SEBM016205
1
MACHINE MODEL
SERIAL NUMBER
D155AX-5
70001 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
D155AX-5 mounts the SA6D140E-2 or SA6D140E-3 engine. For details of the engine, see the 6D140-2 or 140-3 Series Engine Shop Manual.
C 2001 1 All Rights Reserved Printed in Japan 04-01(03) D155AX-5
00-1 5
CONTENTS No. of page
01
GENERAL .............................................................................. 01-1
10
STRUCTURE AND FUNCTION ............................................ 10-1
20
TESTING AND ADJUSTING ................................................ 20-1
30
DISASSEMBLY AND ASSEMBLY ....................................... 30-1
40
MAINTENANCE STANDARD............................................... 40-1
90
OTHERS ................................................................................ 90-1
00-2 1
D155AX-5
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00-2-5 00-7 5
SAFETY
SAFETY
NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper
service
and
repair
is extremely
service and repair techniques are both effective designed
manual.
for the specific
injury to workers,
The cautions
by Komatsu
take the necessary
situation
machine
operation.
and described
in this manual
require the use of tools specially
is used to mark safety precautions
these symbols
should
arises or may possibly
always
arise, first consider
Read the Operation carefully
6. Decide
are extremely
BEFORE operating
Manual
the machine.
out any greasing
read all the precautions which
dangerous.
and Maintenance
1. Before carrying
a place
in the
repair
the tools Always
workshop
parts. Always
and parts in their correct
to keep
places.
keep the work area clean and make
sure that there is no dirt or oil on the floor.
or repairs,
given on the decals
Smoke
only in the areas provided
for smok-
ing. Never smoke while working.
are fixed to the machine.
2. When
carrying
out any operation,
wear safety shoes and helmet. loose work clothes,
always
. Always
or clothes with buttons
wear
safety glasses when
trained,
7. Before
adding
hitting
oil or making
wear
safety
glasses
repairs are needed, experienced
when
welder
out welding gloves,
out the work,
apron,
al-
hand
shield, cap and other clothes suited for welding work.
or more workers,
always before
step of the operation.
with two
agree on the operstarting.
form your fellow workers
Always
in-
before starting any
Before starting
work,
REPAIR signs on the controls
in the operator’s
compartment.
in good condition
the correct way to use them.
the
from moving. starting
work,
lower
blade,
ripper,
bucket or any other work equipment
to the
If this
equipment
is not possible,
from falling.
In addition,
the
be sure
ing signs on them.
the
machine
with
before starting 10. Remove
or assembling, blocks,
jacks
support or stands
work.
all mud and oil from
the steps or
other places used to get on and off the machine. Always steps when Never
and learn
insert
to lock all the control levers and hang warn-
9. When disassembling out any operation
ating procedure
and
safety pin or use blocks to prevent the work
carrying
carrying
to prevent
carry
welding
5. Keep all tools
or tracks
ground.
work. When
hang UNDER
8. Before
repairs,
always have a
ways
wear
grind-
etc.
any
on hard, level ground,
block the wheels machine
ing parts with a grinder, 3. If welding
FOR WORK
park the machine
parts with a hammer. . Always
PREPARATIONS
Do not wear
missing.
4. When
care-
safety, and
actions to deal with the situation.
PRECAUTIONS in operation
in this
be followed
keep tools and removed Mistakes
The
purpose.
the symbol A
accompanying
fully. If any dangerous
GENERAL
recommended
for safe
and safe. Some of these techniques
by Komatsu
To prevent
important
jump
impossible
use the handrails,
getting
ladders
or
on or off the machine.
on or off the machine. to use the handrails,
steps, use a stand to provide
If it is
ladders
or
safe footing.
00-3
SAFETY NOTICE
SAFETY
PRECAUTIONS
DURING
19. Be sure to assemble
WORK
original 11 When or
removing
hydraulic
pressure
loosen them spurting
the oil filler cap, drain plug
slowly
measuring
to prevent
or removing
of the oil, water
remove
the pressure
or air circuits, completely
from
first the
when
and oil in the circuits
the engine
is stopped,
are hot
installing
sure that
high pressure
they
are
installing Also,
are correctly
for the oil and water
carrying
ful when circuits.
so be careful
not to get burned. Wait
20. When
out any work
to cool before
21. When
on the oil or water
13. Before starting work, remove the leads from Always
remove
the negative
(-1 terminal
check that
the lead from
or installing
14. When raising heavy components,
use a hoist
or parts which
22. When
vibrate
aligning
Check that the wire rope, chains and hooks
fingers
caught
lifting
ample
capacity.
slowly
which
has
equipment
Use a hoist to prevent
ting any other
or crane
and operate
the component
24. Take care when
tracks of track-type
any
When
covers which or under
are under in-
always
leave two
bolts in position
sides. Slowly
release the pres-
pressure
from
a
sure, then slowly loosen the bolts to remove. removing
17. When
components,
or damage
removing
be careful not
the wiring.
may cause electrical piping,
Damaged
fires.
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, or can even start fires. 18. As a general
rule, do not use gasoline
to
wash parts. In particular,
use only the mini-
mum
washing
parts.
00-4
of gasoline
when
removing
rates suddenly,
pressure
to break
pressure,
tool is correctly
removing
part. Do not work with
removing
wiring
hydraulic
hit-
ternal
16. When
measuring
that the measuring
from
15. When
on opposite
not to get your
in a hole. check assem-
at the correct
part still raised by the hoist or crane.
spring,
to check
bled before taking any measurements.
Install the lifting places.
23. When
equipment
or rotate at
careful
two holes, never insert your
or hand. Be careful
use
When
correctly.
fingers
are free from damage.
parts, always torques.
violently
be particularly
or crane.
Always
parts
parts such as guards,
that they are installed
first.
connecting
tightening
protective
high speed,
care-
installed.
assembling
installing
Damaged
so be extremely
tubes for high pressure
use the specified
circuits.
the battery.
is be-
hoses, make
not twisted.
tubes are dangerous,
water
be sure
by contact
ing operated.
compo-
circuit. 12. The
hoses and wires,
with other parts when the machine
disconnecting
nents
installing
parts with new parts.
that they will not be damaged
the oil from
out.
Before
Replace any damaged . When
plugs,
all parts again in their
places.
electrical
or installing
the
machines.
the track, the track
sepa-
so never let anyone stand at
either end of the track.
FOREWORD
GENERAL -
FOREWORD GENERAL This
shop
manual
serviceman
has been
an accurate
prepared
as an aid to improve
understanding
repairs and make judgements.
the quality
of the product and by showing
Make sure you understand
of repairs
by giving
the
him the correct way to perform
the contents
of this manual
and use it to full
effect at every opportunity.
This shop manual
mainly
service workshop.
For ease of understanding,
chapters
are further
STRUCTURE
contains
divided
the manual
information is divided
for operations
performed
into the following
chapters;
in a these
AND FUNCTION
an understanding
This
technical
into the each main group of components.
This section explains
TESTING
the necessary
the structure
of the structure,
and function
of each component.
but also serves as reference
It serves not only to give
material
for troubleshooting.
AND ADJUSTING section
adjustments
explains
Troubleshooting DISASSEMBLY
checks
to be made
to be made at completion charts correlating
before
and
after
performing
repairs,
as well
as
of the checks and repairs.
“Problems”
to “Causes” are also included
in this section.
AND ASSEMBLY
This section assembling MAINTENANCE
explains
the order to be followed
each component,
when
as well as precautions
removing,
installing,
disassembling
or
to be taken for these operations.
STANDARD
This section gives the judgement
standards
when
inspecting
disassembled
parts.
NOTICE The
specifications
time
and without
with
the
latest
contained any
advance
in this notice.
shop
manual
Use the
are subject
specifications
to change given
in the
at any book
date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL VOLUMES
REVISED EDITION MARK
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When
Chassis volume: Engine volume:
pages.
Issued for every machine model Issued for each engine series
Electrical volume: Attachments volume: I
Each issued as one volume to cover all models
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION
AND UPDATING
Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
a manual
(@@@....J
is revised,
is recorded
an edition
on the
bottom
mark of the
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
FILING METHOD Symbol
1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume):
A
Item Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
10 - 3
TT
I Example
2 (Engine volume):
Unit number (I. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.
3. Additional cated
pages:
by a hyphen
page number.
Additional
pages are indi-
(-1 and number
after the
File as in the example.
Example: 1o-4 1o-4-1 k 1O-4-2 1o-5
00-6
*
Item number (IO. Structure and Function) Consecutive page number for each item.
Tightening
t
Remarks
w
torque
&
Coat
Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel nust be added, and the caoacity. ‘laces where oil or water nust be drained, and quan:ity to be drained.
12-203 Added
pages ---c:~~~~~~~ 12-204
HOISTING INSTRUCTIONS
FOREWORD
HOISTING
INSTRUCTIONS
HOISTING Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol &
.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: I)
Check for removal
of all bolts fastening
the part to the relative 2) Check for existence ing interference
the
part caus-
part to be re-
moved.
adequate
weight
41%
71%
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one 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.
A
WIRE ROPES I) Use
79%
88%
SAD00479
of another
with
100%
parts.
ropes
depending
of parts to be hoisted,
on the
referring
to
the table below: 4)
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
*
T
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN 11000 kg) vertically, at various hanging angles.
Allowable
load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
to 19.6 kN (2000 kg) of total weight
16
27.5
2.8
suspended.
18
35.3
3.6
(1000
20
43.1
4.4
hanging
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
When two ropes sling a load vertically, This weight
kg) when angle.
two
becomes
ropes
make
On the other
ropes are subjected
can be 9.8 kN a 120”
hand,
to an excessive
up
two force
as large as 39.2 kN (4000 kg) if they sling a 19.6 kN (2000 kg) load at a lifting angle of 150”.
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle of the hook.
portion
30 Liftino
60 anole
90 tdeoree)
120
150 SAD00480
00-7
FOREWORD
METHOD
OF DISASSEMBLING,
CONNECTING
PUSH-PULL
TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER * There are 2 types of push-pull type coupler. The method of disassembling and connecting is different, so see the table below when disassembling
and connecting
We 1 1)
Me 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1)
CWPO6391
2)
Hold in the condition in Step I), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
> E E s : .? n
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
CWPO6392
2)
Hold in the condition in Step I), and turn lever (4) to the right (clockwise).
4
CWPO6393
3)
CWPO6394
Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
CWPO6395
00-8
the coupler.
3)
Hold in the condition in Steps I) and 2), and pull out whole body (2) to disconnect it.
CWP06396
FOREWORD
METHOD OF DISASSEMBLING,
Type 1 l
CONNECTING
PUSH-PULL TYPE COUPLER
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (I) contacts contact surface a of the hexagonal portion at the male end to connect it.
CWP06391
l
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (I) contacts contact surface a of the hexagonal portion at the male end to connect it.
CWP06392
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS * *
coating materials such as adhesives, gasket sealants and greases The recommended disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category
Comatsu code LT-IA
Part No. 790-129-903c
Q’w 150
g
Container Tube
Main applications, features l
l
LT-1 B
790-129-90x
20 9 (2 pes.)
‘olyethylens container
l
LT-2
0994040030
790-I 29-906C
50 g
‘olyethylene container
(Set of adhesive and hardening agent)
id hesive 1 kg lardenint agent: 500 g
Can
LT-4
790-129-904c
250 g
‘olyethylenc container
Holtz MH 705
790-126-9120
75 g
Tube
50 g
‘olyethylene container
LT-3
used for
l
l
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. Used in places requiring an immediately Used for plaseffective, strong adhesive. polyprophylene, tics (except polyethylene, and vinyl chloride), rubtetrafluoroethlene ber, metal and non-metal. Features: Resistance to heat and chemicals and sealant purUsed for anti-loosening pose for bolts and plugs. Used as adhesive or sealant for metal, glass and plastic.
Adhesives l
l
l
Three bond 1735
790-i29-914a
l
l
l
Aron-alpha 201
790-129-9130
29
‘olyethylene container
l
l
Loctite 648-50
79A-129-911C
50 cc
‘olyethylene container
LG-1
790-129-9010
200 g
Tube
l
Gasket 790-129-9070
1 kg
Can l
00-l0
sealant for repair-
Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, bers, plastics and woods.
rub-
Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
Features: Resistance to heat, chemicals . Used at joint portions subject to high temperatures.
l
LG-3
Used as heat-resisting ing engine.
holes.
l
l
sealant
Used as sealant for machined
Used as adhesive or sealant for gaskets and packing of power train case, etc. Features: Resistance to heat Used as sealant for flange surfaces and locations, used bolts at high temperature to prevent seizure. Used as sealant for heat resistance gasket for high temperature locations such as enexhaust chamber, gine precombustion pipe, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Main applications, l
l
LG-4
l
l
l
LG-5
790-129-9080
lkg
p; l
l
Gasket sealant
LG-6
0994040011
Tube
250 g
l
l
l
LG-7
09920-00 150
Tube
150 g
Three bond 1211 Molybdenum disulphide lubricant
l
l
l
LM-G
l
LM-P l
G2-LI
SYG2-4OOLI SYG2-35OLI SYG2-4OOLI-A SYG2-16OLI SYGA-IGOCNLI
G2-CA
SYG24OOCA SYG2-35OCA SYGZ-4OOCA-A Various SYG2-16OCA SYGA-16OCNCI
Grease
Molybdenum disulphide lubricant
SYG2-400M
l
Various
400 g (IO per case)
features
Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc. Used as heat-resisting engine.
sealant for repairing
Used as lubricant for sliding portion (to prevent from squeaking). Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc. General purpose type
Various
I
I l
Various
l
Used for normal temperature, light load bearing at places in contact with water or steam.
Used for places with heavy load
00-l1
FOREWORD
STANDARD
STANDARD TIGHTENING TORQUE
TIGHTENING
TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) Ir
In the case of metric given in the table
nuts and bolts for which there is no special instruction,
tighten
to the torque
below.
Thread diameter of bolt
Width across flats
, mm
mm
I
Nm
I
6 8 10 12 14
10 13 17 19 22
13.2k1.4 31f3 66f7 113+10 177f19
16 18 20 22 24
24 27 30 32 36
279f30 382f39 549f59 745+83 927+103
27 30 33 36 39
41 46 50 55 60
1320f140 1720f190 2210+240 2750f290 3290f340
Thread diameter of bolt
Width across flats
mm
mm
6
10 13 14 27
ii 10 12
kcm
I
I
1.35f0.15 3.2f0.3 6.7f0.7 11.5fl 18f2 28.5+3 39f4 56f6 76f8.5 94.5f 10.5 135f15 175k20 225f25 280f30 335f35
Nm
kgm
7.85k1.95 18.6f 4.9 40.2f 5.9 82.35f7.85
0.8f0.2 1.9f0.5 4.1kO.6 8.4f0.8
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS Sr In the case of flared instruction,
tighten
nuts for which
to the torque
there
is no special
given in the table below. SAD0048”
Thread
00-l 2
diameter
Width
across flat
l-
Tighteni
3 torque
mm
mm
Nm
km
14
19 24 27
24.5f 4.9 49k19.6
2.5f0.5
18 22 24 30 33
32 36 41
36 42
46 55
78.5f 19.6 137.3f29.4 176.5f29.4 196.lf49 245.2f 49 294.2+49
5f2 8+2 14+3 18f3 2Ok5 25+5 30*5
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS Ir In the case of split flange bolts for which there is no special
instruction,
tighten
to the torque
given in the table below.
Thread
diameter mm
Width
across flat mm
I
10 12 16
Tightening Nm
I
14 17 22
torque
km
I
65.7+ 6.8 112f9.8 279f29
6.7rt0.7 11.5fl 28.5f3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS * Unless there are special instructions, tighten the O-ring boss piping joints to the torque
Nominal
No.
-
Thread
diameter
Width
mm 02 03,04 05,06 IO,12 14
14 20 24 33 42
Tightening
across flat mm
torque
Nm
knm
Varies depending on type ofconnector.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS * Unless there are special instructions, tighten the O-ring boss plugs to the torque
Nominal 08 10 12 14 16 18 20 24 30 33 36 42 52
No.
Thread
diameter
below.
Width
across flat
Tightening
below.
torque
mm
mm
Nm
kgm
8 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 -
7.35f1.47 11.27+ 1.47 17.64f1.96 22.54f1.96 29.4f4.9 39.2k4.9 49+ 4.9 68.6f9.8 107.8k14.7 127.4f 19.6 151.9f24.5 210.7f29.4 323.4k44.1
0.75kO.15 1.15f0.15 1.8f0.2 2.3f0.2 3f0.5 4f0.5 5f0.5 7+1 llTk1.5 13+2 15.5k2.5 21.5rt3 33+ 4.5
36 -
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS) Use these torques Thread
for bolts and nuts (unit: mm) of Cummins
diameter mm
Engine.
Tightening
torque
Nm
6 8 10 12
10 24 43 77
kgm
+2 f 4 f 6 f 12
1.02 2.45 4.38 7.85
f + + f
0.20 0.41 0.61 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS) Use these torques Thread
for eye joints (unit: mm) of Cummins
diameter
Engine. Tightening
mm
Nm
6 8 10 12 14
8k2 10 f2 12 f2 24 f 4 36 ic5
torque kgm 0.81 1.02 1.22 2.45 3.67
rf: 0.20 iz0.20 + 0.20 f 0.41 f 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS) Use these torques Thread
00-14
for tapered
screws (unit: inch) of Cummins
diameter
Engine.
Tightening
inch
Nm
1 /I6 l/8 l/4 318 112 314 1
3+1 8+2 12f2 15f2 24 f 4 36 f 5 60 + 9
torque kgm 0.31 0.81 1.22 1.53 2.45 3.67 6.12
f 0.10 f 0.20 AI0.20 + 0.41 + 0.41 f 0.51 f 0.92
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION
Copper wire
N,;.lib”ea,l
N;,naF;sof
0.85 2
BY THICKNESS
Dia. i$str$mds CroT;smezc)tion
11 1
0.32
1
26
0.88
0.32
1
2.09
Cay$$D.
Curreykrating
2.4 1
3.1
Applicable
12
1
20
Starting, lighting, signal etc.
1 Lighting, signal etc.
5
65
0.32
5.23
4.6
37
Charging
15
84
0.45
13.36
7.0
59
Starting
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
17.6
230
Starting
CLASSIFICATION
109.1
circuit
and signal (Glow plug)
BY COLOR AND CODE
1
2
3 ,u+
Color White & Black
-
Code
-
WL
Black & Yellow Red & Black Yellow & Black Green & Red BR
4 arY Color White & Blue
-
RY
-
Color White & Green
-
-
Code
-
-
-
RL
Color
-
-
-
Red & Blue
WG
GY
LY
Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
-
Code 5
YG
Blue & Red
6
RG
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black YW Yellow&White
GL
-
Green & Blue
-
00-l5
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION The Conversion details
Table
of the method
TABLE
in this section
is provided
of using the Conversion
to enable
Table,
simple
conversion
see the example
of figures.
For
given below.
EXAMPLE l
1.
Method Convert (I)
of using the Conversion
Table to convert from millimeters
to inches
55 mm into inches.
Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @.
(2) Locate the number
5 in the row across the top, take this as @I, then draw a perpendicular
line
down from @. (3) Take the point where the two lines cross as 0. from millimeters 2.
to inches.
Therefore,
This point @ gives the value when converting
55 mm = 2.165 inches.
Convert 550 mm into inches.
(I) The number 550 does not appear in the table, so divide 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
0 10 20 30 40
@-
00-l 6
1 mm = 0.03937
0
1
2
3
4
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772
,...50 .......,...,..1.969 . . .. . . .. . . .2.126 . . . . . . . . . ?% . . . . .. . . . ., ..2.008 . . .. . . . .. . ..2.047 . . . . . .. ..a,.... .2.087 .I
60 70 80 90
2.362 2.756 3.150 3.543
..I
2.402 2.795 3.189 3.583
2.441 2.835 3.228 3.622
2.480 2.874 3.268 3.661
2.520 2.913 3.307 3.701
2:953 3.346 3.740
6
7
8
9
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
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
in
FOREWORD
CONVERSIONTABLE
Millimeters to Inches 1 mm
= 0.03937
in
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
0
Kilogram to Pound
0
1 kg = 2.2046
lb
0
1
2
3
4
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
5
6
7
8
9
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-l 7
FOREWORD
CONVERSIONTABLE
Literto U.S. Gallon
If = 0.2642 U.S. Gal 8
9
1.849
2.113
2.378
4.227
4.491
4.755
5.019
6.604
6.869
7.133
7.397
7.661
8.982
9.246
9.510
9.774
10.039
10.303
11.359
11.624
11.888
12.152
12.416
12.680
12.944
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
4
5
6
1
2
3
0
0.264
0.528
0.793
1.057
1.321
1.585
10
2.642
2.906
3.170
3.434
3.698
3.963
20
5.283
5.548
5.812
6.076
6.340
30
7.925
8.189
8.454
8.718
40
10.567
10.831
11.095
50
13.209
13.473
60
15.850
70
7
\ 0
Literto U.K. Gallon
0
It = 0.21997 U.K. Gal 1
2
3
4
5
6
7
8
9
\ 0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
CONVERSIONTABLE
FOREWORD
kgm to ft. lb 1 kgm = 7.233 ft. lb 0
1
2
3
4
5
6
7
8
9
\ 7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
0
0
10
00-19
FOREWORD
CONVERSIONTABLE
kg/cm* to lb/in2 lkg/cm2 = 14.2233lb/in* 4
6
7
8
1
2
3
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
0
0
5
9
1010
1024
038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
387
2901
2916
2930
2944
2958
!973
210
2987
3001
3015
130
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
456
3470
3485
3499
3513
3527
3542
00-20
CONVERSION TABLE
FOREWORD
Temperature Fahrenheit-Centigrade ture reading These
Conversion
or vice versa
figures
If it is desired
; a simple way to convert
is to enter the accompanying
refer to the temperature to convert
from
temperatures
and read the corresponding
If it is desired
to convert
from Centigrade
and read the corresponding
in either
Fahrenheit
Fahrenheit
Fahrenheit
to Centigrade Centigrade
or Centigrade degrees,
degrees,
temperature
in the center
temperature
to Fahrenheit temperature
a Fahrenheit
table
into a Centigrade
column
tempera-
of figures.
degrees.
consider
the center
in the column consider
reading
or boldface
the center
column
as a table
of Fahrenheit
at the left. column
as a table
of Centigrade
values,
on the right. 1°C = 33.8”F
“C
“F
“C
“F
“C
“F
“C
“F
-40.4
-40
-40.0
-11.7
11
51.8
7.8
46
114.8
27.2
81
117.8
-37.2
-35
-31.0
-11.1
12
53.6
8.3
47
116.6
27.8
82
179.6
-34.4
-30
-22.0
-10.6
13
55.4
8.9
46
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9
-20
-4.0
-9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
-28.3
-19
-2.2
-8.9
16
60.8
10.6
51
123.8
30.0
86
186.8
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
-26.7
-16
3.2
-7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
-26.1
-15
5.0
-6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
-25.6
-14
6.8
-6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
-25.0
-13
8.6
-5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
-24.4
-12
10.4
-5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
-23.9
-11
12.2
-4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
-23.3
-10
14.0
-3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
-22.8
-9
15.8
-3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
-22.2
-9
17.6
-2.8
27
80.6
16.7
62
143.6
36.1
97
206.6
-21.7
-7
19.4
-2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
-21.1
-6
21.2
-1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
-20.6
-5
23.0
-1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
-20.0
-4
24.8
-0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
-19.4
-3
26.6
0
32
89.6
19.4
67
152.6
43.3
110
230.0
-18.9
-2
28.4
0.6
33
91.4
20.0
68
154.4
46.1
115
239.0
-18.3
-1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
0
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
-17.2
1
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
-16.7
2
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
-16.1
3
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
-15.6
4
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
-15.0
5
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
-14.4
6
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
-13.9
7
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
-13.3
8
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
-12.8
9
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
-12.2
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
-17.8
00-21
01 GENERAL
Specification drawing .................................. Ol- 2 Specifications ............................................... Ol- 4 Weight table ................................................ .Ol-10 Table of fuel, coolant and Lubricants ....... 01-12
D 155AX-5
01-l
SPECIFICATION
GENERAL
SPECIFICATION l
Semi
U-tiltdozer
DRAWING
DRAWING
+ giant ripper
Unit: mm
3210 8155
I
2510
SWD02751
.
U-tiltdozer
+ giant ripper
SWD02752
01-Z
D 155AX-5
GENERAL
.
Semi
SPECIFICATION
U-tiltdozer
+ multi-shank
DRAWING
ripper Unit: mm
G. L
.
U-tiltdozer
+ multi-shank
3210 81 55
I SWD02754
D155AX-5
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS Machine Serial
D155AX-5
model number
:
Bare tractor
per + ROPS + cab + air conditioner
turning
radius
(Fl,
center
+ side cover
of machine)
Gradeability Stability L g !! % al :: .-6 .-ZJ E Z Z l-
and up
28,400
With semi U-dozer + variable multi-shank rip-
Minimum
70001
(front,
rear, left, right)
kg
38,500
m
2.1
deg
30
deg
35 3.5
1st P E
2nd
6.2
km/h
LL
% t
3rd
10.8
1st
4.8 km/h
2nd
2
8.4
CT
13.9
3rd
77.5 IO.791
Bare tractor With ripper
semi
U-dozer
+ ROPS
+ variable
+ cab
multi-shank
+ air conditioner
104.9 {I .07} + kPa
side cover With
U-dozer
+ variable
multi-shank
+ ROPS + cab + air conditioner
ripper
Ikghm2)
105.9 f1.081
+ side cover
5 0 -E = m & 6 C 5 .3 = ? 9:
4,975
Bare tractor With
semi
U-dozer
+ variable
multi-shank
ripper With
8,155 mm
U-dozer
+ variable
multi-shank
ripper
8,550
2,695
Bare tractor With
semi
U-dozer
+ variable
multi-shank
ripper With
3,955 mm
U-dozer
+ variable
multi-shank
ripper
4,265
B 2 .-0 _E = m &
To top of exhaust To top of cab (to
top of control
3,395
pipe
mm
2,590
lever)
6 -
01-4
D155AX-5
GENERAL
SPECIFICATIONS
Machine Serial
z
With
cab installed
With
ROPS canopy
With
canopy
L-
model number
D155AX-5 70001
and up
3,365
installed
mm
3,500
installed
3,500
.-0
E? Track gauge i.- Length of track n
-
2,100 on ground
Track shoe width
(standard)
Minimum
clearance
ground
(To bottom
surface
(mm)
3,210 mm
560 485
of undercover)
Name Type
SAGDI 40-2 4-cycle, water-cooled, in-line, vertical type, direct injection, with turbocharger and aftercooler
of engine
No. of cylinders
- Bore x Stroke
Piston displacement Flywheel
mm
6-140x165
e {cc}
horsepower
k:W/rpmU-lP/rpn
15.24 {I 5.2401
1)
231/1,900
rr]m/rpm(kgm/rpn 1)
{314/1,9001
Max.
torque
Max.
speed
at no load
rpm
2,050
Min. speed
at no load
rpm
700
Min. fuel consumption Starting
ratio
1,610/1,250
g/kWh(g/HPhI
205 {1531
motor
24V,
Alternator
Torque
11 kW
24V, 35A
Battery Radiator
{164/1,2501
12V 170Ahx2 core type
converter
D-7 3-element,
single-stage,
single
phase
(TCS43-17A) Planetary Transmission
multiple
actuated,
tion
pump,
verse
D155AX-5
gear,
draulically gear
3-speed,
disc clutch,
force-feed
forward
manual
hy-
lubrica-
3-speed,
mechanical
retype
01-5
SPECIFICATIONS
GENERAL
Serial
D 155AX-5
model
Machine
70001
number variable
swash
Max. delivery
HSS pump
Theoretical
Max.
HSS steering
Wet type, Master
plate type
brake
Spur gear
multiple
Track
l-stage,
pump
shoe width:
pump
560 mm)
gear
l-stage,
splash
type
balancing
beam
type
Assembly
type, single grouser,
Gear type
(tandem)
with scavenging
equipment
Gear type pump
pump
(SAR(4)llZ))
Theoretical
Max.
2+1+1
l
For blade
lift
l
For blade tilt
l
For ripper
lift
l
For ripper
tilt
: 4.4 MPa 145 kg/cm? : 206 Umin/1,980 rpm
pressure
delivery
(SAR(4)112) delivery
tandem
Ripper
(112)
(104) delivery
Theoretical
Type
(SAL(3)80+100)
Gear type
(tandem)
pump
41 each side, pitch: 228.6
mm
Gear type
01-6
boost pedal oper-
6 each side
Max.
Work
drive,
2 each side
+ lubrication
HSS, PPC charge (tandem
planetary
roller
Scavenging
motor
actuated
roller
train
gear pump
hydraulicalic
clutch disc, spring
Rigid,
Track shoe (standard
Power
gear,
lubrication
lubrication
Suspension
Carrier
(HMF140)
actuated
ated, hydraulically
Final drive
rpm
: 41.2 MPa {420 kg/cm*)
planetary
hvdraulicallv
% I
(HPV160)
: 41.2 MPa (420 kg/cm21
bevel gear, force-feed
Differential
system
up
: 341 .Umin/2,130
delivery
pressure
Spiral
Bevel gear shaft
plate type pressure
Fixed swash HSS motor
and
: 20.6 MPa 1210 kg/cm21 : 255 .Umin/2,220 rpm
pressure
delivery
spool type,
tilt + ripper
hydraulically
lift + blade
assisted
type
lift + blade tilt
D155AX-5
GENERAL
SPECIFICATIONS
Machine Serial
I
model
-I
number
T
D 155AX-5
Type
70001
Reciprocal,
Cylinder bore Piston
diameter
Max.
piston
stroke
Max.
distance
between
Min. distance
between
piston type
75 mm
1,347
pins
3,187
pins
1,836
bore
180
Piston rod outer
diameter
Max.
piston stroke
Max.
distance
Min. distance
up
120
rod outer
Cylinder
and
mm
between between
90 160
pins
1,468
pins
1,308
. Cylinder
. - :
Piston
bore rod outer
Max.
piston
Max.
distance
Cylinder Piston
between
160
pins
1,468
pins
1,308
bore
Max.
piston
160
Max.
distance
diameter
stroke
Min. distance
I-lydraulic
90 mm
between
rod outer
Cylinder
diameter
stroke
Min. distance
Piston
200
between between
80 mm
510
pins
1,538
pins
1,028
bore
160
rod outer
diameter
stroke
80
Max.
piston
mm
Max.
distance
between
pins
1,545
Min. distance
between
pins
1,195
350
tank
Box type
(control
valve
externally
installed)
L
D155AX-5
01-7
GENERAL
SPECIFICATIONS
Serial
l-
model
Machine
number
70001
Type
and up
Hydraulic semi U-tiltdozer, hydraulic U-tiltdozer
Blade support method
Brace type (right tilt cylinder)
Blade lifting height (from ground level)
mm
1,250
Blade lowering depth (from ground level)
mm
590
Max. blade tilt
mm
1,000
Blade cutting angle variation
deg
+6
Blade capacity
m3
11.7 C SAE 8.8 >
Blade width
mm
3,955
Blade height
mm
1,720
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
1,080
Blade cutting angle variation
deg
Blade capacity
01-8
D155AX-5
m3
f6 13.2 < SAE 11.8 >
Blade width
mm
4,265
Blade height
mm
1,720
Blade cutting angle
deg
52
Max. tilt
mm
1,000
Max. pitch angle
deg
6
Max. pitch-back angle
deg
6
Max. tilt
mm
1,080
Max. pitch angle
deg
6
Max. pitch-back angle
deg
6
D155AX-5
GENERAL
SPECIFICATIONS
Machine Serial
model
D155AX-5
number
70001
and up
Max. digging depth
mm
870
Max. lifting height
mm
925
Ripping angle of point
deg
34.5 - 60
Max. beam width
mm
2,260
No. of holes
2
Max. digging depth
mm
1,220
Max. lifting height
mm
925
Ripping angle of point
deg
34.5 - 60
Max. beam width
mm
1,535
No. of holes
3
Shank positions
; .-i : i
C
3
Shank positions
-
D 155AX-5
01-9
WEIGHT TABLE
GENERAL
WEIGHT TABLE -AThis
weight
table is a guide for use when transporting Machine Serial
Engine,
damper
l
Engine
l
Damper
l
Universal
l
Engine
or handling
D155AX-5
model
70001
number
and up
1,395
assembly
1,275
assembly
117
assembly
18
joint
mount
parts (wiring)
Radiator
assembly
(including
Hydraulic
cooler
3 built-in
oil cooler)
307 77 (47 as individual
Fuel tank assembly
(when
empty)
267
Fuel tank assembly
(when
full)
798
Power
train
. Torque
converter,
342
PTO assembly
645
assembly
.
HSS assembly
.
Brake valve
.
HSSPPC
charge
filter
.
HSSPPC
charge
valve
.
Power
.
Scavenging
pump*HSS*PPC
.
Power
lubrication
.
Work equipment
.
HSS motor
63
.
HSS pump
102
894
Final drive Sprocket
14
assembly
train filter
train
22
assembly
21
assembly
20
assembly charge
pump
19
pump
1,372x2 (12X9)X2
teeth
3,182
assembly
Track group
assembly
3,755
(each side)
1,224
Track frame
410
Idler assembly Recoil spring Bogie, Track
01-10
508
assembly
track roller
410x3
assembly
roller assembly
Track roller assembly Carrier
36 27
pump
assembly
Hull frame
part)
2,318
unit assembly
. Transmission
Unit: kg
components.
roller assembly
(single (double
flange flange
xl) xl)
97x3 109x3 45x2
D 155AX-5
WEIGHT TABLE
GENERAL
Unit: kg Machine Serial
model number
Track shoe assembly (560 mm, wet type) Pivot shaft assembly Equalizer bar
D155AX-5 70001
and up
2,558x2 116x2 229
Hydraulic tank assembly
95
Hydraulic filter assembly
19
Main control valve
99
(Blade lift + blade tilt + ripper lift + ripper tilt) Engine underguard
183
Transmission underguard
228
Operator’s seat Semi U-tiltdozer assembly l
Blade
51 4,903 2,818 690x2
l
Straight frame
l
Tilt brace
98x1
l
Center brace
92x2
l
Tilt cylinder assembly
Semi U-tilt + pitch dozer assembly
190 5,007
l
Blade
2,818
l
Straight frame
690x2
l
Center brace
l
Tilt cylinder assembly
190
Pitch cylinder assembly
215
l
92x2
Blade lift cylinder assembly
165x2
Multi-shank ripper assembly
3,600
l
Bracket, beam
2,014
l
Shank
266x3
l
Lift cylinder assembly
119x2
l
Tilt cylinder assembly
122x2
Giant ripper assembly
3,135 1,728
l
Bracket, beam
l
Shank
333x1
l
Lift cylinder assembly
119x2
l
Tilt cylinder assembly
122x2
l
Pin puller cylinder assembly
7
ROPS assembly
480
Cab
285
FLOPScanopy
698
Canopy
105
Dashboard (including air conditioner unit)
83
Floor frame
310
Side cover
130
Air conditioner (excluding air conditioner unit)
D155AX-5
87
01-11
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT
Engine
Power
AMBIENT TEMPERATURE
KIND OF FLUID
RESERVOIR
AND LUBRICANTS
-22
-4
-10 14
320
50 10
/
/
/
1
68 20
CAPACITY (J?)
I 86 30
Specified
104°F 40~
1
Refill
1
0.59
oil pan
train case
EiGcr-4
Final drive case (each side)Engine
oi
Pivot shaft case (each side)
Hydraulic
system
) Bogie teach)
1
Fuel tank
/
11
1
1
/
0.59
1 0.21 - 0.23 i 0.21 - 0.23
Diesel fuel
Cooling system (including reservoir
tank)
Add antifreeze
Coolan’
*
1
I
99
I
ASTM D975 No. 1
NOTE: (I)
When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %.
Fuel sulphur
content
Change interval of oil in engine oil pan
0.5 to 1.0 %
l/2 of regular
interval
Above
l/4 of regular
interval
ASTM: SAE: API:
1.0 %
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
(2) When starting the engine in an atmospheric temperature of lower than OT, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W-40 even though an atmospheric temperature goes up to 10°C more or less in the day time. CD as engine oil and (3) Use API classification if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, 15W-401, but be sure to add single grade oil that matches the temperature in the table on the left. Komatsu genuine oil which (5) We recommend has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components Refill capacity: Amount of oil needed to refill system during normal
01-12
and oil in piping. inspection and maintenance.
D 155AX-5
10 STRUCTURE AND FUNCTION
Engine control ................................................ IO-2 Radiator, oil cooler ........................................ IO-4 Power train ..................................................... IO-8 Power train system ........................................ IO-9 Overall drawing of power train unit ......... IO-10 Power train hydraulic system drawing .... IO-12 Power train hydraulic piping diagram ..... IO-14 Power train hydraulic circuit diagram.. .... IO-15 Damper universal joint.. .............................. IO-16 Torque converter, PTO ................................ IO-19 Transmission control ................................... IO-22 Transmission ................................................ IO-24 Transmission control valve ........................ 1o-34 Main relief valve .......................................... IO-39 Lubricant relief valve.. ................................. IO-41 Scavenging pump strainer.. ........................ IO-42 Power train pump strainer.. ........................ IO-43 Power train oil filter.. ................................... IO-44 HSS system .................................................. IO-46 HSS pump .................................................... IO-59 HSS motor .................................................... IO-75 PPC, HSS charge filter.. ............................... IO-83 PPC, HSS charge valve ............................... IO-84 HSS oil cooler bypass valve.. ..................... IO-87 Steering, brake control ................................ IO-88 Bevel gear shaft, HSS brake.. ..................... IO-91 Brake valve ................................................. IO-103 Final drive ................................................... IO-107 Track frame.. ............................................... IO-110 Recoil spring ............................................... IO-I 12 Track roller bogie.. ..................................... IO-I 13
D155AX-5
Main frame ................................................. IO-I 14 Suspension ................................................. 1 O-l 16 Work equipment hydraulic piping diagram.. ..................................... IO-I 18 PPC control piping diagram ..................... IO-121 Work equipment control ........................... IO-122 Work equipment hydraulic system and HSS system diagram.. ................... IO-124 Work equipment hydraulic circuit and HSS circuit diagram.. ..................... IO-128 Hydraulic tank and filter.. .......................... IO-130 Accumulator ............................................... IO-132 PPC lock valve ............................................ IO-133 PPC valve .................................................... IO-134 Piston valve ................................................ 1 O-l 44 Pin puller switch ........................................ IO-I 45 Pin puller solenoid valve ......................... .I O-l 46 Tilt/Pitch selector switch ........................... IO-148 Pitch solenoid valve .................................. IO-149 Main control valve ..................................... IO-151 Cylinder stay.. ............................................. IO-178 Work equipment ........................................ IO-179 Cap.. ............................................................. IO-183 Air conditioner ........................................... IO-185 Electric wiring diagram ............................. IO-186 Electric circuit diagram ............................. IO-190 Monitor system .......................................... IO-193 Sensors ....................................................... IO-199 Engine starting system ............................. IO-204 HSS electronic control system ................. IO-206
10-l
ENGINE CONTROL
STRUCTURE AND FUNCTION
ENGINE CONTROL
5
1. 2. 3. 4. 5. 6.
pedal Decelerator Fuel control lever Clutch Stopper Rod Fuel injection pump
Outline . The engine speed is controlled trol lever (2) or decelerator
by fuel conpedal (I).
Lever, pedal positions 0: STOP 0: 0: 0: 0:
LOW HIGH HIGH LOW
1o-2
IDLING IDLING IDLING IDLING
D 155,4X-5
STRUCTURE
AND
RADIATOR, . RADIATOR
RADIATOR,
FUNCTION
OIL COOLER
I
6-'?iidH -
1. Radiator core assembly 2. Fan guard 3. Reservoir tank 4. 5. 6. 7. 8.
Lower tank (power Overflow hose Water filler cap Air bleed hose Inlet hose
1o-4
OIL COOLER
train oil cooler
built-in)
H
H
9. 10. 11. 12.
ra
I
lit-IH
Fan Outlet hose Drain plug Inlet hose (for circulating temperature) 13. Cushion 14. Breather cap 15. Valve
at low water
D155AX-5
STRUCTURE
RADIATOR,
AND FUNCTION
5
6
7
OIL COOLER
8
A-A
B-B
11
12
10
SKI290003
Outline The reservoir l
Radiator tank is provided
for radiator.
I D-7
Core type Fin pitch
D155AX-5
(mm)
4.0
1o-5
STRUCTURE AND FUNCTION
l
RADIATOR, OIL COOLER
OIL COOLER
I c
-_ -_
5
I
+I A-A
SJD02746
1O-6
D155AX-5
RADIATOR, OIL COOLER
STRUCTURE AND FUNCTION
The hydraulic
cooler can be
Core inner fin Cooling method Heat dissipation area
D155AX-5
PTO-OL
SF-4
TF&C
-
Built in lower tank
Air cooled
2.47 m2
20.8 m2
1o-7
STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN
SVDO2730
l
.
.
l
.
The power generated by engine (I) has its torsional vibration dampened by damper (21, and then passes through universal joint (31, and is transmitted to torque converter (IO). The power from the engine is transmitted through the oil by torque converter (IO) to the transmission input shaft (turbine shaft) in accordance with the change in load. Transmission (11) uses a combination of a planetary gear system and hydraulic clutches to reduce the speed and shift the gears (forward 3 gears, reverse 3 gears). It connects two sets of clutches selected according to the change in load, and transmits the power to bevel gear (12) from the bevel pinion at the rear end of rhe transmission. The power transmitted to the bevel gear shaft is transmitted to HSS (Hydrostatic Steering System (13). HSS pump (19) is driven by PTO (81, and output oil of HSS pump drives HSS motor (14).
1O-8
l
.
.
The rotation of the pair of HSS gears on the left and right is controlled by HSS motor (14). The steering is carried out by generating a difference in speed on the left and right. It is also possible to use the HSS mechanism to rotate the left and right sides in opposite directions to carry out counterrotation turns. Brake (15) of the HSS is used only for braking the machine. Brake (15) is a wet type, multiple disc clutch, spring boosted type. The power sent from brake (15) is transmitted to final drive (16). Final drive (16) consists of a single stage spur gear and single stage planetary gear system. It reduces rhe speed and rotates sprocket (17) to drive track shoe (18) and move the machine.
D155AX-5
STRUCTURE AND FUNCTION
POWER TRAIN
SYSTEM
POWER TRAIN SYSTEM
i5
1. Engine (SAGDI 40-2) 2. Damper 3. Universal joint 4. PPC, HSS charge pump (104) 5. Scavenging pump (I 12) 6. Power train lubrication pump (SAL(3)-100) 7. Power train pump (SAL(3)-80) 8. PTO 9. Work equipment pump (SAR(4)-112) 10. Torque converter
D155AX-5
14
11. 12. 13. 14. 15. 16. 17. 18. 19.
13
I
I SVD02729
Transmission Bevel gear HSS unit HSS motor (HMF140) Brake Final drive Sproket Track shoe HSS pump (HPVIGO)
1o-9
STRUCTURE AND FUNCTION
OVERALL DRAWING
OVERALL DRAWING OF POWER TRAIN UNIT
OF POWER TRAIN UNIT
_____--_-__--(? n n
________________y_-.--
(? SWD02747
10-10
D 155/4X-5
STRUCTURE AND FUNCTION
OVERALL DRAWING OF POWER TRAIN UNIT
SJD02748
1. 2. 3. 4. 5. 6. 7. 8.
Work equipment pump (SAR(4)-112) Torque converter, PTO Transmission Brake valve HSS motor (HMF140) HSS unit Charge relief valve HSS oil cooler bypass valve
9. 10. 11. 12. 13. 14. 15. 16.
Transmission main relief valve HSS pump (HPVIGO) Power train pump (SAL(3)-80) Power train lubrication pump (SAL(3klOO) PPC, HSS charge pump (104) Scavenging pump (112) Scavenging pump strainer Power train pump strainer
Outline The power train unit can be broadly divided into torque converter (with PTO) (2), transmission unit (31, and steering unit (6). So, after the power train unit has been removed, it can be disassembled into the torque converter, transmission unit, ans steering unit. . HSS unit consists of the bevel pinion unit, bevel gear shaft, HSS motor, planetary gear and brake. l
l
D155AX-5
10-11
STRUCTURE
AND FUNCTION
POWER TRAIN
POWER TRAIN HYDRAULIC (Engine
started,
joystick
at neutral,
SYSTEM
HYDRAULIC
SYSTEM
DRAWING
DRAWING
gear shift lever at 1st)
I I L____-__________i
1
r-___-----_
;
/
_________!
i___________________------_
I II I
25 I
DCBA 1
+isJ
I
I__________________------7_
b
8
I
9
SWD02749
10-n
D155AX-5
STRUCTURE AND FUNCTION
POWER TRAIN HYDRAULIC SYSTEM DRAWING
1. Power train oil pan IA. Torque converter case 1 B. Transmission case IC. HSS case 2. Oil strainer 3. Power train pump (SAL(3b80) 4. Power train oil filter 5. Main relief valve 6. Transmission control valve 6A. Modulating valve 6B. Quick return valve 6C. Speed valve 6D. Directional valve 7. 1st clutch 8. 3rd clutch 9. 2nd clutch 10. REVERSE clutch 11. FORWARD clutch 12. Torque converter relief valve 13. Torque converter 14. Oil cooler 15. Lubrication relief valve 16. Transmission lubrication 17. PTO lubrication 18. Brake valve 18A. Brake valve 18B. Parking brake valve 19. R.H. brake 20. L.H. brake 21. R.H. brake disc lubrication 22. Bevel gear teeth lubrication 23. L.H. brake disc lubrication 24. Power train lubrication pump (SAL(3)-100) 25. Centralized pressure detection port 26. Oil strainer 27. Scavenging pump (112) 28. Pin puller solenoid valve (for giant ripper) 29. Pin puller cylinder
SWD02750
D155AX-5
10-13
STRUCTURE
AND
FUNCTION
POWER TRAIN HYDRAULIC
POWER TRAIN
HYDRAULIC
PIPING
DIAGRAM
PIPING DIAGRAM
SVD02756
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Scavenging pump (112) Power train lubrication pump (SAL(3)-100) Power train pump (SAL(3)-80) Transmission control valve Brake control valve Main relief valve Centralized pressure detection port Power train oil strainer Power train oil filter Power train oil cooler (built in radiator lower tank)
10-14
A. B.
Brake pressure pickup port Transmission modulating pressure
C. D.
Port Torque converter outlet pressure pickup port Torque converter inlet pressure pickup port
pickup
D155AX-5
I
converter
Torque
Pressure ports
converter
Torque
176Q/min_
mesh size 30pm area 10026cm’
Centralized eletection
Theoretical rated flow
Filter Filter Filterins
ms_s_ure) II
__-__2 kg/cm’ toiffrencial
case
case
;_ II
c-!
Ie---
I
i-i-0=0.
;
1i
case
T-
case
; v
HSS lubr ,icat
, I I’ [ / ( _/’ ____~~~~~~~~~~__Steering
Transmission control valve
___._________________---------~
Transmission
#---w
ion
:
I
rake vslve -__-__-__-
Parking brake
Hoot brake
L. H. brake
R. H. brake
STRUCTURE AND FUNCTION
DAMPER,
DAMPER. UNIVERSAL JOINT
UNIVERSAL
JOINT
I
3
B-B
lo A-A
lo-16
SVD02764
D 155AX-5
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
DAMPER, UNIVERSAL JOINT
Breather Dipstick Drain plug Input shaft Flywheel Outer body Coupling Universal joint Cover Rubber coupling Inner body
Outline l
.
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. This damper has few component parts: it uses a rubber coupling, so the vibration is absorbed by the damping effect of the rubber material.
Operation l
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 (IO), and the power is transmitted to inner body (I I). It passes through universal joint (8). and is then transmitted to the torque converter and transmission.
D155AX-5
10-17
STRUCTURE AND FUNCTION
TORQUE CONVERTER, PTO
PTO
TORQUE CONVERTER, TCS43-17A
L\
P
AB-
E
Z
‘D SVD02733
D155AX-5
10-19
STRUCTURE AND FUNCTION
12
TORQUE CONVERTER, PTO
13
I4
15
17
18
B-B
A-A
E-E
SVDO2734
1O-20
D155AX-5
STRUCTURE AND FUNCTION
TORQUE CONVERTER, PTO
1. Power train, power train lubrication pump mount 2. Scavenging pump mount 3. HSS pump mountin port 4. Power train oil strainer 5. PTO lubrication tube 6. Hydraulic, PPC charge pump mount 7. Input coupling 8. Input shaft 9. PTO drive gear (55 teeth) 10. idler gear shaft 11. Idler gear (66 teeth) 12. PTO case 13. Drive case 14. Turbine 15. Pump 16. Stator 17. Stator shaft 18. Transmission input shaft 19. HSS pump drive gear (49 teeth) 20. Pump drive gear (47 teeth) (Hydraulic, power train, power train lubrication pump) 21. Scavenging pump drive gear (53 teeth) A. B. C. D.
Torque converter oil inlet port To oil cooler To transmission case (from torque converter case) From transmission case (to power train
E.
pump) To transmission
case (passage)
Outline Torque converter is a 3-element, single stage, single phase type, and forms an integrated structure with the transmission. . Pump (15) forms one unit with input coupling (71, input shaft (8), and drive case (131, and is rotated by the motive force from the engine. Turbine (14) forms one unit with transmission input shaft (181, and is rotated by the oil from the pump. Stator (16) forms one unit with stator shaft (17), and is held in position by PTO case (12). . The scavenging pump is driven by PTO drive gear (9), and returns the oil accumulated in the transmission case to the steering case. l
l
l
D155AX-5
10-21
TRANSMISSION
CONTROL
TRANSMISSION
STRUCTURE AND FUNCTION
CONTROL
SVDO2787
Lever positions NEUTRAL FORWARD REVERSE 1st 0: 2nd 0: 3rd 0: FREE @: LOCK
0: 0: 0: 0:
1. Safety lever 2. Joystick (directional, gear shift) 3. Limit switch (for safety lever) 4. Cable control 5. Transmission valve
Outline l
. *
For details of the operation of the joystick the steering system, see STEERING, for BRAKE CONTROL section.
10-22
The
transmission
is controlled
by joystick
(2). The joystick is used to shift between forward and reverse, and to shift gears. is equipped with a safety The transmission if safety lever (I) is not placed mechanism: at the LOCK position, limit switch (3) is not actuated and the engine cannot be started.
D155AX-5
STRUCTURE AND FUNCTION
TRANSMISSION
TRANSMISSION A
0
W
C
D
E
SVDO2757
1 O-24
D 155AX-5
STRUCTURE AND FUNCTION
TRANSMISSION
SVD02758
To FORWARD clutch To REVERSE clutch To 3rd clutch To 2nd clutch To 1st clutch To torque converter case (from power train oil strainer) G. From torque converter case H. To scavenging pump J. To torque converter case K. From scavenging pump L. From power train pump M. To steering valve N. To steering case P. From steering case Q. Transmission lubrication inlet port A. 8. C. D. E. F.
D155AX-5
1o-25
TRANSMISSION
STRUCTURE AND FUNCTION
No.1
. .
REVERSE
36
35
34
33
32
No.2
_.
31
30
26
29 A-A
1O-26
No.3 3rd
FORWARD
.I,
No.4
.I,
27
No.5 1st
2nd
26
25
24
23
22
21 SDW0027
D155AX-5
STRUCTURE
1. Main relief valve case 2. Transmission control valve, valve cover 3. Transmission assembly 4. Lubrication relief valve 5. Input shaft 6. REVERSE sun gear (34 teeth) 7. Pinion shaft 8. REVERSE ring gear (90 inner teeth, 105 outer teeth) 9. REVERSE planet pinion (26 teeth) 10. Disc 11. Plate 12. Piston 13. FORWARD planet pinion (27 teeth) 14. 3rd planet pinion (36 teeth) 15. 3rd ring gear (91 inner teeth, 105 outer teeth) 16. 2nd sun gear (39 teeth) 17. 1st planet pinion (21 teeth) 18. 1st sun gear (49 teeth) 19. Output shaft (20 teeth at 3rd sun gear portion) 20. 1st ring gear (91 inner teeth, 105 outer teeth) 21. 1st carrier (90 teeth) 22. 1st clutch housing 23. 2nd clutch housing 24. 2nd planet pinion (26 teeth) 25. 2nd ring gear (90 inner teeth, 105 outer teeth) 26. 3rd clutch housing 27. 2nd, 3rd carrier 28. FORWARD clutch housing 29. FORWARD sun gear (37 teeth) 30. FORWARD ring gear (91 inner teeth, 105 outer teeth) 31. FORWARD carrier (86 teeth) 32. REVERSE clutch housing 33. Return spring 34. REVERSE ring gear (86 teeth) 35. Pin 36. REVERSE carrier (90 teeth)
D155AX-5
TRANSMISSION
AND FUNCTION
Outline The transmission has three forward speeds and three reverse speeds, and uses a combination of a planetary gear system and disc clutches. In the transmission, two of the clutches of the 5 sets of planetary gears and disc clutches are controlled by the control valve and are held in position by hydraulic force to select one rotational direction and one speed. The No. 1 clutch is held in position for reverse, the No. 2 clutch for forward, the No. 3 clutch for 3rd, the No. 4 clutch for 2nd, and the No. 5 clutch for 1st. Speed
range and clutches
Speed range
actuated
Clutches used (engaged) No. 2, No. 5
FORWARD 1st FORWARD 2nd
No. 2, No. 4
FORWARD 3rd
No. 2, No. 3
Neutral
No. 5
REVERSE 1st
No. 1, No. 5
REVERSE 2nd
No. 1, No. 4
REVERSE 3rd
No. 1, No. 3
No. of plates Clutch No.
and discs used No. of discs
No. of plates. 4
No. 1 clutch
5
No. 2 clutch
6
5
No. 3 clutch
4
3
No. 4 clutch
4
3
No. 5 clutch
3
2
1 O-27
STRUCTURE
AND
TRANSMISSION
FUNCTION
Operation 1. Operation of disc clutch The disc clutch is installed in order to hold ring gear (8) in position. It consists of piston (121, plate (II), disc (IO), pin (351, and piston return spring (33). The inside disc teeth are meshed with the outside teeth of the ring gear. The plate is meshed with pin (35), which is fixed to housing (32) and the protruding notched portion on the plate outer diameter.
33 \
35
I.0
\
I
?I
j2
32
I
I
I
8
Clutch engaged (held in position) The oil from the control valve passes through the port of housing (32) and is forcibly sent to the back of piston (12). The piston pushes plate (11) against disc (IO), and the friction stops the disc rotation. It also holds in position ring gear (81, which is meshed with the inside teeth. l
Clutch disengaged (released) . When the oil from the control valve is shut off, piston (12) is returned to its original position by piston return spring (33). The friction between plate (11) and disc (IO) is released, and ring gear (8) is placed in neutral.
wl=fa=-
SKD00107
1 O-28
D155AX-5
STRUCTURE
AND FUNCTION
TRANSMISSION
31
30
29
27
A-A 2. .
.
.
Forward 1st When the transmission is set to FORWARD Ist, the No. 2 clutch and No. 5 clutch are engaged. The motive force from the torque converter transmitted to input shaft (5) is then transmitted to output shaft (19). No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds ring gear (30) in position. No. 5 clutch is actuated by the hydraulic pressure applied to the clutch piston, and engages ring gear (20). The motive force from the torque converter is transmitted to input shaft (5), and the rotation of the input shaft passes through sun gear (29) and is transmitted to planet pinion (13).
D155AX-5
25
24
21
20
SDD00108
Ring gear (30) is held in position by No. 2 clutch, so the rotation of planet pinion (13) rotates carrier (311, which is on the inside of ring gear (30). Carrier (31) and carrier (27) are joined by a spline, and rotate as one unit, so the rotation of carrier (31) passes through planet pinion (24) and is transmitted to ring gear (25). Carrier (21) is meshed with ring gear (251, and rotates as one unit, so the rotation is transmitted to planet pinion (17). Ring gear (20) is being held in position by No. 5 clutch, so the rotation of planet pinion (17) rotates sun gear (181, and this rotates output shaft (19).
1 O-29
STRUCTURE AND FUNCTION
TRANSMISSION
31
30
29
27
25
24
SWD02802
3. Forward 2nd l
.
l
When the transmission is set FORWARD 2nd the No. 2 clutch and No. 4 clutch are engaged. The motive force from the torque converter transmitted to input shaft (5) is then transmitted to output shaft (19). No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds ring gear (30) in position. No. 4 clutch is actuated by the hydraulic pressure applied to the clutch piston, and engages ring gear (25). The motive force from the torque converter is transmitted to input shaft (51, and the rotation of the input shaft passes through sun gear (29) and is transmitted to planet pinion (13).
1O-30
.
.
.
Ring gear (30) is held in position by No. 2 clutch, so the rotation of planet pinion (13) rotates carrier (311, which is on the inside of ring gear (30). Carrier (31) and carrier (27) are joined by a spline, and rotate as one unit, so the rotation is transmitted to planet pinion (24). Ring gear (25) is being held in position by No. 4 clutch, so the rotation of planet pinion (24) rotates sun gear (161, and this rotates output shaft (19).
D 155AX-5
TRANSMISSION
STRUCTURE AND FUNCTION
No.
l.,. No.
REVERSE
2_,
FORWARD
3_,.No.
3rd
2nd
4%,No.
5
1st
/
31
30
29
27
SWD02803
4. Forward 3rd l
.
l
When the transmission is set to FORWARD 3rd the No. 2 clutch and No. 3 clutch are engaged. The motive force from the torque converter transmitted to input shaft (5) is then transmitted to output shaft (19). No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds ring gear (30) in position. No. 5 clutch is actuated by the hydraulic pressure applied to the clutch piston, and engages ring gear (15). The motive force from the torque converter is transmitted to input shaft (51, and the rotation of the input shaft passes through sun gear (29) and is transmitted to planet pinion (13).
D155AX-5
.
.
.
Ring gear (30) is held in position by No. 2 clutch, so the rotation of planet pinion (13) rotates carrier (311, which is on the inside of ring gear (30). Carrier (31) and carrier (27) are joined by a spline, and rotate as one unit, so the rotation is transmitted to planet pinion (14). Ring gear (15) is being held in position by No. 3 clutch, so the rotation of planet pinion (14) rotates output shaft (19).
10-31
STRUCTURE
AND
FUNCTION
36
TRANSMISSION
34
27
3i A-A
3. .
.
.
.
Reverse 1st When the transmission is set to REVERSE Ist, the No. 1 clutch and No. 5 clutch are engaged. The motive force from the torque converter transmitted to input shaft (5) is then transmitted to output shaft (19). No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds carrier (36) in position. No. 5 clutch is actuated by the hydraulic pressure applied to the clutch piston, and engages ring gear (20). The motive force from the torque converter is transmitted to input shaft (51, and the rotation of the input shaft passes through sun gear (6) and is transmitted to planet pinion (9). Carrier (36) is held in position by No. 1
1 O-32
25
24
21
20
SDDOOlOS
clutch, so the rotation of planet pinion (9) rotates ring gear (34). Ring gear (34) rotates in the opposite direction from the input shaft, and rotates carrier l
.
l
(31). Carrier spline, tion of pinion
(31) and carrier (27) are joined by a and rotate as one unit, so the rotacarrier (31) passes through planet (24) and is transmitted to ring gear
(25). Carrier (21) is meshed with ring gear (251, and rotates as one unit, so the rotation is transmitted to planet pinion (17). Ring gear (20) is held in position by No. 5 clutch, so the rotation of planet pinion (17) rotates sun gear (18), and this rotates output shaft (19).
D 155AX-5
STRUCTURE AND FUNCTION
TRANSMISSION
TRANSMISSION
CONTROL VALVE
CONTROL VALVE
SJD02739
1o-34
D 155AX-5
TRANSMISSION
STRUCTURE AND FUNCTION
I
A-A \.
D 155AX-5
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
CONTROL VALVE
Quick return valve Plug Valve body Stopper Speed valve spool Directional valve spool Collar Cover Stopper Piston Piston spring Modulating valve spool Modulating valve sleeve Modulating valve spring Modulating valve spring Modulating valve spring Stopper Cover
(large) (small)
1o-35
TRANSMISSION
STRUCTURE AND FUNCTION
MODULATING
CONTROL VALVE
VALVE
Outline . The modulating valve assembly consists of the modulating valve and quick return valve, and has a pressure modulating function. . When the gear shift lever is operated to shift gear, the clutch is engaged by the piston, but if high oil pressure is suddenly applied, the piston will suddenly engage the clutch. This will cause the machine to start suddenly and will subject the machine to an excessive shock. To prevent this, the modulating valve is installed to raise the pressure applied to the piston gradually to the set pressure when the gear shift lever is operated to shift gears. This engages the clutch smoothly and prevents any starting shock. In this way, it not only improves the ride for the operator, but also improves the power train durability. The graph on the right shows the amount of time elapsed and the rise in the oil pressure with the modulating valve. For example, when shifting from forward 1st to forward 2nd, the oil from the pump passes through the speed valve spool and flows to the 2nd clutch to fill the circuit to the clutch piston port. The time taken to fill the circuit to the clutch piston port is called the filling time. The oil pressure is 0 to 0.5 MPa (0 to 5 kg/cm*). The time taken for the oil pressure to rise to the set pressure after the circuit to the clutch piston port is filled is called the build-up time. The combination of the filling time and build-up time is called the modulating time.
Modulat,ina
”
time
0. 5
0 Time
t. 0 (set) SWDO2811
l
1 O-36
D155AX-5
STRUCTURE
TRANSMISSION
AND FUNCTION
Operation 1. Immediately after shifting gear When the gear shift lever is operated and the clutch is engaged, the passage from the pump to the clutch cylinder is opened, and oil flows to the clutch cylinder. Using the power of this flow, quick return valve (I) moves to the left, connects ports A to drain port B, and releases the back pressure of modulating valve sleeve (13). When this happens, modulating valve (12) and modulating valve sleeve (13) are pushed back to the right in the arrow direction by the reaction force of springs (141, (15), and
To
c lutch
CONTROL
VALVE
cylinder
Drain .A
PUrnP
SWD02938
(16).
2.
Oil pressure starting to rise, while rising When the oil sent from the pump fills the circuit to the clutch cylinder, the pressure starts to rise. The oil passing through orifice a of quick return valve (I) moves quick return valve (I) to the right in the arrow direction, and closes the passage between port A and drain port B. The oil also passes through orifice b of modulating valve (12), flows to port C, and pushes piston (IO). When this happens, modulating valve (12) uses the reaction force to compress springs (14) and (15), and moves to the left in the arrow direction. The oil passing through the central port of quick return valve (I) passes through orifice c and flows to port A. It forms the back pressure of valve sleeve (131, and moves valve sleeve (13) to the left in the arrow direction to compress spring (16).
D 155AX-5
To
c
Pump
SWD0.2939
1o-37
STRUCTURE
3.
AND FUNCTION
While oil pressure is rising, rise completion As the oil pressure in the circuit rises, the back pressure of valve sleeve (13) also rises, and valve sleeve (13) moves to the left in the arrow direction. In addition, as the oil pressure pushing pisvalve (12) moves ton (IO) rises, modulating to the left in the arrow direction by reaction force. repetition of the above opBy continuous load of springs (14), (15), and eration,‘the (16) increases, and the oil pressure gradually rises. Finally, valve sleeve (13) contacts stopper (17) and cannot move any further, the rise in oil pressure. thus completing
1 O-38
TRANSMlSSbON
To
clutch
VALVE
CONTROL
cylinder
B Drain
I5
14
13
Drain
From Dump
12
10 SWD02940
D 155AX-5
STRUCTURE
AND
MAIN
FUNCTION
RELIEF VALVE
MAIN RELIEF VALVE
7
Pl
P8
E D
A-A
1. 2. 3. 4. 5. 6. 7. 8. 9. A. B. C. D. E. PI. P8.
Body Torque converter Valve spring Piston Piston spring Main relief valve Valve spring Piston spring Piston
relief valve
Drain port (for torque converter relief) Drain port From pump Drain port To torque converter Main relief oil pressure detection port Torque converter relief oil pressure detection port
D155AX-5
Outline 1. Main relief valve Main relief valve (6) sets the set pressure of the oil pressure for the transmission, steering clutch, and brake. 2. Torque converter relief valve Torque converter relief valve (2) acts to protect the torque converter from abnormally high pressure by relieving the circuit if the torque converter inlet port pressure rises above the set pressure. Unit: MPa {kg/cm*} Set pressure Main relief pressure Torque converter relief pressure
2.94 130) 0.87 18.83)
1o-39
STRUCTURE
AND
MAIN
FUNCTION
To torque converter
*\ Operation of main relief valve . The oil from the power train pump passes through the filter, enters port A of the main relief valve, then passes through orifice a and enters port B. When the oil from the pump fills the circuit, the oil pressure starts to rise. . As the oil pressure in the circuit rises, the oil entering port B pushes piston (4). The reaction compresses spring (71, moves main relief valve (6) to the left in the arrow direction, and opens ports A and C. Then, the oil from the pump is relieved from port A to port C, then flows from port C to the torque converter. The oil pressure at port A at this point is 2.94 MPa (30 kg/cm?.
RELIEF VALVE
To oil tank
From pump To torque converter
SYD00295
To oil tank
I
I
‘,
7---lm I
‘, :; I
I
Operation of torque converter relief valve The oil relieved by the main relief valve flows from port C to the torque converter, and at the same time, passes through orifice b and enters port D. When the passage to the torque converter is filled with oil, the oil pressure starts to rise. As the oil pressure to the torque converter rises, the oil entering port D pushes piston (9). The reaction compresses spring (3). moves relief valve (2) to the right in the arrow direction, and opens ports C and E. Then, the oil from port C is relieved to port E and is drained to the oil tank. The oil pressure at port C at this point is 0.87 MPa (8.83 kg/cm*).
7
From pump To torque
D
9
b
C
From pump
1O-40
SYD00297
D155AX-5
STRUCTURE
AND
FUNCTION
LUBRICATION
LUBRICATION
RELIEF VALVE
RELIEF VALVE
SDD00028
1. Forward 2. Spring 3. Piston
clutch housing
A. From oil cooler B. Drain C. Drain Outline . The oil leaving the torque converter passes through the oil cooler built in the radiator lower tank. It then goes through the lubrication relief valve and lubricates the transmission and PTO. Unit: MPa {kg/cm21
.
The lubrication relief valve is installed to the right side face of the forward clutch housing, and prevents any abnormal pressure in the lubricating oil.
D 155AX-5
10-41
STRUCTURE AND FUNCTION
SCAVENGING
1. 2. 3. 4. 5.
Scavenging pump PTO drive gear Pump drive gear PTO case Strainer
SCAVENGING
PUMP STRAINER
(112)
Outline . Scavenging
. A. Scavenging B. Scavenging
lo-42
PUMP STRAINER
pump suction port pump delivery port
pump (I) is driven by PTO drive gear (2). It acts to return the oil accumulated in the transmission case to the steering case. The strainer is made of punched metal with 2-mm diameter holes.
D155AX-5
STRUCTURE
POWER TRAIN PUMP STRAINER
AND FUNCTION
POWER TRAIN PUMP STRAINER
3A
38
3c
A-A
SWD07.780
1. Power train lubrication pump (rear) (SAL(3)-100) 2. Power train pump (front) (SAL(3)-80) 3. Power train pump strainer assembly 3A. Magnet 3B. Strainer 3C. Shaft Performance
A. B.
From steering case To power train pump * The front pump indicates the shaft mount end.
D155AX-5
the pump
at
Mesh size
(u m)
149
Filtering area Pressure
(cm*)
2,100
resistance
(MPa
{kg/cm*})
0.2 (2.01
1
o-43
POWER TRAIN OIL FILTER
STRUCTURE AND FUNCTION
POWER TRAIN OIL FILTER
1A
18
1D
SKD00040
1.
A. B.
Power train oil filter assembly IA. Cover 16. Body 1 C. Element ID. Valve IE. Spring IF. Drain plug To transmission case From power train pump
1o-44
Performance Cracking pressure Mesh
(MPa
size
Filtering
area
Filter flow
{kg/cm*})
0.105 f 0.02 (1.05 f 0.21
(p m)
30
(cm*)
10,026
(Urnin)
169
D155AX-5
HSS SYSTEM
STRUCTURE AND FUNCTION
HSS SYSTEM
1 5
C
I
.
//
,,
I
B
I
I
A
.
SVDO2684
1O-46
D155AX-5
STRUCTURE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
AND
HSS SYSTEM
FUNCTION
Joystick HSS controller Servo valve HSS pump Engine Hydraulic pump Work equipment control Sprocket Final drive HSS motor HSS closed circuit
valve
A. B. C. D. E. F. G.
Travel REVERSE signal 2 Trave; REVERSE signal 1 Steering signal; I,2 Engine speed signal Hydraulic pressure signal Steering circuit pressure signal A Steering circuit pressure signal B
Outline The HSS system is a hydrostatic system; HSS stands for Hydrostatic Steering System. The HSS system consists of a set of piston pump and piston motor as shown in the diagram. With this system, it is possible to turn continuously by generating a difference in speed between the left and right tracks. There is no need to reduce speed. The HSS controller controls the angle of the swash plate in the HSS pump according to the angle of operation of the monolever, and controls the speed and directional of rotation of the HSS motor. The HSS motor uses the planetary gear system of the bevel gear shaft to create a difference in the speed of the left and right sprockets, and this turns the machine. The HSS controller detects the speed of the engine and the hydraulic pressure at all parts, and controls the swash plate angle of the HSS pump to prevent the engine from stalling.
Dl %AX-5
1o-47
STRUCTURE AND FUNCTION
ACTUATION 1.
ACTUATION
OF HSS SYSTEM
OF HSS SYSTEM
Joystick at NEUTRAL and machine stopped
1
2
U
‘70 ,, t
,c -t
6
ii
/i
/
SVDO2685
1 O-48
D155AX-5
STRUCTURE AND FUNCTION
1
ACTUATION OF HSS SYSTEM
I
2
1
3
7
-I? ; 7/
5
” 14
6
I3
:-
SVD02666
D155AX-5
1o-49
STRUCTURE
AND
ACTUATION
FUNCTION
OF HSS SYSTEM
1. Hydraulic tank 2. Charge pump 3. HSS, PPC charge circuit filter 4. Accumulator 5. HSS, PPC charge circuit valve 6. Charge pressure sensor 7. HSS pump 7A. Suction safty valve 7B. Suction safty valve 7C. Charge safty valve 7D. Serve piston 7E. Solenoid B 7F. Solenoid A 7G. Servo valve 8. HSS motor 8A. Flashing shuttle valve 88. Cooling shuttle valve 9. Pump, motor drain circuit block 9A. Charge relief valve sensor 10. Hydraulic temperature 11. Oil cooler bypass valve 12. Hydraulic oil cooler 13. HSS controller 14. Joystick U. To PCC valve V. LEFT TURN W. NEUTRAL X. RIGHT TURN
Actuation when joystick is at NEUTRAL and machine is stopped . When joystick (14) is at NEUTRAL, there is no electric signal from HMT controller (13) to HSS pump solenoids (7E) and (7F). Servo valve (7G) and servo piston (70) are both at neutral, so the swash plate angle of HSS pump (7) is 0, and the delivery from ports PA or PB is also 0.
.
l
To ensure the suction performance of HSS pump (71, the charge pressure in the HSS charge circuit is always detected by charge pressure sensor (6), and feedback is sent to HSS controller (13).
The pressurized oil from charge pump (2) passes through PPC, HSS charge valve (5) and enters the charge circuit. The pressurized oil entering port A is set to the maximum pressure for the charge circuit 3.7MPa {38kg/cm*} by charge safety valve (7C). When the HSS pump is at neutral, all the oil flow is relieved from port D, passes through oil cooler bypass valve (II) and hydraulic cooler (12), and is drained to hydraulic tank (I).
1O-50
D155AX-5
STRUCTURE AND FUNCTION
2.
ACTUATION
OF HSS SYSTEM
Joystick at FORWARD and left turn
2
6 3
m
I
,2
;““““,,‘,,:
iQ 1
/
I
7c,
t
D
I
‘70 ,,
6
SVD01667
1o-52
D155AX-5
STRUCTURE AND FUNCTION
ACTUATION
OF HSS SYSTEM
2
3
I
I
4 -__I
;
5
;
/
e
14 6
I-
13
m I
I
/
fh
m
/
m
m
/
-:
SVD02666
D155AX-5
1o-53
STRUCTURE AND FUNCTION
ACTUATION
OF HSS SYSTEM
U. To PCC valve V. LEFT TURN W. NEUTRAL X. RIGHT TURN
Jovstick at FORWARD and left turn _When monolever (14) is operated to FORWARD and left turn, an electric signal flows from HSS controller (13) to solenoid B (7E). Servo valve (7G) and servo piston (7D) move in the direction of the arrow, change the angle of the swash plate of HSS pump (7) and pressure oil is discharged from port PB. When oil is discharged from PB, the pressure at port PA is low, so safety-suction valve (78) opens, and if there is insufficient oil in the HSS closed circuit, oil is supplied from (7B). The pressure oil leaving PB enters port MB of HSS motor (8) and rotates the HSS motor. The return oil flows from port MA to port PA and circulates inside the HSS closed circuit. At the same time, the pressure oil from port F moves shuttle valve (8A) in the direction of the arrow, and low-pressure ports E and G open. When this happens, the minimum pressure (18 kg/cm*) is maintained at the low-pressure side by charge relief valve (9A), and the suction performance of the HSS pump is ensured. The excess pressure oil is relieved from charge relief valve (9A) to port H, passes through oil cooler bypass valve (11) and hydraulic oil cooler (12), and is drained to hydraulic tank (1). The relief pressure (II kg/cm*) of charge relief valve (9A) is lower than the relief pressure (28 kg/cm*) of charge safety valve (7C). As a result, the charge pressure oil flowing into the HSS circuit is relieved from charge relief valve (9A).
1o-54
D155AX-5
ACTUATION
STRUCTURE AND FUNCTION
3.
OF HSS SYSTEM
Joystick at travel FORWARD and right turn
2
IQ ‘m ,
,
I
y”““,““:
1
I2
I
I
I C 1/
I,,
I
I,,
,
::: 1,111
:
1,111
nrrrrm,
,,
I
:::::::::::::::::::::
::::::::::::::::::::’ :::::::::::::::::::’
I I l,
I
‘70 ,,
ii jj
m-,---7
c-----
6
,
I,,
1
SVD02689
1 O-56
D155AX-5
STRUCTURE AND FUNCTION
ACTUATION
OF HSS SYSTEM
4i
; AA \
/
Q
-
4 14
6
I-
;
13
F
If f’
f’
kl
I ’
9
SVD02690
D155AX-5
1o-57
STRUCTURE AND FUNCTION
U. V. W. X.
ACTUATION
OF HSS SYSTEM
To PCC valve LEFT TURN NEUTRAL RIGHT TURN
Joystick at travel FORWARD and right turn When monolever (14) is operated to FORWARD and right turn, an electric signal flows from HSS controller (13) to solenoid B (7F). Servo valve (7G) and servo piston (7D) move in the direction of the arrow, change the angle of the swash plate of HSS pump (7) and pressure oil is discharged from port PA. When oil is discharged from PA, the pressure at port PB is low, so safety-suction valve (7B) opens, and if there is insufficient oil in the HSS closed circuit, oil is supplied from (7A). The pressure oil leaving PA enters port MA of HSS motor (8) and rotates the HSS motor. The return oil flows from port MB to port PB and circulates inside the HSS closed circuit. At the same time, the pressure oil from port E moves shuttle valve (8A) in the direction of the arrow, and low-pressure ports F and G open. When this happens, the minimum pressure (18 kg/cm*) is maintained at the low-pressure side by charge relief valve (9A), and the suction performance of the HSS pump is ensured. The excess pressure oil is relieved from charge relief valve (9A) to port H, passes through oil cooler bypass valve (11) and hydraulic oil cooler (121, and is drained to hydraulic tank (1). The relief pressure (11 kg/cm*) of charge relief valve (8B) is lower than the relief pressure (28 kg/cm*) of charge safety valve (7C). As a result, the charge pressure oil flowing into the HSS circuit is relieved from charge relief valve (9A).
1O-58
D 155AX-5
HSS PUMP
STRUCTURE AND FUNCTION
HSS PUMP HPVI 60
PC,.PR
1. Servo valve connector
2. Piston pump 3. Servo piston 4. Servo valve
5. Suction safety valve 6. Charge safety valve 7. Plug for measuring (PA and PB pump pressure)
Outline l
The pump is composed of variable displacement piston pump with swash plate, servo valve, suction safety valve, and charge safety valve.
D155AX-5
1o-59
STRUCTURE
1.
AND
HSS PUMP
FUNCTION
PISTON PUMP
PSVO I
PSVA
I
PCS
PSVO PB PA PD2 PR PSVA PSVB PSVI PC
\
PC
PSVB
PSVl
SWD02692
: Servo valve source pressure Pump inlet and outlet port Pump inlet and outlet port Pump drain port Charge safety valve relief pressure : Servo valve outlet : Servo valve outlet pressure : Servo valve source pressure : Charge pressure
: : : :
1 O-60
D 155AX-5
HSS PUMP
STRUCTURE AND FUNCTION
,;
A-A
1. Shaft
2. Case 3. Cradle 4. 5. 6. 7.
Rocker cam Servo piston Slider Shoe
8. 9. 10. 11. 12. 13. 14.
Piston Cylinder block Valve plate End cap Bearing Spline Bearing
.
Rocker cam (4) has plane A, and shoe (7) is always pressed against this surface as it slides in a circle. Rocker cam (4) sends high pressure oil to the space between cylindrical surface B and cradle (3) fixed to the case (21, to form a hydrostatic bearing and carries out a rocking movement. Piston (8) carries out motion relative to the axial direction inside each cylinder chamber of cylinder block (9). Cylinder block (9) carries out rotation relative to valve plate (IO) while sealing the pressurized oil, and this surface ensures that the hydraulic balance is maintained correctly. The oil inside each cylinder chamber of cylinder block (9) is sucked in and discharged through valve plate (IO).
Outline l
.
The rotation torque transmitted to the pump shaft is converted to hydraulic energy and pressurized oil is discharged according to the load. It is possible to change the delivery amount (normal delivery 0 reverse delivery) by changing the swash plate angle.
Structure l
l
Cylinder block (9) is supported to shaft (I) by a spline (131, and shaft (I) is supported by front and rear bearings (12) and (14). The end of piston (8) has a concave ball shape, and shoe (7) is caulked to it to form one unit. Piston (8) and shoe (7) form a spherical bearing.
D155AX-5
.
.
1O-61
STRUCTURE
AND
FUNCTION
Operation 1. Operation of pump Cylinder block (9) rotates together with shaft (I), and shoe (7) slides on plane A. When this happens, angle a of center line X of rocker cam (4) to the axial direction of cylinder block (9) changes. This angle c1 is called the swash plate angle. I) With swash plate angle 01formed by the angle between center line X of rocker cam (4) to the axial direction of cylinder block (91, plane A acts as a cam for shoe (7). In this way, piston (8) slides inside cylinder block (91, and as a result, a difference is generated between volumes E and F inside the cylinder block. The amount of suction and discharge is equal to difference F - E. In other words, cylinder block (9) rotates, and the volume of chamber F becomes smaller, so oil is discharged during this process. At the same time, the volume of chamber E becomes larger and oil is sucked in as the volume increases. 2) When center line X of rocker cam (4) is the same as the axial direction of cylinder block (9) (swash plate angle = 01, the difference between volumes E’ and F’ inside cylinder block (9) is 0, so no oil flows in or out, and no pumping is carried out. 3) With swash plate angle a formed by the angle between center line X of rocker cam (4) to the axial direction of cylinder block (91, plane A acts as a cam for shoe (7). In this way, piston (8) slides inside cylinder block (9), and as a result, a difference is generated between volumes E” and F” inside the cylinder block. The amount of suction and discharge is equal to difference E” - F”. In other words, cylinder block (9) rotates, and the volume of chamber E” becomes smaller, so oil is discharged during this process. At the same time, the volume of chamber F” becomes larger and oil is sucked in as the volume increases. When the swash plate angle changes, the suction/discharge action of ports PA and PB is reversed.
HSS PUMP
l
1 O-62
smo120
PA PB
SKD00121
‘A
‘F” SKDO0122
D155AX-5
HSS PUMP
STRUCTURE AND FUNCTION
2.
Control of discharge amount I)
If swash plate angle a becomes larger, the difference between volumes E and F becomes larger, and oil delivery Q is increased. Swash plate angle CL is changed by servo piston (5). Servo piston (5) carries out reciprocal movement in a straight line (~1 according to the command from the valve. This straight-line movement is transmitted to rocker cam (4) through slider (61, and rocker cam (41, which is supported on the cylindrical surface by cradle (2) slides on the cylindrical surface ( C direction). In the case of the pump, swash plate angle a is a maximum of f20”.
4
3
5
6
A-A
4
5
SDD00123
6
SDD00124
LL_Ll
B-B
D155AX-5
SDD00125
1O-63
HSS PUMP
STRUCTURE AND FUNCTION
2.
Servo valve
k-B PSVl
PSVA
PSVB
A-A
B-0 SWD02694
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connector Solenoid valve B Connector Solenoid valve A Shaft Coil Base Lever 1 Spring
1 O-64
10. 11. 12. 13. 14.
Lever 2 Body Screw Arm Spool
PSVI : Servo valve source pressure PSVB : Servo valve output pressure PSVA : Servo valve output pressure
D155AX-5
STRUCTURE AND FUNCTION
HSS PUMP
‘15
SWD07.695
Actuation 1)
When pressurized oil (servo source pressure) does not enter from the charge pump or when there is no current flowing to solenoid valve coil (6), the servo valve and servo piston (15) are not actuated.
D155AX-5
1O-65
STRUCTURE
2)
3)
AND
FUNCTION
HSS PUMP
When the current flows to solenoid valve coil (6) and coil is excited, solenoid propuland shaft (5) sion force fl is generated pushes spool (14) to the right in the direction of the arrow. Lever 2 (IO), which is with spool (14), uses screw interconnected (12) as a fulcrum and rotates clockwise while pulling spring (9). When spool (14) moves, the passages between ports A and B and ports C and D open, and pressurized oil from the charge pump passes through ports A and B and flows to port F of servo piston (15). At the same time, the oil at port G passes through ports D and E, and is drained.
1O-66
D155AX-5
STRUCTURE
HSS PUMP
AND FUNCTION
-
4)
Y--
’ 15
SWD02793
Servo piston (15) is moved to the right in the direction of the arrow by the pressurized oil entering port F, and the swash plate angle of the variable pump becomes larger by an amount equal to stroke a of the servo piston. At the same time, arm (131, which is connected to servo piston (15) rotates arm (13) around screw (12) as a fulcrum, and lever 1 (8) is moved to the left. Servo piston (15) stops in a position where solenoid propulsion force fl is balanced with spring force f2.
D 15%X-5
1O-67
HSS PUMP
STRUCTURE AND FUNCTION
5) The
stroke of the servo piston, which changes the delivery amount of the variable pump, is controlled by the servo valve. The relationship between the stroke of the servo piston and the current of the solenoid valve is as shown in the diagram.
PSVA
side
solenoid
Current
PSVB I
1 O-68
side
solenoid
SWD0.2804
D 155AX-5
STRUCTURE
3.
1. 2. 3. 4. 5.
Suction
HSS PUMP
AND FUNCTION
safety valve
Charge pump HSS pump Oil cooler Charge safety valve Suction safety valve 5A. Valve 5B. Piston 5C. Sleeve
5D. 5E. 5F. 5G.
Poppet Valve seat Spring Pressure adjustment screw: one turn adjusts pressure by approx. 13.7 MPa U40kg/cm21
6. HSS motor
Function . There are two suction safety valves installed to the HSS pump, and they have the following functions. 1) High pressure relief valve The valve restricts the maximum pressure inside the HSS circuit in order to protect the HSS circuit and to restrict the maximum drawbar pull of the machine. 2) Suction safety valve The valve ensures the flow of charge oil to the HSS circuit and prevents the charge oil from flowing into the pump high pressure side (delivery side).
D155AX-5
1 O-69
STRUCTURE
AND
FUNCTION
HSS PUMP
Actuation when acting as high pressure relief valve (Valve at piston pump delivery side) . Port A is connected to the piston pump circuit and port B is connected to the charge circuit. The pressurized oil also fills port C through drill hole a in piston (5B). In addition, poppet (5D) is in tight contact with valve seat (5E).
.
If abnormal pressure is generated in the piston pump circuit and the oil pressure at port A and C reaches the pressure set by spring (5F), poppet (5D) is pushed to the right in the direction of the arrow, and the oil at port C is relieved from port D to port B to reduce the oil pressure at port C.
B’
.
When the oil pressure at port C goes down, a differential pressure is generated between port A and port C by orifice b in piston (5B). Valve (5A) is pushed to the right in the direction of the arrow by the oil pressure at port A, and the oil at port A is relieved to port B. In this way, the piston pump circuit is prevented from reaching any higher pressure.
1O-70
A
SED00133
5A
5B
C
D155AX-5
STRUCTURE
AND
HSS PUMP
FUNCTION
Operation when acting as suction safety valve 1) When HSS pump delivery is 0 . The HSS circuit is closed, and the charge pressure oil does not flow into the HSS circuit. Therefore, the charge pressure oil from the charge pump all passes through charge safety valve (4) and is drained through oil cooler (3) to the tank.
21 When HSS pump delivery is discharged from port PA (I) Valve at piston pump delivery side . When pressure oil is discharged from port PA of HSS pump (21, port PA becomes the high pressure side. This pressure oil at port PA passes through drill hole a in piston (5B) and flows to port A. When this happens, valve (5A) is pushed to the left in the direction of the arrow against sleeve (5C) because of the difference in area (Al>A2). Therefore, the pressure oil from charge pump (I) is prevented from flowing into the HSS closed circuit.
)”
SWD02943
SED00137
D155AX-5
10-71
STRUCTURE
AND
(2) Valve at piston pump suction side . Port PB becomes the suction side, so it becomes the low pressure side. Because of the difference in area (Al>A2), valve (5A) is pushed to the right in the direction of the arrow by the charge pressure oil and the seat of sleeve (5C) opens. As a result, the charge pressure oil at port B passes through the gap and flows to port PB to carry out the charge function for the HSS circuit.
1 O-72
HSS PUMP
FUNCTION
PB+
Ai
‘u
‘B
Al
SED00138
D155AX-5
STRUCTURE
4.
Charge
’\
1. 2. 3. 4.
AND
HSS PUMP
FUNCTION
safety valve
CA
Charge pump HSS pump Oil cooler Charge safety valve 4A. Valve 4B. Spring
4C. Valve seat 4D. Poppet 4E. Spring 4F. Pressure adjustment 5. Suction safety valve 6. HSS motor
screw
Function . The charge safety valve is installed to the HSS pump between the suction safety valve and the oil cooler. It acts to restrict the maximum pressure in the charge circuit. Set pressure: 3.7 MPa I38 kg/cm? at 204 Umin
D155AX-5
1o-73
STRUCTURE AND FUNCTION
HSS PUMP
Operation . Port A is connected to the charge circuit, and port B is connected to the tank drain
4A
B
4C
4D
circuit. The pressure oil passes through orifice a in valve (4A) and fills C. Poppet (4D) is in tight contact with valve seat (4C).
& .
If abnormal pressure is generated in the circuit or the shuttle valve of the HSS motor is at neutral, and the pressure oil at ports A and C reaches the pressure set by spring (4E), poppet (4D) is pushed to the right in the direction of the arrow, and the oil at C is relieved to port D to reduce the pressure of the oil at C.
4D
I
SED00140
4E
d
A
SED00141
l
.
When the pressure of the oil at port C goes down, a differential pressure is created between ports A and C because of orifice a in valve (4A). Valve (4A) is pushed to the right in the direction of the arrow by the oil pressure at port A, and the oil at port A is relieved to port B. In this way, the pressure in the charge circuit is prevented from going any higher. Drain port D at the poppet portion is drained to the HSS pump case, so the back pressure of drain port B is not added to the charge relief pressure, and the valve always displays the set relief characteristics.
1o-74
A
i SED00142
D 155AX-5
STRUCTURE AND FUNCTION
HSS MOTOR
HSS MOTOR 1.
PISTON MOTOR
2
3 .MB
MA T
CA CB MB
‘MA
SA
.SB
CA
‘CB
l--B
1. HSS motor shuttle valve 3. Cooling shuttle valve
2. Flashing
MA : From HSS pump MB : From HSS pump
PA port PB port
T SA SB CA CB
: : : : :
To hydraulic tank To charge relief valve To charge relief valve Pressure sensor mounting Pressure sensor mounting
SJD02699
port port
Outline . Motor
is composed of fixed capacity, fixed swash plate type piston motor, and flashing shuttle valve, and cooling shuttle valve.
Specifications
D155AX-5
1o-75
STRUCTURE
AND
HSS MOTOR
FUNCTION
If
i4
i3
II
Ii B-0
A-A
SJD02700
1. 2. 3. 4. 5. 6. 7. 8.
Output shaft Motor case Swash plate Piston Cylinder block Valve plate End cover Cover
Outline . Pressurized oil sent from the pump is converted to rotation energy and is transmitted to output shaft.
9. 10. 11. 12. 13. 14. 15. 16.
Return spring Flashing shuttle valve Plug Cooling shuttle valve Bearing Spline Shoe Bearing
.
Piston (4) carries out motion relative to the axial direction inside each cylinder chamber of cylinder block (5). Cylinder block (5) carries out rotation relative to valve plate (6) while sealing the pressurized oil, and this surface ensures that the hydraulic balance is maintained correctly. The oil inside each cylinder chamber of cylinder block (5) is sucked in and discharged through valve plate (6).
. Structure . Cylinder block (5) is supported to shaft (I) by a spline (141, and shaft (I) is supported by front and rear bearings (16) and (13). The end of piston (4) has a concave ball shape, and shoe (15) is caulked to it to form one unit. Piston (8) and shoe (15) form a spherical bearing. l
1 O-76
D 155AX-5
STRUCTURE
AND
HSS MOTOR
FUNCTION
Operation 1: Operation of motor . The pressurized oil sent from the pump enters cylinder block (5) and pushes piston (4) from the back face. In the case of the motor, the center line of plate (3) is always at an angle (swash plate angle a) to the axial direction of cylinder block (5). As a result, if we take the example of one of pistons (41, oil pressure is applied to the back face of the piston as shown in the diagram on the right, and piston axial force FO is generated. . With shoe (151, which is joined to piston (4) by the spherical surface, reaction force FR in a direction at right angles to plane A is generated. The combined force of FO and FR is FP, and this becomes the force to rotate cylinder block (5). . Shaft (I), which is meshed to cylinder block (5) by spline (14) transmits this rotation torque to the output side. Cylinder block (5) rotates, and while the condition changes from volume E to volume F, pressurized oil from the pump flows into the cylinder chamber, and pressure P is generated according to the load. On the other hand, when the condition goes beyond volume F and changes to volume E, the oil is pushed out and returned to the pump. 2.
.
Rotation speed and torque control If flow 0 sent from pump becomes rotation speed N of motor becomes
larger, faster.
SWD02701
.. I
0 = qN (q = E-F) T=-
Pq 27l
D155AX-5
0 q N P T
14
&DO2702
: Total flow
: Flow per 1 turn : Rotation speed : Pressure : Rotating torque
1o-77
STRUCTURE
AND
FUNCTION
HSS MOTOR
3. Flushing shuttle valve Function The shuttle valve acts to switch the shuttle valve spool according to the pressurized oil in the HSS high-pressure circuit, and to return the oil in the HSS low-pressure circuit through the oil cooler to the tank. The shuttle valve is installed to the HSS motor assembly. l
Operation 1) When HSS pump swash plate angle is at neutral position . The swash plate angle of the pump is at the neutral position, so the delivery from HSS pump (2) is 0. When this happens, the same oil pressure is applied to ports A and B at both ends of shuttle valve spool (71, so spool (7) remains at the neutral position. . The pressurized oil from charge pump (I) passes through charge safety valve (41, which is assembled to the pump, and is drained from oil cooler (3) to the tank.
21 When .
.
.
HSS pump is discharging oil from port PA The pressurized oil from HSS pump (2) enters port MA from port PA, passes through orifice a of shuttle valve spool (71, then enters port A. Spool (7) is pushed to the right in the direction of the arrow by the pressurized oil at port A, so the passage between ports MB and D is opened and the oil is connected to charge relief valve (8). When this happens, the relationship of the set pressure of charge relief valve is as follows.
As a result, the pressurized oil from charge pump (I) flows from port C through charge relief valve (81, where the set pressure is lower. It is then relieved and is drained from oil cooler (3) to the tank. SWDO2704
1 O-78
D 155/U-5
STRUCTURE
3) .
.
When HSS pump is discharging oil from port PB The pressurized oil from HSS pump (2) enters port MB from port PB, passes through orifice b of shuttle valve spool (71, then enters port B. Spool (7) is pushed to the left in the direction of the arrow by the pressurized oil at port B, so the passage between ports MA and C is opened and the oil is connected to charge relief valve (8). When this happens, the relationship of the set pressure of charge relief valve is as follows. Set pressure of charge safety valve (4) I
.
HSS MOTOR
AND FUNCTION
>
Set pressure of charge relief I [ valve (8)
As a result, the pressurized oil from charge pump (I) flows from port C through charge relief valve (8), where the set pressure is lower. It is then relieved and is drained from oil cooler (3) to the tank.
t!i!i
D155AX-5
SWD02705
1o-79
STRUCTURE
AND
HSS MOTOR
FUNCTION
3. Cooling shuttle valve Function The shuttle valve acts to switch the shuttle valve spool according to the pressurized oil in the HSS high-pressure circuit, and to flow a part of HSS low pressure circuit oil to HSS motor drain case for cooling oil inside the case. The cooling shuttle valve is installed to the HSS motor. l
Operation 1) When HSS pump swash plate angle is at neutral position The swash plate angle of the pump is at the neutral position, so the delivery from HSS pump (2) is 0. When this happens, the same oil pressure is applied to ports a and b at both ends of cooling shuttle valve spool (8D), so spool (8D) remains at the neutral position, and oil does not flow.
d! J /:,
l
v\ d
2) l
ED
b
SWDO2706
When HSS pump is discharging oil from port PA The pressurized oil from HSS pump (2) enters port MA from port PA. Cooled oil in hydraulic tank flows into MB port through charge pump (I) and suction safety valve (5). High pressure circuit MA is connected with a of cooling shuttle valve spool (8D). Low pressure circuit MB is connected with b of spool (8D). If difference pressure between MA and MB exceeds set pressure, spool (8D) moves toward arrow shown in the figure, and oil flows from MB port through b, orifice c to motor case (d) to cool. * Set pressure: 1.2MPa {12kg/cm2) When HSS pump discharge oil from port MB, spool (8D) moves in opposite side.
SWD02707
1 O-80
D155AX-5
HSS MOTOR
STRUCTURE AND FUNCTION
4.
CHARGE RELIEF VALVE
8A
8B
8C
8E
IjF
SWD02708
1. 2. 3. 4. 5. 6. 7.
Charge pump HSS pump Oil cooler Charge safety valve Suction safety valve HSS motor Shuttle valve
8. Charge relief valve 8A. Valve 8B. Spring 8C. Valve seal 80. Poppet 8E. Spring 8F. Pressure adjustment
screw
Function l
The charge relief valve is installed to the HSS pump and motor drain block. It acts to maintain the minimum pressure at the HSS circuit low-pressure side and ensure the sucof the HSS pump. tion performance Set pressure: 1.8MPa I18kg/cm3 at 120 e /min.
D155AX-5
lo-81
HSS MOTOR
STRUCTURE AND FUNCTION
Operation When oil is being discharged from port PA or port PB of the HSS pump, the oil at the low-pressure side flows from port MA or port MB through shuttle valve (7), port A or B, and hose and enters inlet port A of charge relief valve (8).
l
The pressurized oil entering port A passes through orifice a in valve (8A) and fills port C. Poppet (8D) is in tight contact with valve seat (80.
l
.
SAD00266
If the pressure oil at port C reaches the pressure set by spring (8E), poppet (8D) is pushed to the right in the direction of the arrow, and the oil at port C is relieved to port D to reduce the pressure of the oil at port c.
g&j l
SAD00267
When the pressure of the oil at port C goes down, a differential pressure is created between ports A and C because of orifice a in valve (8A). Valve (8A) is pushed to the right in the direction of the arrow by the oil pressure at port A, and the oil at port A is relieved to port B. In this way, the pressure in the charge circuit is maintained at the set pressure of charge relief valve (8). This charge pressure maintains the supply of oil inside the HSS . closed circuit. SAD00268
.
Drain port D at the poppet portion is gathered to the HSS pump and motor block, so the back pressure of drain port B is not added to the charge relief pressure, and the valve always displays the set relief characteristics.
1 O-82
D155AX-5
STRUCTURE
AND
FUNCTION
PPC, HSS CHARGE
FILTER
PPC, HSS CHARGE FILTER
‘B B-B
E ‘6
tB
Z _-I-I
SAD001 76
A-A
1. 2. 3. 4. 5. 6.
Plug Cover Spring Plate Element Case
A. To PPC relief valve B. To filter bypass valve C. From charge pump
Performance Mesh
size
Filtering area Oil flow
D155AX-5
(pm)
30
km2)
5400
(Q/min)
203
1 O-83
AND
STRUCTURE
VALVE
PPC, HSS CHARGE
FUNCTION
PPC, HSS CHARGE VALVE
A-A
B-B
1. 2. 3.
‘3
check valve Accumulator Filter bypass valve PPC, HSS charge valve
D-D
c-c
SWD02709
PI. From charge pump PC.To HSS charge T. To tank Unit: MPa Ikg/cm? Set pressure
Cl. To main control valve Cl’.To HSS pump, motor servo C2. To PPC valve C3. To accumulator P. From charge filter
1 O-84
PPC, HSS charge Filter valve
valve bypass
Accumulator check valve
Cracking
pressure
Set pressure differenCracking tial pressure Cracking
pressure
3.3 134) 4.1 142) 0.63 (6.4) 0.051
(0.521
D 155AX-5
PPC, HSS CHARGE VALVE
STRUCTURE AND FUNCTION
Outline This valve has the following three valves built in. The accumulator check valve prevents the pressure stored in the accumulator from flowing anywhere except to PPC valve when the engine is stopped. The filter bypass valve acts to keep the differential pressure between the pressures at the charge filter inlet port and outlet port to below the set value. The PPC, HSS charge valve keeps PPC valve pressure and HSS pump and motor servo pressure at the specified pressure and relieves any excess oil. The relieved oil flows to the HSS pump and motor and becomes the charge pressure for the pump and motor. It also sets the maximum pressure in the circuit. l
3
l
l
Operation Z: To PPC valve Y: X: W: V: U: Q:
To accumulator Drain From charge pump To HSS servo, main control Charge filter To HSS charge
8 Q valve
SWD0271D
PPC, HSS charge valve l
l
The oil from the charge pump passes through the charge filter and enters chamber A. When the pressure of the oil from chamber A passing through orifice b and entering chamber C becomes greater than the set load of spring (21, spool (I) moves to the right and connects ports A and D. The oil from the charge pump flows from chamber A through chamber D and becomes the charge pressure for the HSS pump and motor. If the pressure in chamber A becomes low, the circuit between A and D is closed and the pressure in chamber A is maintained. In this way, the PPC valve pressure, HSS pump and motor servo pressure are maintained.
D155AX-5
1 O-85
STRUCTURE
AND
FUNCTION
PPC. HSS CHARGE
VALVE
Accumulator check valve . Accumulator check valve (3) is provided to prevent the accumulator pressure from dropping when the engine is stopped.
Filter bypass valve The oil from the charge pump passing through the charge filter and entering chamber A passes from chamber A through orifice e and enters chamber F of the filter bypass valve. At the same time, the oil from the charge pump entering chamber G of the filter bypass valve directly passes through orifice h and enters chamber J. . If the charge filter becomes clogged and the oil pressure in chamber F drops, and a differential pressure greater than the set pressure is generated between chamber F and chamber J, spool (4) moves to the left, connects ports G and K, and the oil from the charge pump is drained to the suction piping.
.
SWD02712
1O-86
D155AX-5
STRUCTURE
AND
HSS OIL COOLER
FUNCTION
BYPASS
VALVE
HSS OIL COOLER BYPASS VALVE
A-A
1. Plug 2. Valve 3. Shim 4. Plug 5. Spring 6. Body
A. B. C. D. E.
SWD02713
From charge relief valve To tank From oil cooler To oil cooler From charge safety valve
Outline This valve is installed in the circuit between the HSS pump and HSS motor charge relief valve oil return circuit and the oil cooler. 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. l
Set pressure Cracking pressure (MPa (kg/cm?)
D 155AX-5
0.487
(4.971
1 O-87
t 8
7
f-l
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
STEERING, BRAKE CONTROL
Pressure sensor for steering circuit A Pressure sensor for steering circuit I3 Pressure sensor for work equipment PPC, HSS charge valve PPC, HSS charge filter HSS charge pressure sensor Power train pump Travel REVERSE sensing switch Travel REVERSE sensing potentiometer Steering lever potentiometer Steering lever HSS motor Brake valve Transmission HSS pump solenoid valve B HSS pump solenoid valve A HSS pump Engine speed sensor Flywheel housing Joystick Parking limit switch HSS controller
Outline . The electrical signal from joystick (20) passes
.
.
.
. .
through HSS controller (22) and HSS pump solenoid valve A (16) and B (15), actuates HSS motor (12) and operates the steering. If joystick (20) is moved slightly to the left when it is being pushed to the FORWARD position, the machine will turn gradually to the left. If the joystick is moved fully to the left, the machine will turn sharply to the left. If joystick (20) is moved to the left when it is at the NEUTRAL position, the machine will carry out a left counterrotation turn. Brake pedal actuates the spool of brake valve (13) and actuates the left and right brakes at the same time. Safety lever (4) is interconnected with brake valve (131, and acts also as a parking brake. When the gear shift is operated, the electric signal from HSS controller (20) flows to brake valve (13) and operates the brake.
D155AX-5
1 O-89
STRUCTURE AND FUNCTION
BEVEL GEAR SHAFT, HSS BRAKE
BEVEL GEAR SHAFT, HSS BRAKE
SVD02714
D 155AX-5
10-91
STRUCTURE AND FUNCTION
BEVEL GEAR SHAFT, HSS BRAKE
SWD02790
1 O-92
D155AX-5
BEVEL GEAR SHAFT, HSS BRAKE
STRUCTURE AND FUNCTION
c-c 22
23
24
26
25
30
29
28
27 SVD02715
D155AX-5
1o-93
STRUCTURE AND FUNCTION
BEVEL GEAR SHAFT, HSS BRAKE
1. Cover 2. Output shaft 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
Bearing cage Spring Brake piston Plate (I on each side) Brake plate (4 on each side) Brake disc (5 on each side) Brake outer drum Brake inner drum Nut Bearing A Shim (for adjusting preload of bevel gear) Bevel gear shaft Bevel gear (35 teeth) Bearing B Carrier Ring gear Planet pinion gear Hub Sun gear Shim (for adjusting bevel pinion gear) Bearing cage Bearing Nut (for adjusting preload of bearing) Bevel pinion gear (21 teeth) Gear E (for right sun gear drive) Gear D Shaft HSS motor Pinion gear Gear A Gear C Gear B (for left sun gear drive)
1o-94
D155AX-5
STRUCTURE AND FUNCTION
Outline Bevel gear shaft With the bevel gear shaft, the power output from the transmission has its rotating speed reduced and is sent at right angles to the left and right by the meshing of the bevel pinion and bevel gear. The bevel gear shaft system employs spiral bevel gears for the bevel pinion and bevel gear, and employs a forced lubrication system using pressurized oil. The bevel gear shaft system consists of bevel gear (151, which is meshed with bevel pinion (261, bevel gear shaft (141, and bearings (12) and (161, which support the bevel gear shaft.
HSS The HSS (Hydrostatic Steering System) consists of a transfer portion, which reverses the direction of the rotation of HSS motor (30) on the left and right and transmits it to sun gear (211, and a planetary gear system, which increases or decreases the speed of the input, and then outputs it. The direction of steering of the machine is changed by stopping the rotation of the HSS motor or by changing the direction of rotation from the normal direction to the reverse direction. The transfer portion uses a spur gear reduction mechanism. A forced lubrication system using the oil from the power train lubrication pump is employed for lubricating the transfer. A forced lubrication system using the oil from the power train lubrication pump is employed for lubricating the planetary gear. The transfer portion consists of HSS motor pinion (311, gear A (321, gear C (331, shaft (291, gear D (281, gear E (271, gear B (341, and cover (I), which supports these. The planetary gear consists of sun gear (21), planet pinion (191, hub (201, and carrier (17) (which is interconnected with brake inner drum (IO)).
D 155AX-5
BEVEL GEAR SHAFT, HSS BRAKE
Brake The brakes are installed to carry out braking of the machine, and are interconnected with brake inner drum (IO). The brake is a wet type, multiple disc clutch, spring boosted type, and is hydraulically operated using pressurized oil from the brake valve, which is interconnected with the brake pedal. The lubrication is a forced lubrication type using oil from the oil power train lubrication pump circuit, which passes through the housing and cage, and is sent to the discs and plates. The brake consists of brake inner drum (IO) (which is interconnected with carrier (17) and brake outer drum (911, disc (81, plate (71, brake outer drum (91, piston (51, spring (41, bearing cage (31, which support these, brake cover (I), and output shaft (2). Brake outer drum (9) and brake cover (I) are fixed to the HSS case. Output shaft (1) is connected to brake innerdrum (IO) by a spline. When the engine stops, the back pressure of the brake piston drops, so the brake is automatically applied. However, it is dangerous if the brake is released when the engine is started again and the pressure in the circuit rises, so when the parking the machine, always place the parking brake at the LOCK position.
1o-95
STRUCTURE
AND
Flow of Dower
BEVEL GEAR SHAFT,
FUNCTION
for HSS 17
26
18
32
31
30
w
: Mechanical
m
: Hydraulic : Combined
The power from the transmission passes through bevel pinion gear (26) and bevel gear (15), and is transmitted to bevel gear It then goes from bevel gear shaft (14). shaft (14) through hub (20), ring gear (18), carrier (17), and brake inner drum (IO), and is transmitted to left and right output shafts (2). When the steering is operated, HSS motor (30) rotates and the power is transmitted from pinion gear (31) to gear A (32), where it is divided to the left and right. The power sent to the left is transmitted from gear A (32) to gear B (34), sun gear
.
20
27
28
1 O-96
HSS BRAKE
power power power
sK!Joo113
(21), and planet pinion gear (19). It is combined with the power from the transmission at the planetary gear portion, and is transmitted from carrier (17) to output shaft (2). The power sent to the right is transmitted from gear A (32) through gear C (33), gear D (28), and gear E (27) to right sun gear (21) in order to reverse the rotation of the power from the HSS motor. (The flow of power beyond this point is the same as on the left side.) The braking force is applied by braking the rotation of inner drum (IO) (which is interconnected with carrier (17)) at brake outer drum (9), which is fixed to the HSS case. D155AX-5
STRUCTURE
BEVEL GEAR SHAFT,
AND FUNCTION
HSS BRAKE
OPERATION OF HSS 1. When joystick is at NEUTRAL Traveling straight forward
I
I
Transmission output speed @ Right bevel gear shaft output speed
@ Transmission output speed @ Left bevel gear shaft output speed
@
SW002716
m
: Transmission power
The direction of rotation of the HSS motor and gears is as seen from the left side of the machine.
*
Traveling straight forward When the joystick is at the NEUTRAL position, HST motor (301, and transfer gear (33) and left and right sun gears (21) of the planetary gear portion, which are interconnected with the HSS motor, are stopped. In this condition, the power from bevel gear shaft (14) is input to hub (201, passes through
.
Direction
of rotation
Turn
Joystick position direction Travel Neutral Direction of rotation of HSS motor %
D155AX-5
of HSS motor Left turn Forward
z Counter- r$o;terclockwise wise
Counterrotation
ring gear (18) and planet pinion (19), and is transmitted to carrier (17). It then passes through brake inner drum (IO), which forms one unit with the carrier, and is transmitted to output shaft (2). Therefore, the left and right output speeds are the same and the machine travels in a straight line.
Reverse Neutral
Clockwise
Neutral
Right turn
5% Clockwise
Forward Reverse
Clpckwrse
All
Counter- Stopped clockwise
turn
1o-97
BEVEL GEAR SHAFT, HSS BRAKE
STRUCTURE AND FUNCTION
2.
Joystick operated to RIGHT TURN
Forward
SWD02717
Transmission output speed @ Acceleration from HSS motor @ Left bevel gear shaft output speed lo+@, @
Forward When the machine
@ Transmission output speed @ Deceleration from HSS motor @ Right bevel gear shaft output speed (0 - 0,
is traveling forward, bevel gear shaft (14) and hub (201, which is connected to it, rotate clockwise. If the joystick is operated to the RIGHT TURN position when the machine is traveling forward, HSS motor (30) rotates clockwise, the rotation passes through gear A (32), and gear B (34) on the left side of the machine rotates clockwise, while gear E (27) on the right side of the machine is rotated counterclockwise by gear C (33). In other words, the rotation of the HSS motor is transmitted to sun gears (21) as rotation in opposite directions on the left and right by the transfer portion. 1 O-98
m : Transmission power EPZBZZJ: HSS motor power : Combined power
This rotation acts on the left and right planetary gear mechanisms. The speed of carrier (17) on the left is accelerated from the speed when traveling in a straight line by the amount of the power from the HSS motor. On the other hand, the speed of carrier (17) on the right is decelerated from the speed when traveling in a straight line, so a difference in rotation is generated in the output on the left and right. The output speed on the right is lower, so as a result, the machine travels forward and turns to the right.
D 15514X-5
STRUCTURE
AND
BEVEL GEAR SHAFT,
FUNCTION
HSS BRAKE
Reverse
I Transmission output speed @ Acceleration from HSS motor @ Left bevel gear shaft output speed (0 + 0, @
@ Transmission output speed @ Deceleration from HSS motor @ Right bevel gear shaft output speed
W BZZZZZI
: Transmission power : HSS motor power : Combined power
(O-0,
Reverse When the machine is traveling in reverse, bevel gear shaft (14) and hub (201, which is connected to it, rotate counterclockwise. If the joystick is operated to the RIGHT TURN position when the machine is traveling in reverse, HSS motor (30) is rotated counterclockwise in the opposite direction from when traveling forward by the function of the HSS controller. The rotation passes through gear A (321, and gear B (34) on the left side of the machine rotates counter-clockwise, while gear E (27) on the right side of the machine is rotated clockwise by gear C (33). In other words, the rotation of the HSS motor is transmitted to sun gears
D155AX-5
SWD02718
(21) as rotation in opposite directions on the left and right by the transfer portion. This rotation acts on the left and right planetary gear mechanisms. The speed of carrier (17) on the left is accelerated from the speed when traveling in a straight line by the amount of the power from the HSS motor. On the other hand, the speed of carrier (17) on the right is decelerated from the speed when traveling in a straight line, so a difference in rotation is generated in the output on the left and right. The output speed on the right is lower, so as a result, the machine travels in reverse and turns to the right.
10-99
STRUCTURE AND FUNCTION
3.
BEVEL GEAR SHAFT. HSS BRAKE
Joystick operated to LEFT TURN
Forward
@ Transmission output speed @ Acceleration from HSS motor @ Left bevel gear shaft output speed
(0 + 0)
@ Transmission output speed @ Deceleration from HSS motor @ Right bevel gear shaft output speed
w : Transmission power EZBZZZY: HSS motor power : Combined power
(G-0)
Forward When the machine is traveling forward, bevel gear shaft (14) and hub (201, which is connected to it, rotate clockwise. If the joystick is operated to the LEFT TURN position when the machine is traveling forward, HSS motor (30) rotates counterclockwise, the rotation passes through gear A (321, and gear B (34) on the left side of the machine rotates counterclock-wise, while gear E (27) on the right side of the machine is rotated clockwise by gear C (33). In other words, the rotation of the HSS motor is transmitted to sun gears (21) as rotation in opposite directions on the left and right
10-100
by the transfer portion. This rotation acts on the left and right planetary gear mechanisms. The speed of carrier (17) on the right is accelerated from the speed when traveling in a straight line by the amount of the power from the HSS motor. On the other hand, the speed of carrier (17) on the left is decelerated from the speed when traveling in a straight line, so a difference in rotation is generated in the output on the left and right. The output speed on the left is lower, so as a result, the machine travels forward and turns to the left.
D 155AX-5
STRUCTURE AND FUNCTION
BEVELGEARSHAFT,HSS
BRAKE
Reverse
i @ Transmission output speed @ Acceleration from HSS motor @ Left bevel gear shaft output speed (0 + 0)
@ Transmission output speed @ Deceleration from HSS motor @ Right bevel gear shaft output speed (@-@I
Reverse When the machine is traveling in reverse, bevel gear shaft (14) and hub (201, which is connected to it, rotate counterclockwise. If the joystick is operated to the TURN LEFT position when the machine is traveling in reverse, HSS motor (30) is rotated clockwise in the opposite direction from when traveling forward by the function of the HSS controller. The rotation passes through gear A (32), and gear B (34) on the left side of the machine rotates clockwise, while gear E (27) on the right side of the machine is rotated counterclockwise by gear C (33). In other words, the rotation of the HSS
D 155AX-5
I
130 I
SWD02720
EZGZB : Transmission power EZZZZI : HSS motor power : Combined power
motor is transmitted to sun gears (21) as rotation in opposite directions on the left and right by the transfer portion. This rotation acts on the left and right planetary gear mechanisms. The speed of carrier (17) on the right is accelerated from the speed when traveling in a straight line by the amount of the power from the HSS motor. On the other hand, the speed of carrier (17) on the left is decelerated from the speed when traveling in a straight line, so a difference in rotation is generated in the output on the left and right. The output speed on the left is lower, so as a result, the machine travels in reverse and turns to the left.
10-101
STRUCTURE
AND
FUNCTION
BEVEL GEAR SHAFT,
HSS BRAKE
Operation of brake 1. Brake released When the brake pedal is at the RELEASED position, the brake valve is also at the NEUTRAL position, so oil flows to back pressure port A of brake piston (5). When the oil pressure rises, the piston is pushed to the left in the direction of the arrow, compresses spring (41, and releases the pressure pushing disc (8) and plate (7) into tight contact. When this happens, the power transmitted from bevel gear shaft (14) through the HSS to brake inner drum (IO) is transmitted to output shaft (21, and is then transmitted to the final drive.
I
2.
SDD00092
Brake applied (brake pedal depressed) When the brake pedal is depressed, the brake valve is switched, and the oil at port A, which was applying back pressure to piston (51, is connected to the drain circuit. In this condition, piston (5) is pushed to the right in the direction of the arrow by the tension of spring (41, so disc (8) and plate (7) are brought into tight contact with the stopper of brake outer drum (9). The brake outer drum is joined to the HSS case and is locked in position. Therefore, the rotation of brake inner drum (IO) (in other words, output shaft (2)) is braked when the disc and plate are brought into tight contact. By adjusting the amount the brake pedal is depressed, it is possible to adjust the hydraulic pressure applied to piston (51, thereby adjusting the braking force.
10-102
D 155AX-5
BRAKE VALVE
STRUCTURE AND FUNCTION
BRAKE VALVE
14
12
13 A-A
SJD02721
1. 2. 3. 4. 5. 6. 7.
Main brake lever Parking brake lever Plug Body Spring Seat Brake valve
8. 9. IO. 11. 12. 13. 14.
Piston Spring (small) Spring (large) Shaft (main brake) Shaft (parking brake) Spring Plug
T2: Drain BR: To brake piston Tl: Drain
Outline . The brake valve is in the circuit between
l
the power train pump through the main relief valve and the brake piston inside the HSS It consists of the main brake valve, unit. parking brake valve, and solenoid valve. When the brake pedal is depressed, the pressurized oil flowing to the brake piston is shut off, so the brake piston pushes the disc and plate into tight contact because of the force of the spring, and the brake is applied. In the case of the HSS, the brake is used so the left only for braking the machine, and right brakes are actuated at the same time.
D 155AX-5
10-103
STRUCTURE
AND
FUNCTION
Operation 1. Brake released
d
F
(parking
BRAKE VALVE
brake OFF, brake pedal RELEASED)
j
C
SWD0.2722
z: Y:
x: w:
.
.
To main relief valve From power train pump Check valve Brake piston
When the brake pedal is released (not being depressed), each valve is pushed to the set position by the tension of the spring. Shaft (6) is pushed fully to the right in the direction of the arrow by spring (5). The pressurized oil from the power train pump passes through the main relief valve and enters port B. It then passes through ports E and D, flows to the back pressure port of the brake piston, and pushes the piston to the left in the direction of the ar-
10-104
.
row to compress the brake spring and release the brake. The oil pressure at this point is balanced at 2.7 MPa I28 kg/cm?, and this is possible to measure at centralized pressure detection port P. If the oil pressure at port E goes above the set pressure, the pressure of the oil entering port A through orifice a also rises. This pushes brake valve (3) to the left, throttles the passage between ports B and E, and controls the oil pressure.
D155AX-5
STRUCTURE
2.
AND
Brake actuated
BRAKE VALVE
FUNCTION
iparking
brake OFF, brake pedal depressed)
SVD02724 Z: Y:
To main relief valve From power train pump
X:
Check valve Brake piston
W:
.
l
When the brake pedal is depressed, shaft (6) is pushed to the left in the direction of the arrow, and compresses spring (5). The reaction force pushes brake valve (3) to the left in the direction of the arrow. Therefore, the passage ports B and E are closed, and the pressurized oil from the power train pump stops at port B. Seat (2) is also pushed to the left in the direction of the arrow, and the passage between ports E and G is opened. When this happens, the pressurized oil forming the back pressure of the brake piston is pushed back by the force of the brake spring and enters port E from Some of the return oil passes port D. through ports E and G and is drained from port F; the rest of the oil passes from port E through orifice a and enters port A. When the pressure at port E goes down, the pressure at port A also goes down, so force of the spring (I 1 pushes brake valve (3) back
D155AX-5
.
l
to the right in the direction of the arrow. The passage between ports E and G is closed and the passage between ports B and E is opened, so the pressurized oil at port B flows to port E. In this way, the oil pressure is maintained and the pressure beyond port E does not go down any further. If the brake pedal is depressed further, the above operation is repeated, and when the valve reaches the end of its stroke, the brake is completely applied. The oil pressure beyond port E is determined by the tension of spring (51, which changes the load according to the amount the brake pedal is depressed. Therefore, if the brake pedal is depressed a short distance the oil pressure beyond port E is set to a high pressure, and the brake is partially applied. If the brake pedal is depressed a large distance, the oil pressure is set to a low pressure and the brake is applied.
10-105
STRUCTURE AND FUNCTION
3.
BRAKE VALVE
Parking brake ON (brake pedal RELEASED, safety lever at LOCK)
H-
G
-D
9
a
SVDO2723
z: Y:
x: w:
To main relief valve From power train pump Check valve Brake piston
The solenoid valve is excited in the same way as in Item 1. In addition, shaft (6) is pushed fully to the right in the direction of the arrow by spring (5). If the safety lever is placed at the LOCK position, shaft (7) is pushed to the left in the direction of the arrow. The passage between ports E and D is closed, and the passage between ports D and C is opened. Therefore, the pressurized oil from the power train pump enters port E and stops. The pressurized oil flowing to the brake pis-
lo-106
ton port and forming the back pressure passes from port D through port C and is drained. Shaft (8) remains pushed to the left in the direction of the arrow, so the back pressure of the brake piston port continues to drop. The brake piston is pushed to the right in the direction of the arrow by the brake spring, so the brake is completely applied, and this condition is maintained. Even when the engine is started again, this condition is maintained.
D 155AX-5
STRUCTURE
AND
FUNCTION
FINAL DRIVE
FINAL DRIVE
16
Outline 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.
SDDOOlO2
l
D155AX-5
l
Floating seal (4) 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.
10-107
STRUCTURE
AND
15
1. 2. 3. 4. 5. 6. 7. 8.
FUNCTION
14
Sun gear (16 teeth) Carrier Ring gear (65 teeth) Floating seal Cover Cover Final drive case Bearing cage
lo-108
FINAL DRIVE
13
12
11
9. 10. 11. 12. 13. 14. 15.
SDD00103
No. 1 pinion (19 teeth) No. 1 gear (81 teeth) Sprocket hub Sprocket teeth Hub Planet pinion (24 teeth) Pinion shaft
D155AX-5
SDD00104
.
The power from the bevel gear and steering clutch is transmitted to No. 1 pinion (9). It then passes through No. 1 gear (IO), which is meshed with the No. 1 pinion, and is transmitted to sun gear (I) to rotate it. The rotation of sun gear (I) is transmitted to planet pinion (14), but ring gear (31, which is meshed with the planet pinion, is fixed to cover (51, so the planet pinion rotates on its own axis and moves around the sun gear along the ring gear.
D155AX-5
Then, the rotating force of sun gear (I 1forms the rotating force of carrier (21, which supports the planet pinion, and is transmitted to sprocket hub (II). The direction of rotation of carrier (2) is the same as that of sun gear (I). The rotating force transmitted to sprocket hub (11) is transmitted to sprocket teeth (12).
10-109
STRUCTURE
AND
TRACK
FUNCTION
FRAME
TRACK FRAME
SK000152
Outline on an XThe track rollers are mounted the actual bogie. This increases shaped ground contact area between the track shoes and the ground on rough surfaces, and helps increase the drawbar pull. The X-shaped bogies are equipped with rubber pads to absorb the shock from the
Track roller, bogie
l
Positioning of track roller flange
l
ground
10-l10
surface.
D: Double S: Single
D155AX-5
STRUCTURE AND FUNCTION
TRACK FRAME
A-A
sKmo153
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Equalizer bar Idler Track frame Carrier roller Sprocket Sprocket guard Bogie assembly Track roller Track roller guiding Pivot shaft
DI 55AX-5
guard
10-111
STRUCTURE
AND
RECOIL SPRING
FUNCTION
1
2
3
4
5
7
6
8
9
A-A
SKD00154
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1 I.
Yoke Nut Retainer Recoil spring Rod Spring cylinder Retainer Piston Grease chamber cy1inde.r Pin Lubricator (for pumping in and releasing
10-112
Outline . Recoil spring (4) is used to adjust the track tension by pumping in or releasing grease from lubricator (11) to move rod (5) forward or backward. The recoil spring also acts to dampen any sudden shock brought to bear on the idler.
grease)
D155AX-5
STRUCTURE
AND
TRACK ROLLER BOGIE
FUNCTION
TRACK ROLLER BOGIE
A-A
4 +A
/
SWD02762
I. 2. 3. 4. 5. 6. 7. 8. 9.
Rubber mount Track roller Inner bogie Outer bogie Cartridge pin Floating seal Bushing Plug Bogie mount cap
Dl ?&AX-5
Outline . One track roller is mounted to each of inner bogie (3) and outer bogie (4) to ensure that the track roller and track shoe are always in contact. . Rubber mount (I) is used to absorb the machine vibration caused by contact with the ground.
10-l 13
STRUCTURE
AND
MAIN
FUNCTION
FRAME
MAIN FRAME
A4
A-A
1. 2. 3. 4. 5.
B4
B-B
Engine mount Power train unit mount ROPS mount Power train underguard Engine underguard
10-114
D155AX-5
SUSPENSION
STRUCTURE AND FUNCTION
SUSPENSION
SKDOOl56
Outline l
lo-116
The front of the track frame rocks down using the rear pivot shafts (3) as a fulcrum. Equalizer bar (I) rocks using center as a fulcrum. The left and right track are connected by side pin (5).
up and and 14) pin (2) frames
D155AX-5
STRUCTURE
SUSPENSION
AND FUNCTION
A-A 6
5
B-B
SK1300157
1. 2. 3. 4. 5. 6. 7.
Equalizer bar Center pin Left pivot shaft Right pivot shaft Side pin Spherical bushing Greasing tube
D 155AX-5
10-117
STRUCTURE
AND
WORK EQUIPMENT
FUNCTION
WORK EQUIPMENT
HYDRAULIC
HYDRAULIC
PIPING DIAGRAM
PIPING DIAGRAM
SEMI U-DOZER
SWD02624
1. 2. 3. 4. 5.
Tilt cylinder R.H. blade lift cylinder PPC, HSS charge valve Accumulator PPC, HSS charge filter
lo-118
6. Main control valve 7. 8. 9. 10. 11. 12.
Hydraulic filter Hydraulic tank Work equipment pump (SAR(4)112) PPC, HSS charge pump L.H. blade lift cylinder Oil cooler
D 155AX-5
STRUCTURE
AND
FUNCTION
WORK EQUIPMENT
HYDRAULIC
PIPING
DIAGRAM
MULTI-SHANK RIPPER
SED00162
1. 2. 3. 4.
Main control valve Divider block Ripper tilt cylinder Ripper lift cylinder
D 155AX-5
10-119
STRUCTURE
AND
WORK
FUNCTION
EQUIPMENT
HYDRAULIC
PIPING
DIAGRAM
GIANT *
The diagram shows a machine with a pin puller cylinder
equipped
9’
1. 2. 3. 4. 5. 6. 7. 8. 9.
Main control valve Divider block Ripper tilt cylinder Ripper lift cylinder Pin puller cylinder Ripper lift cylinder Ripper tilt cylinder Pin puller solenoid Brake valve
a. To steering
10-120
(right) (right) (left) (left) valve
case
D155AX-5
STRUCTURE AND FUNCTION
PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM BLADE, RIPPER CONTROL
SVD02626
1. 2. 3. 4. 5.
PPC, HSS charge valve Accumulator Blade control PPC valve Main control valve PPC, HSS charge filter
D 155AX-5
6. 7. 8. 9.
Ripper control PPC valve PPC, HSS charge pump (104) Work equipment pump (SAR(4)112) PPC lock valve
10-121
STRUCTURE
AND
FUNCTION
WORK
WORK EQUIPMENT *
EQUIPMENT
CONTROL
CONTROL
The diagram shows a machine equipped with pitch dozer and pin puller cylinder.
SVDO2627
Lever positions 0: Blade HOLD 0: Blade LOWER 0: Blade FLOAT 0: Blade RAISE 0: Blade LEFT TILT/PITCH 0: Blade RIGHT TILT/PITCH 0: Ripper HOLD 8: Ripper RAISE @: Ripper LOWER @: Ripper DIGGING ANGLE 0: Ripper DIGGING ANGLE 0: FREE 0: LOCK
1o-1 22
1. Work equipment safety lever 2. Blade control lever 3. Ripper control lever 4. Pin puller switch 5. PPC lock valve
DECREASE INCREASE
Outline . The work equipment control employs a PPC method which uses a PPC valve to move each control valve spool. . Work equipment safety lever (I) is interconnected with PPC lock valve (61, and at the LOCK position, the oil in the PPC circuit is stopped.
D155AX-5
WORK EQUIPMENT HYDRAULIC SYSTEM AND HSS SYSTEM DIAGRAM
STRUCTURE AND FUNCTION
WORK EQUIPMENT DIAGRAM I5
HYDRAULIC
SYSTEM
AND HSS SYSTEM
-
SVDO2725
1. Hydraulic tank 2. Strainer 3. HSS pump assembly 3A. Servo valve 38. Servo piston 3C. Charge safety valve Setting pressure: 3.7 MPa f38 kg/cm*} 3D. HSS pump 3E. Suction-safety valve Set pressure: 41.2 MPa 1420 kg/cm*)
lo-124
4.
5. 6. 7. 8. 9. 10.
HSS motor assembly 4A. Cooling shuttle valve Set pressure: 1.2 MPa {I2 kg/cm? 4B. Flushing shuttle valve 4C. HSS motor Cooler bypass valve Oil cooler Scavenging pump PPC, HSS charge pump PPC, HSS charge filter PPC, HSS charge valve
Filter bypass valve Cracking differential pressure: 0.63 MPa i6.4 kg/cm*} IOB. PPC, HSS charge valve Set pressure: 4.12 MPa I42 kg/cm? IOC. Accumulator check valve Cracking pressure: 0.05 MPa lo.52 kg/cm*} 11. Accumulator 12. HSS charge pressure sensor IOA.
Dl SAX-5
STRUCTURE AND FUNCTION
WORK EQUIPMENT HYDRAULIC SYSTEM AND HSS SYSTEM DIAGRAM
SVD02726
13. Hydraulic oil temperature sensor 14. PPC lock valve 15. Blade control PPC valve 15A. For blade lift 15B. For blade tilt 16. Ripper control PPC valve 16A. For ripper tilt 16B. For ripper lift 17. Work equipment pump assembly 18. Main control valve 18A. Variable unload valve 18B. Back pressure valve
D155AX-5
18C. Back pressure check valve 18D. Main relief valve 18E. Preset check valve 18F. Load check valve 18G. Blade tilt valve 18H. LS check valve 18J. Blade lift valve 18K. Suction valve 18L. Ripper lift valve 18M. Ripper tilt valve 18N. LS bypass valve 19. Assembly block
20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
19A. Charge relief valve Set pressure: 1.8 MPa I18 kg/cm? Quick drop valve R.H. blade lift cylinder L.H. blade lift cylinder Blade tilt cylinder R.H. ripper tilt cylinder R.H. ripper lift cylinder L.H. ripper lift cylinder L.H. ripper lift cylinder Hydraulic filter Breather
10-125
WORK EQUIPMENT HYDRAULIC SYSTEM AND HSS SYSTEM DIAGRAM
STRUCTURE AND FUNCTION
.
Machine equipped with pitch dozer I5 15AR
Rl5B
I6
16B
IO
SWD02805
1. Hydraulic tank 2. Strainer 3. HSS pump assembly 3A. Servo valve 3B. Servo piston 3C. Charge safety valve Set pressure: 3.7 MPa {38 kg/cm*} 3D. HSS pump 3E. Suction safety valve Set pressure: 41.2 MPa (420 kg/cm21
lo-126
4. HSS motor assembly 4A. Cooling shuttle valve Set pressure: 1.2 MPa {I2 kg/cm*1 4B. Flushing shuttle valve 4C. HSS motor 5. Cooler bypass valve 6. Oil cooler 7. Scavenging pump 8. PPC, HSS charge pump 9. PPC, HSS charge filter 10. PPC, HSS charge valve
lOA.Filter bypass valve Cracking differential pressure: 0.63 MPa (6.4 kg/cm*} IOB. PPC, HSS charge valve Set pressure: 4.12 MPa (42 kg/cm21 lOC.Accumulator check valve Cracking pressure: 0.05 MPa IO.52 kg/cm*) 11. Accumulator 12. HSS charge pressure sensor 13. Hydraulic oil temperature sensor
D155AX-5
WORK EQUIPMENT HYDRAULIC SYSTEM AND HSS SYSTEM DIAGRAM
STRUCTURE AND FUNCTION
ZZi @ r---
61
3
j
3
__
SWD02806
14. PPC lock valve 15. Blade control PPC valve 15A. For blade lift 15B. For blade tilt 16. Ripper control PPC valve 16A. For ripper tilt 16B. For ripper lift 17. Work equipment pump assembly 18. Main control valve 18A. Variable unload valve 18B. Back pressure valve 18C. Back pressure check valve
D 155AX-5
18D. Main relief valve 18E. Preset check valve 18F. Load check valve 18G. Blade tilt valve 18H. LS check valve 18J. Blade lift valve 18K. Suction valve 18L. Ripper lift valve 18M.Ripper tilt valve 18N. LS bypass valve 19. Assembly block 19A. Charge relief valve Set pressure: 1.8 MPa {I8 kg/cm21
20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
Quick drop valve R.H. blade lift cylinder L.H. blade lift cylinder Blade tilt cylinder R.H. ripper tilt cylinder R.H. ripper lift cylinder L.H. ripper lift cylinder L.H. ripper tilt cylinder Hydraulic filter Breather Pitch solenoid valve Pitch cylinder
1O-l 27
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM
STRUCTURE AND FUNCTION
WORK EQUIPMENT DIAGRAM *
For details 2,.
lo-128
HYDRAULIC
of this page, see Section - ^ r: z: :f -I :I :’
CIRCUIT AND HSS CIRCUIT
90. -2 1: :” :_
r: :: _: :f
f
D155AX-5
STRUCTURE
. *
AND
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM
FUNCTION
Machine equipped with pitch dozer For details of this page, see Section
90.
_________~
r” 0
-
I
I
____._-1
L
SWD02'312
D155AX-5
1O-l 29
HYDRAULIC TANK AND FILTER
STRUCTURE AND FUNCTION
HYDRAULIC
TANK AND FILTER
“=====*
4
T====-=
SWD02630
10-130
D155AX-5
HYDRAULIC TANK AND FILTER
STRUCTURE AND FUNCTION
11
A-A
E-E
D-D
Tank capacity 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Sight gauge Hydraulic filter Oil filler cap Hydraulic tank Filter case Cover Air bleeding plug Element Suction valve Spring Drain plug for removing Breather cap Pressure valve Strainer
A. B.
From main control To hydraulic tank
Hydraulic tank
Breather cap
Level inside tank
Hydraulic filter
D155AX-5
85
Center
(.U
82
Low
NJ
79
(kPa Ik9/cm2N
103.0f19.6 (1.05+-0.2)
Mesh size
(,u m)
3018
Filtering area
(cm?
10,026
(Urnin) I
255
(fi m) I
105
(cm21 1
2,300
Filtering oil flow Mesh size
valve
b?,
Cracking (kPa {kg/cm211 {d.!&7,1$7] pressure Vacuum valve actuating o-o.49 pressure (kPa {kg/cr+I) IO-0.005) Cracking pressure
dirt
Hi
Strainer
1Filtering
area
10-l31
STRUCTURE
AND
ACCUMULATOR
FUNCTION
ACCUMULATOR FOR PPC VALVE
1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
Specifications: Type of gas: Nitrogen Gas volume: 300 cc Max. actuation pressure: 3.1 MPa 132 kg/cm*) Min. actuation pressure: 1.2 MPa {I2 kg/cm*)
SYD00309
Function The accumulator is installed between the PPC charge pump and the PPC 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 main control valve to actuate it and enable the work equipment to move down under its own weight.
l
Operation After the engine is stopped, when the PPC valve is at neutral, chamber A inside the bladder is compressed by the oil pressure in chamber B. . When the PPC valve is operated, the oil pressure in chamber B goes below 2.9 MPa I30 kg/cm*}, 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.
A
l
A
B’
B SBD01365
lo-132
D 155AX-5
STRUCTURE AND FUNCTION
PPC LOCK VALVE
PPC LOCK VALVE
1. 2. 3. 4. 5.
Lever End cap Ball Seat Body
SYD00312
Outline . The PPC lock valve
is installed in the PPC circuit between the PPC, HSS charge valve and PPC valve. If the work equipment safety lever is placed at the LOCK position, the PPC lock valve is actuated together with the work equipment safety lever. This stops the oil in the PPC circuit and makes it impossible to operate the work equipment.
D155AX-5
1o-133
STRUCTURE AND FUNCTION
PPC VALVE
PPC VALVE FOR BLADE LIFT, BLADE TILT
SKD01435
P. T. P4. P3. PI. P2.
From PPC, HSS charge valve port P (through PPC lock valve) To hydraulic tank To blade lift valve (LOWER) port PA2 To blade lift valve (RAISE) port PB2 To blade tilt valve (LEFT TILT) port PA1 To blade tilt valve (RIGHT TILT) port PBI
10-134
D 155AX-5
PPC VALVE
STRUCTURE AND FUNCTION
SKD00535
1. 2. 3.
4. 5.
Spool Metering spring Centering spring Pistion Disc
D 155AX-5
6. 7. 8. 9. 10.
Nut (for lever joint) Joint Plate Retainer Body
10-135
STRUCTURE
PPC VALVE
AND FUNCTION
Operation 1) (i)
At neutral PPC value for blade lift Ports PA2 and PB2 of the blade lift control valve, and ports P3 and P4 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I).
LIFT CONTROL VALVE SAD01547
(ii) PPC valve for blade tilt Ports PA1 and PBI of the blade tilt control valve, and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I).
TILT CONTROL VALVE SAD01548
1O-l 36
D155AX-5
STRUCTURE
2)
AND FUNCTION
PPC VALVE
During fine control (neutral- fine control) When piston (4) starts to be pushed by disc (51, retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the charging pump passes through fine control hole f and goes from port P4 to port PA2. When the pressure at port P4 becomes higher, spool (I) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P4. When this happens, spool (I) moves up or down so that the force of metering spring (2) is balanced with pressure at port P4. The relationship in the position of the spool (I) and body (IO) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (I). Therefore, metering spring (2) is compressed proportionally.to the amount of movement of the control level, so the pressure at port P4 also rises in proportion to the travel in the control lever. In this way the control valve spool moves to a position where the pressure in chamber PA2 (the same as the pressure at port P4) and the force of the control valve spool return spring are balanced.
D155AX-5
10-137
STRUCTURE
31
AND
PPC VALUE
FUNCTION
During fine control (when control lever is returned) When disc (5) starts to be returned, spool (I) is pushed up to the force of centering spring (3) and the pressure at port P4. When this happens, fine control hole f is connected to drain chamber D, and the pressure oil at port P4 is released. If the pressure at port P4 drops too far, spool (I) is pushed down by metering spring (21, and fine control hole f is shut off from drain chamber D. At almost the same time it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P4 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P3 and enters chamber PB2 to fill the chamber with oil. SAD01550
41
At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (I), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the charging pump passes through fine control hole f and flows to chamber PA2 from port P4, and pushes the control valve spool. The oil returning from chamber PB2 from port P3 through fine control hole f’ and flows to drain chamber D.
LIFT CONTROL
_
lo-138
SAD01551
D 155AX-5
STRUCTURE
5)
6)
AND FUNCTION
Blade operated to FLOAT When piston (4) at port P4 (LOWER side) is pushed by disc (5) and moves down, protrusion a of the piston contacts ball (11) during the downward stroke. (The detent starts to be actuated.) If piston (4) is pushed further, ball (11) pushes up collar (12), which is being held by detent spring (131, and moves to the outside, so the ball passes over protrusion a of the piston. At this point, piston (4’) at the opposite side is pushed up by the spring (14). As a result, the oil inside chamber F flows through b and c and enters chamber E, and piston (4’) follows disc (5). Passage d is interconnected with port P4, so it is under more or less the same pressure as port P4. Chamber E is normally interconnected with drain chamber D, but when ball (11) passes over protrusion a of the piston, passage d and chamber E (which were shut off) are interconnected and pressurized oil flows. At the same time, the control valve also moves to the FLOAT position, so the blade circuit is set to the FLOAT condition. The pressurized oil inside chamber E pushes up piston (4’1, so even of the lever is released, it is held at the FLOAT position.
PPC VALVE
SAD01552
Blade released from FLOAT When disc (5) is returned from the FLOAT position, it is pushed down by a force greater than the pressure of the oil in chamber E. For this reason, chamber E is shut off from passage d and is connected to the drain chamber. Therefore, the oil pressure inside chamber E is lost, and the FLOAT, position is released.
D155AX-5
1o-1 39
STRUCTURE AND FUNCTION
PPC VALUE
FOR RIPPER
-C
-
-_TT I
P. T. PI. P2.
P3. P4.
.P4
I
From PPC, HSS charge valve pot-t P (through PPC lock valve) To hydraulic tank ANGLE To ripper tilt valve (DIGGING CREASE) port PA4 ANGLE To ripper tilt valve (DIGGING CREASE) port PB4 To ripper lift valve (LOWE!?) port PA3 To ripper lift valve (RAISE) port PB3
10-140
A‘
SKD01448
IN-
DE-
D155AX-5
STRUCTURE
AND FUNCTION
PPC VALVE
A-A
B-B
D-D
E-E SYD00314
1. Spool
2. Metering 3. 4. 5. 6.
spring Centering spring Piston Disc Nut (for lever joint)
D 155AX-5
7. 8. 9. 10. 11.
Joint Plate Retainer Body Filter
10-141
STRUCTURE
AND
PPC VALVE
FUNCTION
Operation 1) At neutral Ports PA4, PB4, PA3 and PB3 of the ripper control valve and ports PI, P2, P3, and P4 of the PPC valve are connected to drain chamber D through fine control hole f of spool (I).
2)
During fine control (neutral + fine control) When piston (4) starts to be pushed by disc (51, retainer (9) is pushed; spool (I) is also pushed by metering spring (21, and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP. so pilot pressure oil from the charging pump passes through fine control hole f and goes from port PI to Port PA4. When the pressure at port PI becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port PI. When this happens, spool (I) moves up or down so that the force of metering spring (2) is balanced with the pressure at port PI. The relationship in the position of the spool (I) and body (IO) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (I). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port Pl also rises in proportion to the travel in the control lever. In this way the control valve spool moves to a position where the pressure in chamber PA4 (the same as the pressure at port PI) and the force of the control valve spool return spring are balanced.
10-142
PA3 (PA41
PB3 (PB4) SWDO2631
SWD02632
D155AX-5
STRUCTURE
AND FUNCTION
3)
During fine control (when control lever is returned) When disc (5) starts to be returned, spool (I) is pushed up by the force of centering spring (3) and the pressure at port PI. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port PI is released. If the pressure at port PI drops too far, spool (I) is pushed down by metering spring (21, and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port PI recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P2 and enters chamber PB4 to fill the chamber with oil.
41
At full stroke When disc (5) pushes down piston (4L and retainer (9) pushes down spool (I 1, fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the charging pump passes through fine control hole f and flows to chamber PA4 from port PI, and pushes the control valve spool. The oil returning from chamber PB4 passes from port P2 through fine control hole f and flows to drain chamber D.
PPC VALVE
SWD02634
D155AX-5
10-143
PISTON
STRUCTURE AND FUNCTION
VALVE
PISTON VALVE FOR BLADE
LIFT CYLINDER
Outline 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 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. l
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. 4 2.
Piston valve OPEN Just before piston rod (I) 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 (31, escapes from piston valve seats (4) and (5L and the pressure inside the cylinder stops rising.
10-144
1
3
SAD00206
6
2
Contact
‘4
Dl SAX-5
PIN PULLER SWITCH
STRUCTURE AND FUNCTION
PIN PULLER SWITCH
Structure
1. 2. 3. 4.
of
circuit
SED01393
Connector Wire Switch Knob
Function l
The pin puller solenoid valve is controlled by turning the pin puller switch ON/OFF. This changes the oil circuit to the pin puller cylinder and sets the shank mounting pin to the PUSH IN or PULL OUT position.
D 155AX-5
10-145
STRUCTURE
AND
FUNCTION
Operation 1. Pin puller switch at PUSH IN position When the pin puller switch is set to the PUSH IN position, no electric current flows to solenoid (9) and it is deenergized. Then, ports P and A and ports B and P of spool (5) open, and the oil from the power train pump flows from port P to port A, and enters the bottom end of pin puller cylinder
PIN PULLER SOLENOID
From
train
dower
Pump
VALVE
Switch at PUSH IN position
(IO). When the oil enters the bottom end of the cylinder and the pressure in the circuit starts to rise, the cylinder extends and pushes shank mounting pin (11) into shank (12).
SLD01394
2.
Pin puller switch at PULL OUT position When the pin puller switch is set to the PULL OUT position, electricity flows to solenoid (9) and it is excited. Then, the solenoid pushes out push pin (8) and spool (5) moves to the left in the arrow direction. At this point, ports P and A and ports B and T close, and ports P and B and ports A and T open, so the oil from the power train pump flows from port P to port B and enters the head end of pin puller cylinder (10). When the oil enters the cylinder head end and the pressure in the circuit rises, the cylinder retracts and pulls shank mounting pin (II) out of shank (12).
From
power
train
Pump
I
:: I,
/I
::
4
IO
/
Switch at PULL OUT posit
ion
A0
12
uu
I
SLD01395
D155AX-5
10-147
STRUCTURE AND FUNCTION
TILT/PITCH
TILT/PITCH SELECTOR SWITCH
SELECTOR SWITCH
SDDO0241
1. 2. 3. 4.
Switch Knob Wire Connector
Function l
The tilt/pitch selector switch is installed to the blade control lever. When the tilt/pitch selector switch is turned ON/OFF, it controls the pitch solenoid valve and opens or closes the flow of oil to the pitch cylinder.
lo-148
D155AX-5
STRUCTURE AND FUNCTION
PITCH SOLENOID
PITCH SOLENOID VALVE
VALVE
From charge pump _)--_-_
,--,
;--t:____, L -ml-q&/: PT
Structure of circuit
SEDWJ242
Outline l
The pitch solenoid valve is installed between the pitch cylinder and tilt cylinder. It acts to open or close the oil pressure circuit to the pitch cylinder according to the signal from the tilt/pitch selector switch.
D 155AX-5
1. Main spool assembly 2. Pilot solenoid valve assembly 3. Connector A. 6. P. T. X. Y.
To pitch cylinder bottom To pitch cylinder head From main control valve To blade tilt cylinder bottom From charge pump To hydraulic tank
10-149
STRUCTURE
AND
Operation selector switch OFF Tilt/pitch . When tilt/pitch selector switch (I) is not being operated (OFF), no electricity flows to In solenoid valve (2), so it is deenergized. this condition, main spool (3) opens ports P and T, and closes ports A and B. Therefore, no oil flows to pitch cylinder (4). Only blade tilt cylinder (5) moves, and the blade is tilted.
selector switch ON Tilt/pitch When tilt/pitch selector switch is operated (ON), electricity flows to solenoid valve (21, so it is excited. When this happens, main spool (3) opens ports P and A, and ports T circuit is the hydraulic and B. Therefore, connected to the head end of pitch cylinder (4) and the bottom end of blade tilt cylinder (5). As a result, when blade tilt cylinder (5) (4) is also repitch cylinder is retracted, tracted, and the blade is pitched. l
PITCH SOLENOID
FUNCTION
From main control valve
VALVE
-
To main control valve
From main _ control valve
SKD00244
10-150
D155AX-5
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
MAIN
CONTROL VALVE
PA4
P04
PA3
PB3
PA2
P02
PA1
PBl
SAD01 553
Al. A2. A3. A4. Bl. B2. B3. B4. PAI. PA2. PA3.
To blade tilt cylinder head To blade lift cylinder head To ripper lift cylinder head To ripper tilt cylinder head To blade tilt cylinder bottom To blade lift cylinder bottom To ripper lift cylinder bottom To ripper tilt cylinder bottom From blade PPC valve port PI From blade PPC valve port P4 From ripper PPC valve port P3
D155AX-5
PA4. PBI. PB2. PB3. PB4. P. T. a. b. c.
From ripper PPC valve port P2 From blade PPC valve port P2 From blade PPC valve port P3 From ripper PPC valve port P4 From ripper PPC valve port PI Pump port Drain port Pump pressure detection plug LS pressure detection plug PPC charge valve pressure port
10-151
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
-8
A-A
I5 14 13
D-D
c-c
E-E
F-F
SWD02635
10-152
D 155AX-5
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
G-G
K-K
SW02636
J-J
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Valve block Ripper tilt spool Ripper lift spool Blade lift spool Blade tilt spool Valve body Load check valve Orifice Unload spring Unload spool
D155AX-5
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Cancel piston Cancel spring LS check valve Main relief valve Back pressure check valve Back pressure valve Check valve (built-in spool) Suction valve Preset check valve LS bypass valve
10-153
STRUCTURE
AND
FUNCTION
Function When the work equipment control levers are at HOLD, the oil discharged from the pump is all unloaded, and the pressure loss of the valve is kept below 0.5 MPa (5 kg/cm*}. In this way, the pressure loss when the lever is at HOLD is small, so the heat loss is also small. Proportional control is carried out by the unload valve, which controls the amount of oil sent to the cylinder to an amount that matches the opening of the spool. The unload valve is controlled by the difference in pressure on both sides of the spool, so there is a little change in the oil flow caused by the load pressure. It also provides the function of pressure compensation.
10-154
MAIN
CONTROL
VALVE
SAW0184
Operation 1. At HOLD (unload valve at low setting) I) When the work equipment spool is at HOLD, LS circuit pressure LS = seal drain pressure TS (hydraulic leak pressure from valve) i 0 MPa (0 kg/cm2), so unload spool (I) is balanced by the difference in load between load F2 of spring (3) and load Fl of spring (2) that is set to oppose pump pressure P which is sent to chamber Al. In other words, A0 x P = Fl - F2 (AO: Area receiving pump pressure in chamber Al). 2) By making Fl - F2 smaller, it is possible to make pump pressure P smaller. When this is done, the area of the opening between ports A and B is determined, so the loss of pressure from A to B (P - T) can be kept more or less constant regardless of back pressure TP between ports A and B.
D155AX-5
STRUCTURE
2.
AND
MAIN
FUNCTION
Control of oil flow (unload Blade lift, tilt valve II Ripper lift, tilt valve I (1) Meter-in oil flow control t The diagram shows the blade tilt valve.
CONTROL
VALVE
valve at high setting)
Blade tilt L. H. tilt
.6
AI
. .
APLS = Differential APLS’ = Differential (APLS ‘: APLS’)
lo-156
pressure between pressure between
ports A and J = 1.8 - 2.9 MPa I18 - 30 kg/cm? ports A and F
D155AX-5
STRUCTURE
.
.
AND FUNCTION
Because of the action of the unload valve, an amount of oil that matches the opening of the spool flows to the cylinder. (Proportional control) The unload valve is controlled by the difference in pressure on both sides of the spool, so the change in the amount of the oil flow caused by the load pressure is small (pressure compensation).
MAIN CONTROL VALVE
4)
When the oil in chamber F flows and the pressure rises, the pressures in chamber J and chamber L both rise at the same time. The pressure in chamber L pushes against the spring (5) and moves piston (4) to the left. Piston (4) is separated from unload spool (31, so the load of spring (5) does not act on unload spool (3).
5)
The unload valve is balanced by differential pressure APLS, which is the difference in pressure between the pressures of chamber Al and chamber J, in other words, meter-in pressure loss (ports A - J) and the load of spring (6). At this balanced position, the unload oil flow of the unload valve is determined. The portion of the oil discharged from the pump which is not unloaded is supplied to the tilt cylinder. The meter-in pressure loss is determined by the area of opening of spool (I), so an amount of oil that matches the area of opening of spool (1) flows to the tilt cylinder, regardless of the load pressure.
1) If the PPC valve output pressure PA1 is sent to the spring (2) chamber of spool (I), spool (1) pushes against spring (2) and moves to the right to a position where it balances with the load of the spring.
2)
If spool (I) is actuated, the passage between ports E and F opens, so part of the oil flow discharged from the pump flows through ports A, 6, C, D, E, and F, and then into the cylinder. But in this condition, almost all the oil discharged from the pump is unloaded.
3)
At the same time, the pressure in chamber F flows into the passage inside the spool from LS throttle dl, then passes through ports G, H, and I, and is sent to spring chamber J of the unload valve. In addition, the pressure in chamber A (pump pressure) is sent to chamber Al of the unload valve, while the pressure in chamber J passes through LS passage K and is sent to chamber L.
APLS
~4 Unloadoilflmv <
01
Q2 z’$%,r
?
I
z Unload
oil flow
(a$scharge SYD00321
*
D155AX-5
Throttle d2 is specially assembled valve to adjust the oil flow.
to the tilt
10-157
STRUCTURE
(2) Meter-out
AND
MAIN
FUNCTION
control using downward (blade control lever at LOWER)
movement
of blade
CONTROL
VALVE
under own weight
Blade lift
,. 1 ‘,
,
as
*,
li_ I
,
‘, , : .
,
,
*
l,,
I
5 , , . , I
2,
: *,,,
.:s : ‘2
SAD00186
lo-158
D155AX-5
STRUCTURE AND FUNCTION
.
If the blade moves down under its own weight, the oil flow of return oil from cylinder is controlled by the area of the opening of the man spool (1).
.
Because of back-pressure valve (3), a back pressure that matches the oil flow is formed in drain circuit Tl of the control valve, so oil is supplied to the cylinder bottom from suction valve (2) to prevent a vacuum from forming in the circuit.
MAIN CONTROL VALVE
I) When the spool port is opened by PPC output pressure PA2, because of the downward movement of the blade, the oil at the cylinder head passes through ports A, B, C, and D, and is drained to the tank. The flow of return oil from the lift cylinder is throttled by the area of the opening between ports A and B, so the lowering speed is controlled.
2) When the blade moves down under its own weight, there is no LS pressure, so the back pressure is formed in chamber C in accordance with the characteristics of back-pressure valve (3). The oil flowing from the cylinder head flows from the drain circuit, passes through suction valve (21, and is supplied to the bottom end of the cylinder. The oil discharged from the pump passes through pots Al, Bl, Cl, Dl, and El, and is supplied to the cylinder bottom.
*
For details of the vacuum prevention function, see 5. UNLOAD VALVE PRESET SYSTEM.
D 155/U-5
10-159
STRUCTURE
AND
FUNCTION
control using downward (3) Meter-out (blade control lever at FLOAT)
MAIN
movement
of blade
under
CONTROL
VALVE
own weight
Blade lift WI Float \
I
,** II
I
‘, , , I
, I
+
;:
‘: ,,,’ ,s,,;,:
sADxm37
lo-160
D155AX-5
STRUCTURE AND FUNCTION
.
.
MAIN CONTROL VALVE
When the lift valve is at FLOAT, the cylinder port and drain port are connected to put the circuit in a no-load condition. When the lift valve is in the FLOAT condition, the pump circuit and cylinder ports A2 and B2 are separated so that the control valve can carry out other operations.
1) With the control
lever at the FLOAT position, when pressure PA2 reaches 3.4 MPa (35 kg/cm*}, lift spool (I) is at the maximum stroke FLOAT position.
2)
In this condition, ports A2 and B2 and LS circuit 0 are all connected to the drain circuit, so there is no load on the lift cylinder.
3)
If the cylinder is driven by the weight of the blade, the oil passes from port A2 through ports A, B, F, and G, and the rest of the oil passes through ports C and D, and is drained. When this happens, the oil flow is throttled by the area of opening between ports A and B of the spool, and the cylinder speed is controlled.
4)
Pump circuit chamber E and ports A2 and B2 are separated, and the pump pressure is formed, so it is possible to carry out compound operations with the other control valves.
D 155/U-5
lo-161
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
3. *
At relief The diagram shows the tilt cylinder immediately after it reaches the end of its stroke. Blade tilt L. H. tilt F)
2;
5: :;, I
,
,
‘, I
:
,
: ;s:= *,
‘/,
.,p:>,:;:;
SAD00188
lo-162
D155AX-5
STRUCTURE
(I)
AND
FUNCTION
MAIN
CONTROL
VALVE
If spool (I) moves to the right because of PPC output pressure PAI, the oil discharged from the pump flows through ports A, B, C, D, E, and F, and flows to the bottom end of the tilt cylinder. When this happens, the pressure in chamber F is sent through LS sensing hole G through ports H, I, J, K, L, M, and N, and goes to ports M and N of unload spool (2).
(2) If the cylinder reaches the end of its stroke and it stops, the condition becomes P k PI % PLS, and unload spool (2) is pushed completely to the left by the load of spring (3), so the unload oil flow becomes 0. (3) In this condition, all the oil discharged by the pump tries to flow to the cylinder, but the cylinder piston is stopped, so the pressure in the pump circuit rises. (4) If the pump pressure reaches the cracking pressure, relief valve (4) is actuated, so the maximum pressure in the pump circuit is set. (5) Throttle Q of relief valve (4) is used to keep the peak pressure to the minimum.
D 155/,X-5
lo-163
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
4. *
Compound operations The diagram
shows the lift valve + tilt valve. Blade tilt
Blade lift
L. H. tilt
0 P2
0 Pl
SAD00189
lo-164
D155AX-5
STRUCTURE
.
AND
FUNCTION
MAIN
CONTROL
VALVE
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.
(1) The tilt valve and lift valve spools are actuated by PPC output pressure PAI, PB2 and each spool is balanced at a position that matches its pilot pressure. (2) When pressure PI I pressure P2 Lift valve load pressure P2 is sent to the unload valve M, N chamber through LS passage. I) When unload valve does not reach fully closed position When the discharge 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 unload valve is at fully closed position (there is no unload oil flow) When the discharge 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 P - PI differential pressure and P - P2 differential pressure. In other words, more oil flows to PI where the load is small.
*
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.
(3) When pressure PI = pressure P2 P - PI = P - P2, so an oil flow proportional to the size of the spool opening is distributed to each spool.
D 155AX-5
lo-165
STRUCTURE
AND
5.
Unload
(I)
Lift valve
MAIN
FUNCTION
valve preset
CONTROL
VALVE
system
Blade
lift
SAD00190
lo-166
D 155AX-5
STRUCTURE AND FUNCTION
l
The response
is improved
MAIN CONTROL VALVE
at blade RAISE.
.
At blade LOWER, all the oil discharged from the pump is supplied to the bottom end of the lift cylinder to prevent any vacuum from forming at the cylinder bottom.
1)
When spool (I) is switched by PPC output pressure PB2, basic pressure PI of the PPC valve goes through preset check valve (3) into the LS passage through ports A, B, C, D, E, and F. (Preset pressure: Min. 3.4 MPa (35 kg/cm21)
2)
Immediately after the spool is switched, pump pressure P is approx. 0.5 - 1.0 MPa (5 - 10 kg/cm*), so unload spool (2) is pushed to the left. The opening between ports G and L is closed, and the oil discharged from the pump all flows through ports G, H, I, J, and K and is supplied to the lift cylinder, so the response is improved.
3)
When the lift cylinder pressure rises and goes above the preset pressure, preset check valve (3) closes, so unload spool (2) returns to the original APLS control.
4)
In cases as with blade LOWER where the flow of oil from the pump cannot keep up with the blade lowering speed, if the load pressure is not reached, unload spool (2) is kept in the condition in Item 2) to make it possible to present a vacuum from forming in the cylinder.
D 155AX-5
lo-167
STRUCTURE
AND
FUNCTION
MAIN
CONTROL
VALVE
(2) Tilt valve Blade tilt L. H. tilt
,’
I,
,
2
I
I,
iiIil3 ,‘,‘,
,
*‘s
‘, :; I
:
I
‘, :; ’
;;;:,
,‘,‘,
;
x:: I,
,p;,2
-B
SAD00191
10-168
D155AX-5
STRUCTURE
l
I)
MAIN
AND FUNCTION
The response
is improved
CONTROL
VALVE
at blade TILT.
When spool (I) is switched by PPC output pressure PAI, basic pressure PI of the PPC valve goes through preset check valve (3) into the LS passage through ports A, B, C, D, E, and F. (Preset pressure: Min. 3.4 MPa 135 kg/cm?)
2)
Immediately after the spool is switched, pump pressure P is approx. 0.5 - 1.0 MPa (5 - 10 kg/cm*), so unload spool (2) is pushed to the left. The opening between ports G and L is closed, and the oil discharged from the pump all flows through ports G, H, I, J, and K and is supplied to the tilt cylinder, so the response is improved.
3)
When the tilt cylinder pressure rises and goes above the preset pressure, preset check valve (3) closes, so unload spool (2) returns to the original APLS control.
D155AX-5
10-169
MAIN CONTROL VALVE
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT BLADE At blade RAISE
Blade
lift
r
Ir
J
a
I
-
TS
SWD02937
10470
D155AX-5
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
OPERATION l
l
l
::::::::::::::::
When blade control lever (I) is operated to the RAISE position, the spool of PPC valve (21, which is directly connected to the lever, is moved. When this happens, the pilot pressure entering PPC valve (2) from PPC pump (3) is sent to port PB2 of blade lift spool (4). This left, and PPC tank
pilot pressure pushes spool (4) to the and connects ports A and B and ports C D. The oil at port PA2 passes through valve (2) and is drained to hydraulic (5).
When this happens, the pressurized oil from pump (6) enters port P, passes hydraulic through unload valve (7) and ports A and B, and goes to the head end of blade lift cylinders (8) and (9) to raise blade (IO). At the same time, the oil at the cylinder bottom passes through ports C, D, and T, and is drained to hydraulic tank (5).
:/1/,1/,,/,,,,,,,
~:::::::::::::::: 111,,,,,,,,,,,,,
SVD02638
D155AX-5
10-171
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
At blade LEFT TILT
BLADE TILT
!\ J
/
i
J 6 7
SVDO2639
lo-172
D155AX-5
STRUCTURE
AND
FUNCTION
MAIN
CONTROL
VALVE
OPERATION When
a
:: ,, ,. ::
::
SVDO2640
D155AX-5
10-173
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
RIPPER At ripper RAISE
RIPPER LIFT
II
I
c’
SVD02641
10-174
Dl SAX-5
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
OPERATION l
l
l
When ripper control lever (1) is operated to the RAISE position, the spool of PPC valve (21, which is directly connected to the lever, is moved. When this happens, the pilot pressure entering PPC valve (2) from PPC pump (3) is sent to port PB3 of ripper lift spool (4). This left, and PPC tank
pilot pressure pushes spool (4) to the and connects ports A and B and ports C D. The oil at port PA3 passes through valve (2) and is drained to hydraulic (5).
When this happens, the pressurized oil from hydraulic pump (6) enters port P, passes through unload valve (7) and ports A and B, and goes to the head end of ripper lift cylinders (8) to raise ripper (9). At the same time, the oil at the cylinder bottom passes through ports C, D, and T, and is drained to hydraulic tank (5).
SVD02642
Dl MAX-5
10-175
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
At ripper TILT IN
_
-
x
SVD02643
lo-176
D155AX-5
STRUCTURE AND FUNCTION
MAIN CONTROL CIRCUIT
OPERATION . When ripper control lever (I) is operated
to the TILT IN position, the spool of PPC valve (21, which is directly connected to the lever, is moved. When this happens, the pilot pressure entering PPC valve (2) from PPC pump (3) is sent to port PA4 of ripper tilt spool (4).
I2-
.
This pilot pressure pushes spool (4) to the right, and connects ports A and B and ports C and D. The oil at port PB4 passes through PPC valve (2) and is drained to hydraulic tank (5).
.
When this happens, the pressurized oil from hydraulic pump (6) enters port P, passes through unload valve (7) and ports A and B, and goes to the bottom end of ripper tilt cylinders (8) to tilt in ripper (9). At the same time, the oil at the cylinder head passes through ports C, D, and T, and is drained to hydraulic tank (5).
SVD02644
D155AX-5
10-177
STRUCTURE
AND
FUNCTION
CYLINDER
STAY
CYLINDER STAY
SAD00208
1. 2. 3. 4. 5. 6.
Grease nipple Yoke Oil seal Bushing Bushing Grease nipple
lo-178
D155AX-5
STRUCTURE
AND FUNCTION
WORK EQUIPMENT
WORK EQUIPMENT SEMI U-DOZER
6
SE000209
1. 2. 3. 4, 5. 6. 7. 8.
End bit Cutting edge Blade Center brace Tilt cylinder Straight frame Trunnion Brace
D155AX-5
10-179
STRUCTURE AND FUNCTION
WORK EQUIPMENT
SED00210
1. 2. 3. 4. 5. 6. 7. 8.
End bit Cutting edge Blade Center brace Tilt cylinder Straight frame Trunnion Brace
10-180
D155AX-5
STRUCTURE AND FUNCTION
WORK EQUIPMENT
MULTI-SHANK RIPPER
SED00212
1. 2. 3. 4. 5. 6. 7. 8.
Mount bracket Tilt cylinder Lift cylinder Beam Shank Protector Ripper point Arm
D155AX-5
lo-181
STRUCTURE AND FUNCTION
GIANT RIPPER . Machine equipped
1. 2. 3. 4. 5. 6. 7. 8. 9.
Bracket Tilt cylinder Lift cylinder Beam Pin puller cylinder Shank Protector Ripper point Arm
1O-l 82
WORK EQUIPMENT
with pin puller
8
SED00213
D155AX-5
CAB
STRUCTURE AND FUNCTION
CAB
1. 2. 3. 4.
D155AX-5
Front wiper Front glass Rear wiper Door
lo-183
STRUCTURE AND FUNCTION
CAB
ROPS GUARD
SDD00247
1. ROPS guard
lo-184
D155AX-5
AIR CONDITIONER
STRUCTURE AND FUNCTION
AIR CONDITIONER AIR CONDITIONER
PIPING
9’
SWD02645
1. Valve
(hot water inlet) defroster Side defroster Air conditioner unit Vent Blower motor Valve (hot water outlet) Hot water pickup piping Condenser with motor fan
2. Window 3. 4. 5. 6. 7. 8. 9.
lo-185
STRUCTURE AND FUNCTION
ELECTRIC WIRING
ELECTRIC WIRING DIAGRAM
DIAGRAM
D155AX-5
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
ELECTRIC WIRING DIAGRAM
Horn Front lamps Engine water temperature sensor Intake air heater relay Hydraulic oil pressure sensor HSS charge pressure sensor Backup alarm switch Ripper lamp Ripper point lamp HSS oil pressure sensor HSS drain oil temperature sensor Torque converter oil temperature sensor HSS pump solenoid A, B Engine speed sensor Starting motor Alternator
D155AX-5
lo-187
STRUCTURE AND FUNCTION
OD -
10-188
ELECTRIC WIRING DIAGRAM
Cn -
D155AX-5
STRUCTURE
17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48.
AND
FUNCTION
ELECTRIC WIRING
DIAGRAM
Monitor panel Starting switch Preheating switch Rear lamp switch Front lamp switch Buzzer Bimetal timer Radio Additional rear working lamp switch Additional front working lamp switch Rear window wiper switch Right door wiper switch Front window wiper switch Left door wiper switch Right door wiper Horn switch Pitch switch Front window wiper Pin puller switch Room lamp Rear window wiper HSS controller Cigarette lighter Fuel level sensor Rear lamp Backup alarm Window washer tank Batteries Battery relay Fuse holder Steering lever Left door wiper
D 155AX-5
1O-l 89
STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM CHASSIS ELECTRIC CIRCUIT DIAGRAM (l/3) * For details of this page, see Section 90.
10-190
D155AX-5
STRUCTURE AND FUNCTION
P/3) * For details of this page, see Section 90. D c I
D155AX-5
ELECTRIC CIRCUIT DIAGRAM
STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM (3/3) For details of this page, see Section 90. *
10-l 92
D155AX-5
STRUCTURE
AND
MONITOR
MONITOR
FUNCTION
SYSTEM
SYSTEM
Sensor
Controller
signal
signal
/-Y
L-J :/
-
Power Each
SUPPIY
sensor
i-l
Buzzer
signal
\ Buzzer
Controller
l
The monitor system uses sensors installed at various parts of the machine to observe the machine condition. It processes this information swiftly and displays it on the panel to keep the operator informed of the machine condition. The information displayed on the panel can be broadly divided into the following categories. 1.
2.
The monitor group, which informs the operator when there is an abnormality in the machine. The gauge group (coolant temperature, power train oil temperature, fuel level), which always displays the condition of the machine.
D 155AX-5
Battery
SWD02810
l
The monitor system consists of the monitor panel, controller, sensors, warning buzzer and power source. The monitor panel and sensors are connected with wiring harnesses, and the power supply for the monitor panel is taken from the battery. If any abnormality occurs in the machine (detected by the sensor), the monitor and warning lamp flash and the buzzer sounds to protect the machine. The buzzer can be stopped temporarily by operating the cancel switch.
10-193
STRUCTURE
MONITOR
AND
MONITOR
FUNCTION
PANEL
1’0
1. 2. 3. 4. 5. 6. 7. 8. 9.
Service meter Service meter indicator Engine coolant temperature Power train oil temperature Fuel level gauge Alarm buzzer cancel switch Alarm buzzer cancel switch Warning lamp Power train oil temperature
10-194
SYSTEM
10. Electronic system caution (HSS controller) 11. HSS charge pressure caution 12. Engine preheating indicator 13. Engine oil pressure caution lamp 14. HSS hydraulic oil temperature caution 15. Battery charge caution lamp 16. Engine coolant temperature caution lamp
gauge gauge indicator
caution
‘9
lamp
D155AX-5
STRUCTURE AND FUNCTION
MACHINE
Outline The monitor panel consists of the monitor group, which gives a warning if any abnormality occurs in the machine, and the service meter and gauge group, which displays the condition of the machine. The service meter and fuel level gauge are driven directly by a signal from the machine, but for the other items, a microcomputer installed in the panel processes the signal from various sensors and displays the result. The items displayed on the indicator type gauges and monitor portion are as shown in the table in MONITOR PANEL DISPLAY. When there is abnormality in HSS system, warning lamp flashes and warning buzzer sounds according to the signal sent from HSS controller. l
Operation 1. Turning on power (turning starting switch to ON) 1) All caution monitor items light up for 3 seconds. 2) The warning lamp lights up for 3 seconds and the alarm buzzer sounds for 1 second. 2.
*
3.
CAUTION items These light up or flash when there is any abnormality. The warning lamp and alarm buzzer flash or sound together depending on the item that is abnormal. The flashing interval for the monitor and warning lamp is approx. 0.8 seconds each repeated ON and OFF. Alarm buzzer cancel switch If any abnormality is detected and alarm buzzer sounds, it is possible to stop the buzzer temporarily by pressing the buzzer cancel switch. In this case, the alarm buzzer cancel switch indicator lights up. If the cancel switch is pressed again after the buzzer has been stopped, the buzzer will sound again and the cancel indicator will go out. If another abnormality is detected when the buzzer has been temporarily stopped, the alarm buzzer will sound again and the cancel switch will go out.
D155AX-5
10-195
STRUCTURE
Monitor
AND
MACHINE
FUNCTION
panel display
Meter
(gauge
SYSTEM
group)
Enginecoolanttemparahrre
50-c.
90-c
102-c
Gauge scale
%$L SYD00338
4.
MONITOR
Fuel level
Powertrain oiltemmperature
I
SYD00340
SYD00339
Gauge display portion This consists of analog type meters with an indicator. The coolant temperature and power train oil temperature gauges are driven by a microcomputer, and the area showing the normal operating range of the machine is made larger to make operations at the limit of the range easier. The red zone for the water and oil temperature is a warning area which uses a caution LED, caution lamp, and caution buzzer.
Connector
terminal
Connector
(signal table)
No.
Connector
Connection Power
l-l
2-1
supply
No.
Connection Engine Torque
water
temperature
converter
oil temperature
l-2
GND
2-2
l-3
-
2-3
Fuel level
2-4
GND
Battery
l-4
change
Starting
l-5
switch
Preheating
l-6 l-7
Working
l-8
Engine
lamp
(c)
2-5
2-7
switch
oil pressure
2-9
I-IO
-
2-10
I-II
-
2-l 1
1-12
-
2-12
1-13
Model
selection
0
1-14
Model
selection
1
Model
selection
2
1-16
lo-196
I
Buzzer
output
-
2-8
-
oil temperature
-
2-6
signal
l-9
1-15
HSS hydraulic
System
network
-
I
-
D155AX-5
STRUCTURE
Monitor
AND
panel display
Display category
MACHINE
FUNCTION
Symbol
(monitor
MONITOR
group)
Display item
HSS hydraulic oil temperature
Buzzer output
Display range
Below Engine water temperature
102°C
Gone
102”C-107°C
Flashes
Above
107°C
Flashes
Below
120°C
Gone
Gone
out
Flashes
Red
Flashes
Gone
out
out
Red Above
120°C
Flashes
Battery charge
Lighted up (when engine is stopped)
Below
SAD00786
HSS charge pressure
Gone
120°C
Lighted
up
Above
Lighted
up
130°C
Below specified valve
Red
OFF
Flashes
Gone
out
Red Flashes
I Red I
up
up
Flashes
I
Flashes
I
I
Lighted
ON
out
Lighted
Flashes (when engine is running)
When defective electronic system
When preheating
Gone
Gone out (when engine is stopped)
II
Preheating
out
Flashes
out
12O”C-130°C
SKD00628
Pilot
Gone Red
SKDO0627
Electronic system
4OFF
Flashes (when engine is running)
SKD00625
Power train oil temperature
OFF
Flashes
Lighted up (when engine is stopped)
Below specified value
out
Red
Flashes (when engine is running)
SKD00624
Engine oil pressure
Gone
-I
ON
Flashes
I When defective charging (below IOU
Remarks
out
SKDOO623
Warning
SYSTEM
I
Green
Gone
out
OFF
SKD00629
D155AX-5
10-197
MACHINE MONITOR SYSTEM
STRUCTURE AND FUNCTION
T Display category
Symbol
Display item
range
0
[Ml
Service meter
0 - 99999.9h
-
-
-
-
Green
-
-
fellow
-
Time on the clock
SKD00631
Service meter Service meter indicator
service
meter
SKD00632
0
Switches
0
Buzzer cancel switcl indicator
OFF
SKD00633
Switches Item
Buzzer cancel
Actuation
OFF t)
ON
Symbol
a @4 CAMCEL SKDO0634
lo-198
D155AX-5
STRUCTURE AND FUNCTION
SENSORS
SENSORS . .
The signals from the sensors are input directly to the machine monitor panel. With the engine oil pressure sensor, if the contacts are open and the signal wire is disconnected from the chassis ground, the panel judges that the signal is normal.
Display Caution Caution,
Type of sensor
category
I gauge
Engine oil pressure Engine
coolant
temperature
Sensor
I
When
method
When
OFF(Open)
Contact Resistance
normal
I
-
abnormal
ON(Closed)
I
-
Resistance
-
-
Fuel level
Resistance
-
-
HMT pump, motor oil temperature
Contact
ONKlosed)
OFF(Open)
Contact
ONKlosed)
OFF(Open)
Gauge
Power train oil temperature
Gauge
Caution HMT charge
D155AX-5
pressure
10-199
STRUCTURE AND FUNCTION
SENSORS
ENGINE OIL PRESSURE SENSOR
1
234
5
6
Structure
of circuit
SYDoo343
1. Plug
2. Contact
ring
3. Contact
4. Diaphragm 5. Spring 6. Thermistor
Function . The engine
oil pressure sensor is installed at the front on the left side of the cylinder block. When the engine oil pressure is above the specified value, diaphragm (4) bends, so contact (3) and contact ring (2) are separated and the circuit is turned OFF. When the engine oil pressure goes below the specified pressure, the curve of the diaphragm becomes smaller, so the contact and contact link come into contact and the circuit is turned ON. The monitor panel display and warning lamp flash, and the alarm buzzer sounds.
1O-200
D155AX-5
SENSORS
STRUCTURE AND FUNCTION
ENGINE COOLANT TEMPERATURE SENSOR POWER TRAIN OIL TEMPERATURE SENSOR
w
Structure
of circuit
1. Connector 2. Plug 3. Thermistor
Function l
l
The engine coolant temperature sensor is installed to the thermostat housing on the right side of the engine. It detects the temperature with thermistor (3) and sends a signal to the monitor panel. The monitor panel moves the gauge indicator to the range that corresponds to the signal, and if it is above the specified temperature, the monitor panel display and warning lamp flash, and the buzzer sounds. The power train oil temperature sensor is installed between from torque converter outlet ports to oil cooler, and operates in the same way as the engine water temperature sensor.
D155AX-5
10-201
SENSORS
STRUCTURE AND FUNCTION
FUEL LEVEL SENSOR
6 7 u
A-A
F
Structure
of circuit
SYD00345
1. Connector Float 3. 4. Body 5. Spring Contact 7. Spacer
1O-202
Function . The fuel level sensor is installed to the center of the front face of the fuel tank. Float (2) moves up and down in accordance with the level of the remaining fuel. The movement of the float passes through arm (31, which actuates a variable resistance, and this sends a signal to the monitor panel to display the level of the remaining fuel.
D155AX-5
SENSORS
STRUCTURE AND FUNCTION
HMT PUMP, MOTOR OIL TEMPERATURE SENSOR
4
\
w----J Structure
of circuit
SYDOO346
Function l
The HMT pump and motor oil temperature sensor is installed to the HMT motor drain outlet block. The temperature is detected by switch (I), and if the oil temperature goes above the set value, the switch is turned OFF. When this happens, the monitor panel display and warning lamp flash, and the alarm buzzer sounds.
1. 2. 3. 4.
Switch Case Wire Connector
HMT CHARGE PRESSURE SENSOR
SE000223
Function l
This sensor is installed to the PPC, EPC, HMT charge valve outlet port. If the charge pressure drops below the set pressure, switch (I) is turned OFF. When this happens, the monitor panel display and warning lamp flash, and the alarm buzzer sounds.
D 155AX-5
1. 2. 3. 4.
Switch Case Wire Connector
1 O-203
STRUCTURE
AND
ENGINE
FUNCTION
ENGINE STARTING
STARTING
SYSTEM
SYSTEM
SAD01559
1. 2. 3.
Joystick (directional, steering lever) Neutral detection limit switch Safety lever
1O-204
Outline . Neutral detection limit switch (2) is installed to Joystick (1). If safety lever (3) is not at the LOCK position, the starting circuit is not switched ON and the engine cannot be started.
D155AX-5
STRUCTURE AND FUNCTION
HSS ELECTRONIC CONTROL SYSTEM
HSS ELECTRONIC CONTROL SYSTEM PARTS LAYOUT
SVD02763
1 O-206
D155AX-5
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1 I. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
HSS ELECTRONIC CONTROL SYSTEM
Steering pressure sensor A Steering pressure sensor B Hydraulic pressure sensor PPC, HSS charge valve PPC, HSS charge filter HSS charge pressure sensor Power train pump Travel REVERSE sensing switch Travel REVERSE sensing potentiometer Steering lever potentiometer Steering lever HSS motor Brake valve Transmission HSS pump solenoid valve B HSS pump solenoid valve A HSS pump Engine speed sensor Engine flywheel housing Joystick Parking detection switch HSS controller
D155AX-5
1 O-207
zresros;itch
HSS charge pressure signal
Limit switch (ON tj OFF)
Potentiometer (analog)
Potentiometer (analog)
Oil pressure sensor (analog)
Engine speed signal
Power source
used
Oil pressure sensor (analog)
Equipment
Electromagnetic pick-up (pulse)
Reverse speed position signal
Steering lever signal 2
Steering lever signal 1
ilVork equipment :ircuit oil pressure signal
Steering circuit B oil xessure signal
Steering circuit A oil pressure signal
Name of signal
-
-
-
-
-
Signal to detect if oil I is being supplied I correctly to HSS ,- pump, motor closet I circuit
Signal to detect actual engine speed I and control swash I- plate angle of HSS pump
Command signal to detect reverse speed position and determine left or right direction of steering when traveling in reverse
Command signal to determine left or right direction and size of turning radius when steering is operated
Command signal to detect work equipment circuit oil pressure and control swash plate of HSS pump
Command signal to detect steering circuit oil pressure and control swash plate of HSS pump
Function
HSS controller
Output signal for sounding alarm to warn of abnormal condition of HSS controller
Output signal for sounding alarm when HSS charge pressure is abnormal
Monitor
3utput signal for soundng backup alarm when Backup alarm relay :raveling in reverse
panel
Relay (ON t;, OFF)
valve
contra
Equipment used
iSS pump and ad- HSS pump solenoid B solenoid ust discharge from )ump
Name of actuator
Iutput signal to “Ove swash plate Of HSS pump solenoid A Proportional
Nature of control
STRUCTURE
AND
Explanation 1) Steering
FUNCTION
HSS ELECTRONIC
CONTROL
SYSTEM
of system system
1 Hydraulic
pressure
sensor
1-y
4
Potentiometer
Travel switch
REVERSE sensino
,
,I I,
HSS Pump solenoid I HSS controller
,I
I,
HSS charge
Pressure
sensor
I,
I
I,
I
Monitor Panel
I,
Buzzer
II
Steering
lever
SWD02813
Outline
siqnal to determine the left or right direction of steering when traveling in reverse. The HSS controller uses the signal input from each oil pressure sensor to control the swash plate angle of the HSS pump and prevent the engine from stalling.
D155AX-5
lo-209
HSS ELECTRONIC CONTROL SYSTEM
STRUCTURE AND FUNCTION
2)
Warning and other systems
HSS charge pressure sensor
II
c
Sensors
,I I,
*
Actuators
,I
HSS controller
EEI
I,
t
Monitor panel
Buzzer
HSS PUMP solenoid
7iL
SWD02814
Outline The HSS pump and motor form a closed circuit. Oil is supplied to the closed circuit from the charge pump continuously to compensate for internal leakage. If this supply amount becomes low, the pump or motor may be broken, so a sensor is installed to detect the charge pressure. If the charge pressure goes below a certain pressure, a signal from the HSS charge pressure sensor enters the HSS controller and uses the alarm buzzer, warning lamp, and caution lamps on the monitor panel to inform the operator of the condition. If any abnormality occurs in the sensors, actuators (solenoid valves, etc.) or HSS controller, a signal is output through the HSS controller to the monitor panel warning lamp and alarm buzzer to warn the operator of the abnormality. The nature of the abnormality is displayed in numbers and letters on the HSS controller display.
10-210
D 155AX-5
HSS ELECTRONIC CONTROL SYSTEM
STRUCTURE AND FUNCTION
HSS CONTROLLER
3 I
I
I
3 CN-1
2
CN,-2
W-3
SJD02653
1. Display window 2. Connectors
CNI
D 155AX-5
CN2 (CN-2Hl)
CN2 (CN-2H2)
10-211
STRUCTURE AND FUNCTION
HSS ELECTRONIC CONTROL SYSTEM
REVERSE SENSING POTENTIOMETER
SWD02654
1. Connector 2. Lever Body 4. Potentiometer
.
.
5. Coupling 6. Shaft 7. Stopper
REVERSE
When the monolever is operated to forward or reverse, the potentiometer shaft is rotated through the link and the resistance value changes. A constant voltage is impressed between pins (I) and (3) of the potentiometer, and a voltage signal matching the position of operation to forward or reverse is sent from pin (2) to the HSS controller.
10-212
D155AX-5
HSS ELECTRONIC CONTROL SYSTEM
STRUCTURE AND FUNCTION
REVERSE position limit switch
1’
1. 2. 3. 4. 5.
Plunger Microswitch Plug Ball Bearing
SJD02655
6. 7. 8. 9. 10.
Cap Railer Stopper Diaphragm Connector
Function l
.
The REVERSE position limit switch is installed to the top of the transmission valve cover. When the monolever is operated to the REVERSE position, it pushes the roller of the limit switch, the circuit is closed, and the REVERSE position signal is sent to the HSS controller.
D 155AX-5
lo-213
STRUCTURE
ENGINE
AND
HSS ELECTRONIC
FUNCTION
CONTROL
SYSTEM
SPEED SENSOR
I
2
3
4
!
\ 5 c
0. 0.75fB 75fG
2,
SWD02815
4. Boot 5. Connector
1. Magnet 2. Terminal 3. Case
Function The engine speed sensor is installed to the top left of the engine flywheel. . As the engine flywheel gear passes through, the change in the magnetic field generates electricity, and the pulse is sent as a pulse signal to the HSS controller.
.
BACKUP
ALARM
RELAY
3 1
6 5
2
Structure of circuit SED00240
Function . The contacts of the electric circuit are opened and closed by the command voltage from the HSS controller and sound the backup alarm.
lo-214
D155AX-5
STRUCTURE AND FUNCTION
HSS ELECTRONIC CONTROL SYSTEM
HSS PRESSURE SENSOR (HSS CHARGE PRESSURE SIGNAL)
SWD02816
1. Switch 2. Case
3. Wire 4. Connector
Function l
The HSS pressure sensor is installed to the PPC, HSS charge valve outlet port. When the charge pressure goes below the specified pressure, switch (I) is turned OFF, the monitor panel display and warning lamp flash, and the alarm buzzer sounds.
STEERING CIRCUIT OIL PRESSURE SENSOR WORK EQUIPMENT CIRCUIT OIL PRESSURE SENSOR
1. Sensor 2. Connector
Function l
These sensors are installed in steering closed circuits A and B and in the hydraulic pump circuit. They convert the oil pressure at various parts to a voltage and send it to the HSS controller.
D 155AX-5
10-215
HSS ELECTRONIC CONTROL SYSTEM
STRUCTURE AND FUNCTION
HSS PUMP PROPORTIONAL SOLENOID VALVES A, B
I
A-A
6
1. Case
2. Coil 3. Shaft 4. Plunger
\ 5
SWD02818
5. Sleeve 6. Filter 7. Connector
Function l
The HSS pump proportional solenoid valve pushes the pilot of the HSS pump servo valve according to the command current from the HSS controller. The swash plate angle of the pump becomes larger in proportion to the electric current which changes the swash plate angle of the pump, and increases the pump discharge amount. There are two proportional solenoids to discharge oil from the pump in both the normal and reverse directions.
lo-216
D155AX-5
STRUCTURE
STEERING
VC
(For
AND
HSS ELECTRONIC
FUNCTION
CONTROL
SYSTEM
LEVER
Vsie
backup)
(For
sienall
I
2
5
A Lever
I
stroke
c
c 7
c-c
4 3 .
fz53
1. 2. 3. 4.
Body Piston Lever Disc
5. 6. 7. 8.
1 2
SWD02819
Retainer Lever Potentiometer Connector
Function The steering potentiometer is installed to the left side part of the floor, and is interconnected by a link to the steering end of the monolever. When the monolever is operated in the steering direction, disc (4) is rotated through the link, pushes piston (2) down, and rotates potentiometer (7). Steering lever potentiometers sense lever angle and output angle signal to HSS controller. Two potentiometers are attached to steering lever and they output signal as shown in the diagram.
l
l
l
D155AX-5
10-217
20
STANDARD
VALUE
TESTING AND ADJUSTING
TABLES
Standard
value table for engine ...................................................................................................
20-
2
Standard
value table for chassis ..................................................................................................
20-
3
Standard
value table for electrical
20-
8
TESTING
.................................................................................................................
AND ADJUSTING
TROUBLESHOOTING
parts .....................................................................................
20-101
............................................................................................................................
The following precautions troubleshooting .
are necessary,
when
using the standard
20-201
value tables for testing and adjusting,
or for
The values in the table are for new machines, and are obtained from reference to values when shipping from the factory. Therefore, they should be used as target values for judging the progress of wear, or when repairing the machine. The standard values for judging failures are based on the results of various tests when shipping the machine from the factory. These values should be used as reference together with the repair condition and operating record of the machine to make judgements on failures. The values in the table should
not be used for judging
a
When carrying out testing, pins and block the tracks.
a
When carrying out work together persons near the machine.
a
When checking the water level, always wait for the water to cool down. the water is still hot, the water will spurt out and cause burns.
a
Be careful
D 155AX-5
not to get caught
adjusting,
or troubleshooting,
claims.
with
other
workers,
in the fan or other rotating
stop the machine
use agreed
signals
on level ground,
install the safety
and do not allow
If the radiator
unauthorized
cap is removed
when
parts.
20-l
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE Serial No. 70001 – 75000 Machine model
D155AX-5
Engine Item
Measurement conditions
SA6D140E-2 Unit
High idling Engine speed
Low idling
rpm
At rated output
Exhaust temperature
Whole speed range (Ambient temperature: 20°C) At sudden acceleration
Exhaust gas color
At high idling
Intake valve Valve clearance (at normal temperature) Exhaust valve
Service limit value
2,050 ± 50
—
+25 700 0
—
1,900
—
kPa {mmHg}
Min. 85.3 {Min. 640}
67.9 {510}
°C
Max. 680
700
Max. 6.0
8.0
Max. 1.0
2.0
0.43
—
0.80
—
Rated speed Air supply pressure
Standard value for new machine
Bosch index mm
Compression pressure (SAE15W-40 or SAE30)
Oil temperature: 40 – 60°C (Engine speed)
MPa {kg/cm2} (rpm)
Min. 3.14 {Min.32} (200 – 250)
2.16 {22} (200 – 250)
Blow-by pressure (SAE15W-40 or SAE30)
At rated output (Water temperature: Operating range)
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
0.29 – 0.49 {3.0 – 5.0} 0.25 – 0.44 {2.5 – 4.5}
0.20 {2.0} 0.18 {1.8}
Min. 0.1 {Min. 1.0} Min. 0.1 {Min. 1.0}
0.07 {0.7} 0.07 {0.7}
°C
80 – 110
120
°
15 ± 0.5
15 ± 0.5
15
15
10
10
Oil pressure (Oil temperature: Min. 80°C)
At high idling SAE15W-40 or SAE30 SAE10W At low idling SAE15W-40 or SAE30 SAE10W
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before top dead center
MPa {kg/cm2}
Alternator belt tension
Air conditioner compressor belt tension
20-2 4
Deflection when pressed with finger force of approx. 59 N {6 kg}
mm
D155AX-5
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
Serial No. 75001 and up Machine model
D155AX-5
Engine Item
Measurement conditions
SA6D140E-3 Unit
High idling Engine speed
Low idling
rpm
At rated output
Exhaust temperature
Whole speed range (Ambient temperature: 20°C) At sudden acceleration
Exhaust gas color
At high idling
Intake valve Valve clearance (at normal temperature) Exhaust valve
Service limit value
2,100 ± 50
—
+25 740 0
—
1,900
—
kPa {mmHg}
Min. 85.3 {Min. 640}
67.9 {510}
°C
Max. 680
700
Max. 4.0
8.0
Max. 1.0
2.0
0.43
—
0.80
—
Rated speed Air supply pressure
Standard value for new machine
Bosch index mm
Compression pressure (SAE15W-40 or SAE30)
Oil temperature: 40 – 60°C (Engine speed)
MPa {kg/cm2} (rpm)
Min. 3.14 {Min.32} (200 – 250)
2.16 {22} (200 – 250)
Blow-by pressure (SAE15W-40 or SAE30)
At rated output (Water temperature: Operating range)
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
0.29 – 0.49 {3.0 – 5.0} 0.25 – 0.44 {2.5 – 4.5}
0.20 {2.0} 0.18 {1.8}
Min. 0.1 {Min. 1.0} Min. 0.1 {Min. 1.0}
0.07 {0.7} 0.07 {0.7}
°C
80 – 110
120
°
15 ± 0.5
15 ± 0.5
15
15
10
10
Oil pressure (Oil temperature: Min. 80°C)
At high idling SAE15W-40 or SAE30 SAE10W At low idling SAE15W-40 or SAE30 SAE10W
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before top dead center
MPa {kg/cm2}
Alternator belt tension
Air conditioner compressor belt tension
D155AX-5
Deflection when pressed with finger force of approx. 59 N {6 kg}
mm
20-2-1 4
20-2-2
(Blank page)
D155AX-5
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS Machine model
Engine stall speed
Category
Item
Service limit value
1,580 ± 100
1,420
1,410 ± 100
1,250
105 ± 20
105 ± 20
60 ± 20
60 ± 20
56 ± 15
56 ± 15
13 ± 5
13 ± 5
13 ± 5
13 ± 5
N ↔ FORWARD
45 ± 15
45 ± 15
N ↔ REVERSE
45 ± 15
45 ± 15
N → Right turn
57 ± 15
63 ± 15
N → Left turn
57 ± 15
63 ± 15
Total travel
79 ± 10
79 ± 10
61
61
HOLD ↔ RAISE, FLOAT
80 ± 15
80 ± 15
HOLD ↔ LEFT, RIGHT TILT
60 ± 10
60 ± 10
HOLD ↔ RAISE, LOWER
85 ± 15
85 ± 15
HOLD ↔ Digging angle decrease, increase
85 ± 15
85 ± 15
98 – 157 {10 – 16} 98 – 177 {10 – 18} 78 ± 29 {8 ± 3} 216 ± 78 {22 ± 8} 372 ± 78 {38 ± 8} 284 ± 78 {29 ± 8} 186 ± 78 {19 ± 8}
177 {18} 196 {20} 147 {15}
Steering relief + work equipment raise stall speed ª1
Fuel control lever
Center of lever knob
Joystick
Gear shift
Control lever travel, pedal travel
Standard value for new machine
Measurement conditions • Engine oil pressure: Within operating range • Engine oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55 °C • F3 • Ripper RAISE stall
Torque converter stall speed
Decelerator pedal
mm
deg.
• Engine at low idling Position until • Center of pedal brake oil pressure becomes 0
Ripper lever
rpm
1st ↔ 2nd
• Engine stopped • Center of lever 2nd ↔ 3rd knob
Steering
Brake pedal
Engine low idling → High idling Engine low idling → Stop
Unit
Center of pedal
Directional
Blade lever
• Engine at low idling • Center of lever knob • Hydraulic oil temperature: 45 – 55°C • Engine at low idling • Center of lever knob • Hydraulic oil temperature: 45 – 55°C
Fuel control lever ª1
Center of lever knob
Decelerator pedal
• Engine stopped • Center of pedal
mm
Engine low idling ↔ High idling Engine low idling ↔ Stop
N {kg}
1st → 2nd
Joystick
Operating force of control lever, pedal
D155AX-5
Gear shift
• Engine stopped 2nd → 3rd • Center of lever knob 2nd → 1st 3rd → 2nd
Nm {kgm}
216 {22 372 {38 284 {29 186 {19
± ± ± ± ± ± ± ±
78 8} 78 8} 78 8} 78 8}
ª 1: Serial No. 70001 – 75000
D155AX-5
20-3 4
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR CHASSIS
Machine model Measurement conditions
Item
) Engine stopped N tf FORWARD
Y
.g 2 _)
Directional
I---
bCenter of lever
l
Steering
l
Brake pedal
l
l
l
l
Blade lever l
l
l
Ripper lever l
l
Torque converter inlet port pressure
Torque converter port pressure
knob
N tf REVERSE ----I
Engine stopped N tf Left turn Center of lever knob N tf Rightturn Engine at low idling Center of pedal Engine at low idling Hydraulic oil t4e5m_p;Fpre: 0 E;&ber of lever Engine at low idling Hydraulic oil temperature: 45 - 55°C Center of lever knob
D155AX-5
I
HOLD tf RAISE, FLOAT
Unit
Standard value for new machine 53.9 rf: 19.1 {5.5 f 2.0} 53.9 f 19.1 15.5 zlz2.01 17.6 + 19.1 {I.8 f 2.0) 17.6 f 19.1
t-Egj-+
Service limit value 78.4 18.01 78.4 18.01 44.1 14.51
. .. .
AA 1
29.4 f 9.8
49.0
13.0 + 1.01
I5.01
29.4 + 9.8
{2.5 f 1.0)
44.1 14.51
HOLD tf RAISE, LOWER
29.4 rf:9.8 12.5 f 1.01
44.1 (4.51
HOLbDigging angle decrease, increase
29.4 + 9.8 12.5 + 1.01
44.1 14.51
H”~~G$zf$[~
Power train oil temperature: Operating range
outlet
Transmission main relief pressure Transmission modulating pressure Brake actuating pressure
HSS main pressure HSS charge pressure HSS servo charge pressure PPC relief pressure
Travel speed
* Measurement
20-4
D 155AX-5
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE
Catf ?-
item
gor Y
Measurement Hydraulic oil temperature: 45 - 55°C
l
Blade LIFT relief pressure
Blade TILT relief pressure -
conditions
20.59 f 0.98 I210 + IO)
20.59 * 0.98 I210 + IO)
Engine at low idling
18.63 f 0.98 I190 + IO)
18.63 f 0.98 {I90 + IO)
Engine at higt idling
20.59 f 0.98 1210 I!I 101
20.59 f 0.98 (210 f IO}
at low
18.63 + 0.98 {I90 f 101
18.63 + 0.98 (190 f IO}
20.59 f 0.98 (210 f IO)
20.59 f 0.98 1210 f IO}
at low
18.63 f 0.98 1190 f IO)
18.63 f 0.98 (190 * IO)
Engine at higt idling
20.59 I?Z0.98 (210 * IO}
20.59 f 0.98 {210 f IO]
at low
18.63 + 0.98 {I90 f 101
18.63 f 0.98 I190 + IO]
20.59 ztz0.98 1210 f IO)
20.59 f 0.98 1210 f IO]
Engine idling
Engine idling
pressure
at high
Engine at high
i idling Enne
PPC valve output pressure L
Work
equipment
Service limit value 18.63 f 0.98 {I90 f IO}
Engine idling
-
Standard value of new machinc 18.63 f 0.98 (190 f 10)
Engine at higt idling
Ripper digging angle relief increase decrease, pressure
Unit
Engine at low idling
Engine idling
Ripper LIFT relief pressure
Load sensing
D155AX-5
model
Machine
at high
g posture
Blade LIFT drift
MPa kg/cm’
2.94 - 4.4 {30 - 45)
2.94 - 4.4 130 - 451
200
250
150
200
TYDOOOOI l l
!E
+3
l
2
=r I
Engine stopped Hydraulic oil temperature: 45 - 55OC drift at edge of Hydraulic blade
Work equipment
-0
posture
I’
Blade TILT drift
-
D155AX-5
TYD00002 B Engine stopped mHydraulic oil temperature: 45 - 55°C drift at edge of - Hydraulic blade
20-5
STANDARD
VALUE
TABLE
STANDARD
Machine Cate
Item
gorl I
r
model
equipment
TABLE FOR CHASSIS
D155AX-5
Measurement
Work
VALUE
conditions
Unit
Standard value If new machine
Service limit value
150
200
90
150
posture
ND00003
9 Engine stopped 9 Hydraulic oil temperature: l
i Hydraulic drift of chassis
45 - 55°C Hydraulic drift at center of idler with blade pushed to height h against ground
Work
equipment
posture
mm/ 5min.
r--I
l l l
TYD00004 Engine stopped Hydraulic oil temperature: 45 - 55°C Hydraulic drift at center of sprocket with ripper pushed to height h against-ground
Work
equipment
posture
3-5
3-5
1 - 1.5
l-I.5
2.7 f 0.5
3.5
2.3 ? 0.5
3.0
Blade LIFT
TYD00005 l l
l l
Engine at high idling Hydraulic oil temperature: 45 - 55°C Blade: No load Ground level H Max. height
Work
equipment
sec.
posture
!i F t
El Blade TILT
l-YD00006 l l
l
.
20-6
Engine at high idling Hydraulic oil temperature: 45 - 55°C Blade: No load LEFT TILT ti RIGHT TILT
D155AX-5
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR CHASSIS
Machine model :e-
item
-r
D155AX-5
Measurement conditions
Unit
Standard value of new machine
limit value
Service
Work equipment posture
2.5 + 0.5
4.0
Ripper LIFT 1 Engine
at high idling
1Hydraulic oil temperature:
3.0 +- 1.0
5.0
3.0 -+ 0.5
4.5
TYD00008 Engine at high idling Hydraulic oil temperature: 45 - 55°C Lowest shank hole Digging angle decrease ++ increase
2.5 + 0.5
4.0
Engine at high idling Hydraulic oil temperature: 45 - 55°C Raise blade to maximum height, then lower blade and measure time taken from point where blade contacts ground to point where idler comes off ground
1.5 * 0.5
2.5
45 - 55°C
1Lowest shank hole Work equipment posture sec.
Ripper TILT
. . . .
. . .
Blade
.
i
. .
Ripper
. . . .
i
D155AX-5
Engine at high idling Hydraulic oil temperature: 45 - 55°C Raise ripper to maximum height, then lower ripper and measure time taken from point where ripper contacts ground to point where sprocket comes off ground Hydraulic oil temperature: 45 - 55°C Extend piston rod fully and disconnect hose at head end Engine at high idling Measure oil leakage during one minute of relief
1.5
Max. 3.0
12
c/min i
20-7
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS Serial No. 70001 – 75000 System
Component
Connector Inspection No. method
Judgement table If the condition is as shown in the table below, it is normal
Measure resistance Engine speed sensor
Between (1) – (2)
500 – 1000 Ω
Measurement condition 1) Turn starting switch OFF. 2) Disconnect connector.
Between (1), (2) – chassis Min.1 MΩ
CN-ENG (male)
If the condition is as shown in the table below, it is normal Measure voltage
Between (1) – (2)
0.5 – 3.0 V
1) Disconnect connectors. 2) Engine running
fl When using circuit tester, select AC voltage range. 1) Turn starting switch ON. 2) Insert Tadapter. Between (4) – (1) 5.0 ± 0.25 V 3) Turn joystick to steering Lever Between (3) – (1) 4.15 ± 0.25 V position. fully at left Between (2) – (1) 0.85 ± 0.25 V
If the condition is as shown in the table below, it is normal
Steering potentiometer
CN-STR
Measure voltage
HSS system
Lever at N
Between (3) – (1) 2.5 ± 0.25 V Between (2) – (1) 2.5 ± 0.25 V
Lever Between (3) – (1) 0.85 ± 0.25 V fully at right Between (2) – (1) 4.15 ± 0.25 V If the condition is as shown in the table below, it is normal REVERSE sensing potentiometer
CN-RSS
Measure voltage
Between (1) – (3) Lever at N Lever at REVERSE
Between (2) – (3)
5.0 ± 0.25 V Max. 3.5 V 3.5 – 4.4 V
If the condition is as shown in the table below, it is normal Steering circuit oil pressure sensor A
Measure CN-STHP1 voltage
Between (2) – (1)
20 – 30 V
20-8 4
Measure CN-STHP2 voltage
1) Turn starting switch ON. 2) Insert Tadapter.
Between Engine stopped 0.8 – 1.2 V (3) – (1) Engine running + 4.0 – 4.6 V Steering relief If the condition is as shown in the table below, it is normal
Steering circuit oil pressure sensor B
1) Turn starting switch ON. 2) Insert Tadapter. 3) Turn joystick to directional position.
Between (2) – (1)
20 – 30 V
1) Turn starting switch ON. 2) Insert Tadapter.
Between Engine stopped 0.8 – 1.2 V (3) – (1) Engine running + 4.0 – 4.6 V Steering relief
D155AX-5
STANDARD VALUE TABLE
Systen
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Judgement
Component
Measurement condition
table
If the condition is as shown table below, it is normal HSS charge oil pressure sensor
Between (1)-(2) IBetween
Engine stopped Engine
I
Max.
Steering neutral adjusting switch
Backup switch
(2) - (I)
CN-CSW (male)
in the
1 20-30
V
1
in the
1) Turn starting switch OFF. 2) Disconnect connectors.
If the condition is as shown table below, it is normal
in the
1) Turn starting switch OFF. 2) Disconnect connectors. 3) Turn joystick to directional position.
If the condition is as shown table below, it is normal
in the
1) Turn starting switch OFF. 2) Disconnect connectors.
Measure resistance
alarm
I
HSS pump solenoid B
Between
(I)
- (2)
I IO - 20 n I
(I), (2) -chassis
Between Between
(I) - (2)
(I), (2) -chassis
relay
Measure resistance
CN-014 (male)
I- (2)
Between
(I
Between
(3) - (5)
Between
(3) - (6)
in the
IO - 20 R
CN-00
1
Measure voltage
Between
(8),(18) -chassis
Between
(8),(18) - (9),(19)
I)
Turn starting switch OFF. 2) Disconnect connectors.
Min. 1 MQ
in the
200 - 400 R
I)
Turn starting switch OFF. 2) Disconnect connectors.
Min. 1 MR Max.
If the condition is as shown table below, it is normal Power supply for controller
I
Min. 1 MD
If the condition is as shown table below, it is normal
alarm
1) Turn starting switch ON. 2) Insert Tadapter.
If the condition is as shown table below, it is normal
If the condition is as shown table below, it is normal
8
1
I
Between
=& g E
MQ
I
HSS pump solenoid A
3ackup
1 Sz
(I), (2) - chassis.1 Min.1
Between
I) Turn starting switch OFF. 2) insert Tadapter.
Min. 1 MQ
running
If the condition is as shown table below, it is normal VVork equipment circuit oil pressure sensor
in the
1 R
in the
I)
Turn starting switch ON. 2) Insert Tadaper.
20 - 30 V
: ~
D 155AX-5
20-9
STANDARD VALUE TABLE
T
Syster n
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
(:onnecto rl nspectiol 7
Component
No.
Judgement
method
Measurement condition
table
is as shown If the condition t,able below, it is normal Power supply for solenoids
CN-001
Measure voltage
System network
CN-001
1 [
Between
(1),(12) - (9),(19)
krwer
speed
CN-2H2
supply
CN-2Hl potentiometer
Measure voltage
Between
[ 7t
(4) - (I 2)
When using circuit tester, voltage range.
II
in the
d
in the
(IO) - (9)
Measure voltage
Lever at N
switch ON. !) Insert T-
15.0 f 0.25 VI
in the
Lever Between (19) - (9) 4.15 + 0.25 V fully at right Between (20) - (9) 0.85 f 0.25 V CN-2Hl
Run engine. Insert Tadaper.
1I) Turn starting i
Between
I) !)
,
select AC
IiF the condition is as shown t able below, it is normal
Steering potentiometer
1
1I) Turn starting switch ON. 2!I Insert Tadaper.
1 0.5 - 3.0 v 1
If the condition is as shown t able below, it is normal
Measure voltage
1
in the
1 4 - 8 V
If the condition is as shown t ,able below, it is normal Engine sensor
ON.
adaper. 20-30V
If the condition is as shown t able below, it is normal
Measure voltage
switch
;!) Insert T-
-1
_
I) Turn starting
in the
Between
(19) - (9) 2.5 f 0.25 V
Between
(20) - (9) 2.5 f 0.25 V
1) Turn starting switch ON. 2!I Insert Tadapter. 3I) Turn joystick to steering position.
Lever Between (19) - (9) 0.85 + 0.25 V fully at left Between (20) - (9) 4.15 + 0.25 V
Travel REVERSE iensing lotentiometer
f the condition is as shown 1, t able below, it is normal CN-PHI CN-2H2
Measure Joltage
in the
1 ) Turn starting switch ON. 2!) Insert Tadapter. 3 ) Turn joystick to directional position
in the
1 ) Turn starting switch ON. 2 ) Insert T-
1 C
iteering
circuit
lil pressure ensor A
is as shown If the condition tzrble below, it is normal ZN-2Hl ZN-2H2
Jleasure roltage
Between
C;N_2H2(1j Engine stopped Engine running + _I C:N-2H1(9) Steerincl relief
iteering circuit sil pressure ensor B
:N-2Hl :N-2H2
vleasure foltage
Between C;N_2H2(9) Engine stopped Engine running + CZN-2Hlt9) Steering relief
adapter.
4.0 _ 4m8 v
is as shown If the condition tzable below, it is normal
I
20-10
0.8 - 1.2 V
in the
0.8 - 1.2 V
1 1 Turn starting switch ON. 2 1 Insert T-
adapter.
4.0 _ 4.8 v
D 155AX-5
STANDARD
Systen
VALUE
TABLE
Component
HSS charge oil pressure sensor
STANDARD
Connector Inspection No. method
CN-2Hl
=t 2
Zf=$”
F g
adjusting switch
CN-2Hl CN-2H2
CN-PHI
Judgement
TABLE FOR ELECTRICAL
PARTS
Measurement condition
table
If the condition is as shown table below, it is normal
in the
1) Turn starting switch ON.
If the condition is as shown table below, it is normal
in the
1) Turn starting switch ON.
If the
is as shown
in the
1) Turn starting switch ON.
If the condition is as shown table below, it is normal
in the
1) Turn starting switch ON.
If the condition is as shown table below, it is normal
in the
1) Turn starting switch ON.
Measure voltage
t Work equipment circuit oil pressure sensor
VALUE
Measure voltage
condition
Measure voltage
% I
Ba!zhp
alarm
;ey$w alarm
CN-2Hl
CN_ool
Measure voltage
Measure voltage
% Voltage changes 20 - 30 V to below IV alternatively every one second.
D155AX-5
20-11
STANDARD
Syster
VALUE
STANDARD
TABLE
Component
T
(Zonnectol nspectiol No.
VALUE
Judgement
method
TABLE FOR ELECTRICAL
Measurement condition
table
If the condition is as shown table below, it is normal
50”c
90’ c
102’C
01
M
I)
Turn starting switch OFF and insert dummy resistor, or measure input resistance. !) Turn starting switch ON and check the display of meter.
in the
k&4 Engine water temperature meter
KInale,
@
wleasure esistancl
loz"c
Approx.
3.7 kQ
120°C
Approx.
2.3 kCI
If the condition is as shown table below, it is normal
Transmission oil temperature meter
Emale)
Measure -esistanc
Fuel level meter
Kmale)
1) Turn starting switch OFF and insert dummy resistor, or measure input resistance. 2) Turn starting switch ON and check the display of meter.
in the
BVD00518
120°C
Approx.
2.3 kR
130°C
Approx.
1.8 kR
If the condition is as shown table below, it is normal
I) Turn starting switch OFF and insert dummy resistor, or measure input resistance. !) Turn starting switch ON and check the display of meter.
in the
Measure ,esistancl BVD00519
I
I /
20-12
Between Fuel level
I
(3) - chassis
I
Resistance
1 Approx.
82 kQ
l/10
Approx.
70 kR
F
Approx.
12 kQ
E
PARTS
1
Dl SAX-5
STANDARD
T
Syster n
VALUE
TABLE
Component
STANDARD
T
C:onnecto lr Inspeotior No.
VALUE
TABLE FOR ELECTRICAL
Judgement
method
Measurement condition
table
If the condition is as shown table
below,
Hydraulic oil temperature caution lamp
Vleasure .esistancc
Yemale)
I
Ffleasure
IEmale)
r,esistancc
chassis
in the
it is normal Lamp goes out
Be(Te_en At above 3.7 kn Engine water temperature caution lamp
Lamp flashes
At below 3.7 ka
If the condition is as shown table below, it is normal Befy_en
At below
1 kQ
chassis
At above
1 MQ
in the
Lamp goes out Lamp flashes
If the condition is as shown table below, it is normal Battery lamp
cahrgc
r/leasure roltage
! I'I
PARTS
in the
21 % Lamp lights up when engine is stopped and flashes when engine is being started. If the condition is as shown table below, it is normal
in the
Turn starting switch OFF and insert dummy resistor, or measure input resistance. 2) Turn starting switch ON and check the display of meter.
I)
1) Turn starting switch ON, or run engine.
I) When starting switch is turned ON or engine is running, measure voltage and check the display of lamp.
1 When
nAeasure r esistance
t
% Lamp lights stopped is being
up
is
If the
is
in the
I) Turn
it
‘2 female)
(’
n r
*
At above
kn
At below
kQ
Lamp or meas-
Lamp
Caution lamp and gauge signal of 1 sensor.
use same
!) Turn ON and of lamp.
If
is
in the
it
i\
h rl
of t
D 155AX-5
) When starting switch is or engine is run-
Sensor
signal
comes
in
lamp.
20-13
STANDARD VALUE TABLE
Systen
Component
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
onnectoi No.
ispactior method
I
Judgement
Vleasurement condition
table
If the condition is as shown t able below, it is normal Preheating pilot lamp
Pl
in the
) When starting switch is turned ON or PREHEAT, measure voltage and check the display of lamp.
in the
) Turn starting
Vleasure doltage
[
If the condition is as shown t able below, it is normal Power
supply
‘1 ‘2
Measure voltage
_I
Between
20 - 30 v
I
- P1(2),P2(4)1
If the condition System network
‘2
Measure voltage
I
Vlachine selection
‘1 imale)
Engine water temperature sensor
CN-402 (male)
below, Between
is as shown it is normal (IO) - (4)
oil sensor
Fuel level sensor
20-14
CN-453 (male)
CN-423 (male)
) Turn starting switch ON. 9 lnntp:t-
in the
1
4-8V
If the condition is as shown table below, it is normal
in the
I) Turn starting switch OFF. !) Disconnect conectors.
If the condition is as shown table below, it is normal
in the
1) Turn
Measure .esistanct 1
starting switch OFF. 2) Disconnect conectors.
Measure resistance 3
(‘I - 12) E+$;,m-!A,,,,,.
Transmission temperature
ON.
1
PI (1) - chassis
Between PI(l)
1[able
switch
I
52 kQ,
1) Turn
If the condition is as shown table below, it is normal
in the
starting switch OFF. 2) Disconnect conectors.
If the condition is as shown table below, it is normal
in the
I) Turn starting switch OFF. :?) Disconnect conectors.
Measure resistancl e
Measure resistant
e
D155AX-5
STANDARD VALUE TABLE
Systen 1
Component
IEngine switch
oil pressure
Alternator
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
(Zonnector No.
Inspection method
Judgement
Measurement condition
table
If the condition is as shown table below. it is normal
in the
1) Turn starting switch OFF.
If the condition is as shown table below, it is normal
in the
1) Run engine. (half throttle or above)
CN-403 (male)
CN-112
Measure voltage
Between terminal R chassis *
27.5 - 29.5 V
If the battery is old, or after starting in cold area, the voltage may not rise for some time.
If the condition is as shown table below, it is normal Neutral switch
safety
Blade pitch solenoid
Pin puller
Dl MAX-5
solenoid
CN-152 (male)
CN-454 (male)
CN-246 (male)
Measure resistance
Between (1) - (3)
Lever at N or FORWARD $&RSE
in the
Min. IM Q Max.
1 Q
-
1) Turn starting switch OFF. 2) Disconnect connectors. 3) Turn joystick to directional position
If the condition is as shown table below, it is normal
in the
1) Turn starting switch OFF.
If the
in the
1) Turn starting switch OFF.
Measure resistance
condition
is as shown
Measure resistance
20-15
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Serial No. 75001 and up System
Component
Connector Inspection No. method
Judgement table If the condition is as shown in the table below, it is normal
Measure resistance Engine speed sensor
Between (1) – (2)
500 – 1000 Ω
Measurement condition 1) Turn starting switch OFF. 2) Disconnect connector.
Between (1), (2) – chassis Min.1 MΩ
CN-E07 (male)
If the condition is as shown in the table below, it is normal Measure voltage
Between (1) – (2)
0.5 – 3.0 V
1) Engine running 2) Insert Tadapter.
fl When using circuit tester, select AC voltage range. 1) Turn starting switch ON. 2) Insert Tadapter. Between (4) – (1) 5.0 ± 0.25 V 3) Turn joystick to steering Lever Between (3) – (1) 4.15 ± 0.25 V position. fully at left Between (2) – (1) 0.85 ± 0.25 V
If the condition is as shown in the table below, it is normal
Steering potentiometer
CN-STR
Measure voltage
Lever at N
Between (3) – (1) 2.5 ± 0.25 V Between (2) – (1) 2.5 ± 0.25 V
HSS system
Lever Between (3) – (1) 0.85 ± 0.25 V fully at right Between (2) – (1) 4.15 ± 0.25 V If the condition is as shown in the table below, it is normal REVERSE sensing potentiometer
CN-RSS
Measure voltage
Between (1) – (3) Lever at N Lever at REVERSE
Between (2) – (3)
5.0 ± 0.25 V Max. 3.5 V 3.5 – 4.4 V
If the condition is as shown in the table below, it is normal Steering circuit oil pressure sensor A
CN-ST1
Measure voltage
Between (2) – (1)
20 – 30 V
CN-ST2
Measure voltage
Between (2) – (1)
20 – 30 V
CN-406 (male)
Measure resistance
1) Turn starting switch ON. 2) Insert Tadapter.
Between Engine stopped 0.8 – 1.2 V (3) – (1) Engine running + 4.0 – 4.6 V Steering relief If the condition is as shown in the table below, it is normal
HSS charge circuit oil pressure sensor
1) Turn starting switch ON. 2) Insert Tadapter.
Between Engine stopped 0.8 – 1.2 V (3) – (1) Engine running + 4.0 – 4.6 V Steering relief If the condition is as shown in the table below, it is normal
Steering circuit oil pressure sensor B
1) Turn starting switch ON. 2) Insert Tadapter. 3) Turn joystick to directional position.
Engine stopped
Between (1) – (2) Engine running
Min. 1 MΩ
1) Turn starting switch ON. 2) Disconnect connector.
Max. 1 Ω
Between (1), (2) – chassis Min. 1 MΩ
20-16 4
D155AX-5
STANDARD VALUE TABLE
System
Component
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector Inspection No. method
Measurement condition
Judgement table If the condition is as shown in the table below, it is normal
Work equipment circuit oil pressure sensor
CN-HHP
Measure voltage
Between (2) – (1)
20 – 30 V
Between Engine stopped 0.8 – 1.2 V (3) – (1) Engine started + work 2.4 – 3.0 V equipment relief If the condition is as shown in the table below, it is normal
Backup alarm switch
CN-251 (male)
Lever at N or Measure resistance Between FORWARD (1) – (3) Lever at REVERSE
Min. 1 MΩ Max. 1 Ω
If the condition is as shown in the table below, it is normal HSS pump solenoid A
1) Turn starting switch ON. 2) Insert Tadapter.
CN-PUPA Measure resistance
Between (1) – (2)
10 – 20 Ω
1) Turn starting switch OFF. 2) Disconnect connectors. 3) Turn joystick to directional position. 1) Turn starting switch OFF. 2) Disconnect connectors.
Between (1), (2) – chassis Min. 1 MΩ If the condition is as shown in the table below, it is normal HSS pump solenoid B
CN-PUPB Measure resistance
Between (1) – (2)
10 – 20 Ω
1) Turn starting switch OFF. 2) Disconnect connectors.
HSS system
Between (1), (2) – chassis Min. 1 MΩ If the condition is as shown in the table below, it is normal Backup alarm relay
CN-014 (male)
Measure resistance
Between (1) – (2)
200 – 400 Ω
Between (3) – (5)
Min. 1 MΩ
Between (3) – (6)
Max. 1 Ω
If the condition is as shown in the table below, it is normal Power supply for controller
CN-ST1
Measure voltage
Between (8),(18) – chassis
1) Turn starting switch OFF. 2) Disconnect connectors.
1) Turn starting switch ON. 2) Insert Tadaper.
20 – 30 V
Between (8),(18) – (9),(19)
HSS controller
If the condition is as shown in the table below, it is normal Power supply for solenoid
CN-ST1
Measure voltage
Between (17) – chassis
1) Turn starting switch ON. 2) Insert Tadaper.
20 – 30 V
Between (17) – (9),(19)
Net work (S-NET)
CN-ST1
Measure voltage
If the condition is as shown in the table below, it is normal Between (1),(12) – (9),(19)
4–8V
If the condition is as shown in the table below, it is normal Engine speed sensor
CN-ST3
Measure voltage
Between (4) – (12)
0.5 – 3.0 V
1) Turn starting switch ON. 2) Insert Tadaper. 1) Engine running 2) Insert Tadaper.
fl When using circuit tester, select AC voltage range.
D155AX-5
20-17 4
STANDARD VALUE TABLE
System
Component 5-V power supply for potentiometer
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector Inspection No. method CN-ST2
Measure voltage
Judgement table If the condition is as shown in the table below, it is normal Between (10) – (9)
5.0 ± 0.25 V
If the condition is as shown in the table below, it is normal Lever Between (19) – (9) 4.15 ± 0.25 V fully at right Between (20) – (9) 0.85 ± 0.25 V Steering potentiometer
CN-ST2
Measure voltage
Measurement condition 1) Turn starting switch ON. 2) Insert Tadaper. 1) Turn starting switch ON. 2) Insert Tadapter. 3) Turn joystick to steering position.
Between (19) – (9) 2.5 ± 0.25 V Lever at N Between (20) – (9) 2.5 ± 0.25 V Lever Between (19) – (9) 0.85 ± 0.25 V fully at left Between (20) – (9) 4.15 ± 0.25 V
HSS controller
HSS system
Travel REVERSE sensing potentiometer
If the condition is as shown in the table below, it is normal CN-ST2 CN-ST3
Steering circuit CN-ST2 oil pressure CN-ST3 sensor A
Steering circuit CN-ST2 oil pressure CN-ST3 sensor B
HSS charge oil pressure sensor
Work equipment circuit oil pressure sensor
Measure voltage
Between CN-ST3(10) Lever at N – Lever CN-ST2(9) at REVERSE
Max. 3.5 V 3.5 – 4.4 V
If the condition is as shown in the table below, it is normal Measure voltage
Between CN-ST3(1) Engine stopped – Engine running + CN-ST2(9) Steering relief
0.8 – 1.2 V
Between CN-ST3(9) Engine stopped – Engine running + CN-ST2(9) Steering relief
0.8 – 1.2 V
Measure voltage
Between Engine stopped (8) – chassis Engine running
20 – 30 V
Measure voltage
Between CN-CH2(2) Engine stopped 0.8 – 1.2 V – Engine running + CN-CH1(9) Work equipment relief 2.4 – 3.0 V
If the condition is as shown in the table below, it is normal Backup alarm switch
20-18 4
CN-ST2
Measure voltage
Between (7) – chassis
Lever at N or FORWARD Lever at REVERSE
1) Turn starting switch ON. 2) Insert Tadapter.
Max. 1 V
If the condition is as shown in the table below, it is normal CN-ST2 CN-ST3
1) Turn starting switch ON. 2) Insert Tadapter.
4.0 – 4.6 V
If the condition is as shown in the table below, it is normal CN-ST2
1) Turn starting switch ON. 2) Insert Tadapter.
4.0 – 4.6 V
If the condition is as shown in the table below, it is normal Measure voltage
1) Turn starting switch ON. 2) Insert Tadapter. 3) Turn joystick to directional position
20 – 30 V Max. 1 V
1) Turn starting switch ON. 2) Insert Tadapter.
1) Turn starting switch ON. 2) Insert Tadapter. 3) Turn joystick to directional position.
D155AX-5
STANDARD VALUE TABLE
System
Component
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector Inspection No. method
Judgement table If the condition is as shown in the table below, it is normal
Backup alarm relay
CN-ST1
Measure voltage
Between (11) – chassis
Lever at N or FORWARD Lever at REVERSE
Max. 1 V 20 – 30 V(ª)
ª Voltage changes 20 – 30 V to below 1V alternatively every one second. If the condition is as shown in the table below, it is normal Buzzer cancel switch 1
CN-ST2
Measure voltage
Between Switch ON ST2(6) – chassis Switch OFF
20 – 30 V
CN-ST2
Measure voltage
Between Switch ON ST2(5) – chassis Switch OFF
20 – 30 V
HSS controller
HSS system
Measure voltage
Between Switch ON ST2(18) – chassis Switch OFF
20 – 30 V
Measure voltage
Between Switch ON ST2(17) – chassis Switch OFF
20 – 30 V
CN-ST2
Measure voltage
Between Switch ON ST2(4) – chassis Switch OFF
20 – 30 V
CN-ST2
Measure voltage
Between Lever at 3rd or ST2(13) – 2nd chassis Lever at 1st
20 – 30 V Max. 1 V
If the condition is as shown in the table below, it is normal 2nd switch
D155AX-5
CN-ST2
Measure voltage
Between Lever at 1st or ST2(14) – 2nd chassis Lever at 3rd
1) Turn starting switch ON. 2) Insert Tadapter.
1) Turn starting switch ON. 2) Insert Tadapter.
Max. 1 V
If the condition is as shown in the table below, it is normal 1st switch
1) Turn starting switch ON. 2) Insert Tadapter.
Max. 1 V
If the condition is as shown in the table below, it is normal Servise switch
1) Turn starting switch ON. 2) Insert Tadapter.
Max. 1 V
If the condition is as shown in the table below, it is normal Mode selection CN-ST2 switch 2
1) Turn starting switch ON. 2) Insert Tadapter.
Max. 1 V
If the condition is as shown in the table below, it is normal Mode selection CN-ST2 switch 1
1) Turn starting switch ON. 2) Insert Tadapter. 3) Turn joystick to directional position.
Max. 1 V
If the condition is as shown in the table below, it is normal Buzzer cancel switch 2
Measurement condition
20 – 30 V Max. 1 V
1) Turn starting switch ON. 2) Insert Tadapter. 3) Turn joystick to 3rd or 2nd position. 1) Turn starting switch ON. 2) Insert Tadapter. 3) Turn joystick to 2nd or 1st position.
20-19 4
STANDARD VALUE TABLE
System
Component
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector Inspection No. method
Judgement table If the condition is as shown in the table below, it is normal
Power train (Torque converter) oil temperature sensor
453 (male)
Measure resistance
When water temperature is 100°C When water temperature is 90°C Between When water tem(1) – (2) perature is 35°C When water temperature is 20°C When water temperature is 10°C
Approx. 3.8 kΩ
423 (male)
Measure resistance
Between At full (1) – (2) At empty
Approx. 29 kΩ Approx. 52 kΩ Approx. 80 kΩ
Max. approx. 12 Ω Approx. 85 – 110 Ω
If the condition is as shown in the table below, it is normal Alternator
ANB
Measure voltage
Between terminal R – chassis
1) Turn starting switch OFF. 2) Disconnect conectors.
Approx. 4.9 kΩ
If the condition is as shown in the table below, it is normal Fuel level sensor
Measurement condition
1) Turn starting switch OFF. 2) Disconnect conectors.
1) Run engine. (half throttle or above)
27.5 – 29.5 V
Monitor panel system
fl If the battery is old, or after starting in cold area, the voltage may not rise for some time.
Hydraulic oil temperature sensor
Monitor panel (Caution module)
S-NET
If the condition is as shown in the table below, it is normal CN1
CN1
Measure resistance
Measure voltage
Between (5) – (2)
When oil temperature is below 105°C When oil temperature is abouve 105°C
Max. 1 V 20 – 30 V
If the condition is as shown in the table below, it is normal Between (11) (12) – (10)
4.0 – 10.0 V
If the condition is as shown in the table below, it is normal Power train (Torque converter) oil temperature sensor
CN1 (female) CN2 (female)
Measure resistance
Oil temperature: 50˚C (Level 1) Oil temperature: 90˚C (Level 2) Oil temperature: Between 110˚C (Level 3) CN2 (2) – Oil temperature: CN1 (2) 116˚C (Level 4) Oil temperature: 120˚C (Level 5) Oil temperature: 130˚C (Level 6)
Approx. 17 kΩ
CN1 (female) CN2 (female)
E
Measure resistance
Between CN2 (3) – CN1 (2)
20-20 4
1) Turn starting switch OFF. 2) Disconnect conectors.
Approx. 2.9 kΩ Approx. 2.5 kΩ Approx. 2.3 kΩ Approx. 2.3 kΩ
Approx. 75 kΩ
Level 3/7
Approx. 50 kΩ
Level 5/7
Approx. 35 kΩ
F
1) Insert Tadapter. 2) Turn starting switch ON.
Approx. 5 kΩ
If the condition is as shown in the table below, it is normal Fuel level sensor
1) Insert Tadapter. 2) Turn starting switch ON.
1) Turn starting switch OFF. 2) Disconnect conectors.
Approx. 14 kΩ
D155AX-5
STANDARD VALUE TABLE
System
Component
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector Inspection No. method
Judgement table If the condition is as shown in the table below, it is normal
Monitor panel (Caution module)
Preheating signal
CN1 CN2
Measure voltage
Between CN2 (5) – CN1 (2)
When preheater is turned ON When preheater is turned OFF
20 – 30 V
CN1 CN2
Measure voltage
Between CN2 (7) – CN1 (2)
When lamp is turned ON When lamp is turned OFF
Max. 6 V
Measure voltage
Between CN2 (8) – CN1 (2)
When buzzer is turned ON When buzzer is turned OFF
Max. 3 V
Monitor pannel system
Backup power source
CN4
T01
Monitor panel (Tachometer module)
Starting switch T01 ON signal
Measure voltage
Measure voltage
Measure voltage
Between (1) – (2)
When lamp switch is turned OFF When lamp switch is turned ON
Max. 1 V
20 – 30 V
If the condition is as shown in the table below, it is normal Between (1) – (2)
20 – 30 V
If the condition is as shown in the table below, it is normal Starting switch T01 STAR signal
Measure voltage
Between (3) – (2)
When starting switch is at ON position When starting switch is at START position
T01
Measure voltage
Between (4) – (2)
While engine is stopped While engine is running
S-NET
D155AX-5
T01
T01
Measure voltage
Measure voltage
Between (5) – (2)
When switch is turned OFF When switch is turned ON
1) Insert Tadapter.
1) Insert Tadapter.
Max. 1 V 27.5 – 29.5 V
20 – 30 V
1) Insert Tadapter. 2) Turn starting switch ON.
Max. 1 V
If the condition is as shown in the table below, it is normal Between (9) (10) – (8)
1) Insert Tadapter. 2) Turn starting switch ON.
20 – 30 V
If the condition is as shown in the table below, it is normal Service switch
1) Insert Tadapter. 2) Turn starting switch OFF.
Max. 1 V
If the condition is as shown in the table below, it is normal Alternator
1) Insert Tadapter. 2) Turn starting switch ON.
20 – 30 V
If the condition is as shown in the table below, it is normal Between (7) – (2)
1) Insert Tadapter. 2) Turn starting switch ON.
20 – 30 V
If the condition is as shown in the table below, it is normal Lighting signal
1) Insert Tadapter. 2) Turn starting switch ON.
20 – 30 V
If the condition is as shown in the table below, it is normal CN1 Caution Buzzer CN2
1) Insert Tadapter. 2) Turn starting switch ON.
Max. 1 V
If the condition is as shown in the table below, it is normal Caution lamp
Measurement condition
4.0 – 10.0 V
1) Insert Tadapter. 2) Turn starting switch ON.
20-21 4
STANDARD VALUE TABLE
System Monitor panel (switch module)
Component
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector Inspection No. method
Measurement condition
Judgement table If the condition is as shown in the table below, it is normal Between (1) – (2)
Power sorce
S01
Measure voltage
20 – 30 V
fl If the battery is old, or after starting in cold area, the voltage may not rise for some time.
If the condition is as shown in the table below, it is normal Hydraulic oil temperature sensor
452 (male)
Measure resistance
Between (1) – chassis
When oil temperature is below 105°C When oil temperature is abouve 105°C
Max. 1 Ω
Monitor panel system
Monitor panel (caution module)
4
Measure resistance
Between (1) – (2)
OFF
ON
Between (2) – (3)
Max.1 Ω
Min.1 MΩ
Between (3) – (4)
Min.1 MΩ
Max.1 Ω
Between (4) – (5)
Max.1 Ω
Min.1 MΩ
Between (5) – (6)
Min.1 MΩ
Max.1 Ω
If the condition is as shown in the table below, it is normal Ribbon heater relay
20-22
X1
Power sorce
HET (male)
CN1
Measure resistance
Measure voltage
Between (1) – (2)
200 – 400 Ω
Between (3) – (5)
Min.1 MΩ
Between (3) – (6)
Max.1 Ω
If the condition is as shown in the table below, it is normal Between (1) – (2)
4.0 – 10.0 V
If the condition is as shown in the table below, it is normal Starting switch CN1 START signal
Measure resistance
Between (3) – (2)
When starting switch is at ON position When starting switch is at START position
CN1
Measure voltage
Between (4) – (2)
While engine is stopped While engine is running
1) Turn starting switch OFF. 2) Disconnect conectors.
1) Turn starting switch OFF. 2) Disconnect conectors.
1) Insert Tadapter. 2) Turn starting switch ON. 1) Insert Tadapter.
Max. 1 Ω 20 – 30 V
If the condition is as shown in the table below, it is normal Alternator
1) Turn starting switch OFF. 2) Disconnect conectors.
Nin. 1 MΩ
If the condition is as shown in the table below, it is normal
Service switch
1) Insert Tadapter. 2) Turn starting switch ON.
1) Insert Tadapter.
Max. 1 V 27.5 – 29.5 V
D155AX-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING Tools for testing, adjusting, and troubleshooting ................................................................................ 20-102 Measuring engine speed ........................................................................................................................ 20-103 Measuring intake air pressure (boost pressure) ................................................................................... 20-104 Measuring exhaust temperature ............................................................................................................ 20-105 Measuring exhaust color ........................................................................................................................ 20-106 Adjusting valve clearance ....................................................................................................................... 20-107 Measuring compression pressure ......................................................................................................... 20-108 Measuring blow-by pressure ................................................................................................................. 20-109 Measuring engine oil pressure .............................................................................................................. 20-110 Testing and adjusting fuel injection timing .......................................................................................... 20-111 Handling equipment in fuel circuit ..................................................................................................... 20-111-1 Rereasing remaining pressure in fuel system ................................................................................... 20-111-1 Measuring fuel pressure ...................................................................................................................... 20-111-2 Reduced cylinder mode operation ...................................................................................................... 20-111-3 Bleeding air from fuel system ............................................................................................................. 20-111-5 Check for leakage in fuel system ........................................................................................................ 20-111-6 Testing and adjusting alternator belt tension ....................................................................................... 20-112 Testing and adjusting air conditioner compressor belt tension ...................................................... 20-112-1 Testing and adjusting fun belt tension ............................................................................................... 20-112-2 Adjusting engine speed sensor .............................................................................................................. 20-113 Handling controller high voltage circuit ............................................................................................. 20-113-1 Adjusting fuel control lever and decelerator pedal .............................................................................. 20-114 Measuring torque converter stall speed ............................................................................................... 20-117 Measuring full stall speed ...................................................................................................................... 20-118 Measuring power train oil pressure ...................................................................................................... 20-119 Testing and adjusting HSS main oil pressure ...................................................................................... 20-122 Testing and adjusting HSS charge oil pressure ................................................................................... 20-124 Testing and adjusting HSS servo charge pressure and PPC relief pressure ...................................... 20-126 Bleeding air from HSS pump ................................................................................................................. 20-128 Simple procedure for testing brake performance ................................................................................ 20-129 Adjusting joystick and parking lever ..................................................................................................... 20-130 Testing and adjusting travel reverse sensing potentiometer .............................................................. 20-133 Adjusting travel reverse limit switch ..................................................................................................... 20-134 Adjusting steering neutral position ....................................................................................................... 20-135 Procedure for operating emergency steering switch ........................................................................... 20-139 Adjusting initial current in HSS steering system ............................................................................... 20-140-3 Adjusting brake pedal ............................................................................................................................. 20-141 Adjusting clearance of idler .................................................................................................................... 20-143 Testing wear of sprocket ........................................................................................................................ 20-144 Testing and adjusting track shoe tension ............................................................................................. 20-145 Testing and adjusting hydraulic pressure ............................................................................................. 20-146 Measuring PPC valve output pressure .................................................................................................. 20-148 Adjusting play of PPC valve ................................................................................................................... 20-150 Measuring solenoid valve output pressure .......................................................................................... 20-151 Testing location causing hydraulic drift of blade and ripper ............................................................... 20-152 Measuring leakage inside hydraulic cylinder ....................................................................................... 20-153 Releasing remaining oil pressure in hydraulic cylinder ....................................................................... 20-154 Bleeding air from hydraulic cylinder ..................................................................................................... 20-154 Adjusting work equipment safety lever ................................................................................................ 20-155 Adjusting semi-U tiltdozer ...................................................................................................................... 20-156
D155AX-5
20-101 4
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Check or measurement item Symbol Engine speed
ª1
Air supply pressure (boost pressure) Temperature of water, oil , and exhaust gas Exhaust color
A
799-203-8001
Multi-tachometer
B
799-201-2202
Boost gauge kit
–101 – 199.9kPa{–750 – 1,500mmHg}
C
799-101-1502
Digital thermometer
– 99.9 – 1299˚C
1
799-201-9000
Handy smoke checker
2
Commercially available 795-125-1210
Smoke meter
Discoloration 0 – 70 % (with standard color) (Discoloration x 1/10 •=• Bosch index)
E
Compression pressure ª1
Feeler gauge
SA6D140E-2 Intake valve: 0.43mm, Exhaust valve: 0.80mm SA6D140E-3 Intake valve: 0.35mm, Exhaust valve: 0.57mm
795-502-1205
Compression gauge
0 – 6.9MPa {0 – 70kg/cm2}
• 795-502-1510
• Adapter
• 795-502-1520
• Plate
799-201-1504
Blow by checker
0 – 4.9MPa {0 – 500mmH2O}
799-101-5002
Hydraulic tester
Pressure gauge: 2.5,5.9,39.2,58.8MPa {25,60,400,600kg/cm2}
790-261-1203
Digital hydraulic tester
Pressure gauge: 58.8MPa{600kg/cm2}
799-101-5220
Nipple
07002-11023
O-ring
799-401-2320
Hydraulic gauge
791-627-1160
Wear gauge
79A-264-0021
Push-pull scale
0 – 294N {0 – 30kg} 0 – 490N {0 – 50kg}
Commercially available
F
Blow-by pressure
Remarks Digital display L : 60 – 2,000rpm H : 60 – 19,999rpm
D
Valve clearance
Part Name
Part No.
G
1 Oil pressure
H
2 Wear of sprocket
J
Operating effort
K 79A-264-0091
Push-pull scale Scale
Stroke, hydraulic drift
L
Work equipment speed
M
Commercially available Commercially available
Measuring voltage and resistance
N
79A-264-0211
Tester
Troubleshooting of wiring harnesses
799-601-8000
T-adapter
P 799-601-7360
Adapter
10 x 1.25 0.98MPa {10kg/cm2}
Stop watch
For 5 pins relay
ª1: SA6D140E-2 engine
20-102 4
D155AX-5
TESTING AND ADJUSTING
MEASURING ENGINE SPEED
MEASURING ENGINE SPEED Serial No. 70001 – 75000
¤ Be
careful not to touch any hot parts when removing or installing the measuring tools.
fl Measure the engine speed under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55°C 1. Remove cap (1) of the speed pickup port. 2. Install sensor 1 of multi-tachometer A to the speed pickup port, then connect to multi-tachometer A. 3. Start the engine and measure the engine speed under the following conditions. 1) Measurement at low idling: i) Set the joystick and work equipment control lever to the neutral position. ii) Set the fuel control lever to the low idling position, then measure the engine speed. 2) Measurement at high idling i) Set the joystick and work equipment control lever to the neutral position. ii) Set the fuel control lever to the high idling position, then measure the engine speed. fl When measuring the “stall speed of torque converter” and “speed to stall the torque converter and relieve the work equipment pump”, see the measurement procedure for them.
A
TLD00010
D155AX-5
20-103 4
TESTING AND ADJUSTING
MEASURING ENGINE SPEED
Serial No. 75001 and up fl Measure the engine speed in the monitoring mode and adjusting mode of the monitor panel. For the general explanation of the monitoring mode and adjusting mode, see DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL in TROUBLESHOOTING. 1. Measuring low idling speed and high idling speed 1) Remove cover (1). 2) Turn starting switch ON. 3) Turn service switch (2) ON. fl The service switch is installed inside the cover. 4) Turn and hold buzzer cancel switch (3) to the right for at least 7 seconds to display the service mode in upper display unit (4). 5) Turn up mode selector switch (5) to display the monitoring mode. fl The mode selector switch is installed inside the cover. fl Each time the mode selector switch is turned up, the mode changes. fl If the monitoring mode is selected, round mark (6) on the left side lights up. 6) Turn buzzer cancel switch (3) to the right to display "99". 7) Start the engine and read its speed under the following conditions indicated in lower display unit (7) of the panel. fl The engine speed is indicated by the unit of rpm. i) Measuring low idling speed: Set the joystick and work equipment control lever in neutral and set the fuel control dial in the low idling position.
20-103-1 4
D155AX-5
TESTING AND ADJUSTING
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
ii) Measuring high idling speed: Set the joystick and work equipment control lever in neutral and set the fuel control dial in the high idling position. 8) After measuring the engine speed, turn OFF service switch (2) and set the panel to the ordinary mode. 9) Install cover (1).
D155AX-5
20-103-2 4
TESTING AND ADJUSTING
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) Serial No. 70001 – 75000
¤ Be
careful not to touch any hot parts when removing or installing the measuring tools.
fl Measure the intake air pressure under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55 °C 1. Remove intake air pressure pickup plug (1) (PT1/ 8). 2. Install nipple 1 of oil pressure gauge H1, then connect to boost gauge B. 3. Start and run the engine at a middle or higher speed to drain oil from the hoses. fl Insert the connecting part of the hose in the pressure gauge halfway and open the selfsealing part on the hose side repeatedly to drain the oil. fl If Pm kit (A) is available, the air bleeding coupling (790-261-113) in it may be used. fl If any oil remains in the hoses, the gauge does not operate. Accordingly, drain the oil without fail. 4. Run the engine at high idling and stall the torque converter, and measure the intake air pressure (boost pressure) at this time. fl For the procedure to stall the torque converter, see MEASURING TORQUE CONVERTER STALL SPEED. fl The normal intake air pressure (boost pressure) must be measured while the machine is operating at the rated output. An approximate value can be obtained in the field, however, by measuring when the torque converter stalls.
20-104 4
D155AX-5
TESTING AND ADJUSTING
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
Serial No. 75001 and up
¤ Be
careful not to touch any hot parts when removing or installing the measuring tools.
fl Measure the intake air pressure under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55 °C 1. Remove intake air pressure pickup plug (1) (PT1/ 8). 2. Install nipple 1 of boost gauge kit B, then connect to boost gauge kit. 3. Start and run the engine at a middle or higher speed to drain oil from the hoses. fl Insert the connecting part of the hose in the pressure gauge halfway and open the selfsealing part on the hose side repeatedly to drain the oil. fl If Pm kit (A) is available, the air bleeding coupling (790-261-113) in it may be used. fl If any oil remains in the hoses, the gauge does not operate. Accordingly, drain the oil without fail. 4. Run the engine at high idling and stall the torque converter, and measure the intake air pressure (boost pressure) at this time. fl For the procedure to stall the torque converter, see MEASURING TORQUE CONVERTER STALL SPEED. fl The normal intake air pressure (boost pressure) must be measured while the machine is operating at the rated output. An approximate value can be obtained in the field, however, by measuring when the torque converter stalls.
D155AX-5
20-104-1 4
TESTING AND ADJUSTING
20-104-2 4
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D155AX-5
TESTING AND ADJUSTING
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE Serial No. 70001 – 75000
¤ Install
or remove the temperature sensor after the exhaust manifold is cooled.
fl Measure the exhaust temperature under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55 °C 1. Remove the turbocharger heat insulation cover.
1
TLD00030
2. Remove exhaust temperature pickup plug (1) (PT1/8). 3. Install sensor 1 of digital thermometer C, then connect to digital thermometer C. fl Clamp the harness of the thermometer so that it will not touch the hot parts during measurement.
4. Measure the maximum exhaust temperature while the machine is actually operating at high idling. fl Use the PEAK mode of the digital thermometer. fl The exhaust temperature largely depends on the ambient air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, carry out temperature compensation by the following calculation. • Compensation value [°C] = Measured value + 2 x (20 – Ambient air temperature)
D155AX-5
20-105 4
TESTING AND ADJUSTING
MEASURING EXHAUST TEMPERATURE
Serial No. 75001 and up
¤ Install
or remove the temperature sensor after the exhaust manifold is cooled.
fl Measure the exhaust temperature under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55 °C 1. Remove the turbocharger heat insulation cover. 2. Remove exhaust temperature pickup plug (1). 3. Install sensor 1 of digital thermometer C, then connect to digital thermometer C. fl Clamp the harness of the thermometer so that it will not touch the hot parts during measurement.
4. Measure the maximum exhaust temperature while the machine is actually operating at high idling. fl Use the PEAK mode of the digital thermometer. fl The exhaust temperature largely depends on the ambient air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, carry out temperature compensation by the following calculation. • Compensation value [°C] = Measured value + 2 x (20 – Ambient air temperature)
20-105-1 4
D155AX-5
TESTING AND ADJUSTING
D155AX-5
MEASURING EXHAUST COLOR
(Blank page)
20-105-2 4
TESTING AND ADJUSTING
MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR ¤ Be
careful not to touch any hot parts when removing or installing the measuring tools.
•
When measuring in the field where there is no air or electric power supply, use Handy Smoke Checker D1; when recording formal data, use Smoke Meter D2. fl Raise the coolant temperature to the operating range before measuring.
1. Measuring with Handy Smoke Checker D1 1) Install filter paper to Handy Smoke Checker D1. 2) Insert the exhaust gas suction port into the exhaust pipe, accelerate the engine suddenly, and operate the handle of Handy Smoke Checker D1 at the same time to collect the exhaust gas on the filter paper. 3) Remove the filter paper and compare it with the scale supplied to judge the condition. 2. Measuring with Smoke Meter D2 1) Insert the probe 1 of Smoke Meter D2 into the outlet port of the exhaust pipe, and tighten the clip to secure it to the exhaust pipe. 2) Connect the air hose and the socket of the probe hose and accelerator switch to Smoke Meter D2. fl Keep the pressure of the air supply below 1.5 MPa {15 kg/cm2}. 3) Connect the power cord to the AC100V socket. fl When connecting the cord, check that the power switch of Smoke Meter D2 is OFF. 4) Loosen the cap nut of the suction pump, and fit the filter paper. fl Fit the filter paper securely so that the exhaust gas cannot leak. 5) Turn the power switch of Smoke Meter D2 ON. 6) Accelerate the engine suddenly, and depress the accelerator pedal of Smoke Meter D2 at the same time to collect the exhaust gas color on the filter. 7) Place the filter paper used to catch the exhaust has color on top of at least 10 sheets of unused filter paper inside the filter paper holder, and read the value shown.
20-106 4
D155AX-5
TESTING AND ADJUSTING
ADJUSTING VALUE CLEARANCE
ADJUSTING VALVE CLEARANCE Serial No. 70001 – 75000 1. Remove the cylinder head cover. fl For details, see REMOVAL OF CYLINDER HEAD ASSEMBLY. 2. Rotating the crankshaft in the normal direction and watching the movement of the valve, align the 1.6 TOP line (2) on the crank pulley with pointer (1) to set the No. 1 cylinder to compression top dead center. fl When the No. 1 cylinder is at the compression top dead center, the rocker arms on both intake side and exhaust side can be moved with the hand. If the rocker arms cannot be moved, the cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn and align the 1.6 TOP line. fl Crank the engine with the hexagon shaft of the water pump pulley. 3.
When No. 1 cylinder is at the compression top dead center, adjust the valves marked ‡ in the table of locations of valves. Next, rotate crankshaft by 360° in the normal direction and adjust the valve clearance of the remaining valves marked fi.
4. To adjust the clearance, insert feeler gauge E between rocker arm (3) and crosshead (4), and adjust with adjustment screw (5), then secure it with locknut (6). 9 Locknut: 45.1 – 51.0Nm {4.6 – 5.2kgm} fl After adjusting the No. 1 cylinder at the compression top dead center, it is also possible to turn the crankshaft 120° each time and adjust the clearance of the valves of each cylinder according the firing order. • Firing order: 1-5-3-6-2-4 fl After tightening the locknut, check the clearance again.
D155AX-5
20-107 4
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
Serial No. 75001 and up 1. Remove cylinder head cover (1). fl See REMOVAL OF CYLINDER HEAD ASSEMBLY in DISASSEMBLY AND ASSEMBLY. 2. Rotate the crankshaft in the normaI direction to set No. 1 cyIinder at compression top dead center, and aIign pointer (2) with the [1.6] mark a on the damper. fl Crank the crankshaft with the hexagonaI portion at the tip of the water pump drive shaft. fl At compression top dead center, the vaIve rocker arm can be moved by hand by the amount of the vaIve clearance. If the rocker arm does not move, the crankskaft is not at compression dead center, so rotate it one more turn. 3. To adjust the valve clearance, insert the feeler gauge into clearance b between rocker arm (3) and crosshead (4), and adjust the valve clearance with adjustment screw (5). fl IInsert the feeler gauge and turn adjustment screw (5) until the clearance is a sliding fit. fl Valve clearance Intake valve: 0.35 mm Exhaust valve: 0.57 mm 4. Tighten locknut (6) to hold adjustment screw (5) in position. 3 Locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm} fl After tightening the locknut, check the clearance again. 5. Turn the crankshaft 120˚ each time in the normal direction and repeat the procedure in Step 2 to 4 to adjust the valves of each cylinder according to the firing order. fl Firing order: 1–5–3–6–2–4 6. After completing the measurement, set to the original condition. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
20-107-1 4
D155AX-5
TESTING AND ADJUSTING
D155AX-5
(Blank page)
20-107-2 4
TESTING AND ADJUSTING
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE Serial No. 70001 – 75000
¤ When measuring the compression pressure, be careful not to touch the exhaust manifold or any other hot parts or get caught in the fan belt or any other rotating parts. 1. Adjust the valve clearance. fl For details, see ADJUSTING VALVE CLEARANCE. 2. Warm up the engine so that the oil temperature is 40 – 60°C. 3. Remove the nozzle holder assembly from the cylinder to be measured. fl For details, see REMOVAL OF NOZZLE HOLDER ASSEMBLY. 4. Set multi-tachometer A. fl For details, see MEASURING ENGINE SPEED. 5. Install adapter 1 of compression gauge F to the nozzle holder mount, then connect to compression gauge F. 6. Set the fuel control lever to the STOP position. 7. Crank the engine with the starting motor and measure the compression pressure. fl Measure the compression pressure at the point where the pressure gauge indicator remains steady. fl When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range.
MEASURING COMPRESSION PRESSURE Serial No.: 75001 and up fl For the method of measuring the compression pressure, see the Engine Shop Manual for the 140-3 Series.
20-108 4
D155AX-5
TESTING AND ADJUSTING
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE Serial No. 70001 – 75000 fl Measure the blow-by pressure under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55°C 1. Install nozzle (1) of blow-by checker G to blowby hose 1. 2. Connect nozzle 1 to blow-by checker G. 3. Run the engine at high idling and stall the torque converter, and measure the gauge value at this time. fl For the procedure to stall the torque converter, see MEASURING TORQUE CONVERTER STALL SPEED. fl The normal blow-by pressure must be measured while the machine is operating at the rated output. An approximate value can be obtained in the field, however, by measuring when the torque converter stalls. fl If it is impossible to check at the rated output or at the torque converter stall speed, measure with the engine at high idling. In this case, the blow-by value will be about 80% of the value at the rated output. fl Blow-by varies greatly according to the condition of the engine. Therefore, if the blowby value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.
D155AX-5
20-109 4
TESTING AND ADJUSTING
MEASURING BLOW-BY PRESSURE
Serial No. 75001 and up fl Measure the blow-by pressure under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55°C 1. Remove blow-by tube (1). fl If a hose is connected to the end of the blow-by tube, it does not need to be removed since the blow-by pressure is measured at the end of that hose. 2. Install nozzle 1 of blow-by checker G, then connect it to the blow-by checker. 3. Run the engine at high idling and stall the torque converter, and measure the gauge value at this time. fl For the procedure to stall the torque converter, see MEASURING TORQUE CONVERTER STALL SPEED. fl The normal blow-by pressure must be measured while the machine is operating at the rated output. An approximate value can be obtained in the field, however, by measuring when the torque converter stalls. fl If it is impossible to check at the rated output or at the torque converter stall speed, measure with the engine at high idling. In this case, the blow-by value will be about 80% of the value at the rated output. fl Blow-by varies greatly according to the condition of the engine. Therefore, if the blowby value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.
20-109-1 4
D155AX-5
TESTING AND ADJUSTING
D155AX-5
MEASURING ENGINE OIL PRESSURE
(Blank page)
20-109-2
TESTING AND ADJUSTING
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE Serial No. 70001 – 75000 fl Measure the engine oil pressure under the following conditions. •
Coolant temperature: Within operating range
1. Remove engine oil pressure pickup plug (1) (PT1/ 8).
2. Install nipple 1of oil pressure gauge H1, then connect to oil pressure gauge H2 (0.98MPa {10kg/cm2}).
3. Start the engine, and measure the oil pressure with the engine at low idling and high idling.
20-110 4
D155AX-5
TESTING AND ADJUSTING
MEASURING ENGINE OIL PRESSURE
Serial No. 75001 and up fl Measure the engine oil pressure under the following condition. • Engine water temperature: Within operating range 1. Remove oil pressure low-pressure switch (1) or oil pressure high-pressure switch (2). fl Wrap the wiring harness of the disconnected switch with tape to prevent it from touching the cylinder block.
2. Install nipple 1 of oil pressure gauge H1 and connect it to the oil pressure gauge H2 (0.98 MPa {10 kg/cm2}). 3. Start the engine and measure the oil pressure when the engine is running at low idling and high idling. 4. After completing the measurement, remove the measurement equipment and set to the original condition. 3 Oil pressure switch: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
D155AX-5
20-110-1 4
TESTING AND ADJUSTING
20-110-2
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TESTING AND ADJUSTING FUEL INJECTION TIMING
D155AX-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING Serial No. 70001 – 75000 Testing 1. Rotate the crankshaft in the normal direction and align 15° line (2) on the crankshaft pulley with pointer (1). fl At this time, check that line (3) on the coupling is near line (4) on the injection pump body. If line (3) on the coupling is not seen, rotate the crankshaft one more turn. fl Crank the engine with the hexagon shaft of the water pump pulley. 2. Remove the lock pin of timing pin (5) and push in the pin to fix the injection pump drive gear. fl If the pin does not go in, turn the crankshaft forward or backward a little. 3. Under this condition, check that coupling line (3) is aligned with injection pump line (4). Adjusting fl If the fuel injection timing is not correct, adjust it according to the following procedure. 1. Loosen the two sets of mounting bolt and nut (6) in the oblong holes of the coupling and set bolt (7) to set the coupling free. 2. Turn the coupling to align coupling line (3) with injection pump line (4). 3. Tighten set bolt (7) and the two sets of mounting bolt and nut (6). 9 Set bolt: 83.8 – 93.1Nm {8.5 – 9.5kgm} Mounting bolt and nut: 58.5 – 63.7Nm {6.0 – 6.5kgm} 4. Pull out the pin of timing pin (5) and secure with the lock pin. fl If the injection pump drive system (crank gear injection pump shaft) is disassembled and assembled without removing the engine from the machine body, the injection timing must be adjusted accurately from the piston stroke. In this case, see the Engine Shop Manual. Serial No. 75001 and up fl Since the match mark on the timing gear case is matched to the key way of the supply pump drive shaft, ADJUSTMENT OF FUEL INJECTION TIMMING is not necessary.
D155AX-5
20-111 4
TESTING AND ADJUSTING
HANDLING EQUIPMENT IN FUEL CIRCUIT RELEASING REMAINING PRESSURE IN FUEL SYSTEM
HANDLING EQUIPMENT IN FUEL CIRCUIT
RELEASING REMAINING PRESSURE IN FUEL SYSTEM
Serial No. 75001 and up
Serial No. 75001 and up
fl Precaution for inspection and maintenance of fuel system With the common rail type fuel injection system, more precise equipment is used than with the conventional fuel injection pump and nozzle, so problems may occur if dirt or dust get in. When carrying out installation and maintenance of the fuel system, pay more attention than usual to prevent dirt or dust from getting in. If there is any dirt stuck to any part, use clean fuel to wash it off completely. fl Precautions when replacing fuel filter cartrige Always use a genuine Komatsu part for the fuel filter cartrige. With the common rail type fuel injection system, mpre precise equipment is used than with the conventional fuel injection pump and nozzle, so a special filter with high efficiency filtering ability is used to prevent dirt or dust from getting in. For this reason, if any filter is used as a substitute for the genuine filter, there is danger that problems will occur with the fuel system. To prevent this, never use such filters.
fl When the engine is running, pressure is generated in both the low-pressure circuit and hifg-pressure circuit of the fuel line. Low-pressure circuit: Feed pump – fuel filter – fuel supply pump High-pressure circuit: Fuel supply pump – common rail – fuel injector fl For both the low-pressure circuit and highpressure circuit, the pressure automatically goes down to a safe level 30 seconds after the engine is stopped. fl The ramaining pressure in the fuel system must be completely released before carrying out inspection of the fuel system or removal or installation of the equipment. Always follow the following precautions when carrying out the operation. ¤ When inspecting the fuel line or removing or installing equipment, wait for at least 30 seconds after the engine is stopped to release the remaining pressure in the fuel system before starting the operation. (There is still pressure remaining in the circuit, so do not start operations immediately after the engine is stopped).
20-111-1 4
D155AX-5
TESTING AND ADJUSTING
MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE Serial No. 75001 and up fl Measure the fuel pressure only for the low-pressure circuit between the feed pump – fuel filter – fuel supply pump. ¤ The high-pressure circuit between the fuel supply pump – common rail – fuel injector is under extremely high pressure, so it cannot be measured. 1. Remove fuel pressure measurement plug (1). 2. Fit nipple 1 of pressure test kit A,then connect to the pressure test kit. 3. Start the engine and measure the fuel pressure at high idling. 4. After completing the measurement, remove the measurement equipment and set to the original condition.
D155AX-5
20-111-2
TESTING AND ADJUSTING
REDUCED CYLINDER MODE OPERATION
REDUCED CYLINDER MODE OPERATION Serial No.: 75001 and up fl 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 (or, combustion in it is abnormal). (For details, see the Engine Shop Manual for the 140-3 Series, too.) fl Perform the reduced cylinder mode operation by using the setting functions of the "reduced cylinder mode" of the monitor panel. For details of the functions of the monitor panel, see DISPLAY AND FUNCTIONS OF MONITOR PANEL in TROUBLESHOOTING. 1. Selecting of reduced cylinder mode 1) Remove cover (1). 2) Turn service switch (2) ON. fl The service switch is installed inside the cover. 3) Turn and hold buzzer cancel switch (3) to the right for at least 7 seconds to display the service mode in upper display unit (4). 4) Turn up mode selector switch (5) to display the adjustment mode. fl The mode selector switch is installed inside the cover. fl Each time the mode selector switch is turned up, the mode changes. fl If the adjustment mode is selected, round marks (6) on the right and left sides light up. 5) Turn buzzer cancel switch (3) to the right to display reduced cylinder mode "E0". 2. Method of performing reduced cylinder mode operation 1) After adjustment mode "E0" is displayed in gear speed display unit (4), turn buzzer cancel switch (3) to the left to select an injector to be disabled. fl The flashing bit display unit indicates each injector No. 1: No. 1 injector 2: No. 2 injector 3: No. 3 injector 4: No. 4 injector
20-111-3 4
D155AX-5
TESTING AND ADJUSTING
2)
3)
4) 5)
REDUCED CYLINDER MODE OPERATION
5: No. 5 injector 6: No. 6 injector fl The injectors are selected in the order of 1 → 2 • • • • 6 → 1. After selecting 1 or more injectors to be disabled with buzzer cancel switch (3), turn down mode selector switch (5). fl The flashing speed rises and the selected injector(s) is (are) disabled and the bit display unit goes off. To reset (operate) the disabled injector(s), turn down mode selector switch (5) again. fl The flashing speed becomes normal and the selected injector(s) start(s) operating again. fl If the system goes out of this mode, the reduced cylinder mode operation is reset. Turn OFF service switch (2). Install cover (1).
D155AX-5
20-111-4 4
BLEEDING AIR FROM FUEL SYSTEM
TESTING AND ADJUSTING
BLEEDING AIR FROM FUEL SYSTEM Serial No. 75001 and up
fl Bleed the air as follows if the engine has run out of fuel or the fuel circuit equipment has been removed and installed. 1. Remove fuel filter (1), fill with fuel, then install again. fl When filling, use clean fuel and be careful not to let dirt get in. fl If clean fuel is not available, do not remove the filter. Operate the priming pump to fill the inside of the filter with fuel. 2. Remove air bleed plug (2) of the fuel filter and operate priming pump (3). fl Continue operating the priming pump until fuel flows out from the pump hole. When fuel comes out, install the plug. 3 Air bleed plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
20-111-5 4
3. Loosen air bleeder (4) of the fuel supply pump and operate priming pump (3) 90 – 100 times. fl Operate the priming pump until fuel flows out from the bleeder. When the fuel flows out, tighten the bleeder, then operate the priming pump several times until the pump becomes stiff. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm} 4. Crank the engine with the starting motor and start the engine. fl When the high-pressure circuit is cranked with the engine, the air is automatically bled. fl If the engine does not start, the air has probably not properly bled from the lowpressure circuit, so repeat the procedure from Step 2.
D155AX-5
TESTING AND ADJUSTING
CHECK FOR LEAKAGE IN FUEL SYSTEM
CHECK FOR LEAKAGE IN FUEL SYSTEM Serial No. 75001 and up
¤ With
the fuel system, the high-pressure circuit is under extremely high pressure, so if fuel leaks when the engine is running, there is danger of fire. Check for fuel leakage as follows when checking the fuel circuit or when equipment has been removed and installed. fl To make it easier to check for fuel leakage, wipe the engine itself and the surrounding area clean and remove all oil and grease before starting the inspection.
9. Check the fuel piping and equipment for fuel leakage. fl Check the high-pressure circuit for fuel leskage, particularly at the places sprayed with color checker. fl If there is fuel leakage, carry out repairs, then repeat the check from Step 2. fl If no fuel leakage is found, the check is complete.
1. Spray the fuel supply pump, common rail, fuel injector, and high-pressure piping connections witha color checker (developing solution). 2. Start the engine, run it at under 1000 rpm, and when the speed stabilizes, stop the engine. 3. Check the fuel piping and equipment for fuel leakage. fl Check the high-pressure circuit for fuel leskage, particularly at the places sprayed with color checker. fl If there is fuel leakage, carry out repairs, then repeat the check from Step 2. 4. Start the engine and run it as low idling. 5. Check the fuel piping and equipment for fuel leakage. fl Check the high-pressure circuit for fuel leakage, paticularly at the places sprayed with color checker. fl If there is fuel leakage, carry out repairs, then repeat the check from Step 2. 6. Start the engine and run it at high idling. 7. Check the fuel piping and equipment for fuel leakage. fl Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. fl If there is fuel leakage, carry out repairs, then repeat the check from Step 2. 8. Start the engine, run it at high idling, then apply load to the engine. fl If this inspection is carried out with the engine mounted on the machine, stall the torque converter or relieve the hydraulic pump.
D155AX-5
20-111-6 4
TESTING AND ADJUSTING
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION Serial No. 70001 – 75000 Testing • Measure deflection a of the belt when it is pushed with a finger force of approx. 58.8 N {approx. 6 kg} at a point midway between the alternator pulley and the water pump pulley. Deflection a of V-belt: approx. 15 mm
Adjusting fl If the deflection of the belt is not normal, adjust it according to the following procedure. 1. Loosen mounting bolt and nut (1), mounting bolt (2) and locknut (3).
2. Turn the adjustment nut and shift alternator (4) to adjust the belt tension.
3. Tighten locknut (3), mounting bolt (2), and mounting bolt and nut (1).
Serial No. 75001 and up 1. Inspecting Measure deflection a when the belt is pressed with a finger at a point midway between the alternator pully and drive pully. fl Pushing force: Approx. 98 Nm {approx. 10 kg} fl Deflection (one belt): 13 – 16 mm 2. Adjusting fl This makes a clearance of 0.75 – 1.00 mm between the tip of the sensor and the tip of the gear tooth. fl If the deflection is not within the specified range, adjust as follows. 1) Loosen 2 mounting bolts of alternator (1) and 1 lock bolt of the bar. 2) Loosen locknut (2), move alternator (1) with adjustment nut (3), adjust the tension of belt (4). fl Deflection (one belt): 13 – 16 mm
20-112 4
D155AX-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
3) Tighten locknut (2). 4) Tighten 2 mounting bolts of alternator (1) and 1 lock bolt of the bar. fl After adjusting, check the belt tension again.
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION Testing • Measure deflection a of the belt when it is pushed with a finger force of approx. 58.8 N {approx. 6 kg} at a point midway between the fan pulley and tension pulley. Deflection a of V-belt: approx. 10 mm
Adjusting fl If the deflection of the belt is not normal, adjust it according to the following procedure. 1. Loosen four mounting bolts (4) and locknut (2). 2. Turn adjustment bolt (3) and shift air conditioner compressor assembly (4) to adjust the belt tension. 3. Tighten locknut (2) and four mounting bolts (1).
D155AX-5
20-112-1 4
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUN BELT TENSION
TESTING AND ADJUSTING FUN BELT TENSION Serial No. 75001 and up
1. Inspection With the semi auto tension type, there is no need to inspect untill the belt is replaced. 2. Adjusting 1) Install 2 belts (1). fl Loosen the stopper bolt when installing the belts. 2) Tighten stopper bolt (2) until it contacts bracket (3). 3) Tighten stopper bolt (2) a futher 2 turns and hold in position with locknut (4). 3 Locknut: 245.0 – 308.7 Nm {35.0 – 31.5 kgm}
20-112-2 4
D155AX-5
TESTING AND ADJUSTING
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR 1. Screw in sensor unit (1) until its end comes in contact with ring gear (2). fl Take care that sensor end will be free from steel chips and will not be damaged. 8 Threads of sensor: Gasket sealant (LG-6) 2. Unscrew sensor unit (1) by 1/2 – 2/3 turns from the position where it comes in contact with ring gear (2) to adjust clearance a. • Clearance a: 0.75 – 1.0mm
3. Tighten locknut (3). 9 Locknut: 69 – 74Nm {7.0 – 7.5kgm} fl Install the sensor wiring carefully so that an excessive force will not be applied to it.
D155AX-5
20-113
TESTING AND ADJUSTING
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT Serial No. 75001 and up
¤ With the controller, a high voltage circuit (110 – 130V) is used for the fuel injector drive.As a result, a high voltage circuit is connected to the wiring harness and connector from the controller to the fuel injector. fl Normally, high voltage is output from the controller to the fuel injector only when the engine is running. When the engine is stopped, the output stops. ¤ If the high voltage circuit is touched directly, there is danger of electrocution, so observe the following precautions when carrying out inspection. 1. The connectors, including these for the high voltage circuit, are as follows. • Controller connector: CN6, CN7 • Intermediate connector: CN-E31, CN-E32, CNE33, CN-E34, CN-E35, CN-E36 • Injector connector: IJ1, IJ2, IJ3, IJ4, IJ5, IJ6 • Terminal at head of injector (inside head cover) 2. When disconnecting or connecting the applicable connector, always turn the starting switch OFF before starting. 3. When a T-adapter has been inserted or connected to the applicable connector to carry out troubleshooting, never start the engine. fl If the starting switch is operated, operate it only to OFF or ON. Never turn it to the START position.
20-113-1 4
D155AX-5
TESTING AND ADJUSTING
D155AX-5
MEASURING EXHAUST COLOR
(Blank page)
20-113-2 4
TESTING AND ADJUSTING
ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL Serial No. 70001 – 75000
20-114 4
D155AX-5
TESTING AND ADJUSTING
ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL
Serial No. 75001 and up
1. Outline of fuel control system • The speed signals from the fuel control dial and the decelerstor pedal potensiometers are each input to the engine controller. The engine controller gives priority to the lower speed of the two input signals and sends a command to the fuel injection pump. • Adjustment of the engine speed is all carried out by the deceletator pedal linkage. 2. Preparatory work 1) Turn the starting switch on and the monitor panel to monitoring code [99]. fl For details, see MEASURING ENGINE SPEED. 2) Start the engine, set the fuel control dial to the FULL position, and check that the engine speed is at least 1000 rpm. fl If the engine speed is below 1000 rpm,adjust by extending installation dimension a of rod (1) to make the engine speed more than 1000 rpm.
D155AX-5
20-115 4
TESTING AND ADJUSTING
ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL
3. Adjusting decelerator pedal speed Set the fuel control dial at the high idling position, depress decelerator pedal (2) until it contact the stopper, and check that the decelerator pedal speed is normal. • Decelerator pedal speed: 850 ± 50 rpm fl If the engine speed is not correct, adjust installation dimention a of rod (1). • Installation dimention a: 122 mm 4. Adjusting high idling speed Set the fuel control dial to the high idling position and check that the high idling speed is corect. • High idling speed: 2,050 rpm fl If engine speed is too low: Adjust the high idling speed with stopper bolt (3).
20-116 4
D155AX-5
TESTING AND ADJUSTING
MEASURING TORQUE CONVERTER STALL SPEED
MEASURING TORQUE CONVERTER STALL SPEED Serial No. 70001 – 75000
¤ When
measuring, secure the safety around the machine. fl Measure the torque converter stall speed under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55°C 1. Install multi-tachometer A. fl For details, see MEASURING ENGINE SPEED. 2. Start and run the engine at low idling. 3. Depress the brake pedal securely and set the joystick to the third speed and set the directional lever to the forward position. 4. Depress the decelerator pedal and set the fuel control lever to the high idling position. 5. Release the decelerator pedal slowly and stall the torque converter with the engine at high idling. ¤ Depress the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
A
TLD00010
6. If the transmission oil thermometer indicates the red range, return the joystick immediately to the neutral position. 7. Repeat above steps 3 through 6 three times. 8. Perform steps 3 through 5 again, and measure the engine speed just when the transmission oil thermometer indicates the red range. fl After finishing the measurement, return the joystick to the neutral position immediately, then lower the transmission oil temperature with the engine at high idling.
D155AX-5
20-117 4
TESTING AND ADJUSTING
MEASURING TORQUE CONVERTER STALL SPEED
Serial No. 75001 and up
¤ Make sure that the area around the machine is safe before starting the operation. fl Measure the torque converter stall speed under the following conditions. • Coolant temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55˚C 1. Turn the starting switch ON and set the monitor panel to monitoring code [99]. fl For details, see MEASURING ENGINE SPEED. 2. Start the engine and set the fuel control dial to low idling. 3. Depress the brake pedal firmly, move the full monolever to 3 and the directional lever to F. 4. Depress the decelerator pedal and set the fuel control dial to high idling. 5. Let the decelerator pedal back slowly, run the engine at high idling, and stall the torque converter. ¤ Depress the brake pedal firmly during operation. For safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation. 6. When the power train oil temperature gauge enters the red gauge, immediately return the full monolever to neutral. 7. Repeat Steps 3 – 6 three times. 8. Repeat Steps 3 – 5 again and measure the engine speed immedeately the power train oil temperature gauge enters the red range. fl After completion of the measurement, return the full monolever swiftly to neutral, and run the engine at high idling to lower the power train oil temperature.
20-117-1 4
D155AX-5
TESTING AND ADJUSTING
D155AX-5
MEASURING ENGINE OIL PRESSURE
(Blank page)
20-117-2
TESTING AND ADJUSTING
MEASURING FULL STALL SPEED
MEASURING FULL STALL SPEED Serial No. 70001 – 75000
¤ When measuring, secure the safety around the machine.
A
fl Measure the full stall speed under the following conditions. • Coolant temperature: Within operating range • Transmission oil temperature: Within operating range • Hydraulic temperature: 45 – 55°C 1. Install multi-tachometer A. fl For details, see MEASURING ENGINE SPEED. 2. Start and run the engine at low idling. Raise the ripper lift cylinder to the stroke end. 3. Depress the brake pedal securely and set the joystick to the third speed and set the directional lever to the forward position. 4. Depress the decelerator pedal and set the fuel control lever to the high idling position. 5. Release the decelerator pedal slowly and stall the torque converter with the engine at high idling. ¤ Depress the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
TLD00010
6. If the transmission oil thermometer indicates the red range, return the joystick immediately to the neutral position. 7. Repeat above steps 3 through 6 three times. 8. Perform steps 3 through 5 again and raise the ripper to relieve its cylinder, and measure the engine speed just when the transmission oil thermometer indicates the red range. fl After finishing the measurement, return the joystick to the neutral position immediately, then lower the transmission oil temperature with the engine at high idling.
20-118 4
D155AX-5
TESTING AND ADJUSTING
MEASURING FULL STALL SPEED
Serial No. 75001 and up
¤ When measuring, confirm the safety around the machine. fl Measure the torque converter stall speed under the following condition. • Engine water temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55˚C 1. Turn on the starting switch and set the monitor panel to monitoring code "99". fl See MEASURING ENGINE SPEED. 2. Start the engine and set the fuel control dial in the low idling position and raise the ripper lift cylinder to the stroke end. 3. Press the brake pedal securely and set the joystick to the 3rd gear speed in the forward direction. 4. Press the decelerator pedal and set the fuel control dial in the high idling position. 5. Return the decelerator pedal slowly to stall the torque converter at high idling. ¤ Press 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 reads the red range, return the joystick into neutral. 7. Repeat above steps 3 – 6 3 times. 8. Perform above steps 3 – 5 again and relieve the ripper by raising it or relieve blade by pitching it back and measure the engine speed just when the power train oil temperature gauge reads the red range. fl After finishing measurement, return the joystick into neutral immediately and lower the power train oil temperature at high idling.
D155AX-5
20-118-1 4
TESTING
MEASURING
A *
MEASURING
AND ADJUSTING
POWER TRAIN OIL PRESSURE
Stop the machine on level ground and lower the work equipment completely to the ground, then set the parking brake lever and safety lever to the respective lock positions. Measure the power train oil pressure under the following condition. Transmission oil temperature: Within operating range l
1.
Table of locations of centralized pressure pickup points for measuring oil pressure and gauges to use No.
Measured oil pressure
1
Transmission main relief pressure
2
Torque converter
inlet pressure
3
Torque
outlet
4
Transmission
converter
modulating
0&$rn2)) 5.9 1601
.
pressure pressure
. *
To use the centralized pressure left-hand the step cover.
2.
Measuring
torque
converter
pickups, remove
inlet pressure
1) Connect
oil pressure gauge H2 (0.98MPa {10kg/cm21) to oil pressure measuring nipple
(2).
2) Start the engine and set the joystick to the neutral position. The transmission * speed. 3)
may be set to any gear
Measure the oil pressure with the engine low idling and high idling.
D155AX-5
at
POWER TRAIN
OIL PRESSURE
3.
3)
OIL PRESSURE
(3). Start the engine and set the joystick to the neutral position. may be set to any gear The transmission * speed. Measure the oil pressure with the engine at low idling and high idling.
main relief pressure Measuring transmission pickup plug (I) (IO x pressure oil I) Remove 1.25). 2) Install nipple @ of oil pressure gauge HI and connect oil pres(5.9MPa {60kg/cm*I), sure gauge HI. 3) Start the engine and set the joystick to the neutral position. may be set to any gear The transmission * 4)
5.
POWER TRAIN
Measuring torque converter outlet pressure I) Connect oil pressure gauge H2 (0.98MPa (lOkg/cm*I) to oil pressure measuring nipple 2)
4.
MEASURING
AND ADJUSTING
TESTING
speed. Measure the main relief engine at high idling.
pressure
with the
pressure modulation Measuring transmission gauge Hi (5.9MPa oil pressure I) Connect {60kg/cm?) to oil pressure pickup nipple (4). 2) Start the engine. 3) Operate the joystick as below with the engine at low idling and high idling, and measpressure at this time. ure the modulation the torque converter is stalled by ASince steps iv) - VI, depress the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. * Keep the steering wheel at the neutral position. Shift the gear to the first speed and the directional lever to the neutral position, and measure the oil pressure. ii) Shift the gear to the second speed and the directional lever to the neutral position, and measure the oil pressure. iii) Shift the gear to the third speed and the directional lever to the neutral position, and measure the oil pressure.
i)
zo- 120
D 155AX-5
TESTING
AND ADJUSTING
MEASURING
POWER TRAIN
OIL PRESSURE
iv) Shift the gear to the third speed and the directional lever to the forward position, and measure the oil pressure. VI Shift the gear to the third speed and the directional lever to the reverse position, and measure the oil pressure.
6.
Measuring brake oil pressure 1) Connect oil pressure gauge HI (5.9MPa {60kg/cm21) to oil pressure pickup nipple (5). 2) Start the engine and set the joystick to the neutral position. The transmission may be set to any gear * speed. 3) Run the engine at low or high idling and operate the parking brake lever and brake pedal as below, and measure the brake oil pressure. i) Set the parking brake lever to the free position and depress the brake pedal. ii) Set the parking brake lever to the lock position and release the brake pedal.
D155AX-5
20-121
TESTING
AND ADJUSTING
TESTING
AND ADJUSTING
HSS MAIN
OIL PRESSURE
1. Loosen locknut (5). 2. Adjust by turning adjustment screw (6). * Turn the adjustment screw as follows. l To INCREASE pressure, turn CLOCKWISE. l To DECREASE pressure, turn COUNTERCLOCKWISE. Ir Amount of adjustment for one turn of adjustment screw: 13.7MPa {140kg/cm2) w Locknut: 29 - 39Nm I3 - 4kgml *
After completion pressure again shown above.
D 155AX-5
of adjustment, check the oil according to the procedure
II
I
BVD00496
20-123
TESTING AND ADJUSTING
TESTING AND ADJUSTING
TESTING
AND ADJUSTING
HSS CHARGE OIL PRESSURE
HSS CHARGE OIL PRESSURE
Measuring
Stop the A the work
machine on level ground and lower equipment completely to the ground, then set the parking brake lever and safety lever to the respective lock positions.
*
Measure the HSS charge oil pressure under the following condition. . Hydraulic oil temperature: 45 - 55°C
1. Remove
the floor inspection
2.
Remove
oil pressure
3.
Install nipple @ of oil pressure gauge HI (5.9MPa {60kg/cm21), and connect oil pressure gauge HI.
4.
Start the engine and set the joystick and work equipment control lever to the respective neutral positions.
5.
Measure the HSS charge engine at high idling.
cover.
pickup plug (I) (PT1/8).
oil pressure
with the
Adjusting + If the HSS charge
oil pressure is not normal, check that the HSS servo-charge pressure and PPC relief pressure are normal, then adjust HSS charge relief valve (2) according to the following procedure. (The main pressure of the HSS charge oil pressure is the pressure reduced once by the HSS servo-charge pressure and PPC relief circuit.
ZO-124
D155AX-5
TESTING
1. 2.
Loosen locknut (3). Adjust by turning adjustment *
Ir m *
TESTING
AND ADJUSTING
screw (4).
Turn the adjustment screw as follows. l To INCREASE pressure, turn CLOCKWISE. l To DECREASE pressure, turn COUNTERCLOCKWISE. Amount of adjustment for one turn of adjustment screw: 1.55MPa {I 5.8kg/cm21 Locknut: 58.8 - 78.5Nm (6 - 8kgm}
AND ADJUSTING
\
HSS CHARGE
\
n
OIL PRESSURE
I3
BVD00500
After completion of adjustment, check the oil pressure again according to the procedure shown above.
D155AX-5
ZO-125
TESTING TESTING
AND ADJUSTING
HSS SERVO CHARGE AND ADJUSTING PRESSURE AND PPC RELIEF PRESSURE
TESTING AND ADJUSTING HSS SERVO CHARGE PRESSURE AND PPC RELIEF PRESSURE Measuring the machine on level ground and lower completely to the ground, the work equipment then set the parking brake lever and safety lever to the respective lock positions.
Astop
*
Measure the HSS servo charge pressure and condiPPC relief pressure under the following tion. . 45 - 55°C Hydraulic oil temperature:
1. Remove
the control oil pressure
valve cover. pickup plug (I) (PT1/8).
2.
Remove
3.
Install nipple @ of oil pressure gauge HI (5.9MPa {60kg/cm*)), and connect oil pressure gauge HI.
4.
Start the engine and set the joystick and work control lever to the respective neuequipment tral positions.
5.
Measure the HSS servo charge oil pressure and PPC relief pressure with the engine at high idling.
Adjusting If the HSS servo charge oil pressure and PPC * relief pressure are not normal, adjust HSS servo charge valve/PPC relief valve (2) according to the following procedure.
20-126
D155AX-5
TESTING TESTING
AND ADJUSTING
HSS SERVO CHARGE AND ADJUSTING PRESSURE AND PPC RELIEF PRESSURE
1. Remove plug (3) and springs (4) and (5). 2. Adjust by increasing or decreasing the number of adjustment shims (6). Increase or decrease the number of the ad* justment shims as follows. . INCREASE pressure, To INCREASE number of adjustment shims. DECREASE pressure, To DECREASE number of adjustment shims. Ir Amount of adjustment for one shim: 0.04MPa 10.4kg/cm21 Plug: 58.8 - 78.4Nm 16 - 8kgml m l
*
After completion again pressure shown above.
D 155AX-5
check the oil of adjustment, to the procedure according
ZO-127
TESTING AND ADJUSTING
BLEDDING AIR FROM HSS PUMP
BLEDDING AIR FROM HSS PUMP * *
Hydraulic oil temperature: 45 - 55°C Check that the hydraulic oil is at the specified level. * When the HSS pump have been removed or replaced, or when the hydraulic piping has been removed, always bleed the air as follows: 1. Loosen air bleed plug (bleeder) (I) at the top of the HSS pump. 2. Wait for 15 minutes, then start the engine and run it at idling. 3. When oil comes out from the air bleed plug hole, tighten the air bleed plug.
20-128
D155AX-5
TESTING AND ADJUSTING
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE
SIMPLE PROCEDURE FOR TESTING Ir
BRAKE PERFORMANCE
Carry out the simple procedure for testing brake under the following condition. performance . Within operoil temperature: Transmission ating range
1. Stop the machine on a level surface and set the blade and ripper to the travel posture. 2. Turn joystick to F2. Never carry out this test in Fl. If this test is carried out in Fl, an excessive load will be brought to bear on the brake. 3. Depress the brake pedal securely at low idling, turn joystick to FORWARD. Ir Keep steering on N. 4. Depress the decelerator pedal and pull the fuel control lever to FULL position. 5. Release the decelerator pedal gradually to raise the engine speed to the full throttle. Check that the machine does not start to move. Because this test is carried out under torque converter stall, depress the decelerator pedal securely during the test and keep right foot on the decelerator pedal until the end of the test for safety.
A
TAD00135
A
D155AX-5
ZO-129
TESTING AND ADJUSTING
ADJUSTING
ADJUSTING
JOYSTICK AND PARKING LEVER
JOYSTICK AND PARKING LEVER
.23
20- 130
D155AX-5
TESTING
AND ADJUSTING
Tighten the locknuts of the rods and cables 03securely, and bend the cotter pins securely. 1.
Adjusting directional lever of joystick I) Remove lever knob (I) and boot (2). 21 Set parking brake lever (3) to the lock position, then set the direction of joystick (4) to the neutral position. Ir If parking brake lever (3) is not installed, raise lever (5) with a screwdriver, etc. toward the lock side (upper side). 3) Adjust. distance a between the pins of rod (6), and connect the rod to joystick (4) and directional lever (7). . Distance a between pins: 68mm the 4) Adjust fitting distance b between center of the end of joystick (4) and the center of the front mounting bolt of the lever box with rod (6). . Fitting distance b: 54 + Imm 5) Set directional lever (8) on the transmission side to the neutral (N) position. 6) Connect cable (9) to directional lever (7) on the lever stand side and directional lever (8) on the transmission side. 7) install boot (2) and lever knob (IL
2.
Adjusting gear speed of joystick 1) Adjust distance c between the pins of rod (IO), and connect the rod to joystick (4) and gear speed lever (II). . Distance c between pins: 93.5mm 2) Set gear speed lever (12) on the transmission side to the first speed. 3) Connect cable (13) to gear speed lever (11) on the lever stand side and gear speed lever (12) on the transmission side.
3.
Adjusting steering system of joystick 1) Adjust distance d between the pins of rod (14), and connect the rod to intermediate lever (15) and potentiometer (16). . Distance d between pins: 92mm 2) Adjust distance e between the pins of rod (17), and connect the rod to joystick (4) and intermediate lever (15). . Distance e between pins: 365mm 3) Adjust rod (17) so that distance f between the center of joystick (4) and left end of handle (18) will be normal. . Distance f: 94mm * When adjusting rod (171, set the steering direction to the neutral.
D155Ax-5
ADJUSTING
4.
JOYSTICK
AND
PARKING
LEVER
General check I) Install the armrest cover and armrest. 2) Turn the joystick to the forward side and check that the clearance between the end of joystick (4) and handle (18) is 50mm. 3) Change the gear speed and check that it is indicated correctly by the gear speed indicator. * If the gear speed is not indicated correctly, adjust it with the turnbuckle at the top of cable (9). 4) Check that the steering stroke is 63 + 15mm on each side. If the machine is equipped with the op5) erator’s cab, operate the joystick to the forward and left steering end, and the clearance between the end of joystick (4) and operator’s cab is about 70mm. * Check that your hand does not touch the operator’s cab.
20-l 31
TESTING AND ADJUSTING
4.
ADJUSTING
JOYSTICK AND PARKING LEVER
Adjusting parking brake lever
1) Adjust distance g between
the pins of rod (191, and connect the rod to parking brake lever (3) and intermediate lever (20). . Distance between rod pins: 105mm 2) Adjust distance h between the pins of rod (211, and connect the rod to intermediate lever (20) and lock (5). . Distance h between rod pins: 91.5mm 3) Set parking brake lever (3) to the free position, and adjust height j of the floor frame above the end of parking brake lever to the following value with stopper (21). . Lever height j: 424mm 4) Set parking brake lever (3) to the free position. 5) Connect cable 22 to lever (23) and brake valve lever (24). 6) Set parking brake lever (3) to the lock position, and adjust cable (23) so that brake valve lever (24) will be at the stroke end. * Take care not to pull brake valve lever (24) more than the stroke end. 7) Operate parking brake lever (3) to the free position and lock position, and check that joystick (4) is reset and locked at the respective positions. 8) Set parking brake lever (3) to the lock position. 9) Adjust so that neutral safety switch (25) will be pushed in and turned on. . Push-in stroke: 2.8mm
20-132
D155AX-5
TESTING TESTING
AND ADJUSTING
TESTING AND ADJUSTING POTENTIOMETER
AND ADJUSTING
TRAVEL
REVERSE SENSING POTENTIOMETER
TRAVEL REVERSE SENSING
-__-__-________ -__-__-__-________
BVDOO521
Testing 1. Insert a T-branch in CN-RSS connector (1) of the travel reverse sensing potentiometer. 2. Turn on the starting switch and set the direction of the joystick to the neutral position. 3. Check that the output voltage between pins @ and @ of CN-RSS connector (I) is in the following range. . Output voltage: 4.2 f 0.2V Adjusting adjust the linkage * If the voltage is abnormal, according to the following procedure. 1. insert a T-branch in CN-RSS connector (I) of the travel reverse sensing potentiometer. 2. Turn on the starting switch and set the direction of the joystick to the reverse position. 3. Loosen two locknuts (3) of rod (2), and adjust the length of rod (2) so that the output voltage will be in the above range. . amount: 2.5 mm per 1 turn of Adjustment
. *
rod. Standard dimension between 2 pins of rod ends: 168 mm check voltage again by After adjustment, procedure mentioned above.
D155AX-5
20-133
TESTING
AND ADJUSTING
ADJUSTING
ADJUSTING
TRAVEL
REVERSE
LIMIT SWITCH
TRAVEL REVERSE LIMIT SWITCH
BvDoo523
*
If the travel reverse limit switch is removed, installed or replaced, adjust its fitting position according to the following procedure.
1.
Set directional lever (I) of the transmission valve to the reverse (R) position. Pressing limit switch (2) against lever (I), secure it to bracket (3). l Stroke a to operate switch: 1.8mm (Max.) l Stroke b from operating point of switch to stopper: 3.0mm (Min.) Under this condition, turn on the starting switch and check that the backup buzzer sounds normally.
2.
3.
20- 134
D155AX-5
TESTING AND ADJUSTING
ADJUSTING STEERING NEUTRAL POSITION
ADJUSTING STEERING NEUTRAL POSITION fl The figure shows for serial No. 70001 – 75000.
D155AX-5
20-135 4
TESTING AND ADJUSTING
ADJUSTING STEERING NEUTRAL POSITION
Serial No. 70001 – 75000 fl If the HSS pump or HSS controller is replaced, adjust the neutral position of the steering system according to the following procedure. Principle of adjustment of neutral position of steering system • If the neutral position of the steering system is not adjusted, even if the joystick is at the neutral position, the HSS pump discharges oil slightly to either PA or PB because of dispersion of the minimum swash plate angle of the HSS pump. • If the HSS pump discharges oil, the HSS motor rotates to change the speed of the track shoes on both sides. Accordingly, the machine may start or may deviate slightly while traveling straight even if the lever is at the neutral position. • To prevent the HSS pump from discharging oil while the lever is at the neutral position, the HSS controller controls the current. • The oil discharging condition of the HSS pump is judged by the differential pressure between two pressure sensors. If the HSS pump discharges a large quantity of oil, the differential pressure becomes large. If the former does not discharge oil at all, the latter becomes 0. • The HSS controller controls the current so that the differential pressure will be kept below 0.98MPa {10kg/cm2} to minimize the discharge from the HSS pump when the lever is at the neutral position. 1. Preparation work Lift up the machine body to raise the track shoes above the ground by using the blade and ripper. ¤ Set the parking brake lever to the lock position so that the track shoes will not turn while lifting up the machine body. ¤ If the machine body cannot be lifted up, the work may be performed without lifting it up. In this case, if the engine starts, the machine starts a spin-turn slowly. Secure the safety around the machine. fl After lifting up the machine body, stop the engine. 2. Setting machine to adjustment mode 1) Remove controller cover (1).
20-136 4
D155AX-5
TESTING
AND ADJUSTING
POSITION
NEUTRAL
STEERING
ADJUSTING
2) Turn the steering neutral position adjustment 3)
3.
4.
switch (2) to the AJUST position. Pressing and holding buzzer cancel switch (3) on the monitor panel, turn on the startKeep pressing buzzer cancel ing switch. switch (3) further for more than three seconds to set the machine in the adjustment mode. If the machine is set in the adjustment * mode, caution lamp (4) on the monitor panel blinks.
Checking travel deviation direction Sr Check the travel deviation direction by step 2) or 3) below. I) Start and run the engine at low idling. Perform all checking work with the en* gine at low idling. 2) Set the parking brake lever to the free position and see which track shoe moves in reverse to judge the travel deviation direction. If the left track shoe moves in reverse, * the machine deviates to the left. If the right track shoe moves in reverse, the machine deviates to the right. 3) Shift the joystick to the right and left to return to the neutral position, and check the indication of the LED of control (5) each time to judge the travel deviation direction. Since the LED of the controller is nor* mally reflected in the mirror, install the cover temporarily to reflect it in the mirror. The LED indicates the pressure (Exam* ple 1). The point at the right shoulder of each figure denotes - (minus) (Example 2). The point at the left shoulder of each figure denotes lOOkg/cm* (Example 3). If the LED indicates a larger figure when * the joystick is shifted to either direction the to return to the neutral position, machine deviates in that direction. 4) After checking, lower chassis to the ground by lifting blade and ripper.
Example
1
55ks/cm*
/ I
-55kdcm
Example 4
Example 3
Example 2
I
I
I
1 155kdcm'
I-155kdcm'/ I
TWD01017
Setting solenoid valve current If the LED indicates 10 or less in each direc* tion in step 3-2) above, the solenoid valve In current does not need to be changed. this case, do not perform steps I) and 2) below, but perform only step 3). 1) Turn parking lever to LOCK position. 2) Start and run the engine at high idling. Perform the all setting work with the en* gine at high idling. 3) Operate the joystick to the stroke end in the opposite direction to the travel deviation direction confirmed by the above procedure.
D155AX-5
20-137
TESTING AND ADJUSTING
ADJUSTING
STEERING NEUTRAL POSITION
+
This operation is performed under the idea that deviation to the left (right) can be prevented by operating the lever to the right (left). Since the track shoes turn at a high speed, secure the safety around the machine. With the lever at the stroke end, press buzzer cancel switch (3) on the monitor panel, then return the lever to the neutral position. * The controller starts calculation and storing of the current. When it finishes, caution lamp (4) stops blinking (About 1 minute)
A 4)
5.
Check of setting I) Turn parking lever to LOCK position. 2) Start and run the engine at low idling. * Perform all checking work with the engine at low idling. 3) Shift the joystick to the right and left to return to the neutral position, and check that the figure indicated by the LED of control (5) each time is in the following range. . Normal differential pressure: 20kg/cm2 max.
6.
Finishing adjustment 1) 2)
mode
Turn steering neutral adjustment to the OPERATE position. Install control cover (I).
20-138
switch
(2)
D155AX-5
TESTING AND ADJUSTING
ADJUSTING STEERING NEUTRAL POSITION
Serial No. 75001 and up fl If the HSS pump or HSS controller is replaced, adjust the neutral position of the steering system according to the following procedure. Principle of adjustment of neutral position of steering system • If the neutral position of the steering system is not adjusted, even if the joystick is at the neutral position, the HSS pump discharges oil slightly to either PA or PB because of dispersion of the minimum swash plate angle of the HSS pump. • If the HSS pump discharges oil, the HSS motor rotates to change the speed of the track shoes on both sides. Accordingly, the machine may start or may deviate slightly while traveling straight even if the lever is at the neutral position. • To prevent the HSS pump from discharging oil while the lever is at the neutral position, the HSS controller controls the current. • The oil discharging condition of the HSS pump is judged by the differential pressure between two pressure sensors. If the HSS pump discharges a large quantity of oil, the differential pressure becomes large. If the former does not discharge oil at all, the latter becomes 0. • The HSS controller controls the current so that the differential pressure will be kept below 0.98MPa {10kg/cm2} to minimize the discharge from the HSS pump when the lever is at the neutral position. 1. Preparation work Lift up the machine body to raise the track shoes above the ground by using the blade and ripper. ¤ Set the parking brake lever to the lock position so that the track shoes will not turn while lifting up the machine body. ¤ If the machine body cannot be lifted up, the work may be performed without lifting it up. In this case, if the engine starts, the machine starts a spin-turn slowly. Secure the safety around the machine. fl After lifting up the machine body, stop the engine.
D155AX-5
20-138-1 4
TESTING AND ADJUSTING
ADJUSTING STEERING NEUTRAL POSITION
2. Selecting HSS neutral adjustment mode fl Adjust the steering system in the monitoring mode and adjusting mode of the monitor panel. For the general explanation of the monitoring mode and adjusting mode, see DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL in TROUBLESHOOTING. 1) Remove cover (1). 2) Turn starting switch ON. 3) Set the engine speed to Hi and turn service switch (2) ON. fl The service switch is installed inside the cover. 4) Turn and hold buzzer cancel switch (3) to the right for at least 7 seconds to display the service mode in upper display unit (4). 5) Turn up mode selector switch (5) to display the adjustment mode. fl The mode selector switch is installed inside the cover. fl Each time the mode selector switch is turned up, the mode changes. fl If the adjustment mode is selected, round mark (6) on the right and left side light up. 6) Turn buzzer cancel switch (3) to the right to display HSS neutral adjustment mode "HN". 3. Operation in HSS neutral adjustment mode fl The differential pressure indicated in this mode is not offset. For confirmation of the differential pressure after adjustment, select "J5" in the monitoring mode (See the display functions in the monitoring mode). 1) After adjustment mode "NH" is displayed, turn the steering lever to the left end and return it into neutral and measure value (7) at this time. Similarly, turn the steering lever to the right end and return it into neutral and measure value (7) at this time. Compare these values with each other.
20-138-2 4
D155AX-5
TESTING AND ADJUSTING
ADJUSTING STEERING NEUTRAL POSITION
fl It can be confirmed that the machine turns in the direction having the larger value. 2) Turn the lever in the direction having smaller value (7) and turn buzzer cancel switch (3) to the left. fl The buzzer makes a pip. fl The segments of gauge (8) are turned on 1 by 1 and all of them are turned on again when adjustment is finished. fl The number of segments of the gauge is normally 5 - 7. 3) How to clear adjustment value Set the control lever in neutral and turn buzzer cancel switch (3) to the left. fl The buzzer makes a pip. 4. How to confirm travel deviation direction How to confirm by movement of track shoe 1) Set the parking brake lever in the free position and check which track shoe moves in reverse to see the travel deviation direction. fl If the left track shoe moves in reverse, the machine deviates to the left. If the right track shoe moves in reverse, the machine deviates to the right. 2) After confirming the travel deviation direction, lower the machine body to the ground by using the blade and ripper. 5. Finishing adjustment mode 1) Turn service switch (2) OFF. 2) Install cover (1).
D155AX-5
20-138-3 4
TESTING AND ADJUSTING
20-138-4
(Blank page)
D155AX-5
TESTING AND ADJUSTING
PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH
PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH Serial No. 70001 – 75000 fl If the machine cannot be steered because of a trouble in the HSS controller or steering potentiometer, it can be moved to a safe place by using the emergency steering switch according to the following procedure. fl Since this switch is for the minimum necessary steering control, use it only for moving to a safe place. 1. Condition of machine for using switch 1) The machine cannot be steered because of a trouble in the steering potentiometer. fl The LED of the HSS controller indicates error code [E-62], [E-61], [E-6E], or [E23]. 2) The machine cannot be steered because of a trouble in the HSS controller. fl The LED of the HSS controller indicates error code [E-57] or nothing. fl If the LED indicates nothing, the electric system of the controller may have trouble. In this case, check the electric system, too. 2. Connection method of switch 1) Turn off the starting switch. 2) Disconnect CN1 connector (1), CN-2H1 connector (2), and CN-2H2 connector (3) from the HSS controller. 3) Disconnect CN-LPL connector (4) from the ROPS bracket, then connect the emergency steering switch (5) to the male connector and female connector.
D155AX-5
20-139 4
TESTING AND ADJUSTING
PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH
3. Precautions for using switch 1) Before using the switch, insulate it with vinyl tape, etc. to prevent a short circuit between the terminals on its back side and the machine body. 2) Since the emergency steering switch allows only ON-OFF operation, unlike the joystick, keep the engine speed as low as possible during operation. ¤ If the switch is operated while the engine is running at a high speed, the steering system operates sharply. 3) Note that the machine moves inversely to the operation of the switch during reverse travel, unlike when the joystick is used. fl Operating directions of switch and steering directions Position
20-140
Forward
Reverse
L
Steering to left Steering to right
R
Steering to right Steering to left
D155AX-5
TESTING AND ADJUSTING
PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH
Serial No. 75001 and up fl If the machine cannot be steered because of a trouble in the HSS controller or steering potentiometer, it can be moved to a safe place by using the emergency steering switch according to the following procedure. fl Since this switch is for the minimum necessary steering control, use it only for moving to a safe place. 1. Condition of machine for using switch 1) The machine cannot be steered because of a trouble in the steering potentiometer. fl The monitor panel indicates error code [E0730], [E0731], [E0732], [E0733], [E0734], or [E0735]. 2) The machine cannot be steered because of a trouble in the HSS controller. fl The monitor panel indicates error code [E0113] or nothing. fl If the monitor panel indicates nothing, the electric system of the controller may have trouble. In this case, check the electric system, too. 2. Connection method of switch 1) Turn off the starting switch. 2) Disconnect CN-ST1 connector (1), CN-ST3 connector (2), and CN-ST2 connector (3) from the HSS controller. 3) Disconnect CN-LPL connector (4) from the ROPS bracket, then connect the emergency steering switch (5) to the male connector and female connector.
D155AX-5
20-140-1 4
TESTING AND ADJUSTING
PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH
3. Precautions for using switch 1) Before using the switch, insulate it with vinyl tape, etc. to prevent a short circuit between the terminals on its back side and the machine body. 2) Since the emergency steering switch allows only ON-OFF operation, unlike the joystick, keep the engine speed as low as possible during operation. ¤ If the switch is operated while the engine is running at a high speed, the steering system operates sharply. 3) Note that the machine moves inversely to the operation of the switch during reverse travel, unlike when the joystick is used. fl Operating directions of switch and steering directions Position
20-140-2 4
Forward
Reverse
L
Steering to left Steering to right
R
Steering to right Steering to left
D155AX-5
TESTING AND ADJUSTING
ADJUSTING INITIAL CURRENT IN HSS STEERING SYSTEM
ADJUSTING INITIAL CURRENT IN HSS STEERING SYSTEM Serial No. 75001 and up fl When the operator steers the machine equipped with the HSS steering system, he (she) may feel the steering condition differently between the steering directions in the initial period of steering. This problem is solved by changing the initial current in the HSS steering system in the adjustment mode. fl Set the rise current freely in the adjustment mode and save the data in the non-volatile ROM. 1. Selecting initial current adjustment mode fl Adjust the initial current in the monitoring mode and adjusting mode of the monitor panel. For the general explanation of the monitoring mode and adjusting mode, see DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL in TROUBLESHOOTING. 1) Remove cover (1). 2) Turn service switch (2) ON. fl The service switch is installed inside the cover. 3) Turn and hold buzzer cancel switch (3) to the right for at least 7 seconds to display the service mode in upper display unit (4). 4) Turn up mode selector switch (5) to display the adjustment mode. fl The mode selector switch is installed inside the cover. fl Each time the mode selector switch is turned up, the mode changes. fl If the adjustment mode is selected, round mark (6) on the right and left side light up. 5) Turn buzzer cancel switch (3) to the right to display initial current adjustment mode "CC". 2. Operation in initial current adjustment mode 1) After adjustment mode "CC" is displayed, turn the lever in the direction to change the initial current. 2) Lever current (7) in mV is displayed.
D155AX-5
20-140-3 4
TESTING AND ADJUSTING
ADJUSTING INITIAL CURRENT IN HSS STEERING SYSTEM
fl Neutral value: Approx. 2,500 mV 3) After the target current is obtained, turn buzzer cancel switch (3) to the right to save the value. fl The buzzer makes a pip. 3. Finishing adjustment mode 1) Turn service switch (2) OFF. 2) Install cover (1).
20-140-4 4
D155AX-5
TESTING
ADJUSTING
AND ADJUSTING
ADJUSTING
BRAKE PEDAL
BRAKE PEDAL
BVD00684
Tighten the locknuts of the CB curely, and bend the cotter
rods and cables sepins securely.
1.
Adjust fitting dimension b of damper (2) so that the stroke of brake pedal (1) will be dimension a. . Pedal stroke a: 79mm . Fitting dimension b of damper: 39mm
2.
Adjust fitting dimension c of rod (3) on the valve side, then connect to brake valve lever (4). . Fitting dimension c of rod: 1,264mm * Fully screw joint (5) into the valve side.
3.
Adjust fitting dimension d of rod (6) on the pedal side, then connect to brake pedal (I). . Fitting dimension d of rod: 174mm
4.
Lightly push rod (3) on the valve side toward the rear of the machine, and turn only joint (7) to connect rods (3) and (6). * Push rod (3) with a force of about 9.8 - 19.6N {I - 2kg}.
D 155,4X-5
VDOO685
ADJUSTING
TESTING AND ADJUSTING
w
Joint: 34.3 - 58.8Nm
13.5 - 6.0kgmI
5.
With brake pedal (I) released, adjust its play with dimension e between the pins of rod assembly (8). . Play of pedal: 1 - 5mm (Center of pedal) . Dimension e between pins of rod assembly: 1,553mm Ir Adjust by turning joints (5) and (7) in the same direction.
6.
With brake pedal (I) released, check that brake pedal (I) is in contact with damper (2).
20-142
BRAKE PEDAL
D 155AX-5
TESTING
AND ADJUSTING
ADJUSTING
CLEARANCE
ADJUSTING
CLEARANCE
OF IDLER
OF IDLER
*
If the idler side guides, top and buttom guides, and guide plate wear, and the idler is at an angle or there is play to the side, adjust as follows.
1.
Adjusting in sideways direction 1) Drive the machine for 1 or 2 m on level ground, then measure clearance “a” (left, right, inside, outside: 4 places). 2) If clearance “a” is more than 4 mm, loosen bolt (I) and adjust with shim (2) as follows. * Clearance on one side: 0.5 - 1.0 mm * Do not loosen bolt (I) more than 3 turns. Ir The maximum adjustment amount is 6 mm.
2.
Adjustment in vertical direction Shim adjustment cannot be used for adjustment in the vertical direction, so measure the clearance between the track frame and guide plate (3). If the clearance is more than 8 mm, replace with a new guide plate (3) and wear plates (welded) (4), (51, and (6). l
‘,
2;
TAD00132
a
TAD00133
D155AX-5
20-143
TESTING
AND ADJUSTING
TESTING
WEAR OF SPROCKET
TESTING WEAR OF SPROCKET
Wear
limit
line
TWdOlOl6
1.
Apply wear gauge J to a part where the sprocket is not meshed with the track shoe. Match the waved part of the sprocket to that * of the wear gauge on the datum line.
2.
Judge the wear of the sprocket. When the sprocket surface is above the wear limit line: The sprocket can be used as it is. When the sprocket surface is below the wear limit line: Replace the sprocket with new one. l
l
20-144
D155AX-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING
TESTING AND ADJUSTING
TRACK SHOE TENSION
TRACK SHOE TENSION
Testing 1. Drive the machine
forward on a level ground, then stop it. * Do not apply the brake when stopping the machine.
2.
Place a straight steel bar (I) between the idler and carrier roller, and measure clearance a between the bottom of the steel bar and grouser of the track shoe. Standard clearance a: 20 - 30mm l
Adjusting * If the track shoe tension according 1.
to the following
EVD00532
is abnormal, procedure.
adjust
it
When tension is too high Loosen valve (2) to discharge grease. Since the valve may jump out because of the internal grease at high pressure, do not loosen it more than one turn.
A
2.
+
When tension is low Supply grease through valve (2). Ir If the track shoe is not tensed well, slowly move the machine forward and backward.
BVD00533
After adjusting the tension, check it again according to the testing procedure shown above.
D 155AX-5
20-145
TESTING AND ADJUSTING
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING HYDRAULIC PRESSURE Measuring ¤ Stop the machine on level ground and lower the work equipment completely to the ground, then set the parking brake lever and safety lever to the respective lock positions. fl Measure the hydraulic pressure under the following conditions. • Hydraulic temperature: 45 – 55°C
1. Measuring main relief pressure 1) Remove the control valve cover. 2) Remove oil pressure pickup plug (1) (10 x 1.25). 3) Install nipple (1) of oil pressure gauge H1 (58.8MPa {600kg/cm2}), and connect oil pressure gauge H1. fl The work equipment oil pressure can be measured in monitoring mode "HA". (See DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL.) Serial No.: 75001 and up
4) Start the engine and set the safety lever to the free position. 5) Run the engine at high idling, and operate the blade lever and ripper lever to relief each cylinder at the stroke end, and measure the oil pressure at this time.
2. Measuring load sensing pressure 1) Remove the control valve cover. 2) Remove oil pressure pickup plug (2) (10 x 1.25).
20-146 4
D155AX-5
TESTING AND ADJUSTING
3)
4) 5)
TESTING AND ADJUSTING
HYDRAULIC PRESSURE
Install nipple (I) of oil pressure gauge HI (58.8MPa (600kg/cm21), and connect oil pressure gauge HI. Start the engine and set the safety lever to the free position. Run the engine at high idling, and operate the blade lever and ripper lever to relief each cylinder at the stroke end, and measure the oil pressure at this time.
Adjusting * If the main relief pressure Ir
1. 2.
is abnormal, adjust main relief valve (3) of the control valve. The load sensing pressure cannot be adjusted.
Loosen locknut (4). Adjust the main relief pressure by with adjustment screw (5). Ir Turn the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. turn pressure, DECREASE To COUNTERCLOCKWISE. * Amount of adjustment for one turn of adjustment screw: 19.6MPa {200kg/cm2) w Locknut: 29.4 - 39.2Nm (3 - 4kgm} l
l
END00536
*
After completion pressure again shown above.
D155AX-5
of adjustment, check the oil according to the procedure
20-147
TESTING
MEASURING
AND ADJUSTING
MEASURING
PPC VALVE OUTPUT
PPC VALVE
OUTPUT
PRESSURE
PRESSURE
the machine on level ground and lower AStop completely to the ground, the work equipment then set the parking brake lever and safety lever to the respective lock positions.
*
Measure the PPC valve output pressure the following conditions. . 45 - 55°C Hydraulic temperature:
1.
Remove
2.
Disconnect ured.
3.
Install adapter @ and nipple @ of oil pressure and connect oil gauge Hl (5.9MPa {60kg/cm*I), pressure gauge HI.
4.
Start the engine free position.
5.
Run the engine at high idling, and operate the control lever of the circuit to be measured, and measure the oil pressure at this time. Measure the oil pressure with the control * lever at the stroke end. the oil pressure on the When measuring * blade lowering side, lower the blade until the machine body is lifted up.
20-148
under
the control valve cover.
the hose (1) of the circuit to be meas-
and set the safety lever to the
D155AX-5
MEASURING
TESTING AND ADJUSTING
Blade
PPC valve
RiPPer
Safety
lock
(Ripper
disaino
anole
Control
D155AX-5
valve
PPC valve
1
I
QPPC
PPC VALVE OUTPUT PRESSURE
connection
is
shown
when
looked
from
lever
side.
increase)
valve TWD00972
20-149
TESTING
ADJUTING
AND ADJUSTING
ADJUTING
PLAY OF PPC VALVE
Ir
If there is excessive play at the ends of the blade lever and ripper blade, adjust the PPC valve according to the following procedure.
.
Standard play a: 1 - 6mm at a point 400mm from center of rotation of lever (in forward and backward direction and lateral direction)
*
The figure ripper.
1.
Remove
2.
Loosen locknut (2), then turn disc (3) to adjust the play. Ir Do not move the piston at this time.
3.
Secure
disc (3) in position
(2). m
Locknut: 8.07 - 127.49Nm
4.
PLAY OF PPC VALVE
at right shows the PPC valve for the
boot (I).
and tighten
locknut
I10 - 13kgmI
Install boot (I).
20-150
D155AX-5
TESTING
AND ADJUSTING
MEASURING
SOLENOID
MEASURING
VALVE OUTPUT
A
Stop the machine on level ground and lower the work equipment completely to the ground, then set the parking brake lever and safety lever to the respective lock positions.
*
Measure the solenoid valve output pressure under the following conditions. . Hydraulic temperature: 45 - 55°C The figures at right show the ripper pin-puller solenoid valve.
*
SOLENOID
VALVE
OUTPUT
PRESSURE
PRESSURE
1. Measuring output pressure of ripper pin-puller solenoid valve I) Disconnect outlet hoses @ and 0. 2) Install adapter (I) and nipple (2) of oil pressure gauge Hl (5.9MPa {60kg/cm*l), and connect oil pressure gauge HI. 3) Start the engine and relieve the ripper pinpuller cylinder, and measure the oil pressure at this time. Since the oil pressure for the power train * circuit is used for the ripper pin-puller cylinder, the ripper pin-puller cylinder relief pressure is normal if it is the same as the transmission main relief pressure.
2.
Measuring output pressure of blade pitch solenoid valve 1) Disconnect the outlet hose. 2) Install adapter @ and nipple @ of oil pressure gauge HI (58.8MPa {600kg/cm*I), and connect oil pressure gauge HI. 3) Start the engine and relieve the blade pitch cylinder, and measure the oil pressure at this time. * The blade pitch cylinder relief pressure is normal if it is the same as the work equipment main relief pressure.
D155AX-5
20-151
TESTING AND ADJUSTING
TESTING LOCATION AND RIPPER *
1.
2.
TESTING LOCATION CAUSING HYDRAULIC DRIFT OF BLADE AND RIPPER
CAUSING
HYDRAULIC
If hydraulic drift occurs in the blade and ripper, check as follows to see if the cause is in the cylinder packing or in the control valve. Set the cylinder to be tested in the following posture, then stop the engine. 1) Blade lift cylinder Push the blade against the ground to raise the front side of the chassis. Ir Since the cylinder has a piston valve, do not operate the cylinder to the stroke end. 2) Blade tilt cylinder Extend the tilt cylinder to the stroke end, then push the blade further against the ground to raise the right side of the chassis. 3) Ripper lift cylinder Push the blade against the ground to raise the rear side of the chassis. Operate the control lever in the direction to extend the cylinder rod. . If the downward movement becomes faster, the packing is defective. . If there is no change, the control valve is defective. If there is no more pressure in the accumu* lator, run the engine for about IO seconds to charge the accumulator before carrying out the operation.
Posture
of
testing
DRIFT OF BLADE lift
cylinder
drift
I
TWO00973
Posture
of
testing
blade
tilt
cylinder
drift
TWD009
Posture
of
testing
ripper
lift
cylinder
drift
[Reference]
1)
2)
3)
If the cause of the hvdraulic drift is in the packing, the speed of downward movement in the above operation will become faster for the following reasons. With the work equipment in the posture given above, (holding pressure applied to the bottom end), the oil will leak from the bottom end to the head end. However, the volume at the head end is smaller than at the bottom end by an amount proportional to the are of the rod, so if the oil flows in from the bottom end, the internal pressure at the head end will rise. If the internal pressure at the head end rises, a balance will be made in proportion to this at a certain pressure (this differs according to the amount of leakage). When the pressure becomes balanced, the speed of downward movement becomes slower. In this condition, if the lever is operated as shown above, the circuit at the head end is connected to the drain circuit (the bottom end is closed by a check valve), and the oil at the head end flows to the drain circuit and the oil pressure is unbalanced to increase the speed of downward movement.
20- 152
I
TWD00975
D155AX-5
TESTING
AND ADJUSTING
MEASURING
MEASURING
LEAKAGE
LEAKAGE INSIDE HYDRAULIC
INSIDE
HYDRAULIC
CYLINDER
CYLINDER
Measure the leakage inside hydraulic cylinder under the following condition. . Hydraulic temperature: 45 - 55°C Since the blade lift cylinder is equipped with a piston valve, the leakage inside cannot be measured.
Extend the cylinder to be measured to the stall end and set it in the measurement posture. 1) Blade tilt cylinder: Tilt the blade to the right end. 2) Ripper lift cylinder: Remove the shank pin and lower the ripper to the lowest position. 3) Ripper tilt cylinder Tilt the ripper to the forward end.
2.
Disconnect the head piping of the cylinder, and block the hose on the chassis side with a blind plug. * Remove the cover of the blade tilt cylinder hose. Be careful not to disconnect the hose at the bottom end.
A 3.
4.
Start and run the engine at high idling, and apply the relief pressure to the bottom side of the cylinder. * Blade lift cylinder: Tilt the blade to the right. Ripper lift cylinder: Lower the ripper. Ripper tilt cylinder: Tilt the ripper to forward.
Wait for 30 seconds, then measure of leakage over next 1 minute.
D155AX-5
Disconnect hose Stroke end
*b
Hose
the amount
20- 153
TESTING
AND ADJUSTING
RELEASING CYLINDER
RELEASING
REMAINING
REMAINING
OIL PRESSURE
IN HYDRAULIC
CYLINDER
OIL PRESSURE IN HYDRAULIC
*
When disconnecting the piping between the work equipment cylinder and control valve, release the remaining oil pressure in the circuit.
1.
Gradually loosen the oil filter cap of the hydraulic tank to release the pressure in the tank.
2.
Operate the work equipment control lever forward, backward and to the right and left. * The pressure in the accumulate is released by operating the work equipment control lever two or three times.
3.
Start and run the engine at low idling for about five seconds, then stop it. Operate the work equipment control lever forward, backward and to the right and left two or three times. * All remaining oil pressure is released by operating the above operation two - three times.
BLEEDING AIR FROM HYDRAULIC CYLINDER *
After replacing or installing hydraulic cylinders or hydraulic piping, bleed the air from the hydraulic cylinders as follows:
1.
Start the engine minutes.
2.
Run the engine at low idling, and extend and retract the cylinder to be bled 4 - 5 times. * Stop the piston rod about IOOmm from the stroke end. Never operate it to the relief position.
3.
Run the engine
4.
Run the engine at low idling and operate the piston rod to the stroke end to relieve the circuit.
20-154
and run at idling for about
5
at high idling and repeat Step 2.
D155AX-5
TESTING AND ADJUSTING
ADJUSTING
ADJUSTING
WORK EQUIPMENT
SAFETY LEVER
/
1.
Adjust distance a between the pins of rod (I), and connect the rod to PPC lock valve (2) and safety lever (3). . Distance a between pins: 330mm
2.
Adjust distance b between the pins of rod (41, and connect the rod to lever (5) and safety lever (3). . Distance b between pins: 63.5mm
3.
Set safety lever (3) to the lock position.
4.
Adjust clearance c between levers (5) and (6) the specified value with rod (4). l Clearance c: 0.5 - l.Omm
5.
With blade lever (7) in the lift position, move safety lever (3) from the free position to the lock position. Confirm that blade lever (7) returns to the neutral position at this time.
6.
With safety lever (3) in the lock position, move blade lever (7). Confirm that safety lever (3) does not move to the free position at this time.
D155AX-5
WORK EQUIPMENT SAFETY LEVER
BVD00687
to
20- 155
TESTING AND ADJUSTING
ADJUSTING
SEMI-U
ADJUSTING
SEMI-U TILTDOZE
TILTDOZER
&000540
*
If the blade has been removed adjust it as follows.
or disassembled,
1. Procedure for adjusting with shims when assembling blade 1) Use shims to adjust the clearance at tilt portion (2), center portion (3), and lift portion (4).
TAD00131
Standard shim thickness:
2)
Max. 4mm
Apply grease to the adjustment locations and check that the parts rotate smoothly. & Each adjustment portion:
Grease (G2-LII
TAD00149
20-156
D 155AX-5
TESTING AND ADJUSTING
2.
ADJUSTING
SEMI-U TILTDOZE
Adjusting blade tilt 1)
2)
3)
Adjust fitting dimension d of brace (4) with the handle. . Fitting dimension d of brace: 1,390mm Measure right tilt el and left tilt e2. . Right tilt el: 450mm . Left tilt e2: 450mm If the tilt is not the same on the left and right sides, adjust fitting dimension d of brace (1) as follows. . el > e2: Increase fitting dimension d. . el < e2: Decrease fitting dimension d.
D155AX-5
20-157
TROUBLESHOOTING
TROUBLESHOOTING Points to remember when troubleshooting ........................................................................................ 20-202 Sequence of events in troubleshooting ............................................................................................... 20-203 Points to remember when carrying out maintenance ....................................................................... 20-204 Checks before troubleshooting ............................................................................................................. 20-212 Type of connector and position of installation ................................................................................... 20-214 Connection table for connector pin numbers ..................................................................................... 20-220 Function of electronic control system ................................................................................................. 20-230 Display of HSS controller .......................................................................................................................20-232 Display and special functions of monitor panel .............................................................................. 20-235-1 How to read judgment table ................................................................................................................. 20-236 Judgment table for engine system, hydraulic and mechanical system, and electrical system .... 20-238 Method of using troubleshooting charts ............................................................................................. 20-240 Troubleshooting of network system (N mode) ................................................................................... 20-251 Troubleshooting of engine system (S mode) ..................................................................................... 20-301 Troubleshooting of HSS controller and electrical system (E mode) (Serial No. 70001 – 75000) ....... 20-401 Troubleshooting of hydraulic and mechanical system (H mode) ..................................................... 20-501 Troubleshooting of monitor system (M mode) (Serial No. 70001 – 75000) .................................... 20-601 Troubleshooting of monitor system (M mode) (Serial No. 75001 and up) ..................................... 20-701 Troubleshooting of engine controller system (G mode) ................................................................... 20-801 Troubleshooting of HSS controller and electrical system (E mode) (Serial No. 75001 and up) ........ 20-901
D155AX-5
20-201 4
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER
A
A
Stop the machine When allow
carrying
WHEN TROUBLESHOOTING
in a level place, and check that the safety
out the operation
any unauthorized
with two or more workers,
person to come
If the radiator cap is removed when the A the engine to cool down before starting
A A A
Be extremely
careful
When
disconnecting
When
removing
the internal
wiring,
always
When
first. When
reoccurrence carrying
However,
1.
When
the negative which
measuring
is to pinpoint
and important that would
are disassembled
produce
immediately
the reported
2)
with
the fail-
4.
3)
when
carrying
to carry
5.
out troubleshoot-
ex-
anything
strange
with the method
*
operating
Had any repairs
When
about
symptoms,
etc.
to reenact
the
do not carry out
or measurement
that may
worse.
of the investigation
and inspec-
down the causes of
then use the troubleshooting
The
basic
of the failure
procedure
flowchart
to
exactly.
for troubleshooting
is
as follows. the
ma-
or were there
condition
before
did the failure
occur?
been carried
of operation,
the machine
and or as
Troubleshooting
Sr
apart from
yourself,
it as a real failure
a problem
failure,
out before
the
1)
Start from the simple
2)
Start from the most likely points.
3)
Investigate
other
points.
related
parts
or infor-
mation. 6.
5)
of the failure
to handle
tion in Items 2 - 4 to narrow
in
occurred?
occur suddenly,
what conditions
extent
whether
locate the position
with the machine
Under
failure
the
Use the results
prior
this?
Measures
to remove
Even if the failure the failure
root cause of failure
is repaired,
is not repaired,
if the root cause of
the same
failure
will
occur again.
failure? When
idea
items can be checked
make the problem
out thorough
occurred
before the failure
4)
6)
some
so check any item that is considered
any investigation
that has been reported?
Did the failure
and function.
to form
items.
troubleshooting
with the fixed procedure.
problems
inspection
Confirming
parts, or
and to carry out troubleshooting
there
chine
Other maintenance
Confirm
to find the cause
of manhours,
Have any other problems Was
Other
of the user or operator.
the problem
and to
symptoms.
ternally,
Points to ask user or operator 1)
swiftly,
the structure
questions
4)
and at the same time, will also lose
ing, it is necessary accordance
various
3)
any
parts will be disas-
impossible
It will also cause a waste
investigation
release
to be necessary.
become
For this reason,
or air, always it properly.
to carry out repairs
point is of course to understand
of the failure. oil or grease,
first.
from oil, water,
be sure to connect
judge
the confidence
parts.
of the battery
is to ask the operator
sembled.
2.
(-1 terminal
equipment,
do not hurry
no connection
ure or other unnecessary It will
in any rotating
is under pressure
the components.
failure occurs: . Parts that have
.
and do not
may spurt out and cause burns, so wait for
the basic cause of the failure,
troubleshooting
out troubleshooting,
If components
signals,
of the failure.
causes of the failure
carrying
is hot, hot water
disconnect
out troubleshooting,
to disassemble
keep strictly to the agreed
fitted.
troubleshooting.
installing
a short cut to effective
of possible
engine
the plug or cap from a location
pressure
brake are securely
near.
not to touch any hot parts or to get caught
The aim of troubleshooting prevent
pin, blocks, and parking
were these
Has the
same
repairs
kind
carried
of failure
To prevent this, always
out?
occurred
be-
lem occurred.
Then,
investigate
remove
why the prob-
the root cause.
fore? 3.
Check before troubleshooting 1)
Check for symptoms
of any abnormality
in
the machine. 2)
Check the CHECKS BEFORE STARTING
20-202
items.
D155AX-5
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TROUBLESHOOTING
SEQUENCE
OF EVENTS IN TROUBLESHOOTING
Office, shop &a
TEW00180 step
1 IExamination, II
When
confirmation
a request
Jobsite
of symptoms
for repairs
ask the following
2)
TwOO18,
\
. .
Name
of customer
Type.
serial number
.
Details
of jobsite,
Ask questions
is received,
first
points. of machine
etc.
to gain an outline
of the prob-
lem. .
Condition
.
Work being carried
of failure out at the time of the
failure .
Operating
*
Past history,
environment details
of maintenance,
etc.
TEWOOl83
step 3 Preparation 1)
of troubleshooting
tools
Look at the table
of troubleshooting
the shop manual
and prepare
tools in
the necessary
tools. . T-adapter . 2)
Hydraulic
pressure
gauge
kit, etc.
Look in the parts book and prepare essary
replacement
the nec1)
parts.
Before
starting
manual, that
Drive
select
matches
troubleshooting,
a troubleshooting the symptoms,
and operate
the condition
locate
the
and judge
flowchart
and carry
machine
and
out
to confirm
if there
is really
a
TEWOO 188
Was there chine
anything
strange
before the failure
Did the failure
the ma-
occur suddenly?
Had any repairs been carried
D155AX-5
about
occurred? out before the
20-203
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 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). 1.
POINTS TO REMEMBER 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.
WHEN
HANDLING
TEW00191
Main failures occurring in wiring harness 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.
Improper
I
insertion
TEW00192
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.
TEW00193
20-204
TROUBLESHOOTING
POINTS
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
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.
\
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. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 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. * When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. * 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 cleanina with comoressed air.
TEWO0194
TEW00195
TEW00196
Y
D 155AX-5
20-205
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2)
Removing, installing, wiring harnesses
and drying connectors
and
l
Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. 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. * Never pull with one hand. When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. + If the connector is twisted up and down or to the left or right, the housing may break.
TBW00485
0
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. * If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
TEW00198
20-206
D155AX-5
TROUBLESHOOTING
0
POINTS
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
Connecting connectors Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. 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. Ir If there is any damage or breakage, replace the connector. Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. I
I
TEWCHIZOO
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. If the connector cannot be corrected eas* ily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
D155AX-5
20-207
TROUBLESHOOTING
l
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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 wawashed in water, do not use high-pressure ter or steam directly on the wiring harness. do as If water gets directly on the connector, follows. @ Disconnect the connector and wipe off the water with a dry cloth. Ir If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. Ir 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 or damage to the connecdeformation tor.
TEW00202
Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to pins check for any short circuits between caused by water. drying the connector, After completely * blow it with contact restorer and reassemble.
T-adapter
TEW00203
20-208
D155AX-5
TROUBLESHOOTING
3)
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Handling control box The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.
TEW00204
Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.
Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
II 2.
TEW00206
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. * 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. Ir If there is any change, there is probably defective contact in that circuit.
D 155AX-5
20-209
TROUBLESHOOTING
3.
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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, repairing the machine in rain or high winds, places where there is a lot of dust.
or or
21 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 confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed 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 on to the ground, 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.
F
TEWOO207
TEW00209
20-210
D155AX-5
TROUBLESHOOTING
POINTS
TO REMEMBER
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. (Do not 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.
WHEN
CARRYING
OUT MAINTENANCE
TEW00210
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 ultrafine (about 3~) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
D 155AX-5
20-211
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING Item
Judgement value
Action
1. Check fuel level, type of fuel
-
Add fuel
2.
Check for impurities in fuel
-
Clean, drain
3.
Check hydraulic oil level
-
Add oil
4.
Check hydraulic strainer
-
Clean, drain
5.
Check power train oil level
-
Add oil
6.
Check engine oil level
Add oil
7.
Check coolant level
Add water
8.
Check dust indicator for clogging
Clean or replace
9.
Check power train oil filter
-
Replace
10. Check hydraulic filter
Replace
11. Check final drive oil level
Add oil
12. Check for looseness, corrosion of battery terminal, wiring 13. Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
-
Tighten or replace
14. Check for looseness, corrosion of starting motor terminal, wiring
Tighten or replace
15. Check operation of gauges
Repair or replace
16. Check for abnormal noise, smell
-
Repair
17. Check for oil leakage
-
Repair
18. Carry out air bleeding
-
Bleed air
19. Check battery voltage (engine stopped)
24 - 26 V
Replace
20. Check battery electrolyte level
-
Add or replace
21. Check for discolored, burnt, exposed wiring
-
Replace
22. Check for missing wiring clamps, hanging wiring
Repair
23. Check for water leaking on wiring (pay particularly careful attention to water leaking on connectors or terminals)
Disconnect connector and dry
24. Check for blown, corroded fuses 25. Check alternator voltage (engine running at l/2 throttle or above) 26. Check operating sound of battery relay (starting switch ON, OFF)
20-212
After running for Several minutes: 27.5 - 29.5 V
Replace Replace -
D155AX-5
TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
TYPE OF CONNECTOR AND POSITION OF INSTALLATION Serial No. 70001 – 75000 Connector Connector No. of type pins No.
Place of use
Address
Connector Connector No. of type pins No.
Place of use
Address
CN-1
MIC
21
HSS controller
V-8
CN-111
—
1
Alternator terminal B
B-2
CN-1
Single pin connector Single pin connector Single pin connector
1
Additional lamp connector
U-9
CN-112
—
1
Alternator terminal R
C-2
1
Rear speaker (Right)
T-9
CN-152
X
3
Neutral safety switch
V-1
1
Rear speaker (Right)
T-9
CN-153
SWP
6
Intermediate connector
L-5 W-2
4
Rear wiper motor
U-9
CN-201
X
1
Intermediate connector
D-1
1
Rear speaker (Left)
V-9
CN-203
M
1
Right head lamp
C-7
1
Rear speaker (Left)
V-8
CN-204
M
1
Left head lamp
B-4
1
Horn
B-6
CN-2 CN-3 CN-4
CN-7
Single pin connector Single pin connector Single pin connector
1
Additional lamp connector
Q-8
CN-205
Single pin connector
CN-8
Single pin connector
1
Room lamp
S-9
CN-206
—
1
Chassis ground
M-5
CN-9
6
Front wiper motor
Q-8
CN-211
KES
4
Rear lamp switch
P-7
CN-10
9
Radio
M-2
CN-212
KES
3
Bimetal timer
N-4
CN-11
6
Left wiper switch
M-2
CN-213
KES
4
Glow switch
CN-5 CN-6
P-7
CN-12
6
Front wiper switch
N-3
CN-214
SWP
16
Intermediate connector
CN-13
6
Right wiper switch
N-3
CN-215
S
8
Intermediate connector
M-6 Q-1 M-6 P-2
CN-14
6
Rear wiper switch
N-3
CN-216
KES
4
Head lamp switch
P-6
CN-15
2
Cab front lamp switch
O-3
CN-217
M
2
Monitor alarm
P-7
1
Alarm buzzer spare connector
V-8
1
Alarm buzzer spare connector
V-9
CN-16
2
Cab rear lamp switch
O-3
CN-217
CN-17
4
Intermediate connector
P-5
CN-218
Single pin connector Single pin connector
CN-18
4
Intermediate connector
X-7
CN-220
M
2
Diode (For starting circuit)
X-6
4
Intermediate connector
S-1
CN-223
X
2
Intermediate connector
X-4
1
Intermediate connector
S-1
CN-224
X
1
Rear lamp
X-6
1
Intermediate connector
T-1
CN-243
X
1
Ripper lamp
I-9
1
Backup alarm
X-5
CN-19
CN-21
Single pin connector Single pin connector
CN-22
Single pin connector
CN-20
1
Cigarette lighter
W-7
CN-244
Single pin connector
CN-245
X
2
Intermediate connector
L-6 X-4
CN-101
SWP
12
Intermediate connector
H-2 P-3
CN-103
X
2
Starting motor terminal R/S
C-1
CN-246
X
2
Ripper pin-puller solenoid valve
X-5
CN-104
M
2
Intermediate connector
T-1
CN-248
X
1
Ripper pin lamp
L-8
CN-105
X
2
Intermediate connector
T-1
CN-250
—
1
Starting switch terminal B
—
CN-106
—
1
Starting motor terminal B
E-8
CN-251
X
3
Backup alarm switch
L-4
CN-107
—
1
Heater relay terminal A
A-9
CN-260
—
1
Starting switch terminal BR
—
CN-108
—
1
Heater relay terminal B
C-8
CN-262
X
2
Intermediate connector
V-9
CN-109
—
1
Heater relay terminal C
A-9
CN-263
X
2
Ripper pin-puller switch
S-9
CN-110
Single pin connector
1
Intermediate connector
D-7
CN-264
SWP
6
Intermediate connector
Q-7
20-214 4
D155AX-5
TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
Connector Connector No. of type pins No. CN-263
X
I-ICN 264
SWP
2
II6
Place of use Ripper pin-puller Intermediate
Addresl switch
CN-ARC CN-C
connector
1 CN-270
1 -
I 1
I Starting switch terminal RI
I
1 CN-280
I
I I
I Starting switch terminal C
I
/ f3l3l~~
iA;{
CN-2H2
-
AMP040 16
I CN-351 I I CN-361
:, 1~~~;:“,:teminal
x
I I
XC1
HSS controller 1Air compressor
I KES I 2 I Window
washer
(Front)/
Connector Connector No. of type pins No.
-
ICN-CRGPI
x
Place of use
Addres:
2
Air conditioner condenser
1
Battery relay
I 2 1HSS chargeoil pressuresensor I
CN-CSW
’
2
Steering neutral position adjustment switch
CN-ENG
X
2
Engine rotation
CN-GO1
M
2
Diode (For monitor alarm)
CN-H
-
1
Battery relay
CN-HHP
’
3
Work equipment circuit oil pressure sensor
CN-LPL
SWP
8
intermediate
sensor
connector
CN-362
KES
2
Window
washer
(Left)
ICN-PUPA1
X
12
CN-363
KES
2
Window
washer
(Right)
ICN-PUPBI
x
I 2 1HSS pump solenoid valve B I
ti CN-364
KES
2
Window
washer (Rear)
I CN-391 I
I 4 1Air conditioner
1CN-392 1
1 2 1Air conditioner
relay
I
CN-393
4
CN-394
3
Air conditioner blower register
1CN-395 1
1 4 1Air conditioner blower switch
I CN-396 I
I 3 I Air conditioner
1CN-397 1
I 2
451
SWP
II 8
switch
Intermediate
2
~;;~e~~~$rs~~sor
D155AX-5
X
3
Steering oil pressure sensor 1
PO1 PO2
IPI
Singlepin , connector Singlepin , connector
Blade
pitch
switch
Blade
pitch
switch
12
I Monitor
panel
AMP040 12
Monitor
panel
Chassis
ground
IAMP
-
1
I
I
connector
X
12
CN-STHPI
SX8
CN-453
SWP
Reverse travel sensing potentiometer
Enginec&ant temperahrre sensor
Hydraulicoil temperaturesensor
CN-701
3
P2
1
1 :
X
Air conditioner clutch relay
X
1 ”
1
I Diode (For air conditioner) 1
CN-452
1 CYZ~~,”
CN-RSS
blower motor
Air conditioner thermostat and pressure switch
I-ICN
1HSS pump solenoid valve A 1
~~;&p~~roieyidvalve~
Intermediate
connector
20-215
TROUBLESHOOTING
TYPE Of CONNECTOR AND POSITION OF INSTALLATION
CN-107
+
Cl+402
cN-206
D155AX-5
TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
Pl
BVP00642
D155AX-5
TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
cN,-Pl
CN-p2
N-213
/
CN-206 CN-396
I
CN-397
\
cN-&l cN-212 ’ Y
CN-14 CN-13
CN-1
\
CN-16
CNlol
cN216 (r-Z9A)
CN214 k9A) BVPOO643
20-218
+
D155AX-5
TROUBLESHOOTING
CN-6
+
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
CN-263
I
/_
CN-3
CN-2
I
’ aN-;N-262
cN-6
cN-244
\ CN-16
D 155AX-5
CN-106
cN-104
CN-21
CN-20
\ CN-c
CN-H
CN-SW
TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
Serial No.: 75001 and up fl The addresses in the following table refer to the locations of the connectors in the actual view drawing. Connector Connector No. of type pins No.
Place of use
Address
Connector Connector No. of type pins No.
Place of use
Address
R
5
Backup alarm relay
X-7
CN-21
DT
1
Intermediate connector
U-1
CN1
AMP
5
Monitor panel
O-9
CN-211
ML
4
Headlamp switch
P-7
CN-1
– 12 1-pin connector 1
Engine controller
N-1
CN-214
DT
12
Intermediate connector
M-6
Connector for additional lamp
U-9
CN-215
DT
12
Intermediate connector
M-7
CN-014
CN-1 CN-10
–
9
Radio
M-4
CN-216
ML
4
Rear lamp switch
P-7
CN-101
X
4
Intermediate connector
G-2
CN-21A
2
Monitor alarm
W-7
CN-104
L
2
Intermediate connector
T-1
CN-22
DT 1-pin connector
1
Cigarette lighter
W-8
CN-105
X
2
Intermediate connector
U-1
CN-220
DT
2
Diode (For starting circuit)
V-1
CN-106
–
1
Starting motor terminal B
P-1
CN-222
DT
12
Intermediate connector
M-7
CN-107
–
1
Heater relay terminal A
D-3
CN-223
X
3
Intermediate connector
X-4
CN-108
–
1
Heater relay terminal B
D-2
CN-224
M
1
Rear lamp (Left)
X-6
CN-109
–
1
Heater relay terminal C
D-3
CN-243
M
1
Rear lamp (Right)
I-9
CN-11
KES
6
M-4
CN-244
DT
2
Backup alarm
X-5
CN-110
–
1
Alternator terminal B
A-3
CN-245
X
2
Intermediate connector
L-6
CN-112
–
1
Alternator terminal R
A-3
CN-246
X
2
Ripper pin puller solenoid
X-5
CN-12
KES
6
Front wiper switch
M-4
CN-247
X
1
Intermediate connector
L-9
CN-13
KES
6
Right wiper switch
N-4
CN-248
M
1
Ripper point lamp
L-8
CN-14
KES
6
Rear wiper switch
N-4
CN-250
–
1
Starting switch terminal B
Q-9
CN-15
M
2
Cab front lamp switch
N-4
CN-251
M
4
Caution lamp
N-9
CN-152
DT
3
Transmission lock switch
X-3
CN-260
–
1
Starting switch terminal BR
P-8
CN-153
DT
12
Intermediate connector
L-5
CN-262
X
2
Horn switch
U-9
CN-16
M
2
Cab rear lamp switch
O-4
CN-263
X
2
Ripper pin puller switch
S-9
CN-17
KES
4
Right door wiper motor
P-5
CN-270
–
1
Starting switch terminal R1
Q-8
CN-18
KES
4
Left door wiper motor
W-8
CN-280
–
1
Starting switch terminal C
P-9
CN-19
M
4
For washer
U-1
CN-290
–
1
Starting switch terminal ACC
O-9
CN-1ST
DT
3
Gear speed switch 1
K-4
CN-2ND
DT
3
Gear speed switch 2
K-4
AMP
8
Monitor panel
N-9
CN-3
–
3
Engine controller
O-1
1-pin connector
1
Rear speaker (Left)
T-9
CN2
wiper switch
8
Engine controller
O-1
CN-3
CN-2
– 1-pin connector
1
Rear speaker (Right)
T-9
CN-361
M
2
Windshield washer (Front)
X-4
CN-20
DT
1
Intermediate connector
T-1
CN-362
M
2
Windshield washer (Left)
X-4
CN-201
X
4
Intermediate connector
F-8
CN-363
M
2
Windshield washer (Right)
X-3
CN-203
M
1
Right headlamp
C-7
CN-364
M
2
Windshield washer (Rear)
X-3
CN-204
M
1
Left headlamp
E-8
CN-391
ML
4
Air conditioner relay
N-5
CN-204
X 1-pin connector
1
Air conditioner compressor
A-2
CN-392
M
2
Air conditioner blower motor
O-6
4
Air conditioner thermostat & dual pressure switch
M-8
CN-2
CN-205
20-219-1 4
1
Horn
B-6
CN-393
ML
D155AX-5
TROUBLESHOOTING
Connector Connector No. of type pins No.
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
Place of use
Address
Connector Connector No. of type pins No.
Place of use
Address
CN-394
ML
3
Air conditioner resistor
P-6
CN-E41
DT
2
Supply pump 1
A-1
CN-395
ML
4
Air conditioner blower switch
M-9
CN-E42
DT
2
Supply pump 2
B-1
CN-396
ML
3
Air conditioner switch
M-8
CN-E51
Intermediate connector
S-1
CN-397
ML
2
Diode (For air conditioner)
N-5
CN-E51
DT
2
Ne sensor
D-2
CN-398
ML
4
Air conditioner clutch relay
M-5
CN-E52
DT
2
G sensor
C-1
CN4
M
2
Monitor panel
M-9
CN-E53
DT
3
Common rail pressure sensor
C-1
CN-4
–
20
Engine controller
O-1
CN-E54
DT
3
Boost pressure sensor
A-2
CN-4
KES
4
Rear wiper motor
U-9
CN-FCD
DT
3
Decelerator pedal
S-1
CN-406
DT
2
HSS charge oil pressure sensor
G-9
CN-FCS
M
3
Fuel control dial
W-8
CN-422
X
2
Intermediate connector
X-5
GND1
–
1
Chassis ground
M-6
CN-423
X
2
Fuel level sensor
X-7
GND2
–
1
Chassis ground
T-1
CN-451
DT
12
Intermediate connector
L-7
CN-H
–
1
Battery relay
W-1
CN-452
DT
2
Hydraulic oil temperature sensor
J-4
CN-HET
–
5
Preheater relay
X-6 H-9
HD30 31
CN-453
DT
2
Transmission oil temperature sensor
I-3
CN-HHP
DT
3
Work equipment circuit pressure sensor
CN-454
X
2
Blade pitch solenoid
I-3
CN-LPL
DT
8
Intermediate connector
L-6
– 16 1-pin connector 1
Engine controller
O-2
CN-M11 HD30
P
Intermediate connector
X-6
Rear speaker (Left)
U-9
CN-M2
2
Starting motor terminals R, S"
A-1
– 10 1-pin connector 1
Engine controller
N-2
CN-M22 HD30
X
Intermediate connector
X-7
Rear speaker (Left)
U-9
CN-P01
2
Blade pitch switch
Q-7
CN-5 CN-5 CN-6 CN-6 CN-7 CN-7 CN-701 CN-8 CN-9
DT
–
– 14 1-pin connector 1
Engine controller
N-1
CN-P31
DT
2
Connector for additional lamp
Q-7
CN-P7
DT
2
Engine water temperature sensor (Low) Engine water temperature sensor (High)
DT 12 1-pin connector 1
Intermediate connector
L-7
CN-P8
–
1
Engine oil pressure switch (Low)
D-1
Room lamp
S-9
CN-P9
–
1
Engine oil pressure switch (High)
C-1
D-2 D-2
KES
6
Front wiper motor
Q-8
CN-PUPA
DT
2
HSS pump solenoid A
H-2
CN-ARC
X
2
Air conditioner condenser
W-1
CN-PUPB
DT
2
HSS pump solenoid B
H-2
CN-BCN
ML
3
Buzzer cancel switch
P-7
CN-RSS
DT
3
Reverse sensing potentiometer
X-2
CN-C
–
1
Battery relay
V-1
CN-ST1
DT
3
Steering oil pressure sensor 1
L-5
CN-CPR
–
5
Engine controller relay
W-7
CN-ST2
DT
3
Steering oil pressure sensor 2
K-4
CN-E07
DT
2
Engine speed sensor
D-3
CN-STR
DT
4
Steering potentiometer
X-2
CN-E21
HD30 31
Intermediate connector
C-4
CN-SW
–
1
Battery relay
V-1
CN-E22
HD30 31
Intermediate connector
D-4
CN-X1
–
6
Service switch
N-5
CN-E31
DT
2
Injector #1
A-4
CN-X2
–
6
Mode selector switch
O-5
CN-E32
DT
2
Injector #2
B-4
CN-ST1
–
21
HSS controller
V-8
CN-E33
DT
2
Injector #3
B-4
CN-ST2
–
20
HSS controller
V-8
CN-E34
DT
2
Injector #4
B-4
CN-ST3
–
16
HSS controller
V-8
CN-E35
DT
2
Injector #5
C-4
CN-T01
AMP
16
Monitor panel
N-9
CN-E36
DT
2
Injector #6
D-4
D155AX-5
20-219-2 4
TROUBLESHOOTING
20-219-3 4
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
D155AX-5
TROUBLESHOOTING
D155AX-5
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
20-219-4 4
TROUBLESHOOTING
20-219-5 4
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
D155AX-5
TROUBLESHOOTING
D155AX-5
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
20-219-6 4
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS Ir The terms male and female refer to the pins, while the terms male housing and female refer to the mating
No. of pins
portion
housing
of the housing.
r
X type connector Male (female
housing)
Female
(male
housing)
TEWO0221
20-220
TEwoo223
TEW00224
TEW00225
TEW00226
D155AX-5
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
r
SWP type connector Male (female
housing)
Female
(male housing)
6
3
6 ‘6 TEwoo235
BLF90033
8
4
8 TEW00237
12
TEW0023B
1
4
5
8
9
12
BLwoO34
1
4
3
i
8
11
11
8
4
1
14
io i4 TEWO0239
4
16
I
1
Id
1
Id i
TEWOO240
4
_*------____-- .
fE!I BLPOO036
D155AX-5
13
16
BLFQOO37
20-221
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T
M type connector Male (female housing)
Female (male housing)
i
i
M.Paoo36
TEWOO243
1
TEW00244
3
3
1
4 ZzI
@$ 2
4
4
2 TEW00246
TEWOO245
4
1
6 @ 3
6
6
TEW00247
1
3
TEW00246
4
8
8'
.5 BLPWO40
20-222
5
8
D 155AX-5
TROUBLESHOOTING
No. of pins
CONNECTION
T
TABLE FOR CONNECTOR
PIN NUMBERS
S type connector Male (female
housing)
Female
(male
housing)
8
4
8
10
12
s
1
6
$
io
TEW00251
BLFVW42
6
1
6
5
12 BLPGoo43
TEWOO2M
1
ii!% 1
8
Ii 8
TEW00254
1
I
16
7
D 155,4X-5
16
BLFuO044
TEW00256
20-223
CONNECTION
TROUBLESHOOTING
No.
of pins
r
TABLE FOR CONNECTOR PIN NUMBERS
MIC connector Female (male housing)
Male (female housing)
5
:Jl
BLPOOO45
BLPOO046
9
BLPOOO46
BLPOoO47
7
1
0
1
ollouo
0 00
13
8
8
13
BLPOCQ49
i
BLPOOO50
9
17
17
H
BLP00051
BLPCO052
21
[
20-224
i
TEW00259
TEW00260
D 155AX-5
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
AMP040 type connector Female (male housing)
Male (female housing) 8
A
8
BLPooo53
5
1
BLFOOO54
12
6
i
i
12
16
8
16
1
9 BLPOOO57
TEWO0232
20
11
1 TEW00234
D155AX-5
20-225
CONNECTION TABLE FOR CONNECTOR
TROUBLESHOOTING
No. of pins
T
AMP070 Male (female
type connector
housing) 1
PIN NUMBERS
Female 7
7
(male
housing)
1
8
6
4
BLFOOO59
12
%=
8 BLmoo61
20-226
D155AX-5
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
2
L type type connector Male (female
al
housing)
Female
(male
housing)
1
q
03
2
IEII
TEW00258
D 155AX-5
20-227
CONNECTION
TROUBLESHOOTING
No. of pins
T
Automobile Male (female
TABLE FOR CONNECTOR
connector Female
housing)
PIN NUMBERS
(male
housing)
BLPM)O64
BLpooO63
3
2
3
2 BLPOOo66
BLFWO65
EB
4
BLPOOO67
6
\
BLPOO069
4
b
8
, fl!r?l 5
'5
20-228
BLPCQ071
8 EiLPOOO72
D155AX-5
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Relay connector Male (female housing)
Female (male housing)
2
2
5
1
5
1
3
5
6
6
3
BLP00073
6
4
BLP00074
6
3
5
6
4 5
2
1
2
1
BLP00075
D155AX-5
3
BLP00076
20-229
TROUBLESHOOTING
Type Shell size code
[ ]
18-8 (1)
18-14 (2)
20-229-1 4
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
D155AX-5
TROUBLESHOOTING
Type Shell size code
[ ]
18-20 (3)
18-21 (4)
D155AX-5
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
20-229-2 4
TROUBLESHOOTING
Type Shell size code
[ ]
24-9 (5)
24-16 (6)
20-229-3 4
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
D155AX-5
TROUBLESHOOTING
Type Shell size code
[ ]
24-21 (7)
24-23 (8)
D155AX-5
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
20-229-4 4
TROUBLESHOOTING
Type Shell size code
[ ]
24-31 (9)
20-229-5 4
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
Pin (female terminal)
Pin (male terminal)
D155AX-5
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[Number is printed on each connector (Wire inserting end).] No. of pins
DT, DT-T series connector Body (Plug)
Body (Receptacle)
2
3
4
D155AX-5
20-229-6 4
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[Number is printed on each connector (Wire inserting end).] No. of pins
DT, DT-T series connector Body (Plug)
Body (Receptacle)
6
8
12
20-229-7 4
D155AX-5
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[Number is printed on each connector (Wire inserting end).] No. of pins
DTM series connector Body (Plug)
Body (Receptacle)
2
D155AX-5
20-229-8 4
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
DTHD series connector Body (Plug)
Body (Receptacle)
1
20-229-9 4
D155AX-5
D155AX-5
(Blank page)
20-229-10 4
TESTING AND ADJUSTING
FUNCTION OF ELECTRONIC CONTROL SYSTEM
FUNCTION OF ELECTRONIC CONTROL SYSTEM Serial No. 70001 – 75000
20-230 4
D155AX-5
TESTING AND ADJUSTING
Functions of HSS system • The HSS system consists of an HSS controller, sensors, switches, solenoid valves, relays, and a monitor panel. • The HSS controller receives input signals from each sensor and switch, and calculates them, then sends them to each solenoid valve and relay to control the HSS system. At the same time, the HSS controller communicates information with the monitor panel through the network circuit (S-NET). • The steering potentiometer measures the quantity of operation of the joystick in the steering direction, and inputs analog signals to the HSS controller. • The steering oil pressure sensor senses the operating pressure of both steering circuit, and inputs analog signals to the HSS controller. • The work equipment circuit oil pressure sensor senses the operating pressure of the work equipment circuit, and inputs analog signals to the HSS controller. • The HSS charge pressure sensor senses the oil pressure in the HSS charge circuit, and inputs ON/OFF signals to the HSS controller. • The engine rotation sensor senses engine rotation, and inputs pulse signals to the HSS controller. • The travel reverse sensing potentiometer senses the reverse position of the joystick, and inputs analog signals to the HSS controller. • The backup alarm limit switch detects the reverse position of the directional lever of the transmission valve, and inputs ON/OFF signals to the HSS controller. • The steering neutral position adjustment switch detects changes of the adjustment mode and working mode, and inputs ON/ OFF signals to the HSS controller. • The HSS pump solenoid valve receives analog signals from the HSS controller, and controls the swash plate angle of the HSS pump. • The backup alarm relay receives ON/OFF signals from the HSS controller, and changes the backup alarm circuit. • The monitor panel communicates with the HSS controller through the network circuit (S-NET). Upon receiving an abnormality signal from the HSS controller, the monitor panel turns on the electric system caution lamp and alarm buzzer.
D155AX-5
FUNCTION OF ELECTRONIC CONTROL SYSTEM
•
The emergency steering switch is installed when the HSS system has trouble. It sends signals directly to the HSS pump solenoid valve without passing through the HSS controller to steering the machine in an emergency.
Functions of monitor panel • The monitor panel receives input signals from each sensor and switch, and calculates them, then turns on the gauges and lamps of itself and sends output signals to the alarm buzzer to control the monitor panel system. At the same time, the monitor panel communicates information with the HSS controller through the network circuit (S-NET). • The engine oil pressure switch senses engine oil pressure, and inputs ON/OFF signals to the monitor panel. • The engine coolant temperature sensor senses the engine coolant temperature, and inputs analog signals to the monitor panel. • The transmission oil temperature sensor senses transmission oil temperature, and inputs analog signals to the monitor panel. • The fuel level sensor senses quantity of the remaining fuel, and input analog signals to the monitor panel. • If the starting switch is turned to the preheating position or another position, it inputs ON/OFF signals to the monitor panel. • The alternator inputs the voltage generated by itself to the monitor panel. • The alarm buzzer receives ON/OFF signals from the monitor panel, and turns on and off itself.
20-231
TROUBLESHOOTING
FUNCTION OF ELECTRONIC CONTROL SYSTEM
Serial No. 75001 and up
20-231-1 4
D155AX-5
TROUBLESHOOTING
Functions of HSS system • The HSS system consists of an HSS controller, sensors, switches, solenoid valves, relays, and a monitor panel. • The HSS controller receives input signals from each sensor and switch, and calculates them, then sends them to each solenoid valve and relay to control the HSS system. At the same time, the HSS controller communicates information with the monitor panel through the network circuit (S-NET). • The steering potentiometer measures the quantity of operation of the joystick in the steering direction, and inputs analog signals to the HSS controller. • The steering oil pressure sensor senses the operating pressure of both steering circuit, and inputs analog signals to the HSS controller. • The work equipment circuit oil pressure sensor senses the operating pressure of the work equipment circuit, and inputs analog signals to the HSS controller. • The HSS charge pressure sensor senses the oil pressure in the HSS charge circuit, and inputs ON/OFF signals to the HSS controller. • The engine rotation sensor senses engine rotation, and inputs pulse signals to the HSS controller. • The travel reverse sensing potentiometer senses the reverse position of the joystick, and inputs analog signals to the HSS controller. • The backup alarm limit switch detects the reverse position of the directional lever of the transmission valve, and inputs ON/OFF signals to the HSS controller. • The service switch, mode selector switch, and buzzer cancel switch are used to input the data for the monitoring function and adjustment mode. • The HSS pump solenoid valve receives analog signals from the HSS controller, and controls the swash plate angle of the HSS pump. • The backup alarm relay receives ON/OFF signals from the HSS controller, and changes the backup alarm circuit. • The monitor panel communicates with the HSS controller through the network circuit (S-NET). Upon receiving an abnormality signal from the HSS controller, the monitor panel turns on the electric system caution lamp and alarm buzzer.
D155AX-5
FUNCTION OF ELECTRONIC CONTROL SYSTEM
•
The emergency steering switch is installed when the HSS system has trouble. It sends signals directly to the HSS pump solenoid valve without passing through the HSS controller to steering the machine in an emergency.
Functions of monitor panel • The monitor panel receives input signals from each sensor and switch, and calculates them, then turns on the gauges and lamps of itself and sends output signals to the alarm buzzer to control the monitor panel system. At the same time, the monitor panel communicates information with the HSS controller through the network circuit (S-NET). • The engine oil pressure switch senses engine oil pressure, and inputs ON/OFF signals to the monitor panel. • The engine coolant temperature sensor senses the engine coolant temperature, and inputs analog signals to the monitor panel. • The transmission oil temperature sensor senses transmission oil temperature, and inputs analog signals to the monitor panel. • The fuel level sensor senses quantity of the remaining fuel, and input analog signals to the monitor panel. • If the starting switch is turned to the preheating position or another position, it inputs ON/OFF signals to the monitor panel. • The alternator inputs the voltage generated by itself to the monitor panel. • The alarm buzzer receives ON/OFF signals from the monitor panel, and turns on and off itself. • The engine oil pressure and engine water temperature are input to the engine controller to control the engine and transmitted as caution information through the communication system to the monitor panel.
20-231-2 4
TESTING AND ADJUSTING
DISPLAY OF HSS CONTROLLER
DISPLAY OF HSS CONTROLLER Serial No. 70001 – 75000
20-232 4
D155AX-5
DISPLAY OF HSS CONTROLLER
TESTING AND ADJUSTING
The HSS controller indicates the following system information and error codes of troubles on the LED unit. I) Output current to HSS pump solenoid valve 2) Differential pressure between both HSS steering circuit 3) Error codes of troubles Since the LED is reflected in the mirror before it is seen, reflect it in a mirror when checking it. Indication pattern of LED
When P error
(5 sec. )
(When operat
ins
lever)
(0. 5 sec.
1
and
(3 sec. 1
L
occured
occured
(0. 5 sec. /
When P error
E error
1
(3 sec.
)
\
When E error
occured TWD00978
0 0 0 Co * 2. *
Indication of start: If the starting switch is turn to the ON position, [881 is displayed (for 5 minutes). Indication of information: If the joystick is operated for steering, the information is displayed prior If the joystick is not operated, the information is not to all other items (during operation). displayed and the LED goes off. P error: All the past error codes stored in the controller are displayed (0.5 seconds + 3 seconds). E error:. All the error codes currently output are displayed (0.5 seconds + 3 seconds). All the stored or currently output error codes are displayed once on P error and E error areas, then the same error codes are displayed from the first one. Indication of information The type of the displayed information depends on the condition of the machine and the position of the steering neutral position adjustment switch. 7) When steering neutral position adjustment switch is at OPERATE position If the joystick is operated for steering while the starting switch is at the ON or START position, the current supplied by the HSS controller to the HSS pump solenoid valve is displayed. * The unit is IOmA (If “12” is displayed, the current is 120mA). * Since the information is displayed prior to all other items, the current can be checked even while an error code is displayed. 2)
When steering neutral position adjustment switch is at ADJUST position If the steering neutral position adjustment mode is selected and the joystick is operated steering, the differential oil pressure between both steering circuit is displayed. Ir For details, see ADJUSTING STEERING NEUTRAL POSITION.
D155AX-5
for
20-233
TESTING AND ADJUSTING
3.
DISPLAY
OF HSS CONTROLLER
Indication of P error and E error I) Contents of displayed error codes See the following table of the error codes and troubled systems. 2) Deleting method of error codes With the buzzer cancel switch on the monitor panel pressed, turn the starting switch to the ON position and keep the buzzer cancel switch pressed for 3 seconds or longer. Ir Check that the steering neutral position adjustment switch is at the OPERATE position. If the deleting operation is performed while the steering neutral position adjustment switch is at the ADJUST position, the steering neutral position adjustment mode is selected. 3) Using method of error codes When performing troubleshooting after displaying the error codes, take a note of the all displayed error codes, then delete them. Then, perform the error code reproducing operation and troubleshoot according to the displayed error codes. * There may be trouble caused by misoperations or disconnections of connectors among the stored error codes. Avoid unnecessary troubleshooting work for such trouble. * After finishing troubleshooting, delete the error codes again.
20-234
D 155AX-5
TESTING
DISPLAY
AND ADJUSTING
Error codes and contents Error code
of troubles
Troubled
system
19
Short circuit in steering
20
Disconnection
1
21
1 Short circuit in steering
1
22
I Disconnection
1
23
1 Trouble
oil pressure
Disconnection
25
Short circuit in steering
Alarm buzzer
sensor system A
0
0
E+
0
0
E+
sensor system A sensor system
oil pressure
potentiometer
24
Alarm lamp
oil pressure
in steering
of steering
of trouble
and contents
oil pressure
in steering
in steering
1
27
1 Short circuit in steering
1
29
1 Trouble
systems
potentiometer
system
system
Short circuit in travel
52
Disconnection
r~ 53
I Disconnection
1
1 Short circuit in backup alarm relay system
I
I
Ir
54
reverse sensing
in backup alarm
system
potentiometer
system
relay system
Lowering
62
Excessive difference of signal value between potentiometer systems 1 and 2 [II
steering
6d
Excessive difference of signal value between potentiometer systems 1 and 2 [III
steering
6E
Trouble of either steering potentiometer deviation of either system from neutral
I Disconnection
S+
65
Short circuit in HSS pump solenoid
66
Disconnection
67
Short circuit in HSS pump solenoid
in HSS pump solenoid
in work equipment
0
0
s+
0
0
s+
system point
valve system
0
0
s+
0
0
s+
I
x
I
s+
I
x
I
x
I
s+
0
0
S
0
0
S
0
0
s+
.
.
1~1~1
B B
circuit oil pressure sensor system1
s+
0
0
s+
x
I
x
1
E+
x
I
x
I
E+
71
I Short circuit in work equipment circuit oil pressure sensor system
I
8d
I S-NET communication
1.1.1
error
Trouble
The S: S+: E: E+:
symbols Turn the Turn the Start the Start the
D 155AX-5
of offset current
memory
s+
0
1 Disconnection
EO
s+
a
70
Disagreement of reverse sensing potentiometer alarm switch signals with each other
S
1.1.1
valve system A valve system
E
x
and excessive
valve system A
99
s+ s+
I
of controller
in HSS pump solenoid
E+
txlxl
57
64
of source voltage
Ial.
Id@I
14.1 Id@1
2
potentiometer
reverse sensing
E+
1
sensor system
51
Reproducing operation
1.1.1
1
system 2
potentiometer
in travel
B
1 and 2
system
potentiometer
rotation
B
sensor system
Disconnection in steering potentiometer ET----~~~~~~~~
of engine
OF HSS CONTROLLER
s
and backup
0
of the reproducing operation denote the following operations. starting switch to the ON position. starting switch to the ON position, then operate the concerned engine. engine, then operate the concerned switch or lever.
0
switch
S
or lever.
20-235
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL Serial No. 75001 and up
fl1: Monitoring mode Sending and returning of items = Buzzer cancel switch fl2: Service code mode E: Error which is occurring currently, P: Error which occurred in past = Code and service meter reading at time of occurrence of error are displayed alternately. Sending of items = Buzzer cancel switch, Clearing code (history) = Mode selector switch fl3: Adjustment mode Sending of items = Buzzer cancel switch
20-235-1 4
D155AX-5
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
Selection of each mode
D155AX-5
20-235-2 4
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
1. Ordinary display function Gear speed (1) is displayed in the upper display unit and service meter (2) is displayed in the lower display unit during ordinary work.
2. Function of displaying user code when error occurs If any error to be notified to the operator occurs during work, user code (3) and service meter (4) are displayed alternately in the lower display unit. When a user code of high importance is displayed, the caution lamp flashes and caution buzzer sounds. A user code is displayed only when an error of high importance is detected. An error may have occurred even if a user code is not displayed. Accordingly, if you feel any abnormality, be sure to check for a service code in the service code display mode.
20-235-3 4
D155AX-5
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
User codes and abnormal phenomena (Which indicate actions to be taken by operator) User code
Abnormal phenomenon
Caution lamp
Caution buzzer
E01
Work can be continued with some functions stopped. • Abnormality in backup alarm relay • Abnormality in engine speed sensor of monitor panel • Abnormality in buzzer cancel switch
—
—
E02
Some functions, including limiting function, etc. are stopped (Work can be continued with care). • Abnormality in water temperature sensor • Abnormality in power distribution control function of HSS
fi
fi
CALL03
Move to a safe place and call a serviceman. • Abnormality in injector • Abnormality in steering position 1 system • Abnormality in forward-reverse travel sensor
fi
fi
CALL
Stop the machine immediately and call a serviceman. • Abnormality in control power source • Abnormality in steering position 2 system • Abnormality in engine pump
fi
fi
D155AX-5
20-235-4 4
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
3. Function of displaying in monitoring mode The condition of each part of the machine can be checked on the monitor panel by the signals from the sensors installed to various parts of the machine. Among the monitored information items, the engine speed, voltage, current, etc. are indicated by values and the other items are indicated by bits as the condition of pressure switches. 1) Monitoring code (5) 2) Monitoring mode mark (6) (Lamp on the left side) lights up. 3) Monitor information (7)
20-235-5 4
D155AX-5
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
TROUBLESHOOTING
Monitoring code Nos. and indicated items fl For details of an item, the indication unit of which is bit, see "Details of items indicated by bits". Code No.
Monitoring item
Indication unit
Component
99
Engine speed
rpm
HSS controller
bA
Battery voltage
mV
Monitor panel
HA
Work equipment hydraulic pressure
J5
HSS pump (A-B) differential pressure
kg/cm2
HSS controller
2
HSS controller
2
kg/cm
JA
HSS pump A oil pressure
kg/cm
HSS controller
Jb
HSS pump B oil pressure
kg/cm2
HSS controller
PA
HSS pump A output current
mA
HSS controller
CA
HSS pump feedback current
mA
HSS controller
Pb
HSS pump B output current
mA
HSS controller
L1
Steering lever position voltage 1
mV
HSS controller
L2
Steering lever position voltage 2
mV
HSS controller
RU
Reverse travel signal potentiometer voltage
mV
HSS controller
7H
Transmission switch input condition
bit
HSS controller
75
High engine water temperature sensor
˚C
Engine controller
76
Low engine water temperature sensor
˚C
Engine controller
77
Torque converter oil temperature sensor voltage
˚C
Monitor panel
Fd
Fuel control dial voltage
mV
Engine controller
FA
Acceleration percentage
%
Engine controller
dU
Decelerator voltage
mV
Engine controller
FC
Throttle correction percentage
%
Engine controller
CP
Common rail pressure
MPa
Engine controller
CO
Common rail command pressure
MPa
Engine controller
bP
Boost pressure
kPa
Engine controller
HE
Transmission switch input condition
bit
HSS controller
EC
Engine control mode
–
Engine controller
EO
Engine Q regulator command value
–
Engine controller
C7
Injecting timing command
–
Engine controller
2
mm /st
Engine controller
F1
Fuel injection rate command value
FP
Converted torque
%
Engine controller
67
Fuel temperature
˚C
Engine controller
IE
Engine speed
rpm
Engine controller
5N
Indication of condition of S-NET
U1
Engine controller program version
–
Engine controller
U2
Monitor panel tachometer module program version
–
Monitor panel
U4
Monitor panel caution module program version
–
Monitor panel
U5
HSS controller program version
–
HSS controller
FL
Fuel level sensor voltage
mV
Monitor panel
D155AX-5
bit
Monitor panel
20-235-6 4
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
Details of items indicated by bits fl An example of indication by bit is shown in the figure at right. 1, 3, and 5 indicate the OFF state. 2, 4, and 6 indicate the ON state. HE: Transmission switch input condition (Neutral) 1: Neutral stage 1 2: Neutral stage 2 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) fl The neutral state is shown in the figure at right. 1 and 2 are always in the same state. Difference between them in indication shows an abnormality. fl The HSS controller notifies the engine controller whether the transmission is in neutral with this signal.
7H: Transmission command condition 1: Forward travel command 2: Reverse travel command 3: 1st gear speed command 4: 2nd gear speed command 5: 3rd gear speed command 6: (Unused) fl The state of the "forward 1st gear speed" is shown as an example in the figure at right.
20-235-7 4
D155AX-5
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
5N: Condition of connection of S-NET 1: Engine controller 2: Monitor panel (Tachometer module) 3: (Unused) 4: HSS controller 5: Monitor panel (Caution module) 6: (Unused) fl Indication under the normal condition is shown in the figure at right. (All are turned ON.)
4. Function of indicating service code The engine controller, machine controller, or monitor panel detects abnormalities in the electric system and saves the contents and occurrence time of the abnormalities in he monitor panel in the order of occurrence. In this mode, the saved service codes and the service meter readings at the times when those codes were output are displayed alternately. If the letter at the left end of a service code is • E, the abnormality is not corrected yet. • P, the abnormality is corrected. Up to 20 service codes can be saved. If any service code is not saved, "– –" is displayed in the upper display unit. 1) Output error No. is displayed (8). 2) Service code mark (9) lights up. 3) Service code (10). 4) Time when error occurred is displayed (11).
D155AX-5
20-235-8 4
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
Service codes and abnormal systems Service code
Contents of abnormality
Reproduction method
Troubleshooting mode
User code
E0101
Abnormality in network system (engine controller system)
S
N mode
CALL03
E0104
Abnormality in network system (monitor panel system)
S
N mode
CALL03
E0105
Abnormality in network system (HSS controller system)
S
N mode
CALL03
E0113
Lowering of HSS controller power source voltage
S
E mode
CALL03
E0120
Abnormality in monitor panel caution lamp system
S
M mode
CALL03
E0121
Abnormality in monitor panel caution buzzer system
S
M mode
CALL03
E0143
Abnormality in HSS controller 5-V power source
S
E mode
CALL03
E0145
Abnormality in HSS controller sensor power source
S
E mode
CALL03
E0152
Abnormality in network system (HSS controller system)
S
N mode
CALL03
E0161
Abnormality in saving of offset current
S
E mode
CALL03
E0165
Error in network communication
S
N mode
CALL03
E0211
Abnormality in power train (torque converter) oil temperature
E
M mode
–
E0221
Abnormality in gear speed switch system
S+
E mode
–
E0233
Abnormality in reverse sensing potentiometer system
S+
E mode
CALL03
E0237
Abnormality in transmission neutral signal
S+
E mode
E01
E0272
Nonconformity of reverse sensing potentiometer and backup alarm switch signal
S+
E mode
E02
E0329
Abnormality in HSS oil charging pressure
E
M mode
E01
E0360
Disconnection in work equipment circuit oil pressure sensor system
E+
E mode
E01
E0361
Short circuit in work equipment circuit oil pressure sensor system
E+
E mode
E01
E0401
Abnormality in engine controller power source
S
G mode
CALL
E0402
Abnormality in engine controller
S
G mode
CALL
E0405
Abnormality in fuel control dial system
S
G mode
CALL03
E0406
Abnormality in decelerator potentiometer system
S
G mode
CALL03
E0409
Abnormality in engine Ne speed sensor system
E
G mode
CALL03
E0410
Abnormality in engine G speed sensor system
E
G mode
CALL03
E0430
Abnormality in engine oil pressure
E
M mode
CALL
E0432
Abnormality in engine water temperature
E
M mode
E01
E0436
Abnormality in network system (engine controller)
S
N mode
CALL03
E0458
Short circuit in fuel injector No. 1/No. 2/No. 3 system
S
G mode
CALL03
E0459
Short circuit in fuel injector No. 4/No. 5/No. 6 system
S
G mode
CALL03
E0460
Abnormality in controller drive circuit
S
G mode
CALL03
E0461
Disconnection in fuel injector No. 1 system
S
G mode
E02
E0462
Disconnection in fuel injector No. 2 system
S
G mode
E02
E0463
Disconnection in fuel injector No. 3 system
S
G mode
E02
E0464
Disconnection in fuel injector No. 4 system
S
G mode
E02
E0465
Disconnection in fuel injector No. 5 system
S
G mode
E02
E0466
Disconnection in fuel injector No. 6 system
S
G mode
E02
E0468
Overcurrent in fuel supply pump PCV1 system
S
G mode
CALL03
20-235-9 4
D155AX-5
TROUBLESHOOTING
Service code
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
Contents of abnormality
Reproduction method
Troubleshooting mode
User code
E0469
Disconnection in fuel supply pump PCV1 system
S
G mode
CALL03
E0470
Overcurrent in fuel supply pump PCV2 system
S
G mode
CALL03
E0471
Disconnection in fuel supply pump PCV2 system
S
G mode
CALL03
E0472
Abnormality in boost pressure sensor system
E
G mode
E02
E0474
Abnormality in common rail fuel pressure sensor system
E
G mode
CALL03
E0476
Abnormality in high engine water temperature sensor system
E
G mode
E01
E0478
Abnormality in low engine water temperature sensor system
E
G mode
E02
E0480
Abnormality in common rail fuel pressure
E
G mode
CALL03
E0481
Abnormality in high common rail fuel pressure 1
E
G mode
CALL03
E0482
Abnormality in high common rail fuel pressure 2
E
G mode
CALL03
E0483
No-pressure feed by fuel supply pump 1
E
G mode
CALL03
E0484
No-pressure feed by fuel supply pump 2
E
G mode
CALL03
E0487
Abnormality in engine oil pressure switch system
E
G mode
E01
E0488
Abnormality in power source system 1
S
G mode
CALL
E0489
Abnormality in power source system 2
S
G mode
E02
E0490
Abnormality in Q regulator switch signal
S
G mode
E02
E0491
Short circuit in starting switch C system
E
G mode
CALL
E0493
Abnormality in fuel temperature sensor system
E
G mode
E01
E0610
Disconnection in backup alarm relay system
S+
E mode
E01
E0611
Short circuit in backup alarm relay system
S+
E mode
E01
E0730
Abnormality in both steering potentiometer systems 1 and 2
E+
E mode
CALL03
E0731
Large difference between signal values of steering potentiometer systems 1 and 2 I
E+
E mode
CALL03
E0732
Abnormality in one steering potentiometer system and large deviation of neutral position of other system
E+
E mode
CALL03
E0733
Abnormality in steering potentiometer system 1
E+
E mode
CALL03
E0734
Abnormality in steering potentiometer system 2
E+
E mode
CALL03
E0735
Large difference between signal values of steering potentiometer systems 1 and 2 II
E+
E mode
CALL03
E0768
Disconnection in steering oil pressure sensor A system
E+
E mode
CALL03
E0769
Short circuit in steering oil pressure sensor A system
E+
E mode
CALL03
E0770
Disconnection in steering oil pressure sensor B system
E+
E mode
CALL03
E0771
Short circuit in steering oil pressure sensor B system
E+
E mode
CALL03
E0772
Disconnection in HSS pump solenoid A system
S+
E mode
CALL03
E0773
Short circuit in HSS pump solenoid A system
S+
E mode
CALL03
E0774
Disconnection in HSS pump solenoid B system
S+
E mode
CALL03
E0775
Short circuit in HSS pump solenoid B system
S+
E mode
CALL03
E0930
Abnormality in engine speed sensor system
E+
E mode
E01
D155AX-5
20-235-10 4
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
TROUBLESHOOTING
fl Reproduction method S: Service code reproduced by turning the starting switch ON S+: Service code reproduced by turning the starting switch ON and operating the corresponding switch or lever E: Service code reproduced by starting the engine E+: Service code reproduced by starting the engine and operating the corresponding switch or lever fl Troubleshooting mode N mode: Troubleshooting G mode: Troubleshooting E mode: Troubleshooting M mode: Troubleshooting
of of of of
network system (N mode) engine controller system (G mode) HSS controller system and electric system (E mode) monitor panel system (M mode)
fl Method of reproducing service codes and confirming resetting of them Reproduce the service codes and confirm resetting of them after the repair according to the following procedure. 1) Select the service code display mode and check the displayed service codes. fl Record the all service codes. 2) Delete the service codes. fl Turn mode selector switch downwards. 3) Reproduce the all service codes which have been displayed. fl For the reproduction method, see the above list or the text of troubleshooting. 4) Confirm that the service codes are "displayed" or "not displayed" in the service code display unit.
20-235-11 4
D155AX-5
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
5. Display function in adjustment mode 1) Adjustment items (12) are displayed. 2) Adjustment mode marks (13) light up (on both sides). 3) Adjustment value (14) is displayed. i) HSS neutral adjustment mode "HN" is displayed. ii) HSS initial current adjustment mode "CC" is displayed. iii) Reduced cylinder mode (EO) is displayed.
Adjustment code Nos. and adjustment items Code No.
Adjustment item
Contents
HSS neutral adjustment mode
A machine equipped with the HSS steering system may turn in either direction while the lever is in neutral because of dispersion of the pump output, etc. This mode is used to slant the swash plate to prevent the machine from turning while the lever is in neutral. (For details of usage of this mode, see TESTING AND ADJUSTING.)
CC
HSS initial current adjustment mode
When an operator steers a machine equipped with the HSS steering system, he (she) may feel the steering condition differently between the steering directions in the initial period of steering. This mode is used to change the initial current for the period just after steering is started to solve the above problem. (For details of usage of this mode, see TESTING AND ADJUSTING.)
E0
Reduced cylinder mode
This mode is used to stop one or more injectors of a common rail engine to find out an abnormal injector. (For details of usage of this mode, see TESTING AND ADJUSTING.)
HN
D155AX-5
20-235-12 4
TESTING AND ADJUSTING
HOW TO READ JUDGMENT TABLE
HOW TO READ JUDGMENT TABLE This judgment table is used to see if each machine trouble is caused by a fault of the engine system, hydraulic and mechanical system or electrical system, then go to the troubleshooting code (S-fifi, Efifi, H-fifi) matched to the trouble. fl Trouble with the monitor panel are not contained in this judgment table. If the monitor panel has any trouble, go to “TROUBLESHOOTING FOR MONITOR PANEL SYSTEM (M-MODE)” directly. 1. Specify each machine trouble in the column of Trouble (Trouble code), then go to the right section of the table. 2. If there is ‡ or S in a box of the table, judge by the item in the upper box to determine the moving direction. When there is ‡: Referring to “INDICATION ON LED OF HSS CONTROLLER”, check the error code displayed by the HSS controller. When there is S: Insert a T-branch in the blade pitch solenoid valve (CN-454) or ripper pin-puller solenoid valve (CN-246), and see if the operation of the blade pitch switch or ripper pin-puller switch and the ON/OFF operation of the solenoid valve input voltage are normal. 3. Go to the trouble code at the bottom of the judgment table according to the judgment result or go to the right of the table further. When there is ‡: If the concerned error code is displayed, go to the trouble code at the bottom of the judgment table. If the concerned error code is not displayed, go to the right of the table further. When there is S: If the solenoid valve input voltage is not turned on/off normally, go to the trouble code at the bottom of the judgment table. If the solenoid valve input voltage is turned on/off normally, go to the right of the table further.
20-236
D155AX-5
TESTING AND ADJUSTING
D155AX-5
(Blank page)
20-237
JUDGMENT TABLE FOR ENGINE SYSTEM, HYDRAULIC AND TESTING AND ADJUSTING MECHANICAL SYSTEM, AND ELECTRICAL SYSTEM Judgment item
Trouble (Trouble code)
Indication by LED of HSS controller (Error code)
19
20
21
22
23
24
25
26
27
E-6
E-7
E-8
E-9
Engine does not start easily (It always takes long time to start engine). Engine does not rotate. Engine does Engine rotates but does not discharge exhaust gas. not start. Engine discharges exhaust gas but does not start (Fuel is injected). Engine speed does not rise sharply.
Engine system
Engine stops during operation. Engine rotation is irregular (hunts). Output is insufficient or power is low. Exhaust gas black (Incomplete combustion) Oil consumption is excessive or exhaust gas is blue. Oil becomes dirty prematurely. Fuel consumption is excessive. Coolant contains oil, blows back or reduces. Oil pressure caution lamp lights up. Oil level rises (Oil contains water or fuel). Coolant temperature rises too high (Overheating). Abnormal sound is generated. There is excessive vibration. Machine does not move or moves slowly at any gear speed in each direction. Machine does not move or travel power is low in one direction.
Power train system
Machine does not move or moves slowly at specific gear speed. Long time lag is made in changing travel direction or gear speed. Travel power (Drawbar pull) is low. Machine cannot be steered (to one direction). Steering speed or power is low.
‡ ‡ ‡ ‡
‡
Steering direction is reversed in reverse travel. Machine steers by itself in neutral position (during travel or at standstill). If machine is steered, engine stops.
‡ ‡ ‡ ‡
‡
Abnormal sound comes out of HSS pump or HSS motor. Brake does not work. Power train oil overheats. Backup alarm does not sound.
Work equipment system
Work equipment does not work at all. Work equipment speed or power is low. Blade lifting speed or power is low. Blade tilting speed or power is low. Ripper lifting speed or power is low. Ripper tilting speed or power is low. Hydraulic drift is large in blade lifting direction. Hydraulic drift is large in blade tilting direction. Hydraulic drift is large in ripper lifting direction. Blade pitch does not work normally (When equipped with pitch dozer). Ripper pin puller does not work normally (When equipped with giant ripper). Abnormal sound comes out of work equipment pump. Troubleshooting code
20-238 4
E-1
E-2
E-3
E-4
E-5
D155AX-5
29
51
52
53
54
57
62
6d
6E
64
65
66
67
70
71
8d
99
E0
Troubleshooting code
Indication by LED of HSS controller (Error code)
Measure- Blade pitch ment of voltage solenoid valve Measure- Ripper pin-puller ment of voltage solenoid valve
TESTING AND ADJUSTING
S-1 E-31 S-2 S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 H-1 H-2 H-3 H-4 H-5
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
‡
H-6
‡ ‡ ‡ ‡
H-7
‡
–
‡
– – H-8 H-9 H-10
‡ ‡
E-28 H-11 H-12 H-13 H-14 H-15 H-16 H-17 H-18 H-19
♦
H-20
♦
H-21 H-22
E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-23 E-24 E-25 E-26 E-27 E-29 E-30
D155AX-5
20-239 4
TESTING AND ADJUSTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number Serial No. 70001 – 75000 Component
Troubleshooting code No. S–fifi
Troubleshooting of engine
E–fifi
Troubleshooting of HSS controller and electrical system
H–fifi
Troubleshooting of hydraulic and mechanical system
M–fifi
Troubleshooting of monitor system
Serial No. 75001 and up Component
Troubleshooting code No. N–fifi G–fifi E–fifi H–fifi M–fifi
Troubleshooting Troubleshooting Troubleshooting Troubleshooting Troubleshooting
of of of of of
network system engine controller system HSS controller system and electric system hydraulic system and mechanical systems monitor panel system and electric parts system
2. Method of using troubleshooting table for each troubleshooting mode 1 Troubleshooting code number and problem The title of the troubleshooting chart gives the troubleshooting code and failure mode (problem with the machine). 2 General precautions When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at the top of the page and marked with fl. The precautions marked fl are not given in the , but must always be followed when carrying out the check inside the . 3 Distinguishing conditions Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. 4 Method of following troubleshooting chart YES
•
Check or measure the item inside
, and according to the answer follow either NO
the YES line or the NO line to go to the next . (Note: The number written at the top right corner of the is an index number; it does not indicate the order to follow.) • Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. • Below the there are the methods for inspection or measurement, and the judgement values. If the judgement values below the are correct or the answer to the question inside the is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. • Below the is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and carry out the work in the correct order. 5 Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. 6 Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem).
20-240 4
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF NETWORK SYSTEM (N MODE) [Serial No. 75001 and up]
Action taken by controller when abnormality occurs and problems on machine ....................... 20-252 N mode system electrical circuit diagram ........................................................................................... 20-254 Service codes of network system ........................................................................................................ 20-255 N-1 [E0101] (Abnormality in network system: engine controller system) is displayed .............. 20-256 N-2 [E0104] (Abnormality in network system: monitor panel system) is displayed ................... 20-257 N-3 [E0105] (Abnormality in network system: HSS controller system) is displayed .................. 20-258 N-4 [E0101], [E0104], and [E0105] (Abnormality in network system) are displayed at same time .... 20-259 N-5 [E0152] (Abnormality in network system: HSS controller system) is displayed .................. 20-260 N-6 [E0165] (Error in network communication) is displayed .......................................................... 20-261 N-7 [E0436] (Abnormality in network system: engine controller) is displayed ............................... 20-262
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.
D155AX-5
20-251 4
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User Service code code
E0101
E0104
Abnormal system
Abnormality in network system (engine controller system)
Abnormality in network system (monitor panel system)
Contents of abnormality ª When monitor panel detects abnormality in network of engine controller system • When service code E0101 is displayed singly 1. Disconnection or defective contact in wiring harness between monitor panel T01 (9) - engine controller CN-2 (8), (18) 2. Defective engine controller • When service code E0101 is displayed together with E0104 and E0105 1. Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between monitor panel T01 (10) monitor panel CN1 (11), (12) - monitor panel T01 (9) - HSS controller CN-ST1 (1) - HSS controller CN-ST1 (12) - engine controller CN-2 (8), (18) 2. Defective monitor panel (Tachometer module) ª When monitor panel detects abnormality in network of monitor panel (caution module) system • When service code E0104 is displayed singly 1. Disconnection or defective contact in wiring harness between monitor panel T01 (10) - monitor panel CN1 (11), (12) 2. Defective monitor panel (caution module) • When service code E0104 is displayed together with E0101 and E0105 1. Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between monitor panel T01 (10) monitor panel CN1 (11), (12) - monitor panel T01 (9) - HSS controller CN-ST1 (1) - HSS controller CN-ST1 (12) - engine controller CN-2 (8), (18) 2. Defective monitor panel (Tachometer module)
CALL03
Abnormality in network system (HSS controller system)
ª When monitor panel detects abnormality in network of HSS controller system • When service code E0105 is displayed singly 1. Disconnection or defective contact in wiring harness between monitor panel T01 (9) - HSS controller CN-ST1 (1) 2. Defective HSS controller • When service code E0105 is displayed together with E0101 and E0104 1. Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between monitor panel T01 (9) HSS controller CN-ST1 (1), (12) - engine controller CN-2 (8), (18) 2. Defective monitor panel (Tachometer module)
E0152
Abnormality in network system
ª When HSS controller detects abnormality in network • When service code E0152 is displayed singly 1. Defective HSS controller • When service code E0152 is displayed together with E0101, E0104, and E0105 fl Same as each service code
E0165
Error in network communication
1. Defective monitor panel 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-ST1 (1) - monitor panel T01 (9)
Abnormality in network system
ª When engine controller detects abnormality in network • When service code E0436 is displayed singly 1. Defective engine controller • When service code E0436 is displayed together with E0101, E0104, and E0105 fl Same as each service code
E0105
E0436
20-252 4
D155AX-5
TROUBLESHOOTING
Normal condition (Voltage, current, resistance)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action taken by controller when abnormality occurs
Problems on machine
1. Flashes caution lamp. 2. Turns on caution buzzer.
1. Flashes caution lamp. 2. Turns on caution buzzer.
1. Flashes caution lamp. 2. Turns on caution buzzer.
1. Gear speed cannot be displayed. 2. Tachometer is not displayed. 3. Lock-up lamp goes off.
1. Gear speed cannot be displayed. 2. Tachometer is not displayed. 3. Lock-up lamp goes off.
1. Gear speed cannot be displayed. 2. Tachometer is not displayed. 3. Warning lamp and buzzer do not work.
D155AX-5
20-253 4
TROUBLESHOOTING
N MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
N MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM Engine controller system
20-254 4
D155AX-5
TROUBLESHOOTING
SERVICE CODES OF NETWORK SYSTEM
SERVICE CODES OF NETWORK SYSTEM The monitor panel, engine controller, and HSS controller form a network as shown in the "N mode system electrical circuit diagram". The monitor panel, engine controller, and HSS controller monitor the communication condition of the network respectively. If any abnormality occurs, these controllers display the service code corresponding to that abnormality. 1) Monitor panel The monitor panel monitors the communication condition of the network components and displays the following service codes when an abnormality occurs. (1) E0101: When abnormality occurs in the engine controller system (2) E0104: When abnormality occurs in the monitor panel (caution module) (3) E0105: When abnormality occurs in the HSS controller 2) Engine controller The engine controller monitors the communication condition of the whole network and displays the following service codes when an abnormality occurs. (4) E0152: When abnormality occurs in any system in the whole network (The abnormal system is not specified) 3) HSS controller The HSS controller monitors the communication condition of the whole network and displays the following service codes when an abnormality occurs. (4) E0436: When abnormality occurs in any system in the whole network (The abnormal system is not specified) As the network is monitored by multiple devices as explained above, if any abnormality occurs in the network system, multiple service codes are displayed simultaneously. It is important to understand which system each service code indicates by using the monitoring mode, etc. before starting troubleshooting.
D155AX-5
20-255 4
N-1
TROUBLESHOOTING
N-1 [E0101] (Abnormality in network system: engine controller system) is displayed Cause
Remedy
1 • Turn starting switch ON.
NO
Are service codes [E0104] and [E0105] displayed, too?
YES
Go to N-4
2 • Turn starting switch OFF. • Disconnect T01 and CN1. • Max. 1 Ω
Is resistance between T01 (female) (9) and CN-ST1 (female) (1), (12) and CN2 (female) (8), (18) normal?
YES
NO
Disconnection or defective contact in wiring harness between T01 (female) (9) Repair or - CN-ST1 (female) (1), (12) - CN2 (female) replace (8), (18)
Defective engine controller
Replace
N-1. Related electrical circuit diagram
20-256 4
D155AX-5
N-2
TROUBLESHOOTING
N-2 [E0104] (Abnormality in network system: monitor panel system) is displayed Cause
Remedy
1 • Turn starting switch ON.
NO
Are service codes [E0101] and [E0105] displayed, too?
YES
Go to N-4
2 • Turn starting switch OFF. • Disconnect T01 and CN1. • Max. 1 Ω
Is resistance between T01 (female) (10) and T01 (female) (11), (12) normal?
YES
NO
Disconnection or defective contact Repair or in wiring harness between T01 (female) (10) - T01 (female) (11), (12) replace
Defective monitor panel (caution module)
Replace
N-2. Related electrical circuit diagram
D155AX-5
20-257 4
N-3
TROUBLESHOOTING
N-3 [E0105] (Abnormality in network system: HSS controller system) is displayed Cause
Remedy
1 • Turn starting switch ON.
NO
Are service codes [E0101] and [E0104] displayed, too?
YES
Go to N-4
2 • Turn starting switch OFF. • Disconnect T01 and CN1. • Max. 1 Ω
Is resistance between T01 (female) (9) and CN-ST1 (female) (1) normal?
NO
Disconnection or defective contact in wiring harness between T01 (female) (9) - ST1 (female) (1)
Repair or replace
Defective HSS controller
Replace
YES
N-3. Related electrical circuit diagram
20-258 4
D155AX-5
N-4
TROUBLESHOOTING
N-4 [E0101], [E0104], and [E0105] (Abnormality in network system) are displayed at same time Cause
Remedy
1 • Disconnect CN1. • Turn starting switch ON.
NO
When CN1 is disconnected, are all service codes turned off?
YES
Defective monitor panel (caution module)
Replace
Defective HSS controller
Replace
Defective engine controller
Replace
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between T01 (10) - CN1 (female) (11), (12) or between T01 (9) - CN-ST1 (female) (1), or between CN-ST1 (female) (12) - CN-2 (female) (8), (13)
Repair or replace
Defective monitor panel (tachometer module)
Replace
2 • Disconnect CN-ST1. • Turn starting switch ON.
NO
When CN-ST1 is disconnected, are all service codes turned off?
YES
3 • Disconnect CN-2. • Turn starting switch ON.
NO
When CN-2 is disconnected, are all service codes turned off?
YES
4 • Disconnect T01. • Turn starting switch ON. • Min. 7.5 V
Is voltage between T01 (female) (9) and chassis ground normal?
NO
YES
N-4. Related electrical circuit diagram
D155AX-5
20-259 4
TROUBLESHOOTING
N-5
N-5 [E0152] (Abnormality in network system: HSS controller system) is displayed Cause
Remedy
1 • Turn starting switch ON.
NO
Are all of service codes [E0101], [E0104], and [E0105] displayed, too?
YES Go to N-4
2 • Turn starting switch ON.
Is any one of service codes [E0101], [E0104], and [E0105] displayed, too?
NO
Defective HSS controller
Replace
YES Go to N-1, 2, or 3 according to displayed service code
20-260 4
D155AX-5
TROUBLESHOOTING
N-6
N-6 [E0165] (Error in network communication) is displayed Cause
Remedy
1 • Turn starting switch ON.
NO
Does monitor panel display normally?
YES Defective monitor panel
Replace
Disconnection or defective contact in wiring harness between T01 (female) (9) and CN-ST1 (female) (1)
Repair or replace
Defective HSS controller
Replace
2 • Turn starting switch OFF. • Disconnect T01 and CN-ST1. • Max. 1 Ω
Is resistance between T01 (female) (9) and CN-ST1 (female) (1) normal?
YES
NO
N-6. Related electrical circuit diagram
D155AX-5
20-261 4
TROUBLESHOOTING
N-7
N-7 [E0436] (Abnormality in network system: engine controller) is displayed
Cause
Remedy
1 • Turn starting switch ON.
NO
Are all of service codes [E0101], [E0104], and [E0105] displayed, too?
YES
Go to N-4
2 • Turn starting switch ON.
Is any one of service codes [E0101], [E0104], and [E0105] displayed, too?
NO
Defective engine controller
Replace
YES Go to N-1, 2, or 3 according to displayed service code
20-262 4
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) [Serial No. 70001 – 75000]
Method of using troubleshooting charts ............................................................................................. 20-302 S- 1
Starting performance is poor (starting always takes time) .................................................. 20-306
S- 2
Engine does not start ............................................................................................................... 20-307 1 Engine turns but exhaust gas does not comes out (fuel is not being injected) ......... 20-307 2 Exhaust gas comes out but engine does not start (fuel is being injected) ................. 20-308
S- 3
Engine does not pick up smoothly (follow-up is poor) ........................................................ 20-309
S- 4
Engine stops during operation ................................................................................................ 20-310
S- 5
Engine does not rotate smoothly (hunting) ........................................................................... 20-311
S- 6
Engine lacks power ................................................................................................................... 20-312
S- 7
Exhaust gas is black (incomplete combustion) ...................................................................... 20-313
S- 8
Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20-314
S- 9
Oil becomes contaminated quickly ......................................................................................... 20-315
S-10
Fuel consumption is excessive ................................................................................................ 20-316
S-11
Oil is in cooling water, or water spurts back, or water level goes down .......................... 20-317
S-12
Oil pressure caution lamp lights up (drop in oil pressure) .................................................. 20-318
S-13
Oil level rises (water or fuel mixed with oil) ......................................................................... 20-319
S-14
Water temperature becomes too high (overheating) ............................................................ 20-320
S-15
Abnormal noise is made .......................................................................................................... 20-321
S-16
Vibration is excessive ............................................................................................................... 20-322
fl Serial No. 75001 and up: See 140-3 series engine shop manual.
D155AX-5
20-301 4
TROUBLESHOOTING
METHOD
METHOD
OF USING
OF USING TROUBLESHOOTING
TROUBLESHOOTING
CHARTS
CHARTS
This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspection without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections @ + @ in the chart on the right correspond to the items where answers can be obtained from the user. The items in @ are items that can be obtained from the user, depending on the user’s level. [Check items1 The serviceman carries out simple inspection to narrow down the causes. The items under @ in the chart on the right correspond to this. The serviceman narrows down the causes from information @ that he has obtained from the user and the results of @ that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].
I
f
@
(a)
5
(b)
2
(c)
u
(d)
20-302
Causes I
0 0 0 0
D155AX-5
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items1 that have a relationship with the Cause items are marked with 0, and of these, causes that have a high probability are marked with Q. Check each of the [Questions] and [Check items1 in turn, taking note of the 0 or Q marks in the chart for the horizontal lines of symptoms applicable to the machine. The vertical column (Causes) that has the highest number of applicable 0 or Q marks is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. %I. For (Confirm recent repair history) in the [Questions] Section, ask the user, and mark the Cause column with A to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. 332. Use the A in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.
D155AX-5
20-303
METHOD
TROUBLESHOOTING
OF USING
TROUBLESHOOTING
CHARTS
.
Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have a causal relationship with this problem: [Exhaust gas gradually became black], [Power gradually became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with 5 causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. s-7
Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black. . Insufficient intake of air. . Improper condition of fuel injection. . Excessive injection of fuel.
Dust indicator is red
D
Clanging sound is heard from around cylinder head Exhaust Muffler
noise is abnormal is crushed
Air leakagelloose
clamp between turbocharger and cyl. head
0
>.* j$ 0
0
&
0
k$$i
0
tiil When muffler is removed, exhausx gas color ret”rns to normal When control rack is pushed, it is found fo be heavy or doer “at retUrn
20-304
D155AX-5
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items1 section and the 5 Cause items in the vertical column.
Three symptoms
Step 2 Add up the total of Oand Omarked where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (I) Clogged air cleaner element: 000 (2) Air leakage between turbocharger 00 and cyl. head: (3) Clogged, seized injection nozzle: 0 (4) Defective contact of valve, valve seat: 0 (5) Worn piston ring, cylinder: 0 Step 3 The calculations in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.
D155AX-5
20-305
TROUBLESHOOTING
S-l
Starting
S-l
performance
is poor (starting
Possible causes of the engine not starting discharged. . Electrical system is defective. . Fuel supply is insufficient. . Air intake is insufficient. . improper selection of fuel (At ambient
temperature
though
exhaust
always takes time)
gas is
or below, use ASTEM D975
of -10°C
No. 1)
*
.
. -f
Causes
Batterv
charaina rate
20°C
1.28
1.26
1.24
1.23
1.22
0°C
1.29
1.27
1.25
1.24
1.23
-10°C
1.30
1.28
1.26
1.25
1.24
A battery can be used if the specific gravity shows 70% or higher charging rate as per the above table. In cold weather, 75% or higher charging rate is required. Confirm no abnormality display of electronic governor controller system.
//
Compression pressure measurement found low pressure Direct inspection of the air cleaner found clogging 1 1 Direct inspection of the fuel fi lter and strainer found clogging Direct inspection of the feed pump strainer found clogging I cnr-LB__*__lll”“lll - ^..^. DcbLI”II ^^A:^.. :^ ..-+ !-._%+_A “calm ID
.g
8 f z
:
1’=
ll”L
1-1 , , I I.1 I
, , , , , , , I I I I I I I I.1
IlrmLr”
Voltage (26 -30 v) rises between alternator terminals R and E % No voltage (26 - 30 V) between alternator terminals R and E Either specific gravity or voltage of the battery is low Stop fuel injection to one cylinder at a time. If there is no chanqe in engine speed, that cylinder is not workino. Checking deliven/ method found deviation in injection timing When pushed, the control rack is heavy, or does not return (Remove the blind cover at the rear of the pump. Plunger control sleeve does not move) Direct inspection of the fuel cap found clogging
I % Replacement permissible.
20-306
of regulator
only is not
Remedy
D 155AX-5
TROUBLESHOOTING
s-2
Engine does not start
s-2 0
Engine runs but exhaust gas does not come out (fuel is not being injected)
Ir
Confirm that no abnormality of governor controller is displayed on the machine monitor panel. Possible causes of no exhaust gas coming out though engine is running. . Fuel is not supplied. . Fuel supply is very low. . Improper fuel is used. (particularly in winter)
*
Fuel selection
standard
I
*
I
I
I
I
,
In winter, if Class 3 oil is not available, you may use mixture of Class 2 diesel fuel and kerosene at the rate of 1 : 1.
CConfirm recent
.-6 v !z
1
repair history
C)egree of use
Operated for long perioc
Eixhaust gas suddenly (when starting again) stops coming out
u
:iltershave not bean replaced accordingto the operation manual
/
rlud is stucking to fuel tank cap
‘here is leakage from fuel piping
Jo fuel comes out when draining fuel filter When the engine is cranked by the starter motor, 1) Injection pump coupling does not rotate 2) Even though the fuel filter air bleeder plug is loosened, fuel does not come out 3) Even though the injection pipe sleeve nut is loosened, fuel does not spurt out Nhen fuel is drained, rust and water come out
D 155AX-5
20-307
s-2
TROUBLESHOOTING
Causes
@
Exhaust gas comes out but engine does not start (fuel is being injected)
General causes why exhaust gas comes out but engine does not start. . Lack of rotating force due to defective electrical system. . Insufficient supply of fuel. . Insufficient intake of air. . Improper selection of fuel.
When fuel lever contact stopper
E
a, C Y
When
engine
is placed
at FULL position,
it does
not
I loI
is cranked
with
starting
I I I I
I I I I I I
motor,
1) Little fuel comes nut is loosened
out even when
injection
pump
2) Little fuel comes is loosened
out even when
fuel filter
air bleed
0
sleeve
4
6
There
is leakage
from
fuel filter
Remove
is drained,
head cover
@
fuel piping
When exhaust manifold is touched immediately starting engine, temperature of some cylinders When
plug
no fuel comes
after is low
out
and check directly
When control rack is pushed, does not return
it is found
0 to be heavy,
or
0
finer are mspacte
20-308
D155AX-5
s-3
TROUBLESHOOTING
S-3
Engine does not pick up smoothly
(follow-up
is poor)
*
Confirm that no abnormality of electric governor controller is displayed. General causes why engine does not pick up smoothly. . Insufficient intake of air. . Insufficient supply of fuel. . Improper condition of fuel injection. . Use of improper fuel.
operation
manual
Non-specified Engine
fuel has been
oil must
Dust indicator
be added
Engine
freauentlv
when
fuel
is red
Rust and water Interference
used
more
are found
sound
heard
pick-up
suddenly
of exhaust
gas
around
is drained
became
poor Blue
Color
I I I I I I PI
turbocharger
under
light
load
Black
1 Blow-by
I I I I I
gas is excessive
When air cleaner
is inspected
directly,
it is found to be clogged
iner are inspected
When
control
Turbocharger
rack is pushed,
cannot
it is found
be hand-rotated
When valve clearance is checked outside standard value When
fuel cap is inspected
When feed pump is operated,
directly,
operation
l
are
to be heavy
or does
it is found
it is found
to be
l
to be clogged
is too light or tw
heavy
0 c
Remedy
D 155AX-5
I I I I I
smoothly
directly,
directly,
they
I I I
1 101 [ 101 lolo] 1 I I I 1 10 lel I lol I lot I I lo
c
r
.i
2
4 4 z e $ UUO~~~~QUrC~
$8 $
;; 2
$
c i
$,
z
0
2
20-309
s-4
TROUBLESHOOTING
S-4
Engine stops during operation
*
Confirm that fuel gauge on machine monitor indicates certain amount of fuel. Possible causes of engine stoppage during operation. l Seizure of parts inside the engine. . Fuel supply amount is insufficient. . Overheating. * If the engine stops due to overheating, carry out appropriate troubleshooting. l Trouble in the power train. Ir If the engine stops due to trouble in the power train, carry out troubleshooting of the body.
Confirm
recent
Degree
repair
history Operated
of use
Conditions stopped
when
the engine
When operating the feed operation is difficult Mud
pump,
1 Remove Remove When
2
The engine
checked,
t
Inspection
2
Inspection
e k
Engine stopped suddenly with abnormal sound
000000
Engine stopped overheating
00
no response
with
is returned,
0
00
0
or
I I I
I I I I I I I
Directly
by etc.
1.101
when
pump
of the fuel filter of the feed
+hn mn+.,4
does
not turn
accessories
and strainer
pump
check the feed
c 2 a 2
I
and the ck directly
the gear train
turns
\A,hnn n, *&3&i
20-310
nn
period
the oil oan and check directly the head cover
‘g
rr
for long
is stuck to fuel tank ca
When turning the engine hand with a barring tool,
P
Causes
strainer
found
clogging
! ! ! ! ! ! ! !.! 0
clogging
cx ! ! ! ! 4 I I I! 0
pump r%.k ic x,0_, h~.\,v
&a
are removed
found
nr rln-
nnt r&l ,r”
D155AX-5
TROUBLESHOOTING
S-5
s-5
Engine does not rotate smoothly
(hunting)
Ir
Confirm that no abnormality of electric governor is displayed. General causes why engine does not rotate smoothlv (hunting). Air in fuel system. . Defective governor mechanism. . Defective electrically controlled throttle mechanism. (electrically controlled throttle type) Ir If hunting does not occur when rod connecting governor motor and fuel injection pump is disconnected, carry out troubleshooting for electrical system.
Causes
l
When feed pump is operated
When feed pump stramer IS mpecte
When fuel filter, strainer are inspected directly, they are found to be clogged
D155AX-5
20-311
S-6
TROUBLESHOOTING
S-6
Causes
Engine lacks power /////I/
General causes why engine lacks output. . Insufficient intake of air. . Insufficient supply of fuel. . Improper condition of fuel injection. . Use of improper fuel. (if non-specified fuel is used, output drops) . Lack of output due to overheating. * If there is overheating and insufficient output, carry out troubleshooting for overheating.
Power was lost
ration manual
Blow-by gas is excessive Engine pickup is poor and combustion is irregular High idling speed under no load is normal, but speed suddenly drops when load is applied exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
opfuel
20-312
0
0 00
I I I I I
00
0
I I I I
injection to 0
D155AX-5
s-7
TROUBLESHOOTING
S-7
Exhaust gas is black (incomplete
General causes why exhaust gas is black. . Insufficient intake of air. . improper condition of fuel injection. . Excessive injection of fuel.
s .I
Color
combustion) Causes
/////////l
of exhaust gas
2
u
Power was lost
D155AX-5
20-313
S-8
TROUBLESHOOTING
S-8
Oil consumption
is excessive (or exhaust gas is blue)
*
Do not run the engine at idling for more than 20 minutes continuously. (both low and high idling) is excesGe neral causes why oil consumption siv le. . Abnormal combustion of oil. . External leakage of oil. . Wear of lubrication system.
Amount of blow-by gas Area around engine is dirty with oil There is oil in engine cooling water When exhaust pipe is removed, inside is found t
20-314
D155AX-5
s-9
TROUBLESHOOTING
S-9
Oil becomes contaminated
quickly
General causes why oil becomes contaminated quickly. . Intake of exhaust gas due to internal wear. . Clogging of lubrication passage. . Improper combustion. . Use of improper oil. Operation under excessive load.
Causes
l
Confirm recent repair history .-s
Degree of use
5
Engine oil must be added more frequently
z
Non-specified fuel has been used
Operated for long period
n
n
a
0
0 Blue under light
I
Color of exhaust gas Black Abnormally exe Amount of blow-by gas
I
When compression pressure is measured, it is found to be low When breather element is inspected directly, it is found to be clogged with
0
dirty oil, or hose is broken When oil filter is inspected directly, it is found to be clogged When oil cooler is inspected directly, it is found to be clogged
0
Clogged turbocharger drain tube
.
Excessive play of turbocharger shaft
E z
When safety valve is directly inspected, spring is found to be catching or broken
D 155AX-5
I
I
I
I
I
I
I
1.1
20-3 15
s-10
TROUBLESHOOTING
S-IO Fuel consumption
is excessive
General causes why fuel consumption is excessive. . Leakage of fuel. . Improper condition of fuel injection. . Excessive injection of fuel.
More Condition
than for other
machines
of
of fuel consumption
Black Exhaust
gas color White
When
exhaust
temperature
manifold of some
Match
mark
There
is external
on injection
Engine
oil level
Engine
low
lniection Stop fuel speed,
injection
When
control
When
check
engine,
I
IQ/C
0
0
fuel
0
that iniection
amount
at a time.
I 0
engine
of diesel
to one cylinder
00 0
is incorrect
If there
is no change
in engine
is not working.
rack is pushed, is made
starting
is high
test shows
that cylinder
after
is misaligned
of fuel from
rises and smells speed
immediately
is low
pump
leakage
idling
oumo
is touched
cylinders
using
it is found
delivery
to be heavy
method,
or does
injection
timing
not return is found
to be
incorrect Remove
head cover
and check directly
Remove
feed
pump
and check directly
engine
speed
is measured,
When
low
idling
speed
is found
to be high
Remedy
20-3 16
D 155AX-5
TROUBLESHOOTING
S-II
S-l 1
Oil is in cooling water, down
or water spurts back, or water level goes
General causes why oil is in cooling water. . Internal leakage in lubrication system. . Internal leakage in cooling system.
Pressure-tightness
test of oil cooler
Pressure-tightness
test of cylinder
Remove
cylinder
head
Remove
oil pan and check
shows head
there
shows
is leakage there
is leakage
and check directly directly
I
D 155AX-5
Remedy
20-3 17
s-12
TROUBLESHOOTING
S-12 Oil pressure caution lamp lights up (drop in oil pressure) Possible causes of the oil pressure caution lamp lighting up. . Leakage, clogging, or wear of the lubricating system. . Oil pressure control failure. . Use of improper oil. (improper viscosity) . Dearadation of oil due to overheating. sr Confirm engine oil level is normal before troubleshooting.
*
Standard
for engine
-22
-4
oil selection
14
Filters
32
50
have not been
Non-specified
68
replaced
oil has been
as specified
used for long
1 Lights Leakage
or crushing
in the oil piping
When
the oil is drained,
Metal
chips
attach
Oil is cloudy
white,
in the operation
metal
chips
up once
system come
in a while
(external) 0
out
I
to the oil filter
in the relief
20-3 18
or smells
valve
0
element
like diesel
or regulator
01
I
I
I
I
1 1 1 1
oil
valve,
or damage
of
D155AX-5
TROUBLESHOOTING
s-13
S-13 Oil level rises (water or fuel mixed with oil) *
If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”. Ger leral causes why oil level rises. . Water in oil. . Fuel in oil. (diluted, and smells of diesel fuel)
D155AX-5
20-3
19
s-14
TROUBLESHOOTING
S-14 Water temperature
becomes too high (overheating)
If coolant level lamp on monitor panel is not lighted. If coolant temperature checked by water temp. gauge on machine monitor is normal, refer to “Machine monitor troubleshooting M-mode”. General causes why water temperature becomes too high. . Lack of cooling air. (deformation, damage of fan) . Drop in heat dissipation efficiency. . Defect in cooling circulation system. Ir Carry out troubleshooting for chassis.
Confirm
recent
1Degree
repair
CY
Condition
Causes
history
1Operated
of use
for long period
Suddenly
.-6 j; 2
I lllllllllll/
overheated
of overheating Always
tends
to overheat
Rises auicklv Water
temperature
gauge /
/I Fan belt whines Cloudy
white
Cooling
water
Excessive 1 Engine
under
sudden
oil is floating flows
out from
air bubbles
oil level
load
on cooling
inside
has risen,
radiator,
When
light bulb is held behind
Water
is leaking
Belt tension
is found
Temperature tanks
spurts
back
white
are clogged with dirt or muc
radiator,
of cracks
no light passes through
in hose or loose
clamps
to be slack
difference
between top and bottom
radiator
between
radiator
is excessive
Temperature tanks
hose water
oil is cloudy
Radiator shroud, inside of underguard
because
water
overflow
difference
top and bottom
I
slight
I@I
When
a function
not open
even
test is carried at the cracking
When water temperature
measurement
pressure When
is made
is found
to be low
compression
pressure
Remove
directly, with
it is found to be normal
I
I
I
I
I
I
radiator
cap tester,
I I I I Iel I I I I I I I I I I I I I.1 I I I I
set
I it
isfound to
I
I
I
I
I
I
I
be low
I
I
0
oil pan and check directly
a $ Remedy
20-320
I
0
it is found to be clogged
is measured,
I
it does
temperature
is measured,
When oil cooler is inspected When
out on the thermostat,
I
l
When water filler port is inspected, the core is found to be clogged
.=
.;
$ 0 8 ~cccc$drc~$$
z
4
.;
%
$
g
g
$
g
g
$
$j
$
$
5
{g
LT a:
D 155AX-5
TROUBLESHOOTING
s-15
S-15 Abnormal
noise is made Causes
*
Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made. Abnormality due to defective parts. Abnormal combustion noise. Air sucked in from intake system.
Engine
oil must
be added
more
frequently Blue under
Color
of exhaust
light
load
Metal
particles
are found
Vibrating
noise
clamp is heard
Whencomoression Turbocharger
When
D 155AX-5
in oil filter
gas is excessive
Air leakage/loose
valve
between from
turbocharger
around
be hand-rotated
clearance
is checked
and cy~. head
101
1 1 1 I
lol lol
101 I I I I I I I I I I I I I I I I I I
I
1 I
it isfoundto
below
smoothly
directly,
it is found
I
I
I
I lol
1
I I I I I I I I I I I IG
muffler
oressureismeasured.
cannot
I I I I I I I I I I
I 101 I I I I lol
gas Black
Blow-by
lol
IO I I I I I I I I I I I I I.1 I I I I I I I I I
to be
20-321
TROUBLESHOOTING
S-16 Vibration
S-16
is excessive
Ir
If there is abnormal noise together with the vibration, carry out troubleshooting for “Abnormal noise is made”. General causes why vibration is excessive. . Defective parts. (abnormal wear, breakage) . Improper alignment. . Abnormal combustion.
20-322
7~~
Causes
D155AX-5
/
TROUBLESHOOTING OF HSS CONTROLLER AND ELECTRICAL SYSTEM (E MODE)
Action taken by controller when abnormality occurs and problems on machine.. ....................... .20-402 Electrical circuit diagram for E mode .................................................................................................. 20-410 20-412 E-l. [I91 Short circuit in steering oil pressure sensor system A is displayed ............................. E-2. PO1 Disconnection in steering oil pressure sensor system A is displayed.. ....................... .20-413 E-3. I211 Short circuit in steering oil pressure sensor system B is displayed.. .......................... .20-414 E-4. 1221 Disconnection in steering oil pressure sensor system B is displayed.. ....................... .20-415 systems 1 and 2 is displayed ................................ -20-416 E-5. 1231 Trouble of steering potentiometer system 1 is displayed ................................... 20-417 E-6. 1241 Disconnection in steering potentiometer system 1 is displayed ..................................... .20-418 E-7. 1251 Short circuit in steering potentiometer system 2 is displayed .................................. .20-419 E-8. [261 Disconnection in steering potentiometer system 2 is displayed ...................................... 20-420 E-9. 1251 Short circuit in steering potentiometer 20-421 E-10. [291 Trouble of engine rotation sensor system is displayed ................................................. system is displayed ................ .20-422 E-11. [511 Short circuit in travel reverse sensing potentiometer in travel reverse sensing potentiometer system is displayed ............. .20-423 E-12. 1521 Disconnection in backup alarm relay system is displayed ............................................ 20-425 E-13. 1531 Disconnection 20-426 E-14. I541 Short circuit in backup alarm relay system is displayed ............................................... 20-427 E-15. 1571 Low voltage of controller is displayed ............................................................................. E-16. [621 Excessive difference of signal value between steering potentiometer systems 1 and 2 is displayed [II ................................................................................. 20-428 E-17. [6dl Excessive difference of signal value between steering potentiometer systems 1 and 2 is displayed [III ................................................................................ 20-429 system and excessive deviation E-18. [6El Trouble of either steering potentiometer of neutral point signal of either system is indicated.. .............................................. 20-430 in HSS pump solenoid valve system A is displayed.. .......................... .20-431 E-19. [641 Disconnection .20-432 E-20. I651 Short circuit in HSS pump solenoid valve system A is displayed.. ............................. in HSS pump solenoid valve system B is displayed ............................ .20-433 E-21. 1661 Disconnection 20-434 E-22. 1671 Short circuit in HSS pump solenoid valve system B is displayed ................................ E-23. I701 Short circuit in work equipment circuit oil pressure sensor system is displayed.. .... .20-435 in work equipment circuit oil pressure sensor system is displayed.. . .20-436 E-24. 1711 Disconnection error is displayed ....................................................... 20-437 E-25. [8dl System network communication of reverse sensing potentiometer and E-26. 1991 Disagreement backup alarm switch signals with each other is displayed ..................................... 20-438 20-440 E-27. [EOI Trouble of offset current memory is displayed.. ............................................................. 20-441 E-28. Backup alarm does not sound ................................................................................................... E-29. Blade pitch does not work normally (When equipped with pitch dozer) ............................ .20-442 E-30. Ripper pin puller does not work normally (When equipped with giant ripper). ................. .20-444 E-31. Engine does not start (Engine does not rotate). ...................................................................... 20-446
D155Ax-5
20-40 1
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE irror
Abnormal
Lode
system
Nature
Condition
of abnormality
(voltage,
% When signal voltage of oil pressure sensor A exceeds 6.OOOV * Voltage between Short circuit in steering oil 19
pressure sensor system
Disconnection in steering oil pressure sensor system
A
Short circuit in steering oil 21
pressure sensor system B
Disconnection in steering oil
22
pressure sensor system
B
.
% When signal 6.OOOV
- Voltage
sensor
A exceeds
1. Defective steering oil pressure sensor B 2. Short circuit with power source in wiring harness
between
1
steering
CN-2H2 system
(1) -CN-2Hl is in neutral:
0.90 - 1.5ov When steering system is relieved: 3.95 - 4.6OV (Both sides)
between steering
CN-2H2 system
(9) - CN-2Hl is in neutral:
0.90 - 1.5ov When steering system is relieved: 3.95 - 4.6OV (Both sides)
* Voltage between CN-PHI (19) - (9) (System 1) when steering system is in neutral: 2.4 - 2.6V When machine is fully steered to left: 4.1 4.3v When machine is fully steered to right: 0.73 0.89v * Voltage between CN-2Hl (20) - (9) (System 2) When steering system is in neutral: 2.4 - 2.6V When machine is fully steered to I& 0.6 l.lV When machine is fully steered to right: 3.9 4.4v . Sum of above signal voltages of systems 1 and 2 ~/SUM) 4.6V t VSUMt 5.4v
signal voltages 1 and 2 lower
of both steering
potentiometer
below 0.5OOV or exceed
sys-
4.5OOV
signal
voltage
of steering
potentiometer
system
(9) When
between steering
CN-2H2 system
(9) - CN-2Hl is in neutral:
0.90 - 1.5ov When steering system is relieved: 3.95 - 4.6OV (Both sides)
1 * Voltage between CN-2Hl (19) - (9) When steering system is in neutral:
exceeds 4.5OOV 1. Defective steering potentiometer 2. Defective contact, disconnection or short circuit with power source in wiring harness between controller CN-2Hl (19) -
potentiometer CN-STR (3) 3. Defective contact or disconnection in wiring harness between controller CN-2Hl (9) - potentiometer CN-STR (I) 4. Defective
20-402
between
x When
% When
system
(9) When
* Voltage
and 2
24
(1) -CN-2Hl
% When signal voltage of oil pressure sensor B lowers below 0.5oov 1. Defective steering oil pressure sensor B 2. Defective contact or disconnection in wiring harness between fuse 5 - oil pressure sensor STHP2 (2) 3. Defective contact, disconnection or short circuit with chassis ground in wiring harness between controller CN-2H2 (9) - oil pressure sensor STHP2 (3) 4. Defective HSS controller
Trouble of steering potentiometer systems 1
Disconnection in steering potentiometer
Voltage
(9) When
controller CN-2H2 (9) - oil pressure sensor STHP2 (3) 3. Defective contact or disconnection in wiring harness between controller CN-2Hl (9) -oil pressure sensor STHP2 (I) 4. Defective HSS controller
terns
23
of oil pressure
CN-2H2
- 4.6OV (Both sides)
(1)
% When signal voltage of oil pressure sensor A drops below 0.5oov 1. Defective steering oil pressure sensor A 2. Defective contact or disconnection in wiring harness between fuse 5 - oil pressure sensor STHPl (2) 3. Defective contact, disconnection or short circuit with chassis ground in wiring harness between controller CN-2H2 (1) - oil pressure sensor STHPl (2) 4. Defective HSS controller voltage
normal resistance)
(9) When steering system is in neutral: 0.90 - 1.5ov When steering system is relieved: 3.95
2. Short circuit with power source in wiring harness between controller CN-2H2 (1) - oil pressure sensor STHPI (3) 3. Defective contact or disconnection in wiring harness between controller CN-2Hl (9) - oil pressure sensor STHPl 4. Defective HSS controller
A
20
1. Defective steering oil pressure sensor A
when
current,
2.4 - 2.6V When machine is fully steered to left: 4.1 - 4.3v When machine is fully steered to right: 0.73 - 0.89V
HSS controller
D155AX-5
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Action
by controller
when abnormality
I. Calculates with steering circuit oil pressure !. Cannot limit swash plate angle of pump
Problem
is detected as 0. when
that appears
on machine
when there is abnormality
steering
1. If machine
is steered
under heavy
2. If machine
is steered
under light load, it operates
load, engine
stalls. normally
circuit oil pressure is high or steering circuit is relieved. 3. Flashes alarm lamp and turns alarm buzzer on.
1. Calculates with steering circuit oil pressure 2. Cannot limit swash plate angle of pump
as 0. when
steering
1. If machine
is steered
2. If machine
is steered
under heavy
load, engine
under light load, it operates
stalls. normally
circuit oil pressure is high or steering circuit is relieved. 3. Flashes alarm lamp and turns alarm buzzer on.
I. Calculates with steering circuit oil pressure !. Cannot limit swash plate angle of pump
as 0. when
steering
1. If machine
is steered
under heavy
2. If machine
is steered
under light load, it operates
load, engine
stalls. normally
circuit oil pressure is high or steering circuit is relieved. 3. Flashes alarm lamp and turns alarm buzzer on.
I. Calculates with steering circuit oil pressure as 0. 3. Cannot limit swash plate angle of pump when steering circuit oil pressure is high or steering circuit is relieved. 3. Flashes alarm
lamp and turns alarm
1. Controls
with signals of steering
D155AX-5
potentiometer
lamp and turns alarm
is steered
under heavy
is steered
under light load, it operates
load, engine
stalls. normally
buzzer on.
I. Controls with signals before occurrence of abnormality til machine stops. 3. Flashes alarm lamp and turns alarm buzzer on.
2. Flashes alarm
1. If machine 2. If machine
2.
un-
1. Steering before occurrence of abnormality is continued machine stops. 2. Once machine stops, it cannot be steered.
1. Machine
can travel
unti
and steer normally.
buzzer on.
20-403
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
rror
Abnormal
Dde
system
Nature
Condition
of abnormality
(voltage, 3%When
Short circuit
5
in steering potentiometer system
1
signal voltage of steering potentiometer system 1 lowers below 0.5OOV 1. Defective steering potentiometer 2. Defective contact, disconnection or short circuit with chassis ground in wiring harness between controller CN2Hl (10) - potentiometer CN-STR (4) 3. Short circuit with chassis ground in wiring harness between controller CN9Hl (19) - potentiometer 4. Defective HSS controller % When
signal voltage
exceeds
‘6
Disconnection in steering potentiometer system 2
Short circuit !7
potentiometer
!9
of
rotation sensor system
system
2
or short circuit with between controller CN-
il
sensing potentiometer system
Disconnection
2
in travel reverse sensing potentiometer system
13
Disconnection in backup alarm relay system
Short circuit i4
in backup alarm relay system
machine left: 4.1 - 4.3V When machine
is fully steered
to
is fully steered right: 0.73 - 0.89V
to
* Voltage between CN-2Hl (20) - (9) When steering system is in neutral: 2.4 - 2.6V When machine is fully steered to left: 0.6 - l.lV When machine is fully steered right: 3.9 - 4.4V
of steering potentiometer system 2 lowers below 0.5OOV 1. Defective steering potentiometer 2. Defective contact, disconnection or short circuit with chassis ground in wiring harness between controller CN2Hl (10) - potentiometer CN-STR (4) 3. Short circuit with chassis ground in wiring harness between
* Voltage between CN-2Hl (20) - (9) When steering system is in neutral: 2.4 - 2.6V When machine is fully steered to left: 0.6 - l.lV When machine is fully steered right: 3.9 - 4.1V
chassis ground in wiring harness between 2H2 (12) - rotation sensor CN-ENG (2) 5. Defective HSS controller
controller
* Resistance between CN-ENG (male) (1) - (2): 500 - 1,000 n * Resistance between CN-ENG (female) (4) - (12): 500 - 1,000 D
CN-
signal voltage of travel reverse sensing potentiometer exceeds 4.7OOV 1. Defective travel reverse sensing potentiometer 2. Defective contact or disconnection in wiring harness between controller CN-2Hl (9) - potentiometer CN-RSS (3) 3. Short circuit with power source in wiring harness between controller CN-2H2 (IO) - potentiometer CN-RSS (2) 4. Defective HSS controller
* Voltage
.% When signal voltage of travel reverse sensing potentiometer lowers below 0.3OOV 1. Defective travel reverse sensing potentiometer 2. Defective contact, disconnection or short circuit with chassis ground in wiring harness between controller CN2H2 (IO) - potentiometer CN-RSS (2) 3. Defective contact, disconnection or short circuit with chassis ground in wiring harness between controller CN2Hl (IO) - potentiometer CN-RSS (1) 4. Defective HSS controller
* Voltage
1. Defective 2. Defective
.
backup contact
alarm
relay or disconnection
in wiring
harness
between controller CNI (11) - relay CN-014 (1) 3. Defective contact or disconnection in wiring harness between relay CN-014 (2) - CN-SX8 (Chassis ground) 4. Defective HSS controller 1. Defective backup alarm relay 2. Short circuit with chassis ground between CNI (11) - relay CN-014 HSS controller
to
CN-STR (2)
1. Defective engine rotation sensor 2. Wrong installation of engine rotation sensor 3. Defective contact or disconnection in wiring harness between controller CN-2H2 (4) - rotation sensor CN-ENG (I) 4. Defective contact, disconnection or short circuit with
3. Defective
to
HSS controller
signal voltage
% When
Short circuit in travel reverse
When
(20) - potentiometer CN-STR (2) 3. Defective contact or disconnection in wiring harness between controller CN-2Hl (9) - potentiometer CN-STR
controller CN9Hl (20) - potentiometer 4. Defective HSS controller
Trouble engine
* Voltage between CN-2H1 (19) - (9) When steering system is in neutral: 2.4 - 2.6V
2Hl
% When
normal resistance)
CN-STR (3)
4.5OOV
1. Defective steering potentiometer 2. Defective contact, disconnection power source in wiring harness
(1) 4. Defective
in steering potentiometer system 2
of steering
when
current,
between
harness
(IO) - CN-
is in neutral:
Max.
3.5oov When joystick
is in reverse
position
3.500 - 4.4oov
between
CN-2H2
(IO) - CN-
2Hl (9) When joystick
is in neutral: Max. 3.5oov When joystick is in reverse position: 3.500 - 4.4oov
Voltage
between
ground When joystick When
joystick
CN-1 (I I) - chassis
is in neutral: Max. IV is in reverse position:
20 - 3ov
* Voltage in wiring (1)
CN-2H2
2Hl (9) When joystick
between
ground When joystick When
joystick
CN-1 (11) - chassis
is in neutral: Max. 1V is in reverse position:
20 - 3ov
20-404
D 155AX-5
OCCURS AND PROBLEMS ON MACHINE
rROUBLESHOOTlNG
Problem that appears on machine when there is abnormality
Action by controller when abnormality is detected
i . Controls
2.
1. Machine
can travel
and steer normally.
i . Controls 2 . Flashes
with signals of steering potentiometer 1. alarm lamp and turns alarm buzzer on.
1. Machine
can travel
and steer normally.
i . Controls 2 . Flashes
1. Machine
can travel
and steer normally.
alarm
with signals of steering
2 Flashes alarm
potentiometer
lamp and turns alarm
with signals
of steering
buzzer on.
potentiometer
lamp and turns alarm
i . Calculates with 2 . Cannot control engine
speed
i . Controls 2 . Flashes
1.
buzzer on.
engine speed as Orpm. swash plate angle of HSS pump when is high.
1. Machine can travel and steer normally. 2. If machine is steered frequently on downhills, durability of HSS motor may be lowered. 3. Neutral position for steering cannot be adjusted.
with signals of backup alarm software alarm lamp and turns alarm buzzer on.
1. Machine
can travel
and steer normally.
with signals of backup alarm software 2 . Flashes alarm lamp and turns alarm buzzer on.
1. Machine
can travel
and steer normally.
3. Controls
. Takes
no particular
action.
1. Backup alarm
does not sound.
1. Backup alarm
does not sound.
L
11. Turns
off output
to backup alarm
relay
L
D155AX-5
20-405
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
rror ode
Abnormal system x
When
source voltage of controller contact or disconnection
1. Defective Dropping i7
of
source voltage of controller
Condition when normal (voltage, current, resistance)
Nature of abnormality drops below 17V in wiring harness
;2
signal value between steering potentiometer systems 1 and 2 [II
of following range 4.41v < VSUM < 5.59v 1. Defective steering potentiometer 2. Defective HSS controller
id
between steering potentiometer
When starting switch is turned on, displayed values are normal, but sum of signal voltages (VSUM) of steering potentiometers 1 and 2 is out of following range after a
while 1. Defective
steering
2. Defective
HSS controller
potentiometer
of
iE
system and excessive deviation of neutral point signal of either system
Disconnection in HSS pump j4
solenoid valve system A
Short circuit 55
in HSS pump solenoid valve system A
20-406
-
Sum (VsuMIof above signal voltages of systems 1 and 2 4.6V c VSUMt 5.4v
.
Voltage between CN-2Hl (19) - (9) (System 1 steering sys?emis in neutral: 2.4 - 2.61 machine is fully steered to left: 4.1 4.3v When machine is fully steered to right: 0.73 0.69v Voltage between CN-2Hl (20) - (9) (System 1 When When
When
-
% When
either steering potentiometer
* Voltage between CN-ZHl (19l- (9) (System 1) When steering system is in neutral: 2.4 - 2.6V When machine is fully steered to left: 4.1 4.3v When machine is fully steered to right: 0.73 0.69v - V&age between CN-2Hl (20) - (9) (System 2) When steering system is in neutral: 2.4 - 2.6V When machine is fully steered to left: 0.6 l.lV When machine is fully steered to right 3.9 -
-
systems 1 and 2 [III
Trouble
(81, (18) - (9).
4.4v
I Excessive difference of signal value
CNI
HSS controller
% When starting switch is turned on, sum of signal voltages (VSVM) of steering potentiometers 1 and 2 is out
of
Voltage between (19): 20 - 3ov
between controller CNl (81, (18) - fuse 5 2. Defective contact or disconnection in wiring harness between controller CNl (91, (19) - chassis ground 3. Dropping of battery voltage or defective fuse 5 4. Defective
Excessive difference
-
starting
switch is turned
on, either
of following
trouble occurs in both steering potentiometers 1) Defective contact, disconnection or short circuit in either system 2) Either system
deviates
from neutral
point excessively
(2.7V t Signal voltage t 2.3V) 1. Defective steering potentiometer 2. Defective HSS controller
1. Defective HSS pump solenoid valve A 2. Defective contact, disconnection or short circuit with chassis ground in wiring harness between controller CN1 (4) - solenoid valve CN-PUPA (I I 3. Defective contact or disconnection in wiring harness between controller CNI (15) - solenoid valve CN-PUPA (2) 4. Defective
HSS controller
1. Defective HSS pump solenoid valve A 2. Short circuit with chassis ground in wiring harness between controller CN-1 (4) - solenoid valve CN-PUPA (1) 3. Short circuit with power source in wiring harness between controller CNl (15) - solenoid valve CN-PUPA (2) 4. Defective
HSS controller
steering
system
is in neutral:
2.4 - 2.6)
when machine is fully steered to left 0.6 l.lV when machine is fully steered to right: 3.9 4.4v Sum (VSVM~of above signal voltages of systems 1 and 2 4.6V t VSUMt 5.4v
.
Voltage between CNdHl (19) - 19) (System 1) steering system is in neutral: 2.4 - 2.6V When machine is fully steered to left: 4.1 4.3v When machine is fully steered to right: 0.73 0.69v + Voltage between CN-2Hl (20) - (9) (System 2) When steering system is in neutral: 2.4 - 2.6V when machine is fully steered to left 0.6 l.lV when machine is fully steered to rigM: 3.9 4.4v * Sum (VSUM)cf above signal voltages of q&ems 1 and 2 4.6V t VSUM t 5.4V When
* Resistance between CN-PUPA (male1 (1) - (2): 10 - 20 n - Resistance between CNl (female) (41 -(15): IO-20R * Indication by LED when starting switch is turned on (in normal state) When machine is fully steered to right or left: 93 - 94 (Output current: 930 - 9940mA) -
Resistance between CN-PUPA (male1 (1) - (2): 10 - 20 n - Resistance between CNl (female) (41 - (15): 10 - 20 n * Indication by LED when starting switch is turned on (in normal state) When machine is fully steered to right or left: 93 - 94 (Output current: 930 - 9940mA)
D155AX-5
ACTION
TAKEN
TROUBLESHOOTING
Action
. Turns
by controller
when abnormality
Problem
is detected
off all outputs.
. Controls
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
that appears
1. Machine
cannot
1. Steering
before
be steered.
occurrence
of abnormality
with signals before occurrence of abnormality until machine stops. I. Flashes alarm lamp and turns alarm buzzer on.
until machine stops. 2. Once machine stops, it cannot
. Controls
1. Steering
before
occurrence
until machine stops. 2. Once machine stops, it cannot
. Controls
1. Steering
Since current
does not flow in solenoid
angle of HSS pump becomes 0. I. Flashes alarm lamp and turns alarm
. Since
output to solenoid
D155AX-5
swash
occurrence
plate
is continued
be steered.
of abnormality
is continued
be steered.
1. Machine cannot right normally).
be steered
to left (but can be steered
to
1. Machine
be steered
to left (but can be steered
to
buzzer on.
valve is turned
angle of HSS pump becomes 0. I. Flashes alarm lamp and turns alarm
valve,
before
until machine stops. 2. Once machine stops, it cannot
is continued
be steered.
of abnormality
with signals before occurrence of abnormality until machine stops. I_ Flashes alarm lamp and turns alarm buzzer on.
with signals before occurrence of abnormality until machine stops. I. Flashes alarm lamp and turns alarm buzzer on.
on machine
when there is abnormality
off, swash
plate
cannot
right normally). buzzer on.
20-407
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
3ror
Abnormal
:ode
system
Disconnection in HSS pump
66
solenoid valve system B
Short circuit in HSS pump 67
solenoid valve system B
Nature
70
equipment circuit oil pressure sensor
system
Disconnection in work 71
8d
equipment circuit oil pressure sensor system
S-NET communication error
99
Disagreement of reverse sensing potentiometer and backup alarm switch signals with each other
1 (5) - solenoid valve CN-PUPB (1) in wiring harness 3. Defective contact or disconnection between controller CNl (15) - solenoid valve CN-PUPB (2) 4. Defective
EO
of
offset current memory
20-408
HSS controller
(1) 3. Short circuit with power source in wiring harness between controller CNl (15) - solenoid valve CN-PUPB HSS controller
Resistance between CN-PUPB (male) (1) - (2): IO - 20 n - Resistance between CNI (female) (5) - (15): 10 - 20 n * Indication by LED when starting switch is turned on (in normal state) When machine is fully steered to right or left: 93 - 94 (Output current: 930 - 9940mA)
Resistance between CN-PUPB (male) (1) - (2): 10 - 20 n * Resistance between CNI (female) (5) -115): IO-20n - Indication by LED when starting switch is turned on (in normal state) When machine is fully steered to right or left: 93 - 94 (Output current: 930 - 9940mA) * Voltage
x When signal voltage of work equipment circuit oil pressure sensor lowers below 0.5OOV circuit oil pressure sensor 1. Defective work equipment in wiring harness 2. Defective contact or disconnection between fuse 5 - oil pressure sensor CN-HHP (2) or short circuit with 3. Defective contact, disconnection
* Voltage
1. Defective monitor 2. Defective contact, chassis ground in (1). (12) - monitor
controller
CN-2H2
(2) - CN-
2.45 - 2.9OV
between
CN-2H2
(2) - CN-
2Hl (9) is in When all work equipment neutral: 0.90 - 1.2OV When blade is raised and relieved: 2.45 - 2.9OV CN-
alarm
1. Outputting of error code 1511, 1521 2. Defective backup alarm switch or short circuit with 3. Defective contact, disconnection chassis ground in wiring harness between controller CN2Hl (7) - backup alarm switch CN-251 (3) in wiring harness 4. Defective contact or disconnection backup alarm
switch
CN-251
(3) - chassis
-
When joystick is in neutral Voltage between CN-2H2 (IO) - CN-
2Hl (9): Max. 3.5OOV Voltage between CN-2Hl (7) - (9): 20 - 3ov * When joystick is in reverse position Voltage between CN-2H2 (10) - CN2Hl
(9): 3.5OOV - 4.4OOV
Voltage between Max. IV
CN-2Hl
(7) - (9):
HSS controller
of neutral by adjustment ,X When offset current determined position of steering cannot be stored in non-volatile memory 1. Defective
between
2Hl (9) is in When all work equipment neutral: 0.90 - 1.2OV When blade is raised and relieved:
panel or short circuit with disconnection wiring harness between controller CN1 panel P2 (IO)
and backup % When reverse sensing potentiometer switch signals do not agree with each other
between
normal resistance)
*
% When signal voltage of work equipment circuit oil pressure sensor exceeds 6.OOOV 1. Defective work equipment circuit oil pressure sensor 2. Short circuit with power source in wiring harness between controller CN-2H2 (2) - oil pressure sensor CNHHP (3) in wiring harness 3. Defective contact or disconnection between controller CN-2Hl (9) - oil pressure sensor CNHHP (1) 4. Defective HSS controller
chassis ground in wiring harness between 2H2 (2) - oil pressure sensor CN-HHP (3) 4. Defective HSS controller
when
current,
*
1. Defective HSS pump solenoid valve B 2. Short circuit with chassis ground in wiring harness between controller CN-1 (5) - solenoid valve CN-PUPB
ground 5. Defective
Trouble
(voltage,
1. Defective HSS pump solenoid valve B or short circuit with 2. Defective contact, disconnection chassis ground in wiring harness between controller CN-
(2) 4. Defective
Short circuit in work
Condition
of abnormality
* When starting switch is turned to OFF position, offset current is stored in non-volatile memory.
HSS controller
D155AX-5
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Action
by controller
1. Since current
when abnormality
does not flow in solenoid
angle of HSS pump becomes 0. 2. Flashes alarm lamp and turns alarm
valve,
swash
work
1. Calculates with hydraulic pressure as 0. 2. Cannot limit swash plate angle of pump when equipment is relieved.
work
with signals
of backup
on machine
1. Machine cannot left normally).
be steered
to right (but can be steered
to
cannot
alarm
plate
1. Machine
be steered
to right (but can be steered
to
communicate
switch when
cannot
left normally).
1. If machine
1. Calculates with hydraulic pressure as 0. 2. Cannot limit swash plate angle of pump when equipment is relieved.
1. Controls
plate
that appears
when there is abnormality
buzzer on.
1. Since output to solenoid valve is turned off, swash angle of HSS pump becomes 0. 2. Flashes alarm lamp and turns alarm buzzer on.
1. Since S-NET circuit is cut, controller with monitor panel.
Problem
is detected
is steered
when
engine may stall. 2. Only travel and steering normally.
work equipment
operation
is relieved,
can be performed
1. If machine is steered when work equipment is relieved, engine may stall. 2. Only travel and steering operation can be performed normally.
1. Alarm
lamp and alarm
1. Machine
can travel
1. Machine
may deviate
buzzer do not work.
and steer normally.
trouble [51] and [521 are displayed simultaneously. 2. Controls with signals of travel reverse sensing potentiometer played
1. Cannot
when trouble
I511 and 1521 are not dis-
simultaneously.
take any action (Trouble
D 155AX-5
in controller).
during
straight
travel.
20-409
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
FOR E MODE
HSS control system Sackur
alarm
witch
CN-25I
Engine
speed
Steering
oi I sureswitch charle
NSS PU~IP solenoid A CN-PUPS
NSS DUMP 30Ienaid E
TWD00979
20-410
D 155AX-5
TROUBLESHOOTING
Engine
starting
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
system Alternator With cab:SOA
P. s6ul
25R 0. L16,”
TWDOOSBO
Blade pitch solenoid Blade solenoid
and ripper pin puller
solenoid
system
gitch CN-451
valve
CN0. asp
I53
Pin Puller solenoid
CN-246
0. e6
valve
YlT]jX~
A7 CN-456
Blade Pitch switch
I I
CN-424
Pin puller switch
I
latterv elaY J7 CN-SW
Fender GND
J
TWD00981
D 155AX-5
20-411
E-l
TROUBLESHOOTING
E-l. 9% *
* *
[I91 Short circuit in steering oil pressure sensor system A is displayed
This is displayed when the signal voltage from the steering oil pressure sensor A exceeds 6.OOOV. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
YES
I YES 1 Is E-19 displayed when connectors
Is voltage between CN-2H2 (1) and CN-2Hl (9) as shown in following table? . Engine at high idling
-With starting switch at OFF position, exchange connectors. * Engine at high idling.
defective HSS controller
R;eplace
Defective contact or disconnection in wiring harness between CN-2Hl (female) (9) - CN-STHPl (female) (1)
Flepair or rleplace
2, I 3 YES Is CN-2H2 (1) and _ chassis ground normal when NO CN-STHPI is disconnected? * Disconnect CN-STHPI. . Turn starting switch ON. * Max. 1V
_
NO
Short circuit with power Flepair or source in wiring harness rleplace between CN-2H2 (female) (1) - CN-STHPl (female) (31I Defective steering oil pressure switch A
rJO
Fleplace
Table
E-l. Related
electrical
CN-70 1
HSS controller
eerlns
circuit diagram
CN-STHP 1
Steering oil Pressure sensor A
01
TWO00982
20-412
D155AX-5
TROUBLESHOOTING
E-2. % *
* * *
E-2
[20] Disconnection displayed
in steering oil pressure sensor system A is
This is displayed when the signal voltage from the steering oil pressure sensor A lowers below 0.5oov. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Check that fuse 5 is not broken. (If it is broken, check the circuits related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
I
61
Defective HSS controller
YE
normalwhenCN-SlHPl
* Engine at high idling.
CN-STHPl (1) and N
Rleolace
Defective contact or : disconnection in wiring harness between CN-2H2 (female) (1) - CN-STHPI (female) (3) Short circuit with power source in wiring harness between CN-2H2 (female) (1) - CN-STHPI (female) (3
I *Diinnect I CN-STHP’Iand CN-2H2
with oil pressure *With starting switch at OFF position, exchange connectors * Engine at high idling.
Remedy
Cause
lepair or eplace
Defective contact or lepair or eplace
*Turn starting switch ON. *20-30V
o
lepair or eplace
roil
leplace
Table
~~
E-2. Related
electrical
circuit diagram CN-70 1
HSS
controller
Steering
CN-STHP
1
Steer
in9
oi
I
Pressure
oil
TWD00982
D155AX-5
20-413
E-3
TROUBLESHOOTING
E-3. :. x Ir
* *
[21] Short circuit in steering oil pressure sensor system B is displayed
This is displayed when the signal voltage from the steering oil pressure sensor B exceeds 6.OOOV. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
1
YES -
lp Is “E-21” displayed when connectors are exchanged with oil pressure sensor A?
Is voltage between CN-2H2 (9) and CN-2H1 (9) es shown in following table?
* Engine at high idling.
3 YES p
Is voltage between CN-2H2(9)andchassis - ground normalwhen NO CN-STHPZis disconnected?
* Disconnect NO CN-STHP2. -Turn starting switch ON. * Max. 1 V
*With starting switch at OFF position, exchange NO connectors. *Engine at high idling.
Defective contact or disconnection in wiring harness between CN-2Hl ~e~~~eor (female) (9) - CN-STHPZ (female) (1) Short circuit with power source in wiring harness Repair or between CN-2H2 (female) replace (1) - CN-STHPZ (female) (3) Defective steering oil pressure switch B
Replace
Table Steering
CN-2H2, CN-2Hl Between CN-PHI
CN-2H2
(9) -
(9)
E-3. Related
In neutral When relieved
electrical
Voltage 0.9-1.5v 3.95 - 4.60 V
circuit diagram
CN-70 1
I
I
CN-STHPi
Steering
oil
I TWD00984
20-414
Dl SAX-5
TROUBLESHOOTING
E-4. % *
Ir Ir *
E-4
[22] Disconnection displayed
in steering oil pressure sensor system B is
This is displayed when the signal voltage from the steering oil pressure sensor B lowers below 0.5oov. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Check that fuse 5 is not broken. (If it is broken, check the circuits related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
Remedy
Defective HSS controller
YEis CN-2H2 (9) and CN-2Hl (9) as shown in
1 - Engine
1Is resistanceb&wee: FEr
at high
idling.
h
with oil pressure
switch ON. *20-30V
*With starting switch at OFF position, exchange connectors. . Engine at high idling.
NO
N
Defective contact or disconnection in wiring harness between CN-2H2 (female) (9) - CN-STHP2 (female) (3)
Replace
ilepair or replace
Short circuit with power source in wiring harness between CN-2H2 (female) (9) - CN-STHPP (female) (3)
Repair or replace
Defective contact or disconnection in wiring harness between fuse 5 CN-STHP2 (female) (2)
Repair or replace
Defective steering oil pressure switch 5
Replace
Table
~
E-4. Related
electrical
circuit diagram CN-70 1
Pressure
sensor
CN-STHPl
Steering
oil
2
TWD00984
D 155/J-5
20-415
E-5
TROUBLESHOOTING
E-5.
[23] Trouble of steering potentiometer displayed
systems 1 and 2 is
This is displayed when both signal voltages from the steering potentiometers lower below 0.5OOV or exceed 4.5OOV. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
Go to troubleshooting error code displayed simultaneously.
YES 1
I
*Turn starting switch ON.
of
Defective HSS controller
leplace
Defective steering potentiometer
3eplace
Table
E-5. Related
HSS
electrical
circuit diagram
controller
I CN-LH 1 (040201
Analog
Steering potentiometer
pJ
GND
Potentiometer
CN-STR (X41
Power
SUPPI
3
Steering
potentiometer
1
3
Steering
Potentiometer
2
3
TWD00986
20-4 16
D 155AX-5
E-6
TROUBLESHOOTING
E-6. % Ir
* *
[24] Disconnection displayed
in steering potentiometer
system 1 is
This is displayed when the signal voltage from steering potentiometer system 1 exceeds 4.5OOV. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
I
Replace
Defective HSS controller
4YES Is voltage between YES CN-2Hl (19) and - chassis ground 3 norrnalwhen CN-SIR is disconnected?
between CH-2Hl shown in Table l?
Is resistance between CN-2Hl * Disconnect CN-STR. (female) (19) and *Turn starting switch CN-STR (female) ON. (3) normal? P .Max.lV Turn starting switch OFF. NO Disconnect CN-2Hl and CN-STR. Max. 1 Q
YE
. Turn starting switch ON.
CN-2Hl (1) and (4). bahvaen(2)and(4).and
* Turn starting switch OFF. * Disconnect CN-STR.
Table
N(
NC1
Remedy
Defective contact or disconnection in wiring harness between CN-2Hl (female) (9) - CN-STR (female) (I)
Repair or replace
Short circuit with power source in wiring harness between CN-2Hl (female) (19) - CN-STR (female) (3)
Repair or replace
Defective contact or disconnection in wiring harness between CN-2Hl (female) (19) - CN-STR (female) (3)
Repair or replace
Defective steering potentiometer
Replace
Table 2
1 CN-ZH
Steering
1
When fully
In neutral Between (19) - (9)
steered
2.4 - 2.6 V
to left
4.1 - 4.3 V
When fully steered to right 0.73 - 0.89 V Between (3) - (4)
E-6. Related HSS controller
electrical
circuit diagram
I CN-PH 1 (040201
CN-STR (X4)
Steer in9 potentiometer
TWD00986
D155AX-5
20-417
E-7
TROUBLESHOOTING
E-7. x * * *
[251 Short circuit in steering potentiometer
system 1 is displayed
This is displayed when the signal voltage from steering potentiometer system 1 lowers below 0.5oov. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
~ ‘ES
I
Defective contact or disconnection in wiring between CN-2Hl Is resistance between (female) (4) - CN-STR YES CNZHl(10) and (female) (4) - chassisground 3 Short circuit with power normalwhen CN-STR is disconnected? Is resistancebetween source in wiring harness YES CN-2Hl (femala)(19) P - between CN-2Hl (female) *Turn starting NO and chassisground switch OFF. (10) - CN-STR (female) (4) normalwhen CN-STR . Disconnect CN-STR ISdrsmnnected? Short circuit with chassis and CN-2Hl. * Min. 1 Ma ground in harness zN1?fil !‘lj 1 1 -Turn starting and f4), between ELI between CN-2Hl (female) switch OFF. NO NO (19) - CN-STR (female) (3) * Disconnect CN-STR and CN9Hl. * Turn starting Defective steering switch OFF. potentiometer - Disconnect CN-STR.
. VFS .__ I harness
A
1 CH-ZHl (19) and (9) as shown in
-Turn starting switch ON.
Table
Replace
Defective HSS controller
Repair or replace
Repair or replace
Repair or replace
Replace
1 Steering
CN-2H 1 Between (19) - (9)
E-7. Related HSS
electrical
In neutral
When to fully steered left
When tcfully steered right
2.4 - 2.6 V
4.1 - 4.3 v
0.73 - 0.89 V
~~
circuit diagram
controller I
CN-2H 1 (040201
CN-STR (X4)
Steer ine Potentiometer
3 3 3 3
TWO00986
20-418
D155AX-5
E-8
TROUBLESHOOTING
E-8.
[26] Disconnection displayed
in steering
potentiometer
system 2 is
%
This is displayed when the signal voltage from steering potentiometer system 2 exceeds 4.5OOV. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) * Before carrying out troubleshooting, check that all the related connectors are properly inserted. -Sr Always connect any disconnected connectors before going on the next step. +
Cause
4YES Is voltage between YES CN-2Hl (20) and -chassis ground 3_ normalwtwnCNSiR Is resistance is disconnected? * y+;ct YES between CN-2Hl NC - (female) (20) and CN-STR (female) * Turn starting 2 (2) normal? switch ON. * Max. IV * Turn starting between CN-ZHl (1) switch OFF. and(4).between(2)and NO * Disconnect (4).and between(3)and CN-2Hl and (4)as showninTableZ? CN-STR. . Turn starting * Max. 1 D switch OFF. LIT\ . Disconnect I’” CN-STR.
-Turn starting switch ON.
Table
1
Defective HSS controller
Replace
Defective contact or disconnection in wiring harness between CN-2Hl (female) (9) - CN-STR (female) (I)
Repair or replace
Short circuit with power source in wiring harness between CN-2H1 (female) (20) - CN-STR (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between CN-2Hl (female) (20) - CN-STR (female) (2)
Repair or replace
Defective steering potentiometer
Replace
Table 2 CN-STR
Steering CN-2H1 Between
E-8. Related I
Remedy
(20) - (9)
electrical
(male)
Resistance
In neutral
When fully steered to left
When fully steered to right
Between (I) - (4)
2.4 - 4.0 R
2.4 - 2.6 V
0.6 - 1.1 V
3.9 - 4.4 v
Between (2) - (4)
5.0 - 8.0 Q
Between
5.0 - 8.0 Q
(3) - (4)
circuit diagram
HSS controller
I
CN-2H
1 (040201
CN-STR (X4)
Steering Potentiometer
TWD00986
D 155AX-5
20-419
TROUBLESHOOTING
E-9. % *
* *
E-9
[25] Short circuit in steering potentiometer
system 2 is displayed
This is displayed when the signal voltage from steering potentiometer system 2 lowers below 0.5oov. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inset-ted. Always connect any disconnected connectors before going on the next step.
Remedy
Rleplace
4YES Is resistancebetween YES CN-2Hl (female) (10) - and chassis ground 3 normalwhen CN-SIR is disconnected? Is resistancebatwxn YES CN-2Hl (female) (20) P NO *Turn starting - and chassis ground switch OFF. normal when CNSIR - Disconnect 2 is disconnected? CN-STR and CN-2Hl. Are resistances * Min. 1 MQ * Turn starting between CN-2Hl (1) - and(4).between(2)and switch OFF. NO 1 (4).andbetween(3)and * Disconnect CN-STR (4)asshowninTable2? and CN-2Hl. * Min. 1 MR *Turn starting switch OFF. NO * Disconnect CN-STR.
CH-2Hl (20) and (9) as shown in
. Turn starting switch ON.
Table
1
dlsconnectlon m wmng harness between CN-2Hl (female) (4) - CN-STR
Rlepair or neplace
(fema’e) (4) Short circuit with power source in wiring harness between CN-2Hl (female) (10) - CN-STR (female) (4)
Rlepair or r,eplace
Short circuit with chassis ground in harness between CN-2H1 (female) (20) - CN-STR (female) (2)
Flepair or rfeplace
Defective steering potentiometer
Fleplace
Table 2 Steering CN-PHI In neutral
Between
(19) - (9)
2.4 - 2.6 V
When steered
fully to left
0.6 - 1.1 V
When fully steered to right 3.9 - 4.4 v Between
E-9. Related
electrical
(3) - (4)
circuit diagram
HSS controller
CN-2H Analog
1 (04O;O)
CN-STR (X4)
Steer ina Dotentiometer
GND
Potentiometer
Dower
SUPPI
Steering
potentiometer
1
Steering
Potentiometer
2
I TWO00986
20-420
D155AX-5
E-10
TROUBLESHOOTING
E-10. * *
* *
[29] Trouble of engine rotation
sensor system is displayed
Before carrying out troubleshooting, check that the engine rotation sensor has been adjusted normally. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
YES
Defective HSS controller
4 YE: 1r
1
Is resistance YES between CN-2H2 Is voltage between (female) (4) and CN-2H2 (4) and 3 _ chassis ground (12) normal? Is resistance normal? * Turn starting N( YES between CN-2H2 - (female) (4) and . Start engine. switch OFF. CN-ENG (female) . Disconnect CN-2H2 -Taster in AC 2 (1) normal? and CN-ENG. range. Is resistance *Min. 1 MQ -Turn starting * 0.5 - 3.ov between CN-ENG switch OFF. NO NO (male) (1) and (2) * Disconnect normal? CN-2H2 and CN-ENG. * Max. 1 fi . Turn starting switch OFF. NO - Disconnect CN-ENG. -500-1,ooon
E-10. Related
HSS
electrical
Defective contact or disconnection in wiring harness between CN-2H2 [female) (12) - CN-ENG (female) (2) Short circuit with chassis ground in harness between CN-2H2 (female) (4) - CN-ENG (female) (I) Defective contact or disconnection in wiring harness between CN-2H2 (female) (4) - CN-ENG (female) (1) Defective engine rotation sensor
Remedy
leplace
lepair or eplace
lepair or eplace
lepair or eplace
leplace
circuit diagram
controller
CN-701
(SWP12)
CN-ENG (X2)
Engine speed sensor
JJ Pulse
input
(-1
-3
TwD009aa
D 155,&t-5
20-42
1
TROUBLESHOOTING
E-11
E-l 1. 1511 Short circuit in travel reverse sensing potentiometer is displayed
system
This is displayed when the input signal from the travel reverse sensing potentiometer exceeds 4.7V. Before carrying out troubleshooting, check that the travel reverse sensing potentiometer has been adjusted normally. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
Is voltage between CN-ZHl (10) and CN-PHl (9) as shown in Table l? . Turn starting switch ON.
Table
3 YES Is voltage between YES CN-2H2 (10) and - chassis ground 2 nofmalwhenCN-RSS is disconnected?
-
Are resistances between CN-RSS NO . Disconnect - (male) (1) and (2) and CN-RSS. NO between (1) and (3) -Turn starting switch ON. as shown in Table 2? .Max. 1 v I .-.---. Turn starting NO switch OFF.* Disconnect CN-RSS.
Defective HSS controller
Replace
Defective contact or disconnection in wiring harness between CN-2Hl (female) (9) - CN-RSS (female) (3)
Repair or replace
Short circuit with power source in wiring harness between CN-2H2 (female) (IO) - CN-RSS (female) (2)
Repair or replace
Defective travel reverse sensing potentiometer
Replace
Table 2
1
E-l 1. Related
HSS
! I
Remedy
electrical
circuit diagram
controller
I Ct+2H 1 (04020)
Analog
Power
I
SUPPIY I
CN-2H2 Travel REVERSE Potentiometer
20-422
Travel REVERSE senslns Potentiometer
3
GND
Potentiometer
I
CN-RSS (X3)
3 3
(040 16)
sensing
I
TWD00989
D 155AX-5
E-12
TROUBLESHOOTING
E-12. % * *
* *
[52] Disconnection in travel reverse sensing potentiometer system is displayed
This is displayed when the input signal from the travel reverse sensing potentiometer lowers below 0.3OOV. Before carrying out troubleshooting, check that the travel reverse sensing potentiometer has been adjusted normally. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
aYES reststance YES between CN-2H2 - (female) (IO) and 3 CN-RSS (female) Is resistancebetween (2) normal? YES CN-2H2 (female) (10) P * Turn starting and chassis ground Is
Is voltage between CN-2H2 (IO) and CN-2H1 (9) as shown in Table I? * Turn starting switch ON. II
lasshown in Table 2? 1 1
-
Defective HSS controller
Replace
Go to
Replace
A.
Defective contact or disconnection in wiring harness between CN-2H2 (female) (IO) - CN-RSS (female) (2)
Repair or replace
Short circuit with chassis ground in harness between CN-2H2 (female) (IO) - CN-RSS (female) (2)
Repair or replace
Defective travel reverse sensing potentiometer
Replace
Defective contact or disconnection in wiring harness between CN9Hl (female) (IO) - CN-RSS (female) (I)
Repair or replace
Short circuit with chassis ground in harness between CN-2Hl (female) (IO) - CN-RSS (female) (I)
Repair or replace
k::Fz;. ana
-Turn starting switch OFF. - Disconnect CN-RSS.
Is resistancabetween CN-PHI (female) (IO) A - and chassis ground normalwhen CNRSS is disconnected? NO . Turn starting switch OFF. * Disconnect CN-RSS and CN-2Hl. * Min. 1 MD
Table 1
-
Remedy
Table 2
~
D155AX-5
20-423
E-12
TROUBLESHOOTING
E-12. Related
I
HSS
electrical
controller
Analog
circuit diagram
I CN-2H 1 (04020)
CN-RSS (X3)
Travel REVERSE sensing Potentiometer
GND
Potentiometer
Power
SuPPI
I CN-2H2 (04016) Travel REVERSE Potentiometer
sensing
TWD00989
20-424
D155AX-5
TROUBLESHOOTING
E-13. * * *
E-13
[53] Disconnection
in backup alarm relay system is displayed
If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
3 YES
n ‘N-014
) (2)and 1 ‘;
((.m$;)
and (2)
[
* Turn starting switch OFF. - Disconnect CN-014. .200-400n
E-13. Related
around normal?
I
-Turn starting switch OFF. * Disconnect CN-014. . Max. 1 Q
NO . Turn starting switch OFF. - Disconnect CN-001. ~200-400R NO
Replace
Defective contact or disconnection in wiring harness between CNI (female) (11) - CN-014 ‘female) (1)
Repair or replace
Iefective contact or iisconnection in wiring larness between CN-014 female) (2) - CNSX8 chassis ground) Defective backup alarm .elav
40
electrical
Defective HSS controller
Replace
circuit diagram
,
Backw
alarm
relay
Backup buzzer
HSS
Repair or replace
alarm
controller
R&
I
D155AX-5
I
20-425
E-14
TROUBLESHOOTING
E-14. [54] Short circuit in backup alarm relay system is displayed *
* *
If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
2 YES Is resistancebetween YES CN-1 (female) (11) - and chassis ground 1 ~_ normal when CN-014 is disconnected? Is resistance between CN-014 -Turn starting NO (male) (1) and (2) switch OFF. . Disconnect normal? CN-014 and CNI. * Min. 1M Q *Turn starting NO switch OFF. . Disconnect CN-014. *200-400R
E-14. Related
electrical
Defective HSS controller
Replace
Short circuit with chassis ground in harness between CNI (female) 11 - CN-014 (female) (I)
Repair or replace
Defective backup alarm relay
Replace
circuit diagram
Backup alarm relay
Backup alarm
HSS controller
TWD00990
20-426
D155AX-5
TROUBLESHOOTING
E-15. % *
* * *
E-15
[57] Low voltage of controller
is displayed
This is displayed when the source voltage of the controller lowers below 17V. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Check that fuse 5 is not broken. (If it is broken, check the circuits related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
Remedy
Defective HSS controller
Replace
1 Is voltage between CNl (8Ml8) and (9)/(19) normal? 1 * Turn starting switch ON. .20-30V
YES 2 Is voltage between CNl (8M18) and NO chassis ground normal? *Turn starting switch ON. -2O-30V
3 YES Is voltage between inlet of fuse 5 and NO chassis ground normal? * Remove fuse 5. . Turn starting switch ON. .20-3ov
E-15. Related
electrical
NO
Defective contact or disconnection in wiring harness between CNl (female) (9)/(19) - CNSXI (chassis ground) Defective fuse or defective contact or disconnection in wiring harness between outlet of fuse 5 CNl (female) (8M18) Defective power supply circuit of fuse box or lowering of battery voltage
Repair or replace
Repair or replace
Repair or replace
circuit diagram
HSS controller I
CN-001 (MIC21)
Fuse
box
0
rffr
CN-SX8 TWD00991
D 155AX-5
20-427
TROUBLESHOOTING
E-16. % Ir
* *
E-16
[62] Excessive difference of signal value between potentiometer systems 1 and 2 is displayed [II
steering
This is displayed when the signal voltages of steering potentiometer systems 1 and 2 are excessively different from each other. (When the starting switch is turned ON, the trouble occurs.) If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
switch ON. _ - See Note. * 4.41 - 5.59v WSUM)
Note:
Measure the voltage according to the following procedure. 1) Measure the voltage (VI) between CN-2Hl (19) and (9). and that (V2) between and (9). 2) Add up the two measured voltages (VI, V2) to obtain the total (VSUM). * The joystick does not move while the voltage is measured.
E-16. Related
HSS
electrical
(20)
circuit diagram
controller
Fuse Power
I
CN-2Hl
lOA@
supply(+)
Power
SUPPIYI-1
Power
supply(+)
Power
SUPPIY(-1
box
I
,
Ct+SXS TWD00991
20-428
D 155AX-5
E-17
TROUBLESHOOTING
E-17.
[6d] Excessive difference of signal value between potentiometer systems 1 and 2 is displayed [III
steering
This is displayed when the signal voltages of steering potentiometer systems 1 and 2 are excessively different from each other. (When the starting switch is turned ON, the systems are normal.) If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
YES
1
Is total
of voltage between CN-2H1 (19) and (9) and that between (20) and (9) normal?
Replace
Defective steering potentiometer
Replace
-
. Turn starting switch ON. * See Note. * 4.41 - 5.59v PkUM)
Note:
Defective HSS controller
NO
Measure the voltage according to the following procedure. 1) Measure the voltage (VI) between CN-2Hl (19) and (9), and that (V2) between and (9). 2) Add up the two measured voltages (VI, V2) to obtain the total (VSUM). t The joystick does not move while the voltage is measured.
E-17. Related
electrical
HSS controller CN-001
CN-2H1
(20)
circuit diagram
I (MIC21)
Fuse
box
TWD00991
D155AX-5
20-429
TROUBLESHOOTING
E-18.
% *
* Ir
E-18
[6E] Trouble of either steering potentiometer system and excessive deviation of neutral point signal of either system is indicated
This is displayed when either steering potentiometer system has trouble and the neutral position signal of either system is deviated. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
Go to troubleshooting of error code displayed simultaneously.
YES 1 Are error codes “24”. “25”. “26” and “27” displayed simultaneously?
Remedy
2 YES Are voltages between CN-2H109) NE and (9). and between (20) and (9) as shown in following table? * Turn starting switch ON.
Defective HSS controller
Replace
Defective steering NO
Table
1
E-18. Related
HSS
electrical
circuit diagram
controller Fuse
Power
box
supply(+) 0
$j+
CN-SX8 TWD00991
20-430
D 155AX-5
E-19
TROUBLESHOOTING
E-19. * * *
[64] Disconnection displayed
in HSS pump solenoid valve system A is
If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
I Is
j
_.__ - ..__
mcisttancn
1 112) normal?
zcI between
CNl Imale) 14) and -- ._4 (female) , ,,,,,,ial? t
a) (1)I I * Turn starting and (2) and between nritch OFF. (2) and chassis isconnect CNl and CN-PUPA. - Max. 1 D *Turn starting switch OFF. . Disconnect CN-PUPA.
* Turn starting switch OFF. . Disconnect CNl and CN-PUPA * Max. 1 G I
4 YE: Is resistancebetween CNl (female) (15) and YES chassis ground _ 3 I- normal when CN-PUPA is disconnected? -Turn starting N( -..,:*^I. r-JFF. ,.,,,...lect 1 1 CN-PUPA and CNl. 1 -Min. 1 bVlR NO
NO
Defective HSS controller
Short circuit with chassis ground in harness between CNl (female) (15) - CN-PUPA (female) (2) Defective contact or disconnection in wiring harness between CNI (female) (15) - CN-PUPA (female) (2) Defective contact or disconnection in wiring harness between CNl (female) (4) - CN-PUPA (female) (1) Defective HSS pump solenoid valve A
NO
Remedy
Fleplace
lepair or eplace
Flepair or rieplace
Flepair or rleplace
Fleplace
Table CN-PUPA
(male)
Voltage
Between (I) - (2) B;oF;;n 9
HSS
I
IO-20R
(2) - chassis
E-19. Related
I
electrical
I
Min.
1 MQ
circuit diagram
controller
CN-001 (M&I \
I
CN-LPL
I
\
(SWP8)
CN-PUPA
(X21
HSS Pump solenoid
A
I
TWD00992
D155AX-5
20-431
E-20
TROUBLESHOOTING
E-20. * Ir *
[65] Short circuit in HSS pump solenoid valve system A is displayed
If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
YES
Defective HSS controller
Replace
Short circuit with power source in wiring harness between CNI (female) (15) - CN-PUPA (female) (2)
Repair or replace
I
NO
II
nnormal when Is resstance betw CN-PUPA (male; ~., and (2) and between (1)and chassis jj;;~j~;;~yn in -
-Turn starting switch OFF.-
Short circuit with chassis ground in harness between CNl (female) (4) - CN-PUPA (female) (I)
Lln I’”
Repair or replace
’ ~f~~_~~f~’
-Min.
*Turn starting switch OFF. - Disconnect CN-PUPA.
*Turn startina
Defective HSS pump solenoid valve A
1 MD
NO
Replace
Table CN-PUPA
(male)
Between
(I) - (2)
Voltage 10 - 20 a I
B;oyi;n 9
(1) - chassis
E-20. Related
electrical
Min. 1 ML?
circuit diagram
HSS controller
CN-001 (MI&l)
,
CN-LPL
(SWPB)
,
CN-PUPA
(X2)
HSS Pump solenoid A
a p
@
TWD00992
20-432
D155AX-5
TROUBLESHOOTING
E-21. * Ir Ir
E-21
[66] Disconnection displayed
in HSS pump solenoid valve system B is
If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
4
(female) (15) and CN-PUPB (female) YE
* Turn starting switch OFF. * Disconnect CNl and CN-PUPB. - Max. 1 R
* Turn starting switch OFF. * Disconnect CN-PUPB.
YES1
Defective HSS controller
Replace
Short circuit with chassis ground in harness between CNI (female) (151 - CN-PUP6 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between CNl (female) (15) CN-PUPB {female) (2) Defective contact or I disconnection in wiring harness between CNI (female) (5) - CN-PUPB (female) (I)
* Turn starting switch OFF. * Disconnect CNl and CN-PUPB . Max. 1 R
Bepair or replace
Repair or replace
3eplace
Table CN-PUPB (male) Between BFoy;;n 9
(I) - (2)
I
IO-20n
(2) - chassis
E-21. Related
HSS
Voltage
electrical
I
Min. 1 MR
circuit diagram
controller
CN-001
I (MIC21)
CN-LPL
(SWP81
CN-PUP6
(X21
HSS Pump solenoid
B
TWD00993
D155AX-5
20-433
E-22
TROUBLESHOOTING
E-22. * Ir Ir
[67] Short circuit in HSS pump solenoid valve system B is displayed.
If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
3 YES Is resistancebetween CNl (15) and YES_ chassis ground _ normal when 2 p CN-PUPB is Is resistancebetween disconnected? YES CNl (female) (5) NO _ and chassis ground _ - Disconnect CN-PUPB. normal when 1 -Turn starting CN-PUPB is disconnected? switch ON. 7s resrstancebetween CN-PUPB (male1 (1) . Max. 1 V . Turn starting and (2) and between switch OFF. (1) and chassis jr;;ir$ast;kF in No * Min. 1 Ma
* Turn starting switch OFF. * Disconnect CN-PUPB.
NO
Remedy
3efective HSS controller
Replace
Short circuit with power source in wiring harness between CNl (female) (15) CN-PUPB (female) (2)
Repair or replace
Short circuit with chassis ground in harness between CNI (female) (5) CN-PUPB (female) (1)
Repair or replace
Ilefective HSS pump solenoid valve B
Replace
Table CN-PUPB (male)
Voltage
Between (I) - (2)
10 - 20 n
B;oet;vnn(1)-chassis 9
Min. 1 MQ
E-22. Related
electrical
I
circuit diagram
HSS controller
CN-LPL
CN-PUPB
(SWP81 @
@
(X2)
HSS Pump solenoid
B
c
~
@
TWD00993
20-434
D155AX-5
TROUBLESHOOTING
E-23.
E-23
[70] Short circuit in work equipment system is displayed
circuit oil pressure sensor
This is displayed when the input signal from the work equipment circuit oil pressure sensor exceeds 6.OOOV. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
3 YES
Replace
Defective work equipment oil pressure sensor
Replace
Defective contact or disconnection in wiring harness between CN-2Hl (female) (9) - CN-HHP (female) (1) Short circuit with power source in wiring harness between CN-2H2 (female) (2) - CN-HHP (female) (3)
* Start engine.
- Disconnect CN-HHP. * Max. 1 V
Defective HSS controller
and CN-HHP. * Max. 1 R NO
Repair or replace
Repair or replace
Table
~:
E-23. Related
HSS
electrical
CN-70 1 (SWP 12)
controller
CN-2H
1
circuit diagram
Hydraulic Pressure
Hydraulic
oil
1 (04020)
Analog GND CN-2H2
CN-HHP (X3)
(04016) oil sensor
a\ r Fuse
-\
t-i-
box
TWD00994
D155AX-5
20-435
E-24
TROUBLESHOOTING
E-24. % *
* * *
[71] Disconnection in work equipment system is displayed
circuit oil pressure sensor
This is displayed when the input signal from the work equipment circuit oil pressure sensor lowers below 0.5OOV. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Check that fuse 5 is not broken. (If it is broken, check the circuits related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
Y
ES
4YES
- Start engine.
.-..A..&. ncF,
1 1 . KzEA,“d,
CN-HHP (female) 1 (3) normal? CN-HHP (2) and
* Turn starting switch ON. .20-30V
* Turn starting switch OFF. NO * Disconnect CN-2H2 and CN-HHP. * Max. 1 D NO
Defective HSS controller
qeplace
Defective work equipmeni oil pressure sensor
Replace
Short circuit with chassis ground in harness between CN-2H2 (female) (2) - CN-HHP (female) (3)
Repair or replace
Defective contact or disconnection in wiring harness between CN-2H2 (female) (2) - CN-HHP (female) (3) Defective contact or disconnection in wiring harness between fuse 5 CN-HHP (female) (2)
Repair or replace
Repair or replace
Table
~
E-24. Related
electrical
HSS controller
circuit diagram
I
I
CN-2H 1 (04020)
CN-70 1 fSWPl2!
I_,
CN-HHP (X31 -
,,
I
HYdraUlic Pressure
oil sensor
@ 3
CN-2H2
(04016)
3 Fuse
Pressure
box
sensor
I TWD00994
20-436
D155AX-5
TROUBLESHOOTING
E-25.
E-25
[8d] System network
communication
error is displayed
If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
YE 1
Does LED of controller indicates? *Turn starting switch ON.
E-25. Related
HSS
Is resistance between CN 1
. (female) (1). (12) and P2 (female) (10) normal? * Turn starting switch OFF. * Disconnect CNl and P2. . Max. 1 R
3 YES Is resistance between CNl YES (female) (I), (12) _ and chassis ground 2_ normal when P2 is disconnected? * Turn starting NO switch OFF. * Disconnect P2 and CNI. * Min. 1 MQ NO
Defective monitor panel
eplace
Short circuit with chassis ground in harness between CNI (female) (11, (12) - P2 (female) (10) Defective contact or disconnection in wiring harness between CNl (female) (1). (12) - P2 (female) (IO) Lowering of source voltage of controller
JO
electrical
Remedy
;epair or splace
;epair or splace
;o to A.
circuit diagram
controller
Monitor
I
CN-2
14 (SWP 16)
Panel
P2 (04016) system
network
TWD00995
D155AX-5
20-437
E-26
TROUBLESHOOTING
E-26. z Ir +
* *
[99] Disagreement of reverse sensing potentiometer alarm switch signals with each other is displayed
and backup
This is displayed when the reverse sensing potentiometer and backup alarm switch signals do not agree with each other. Before carrying out troubleshooting, check that the backup alarm switch has been adjusted normally. If the starting switch is turned to the OFF position after trouble occurs, perform the error code reproducing operation and check that “E-” is displayed at the head of the error code. (If “P-” is displayed, the trouble has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
C$0 to troubleshooting -e !rror code displayed S ,imultaneously.
YES
1
YES
-c defective
-Turn starting switch ON.
4 YE! ;
Nc
Is resistance between CN-251 (male) (1) and (3) as shown in Table 2? . Turn starting switch OFF. * Disconnect CN-251.
Is resistance YES between CN-2Hl - (female) (7) and _3 CN-251 (female) (3) normal? -
-c ;o to
-
leplace
A.
Clefective contact or clisconnection in wiring rarness between CN-2Hl female) (7) CN-251 (female) (3)
1:
* Turn starting NC switch OFF. . Disconnect CN-2Hl and CN-251. * Max. 1 D
CDefective backup alarm
S;witch
NO
CIefective contact or dlisconnection in wiring rarness between CN-251 : female) (1) CN-SX8 chassis ground) (1
5 YES Is resistancebetween CN-2Hl (female1 (7) A -and chassis ground normal when CN-251 is disconnected?
;epair or eplace
leplace
;epair or aplace
s;hort
circuit with chassis /round in harness ifretween CN9Hl (female) 1’7) - CN-251 (female) (3)
NO * Turn starting switch OFF. * Disconnect CN-251 and CN-2Hl. *Min. 1 MR
20-438
HSS controller
2 Is voltage between CN-2Hl (7) and NO chassis ground as shown in Table l?
1
of
I
Are error codes 1511and f521 displayed simultaneously?
Table
Remedy
epair or
Table 2
D155AX-5
E-26
TROUBLESHOOTING
E-26. Related electrical circuit diagram
-3
CN-SX8 HSS
CN-45 1 (SWPB)
CN-2 5 1 1x31
3
.a
3 3
Backup switch
1 1
alarm
A lWV&
n
controller
CN-RSS (X31
I
Travel REVERSE sensing Potentiometer
I
CN-2H2 (04016) Travel REVERSE Dotentiometer
sensing
TWD00996
D155AX-5
20-439
TROUBLESHOOTING
E-27. % Ir
E-27
[EO] Trouble of offset current memory
This is displayed when controller. If the starting switch reproducing operation displayed, the trouble
is displayed
the offset current cannot be stored in the memory
because of trouble
in the
is turned to the OFF position after trouble occurs, perform the error code and check that “E-” is displayed at the head of the error code. (If “P-” is has been reset.)
Cause
1 YES Does machine deviate during travel with steering system in neutral? - Start engine. * On flat ground. -Travel at forward first gear speed.
Defective HSS controller (See Note I).
Defective HSS controller NO
Replace next time (See Note 2).
Note 1: If the machine deviates, it must be corrected by performing ADJUSTMENT OF NEUTRAL POSITION OF STEERING SYSTEM. When the steering system is adjusted, however, the offset current cannot be stored because of this trouble. Accordingly, replace the HSS controller with new one before starting adjustment. Note 2: The machine can be used as it is since the machine does not deviate. The HSS controller should be replaced in the first chance, however, as the permanent countermeasure against this trouble. (If the controller is replaced, be sure to perform ADJUSTMENT OF NEUTRAL POSITION OF STEERING SYSTEM.)
20-440
D155AX-5
TROUBLESHOOTING
E-28. Ir Ir *
E-28
Backup alarm does not sound
Check that fuse 9 is not broken. (If it is broken, check the circuits related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
Remedy
30 to troubleshooting arror code displayed simultaneously.
YES
controller indicate error codes “53”
of
Defective backup alarm relay
Replace
Defective backup alarm
Replace
‘ES replacing backup
Is voltage between CN-014 (3) and
-Turn starting . Turn starting switch ON. .20-30V
E-28. Related
electrical
N0
tlSS controller
Repair or replace
CN-25 1 (X3)
Backup switch
alarm
I CN-2H 1 (04020)
I
1
/ Analo;
Repair or replace
circuit diagram CN-45 1 (SWP8)
1 Travel
N(
switch OFF. * Disconnect CN-014 and CN-244. - Max. 1 Q
Defective contact or disconnection in wiring harness between CN-014 [female) (6) - CN-244 Ifemale) Defective contact or disconnection in wiring harness between fuse 9 CN-014 (female) (3)
REVERSE sianal
CN-RSS (X3)
inPut\q-
GND
Potentiometer
1
-3
/a~ Power
supply
Travel REVERSE sensing potentiometer
c
I CN-2H2 Travel REVERSE potentiometer
(04016)
sensing
I TWDOOg96
D 155AX-5
20-441
TROUBLESHOOTING
E-29. *
E-29
Blade pitch does not work normally dozer)
(When equipped
with pitch
* Jr
Check that fuse 8 is not broken. (If it is broken, check the circuits related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
a)
Blade pitch system
does not work (Solenoid
valve is not excited)
Remedy
2 YES Is resistancebetween CN-454 (male) (1) YE _ and (2) and between _ (1) and chassis
Defective contact or disconnection in wiring harness between CN-454 (female) (2) - CN-456 (chassis ground)
Kzz!!G”
Replace
* Turn starting switch OFF. * Disconnect CN-454.
1 Is voltagebetween CN-454 (1) and chassis ground 1normal?
Repair or replace
[
* Turn starting switch ON.
Repair or replace
I
Replace
NO
*20-30V
’ normal?
I Repair or replace
* Disconnect
POl. . Turn starting switch ON. .20-30V
Table CN-454
Between B;oF;;n 9
b)
(male) (1) - (2)
(1) - chassis
Blade tilt system
Voltage 40 - 80 i-l
Min.
1
MR
does not work (Solenoid
valve is not demagnetized)
Cause
1 YES Is trouble corrected by disconnecting PO1 and PO2? -Start
engine.
20-442
NO
Remedy
Defective blade pitch switch
Replace
Short circuit with power source in wiring harness between 02 (male) CN-454 (female) (1)
Repair or replace
D 155AX-5
E-29
TROUBLESHOOTING
E-29. Related
Blade switch
pitch
electrical
PO2
circuit diagram
CN-451
(SWP8)
CN-454
(x2)
Blade solenoid
pitch valve
gg
PO1
Fuse
I
D155AX-5
box
I
TWD00997
20-443
TROUBLESHOOTING
E-30. Ir
E-30
Ripper pin puller does not work normally giant ripper)
(When equipped
with
* *
Check that fuse 8 is not broken. (If it is broken, check the circuits related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
a)
Pin cannot
be pulled out (Solenoid
valve is not excited)
Cause
2
YES
Is resistancebetween YES CN-246 (male) (1) and (2) and between _ (I) and chassis round as shown 9ollowing table? 1 1 -Turn starting switch OFF. * Disconnect CN-246.
CN-246 (1) and
No
4 YES
YES Is resistance between CN-263 (male) (1) and (2) normal?
. Turn starting switch ON. - Pin puller switch: PULL *20-30V
*Turn starting NO _ switch OFF. - Disconnect CN-263. : PI%&~ switch: PULL -Turn starting switch ON. -2O-30V
NO
Remedy
Defective contact or disconnection in wiring harness between CN-246 (female) (2) CN-424 (chassis ground)
qepair or replace
Defective ripper pin puller solenoid valve
Replace
Defective contact or disconnection in wiring harness between CN-263 (female) (2)- CN-264 (female) (1)
Repair or replace
Defective ripper pin puller switch
Replace
Defective contact or disconnection in wiring harness between fuse 8 CN-263 (female) (1)
Repair or replace
Table CN-246 (male)
Voltage
Between (I) - (2) I
Between (1) - chassis ground
b)
Pin cannot
be pushed
1 YES Is trouble corrected by disconnecting CN-263? * Start engine.
20-444
NO
40 - 80 Q Min. 1 MQ
in (Solenoid
valve is not demagnetized)
Defective ripper pin-puller switch Short circuit with power source in wiring harness between CN-263 (female) (2) - CN-264 (female) (1)
Peplace
Repair or replace
D155AX-5
TROUBLESHOOTING
E-30. Related
electrical
E-30
circuit diagram
Fuse
;:y+;; _.. _
ler
box
CN-263 (X2)
(SWPG)
D155AX-5
1 7% CN-424
TWD00998
20-445
TROUBLESHOOTING
E-31. * * * *
E-31
Engine does not start (Engine does not rotate)
Check that fuse 10 is not broken. (if it is broken, check the circuits related to it for short circuit with chassis ground.) When carrying out troubleshooting, set the parking brake lever to the lock position. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
5 YES YE 4 YE!
1Isconnection
1 I-
.
-
of wiring harness between starter and battery relay normal?
* Check visually.
Is voltage between CN-103 (2) and
NO
YES 81 . Turn starting switch ON. . Max. 1V
Is voltage between CN103 and chassis ground normal? Turn starting switch ON. 20 - 3ov
Is voltage between CN-103 (2) and _ chassis ground _ normal when 7 YES NO CN-112 is Is voltage between disconnected? P CN-103 (2) and * Disconnect - chassis ground alternator NO normal when CN-220 is disconnected? terminal FL * Turn starting * Disconnect diode. NO switch ON. . Turn starting switch ON. - Max. 1 V *Max. 1V _ 9
I
Is resistance YES between CN-152 n (male)(l) and (3) normal? . Turn starting switch OFF. . Disconnect CN-152. * Max. 1 42
CN-152 (3) and
YE starting switch is
. Turn starting switch ON. *20-30V
* Turn starting switch ON .x OFF.
YES
II n
10 YES
IiFHP NC . Turn starting switch ON. .20-30V
NO
Are voltage of 1 SN-SW and
-Voltage:Min. 24V * Specific gravity: Min. 1.26
YES
* Turn starting switch ON. -2O-30V
* Disconnect starting NO switch terminals B and BR. : zm, slfa$ing switch ON.
NO
20-446
D155AX-5
E-31
TROUBLESHOOTING
Cause
Remedy
Defective starting motor
leplace
Defective connection of power wiring harness between starting motor and battery relay
lepair or splace
Leplace
Defective diode (CN-220) Short circuit with power source in wiring harness between CN-103 (female) (2) - CNI 12 or between CN-103 (female) (2) CN220 (female) (2) Defective contact or disconnection in wiring harness between CN-152 (female) (1) - CN-103 (female) (1)
Ieplace
lepair or eplace
lepair or eplace
Defective neutral safety switch
leplace
Defective contact or disconnection in wiring harness between starting switch terminal C (CN280) CN-152 (female) (3)
iepair or eplace
Defective starting switch
teplace
Defective battery relay
Defective contact or disconnection in wiring harness between starting switch terminal BR (CN260) - CN-SW Defective contact or disconnection in wiring harness between starting switch terminal B (CN250) -fuse 10 - CNH
Xepair or eplace
Iepair or eplace
Defective starting switch
Defective battery
D 155AX-5
qeplace
TROUBLESHOOTING
E-31
electrical
E-31. Related
circuit diagram
Alternator
Neutral
Battery
1
[
C”‘,Ol#l2)
7b
safety
relay
Fender GND
Battery
Sta;t
ine
sw,i tch
7h ctq-220
I
I
TWD00999
20-448
D 155AX-5
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
Table of failure
and causes .. . . . . . . .. . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . .. . .. . . . . . .. . . . .. . . . .. .. .. . . . . . . . . .. . . . . 20-502
modes
H- 1.
Machine
does not move or moves
H- 2.
Machine
does not move or travel power
H- 3.
Machine
does not move or moves slowly
H- 4.
Long time lag is made in changing
H- 5.
Travel
power
(Drawbar
slowly
at any gear speed
in each direction..
...... .20-504
is low in one direction .................................
20-506
at specific gear speed ...............................
.20-506
or gear speed.. ...........................
.20-507
travel direction
20-508
pull) is low ..................................................................................
be steered
................................................................
H- 6.
Machine
cannot
(to one direction)
H- 7.
Steering
speed or power
H- 8.
Abnormal
H- 9.
Brake does not work ..........................................................................................................
20-509 20-509
is low ........................................................................................
sound comes out of HSS pump or HSS motor ............................................
20-510 20-512 20-513
...................................................................................................
H-10.
Power train oil overheats
H-II.
Work equipment
does not work at all ..............................................................................
20-514
H-12.
Work equipment
speed or power
is low ..........................................................................
20-515
H-13.
Blade lifting speed or power
is low.. ................................................................................
20-516
H-14.
Blade tilting speed or power
is low.. ................................................................................
20-516
H-15.
Ripper lifting speed or power
is low ................................................................................
20-517
H-16.
Ripper tilting speed or power
is low ................................................................................
20-517
H-17.
Hydraulic
drift is large in blade lifting direction
.............................................................
20-518
.............................................................
20-518
...........................................................
20-519
H-18.
Hydraulic
drift is large in blade tilting
H-19.
Hydraulic
drift is large in ripper lifting direction..
H-20.
Blade pitch does not work normally
H-21.
Ripper pin puller does not work normally
H-22.
D 155AX-5
Abnormal
sound comes
direction
(When
equipped (When
out of work equipment
with pitch dozer) .....................
equipped
20-519
with giant ripper) ........ ..20-52 0
pump.. ...............................................
20-520
20-50 1
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES -
-
-
r
E
L
2 P
.z
?l & 3 3 FL 2
Machine does not move or moves slowly at any gear speed in each direction.
-
Machine does not move or travel power is low in one direction. Machine
does not move or moves slowly
at specific gear speed.
Long time lag is made in changing travel direction or gear speed. Travel
power
(Drawbar
Machine
cannot
Steering
speed
Abnormal
pull) is low.
be steered or power
(to one direction).
is low.
sound comes
out of HSS pump
or HSS motor.
Brake does not work.
-5 -
-
6
-
-6
-
-
-
-
-
-
-6
Power train oil overheats. Work
equipment
does not work at all.
Work
equipment
speed
or power
-i
is low.
-
Blade liftina
speed
or power
is low.
-
-
Blade tilting
speed
or power
is low.
-
-
or power
is low.
-
-
SDeed or power
is low.
-
-
Ripper
lifting speed
Ripper
tiltins
Hydraulic
drift is large in blade
Hydraulic
drift is large in blade tilting
Hvdraulic
drift is large in ripper
lifting direction.
-
-
direction.
-
-
lifting direction.
-
-
Blade pitch does not work normally (When equipped with pitch dozer).
-
-
Ripper pin puller does not work normally (When equipped with giant ripper).
-
-
Abnormal
-
-
20-502
sound
comes
out of work equipment
pump.
E
2 P
z -5 5 -5 -
-
-
-
-
-
E z
F
2”
z
6 E
‘5 .F!
9
s T
EE z s2 m
I=
-5 5 - 6 -3 6 -6 -i - - - i - - - - - - - - - -
d F
P
m -
i -
-
-
-
-
-
-
-
-
-
-
-
-
-
5 i-
k ti
E & m ii 5 5 i i
-
6 5 -5 -
-5 6 -6 - -I, - - - _ - - - - - - - - - -
D155AX-5
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING
r
-23
-P
l-
F or
-
-
-
l-
-
Control
-
-
valve
-
-
-
r
-
-
-
-
-
E 3
8
0
b
8
9
2
T
Es z s - - - - - 6 6 6 -G -6 - - - - - - - - - - - - - - -
D 155AX-5
T
z-
Y
E c?6 - - - - - -
-
-
-
E
-
z
5
5 -5 -
4z
72
9
Ei 5 ul
I” -
-
s
-
-
z .E
9 -
-
i -a -i 5 - -
5 5 5 5 6 -5 -
i
-
z ::
=h ii $ 2 L = 2 F 2 2 9 5 g z !z C5 .G Y a a
2” 9
i
-s 5 G5 3 5 G5 i -5 -6 -G -6 - - - - 6 -
L
3 5 .a T! .o ti 5 ii it u2 +f
E
9 i% ti
t
2” $fn E2
L
0 2 8
.r
E
2
-
k : t: 5
2 -
Y -
-
z E 3 ‘G Gi ::G 2 m m z I? VJ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - i -i -
-r -
-.s t
%
2 b .c 5
2
-.E :: ‘Z
x
v)
4
% _)
E m
-
s
2
-5 -
6 6 -6 - i - -i - - - - - - - - - - - - -
2
P
P ._ I F e W i 5 if
-
H-l H-2 H-3 H-4
-6 -
H-5 H-6 H-7 H-8 H-9
-5 -
-r -
H-10 H-l 1 H-12 H-13 H-14 H-15
-
H-16 H-17 H-18 H-19 H-20 H-21 H-22
20-503
TROUBLESHOOTING
H-l. +
H-l
Machine does not move or moves slowly at any gear speed in each direction
Before carrying
out troubleshooting,
check that the oil level in the power
line is normal.
5 YES
YE
3 Is transmission
YE 2 Is linkage of joystick (direction, gear speed) adjusted normally?
YE
- Engine at high idling. -Joystick: Neutral + 2.74 MPa {28kg/cm2)
* Engine at high idling. * Joystick: Neutral - 2.74 MPa {28kg/cm?
NO
1 YE 6
NC 1
NO
- Engine at high idling. -Joystick: Neutral - Inlet pressure: 0.83&0.15MPa {8.5*1.5kg/cm21 * Outlet pressure: 0.44+1.15MPa f4.51!11.5kg/cm*l
I
Does spool of main relief valve ) move smoothly?
1 Y
1
NO
springs and number of shims in main relief valve normal?
- Large: 122mm - Small: 108mm
YES
IO
* Shim: 5 pcs. pressure normal? -Engine at high idlina. - Parking brake lever: Free * 2.16 MPa (22kg/cm2)
1
NO
20-504
I L
NIO a
YES
Are linkages of brake pedal and parking brake lever adjusted normally?
NO
D155AX-5
TROUBLESHOOTING
c/a*Uive
H-l
c
~~$creo’
/ r3;3ivertorque
1 “,“,9a&or
transmission
Defective transmission modulating valve
Repair or replace
Defective power train
Repair or replace
pump
Defective transmission main relief valve spool
Replace
Defective transmission main relief valve spring/shim
Repair or replace
Defective adjustment of joystick linkage
Adjust
_ Defective brake valve
tpf”Lr
D155AX-5
Repair or replace
Adjust
20-505
TROUBLESHOOTING
H-2. *
Machine
H-2, H-3
does not move or travel power is low in one direction
Before carrying out troubleshooting, check that the transmission speed. (If two or more problems have occurred, perform H-l.)
operates
normally
at each gear
Cause
1 YES Is linkage of joystick (direction) adjusted normally? NO
H-3. Ir
Machine
1 YES II
NO
20-506
Slip of transmission clutch
Repair or replace
Defective adjustment of linkage of joystick (direction)
Repair or replace
does not move or moves slowly at specific gear speed
Before carrying out troubleshooting, check that the transmission (If two or more problems have occurred, perform H-l.)
Is linkage of joystick (gear speed) adjusted normally?
Remedy
changes
the direction
normally.
Slip of transmission clutch
Repair or replace
Defective adjustment of linkage of joystick (gear speed)
Repair or replace
D155AX-5
TROUBLESHOOTING
H-4.
H-4
Long time lag is made in changing travel direction
*
Before carrying
Ir
Before carrying out troubleshooting, mal, perform H-l.)
out troubleshooting,
check that the oil level in the power check that the speed is normal.
or gear speed line is normal.
(If the speed is also abnor-
Remedy
Cause
YES
YE
1 joystick (direction,
Dl SAX-5
Repair or replace
pump
YE 3
I[
IL NC
Defective transmission main relief valve spool
Replace
Defective transmission main relief valve spring/shim
Repair or replace
springs and number h relief valve normal? - Large: 122mm * Small: 108mm - Shim: 5 pcs.
NO
Repair or replace
4 YES Defective power train
Is transmission main relief pressure normal? Engine at high idling. Joystick: Neutral 2.74 MPa {28kg/cm2)
Defective transmission modulating valve
Defective adjustment linkage of joystick
of
Repair or replace
20-507
H-5
TROUBLESHOOTING
H-5.
Travel power (Drawbar
*
Before carrying
*
Before carrying out troubleshooting, mal, perform H-l.)
out troubleshooting,
pull) is low check that the oil level in the power check that the speed is normal.
line is normal.
(If the speed is also abnor-
Cause
u-l
4 YES I
YES 3 -
1 Is transmission main relief pressure normal? I-l
* y&%ck:Operated . 2.74 MPa (28kg/cm2)
NO
Defective engine
Go to S mode.
Defective transmission
Repair or replace
Defective torque converter
Repair or replace
Defective transmission modulating valve
Repair or replace
Defective
Repair or replace
-
* Engine at high idling. Nc . Forward + 3rd gear
speed - 1,420rpm Is transmission . Engine at high idling. . modulating - * Joystick: Neutral NO pressure normal? * Inlet pressure: 0.83&0.15MPa {8.5~1.5kg/cm21 . - Outlet pressure: 0.44+1.15MPa {4.5+1.5kg/cm * Engine at high -
YI
Is inlet pressure YES and outlet _ pressure of torque 2 converter normal?
Is torque converter stall speed normal?
power train
* Engine at high idling. . Joystick: Neutral . 2.74 Ml% {28kg/cm’)
Replace
* Small: 108mm - Shim: 5 pcs.
20-508
Remedy
NO
Defective transmission main relief valve spring/shim
Repair or replace
D 155AX-5
TROUBLESHOOTING
H-6. Sr
Machine
Before carrying
H-6, H-7
cannot be steered (to one direction) out troubleshooting,
check that the hydraulic
oil level is normal. Cause
Remedy
2 YES YE 1
30 to H-8.
Is abnormal sound produced bv HSS pump and HSS motor?
Are HSS servo charge pressure and PPC relief
‘L
NO
H-7. *
Steering
Before carrying
Defective HSS pump ;olenoid valve
Repair or replace
Defective adjustment of HSS servo charge valve/PPC relief valve
Adjust
Defective HSS servo charge valve/PPC relief valve
Repair or replace
speed or power is low out troubleshooting,
check that the hydraulic
oil level is normal. Cause
Remedy
YES $0 to H-8. 2 YEIS
s abnormal ;ound produced ,y HSS pump md HSS motor?
YES
N~
Is HSS main pressure normal?
*Engine at high idling. . All levers: Neutral -3.53 MPa {36kg/cm*}
Defective HSS pump ;olenoid valve
tepair or eplace
Defective HSS main relief tialve
idjust
Defective HSS main relief valve
Iepair or eplace
(415t10kg/cm2) 5 YES Is oil pressure set to normal level by adjusting HSS se~c
Defective adjustment of HSS servo charge valve/PPC relief valve
-
charge valve/PPC relief valve?
NO
D155AX-5
4 YE!
Is oil pressure set . Engine at high _ to normal level by _ idling. NO adjusting HSS main relief valve? . Steering: Relieved . 40.7+0.98MPa NC
charge pressure
I NO
3
F
Defective HSS servo charge valve/PPC relief valve
Repair or replace
20-509
TROUBLESHOOTING
H-8. *
H-8
Abnormal
Before carrying
sound comes out of HSS pump or HSS motor out troubleshooting,
check that the hydraulic
oil level is normal.
YES
YES 3
YE!
Is oil leakage from HSS charge circuit?
* Start engine.
YES
4
N<
Is oil pressure set to normal level by adjusting HSS charge safety valve? p
YES 5
Is oil pressure set to normal level by NO replacing HSS charge safety valve?
6 YES Is oil pressure set to normal level by Ns replacing HSS charge relief valve? NO
*Engine at high idling. -All levers: Neutral - 3.53 MPa (36kg/cm*>
YES
4
Is oil pressure set to normal level by adjusting HSS servo NO charge valve and PPC relief valve?
YES
17 Is charge filter clogged?
9 YES
H NO
Table
Measuring condition When steering
Low idling
system neutral
High idling
2.75MPa {Min. 28kg/cm21
is in
When steering system is relieved
Note:
HSS charge pressure Min.
3.43 - 4.12MPa
Low idling
Min.
1.77MPa
High idling
Min. 2.75MPa
(35 - 42kg/cm? {Min.
18kg/cm*)
{Min. 28kg/cm*I
If the HSS charge pressure is low when the steering system is in neutral, the HSS safety valve probably has trouble. If the HSS charge pressure is low when the steering system is relieved, the HSS relieve valve probably has trouble.
20-510
D155AX-5
H-8
TROUBLESHOOTING
Cause
D 155AX-5
Remedy
Defective HSS pump or HSS motor
Repair or replace
Looseness of HSS charge piping clamp or damage of O-ring
Repair or replace
Defective adjustment of HSS charge safety valve
Adjust
Defective HSS charge safety valve
Repair or replace
Defective HSS charge relief valve
Repair or replace
Defective HSS pump or HSS motor
Repair or replace
Defective adjustment of HSS servo charge valve/PPC relief valve
Adjust
Clogging of hydraulic tank strainer
Clean or replace
Clogging of charge filter
Clean or replace
Defective charge pump
Repair of replace
20-511
TROUBLESHOOTING
H-9. Ir
H-9
Brake does not work
Before carrying
out troubleshooting,
check that the oil level in the power train is normal.
Cause
‘ES Is brake oil pressure as shown in following table?
2 YES Is linkage of brake pedal adjusted normally?
Slip of brake disk/plate
3epair or replace
Defective brake valve
Repair or replace
Defective adjustment of linkage of brake pedal
NO
Repair or
Table Measuring When brake pedal is pressed When brake pedal is released
20-512
condition Low idling High idling
Brake oil pressure OMPa IOkg/cm*I OMPa {0kg/cm21
Low idling
2.16MPa
122kg/cm21
High idling
2.16MPa
{22kg/cm*I
D155AX-5
TROUBLESHOOTING
H-10
H-10. Power train oil overheats *
If the temperature of power train oil exceeds (when the electric system is normal).
Ir
Before carrying
out troubleshooting,
about 12O”C, the lamp on the monitor
check that the oil level in the power train is normal.
YES
3 Is torque converter stall speed normal?
YE
-
4YEI
_ . Engine at high idling. s Forward + 3rd gear speed * 1,420rpm
2 YES
Is transmission main relief pressure normal?
No
Is machine kept stopped during _ operation in Step 3?
I: 1
6
Is brake oil pressure normal?
-Engine at high idling. * Parking brake
YES S Are free length of springs and number of shims in main relief valve normal?
h
* Large: 122mm . Small: 108mm . Shim: 5 pcs.
a
YES
Is inlet pressure and outlet pressure of torque converter normal? NO *Engine at high idling. . Joystick: Neutral - Inlet pressure: 0.83t0.15MPa {8.5+1.5kg/cm*} . Outlet pressure: 0.44+1.15MPa (4.5*1.5kg/cm2)
D155AX-5
Remedy
Defective engine cooling system
Go to S mode.
GotoA
Slip of brake disc/plate
Repair or replace
NO
Does spool of main relief valve move smoothly?
YES
Defective power train
Repair or replace
pump -
NC
Defective transmission main relief valve spool Defective transmission main relief valve spring/shim
Repair or replace
Defective brake valve
Repair or replace
Defective adjustment of linkage of brake pedal or oarking brake lever
Adjust
Slip of transmission clutch or too high output of engine
Repair or replace
Defective torque converter
Repair or replace
I
NO
A-
Cause
NC
d * Engine at high idling. . Joystick: Neutral -2.14 MPa f28kg/cm2)
panel flashes
20-513
H-II
TROUBLESHOOTING
H-l 1. Work equipment *
Before carrying
does not work at all
out troubleshooting,
check that the hydraulic
oil level is normal.
I
1 pressure normal?
1
Are HSS servo and PPC relief
- Engine at high idling. * Blade tilt: Relieved . 20.59+0.98MPa f210~10kg/cm*~
1
4 Is oil pressure set to normal level by
- adjusting main relief NO valve of control valve?
5 YE
Is oil pressure set to normal level by - replacing main relief NO valve of control valve?
- Engine at high idling. * All levers: Neutral * 3.53 MPa {36kg/cm2)
NI
6 YES Does foreign - matter come out NO of charge fitter?
Development work equipment pump
Repair or replace
Defective PTO
Repair or replace
Defective adjustment of main relief valve of control valve
Adjust
Defective main relief valve of control valve
Repair or replace
Defective unload valve of control valve
Repair or replace
Defective charge pump
Repair or replace
Defective HSS servo charge valve/PPC relief valve
Repair or replace
-
NO
20-514
YES
Cause
D 155AX-5
H-12
TROUBLESHOOTING
H-12. Work equipment *
Before carrying
speed or power is low
out troubleshooting,
check that the hydraulic
oil level is normal.
Remedy
YES 2 Is work YES _ equipment
YES
relief
1
Repair cr replace
Defective adjustment of main relief valve of control valve
Adjust
I
I
. Engine at high
Development work equipment pump
adjustingmain relief
. Blade tilt:
Is oil pressureset to
Relieved 20.59+0.98MPa (210+10kg/cm*)
Are HSS servo charge pressure and PPC relief pressure normal? - Engine at high idling. - All lever: Neutral - 3.53 MPa (36kg/cm*)
valve of control valve
replacingmain relief
YES
Defective unload valve of
Repair or replace
Defective PPC valve
Repair or replace
Defective charge pump
Repair or replace
5 Is oil pressure in Step 1 set to normal level by blocking
1 YES
NO
6
matter come out of charge filter?
I 7 Ycc ’ ‘=a Is conditionset normal by adjusting HSS serve charge NC valve or PPC relief valve? _._
l-d
NU
I Defective
adjustment of HSS servo charge valve/PPC relief valve
Adjust
Defective HSS servo charge valve/PPC relief valve
Repair or replace
Blade valve
_I HSS PPC
L
D155AX-5
Repair or replace
To
charge relief
HSS
charge
PPC
Ripper va I ve
PPC
and valve circuit
TWDOlOOO
20-515
TROUBLESHOOTING
H-13, H-14
H-13. Blade lifting speed or power is low *
Before carrying
Ir
Before carrying out troubleshooting, check that the quantity quantity of hydraulic drift is also abnormal, perform H-17.)
out troubleshooting,
check that the hydraulic
oil level is normal. of hydraulic
drift is normal.
Cause
(If the
Remedy
Repair or replace YE 1 Repair or replace
II
Does cylinder operate smoothly?
* Engine at high idling.NO * Blade lever: Operated.
* 3.53MPa
* Start engine. * Lift blade.
(36kg/cm’) Air in blade lift cylinder
JO
Bleed air
H-14. Blade tilting speed or power is low Ir
Before carrying
*
Before carrying out troubleshooting, check that the quantity quantity of hydraulic drift is also abnormal, perform H-18.)
out troubleshooting,
check that the hydraulic
oil level is normal. of hydraulic
drift is normal.
Cause
2 YES II
I Does cylinder operate smoothly? - Start engine. - Tilt blade.
20-5 16
YES 1 _
Is output pressure of PPC valve normal?
NO
Remedy
Defective operation of control valve spool
Repair or replace
Defective PPC valve
Repair or replace
Air in blade tilt cylinder
Bleed air
-
. Engine at high idling.NO . Blade lever: Operated. - 3.53MPa {36kg/cm*)
I
(If the
D155AX-5
H-15, H-16
TROUBLESHOOTING
H-15. Ripper lifting speed or power is low *
Before carrying
*
Before carrying out troubleshooting, check that the quantity quantity of hydraulic drift is also abnormal, perform H-19.)
out troubleshooting,
check that the hydraulic
oil level is normal. of hydraulic
drift is normal.
Cause
3 YES Does control YES_ valve spool _2 move smoothly?
; Is output - pressure of PPC valve normal?
NO
-
* Engine at high id5ng.L * Lift ripper. NO * 3.53MPa {36kg/cm*)
(If the
Remedy
Defective operation of suction valve of control valve
Repair or replace
Defective operation of control valve spool
Repair or replace
Defective PPC valve
Repair or replace
Air in ripper lift cylinder
Bleed air
- Start engine. * Lift ripper.
H-16. Ripper tilting speed or power is low Ir
Before carrying
out troubleshooting,
check that the hydraulic
oil level is normal.
Cause
3 YES Does control YES_ valve spool _2 move smoothly? YES 1 Does cylinder operate smoothly? . Start engine. *Tilt ripper.
D155AX-5
Is output pressure of PPC valve normal?
NO
Defective operation of suction valve of control valve
Repair or replace
Defective operation of control valve spool
Repair or replace
Defective PPC valve
Repair or replace
Air in ripper tilt cylinder
Bleed air
-
* Engine at high idling. . Tilt ripper. NO * 3.53MPa f36kg/cm*)
‘I
Remedy
NO
20-5
17
H-17, H-18
TROUBLESHOOTING
H-l 7. Hydraulic drift is large in blade lifting direction
Cause
1 YES Is lowering speed increased by operating blade lever in lowerina direction? -
- Stop engine.
Defective blade lift cylinder packing
I-
Remedy
Repair or replace
-
NO
Defective oil-tightness of control valve spool
Repair or replace
* See TESTING AND ADJUSTMENT.
H-18. Hydraulic drift is large in blade tilting
direction
Cause
1 YES
I
II
Remedy
Defective oil-tightness of control valve spool
Repair or replace
Defective blade tilt cylinder packing
Repair or replace
Is leakage in cylinder normal?
. Engine at high idling. NO * Blade lift cylinder: Relieved - lZcc/min.
20-518
D 155AX-5
TROUBLESHOOTING
H-19, H-20
H-19. Hydraulic drift is large in ripper lifting direction Remedy
Cause
i1 YES
Defective oil-tightness of control valve spool
Repair or replace
Defective ripper lift cylinder packing
Repair or replace
Is leakage in cylinder normal?
* Engine at high idling. NO * Ripper lift cylinder: Relieved - llcc/min.
H-20. Blade pitch does not work normally dozer)
(When equipped
with pitch
Cause
YES 1 Is output pressure of blade _ 2 YES pitch valve normal? ~ Dose blade pitch - Engine at - valve spool high idling. NO move smoothly? - Blade pitch cylinder: Relieved NO * 20.5950.98MPa {210~10kg/cm*~
D155AX-5
Remedy
Defective blade pitch cylinder
Repair or replace
Defective blade pitch valve solenoid valve
Repair or replace
Defective main valve of blade pitch valve
Repair or replace
20-5 19
H-21, H-22
TROUBLESHOOTING
H-21. Ripper pin puller does not work normally giant ripper) *
Before carrying
out troubleshooting,
(When equipped
check that the power train system
1 YES
solenoid valve normal?
Repair or replace
u Defective ripper pin puller solenoid valve
I . Enaine at hiah
II idlina.NO - Ripper pin &ller: Relieved - 2.74MPa 128kg/cm2)
H-22. Abnormal Ir
is normal.
Defective ripper pin puller cylinder
Is outputpressure of ripperpin puller
with
Before carrying
sound comes out of work equipment
out troubleshooting,
check that the hydraulic
oil level is normal.
Looseness of suction
YES
Is air sucked in suction circuit of
Repair or replace
pump
Cause
YE
I
piping clamp of pump or damage of O-ring
YES
Remedy
Repair or replace
Clogging of hydraulic tan1 strainer
Repair or replace
Defective work equipmen
Repair or replace
pump Is oil used proper? I
tank?
IL NC
0
20-520
Operate for a while, then check condition for change.
Inspect again according to change of condition.
Use of improper oil
Replace
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE) [Serial No. 70001 – 75000] Electrical circuit diagram for M mode ............................................................................................ 20-602 M- 1. Monitor lamps do not light up for 3 seconds when starting switch is turned ON ........ 20-603 M- 2. When starting switch is turned ON, monitor lamps all light up but do not go out ............................................................................................... 20-603 M- 3. Abnormality in preheating monitor lamp ........................................................................... 20-604 M- 4. Abnormality in battery charge lamp .................................................................................... 20-606 M- 5. Abnormality in engine oil pressure caution lamp .............................................................. 20-608 M- 6. Engine water temperature caution lamp flashes ................................................................ 20-610 M- 7. Transmission oil temperature caution lamp flashes .......................................................... 20-610 M- 8. HSS oil temperature caution lamp flashes ......................................................................... 20-611 M- 9. HSS charge oil pressure caution lamp flashes ................................................................... 20-612 M-10. Electronic system caution lamp on monitor panel does not work in accordance with LED display on HSS controller .................................................................................... 20-613 M-11. Monitor caution lamp on monitor panel does not work in accordance with each caution lamp ......................................................................................................... 20-613 M-12. Alarm buzzer does not sound or sounds continuously ..................................................... 20-614 M-13. Abnormality in engine water temperature gauge .............................................................. 20-616 M-14. Abnormality in transmission oil temperature gauge ......................................................... 20-618 M-15. Abnormality in fuel level gauge ........................................................................................... 20-620 M-16. Service meter does not work after engine is started ......................................................... 20-622 M-17. Monitor panel night lighting does not light up when head lamp switch is turned on .................................................................................. 20-623 M-18. Head lamps or rear lamps do not light up ......................................................................... 20-624 M-19. Automatic preheating is not carried out when preheating switch is turned to AUTO .. 20-626 M-20. Window wipers and window washers do not work .......................................................... 20-628 M-21. Air conditioner does not work .............................................................................................. 20-632
D155AX-5
20-601 4
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
FOR M MODE
Monitor panel system CN-GDI
s
Eva ine -----~------------------------
I
Alternator With cab:5DA Ensine rater
Engine oi
CN-2 I1
Monitor
Heater
caneI
I
relay
p2 I ___---,--_~_._..~___,__
r
I
I
CN-264
Ill Binetal timer Startino
1
I
X X
CN-206
sr,te.
Toraw converter oil tewerature sensor
CN-451
E:
switch
HSS controller
For spare alarm huller
&
CN-424
&
1 netrorl:
srats.nstwrt CN-452
NSS oil temperature switch w
CN-SXB
I
HSS charge oil ~reszure switch
TWDOIOOI
20-602
D15SAX-5
M-l,
TROUBLESHOOTING
M-l.
Monitor lamps do not light up for 3 seconds when starting _ switch is turned ON _
Check that No.3 fuse is not broken. chassis ground. Before carrying
out troubleshooting,
Always
any disconnected
connect
If it is broken,
check if the related
check that all the related connectors
circuit is in contact
connectors
are properly
YES
* Turn starting switch ON. *20-30V
Is voltage between PI (I) and chassis ground normal? * Turn starting switch ON. -2O-30V
Related
Monitor
Defective contact or disconnection in wiring harness between PI (female) (21, P2 (female) (4) - CN-SX8 (chassis ground) Defective contact or disconnection in wiring harness between fuse 3 PI (female) (1)
2 YES
Ne
electrical
Panel
I
NO
CN-215 (SWPBI
I
SUPPIY
Fuse
box
CN-214 (SWP8)
P2 (040121 @
I
@ CN-SX8
I
TWD01002
When starting switch is turned ON, monitor but do not go out
lamps all light up
Cause
Defective monitor panel
D 155AX-5
Replace
@ I
M-2.
Repair or replace
a-3
GND
GND
Replace
circuit diagram
Pl (04016) Power
inserted.
Remedy
Defective monitor panel
1 Is voltage between Pl (1) and Pl (2). P2 (4) normal?
with
before going on the next step. Cause
M-l.
M-2
Remedy
Replace
20-603
TROUBLESHOOTING
M-3.
M-3
Abnormality
in preheating
Ir
Before mally.
*
Before carrying
out troubleshooting,
*
Always
any disconnected
a)
Preheating
monitor
lamp
carrying out troubleshooting, check that the automatic preheating If the automatic preheating system is also abnormal, see M-19.
connect
monitor
check that all the related connectors connectors
before going
system
are properly
Defective monitor panel
qeplace
Defective contact or disconnection in wiring harness between Pl (female) (9) - CN-108
Repair or replace
monitor
lamp stays lighted
up Cause
1 YES Is voltage between Pl (9) and chassis ground normal? * Turn starting switch ON. * Max. 1 V
20-604
Remedy
_
*Turn starting NO switch to PREHEAT. *20-30V
Preheating
inserted.
lamp does not light up
1 YES
b)
nor-
on the next step.
Cause
Is voltage between Pl (9) and chassis ground normal?
operates
NO
Remedy
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between Pl (female) (9) - CN-108
Repair or replace
D155AX-5
TROUBLESHOOTING
M-3. Related
M-3
electrical
circuit diagram
Intake
air
heater
CN-101
(SWP12)
Monitor
~
Panel Pl (040 16)
II’ir::i::
p(
y
j
Heater
relay1
h,
CN-2 11 LSWP11
-
I
I
I
I TWD01003
D 155AX-5
20405
M-4
TROUBLESHOOTING
M-4.
Abnormality
in battery charge lamp
*
Before carrying
out troubleshooting,
*
Always
connect
any disconnected
a)
Battery
charge lamp does not light up when starting
check that all the related connectors
connectors
are properly
before going on the next step.
switch
is turned
ON while
engine is stopped
Remedv
Cause
YES
- See
Note. *Turn starting switch ON. * Max. 1 V
NO
Note: When measuring voltage tor terminal side.
b)
Battery
charge
disconnect
lamp flashes
while
alternator
engine
inserted.
terminal
Defective monitor panel
Replace
Short circuit with power supply in wiring harness between PI (female) (4) CN-220 (female) (2) - CN-11: - CN-103 (female) (2)
Repair or replace
Defective alternator
Replace
R, and measure
voltage
on the alterna-
is running
>
between PI (4)
, between CN-112
Defective monitor panel
Reolace
Short circuit with power supply in wiring harness between Pl (female) (4) CN-112 - CN-103 (female) (2) - CN220 - CN-SW
Repair or replace
Defective alternator
Replace
1ground normal?
* See
Note. . Start engine. *IO-3ov
Note: When measuring voltage tor terminal side.
20-606
NO
disconnect
alternator
terminal
R, and measure
voltage
on the alterna-
D155AX-5
M-4
TROUBLESHOOTING
M-4. Related
electrical
circuit diagram
Alternator
Battery
relay
TWD01004
D 1554X-5
20-607
TROUBLESHOOTING
M-5.
M-5
Abnormality
in engine oil pressure caution lamp
*
Before carrying
out troubleshooting,
Ir
Always
connect
any disconnected
a1
Caution
lamp does not light up when
check that all the related connectors
starting
before going
switch
connectors
YES
Is resrstance between Pl (female) (8) and chassis ground normal? p *Turn starting switch OFF. * Disconnect Pl. - Max. 1 R
IS between CN-403 - (switch side) and NO chassis ground normal?
2 YES z
is turned
ON while
engine
is stopped
Cause
Remedy
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between Pl (female) (8) CN-403
Repair or replace
Defective engine oil pressure sensor
Replace
-
*Turn starting NO switch OFF. * Disconnect CN-403. - Max. 1 D
b)
Caution
*
Before carrying out troubleshooting, check that the engine oil pressure is normal. pressure lowers below about 0.49MPa {0.5kg/cm21, the caution lamp flashes.
lamp flashes
while
engine
is running If the engine
Cause
YES 1 Is resrstance between Pl (female) (81 and chassis ground normal? p - Disconnect PI. * Start engine. . Min. 1 fi
-
2 YES
IS between CN-403 - (switch side) and NO chassis ground normal?
-
* Disconnect CN-403N0 - Start engine. * Min. 1 R
20-608
inserted.
on the next step.
I 1
are properly
oil
Remedy
Defective monitor panel
Replace
Short circuit with chassis ground in harness between PI (female) (8) CN-403
Repair or replace
Defective engine oil pressure sensor
D155AX-5
M-5
TROUBLESHOOTING
M-5.
Related
Monitor
electrical
Panel
circuit diagram
I Pl (04016)
CN-214 (SWP 16)
CN-101 SWP 12)
Engine Pressure
oil switch
-3
I TWD01005
D155AX-5
20-609
TROUBLESHOOTING
M-6. *
M-6,
Engine water temperature
M-7
caution lamp flashes
Before carrying out troubleshooting, check that the engine water is not overheated. water temperature exceeds about 102”C, the caution lamp flashes.
If the engine
Remedy
1 YES Is engine water temperature gauge in red r~nlX=?? * Turn starting switch ON.
M-7. *
H
Go to M-13.
Defective monitor panel
Transmission
oil temperature
Before carrying out troubleshooting, If the transmission oil temperature
caution lamp flashes
check that the transmission oil temperature is not overheated. exceeds about 120X, the caution lamp flashes.
I 1 YES
I
-
. Turn starting switch ON.
20-610
Replace
NO
I
I
Cause
Go to M-14.
Defective monitor panel
Replace
NO
D 155AX-5
M-8
TROUBLESHOOTING
HSS oil temperature
M-8.
caution lamp flashes
*
Before carrying out troubleshooting, check that the HSS oil is not overheated. temperature exceeds about 120X, the caution lamp flashes.
*
Before carrying
out troubleshooting,
*
Always
any disconnected
connect
check that all the related connectors
connectors
If the HSS oil
are properly
inserted.
before going on the next step.
Remedy
Cause
YES
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between P2 (female) (5) - CN-452 (female) (1)
Repair or replace
1
~
Defective engine oil pressure sensor
NO -Turn starting switch OFF. . Disconnect CN-452. * Max. 1 !J
M-8. Related Monitor
electrical Panel
I
circuit diagram
I P2 (040 121
temperature
CN-70 1 (SWP12)
CN-215 (SWP8) t
HSS drain temperature switch
CN-452 (xl 1
oil
I
TWD01006
D 155AX-5
20-611
M-9
TROUBLESHOOTING
M-9.
HSS charge oil pressure caution lamp flashes
*
Before carrying out troubleshooting, pressure drops below about 0.78MPa
*
Before carrying
out troubleshooting,
*
Always
any disconnected
connect
check that the HSS oil pressure is normal. {8kg/cm2}, the caution lamp flashes. check that all the related
connectors
connectors
If the HSS oil
are properly
before going on the next step. Remedy
Cause
1
I Isresistance
. Disconnect CN-2Hl. - Start engine. + Max. 1 R
I
3 YES
~
1 : ~liygct
[normal? . Disconnect CN-CRGP. + Start engine. * Max. 1 Q
inserted.
Defective HSS controller or monitor panel
Replace
Defective contact or disconnection in wiring harness between CN-2Hl (female) (8) - CN-CRGP (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between CN-CRGP (female) (2) - CN-SX8 (Chassis ground
Repair or replace
Defective HSS charge pressure sensor
Replace
CN-CRGP.
NO
M-9. Related electrical circuit diagram
HSS
controller
HSS charge
I PM-7n
Pressure
1 lCWD f 91
f’hl-dnfi
(~31
PN-rar,p
(~2)
i I Pressure switch 0
km
sensor
CN-SX8 TWD01007
20-612
D155AX-5
M-10,
TROUBLESHOOTING
M-10.
M-11
Electronic system caution lamp on monitor panel does not work in accordance with LED display on HSS controller Cause
Defective monitor panel
Remedy
Replace
M-l 1. Monitor caution lamp on monitor panel does not work in accordance with each caution lamp Cause
Defective monitor panel
D155AX-5
Remedy
Replace
20413
M-12
TROUBLESHOOTING
M-12.
Alarm buzzer does not sound or sounds continuously
*
Before carrying
out troubleshooting,
*
Always
any disconnected
a)
Caution
*
Note that the buzzer may not sound in certain ranges of the coolant temperature oil temperature even if their caution lamps flash.
*
Check that fuse 3 is not broken. chassis ground.)
connect
lamp flashes
but buzzer
check that ail the related connectors
connectors
are properly
inserted.
before going on the next step.
does not sound and transmission
(If it is broken, check the circuits related to it for short circuit with
Remedy
Cause
YES
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between CN-217 (femaleH2) - P2 (female) (7)
Repair or replace
Defective alarm buzzer
Replace
Defective contact or disconnection in wiring harness between fuse 3 CN-217 (female) (1)
Repair or replace
1 Does buzzer sound when P2 (7) is connected to chassis ground? p -Turn starting switch ON.
YES 2 Does buzzer sound when CN-217 (2) is NO connected to chassis ground? -Turn starting switch ON.
3 YES Is voltage between CN-217 NO (1) and chassis ground normal? + Remove fuse 5. NO *Turn starting switch ON. .20-30V
b)
Caution
lamp does not flash but buzzer sounds continuously
I YES 1 Does buzzer stop sounding when P2 is disconnected? * Disconnect P2. * Turn starting switch ON.
20-614
I
2 YES Is resistance between P2 (female) _ (71 and chassis _ NO ground normal when CN-217 is disconnected? NO * Turn starting switch OFF. * Disconnect CN-217 and Pl. * Min. 1 MR
Cause
Defective monitor panel
I
Remedy
Replace
Defective alarm buzzer
Short circuit with chassis ground in harness between P2 (female) (7) CN-217 (female) (2) CN-217 (spare)
Repair or replace
D155AX-5
TROUBLESHOOTING
M-12. Related
Monitor
electrical
M-12
circuit diagram
CN-215 (iWP8)
Panel
I
3
~2p21040;21, Alarm
CN-264 (iWP6)
=
output
Qg
,w
Fuse
CN-GO 1
w
(IN-218
c__ I “I
,$-2
spare alarm buzzer
17
box
0
TWD01008
D 155AX-5
20-615
M-13
TROUBLESHOOTING
M-13.
Abnormality
in engine water temperature
*
Before carrying
out troubleshooting,
*
Always
any disconnected
connect
a) Coolant temperature *
check that all the related connectors
gauge connectors
are properly
inserted.
before going on the next step.
gauge stays in C range and does not rise
If the coolant Before carrying out troubleshooting, check that the coolant temperature is normal. temperature rises above about 5O’C, the coolant temperature gauge rises into the white range.
Cause
I Is resistance
* Disconnect CN-402. *Turn starting switch ON.
N
switch OFF. NO * Disconnect CN-402. * Max. 1 D
temperature
3 YES
I I
Remedy
Defective coolant temperature gauge
Replace
Defective monitor panel
Replace
Iefective contact or discomection in wiring harness oetween P2 (female) (1) 3N-402 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between CN-402 (female) (2) CN-SX8 (chassis ground)
Repair or replace
bl
Coolant
gauge stays in H range and does not lower
*
Before carrying out troubleshooting, check that the coolant temperature is normal. If the coolant temperature rises above about 102”C, the coolant temperature gauge rises into the red range.
Cause
YES 1
I
Does gauge lower gradually toward C side when CN-402 2 YES Is resistance is disconnected? p between P2 (female) * Disconnect _ (1) andchassis _ NO ground normal CN-402. when CN-402 is *Turn starting disconnected? switch ON. NO . Turn starting switch OFF. . Disconnect CN-402 and P2. * Min. 1 MD
20-616
Remedy
Defective coolant temperature gauge
Replace
Defective monitor panel
Replace
Short circuit with chassis ground in harness between P2 (female) (I) CN-402 (female) (1)
Repair of replace
D155AX-5
TROUBLESHOOTING
M-13.
Related
Monitor
1
panel
electrical
M-13
circuit diagram
I P2 (04Oi2)
CN-214
LsWP161
CN-101 (SWP12)
CN-402 o(2)
Engine water temperature sensor
3 3
TWD01009
D155AX-5
20-617
M-14
TROUBLESHOOTING
M-14.
Abnormality
in transmission
*
Before carrying
out troubleshooting,
*
Always
any disconnected
connect
a) Oil temperature Ir
oil temperature
check that all the related connectors
gauge
connectors
are properly
inserted.
before going on the next step.
gauge stays in C range and does not rise
Before carrying out troubleshooting, check that the transmission oil temperature is normal. If the transmission oil temperature rises above about 50-C, the coolant temperature gauge rises into the white range. Cause
3 YES
Defective transmission oil temperature gauge
Replace
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between P2 (female) (2) CN-453 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between CN-453 (female) (2) - CN-SX8 (chassis ground)
Repair or replace
!II
CN-453 (female) (I) is connected to (2)? * Disconnect CN-453. -Turn starting switch ON.
Remedy
_ l-l-
CN-453 (female) (I)
I Is resistance between CN-453 (female) (2) and
I\
F+.+g Turn e.Y. .., r...;trh WE
NO
lnnect P2 and CN-453 switch OFF. NO . Disconnect CN-453. - Max. 1 Q
b)
Oil temperature
gauge stays in H range and does not lower
sr
Before carrying out troubleshooting, check that the transmission oil temperature is normal. If the transmission oil temperature rises above about 120X, the coolant temperature gauge rises into the red range. Cause
YES 1 Does gauge lower gradually toward C side when CN-453 is disconnected? * Disconnect CN-453. * Turn starting switch ON.
20-618
I
’ YES Is resiStance between P2 (female) _ (2) and chassis NO ground normal when CN-453 is disconnected? NO *Turn starting switch OFF. - Disconnect CN-453 and P2. f Min. 1 MD
Remedy
Defective transmission oil temperature gauge
Defective monitor panel
Replace
Short circuit with chassis ground in harness between P2 (female) (2) CN-453 (female) (1)
Repair or replace
D155AX-5
M-14
TROUBLESHOOTING
M-14.
Related
Monitor
1
I
electrical
Panel
circuit diagram
I P? ,_ (04Oi9l ._._.-.
Transmission oil temperature
I Pl (04016)
GND
CN-214 (SWP 16)
w-45 (SWPBI
1
CN-453 (x21
3
3
3
3
Transmission oil temperature sensor
CkSX8 TWDOlOlO
D155AX-5
20-619
M-15
TROUBLESHOOTING
M-15.
Abnormality
in fuel level gauge
*
Before carrying
out troubleshooting,
*
Always
any disconnected
a)
Fuel level gauge stays in E
Ir
Before carrying
connect
out troubleshooting,
check that all the related connectors
connectors
are properly
inserted.
before going on the next step.
check that there is some fuel in the fuel tank.
Cause
3 YES Is resistance -_
Remedy
Defective fuel level sensor
Replace
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between P2 (female) (3) EN-423 (female) (I)
Repair or replace
Defective contact or disconnection in wiring harness between CN-423 (female) (2) - CN-424 (chassis ground)
Repair or replace
CN-423tfemale) (1)
- ursconnect CN-423. -Turn starting switch ON.
Nq*~y
.$jg:;
switch OFF. NO * Disconnect CN-423. * Max. 1 Q
b)
Fuel level gauge stays in F
*
Before carrying
out troubleshooting,
‘2 and CN-423
check that the fuel level in the fuel tank is low.
F
Cause
YES 1 Does gauge lower gradually toward E side when CN-423 is disconnected? . Disconnect CN-423. * Turn starting switch ON.
20-620
2 YES Is resistance between P2 (female) _ (3) and chassis _ NO ground normal when CN-423 is disconnected? _ NO * Turn starting switch OFF. . Disconnect CN-423 and P2. * Min. 1 MQ
Remedy
Defective fuel level sensor
Defective monitor panel
Replace
Short circuit with chassis ground in harness between P2 (female) (3) CN-423 (female) (1)
Repair or replace
D 155AX-5
TROUBLESHOOTING
M-15
M-15. Related electrical circuit diagram
Monitor
Panel
I P2 (040201
CN-214 (SWP161
CN- 153 (SWP6)
CN-422 (x21
CN-423 o(2)
3
3
3
3
Fuel level sensor
-J
CN-424 TWDOlOll
D155AX-5
20-621
TROUBLESHOOTING
M-16.
M-16
Service meter does not work after engine is started
Cause
1 YES
Remedy
See M-4
Is battery charge caution lamp flashing? Defective monitor panel * Start engine.
20-622
Replace
NO
D155AX-5
M-17
TROUBLESHOOTING
M-17.
Monitor panel night lighting does not light up when head lamp switch is turned on
Before carrying out troubleshooting, light up, see M-18.
check that the head lamps light up.
Before carrying
out troubleshooting,
check that all the related connectors
Always
any disconnected
connect
connectors
If the head lamps do not
are properly
before going on the next step.
Remedy
Cause
1 YES
1Is voltage between P2 (7) chassis ground normal? . Turn starting switch ON. *Turn head lamp switch ON. *20-30V
M-17.
inserted.
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between P2 (female) (7) - CN-216 (female) (2)
Replace
I
NO
Related
electrical
Monitor
Panel
circuit diagram
Ck215 LSWPB)
Pl (04016)
CR-101 LSWP121
CN-20 1 (x2)
CN-203 (x 1I
Head lamp (R.H. )
",fl;fo4
Head lamp (L.H. )
3
l
-3 ,
;:;;,;amp _
CN-2 16 (KES4)
1 -TP TWD01012
D 155AX-5
20-623
M-18
TROUBLESHOOTING
M-18.
Head lamps or rear lamps do not light up
*
Before carrying
out troubleshooting,
*
Always
any disconnected
al
Front lamps do not light up
*
Check that No.4 fuse is not broken. chassis ground.
connect
check that all the related connectors
connectors
are properly
before going on the next step.
If it is broken,
check if the related
circuit is in contact
YES
1
M-18 a) Related
Monitor
3 YES 2 PIs voltage between CN-216 (female) (3) and chassis ground normal?
Is resistance between CN-216 (male) (2) and (3Jnormal? *Turn starting switch 0~
Replace
Defective contact or disconnection m wiring harness between CN-216 (female) (2) - CN-203 (female) (I) or CN-204 (female) (1)
Repair or replace
Defective front lamp switch
Replace
Repair or replace
circuit diagram
Panel
W-215 (SWPB)
pG++
,a T-
Head lamp switch
Breakage of front lamp which does not light up
* Disconnect CN-216. . Turn starting switch ON. *20-30V
electrical
with
Remedy
Cause
lls voltage between CN-203/CN-204 (female) (I) and chassis ground normal? * Disconnect CN-203 and CN-204. NE -Turn starting switch ON. -Turn front lamp switch ON. *20-30V
inserted.
CN-101 LSWP12)
cl+20 (X21
1
CN-203
Head lamp (R. H. 1
:z;fO”
Head lamp (L. H. )
>I-
3
CN-2 16 (KES4)
1
l-
TP TWD01012
20-624
D 155AX-5
M-18
TROUBLESHOOTING
b1 Rear lamps *
do not light up
Check that No.3 fuse is not broken. chassis ground.
If it is broken,
check if the related
circuit
is in contact
Cause
YES
voltage oetween CN-224lCN-243/ CN-243 (female) (1) H and chassis Is
* Disconnect CN-211. * Turn starting switch ON. -2O-30V
* Turn rear lamp switch ON. .20-30V
M-18 b) Related
Rear lamp
switch
YES
electrical
CN-211 (KES4)
NO
with
Remedy
Breakage of rear lamp which does not light up
Replace
Defective contact or disconnection in wiring harness between CN-211 (female) (2) - CN-224 (female) (1). CN-243 (female) (1) or CN-248 (female) (1)
Repair or replace
Defective rear lamp switch
Replace
Defective contact or disconnection in wiring harness between fuse 3 CN-211 (female) (3)
Repair or replace
circuit diagram
CN-215 (SWPB)
a.
3
@
3
CN- 153 LSWP6)
CN-223 (x 1)
CN-224
(x 1) Rear I amp
CN-24 5 Ripper I amp
Fuse
box Ripper Point I amp TWDOlOl3
D155AX-5
20-625
M-19
TROUBLESHOOTING
M-19.
Automatic preheating is turned to AUTO
*
Before carrying
out troubleshooting,
*
Always
any disconnected
connect
is not carried out when preheating check that all the related connectors
connectors
are properly
4 YEI
H
between CN-212 (2) and chassis ground normal?
-Turn starting switch ON. *20-30V
NO
YES
5
I Is voltage A-
switch OFF.* Disconnect CN-212.
I
between CN-109 and chassis ground normal? * Turn starting switch ON. .20-30V
20-626
NO
I NO
Go to
Remedy
A.
between CN-213 (male) (2) and (3) . Turn starting NC switch OFF. * Disconnect CN-213. . Max. 1 R
I
inserted.
before going on the next step.
Cause
Yf
switch
Defective glow switch
Ieplace
Defective contact or disconnection in wiring harness between CN-212 (female) (1) - CN-213
qepair or .eplace
Defective bimetal timer
qeplace
Defective contact or disconnection in wiring harness between starting switch terminal BR CN-212 (female1 (2)
qepair or ,eplace
Defective heater relay
leplace
Defective contact or disconnection in wiring harness between CN-213 (female) (2) - CN-109
lepair or eplace
D155AX-5
M-19
TROUBLESHOOTING
M- 19. Related
electrical
Preheating
circuit diagram
Battery
switch
Intake
1
CN-213
I
air
heater
I I -I
Bimeta
1
I
timer
Monitor
Panel
Heater
7%
I
I
I
I
relay1
h
CN-214
TWD01003
D 155AX-5
20-627
M-20
TROUBLESHOOTING
M-20.
Window
wipers and window
*
Before carrying
out troubleshooting,
Sr
Always
any disconnected
a)
All window
connect
wipers
and window
washers do not work
check that all the related connectors
washers
connectors
are properly
before going on the next step.
do not work
Cause
Defective contact or disconnection in wiring harness between CN-C fuse box for cab
b)
Front window
wiper
Defective wiper switch
r
Does Yviper work norma Ily when switch is replaced?
*Turn starting switch ON.
20-628
Remedy
Repair or replace
does not work
Cause
1I
inserted.
Ii-l
Remedy
Replace
4 YES I Is
resistance
between switch YES connector (female) _ (4) and motor 3 ~ connector (female) Is resistance (2) normal? YES between switch Nl - connector (female) - . Turn starting switch OFF. (3) and chassis 2 P ground normal? * Disconnect connector Is voltage between * Max. 1 Q *Turn starting motor connector switch OFF. NO N5 (5) and chassis - Disconnect connector. ground normal? * Max. 1 Q -Turn starting I switch ON. .20-30V
Defective wioer motor
Replace
Defective contact or disconnection in wiring harness between switch connector (female) (4) motor connector (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between switch connector (female) (3) chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between fuse box for cab - motor connector (female) (5)
Repair or replace
D155AX-5
TROUBLESHOOTING
c)
Right or left window
M-20
wiper
does not work
Cause
YES
Remedy
Iefective wiper switch
Replace
Defective wiper motor
Replace
4 YES
I Is resistance
Itbetween switch YES connector (female) _ (4) and motor 3 connector (female) Is resistance (2) normal? YES between switch - connector (female) - -Turn starting NC (3) and chassis switch OFF. 2 P ground normal? . Disconnect connector. Is voltage between P .Max.lR . Turn starting switch connector switch OFF. NO N j- (3) and chassis - Disconnect connector. ground? . Max. 1 R . Turn starting switch ON. NO .20-30V
. Turn starting switch ON.
d)
Washer
fluid is not sprayed
I Iefective contact or disconnection in wiring harness between switch :onnector (female) (4) motor connector (female) (2) Defective contact or disconnection in wiring harness between fuse box for cab - motor connector [female) (3) Defective contact or disconnection in wiring harness between motor connector (female) (3) chassis ground
YES 1
P. Turn starting switch ON. -Turn washer ON.
YES
-
Repair or replace
Remedy
Insufficiency of washer fluid, clogging of nozzle or defective piping
Supply washer fluid, repair or replace
Defective window washer motor
Replace
Defective wiper switch
Replace
2 Does washer work when motor No connector is replaced? P . Turn starting switch ON. . Turn washer ON.
D155AX-5
Repair or replace
out Cause
Does motor produce rotating sound?
Repair or replace
YES 3 Does washer work - when switch is NO replaced? _
Defective contact or ,, YES disconnection in wiring Repair or P _ harness between switch replace Is resistance connector (female) (1) between motor motor connector (female) (1) - connector (female) Defective contact or NO (2) -chassisground disconnection in wiring Repair or normal? harness between motor replace . Turn starting No connector (female) (2) switch OFF. CN-SX8 (chassis ground) . Disconnect connector. I I - Max. 1 R
20-629
M-20
TROUBLESHOOTING
M-20.
Related
electrical
circuit diagram CN-361 Front
window
washer
motor
CN-362 Left
window
washer
motor
CN-363 Right
window
washer
motor
CN-364 1
Washer
Rear
circuit CN-SX8
Front
wiper
window
washer
CN-18
motor Left motor
wiper
Rear
wiper
I
Front motor
Right switch
Rear switch
wiper
wiper
wiper Right wiper CN-
motor
11
Bat
Fuse for
terv
c TWDO
20-630
D155AX-5
TROUBLESHOOTING
M-21.
M-21
Air conditioner
does not work
*
Check that No.8 fuse is not broken. chassis ground.
*
Before carrying
out troubleshooting,
Ir
Always
any disconnected
a)
Air does not flow
connect
out.
Blower
If it is broken,
check if the related
check that all the related connectors
circuit is in contact
connectors
are properly
with
inserted.
before going on the next step.
does not work.
Table
Table 1
2
YES 6 Is voltage YES 5 Is resistance YES between CN-395 - (female) (4) and chassis ground 4 normal? YES 3 YEz
Is voltage between CN-395 (3) and chassis
2 Is resistance YES between CN-391 _ (male) (I) and (3) 1 normal? Is voltage between CN-391 _ (1) (2) and chassis ground normal? * Turn starting switch ON. -2O-30V
- Turn starting switch OFF. - Disconnect CN-391. - 240+4OI2
* Turn starting switch ON. -2O-30V
_
between CN-391 (4) and chassis ground normal?
_
* Turn starting -
switch ON’ * Set blower switch to oosition other
NO
Is continuity * Turn starting between CN-395 (male) and each switch OFF. * Disconnect terminal as shown CN-395. in Table l? * Max. 1 Q *Turn starting switch OFF. * Disconnect NO CN-395.
NO
NO
NO
11
YES
Is resistance between CN-394 (female) (1) and CN-395 (female) (2) normal? -Turn starting NO switch OFF. - Disconnect CN-394 and CN-395. * Max. 1 D
20-632
D155AX-5
TROUBLESHOOTING
M-21
Cause
10
YES
YEI
r-----G of condenser
ground normal? . Turn starting switch ON. . Set blower switch to position other than OFF. *20-30V
1 H
and (3) as shown in Table 2? II 1,
1 1 - Turn starting switch ON. . Set blower switch No to position other than OFF.
JO
* Disconnect CN-394. . Max. 1 R
_
* Turn starting switch OFF. s Disconnect CN-394.
Remedy
Defective contact or disconnection in wiring harness between CN-394 (female) (3) - chassis ground
Repair or replace
Defective blower resistor
Replace
Defective blower motor
Replace
Defective contact or disconnection in wiring harness between CN-391 (female) (4) - CN-392 (female) (1)
Repair or replace
Defective air conditioner relay
Replace
Defective contact or disconnection in wiring harness between CN-395 (female) (4) - CN-204 (Chassis ground)
Repair or replace
Defective blower switch
Replace
Defective contact or disconnection in wiring harness between CN-391 (female) (3) - CN-395 (female) (3)
Repair or replace
NO
Defective air conditioner relay Defective contact or disconnection in wiring larness between fuse 8 EN391 (female) (1) (2)
Repair or replace
Go to b). Defective contact or disconnection in wiring harness between CN-394 [female) (1) - CN-395 [female) (2)
D155AX-5
Xepair or eplace
20-633
M-21
TROUBLESHOOTING
b)
Air does not flow out.
Note:
Air conditioner
does not work.
Measure the voltage with the dual pressure switch and thermostat switch turned on. Dual pressure switch changing pressure (Refrigerant circuit pressure): High pressure side: ON (when pressure lowers) at 2.06MPa 121 kg/cm?, OFF (when pressure rises) at 2.65MPa {27kgc/m*l Low pressure side: ON (when pressure rises) at 0.23MPa {2.35kg/cm21, OFF (when pressure lowers) at 0.21 MPa (2.1 kg/cm*) Thermometer switch changing temperature (Evaporator discharge temperature): ON (when temperature lowers) at 4.5’C or below, OFF (when temperature rises) at 1°C or higher l
l
YES I--
(male) (1) and (3) 5
YES
., I ICN-395 (female) (3) I
Is resistance YES between CN-396 _ - (female) (2) and CN-398 (female) 4 (3) normal? Is resistance * Turn starting between CN-396 _ switch OFF. . Disconnect (male) (2) and (3) CN-396 and CN-391 normal? -
-
* Turn starting switch OFF. Disconnect CN-398. *240+40R
‘L NO
r10
I *
I urn arr conditioner switch ON.
(male) (1) and (3) Is voltage between CN-396 (3) and chassis ground normal? * Turn starting switch ON. .20-30V
_
.
’ -Max. * Turn starting switch OFF. * Disconnect NO CN-396. -Turn air conditioner switch ON. - Max. 1 R
1 fJ
NO
13
YES
Is voltage YES between CN-ARC t2 r (2) and chassis
I A
Same condition
between CN-393 (4) and chassis
NO
___ . ___ .20-30V
20-634
NO
D 15514X-5
M-21
TROUBLESHOOTING
Cause
10 YES
YES 8 Is resistance between CN-398 (2) and chassis ground normal?
YEz 7
-
Is resistance between CN-398 (female) (1) and CN-395 (female) (3) normal?
--
-
Turn starting switch ON. . 2. _ 3oV
-Turn starring switch OFF . Disconnect CN-395 NO and CN-398. - Max. 1 Q
_
Is resistance between CN-398 (4) and chassis ground normal?
Is voltage YES_ between CN-393 (1) and chassis 9 ground normal? . Same condition under Step 9.
-Turn starring switch ON. . Turn air conditioner NO switch ON. * Set blower switch to position other than OFF. * zo-3ov NO
_
NO /
Goto
Remedy
A.
Defective contact or disconnection in wiring harness between CN-393 (female) (I) - CN-394 (female) (4)
Repair or replace
Defective clutch relay
Replace
Defective contact or disconnection in wiring harness between fuse 8 CN-398 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between CN-398 (female) (1) - CN-395 (female) (3)
Repair or replace
Defective clutch relay
Replace
Defective contact or disconnection in wiring harness between CN-396 (female) (2) - CN-398 (female) (3)
Repair or replace
Defective air conditioner switch Defective contact or disconnection in wiring harness between CN-396 (female) (I I- CN-395 (female) (3)
Repair or reolace
Defective air conditioner switch
Replace
Defective contact or disconnection in wiring harness between fuse 8 CN-396 (female) (3)
Repair or replace
Defective air conditioner fan motor or compressor
Replace
Defective contact or disconnection in wiring harness betweenCN-215 (male) (7) - CN-ARC (female) (5)
Repair or replace
Defective contact or disconnection in wiring harness between CN-393 (female) (4) - CN-351 (female) (I) Defective dual pressure switch
D155AX-5
Repair or
Replace
20-635
TROUBLESHOOTING
M-21.
Related
M-21
electrical
circuit diagram
Blower
switch
CN391 (KES4)
CN-396 042)
Air
conditioner
Air conditioner rritch
condenser
I I I Cllo.” I CN-SX8 Blower
mater
CN-351 (Xl)
CN-101 (SWPlL)
hemostat
I
I Air conditioner CmPreSSOr
20-636
Dus oressure switch
TWO01015
D 1594X-5
TROUBLESHOOTING
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE) [Serial No. 75001 and up]
Action taken by controller when abnormality occurs and problems on machine .......................... 20-702 M mode system electrical circuit diagram .......................................................................................... 20-704 M-1. [E0120] (Abnormality in monitor panel caution lamp system) is displayed ......................... 20-706 M-2. [E0121] (Abnormality in monitor panel caution buzzer system) is displayed ...................... 20-707 M-3. [E0211] (Abnormality in oil temperature of power line: torque converter) is displayed ..... 20-708 M-4. [E0329] (Abnormality in HSS oil temperature) is displayed ................................................... 20-708 M-5. [E0430] (Abnormality in engine oil pressure) is displayed ..................................................... 20-709 M-6. [E0432] (Abnormality in engine water temperature) is displayed ......................................... 20-709 M-7 When starting switch is turned ON, all segments of monitor panel do not light up .......... 20-710 M-8. When starting switch is turned ON, all segments of monitor panel light up but do not go out. ......................................................................................................................20-712 M-9. When starting switch is turned ON (with engine stopped), caution items (excluding battery charge level and engine oil pressure) flash ............ 20-713 M-10. When engine is started, caution items flash (daily check items and engine related items are normal) .............................................. 20-715 M-11. HSS charging oil pressure caution lamp flashes ..................................................................... 20-718 M-12. Preheater lamp does not light up or stays lighted up ............................................................ 20-719 M-13. Abnormality in caution buzzer ................................................................................................... 20-720 M-14. Abnormality in CAUTION lamp ................................................................................................. 20-722 M-15. Abnormality in engine water temperature gauge ................................................................... 20-724 M-16. Abnormality in power train (torque converter) oil pressure gauge ....................................... 20-725 M-17. Abnormality in fuel level gauge ................................................................................................ 20-727 M-18. Gear speed display segments indicate [– –], and engine speed is not displayed ............... 20-729 M-19. Service meter does not advance while engine is running ..................................................... 20-729 M-20. Abnormality in service mode display ....................................................................................... 20-730 M-21. Monitor panel lighting does not light up (though headlamps and working lamps light up) ........................................................... 20-732 M-22. When head lamp switch is turned on, monitor panel lighting does not light up ............... 20-734 M-23. Head lamps or rear lamps do not light up ............................................................................... 20-735 M-24. Electric intake air heater does not work ................................................................................... 20-737 M-25. Windshield wiper or washer does not work ............................................................................ 20-739 M-26. Air conditioner does not work ................................................................................................... 20-742
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.
D155AX-5
20-701 4
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User Service code code Abnormal system
Abnormality in E0120 monitor panel caution lamp system
CALL 03
E0121
–
E01
Abnormality in monitor panel caution buzzer system
Abnormality in power E0211 train (torque converter) oil temperature
E0329
Abnormality in HSS charging oil pressure
Contents of abnormality ª When ground output voltage to caution lamp is high 1. Defective caution lamp 2. Short circuit with power source in wiring harness between monitor panel CN2 (7) - caution lamp CN-251 (2) 3. Defective monitor panel
ª When ground output voltage to caution buzzer is high 1. Defective caution buzzer 2. Short circuit with power source in wiring harness between monitor panel CN2 (8) - caution buzzer CN-21A (1) 3. Defective monitor panel
ª When torque converter oil temperature caution lamp on monitor panel flashes 1. Torque converter oil temperature rises above about 80˚C 2. Defective torque converter oil temperature sensor
ª When HSS oil temperature caution lamp on monitor panel flashes 1. HSS oil temperature rises above about 108˚C 2. Disconnection or defective contact in wiring harness between monitor panel CN1 (5) - sensor 452 (1) 3. Defective HSS oil temperature sensor
ª When engine oil pressure caution lamp on monitor panel flashes 1. Lowering of engine oil pressure 2. Defective engine oil pressure sensor CALL
Abnormality in engine E0430 oil pressure
ª When engine water temperature caution lamp on monitor panel flashes 1. Defective engine water temperature sensor E01
Abnormality in engine E0432 water temperature
20-702 4
D155AX-5
TROUBLESHOOTING
Normal condition (Voltage, current, resistance) • Voltage between CN2 (7) - chassis ground: Max. 6 V (When lamp lights up)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action taken by controller when abnormality occurs 1. Turns on caution buzzer.
• Voltage between CN2 (8) - chassis 1. Turns on caution lamp. ground: Max. 3 V (When buzzer sounds)
• Resistance between 453 (1) - (2) At 100˚C: Approx. 3.8 kΩ At 90˚C: Approx. 4.9 kΩ At 35˚C: Approx. 29 kΩ At 20˚C: Approx. 52 kΩ At 10˚C: Approx. 80 kΩ
Problems on machine 1. Caution lamp does not light up.
1. Caution buzzer does not sound.
1. Turns on caution lamp and caution buzzer.
• When voltage sensor between 452 (1) 1. Turns on caution lamp and caution buzzer. (CN1 (5)) and chassis ground is turned ON (hydraulic oil temperature is below about 104˚C): Max. 1 V • When sensor is turned OFF (hydraulic oil temperature is above about 108˚C): 20 - 30 V
• Low-pressure switch resistance 1. Turns on caution lamp and caution When engine is stopped: Max. 1 Ω buzzer. When engine speed is above about 600 rpm: Min. 1 MΩ • High-pressure switch resistance When engine is stopped: Max. 1 Ω When engine speed is above about 1,300 rpm: Min. 1 MΩ 1. Turns on caution lamp and caution • Sensor resistance (10 - 100˚C) High-temperature sensor: 90 k - 3.5 Ω buzzer. Low-temperature sensor: 9 k - 0.3 Ω
D155AX-5
20-703 4
TROUBLESHOOTING
M MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
M MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM Monitor panel system
20-704 4
D155AX-5
TROUBLESHOOTING
D155AX-5
M MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
20-705 4
M-1
TROUBLESHOOTING
M-1. [E0120] (Abnormality in monitor panel caution lamp system) is displayed
Cause
Remedy
1 • Turn starting switch OFF. • Disconnect 251. • 100 - 400Ω
NO
Is resistance between 251 (male) (1) and 2 normal?
Defective caution lamp
Replace
Short circuit with power source in wiring harness between CN2 (female) (7) - 251 (female) (2)
Repair or replace
Defective monitor panel (caution module)
Replace
YES 2 • Disconnect 251 and CN2. • Turn starting switch ON. • Max. 1 V
When 251 is disconnected, is voltage between CN2 (female) (7) and chassis ground normal?
YES
NO
M-1. Related electrical circuit diagram
20-706 4
D155AX-5
M-2
TROUBLESHOOTING
M-2. [E0121] (Abnormality in monitor panel caution buzzer system) is displayed
Cause
Remedy
1 • Turn starting switch OFF. • Disconnect 21A. • Min. 200Ω
NO
Is resistance between terminals of 21A (buzzer side) normal?
Defective caution lamp
Replace
Short circuit with power source in wiring harness between CN2 (female) (8) - 222 (5) - 21A (female) (1)
Repair or replace
Defective monitor panel (caution module)
Replace
YES 2 • Disconnect 21A and CN2. • Turn starting switch ON. • Max. 1 V
When 21A is disconnected, is voltage between CN2 (female) (8) and chassis ground normal?
YES
NO
M-2. Related electrical circuit diagram
D155AX-5
20-707 4
M-3, M-4
TROUBLESHOOTING
M-3. [E0211] (Abnormality in oil temperature of power line: torque converter) is displayed Cause
Remedy
1 NO
Is power train (torque converter) oil pressure lamp of monitor flashing?
YES
Go to M-10 c)
2 NO
Is [E] is displayed at head of service code?
YES
Defective power train
See note.
Defective monitor panel (caution module)
Replace
Note: This means that the power train oil temperature sensor has detected abnormal temperature but the display of the monitor panel has become normal. Accordingly, inspect the power train and remove the cause of the abnormal temperature.
M-4. [E0329] (Abnormality in HSS oil temperature) is displayed Cause
Remedy
1 NO
Is hydraulic oil lamp of monitor flashing?
YES
Go to M-10 d)
2 Is [E] is displayed at head of service code?
YES
NO
Defective HSS hydraulic system
See note.
Defective monitor panel (caution module)
Replace
Note: This means that the HSS oil temperature sensor has detected abnormal temperature but the display of the monitor panel has become normal. Accordingly, inspect the HSS oil temperature system and remove the cause of the abnormal temperature.
20-708 4
D155AX-5
M-5, M-6
TROUBLESHOOTING
M-5. [E0430] (Abnormality in engine oil pressure) is displayed fl If an error in N mode is detected, inspect in N mode first.
Cause
Remedy
1 NO
Is engine oil pressure lamp of monitor flashing?
YES
Go to M-10 b)
2 NO
Is [E] is displayed at head of service code?
YES
Defective engine
See note.
Defective monitor panel (caution module)
Replace
Note: This means that the engine oil pressure sensor has detected abnormal oil pressure but the display of the monitor panel has become normal. Accordingly, inspect the engine and remove the cause of the abnormal pressure.
M-6. [E0432] (Abnormality in engine water temperature) is displayed fl If an error in N mode is detected, inspect in N mode first.
Cause
Remedy
1 Is engine water temperature lamp of NO monitor flashing?
YES
Go to M-10 b)
Replace
Defective engine
See note.
Defective monitor panel (caution module)
Replace
2 Is [E] is displayed at head of service code?
YES
NO
Note: This means that the engine water temperature sensor has detected abnormal temperature but the display of the monitor panel has become normal. Accordingly, inspect the engine and remove the cause of the abnormal temperature.
D155AX-5
20-709 4
TROUBLESHOOTING
M-7
M-7. When starting switch is turned ON, all segments of monitor panel do not light up a) The caution module (gauge and lamp display unit) does not light up. fl Check that fuse 6 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Cause
Remedy
1 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN (1) and (2) normal?
YES
Defective monitor panel (caution module)
Replace
Disconnection or defective contact in wiring harness between CN1 (female) (1) - fuse 6
Repair or replace
Disconnection or defective contact in wiring harness between CN1 (female) (2) - chassis ground
Repair or replace
2 • Turn starting switch ON. • 20 - 30 V
Is voltage between CN1 (1) and chassis ground normal?
YES
NO
M-7 a). Related electrical circuit diagram
20-710 4
D155AX-5
TROUBLESHOOTING
M-7
b) The tachometer module (tachometer and service meter display unit) does not light up. fl Check that fuses 6 and 10 are normal. (If they are broken, check the circuit related to them for short circuit with chassis ground.)
Cause
Remedy
1 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between T01 (7) and (2) normal?
YES 2 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between T01 (1) and (2) normal?
YES
Disconnection or defective contact in wiring harness between T01 (female) (1) - fuse 6
Repair or replace
Defective monitor panel (caution module)
Replace
Disconnection or defective contact in wiring harness between T01 (female) (7) - fuse 10
Repair or replace
Disconnection or defective contact in wiring harness between T01 (female) (2) - chassis ground
Repair or replace
3 • Turn starting switch ON. • 20 - 30 V
Is voltage between T01 (7) and chassis ground normal?
YES
NO
M-7 b). Related electrical circuit diagram
D155AX-5
20-711 4
TROUBLESHOOTING
M-8
M-8. When starting switch is turned ON, all segments of monitor panel light up but do not go out. a) Caution module (Gage and lamp display unit) does not go off.
Cause
Defective monitor panel (caution module)
Remedy
Replace
b) The tachometer module (tachometer and service meter display unit) does not go off.
Cause
Defective monitor panel (caution module)
20-712 4
Remedy
Replace
D155AX-5
TROUBLESHOOTING
M-9
M-9. When starting switch is turned ON (with engine stopped), caution items (excluding battery charge level and engine oil pressure) flash fl Any error in N mode must not be detected at this time. fl Inspect both of the engine oil pressure sensor system and alternator system. a) Engine oil pressure sensor
Cause
Remedy
1
• Turn starting switch OFF.
Is engine oil pressure system normal?
NO
See troubleshooting of engine controller.
Repair or replace
NO
See troubleshooting of engine controller.
Repair or replace
Defective monitor panel (Caution module)
Replace
YES 2
• Turn starting switch OFF.
Is N mode normal?
YES
b) Alternator system Cause
Remedy
1 • Disconnect ANR. • Turn starting switch ON. • Max. 1 V
NO
Is voltage between ANR (alternator side) and chassis ground normal?
Defective alternator
Replace
Defective monitor panel (Caution module)
Replace
Defective monitor panel (Caution module)
Replace
YES 2 • Disconnect CN1. • Turn starting switch ON. • Max. 1 V
NO
Is voltage between CN1 (female) (4) and chassis ground normal?
YES
3 • Disconnect T01. • Turn starting switch ON. • Max. 1 V
Is voltage between CN1 (female) (4) and chassis ground normal?
NO
YES
• Disconnect 220 and CN1. • Turn starting switch ON. • Max. 1 V
4 When 220 is disconnected, is voltage NO between CN1 (female) (4) and chassis ground normal?
Short circuit with power source in Repair or wiring harness between CN1 (female) (4) - T01 (female) (4) - ANR replace - M2 (female) (2) - 220 (male) (2)
YES Defective diode (220)
D155AX-5
Replace
20-713 4
TROUBLESHOOTING
M-9
M-9 b). Related electrical circuit diagram
20-714 4
D155AX-5
TROUBLESHOOTING
M-10
M-10. When engine is started, caution items flash (daily check items and engine related items are normal) a) Charge level lamp flashes Cause
Remedy
1 • Disconnect ANR. • Start engine (at medium or higher speed). • 20 - 30 V
NO
Is voltage between ANR (alternator side) and chassis ground normal?
Defective alternator
Replace
Defective monitor panel (Caution module)
Replace
Delta connection CN1 (female) (4) ANR
Repair or replace
Defective monitor panel (Tachometer module)
Replace
YES 2 • Disconnect CN1. • Start engine (at medium or higher speed). • 20 - 30 V
Is voltage between CN-1 (female) (4) NO and chassis ground normal?
YES
3 • Disconnect T01, CN1. • Start engine (at medium or higher speed). • 20 - 30 V
When T01 is disconnected, is voltage between CN1 (female) (4) and chassis ground normal?
YES
NO
M-10 a). Related electrical circuit diagram
D155AX-5
20-715 4
TROUBLESHOOTING
M-10
b) Engine oil pressure lamp flashes fl Check that the engine oil pressure is normal before troubleshooting. Cause
Remedy
1 Is oil pressure switch judged defective by troubleshooting of engine controller?
NO
YES
Defective engine oil pressure sensor
Check according to standard values table, then replace
2 • Turn starting switch OFF.
NO
Is N mode normal?
YES
See N mode.
Defective monitor panel (Caution module)
Repair or replace
c) Power train (Torque converter) oil temperature lamp flashes. fl Check that the power train (torque converter) oil temperature is normal before troubleshooting.
Cause
Remedy
1 • Start engine.
Does power train oil temperature gauge indicate level 7 (highest)?
NO
Defective monitor panel (Caution module)
Replace
NO
Defective monitor panel (Caution module)
Replace
Defective power train oil temperature sensor
Check according to standard values table, then replace
YES 2 • Connect short connector to 453. • Start engine.
When short connector is connected to 453 (female), does lamp go off?
YES
M-10 c). Related electrical circuit diagram
20-716 4
D155AX-5
TROUBLESHOOTING
M-10
d) HSS oil temperature lamp flashes fl Check that the hydraulic oil temperature is normal before troubleshooting.
Cause
Remedy
1 • Connect 452 to chassis ground. • Start engine.
When 452 (female) (1) is connected to chassis ground, does lamp go off?
NO
YES
Defective HSS sensor
Check according to standard values table, then replace
Disconnection or defective contact in wiring harness between CN1 (female) (5) - 452 (female) (1)
Repair or replace
Defective monitor panel (Caution module)
Replace
2 • Turn starting switch OFF. • Disconnect CN1. • Max. 1 Ω
Is resistance between CN1 (female) (5) and chassis ground normal?
YES
NO
M-10 d). Related electrical circuit diagram
D155AX-5
20-717 4
TROUBLESHOOTING
M-11
M-11. HSS charging oil pressure caution lamp flashes fl Check that the HSS charge oil pressure is normal before troubleshooting (The caution lamp flashes when the HSS charge oil pressure lowers below about 0.78 MPa {8 kg/cm2}).
Cause
Remedy
1 • Disconnect CN1. • Start engine. • Max. 1 Ω
NO
Is resistance between CN1 (female) (8) and chassis ground normal?
YES Defective monitor panel
Replace
Defective HSS charge pressure sensor
Replace
Disconnection or defective contact in wiring harness between CN-406 (female) (2) - GND2 (chassis ground)
Repair or replace
Disconnection or defective contact in wiring harness between CN1 (female) (8) - CN-406 (female) (1)
Repair or replace
2 • Disconnect CN-406. • Start engine. • Max. 1 Ω
Is resistance between CN-406 (male) NO (1) and (2) normal?
YES 3 • Turn starting switch OFF. • Disconnect CN-406. • Max. 1 Ω
Is resistance between CN-406 (female) and chassis ground normal?
YES
NO
M-11. Related electrical circuit diagram
20-718 4
D155AX-5
TROUBLESHOOTING
M-12
M-12. Preheater lamp does not light up or stays lighted up fl Check that the preheater is normal. a) The preheater lamp does not light up during the preheating operation
Cause
Remedy
1 • Disconnect CN2. • Turn starting switch to PREHEAT position (See note). • 20 - 30 V
NO
Is voltage between CN2 (female) (5) and chassis ground normal?
Disconnection or defective contact in wiring harness between CN2 (female) (5) - ribbon heater
Repair or replace
Defective monitor panel (Caution module)
Replace
YES
Note: Turn the starting switch in the opposite direction to the ON position and hold it.
b) The preheater lamp lights up while preheater is turned off
Cause
Remedy
1 • Disconnect CN2. • Turn starting switch ON. • Max. 1 V
Is voltage between CN2 (female) (5) and chassis ground normal?
YES
NO
Disconnection or defective contact in wiring harness between CN2 (female) (5) - ribbon heater
Repair or replace
Defective monitor panel (Caution module)
Replace
M-12. Related electrical circuit diagram
D155AX-5
20-719 4
TROUBLESHOOTING
M-13
M-13. Abnormality in caution buzzer fl Check that any service code is not displayed (If any one is displayed, troubleshoot according to it). fl Even if the charge level lamp among the caution items flashes, the caution buzzer does not sound. a) The buzzer does not sound for 1 second after the starting switch is turned on fl Check that fuse 6 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Cause
Remedy
1 • Disconnect CN2 and connect (female) (8) to chassis ground. • Turn starting switch ON.
NO
When CN2 (female) (8) is connected to chassis ground, does buzzer sound?
YES
Defective monitor panel (Caution module)
Replace
NO
Disconnection or defective contact in wiring harness between fuse 6 21A
Repair or replace
NO
Disconnection or defective contact in wiring harness between CN2 (female) (8) - 21A
Repair or replace
Defective caution buzzer
Replace
2 • Disconnect 21A. • Turn starting switch ON. • 20 - 30 V
Is voltage between 21A (power source side) and chassis ground normal?
YES 3 • Turn starting switch OFF. • Disconnect CN2 and 21A. • Max. 1 Ω
Is resistance between CN2 (female) (8) and 21A (monitor side) normal?
YES
b) The buzzer sounds while monitor is displaying normally
Cause
Remedy
1 • Disconnect CN2. • Turn starting switch ON.
NO
When CN2 is disconnected, does buzzer stop sounding?
YES
Defective monitor panel (Caution module)
Replace
Short circuit with chassis ground in wiring harness between CN2 (female) (8) - 21A
Repair or replace
Defective caution buzzer
Replace
2 • Turn starting switch OFF. • Disconnect 21A and CN2. • Max. 1 Ω
When 21A (monitor side) is disconnected, is resistance between CN2 (female) (8) and chassis ground normal?
NO
YES
20-720 4
D155AX-5
TROUBLESHOOTING
M-13
M-13. Related electrical circuit diagram
D155AX-5
20-721 4
TROUBLESHOOTING
M-14
M-14. Abnormality in CAUTION lamp fl Check that any service code is not displayed (If any one is displayed, troubleshoot according to it). a) The lamp does not light up for 2 seconds after the starting switch is turned on or it does not light up while a caution item is flashing fl Check that fuse 6 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Cause
Remedy
1 • Disconnect CN2 and connect (female) (7) to chassis ground. • Turn starting switch ON.
When CN2 (female) (7) is connected to chassis ground, does lamp light up?
NO
YES
Defective monitor panel (Caution module)
Replace
NO
Disconnection or defective contact in wiring harness between fuse 6 - 251 (female) (1)
Repair or replace
NO
Disconnection or defective contact in wiring harness between CN2 (female) (7) - 251 (female)
Repair or replace
Defective caution lamp
Replace
2 • Disconnect 251. • Turn starting switch ON. • 20 - 30 V
Is voltage between 251 (female) (1) and chassis ground normal?
YES 3 • Turn starting switch OFF. • Disconnect CN2 and 251. • Max. 1 Ω
Is resistance between CN2 (female) (7) and 251 (female) normal?
YES
b) The lamp light up while monitor is displaying normally
Cause
Remedy
1 • Disconnect CN2. • Turn starting switch ON.
NO
When CN2 is disconnected, does lamp go off?
YES
Defective monitor panel (Caution module)
Replace
2 • Turn starting switch OFF. • Disconnect 251 and CN2. • Max. 1 MΩ
When 251 is disconnected, is resistance between CN2 (female) (7) and chassis ground normal?
NO
Short circuit with chassis ground in wiring harness between CN2 (female) (7) Repair or replace - 251 (female) (2)
YES Defective caution lamp
20-722 4
Replace
D155AX-5
TROUBLESHOOTING
M-14
M-14. Related electrical circuit diagram
D155AX-5
20-723 4
TROUBLESHOOTING
M-15
M-15. Abnormality in engine water temperature gauge fl Check that the engine water temperature is normal (If it is abnormal, troubleshoot the engine). fl The following troubleshooting procedure is prepared on the assumption that the engine controller is operating normally.
Cause
Remedy
Defective engine water temperature sensor
Check according to standard values table, then replace
1 • Turn starting switch ON.
NO
Is water temperature sensor of engine controller is judged defective by troubleshooting?
YES
2 Is N mode normal?
YES
20-724 4
NO
Check N mode.
Defective monitor panel (Caution module)
Replace
D155AX-5
M-16
TROUBLESHOOTING
M-16. Abnormality in power train (torque converter) oil pressure gauge fl Check that the power train oil temperature is normal (If it is abnormal, troubleshoot the power train). a) The power train oil temperature gauge displays abnormally low temperature Cause
Remedy
Defective power train oil temperature sensor
Check according to standard values table, then replace
Disconnection or defective contact in wiring harness between CN1 (female) (2) - 453 (female) (2)
Repair or replace
Disconnection, defective contact, or short circuit with power source in wiring harness between CN2 (female) (2) - 453 (female) (1)
Repair or replace
Defective monitor panel (Caution module)
Replace
1 • Connect short connector to 453. • Turn starting switch ON.
NO
When short connector is connected to 453, does displayed value go off?
YES
2 • Turn starting switch OFF. • Disconnect CN1 and 453. • Max. 1 Ω
NO
Is resistance between CN1 (female) (2) and 453 (female) (1) normal?
YES 3 • Turn starting switch OFF. • Disconnect CN2 and 453 • Max. 1 Ω
NO
Is resistance between CN2 (female) (2) and 453 (female) (1) normal?
YES
b) The power train oil temperature gauge does not display (even 1 bar)
Cause
Remedy
1 • Disconnect 453. • Turn starting switch ON.
NO
When 453 is disconnected, does gauge display normally?
YES
Defective power train oil temperature sensor
Check according to standard values table, then replace
Short circuit with chassis ground in wiring harness between CN2 (female) (2) - 453 (female) (1)
Repair or replace
Defective monitor panel (Caution module)
Replace
2 • Turn starting switch OFF. • Disconnect 453 and CN2. • Min. 1 MΩ
When 453 is disconnected, is resistance between CN2 (female) (2) and chassis ground normal?
NO
YES
D155AX-5
20-725 4
TROUBLESHOOTING
M-2
M-16. Related electrical circuit diagram
20-726 4
D155AX-5
M-17
TROUBLESHOOTING
M-17. Abnormality in fuel level gauge fl Check that the fuel level is sufficiently high. a) The fuel level gauge always displays full
Cause
Remedy
1 • Disconnect 423. • Turn starting switch ON.
NO
When 423 is disconnected, does displayed level go off?
YES
Defective fuel level sensor
Check according to standard values table, then replace
Short circuit with chassis ground in wiring harness between CN2 (female) (3) - 423 (female) (1)
Repair or replace
Defective monitor panel (Caution module)
Replace
2 • Turn starting switch OFF. • Disconnect 423 and CN2. • Min. 1 MΩ
NO
When 423 is disconnected, is resistance between CN2 (female) (3) and chassis ground normal?
YES
b) The fuel level gauge does not display (even 1 bar)
Cause
Remedy
1 • Connect short connector to 423. • Turn starting switch ON.
NO
When short connector is connected to 423, does gauge display full?
YES
Defective fuel level sensor
Check according to standard values table, then replace
Disconnection or defective contact in wiring harness between CN1 (female) (2) - 423 (female) (2)
Repair or replace
Disconnection, defective contact, or short circuit with power source in wiring harness between CN2 (female) (3) - 423 (female) (1)
Repair or replace
Defective monitor panel (Caution module)
Replace
2 • Turn starting switch OFF. • Disconnect CN1 and 423. • Max. 1 Ω
NO
Is resistance between CN1 (female) (2) and 423 (female) (2) normal?
YES 3 • Turn starting switch OFF. • Disconnect CN2 and 423. • Max. 1 Ω
Is resistance between CN2 (female) (3) and 423 (female) (1) normal?
YES
D155AX-5
NO
20-727 4
TROUBLESHOOTING
M-17
M-17. Related electrical circuit diagram
20-728 4
D155AX-5
TROUBLESHOOTING
M-18, M-19
M-18. Gear speed display segments indicate [– –], and engine speed is not displayed Cause
Abnormality in network system
Remedy
Go to N-3
M-19. Service meter does not advance while engine is running
Cause
Remedy
1 • Start engine.
Is sandglass displayed in service meter unit?
NO
Go to M10 a)
YES Defective monitor panel (Tachometer module)
D155AX-5
Replace
20-729 4
TROUBLESHOOTING
M-20
M-20. Abnormality in service mode display a) When service switch is turned on, the service mode is not displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect T01. • Turn service switch ON. • Max. 1 Ω
NO
Is resistance between T01 (female) (5) and chassis ground normal?
YES
Defective monitor panel (Caution module)
Replace
Defective service switch
Replace
Disconnection or defective contact in wiring harness between T01 (female) (5) - X1 (3)
Repair or replace
Disconnection or defective contact in wiring harness between X1 (2) chassis ground
Repair or replace
2 • Turn starting switch OFF. • Turn service switch ON. • Max. 1 Ω
NO
Is resistance between X1 (2) and (3) normal?
YES 3 • Turn starting switch OFF. • Turn service switch ON. • Max. 1 Ω
NO
Is resistance between T01 (female) (5) and (3) normal?
YES
b) When the service switch is turned off, the service mode does not change to the normal mode
Cause
Remedy
1 • Turn starting switch OFF. • Disconnect T01. • Turn service switch OFF. • Min. 1 MΩ
NO
Is resistance between T01 (female) (5) and chassis ground normal?
YES
Defective monitor panel (Caution module)
Replace
Defective service switch
Replace
Short circuit with chassis ground in wiring harness between T01 (female) (5) - X1 (3)
Repair or replace
2 • Turn starting switch OFF. • Turn service switch OFF. • Min. 1 MΩ
Is resistance between X1 (2) and (3) normal?
YES
20-730 4
NO
D155AX-5
TROUBLESHOOTING
M-20
M-20. Related electrical circuit diagram
D155AX-5
20-731 4
TROUBLESHOOTING
M-21
M-21. Monitor panel lighting does not light up (though headlamps and working lamps light up) fl Check that the bulb is not broken (If it is broken, replace it). fl Check that fuse 4 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) a) The panel lamp of the tachometer module does not light up
Cause • Disconnect T01. • Turn starting switch ON. • Turn head-lamp and working lamp switches ON. • 20 - 30 V
Remedy
1 NO
Is voltage between T01 (female) (6) and chassis ground normal?
YES
Disconnection or defective contact in wiring harness between T01 (female) (6) - 211 (female) (2)
Repair or replace
Defective monitor panel (Tachometer module)
Replace
b) The panel lamp of the caution module does not light up
Cause
Remedy
1 • Disconnect T01. • Turn starting switch ON. • Turn headlamp and working lamp switches ON. • 20 - 30 V
NO
Is voltage between CN4 (female) (1) and chassis ground normal?
YES
Defective lamp or defective contact of lamp
Replace
Disconnection or defective contact in wiring harness between CN4 (female) (2) - chassis ground
Replace
Disconnection or defective contact in wiring harness between CN4 (female) (1) - 211 (female) (2)
Repair or replace
2 • Disconnect CN4. • Turn starting switch OFF. • Max. 1 Ω
Is resistance between CN4 (female) (2) and chassis ground normal?
YES
20-732 4
NO
D155AX-5
M-9
TROUBLESHOOTING
M-21. Related electrical circuit diagram
D155AX-5
20-733 4
TROUBLESHOOTING
M-22
M-22. When head lamp switch is turned on, monitor panel lighting does not light up fl Check that the headlamp light up normally before troubleshooting (If it does not light up, perform M-23).
Cause
Remedy
1 • Turn starting switch ON. • Turn headlamp switch ON. • 20 - 30 V
Is voltage between T01 (6) and chassis ground normal?
NO
Disconnection or defective contact in wiring harness between T01 (female) (6) - CN-211 (female) (2)
Replace
Defective monitor panel
Replace
YES
M-22. Related electrical circuit diagram
20-734 4
D155AX-5
TROUBLESHOOTING
M-23
M-23. Head lamps or rear lamps do not light up a) The headlamp does not light up fl Check that fuse 4 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Cause
Remedy
1 • Disconnect CN-203 and CN-204. • Turn starting switch ON. • Turn headlamp switch ON. • 20 - 30 V
NO
Is voltage between CN-203, CN-204 (female) (1) and chassis ground normal?
YES Defective bulb
Replace
Disconnection or defective contact in wiring harness between fuse 4 CN-211 (female) (3)
Repair or replace
Defective headlamp switch
Replace
Disconnection or defective contact in wiring harness between CN-211 (female) (2) - CN-203 (female) (1) or CN-204 (female) (1)
Repair or replace
2 • Disconnect CN-211. • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-211 (female) (3) and chassis ground normal?
YES • Turn starting switch OFF. • Disconnect CN-211. • Turn headlamp switch ON. • Max. 1 Ω
3 Is resistance between CN-211 (male) NO (2) and (3) normal?
YES
M-23 a). Related electrical circuit diagram
D155AX-5
20-735 4
TROUBLESHOOTING
M-23
b) The rear lamp does not light up fl Check that fuse 3 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Cause • Disconnect CN-224, CN-243, and CN-248. • Turn starting switch ON. • Turn rear lamp switch ON. • 20 - 30 V
Remedy
1 NO
Is voltage between CN-224, CN-243, CN248 (female) (1) and chassis ground normal?
YES Defective bulb
Replace
Disconnection or defective contact in wiring harness between fuse 3 CN-216 (female) (3)
Repair or replace
Defective rear lamp switch
Replace
Disconnection or defective contact in wiring harness between CN-216 (female) (2) - CN-224 (female) (1) or CN-248 (female) (1)
Repair or replace
2 • Disconnect CN-216. • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-216 (female) (3) and chassis ground normal?
YES 3 • Turn starting switch OFF. • Disconnect CN-216. • Turn rear lamp switch ON. • Max. 1 Ω
Is resistance between CN-216 (male) (2) and (3) normal?
YES
NO
M-23 b). Related electrical circuit diagram
20-736 4
D155AX-5
TROUBLESHOOTING
M-24
M-24. Electric intake air heater does not work fl The automatic preheater works only when the coolant temperature is low. fl In this troubleshooting, only manual preheating with the key switch is inspected.
Cause
Remedy
1
• Turn key switch to left end. • 20 - 30 V
NO
Is voltage between key switch R1 and chassis ground normal?
Defective key switch
Replace
NO
Disconnection or defective contact in wiring harness between key switch R1 CN-109
Repair or replace
NO
Disconnection or defective contact in wiring harness between CN-214 (female) (10) - CN-109
Repair or replace
Defective heater relay
Replace
YES 2 • Turn starting switch OFF. • Disconnect CN-214.
Is there continuity between key switch R1 and CN-109?
YES 3
• Turn starting switch ON. • 20 - 30 V
Is voltage between CN-109 and chassis ground normal?
YES
D155AX-5
20-737 4
TROUBLESHOOTING
M-24
M-24. Related electrical circuit diagram
20-738 4
D155AX-5
TROUBLESHOOTING
M-25
M-25. Windshield wiper or washer does not work a) All windshield wipers and windshield washers do not operate
Cause Disconnection or defective contact in wiring harness between CN-C - cab fuse box
Remedy Repair or replace
b) Front windshield wiper does not operate
Cause
Remedy
1
• Turn starting switch ON.
When switch is replaced with another one, does wiper operate normally?
NO
YES Defective wiper switch
Replace
Disconnection or defective contact in wiring harness between cab fuse box - motor connector (female) (5)
Repair or replace
Disconnection or defective contact in wiring harness between switch connector (female) (3) - chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between switch connector (female) (4) - motor connector (female) (2)
Repair or replace
Defective wiper motor
Replace
2
• Turn starting switch ON. • 20 - 30 V
NO
Is voltage between motor connector (5) and chassis ground normal?
YES 3 • Turn starting switch OFF. • Disconnect connector. • Max. 1 Ω
Is resistance between switch connector (female) (3) and chassis ground normal?
NO
YES 4 • Turn starting switch OFF. • Disconnect connector. • Max. 1 Ω
Is resistance between switch connector (female) (4) and motor connector (female) (2) normal?
NO
YES
D155AX-5
20-739 4
TROUBLESHOOTING
M-25
c) The left windshield wiper, right windshield wiper, or rear wiper does not operate
Cause
Remedy
1 • Turn starting switch ON.
When switch is replaced with another one, does wiper operate normally?
NO
YES
• Turn starting switch ON. • 20 - 30 V
2 Is voltage between switch connector NO (3) and chassis ground normal?
Defective wiper switch
Replace
Disconnection or defective contact in wiring harness between motor connector (female) (3) - chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between cab fuse box - switch connector (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between switch connector (female) (4) - motor connector (female) (2)
Repair or replace
Defective wiper motor
Replace
YES 3 • Turn starting switch OFF. • Disconnect connector. • Max. 1 Ω
Is resistance between motor connector (female) (3) and chassis ground normal?
NO
YES 4 • Turn starting switch OFF. • Disconnect connector. • Max. 1 Ω
Is resistance between switch connector (female) (4) and motor connector (female) (2) normal?
NO
YES
d) Washing liquid does not come out of windshield washer
Cause
Remedy
1 • Turn starting switch ON. • Turn washer ON.
NO
Is motor sound heard?
Supplying Insufficient washing liquid, clogging washing liquid, then of nozzle, or defective piping repair or replace
YES
2 • Turn starting switch ON. • Turn washer ON.
When motor connector is replaced with another one, does washer operate?
NO
YES
Defective windshield washer motor
Replace
Defective wiper switch
Replace
Disconnection or defective contact in wiring harness between motor connector (female) (2) - CN-SX8 (chassis ground)
Repair or replace
Disconnection or defective contact in wiring harness between switch connector (female) (1) - motor connector (female) (1)
Repair or replace
3 • Turn starting switch ON. • Turn washer ON.
NO
When switch is replaced with another one, does washer operate?
YES
4 • Turn starting switch OFF. • Disconnect connector. • Max. 1 Ω
Is resistance between motor connector (female) (2) and chassis ground normal?
YES
20-740 4
NO
D155AX-5
TROUBLESHOOTING
M-25
M-25. Related electrical circuit diagram
D155AX-5
20-741 4
TROUBLESHOOTING
M-26
M-26. Air conditioner does not work fl Check that fuse 8 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) a) Air does not blow out Table 1
Table 2 Terminal
Position
0 1 2 3
1
fi fi fi fi
2
fi fi fi
3
4
CN-394 (male)
Resistance
Between (2) – (3)
3 ± 0.5 Ω
Between (2) – (1)
1 ± 0.1 Ω
fi fi Cause
Remedy
1 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-391 (1), (1) and chassis ground normal?
Disconnection or defective contact in wiring harness between fuse 8 and CN-391 (female) (1), (2)
Repair or replace
Defective air conditioner relay
Replace
Disconnection or defective contact in wiring harness between CN-391 (female) (3) - CN-395 (female) (3)
Repair or replace
Defective blower switch
Replace
Disconnection or defective contact in wiring harness between CN-395 (female) (4) - CN-206 (chassis ground)
Repair or replace
Defective air conditioner relay
Replace
YES
2 • Turn starting switch OFF. • Disconnect CN-391. • 240 ± 40 Ω
Is resistance between CN-391 (male) NO (1) and (3) normal?
YES
3 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-395 (3) and chassis ground normal?
YES
4 • Turn starting switch OFF. • Disconnect CN-395.
NO
Is continuity between terminals of CN395 (male) as shown in Table 1?
YES
5 • Turn starting switch OFF. • Disconnect CN-395. • Max. 1 Ω
Is resistance between CN-395 (female) (4) and chassis ground normal?
NO
YES
6 • Turn starting switch ON. • Set blower switch to position other than OFF. • 20 - 30 V
Is voltage between CN-39 (4) and chassis ground normal?
NO
YES
See next page A
20-742 4
D155AX-5
TROUBLESHOOTING
M-26
A
Cause
Remedy
7 • Turn starting switch ON. • Set blower switch to position other than OFF. • 20 - 30 V
Disconnection or defective contact in wiring harness between CN-391 (female) (4) - CN-392 (female) (1)
Repair or replace
Defective blower motor
Replace
Defective blower register
Replace
NO
Disconnection or defective contact in wiring harness between CN-394 (female) (3) and chassis ground
Repair or replace
NO
Disconnection or defective contact in wiring harness between CN-394 (female) (1) - CN-395 (female) (2)
Repair or replace
Go to b)
Replace
NO
Is voltage between CN-392 (1) and chassis ground normal?
YES
8 • Turn starting switch ON. • Set blower switch to position other than OFF.
NO
Is blower motor of condenser rotating?
YES
9 • Turn starting switch OFF. • Disconnect CN-394.
Are resistance between CN-394 (male) (2) and (3) and that between (2) and (1) as shown in Table 2?
NO
YES
10 • Turn starting switch OFF. • Disconnect CN-394. • Max. 1 Ω
Is resistance between CN-394 (female) (3) and chassis ground normal?
YES
11 • Turn starting switch OFF. • Disconnect CN-394 and CN-395. • Max. 1 Ω
Is resistance between CN-394 (female) (1) and CN-395 (female) (2) normal?
YES
D155AX-5
20-743 4
TROUBLESHOOTING
M-26
b) b) Air does not blow out (Air conditioner does not operate) Note: Measure the voltage after the dual pressure switch and thermostat switch are turned ON. • Switching pressure of dual pressure switch (Refrigerant circuit pressure): High pressure side: Turned ON at 2.06 MPa {21 kg/cm2} (when pressure lowers) and turned OFF at 2.65 MPa {27 kg/cm2} (when pressure rises) Low pressure side: Turned ON at 0.23 MPa {2.35 kg/cm2} (when pressure rises) and turned OFF at 0.21 MPa {2.1 kg/cm2} (when pressure lowers) • Switching temperature of thermostat switch (Evaporator discharge temperature): Turned ON at 4.5˚C (when temperature lowers) and turned OFF at 1˚C (when temperature rises)
Cause
Remedy
1 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-396 (3) and chassis ground normal?
Disconnection or defective contact in wiring harness between fuse 8 CN-396 (female) (3)
Repair or replace
Defective air conditioner switch
Replace
Disconnection or defective contact in wiring harness between CN-396 (female) (1) - CN-395 (female) (3)
Repair or replace
Defective air conditioner switch
Replace
Disconnection or defective contact in wiring harness between CN-396 (female) (2) - CN-398 (female) (3)
Repair or replace
Defective clutch relay
Replace
YES
• Turn starting switch OFF. • Disconnect CN-396. • Turn air conditioner switch ON. • Max. 1 Ω
2 Is resistance between CN-396 (male) NO (1) and (3) normal?
YES
3 • Turn starting switch OFF. • Disconnect CN-396 and CN-395. • Max. 1 Ω
Is resistance between CN-396 (female) (1) and CN-395 (female) (3) normal?
NO
YES
• Turn starting switch OFF. • Disconnect CN-396. • Turn air conditioner switch ON. • Max. 1 Ω
4 Is resistance between CN-396 (male) NO (2) and (3) normal?
YES
5 • Turn starting switch OFF. • Disconnect CN-396 and CN-398. • Turn air conditioner switch ON. • Max. 1 Ω
Is resistance between CN-396 (female) (2) and CN-398 (female) (3) normal?
NO
YES
6 • Turn starting switch OFF. • Disconnect CN-398. • 240 ± 40 Ω
Is resistance between CN-398 (male) NO (1) and (3) normal?
YES
See next page A
20-744 4
D155AX-5
TROUBLESHOOTING
M-26
A
Cause
Remedy
7 • Turn starting switch OFF. • Disconnect CN-398 and CN395. • Max. 1 Ω
Is resistance between CN-398 (female) (1) and CN-395 (female) (3) normal?
NO
Disconnection or defective contact in wiring harness between CN-398 (female) (1) - CN-395 (female) (3)
Repair or replace
NO
Disconnection or defective contact in wiring harness between fuse 8 and CN-398 (female) (2)
Repair or replace
Defective clutch relay
Replace
Disconnection or defective contact in wiring harness between CN-393 (female)(1) - CN-398 (female) (4)
Repair or replace
Defective dual pressure switch
Replace
NO
Disconnection or defective contact in wiring harness between CN-393 (female) (4) - CN-351 (female) (1)
Repair or replace
NO
Disconnection or defective contact in wiring harness between CN-215 (male) (7) - CN-ARC (female) (2)
Repair or replace
Defective air conditioner fan motor or compressor
Replace
YES
8 • Turn starting switch ON. • 20 - 30 V
Is resistance between CN-398 (2) and chassis ground normal?
YES
•Turn starting switch ON. •Turn air conditioner switch ON. •Set blower switch to position other than OFF. •20 - 30 V
9 NO
Is resistance between CN-398 (4) and chassis ground normal?
YES
10
• Turn starting switch ON. • Turn air conditioner switch ON. • Set blower switch to position other than OFF. • 20 - 30 V
Is resistance between CN-393 (female) (1) and chassis ground normal?
• For condition, see note. • 20 - 30 V
Is voltage between CN-393 (4) and chassis ground normal?
NO
YES
11 NO
YES
12 • For condition, see note. • 20 - 30 V
Is voltage between CN-3951 (1) and chassis ground normal?
YES
13 • For condition, see note. • 20 - 30 V
Is voltage betweenYES CN-ARC (2) and chassis ground normal?
YES
D155AX-5
20-745 4
TROUBLESHOOTING
M-26
M-26. Related electrical circuit diagram
20-746 4
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE CONTROLLER (G MODE) [Serial No. 75001 and up]
Action taken by controller when abnormality occurs and problems on machine .......................... 20-802 Judgment table for engine controller and engine ............................................................................. 20-810 G mode system electrical circuit diagram ........................................................................................... 20-812 G-1. [E0401] (Abnormality in engine controller power supply) is displayed ................................ 20-814 G-2. [E0402] (Abnormality in engine controller) is displayed ......................................................... 20-815 G-3. [E0405] (Abnormality in fuel control dial system) is displayed ............................................. 20-816 G-4. [E0406] (Abnormality in decelerator potentiometer system) is displayed ............................ 20-817 G-5. [E0409] (Abnormality in Ne speed sensor system) is displayed ............................................ 20-818 G-6. [E0410] (Abnormality in G speed sensor system) is displayed .............................................. 20-819 G-7. [E0458] (Short circuit in fuel injector No. 1, No. 2, No. 3 system) is displayed ................... 20-820 G-8. [E0459] (Short circuit in fuel injector No. 4, No. 5, No. 6 system) is displayed ................... 20-823 G-9. [E0460] (Abnormality in controller chassis ground circuit) is displayed ............................... 20-826 G-10. [E0461] (Disconnection in fuel injector No. 1 system) is displayed ....................................... 20-827 G-11. [E0462] (Disconnection in fuel injector No. 2 system) is displayed ....................................... 20-828 G-12. [E0463] (Disconnection in fuel injector No. 3 system) is displayed ....................................... 20-829 G-13. [E0464] (Disconnection in fuel injector No. 4 system) is displayed ....................................... 20-830 G-14. [E0465] (Disconnection in fuel injector No. 5 system) is displayed ....................................... 20-831 G-15. [E0466] (Disconnection in fuel injector No. 6 system) is displayed ....................................... 20-832 G-16. [E0468] (Overcurrent in fuel supply pump PCV1 system) is displayed ................................. 20-833 G-17. [E0469] (Disconnection in fuel supply pump PCV1 system) is displayed ............................. 20-834 G-18. [E0470] (Overcurrent in fuel supply pump PCV2 system) is displayed ................................. 20-835 G-19. [E0471] (Disconnection in fuel supply pump PCV2 system) is displayed ............................. 20-836 G-20. [E0472] (Abnormality in boost pressure sensor system) is displayed .................................. 20-837 G-21. [E0474] (Abnormality in common rail fuel pressure sensor system) is displayed............... 20-838 G-22. [E0476] (Abnormality in high engine water temperature sensor system) is displayed ....... 20-839 G-23. [E0478] (Abnormality in low engine water temperature sensor system) is displayed ........ 20-840 G-24. [E0480] (Abnormality in common rail fuel pressure system) is displayed ........................... 20-841 G-25. [E0481] (Abnormality in high common rail fuel pressure 1 system) is displayed [E0482] (Abnormality in high common rail fuel pressure 2 system) is displayed ............... 20-842 G-26. [E0483] (No-pressure feed by fuel supply pump 1) is displayed [E0484] (No-pressure feed by fuel supply pump 2) is displayed ........................................... 20-843 G-27. [E0487] (Abnormality in engine oil pressure switch system) is displayed ........................... 20-845 G-28. [E0488] (Abnormality in power supply system 1) is displayed .............................................. 20-847 G-29. [E0489] (Abnormality in power supply system 2) is displayed .............................................. 20-849 G-30. [E0490] (Abnormality in Q regulator switch signal) is displayed ........................................... 20-850 G-31. [E0491] (Short circuit in starting switch C system) is displayed ............................................ 20-851
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.
D155AX-5
20-801 4
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Service code Abnormal system
E0405
E0406
E0409
E0410
Contents of abnormality
Abnormality in fuel control dial system
1. Disconnection, defective contact, short circuit, or short circuit with chassis ground in fuel control dial 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-1 (4) (power source) - fuel control dial CN-FCS (1) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-1 (6) (signal) - fuel control dial CN-FCS (2) 4. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-2 (10) (ground) - fuel control dial CN-FCS (3) 5. Defective engine controller
Abnormality in decelerator potentiometer system
1. Disconnection, defective contact, short circuit, or short circuit with chassis ground in decelerator potentiometer 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-1 (4) (power source) - decelerator potentiometer CN-FCD (1) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-1 (7) (signal) - decelerator potentiometer CN-FCD (2) 4. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-2 (10) (ground) - decelerator potentiometer CN-FCS (3) 5. Defective engine controller
Abnormality in Ne speed sensor system
1. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between Ne speed sensor 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-1 (5) (+ side) - Ne speed sensor CN-E51 (1) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-1 (12) (- side) - Ne speed sensor CN-E51 (2) 4. Defective engine controller
Abnormality in G speed sensor system
1. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between G speed sensor 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-2 (1) (+ side) - G speed sensor CN-E52 (1) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-2 (9) (- side) - G speed sensor CN-E52 (2) 4. Defective engine controller 1. 2. 3. 4. 5.
E0458
Short circuit in No. 1, No. 2, No. 3 fuel injector system
6. 7. 8. 9. 10. 11. 1. 2. 3. 4. 5.
E0459
Short circuit in No. 4, No. 5, No. 6 fuel injector system
6. 7. 8. 9. 10. 11.
20-802 4
Defective fuel injector No. 1 Defective fuel injector No. 2 Defective fuel injector No. 3 Short circuit with chassis ground or power source in wiring harness between controller CN-6 (7) (+ side) - injector No. 1 (1) Short circuit with chassis ground or power source in wiring harness between controller CN-6 (8) (- side) - injector No. 1 (2) Short circuit with chassis ground or power source in wiring harness between controller CN-6 (4) (+ side) - injector No. 2 (1) Short circuit with chassis ground or power source in wiring harness between controller CN-6 (10) (- side) - injector No. 2 (2) Short circuit with chassis ground or power source in wiring harness between controller CN-6 (3) (+ side) - injector No. 3 (1) Short circuit with chassis ground or power source in wiring harness between controller CN-6 (9) (- side) - injector No. 3 (2) Disconnection or defective contact in wiring harness between controller CN-7 (5), (13) chassis ground Defective engine controller Defective fuel injector No. 4 Defective fuel injector No. 5 Defective fuel injector No. 6 Short circuit with chassis ground or power source in wiring harness between controller CN-7 (3) (+ side) - injector No. 4 (1) Short circuit with chassis ground or power source in wiring harness between controller CN-9 (9) (- side) - injector No. 4 (2) Short circuit with chassis ground or power source in wiring harness between controller CN-7 (1) (+ side) - injector No. 5 (1) Short circuit with chassis ground or power source in wiring harness between controller CN-7 (7) (- side) - injector No. 5 (2) Short circuit with chassis ground or power source in wiring harness between controller CN-7 (2) (+ side) - injector No. 6 (1) Short circuit with chassis ground or power source in wiring harness between controller CN-7 (9) (- side) - injector No. 6 (2) Disconnection or defective contact in wiring harness between controller CN-7 (5), (13) chassis ground Defective engine controller
D155AX-5
TROUBLESHOOTING
Normal condition
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action taken by controller
Problems on machine
• Sensor source voltage 1. Holds present voltage until transmis- 1. When fuel control dial is operated, Between CN-1 (4) - CN-2 (10): 4.6 - 5.4 V sion is set in "neutral" and lowers set speed does not change • Sensor signal voltage speed command value to 1,300 rpm CN-1 (6) - CN-2 (10): 0.3 - 4.5 V after transmission is set in "neutral"
1. Holds present voltage until transmis- 1. When decelerator is operated, set • Sensor source voltage sion is set in "neutral" and lowers speed does not change Between CN-1 (4) - CN-2 (10): 4.6 - 5.4 V speed command value to 1,300 rpm • Sensor signal voltage after transmission is set in "neutral" CN-1 (7) - CN-2 (10): 0.3 - 4.5 V
• Sensor resistance Between CN-E51 (1) - (2): 85 - 210 Ω
1. Operates machine with output lim- 1. Output is lowered. ited
• Sensor resistance Between CN-E52 (1) - (2): 1 k - 2 kΩ
1. Operates machine with output lim- 1. Output is lowered. ited
• Injector No. 1 resistance Between CN-E31 (1) - (2): 0.4 - 1.1 Ω • Injector No. 2 resistance Between CN-E32 (1) - (2): 0.4 - 1.1 Ω • Injector No. 3 resistance Between CN-E33 (1) - (2): 0.4 - 1.1 Ω
1. Stops outputting to fuel injectors No. 1. Output is lowered largely (When er1, No. 2 and No. 3 (When error is ror is displayed singly) displayed singly) 2. Engine stops (When E0459 is also dis2. Stops outputting to fuel supply pump played) and all fuel injectors (When E0459 is also displayed)
• Injector No. 4 resistance Between CN-E34 (1) - (2): 0.4 - 1.1 Ω • Injector No. 5 resistance Between CN-E35 (1) - (2): 0.4 - 1.1 Ω • Injector No. 3 resistance Between CN-E36 (1) - (2): 0.4 - 1.1 Ω
1. Stops outputting to fuel injectors No. 1. Output is lowered largely (When error is displayed singly) 4, No. 5 and No. 6 (When error is 2. Engine stops (When E0458 is also disdisplayed singly)" played) 2. Stops outputting to fuel supply pump and all fuel injectors (When E0458 is also displayed)
D155AX-5
20-803 4
TROUBLESHOOTING
Service code Abnormal system
E0460
Abnormality in controller drive circuit
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Contents of abnormality 1. Disconnection or defective contact in wiring harness between controller CN-7 (5), (13) chassis ground (When E0458 and E0459 are also displayed) 2. Defective engine controller
Disconnection in fuel injector No. 1 system
1. Defective fuel injector No. 1 2. Short circuit with chassis ground or power source in wiring harness between controller CN-6 (7) (+ side) - fuel injector No. 1 CN-E31 (1) 3. Short circuit with chassis ground or power source in wiring harness between controller CN-6 (8) (- side) - fuel injector No. 1 CN-E31 (2) 4. Defective engine controller
Disconnection in fuel injector No. 2 system
1. Defective fuel injector No. 2 2. Short circuit with chassis ground or power source in wiring harness between controller CN-6 (4) (+ side) - fuel injector No. 2 CN-E32 (1) 3. Short circuit with chassis ground or power source in wiring harness between controller CN-6 (10) (- side) - fuel injector No. 2 CN-E32 (2) 4. Defective engine controller
Disconnection in fuel injector No. 3 system
1. Defective fuel injector No. 3 2. Short circuit with chassis ground or power source in wiring harness between controller CN-6 (3) (+ side) - fuel injector No. 3 CN-E33 (1) 3. Short circuit with chassis ground or power source in wiring harness between controller CN-6 (9) (- side) - fuel injector No. 3 CN-E33 (2) 4. Defective engine controller
Disconnection in fuel injector No. 4 system
1. Defective fuel injector No. 4 2. Short circuit with chassis ground or power source in wiring harness between controller CN-7 (3) (+ side) - fuel injector No. 4 CN-E34 (1) 3. Short circuit with chassis ground or power source in wiring harness between controller CN-7 (9) (- side) - fuel injector No. 4 CN-E34 (2) 4. Defective engine controller
Disconnection in fuel injector No. 5 system
1. Defective fuel injector No. 5 2. Short circuit with chassis ground or power source in wiring harness between controller CN-7 (1) (+ side) - fuel injector No. 5 CN-E35 (1) 3. Short circuit with chassis ground or power source in wiring harness between controller CN-7 (7) (- side) - fuel injector No. 5 CN-E35 (2) 4. Defective engine controller
Disconnection in fuel injector No. 6 system
1. Defective fuel injector No. 6 2. Short circuit with chassis ground or power source in wiring harness between controller CN-7 (2) (+ side) - fuel injector No. 6 CN-E36 (1) 3. Short circuit with chassis ground or power source in wiring harness between controller CN-7 (8) (- side) - fuel injector No. 6 CN-E36 (2) 4. Defective engine controller
Overcurrent in fuel supply pump PCV1 system
1. Defective fuel supply pump PCV1 2. Short circuit with chassis ground or power source in wiring harness between controller CN-7 (10) (+ side) - PCV1 solenoid CN-E41 (1) 3. Short circuit with power source in wiring harness between controller CN-7 (11) (- side) PCV1 solenoid CN-E41 (2) 4. Defective engine controller
E0459
Disconnection in fuel supply pump PCV1 system
1. Defective fuel supply pump PCV1 2. Disconnection or defective contact in wiring harness between controller CN-7 (10) (+ side) - PCV1 solenoid CN-E41 (1) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-7 (11) (- side) - PCV1 solenoid CN-E41 (2) 4. Defective engine controller
E0470
Overcurrent in fuel supply pump PCV2 system
1. Defective fuel supply pump PCV2 2. Short circuit with chassis ground or power source in wiring harness between controller CN-7 (4) (+ side) - PCV2 solenoid CN-E42 (1) 3. Short circuit with power source in wiring harness between controller CN-7 (12) (- side) PCV2 solenoid CN-E42 (2) 4. Defective engine controller
E0461
E0462
E0463
E0464
E0465
E0466
E0468
20-804 4
D155AX-5
TROUBLESHOOTING
Normal condition
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action taken by controller
Problems on machine
1. Operates machine with output lim- 1. Engine speed does not rise to high idling with no load applied ited 2. If high load is applied, engine stops 3. Engine stops during operation 4. Engine does not start
• Injector No. 1 resistance Between CN-E31 (1) - (2): 0.4 - 1.1 Ω
1. Stops outputting to fuel injector No. 1. Output is lowered (When error is displayed singly) 1 (When error is displayed singly) 2. Stops outputting to fuel supply pump 2. Engine stops (When E0462 - E0466 are also displayed) and all fuel injectors (When E0462 E0466 are also displayed)
• Injector No. 2 resistance Between CN-E32 (1) - (2): 0.4 - 1.1 Ω
1. Stops outputting to fuel injector No. 1. Output is lowered (When error is displayed singly) 2 (When error is displayed singly) 2. Stops outputting to fuel supply pump 2. Engine stops (When E0462 - E0466 are also displayed) and all fuel injectors (When E0462 E0466 are also displayed)
• Injector No. 3 resistance Between CN-E33 (1) - (2): 0.4 - 1.1 Ω
1. Stops outputting to fuel injector No. 1. Output is lowered (When error is displayed singly) 3 (When error is displayed singly) 2. Stops outputting to fuel supply pump 2. Engine stops (When E0462 - E0466 are also displayed) and all fuel injectors (When E0462 E0466 are also displayed)
• Injector No. 4 resistance Between CN-E34 (1) - (2): 0.4 - 1.1 Ω
1. Stops outputting to fuel injector No. 1. Output is lowered (When error is displayed singly) 4 (When error is displayed singly) 2. Stops outputting to fuel supply pump 2. Engine stops (When E0462 - E0466 are also displayed) and all fuel injectors (When E0462 E0466 are also displayed)
• Injector No. 5 resistance Between CN-E35 (1) - (2): 0.4 - 1.1 Ω
1. Stops outputting to fuel injector No. 1. Output is lowered (When error is displayed singly) 5 (When error is displayed singly) 2. Stops outputting to fuel supply pump 2. Engine stops (When E0462 - E0466 are also displayed) and all fuel injectors (When E0462 E0466 are also displayed)
• Injector No. 6 resistance Between CN-E36 (1) - (2): 0.4 - 1.1 Ω
1. Stops outputting to fuel injector No. 1. Output is lowered (When error is displayed singly) 6 (When error is displayed singly) 2. Stops outputting to fuel supply pump 2. Engine stops (When E0462 - E0466 are also displayed) and all fuel injectors (When E0462 E0466 are also displayed)
• Solenoid resistance Between CN-E41 (1) - (2): 2.3 - 5.3 Ω
1. Stops outputting to PCV1 (When er- 1. Machine can be operated normally (When error is displayed singly) ror is displayed singly) 2. Stops outputting to PCV1 and PCV2 2. Engine stops (When E0470 is also displayed) (When E0470 is also displayed)
• Solenoid resistance Between CN-E41 (1) - (2): 2.3 - 5.3 Ω
1. Stops outputting to PCV1 (When er- 1. Machine can be operated normally (When error is displayed singly) ror is displayed singly) 2. Stops outputting to PCV1 and PCV2 2. Engine stops (When E0470 is also displayed) (When E0470 is also displayed)
• Solenoid resistance Between CN-E42 (1) - (2): 2.3 - 5.3 Ω
1. Stops outputting to PCV2 (When er- 1. Machine can be operated normally (When error is displayed singly) ror is displayed singly) 2. Stops outputting to PCV1 and PCV2 2. Engine stops (When E0469 is also displayed) (When E0469 is also displayed)
D155AX-5
20-805 4
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Service code Abnormal system
Contents of abnormality 1. Defective fuel supply pump PCV2 2. Disconnection or defective contact in wiring harness between controller CN-7 (7) (+ side) - PCV2 solenoid CN-E42 (1) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-7 (12) (- side) - PCV2 solenoid CN-E42 (2) 4. Defective engine controller
E0471
Disconnection in fuel supply pump PCV2 system
E0472
1. Defective boost pressure sensor 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-2 (2) (power source) - boost pressure sensor CN-E54 (1) Abnormality in boost 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-1 (3) (signal) - boost pressure sensor CN-E54 (2)" pressure sensor system 4. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-2 (10) (ground) - boost pressure sensor CN-E54 (3) 5. Defective engine controller
E0474
1. Defective common rail fuel pressure sensor 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-2 (2) (power source) - fuel pressure sensor CN-E53 (1) Abnormality in common rail fuel pressure sensor 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-1 (1) (signal) - fuel pressure sensor CN-E53 (2) system 4. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-2 (10) (ground) - fuel pressure sensor CN-E53 (3) 5. Defective engine controller
E0476
1. Defective high water temperature sensor 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness Abnormality in high wabetween controller CN-2 (4) (signal) - high water temperature sensor CN-P7 (1) ter temperature sensor 3. Disconnection or defective contact in wiring harness between controller CN-2 (10) (ground) system - high water temperature sensor CN-P7 (2) 4. Defective engine controller
E0478
E0480
E0481
E0482
E0483
1. Defective low water temperature sensor 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness Abnormality in low wabetween controller CN-2 (3) (signal) - low water temperature sensor CN-P31 (1) ter temperature sensor 3. Disconnection or defective contact in wiring harness between controller CN-2 (10) (ground) system - low water temperature sensor CN-P31 (2) 4. Defective engine controller Abnormality in com- fl See E0481 and E0482 mon rail fuel pressure 1. 2. 3. High common rail fuel 4. 5. pressure 1
High common rail fuel fl See E0481 pressure 2 1. 2. 3. No-pressure feed by 4. 5. fuel supply pump 1 6.
20-806 4
Fuel viscosity is high (Improper fuel) Overflow valve Defective pressure limiter Defective common rail fuel pressure sensor Clogging of overflow piping
Defective low-pressure fuel circuit Defective fuel supply pump PCV Defective pressure limiter Defective common rail fuel pressure sensor Defective fuel injector Leakage from high-pressure fuel piping
D155AX-5
TROUBLESHOOTING
Normal condition
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action taken by controller
Problems on machine
• Solenoid resistance Between CN-E42 (1) - (2): 2.3 - 5.3 Ω
1. Stops outputting to PCV2 (When er- 1. Machine can be operated normally (When error is displayed singly) ror is displayed singly) 2. Stops outputting to PCV1 and PCV2 2. Engine stops (When E0469 is also displayed) (When E0469 is also displayed)
• Sensor source voltage Between CN-E54 (3) - (1): 4.6 - 5.4 V • Sensor signal voltage Between CN-E54 (2) - (1): 0.3 - 4.7 V
1. Operates in normal control mode
1. Machine can be operated normally
• Sensor source voltage Between CN-E53 (3) - (1): 4.6 - 5.4 V • Sensor signal voltage Between CN-E53 (2) - (1): 0.3 - 4.7 V
1. Limits output in open control mode
1. Output is lowered
• Sensor resistance (When water tem- 1. Operates in normal control mode perature is 10 - 100˚C Between CN-P7 (1) - (2): 90 k - 3.5 Ω
1. Water temperature signal output on monitor panel is fixed to 90˚C
• Sensor resistance (When water tem- 1. Operates in normal control mode perature is 10 - 100˚C Between CN-P31 (1) - (2): 9 k - 0.3 Ω
1. Exhaust gas color is bad when temperature is low 2. Engine does not start easily when temperature is low
1. Operates in normal control mode
1. Output is lowered
1. Operates machine with output lim- 1. Output is lowered ited
1. Stops outputting to fuel supply pump 1. Output is lowered 2. Stops outputting to fuel injector 1. Output is lowered 1. Derates engine output 2. Operates machine with output limited
D155AX-5
20-807 4
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Service code Abnormal system E0484
E0487
E0488
E0489
E0490
E0491
No-pressure feed by fuel supply pump 2
fl See E0483
1. Defective low oil pressure sensor 2. Defective high oil pressure sensor 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-4 (5) (low pressure) - low oil pressure sensor CN-P8 Abnormality in oil pres4. Disconnection or defective contact in wiring harness between controller CN-4 (6) (high sure switch system pressure) - high oil pressure sensor CN-P9 5. Defective engine controller
1. Defective power source relay 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between starting switch terminal ACC - power source relay CN-CPR (1) 3. Disconnection or defective contact in wiring harness between power source relay CNCPR (2) - chassis ground Abnormality in power 4. Disconnection, defective contact, or short circuit with chassis ground in wiring harness supply system 1 between controller CN-7 (6), (14) - power source relay CN-CPR (3) 5. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between battery relay terminal B - power source relay CN-CPR (5) 6. Defective engine controller 1 Defective power source relay 2. Short circuit with power source in wiring harness between controller CN-7 (6), (14) Abnormality in power power source relay CN-CPR (3) supply system 2 3. Defective engine controller
1. Defective setting of Q regulator switch Abnormality in Q regu- 2. Defective engine controller lator switch signal 1. 2. Short circuit in starting switch C system 3.
20-808 4
Contents of abnormality
Defective starting switch Short circuit with power source in wiring harness between controller CN-4 (2) - starting switch terminal C Defective engine controller
D155AX-5
TROUBLESHOOTING
Normal condition
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action taken by controller
Problems on machine
1. Stops outputting to fuel supply pump 1. Engine stops. 2. Stops outputting to fuel injector 1. Operates in normal control mode • Low-pressure switch resistance Between CN-P8 - chassis ground When engine is stopped: Max. 1 Ω When engine speed is above 600 rpm: Min. 1 MΩ • High-pressure switch resistance Between CN-P9 - chassis ground When engine is stopped: Max. 1 Ω When engine speed is above 1,300 rpm: Min. 1 MΩ
1. Machine can be operated normally
• Source voltage Between CN-7 (6), (14) - (5), (13) When starting switch is turned ON: 20 - 30 V
1. Engine stops during operation 2. Engine cannot be started.
• Source voltage 1. Operates in normal control mode Between CN-7 (6), (14) - (5), (13) When starting switch is turned OFF: Max. 8 V
1. Machine can be operated normally
• Either of Q regulator switches 1 and 2 1. Operates in normal control mode of controller is set to "F"
1. Setting of Q regulator cannot be changed
1. Operates in normal control mode • Starting switch C signal voltage Voltage between CN-4 (2) - chassis ground When starting switch is turned ON: Max. 1 V When starting switch is turned to START position: 20 - 30 V
1. Machine can be operated normally 10 seconds after started
D155AX-5
20-809 4
TROUBLESHOOTING
JUDGMENT TABLE FOR ENGINE CONTROLLER AND ENGINE
JUDGMENT TABLE FOR ENGINE CONTROLLER AND ENGINE
Abnormality in controller drive circuit
Disconnection in fuel injector No. 2 system
Short circuit in fuel injector No. 4, No. 5, No. 6 system
Short circuit in fuel injector No. 1, No. 2, No. 3 system
Abnormality in G speed sensor system
Abnormality in Ne speed sensor system
E02
Abnormality in fuel control dial system
CALL CALL CALL0 CALL0 CALL0 CALL0 CALL0 CALL0 CALL0 E02 3 3 3 3 3 3 3
Abnormality in engine controller
Disconnection in fuel injector No. 1 system
User code Service code
Abnormality in decelerator potentiometer system
Abnormality in engine controller power supply
Self-diagnosis display
E0401 E0402 E0405 E0406 E0409 E0410 E0458 E0459 E0460 E0461 E0462
Trouble mode
1
Engine does not start
2
Exhaust gas is discharged but engine does not Engine does not start (does not start easily) start easily Exhaust gas is not discharged
3
Engine stops during operation
4
Output is insufficient
5
Acceleration is low
6
Engine speed keeps Exhaust gas is normal at low idling and does not follow up Exhaust gas is very black fuel control dial
7
Engine speed rises to high idling of itself
8
Engine speed is not set to low-low idling Engine speed cannot be set to low idling Engine speed is not set to high-low idling
9
Much fuel is consumed
‡ ‡ ‡ ‡
‡ ‡
‡ ‡
‡ ‡
‡ ‡
‡ ‡
‡ ‡ ‡ ‡
‡ ‡ ‡ ‡
‡ ‡ ‡ ‡
Engine speed rises immediately when error is displayed Engine speed rises while error is displayed
Exhaust gas is normal Exhaust gas is very black
10
Engine speed does not rise to high idling Engine speed cannot be set to Engine speed rises to high idling but returns to high idling low idling
11
Automatic warm-up operation is abnormal
12
Automatic decelerator does not work
13
Engine speed does not change when working mode is changed
14
Engine speed does not lower Engine does not Engine keeps running at low idling even after stop starting switch is turned off
15
Hunting in engine speed
16
Much oil is consumed or exhaust gas color is bad
17
Oil becomes dirty soon
18
Cooling water contains oil
19
Oil pressure caution lamp lights up
20
Oil level rises
21
Water temperature rises too high
22
Abnormal sound is made
23
Vibration is too high
‡
Troubleshooting G-1 G-2 G-3 G-4 G-5 G-6 G-7 G-8 code
20-810 4
G-9 G-10 G-11
D155AX-5
Disconnection in fuel injector No. 4 system Disconnection in fuel injector No. 5 system Disconnection in fuel injector No. 6 system
E02 E02 E02 E02 CALL0 CALL0 CALL0 CALL0 E02 CALL0 E02 CALL0 E02 3 3 3 3 3 3
D155AX-5
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
‡ ‡ ‡ ‡ ‡ ‡
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
Abnormally high common rail fuel pressure 2 No feed by fuel supply pump 1 No feed by fuel supply pump 2
E02 E02 E02 E02 CALL0 CALL CALL CALL0 CALL 3 3
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
‡ ‡
Does starting motor rotate?
Short circuit in starting switch C signal system
Abnormality in Q regulator switch signal
Abnormality in power source system 2
Abnormality in power source system 1
Abnormality in pressure switch system
Abnormally high common rail fuel pressure 1
Abnormality in common rail fuel pressure
Abnormality in low water temperature sensor system
Abnormality in high water temperature sensor system
Abnormality in common rail fuel pressure sensor system
Abnormality in boost pressure sensor system
Disconnection in fuel supply pump PCV2 system
Overcurrent in fuel supply pump PCV2 system
Disconnection in fuel supply pump PCV1 system
Overcurrent in fuel supply pump PCV1 system
Disconnection in fuel injector No. 3 system
TROUBLESHOOTING JUDGMENT TABLE FOR ENGINE CONTROLLER AND ENGINE
Self-diagnosis display
Troubleshooting code displayed when service code is not displayed
E0463 E0464 E0465 E0466 E0468 E0469 E0470 E0471 E0472 E0474 E0476 E0478 E0480 E0481 E0482 E0483 E0484 E0487 E0488 E0489 E0490 E0491
See volume of engine
See volume of engine
See volume of engine
‡ See volume of engine
‡ See volume of engine
‡ ‡ ‡ ‡ ‡
See volume of engine
See volume of engine
See volume of engine
See volume of engine
See volume of engine
See volume of engine
See volume of engine
See volume of engine
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
G-12 G-13 G-14 G-15 G-16 G-17 G-18 G-19 G-20 G-21 G-22 G-23 G-24 G-25 G-25 G-26 G-26 G-27 G-28 G-29 G-30 G-31
20-811
4
TROUBLESHOOTING
G MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
G MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
20-812 4
D155AX-5
TROUBLESHOOTING
D155AX-5
G MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
20-813 4
G-1
TROUBLESHOOTING
G-1.
[E0401] (Abnormality in engine controller power supply) is displayed Cause
Remedy
1 • Disconnect CN-4. • Turn starting switch ON. • 20 - 30 V
Is voltage between CN-4 (female) (7), NO (18) and (8), (19) normal?
YES Defective engine controller
Replace
Defective wiring harness between CN4 - CN-E51
Replace
Defective wiring harness between CN-E51 (14) - GND2
Repair or replace
Defective wiring harness between CN-E51 (female) (12) - CN-214 (female) (11)
Repair or replace
Is voltage between CN-214 (male) (8) NO and chassis ground normal?
Defective wiring harness between CN-214 (8) - battery
Repair or replace
YES
Defective wiring harness between CN-214 (8) - (11) or defective starting switch
Repair or replace
2 • Disconnect CN-E51. • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-E51 (female) (12) and (14) normal?
YES
3 • Disconnect CN-E51. • Turn starting switch ON. •0Ω
NO
Is resistance between CN-E51 (14) and chassis ground normal?
YES 4 • Disconnect CN-214. • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-214 (male) (11) and chassis ground normal?
YES
5 • Disconnect CN-214. • Turn starting switch ON. • 20 - 30 V
G-1. Related electrical circuit diagram
20-814 4
D155AX-5
G-2
TROUBLESHOOTING
G-2.
[E0402] (Abnormality in engine controller) is displayed
fl Go to troubleshooting of error code [E0460].
D155AX-5
20-815 4
G-3
TROUBLESHOOTING
G-3.
[E0405] (Abnormality in fuel control dial system) is displayed Cause
Remedy
1 • Insert T-adapter in CN-FCS. • Turn starting switch ON.
NO
Is voltage between CN-FCS (1) and (3) 4.6 - 5.4 V?
YES
2 • Insert T-adapter in CN-1 and CN-2. • Turn starting switch ON.
Is voltage between CN-1 (4) and CN-2 NO (10) 4.6 - 5.4 V?
3 Is resistance between CN-FCS (male) (1) and (3), between (2) and (3), and between (2) and chassis ground as shown in Table 1?
Repair or replace
Disconnection, defective contact, or short circuit with chassis ground in Repair or wiring harness between CN1 (female) (4) - CN-FCS (female) (1) or replace between CN-2 (female) (10) - CNFCS (female) (3)
YES
• Turn starting switch OFF. • Disconnect CN-FCS.
Defective engine controller
NO
Defective fuel control dial
Replace
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-1 (female) (6) - CN-FCS (female) (2)
Repair or replace
Defective engine controller
Replace
YES
4 • Turn starting switch OFF. • Disconnect CN-1 and CN-2.
Is resistance between CN-1 (female) (4) and CN-2 (10), between (6) and (10), and between (6) and chassis ground as shown in Table 2?
NO
YES
Table 1
Table 2
CN-FCS (male)
Resistance
CN-1, CN-2 (male)
Resistance
Between (1) – (3)
4.0 – 6.0 kΩ
Between CN-1 (4) – CN-2 (10)
4.0 – 6.0 kΩ
Between (2) – (3)
0.24 – 7.0 kΩ
Between CN-1 (6) – CN-2 (10)
0.24 – 7.0 kΩ
Between (2) – GND
Min. 1MΩ
Between CN-1 (6) – GND
Min. 1MΩ
G-3. Related electrical circuit diagram
20-816 4
D155AX-5
G-4
TROUBLESHOOTING
G-4.
[E0406] (Abnormality in decelerator potentiometer system) is displayed Cause
Remedy
1 • Insert T-adapter in TS. • Turn starting switch ON.
NO
Is voltage between CN-FCD (1) and (3) 4.6 - 5.4 V?
YES
2 • Insert T-adapter in CN-1 and CN-2. • Turn starting switch ON.
Is voltage between CN-1 (4) and CN- NO 2 (10) 4.6 - 5.4 V?
Defective engine controller
Repair or replace
Disconnection, defective contact, or short circuit with chassis ground in Repair or wiring harness between CN1 (female) (4) - CN-FCD (female) (1) or replace between CN-2 (female) (10) - CNFCD (female) (3)
YES
3 • Turn starting switch OFF. • Disconnect CN-FCD.
Is resistance between CN-FCD (male) (1) and (3), between (2) and (3), and between (2) and chassis ground as shown in Table 1?
NO
Defective decelerator potentiometer
Replace
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-1 (female) (6) - CN-FCD (female) (2)
Repair or replace
Defective engine controller
Replace
YES
4 • Turn starting switch OFF. • Disconnect CN-1 and CN-2.
Is resistance between CN-1 (female) (4) and CN-2 (10), between (7) and CN-2 (10), and between CN-1 (7) and chassis ground as shown in Table 2?
NO
YES
Table 1
Table 2
CN-FCD (male)
Resistance
CN-1, CN-2 (male)
Resistance
Between (1) – (3)
4.0 – 6.0 kΩ
Between CN-1 (4) – CN-2 (10)
4.0 – 6.0 kΩ
Between (2) – (3)
0.24 – 7.0 kΩ
Between CN-1 (7) – CN-2 (10)
0.24 – 7.0 kΩ
Between (2) – GND
Min. 1MΩ
Between CN-1 (7) – GND
Min. 1MΩ
G-4. Related electrical circuit diagram
D155AX-5
20-817 4
TROUBLESHOOTING
G-5.
G-5
[E0409] (Abnormality in Ne speed sensor system) is displayed Cause
• Turn starting switch OFF. • Disconnect CN-E51.
1 Is resistance between CN-E51 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 1?
Remedy
Defective Ne speed sensor
Replace
Disconnection or defective contact in wiring harness between CN-1 (female) (5) - CN-E51 (female) (1) or between CN-1 (female) (12) - CNE51 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between CN-1 (female) (5) - CN-E51 (female) (1) or between CN-1 (female) (12) - CNE51 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2
• Turn starting switch OFF. • Disconnect CN-1.
NO
Is resistance between CN-1 (female) (5) and (12) 85 - 210 Ω
YES 3
• Turn starting switch OFF. • Disconnect CN-1 and CN-E51.
Is resistance between CN-1 (female) (5) and (12) above 1 MΩ?
NO
YES
Table 1 CN-E51 (male)
Resistance
Between (1) – (2)
85 – 210 Ω
Between (1) (2) – GND
Min. 1MΩ
G-5. Related electrical circuit diagram
20-818 4
D155AX-5
TROUBLESHOOTING
G-6.
G-6
[E0410] (Abnormality in G speed sensor system) is displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E52.
Is resistance between CN-E52 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 1?
Defective G speed sensor
Replace
Disconnection or defective contact in wiring harness between CN-2 (female) (1) - CN-E52 (female) (1) or between CN-2 (female) (9) - CN-E52 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between CN-2 (female) (1) - CN-E52 (female) (1) or between CN-2 (female) (9) - CN-E52 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2 • Turn starting switch OFF. • Disconnect CN-2.
NO
Is resistance between CN-2 (female) (1) and (9) 1 - 2 kΩ?
YES 3 • Turn starting switch OFF. • Disconnect CN-2 and CN-E52.
Is resistance between CN-2 (female) (1) and (9) above 1 MΩ?
NO
YES
Table 1 CN-E52 (male)
Resistance
Between (1) – (2)
1 – 2 kΩ
Between (1) (2) – GND
Min. 1MΩ
G-6). Related electrical circuit diagram
D155AX-5
20-819 4
TROUBLESHOOTING
G-7.
G-7
[E0458] (Short circuit in fuel injector No. 1, No. 2, No. 3 system) is displayed
¤ Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit". a) Judgment of abnormal system Cause
Remedy
Abnormality in fuel injector system No. 1
Go to troubleshooting step b)
Abnormality in fuel injector system No. 2
Go to troubleshooting step c)
Abnormality in fuel injector system No. 3
Go to troubleshooting step d)
Disconnection or defective contact in wiring harness between CN-7 (female) (5), (13) - chassis ground
Repair or replace
Defective engine controller
Replace
1 • Turn starting switch OFF. • Disconnect CN-6.
Is resistance between CN-6 (female) (7) and (8) and between (7), (8) and chassis ground as shown in Table 1?
NO
YES 2 • Turn starting switch OFF. • Disconnect CN-6.
Is resistance between CN-6 (female) NO (4) and (10) and between (4), (10) and chassis ground as shown in Table 1?
YES 3 • Turn starting switch OFF. • Disconnect CN-6.
Is resistance between CN-6 (female) (3) and (9) and between (3), (9) and chassis ground as shown in Table 1?
NO
YES
4 • Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) (5), NO (13) and chassis ground below 1 Ω? YES
Table 1 CN-6 (female)
CN-6 (female)
CN-6 (female)
Resistance
Between (7) – (8)
Between (4) – (10)
Between (3) – (9)
0.4 – 1.1 Ω
Between (7) (8) – GND Between (4) (10) – GND Between (3) (9) – GND
20-820 4
Min. 1MΩ
D155AX-5
TROUBLESHOOTING
G-7
b) Troubleshooting of fuel injector No. 1 system
Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E31.
Is resistance between CN-E31 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 2?
YES
Defective fuel injector No. 1
Replace
Short circuit with chassis ground or power source in wiring harness between CN-6 (female) (7) - CN-E31 (female) (1) or between CN-6 (female) (8) - CN-E31 (female) (2)
Repair or replace
Table 2 CN-E31 (female)
Resistance
Between (1) – (2)
0.4 – 1.1 Ω
Between (1) (2) – GND
Min. 1MΩ
c) Troubleshooting of fuel injector No. 2 system Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E32.
Is resistance between CN-E32 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 3?
YES
Defective fuel injector No. 2
Replace
Short circuit with chassis ground or power source in wiring harness between CN-6 (female) (4) - CN-E32 (female) (1) or between CN-6 (female) (10) - CN-E32 (female) (2)
Repair or replace
Table 2 CN-E32 (female)
Resistance
Between (1) – (2)
0.4 – 1.1 Ω
Between (1) (2) – GND
Min. 1MΩ
d) Troubleshooting of fuel injector No. 3 system
Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E33.
Is resistance between CN-E33 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 4?
YES
Defective fuel injector No. 3
Replace
Short circuit with chassis ground or power source in wiring harness between CN-6 (female) (3) - CN-E33 (female) (1) or between CN-6 (female) (9) - CN-E33 (female) (2)
Repair or replace
Table 2 CN-E33 (female)
Resistance
Between (1) – (2)
0.4 – 1.1 Ω
Between (1) (2) – GND
Min. 1MΩ
D155AX-5
20-821 4
TROUBLESHOOTING
G-7
G-7 a), b). Related electrical circuit diagram
G-7 a), c). Related electrical circuit diagram
G-7 a), d). Related electrical circuit diagram
20-822 4
D155AX-5
TROUBLESHOOTING
G-8.
G-8
[E0459] (Short circuit in fuel injector No. 4, No. 5, No. 6 system) is displayed
¤ Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit". a) Judgment of abnormal system Cause
Remedy
Abnormality in fuel injector system No. 4
Go to troubleshooting step b)
Abnormality in fuel injector system No. 5
Go to troubleshooting step c)
Abnormality in fuel injector system No. 6
Go to troubleshooting step d)
Disconnection or defective contact in wiring harness between CN-7 (female) (5), (13) - chassis ground
Repair or replace
Defective engine controller
Replace
1 • Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) (3) and (9) and between (3), (9) and chassis ground as shown in Table 1?
NO
YES 2 • Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) NO (1) and (7) and between (1), (7) and chassis ground as shown in Table 1?
YES 3 • Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) (2) and (8) and between (2), (8) and chassis ground as shown in Table 1?
NO
YES
4 • Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) (5), NO (13) and chassis ground below 1 Ω? YES
Table 1 CN-7 (female)
CN-7 (female)
CN-7 (female)
Resistance
Between (3) – (9)
Between (1) – (7)
Between (2) – (8)
0.4 – 1.1 Ω
Between (3) (9) – GND
D155AX-5
Between (1) (7) – GND Between (2) (8) – GND
Min. 1MΩ
20-823 4
TROUBLESHOOTING
G-8
b) Troubleshooting of fuel injector No. 4 system Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E34.
Is resistance between CN-E34 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 2?
YES
Table 2 CN-E34 (female)
Resistance
Between (1) – (2)
0.4 – 1.1 Ω
Between (1) (2) – GND
Min. 1MΩ
Defective fuel injector No. 4
Replace
Short circuit with chassis ground or power source in wiring harness between CN-7 (female) (3) - CN-E34 (female) (1) or between CN-7 (female) (9) - CN-E34 (female) (2)
Repair or replace
c) Troubleshooting of fuel injector No. 5 system Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E35.
Is resistance between CN-E35 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 3?
YES
Defective fuel injector No. 5
Replace
Short circuit with chassis ground or power source in wiring harness between CN-7 (female) (1) - CN-E35 (female) (1) or between CN-7 (female) (7) - CN-E35 (female) (2)
Repair or replace
Table 3 CN-E35 (female)
Resistance
Between (1) – (2)
0.4 – 1.1 Ω
Between (1) (2) – GND
Min. 1MΩ
d) Troubleshooting of fuel injector No. 6 system Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E36.
Is resistance between CN-E36 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 4?
YES
Defective fuel injector No. 6
Replace
Short circuit with chassis ground or power source in wiring harness between CN-7 (female) (2) - CN-E36 (female) (1) or between CN-7 (female) (8) - CN-E36 (female) (2)
Repair or replace
Table 4 CN-E36 (female)
Resistance
Between (1) – (2)
0.4 – 1.1 Ω
Between (1) (2) – GND
Min. 1MΩ
20-824 4
D155AX-5
TROUBLESHOOTING
G-8
G-8 a), b). Related electrical circuit diagram
G-8 a), c). Related electrical circuit diagram
G-8 a), d). Related electrical circuit diagram
D155AX-5
20-825 4
TROUBLESHOOTING
G-9.
G-9
[E0460] (Abnormality in controller chassis ground circuit) is displayed
fl When starting switch is turned on, error codes [E0458] and [E0459] are displayed, too. Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN7 (female) (5), NO (13) and chassis ground below 1 Ω?
Disconnection or defective contact in wiring harness between CN7 (female) (5), (13) - chassis ground
Repair or replace
Defective engine controller
Replace
YES
G-9. Related electrical circuit diagram
20-826 4
D155AX-5
G-10
TROUBLESHOOTING
G-10. [E0461] (Disconnection in fuel injector No. 1 system) is displayed ¤ Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit". Cause
Remedy
1
• Turn starting switch OFF. • Disconnect CN-E31.
Is resistance between CN-E31 (male) NO (1) and (2) 0.4 - 1.1 Ω?
Defective fuel injector No. 1
Replace
Disconnection or defective contact in wiring harness between CN-6 (female) (7) - CN-E31 (female) (1) or between CN-6 (female) (8) - CN-E31 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2
• Turn starting switch OFF. • Disconnect CN-6.
Is resistance between CN-6 (female) (7) and (8) 0.4 - 1.1 Ω?
NO
YES
G-10. Related electrical circuit diagram
D155AX-5
20-827 4
G-11
TROUBLESHOOTING
G-11. [E0462] (Disconnection in fuel injector No. 2 system) is displayed ¤ Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit".
Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E32.
Is resistance between CN-E32 (male) NO (1) and (2) 0.4 - 1.1 Ω?
Defective fuel injector No. 2
Replace
Disconnection or defective contact in wiring harness between CN-6 (female) (4) - CN-E32 (female) (1) or between CN-6 (female) (10) - CNE32 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2 • Turn starting switch OFF. • Disconnect CN-6.
Is resistance between CN-6 (female) (4) and (10) 0.4 - 1.1 Ω?
NO
YES
G-11. Related electrical circuit diagram
20-828 4
D155AX-5
G-12
TROUBLESHOOTING
G-12. [E0463] (Disconnection in fuel injector No. 3 system) is displayed ¤ Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit". Cause
Remedy
1
• Turn starting switch OFF. • Disconnect CN-E33.
Is resistance between CN-E33 (male) NO (1) and (2) 0.4 - 1.1 Ω?
Defective fuel injector No. 3
Replace
Disconnection or defective contact in wiring harness between CN-6 (female) (3) - CN-E33 (female) (1) or between CN-6 (female) (9) - CN-E33 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2
• Turn starting switch OFF. • Disconnect CN-6.
Is resistance between CN-6 (female) (3) and (9) 0.4 - 1.1 Ω?
NO
YES
G-12. Related electrical circuit diagram
D155AX-5
20-829 4
G-13
TROUBLESHOOTING
G-13. [E0464] (Disconnection in fuel injector No. 4 system) is displayed ¤ Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit".
Cause • Turn starting switch OFF. • Disconnect CN-E34.
1 Is resistance between CN-E34 (male) NO (1) and (2) 0.4 - 1.1 Ω?
Remedy
Defective fuel injector No. 4
Replace
Disconnection or defective contact in wiring harness between CN-7 (female) (3) - CN-E34 (female) (1) or between CN-7 (female) (9) - CN-E34 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2
• Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) (3) and (9) 0.4 - 1.1 Ω?
NO
YES
G-13. Related electrical circuit diagram
20-830 4
D155AX-5
TROUBLESHOOTING
G-14
G-14. [E0465] (Disconnection in fuel injector No. 5 system) is displayed ¤ Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit". Cause
Remedy
1
• Turn starting switch OFF. • Disconnect CN-E35.
Is resistance between CN-E35 (male) NO (1) and (2) 0.4 - 1.1 Ω?
Defective fuel injector No. 5
Replace
Disconnection or defective contact in wiring harness between CN-7 (female) (1) - CN-E35 (female) (1) or between CN-7 (female) (7) - CN-E35 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2
• Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) (1) and (7) 0.4 - 1.1 Ω?
NO
YES
G-14. Related electrical circuit diagram
D155AX-5
20-831 4
TROUBLESHOOTING
G-15
G-15. [E0466] (Disconnection in fuel injector No. 6 system) is displayed ¤ Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit". Cause
Remedy
1
• Turn starting switch OFF. • Disconnect CN-E36.
Is resistance between CN-E36 (male) NO (1) and (2) 0.4 - 1.1 Ω?
Defective fuel injector No. 6
Replace
Disconnection or defective contact in wiring harness between CN-7 (female) (2) - CN-E36 (female) (1) or between CN-7 (female) (8) - CN-E36 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2
• Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) (2) and (8) 0.4 - 1.1 Ω?
NO
YES
G-15. Related electrical circuit diagram
20-832 4
D155AX-5
TROUBLESHOOTING
G-16
G-16. [E0468] (Overcurrent in fuel supply pump PCV1 system) is displayed
Cause • Turn starting switch OFF. • Disconnect CN-E41.
1 Is resistance between CN-E41 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 1?
Remedy
Defective fuel supply pump PCV1
Replace
Short circuit with chassis ground or power source in wiring harness between CN-7 (female) (10) - CNE41 (female) (1) or between CN-7 (female) (11) - CN-E41 (female) (2)
Repair or replace
Defective engine controller
Replace
YES
• Turn starting switch OFF. • Disconnect CN-7.
2 Is resistance between CN-7 (female) (10) NO and (11) and between (10), (11) and chassis ground as shown in Table 2?
YES
Table 1
Table 2
CN-E41 (male)
Resistance
CN-7 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 Ω
Between (10) – (11)
2.3 – 5.3 Ω
Min. 1MΩ
Between (10), (11) chassis ground
Min. 1MΩ
Between (1), (2) chassis ground
G-16. Related electrical circuit diagram
D155AX-5
20-833 4
TROUBLESHOOTING
G-17
G-17. [E0469] (Disconnection in fuel supply pump PCV1 system) is displayed
Cause • Turn starting switch OFF. • Disconnect CN-E41.
1 Is resistance between CN-E41 (male) NO (1) and (2) 2.3 - 5.3 Ω?
Defective fuel supply pump PCV1
Remedy Replace
YES
• Turn starting switch OFF. • Disconnect CN-7.
2 Is resistance between CN-7 (female) NO (10) and (11) and between (11) and chassis ground as shown in Table 1?
YES
Disconnection, defective contact, or short circuit with chassis ground in Repair or wiring harness between CN-7 replace (female) (10) - CN-E41 (female) (1) or between CN-7 (female) (11) - CNE41 (female) (2) Defective engine controller
Replace
Table 1 CN-7 (male)
Resistance
Between (10) – (11)
2.3 – 5.3 Ω
Between (11) chassis ground
Min. 1MΩ
G-17. Related electrical circuit diagram
20-834 4
D155AX-5
G-18
TROUBLESHOOTING
G-18. [E0470] (Overcurrent in fuel supply pump PCV2 system) is displayed Cause
Remedy
1
• Turn starting switch OFF. • Disconnect CN-E42.
Is resistance between CN-E42 (male) NO (1) and (2) and between (1), (2) and chassis ground as shown in Table 1?
Defective fuel supply pump PCV2
Replace
Short circuit with chassis ground or power source in wiring harness between CN-7 (female) (4) - CN-E42 (female) (1) or between CN-7 (female) (12) - CN-E42 (female) (2)
Repair or replace
Defective engine controller
Replace
YES 2
• Turn starting switch OFF. • Disconnect CN-7.
Is resistance between CN-7 (female) (4) and (12) and between (4), (12) and chassis ground as shown in Table 2?
NO
YES
Table 1
Table 2
CN-E42 (male)
Resistance
CN-7 (male)
Resistance
Between (1) – (2)
2.3 – 5.3 Ω
Between (4) – (12)
2.3 – 5.3 Ω
Between (1), (2) chassis ground
Min. 1MΩ
Between (4), (12) chassis ground
Min. 1MΩ
G-18. Related electrical circuit diagram
D155AX-5
20-835 4
TROUBLESHOOTING
G-19
G-19. [E0471] (Disconnection in fuel supply pump PCV2 system) is displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-E42.
Is resistance between CN-E42 (male) NO (1) and (2) 2.3 - 5.3 Ω?
Defective fuel supply pump PCV2
Replace
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-7 (female) (4) - CN-E42 (female) (1) or between CN-7 (female) (12) - CNE42 (female) (2)
Repair or replace
Defective engine controller
Replace
YES
• Turn starting switch OFF. • Disconnect CN-7.
2 Is resistance between CN-7 (female) NO (4) and (12) and between (12) and chassis ground as shown in Table 1?
YES
Table 1 CN-7 (male)
Resistance
Between (4) – (12)
2.3 – 5.3 Ω
Between (12) chassis ground
Min. 1MΩ
G-19. Related electrical circuit diagram
20-836 4
D155AX-5
TROUBLESHOOTING
G-20
G-20. [E0472] (Abnormality in boost pressure sensor system) is displayed Cause
Remedy
1 • Connect T-adapter to CN-2. • Turn starting switch ON.
Is voltage between CN-2 (2) and (10) NO 4.6 - 5.4V?
YES
2 • Disconnect CN-E54. • Turn starting switch ON.
NO
Is voltage between CN-E54 (3) and (1) 4.6 - 5.4V?
YES
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-2 (female) (2) - CN-E54 (female) (1) or between CN-2 (female) (10) - CNE54 (female) (3)
Repair or replace
Defective boost pressure sensor
Repair
Defective engine controller
Repair
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-1 (female) (3) - CN-E54 (female) (2)
Repair or replace
Defective boost pressure sensor
Repair
3 • Connect T-adapter to CN-1 and CN-2. • Turn starting switch ON.
Is voltage between CN-1 (3) and CN- NO 2 (10) 0.3 - 4.7 V?
YES
4 • Disconnect CN-1 and CNE54 • Turn starting switch ON.
Is resistance between CN-1 (female) (3) and CN-E54 (female) (2) and between CN-1 (female) (3) and chassis ground as shown in Table 1?
NO
YES
Table 3 CN-1 and CN-E35 (female)
Resistance
Between CN-1 (3) - CN-E54 (2)
Max. 1 Ω
CN-1 (3) and chassis ground
Max. 1MΩ
G-20. Related electrical circuit diagram
D155AX-5
20-837 4
TROUBLESHOOTING
G-21
G-21. [E0474] (Abnormality in common rail fuel pressure sensor system) is displayed Cause
Remedy
1 • Connect T-adapter to CN-2. • Turn starting switch ON.
Is voltage between CN-2 (2) and (10) NO 4.6 - 5.4V?
YES
2 • Disconnect CN-E53. • Turn starting switch ON.
NO
Is voltage between CN-E53 (1) and (3) 4.6 - 5.4V?
YES
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-2 (female) (2) - CN-E53 (female) (1) or between CN-2 (female) (10) - CNE53 (female) (3)
Repair or replace
Defective common rail fuel pressure sensor
Repair
Defective engine controller
Repair
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-1 (female) (1) - CN-E53 (female) (2)
Repair or replace
Defective common rail fuel pressure sensor
Repair
3 • Connect T-adapter to CN-1 and CN-2. • Turn starting switch ON.
Is voltage between CN-1 (1) and CN- NO 2 (10) 0.3 - 4.7 V?
YES
4 • Disconnect CN-1 and CN-E53 • Turn starting switch ON.
Is resistance between CN-1 (female) (1) and CN-E53 (female) (2) and between CN-1 (female) (1) and chassis ground as shown in Table 1?
YES
NO
Table 1 CN-1, CN-E53 (female)
Resistance
Between CN-1 (1) – CN-E53 (2)
Max. 1 Ω
CN-1 (1) and chassis ground
Max 1MΩ
G-21. Related electrical circuit diagram
20-838 4
D155AX-5
TROUBLESHOOTING
G-22
G-22. [E0476] (Abnormality in high engine water temperature sensor system) is displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-P7. • Water temperature: 10 - 100˚C
Is resistance between CN-P7 (male) NO (1) and (2) and between (1) and chassis ground as shown in Table 1?
Defective high water temperature sensor
Replace
Disconnection or defective contact in wiring harness between CN-2 (female) (4) - CN-P7 (female) (1) or between CN-2 (female) (10) - CN-P7 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between CN-2 (female) (4) - CN-P7 (female) (1)
Repair or replace
Defective engine controller
Replace
YES 2 • Turn starting switch OFF. • Disconnect CN-2. • Water temperature: 10 - 100˚C
NO
Is resistance between CN-2 (female) (4) and (10) 90 k - 3.5 kΩ?
YES 3
• Turn starting switch OFF. • Disconnect CN-2 and CN-P7.
Is resistance between CN-2 (female) (4) and chassis ground above 1 MΩ?
NO
YES
Table 1 CN-P7 (male)
Resistance
Between (1) – (2)
90 k – 3.5 kΩ
Between (1) chassis ground
Min. 1MΩ
G-22. Related electrical circuit diagram
D155AX-5
20-839
G-23
TROUBLESHOOTING
G-23. [E0478] (Abnormality in low engine water temperature sensor system) is displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-P31. • Water temperature: 10 - 100˚C
Is resistance between CN-P31 (male) NO (1) and (2) and between (1) and chassis ground as shown in Table 1?
Defective low water temperature sensor
Replace
Disconnection or defective contact in wiring harness between CN-2 (female) (3) - CN-P31 (female) (1) or between CN-2 (female) (10) - CNP31 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between CN-2 (female) (3) - CN-P31 (female) (1)
Repair or replace
Defective engine controller
Replace
YES 2 • Turn starting switch OFF. • Disconnect CN-2. • Water temperature: 10 - 100˚C
NO
Is resistance between CN-2 (female) (3) and (10) 9 k - 0.3 kΩ?
YES 3
• Turn starting switch OFF. • Disconnect CN-2 and CN-P31.
Is resistance between CN-2 (female) (3) and chassis ground above 1 MΩ?
NO
YES
Table 1 CN-P31 (male)
Resistance
Between (1) – (2)
9 k – 0.3 kΩ
Between (1) chassis ground
Min. 1MΩ
G-23. Related electrical circuit diagram
20-840
D155AX-5
TROUBLESHOOTING
G-24
G-24. [E0480] (Abnormality in common rail fuel pressure system) is displayed fl
Go to error code [E0481] and [E0482].
D155AX-5
20-841 4
TROUBLESHOOTING
G-25
G-25. [E0481] (Abnormality in high common rail fuel pressure 1 system) is displayed [E0482] (Abnormality in high common rail fuel pressure 2 system) is displayed Cause
Remedy
—
Go to troubleshooting of displayed error code.
1 • Turn starting switch ON.
NO
Is any other error code displayed, too?
YES
2 NO
Is proper fuel matched to atmospheric temperature used?
Improper fuel
Replace
YES
3 • Loosen joint of fuel supply pump overflow valve
When priming pump is operated, does NO fuel leak through joint connector?
YES
4 • Disassemble fuel supply pump overflow valve
Is spring broken or is seat worn or is NO ball seized in overflow valve?
YES
—
Go to troubleshooting No. 7
Defective overflow valve
Replace
Defective pressure limiter
Replace
Defective electrical system of common rail fuel pressure sensor
Repair or replace
Defective mechanical system of common rail fuel pressure sensor
Replace
Clogging of overflow pipe
Repair or replace
5 • Loosen joint of common rail pressure limiter
NO
When engine is started, does fuel leak through joint connector?
YES
6 Is any trouble in electrical system detected by troubleshooting of error code [E0474]?
NO
YES
7 Is overflow pipe clogging?
NO
YES
20-842 4
D155AX-5
TROUBLESHOOTING
G-26
G-26. [E0483] (No-pressure feed by fuel supply pump 1) is displayed [E0484] (No-pressure feed by fuel supply pump 2) is displayed Cause
Remedy
—
Go to troubleshooting of displayed error code.
1 • Turn starting switch ON.
NO
Is any other error code displayed, too?
YES
2 NO
Is proper fuel matched to atmospheric temperature used?
Improper fuel
Replace
Fuel leakage through high-pressure circuit
Repair or replace
Defective low-pressure circuit devices (See Note 1)
Repair or replace
Defective pressure limiter
Replace
Defective fuel injector
Replace
Defective common rail fuel pressure sensor
Replace
Defective fuel supply pump
Replace
Defective electrical system of fuel supply pump PCV
Repair or replace
YES 3 • Visually inspect while engine is stopped, then inspect while engine is running at low idling.
NO
Does fuel leak through fuel pump, highpressure primary piping, common rail, or high-pressure secondary piping?
YES
4 • Measure fuel pressure (See TESTING AND ADJUSTING). • Run engine at high idling.
Is pressure in low-pressure fuel circuit NO 0.15 - 0.3 MPa {1.5 - 3.0 kg/cm2}?
YES • Disconnect outlet pipe of common rail pressure limiter. • Start engine.
5 NO
Is fuel drainage from pressure limiter below 10 cc/min?
YES 6 • Disconnect either PCV connector. • Start engine.
When either PCV connector of fuel pump is disconnected, does engine stop?
NO
YES
7 • Disconnect spill collection hose of injector. • Start engine.
NO
Is spill rate of injector normal (See Note 2)?
YES
8 Is any trouble in electrical system detected NO by troubleshooting of error codes [E0468], [E0469], [E0470], and [E0471]?
YES
D155AX-5
20-843 4
TROUBLESHOOTING
G-26
Note 1: If the equipment in the low-pressre circuit is defective, inspect the following points. 1) Remaining amount of fuel 2) Stuck, worn feed pump, clogged filter 3) Leakage, clogged low-pressure fuel piping 4) Defective actuation of bypass valve, incorrect assembly with other parts (See Fig. 1) 5) Clogged fuel filter 6) Fuel entering oil pan (fuel leakage inside head cover) Fig. 1 Mounting positions of bypass valve (1), bypass valve (2), fuel inlet port joint
Note 2: Method of measuring amount of fuel spill flow ¤ The fuel in the spill line is at high temperature (up to 90˚C), so be careful not to burn youself during the operation. 1) Disconnect the hose connected to the spill tube return collection portion (rear of engine). 2) Connect another hose to the tip of the spill tube, and collect the spill fuel in a container. 3) Start the engine, stall the engine at each speed, and measure the spill fuel amount for 1 minute. Limits for fuel spill amount (total for 6 cylinders) Stall speed (rpm)
Spill limit (cc/min)
1,600
720
1,700
765
1,800
810
1,900
855
2.000
900
20-844 4
D155AX-5
TROUBLESHOOTING
G-27
G-27. [E0487] (Abnormality in engine oil pressure switch system) is displayed Cause
Remedy
1 • Insert T-adapter in CN-4.
NO Is voltage between CN-4 (5) and chassis ground as shown in Table 1? YES
2 • Disconnect CN-P8.
Is resistance between CN-P8 (switch side) and chassis ground as shown in Table 2?
NO
YES
Defective low oil pressure switch
Replace
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-4 (female) (5) - CN-P8
Repair or replace
Defective engine controller
Replace
Defective high oil pressure switch
Replace
Disconnection or defective contact in wiring harness between CN-4 (female) (5) - CN-P9
Repair or replace
3 • Insert T-adapter in CN4.
NO Is voltage between CN-4 (6) and chassis ground as shown in Table 3? YES
4 • Disconnect CN-P9.
Is resistance between CN-P9 (switch side) and chassis ground as shown in Table 4?
NO
YES
Table 1 CN-4 (male) Between (5) – chassis ground
Table 2 Engine
Voltage
CN-P8
Engine
Resistance
Stopped
Max. 1 V
Stopped
Max. 1 Ω
Above 600 rpm
20 – 30 V
Between CN-P8 (switch) - chassis ground
Above 600 rpm
Min. 1 MΩ
Table 3 CN-4 Between (6) – chassis ground
D155AX-5
Table 4 Engine
Resistance
CN-P9
Engine
Resistance
Stopped
Max. 1 V
Stopped
Max. 1 Ω
Above 600 rpm
20 – 30 V
Between CN-P9 (switch) - chassis ground
Above 1,300 rpm
Min. 1 MΩ
20-845 4
TROUBLESHOOTING
G-27
G-27. Related electrical circuit diagram
20-846 4
D155AX-5
TROUBLESHOOTING
G-28
G-28. [E0488] (Abnormality in power supply system 1) is displayed Cause
Remedy
1 • Insert T-adapter in CN-7. • Turn starting switch ON.
NO
Is voltage between CN-7 (6), (14) and (5), (13) 20 - 30 V?
YES
Defective engine controller
Replace
Defective power source relay (coil side)
Replace
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between starting switch terminal ACC - CN-CPR (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between CN-CPR (female) (2) - chassis ground
Repair or replace
2 • Turn starting switch OFF. • Disconnect CN-CPR.
NO
Is resistance between CN-CPR (male) (1) and (2) 200 - 400 Ω?
YES
3 • Turn starting switch OFF. • Insert T-adapter in CNCPR.
NO
Is voltage between CN-CPR (1) and chassis ground 20 - 30 V?
YES
4 • Turn starting switch OFF. • Disconnect CN-CPR.
Is resistance between CN-CPR (female) (2) and chassis ground below 1Ω?
NO
YES
5 • Insert T-adapter in CNCPR. • Turn starting switch ON.
NO
Is voltage between CN-CPR (5) and chassis ground 20 - 30 V?
Defective battery relay or disconnection, defective contact, or short circuit with chassis ground in wiring Repair or replace harness between terminal B - CNCPR (female) (5)
YES
6 • Turn starting switch OFF. • Insert T-adapter in CNCPR.
Is voltage between CN-CPR (3) and chassis ground 20 - 30 V?
YES
D155AX-5
NO
Defective power source relay (contact side)
Replace
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-7 (female) (6), (14) - CN-CPR (female) (3)
Repair or replace
20-847 4
TROUBLESHOOTING
G-28
G-28. Related electrical circuit diagram
20-848 4
D155AX-5
TROUBLESHOOTING
G-29
G-29. [E0489] (Abnormality in power supply system 2) is displayed Caution
Remedy
1 • Turn starting switch OFF. • Insert T-adapter in CN-7.
Is voltage between CN-7 (6), (14) and NO (5), (13) below 8 V?
YES
Defective engine controller
Replace
Defective power source relay (contact side)
Replace
Short circuit with power source in wiring harness between CN-7 (female) (6) (14) - CN-CPR (female) (5)
Repair or replace
2 • Turn starting switch OFF. • Disconnect CN-CPR. • Insert T-adapter in CN-7.
Is voltage between CN-7 (6), (14) (5), (13) below 8 V?
YES
NO
G-29. Related electrical circuit diagram
D155AX-5
20-849 4
TROUBLESHOOTING
G-30
G-30. [E0490] (Abnormality in Q regulator switch signal) is displayed
Caution
Remedy
1 Are both of Q regulator switches 1 and 2 set to "F"?
NO
Defective engine controller
Replace
Defective setting of Q regulator
Readjust
YES
20-850 4
D155AX-5
G-31
TROUBLESHOOTING
G-31. [E0491] (Short circuit in starting switch C system) is displayed Caution
Remedy
1 • Connect T-adapter to CN-4. • Turn starting switch ON.
NO
Is voltage between CN-4 (2) and chassis ground below 1 V?
YES
Defective engine controller
Replace
Defective starting switch
Replace
Short circuit with power source in wiring harness between CN-4 (female) (2) - starting switch terminal C
Repair or replace
2 • Disconnect starting switch terminal C. • Turn starting switch ON.
Is voltage between starting switch terminal C and chassis ground below 1 V?
YES
NO
G-31. Related electrical circuit diagram
D155AX-5
20-851 4
TROUBLESHOOTING
20-852 4
(Blank page)
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF HSS CONTROLLER AND ELECTRICAL SYSTEM (E MODE) [Serial No. 75001 and up] Action taken by controller when abnormality occurs and problems on machine .......................... 20-902 Electrical circuit diagram for E mode .................................................................................................. 20-910 E-1. [E0113] (Drop of HSS controller power supply voltage) is displayed ................................... 20-912 E-2. [E0143] (Abnormality in HSS controller 5V power supply voltage) is displayed ................. 20-913 E-3. [E0145] (Abnormality in HSS controller sensor power supply voltage) is displayed .......... 20-914 E-4. [E0161] (Abnormality in HSS controller memory data of offset current) is displayed ........ 20-915 E-5. [E0221] (Abnormality in gear speed switch system) is displayed ......................................... 20-916 E-6. [E0233] (Short circuit in travel REVERSE sensing potentiometer system) is displayed ...... 20-917 E-7. [E0233] (Disconnection in travel REVERSE sensing potentiometer system) is displayed ... 20-918 E-8. [E0237] (Abnormality in transmission NEUTRAL signal) is displayed .................................. 20-920 E-9. [E0272] (Unequality between travel REVERSE sensing potentiometer signal and backup alarm switch signal) is displayed .................................................................. 20-921 E-10. [E0360] (Disconnection in work equipment oil pressure sensor system) is displayed ........ 20-923 E-11. [E0361] (Short circuit in work equipment oil pressure sensor system) is displayed ........... 20-924 E-12. [E0610] (Disconnection in backup alarm relay system) is displayed ..................................... 20-925 E-13. [E0611] (Short circuit in backup alarm relay system) is displayed ........................................ 20-926 E-14. [E0730] (Abnormality in both steering potentiometer systems 1 and 2) is displayed ........ 20-927 E-15. [E0731] (Large difference between steering potentiometer systems 1 and 2: Case I) is displayed ...................................................................................................................... 20-928 E-16. (Abnormality in steering potentiometer system on one side and large deviation of neutral position on one side) is displayed ....................................... 20-929 E-17. [E0733] (Disconnection in steering potentiometer system 1) is displayed ........................... 20-930 E-18. [E0733] (Short circuit in steering potentiometer system 1) is displayed .............................. 20-931 E-19. [E0734] (Disconnection in steering potentiometer system 2) is displayed ........................... 20-932 E-20. [E0734] (Short circuit in steering potentiometer system 2) is displayed .............................. 20-933 E-21. [E0735] (Large difference between steering potentiometer systems 1 and 2: Case II) is displayed ....................................................................................................................... 20-934 E-22. [E0768] (Disconnection in steering oil pressure sensor A system) is displayed .................. 20-935 E-23. [E0769] (Short circuit in steering oil pressure sensor A system) is displayed ..................... 20-936 E-24. [E0770] (Disconnection in steering oil pressure sensor B system) is displayed .................. 20-937 E-25. [E0771] (Short circuit in steering oil pressure sensor B system) is displayed ..................... 20-938 E-26. [E0772] (Disconnection in HSS pump solenoid A system) is displayed ............................... 20-939 E-27. [E0773] (Short circuit in HSS pump solenoid A system) is displayed .................................. 20-940 E-28. [E0774] (Disconnection in HSS pump solenoid B system) is displayed................................ 20-941 E-29. [E0775] (Short circuit in HSS pump solenoid B system) is displayed ................................... 20-942 E-30. [E0930] (Abnormality in engine speed sensor system) is displayed ..................................... 20-943 E-31. Backup alarm does not sound ................................................................................................... 20-944 E-32. Blade pitch malfunctions (Machine equipped with pitch dozer) ............................................ 20-945 E-33. Ripper pin puller malfunctions (Machine equipped with giant ripper) ................................. 20-947 E-34. Engine does not start (Engine does not rotate) ....................................................................... 20-949
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.
D155AX-5
20-901 4
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Error code
Abnormal system
Drop of HSS E0113 controller power supply voltage
Nature of abnormality
Condition when normal (voltage, current, resistance)
ª When controller power source voltage lowers below 17 V • Voltage between CN-ST1 (8), (18) - (9), 1. Disconnection or defective contact in wiring harness between (19): 20 - 30 V controller CN-ST1 (8), (18) - fuse 5 2. Disconnection or defective contact in wiring harness between CN-ST1 (9), (19) - chassis ground 3. Lowering of battery voltage or defective fuse 5 4. Defective HSS controller
ª When source voltage of 5 V for HSS controller sensor lowers • Voltage between CN-ST2 (10) - CN-RSS below 4.5 V or rises above 5.5 V (3): 4.5 - 5.5 V Abnormality in 1. Disconnection or defective contact in wiring harness between • Voltage between CN-ST2 (10) - CN-STR HSS controller CN-RSS (1) - CN-ST2 (10) (4): 4.5 - 5.5 V E0143 5V power 2. Disconnection or defective contact in wiring harness between supply CN-STR (4) - CN-ST2 (10) 3. Defective HSS controller ª When source voltage for HSS controller sensor lowers below • Voltage between CN-ST1 (13) - (9), (19): Abnormality in 17 V 17 - 30 V E0145 HSS controller 1. Disconnection or defective contact in wiring harness between sensor power CN-ST (13) - (9), (19) supply 2. Defective HSS controller Abnormality in ª When offset current determined by neutral adjustment of steer- • When starting switch is turned OFF, offing system cannot be saved in non-volatile memory set current is saved in non-volatile E0161 memory data of 1. Defective HSS controller memory. offset current Abnormality in E0221 gear speed switch system
1. Abnormality in signal of switch used to display gear speed on • Set joystick in 3rd or 2nd gear speed position. monitor panel 3rd or 2nd gear speed: 20 - 30 V • Set joystick in 1st or 2nd gear speed position. 1st or 2nd gear speed: 20 - 30 V
ª When signal voltage of sensing potentiometer rises above • Voltage between CN-ST3 (10) - CN-ST2 4.700 V (9) Short circuit in When joystick is in neutral: Max. 3.500 V travel REVERSE 1. Defective reverse sensing potentiometer 2. Disconnection or defective contact in wiring harness between When joystick is in reverse position: 3.500 E0233 sensing controller CN-ST2 (9) - potentiometer CN-RSS (3) - 4.400 V potentiometer 3. Short circuit with power source in wiring harness between system controller CN-ST3 (10) - potentiometer CN-RSS (2) 4. Defective HSS controller ª When signal voltage of sensing potentiometer lowers below • Voltage between CN-ST3 (10) - CN-ST2 0.300 V (9) 1. Defective reverse sensing potentiometer When joystick is in neutral: Max. 3.500 V 2. Disconnection, defective contact, or short circuit with chassis When joystick is in reverse position: 3.500 ground in wiring harness between controller CN-ST3 (10) - 4.400 V potentiometer CN-RSS (2) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-ST2 (10) potentiometer CN-RSS (1) • Voltage between CN-6 (1) - chassis 1. Defective HSS controller Abnormality in ground: 18 - 30 V 2. Defective engine controller transmission E0237 3. Disconnection or defective contact in wiring harness between • Voltage between CN-ST3 (6) - chassis NEUTRAL signal ground: 18 - 30 V CN-6 (1), (5) - CN-ST3 (6), (4) Disconnection in travel E0233 REVERSE sensing potentiometer system
Unequality of travel REVERSE sensing E0272 potentiometer signal and backup alarm switch signal
ª When reverse sensing potentiometer and backup alarm switch • When joystick is in neutral signal do not conform to each other Voltage between CN-ST3 (10) - CN-ST2 1. When error code [E0233] is displayed (9): Max. 3.500 V 2. Defective backup alarm switch Voltage between CN-ST2 (7) - (9): 20 - 30 V 3. Disconnection, defective contact, or short circuit with chassis • When joystick is in reverse position ground in wiring harness between controller CN-ST2 (7) Voltage between CN-ST3 (10) - CN-ST2 backup alarm switch CN-25 (3) (9): Max. 3.500 - 4.400 V 4. Disconnection or defective contact in wiring harness between Voltage between CN-ST2 (7) - (9): Max. 1 V backup alarm switch CN-25 (3) - chassis ground 5. Defective HSS controller
Disconnection in work E0360 equipment oil pressure sensor system
ª When signal voltage of work equipment circuit oil pressure • Voltage between CN-ST3 (2) - CN-ST2 (9) sensor lowers below 0.500 V When all work equipment is in neutral: 1. Defective work equipment circuit oil pressure sensor 0.90 - 1.20 V 2. Disconnection or defective contact in wiring harness between When blade is raised to relief: 2.45 - 2.90 V CN-S51 (13) - oil pressure sensor CN-HHP (2) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-ST3 (2) oil pressure sensor CN-HHP (3) 4. Defective HSS controller
20-902 4
D155AX-5
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
1. Stops all outputs.
1. Machine cannot be steered.
1. Cannot repair (Internal trouble of controller).
1. Machine may deviate from straight travel line.
1. Outputs error code and display "– –" on panel.
1. Gear speed is not displayed on monitor panel.
1. Controls with signal of backup alarm switch. 2. Flashes warning lamp and sounds warning buzzer.
1. Machine can be driven and steered normally.
1. Controls with signal of backup alarm switch. 2. Flashes warning lamp and sounds warning buzzer.
1. Machine can be driven and steered normally.
1. Controls with signal of backup alarm switch, if error code [E0233] is displayed. 2. Controls with signal of reverse sensing potentiometer, if error code [E0233] is not displayed. 3. Flashes warning lamp and sounds warning buzzer.
1. Machine can be driven and steered normally.
1. If machine is steered when work equipment is relieved, engine 1. Calculates with work equipment oil pressure at 0. may stall. 2. Cannot limit inclination angle of HSS pump when work equip2. Only travel and steering operations can be executed normally. ment is relieved.
D155AX-5
20-903 4
TROUBLESHOOTING
Error code
Abnormal system
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Nature of abnormality
Condition when normal (voltage, current, resistance)
Short circuit in work equipE0361 ment oil pressure sensor system
ª When signal voltage of oil pressure sensor B rises above 6.000 V • Voltage between CN-ST3 (2) - CN-ST2 (9) 1. Defective work equipment circuit oil pressure sensor When all work equipment is in neutral: 2. Short circuit with power source in wiring harness between 0.90 - 1.20 V When blade is raised to relief: 2.45 - 2.90 V controller CN-ST3 (2) - oil pressure sensor CN-HHP (3) 3. Disconnection or defective contact in wiring harness between controller CN-ST2 (9) - oil pressure sensor CN-HHP (1) 4. Defective HSS controller
Disconnection in backup E0610 alarm relay system
1. Defective backup alarm relay • Voltage between CN-ST1 (11) - chassis 2. Disconnection or defective contact in wiring harness between ground controller CN-ST1 (11) - relay CN-014 (1) When joystick is in neutral: Max. 1 V 3. Disconnection or defective contact in wiring harness between When joystick is in reverse position: 20 relay CN-014 (2) - chassis ground 30 V 4. Defective HSS controller
Short circuit in backup E0611 alarm relay system
• Voltage between CN-ST1 (11) - chassis 1. Defective backup alarm relay ground 2. Short circuit with chassis ground in harness between controlWhen joystick is in neutral: Max. 1 V ler CN-ST (11) - relay CN-014 (1) When joystick is in reverse position: 20 - 30 V 3. Defective HSS controller
Abnormality in both E0730 steering potentiometer systems 1 and 2
ª When signal voltages of steering potentiometer systems 1 and • Voltage between CN-ST2 (19) - (9) (System 1) When steering system is in neutral: 2.4 - 2.6 V 2 lower to 0.500 V or rise to 4.500 V at same time When steering system is turned to left end: 4.1 - 4.3 V When steering system is turned to right end: 0.73 - 0.89 V • Voltage between CN-ST2 (20) - (9) (System 2) When steering system is in neutral: 2.4 - 2.6 V When steering system is turned to left end: 0.6 - 1.1 V When steering system is turned to right end: 3.9 - 4.4 V • Sum of signal voltages of above systems 1 and 2 (VSUM) 4.6 V < VSUM < 5.4 V
Large difference between E0731 steering potentiometer systems 1 and 2I
ª If both potentiometers are normal when starting switch is • Voltage between CN-ST2 (19) - (9) (System 1) turned ON but sum of signal voltages (VSUM) of potentiometer When steering system is in neutral: 2.4 - 2.6 V system 1 and potentiometer system 2 goes out of following When steering system is turned to left end: range afterward 4.1 - 4.3 V When steering system is turned to right end: 1. Defective steering potentiometer 2. Defective HSS controller 0.73 - 0.89 V • Voltage between CN-ST2 (20) - (9) (System 2) When steering system is in neutral: 2.4 - 2.6 V When steering system is turned to left end: 0.6 - 1.1 V When steering system is turned to right end: 3.9 - 4.4 V • Sum of signal voltages of above systems 1 and 2 (VSUM) 4.6 V < VSUM < 5.4 V
Abnormality in steering potentiometer system of one E0732 side and large deviation of neutral position
ª If both steering potentiometer systems have following abnor- • Voltage between CN-ST2 (19) - (9) (System 1) When steering system is in neutral: 2.4 - 2.6 V malities when starting switch is turned on When steering system is turned to left end: 1) Disconnection, defective contact, or short circuit in one sys4.1 - 4.3 V tem When steering system is turned to right end: 2) Large deviation of neutral position of one system (2.3 V < Signal 0.73 - 0.89 V voltage < 2.7 V) • Voltage between CN-ST2 (20) - (9) (System 2) 1. Defective steering potentiometer When steering system is in neutral: 2.4 - 2.6 V 2 Defective HSS controller When steering system is turned to left end: 0.6 - 1.1 V When steering system is turned to right end: 3.9 - 4.4 V • Sum of signal voltages of above systems 1 and 2 (VSUM) 4.6 V < VSUM < 5.4 V
Disconnection E0733 in steering potentiometer system 1
ª When signal voltage of steering potentiometer 1 rises above • Voltage between CN-ST2 (19) - (9) When steering system is in neutral: 2.4 - 2.6 V 4.500 V When steering system is turned to left end: 1. Defective potentiometer 4.1 - 4.3 V 2. Disconnection, defective contact, or short circuit with power When steering system is turned to right end: source in wiring harness between controller CN-ST2 (19) 0.73 - 0.89 V potentiometer CN-STR (3) 3. Disconnection or defective contact in wiring harness between controller CN-ST2 (9) - potentiometer CN-STR (1) 4. Defective HSS controller
20-904 4
D155AX-5
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
1. If machine is steered when work equipment is relieved, engine 1. Calculates with work equipment oil pressure at 0. may stall. 2. Cannot limit inclination angle of HSS pump when work equip2. Only travel and steering operations can be executed normally. ment is relieved.
1. Does not take particular action.
1. Backup alarm does not sound.
1. Stops outputting to backup alarm relay.
1. Backup alarm does not sound.
1. Controls with signal before occurrence of abnormality until 1. Steering operation before occurrence of abnormality is continued until machine is stopped. machine is stopped. 2. Machine cannot be steered once it is stopped. 2. Flashes warning lamp and sounds warning buzzer.
1. Controls with signal before occurrence of abnormality until 1. Steering operation before occurrence of abnormality is continued until machine is stopped. machine is stopped. 2. Flashes warning lamp and sounds warning buzzer. 2. Machine cannot be steered once it is stopped.
1. Controls with signal before occurrence of abnormality until ma- 1. Steering operation before occurrence of abnormality is continued chine is stopped. until machine is stopped. 2. Flashes warning lamp and sounds warning buzzer. 2. Machine cannot be steered once it is stopped.
1. Controls with signal of steering potentiometer system 2. 2. Flashes warning lamp and sounds warning buzzer.
D155AX-5
1. Machine can be driven and steered normally.
20-905 4
TROUBLESHOOTING
Error code
Abnormal system
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Nature of abnormality
Condition when normal (voltage, current, resistance)
Short circuit in steering E0733 potentiometer system 1
ª When signal voltage of steering potentiometer 1 lowers below • Voltage between CN-ST2 (19) - (9) When steering system is in neutral: 0.500 V 2.4 - 2.6 V 1. Defective potentiometer When steering system is turned to left end: 2. Disconnection, defective contact, or short circuit with chassis 4.1 - 4.3 V ground in wiring harness between CN-ST2 (10) - potentiometer When steering system is turned to right end: CN-STR (4) 0.73 - 0.89 V 3. Short circuit with chassis ground in harness between controller CN-ST2 (19) - potentiometer CN-STR (3) 4. Defective HSS controller
Disconnection in steering E0734 potentiometer system 2
ª When signal voltage of steering potentiometer 2 rises above • Voltage between CN-ST2 (20) - (9) 4.500 V When steering system is in neutral: 1. Defective potentiometer 2.4 - 2.6 V 2. Disconnection, defective contact, or short circuit with power When steering system is turned to left end: source in wiring harness between controller CN-ST2 (20) 0.6 - 1.1 V potentiometer CN-STR (2) When steering system is turned to right end: 3. Disconnection or defective contact in wiring harness between 3.9 - 4.4 V controller CN-ST2 (9) - potentiometer CN-STR (1) 4. Defective HSS controller
Short circuit in steering E0734 potentiometer system 2
ª When signal voltage of steering potentiometer 2 lowers below 0.500 V 1. Defective potentiometer 2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-ST2 (10) - potentiometer CN-STR (4) 3. Short circuit with chassis ground in harness between controller CN-ST2 (20) - potentiometer CN-STR (2) 4. Defective HSS controller
Large difference between signal values E0735 of steering potentiometer systems 1 and 2 II
• Voltage between CN-ST2 (20) - (9) When steering system is in neutral: 2.4 - 2.6 V When steering system is turned to left end: 0.6 - 1.1 V When steering system is turned to right end: 3.9 - 4.4 V
ª If sum of signal voltages (VSUM) of potentiometer system 1 • Voltage between CN-ST2 (19) - (9) (System 1) When steering system is in neutral: 2.4 - 2.6 V and potentiometer system 2 goes out of following range when When steering system is turned to left end: starting switch is turned on 4.1 - 4.3 V 4.41 V < VSUM < 5.59 V When steering system is turned to right end: 1. Defective steering potentiometer 0.73 - 0.89 V 2. Defective HSS controller • Voltage between CN-ST2 (20) - (9) (System 2) When steering system is in neutral: 2.4 - 2.6 V When steering system is turned to left end: 0.6 - 1.1 V When steering system is turned to right end: 3.9 - 4.4 V • Sum of signal voltages of above systems 1 and 2 (VSUM) 4.6 V < VSUM < 5.4 V
Disconnection in steering oil E0768 pressure sensor A system
ª When signal voltage of oil pressure sensor A lowers below 0.500 V 1. Defective steering oil pressure sensor A 2. Disconnection or defective contact in wiring harness between CN-ST1 (13) - oil pressure sensor CN-ST1 (2) 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-ST3 (1) - oil pressure sensor CN-ST1 (3) 4. Defective HSS controller
Short circuit in steering oil E0769 pressure sensor A system
ª When signal voltage of oil pressure sensor A rises above • Voltage between CN-ST3 (1) - CN-ST2 (9) 6.000 V When steering system is in neutral: 1. Defective steering oil pressure sensor A 0.90 - 1.50 V 2. Short circuit with power source in wiring harness between When steering system is relieved (on right controller CN-ST3 (1) - oil pressure sensor CN-ST1 (3) or left side): 3.95 - 4.60 V 3. Disconnection or defective contact in wiring harness between controller CN-ST2 (9) - oil pressure sensor CN-ST1 (1) 4. Defective HSS controller
Disconnection in steering oil E0770 pressure sensor B system
ª When signal voltage of oil pressure sensor B lowers below • Voltage between CN-ST3 (9) - CN-ST2 (9) 0.500 V When steering system is in neutral: 1. Defective steering oil pressure sensor B 0.90 - 1.50 V 2. Disconnection or defective contact in wiring harness between When steering system is relieved (on right CN-ST1 (13) - oil pressure sensor CN-ST2 (2) or left side): 3.95 - 4.60 V 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-ST3 (9) - oil pressure sensor CN-ST2 (3) 4. Defective HSS controller
20-906 4
• Voltage between CN-ST3 (1) - CN-ST2 (9) When steering system is in neutral: 0.90 - 1.50 V When steering system is relieved (on right or left side): 3.95 - 4.60 V
D155AX-5
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
1. Controls with signal of steering potentiometer system 2. 2. Flashes warning lamp and sounds warning buzzer.
1. Machine can be driven and steered normally.
1. Controls with signal of steering potentiometer system 1. 2. Flashes warning lamp and sounds warning buzzer.
1. Machine can be driven and steered normally.
1. Controls with signal of steering potentiometer system 1. 2. Flashes warning lamp and sounds warning buzzer.
1. Machine can be driven and steered normally.
1. Controls with signal before occurrence of abnormality until 1. Steering operation before occurrence of abnormality is continued until machine is stopped. machine is stopped. 2. Machine cannot be steered once it is stopped. 2. Flashes warning lamp and sounds warning buzzer.
1. Calculates with steering circuit oil pressure at 0. 1. If machine is steered under heavy load, engine may stall. 2. Cannot limit inclination angle of HSS pump when steering 2. Machine is steered normally under light load. circuit pressure is high or steering circuit is relieved. 3. Flashes warning lamp and sounds warning buzzer.
1. Calculates with steering circuit oil pressure at 0. 1. If machine is steered under heavy load, engine may stall. 2. Cannot limit inclination angle of HSS pump when steering cir- 2. Machine is steered normally under light load. cuit pressure is high or steering circuit is relieved. 3. Flashes warning lamp and sounds warning buzzer.
1. Calculates with steering circuit oil pressure at 0. 1. If machine is steered under heavy load, engine may stall. 2. Cannot limit inclination angle of HSS pump when steering cir- 2. Machine is steered normally under light load. cuit pressure is high or steering circuit is relieved. 3. Flashes warning lamp and sounds warning buzzer.
D155AX-5
20-907 4
TROUBLESHOOTING
Error code
Abnormal system
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Nature of abnormality
Condition when normal (voltage, current, resistance)
Short circuit in steering oil E0771 pressure sensor B system
ª When signal voltage of oil pressure sensor B rises above 6.000 V • Voltage between CN-ST3 (9) - CN-ST2 (9) 1. Defective steering oil pressure sensor B When steering system is in neutral: 2. Short circuit with power source in wiring harness between 0.90 - 1.50 V controller CN-ST3 (9) - oil pressure sensor CN-ST2 (3) When steering system is relieved (on right 3. Disconnection or defective contact in wiring harness between or left side): 3.95 - 4.60 V controller CN-ST2 (9) - oil pressure sensor CN-ST2 (1) 4. Defective HSS controller
Disconnection in HSS pump E0772 solenoid A system
1. Defective HSS pump solenoid A 2. Disconnection or defective contact in wiring harness between controller CN-ST1 (4) - solenoid CN-PUPA (1) 3. Disconnection or defective contact in wiring harness between controller CN-ST1 (15) - solenoid CN-PUPA (2) 4. Defective HSS controller
• Resistance between CN-PUPA (male) (1) - (2): 10 - 20 Ω • Between CN-ST1 (female) (4) - (15): 10 - 20 Ω • Display of LED when starting switch is turned on (under normal condition) • When machine is steered to right or left end: 93 - 94 (Output current: 930 - 940 mA)
Short circuit in E0773 HSS pump solenoid A system
1. Defective HSS pump solenoid A 2. Short circuit with chassis ground in harness between controller CN-ST1 (4) - solenoid CN-PUPA (1) 3. Short circuit with power source in wiring harness between controller CN-ST1 (15) - solenoid CN-PUPA (2) 4. Defective HSS controller
• Resistance between CN-PUPA (male) (1) (2): 10 - 20 Ω • Between CN-ST1 (female) (4) - (15): 10 - 20 Ω • Display of LED when starting switch is turned on (under normal condition) • When machine is steered to right or left end: 93 - 94 (Output current: 930 - 940 mA)
Disconnection in HSS pump E0774 solenoid B system
• Resistance between CN-PUPB (male) (1) 1. Defective HSS pump solenoid B (2): 10 - 20 Ω 2. Disconnection or defective contact in wiring harness between • Between CN-ST1 (female) (4) - (15): controller CN-ST1 (5) - solenoid CN-PUPB (1) 10 - 20 Ω 3. Disconnection or defective contact in wiring harness between • Display of LED when starting switch is controller CN-ST1 (15) - solenoid CN-PUPB (2) turned on (under normal condition) 4. Defective HSS controller • When machine is steered to right or left end: 93 - 94 (Output current: 930 - 940 mA)
Short circuit in HSS pump E0775 solenoid B system
Abnormality in engine E0930 speed sensor system
20-908 4
1. Defective HSS pump solenoid B 2. Short circuit with chassis ground in harness between controller CN-ST1 (5) - solenoid CN-PUPB (1) 3. Short circuit with power source in wiring harness between controller CN-ST1 (15) - solenoid CN-PUPB (2) 4. Defective HSS controller
• Resistance between CN-PUPB (male) (1) (2): 10 - 20 Ω • Between CN-ST1 (female) (4) - (15): 10 - 20 Ω • Display of LED when starting switch is turned on (under normal condition) • When machine is steered to right or left end: 93 - 94 (Output current: 930 - 940 mA)
1. Abnormality in engine speed sensor 2. Defective installation of engine speed sensor 3. Disconnection or defective contact in wiring harness between controller CN-ST3 (4) - speed sensor CN-E07 (1) 4. Disconnection, defective contact, or short circuit with chassis ground in wiring harness between controller CN-ST3 (12) speed sensor CN-E07 (2) 5. Defective HSS controller
• Resistance between CN-E07 (male) (1) (2): 500 - 1,000 Ω • Resistance between CN-ST3 (female) (4) - (12): 500 - 1,000 Ω
D155AX-5
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected 1. Calculates with steering circuit oil pressure at 0. 2. Cannot limit inclination angle of HSS pump when steering circuit pressure is high or steering circuit is relieved. 3. Flashes warning lamp and sounds warning buzzer.
Problem that appears on machine when there is abnormality 1. If machine is steered under heavy load, engine may stall. 2. Machine is steered normally under light load.
1. Since current does not flow in solenoid, inclination angle of 1. Machine cannot be steered to left (can be steered to right norHSS pump becomes 0. mally, however). 2. Flashes warning lamp and sounds warning buzzer.
1. Since outputting to solenoid is stopped, inclination angle of HSS pump becomes 0. 2. Flashes warning lamp and sounds warning buzzer.
1. Machine cannot be steered to left (can be steered to right normally, however).
1. Since current does not flow in solenoid, inclination angle of 1. Machine cannot be steered to right (can be steered to left norHSS pump becomes 0. mally, however). 2. Flashes warning lamp and sounds warning buzzer.
1. Since outputting to solenoid is stopped, inclination angle of 1. Machine cannot be steered to right (can be steered to left norHSS pump becomes 0. mally, however). 2. Flashes warning lamp and sounds warning buzzer.
1. Calculates with engine speed at 0 rpm. 1. Machine can be driven and steered normally. 2. Cannot control inclination angle of HSS pump when engine 2. If machine is steered frequently while traveling down slope, speed is high. durability of HSS motor may be lowered. 3. Neutral position of steering cannot be adjusted.
D155AX-5
20-909 4
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE HSS control system
20-910 4
D155AX-5
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
Engine starting system
Blade pitch solenoid and ripper pin puller solenoid system
D155AX-5
20-911 4
TROUBLESHOOTING
E-1.
E-1
[E0113] (Drop of HSS controller power supply voltage) is displayed
ª This error code is displayed when the source voltage for the controller lowers below 17 V. fl Check that fuse 5 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Cause
Remedy
1 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-ST1 (8), (18) and (9), (19) normal?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Disconnection or defective contact in wiring harness between CN-ST1 (female) (9), (19) - chassis ground
Repair or replace
Defective fuse box power source circuit or lowering of battery voltage
Repair or replace
Defective fuse, or disconnection or defective contact in wiring harness between outlet of fuse 5 - CN-ST1 (female) (8), (18)
Repair or replace
YES
2 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-ST1 (8), (18) and chassis ground normal?
YES
3 • Remove fuse 5. • Turn starting switch ON. • 20 - 30 V
Is voltage between inlet of fuse 5 and chassis ground normal?
YES
NO
E-1. Related electrical circuit diagram
20-912 4
D155AX-5
TROUBLESHOOTING
E-2. ª
E-2
[E0143] (Abnormality in HSS controller 5V power supply voltage) is displayed
This error code is displayed when the source voltage of 5 V for the controller sensor lowers below 4.5 V or rises above 5.5 V.
Cause
Remedy
1 • Disconnect CN-ST2. • Turn starting switch ON. • 4.5 - 5.5 V
Defective HSS controller
Replace (Adjust neutral position of steering system)
NO
Disconnection or defective contact in wiring harness between CN-RSS (1) CN-ST2 (10)
Repair or replace
NO
Disconnection or defective contact in wiring harness between CN-STR (4) CN-ST2 (10)
Repair or replace
NO
Is voltage between CN-ST2 (9) and (10) normal?
YES 2 • Disconnect CN-RSS. • Turn starting switch ON. • 4.5 - 5.5 V
Is voltage between CN-RSS (1) and (3) normal?
YES 3 • Disconnect CN-STR. • Turn starting switch ON. • 4.5 - 5.5 V
Is voltage between CN-STR (1) and (4) normal?
YES Restart and check that error does not occur.
E-2. Related electrical circuit diagram
D155AX-5
20-913 4
TROUBLESHOOTING
E-3. ª
E-3
[E0145] (Abnormality in HSS controller sensor power supply voltage) is displayed
This error code is displayed when the source voltage of 5 V for the controller sensor lowers below 4.5 V or rises above 5.5 V.
Cause
Remedy
1 NO
Does HSS controller display error code [E0113]?
YES
Go to troubleshooting of displayed error code
2 • Disconnect CN-ST1. • Turn starting switch ON. • 17 - 30 V
Is voltage between CN-ST1 (13) and (9), (19) normal?
NO
Defective HSS controller
Replace (Adjust neutral position of steering system)
YES Restart and check that error does not occur.
E-3. Related electrical circuit diagram
20-914 4
D155AX-5
TROUBLESHOOTING
E-4. ª
E-4
[E0161] (Abnormality in HSS controller memory data of offset current) is displayed
This error code is displayed when the offset current cannot be saved in the memory for an internal trouble of the controller.
Cause
Remedy
1 • Start engine. • On level ground. • Travel at F1.
Does machine deviate while traveling with steering system in neutral?
NO
Defective HSS controller
Replace next time (See Note 2)
Defective HSS controller
Replace immediately (See Note 1)
YES
Note 1: If the machine deviates, it must be corrected by "Adjusting the neutral position of the steering system". If this error occurs, however, the offset current after adjustment cannot be memorized. Accordingly, replace the HSS controller with new one and carry out adjustment. Note 2: Since the machine does not deviate, it can be used as it is for the present. Replace the HSS controller, however, at the earliest chance as a permanent action. (After replacing the controller, be sure to "Adjust the neutral position of the steering system".)
D155AX-5
20-915 4
TROUBLESHOOTING
E-5. ª
E-5
[E0221] (Abnormality in gear speed switch system) is displayed
This error code is displayed when the information on the limit switches on the power train is abnormal. Cause Remedy 1 NO
Is resistance of each switch as shown in table?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Limit switches 1st and 3rd are connected reversely.
Repair or replace
Short circuit with chassis ground in wiring harness between CN-1ST (3), CN2ND (3) - CN-ST2 (13), (14)
Repair or replace
Reconnect and check
Repair or replace
Disconnection in wiring harness between CN-1ST (3) - CN-2ND (3), defective installation of limit switch, or defective limit switch
Repair or replace
YES
2 • Turn starting switch ON.
Are 1st and 3rd reversed? (Are gear NO speeds displayed on monitor panel reversed?)
YES
3 NO
Is resistance of both 1st and 3rd below 1 Ω respectively?
YES
4 Is resistance of both 1st and 3rd above 100 Ω respectively?
NO
YES
Table Location
Between ST2 (13) – GND
Between ST2 (14) – GND
1st
Max 1Ω
Min. 100 Ω
2nd
Min. 100 Ω
Min. 100 Ω
3rd
Min. 100 Ω
Max 1Ω
E-5. Related electrical circuit diagram
20-916 4
D155AX-5
TROUBLESHOOTING
E-6.
E-6
[E0233] (Short circuit in travel REVERSE sensing potentiometer system) is displayed
ª
This error code is displayed when the input signal from the reverse sensing potentiometer rises above 4.7 V. fl Check that the reverse sensing potentiometer is adjusted normally before troubleshooting. Cause
Remedy
1 • Turn starting switch ON.
NO
Is voltage between CN-ST3 (10) and CN-ST2 (9) as shown in table 1?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Defective reverse sensing potentiometer
Replace
Short circuit with power source in wiring harness between CN-ST3 (female) (10) CN-RSS (female) (2)
Repair or replace
YES
2 • Turn starting switch OFF. • Disconnect CN-RSS.
Is resistance between CN-RSS (male) NO (1) and (2) and between (1) and (3) as shown in Table 2?
YES 3 • Disconnect CN-RSS. • Turn starting switch ON. • Max. 1 V
When CN-RSS is disconnected, is voltage between CN-ST3 (female) (10) and chassis ground normal?
YES
NO
Disconnection or defective contact in wiring harness between CN-ST2 (female) Repair or replace (9) - CN-RSS (3)
Table 2
Table 1 CN-ST3, CN-ST2
Forward/Reverse
Voltage
CN-RSS (male)
Resistance
Between CN-ST3 (10) – CN-ST2 (9)
In neutral
Max. 3.5 V
Between (1) – (2)
0.3 – 5.7 kΩ
Reverse
3.5 – 4.4 V
Between (2) – (3)
4 – 6 kΩ
E-6. Related electrical circuit diagram
D155AX-5
20-917 4
TROUBLESHOOTING
E-7.
E-7
[E0233] (Disconnection in travel REVERSE sensing potentiometer system) is displayed
ª
This error code is displayed when the input signal from the reverse sensing potentiometer lowers below 0.300 V. fl Check that the reverse sensing potentiometer is adjusted normally before troubleshooting. Cause
Remedy
1
• Turn starting switch ON.
NO
Is voltage between CN-ST3 (10) and CN-ST2 (9) as shown in table 1?
Defective HSS controller
Replace (Adjust neutral position of steering system)
NO
Defective reverse sensing potentiometer
Replace
NO
Short circuit with chassis ground in wiring harness between CN-ST3 (female) (10) - CN-RSS (female) (2)
Repair or replace
NO
Disconnection or defective contact in wiring harness between CN-ST3 (female) (10) - CN-RSS (female) (2)
Repair or replace
NO
Short circuit with chassis ground in Repair or wiring harness between CN-ST2 (female) replace (10) - CN-RSS (female) (1)
YES
2 • Turn starting switch OFF. • Disconnect CN-RSS.
Is resistance between CN-RSS (male) (1) and (2) and between (1) and (3) as shown in Table 2?
YES 3 • Turn starting switch OFF. • Disconnect CN-RSS and CN-ST3. • Min. 1 MΩ
When CN-RSS is disconnected, is resistance between CN-ST3 (female) (10) and chassis ground normal?
YES 4 • Turn starting switch OFF. • Disconnect CN-RSS and CN-ST3. • Max. 1 Ω
Is resistance between CN-ST3 (female) (10) and CN-RSS (female) (2) normal?
YES 5 • Turn starting switch OFF. • Disconnect CN-RSS and CN-ST3. • Min. 1 MΩ
When CN-RSS is disconnected, is resistance between CN-ST2 (female) (10) and chassis ground normal?
YES
Table 2
Table 1
Between CN-ST3 (10) – CN-ST2 (9)
20-918 4
Disconnection or defective contact in Repair or wiring harness between CN-ST2 (female) replace (10) - CN-RSS (female) (1)
Lever position
Voltage
CN-RSS (male)
Resistance
NEUTRAL
Max. 3.5 V
Between (1) – (2)
0.3 – 5.7 kΩ
REVERSE
3.5 – 4.4 V
Between (2) – (3)
4 – 6 kΩ
D155AX-5
TROUBLESHOOTING
E-7
E-7. Related electrical circuit diagram
D155AX-5
20-919 4
TROUBLESHOOTING
E-8.
E-8
[E0237] (Abnormality in transmission NEUTRAL signal) is displayed Cause
Remedy
1 • Disconnect CN-6. • Turn starting switch ON.
NO
Are voltage between CN-6 (1) and chassis ground and that between CN-6 (5) and chassis ground as shown in table?
YES
Defective engine controller
Replace
Disconnection or short circuit with chassis ground in wiring harness between CN-ST3 (6), (16) - CN-6 (1), (5)
Repair or replace
Defective HSS controller
Replace
2 • Disconnect CN-ST3. • Turn starting switch ON. • 18 - 30 V
Are voltage between CN-ST3 (6) and chassis ground and that between CN-ST3 (14) and chassis ground normal?
NO
YES
Table Transmission F-N signal Transmission R-N signal
When transmission lever is in F or R
When transmission lever is in neutral
Between CN-6 (1) - chassis ground
18 – 30 V
Max. 3 V
Between CN-6 (5) - chassis ground
18 – 30 V
Max. 3 V
E-8. Related electrical circuit diagram
20-920 4
D155AX-5
TROUBLESHOOTING
E-9.
E-9
[E0272] (Unequality between travel REVERSE sensing potentiometer signal and backup alarm switch signal) is displayed
ª
This error code is displayed when the reverse sensing potentiometer does not conform to the input signal of the backup alarm switch. fl Check that the backup alarm switch and reverse sensing potentiometer are adjusted normally before troubleshooting. Cause
Remedy
1
NO
Is error code [E0233] displayed?
YES
Go to troubleshooting of displayed error code 2
• Turn starting switch ON.
NO Is voltage between CN-ST2 (7) and chassis ground as shown in Table 1? Defective HSS controller
Replace (Adjust neutral position of steering system)
Defective backup alarm switch
Replace
YES
3
Is resistance between CN-251 (male) NO (1) and (3) as shown in Table 2?
• Turn starting switch OFF. • Disconnect CN-251.
YES 4 • Turn starting switch OFF. • Disconnect CN-ST2 and CN-251. • Max. 1 Ω
Is resistance between CN-ST2 (female) (7) and CN-251 (female) (3) normal?
NO
Disconnection or defective contact in Repair or wiring harness between CN-ST2 (female) replace (7) - CN-251 (female) (3)
NO
Short circuit with chassis ground in wiring harness between CN-ST2 (female) (7) - CN-251 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between CN-251 (female) (1) - chassis ground
Repair or replace
YES 5 • Turn starting switch OFF. • Disconnect CN-251 and CN-ST2. • Min. 1 MΩ
When CN-251 is disconnected, is resistance between CN-ST2 (male) (7) and chassis ground normal?
YES
Table 1
Table 2
CN-ST2
Forward/Reverse
Voltage
CN-251 (male)
Forward/Reverse
Resistance
Between (7) – chassis
In neutral
20 – 30 V
In neutral
Min. 1 MΩ
Reverse
Max. 1 V
Between (1) – (3) chassis
Reverse
Max. 1 Ω
D155AX-5
20-921 4
TROUBLESHOOTING
E-9
E-9. Related electrical circuit diagram
20-922 4
D155AX-5
TROUBLESHOOTING
E-10
E-10. [E0360] (Disconnection in work equipment oil pressure sensor system) is displayed ª
This error code is displayed when the input signal from the work equipment circuit oil pressure sensor lowers below 0.500 V.
Cause
Remedy
1 • Start engine.
NO
Is voltage between CN-ST3 (2) and CN-ST2 (9) normal?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Disconnection or defective contact in wiring harness between CN-ST1 (13) CN-HHP (female) (2)
Repair or replace
YES
2 • Turn starting switch ON. • 20 - 30V
NO
Is voltage between CN-HHP (2) and chassis ground normal?
YES
• Turn starting switch OFF. • Disconnect CN-ST3 and CN-HHP. • Max. 1 Ω
3 Is resistance between CN-ST3 NO (female) (2) and CN-HHP (female) (3) normal?
Disconnection or defective contact in Repair or wiring harness between CN-ST3 (female) replace (2) - CN-HHP (female) (3)
YES 4 • Turn starting switch OFF. • Disconnect CN-ST3 and CN-HHP. • Min. 1 MΩ
When CN-HHP is disconnected, is resistance between CN-ST3 (2) and chassis ground normal?
YES
NO
Short circuit with chassis ground in wiring harness between CN-ST3 (female) (2) - CN-HHP (female) (3)
Repair or replace
Defective work equipment circuit oil pressure sensor
Replace
Table CN-ST3, CN-ST2 Between CN-ST3 (2) – CN-ST2 (9)
Work equipment circuit
Voltage
In neutral
0.9 – 1.2 V
When relieved
2.45 – 2.90 V
E-10. Related electrical circuit diagram
D155AX-5
20-923 4
TROUBLESHOOTING
E-11
E-11. [E0361] (Short circuit in work equipment oil pressure sensor system) is displayed ª
This error code is displayed when the input signal from the work equipment circuit oil pressure sensor rises above 6.000 V. Cause
Remedy
1 • Start engine.
NO
Is voltage between CN-ST3 (2) and CN-ST2 (9) normal?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Short circuit with power source in wiring harness between CN-ST3 (female) (2) CN-HHP (female) (3)
Repair or replace
YES
2 • Disconnect CN-HHP. • Max. 1 V
When CN-HHP is disconnected, is resistance between CN-ST3 (2) and chassis ground normal?
NO
YES 3 • Turn starting switch OFF. • Disconnect CN-ST2 and CN-HHP. • Max. 1 Ω
Is resistance between CN-ST2 NO (female) (9) and CN-HHP (female) (1) normal?
YES
Disconnection or defective contact in Repair or wiring harness between CN-ST2 (female) replace (9) - CN-HHP (female) (1)
Defective work equipment circuit oil Replace pressure sensor
Table CN-ST3, CN-ST2 Between CN-ST3 (2) – CN-ST2 (9)
Work equipment circuit
Voltage
In neutral
0.9 – 1.2 V
When relieved
2.45 – 2.90 V
E-11. Related electrical circuit diagram
20-924 4
D155AX-5
TROUBLESHOOTING
E-12
E-12. [E0610] (Disconnection in backup alarm relay system) is displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-014. • 200 - 400 Ω
Is resistance between CN-014 (male) NO (1) and (2) normal?
Defective backup alarm relay
Replace
NO
Disconnection or defective contact in wiring harness between CN-014 (female) (2) - chassis ground
Repair or replace
NO
Disconnection or defective contact in wiring harness between CN-ST1 (female) (11) - CN-014 (female) (1)
Repair or replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
YES 2 • Turn starting switch OFF. • Disconnect CN-014. • Max. 1 Ω
Is resistance between CN-014 (female) (2) and chassis ground normal?
YES 3 • Turn starting switch OFF. • Disconnect CN-ST1. • 200 - 400 Ω
Is resistance between CN-ST1 (female) and chassis ground normal?
YES
E-12. Related electrical circuit diagram
D155AX-5
20-925 4
TROUBLESHOOTING
E-13
E-13. [E0611] (Short circuit in backup alarm relay system) is displayed
Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-014. • 200 - 400 Ω
NO
Is resistance between CN-041 (female) (1) and (2) normal?
Defective backup alarm relay
Replace
YES 2 • Turn starting switch OFF. • Disconnect CN-014 and CN-ST1. • Min. 1 MΩ
When CN-014 is disconnected, is resistance between CN-ST1 (female) (11) and chassis ground normal?
NO
Short circuit with chassis ground in Repair or wiring harness between CN-ST1 (female) replace (11) - CN-014 (female) (1)
YES Defective HSS controller
Replace (Adjust neutral position of steering system)
E-13. Related electrical circuit diagram
20-926 4
D155AX-5
TROUBLESHOOTING
E-14
E-14. [E0730] (Abnormality in both steering potentiometer systems 1 and 2) is displayed ª
This error code is displayed when signal voltages from both steering potentiometers are below 0.500 V or above 4.500 V. Cause
Remedy
1 NO
Are error codes [E0733] and [E0734] displayed, too?
YES
Go to troubleshooting of displayed error code
2 • Turn starting switch ON.
Are voltage between CN-ST2 (19) and (9) and that between (20) and (9) as shown in table?
NO
Defective steering potentiometer
Replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
YES
Table CN-ST2 Steering
Steering When fully When fully steered to left steered to right
Between (19) – (9)
2.4 – 2.6 V
4.1 – 4.3 V
0.73 – 0.89 V
Between (20) – (9)
2.4 – 2.6 V
0.6 – 1.1 V
3.9 – 4.4 V
E-14. Related electrical circuit diagram
D155AX-5
20-927 4
TROUBLESHOOTING
E-15
E-15. [E0731] (Large difference between steering potentiometer systems 1 and 2: Case I) is displayed ª
This error code is displayed when the difference between the signal voltages of steering potentiometer systems 1 and 2 becomes large (If the signal voltages are normal when the starting switch is turned on). Cause
Remedy
1 • Turn starting switch ON. • See note. • 4.41 - 5.59 V (VSUM)
Is sum of voltage between CN-ST2 (19) and (9) and that between (20) and (9) normal?
NO
Defective steering potentiometer
Replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
YES
Note: Measure the voltage according to the following procedure. 1) Measure voltage (V1) between CN-ST2 (19) and (9) and voltage (V2) between CN-ST2 (20) and (9). 2) Add up 2 voltages (V1 and V2) to obtain the sum (VSUM). fl The joystick does not move while the voltage is being measured.
E-15. Related electrical circuit diagram
20-928 4
D155AX-5
TROUBLESHOOTING
E-16
E-16. (Abnormality in steering potentiometer system on one side and large deviation of neutral position on one side) is displayed ª
This error code is displayed when 1 steering potentiometer system is abnormal and the neutral position of the other system is deviated.
Cause
Remedy
1 NO
Are error codes [E0733] and [E0734] displayed, too?
YES
Defective HSS controller
Replace (Adjust neutral position of steering system)
Defective steering potentiometer
Replace
2 • Turn starting switch ON.
Are voltage between CN-ST2 (19) and (9) and that between (20) and (9) as shown in table?
NO
YES Go to troubleshooting of displayed error code
E-16. Related electrical circuit diagram
D155AX-5
20-929 4
TROUBLESHOOTING
E-17
E-17. [E0733] (Disconnection in steering potentiometer system 1) is displayed ª
This error code is displayed when the signal voltage from steering potentiometer system 1 rises above 4.500 V. Cause Remedy 1
• Turn starting switch ON.
NO
Is voltage between CN-ST2 (19) and (9) as shown in Table 1?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Defective steering potentiometer
Replace
NO
Disconnection or defective contact in wiring harness between CN-ST2 (female) (19) - CN-STR (female) (3)
Repair or replace
NO
Short circuit with power source in wiring harness between CN-ST2 (female) (19) CN-STR (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between CN-ST2 (female) (9) - CN-STR (female) (1)
Repair or replace
YES
2 • Turn starting switch OFF. • Disconnect CN-STR.
NO
Are resistance between CN-STR (male) (1) and (4), that between (2) and (4), and that between (3) and (4) as shown in Table 2?
YES 3 • Turn starting switch OFF. • Disconnect CN-ST2 and CN-STR. • Max. 1 Ω
Is resistance between CN-ST2 (female) (19) and CN-STR (female) (3) normal?
YES 4 • Disconnect CN-STR. • Turn starting switch ON. • Max. 1 V
When CN-STR is disconnected, is voltage between CN-ST2 (19) and chassis ground normal?
YES
Table 1
Table 2 CN-ST2 In neutral
Between (19) – (9)
2.4 – 2.6 V
Steering When fully When fully steered to left steered to right 4.1 – 4.3 V
0.73 – 0.89 V
CN-STR (male)
Resistance
Between (1) – (4)
2.4 – 4.0 Ω
Between (2) – (4)
5.0 – 8.0 Ω
Between (3) – (4)
5.0 – 8.0 Ω
E-17. Related electrical circuit diagram
20-930 4
D155AX-5
TROUBLESHOOTING
E-18
E-18. [E0733] (Short circuit in steering potentiometer system 1) is displayed ª
This error code is displayed when the signal voltage from steering potentiometer system 1 lowers below 0.500 V. Cause
Remedy
1
• Turn starting switch ON.
NO
Is voltage between CN-ST2 (19) and (9) as shown in Table 1?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Defective steering potentiometer
Replace
NO
Short circuit with chassis ground in wiring harness between CN-ST2 (female) (19) - CN-STR (female) (3)
Repair or replace
NO
Short circuit with chassis ground in Repair or wiring harness between CN-ST2 (female) replace (10) - CN-STR (female) (4)
YES
2 • Turn starting switch OFF. • Disconnect CN-STR.
NO
Are resistance between CN-STR (male) (1) and (4), that between (2) and (4), and that between (3) and (4) as shown in Table 2?
YES 3 • Turn starting switch OFF. • Disconnect CN-STR and CN-ST2. • Min. 1 MΩ
When CN-STR is disconnected, is resistance between CN-ST2 (19) and chassis ground normal?
YES 4 • Turn starting switch OFF. • Disconnect CN-STR and CN-ST2. • Min. 1 MΩ
When CN-STR is disconnected, is resistance between CN-ST2 (female) (10) and chassis ground normal?
YES
Disconnection or defective contact in wiring harness between CN-ST2 (female) (10) - CN-STR (female) (4)
Table 1
Repair or replace
Table 2 CN-ST2 In neutral
Between (19) – (9)
2.4 – 2.6 V
Steering When fully When fully steered to left steered to right 4.1 – 4.3 V
0.73 – 0.89 V
CN-STR (male)
Resistance
Between (1) – (4)
2.4 – 4.0 Ω
Between (2) – (4)
5.0 – 8.0 Ω
Between (3) – (4)
5.0 – 8.0 Ω
E-18. Related electrical circuit diagram
D155AX-5
20-931 4
TROUBLESHOOTING
E-19
E-19. [E0734] (Disconnection in steering potentiometer system 2) is displayed ª
This error code is displayed when the signal voltage from steering potentiometer system 2 rises above 4.500 V. Cause
Remedy
1
• Turn starting switch ON.
NO
Is voltage between CN-ST2 (20) and (9) as shown in Table 1?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Defective steering potentiometer
Replace
NO
Disconnection or defective contact in wiring harness between CN-ST2 (female) (20) - CN-STR (female) (2)
Repair or replace
NO
Short circuit with power source in wiring harness between CN-ST2 (female) (20) CN-STR (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between CN-ST2 (female) (9) - CN-STR (female) (1)
Repair or replace
YES
2 • Turn starting switch OFF. • Disconnect CN-STR.
Are resistance between CN-STR (male) (1) and (4), that between (2) and (4), and that between (3) and (4) as shown in Table 2?
NO
YES 3 • Turn starting switch OFF. • Disconnect CN-ST2 and CN-STR. • Max. 1 Ω
Is resistance between CN-ST2 (female) (20) and CN-STR (female) (2) normal?
YES 4 • Disconnect CN-STR. • Turn starting switch ON. • Max. 1 V
When CN-STR is disconnected, is voltage between CN-ST2 (20) and chassis ground normal?
YES
Table 1
Table 2 CN-ST2 In neutral
Between (20) – (9)
2.4 – 2.6 V
Steering When fully When fully steered to left steered to right 0.6 – 1.1 V
3.9 – 4.4 V
CN-STR (male)
Resistance
Between (1) – (4)
2.4 – 4.0 Ω
Between (2) – (4)
5.0 – 8.0 Ω
Between (3) – (4)
5.0 – 8.0 Ω
E-19. Related electrical circuit diagram
20-932 4
D155AX-5
TROUBLESHOOTING
E-20
E-20. [E0734] (Short circuit in steering potentiometer system 2) is displayed ª
This error code is displayed when the signal voltage from steering potentiometer system 2 lowers below 0.500 V. Cause Remedy 1
• Turn starting switch ON.
NO
Is voltage between CN-ST2 (20) and (9) as shown in Table 1?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Defective steering potentiometer
Replace
Short circuit with chassis ground in wiring harness between CN-ST2 (female) (20) - CN-STR (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between CN-ST2 (female) (10) - CN-STR (female) (4)
Repair or replace
YES
2 • Turn starting switch OFF. • Disconnect CN-STR.
NO
Are resistance between CN-STR (male) (1) and (4), that between (2) and (4), and that between (3) and (4) as shown in Table 2?
YES
• Turn starting switch OFF. • Disconnect CN-STR and CN-ST2. • Min. 1 MΩ
3 When CN-STR is disconnected, is NO resistance between CN-ST2 (20) and chassis ground normal?
YES 4 • Turn starting switch OFF. • Disconnect CN-STR and CN-ST2. • Min. 1 MΩ
When CN-STR is disconnected, is resistance between CN-ST2 (10) and chassis ground normal?
YES
NO
Disconnection or defective contact in Repair or wiring harness between CN-ST2 (female) replace (10) - CN-STR (female) (4)
Table 1
Table 2 CN-ST2 In neutral
Between (20) – (9)
2.4 – 2.6 V
Steering When fully When fully steered to left steered to right 0.6 – 1.1 V
3.9 – 4.4 V
CN-STR (male)
Resistance
Between (1) – (4)
2.4 – 4.0 Ω
Between (2) – (4)
5.0 – 8.0 Ω
Between (3) – (4)
5.0 – 8.0 Ω
E-20. Related electrical circuit diagram
D155AX-5
20-933 4
TROUBLESHOOTING
E-21
E-21. [E0735] (Large difference between steering potentiometer systems 1 and 2: Case II) is displayed ª
This error code is displayed when the difference between the signal voltages of steering potentiometer systems 1 and 2 becomes large (If the signal voltages are normal when the starting switch is turned on). Cause
Remedy
1 • Turn starting switch ON. • See note. • 4.41 - 5.59 V (VSUM)
Is sum of voltage between CN-ST2 (19) and (9) and that between (20) and (9) normal?
NO
Defective steering potentiometer
Replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
YES
Note: Measure the voltage according to the following procedure. 1) Measure voltage (V1) between CN-ST2 (19) and (9) and voltage (V2) between CN-ST2 (20) and (9). 2) Add up 2 voltages (V1 and V2) to obtain the sum (VSUM). fl The joystick does not move while the voltage is being measured.
E-21. Related electrical circuit diagram
20-934 4
D155AX-5
TROUBLESHOOTING
E-22
E-22. [E0768] (Disconnection in steering oil pressure sensor A system) is displayed ª
This error code is displayed when the signal voltage from steering oil pressure sensor A lowers below 0.500 V. Cause Remedy 1
• Turn starting switch OFF and exchange connectors. • Run engine at high speed.
NO
When connector is exchanged with oil pressure sensor B, is [E0773] displayed?
Defective steering oil pressure switch A
Replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-ST1 (13) - CN-ST1 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between CN-ST3 (female) (1) - CN-ST1 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between CN-ST3 (female) (1) - CN-ST1 (female) (3)
Repair or replace
YES 2
• Run engine at high speed.
NO
Is voltage between CN-ST3 (1) and CN-ST2 (9) as shown in table?
YES
3
• Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-ST1 (2) and chassis ground normal?
YES 4 • Turn starting switch OFF. • Disconnect CN-ST1 and CN-ST3. • Min. 1 MΩ
When CN-ST1 is disconnected, is resistance between CN-ST3 (female) (1) and chassis ground normal?
YES
NO
Table CN-ST3, CN-ST2
Steering
Voltage
Between CN-ST3 (1) – CN-ST2 (9)
In neutral
0.9 – 1.5 V
When relieved
0.39 – 4.60 V
E-22. Related electrical circuit diagram
D155AX-5
20-935 4
TROUBLESHOOTING
E-23
E-23. [E0769] (Short circuit in steering oil pressure sensor A system) is displayed ª
This error code is displayed when the signal voltage from steering oil pressure sensor A rises above 6.000 V. Cause
Remedy
1 • Turn starting switch OFF and exchange connectors. • Run engine at high speed.
NO
Defective steering oil pressure switch A
Replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
When CN-ST1 is disconnected, is NO voltage between CN-ST3 (female) (1) and chassis ground normal?
Short circuit with power source in wiring harness between CN-ST3 (female) (1) CN-ST1 (female) (3)
Repair or replace
YES
Disconnection or defective contact in wiring harness between CN-ST2 (female) (9) - CN-ST1 (female) (1)
Repair or replace
When connector is exchanged with oil pressure sensor B, is [E0772] displayed?
YES 2 • Run engine at high speed.
NO
Is voltage between CN-ST3 (1) and CN-ST2 (9) as shown in table?
YES
3 • Disconnect CN-ST1. • Turn starting switch ON. • Max. 1 V
Table CN-ST3, CN-ST2
Steering
Voltage
Between CN-ST3 (1) – CN-ST2 (9)
In neutral
0.9 – 1.5 V
When relieved
3.95 – 4.60 V
E-23. Related electrical circuit diagram
20-936 4
D155AX-5
TROUBLESHOOTING
E-24
E-24. [E0770] (Disconnection in steering oil pressure sensor B system) is displayed ª
This error code is displayed when the signal voltage from steering oil pressure sensor B lowers below 0.500 V. Cause Remedy 1
• Turn starting switch OFF and exchange connectors. • Run engine at high speed.
NO
When connector is exchanged with oil pressure sensor A, is [E0775] displayed?
Defective steering oil pressure switch B
Replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
NO
Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CN-ST1 (13) - CN-ST2 (female) (2)
Repair or replace
NO
Short circuit with chassis ground in wiring harness between CN-ST3 (female) (9) - CN-ST1 (female) (3)
Repair or replace
YES 2
• Run engine at high speed.
NO
Is voltage between CN-ST3 (9) and CN-ST2 (9) as shown in table?
YES
3
• Turn starting switch ON. • 20 - 30 V
Is voltage between CN-ST1 (2) and chassis ground normal?
YES 4 • Turn starting switch OFF. • Disconnect CN-ST2 and CN-ST3. • Min. 1 MΩ
When CN-ST2 is disconnected, is resistance between CN-ST3 (female) (9) and chassis ground normal?
YES
Disconnection or defective contact in Repair or wiring harness between CN-ST3 (female) replace (9) - CN-ST2 (female) (3)
Table CN-ST3, CN-ST2
Steering
Voltage
Between CN-ST3 (9) – CN-ST2 (9)
In neutral
0.9 – 1.5 V
When relieved
3.95 – 4.60 V
E-24. Related electrical circuit diagram
D155AX-5
20-937 4
TROUBLESHOOTING
E-25
E-25. [E0771] (Short circuit in steering oil pressure sensor B system) is displayed ª
This error code is displayed when the signal voltage from steering oil pressure sensor B rises above 6.000 V. Cause
Remedy
1 • Turn starting switch OFF and exchange connectors. • Run engine at high speed.
NO
Defective steering oil pressure switch B
Replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
When CN-ST2 is disconnected, is NO voltage between CN-ST3 (female) (9) and chassis ground normal?
Short circuit with power source in wiring harness between CN-ST3 (female) (9) CN-ST2 (female) (3)
Repair or replace
YES
Disconnection or defective contact in wiring harness between CN-ST2 (female) (9) - CN-ST2 (female) (1)
Repair or replace
When connector is exchanged with oil pressure sensor A, is [E0774] displayed?
YES 2 • Run engine at high speed.
NO
Is voltage between CN-ST3 (9) and CN-ST2 (9) as shown in table?
YES
3 • Disconnect CN-ST2. • Turn starting switch ON. • Max. 1 V
Table CN-ST3, CN-ST2
Steering
Voltage
Between CN-ST3 (9) – CN-ST2 (9)
In neutral
0.9 – 1.5 V
When relieved
3.95 – 4.60 V
E-25. Related electrical circuit diagram
20-938 4
D155AX-5
TROUBLESHOOTING
E-26
E-26. [E0772] (Disconnection in HSS pump solenoid A system) is displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-PUPA
NO
Are resistance between CN-PUPA (male) (1) and (2) and that between (1) and chassis ground as shown in table?
Defective HSS pump solenoid
Replace
YES 2 • Turn starting switch OFF. • Disconnect CN-ST1 and CN-PUPA. • Max. 1 Ω
Is resistance between CN-ST1 (female) (4) and CN-PUPA (female) (1) normal?
NO
Disconnection or defective contact in Repair or wiring harness between CN-ST1 (female) replace (4) - CN-PUPA (female) (1)
NO
Disconnection or defective contact in wiring harness between CN-ST1 (female) (15) - CN-PUPA (female) (2)
NO
Short circuit with chassis ground in Repair or wiring harness between CN-ST1 (female) replace (15) - CN-PUPA (female) (2)
YES 3 • Turn starting switch OFF. • Disconnect CN-ST1 and CN-PUPA. • Max. 1 Ω
Is resistance between CN-ST1 (female) (15) and CN-PUPA (female) (2) normal?
Repair or replace
YES
4 • Turn starting switch OFF. • Disconnect CN-PUPA and CN-ST1. • Min. 1 MΩ
When CN-PUPA is disconnected, is resistance between CN-ST1 (female) (15) and chassis ground normal?
YES Defective HSS controller
Repair or replace
Table CN-PUPA (male)
Resistance
Between (1) – (2)
10 – 20 Ω
Between (1) – chassis
Min. 1 MΩ
E-26. Related electrical circuit diagram
D155AX-5
20-939 4
TROUBLESHOOTING
E-27
E-27. [E0773] (Short circuit in HSS pump solenoid A system) is displayed
Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-PUPA.
NO
Are resistance between CN-PUPA (male) (1) and (2) and that between (1) and chassis ground as shown in table?
Defective HSS pump solenoid
Replace
NO
Short circuit with chassis ground in wiring harness between CN-ST1 (female) (4) - CN-PUPA (female) (1)
Repair or replace
NO
Short circuit with power source in wiring harness between CN-ST1 (female) (15) CN-PUPA (female) (2)
Repair or replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
YES 2 • Turn starting switch OFF. • Disconnect CN-PUPA and CNST1. • Min. 1 MΩ
When CN-PUPA is disconnected, is resistance between CN-ST1 (female) (4) and chassis ground normal?
YES 3 • Disconnect CN-PUPA. • Turn starting switch ON. • Max. 1 V
When CN-PUPA is disconnected, is voltage between CN-ST1 (female) (15) and chassis ground normal?
YES
Table CN-PUPA (male)
Resistance
Between (1) – (2)
10 – 20 Ω
Between (1) – chassis
Min. 1 MΩ
E-27. Related electrical circuit diagram
20-940 4
D155AX-5
TROUBLESHOOTING
E-28
E-28. [E0774] (Disconnection in HSS pump solenoid B system) is displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-PUPB
NO
Are resistance between CN-PUPB (male) (1) and (2) and that between (1) and chassis ground as shown in table?
Defective HSS pump solenoid
Replace
YES 2 • Turn starting switch OFF. • Disconnect CN-ST1 and CN-PUPB. • Max. 1 Ω
Is resistance between CN-ST1 (female) (5) and CN-PUPB (female) (1) normal?
NO
Disconnection or defective contact in wiring harness between CN-ST1 (female) Repair or replace (5) - CN-PUPB (female) (1)
NO
Disconnection or defective contact in Repair or wiring harness between CN-ST1 (female) replace (15) - CN-PUPB (female) (2)
NO
Short circuit with chassis ground in wiring harness between CN-ST1 (female) Repair or replace (15) - CN-PUPB (female) (2)
YES 3 • Turn starting switch OFF. • Disconnect CN-ST1 and CN-PUPB. • Max. 1 Ω
Is resistance between CN-ST1 (female) (15) and CN-PUPB (female) (2) normal?
YES
4 • Turn starting switch OFF. • Disconnect CN-PUPB and CN-ST1. • Min. 1 MΩ
When CN-PUPB is disconnected, is resistance between CN-ST1 (female) (15) and chassis ground normal?
YES Defective HSS controller
Replace (Adjust neutral position of steering system)
Table CN-PUPB (male)
Resistance
Between (1) – (2)
10 – 20 Ω
Between (1) – chassis
Min. 1 MΩ
E-28. Related electrical circuit diagram
D155AX-5
20-941 4
TROUBLESHOOTING
E-29
E-29. [E0775] (Short circuit in HSS pump solenoid B system) is displayed Cause
Remedy
1 • Turn starting switch OFF. • Disconnect CN-PUPB
NO
Are resistance between CN-PUPB (male) (1) and (2) and that between (1) and chassis ground as shown in table?
Defective HSS pump solenoid
Replace
NO
Short circuit with chassis ground in wiring harness between CN-ST1 (female) (5) - CN-PUPB (female) (1)
Repair or replace
NO
Short circuit with power source in wiring harness between CN-ST1 (female) (15) CN-PUPB (female) (2)
Repair or replace
Defective HSS controller
Replace (Adjust neutral position of steering system)
YES 2 • Turn starting switch OFF. • Disconnect CN-PUPB and CN-ST1. • Min. 1 MΩ
When CN-PUPB is disconnected, is resistance between CN-ST1 (female) (5) and chassis ground normal?
YES 3 • Disconnect CN-PUPB. • Turn starting switch ON. • Max. 1 V
When CN-PUPB is disconnected, is voltage between CN-ST1 (female) (15) and chassis ground normal?
YES
Table CN-PUPB (male)
Resistance
Between (1) – (2)
10 – 20 Ω
Between (1) – chassis
Min. 1 MΩ
E-29. Related electrical circuit diagram
20-942 4
D155AX-5
TROUBLESHOOTING
E-30
E-30. [E0930] (Abnormality in engine speed sensor system) is displayed ª
Check that the engine speed sensor is adjusted normally before troubleshooting.
Cause
Remedy
1 • Start engine. • Measure with tester in AC range. • 0.5 - 3.0 V
NO
Is voltage between CN-ST3 (4) and (12) normal?
Defective HSS controller
Replace (Adjust neutral position of steering system)
Defective engine speed sensor
Replace
NO
Disconnection or defective contact in wiring harness between CN-ST3 (female) (4) - CN-E7 (female) (1)
Repair or replace
NO
Short circuit with chassis ground in wiring harness between CN-ST3 (female) (4) - CN-E7 (female) (1)
Repair or replace
YES
• Turn starting switch OFF. • Disconnect CN-E07. • 500 - 1,000 Ω
2 Is resistance between CN-E07 (male) NO (1) and (2) normal?
YES 3 • Turn starting switch OFF. • Disconnect CN-ST3 and CN-E07. • Max. 1 Ω
Is resistance between CN-ST3 (female) (4) and CN-E07 (female) (1) normal?
YES 4 • Turn starting switch OFF. • Disconnect CN-ST3 and CN-E07. • Min. 1 MΩ
When CN-E07 is disconnected, is resistance between CN-ST3 (female) (4) and chassis ground normal?
YES
Disconnection or defective contact in Repair or wiring harness between CN-ST3 (female) replace (12) - CN-E07 (female) (2)
E-30. Related electrical circuit diagram
D155AX-5
20-943 4
TROUBLESHOOTING
E-31
E-31. Backup alarm does not sound fl Check that fuse 9 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.)
Cause
Remedy
1 Does HSS controller display error code [E0610] [E0611]?
YES
Go to troubleshooting of displayed error code
2 • Turn starting switch ON. • 20 - 30 V
NO
Is voltage between CN-014 (4) and chassis ground normal?
Disconnection or defective contact in wiring harness between fuse 9 - CN-014 (female) (3)
Repair or replace
Defective backup alarm relay
Replace
Disconnection or defective contact in wiring harness between CN-041 (female) (5) - CN-244 (female) (2)
Repair or replace
Defective backup alarm
Replace
YES 3 When backup alarm relay is replaced, does system become normal?
NO
YES
4 • Turn starting switch OFF. • Disconnect CN-014 and CN-244. • Max. 1 Ω
Is resistance between CN-014 (female) (5) and CN-244 (female) (2) normal?
NO
YES
E-31. Related electrical circuit diagram
20-944 4
D155AX-5
TROUBLESHOOTING
E-32
E-32. Blade pitch malfunctions (Machine equipped with pitch dozer) fl Check that fuse 1 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) a) Blade pitch does not work (Solenoid is not turned on) Cause
Remedy
1 • Turn starting switch ON. • Turn on pitch switch. • 20 - 30 V
NO
Is voltage between CN-454 (female) (1) and chassis ground normal?
YES
2 • Turn starting switch OFF. • Disconnect CN-454.
NO
Are resistance between CN-454 (female) (1) and (2) and that between (1) and chassis ground as shown in table?
YES
Defective blade pitch solenoid
Replace
Disconnection or defective contact in wiring harness between CN-454 (female) (2) - chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between fuse 1 - CN-P01 (female) (1)
Repair or replace
Defective blade pitch switch
Replace
Disconnection or defective contact in wiring harness between CN-P01 (female) (1) - fuse (1)
Repair or replace
3 • Disconnect CN-P01. • Turn starting switch ON. • 20 - 30V
NO
Is voltage between CN-P01 (female) (2) and chassis ground normal?
YES
• Turn starting switch OFF. • Disconnect CN-P01. • Turn on pitch switch. • Max. 1 Ω
4 NO
Is resistance between CN-P01 (1) and (2) normal?
YES
Table CN-454 (male)
Voltage
Between (1) – (2)
40 – 80 Ω
Between (1) – chassis
Min. 1 MΩ
b) Blade tilt does not work (Solenoid is not turned off) Cause
Remedy
1 • Start engine.
When CN-P01 is disconnected, does system become normal?
NO
Short circuit with power source in wiring harness between CN-P01 (female) (2) CN-454 (female) (1)
Repair or replace
Defective blade pitch switch
Replace
YES
D155AX-5
20-945 4
TROUBLESHOOTING
E-32
E-32. Related electrical circuit diagram
20-946 4
D155AX-5
TROUBLESHOOTING
E-33
E-33. Ripper pin puller malfunctions (Machine equipped with giant ripper) fl Check that fuse 1 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) a) Pin cannot be pulled out (Solenoid is not turned on) Cause
Remedy
1 • Turn starting switch ON. • Pin puller switch: PULL OUT • 20 - 30 V
NO
Is voltage between CN-246 (1) and chassis ground normal?
YES
2 • Turn starting switch OFF. • Disconnect CN-246.
Are resistance between CN-246 (fmale) (1) and (2) and that between (1) and chassis ground as shown in table?
NO
YES
Defective ripper pin puller switch
Replace
Disconnection or defective contact in wiring harness between CN-264 (female) (2) - chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between fuse 1 - CN-263 (female) (1)
Repair or replace
Defective ripper pin puller switch
Replace
Disconnection or defective contact in wiring harness between CN-263 (female) (2) - CN-246 (female) (1)
Repair or replace
3 • Turn starting switch ON. • 20- 30 V
NO
Is voltage between CN-263 (1) and chassis ground normal?
YES
• Turn starting switch OFF. • Disconnect CN-263. • Pin puller switch: PULL OUT • Max. 1 Ω
4 Is resistance between CN-263 (male) NO (1) and (2) normal?
YES
Table CN-246 (male)
Voltage
Between (1) – (2)
40 – 80 Ω
Between (1) – chassis
Min. 1 MΩ
b) Pin cannot be pushed in (Solenoid is not turned off) Cause
Remedy
1 • Start engine.
When CN-263 is disconnected, does system become normal?
NO
Short circuit with power source in wiring Repair or harness between CN-263 (female) (2) replace CN-246 (female) (1)
YES Defective ripper pin puller switch
D155AX-5
Replace
20-947 4
TROUBLESHOOTING
E-33
E-33. Related electrical circuit diagram
20-948 4
D155AX-5
TROUBLESHOOTING
E-34
E-34. Engine does not start (Engine does not rotate) fl Check that fuse 10 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) fl When troubleshooting, set the parking brake lever in the lock position. fl Check that any error code related to the engine (E mode) is not displayed. Note: In this section, troubleshooting related to the battery relay will be performed on the assumption that the engine controller is free from error. Cause
Remedy
1 • Voltage: Min. 24 V • Specific gravity: Min. 1.26
NO
Are battery voltage and specific gravity of battery fluid normal?
Defective battery relay
Replace
Disconnection or defective contact in wiring harness between starting motor battery relay
Repair or replace
Defective starting motor
Replace
Defective alternator
Replace
Short circuit with power source in wiring harness between CN-M2 (female) (2) CN-E22 or between CN-M2 (female) (2) CN-220 (female) (2)
Repair or replace
Defective diode (CN-220)
Replace
YES
2 When starting switch is operated, does operating sound of battery relay come out?
• Starting switch ON and OFF.
NO
YES
3 • Turn starting switch to START position. • 20 - 30 V
NO
Is voltage between CN-M2 (1) and chassis ground normal?
YES
4 • Turn starting switch ON. • Max. 1 V
NO
Is voltage between CN-M2 (2) and chassis ground normal?
5 NO
Is connection between starting motor and battery relay normal?
• Check visually.
YES
6
• Disconnect alternator terminal R. • Turn starting switch ON. • Max. 1 V
NO
When CN-E22 is disconnected, is voltage between CN-M2 (2) and chassis ground normal?
YES
7 When CN-220 is disconnected, is voltage between CN-M2 (2) and chassis ground normal?
• Disconnect diode. • Turn starting switch ON. • Max. 1 V
NO
YES
See next page A
D155AX-5
See next page B
20-949 4
TROUBLESHOOTING
E-34
A
B
Cause
Remedy
8 • Turn starting switch to START position. • 20 - 30 V
NO
Is voltage between CN-152 (3) and chassis ground normal?
YES
9 • Turn starting switch OFF. • Disconnect CN-252. • Max. 1 Ω
• Turn starting switch to START position. • 20 - 30 V
Is resistance between CN-252 (male) NO (1) and (3) normal?
Defective neutral safety switch and wrong adjustment of it
Repair or replace
YES
Disconnection or defective contact in wiring harness between CN-152 (female) (1) - CN-M2 (female) (1)
Repair or replace
Defective starting switch
Replace
Is voltage between starting motor terminal C and chassis ground normal?
10 NO
Disconnection or defective contact Repair or in wiring harness between starting switch terminal C (CN-280) - CN-152 replace (female) (3)
YES
• Turn starting switch ON. • 20 - 30 V
Is voltage between SN-SW and chassis ground normal?
11 NO
YES
• Turn starting switch ON. • 20 - 30 V
Is voltage between starting switch terminal BR and chassis ground normal?
4
Disconnection or defective contact in wiring harness between starting switch terminal BR (CN-260) - CNSW
Repair or replace
Defective starting switch
Replace
13 Is resistance between starting switch NO terminals B and BR normal?
YES
20-950
Replace
12 NO
YES
• Disconnect starting switch terminals B and BR. • Turn starting switch ON. • Max. 1 Ω
Defective battery relay
Disconnection or defective contact Repair or in wiring harness between starting switch terminal B (CN-260) - fuse 10 replace - CN-H
D155AX-5
TROUBLESHOOTING
E-34
E-34. Related electrical circuit diagram
D155AX-5
20-951 4
30 DISASSEMBLY AND ASSEMBLY Method of using manual ............................ 30- 3 Precautions when carring out operation ... 30- 5 Special tool list ............................................. 30- 7 Special tool sketch ....................................... 30-17 STARTING MOTOR Removal and Installation ...................... 30-26 ALTERNATOR Removal and Installation ...................... 30-27 ENGINE OIL COOLER CORE Removal and Installation ...................... 30-28 FUEL INJECTION PUMP Removal .................................................. 30-29 Installation .............................................. 30-30 WATER PUMP Removal and Installation ...................... 30-31 TURBOCHARGER Removal and Installation ...................... 30-32 NOZZLE HOLDER Removal and Installation ...................... 30-33 FUEL INJECTOR Removal and Installation ................... 30-33-1 ENGINE FRONT SEAL Removal .................................................. 30-34 Installation .............................................. 30-35 ENGINE REAR SEAL Removal .................................................. 30-37 Installation .............................................. 30-38 CYLINDER HEAD Removal .................................................. 30-42 Installation .............................................. 30-47 THERMOSTAT Removal and Installation ...................... 30-49 AIR CONDITIONER COMPRESSOR Removal .................................................. 30-50 Installation .............................................. 30-51 AIR CONDITIONER CONDENSER Removal and Installation ...................... 30-52 FUEL TANK Removal and Installation ...................... 30-53 RADIATOR Removal .................................................. 30-54 Installation .............................................. 30-56 RADIATOR, OIL COOLER, GUARD Removal .................................................. 30-57 Installation .............................................. 30-59 FAN DRIVE Removal .................................................. 30-60 Installation .............................................. 30-61
D155AX-5
HYDRAULIC COOLER Removal and Installation ...................... 30-62 ENGINE Removal .................................................. 30-63 Installation .............................................. 30-65 DAMPER Removal .................................................. 30-66 Installation .............................................. 30-67 Disassembly ........................................... 30-68 Assembly ................................................ 30-71 POWER TRAIN UNIT Removal .................................................. 30-75 Installation .............................................. 30-79 Separation .............................................. 30-80 Connection ............................................. 30-84 PTO Disassembly ........................................... 30-85 Assembly ................................................ 30-89 TORQUE CONVERTER Disassembly ........................................... 30-94 Assembly ................................................ 30-97 TORQFLOW TRANSMISSION Disassembly ......................................... 30-100 Assembly .............................................. 30-109 HSS CASE Disassembly ......................................... 30-120 Assembly .............................................. 30-129 HYDRAULIC PUMP Removal ................................................ 30-142 Installation ............................................ 30-146 HSS PUMP Disassembly ...................................... 30-146-1 Assembly ........................................... 30-146-8 HSS MOTOR Removal and Installation .................... 30-147 POWER TRAIN MAIN RELIEF VALVE Removal and Installation .................... 30-148 Disassembly and Assembly ............... 30-149 HSS, PPC CHARGE VALVE Removal and Installation .................... 30-150 HSS, PCC CHARGEING VALVE Disassembly ......................................... 30-151 Assembly .............................................. 30-152 TRANSMISSION CONTROL VALVE Removal ................................................ 30-153 Installation ............................................ 30-154 Disassembly and Assembly ............... 30-155
30-1 5
BRAKE VALUE Removal and installation .................... Disassembly and Assembly ............... FINAL DRIVE Removal ................................................ Installation ........... . ................................ Disassembly ......................................... Assembly .............................................. TRACK FRAME Removal ................................................ Installation ............................................ IDLER ASSEMBLY Removal ................................................ Installation ............................................ Disassembly ......................................... Assembly .............................................. RECOIL SPRING Removal and Installation .................... Disassembly ......................................... Assembly .............................................. TRACK ROLLER Removal ................................................ Installation ............................................ Disassembly ......................................... Assembly .............................................. BOGIE Removal ................................................ Installation ............................................ Disassembly ......................................... Assembly .............................................. CARRIER ROLLER Removal and Installation.. ................. Disassembly ......................................... Assembly .............................................. TRACK SHOE Checking before removal ................... Removal (normal) ................................ Removal (when there is abnormality inside track frame) ................. Installation ............................................ Overall disassembly ............................ Overall assembly ................................. Press-fitting jig dimention table for link press .............................................. ONE LINK Disassembly ......................................... Assembly .............................................. MASTER LINK Disassembly ......................................... Assembly .............................................. PIVOT SHAFT Removal and Installation .................... EQUALIZER BAR Removal ................................................ Installation ............................................ EQUALIZER BAR SIDE BUSHING Removal and Installation ....................
30-2 0
30-I 57 30-158 30-160 30-162 30-I 63 30-168 30-174 30-176 30-177 30-178 30-179 30-181 30-I 84 30-I 85 30-190 30-194 30-195 30-196 30-199 30-202 30-204 30-205 30-209 30-213 30-214 30-216 30-219 30-219 30-220 30-221 30-222 30-227 30-241 30-242 30-244 30-246 30-248 30-251 30-252 30-253 30-254
SEGMENT TEETH Removal and Installation . . . . . . .. . . . . . . .. . . .. 30-255 HYDRAULIC TANK Removal and Installation . . . . . . .. . . .. . . .. . . . . 30-256 MAIN CONTROL VALVE Removal . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . .. . .. . . . . . 30-257 installation . .. . . . . .. . . . . .. . . .. . . . . . . . . . . . . .. . .. . . .. . . . . 30-258 Disassembly . . . . . . . . . . . . . . .. .. .. . . . . . . . . . . . .. . . .. . . . . 30-259 Assembly . . .. .. . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . .. . . .. . . . . 30-262 HSS OIL COOLER BYPASS VALVE Removal and Installation . . . . . . . .. . . .. . . . . .. . 30-266 Disassembly, assembly of HMT oil cooler bypass valve .. .. . . .. .. . . . . . . . .. . . . . 30-267 BLADE PPC-VALVE Removal . . . . . .. . .. . .. . . . . . . .. . .. . . . . . . . . . . . . .. . . . . . . . . . . 30-268 Installation . . . . . . .. . . . . . .. . . . . . . . . . . .. . . . .. . . .. . . .. . . . . 30-269 RIPPER PPC VALVE Removal . . . . . . . .. . . . . . . . . . . . . . . .. . . . .. . . . . . . . . .. . . .. . . .. 30-270 Installation . .. . . . . . . . . . . . . . . . .. . . . . .. . . .. . . . . . . .. . . . .. . 30-271 BLADE PPC VALVE Disassembly .. . . . . . . .. . . . .. . .. . . . . . . . . . . . . . .. . . . . . . . . 30-272 Assembly ..,....._.................................. 30-273 BLADE LIFT CYLINDER Removal and Installation . . . . .. . . .. .. . . . . . . . . 30-275 BLADE TILT CYLINDER Removal and Installation .. . . . .. . . . . . .. . . . . .. 30-276 RIPPER LIFT CYLINDER Removal and Installation .. . . . . . .. . . . . . .. . . . . 30-277 RIPPER TILT CYLINDER Removal and Installation . . . . . . . .. . .. . . . . . . . . 30-278 HYDRAULIC CYLINDER Disassembly .. . . . . . . . . . . . . .. .. . . . . . . . . . . . . .. . . . . . . . . . 30-279 Assembly . . .. . .. . . . . . . . . . . . . .. . . .. . . . . . . . . . . . .. . . . . . . . . 30-282 BLADE Removal . . . . . . . . .. .. . . . . . . . . . . . .. . .. .. . . . . . . . . .. . . . .. . . . 30-286 Installation . .. . . . . . . . . . . . . . . . . .. . .. .. . . . . . . .. . . .. . . . .. . 30-287 Disassembly . .. . . . .. . . .. .. . . . . .. . . .. .. .. .. . . . . . . .. . . . 30-288 Assembly . . . . . . .. . . . . . .. . . .. . . . . . . .. . . . . .. . . . . . .. . . . . .. 30-290 MULTI-SHANK RIPPER Disassembly . . . . . . . . . . . . .. . . .. .. . . . . . . . . . .. . . . . . . . . . . 30-292 Assembly . . . . . . .. .. . . . .. . . .. . . . . . . . .. . . . . .. . . .. . . . . . . . . 30-294 ROPS GUARD Removal and Installation . . . . . . . . .. .. .. . . . . .. 30-296 OPERATOR CAB Removal and Installation .. . . . .. . . . . . .. .. . . . . 30-297 HOOD Removal and Installation .. . . . .. . . . .. . . . . . . . . 30-298 FLOOR FRAME Removal . . . . . .. . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . .. . . .. . . . . 30-299 Installation . .. . . . . . .. . . .. . . . .. . . . . . . . . . . . . .. . . . .. . . . .. . 30-304 DASHBOARD Removal . . . . . . . .. . .. . . . . .. . .. . . . . . .. . . . . . . . .. . . . .. . . . . . . 30-305 Installation .,.......................................... 30-306 MONITOR Removal and Installation . . . . . . . .. . . . .. . . . . . . 30-307 HSS CONTROLLER Removal and Installation . . .. . . .. . . . . . . . . . . . . 30-308
D 155AX-5
DISASSEMBLY
METHOD OF USING MANUAL
AND ASSEMBLY
METHOD OF USING MANUAL 1.
When removing or installing unit assemblies @ When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. @ Any special techniques applying only to the installation procedure are marked a, and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
(Example) REMOVAL
ASSEMBLY
.. . . . . . . . . . Title of operation
xxxx(1) . . . . . . . .. . . . . . . . . .. . . . . . .. . . . .. . .. . .. . .. .. . .. . Step in operation * .. . . . . .. . . . . .. . . . .. . . . .. . . . . . . . .. . .. . . . . . . . .. . . . . .. . . . .. .. . . Technique or important point to remember when removing x x x x (1). . .........Indicates that a technique is listed for use n n a A(2) . . . . . . .. . . . . . . . . .. . . .. .. . . . . . . . .. . . . .. . . . . . . m during installation 0 0 0 0 assembly (3)
2. 3. -
OF 0000
. ........................................ ...... ............. ... . Precautions related to safety when carrying out the operation
a 1.
:
. . . . . . . . .. . . . . . . . . . . .. .. .l...................................
See Lubricant
and Coolant
Table
INSTALLATION OF 0000 ASSEMBLY . . Title of operation Carry out installation in the reverse order to removal. m . . . . . . . . .. .. . .. . . . . . . . .. . .. . . . . . . . .. .. . . . . .. . . . . . . . . .. . . . . . . . . .Technique used during installation * .. .............. .............. .... .......................... Technique or important point to remember when installing (2). . Adding water, oil . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . . . Step in operation * . . . . . . . .. . . . . . . . . . . . .. .. . . . . . . . . . . . . .. . . .._................. Point to remember when adding water or oil l
I&
. . .. .. . . .. . . . .. . . .. . .. . .. . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . Quantity
when
filling with oil and water
2.
General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation.
3.
Listing of special tools For details of the description, part number, and quantity of any tools (Al, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual. Special tools marked * in the table cannot be supplied. Special tools with part number 790T-000-0000 in the table are prohibited for supply. Special tools marked 0 in the sketch column are tools introduced in this manual in sketches for special tools. However, note that Komatsu cannot accept any responsibility for special tools manufactured according to the sketch.
D 155AX-5
30-3 0
DISASSEMBLY
4. Ir
General
AND ASSEMBLY
tightening
torque
METHOD OF USING MANUAL
table
(when
using torque
In the case of metric nut and bolts for which there given in the table below.
Thread
diameter
Width
across flats 0
5. Ir
wrench)
is no special
instruction,
tighten
z
0
SAW281
to the torque
z SAC03482
mm
mm
kgm
Nm
6 8 10 12 14
10 13 17 19 22
1.3520.15 3.2kO.3 6.7r0.6 11.5~1.0 18.Ok2.0
13.2k1.4 31.4r2.9 65.7k6.8 112k9.8 177+19
16 18 20 22 24
24 27 30 32 36
28.5+3 39+4 56+6 76+8 94.5klO
279229 383239 549258 745+78 927298
27 30 33 36 39
41 46 50 55 60
135k15 175*20 225k25 280+30 335k35
1320+140 1720+190 22105240 27502290 32802340
Table of tightening
torques
for flared
nuts
In the case of flared nuts for which there is no soecial instruction, tighten to the torque given in the’table below. SAW0483
Thread
6. Ir
Table
diameter
Width
30-4 0
T
mm
mm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
2.520.5 5kl 8&l 14*3 18*3 20~5 2525 3Ok5
of tightening
torques
In the case of split flange in the table below. Thread
across flats
Tightening
diameter
for split flange
Nm 24.5r4.9 49k19.6 78.5k19.6 137.3k29.4 176.5k29.4 196.1*49 245.2*49 294.2249
bolts
bolts for which there is no special instruction,
Width
torque
Tightening
across flats
tighten
to the torque
given
torque
mm
mm
kgm
Nm
14 18 22
14 17 22
6.7r0.7 11.5+1 28.523
65.7k6.8 112-cg.8 279k29
D155AX-5
DISASSEMBLY
METHOD
AND ASSEMBLY
PRECAUTIONS
WHEN CARRYING
OF USING
MANUAL
OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.1 1. Precautions when carrvinn out removal work . If the coolant contains antifreeze, dispose of it correctly. . After disconnecting hoses or tubes, cover them or fit blind 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 Ir Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal
number 02 03 04 05 06 10 12
2) Split flange Nominal
Flange (hose end) 07379-00400 07379-00500
3) If the part is not under hydraulic
pressure,
02430 27
D155AX-5
nut (elbow end) Use 07221-20210(Nut), 07221-20315(Nut), 07221_20422(Nut), 07221-20522(Nut), 07221_20628(Nut), 07221-21034(Nut), 07221-21234(Nut),
the two items below 07222-0021O(Plug) 07222-00312(Plug) 07222-00414(Plug) 07222-00515(Plug) 07222-00616(Plug) 07222-01018(Plug) 07222-01219(Plug)
as a set
type hoses and tubes number
04 05
Sleeve
Plug 07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234
07049-02734
1 24 1 27
Sleeve head (tube end) 07378-I 0400 07378-I 0500
the following
1 20 1 22.5
Split flange 07371-30400 07371-30500
corks can be used.
25 28 I 30 1 34
DEW00401
30-5 0
DISASSEMBLY
2. Precautions
METHOD OF USING MANUAL
AND ASSEMBLY
when
carrying
out installation
work
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate 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 idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 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
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run Then check the water level again. the engine to circulate the water through the system. 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. If the hydraulic equipment has been removed for repair, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. disulohide arease) to the work eouioment oar&. Add the soecified amount of arease (molvbdenum
30-6 a
D 155AX-5
DISASSEMBLY
SPECIAL TOOL LIST
AND ASSEMBLY
SPECIAL TOOL LIST * Ir *
Ir
with part number 790T-000-0000 cannot be supplied (they are items to be locally manufactured). Necessity:= : Cannot be substituted, should always be prepared (used). 0 : Extremely useful if available, can be substituted with commercially available part. New/remodel: N . .. . . . .. Tools with new part numbers, newly developed for this model R . . .. . . . . . Tools with upgraded part numbers, remodeled from items already available for other models Blank.. Tools already available for other models, used without any modification Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Gil r Part Name $2 -2 s$ % Nature of work, remarks ymbol Part No. Nature of work Z’B CY SE rz Tools
1
790-331-I 110
Wrench
n
1
2
795-931-1100
Seal puller
w
1
795-521-1110
n
Push tool
I
I
Removal, installation of cylinder head Removal of engine oil seal
1
I
I
790-101-5221
Grip
w
1
01010-51225
Bolt
n
1
01050-31640
Bolt
n
6
795-521-1131
Push tool
I Press fitting of crankshaft front oil seal
3
I
n
1
I
I
I Press fitting of crankshaft rear oil seal
Disassembly assembly
and
of engine
5
6
795T-473-1110 795-570-I
100
Remover
Disassembly assembly
and
of damper
assembly I
I
7
n
Push tool
n
1
0
Press fitting of injection pump oil seal
1 I
I
796-514-2110
Wrench
n
1
01011-81090
Bolt
n
1
791-612-1100
Installer
w
1
I
;;+z~TI
of nozzle
Press fitting
of damper
assembly Disassembly and assembly of transmission assembly
Removal, installation of clutch brake assembly
Disassembly assembly
D 155AX-5
and
of HSS
DISASSEMBLY
Nature
SPECIAL TOOL LIST
AND ASSEMBLY
of work
T
S;ymbol
Part No.
Part Name
i> c Z’Gj a
5
$3 Tj Nature of work, remarks SE cn
Removal, installation final drive assembly
Removal
Removal
of
of sprocket
and installa-
tion of final
drive
assembly
Press fitting
Removal
Disassembly assembly
of planetary
and
of idler, track
Press-fitting
of idler
roller,
roller
carrier
bogie
assembly
30-8 0
of sprocket
D155AX-5
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL LIST
d,
Nature
of work
iymbol
Nut
n
2
0 1643-31445
Washer
n
2
790-101-2102
Puller (294 kN (30 ton}) n
1
790-101-1102
Hydraulic
2
796-670-1020
installer
n
1
3
791T-630-1290
Plate
n
1
790-101-2680
Adapter
n
2
790-101-2550
Leg
n
2
790-101-2510
Block
n
1
790-101-2570
Washer
790-101-2560
Nut
790-101-1102
Hydraulic
5
791-651-1510
5
4
assembly
Press fitting bushing
Id41
roller,
n
1
Installer
n
1
o
I
I Removal
790-102-1891
Nut wrench
n
1
791-651-1510
Installer
n
1
I3
791T-630-1350
Spacer
n
1
!3
791-601-1000
t
I Oil pump
O
(n I 1 I
I
IFilling
Id31
I
I
l
791-685-9550
l
l
791-630-1540
l
Adapter
n
l
791-630-1560
l
Adapter
I=111
I
I
l
04530-I
l
Eyebolt
l
04530-11018
l
Eyebolt
IdI1 I I I=121 I I
l
01643-31032
l
Washer
Id41
I
I
Nut
of ring
fitting
of ring
Installation of floating seal __-. Removal, installation of carrier roller nut Installation of floating seal Press fitting of carrier roller ring
bogie assembly 7 Ic
of idler
installation of idler floating seal Press fitting of track roller bushing
I=121 I IPress
pump
remarks
I I
I=111
and
of idler, track
roller carrier
pump
J=
$, -2 $$ g Nature of work, Z’B u SE c/3
01580-01411 1
Disassembly
Part Name
Part No.
with oil
O-
D155AX-5
2030
1
Removal, press-fitting pin assembly
1
of
30-9 0
DISASSEMBLY
Nature
SPECIAL
AND ASSEMBLY
of work
l
791-630-1440
790-101-4300 10
Part Name
Part No.
;ymbol
n
1
(1470kN(150ton)) n Cylinder
1
l
Spacer
5
s ‘= & .w q Z‘B a SE
cn
Remover, installer assembly part No.: 791-630-1500
790-101-1102
Hydraulic pump
n
1
Bracket
n
1
0
791T-630-1590
Stand
l
l
0
791-685-9510
l
Frame
n
1
l
791-685-9520
l
Frame
U
1
l
791-630-1530
l
Extension
IWIll
l
04530-I 2030
l
Eyebolt
I r-r-i
l
791-630-1430
l
Guide
Nature of work, remarks
2
79lT-630-1580
l
TOOL LIST
Removal, press-fitting of pin assembly
Remover, installer assembly part No.: 791-630-1500
,
I
I
1
Disassembly and assembly of idler, track roller carrier roller, bogie assembly
L
1 796101-1102
1 Hydraulic pump
I
n
Id11 I I
1n 1 1 I
n
Assembly of shaft
Remover, installer assembly part No.: 791-630-1500
12
30-10 a
l
791-685-9620
l
Extension
w
1
l
791-630-1510
l
Shaft
n
2
l
791-630-1520
l
Nut
n
2
l
791-630-1530
l
Extension
W
1
l
791-630-1540
l
Adapter
W
1
D 155AX-5
DISASSEMBLY
Nature
AND ASSEMBLY
of work
1s
iymbol
SPECIAL
Part Name
Part No. l
791-630-1570
I
TOOL LIST
5
&_ .+ r ‘z 38 2 Nature of work, remarks 2.5 cf SE UY Assembly of shaft
Disassembly and assembly of idler, tracl roller carrier roller, bogie assembly
g case cover
recoil spring case
Disassembly and assembly of recoil spring assembly
Removal of yoke from recoil spring case
r.5
L D155AX-5
791-730-I 130
Bolt
H
4
01580-12016
Nut
n
4
01643-32060
Washer
n
4
Disconnection of yoke from recoil spring case
30-11 0
SPECIAL TOOL LIST
Part Name
■
1
791T-650-2010
Remover assembly
791T-650-2130
Sleeve
1
791-181-1010
Adapter
1
791-520-4140
Screw
1
790-101-2540
Washer
1
791-112-1180
Nut
1
790-101-4000
Puller (490 kN {50 ton}) ■
1
790-101-1102
Hydraulic pump
■
1
791T-650-2200
Remover & installer ■
1
791-827-1510
Sleeve
1
791T-650-2210
Sleeve
1
790-438-1110
Screw
1
790-101-2540
Washer
2
790-112-1180
Nut
2
790-101-2102
Puller (294 kN {30 ton}) ■
1
790-101-1102
Hydraulic pump
■
1
791T-650-2100
Installer assembly
■
1
791T-650-2110
Sleeve
1
791T-650-2120
Plate
1
790-201-3310
Bolt
2
790-101-2510
Block
1
790-101-2570
Washer
2
01580-01613
Nut
2
790-105-2300
Jack assembly (196 kN {20 ton}) ■
1
790-101-1102
Hydraulic pump
■
1
790-501-5000
Unit repair stand (for 100V)
790-501-5200
Unit repair stand (for 220V, 240V)
790-901-2110
Bracket
● 1
790-901-1343
Plate
● 1
790-201-3610
Bolt
■
1
795-465-1110
Washer
■
1
01643-33080
Washer
■
1
01643-32060
Washer
■
1
01582-02016
Nut
■
1
790-201-2220
Plate
■
1
790-201-2750
Spacer
■
1
Sketch
Part No.
Q’ty
Symbol
New/remodel
Nature of work
Necessity
DISASSEMBLY AND ASSEMBLY
fi
Nature of work, remarks Removal of equalizer bar center pin
1
Disassembly and assembly of equalizer bar assembly
N
2
Disassembly and assembly of pivot shaft
P
1
Removal, press fitting of equalizer bar side pin spherical bushing
fi
fi fi
Press fitting of pivot shaft ring
● 1 1
Disassembly and assembly of HSS pump assembly
Q 2
3
30-12 2
Disassembly, assembly of pump assembly
Disassembly, assembly of cylinder block assembly
Removal of roller bearing
D155AX-5
SPECIAL TOOL LIST
Q’ty
790-201-2850
Spacer
■
1
790-201-2190
Plate
■
1
790-201-2740
Spacer
■
1
790-201-2240
Plate
■
1
790-201-2750
Spacer
■
1
790-101-5001
Push tool kit
■
1
790-101-5111
• Plate
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
796-730-2300
Wrench
■
1
795-630-1803
Torque wrench
■
1
790-201-2700
Push tool kit
■
1
790-201-2740
• Plate
1
791-675-9701
Remover & installer ■
1
790-101-4300
Cylinder (1470 kN {150 ton}) ■
1
790-101-4200
Puller (294 kN {30 ton})
■
1
790-101-1102
Hydraulic pump
■
1
2
791-646-7531
Remover
■
1
3
791-660-7460
Pin brush
■
1
4
791-432-1110
Plug push tool
■
1
5
791-932-1110
Plug push tool
■
1
6
791-632-1052
Installer
■
1
Insertion of link seal Filling with oil and checking air tightness
Symbol 3
Part No.
Part Name
4
5
Disassembly and assembly of HSS pump assembly
Q 6
7
8
790-701-3000
Seal checker
■
1
791-675-9581
Adapter
■
1
791-675-9590
Guide
■
1
01010-52460
Bolt
■
2
01010-51440
Bolt
■
2
790-101-1102
Pump
■
1
790-101-4300
Cylinder (1470 kN {150 ton}) ■
1
791-685-9510
Frame
■
1
791-685-9520
Frame
■
1
791-685-9530
Rod
■
1
10 791-685-9550
Nut
■
1
791-685-9560
Bolt
■
1
791-675-9570
Adapter
■
1
01010-51030
Bolt
■
1
7
R 8
9
D155AX-5
Nature of work, remarks Removal of roller bearing Press fitting of roller bearing
Press fitting of shaft assembly
Press fitting of needle bearing
Inspection of shaft rotating torque
Press fitting of oil seal
1
Overall disassembly and assembly of track shoe assembly
Sketch
Necessity
Nature of work
New/remodel
DISASSEMBLY AND ASSEMBLY
Disassembly, assembly of track shoe assembly
Removal of pin plug Cleaning of oil-sealed track pin Knocking out pin plug (large) Knocking out pin plug (small)
Disassembly of 1 link
30-13 2
SPECIAL TOOL LIST
Eyebolt
■
1
Pump
■
1
790-101-4300
Cylinder (1470 kN {150 ton}) ■
1
791-685-9540
Rod
■
1
791-685-9550
Nut
■
3
791-685-9510
Frame
■
1
791-685-9520
Frame
■
1
791-685-9530
Rod
■
1
791-685-9550
Nut
■
1
791-685-9560
Bolt
■
1
791-126-0150
Adapter
■
1
791-675-5520
Guide
■
1
791-675-5530
Pusher
■
1
791-675-9570
Adapter
■
1
01010-51030
Bolt
■
1
04530-12030
Eyebolt
■
1
791-685-9620
Extension
■
1
790-101-1102
Pump
■
1
790-101-4300
Cylinder (1470 kN {150 ton}) ■
1
790-101-1102
Pump
■
1
790-101-4200
Puller (294 kN {30 ton})
■
1
791-675-5542
Adapter
■
1
791-675-5571
Adapter
■
1
790-101-1102
Pump
■
1
790-101-4300
Cylinder (1470 kN {150 ton}) ■
1
Part No. 04530-12030
10 790-101-1102
Part Name
11
12
Overall disassembly and assembly of track shoe assembly
R
13
14
15 791-675-5580
Guide
■
1
791-685-9510
Frame
■
1
791-685-9520
Frame
■
1
791-685-9530
Rod
■
1
791-685-9540
Rod
■
1
791-685-9550
Nut
■
3
791-685-9560
Bolt
■
4
791-126-0150
Adapter
■
1
01010-51030
Bolt
■
1
791-685-9620
Extension
■
1
791-675-5542
Adapter
■
1
16
30-14 2
Sketch
Q’ty
Symbol
New/remodel
Nature of work
Necessity
DISASSEMBLY AND ASSEMBLY
Nature of work, remarks
Disassembly of 1 link
Assembly of 1 link
D155AX-5
SPECIAL TOOL LIST
791-675-5571 16 790-101-1102
Part Name Adapter
■ 1
Pump
■ 1
790-101-4300
Cylinder (1470 kN {150 ton}) ■ 1
791-685-9510
Frame
■ 1
791-685-9520
Frame
■ 1
791-685-9530
Rod
■ 1
791-685-9540
Rod
■ 1
791-685-9550
Nut
■ 3
791-685-9560
Bolt
■ 4
791-126-0150
Adapter
■ 1
01010-51030
Bolt
■ 1
791-685-9620
Extension
■ 1
791-675-5550
Guide
■ 1
791-675-5571
Adapter
■ 1
791-675-9631
Adapter
■ 1
790-101-1102
Pump
■ 1
790-101-4300
Cylinder (1470 kN {150 ton}) ■ 1
17
Overall disassembly and assembly of track shoe assembly
R 18 791-670-3270
Guide
■ 1
791-685-9510
Frame
■ 1
791-685-9520
Frame
■ 1
791-685-9530
Rod
■ 1
791-685-9540
Rod
■ 1
791-685-9550
Nut
■ 1
791-685-9560
Bolt
■ 1
Adapter
■ 1
791-675-5560
Guide
■ 1
791-675-9570
Adapter
■ 1
01010-51030
Bolt
■ 1
791-670-3270
Guide
■ 1
790-101-1102
Pump
■ 1
790-101-4300
Cylinder (1470 kN {150 ton}) ■ 1
790-101-1102
Pump
790-101-4200
Puller (294 kN {30 ton}) ■ 1
791-675-9701
Remover & installer ■ 1
19 791-126-0150
20
21 790-101-1102 790-101-4200
D155AX-5
Pump
Sketch
Part No.
Q’ty
Symbol
New/remodel
Nature of work
Necessity
DISASSEMBLY AND ASSEMBLY
Nature of work, remarks
Assembly of 1 link
■ 1
■ 1
Puller (294 kN {30 ton}) ■ 1
Kit for filling with oil Removal, press fitting of track link
30-15 2
SPECIAL TOOL LIST
21 790-101-4300
Cylinder (1470 kN {150 ton}) ■
1
■
1
790-101-4200
Puller (294 kN {30 ton}) ■
1
791-646-7900
Push tool kit
■
1
• Bar
■
1
• 790-434-1210
• Guide
■
1
791-646-7523
Bar
■
1
791-646-7590
Guide
■
1
790-502-1003
Cylinder repair stand ■
1
790-101-1102
Hydraulic pump
■
1
790-102-3802
Multi-wrench
■
1
790-720-1000
Expander
■
1
Installation of round head (blade lift cylinder) Installation of cylinder piston ring
796-720-1670
Ring
■
1
Blade lift cylinder
07281-01279
Clamp
■
1
Ripper lift & tilt cylinder
796-720-1690
Ring
■
1
07281-01919
Clamp
■
1
796-720-1690
Ring
■
1
07281-02169
Clamp
■
1
790-201-1702
Push tool kit
■
1
Press fitting coil bushing
790-201-1821
• Push tool
1
Blade lift cylinder
790-201-1831
• Push tool
1
Ripper lift & tilt cylinder
790-201-1841
• Push tool
1
Blade tilt cylinder
790-101-5021
• Clip
1
01010-50816
• Bolt
1
790-201-1500
Push tool kit
790-201-1630
23 • 791-434-1220
24
1
3
Disassembly and assembly of hydraulic cylinder assembly
U
Removal, press fitting of track link
Pump
R
2
Nature of work, remarks
790-101-1102 22 Overall disassembly and assembly of track shoe assembly
Part Name
Sketch
Part No.
Q’ty
Symbol
New/remodel
Nature of work
Necessity
DISASSEMBLY AND ASSEMBLY
For large plug
For small plug
Disassembly, assembly of hydraulic cylinder
Blade tilt cylinder
4
■
1
Press fitting dust seal
• Plate
1
Blade lift cylinder
790-201-1640
• Plate
1
Ripper lift & tilt cylinder
790-201-1650
• Plate
1
Blade tilt cylinder
790-101-5021
• Grip
1
01010-50816
• Bolt
1
799-703-1200
Service tool kit
■
1
799-703-1100
Vacuum pump (100 V) ■
1
799-703-1110
Vacuum pump (220 V) ■
1
790-703-1120
Vacuum pump (240 V) ■
1
799-703-1400
Gas leak detector
■
1
5
Collection, reuse of freon gas
30-16 2
X
Collecting, charging with freon gas
D155AX-5
DISASSEMBLY
SPECIAL TOOL SKETCH
AND ASSEMBLY
SPECIAL TOOL SKETCH Note:
Komatsu sketches.
cannot
accept
any responsibility
for special
tools
manufactured
according
to these
A4 Push tool
100
Unless be no
otherwise burrs or
specified, flushes at
the
there shall corner.
J-l Plate
-I s
8
if?
Cl0
2-22
DRILLS
~
25
67.5 36.5
I I
... PART NAME PLATE
791T-627-1340
D155AX-5
MATERIAL
HEAT TREATMENT
Ss4ooP I
an, 1
A
30-l 7 0
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL SKETCH
J-4 Plate
522 DRILLS Equally divided around circumference
I
HEAT TREATMENT
MATERIAL I
SS4OOP WI-Y 1
n J-4 Sleeve
4 cv
c
T
I
f
!? F
791T-627-1360
30-18 0
D155AX-5
DISASSEMBLY
SPECIAL TOOL SKETCH
AND ASSEMBLY
J-5 Spacer
a
D
B
iI
a co.5
Co.5
__
__ Y
co.5
co.5
__ 230
DDwo857
I I
HEAT TREATMENT
MATERIAL STKM13A
PART NAME SPACER
QTY I
1
A
791T-627-1380
L-l Plate
2-14 DRILLS HEAT TREATMENT
MATERIAL
PART NAME PLATE
L-4 32
D155AX-5
v
QN I
1
791T-630-1230
30-19 0
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL SKETCH
L-3 Plate
DDlYJJSZ HEAT TREATMENT
MATERIAL SS4caP
PART NAME
Q-W
PLATE
1
791T-630-1290
n
791T-630-1340
A
L-4 Spacer
, C t-
D
3
-g
, Cl
+
-3
<
30-20 0
48.5kO.2
Cl
3
D155AX-5
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL SKETCH
L-8 Spacer
a
C
V
DDD00865
Cl
_ a:+ <
131.9520.2
+ > 791T-630-1350
D155AX-5
A
30-21 0
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL SKETCH
L-10 Bracket I-
23 DRILL
I
280
_
_
5v
2
PLACE
_@40
-I
A-A
LA
I
The
A
Paintwork
shall
be PT-9
munsell
8.5845/g.
0 Lo I
02
BOSS
SS4008
I
1.75
440
I
0.17
116
01
PLATE
SS4OOP
SYM.
PART NAME
MATERIAL
DXD0317' MATERIAL
PART NAME
PTY
SEE DWG
BRACKET REMARKES
QTYISET "(#
HEAT TREATMENT ----
791T-630-1580
'A
L-10 Stand
1
,-+-<2PLACES
4-0 0 0
02
24DRIL
4----O 01
15
/
-I j
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)1580-02016
02
ZPLACES
300
l--A
CWD02536
NUT
SID
3
--
CHANNEL
SS400A
1
5. 58
01
PLATE
SS4OOP
SYM.
PART NAME
MATERIAL
30-22 0
A-A
.!A
:
2
2.63
QTY/SET "z;;B
---$150, 75. 6. 5
HEAT TREATMENT
MATERIAL
----
SEE DWG
PART NAME
QTY
STAND
116 REMARKES
791T-630-1590
'A
D 155/J-5
DISASSEMBLY
M-l
SPECIAL TOOL SKETCH
AND ASSEMBLY
Spacer
T
t
1
DDW0858 HEAT TREATMENT
i
MATERIAL
1223w19W
I
50
M-l
STKM16A
PART NAME SPACER
QTY I
1
n
791T-630-1150
Spacer 250
12 x 1.75
Cl
500
I
HEAT TREATMENT
I
PART NAME SPACER
791T-630-1160
D155AX-5
MATERIAL
1223301sal
STKMltiA I
ON 1
n
30-23 0
DISASSEMBLY
N-l
AND ASSEMBLY
SPECIAL TOOL SKETCH
Sleeve
02
1
TUBE
5.54
012oxt7
HEAT TREATMENT
MATERIAL
_._
SEE DWG
PART NAME
cm
SLEEVE 01
PLATE
1
039
SYM.
PART NAME
QlY/SET
Es
1
t12
791T-650-2130
REMAJKES
A
N-2 Sleeve
DDDC4870 HEAT TREATMENT
MATERIAL SEE DEG
02 01 SYM.
30-24 0
I
I
TUBE
I
sTKh416A
I
1
I 1.55
I 012oxta
I
PART NAME SLEEVE
I
Q-rf 1
PLATE PART NAME
MATERIAL
Im/SETI
%?S
I
REMARKES
1
791T-650-2210
/\
D155AX-5
DISASSEMBLY
SPECIAL TOOL SKETCH
AND ASSEMBLY
P Sleeve
I
465.5kO.2 \
02
TUBE
STKMlBA
1
11.7
DDDWBffi
I
V
HEAT TREATMENT
PLATE
SYM.
PART NAME
SrnP MATERIAL
1 QTY,SET
2.7
MATERIAL SEE DWG
01sOxt10
PART NAME SLEEVE
01
1
ON 1
r22 REMAKES
;F
791T-650-2110
A
P Plate
2-20 DRILLS
HEAT TREATMENT
MATERIAL SS4OOP
PART NAME PLATE
v D155AX-5
791T-650-2120
QTY 1
A
30-25 0
DISASSEMBLY AND ASSEMBLY
REMOVAL OF STARTING MOTOR ASSEMBLY
STARTING MOTOR
Serial 70001 – 75000 2
Disconnect
the cable from the negative (–) terminal of the battery.
1. Open engine right side cover (top) and remove cover (bottom). 2. Disconnect 3 starting motor wires (1) and 1 wiring connector (2). 3. Remove 3 bolts, then remove starting motor assembly (3).
1 DED00001
Serial No. 75001 and up
INSTALLATION OF STARTING MOTOR ASSEMBLY •
Carry out installation in the reverse order to removal.
1
3 DED00002
30-26 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
REMOVAL OF ALTERNATOR ASSEMBLY
ALTERNATOR
Serial No. 70001-75000
Disconnect
the cable from the negative (–) terminal of the battery.
1 1. Open engine right side cover (top) and remove cover (bottom). 2. Disconnect alternator wiring (1) and (2).
2 DED00003
Serial No. 75001 and up 3. Loosen locknut (3), then turn adjustment nut (4) to loosen tension of V-belt (5). 4. Remove bolts (6) and (7), then remove alternator assembly (8) together with belt cover. 1 e Remove the V-belt from the pulley when removing the alternator assembly.
INSTALLATION OF ALTERNATOR ASSEMBLY •
8
Carry out installation in the reverse order to removal.
1 e
After installing the alternator, adjust the belt tension. For details, see TESTING AND ADJUSTING, TESTING AND ADJUSTING ALTERNATOR BELT TENSION.
D155AX-5
6 5 3 4
7
DED00004
30-27 5 5
ENGINE OIL COOLER
DISASSEMBLY AND ASSEMBLY
REMOVAL OF ENGINE OIL COOLER CORE ASSEMBLY e
Serial No. 70001 – 75000 6
Drain coolant.
1. Remove wiring clamp (1).
1
1
3
2. Remove muffler water drain tube (2). 3. Remove adiabatic plate (3).
4
4. Disconnect turbocharger lubrication tube (4) at turbocharger end, then move it towards rear. 2
5
DED00005
5. Disconnect connector (5). Serial No. 75001 and up 6. Remove oil cooler assembly (6). 7. Remove core assembly (8) from cover (7).
INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY •
Carry out installation in the reverse order to removal.
•
Refilling with water Add water through water filler to the specified level. e Run the engine to circulate the water through the system. Then check the water level again.
8
7
DDD00006
30-28 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY Serial No. 70001 – 75000 1. Close valve of fuel supply piping. 2. Rotate crankshaft in normal direction and align match mark of fuel injection pump. fl This makes it easier to check the compression top dead center position of the No. 1 cylinder when installing the fuel injection pump. 3. Open engine left side cover (top) and remove cover (bottom). 4. Disconnect fuel control rod (1), and fuel hoses (2), (3), (4), and (5). 1
7
5. Remove boost compensator tube (19). 6. Disconnect fuel hose (6) and tube (7). 7. Remove coupling cover (8).
6 8
DED00008
8. Remove lubrication tubes (9) and (10).
10
9. Disconnect 6 delivery tubes (11).
9
DED00009
2
11
DED00010
D155AX-5
30-29 5 5
FUEL INJECTION PUMP
DISASSEMBLY AND ASSEMBLY
10. Loosen tightening bolt (12) at drive shaft end, and remove 4 pump mounting bolts (13).
12 13 DED00011
11. Remove fuel injection pump assembly (14) together with coupling. 3
14
13
13
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
DED00012
16
Serial No. 70001 – 75000 •
Carry out installation in the reverse order to removal.
1 e
15
Adjust the linkage. For details, see TESTING AND ADJUSTING, ADJUSTING FUEL CONTROL LINKAGE. DED00013
2 3 Sleeve nut: 123.5 ± 1.0 Nm {2.4 ± 0.1 kgm} 3 e
Install the fuel injection pump as follows. 1) After installing pump assembly, align damper (I,J) marks (15) and pointer (16) correctly. 2) Loosen bolt of coupling (18) to align match mark (17) of injection pump.
18
17
DED00014
30-30 5
D155AX-5
WATER PUMP
DISASSEMBLY AND ASSEMBLY
REMOVAL OF WATER PUMP ASSEMBLY 1. Drain coolant. 1 2. Using an adjustable wrench, push tension pulley (2) of fan belt (1), and remove fan belt. 3. Loosen locknut (3), then loosen adjustment nut (4), and remove V-belt (5). 1 4. Remove connectors (6) and (7). 5. Remove pulley (8). 6. Remove water pump assembly (9).
3 2
4 5 DED00016
DED00015
Serial No. 70001 – 75000
Serial No. 75001 and up
INSTALLATION OF WATER PUMP ASSEMBLY •
Carry out installation in the reverse order to removal.
1 e
•
After installing the V-belt, adjust the belt tension. For details, see TESTING AND ADJUSTING, TESTING AND ADJUSTING ALTERNATOR BELT TENSION.
Refilling with water Add water through water filler to the specified level. e Run the engine to circulate the water through the system. Then check the water level again.
8 DED00018
D155AX-5
30-31 1 5
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
REMOVAL OF TURBOCHARGER ASSEMBLY Serial No. 70001 - 75000 1. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. 2. Remove adiabatic covers (2) and (3). 3. Disconnect tube (4) and hose (5), then lift off air cleaner assembly (6). 4 Air cleaner assembly: 35 kg 4. Disconnect lubrication hose (7) and drain tube (8). 1 5. Remove turbocharger assembly (9).
2 6
5
4 DBD00026
INSTALLATION OF TURBOCHARGER ASSEMBLY Serial No. 70001 – 75000 •
7
Carry out installation in the reverse order to removal.
1 3 Hose mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
8
2 3 Turbocharger mounting bolt: 49.0 ± 9.8 Nm {5 ± 1 kgm}
DED00021
9 DED00020
30-32 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
TURBOCHARGER
REMOVAL OF TURBOCHARGER ASSEMBLY Serial No. 75001 and up 1. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. 2. Remove adiabatic covers (1) and (2). 3. Disconnect tube (3) and hose (4), then lift off air cleaner assembly (5). 4
Air cleaner assembly: 35 kg
4. Disconnect lubrication hose (6) and drain tube (7). 1 5. Remove turbocharger assembly (8).
2
INSTALLATION OF TURBOCHARGER ASSEMBLY Serial No. 75001 and up •
Carry out installation in the reverse order to removal.
1 3
2 3
D155AX-5
Hose mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
Turbocharger mounting bolt: 49.0 ± 9.8 Nm {5 ± 1 kgm}
30-32-1 5
30-32-2
(Blank Page)
D155AX-5
DISASSEMBLY AND ASSEMBLY
NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER ASSEMBLY Serial No. 70001 – 75000 1. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. 2. Remove cylinder head cover (1). 1 e For No. 4 and 5 cylinders, remove the air cleaner assembly and air supply connector. 3. Disconnect delivery tube (2).
1
2
2 DBD00413
4. Loosen locknut (3), and remove connector (4). 3 5. Remove holder (5).
5
4
6. Using tool A, remove nozzle holder assembly (6). 5
3 4
INSTALLATION OF NOZZLE HOLDER ASSEMBLY DBD00414
Serial No. 70001 – 75000 •
Carry out installation in the reverse order to removal. 1 3 Cylinder head cover mounting bolt: 24.5 ± 4.9 Nm {2.5 ± 0.5 kgm} 2 3 Delivery tube sleeve nut: 23.5 ± 0.98 Nm {2.4 ± 0.1 kgm}
5 4
3
6
3 3 Connector: 31.9 ± 2.5 Nm {3.25 ± 0.25 kgm} 3 Locknut: 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm} 4 3 Holder mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} 5 e When assembling the nozzle holder, clean the nozzle holder mount and check that there is no dirt or dust inside the sleeve before assembling. Tighten the mounting bolts uniformly in turn to prevent excessive tightening on one side.
DBD00415
A
6
DBD00416
D155AX-5
30-33 5 5
DISASSEMBLY AND ASSEMBLY
FUEL INJECTOR
REMOVAL OF FUEL INJECTOR ASSEMBLY Serial No. 75001 and up 1. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. 2. Remove common rail high-pressure pipe (1). 1
3. Disconnect wiring connector (2). fl Insert a flat-head screwdriver in the slit of the connector to press the stopper and disconnect the connector. 4. Remove cylinder head cover (3). 2 fl For Nos. 4 and 5, remove the air cleaner assembly and air intake connector.
5. Remove mounting bolts and rocker arm (4). fl Loosen locknut (5) and then loosen adjustment screw (6) by 2 - 3 turns so that an excessive force will not be applied to the push rod when the rocker arm is installed. 3
6. Remove 2 nuts (7) of solenoid valve above fuel injector. 4 7. Pull out spring clamp (8) and disconnect clamp (9). 8. Remove mounting bolts (12) of holder (11) of connector (having an O-ring) (10) and to remove holder, then insert connector (10) to remove it. 4
30-33-1 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
FUEL INJECTOR
9. Remove holder (13) of fuel injector, then remove injector assembly (14). 5 fl Do not hold the solenoid of the injector with priers, etc. to remove the injector.
INSTALLATION OF FUEL INJECTOR ASSEMBLY Serial No. 75001 and up •
Carry out installation in the reverse order to removal.
1 3 High-pressure pipe sleeve nut: 39.2 ± 7.4 Nm {4.0 ± 5.0 kgm} fl If there is any slit "b" or pit "c" on the taper sealing part (Part "a": The part of 2 mm from the end) of the high-pressure pipe joint or if part "d" (Tape seal end: Part of 2 mm from the end) has level difference that is felt with a nail (or if part "d" is fatigued) and the fuel may leak, replace the high-pressure pipe. 2 3 Cylinder head mounting bolt: 29.4 ± 34.3 Nm {3.0 ± 3.5 kgm} 3 fl When tightening the mounting bolts, check that the ball of the adjustment screw is fitted to the socket of the push rod. 3 Rock arm mounting bolt: 93 ± 103 Nm {9.5 ± 10.5 kgm} fl Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE.
D155AX-5
30-33-2 5
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL
4 fl Method of installing wiring harness. 1) Fit O-ring (15). 2) Install cap (16). 3) Tighten nut (14). 4) Secure clamp with bolt (18). 3 Terminal nut: 1.8 ± 2.2 Nm {0.18 ± 0.22 kgm} fl Eliminate the slack of the wiring harness and press it against the injector body. 5 fl Method of installing fuel injector. 1) Install fuel injector assembly (14) and holder (13) to the cylinder head temporarily. 2) Tighten mounting bolt (19) of holder (13) temporarily. 3) Tighten sleeve (20) temporarily. 4) Tighten holder mounting bolt (19) se curely. 5) Tighten sleeve (20) securely. fl Apply engine oil to the spherical part of the spherical washer. 3 Holder mounting bolt: 58.8 ± 73.5 Nm {6.0 ± 7.5 kgm}
30-33-3 5
D155AX-5
DISASSEMBLY
REMOVAL SEAL
AND ASSEMBLY
ENGINE FRONT SEAL
OF ENGINE FRONT
1.
Remove radiator, oil cooler, and guard assembly. For details, see REMOVAL OF RADIATOR, OIL COOLER, GUARD ASSEMBLY.
2.
Remove
crankshaft
3.
Remove
rear seal (2).
.
Removing standard seal Hook tip of tool A2 to metal ring of seal (2), and use impact force of a slide hammer to pull out. Ir Before pulling out, knock the oil seal in slightly. This separates the seal from the housing and makes it easier to pull out the seal. * Do not use a drill. The metal powder will get inside the engine.
pulley (I).
a
Tool
.
Removing seal with sleeve 1) Hook tip of tool A2 to metal ring of seal (21, and use impact force of a slide hammer to pull out. * Before pulling out, knock the oil seal in slightly. This separates the seal from the housing and makes it easier to pull out the seal. 2) Using a chisel and hammer, cut sleeve (3) and remove. * Be extremely careful not to damage the crankshaft when cutting the sleeve. * Remove all the metal particles that are produced.
k?
Slide
hammer
=--===-I
DXD03181
Standard
:iesl
seal
with
sleeve
Flvwheel houshina
Flywheel houshino
I
Metal ring of seal
I
Metal
rina
Crankshaft DXD03182
30-34 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
INSTALLATION FRONT SEAL 1.
ENGINE FRONT SEAL
OF ENGINE -
I
Installation of front seal (I) Before assembling the seal, check that there are no scratches, burrs, flashes, or rust on the housing, lip sliding surface, or at the corner of the end face of the crankshaft. When assembling the seal, do not coat the shaft and seal lip with oil or grease. Wipe off all oil from the shaft. Do not remove the internal plastic tube from the standard seal until the seal is assembled.
Plastic tube installation
Smaller
for
end
Put large inside diameter end of internal plastic tube (2) in contact with end of crankshaft (3). Ir Be particularly careful to assemble ing in the correct direction.
fac-
CDE00230
2)
3)
4)
Hold metal ring of seal (I) with both hands and push in with sudden force until it feels that it has gone over large diameter of internal plastic cylinder. After pushing seal in, remove internal plastic tube (2). * When removing, be particularly careful not to damage the seal lip. Tighten bolts of tool A3 uniformly until end face of tool A3 contacts end face of crankshaft (3) and press fit seal (I). * When press fitting the seal, be extremely careful not to damage the lip at the PTO end when setting the tool in position. * After press fitting the seal, remove all the remains of the red sealant on the outside circumference.
CWD02540
D155AX-5
DISASSEMBLY
2.
AND ASSEMBLY
ENGINE FRONT SEAL
Installation of damper pulley assembly Fit damper pulley assembly (2) and tighten with mounting bolts (1). w Mounting bolt: 245 - 308.7 Nm I25 - 31.5 kgm1
30-36 0
D155AX-5
DISASSEMBLY
REMOVAL SEAL
ENGINE REAR SEAL
AND ASSEMBLY
OF ENGINE REAR
1. Remove damper assembly. For details, see REMOVAL OF DAMPER BLY. bolt of flywheel
ASSEM-
(I),
2.
Remove 1 mounting install guide bolt 0.
3.
Using eyebolts 0, sling flywheel move remaining mounting bolts.
4.
Pull flywheel (I) out and lift off. The flywheel pilot portion is shallow, may fall out suddenly, so be careful get your fingers caught.
A
&I kg
Flywheel:
(I),
and
then rea DBCW417
and it not to
60 kg m from the end face of
5.
Remove rear seal (2). Measure the dimension * the housing.
.
Removing standard seal Hook tip of tool A2 to metal ring of seal (21, and use impact force of a slide hammer to pull out. Before pulling out, knock the oil seal in * This separates the seal from the slightly. housing and makes it easier to pull out the seal. Ir Do not use a drill. The metal powder will
I
DBD00418
Tool
A2
Slide
get inside the engine.
.
Removing seal with sleeve I) Hook tip of tool A2 to metal ring of seal (2), and use impact force of a slide hammer to pull out. Before pulling out, knock the oil seal in * This separates the seal from slightly. the housing and makes,it easier to pull 2)
out the seal. Using a chisel and hammer, cut sleeve (3) and remove. Be extremely careful not to damage the * crankshaft when cutting the sleeve. Ir Remove all the metal particles that are
U’
hammer
-,/,
DXD03181
I Standard
with
sleeve
Flywheel houshins
Flywheel houshina
I
‘es1
seal
I
rino Metal of seal
produced.
Crankshaft
3 DXD03182
D155AX-5
30-37 0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION REAR SEAL *
ENGINE
REAR SEAL
OF ENGINE
With the Teflon seal (lay-down lip seal), check the condition of the wear of the shaft, then select either a’standard seal or a seal with a sleeve, and assemble the seal. The condition of wear is judged by the smoothness (depth of wear less than 10 urn when touched with the flat of a finger). If there are no scratches, assemble a standard seal; in all other cases, assemble a seal with a sleeve.
Assembly (Plastic
auide tube)
Standard
seal
Seal
with
sleeve
DEE00103
1.
Procedure for assembling standard seal Before assembling the seal, check that there are no scratches, burrs, flashes, or rust on the housing, lip sliding surface, or at the corner of the end face of the crankshaft. When assembling the seal, do not coat the shaft and seal lip with oil or grease. Wipe off all oil from the shaft. Do not remove the internal plastic tube from the standard seal until the seal is assembled. Put large inside diameter end of internal plastic tube (3) in contact with end of crankshaft (4). Ir Be particularly careful to assemble facing in the correct direction.
Lip
at
engine
end
DEE00104
Lip
at
PTO and
Assembly (Plastic
Large inside diameter end
guide tube)
Small inside diameter end DEE00105
2) Hold metal ring of seal (1) with both hands 3)
and push in with sudden force. After pushing seal in, remove internal plastic tube (3). Ir When removing, be particularly careful not to damage the seal lip.
CEE00434
30-38 0
D155AX-5
DISASSEMBLY
4)
2.
AND
ENGINE
ASSEMBLY
Tighten 3 bolts uniformly until end face of tool A5 (for press fitting seal) contacts end face of crankshaft (4) and press fit seal (I). First, tighten tool A5 ‘(for press fitting seal) until bolt (45 mm) comes into contact, then tighten with bolt (25 mm). When press fitting the seal, be extremely careful not to damage the lip at the PTO end when setting the tool in position. After press fitting the seal, remove all the remains of the red sealant on the outside circumference.
Assembly procedure for seal with sleeve Before assembling the seal, check that there are no scratches, burrs, flashes, or rust on the housing, lip sliding surface, or at the corner of the end face of the crankshaft. When assembling the seal, do not coat the shaft and the area between the sleeve and seal lip with oil or grease. Wipe off all oil from the crankshaft. Always handle the seal and sleeve as a set. Never disassemble it. Set sleeve/seal (2) to tool A5 (for press fitting seal with sleeve). & Surface of tube inside sleeve : Gasket sealant (LG-71
REAR SEAL
CWD02541
Lip of crankshaft side
DXD03186
DXD03187
2)
Put sleeve of seal in contact with end face of crankshaft, then tighten 3 bolts uniformly until end face of tool A5 contacts end face of crankshaft (4) to press fit sleeve/seal (2). Ir First, tighten tool A5 (for press fitting seal with sleeve) until bolt (45 mm) comes into contact, then tighten with bolt (25 mm).
CWDO2543
D155AX-5
DISASSEMBLY
3)
4)
Remove sleeve) seal). Tighten tool A5 face of
ENGINE REAR SEAL
AND ASSEMBLY
tool A5 (for press fitting seal with and install tool A5 (for press fitting 3 bolts uniformly until end face of (for press fitting seal) contacts end crankshaft (4) to press fit sleeve/seal
(2). Ir First, tighten tool A5 (for press fitting seal) until bolt (45 mm) comes into contact, then tighten with bolt (25 mm). Ir After press fitting the seal, remove all the remains of the red sealant on the outside circumference. 3.
CWD02544
Flywheel Using eyebolt @ (12 mm, P=1.75), raise flywheel (I) and tighten to crankshaft with mounting bolts. & Coat the thread and seat of the bolt completely with SAE No. 30 engine oil. & kg Ir
Flywheel
: 60 kg
Tighten the flywheel mounting bolts as follows. & Flywheel mounting bolt : 1st step :
Tighten to 112.7 - 122.5 Nm Ill.5 - 12.5 kgm1 2nd step : I) When using tool Al Using an angle tightening wrench (tool Al), tighten bolts a further 90”+3$ in order @ to 0.
2) When not using tool Al Make wheel bolts @ to
marks on bolt and flywith paint, then tighten a further 90”+3to in order @. DXD03188
*
30-40 0
After tightening, make one punch mark on the bolt head to indicate the number of times it has been tightened. . If any bolt already has five punch marks, do not reuse it. Replace it with a new bolt.
I
Makemarkson
D155AX-5
DISASSEMBLY
AND ASSEMBLY
ENGINE REAR SEAL
DhDOW46
*
After installing the flywheel, use tool CiJ to measure the face runout and radial runout. * Face runout: Max. 0.30 mm * Radial runout: Max. 0.30 mm
D155AX-5
30-41 0
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
REMOVAL OF CYLINDER HEAD ASSEMBLY Serial No. 70001 – 75000 Disconnect the cable from the negative (-) terminal of the battery. 1. Drain coolant. 2. Close fuel supply valve. 3. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. 4. Remove engine side covers (left, right). 5. Remove adiabatic covers (2) and (3). 6. Disconnect tube (4) and hose (5), and lift off air cleaner assembly (6). 6 4 Air cleaner assembly : 35 kg
5
4 DBD00026
7. Remove tube (7), then lift off muffler assembly (8).
8
4 Muffler assembly : 45 kg
7 DBD00027
8. Remove bracket (9).
9
10 9. Disconnect turbocharger lubrication hose (10) and return tube (11). 1
11
30-42 5
DBD00028
D155AX-5
DISASSEMBLY
10. Lift off turbocharger sembly I+ kg
11. Remove
CYLINDER HEAD
AND ASSEMBLY
and exhaust
a
(12). Turbocharger, bly : 50 kg aeration
as-
manifold
exhaust
manifold
tube (13).
assem-
m
hose (14) and tube (151, and remove corrosion resistor (16) and fuel filter (17) together a with bracket. of the electrical inThe ground connection * with the same take air heater is tightened bolt.
12. Disconnect
13. Remove engine oil filter (18). 14. Disconnect dust indicator hose (19). 15. Disconnect 4 heater relay wires (20). +
Make marks when bracket (21).
.
disconnecting.
16. Remove
oil tube (22), oil filler (23), and boost tube (44). compensator 18. Remove clamp bolts of air conditioner hose (241, wiring (251, level gauge (261, fuel hose (271, and m corrosion hose (28). the The bolts are used also for tightening * and length the check so manifold, intake position of installation of the bolts.
17. Remove
Dl!SAX-5
30-43 0
DISASSEMBLY
19. Remove
CYLINDER
AND ASSEMBLY
aftercooler
piping
(451, (46).
45
20. Remove
intake connector
21. Remove
delivery
22. Remove
clamp
of PTO level gauge
CLD02173
(31).
‘and aftercooler
assemm
spill tube (33).
m
25. Remove
delivery
jzJ
tube (34).
26. Remove turbocharger lubrication * No. 3 cylinder head only
head cover.
46
(30).
24. Remove
27. Remove
CL002172
a
(29).
tube clamp
23. Remove intake manifold bly (32).
HEAD
hose (IO). m
a
m 28. Remove rocker arm assembly (35). * Loosen the locknut and turn the adjustment screw back 2 - 3 turns.
30-44 0
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
29. Remove
crosshead
30. Remove
push rod (37).
CYLINDER HEAD
(36).
31. Loosen locknut (38). 32. Remove
connector
33. Remove
holder
34. Using
tool
(39).
(40).
A, remove
nozzle
holder
assembly
(41).
DEW1246
35. Remove
D155AX-5
housing
(42).
DISASSEMBLY
36. Remove f?lkg
30-46 0
AND
cylinder Cylinder
CYLINDER
ASSEMBLY
head assembly head assembly
(43).
HEAD
m
: 30 kg (each)
D155AX-5
CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY
INSTALLATION OF CYLINDER HEAD ASSEMBLY Serial No. 70001 – 75000 • Carry out installation in the reverse order to removal. 1 3 Mounting bolt : 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} 2 fl Tighten the bolts in the order 1 - 3 as shown in the diagram on the right, then tighten in the order 4 - N. 3 Exhaust manifold mounting bolt : 1st step : 29.4 ± 4.9 Nm {3.0 ± 0.5 kgm} 2nd step : 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} 3 3 Joint bolt : 29.4 ± 4.9 Nm {1.15 ± 0.15 kgm) 4 fl Install the hoses without twisting or interference. 3 Joint bolt : 29.4 ± 4.9 Nm {3.0 ± 0.5 kgm} 5 fl Tighten the bolts in the order of 1 - N as shown in the diagram on the right. 3 Intake manifold mounting bolt : 1st step : 29.4 ± 4.9 Nm {3.0 ± 0.5 kgm} 2nd step : 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} 6 3 Intake connector mounting bolt : 49.0 ± 9.8 Nm {5 ± 1 kgm} 7 3 Joint bolt : 8.8 ± 1.0 Nm {0.9 ± 0.1 kgm} 8 3 Delivery tube sleeve nut : 23.5 ± 1.0 Nm {2.4 ± 0.1 kgm} 9 3 Head cover mounting bolt : 24.5 ± 9.8 Nm {2.5 ± 1.0 kgm} 0 fl Clean the mounting bolt oil holes before installing. fl Check that the ball of the adjustment screw is fitted properly into the socket of the push
D155AX-5
i !8
!9 o r!4
u!7
@0 w
q!3
!5 t !0 @2
!6 y
e@1
@3 !1
@4 !2
DBD00041
@2 !8 !4 !0 y w e
@1 !7
u
!1 !5 !9 @3
!3 o t q r i !2 !6 @0 @4
DAD00042
rod. fl Adjust the valve clearance. For details, see TESTING AND ADJUSTING, ADJUSTING VALVE CLEARANCE. 3 Rocker arm assembly : 98 ± 4.9 Nm {10 ± 0.5 kgm} 3 Locknut : 48.0 ± 2.9 Nm {4.9 ± 0.3 kgm} A fl Adjust the crosshead as follows. 1) Loosen locknut, then turn adjustment screw back. 2) Press top of crosshead lightly and tighten adjustment screw. 3) When adjustment screw contacts valve stem, screw in a further 20°. 4) Tighten locknut to hold in position. 3 Locknut : 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm} B 3 Locknut : 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
30-47 5
DISASSEMBLY
CYLINDER HEAD
AND ASSEMBLY
m w
Connector
m
Holder
: 31.9 +. 2.5 Nm (3.25 2 0.25 kgm)
1 mounting
bolt : 66.2 + 7.4 Nm 16.75 t 0.75 kgm}
*
+ * *
Check that there is no dirt or dust on the cylinder head mounting surface or inside the cylinder. When installing the gasket, check that the grommet does not come out. Coat the bolt thread and seat face completely with molybdenum disulphide (LM-PI. Tighten the cylinder head mounting bolts in the order given in the diagram. & Cylinder head mounting bolt : Anti-friction compound (LM-PI w Cylinder head mounting bolt :
1st step : Tighten
to 147 r 9.8 Nm {I5 f 1 kgml 2nd step : Tighten to 215.6 + 4.9 Nm (22 f 0.5 kgm} 3rd step : 1) When using tool B . Using an angle tightening wrench, tighten bolt 90°+3r. 2) When not using tool B . Make marks on bolt and flywheel with a felt pen, then tighten bolt 90”.
Make marks on cylinderhead and bolt
Ir Tighten bolt 0 to 66.2 * 7.4 Nm (6.75 f 0.75 kgm) one time. * After tightening, make one punch mark on the bolt head to indicate the number of times it has been tightened. If any bolt already has five punch marks, do not reuse it. Replace it with a new bolt.
I
DAD03345
l
.
Refilling with water l
*
30-48 0
Make mark with punch
Add water through water filler to the specified level. Run the engine to circulate the water through Then check the water level the system. again.
D155AX-5
DISASSEMBLY
THERMOSTAT
AND ASSEMBLY
REMOVAL OF THERMOSTAT ASSEMBLY 1.
Drain coolant.
2.
Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR SEMBLY. inlet hose (1).
3.
Disconnect
radiator
4.
Disconnect
bypass tube (2).
5.
Remove
cover (3).
6.
Remove
2 thermostats
INSTALLATION THERMOSTAT l
l
Carry out installation removal.
AS-
(4).
OF ASSEMBLY in the
reverse
order
to
Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through t Then check the water level the system. again.
D155AX-5
DBDW422
30-49 0
DISASSEMBLY AND ASSEMBLY
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY
AIR CONDITIONER COMPRESSOR
Serial No. 70001 – 75000
1 3
Using tool X, collect freon gas (R134a).
2 1. Open engine left side cover (top) and remove cover (bottom). 2. Remove wiring connector (1).
4
3. Disconnect hoses (2) and (3). 1 fl Fit blind plugs to prevent dirt or water from entering the hoses.
DBD00423
Serial No. 70001 – 75000 4. Loosen 4 mounting bolts (4). 5. Remove V-belt cover (5). 6 6. Loosen adjustment bolt (6) and remove. 7. Remove mounting bolts (4), remove V-belt (7) from pulley, then remove compressor assembly (8). 2
5 DBD00424
Serial No. 70001 – 75000 4
8
7
DBD00425
Serial No. 75001 and up
30-50 5
D155AX-5
DISASSEMBLY
AIR CONDITIONER COMPRESSOR
AND ASSEMBLY
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY .
Carry out installation removal.
m*
sr *
m
in the
reverse
order
to
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Showa Shell Suniso 4G or 5G). Tighten the air conditioner gas piping to the following tightening torques. Thread
size Tightening
torque
(Nm {knmH
Remarks
16 x 1.5
11.8.- 14.7 II.2 - 1.51 Liquid
22 x 1.5
19.6 - 24.5 (2.0 - 2.5) Discharge
24 x 1.5
29.4 - 34.3 (3.0 - 3.51 Suction
p?J *
l
After installing the V-belt, adjust the belt tension. For details, see TESTING AND ADJUSTING, TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.
Charging with air conditioner
gas
Using tool S, charge the air conditioner with air conditioner gas (R134a).
D155AX-5
circuit
30-5 1 0
DISASSEMBLY
AIR CONDITIONER
AND ASSEMBLY
COMPRESSOR
REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY APark
the
machine on level ground, lower the completely to the ground, then disconnect the cable from the negative (-1 terminal of the battery.
work equipment
1. Using tool X, collect freon gas (R134a).
2.
Open side cover (I) and disconnect nector (2) (CN223).
3.
Remove & kg
wiring
con-
cover (3). Cover : 30 kg
4.
Disconnect hose (4) from receiver tank and hose (5) from air conditioner compressor. a Ir The condenser hose mount breaks easily, so always use wrenches on both sides.
5.
Disconnect
6.
Remove mounting bolts, then remove tioner condenser assembly (7).
wiring
connector
INSTALLATION CONDITIONER ASSEMBLY l
m
Carry out removal.
* * *
l
installation
(6) (ARC). air condi-
OF AIR CONDENSER in the
reverse
order
to
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses, and coat the O-rings thoroughly with compressor oil before connecting.
Charging with air conditioner gas Using tool X, charge with freon gas (R134a).
30-52 0
D155AX-5
DISASSEMBLY
AIR CONDITIONER COMPRESSOR
AND ASSEMBLY
REMOVAL OF FUEL TANK ASSEMBLY a
Park the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (-1 terminal of the battery.
1.
Remove
2.
Close lever (2) of fuel valve.
3.
Disconnect
hose (3) leading
4.
Disconnect
fuel return hoses (4) and (5).
5.
Disconnect fuel (6) (CN422).
6.
Lift off fuel tank assembly (7). + Sling at three points and use a lever block at the center to keep the tank horizontal. + Move the tank to the rear, and when it clears the floor frame, raise the rear of the tank slightly with the lever block. (Do this to avoid interference with the ripper hoses.)
cover (I) at bottom
level sensor
of fuel tank.
to priming
wiring
pump.
connector
INSTALLATION OF FUEL TANK ASSEMBLY . Carry out installation in the reverse order to removal.
D155AX-5
30-53 a
DISASSEMBLY
RADIATOR
AND ASSEMBLY
REMOVAL OF RADIATOR ASSEMBLY Lower the A ground.
work equipment
completely
to the
Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the cable from the negative (-1 terminal of the battery.
A..
7
/
_.
1. Remove hood assembly.
For details, see REMOVAL OF HOOD ASSEMBLY. 2. Drain coolant. 3. Lift opposite side of hinge and gradually open underguard under engine. 4. Disconnect 2 power train oil cooler hoses (I). 5. Disconnect 2 radiator hoses (2). 6. Disconnect clamp (3) for hydraulic cooler hose from radiator. 7. Open radiator grill (4). 8. Remove radiator top cover (5) and left and right side plates. 9. Disconnect hydraulic cooler hose (6) and remove clamp.
10. Loosen locknuts on locknuts on hydraulic cooler assembly swing bolts (71, and screw bolts into both top and bottom swing holes (condition a). 11. Remove 8 bracket mounting bolts (81, and open hydraulic cooler assembly (9) to front.
30-54 0
D155AX-5
RADIATOR
DISASSEMBLY
AND ASSEMBLY
12. Disconnect
radiator
inlet hose (IO).
m
13. Disconnect
aeration
hose (1 I).
a
14. Disconnect
sub-tank
hose (12).
15. Disconnect head lamp connector (13) (CN2011, then remove 6 clamps and move wiring towards head lamp. 16. Remove
left and right hood mount brackets (14).
17. Remove
seal (15).
18. Remove
bottom
19. Remove
seal (17).
20. Remove
top mount
mount
bracket (16).
bolt (18).
17
16
21. Lift off radiator assembly (19). * Be extremely careful not to damage the seal or radiator core when removing the radiator. &l kg
D155AX-5
Radiator
assembly
: 329 kg
30-55 0
DISASSEMBLY
AND ASSEMBLY
RADIATOR
INSTALLATION OF RADIATOR ASSEMBLY l
Carry out installation removal.
I
in the reverse order to
If *
After installing the hydraulic cooler assembly, remove bolts (7) from both top and bottom swing holes, then fix them at the original positions with the locknuts (condition b).
m m
Radiator inlet hose clamp : 882.6 + 49.0 Ncm I90 t 5 kgcm)
m
Aeration hose clamp : 333.4 2 49.0 Ncm (34 + 5 kgcml
Refilling
with
a
b
water
Add water through water filler to the specified level. * Run the engine to circulate the water through the system. Then check the water level again. Refilling case)
with
oil (hydraulic
tank,
power
train
Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
30-56 0
Dl MAX-5
RADIATOR,
AND ASSEMBLY
DISASSEMBLY
OIL COOLER,
GUARD
REMOVAL OF RADIATOR, OIL COOLER, GUARD ASSEMBLY 1. Drain coolant. from assembly blade lift cylinder 2. Disconnect guard. to secure blade, then For details, see REMOVAL OF BLADE ASSEMBLY. 3. Lift engine undercover at opposit end of hinge and open engine undercover gradually. hoses (I).
4. Disconnect
2 blade lift cylinder
5. Disconnect
2 hydraulic
6. Disconnect
2 power train oil cooler hoses (3).
7. Disconnect
2 radiator
cooler hoses (2).
hoses (4).
8. Remove hood assembly (5). For details, see REMOVAL OF HOOD ASSEMBLY. 9. Remove
left and right covers (6).
IO. Remove
left and right side covers (7).
11. Remove
radiator
I
DELM429
I
B/---T
top cover (8).
If 12. Disconnect radiator inlet hose (9). move and end at the radiator Disconnect * towards the engine. @ 13. Disconnect aeration hose (IO). Sr Disconnect at the radiator end, then remove 2 clamps and move towards the engine. m hose (II). 14. Disconnect air conditioner + Loosen the sleeve nut slightly, and release gas (R134a) completely the air conditioner the hose. before disconnecting * Fit blind plugs to prevent dirt or water from entering 15. Disconnect (CN201).
D155AX-5
the hoses. head lamp
wiring
connector
(12)
30-57
DISASSEMBLY
AND ASSEMBLY
RADIATOR, OIL COOLER, GUARD
16. Remove fan guard (13).
17. Push tension and remove
pulley (141, loosen fan belt (15).
belt tension,
DElXM4.23
18. Remove
head lamp (16).
/
I- II DEW0434
19. Sling radiator,
oil cooler, guard assembly (171, remove lock plate, then remove 4 pins (181, and lift off radiator, oil cooler, guard assembly (17). Ir Be extremely careful not to damage the wiring and hoses when removing.
&I kg
30-58 0
Radiator,
oil cooler,
guard assembly : 2,050 kg
Dl E&AX-5
DISASSEMBLY
AND ASSEMBLY
RADIATOR,
OIL COOLER,
GUARD
INSTALLATION OF RADIATOR, OIL COOLER, GUARD ASSEMBLY .
Carry out removal.
installation
w
Radiator
w
Aeration
in the
reverse
order
to
inlet hose clamp : 882.6 t 49.10 Ncm I90 z 5 kgcm}
hose clamp
: 333.4 + 49.0 Ncm 64
+. 5 kgcml
.
Refilling with water Add water through water filler to the specified level. Ir Run the engine to circulate the water through the system. Then check the water level again.
.
Refilling with oil (hydraulic tank, power train case) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
D155AX-5
30-59 0
DISASSEMBLY
FAN DRIVE
AND ASSEMBLY
REMOVAL OF FAN DRIVE ASSEMBLY Disconnect the cable A minal of the battery.
(-1 ter-
the negative
from
1. Drain coolant.
2. Remove
hood assembly. For details, see REMOVAL BLY.
3. Remove
radiator side plates.
OF HOOD
top cover
left and
and
radiator inlet hose (I) engine end.
4. Disconnect towards
5. Disconnect clamp
aeration bracket (3).
6. Disconnect wards
sub-tank sub-tank end.
7. Disconnect
right
and move m
it
hose (2) and remove
hose m
(4) and move
it to-
hose (5).
a
hose
air conditioner
8. Remove condenser,
ASSEM-
guard, and sub-tank
assem-
bly (6). +I kg
Condenser,
guard,
sub-tank
assembly : 25 kg
wrench, push tension pulley (8) of fan belt (71, and remove fan belt (7).
9. Using an adjustable
IO. Remove
fan guard
as 3 parts.in
order (91, (IO),
(II).
30-60 0
D155AX-5
DISASSEMBLY
FAN DRIVE
AND ASSEMBLY
head lamp connector (12) (CN201), then remove 2 clamps and move wiring towards radiator.
11. Disconnect
12. Remove left and right hood mount brackets (13). 13. Remove
seal (14).
eyebolts 0, sling fan drive and guard assembly (151, then remove mounting bolts, and remove assembly.
14. Using
&I kg
Fan drive, guard assembly
: 150 kg
15. Remove guard (17) from fan drive assembly
(16).
16
INSTALLATION ASSEMBLY .
Carry out removal.
installation
OF FAN DRIVE in the
reverse
order
to
B
Radiator
inlet hose clamp : 882.6 t 49.0 Ncm I90 +. 5 kgcm}
B
Aeration
hose clamp : 333.4 + 49.0 Ncm I34 2 5 kgcm1
D155AX-5
30-61 0
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC COOLER
REMOVAL OF HYDRAULIC COOLER ASSEMBLY ALower the work equipment completely to the ground. Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank. 1.
Open radiator grill (1).
2.
Remove cover (2).
3.
Disconnect hoses (3) and (41, and clamp (5).
4.
Loosen locknuts on hydraulic cooler assembly swing bolts (61, and screw bolts into both top and bottom swing holes (condition a).
5.
Remove 8 bracket mounting bolts (7)
6.
Open hydraulic cooler assembly (8) to front.
7.
List off hydraulic cooler assembly (8). kg rz+l
Hydraulic cooler assembly : 1’05 kg
INSTALLATION OF HYDRAULIC COOLER ASSEMBLY l
.
Carry out installation removal.
in the reverse order to
Refilling with oil (hydraulic tank) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
30-62 0
D155AX-5
DISASSEMBLY AND ASSEMBLY
ENGINE
REMOVAL OF ENGINE ASSEMBLY Serial No. 70001 – 75000
Disconnect
the cable from the negative (–) terminal of the battery.
fl Close the supply valve of the fuel tank. 1. Remove radiator, oil cooler, guard assembly. For details, see REMOVAL OF RADIATOR, OIL COOLER, GUARD ASSEMBLY.
1 DED00436
2. Disconnect starting motor wiring (1). 3. Disconnect engine speed sensor connectors (2) (CN009, CN010).
2
DED00437
4. Disconnect wiring connector (3) (CN101). 5. Disconnect 2 air conditioner hoses (4). 1 fl Loosen the sleeve nut slightly, and release the air conditioner gas (R134a) completely before disconnecting the hose. fl Fit blind plugs to prevent dirt or water from entering the hoses. fl Disconnect at the air conditioner end, then remove all the clamps from the floor frame and move towards the engine.
3
DED00438
6. Disconnect 2 heater hoses (5). fl Disconnect at the air conditioner end, then move towards the engine.
4
5 DED00439
D155AX-5
30-63 5
DISASSEMBLY
hose (6).
7. Disconnect
fuel supply
8. Disconnect
fuel return hose (7).
9. Disconnect
fuel control
10. Disconnect
ENGINE
AND ASSEMBLY
ground
rod (8).
wiring
(9).
-”
11. Disconnect
universal
12. Remove front mount bolts (12).
joint (IO) at damper
7 -
‘6
DEW0440
end.
bolts (11) and rear mount m
11
12
(13) towards front of 13. Move engine assembly machine, and lift off gradually. Be careful not to damage the wiring or hoses * when removing the engine assembly. &I kg
30-64 0
Engine assembly
: 1,750 kg
D155AX-5
DISASSEMBLY AND ASSEMBLY
ENGINE
Serial No. 75001 and up
¤ Disconnect
the cable from the negative (-) terminal of the battery. fl Close the fuel feed valve. 1. Remove radiator and oil cooler and guard assembly. For details, see REMOVAL OF RADIATOR AND OIL COOLER AND GUARD ASSEMBLY.
2. Disconnect starting motor wiring (1). 3. Disconnect wiring connector (2). 4. Disconnect 2 air conditioner house (3). 1 fl Loosen the sleeve nut of each hose a little to discharge the all air conditioner refrigerant (R134a), then disconnect the hose. fl Plug the hoses to prevent dirt, water, etc. from entering them. fl Remove the all clamps on the floor frame and move the hoses toward the engine.
5. Disconnect 2 heater hoese (4).
6. Disconnect air conditioner wiring connector (5). 7. Disconnect fuel hoses (6), (7), and (8).
D155AX-5
30-64-1 5
DISASSEMBLY AND ASSEMBLY
ENGINE
8. Disconnect ground wire (9).
9. Disconnect universal joint (10) from damper.
10. Remove front mounting bolts (11) and rear mounting bolts (12). 2
11. Moving engine assembly (13) to front of machine body, lift it off gradually. fl After removing the engine assembly, take care not to damage the wires, hoses, etc. 4 Engine assembly : 1,750 kg
30-64-2 5
D155AX-5
DISASSEMBLY
INSTALLATION ASSEMBLY l
a
Carry out installation removal.
* * *
w
ENGINE
AND ASSEMBLY
OF ENGINE in the
reverse
order
to
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Shell Suniso 4G or 5G). Tighten the air conditioner gas piping to the following tightening torques. Thread
m
size Tightening torque (Nm Mm))
Remarks
16 x 1.5
11.8 - 14.7 Il.2 - 1.5} Liquid
22 x 1.5
19.6 - 24.5 {2.0 - 2.5) Discharge
24 x 1.5
29.4 - 34.3 13.0 - 3.51 Suction
Engine
mount
bolt:
931.7 + 98.1 Nm I95 t 10 kgm1
D155AX-5
30-65 0
DISASSEMBLY
AND ASSEMBLY
DAMPER
REMOVAL OF DAMPER ASSEMBLY 1.
Drain oil from damper -
2.
3.
:
Damper
chamber.
chamber
: 1.5 1
Remove floor frame assembly. For details, see REMOVAL OF FLOOR ASSEMBLY.
FRAME
Lift off HMT pump assembly. For details, see REMOVAL OF HMT PUMP SEMBLY.
AS-
4.
Disconnect or to power train FOR DETAILS, LUBRICATION
5.
Disconnect breather hose (I) and remove stick tube (2) together with hose.
6.
Lift off universal joint assembly (31, then remove coupling (4) at torque converter end. m
7.
Remove mounting bolts of damper cover assembly (5), then install (2) guide bolts @ on opposite sides, and use forcing screws @ to pull damper cover (6) out to position where it is possible to install lifting tool. /KJ
8.
Lift off damper
cover assembly
(6).
Damper
cover assembly
: 117 kg
kg rz?l
30-66 0
remove piping and hoses installed and lubrication pump. SEE REMOVAL OF POWER TRAIN, PUMP ASSEMBLY. dip-
a
Dl !XAX-5
DISASSEMBLY
9.
DAMPER
AND ASSEMBLY
Removal of Damper 1) Remove 2 mounting bolts of damper (71, then m set guide bolts @ in position. 2) Remove remaining mounting bolts, then use m forcing screws @I to pull out. 3) Pull out to position where it is possible to install eyebolts 0, set lifting tool to damper (7), then remove.
INSTALLATION ASSEMBLY l
Carry out removal.
OF DAMPER
installation
in the
reverse
order
to
a bolt : Thread tightener (LT-2) Universal joint mounting bolt : 110.8 + 12.7 Nm (II.3 +11.3 kgm) joint mounting
Universal
& w
Damper cover Mounting bolt : 110.8 = 12.7 Nm Ill.3 F 1.3 kgm)
m m *
When installing the damper cover assembly, remove all oil and grease from the shaft spline, coat with dry lubricant A, leave for 2 or 3 minutes, then coat with lithium-based pressure extreme disulphide molybdenum grease B, and assemble. Level Dlua.
A
Dry type molybdenum disulphide
SUMICO LUB: ROCOL DRY SPRAY
-
B
m
l
Mounting bolt : 110.8 + 12.7 Nm Ill.3
Damper
I 1.3 kgm}
Refilling with oil chamber
: 1.5 e (SAE30CDl
Q
Damper
w
Plug : 152.0 + 24.5 Nm 115.5 z 2.5 kgm}
D 155/4X-5
30-67 0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
DAMPER
OF DAMPER ASSEMBLY
I
16
lXiXJ1208
Disassembly of damper cover assembly (II 1. Coupling Remove bolt (3) from cover (21, then remove holder (4) and coupling (5).
DEEOG3.M
30-68 0
D155AX-5
DISASSEMBLY
2.
DAMPER
AND ASSEMBLY
Shaft I)
Set damper cover assembly (I) to block 0, then tap from output end with a plastic hammer, and pull out shaft (6). * Remove shaft (6) together with oil seal (8) and inner race (7-I) of bearing (7).
8
7-l
2)
Remove collar (7-2) and O-ring of bearing (7) from shaft (61, then remove inner race (7-
7-l
I).
DDiXI1209
7-2
I
/
/ O-ring DEW1210
3.
Bearing, oil seal 1)
9
Remove oil seal (9) from cover (2), then remove inner race (7-3) of bearing (7).
7-3
I 2)
2
DDWl211
Remove outer races (7-4) and (7-5) of bearing (7) from cover (2).
7-k
D155AX-5
DDco1212
30-69
DISASSEMBLY
AND ASSEMBLY
DAMPER
Disassembly of damper assembly (101 4. Remove bolt (111, then remove flange
(12).
5.
Remove outer cushion (15).
(14), and
6.
Pull out plug (17) from flange (16). Ir Only when replacing the plug.
body
(131, inner
body
16
15
17
14
13 DDDO1213
30-70 0
Dl SAX-5
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
DAMPER
OF DAMPER ASSEMBLY
I
16
Assembly of damper assembly (101 1. Align bolt holes of flange (16) and outer body (13) with cylinder 0, then assemble inner body (14). & & &
surface of flange, outer body : Gasket sealant (LG-41 Inside surface of outer body : Grease (G2-LII Cushion contact surface of inner body : Grease (G2-LII
14
Mating
‘13
DDccl1214
D155AX-5
30-71 0
DISASSEMBLY
2.
AND ASSEMBLY
DAMPER
Assemble cushion (15). Ir Coat the whole surface of the cushion with grease (G2-LI). Ir After assembling the cushion, fill 30% of the clearance (16 places) between the inner body and outer body with grease.
‘Cushion
DEDo1215
3.
Assemble flange -Mounting
(12) and tighten with bolt (11). bolt : 66.2 = 7.4 Nm 16.75 = 0.75 kgm}
4.
Filling with grease I) Fill inner body @ with 800 g of grease listed below. 6 : Grease Brand name
Grease
KYODO YUSHI: MORILEX NO. 2 SHOWA SHELL: RETINAX AM NIPPON OIL: MORITEX NO. 2 or equivalent l
Lithium lubricant grease with molybdenum disulphide
l
l
‘0 a
DOD01217
Assembly of damper cover assembly (1) 5. Using push tool 0, press fit outer races (7-4) and (7-5) of bearing (7) to cover (2) with press.
30-72 0
D155AX-5
DISASSEMBLY
DAMPER
AND ASSEMBLY
Press fit inner race (7-I) of bearing (6) with tools Cl and C2.
(7) to shaft
6
7.
Assemble
collar (7-2) and O-ring to shaft (6). 6 \
7-l I
7-2 /
/ O-ring DEW1210
8.
Set cover (2) to shaft (6), and using tool B, press fit bearing inner race (7-3).
CWD02546
9.
Install oil seals (8) and (9) to cover assembly & Oil seal press-fitting surface :
(2).
Gasket sealant (LG-5) & *
Lip of oil seal : Grease (G2-LII Coat the oil seal surface thinly with gasket sealant and wipe off any sealant that is squeezed out.
/
/
D155AX-5
/Lu /
//
/
30-73 0
DISASSEMBLY
DAMPER
AND ASSEMBLY
10. Coupling Assemble coupling (5) and holder (41, and tighten bolt (3). w Mounting bolt : 277.5 + 32.4 Nm 128.3 + 3.3 kgm}
2 DE!xo504
30-74 0
D155AX-5
DISASSEMBLY AND ASSEMBLY
POWER TRAIN UNIT
REMOVAL OF POWER TRAIN UNIT ASSEMBLY Serial No. 70001 – 75000
¤ Park
the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (-) terminal of the battery.
1. Drain oil 6 Hydraulic tank : Approx. 97 ¬ 6 Power train case: Approx. 60 ¬ 2. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 3. Open bottom plate at bottom of power train unit. 4. Remove cover (1) at bottom of fuel tank. 5. Close lever (2) of fuel valve. 6. Disconnect hose (3) leading to priming pump. 7. Disconnect fuel return hoses (4) and (5). 8. Disconnect fuel level sensor wiring connector (6) (CN422). 9. Lift off fuel tank assembly (7). fl Sling at three points and use a lever block at the center to keep the tank horizontal. fl Move the tank to the rear, and when it clears the floor frame, raise the rear of the tank slightly with the lever block. (Do this to avoid interference with the ripper hoses.) 4 Fuel tank assembly (when full) : 760 kg 10. Disconnect engine speed sensor wiring connector (8). 11. Disconnect suction tube (9) of 3-spool pump (HSS lubrication, torque converter, transmission charge). fl Remove the cover at the top of the pump.
D155AX-5
30-75 5
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN UNIT
12. Remove suspension rod (IO).
13. Remove top cover of centralized pressure detection port, then remove centralized pressure detection block (11) from frame.
14. Disconnect hose (12) between hydraulic pump and control valve. 15. Disconnect wiring connector (13) (HHP). 16. Remove suction tube (14). * Be careful not to damage the gasket of the joint.
17. Disconnect hose (15) between cooler bypass valve and hydraulic tank. 18. Disconnect hose (16) between charge relief valve and hydraulic tank. 19. Remove power train oil supply pipe (17). 20. Disconnect power train dipstick tube (18) from case, and move towards right side of chassis.
30-76 0
D155AX-5
POWER TRAIN UNIT
DISASSEMBLY
AND ASSEMBLY
21. Disconnect
(19)
between
oil cooler
(22)
between
filter
hose transmission. 22. Disconnect hose transmission. 23. Disconnect hoses bypass valve and
and
case and
(20) and (21) between oil cooler.
cooler
24. Disconnect hose (23) between HSS pump and charge filter. 25. Disconnect hose (24) between charge + scavenging pump and charge filter. 26. Disconnect hose (25) between HSS solenoid valve and HSS, PPC charge valve at solenoid valve end.
27. Disconnect hose (26) between oil cooler and transmission lubrication valve. * Open the guard (bottom plate) under the transmission when carrying out the operation.
28. Disconnect drive shaft (27) at torque converter m end. Ir After disconnecting, push the yoke towards the torque converter and disconnect completely.
D155AX-5
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN UNIT
Remove final drive shaft cover (281, then use bolt @ to pull out drive shaft (29) to a point where spline at steering case end comes out. Ir If the shaft does not come out, move the sprocket (push up the shoe grouser from the ground surface with a jack) to adjust to a position where the shaft comes out, then pull out the shaft.
30. Remove mount caps (30) at both ends of steerm ing case together with cover.
31. Loosen coupling clamp (311, and move (open) m seal (32) slightly to outside.
32. Remove front mount bolt (33).
30-78 0
Dl SAX-5
DISASSEMBLY AND ASSEMBLY
POWER TRAIN UNIT
33. Lift off power train unit assembly (34). 5 fl Check that the wiring and piping has all been removed, then lift off the power train unit assembly. 4
Power train unit assembly : 2800 kg
INSTALLATION OF POWER TRAIN UNIT ASSEMBLY Serial No. 70001 – 75000 •
Carry out installation in the reverse order to removal.
1 3 Universal joint mounting bolt : 110.3 ± 22.1 Nm {11.3 ± 2.3 kgm} 2 3 Mount cap mounting bolt : 277.5 ± 32.4 Nm {28.3 ± 3.3 kgm} 3 fl Clamp the protruding portion of the coupling seal, then assemble the clamp thread so that it is parallel to the cap mount seat surface. 4 3 Front mount mounting bolt : 926.8 ± 103.0 Nm {94.5 ± 10.5 kgm} 5 fl When assembling the power train assembly, be extremely careful not to damage seal (32). •
Refilling with oil (Hydraulic tank. power train case.) Add engine oil through oil filler to the specified level. fl Run the engine to circulate the oil through the system. Then check the oil level again. 5
Hydraulic tank : Approx. 97 ¬
5
Power train case : Approx. 60 ¬
D155AX-5
30-79 5 1
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN UNIT
SEPARATION OF POWER TRAIN UNIT ASSEMBLY .
Drain oil Before setting the power train unit assembly on the block, drain the oil from the PTO case. 1. Raise power train unit assembly (I) and set on block 0. &I kg
2. 3. 4.
5. 6. 7.
8.
Power train unit assembly : 2800 kg
Disconnect 3 hoses (2) connected to cooler bypass valve. Disconnect HSS pump connecting hose (3). Remove cooler bypass valve assembly (4) together with bracket.
Disconnect 5 charge relief valve connecting hoses (5). Disconnect wiring connector (6) (CN406). Remove charge relief valve (7).
Disconnect pressure detection hoses (8) and (9), and remove reducing pressure valve hose (IO). m Ir Disconnect the transmission modulation pressure detection hose.
30-80 a
D155AX-5
DISASSEMBLY
9. Disconnect
10. Remove
POWER TRAIN
AND ASSEMBLY
pressure
hydraulic Hydraulic
hose (11).
detection
pump
assembly
UNIT
m
(12).
: 19 kg
pump assembly
j, Disconnect the wiring connector (HHP). 11. Remove 2 suction tubes (13) from S-spool pump and charge pump. 12. Disconnect PTO lubrication tube (14). lubrication tube (15). 13. Disconnect transmission m
14. Disconnect 3 HSS pump connecting hoses (16). HSS pump solenoid valve wiring 15. Disconnect connectors (17) (PUPA-A, B). 16. Disconnect piping (18) and lift off 3-spool pump assembly (19). &I kg
3-spool
pump assembly
17. Lift off HSS pump assembly & kg
D155AX-5
HSS pump assembly
: 24 kg
(20).
: 116 kg
30-81 0
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN UNIT
18. Remove suction tube (21) and lift off PPC charge + scavenging pump assembly (22). +I kg
Pump assembly : 36 kg
G-l 19. Disconnection of steerina case Raise steering case &d of power train unit 1) assembly. 2) Remove mounting bolts at bottom of steering case (231, and set block @ under transmission case. 3) Remove remaining mounting bolts, then raise steering case assembly (23) and disconnect. A kg
2
Steering case assembly : JO00 kg
20. Set PTO, torque converter, and transmission assembly (24) on block @ with PTO facing up. 24
21. Remove strainer cover (251, then remove spring (26) and strainer (27). m
30-82 0
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
22. Remove
temperature sensor pull out 2 sleeves (29).
23. Remove sembly
mounting (30).
bolts,
r+ kg
PTO assembly
POWER TRAIN UNIT
bracket
then
(281, and
lift off PTO as-
: 200 kg
m
24. Sling torque
converter assembly (311, and remove mounting bolts, then use forcing screws @ to remove torque converter assembly (31).
& kg
D155AX-5
Torque
converter
assembly
: 130 kgm
30-83 0
DISASSEMBLY
POWER TRAIN
AND ASSEMBLY
CONNECTION OF POWER TRAIN ASSEMBLY Carry out connection disconnection.
l
in the reverse order to
m .
Install the piping of the pressure detection tubes as shown in the diagram below. (There are distinguishing color bands installed to each detection tube.)
WHITE
:
b BLACK
Transmission Pressure
YELLOW
RED WHITE
:
Torque RED
converter
:
YELLOW
:
Brake
m
Suction tube mounting bolt : 66.2 +. 7.4 Nm 16.75 + 0.75 kgm}
m
Steering case mounting bolt : 110.3 = 12.3 Nm Ill.25 2 1.25 kgm1
w
Strainer mounting bolt : 66.2 = 7.4 Nm 16.75 + 0.75 kgm}
converter
Torque
WHITE
I BLACK
Pressure
L
Torque
:
Brake
Pressure
converter
L
inlet
outlet
Torque
:
WHITE
:
:
modurated
converter
Transmission Pressure
inlet outlet modurated DXD03 189
If
pJ
-PTO
assembly mounting bolt : 110.3 f 12.3 Nm (11.25 + 1.25 kgm}
116 & m
30-84 0
Torque converter mounting bolt : Thread tightener (LT-21 Torque converter mounting bolt : 66.2 + 7.4 Nm I6.75 2 0.75 kgm}
D155AX-5
DISASSEMBLY
PTO
AND ASSEMBLY
DISASSEMBLY
OF PTO
ASSEMBLY 1.
Lubrication tube 1) Remove shaft lubrication
2)
Remove
pump
drive
tube (I).
gear
lubrication
tube
(2).
2.
HSS pump drive gear, cover assembly 1) Remove mounting bolts, set guide bolt @ in position, then use forcing screws @ to remove gear and cover assembly (3).
2)
Disassemble gear and cover assembly as follows. i) Remove cover (4) from gear and bearing assembly (5).
CWD02587
D 155AX-5
30-85 a
DISASSEMBLY
ii)
PTO
AND ASSEMBLY
Remove
bearing
(6) from gear (7).
CWD02589
3.
Cover assembly bolts, then use forcing I) Remove mounting screws @ and guide bolt @ to remove gear and cover assembly (8).
CWD02591
2)
Remove
3)
(IO). Using puller 0, remove gear assembly from cover assembly (12).
snap ring (91, then
remove
spacer (11)
CWD02592
4) 5)
Remove snap race (14) from Remove snap ing (17) from
ring gear ring cover
(131, then remove assembly (15). (161, then remove assembly.
inner bear-
I
30-86 a
CWD02594
D155AX-5
DISASSEMBLY
4.
PTO
AND ASSEMBLY
Scavenging pump drive gear 1) Remove snap ring (18).
2)
Knock end.
3)
Remove snap ring (20), then ing (21).
out drive
gear
I/
(19) from
snap
remove
L 18
I
ring
bear-
CWD02598
5.
idler gear 1) Remove
mounting
bolts, then remove
plate
(22).
CWD02599
D 155AX-5
30-87 0
DISASSEMBLY
2)
Remove mounting bolts, set guide bolt @ in position, then use forcing screws 0 to remove shaft (23).
3)
Remove bearing (25) and spacer (26) from gear (24). * If the parts are to be used again, keep them as a set with the outer race to prevent the set from being changed. Remove bearing outer race (27) and snap ring (28) from gear (24).
4)
6.
PTO
AND ASSEMBLY
Input shaft outer race Remove snap ring (291, then remove outer race (30).
input shaft
CWD02602
7.
Magnet assembly I) Remove mounting 2)
(31). Remove
spring
bolts, then remove
(32) and magnet
cover
assembly
(33).
I
30-88 0
CWD02603
D155AX-5
DISASSEMBLY
ASSEMBLY ASSEMBLY Ir *
*
1.
OF PTO
Clean all parts, and check for dirt or damage. After press fitting the bearing, apply 6 cc of SAEIOWCD or SAE30CD in drops, then rotate about 10 times. Check that the snap ring is fitted securely in the groove. Magnet assembly 1) Assemble magnet 2)
2.
PTO
AND ASSEMBLY
assembly
(33) and spring
(32). Install cover (31).
I
CWD02603
input shaft outer race 1) Press fit input shaft outer race (301, and install snap ring (29).
CWD02602
3.
idler gear There are manufacturing numbers and symbols on the bearing and spacer, so form sets with the same manufacturing number and symbol when assembling.
Fit snap ring (28) to gear (241, and press fit outer race (27).
24
27
I
\ 1
L
J
CWD02606
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
PTO
Using 3 guide bolts (91, insert shaft (23) to position shown in diagram. * If shaft (23) is inserted fully, gear (24) cannot be .installed. & : Grease (G2-LI)
CWD0260Y L
3) 4)
Install bearing (25) to shaft (23). Install spacer (26).
5) 6)
Install gear (24). Fit bearing (25), then tighten plate (22) with bolt and press fit to shaft. & Mounting bolt : Thread tightener (LT-21 m Mounting bolt : 277.0 f 31.9 Nm (28.25 i 3.25 kgml Secure shaft (23) with mounting bolts. & Mounting bolt : Thread tightener (LT-2) m Mounting bolt : 110.3 z 12.3 Nm Ill.25 + 1.25 kgm)
7)
7.
I
CWD02610
Scavenging pump drive gear I) Press fit bearing (20) to case, and install snap ring (37).
CWD0259t
30-90 0
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
PTO
Hold inner race end of bearing with tool @, and install drive gear (19).
push
CWD0'2612
3)
tnstall snap ring (16).
CWDO2596
5.
Cover assembly
1) Press fit bearing (17) to cover assembly,
and
install snap ring (16).
2)
Press fit inner race (14) to gear (15), and install snap ring (13).
assembly
CWD02594
3)
Using push tool 0, gear assembly (1 I).
4)
Fit spacer (IO), and install snap ring (9).
press fit cover
(12) to
CWD02592
D155AX-5
30-91 0
DISASSEMBLY
5)
6.
PTO
AND ASSEMBLY
Mesh with idler gear and install cover assembly (8). & O-ring : Grease (G2-LII & Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 110.3 + 12.3 Nm 01.25 = 1.25 kgm)
HSS pump drive gear, cover assembly I) Asserkble gear and cover assembly lows. i) Press fit bearing (6) to gear (7).
as fol-
7’
ii)
Install gear and bearing cover (4).
assembly
DXD03212
(5) to
CWD02616
2) Install gear and cover assembly & m
(3) to case. Cover O-ring portion : Grease (G2-LI) Mounting bolt : 110.3 = 12.3 Nm {Il.25 + 1.25 kgm1
CWDO2617
30-92 0
D155AX-5
DISASSEMBLY AND ASSEMBLY
7.
PTO
Lubrication tube 1) install lubrication tube (2). B Joint bolt : 5.0 L 4.9 Nm I4 = 0.5 kgml
2)
Install lubrication tube (1). m Joint bolt : 5.0 z 4.9 Nm I4 2 0.5 kgml
D155AX-5
30-93 0
DISASSEMBLY
TORQUE CONVERTER
AND ASSEMBLY
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY 1.
Case, turbine assembly Remove 30 bolts from below, then use eyebolts 0, and remove case and turbine assembly (IL
2.
Input shaft 1)
Remove
2) Remove
input shaft (2).
snap
ring (31, then
remove
inner
race (4).
4
3.
Case 1) 2)
Remove Remove
snap ring (5). spacer (6).
5 DLCOX92
30-94 0
D155AX-5
DISASSEMBLY
4.
TORQUE CONVERTER
AND ASSEMBLY
3)
Using puller 0, disconnect (7) and turbine (8).
4)
Remove
bearing
case assembly
(IO) from case (9).
Stator Remove
snap ring (1 I), then remove
stator (12). 11
5.
Pump assembly 1) Using forcing screws @ from stator shaft end, remove pump assembly (13) from stator shaft (14).
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
TORQUE CONVERTER
2) Remove seal ring (15) and flange (16) from stator shaft (14).
3)
Remove
cage assembly
(17) from pump (18). 18
4)
30-96 0
Remove snap ring (191, then ing (21) from cage (20).
remove
bear20
21
Dl SAX-5
DISASSEMBLY
TORQUE
AND ASSEMBLY
CONVERTER
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY * *
* *
Clean all parts, and check for dirt or damage. After press fitting the bearing, apply 6 cc of SAEIOWCD or SAE30CD in drops, then rotate about 10 times. Check that the snap ring is fitted securely in the groove. Coat the seal ring with grease (G2-LI) and align the end gaps.
DKWJlOl
1.
Pump assembly 1) Press fit bearing snap ring (19).
18
(21) to cage (201, and install
2) Install cage assembly w
(17) to pump (18). Mounting bolt: 66.2 t 7.4 Nm I6.75 t 0.75 kgm1
I 3)
Install seal ring (15) and flange (16) to stator shaft (14). 6 Mounting bolt: . Thread tightener (LT-2)
4)
Using push tool 0, install pump assembly (13) to stator shaft (14). * Push the inner race of the bearing to press fit.
DLCOX99
DLEW103
D155AX-5
DISASSEMBLY
2.
TORQUE
AND ASSEMBLY
Stator 1) Install stator (12). 2) Install snap ring (II).
CONVERTER
IL
11
3.
Case 1) Install bearing
2)
(IO) to case (9).
Using push tool 0, push inner race end of bearing, then install case assembly (7) to boss portion of turbine (8).
i3 DUO3104
3) 4)
Install spacer (6). Install snap ring (5).
5 DlDCQO93 I
30-98 0
DLCW392 I
I
D155AX-5
DISASSEMBLY
4.
AND ASSEMBLY
TORQUE
CONVERTER
Input shaft 1) Press fit inner race (41, and install snap ring (3).
DLDCQ391
2)
5.
Install input shaft (2). & Mounting bolt: Thread tightener (LT-21 m Mounting bolt: 110.3 t 12.3 Nm (II.25 + 1.25 kgml
Case, turbine assembly 1) Using eyebolts 0, align groove of case with drain plug, and install case and turbine assembly (1). & Mounting bolt: Thread tightener (LT-21 w Mounting bolt: 54.0 t 4.9 Nm I5.5 = 0.5 kgm} 2) Install drain plug. w Drain plug: 17.2 + 2.5 Nm (I.75 + 0.25 kgm1
D155AX-5
30-99 0
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
DISASSEMBLY TRANSMISSION
OF TORQFLOW ASSEMBLY
*
After removing the discs and plates, keep them in a flat place to prevent bending or deformation.
1.
Relief valve assembly Remove relief valve assembly
(I).
’
2.
Control valve assembly 1) Remove cover assembly
sleeve
TRANSMISSION
J-l
DEW0459
(2).
2)
Remove
(3) and flanges
(4) and (5).
3)
Remove control valve assembly (6). * Remove the bolt marked %.
DEW0462
30-100 0
D155AX-5
DISASSEMBLY
3.
AND ASSEMBLY
Transmission case 1) Fit a block and set with side at top. 2) Remove sleeve (7).
3)
TORQFLOW
torque
TRANSMISSION
converter
Using eyebolts 0, sling transmission case (8), then remove 13 tie bolts (9) (tightened together with transmission case), and remove case (8).
8--
DEiY30464
4.
5.
Tie bolts Remove remaining
4 tie bolts (9).
Input shaft, front cover, No. 1 carrier assembly I) Using eyebolts 0, remove input shaft, front cover, and No. 1 carrier assembly (II).
DEDW466
D155AX-5
30-101 0
DISASSEMBLY
2)
TORQFLOW TRANSMISSION
AND ASSEMBLY
Disassemble input shaft, front cover, and No. 1 carrier assembly as follows. Remove snap ring (121, then remove No. i) 2 sun gear (13) and snap ring (14). ii) Remove snap ring (151, then remove No. 1 sun gear (16) and collar (17).
iii) Remove snap ring (18). iv) Knock input shaft towards torque converter, and remove front cover (19). 18
v)
Remove snap ring (201, then knock input shaft (21) out towards torque converter to remove.
Remove snap ring (221, then remove No. 1 ring gear (23). vii) Pull out shaft (241, then remove thrust washer (251, gear (261, bearing (279, and ball (28). * Be careful not to lose the ball. vi)
24
23
28
25
26 25 DEW0471
30-102 0
27 WDCO472
D155AX-5
DISASSEMBLY
AND ASSEMBLY
TORQFLOW
TRANSMISSION
6. No. 1 disc, plate, springs I) Remove spring (29). 2) Remove spring (301, disc (311, and plate (32).
DECCO473
7. No. 1 housing assembly 1) Using eyebolts 0, remove No. 1 housing assembly (33). 2) Remove No. 1 piston (34) from housing.
8. Guide pin Remove guide
pin (35).
9. No. 2 disc, plate, springs 1) Remove spring (36). 2) Remove spring (371, disc (381, and plate (39).
39
37
36
10. Remove through bolt guide (401, lubrication lief valve (411, and spring (120).
re-
DDWO476
D155AX-5
DDm477
30-103 0
DISASSEMBLY
AND ASSEMBLY
TORQFLOW TRANSMISSION
11. No. 2 housing, No. 2 carrier assembly 1) Using eyebolts 0, remove No. 2 housing and No. 2 carrier assembly (42). 2) Remove No. 2 piston (43). 43
3)
Disassemble No. 2 housing and No. 2 carrier assembly as follows. i) Remove snap ring (441, then pull out No. 2 carrier assembly (45) from No. 2 housing (46).
ii)
46 /
Remove spacer (47) and No. 2 ring gear (48) from No. 2 carrier assembly (49).
iii) Pull out shaft (501, and remove thrust washer (511, gear (521, bearing (53), and ball (54). * Be careful not to lose the ball.
51 52 53
4
iv) Remove snap ring (551, then remove gear (56).
30-104 0
DDCCO481
ring
D155AX-5
DISASSEMBLY
TORQFLOW TRANSMISSION
AND ASSEMBLY
VI Remove seal ring (57) and snap ring (58) from No. 2 housing, ing (59).
then remove
bear-
59
46 58
DEixoe3
12. No. 3 disc, plate, springs 1) Remove spring (60). 2) Remove spring (611, disc (621, and plate (63).
13. No. 3 ring gear Remove No. 3 ring gear (64).
14. No. 3, 4 carrier assembly 1) Remove No. 3 and 4 carrier assembly
D155AX-5
(65).
.65
DISASSEMBLY
2)
TRANSMISSION
TORQFLOW
AND ASSEMBLY
No. 3, 4 carrier assembly as Disassemble follows. i) Remove seal ring (66). ii) Knock pin (67) into shaft (68). iii) Knock out shaft (68) from No. 3 carrier end. iv) Remove thrust washer (69), No. 4 planet gear (701, and bearing (71). Remove the pin from the shaft. * VI Knock out shaft (721, then remove thrust washer (73). No. 3 planet gear (741, bearing (751, and ball (76). Be careful not to lose the ball. *
n
II
I
I
76
74 73 72
167
15. No. 3 housing 1) Remove No. 3 housing (77). 2) Remove No. 3 piston (78).
DDDW487
/78 -77
DEW0488
16. No. 4 disc, plate, springs, guide pin I) Remove spring (79). 2) Remove spring (801, No. 4 disc (81), 3)
(82). Remove
guide
plate
79
pin (83).
81
83
80
82
17. No. 5 carrier, No. 4 ring gear assembly I) Remove mounting bolts (84). 2) Remove No. 5 carrier and No. 4 ring gear assembly (85).
DE&O491
30- 106 0
D155Ax-5
DISASSEMBLY
3)
AND ASSEMBLY
TORQFLOW
Disassemble No. 5 carrier, No. 4 ring gear assembly as follows. i) Knock out shaft (86), then remove thrust washer (87), gear (88), bearing (89), and ball (90). * Be careful not to lose the ball.
90
TRANSMISSION
86
87 88 89 87 93
ii)
Remove snap ring (91), then remove 4 ring gear (92) from carrier (93).
18. No. 4 housing assembly 1) Remove No. 4 housing assembly 2) Remove No. 4 piston (95).
No.
(94).
19. No. 5 disc, plate, springs 1) Remove spring (96). 2) Remove disc (97), plate (98), and spring
(99).
96
D155AX-5
30-107 0
DISASSEMBLY
AND ASSEMBLY
TORQFLOW
TRANSMISSION
20. No. 5 ring gear Remove No. 5 ring gear (100); 101 21. Collar, No. 4 sun gear, bearing Remove snap ring (IOI), then remove collar (1021, No. 4 sun gear (1031, and bearing (104).
102
22. No. 5 sun gear Remove No. 5 sun gear (105).
100
23. No. 5 piston Remove No. 5 piston (106).
24. Shaft, collar Remove shaft (107) and collar (108) from cover (109).
25. Bearing 1) 2) 3)
cage
Remove snap ring (1 IO), then remove bearing (111). Remove snap ring (1121, then remove bearing (113). Remove cage (1141, then remove seal rings (115) and (116).
30-108 0
115
114
112
113
D 155AX-5
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
TRANSMISSION
ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY .
Precautions when assembling * Clean all parts, and check for dirt or damage. * 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 as shown in the diagram. * When installing metal seal rings, coat with grease (G2-LI) and install uniformly, taking care that they do not move to one side.
1.
Cage, bearing 1) Install seal rings (116) and (1151, then install cage (114) to cover (109). 2) Press fit bearing (1131, and install snap ring (112). 3) Press fit bearing (I 1 I), and install snap ring (I IO).
I 2.
116
111
110 DDDoo498
Shaft, collar Install shaft (107) and collar (108) to cover (109). 1
-7
3.
No. 5 sun gear Install No. 5 sun gear (105). 10
4.
No. 5 ring gear Install No. 5 ring gear (100).
5.
No. 5 piston Install No. 5 piston (106).
100
106
D155AX-5
30-109 0
DISASSEMBLY
6.
7.
Guide pin Install guide
AND ASSEMBLY
TORQFLOW TRANSMISSION
pin (83).
No. 5 disc, plate, springs 1) Install disc (971, plate (981, and spring * Discs: 3, Plates: 2 2) Install spring (96). * Free length of spring: 66 mm
(9% 98
DEW0501
I 8.
No. 4 housing assembly 1) Fit seal ring and install No. 4 piston (95). 2) Install No. 4 housing (94). * Check that the spring is fitted securely in the groove.
I 9.
No. 5 carrier, No. 4 ring gear assembly 1) Assemble No. 5 carrier and No. 4 ring gear assembly as follows. i) Set No. 4 ring gear (92) to carrier (931, and install snap ring (91).
DEW0502
93.
Assemble bearing (89) to gear (881, then put thrust washers (87) in contact on both sides, and set in carrier. iii) Fit ball (90) and install shaft (86). ii)
89 87 93
30-110 0
D 155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
TORQFLOW TRANSMISSION
Using guide bolts 0, install No. 5 carrier and No. 4 ring gear assembly (85). w Mounting bolt: 66.2 t: 7.4 Nm (6.75 = 0.75 kgm}
85
I
10. No. 4 disc, plate, springs I) Install No. 4 disc (811, plate (821, and spring
(80). Discs: 4, Plates: 3 * 2)
79.
Install spring (79). Free length of spring: 70 mm *
80
11. No. 3 housing assembly 1) Fit seal ring and install No. 3 piston (78). 2) Install No. 3 housing (77). Check that the spring is fitted securely in * the groove.
12. No. 3, 4 carrier assembly 1) Assemble No. 3 and 4 carrier assembly as follows. Press fit bearing (1171, and install snap i) ring (118).
D155AX-5
DISASSEMBLY
TORQFLOW TRANSMISSION
AND ASSEMBLY
ii)
Assemble bearing (75) to No. 3 planet gear (741, then put thrust washers (73) in contact on both sides and set to carrier. iii) Fit ball (761, then install shaft (72). iv) Assemble bearing (71) to No. 4 planet gear (701, then put thrust washers (69) in contact on both sides and set to carrier. VI Align shaft pin hole with carrier pin hole and install shaft (68). vi) Check that pin holes are aligned, then knock in pin (67). vii) Install seal ring (66). 2)
76
74 73 72 67’
Dlxc04a7
Align sun gear and ring gear, then install No. 3 and 4 carrier assembly (65). * Be careful not to get your fingers caught.
MDCKM66
13. No. 3 ring gear Install No. 3 ring gear (64). * Install so that the side with the notch in the outside teeth is facing down.
14. No. 3 disc, plate, springs 1) Install disc (621, plate (631, and spring * Discs: 4, Plates: 3 2) Install spring,(60). * Free length of spring: 70 mm
(61).
60\ H-62 63-
DECW46.4
30-112 0
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
TORQFLOW TRANSMISSION
15. No. 2 housing, No. 2 carrier assembly 1) Assemble No. 2 housing and No. 2 carrier assembly as follows. Press fit bearing (59) to No. 2 housing i) (461, and install snap ring (58). ii) Install seal ring (57).
iii) Set ring gear (56) to No. 2 carrier then install snap ring (55).
46-
(451,
I
56.
DEW0506
iv) Assemble bearing (53) to gear (521, then put thrust washers (51) in contact on both sides, and set to carrier. VI
51
Fit ball (54) and install shaft (50).
52 53 54
vi) Install seal ring. vii) Install No. 2 ring gear (48). viii) Install spacer (47). * Install so that the side where the inside is cut is facing the carrier.
48
D155AX-5
DEDOO508
30-113 0
DISASSEMBLY
ix)
x)
2) 3)
TORQFLOW
AND ASSEMBLY
TRANSMISSION
Install No. 2 housing (46) to No. 2 carrier assembly (45). * Press fit the inner race of the housing bearing. Install snap ring (44).
Install No. 2 piston (43). Using eyebolts 0, install No. 2 housing and No. 2 carrier assembly (42). * Check that the spring is fitted securely in the groove.
DECO0478
16. Install through bolt guide (401, spring (1201, and lubrication relief valve (41).
40
17. Guide pin Install guide pin (35). 18. No. 2 disc, plate, springs I) Install No. 2 disc (381, plate (391, and spring
2)
(37). * Discs: 5, Plates: 4 Install spring (36). * Free length of spring: 81.7 mm
30-114 0
39
37
36
D155AX-5
DISASSEMBLY
AND ASSEMBLY
TORQFLOW TRANSMISSION
19. No. 1 housing assembly 1) Fit seal ring and install No. 1 piston (34). 2) Using eyebolts 0, align with No. 2 piston, then install No. 1 housing assembly (33). * Push the housing and tap the dowel pin portion.
.33
‘34
20. Input shaft, No. 1 carrier assembly 1) Assemble input shaft and No. 1 carrier assembly as follows. i) Assemble bearing (27) to gear (261, then put thrust washers (25) in contact on both sides, and set to carrier. ii) Fit ball (28) and install shaft (24). iii) Set No. 1 ring gear (23) to No. 1 carrier, and install snap ring (22).
24
28 22
25
26 25
27 DDcOo472
iv) Press fit bearing VI
23 /
DEMO471
(117) to input shaft (21).
Fit No. 1 carrier assembly (118) to input shaft (211, then install snap ring (18).
DEW0510
vi)
Install collar (17).
vii) Install No. 1 sun gear (161, then snap ring (15). viiijlnstall
D155AX-5
snap ring (14).
install
16
DISASSEMBLY
ix) Install No 2 sun gear (131, then snap ring ‘(12).
2)
TORQFLOW TRANSMISSION
AND ASSEMBLY
install
Raise input shaft, No. 1 carrier assembly (11% align meshing of No. 2 sun gear and No. 1 planet gear, then install.
DEW0514
21. No. 1 disc, plate, springs 1) Install No. 1 disc (31), plate (321, and wring
2)
(30). * Discs: 5, Plates: 4 Install spring (29). * Free length of spring: 81.7 mm
22. From cover 1) Install seal ring (121) to front cover (122).
DDDoo516
30-116 0
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
TORQFLOW
Using eyebolts @, align front cover (122) with guide pin and spring, then install. Press fit inner race end of bearing (123) to input shaft, then install snap ring (124). * Check that the spring is fitted securely in the cover.
122
DECO0517
TRANSMISSION
123 124
DDlX0518
23. Tie bolts Install 4 tie bolts (9). (The 4 bolts marked * in the diagram) m Tie bolt: 166.7 + 9.8 Nm I17 = 1 kgm}
24. Operation test of piston Using tool C, test the operating stroke of each piston. Piston
Standard
condition
and
stroke (mm)
No. 1
6
No. 5
6.
DEW0520
case 25. Transmission Fit O-ring, then using eyebolts 0, install transmission case (81, and install remaining 13 tie bolts (9).
-0
8-
DEDXJ464
D155AX-5
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
26. Sleeve Install sleeve
TRANSMISSION
(7).
I
DECYJO463
27. Control valve assembly 1) Install control valve assembly (6). w Mounting bolt: 49.1 + 4.9 Nm I5.0 = 0.5 kgm)
2)
Install flanges
3) &
Install cover assembly (2). Mounting bolt thread portion: Gasket sealant (LG-1 or LG-51
30-118 0
(4) and (5), and sleeve (3).
D155AX-5
DISASSEMBLY
TORQFLOW TRANSMISSION
AND ASSEMBLY
28. Main relief valve assembly Install main relief valve assembly w Mounting bolt:
(I).
49.1 +. 4.9 Nm 15.0 + 0.5 kgm}
D155AX-5
30-119 0
DISASSEMBLY
AND ASSEMBLY
HSS CASE
DISASSEMBLY OF HSS CASE ASSEMBLY 1.
Brake, carrier assembly 1) Angie the HSS case assembly approx. 15” so that tool El is perpendicular to ground surface. 2) Remove mounting bolts, then using tool El, remove brake, carrier assembly (1). * Do not remove the hexagon socket head bolt. Sr Remove the brake and carrier assembly on the other side in the same way. DLCOG997
.
Disassembly 1) Remove
2)
of brake, carrier assembly flange (2) and plate (3).
Loosen hexagon socket head bolts uniformly, then using eyebolts 0, remove brake case (5). Ir The case is being pushed by the brake spring, so loosen it slowly and uniformly. * The outside bearing will come out together with the cover.
3)
Remove spacer (6), brake spring (8), and cylinder (9).
G’), piston
DKDOlCO3
30-120 0
D155AX-5
DISASSEMBLY
4)
HSS CASE
AND ASSEMBLY
Remove brake drum (12) together and plate.
with disc
I 5)
Remove plate (131, disc (151, spring (161, and plate (14) from brake drum.
6)
Remove mounting bolts, then remove carrier assemblv (19) from hub (18). Remove gear assembly (20) from hub assembly (18).
7)
DKWlWl
r
DLCOlCO3
8) 9)
DLDO1004
Remove ring (211, then remove ring gear (22) from gear (108). Remove snap ring (231, and pull out shaft
(24).
DLDD1005
D 155AX-5
DLiYJOO6
30-121 0
DISASSEMBLY AND ASSEMBLY
HSS CASE
10) Remove planetary gear (25), bearing (26), thrust washer (27), shaft (24), and ball (28).
25 26
24
28 27
DLD01007
11) Remove snap ring (31), then remove stopper (32) from hub (18).
32
31
18 DKD01008
2. Bevel pinion assembly 1) Using guide bolts 3 and forcing screws remove bevel pinion assembly (33) and shim (34). fl Check the number and thickness of the shims, and keep in a safe place.
e
34
33 r DLD01009
2) Disassembly of bevel pinion assembly i) Remove bolts (35), (36) and pin (37). Serial No. 75001 –
t
E2
41
40
ii) Hold with press to prevent pinion from moving, then use tool E2 to remove locknut (39). iii) Using push tool 5, remove bevel pinion (40) from cage (41). 39 DLD01010
30-122 5
DKD01011
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS CASE
iv) Remove bearing (42). v) Remove outer races (43) and (107) from cage (41).
42
107
43
41 DLD01013
DLD01012
vi) Remove bearing (109) from bevel pinion (40).
40
109 DLD01014
3. Sun gear Remove sun gear (45). fl Remove the sun gear on the opposite side in the same way.
45
47
4. Gear 1) Remove snap ring (47), then remove spacer (48).
48
DLD01016
DLD01015
2) Using gear puller 6, remove gear (49).
49 y
DLD01017
D155AX-5
30-123 5
DISASSEMBLY
AND ASSEMBLY
HSS CASE
Only inner race (50) of bearing (55) will remain. Remove the gear on the opposite side in the same way.
DKco1018
5.
Valve seat 1) Pull out 2 brake circuit tubes (51) and 3 lubrication tubes (52), then remove. 2) Remove valve seat (53).
DKW1019
6.
Lubrication tubes, dipstick tube, suction tube 1) Remove lubrication tubes (52) and (56).
2) 3)
Remove Remove
lubrication tubes (57) and (58). dipstick tube (59) and suction tube
(60).
30-124 0
D155AX-5
DISASSEMBLY
7.
HSS CASE
AND ASSEMBLY
Motor output gear 1) Remove flange (61) from case (62). 2) Remove flange and gear assembly (63).
3)
Remove gear assembly
(65) from flange (64). 65
%
64
&
4) 5)
Remove inner race (67) and bearing (68) from gear (66). Remove bearing (69) from flange (61).
Ic 69
61
66
8.
Right carrier drive gear 1) Remove bolt (701, then and gear (72).
remove
plate
DKDO1026
(71)
I
D155AX-5
DKCO1025
DLCO1027
DUO1028
30-125 0
DISASSEMBLY
HSS CASE
AND ASSEMBLY
2)
Knock out shaft (73) with to remove.
3) 4)
Remove Remove
a plastic hammer
inner race (75) from bearing bearing (74).
(74).
DLDOlOBl
gear 9. Intermediate 1) Remove shaft mounting bolt. 2) Using shock hammer @, pull out shaft (76), then remove gear (77) and bearing (78).
Bevel gear shaft, bevel gear assembly 1) Remove left retainer mounting bolts (85). 2) Remove right retainer mounting bolts (86). 3) Using eyebolts 0, lift off bevel gear shaft and bevel gear assembly (87). Check the number and thickness of the * shims at the left cage, and keep in a safe place.
30-126 0
D 155AX-5
DISASSEMBLY
4)
HSS CASE
AND ASSEMBLY
Disassembly of bevel gear shaft, bevel gear assembly Using puller 0, remove inner race (91) i) from right shaft (92). Remove inner race (91) from the left shaft * in the same way.
ii)
Remove
right
retainer
(89) from
shaft
92
(92).
88
L-?--A
DLLWlO?J
iii) Remove hexagon socket head bolt (95), then remove plate (93) and shim (94).
iv) Using tool E3, remove
D155AX-5
nut (96).
30-127 0
DISASSEMBLY
v) vi)
HSS CASE
AND ASSEMBLY
Using puller 0, pull out left retainer (97) from shaft (92). Remove bearing (98) from retainer (97).
r-l
DLDO1040
DID01041
vii) Remove nut (991, then remove bevel gear (100) from shaft (92).
viii)Remove
bearing (101) from right retainer
(89).
DLC01043
30-128 0
D155AX-5
DISASSEMBLY
HSS CASE
AND ASSEMBLY
ASSEMBLY ASSEMBLY
OF HSS CASE
Precautions when assembling Clean all parts, and check for dirt or damage. Apply drops of engine oil to the rotating portion of the bearing, then rotate several 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. 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. Bevel gear shaft, bevel 1) Assembly of bevel assembly i) Using push tool, and (74) to right
gear assembly gear shaft, bevel press fit bearings retainer (89).
gear (101)
L f
Ii I
/ 9 Piston
\
/
DLDYOM
1
r
Q
8
DKtM1045
ii)
1 1
DLt6046
Shrink fit inner race (106) to shaft (92). * Shrink-fitting temperature: 100°C for approx. 30 minutes
g2-
DiCQ1047
iii) Set bevel gear (100) to shaft (921, and tighten nut (99). m Nut : 215.8 - 274.6 Nm (22.0 - 28.0 kgml iv) Install seal ring.
DLCO1042
D155AX-5
30- 129 0
DISASSEMBLY
AND ASSEMBLY
HSS CASE
VI Assemble
outer race (103), bearing (104), spacer (105), bearing (104) and outer race (103) to left retainer (97) in order. tighten vi) Fit plate (93), then temporarily with several hexagon socket head bolts.
DKJXM048
vii) Support bevel gear with block 0, then using push tool @I, press fit retainer assembly (102) to shaft.
DKW1049
viii)Secure shaft, then using tool E3, tighten nut (96). 6 Nut : Thread tightener (LT-2) m Nut : 735.5 - 902.2 Nm
i75.0 - 92.0 kgml *
Remove the hexagon socket head bolts at the portion where the tool contacts the bolts.
DLC01050
ix) Adjusting shim Tighten 4 bolts lightly, measure dimension @ and dimension @ to calculate dimension @, then decide thickness of shim @. Shim thickness @ = (0 - 0) - (0.1 to 0.2 mm) selected shim (941, then XI Assemble tighten bolts (95).
30-130 0
D155AX-5
DISASSEMBLY
xi)
HSS CASE
AND ASSEMBLY
Install right retainer
(89) to shaft (92). 92
DLiXlO37
xii) Shrink fit inner race (91) to shaft (92). j, Shrink-fitting temperature: 100°C for approx. 20 minutes
I
DLDO1052
2) Install left retainer (88) and guide bolt @. 3)
Using eyebolts @I, raise right retainer, then align guide bolt with bolt hole, and install bevel gear shaft assembly (90) to case.
DLD01054
4)
Assemble shim to left retainer, then tighten mounting bolts (85) and (86) of left and right retainers. * There are three types of shims: 0.1, 0.2, 0.5 mm * The mounting bolts of the left retainer are loosened when adjusting the backlash and tooth contact, but tighten them fully here in order to check the starting torque of the bevel gear shaft.
D155AX-5
30-131 0
DISASSEMBLY
5)
2.
HSS CASE
AND ASSEMBLY
Push tip of teeth of bevel gear (100) with starting scale 0, and measure push-pull torque of bevel gear shaft. Starting torque: Max. 3.0 Nm (0.31 kgm} * (At tip of bevel gear teeth: Max. 19.6 N (2.0 kg})
gear Intermediate 1) Assemble snap ring (83) and spacer (84) to gear (771, then using push tool, press fit outer race (82). lower bearing (781, spacer (811, 2) Assemble and upper bearing (78).
77
78
DKDJ1057
3)
gear assembly (79) to case (801, Assemble then align bolt hole and install shaft (76). Align the bolt holes of the plate when * installing the shaft.
DLD01059
DLCG1059
3.
Right carrier drive gear 1) Using push tool, press fit bearing (74) to case. 2) Using push tool, press fit inner race (75) to shaft (73). * Press fit to a point approx. 27 mm from shaft surface. * Install to one side only.
DLKHO&l
30-132 0
73
DL!M1061
D155AX-5
DISASSEMBLY
AND ASSEMBLY
HSS CASE
3)
Align shaft (73) with bearing
4)
Using push tool, install inner race (75) to between shaft and bearing. + Hold the shaft from the opposite side.
5)
and install.
Fit gear (72) and plate (711, then tighten (70). w
Mounting
bolt
bolt : 98.1 - 122.6 Nm IlO.
- 12.5 kgm1
DLC01028
DLDO1027
4.
Lubrication tubes, 1) Install suction 2)
dipstick tube, suction tube tube (60) and dipstick tube
(59). Install lubrication tube (57), (58). w Joint bolt: 7.8 - 9.8 Nm IO.8 - 1.0 kgm)
DLC41022
D 155AX-5
I
/
DtDO1021
DISASSEMBLY
3)
5.
AND ASSEMBLY
HSS CASE
Install lubrication tube (56). m Joint bolt: 7.8 - 9.8 Nm IO.8 - 1.0 kgm}
Bevel pinion assembly 1) Assemble bevel pinion as follows. i) Using push tool, press fit bearing to bevel pinion (40).
(109)
Using push tool, press fit outer races (43) and (107) to cage (41). iii) Put bevel pinion (40) on press stand, and set cage (41) in position. ii)
J
iv) Press fit bearing (42) to cage (41) with press. VI Hold in press so that pinion does not move, then use tool E2 and tighten locknut (39). & Locknut: Thread tightener (LT-2) w Locknut : 696.3 - 863.0 Nm * *
I
I
(71 - 88 kgm) Rotate the cage when tightening. After tightening the nut, check that the bevel pinion rotates smoothly. ’
30-134 0
DID01067
1
D155AX-5
HSS CASE
DISASSEMBLY AND ASSEMBLY
• Serial No. 75001 – vi) Turn the nut unit the phase of any one of the pin insertion holes of the nut (8 places) is matched to that of any one of the pin insertion holes of the pinion shaft (5 places). (Returning angle: 0 - 9°) vii) Insert pin (37) in the above holes. Fit plate (36) and tighten bolts (35). 2 Bolt : Thread tightener (LT-2) 3 Bolt : 11.8 - 14.7 Nm {1.2 - 1.5 kgm} 2) Using guide bolt 3, assemble shim (34) and install bevel pinion assembly (33). fl There are three types of shim: 0.1, 0.2, 0.5 mm y 6. Adjusting tooth contact, backlash 1) Adjusting backlash Put the probe of dial gauge 6 at right angles in contact with the tip of the bevel gear teeth. Hold the bevel pinion in position, and read the measurement when the bevel gear is moved forward and backward. fl Standard value for backlash : 0.25 - 0.33 mm fl Measure at least three points on opposite sides. • If the result of the inspection shows that the correct backlash is not being obtained, adjust as follows. fl Adjust the shim thickness at the left cage. • If backlash is too small Loosen mounting bolt of cage and remove shim. • If backlash is too large Loosen mounting bolt of cage and add shim.
DBD00156
Front
A
DAD00157
Front
B
DAD00158
D155AX-5
30-135 1 5
DISASSEMBLY
2)
AND ASSEMBLY
Adjusting tooth contact Testing i) Coat the tooth face of the bevel pinion lightly with red lead (miniurn). Rotate the bevel gear forward and backward and inspect the pattern left on the teeth. ii) Tooth contact should be checked as follows (from tip of teeth of bevel pinion). a) Center of tooth contact: 20 - 40 % of tooth width (from small end) b) Width of tooth contact: 30 - 50 % of tooth width c) Center of tooth contact: 35 - 65 % of tooth height (from root of tooth) d) Width of tooth contact: 60 - 80 % of tooth height In addition, there should be no strong contact at the addendum or dedendum (tip or root of the gear teeth) or at the big and small ends. * If the gears are adjusted to this pattern, the tooth contact will be correct when load is applied.
HSS CASE
Root of tooth
Tip of tooth
\
I I
I
Small end DBDOOES
,
Big end -
\ Adjustment If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows. If bevel pinion is too far from center line of i) bevel gear. Contact is at the small end of the convex tooth face of the bevel gear and at the big end of the concave tooth face. . Correct the tooth contact as follows. Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction A. Move the bevel gear in direction B, then check the tooth contact pattern and backlash again. ii) If bevel pinion is too close to center line of bevel gear. Contact is at the big end of the convex tooth face of the bevel gear and the small end of the concave tooth face. . Correct the tooth contact as follows. Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction B. Move the bevel gear in direction A, then check the tooth contact pattern and backlash again.
30-136 0
DBtXJO160
B*
-
,:
t A DBW0161
BC
3 + A DBW0162
D155AX-5
DISASSEMBLY
7.
HSS CASE
AND ASSEMBLY
Motor output gear 1) Using push tool, press fit bearing (69) to flange (61). 2) Using push tool, press fit inner race (67) and bearing (68) to gear (66).
f 61
66
3)
Install gear assembly
(65) to flange
DKw1025
(64).
DKD01024
4)
Install flange and gear assembly
5)
(62). Install flange
(61).
(63) to case
61
KDO1023
8.
Valve seat 1) Install lubrication
D155AX-5
tube (52).
DISASSEMBLY
2) 3)
HSS CASE
AND ASSEMBLY
Align with lubrication tube (52) (installed in Step 8-111, then install valve seat (53). Install brake circuit tube (51) and lubrication tube (52).
52
d
\ 51
9. Gear 1) Install outer 2) Align shaft
inner bearing (551, snap ring (54), and bearing (55) to gear (49). gear (49) with bearing of bevel gear and install.
DLDJ1072
3) 4)
Using push tool, press fit inner race (50). Fit spacer (48) and install snap ring (47).
10. Sun gear 1) Install thrust washer 2)
(46) to sun gear (45).
Install sun gear (45).
457 30-138 0
DKW1073
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
11. Brake, carrier assembly * Assemble both sets in . Assembly of brake, carrier 1) Assemble stopper (32) stall snap ring (31). 2) Install bushing (38). 3) Using push tool, press
4)
HSS CASE
the same way. assembly to hub (181, then in-
32
fit inner race (37).
Carrier assembly i) Assemble bearing (26) to gear (251, then put thrust washers (27) in contact on both sides, and set to carrier. ii) Fit ball (28) and install shaft (24). iii) Remove snap ring (23). iv) Install sleeve (36) to carrier (35).
24
35
36 DKCQ1076
v) vi)
Install bushings (29) and (30) to gear (108). Set gear (108) to ring gear (221, then fit ring (21) and install ring gear to gear.
vii) Install gear assembly (20) to hub (18). viiijlnstall carrier assembly (19) to hub (18). m Mounting bolt : 98.1 - 122.6 Nm {IO - 12.5 kgm1
18 DLD8004
D155AX-5
DISASSEMBLY
5) 6)
HSS CASE
AND ASSEMBLY
Set brake drum (12) to hub assembly (18). Install discs (15), plates (14) and (13), and spring (16). * Discs: 5,
18
13 Plate (14): 4,
Plate (13): 1
14
16
15
DLD01078
7)
8) 9)
Hub i) Using push tool, press fit bearing hub (9).
(17) to
ii) Fit seal ring and install hub (9). Install spacer (6). Install piston (8) and spring (7). * Install so that the outside circumference of the spring opens.
DWlOCO
10) Brake cover assembly i) Using push tool, press fit bearing brake cover (IO). ii) Install guide bolt @ to hub (9).
(‘I I) to
---1’ 30-140 0
DKCO1082
D155AX-5
DISASSEMBLY
AND ASSEMBLY
HSS CASE
iii) Using eyebolts 0, align bolt hole with hub and brake drum, then install brake cover assembly (5). Ir Tighten the mounting bolts temporarily. * The force of the spring is applied, so tighten the hexagon socket head bolts uniformly.
iv) Using push tool, press fit inner race (4. Install plate (3) and flange (2). Flange: 58.8 - 73.6 Nm (6 - 7.5 kgm1 vi) Fully tighten bolts temporarily tightened in Step iii). m Mounting bolt: 98.1 - 122.6 Nm I10 z 12.5 kgm) v) m
4-u
1
.
DLEO1255
Installation of brake, carrier assembly Angle steering case assembly approx. 15” I) so that tool El is perpendicular to ground surface. 2) Using tool El, install brake, carrier assembly (I). w *
Ir
&
Mounting
bolt: 98.1 - 122.6 Nm {IO - 12.5 kgm} Assemble the brake, carrier assembly the opposite side in the same way.
on
When cover (109) of the rear surface on HSS case (107) has been removed, install new gasket (108). Gasket (apply to both surfaces): Gasket sealant (LG-II
I
D155AX-5
DAD02453
HYDRAULIC PUMP
DISASSEMBLY AND ASSEMBLY
REMOVAL OF HYDRAULIC PUMP ASSEMBLY ¤ Park
the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (–) terminal of the battery.
1. Drain hydraulic oil and power train oil. 6 Hydraulic oil : Approx. 97 ¬ 6 Power train case : Approx. 60 ¬ 2. Remove cab. For details, see REMOVAL OF CAB ASSEMBLY.
Serial No. 70001 – 75000
3. Lift off operator’s seat assembly (1). 4 Operator’s seat : 54 kg 4. Remove floor frame left and right side covers (2).
Serial No. 75001 and up
5. Remove floor mat, then remove cover (3).
30-142 1 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
6. Disconnect acceleration rod (4) from yoke.
7. Disconnect deceleration rod (5) from yoke. 8. Disconnect brake rod (6). fl Loosen locknut (7), and turn joint (8) to disconnect. Joint (8) has a reverse thread. 9. Remove floor assembly (9). 4 Floor assembly: 26 kg
A. Removal of hydraulic pump assembly 1) Disconnect hose (1) leading to work equipment control valve. 2) Disconnect wiring connector (2) (HHP). 3) Disconnect suction tube joints (3) and (4). 4) Remove 4 mounting bolts (5), then remove tube (6).
5) Remove mounting bolts, then remove hydraulic pump assembly (7). 4 Hydraulic pump assembly : 19 kg
D155AX-5
30-143 1 5
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
B. Removal of 3-spool pump assembly (HSS lubrication + torque converter, transmission charge + torque converter charge pump) 1) Remove cover (1).
2) Disconnect HSS motor and brake lubrication tube (2). 3) Disconnect suction tube (3) from power train case. 4) Disconnect transmission filter hose (4).
5) Disconnect filter bypass valve hose (5). fl It is difficult to disconnect the hose at the pump end.
6) Remove mounting bolts, then lift off 3-spool pump assembly (6). fl Remove together with hose (5). 4 3-spool pump assembly : 24 kg
30-144 1 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
C. Removal of HSS pump assembly 1) Disconnect HSS and PPC charge valve hose (1). 2) Disconnect cooler bypass valve hose (2).
3) Disconnect charge filter hose (3). 4) Disconnect solenoid wiring connector (4) (PUP.A). 5) Disconnect cooler bypass valve hose (5). 6) Disconnect HSS motor hoses (6) and (7). 7) Disconnect charge relief valve hose (8).
8) Disconnect engine speed sensor wiring connector (9) (CN010). 9) Disconnect solenoid wiring connector (10) (PUP.B).
10) Remove mounting bolts, then lift off HSS pump assembly (10). 4 HSS pump assembly : 116 kg
D155AX-5
30-145 1 5
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
D. Removal of charge + scavenging pump assembly 1) Disconnect charge filter hose (1). fl It is difficult to disconnect the hose at the pump end.
2) Disconnect power train case suction tube (2). 3) Disconnect suction hydraulic tank tube (3).
4) Lift off charge + scavenging pump assembly (4). fl Raise, then move slowly towards the engine, and lower gradually from clearance. 4 Charge + scavenging pump assembly : 30 kg
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY •
Carry out installation in the reverse order to removal.
•
Refilling oil
•
5
Hydraulic oil : Approx. 97 ¬
5
Power train case : Approx. 60 ¬
Bleeding air Bleed the air from the pumps and power train. For details, see TESTING AND ADJUSTING, Bleeding air.
30-146 1 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
DISASSEMBLY OF HSS PUMP ASSEMBLY HPV160 1. HSS pump assembly Set hydraulic pump assembly (1) to tool Q1.
2. Servo valve assembly Remove 4 mounting bolts, then remove servo valve assembly (2).
fl Remove the four mounting bolts marked by hatching in the diagram on the right.
3. Safety-suction valve assemblies Remove 2 safety-suction valve assemblies (3). fl It is impossible to adjust the pressure of the safety- suction valve, so do not disassemble it.
D155AX-5
30-146-1 2
DISASSEMBLY AND ASSEMBLY
HSS PUMP
4. Charge relief valve assembly 1) Remove charge relief valve assembly (4).
2) Disassemble charge relief valve assembly as follows. fl Measure screwed-in depth a of the adjustment screw before disassembling.
i)
Remove locknut (5), then remove adjustment screw (6) from sleeve (7). ii) Remove spring (8) and poppet (9).
5. End cap assembly 1) Remove 2 plugs (10) and 3 plugs (11).
30-146-2 2
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
2) Remove plug (12).
3) Remove 6 mounting bolts, then remove end cap assembly (13).
4) Disassemble end cap assembly as follows. i) Remove valve plate (14) from end cap (15).
ii) Remove needle bearing (16).
D155AX-5
30-146-3 2
DISASSEMBLY AND ASSEMBLY
HSS PUMP
6. Cylinder block, piston assembly 1) Remove cylinder block and piston assembly (17). fl The piston is fitted tightly to the rocker cam, so check that the cylinder block and piston come off together as one unit.
2) Disassemble cylinder block and piston assembly as follows. i) Remove piston assembly (18) from cylinder block assembly (19). fl Remove the piston and shoe retainer as one unit. ii) Remove 9 pistons (20) from shoe retainer (21).
iii) Remove retainer guide (22). iv) Remove 3 pins (23).
v) Set tool Q2 to cylinder block assembly and compress spring. vi) Remove snap ring (24) from cylinder block (25). vii) Remove tool Q2. viii)Remove seat (26), spring (27), and seat (28).
30-146-4 2
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
7. Rocker cam 1) Remove rocker cam (29) together with slider.
2) Remove slider (30) from rocker cam (29).
8. Shaft, cradle assembly 1) Remove 6 mounting bolts, then remove shaft and cradle assembly (31). fl Push the input spline end of the shaft to remove.
2) Disassemble shaft and cradle assembly as follows. i) Using press, remove shaft assembly (32) from cradle (33).
D155AX-5
30-146-5 2
DISASSEMBLY AND ASSEMBLY
HSS PUMP
ii) Remove snap ring (34) and washer (35) from shaft (36). fl The washer is a selected part, so check the thickness. iii) Using tool Q3, remove roller bearing (37).
9. Servo piston 1) Remove stopper assemblies (38) and (39).
2) Disassemble stopper assembly as follows. i) Remove locknut (40). ii) Remove rod (41) from cap (42). iii) Remove retainer (43) and spring (44).
3) Remove servo piston (45).
30-146-6 2
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
10. Oil seal 1) Remove snap ring (46), then remove spacer (47).
2) Remove oil seal (48).
11. Pump case Remove 2 plugs (49) from pump case (50).
D155AX-5
30-146-7 2
DISASSEMBLY AND ASSEMBLY
HSS PUMP
ASSEMBLY OF HSS PUMP ASSEMBLY HPV160 fl Clean all parts, remove all burrs, check for dirt or damage, and be particularly sure to clean the drill hole oil passage. fl Coat the rotating and sliding surfaces of all parts with engine oil (EO-10CD) before assembling. fl Always check the contact of the following parts before assembling. For details, see CHECKING CONTACT BETWEEN PARTS. 1) Cradle and rocker cam 2) Cylinder block and valve plate 3) Valve plate and end cap 1. Pump case 1) Set pump case (50) to tool Q1. 2) Fit O-rings and install 2 plugs (49). 3 Plug: 58.8 - 78.4 Nm {6 - 8 kgm} 2. Servo piston 1) Insert servo piston (45) in pump case. fl When the slider groove is set facing the bottom of the case, insert the servo piston so that the part receiving the servo valve lever faces the mounting surface of the servo valve. 2) Assemble stopper assembly as follows. i) Set spring (44) and retainer (43) to cap (42). ii) Fit O-ring and install rod (41). iii) Install locknut (40).
iv) Adjust dimension b from flange surface of cap (42) to tip of retainer (43), then tighten locknut (40). fl Dimension b = 80 ± 0.1 mm 3 Locknut : 265 - 323 Nm {27 - 33 kgm} fl Adjust the cap assemblies on both sides to the same dimension.
30-146-8 2
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
3) Fit O-rings and install cap assemblies (38) and (39). 3 Mounting bolt: 59 - 74 Nm {6 - 7.5 kgm}
3. Shaft, cradle assembly 1) Assemble shaft and cradle assembly as follows. i) Using tool Q4 and press, press fit roller bearing (37) to shaft (36). 2 Press-fitting surface of bearing: Grease (G2-LI)
ii) Select washer thickness as follows. Select washer (35) of each thickness and assemble temporarily. Measure dimension c from top surface of washer to top end of snap ring groove. Then select washer so that dimension is within range below. • Dimension c = 1.8 - 2.0 mm • Washer thickness : 3.0, 3.1, 3.2 mm
iii) Fit selected washer (35), and secure with snap ring (34).
D155AX-5
30-146-9 2
DISASSEMBLY AND ASSEMBLY
HSS PUMP
iv) Using tool Q5 and press, press fit shaft assembly (32) to cradle (33). 2 Press-fitting surface of bearing: Grease (G2-LI)
2) Install shaft and cradle assembly (31) to pump case. 3 Mounting bolt: 98 - 123 Nm {10 - 12.5 kgm}
4. Rocker cam 1) Install slider (30) to rocker cam (29). fl Install the slider so that the chamfered part faces the rocker cam.
2) Install rocker cam (29) to cradle. fl Check that the sliding portion is fitted together tightly, and that the slider is fitted securely in the servo piston groove.
30-146-10 2
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
5. Cylinder block, piston assembly 1) Assemble cylinder block and piston assembly as follows. 1) Set seat (28), spring (27), and seat (26) to cylinder block (25). ii) Set tool Q2 to cylinder block and compress spring. iii) Install snap ring (24) and remove tool Q2.
iv) Install 3 pins (23). v) Install retainer guide (22).
vi) Assemble 9 pistons (20) to shoe retainer (21). vii) Assemble piston assembly (18) to cylinder block assembly (19).
2) Assemble rear cylinder block and piston assembly (17). fl Check that the spline of the cylinder block and shaft is meshed and that the sliding portion of the rocker cam and piston shoe is tightly fitted.
D155AX-5
30-146-11 2
DISASSEMBLY AND ASSEMBLY
HSS PUMP
6. End cap assembly 1) Assemble end cap assembly as follows. i) Using tool Q6, press fit needle bearing (16) to end cap (15). 2 Press-fitting surface of bearing: Grease (G2-LI)
ii) Install valve plate (14) to end cap (15). fl Align the pin groove of the valve plate end and the pin of the end cap end, and check that the valve plate and end cap are in tight contact.
2) Fit O-ring and install end cap assembly (13). 2 Mating surface of pump case: Gasket sealant (LG-7 or LG-5) 3 Mounting bolt: 343 - 427 Nm {35 - 43.5 kgm}
3) Measure rotating torque of shaft as follows. Using tool Q7, measure rotating torque of input shaft. fl Rotate shaft at a constant speed (3 - 5 sec/1 turn) and measure rotating torque. • Rotating torque: Max. 17.6 Nm {Max. 1.8 kgm} (Torque variation range: Max. 2.94 Nm {Max. 0.3 kgm}) fl If the rotating torque is not normal, disassemble again and look for the cause.
30-146-12 2
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
4) Fit O-ring and install plug (12). 3 Plug: 24.5 - 34.3 Nm {2.5 - 3.5 kgm}
5) Fit O-ring and install 3 plugs (11). 3 Plug: 147 - 186 Nm {15 - 19 kgm} 6) Fit O-rings and install 2 plugs (10). 3 Plug : 147 - 186 Nm {15 - 19 kgm} fl When pressure inspection plug has been removed 3 Pressure inspection plug: 17.7 - 22.6 Nm {1.8 - 2.3 kgm}
7. Oil seal 1) Using tool Q8, press fit oil seal (48). 2 Oil seal lip: Grease (G2-LI)
2) Fit spacer (47) and secure with snap ring (46).
D155AX-5
30-146-13 2
DISASSEMBLY AND ASSEMBLY
HSS PUMP
8. Charge relief valve assembly 1) Assemble charge relief valve assembly as follows. i) Assemble poppet (9) and spring (8) to sleeve (7). ii) Fit O-ring and install adjustment screw (6) and locknut (5).
iii) Align with screwed-in dimension a of adjustment screw measured before disassembly, then tighten locknut.
2) Fit O-ring and install charge relief valve assembly (4). 3 Charge relief valve: 49 - 59 Nm {5 - 6 kgm}
9. Safety-suction valve assembly Fit O-ring and install 2 safety-suction valve assemblies (3). 3 Safety-suction valve: 216 - 235 Nm {22 - 24 kgm}
30-146-14 2
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
10. Servo valve assembly Fit O-ring and install servo valve assembly (2). 2 Mating surface: Gasket sealant (LG-7 or LG-5) fl When inserting the arm of the servo valve into the servo piston, be careful not to cause any gouging. fl Gradually tighten the mounting bolts on opposite sides in turn. 3 Mounting bolt: 27.5 - 34.3 Nm {2.8 - 3.5 kgm}
D155AX-5
30-146-15 2
DISASSEMBLY AND ASSEMBLY
HSS PUMP
CHECKING CONTACT BETWEEN PARTS fl If either part of the following pairs of sliding parts has been repaired or replaced with a repair part (new part), check the contact as follows. There is no need for this check if both parts of the pair have been repaired or replaced with a repair part (new part). 1) Cradle and rocker cam 2) Cylinder block and valve plate 3) Valve plate and end cap 1. Cradle and rocker cam 1) Remove all oil and grease from the parts to be checked. fl Do not wipe with a cloth. 2) Paint the cradle with inspection paint, then put the rocker cam on top. fl Coat thinly with paint. fl Assemble in the direction shown in the diagram on the right. 3) Push the rocker cam with a force of 39.2 49.0 N {4 - 5 kg}, and move it from the position where it contacts the stopper to the maximum swash plate angle. Repeat this process 2 or 3 times. 4) Remove the rocker cam, transfer the contact surface to a tape, and check the contact surface. fl The standard for the contact is as given below. (1) Within 36 - 50 mm of center (center portion): Contact of more than 90% (2) Range from center portion (36 - 50 mm) to 67 mm: Contact of 50% 90% (3) Not within width of 67 mm (outside): Contact of less than 50% (It is not permitted to have contact only at the outside and no contact at the center.) fl If the contact is defective and lapping is carried out, it must always be carried out for both parts together.
30-146-16 2
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS PUMP
2. Cylinder block and valve plate 1) Make a centering tool for the cylinder block and valve plate. fl The tool can be made from plastic, bakelite or any other soft material. 2) Remove all oil and grease from the parts to be checked. fl Do not wipe with a cloth. 3) Paint the cylinder block with inspection paint, then put the tool and valve plate on top. fl Coat thinly with paint. 4) Push the valve plate with a force of 39.2 49.0 N {4 - 5 kg} against the cylinder block, turn the valve plate 90˚, then turn it back to the original position. Repeat this process 2 or 3 times. 5) Remove the valve plate, transfer the contact surface to a tape, and check the contact surface. fl The standard for the contact is as given below. (1) Seal portion (range of φ 101.5 mm): Contact of more than 80% and no break around whole circumference (2) Land portion (range of φ 101.5 mm - φ 128 mm): Contact of more than 60% and no break around whole circumference
3. Valve plate and end cap 1) Remove all oil and grease from the parts to be checked. fl Do not wipe with a cloth. 2) Paint the end cap with inspection paint, then put the valve plate on top. fl Coat thinly with paint. 3) Push the valve plate with a force of 39.2 49.0 N {4 - 5 kg} against the end cap, turn the valve plate 90˚, then turn it back to the original position. Repeat this process 2 or 3 times. 4) Remove the valve plate, transfer the contact surface to a tape, and check the contact surface. fl The contact of the mating surface of the valve plate and end cap must cover at least 80% without any variation. fl If the contact is defective, use a surface plate and correct by lapping.
D155AX-5
30-146-17 2
DISASSEMBLY
HSS MOTOR
AND ASSEMBLY
REMOVAL OF HSS MOTOR ASSEMBLY
A
Park the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (-1 terminal of the battery.
1. Remove fuel tank assembly. For details, see REMOVAL OF FUEL TANK SEMBLY. 2. 3.
Disconnect Disconnect
AS-
HSS pump hoses (I) and (2). charge relief valve hoses (31, (41, and
(5). 4. 5.
Disconnect HSS circuit pressure sensor wiring connectors (6) and (7) (CNSTAP1.2). Remove mounting bolts, then lift off HSS motor assembly (8). & kg
HSS motor assembly
: 64 kg
INSTALLATION OF HSS MOTOR ASSEMBLY . Carry out installation in the reverse
order
to
removal.
D 155AX-5
30-147 0
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN MAIN RELIEF VALVE
REMOVAL OF POWER TRAIN MAIN RELIEF VALVE ASSEMBLY 1.
Remove fuel tank assembly. For details, see REMOVAL OF FUEL TANK ASSEMBLY.
2.
Disconnect hose (I).
3.
Disconnect pressure detection hose (2).
4.
Remove power train main relief valve assembly a (3).
INSTALLATION OF POWER TRAIN MAIN RELIEF VALVE ASSEMBLY l
a
Carry out installation removal.
. w
in the reverse order to
Check that there is no damage to the O-ring, and assemble securely. Main relief valve mounting bolt: 44.1 - 53.9 Nm (4.5 - 5.5 kgm)
30-l 48 a
D155AX-5
DISASSEMBLY
POWER TRAIN MAIN RELIEF VALVE
AND ASSEMBLY
DISASSEMBLY OF POWER TRAIN MAIN RELIEF VALVE ASSEMBLY 1.
@@---I 0
Remove plug (I), then remove valve (21, spring (31, valve (41, valve (51, shim (61, and springs (7) and (8) from valve body (9). * Check the number and thickness of the shims, and keep in a safe place.
2.
Remove
3.
Remove plug (131, then remove guide spring (151, spool (161, valve (171, spring and valve (19).
4.
Remove
0------z D Y---3
L4
plug (IO). (141, (181,
16
plug (20).
ASSEMBLY OF POWER TRAIN MAIN RELIEF VALVE ASSEMBLY *
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Assemble
spring
(i5)
and guide
(14) to spool
(16). 2. Assemble valve (191, spring (181, and valve (17) to spool (161, then assemble to valve body (91, and install plugs (20) and (13). 3.
Assemble springs (8) and (7) to plug (IO), and install to valve body (9).
4.
Assemble valve (21, spring (31, and valve (41, then assemble to valve (5) and install shim (6) on opposite side. * Check the thickness and number of shims when assembling. Standard shim thickness: 0.5 mm
5.
Assemble
valve (5) to valve body (91, and install
plug (I). 6.
Tighten
D 155AX-5
plugs (IO) and (I).
30-l 49 0
DISASSEMBLY
AND ASSEMBLY
HSS, PPC CHARGE VALVE
REMOVAL OF HSS, PPC CHARGE VALVE ASSEMBLY a
Park the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (-1 terminal of the battery.
1. 2. 3. 4. 5.
Disconnect clamp (I) from filter case. Disconnect PPC lock valve hose (2). Disconnect accumulator hose (3). Disconnect tube (4) coming from charge Remove filter case assembly (5).
6. Disconnect 7. Disconnect
pump.
main control valve hose (6). drain hose (7).
8. Disconnect charge pressure sensor wiring connector (8) (CN406). 9. Disconnect HSS pump hose (9). 10. Disconnect HSS pump solenoid valve hose (IO). 11. Remove mounting bolts, then remove HSS and PPC charge valve assembly (1 I).
INSTALLATION OF HSS, PPC CHARGE VALVE ASSEMBLY .
.
Carry out removal.
installation
in the
reverse
order
to
Refilling with oil (hydraulic tank) Add engine oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Loosen the air bleed plug of the filter and bleed the air. After bleeding the air, check the oil level again with the sight gauge.
30- 150 0
D155AX-5
HSS, PPC CHARGING VALVE
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF HSS, PPC CHARGING VALVE ASSEMBLY 20
14 21 22
1 15 3
17 18
4
19 16 13 11
2
7
12 10 9 8 6 5
23 DKD01197
1. Remove plug (1), then remove springs (3) and (4) from valve body (2). 2. Remove plug (5), then remove spool assembly (6). 3. Remove valve (8), spring (9), valve (10), and shim (11) from spool (7). 4. Remove plug (12), then remove spring (13). 5. Remove plug (14), then remove spool assembly (15). 6. Remove valve (17), spring (18), and valve (19) from spool (16). 7. Remove plug (20), then remove spring (21) and valve (22). 8. Remove plug (23).
D155AX-5
30-151 1 5
HSS, PPC CHARGING VALVE
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF HSS, PPC CHARGING VALVE ASSEMBLY 20
14 21 22
1 15 3
17 18
4
19 16 13 11
2
7
12 10 9 8 6 5
fl Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Tighten plug (23). 2. Assemble valve (22) and spring (21) to valve body (2), and tighten plug (20). 3. Assemble valve (19), spring (18), and valve (17) to spool (16). 4. Assemble spool assembly (15) to valve body (2), and tighten plug (14). 3 Plug : 63.7 ± 14.7 Nm {6.5 ± 1.5 kgm} 5. Assemble spring (13) and tighten plug (12). 3 Plug : 68.6 ± 9.8 Nm {7 ± 1 kgm} 6. Assemble valve (10), spring (9), valve (8), and shim (11) to spool (7). fl Check the number and thickness of the shims, then assemble. Shim thickness: 0.5 mm No. of shims: 4 7. Assemble spool assembly (6) to valve body (2) and tighten plug (5). 3 Plug : 68.6 ± 9.8 Nm {7 ± 1 kgm}
30-152 1 5 5
23 DKD01197
8. Assemble springs (4) and (3), and tighten plug (1). 3 Plug : 68.6 ± 9.8 Nm {7 ± 1 kgm}
D155AX-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY ¤ Park
the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (–) terminal of the battery.
1. Remove operator’s seat and floor plate. For details, see REMOVAL OF HYDRAULIC PUMP ASSEMBLY. 2. Disconnect hose brackets (1) and (2) from transmission case cover.
3. Disconnect speed control cable (3), and remove bracket from case cover. fl Do not disconnect the cable from the bracket. 4. Disconnect directional control cable (4), and remove bracket from case cover. fl Do not disconnect the cable from the bracket. 5. Disconnect transmission modulation pressure detection hose (5). 6. Disconnect wiring connector of gear speed detection limit switch (5-1). • Serial No. Only 75001 and up 7. Disconnect backup alarm limit switch wiring connector (6) (CN251), and remove limit switch (7). 8. Using forcing screws, remove transmission cover (8). 1 9. Disconnect hose (9) coming from charge pump, and remove plate (10). 10. Remove sleeve (11), then remove block (12).
D155AX-5
30-153 1 5
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
CONTROL VALVE
(13) and (14).
10. Remove
sleeves
11. Remove
block (151, then remove sleeve (16). a
12. Remove
mounting bolts, then remove transmism sion control valve assembly (17).
INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY l
Carry out removal.
*
*
installation
in the
reverse
order
to
Look through the inspection window in the cover to check that the lever and yoke are meshed, then tighten the mounting bolts. When installing the cover, tap with a plastic hammer. If the dowel pin portion is not inserted, remove the cover, correct the meshing of the lever and yoke, then install again.
&
Sleeve
w
Transmission
30- 154 0
: Grease (G2-LII
control valve mounting bolt : 49.0 2 4.9 Nm 15.0 = 0.5 kgm)
D155AX-5
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
CONTROL
VALVE
DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY
ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY
1.
*
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Assembly of directional valve, modulation valve 1) Assemble valves (29) and (28), spring (27), and valve (26) to valve (23), then fit stopper (25) and install snap ring (24). 2) Assemble valve assembly (23) to body (I), then assemble springs (19) and (18), washer (17) and spring (16) from opposite side, assemble spring (16), then install spacer (15). 3) Install shim (14) and cover (13).
Disassembly of quick return valve Remove plug (2), then pull out valve gether with valve (4).
(3) to-
2.
Disassembly of speed valve 1) Pull out spool assembly (5) from valve body (1). 2) Loosen nut (6), and disconnect spool (7) and yoke (8).
3.
Disassembly of directional valve, modulation valve 1) Remove snap ring (9), then remove stopper (10). 2) Loosen nut (II), then remove yoke (12). 3) Remove cover (13), shim (14), and spacer (15), then remove spring (16), washer (17), and springs (18) and (19). Remove cover (20). 4) 5) Remove collar (21) and spool (22). 6) Remove valve assembly (23). snap ring (24), stopper (25), 7) Remove valve (26), spring (27), valve (28), and valve (29) from valve assembly (23).
Free length of spring (mm)
83.8 - 84.2
84.3 - 84.7
84.8 - 85.2
No. of standard shims
7
8
9
4) 5) 6)
Dl SAX-5
Install spool (22) and collar (21) to body (I), then install cover (20). Assemble stopper (IO), and install snap ring (9). Assemble nut (11) to yoke (12), then install to spool (22). w Locknut : 27.5 - 34.3 Nm I2.8 - 3.5 kgm} * Installation dimension a of yoke: 29.1 mm
2.
Assembly of speed valve 1) Assemble nut (6) to yoke (8), and install to spool (7). w Locknut : 27.5 - 34.3 Nm 12.8 - 3.5 kgml 2) Install spool assembly (5) to body (1).
3.
Assembly of quick return valve 1) Assemble valve (4) to valve (3), then insert in body and install plug (2).
30-155 0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CONTROL VALVE
2 3
DED01247
30-156 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
BRAKE VALVE
REMOVAL OF BRAKE VALVE ASSEMBLY
A
Park the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (-1 terminal of the battery.
1.
Disconnect
foot brake rod (I).
2.
Disconnect
parking
3.
Remove bolts (31, then remove bracket (4). Jr Do not loosen the lock of the cable.
4.
Disconnect
5.
Remove mounting valve assembly (6).
brake cable (2).
HSS case hose (5). bolts,
then
remove
brake
INSTALLATION OF BRAKE VALVE ASSEMBLY .
Carry out removal.
D155AX-5
installation
in the
reverse
order
to
30-l 57 0
DISASSEMBLY
DISASSEMBLY OF BRAKE VALVE ASSEMBLY 1.
2. 3. 4. 5. 6.
7.
Remove Remove Remove
(24). Remove lever assemblies (16) and (26). Remove seals (19) and (22) from case (25), then remove bearings (20), (21), and (27).
30-158 0
ASSEMBLY OF BRAKE VALVE ASSEMBLY
solenoid valve (1). lever and cover assembly (28). check valve assembly (31) from
body (6). Remove plug (33), then remove spring (32) and spool (30). Remove plug (2), then remove spring (3), piston (4), and valve (5). Remove cover (29), remove guides (13) and (12), and spring (IO), then remove shaft (bolt) (7), guide (8), spring (9), guide (II), and nuts (14) and (15) as one unit. Disassembly of lever case (26) 1) Remove levers (18) and (23). * Be careful not to lose keys (17) and 2) 3)
BRAKE VALVE
AND ASSEMBLY
1.
2. 3. 4. 5. 6. 7. 8. 9.
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Install shaft (bolt) (7), guide (8), spring (9), guide (II), and nuts (14) and (15) as one unit to body (6). Assemble spring (IO), and guides (12) and (13), then install cover (17). Assemble valve (5), piston (4), and spring (3), then install plug (2). Assemble spool (30) and spring (32), then install plug (33). Install cover (29). Install check valve assembly (31) to body (6). Install lever and cover assembly (16). Install solenoid valve (1). Assemblv of lever case assembly (26) 1) Instail bearings (20), (21), and (27), and oil seals (19) and (22) to case (25). 2) Install lever assemblies (16) and (26), then install levers (18) and (23). * Install key (17) and (24) securely to levers (18) and (23). 3) Install lever case (28) to valve body (6) using cover (29).
Dl SAX-5
DISASSEMBLY
D155AX-5
AND ASSEMBLY
BRAKE VALVE
30-159 0
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
REMOVAL OF FINAL DRIVE ASSEMBLY 1. Remove track shoe assembly.’ For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Remove 8 mounting drive assembly (1).
3.
Jacking &)
2) *
bolts (2) on inside of final a
up chassis Using hydraulic jack (686 kN (70 ton)) and ripper of machine, jack up chassis and set stands @ under steering case on left and right. Set stands @ on left and right under main frame at front of chassis. After setting stands @I and 0, set the hydraulic jack and ripper again to act as extra support. DUOX75
0 4.
DLCO3176
Lift off guard (3). & kg
Guard : 45 kg
-
30-160 a
Ly
DBDOO726
D155AX-5
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
5.
Remove
2 segment
teeth (4).
6.
Remove
drive shaft cover (5).
7.
Pull out drive shaft (6). * Use a forcing screw to pull out the drive shaft to a point where the spline comes out. * If the shaft does not come out, move the sprocket backward and forward to adjust to a position where the shaft comes out, then pull out the shaft.
8.
Align place where with track frame.
9.
Remove mounting bolts on top assembly, then install tool F2.
segment
teeth were removed
of final
drive m
DBDoo729
D 155AX-5
30-161 0
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
10. Using tool Jl, sling final drive assembly (I), and remove remaining bolts. To prevent the final drive from flying out, slightly loosen one mounting bolt each on both sides of the final drive, then loosen while pulling out the final drive assembly, and remove.
A
11. Lift off final drive assembly E?lkg
(I).
Final drive assembly
: 1500 kg CWD02648
INSTALLATION OF FINAL DRIVE ASSEMBLY l
Carry out removal.
&
installation
in the
reverse
order
to
Final drive mounting bolt : Thread tightener (LT-2) Final drive mounting bolt : 1323.9 + 147.1 Nm I135 t 15 kgm1
bolt : Thread tightener (LT-21 Guard mounting bolt : 745.3 = 83.4 Nm {76 f 8.5 kgm1 Guard mounting
teeth mounting bolt : Thread tightener (LT-21 Segment teeth mounting bolt : 1176.8 = 98.1 Nm (120 = 10 kgm}
Segment
30-l 62 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1.
Carrier assembly 1) Remove cover. 2) Remove mounting bolts, then using eyebolts 0, remove carrier assembly (I).
3)
Remove
lock plate (2).
DEW1143
4)
Using tool 55, pull out shaft (3). * Remove all three shafts.
CWD02649
5)
Remove gear assembly (4). * When removing the gear assembly, push the gears which are not being removed against the outside wall, then remove the gear which is to be removed.
DKDX145
D 1 SAX-5
30-163 0
DISASSEMBLY
6) 7)
Remove Remove
ASSEMBLY
AND
FINAL DRIVE
bearing (6) from gear (5). outer race (7) from gear (5). 6
5
6.
7 DKDO1146
2.
3.
Shaft Using eyebolts
0,
Holder Remove
(IO).
holder
remove
shaft (9).
I 4.
Ring gear, hub assembly gear and hub asI) Using wire, remove-ring sembly (11). 2) Remove 6 plates (121, then remove ring gear (14) from hub (13).
5.
Sprocket, hub assembly Fit eyebolts, pull out sprocket and hub asI) sembly (15) with tool 52 and remove.
30-164 0
DEW1147
D155AX-5
DISASSEMBLY
*
2)
3)
6.
AND ASSEMBLY
Bearing time.
(19) will come
FINAL DRIVE
out at the same
Remove floating seal (16). Ir If the floating seal to be used again, be careful not to damage the seal surface, and keep it in a safe place. Remove outer race (18).
16
18
Cover assembly 1) Screw in forcing screws 0, and pull out cover assembly (21) from case (22). then use eyebolts @ to remove.
/
22
DEm1154
2)
3) 4)
Remove floating seal (16). Ir If the floating seal to be used again, be careful not to damage the seal surface, and keep it in a safe place. Using bolts 0, knock out spacer (20) and bearing (19) from cover. Remove bearing (8).
DKD01155
D155AX-5
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
7. Gear Remove mounting bolts (211, pull out with forcing screws @, then using eyebolts 0, remove gear (24) from hub (25). * Turn the gear at an angle and remove it.
DEW1166
8. Hub 1) Using eyebolts @, remove hub (25). 2) Using puller 0, remove inner race (26) from hub (25).
DEW1166
26
DECO1169
L
9. Guide plate Remove guide
r plate (37).
10. Pinion assembly 1) Using forcing
screws @, remove
cage (27).
DEDOll61
30-166 0
D155AX-5
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
2)
Remove
pinion assembly
3)
Remove
bearing
(29).
(31) from pinion (30).
ill
3i
DLD31163
DLm1162
4)
Remove outer race (32) and oil seal (33) from cage (28). 32
5)
Remove
2
outer race (34) from case.
34 0
39 L_--/ 1
0
0
0
0
DLDJllM
D 155AX-5
0
DLDO1165
30-167 0
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
ASSEMBLY ASSEMBLY
OF FINAL DRIVE
* *
Clean all parts, and check for ‘dirt or damage. Coat the sliding surfaces of all parts and the rotating parts of the bearings with engine oil before installing.
1.
Pinion assembly
1) Using push- tool 0,
install oil seal (33) to cage (28). & Lip of oil seal : Grease (G2-LI) DKD01166
2) Using push tool, install outer race (32) to cage (28).
3)
32 \
Using push tool, case (35).
press fit oil seal
(36) to
!I! 35
DKD01168
DLDY167
4)
Using push tool, press fit outer race (34) to case (35).
5)
Using pinion
36
34 push tool, (30).
press fit bearing
(31) to
0
0
0
, e
0
0
_,
35.
6)
Install pinion
assembly
7)
Assemble shim, and install cage (28). Ir Be careful not to damage the oil seal.
DLCM1166
(29) to case. 28
DLDJ1171
30- 168 0
DtDOll72
D155AX-5
DISASSEMBLY
*
2.
3.
AND ASSEMBLY
FINAL DRIVE
Select the shim thickness as follows. Install pinion to cage without assembling i) O-ring. bolts to specified ii) Tighten 4 mounting tightening torque. w Mounting bolt : 9.8 Nm 11 kgml iii) Using a clearance gauge, measure clearance a between cage and case at 2 places around circumference, then calculate average value. iv) Select shim of measured average value + (0.05 - 0.1 mm). Ir There are four types of shim: 0.15, 0.5, 0.6, 0.7 mm
Guide plate Install guide
plate (37).
Hub 1) Using push tool, press fit inner race (26) to hub (25). 2) Using eyebolts 0, install hub (25).
37 DEW1174
4.
Gear 1) Using
2)
eyebolts
0,
install
gear
(24) to hub
(25). * Turn the gear at an angle and insert it. Tighten mounting bolts (21). w Mounting bolt : 277.0 t 31.9 Nm I28.25 + 3.25 kgml
DEW1153
5.
DED01176
Cover assembly 1) Using push tool, press fit bearing (8) to cover (38).
8
DK!M1177
D155AX-5
30-169 0
DISASSEMBLY
2) 3) 4)
FINAL DRIVE
AND ASSEMBLY
Install spacer (20). Using tool 54, press fit bearing
(19) to case
ilk
(38). Using tool 53, install floating seal (16). + Remove all oil and grease from the Oring and O-ring contact surface, then dry before installing. Ir After installing the floating seal, check that the angle of the seal is less than 1 mm.
54
18 CWD02652
5)
Using eyebolts 0, install cover assembly (21) to case (221, and tighten mounting bolts. & Mounting bolt :
Thread tightener m
Mounting
(LT-21
2
bolt : 549.2 2 58.8 Nm 156 t 6 kgm)
DEDO1180
6.
Sprocket, hub assembly
1) Install outer race (18) to hub (13). 2) Using tool J3, install floating seal (16). *
3)
4)
Remove all oil and grease from the Oring and O-ring contact surface, then dry before installing. * After installing the floating seal, check that the angle of the seal is less than 1 mm. Check that there is no dirt or dust on sliding surface of floating seal, then coat thinly with engine oil.
Using eyebolts 0, set sprocket sembly (15) to cover.
30-170 0
CWD02654
and hub as-
D155AX-5
DISASSEMBLY
5)
FINAL DRIVE
AND ASSEMBLY
Using tool J4, rotate sprocket and hub assembly, and press fit bearing (19). Ir Press fit within a range where no preload is applied.
CWD02655
7.
Ring gear, hub assembly ring gear (14) to hub (131, and 1) A&emble tighten plate (12). a Mounting bolt : Thread tightener (LT-2) m Mounting bolt : 66.2 = 7.4 Nm 16.75 = 0.75 kgm} 2) Using wire, install ring gear and hub assembly (11).
8.
Holder 1) Assemble shim and tighten holder (IO). & Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 549.2 = 58.8 Nm I56 + 6 kgm) 2) Select shim thickness as follows. i) Tighten 4 bolts to specified torque, then settle all parts. & Mounting bolt : Thread tightener (LT-2) w Mounting bolts : 549.2 + 58.8 Nm I56 + 6 kgml ii) Remove bolts, then turn sprocket hub and check that bearing rotates smoothly. Ir At position of carrier assembly mounting bolts: 216 - 265 N (22 - 27 kg) iii) Tighten 4 bolts to 34.3 Nm (3.5 kgml, measure clearance b between holder and hub at 4 places around circumference, calculate average value, then select shim thickness. Shim thickness = Average clearance b + (0 - 0.1 mm) iv) Finally adjust so that clearance a between holder and hub is 0.05 - 0.1 mm.
D 155,4X-5
DEW1148
II
DEco1185
b $
DK!MllE6
30-171 0
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
10. Shaft Using eyebolts
0,
install shaft (9).
11. Carrier assemblv
1) Using push tool, press fit outer race (7) to
2)
gear. * Make match marks on the outer race and bearing. Assemble bearing (6) to gear (5).
6
I
3)
5)
DKDOllSO
Set gear assembly (4) to carrier, then align shaft hole and inner race hole of bearing. Ir Insert the gear assembly through the hole in the center of the carrier, push against the outside wall, then set the gear assemblies in the mounting position after inserting all three gear assemblies.
I 4)
DKD01189
,6
DKDO1145
Expand-fit shaft (3) to install. * Cool in dry ice for approx. 30 minutes. Ir When the shaft warms up it will be impossible to push it in by hand, so align the notched portion with the hole in the plate and push in quickly. Tighten lock plate (2). 6 Mounting bolt : Thread tightener (LT-21 w Mounting bolt : 109.3 2 12.3 Nm (11.15 + 1.25 kgm} DEW1192
30-172 0
D155AX-5
1
DISASSEMBLY
6)
Using
FINAL DRIVE
AND ASSEMBLY
eyebolts
0,
install
carrier
assembly
(1). &
Mounting
bolt :
m
Mounting
bolt : 549.2 i 58.8 Nm
Thread tightener
(LT-21
156 f 6 kgml 7)
Install center cover.
DEW1142
D155AX-5
30-173 0
DISASSEMBLY
AND ASSEMBLY
TRACK FRAME
REMOVAL OF TRACK FRAME ASSEMBLY 1.
Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Jacking
2) 3)
3.
up chassis
Using hydraulic jack (686 kN 170 ton}) A 1) and ripper of machine, jack up chassis and set stands @ under steering case on left and right. Set stands @ on left and right under main frame at front of chassis. Set blocks under front of raised track frame to ensure safety during operation. Ir After setting stand @ and 0, set the hydraulic jack and ripper again to act as extra support.
Disconnection of equalizer bar 1) Sling track frame assembly, and remove cover (I) of equalizer bar, then remove pin cover (2) and spacer (3).
2)
Remove equalizer bar side pin (4) together with collars (5) and (6).
3 56
4 DKJNO178
30- 174 0
D155AX-5
DISASSEMBLY
4.
TRACK FRAME
AND ASSEMBLY
Disconnection of track frame assembly . Left track frame assembly Remove cover (71, then remove spacer (8).
I
I .
Right track frame assembly I) Remove cover (91, and disconnect
L
DLDoo179 1
DL!XOWl
block
(IO).
I DLCCO182
DLDOO181
2) 3)
5.
Disconnect hose (I I) from block (IO), then remove spacer (12). Remove seal (131, then remove washer a (14) and washer (15).
Lift off track frame r+ kg
Track frame
assembly assembly
-1
-
‘7
(16). : 3,960
kg
i6
D155AX-5
:
OLD20185
30-175 0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION l
Carry out removal.
*
installation
TRACK FRAME
OF TRACK in the ‘reverse
order
to Maker’s
Assemble seal (13) as follows. 1) Keep seal in direction @ in relation to pivot shaft. Set with the maker’s mark on the outside. 2) Turn seal by hand from condition @ in direction of arrow to position @. Set with the maker’s mark on the inside. 3) Coat surface @ of washer (15) with oil (EO-30). 4) Keep the seal in condition @I, and assemble between washer (14) and washer
12
l
DlllCO186
l
*
.
(15). Be careful not to let seal (13) extend surface @.
outside
Refilling with oil Ia *
Pivot chamber oil : Approx. 8.2 k! (EO-301 The oil level in the pivot chamber will be 25 mm from the end face of the shaft.
30- 176 0
wmia7
D155AX-5
DISASSEMBLY
AND ASSEMBLY
IDLER
REMOVAL OF IDLER ASSEMBLY 1. Remove track shoe assembly. OF TRACK SHOE For details, see REMOVAL ASSEMBLY. To prevent danger, never stand in front of g the idler assembly. 2. Remove side covers (I). Remove one each on the inside and out* side.
3.
Loosen support mounting bolts, remove shim, m then remove supports (2). of the and thickness Check the number * shims, and keep in a safe place. Remove one each on the inside and outside. *
2
4.
Loosen guide tension bolt (3). Loosen two each on the inside and outside. *
5.
Remove
6.
Raise idler assembly and remove. &I kg
7.
idler guide mounting
Idler assembly:
(51, then
DLCCOlSS
bolts (4).
lift out to front
341 kg
Remove spring seat (61, then remove tension spring (7). The above parts are assembled between the * support and track frame.
6
DLiXOlSl
D155AX-5
30- 177 0
DISASSEMBLY
IDLER
AND ASSEMBLY
INSTALLATION OF IDLER ASSEMBLY l
Carry out removal.
*
l
l
installation
in the
reverse
order
to
Set the idler assembly at the center of the track frame, then adjust clearance a between the track frame and guide plate with shims. Standard clearance a : 0.5 - 1.0 mm Standard shim thickness : 6 mm
30- 178 0
D 15514X-5
DISASSEMBLY
AND ASSEMBLY
IDLER
DISASSEMBLY OF IDLER ASSEMBLY 1.
Remove -
:
oil drain plug and drain oil. idler : Approx.
2.
Set idler assembly
3.
support I) 2)
4.
5.
Remove Remove
530 - 590 cc
(I) on block 0.
nut (21, and pull out bolt (3). support (4).
Retainer Remove mounting screws 0, remove
bolts, retainer
then (5).
using
Shaft 1) Turn over idler assembly. 2) Remove nut (6) and bolt (71, then support (8).
3) 4)
Using forcing screws 0, Lift off shaft (IO).
D 155AX-5
remove
forcing
remove
retainer (9).
DISASSEMBLY
6.
7.
AND ASSEMBLY
Disassembly of support Remove floating seals and (8).
(11) from
Disassembly of retainer Remove floating seals and (9).
(12) from
IDLER
supports
retainers
(4)
4I,8
11
Bushing Remove
30-180 0
bushing
59
(5) ’ Q
DEW0197
8.
12
MIX0199
(13) from idler (I).
D155AX-5
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY ASSEMBLY
OF IDLER
Ir
Clean all parts, and check for dirt or damage.
1.
Bushing Set tool
Ll to idler
(I),
and press fit bushing
(13). Ir When press fitting the bushing, use a plastic hammer to align the center, then press fit with a puller. * Press fit the bushing so that the dimension from the end face of the idler to the top face of the bushing is 15 + 1 mm.
2.
IDLER
I
-13
CWD02656
Assembly of retainer Using tool L2, assemble floating seals (12) to retainers (5) and (9). See Fig. @ for the protrusion of the seal. After inserting, check that the angle of the seal is less than 1 mm. When assembling the seal, wash the area marked by the bold line in Fig. @ (the Oring and O-ring contact surface), remove all oil and grease, then dry completely.
12 CWD02657
3.
Assembly of support Using tool L2, assemble floating seals (11) to supports (8) and (4). * See Fig. @ for the protrusion of the seal. * After inserting, check that the angle of the seal is less than 1 mm. * When assembling the seal, wash the area marked by the bold line in Fig. @J (the Oring and O-ring contact surface), remove all oil and grease, then dry completely.
-@--
57mm
TJ
L DEm202
DEDC0203
CWD02656
D155AX-5
30-l 81 0
DISASSEMBLY
4.
IDLER
AND ASSEMBLY
Shaft, retainer 1). Set idler @ on block (I). 2). Install retainer (9). 3). Raise idler (I) and turn block 0.
over,
then
set on
mm205
4). Raise shaft (IO) and assemble to idler. * When assembling, be careful not to damage the retainer mount floating seal at the bottom. 5)
5.
Install retainer
(5).
supports 1) Assemble
support (4) to shaft, then fit bolt (3) and tighten nut (2). * Before assembling the support, coat the floating seal mating surface thinly with engine oil.
2)
Turn over shaft, then * Before floating engine
30-182 0
idler (I), assemble support (8) to fit bolt (7) and tighten nut (6). assembling the support, coat the seal mating surface thinly with oil.
D155AX-5
DISASSEMBLY
6.
AND ASSEMBLY
Refilling with oil Using tool L9, add oil to specified
IDLER
level
tighten
plug.
Q
Idler : Approx. 530 - 590 cc (G0140B) Plug : 205.9 + 49.0 Nm I21 = 5 kgm1
w
*
-
and
-)
To vacuum tank
To oi I
PUIIIP
If oil has been added with tool L9, always angle approx. IO” as shown in the diagram on the right, and check that the oil level is at the bottom face of the oil filler port.
D155AX-5
30-183 0
DISASSEMBLY
AND ASSEMBLY
RECOIL SPRING
REMOVAL OF RECOIL SPRING ASSEMBLY 1.
Remove idler assembly. For details, see REMOVAL BLY.
OF IDLER ASSEM.I
2.
Remove
cover (I) from track frame.
DLDC0210
3.
Remove
lock plate (21, then remove
pin (3).
0
DLCOOZll
4.
Lift off recoil spring assembly r+ kg
Recoil spring
assembly
(4).
: 510 kg
DLCGOZ12
INSTALLATION OF RECOIL SPRING ASSEMBLY .
Carry out installation removal.
30-184 0
in the reverse order to
D155AX-5
DISASSEMBLY
AND ASSEMBLY
RECOIL SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY 1.
Disconnection of cover assembly * Remove cover assembly (2) from recoil spring case assembly (I) as follows. 1) Set recoil spring assembly (I) on block 0. Ir When doing this, check that there is no damage to the weld of recoil spring case (I).
1
2
@3l+----’ CKD01030
2)
Loosen mounting bolts (24) of cover (2) gradually in turn on diagonally opposite sides. To prevent danger, never stand in front of the cover assembly or behind the recoil spring case assembly.
A
CLD01049
AThe recoil spring inside the recoil spring case is applying a pushing force of 294 kN (30 tons} on the yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange of the recoil spring case and idler yoke assembly is 10 - 13 mm. 3)
A
When the bolts are loosened, the torque will suddenly drop. Check that the spring is not applying any pushing force. on the mounting bolts, then remove all bolts. Ir If the torque increases (the pushing force of the spring is applied) during the loosening operation, stop the loosening operation and disassemble as follows.
If the torque does not drop during Steps 2) and 3) described above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolt (181, or nut (16) at the tip of the shaft has fallen off, so there is danger that the yoke assembly may fly off to the front. For this reason, disassemble as follows.
Dl MAX-5
a
CR
18
16 CLDO1051
30-185 0
DISASSEMBLY
RECOIL SPRING
AND ASSEMBLY
AWhen disconnecting the cover assembly and recoil spring case assembly, do not stand in front of the yoke assembly or behind the recoil spring case assembly until safety has been confirmed and the recoil spring assembly has been removed. i)
Prepare the following parts. 791-730-I 130 Bolt @ (x4): 01580-12016 Nut @ (x4): Washer @ (x4): 01643-32060 (use again) CLW1052
Remove 4 bolts marked %, then install bolts 0, nuts 0, and washers @ listed in Step i). Ir Check that dimension L is less than 300 mm. * Screw in bolts @ until they contact the bottom of the yoke thread. iii) Remove remaining 8 bolts (those not marked Zc).
ii)
iv)
VI
Hold bolts @ with a wrench to prevent them from turning, then loosen 2 nuts Qsimultaneously on opposite sides. * Be careful not to let the load bear on only one bolt.
DLD02850
When recoil spring is fully extended and torque has completely dropped in loosening direction of nut 0, remove bolt 0. * When clearance b is approx. 180 mm, the spring is fully extended.
b CLD01054
4)
Sling cover assembly (21, then remove mounting bolts, and lift off cover assembly. * The oil inside the spring chamber will flow out, so set a container under the cover to catch the oil. -
:
Spring chamber
: Approx.
12 !Z
l3!3JOO214
30-186 0
Dl55AX-5
DISASSEMBLY
2.
3.
Recoil spring assembly Raise recoil spring assembly from case.
Disconnection of yoke 1) Remove mounting remove spacer (5).
2)
RECOIL SPRING
AND ASSEMBLY
bolts
(3) and
of yoke
remove
(41, then
i‘C/ is/[
Using tool M4, disconnect yoke (4) from case. Disconnection pressure for yoke: Approx. 147 kN {I 5 ton} * Before disconnecting the yoke, make match marks on the yoke and case.
*
4.
Disassembly 1) Remove bly (2). 2) Remove
D155AX-5
of cover assembly cylinder rod (22) from cover assem-
. bracket, then remove
lubricator
(6).
30487 a
DISASSEMBLY
3)
RECOIL SPRING
AND ASSEMBLY
Remove piston (7) from cylinder rod (22). Sr Using an air gun, blow in compressed air through the lubricator mounting hole to remove the piston.
DEW0219
4)
Remove snap ring (8) from piston (71, then remove U-packing (9) and wear ring (IO).
7 8
DEDOOZO
5) 6)
5.
Remove cover (12) from cover (II), then remove oil seal (13). Remove bushing (14) from cover (11).
Disassembly of recoil spring assembly II
Set recoil spring assembly (3) in tool Ml. spring is under high installed load, AThe so be careful to set it correctly to tool Ml. Installed load of spring: * 285.8 kN (29,160 kg}
CWD07.661
30-188 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
RECOIL SPRING
2) Apply hydraulic pressure slowly to compress spring, then remove move nut (16).
lock plate (15) and re-15
3)
Release hydraulic pressure gradually lieve tension of spring.
and re-
DEcccl223
4)
Remove set bolt (18), rear pilot (1% (20), and pilot (21) from spring (17).
shaft 18
@@’ DEDOOZ24
D155AX-5
30-189 0
DISASSEMBLY
AND
ASSEMBLY ASSEMBLY 1.
ASSEMBLY
RECOIL SPRING
OF RECOIL SPRING
Assembly of recoil spring assembly 1) Assemble pilot (21), shaft (20), rear pilot (19), and set bolt (18) to spring (17), then set in tool Ml. The spring is under high installed load, so be careful to set all parts correctly.
A
DElXOZZ4
I 2)
Apply hydraulic pressure gradually to compress spring, and set so that installed length @ of spring is standard value. When doing this, check clearance @ between shaft (20) and rear pilot (19). Installed load of spring: * 285.8 kN (29,160 kg) * Installed length 0: 945 mm * Clearance @: 60 mm
3)
Fit nut (16), then install lock plate (15). When securing nut (16), make a clear* ance of 0 - 1 mm between lock plate (15) and nut (16), then bring lock plate (15) and bolt (18) into tight contact. Purpose of making clearance i) If the nut is screwed in a small amount and nut (16) protrudes beyond bolt (18), lock plate (15) may bend and lock bolt (23) may fall off. ii) If the nut is screwed in too far, the load of the spring will always be applied to the set bolt, and the set bolt will break. Gradually release hydraulic pressure to completely relieve tension of spring, then remove recoil assembly (3) from tool Ml.
*
4)
30- 190 0
CWD02661
I-
a
DEW0225
,, Clearance O-l.Omm
OLD02921
D 155AX-5
DISASSEMBLY
2.
RECOIL SPRING
AND ASSEMBLY
Assembly of cylinder assembly I) Using tool M2, press fit bushing (14) to cover (II). . Bushing
press-fitting force : 19.6 - 29.4 kN 12 - 3 tons)
2)
Assemble oil seal (13) to cover cover (12) and O-ring.
(II),
install
3)
Assemble wear ring (IO) and U-packing to piston (71, then install snap ring (8).
(9) 8
4)
Assemble piston (7) to cylinder rod (5) from U-packing end. * To prevent air from remaining inside the cylinder when carrying out the operation in Step 4) above, fill with grease as follows, and assemble piston (7). i) Fill inside of cylinder with approx. 65 cc of grease. ii) Set with drain hole in cylinder rod (22) facing up, then fit lubricator (61, and loosen. iii) Push in until piston (7) contacts stopper face of cylinder rod, and push out all air and remaining grease.
D 155AX-5
7
DISASSEMBLY
RECOIL SPRING
AND ASSEMBLY
iv) Tighten lubricator (61, then install bracket. w Lubricator : 49.0 f 2.5 Nm I5 t 0.25 kgm}
5)
Assemble
cylinder
6
22
2
rod (22) to cover assem-
bly (2).
3.
Press fitting yoke 1) Align match marks on yoke and case (made 2)
before disconnecting) and assemble. Using tool M3 and spacer (51, press fit yoke (4) to case. * Do not coat press-fitting surface @ with Molycoat. . Press-fitting force: 245.2 kN 125 ton)
I 3)
Fit spacer (5) and tighten A Mounting bolt :
mounting
Thread tightener
4.
CWDO.2663
bolts.
(LT-2)
Raise spring assembly (3) and assemble to case. * Before assembling, coat surface @ of spring assembly (3) with grease. & Spring assembly surface
@ : Grease (G2-LII
CKD01056
30-192 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
RECOIL SPRING
Raise cover assembly (2) and install to case assembly (II. & Mounting bolt : Thread tightener (LT-2) QFJ Mounting bolt : 549.2258.8 Nm I56=6 kgml
Refilling with oil Add oil to spring chamber. %#
D 155AX-5
Spring
chamber
: 12 4 (SAEBOCDI
30-193 0
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
REMOVAL OF TRACK ROLLER ASSEMBLY 1. Loosen track shoe tension. For details, see REMOVAL SEMBLY.
OF TRACK SHOE AS-
2.
Remove 7 mounting bolts of guard (I), and drop m on top of shoe. . Remove guard (I) only for the track roller assembly at the rear.
3.
Remove 4 mounting bolts of track roller assemm bly (21, and disconnect from bogie (3).
4.
Using work equipment, guard (1). &I kg
raise chassis and lift off 113
Guard : 45 kg
DBDJO732
5.
Pull out track roller assembly top of shoe link.
(2) to outside from
Track roller assembly 0: Single flange: 97 kg @: Double flange: 109 kg
.
Mounting
position
of track roller assembly
0: Single flange type @I: Double flange type
30-194 0
D155AX-5
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
INSTALLATION OF TRACK ROLLER ASSEMBLY .
Carry out installation removal.
&
w
&
m
in the
reverse
order
to
bolt : Thread tightener (LT-21 Guard mounting bolt : 662.0 - 828.7 Nm I67.5 - 84.5 kgm} Guard mounting
bolt : Thread tightener Track roller mounting bolt : Track roller mounting
(LT-2)
662.0 - 828.7 Nm
I67.5 - 84.5 kgml
m
*
Install the track roller assembly as follows. I) Install guard (I) temporarily. 2) Lower chassis to a position where track roller assembly mounting bolts can be assembled, then install mounting bolts. 3) Tighten guard mounting bolts.
Dl!SAX-5
30- 195 0
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
DISASSEMBLY OF TRACK ROLLER ASSEMBLY 1.
Remove -
:
plug and drain oil. Track roller : Approx. 390 - 450 cc
2.
Remove mounting roller (I 1.
3.
Turn over track roller, and set cylinder @ or block so that there is enough space to remove shaft from bottom.
4.
Remove 2 mounting bolts of retainer (31, then set tool L4 in position and pull out shaft (4) from bottom.
bolts of retainer
(2) of track
.4 .3
CWD02664
5.
Remove seal guide (51, then bolts of retainer (3).
6.
Using forcing
screws
0,
remove
remove
mounting
retainer
(3).
DEDXQ33
7.
DEDoozx
Raise roller (61, and pull out from shaft assembly (7).
DEW0235
30- 196 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
8. Set shaft assembly
TRACK ROLLER
(7) to cylinder
9. Using tool L4, remove (8) from shaft (7).
0.
retainer (2) and seal guide
CWD0.2665
10. Remove and (8).
floating
seals (9) from
seal guides
11. Remove floating seals (IO) from and (3). then remove O-ring.
DI 55AX-5
retainers
(5)
(2)
23
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
O-ring DE000240
12. Remove 2 coil bushings (11) from roller (6).
6
'11
DEW0241
30-198 0
D 155AX-5
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
ASSEMBLY OF TRACK ROLLER ASSEMBLY *
1.
Clean all parts, and check for dirt or damage. Set roller (6) in press, then use tool L3 to press fit 2 bushings (II). * When press fitting the bushing, use a plastic hammer to align the center, then press fit with a press. * Press fit the bushing so that the dimension from the end face of the roller to the top face of the bushing is 17 + 1 mm.
,
2.
'
CUD02666
Using tool 53, assemble floating seals (IO) to retainers (3) and (2). Ir After inserting, check that the angle of the seal is less than 1 mm. * See Fig. @ for the protrusion of the seal.
J3
I-~
3.
-
Fig. @ -
Using tool 53, assemble floating seals (9) to seal guides (8) and (5). * After inserting, check that the angle of the seal is less than 1 mm. * See Fig. @ for the protrusion of the seal.
D155AX-5
30499 0
DISASSEMBLY
4.
TRACK ROLLER
AND ASSEMBLY
Set roller (6) to cylinder (7) to roller.
0,
and assemble
shaft
DEW0245
5.
After installing retainer (3), turn over with shaft assembled to roller and set on block 0.
6.
Install retainer (21, assemble seal guide (8) to shaft, then using tool L4, press fit seal guide (8). Press fit the seal guide so that dimension a * from the end face of the shaft to the top surface of the seal guide is 48.5 + 0.2 mm. Turn over the track roller assembly and press * fit seal guide (5) in the same way as above. coat the mating surface Before assembling, * at the seal guide end seals floating the of and retainer end thinly with engine oil.
5
CWD02667
30-200 0
D155AX-5
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
7.
Using tool L9, apply standard pressure to roller oil filler port, and check for leakage of air from seal. Ir Standard pressure : 0.1 MPa (1 kg/cm*) * Method of checking : Hold standard pressure for 10 seconds. Gauge indicator must not go down.
8.
Using tool L9, fill track roller assembly Q
9.
with oil.
Track roller oil : 390 - 450 cc (GO1401
After filling with oil, check that the oil is at specified level, then tighten plug. * Checking oil level: Angle track roller approx. IO” and check that oil level is up to bottom face of oil filler. m Plug : 160.0 - 250.0 Nm US.0 - 25.0 kgml
D 155AX-5
30-201 0
DISASSEMBLY
AND ASSEMBLY
BOGIE
REMOVAL OF BOGIE ASSEMBLY 1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Remove 7 mounting on top of shoe.
3.
Sling guard (I), then use work equipment jack up chassis, and remove guard (I). r+ kg
bolts of guard (I), and drop m to
Guard : 45 kg
4.
Lower chassis, then remove mounting bolts of bogie guard (2). 112 . Bogie guard mounting bolt : 2 each on inside and outside of track frame
5.
Use work equipment to jack up chassis, then use clearance a between bogie assemblies to remove bogie guard (2).
6.
Using tool L13, secure inner bogie (3) and outer bogie (4).
I
30-202 0
CWDO2669
D155AX-5
DISASSEMBLY
AND ASSEMBLY
7.
Set steel plate @) between bogie assembly and shoe link, then lower chassis and remove mounting bolts of bogie assembly (5). * After removing the bogie assembly, set block @ between the bogie assemblies to prevent it from moving.
8.
Using work equipment, jack up chassis, fit rope around bogie assembly (51, then slide on steel plate @ and pull to outside. a r3 kg
Bogie assembly
BOGIE
: 410 kg
DBCGO740
D155AX-5
30-203 0
DISASSEMBLY
AND
ASSEMBLY
INSTALLATION ASSEMBLY .
Carry out removal.
& w
& w
a
BOGIE
OF BOGIE
installation
in the
reverse
order
to
bolt : Thread tightener (LT-2) Guard mounting bolt : 662.0 - 828.7 Nm (67.5 - 84.5 kgm}
Guard mounting
bolt : Thread tightener (LT-2) Bogie mounting bolt : 1863.3 - 2353.7 Nm I190.0 - 240.0 kgm1
Bogie mounting
.
Procedure for setting bogie assembly on link I) Set steel plate @ on top of link as shown in Fig. 2) Fit wire @to bogie bracket (6) of track frame on opposite side. 3) Fit wire @I to 2 track rollers of bogie assembly to be installed, then use lever block @ to pull up to top of link. in mounting position, 4) Set bogie assembly then secure with block so that it does not move. 5) Using work equipment, gradually lower chassis to position where bogie mounting bolts can be assembled, then install mounting bolts. then tighten bo6) Lower chassis completely, gie mounting bolts. 7) Raise chassis, then remove steel plate and install bogie guard (2).
DAD00741
DAwo742
30-204 0
D 155AX-5
DISASSEMBLY
DISASSEMBLY ASSEMBLY
OF BOGIE
*
Fixture tool L13 (used when removing the bogie assembly) is also used for the disassembly operation, so leave it installed.
1.
Track roller assembly Turn over bogie assembly, and lift off 2 track a roller assemblies (I). * When removing the track roller, check the mounting positions of the @ single flange and @ double flange.
2.
Pulling out pin assembly 1) Set bogie assembly (2) to tool LIO. * When removing the pin assembly from the bogie assembly, the pin assembly must be removed in the correct direction, so check casting mark @ (INSERT I)) on the inside of the outer bogie, and set the bogie assembly correctly in the direction for removal.
2)
BOGIE
AND ASSEMBLY
a--
Using tool LIO, pull out pin assembly (3) from bogie assembly (2). * Removal pressure for pin assembly : Approx. 800.2 kN (81.6 ton1
LlO
CWD02670
D155AX-5
30-205 0
DISASSEMBLY
3.
AND ASSEMBLY
BOGIE
PuWing out shaft I) Set pin assembly (3) to tool Lll. 2) Push in shaft (4) with tool Lll, remove
collar (51, then remove spacer (6) and floating seal (7). Ir Dimension for pushing in shaft (4): 78.2 mm * Pressure for pushing in shaft (4): 58.8-103.9 kN (6-10.6 ton)
Lll
CUD02671
3)
Turn over pin assembly (3) while still assembled, then set to tool Lll again.
I U
/--
I CUD02672
4)
Push in shaft (4) with tool Lll, then remove collar (8). * Dimension for pushing in shaft (4): 156.4 mm * Pressure for pushing in shaft (4): 58.8 - 103.9 kN 16 - 10.6 ton)
D 155AX-5
30-207 0
DISASSEMBLY
5)
BOGIE
AND ASSEMBLY
Remove pin assembly (3) from tool Lll, and pull out spacer (91, ring (IO), spacer (II), ring (121, spacer (131, and ring (14) from shaft (4).
4.
Disassembly of ring 1) Remove floating seals (15) and (16) from ring (IO). 2) Remove floating seals (17) and (18) from ring (12). 3) Remove floating seal (19) from ring (14).
15,19 IO,14
16
17
18
12
DLW0749
5.
Disassembly of collar Remove floating seals (20) from
collars
(5) and
(8).
58
I
6.
Disconnection of bogie Remove tool L13, and disconnect (21) and outer bogie (22).
inner
DLDCO7SO
bogie
CUD02673
30-208 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY ASSEMBLY
BOGIE
OF BOGIE
1.
Securing bogie Assemble outer bogie (22) and inner bogie (211, and secure with tool L13. * After securing with tool L13, check that the center of the pin assembly hole is showing.
2.
Shaft, collar 1) Set collar (8) to tool L12, and assemble bushing (12) to shaft (4) temporarily, assemble to spacer, set in position, then press fit. Ir When press fitting the shaft, center the shaft with the collar, then press fit. Ir Press-fitting force for collar: 6 - 10.6 ton Ir Press-fitting dimension: 78.2 mm 6 Collar press-fitting surface of shaft: Anti-friction compound (LM-PI * After press fitting, there must be no stepped difference at the end face of the collar and shaft. 2)
Remove bushing
3)
Using tool L14, assemble floating seal (20) to collar (8). When assembling the floating seal, remove all oil and grease from the O-ring and O-ring contact surface. The angle of the floating seal must be less than 1 mm. Protrusion @ of the seal must be within 5- 7 mm.
shaft (12).
from
spacer,
then
CWD02673
remove
CWD02674
12
D155AX-5
4
CWD02675
30-209 0
DISASSEMBLY
3.
AND ASSEMBLY
BOGIE
Assembly of ring, collar 1) Using tool L14, install floating seals (191, (181, (171, (161, and (15) to rings (14). (121, and (IO). Ir When assembling the floating seals, remove all oil and grease from the O-ring and O-ring contact surface. Ir The floating seal must be tilted less than 1 mm. * Protrusion @ of the seal must be within 5-7 mm.
2)
Using tool L14, assemble floating seal (7) to collar (5). Ir The precautions are the same as the items marked * for Step 1) above.
I 4.
CWO02678
Assembly of pin assembly * When assembling the floating seals for each bushing and collar, coat the seal mating surface thinly with oil (EO-30). 1) Install spacer (6) to shaft (41, then assemble ring (14). 2) Install spacer (131, then assemble ring (12). 3) Install spacer (II), then assemble ring (IO). 4) Install spacer (9).
6
30-210 0
D155Ax-5
DISASSEMBLY
5)
AND ASSEMBLY
BOGIE
Set pin assembly (3) to tool L12, press fit collar (5). * Press-fitting force for collar: 6 - 10.6 ton Ir Press-fitting dimension: 78.2 mm & Collar press-fitting surface of shaft: Anti-friction compound (LM-P) * Stepped difference at the end face of the collar and shaft after press fitting: O-2mm
5
5.
3
CWD02679
Press fitting pin assembly 1) The bogie and pin assembly must be press fitted in the correct direction, so check the press-fitting direction and set tool LIO in position. i) On the inside of the outer bogie @, there is an [INSERT+) casting mark and arrow, so set the bogie with the letters and arrow facing the hydraulic cylinder end of tool LIO. ii) The pin assembly with the distinguishing mark machined on the outside circumference of the bushing has the larger diameter, so press fit the bushing that has no distinguishing mark first.
D155AX-5
30-211 0
DISASSEMBLY
2)
AND ASSEMBLY
BOGIE
Press fit pin assembly (2) to bogie assembly. 6 Outside circumference of pin assem bly: Anti-friction compound (LM-PI * Press fit with the [UP] mark on the tip of the pin at the top. * Press-fitting force for pin: Approx. 800.2 kN (81.6 ton)
6.
Track roller assembly Install 2 track roller assemblies (1). * Check the installation position of the @ single flange and @ double flange, then install. & Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 662.0-828.7 Nm {67.5-84.5 kgm1
7.
Refilling with oil After assembling, %8
30-212 0
add oil to bogie assembly.
Bogie assembly
: 210-230
cc (60140)
D155AX-5
DISASSEMBLY
CARRIER ROLLER
AND ASSEMBLY
REMOVAL OF CARRIER ROLLER ASSEMBLY 1.
Remove top cover of track frame, loosen lubricator (11, then loosen track shoe tension. The recoil spring cylinder is under high internal pressure, so never loosen lubricator (I) more than one turn. Ir If the track tension is not relieved when the lubricator is loosened, move the machine backwards and forwards.
A
2.
Using
3.
Remove
4.
Pass rope @ carrier roller loosen rope support and & kg
hydraulic
jack 0,
mounting
raise track shoe.
bolts (2).
through hole in link, wrap around (31, and tighten rope. Gradually to pull out carrier roller (3) from a remove it.
Carrier
roller : 45 kg
I
DLDW255
INSTALLATION OF CARRIER ROLLER ASSEMBLY .
Carry out installation removal.
in the
reverse
order
to
pJ *
&
When installing the carrier roller to the support, leave a clearance as shown in the diagram. Support mounting bolt :
Thread tightener .
(LT-2)
Adjust the tension of the track shoe assembly. For details, see TESTING AND ADJUSTING, ADJUSTING TENSION OF TRACK SHOE ASSEMBLY.
DLDW257
DI 55AX-5
30-213 0
DISASSEMBLY
CARRIER ROLLER
AND ASSEMBLY
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY 1.
Remove plug and drain oil. * Rotate the shaft when draining -
:
Carrier
the oil.
roller : 570 - 680 cc
2.
Set carrier
3.
Remove
mounting
4.
Remove
ring (3).
5.
Using tool L6, remove
6.
Using puller 0, remove press-fitting portion of seal guide, then using eyebolts, remove bearing (5) and roller (6) as one unit.
roller assembly
(1) on block 0.
bolts, then remove
cover (2).
nut (4).
CWD02681
7.
Remove
8.
Using puller 0, remove ing (9) as one unit.
outer race (7) from
roller.
seal guide (8) and bear-
DEW0263
QED00262
9.
Remove
floating
seal (IO) from seal guide (8). 8
30-214 0
10
D155AX-5
DISASSEMBLY
10. Using push tool 0, 11. Remove
D 155,4X-5
CARRIER ROLLER
AND ASSEMBLY
floating
remove
seal guide (II).
seal (12) from seal guide
(II).
30-215 0
DISASSEMBLY
AND ASSEMBLY
CARRIER ROLLER
ASSEMBLY OF CARRIER ROLLER ASSEMBLY *
Clean all parts, and check for dirt or damage.
1. Using push tool 0,
press fit bearing
(9).
2.
Using push tool @, press fit outer race (7).
3.
Set roller (6) and bearing
4.
Using push tool 0, press fit bearing (5) to shaft. * Rotate the roller when press fitting the bearing, and press fit to a position where the rotation of the roller becomes slightly heavier.
(5) to shaft.
Mm269
5.
Using
tool
L6, tighten
nut (4) to 58.8
Nm
DEDCXI270
(6
kgm1. * After tightening the nut, if the nut hole and shaft hole are not aligned, turn the nut in the direction of loosening to align.
6.
Install ring (3).
CWDOZ.682
7.
Fit O-ring, then fit cover (2) and tighten mounting bolts. * Temporarily tighten the oil filler plug.
30-216 0
with
D155AX-5
DISASSEMBLY
CARRIER ROLLER
AND ASSEMBLY
8. Turn over roller (61, and add oil between
shaft
and roller. Sk
Oil : 570 - 680 cc (GO1401
9. Using tool L5, install guide (8).
floating
seal (IO) to seal
10. Fit O-ring, then align with dowel seal guide (8).
pin, and install
I 11. Using tool L5, install guide (11).
floating
CWD02683
seal (12) to seal
0
Q L8
II
r-t!zk 'CWD02684
12. Using tool L8, press fit seal guide (II). * Press fit the seal guide until dimension a from the end face of the shaft to the top surface of the seal guide is 131.95 f 0.2 mm.
D155AX-5
30-217 0
DISASSEMBLY
CARRIER
AND ASSEMBLY
13. Using tool L9, apply standard pressure to oil filler port, and check for leakage of air seal. Ir Standard pressure : 1 kg/cm* * Method of checking : Hold standard sure for 10 seconds. Gauge indicator not go down.
ROLLER
roller from
presmust
14. After checking for air leakage, check again that level of oil added in Step 8 is at specified level. * Method of checking oil level Remove the oil filler plug and tilt the carrier roller assembly to an angle of approx. IO” to check the oil level. 15. Tighten oil filler plug. w Plug : 157.0 - 255.0 Nm US.0 - 26 kgml
I
30-218 0
wwo279
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
TRACK SHOE
CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY AIn
l
some cases, it may be extremely dangerous to remove the track shoe assembly. To prevent danger, carry out the following checks before removing the track shoe assembly.
Checks before starting
1) Loosen the lubricator at the adjustment
cylinder, release the grease, then move the machine backward and forward a short distance, and check that the track tension is relieved. If the track tension is not relieved and the track shoe assembly remains tense, there may be an abnormality inside the track frame (the recoil spring case is broken, the recoil spring set bolt is broken, or the nut at the end of the shaft has fallen off). Never loosen the lubricator more than one turn. Check that there is no interference between the track frame and the guide shown in the diagram. If there is any interference (when progress of link pitch elongation is extreme), there are cases where it is impossible to know if there is any abnormality inside the track frame.
A
2)
REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL) *
If CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows that there is no abnormality, do as follows.
1.
Remove blade assembly. For details, see REMOVAL OF BLADE ASSEMBLY. 2. Loosen lubricator (1) and loosen track shoe tension. m AThe recoil spring cylinder is under high internal pressure, so never loosen lubricator (1) more than one turn. If the track tension is not relieved, move the machine backwards and forwards. 3. Using block 0, adjust position so that master link is perpendicular. 4. Remove mounting bolts, then remove track shoe a (2).
DLWO280
D 155AX-5
30-2 19 0
DISASSEMBLY
5.
TRACK SHOE
AND ASSEMBLY
Disconnect master link (31, guide end of track link with a crane, move machine slowly in reverse, and lay out track shoe assembly.
I
DLD00281
REMOVAL OF TRACK SHOE ASSEMBLY (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) *
When CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows any abnormality, do as follows.
A
If there is any abnormality inside the track frame, there is danger that the track shoe assembly may spring back when it is removed or that the idler may spring out when the track shoe assembly is removed. This may lead to serious injury, so remove the track shoe assembly as fo-IIOWS. If there is any interference or abnormal catching around the idler assembly, examine carefully and remove the problem before starting. Remove blade assembly. For details, see REMOVAL OF BLADE ASSEMBLY. Loosen lubricator (I) of adjustment cylinder, then move machine b.ackwards and forwards to release grease. Never loosen the lubricator more than one turn. * Check that all the grease has been removed.
A
1.
2.
A
m
DLD00254
30-220 0
D155AX-5
DISASSEMBLY
3.
4.
5.
6.
AND
ASSEMBLY
TRACK SHOE
Drive slowly forward to put track shoe at idler end in contact with large block @ or a wall (if another large bulldozer of the same capacity as the machine being repaired is available, put in contact with the blade). Stop machine when recoil spring bends and slack is formed in track shoe assembly, then apply brake. When doing this, set so that master link is between idler and front carrier roller. For safety reasons, fit a lever block between carrier roller support and link. Remove idler guide (2). AAlways remove the idler guide without fail at this point. If the track shoe is opened without removing idler guide (21, it will move to the front when it opens, and idler guide (2) will be pushed against the track frame. If the idler guide is removed in this condition, the idler yoke assembly will fly out to the front. Remove shoe (41, then disconnect master link m (5). Be extremely careful to ensure safety when a disconnecting the track shoe. Move machine towards rear slowly, and lay out track shoe assembly. CLD01058
INSTALLATION OF TRACK SHOE ASSEMBLY . Carry out installation in the reverse
order
to
removal.
u *
Track shoe tension
: 20 - 30 mm
m w
Master
link mounting
1st step
590.0&60.0
2nd step
180”+10”
*
Ir *
bolt :
Nm {60.0&6.0
kgm}
When winding on the track, use a bar and make sure that the link does not come off the sprocket. When winding on the track, make sure that the track tension does not become loose. Check that there is no dirt or dust on the mating surface or thread of the master link. Tighten the track shoe bolts in the order 0 0.
D155AX-5
DKD00282
30-221 0
DISASSEMBLY
TRACK SHOE
AND ASSEMBLY
OVERALL DISASSEMBLY TRACK SHOE
OF
*
This section describes the lubricated track.
1.
Shoe (master link portion) Set the track assembly on a flat floor with the shoe facing up, then remove the shoe bolt at the master link, and remove the shoe. * Do not use an impact wrench when loosening the master link bolt. Disassembly into l/4 parts Because of the weight of the track assembly, if the l/2 assembly is too large and there are problems with disassembly and assembly work, divide into l/4 assemblies. Shoe (regular link portion) Raise the track assembly and set it on the floor with the shoe facing up, then use a shoe bolt impact wrench to remove the shoes. * When moving the track assembly, be careful not to damage the master link portion. Ir If a gas cutter has to be used to remove the shoe nut, to prevent deterioration of the seal due to the heat, keep the temperature of the seal portion below 8O”C, and take action to prevent welding spatter from entering the gap between the links. Draining oil Before disassembling the link assembly, drain the oil from inside the pin and take precautions so that the link press does not become dirty with oil. * Before disassembling, if it is judged that it is necessary to rebuild the track as a dry type track, the following work need not be carried out. 1) Set the link assembly on a flat floor with the large plug side facing up, then chamfer the burrs on the end face of the pin with a grinder. * If the track is disassembled with burrs still at the end face of the pin, the pin press-fitting hole of the link will be scratched, and this will cause leakage from the pin press-fitting portion after rebuilding. 2) Using a drill (al0 mm), make a hole in the large plug, then remove the large plug. * If any dirt or deteriorated oil is stuck to the pin hole, drill through with a longer drill to remove it. When doing this, be careful not to damage the oil hole.
2.
3.
4.
30-222 0
only the procedure
for
Burrs
Chamfer
DLD02923
D155AX-5
DISASSEMBLY
3)
4)
5) 6)
5.
TRACK SHOE
AND ASSEMBLY
After removing the large plug, use a baby grinder (angle of grinder tip: 45” - SO”), and chamfer the pin hole so that the plug is not damaged when the plug is knocked in. Turn over the link assembly so that the small plug side is facing up, remove the burrs at the end face of the pin with a grinder, then use tool R5 to knock the small plug to the inside. * If the small plug hole is blocked with burrs, grind with a grinder until the hole can be seen completely. Using a drill (@IO mm), chamfer the small plug hole. Blow with compressed air to remove the metal particles when draining the oil inside the pin or removing the burrs, then wash the link assembly with high-pressure water or steam.
Disassembly of link 1)
2)
Set hit jaw *
the link assembly on a link press, then with a hammer so that the bushing and are in tight contact. If the link tread and outside diameter of the bushing are worn, adjust the height of the shoe or guide plate, and center the disassembly jig with the pin and bushing center to prevent damage to the link hole when disassembling. Ir If the centering is not carried out properly, the link hole may be damaged, the pin may break, or the bushing may crack during disassembly. Operate the left cylinder and remove the left link and pin and bushing press-fitting portion at the same time. + Check the removal force of the pin and bushing, and use this value as reference to judge if it is possible to obtain the necessary pin and bushing press-fitting force when turning and reassembling. * Do not push the disassembly jig inside more than is necessary as the spacer may break.
Left
r
disassembly
Jio
Jaw
Right
\
disassembly jio DLD02924
r)
DLWO29C
D155AX-5
30-223 0
DISASSEMBLY
3)
4)
6.
AND ASSEMBLY
Return the left cylinder, then operate the right cylinder and remove the right link and pin and bushing press-fitting portion at the same time. Return the right cylinder, remove the left and right links, pins, bushings, and spacers, then feed the following set for one link assembly into the jaw. To decide if the seal can be used again, carry out inspection when the seal is still installed to the link, so do not remove the seal from the link. If oil is remaining, this can be used as a guideline for reuse of the seal, so mark such links or seals. If the end face of the bushing and seal surface are damaged, it will cause oil leakage, so be extremely careful when handling.
Inspection Check the following items to determine if the part can be reused as a lubricated track or as a grease-filled track. Carry out a comprehensive check to determine if the link assembly can be rebuilt as a lubricated track or as a grease-filled track. * When making judgments about reuse of parts, see “Guidance for Reusable Parts, Undercarriage, Lubricated Track”. 1) Check the pins, bushings, links, and spacers visually for damage, and carry out a color check or use a flaw detector to check parts that are suspected of being damaged. Any part that is cracked must not be used again, so scrap it. 2) Check the external appearance of the seal and the end face of the bushing visually to determine if they can be used again. * If only the bushing is replaced with a new part, the worn or damaged part of the seal lip will contact the end face of the bushing directly, so it may not be able to carry out its sealing function. For this reason, always replace the seal together with the bushing, or rebuild as a grease-filled track.
30-224 0
TRACK SHOE
DLDO0291
DLD00292
D155AX-5
DISASSEMBLY
3)
AND ASSEMBLY
Using calipers, measure spacer thickness a and overall length b of the sliding portion of the bushing and spacer. Check if it is possible to obtain the specified seal mounting dimension when reassembling. * If the amount of wear of the spacer and bushing is greater than the specified amount, the assembly precision of the seal portion cannot be guaranteed, so replace with new parts, or rebuild as a grease-filled track.
TRACK SHOE
b
DLiXfJ293
4)
5)
Using a micrometer, cylinder gauge, and calipers, measure the outside diameter of the pin and the inside diameter of the bushing at the worn portion, and judge if the parts can be used again. * If the amount of wear is greater than the specified amount, there will be play during travel, and it will also cause oil leakage, so replace with new parts or rebuild as a grease-filled track. * For details of the dimensions when making judgment, see MAINTENANCE STANDARDS. Using a micrometer and cylinder gauge, measure the outside diameter of the pin and bushing press-fitting portion, and the inside diameter of the pin and bushing press-fitting portion of the link to determine if the permitted interference can be obtained. However, when rebuilding as a lubricated track, check that the standard interference for the pin and link can be obtained. * If the permitted interference can not be obtained, replace with new parts or replace with an oversize part. Ir For details of the dimensions when making judgment, see MAINTENANCE STANDARDS.
D155AX-5
DLL%0294
DLBXCS5
DISASSEMBLY
*
AND ASSEMBLY
TRACK SHOE
Precautions
for storage rust of the counterbore portion of the link, leave the seal installed to the link and be careful not to damage the seal lip during storage. Coat the pin and bushing press-fitting portion, shoe mating surface, and master link mating surface of the link with rust prevention oil to prevent rust. Coat the whole circumference of the pins, bushings, and spacers with rust prevention oil to prevent rust, and be particularly careful not to damage the end face of the bushing during storage.
1) To prevent
2)
3)
30-226 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
TRACK SHOE
OVERALL ASSEMBLY 1.
When
1.
Preparatory work I) Washing seal assembly .
.
rebuilding
as lubricated
track
Machines fitted with F3 type seals Remove the seal assembly from the link, then separate into the seal ring and load ring, and clean the parts. * The seal ring and load ring deteriorate easily when brought into contact with cleaning agent (trichlene, etc.), so wash the parts quickly. After cleaning, wipe the parts with a clean cloth to remove all the cleaning agent. Machines fitted with W7 type seals For seals that are to be reused, leave the seal installed to the link, and do not wash it.
2)
When reusing the pin, chamfer the corner of the end face smooth with a grinder. Use a grinder to remove any protruding parts stuck to the press-fitting portion. * If the corner of the end face has become sharp due to wear, there will be scuffing at the press-fitting portion and this will cause oil leakage.
3)
Make a mark on the end face at the small plug end to show the direction of the side hole (hole in the radial direction) in the pin when assembling. * When reusing the pin, assemble in the same direction as when the part is new (side hole on the link tread side).
Make mark to indicate
DLD32301
D155AX-5
30-227 0
DISASSEMBLY
AND ASSEMBLY
If the link, pin, bushing, or spacer are dirty, wash them. Remove any protruding parts stuck to the link and bushing with a grinder. Ir These parts easily rust, so wash them immediately before assembly. * Use tool R3 to wash the pin hole. Ir Do not polish or carry out any other treatment of the end face of the bushing as this will cause oil leakage. 5) Use tool R4 to knock the large plug into the pin. i) Insert the plug into the guide hole through the plug insertion window. ii) Push the bar by hand and insert the plug as far as possible. iii) Push the plug with the bar and push the guide itself against the pin. iv) Knock in the bar with a hammer. * Dimension a to knock in from end face of pin: 6 + 2 mm * If there is no more place to chamfer at the pin hole because of wear, use a baby grinder (angle of grinder tip: 45” - 60”) to carry out chamfering. * Coat the outside circumference of the plug with GO90 and knock in the smaller diameter part first. 6) Installation of seal assembly . Machines fitted with F3 type seal Clean the link counterbore, then use tool R6 to push the seal in fully to the bottom. Ir If there is oil stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with oil. In addition, be careful not to let oil get into the counterbore portion of the seal when pushing in. . Machines fitted with W7 type seal When reusing the link and replacing the seal with a new part, clean the link counterbore, then push the seal in fully to the bottom. * If there is oil stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with oil. In addition, be careful not to let oil get into the counterbore portion of the seal when pushing in.
TRACK SHOE
4)
30-228 0
CWD02666
Remove oil and from bold line
ereaee
Direction
I
of
DXD03191
D155AX-5
DISASSEMBLY
AND ASSEMBLY
7)
In order to keep the protrusion of the pin and bushing constant and the installation dimensions of the seal within the specified value during assembly, adjust the press-fitting jig dimensions of the link press. * For details of the standard dimensions, see PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS. Ir To leave a small space for the pin when assembling, ensure that the dimension (dimension a’) is greater than dimension a at the pin pushing portion of the left press-fitting jig. When assembling in order @ press fit ting left link, @ press fitting right link, provide the extra space for the pin on the right press-fitting jig. * If the end face of the pin (portion PI or the side face of the link (portions Q, R) are worn, add the amount of wear to the standard dimension when adjusting the dimension of the press-fitting jig so that the amount of protrusion of the left and right pin and bushing is uniform.
8)
Adjust the relief pressure of the link press to make sure that the pushing force of the press does not exceed the specified value. Ir If the pushing force is too strong, excessive force will be brought to bear on the spacer, and it will be pushed against the bushing. This will cause the spacer to break or will cause abnormal wear between the spacer and bushing end face. Ir If the interference at the press-fitting portion is different from when the part is new, as when reusing a pin or bushing, measure several of the press-fitting portions, and use the table below to determine the set pushing force according to the average interference. * Pushing force for pin, bushing: 785 kN {80 ton1 Pushing force L. 1.8 x average press-fitting force (Adjust the relief pressure of the link press and set the pushing force.)
D155AX-5
TRACK SHOE
30-229 0
DISASSEMBLY
2.
AND ASSEMBLY
TRACK SHOE
Assembly of link 1)
Use a clean brush to coat the area between the pin and bushing with oil (GOgO), set in position, then set in front of the jaw of the link Dress. * When reusing (turning) the bushing, set the worn surface on the outside circumference of the bushing facing the shoe mounting surface of the link (facing up on the link press).
2)
Set link up, Ir *
3)
the left and right bushing end master with the shoe mounting surface facing then press fit to the bushing. When doing this, use the pin end master link as a support. Press-fitting force for bushing: 49 - 196 kN (5 - 20 ton1
Using a shoe bolt hole pitch gauge, press fit until the distance between the shoe bolt holes of the left and right link is the specified value. Ir Use compressed air to remove all metal particles from burrs caused by press fitting the bushing.
DLDIO311
4)
30-230 0
Turn over the master link, and check that the left and right master links have been press fitted in parallel.
D 155AX-5
DISASSEMBLY
5)
Measure the amount of protrusion of the left and right bushings with a depth gauge. * Adjust the press-fitting jig for the link press so that the protrusion of the left and right bushings is uniform.
6)
Feed the master link portion, then set the pin and bushing in position. When reusing the pin, assemble so that the side hole is on the link tread side in the same way as when the part is new. If the parts are not assembled facing the specified direction, the strength may drop, so mark the direction of the side hole clearly on the end face to prevent any mistake during assembly. + Align the large plugs so that they are on the left side facing the link press when assembling.
7)
TRACK SHOE
AND ASSEMBLY
DLD02925
To prevent oil from leaking out from scuff marks on the pin press-fitting portion, coat the pin press-fitting hole in the link and the outside diameter of the pin press-fitting portion with gasket sealant (198-32-19890).
Coat
whole
circumference)
) DLD02926
8)
Set the right link in position and install the spacer to the pin. * Check that there is no dirt or dust stuck to the seal surface and bushing end face, then use a clean cloth or brush to coat with oil (G090). f Wipe the spacer with a clean cloth, then install it.
I D 155,4X-5
DLD00315
30-231 0
DISASSEMBLY
9)
TRACK SHOE
AND ASSEMBLY
Using the right jig as the receiving end and the left jig as the pushing end, press fit the pin and bushing at the same time. * The seal may come off the link due to the play when press fitting, so press fit smoothly. If the seal comes off the link, stop the press-fitting operation and fit the seal correctly on the link, then start the press-fitting operation again. Jr Press-fitting force for pin, bushing: 25 - 50 ton
I IO) Using a fine adjustment spacer, press fit so that the end face of the pin is in tight contact with the bottom of the receiving jig. * Adjust the depth of the hole in the receiving jig so that the protrusion of the left and right pins is uniform.
DLD00316
Fine a djust,ment, spacer
,
/
/
11) Set the left link in position and install the spacer to the pin. * Coat with oil in the same way as when installing the right link.
I
DLD00318
12) Using the left jig as the receiving end and the right jig as the pushing end, press fit the left link. When press fitting, be careful that the left and right seal and spacer do not come out of position. Provide enough space on the left jig so that the end face of the pin does not contact the bottom of the jig. Press-fitting force for link: 245 - 490 kN 125 - 50 ton) DLD00319
30-232 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
TRACK SHOE
13) Press fit the link, spacer, and bushing so that they are each in tight contact. * It is impossible to check from outside if they are in tight contact, so control the hydraulic force of the link press and set the relief pressure to a constant value. Then apply hydraulic force and push in until this pressure is reached. For details of the setting for the relief pressure, see “Preparatory work”. * Check that adjacent links swivel freely in relation to each other. 14) After assembling each link, use a dial gauge and pinch bar to measure the end play from the link previously assembled, to check that the link is assembled within the specified value. If the end play does not come within 0 0.13 mm even when applying the pushing force until the relief valve is actuated, raise the relief pressure setting gradually to adjust. Adjust the relief pressure setting carefully and be sure not to raise the pushing force of the link press higher than necessan/. 15) Using a shoe bolt hole pitch gauge, check that the distance between the shoe bolt holes is within the standard value. * If the distance between the shoe bolt holes is greater than the specified value, disassemble and check for any abnormality, then press fit again. * If the distance between the shoe bolt holes is smaller than the specified value, and the shoe cannot be installed, the wear of the spacer or bushing end face is probably greater than the repair limit, so disassemble and replace with a new part. Ir If the end play is too large, the sealing performance will drop, so set the end play to a small value. 16) After assembling each link, use tool R7 to remove the air from inside the pin, and check the sealing performance. jl Hold the space inside the pin at a vacuum of 650 - 700 mmHg for 5 seconds and check that there is no change in pressure. If the pressure changes, disassemble and check the seal for any abnormality, then assemble again.
D155AX-5
30-233 0
DISASSEMBLY
TRACK SHOE
AND ASSEMBLY
17) Assemble the pin end master link as the final link. * Check that the left and right master links are press fitted in parallel.
3.
Filling with oil After completion of assembly of the link assembly, add oil through the pin hole. I) Using tool R7, remove the air inside the pin from the small plug hole, set to a vacuum of 650 - 700 mmHg, then fill with oil (GO901 until the pressure is 0.2 - 0.3 MPa (2 - 3 kg/ cm*). * In cold or extremely cold areas, instead of G090, fill with Komatsu genuine oil (150-09-19270) which has excellent lowtemperature qualities. Ir Be careful not to raise the oil pressure too high as this will have an adverse effect on the seal. Ir To determine the oil amount, set the small plug end at the top (stand the link assembly on its side), leave for 30 minutes, then fill with oil so that depth L of the space at the pin hole is within the specified value below. Dimension L: 35 - 65 mm
IrL
GO90
Oil
level
Pin
+---
2) After completion
of filling with oil, use tool R5 to knock in the small plug to the specified position. * Coat the outside circumference of the small plug with G090. -k The depth to knock in the plug is as follows. Depth from end face: 7.5 + 1 mm
30-234 0
Large
PIUD
0L00.2929
D155AX-5
DISASSEMBLY
4.
TRACK SHOE
AND ASSEMBLY
Shoe (regular link portion) Set the link assembly on the bed, then use a shoe bolt impact wrench and torque wrench to install the shoe. m Shoe bolt (regular link): Initial torque: 588.4 z 58.8 Nm
I60 t 6 kgml Tightening
5.
angle: 120” + IO”
Connecting to make l/2 assembly Set two completely assembled portions of track on a flat surface in a straight line with the shoes facing up. Pull master link (I) at the pin end to master link (2) at the bushing end, and set at the mating surfaces. Then put shoe (3) on top, check that shoe bolt (4) goes in easily by hand, and connect the two parts with the master bolt. & Shoe bolt: Anti-friction compound UVl-PI w Shoe bolt (regular link): Initial torque: 590.0 t 60.0 Nm {SO.0 t. 6.0 kgm) Tightening angle: 180” + IO” *
When
tightening,
tighten
in the order
-
DLDBO327
@ -
o-
DLDD3328
*
Do not use an impact wrench link.
for the master
DLDO0298
D155AX-5
30-235 0
DISASSEMBLY
AND ASSEMBLY
2.
When
rebuilding
1.
Preparatory work
as grease-filled
TRACK SHOE
track
I) Washing seal assembly . Machines fitted with F3 type seals Remove the seal assembly from the link, then separate into the seal ring and load ring, and clean the parts. Ir The seal ring and load ring deteriorate easily when brought into contact with cleaning agent, so wash the parts quickly. After cleaning, wipe the parts with a clean cloth to remove all the cleaning agent.
.
Machines fitted with W7 type seals For seals that are to be reused, leave the seal installed to the link, and do not wash it.
2) When reusing the pin, chamfer the corner of the end face smooth with a grinder so that press fitting can be carried out smoothly.
3)
30-236 0
Make a mark on the end face at the small plug end to show the direction of the side hole (hole in the radial direction) in the pin when assembling. * When reusing the pin, assemble in the same direction as when the part is new (side hole on the link tread side).
Dl SAX-5
DISASSEMBLY
TRACK SHOE
AND ASSEMBLY
Use tools R4 and R5 to knock the large plug and small plug into the pin. i) Insert the plug into the guide hole through the plug insertion window. (Coat the plug with oil.) ii) Push the bar by hand and insert the plug as far as possible. iii) Push the plug with the bar and push the guide itself against the pin. iv) Knock in the bar with a hammer. Dimension a to knock in from end face of pin: Small pin: 7.5 r 1 mm Large pin: 6 + 2 mm If the plug was not removed from the pin during disassembly, it can be used again as it is. of 5) Clean any part where outside diameter the pin, front face of the spacer, or end face or inside diameter of the bushing are dirty. 6) Coat the outside diameter of the pin and the front face of the spacer with grease. 7) Installation of seal assembly . Machines fitted with F3 type seal Clean the link counterbore, then use tool R6 to push the seal in fully to the bottom. If there is grease stuck to the link coun* terbore and’seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with grease. . Machines fitted with W7 type seal When reusing the link and replacing the seal with a new .part, clean the link counterbore, then push the seal in fully to the bottom. * If there is grease stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with grease. of the pin 8) In order to keep the protrusion and bushing constant and the installation dimensions of the seal within the specified value during assembly, adjust the press-fitting jig dimensions of the link press. Ir For details of the standard dimensions, see PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS. If the end face of the pin (portion PI or * the side face of the link (portions 0, RI are worn, add the amount of wear to the standard dimension when adjusting the dimension of the press-fitting jig so that the amount of protrusion of the left and right pin and bushing is uniform. 4)
D155AX-5
a: a
-1
-
/
DXD031g2
Remove all oil and araase from
the Direction to push in
I
DXD03193
Remove all o' from the sha
DLD02932
30-237 0
DISASSEMBLY
2.
AND ASSEMBLY
TRACK SHOE
Assembly of link 1)
Coat the area between the pin and bushing with lithium grease (G2-LII, set in position, then set in front of the jaw of the link press. Ir When reusing (turning) the bushing, set the worn surface on the outside circumference of the bushing facing the shoe mounting surface of the link (facing up on the link press).
2)
Set the left and right bushing end master link with the shoe mounting surface facing up, then press fit to the bushing. * When doing this, use the pin end master link as a support. * Press-fitting force for bushing: 49 - 196 kN 15 - 20 ton}
3) Using a shoe bolt hole pitch gauge, press fit until the distance between the shoe bolt holes of the left and right link is the specified value. * Use compressed air to remove all metal particles from burrs caused by press fitting the bushing.
4) Turn over the master
link, and check that the left and right master links have been press fitted in parallel. DLlBI311
5) Measure
the amount of protrusion of the left and right bushings with a depth gauge. Ir Adjust the press-fitting jig for the link press so that the protrusion of the left and right bushings is uniform.
30-238 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
Feed the master link portion, then set the pin and bushing in position. Ir When reusing the pin, assemble so that the side hole is on the link tread side in the same way as when the part is new. If the parts are not assembled facing the specified direction, the strength may drop, so mark the direction of the side hole clearly on the end face to prevent any mistake during assembly. Ir If the outside diameter of the pin is worn, assemble so that the face that is not worn is on the pulling side. However, in this case also assemble so that the side hole faces the tread surface of the link. 7) Set the left and right links in position, then operate the left and right pushing jigs to press fit the pin and bushing at the same time. * The seal may come off the link due to the play when press fitting, so press fit smoothly. If the seal comes off the link, stop the press-fitting operation and fit the seal correctly on the link, then start the press-fitting operation again. * Pushing force for pin, bushing: 785 kN 180 ton} Pushing force = 1.8 x average press-fitting force (Adjust the relief pressure of the link press and set the pushing force.) 8) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes and stop press fitting when it is within the standard value. 9) Assemble the pin end master link as the final link. * Check that the left and right master links are press fitted in parallel.
TRACK SHOE
6)
OLD00329
DLDOBll
3.
Shoe (regular link portion) Set the link assembly on the bed, then use a shoe bolt impact wrench and torque wrench to install the shoe. w Shoe bolt (regular link): Initial torque: 588.4 t 58.8 Nm {SO + 6 kgm} Tightening angle: 120” + IO”
Dl %AX-5
30-239 0
DISASSEMBLY
4.
TRACK SHOE
AND ASSEMBLY
Connecting to make l/2 assembly Set two completely assembled portions of track on a flat surface in a straight line with the shoes facing up. Pull master link (I) at the pin end to master link (2) at the bushing end, and set at the mating surfaces. Then put shoe (3) on top, check that shoe bolt (4) goes in easily by hand, and connect the two parts with the master bolt. & Shoe bolt: Anti-friction compound UVI-PI w Shoe bolt (master link): Initial torque: 590.0 t 60.0 Nm 160.0 + 6.0 kgm1 Tightening angle: 180” + IO” *
When
tightening,
tighten
in the order
DlJm327
@ -
o-
*
Do not use an impact wrench link.
for the master
lJLD00298
30-240 0
D155AX-5
PRESS-FITTING JIG DIMENSION
DISASSEMBLY AND ASSEMBLY
TABLE FOR LINK PRESS
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
-a
a
DLD00331
Unit: mm Jig dimension
5.7
D155AX-5
I
3.25
I
50.6
30-241 0
ONE LINK
.DISASSEMBLY AND ASSEMBLY
FIELD DISASSEMBLY OF ONE LINK -k This section describes only the procedure for using the tools. For details of the procedure for disassembly or assembly, see OVERALL DISASSEMBLY (or ASSEMBLY) OF TRACK SHOE. 1.
Using two bolts (21, install tool R8 (adapter, guide, bolt) to link (1). * It is also possible to use two track bolts for bolt (2).
2.
Assemble tool R9 (pump, cylinder 150t) and tool RlO (frame, rod, adapter, bolt x 1, eyebolt), then raise the assembly and set on the track.
3.
Insert the rod of tool RI1 from the cylinder end, and install with two nuts. Pass the rod through the hole in link (I) to install.
4.
Set tool RI2 (adapter, guide, pusher) in position, then apply hydraulic pressure and remove pin (3). When the cylinder reaches the end of its stroke, insert tool RI2 (extension) between the adapter and guide, and repeat the operation.
30-242 0
i”“i
CWD02696
DISASSEMBLY
5.
AND ASSEMBLY
ONE LINK
Set tool R13 (294 kN {3OtI puller) and spacer @ to the center of the roller tread of the link to be disassembled, then apply hydraulic pressure to the puller, open the link 5 - 6 mm, and disconnect the link.
I
D155AX-5
CWD02700
30-243 0
DISASSEMBLY
AND
ASSEMBLY
FIELD ASSEMBLY LINK
ONE LINK
OF ONE Press or remover
1.
Assemble the link sub-assembly. I) Set tool RI4 to the end face of the link, then press fit bushing (1). * Press-fitting force for bushing: 49 - 196 kN (5 - 20 ton]
+ I
yt-L-2)
Set tool RI4 to the end face of the link (pin end), and press fit bushing (I). * Set with the side hole in the pin facing the link tread. * Press-fitting force for pin: 196 - 294 kN 120 - 30 ton1
m Press or
R
side I /
Set link sub-assembly
rePOVer
+
Tread
2.
DXD03197
a
I
DXD03198
(3) on the link to be con-
netted .
.3
3.
Set link (4) on the opposite with tool RI5 (guide).
side, and support
:WD0’2 703
30-244 0
D155AX-5
DISASSEMBLY
4.
5.
AND ASSEMBLY
ONE LINK
Set tools RI6 and RI7 in the same way as for the operation to remove the pin, then use tool RI6 (adapter, extension, guide, adapter, bolt) for press fitting the pin, and tool RI7 (extension, guide, adapter, bolt) for press fitting the bushing, and press fit in turn. * Press-fitting force for pin: 196 - 294 kN (20 - 30 ton1 * Press-fitting force for bushing: 98 - 196 kN {IO - 20 ton}
Cylinder at
Use tool R20 (294 kN {30t) puller) in the same way as when disassembling, and push open link (5) at the bushing end.
R20
6.
CWD02705
Set link (6) at the pin end to link (5) at the bushing end, connect with tool RI8 (guide), then remove tool R20 (puller).
CWD02706
7.
Set tool RI2 at pin (7) end, then use tool RI9 (adapter, bolt, guide) to press fit pin (7). & Pin press-fitting hole in link:
Gasket sealant (198-32-198901 * *
Set with the side hole in the pin facing link tread. Press-fitting force for pin: 392 - 588 kN (40 - 60 ton}
the
$fiTfq DXD03200
D155AX-5
DISASSEMBLY
MASTER LINK
AND ASSEMBLY
DISASSEMBLY OF MASTER LINK 1.
Removal of track assembly Remove the track assembly from the track frame. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Separation of track Disconnect all master link portions, and divide into four parts.
3. .
Removal of master link Master pin tvpe 1) Gas-cutting of regular link Gas cut the portion marked W, move a. Special tool to use: Gas cutter
and re-
Bushi
OLD02940
2) Removal of regular link Push pin (1) with a press, move pin (1) from bushing
.
in the direction of the arrow remove from link (21, then reand link (3) at the same time (4).
Master link type
1) Gas cutting, removal of master link at bushing end Gas cut the portion marked WW, remove @ , then move master links (5) and (6) up or down to remove them. Push pins (8) and (9) press fitted to regular link (7) with a press in the direction of the arrows to remove them. Special tool to use: 1. Gas cutter 2. Tool 01 l
30-246 0
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
MASTER LINK
Removal of master link at pin end Gas cut the portion marked MAN, remove @ , push pin (IO) with a press in the direction of the arrow and remove from link (111, then remove pin (IO) and link (12) at the same time from bushing (13). Special tool to use: 1. Gas cutter 2. Tool 02 l
D 155,4X-5
30-247 0
DISASSEMBLY
AND
ASSEMBLY 1.
MASTER
ASSEMBLY
OF MASTER
LINK
LINK
Assembly of link at bushing end I) Using a press, press fit master link (I) at the bushing end to bushing (2). * When press fitting the left and right master links, be extremely careful to keep them parallel. + Be careful not to scratch or damage the mating surface of the master link and the end face of the bushing. D2 Unit: mm
D2
2.
24 x 2.0
Installation of link at bushing end I) Push open the central part of the link tread with tool R20 as shown in the diagram. (Open approx. IO mm at the tip of the link.)
DXD03213
2) Set spacer (3) and seal assembly counterbore
(4) at the of the link at the connection.
DLD02941
30-248 0
D155AX-5
1
DISASSEMBLY
MASTER
AND ASSEMBLY
3)
Align the pin hole and bushing connect with guide pin 0.
4)
Remove tool R20, press fit pin (5) with tool, and install master link (I) at the bushing end. & Pin press-fitting hole in link: Gasket sealant (198-32-19890) * Set with the side hole in the pin facing the link tread.
hole,
LINK
and
+ Press
5)
Install the shoe to the link at the connection.
6)
After knocking in large plug (6) with tool R4, fill with oil using tool R7, then knock in small plun (7) with tool R5. * When press fitting the left and right master links, be extremely careful to keep the left and right links parallel. (Bushing end and pin end) * Be careful not to scratch or damage the mating surface of the master link and the end face of the bushing. * End play at connection (play in thrust direction of links on both sides of pin): 0 - 0.13 mm Ir Be extremely careful not to get mud or dust on the tap hole mating face of the master link, bushing end face, spacer, or seal.
D 155AX-5
fit
DLD02943
30-249 0
DISASSEMBLY
3.
MASTER
AND ASSEMBLY
Assembly of link at pin end 1) Set spacer (3) and seal assembly counterbore of the master link.
LINK
(4) in the
DLD07.941
2) Pass pin (9) through
bushing (81, set pin master link (10) from the left and right, then press fit with tool.
3)
After knocking in large plug (I I) with tool R4, fill with oil using tool R7, then knock in small plug (12) with tool R5.
I 4.
Connecting master link portion Set two completely assembled portions of track on a flat surface in a straight line with the shoes facing up. Pull master link (13) at the pin end to master link (14) at the bushing end, and set at the mating surfaces. Then put the shoe on top, and check that the shoe bolt goes in easily by hand. & Shoe bolt: Anti-friction compound (LM-PI m Shoe bolt (master link): Initial torque: 590.0 t 60.0 Nm {SO t. 6 kgm} Tightening angle: 180” t 10”
30-250 0
I
9
11
DBCOX55
14
DBDCG356
D155AX-5
DISASSEMBLY
AND ASSEMBLY
PIVOT SHAFT
REMOVAL OF PIVOT SHAFT ASSEMBLY 1.
2. 3.
Remove track frame assembly. For details, see REMOVAL OF TRACK FRAME ASSEMBLY. Remove seal (I), then remove ring (2). m Sling pivot shaft assembly (31, then remove mounting bolts, and using forcing screws 0, raise pivot shaft assembly (3) and pull out.
el kg
Pivot shaft assembly
: 116 kg
INSTALLATION OF PIVOT SHAFT ASSEMBLY l
Carry out installation removal.
in the
reverse
order
to
M *
* *
Assemble the seal as follows. (See diagram on right) 1) Turn over seal so that embossed letters on seal are on inside. 2) With seal turned over, insert seal on shaft. When inserting the seal, be careful not to scratch or damage the surface. Use tool Pl to press fit ring (2). . Press-fitting force : 8.8 - 22.6 kN (0.9 - 2.3 ton)
a
Ring
Embossed letter
Seal
-ii!f!d -
A
Pivot shaft
,
(2) Insert
a
0-J
(lITurn
DLDOLU59
bolt :
&
Pivot shaft mounting
m
Pivot shaft mounting bolt : 823.8 - 1029.7 Nm I84.0 - 105.0 kgm)
Thread tightener
D155AX-5
(LT-21
30-251 0
DISASSEMBLY
AND ASSEMBLY
EQUALIZER BAR
REMOVAL OF EQUALIZER ASSEMBLY
BAR
1.
Remove
2.
Set jack (490 kN 150 ton11 under radiator, jack up, then raise work equipment and set stand @ in position. * Set at a height where the center pin will come out.
3.
Remove equalizer bar side pin cover (21, then pull out outside bushing (3) and side pin (41, and remove inside bushing (5). a * Operate the jack to carry out fine adjustment of the height, and when the pin is at a point where it moves easily, tap the pin to remove it.
4.
Sling equalizer chain block.
5.
Remove lock plate (71, then using tool Nl, pull out center pin (8). B the hydraulic system, do &A When operating not stand under or in front of the puller. Stand as far as away as possible when operating it.
6.
side pin top cover (I).
bar assembly
(6) with crane and
Operate chain block and crane, equalizer bar assembly (6). Equalizer
L&l
Ai
bar assembly
and
DtLW176
remove
: 229 kg
Do not lower the chassis after removing equalizer bar assembly.
the
DEW0764
235
4
DEDO0765
30-252 0
D155AX-5
DISASSEMBLY
BAR
EQUALIZER
AND ASSEMBLY
INSTALLATION OF EQUALIZER BAR ASSEMBLY .
Carry out removal.
installation
in the
reverse
order
to
Inside cover : Fill with grease (G2-LI) Between equalizer bar side pin portion and bushing : Fill with grease (G2-LI)
a & a
portion of pin and bushing : Coat with grease (G2-LI) Frame boss portion : Coat with anti-friction compound (LM-P) Between bushing and bushing : Fill with grease (G2-LI)
Connecting
CWD07.708
\
I -
\._ \ / /
6 DEW0767
D155AX-5
30-253 0
DISASSEMBLY
AND ASSEMBLY
EQUALIZER BAR SIDE BUSHING
REMOVAL OF EQUALIZER SIDE BUSHING 1.
BAR
Remove equalizer bar assembly. For details, see REMOVAL OF EQUALIZER ASSEMBLY.
2.
Remove
seal (I).
3.
Remove
ring (2).
4.
Remove
spherical
bushing
BAR
(3).
INSTALLATION OF EQUALIZER BAR SIDE BUSHING 1. Install ring (2) to one side.
2.
Press fit spherical bushing (3) with press. * Press-fitting force : 15.7 kN (I.6 ton)
3.
Install ring (2) on opposite
4.
Install seal (1). & Between
5.
bushing
side.
and seal : Fill with grease (G2-LII
Install equalizer bar assembly. For details, see INSTALLATION BAR ASSEMBLY.
30-254 0
OF EQUALIZER
D155AX-5
DISASSEMBLY
SEGMENT TEETH
AND ASSEMBLY
REMOVAL TEETH
OF SEGMENT
1.
Stop machine at position where it is easy to remove teeth (between shoe and track frame).
2.
Remove
mounting
bolts, then remove
INSTALLATION TEETH l
Carry out removal.
&
w
installation
Thread Teeth
OF SEGMENT in the
reverse
of teeth mounting mounting
teeth (1). a
order
to
bolt:
Thread tightener (LT-2) nut : 1176.8 + 98.1 Nm I120 t: 10 kgml
D155AX-5
30-255 0
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC TANK
REMOVAL OF HYDRAULIC TANK ASSEMBLY a
Lower the work equipment completely to the ground, and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Drain oil from hydraulic -
:
Hydraulic
tank.
tank : Approx. 97 &?
2. Remove right side cover. 3. Disconnect control valve hose (I) at filter end. 4. Disconnect hydraulic tank tube (2) at joint end, then remove. 5. Remove filter case assembly (3). r+ kg
Filter case assembly
: 24 kg
Disconnect charge relief valve hose (4). Disconnect cooler bypass valve hose (5). Disconnect suction tube (6) from tank. Disconnect block (7) from tank. 10. Lift off hydraulic tank assembly (8). 6. 7. 8. 9.
r+lkg
Hydraulic
: 92 kg
tank assembly
INSTALLATION OF HYDRAULIC TANK ASSEMBLY l
l
Carry out removal.
installation
in the
reverse
order
to
Refilling with oil (hydraulic tank) Add engine 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 with the sight gauge.
.
Bleeding air Bleed the air. For details, see TESTING Bleeding air.
30-256 a
AND
ADJUSTING,
D155AX-5
DISASSEMBLY
MAIN CONTROL VALVE
AND ASSEMBLY
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY Lower the work equipment completely to the A ground, and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. After disconnecting the pipes and hoses, fit blind plugs to prevent dirt or dust from entering. Make match marks or fit tags to the hoses and pipes to prevent any mistake in the position when installing. 1. Drain oil from hydraulic tank. A 2. 3. 4. 5.
Hydraulic tank : Approx. 97 .t
Remove right side cover. Disconnect clamp (I) from filter case. Disconnect charge pump tube (2). Remove filter case assembly (3). &l kg
Filter case assembly : 24 kg
Disconnect hydraulic tank return hose (4). Remove return filter hose (5). Disconnect PPC hose (6) (green) (blade left tilt). Disconnect PPC hose (7) (colorless) (blade LOWER). 10. Disconnect PPC hose (8) (black) (ripper DOWN). 11. Disconnect PPC hose (9) (white) (ripper TILT BACK).
6. 7. 8. 9.
12. 13. 14. 15.
Disconnect Disconnect Disconnect Disconnect tilt).
PPC hose (IO) (red) (ripper TILT IN). PPC hose (11) (colorless) (ripper UP). PPC hose (12) (black) (blade RAISE). PPC hose (13) (yellow) (blade right
16. 17. 18. 19.
Disconnect Disconnect Disconnect Disconnect
hose hose hose hose
D155AX-5
(14) (15) (16) (17)
(ripper (ripper (ripper (ripper
TILT BACK). TILT IN). DOWN). UP).
30-257
DISASSEMBLY
AND ASSEMBLY
MAIN CONTROL VALVE
20. Disconnect tube (18) (blade LOWER). 21. Disconnect tube (19) (blade RAISE). 22. Disconnect hose (20) (blade right tilt). 23. Disconnect hose (21) (blade left tilt). 24. Disconnect hose (22) from hydraulic pump. 25. Remove mounting bolts, then lift off main control valve assembly (23). & kg
Main control valve assembly : 99 kg
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY l
Carry out installation removal.
in the reverse order to
.
Refilling with oil (hydraulic tank) Add engine 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 with the sight gauge.
.
Bleeding air Bleed the air. For details, see TESTING Bleeding air.
30-258 a
AND ADJUSTING,
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
MAIN CONTROL VALVE
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
23
, 22 nm -C.-J0
LO
28
72 J
DDcowJ4
30-259 0
DISASSEMBLY
AND ASSEMBLY
*
This section uses the 4-spool assembly as an example for the disassembly procedure.
1.
Remove bolt (I), and disconnect bodies (2) and (3) from body (4).
2.
Disassembly of ripper (tilt, lift1 or scraper (ejector, apron, bowl) valve spool 1) Remove case (5) from bodies (2) and (3). 2) Remove case (6), pull out to point where portion @ of spool assembly (7) comes out, then hold portion @ with wrench (width across flats: 14 mm), and loosen bolt (8). * If it is possible to carry out work without scratching or bending the spool, remove spool assembly (7) and carry out disassembly work. 3) Pull out spool assembly (7) from bodies (2) and (3). 4) Remove bolt (81, then remove washer (91, spacer (IO), retainer (II), spring (121, and retainer (13) from spool (14). 5) Remove plug (151, then remove spring (16) and valve (17). 6) Remove plugs (18) and (201, then remove check valve (19). 7) Remove check valve (21) and suction valve (22). 8) Remove plug (231, then remove retainer (24).
3.
Disassemblv of blade lift valve spool 1) Remove case (25) from body (41, then remove spring (26) and retainer (27). 2) Remove case (281, pull out to point where portion @ of spool assembly (29) comes out, then hold portion (@ with wrench (width across flats: 14 mm), and loosen bolt (30). * If it is possible to carry out work without scratching or bending the spool, remove spool assembly (29) and carry out disassembly work. 3) Pull out spool assembly (29) from body (4). 4) Remove bolt (301, then remove washer (311, spacer (321, retainer (331, spring (341, and retainer (35) from spool (36). 5) Remove plug (371, spring (381, and valve (39) from spool (36).
30-260 0
MAIN CONTROL VALVE
DLZiX1201
I
DDW1202
D155AX-5
DISASSEMBLY
4.
AND ASSEMBLY
Disassembly of blade tilt valve spool 1) Remove case (40) from body (4). 2) Remove case (41), pull out to point where portion @ of spool assembly (42) comes out, then hold portion @ with wrench (width across flats: 14 mm), and loosen bolt (43). * If it is possible to carry out work without scratching or bending the spool, remove spool assembly (42) and carry out disassembly work. 3) Pull out spool assembly (42) from body (4). 4) Remove bolt (43), then remove washer (44), retainer (45), spring (46), and retainer (47). 5) Remove plug (48), and pull out spring (50) and valve (51) from spool (49).
5.
Disassembly of unload valve spool 1) Remove plug (52) from body (4), then remove spring (53) and retainer (54). 2) Remove plugs (55) and (56), then remove spring (57), piston (58), and guide (59). 3) Remove bolt (61) from spool (60).
6.
Plugs, valves 1) Remove plug (62), then remove spring (63) and valve (64). 2) Remove plug (65), then remove retainer (66). 3) Remove plug (67), then remove orifice (68). 4) Remove safety and suction valve (69), suction valve (70), and valve (71). 5) Remove check valve (72). 6) Remove plugs (73), (74), (75), and (76).
D155AX-5
MAIN
CONTROL
VALVE
DDE01203
30-261 0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
MAIN CONTROL VALVE
OF MAIN CONTROL VALVE ASSEMBLY 21 \
fei-”
30-262 0
23
,20
D155AX-5
DISASSEMBLY
*
AND ASSEMBLY
MAIN CONTROL VALVE
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1. Plugs, valves 1) iit O-rings to plugs (761, (751, (741, and (73) and install. m Plug (76):
w m
29.4 - 39.2 Nm j3.0 - 4.0 kgm1 Plug (75): 117.6 - 161.7 Nm 112.0 - 16.5 kgml Plug (74): 107.8 - 140.7 Nm ill.0 - 15.0 kgm1
w
2)
Plug (73): 176.6 - 196.1 Nm I18.0 - 20.0 kgml Install check valve (72). w Check valve:
58.8 - 78.5 Nm (6.0 - 8.0 kgml 3)
4)
5)
6)
2.
Fit O-rings to valve (711, suction valve (70), and safety and suction valve (691, then install. w Valve (71): 107.9 - 147.1 Nm (II.0 - 15.0 kgm1 w Valve (70): 181.4 - 240.3 Nm 118.5 - 24.5 kgml m Valve (69): 137.3 - 156.9 Nm I14.0 - 16.0 kgml Assemble orifice (681, then fit ring and Oring to plug (67) and install. w Plug (67): 274.6 - 367.7 Nm (28.0 - 37.5 kgml Assemble retainer (661, then fit ring and Oring to plug (65) and install. w Plug (65): 274.6 - 307.7 Nm 128.0 - 37.5 kgml Assemble valve (64) and spring (631, then fit O-ring to plug (62) and install. w Plug (62): 127.5 - 176.6 Nm I13.0 - 18.0 kgm)
Assembly of unload valve spool
1) Assemble
2)
3)
guide (59) to -spool (601, then install bolt (61). w Bolt: 5.9 - 8.8 Nm iO.6 - 0.9 kgm1 Install plug (561, assemble piston (58) and spring (571, then install plug (55). w Plug (56): 181.4 - 240.3 Nm 118.5 - 24.5 kgml m Plug (55): 137.3 - 156.9 Nm (14.0 - 16.0 kgml Assemble retainer (54) and spring (53) to body (41, and install plug (52). m Plug (52): 372.7 - 465.8 Nm I38.0 - 47.5 kgml
D 1 SSAX-5
30-263 0
DISASSEMBLY
AND ASSEMBLY
3.
Assembly of blade tilt valve spool 1) Assemble valve (51) and spring (50) to spool (491, then temporarily tighten plug (48). 2) Assemble retainer (471, spring (461, and retainer (45) to spool, then fit washer (44) to bolt (43) and temporarily assemble. 3) Push spool assembly (42) into body to a point where wrench fits spool portion 0, hold spool in position with wrench, then tighten plug (48) and bolt (431, and push into body. m Plug (48): 58.8 - 73.5 Nm j6.0 - 7.5 kgml w Bolt (43): 39.2 - 53.9 Nm t4.0 - 5.5 kgm1 4) Fit O-rings to cases (41) and (401, then assemble to body. w Case mounting bolt: 27.4 - 34.3 Nm (2.8 - 3.5 kgm}
4.
Assembly of blade lift valve spool 1) Assemble valve (39) and spring (38) to spool (361, then temporarily tighten plug (37). 2) Assemble retainer (351, spring (341, retainer (331, and spacer (32) to spool, then fit washer (31) to bolt (30) and temporarily assemble. 3) Push spool assembly (29) into body to a point where wrench fits spool portion @ hold spool in position with wrench, then tighten bolt (30). m Bolt (30): 58.8 - 73.5 Nm 16.0 - 7.5 kgml 4) Assemble spool assembly (29) to body (41, then install case (28). w Case mounting bolt: 27.4 - 34.3 Nm 12.8 - 3.5 kgml 5) Assemble retainer (27) and spring (26) from opposite side, then fit O-ring to case (25) and install to body. w Case mounting bolt: 27.4 - 34.3 Nm 12.8 - 3.5 kgm}
30-264 0
MAIN CONTROL VALVE
DDw1202
Dl SAX-5
DISASSEMBLY
5.
MAIN
AND ASSEMBLY
CONTROL
VALVE
Assembly of ripper (tilt, lift) or scraper (ejector, apron, bowl) valve spool 1) Fit O-ring and ring to valve (151, assemble spring (16) and valve (17). then assemble to bodies (3) and (2). w Valve (15): 127.5 - 176.6 Nm I13.0 - 18.0 kgm} retainer (24), then fit O-ring and 2) Assemble ring to plug (23) and install to body. w Plug (23): 274.6 - 367.7 Nm (28.0 - 37.5 kgm} 3) Install suction valve (22) and check valve (21). w w Install
4)
Suction valve (22): 58.8 - 78.5 Nm (6.0 - 8.0 kgm} Check valve (21): 58.8 - 78.5 Nm (6.0 - 8.0 kgm} plugs (20) and (181, and check valve
(19). w
5)
6)
7)
6.
Plug (20): 19.6 - 27.5 Nm I2.0 - 2.8 kgm1 w Plug (18): 29.4 - 39.2 Nm (3.0 - 4.0 kgm} w Check valve (19): 19.6 - 27.5 Nm (2.0 - 2.8 kgm} Assemble retainer (131, spring (121, retainer (1 I), and spacer (IO) to spool (141, then fit washer (9) to bolt (8) and temporarily assemble. Push spool assembly (7) into body to a point where wrench fits spool portion (a), hold spool in position with wrench, then tighten bolt (8). w Bolt (8): 58.8 - 73.5 Nm IS.0 - 7.5 kgm} Assemble spool assembly to bodies (2) and (31, and install cases (6) and (5). w Case mounting bolt: 27.4 - 34.3 Nm (2.8 - 3.5 kgm)
Assemble bodies tighten mounting w Mounting 157.0 * Assemble the face securely.
D155AX-5
(2) and (3) to body (4), and bolts (1). bolt: - 176.7 Nm (IS.0 - 18.0 kgm) O-ring at the body mating sur-
I
DDDOlZOl
30-265 0
DISASSEMBLY
AND ASSEMBLY
HSS OIL COOLER BYPASS VALVE
REMOVAL OF HSS OIL COOLER BYPASS VALVE ASSEMBLY a
Park the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (-1 terminal of the battery.
1.
Remove operator’s seat and floor plate. For details, see REMOVAL OF HYDRAULIC PUMP ASSEMBLY.
2.
Disconnect oil cooler hoses (I) and (2).
3.
Disconnect
hydraulic
4.
Disconnect
charge
5.
Disconnect
HSS pump hose (5).
6.
Remove mounting bolts, then remove cooler bypass valve assembly (6).
tank hose (3).
relief valve hose (4).
HSS oil
INSTALLATION OF HSS OIL COOLER BYPASS VALVE ASSEMBLY . Carry out installation in the reverse order
to
removal.
30-266 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
HMT OIL COOLER BYPASS VALVE
DISASSEMBLY, ASSEMBLY OF HMT OIL COOLER BYPASS VALVE ASSEMBLY
mDo1200
Disassembly 1. Remove plug (I), 2. 3.
Assembly then
remove
shim
(2) from
plug (I). Remove spring (3) and spool (4) from body (5). Remove plug (6).
*
2.
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Tighten plug (6). Assemble spool (4) and spring (3) to body
3.
(5). Assemble
1.
shim
(2) to plug (I),
and tighten
plug (3). Ir Check the number and thickness shims, then assemble. Shim thickness: 0.5 mm No. of shims: 2
D 1SSAX-5
of the
30-267 0
DISASSEMBLY
BLADE PPC VALVE
AND ASSEMBLY
REMOVAL OF BLADE PPC VALVE ASSEMBLY to the completely the work equipment ALower pressure in ground, and release the remaining the circuit. For details, see TESTING AND ADPRESSURE RELEASING REMAINING JUSTING, the oil filler loosen Then IN HYDRAULIC CIRCUIT. inside the pressure the release to cap slowly hydraulic tank. 1 remove right side
seat assembly, operator’s 1. Remove cover on inside right, then remove cover of chassis. & kg
2.
Operator’s
seat assembly
Remove cover (1). Ir Disconnect horn switch at the same time.
: 50 kg
connector
(CN-262)
bracket (2).
3.
Remove
4.
Loosen lock bolt of lever (31, and pull out lever (3) together with boot.
5.
Disconnect
pump
6.
Disconnect
drain hose (5).
m
7.
Disconnect
PPC hose (6).
m
8.
Remove
m
hose (4).
blade PPC valve assembly
(7).
m
6
30-268 0
D155AX-5
DISASSEMBLY
BLADE PPC VALVE
AND ASSEMBLY
INSTALLATION OF BLADE PPC VALVE ASSEMBLY .
Carry out installation removal.
*
in the
reverse
order
to
The connection position for the pump hose, drain hose, and PPC hose are distinguished by color bands at the caulking portion for the hoses, so check the colors when connecting.
P3
alve from above) DAD00788
pJ *
.
Set the PPC valve in the mounting direction shown in the diagram on the right when installing. (The diagram on the right shows the PPC valve as seen from the top of the panel.)
Refilling with oil (hydraulic tank) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
D155AX-5
30-269 0
DISASSEMBLY AND ASSEMBLY
RIPPER PPC VALVE
REMOVAL OF RIPPER PPC VALVE ASSEMBLY Fully
lower work equipment to the ground. Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Remove operator’ seat, remove 1 cover on inside right, then remove side cover on right side of chassis. 4 Operator’s seat: 50 kg 2. Remove cover (1). e Disconnect the horn switch connector (CN262) at the same time. 3. Loosen lock bolt of lever (2), and pull out lever (2) together with boot. 4. Remove lever guide. Serial No. Only 75001 and up
5. Disconnect pump hose (4).
1
6. Disconnect drain hose (5).
2
5
4
7. Disconnect PPC hose (6).
3
6 6 DBD00791
7. Remove ripper PPC valve assembly (7).
30-270 1 5
4
D155AX-5
DISASSEMBLY
RIPPER PPC VALVE
AND ASSEMBLY
INSTALLATION OF RIPPER PPC VALVE ASSEMBLY .
Carry out removal.
installation
in the
reverse
order
to
m *
m
.
*
The connection position for the pump hose, drain hose, and PPC hose are distinguished by color bands at the caulking portion for the hoses, so check the colors when connecting.
PI
T
d
(Viewofvalvetiomabove) DAwo793
Set the PPC valve in the mounting direction shown in the diagram on the right when installing. (The diagram on the right shows the PPC valve as seen from the top of the panel.)
Refilling with oil (hydraulic tank) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
D155AX-5
30-271 0
DISASSEMBLY
AND ASSEMBLY
BLADE PPC VALVE
DISASSEMBLY OF BLADE PPC VALVE ASSEMBLY 1. 2. 3. 4. 5. 6. 7.
8.
9.
Remove
nut (I), then remove
disc (2) and boot
(3). Remove joint (41, then remove plate (5). Remove seal (6) and collar (7). Remove body (8). Remove plate (9). Remove orifice (IO). Remove blade TILT valve. I) Remove pistons (11) and (121, retainer (131, springs (14) and (151, and shim (16). Ir Check the installation position (oil pressure port) of spring (141, mark the spring with a tag, and keep it in a safe place. 2) Pull out valve (17) from body (18). Remove blade LOWER valve. 1) Remove piston (191, spacer (201, spring (211, collar (22), ball (23), retainer (241, shim (25), piston (261, retainer (271, springs (28) and (291, and shim (30). + Check the installation position (oil pressure port) spring (281, mark the spring with a tag, and keep it in a safe place. 2) Pull out valve (31) from body (18). Remove blade RAISE valve. 1) Remove piston (32), spring (33), piston (341, retainer (351, springs (36) and (37), and shim
2)
(38). * Check the sure port) with a tag, Pull out valve
installation position (oil presspring (36), mark the spring and keep it in a safe place. (39) from body (18).
CED02 160
30-272 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
BLADE PPC VALVE
INSTALLATION OF BLADE PPC VALVE ASSEMBLY 1.
2.
3.
Install blade RAISE valve. 1) Assemble valve (39) to body (18). 2) Assemble shim (38) and spring (37) to valve (39). * Install spring (37) with the small coiled seat face (inside diameter) at shim (38) end. 3) Assemble spring (361, retainer (351, piston (34), spring (331, and piston (32). * When assembling piston (34), coat the outside circumference of the piston and the inside circumference of the hole in the body with grease (G2-LI). Ir When assembling piston (321, coat the inside circumference of the hole in the body with grease (G2-LI). Install blade LOWER valve. 1) Assemble valve (31) to body (18). 2) Assemble shim (30) and spring (29) to valve (31). * Install spring (29) with the small coiled seat face (inside diameter) at shim (30) end. 3) Assemble spring (281, retainer (271, piston (261, shim (251, retainer (241, ball (231, collar (231, spring (211, spacer (201, and piston (19). * When assembling piston (26), coat the outside circumference of the piston and the inside circumference of the hole in the body with grease (G2-LI). + When assembling piston (191, coat the inside circumference of the hole in the body with grease (G2-LI). Install blade TILT valve. I) Assemble valve (17) to body (18). 2) Assemble shim (16) and spring (15) to valve (17). * Install spring (15) with the small coiled seat face (inside diameter) at shim (16) end.
D155AX-5
CEDO
30-273 a
DISASSEMBLY
AND ASSEMBLY
BLADE PPC VALVE
3)
4. 5. 6. 7. 8.
9.
10.
Assemble spring (141, retainer (13), and pistons (12) and (11). Ir When assembling piston (121, coat the outside circumference of the piston and the inside circumference of the hole in the body with grease (G2-Lb. * When assembling piston (I I), coat the inside circumference of the hole in the body with grease (G2-Lb. Install orifice (IO). m Orifice : 11.8 f: 14.7 Nm (1.2 z 1.5 kgm1 Fit O-ring and install plate (9). Fit O-ring and install body (8). Fit O-ring to collar (71, then assemble to body (8) and install seal (6). Install plate (5). m Mounting bolt : 11.8 = 14.7 Nm (I.2 = 1.5 kgml Install joint (4). * When installing the joint, coat the thread of body (8) with adhesive (LT-2). w Joint : 44.1 = 4.9 Nm j3.5 z 0.5 kgml * Coat the sliding portion of the joint with grease (G2- Lb. Assemble boot (3) and disc (21, and tighten with nut (I). * Coat the contact surface of disc (2) and pistons (321, (191, and (11) with grease (G2-LI). w Nut : 112.7 + 14.7 Nm Ill.5 + 1.5 kgm}
*
30-274 0
After installing the disc, adjust the disc height. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.
D155AX-5
DISASSEMBLY
AND
BLADE LIFT CYLINDER
ASSEMBLY
REMOVAL OF BLADE LIFT CYLINDER ASSEMBLY Lower the work A ground and stop 1.
equipment the engine.
completely
to the
Sling head end of lift cylinder assembly, then a remove cap (I). * Check the number and thickness of the shims, and keep in a safe place. Start the engine and retract piston rod fully, then tie the piston rod with wire to prevent it from coming out.
A 2.
Sling lift cylinder assembly, then disconnect hose (2). Release the remaining pressure inside the hydraulic circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE INSIDE HYDRAULIC CIRCUIT. * Fit blind plugs to prevent dirt or dust from entering the piping.
A
3.
Remove
cap (3) and lift off cylinder
assembly m
(4). & kg
Blade lift cylinder
assembly:
170 kg
INSTALLATION OF BLADE LIFT CYLINDER ASSEMBLY .
Carry out removal.
*
installation
Standard
in the
shim thickness:
reverse
order
to
4 mm
m &
Yoke: Grease
(G2-LI)
.
Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING.
.
Refilling with oil (hydraulic tank) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
D155AX-5
30-275 0
DISASSEMBLY
BLADE TILT CYLINDER
AND ASSEMBLY
REMOVAL OF BLADE TILT CYLINDER ASSEMBLY
A
Lower the work equipment ground and stop the engine.
1.
Remove cylinder protection protection cover (2).
2.
Sling tilt cylinder assembly, remove bolt (I ), then m disconnect cap (3) and remove shim. * Check the number and thickness of the shims, and keep in a safe place. Start the engine and retract piston rod fully, then tie the piston rod with wire to prevent it from coming out.
completely
to the
cover (I) and hose
A 3.
Disconnect 2 hoses (4). Release the remaining pressure inside the hydraulic circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE INSIDE HYDRAULIC CIRCUIT. * Fit blind plugs to prevent dirt or dust from entering the piping.
A
4.
Remove lock bolt, then pull out pin (5) and lift a off cylinder assembly (6). * Be careful not to damage the hose at the bottom end when lifting off. & kg
Blade tilt cylinder
assembly:
I
DEW1112
190 kg
INSTALLATION OF BLADE TILT CYLINDER ASSEMBLY l
Carry out removal.
*
installation
Standard
shim thickness:
Y 0 ke : Grease
@!&
in the
reverse
order
to
4 mm
(G2-LII
.
Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING.
.
Refilling with oil (hydraulic tank) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
30-276 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
RIPPER LIFT CYLINDER
REMOVAL OF RIPPER LIFT CYLINDER ASSEMBLY 1.
Sling lift cylinder assembly (I), then remove lock plate and pull out pin (2) at head end. m AStart the engine and retract the piston rod fully. AStop the engine and operate the control lever several times to release the pressure inside the piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 2.
3.
Disconnect 2 hoses (3). * Fit blind plugs to prevent entering the piping.
dirt or dust from
Remove lock plate, pull out pin (4) at bottom end and lift off cylinder assembly (I). 112 I+ kg *
Ripper lift cylinder
assembly:
120 kg
One pin (4) is supporting the bottom end of the lift and tilt cylinders, so pull out the pin only far enough to remove the lift cylinder.
INSTALLATION OF RIPPER LIFT CYLINDER ASSEMBLY . Carry out installation in the reverse order to removal.
a &
Pin: Grease
(G2-LI)
Pin: Grease
(G2-LII
@2J a
.
Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING.
.
Refilling with oil (hydraulic tank) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
D155AX-5
30-277 0
DISASSEMBLY
AND ASSEMBLY
RIPPER TILT CYLINDER
REMOVAL OF RIPPER TILT CYLINDER ASSEMBLY 1.
Sling tilt cylinder assembly (I), then remove lock plate and pull out pin (2) at head end. m AStart the engine and retract the piston rod fully. AStop the engine and operate the control lever several times to release the pressure inside the piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 2.
3.
Disconnect 2 hoses (3). * Fit blind plugs to prevent entering the piping. Remove &I kg *
dirt or dust from
lock plate and pull out pin (4). Ripper tilt cylinder
assembly:
m
130 kg
One pin (4) is supporting the bottom end of the lift and tilt cylinders, so when removing the tilt cylinder assembly, put a block @ under lift cylinder (5) to prevent the lift cylinder from falling, or pull out the pin gradually and set a temporary pin in the bottom end of the lift cylinder.
INSTALLATION OF RIPPER TILT CYLINDER ASSEMBLY . Carry out installation in the reverse order to removal.
&
Pin: Grease
(G2-LII
6
Pin: Grease
(G2-LII
.
Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING.
.
Refilling with oil (hydraulic tank) Add engine oil to circulate the oil through system. Then check the oil level again.
30-278 0
the
Dl!ZAX-5
HYDRAULIC
AND ASSEMBLY
DISASSEMBLY
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER) 1.
2.
Tube Remove
TILT,
RIPPER
LIFT, RIPPER
tube.
Quick drop valve (blade lift cylinder only) Remove block (I), and pull out spring (21, spacer (31, valves (4) and (51, and collar (6).
3. Piston rod assembly . Blade lift cylinder 1) Set cylinder assembly (7) on tool Ul. 2) Using hydraulic pump or power wrench, disconnect head assembly (8) with tool U2. 3) Pull out piston rod assembly (9). Place a container under the cylinder to * catch the oil.
.
Blade tilt, ripper lift, ripper tilt cylinder bolts, and disconnect mounting Remove head assembly (IO).
I)
,
I
2)
4.
/
24 mm
1 Ripper/--$--i
I
1
Pull out piston rod assembly (11). Place a container under the cylinder * catch the oil.
to
Piston assembly Blade lift cylinder 1) Remove mounting bolts, then remove spacer (121, and pull out valve (13). 2) Pull out piston assembly (14). 3) Remove backup ring (15) and O-ring (16). 4) Remove retainer (17).
.
D155AX-5
CYLINDER
DISASSEMBLY
5)
HYDRAULIC
AND ASSEMBLY
of piston assembly Disassembly ring (18). wear Remove i) ii) Remove piston ring (19). Do not remove seat (20) and valve * from the piston.
CYLINDER
(21)
18
18
. I) 2) 3)
DBDW365
Blade tilt, ripper lift, ripper tilt cylinder Remove mounting bolts, then remove spacer (22). Pull out piston assembly (23). Remove backup ring (24) isnd O-ring (25).
24
4)
Disassembly Remove i) ii) Remove
of piston assembly wear ring (26). piston ring (27).
26 27
DBWO375
5.
Head assembly 1) Remove head assembly
(8) or (IO).
I
Blade lift
Blade tilt Ripper lift Ripper tik
30-280 0
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
Disassembly i) Remove
of head assembly O-ring (28). (Blade
HYDRAULIC
CYLINDER
lift cylinder
only) ii) Remove O-ring (29) and backup ring (30). iii) Remove packing (31). iv) Remove snap ring (32), then remove dust seal (33). v) Remove bushing (34).
32 33
34 31 30
29
Blade tilt Ripper litl Rippertilt
D 155AX-5
30-281 a
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY CYLINDER *
HYDRAULIC
CYLINDER
OF HYDRAULIC
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil, and be careful not to scratch or damage the rod packing, dust seal, or O-ring when install-
34
32 33
31 20 30
29
DLD02944
1.
Head assembly 1) Assembly of head assembly i) Using tool U4, press fit bushing
(34).
34
-
CWD02728
-
ii)
Using tool U5, assemble dust seal (33), and secure with snap ring (32). iii) Assemble packing (31).
1 31
iv) Assemble
VI
backup
CWD02730
ring (30) and O-ring
(29). * Do not try to force the backup ring into position. Warm it in warm water (50 - 60°C) before fitting it. Assemble O-ring (28). (Blade lift cylinder
32 32 /
/
only)
30-282 0
D155AX-5
DISASSEMBLY
2)
2.
Assemble ton rod.
AND ASSEMBLY
head assembly
HYDRAULIC
CYLINDER
(8) or (IO) to pis-
Piston assembly . Blade lift cylinder 1) Assembly of piston assembly i) Using tool U3, expand piston ring (19). * Set the piston ring on tool U3 and turn the handle 8 - 10 times to expand the ring. ii) Remove piston ring (19) from tool U3, and install to piston. iii) Using tool U3, compress piston ring (19). iv) Assemble wear ring (18).
Blade
lift
Blade Ripper Ripper
tilt lift tilt
u3
19
0
Q
kh CWD02732
2)
Install retainer
(17). 18 18
ti
3)
4) 5)
Fit O-ring (16) and install backup ring (15). * Do not try to force the backup ring into position. Warm it in warm water (50 60°C) before fitting it. * Coat the O-ring and backup ring with grease, and secure so that the backup ring does not open. Install piston assembly (14). Assemble valve (13) to spacer (121, then fit spacer and tighten with mounting bolts. & Mounting bolt: Thread tightener (LT-2) w Mounting bolt: 110.3 2 12..3 Nm (II.25 + 1.25 kgm}
D155AX-5
DBtMo37Q
16
30-283 0
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC
CYLINDER
.
Blade tilt, ripper lift, ripper tilt cylinder piston ring (271, I) Using tool U3, assemble then assemble wear ring (26) in same way as in Step 2-I) -i) - iv) above.
26 27
2) Assemble
3)
O-ring (251, backup ring (24), and piston assembly (23) in same way as in Step 2-3) - 4) above. Secure with spacer (22) and tighten with mounting bolts. & Mounting bolt: Thread tightener (LT-21 m Mounting bolt: 98.1 - 122.6 Nm I10.0 - 12.5 kgml
24
DBwO366
3.
Piston rod assembly Blade lift cylinder I) Set cylinder (7) to tool Ul. piston rod assembly (9) to 2) Assemble der. & Seal portion: Grease (G2-LI) It Push the piston rod in to the end stroke. 3) Using tool U2, tighten head assembly m Head assembly: 980.7 2 98.1 Nm II00 + 10
.
cylin-
w thJ2
89
7
of its (8). kgm} CWDd2727
. I)
30-284 0
Blade tilt, ripper lift, ripper tilt cylinder Assemble piston rod assembly (II) to cylinder (7). 6 Seal portion: Grease (G2-LI) * Push the piston rod in to the end of its stroke.
D155AX-5
DISASSEMBLY
2)
HYDRAULIC
AND ASSEMBLY
Tighten head assembly bolts. w Mounting bolt:
(10) with
CYLINDER
mounting
Unit: Nm (kgm) Blade tilt
343.2 +. 34.3 (35 + 3.5}
Ripper lift 1 245.2 +124.5 (25 f 2.51 Ripper tilt
4.
245.2 + 24.5 I25 z 2.5)
Quick drop valve (blade lift cylinder only) Assemble collar (6), valves (5) and (4), spacer (3), and spring (2), then fit O-ring and install
V
DEW0361
block (1). 5.
Tube Fit O-ring
D155AX-5
and install tube.
30-285 0
-I
DISASSEMBLY
BLADE
AND ASSEMBLY
REMOVAL OF BLADE ASSEMBLY
A
Lower the work equipment completely to the ground at a flat place, then set blocks @ securely under the left and right straight frame.
1.
Remove cap (I) of lift cylinder. * Check the number and thickness shims, and keep in a safe place.
2.
m of the
Sling lift cylinder assembly (21, start engine, retract piston rod fully, then fit cylinder clamp and secure to radiator guard. * Tie the piston rod with wire to prevent it from coming out. . Disconnect the cylinder from the blade on the opposite side in the same way. . Release the remaining pressure inside the hydraulic circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE INSIDE HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
I
DLCQO381
A
3.
Remove
left and right covers (3).
4.
Disconnect hose (4). * Fit blind plugs to prevent entering the piping.
caps (5).
m
5.
Remove
6.
m Remove plate assembly (6). t Start the engine, drive the machine slowly in reverse, and disconnect the blade assembly from the trunnion.
30-286
left and right trunnion
dirt or dust from
D155AX-5
DISASSEMBLY
AND ASSEMBLY
BLADE
INSTALLATION OF BLADE ASSEMBLY l
Carry out removal.
installation
in the
reverse
order
to
m *
*
Adjust with shims so that clearance a at the cap mating surface is the dimension given below. Check also that it rotates smoothly. l Standard clearance a: 0.2 - 0.5 mm l Standard shim thickness: 4 mm After installing the blade, adjust the blade tilt. For details, see TESTING AND ADJUSTING, ADJUSTING SEMI U-TILTDOZER.
w
Trunnion cap mounting bolt: 730.5 + 98.1 Nm (74.5 + 10 kgml
a *
.
Adjust with blocks @I so that height b and width c of the left and right straight frames is the dimension below. . Height b at trunnion: Approx. 633.5 mm . Frame width c: Approx. 2,940 mm
Refilling with oil (hydraulic tank) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
D155AX-5
30-287 0
DISASSEMBLY
BLADE
AND ASSEMBLY
DISASSEMBLY ASSEMBLY
OF BLADE
A
Put blocks 0 and hydraulic jack @ under left and right straight frame and blade, and set securely so that the blade is stable.
1.
Remove right frame cover tilt cylinder hose (2).
(I),
and disconnect
DEW030
2.
Sling tilt cylinder assembly (3), and remove plate, then remove pin (4).
3.
Remove mounting bolts, disconnect cap (5), then lift off tilt cylinder assembly (3). * There are shims at the cap portion, so check the number and thickness of the shims, and keep in a safe place. I+ kg
4.
Tilt cylinder
assembly:
lock
190 kg
Set block @ under right center brace (61, and remove mounting bolts of cap (7) at center frame end. * There are shims at the cap portion, so check the number and thickness of the shims, and keep in a safe place.
30-288 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
BLADE
5. Sling right straight frame (8) and disconnect right center brace (6). 6. Remove lock plate, then remove pin (9), and lift off right straight frame (8).
el kg
Straight
frame:
900 kg
6
DECO0393
7. Remove
left frame
6. Sling tilt brace (II), move pin (12).
cover (IO). remove
lock plate, then re-
bolts, disconnect cap (131, 9. Remove mounting then lift off tilt brace (11). * There are shims at the cap portion, so check the number and thickness of the shims, and keep in a safe place.
el kg
Tilt brace: 100 kg
left center brace (14) and remove 10. Disconnect left straight frame (15) in same way as in Steps 4 - 6 above. 11. Sling center brace (141, remove mounting bolts, disconnect cap (161, then lift off left and right center braces (14) and (6). * There are shims at the cap portion, so check the number and thickness of the shims, and keep in a safe place.
el kg
Center brace: 95 kg
I
14
6
DEW0395
12. Raise blade (171, then tip blade over. & kg
Blade: 2,900 kg
DEW0396
D155AX-5
DISASSEMBLY
BLADE
AND ASSEMBLY
ASSEMBLY OF BLADE ASSEMBLY *
*
Check the number and thickness of the shims removed from each place during disassembly, then assemble them again in the same position. When carrying out shim adjustment, see TESTING AND ADJUSTING, ADJUSTING SEMI UTILTDOZER.
1. Raise blade (171, and insert block and hydraulic jack under blade, and set securely so that the blade is stable. DEW0396
r3 kg
2.
Blade: 2,900
kg
Raise center brace (141, assemble shim, and tighten mounting bolts of cap (16). * Set a block under the center brace to match the height of the straight frame. * Standard shim thickness: 4 mm & kg
Center brace: 95 kg
14
3.
Raise right center frame (81, then install pin (9) and secure with lock plate. &I kg
4.
DEW0395
Straight
frame:
900 kg
Sling right center frame (8), then set spherical portion of right center brace (6) to right center frame (8). 6
5.
Assemble shim to cap (7) of right center (6), and tighten mounting bolts. * Standard shim thickness: 4 mm
30-290 0
brace
D155AX-5
DISASSEMBLY
BLADE
AND ASSEMBLY
6. Sling tilt cylinder
assembly (31, assemble to cap (51, then tighten mounting bolts. * Standard shim thickness: 4 mm
&I kg
Tilt cylinder
assembly:
shim
190 kg
7. Install pin (41, and secure with lock plate. 8. Connect tilt cylinder
hose (2).
9. Install right frame cover (I).
10. Install left straight
frame (15) and connect left center brace (14) in same way as in Steps 3 - 5 above.
11. Sling tilt brace, assemble
shim to cap (131, and tighten mounting bolts. * Standard shim thickness: 4 mm E?lkg
Tilt brace: 100 kg
12. Install pin (121, and secure with lock plate. 13. Install left frame cover. 14. Greasing After completion of assembly, grease the points in the diagram on the right thoroughly. & Parts of work equipment: Grease (G2-LII
D155AX-5
DISASSEMBLY
AND ASSEMBLY
MULTI-SHANK
RIPPER
DISASSEMBLY OF MULTISHANK RIPPER ASSEMBLY *
After disconnecting the pipes and hoses, cover with blind plugs to prevent dirt or dust from entering.
1. Start engine and set ripper to maximum and maximum tilt in.
2.
2
height
Sling shank (I), remove lock pin, then remove mounting pin (21, and lower shank (I) slowly to remove.
el kg
IX1330398
Shank: 270 kg
3.
Set stand @ under beam and block @ under arm, then lower ripper assembly.
4.
Sling lift cylinder assembly (3), remove lock plate, then remove pin (4) at rod end. * Start the engine, retract the piston rod fully, then lower on top of the arm.
5.
Sling tilt cylinder assembly (51, remove lock plate, then remove pin (6) at rod end. * Start the engine, retract the piston rod fully, then lower on top of the arm. * The pin is used when removing the beam, so leave the pin temporarily installed to the beam. ARelease the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
30-292 0
I
DUXQ401
Dl %AX-5
DISASSEMBLY AND ASSEMBLY
MULTI-SHANK
6. Disconnect
lift cylinder hose (7) and tilt cylinder hose (8) and move towards fuel tank end.
8
RIPPER
8
7. Sling lift cylinder assembly (31, remove lock plate and pull out pin (91, then lift off lift cylinder assembly (3). * The pin is the same for the lift cylinder and tilt cylinder, so pull it out to a position where the lift cylinder can be removed. * The mounting bolt for the lock plate of the pin on the right is also used to tighten the rear lamp, so remove the rear lamp at the same time.
el kg
Lift cylinder
assembly:
130 kg
8. Sling tilt cylinder assembly (51, remove then remove tilt cylinder assembly (5). &I kg
Tilt cylinder
assembly:
7
pin (91,
130 kg
I
9. Sling beam (IO), remove lock plate, then remove left and right pins (1 I), and lift off beam (IO). kg CE?l
Beam: 1,200 kg
10. Sling arm (12), remove lock plate, then remove left and right pins (131, and lift off arm (12). & kg
D 155AX-5
Arm: 470 kg
30-293
DISASSEMBLY
MULTI-SHANK
AND ASSEMBLY
RIPPER
ASSEMBLY OF MULTI-SHANK RIPPER ASSEMBLY 1.
Raise arm (121, install left and right pins (13L then secure with lock plate. Arm: 470 kg &I kg * Set block @ under the arm.
2.
Raise beam (IO), install left and right pins (II), then secure with lock plate. Beam: 1,200 kg f?lkg * Set stand @ under the beam.
3.
Raise tilt cylinder assembly (51, then install pin (9). * The same pin is used for the tilt cylinder and lift cylinder, so push it in to a position where the tilt cylinder can be installed. Tilt cylinder assembly: 130 kg l+l kg * After installing, lower the rod end on top of the arm.
4.
Raise lift cylinder assembly (31, then install (9). * The mounting bolt for the lock plate of pin on the right is also used to tighten rear lamp, so install the rear lamp at same time.
pin the the the
8
8,
Lift cylinder assembly: 130 kg &I kg * After installing, lower the rod end on top of the arm. 5.
Connect tilt cylinder hose (7).
hose
(8) and lift cylinder
7
30-294 0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
MULTI-SHANK
RIPPER
6. Sling tilt cylinder
assembly (51, start engine, extend piston rod, align pin holes, then install pin (6) and secure with lock plate.
7. Sling lift cylinder
assembly (31, start engine, extend piston rod, align pin holes, then install pin (4) and secure with lock plate.
6. Start engine and set ripper to maximum maximum
9. Pass wire from shank mounting raise shank (I), and install, and secure with lock pin.
el kg
lift and
tilt in.
Shank:
then
hole in beam, install pin (2)
130 kg
10. Greasing After completion of assembly, grease points in diagram on right thoroughly. & Pin: Grease (G2-LI) .
Refilling with oil (hydraulic tank) Add engine oil through oil filler to the specified level. * Run the engine to circulate the oil through the system. Then check the oil level again.
D155AX-5
30-295 0
DISASSEMBLY
REMOVAL 1.
2.
AND ASSEMBLY
ROPS GUARD
OF ROPS GUARD
Sling ROPS guard bolts (12).
(I) and remove
12 mounting fKJ
Lift off ROPS guard (I). &l kg
Rops guard: 700 kg
INSTALLATION OF ROPS GUARD . Carry out installation in the reverse
order
to
removal.
w
30-296 0
ROPS guard mounting bolt: 926.8 1. 103.0 Nm t94.5 + 10.5 kgm}
D 15%X-5
DISASSEMBLY AND ASSEMBLY
OPERATOR CAB
REMOVAL OF OPERATOR CAB ASSEMBLY 2
Serial No. 70001 – 75000
Disconnect
the cable from the negative (–) terminal of the battery.
3 4
1. Remove ROPS guard. For details, see REMOVAL OF ROPS GUARD.
1
2. Open left side cover. 3. Disconnect connectors (1) (CN360), (2) (CNCAB1), and (3) (CN-CAB2). 4. Disconnect 4 washer hoses (4).
DED01132
1
5. Remove step (5), then remove cover (6).
5
5
6. Remove garnishes (7), (8), and (9). 7. Remove 19 mounting bolts, then lift off operator cab assembly (10). Operator cab assembly: 290 kg
4
6
6
DED01133
INSTALLATION OF OPERATOR CAB ASSEMBLY Serial No. 70001 – 75000 •
8
9
7
Carry out installation in the reverse order to removal.
1 e
Match the color bands and connect the washer hoses.
DED01134
10
DED01135
D155AX-5
30-297 1 5
DISASSEMBLY AND ASSEMBLY
HOOD
REMOVAL OF HOOD ASSEMBLY 1. Remove exhaust pipe (1).
1
2. Remove partition (2), then remove rubber seal. 3. Loosen clamp (3) and disconnect connector (4) from hood end. 4. Lift off hood assembly (5). 4
Hood assembly: 90 kg DED00795
INSTALLATION OF HOOD ASSEMBLY •
Carry out installation in the reverse order to removal.
2
DED00796
3
4 DED00797
5
DED00798
30-298 1
D155AX-5
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
REMOVAL OF FLOOR FRAME ASSEMBLY Serial No. 70001 – 75000
¤ Park
the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (-) terminal of the battery.
1. Remove operator cab assembly. For details, see REMOVAL OF OPERATOR CAB ASSEMBLY. 2. Lift off operator’s seat (1). 4 Operator’s seat : 54 kg 3. Remove floor plate (2). 4. Disconnect deceleration rod (3).
5. Remove left armrest (4) and right armrest (5). 6. Remove right side covers (6) and (7). 7. Remove left side covers (8) and (9).
8. Disconnect engine wiring connector (10) (CN101). 9. Disconnect monitor wiring connector (11) (CN214). 10. Disconnect panel lighting wiring connector (12) (CN215).
D155AX-5
30-299 5 1
DISASSEMBLY
FLOOR FRAME
AND ASSEMBLY
11. Disconnect air conditioner
hoses (13). (I * Using tool X, collect new freon gas (R134a). 12. Remove bracket (74), and move receiver tank (15) towards outside. 13. Disconnect 2 heater hoses (16). * Close the heater hose valve at the engine end. * Fit blind plugs after disconnecting. 14. Loosen bellows hose clamp (171, and disconnect bellows hose from engine hood.
15. Remove 2 covers (18).
16. Open cover (19), remove cleaner cover (20) and filter, then remove cover (19).
17. Remove covers (21) and (221, and install eyebolts.
I/
30-300 0
CWD02747
D155AX-5
DISASSEMBLY
AND ASSEMBLY
18. Remove mounting bolts, then lift off dashboard assembly (23). &I kg
Dashboard assembly : 85 kg
19. Disconnect wiring connectors (24) KN-105) and (25) (CN-104) between battery relay and fuse box. 20. Disconnect chassis ground (26).
21. Disconnect wiring connectors (27) (CN-153), (28) (LPL), (29) (CN-4511, and (30) (CN-701). Ir Disconnect the wiring clamps (2 places). Tightened together with ground (CN-456).
22. Disconnect window washer motor wiring connectors (31) (CN-3611, (32) (CN-3621, (33) KN3631, and (34) KN-364). 23. Disconnect wiring clamp (35). * Gather wiring harnesses together and move towards floor frame.
D155AX-5
FLOOR FRAME
DISASSEMBLY
FLOOR FRAME
AND ASSEMBLY
24. Disconnect return hoses (36) and (37) coming from blade and ripper control PPC valves.
25. Disconnect PPC hose (38) (white) (ripper TILT BACK). 26. , Disconnect PPC hose (39) (black) (ripper DOWN). 27. Disconnect PPC hose (40) (colorless) (blade LOWER). 28. Disconnect PPC hose (41) (green) (blade left tilt). m
29. Disconnect clamp (42). 30. Disconnect hose (43) between charge filter.
31. 32. 33. 34.
Disconnect Disconnect Disconnect Disconnect
30-302 0
lock valve and
PPC hose (44) (red) (ripper TILT IN): PPC hose (45) (colorless) (ripper UP). PPC hose (46) (black) (blade RAISE). PPC hose (47) (yellow) (blade right
D155AX-5
DISASSEMBLY
AND ASSEMBLY
35. Disconnect speed control cable (481, and remove bracket (49) from transmission case. 36. Disconnect directional selector control cable (501, and remove bracket (51) from transmission case.
37. Disconnect parking brake cable (52) from brake valve, and remove bracket (53) from HSS case. 38. Disconnect brake control rod (54) from brake valve. Sr After disconnecting the cable and rod, tie them to the floor frame.
39. Remove 8 front mount bolts (55).
40. Remove 8 suspension mounting bolts (56).
D155AX-5
FLOOR FRAME
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
41. Lift off floor frame assembly (57). 4 Floor frame assembly : 230 kg fl Control with a lever block to avoid interference when removing.
INSTALLATION OF FLOOR FRAME ASSEMBLY Serial No. 70001 – 75000 •
Carry out installation in the reverse order to removal.
1 fl Install the hoses without twisting or interference. fl Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. fl Check that there are O-rings at the piping connection of the air conditioner hoses, and coat the O-rings thoroughly with compressor oil before connecting. 2 fl The positions for connecting the PPC hoses are distinguished by color bands at the quick coupler, so check the colors when installing.
30-304 1 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
DASHBOARD
REMOVAL OF DASHBOARD ASSEMBLY Serial No. 70001 – 75000
¤ Park
the machine on level ground, lower the work equipment completely to the ground, then disconnect the cable from the negative (–) terminal of the battery. 1. Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S CAB ASSEMBLY. 2. Disconnect engine wiring connector (1) (CN101). 3. Disconnect monitor wiring connector (2) (CN214). 4. Disconnect panel lighting wiring connector (3) (CN215). 5. Disconnect air conditioner hoses (4). 1 fl Using tool X, collect freon gas (R134a). 6. Remove bracket (5), and move receiver tank towards outside. 7. Disconnect 2 heater hoses (6). fl Close the heater hose valve at the engine end. fl After disconnecting, fit with blind plugs. 8. Loosen bellows hose clamp (7), and disconnect bellows hose from engine hood.
9. Remove 2 covers (8).
8
8
DED01138
10. Open cover (9), remove cleaner cover (10) and filter, then remove cover (9). 9 10
DED01139
D155AX-5
30-305 5 1
DISASSEMBLY AND ASSEMBLY
DASHBOARD
11. Remove covers (11) and (12), and install eyebolts.
11 12
DED01140
12. Remove mounting bolts, then lift off dashboard assembly (13). 4 Dashboard assembly : 85 kg
13
INSTALLATION OF DASHBOARD ASSEMBLY Serial No. 70001 – 75000 •
DED01141
Carry out installation in the reverse order to removal.
1 fl Install the hoses without twisting or interference. fl Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. fl Check that there are O-rings at the piping connection of the air conditioner hoses, and coat the O-rings thoroughly with compressor oil before connecting. •
Charging with air conditioner gas Using tool X, charge air conditioner circuit with new freon gas (R134a).
30-306 1 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
REMOVAL OF MONITOR ASSEMBLY
MONITOR
Serial No. 70001 – 75000
Disconnect
the cable from the negative (–) terminal of the battery.
1
1. Remove mounting bolts and open monitor assembly (1). 2. Disconnect connectors (2) (CN-P1 and CN-P2), and remove monitor assembly (1). • Serial No. 70001 – 75000 3. Disconnect connectors (T01, CN4, CN1, CN2), and remove monitor assembly (1). • Serial No. 75001 –
DED01117
Serial No. 70001 – 75000
1
INSTALLATION OF MONITOR ASSEMBLY •
2
Carry out installation in the reverse order to removal. DED01118
Serial No. 75001 and up
D155AX-5
30-307 1 5
DISASSEMBLY AND ASSEMBLY
HSS CONTROLLER
REMOVAL OF HSS CONTROLLER ASSEMBLY Serial No. 70001 – 75000
¤ Disconnect
the cable from the negative (–) terminal of the battery.
1. Remove cover (1) at rear of operator’s seat. 2. Disconnect steering neutral adjustment switch wiring connector (2) (CN-CSW). 3. Disconnect HSS controller wiring connectors (3) (CN-1), (4) (CN-2H1), and (5) (CN-2H2). 4. Remove mounting bolts, then remove HSS controller assembly (6).
INSTALLATION OF HSS CONTROLLER ASSEMBLY Serial No. 70001 – 75000 •
Carry out installation in the reverse order to removal.
30-308 1 5
D155AX-5
DISASSEMBLY AND ASSEMBLY
HSS CONTROLLER
REMOVAL OF HSS CONTROLLER ASSEMBLY Serial No. 75001 and up
¤ Disconnect
the cable from the negative (–) terminal of the battery
1. Remove cover (1) from rear of operator's seat. 2. Disconnect HSS controller wiring connector (2) (CN-ST1), (3) (CN-ST2), and (4) (CN-ST3.) 3. Remove mounting bolts and HSS controller assembly (5).
INSTALLATION OF HSS CONTROLLER ASSEMBLY Serial No. 75001 and up •
Carry out installation in the reverse order to removal.
D155AX-5
30-309 5 5
40
MAINTENANCE
ANDARD ST
.40- 2 Engine mount ............................................... 40- 3 Power train unit mount ............................... 40- 4 Damper, universal joint ............................... 40- 6 Torque converter, PTO ................................ .40-10 ................................................ Transmission 40-13 control valve ......................... Transmission .40-14 Main relief valve.. ......................................... 40-16 Bevel gear shaft, HSS brake ....................... .40-20 Brake valve ................................................... pump, Scavenging 40-21 PPC, HSS charge pump ........................ Power train pump, lubrication pump.. ....... 40-22 40-24 PPC, HSS charge valve.. .............................. 40-26 Oil cooler bypass valve ............................... Final drive ...................................................... 40-28 .40-30 Main frame ................................................... .40-32 Track frame ................................................... .40-33 Recoil spring ................................................. .40-34 Track roller bogie ......................................... 40-36 Idler.. ............................................................... .40-38 Track roller.. .................................................. .40-40 Carrier roller ................................................. .40-42 Track shoe.. ................................................... .40-50 Suspension ................................................... 40-52 pump ............................... Work equipment .40-53 HSS pump.. ................................................... .40-54 HSS motor .................................................... .40-56 PPC valve ...................................................... .40-59 Steering lever ............................................... Main control valve ........................................ 40-60 40-66 cylinder.. .......................... Work equipment .40-70 Quick drop valve .......................................... .40-71 Cylinder stay ................................................. .40-72 Work equipment.. .........................................
D155AX-5
40-l
MAINTENANCE
STANDARD
ENGINE MOUNT
ENGINE MOUNT
m
m
926.7z102.9Nm (94.5210.5kgm)
926.7k102.9Nm (94.5-cl0.5kgm)
A-A
B-B
SAD00410
Unit:
No
Check item
Criteria
mm
Remedy
-
1
Clearance between and cushion
bracket
Tolerance
Standard size
60
Shaft -0.1 -0.3 Standard
2
Free height rubber
40-2
size
Hole +0.046 0
Standard clearance
Clearance limit
0.100 0.346 Repair
0.4 Replace limit
of mount 90
88
D155AX-5
MAINTENANCE
STANDARD
POWER TRAIN UNIT MOUNT
POWER TRAIN UNIT MOUNT
A-A
Unit: mm
No
Check item
Criteria
Remedy
-
1
between Interference steering case and bushing
Standard size 204
2
Clearance between and cushion
bracket
60
Tolerance Shaft
Hole
Standard clearance
+0.096 +0.050
+0.046 0
-0.096 - 0.004
Max.
-0.1 -0.3
+0.046 0
0.100 0.346
0.4
Standard 3
4
Free height rubber
of front mount
Free height rubber
of rear mount
D 155AX-5
size
Repair
90
88
43
41
Clearance limit 0
Replace limit
40-3
DAMPER,
MAINTENANCE
STANDARD
DAMPER,
UNIVERSAL
UNIVERSAL
JOINT
JOINT
m
276.85+31.85Nm (28.25+3.25kgm)
2
IlO.O-cl2.ONm (11.2-cl.2kgm)
66.15+7.35Nm (6.75-cO.75kgm)
(11.2z1.2kgm)
Unit:
Tolerance
Standard Clearance between 1
flywheel housing and cover
2
Clearance between flywheel and damper
3
Outer circumference of coupling oil seal contact surface
40-4
Remedy
Criteria
Check item
size
Shaft
511.18
-0.022 -0.092
466.72
-0.020 -0.083
Standard 90
size
Standard
Clearance
Hole
clearance
limit
+0.070 0
0.022 0.162
0.2
+0.063
0.020 -
0 Tolerance 0 -0.087
mm
Replace 0.2
0.146 Repair
limit
89.8
D155AX-5
MAINTENANCE
TORQUE CONVERTER, PTO
STANDARD
TORQUE CONVERTER,
PTO
TCS43-17A
m
40-6
277*319Nm i2825*325kPml
D 155AX-5
MAINTENANCE
TORQUE CONVERTER, PTO
STANDARD
llOr12.3Nm 11.25*1.25kom)
/
A
2.3Nm :1.25bd
SWD02770
D155AX-5
40-7
MAINTENANCE
STANDARD
TORQUE CONVERTER, PTO
Unit: mm
No
Check
item
Outer diameter of input coupling oil seal contact surface
1
Inner diameter of retainer seal ring contact surface
2
Wear 3
of stator
Width
Criteria Standard
size
Remedy Repair
Tolerance
limit
100
0 -0.054
99.8
140
+0.040 0
140.5
4.45
0 -0.1
4
5.2
+0.1
4.7
Hard chrome plating or replace
shaft seal ring Thickness
Backlash between PTO drive gear and PTO idler gear
4
Standard
clearance
Clearance
0.204 - 0.516
-
-
limit
-
-
5
Backlash between PTO idler gear and HSS pump drive gear
0.204 - 0.516
6
Backlash between PTO idler gear and power train, work equipment pump drive gear
0.204 - 0.516
-
7
Backlash between PTO drive gear and scavenging pump drive gear
0.204 - 0.516
-
40-8
Replace
D155AX-5
MAINTENANCE
TRANSMISSION
STANDARD
TRANSMISSION
1
6
P *9.8Nm l.OkPml
SWD02771
40-10
D155AX-5
MAINTENANCE
/ I
STANDARD
TRANSMISSION
F7 i I 2
7
0
3
A-A
\ 4
5 SW002772
D155AX-5
40-11
MAINTENANCE
STANDARD
TRANSMISSION
Unit: mm
No
Check
item
Criteria Standard
1
No. 1 clutch spring
(x12)
size
Repair
limit
Free length
Installed length
Installed load
Free length
Installed load
81.7
70.2
73.5 N 17.5 kg1
76.8
62.8 N 16.4 kg)
No. 2 clutch spring
(x12)
81.7
75.4
40.2 N 14.1 kg1
76.8
34.3 N 13.5 kg}
No. 3 clutch spring
(x12)
70
50
98.1 N 110 kg}
65.8
83.4 N 18.5 kg}
No. 4 clutch spring
(x12)
No. 5 clutch spring
(x12)
Lubrication spring
/
relief valve
7o
/
Clutch disc thickness (No. 1 - No. 5 clutch)
51
66
51.8
26
23.6
Standard 7
Remedy
/
z52k;j
/
65’8
66.7 N 16.8 kg1 12.5 N {I.27 kg]
size
/
62
56.9 N 15.8 kg) 11.9 N II.21 kg}
25.2
Tolerance
5.4
;i4k$
Repair
+0.1
4.9
8
Clutch plate thickness (No. 1 - No. 5 clutch)
9
Overall assembled thickness of No. 1 clutch
50.2
f0.3
47.5
Overall assembled IO thickness of No. 2 clutch
61.4
+0.3
58.2
I
5.8
I
fO.1
limit
5.2
I
Replace
11
Overall assembled thickness of No. 3 clutch
39
f0.3
36.9
12
Overall assembled thickness of No. 4 clutch
39
+0.3
36.9
13
Overall assembled thickness of No. 5 clutch
27.8
f0.2
26.2
14
Backlash between sun gears and planet pinion (FORWARD, REVERSE, 1st - 3rd)
15
16
Standard
Backlash between planet pinions and ring gear inner teeth (FORWARD, REVERSE, lst, 2nd) Backlash between planet pinion and ring gear inner teeth (3rd)
Backlash between carrier and ring gear inner teeth (REVERSE) Backlash between carrier 18 and ring gear inner teeth (FORWARD, 1st)
17
40-12
clearance
Clearance
0.14 - 0.35
-
0.15 - 0.38
-
0.16 - 0.41
-
0.18 - 0.54
-
0.18 - 0.48
-
limit
1
D 155AX-5
MAINTENANCE
TRANSMISSION
STANDARD
TRANSMISSION
CONTROL VALVE
CONTROL VALVE
SJDO2773
E-B
Unit: mm
No
1
5
6
Check
Criteria
item
Tolerance
Standard size
Clearance between clutch selector valve and valve body, and directional valve valve body
Hole
Standard clearance
Clearance limit
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
-0.1 -0.2
+0.033 0
0.1 0.233
0.26
-0.035 -0.045
+O.Oll 0
0.035 0.056
0.08
Shaft
22
Clearance between modulating valve and sleeve
20
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
Clearance between modulating valve sleeve and valve body
30
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
+0.018 0
0.020 0.048
Replace
Clearance between modulating valve and oiston
12
-0.020 -0.030 Standard
I 7
Modulating spring
valve
9
IO
Modulating spring
valve
Modulating
valve
spring
Modulating spring
valve
piston
-
D155AX-5
0.07
Repair
size
I
I
limit
I
Installed length
Installed load
Free length
Installed load
1
46.6
130 N 1 113.23 kg1
57.2
124 N 112.6 kg}
/
676
1 ,,:%Nkg]
Free length
inside
59
8
Remedy
outer 1
84.5 52
21
26
20
267 N (27.2 kg} 4.9 N IO.5 kg}
1
82 50.4
25.2
1 &?
:gI
1
253 N 125.8 kg} 4.7 N (0.48 kg}
40-13
MAINTENANCE
MAIN
MAIN RELIEF VALVE
STANDARD
RELIEF VALVE
7
3
I 5
rl
6 n
-
-
SJD02774
Unit: mm
No.
Criteria
Clearance between main relief valve and valve body
Clearance
between
Main relief valve spring
main
outside
6
8
40-14
D155AX-5
MAINTENANCE
BVEL GEAR SHAFT,
STANDARD
HSS BRAKE
IEVEL GEAR SHAFT, HSS BRAKE (l/2)
I I I I
40-16
II II II ,u&’ --------------------
/ / I
l.
!! r---
D155AX-5
MAINTENANCE
BEVEL GEAR SHAFT, HSS BRAKE
STANDARD
Unit:
mm
NC
Brake
plate
thickness
Brake
plate
distortion
Brake
disc thickness
Brake
disc distortion
1
Within
0.15
2
3
Overall assembled of brake thickness
6
7
Seal ring contact surface at brake piston smallportion diameter
D155AX-5
40-17
MAINTENANCE
STANDARD
BVEL GEAR SHAFT, HSS BRAKE
BEVEL GEAR SHAFT, HSS BRAKE
10.0~12.ONm 1.2*1.2kaml
SVD02766
40-18
D155AX-5
MAINTENANCE
STANDARD
BEVEL GEAR SHAFT, HSS BRAKE
Unit: mm
No. -
Check
item
Criteria Standard
Backlash between and pinion
gear A
Backlash between and gear C
gear A
3
Backlash between and gear E
gear D
4
Backlash between and B geara
gear A
5
Backlash between gear and pinion
bevel
1
2
clearance
Remedy Clearance
0.19 - 0.62
0.70
0.18 - 0.58
0.70
0.19 - 0.61
0.80
0.20 - 0.67
0.80
0.25 - 0.33
0.50
-
D155AX-5
limit
Replace
Adjust or replace
40-19
MAINTENANCE
STANDARD
BRAKE VALVE
BRAKE VALVE
ml-.lr----Y m
3
6
686+98Nm (7.0kl.Okgm)
SKD00434
Unit: mm
No
Check
item
Criteria
Remedy
-
1
Clearance between valve and body
Standard size
brake
Hole
Standard clearance
Clearance limit
-0.020 -0.030
+0.021 0
0.020 0.051
0.07
9
-0.03 -0.04
+0.015 0
0.030 0.055
0.08
19
-0.034 -0.043
+0.013 0
0.034 0.056
0.08
19 Clearance between valve and piston
brake
Clearance between parking brake valve and body
Tolerance Shaft
~~ 4
Brake modulating
5
Brake valve
6
Parking spring
-
40-20
Peplace
spring
return
brake valve
spring return
52.5
35
157.98 N f16.12 kg}
51
149.9 N (15.3 kg}
69.5
42
24.30 N (2.48 kg}
67.4
23.03 N (2.35 kg}
D
155AX-5
MAINTENANCE
STANDARD
SCAVENGING
SCAVENGING
PUMP,
PPC, HSS CHARGE
PUMP
PUMP, PPC, HSS CHARGE PUMP
112 + 104
(16.5-cl.5kgm) SDDO0438
Unit: mm
No
Criteria
Check item
I 1
1Standard
Twe
Side clearance
Clearance
between plain inner diameter and gear shaft outer diameter
Pin driving
1 Clearance
0.10 - 0.14
0.18
104
0.05 - 0.10
0.14
0.06 - 0.13
0.18
depth
Standard
size
Tolerance
112 13
Spline
shaft rotation
torque
6.86 - 11.77Nm
Type Delivery Oil temperature: Oil: EOIO-CD
45 - 50°C
1
Speed
112 2,200 104
D 155AX-5
Replace
0 -0.5
104 4
limit
104
Tvpe 3
clearance
112
112
2 bearing
Remedy
lo.7 - 1.2 kgm}
Delivery pressure
Standard delivery
Delivery limit
I30.3kg,cm2I MPa
230 e/min
210 e/min
4.4 MPa (45 kg/cm*}
215 e’min
195 e/min
rpm
40-21
MAINTENANCE
POWER TRAIN
STANDARD
POWER TRAIN PUMP, LUBRICATION
PUMP,
LUBRICATION
PUMP
PUMP
SAL (3) 80 + 100
,
\
SAL(3)80
SAL(S) 100 /
&
m
277.0?32.ONm (28.5=3.0kgm)
27.0*32.ONm (28.5*3.0kgm) SYWO420
Unit: mm
No
1
Check item
Side clearance SAL (3) 100
2
Clearance between plain bearing inner diameter and gear shaft outer diameter
Pin driving
4
Spline
0.60 - 0.149
0.20
SAL (3) 100 1
Standard
size
1
Tolerance
1
depth
shaft rotation
13.7 - 23.5 Nm {I.4 - 2.4 kgm}
torque
Type Delivery Oil: EOIO-CD Oil temperature:
1
Speed
SAL (3) 80
45 - 50°C
SAL (3) 100
40-22
0.22 Replace
SAL (3) 80
Tvoe 3
0.13 - 0.18
2,500
Delivery pressure
Standard delivery
Delivery limit
2.9 MPa (30 kg/cm*}
lg2 Umin
176 Urnin
I3o 2.9kg,cm2I MPa
241 Umin
221 Umin
-
rpm
D 155AX-5
MAINTENANCE
STANDARD
PPC. HSS CHARGE
VALVE
PPC, HSS CHARGE VALVE
8
2 B-B
I c-c SAD00436
40-24
D155AX-5
MAINTENANCE
STANDARD
PPC. HSS CHARGE
VALVE
Unit: mm
No
Check
item
Criteria
Clearance between charge valve and valve body
Clearance
between
charge
Clearance
between
filter
Clearance
between
check
6
Charge
valve spring
(large)
7
Charge
valve spring
(small)
a
s -
D155AX-5
40-25
MAINTENANCE
STANDARD
OIL COOLER BYPASS VALVE
COOLER BYPASS VALVE
-_--_--
T
A-A SAD00437
Unit: mm
No
Check item
Criteria
Clearance between oil 1 cooler bypass valve and
valve body
2 Spring
40-26
D155AX-5
MAINTENANCE
FINAL DRIVE
STANDARD
FINAL DRIVE
-m276.85=31.85Nm (28.25*3.25kgm) 3
m
40-28
151.9d4.5Nm (15.5-c2.5kgm)
548.8+58.8Nm (56.0t6.0kgm)
m
1;76.8?98.lNm (120.0+10.0kgm)
m
;48.8+58.8Nm (56.0?6.0kgm)
m
;51.9&24.5Nm (15.5s2.5kgm)
D 155AX-5
MAINTENANCE
FINAL DRIVE
STANDARD
Unit: mm
No
Check item Standard
1
0.28 - 0.93
1.0
Backlash between and planet pinion
0.24 - 0.79
1.0
0.26 - 0.87
1.0
sun gear
Backlash between planet pinion and ring gear
Standard
Outer diameter of No. 1 pinion oil seal contact surface
94.9
95
E
Clearance at ball between cover and shaft
3
Clearance between shaft and carrier
pinion
58
8
Clearance of No. 1 pinion bearing in axial direction
9
Wear of dia. of sprocket tooth tip
-0.010 -0.003
Wear of dia. of sprocket tooth root
12
Wear
of width
of sprocket
Wear tooth
of width root
of sprocket
D 155AX-5
-0.009 -0.039
0.006 0.049
shim thickness:
Tolerance
size
I Clearance limit 0.1
Adjust
2) Repair
limit
1,002
f2
962
909.4
f0.6
895.0
Standard 11
Standard clearance
0 - 0.1 (standard Standard
10
Hole
Shaft
Replace
2
I Tolerance
Standard size
limit
limit
94.9
Outer diameter of No. 1 pinion oil seal contact surface
7
Repair
size
95
E
-
Clearance
clearance
Backlash between No. 1 pinion and No. 1 gear
103
size
Repair
limit
Rebuild or replace
95
40-29
MAINTENANCE
MAIN
STANDARD
FEAME
MAIN FRAME
6
D-D
SKD00441
40-30
D155AX-5
MAINTENANCE
STANDARD
MAIN FRAME
Unit: mm
No -
Remedy
Criteria
Check item
I ince Clearance
between
Hole
HSS
1 case and main frame
+0.046 0
2
Clearance between frame and radiator bushing
main guard
95
+0.054 0
+0.154 +0.124
3
Clearance between frame and radiator bushing
main guard
95
io.054 0
+o. 154 +0.124
4
Clearance between equalizer bar center and bushing
pin
85
-0.120 -0.174
+0.207 +0.120
5
Press-fitting force for radiator guard mount bushing
-
-
-
Press-fitting force for 6, radiator guard mount bushing 7 -
Press-fitting force for equalizer bar center pin bushing
D 155AX-5
I
73.5 - 122.6 kN (7.5 - 12.5 ton1
73.5 - 122.6 kN t7.5 - 12.5 ton1
63.7 - 132.4 kN (6.5 - 13.5
I -
tOnI
40-31
MAINTENANCE
TRACK FRAME
STANDARD
TRACK FRAME
745+83Nm (76.0&5kgm)
m
m.
745+83Nm (76.0+8.5kgm)
m
745G33Nm (76.0?8.5kgm)
m
;45+83Nm (76.0&5kgm)
A-A SKD00442
Unit: mm
No.
I
I
I Check item
Item 1 Deformation
of track frame
Curvature Twisting Dents (pipe portion) Standard
2 Clearance between and guide
40-32
Remedy
Criteria
I
clearance
Repair
limit
7 (over length 3 (over length 12 Clearance
idler
of 3000) of 300)
Correct or replace
limit Adjust
0.5 - 1.0
3
D155AX-5
MAINTENANCE
RICOIL SPRING
STANDARD
RECOIL SPRING
u
u
A-A
SKD00443
Unit: mm
.
No
Remedy
Criteria
Check item
limit Installed load
Recoil spring 1,125
Clearance between inner c&i$;rg and outer cylinder
937
298.7 kN (30,456 kg]
1,091
283.7 kN :28,930 kg} Clearance limit
Replace
fl 0.7
Clearance between inner cylinder and protrusion of adiustment cvlinder Press-fitting force for outer cylinder bushing (outer cylinder side) Press-fitting yoke
D 155AX-5
force for idler
75
+0.039 +0.009
+0.130 +O.lOO
0.061 0.121
1.0
19.6 - 29.4 kN (2 - 3 ton}
245 kN 125 ton)
40-33
MAINTENANCE
TRACK ROLLER BOGIE
STANDARD
TRACK ROLLER BOGIE
2108*245Nm (215*25taml
\5
‘9 A-A
40-34
SWD02789
D155AX-5
MAINTENANCE
TRACK ROLLER BOGIE
STANDARD
Unit: mm
I
I
I
Check item
,
Criteria
Standard size
Clearance between cartridge pin and bushing
80
Tolerance
Remedy
Hole
Standard clearance
Clearance limit
-0.165 -0.195
+0.189 +0.129
0.294 0.384
0.8
+0.203 +0.183
+0.083 +0.020
-0.183 -0.100
-
Shaft
2
Clearance and outer
between bogie
collar
133
3
Clearance and outer
between bogie
collar
135
+0.203 +0.183
+0.083 +0.020
-0.183 -0.100
-
4
Clearance and inner bogie between
collar
134
+0.203 +O. 183
+0.083 +0.020
-0.183 -0.100
-
5
Clearance
6
Press-fitting bushing
force for
0.98 - 18.6 kN iO.1 - 1.9 ton}
7
Press-fitting washer
force for
2.94 - 5.88 kN (0.3 - 0.6 ton)
8
Press-fitting washer
force for
g
Press-fitting collar
force for
1o
Press-fitting outer bogie
force for
11
Press-fitting Inner bogie
I2
Press-fitting outer bogie
of collar
--
1.5 I
D155AX-5
force for
I
0.98 - 3.92 kN IO.1 - 0.4 ton}
1
force for
Replace
58.8 - 103.9 kN i6.0 - 10.6 ton}
88.3 - 202 kN (9.0 - 20.6 ton}
198 - 436 kN (20.2 - 44.5 ton1
94 - 206 kN 19.6 - 21.0 ton}
40-35
MAINTENANCE
IDLER
STANDARD
IDLER
SWD02767
40-36
D 155AX-5
MAINTENANCE
STANDARD
IDLER
Unit: mm
No
Criteria
Check item
Remedy
Standard
size
of
Outer
diameter
of tread
Depth
of tread
21
-
Overall
width
240
-
of tread
58.5
-
Width
792
-
750
725
I 6
Clearance between and bushing
Standard size
shaft
140
7
Interference between and bushing
idler
_
Standard size
Shaft flange
D155AX-5
width
I
Tolerance
-0.350 -0.413
I
+0.270 -0.040
0.310 0.683
-
Standard interference
Interference limit
Hole +0.063 -0.100
216
Rebuild or replace
Hole
Tolerance Shaft
limit
Standard clearance
Shaft
150
8
Repair
Outer diameter prorusion
Clearance limit
Replace bushing
-
-
Rebuild or replace
40-37
MAINTENANCE
STANDARD
TRACK ROLLER
TRACK ROLLER
L
-1
-
B
d i
y
! j I
\,I
!i
IO II
1 I
__ __-.. L-
,k---------__-.--..dI TT----i __.__
iL
; - t
i
I_ __ --. i
a
5 SW802776
40-38
D155AX-5
MAINTENANCE
STANDARD
TRACK ROLLER
Unit: mm
No. -
Check
Criteria
item Standard
1
Outer diameter of flange (outside flange)
2
Outer diameter (inside flange)
of flange
3
Outer
of tread
4
Thickness
5
Overall
6
Inner width
diameter
of tread
width
Repair
size
285
-
275
-
250
210
57.5
37.5
295
I
Remedy
I
limit
Rebuild or replace
Replace
-
single flange
113
-
double
69
-
flange
7
Width of tread (single flange)
61
-
8
Width of tread (double flange)
61
-
9
Flange width (outside of double
25
-
22
-
flange)
10
Flange width (inside of double
11
Shaft flange
width
12
Press-fitting for collar
dimension
13
14
flange)
Clearance between and bushing
Interference between and seal guide
246.0
I
I
shaft
-
-
I
shaft
Rebuild or replace
Standard size r
Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
Hole
Standard interference
lnterferenct limit
Tolerance Shaft
Replace bushing
3
-
-
Dl SAX-5
40-39
MAINTENANCE
STANDARD
CARRIER ROLLER
CARRIER ROLLER
SWD02777
Unit: mm
Check item
No
Criteria Standard size
1
Outer
diameter
Outer diameter
Width
of tread
Thickness
5
6
7
Width
of tread
Interference between bearing and shaft
Play of roller in axial direction
40-40
-
190
171
63
-
Standard size
limit
Rebuild replace
or
28
-
21
of flange
interference between bearing and roller
220
37.5
Tolerance
Standard interference
Interference limit
-0.024 -0.059
0.009 0.059
-
0 -0.015
0.002 0.036
-
Shaft
Hole
110
0 -0.015
60
+0.021 +0.002
Standard 8
Repair
of flange
of tread
Remedy
clearance
Clearance
Replace
limit
-
Dl !ZAX-5
MAINTENANCE
TRACK SHOE
STANDARD
TRACK SHOE DRY TYPE 12
I
Y
21
22
16
i
18
40-42
5
4
IL=d+\
ii
shows the link of bushing
press fitting
i
19
25
I5
SWD02429
I P portion
II
/
23.
Ir
Ei
end.
D155AX-5
MAINTENANCE
STANDARD
TRACK SHOE
Unit: mm
I
I
No.
Check item
Criteria Standard
1
Remedy
size
Repair
Link pitch
231.85 233.85
228.85
When Standard 2
Bushing
outside
Normal
Reverse replace
turned
load
Impact
load
81
II
75.0
77.0
I I
Repair
size
I
limit Repair or replace
Link height 144
4
128
Thickness of link metal (bushing press-fitting portion)
--I
45.5
5
6
Shoe
or
I
Standard 3
(Heavy-duty areas) (Standard areas)
size
diameter
I
limit
219.8 Replace bolt pitch
76.2
7
25.4
I
81 9
1Inside width
1
122.8
I
I
Overall
Link
10
Tread
11
Protrusion
of pin
12
Protrusion bushing
of regular
13
Overall
length
width
Repair or replace
61.4
width
54.3
4.5
10.4
of pin
294 Adjust or replace
I4
Overall
15
Thickness
of bushing
16
Thickness
of spacer
length
of bushing
metal
!
Press-fitting force
% 19
Regular
Master
15.8
-
I
Bushing ,8
202.2
I pin
pin
88.2 - 313.6
kN (9 - 32 ton)
205.8 - 568.4 kN 121 - 58
107.8 - 274.4
I
tOnI
I I
kN 111 - 28 ton1
.x : Dry type track link
D155AX-5
40-43
MAINTENANCE
STANDARD
TRACK SHOE
Unit: mm l-
NC -
Check
item
Criteria
Tightening torque (Nm Ikgm}) a. Regular
I
link
Remedy
Additional angle
588.4 f 58.8 160 f 61 2c
Shoe
Retighten torque
(Nm Ikgm}) b. Master
Additional angle
I
No. of shoes (each side)
Interference between bushing and link
22
Interference between regular pin and link
2:
Clearance between regular pin and bushing
5%
Interference between master pin and link
tightening (deg.)
Lower limit torque (Nm {kgm))
link
-
24
120 + 10
bolt Tightening
21
tightening (deg.)
-
I
-
41
Standard size
Tolerance Shaft
Hole
Standard interference
77.0
+0.404 +0.304
+0.074 0
0.230 0.404
48.5
+0.584 +0.434
+0.062 0
0.272 0.584
Adjust or replace Standard size
48.5
Tolerance Shaft
Hole
Standard interference
+0.330 -0.300
+0.062 0
0.238 0.330
Clearance between master pin and bushing
%X: Dry type track link
40-44
D155AX-5
MAINTENANCE
STANDARD
SEALED AND LUBRICATED
TRACK SHOE
TRACK 21
22
5
II
24
16
13
\ 2
\ \23
7
19
\ 25
\ 15
SW002430
Ir
P portion
40-46
shows the link of bushing
pres: s fitting
end.
D155AX-5
MAINTENANCE
-
STANDARD
TRACK SHOE
l-
No
Check
item
Criteria
Remedy
Standard
Repair
size
1 Link pitch
231.85 233.85
228.85
When Standard 2
outside
(Heavy-duty areas) (Standard areas) Reverse replace
turned
size Normal
Bushing
limit
load
Impact
or
load
diameter 81
72.5
75.0
Standard 3
Link height
4
Thickness of link metal (bushing press-fitting portion)
-
Repair
size
144
limit Repair or replace
128
45.5
5
219.8 Replace
6
Shoe
bolt pitch
169
7
76.2 1
I 8
IInside
width
I (
122.8
I
9
Overall
Link
width
Repair or replace
61.4
10
54.3
Trea width
11
Protrusion
of pin
12
Protrusion bushing
of regular
13
Overall
4.5
-
-
I
length
3.25
I
291.6
of pin
Adjust or replace
14 -
Overall
length
of bushing
187.9
_ 15
Thickness
of bushing
16
Thickness
of spacer
metal
15.9
11.1
17
Bushing
49 - 196 kN 15 - 20 ton)
18, x
Press-fitting force
19
Regular
Master
pin
pin
196 - 294 kN I20 - 30 ton}
-
-
% : Dry type track link
D155AX-5
40-47
TRACK SHOE
STANDARD
MAINTENANCE
Unit: mm
NC
Check
link 588.4 f 58.8 160 + 61
20
Shoe
tightening (deg.)
Additional angle
torque Tightening (Nm {kgm)) a. Regular
Remedy
Criteria
item
120 + IO Retighten
bolt Additional tightening angle (deg.)
Tightening torque (Nm IkgmI) b. Master
Lower limit torque Wm IkgmI)
link 588.4 f 58.8 (60 f 6)
882.6
180 + 10
190)
-
No. of shoes (each side)
21
Interfere1 bushing
’
I
size ------
I
Che.f=+
I 22
23
between Interference regular pin and link
+0.484 +0.434
48.5
Shaft +0.484 +0.334
48.5 *X 24
between Interference master pin and link
25
Clearance between master pin and bushing I
Hole
Standard clearance
+0.664 +O. 164
0.230 0.830
Tolerance
Standard size
Shaft
Hole
Standard interference
-
-
-
-
Tolerance
Standard size
9%
0.372 0.584
Tolerance
Standard size
Clearance between regular pin and bushing
-0.038 -0.100
-
Shaft I
-
_
Standard clearance
I
-
Hole I
-
Adjust or replace
.X : Dry type track link
40-48
D155AX-5
MAINTENANCE
STANDARD
TRACK SHOE
SINGLE SHOE
SED01627
Unit: mm
Criteria
Check item
No.
Standard 1
Remedy Repair
size
limit
Height 30
80
2Thiiineri
17
3
Length
at bottom
33
4
Length
at top
15
D 155AX-5
Repair replace
or
MAINTENANCE
SUSPENSION
STANDARD
SUSPENSION
-1
1
1
-1
(56?6kgm)
(56+6kgm)
3
4
5
A-A
8
B-B
SKD00450
40-50
D 155AX-5
MAINTENANCE
STANDARD
SUSPENSION
m
9275103Nm
6
(94.5210.5kgm) \
I\
2 i
c
C-C
(Left side)
C-C
(Right side)
SKW0451
Unit:
No -
1
Check
item
Criteria
Clearance between pivot shaft and bushing (inner)
Standard size
Clearance between pivot shaft and bushing (outer)
3
Clearance between pin and bushing
center
Clearance between pin and bushing
side
4
Clearance
between side pin surface of
bushing
-
Hole
Standard clearance
+0.125 +0.085
0.2300.333
1.0
148
-0.145 -0.208
+0.125 +0.085
0.230 0.333
1.0
-0.120 -0.174
+0.279 +0.190
0.310 0.453
1.0
75
-0.048 -0.078
0 -0.015
0.033 0.078
1.0
82
-0.1 -0.3
+0.3 +O.l
0.2 - 0.6
1.0
85
E
Press-fitting force for pivot shaft bushing (inner)
1.96 - 38.2 kN (0.2 - 3.9 ton1
7
Press-fitting force for pivot shaft bushing (outer)
0.98 - 33.3 kN IO.1 - 3.4 ton)
a
Press-fitting pin bushing
D155AX-5
force for side
Clearance limit
-0.145 -0.208
-
E and spherical
Shaft
Remedy
175 2
Tolerance
mm
43.1 - 213.8 kN 14.4 - 21.8 ton)
Replace bushing
!
-
40-51
MAINTENANCE
WORK EQUIPMENT
STANDARD
WORK EQUIPMENT
PUMP
PUMP
SAR(4)112
1279*29Nm (28.5~3kml
SWDO2768
Unit: mm
No
Remedy
Criteria
Check item
I
Standard
clearance
I
Clearance
Side clearance
Clearance between plain bearing inner diameter and gear shaft outer diameter
0.11 - 0.16
0.19
0.060 - 0.140
0.20 Replace
Standard 3
Pin driving
Tolerance
size
depth
0 -0.5
21
4
Spline
shaft rotation
temperature:
40-52
11.8 - 19.6 Nm II.2
torque
Speed
Delivery 45 - 50°C
limit
1
2,200
rpm
Delivery pressure 20.6 MPa 1210 kg/cm*}
- 2.0 kgm)
Standard delivery 233 .r?/min
I---Delivery limit
215 L?/min
D 155AX-5
MAINTENANCE
HSS PUMP
STANDARD
HSS PUMP HPVl60
m
20.15*2.45Nm (2.05*0.25kd SWD02941
D 155AX-5
40-53
MAINTENANCE
STANDARD
HSS MOTOR
HSS MOTOR
373-t49Nm (38* 5kPml
55002775
Unit: mm
No.
Check item
Criteria Standard
1
Spool
40-54
return spring
Remedy Repair
size
Free length xOD
Installed length
Installed load
Free length
45.74 x 24
36.0
115.7 N {I 1.8 kg)
-
limit Installed load 92.6N 19.5 kg1
Replace spring if damaged or deformed
D 155AX-5
MAINTENANCE
PPC VALVE
STANDARD
PPC VALVE For blade
w
/
112.7214.7Nm (11.511.5kgm)
44.124.9Nm (4.520.5kgm)
14.4+1.9Nm (1.47?0.2kgm)
w
13.2k1.47Nm (1.3550.15kgm)
-6.37+2.45Nm (0.65=0.25kgm)
m
-8.34i2.45Nm (0.85?0.25kgm)
40-56
7.36?1.47Nm (0.75k0.15kgm)
SKD00595
D155AX-5
MAINTENANCE
PPC VALVE
STANDARD
Unit: mm
No -
Standard
1
Centering (for P4)
size
I
Repair
limit
I
spring
Metering spring (for P3, P4) Centering (for P3)
Remedy
Criteria
Check item
spring
Replace spiing if damaged or deformed
Centering spring (for PI, P2) Metering spring (for PI, P2) Detent spring (for P4) 7
Detent spring (for P3)
-
D 155AX-5
40-57
MAINTENANCE
PCC VALVE
STANDARD
For ripper
112.8t14.7Nm (11.5&1.5kgm) 13.2+1.5Nm (1.35+0.15kgm)
44.1-c4.9Nm (4.5k0.5kgm)
39.2k4.9Nm (420.5kgm)
8.5t2.5Nm (0.85t0.25kgm)
2.
3’
SYWO454
Unit: mm
No
Check item
Standard
1
Centering spring (for P3, P4)
Remedy
Criteria
I
Repair
size
limit
Free length xOD
Installed length
Installed load
Free length
Installed load
50.05 x 15.5
34
71.4 N (7.28 kg)
-
56.9 N 15.8 kg}
2
Centering spring (for PI, P2)
50.35 x 15.5
34
55.9 N (5.7 kg}
-
45.1 N 14.6 kg1
3
Metering
26.53 x 8.15
24.9
16.7 N il.7 kg}
-
13.7 N Il.4 kg1
spring
Replace spring if damaged or deformed
-
D155AX-5
MAINTENANCE
STEERING
STEERING LEVER
STANDARD
LEVER
SWD02788
Unit: mm
No.
Standard
1
2
Spring
Spring
D 155AX-5
Remedy
Criteria
Check item size
Repair
limit Installed load
Free length x OD
Installed length
Installed load
Free length
45.8 x 75.5
32
73.5 N 17.5 kg}
-
58.8N 16.0 kg1
49 x 7.0
25
5.88 N IO.6 kg1
-
4.7 N IO.48 kg}
Replace spring if damaged or deformed
40-59
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
MAIN CONTROL VALVE *
Precautions when tightening portions marked -X. To ensure that the 3 bolts are tightened evenly, tighten the bolts in three mx steps as follows. 1st pass: 58.8 + 9.8 Nm (6 f 1 kgm) 2nd pass: 137.3 f 9.8 Nm (14 + 1 kgm} 3rd pass: 186.3 + 9.8 Nm (19 f 1 kgm}
W-C
31.4*2.9Nm (3.2+0.3koml
w
34.3*4.9Nm (3.5*0.5kml
K4
m
23.5*3.9Nm 12.4*0.4keml
SAD01560
40-60
D155AX-5
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
m
66.b7.4Nm (6.75&0.75kgm)
a=
3
\m
//Llzz&ulL
66.227.4Nm (6.75+0.75kam)
tEl
1
m
46.627.4Nm (4.75+0.75kgm)
A-A /
m
4
139.7222.1Nm (14.25k2.25kgm)
m 321.2+46.6Nm (32.75-c4.75kgm)
a=
152.0k24.5Nm (15.5+2.5kgm) @210.8+29.4Nm (21.5+3.0kgm)
\
B-B @147.1-c9.8Nm (15elkgm)
\
5
@419.2+46.6Nm (42.75=4.75kgm)
7.4-cl.5Nm (0.75+0.15kgm) SAD00456
D155AX-5
40-61
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
a=
127.5-cl9.6Nm (13+2kgm)
186.3+9.8Nm (19+lkgm)
m
m
147.1+9.8Nm (15-clkgm)
23.523.9Nm ,(2.4=0.4kgm)
\ 139.7+22.1Nm (14.25~2.2 kgm) K
D-D
8
9
7
SAD00457
Unit: mm
No.
Check item
,
Spool return spring (for blade LIFT only)
2
Spool
3
Spool return spring (for blade LIFT [FLOAT])
4
Load check valve spring
return
spring
or deformed
7 7
Back pressure
8
Relief valve
9
Relief valve spring
40-62
valve
spring
spring
(45.1 kg)
-
118.4 x 19.5
92.5
443.23 N l45.2 kg1
-
354.98 N (36.2 kg1
99.5 x 14.9
96
71.58 N (7.3 kg}
-
56.87 N i5.8 kg1
16.3 x 21.3
9
2.16N IO.22 kg}
-
0.98 N (0.10 kg1
20 x 7
13.7
1.27 N IO.13 kg1
-
19.02 N II.94 kg1
D155AX-5
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
m
68.629.8Nm (7alkgm)
m
23.5+3.9Nm (2.4&0.4kgm)
(1.15-cO.15kgm)
J-J
34.3k4.9Nm (3.5+0.5kgm)
,,,/
K-K
?2= 66.2+7.4Nm (6.75?0.75kgm)
E-E
SAD004S3
D155AX-5
40-63
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
m
186.3*9.8Nm (19*1kml
CsJ
23.5*3.9Nm (2.4*0.4bm)
F-F
m
68.6*9.8Nm (7*lksml
G-G H-H
SAD01561
Unit: mm
No -
Remedy
Check valve spring spool
inside
Replace spring if damaged or deformed
Dl !%AX-5
MAINTENANCE
WORK EQUIPMENT .
WORK EQUIPMENT CYLINDER
STANDARD
CYLINDER
BLADE LIFT CYLINDER
110.3+12.3Nm (11.25t1.25kgm)
981+98Nm (100+10kgm)
SAD00460
.
BLADE TILT CYLINDER
m
m
110.3+12.3Nm (11.25+1.25kgm)
343234.3Nm
(35+3.5kgm)
.
SAD00461
PIN PULLER CYLINDER
4
1
6
m
441244Nm (45.0+4.5kgm)
40-66
SBD00462
D155AX-5
MAINTENANCE
STANDARD
WORK EQUIPMENT CYLINDER
Unit: mm
NC
Check item
Criteria
T
Tolerance Shaft
Clearance between oiston rod and bushing
Blade TILT
g0
1.1;Clearance between piston rod spherical surface and blade ball portion Clearance between zylinder support shaft bushing and yoke
Hole
“““,“.,,
-0.036 -0.123
+0.270 +0.061
0.097 0.393
-0.065 -0.117
+0.133 +0.007
0.072 0.250
-0.200 -0.300
+0.030 0
0.200 0.330
-0.120 -0.207
+0.054 0
0.120 0.261
65
Blade TILT
115
-0.200 -0.300
+0.300 0
Pin puller
2g
-0.100 -0.200
+I .300 +I.200
;;;;e
60
-0.300 -0.500
+0.174 +O.lOO
Clearance between E zylinder bottom sup- lfi,,, port shaft and boss
26
-1.1 -1.2
fO.l
Clearance between ;+$;r&b~;;;u;;;-g
Clearance limit 1
0.675
0.673 I
Blade LlFT
F
Standard clearance
+0.27 1 +0.075
65
4
1
--I
-0.030 -0.104
Blade LIFT
Clearance between piston rod spherical surface and cap
Remedy
0.55
1.0 Replace 0.5
-
D 155AX-5
40-67
MAINTENANCE
.
WORK EQUIPMENT CYLINDER
STANDARD
RIPPER LIFT CYLINDER
245+24.5Nm (25t2.5kgm)
.
110.3-c12.3Nm (11.25+1.25kgm)
SAD00463
RIPPER TILT CYLINDER
245+24.5Nm (25a2.5kgm)
40-68
110.3e.12.3Nm (11.25s1.25kgm)
SAD00464
D155AX-5
MAINTENANCE
WORK EQUIPMENT CYLINDER
STANDARD
Unit: mm
-
Remedy
Criteria
Check item
No -
Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
Clearance between
1 piston rod and bushing
Clearance between piston rod support shaft and bushing
$&?;r!cc’brff;~en support shaft and bushing
D155AX-5
Ripper LIFT
80
-0.030 -0.104
+0.271 +0.061
0.091 0.375
0.675
Ripper TILT
80
-0.030 -0.104
+0.271 +0.061
0.091 0.375
0.675
Ripper LIFT
85
-0.036 -0.090
+0.207 +0.120
0.156 0.297
1.0
Ripper TILT
85
-0.036 -0.090
+0.207 +0.120
0.156 0.297
1.0
LIFT Ripper
85
-0.090 -0.036
+0.120 +0.207
0.156 0.297
1.0
Ripper TILT
85
-0.036 -0.090
+0.207 +0.120
0.156 0.297
1.0
Replace
40-69
MAINTENANCE
STANDARD
QUICK DROP VALVE
QUICK DROP VALVE .
FOR BLADE LIFT CYLINDER
SED00465
Unit: mm
No.
Check item
Clearance and valve
’
between body
Criteria Tolerance
Standard size
spool
Shaft
38.0
I
I
-0.011 -0.016 I
Valve
40-70
spring
Hole
Standard clearance
+O.OlO 0
0.011 0.026
I
Standard
2
Remedy
I
size
Clearance limit 0.03 I
Repair
limit
Free length
Installed length
Installed load
Free length
Installed load
75.2
55.9
136.3 N (13.9 knl
67.7
122.6N (12.5 kg}
Replace
D155AX-5
CYLINDER STAY
STANDARD
MAINTENANCE
CYLINDER STAY
Z
SAD00466
Unit: mm
No -
Check
Clearance
between
1 yoke and bushing
Clearance between 2 yoke and bushing
D155AX-5
Remedy
Criteria
item
cylinder
cylinder
Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
125
-0.172 -0.235
+0.063 0
0.172 0.298
0.5
100
-0.170 -0.224
io.054 0
0.170 0.278
0.5
Replace
40-71
MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT SEMI U-DOZER
3
6
9
10
?4
I k A-A
7
8
5
I D-D
E-E
F-F
G-G SED00467
40-72
D155AX-5
MAINTENANCE
STANDARD
WORK EQUIPMENT
Unit: mm
No.
,
Criteria
Check item
Clearance and pin
between
Tolerance
Standard size
brace
Shaft
Hole
Remedy
Standard clearance
Clearance limit
60
-0.3 -0.5
+0.5 +0.3
0.6 - 1.0
2
60
-0.3 -0.5
+0.5 +0.3
0.6 - 1.0
2
3 Clearance between brace spherical surface and cap
115
-0.2 -0.3
+0.3 0
0.2 - 0.6
1
Clearance between center 4 brace spherical surface and cap
115
-0.2 -0.3
+0.3 0
0.2 - 0.6
1
5
Clearance between and blade bracket
joint
120
-0.2 -0.7
+0.5 +0.3
0.5 - 1.2
2
6
Clearance between and frame
joint
120
-0.2 -0.7
+0.5 +0.3
0.5 - 1.2
2
60
-0.3 -0.5
+0.3 0
0.3 - 0.8
3
2 Clearance between pin and bracket
7 Cjearance between pm and joint
brace
frame
Replace
Adjust shims or replace
Replace 8
Clearance between pin and frame
frame
60
-0.3 -0.5
+0.3 0
0.3 - 0.8
3
’
Clearance between blade bracket pin and joint
60
-0.3 -0.5
+0.3 0
0.3 - 0.8
3
lo
Clearance between blade bracket pin and bracket
+;‘3
1 0.3 - 0.8
-0.2 -0.3
+0.3 0
0.2 - 0.6
Clearance between center 11 brace spherical surface and cap
60 115
1
2:;
1
1
3 1
center link
85
-0.3 -0.5
+0.3 0
0.6 - 0.8
2
13 Clearance center hnk pin andbetween blade bracket
85
-0.3 -0.5
+O.l -0.1
0.2 - 0.6
2
I2
Clearance between link pin and center
1
/ Adjust shims or replace
Replace l4
Clearance between center link and blade bracket
15 Clearance between trunnion and cap spherical surface
D155AX-5
196
-0.1
160
-0.5 -1.0
0
+0.3 +0.5
0.3 - 0.6
2
+0.5 0
0.5 - 1.5
8
40-73
MAINTENANCE
STANDARD
WORK EQUIPMENT
U-DOZER
3
6 10
9
14 12
I
13
k A-A
c-c 7.
8
‘5
1
2
I
D-D
E-E
F-F
G-G SEW0468
40-74
D 155AX-5
MAINTENANCE
STANDARD
WORK EQUIPMENT
Unit: mm
I
I
No.
Check item
I Criteria
I
Tolerance
Standard size
, Clearance between brace and pm
Remedy
Shaft
60
Hole
-0.3 -0.5
+0.5 +0.3
-0.3 -0.5
+0.5 +0.3
Standard clearance
Clearance limit
0.6 - 1.0
2
Replace
1
I
Clearance between brace 2 pin and bracket
60
3 Clearance between brace spherical surface and cap
I
0.6 - 1.0
2 1
115
-0.2 -0.3
+0.3 0
0.2 - 0.6
Clearance between center 4 brace spherical surface and cap
115
-0.2 -0.3
+0.3 0
0.2 - 0.6
1
5 Clearance between joint and blade bracket
120
-0.2 -0.7
+0.5 +0.3
0.5 - 1.2
2
and frame between joint 6 Clearance I
120
-0.2 -0.7
+0.5 +0.3
I
I
I
Adjust shims or replace
0.5 - 1.2 I
7 Clearance between frame ptn and joint
60
-0.3 -0.5
+0.3 0
8 Clearance between frame pin and frame
60
-0.3 -0.5
+0.3 0
I
2
I
I
0.3 - 0.8
3 Replace
9 Clearance between blade bracket pin and jornt I
60 I
-0.3 -0.5
+0.3 0
I
I
I
Clearance between blade bracket pin and bracket
0.3 - 0.8
3
0.3 - 0.8
3
I
I
I
60
-0.3 -0.5
io.3 0
0.3 - 0.8
3
Clearance between center 11 brace spherical surface and cap
115
-0.2 -0.3
+0.3 0
0.2 - 0.6
1
Clearance between center link pin and center link
85
-0.3 -0.5
io.3 0
lo
I2 I
I
I
I
0.6 - 0.8 I
Adjust shims or replace
2 ,
1
13 Clearance between center link pin and blade bracket
85
Clearance between center link and blade bracket
196
-0.3 -0.5
+O.l -0.1
0.2 - 0.6
2
-0.1
+0.3 +0.5
0.3 - 0.6
2
-0.5 -1.0
+0.5 0
0.5 - 1.5
8
Replace I4
15 Clearance between trunnion and cap spherical surface
D 155/4X-5
160
0
40-75
MAINTENANCE
CUlTlNG
WORK EQUIPMENT
STANDARD
EDGE, END BIT
m ,
1495+162Nm (152.5+16.5kgm)
m
‘149Eel62Nm (152.5+16.5kgm) SDD00469
Unit: mm
Standard 1
Height
of outside
Remedy
Criteria
Check item
No.
of end bit
size
Repair
415
300
662
500
limit
Replace 2
Width
3
Height
of inside of end bit
330
260
4
Height
of cutting
330
260 (215 to turning)
40-76
of end bit
edge
Turn or replace
Dl PAX-5
MAINTENANCE
STANDARD
WORK EQUIPMENT
MULTI-SHANK RIPPER GIANT RIPPER
A-A
5
B-B
6
SDD00470
40-78
D155AX-5
MAINTENANCE
WORK EQUIPMENT
STANDARD
Unit: mm
No,
Criteria
Check item
Clearance between arm 1 mounting pin and mounting bracket
Remedy
Tolerance
Standard size
Shaft
I
Hole
Standard clearance
Clearance limit
110
-0.036 -0.090
+0.207 +0.120
0.156 0.297
1.5
Clearance between arm 2 mounting pin and bushing
110
-6.036 -0.090
+0.520 +0.312
0.348 0.610
1.5
Clearance between arm 3 mounting pin and beam bracket
110
-0.036 -0.090
+0.207 +0.120
0.156 0.297
1.5
Clearance between arm 4 mounting pin and bushing
110
-0.036 -0.090
+0.520 +0.312
0.348 0.610
1.5
1.4 - 2.6
10.0
-
Clearance 5 mounting holder Clearance 6 mounting hole -
between shank pin and shank
Shaft Hole
+0.300 -0.300
75 77 I
between shank pin and shank
I
Shaft Hole
+0.300 -0.300 I
I
I
+0.300 -0.300
75 80
I
I
I
+O.lOO -0.100
I
I
4.6 - 5.4 I
Replace
15.0 I
Repair limit
Standard size 7 Wear of point
8 Wear of protector -
D155AX-5
115
I
90
I
40-79
i
;
90 OTHERS
Work equipment hydraulic circuit and HSS circuit diagram ............................. 90- 3 Machine equipped with pitch dozer ...... 90- 5 Electric circuit diagram (1/3) (Serial No. 70001-75000) ......................... 90- 7 Electric circuit diagram (2/3) (Serial No. 70001-75000) ......................... 90- 9 Electric circuit diagram (3/3) (Serial No. 70001-75000) ........................ 90-11 Electric circuit diagram (1/3) (Serial No. 75001 and up) ...................... 90-13 Electric circuit diagram (2/3) (Serial No. 75001 and up) ...................... 90-15 Electric circuit diagram (3/3) (Serial No. 75001 and up) ...................... 90-17 Electric circuit diagram inside cab (Serial No. 75001 and up) ...................... 90-19
D155AX-5
90-1 3
ELECTRIC CIRCUIT DIAGRAM (1/3) Serial No. 70001 – 75000
D155AX-5
90-7 3
ELECTRIC CIRCUIT DIAGRAM (2/3) Serial No. 70001 – 75000
D155AX-5
90-9 3
ELECTRIC CIRCUIT DIAGRAM (3/3) Serial No. 70001 – 75000
D155AX-5
90-11 3
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB Serial No. 75001 and up
D155AX-5
90-19 3
ELECTRIC CIRCUIT DIAGRAM (1/3) Serial No. 75001 and up
D155AX-5
90-13 3
ELECTRIC CIRCUIT DIAGRAM (2/3) Serial No. 75001 and up
D155AX-5
90-15 3
ELECTRIC CIRCUIT DIAGRAM (3/3) Serial No. 75001 and up
D155AX-5
90-17 3
Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186
PROPOSAL
1
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR 2
NAME OF COMPANY:
:
PHONE NO:
: S
DEPARTMENT:
E R
NAME:
MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:
PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:
