (27).
50 Disassembly and assembly
10. Connect ground wire (26) with bolt (26a). Tools: Torque wrench (socket) Bolts (26a): Width across flats 19 mm, M12 3 Bolts (26a): 98 to 123 Nm {10 to 12.5 kgm}
11. Use clamp (24a) to connect fresh air duct (24) at the side of flange (25) (operator's cab side). Tools: Torque wrench (socket) Mounting bolts of clamp (24a): Width across flats 7 mm 3 Mounting bolts of clamp (24a): 6.8±0.49 Nm {0.69±0.05 kgm}
24
D155A-6
50 Disassembly and assembly
SEN03375-01
12. Attach the lifting tool to parts (a), sling battery top cover (23), and set it to its installed position. Tools: Belt sling 4
Cover (23): 75 kg
13. Install cover (23) and install bolts (23a) (5 pieces). Tools: Torque wrench (socket), Eyebolt, Wire Bolts (23a): Width across flats 19 mm, M12 3 Bolts (23a): 98 to 123 Nm {10 to 12.5 kgm}
14. Connect duct hose and flange (24) with bolts (22) (2 pieces). Tools: Torque wrench (socket) Bolts (22): Width across flats 17 mm, M10 3 Bolts (22): 59 to 74 Nm {6 to 7.5 kgm}
15. Connect battery cable (21). 16. Connect heater hoses (19) and (20).
17. Connect air conditioner hoses (17) and (18). Tools: Torque wrench (spanner) Hose (17): Width across flats 27 mm, M24 3 Hose (17): 30 to 35 Nm {3.06 to 3.57 kgm} Connection bolt of hose (18): Width across flats 10 mm, M6 3 Connection bolt of hose (18): 4 to 7 Nm {0.41 to 0.71 kgm} 18. Install bolts (2 pieces) of clamp. Bolt of clamp: Width across flats 19 mm, M12 3 Bolt of clamp: 98 to 123 Nm{10 to 12.5 kgm }
D155A-6
Install bolts (2 pieces) of Clamp.
25
SEN03375-01
50 Disassembly and assembly
19. Install cover (16) with bolts (16a) (4 pieces). Tools: Torque wrench (socket) Bolts (16a): Width across flats 19 mm, M12 3 Bolts (16a): 98 to 123 Nm {10 to 12.5 kgm} a Both side of left and right. 20. Install cover (15) with bolts (15a) (3 pieces). Tools: Torque wrench (socket) Bolts (15a): Width across flats 19 mm, M12 3 Bolts (15a): 98 to 123 Nm {10 to 12.5 kgm} a Both side of left and right. 21. Close side cover (14), both side of right ande left. 22. Connect 4 clamps (10) to (13) with bolts (10a) to (13a) (each 1 piece). Tools: Torque wrench (socket) Bolts (10a) to (13a): Width across flats 19 mm, M12 3 Bolts (10a) to (13a): 98 to 123 Nm {10 to 12.5 kgm}
23. Connect PPC hoses (2) to (9). Tools: Torque wrench (spanner) Hose (2) to (9): Width across flats 22, #03 size 3 Hose (2) to (9): 54 to 93 Nm {5.5 to 9.5 kgm} a (Color code of each hoses) (2) Red (6) Black-red (3) Yellow (7) Black-yellow (4) Green (8) Black-green (5) Brown (9) Black-brown
24. Install control valve cover (1) with bolts (1a) (5 pieces). Tools: Torque wrench (socket) Bolt (1a): Width across flats 19 mm, M12 3 Bolts (1a): 98 to 123 Nm {10 to 12.5 kgm}
25. Install fuel tank assembly For details see "Removal and installation of fuel tank assembly". 26. Filling air conditioner circuit with refrigerant (R134a). a Refrigerant to be collected: 900±50 g
26
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50 Disassembly and assembly
D155A-6
SEN03375-01
27
SEN03375-01
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03375-01
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
28
D155A-6
SEN03376-03
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
50 Disassembly and assembly1 Electrical system Removal and installation of air conditioner unit assembly .............................................................................. 2 Removal and installation of engine controller assembly ................................................................................. 9 Removal and installation of power train controller ........................................................................................ 12 Removal and installation of KOMTRAX assembly ........................................................................................ 15
D155A-6
1
SEN03376-03
50 Disassembly and assembly
Removal and installation of air conditioner unit assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
2
Socket wrench
(Commercially available)
10 mm
1
3
Socket wrench
(Commercially available)
12 mm
1
4
Socket wrench
(Commercially available)
13 mm
1
5
Socket wrench
(Commercially available)
17 mm
1
6
Socket wrench
(Commercially available)
19 mm
1
7
Hexagonal wrench
(Commercially available)
5 mm
1
8
Torque wrench (socket)
(Commercially available)
3.3 ± 0.49 Nm, 8 to 12 Nm, 27 to 34 Nm, 59 to 74 Nm, 98 to123 Nm
9
Torque wrench (hexagonal)
(Commercially available)
25.5 Nm
10
Belt sling
(Commercially available)
7 mm
1
Remarks
As needed 1
Target value
1
55 kg
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 Leave the negative (-) terminal of the battery disconnected.
k If you drain the coolant when it is still hot, you may be scalded. Wait until the coolant tempera-
ture drops, and then drain the coolant. k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit. a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). (Only registered persons are allowed to perform this work.) a Never release the refrigerant (air conditioner gas: R134a) into the atmosphere. k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long sleeves while collecting or filling with the refrigerant. a Check and note the connector numbers and installed positions before disconnecting wiring harnesses and hoses. a When disconnecting wiring, hoses, etc., take care that they are not damaged or deformed by clips, clamps, or the like. When it appears that wiring and hoses may be damaged or deformed, remove clips and clamps in advance.
2
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50 Disassembly and assembly
SEN03376-03
Removal
1. 2. 3.
4.
Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit. a Quantity of refrigerant to be collected: 900±50 g Remove the operator's cab assembly. For details, see "Removal of operator's cab assembly." Remove screws (16) (5 pieces) to remove upper cover (17) at the right bottom of the operator's seat. Tool: Hexagonal wrench Screw (16): M8 with width across flats of 5 mm
Sling operator's seat assembly (1) and remove it. Tool: Belt sling 4
a
Operator's seat assembly: 55 kg The crane cannot be used inside the operator's cab. Remove operator's seat assembly (1) by 2 persons.
5.
Remove bolts (2a) (6 pieces) to remove cover (2). Tool: Socket wrench Bolt (2a): M12 with width across flats of 19 mm
6.
Remove bolt (3a), and disconnect air conditioner hoses (3) and (4). Tool: Socket wrench Bolt (3a): M6 with width across flats of 10 mm Disconnect heater hoses (5) and (6).
7.
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SEN03376-03
8.
Remove bolts (7a) (4 pieces) to disconnect work equipment controller (7) from the operator’s cab. Tool: Socket wrench Bolt (7a): M8 with width across flats of 12 mm
9.
Remove filter (8).
50 Disassembly and assembly
10. Remove bolts (9a) (6 pieces), and remove cover (9). Tool: Socket wrench Bolt (9a): M8 with width across flats of 13 mm a 3 bolts are installed at the bottom of the front and remaining 3 bolts at the top of the rear.
11. Disconnect wiring harness connectors AC01 (10) and AC02 (11). 12. Disconnect wiring harness clamp (12), and reposition wiring harness (13) out of the way. Tool: Socket wrench Bolt for clamp (12): M10 with width across flats of 17 mm
13. Loosen respective clamps (14a) and disconnect ducts (14) (2 pieces). Tool: Socket wrench Bolt for clamp (14a): Width across flats of 7 mm
4
D155A-6
50 Disassembly and assembly
SEN03376-03
14. Remove bolts (15a) (7 pieces), then remove air conditioner unit (15). 4 Air conditioner unit: 10 kg Tool: Socket wrench Bolt (15a): M8 with width across flats of 13 mm
D155A-6
5
SEN03376-03
50 Disassembly and assembly
Installation
1.
Use bolts (15a) (7 pieces) to install air conditioner unit (15).
4 Air conditioner unit: 10 kg Tool: Torque wrench (socket) Bolt (15a): M8 with width across flats of 13 mm
3 Bolt (15a): 27 to 34 Nm {2.8 to 3.5 kgm}
2.
Connect ducts (14) (2 pieces) and use respective clamps (14a) to fix them. Tool: Torque wrench (socket) Bolt for clamp (14a): Width across flats of 7 mm 3 Bolt for clamp (14a): 3.3±0.49 Nm {0.34±0.05 kgm}
3. 4.
Connect wiring harness connectors AC01(10) and AC02 (11). Use wiring harness clamp (12) to fix wiring harness (13). Tool: Torque wrench (socket) Bolt for clamp (12): M10 with width across flats of 17 mm 3 Bolt for clamp (12): 59 to 74 Nm {6 to 7.5 kgm}
5.
Use bolts (9a) (6 pieces) to install cover (9). Tool: Torque wrench (socket) Bolt (9a): M8 with width across flats of 13 mm
3 Bolt (9a): 27 to 34 Nm {2.8 to 3.5 kgm}
6.
6
Install filter (8). a When the filter is contaminated, clean it before installation. If the filter is badly contaminated, replace it with a new one.
D155A-6
50 Disassembly and assembly
7.
8.
9.
SEN03376-03
Use bolts (7a) (4 pieces) to connect work equipment controller (7) to the operator’s cab. Tool: Torque wrench (socket) Bolt (7a): M8 with width across flats of 12 mm
3 Bolt (7a): 27 to 34 Nm {2.8 to 3.5 kgm} Connect heater hoses (5) and (6).
Use respective bolts (3a) to connect air conditioner hoses (3) and (4). Tool: Torque wrench (socket) Bolt (3a): M6 with width across flats of 10 mm 3 Bolt (3a): 8 to 12 Nm {0.8 to 1.2 kgm}
a q q q q q
When connecting the air conditioner circuit piping, observe the following: Do not remove the plug from the fitting before connecting the pipe. Be careful that dirt, dust, water, etc. do not enter the air conditioner piping. Check that the O-rings are fitted to the joints when connecting the air conditioner piping. Check that the O-ring is not damaged or deteriorated. When connecting air conditioner piping, apply compressor oil for new refrigerant (R134a) to the O-rings and threaded parts.
2 O-ring and threaded part:
Compressor oil (DENSO: ND-OIL8) 10. Use bolts (2a) (6 pieces) to install cover (2). Tool: Torque wrench (socket) Bolt (2a): M12 with width across flats of 19 mm
3 Bolt (2a): 98 to 123 Nm {10 to 12.5 kgm}
11. Sling operator's seat assembly (1) and install it. Tool: Belt sling 4
D155A-6
Operator's seat assembly: 55 kg
7
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50 Disassembly and assembly
12. Use screws (16) (5 pieces) to install cover (17) at the right bottom of the operator's seat. Tool: Torque wrench (hexagonal) Screw (16): M8 with width across flats of 5 mm 3 Screw (16): 25.5 Nm {2.6 kgm} (target value)
13. Install the operator's cab assembly. For details, see "Removal and installation of operator's cab assembly." 14. Refill the refrigerant (air conditioner gas: R134a) to the air conditioner circuit. a Refill quantity of refrigerant: 900±50 g 15. Refilling with air conditioner compressor oil. a See Air conditioner, "Handling of compressor oil".
8
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50 Disassembly and assembly
SEN03376-03
Removal and installation of engine controller assembly
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
2
Socket wrench
(Commercially available)
19 mm
1
3
Hexagonal wrench
(Commercially available)
4 mm
1
4
Torque wrench (socket)
(Commercially available)
27 to 34 Nm, 98 to 123 Nm
5
Torque wrench (hexagonal)
(Commercially available)
2.82 Nm
1
6
Belt sling
(Commercially available)
40 kg
1
12 mm
1
Remarks
As needed
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 Leave the battery (-) terminal disconnected.
k If temperature of the engine and its accessories (turbocharger, etc. of exhaust system) is still
high, wait until the temperature drops enough to perform the work.
D155A-6
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50 Disassembly and assembly
Removal
1. 2.
Open the left engine side cover. Remove bolts (1a) (3 pieces), sling side cover assembly (1), and remove it. a Wrap a belt sling around it, and sling and remove it. Tool: Socket wrench, belt sling Bolt (1a): M12 with width across flats of 19 mm 4
Side cover assembly: 40 kg
3.
Remove oil filters (2) (2 pieces).
4.
Remove bolts (7a) (3 pieces), and remove cover (7). Tool: Socket wrench Bolt (7a): M8 with width across flats of 12 mm Remove bolt (8a) (1 piece), and remove cover (8). Tool: Socket wrench Bolt (8a): M8 with width across flats of 12 mm
5.
6.
7.
10
Remove screws (3a) and disconnect wiring harness connectors EGC1 (3), EGC2 (4), and EGC3 (5). Tool: Hexagonal wrench Screw (3a): Width across flats of 4 mm Remove bolts (6a) (3 pieces) to remove engine controller assembly (6). Tool: Socket wrench Bolt (6a): M8 with width across flats of 12 mm
D155A-6
50 Disassembly and assembly
SEN03376-03
Installation
1.
Use bolts (6a) (3 pieces) to install engine controller assembly (6). Tool: Torque wrench (socket) Bolt (6a): M8 with width across flats of 12 mm 3 Bolt (6a): 27 to 34 Nm {2.8 to 3.5 kgm}
2.
Use screws (3a) to connect wiring harness connectors EGC1 (3), EGC2 (4), and EGC3 (5). Tool: Torque wrench (hexagonal) Screw (3a): Width across flats of 4 mm 3 Screw (3a): 2.82 Nm {0.288 kgm} a Be sure to remove all foreign materials (dirt, dust, water, etc.) completely from the wiring harness connectors of the engine controller assembly by air-blowing before installation.
3.
Use bolt (8a) (1 piece) to install cover (8). Tool: Torque wrench (socket) Bolt (8a): M8 with width across flats of 12 mm 3 Bolt (8a): 27 to 34 Nm {2.8 to 3.5 kgm} Use bolts (7a) (3 pieces) to install cover (7). Tool: Torque wrench (socket) Bolt (7a): M8 with width across flats of 12 mm 3 Bolt (7a): 27 to 34 Nm {2.8 to 3.5 kgm}
4.
5.
Install oil filters (2) (2 pieces). a Be sure to replace the oil filter cartridge with a new one.
6.
Sling side cover assembly (1), set it to its installed position, and use bolts (1a) (3 pieces) to install side cover assembly (1). a Wrap a belt sling around it, and sling and attach it. Tool: Torque wrench (socket), wire Bolt (1a): M12 with width across flats of 19 mm 3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm} 4
7.
Side cover assembly: 40 kg
Close the left engine side cover.
D155A-6
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50 Disassembly and assembly
Removal and installation of power train controller
1
Standard tools list Tools listed here are for reference. You can use any tool other than listed tools if it serves your purpose. No.
Part name
Part No.
Specifications
Q'ty
1
Socket wrench
(Commercially available)
2
Hexagonal wrench
(Commercially available)
4 mm
1
3
Hexagonal wrench
(Commercially available)
5 mm
1
4
Torque wrench (socket)
(Commercially available)
27 to 34 Nm
1
5
Torque wrench (hexagonal)
(Commercially available)
2.82 Nm, 25.5 Nm (target value)
12 mm
1
Remarks
As needed
Removal
k Leave the battery (-) terminal disconnected.
1.
Remove screws (6a) (4 pieces) to remove cover (6). a The power train controller is installed in the left console box within the operator’s cab. Tool: Hexagonal wrench Screw (6a): M8 with width across flats of 5 mm
2.
Remove mounting bolts (1) (4 pieces) of power train controller assembly (5). Tool: Socket wrench Bolt (1): M8 with width across flats of 12 mm
12
D155A-6
50 Disassembly and assembly
3.
SEN03376-03
Slide the controller, disconnect connectors STC1 (2), STC2 (3), and STC3 (4), and remove the power train controller assembly (5).
D155A-6
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SEN03376-03
50 Disassembly and assembly
Installation
1.
Connect wiring harness connectors STC1 (2), STC2 (3), and STC3 (4). Tool: Torque wrench (hexagonal) Screw for connectors (2), (3), and (4): Width across flats of 4 mm 3 Screw for connectors (2), (3), and (4): 2.82 Nm {0.288 kgm} a Be sure to remove all foreign materials (dirt, dust, water, etc.) completely from the wiring harness connectors of the power train controller assembly by air-blowing before installation.
2.
Install mounting bolts (1) (4 pieces) of power train controller assembly (5). Tool: Torque wrench (socket) Bolt (1): M8 with width across flats of 12 mm 3 Bolt (1): 27 to 34 Nm {2.8 to 3.5 kgm}
3.
Use screws (6a) (4 pieces) to install cover (6). Tool: Torque wrench (hexagonal) Screw (6a): M8 with width across flats of 5 mm 3 Screw (6a): 25.5 Nm {2.6 kgm} (target value)
14
D155A-6
50 Disassembly and assembly
SEN03376-03
Removal and installation of KOMTRAX assembly
1
Standard tools The described tool is a reference. If it has a purpose, it can be used other than the described tool. No.
Part name
Part No
Specification
Q'ty
1
Socket wrench
(Commercially available)
10 mm
1
2
Hexagonal wrench
(Commercially available)
4 mm
1
3
Torque wrench (socket)
(Commercially available)
11.8 to 14.7 Nm
1
4
Torque wrench (hexagonal wrench)
(Commercially available)
9.8 Nm(target value)
1
Remarks
Removal k Disconnect the cable from the negative (–) terminal of
the battery.
1.
Remove 4 mounting screws (1) and remove cover (2). a Komtrax is set in the rear right side of the operator's cab. Tools: Hexagonal wrench Screw (1): Width across flat 4 mm, M6
2. 3. 4.
Disconnect wire harness connector (4). Disconnect antenna cable (3). Remove 4 mounting bolts (5), and KOMTRAX assembly (6). Tools: Socket wrench Bolts (5): Width across flat 10 mm, M6
D155A-6
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SEN03376-03
50 Disassembly and assembly
Installation
1.
2. 3. 4.
16
Install KOMTRAX assembly (6) with 4 mounting bolts (5). Tools:Torque wrench set (socket) Bolts (5): Width across flat 10 mm, M6 3 Bolts (5): 11.8 to 14.7 Nm {1.2 to 1.5 kgm} Connect antenna cable (3). Connect wire harness connector (4). Install cover (2) with 4 mounting screws (1). Tools:Torque wrench set (hexagonal wrench) Screw (1): Width accross flat 4 mm, M6 3 Screw (1): 9.8 Nm {1.0 kgm} (target value)
D155A-6
50 Disassembly and assembly
D155A-6
SEN03376-03
17
SEN03376-03
50 Disassembly and assembly
D155A-6 Bulldozer Form No. SEN03376-03
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
18
D155A-6
SEN04442-02
BULLDOZER 1SHOP MANUAL
D155A-6
Machine Model
Serial Number
D155A-6
85001 and up
60 Air conditioner
1
Structure, function, testing, adjusting, and troubleshooting Structure and function ..................................................................................................................................... 3 Air conditioner component ....................................................................................................................... 3 Configuration and function of refrigerating cycle ..................................................................................... 4 Outline of refrigerating cycle .................................................................................................................... 5 Air conditioner unit ................................................................................................................................... 7 Functions of major components in the air conditioner unit ...................................................................... 9 Control plate ...........................................................................................................................................11 Compressor ........................................................................................................................................... 13 Condenser ............................................................................................................................................. 14 Receiver drier ........................................................................................................................................ 15 Testing, adjusting and troubleshooting.......................................................................................................... 17 Caution about refrigerant ....................................................................................................................... 17 Troubleshooting procedure .................................................................................................................... 18 Block diagram ........................................................................................................................................ 19
D155A-6
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SEN04442-02
60 Air conditioner
Circuit diagram and arrangement of connector pins .............................................................................. 20 Detail of air conditioner unit ................................................................................................................... 22 Part and connector locations ................................................................................................................. 24 Testing air leakage (duct)....................................................................................................................... 31 Testing with self-diagnosis function........................................................................................................ 33 Testing temperature control ................................................................................................................... 36 Testing vent (mode) changeover............................................................................................................ 39 Testing Recirc/Fresh changeover .......................................................................................................... 42 Testing inner sensor............................................................................................................................... 44 Testing evaporator temperature sensor ................................................................................................. 45 Testing sunlight sensor .......................................................................................................................... 48 Testing (dual) pressure switch for refrigerant......................................................................................... 49 Testing relays and diodes ...................................................................................................................... 51 Troubleshooting chart 1 ......................................................................................................................... 53 Troubleshooting chart 2 ......................................................................................................................... 54 Troubleshooting for electrical system (E mode)..................................................................................... 57 E-1 Power supply system (Air conditioner does not operate)......................................................... 58 E-2 Compressor system (Air is not cooled) .................................................................................... 62 E-3 Blower motor system (No air comes out or air flow is abnormal)............................................. 66 E-4 Temperature cannot be controlled............................................................................................ 72 E-5 Vent (mode) cannot be changed over ...................................................................................... 75 E-6 Recirc/Fresh air cannot be changed over ................................................................................ 78 Troubleshooting with gauge pressure .................................................................................................... 81 Connection of service tool...................................................................................................................... 83 Precautions for connecting air conditioner piping .................................................................................. 84 Handling of compressor oil .................................................................................................................... 85 1. Control of compressor oil .......................................................................................................... 85 2. Adding of compressor oil .......................................................................................................... 85 3. Compressor replacement.......................................................................................................... 86 4. Applying compressor oil for O-ring............................................................................................ 86
2
D155A-6
60 Air conditioner
SEN04442-02
Structure and function
1
Air conditioner component
1
1. 2. 3. 4. 5. 6. 7. 8. 9.
Condenser Hot water return piping Hot water piping Front window defroster Side window defroster Air outlet for face Air outlet for center Air outlet for rear Air conditioner unit
10. Air outlet for foot 11. Receiver drier 12. Refrigerant piping 13. Valve (hot water outlet) 14. Air conditioner compressor 15. Valve (hot water inlet) 16. (Dual) pressure switch A. B.
Fresh air filter Recirculated air filter
Specifications
D155A-6
Refrigerant
R134a
Refrigerant refilling level (g)
870 ± 50
3
SEN04442-02
60 Air conditioner
Configuration and function of refrigerating cycle
1
Component Item Location
Function
State of refrigerant
4
Compressor
Condenser
Expansion valve
Evaporator
Engine compartment
Front of radiator
In operator’s cab (In air conditioner unit)
In operator’s cab (In air conditioner unit)
Circulates refrigerant gas and increases its temperature and pressure so that it can be liquefied easily in condenser.
Condenses refrigerant Lowers temperature and Evaporates refrigerant to discharge heat pressure of refrigerant to absorb heat from (or absorbed in evaporator. liquid and gas for easy cool) air around evaporation with throttle. evaporator. Controls flow rate, too.
(Compression of refrig- (condensation of refrig- (Throttle of refrigerant) erant) erant)
(Evaporation of refrigerant)
Gas o Liquid Constant pressure change
Liquid and gas o Gas Constant pressure change
Gas o Gas Adiabatic compression
Liquid o Liquid and gas Adiabatic expansion
D155A-6
60 Air conditioner
Outline of refrigerating cycle
SEN04442-02
1
3.
Receiver drier The refrigerant liquefied in the condenser is reserved in the receiver drier temporarily so that it can be supplied to the evaporator according to the cooling load. A strainer and a drying agent are sealed in the receiver drier to remove “dirt” and “water” in the refrigerating cycle. If any water is in the refrigerating cycle, it is frozen in the small hole of the expansion valve and retards the flow of the refrigerant. It can cause a cooling trouble.
4.
Expansion (Expansion valve) The pressure of the refrigerant liquid is lowered by the restricting action [*1] of the expansion valve to a level at which the refrigerant is evaporated easily. The action to lower the pressure of the refrigerant to a level at which the refrigerant is evaporated easily before the refrigerant is sent to the evaporator is called expansion. The expansion valve which performs this action also controls the flow rate of the refrigerant. In other words, the quantity of the refrigerant liquid evaporated in the evaporator is decided by the quantity of heat to be removed (refrigeration load) at the specified evaporation temperature (evaporation pressure), and the expansion valve senses it and controls the refrigerant flow rate properly. [*1] Restricting action If there is a suddenly narrowed part in a pipe in which a liquid is flowing, there is resistance to the flow. Since the sectional area is increased suddenly through this part, the liquid expands suddenly and its pressure and temperature lower. No heat is exchanged between the inside and outside of the pipe during this action.
The refrigerating cycle performs the following four actions. The refrigerant is liquefied and gasified repeatedly while it is circulated in the cycle. 1.
2.
Compression (Compressor) The refrigerant gas is compressed by the compressor to the state where it can be liquefied easily at the normal temperature (ambient temperature). The refrigerant evaporated in the evaporator is sucked into the compressor. This action is performed to keep the refrigerant pressure in the evaporator low so that the refrigerant liquid can continue evaporation actively even if the ambient temperature is close to 0°C. The refrigerant gas sucked into the compressor is compressed in the cylinder and its pressure and temperature are so changed that is can be liquefied easily when it is cooled with the external air at the normal temperature. Condensation (Condenser) The refrigerant gas in the condenser is cooled to be liquefied with the external air. The refrigerant gas of high temperature and high pressure discharged from the compressor is cooled to be liquefied with the external air and then stored in the receiver drier. The heat discharged from the refrigerant of high temperature and high pressure discharged from the compressor is called the condensation heat, which is the total of the heat that the refrigerant absorbed from the operator’s cab through the evaporator (vaporization heat) and the work performed to compress the refrigerant (the value converted into heat). During condensation, the refrigerant gas and refrigerant liquid are mixed together in the condenser. While the refrigerant gas changes to the refrigerant liquid, the relationship between the pressure (condensation pressure) and temperature (condensation temperature) is kept constant. Reference: The pressure varies with the type of refrigerant and the condensation temperature.
D155A-6
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5.
6
60 Air conditioner
Evaporation (Evaporator) The refrigerant changes from liquid to gas (superheated vapor) in the evaporator. The refrigerant mist in the evaporator evaporates actively. At this time, the refrigerant evaporates quickly, absorbing heat necessary for evaporation (latent heat of vaporization) from the air around the cooling fins (air in the operator’s cab). The cooled air is spread in the operator’s cab by the fan to lower the temperature in the operator’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 relationship between the pressure (evaporation pressure) and temperature (evaporation temperature) is kept constant. If the pressure is set, the temperature is decided automatically. That is, the relationship between the above pressure and temperature is equal to the relationship between saturation pressure and saturation temperature. To evaporate the refrigerant at lower temperature, the pressure in the evaporator must be kept lower. Accordingly, the evaporated refrigerant is sucked into the compressor. The refrigerant circulates in the refrigerating cycle, repeating the above four actions, to move the heat from the 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 evaporator capacity decreases. It can cause a cooling trouble. To the contrary, if the amount of the refrigerant is too much, a part of it is not evaporated in the evaporator and is absorbed in the compressor. As a result, the compressor compresses the liquid and may be broken.
D155A-6
60 Air conditioner
Air conditioner unit a
This air conditioner unit is auto temperature control type.
a
Inside temp. sensor is the same as inner (air temperature) sensor.
D155A-6
SEN04442-02
1
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SEN04442-02
60 Air conditioner
Outline q The air conditioner unit consists of the evaporator, heater core and fan (blower) and generates cool air and hot air. q
Temperature control The machine monitor sends temperature setting data to the control amplifier (See “Control plate”) according to the temperature control switch operation. The control amplifier controls the air mix servomotor to adjust the angle of the cool door, hot door and sub hot door for temperature control.
q
Over-cooling (Freezing) prevention The evaporator temperature sensor senses evaporator temperature by the change of resistance. The control amplifier converts the change of resistance of the evaporator temperature sensor into a change of voltage and detects the evaporator temperature by the change of voltage. The control amplifier turns OFF the compressor clutch relay so that the evaporator will not be frozen.
q
Air flow adjustment The machine monitor sends air flow data to the control amplifier (described later) according to the air flow adjustment switch. The control amplifier controls the air flow with the power transistor.
q
Vent (mode) changeover The machine monitor sends mode data to the control amplifier according to the vent selector (mode) switch. The control amplifier controls the blowing out (mode) servomotor to adjust the angles of the foot door, defroster door, front door and rear door for vent changeover.
q
Automatic air conditioner The inner temperature sensor senses the room temperature by the change of resistance. The control amplifier converts the change of resistance of the inner temperature sensor into a change of voltage and detects the room temperature by the change of voltage. The control amplifier checks the inner air temperature sensor voltage so that the room temperature will be kept at the temperature set with the machine monitor.
a
The 5 A fuse for the air conditioner unit is installed to the wiring harness. The door is the same as the damper.
a
8
D155A-6
60 Air conditioner
Functions of major components in the air conditioner unit 1 q
Evaporator Evaporator fins are cooled by low-pressure, low-temperature refrigerant gas being sent from the expansion valve. Air from the blower motor is cooled and dehumidified when passing through the fins.
q
Heater core Fins of the heater core are heated by the hot water (cooling water) being sent from the engine. Air from the blower motor is heated as it passes through the fins.
q
Expansion valve This valve converts high-pressure, high-temperature liquid refrigerant coming from the receiver to low-pressure, low-temperature misty refrigerant through the throttling function. It controls the flow rate of the refrigerant by changing the level of throttling depending on the thermal load (temperature) in the operator's cab. As a result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in evaporator. 1) Structure The box-type expansion valve consists of the diaphragm, thermosensing rod, needle valve (ball), spring, etc. The outside of diaphragm (hatched part) is pre-enclosed with refrigerant gas. The spring is installed on the needle valve (ball) side of the thermosensing rod. The needle valve opening ratio is decided when the constant force of the spring to push the ball to the right is balanced with the force (Fg) of the refrigerant gas to push the thermosensing rod to the left through the diaphragm. As a result, the refrigerant flow rate to the evaporator is decided and the temperature is controlled.
D155A-6
SEN04442-02
2)
Operation The thermosensing rod senses the temperature of the refrigerant which passed the evaporator. The temperature at this time is conducted through the thermosensing rod to the refrigerant gas in the diaphragm chamber (hatched part). As the pre-enclosed refrigerant gas temperature changes, the gas pressure changes and pressing force (Fg) also changes. The thermosensing rod attached directly to the diaphragm so moves that the constant force of the spring to push the ball will be balanced with variable force (Fg) to adjust the needle valve opening ratio. A: When the evaporator outlet temperature is high (at start of cooling (air is not cooled yet)) The gas pressure in the diaphragm chamber increases and the gas volume increases. Pushing force (Fg) of the refrigerant gas increases and the thermosensing rod (ball) moves to the left and the needle valve op ens wide . Mu ch refrigerant is supplied to the evaporator and the cooling capacity increases. B.
When the evaporator outlet temperature is low (during cooling (air is cooled already)) The gas pressure in the diaphragm chamber decreases and the gas volume decreases. Since pushing force (Fg) of the refrigerant gas is small, the thermosensing rod (ball) moves to the right and the needle valve is narrowed. Accordingly, refrigerant supply and the cooling capacity decrease.
9
SEN04442-02
q
Power transistor (PTR) It controls the blower motor speed by receiving signal current from the air conditioner control amplifier. (See “Control plate”.)
q
Servomotor
a
This servomotor is used for temperature control (AIR MIX) and blowing out (MODE).
1.
If the switch on the control panel is operated, the control amplifier supplies 24 V power across (6) and (7). (The rotation direction changes according to the polarities of the supplied power.)
10
60 Air conditioner
2.
There is a variable resistor in the servomotor and its resistance varies with the angle of the motor shaft. The control amplifier applies 5 V voltage to this variable resistor and judges the rotation angle of the motor by the potential difference (PT). When the door (damper) comes to the position set with each switch, the control amplifier stops supplying the power to the servomotor. a Do not apply the power directly to the motor terminal to drive the motor because the motor output shaft is damaged or the motor coil is broken.
3.
If the potential difference (PT) does not reach the voltage set for the servomotor control, the control amplifier notifies the error to the machine monitor. Then, the letters of “A/C Controller Error” are displayed red on the air conditioner operation screen of the machine monitor. a The Recirc/Fresh changeover servomotor does not have this potential difference (PT). Accordingly, it does not have the self-diagnosis function.
D155A-6
60 Air conditioner
Control plate
1.
SEN04442-02
1
Control amplifier (CNTAMP)
A/C U: Air conditioner unit AC01: Intermediate connector to air conditioner control amplifier (CNTAMP) (GND, sunlight sensor, pressure switch, connectors for relay) AC02: Intermediate connector to air conditioner control amplifier (CNTAMP) (24 V, CAN communication with machine monitor)
D155A-6
Functions of main component parts q Control amplifier (CNTAMP) (1) 1) Communicates with the machine monitor through CAN communication system and controls the air conditioner unit with the switch inputs related to the air conditioner. 2) Controls the three servomotors in the air conditioner unit to adjust the temperature, changeover the vent (mode), and changeover the recirculated air or fresh air. 3) Turns ON and OFF blower main relay (switch to blow air) and compressor clutch relay (switch to operate the compressor). See item 8 in “Part and connector locations”. a Control amplifier (CNTAMP) (1) controls compressor clutch relay on the basis of following three (input) data. 1] “A/C” switch or “AUTO” switch on the machine monitor 2] Evaporator temperature sensor 3] (Dual) pressure switch 4) Has the self-diagnosis function. If any abnormality is detected, the control amplifier notifies it to the machine monitor by the CAN communication. Then, the letters of “A/C Controller Error” are displayed red on the air conditioner operation screen of the machine monitor. 5) Adjusts the room temperature to the set temperature on the basis of the data of the sunlight sensor and inner air sensor in the automatic air conditioner mode.
11
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60 Air conditioner
Input and output signals of control amplifier (CNTAMP) Connector on controller side: ACCN AMP 040-36PM Connector on wiring harness side: [1], [2] [1] AMP 040-16PF Pin No.
Symbol
[2] AMP 040-20PF Signal name
Symbol
17
CAN (+)
CAN communication +
Input/ Output
Signal name
—
2
A/M P
A/M servo potentiometer voltage
3
POT 5V
Servo potentiometer 5V power supply Output
18
CAN (–)
CAN communication –
4
PRESS SW
(Dual) pressure switch (Refrigerant pressure)
Input/ Output
Input
19
R/F A
Output
5
—
—
—
Recirculated air and fresh air servo terminal A
6
+24 V
Input
20
R/F B
Recirculated air and fresh air servo terminal B
Output
Input
21
A/M A
A/M servo terminal A
Output
Output
22
A/M B
A/M servo terminal B
Output
23
MODE A Blowing out (mode) servo terminal A
Output
24
MODE B Blowing out (mode) servo terminal B
Output
Power supply
BLOW F/B Blower feedback signal
8
PTR B
Power transistor control signal
9
Blowing out (mode) servo MODE P potentiometer voltage —
—
Input and output
Pin No.
1
7
—
Input and output Input
Input
10
—
—
11
THI
Inner air temperature sensor
Input
12
THEVA
Evaporator temperature sensor
Input
13
—
—
—
14
—
—
—
15
SS
Sunlight sensor
Input
16
GND
GND
Input
25
—
—
26
—
—
27
GND S
28
—
—
—
29
—
—
—
30
—
—
—
31
—
—
—
32
—
—
—
33
—
—
—
34
—
—
35
CCRL
Sensor GND
q q
12
— Input
Compressor clutch relay
36 BLOW RL Blower main relay q
—
— Output Output
A/M: Air mix F/B: Feedback R/F: Recirculation/Fresh
D155A-6
60 Air conditioner
SEN04442-02
Compressor
1
A: Refrigerant inlet port from air conditioner unit B: Refrigerant outlet port to condenser C: Pulley D: Relief valve
Function q Other than circulating the refrigerant, compressor compresses the refrigerant gas from the evaporator to a high-pressure, high-temperature misty refrigerant so that it may be easily regenerated (liquefied) at normal temperature. q The magnetic clutch in the compressor is engaged depending on the evaporator temperature and refrigerant pressure. If the magnetic clutch is engaged, the shaft in the compressor rotates to operate the compressor. Specifications
D155A-6
Piston capacity (cc/rev)
157.3
Allowable maximum speed (rpm)
6,000
Refrigerant oil used
Denso: ND-OIL8 (For R134a)
Refrigerant oil refilling volume (cc)
180
13
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60 Air conditioner
Condenser
1.
Condenser
A: Refrigerant inlet from compressor B: Refrigerant outlet to receiver drier Function Condenser (1) q Condenser cools and liquefies the high-pressure, high-temperature misty refrigerant from the compressor. a
If the fins are crushed or clogged with dirt, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As a result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.
Specifications Fin pitch (mm)
4.0
Height × Width × Thickness
357 × 540 × 16
Max. pressure used (MPa {kg/cm2})
3.6 {36}
14
D155A-6
60 Air conditioner
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Receiver drier
1
1. 2.
Receiver drier (Dual) pressure switch
A: B:
Refrigerant inlet from condenser Refrigerant outlet to air conditioner unit
q
SG: Sight glass Function Receiver drier (1) q It is used to store liquefied high-pressure, hightemperature misty refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. q It eliminates foreign substances in the circulation circuit and water content in the refrigerant by use of the built-in filter and desiccating agent. q Sight glass (1) allows inspection of the refrigerant flow. Even if 5 minutes elapsed after engine start up and turning ON of A/C switch, when bubbles are seen through sight glass (1), the amount of the refrigerant is insufficient. If the amount of the refrigerant is proper, no bubbles are seen there. a If there is no (or excessive) refrigerant in the refrigerating cycle, no bubbles are seen through sight glass (1), too.
(Dual) pressure switch (2) a Connector is AC05 If abnormally low or high pressure is generated in the refrigerant circulation circuit, the (dual) pressure switch is turned “OFF”. (it is normally turned “ON”.) When the (dual) pressure switch become “OFF”, the control amplifier turns the compressor clutch relay “OFF”. So the magnetic clutch of the compressor is disengaged and the devices related to the air conditioner are protected.
LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}
Specifications Weight of desiccating agent (g)
D155A-6
370
15
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16
60 Air conditioner
D155A-6
60 Air conditioner
SEN04442-02
Testing, adjusting and troubleshooting Caution about refrigerant k Collect
a a
1
1
the air conditioner refrigerant (R134a) from air conditioner circuit to before disconnecting air conditioner hose replace air conditioner unit, air conditioner compressor or receiver drier and so on. Ask a qualified shop for collecting, adding and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes,
q
you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on protective goggles, gloves and working suits with long sleeves while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person. Refrigerant (R134a) filling up quantity: 870 g ± 50 g
D155A-6
17
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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. 2.
3.
1
After basic check, find the troubled section according to the detected trouble of the air conditioner. Find the troubled section with the self-diagnosis function (See “Inspection with self-diagnosis”). If the air conditioner unit does not operate at all, check that the power supplied to the control amplifier is normal and that CAN communication between machine monitor and the control amplifier is normal. If any part of the air conditioner unit operates, the power supply and CAN communication do not need to be checked. After finding out the troubled section, inspect the component parts in that section and repair the troubled part.
Basic flow of troubleshooting Occurrence of trouble: Examination, confirmation of failure
Basic check
operate?
1. Battery voltage (24 V) 2. Tension of compressor belt 3. Oil stain at air conditioner hose joints (*2) 4. Abnormal sound check (*3) Compressor, blower motor and air conditioner hose (clamp) E-1 Power supply system (Air conditioner does not operate)
Inspection with self-diagnosis function (*1) and with each switch
Troubleshooting with troubleshooting chart 1
Troubleshooting with E mode
Troubleshooting with gauge pressure
Inspection with troubleshooting chart 2
*1: By error display or abnormal display on “Abnormality Record” screen on machine monitor. *2: If refrigerant leaks, recirculating compressor oil in the air conditioner circuit always leaks, too. *3: Start engine and then air conditioner switch ON.
18
D155A-6
60 Air conditioner
Block diagram a
SEN04442-02
1
This air conditioner unit is auto temperature control type.
D155A-6
19
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Circuit diagram and arrangement of connector pins
20
60 Air conditioner
1
D155A-6
60 Air conditioner
a a
SEN04442-02
INSIDE TEMP. SENSOR means “Inner sensor” on “Abnormality Record” screen: “03 Air-conditioning System”. BLOWING OUT (MODE) SERVOMOTOR means BLOWING OUT (MODE) CHANGEOVER SERVOMOTOR.
D155A-6
21
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Detail of air conditioner unit
22
60 Air conditioner
1
D155A-6
60 Air conditioner
D155A-6
SEN04442-02
23
SEN04442-02
Part and connector locations a
a 1.
2.
24
60 Air conditioner
1
3.
Remove foot duct (2).
4.
Remove cover (3).
There are a circuit breaker and a fuse. The circuit breaker is in the battery cover on the left side of the machine and the fuse is wound onto the wiring harness between the air conditioner unit and control amplifier. The air conditioner unit is at the rear of the operator seat. Open the battery cover on the left side of the machine. (See the fuse locations in Troubleshooting Volume.) q Circuit breaker CB3 (5th from left) (20 A): For power supply for air conditioner compressor and air conditioner unit (for all devices related to air conditioner) a If the reset button (RB) of the circuit breaker is projected, the circuit is turned OFF. In this case, push in the reset button (RB). If it is kept pushed in, the circuit is normal. If it is soon projected again, the circuit may have a ground fault etc. (See E-1.)
Remove recirculated air filter (1) from the rear of the operator seat.
D155A-6
60 Air conditioner
SEN04442-02
a
5.
State without cover (3) q A/C U: Air conditioner unit q CNTAMP: Control amplifier q [1] and [2]: Control amplifier connectors q AC01: Connector to air conditioner unit for GND, compressor, pressure switch, relay and sunlight sensor q AC02: Connector to air conditioner unit for 24 V power supply and CAN communication connector to monitor panel (Communication circuit common to engine controller and pump controller) Disconnect connectors AC01 and AC02.
6.
Disconnect clamp (4).
7.
Remove bracket (5). a Fu5A: Fuse 5 A is installed to the bracket bottom of wiring harness (H). For power supply for air conditioner unit (including primary side of relays for blower (fan) and air conditioner compressor) q Fuse part No. Fu5A: ND93950-05003 q [5]: Blowingout (Mode) servomotor connector q [6]: Temperature control (Air mix) servomotor connector
D155A-6
25
SEN04442-02
q q q q q q q
26
60 Air conditioner
[3]: Blower (Fan) motor connector [4]: Power transistor (PTR) connector [5]: Blowingout (Mode) servomotor connector [6]: Temperature control (Air mix) servomotor connector [7]: Recirc/Fresh changeover servomotor connector [8]: Recirculated air sensor connector [9]: Evaporator temperature sensor connector
D155A-6
60 Air conditioner
8.
9.
Relays and diodes The relays and diodes are at the left rear of the operator seat. q AC03: Blower main relay connector --- For turning fan motor ON/OFF q AC04: Compressor clutch relay connector --- For turning air conditioner compressor (clutch) ON/OFF q Diodes: ACD1 and ACD2 --- For cutting back electromotive force generated in the primary coils of the blower main relay and compressor clutch relay. For protection of control amplifier (CNTAMP) IF: Recirculated air filter
SEN04442-02
q q q
AC05: Pressure switch connector RD: Receiver drier SG: Sight glass
Pressure switch Open engine left cover (6) and remove covers (7) – (9).
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27
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60 Air conditioner
10. Air conditioner compressor q ACC: Air conditioner compressor q A/C: Air conditioner compressor connector q ACS: Diode connector of air conditioner compressor q GND09: Ground q A/C1: Intermediate connector of air conditioner compressor
28
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60 Air conditioner
11. Sunlight sensor connector SLS and machine monitor connector CM02 (CAN communication connector) a If the machine monitor connector CM02 is disconnected, the engine controller and other controller(s) can not perform the CAN communication. Accordingly, failure code: [DAFRMC] is displayed. If the screen changes to the air conditioner operation screen at this time, “A/C Controller error” is displayed red. If the above error is not displayed, no check is necessary. Note: “A/C Controller error” on the air conditioner operation screen is also displayed when the vent cannot be changed, when the temperature control is abnormal or when the refrigerant pressure switch is turned OFF. (“A/C Controller error” display for “the refrigerant pressure switch is turned OFF” will be abolished in the future.) 1) Remove dashboard cover (10). 2) Disconnect sunlight sensor (S) connector (SLS).
3) 4)
D155A-6
SEN04442-02
5)
Float dashboard (14) and pull it out toward you. a Since the wiring harness is connected, pull out the dashboard slowly. q DSH: Intermediate connector of machine monitor a Connector DSH is DRC-70. Take care in handling it. See the next page.
6)
Disconnect the following connectors. q (15): KEY q (16): BKSW --- Red band q (17): DCL --- Blue band q (18): BRK --- Yellow band q (19): FLSW q (20): RLSW
Remove duct (11). Remove covers (12) and (13).
29
SEN04442-02
7)
Inspect connectors CM01, CM02, CM03 and GPS from the backside of dashboard (14). a CM02 and CM03 can be connected reversely. Take care. CM03 is green.
12. Intermediate connector 1) Open cover (21).
2) 3)
30
60 Air conditioner
q
How to disconnect connector DSH Disconnect the connector straight slowly and check the seal for breakage, peeling and sticking foreign matter. a If the seal is damaged, replace it.
q
How to connect connector DSH 1) Check that the seal is correctly installed to the plug. 2) Check that the key is positioned to be matched to the groove of the receptacle (key is not positioned oppositely). 3) Set the plug connector to the receptacle straight (since the seal is projected) and fit it a little, while check that the seal is not rolled up. 4) Tighten the hexagon bolt at the center of the connector by 2 – 3 turns. 5) Fit the plug connector to the end and adjust it so that the clearance between it and the fitted receptacle will be even when seen from each direction. 6) Tighten the lock bolt to the specified torque. 3 Hexagon lock bolt: 2.8 ± 0.3 Nm {0.28 ± 0.03 kgm} a If the lock bolt is tightened to strongly, it will be broken and cannot lock. Take care.
Disconnect battery ground cable. Inspect connectors FSB, FD1 and FD4.
D155A-6
60 Air conditioner
Testing air leakage (duct) 1.
2.
SEN04442-02
1
3.
Remove cover (3).
Remove recirculated air filter (1) from the rear of the operator seat.
4.
Remove cover (4).
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
Remove foot duct (2).
D155A-6
31
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6.
32
60 Air conditioner
For air leakage through the defroster blowingout route of C2 and C3, check each duct joint for air leakage in the defroster mode at the maximum air flow. a When air does not come out of only C2 (Air comes out of C1 and C3) 1) Remove duct (6). 2) Check to see if air comes out of (P) in the defroster mode at the maximum air flow. 3) If no air comes out of (P), inspect duct (7). 4) If air comes out of (P), remove dashboard (8), referring to “Part and connector locations”, Item 11. 5) Inspect duct (9).
D155A-6
60 Air conditioner
Testing with self-diagnosis function
SEN04442-02
1
Outline On the air conditioner operation screen of the machine monitor, the system performs self-diagnosis for the communication with the air conditioner unit, temperature control, vent (mode) changeover and refrigerant pressure with the pressure switch. If any of these items has trouble, “A/C Controller error” is displayed red to notify the trouble. a “A/C Controller error” display for “the refrigerant pressure switch is turned OFF” will be abolished in the future.
a
1.
While pressing numeral key [4] on the normal screen, press [1], [2] and [3] in order.
2.
On the service menu screen, press [F3] (R) once to select “02 Abnormality Record”.
3.
Press [F6] (
Once a problem is detected, its indication is not reset even if it becomes normal. The indication can be reset after the starting switch is turned OFF.
On the air conditioner “Abnormality Record” screen in the service mode of the machine monitor, the system performs self-diagnosis for various sensors, in addition to the above items, and displays “Error” red if any problem is detected. a The system does not have self-diagnosis function for the Recirc/Fresh changeover servomotor. q
Explanation of machine monitor operating procedure
) to confirm.
How to enter air conditioner “Abnormality Record” screen in service mode of machine monitor.
Outline of machine monitor operation Normal screen O While pressing [4], press [1], [2] and [3] in order. Service menu (Mode) O Press [F3] once. Press [F6]. 02 Abnormality Record O Press [F3] twice. Press [F6]. 03 Air-conditioning system “Abnormality Record” screen
D155A-6
33
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60 Air conditioner
4.
On the “Abnormality Record” screen, press [F3] (R) twice to select “03 Air-conditioning System”.
5.
Press [F6] (
q
34
q
) to confirm.
Information displayed on Abnormality Record screen: “03 Air-conditioning System” screen (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) (d): If CAN status is abnormal in condition, CAN communication cannot be carried out normally but air conditioner unit is disconnected. Accordingly, the conditions (d) of other items are not displayed. (e): If [E] is displayed on the left of a condition, the abnormality is still occurring or clearing of it has not been confirmed. q [F2]: Clear “Abnormality Record” q [F5]: Return to “Abnormality Record” screen
Clearing “Abnormality Record” by machine monitor While the “Abnormality Record” screen is displayed, press [F2], and the number of occurrence time of abnormality is reset. If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.
Caution Inner Sensor means inside temperature sensor on “block diagram” or “circuit diagram”. “Ventilating Sensor is abnormal” means that evaporator temperature sensor is short circuit or disconnected. “Sunlight Sensor is abnormal” means that Sunlight Sensor is short circuit only. “Ventilation is abnormal” means servomotor for blowing out changeover (mode) damper does not rotate judging from the servomotor potentiometer voltage. a Damper is the same as door. “Air Mix is abnormal” means servomotor for Air Mix (temperature adjustment) damper does not rotate judging from the servomotor potentiometer voltage. “Refrigerant” means refrigerant pressure from (dual) pressure switch. Namely, “refrigerant is abnormal” means that (dual) pressure switch of refrigerant is OFF. 1.
CAN Status (communication) is abnormal The CAN communication between the machine monitor and air conditioner control amplifier (CNTAMP) is not carried out normally. a If failure code [DAFRMC] (Error of CAN communication with engine controller) is displayed, all the communication circuit is abnormal. In this case, see failure code [DAFRMC] in Chapter 40. If [DAFRMC] is not displayed, only the communication between control amplifier (CNTAMP) and machine monitor is abnormal. (Check connectors CN-N10, CN-AC01, [1] and [2] for disconnection. See “Part and connector locations” 2., 3., and 6. or see E-1.)
2.
Setting abnormal The software of the air conditioner amplifier does not match that of the monitor. Check the part numbers of those components.
D155A-6
60 Air conditioner
3.
Inner Sensor abnormal a Inner Sensor is the same as inside temperature sensor on “block diagram” or “circuit diagram”. a There is a Disconnection or a short circuit in the line between the control amplifier and Inside temperature sensor. a Action of air conditioner amplifier: The air conditioner amplifier controls with only the set temperature since the data of the Inside temperature sensor are not available. a Trouble: The air conditioner does not function automatically but functions when operated manually. a See “Testing Inner Sensor”.
4.
Ventilating Sensor abnormal a Ventilating Sensor is the same as evaporator temperature sensor. a There is a disconnection or a short circuit in the line between the control amplifier and evaporator temperature sensor. a Action of control amplifier: The control amplifier stops outputting to the compressor. a Trouble: The air conditioner does not work. (See “Testing evaporator temperature sensor”.)
5.
Sunlight Sensor abnormal There is a short circuit between the control amplifier and Sunlight Sensor. a Action of control amplifier: The control amplifier controls without the Sunlight Sensor. a Trouble: The automatic air conditioner does not work when the machine is exposed to the direct sunlight in the automatic air conditioner mode. a See “Testing sunlight sensor”.
SEN04442-02
6.
Ventilation is abnormal Servomotor for blowing out changeover (mode) damper does not rotate judging from the servomotor potentiometer voltage. a Damper is the same as door. a Trouble: Blowing out is not changed. a Action of control amplifier: The control amplifier stops outputting to the servomotor for blowing out changeover (mode). a Even if the link is disconnected and the damper does not rotate, the self-diagnosis system judges the damper normal since the servomotor potentiometer voltage changes normally. (For mechanical troubles, see “Testing vent (mode) changeover”.
7.
Air Mix is abnormal Servomotor for Air Mix (temperature adjustment) damper does not rotate judging from the servomotor potentiometer voltage. a Damper is the same as door. a Trouble: The temperature control system does not work. a Action of control amplifier: The control amplifier stops outputting to the air mix servomotor. a Even if the link is disconnected and the damper does not rotate, the self-diagnosis system judges the damper normal since the servomotor potentiometer voltage changes normally. (For mechanical troubles, see “Testing temperature control”.
8.
Refrigerant is abnormal (Dual) pressure switch signal for refrigerant is abnormal. Namely pressure switch for refrigerant is OFF. a Trouble: The air conditioner does not work. a Action of control amplifier: The control amplifier stops outputting to the compressor. k When
replacing the pressure switch, be sure to collect the refrigerant. See “Cautions about refrigerant”.
a
D155A-6
See “Testing (dual) pressure switch for refrigerant”.
35
SEN04442-02
Testing temperature control
60 Air conditioner
1
2.
Remove foot duct (2).
3.
Remove cover (3).
a
State with cover (3) removed q A/C U: Air conditioner unit q CNTAMP: Control amplifier
4.
Check contacts of connector [6] of the air mix servomotor (for disconnection).
Outline q Temperature is controlled by mixing ratio of the hot air from the heater and cooled air from the evaporator by changing the angles of the four doors (dampers) in the air mix section. The angle of each door (damper) is set changed by the air mix servomotor through plate (P1), lever 1 (L1) – lever 6 (L6) and rod (RODAM). Only rod (RODAM), lever 5 (L5) and lever 6 (L6) are seen from outside. (For the figure, see item 5.) a
a
a
1.
36
If lever 5 (L5) and lever 6 (L6) move smoothly between COOL MAX and HOT MAX, plate (P1) and lever 1 (L1) – lever 4 (L4) operate normally, too. Control amplifier (CNTAMP) control temperature is automatically based on inside temperature sensor. So to operate between COOL MAX and HOT MAX inside temperature sensor connector may have to be disconnected. To reset the self-diagnosis system (To clear the air conditioner error displayed on the air conditioner screen of the machine monitor), the starting switch must be turned OFF (While the self-diagnosis system is indicating a problem, no signals are output to the servomotor). Remove recirculated air filter (1) from the rear of the operator seat.
D155A-6
60 Air conditioner
5.
Check the rod (RODAM) for disconnection.
6.
Start the engine and turn the air conditioner power ON.
7.
Set the temperature to 18°C and 32°C on the air conditioner screen of the monitor and check visually that lever 5 (L5) and lever 6 (L6) move smoothly between COOL MAX and HOT MAX. a Figure is PC200-8 type, so duct is different from this type. a For COOL MAX and HOT MAX, see the right.
q
When Lever 5 (L5) and Lever 6 (L6) do not move between COOL MAX and HOT MAX. 1) Starting switch OFF. 2) Disconnect connector [8] under box assembly (11).
3)
D155A-6
SEN04442-02 a
Plate (P1), lever 1 (L1) – lever 4 (L4) are not seen from outside.
Retry steps 6 and 7. a After checking the operation and connect [8], confirm “Inner sensor is normal” on Abnormality Record screen: "03 Air-conditioning System" screen.
37
SEN04442-02
q
38
60 Air conditioner
When lever 5 (L5) and lever 6 (L6) do not move smoothly through the range shown in the figure 4)
Disconnect connectors [5] and [6] of the servomotor.
5)
Make match marks on servomotors (5) and (6) to show which connector has been connected to which servomotor. (The servomotor will be exchanged with each other later.)
6)
Remove servomotors (5) and (6).
7) a
Remove cover (7). Figure is PC200-8 type, so duct is different from this type.
8)
Rotate plate (P1) with the hand between COOL MAX and HOT MAX to see where lever 1 (L1) – lever 6 (L6) are hitched and then repair. a If the levers do not move smoothly, clean them and apply grease to the links. 2 Link: Molykote ® MH-62 Grease (Dow Corning Toray Co. Ltd.)
9)
When plate (P1) is rotated with the hand between COOL MAX and HOT MAX, if lever 1 (L1) – lever 6 (L6) move smoothly, the servomotor may have trouble. In this case, exchange servomotors (5) and (6) and operate them. a For electrical problems, see “E-4 Temperature cannot be controlled”.
D155A-6
60 Air conditioner
SEN04442-02
Testing vent (mode) changeover 1 Outline The vent (modes) are selected by changing the angles of the 4 internal doors (dampers). The angles of the doors (dampers) are changed by the servomotor through plate (P2), defroster rod (RODD), front face rod (RODF) and lever 7 (LEVER 7) – lever 12 (LEVER 12). Only defroster rod (RODD), front face rod (RODF), lever 7 (L7) and lever 8 (L8) are seen from outside. (For the figure, see item 5.) Visually check the positions of the levers and opening and closing operations of the doors (dampers) of the front face and rear face. The rear face door (damper) angle is changed by the servomotor through lever (L13) and rod (RODR). Since lever (L11) of the front face and lever (L13) and rod (RODR) of the rear face are not seen from outside, remove the duct and check the revolution of the door (damper) directly. a To reset the self-diagnosis system (To delete the air conditioner error displayed on the air conditioner screen of the machine monitor), the starting switch must be turned OFF (While the self-diagnosis system is indicating a trouble, no signals are output to the servomotor). 1.
Referring to “Testing temperature control, 1. – 3.,” remove recirculated filter (1), duct (2) and cover (3).
2.
Check contacts of connector [5] of the servomotor (for disconnection).
3.
Check the defroster rod (RODD) and foot rod (RODF) for disconnection.
4.
Start the engine and turn the air conditioner power ON.
5.
Press the vent selector switch on the air conditioner screen of the monitor and check visually that lever 7 (L7) and lever 8 (L8) move smoothly between the foot mode and defroster mode shown in the figure.
6.
Stop the engine.
7.
Remove rear face duct (RFD).
8.
Referring to “Testing for air leakage (ducts)”, remove the ducts in order from the one on the monitor side and remove front face duct (FFD).
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39
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60 Air conditioner
9.
Start the engine and turn the air conditioner power ON.
10. Press the vent selector switch on the air conditioner screen of the monitor and check the opening and closing operations of the front face door and rear face door (damper).
q
When lever 7 (L7) and lever 8 (L8) do not move smoothly through the range shown in the figure or the front face door and rear face door (damper) do not open or close 1) 2)
3) 4)
40
Disconnect connectors [5] and [6] of the servomotor. Make match marks on servomotors (5) and (6) to show which servomotor has been installed. (The servomotor will be exchanged with each other later.) Remove servomotors (5) and (6). Remove cover (7). a Figure is PC200-8 type, so duct is different from this type.
D155A-6
60 Air conditioner
5)
a
Rotate plate (P2) with the hand to see where lever 7 (L7) – lever 12 (L12) are hitched and then repair. a If the levers do not move smoothly, clean them and apply grease to the links. 2 Link: Molykote ® MH-62 Grease (Dow Corning Toray Co. Ltd.) 6) When plate (P2) is rotated with the hand, if lever 7 (L7) – lever 12 (L12) move smoothly, the servomotor may have trouble. In this case, exchange servomotors (5) and (6) and operate them. a The figures of the foot mode and defroster mode are shown before. For electrical problem, see “E-5 Vent (mode) cannot be changed over”.
D155A-6
SEN04442-02 a
F. Face door position will change from “OPEN” to “Half” gradually when raising the setting temperature from 18°C to 32°C gradually.
41
SEN04442-02
Testing Recirc/Fresh changeover1 Outline Recirculated air or fresh air is selected by changing the door (damper) angle in the air conditioner unit with the servomotor. Check the opening and closing operations of the door (damper) visually. a The system does not have self-diagnosis function for the Recirc/Fresh changeover servomotor. 1.
Remove recirculation air filter from behind the operator seat.
2.
Start the engine and turn the air conditioner power ON.
3.
Press the Recirc/Fresh selector switch on the air conditioner screen of the monitor and check visually that door (damper) (F/R D) opens and closes.
4.
When door (damper) (F/R D) does not open and close, check contacts of connector [7] of the servomotor (for disconnection), referring to “Testing temperature control, 1. –3.”, recirculated filter (1), duct (2) and cover (3).
a
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60 Air conditioner
Reference q How to remove fresh air duct. 1. Remove duct (4).
For electric problems, see “E-6 Recirc/ Fresh cannot be changed over”.
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60 Air conditioner
q
a
SEN04442-02
Method of replacing Recirc/Fresh changeover servomotor Remove fresh air duct in advance. 1) Disconnect connector [7]. (Explained before) 2) Disconnect inner sensor connector [8]. 3) Remove box assembly (11). 4) Remove the Recirc/Fresh changeover servomotor from box assembly (11).
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Testing inner sensor a
q
q
60 Air conditioner
1
8.
Inner Sensor is the same as inside temperature sensor on “block diagram” or “circuit diagram”. If “Inner Sensor abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”), test the inner sensor. To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
Check that the resistance between female connector [8] (2) (PB) (on the wiring harness side) and connector [1] (11) (PB) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.)
9.
Check that the resistance between female connector [8] (1) (BrR) (on the wiring harness side) and connector [2] (27) (BrR) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.)
1.
Referring to “Testing temperature control, 1. – 3.,” recirculated filter (1), duct (2) and cover (3).
2.
Check contacts of inner sensor connector [8] (for disconnection).
3.
Referring to “Testing Recirc/Fresh changeover door (damper)”, remove the fresh air duct.
4.
Referring to “Method of replacing Recirc/Fresh changeover servomotor”, remove box assembly (11).
5.
Resistance between terminals on sensor side of connector [8]: Normal value: 0°C ----- 1.6 kz 25°C --- 5 kz
6.
Disconnect connectors [1] and [2] from control amplifier (CNTAMP).
7.
Check that the female terminals (on the wiring harness side) of connector [8] are not shorted to each other. (If they are shorted, the wiring harness is defective.)
44
10. Connect all the connectors. 11. Turn the starting switch ON and carry out selfdiagnosis (“Abnormality Record” screen on the machine monitor: “03 Air-conditioning System”). If “Inner Sensor abnormal” is still displayed, replace the control amplifier.
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60 Air conditioner
Testing evaporator temperature sensor 1 q
q
If “Ventilating Sensor abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”), test the evaporator temperature sensor. To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
1.
Remove recirculated air filter (1), duct (2) and cover (3) according to Testing temperature control, 1 – 3.
2.
Disconnect connectors AC01 and AC02 from air conditioner unit (A/C U).
3.
Disconnect clamp (4).
4.
Remove control amplifier (CNTAMP) and its bracket together.
SEN04442-02
6.
Disconnect connector [9].
7.
Measure the resistance between the mate (female) of connector [9] and the terminal on the evaporator temperature sensor side. Normal value: 0°C ----- 4.8 kz 15°C --- 2.3 kz
a
8.
5.
Ensure contact of connector [9] along wiring harness (H). (Check for disconnection.)
D155A-6
If an error is detected by the self-diagnosis and evaporator temperature sensor is normal, control amplifier (CNTAMP) or the wiring harness is defective.
Disconnect connectors [1] and [2] from control amplifier (CNTAMP). (Connect connector [9].) Resistance between terminal (11) (PB) of connector [1] and (27) (BrR) of [2]: Normal value: 0°C ----- 4.8 kz 15°C --- 2.3 kz a If the result of 8. above is normal, control amplifier (CNTAMP) is defective. If the result of 8. above is abnormal, and the result of 7. is normal, the wiring harness is defective.
45
SEN04442-02 a
If the evaporator temperature sensor is defective, replace it according to the following procedure.
q
Replacing evaporator temperature sensor. Remove air conditioner unit assembly (A/C U). For details, see Shop Manual, Chapter 50, “Removal and installation of air conditioner unit assembly”.
1.
2.
Remove wiring harness. (For each connector, see the “Part and connector locations”.)
3.
Remove servomotors (2) and (3).
4.
Remove cover (4).
5.
Remove the link section. For details, see Shop Manual, Chapter 60, Structure and function, “Air conditioner unit”.
6.
Separate cases (5) and (6).
46
60 Air conditioner
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60 Air conditioner
7.
Remove the evaporator.
8.
Remove the holder from part (P) and remove the evaporator temperature sensor.
SEN04442-02
Installation 1.
Install the evaporator temperature sensor to the position shown in the previous figure with the holder.
2.
Carry out the following installation in the reverse order to removal.
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47
SEN04442-02
Testing sunlight sensor q
q
1.
2.
48
60 Air conditioner
1
If “Sunlight Sensor abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”), test sunlight sensor connector SLS. To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF. a A short circuit between the terminals of the sunlight sensor unit is a defect. Whether the sunlight sensor is normal cannot be checked by measuring resistance, etc., however. Accordingly, if the wiring is normal, presume the sunlight sensor to be abnormal and replace it. If “Sunlight Sensor abnormal” is still displayed, replace the control amplifier. Remove cover (10) and check connector SLS of sunlight sensor (S) on the rear side of the cover (for disconnection).
3.
Referring to “Testing temperature control, 1. – 3.,” recirculated filter (1), duct (2) and cover (3).
4.
Referring to “Testing evaporator temperature sensor item 1, 5.”, disconnect connector [1] from control amplifier (CNTAMP).
5.
Ensure that the terminals of female connector SLS (on the wiring harness side) are not shorted to each other. (If they are shorted, the wiring harness is defective.)
6.
Check that the resistance between female connector SLS (2) (L) (on the wiring harness side) and connector [1] (3) (YW) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.) a If the result of item 6 or item 7 is abnormal, check the contact of connector CN-AC01. (See “Part and connector locations.”)
7.
Check that the resistance between female connector SLS (1) (O) (on the wiring harness side) and connector [1] (15) (RB) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.)
8.
Connect all the connectors.
9.
Turn the starting switch ON and carry out selfdiagnosis (on the air conditioner fault history screen of the machine monitor). If “Sunlight Sensor abnormal” is still displayed, replace the control amplifier.
Disconnect SLS connector and measure voltage between male terminals on sunlight sensor (S) at voltage range of tester because the sensor (S) may be broken by measurement of resistance at resistance range of tester. q Approximate voltage of sunlight sensor unit 0.55 (V): direct sunlight 0.45 (V): cloudy 0.4 (V): in room
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Testing (dual) pressure switch for refrigerant 1 q
q
q
a
1.
If “Refrigerant abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”), test pressure switch connector AC05. To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF. The pressure switch unit is turned ON when the refrigerant pressure is normal and OFF when the refrigerant pressure is abnormal. The pressure switch unit may be OFF when ambient temperature below 0°C because the refrigerant pressure becomes down. The pressure switch unit is not defective but normal.
SEN04442-02
3.
Ensure that the terminals on the switch side of connector AC05 are shorted to each other (ON). (When they are not shorted (OFF), the pressure switch detects abnormal refrigerant pressure.) a When the pressure switch is OFF, connect a pressure gauge to the high pressure side of the air conditioner compressor and check the refrigerant pressure. See “Connection of service tool” and “Troubleshooting with gauge pressure.” a If refrigerant pressure is normal, the pressure switch is defective.
q
(Dual) pressure switch
Open engine left cover (1) and remove covers (2) – (4).
LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2} 2.
Disconnect pressure switch connector AC05. RD: Receiver drier SG: Sight glass
D155A-6
k When
replacing the pressure switch, be sure to collect the refrigerant.
49
SEN04442-02
q
50
60 Air conditioner
When the terminals on the switch side of connector AC05 are shorted (ON) (See E-2 for circuit) 1) Referring to “Testing temperature control, 1., 3.,” recirculated filter (1), duct (2) and cover (3). 2)
Disconnect connector [1] from control amplifier (CNTAMP).
3)
Check that the resistance between female connector AC05 (2) (B) (on the wiring harness side) and the ground is 1 z or below. (If not, the wiring harness is defective.)
4)
Check that the resistance between female connector AC05 (1) (G) (on the wiring harness side) and connector [1] (4) (GB) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.) a If the result of item 4) is abnormal, check the contact of connector CNAC01. (See “Part and connector locations.”)
5)
Connect all the connectors.
6)
Turn the starting switch ON and carry out self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”). If “Refrigerant abnormal” is still displayed, replace the control amplifier.
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60 Air conditioner
Testing relays and diodes a a
SEN04442-02
1
If the air conditioner compressor is normal (air is cooled) and air comes out, the relays are normal. Accordingly, skip these relay tests. Bring your ear to each relay to check its operation by sound.
There are two relays. q Blower main relay (connector AC03): Used to turn the fan motor ON/OFF. q Compressor clutch relay (connector AC04): Used to turn the air conditioner compressor (clutch) ON/OFF 1.
Check contacts of connectors AC03 and AC04 (for disconnection) from left behind of operator seat.
2.
Turn the starting switch ON (do not start the engine) and turn the main power of the air conditioner ON. If the blower-off relay is normal, it is turned ON. Check its click.
3.
If the air conditioner switch is turned ON at this time, the compressor relay is turned ON if it is normal. Check its click. a Control amplifier (CNTAMP) does not turn the compressor relay ON in the following cases. 1) When the evaporator temperature is below 3°C (depending on the input voltage from the evaporator temperature sensor). 2) When the pressure switch detects abnormality (it is turned OFF). a If the fan sound is too loud to hear the compressor relay sound, disconnect connector AC03 with the starting switch in the OFF position, and then check. IF: Recirculated air filter
D155A-6
q
Checking relay unit a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil actually.
Blower main relay (AC03) 1) The resistance of the coil between terminals (1) and (2) is 140 – 340 z. 2) While the voltage (DC20 – 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are disconnected from each other and terminals (3) and (5) are connected to each other. 3) While the voltage (DC20 – 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (4) are connected to each other and terminals (3) and (5) are disconnected from each other.
Compressor clutch relay (AC04) 1) The resistance of the coil between terminals (1) and (3) is 140 – 340 z. 2) Without voltage (DC20 – 30 V) applied between terminals (1) (+) and (3), terminals (2) and (4) are disconnected from each other. 3) With the voltage (DC20 – 30 V) applied between terminals (1) (+) and (3), terminals (2) and (4) are connected to each other.
51
SEN04442-02
q
52
60 Air conditioner
Testing diode units (ACD1) and (ACD2) (male) a Measure with a circuit tester in the diode range. a Test ACD2 similarly to ACD1. Between ACD1 (2) (+) and (1) (–): There is continuity. Between ACD1 (2) (–) and (1) (+): There is no continuity.
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60 Air conditioner
Troubleshooting chart 1
SEN04442-02
1
a a 1.
The numbers in the boxes are the item numbers in the troubleshooting table. E-2, E-3 means Troubleshooting for electrical system (E mode). Cooling trouble
2.
Heating trouble
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60 Air conditioner
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 troubleshooting for the electrical system. Possible cause
Check method
Defective BLOWER MAIN RELAY See “Testing relays and diodes”
Remedy Replace
Disconnection of wire or defective Check connector of blower fan motor for disconnec- Repair broken parts and conconnection tion. See E-3 and “Part and connector locations” nect correctly Defective blower motor
Check two lead wires of motor with circuit tester. If there is not continuity, motor is defective. See E-3 and “Part and connector locations”
Replace
Defective POWER TRANSISTOR Move fan switches in sequence and check fan speed. Replace (PTR) Defective diode (ACD1)
2.
Check diode (ACD1). See E-3 and “Testing relays and diodes”.
Replace
Blower fan motor is normal but air flow is insufficient. Possible cause
Check method
Remedy
Large duct resistance
Check duct for crushing and filter for clogging
Repair
Air leakage
See “Testing air leakage (duct)”
Repair or replace
Obstruction on suction side of evaporator
Check evaporator for stain and obstruction
Remove obstruction and clean
Evaporator is frozen. Check sensor clip. Check senDefective evaporator temperature sensor, defective contact of sor for dirt. evaporator temperature sensor or Check the frost on the hose near pressure switch (when freezing advances furthermore) defective expansion valve
3.
Low/high pressure Possible cause
Check method
Insufficient refrigerant
If R-134a is used as refrigerant, its quantity cannot be checked through sight glass. Accordingly, check by connecting gauge manifold. Purpose of sight glass is to check refrigerant flow.
Repair leaking part, then charge with proper quantity of refrigerant again Collect refrigerant, then charge with proper quantity of refrigerant again
Overcharge with refrigerant
Judgment by pressure at inlet/ outlet of compressor
Remedy Collect refrigerant, then charge with proper quantity of refrigerant again
Excessive or insufficient refrigerant
54
Repair or replace (Evaporator temperature sensor and expansion valve are in air conditioner unit)
Normal pressure range Low pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2} High pressure: Appox. 1.5 – 1.7 MPa {15 – 17 kg/cm2} These values are for following condition, however. Temperature in cab: 30 – 35°C Engine speed: Appox. 1500 rpm
See Troubleshooting with gauge pressure
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60 Air conditioner
4.
SEN04442-02
Compressor does not revolve at all or its speed is low. a See "E-2 compressor system (Air is not cooled)" for troubleshooting for the electrical system.
Troubled part
Possible cause
Compressor belt Loosened compressor belt Trouble in compressor Compressor
Magnet clutch
Check method
Remedy
Vibration amplitude of belt is large Adjust tension Slip of belt
Repair or replace
Insufficient compressor oil or seizure Heating of compressor in the compressor
See "Handling compressor oil"
Low battery voltage
Slip of clutch
Charge battery
Disconnection or short circuit in coil
Inspect with circuit tester (10 – 20 z)
Replace
Disconnection in wiring or defective Check ground wire and connecconnection of ground wire tions
Repair
Relay
Defective compressor clutch relay
See “Testing relays and diodes.” Replace
Refrigerant pressure
Low/high pressure (Operation of pressure switch)
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure
Pressure switch Defective pressure switch
See “Testing (dual) pressure switch for refrigerant” and E-2
Replace
Diode
Check diode (ACD2). See E-2 and “Testing relays and Replace diodes.”
5.
Defective diode (ACD2)
Blower fan motor is normal but air flow is insufficient. Possible cause
Check method
Remedy
Large duct resistance
Check duct for crushing and filter for clogging
Repair
Air leakage through duct joints
Check duct joints for defective duct seal and disconnection of duct
Repair
Clogging of heater core fins
Check heater core fins for clogging
Repair
6.
Check of hot water Possible cause
Check method
Low engine coolant temperature
Warm up engine, and then check engine coolant temperature
Find out cause
Low engine coolant level
Check coolant level in radiator
Add coolant
Insufficient circulation of engine coolant
Check engine coolant piping for clogging (Hose, pipe, and core)
Bleed air and repair
Contrary connection of IN and OUT Check the destination of heater hoses heater hoses
7.
Remedy
Repair
Fan rotation speed Possible cause
Fan rotation speed is low
D155A-6
Check method See "Checking and adjusting air conditioner compressor belt tension" in chapter 30 "Testing and adjusting" of shop manual.
Remedy Repair
55
SEN04442-02
8.
60 Air conditioner
Other items Possible cause
Check method
Temperature cannot be adjusted
See "Testing temperature control" and "Troubleshooting for electrical system, E-4"
Vent (mode) cannot be changed over
See "Testing vent (mode) changeover" and "Troubleshooting for electrical system, E-5"
Recirc/Fresh cannot be changed over
See "Testing Recirc/Fresh changeover" and "Troubleshooting for electrical system, E-6"
Excessive compressor oil
See "Handling compressor oil"
Water leakage into the cab
Clogging of drain hole
56
Remark
Common to cooling and heating
Cooling only
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60 Air conditioner
SEN04442-02
Troubleshooting for electrical system (E mode) a
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before troubleshooting, understand the information fully. Trouble Related information
No. 1
2
3
4
5
a
1
Problem that appears on machine Information related to detected trouble or troubleshooting
Check item
Procedure of troubleshooting
Possible check items for trouble<Described contents> shooting • Standard (value) required for judgement (Normal state value) (Given num- • Remarks required for judgement bers are reference <Notes on troubleshooting> (1) Pin number description sequence and tester lead handling numbers, For troubleshooting, connect the plus (+) and minus (–) which do not leads as shown below unless otherwise specified. indicate prior• Connect the plus (+) lead to pin or harness indicated in ity) the front. • Connect the minus (–) lead to a pin or harness indicated Reconfirmain the rear. tion of check (2) Example of troubleshooting by inspection of multiple items item a Normal in 1 but abnormal in 2 At this time “- defective” shown at left is applied Confirmation of repair
Judgment and remedy
YES
Remedy when criterion is judged to be "YES"
NO
Remedy when criterion is judged to be "NO"
If a wiring harness is burnt, replace it.
<Phenomenon of defective harness> q Disconnection in wiring The connector connection is defective or wiring harness is disconnected. q Ground fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit accidentally. q Hot short circuit A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit accidentally. q Short circuit A harness of an independent circuit abnormally comes into contact with one of another circuit. Related circuit diagram This is the excerpted circuit diagram related to troubleshooting q Connector No.: Indicates (Model – No. of pins) (Color). q See “Arrangement of connector pins” and “Arrangement of parts and connectors” q The circuit diagram shows the size and colors of wires. W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown a When there are 2 colors Example: WY: Yellow line on white background a The number before the wire color indicates the wire size. q N.C.: Normally closed (Normally turned ON) q [1], [2], ... are connector numbers. q Arrow (io ): Roughly indicates mounting place on machine.
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E-1 Power supply system (Air conditioner does not operate) Problem Indication of problem on machine
Air conditioner does not operate due to power supply system failure. • “A/C Controller Error” is displayed red on air conditioner screen of machine monitor. • No air blows out (Blower motor does not rotate). • If failure code [DAFRMC] is displayed on machine monitor, see Chapter 40 Troubleshooting first and repair so that [DAFRMC] will not be displayed. a CAN communication is connected to machine monitor, engine controller, pump controller and air conditioner controller.
Related information
• “A/C Controller Error” is displayed on air conditioner operation screen of machine monitor in following cases. In E-1, 1), 2) and 3) of following cases are explained. 1) Power is not supplied to control amplifier. 2) Control amplifier is broken. 3) Control amplifier (CNTAMP) cannot communicate with machine monitor. 4) Blowing out door (damper) servomotor does not rotate. 5) Temperature control (AIRMIX) door (damper) servomotor does not rotate. 6) Refrigerant pressure is abnormal. • Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine monitor: “03 Air-conditioning System” and check to see if “CAN Status” is abnormal. Abnormality of “CAN Status” indicates that control amplifier at rear of air conditioner unit cannot communicate with machine monitor. “CAN Status” is indicated as abnormal in any case of 1), 2) and 3) above. • Referring to “Part and connector locations”, ensure the following. 1) Circuit breaker CB3 is not OFF (Its reset button is not projected). (It is ON, if normal.) 2) Fuse Fu5A is not broken. • Ground cable of air conditioner is grounded together with that of machine wiring harness for electrical equipment of machine. • For each connector and relay, see “Part and connector locations”. • If fuse is broken when A/C switch is pressed, see E-2. • T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a T-adapter is not prepared for other connectors.
No.
1
2
Check item
Wiring harness (ground cable)
Circuit breaker and fuse
Procedure of troubleshooting
Judgment and remedy
1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect connector [1] from control amplifier and carry out troubleshooting without turning starting switch ON.
• The state of the wiring harness is normal. YES • Proceed to the next check item.
Between (16) (black) on wiring harness side of connector [1] – ground
Resistance
Max. 1 z
1) Turn starting switch OFF. 2) Referring to “Part and connector locations”, check circuit breaker CB3 is not OFF (Its reset button is not projected) and check fuse Fu5A.
NO
• The state of the circuit breaker and fuse is norYES mal. • Proceed to the next check item.
NO
58
• The wiring harness is defective. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• If the circuit breaker or fuse is tripped, the circuit may have a ground fault. • Proceed to "Ground fault in wiring harness".
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60 Air conditioner
No.
Check item
SEN04442-02
Procedure of troubleshooting
Judgment and remedy
a If fuse described in related information is broken, replace it. 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect connectors [1] and [2] from control amplifier. 4) Turn starting switch ON and carry out troubleshooting.
• The state of the wiring harness is normal. YES • Proceed to the next check item.
Between (6) (red) – (16) (B) on wiring harness side of connector [1]
3
4
5
Wiring harness
Ground fault in wiring harness
Open circuit in wiring harness
Voltage 20 – 30 V
A
a If fuse is broken again in test A above, perform following procedure. (Replace broken fuse.) 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect control amplifier connector [1] and carry out troubleshooting without turning starting switch ON. a If fuse is broken again in test A above and results B and C below are normal, blower motor circuit may be cause of trouble. See E-3. Between (6) (red) – (16) (black) wiring harness side of connector [1]
Resistance
Min. 1 Mz
B
Between (6) (red) on wiring harness side of connector [1] – ground
Resistance
Min. 1 Mz
C
a If fuse is broken again in test A for check item 3 and result of B or C is abnormal, identify wiring harness having ground fault. 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect connectors AC01, AC02 and [1]. 4) Connect T-adapter to wiring harness side of connector [1] and carry out troubleshooting without turning starting switch ON. a If result D or E below is abnormal: Short circuit in air conditioner wiring harness (on plate) a If result F or G below is abnormal: Short circuit in machine wiring harness Between (6) (red) – (16) (black) on wiring harness side of connector [1]
Resistance
Min. 1 Mz
D
Between (6) (red) on wiring harness side of connector [1] – ground
Resistance
Min. 1 Mz
E
Between connector AC02 (female) (4) – AC01 (female) (5) (black)
Resistance
Min. 1 Mz
F
Between connector AC01 (female) (4) (red) – (5) (black)
Resistance
Min. 1 Mz
G
NO
• No ground fault occurs in the wiring harness. YES • Proceed to the next check item.
NO
a If fuse described in related information is not broken and test result A for check item 3 is abnormal, check with circuit diagram.
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • If the fuse is burnt out, replace it. • Proceed to "Confirmation of repair".
• No open circuit occurs in the wiring harness. YES • Proceed to the next check item
NO
D155A-6
• The wiring harness is defective. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
59
SEN04442-02
No.
Check item
60 Air conditioner
Procedure of troubleshooting
Judgment and remedy
a If CAN communication circuit has short circuit or ground fault, [DAFRMC] error is displayed. a Terminal resistors of about 120 z are in machine monitor and on engine. Since they are connected in parallel, combined resistance is about 60 z. 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect control amplifier connectors [1] and [2] and connect T-adapter to wiring harness side. 4) Carry out troubleshooting without turning starting switch ON.
• The state of the CAN communication circuit is YES normal. • Proceed to the next check item.
Between connector [2] (17) – (18) 6
Approx. 60 z
H
CAN commu- a If result H above is abnormal, perform following procedure. nication a If result H above and J below are abnormal, operator cab wircircuit ing harness is abnormal. a If result H above is abnormal and J below is normal, air conditioner wiring harness (on plate) is abnormal. a Terminal resistors of about 120 z are in machine monitor and on engine. Since they are connected in parallel, combined resistance is about 60 z. 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect control amplifier connectors [1] and [2] and connect T-adapter to wiring harness side. 4) Carry out troubleshooting without turning starting switch ON. Between connector AC02 (female) (1) – (2)
7
Resistance
Control amplifier
Resistance
Approx. 60 z
NO
• The CAN communication circuit is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
J
When test results for check items 1, 2, result A for check item 3 and result H for check item 6 are normal, replace control amplifier.
• The state of the control amplifier is normal. YES • Proceed to the next check item.
NO
• The control amplifier is defective. • Replace the control amplifier. • Proceed to "Confirmation of repair".
YES The repair is completed.
8
Reconfirmation of check item
1) Reconfirm the preceding troubleshooting. 2) Can you identify the cause of failure by reconfirmation?
9
Confirmation of repair
1) Turn the starting switch OFF. 2) Connect all the composed equipment. 3) Start the engine. 4) Operate the air conditioner switch. 5) Does this failure recur?
60
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
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60 Air conditioner
SEN04442-02
Related circuit diagram
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61
SEN04442-02
60 Air conditioner
E-2 Compressor system (Air is not cooled) Problem
Air is not cooled due to compressor system failure.
Indication of problem on machine
• When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is not cooled as displayed on screen. • Air conditioner compressor does not operate. • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. Causes of this phenomenon are 1) – 6). For 1) – 5), see “Related information” in E-1.
Related information
In E-2, “6) Refrigerant pressure is abnormal” of “Related information” in E-1 is explained. • Referring to “Testing with self-diagnosis function”, display air conditioner fault history screen on machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is abnormal, compressor is not turned ON and air is not cooled consequently. a Abnormal refrigerant pressure indicates that “Signal (connector [1] (4)) from pressure switch is not grounded”. • Air conditioner may not be turned ON even when ambient temperature is below 5°C (Normal). • 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 T-adapter is not prepared for other connectors.
No.
1
Check item
Pressure switch
Procedure of troubleshooting
Judgment and remedy
a If “A/C Controller Error” is displayed red on air conditioner operation screen of machine monitor, perform following procedure. 1) Turn starting switch OFF. 2) Disconnect battery ground terminal. 3) Disconnect pressure switch connector P17 and carry out troubleshooting without turning starting switch ON. a Pressure switch may operate normally and turn off itself. Accordingly, if following is abnormal (if switch is turned OFF), install pressure gauge to low pressure side of air conditioner compressor and check refrigerant pressure.
• The state of the pressure switch is normal. YES • Proceed to the next check item.
Between (1) – (2) on pressure switch side of connector AC05
Resistance
Max. 1 z
k Before replacing pressure switch, collect refrigerant.
2
1) Turn starting switch OFF. 2) Disconnect connector A/C from air conditioner compressor and carry out troubleshooting without turning starting switch ON. a Ensure connection of air conditioner compressor ground cable and GND09. (See “Part and connector locations”.) Air conditioner Resistance
Approx. 15 z
1) Turn starting switch OFF. 2) Disconnect connectors ACS, ACD2 and carry out troubleshooting without turning starting switch ON. a Test at diode range.
62
• The state of the air conditioner compressor is YES normal. • Proceed to the next check item.
compressor Between (1) on air conditioner compressor side of connector A/C – ground (Air conditioner compressor coil resistance)
3
NO
Diode
Between ACS (male) (1) (+) – (2) (–)
There is no continuity
Between ACS (male) (1) (–) – (2) (+)
There is continuity
Between ACD2 (male) (1) (+) – (2) (–)
There is no continuity
Between ACD2 (male) (1) (–) – (2) (+)
There is continuity
• The pressure switch is defective. • Replace the pressure switch. • Proceed to "Confirmation of repair".
NO
• The air conditioner compressor is defective. • Replace the air conditioner compressor. • Proceed to "Confirmation of repair".
• The state of the diode is normal. YES • Proceed to the next check item.
NO
• The diode is defective. • Replace the diode. • Proceed to "Confirmation of repair".
D155A-6
60 Air conditioner
No.
4
Check item
SEN04442-02
Procedure of troubleshooting
Judgment and remedy
1) Turn starting switch OFF. 2) Disconnect connectors [1], AC04 and ACS and carry out troubleshooting without turning starting switch ON. a Ensure that test result for check item 1 is normal (pressure switch is turned ON) and that for check item 2 is normal (air conditioner compressor is normal) and that check item 3 is Open circuit in normal. wiring Between connector [1] (4) – ground ResisMax. 1 z harness (Pressure switch is turned ON) tance Between connector AC04 (female) (2) – ground (Air conditioner compressor coil resistance)
Resistance
Approx. 15 z
Between connector ACS (male) (2) – ground
Resistance
Max. 1 z
• Referring to “Testing relays”, check sound made when compressor clutch relay is turned ON. a If blower sound is too large to hear operating sound of compressor clutch relay, turn starting switch OFF temporarily and disconnect connector R30.
Click is heard.
A
• No open circuit occurs in the wiring harness. YES • Proceed to the next check item
NO
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the compressor clutch relay is YES normal. • Proceed to the next check item.
a If A above and B below are abnormal and C is normal (relay is normal), go to check items 7 and 8. 5
Compressor clutch relay
1) Turn starting switch OFF. 2) Disconnect connector AC04. 3) Short (2) (white) and (4) (green) of connector AC04 (on wiring harness side) wire. (Turn compressor ON forcibly without using relay.) 4) Turn starting switch ON.
Air is cooled.
B NO
1) Turn starting switch OFF. 2) Disconnect connector AC04 and carry out troubleshooting without turning starting switch ON. Between AC04 (relay side) (1) – (3) (coil resistance)
6
7
Ground fault in wiring harness
Short circuit in wiring harness
D155A-6
Resistance
Approx. 140 – 340 z
C
a If fuse is not broken, skip troubleshooting. 1) Turn starting switch OFF. 2) Disconnect connector AC04 and carry out troubleshooting without turning starting switch ON. a Ensure that test result for cause is normal. Between (2) on machine wiring harness side of connector AC04 – ground (Air conditioner compressor coil resistance)
Resistance
Approx. 15 z
Resistance
• No ground fault occurs in the wiring harness. YES • Proceed to the next check item.
NO
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. YES • Proceed to the next check item.
1) Turn starting switch OFF. 2) Disconnect connector AC04 and [2] and carry out troubleshooting without turning starting switch ON. a Ensure that test result for check item 2 is normal.
Between (3) – (1) on machine wiring harness side of connector AC04
• The compressor clutch relay is defective. • Replace the compressor clutch relay. • Proceed to "Confirmation of repair".
Min. 1 Mz
NO
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
63
SEN04442-02
No.
8
Check item
60 Air conditioner
Procedure of troubleshooting
Judgment and remedy • No open circuit occurs in the wiring harness. YES • Proceed to the next check item
Open circuit in wiring Check with circuit diagram. harness
NO
9
Control amplifier
1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter in wiring harness side. 3) Turn starting switch ON. 4) Display air conditioner operation screen on machine monitor and press A/C switch.
Between connector [2] (35) – [1] (16)
Voltage
Max. 1 V
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the control amplifier is normal. YES • Proceed to the next check item.
NO
• The control amplifier is defective. • Replace the control amplifier. • Proceed to "Confirmation of repair".
YES The repair is completed. Reconfirma10 tion of check item
11
64
Confirmation of repair
1) Reconfirm the preceding troubleshooting. 2) Can you identify the cause of failure by reconfirmation?
1) Turn the starting switch OFF. 2) Connect all the composed equipment. 3) Start the engine. 4) Operate the air conditioner switch. 5) Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
D155A-6
60 Air conditioner
SEN04442-02
Related circuit diagram
D155A-6
65
SEN04442-02
60 Air conditioner
E-3 Blower motor system (No air comes out or air flow is abnormal) Problem
No air comes out or air flow is abnormal due to blower motor system failure.
Indication of problem on machine
• LCD of machine monitor on air conditioner operation screen lights normally but air does not come out. • Air flow does not match fan switch setting on air conditioner operation screen.
Related information
• This trouble is not checked with self-diagnosis function. • If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. Possible causes for this trouble are as follows. 1) Compressor clutch relay is defective (Stuck closed). (See E-2, 5, A.) 2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air conditioner unit.) 3) Expansion valve is adjusted improperly. (Remove air conditioner unit and replace expansion valve.) • If air comes out, fuse and relay are normal and wiring harness is seldom abnormal. • If air comes out but its flow is abnormal in heating mode, replace power transistor first. • For each connector, relay, and power transistor, see “Part and connector locations”. • 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.
No.
Check item
Procedure of troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector [3] and carry out troubleshooting without turning starting switch ON.
1
There is continuity
a If power transistor is normal, all of following are normal. Reverse is not always true, however (Transistor itself cannot be checked if transistor unit is removed). 1) Turn starting switch OFF. 2) Disconnect connector [4] and carry out troubleshooting without turning starting switch ON.
66
• The state of the blower motor is normal. YES • Proceed to the next check item.
Bower motor Between wiring harness terminals on blower motor side of connector [3]
2
Judgment and remedy
Power transistor
Between (2) (+) – (1) of connector [4] (male) (power transistor) (Internal fuse and resistor must not be broken) a If test result is abnormal, overcurrent has flowed. In this case, replace blower motor, too.
Approx. 11 kz
Between (3) – (4) of connector [4] (male) (power transistor) (Internal resistor must not be broken)
Approx. 2.2 kz
Between (1) (+) – (3) (–) of connector [4] (male) (power transistor)
There is continuity * Diode range
Between (3) (+) – (1) (–) of connector [4] (male) (power transistor)
There is no continuity * Diode range
NO
• The blower motor is defective. • Replace the blower motor. • Proceed to "Confirmation of repair".
• The state of the power transistor is normal. YES • Proceed to the next check item.
NO
• The power transistor is defective. • Replace the power transistor. • Proceed to "Confirmation of repair".
D155A-6
60 Air conditioner
No.
Check item
SEN04442-02
Procedure of troubleshooting Referring to “Testing relay”, check turn-on sound of blower main relay.
Judgment and remedy
Click is heard.
A
• The state of the blower main relay is normal. YES • Proceed to the next check item.
a If test results A above and B below are abnormal and C is normal (relay is normal), go to check items 8-J and 10.
3
Blower main relay
1) Turn starting switch OFF. 2) Disconnect connector AC03. 3) Short (3) (red/yellow) and (4) (red/blue) of connector AC03 (wiring harness side) with wire. (Turn blower ON forcibly without using relay.) 4) Turn starting switch ON. Operate fan on air conditioner operation screen.
Air comes out.
B
NO
a If air does not come out even when blower is turned ON forcibly without using relay, cause is part other than relay.
• The blower main relay is defective. • Replace the blower main relay. • Proceed to "Confirmation of repair".
1) Turn starting switch OFF. 2) Disconnect connector AC03 and carry out troubleshooting without turning starting switch ON. Between (1) – (2) of AC03 (relay side) (coil resistance)
4
Diode
Resistance
Approx. 140 – 340 z
C
1) Turn starting switch OFF. 2) Disconnect connector ACD1 and carry out troubleshooting without turning starting switch ON. a Test at diode range. Between ACD1 (male) (1) (+) – (2) (–)
There is no continuity
Between ACD1 (male) (1) (–) – (2) (+)
There is continuity
1) Turn starting switch OFF. 2) Disconnect connector [4] and carry out troubleshooting without turning starting switch ON. 5
• The state of the diode is normal. YES • Proceed to the next check item. NO
• The state of the wiring harness is normal. YES • Proceed to the next check item.
Wiring harness Between (1) (black) on wiring harness side of connector [4] – ground
D155A-6
Resistance
Max. 1 z
• The diode is defective. • Replace the diode. • Proceed to "Confirmation of repair".
NO
• The wiring harness is defective. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
67
SEN04442-02
No.
60 Air conditioner
Check item
Procedure of troubleshooting
Judgment and remedy
• Blower motor input voltage 1) Turn starting switch OFF. 2) Disconnect connector [3]. 3) Turn starting switch ON. 4) Press fan switch on air conditioner operation screen. (Air flow may be set to any position.) a If result is abnormal, go to check items 8-J and 10. Between (1) (red/yellow) on wiring harness side of connector [3] – ground
6
Input/output voltage
Voltage
Approx. 24 V
• The state of the input/ output voltage is norYES mal. • Proceed to the next check item.
• Power transistor input voltage 1) Turn starting switch OFF. 2) Disconnect connector [4]. (Since no current flows to blower motor, blower motor does not rotate.) 3) Turn starting switch ON. 4) Press fan switch on air conditioner operation screen. (Air flow may be set to any position.) a If D below is abnormal, go to G below. a If E below is abnormal, go to check items 9 and 10. Between (2) (brown/black) – (1) (black) on wiring harness side of connector [4]
Voltage
Max. 2 V
D
Between (3) (black/blue) – (1) (black) on wiring harness side of connector [4]
Voltage
Approx. 24 V *1
E
NO
• Control amplifier 1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. 4) Press fan switch on air conditioner operation screen. (Air flow may be set to any position.) a If F below is abnormal, go to causes 7-J and 9. a If G below is abnormal, go to check items 9 and 10.
7
Between (36) – (16) of connector [2]
Voltage
Max. 1 V
F
Between (8) – (16) of connector [1]
Voltage
Max. 2 V
G
When test results D for check item 6 are normal (voltage is Blower motor normal but motor does not rotate), blower (fan) motor is defective.
• The state of the blower motor is normal. YES • Proceed to the next check item.
NO
Short circuit in Between (2) – (1) on wiring wiring harness side of connector harness AC03 Between (6) – (7) on wiring harness side of connector [1]
Resistance
Min. 1 Mz
J NO
Resistance
• The blower motor is defective. • Replace the blower motor. • Proceed to "Confirmation of repair".
• No short circuit occurs in the wiring harness. YES • Proceed to the next check item.
1) Turn starting switch OFF. 2) Disconnect connectors AC03 and [1] and carry out troubleshooting without turning starting switch ON. 8
• The input/output voltage is defective. • Repair the defective part. • Proceed to "Confirmation of repair".
Min. 1 Mz
• A short circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
*1: At blower main relay ON
68
D155A-6
60 Air conditioner
No.
Check item
SEN04442-02
Procedure of troubleshooting
Judgment and remedy
1) Turn starting switch OFF. 2) Disconnect connectors [1] and [4] and carry out troubleshooting without turning starting switch ON. 9
Ground fault in wiring harness
Open circuit 10 in wiring harness
Between (2) – (1) on wiring harness side of connector [4]
Resistance
Min. 1 Mz
• No ground fault occurs in the wiring harness. YES • Proceed to the next check item.
NO
• No open circuit occurs in the wiring harness. YES • Proceed to the next check item Check with circuit diagram. NO
Control 11 amplifier
• Ground fault occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
Control amplifier is defective in following cases. 1) F for cause 6 is abnormal, J for check item 8 is normal, and cause 10 is normal. 2) G for cause 6 is abnormal and check items 9 and 10 are normal.
• An open circuit occurs in the wiring harness. • Repair or replace the wiring harness. • Proceed to "Confirmation of repair".
• The state of the control amplifier is normal. YES • Proceed to the next check item.
NO
• The control amplifier is defective. • Replace the control amplifier. • Proceed to "Confirmation of repair".
YES The repair is completed. Reconfirma12 tion of check item
13
Confirmation of repair
D155A-6
1) Reconfirm the preceding troubleshooting. 2) Can you identify the cause of failure by reconfirmation?
1) Turn the starting switch OFF. 2) Connect all the composed equipment. 3) Start the engine. 4) Operate the air conditioner switch. 5) Does this failure recur?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
69
SEN04442-02
60 Air conditioner
Related circuit diagram
70
D155A-6
60 Air conditioner
D155A-6
SEN04442-02
71
SEN04442-02
60 Air conditioner
E-4 Temperature cannot be controlled Problem
Temperature cannot be controlled.
Indication of problem on machine
• “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-1.) • While air conditioner operation screen of machine monitor is displayed, temperature does not change even if temperature control switch is operated.
Related information
a Temperature control means “Air Mix” of cooled air and hot air. • Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine monitor: “03 Air-conditioning System” and check to see if “Air Mix is abnormal” and “Inner sensor is abnormal”. See “Testing inner sensor” when “Inner sensor is abnormal”. • Even if rod etc. is disconnected (See “Testing temperature control”), if current is supplied to air mix servomotor by operating switches and potentiometer in servomotor reaches normal voltage, selfdiagnosis function judges system normal. • Referring to “Testing temperature control”, check that there is not contact of connector [6] or mechanical trouble (removal or interference of link, etc.) • Air mix servomotor and air blowing out (mode) servomotor are same part number. Operating angle of temperature control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and blowing out (mode) servomotor to see if they are normal. • Air mix servomotor can be checked for trouble by connecting new servomotor to connector [6] and see if it operates normally. • 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.
No.
Check item
Procedure of troubleshooting
Judgment and remedy
1) Turn starting switch OFF. 2) Disconnect connector [6] and carry out troubleshooting without turning starting switch ON.
1
72
Air mix servomotor
Between (6) – (7) of connector [6] (on servomotor side) (There must not be disconnection or short circuit)
Resistance
400 – 3000 z
Between (1) – (3) of connector [6] (on servomotor side) (There must not be disconnection or short circuit)
Resistance
4k–8 kz
Between (1) – (5) of connector [6] (on servomotor side) (There must not be disconnection or short circuit)
Resistance
4k–8 kz
• The state of the air mix servomotor is normal. YES • Proceed to the next check item.
NO
• The air mix servomotor is defective. • Replace the air mix servomotor. • Proceed to "Confirmation of repair".
D155A-6
60 Air conditioner
No.
Check item
SEN04442-02
Procedure of troubleshooting
Judgment and remedy
1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. Between connector [1] (3) – [2] (27)
2
Voltage
5V
1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. 4) Set temperature control switch on air conditioner operation Air mix screen to COOL MAX. servomotor or 5) Set temperature control switch on air conditioner operation air conditioner screen to HOT MAX. wiring a Voltage appears across (21) and (22) of connector [2] for harness about 3 seconds (only while door moves). a Voltage across connectors [1] (2) and [2] (27) changes for about 3 seconds (only while door moves) (It is stabilized after door stops). Between (21) (+) – (22) (–) of connector [2] a If temperature is changed from HOT MAX to COOL MAX, voltage polarities are reversed.
Voltage
Approx. 24 V
Between connector [1] (2) (+) – [2] (27) (–) Voltage
Change below 5 V
a When test result for check item 1 is normal and that for check item 2 is abnormal, perform following procedure.
3
Air conditioner wiring harness Check with circuit diagram.
4
Control amplifier
• The state of the air mix servomotor or air conditioner wiring harness is YES normal. • Proceed to the next check item.
a When test result for check item 1 is normal and that for check item 2 is abnormal and that for check item 3 is normal, control amplifier is defective.
NO
• The air mix servomotor or air conditioner wiring harness is defective. • Repair or replace the air mix servomotor or air conditioner wiring harness. • Proceed to "Confirmation of repair".
• The state of the air conditioner wiring harness YES is normal. • Proceed to the next check item.
NO
• The air conditioner wiring harness is defective. • Repair or replace the air conditioner wiring harness. • Proceed to "Confirmation of repair".
• The state of the control amplifier is normal. YES • Proceed to the next check item.
NO
• The control amplifier is defective. • Replace the control amplifier. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation of check item
D155A-6
1) Reconfirm the preceding troubleshooting. 2) Can you identify the cause of failure by reconfirmation?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
73
SEN04442-02
No.
6
60 Air conditioner
Check item Confirmation of repair
Procedure of troubleshooting 1) Turn the starting switch OFF. 2) Connect all the composed equipment. 3) Start the engine. 4) Operate the air conditioner switch. 5) Does this failure recur?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
74
D155A-6
60 Air conditioner
SEN04442-02
E-5 Vent (mode) cannot be changed over Problem Indication of problem on machine
Vent (mode) cannot be changed over. • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-1.) • When vent selector switch on air conditioner operation screen of machine monitor is operated, vent does not change. • Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine monitor: “03 Air-conditioning System” and check to see if “Ventilating sensor is abnormal”. • Even if rod etc. is disconnected (See “Testing vent (mode) changeover”), if current is supplied to blowing out (mode) servomotor by operating switches and potentiometer in servomotor reaches normal voltage, self-diagnosis function judges system normal.
Related information
No.
• Referring to “Testing vent (mode) changeover”, check that there is not contact of connector [5] or mechanical trouble (removal or interference of link, etc.) • Air mix servomotor and blowing out (mode) servomotor are same. Operating angle of temperature control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and blowing out (mode) servomotor to see if they are normal. • Blowing out servomotor can be checked for trouble by connecting new servomotor to connector [5] and see if it operates normally. • 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.
Check item
Procedure of troubleshooting
Judgment and remedy
1) Turn starting switch OFF. 2) Disconnect connector [5] and carry out troubleshooting without turning starting switch ON.
1
Blowing out (mode) servomotor
D155A-6
Between (6) – (7) of connector [5] (on servomotor side) (There must not be disconnection or short circuit)
Resistance
400 – 3000 z
Between (1) – (3) of connector [5] (on servomotor side) (There must not be disconnection or short circuit)
Resistance
4k–8 kz
Between (3) – (5) of connector [5] (on servomotor side) (There must not be disconnection or short circuit)
Resistance
4k–8 kz
• The state of the blowing out (mode) servomotor is normal. YES • Proceed to the next check item.
NO
• The blowing out (mode) servomotor is defective. • Replace the blowing out (mode) servomotor. • Proceed to "Confirmation of repair".
75
SEN04442-02
No.
Check item
60 Air conditioner
Procedure of troubleshooting
Judgment and remedy
1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON.
Between connector [1] (3) – [2] (27)
2
Voltage
5V
1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. Blowing out 3) Turn starting switch ON. (mode) 4) Set vent selector switch on air conditioner operation screen to servomotor or FACE. air conditioner 5) Set vent selector switch on air conditioner operation screen to DEFROST. wiring a Voltage appears across (24) and (23) of connector [2] for harness about 3 seconds (only while door moves). a Voltage across connectors [1] (9) and [2] (27) changes for about 3 seconds (only while door moves) (It is stabilized after door stops). Between (24) (+) – (23) (–) of connector [2] a If vent is changed from DEFROST to FACE, voltage polarities are reversed.
Voltage
Approx. 24 V
Between connector [1] (9) (+) – [2] (27) (–) Voltage
Changes below 5 V
a When test result for check item 1 is normal and that for check item 2 is abnormal, perform following procedure.
3
Air conditioner wiring harness Check with circuit diagram.
4
Control amplifier
• The state of the blowing out (mode) servomotor or air conditioner YES wiring harness is normal. • Proceed to the next check item.
a When test result for check item 1 is normal and that for check item 2 is abnormal and that for check item 3 is normal, control amplifier is defective.
NO
• The blowing out (mode) servomotor or air conditioner wiring harness is defective. • Repair or replace the blowing out (mode) servomotor or air conditioner wiring harness. • Proceed to ""Confirmation of repair".
• The state of the air conditioner wiring harness YES is normal. • Proceed to the next check item.
NO
• The air conditioner wiring harness is defective. • Repair or replace the air conditioner wiring harness. • Proceed to "Confirmation of repair".
• The state of the control amplifier is normal. YES • Proceed to the next check item.
NO
• The control amplifier is defective. • Replace the control amplifier. • Proceed to "Confirmation of repair".
YES The repair is completed.
5
76
Reconfirmation of check item
1) Reconfirm the preceding troubleshooting. 2) Can you identify the cause of failure by reconfirmation?
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
D155A-6
60 Air conditioner
No.
Check item
6
Confirmation of repair
SEN04442-02
Procedure of troubleshooting 1) Turn the starting switch OFF. 2) Connect all the composed equipment. 3) Start the engine. 4) Operate the air conditioner switch. 5) Does this failure recur?
Judgment and remedy YES
Return to the first check item.
NO
The repair is completed.
Related circuit diagram
D155A-6
77
SEN04442-02
60 Air conditioner
E-6 Recirc/Fresh air cannot be changed over Problem
Recirc/Fresh air cannot be changed over.
Indication of problem on machine
When Recirc/Fresh selector switch of machine monitor is operated, recirculated or fresh air does not changeover (Recirc/Fresh changeover door (damper) does not rotate).
Related information
• Recirc/Fresh changeover is not checked with self-diagnosis function. • Referring to “Testing Recirc/Fresh changeover”, operate Recirc/Fresh selector switch and check that there is not mechanical trouble (removal or interference of link, etc.) in Recirc/Fresh changeover door. • Operating angle of Recirc/Fresh changeover servomotor is 90°. • 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.
No.
1
Check item
Procedure of troubleshooting
Judgment and remedy
a Since connector [7] cannot be disconnected easily, test on control amplifier side. 1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and connect T-adapter to wiring harness side. 3) Carry out troubleshooting without turning starting switch ON.
• The state of the Recirc/ Fresh changeover servomotor (Unit test) or air YES conditioner wiring harness is normal. • Proceed to the next check item.
Recirc/Fresh changeover Between connector [1] (wiring harness servomotor side) (6) – connector [2] (wiring harness (Unit test) or side) (19) (There must not be air conditioner disconnection or short circuit) wiring harness Between connector [1] (wiring harness side) (6) – connector [2] (wiring harness side) (20) (There must not be disconnection or short circuit)
2
Air conditioner wiring harness
400 – 3000 z
NO Resistance
400 – 3000 z
• The Recirc/Fresh changeover servomotor (Unit test) or air conditioner wiring harness is defective. • Repair or replace the Recirc/Fresh changeover servomotor (Unit test) or air conditioner wiring harness. • Proceed to "Confirmation of repair".
• The state of the air conditioner wiring harness a When test result for check item 1 is abnormal, perform followYES is normal. ing procedure. • Proceed to the next check item.
Check with circuit diagram.
78
Resistance
NO
• The air conditioner wiring harness is defective. • Repair or replace the air conditioner wiring harness. • Proceed to "Confirmation of repair".
D155A-6
60 Air conditioner
No.
3
Check item
Control amplifier or Recirc/Fresh changeover servomotor
SEN04442-02
Procedure of troubleshooting
Judgment and remedy
1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. 4) Set Recirc/Fresh selector switch on air conditioner operation screen to Recirc. 5) Set Recirc/Fresh selector switch on air conditioner operation screen to Fresh. a Voltage appears across connector [1] (6) and connector [2] (20) for about 3 seconds (only while door moves to Fresh position).
• The state of the control amplifier or Recirc/ Fresh changeover serYES vomotor is normal. • Proceed to the next check item.
Between connector [1] (6) (+) and connector [2] (20) (–)
4
Approx. 24 V
See 1) – 3) above. 4) Set Recirc/Fresh selector switch on air conditioner operation screen to Fresh. 5) Set Recirc/Fresh selector switch on air conditioner operation screen to Recirc. a Voltage appears across connector [1] (6) and connector [2] (19) for about 3 seconds (only while door moves to Recirc position). Between connector [1] (6) (+) and connector [2] (19) (–)
Recirc/Fresh changeover servomotor
Voltage
Voltage
NO
Approx. 24 V
a When test result for check item 1 is abnormal and that for check item 2 is normal, Recirc/Fresh changeover servomotor is defective. (If all test results for check items 1, 2 and 3 are normal, check item may be mechanical trouble such as hitch.)
• The control amplifier or Recirc/Fresh changeover servomotor is defective. • Replace the control amplifier or Recirc/ Fresh changeover servomotor. • Proceed to "Confirmation of repair".
• The state of the Recirc/ Fresh changeover serYES vomotor is normal. • Proceed to the next check item.
NO
• The Recirc/Fresh changeover servomotor is defective. • Replace the Recirc/ Fresh changeover servomotor. • Proceed to "Confirmation of repair".
• The state of the control amplifier is normal. YES • Proceed to the next check item. 5
Control amplifier
a When test results for check items 1 and 2 are normal and that for check item 3 is abnormal, control amplifier is defective. NO
• The control amplifier is defective. • Replace the control amplifier. • Proceed to "Confirmation of repair".
YES The repair is completed.
6
7
Reconfirmation of check item
1) Reconfirm the preceding troubleshooting. 2) Can you identify the cause of failure by reconfirmation?
Confirmation of repair
1) Turn the starting switch OFF. 2) Connect all the composed equipment. 3) Start the engine. 4) Operate the air conditioner switch. 5) Does this failure recur?
D155A-6
NO
• The machine monitor may be defective. • Replace the machine monitor. • Proceed to "Confirmation of repair".
YES
Return to the first check item.
NO
The repair is completed.
79
SEN04442-02
60 Air conditioner
Related circuit diagram
80
D155A-6
60 Air conditioner
SEN04442-02
Troubleshooting with gauge pressure
1
Referring to “Connection of service tool”, carry out troubleshooting by reading the high and low gauge pressures of the cooling cycle.
<Measurement condition for pressure> Atmospheric temperature
20 – 50°C
a
The gauge pressure varies largely with the weather condition and operating condition of the machine. Take care.
Engine speed
Low idle
Air conditioner switch
ON
Fan switch
Hl
High pressure is too high: Above approx. 2.5 MPa {25 kg/cm2} High pressure is too low: Below approx. 1 MPa {10 kg/cm2} Low pressure is too high: Above approx. 0.3 MPa {3 kg/cm2} Low pressure is too low: Below approx. 0.05 MPa {0.5 kg/cm2}
Set temperature
Full cool
q q q q
a
Item
q
a
Condition value
Dual pressure switch Normally "ON", abnormal pressure "OFF" for compressor.
(Dual) pressure switch on high pressure side protects air conditioner circuit with OFF: See right LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}
Indicated gauge pressure
Pressure is normal
Cause
Check method
Air conditioner cycle is operating normally. If there is any trouble (cooling trouble), there is another check item. High pressure: Approx. 1.5 – 1.7 MPa {15 – 17 kg/cm2} Low pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2} Insufficient refrigerant
Collect refrigerant, then fill Bubble can be seen in the up with proper quantity of sight glass (*1) refrigerant again (*2)
Clogging of receiver drier
There is a temperature difference between inlet and Replace outlet pipes of receiver drier. Tank is frosty
Clogging of expansion valve Expansion valve is frosty Both high pressure and low pressure are too low
Gas leakage at heat sensing tube of expansion valve
Low pressure becomes vacDefective evaporator sensor uum or defective contact of sensor (removal of mounting clip)
Low pressure gauge becomes vacuum
(*2)
Clean or replace (*2) Replace (*2)
Evaporator is frozen Repair or replace Air flow is down by freezing Replace receiver drier (At cool max. and HI speed Collect refrigerant, then fill of fan, later it becomes not to up with proper quantity of cold.) refrigerant again (*2)
Piping between receiver drier and compressor is Clogging or flattening or pip- clogged or flattened. If ing clogged completely, low gauge pressure becomes vacuum
D155A-6
Remedy
Clean or replace (*2)
81
SEN04442-02
60 Air conditioner
Indicated gauge pressure
Cause
Check method
Filling too much with refrigerConnect gauge manifold ant
Both high pressure and low pressure are too high
High pressure is too high and low pressure is too low
Remedy Collect refrigerant, then fill up with proper quantity of refrigerant again (*2)
Defective cooling of condenser
Stain of condenser, clogging Clean, repair fins, or repair or crushing of fins, or defec- or replace condenser tive revolution of cooling fan (*2)
Defective adjustment of expansion valve (Valve is opened too wide)
Bubble can be seen in the sight glass
Air in cycle
Bubble can be seen in the sight glass
Replace (*2) Evacuate and then fill up with proper quantity of refrigerant again (*2)
Clogging or flattening of pip- There is a remarkable tem- Clean inside of cycle or ing between compressor and perature difference between replace condenser before and after clogged part (*2)
Both high pressure and low Defective compressor (Com- pressure are balanced while High pressure is too low and Replace pression trouble of compres- compressor is in operation. low pressure is too high sor) Compressor has seized and is extremely hot. *1
(*2)
If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are stained with oil. Increase tightening of the joints or replace parts.
*2.
k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After replacing it, fill up the air conditioner system with refrigerant again.
a
Sight glass (SG) is on the receiver drier (RD).
82
D155A-6
60 Air conditioner
SEN04442-02
Connection of service tool Symbol X
a
Part No.
Part name
799-703-1200
Service tool kit
1
Use the service tool kit for R134a.
Service tool kit 1. Gauge manifold 2. High pressure charging hose (red) 3. Low pressure charging hose (blue) 4. Quick joint (Hi) (Large diameter) 5. Quick joint (Lo) (Small diameter) a. The thread is rough. So be careful not to loosen.
D155A-6
Connect the gauge manifold, hoses and other service tools according to the following procedure. 1. 2. 3. 4.
Close the high-pressure valve (HI) and lowpressure valve (LO) of gauge manifold (1). Connect red charging hose (2) to the (HI) side and blue charging hose (3) to the (LO) side. Connect quick joints (4) and (5) to each hose. Connect the quick joints to the service valves of the high and low-pressure pipings.
83
SEN04442-02
Precautions for connecting air conditioner piping q
q
q
q
60 Air conditioner
1
When connecting the piping, apply compressor oil NDOIL-8 for R134a to the O-rings. (See item 4. in “Handling of compressor oil”) Do not apply oil to the threads of a bolt, nut or union, however. Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged. Push in each pipe to the stopper (until it clicks) and tighten the bolt or nut fully with your fingers. Be sure to use two wrenches to tighten each nut (Apply a torque wrench to the tightening side). Place one wrench and tighten the nut with the other wrench to the specified torque.
Refrigerant piping diagram
Table of tightening torque for refrigerant piping adapter and installation Screw size
84
Unit: Nm {kgm}
Tightening torque
M6 × 1.0
8 – 12 {0.8 – 1.2}
M16 × 1.5
12 – 15 {1.2 – 1.5}
M24 × 1.5
30 – 35 {3.1 – 3.6}
D155A-6
60 Air conditioner
SEN04442-02
Handling of compressor oil 1.
1
Control of compressor oil (Denso: ND-OIL8: For R134a) Compressor oil does not need to be checked or added so frequently as engine oil. Insufficiency or excess of compressor oil can cause the following troubles. Condition
Contents
Insufficiency of oil
Lubrication trouble and seizure of compressor
Excess of oil
Cooling trouble (Excessive oil stick to parts and lower heat exchange performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2.
Adding of compressor oil
k Since refrigerant is dangerous and bad
for environment, collect the refrigerant before disconnecting the air conditioner hose. See “Caution about refrigerant”. k If refrigerant gets in your eyes, you may lose your sight. (Put on protective goggles.) a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized. Be sure to use the specified oil for R134a (Denso: ND-OIL8) a Oil for R134a absorbs moisture very easily. Accordingly, fit the cap immediately after using oil to stop the atmosphere. Store the oil can in a dry and ventilated place. a Precautions for using oil Oil for R134a (Denso: ND-OIL8 in particular) may dissolve acrylic resin and polystyrene (excluding baked polystyrene paint film). Accordingly, do not stick oil to those plastics.
D155A-6
Check compressor oil in the following cases, and then add new oil if necessary. q When much refrigerant is discharged because of leakage. q When the compressor is troubled and replaced. q When a cycle parts such as the air conditioner unit, condenser, receiver drier, evaporator unit, etc. is replaced. Quantity of oil to be added when cycle part is replaced Air conditioner part
Quantity to be added (cm3)
Air conditioner unit, evaporator
Approx. 40
Condenser
Approx. 40
Receiver drier
Approx. 20
Hose (Compressor – Condenser)
Approx. 10
Hose (Condenser – Receiver)
Approx. 20
Each hose (Compressor – M24 joint – Cab)
Approx. 15
Hose (Cab – Receiver)
Approx. 10
85
SEN04442-02
3.
Compressor replacement q
q
In case of compressor seizure or breakage. Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely. In this case, flush the air conditioner circuit and replace the compressor and receiver drier. The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new compressor with the oil of the specified quantity (180 cc) filled in it. Other cases New compressor has 180 cc compressor oil in it. So drain excessive compressor oil before installing new compressor in the following. 1) Prepare an oil pan and drain oil from old compressor. 2) Measure the quantity of the drained oil with a graduated cylinder, and note the quantity or mark the level.
3)
86
60 Air conditioner
4.
Applying compressor oil for O-ring When connecting a pipe or hose, apply oil (Denso: ND-OIL8) to its O-ring to prevent refrigerant leakage. k When discarding a can which still has some oil in it, make a hole on it to discharge gas and oil.
Drain below-mentioned quantity of oil from new compressor. 180 cc – “the noted quantity”. EX. If drained oil quantity from removed compressor is 30cc, drain oil of 180 – 30 cc = 150 cc from new one.
D155A-6
60 Air conditioner
D155A-6
SEN04442-02
87
SEN04442-02
60 Air conditioner
D155A-6 Bulldozer Form No. SEN04442-02
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
88
D155A-6
SEN02875-01
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
90 Diagrams and drawings
1
Hydraulic diagrams and drawings Power train hydraulic circuit diagram .............................................................................................................. 3 Hydraulic circuit diagram Serial No.: 85001 – 85024...................................................................................... 5 Hydraulic circuit diagram Serial No.: 85025 and up........................................................................................ 7
D155A-6
1
SEN02875-01
2
90 Diagrams and drawings
D155A-6
90 Diagrams and drawings
Power train hydraulic circuit diagram
D155A-6
SEN02875-01
Power train hydraulic circuit diagram D155A-6
3
Hydraulic circuit diagram Serial No.: 85001 – 85024
D155A-6
Hydraulic circuit diagram D155A-6
1
SEN02875-01
5
Hydraulic circuit diagram Serial No.: 85025 and up
D155A-6
Hydraulic circuit diagram D155A-6
1
SEN02875-01
7
90 Diagrams and drawings
D155A-6
SEN02875-01
9
SEN02875-01
90 Diagrams and drawings
D155A-6 Bulldozer Form No. SEN02875-01
© 2008 KOMATSU All Rights Reserved Printed in Japan 06-08 (02)
10
D155A-6
SEN02874-04
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model
Serial number
D155A-6
85001 and up
90 Diagrams and drawings
1
Electrical diagrams and drawings Electrical circuit diagram ................................................................................................................................. 3 Electrical circuit diagram for inside cab ....................................................................................................... 31 Connector/electrical wiring connection table ............................................................................................... 33 Connectors table and arrangement drawing ............................................................................................... 97 Wiring harness diagram ................................................................................................................................ 99
D155A-6
1
SEN02874-04
2
90 Diagrams and drawings
D155A-6
Electrical circuit diagram (1/14)
Electrical circuit diagram (1/14) D155A-6
1
SEN02874-04
D155A-6
3
Electrical circuit diagram (2/14)
Electrical circuit diagram (2/14) D155A-6
1
SEN02874-04
D155A-6
5
Electrical circuit diagram (3/14)
Electrical circuit diagram (3/14) D155A-6
1
SEN02874-04
D155A-6
7
Electrical circuit diagram (4/14)
Electrical circuit diagram (4/14) D155A-6
1
SEN02874-04
D155A-6
9
Electrical circuit diagram (5/14)
Electrical circuit diagram (5/14) D155A-6
1
SEN02874-04
D155A-6
11
Electrical circuit diagram (6/14)
Electrical circuit diagram (6/14) D155A-6
1
SEN02874-04
D155A-6
13
Electrical circuit diagram (7/14)
Electrical circuit diagram (7/14) D155A-6
1
SEN02874-04
D155A-6
15
Electrical circuit diagram (8/14)
Electrical circuit diagram (8/14) D155A-6
1
SEN02874-04
D155A-6
17
Electrical circuit diagram (9/14)
Electrical circuit diagram (9/14) D155A-6
1
SEN02874-04
D155A-6
19
Electrical circuit diagram (10/14)
Electrical circuit diagram (10/14) D155A-6
1
SEN02874-04
D155A-6
21
Electrical circuit diagram (11/14)
Electrical circuit diagram (11/14) D155A-6
1
SEN02874-04
D155A-6
23
Electrical circuit diagram (12/14)
Electrical circuit diagram (12/14) D155A-6
1
SEN02874-04
D155A-6
25
Electrical circuit diagram (13/14)
Electrical circuit diagram (13/14) D155A-6
1 1
SEN02874-04
D155A-6
27
Electrical circuit diagram (14/14)
Electrical circuit diagram (14/14) D155A-6
1 1
SEN02874-04
D155A-6
29
90 Diagrams and drawings
Electrical circuit diagram for inside cab
D155A-6
SEN02874-04
Electrical circuit diagram for inside cab D155A-6
31
90 Diagrams and drawings
SEN02874-04
Connector/electrical wiring connection table Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
1STSW
2NDSW
3RDSW
A
A/C A/C1 (Female) A/C1 (Male) A_LF
AA
AC01 (Female)
AC01 (Male)
D155A-6
-
-
-
-
K597
K597
K598
J485
AE1
E547
F7, AG8
K417
F7, AG8
E553
-
-
K8, AB8
K8, AB8
B626
G489
C253
-
Device Name
1ST SW
2ND SW
3RD SW
Joint Air conditioner compressor Intermediate conncector (Engine harness) Intermediate connector (Left fender harness) Joint
Joint
Intermediate conncector (Air conditionar harness)
Intermediate conncector (Floor harness)
Type
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
PNL(Female)
8
1.25W
2
JPT5
-
1.25G
5
JPT5
-
1.25G
Number Pin of Pins No.
6
6
6
-
6
JPT6
-
1.25G
1
PNL(Female)
9
1.25Y
2
JPT6
-
1.25G
5
JPT6
-
1.25G
6
3RDSW
2
1.25Br
1
PNL(Female)
10
1.25Sb
2
2NDSW
6
1.25Br
CB4
2
2W
-
LMFL
3
1.25W
LMFR
3
1.25W
DT
2
1
JPA9
-
1.25W
DT
2
1
FD4(Male)
14
1.25W
DT
2
1
JPA9
-
1.25W
LHD(Male)
2
1.25G
-
-
YAZAKI
YAZAKI
-
-
8
8
-
-
LHDL0(Female)
1
1.25G
LHDR0(Female)
3
1.25G
CB6
1
2R
CB7
1
2R
CB8
1
3R
F30(Male)
1
5R
FS11
1
3R
FS21
1
1.25R
1
JPAE
-
0.85V
2
JPAF
-
0.85Br
3
AC03
5
2O
4
JPAC
-
0.85P
5
GND12
-
0.85B
6
DSH(Female)
44
0.85L
7
FD4(Female)
3
0.85G
8
DSH(Female)
43
0.85O
1
ACCN
36
0.5LY
2
ACCN
35
0.5Lg
3
ACBM
1
2RY
4
JPA1
-
0.5R
5
JOA1
-
2B
6
ACCN
15
0.5YW
7
ACCN
4
0.5GB
8
JPAG
-
0.5RB
33
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Intermediate conncector (Air conditionar harness)
SUMITOMO 4
Connector (pin) No.
Pin No.
Wire diameter/ Color
JNH
-
0.75W
2
JNL
-
0.75B
3
JNXE
-
0.85B
Number Pin of Pins No. 1
AC02 (Female)
AC02 (Male)
AC03
AC04
AC05
ACB1
ACB2
ACBM
34
K9, AB7
K9, AB7
AB5
AB4
I1
-
-
-
C255
-
J232
I232
M408
-
-
-
Intermediate conncector (Floor harness)
Air conditioner blower relay
Air conditioner compressor relay
Air conditioner gas pressure sensor
Blow OFF motor 1
Blow OFF motor 2
Blower motor
SUMITOMO 4
Relay
Relay
S090
-
-
-
4
4
5
4
2
7
7
2
4
JPAA
-
0.85G
1
ACCN
17
0.5VW
2
ACCN
18
0.5VB
4
FUSE_R
1
2R
1
JPAC
-
0.85P
3
JPAE
-
0.85V
4
JPAA
-
2G
5
AC01(Female)
3
2O
1
JPAC
-
0.85P
2
FD4(Female)
14
1.25W
3
JPAF
-
0.85Br
4
JPAA
-
1.25G
1
FD4(Male)
3
1.25G
2
FD4(Male)
4
1.25B
1
JPAG
-
0.85RB
3
JOA2
-
0.5BrR
5
ACCN
9
0.5GrB
6
ACCN
24
0.5GR
7
ACCN
23
0.5YR
1
JPAG
-
0.5RB
3
JOA2
-
0.5BrR
5
ACCN
10
0.5BG
6
ACCN
26
0.5LgR
7
ACCN
25
0.5VY
1
AC01(Male)
3
2RY
2
ACPT
-
2BL
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 2
ACCN
L8
-
Air conditioner controller
040
36
ACD1
AB2
I239
Diode
DT
2
ACD2
AB2
J238
Diode
DT
2
ACFS
-
-
Flost sensor
-
2
ACIS
-
-
In outside servo motor
-
7
ACPS
ACPT
ACS
D155A-6
-
-
AE2
-
-
C548
Pressure sensor
Power transister
Diode
-
-
DT
2
6
2
Connector (pin) No.
Pin No.
Wire diameter/ Color
ACSM
5
0.5WB
3
JPAG
-
0.5RB
4
AC01(Male)
7
0.5GB
6
JPA1
-
0.5R
7
ACPT
-
-
8
ACPT
-
-
9
ACB1
5
0.5GrB
10
ACB2
5
0.5BG
11
ACPS
2
0.5PB
12
ACFS
2
0.5OB
15
AC01(Male)
6
0.5YW
16
JOA1
-
2B
17
AC02(Male)
1
0.5VW
18
AC02(Male)
2
0.5VB
19
ACIS
3
0.5WR
20
ACIS
1
0.5BR
21
ACSM
6
0.5PW
22
ACSM
7
0.5OW
23
ACB1
7
0.5YR
24
ACB1
6
0.5GR
25
ACB2
7
0.5VY
26
ACB2
6
0.5LgR
27
JOA2
-
0.5BrR
35
AC01(Male)
2
0.5Lg
36
AC01(Male)
1
0.5LY
1
JPAC
-
0.85P
2
JPAE
-
0.85V
1
JPAC
-
0.85P
2
JPAF
-
0.85Br
1
JOA2
-
0.5BrR
2
ACCN
12
0.5OB
1
ACCN
20
0.5BR
3
ACCN
19
0.5WR
7
JPA1
-
0.5R
1
JOA2
-
0.5BrR
2
ACCN
11
0.5PB
-
ACBM
2
2BL
-
ACCN
7
-
-
ACCN
8
-
-
JOA1
-
2B
1
JPA9
-
1.25W
2
GND09
-
1.25B
35
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 1
ACSM
ACT
AF1
-
D8
E7
-
G484
J438
AF1
E7
J416
AL
AC4
O365
A/M servo motor
-
Engine ACC signal cut relay Relay
Air cleaner clogging switch (If equipped) (Cab less spec) Air cleaner clogging switch (If equipped) (Cab spec)
DT
7
5
2
Connector (pin) No.
Pin No.
Wire diameter/ Color
JOA2
-
0.85BrR
3
JPAG
-
0.5RB
5
ACCN
2
0.5WB
6
ACCN
21
0.5PW
7
ACCN
22
0.5OW
1
G
-
1.25Br
2
FSB(Female)
W
0.85V
3
G
-
1.25Br
6
P
-
1.25O
1
FD1(Female)
24
1.25Gr
2
JOL3
-
1.25B
1
FD4(Male)
15
1.25Gy
2
FD4(Male)
16
1.25B
B1
40W
DT
2
Alternator terminal B
Terminal
1
B
ST/B
AL
AC5
O457
Alternator terminal R
Terminal
1
R
JPR1
-
Gy
AT11
F8
K524
Machine monitor
-
1
-
AT12
-
B
AT12
I9
K531
GPS antenna
-
1
-
AT11
-
B
-
1
-
AT22
-
B
-
1
-
AT21
-
B
AT21
H8
N542
KOMTRAX communication module
AT22
I9
N536
ORBCOMM antenna
AUX0
K2
O485
Service connector
-
1
-
W
-
2L
B105HL
M3
N553
Circuit breaker (105A)
Terminal
1
-
HT/A
A
20L
B105HS
M3
H552
Circuit breaker (105A)
Terminal
1
-
BRC
-
20L
Terminal
1
-
F105(Female)
1
15W
Terminal
1
-
BRC
-
20W
Terminal
1
-
BRC
-
20W
Terminal
1
-
F105(Female)
1
15W
Terminal
1
-
F30(Female)
1
5R
Terminal
1
-
BRB
-
5R
Terminal
1
-
BRB
-
5R
Terminal
1
-
F30(Female)
1
5R
1
F
-
1.25Sb
2
FD2(Female)
9
1.25O
3
F
-
1.25Sb
5
FD2(Female)
10
1.25W
1
JPZ6
-
1.25W
2
GND03
-
1.25B
1
JPZ6
-
1.25W
2
GND03
-
1.25B
1
BUA
1
1.25W
2
BUA
2
1.25B
B105L
L2
H438
B105L
L2
J552
B105S
L2
-
B105S
L2
G416
B30L
L2
G438
B30L
L2
F416
B30S
L2
F438
B30S
L2
F414
BKA
BKAL
A8
M5
K494
Circuit breaker (105A) (Cab less spec) Circuit breaker (105A) (Cab spec) Circuit breaker (105A) (Cab less spec) Circuit breaker (105A) (Cab spec) Circuit breaker (30A) (Cab less spec) Circuit breaker (30A) (Cab spec) Circuit breaker (30A) (Cab less spec) Circuit breaker (30A) (Cab spec)
Backup alarm relay
Backup alarm (Cab spec)
DT
2
DT
2
BKAL (Female)
M5
I448
BKAL (Male)
M5
-
Intermediate connector (Left fender harness)
DT
5
I425
Intermediate connector (Backup alarm) (Cab less spec)
36
Relay
2
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. A
BKSW
BKSW
BNSL
BNSU
BNSW (Female)
BNSW (Male)
P6
P6
-
-
-
-
G386
E364
H528
F528
-
F537
BRB
N3
I443
BRB
N3
H420
BRC
M3
J548
BRC
M3
-
BRC
M3
J548
BRC
M3
N565
BRK
P5
I386
BRK
D155A-6
P5
H363
Brake pedal switch (Cab less spec)
Brake pedal switch (Cab spec)
Blade knob lower SW
Blade knob upper SW
Intermediate connector (Floor harness)
Intermediate connector (W/E controller harness)
Battery relay (Contact input terminal) (Cab less spec) Battery relay (Contact input terminal) (Cab spec) Battery relay (Contact output terminal) (Ribbon heater relay) Battery relay (Contact output terminal) (Main power 24V) (Cab less spec) Battery relay (Contact output terminal) (Main power 24V) (Cab spec) Battery relay (Contact output terminal) (Starter) Brake pedal potentiometer (Cab less spec) Brake pedal potentiometer (Cab spec)
DT
DT
-
-
DT
DT
3
3
3
3
6
6
Connector (pin) No.
Pin No.
Wire diameter/ Color
DSH(Male)
57
1.25R
B
DSH(Male)
58
0.85W
C
DSH(Male)
59
0.85Y
A
DSH(Male)
57
1.25R
B
DSH(Male)
58
0.85W
C
DSH(Male)
59
0.85Y
1
BNSW(Male)
2
0.85G
2
BNSW(Male)
1
0.85B
3
BNSW(Male)
5
0.85Br
1
BNSW(Male)
4
0.85L
2
BNSW(Male)
3
0.85B
3
BNSW(Male)
6
0.85Y
1
JGW3
-
0.85B
2
WEC2
16
0.85G
3
JGW3
-
0.85B
4
WEC2
36
0.85L
5
WEC2
6
0.85Br
6
WEC2
26
0.85Y
1
BNSL
2
0.85B
2
BNSL
1
0.85G
3
BNSU
2
0.85B
4
BNSU
1
0.85L
5
BNSL
3
0.85Br
6
BNSU
3
0.85Y
Terminal
1
-
B30S
-
5R
Terminal
1
-
B30L
-
5R
Terminal
1
-
B105HS
-
20L
Terminal
1
-
B105S
-
20W
Terminal
1
-
B105L
-
20W
Terminal
1
-
ST/B
B2
100R
A
DSH(Male)
61
0.85B
DT
3
B
DSH(Male)
62
0.85W
C
DSH(Male)
63
0.85P
A
DSH(Male)
61
0.85B
DT
3
B
DSH(Male)
62
0.85W
C
DSH(Male)
63
0.85P
37
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing BUA BVRV
C
C_LF
CA
CA1
M5 AK6
-
-
-
AH3
B519
J492
B626
D488
D465
Device Name
Type
Backup alarm
DT
Transmission bevel speed sensor
Joint
Joint
Joint
CAN terminal resistance
DT
-
-
-
DT
Number Pin of Pins No.
2 2
-
-
-
3
CB1
C6
I497
Circuit breaker (20A)
-
1
CB2
C6
H496
Circuit breaker (20A)
-
1
CB3
C6
G496
Circuit breaker (20A)
-
1
CB4
B6
F496
Circuit breaker (20A)
-
1
CB5
B6
F495
Circuit breaker (20A)
-
1
CB6
B6
E494
Circuit breaker (20A)
-
1
CB7
B6
D494
Circuit breaker (20A)
-
1
CB8
A6
D492
Circuit breaker (30A)
-
1
CB9
D6
K496
Circuit breaker (20A)
-
1
CBPW
X9
K260
Intermediate connector
DTP
4
CBR
CBZ
38
-
-
H319
G325
Caution buzzer relay
Caution buzzer
-
DT
5
2
1
Connector (pin) No.
Pin No.
Wire diameter/ Color
BKAL(Male)
1
1.25W
2
BKAL(Male)
2
1.25B
1
PL1(Female)
55
1.25Br
2
PL1(Female)
56
1.25B
CB5
2
2Gy
LMRE
3
1.25Gy
LMRP
3
1.25Gy
-
-
-
LHD(Male)
1
1.25L
LHDL0(Female)
3
1.25L
LHDR0(Female)
1
1.25L
CC
-
5Y
CF
3
8W
CG
3
5Br
F105(Male)
1
15W
A
NA
-
0.85W
B
NC
-
0.85B
C
NE
-
0.85B
1
CC
-
2Y
2
FSB(Female)
H
2Br
1
CC
-
2Y
2
FSB(Female)
J
2O
1
CE
-
2Y
2
FSB(Female)
L
2G
1
CC
-
2Y
2
A
-
2W
1
CE
-
2Y
2
C
-
2Gy
1
AA
-
2R
2
J
-
2R
1
AA
-
2R
2
FSB(Female)
K
2R
1
AA
-
3R
2
EGPW(Female)
1
3R
2
EGPW(Female)
2
3R
2
FD3(Female)
2
1.25R
1
CE
-
2Y
2
W
-
2L
1
FSB(Male)
B
3L
2
FSB(Male)
D
3Y
3
FSB(Male)
E
3R
1
STC3
17
0.85Y
2
JRP2
-
0.85B
3
FSB(Male)
L
1.25G
5
CBZ
2
1.25O
1
GND12
-
1.25B
2
CBR
5
1.25O
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
CC
CE
CF
CG
CK01
CK02
D155A-6
-
-
-
-
Y9
Y9
G489
D488
I479
I479
J253
J256
Device Name
Joint
Joint
Joint
Joint
KOMTRAX communication module
KOMTRAX communication module
Type
-
-
-
-
070
070
Connector (pin) No.
Pin No.
Wire diameter/ Color
CA
-
5Y
CB1
1
2Y
CB2
1
2Y
CB4
1
2Y
CE
-
5Y
CB3
1
2Y
CB5
1
2Y
CB9
1
2Y
CC
-
5Y
1
FS11
3
-
2
FS11
2
-
Number Pin of Pins No.
-
-
-
-
14
10
-
-
3
CA
-
8W
4
FS11
4
-
1
FS21
3
-
2
FS21
2
-
3
CA
-
5Br
4
FS21
4
-
1
DSH(Female)
8
0.85Y
4
DSH(Female)
70
0.85P
7
DSH(Female)
9
0.85B
8
DSH(Female)
36
0.85B
9
DSH(Female)
37
0.85G
10
DSH(Female)
38
0.85Y
11
DSH(Female)
39
0.85V
12
DSH(Female)
40
0.85O
13
DSH(Female)
41
0.85L
1
DSH(Female)
51
0.85V
2
DSH(Female)
52
0.85Br
3
DSH(Female)
53
0.85G
4
DSH(Female)
54
0.85W
5
DSH(Female)
55
0.85L
6
DSH(Female)
56
0.85O
7
DSH(Female)
67
0.85Br
8
DSH(Female)
68
0.85Gy
9
DSH(Female)
69
0.85Y
39
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
CM01
CM01
CM02
CM02
40
R6
R6
R5
R5
D394
D371
D397
D374
Device Name
Machine monitor (Cab less spec)
Machine monitor (Cab spec)
Machine monitor (Cab less spec)
Machine monitor (Cab spec)
Type
070
070
070
070
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
DSH(Male)
4
1.25R
2
DSH(Male)
5
1.25R
3
DSH(Male)
6
1.25B
4
DSH(Male)
7
1.25B
5
DSH(Male)
14
0.85V
6
DSH(Male)
13
0.85L
7
DSH(Male)
20
0.85B
Number Pin of Pins No.
18
18
12
12
8
DSH(Male)
24
0.85G
9
DSH(Male)
22
0.85L
11
DSH(Male)
1
0.85Gy
12
JGM1
-
0.85B
13
JPLF
-
0.85G
14
DSH(Male)
3
0.85Br
15
DSH(Male)
2
0.85G
16
DSH(Male)
19
0.85W
1
DSH(Male)
4
1.25R
2
DSH(Male)
5
1.25R
3
DSH(Male)
6
1.25B
4
DSH(Male)
7
1.25B
5
DSH(Male)
14
0.85Y
6
DSH(Male)
13
0.85L
7
DSH(Male)
20
0.85B
8
DSH(Male)
24
0.85G
9
DSH(Male)
22
0.85L
11
DSH(Male)
1
0.85Gy
12
JGM1
-
0.85B
13
JPLF
-
0.85G
14
DSH(Male)
3
0.85Br
15
DSH(Male)
2
0.85G
16
DSH(Male)
19
0.85W
3
DSH(Male)
15
0.85Y
4
DSH(Male)
16
0.85Gy
7
DSH(Male)
17
0.85B
8
JNMH
-
0.85W
9
JNMH
-
0.85W
10
DSH(Male)
11
0.75B
3
DSH(Male)
15
0.85Y
4
DSH(Male)
16
0.85Gy
7
DSH(Male)
17
0.85B
8
JNMH
-
0.85W
9
JNMH
-
0.85W
10
DSH(Male)
11
0.85B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
CM03
CM05
CN1 CN2 CN3 CN4 CN5 CN6
DCL
DCL
D155A-6
R5
-
AC4 AC5 AD7 AE7 AE7 AH7
P6
P6
F363
C525
F340 F342 F344 H345 H346 H348
K387
J363
Device Name
Machine monitor
Machine monitor
Injecter #1 Injecter #2 Injecter #3 Injecter #4 Injecter #5 Injecter #6
Type
070
070
DT DT DT DT DT DT
Decelerator pedal potentiometer (Cab less spec)
DT
Decelerator pedal potentiometer (Cab spec)
DT
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
DSH(Male)
51
0.85V
2
DSH(Male)
52
0.85Br
3
DSH(Male)
55
0.85L
4
DSH(Male)
36
0.85B
5
DSH(Male)
70
0.85P
6
DSH(Male)
67
0.85Br
7
DSH(Male)
53
0.85G
8
DSH(Male)
54
0.85W
9
DSH(Male)
56
0.85O
10
DSH(Male)
68
0.85Gy
11
DSH(Male)
69
0.85Y
12
DSH(Male)
9
0.85B
13
DSH(Male)
40
0.85O
14
DSH(Male)
37
0.85G
15
DSH(Male)
38
0.85Y
16
DSH(Male)
39
0.85V
17
DSH(Male)
41
0.85L
18
DSH(Male)
8
0.85Y
1
REAR VIEW CAMERA
1
L
2
REAR VIEW CAMERA
2
W
3
REAR VIEW CAMERA
3
Br
4
REAR VIEW CAMERA
4
O
5
REAR VIEW CAMERA
5
B
6
REAR VIEW CAMERA
6
B
7
REAR VIEW CAMERA
7
-
8
REAR VIEW CAMERA
8
-
1
INJ(Male)
1
0.85R
2
INJ(Male)
12
0.85B
1
INJ(Male)
2
0.85R
2
INJ(Male)
11
0.85B
1
INJ(Male)
3
0.85R
2
INJ(Male)
10
0.85B
1
INJ(Male)
4
0.85R
2
INJ(Male)
9
0.85B
1
INJ(Male)
5
0.85R
2
INJ(Male)
8
0.85B
1
INJ(Male)
6
0.85R
Number Pin of Pins No.
18
8
2 2 2 2 2 2
3
3
2
INJ(Male)
7
0.85B
A
DSH(Male)
65
0.85Y
B
DSH(Male)
64
0.85P
C
DSH(Male)
66
0.85B
A
DSH(Male)
65
0.85Y
B
DSH(Male)
64
0.85P
C
DSH(Male)
66
0.85B
41
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing DIAL
DIAL
DPNL
DSH (Female)
42
AB8
AB8
-
P2, V1
O270
N220
C607
B272
Device Name
Fuel control dial (Cab less spec)
Fuel control dial (Cab spec)
Surge killer
Intermediate connector (Dash board harness) (Cab less spec)
Type
M
M
DT
DRC70A
Connector (pin) No.
Pin No.
Wire diameter/ Color
A
JJP1
-
0.85P
B
STC1
1
0.85V
C
JGP1
-
0.85B
Number Pin of Pins No.
3
3
2
70
1
JJP1
-
0.85P
2
STC1
1
0.85V
3
JGP1
-
0.85B
1
JPT1
-
1.25Br
2
JOT1
-
1.25B
1
JPR2
-
0.85Gy
2
JPK2
-
0.85G
3
JPK1
-
0.85Br
4
JUF2
-
1.25R
5
JUF2
-
1.25R
6
GND11
-
1.25B
7
GND11
-
1.25B
10
JNH
-
0.75W
11
JNL
-
0.75B
12
JNX5
-
0.85B
13
STC2
7
0.85L
14
JNH3
-
0.85V
15
FD1(Male)
23
0.85Y
16
FD1(Male)
24
0.85Gr
17
JGM5
-
0.85B
19
JPK4
-
0.85W
20
JGM4
-
0.85B
22
FD1(Male)
6
0.85L
23
FD1(Male)
7
0.85B
24
PL1(Male)
24
1.25G
25
PL1(Male)
25
1.25B
29
JPK1
-
1.25Br
30
JPK4
-
1.25W
31
JPK2
-
1.25G
32
JPK3
-
1.25V
33
FSB(Male)
S
1.25R
34
FSB(Male)
U
1.25L
45
FD1(Male)
30
1.25V
46
FD1(Male)
31
1.25L
47
JGM4
-
0.85B
49
JPK1
-
0.85Br
57
FSB(Male)
C
1.25R
58
STC1
11
0.85W
59
JS19
-
0.85Y
61
JGP1
-
0.85B
62
STC1
3
0.85W
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing DSH (Female)
DSH (Female)
D155A-6
P2, V1
P2, V1
B272
E203
Device Name
Intermediate connector (Dash board harness) (Cab less spec)
Intermediate connector (Dash board harness) (Cab spec)
Type
DRC70A
DRC70A
Connector (pin) No.
Pin No.
Wire diameter/ Color
63
JJP1
-
0.85P
64
FD1(Male)
13
0.85P
65
FD1(Male)
11
0.85Y
66
FD1(Male)
12
0.85B
1
JPR2
-
0.85Gy
2
JPK2
-
0.85G
3
JPK1
-
0.85Br
Number Pin of Pins No.
70
70
4
JUF2
-
1.25R
5
JUF2
-
1.25R
6
GND11
-
1.25B
7
GND11
-
1.25B
8
CK01
1
0.85Y
9
CK01
7
0.85B
10
JNH
-
0.75W
11
JNL
-
0.75B
12
JNX5
-
0.85B
13
STC2
7
0.85L
14
JNH3
-
0.85V
15
FD1(Male)
23
0.85Y
16
FD4(Female)
15
0.85Gy
17
JGM5
-
0.85B
19
JPK4
-
0.85W
20
JGM4
-
0.85B
22
FD1(Male)
6
0.85L
23
FD1(Male)
7
0.85B
24
PL1(Male)
24
0.85G
25
PL1(Male)
25
0.85B
29
JPK1
-
1.25Br
30
JPK4
-
1.25W
31
JPK2
-
1.25G
32
JPK3
-
1.25V
33
FSB(Male)
S
1.25R
34
FSB(Male)
U
1.25L
36
CK01
8
0.85B
37
CK01
9
0.85G
38
CK01
10
0.85Y
39
CK01
11
0.85V
40
CK01
12
0.85O
41
CK01
13
0.85L
43
AC01(Female)
8
0.85O
44
AC01(Female)
6
0.85L
45
FD1(Male)
30
1.25V
46
FD1(Male)
31
1.25L
47
JGM4
-
0.85B
43
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
DSH (Female)
DSH (Female)
44
P2, V1
P2, V1
E203
E203
Device Name
Intermediate connector (Dash board harness) (Cab spec)
Intermediate connector (Dash board harness) (Cab spec)
Type
DRC70A
DRC70A
Connector (pin) No.
Pin No.
Wire diameter/ Color
49
JPK1
-
0.85Br
51
CK02
1
0.85V
52
CK02
2
0.85Br
53
CK02
3
0.85G
54
CK02
4
0.85W
55
CK02
5
0.85L
56
CK02
6
0.85O
57
FSB(Male)
C
1.25R
58
STC1
11
0.85W
Number Pin of Pins No.
70
70
59
JS19
-
0.85Y
61
JGP1
-
0.85B
62
STC1
3
0.85W
63
JJP1
-
0.85P
64
FD1(Male)
13
0.85P
65
FD1(Male)
11
0.85Y
66
FD1(Male)
12
0.85B
67
CK02
7
0.85Br
68
CK02
8
0.85Gy
69
CK02
9
0.85Y
70
CK01
4
0.85P
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Connector (pin) No.
Pin No.
Wire diameter/ Color
CM01
11
0.85Gy
2
CM01
15
0.85G
3
CM01
14
0.85Br
4
CM01
1
1.25R
5
CM01
2
1.25R
6
CM01
3
1.25B
7
CM01
4
1.25B
10
JNMH
-
0.75W
11
CM02
10
0.75B
Number Pin of Pins No. 1
DSH (Male)
D155A-6
P2, V1
H404
Intermediate connector (Floor harness) (Cab less spec)
DRC70A
70
12
JNX4
-
0.85B
13
CM01
6
0.85L
14
CM01
5
0.85V
15
CM02
3
0.85Y
16
CM02
4
0.85Gy
17
CM02
7
0.85B
19
CM01
16
0.85W
20
CM01
7
0.85B
22
CM01
9
0.85L
23
JGM1
-
0.85B
24
CM01
8
0.85G
25
JGM1
-
0.85B
29
KEY(Female)
1
1.25Br
30
KEY(Female)
2
1.25W
31
KEY(Female)
3
1.25G
32
KEY(Female)
4
1.25V
33
KEY(Female)
5
1.25R
34
KEY(Female)
6
1.25L
45
JPL2
-
1.25V
46
JPL8
-
1.25L
47
JGM3
-
1.25B
49
JPKA
-
0.85Br
57
BKSW
A
1.25R
58
BKSW
B
0.85W
59
BKSW
C
0.85Y
61
BRK
A
0.85B
62
BRK
B
0.85W
63
BRK
C
0.85P
64
DCL
B
0.85P
65
DCL
A
0.85Y
66
DCL
C
0.85B
45
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
DSH (Male)
46
P2, V1
H381
Device Name
Intermediate connector (Floor harness) (Cab spec)
Type
DRC70A
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
CM01
11
0.85Gy
2
CM01
15
0.85G
3
CM01
14
0.85Br
4
CM01
1
1.25R
5
CM01
2
1.25R
6
CM01
3
1.25B
7
CM01
4
1.25B
8
CM03
18
0.85Y
9
CM03
12
0.85B
10
JNMH
-
0.75W
11
CM02
10
0.85B
Number Pin of Pins No.
70
12
JNX4
-
0.85B
13
CM01
6
0.85L
14
CM01
5
0.85Y
15
CM02
3
0.85Y
16
CM02
4
0.85Gy
17
CM02
7
0.85B
19
CM01
16
0.85W
20
CM01
7
0.85B
22
CM01
9
0.85L
23
JGM1
-
0.85B
24
CM01
8
0.85G
25
JGM1
-
0.85B
29
KEY(Female)
1
1.25Br
30
KEY(Female)
2
1.25W
31
KEY(Female)
3
1.25G
32
KEY(Female)
4
1.25V
33
KEY(Female)
5
1.25R
34
KEY(Female)
6
1.25L
36
CM03
4
0.85B
37
CM03
14
0.85G
38
CM03
15
0.85Y
39
CM03
16
0.85V
40
CM03
13
0.85O
41
CM03
17
0.85L
43
SLS
1
0.85O
44
SLS
2
0.85L
45
JPL2
-
1.25V
46
JPL8
-
1.25L
47
JGM3
-
1.25B
49
JPKA
-
0.85Br
51
CM03
1
0.85V
52
CM03
2
0.85Br
53
CM03
7
0.85G
54
CM03
8
0.85W
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 55
DSH (Male)
DTS (Female)
DTS (Male)
P2, V1
Z9
Z9
H381
C258
-
Intermediate connector (Floor harness) (Cab spec)
Intermediate connector (used when work equipment controller is installed)
Intermediate connector (Floor harness)
DRC70A
DT
DT
70
12
12
DUL
-
-
Dual tilt select solenoid
DT
2
E
-
J492
Joint
-
-
E22 (Female) E22 (Male)
D155A-6
AG2 AG2
F459 O470
Intermediate connector (Starter, Alternator harness) Intermediate connector (Engine harness)
DT DT
6 6
Connector (pin) No.
Pin No.
Wire diameter/ Color
CM03
3
0.85L
56
CM03
9
0.85O
57
BKSW
A
1.25R
58
BKSW
B
0.85W
59
BKSW
C
0.85Y
61
BRK
A
0.85B
62
BRK
B
0.85W
63
BRK
C
0.85P
64
DCL
B
0.85P
65
DCL
A
0.85Y
66
DCL
C
0.85B
67
CM03
6
0.85Br
68
CM03
10
0.85Gy
69
CM03
11
0.85Y
70
CM03
5
0.85P
1
FSB(Male)
J
2O
2
JUF2
-
2R
3
JPKC
-
0.85Br
4
GND11
-
2B
5
JNH3
-
0.85V
6
JNH
-
0.75W
7
JNL
-
0.75B
8
JNXG
-
0.85B
9
STC3
30
0.85B
10
JPR2
-
0.85Gy
1
JPW1
-
2O
2
JUW1
-
2R
3
JPKF
-
0.85Br
4
JOW1
-
2B
5
WEC2
24
0.85V
6
WEC2
32
0.75W
7
WEC2
22
0.75B
8
JNX9
-
0.85B
9
JOW2
-
0.85B
10
WEC1
15
0.85Gy
1
WEC3
38
0.85O
2
JRW1
-
0.85B
FD2(Female)
5
1.25L
-
LMRE
1
1.25L
LMRP
1
1.25L
1
EG2(Male)
8
1.25L
2
EG2(Male)
7
1.25Gy
1
ST
1
1.25L
2
JPR1
-
Gy
47
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing EG1 (Female)
H1, AH5
O435
EG1 (Female)
H1, AH5
O413
EG1 (Male)
H1, AH5
J461
EG2 (Female)
EG2 (Female)
EG2 (Male)
48
H1, AH5
H1, AH5
H1, AH5
O433
O411
K463
Device Name Intermediate connector (Engine harness) (Cab less spec) Intermediate connector (Engine harness) (Cab spec) Intermediate connector (Left fender harness)
Intermediate connector (Engine harness) (Cab less spec)
Intermediate connector (Engine harness) (Cab spec)
Intermediate connector (Left fender harness)
Type
DTP
2
DTP
2
DTP
2
DT-B
DT-B
DT-B
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
EGPW(Male)
1
3R
2
EGPW(Male)
2
3R
1
EGPW(Male)
1
3R
2
EGPW(Male)
2
3R
1
EGC3
3
3R
2
EGC3
4
3R
1
FD1(Female)
8
0.75W
2
FD1(Female)
9
0.75B
Number Pin of Pins No.
12
12
12
3
JNXF
-
0.85B
4
FD3(Male)
1
1.25O
5
FD3(Male)
4
1.25Gr
7
FD1(Female)
2
1.25Gr
8
FD1(Female)
1
1.25W
10
FD1(Female)
13
0.85P
11
FD1(Female)
11
0.85Y
12
FD1(Female)
12
0.85B
1
FD1(Female)
8
0.75W
2
FD1(Female)
9
0.75B
3
JNXF
-
0.85B
4
FD3(Male)
1
1.25O
5
FD3(Male)
4
1.25Gy
7
FD1(Female)
2
1.25Gy
8
FD1(Female)
1
1.25W
10
FD1(Female)
13
1.25P
11
FD1(Female)
11
1.25Y
12
FD1(Female)
12
1.25B
1
NA
-
0.75W
2
NC
-
0.75B
3
NE
-
0.85B
4
EGC2
39
0.85O
5
EGC2
40
0.85Gy
7
E22(Female)
2
1.25Gy
8
E22(Female)
1
1.25L
10
EGC2
22
0.85P
11
EGC2
9
0.85Y
12
EGC2
23
0.85B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 3
EGC1
EGC2
EGC3
D155A-6
AH4
AH4
AG3
G356
F469
A464
Engine controller
Engine controller
Engine controller
DRC-60
DRC-50
DTP
60
50
4
Connector (pin) No.
Pin No.
Wire diameter/ Color
PAMB
3
0.85G
4
PCV1
1
0.85R
5
PCV1
2
0.85B
6
J1939
B
0.85B
7
JNX2
-
0.85B
8
J1939
A
0.85R
9
PCV2
1
0.85R
10
PCV2
2
0.85B
13
POIL
3
0.85G
15
TWTR
1
0.85R
16
NE
1
0.85R
23
TIM
1
0.85R
25
PFUEL
2
0.85G
26
JM05
3
0.85G
27
NE
3
0.85G
30
TFUEL
1
0.85R
33
PFUEL
1
0.85R
37
JM04
4
0.85R
38
JM03
4
0.85B
44
PIM
3
0.85G
45
INJ(Female)
1
0.85R
46
INJ(Female)
5
0.85R
47
JM02
6
0.85B
48
NE
2
0.85B
51
INJ(Female)
11
0.85B
52
INJ(Female)
10
0.85B
53
INJ(Female)
12
0.85B
54
INJ(Female)
2
0.85R
55
INJ(Female)
3
0.85R
56
INJ(Female)
4
0.85R
57
INJ(Female)
6
0.85R
58
INJ(Female)
9
0.85B
59
INJ(Female)
7
0.85B
60
INJ(Female)
8
0.85B
9
EG2(Male)
11
0.85Y
22
EG2(Male)
10
0.85P
23
EG2(Male)
12
0.85B
37
NE
-
0.85B
39
EG2(Male)
4
0.85O
40
EG2(Male)
5
0.85Gy
46
NA
-
0.85W
47
NC
-
0.85B
1
GND20
-
3B
2
GND20
-
3B
3
EG1(Male)
1
3R
4
EG1(Male)
2
3R
49
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing EGPW (Female)
L3
M479
EGPW (Male)
L3
G445
EGPW (Male)
L3
G422
EHL
ESD
ESD
F
F/R SW
D9
Z9
Z9
-
-
I484
H331
C262
J493
L598
F105 (Female)
K2
H440
F105 (Female)
K2
G417
F105 (Male)
K2
O484
F1T
AJ9
-
F2T
AJ7
-
F30 (Female)
L3
H441
F30 (Female)
L3
G419
F30 (Male)
L3
O483
50
Device Name
Type
Intermediate connector (Left fender harness)
DTP
Intermediate connector (Fuse box harness) (Cab less spec) Intermediate connector (Fuse box harness) (Cab spec)
Engine hold relay
Service connector (for engine option) (Cab less spec)
2
DTP
2
Relay
DT
DT
Joint
-
Intermediate connector (Fuse box harness) (Cab less spec) Intermediate connector (Fuse box harness) (Cab spec) Intermediate connector (Left fender harness) Transmission 1st clutch ECMV (Fill switch) Transmission 2nd clutch ECMV (Fill switch) Intermediate connector (Fuse box harness) (Cab less spec) Intermediate connector (Fuse box harness) (Cab spec) Intermediate connector (Left fender harness)
2
DTP
Service connector (for engine option) (Cab spec)
F/R SW
Number Pin of Pins No.
-
5
3
3
-
12
1
Connector (pin) No.
Pin No.
Wire diameter/ Color
CB8
2
3R
2
CB8
2
3R
1
EG1(Female)
1
3R
2
EG1(Female)
2
3R
1
EG1(Female)
1
3R
2
EG1(Female)
2
3R
1
J
-
1.25R
2
FSB(Female)
X
1.25Gy
3
J
-
1.25R
5
P
-
1.25O
A
STC2
17
0.85G
B
FSB(Male)
V
1.25Br
C
STC2
27
0.85P
A
STC2
17
0.85G
B
FSB(Male)
V
1.25Br
C
STC2
27
0.85P
BKA
1
1.25Sb
-
BKA
3
1.25Sb
FS12
2
1.25Sb
1
PNL(Female)
2
1.25O
2
JPT2
-
1.25R
3
PNL(Female)
3
1.25P
4
JPT3
-
1.25V
5
JPT2
-
1.25R
6
JPT3
-
1.25V
7
JPT4
-
1.25L
8
JPT2
-
1.25R
9
JPT4
-
-
11
JPT2
-
1.25R
12
PNL(Female)
6
1.25Gy
DTHD
1
1
B105L
-
15W
DTHD
1
1
B105S
-
15W
DTHD
1
1
CA
-
15W
DT
2
1
TMV(Male)
P
-
DT
2
1
TMV(Male)
O
-
DTHD
1
1
B30L
-
5R
DTHD
1
1
B30S
-
5R
DTHD
1
1
AA
-
5R
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
F3T
AI8
-
Transmission 3rd clutch ECMV (Fill switch)
DT
2
FAC
AI3
C503
Fan pump control valve
DT
2
FAR
C1
O579
FBRL
AL7
F516
FBRR
AM7
F519
FCLL
AN6
H520
FCLR
AN7
H518
FD1 (Female)
D155A-6
K2, AB4
B433
Fan reverse solenoid valve Left brake ECMV (Fill switch) Right brake ECMV (Fill switch) Left steering clutch ECMV (Fill switch) Right steering clutch ECMV (Fill switch)
Intermediate connector (Floor harness) (Cab less spec)
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
TMV(Male)
N
-
1
PL1(Female)
36
1.25Sb
2
PL1(Female)
37
1.25B
1
RDG(Male)
6
1.25W
2
RDG(Male)
7
1.25B
Number Pin of Pins No.
DT
2
DT
2
1
PL1(Female)
15
1.25Gr
DT
2
1
PL1(Female)
21
1.25P
DT
2
1
PL1(Female)
1
1.25V
DT
2
1
PL1(Female)
7
1.25L
1
EG2(Female)
8
1.25W
2
EG2(Female)
7
1.25Gr
3
JPZ6
-
1.25W
4
PRT(Female)
6
1.25W
5
PRT(Female)
7
1.25B
6
FTK(Female)
3
1.25L
7
FTK(Female)
4
1.25B
8
EG2(Female)
1
0.75W
9
EG2(Female)
2
0.75B
24-31
31
10
JNXJ
-
0.85B
11
EG2(Female)
11
0.85Y
12
EG2(Female)
12
0.85B
13
EG2(Female)
10
0.85P
14
JOL1
-
1.25B
15
FD2(Male)
11
1.25Br
16
PRT(Female)
3
1.25P
17
FD2(Male)
12
1.25Y
18
PPL
1
1.25V
19
GND03
-
1.25B
20
PT1
A
1.25B
21
PT1
B
1.25W
22
PT1
C
1.25P
23
PRT(Female)
4
1.25Y
24
AF1
1
1.25Gr
25
JPLN
-
1.25L
26
JPLM
-
1.25B
27
SW
-
1.25V
28
FD2(Male)
9
1.25O
29
GND03
-
1.25B
30
FD2(Male)
2
1.25V
31
FD2(Male)
5
1.25L
51
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
FD1 (Female)
52
K2, AB4
B411
Device Name
Intermediate connector (Floor harness) (Cab spec)
Type
24-31
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
EG2(Female)
8
1.25W
2
EG2(Female)
7
1.25Gy
3
JPZ6
-
1.25W
4
PRT(Female)
6
1.25W
5
PRT(Female)
7
1.25B
6
FTK(Female)
3
1.25L
7
FTK(Female)
4
1.25B
8
EG2(Female)
1
0.75W
9
EG2(Female)
2
0.75B
Number Pin of Pins No.
31
10
JNXJ
-
0.85B
11
EG2(Female)
11
1.25Y
12
EG2(Female)
12
1.25B
13
EG2(Female)
10
1.25P
14
JOL1
-
1.25B
15
FD2(Male)
11
1.25Br
16
PRT(Female)
3
1.25P
17
FD2(Male)
12
1.25Y
18
PPL
1
1.25V
19
GND03
-
1.25B
20
PT1
A
1.25B
21
PT1
B
1.25W
22
PT1
C
1.25P
23
PRT(Female)
4
1.25Y
24
PRT(Female)
5
1.25B
27
SW
-
1.25V
28
FD2(Male)
9
1.25O
29
GND03
-
1.25B
30
FD2(Male)
2
1.25V
31
FD2(Male)
5
1.25L
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 1
FD1 (Male)
D155A-6
K2, AB4
M303
Intermediate connector (Left fender harness) (Cab less spec)
24-31
31
Connector (pin) No.
Pin No.
Wire diameter/ Color
FSB(Male)
F
1.25W
2
JPR2
-
1.25Gy
3
PL1(Male)
69
1.25W
4
STC3
18
0.85W
5
JRP2
-
0.85B
6
DSH(Female)
22
0.85L
7
DSH(Female)
23
0.85B
8
JNH
-
0.75W
9
JNL
-
0.75B
10
JNX6
-
0.85B
11
DSH(Female)
65
0.85Y
12
DSH(Female)
66
0.85B
13
DSH(Female)
64
0.85P
14
JGM5
-
1.25B
15
HNSW(Female)
2
0.85Br
16
HNSW(Female)
1
0.85P
17
PLSW(Female)
1
0.85Y
18
PLSW(Female)
2
0.85V
19
JOL2
-
1.25B
20
JGP2
-
0.85B
21
STC1
8
0.85W
22
STC1
16
0.85P
23
DSH(Female)
15
0.85Y
24
DSH(Female)
16
0.85Gr
25
LBP(Female)
3
1.25L
26
LBP(Female)
1
1.25G
27
JPK3
-
1.25V
28
STC2
18
0.85O
29
JOL2
-
1.25B
30
DSH(Female)
45
1.25V
31
DSH(Female)
46
1.25L
53
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 1
FD1 (Male)
FD2 (Female)
54
K2, AB4
L3
L237
O480
Intermediate connector (Left fender harness) (Cab spec)
Intermediate connector (Left fender harness)
24-31
DT-C
31
12
Connector (pin) No.
Pin No.
Wire diameter/ Color
FSB(Male)
F
1.25W
2
JPR2
-
1.25Gy
3
PL1(Male)
69
1.25W
4
STC3
18
0.85W
5
JRP2
-
0.85B
6
DSH(Female)
22
0.85L
7
DSH(Female)
23
0.85B
8
JNH
-
0.75W
9
JNL
-
0.75B
10
JNX6
-
0.85B
11
DSH(Female)
65
0.85Y
12
DSH(Female)
66
0.85B
13
DSH(Female)
64
0.85P
14
JGM5
-
1.25B
15
HNSW(Female)
2
0.85Br
16
HNSW(Female)
1
0.85P
17
PLSW(Female)
1
0.85Y
18
PLSW(Female)
2
0.85V
19
JOL2
-
1.25B
20
JGP2
-
0.85B
21
STC1
8
0.85W
22
STC1
16
0.85P
23
DSH(Female)
15
0.85Y
24
JGM5
-
0.85B
27
JPK3
-
1.25V
28
STC2
18
0.85O
29
JOL2
-
1.25B
30
DSH(Female)
45
1.25V
31
DSH(Female)
46
1.25L
1
M
-
1.25B
2
H
-
1.25V
3
LMFL
5
1.25G
4
LMFR
5
1.25L
5
E
-
1.25L
6
N
-
1.25O
7
N
-
1.25W
8
LMRP
5
1.25Y
9
BKA
2
1.25O
10
BKA
5
1.25W
11
FS22
4
1.25Br
12
L
-
1.25Y
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
FD2(Male)
FD2(Male)
FD3 (Female)
FD3 (Male)
FD3 (Male)
D155A-6
L3
L3
M3
M3
M3
G443
G421
K479
H446
G424
Device Name
Intermediate connector (Fuse box harness) (Cab less spec)
Intermediate connector (Fuse box harness) (Cab spec)
Intermediate connector (Left fender harness)
Intermediate connector (Fuse box harness) (Cab less spec)
Intermediate connector (Fuse box harness) (Cab spec)
Type
DT-C
DT-C
DT
DT
DT
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
JOL1
-
1.25B
2
FD1(Female)
30
1.25V
3
JPLM
-
1.25G
Number Pin of Pins No.
12
12
6
6
6
4
JPLN
-
1.25L
5
FD1(Female)
31
1.25L
6
FTK(Female)
5
1.25O
7
FTK(Female)
1
1.25W
8
LRP2
1
1.25Y
9
FD1(Female)
28
1.25O
10
JPZ6
-
1.25W
11
FD1(Female)
15
1.25Br
12
FD1(Female)
17
1.25Y
1
JOL1
-
1.25B
2
FD1(Female)
30
1.25V
3
PRT(Female)
2
1.25G
4
PRT(Female)
1
1.25L
5
FD1(Female)
31
1.25L
6
FTK(Female)
5
1.25O
7
FTK(Female)
1
1.25W
8
LRP2
1
1.25Y
9
FD1(Female)
28
1.25O
10
JPZ6
-
1.25W
11
FD1(Female)
15
1.25Br
12
FD1(Female)
17
1.25Y
1
FS12
5
1.25O
2
CB8
2
1.25R
3
R
-
1.25W
4
PHR
1
1.25Gy
5
PHR
2
1.25B
6
L
-
1.25Y
1
EG2(Female)
4
1.25O
3
HT/C
C
1.25W
4
EG2(Female)
5
1.25Gr
5
JOL1
-
1.25B
1
EG2(Female)
4
1.25O
3
HT/C
C
1.25W
4
EG2(Female)
5
1.25Gy
5
JOL1
-
1.25B
55
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
FD4 (Female)
FD4 (Male)
FFT
FLSW
FLSW
FLV FRT
FS11
FS12
56
J2, AB3
J2, AB3
AK9
P5
P5
M4 AK9
A8
A7
L234
B416
-
O390
O367
Device Name
Intermediate connector (Left fender harness)
Intermediate connector (Floor harness)
Transmission F clutch ECMV (Fill switch)
Headlamp switch (Cab less spec)
Headlamp switch (Cab spec)
Type
24-31
24-31
DT
SWP
SWP
31
31
2
6
6
F560
Fuel level sensor
DT
2
-
Transmission R clutch ECMV (Fill switch)
DT
2
A486
C486
Fuse box
Fuse box
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
3
AC01(Female)
7
0.85G
4
GND12
-
0.85B
6
WSH
1
0.85W
Number Pin of Pins No.
5
5
7
WSH
2
0.85V
8
WSH
3
0.85L
9
WSH
4
0.85G
14
AC04
2
1.25W
15
DSH(Female)
16
0.85Gy
16
JGM5
-
0.85B
3
AC05
1
1.25G
4
AC05
2
1.25B
6
WSH1
3
1.25W
7
WSH2
3
1.25V
8
WSH1
1
1.25L
9
WSH2
1
1.25G
14
A/C1(Female)
1
1.25W
15
AF1
1
1.25Gy
16
AF1
2
1.25B
1
TMV(Male)
M
-
1
JPLF
-
1.25Y
2
JGM3
-
1.25B
3
JPLE
-
1.25G
4
JPLE
-
1.25G
5
JPKA
-
1.25Br
6
JPLF
-
1.25Y
1
JPLF
-
1.25Y
2
JGM3
-
1.25B
3
JPLE
-
1.25G
4
JPLE
-
1.25G
5
JPKA
-
1.25Br
6
JPLF
-
1.25Y
1
FTK(Male)
3
1.25L
2
FTK(Male)
4
1.25B
1
TMV(Male)
L
-
1
AA
-
3R
2
CF
2
-
3
CF
1
-
4
CF
4
-
5
P
-
1.25O
1
FSB(Female)
E
3R
2
F
-
1.25Sb
3
FSB(Female)
B
3L
4
FSB(Female)
D
3Y
5
FD3(Female)
1
1.25O
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
FS21
FS22
FSB (Female)
FSB (Male)
D155A-6
A7
A7
B9, AB4
B9, AB4
A494
C494
N495
L299
Device Name
Fuse box
Fuse box
Intermediate connector (Floor harness)
Intermediate connector (Fuse box harness) (Cab less spec)
Type
-
-
24-21
24-21
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
AA
-
1.25R
2
CG
2
-
3
CG
1
-
4
CG
4
-
5
G
-
1.25Br
1
FSB(Female)
C
1.25R
2
FSB(Female)
A
1.25O
Number Pin of Pins No.
5
5
21
21
3
L
-
1.25Y
4
FD2(Female)
11
1.25Br
5
FSB(Female)
V
1.25Br
A
FS22
2
1.25O
B
FS12
3
3L
C
FS22
1
1.25R
D
FS12
4
3Y
E
FS12
1
3R
F
NSF
5
1.25G
H
CB1
2
2Br
J
CB2
2
2O
K
CB7
2
2R
L
CB3
2
2G
M
W
-
2L
N
NSF
2
1.25P
P
NSF
3
1.25G
R
G
-
1.25Br
S
J
-
1.25R
T
R
-
1.25W
V
FS22
5
1.25Br
W
ACT
2
0.85V
X
EHL
2
1.25Gy
A
PKSW
A
1.25O
C
DSH(Female)
57
1.25R
F
FD1(Male)
1
1.25W
H
JPP1
-
2Br
K
JUF2
-
2R
L
CBR
3
1.25G
M
OPPW
1
2W
N
STC2
8
1.25P
P
JPK2
-
1.25G
R
JPKC
-
1.25Br
S
DSH(Female)
33
1.25R
T
JPK4
-
1.25W
U
DSH(Female)
34
1.25L
V
ESD
B
1.25Br
W
STC2
19
0.85V
X
STC2
9
0.85Gy
57
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. A
FSB (Male)
FTK (Female)
FTK (Female)
FTK (Male)
B9, AB4
M7
M7
M7
L230
F451
F428
D563
Intermediate connector (Fuse box harness) (Cab spec)
Intermediate connector (Fuel tank harness) (Cab less spec)
Intermediate connector (Fuel tank harness) (Cab spec)
Intermediate connector (Left fender harness)
24-21
DT
DT
DT
21
6
6
6
FUSE_L
-
-
Fuse 5A
-
-
FUSE_R
-
-
Fuse 5A
-
-
G
58
AD2
I340
Engine Bkup speed sensor
SUMITOMO
3
Connector (pin) No.
Pin No.
Wire diameter/ Color
PKSW
A
1.25O
B
CBPW
1
3L
C
DSH(Female)
57
1.25R
D
CBPW
2
3Y
E
CBPW
3
3R
F
FD1(Male)
1
1.25W
H
JPP1
-
2Br
J
DTS(Female)
1
2O
K
JUF2
-
2R
L
JPAA
-
2G
M
OPPW
1
2W
N
STC2
8
1.25P
P
JPK2
-
1.25G
R
JPKC
-
1.25Br
S
DSH(Female)
33
1.25R
T
JPK4
-
1.25W
U
DSH(Female)
34
1.25L
V
ESD
B
1.25Br
W
STC2
19
0.85V
X
STC2
9
0.85Gy
1
FD2(Male)
7
1.25W
2
GND03
-
1.25B
3
FD1(Female)
6
1.25L
4
FD1(Female)
7
1.25B
5
FD2(Male)
6
1.25O
6
GND03
-
1.25B
1
FD2(Male)
7
1.25W
2
GND03
-
1.25B
3
FD1(Female)
6
1.25L
4
FD1(Female)
7
1.25B
5
FD2(Male)
6
1.25O
6
GND03
-
1.25B
1
LRER
1
1.25W
2
LRER
2
1.25B
3
FLV
1
1.25L
4
FLV
2
1.25B
5
LREL
1
1.25O
6
LREL
2
1.25B
1
JPA1
-
0.5R
1
AC02(Male)
4
2R
1
JM01
1
0.85R
2
JM08
5
0.85B
3
JM05
1
0.85G
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
G
GND03
GND03
GND06
-
M5
M5
J1
H485
C448
C425
G409
GND07
G1
K435
GND07
G1
K413
Device Name
Joint
Ground (ROPS) (Cab less spec)
Ground (ROPS) (Cab spec)
Ground (Fender)
Ground (Bulkhead) (Cab less spec) Ground (Bulkhead) (Cab spec)
GND08
-
C627
Ground (Guard) [Additional headlamp specification]
GND09
AE2
F548
Ground (Engine)
GND11
GND11
GND12
D155A-6
AB6
AB6
AB6
F319
F247
F320
Ground (Floor) (Cab less spec)
Ground (Floor) (Cab spec)
Ground (Floor) (Cab less spec)
Type
-
Terminal
Terminal
Terminal
Number Pin of Pins No.
-
1
1
1
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
ACT
1
1.25Br
ACT
3
1.25Br
FS21
5
1.25Br
FSB(Female)
R
1.25Br
NSF
1
1.25Br
BKAL(Female)
2
1.25B
FD1(Female)
19
1.25B
FD1(Female)
29
1.25B
FTK(Female)
2
1.25B
FTK(Female)
6
1.25B
JOL1
-
2B
BKAL
2
1.25B
FD1(Female)
19
1.25B
FD1(Female)
29
1.25B
FTK(Female)
2
1.25B
FTK(Female)
6
1.25B
JOL1
-
2B
WSH1
2
1.25B
WSH1
4
1.25B
WSH2
2
1.25B
WSH2
4
1.25B
Terminal
1
-
HTD
2
2B
Terminal
1
-
HTD
2
2B
LHDL0(Female)
2
1.25B
Terminal
4
-
Terminal
1
-
Terminal
Terminal
Terminal
1
1
1
-
-
-
LHDL0(Female)
4
1.25B
LHDR0(Female)
2
1.25B
LHDR0(Female)
4
1.25B
ACS
2
1.25B
DSH(Female)
6
1.25B
DSH(Female)
7
1.25B
JOP2
-
2B
SRV
9
0.85B
SRV
12
1.25B
DSH(Female)
6
1.25B
DSH(Female)
7
1.25B
DTS(Female)
4
2B
JOP2
-
2B
SRV
9
0.85B
SRV
12
1.25B
CBZ
1
1.25B
JNG1
-
0.85B
JOP4
-
0.85B
LBP(Female)
2
1.25B
LBP(Female)
4
1.25B
59
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
GND12
GND20
H
AB6
AF2
-
D248
E459
J485
Device Name
Type
Ground (Floor) (Cab spec) Terminal
Ground (Engine)
Joint
Terminal
-
Number of Pins
1
2
-
HDT
AI2
G502
Hydraulic oil temperature sensor
DT
2
HHP
AI4
E500
Work equipment and HSS pump pressure sensor
DT
3
HNSW
V9
N530
Horn switch
DT
1
HNSW
V9
N530
Horn switch
DT
1
DT
2
HNSW (Female)
V9
O285
Intermediate connector (Horn switch) (Cab less spec)
HNSW (Female)
V9
F267
Intermediate connector (Horn switch) (Cab spec)
DT
2
HNSW (Male)
V9
N525
Intermediate connector (Floor harness)
DT
2
Horn
-
Pin No.
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
AC01(Female)
5
0.85B
FD4(Female)
4
0.85B
JNG1
-
2B
JOP4
-
0.85B
EGC3
1
3B
EGC3
2
3B
FD2(Female)
2
1.25V
LMFL
1
1.25V
LMFR
1
1.25V
1
PL1(Female)
24
1.25G
2
PL1(Female)
25
1.25B
A
PL1(Female)
29
1.25B
B
PL1(Female)
31
1.25P
C
PL1(Female)
30
1.25Y
-
HNSW(Male)
1
0.85L
-
HNSW(Male)
2
0.85L
1
FD1(Male)
16
0.85P
2
FD1(Male)
15
0.85Br
1
FD1(Male)
16
0.85P
2
FD1(Male)
15
0.85Br
1
HNSW
-
0.85L
2
HNSW
-
0.85L
HRN
C2
M574
1
-
RDG(Male)
3
1.25W
HT/A
B5
N548
Heater relay (Terminal A) Terminal
1
A
B105HL
-
20L
HT/B
A4
J565
Heater relay (Terminal B) Terminal
1
B
RHT
1
20R
C
FD3(Male)
3
1.25W
C
HTD
1
2W
C
FD3(Male)
3
1.25W
HT/C HT/C HTD HTD
INJ (Female)
60
A5 A5 H1 H1
AG3
O431 O409 N437 N415
C352
Heater relay (Terminal C) Terminal (Cab less spec) Heater relay (Terminal C) Terminal (Cab spec) Diode (Cab less spec) Diode (Cab spec)
Intermediate connector (Injector)
DT DT
DT
2 1 2 2
12
C
HTD
1
2W
1
HT/C
C
2W
2
GND07
-
2B
1
HT/C
C
2W
2
GND07
-
2B
1
EGC1
45
0.85R
2
EGC1
54
0.85R
3
EGC1
55
0.85R
4
EGC1
56
0.85R
5
EGC1
46
0.85R
6
EGC1
57
0.85R
7
EGC1
59
0.85B
8
EGC1
60
0.85B
9
EGC1
58
0.85B
10
EGC1
52
0.85B
11
EGC1
51
0.85B
12
EGC1
53
0.85B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
INJ(Male)
J
J1939
JCE6
JCE6
JCE7
JCE7
JGM1
JGM1
JGM3
JGM3
JGM4
D155A-6
AG3
-
AF8
-
-
-
-
-
-
-
-
-
F351
I485
K346
J310
I241
J310
I241
F396
F373
K390
K367
F277
Device Name
Intermediate connector (Engine harness)
Joint
Service connector
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Type
DT
-
DT
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
CN1
1
0.85R
2
CN2
1
0.85R
3
CN3
1
0.85R
4
CN4
1
0.85R
5
CN5
1
0.85R
Number Pin of Pins No.
12
-
3
-
-
-
-
-
-
-
-
-
6
CN6
1
0.85R
7
CN6
2
0.85B
8
CN5
2
0.85B
9
CN4
2
0.85B
10
CN3
2
0.85B
11
CN2
2
0.85B
12
CN1
2
0.85B
CB6
2
2R
EHL
1
1.25R
EHL
3
1.25R
-
FSB(Female)
S
1.25R
A
EGC1
8
0.85R
B
EGC1
6
0.85B
C
JNX3
-
0.85B
JS15
-
0.85G
PKD
1
0.85G
PL1(Male)
8
1.25G
JS15
-
0.85G
-
-
-
-
-
-
-
-
-
PKD
1
0.85G
PL1(Male)
8
0.85G
JS19
-
0.85Y
PBD
1
0.85Y
PL1(Male)
10
1.25Y
JS19
-
0.85Y
PBD
1
0.85Y
PL1(Male)
10
0.85Y
CM01
12
0.85B
DSH(Male)
23
0.85B
DSH(Male)
25
0.85B
CM01
12
0.85B
DSH(Male)
23
0.85B
DSH(Male)
25
0.85B
DSH(Male)
47
1.25B
FLSW
2
1.25B
RLSW
2
1.25B
DSH(Male)
47
1.25B
FLSW
2
1.25B
RLSW
2
1.25B
DSH(Female)
20
0.85B
DSH(Female)
47
0.85B
JGM5
-
0.85B
61
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing JGM4
JGM5
JGM5
JGP1
JGP1
JGP2
JGP2
JGP3
JGP3
JGW3
JJP1
62
-
-
-
-
-
-
-
-
-
-
-
D205
J304
J236
D296
D227
D296
D227
L274
I217
-
D296
Device Name
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint (Cab less spec)
Type
-
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
DSH(Female)
20
0.85B
DSH(Female)
47
0.85B
JGM5
-
0.85B
DSH(Female)
17
0.85B
FD1(Male)
14
1.25B
JGM4
-
0.85B
DSH(Female)
17
0.85B
FD1(Male)
14
1.25B
FD1(Male)
24
0.85B
FD4(Female)
16
0.85B
JGM4
-
0.85B
DIAL
C
0.85B
DSH(Female)
61
0.85B
JGP2
-
0.85B
STC1
21
0.85B
TLV1
1
0.85B
TLV1
8
0.85B
DIAL
3
0.85B
DSH(Female)
61
0.85B
JGP2
-
0.85B
STC1
21
0.85B
TLV1
1
0.85B
TLV1
8
0.85B
FD1(Male)
20
0.85B
JGP1
-
0.85B
PL1(Male)
29
1.25B
PL1(Male)
40
1.25B
FD1(Male)
20
0.85B
JGP1
-
0.85B
PL1(Male)
29
0.85B
PL1(Male)
40
0.85B
STC1
4
0.85B
TLV2
2
0.85B
TLV2
5
0.85B
STC1
4
0.85B
TLV2
2
0.85B
TLV2
5
0.85B
BNSW(Female)
1
0.85B
BNSW(Female)
3
0.85B
WEC1
4
0.85B
DIAL
A
0.85P
DSH(Female)
63
0.85P
STC1
22
0.85P
TLV1
4
0.85P
TLV1
5
0.85P
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
JJP1
JM01
JM02
JM03
JM04
JM05
JM08
NE
NA
NC
JNG1
D155A-6
-
AH4
AH3
AH3
AG2
AH5
AG8
-
-
-
-
D227
M350
M351
M352
M352
L345
I344
F463
F463
F463
G309
Device Name
Joint (Cab spec)
Junction wiring harness
Junction wiring harness
Junction wiring harness
Junction wiring harness
Junction wiring harness
Junction wiring harness
Joint
Joint
Joint
Joint (Cab less spec)
Type
-
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
5
6
4
4
3
6
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
DIAL
1
0.85P
DSH(Female)
63
0.85P
STC1
22
0.85P
TLV1
4
0.85P
TLV1
5
0.85P
1
G
1
0.85R
2
POIL
1
0.85R
3
PIM
1
0.85R
4
RES
1
0.85R
5
JM04
1
0.85R
1
JM08
6
0.85B
2
PIM
2
0.85B
4
TIM
2
0.85B
5
TFUEL
2
0.85B
6
EGC1
47
0.85B
1
PAMB
2
0.85B
3
TWTR
2
0.85B
4
EGC1
38
0.85B
1
JM01
5
0.85R
2
PAMB
1
0.85R
4
EGC1
37
0.85R
1
G
3
0.85G
2
RES
2
0.85G
3
EGC1
26
0.85G
1
PFUEL
3
0.85B
3
POIL
2
0.85B
5
G
2
0.85B
6
JM02
1
0.85B
CA1
C
0.85B
EG2(Male)
3
0.85B
EGC2
37
0.85B
-
-
-
-
CA1
A
0.85W
EG2(Male)
1
0.75W
EGC2
46
0.85W
CA1
B
0.85B
EG2(Male)
2
0.75B
EGC2
47
0.85B
GND12
-
0.85B
JNX5
-
BRAID
JNX6
-
BRAID
JNX8
-
BRAID
JNXC
-
BRAID
63
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
JNG1
JNG2
JNH
JNH
JNH3
JNH3
JNL
JNL
JNMH
JNMH
JNX2 JNX3
64
-
-
-
-
-
-
-
-
-
-
-
F240
F240
G309
F240
G309
F240
G309
F240
F396
F373
-
Device Name
Joint (Cab spec)
Joint
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint Joint
Type
-
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
GND12
-
2B
JNG2
-
0.85B
JNX5
-
BRAID
JNX6
-
BRAID
JNX8
-
BRAID
JNXG
-
BRAID
JNG1
-
0.85B
JNXC
-
BRAID
JNXE
-
BRAID
DSH(Female)
10
0.75W
FD1(Male)
8
0.75W
SRV
3
0.75W
STC2
32
0.75W
AC02(Female)
1
0.75W
DSH(Female)
10
0.75W
DTS(Female)
6
0.75W
FD1(Male)
8
0.75W
SRV
3
0.75W
STC2
32
0.75W
DSH(Female)
14
0.85V
SRV
6
0.85V
STC2
24
0.85V
DSH(Female)
14
0.85V
DTS(Female)
5
0.85V
SRV
6
0.85V
STC2
24
0.85V
DSH(Female)
11
0.75B
FD1(Male)
9
0.75B
SRV
10
0.75B
STC2
22
0.75B
AC02(Female)
2
0.75B
DSH(Female)
11
0.75B
DTS(Female)
7
0.75B
FD1(Male)
9
0.75B
SRV
10
0.75B
STC2
22
0.75B
CM02
8
0.85W
CM02
9
0.85W
DSH(Male)
10
0.75W
CM02
8
0.85W
CM02
9
0.85W
DSH(Male)
10
0.75W
EGC1
7
0.85B
JNX3
-
-
J1939
C
0.85B
JNX2
-
-
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No.
JNX4
-
I402
Joint (Cab less spec)
-
-
-
JNX4
-
I378
Joint (Cab spec)
-
-
-
JNX5 JNX5 JNX6 JNX6 JNX8 JNX8 JNX9 JNXA JNXC JNXC JNXE JNXF JNXF JNXG JNXJ JNXJ
JOA1
JOA2
D155A-6
-
-
-
E275 F206 J305 J236 E299 D230 J327 H265 E254 M434 L412 E259 E434 E412
-
-
Joint (Cab less spec) Joint (Cab spec) Joint (Cab less spec) Joint (Cab spec) Joint (Cab less spec) Joint (Cab spec) Joint Joint Joint (Cab less spec) Joint (Cab spec) Joint Joint (Cab less spec) Joint (Cab spec) Joint Joint (Cab less spec) Joint (Cab spec)
Joint
Joint
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
DSH(Male)
12
0.85B
DSH(Male)
12
0.85B
DSH(Female)
12
0.85B
JNG1
-
BRAID
DSH(Female)
12
0.85B
JNG1
-
BRAID
FD1(Male)
10
0.85B
JNG1
-
BRAID
FD1(Male)
10
0.85B
JNG1
-
BRAID
JNG1
-
BRAID
STC2
12
0.85B
JNG1
-
BRAID
STC2
12
0.85B
DTS(Male)
8
0.85B
JNXA
-
-
JNX9
-
-
WEC2
12
0.85B
JNG1
-
BRAID
SRV
11
0.85B
JNG2
-
BRAID
SRV
11
0.85B
AC02(Female)
3
0.85B
JNG2
-
BRAID
EG2(Female)
3
0.85B
JNXJ
-
BRAID
EG2(Female)
3
0.85B
JNXJ
-
-
DTS(Female)
8
0.85B
JNG1
-
BRAID
FD1(Female)
10
0.85B
JNXF
-
BRAID
FD1(Female)
10
0.85B
JNXF
-
-
AC01(Male)
5
2B
ACCN
16
2B
ACPT
-
2B
ACB1
3
0.5BrR
ACB2
3
0.5BrR
ACCN
27
0.5BrR
ACFS
1
0.5BrR
ACPS
1
0.5BrR
ACSM
1
0.85BrR
65
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
JOL1
JOL1
JOL2
JOL2
JOL3
JOP1
JOP1
JOP2
JOP2
JOP3
66
-
-
-
-
-
-
-
-
-
-
E447
E422
J304
J234
E447
G297
F228
G297
F228
J310
Device Name
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Type
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
FD1(Female)
14
1.25B
FD2(Male)
1
1.25B
FD3(Male)
5
1.25B
GND03
-
2B
JOL3
-
1.25B
PPL
2
1.25B
FD1(Female)
14
1.25B
FD2(Male)
1
1.25B
FD3(Male)
5
1.25B
GND03
-
2B
PPL
2
1.25B
FD1(Male)
19
1.25B
FD1(Male)
29
1.25B
OPPW
2
2B
FD1(Male)
19
1.25B
FD1(Male)
29
1.25B
OPPW
2
2B
AF1
2
1.25B
JOL1
-
1.25B
PRT(Female)
5
1.25B
JOP2
-
1.25B
PL1(Male)
67
0.85O
PL1(Male)
70
1.25B
STC3
10
0.85B
JOP2
-
1.25B
PL1(Male)
67
0.85O
PL1(Male)
70
1.25B
STC3
10
0.85B
GND11
-
2B
JOP1
-
1.25B
STC3
21
0.85B
STC3
31
0.85B
STC3
32
0.85B
STC3
33
0.85B
GND11
-
2B
JOP1
-
1.25B
STC3
21
0.85B
STC3
31
0.85B
STC3
32
0.85B
STC3
33
0.85B
JOP4
-
1.25B
PL1(Male)
42
0.85B
PL1(Male)
46
0.85B
PL1(Male)
53
0.85B
PL1(Male)
60
0.85B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
JOP3
JOP4
JOP4
JOT1
JOT2
JOW1
JOW2
JPA1
JPA9
D155A-6
-
-
-
-
-
-
-
-
-
I241
J310
I241
F604
F598
-
-
-
E549
Device Name
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint
Joint
Joint
Joint
Joint
Type
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
JOP4
-
1.25B
PL1(Male)
42
0.85B
PL1(Male)
46
0.85B
PL1(Male)
53
0.85B
PL1(Male)
60
0.85B
GND12
-
0.85B
JOP3
-
1.25B
PL1(Male)
4
0.85B
PL1(Male)
18
0.85B
PL1(Male)
38
0.85B
GND12
-
0.85B
JOP3
-
1.25B
PL1(Male)
4
0.85B
PL1(Male)
18
0.85B
PL1(Male)
38
0.85B
DPNL
2
1.25B
JOT2
-
-
PL1F(Female)
70
1.25B
PL1M(Male)
52
1.25B
PL1M(Male)
59
1.25B
PL1M(Male)
62
1.25B
JOT1
-
-
PL1M(Male)
23
1.25B
PL1M(Male)
64
-
PNL(Male)
25
1.25B
PNL(Male)
26
1.25B
DTS(Male)
4
2B
JOW2
-
-
WEC3
21
0.85B
WEC3
31
0.85B
WEC3
32
0.85B
WEC3
33
0.85B
DTS(Male)
9
0.85B
JOW1
-
-
WEC3
20
0.85B
WEC3
40
0.85O
AC01(Male)
4
0.5R
ACCN
6
0.5R
ACIS
7
0.5R
FUSE_L
1
0.5R
A/C
1
1.25W
A/C1(Male)
1
1.25W
ACS
1
1.25W
67
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
JPAA
JPAC
JPAE
JPAF
JPAG
JPK1
JPK1
JPK2
JPK2
JPK3
JPK3
JPK4
68
-
-
-
-
-
-
-
-
-
-
-
-
H234
H234
H234
H234
-
F277
D205
F277
D205
J304
J236
F277
Device Name
Joint
Joint
Joint
Joint
Joint
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Type
-
-
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
AC02(Female)
4
0.85G
AC03
4
2G
AC04
4
1.25G
FSB(Male)
L
2G
AC01(Female)
4
0.85P
AC03
1
0.85P
AC04
1
0.85P
ACD1
1
0.85P
ACD2
1
0.85P
AC01(Female)
1
0.85V
AC03
3
0.85V
ACD1
2
0.85V
AC01(Female)
2
0.85Br
AC04
3
0.85Br
ACD2
2
0.85Br
AC01(Male)
8
0.5RB
ACB1
1
0.85RB
ACB2
1
0.5RB
ACCN
3
0.5RB
ACSM
3
0.5RB
DSH(Female)
3
0.85Br
DSH(Female)
29
1.25Br
DSH(Female)
49
0.85Br
JPKC
-
1.25Br
DSH(Female)
3
0.85Br
DSH(Female)
29
1.25Br
DSH(Female)
49
0.85Br
JPKC
-
1.25Br
DSH(Female)
2
0.85G
DSH(Female)
31
1.25G
FSB(Male)
P
1.25G
DSH(Female)
2
0.85G
DSH(Female)
31
1.25G
FSB(Male)
P
1.25G
DSH(Female)
32
1.25V
FD1(Male)
27
1.25V
RSD
1
0.85V
STC3
4
0.85V
DSH(Female)
32
1.25V
FD1(Male)
27
1.25V
RSD
1
0.85V
STC3
4
0.85V
DSH(Female)
19
0.85W
DSH(Female)
30
1.25W
FSB(Male)
T
1.25W
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing JPK4
JPKA
JPKA
JPKC
JPKC
JPKE
JPKE
JPKF
JPL2
JPL2
JPL8
JPL8
JPLE
JPLE
D155A-6
-
-
-
-
-
-
-
-
-
-
-
-
-
-
D205
K390
K367
G297
F228
D302
D232
-
K390
K367
K390
K367
K390
K367
Device Name
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Type
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
DSH(Female)
19
0.85W
DSH(Female)
30
1.25W
FSB(Male)
T
1.25W
DSH(Male)
49
0.85Br
FLSW
5
1.25Br
RLSW
5
1.25Br
DSH(Male)
49
0.85Br
FLSW
5
1.25Br
RLSW
5
1.25Br
FSB(Male)
R
1.25Br
JPK1
-
1.25Br
JPKE
-
0.85R
SRV
2
0.85Br
DTS(Female)
3
0.85Br
FSB(Male)
R
1.25Br
JPK1
-
1.25Br
JPKE
-
0.85Br
SRV
2
0.85Br
JPKC
-
0.85R
STC3
14
0.85Br
STC3
24
0.85Br
JPKC
-
0.85Br
STC3
14
0.85Br
STC3
24
0.85Br
DTS(Male)
3
0.85Br
WEC3
14
0.85Br
WEC3
24
0.85Br
DSH(Male)
45
1.25V
LMD1
1
1.25V
LMD2
1
1.25V
DSH(Male)
45
1.25V
LMD1
1
1.25V
LMD2
1
1.25V
DSH(Male)
46
1.25L
RLSW
1
1.25L
RLSW
6
1.25L
DSH(Male)
46
1.25L
RLSW
1
1.25L
RLSW
6
1.25L
FLSW
3
1.25G
FLSW
4
1.25G
LMD2
2
1.25Y
FLSW
3
1.25G
FLSW
4
1.25G
LMD2
2
1.25Y
69
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
JPLF
JPLF
JPLM
JPLN
JPP1
JPP1
JPR1
JPR2
JPR2
JPT1
JPT2
70
-
-
-
-
-
-
-
-
-
-
-
K390
K367
E447
E447
G297
F228
O462
D296
D227
F605
N601
Device Name
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint
Type
-
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
CM01
13
0.85G
FLSW
1
1.25Y
FLSW
6
1.25Y
LMD1
2
1.25G
CM01
13
0.85G
FLSW
1
1.25Y
FLSW
6
1.25Y
LMD1
2
1.25G
FD1(Female)
26
1.25B
FD2(Male)
3
1.25G
PRT(Female)
2
1.25G
FD1(Female)
25
1.25L
FD2(Male)
4
1.25L
PRT(Female)
1
1.25L
FSB(Male)
H
2Br
PL1(Male)
68
1.25Br
STC3
2
0.85Br
STC3
12
0.85Br
STC3
22
0.85Br
FSB(Male)
H
2Br
PL1(Male)
68
1.25Br
STC3
2
0.85Br
STC3
12
0.85Br
STC3
22
0.85Br
AL
R
Gy
E22(Male)
2
Gy
ST
2
Gy
DSH(Female)
1
0.85Gy
FD1(Male)
2
1.25Gy
RSD
2
0.85Gy
STC1
15
0.85Gy
DSH(Female)
1
0.85Gy
DTS(Female)
10
0.85Gy
FD1(Male)
2
1.25Gy
RSD
2
0.85Gy
STC1
15
0.85Gy
DPNL
1
1.25Br
PL1F(Female)
68
1.25Br
PL1M(Male)
54
-
PNL(Male)
1
1.25BR
RPNL
1
1.25B
F/R SW
2
1.25R
F/R SW
5
1.25R
F/R SW
8
1.25R
F/R SW
11
1.25R
PNL(Female)
1
1.25R
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing JPT3
JPT4
JPT5
JPT6
JPT7
JPT8
JPW1
JPZ6
JPZ6
JRP1
JRP1
JRP2
D155A-6
-
-
-
-
-
-
-
-
-
-
-
-
O601
O601
N603
O603
F598
F597
-
E447
E422
D302
D232
D302
Device Name
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Type
-
-
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
F/R SW
4
1.25V
F/R SW
6
1.25V
PNL(Female)
4
1.25V
F/R SW
7
1.25L
F/R SW
9
-
PNL(Female)
5
1.25L
1STSW
2
1.25G
1STSW
5
1.25G
PNL(Female)
7
1.25G
1STSW
6
1.25G
2NDSW
2
1.25G
2NDSW
5
1.25G
PNL(Male)
5
1.25W
PNL(Male)
11
1.25W
PNL(Male)
12
1.25W
PL1M(Male)
45
1.25B
PL1M(Male)
48
1.25B
PNL(Male)
7
1.25B
DTS(Male)
1
2O
WEC3
2
0.85O
WEC3
12
0.85O
WEC3
22
0.85O
BKAL(Female)
1
1.25W
FD1(Female)
3
1.25W
FD2(Male)
10
1.25W
BKAL
1
1.25W
FD1(Female)
3
1.25W
FD2(Male)
10
1.25W
PL1(Male)
3
1.25B
PL1(Male)
6
0.85B
PL1(Male)
17
1.25B
PL1(Male)
20
1.25B
PL1(Male)
64
1.25B
STC3
3
0.85B
PL1(Male)
3
0.85B
PL1(Male)
6
0.85B
PL1(Male)
17
0.85B
PL1(Male)
20
0.85B
PL1(Male)
64
0.85B
STC3
3
0.85B
CBR
2
0.85B
FD1(Male)
5
0.85B
PL1(Male)
45
0.85B
PL1(Male)
48
0.85B
STC3
13
0.85B
71
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
JRP2
JRP3
JRP3
JRP4
JRP4
JRP5
JRP5
JRP6
JRP6
JRW1
JS15
JS15
72
-
-
-
-
-
-
-
-
-
-
-
-
D232
D302
D232
D302
D232
J310
I241
J310
I241
-
D296
D227
Device Name
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint (Cab less spec)
Joint (Cab spec)
Type
-
-
-
-
-
-
-
-
-
-
-
-
Number Pin of Pins No.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
FD1(Male)
5
0.85B
PL1(Male)
45
0.85B
PL1(Male)
48
0.85B
STC3
13
0.85B
JRP4
-
0.85B
PL1(Male)
52
0.85B
PL1(Male)
59
0.85B
PL1(Male)
62
0.85B
STC3
23
0.85B
JRP4
-
0.85B
PL1(Male)
52
0.85B
PL1(Male)
59
0.85B
PL1(Male)
62
0.85B
STC3
23
0.85B
JRP3
-
0.85B
JRP5
-
0.85B
JRP6
-
0.85B
PL1(Male)
23
1.25B
PL1(Male)
37
0.85B
JRP3
-
0.85B
JRP5
-
0.85B
JRP6
-
0.85B
PL1(Male)
23
0.85B
PL1(Male)
37
0.85B
JRP4
-
0.85B
PKD
2
0.85B
PL1(Male)
9
1.25B
JRP4
-
0.85B
PKD
2
0.85B
PL1(Male)
9
0.85B
JRP4
-
0.85B
PBD
2
0.85B
PL1(Male)
11
1.25B
JRP4
-
0.85B
PBD
2
0.85B
PL1(Male)
11
0.85B
DUL
2
0.85B
PTH
2
0.85B
WEC3
3
0.85B
JCE6
-
0.85G
PKSW
C
0.85G
STC1
17
0.85G
JCE6
-
0.85G
PKSW
C
0.85G
STC1
17
0.85G
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing JS19
JS19
JTP9
JUF2
JUF2
JUP1
JUP1
JUW1
KEY SW
KEY (Female)
D155A-6
-
-
-
-
-
-
-
-
-
R6
D296
D227
F598
G297
F228
G297
F228
-
K538
N396
Device Name
Joint (Cab less spec)
Joint (Cab spec)
Joint
Joint (Cab less spec)
Joint (Cab spec)
Joint (Cab less spec)
Joint (Cab spec)
Joint
Starting switch
Intermediate connector (Starting switch) (Cab less spec)
Type
-
-
-
-
-
-
-
-
TERMINAL
DT
Number Pin of Pins No.
-
-
-
-
-
-
-
-
1
6
-
-
-
-
-
-
-
Connector (pin) No.
Pin No.
Wire diameter/ Color
DSH(Female)
59
0.85Y
JCE7
-
0.85Y
STC1
5
0.85Y
DSH(Female)
59
0.85Y
JCE7
-
0.85Y
STC1
5
0.85Y
PNL(Male)
17
1.25W
PNL(Male)
18
1.25W
PNL(Male)
19
1.25W
PNL(Male)
20
1.25W
DSH(Female)
4
1.25R
DSH(Female)
5
1.25R
FSB(Male)
K
2R
JUP1
-
2R
SRV
1
1.25R
DSH(Female)
4
1.25R
DSH(Female)
5
1.25R
DTS(Female)
2
2R
FSB(Male)
K
2R
JUP1
-
2R
SRV
1
1.25R
JUF2
-
2R
STC3
1
0.85R
STC3
11
0.85R
JUF2
-
2R
STC3
1
0.85R
STC3
11
0.85R
DTS(Male)
2
2R
-
WEC3
1
0.85R
WEC3
11
0.85L
ACC
KEY(Male)
1
1.25Br
B
KEY(Male)
5
1.25R
BR
KEY(Male)
4
1.25Y
C
KEY(Male)
3
1.25G
R1
KEY(Male)
2
1.25W
R2
KEY(Male)
6
1.25L
1
DSH(Male)
29
1.25Br
2
DSH(Male)
30
1.25W
3
DSH(Male)
31
1.25G
4
DSH(Male)
32
1.25V
5
DSH(Male)
33
1.25R
6
DSH(Male)
34
1.25L
73
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
KEY (Female)
KEY (Male)
R6
R6
N373
K542
Device Name
Intermediate connector (Starting switch) (Cab spec)
Intermediate connector (Dash board harness)
Type
DT
DT
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
DSH(Male)
29
1.25Br
2
DSH(Male)
30
1.25W
3
DSH(Male)
31
1.25G
4
DSH(Male)
32
1.25V
5
DSH(Male)
33
1.25R
6
DSH(Male)
34
1.25L
1
KEY SW
ACC
1.25Br
2
KEY SW
R1
1.25W
3
KEY SW
C
1.25G
4
KEY SW
BR
1.25Y
5
KEY SW
B
1.25R
Number Pin of Pins No.
6
6
6
L
L/T SW
LBP (Female)
LBP (Male)
LBPL LBPR LHD (Female)
-
-
-
-
C3
D488
L597
G278
M630
O624 M620
Joint
L Turn SW
Intermediate connector (Radiator guard harness)
Intermediate connector (Floor harness)
Front lamp ADD (L, H,) Front lamp ADD (R, H,)
-
-
DT
DT
DT DT
-
12
4
4
2 2
B573
Intermediate connector (Front lamp)
DT
2
DT
2
LHD (Female)
C3
B584
Intermediate connector (Front lamp) (Only for indonesia spec)
LHD (Male)
C3
G581
Intermediate connector (Radiator guard harness)
DT
2
LHD (Male)
C3
B627
Intermediate connector (Radiator guard harness) (ADD front lamp spec)
DT
2
LHDL
C3
I579
Left headlamp
DT
2
74
-
KEY SW
R2
1.25L
FD2(Female)
12
1.25Y
FD3(Female)
6
1.25Y
FS22
3
1.25Y
PHR
3
1.25Y
2
PNL(Female)
19
1.25Y
3
PNL(Female)
23
1.25P
4
PNL(Female)
24
1.25V
5
PNL(Female)
20
1.25Sb
8
PNL(Female)
21
1.25Br
9
PNL(Female)
25
1.25L
10
PNL(Female)
26
1.25Gy
11
PNL(Female)
22
1.25O
1
FD1(Male)
26
1.25G
2
GND12
-
1.25B
3
FD1(Male)
25
1.25L
4
GND12
-
1.25B
1
LBPL
1
1.25G
2
LBPL
2
1.25B
3
LBPR
1
1.25L
4
LBPR
2
1.25B
1
LBP(Male)
1
1.25G
2
LBP(Male)
2
1.25B
1
LBP(Male)
3
1.25L
2
LBP(Male)
4
1.25B
1
PRT(Male)
1
1.25L
2
PRT(Male)
2
1.25G
1
PRT(Male)
1
1.25L
2
PRT(Male)
2
1.25G
1
LHDR
1
1.25L
2
LHDL
1
1.25G
1
C_LF
-
1.25L
2
A_LF
-
1.25G
1
LHD(Male)
2
1.25G
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing LHDL0 (Female)
LHDL0 (Male)
-
-
E625
I634
LHDL1
-
J627
LHDL2
-
H627
LHDR
C4
G577
LHDR0 (Female)
LHDR0 (Male)
-
-
B621
I622
LHDR1
-
J615
LHDR2
-
H615
LMD1
Q8
E389
LMD1
Q8
LMD2 LMD2
LMFL
LMFR
LMRE
D155A-6
Device Name
Intermediate connector (Additional front lamp)
Intermediate connector (Radiator guard harness) Additional left headlamp [Additional headlamp specification] Additional left headlamp [Additional headlamp specification] Right headlamp
Intermediate connector (Additional front lamp)
Intermediate connector (Radiator guard harness) Additional right headlamp [Additional headlamp specification] Additional right headlamp [Additional headlamp specification]
Type
DT
DT
4
4
DT
2
DT
2
DT
2
DT
DT
4
4
DT
2
DT
2
Diode (Cab less spec)
DT
2
C366
Diode (Cab spec)
DT
2
Q8
E390
Diode (Cab less spec)
DT
2
Q8
C368
Diode (Cab spec)
DT
2
C9
C9
A9
J484
K484
L492
Left headlamp relay
Right headlamp relay
Rear lamp relay
Relay
Relay
Relay
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
A_LF
-
1.25G
2
GND08
-
1.25B
3
C_LF
-
1.25L
Number Pin of Pins No.
5
5
5
4
GND08
-
1.25B
1
LHDL1
1
1.25G
2
LHDL1
2
1.25B
3
LHDL2
1
1.25L
4
LHDL2
2
1.25B
1
LHDL0(Male)
1
1.25G
2
LHDL0(Male)
2
1.25B
1
LHDL0(Male)
3
1.25L
2
LHDL0(Male)
4
1.25B
1
LHD(Male)
1
1.25L
1
C_LF
-
1.25L
2
GND08
-
1.25B
3
A_LF
-
1.25G
4
GND08
-
1.25B
1
LHDR2
1
1.25L
2
LHDR2
2
1.25B
3
LHDR1
1
1.25G
4
LHDR1
2
1.25B
1
LHDR0(Male)
3
1.25G
2
LHDR0(Male)
4
1.25B
1
LHDR0(Male)
1
1.25L
2
LHDR0(Male)
2
1.25B
1
JPL2
-
1.25V
2
JPLF
-
1.25G
1
JPL2
-
1.25V
2
JPLF
-
1.25G
1
JPL2
-
1.25V
2
JPLE
-
1.25Y
1
JPL2
-
1.25V
2
JPLE
-
1.25Y
1
H
-
1.25V
2
M
-
1.25B
3
A
-
1.25W
5
FD2(Female)
3
1.25G
1
H
-
1.25V
2
M
-
1.25B
3
A
-
1.25W
5
FD2(Female)
4
1.25L
1
E
-
1.25L
2
M
-
1.25B
3
C
-
1.25Gy
5
N
-
1.25O
75
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
LMRP
LREL LRER
D7
M7 I9
F484
B560 D557
LRP2
M6
J449
LRP2
M6
J426
M
N
NE
NSF
OPPW OPPW
P
PAMB
PBD PBD PBS PCV1 PCV2
76
-
-
AH4
C9
Z9 Z9
-
AH3
AB6 AB6 AL7 AD2 AD2
J485
L485
K350
E484
F331 C260
H485
K351
M322 C239 F515 B340 C341
Device Name
Ripper lamp relay
Left rear lamp Right rear lamp Ripper lamp (Cab less spec) Ripper lamp (Cab spec)
Joint
Joint
Engine Ne speed sensor
Neutral safety relay
Intermediate connector (Cab less spec) Intermediate connector (Cab spec)
Joint
Ambient pressure sensor
Diode (Cab less spec) Diode (Cab spec) Pedal brake solenoid Supply pump #1 Supply pump #2
Type
Relay
DT
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
E
-
1.25L
2
M
-
1.25B
3
C
-
1.25Gy
5
FD2(Female)
8
1.25Y
1
FTK(Male)
5
1.25O
2
FTK(Male)
6
1.25B
1
FTK(Male)
1
1.25W
2
FTK(Male)
2
1.25B
Number Pin of Pins No.
5
2
DT
2
DT
3
1
FD2(Male)
8
1.25Y
DT
3
1
FD2(Male)
8
1.25Y
FD2(Female)
1
1.25B
LMFL
2
1.25B
-
-
FRAMATONE
Relay
DT DT
-
FRAMATONE
DT DT DT SUMITOMO SUMITOMO
-
-
3
5
2 2
-
4
2 2 2 2 2
-
-
LMFR
2
1.25B
LMRE
2
1.25B
LMRP
2
1.25B
FD2(Female)
6
1.25O
FD2(Female)
7
1.25W
LMRE
5
1.25O
1
EGC1
16
0.85R
2
EGC1
48
0.85B
3
EGC1
27
0.85G
1
G
-
1.25Br
2
FSB(Female)
N
1.25P
3
FSB(Female)
P
1.25G
5
FSB(Female)
F
1.25G
1
FSB(Male)
M
2W
2
JOL2
-
2B
1
FSB(Male)
M
2W
2
JOL2
-
2B
ACT
6
1.25O
EHL
5
1.25O
FS11
5
1.25O
1
JM04
2
0.85R
2
JM03
1
0.85B
3
EGC1
3
0.85G
1
JCE7
-
0.85Y
2
JRP6
-
0.85B
1
JCE7
-
0.85Y
2
JRP6
-
0.85B
1
PL1(Female)
10
1.25Y
2
PL1(Female)
11
1.25B
1
EGC1
4
0.85R
2
EGC1
5
0.85B
1
EGC1
9
0.85R
2
EGC1
10
0.85B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing PFUEL
PHR
PIM
PKD PKD PKS
PKSW
PKSW
PL1 (Female)
D155A-6
AF2
B9
AH6
AB6 AB6 AL6
L8, AB5
L8, AB5
AB4, AN7
J354
C484
N346
M323 C237 F514
D322
D250
O509
Device Name
Common rail pressure sensor
Preheat relay
Charge pressure sensor
Diode (Cab less spec) Diode (Cab spec) Parking brake solenoid
Parking brake lever switch (Cab less spec)
Parking brake lever switch (Cab spec)
Intermediate connector (Floor harness)
Type
AMP
Relay
CANNON
DT DT DT
DT
DT
DRC70A
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
EGC1
33
0.85R
2
EGC1
25
0.85G
3
JM08
1
0.85B
1
FD3(Female)
4
1.25Gy
2
FD3(Female)
5
1.25B
3
L
-
1.25Y
5
R
-
1.25W
Number Pin of Pins No.
3
5
4
2 2 2
3
3
70
1
JM01
3
0.85R
2
JM02
2
0.85B
3
EGC1
44
0.85G
1
JCE6
-
0.85G
2
JRP5
-
0.85B
1
JCE6
-
0.85G
2
JRP5
-
0.85B
1
PL1(Female)
8
1.25G
2
PL1(Female)
9
1.25B
A
FSB(Male)
A
1.25O
B
STC1
23
0.85W
C
JS15
-
0.85G
A
FSB(Male)
A
1.25O
B
STC1
23
0.85W
C
JS15
-
0.85G
1
FCLL
1
1.25V
2
SCLL
1
1.25W
3
SCLL
2
1.25B
5
SCLR
1
1.25Gr
6
SCLR
2
1.25B
7
FCLR
1
1.25L
8
PKS
1
1.25G
9
PKS
2
1.25B
10
PBS
1
1.25Y
11
PBS
2
1.25B
15
FBRL
1
1.25Gr
16
SBRL
1
1.25Y
17
SBRL
2
1.25B
19
SBRR
1
1.25L
20
SBRR
2
1.25B
21
FBRR
1
1.25P
22
SSP
1
1.25L
23
SSP
2
1.25B
24
HDT
1
1.25G
25
HDT
2
1.25B
29
HHP
A
1.25B
30
HHP
C
1.25Y
31
HHP
B
1.25P
77
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Connector (pin) No.
Pin No.
Wire diameter/ Color
FAC
1
1.25Sb
37
FAC
2
1.25B
39
TCT
1
1.25O
Number Pin of Pins No. 36
PL1 (Female)
PL1 (Male)
78
AB4, AN7
AB4, AN7
O509
O310
Intermediate connector (Floor harness)
Intermediate connector (P/L harness) (Cab less spec)
DRC70A
DRC70A
70
70
40
TCT
2
1.25B
43
TMV(Female)
M
1.25G
44
TMV(Female)
C
1.25L
45
TMV(Female)
D
1.25B
47
TMV(Female)
A
1.25O
48
TMV(Female)
B
1.25B
49
TMV(Female)
L
1.25Gr
50
TMV(Female)
N
1.25Br
51
TMV(Female)
E
1.25Y
52
TMV(Female)
F
1.25B
54
WLK
1
1.25Br
55
BVRV
1
1.25Br
56
BVRV
2
1.25B
57
TMV(Female)
P
1.25L
58
TMV(Female)
J
1.25Br
59
TMV(Female)
K
1.25B
61
TMV(Female)
G
1.25G
62
TMV(Female)
H
1.25B
63
TMV(Female)
O
1.25P
64
WLK
2
1.25B
65
PL1(Female)
67
1.25B
67
PL1(Female)
65
1.25B
1
STC2
13
0.85O
2
STC3
25
0.85W
3
JRP1
-
1.25B
4
JOP4
-
0.85B
5
STC3
35
0.85Gy
6
JRP1
-
0.85B
7
STC2
3
0.85L
8
JCE6
-
1.25G
9
JRP5
-
1.25B
10
JCE7
-
1.25Y
11
JRP6
-
1.25B
15
STC2
2
0.85Gy
16
STC3
5
0.85Y
17
JRP1
-
1.25B
18
JOP4
-
0.85B
19
STC3
15
0.85L
20
JRP1
-
1.25B
21
STC2
38
0.85P
22
STC3
7
0.85L
23
JRP4
-
1.25B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
PL1 (Male)
D155A-6
AB4, AN7
O310
Device Name
Intermediate connector (P/L harness) (Cab less spec)
Type
DRC70A
Connector (pin) No.
Pin No.
Wire diameter/ Color
24
DSH(Female)
24
1.25G
25
DSH(Female)
25
1.25B
29
JGP2
-
1.25B
30
STC1
20
0.85Y
31
STC3
34
0.85P
36
STC3
36
0.85Sb
37
JRP4
-
0.85B
Number Pin of Pins No.
70
38
JOP4
-
0.85B
39
STC1
9
0.85O
40
JGP2
-
1.25B
42
JOP3
-
0.85B
43
STC2
35
0.85G
44
STC3
27
0.85L
45
JRP2
-
0.85B
46
JOP3
-
0.85B
47
STC3
37
0.85O
48
JRP2
-
0.85B
49
STC2
25
0.85Gy
50
STC3
39
0.85Br
51
STC3
26
0.85Y
52
JRP3
-
0.85B
53
JOP3
-
0.85B
54
STC3
8
0.85Br
55
STC2
30
0.85Br
56
STC2
29
0.85B
57
STC3
19
0.85L
58
STC3
6
0.85Br
59
JRP3
-
0.85B
60
JOP3
-
0.85B
61
STC3
16
0.85G
62
JRP3
-
0.85B
63
STC3
29
0.85P
64
JRP1
-
1.25B
65
STC3
40
0.85O
67
JOP1
-
0.85O
68
JPP1
-
1.25Br
69
FD1(Male)
3
1.25W
70
JOP1
-
1.25B
79
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
PL1 (Male)
80
AB4, AN7
N241
Device Name
Intermediate connector (P/L harness) (Cab spec)
Type
DRC70A
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
STC2
13
0.85O
2
STC3
25
0.85W
3
JRP1
-
0.85B
Number Pin of Pins No.
70
4
JOP4
-
0.85B
5
STC3
35
0.85Gy
6
JRP1
-
0.85B
7
STC2
3
0.85L
8
JCE6
-
0.85G
9
JRP5
-
0.85B
10
JCE7
-
0.85Y
11
JRP6
-
0.85B
15
STC2
2
0.85Gy
16
STC3
5
0.85Y
17
JRP1
-
0.85B
18
JOP4
-
0.85B
19
STC3
15
0.85L
20
JRP1
-
0.85B
21
STC2
38
0.85P
22
STC3
7
0.85L
23
JRP4
-
0.85B
24
DSH(Female)
24
0.85G
25
DSH(Female)
25
0.85B
29
JGP2
-
0.85B
30
STC1
20
0.85Y
31
STC3
34
0.85P
36
STC3
36
0.85Sb
37
JRP4
-
0.85B
38
JOP4
-
0.85B
39
STC1
9
0.85O
40
JGP2
-
0.85B
42
JOP3
-
0.85B
43
STC2
35
0.85G
44
STC3
27
0.85L
45
JRP2
-
0.85B
46
JOP3
-
0.85B
47
STC3
37
0.85O
48
JRP2
-
0.85B
49
STC2
25
0.85Gy
50
STC3
39
0.85Br
51
STC3
26
0.85Y
52
JRP3
-
0.85B
53
JOP3
-
0.85B
54
STC3
8
0.85Br
55
STC2
30
0.85Br
56
STC2
29
0.85B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
PL1 (Male)
PL1F (Female)
D155A-6
AB4, AN7
AB4, AN7
N241
I610
Device Name
Intermediate connector (P/L harness) (Cab spec)
Intermediate connector (Floor harness)
Type
DRC70A
DRC70A
Connector (pin) No.
Pin No.
Wire diameter/ Color
57
STC3
19
0.85L
58
STC3
6
0.85Br
59
JRP3
-
0.85B
Number Pin of Pins No.
70
70
60
JOP3
-
0.85B
61
STC3
16
0.85G
62
JRP3
-
0.85B
63
STC3
29
0.85P
64
JRP1
-
0.85B
65
STC3
40
0.85O
67
JOP1
-
0.85O
68
JPP1
-
1.25Br
69
FD1(Male)
3
1.25W
70
JOP1
-
1.25B
8
PL1M(Male)
8
1.25G
9
PL1M(Male)
9
1.25B
10
PL1M(Male)
10
1.25Y
11
PL1M(Male)
11
1.25B
65
PL1F(Female)
67
1.25B
67
PL1F(Female)
65
1.25B
68
JPT1
-
1.25Br
69
PNL(Male)
6
1.25O
70
JOT1
-
1.25B
81
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
PL1M (Male)
AB4, AN7
D610
PLSW
W9
N530
PLSW
W9
N530
PLSW (Female)
W9
M288
PLSW (Female)
W9
D265
PLSW (Male)
W9
N525
82
Device Name
Intermediate connector (P/L harness)
Type
DRC70A
70
Pin puller switch
DT
1
Pin puller switch
DT
1
Intermediate connector (Pin puller switch) (Cab less spec) Intermediate connector (Pin puller switch) (Cab spec) Intermediate connector (Floor harness)
Connector (pin) No.
Pin No.
Wire diameter/ Color
2
PNL(Male)
24
1.25W
3
PNL(Male)
22
1.25B
5
PNL(Male)
16
1.25W
6
PNL(Male)
14
1.25B
8
PL1F(Female)
8
1.25G
Number Pin of Pins No.
DT
2
DT
2
DT
2
9
PL1F(Female)
9
1.25B
10
PL1F(Female)
10
1.25Y
11
PL1F(Female)
11
1.25B
16
PNL(Male)
23
1.25L
17
PNL(Male)
21
1.25B
19
PNL(Male)
15
1.25W
20
PNL(Male)
13
1.25L
22
RPNL
2
1.25O
23
JOT2
-
1.25B
44
PNL(Male)
2
1.25W
45
JPT8
-
1.25B
47
PNL(Male)
3
1.25W
48
JPT8
-
1.25B
51
PNL(Male)
10
1.25W
52
JOT1
-
1.25B
54
JPT1
-
-
58
PNL(Male)
8
1.25W
59
JOT1
-
1.25B
61
PNL(Male)
9
1.25W
62
JOT1
-
1.25B
64
JOT2
-
-
-
PLSW(Male)
1
0.85L
-
PLSW(Male)
2
0.85L
1
FD1(Male)
17
0.85Y
2
FD1(Male)
18
0.85V
1
FD1(Male)
17
0.85Y
2
FD1(Male)
18
0.85V
1
PLSW
-
0.85L
2
PLSW
-
0.85L
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
PNL (Female)
D155A-6
-
M602
Device Name
Intermediate connector (Travel switch harness for emergency)
Type
24-31
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
JPT2
-
1.25R
2
F/R SW
1
1.25O
3
F/R SW
3
1.25P
4
JPT3
-
1.25V
5
JPT4
-
1.25L
6
F/R SW
12
1.25Gy
7
JPT5
-
1.25G
8
1STSW
1
1.25W
9
2NDSW
1
1.25Y
10
3RDSW
1
1.25Sb
11
R/T SW
2
1.25Br
12
R/T SW
5
1.25O
13
R/T SW
8
1.25P
14
R/T SW
11
1.25V
15
R/T SW
3
1.25L
16
R/T SW
4
1.25Gy
17
R/T SW
9
1.25G
18
R/T SW
10
1.25W
19
L/T SW
2
1.25Y
20
L/T SW
5
1.25Sb
21
L/T SW
8
1.25Br
22
L/T SW
11
1.25O
23
L/T SW
3
1.25P
24
L/T SW
4
1.25V
25
L/T SW
9
1.25L
26
L/T SW
10
1.25Gy
Number Pin of Pins No.
31
83
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
PNL (Male)
POIL
PPL PPL
PRT (Female)
PRT (Female)
84
-
AG2
M4 M4
E7
E7
F593
I353
I450 H428
M443
M420
Device Name
Intermediate connector (Common part for all)
Engine oil pressure sensor
Pin puller solenoid valve (Cab less spec) Pin puller solenoid valvev (Cab spec)
Intermediate connector (Radiator guard harness) (Cab less spec)
Intermediate connector (Radiator guard harness) (Cab spec)
Type
24-31
CANNON
DT DT
DT-A
DT-A
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
JPT1
-
1.25BR
2
PL1M(Male)
44
1.25W
3
PL1M(Male)
47
1.25W
Number Pin of Pins No.
31
4
2 2
12
12
5
JPT7
-
1.25W
6
PL1F(Female)
69
1.25O
7
JPT8
-
1.25B
8
PL1M(Male)
58
1.25W
9
PL1M(Male)
61
1.25W
10
PL1M(Male)
51
1.25W
11
JPT7
-
1.25W
12
JPT7
-
1.25W
13
PL1M(Male)
20
1.25L
14
PL1M(Male)
6
1.25B
15
PL1M(Male)
19
1.25W
16
PL1M(Male)
5
1.25W
17
JTP9
-
1.25W
18
JTP9
-
1.25W
19
JTP9
-
1.25W
20
JTP9
-
1.25W
21
PL1M(Male)
17
1.25B
22
PL1M(Male)
3
1.25B
23
PL1M(Male)
16
1.25L
24
PL1M(Male)
2
1.25W
25
JOT2
-
1.25B
26
JOT2
-
1.25B
1
JM01
2
0.85R
2
JM08
3
0.85B
3
EGC1
13
0.85G
1
FD1(Female)
18
1.25V
2
JOL1
-
1.25B
1
FD1(Female)
18
1.25V
2
JOL1
-
1.25B
1
JPLN
-
1.25L
2
JPLM
-
1.25G
3
FD1(Female)
16
1.25P
4
FD1(Female)
23
1.25Y
5
JOL3
-
1.25B
6
FD1(Female)
4
1.25W
7
FD1(Female)
5
1.25B
1
FD2(Male)
4
1.25L
2
FD2(Male)
3
1.25G
3
FD1(Female)
16
1.25P
4
FD1(Female)
23
1.25Y
5
FD1(Female)
24
1.25B
6
FD1(Female)
4
1.25W
7
FD1(Female)
5
1.25B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 1
PRT (Male)
PRT (Male)
PT1
PT1
PTF
PTF
PTH
R
R/T SW
D155A-6
E7
E7
D6
D6
-
-
-
-
-
D578
D589
O440
O419
M331
J227
-
L485
L597
Intermediate connector (Left fender harness)
Intermediate connector (Left fender harness) (Only for indonesia spec)
Pitch angle sensor (Cab less spec)
Pitch angle sensor (Cab spec)
Flash P/T controller (Cab less spec)
Flash P/T controller (Cab spec)
Pitch select solenoid
Joint
R Turn SW
DT-A
DT-A
DT
DT
X
X
DT
-
-
12
12
3
3
4
4
2
-
12
Connector (pin) No.
Pin No.
Wire diameter/ Color
LHD(Female)
1
1.25L
2
LHD(Female)
2
1.25G
3
RDG(Female)
3
1.25W
4
RDG(Female)
4
1.25Y
5
RDG(Female)
5
1.25B
6
RDG(Female)
6
1.25W
7
RDG(Female)
7
1.25B
8
RDG(Female)
8
1.25Br
9
RDG(Female)
9
1.25B
1
LHD(Female)
1
1.25L
2
LHD(Female)
2
1.25G
3
RDG(Female)
3
1.25W
4
RDG(Female)
4
1.25Y
5
WLV2
2
1.25B
6
RDG(Female)
6
1.25W
7
RDG(Female)
7
1.25B
8
RDG(Female)
8
1.25Br
9
RDG(Female)
9
1.25B
A
FD1(Female)
20
1.25B
B
FD1(Female)
21
1.25W
C
FD1(Female)
22
1.25P
A
FD1(Female)
20
1.25B
B
FD1(Female)
21
1.25W
C
FD1(Female)
22
1.25P
1
STC2
14
0.85P
2
STC2
4
0.85L
4
STC2
34
0.85B
1
STC2
14
0.85P
2
STC2
4
0.85L
4
STC2
34
0.85B
1
WEC3
28
0.85Y
2 -
JRW1
-
0.85B
FD3(Female)
3
1.25W
FSB(Female)
T
1.25W
PHR
5
1.25W
2
PNL(Female)
11
1.25Br
3
PNL(Female)
15
1.25L
4
PNL(Female)
16
1.25Gy
5
PNL(Female)
12
1.25O
8
PNL(Female)
13
1.25P
9
PNL(Female)
17
1.25G
10
PNL(Female)
18
1.25W
11
PNL(Female)
14
1.25V
85
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
RDG (Female)
RDG (Female)
RDG (Male)
REAR VIEW CAMERA
C5
C5
C5
-
D569
D581
M584
C540
Device Name
Intermediate connector (Horn,Coolant level,Fan reverse solenoid)
Intermediate connector (Horn, Fan reverse solenoid) (Only for indonesia spec)
Intermediate connector (Radiator guard harness)
Rear view camera
Type
DT-A
DT-A
DT-A
-
12
12
12
8
RES
AG7
K343
Service connector
DT
2
RHT
AC6
J559
Intake air heater (Ribbon heater)
Terminal
1
RLSW
RLSW
P4
P4
N392
N369
Rear lamp switch (Cab less spec)
Rear lamp switch (Cab spec)
SWP
SWP
6
6
RPNL
-
I607
Resistor
X
2
RSD
AB1
M320
Diode (Cab less spec)
DT
2
RSD
AB1
K233
Diode (Cab spec)
DT
2
86
Connector (pin) No.
Pin No.
Wire diameter/ Color
3
PRT(Male)
3
1.25W
4
PRT(Male)
4
1.25Y
5
PRT(Male)
5
1.25B
6
PRT(Male)
6
1.25W
7
PRT(Male)
7
1.25B
Number Pin of Pins No.
8
PRT(Male)
8
1.25Br
9
PRT(Male)
9
1.25B
3
PRT(Male)
3
1.25W
4
PRT(Male)
4
1.25Y
5
WLV2
1
1.25B
6
PRT(Male)
6
1.25W
7
PRT(Male)
7
1.25B
8
PRT(Male)
8
1.25Br
9
PRT(Male)
9
1.25B
3
HRN
-
1.25W
4
WLV
1
1.25Y
5
WLV
2
1.25B
6
FAR
1
1.25W
7
FAR
2
1.25B
1
CM05
1
L
2
CM05
2
W
3
CM05
3
Br
4
CM05
4
O
5
CM05
5
B
6
CM05
6
B
7
CM05
7
-
8
CM05
8
-
1
JM01
4
0.85R
2
JM05
2
0.85G
1
HT/B
B
20R
1
JPL8
-
1.25L
2
JGM3
-
1.25B
5
JPKA
-
1.25Br
6
JPL8
-
1.25L
1
JPL8
-
1.25L
2
JGM3
-
1.25B
5
JPKA
-
1.25Br
6
JPL8
-
1.25L
1
JPT1
-
1.25B
2
PL1M(Male)
22
1.25O
1
JPK3
-
0.85V
2
JPR2
-
0.85Gy
1
JPK3
-
0.85V
2
JPR2
-
0.85Gy
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing S1T S2T S3T SBRL SBRR SCLL SCLR SFT
SFTD
SFTU
SLS SRT
SRV
SRV
SSP ST
D155A-6
AI8 AJ7 AI8 AM7 AM7 AN6 AN7 AJ7
X1
Y1
P7 AI8
W9
W9
AK6 AC3
F517 E521 H519 H517 -
-
-
D365 -
J331
I266
M515 M462
Device Name
Type
Transmission 1st clutch ECMV (Solenoid)
DT
Transmission 2nd clutch ECMV (Solenoid) Transmission 3rd clutch ECMV (Solenoid) Left brake ECMV (Solenoid) Right brake ECMV (Solenoid) Left steering clutch ECMV (Solenoid) Right steering clutch ECMV (Solenoid) Transmission F clutch ECMV (Solenoid)
Shift-down switch
Shift-up switch
Daylight sensor Transmission R clutch ECMV (Solenoid)
Service connector (for CAN communication) (Cab less spec)
Service connector (for CAN communication) (Cab spec)
Sudden stop prevent valve Starting motor (Terminal R, S)
DT DT DT DT DT DT DT
-
-
050 DT
DT-A
DT-A
DT DT
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
TMV(Male)
J
-
2
TMV(Male)
K
-
1
TMV(Male)
G
-
2
TMV(Male)
H
-
1
TMV(Male)
E
-
Number Pin of Pins No.
2 2 2 2 2 2 2 2
3
3
2 2
12
12
2 2
2
TMV(Male)
F
-
1
PL1(Female)
16
1.25Y
2
PL1(Female)
17
1.25B
1
PL1(Female)
19
1.25L
2
PL1(Female)
20
1.25B
1
PL1(Female)
2
1.25W
2
PL1(Female)
3
1.25B
1
PL1(Female)
5
1.25Gr
2
PL1(Female)
6
1.25B
1
TMV(Male)
C
-
2
TMV(Male)
D
-
1
TLV2(Male)
4
0.5G
2
TLV2(Male)
5
0.5B
3
TLV2(Male)
6
0.5Br
1
TLV2(Male)
1
0.5L
2
TLV2(Male)
2
0.5B
3
TLV2(Male)
3
0.5Y
1
DSH(Male)
43
0.85O
2
DSH(Male)
44
0.85L
1
TMV(Male)
A
-
2
TMV(Male)
B
-
1
JUF2
-
1.25R
2
JPKC
-
0.85Br
3
JNH
-
0.75W
6
JNH3
-
0.85V
9
GND11
-
0.85B
10
JNL
-
0.75B
11
JNXC
-
0.85B
12
GND11
-
1.25B
1
JUF2
-
1.25R
2
JPKC
-
0.85Br
3
JNH
-
0.75W
6
JNH3
-
0.85V
9
GND11
-
0.85B
10
JNL
-
0.75B
11
JNXC
-
0.85B
12
GND11
-
1.25B
1
PL1(Female)
22
1.25L
2
PL1(Female)
23
1.25B
1
E22(Male)
1
1.25L
2
JPR1
-
Gy
87
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing ST/B
AD7
-
ST/B
AD7
N559
STC1
88
Z1
B295
Device Name
Type
Starting motor (Terminal B) Terminal (Alternator) Starting motor (Terminal B) Terminal (Battery relay)
Power train controller (Cab less spec)
DRC2624
Number Pin of Pins No.
Connector (pin) No.
Pin No.
Wire diameter/ Color
1
B1
AL
B
40W
1
B2
BRC
-
100R
1
DIAL
B
0.85V
2
TLV1
7
0.85Y
3
DSH(Female)
62
0.85W
4
JGP3
-
0.85B
24
5
JS19
-
0.85Y
7
TLV1
2
0.85Br
8
FD1(Male)
21
0.85W
9
PL1(Male)
39
0.85O
10
WELK
A
0.85B
11
DSH(Female)
58
0.85W
12
TLV2
3
0.85Y
13
TLV1
3
0.85W
15
JPR2
-
0.85Gy
16
FD1(Male)
22
0.85P
17
JS15
-
0.85G
18
TLV2
4
0.85G
19
TLV1
6
0.85Br
20
PL1(Male)
30
0.85Y
21
JGP1
-
0.85B
22
JJP1
-
0.85P
23
PKSW
B
0.85W
24
TLV2
6
0.85Br
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 1
STC1
STC2
D155A-6
Z1
Z1
B226
B299
Power train controller (Cab spec)
Power train controller (Cab less spec)
DRC2624
DRC2640A
24
40
Connector (pin) No.
Pin No.
Wire diameter/ Color
DIAL
2
0.85V
2
TLV1
7
0.85Y
3
DSH(Female)
62
0.85W
4
JGP3
-
0.85B
5
JS19
-
0.85Y
7
TLV1
2
0.85Br
8
FD1(Male)
21
0.85W
9
PL1(Male)
39
0.85O
10
WELK
A
0.85B
11
DSH(Female)
58
0.85W
12
TLV2
3
0.85Y
13
TLV1
3
0.85W
15
JPR2
-
0.85Gy
16
FD1(Male)
22
0.85P
17
JS15
-
0.85G
18
TLV2
4
0.85G
19
TLV1
6
0.85Br
20
PL1(Male)
30
0.85Y
21
JGP1
-
0.85B
22
JJP1
-
0.85P
23
PKSW
B
0.85W
24
TLV2
6
0.85Br
2
PL1(Male)
15
0.85Gy
3
PL1(Male)
7
0.85L
4
PTF
2
0.85L
5
WELK
B
0.85Gy
7
DSH(Female)
13
0.85L
8
FSB(Male)
N
1.25P
9
FSB(Male)
X
0.85Gy
12
JNX8
-
0.85B
13
PL1(Male)
1
0.85O
14
PTF
1
0.85P
15
WELK
C
0.85O
17
ESD
A
0.85G
18
FD1(Male)
28
0.85O
19
FSB(Male)
W
0.85V
22
JNL
-
0.75B
24
JNH3
-
0.85V
25
PL1(Male)
49
0.85Gy
27
ESD
C
0.85P
29
PL1(Male)
56
0.85B
30
PL1(Male)
55
0.85Br
32
JNH
-
0.75W
34
PTF
4
0.85B
35
PL1(Male)
43
0.85G
38
PL1(Male)
21
0.85P
89
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
STC2
90
Z1
B230
Device Name
Power train controller (Cab spec)
Type
DRC2640A
Connector (pin) No.
Pin No.
Wire diameter/ Color
2
PL1(Male)
15
0.85Gy
3
PL1(Male)
7
0.85L
4
PTF
2
0.85L
Number Pin of Pins No.
40
5
WELK
B
0.85Gy
7
DSH(Female)
13
0.85L
8
FSB(Male)
N
1.25P
9
FSB(Male)
X
0.85Gy
12
JNX8
-
0.85B
13
PL1(Male)
1
0.85O
14
PTF
1
0.85P
15
WELK
C
0.85O
17
ESD
A
0.85G
18
FD1(Male)
28
0.85O
19
FSB(Male)
W
0.85V
22
JNL
-
0.75B
24
JNH3
-
0.85V
25
PL1(Male)
49
0.85Gy
27
ESD
C
0.85P
29
PL1(Male)
56
0.85B
30
PL1(Male)
55
0.85Br
32
JNH
-
0.75W
34
PTF
4
0.85B
35
PL1(Male)
43
0.85G
38
PL1(Male)
21
0.85P
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Connector (pin) No.
Pin No.
Wire diameter/ Color
JUP1
-
0.85R
2
JPP1
-
0.85Br
3
JRP1
-
0.85B
Number Pin of Pins No. 1
STC3
D155A-6
AA1
B303
Power train controller (Cab less spec)
DRC2640B
40
4
JPK3
-
0.85V
5
PL1(Male)
16
0.85Y
6
PL1(Male)
58
0.85Br
7
PL1(Male)
22
0.85L
8
PL1(Male)
54
0.85Br
9
TLV2
1
0.85L
10
JOP1
-
0.85B
11
JUP1
-
0.85R
12
JPP1
-
0.85Br
13
JRP2
-
0.85B
14
JPKE
-
0.85Br
15
PL1(Male)
19
0.85L
16
PL1(Male)
61
0.85G
17
CBR
1
0.85Y
18
FD1(Male)
4
0.85W
19
PL1(Male)
57
0.85L
21
JOP2
-
0.85B
22
JPP1
-
0.85Br
23
JRP3
-
0.85B
24
JPKE
-
0.85Br
25
PL1(Male)
2
0.85W
26
PL1(Male)
51
0.85Y
27
PL1(Male)
44
0.85L
29
PL1(Male)
63
0.85P
31
JOP2
-
0.85B
32
JOP2
-
0.85B
33
JOP2
-
0.85B
34
PL1(Male)
31
0.85P
35
PL1(Male)
5
0.85Gy
36
PL1(Male)
36
0.85Sb
37
PL1(Male)
47
0.85O
39
PL1(Male)
50
0.85Br
40
PL1(Male)
65
0.85O
91
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Connector (pin) No.
Pin No.
Wire diameter/ Color
JUP1
-
0.85R
2
JPP1
-
0.85Br
3
JRP1
-
0.85B
Number Pin of Pins No. 1
STC3
AA1
B234
SW
N1
K439
SW
N1
J419
TCT
AM2
N505
TFUEL
AH7
N344
92
Power train controller (Cab spec)
Battery relay (Coil signal terminal) (Cab less spec) Battery relay (Coil signal terminal) (Cab spec)
DRC2640B
40
4
JPK3
-
0.85V
5
PL1(Male)
16
0.85Y
6
PL1(Male)
58
0.85Br
7
PL1(Male)
22
0.85L
8
PL1(Male)
54
0.85Br
9
TLV2
1
0.85L
10
JOP1
-
0.85B
11
JUP1
-
0.85R
12
JPP1
-
0.85Br
13
JRP2
-
0.85B
14
JPKE
-
0.85Br
15
PL1(Male)
19
0.85L
16
PL1(Male)
61
0.85G
18
FD1(Male)
4
0.85W
19
PL1(Male)
57
0.85L
21
JOP2
-
0.85B
22
JPP1
-
0.85Br
23
JRP3
-
0.85B
24
JPKE
-
0.85Br
25
PL1(Male)
2
0.85W
26
PL1(Male)
51
0.85Y
27
PL1(Male)
44
0.85L
29
PL1(Male)
63
0.85P
30
DTS(Female)
9
0.85B
31
JOP2
-
0.85B
32
JOP2
-
0.85B
33
JOP2
-
0.85B
34
PL1(Male)
31
0.85P
35
PL1(Male)
5
0.85Gy
36
PL1(Male)
36
0.85Sb
37
PL1(Male)
47
0.85O
39
PL1(Male)
50
0.85Br
40
PL1(Male)
65
0.85O
Terminal
1
-
FD1(Female)
27
1.25V
Terminal
1
-
FD1(Female)
27
1.25V
Torque converter oil temperature sensor
DT
2
1
PL1(Female)
39
1.25O
2
PL1(Female)
40
1.25B
Fuel temperature sensor
PACKARD
2
1
EGC1
30
0.85R
2
JM02
5
0.85B
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing TIM
TLV1
TLV1
TLV2 (Female)
TLV2 (Female)
TLV2 (Male)
D155A-6
AH6
Y1
Y1
Y1
Y1
Y1
O345
M270
N218
J270
N215
-
Device Name
Type
Charge temperature sensor
PACKARD
Steering/directional/ gearshift lever (Potentiometer) (Cab less spec)
Steering/directional/ gearshift lever (Potentiometer) (Cab spec)
Steering/directional/ gearshift lever (Shift switch) (Cab less spec)
Steering/directional/ gearshift lever (Shift switch) (Cab spec)
Intermediate connector (Floor harness)
DT-B
DT-B
DT
DT
DT
Number Pin of Pins No.
2
8
8
6
6
6
1
Connector (pin) No.
Pin No.
Wire diameter/ Color
EGC1
23
0.85R
2
JM02
4
0.85B
1
JGP1
-
0.85B
2
STC1
7
0.85Br
3
STC1
13
0.85W
4
JJP1
-
0.85P
5
JJP1
-
0.85P
6
STC1
19
0.85Br
7
STC1
2
0.85Y
8
JGP1
-
0.85B
1
JGP1
-
0.85B
2
STC1
7
0.85Br
3
STC1
13
0.85W
4
JJP1
-
0.85P
5
JJP1
-
0.85P
6
STC1
19
0.85Br
7
STC1
2
0.85Y
8
JGP1
-
0.85B
1
STC3
9
0.85L
2
JGP3
-
0.85B
3
STC1
12
0.85Y
4
STC1
18
0.85G
5
JGP3
-
0.85B
6
STC1
24
0.85Br
1
STC3
9
0.85L
2
JGP3
-
0.85B
3
STC1
12
0.85Y
4
STC1
18
0.85G
5
JGP3
-
0.85B
6
STC1
24
0.85Br
1
SFTU
1
0.5L
2
SFTU
2
0.5B
3
SFTU
3
0.5Y
4
SFTD
1
0.5G
5
SFTD
2
0.5B
6
SFTD
3
0.5Br
93
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. A
TMV (Female)
TMV (Male)
TWTR
W
WEC1
94
AN3
AN3
AF8
-
-
O514
-
O349
L485
-
Intermediate connector (Awazu plant assembly tm clutch ecmv)
Intermediate connector (P/L harness)
Engine coolant temperature sensor
Joint
Work equipment controller
24-23
24-23
PACKARD
-
DRC2624
23
23
2
-
24
Connector (pin) No.
Pin No.
Wire diameter/ Color
PL1(Female)
47
1.25O
B
PL1(Female)
48
1.25B
C
PL1(Female)
44
1.25L
D
PL1(Female)
45
1.25B
E
PL1(Female)
51
1.25Y
F
PL1(Female)
52
1.25B
G
PL1(Female)
61
1.25G
H
PL1(Female)
62
1.25B
J
PL1(Female)
58
1.25Br
K
PL1(Female)
59
1.25B
L
PL1(Female)
49
1.25Gr
M
PL1(Female)
43
1.25G
N
PL1(Female)
50
1.25Br
O
PL1(Female)
63
1.25P
P
PL1(Female)
57
1.25L
A
SRT
1
-
B
SRT
2
-
C
SFT
1
-
D
SFT
2
-
E
S3T
1
-
F
S3T
2
-
G
S2T
1
-
H
S2T
2
-
J
S1T
1
-
K
S1T
2
-
L
FRT
1
-
M
FFT
1
-
N
F3T
1
-
O
F2T
1
-
P
F1T
1
-
1
EGC1
15
0.85R
JM03
3
0.85B
AUX0
-
2L
2 -
CB9
2
2L
FSB(Female)
M
2L
4
JGW3
-
0.85B
15
DTS(Male)
10
0.85Gy
D155A-6
90 Diagrams and drawings
SEN02874-04
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
WEC2
WEC3
WEF
WELK
WELK
WLK WLV WLV2
WSH
D155A-6
-
-
-
W9
W9
AJ6 C2 C2
X9
-
-
-
L289
M265
C504 O577 C582
K259
Device Name
Work equipment controller
Work equipment controller
Flash W/E controller
Work equipment lock lever switch (Cab less spec)
Work equipment lock lever switch (Cab spec) Work equipment lock solenoid valve Radiator coolant level sensor Radiator coolant level sensor
Intermediate connector
Type
DRC2640A
DRC2640B
X
DT
DT
DT DT DT
DT
Connector (pin) No.
Pin No.
Wire diameter/ Color
4
WEF
2
0.85L
6
BNSW(Female)
5
0.85Br
12
JNXA
-
0.85B
Number Pin of Pins No.
40
40
4
3
3
2 2 2
4
14
WEF
1
0.85P
16
BNSW(Female)
2
0.85G
22
DTS(Male)
7
0.75B
24
DTS(Male)
5
0.85V
26
BNSW(Female)
6
0.85Y
32
DTS(Male)
6
0.75W
34
WEF
4
0.85B
36
BNSW(Female)
4
0.85L
1
JUW1
-
0.85R
2
JPW1
-
0.85O
3
JRW1
-
0.85B
11
JUW1
-
0.85L
12
JPW1
-
0.85O
14
JPKF
-
0.85Br
20
JOW2
-
0.85B
21
JOW1
-
0.85B
22
JPW1
-
0.85O
24
JPKF
-
0.85Br
28
PTH
1
0.85Y
31
JOW1
-
0.85B
32
JOW1
-
0.85B
33
JOW1
-
0.85B
38
DUL
1
0.85O
40
JOW2
-
0.85O
1
WEC2
14
0.85P
2
WEC2
4
0.85L
4
WEC2
34
0.85B
A
STC1
10
0.85B
B
STC2
5
0.85Gy
C
STC2
15
0.85O
A
STC1
10
0.85B
B
STC2
5
0.85Gy
C
STC2
15
0.85O
1
PL1(Female)
54
1.25Br
2
PL1(Female)
64
1.25B
1
RDG(Male)
4
1.25Y
2
RDG(Male)
5
1.25B
1
RDG(Female)
5
1.25B
2
PRT(Male)
5
1.25B
1
FD4(Female)
6
0.85W
2
FD4(Female)
7
0.85V
3
FD4(Female)
8
0.85L
4
FD4(Female)
9
0.85G
95
SEN02874-04
90 Diagrams and drawings
Connector (To)
Connector (From) Address Connector Connectors Harness (pin) No. Arrangement Drawing drawing
Device Name
Type
Number Pin of Pins No. 1
WSH1
WSH2
96
J2
I1
F408
C409
Window washer tank (Front, left)
Window washer tank (Rear, right)
DT
DT
6
6
Connector (pin) No.
Pin No.
Wire diameter/ Color
FD4(Male)
8
1.25L
2
GND06
-
1.25B
3
FD4(Male)
6
1.25W
4
GND06
-
1.25B
1
FD4(Male)
9
1.25G
2
GND06
-
1.25B
3
FD4(Male)
7
1.25V
4
GND06
-
1.25B
D155A-6
Connectors table and arrangement drawing D155A-6
Connectors table and arrangement drawing D155A-6 Address
Connector No.
Type of connector
Number of pin
Starting switch (Terminal B)
R-9
GND03
Terminal
6
Ground (ROPS)
M-5
Starting switch (Terminal R1)
R-8
GND06
Terminal
4
Ground (Fender)
J-1
1
Starting switch (Terminal R2)
R-8
GND07
Terminal
1
Ground (Bulkhead)
G-1
1
Starting switch (Terminal BR)
R-8
GND08
Terminal
4
Ground (Guard) [Additional headlamp specification]
—
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
Connector No.
Type of connector
Number of pin
250
Terminal
1
255
Terminal
1
256
Terminal
260
Terminal
270
Location
Location
Address
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 M-7
BVRV
DT
2
Transmission bevel speed sensor
AK-6
LREL
DT
2
Left rear lamp
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 Z-9
DTS
DT
12
Intermediate connector (used when work equipment controller is installed)
E22
DT
6
Intermediate connector
AG-2
EFP
DT
2
Electric air bleeding pump
AF-2
EG1
DTP
2
Intermediate connector
H-1, AH-5
EG2
DT-B
12
Intermediate connector
H-1, AH-5
EGC1
DRC-60
60
Engine controller
AH-4
EGC2
DRC-50
50
Engine controller
AH-4
EGC3
DTP
4
Engine controller
AG-3
EGPW
DTP
2
Intermediate connector
L-3
EHL
Relay
5
Engine hold relay
D-9
EPP
DT
6
Electric air bleeding pump switch
F-7
ESD
DT
3
Service connector (for engine option)
Z-9
F105
DTHD
1
Intermediate connector
K-2
F1T
DT
2
Transmission 1st clutch ECMV (Fill switch)
AJ-9
F2T
DT
2
Transmission 2nd clutch ECMV (Fill switch)
AJ-7
F3T
DT
2
Transmission 3rd clutch ECMV (Fill switch)
AI-8
F30
DTHD
1
Intermediate connector
L-3
FAC
DT
2
Fan pump control valve
AI-3
FAR
DT
2
Fan reverse solenoid valve
C-1
FBRL
DT
2
Left brake ECMV (Fill switch)
AL-7
FBRR
DT
2
Right brake ECMV (Fill switch)
AM-7
FCLL
DT
2
Left steering clutch ECMV (Fill switch)
AN-6
FCLR
DT
2
Right steering clutch ECMV (Fill switch)
AN-7
FD1
24-31
31
Intermediate connector
K-2, AB-4
FD2
DT-C
12
Intermediate connector
L-3
FD3
DT
6
Intermediate connector
M-3
FD4
24-31
31
Intermediate connector
J-2, AB-3
FFT
DT
2
Transmission F clutch ECMV (Fill switch)
AK-9
FLSW
SWP
6
Headlamp switch
P-5
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
FSB
24-21
21
Intermediate connector
FTK
DT
6
Intermediate connector
M-7
G
SUMITOMO
3
Engine Bkup speed sensor
AD-2
GND
Terminal
1
Ground (ROPS)
M-3
S3T
DT
2
Transmission 3rd clutch ECMV (Solenoid)
AI-8
SBRL
DT
2
Left brake ECMV (Solenoid)
AM-7
SBRR
DT
2
Right brake ECMV (Solenoid)
AM-7
SCLL
DT
2
Left steering clutch ECMV (Solenoid)
AN-6
SCLR
DT
2
Right steering clutch ECMV (Solenoid)
AN-7
SFT
DT
2
Transmission F clutch ECMV (Solenoid)
AJ-7
SFTD
—
3
Shift-down switch
X-1
SFTU
—
3
Shift-up switch
Y-1
SLS
050
2
Daylight sensor
P-7
SRT
DT
2
Transmission R clutch ECMV (Solenoid)
AI-8
SRV
DT-A
12
Service connector (for CAN communication)
W-9
SSP
DT
2
Sudden stop prevent valve
AK-6
ST
DT
2
Starting motor (Terminal R, S)
AC-3
ST/B
Terminal
1
Starting motor (Terminal B)
AD-7
STC1
DRC26-24
24
Power train controller
Z-1
STC2
DRC26-40A
40
Power train controller
Z-1
STC3
DRC26-40B
40
Power train controller
AA-1
SW
Terminal
1
Battery relay (Coil signal terminal)
N-1
TCT
DT
2
Torque converter oil temperature sensor
AM-2
TFUEL
PACKARD
2
Fuel temperature sensor
AH-7
TIM
PACKARD
2
Charge temperature sensor
AH-6
TLV1
DT-B
8
Steering/directional/gearshift lever (Potentiometer)
Y-1
TLV2
DT
6
Steering/directional/gearshift lever (Shift switch)
Y-1
TMV
24-23
23
Intermediate connector
AN-3
TWTR
PACKARD
2
Engine coolant temperature sensor
AF-8
WELK
DT
3
Work equipment lock lever switch
W-9
WLK
DT
2
Work equipment lock solenoid valve
AJ-6
WLV
DT
2
Radiator coolant level sensor
C-2
WSH
DT
4
Intermediate connector
X-9
WSH1
DT
6
Window washer tank (Front, left)
J-2
WSH2
DT
6
Window washer tank (Rear, right)
I-1
A-7 B-9, AB-4
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)
B
D
(TO 8/19) 䝎䝑䝅䝳䝪䞊䝗䝝䞊䝛䝇䜈 TO DASH BOARD HARNESS
CN-DSH_F (DRC16-70SAE-P066)
E
F
G
15
29
43
57
FD1_M-23 0.85Y .
JPK1 1.25Br .
AC01_F-8 0.85O .
FSB_M-C 1.25R .
JPK2 0.85G .
FD4_F-15 0.85Gy .
JPK4 1.25W .
AC01_F-6 0.85L .
STC1-11 0.85W .
JPK1 0.85Br .
JGM5 0.85B .
JPK2 1.25G .
FD1_M-30 1.25V .
JS19 0.85Y .
JUF2 1.25R .
. GRO .
JPK3 1.25V .
FD1_M-31 1.25L .
. GRO .
JUF2 1.25R .
JPK4 0.85W .
FSB_M-S 1.25R .
JGM4 0.85B .
JGP1 0.85B .
GND11 1.25B .
JGM4 0.85B .
FSB_M-U 1.25L .
. GRO .
STC1-3 0.85W .
GND11 1.25B .
. GRO .
. GRO .
JPK1 0.85Br .
JJP1 0.85P .
CK01-1 0.85Y .
FD1_M-6 0.85L .
CK01-8 0.85B .
. GRO .
FD1_M-13 0.85P .
CK01-7 0.85B .
FD1_M-7 0.85B .
CK01-9 0.85G .
CK02-1 0.85V .
FD1_M-11 0.85Y .
JNH 0.75W .
PL1_M-24 0.85G .
CK01-10 0.85Y .
CK02-2 0.85Br .
FD1_M-12 0.85B .
JNL 0.75B .
PL1_M-25 0.85B .
CK01-11 0.85V .
CK02-3 0.85G .
CK02-7 0.85Br .
JNX5 0.85B .
. GRO .
CK01-12 0.85O .
CK02-4 0.85W .
CK02-8 0.85Gy .
STC2-7 0.85L .
. GRO .
CK01-13 0.85L .
CK02-5 0.85L .
CK02-9 0.85Y .
JNH3 0.85V .
. GRO .
. GRO .
CK02-6 0.85O .
CK01-4 0.85P .
14
28
42
56
70
JPK1,JPK2 JGM4,JPK4
28
C
1 JPR2 0.85Gy .
䈜 JNX5
H
I JGP3
J
K
JGP3
STC1-4 0.85B .
JGM4
JGM5 DSH_F-20 DSH_F-47 0.85B 0.85B 0.85B . . .
JPK1
DSH_F-29 DSH_F-49 JPKC 1.25Br 0.85Br 1.25Br . . .
JPK2
FSB_M-P DSH_F-31 DSH_F-2 1.25G 1.25G 0.85G . . .
JPK4
FSB_M-T DSH_F-19 DSH_F-30 1.25W 0.85W 1.25W . . .
䈜 JNX5
L
TLV2_F-5 0.85B .
TLV2_F-2 0.85B .
DSH_F-3 0.85Br .
JNG1 DSH_F-12 BRAID 0.85B . .
4
M
1
3
N
STC3-9 0.85L .
STC1-24 0.85Br .
JGP3 0.85B .
JGP3 0.85B .
STC1-12 0.85Y .
STC1-18 0.85G .
6
STC1-13 0.85W .
STC1-7 0.85Br .
JGP1 0.85B .
JJP1 0.85P .
STC1-19 0.85Br .
STC1-2 0.85Y .
JGP1 0.85B .
5
4
3
JGP1 0.85B .
1
STC1-1 0.85V .
2
JJP1 0.85P .
8
CN-TLV1 (DT-B) ㉮⾜䝺䝞䞊䜈
CN-TLV2_F (DT) 䝅䝣䝖SW䜈
(TO 2/19)
1
JJP1 0.85P .
DIAL (M) ⇞ᩱ䝎䜲䜰䝹䜈
TO TRAVEL LEVER
TO FUEL DIAL
TO SIFT SW
O
P
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
P/T䝁䞁䝖䝻䞊䝷䜈
(FROM 1/19)
CN-STC2
CN-STC1
B
CN-STC3
19
TLV1-6 0.85Br .
PL1_M-30 0.85Y .
JGP1 0.85B .
JJP1 0.85P .
PKSW-B 0.85W .
TLV2_F-6 0.85Br .
13
TLV1-3 0.85W .
. GRO .
JPR2 0.85Gy .
FD1_M-22 0.85P .
JS15 0.85G .
TLV2_F-4 0.85G .
7
TLV1-2 0.85Br .
FD1_M-21 0.85W .
PL1_M-39 0.85O .
WELK-A 0.85B .
DSH_F-58 0.85W .
TLV2_F-3 0.85Y .
1
DIAL-2 0.85V .
TLV1-7 0.85Y .
DSH_F-62 0.85W .
JGP3 0.85B .
JS19 0.85Y .
. GRO .
31
. GRO .
JNH 0.75W .
. GRO .
PTF-4 0.85B .
PL1_M-43 0.85G .
. GRO .
. GRO .
PL1_M-21 0.85P .
. GRO .
. GRO .
18
21
. GRO .
JNL 0.75B .
. GRO .
JNH3 0.85V .
PL1_M-49 0.85Gy .
. GRO .
ESD-C 0.85P .
. GRO .
PL1_M-56 0.85B .
PL1_M-55 0.85Br .
12
11
. GRO .
JNX8 0.85B .
PL1_M-1 0.85O .
PTF-1 0.85P .
WELK-C 0.85O .
. GRO .
ESD-A 0.85G .
FD1_M-28 0.85O .
FSB_M-W 0.85V .
6
1
. GRO .
PL1_M-15 0.85Gy .
PL1_M-7 0.85L .
PTF-2 0.85L .
WELK-B 0.85Gy .
. GRO .
DSH_F-13 0.85L .
FSB_M-N 1.25P .
FSB_M-X 0.85Gy .
24
C
10
JOP1 0.85B .
TLV2_F-1 0.85L .
PL1_M-54 0.85Br .
PL1_M-22 0.85L .
PL1_M-58 0.85Br .
PL1_M-16 0.85Y .
JPK3 0.85V .
JRP1 0.85B .
JPP1 0.85Br .
JUP1 0.85R .
1
30
20
. GRO .
PL1_M-57 0.85L .
FD1_M-4 0.85W .
. GRO .
PL1_M-61 0.85G .
PL1_M-19 0.85L .
JPKE 0.85Br .
JRP2 0.85B .
JPP1 0.85Br .
JUP1 0.85R .
11
. GRO .
20
30
DTS_F-9 0.85B .
PL1_M-63 0.85P .
. GRO .
PL1_M-44 0.85L .
PL1_M-51 0.85Y .
PL1_M-2 0.85W .
JPKE 0.85Br .
JRP3 0.85B .
JPP1 0.85Br .
JOP2 0.85B .
21
䝎䜲䜸䞊䝗
. GRO .
10
40
PL1_M-65 0.85O .
PL1_M-50 0.85Br .
. GRO .
PL1_M-47 0.85O .
PL1_M-36 0.85Sb .
PL1_M-5 0.85Gy .
PL1_M-31 0.85P .
JOP2 0.85B .
JOP2 0.85B .
JOP2 0.85B .
31
CN-PKD (DT)
40
DIODE
JJP1,JPR2 JGP1,JGP2
JCE6
PL1_M-8 0.85G .
PKD-1 0.85G .
JS15 0.85G .
JCE7
PL1_M-10 0.85Y .
PBD-1 0.85Y .
JS19 0.85Y .
JGP1
TLV1-8 0.85B .
DSH_F-61 STC1-21 TLV1-1 0.85B 0.85B 0.85B . . .
JGP2
JGP1 0.85B .
FD1_M-20 PL1_M-29 PL1_M-40 0.85B 0.85B 0.85B . . .
JGM5
FD1_M-14 FD1_M-24 FD4_F-16 1.25B 0.85B 0.85B . . .
1
JRP4,JPKE
D
2 JCE6 0.85G .
1
JRP5 0.85B .
JGM4 0.85B .
JJP1
TLV1-4 0.85P .
STC1-22 0.85P .
TLV1-5 0.85P .
DSH_F-63 0.85P .
DIAL-1 0.85P .
1
JNG1
JNX8 BRAID .
JNXG BRAID .
JNG2 0.85B .
GND12 2B .
JNX5 BRAID .
JNG2
JNXC BRAID .
JNG1 0.85B .
JNXE BRAID .
2
1
JNH3
DSH_F-14 STC2-24 0.85V 0.85V . .
SRV-6 0.85V .
DTS_F-5 0.85V .
JNH
STC2-32 DSH_F-10 0.75W 0.75W . .
FD1_M-8 0.75W .
AC02_F-1 0.75W .
SRV-3 0.75W .
DTS_F-6 0.75W .
JNL
AC02_F-2 DSH_F-11 FD1_M-9 STC2-22 0.75B 0.75B 0.75B 0.75B . . . .
SRV-10 0.75B .
DTS_F-7 0.75B .
JOL2
OPPW-2 FD1_M-19 FD1_M-29 2B 1.25B 1.25B . . .
2 JCE7 0.85Y .
JRP6 0.85B .
2
䈜 JNX8
E
DIAL-3 0.85B .
CN-PBD (DT)
JRP1,JRP2,JRP3
JS15,JS19
DSH_F-17 0.85B .
JGP2 0.85B .
JOP1,JOP2 JPKC,JPP1 JUF2,JUP1
JNX6 BRAID .
JOP2 1.25B .
JOP1
PL1_M-67 PL1_M-70 STC3-10 0.85O 1.25B 0.85B . . .
JOP2
STC3-21 0.85B .
JOP1 1.25B .
GND11 STC3-31 STC3-32 2B 0.85B 0.85B . . .
JOP3
JOP4 1.25B .
PL1_M-60 0.85B .
PL1_M-42 0.85B .
PL1_M-46 0.85B .
PL1_M-53 0.85B .
JOP4
PL1_M-18 0.85B .
GND12 PL1_M-4 0.85B 0.85B . .
JOP3 1.25B .
PL1_M-38 0.85B .
JPAA
AC02_F-4 FSB_M-L AC03-4 0.85G 2G 2G . . .
AC04-4 1.25G .
JPAC
AC03-1 AC01_F-4 0.85P 0.85P . .
AC04-1 0.85P .
ACD1-1 0.85P .
JPAE
ACD1-2 AC01_F-1 AC03-3 0.85V 0.85V 0.85V . . .
JPAF
ACD2-2 AC01_F-2 AC04-3 0.85Br 0.85Br 0.85Br . . .
JPK3
STC3-4 DSH_F-32 FD1_M-27 0.85V 1.25V 1.25V . . .
JPKC
JPK1 1.25Br .
SRV-2 0.85Br .
JPKE
JPKC 0.85Br .
STC3-14 STC3-24 0.85Br 0.85Br . .
JPP1
STC3-12 PL1_M-68 STC3-2 0.85Br 1.25Br 0.85Br . . .
STC3-22 FSB_M-H 0.85Br 2Br . .
JPR2
STC1-15 DSH_F-1 RSD-2 0.85Gy 0.85Gy 0.85Gy . . .
FD1_M-2 DTS_F-10 1.25Gy 0.85Gy . .
STC3-33 0.85B .
ACD2-1 0.85P .
RSD-1 0.85V .
DTS_F-3 FSB_M-R JPKE 0.85Br 1.25Br 0.85Br . . .
JNG1,JNG2,JNH3 JNH,JNL
F
(TO 3/19) G
H
I
JRP1
PL1_M-6 PL1_M-20 PL1_M-17 PL1_M-3 0.85B 0.85B 0.85B 0.85B . . . .
JRP2
PL1_M-48 PL1_M-45 FD1_M-5 STC3-13 0.85B 0.85B 0.85B 0.85B . . . .
JRP3
PL1_M-59 0.85B .
JRP4 0.85B .
PL1_M-62 PL1_M-52 0.85B 0.85B . .
STC3-23 0.85B .
JRP4
PL1_M-23 0.85B .
JRP6 0.85B .
PL1_M-37 0.85B .
JRP5 0.85B .
JRP3 0.85B .
PL1_M-9 0.85B .
PKD-2 0.85B .
JRP4 0.85B .
JRP5
J
K
JRP6
PL1_M-11 0.85B .
PBD-2 0.85B .
JRP4 0.85B .
JS15
PKSW-C STC1-17 0.85G 0.85G . .
JCE6 0.85G .
JS19
DSH_F-59 0.85Y .
STC1-5 0.85Y .
JUF2
DSH_F-5 DSH_F-4 FSB_M-K 1.25R 1.25R 2R . . .
JUP1 䈜 JNX6 䈜 JNX8
JUF2 2R .
JCE7 0.85Y .
JUP1 2R .
PL1_M-64 0.85B .
SRV-1 1.25R .
STC3-3 0.85B .
CN-AC04 䝁䞁䝥䝺䝑䝃䝸䝺䞊䜈 TO COMPRESSOR RELAY
4
STC2-34 0.85B .
. GRO .
3
2
STC2-4 0.85L .
STC2-14 0.85P .
1
2
. GRO .
. GRO .
4
. GRO .
. GRO .
STC3-11 STC3-1 0.85R 0.85R . .
CN-AC03 䝤䝻䜰䝸䝺䞊䜈
1
TO BLOWER RELAY
3
1 JPAC 0.85P .
JPAC 0.85P .
JPAF 0.85Br .
JPAA 1.25G .
JPAE 0.85V .
3
4
䝎䜲䜸䞊䝗
1
4
JPAC 0.85P .
JPAA 2G .
JPAE 0.85V .
AC01_F-3 2O .
3
5
JOL2
2
2
1
1
JPK3 0.85V .
JGM5,JPK3
CN-RSD (DT) 2
2
CN-FSB_M (24-21)
JRP5,JRP6 JOP3,JOP4
CN-ACD2 (DT)
JPAF 0.85Br .
䈜 JNX6
JCE6,JCE7
1
JPAC 0.85P .
. . .
DIODE
CN-ACD1 (DT) 2
2
TO FUSE HARNESS
CN-FD4_F (24-31)
䝠䝳䞊䝈䝝䞊䝛䝇䜈
JNG1 STC2-12 BRAID 0.85B . .
L W STC2-19 0.85V . V ESD-B 1.25Br .
M
1
1
JPR2 0.85Gy .
P/T CONTOROLLER FLASH CONNECTOR
JNG1 FD1_M-10 BRAID 0.85B . .
2 FD4_F-14 1.25W .
1
CN-PTF (X) P/T䝁䞁䝖䝻䞊䝷 ᭩㎸䜏䝁䝛䜽䝍
DTS_F-2 2R .
JPAA,JPAC JPAE,JPAF
U DSH_F-34 1.25L . T JPK4 1.25W .
N
H JPP1 2Br .
X STC2-9 0.85Gy . G . GRO . F FD1_M-1 1.25W .
J DTS_F-1 2O . B CBPW-1 3L .
A PKSW-A 1.25O . E CBPW-3 3R .
S DSH_F-33 1.25R .
C DSH_F-57 1.25R . D CBPW-2 3Y .
R JPKC 1.25Br .
P JPK2 1.25G .
K JUF2 2R .
20 . GRO .
21 . GRO .
L JPAA 2G .
10
M OPPW-1 2W .
22 . GRO .
N STC2-8 1.25P .
23 . GRO .
. GRO .
11 . GRO .
12 . GRO .
9 WSH-4 0.85G .
3 AC01_F-7 0.85G .
4 GND12 0.85B .
24 . GRO .
(TO 13/19)
O
13 . GRO .
25 . GRO .
CN-FD1_M (24-31)
31
8 WSH-3 0.85L .
2 . GRO .
1 . GRO .
5 . GRO .
14 AC04-2 1.25W .
31
. GRO .
30
19 . GRO .
. GRO .
WSH-2 0.85V .
17 . GRO .
6
15
DSH_F-45 1.25V .
18
7
WSH-1 0.85W .
30
. GRO .
16 JGM5 0.85B .
DSH_F-16 0.85Gy .
26
18 29
29
. GRO .
JOL2 1.25B .
28
28
. GRO .
STC2-18 0.85O .
PLSW-2 0.85V .
17 PLSW-1 0.85Y .
16 HNSW-1 0.85P .
27
27
. GRO .
JPK3 1.25V .
. GRO .
DSH_F-46 1.25L .
19 JOL2 1.25B .
7 DSH_F-23 0.85B .
6 DSH_F-22 0.85L .
15 HNSW-2 0.85Br .
26 . GRO .
20
8 JNH 0.75W .
2 JPR2 1.25Gy .
1 FSB_M-F 1.25W .
5 JRP2 0.85B .
14 JGM5 1.25B .
JGP2 0.85B .
9 JNL 0.75B .
3 PL1_M-69 1.25W .
4 STC3-18 0.85W .
13 DSH_F-64 0.85P .
25
21 STC1-8 0.85W .
11 DSH_F-65 0.85Y .
12 DSH_F-66 0.85B .
STC3-19 0.85L .
STC3-6 0.85Br .
JRP3 0.85B .
JOP3 0.85B .
STC3-16 0.85G .
JRP3 0.85B .
STC3-29 0.85P .
JRP1 0.85B .
STC3-40 0.85O .
. GRO .
JOP1 0.85O .
JPP1 1.25Br .
FD1_M-3 1.25W .
JOP1 1.25B .
70
STC3-27 0.85L .
JRP2 0.85B .
JOP3 0.85B .
STC3-37 0.85O .
JRP2 0.85B .
STC2-25 0.85Gy .
STC3-39 0.85Br .
STC3-26 0.85Y .
JRP3 0.85B .
JOP3 0.85B .
STC3-8 0.85Br .
STC2-30 0.85Br .
STC2-29 0.85B .
56
43
STC2-35 0.85G .
STC1-16 0.85P .
29
JGP2 0.85B .
STC1-20 0.85Y .
STC3-34 0.85P .
. GRO .
. GRO .
. GRO .
. GRO .
STC3-36 0.85Sb .
JRP4 0.85B .
JOP4 0.85B .
STC1-9 0.85O .
JGP2 0.85B .
. GRO .
JOP3 0.85B .
42
23
15
STC2-2 0.85Gy .
STC3-5 0.85Y .
JRP1 0.85B .
JOP4 0.85B .
STC3-15 0.85L .
JRP1 0.85B .
STC2-38 0.85P .
STC3-7 0.85L .
JRP4 0.85B .
DSH_F-24 0.85G .
DSH_F-25 0.85B .
. GRO .
. GRO .
. GRO .
28
1
STC2-13 0.85O .
STC3-25 0.85W .
JRP1 0.85B .
JOP4 0.85B .
STC3-35 0.85Gy .
JRP1 0.85B .
STC2-3 0.85L .
JCE6 0.85G .
JRP5 0.85B .
JCE7 0.85Y .
JRP6 0.85B .
. GRO .
. GRO .
. GRO .
14
10 JNX6 0.85B .
57 22
DSH_F-15 0.85Y .
24 JGM5 0.85B .
䝟䝽䞊䝷䜲䞁䝝䞊䝛䝇䜈 TO P/L HARNESS
. GRO .
CN-PL1_M (DRC12-70PAE)
(TO 14,18/19) ᕥ䝣䜵䞁䝎䞊䝝䞊䝛䝇䜈 TO LEFT FENDER HARNESS
(TO 10/19)
P
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
CN-AC02_F
CN-AC01_F TO PARKING BRAKE SWITCH
C
䝟䞊䜻䞁䜾䝤䝺䞊䜻䝇䜲䝑䝏䜈 CN-PKSW (DT) C
D
B
CN-GND12
JOP4 0.85B .
JNG1 2B .
DSH_F-43 0.85O .
8
JPAC 0.85P .
4
JS15 0.85G . STC1-23 0.85W .
FSB_M-A 1.25O .
FD4_F-3 0.85G . AC03-5 2O .
DSH_F-44 0.85L . JPAF 0.85Br .
GND12 0.85B . JPAE 0.85V .
5
1
1
3
JNH 0.75W .
JNL 0.75B .
JNXE 0.85B .
䈜 JNXE
CN-ESD (DT)
CN-OPPW (DT)
4
A
AC01_F-5 FD4_F-4 0.85B 0.85B . .
LOCAL OPTION CONNECTOR
OPTION POWER CONNECTOR
(DT-A)
2
JPAA 0.85G .
䝻䞊䜹䝹䜸䝥䝅䝵䞁䝁䝛䜽䝍
䝕䝳䜰䝹䝏䝹䝖ᵝ⏝䝁䝛䜽䝍 DUAL TILT SPEC CONNECTOR 䜸䝥䝅䝵䞁㟁※⏝䝁䝛䜽䝍 CN-DTS_F
7
JNL 0.75B .
JNXG 0.85B .
STC3-30 0.85B .
JPR2 0.85Gy .
. GRO .
. GRO .
6
JNH 0.75W .
JNH3 0.85V .
GND11 2B .
JPKC 0.85Br .
JUF2 2R .
FSB_M-J 2O .
12 1
1 1
A
. GRO .
. GRO .
2
FSB_M-M 2W .
JOL2 2B .
2
C B
STC2-17 0.85G .
. GRO .
䝢䞁䝥䝷䝇䜲䝑䝏䜈
B
TO PINPULLER SWITCH
CN-PLSW (DT)
. GRO .
STC2-27 0.85P . FSB_M-V 1.25Br .
(TO 15/19)
. GRO .
A
C 1
FD1_M-17 0.85Y .
FD1_M-18 0.85V .
2
CN-GND11 SRV-9 0.85B .
E
SRV-12 DTS_F-4 1.25B 2B . .
JOP2 2B .
DSH_F-6 DSH_F-7 1.25B 1.25B . .
(TO 15/19)
䈜 JNXG
䝩䞊䞁䝇䜲䝑䝏䜈 TO HORN SWITCH
CN-HNSW (DT)
F
(FROM 2/19)
1 28
15
28
FD1_M-16 0.85P .
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 .
. GRO .
. GRO .
. GRO .
GND11 0.85B .
JNH 0.75W .
JNL 0.75B .
JPKC 0.85Br .
JNXC 0.85B .
JUF2 1.25R .
GND11 1.25B .
1
12
I
J
14
. . .
DSH_F-41 0.85L .
DSH_F-40 0.85O .
6
. . .
. . .
DSH_F-70 0.85P .
DSH_F-39 0.85V .
DSH_F-38 0.85Y .
DSH_F-37 0.85G .
DSH_F-36 0.85B .
DSH_F-9 0.85B .
7
. . .
. . .
DSH_F-8 0.85Y .
1
10
. . .
DSH_F-69 0.85Y .
4
DSH_F-54 0.85W .
DSH_F-53 0.85G .
CN-CK01 KOMTRAX
K
DSH_F-68 0.85Gy .
DSH_F-67 0.85Br .
DSH_F-56 0.85O .
DSH_F-55 0.85L .
5
DSH_F-52 0.85Br .
DSH_F-51 0.85V .
1
CN-CK02 KOMTRAX
4
FD4_F-9 0.85G .
FD4_F-6 0.85W .
3
FD4_F-8 0.85L .
FD4_F-7 0.85V .
1 2
1
FSB_M-B 3L .
. GRO .
4
2
FSB_M-D 3Y .
FSB_M-E 3R .
3
㻷㻻㻹㼀㻾㻭㼄㻌䝰䝕䝮䜈 TO KOMTRAX MODEM
CN-WSH (DT)
L
CN-CBPW (DTP)
䜻䝱䝤䝝䞊䝛䝇䜈 TO CAB HARNESS
A
STC1-10 0.85B .
STC2-5 0.85Gy .
STC2-15 0.85O .
M
B C
CN-WELK (DT) సᴗᶵ䝻䝑䜽䝇䜲䝑䝏䜈
TO WORK EQUIPMENT LOCK SWITCH
N
O
䈜JNXC
SRV-11 0.85B .
JNG2 BRAID .
䈜JNXE
AC02_F-3 0.85B .
JNG2 BRAID .
䈜JNXG
DTS_F-8 0.85B .
JNG1 BRAID .
P
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) B
C
TO DASH BOARD HARNESS
CN-DSH_F (DRC16-70SAE-P066)
14
JNH3 0.85V .
STC2-7 0.85L .
JNX5 0.85B .
JNL 0.75B .
JNH 0.75W .
. GRO .
. GRO .
GND11 1.25B .
GND11 1.25B .
JUF2 1.25R .
JUF2 1.25R .
JPK1 0.85Br .
JPK2 0.85G .
JPR2 0.85Gy .
1
28
. GRO .
. GRO .
. GRO .
PL1_M-25 1.25B .
PL1_M-24 1.25G .
FD1_M-7 0.85B .
FD1_M-6 0.85L .
. GRO .
JGM4 0.85B .
JPK4 0.85W .
. GRO .
JGM5 0.85B .
FD1_M-24 0.85Gr .
FD1_M-23 0.85Y .
15
42
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
FSB_M-U 1.25L .
FSB_M-S 1.25R .
JPK3 1.25V .
JPK2 1.25G .
JPK4 1.25W .
JPK1 1.25Br .
29
56
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
JPK1 0.85Br .
. GRO .
JGM4 0.85B .
FD1_M-31 1.25L .
FD1_M-30 1.25V .
. GRO .
. GRO .
43
70
. GRO .
. GRO .
. GRO .
. GRO .
FD1_M-12 0.85B .
FD1_M-11 0.85Y .
FD1_M-13 0.85P .
JJP1 0.85P .
STC1-3 0.85W .
JGP1 0.85B .
. GRO .
JS19 0.85Y .
STC1-11 0.85W .
FSB_M-C 1.25R .
57
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 . . .
JGM4
JGM5 0.85B .
DSH_F-20 DSH_F-47 0.85B 0.85B . .
JPK4
FSB_M-T DSH_F-19 DSH_F-30 1.25W 0.85W 1.25W . . .
JPK1
DSH_F-29 DSH_F-49 JPKC 1.25Br 0.85Br 1.25Br . . .
DSH_F-3 0.85Br .
䈜JNX5
JNG1 BRAID .
DSH_F-12 0.85B .
䈜 JNX5
D
E
F JPK1,JPK2 JPK4,JGM4
G
(TO 19/19)
1
2
2
1
TO ADDITIONAL LIGHT
GRO
GRO
CN-LBP_F (DT)
GND12 1.25B .
FD1_M-26 1.25G .
GRO
GRO
FD1_M-25 1.25L .
GND12 1.25B .
4
3
3
4
ቑタ䝷䜲䝖䜈
H
I 3
䝅䝣䝖SW䜈 TO SIFT SW
J
CN-TLV2_F (DT)
1
STC1-12 0.85Y .
JGP3 0.85B .
STC3-9 0.85L .
STC1-18 0.85G .
JGP3 0.85B .
STC1-24 0.85Br .
4
6
K
B STC2-5 0.85Gy .
JGP3 5
L ㉮⾜䝺䝞䞊䜈 TO TRAVEL LEVER
CN-TLV1 (DT-B) M
JJP1 0.85P .
JJP1 0.85P .
STC1-19 0.85Br .
STC1-13 0.85W .
STC1-2 0.85Y .
STC1-7 0.85Br .
JGP1 0.85B .
JGP1 0.85B .
8
STC1-10 0.85B .
4
A 1 FD1_M-17 0.85Y . FD1_M-18 0.85V .
2
1
STC2-15 0.85O .
C
CN-WELK (DT) సᴗᶵ䝻䝑䜽䝇䜲䝑䝏䜈 TO WORK EQUIPMENT LOCK SWITCH
CN-PLSW (DT) 䝢䞁䝥䝷䝇䜲䝑䝏䜈 TO PINPULLER SWITCH
(TO 15/19)
N
B
O
⇞ᩱ䝎䜲䜰䝹䜈 TO FUEL DIAL
CN-DIAL (DT)
STC1-1 0.85V . JJP1 0.85P .
JGP1 0.85B .
2
(TO 5/19)
C
FD1_M-15 0.85Br .
FD1_M-16 0.85P .
1
CN-HNSW (DT) 䝩䞊䞁䝇䜲䝑䝏䜈
A
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) 19
TLV1-6 0.85Br .
PL1_M-30 0.85Y .
JGP1 0.85B .
JJP1 0.85P .
PKSW-B 0.85W .
TLV2_F-6 0.85Br .
13
TLV1-3 0.85W .
. GRO .
JPR2 0.85Gy .
FD1_M-22 0.85P .
JS15 0.85G .
TLV2_F-4 0.85G .
7
TLV1-2 0.85Br .
FD1_M-21 0.85W .
PL1_M-39 0.85O .
WELK-A 0.85B .
DSH_F-58 0.85W .
TLV2_F-3 0.85Y .
1
DIAL-B 0.85V .
TLV1-7 0.85Y .
DSH_F-62 0.85W .
JGP3 0.85B .
JS19 0.85Y .
. GRO .
C
CN-STC3
CN-STC2
CN-STC1 24 18 12
31
. GRO .
JNH 0.75W .
. GRO .
PTF-4 0.85B .
PL1_M-43 0.85G .
. GRO .
. GRO .
PL1_M-21 0.85P .
. GRO .
. GRO .
21
. GRO .
JNL 0.75B .
. GRO .
JNH3 0.85V .
PL1_M-49 0.85Gy .
. GRO .
ESD-C 0.85P .
. GRO .
PL1_M-56 0.85B .
PL1_M-55 0.85Br .
11
. GRO .
JNX8 0.85B .
PL1_M-1 0.85O .
PTF-1 0.85P .
WELK-C 0.85O .
. GRO .
ESD-A 0.85G .
FD1_M-28 0.85O .
FSB_M-W 0.85V .
. GRO .
1
. GRO .
PL1_M-15 0.85Gy .
PL1_M-7 0.85L .
PTF-2 0.85L .
WELK-B 0.85Gy .
. GRO .
DSH_F-13 0.85L .
FSB_M-N 1.25P .
FSB_M-X 0.85Gy .
. GRO .
6
JGP1,JGP2 JJP1,JPR2 JS19,JS15
D
40 30 20 10
10
JOP1 0.85B .
TLV2_F-1 0.85L .
PL1_M-54 0.85Br .
PL1_M-22 0.85L .
PL1_M-58 0.85Br .
PL1_M-16 0.85Y .
JPK3 0.85V .
JRP1 0.85B .
JPP1 0.85Br .
JUP1 0.85R .
1
20
. GRO .
PL1_M-57 0.85L .
FD1_M-4 0.85W .
CBR-1 0.85Y .
PL1_M-61 0.85G .
PL1_M-19 0.85L .
JPKE 0.85Br .
JRP2 0.85B .
JPP1 0.85Br .
JUP1 0.85R .
11
30
. GRO .
PL1_M-63 0.85P .
. GRO .
PL1_M-44 0.85L .
PL1_M-51 0.85Y .
PL1_M-2 0.85W .
JPKE 0.85Br .
JRP3 0.85B .
JPP1 0.85Br .
JOP2 0.85B .
21
40
PL1_M-65 0.85O .
PL1_M-50 0.85Br .
. GRO .
PL1_M-47 0.85O .
PL1_M-36 0.85Sb .
PL1_M-5 0.85Gy .
PL1_M-31 0.85P .
JOP2 0.85B .
JOP2 0.85B .
JOP2 0.85B .
31
JRP1,JRP2 JRP3,JRP4 JPKE
E 䈜 JNX8
F
JNH,JNL,JNH3
JOP1,JOP2 JPKC,JPP1 JUF2,JUP1
JNG1
G
(TO 6/19)
H
I
J
K
JCE6
PL1_M-8 1.25G .
PKD-1 0.85G .
JS15 0.85G .
JCE7
PL1_M-10 1.25Y .
PBD-1 0.85Y .
JS19 0.85Y .
JGP1
TLV1-8 0.85B .
JGP2 0.85B .
DIAL-C 0.85B .
TLV1-1 0.85B .
JGP2
JGP1 0.85B .
FD1_M-20 PL1_M-29 0.85B 1.25B . .
PL1_M-40 1.25B .
JGM5
FD1_M-14 DSH_F-17 1.25B 0.85B . .
JJP1
TLV1-4 0.85P .
DSH_F-63 DIAL-A 0.85P 0.85P . .
STC1-22 0.85P .
JNG1
JNX8 BRAID .
JNX5 BRAID .
GND12 0.85B .
JNH3
SRV-6 0.85V .
DSH_F-14 STC2-24 0.85V 0.85V . .
L
JNH
SRV-3 0.75W .
JNL
SRV-10 STC2-22 0.75B 0.75B . .
M
JOL2
N
JOP1
O
P
JPKC
SRV-2 0.85Br .
JPK1 1.25Br .
FSB_M-R JPKE 1.25Br 0.85R . .
JPKE
JPKC 0.85R .
STC3-14 0.85Br .
STC3-24 0.85Br .
JPP1
STC3-12 0.85Br .
STC3-22 0.85Br .
FSB_M-H PL1_M-68 2Br 1.25Br . .
JPR2
STC1-15 0.85Gy .
DSH_F-1 FD1_M-2 RSD-2 0.85Gy 1.25Gy 0.85Gy . . .
JRP1
PL1_M-6 PL1_M-64 0.85B 1.25B . .
TLV1-5 0.85P .
JRP2
JNXC BRAID .
DSH_F-61 STC1-21 0.85B 0.85B . .
JGM4 0.85B .
JNX6 BRAID .
STC2-32 DSH_F-10 FD1_M-8 0.75W 0.75W 0.75W . . .
DSH_F-11 FD1_M-9 0.75B 0.75B . .
OPPW-2 FD1_M-19 FD1_M-29 2B 1.25B 1.25B . . .
PL1_M-67 0.85O .
PL1_M-70 1.25B .
STC3-10 0.85B .
STC3-21 STC3-32 0.85B 0.85B . .
STC3-33 0.85B .
STC3-31 0.85B .
JOP1 1.25B .
JOP3
JOP4 1.25B .
PL1_M-53 0.85B .
PL1_M-42 0.85B .
PL1_M-46 0.85B .
PL1_M-60 0.85B .
JOP4
PL1_M-18 0.85B .
JOP3 1.25B .
JPK3
STC3-4 0.85V .
DSH_F-32 FD1_M-27 1.25V 1.25V . .
PL1_M-38 0.85B .
PL1_M-20 1.25B .
PL1_M-45 0.85B .
FD1_M-5 STC3-13 0.85B 0.85B . .
CBR-2 0.85B .
PL1_M-48 0.85B .
JRP3
PL1_M-59 0.85B .
PL1_M-52 0.85B .
STC3-23 0.85B .
JRP4 0.85B .
PL1_M-62 0.85B .
JRP4
PL1_M-23 1.25B .
JRP5 0.85B .
JRP3 0.85B .
JRP6 0.85B .
PL1_M-37 0.85B .
JRP5
PL1_M-9 1.25B .
PKD-2 0.85B .
JRP4 0.85B .
JRP6
PL1_M-11 1.25B .
PBD-2 0.85B .
JRP4 0.85B .
GND12 PL1_M-4 0.85B 0.85B . .
RSD-1 0.85V .
GND11 2B .
PKSW-C STC1-17 0.85G 0.85G . .
DSH_F-59 0.85Y .
JCE7 0.85Y .
JUP1 2R .
DSH_F-5 1.25R .
JUP1
JUF2 2R .
STC3-11 0.85R .
STC3-1 0.85R .
JNG1 BRAID .
FD1_M-10 0.85B .
䈜JNX8
JNG1 BRAID .
STC2-12 0.85B .
PL1_M-17 1.25B .
TO FUSE HARNESS
䝠䝳䞊䝈䝝䞊䝛䝇䜈 CN-FSB_M (24-21)
W STC2-19 0.85V . V ESD-B 1.25Br .
T JPK4 1.25W . SRV-1 1.25R .
H JPP1 2Br .
X STC2-9 0.85Gy . G . GRO . F FD1_M-1 1.25W .
U DSH_F-34 1.25L .
STC1-5 0.85Y .
FSB_M-K 2R .
䈜JNX6
JPK3
JCE6 0.85G .
JUF2
JOP3,JOP4
JGM5,JOL2
STC3-2 0.85Br .
PL1_M-3 1.25B .
JS19
JOP2
JRP5,JRP6 䈜 JNX6
STC3-3 0.85B .
JS15 JOP2 1.25B .
JCE6,JCE7
DSH_F-4 1.25R .
B . GRO . A PKSW-A 1.25O .
E . GRO . S DSH_F-33 1.25R .
J . GRO .
C DSH_F-57 1.25R . D . GRO .
R JPKC 1.25Br .
P JPK2 1.25G .
TO LEFT FENDER HARNESS
ᕥ䝣䜵䞁䝎䞊䝝䞊䝛䝇䜈 CN-FD1_M (24-31)
K JUF2 2R . L CBR-3 1.25G .
30 DSH_F-45 1.25V .
M OPPW-1 2W .
18
N STC2-8 1.25P .
29 JOL2 1.25B .
28 STC2-18 0.85O .
(TO 13/19)
PLSW-2 0.85V .
17 PLSW-1 0.85Y .
16 HNSW-1 0.85P .
27 JPK3 1.25V .
31
20
DSH_F-46 1.25L .
JGP2 0.85B .
19 JOL2 1.25B .
7 DSH_F-23 0.85B .
6 DSH_F-22 0.85L .
15 HNSW-2 0.85Br .
26 LBP_F-1 1.25G .
8 JNH 0.75W .
2 JPR2 1.25Gy .
1 FSB_M-F 1.25W .
5 JRP2 0.85B .
14 JGM5 1.25B .
9 JNL 0.75B .
3 PL1_M-69 1.25W .
4 STC3-18 0.85W .
13 DSH_F-64 0.85P .
25
21 STC1-8 0.85W .
10 JNX6 0.85B .
22
11
STC1-16 0.85P .
DSH_F-65 0.85Y .
23
12 DSH_F-66 0.85B .
57
STC3-19 0.85L .
STC3-6 0.85Br .
JRP3 0.85B .
JOP3 0.85B .
STC3-16 0.85G .
JRP3 0.85B .
STC3-29 0.85P .
JRP1 1.25B .
STC3-40 0.85O .
. GRO .
JOP1 0.85O .
JPP1 1.25Br .
FD1_M-3 1.25W .
JOP1 1.25B .
70
43
STC2-35 0.85G .
STC3-27 0.85L .
JRP2 0.85B .
JOP3 0.85B .
STC3-37 0.85O .
JRP2 0.85B .
STC2-25 0.85Gy .
STC3-39 0.85Br .
STC3-26 0.85Y .
JRP3 0.85B .
JOP3 0.85B .
STC3-8 0.85Br .
STC2-30 0.85Br .
STC2-29 0.85B .
56
29
JGP2 1.25B .
STC1-20 0.85Y .
STC3-34 0.85P .
. GRO .
. GRO .
. GRO .
. GRO .
STC3-36 0.85Sb .
JRP4 0.85B .
JOP4 0.85B .
STC1-9 0.85O .
JGP2 1.25B .
. GRO .
JOP3 0.85B .
42
15
STC2-2 0.85Gy .
STC3-5 0.85Y .
JRP1 1.25B .
JOP4 0.85B .
STC3-15 0.85L .
JRP1 1.25B .
STC2-38 0.85P .
STC3-7 0.85L .
JRP4 1.25B .
DSH_F-24 1.25G .
DSH_F-25 1.25B .
. GRO .
. GRO .
. GRO .
28
1
STC2-13 0.85O .
STC3-25 0.85W .
JRP1 1.25B .
JOP4 0.85B .
STC3-35 0.85Gy .
JRP1 0.85B .
STC2-3 0.85L .
JCE6 1.25G .
JRP5 1.25B .
JCE7 1.25Y .
JRP6 1.25B .
. GRO .
. GRO .
. GRO .
14
DSH_F-15 0.85Y .
TO P/L HARNESS
䝟䝽䞊䝷䜲䞁䝝䞊䝛䝇䜈 CN-PL1_M (DRC12-70PAE)
24 DSH_F-16 0.85Gr .
LBP_F-3 1.25L .
(TO 14,18/19)
(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)
B
C TO PARKING BRAKE SWITCH
䈜JNXC
䝟䞊䜻䞁䜾䝤䝺䞊䜻䝇䜲䝑䝏䜈 CN-PKSW (DT)
D
C B
SRV-11 0.85B .
JNG1 BRAID .
JS15 0.85G . STC1-23 0.85W .
FSB_M-A 1.25O .
A
E CN-GND12 JOP4 0.85B .
F
JNG1 0.85B .
LBP_F-2 1.25B .
CBZ-1 1.25B .
LBP_F-4 1.25B .
CN-GND11 SRV-9 0.85B .
SRV-12 1.25B .
JOP2 2B .
CN-CBZ (DT) ㆙ሗ䝤䝄䞊
DSH_F-6 DSH_F-7 1.25B 1.25B . .
1
1
FSB_M-M 2W .
GRO
JOL2 2B .
GRO
2
2
CAUTION BUZZER
G
1
GND12 1.25B .
CBR-5 1.25O .
CN-CBR ㆙ሗ䝤䝄䞊䝸䝺䞊
H
CAUTION BUZZER RELAY
5
FSB_M-L 1.25G .
CBZ-2 1.25O .
2
STC2-17 0.85G .
STC2-27 0.85P .
GRO
GRO
C
STC3-17 0.85Y .
K
GRO
GRO
. GRO .
. GRO .
GRO
GRO
. GRO .
GND11 0.85B .
GRO
GRO
JNH 0.75W .
JNL 0.75B .
GRO
GRO
JPKC 0.85Br .
JNXC 0.85B .
GRO
GRO
JUF2 1.25R .
GND11 1.25B .
GRO
GRO
L JPK3 0.85V .
2
1 1
2
JRP6 0.85B .
JCE7 0.85Y .
2
CN-RSD (DT) 䝎䜲䜸䞊䝗
1 1
CN-PBD (DT) 䝎䜲䜸䞊䝗
DIODE
2
JRP5 0.85B .
JCE6 0.85G .
2
1
6
7 . GRO .
1
JPR2 0.85Gy .
7
6 JNH3 0.85V .
J
N
B
䈜 JNXC
(FROM 5/19)
M
LOCAL OPTION CONNECTOR
GRO
. . .
2
CN-ESD (DT) 䝻䞊䜹䝹䜸䝥䝅䝵䞁䝁䝛䜽䝍
C A
A
JRP2 0.85B .
1 CN-RSD CN-PKD,CN-PBD
I
OPTION POWER CONNECTOR
B FSB_M-V 1.25Br .
2 3
CN-OPPW (DT) 䜸䝥䝅䝵䞁㟁※⏝䝁䝛䜽䝍
SERVICE CONNECTOR
12 12
1
3
1
1
3
. GRO .
STC2-14 0.85P .
. GRO .
. GRO .
STC2-34 0.85B .
STC2-4 0.85L .
. GRO .
. GRO .
2
4
4
1
2
CN-SRV (DT-A) 䝃䞊䝡䝇䝁䝛䜽䝍
CN-PTF (X) P/T䝁䞁䝖䝻䞊䝷 ᭩㎸䜏䝁䝛䜽䝍 P/T CONTOROLLER FLASH CONNECTOR
CN-PKD (DT) 䝎䜲䜸䞊䝗
DIODE
DIODE
O
P
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
B
14
PCV1 ఫ䝝䜴䝆䞁䜾 : 6189-0039(⅊) SUMITOMO HOUSING : (GRAY)
䝍䞊䝭䝘䝹:1500-0110 TERMINAL
C
䝽䜲䝲䝅䞊䝹:7161-9785(Ⲕ)
2
WIRE SEAL : (BROWN)
(TO 7/19)
PCV2 ఫ䝝䜴䝆䞁䜾:6189-0074(⃰䛔⅊Ⰽ)
1
10
16
8
12
12
11
10
9
8
7
1
2
3
4
5
6
INJ
5
13
9
15
7
11
06
13
09
15
11
16
12
62
57
08
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
E
(FROM 7/19) 10
CN INJ
F
2
CN1
1
2
CN2
1
1
2
14
CN3
37
05
07
61
01
04
03
06
05
24
PFUEL AMP 䝝䜴䝆䞁䜾:174357-2(㯮)
G
ENG
HOUSING :(BLACK)
䝍䞊䝭䝘䝹:171662-1 TERMINAL
G ఫ䝝䜴䝆䞁䜾: 6189-0058 (㯮)
CN4
CN5
1
2
1
2
䝽䜲䝲䝅䞊䝹:172888-2(⅊)
CN6
WIRE SEAL:(GRAY) FRONT HOLDER
TERMINAL
12
11
55
44
45
56
57
58
59
60
46
47
48
49
31
32
33
34
35
50
36
37
38
39
40
21
22
23
24
11
12
13
14
25
26
27
28
29
30
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
64 49
33
POIL FRAMATOME 䝝䜴䝆䞁䜾:54200308
53 56
57
26
47
79
58
78
35
34
22
01
02
12
10
56
65
03
04
24 26 1
09
25 2
10
321
54
I
07
54
43
3
08
55
1
WIRE SEAL : (BLACK)
53
42
35
JM08
䝽䜲䝲䝅-䝹:7160-8234(㯮)
52
41
䝣䝻䞁䝖䝩䝹䝎䞊:174358-7
䝍䞊䝭䝘䝹:1500-0110
3 2
H
1
2
SUMITOMO HOUSING : (BLACK)
45
51
A
02
HOUSING(KEY A,BLACK)
58
䝍䞊䝭䝘䝹:54001803
(GOLD COATING,FEMALE)TERMINAL
J
RES
1 2 3
78 68
1
RES
22
23
A
2
K
21
67
NE FRAMATOME 䝝䜴䝆䞁䜾:54200311
C
B J1939
1 2 3
PAMB AMP 䝝䜴䝆䞁䜾:1318670-2(㯮)
HOUSING(KEY D,WHITE)
79
䝍䞊䝭䝘䝹:54001803
TERMINAL(GOLD COATING,FEMALE)
L
06
04
HOUSING : (BLACK)
7
8
9
10
11
12
䝍䞊䝭䝘䝹:1318329-1(FEMALE)
6
5
4
3
2
1
TERMINAL
JM05
08
11
09
07
05
03
02
INJ
01
PIM 䝝䜴䝆䞁䜾:ఫ 6098-0141(⅊)
M
HOUSING : SUMITOMO : (GRAY)
䝸䝔䞊䝘:ఫ 6920-0080(㯤) RETAINER:SUMITOMO : (YELLOW)
TFUEL PACKARD 䝝䜴䝆䞁䜾:12162193(㯮)
N
䝍䞊䝭䝘䝹:ఫ(▮ᓮ) 1410-0096(7116-1530)
TERMINAL
B
A
3
B A
2
1
WIRE SEAL:SUMITOMO(YAZAKI) : (YELLOW)
36 37
O 49
46
45
JM02
JM03
JM04
䝽䜲䝲䝅䞊䝹:ఫ(▮ᓮ) 7165-0159(7157-3881-70)(㯤)
䝍䞊䝭䝘䝹:12124075 50
JM01
TERMINAL:SUMITOMO(YAZAKI)
HOUSING : (BLACK)
TIM 38 PACKARD 䝝䜴䝆䞁䜾:12162197(⅊)
B A
48
HOUSING : (GRAY)
47
TWTR PACKARD 䝝䜴䝆䞁䜾:12162193(㯮) HOUSING : (BLACK)
䝍䞊䝭䝘䝹:12124075 TERMINAL
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 (DT) 䝎䜲䜸䞊䝗
B
CN-LMD2 (DT) 䝎䜲䜸䞊䝗
DIODE
DSH-12
.
.
.
䈜N1 0.85B BRAID
DIODE
DSH-10 CM02-8 CM02-9 NA 0.75W 0.85W 0.85W . . . FLSW-3 FLSW-4 LMD2-2
1
2
1
A 1.25Y 1.25Y 1.25Y
2
SUNSHINE SENSOR E 1.25G
.
D
DSH-43 DSH-44 0.85O 0.85L . .
C 1.25V
2
1
C 1.25V
A 1.25Y
.
1
1
.
᪥ᑕ䝉䞁䝃 CN-SLS (050)
.
C
2
2
CN-BKSW (DT) 䝤䝺䞊䜻䝨䝎䝹䝸䝭䝑䝖䝇䜲䝑䝏
1
DSH-4 DSH-5 DSH-6 DSH-7 DSH-14 1.25R 1.25R 1.25B 1.25B 0.85V . . . . .
9
DSH-22 0.85L .
.
. .
DSH-1 0.85Gy .
.
MONITOR
MONITOR
䝰䝙䝍䞊 CN-CM01 (070)
䝰䝙䝍䞊 CN-CM02 (070)
E X DSH-3 0.85B 0.85G 0.85Br . . .
DSH-13 0.85L . DSH-2 DSH-19 0.85G 0.85W . .
DSH-20 DSH-24 0.85B 0.85G . . .
.
. .
. .
8
1
18
6
.
. .
.
. .
.
. .
DSH-15 0.85Y .
NA NA DSH-11 DSH-17 0.85B 0.85W 0.85W 0.75B . . . .
C
FLSW-1 FLSW-6 .
DSH-16 0.85Gy . . . .
.
. .
.
. .
5
F
12
MONITOR
䝰䝙䝍䞊 CN-CM03 (070)
F 1
DSH-51 0.85V .
DSH-52 0.85Br .
9
DSH-56 DSH-68 0.85O 0.85Gy . .
DSH-55 0.85L .
LMD1-2 CM01-13 .
.
RLSW-1 RLSW-6 DSH-46 1.25L 1.25L 1.25L . . . RLSW-5 FLSW-5 .
H
.
DSH-49 .
RLSW-2 FLSW-2 DSH-47 1.25B 1.25B 1.25B . . . DSH-23 DSH-25 CM01-12
X 0.85B 0.85B 0.85B
DSH-57 0.85R .
.
DSH-59 0.85Y DSH-58 . 0.85W .
B
.
.
57
43
29
BKSW-A SLS-1 KEY-1 0.85R 0.85O 1.25Br . . .
DSH-36 DSH-70 0.85B 0.85P . .
DSH-67 0.85Br .
DSH-69 DSH-9 DSH-40 DSH-37 DSH-38 DSH-39 0.85Y 0.85B 0.85O 0.85G 0.85Y 0.85V . . . . . .
DSH-53 DSH-54 0.85G 0.85W . .
8
DSH-41 0.85L .
18
DSH-8 0.85Y .
NA,X
15
1
CM02-3 CM01-11 0.85Y 0.85Gy . .
BKSW-B SLS-2 0.85W 0.85L . .
KEY-2 CM02-4 1.25W 0.85Gy . .
C BKSW-C 0.85Y 1.25V . .
KEY-3 CM02-7 CM01-14 1.25G 0.85B 0.85Br . . .
. F KEY-4 GRO 1.25L 1.25V . . .
G
. GRO .
CM01-15 0.85G .
CM01-1 1.25R .
H BRK-A KEY-5 CM01-16 CM01-2 0.85B 1.25B 1.25R 0.85W 1.25R . . . . . BRK-B 0.85W .
A
CN-BRK DSH-63 (DT) C 0.85P DSH-62 . 0.85W 䝤䝺䞊䜻䝨䝎䝹䝫䝔䞁䝅䝵 DSH-61 0.85B .
BREAKE PEDAL POTENTIO
G BRK-C 0.85P 1.25Br . .
䈜 N1
DCL-B 0.85P .
.
B
I A DSH-65 CN-DCL 0.85Y DSH-66 . (DT) C 0.85B DSH-64 . 0.85P 䝕䝉䝹䝫䝔䞁䝅䝵
J
DECEL PEDAL POTENTIO
. GRO .
KEY-6 CM01-7 CM01-3 1.25L 0.85B 1.25B . . . . GRO .
. CM01-4 GRO 1.25B . .
A
H
.
G 1.25Br 1.25Br 1.25Br
A C
.
E 1.25G 1.25G 1.25G 0.85G
BRAKE PEDAL SWITCH
E
.
LMD2-1 LMD1-1 DSH-45 1.25V 1.25V 1.25V . . .
.
B
. CM03-4 CM01-9 CM03-18 GRO 0.85B 0.85L 0.85Y . . . .
DCL-A CM03-1 0.85Y 0.85V . .
X CM03-14 CM03-12 0.85G 0.85B 0.85B . . .
DCL-C CM03-2 0.85B 0.85Br . .
NA CM03-15 CM01-8 0.85Y 0.85G 0.75W . . .
CM03-6 0.85Br .
CM03-7 CM03-16 0.85G 0.85V . .
X CM02-10 0.85B 0.75B . .
CM03-10 0.85Gy .
CM03-8 CM03-13 0.85W 0.85O . .
. N1 GRO 0.85B . .
CM03-11 CM03-3 0.85Y 0.85L . .
CM03-17 0.85L .
. CM01-6 GRO 0.85L . .
CM03-5 CM03-9 0.85P 0.85O . .
. GRO .
. CM01-5 GRO 0.85V . .
70
42
28
56
(FROM 1/19) TO FLOOR HARNESS
䝣䝻䜰䝝䞊䝛䝇䜈 CN-DSH (DRC12-70PAE)
14
A,C,E,F,G,H
K
L
M 1 6
4
F G 1.25L 1.25Br . .
N
6
4
E G A 1.25G 1.25Br 1.25Y . . .
3
3
1
3
1
DSH-31 DSH-32 1.25G 1.25V . .
4
TO KEY SWITCH
(TO 15/19)
REAR LAMP SWITCH
CN-FLSW (SWP) ๓↷ⅉ䝇䜲䝑䝏
6
CN-KEY (DT) 䜻䞊䝇䜲䝑䝏䜈
CN-RLSW (SWP) ᚋ↷ⅉ䝇䜲䝑䝏
A H E 1.25Y 1.25B 1.25G . . .
O
. .
H F 1.25B 1.25L . .
DSH-34 1.25L .
DSH-30 DSH-33 1.25W 1.25R . .
. . .
.
DSH-29 1.25Br .
FRONT LAMP SWITCH
P
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 JNX4
B
C
D
CN-LMD1 (DT) 䝎䜲䜸䞊䝗
CN-LMD2 (DT) 䝎䜲䜸䞊䝗
DIODE
1
DSH_M-4 1.25R .
DSH_M-5 1.25R .
DSH_M-6 1.25B .
DSH_M-7 1.25B .
9
DSH_M-22 0.85L .
. . .
DSH_M-1 0.85Gy .
JGM1 0.85B .
MONITOR
MONITOR
䝰䝙䝍䞊 CN-CM01 (070)
䝰䝙䝍䞊 CN-CM02 (070)
JPLF 0.85G .
DSH_M-3 0.85Br .
DSH_M-14 0.85V .
DSH_M-13 0.85L .
DSH_M-20 0.85B .
DSH_M-24 0.85G .
DSH_M-2 0.85G .
DSH_M-19 0.85W .
. . .
. . .
8 18
1
. . .
. . .
DSH_M-15 0.85Y .
6
. . .
DSH_M-17 0.85B .
JNMH 0.85W .
JNMH 0.85W .
DSH_M-11 0.75B .
DSH_M-16 0.85Gy .
. . .
5
. . .
. . .
12
DIODE
DSH_M-12 0.85B .
. BRAID .
JNMH
CM02-9 0.85W .
CM02-8 DSH_M-10 0.85W 0.75W . .
JPLE
LMD2-2 FLSW-4 FLSW-3 1.25Y 1.25G 1.25G . . .
JPL2
LMD1-1 LMD2-1 DSH_M-45 1.25V 1.25V 1.25V . . .
JPLF
LMD1-2 FLSW-6 CM01-13 FLSW-1 0.85G 1.25Y 1.25G 1.25Y . . . .
JPL8
DSH_M-46 RLSW-6 RLSW-1 1.25L 1.25L 1.25L . . .
JPKA
RLSW-5 DSH_M-49 FLSW-5 1.25Br 0.85Br 1.25Br . . .
JGM3
RLSW-2 DSH_M-47 FLSW-2 1.25B 1.25B 1.25B . . .
JGM1
DSH_M-23 CM01-12 DSH_M-25 0.85B 0.85B 0.85B . . .
E 1
2
1
2 JPL2 1.25V .
JPLE 1.25Y .
57
43
29
15
1
BKSW-A 1.25R .
. GRO .
KEY-1 1.25Br .
CM02-3 0.85Y .
CM01-11 0.85Gy .
BKSW-B 0.85W .
. GRO .
KEY-2 1.25W .
CM02-4 0.85Gy .
CM01-15 0.85G .
BKSW-C 0.85Y .
JPL2 1.25V .
KEY-3 1.25G .
CM02-7 0.85B .
CM01-14 0.85Br .
. GRO .
JPL8 1.25L .
KEY-4 1.25V .
. GRO .
CM01-1 1.25R .
BRK-A 0.85B .
JGM3 1.25B .
KEY-5 1.25R .
CM01-16 0.85W .
CM01-2 1.25R .
BRK-B 0.85W .
. GRO .
KEY-6 1.25L .
CM01-7 0.85B .
CM01-3 1.25B .
BRK-C 0.85P .
JPKA 0.85Br .
. GRO .
. GRO .
CM01-4 1.25B .
DCL-B 0.85P .
. GRO .
. GRO .
CM01-9 0.85L .
. GRO .
A
DCL-A 0.85Y .
. GRO .
. GRO .
JGM1 0.85B .
. GRO .
DSH_M-61 0.85B .
DCL-C 0.85B .
. GRO .
. GRO .
CM01-8 0.85G .
JNMH 0.75W .
DSH_M-62 0.85W .
. GRO .
. GRO .
. GRO .
JGM1 0.85B .
CM02-10 0.75B .
. GRO .
. GRO .
. GRO .
. GRO .
JNX4 0.85B .
. GRO .
. GRO .
. GRO .
. GRO .
CM01-6 0.85L .
. GRO .
. GRO .
. GRO .
. GRO .
CM01-5 0.85V .
70
56
42
28
14
1
F
JPL2 1.25V .
JPLF 1.25G .
2 1
2
JGM1,JNMH
CN-LMD1,CN-LMD2
G
A
CN-BKSW (DT) 䝤䝺䞊䜻䝨䝎䝹䝸䝭䝑䝖䝇䜲䝑䝏
DSH_M-59 0.85Y .
BRAKE PEDAL SWITCH
C
DSH_M-57 1.25R . DSH_M-58 0.85W .
B
H
I
䈜 JNX4
CN-BRK (DT) 䝤䝺䞊䜻䝨䝎䝹䝫䝔䞁䝅䝵 BREAKE PEDAL POTENTIO
DSH_M-63 0.85P .
C
B
J CN-DCL (DT) 䝕䝉䝹䝫䝔䞁䝅䝵
K
DECEL PEDAL POTENTIO
A DSH_M-66 0.85B .
C
DSH_M-65 0.85Y .
(FROM 4/19) TO FLOOR HARNESS
䝣䝻䜰䝝䞊䝛䝇䜈 CN-DSH_M (DRC12-70PAE)
JPL2,JPLE,JPLF
DSH_M-64 0.85P .
JGM3,JPKA,JPL8
B
L
M 1
N
O
6
JPLF 1.25Y .
JPKA 1.25Br .
JPLE 1.25G .
4
3
JPLE 1.25G .
JGM3 1.25B .
JPLF 1.25Y .
1
6
JPL8 1.25L .
JPKA 1.25Br .
. . .
4
3
. . .
JGM3 1.25B .
JPL8 1.25L .
1
3
DSH_M-34 1.25L .
DSH_M-30 1.25W .
DSH_M-33 1.25R .
DSH_M-31 1.25G .
DSH_M-32 1.25V .
6
4
CN-KEY (DT) 䜻䞊䝇䜲䝑䝏䜈
CN-RLSW (SWP) ᚋ↷ⅉ䝇䜲䝑䝏
TO KEY SWITCH
REAR LAMP SWITCH
CN-FLSW (SWP) ๓↷ⅉ䝇䜲䝑䝏
DSH_M-29 1.25Br .
(TO 15/19)
FRONT LAMP SWITCH
P
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.
A
(FROM 2/19)
CAB SPEC
20
TO FLOOR FRAME
21
䝣䝻䜰䝣䝺䞊䝮䜈 CN-FD1_F (24-31)
PT1-B 1.25W .
10 JNXJ 0.85B .
22 PT1-C 1.25P .
B
23 PRT_F-4 1.25Y .
CN-WSH2 4 (DT) 䜴䜷䝑䝅䝱䝰䞊䝍㻔ෆ㻕䜈
C
GND06 1.25B .
TO WASHER MOTOR (IN)
6
FD4_M-7 1.25V .
. GRO .
GND06 1.25B .
. GRO .
FD4_M-9 1.25G .
11 EG2_F-11 1.25Y .
12 EG2_F-12 1.25B .
24
3
PRT_F-5 1.25B .
31
PT1-A 1.25B .
8 EG2_F-1 0.75W .
9 EG2_F-2 0.75B .
2 EG2_F-7 1.25Gy .
3 JPZ6 1.25W .
1 EG2_F-8 1.25W .
4 PRT_F-6 1.25W .
5 PRT_F-7 1.25B .
13 EG2_F-10 1.25P .
14 JOL1 1.25B .
25 . GRO .
FD2_M-5 1.25L .
19 GND03 1.25B .
7 FTK_F-4 1.25B .
6 FTK_F-3 1.25L .
15 FD2_M-11 1.25Br .
26
31 30
30
FD2_M-2 1.25V .
. GRO .
18
18
PPL-1 1.25V .
29 GND03 1.25B .
17 FD2_M-12 1.25Y .
. GRO .
28
16
17 . GRO .
28
FD2_M-9 1.25O .
PRT_F-3 1.25P .
. GRO .
29
. GRO .
16 AF1-2 1.25B .
27
27
SW 1.25V .
. GRO .
. GRO .
. GRO .
19
WSH1-1 1.25L .
AC05-1 1.25G .
1
6 WSH1-3 1.25W .
4 AC05-2 1.25B .
5 . GRO .
15
14
11 . GRO .
23 . GRO .
12
. GRO .
A/C1_F-1 1.25W .
22 . GRO .
. GRO .
13
24 . GRO .
25
. GRO .
1
10 . GRO .
3
. GRO .
䝣䝻䜰䝣䝺䞊䝮䜈 CN-FD4_M (24-31)
. GRO .
WSH2-1 1.25G .
2
WSH2-3 1.25V .
21
9
. GRO .
7
26
TO FLOOR FRAME
. GRO .
8
. GRO .
AF1-1 1.25Gy .
(FROM 2/19)
20
JOL1
FD3_M-5 FD1_F-14 1.25B 1.25B . .
GND03 2B .
JPZ6
BKAL-1 FD1_F-3 1.25W 1.25W . .
FD2_M-10 1.25W .
JNXF
JNXJ . .
EG2_F-3 0.85B .
JNXJ
FD1_F-10 0.85B .
JNXF . .
PPL-2 1.25B .
FD2_M-1 1.25B .
CN-GND03 ಙྕ䜰䞊䝇 SIGNAL EARTH
JOL1 2B .
BKAL-2 1.25B .
FD1_F-29 1.25B .
FD1_F-19 1.25B .
JOL1 JPZ6
JNXJ
1
6
FD4_M-6 1.25W .
GND06 1.25B .
FD4_M-8 1.25L .
GND03 1.25B .
FD2_M-6 1.25O .
FD1_F-7 1.25B .
GND06 1.25B .
. GRO .
. GRO .
FD2_M-7 1.25W .
GND03 1.25B .
FD1_F-6 1.25L .
3
4
F
FTK_F-2 1.25B .
. GRO .
D
E
FTK_F-6 1.25B .
CN-B30S
6
CN-WSH1 (DT) 䜴䜷䝑䝅䝱䝰䞊䝍㻔እ㻕䜈
F30_F 5R .
TO WASHER MOTOR (OUT)
䝃䞊䜻䝑䝖䝤䝺䞊䜹 (ᖖ㟁※⏝)
WSH2-4 WSH2-2 WSH1-4 WSH1-2 1.25B 1.25B 1.25B 1.25B . . . .
G
WASHER MOTOR EARTH
䝃䞊䜻䝑䝖䝤䝺䞊䜹 (ᖖ㟁※⏝)
1 12
CN-B105S B105S 15W . 䝃䞊䜻䝑䝖䝤䝺䞊䜹 CN-F105_F (㟁※⏝) CIRCUIT BREAKER (DTHD) (FOR MAIN POWER)
JOL1 1.25B . FD1_F-17 1.25Y .
FD1_F-30 1.25V .
PRT_F-2 1.25G . JPZ6 1.25W .
FD1_F-15 1.25Br .
B30S 5R .
FD1_F-28 1.25O .
FD1_F-31 1.25L . LRP2-1 1.25Y .
CN-BRB 䝞䝑䝔䝸䝸䝺䞊䜈
FTK_F-1 1.25W .
6 7
TO FUEL TANK
2
EG1_F-2 3R .
EG1_F-1 3R .
1
6
CN-FD3_M (DT)
B30L 5R .
TO BATTERY RELAY
FTK_F-5 1.25O .
CN-EGPW_M (DTP)
CN-FD2_M (DT-C)
CN-F30_F (DTHD)
H
PRT_F-1 1.25L .
3
CN-FTK_F (DT) ⇞ᩱ䝍䞁䜽䜈
CIRCUIT BREAKER (FOR UNSWITCHED POWER)
BRB 5R .
F105_F 15W .
CN-GND06 䜴䜷䝑䝅䝱䝰䞊䝍䜰䞊䝇
1
CN-B30L
CIRCUIT BREAKER (FOR UNSWITCHED POWER)
4
4
. GRO .
EG2_F-4 1.25O .
JOL1 1.25B .
. GRO .
EG2_F-5 1.25Gy .
HT 1.25W .
(TO 16/19)
1
3
䝠䝳䞊䝈䝪䝑䜽䝇䜈 TO FUSE BOX
2
(FROM 13/19)
CN-BKAL (DT) 䝞䝑䜽䜰䝑䝥䜰䝷䞊䝮䜈
I
2
GND03 1.25B .
JPZ6 1.25W .
JOL1 1.25B .
FD1_F-18 1.25V .
CN-PPL (DT) 1 䝢䞁䝥䝷䝋䝺䝜䜲䝗䜈 TO PIN PULLER SOLENOID
1
TO BACK UP ALARM
CN-GND07 䝠䞊䝍䝸䝺䞊䜰䞊䝇
J
HEATER RELAY EARTH
1
AF1-2 1.25Gy .
AF1-1 1.25Gy .
2
1
FD4_M-15 1.25Gy .
FD4_M-16 1.25B .
2
CN-AF1 (DT) (OPT)䜶䜰䜽䝸䞊䝘 ┠䛵䜎䜚䝉䞁䝃䞊䜈 TO AIR CLEANER CLOGGED SENSOR
FD1_F-27 1.25V .
CN-SW 䝞䝑䝔䝸䝸䝺䞊䜈
1
K
FD4_M-14 1.25W . . GRO .
2
JNXF
(TO 16/19)
1
CN-A/C1_F (DT) A/C䝁䞁䝥䝺䝑䝃䜈 TO A/C COMPRESSOR
2 FD4_M-4 1.25B . FD4_M-3 1.25G .
1
TO A/C REFRIGERANT PRESSURE SW
N
䝎䜲䜸䞊䝗 CN-HTD (DT)
6 HTD-1 FD3_M-3 2W 1.25W . .
CN-HT 䝸䝪䞁䝠䞊䝍䝸䝺䞊䜈
7
. GRO .
FD3_M-4 1.25Gy .
FD3_M-1 1.25O .
JNXF 0.85B .
FD1_F-9 0.75B .
FD1_F-8 0.75W .
FD1_F-2 1.25Gy .
FD1_F-1 1.25W .
. GRO .
FD1_F-13 1.25P .
FD1_F-11 1.25Y .
FD1_F-12 1.25B .
1
12
CN-EG2_F (DT-B)
TO RIBBON HEATER RELAY
2
EGPW_M-2 3R .
EGPW_M-1 3R .
2
1
. GRO .
. GRO .
2
. GRO .
FD2_M-3 1.25G .
. GRO .
FD1_F-16 1.25P .
. GRO .
FD1_F-23 1.25Y .
. GRO .
FD1_F-24 1.25B .
. GRO .
FD1_F-4 1.25W .
FD1_F-5 1.25B .
(TO 17/19)
7
CN-PRT (DT-A) 䝣䞊䝗䜈
DIODE
GND07 2B .
2
O
1
HT 2W .
1
12
FD2_M-4 1.25L .
6
1
CN-AC05 (S090) A/C෭፹ᅽຊSW䜈
FD2_M-8 1.25Y .
TO RIPPER POINT LAMP
L
M
. GRO .
CN-LRP2 (DT) (OPT)䝸䝑䝟䝫䜲䞁䝖䝷䞁䝥䜈
TO BATTERY RELAY
HTD-2 2B .
2
TO HOOD
A
FD1_F-20 1.25B .
FD1_F-21 1.25W .
FD1_F-22 1.25P .
1
B C
CN-PT1 (DT) 䝢䝑䝏䜰䞁䜾䝹䝉䞁䝃䞊䜈
CN-EG1_F (DTP)
TO PITCH ANGLE SENSOR
䜶䞁䝆䞁䜈
P
TO ENGINE
(TO 12/19) 407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429 SEN02874-04
D155A-6
117
Wiring harness diagram (11/19)
Wiring harness diagram (11/19) 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
(FROM 5/19)
20
TO FLOOR FRAME
21
䝣䝻䜰䝣䝺䞊䝮䜈 CN-FD1_F (24-31)
PT1-B 1.25W .
10 JNXJ 0.85B .
22 PT1-C 1.25P .
B
23 PRT_F-4 1.25Y .
11 EG2_F-11 0.85Y .
12 EG2_F-12 0.85B .
24
C
AF1-1 1.25Gr .
PT1-A 1.25B .
9 EG2_F-2 0.75B .
3 JPZ6 1.25W .
4 PRT_F-6 1.25W .
13 EG2_F-10 0.85P .
25
31
8 EG2_F-1 0.75W .
2 EG2_F-7 1.25Gr .
1 EG2_F-8 1.25W .
5 PRT_F-7 1.25B .
14 JOL1 1.25B .
JPLN 1.25L .
FD2_M-5 1.25L .
19 GND03 1.25B .
7 FTK_F-4 1.25B .
6 FTK_F-3 1.25L .
15 FD2_M-11 1.25Br .
26
30 FD2_M-2 1.25V .
18 PPL-1 1.25V .
29 GND03 1.25B .
17 FD2_M-12 1.25Y .
16 PRT_F-3 1.25P .
JPLM
PRT_F-2 1.25G .
FD1_F-26 1.25B .
FD2_M-3 1.25G .
JPLN
PRT_F-1 FD1_F-25 1.25L 1.25L . .
FD2_M-4 1.25L .
JPZ6
BKAL_F-1 FD1_F-3 1.25W 1.25W . .
FD2_M-10 1.25W .
JOL1
FD3_M-5 FD1_F-14 1.25B 1.25B . .
GND03 FD2_M-1 2B 1.25B . .
28 FD2_M-9 1.25O .
27 SW 1.25V .
JPLM 1.25B .
䈜JNXF
JNXJ BRAID .
EG2_F-3 0.85B .
JNXJ
FD1_F-10 0.85B .
JNXF BRAID .
JOL3
PRT_F-5 1.25B .
AF1-2 1.25B .
D
JOL3 1.25B .
JOL1 2B .
PPL-2 1.25B .
FTK_F-6 1.25B .
FTK_F-2 BKAL_F-2 FD1_F-29 FD1_F-19 1.25B 1.25B 1.25B 1.25B . . . .
CN-GND03 ಙྕ䜰䞊䝇 SIGNAL EARTH
JOL1 1.25B .
JPLM,JPLN JOL1,JPZ6 JOL3 6
E
JNXJ BRB 5R .
F
CN-B30S 䝃䞊䜻䝑䝖䝤䝺䞊䜹 (ᖖ㟁※⏝) CN-B30L
G
FD1_F-30 1.25V .
JPLM 1.25G .
JPLN 1.25L .
FD1_F-31 1.25L .
FTK_F-5 1.25O .
12
FD1_F-17 1.25Y .
FD1_F-15 1.25Br .
JPZ6 1.25W .
FD1_F-28 1.25O .
LRP2-1 1.25Y .
FTK_F-1 1.25W .
䝃䞊䜻䝑䝖䝤䝺䞊䜹 (ᖖ㟁※⏝)
F105_F 15W .
H
JOL1 1.25B .
1
CIRCUIT BREAKER (FOR UNSWITCHED POWER)
F30_F 5R .
CN-B105L
CIRCUIT BREAKER (FOR MAIN POWER)
䝃䞊䜻䝑䝖䝤䝺䞊䜹 (㟁※⏝)
2
7
EG1_F-2 3R .
EG1_F-1 3R .
B30L 5R .
CN-F105_F (DTHD)
CN-F30_F (DTHD)
4
CN-BRB 䝞䝑䝔䝸䝸䝺䞊䜈
. GRO .
EG2_F-4 1.25O .
JOL1 1.25B .
. GRO .
EG2_F-5 1.25Gr .
HT 1.25W .
6
B30S 5R .
3
(FROM 13/19)
FD1_F-24 1.25Gr .
JOL3 1.25B .
2
FD1_F-27 1.25V .
CN-SW 䝞䝑䝔䝸䝸䝺䞊䜈 TO BATTERY RELAY
L 䈜JNXF
M
HTD-1 FD3_M-3 2W 1.25W . .
O
7
CN-HT 䝸䝪䞁䝠䞊䝍䝸䝺䞊䜈
. GRO .
FD3_M-4 1.25Gr .
FD3_M-1 1.25O .
JNXF 0.85B .
FD1_F-9 0.75B .
FD1_F-8 0.75W .
FD1_F-2 1.25Gr .
FD1_F-1 1.25W .
. GRO .
FD1_F-13 0.85P .
FD1_F-11 0.85Y .
FD1_F-12 0.85B .
1
12
CN-EG2_F (DT-B)
TO RIBBON HEATER RELAY
P
2
EGPW_M-2 3R .
EGPW_M-1 3R .
1
JPZ6 1.25W .
CN-PPL (DT) 䝢䞁䝥䝷䝋䝺䝜䜲䝗䜈
1
2
. GRO .
FD2_M-8 1.25Y .
1
1
. GRO .
. GRO .
2
TO PIN PULLER SOLENOID
CN-LRP2 (DT) (OPT)䝸䝑䝟䝫䜲䞁䝖䝷䞁䝥䜈
12
JPLN 1.25L .
. GRO .
JPLM 1.25G .
. GRO .
FD1_F-16 1.25P .
. GRO .
FD1_F-23 1.25Y .
. GRO .
JOL3 1.25B .
. GRO .
FD1_F-4 1.25W .
FD1_F-5 1.25B .
6
6
GND03 1.25B .
2
1
䝎䜲䜸䞊䝗
GND07 2B .
CN-HTD (DT)
TO RIPPER POINT LAMP
(TO 17/19)
7
CN-PRT_F (DT-A) 䝣䞊䝗䜈
1
HT 2W .
DIODE
2
FD1_F-18 1.25V .
TO FUSE BOX
CN-BKAL (DT) 䝞䝑䜽䜰䝑䝥 䜰䝷䞊䝮䜈
K
2
JOL1 1.25B .
䝠䝳䞊䝈䝪䝑䜽䝇䜈
HTD-2 2B .
N
3
TO BACK UP ALARM
1
1
FD1_F-6 1.25L .
1
2
TO AIR CLEANER CLOGGED SENSOR
HEATER RELAY EARTH
GND03 1.25B .
(TO 16/19)
1
䜶䜰䜽䝸䞊䝘┠䛵䜎䜚䝉䞁䝃䞊䜈 CN-AF1 (DT)
FD2_M-7 1.25W .
TO FUEL TANK
6
CN-FD3_M (DT)
B105L 15W .
TO BATTERY RELAY
CN-GND07 䝠䞊䝍䝸䝺䞊䜰䞊䝇
FD1_F-7 1.25B .
CN-FTK_F (DT) ⇞ᩱ䝍䞁䜽䜈
CN-EGPW_M (DTP)
CN-FD2_M (DT-C)
I
J
FD2_M-6 1.25O .
1
CIRCUIT BREAKER (FOR UNSWITCHED POWER)
4
GND03 1.25B .
TO HOOD
A
FD1_F-20 1.25B .
FD1_F-21 1.25W .
FD1_F-22 1.25P .
1
B C
CN-PT1 (DT) 䝢䝑䝏䜰䞁䜾䝹䝉䞁䝃䞊䜈
CN-EG1_F (DTP)
TO PITCH ANGLE SENSOR
䜶䞁䝆䞁䜈 TO ENGINE
(TO 12/19) 430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452 SEN02874-04
D155A-6
119
Wiring harness diagram (12/19)
Wiring harness diagram (12/19) 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
B
1
GND20 3B .
EG1-2 3R .
4
2
GND20 3B .
EG1-1 3R .
3
CN-EGC3 (DTP06-4S) ENG䝁䞁䝖䝻䞊䝷CM850䜈 TO ENG CONTOROLLER CM850
ᔐྜ㠃䛛䜙ぢ䜛
EGC2-46 EG2-1 CA1-A
0.75W 0.85W NA 0.85W . . .
SEE FROM CONNECTING SURFACE
EGC2-47 EG2-2 CA1-B
0.75B 0.85B NC 0.85B . . . EGC2-37 CA1-C
.
EG2-3
0.85B BRAID 0.85B NE 0.85B . . . .
C
C
D
B
A . . .
NE 0.85B .
B
CN-GND20 ENG䝁䞁䝖䝻䞊䝷㟁※䜰䞊䝇
E
ENG CONTROLLER POWER EARTH
A
C
50
TO CAN TERMINATER
EGC3-1 EGC3-2 3B 3B . .
CN-E22 (DT) 䜶䞁䝆䞁ྑ(䝇䝍䞊䝍䚸䜸䝹䝍䝛䞊䝍)䜈
F
NC NA 0.85B 0.85W . .
CN-CA1 (DT) CAN䝍䞊䝭䝛䞊䝍䜈
TO RIGHT OF ENGINE(STARTER,ALTERNATOR)
2 EG2-7 1.25Gy . EG2-8 1.25L .
1
(TO 12/19)
NA,NC,NE
G
40
30
20
10
. EG2-5 GRO 0.85Gy . .
. GRO .
. GRO .
. GRO .
. EG2-4 GRO 0.85O . .
. GRO .
. EG2-11 GRO 0.85Y . .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
NC 0.85B .
NE 0.85B .
. GRO .
. GRO .
. GRO .
NA 0.85W .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. EG2-12 GRO 0.85B . .
. GRO .
. GRO .
. GRO .
. EG2-10 GRO 0.85P . .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
41
31
21
11
1
CN-EGC2 (DRC26-50S04) ENG䝁䞁䝖䝻䞊䝷CM850䜈 TO ENG CONTOROLLER CM850
H ᔐྜ㠃䛛䜙ぢ䜛
SEE FROM CONNECTING SURFACE
I
J
1
EGC3-3 3R .
EGC3-4 3R .
2
1
CN-EG1 (DTP04-2P-E003)
12
NA NC NE EGC2-39 EGC2-40 0.75W 0.75B 0.85B 0.85O 0.85Gy . . . . . EGC2-23 EGC2-9 EGC2-22 0.85B 0.85Y 0.85P . . .
. GRO .
. E22-1 E22-2 GRO 1.25L 1.25Gy . . .
6 7
CN-EG2 (DT-B)
K
ᕥ䝣䜵䞁䝎䜈 TO LEFT FENDER
(FROM 10,11/19)
L
M
ST
1
2
A
E22-2 ST-2
R
N
E22
2
ALTERNATOR O
1
R A
(FROM 12/19)
P
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475 SEN02874-04
D155A-6
121
Wiring harness diagram (13/19)
Wiring harness diagram (13/19) 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-FS1
CN-FS2
5A
FS21
5 G 1.25Br .
CG . .
CG . .
CG . .
20A
AA 1.25R .
5A
1
P 1.25O .
20A
5
5A
CF . .
20A
5A
20A
A
CF . .
20A
CF . .
AA 3R .
5A
FS11
1
B 1 FSB_F-E 3R .
2
CN-PHR 䝥䝸䝠䞊䝍
C
PRE HEATER
FD3_F-5 1.25B .
3
5
L 1.25Y .
R 1.25W .
FSB_F-B 3L .
NEUTRAL SAFTY
1 2
2
2
FD3_F-4 1.25Gy .
FD3_F-2 1.25R .
EGPW-2 3R .
EGPW-1 3R .
AA 3R .
3
5 FSB_F-F 1.25G .
L 1.25Y .
FD2_F-11 1.25Br .
FSB_F-V 1.25Br .
FS22 CN-CB8 䜶䞁䝆䞁䝁䞁䝖䝻䠉䝷 ENGINE CONTROLLER
L,CA,CE
2 FSB_F-K 2R .
FSB_F-N 1.25P .
FSB_F-P 1.25G .
5
FSB_F-C FSB_F-A 1.25R 1.25O . .
FD3_F-1 1.25O .
FS12
2
CN-NSF 䝙䝳䞊䝖䝷䝹䝉䜲䝣䝔䜱
FSB_F-D 3Y .
. . .
1
D
1
5 F 1.25Sb .
1 AA 2R .
CN-CB7 䝁䞁䝖䝻䠉䝷ᖖ㟁※ CONTROLLER UNSWITCHED POWER
. . .
AA 2R .
J 2R .
G 1.25Br .
E
1
2
CN-CB6 䜻䠉B KEY-B
1 2
CN-LMRP 䝸䝑䝟䝷䞁䝥
F
A
G
H
I
CB4-2 2W .
LMFR-3 LMFL-3 1.25W 1.25W . .
P
FS11-5 1.25O .
EHL-5 1.25O .
ACT-6 1.25O .
PHR-5 1.25W .
FD3_F-3 1.25W .
RIPPER LAMP
CB5-2 2Gy .
LMRP-3 LMRE-3 1.25Gy 1.25Gy . .
R
E
FD2_F-5 1.25L .
LMRP-1 1.25L .
LMRE-1 1.25L .
W
FSB_F-M 2L .
CB9-2 2L .
AUX0 2L .
F
FS12-2 1.25Sb .
BKA-3 1.25Sb .
BKA-1 1.25Sb .
AA
CB8-1 3R .
FS21-1 1.25R .
F30_M 5R .
FS11-1 3R .
G
NSF-1 1.25Br .
ACT-3 1.25Br .
ACT-1 1.25Br .
CA
CF 8W .
CC 5Y .
CG 5Br .
F105_M 15W .
H
FD2_F-2 1.25V .
LMFR-1 1.25V .
LMFL-1 1.25V .
CC
CB2-1 2Y .
CB4-1 2Y .
CA 5Y .
CB1-1 2Y .
J
EHL-3 1.25R .
EHL-1 1.25R .
FSB_F-S 1.25R .
CB6-2 2R .
CE
CB5-1 2Y .
CB3-1 2Y .
CB9-1 2Y .
CC 5Y .
L
FD3_F-6 1.25Y .
FD2_F-12 1.25Y .
PHR-3 1.25Y .
FS22-3 1.25Y .
CF
FS11-3 . .
FS11-2 . .
CA 8W .
FS11-4 . .
M
LMFR-2 1.25B .
FD2_F-1 1.25B .
LMFL-2 1.25B .
LMRP-2 1.25B .
CG
FS21-3 . .
FS21-2 . .
CA 5Br .
FS21-4 . .
N
LMRE-5 FD2_F-7 1.25O 1.25W . .
FD2_F-6 1.25O .
LMRE-2 1.25B .
C 1.25Gy .
FD2_F-8 1.25Y .
CB7-1 2R .
CB6-1 2R .
CN-ACT ACC䜹䝑䝖(ENG) ACC CUT(ENG)
2
E 1.25L .
A 2W .
AA,CC
1
G 1.25Br .
G 1.25Br .
P 1.25O .
. . .
6
5
FRONT LAMP
CN-EHL 䜶䞁䝆䞁䝩䞊䝹䝗
1
J 1.25R .
J 1.25R .
. . .
P 1.25O .
6
5
ENGINE HOLD
1 CE 2Y .
2
G,P
FSB_F-J 2O .
FSB_F-X 1.25Gy .
2 FSB_F-H 2Br .
2
3
5
A 1.25W .
FD2_F-3 1.25G .
CN-FD3_F (DT)
M 1.25B .
CB8-2 1.25R .
FS12-5 1.25O .
PHR-1 1.25Gy .
PHR-2 1.25B .
L 1.25Y .
4
C,E
1 2
CN-LMFR 䝣䝻䞁䝖䝷䞁䝥,ྑ
6
FRONT LAMP RH
5
A 1.25W .
FD2_F-4 1.25L .
2
M 1.25B . . . . H 1.25V .
L
N,R,W
1
M 1.25B .
. . .
E 1.25L .
N 1.25O .
5
C 1.25Gy .
3
. . .
1
5
3
FD2_F-10 1.25W .
F 1.25Sb .
W ACT-2 0.85V .
G . GRO .
V FS22-5 1.25Br .
F NSF-5 1.25G .
U . GRO . T R 1.25W .
7
N 1.25O .
E 1.25L .
LMFR-5 1.25L .
LMFL-5 1.25G .
H 1.25V .
M 1.25B .
N 1.25W .
LMRP-5 1.25Y .
BKA-2 1.25O .
BKA-5 1.25W .
FS22-4 1.25Br .
L 1.25Y .
O
AA 5R .
1
CA 15W .
CN-FD2_F (DT)
CN-F30_M (DTHD) ᖖ㟁※
UNSWITCHED POWER 24V
WORK EQUIPMENT CONTROLLER
CN-F105_M (DTHD) 㟁※
1 CC 2Y .
CN-CB1 P/T䝁䞁䝖䝻䠉䝷 P/T CONTROLLER
CN-CB9 OPT䝕䝞䜲䝇 OPT DEVICE
B FS12-3 3L . A FS22-2 1.25O .
E FS12-1 3R . S J 1.25R .
J CB2-2 2O .
L CB3-2 2G .
C FS22-1 1.25R . D FS12-4 3Y .
R G 1.25Br .
K CB7-2 2R .
P NSF-3 1.25G .
M W 2L . N NSF-2 1.25P .
CN-FSB_F (24-21) 䝣䝻䜰䝝䞊䝛䝇䜈
W 2L .
12
H CB1-2 2Br .
X EHL-2 1.25Gy .
BACK ALARM
CB8-2 3R .
6
CN-CB2 సᴗᶵ䝁䞁䝖䝻䠉䝷
2
CN-BKA 䝞䝑䜽䜰䝷䠉䝮
1
N
CE 2Y .
W 2L .
REAR LAMP
CB8-2 3R .
TO LEFT FENDER HARNESS
1 CC 2Y .
FD2_F-9 1.25O .
CN-LMRE 䝸䜰䝷䞁䝥
2
CN-EGPW (DTP)
F 1.25Sb .
F
1
2
1
H 1.25V .
3
A/C
A,H,M
. . .
1
R 1.25W .
CN-CB3 䜶䜰䝁䞁
J
2
3
M
CN-CB4 ๓↷ⅉ
2
FSB_F-W 0.85V .
3
FRONT LAMP LH
ᕥ䝣䜵䞁䝎䝝䞊䝛䝇䜈
1 CC 2Y .
FSB_F-L 2G .
2
CN-LMFL 䝣䝻䞁䝖䝷䞁䝥,ᕥ
(TO 10,11/19)
REAR LAMP
. . .
3
CE 5Y .
J
K
CN-CB5 ᚋ↷ⅉ
1
C
FSB_F-T 1.25W .
FSB_F-R FS21-5 1.25Br 1.25Br . .
5
CE 2Y .
C 2Gy .
M 1.25B .
3
1
2
TO FLOOR MAIN HARNESS
CN-AUX0 OPT DEVICE DRIVE 0
(FROM 2,5/19)
MAIN POWER 24V
ᕥ䝣䜵䞁䝎䝝䞊䝛䝇䜈
P
TO LEFT FENDER HARNESS
(TO 10,11/19) 476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498 SEN02874-04
D155A-6
123
Wiring harness diagram (14/19)
Wiring harness diagram (14/19) 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
T/M䜉䝧䝹ᅇ㌿䝉䞁䝃䜈 TO T/M BEVEL REV SENSOR
CN-BVRV (DT) 䝣䜯䞁䝫䞁䝥㻿㻻㻸䜈 㼀㻻㻌㻲㻭㻺㻌㻼㼁㻹㻼㻌㻿㻻㻸
B
PL1_F-55 1.25Br .
1
㻯㻺㻙㻲㻭㻯 㻔㻰㼀㻕
PL1_F-56 1.25B .
2
సᴗᶵ䝻䝑䜽EPC䜈 1
PL1_F-36 1.25Sb .
PL1_F-37 1.25B .
2
TO WORK EQUIPMENT LOCK EPC
CN-WLK (DT)
C 1
PL1_F-54 1.25Br .
PL1_F-64 1.25B .
2
సືἜᅽ䝉䞁䝃䜈
D
㼀㻻㻌㻴㼅㻰㻚㻻㻵㻸㻌㻼㻾㻱㻿㻿㼁㻾㻱㻌㻿㻱㻺㻿㻻㻾
1
㻯㻺㻙㻴㻴㻼 㻔㻰㼀㻕
PL1_F-19 1.25L . PL1_F-20 1.25B .
A PL1_F-30 1.25Y .
E
C
PL1_F-29 1.25B .
2
CN-SBRR (DT)
PL1_F-31 1.25P .
B 2
PL1_F-9 1.25B .
PL1_F-8 1.25G .
CN-PKS (DT) 㥔㌴䝤䝺䞊䜻㻿㻻㻸䜈
F
TO PARKING LOCK SOL
2
PL1_F-25 1.25B .
PL1_F-24 1.25G .
1
2
PL1_F-11 1.25B .
PL1_F-10 1.25Y .
1
2
. GRO .
PL1_F-15 1.25Gr .
1
2
CN-PBS (DT) CN-FBRL 䝨䝎䝹䝤䝺䞊䜻SOL䜈 (DT)
PL1_F-16 1.25Y .
1
PL1_F-21 1.25P .
. GRO .
2
CN-SBRL (DT)
TO PEDAL BRAKE SOL
1
PL1_F-17 1.25B .
CN-FBRR (DT) ྑ䝤䝺䞊䜻ECMV䜈
ᕥ䝤䝺䞊䜻ECMV䜈 TO LEFT BRAKE ECMV
G
CN-HDT (DT) సືἜ 䝉䞁䝃䜈
1
TO RIGHT BRAKE ECMV
TO RIGHT CLUTCH ECMV
TO LEFT CLUTCH ECMV
ྑ䜽䝷䝑䝏ECMV䜈
ᕥ䜽䝷䝑䝏ECMV䜈
TO HYD.OIL TEMP SENSOR
CN-SCLR
CN-FCLR
CN-SCLL
CN-FCLL
H
1
1
PL1_F-5 1.25Gr .
PL1_F-6 1.25B .
2
1
PL1_F-7 1.25L .
. GRO .
2
1
PL1_F-2 1.25W .
PL1_F-3 1.25B .
2
1
PL1_F-1 1.25V .
. GRO .
2
I
J
K
L 2
PL1_F-40 1.25B .
PL1_F-39 1.25O .
CN-TCT (DT) T/CἜ 䝉䞁䝃䜈
N
X
K
1
TO T/C OIL TEMP SENSOR
O
L
57
TMV_F-P 1.25L .
TMV_F-J 1.25Br .
TMV_F-K 1.25B .
. GRO .
TMV_F-G 1.25G .
TMV_F-H 1.25B .
TMV_F-O 1.25P .
WLK-2 1.25B .
PL1_F-67 1.25B .
. GRO .
PL1_F-65 1.25B .
. GRO .
. GRO .
. GRO .
70
43
TMV_F-M 1.25G .
TMV_F-C 1.25L .
TMV_F-D 1.25B .
. GRO .
TMV_F-A 1.25O .
TMV_F-B 1.25B .
TMV_F-L 1.25Gr .
TMV_F-N 1.25Br .
TMV_F-E 1.25Y .
TMV_F-F 1.25B .
. GRO .
WLK-1 1.25Br .
BVRV-1 1.25Br .
BVRV-2 1.25B .
56
29
HHP-A 1.25B .
HHP-C 1.25Y .
HHP-B 1.25P .
. GRO .
. GRO .
. GRO .
. GRO .
FAC-1 1.25Sb .
FAC-2 1.25B .
. GRO .
TCT-1 1.25O .
TCT-2 1.25B .
. GRO .
. GRO .
42
15
FBRL-1 1.25Gr .
SBRL-1 1.25Y .
SBRL-2 1.25B .
. GRO .
SBRR-1 1.25L .
SBRR-2 1.25B .
FBRR-1 1.25P .
SSP-1 1.25L .
SSP-2 1.25B .
HDT-1 1.25G .
HDT-2 1.25B .
. GRO .
. GRO .
. GRO .
1
FCLL-1 1.25V .
SCLL-1 1.25W .
SCLL-2 1.25B .
. GRO .
SCLR-1 1.25Gr .
SCLR-2 1.25B .
FCLR-1 1.25L .
PKS-1 1.25G .
PKS-2 1.25B .
PBS-1 1.25Y .
PBS-2 1.25B .
. GRO .
. GRO .
. GRO .
28
PL1_F-49 1.25Gr .
PL1_F-59 1.25B .
B
M
PL1_F-43 1.25G .
C
PL1_F-44 1.25L .
N PL1_F-50 1.25Br .
O
PL1_F-63 1.25P .
14
PL1_F-48 1.25B .
D
PL1_F-45 1.25B .
P PL1_F-57 1.25L .
. GRO .
J PL1_F-58 1.25Br .
A PL1_F-47 1.25O .
E PL1_F-51 1.25Y .
Q . GRO .
W . GRO .
F
R . GRO .
U . GRO .
G
PL1_F-61 1.25G .
PL1_F-52 1.25B .
1
TO SUDDEN STOPPREVENT SOL
V . GRO .
H PL1_F-62 1.25B .
PL1_F-22 1.25L .
CN-SSP (DT) ᛴṆ㜵ṆSOL䜈
M 2
PL1_F-23 1.25B .
T
S
. GRO .
. GRO .
CN-TMV_F (24-23) TM䜽䝷䝑䝏ECMV䜈 TO TM CLUTCH ECMV
CN-PL1_F (DRC16-70SAE-P066) 䚷䝣䝻䜰䝝䞊䝛䝇䜈 TO FLOOR HARNESS
P
(FROM 2,5,18/19) 499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521 SEN02874-04
D155A-6
125
Wiring harness diagram (15/19)
Wiring harness diagram (15/19) 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
CM05 (MITSUMI)
B
3:Ⲕ
6:(㯮) (ྠ㍈GND)
1:㟷
7:(ྠ㍈GND)
2:(ⓑ) (ྠ㍈)
C
(TAJIMI)
G:እ⿕䝅䞊䝹䝗
A
B
8:(ྠ㍈GND)
H:(㯮) (ྠ㍈GND)
A (䝰䝙䝍ഃ㠀㜵Ỉ䝁䝛䜽䝍)
D
D:Ⲕ C:(ⓑ) (ྠ㍈) B:㯮
A:እ⿕䝅䞊䝹䝗
5:㯮
4:ᶳ
F:㟷 E:ᶳ
B (䜹䝯䝷ഃ㜵Ỉ䝁䝛䜽䝍)
E
3 0.5Y 2 0.5R
F
BNSU 0.5Y 0.5R 0.5L
3 0.5G
0.5Y 0.5G
TO ″A″ BOTTUM
0.5L 0.5R
1 0.5B 2 0.5W
H
6 3 4
A䝪䝍䞁䜈
1 0.5L
G
BNSW (DT)
0.5B 0.5B 0.5W 0.5G
2 1 5
0.5W
6 5 4 3 2 1
B䝪䝍䞁䜈
TO ″B″ BOTTUM
BNSL
I
J CN-280 CN-270
AT11 䝠䝻䝉㟁ᶵ〇 GT5-1PP-HU
K
CN-255 CN-250 CN-256
L
KEY-2 1.25W . KEY-5 1.25R . KEY-6 1.25L .
C ACC
1
BR KEY
AT12 䝠䝻䝉㟁ᶵ〇 GT5-1S-HU GPS ANTENNA
CN-260
KEY-3 1.25G . KEY-1 1.25BR . KEY-4 1.25Y .
R1 B
3
270
255
280
1.25BR .
1.25W .
1.25G .
256
250
260
1.25L .
1.25R .
1.25Y .
(FROM 8,9/19) CN-KEY (DT)
4
6
R2
08086-5000 KEY SWITCH0
M AT22
(FROM 3,4/19)
08031-10104 TERMINAL HORN SWITCH PINPULLER SWICH
N 08192-22830 CONNECTOR CN-HNSW_M (DT) CN-PLSW_M (DT)
O
AT21
MLJ䝁䝛䜽䝍C3604 Ni
BNCP䝁䝛䜽䝍 C3604 Ni
MLJ connetor C3604 Ni
BNCP connector C3604 Ni etc.
ORBCOMM ANTENNA
P
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544 SEN02874-04
D155A-6
127
Wiring harness diagram (16/19)
Wiring harness diagram (16/19) 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-LREL (DT) ᕥᚋ↷ⅉ䜈
A
TO REAR LAMP(L.H)
CN-ACS (DT) 䝎䜲䜸䞊䝗
B
DIODE
1
C
1
2 A GND09 1.25W 1.25B . .
2
CN-LRER (DT) ྑᚋ↷ⅉ䜈(OPT)
ONLY FOR CAB SPEC
(FROM 10/19)
A
CN-A/C2 (DT) A/C䝁䞁䝥䝺䝑䝃䜈 TO A/C COMPRESSOR
E
2
2
. GRO .
. GRO .
A 1.25W .
A 1.25W .
1
1
ACS-2 1.25B .
. GRO .
2
1
FTK-5 FTK-6 1.25O 1.25B . .
2
TO REAR LAMP(R.H)
2
1
LRER-1 LRER-2 FLV-1 1.25W 1.25B 1.25L . . .
FTK-1 1.25W .
LREL-2 LREL-1 FLV-2 1.25B 1.25O 1.25B . . .
1
CN-A/C1 (DT) ᕥ䝣䜵䞁䝎䜈
3
FTK-2 1.25B .
6
CN-FTK (DT) ᕥ䝣䜵䞁䝎䜈
(FROM 10,11/19)
TO LEFT FENDER
4
TO LEFT FENDER
CN-GND09 A/C䝁䞁䝥䝺䝑䝃 䝎䜲䜸䞊䝗䜰䞊䝇
F
. GRO .
A/C-1 A/C-2 ACS-1 1.25W 1.25W 1.25W . . .
A
D
1
2
A/C COMPRESSOR DIODE EARTH
FTK-4 FTK-3 1.25B 1.25L . .
1
CN-FLV (DT) ⇞ᩱ䝺䝧䝹䝉䞁䝃䜈 TO FUEL LEVEL SENSOR
G
CN-B105HS 䝃䞊䜻䝑䝖䝤䝺䞊䜹䜈(䝸䝪䞁䝠䞊䝍䞊⏝)
H
TO CIRCUIT BREAKER(FOR RIBBON HEATER) BRC 20L .
I CN-B105L 䝃䞊䜻䝑䝖䝤䝺䞊䜹䜈(㟁※⏝) TO CIRCUIT BREAKER(FOR MAIN POWER)
J
BRC 20W .
B105L B105HS 20W 20L . .
TO BATTERY RELAY
䝞䝑䝔䝸䝸䝺䞊䜈 CN-BRC
HT/B 20R .
RHT 20R .
CN-RHT 䝸䝪䞁䝠䞊䝍䜈
CN-HT/B 䝸䝪䞁䝠䞊䝍䝸䝺䞊䜈
TO RIBBON HEATER
TO RIBBON HEATER RELAY
K
L
M
N
B105HL 20L .
HT/A 20L .
BRC 100R .
ST/B 100R .
CN-HT/A 䝸䝪䞁䝠䞊䝍䝸䝺䞊䜈
CN-B105HL 䝃䞊䜻䝑䝖䝤䝺䞊䜹䜈
CN-ST/B 䝇䝍䞊䝍
CN-BRC 䝞䝑䝔䝸䝸䝺䞊
TO RIBBON HEATER RELAY
TO CURCUIT BRAKER
STARTER
BATTERY RELAY
O
P
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567 SEN02874-04
D155A-6
129
Wiring harness diagram (17/19)
Wiring harness diagram (17/19) 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.
(TO 17,19/19)
A
(TO 17,19/19)
๓↷ⅉ䜈
CN-LHD_F (DT) ๓↷ⅉ䜈
TO HEAD LAMP
CN-LHD_F (DT) B 1
PRT_M-1 1.25L .
PRT_M-2 1.25G .
TO HEAD LAMP
2
1
PRT_M-1 1.25L .
PRT_M-2 1.25G .
2
ONLY FOR INDONESIA SPEC
(TO 17/19)
C
7
D
CN-RDG_F (DT-A) 䝷䝆䜶䝍䞊䜺䞊䝗䜈
(FROM 10,11/19)
6
6
(TO 17/19) 7
7
6
PRT_M-7 1.25B .
PRT_M-6 1.25W .
RDG_F-6 1.25W .
RDG_F-7 1.25B .
PRT_M-7 1.25B .
PRT_M-6 1.25W .
PRT_M-8 1.25Br .
PRT_M-5 1.25B .
RDG_F-5 1.25B .
RDG_F-8 1.25Br .
PRT_M-8 1.25Br .
WLV2-1 1.25B .
PRT_M-9 1.25B .
PRT_M-4 1.25Y .
RDG_F-4 1.25Y .
RDG_F-9 1.25B .
PRT_M-9 1.25B .
. GRO .
PRT_M-3 1.25W .
RDG_F-3 1.25W .
. GRO .
. GRO .
. GRO .
LHD_F-2 1.25G .
. GRO .
. GRO .
TO RADIATOR GUARD
E 12
1
(FROM 10,11/19)
2
CN-WLV2 (DT)
PRT_M-5 1.25B .
6
7
RDG_F-6 1.25W .
RDG_F-7 1.25B .
WLV2-2 1.25B .
RDG_F-8 1.25Br .
PRT_M-4 1.25Y .
RDG_F-4 1.25Y .
RDG_F-9 1.25B .
. GRO .
PRT_M-3 1.25W .
RDG_F-3 1.25W .
. GRO .
. GRO .
. GRO .
. GRO .
LHD_F-2 1.25G .
. GRO .
LHD_F-1 1.25L .
. GRO .
. GRO .
. GRO .
LHD_F-1 1.25L .
. GRO .
1
12
1
12
CN-RDG_F (DT-A) 䝷䝆䜶䝍䞊䜺䞊䝗䜈
ᕥ䝣䜵䞁䝎䜈 TO LEFT FENDER
CN-PRT_M (DT-A)
TO RADIATOR GUARD
12
RDG_F-5 1.25B .
1
1
CN-PRT_M (DT-A) ᕥ䝣䜵䞁䝎䜈 TO LEFT FENDER
F
G
CN-LHDR (DT) ྑ๓↷ⅉ䜈
TO HEAD LAMP(R.H)
2
2
. GRO .
LHDL-1 1.25G .
LHD-1 1.25L .
LHDR-1 1.25L .
1
1
CN-LHD (DT) 䝣䞊䝗䜈
(FROM 17/19)
TO HOOD
H
I
. LHD-2 GRO 1.25G . .
2
1
CN-LHDL (DT) ᕥ๓↷ⅉ䜈
J
TO HEAD LAMP(L.H)
K 6
FAR-2 1.25B .
WLV-2 1.25B .
. GRO .
WLV-1 1.25Y .
. GRO .
HRN 1.25W .
. GRO .
RDG-3 1.25W .
. GRO .
. GRO .
CN-HRN 䝩䞊䞁䜈
. GRO .
. GRO .
1
12
L
M
7
FAR-1 1.25W .
TO HORN
CN-RDG (DT-A) 䝣䜵䞁䝎䜈
(FROM 17/19)
TO FENDER
N
2
O
RDG-5 1.25B .
RDG-4 1.25Y .
1
CN-WLV (DT) 䝷䝆䜶䞊䝍Ỉ䝉䞁䝃䜈 TO COOLANT LEVEL SENSOR
P
2
RDG-7 1.25B .
RDG-6 1.25W .
1
CN-FAR (DT) 䝣䜯䞁㏫㌿䝋䝺䝜䜲䝗䜈 TO FAN REVERSE SOLENOID
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590 SEN02874-04
D155A-6
131
Wiring harness diagram (18/19)
Wiring harness diagram (18/19) 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
<⥭ᛴ㉮⾜䝇䜲䝑䝏䝝䞊䝛䝇> TRAVEL SW HARNESS FOR EMERGENCY(OPT)
JOT1
B
30 . GRO .
29 . GRO .
C
28 . GRO .
18 JTP9 1.25W . 17 JTP9 1.25W . 16 PL1M-5 1.25W . 27 . GRO .
D
31 . GRO . 19 JTP9 1.25W . 7 JPT8 1.25B .
8 PL1M-58 1.25W . 2 PL1M-44 1.25W . 1 JPT1 1.25Br .
6 PL1F-69 5 1.25O JPT7 . 1.25W . 15
PL1M-19 1.25W . 26 JOT2 1.25B .
14 PL1M-6 1.25B .
20 JTP9 1.25W . 9 PL1M-61 1.25W . 3 PL1M-47 1.25W . 4 . GRO . 13 PL1M-20 1.25L . 25 JOT2 1.25B .
PL1M-52 JOT2 PL1M-59 PL1M-62 PL1F-70 DPNL-2 1.25B 1.25B 1.25B 1.25B 1.25B 1.25B . . . . . .
21 PL1M-17 1.25B .
JOT2
12 JPT7 1.25W .
JPT1
22 PL1M-3 1.25B .
DPNL-1 PL1F-68 PNL-1 PL1M-54 RPNL-1 1.25Br 1.25Br 1.25Br 1.25Br 1.25Br . . . . . PNL-5 PNL-11 PNL-12 1.25W 1.25W 1.25W . . .
2
JPT8
JPT1 JOT1 1.25Br 1.25B . .
2
PL1M-45 PL1M-48 PNL-7 1.25B 1.25B 1.25B . . .
24 PL1M-2 1.25W .
JTP9
PNL-17 PNL-18 PNL-19 PNL-20 1.25W 1.25W 1.25W 1.25W . . . .
JPT8
CN-PNL (24-31)
JTP9
JOT2
JPT7
JOT1
JPT1
D155A
(TO 18/19)
1
D155A
F
1
JPT7
23 PL1M-16 1.25L .
CN-PNL (24-31)
E
DIODE 䝎䜲䜸䞊䝗
JOT1 PL1M-23 PNL-25 PNL-26 PL1M-64 1.25B 1.25B 1.25B 1.25B 1.25B . . . . .
10 PL1M-51 1.25W . 11 JPT7 1.25W .
CN-DPNL (DT)
G
H
2
I
PL1M-22 JPT1 1.25O 1.25Br . .
1
2
1
CN-RPNL (X) J
20 21 LTS-8 1.25Br .
10 22
K
LTS-11 1.25O .
23 LTS-3 1.25P .
3SS-1 1.25Sb .
11 RTS-2 1.25Br .
12 RTS-5 1.25O .
L
24
PNL (24-31)
LTS-4 1.25V .
31
LTS-5 1.25Sb .
9 2SS-1 1.25Y .
3 FRS-3 1.25P .
4 B 1.25V .
13 RTS-8 1.25P .
25
.
8
GRO .
1SS-1 1.25W .
19 LTS-2
2
1.25Y .
FRS-1 1.25O .
7 D
1
1.25G .
A 1.25R .
6 FRS-12
5
1.25Gy .
C
1.25L .
15 RTS-3
14
1.25L .
RTS-11 1.25V .
26
LTS-9
LTS-10
1.25L .
1.25Gy .
30 . GRO .
18 RTS-10 1.25W .
17 RTS-9 1.25G .
16 RTS-4
29 . GRO .
28 . GRO .
57
43
29
15
1
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
PNL-8 PNL-2 1.25W 1.25W . .
. PNL-23 PNL-24 GRO 1.25L 1.25W . . .
JOT1 JPT8 1.25B 1.25B . .
. PNL-21 PNL-22 GRO 1.25B 1.25B . . .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
PNL-9 PNL-3 1.25W 1.25W . .
. PNL-15 PNL-16 GRO 1.25W 1.25W . . .
JOT1 JPT8 1.25B 1.25B . .
. PNL-13 PNL-14 GRO 1.25L 1.25B . . .
. GRO .
. GRO .
. GRO .
JOT2 1.25B .
. GRO .
. RPNL-2 PL1F-8 GRO 1.25O 1.25G . . .
. PNL-10 GRO 1.25W . .
. JOT2 PL1F-9 GRO 1.25B 1.25B . . .
. JOT1 GRO 1.25B . .
. GRO .
. PL1F-10 GRO 1.25Y . .
. GRO .
. GRO .
. GRO .
. PL1F-11 GRO 1.25B . .
. JPT1 GRO 1.25Br . .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
70
56
42
28
14
70
56
42
28
14
JOT1 1.25B .
. GRO .
. GRO .
. GRO .
. GRO .
PNL-6 1.25O .
. GRO .
. GRO .
. GRO .
. GRO .
JPT1 1.25Br .
. GRO .
. GRO .
. GRO .
. GRO .
PL1F-65 1.25B .
. GRO .
. GRO .
PL1M-11 . GRO 1.25B . .
. GRO .
. GRO .
. GRO .
PL1M-10 . GRO 1.25Y . .
PL1F-67 1.25B .
. GRO .
. GRO .
PL1M-9 . GRO 1.25B . .
. GRO .
. GRO .
. GRO .
PL1M-8 . GRO 1.25G . .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
. GRO .
57
43
29
15
1
. GRO .
. GRO .
CN-PL1M (DRC14-70PA)
(TO 14/19)
CN-PL1F (DRC16-70SAE-P013)
(FROM 2,5/19)
1.25Gy .
27 . GRO .
PNL (24-31)
M
(FROM 18/19) A
N
FRS-2 FRS-5 FRS-8 FRS-11 PNL-1 1.25R 1.25R 1.25R 1.25R 1.25R . . . . .
B
FRS-4 1.25V .
FRS-6 1.25V .
PNL-4 1.25V .
D
1SS-2 1SS-5 PNL-7 1.25G 1.25G 1.25G . . .
E
2SS-2 2SS-5 1SS-6 1.25G 1.25G 1.25G . . .
C
O
FRS-7 FRS-9 PNL-5 1.25L 1.25L 1.25L . . .
P
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613 SEN02874-04
D155A-6
133
Wiring harness diagram (19/19)
Wiring harness diagram (19/19) 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
<ቑタ๓↷ⅉᵝ>
A,C
ADD FRONT LAMP SPEC(OPT)
1
2
GRO
.
C 1.25L .
A 1.25G .
GRO
A 1.25G .
GND08 1.25B .
C 1.25L .
3
4
1
.
.
4
.
2 GND08 1.25B .
.
(TO 19/19)
GRO
.
TO HEAD LAMP(R.H)
GRO
.
B
2
1 .
CN-LHDRO (DT) ྑ๓↷ⅉ䜈
3
CN-LHD (DT) 䝣䞊䝗䜈
(FROM 17/19)
TO HOOD
GND08 C
D
E
1
A 1.25G .
GND08 1.25B .
4
2
GND08 1.25B .
C 1.25L .
3
2
. GRO .
. GRO .
3
1
. GRO .
. GRO .
4
CN-LHDLO (DT) ᕥ๓↷ⅉ䜈 TO HEAD LAMP(L.H
A
LHDLO-1 LHDRO-3 LHD-2 1.25G 1.25G 1.25G . . .
C
LHDLO-3 LHDRO-1 LHD-1 1.25L 1.25L 1.25L . . .
)
(TO 19/19)
F
G 1
CN-LHDR2 (DT)
H
1
LHDRO-1 1.25L .
CN-LHDL2 (DT)
LHDRO-2 1.25B .
2
1
2
LHDR2-1 LHDR2-2 1.25L 1.25B . . LHDR1-2 LHDR1-1 1.25B 1.25G . .
I
4
1
CN-LHDR1 (DT)
J
LHDLO-3 1.25L . LHDLO-4 1.25B .
2
(FROM 19/19)
1
2
LHDL1-1 LHDL1-2 1.25G 1.25B . .
CN-LHDR0 (DT)
LHDL2-2 LHDL2-1 1.25B 1.25L . .
3
4
1
LHDRO-3 1.25G .
CN-LHDL1 (DT)
LHDRO-4 1.25B .
2
(FROM 19/19) CN-LHDLO (DT)
3
LHDLO-1 1.25G . LHDLO-2 1.25B .
2
K
L
<ቑタ๓↷ⅉᵝ> ADD FRONT LAMP SPEC(OPT)
ONLY FOR CABLESS SPEC
M
2
1
2
LBP_M-4 1.25B .
LBPL-1 1.25G .
LBPL-2 1.25B .
LBP_M-3 1.25L .
LBPR-2 1.25B .
LBPR-1 1.25L .
1
4
3
CN-LBPR (DT) ቑタ䝷䜲䝖(ྑ)䜈
CN-LBP_M (DT) 䝣䝻䜰䝝䞊䝛䝇䜈
TO ADD HEAD LAMP(RIGHT)
TO FLOOR HARNESS
(FROM 4/19)
N
2
O
LBP_M-2 1.25B .
LBP_M-1 1.25G .
1
CN-LBPL (DT) ቑタ䝷䜲䝖(ᕥ)䜈
TO ADD HEAD LAMP(LEFT)
P
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636 SEN02874-04
D155A-6
135
90 Diagrams and drawings
SEN02874-04
90 Diagrams and drawings SEN02874-04
D155A-6
137
SEN02874-04
90 Diagrams and drawings
D155A-6 Bulldozer Form No. SEN02874-04
© 2019 KOMATSU All Rights Reserved Printed in Japan 04-19(01)
138
D155A-6