Shop Manual D155-6

SEN02854-04

BULLDOZER

D155A -6 SERIAL NUMBERS

85001

and up

SEN02856-04

BULLDOZER 1SHOP MANUAL

D155A-6

Machine model

Serial number

D155A-6

85001 and up

00 Index and foreword

1

Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

D155A-6

1

SEN02856-04


Composition of shop manual

1

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

Form Number

Shop Manual, contents binder, binder label and tabs

SEN02854-04

00 Index and foreword Index Foreword and general information

SEN02855-04 SEN02856-04 q SEN02857-02 q

01 Specification Specification and technical data

SEN02858-02 SEN02859-02 q

10 Structure, function and maintenance standard Engine and cooling system Power train, Part 1 Power train, Part 2 Undercarriage and frame Hydraulic system Work equipment Cab and its attachments Electrical system

SEN02860-02 SEN02861-01 SEN02862-01 q SEN02863-00 SEN02864-00 SEN02865-02 q SEN02866-00 SEN02867-00 SEN02868-01 q

20 Standard value table Standard service value table

SEN02869-00 SEN03199-00

30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3 Testing and adjusting, Part 4

SEN02870-02 SEN03200-01 q SEN03201-00 SEN03202-02 q SEN03203-00

40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure and error codes, Part 1 Troubleshooting by failure and error codes, Part 2 Troubleshooting by failure and error codes, Part 3 Troubleshooting by failure and error codes, Part 4 Troubleshooting of electrical system (E-mode)

SEN02871-01 SEN03204-01 SEN03205-01 SEN03206-00 SEN03207-01 SEN03208-00 SEN03209-00 SEN03210-01

2

q q q

q

D155A-6


Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode)

SEN02856-04

SEN03211-00 SEN03212-01 q

50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Power train, Part 1 Power train, Part 2 Power train, Part 3 Undercarriage and frame Hydraulic system Work equipment Cab and its attachments Electrical system

SEN02872-01 SEN03366-01 q SEN03367-01 q SEN03368-01 q SEN03369-00 SEN03370-00 SEN03371-00 SEN03372-00 SEN03373-00 SEN03375-00 SEN03376-00

60 Air conditioner Structure, function, testing, adjusting, and troubleshooting

SEN04441-00 SEN04442-00 Q

90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings

SEN02873-02 SEN02875-01 q SEN02874-01

D155A-6

3

SEN02856-04


Table of contents

1

00 Index and foreword Index SEN02856-04 Composition of shop manual....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN02857-02 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard.......................................................................... 9 Handling of electric equipment and hydraulic component........................................................... 11 Handling of connectors newly used for engines.......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN02859-02 Specification dimension drawings ............................................................................................... 2 Specifications .............................................................................................................................. 3 Weight table ................................................................................................................................ 9 Table of fuel, coolant and lubricants ............................................................................................ 12 10 Structure, function and maintenance standard Engine and cooling system SEN02861-01 Radiator, oil cooler....................................................................................................................... 2 Engine mount .............................................................................................................................. 9 Cooling fan pump ........................................................................................................................ 10 Cooling fan motor ........................................................................................................................ 18 Power train, Part 1 SEN02862-01 Power train skeleton.................................................................................................................... 2 Overall drawing of power train unit.............................................................................................. 4 Power train hydraulic piping drawing........................................................................................... 6 Damper, universal joint................................................................................................................ 8 Torque converter, PTO ................................................................................................................ 10 Transmission ............................................................................................................................... 18 Transmission ECMV.................................................................................................................... 34 Main relief valve and torque converter relief valve ...................................................................... 40 Lubricating oil relief valve ............................................................................................................ 42 Scavenging pump........................................................................................................................ 44 Power train and steering lubrication pump .................................................................................. 46 Power train, Part 2 SEN02863-00 Work equipment pump ................................................................................................................ 2 Work equipment cooler bypass valve.......................................................................................... 15 Steering, brake control ................................................................................................................ 16 Steering unit ................................................................................................................................ 18 Steering control valve .................................................................................................................. 32 Steering clutch ECMV, steering brake ECMV ............................................................................. 34 Parking brake solenoid valve ...................................................................................................... 40 Sudden stop prevention valve ..................................................................................................... 42 Final drive.................................................................................................................................... 45 Sprocket ...................................................................................................................................... 50

4

D155A-6


SEN02856-04

Undercarriage and frame SEN02864-00 Track frame ................................................................................................................................. 2 Recoil spring ............................................................................................................................... 4 Idler ............................................................................................................................................. 6 Track roller .................................................................................................................................. 8 Carrier roller ................................................................................................................................ 10 Track shoe................................................................................................................................... 12 Main frame .................................................................................................................................. 18 Suspension ................................................................................................................................. 20 Hydraulic system SEN02865-02 Work equipment hydraulic piping diagram .................................................................................. 2 Work equipment control piping diagram...................................................................................... 6 Work equipment control .............................................................................................................. 8 Hydraulic tank and filter............................................................................................................... 10 Accumulator ................................................................................................................................ 12 PPC valve ................................................................................................................................... 13 Work equipment lock valve ......................................................................................................... 26 Control valve ............................................................................................................................... 28 Work equipment cylinder............................................................................................................. 50 Piston valve................................................................................................................................. 52 Quick drop valve ......................................................................................................................... 54 Self pressure reducing valve....................................................................................................... 55 Work equipment SEN02866-00 Cylinder stay ............................................................................................................................... 2 Blade ........................................................................................................................................... 4 Cutting edge, end bit ................................................................................................................... 6 Ripper.......................................................................................................................................... 8 Cab and its attachments SEN02867-00 Cab mount + ROPS pin............................................................................................................... 2 ROPS cab ................................................................................................................................... 3 ROPS floor .................................................................................................................................. 4 Air conditioner ............................................................................................................................. 5 Electrical system SEN02868-01 Engine control ............................................................................................................................. 2 Engine control system................................................................................................................. 3 Deceleration potentiometer ......................................................................................................... 4 Monitor system............................................................................................................................ 6 Sensors ....................................................................................................................................... 25 Palm command control system ................................................................................................... 28 KOMTRAX system ...................................................................................................................... 31 20 Standard value table Standard service value table SEN03199-00 Standard value table for engine .................................................................................................. 2 Standard value table for machine................................................................................................ 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN03200-01 Tools for testing, adjusting, and troubleshooting ......................................................................... 3 Sketches of special tools............................................................................................................. 7 Measuring engine speed............................................................................................................. 8 Measuring intake air pressure (boost pressure).......................................................................... 10 Measuring exhaust temperature ................................................................................................. 12 Measuring exhaust gas color ...................................................................................................... 14 Adjusting valve clearance ........................................................................................................... 15 Measuring compression pressure ............................................................................................... 16 D155A-6

5

SEN02856-04


Measuring blow-by pressure ....................................................................................................... 18 Measuring engine oil pressure .................................................................................................... 19 Handling fuel system parts .......................................................................................................... 20 Releasing residual pressure from fuel system ............................................................................ 20 Measuring fuel pressure.............................................................................................................. 21 Measuring fuel return rate and fuel leakage................................................................................ 22 Bleeding air from fuel circuit ........................................................................................................ 26 Measuring fuel circuit for leakage................................................................................................ 28 Testing and adjusting alternator belt tension ............................................................................... 29 Testing and adjusting air conditioner compressor belt tension.................................................... 30 Measuring fan speed................................................................................................................... 31 Measuring fan circuit oil pressure................................................................................................ 32 Bleeding air from fan pump ......................................................................................................... 33 Bleeding air from work equipment pump..................................................................................... 34 Adjusting fuel control dial and decelerator pedal......................................................................... 35 Testing and adjusting, Part 2 SEN03201-00 Measuring power train oil pressure ............................................................................................. 3 Adjusting transmission output shaft speed sensor ...................................................................... 11 Simple test procedure for brake performance ............................................................................. 12 Adjusting brake pedal.................................................................................................................. 13 Adjusting parking brake lever ...................................................................................................... 15 Emergency escape method when power train has trouble ......................................................... 17 Adjusting idler clearance ............................................................................................................. 20 Testing and adjusting track shoe tension .................................................................................... 22 Measuring and adjusting work equipment oil pressure ............................................................... 23 Measuring control circuit basic pressure ..................................................................................... 26 Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure) ... 27 Measuring PPC valve output pressure........................................................................................ 28 Adjusting play of work equipment PPC valve.............................................................................. 30 Measuring ripper pin puller solenoid valve output pressure ........................................................ 31 Testing parts which cause hydraulic drift of blade and ripper ...................................................... 32 Measuring internal leakage of work equipment cylinder ............................................................. 33 Releasing residual pressure from work equipment cylinder........................................................ 34 Bleeding air from work equipment cylinder ................................................................................. 34 Adjusting work equipment lock lever ........................................................................................... 35 Adjusting blade............................................................................................................................ 36 Adjusting operator's cab .............................................................................................................. 38 Testing and adjusting, Part 3 SEN03202-02 Special functions of machine monitor (EMMS)............................................................................ 2 Testing and adjusting, Part 4 SEN03203-00 Handling of power supply circuit of engine controller .................................................................. 2 Preparation work for troubleshooting of electrical system........................................................... 3 Pm Clinic ..................................................................................................................................... 5 40 Troubleshooting Failure code table and fuse locations SEN03204-01 Failure codes table ...................................................................................................................... 2 Fuse locations ............................................................................................................................. 8 General information on troubleshooting SEN03205-01 Points to remember when troubleshooting.................................................................................. 2 Sequence of events in troubleshooting ....................................................................................... 3 Check before troubleshooting ..................................................................................................... 4 Classification and procedures for troubleshooting ...................................................................... 5 Information in troubleshooting table ............................................................................................ 8 Connection table for connector pin numbers............................................................................... 10 T-branch box and T-branch adapter table ................................................................................... 46

6

D155A-6


SEN02856-04

Troubleshooting by failure and error codes, Part 1 SEN03206-00 Failure code [1500L0] Transmission clutch: Abnormal ............................................................... 3 Failure code [15SAL1] Forward clutch: Fill high.......................................................................... 4 Failure code [15SALH] Forward clutch: Fill low .......................................................................... 5 Failure code [15SBL1] Reverse clutch: Fill high ......................................................................... 6 Failure code [15SBLH] Reverse clutch: Fill low .......................................................................... 7 Failure code [15SEL1] Speed 1st clutch: Fill high....................................................................... 8 Failure code [15SELH] Speed 1st clutch: Fill low........................................................................ 9 Failure code [15SFL1] Speed 2nd clutch: Fill high...................................................................... 10 Failure code [15SFLH] Speed 2nd clutch: Fill low....................................................................... 11 Failure code [15SGL1] Speed 3rd clutch: Fill high ...................................................................... 12 Failure code [15SGLH] Speed 3rd clutch: Fill low....................................................................... 13 Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON ..................................................................................................................... 14 Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF ................................................................................................................... 16 Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON ..................................................................................................................... 18 Failure code [2202LH] When left steering clutch oil pressure command current is ON, fill signal is OFF ................................................................................................................... 20 Failure code [2300KM] Stall in 1st gear speed............................................................................ 22 Failure code [2301L1] Right brake: Fill high................................................................................ 23 Failure code [2301LH] Right brake: Fill low ................................................................................ 24 Failure code [2302L1] Left brake: Fill high .................................................................................. 25 Failure code [2302LH] Left brake: Fill low................................................................................... 26 Failure code [7RFAKA] ECM HOLD RELAY: Disconnection....................................................... 28 Failure code [AA10NX] Air Cleaner Clogging ............................................................................. 30 Failure code [AB00MA] Battery Charge Abnormal...................................................................... 32 Failure code [B@BAZG] Eng Oil Press Low ............................................................................... 34 Failure code [B@BCNS] Eng Water Overheat............................................................................ 34 Failure code [B@BCZK] Eng Water Level Low........................................................................... 35 Failure code [B@CENS] T/C Oil Overheat ................................................................................. 35 Failure code [B@HANS] Hyd Oil Overheat................................................................................. 36 Failure code [CA111] EMC Critical Internal Failure ..................................................................... 38 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................ 40 Failure code [CA122] Chg (boost) Air Press Sensor High Error ................................................. 42 Failure code [CA123] Chg (boost) Air Press Sensor Low Error .................................................. 44 Failure code [CA131] Throttle Sensor High Error ....................................................................... 46 Failure code [CA132] Throttle Sensor Low Error ........................................................................ 48 Failure code [CA135] Eng Oil Press Sensor High Error.............................................................. 50 Failure code [CA141] Eng Oil Press Sensor Low Error .............................................................. 52 Failure code [CA144] Coolant Temp Sens High Error................................................................. 54 Failure code [CA145] Coolant Temp Sens Low Error ................................................................. 56 Failure code [CA153] Chg (boost) Air Temp Sensor High Error.................................................. 58 Failure code [CA154] Chg (boost) Air Temp Sensor Low Error .................................................. 60 Failure code [CA187] Sens Supply 2 Volt Low Error................................................................... 60 Failure code [CA221] Ambient Press Sens High Error ............................................................... 62 Failure code [CA222] Ambient Press Sens Low Error ................................................................ 64 Failure code [CA227] Sens Supply 2 Volt High Error.................................................................. 66 Troubleshooting by failure and error codes, Part 2 SEN03207-01 Failure code [CA234] Eng Overspeed ........................................................................................ 3 Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................ 4 Failure code [CA263] Fuel Temp Sensor High Error................................................................... 6 Failure code [CA265] Fuel Temp Sensor Low Error.................................................................... 8 Failure code [CA271] PCV1 Short Error ..................................................................................... 9 Failure code [CA272] PCV1 Open Error ..................................................................................... 10 Failure code [CA273] PCV2 Short Error ..................................................................................... 11 Failure code [CA274] PCV2 Open Error ..................................................................................... 12 D155A-6

7

SEN02856-04


Failure code [CA322] Inj #1 Open/Short Error ............................................................................ 14 Failure code [CA323] Inj #5 Open/Short Error ............................................................................ 16 Failure code [CA324] Inj #3 Open/Short Error ............................................................................ 18 Failure code [CA325] Inj #6 Open/Short Error ............................................................................ 20 Failure code [CA331] Inj #2 Open/Short Error ............................................................................ 22 Failure code [CA332] Inj #4 Open/Short Error ............................................................................ 24 Failure code [CA342] Calibration Code Incompatibility ............................................................... 26 Failure code [CA351] Injectors Drive Circuit Error ...................................................................... 28 Failure code [CA352] Sens Supply 1 Volt Low Error................................................................... 30 Failure code [CA386] Sens Supply 1 Volt High Error .................................................................. 32 Failure code [CA441] Battery Voltage Low Error......................................................................... 34 Failure code [CA442] Battery Voltage High Error ........................................................................ 34 Failure code [CA449] Rail Press Very High Error........................................................................ 35 Failure code [CA451] Rail Press Sensor High Error ................................................................... 36 Failure code [CA452] Rail Press Sensor Low Error .................................................................... 38 Failure code [CA553] Rail Press High Error................................................................................ 38 Failure code [CA554] Rail Press Sensor In Range Error ............................................................ 39 Failure code [CA559] Rail Press Low Error................................................................................. 40 Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................... 44 Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................... 46 Failure code [CA757] All Continuous Data Lost Error ................................................................. 46 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 48 Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................... 50 Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................. 52 Failure code [CA2186] Throt Sens Sup Volt Low Error ............................................................... 54 Failure code [CA2249] Rail Press Very Low Error ...................................................................... 54 Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................. 55 Failure code [CA2556] Grid Htr Relay Volt High Error ................................................................ 56 Failure code [D110KA] Battery relay: Disconnection................................................................... 58 Failure code [D110KB] Battery Relay: Drive Short Circuit........................................................... 60 Failure code [D130KA] Neutral relay: Disconnection .................................................................. 62 Failure code [D130KB] Neutral relay: Short circuit...................................................................... 64 Failure code [D161KA] Back-up alarm relay: Disconnection....................................................... 66 Failure code [D161KB] Back-up alarm relay: Short circuit .......................................................... 68 Failure code [D190KA] ACC signal relay: Disconnection............................................................ 70 Failure code [D190KB] ACC signal relay: Short circuit ............................................................... 72 Troubleshooting by failure and error codes, Part 3 SEN03208-00 Failure code [D5ZKKX] Throttle Dial: Out of normal range ......................................................... 4 Failure code [DAFRKR] CAN Disconnection (Monitor) ............................................................... 6 Failure code [DB2RKR] CAN Disconnection (Engine controller) ................................................ 8 Failure code [DB90KR] PT controller: Can communication lost.................................................. 10 Failure code [DBE0KK] PT controller: Source voltage reduction ................................................ 12 Failure code [DBE0KT] PT controller: Abnormality in controller.................................................. 14 Failure code [DBE6KK] PT controller: Source voltage reduction ................................................ 16 Failure code [DBE7KK] PT controller: Source voltage reduction ................................................ 18 Failure code [DBE9KQ] PT controller: Type select signal ........................................................... 20 Failure code [DD12KA] Shift up Sw: Disconnection.................................................................... 22 Failure code [DD12KB] Shift up Sw: Short circuit ....................................................................... 24 Failure code [DD13KA] Shift down Sw: Disconnection ............................................................... 26 Failure code [DD13KB] Shift down Sw: Short circuit................................................................... 28 Failure code [DD14KA] Parking lever Sw: Disconnection ........................................................... 30 Failure code [DD14KB] Parking lever Sw: Short circuit............................................................... 32 Failure code [DDDDKA] Back up brake Sw: Disconnection........................................................ 34 Failure code [DDDDKB] Back up brake Sw: Short circuit ........................................................... 36 Failure code [DDDDKX] Back up brake Sw: Signal mismatch .................................................... 38 Failure code [DGT1KA] T/C oil temp sensor: Abnormal.............................................................. 40 Failure code [DGT1KX] T/C oil temp sensor: Abnormal.............................................................. 42 Failure code [DH21KA] Weq pressure sensor: Disconnection .................................................... 44

8

D155A-6


SEN02856-04

Failure code [DH21KB] Weq pressure sensor: Short circuit ....................................................... 46 Failure code [DK10KX] Fuel control Dial: Out of normal range................................................... 48 Failure code [DK30KA] ST lever 1: Disconnection...................................................................... 50 Failure code [DK30KB] ST lever 1: Short circuit ......................................................................... 52 Failure code [DK30KX] ST lever 1: Out of normal range ............................................................ 54 Failure code [DK30KZ] RL lever: Disconnection or short circuit ................................................. 54 Failure code [DK30L8] ST lever: Signal mismatch...................................................................... 55 Failure code [DK31KA] ST lever 2: Disconnection...................................................................... 56 Failure code [DK31KB] ST lever 2: Short circuit ......................................................................... 58 Failure code [DK40KA] Brake potentiometer: Disconnection...................................................... 60 Failure code [DK40KB] Brake potentiometer: Short circuit ......................................................... 62 Failure code [DK55KX] FR lever: Out of normal range ............................................................... 64 Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................. 64 Failure code [DK55L8] FR lever: Signal mismatch ..................................................................... 65 Failure code [DK56KA] FR lever 1: Disconnection ..................................................................... 66 Failure code [DK56KB] FR lever 1: Short circuit ......................................................................... 68 Troubleshooting by failure and error codes, Part 4 SEN03209-00 Failure code [DK57KA] FR lever 2: Disconnection ..................................................................... 4 Failure code [DK57KB] FR lever 2: Short circuit ......................................................................... 6 Failure code [DKH1KA] Pitch angle sensor: Disconnection........................................................ 8 Failure code [DKH1KB] Pitch angle sensor: Short circuit ........................................................... 10 Failure code [DLT3KA] T/M out-speed sensor: Disconnection.................................................... 12 Failure code [DLT3KB] T/M out-speed sensor: Abnormal........................................................... 13 Failure code [DW7BKA] Fan rev EPC: Disconnection ................................................................ 14 Failure code [DW7BKB] Fan rev EPC: Short circuit.................................................................... 15 Failure code [DWN3KA] Ssp solenoid: Disconnection................................................................ 16 Failure code [DWN3KB] Ssp solenoid: Short circuit ................................................................... 18 Failure code [DWN3KY] Ssp solenoid: Short circuit ................................................................... 20 Failure code [DWN5KA] Fan pump solenoid: Disconnection...................................................... 22 Failure code [DWN5KB] Fan pump solenoid: Short circuit ......................................................... 23 Failure code [DXH4KA] 1st clutch ECMV: Disconnection ........................................................... 24 Failure code [DXH4KB] 1st clutch ECMV: Short circuit............................................................... 25 Failure code [DXH4KY] 1st clutch ECMV: Short circuit............................................................... 26 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection.......................................................... 27 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................. 28 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................. 29 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection........................................................... 30 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit .............................................................. 31 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit .............................................................. 32 Failure code [DXH7KA] R clutch ECMV: Disconnection ............................................................. 33 Failure code [DXH7KB] R clutch ECMV: Short circuit................................................................. 34 Failure code [DXH7KY] R clutch ECMV: Short circuit................................................................. 35 Failure code [DXH8KA] F clutch ECMV: Disconnection.............................................................. 36 Failure code [DXH8KB] F clutch ECMV: Short circuit ................................................................. 37 Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................. 38 Failure code [DXH9KA] Right steering clutch ECMV disconnection ........................................... 40 Failure code [DXH9KB] Right steering clutch ECMV short circuit............................................... 42 Failure code [DXH9KY] Right steering clutch ECMV hot short ................................................... 44 Failure code [DXHAKA] Left steering clutch ECMV disconnection ............................................. 46 Failure code [DXHAKB] Left steering clutch ECMV short circuit................................................. 48 Failure code [DXHAKY] Left steering clutch ECMV hot short ..................................................... 50 Failure code [DXHBKA] Right brake ECMV: Disconnection ....................................................... 52 Failure code [DXHBKB] Right brake ECMV: Short circuit ........................................................... 54 Failure code [DXHBKY] Right brake ECMV: Short circuit ........................................................... 56 Failure code [DXHCKA] Left brake ECMV: Disconnection.......................................................... 58 Failure code [DXHCKB] Left brake ECMV: Short circuit ............................................................. 60 Failure code [DXHCKY] Left brake ECMV: Short circuit ............................................................. 62 Failure code [DXJ4KA] Weq lock Sol.: Disconnection ................................................................ 64 Failure code [DXJ4KB] Weq lock Sol.: Short circuit .................................................................... 65

D155A-6

9

SEN02856-04


Troubleshooting of electrical system (E-mode) SEN03210-01 Before carrying out troubleshooting for electrical system............................................................ 3 Information in troubleshooting table ............................................................................................ 7 E-1 When starting switch turned ON, machine monitor displays nothing.................................... 8 E-2 When starting switch turned ON (before starting engine), basic check item lights up .......... 10 E-3 Engine does not start (Engine does not turn) ....................................................................... 12 E-4 Preheater does not operate .................................................................................................. 15 E-5 Precaution item lights up while engine is running................................................................. 18 E-6 Emergency stop item lights up while engine is running ........................................................ 20 E-7 Engine coolant temperature gauge does not indicate normally............................................ 22 E-8 Fuel level gauge does not indicate normally......................................................................... 23 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally....................... 25 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ............................ 26 E-11 Contents of display by machine monitor are different from applicable machine ................. 28 E-12 Machine monitor does not display some items................................................................... 28 E-13 Function switch does not work............................................................................................ 28 E-14 Operation mode does not change ...................................................................................... 29 E-15 Gearshift mode does not change........................................................................................ 29 E-16 Customize function does not operate normally................................................................... 30 E-17 Customize memory function does not normally.................................................................. 30 E-18 Alarm buzzer cannot be stopped ........................................................................................ 31 E-19 Air conditioner does not operate normally (including air conditioner fault history).............. 32 E-20 When starting switch is turned OFF, service meter is not displayed................................... 46 E-21 Machine monitor cannot be set in service mode ................................................................ 46 E-22 Ripper pin puller cylinder does not operate ........................................................................ 48 E-23 Backup alarm does not sound or does not stop ................................................................. 50 E-24 Headlamp, rear lamp, and ripper point lamp do not light up............................................... 52 E-25 Windshield wiper and window washer do not operate........................................................ 57 E-26 KOMTRAX terminal does not operate normally.................................................................. 73 E-27 Fan does not reverse.......................................................................................................... 74 E-28 Gear cannot be shifted ....................................................................................................... 76 E-29 Electric priming pump does not operate or does not stop automatically ............................ 78 Troubleshooting of hydraulic and mechanical system (H-mode) SEN03211-00 Information in troubleshooting table ............................................................................................ 3 H-1 Power is low (Drawbar pull is low)........................................................................................ 4 H-2 Machine does not travel (at 2nd or 3rd gear speed)............................................................. 5 H-3 Machine does not start at any gear speed ........................................................................... 6 H-4 Machine can travel only forward or in reverse...................................................................... 7 H-5 When gear speed or travel direction is changed, time lag is large ....................................... 8 H-6 Steering is not possible......................................................................................................... 9 H-7 Steering is possible only on one side ................................................................................... 10 H-8 Steering overrun occurs........................................................................................................ 11 H-9 Brake does not work............................................................................................................. 12 H-10 Power train oil is overheated .............................................................................................. 13 H-11 Speed of all work equipment is low..................................................................................... 14 H-12 No work equipment moves ................................................................................................. 15 H-13 Blade lift speed or power is low .......................................................................................... 16 H-14 Blade tilt speed or power is low .......................................................................................... 17 H-15 Ripper lift speed or power is low......................................................................................... 18 H-16 Ripper tilt speed or power is low......................................................................................... 19 H-17 Hydraulic drift of blade lift is large....................................................................................... 19 H-18 Hydraulic drift of blade tilt is large....................................................................................... 20 H-19 Hydraulic drift of ripper lift is large ...................................................................................... 20 H-20 Ripper pin puller cylinder does not operate ........................................................................ 21 H-21 Abnormal sound comes out from around work equipment pump ....................................... 22 H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats) ................................... 23

10

D155A-6


SEN02856-04

Troubleshooting of engine (S-mode) SEN03212-01 Method of using troubleshooting chart ........................................................................................ 3 S-1 Starting performance of engine is poor................................................................................. 6 S-2 Engine does not start............................................................................................................ 7 S-3 Engine does not pick up smoothly........................................................................................ 10 S-4 Engine stops during operation .............................................................................................. 11 S-5 Engine does not rotate smoothly .......................................................................................... 12 S-6 Engine lack output (or lacks power) ..................................................................................... 13 S-7 Exhaust gas is black (incomplete combustion)..................................................................... 14 S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 15 S-9 Oil becomes dirty quickly...................................................................................................... 16 S-10 Fuel consumption is excessive........................................................................................... 17 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 18 S-12 Oil pressure drops .............................................................................................................. 19 S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 20 S-14 Coolant temperature becomes too high (Overheating) ...................................................... 21 S-15 Abnormal noise is made ..................................................................................................... 22 S-16 Vibration is excessive ......................................................................................................... 23 S-17 Air cannot be bled from fuel circuit ..................................................................................... 24 50 Disassembly and assembly General information on disassembly and assembly SEN03366-01 How to read this manual ............................................................................................................. 2 Coating materials list................................................................................................................... 4 Special tool list ............................................................................................................................ 7 Sketches of special tools............................................................................................................. 13 Engine and cooling system SEN03367-01 Removal and installation of fuel supply pump assembly............................................................. 2 Removal and installation of fuel injector assembly ..................................................................... 7 Removal and installation of cylinder head assembly .................................................................. 13 Removal and installation of radiator assembly............................................................................ 24 Removal and installation of aftercooler assembly ....................................................................... 27 Removal and installation of engine assembly ............................................................................. 30 Removal and installation of engine hood assembly .................................................................... 34 Removal and installation of engine front seal ............................................................................. 36 Removal and installation of engine rear seal .............................................................................. 40 Removal and installation of fuel tank assembly .......................................................................... 45 Removal and installation of fan drive assembly .......................................................................... 47 Removal and installation of fan motor assembly......................................................................... 48 Power train, Part 1 SEN03368-01 Removal and installation of damper assembly............................................................................ 2 Disassembly and assembly of damper assembly ....................................................................... 5 Removal and installation of power train unit assembly ............................................................... 11 Disconnection and connection of power train unit assembly ...................................................... 16 Power train, Part 2 SEN03369-00 Disassembly and assembly of PTO assembly ............................................................................ 2 Disassembly and assembly of torque converter assembly ......................................................... 9 Disassembly and assembly of transmission assembly ............................................................... 14 Disassembly and assembly of steering case assembly .............................................................. 31 Power train, Part 3 SEN03370-00 Removal and installation of final drive assembly ........................................................................ 2 Disassembly and assembly of final drive assembly .................................................................... 4 Undercarriage and frame SEN03371-00 Removal and installation of track frame assembly ...................................................................... 3 Removal and installation of idler assembly ................................................................................. 6 Disassembly and assembly of idler assembly............................................................................. 7 D155A-6

11

SEN02856-04


Removal and installation of recoil spring assembly..................................................................... 11 Disassembly and assembly of recoil spring assembly ................................................................ 12 Removal and installation of track roller assembly ....................................................................... 17 Disassembly and assembly of track roller assembly................................................................... 18 Removal and installation of carrier roller assembly..................................................................... 20 Disassembly and assembly of carrier roller assembly ................................................................ 21 Removal and installation of pivot shaft assembly........................................................................ 25 Spreading and installation of track shoe assembly ..................................................................... 27 General disassembly and assembly of track shoe ...................................................................... 30 Disassembly and assembly of 1 link in field ................................................................................ 44 Disassembly and assembly of master link .................................................................................. 48 Removal and installation of equalizer bar assembly ................................................................... 51 Disassembly and assembly of equalizer bar assembly............................................................... 53 Removal and installation of segment teeth ................................................................................. 55 Hydraulic system SEN03372-00 Removal and installation of hydraulic tank assembly .................................................................. 2 Removal and installation of hydraulic pump assembly................................................................ 4 Disassembly and assembly of hydraulic cylinder assembly........................................................ 7 Work equipment SEN03373-00 Removal and installation of blade assembly ............................................................................... 2 Disassembly and assembly of multi-shank ripper ....................................................................... 4 Cab and its attachments SEN03375-00 Removal and installation of operator's cab assembly ................................................................. 2 Removal and installation of operator's cab glass (Stuck glass)................................................... 4 Removal and installation of operator's cab and floor frame assembly ........................................ 13 Electrical system SEN03376-00 Removal and installation of air conditioner unit assembly........................................................... 2 Removal and installation of engine controller assembly ............................................................. 4 Removal and installation of power train controller assembly ...................................................... 5 Removal and installation of KOMTRAX assembly ...................................................................... 5 60 Air conditioner Structure, function, testing, adjusting, and troubleshooting SEN04442-00 Structure and function ................................................................................................................. 3 Air conditioner component ....................................................................................................... 3 Configuration and function of refrigerating cycle ..................................................................... 4 Outline of refrigerating cycle .................................................................................................... 5 Air conditioner unit ................................................................................................................... 7 Functions of major components in the air conditioner unit ...................................................... 9 Control plate ............................................................................................................................ 11 Compressor ............................................................................................................................. 13 Condenser ............................................................................................................................... 14 Receiver drier .......................................................................................................................... 15 Testing, adjusting and troubleshooting ........................................................................................ 17 Caution about refrigerant ......................................................................................................... 17 Troubleshooting procedure ...................................................................................................... 18 Block diagram .......................................................................................................................... 19 Circuit diagram and arrangement of connector pins................................................................ 20 Detail of air conditioner unit ..................................................................................................... 22 Part and connector locations ................................................................................................... 24 Testing air leakage (duct)......................................................................................................... 31 Testing with self-diagnosis function ......................................................................................... 33 Testing temperature control ..................................................................................................... 36 Testing vent (mode) changeover ............................................................................................. 39 Testing Recirc/Fresh changeover ............................................................................................ 42 Testing inner sensor................................................................................................................. 44

12

D155A-6


SEN02856-04

Testing evaporator temperature sensor................................................................................... Testing sunlight sensor ............................................................................................................ Testing (dual) pressure switch for refrigerant .......................................................................... Testing relays and diodes ........................................................................................................ Troubleshooting chart 1 ........................................................................................................... Troubleshooting chart 2 ........................................................................................................... Troubleshooting for electrical system (E mode) ...................................................................... E-1 Power supply system (Air conditioner does not operate) .............................................. E-2 Compressor system (Air is not cooled) ......................................................................... E-3 Blower motor system (No air comes out or air flow is abnormal) .................................. E-4 Temperature cannot be controlled................................................................................. E-5 Vent (mode) cannot be changed over ........................................................................... E-6 Recirc/Fresh air cannot be changed over ..................................................................... Troubleshooting with gauge pressure...................................................................................... Connection of service tool ....................................................................................................... Precautions for connecting air conditioner piping.................................................................... Handling of compressor oil ...................................................................................................... 1. Control of compressor oil ................................................................................................ 2. Adding of compressor oil ................................................................................................ 3. Compressor replacement................................................................................................ 4. Applying compressor oil for O-ring..................................................................................

45 48 49 51 53 54 57 58 62 65 70 72 74 76 78 79 80 80 80 81 81

90 Diagrams and drawings Hydraulic diagrams and drawings SEN02875-01 Power train hydraulic circuit diagram .......................................................................................... 3 Hydraulic circuit diagram Serial No.: 85001 – 85024 .................................................................. 5 Hydraulic circuit diagram Serial No.: 85025 and up .................................................................... 7 Electrical diagrams and drawings SEN02874-01 Electrical circuit diagram (Cab spec.).......................................................................................... 3 Electrical circuit diagram (Cab less spec.) .................................................................................. 5 Electrical circuit diagram for inside cab....................................................................................... 7 Connectors table and arrangement drawing ............................................................................... 9

D155A-6

13

SEN02856-04


D155A-6 Bulldozer Form No. SEN02856-04

© 2008 KOMATSU All Rights Reserved Printed in Japan 06-08 (02)

14

D155A-6

SEN02857-02


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36

D155A-6

1

SEN02857-02


Safety notice

(Rev. 2008/02) 1

Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.

2

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)

8) 9)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

8

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

Precautions against work which you are not used to or you are used to too much

D155A-6


2.

3.

SEN02857-02

Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

6)

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

11)

D155A-6

7)

8)

9) 10)

12)

13) 14) 15)

16)

When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

3

SEN02857-02

4.

4

Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.


8)

When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

D155A-6


If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN02857-02

13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

q

5.

6.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.

D155A-6

7.

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

a

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

5

SEN02857-02

8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)

6

00 Index and foreword a

Example of O-ring (Fitted to every joint of hoses and tubes)

a

For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.

D155A-6


How to read the shop manual q q q

1.

SEN02857-02

1

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

2.

Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

D155A-6

7

SEN02857-02

3.

4.


Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q

Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)

q

Revisions Revised brochures are shown in the shop manual composition table.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol

Item

k

Safety

a

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

4

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

3

Tightening torque

2

Coat

5

Oil, coolant

6

Drain

Remarks Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

5.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

8

D155A-6


SEN02857-02

Explanation of terms for maintenance standard

1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.

Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q

Example: Standard size 120

Tolerance –0.022 –0.126

a

The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)

q

Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

q

Example: Standard size 60

D155A-6

Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

9

SEN02857-02

2.

Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.


5.

q

3.

Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

4.

Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.

10

Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

6.

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

D155A-6


Handling of electric equipment and hydraulic component

SEN02857-02

1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.

Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)

D155A-6

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.

11

SEN02857-02

12

3)

Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

4)

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

5)

Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.


D155A-6


3.

SEN02857-02

Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q

D155A-6

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

q

When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.

3]

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

13

SEN02857-02

2)

14


Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

D155A-6


3)

D155A-6

Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks

SEN02857-02

q

Disconnection

q

Connection (Example of incomplete setting of (a))

15

SEN02857-02

4)

16


Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

D155A-6


4.

Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

5.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

D155A-6

SEN02857-02

17

SEN02857-02


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

Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.

2.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

3.

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.

4.

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

18

D155A-6


5.

Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

6.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7.

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

D155A-6

SEN02857-02

19

SEN02857-02


Handling of connectors newly used for engines a

1.

Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

2.

1

Pull lock type (PACKARD-2) 95 – 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

q

Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

20

D155A-6


3.

SEN02857-02

Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

q

114 engine

q

107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)

3)

While pressing lock (D), pull out connector (4) in the direction of the arrow.

107 engine

a

2)

D155A-6

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

21

SEN02857-02

q

4)

95, 125 – 170, 12V140 engine While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)


4.

Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

q

1)

Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

2)

Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.

Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.

22

D155A-6


SEN02857-02

How to read electric wire code a

1

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile

Symbol AV

AVS

Heat-resistant low-voltAEX age wire for automobile

D155A-6

Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

23

SEN02857-02

2.


Dimensions

(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

8

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“f” of nominal No. denotes flexible”.

24

D155A-6


3.

SEN02857-02

Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White. 4.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others

D155A-6

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

–

R B R D Y G L

–

–

WG

–

–

–

–

–

–

–

–

–

– –

–

–

–

–

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

YW GL

– –

Gr Br – –

25

SEN02857-02


Precautions when carrying out operation

1

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

a

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)

26

Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30

27

07049-02734

27

22.5

34

D155A-6


2. q q q q q q q q q q q q q

a

a 3.

SEN02857-02

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

D155A-6

27

SEN02857-02

4)

5)

28


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

D155A-6


SEN02857-02

Method of disassembling and connecting push-pull type coupler k k

1

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1 1.

Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.

2.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

D155A-6

29

SEN02857-02


Type 2 1.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)

2.

Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

30

D155A-6


SEN02857-02

Type 3 1.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

2.

Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

D155A-6

31

SEN02857-02


Standard tightening torque table 1.

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a

The following table corresponds to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630

kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12

32

1

Width across flats mm 10 13 14 27

Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B

D155A-6


2.

Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

3.

Width across flats mm 14 17 22

Tightening torque Nm 59 – 74 98 – 123 235 – 285

kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5

Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Nominal No. 02 03,04 05,06 10,12 14

4.

SEN02857-02

Thread diameter mm 14 20 24 33 42

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

D155A-6

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

33

SEN02857-02

5.


Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}

Nominal No. of hose

Width across flats

02

19

03 04 05 06 (10) (12) (14)

6.

22 24 27 32 36 41 46 55

Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Target

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42

Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).

Outer diameter of pipe (mm)

Width across flats (mm)

8 10 12 15 (16) 22 (20)

19 22 24 (27) 30 (32) 36

Tightening torque Nm {kgm} Range

Target

14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}

15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}

Face seal Nominal No. – Thread diameter Number of threads, (mm) type of thread (Reference) 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2

Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification. 7.

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts

Thread size mm 6 8 10 12 14

34

Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —

D155A-6


8.

Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14

9.

SEN02857-02

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1

D155A-6

Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

35

SEN02857-02


Conversion table

1

Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.

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

2.

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

Millimeters to inches

(A)

36

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

D155A-6


SEN02857-02

Millimeters to inches

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

D155A-6

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

37

SEN02857-02


Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

38

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

D155A-6


SEN02857-02

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

D155A-6

39

SEN02857-02


Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

°F

°C

°F

°C

°F

°C

1°C = 33.8°F °F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

177.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

40

D155A-6


D155A-6

SEN02857-02

41

SEN02857-02


D155A-6 BULLDOZER Form No. SEN02857-02


42

D155A-6

SEN02859-02


D155A-6

Machine model

Serial number

D155A-6

85001 and up

01 Specification

1

Specification and technical data Specification dimension drawings ................................................................................................................... 2 Specifications .................................................................................................................................................. 3 Weight table .................................................................................................................................................... 9 Table of fuel, coolant and lubricants.............................................................................................................. 12

D155A-6

1

SEN02859-02

01 Specification

Specification dimension drawings

Item

2

Unit

Semi U-tilt dozer + Variable multiple shank ripper

Sigma-tilt dozer + Variable multiple shank ripper

A

Overall length

mm

8,325

8,275

B

Overall height (with ROPS)

mm

3,510

3,510

C

Overall width

mm

4,130

4,060

Item

Unit

Semi U-tilt dozer + Variable giant ripper

Sigma-tilt dozer + Variable giant ripper

A

Overall length

mm

8,680

8,630

B

Overall height (with ROPS)

mm

3,510

3,510

C

Overall width

mm

4,130

4,060

D155A-6

01 Specification

SEN02859-02

Specifications Machine model

D155A-6

Serial number

85001 and up

Weight

• Bare tractor • With semi U-tilt dozer + variable giant ripper + ROPS cab + air conditioner + 560mm HD shoe + side cover

31,200 kg

• With multi ripper

42,080

Minimum turning radius (F1, center of machine)

mm

2.1

Gradeability

deg.

30

Stability (front, rear, left, right)

deg.

35

D155A-6

Forward Reverse

Transmission speed ranges Overall height Overall width Overall length Ground pressure

Performance

1st

Dimensions

41,700

2nd 3rd (low speed)

3.9 km/h

5.7 7.5

3rd

11.4

1st

4.7

2nd 3rd (low speed)

km/h

6.8 9.2

3rd

13.7

• Bare tractor

86.73 {0.88}

• With semi U-tilt dozer + variable giant ripper + ROPS cab + air conditioner + 560mm HD shoe + side cover

kPa {kg/cm2}

• With multi ripper

115.13 {1.17}

Bare tractor With semi U-tilt dozer + tractor

113.97 {1.16}

4,875 mm

6,225

With semi U-tilt dozer + variable giant ripper

8,680

Bare tractor

2,765

With semi U-dozer + tractor

mm

4,130

With Sigma-tilt dozer + variable multi-shank ripper

4,060

To blade lift cylinder

3,510

To top of cab With ROPS cab installed

mm

2,210 3,395

3

Dimensions

SEN02859-02

01 Specification

Machine model

D155A-6

Serial number

85001 and up

Track gauge

2,140

Length of track on ground

3,150

Track shoe width (Standard)

mm

Minimum ground clearance (To bottom surface of undercover)

500

Name

SAA6D140E-5 4-cycle, water-cooled, in-line, vertical type, direct injection, with turbocharger, aftercooler

Type of engine No. of cylinders - Bore x Stroke

mm

6 – 140 x 165

l {cc}

15.24 {15,240}

Flywheel horsepower

kW {HP}/rpm

239 {320}/1,900

Max. torque

Nm {kgm}/rpm

1,834 {187}/1,300

Max. speed at no load

rpm

2,100

Min. speed at no load

rpm

740

g/kWh {g/HPh}

193 {142}

Performance

Engine

Piston displacement

Min. fuel consumption ratio Starting motor Alternator Battery Radiator core type

Power train system

Torque converter

4

560

24V, 11kW 24V, 50A 12V, 136Ah x 2 Rectangle wave fin 3-element, 1-stage, 2-phase

Transmission

Planetary gear, multiple disc clutch, hydraulically actuated, (electrically type) force-feed lubrication gear pump, forward 3-speed, reverse 3-speed, electrically actuated type

Bevel gear shaft

Spiral bevel gear, force-feed lubrication gear pump

Steering clutch

Wet type, multiple disc clutch type, springboosted type, hydraulic actuation type (manual type), brake linkage type

Steering brake

Wet type, multiple disc clutch type, springboosted type, hydraulic actuation type (foot operation, manual type), clutch linkage type

Final drive

Spur gear 1-stage, planetary gear 1-stage, splash type lubrication

D155A-6

Undercarriage

01 Specification

SEN02859-02

Machine model

D155A-6

Serial number

85001 and up

Suspension

Rigid, balancing beam type

Carrier roller

2 each side

Track roller

7 each side Assembly type, single grouser, 41 each side, pitch: 228.6 mm

Track shoe (shoe width: 560 mm)

Lubrication pump + power train (tandem)

Gear type (SAR(3)100 + (2)40) 85001 – 85024 Gear type (SAR(4) + 125) 85025 and up Gear type (SAR(3) + 125)

Scavenging pump (tandem)

Hydraulic pump

MPa {kg/cm2}

Variable swash plate type (HPV112) Max. delivery pressure: 27.5 {280}

l/min/rpm

Theoretical delivery: 216/2,250 1+1+2 tandem spool type, hydraulically assisted type

Control valve

Variable multi-shark ripper type • For ripper tilt

+ Ripper tilt

• For ripper lift

+ Ripper lift

• For blade lift

+ (Blade lift + blade tilt)

• For blade tilt

D155A-6

Dimensions of blade tilt Dimensions of blade tilt Dimensions of blade lift (For semi U-dozer) (For sigma-tilt dozer)

Hydraulic cylinder

Work equipment hydraulic system

Type

Reciprocal, piston type

Cylinder bore

mm

110

Piston rod outer diameter

mm

75

Max. piston stroke

mm

1,404

Max. distance between pins

mm

2,093

Min. distance between pins

mm

687.5

Cylinder bore

mm

160


mm

90

Max. piston stroke

mm

205


mm

1,395


mm

1,190

Cylinder bore

mm

160


mm

90

Max. piston stroke

mm

210


mm

1,475


mm

1,265

5

01 Specification

D155A-6

Serial number

85001 and up

Dimensions of variable Dimensions of variable Dimensions of blade giant ripper tilt cylinder multi ripper lift cylinder (For sigma-tilt dozer tilt and pitch)

Machine model

Cylinder bore

mm

160


mm

90

Max. piston stroke

mm

165


mm

1,430


mm

1,265

Cylinder bore

mm

180


mm

100

Max. piston stroke

mm

565


mm

1,730


mm

1,165

Cylinder bore

mm

180


mm

100

Max. piston stroke

mm

630


mm

1,795


mm

1,165

Dimensions of ripper tilt

Hydraulic cylinder

Work equipment hydraulic system

SEN02859-02

Cylinder bore

mm

200


mm

110

Max. piston stroke

mm

605


mm

1,815


mm

1,210

Fan drive system

Hydraulic tank

6

Box type (control valve externally installed)

Cooling fan pump

MPa {kg/cm2} l/min

Variable swash plate (LPV45) Max. delivery pressure: 31.9 {325} Theoretical delivery pressure: 103/2,296

Cooling fan motor

MPa {kg/cm2}

Fixed swash plate (LMF65) Max. delivery pressure: 31.9 {325}

D155A-6

01 Specification

SEN02859-02

Machine model

D155A-6

Serial number

85001 and up Hydraulic sigma-tilt dozer Hydraulic semi U-tilt dozer Hydraulic U-tilt dozer

Type

D155A-6

Performance Dimensions Performance Dimensions Performance Dimensions

Semi U-tilt dozer Full U-dozer

Work equipment

Sigma tilt dozer

Blade support method

Brace type (right tilt cylinder)

Blade lifting height (from ground level)

mm

1,311

Blade lowering depth (from ground level)

mm

627

Max. blade tilt

mm

1,000

Blade cutting angle variation

deg.

±5

Blade capacity (SAE)

m3

9.4

Blade width

mm

4,060

Blade height

mm

1,850

Blade cutting angle

deg.

46


mm

1,250


mm

590

Max. blade tilt

mm

935


deg.

±6


m3

9.4

Blade width

mm

4,130

Blade height

mm

1,790

Blade cutting angle

deg.

52


mm

1,250


mm

590

Max. blade tilt

mm

970


deg.

±6


m3

11.9

Blade width

mm

4,225

Blade height

mm

1,790

Blade cutting angle

deg.

52

7

8

Dimensions Performance Dimensions Performance

Variable multi-shank ripper Variable giant ripper

Work equipment

SEN02859-02

01 Specification

Machine model

D155A-6

Serial number

85001 and up

Max. digging depth

mm

835

Max. lifting height

mm

890

Ripping angle of point

deg.

30 – 70

Max. beam width

mm

2,320

Shank positions

No. of holes

2

Max. digging depth

mm

1,370

Max. lifting height

mm

900

Ripping angle of point

deg.

30 – 70

Max. beam width

mm

1,520

Shank positions

No. of holes

4

D155A-6

01 Specification

SEN02859-02

Weight table

k This weight table is for reference in handling or transporting components. Machine model

D155A-6

Serial number

85001 and up

Engine, damper assembly

1,900

• Engine assembly

1,725

• Damper assembly

120

• Universal joint

18

• Engine mount parts (wiring)

3

Radiator assembly (including built-in oil cooler hydraulic cooler and codenser)

333

Air flow control grid

81

Fuel tank assembly (when empty)

383

Fuel tank assembly (when full)

913

Power train unit assembly

2,412

• Torque converter, PTO assembly

410

• Transmission assembly

634

• C & B assembly • Brake valve assembly • Power train filter assembly

1,038 63 16.5

• Scavenging pump

20

• Power train, lubrication pump

28

• Hydraulic pump

145

Final drive assembly Sprocket teeth

1,395 x 2 (12 x 9) x 2

Hull frame assembly

4,440

Track group assembly (each side)

3,900

• Track frame

1,607

• Idler assembly

458

• Recoil spring assembly

449

• Track roller assembly (single flange x1) (double flange x1) • Carrier roller assembly

D155A-6

112 x 2 124 x 5 48 x 2

9

SEN02859-02

01 Specification

Machine model

D155A-6

Serial number

85001 and up

Track shoe assembly (560 mm, wet type)

2,280 x 2

Pivot shaft assembly (Left)

126

Pivot shaft assembly (Right)

142

Equalizer bar

231

Hydraulic tank assembly (including hydraulic filter)

99

Control valve (Blade lift + blade tilt + ripper lift + ripper tilt + steering)

104

Engine underguard

248

Transmission underguard

285

Operatorís seat

68

Sigma tilt dozer assembly

5,364 (Standard 4,937)

• Blade

3,200 (Standard 2,929)

• Straight frame

1,687 (Standard 1,531)

• Tilt brace

97 x 1

• Center brace

250 x 1

• Tilt cylinder assembly

130

Semi U-tilt dozer assembly

5,623 (Standard 4,962)

• Blade

3,459 (Standard 2,954)

• Straight frame

1,687 (Standard 1,531)

• Tilt brace

97 x 1

• Center brace

250 x 1


130

Blade lift cylinder assembly

187 x 2

Multi-shank ripper assembly

4,330

• Bracket, beam, arm

2,300

• Shank

266 x 3

• Lift cylinder assembly

184 x 1


252 x 1

10

D155A-6

01 Specification

SEN02859-02

Machine model

D155A-6

Serial number

85001 and up

Giant ripper assembly

3,950

• Bracket, beam, arm

2,975

• Shank

446 x 1

• Lift cylinder assembly

188 x 1


252 x 1

• Pin puller cylinder assembly

7

Cab assembly

410

Dashboard

54

Floor frame (including air conditioner unit)

611

Side cover

20

Air conditioner unit assembly

10

D155A-6

11

SEN02859-02

01 Specification

Table of fuel, coolant and lubricants a

12

For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.

D155A-6

01 Specification

SEN02859-02

Unit: l Engine oil Power train pan case

Damper case

Hydraulic system Fainal drive (with blade, without case ripper)

Fuel tank

Cooling system

Specified capacity (l)

45

105

1.5

(each left and right) 31

240

625

82

Refill capacity (l)

37

70

1.5

(each left and right) 31

85

—

—

D155A-6

13

SEN02859-02

01 Specification



14

D155A-6

SEN02861-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up

10 Structure, function and maintenance standard

1

Engine and cooling system Radiator, oil cooler .......................................................................................................................................... 2 Engine mount.................................................................................................................................................. 9 Cooling fan pump.......................................................................................................................................... 10 Cooling fan motor.......................................................................................................................................... 18

D155A-6

1

SEN02861-01

Radiator, oil cooler


1

Radiator (without sand protection grill)

2

D155A-6


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Overflow hose Air bleed hose Inlet hose Coolant filler cap Radiator core assembly Reservoir tank Inlet hose (for circulating at low coolant temperature) Outlet hose Lower tank (power train oil cooler built-in) Fan Drain plug Cushion Breather cap Pressure valve

a: b: c:

Aftercooler Aftercooler outlet hose Aftercooler inlet hose

SEN02861-01

Outline q The reservoir tank is provided for radiator. q The power train oil cooler is built in the lower tank of the radiator.

D155A-6

3

SEN02861-01


Oil cooler

1. 2.

Hydraulic cooler Power train oil cooler

A: B:

Power train oil cooler inlet port Power train oil cooler outlet port

Outline q The power train oil cooler is built in the lower tank of the radiator.

4

D155A-6


D155A-6

SEN02861-01

5

SEN02861-01


Radiator (with sand protection grill)

6

D155A-6


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Overflow hose Air bleed hose Inlet hose Coolant filler cap Radiator core assembly Reservoir tank Inlet hose (for circulating at low coolant temperature) Outlet hose Lower tank (power train oil cooler built-in) Fan Drain plug Cushion Breather cap Pressure valve

a: b: c:

Aftercooler Aftercooler outlet hose Aftercooler inlet hose

SEN02861-01

Outline q The reservoir tank is provided for radiator. q The power train oil cooler is built in the lower tank of the radiator.

D155A-6

7

SEN02861-01


Oil cooler (sand protection grill)

1. 2. 3.

Hydraulic cooler Power train oil cooler Sand protection grill

A: B:

Power train oil cooler inlet port Power train oil cooler outlet port

Outline q The power train oil cooler is built in the lower tank of the radiator.

8

D155A-6


SEN02861-01

Engine mount

1

Unit: mm No.

1

2

Check item Clearance between bracket and cushion

Free height of mount rubber

D155A-6

Criteria Standard size 60

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

–0.1 –0.3

+0.046 +0.046

0.1 – 0.346

—

Standard clearance

Clearance limit

86

84

Replace

9

SEN02861-01


Cooling fan pump

1

Type: LPV45

P1: Pump discharge port PAEPC: EPC output pressure pickup plug PEPC: EPC valve basic pressure input port PS: Pump suction port TO: Drain port

10

1. 2.

Servo valve Air bleeder

D155A-6


1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

SEN02861-01

Shaft Oil seal Case Rocker cam Shoe Piston Cylinder block Valve plate Spring Servo piston

D155A-6

11

SEN02861-01

Function q The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.


q q q

Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).

Structure Cylinder block (7) is supported to shaft by spline (11). q Shaft (1) is supported with front and bearings (12). q The end of piston (6) has a spherical hollow and is combined with shoe (5). q Piston (6) and shoe (5) form a spherical bearing. q Shoe (5) is kept pressed against plane (A) of rocker cam (4) and slid circularly. q Rocker cam (4) slides around ball (13). q Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). q

12

D155A-6


Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q At this time, rocker cam (4) slants around ball (13). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. q Angle (a) is called the swash plate angle.

SEN02861-01

q

q

q q

q

D155A-6

With the condition of center line (X) of rocker cam (4) has swash plate angle (a) to axial direction of cylinder block (7), flat surface (A) functions as cam against shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) sucks and discharges the oil by the amount (F) - (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.

13

SEN02861-01

q

q

q

14

As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) [swash plate angle (a) = 0], the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)


Control of delivery If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) be c o me s la r g er a nd pu m p d el i v er y ( Q ) increases. q Swash plate angle (a) is changed with servo piston (10). q Servo piston (10) reciprocates straight according to the signal pressure of the servo valve. q This straight motion is transmitted to rocker cam (4). q Rocker cam (4) supported with ball (13) slides around ball (13). q

Swash plate angle (a) is in proportion to the pump delivery.

D155A-6


D155A-6

SEN02861-01

15

SEN02861-01


Servo valve

P: PE: PH: T:

16

EPC valve basic pressure Control piston pressure Pump discharge pressure Drain port

1. 2. 3. 4. 5. 6. 7. 8.

Plug Lever Retainer Seat Spool Piston Sleeve Spring

D155A-6


Function q The servo valve controls the current input to the EPC valve and the pump delivery (Q) so that they will be related as shown in the diagram.

SEN02861-01

q

q

q

q

q

q

q q

The output pressure of the EPC valve flows in the piston chamber to push piston (6). Piston (6) pushes spool (5) until it is balanced with the spring.

D155A-6

Then, the land of the servo piston pressure passage is connected to the pump discharge passage by the notch of spool (5) and the discharge pressure is led to the servo piston. When the rocker cam is pushed up by the servo piston, a position feedback is applied and lever (2) moves to compress spring (8). When spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are cut off. Pressure in the servo piston chamber drops and the rocker cam returns in the direction of a maximum swash plate angle. These processes are repeated until the swash plate is fixed to a position where the EPC output pressure is balanced with spring (8) force. The greater the EPC output pressure, the smaller the swash plate angle. Conversely, the smaller the EPC output pressure, the greater the swash plate angle.

17

SEN02861-01

Cooling fan motor


1

Type: LMF75(65)

P: From fan pump T: From cooler to tank TC: To tank

18

Specifications Type: LMF75(65) Capacity: 65.1 cc/rev Rated speed: 1,250 rpm Rated flow: 81.4 l/mm Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}

D155A-6


1. 2. 3. 4. 5. 6.

SEN02861-01

7. 8. 9. 10. 11. 12.

Output shaft Case Thrust plate Piston assembly Cylinder block Valve plate

End cover Center spring Check valve Pilot valve Spool for reversible valve Safety valve Unit: mm

No.

Check item

Criteria

Remedy

Standard size 13 Spool return spring

14 Check valve spring

D155A-6

Free length x Installation outer diameter length

Repair limit Installation load

Free length

62.66 x 19.8

53.5

146 N {14.9 kg}

—

16.4 x 8.9

11.5

13.7 N {1.4 kg}

—

Installation load Replace spring if damaged or 117 N {11.9 kg} deformed. 11.0 N {1.12 kg}

19

SEN02861-01


1. Hydraulic motor Function q This hydraulic motor is called a swash platetype axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation q The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5). This oil can flow on only one side of the (Y-Y) line connecting the top dead center and bottom dead center of the stroke of piston (4). q The oil sent to one side of cylinder block (5) presses piston (4) [4 or 5 pieces], and generates force (F1)[F1 = P x xD2/4]. q This force is applied to thrust plate (2). Since thrust plate (2) is fixed to the angle of (a°) degrees to the output shaft(1), the force is divided into components (F2) and (F3). q The radial component (F3) generates torque [T = F3 x ri] against the (Y-Y) line connecting the top dead center and bottom dead center. q The result of this torque [T = (F3 x ri)] rotates cylinder block (5) through the piston. q Since this cylinder block (5) is splined to the output shaft, the output shaft revolves to transmit the torque.

20

D155A-6


SEN02861-01

2. Suction valve Function q If the fan pump stops, the pressurized oil does not flow into the motor. Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. q When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and supplies it to port (MA) where there is not sufficient oil to prevent cavitation. Operation 1) q

2) q

q

When the pump is stopped If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm, the pressurized oil from the pump is not supplied to port (P) any more. As the pressurized oil is not supplied to the (MA) side of the motor, the motor speed lowers gradually to stop. If the motor shaft is revolved by the force of inertia while the oil flow in the port (P) is reducing, the oil in port (T) on the outlet side is sent by the suction valve (1) to the (MA) side to prevent cavitation.

When pump is started If the pressurized oil from the pump is supplied to port (P) and the pressure on (MA) side rises and starting torque is generated in the motor, the motor starts revolution.The pressurized oil on the motor outlet (MB) side of the motor returns through port (T) to the tank.

D155A-6

21

SEN02861-01


3. Operation of reversible valve 1) q

q q

22

When the ON-OFF solenoid is de-energized. If ON-OFF solenoid (1) is “de-energized“, the pressurized oil from the pump is blocked by ON-OFF selector valve (2), and port (C) opens for the tank circuit. Spool (3) is pushed to the right by spring (4). Motor port (MA) opens and pressurized oil flows in to revolve the motor in forward (clockwise).

2) q

q q

When the ON-OFF solenoid is energized. If ON-OFF solenoid (1) is “energized“, ONOFF selector valve (2) changes to let the pressurized oil from the pump flow through port (C) into spool chamber (D). The pressurized oil in chamber (D) pushes valve spool (3) to the left against spring (4). Motor port (MB) opens and pressurized oil flows in to revolve the motor in reverse (counterclockwise).

D155A-6


SEN02861-01

4. Safety valve

Function q When the engine is started, the pressure in port (P) of the fan motor is heightened in some cases. q Safety valve (1) is installed to protect the fan system circuit. Operation q If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1) opens to release the pressurized oil into port (T). q By this operation, generation of abnormal pressure in port (P) is prevented.

D155A-6

23

SEN02861-01




24

D155A-6

SEN02862-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Power train, Part 1 Power train skeleton ....................................................................................................................................... 2 Overall drawing of power train unit ................................................................................................................. 4 Power train hydraulic piping drawing .............................................................................................................. 6 Damper, universal joint ................................................................................................................................... 8 Torque converter, PTO .................................................................................................................................. 10 Transmission................................................................................................................................................. 18 Transmission ECMV ..................................................................................................................................... 34 Main relief valve and torque converter relief valve........................................................................................ 40 Lubricating oil relief valve.............................................................................................................................. 42 Scavenging pump ......................................................................................................................................... 44 Power train and steering lubrication pump.................................................................................................... 46

D155A-6

1

SEN02862-01


Power train skeleton

Outline q The power generated by engine (1) has its torsional vibration dampened by damper (2), and then passes through universal joint (3), and is transmitted to torque converter (8). q The power from the engine is transmitted through the oil by torque converter (8) to the transmission input shaft (turbine shaft) in accordance with the change in load. (with L/U) q Transmission (9) uses a combination of a planetary gear system and hydraulic clutches to reduce the speed and shift the gears (3 forward gears and 3 reverse gears). It connects 2 sets of clutches selected according to the change in load, and transmits the power to bevel gear (10) from the bevel pinion at the rear end of the transmission.

1

q

q

2

The power transmitted to the bevel gear shaft is transmitted to divided at right angles to the left and right and transmitted to the respective steering clutches (11). The power transmitted from the bevel gear shaft to the final drive is used to steer the machine by engaging or disengaging steering clutch (11). The steering lever is operated to disengage the steering clutch on the side to which the machine is to be steered in order to change the direction of travel. The side of the turning radius id controlled by steering brake (12) installed to the outside of the steering clutch. Steering brake (12) uses the same disc system that is used for the steering clutch. The power sent from steering brake (12) is transmitted to final drive (13). Final drive (13) consists of a single-stage spur gear and a single-stage planetary gear system. It reduces the speed and rotates sprocket (14) to drive track shoe (15) and move the machine. It also rotates cooling fan motor (17) with the oil discharged from cooling fan pump (16) driven with PTO (6).

D155A-6


1. 2. 3. 4. 5. 6. 7. 8. 9.

Engine (SAA6D140E-5) Damper Universal joint Scavenging pump (SAR(4)125) Hydraulic pump (HPV112) PTO Power train, lubricating pump (SAR(3)100+40) Torque converter Transmission

D155A-6

SEN02862-01

10. 11. 12. 13. 14. 15. 16. 17.

Bevel gear Steering clutch Steering brake Final drive Sprocket Track shoe Cooling fan pump (LPV45) Cooling fan motor (LMF65)

3

SEN02862-01

Overall drawing of power train unit

4


1

D155A-6


1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Steering brake Transmission Power train, lubricating pump (SAR(3)100+40) Power train oil strainer Main relief, torque converter relief valve Torque converter, PTO Scavenging pump (SAR(4)125) Cooling fan pump (LPV45) Hydraulic pump (HPV112) Brake control valve

D155A-6

SEN02862-01

Outline q The power train unit can be broadly divided into torque converter, PTO (7), transmission (2), and steering brake (1). So, a fter the power train unit h as be en removed, it can be disassembled into the torque converter, PTO (7), transmission (2), and steering brake (1). q Steering clutch consists of the bevel pinion unit, bevel gear shaft, and steering brake.

5

SEN02862-01


Power train hydraulic piping drawing

6

1

D155A-6


1. 2. 3. 4. 5. 6. 7. 8.

SEN02862-01

Hydraulic pump (HPV112) Centralized pressure detection port Power train, lubrication pump (SAR(3)100+(3)40) Brake control valve Main relief, torque converter relief valve Power train oil filter Scavenging pump (SAR(4)125) Power train oil cooler (built in radiator lower tank)

A: B: C:

Left brake oil pressure pickup port (LB) Right brake oil pressure pickup port (RB) 3rd transmission clutch oil pressure pickup port (3RD) D: 2nd transmission clutch oil pressure pickup port (2ND) E: 1st transmission clutch oil pressure pickup port (1ST) F: Reverse transmission clutch oil pressure pickup port (R) G: Forward transmission clutch oil pressure pickup port (F) H: Transmission main relief oil pressure pickup port (TM) J: Left clutch oil pressure pickup port (LC) K: Right clutch oil pressure pickup port (RC) L: Torque converter oil pressure pickup port (IN) M: Torque converter oil pressure pickup port (OUT)

D155A-6

7

SEN02862-01

Damper, universal joint

8


1

D155A-6


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

SEN02862-01

Breather Dipstick Drain plug Output shaft Flywheel Outer body Coupling Universal joint Cover Rubber coupling Inner body Unit: mm

No.

12

Check item Clearance between flywheel housing and cover

13

Clearance between flywheel and damper

14

Outside diameter of coupling oil seal contact surface

Criteria Standard size

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

511.18

–0.022 –0.092

+0.070 +0.070

0.022 – 0.162

0.2

466.72

–0.020 –0.083

+0.063 +0.070

0.020 – 0.146

0.2

Standard size

Tolerance

Repair limit

90

–0.087 –0.087

89.8

Replace

Outline q The damper, dampens the torsional vibration caused by the change in engine torque and the impact torque generated when accelerating suddenly or when carrying out heavy-duty digging. In this way, it acts to protect the torque converter, transmission, and other parts of the power train. q The damper has few component parts: it uses a rubber coupling, so the vibration is absorbed by the damping effect of the rubber material. Operation q The motive force from the engine passes through flywheel (5) and is transmitted to outer body (6). The torsional vibration of the engine is absorbed by rubber coupling (10), and the power is transmitted to inner body (11). It passes through universal joint (8), and is then transmitted to the torque converter and transmission.

D155A-6

9

SEN02862-01


Torque converter, PTO a

PTO: Abbreviation for Power Take Off

A: B: C:

To power train oil cooler From main relief valve From transmission case

10

1

D: E:

To transmission case From power train oil cooler

D155A-6


D155A-6

SEN02862-01

11

SEN02862-01


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

12

Work equipment pump mounting port Cooling fan pump mounting port Scavenging pump mounting port Power train and steering lubrication pump mounting port Torque converter case Coupling Input transfer drive gear (Number of teeth: 58) PTO idler gear (Number of teeth: 66) PTO idler gear shaft Turbine Drive case Rase Stator Pump Retainer Stator shaft Transmission input shaft Turbine boss PTO gear A (Number of teeth: 49) PTO gear B (Number of teeth: 48) Scavenging pump drive gear (Number of teeth: 56) Power train oil strainer Sleeve

D155A-6


SEN02862-01

General q 3-element, 1-stage and 2-phase type is employed for the torque converter. It is integrated with the transmission. q Pump (14) is integrated with coupling (6), input shaft (7) and drive case (11), and rotated by the power from the engine. q Turbine (10) is integrated with turbine boss (18) and transmission input shaft (17), and rotates using the oil from pump (14) as the medium. q Stator (13) is integrated with stator shaft (16), and fixed to torque converter case (5). q The PTO system is consisted of input shaft (7), PTO idler gear (8), PTO gear A (19), PTO gear B and scavenging pump drive gear (21).

D155A-6

13

SEN02862-01

14


D155A-6


SEN02862-01

Unit: mm No.

Check item

Criteria

1

Outside diameter of coupling oil seal contact surface

Remedy

Standard size

Tolerance

Repair limit

100

-0.054 -0.054

99.8

65

+0.030 +0.025

65.1

Width

3

-0.01 -0.03

2.7

Thickness

2.7

±0.1

2.55

3

Inside diameter of retainer seal ring contact surface

150

+0.040 +0.040

150.5

4

Backlash between input shaft and PTO idler gear

0.198 – 0.484

5

Backlash between PTO idler gear and PTO gear A

0.198 – 0.484

6

Backlash between PTO idler gear and PTO gear B

0.198 – 0.484

7

Backlash between input shaft and scavenging pump drive gear

0.198 – 0.484

Inside diameter of stator shaft seal ring contact surfac 2

Wear on seal ring of the transmission input shaft

Standard size 8

9

Tolerance for fitness of PTO idler gear bearing

Tolerance for fit11 ness of scavenging pump drive gear bearing

D155A-6

Replace Repair by hard chromium-plating or replace

Shaft

Hole

Standard clearance

Clearance limit

Outside diameter

140

-0.018 -0.018

-0.008 -0.033

0.033 – 0.010

—

Inside diameter

80

-0.019 -0.019

-0.015 -0.015

0.015 – 0.019

—

Outside diameter (Cover side)

140

-0.018 -0.018

+0.026 -0.014

0.014 – 0.044

—

120

-0.015 -0.015

+0.022 -0.013

0.013 – 0.037

—

65

+0.030 +0.011

-0.015 -0.015

0.045 – 0.011

—

Inside diameter (Case side)

65

+0.030 +0.011

-0.015 -0.015

0.045 – 0.011

—

Outside diameter (Cover side)

120

-0.015 -0.015

+0.022 -0.013

0.013 – 0.037

—

Outside diameter (Case side)

120

-0.015 -0.015

+0.022 -0.013

0.013 – 0.037

—

Inside diameter (Cover side)

55

+0.030 +0.011

-0.015 -0.015

0.045 – 0.011

—

Inside diameter (Case side)

65

+0.030 +0.011

-0.015 -0.015

0.045 – 0.011

—

Outside diameter

85

-0.015 -0.015

+0.010 -0.025

0.025 – 0.025

—

Inside diameter

45

+0.018 +0.002

-0.012 -0.012

0.030 – 0.002

—

Outside Tolerance for fitdiameter ness of drive gear (Case side) bearing on work equipment, power Inside train and steering diameter lubrication pump (Cover side)

Tolerance for fit10 ness of fan pump drive gear bearing

Tolerance

Repair by hard chromium-plating or replace

Replace

15

SEN02862-01


Power transmitting route

Oil flow

Power generated from engine O Damper O Universal joint O Input coupling (1) O Input shaft (2) O Drive case (3) and pump (4) rotate integral to each other O Oil is used as medium O Turbine (5) O Transmission input shaft (6)

q

16

q

q

The oil flows through the main relief valve and its pressure is reduced to less than the set pressure by the torque converter relief valve, then it flows through inlet port (A) and oil passage of torque converter case (1), stator shaft (2), retainer (3), to pump (4). The oil is given a centrifugal force by pump (4), and then it enters turbine (5) to transmit its energy to turbine (5). The oil from turbine (5) is sent to stator (6), and then returned to pump (4). Part of this oil is sent to the power train oil cooler through stator (6) and outlet port (B).

D155A-6


D155A-6

SEN02862-01

17

SEN02862-01

Transmission

18


1

D155A-6


A: B: C: D: E: F: G: H: J:

1st clutch pressure pickup port (1ST) 3rd clutch pressure pickup port (3RD) R clutch oil pressure pickup port (R) 2nd clutch pressure pickup port (2ND) F clutch oil pressure pickup port (F) From power train pump To brake control valve From steering case From power train oil cooler

D155A-6

SEN02862-01

K: L: M: N: P: R: S: T: U:

To torque converter To scavenging pump To torque converter case From torque converter case To R clutch To 3rd clutch To 1st clutch To 2nd clutch To F clutch

19

SEN02862-01

20


D155A-6


1. 2. 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. 35. 36. 37. 38. 39. 40. 41. 42.

Transmission ECMV Main relief valve and torque converter relief valve Transmission case Sleeve Transmission input shaft Tie bolt R ring gear (hub) R planetary pinion (number of teeth: 26) R ring gear (number of internal teeth: 86) F planetary pinion (number of teeth: 24) F ring gear (number of internal teeth: 91) 3rd planetary pinion (number of teeth: 35) 3rd ring gear (number of internal teeth: 89) 2nd planetary pinion (number of teeth: 31) 2nd ring gear (number of internal teeth: 91) 1st ring gear (number of internal teeth: 91) 1st planetary pinion (number of teeth: 27) Transmission output shaft (3rd sun gear)(number of teeth: 19) 1st clutch housing 1st clutch piston 1st sun gear (number of teeth: 37) 1st carrier 2nd clutch housing 2nd clutch piston 2nd sun gear (number of teeth: 29) 2nd carrier 3rd clutch housing 3rd clutch piston 3rd carrier F clutch housing F clutch piston F carrier R clutch housing F sun gear (number of teeth: 44) R clutch piston Washer spring Clutch plate Clutch disc Piston return spring R carrier Front housing R sun gear (number of teeth: 34)

D155A-6

SEN02862-01

General q The transmission consists of planetary gear systems and disc clutches and has "3 forward gear speeds and 3 reverse gear speeds". q Among the 5 sets of planetary gear system and disc clutches of the transmission, 2 clutches are fixed hydraulically with the ECMV to select 1 rotating direction and gear speed. q The transmission transfers the power received by the transmission input shaft to the output shaft while changing the gear speed (forward 1st-3rd or reverse 1st-3rd) by any combination of the F, R clutches and 3 speed clutches. Number of plates and discs used Clutch No.

Number of plates

Number of discs

R clutch

6

6

F clutch

6

7

3rd clutch

3

4

2nd clutch

3

4

1st clutch

2

3

Combinations of clutches at respective gear speeds and reduction ratio Gear speed

Operated clutches

Reduction ratio

Forward 1st

F x 1st

1.705

Forward 2nd

F x 2nd

1.151

Forward 3rd

F x 3rd

0.540

Neutral

*

—

Reverse 1st

R x 1st

1.406

Reverse 2nd

R x 2nd

0.949

Reverse 3rd

R x 3rd

0.445

*: The 1st, 2nd, or 3rd clutch is filled with low-pressure oil.

21

SEN02862-01

22


D155A-6


SEN02862-01

Unit: mm No.

Check item


1

R clutch spring (12 springs)

Remedy Repair limit

Free length

Installed length

Installed load

Free length

Installed load

81.7

72.4

59.8 N {6.1 kg}

76.8

51.0 N {5.2 kg}

2

F clutch spring (12 springs)

81.7

76.4

34.3 N {3.5 kg}

76.8

29.4 N {3.0 kg}

3

3rd clutch spring (12 springs)

70.0

50.2

97.1 N {9.9 kg}

65.8

82.4 N {8.4 kg}

4

2nd clutch spring (12 springs)

70.0

51.6

90.2 N {9.2 kg}

65.8

76.5 N {7.8 kg}

5

1st clutch spring (12 springs)

66.0

51.8

66.7 N {6.8 kg}

62.0

56.9 N {5.8 kg}

6

Total assembled thickness of 6 disks and 6 plates for R clutch

7

Standard size

Tolerance

Repair limit

51.6

±0.35

48.4

Total assembled thickness of 7 disks and 6 plates for F clutch

57.0

±0.36

53.3

8

Total assembled thickness of 4 disks and 3 plates for 3rd clutch

31.2

±0.26

29.1

9

Total assembled thickness of 4 disks and 3 plates for 2nd clutch

31.2

±0.26

29.1

10

Total assembled thickness of 3 disks and 2 plates for 1st clutch

22.6

±0.22

21.0

11 Thickness of clutch disk

5.4

±0.1

4.9

12 Thickness of clutch plate

3.2

±0.1

2.9

Width

3.0

-0.01 -0.03

2.70

Thickness

2.7

±0.1

2.55

Width

4.0

-0.01 -0.04

3.60

Thickness

5.0

±0.15

4.85

Width

4.0

-0.01 -0.04

3.60

Thickness

4.0

±0.15

3.85

Width

4.0

-0.01 -0.04

3.60

Thickness

4.0

±0.15

3.85

Width

4.0

-0.01 -0.04

3.60

Thickness

4.0

±0.15

3.85

Wear of input shaft 13 seal ring Wear of seal ring on the front housing, F 14 clutch housing and 3rd carrier Wear of seal ring 15 (large) on 2nd carrier

Wear of seal ring 16 (small) on 2nd carrier

Wear of seal ring 17 (large) on 1st carrier

D155A-6

Replace

23

SEN02862-01


Unit: mm No.

18

Check item

Wear of seal ring (small) on 1st carrier

Backlash between 19 sun gear and planetary pinion

Backlash between 20 planetary pinion and ring gear

Criteria Tolerance

Repair limit

Width

4.0

-0.01 -0.04

3.60

Thickness

5.0

±0.15

4.85

R, F, 3rd, 1st

0.14 – 0.35

2nd

0.13 – 0.32

R

0.15 – 0.39

F, 2nd, 1st

0.15 – 0.38

3rd

0.16 – 0.42

Disc clutch Structure

q

q q

The disc clutch consists of piston (2), plates (3), discs (4), pin (5), return spring (6) etc. to fix ring gear (1). Inside teeth of disc (4) are engaged with outside teeth of ring gear (1). Plate (3) is assembled to clutch housing (7) with pin (5).

Replace

Operation When clutch is "engaged" (fixed)

q

q

q

24

Remedy

Standard size

The oil sent from the ECMV flows through the oil passage in clutch housing (7), is pressurefed to the back side of piston (2), and pushes piston (2) to the left. Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by use of the friction force generated between them. Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), move of ring gear (1) is stopped.

D155A-6


When clutch is "disengaged" (released)

q q

As the oil from ECMV is stopped, piston (2) is pushed back rightward by return spring (6). The friction force between plates (3) and discs (4) is released and ring gear (1) is released.

SEN02862-01

Oil passage in speed clutch a The figure shows the case in which "1st" gear speed is selected.

q

q

q

q

q

D155A-6

When the steering/directional/gear shift lever is set in the "neutral" position, the 1st, 2nd, or 3rd speed is selected. The piston chamber of the clutch corresponding to the selected gear speed is filled with oil by electronically controlling the hydraulic circuit of each clutch. When the steering/directional/gear shift lever is shifted from the "neutral" position to the"forward" or "reverse" position, the pump is required to supply oil of quantity to fill the piston chamber of the F clutch or R clutch. When the gear speed is changed from "forward 1st" to "forward 2nd", the pump is required to supply oil of only quantity to fit the plate and disc of the 2nd clutch together since the F clutch has been filled with the oil. The time lag in the gear shifting operation is reduced by controlling the oil in the clutch circuit as explained above.

25

SEN02862-01


Power transmitting route Forward 1st speed

26

D155A-6


SEN02862-01

F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed with oil pressure. Power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd ring gear (16) O 1st carrier (17) O 1st planetary pinion (18) O 1st sun gear (20) O Output shaft (22)

D155A-6

2nd sun gear (21)

27

SEN02862-01


Forward 2nd speed

28

D155A-6


SEN02862-01

F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed with oil pressure. Power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd sun gear (21) O Output shaft (22)

D155A-6

29

SEN02862-01


Forward 3rd speed

30

D155A-6


SEN02862-01

F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed with oil pressure. Power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O Output shaft (22)

D155A-6

31

SEN02862-01


Reverse 1st speed

32

D155A-6


SEN02862-01

R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are fixed with oil pressure. Power from torque converter O Input shaft (1) O R sun gear (5) O R planetary pinion (6) O R ring gear (9) (R carrier (8) is fixed with R ring gear = R ring gear (9) rotates in reverse with regard to input shaft (1) Not translated O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd ring gear (16) O 1st carrier (17) O 1st planetary pinion (18) O 1st sun gear (20) O Output shaft (22)

D155A-6

2nd sun gear (21)

33

SEN02862-01


Transmission ECMV a a

34

1

ECMV: Abbreviation for Electronic Control Modulation Valve Don't try to disassemble it since adjustment for maintaining the performance will be needed.

D155A-6


AF: AR: A1: A2: A3: P: T: Dr: PF: PR: P1: P2: P3:

To F clutch To R clutch To 1st clutch To 2nd clutch To 3rd clutch From power train pump Drain Drain F clutch oil pressure pickup port R clutch oil pressure pickup port 1st clutch oil pressure pickup port 2nd clutch oil pressure pickup port 3rd clutch oil pressure pickup port

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

3rd clutch proportional solenoid 1st clutch proportional solenoid R clutch proportional solenoid F clutch proportional solenoid 2nd clutch proportional solenoid 3rd clutch fill switch 2nd clutch fill switch 1st clutch fill switch R clutch fill switch F clutch fill switch Transmission oil filter Connector for 1st clutch proportional solenoid Connector for 3rd clutch fill switch Connector for 3rd clutch proportional solenoid Connector for R clutch proportional solenoid Connector for 2nd clutch fill switch Connector for 2nd clutch proportional solenoid Connector for F clutch proportional solenoid Connector for 1st clutch fill switch Connector for R clutch fill switch Connector for F clutch fill switch

D155A-6

SEN02862-01

Operation table of ECMV Gear speed

ECMV

F

R

N

a

F1

Q

F2

Q

F3

Q

1st

2nd

3rd

Q

Q

Q

Q Q Q

R1

Q

R2

Q

R3

Q

Q Q Q

When the directional lever is in (neutral) position, the speed clutch of the speed selected by gear shift lever activates.

35

SEN02862-01

1. 2. 3. 4. 5. 6. 7. 8.

36


Fill switch Pressure control valve Body (upper) Body (lower) Proportional solenoid Filter Pressure detection valve Sleeve

D155A-6


Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q Pressure control valve A proportional solenoid in this valve receives a current sent from the controller and this valve converts it to an oil pressure. q Fill switch This switch detects that the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2. Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch.

SEN02862-01

ECMV and proportional solenoid q For each ECMV, 1 proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. Current - propulsion force characteristics of proportional solenoid

Propulsion force - Hydraulic pressure characteristics of proportional solenoid

Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned "ON" during triggering (Range D).

D155A-6

ECMV and fill switch For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. The oil pressure is built up according to this signal.

q

37

SEN02862-01

Operation of ECMV q ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal. The relationship between the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown below.


Before shifting gear (when draining) (Range A in chart)

q

Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned "ON" during triggering (Range D). q When gear is shifted with gear shift switch, the clutch is compressed by piston. If high pressure is suddenly applied, the piston suddenly engages clutch, causing sudden start of machine and excessive shock. ECMV reduces a shock at the start of the machine by increasing the oil pressure applied to the piston gradually to set pressure, and puts clutch smoothly "engaged". It aims to increase durability of power transmitting route and enhances an operator comfort.

38

Under the condition where any current is not sent to the proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T). Also at this time, fill switch (5) is turned "OFF" because oil pressure is not applied to pressure detection valve (4).

D155A-6


During filling (Range B in chart)

q

If current is supplied to proportional solenoid (1) with no oil in the clutch, the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the right. As a result, pump port (P) and clutch port (A) are opened and oil starts filling the clutch. If the clutch is filled with oil, fill switch (5) is turned "on".

D155A-6

SEN02862-01

Pressure adjustment (Range C in chart)

q

If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the repulsion of pressure control valve spring (2) to regulate the pressure.

39

SEN02862-01


Main relief valve and torque converter relief valve

1

Unit: mm No.

1

2

Check item Clearance between main relief valve and body Clearance between the torque converter relief valve and the body


Tolerance Shaft

Hole

Standard clearance

Clearance limit

28

-0.035 -0.045

+0.013 +0.013

0.035 – 0.058

0.078

22

-0.035 -0.045

+0.013 +0.013

0.035 – 0.058

0.078

Standard size 3

Main relief valve spring (outside)

Remedy

Free length

Repair limit

Installation Installation Installation Free length length load load

122

78.0

481 N {49 kg}

118.3

457 N {46.6 kg}

4

Main relief valve spring (inside)

108

78.0

368 N {37.5 kg}

104.8

349 N {35.6 kg}

5

Torque converter relief valve spring

50

40.5

182 N {18.6 kg}

48.5

174 N {17.7 kg}

6. 7. 8. 9. 10.

40

Body Piston Torque converter relief valve Piston Main relief valve

Replace

A: Drain (Torque converter relief) B: Drain C: From pump D: Drain E: To torque converter P1: Main relief oil pressure pickup port P8a: Torque converter relief oil pressure pickup port P8b: Torque converter inlet oil pressure pickup port D155A-6


General

SEN02862-01

Operation of main relief valve

Torque converter relief valve q The torque converter relief valve maintains the oil pressure in the torque converter inlet circuit always below the set pressure in order to protect the torque converter from abnormally high pressure. Set pressure: 1.06 ± 0.05 MPa {10.8 ± 0.5 kg/cm2} (Cracking pressure) Main relief valve q The main relief valve is keeping each hydraulic circuit of the transmission and the parking brake at set pressure. Set pressure: 3.18 ± 0.1 MPa {32.4 ± 1.0 kg/cm2} (Engine at rated speed)

q

The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief valve and orifice (a) of main relief valve (1).

q

As the oil pressure in the circuit goes beyond the set pressure, the oil conducted to chamber (F) pushes piston (2) and the resulting reaction force pushes main relief valve (1) leftward, opening ports (C) and (E). Above operation conducts the oil from port (E) to the torque converter.

Operation Operation of torque converter relief valve

q

q

The oil from the main relief valve is conducted to the torque converter through port (E) and, at the same time, also conducted to chamber (G) through orifice (b) of torque converter relief valve (3). As the oil pressure to the torque converter rises beyond the set pressure, the oil conducted to chamber (G) pushes piston (4) and the resulting reaction force pushes torque converter relief valve (3) rightward, opening ports (E) and (A). As a result, the oil in port (E) is drained through port (A).

D155A-6

41

SEN02862-01


Lubricating oil relief valve

1

Unit: mm No.

Check item

Criteria

Remedy

Standard size 1

Lubrication relief valve spring

Free length 26

2. 3. 4.

F clutch housing R clutch housing Piston

A: B: C:

From oil cooler Drain Drain

42

Repair limit

Installation Installation Installation Free length length load load Replace 12.5 N {1.27 kg}

23.6

25.2

11.9 N {1.21 kg}

General The oil leaving the torque converter passes through the power train oil cooler built in the radiator lower tank. It then goes through the lubrication relief valve and lubricates the transmission and PTO. q The lubrication relief valve is installed to the right side face of the F clutch housing. It keeps the lubricating oil pressure below the set pressure. q

s

Specified value

Normal pressure (MPa{kg/cm2})

0.14 ± 0.05 {1.4 ± 0.5}

Cracking pressure (MPa{kg/cm2})

0.30 ± 0.03 {3.0 ± 0.3}

D155A-6


D155A-6

SEN02862-01

43

SEN02862-01


Scavenging pump

1

Type: SAR(4)125 Serial No.: 85001 – 85024

Unit: mm No.

Check item

1

Side clearance

2

Clearance between plain bearing inner diameter and gear shaft outer diameter

3

Pin driving depth

4

Spline shaft rotating torque

–

Delivery amount Oil: SAE10WCD Oil temperature: 45 – 55°C

Criteria

Remedy

Standard clearance

Clearance limit

0.11 – 0.16

0.19

0.06 – 0.14

0.20

Replace

Standard size

Tolerance

Repair limit

21

-0.5 -0.5

—

9.8 - 14.7 Nm {1.0 - 1.5 kgm} Rotation speed (rpm)

Delivery pressure MPa{kg/cm2}

Standard discharge amount (l/min)

Discharge amount limit (l/min)

2,200

2.94{30}

264

234

—

General q The scavenging pump is installed to the torque converter case and is driven with the power from the engine. It returns the oil collected in the bottom of the transmission case to the steering case.

44

D155A-6


SEN02862-01

Type: SAR(3)125 Serial No.: 85025 and up

Unit: mm No.

Check item

1

Side clearance

2

Clearance between plain bearing inner diameter and gear shaft outer diameter

3

Pin driving depth

4

Spline shaft rotating torque

–


Criteria

Remedy

Standard clearance

Clearance limit

0.10 – 0.15

0.19

0.078 – 0.149

0.20

Replace

Standard size

Tolerance

Repair limit

14

-0.5 -0.5

—

6.9 - 11.8 Nm {0.7 - 1.2 kgm} Rotation speed (rpm)

Delivery pressure MPa{kg/cm2}



2,000

2.94{30}

240.7

213.1

—

General q The scavenging pump is installed to the torque converter case and is driven with the power from the engine. It returns the oil collected in the bottom of the transmission case to the steering case.

D155A-6

45

SEN02862-01


Power train and steering lubrication pump

1

Type: SAR (3) 100 + (3) 40

1. 2.

46

Power train pump Steering lubrication pump

General q The power train pump and the steering lubrication pump are installed to the torque converter case. They are driven by the power from the engine to supply the oil pressure to the torque converter, the transmission and the steering unit.

D155A-6


SEN02862-01

Unit: mm No.

Check item

Criteria Type

3

Side clearance

SAR(3)100 SAR(3)40

4

Clearance between plain bearing inner diameter and gear shaft outer diameter Pin driving depth

SAR(3)40 SAR(3)100 SAR(3)40

6

–

Rotating torque of spline shaft


D155A-6

Clearance limit

0.10 – 0.15

0.19

0.06 – 0.15

0.20

SAR(3)100

Type 5

Remedy

Standard clearance

Replace

Standard size

Tolerance

Repair limit

14

-0.5 -0.5

—

13.7 – 23.5 Nm {1.4 – 2.4 kgm} Type

Rotation speed (rpm)

Delivery pressure (MPa{kg/ cm2})

SAR(3)100

2,500

2.94{30}

241

96

SAR(3)40

2,500

2.94{30}

239

85



—

47

SEN02862-01




48

D155A-6

SEN02863-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

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

D155A-6

1

SEN02863-00

Work equipment pump


1

Type: HPV95 (112)

2

D155A-6


SEN02863-00

Outline q The pump unit is composed of the variable capacity swash plate type piston pump and LS valve. PA: Pump discharge port PB: Pump pressure input port PC: Pump discharge pressure pickup port PD1: Case drain port PD2: Drain plug PEN: Control pressure pickup port PLS: Load pressure input port PLSC: Load pressure pickup port PS: Pump suction port 1. 2.

Main pump LS valve

D155A-6

3

SEN02863-00

1. 2. 3. 4. 5. 6. 7 8. 9. 10.

4


Shaft Cradle Front case Rocker cam Shoe Piston Cylinder block Valve plate End cap Servo piston

D155A-6


Function q The pump converts the engine and torque rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.

SEN02863-00

q

q q q

Structure q Cylinder block (7) is supported to shaft (1) by spline (12). q Shaft (1) is supported with bearings (13). q The end of piston (6) has a spherical hollow and is combined with shoe (5). q Piston (6) and shoe (5) form a spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement. q Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides.

D155A-6

Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).

5

SEN02863-00

Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the ax ial di rec tio n of cy li nder b loc k (7) changes. q Angle (a) is called the swash plate angle.

q

q

q q

q

6


q

q

As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)

With center line (X) of rocker cam (4) at swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) sucks and discharges the oil by the amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.

D155A-6


SEN02863-00

Control of delivery q If swash plate angle (a) becomes larger, the difference between volumes (E) and (F) b ec o me s l ar g er a nd pu m p d el i v e r y ( Q ) increases. q Servo piston (10) is used for changing swash plate angle (a). q Servo piston (10) carries out linear reciprocal movement according to the signal pressure from the LS valve. q This linear movement is transmitted to rocker cam (4) through slider (14). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q Space of the pressure receiving area of servo piston (10) are not identical on the left side and right side. Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (10).

D155A-6

7

SEN02863-00


LS valve

PA: Pump port PDP: Drain port PLP: LS control pressure output port PLS: LS pressure input port PP: Pump port PSIG: Drain port

1. 2. 3. 4. 5. 6. 7. 8.

Sleeve Piston Spool Spring Seat Sleeve Plug Locknut

Function q The LS (load sensing) valve detects the load and controls the delivery. q This valve controls pump delivery (Q) according to differential pressure (dPLS) [ = (PP) – (PLS)] (called LS differential pressure) between pump discharge pressure (PP) and control valve outlet port pressure (PLS). q Main pump pressure (PP), pressure (PLS) (called the LS pressure) coming from the control valve output enter this valve.

8

D155A-6


D155A-6

SEN02863-00

9

SEN02863-00


Operation 1)

10

When the control valve is situated at neutral

D155A-6


q

q

q

q

q q q q

SEN02863-00

The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the inlet port of the control valve brought to spring chamber (B), and pump discharge pressure (PP) brought to port (H) of sleeve (1). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge pressure (self pressure) (PP) determine the position of spool (3). Before starting engine, servo piston (10) is pressed to the right. (See the figure to the right) If the control lever is in neutral at start of the engine, LS pressure (PLS) is set to 0 MPa {0 kg/cm2}. (It is connected with the drain circuit through the control valve spool.) Spool (3) is pushed to the right, and port (C) and port (D) will be connected. Pump discharge pressure (PP) enters the large diameter side of the piston from port (K). Pump pressure (PP) is present in port (J) on the small diameter side of the piston. According to the difference in the areas on servo piston (10), servo piston (10) moves in to the direction of minimizing the swash plate angle.

D155A-6

11

SEN02863-00


2)

Action for the direction of maximizing the pump delivery

q

When the difference between pump discharge pressure (PP) and LS pressure (PLS), in other wo r ds , L S d iff er e nti a l p re s s ur e (dP L S) becomes smaller [for example, when the area of opening of the control valve becomes larger and pump discharge pressure (PP) drops], spool (3) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4). When spool (3) moves, port (D) and port (E) are interconnected and connected to the drain port.

q

12

q

The pressure at the large diameter end of servo piston (10) becomes drain pressure (PT), and pump pressure (PP) enters port (J) at the small diameter end, so servo piston (10) is pushed to the left side. Therefore, servo piston (10) is moved in the direction to make the delivery larger.

D155A-6


3)

Action for the direction of minimizing the pump delivery

q

If LS differential pressure (dPLS) becomes larger (for example, when the area of control valve opening becomes smaller and the pump pressure (PP) increases), spool (3) is pressed to the right by the force of pump pressure (PP). As a result of the movement of spool (3), pump discharge pressure (PP) flows from port (C) to port (D), then from port (K) to the large diameter side of the piston. While main pump pressure (PP) is present in port (J) of the smaller diameter side of the piston, servo piston (10) is pressed to the right by its area difference between the larger and the smaller diameter sides. As the result, servo piston (10) moves in the direction to minimize the swash plate angle.

q

q

D155A-6

SEN02863-00

13

SEN02863-00

4)

When servo piston is balanced

q

Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced, and the relationship is (A0) × (PP) = (A1) × (PEN), servo piston (10) will stop in that position.

q


q

q

q

14

And the swash plate of the pump will be held in an intermediate position. [Spool (3) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] The formula (A0) : (A1) = 3 : 5 represents the relation of pressure receiving areas across the end of servo piston (10). And (PP) : (PEN) C 5 : 3 represents the pressure applied across the piston when balanced. The force of spring (4) is adjusted to determine the balanced stop position of this spool (3) at the center of the standard when (PP) – (PLS) = 2.0 MPa {20 kg/cm2}.

D155A-6


SEN02863-00

Work equipment cooler bypass valve

1. 2. 3.

Body Valve Spring

A: B:

Hydraulic oil cooler inlet To hydraulic tank

1

Outline This valve is installed in the oil cooler inlet circuit. If any abnormal pressure is generated in the oil flowing to the oil cooler, this valve acts to return the oil directly to the hydraulic tank.

q

Set pressure Cracking pressure ( MPa {kg/cm }) 2

D155A-6

0.5 {5.1}

15

SEN02863-00

Steering, brake control a a

16


1

Regarding the transmission-related description of the operation of the PCCS lever, see Transmission control. PCCS: Palm Command Control System

D155A-6


1. 2. 3. 4. 5. 6. 7.

Potentiometer Lock lever PCCS lever (Steering) Limit switch Power train controller Rod (From brake pedal) Brake pedal

Positions of levers and pedals A: Neutral B: Forward straight C: Reverse straight D: Left turn E: Right turn F: Brake OFF G: Brake ON H: Free J: Lock

D155A-6

SEN02863-00

Outline q PCCS lever (3) sends electric signals to power train controller (5). Upon receiving those signals, power train controller (5) sends signals to the EPC valve of the control valve. q Brake pedal (7) receives signals from potentiometer (1) through rod (6). Then, power train controller (5) sends signals to the brake valve to operate the brake. q Lock lever (2) is connected to limit switch (4) and used as the parking brake lever, too. When it is in lock position "J", power train controller (5) does not send turning signals to the EPC valve of the control valve.

17

SEN02863-00

Steering unit


(Bevel gear shaft, steering clutch and steering brake)

18

1

D155A-6


A: B: C: D: E: F: G:

SEN02863-00

To transmission case From scavenging pump and steering lubrication pump R.H. brake oil pressure pickup port (RB) L.H. brake oil pressure pickup port (LB) From pin puller solenoid valve (drain) R.H. steering clutch oil pressure pickup port (RC) L.H. steering clutch oil pressure pickup port (LC)

D155A-6

19

SEN02863-00

20


D155A-6


D155A-6

SEN02863-00

21

SEN02863-00

1. 2. 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.

22


Bevel gear rotation sensor Drain plug Drain valve Steering clutch and brake control valve Case Brake cylinder Brake spring Brake piston Brake plate Brake disk Brake drum Brake hub Tube Bevel gear shaft Bevel gear (Number of teeth: 32) Clutch hub Clutch plate Clutch disk Clutch piston Clutch spring Clutch cylinder Clutch drum Clutch stopper Shim B (For bevel gear adjustment) Bevel gear shaft bearing B Bevel gear shaft bearing A Shim A (For bevel gear adjustment) Retainer Spacer Shim C (For bevel pinion adjustment) Gauge Bevel pinion bearing Nut (For bevel pinion) Bevel pinion (Number of teeth: 17)

D155A-6


SEN02863-00

General Bevel gear shaft q Using the meshing of bevel pinion (34) and bevel gear (15), the bevel gear shaft system directs the power being transmitted through the engine, torque converter and transmission orthogonally in the right and left directions and, at the same time, reduces the revolution. q A spiral bevel gear is employed for bevel pinion (34) and bevel gear (15) on the bevel gear shaft system. And as for the lubrication, spattering by use of the oil from the steering lubrication pump and scavenging pump is employed. q The bevel gear shaft system is consisted of bevel pinion (34), bearing (32) and cage (31) supporting the bevel pinion, bevel gear (15) to be meshed with the bevel pinion, bevel gear shaft (14) and bearings (25) and (26) and retainer (28) supporting the bevel gear shaft. Steering clutch The steering clutch is connected to both ends of bevel gear shaft (14) through the spline. It changes the machine turn direction by connecting or disconnecting the power from bevel gear shaft (14) to the final drive. q The wet type multi-disk clutch and springboosted type are employed for the steering clutch. It is hydraulically actuated, in conjunction with the brake, by the pressurized oil from the steering clutch valve. q The lubrication system employed the forced lubrication approach by use of the oil from the steering lubrication pump and scavenging pump. q The steering clutch is consisted of clutch hub (16) (connected to the bevel gear shaft), clutch disk (18), clutch plate (17), clutch drum (22), clutch piston (19), cluch spring (20), and clutch cylinder (21) supporting above components. Clutch drum (22) and the clutch cylinder being connected to the brake hub transmit the power from the bevel gear shaft to the output shaft through brake hub (12). q

D155A-6

Steering brake The steering brake being connected to the R.H. and L.H. steering clutches damps the machine by damping the power from the steering clutch to the final drive. q The wet type multi-disk clutch and springboosted type are employed for the steering clutch. It hydraulically actuates steering brake control valve (4) through the operation of its brake pedal. q The forced lubrication approach employed for the lubrication conducts the oil from the steering lubrication pump and scavenging pump to brake disk (10) and brake plate (9) through passage in the steering case, case (5) and brake drum (11). q When the engine is stopped, back pressure of brake piston (8) drops without pressing the brake piston, setting the steering brake to "actuated" state. However, if the engine is restarted and oil pressure in the circuit increases, the brake is "released". Thus, the parking brake must be set to the "lock" position. q The steering brake is consisted of clutch cylinder (21), clutch drum (22) (connected to brake hub (12)), brake disk (10), brake plate (9), brake drum (11), brake piston (8), brake spring (21) and brake cylinder (6) supporting above components. Brake drum (11) is fixed to the steering case. q

23

SEN02863-00

24


D155A-6


SEN02863-00

Unit: mm No.

1

2

3

4

5

6

7

8

9

Check item

Steering brake disk

Criteria Tolerance

Repair limit

Thickness

4.5

±0.1

4.0

Strain

—

0.05

0.14

Repair or replace

Thickness

2.9

±0.1

2.6

Replace

Strain

—

0.05

0.15

Repair or replace

41.5

±0.33

38.3

11

Replace

Steering brake plate Total assembled thickness of 6 disks and 5 plates for steering brake

Replace

Thickness

4.5

±0.1

4.1

Strain

—

0.05

0.14

Repair or replace

Thickness

2.9

±0.1

2.6

Replace

Strain

—

0.05

0.15

Repair or replace

Total assembled thickness of 5 disks and 5 plates for steering clutch

37.0

±0.32

34.3

Inside diameter of brake cylinder seal ring contact surface

125

+0.040 +0.035

125.5

Width

5

–0.08 –0.13

4.2

Thickness

4.5

±0.15

4.05

280

+0.081 +0.081

280.1

220

+0.072 +0.081

220.1

280

+0.081 +0.081

280.1

220

+0.072 +0.081

220.1

Steering clutch disk

Steering clutch plate

Wear of brake hub seal ring

Large diamete Inside diameter of portion contact surface of seal ring on steering Small brake piston diameter portion Large diamete Inside diameter of portion contact surface of seal ring on steering Small clutch piston diameter portion

Standard size 10

Remedy

Standard size

Steering brake spring (2 springs Free length make up a set)

Steering clutch spring (2 springs make up a set)

Clearance between bevel gear 12 and reamer bolt

D155A-6

Replace

Repair limit

Installation Installation Installation Free length load length load

33

19.6

35.7 kN {3,640 kg}

32.0

33.9 kN {3,460 kg}

33

19.6

35.7 kN {3,640 kg}

32.0

33.9 kN {3,460 kg}

Standard size

Shaft

Hole

Standard clearance

Clearance limit

+0.019 +0.001

+0.027 +0.027

-0.019 – 0.026

0.026

16

Tolerance

25

SEN02863-00


Unit: mm No.

Check item

Backlash between brake hub 13 and disk

Criteria 0.23 – 0.42

14

Backlash between brake drum and plate

0.23 – 0.42

15

Backlash between clutch hub and disk

0.23 – 0.42

16

Backlash between clutch drum and plate

0.23 – 0.42

17

Standard shim thickness of retainer A

2.0

18

Standard shim thickness of retainer B

2.0

19

Preload of bevel gear shaft bearings A and B

26

Remedy

Replace

Adjustment of shims

Rotary torque: 4.2 – 5.1 Nm {0.43 – 0.52 kgm} (22.6 – 26.5 Nm {2.3 – 2.7 kgm} at the bevel gear addendum Adjusting when the bevel pinion gear is not meshed)

D155A-6


SEN02863-00

Unit: mm No.

Check item

1

Backlash between bevel gear and bevel pinion

2

Standard shim thickness of cage

D155A-6

Criteria 0.25 – 0.33 2.0

Remedy Adjust or replace Adjustment of shims

27

SEN02863-00


Operation of the steering clutch When the steering clutch is turned "on"

When the steering clutch is turned "off"

Oil pressure to the back side of clutch piston (19) is stopped, and the repulsion of clutch spring (20) is used for fixing clutch hub (16).

Oil being pressure-fed to the back side of clutch piston (19) releases clutch hub (16).

Power from transmission O Bevel pinion O Bevel gear O Bevel gear shaft (14) O Clutch hub (16) O Clutch drum (22) O Brake hub (12) O Output shaft O Final drive

28

Power from transmission O Bevel pinion O Bevel gear O Bevel gear shaft (14) O Clutch hub (16)

D155A-6


SEN02863-00

Operation of steering brake When the steering brake is "released"

q

q

q

When the PCCS lever is set to the "neutral" position and the brake pedal is not pressure, the brake pressure alone is set to the maximum pressure by the steering control valve. Thus, oil pressure works on the back side of brake piston (8) as soon as the steering clutch is "engaged". At this point, brake piston (8) compresses and moves brake spring (7) leftward with the increased oil pressure, relieving the pressurebonding force of disk (10) and plate (9). The power being transmitted from bevel gear shaft (14) to brake hub (12) through the steering clutch is then transmitted to the final drive through the output shaft.

When the steering brake is "actuated" (When PCCS lever is in "operation")

q

q

q q

q

D155A-6

As the PCCS lever is operated in the right or left, the steering clutch is "disengaged" by the steering control valve and, at the same time, draining of oil to the back side of brake piston (8) is started. At this point, brake piston (8) is pushed back rightward by the tension of brake spring (7), pressure-bonding disk (10) and plate (9) against brake drum (11). Brake piston (8) and brake drum (11) are fixed to the steering case. Pressure-bonding disk (10) and plate (9) stops the inertia-based rotation of brake hub (12) and output shaft even if the steering clutch is "disengaged". Adjustment of the turn radius and swing becomes available by adjusting the braking force through controlling the oil pressure to the back side of brake piston (8) corresponding to the rightward and leftward stroke of the PCCS lever.

29

SEN02863-00


When the steering brake is "applied" (When the PCCS lever is in "neutral" and brake pedal is "depressed")

q

q

30

If the brake pedal is pressed while the PCCS lever is at "neutral", the steering control valve starts draining the oil on the back side of brake piston (8), "engaging" the steering clutch and actuating the steering brake. Thus, rotation of the output shaft is stopped. Adjusting the braking force becomes available by controlling the oil pressure to the back side of brake piston (8) corresponding to the stroke of the brake pedal.

D155A-6


D155A-6

SEN02863-00

31

SEN02863-00

Steering control valve

32


1

D155A-6


P: L:

From power train pump Scavenging pump From steering lubrication pump PS: To pin puller solenoid valve LB: To L.H. steering brake LL: To L.H. steering brake lubrication LC: To L.H. steering clutch RB: To R.H. brake RL: To R.H. brake lubrication RC: To R.H. steering clutch BSL: To bevel gear shaft and bearing lubrication BGL: To bevel gear lubrication DLB: Drain (L.H. steering brake) DRB: Drain (R.H. steering brake) DLC: Drain (L.H. steering clutch) DRC: Drain (R.H. steering clutch) DB: Drain (Sudden stop prevention valve) DPB: Drain (Parking brake) PLB: L.H. steering brake oil pressure pickup port PRB: R.H. steering brake oil pressure pickup port PLC: L.H. steering clutch oil pressure pickup port PRC: R.H. steering clutch oil pressure pickup port 1. 2. 3. 4. 5. 6. 7. 8. 9.

L.H. steering brake ECMV R.H. steering brake ECMV L.H. steering clutch ECMV R.H. steering clutch ECMV Steering oil filter Valve seat Parking brake solenoid valve Sudden stop prevention valve Check valve

D155A-6

SEN02863-00

General The steering control valve controls the steering clutch and steering brake by use of 4 ECMVs, parking brake solenoid valve and sudden stop prevention valve installed on the valve seat. q The steering control valve is provided in the circuit across the power train pump, steering clutch and steering brake piston. It is consisted of the steering clutch ECMV (R.H. and L.H.) and steering brake ECMV (R.H. and L.H.). q The steering control valve conducts the oil from the power train pump to the steering clutch and steering brake to control the R.H. and L.H. disk clutches and the disk brake. q If the PCCS lever is leaned to the right or left, the steering clutch is disengaged. The steering brake will operate by further leaning the PCCS lever. q The controller sends signals to each ECMV according to the right or left stroke of the PCCS lever and adjusts the gradual or sharp turns. q As the brake pedal is pressed, the controller sends the command, corresponding to the pedal stroke, to the steering brake ECMV to actuate the R.H. and L.H. brakes and, thus, to apply braking to the machine. q The controller, which is electrically connected to the PCCS lever and brake pedal, operates the steering clutch and steering brake by controlling each ECMV and solenoid valve. q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly, when an abnormality takes place in the electric system. q As the parking brake lever is set to the "lock" position, the controller sends the signal to the parking brake solenoid valve to drain the oil between the R.H. and L.H. steering brake ECMVs and brake piston in order for actuating the brake. The parking brake solenoid valve is electrically connected to the brake pedal, too. q

33

SEN02863-00


Steering clutch ECMV, steering brake ECMV a a

ECMV: Abbreviation for Electronic Control Modulation Valve Don't try to disassemble it since adjustment for maintaining the performance will be needed.

A: To clutch or brake P: From pump S: To parking brake solenoid valve T: Drain DR: Drain P1: Brake oil pressure pickup port 1. 2. 3. 4. 5. 6. 7.

1

General Each ECMV keeps the steering clutch oil pressure and steering brake oil pressure to the set pressure and furthermore changes the circuit to the piston chamber of the steering clutch and steering brake.

q

Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve Name plate (*1)

*1:

34

The clutch used

Name plate stamp

Steering clutch, Steering brake

R*******

D155A-6


SEN02863-00

Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q Pressure control valve A proportional solenoid in this valve receives a current sent from the controller and this valve converts it to an oil pressure. q Fill switch This is a switch to detect that a clutch or brake is filled with oil and has the following functions. 1. At the moment when the clutch or brake is filled with oil, the fill switch outputs the signal (fill signal) to the controller to notify the finishing of filling. 2. While the oil pressure is applied to the clutch or brake, the fill switch outputs the signal (fill signal) to the controller to notify the presence of the oil pressure. ECMV and proportional solenoid q One proportional solenoid is mounted for each ECMV. The propulsion force is generated according to the command current from the controller. The propulsion force generated by the proportional solenoid is actuated on the spool of the pressure control valve and generates the oil pressure. Accordingly, by controlling the amount of the command current, the propulsion force changes and the pressure control valve is actuated, then the oil flow and oil pressure is controlled. ECMV and fill switch For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. The oil pressure is built up according to this signal.

q

Operation of ECMV The ECMV is controlled by the command current from the controller to the proportional solenoid and the fill switch output signal.

q

D155A-6

35

SEN02863-00


When the PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in "free" position: Straight travel (L.H. and R.H. brake are "released", parking brake is "released")

q

q

q

q q

36

When the PCCS lever is in "neutral" position and the brake pedal is "released", proportional solenoid (1) of the clutch ECMV is demagnetized and the sealing part of ball (2) is opened. The oil from the power train pump flows through port (Pc) of the clutch ECMV to orifice (a), then it is drained through the sealing part of ball (2). Valve (3) is moved to the right by the tension of spring (4) to disconnect port (Pc) from port (C), and connect port (C) with port (Dr). At this time, the oil from the back pressure port of the clutch piston is drained through port (C) and the clutch is turned "on" by the tension of the clutch spring. The oil pressure in the brake circuit, etc. is secured by orifice (a). Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left and closes the sealing part.

q

q

The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left to connect port (Pb) with port (B) and disconnect port (B) from port (Dr). At this time, the oil flows in the back pressure port of the brake piston. As the oil pressure rises, the brake piston is pushed to the left to compress the brake spring, then the brake is "released". When the parking brake lever is set in the "free" position, the pilot pressure of brake ECMV port (S) remains, because the parking brake solenoid valve is de-energized.

D155A-6


SEN02863-00

When the PCCS lever is "operated to the left halfway", brake pedal is "released", and parking brake lever is in "free" position: Gradual left turn (L.H. brake is "half released", R.H. brake is "released", parking brake is "released")

q

q

q

q

When the PCCS lever is "operated to left halfway" and the brake pedal is "released", proportional solenoid (1) of the L.H. clutch ECMV is energized and the sealing part of ball (2) is closed. The oil from the power train pump flows through port (C) of the clutch EMCV and orifice (a) to port (F) and pushes valve (3) to the left to connect port (Pc) with port (C) and disconnect port (C) from port (Dr). At this time, the oil flows in the back pressure port of the clutch piston. As the oil pressure rises, the clutch piston is pushed to the left to compress the clutch spring, then the clutch is turned "off". Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left and closes the sealing part. The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left. As for the oil pressure after port (B), the controller outputs the command current to proportional

D155A-6

q

q

q

solenoid (5) according to the stroke of the PCCS lever. Proportional solenoid (5) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pressure port of the brake piston and the tension of spring (8), then the brake pressure is set up to adjust the brake force. Accordingly, if the stroke of the PCCS lever is short, the oil pressure after port (B) is set high and the brake is turned from "released" to "half released". If the stroke of the PCCS lever is long, the oil pressure after port (B) is set low and the brake is turned from "half released" to "applied". When the parking brake lever is set in the "free" position, the pilot pressure of brake ECMV port (S) remains, because the parking brake solenoid valve is de-energized.

37

SEN02863-00


When the PCCS lever is "operated fully to the left", brake pedal is "released", and parking brake lever is in "free" position: Sharp left turn (L.H. clutch is turned "off", L.H. brake is "applied", R.H. clutch is turned "on", R.H. brake is "released", and parking brake is "released".)

q

q

q

q

38

When the PCCS lever is shifted from "operated to left halfway" to "operated to left fully", proportional solenoid (5) of the L.H. brake ECMV is demagnetized and the sealing part of ball (6) is fully opened. Since the oil in port (E) is drained through the sealing part, valve (7) is moved to the right by the tension of spring (8) to disconnect port (Pb) from (B) and connect port (B) with port (Dr). At this time, the oil from the back pressure port of the brake piston is drained through port (B) and the brake is turned "applied" by the tension of the brake spring. The oil from the power train pump flows through port (Pb) of the brake ECMV and orifice (b), then it is drained through sealing part of ball (6). The oil pressure in the clutch circuit, etc. is secured by orifice (b).

q

When the parking brake lever is set in the "free" position, the pilot pressure of brake ECMV port (S) remains, because the parking brake solenoid valve is de-energized.

D155A-6


SEN02863-00

When the PCCS lever is in "neutral", brake pedal is "depressed", and parking brake lever is in "free" position: Stop (L.H. and R.H. brake are "operated", parking brake is "released")

q

q

q

q

When the brake pedal is depressed fully, proportional solenoids (5) of L.H. and R.H. brake ECMV are demagnetized to open the sealing part of ball (6). The controller outputs the command current to proportional solenoids (5) according to the brake pedal stroke. Proportional solenoid (5) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pressure port of the brake piston and the tension of spring (8), then the brake pressure is set up to adjust the brake force. Since the PCCS lever is in "neutral" position, proportional solenoids (1) of L.H. and R.H. clutch ECMV are demagnetized and L.H. and R.H. clutch are turned "on".

D155A-6

q

When the brake pedal is depressed fully, the brake pedal switch is turned "ON", and the parking brake solenoid valve is energized to drain the pilot pressure of the brake ECMV port (S).This carries out the same function as when the parking brake lever is set at the "lock" position.

39

SEN02863-00

Parking brake solenoid valve


1

P: From brake ECMV T: Drain Dr: Drain 1. 2. 3. 4.

Parking brake lever solenoid valve Brake pedal solenoid valve Connector for parking brake lever solenoid valve Connector for brake pedal solenoid valve

Solenoid valve 5. Coil (ON-OFF type) 6. Push pin 7. Spring 8. Spool 9. Body

40

D155A-6


SEN02863-00

When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in "lock" position: Parking (L.H. and R.H. brake are "operated", parking brake is "operated")

q

q

q

q

q

When the parking brake lever is in the "lock" position, the parking brake lever switch is turned "ON" and coil (1) of the parking brake solenoid valve is energized. Spool (3) is pushed to the right direction by push pin (2), then port (P) and (T) are opened to drain the pilot pressure of the L.H. and R.H. brake ECMV. The oil which had flown into the brake piston back pressure port is drained through the brake ECMV. The oil pressure in the back pressure port of the brake piston continues to decrease, then the brake is fully "applied" and that situation is kept. When the engine is started again, as port (P) and (T) are still opened, the brake is continuously "applied".

D155A-6

q

q

q

When the parking brake lever is in the "free" position, the parking brake lever switch is "OFF" and coil (1) of the parking brake solenoid valve is de-energized. Spool (3) is returned to the left, and close port (P) and (T) to remain the pilot pressure of the L.H. and R.H. brake ECMV. The oil pressure from the brake ECMV is applied to the back pressure port of the brake piston, and brake is "released".

41

SEN02863-00

Sudden stop prevention valve


1

A: From power train pump B: From brake ECMV dr1: Drain dr2: Drain 1.

Sudden stop prevention valve

EPC valve 2. Coil (proportional type) 3. Push pin 4. Valve 5. Ball 6. Spool 7. Body

42

D155A-6


SEN02863-00

General q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly when an abnormality takes place in the electric system. q Sudden stop prevention valve (1) is installed in the drain circuit of the brake ECMV so that the sudden oil pressure drop of port (DR) and consequently the sudden brake can be avoided when coil (2) of brake ECMV is de-energized. q If an abnormality takes place in the electric system, also coil (3) of the sudden stop prevention valve (1) is de-energized. Then, the oil of port (DR) is drained through orifice (a) so that the brake is applied gradually.

D155A-6

43

SEN02863-00

44


D155A-6


Final drive

SEN02863-00

1

Outline q The final drive is a single stage spur gear, single stage planetary gear reduction type. The lubrication is of splash type using the rotation of the gears. The final drive can be removed and installed as a single unit. q Floating seal (1) is installed to the rotating sliding portion of the sprocket to prevent the entry of dirt or sand and to prevent leakage of lubricating oil.

D155A-6

45

SEN02863-00

46


D155A-6


1. 2. 3. 4. 5. 6. 7. 8. 9.

SEN02863-00

10. 11. 12. 13. 14. 15. 16. 17.

Floating seal Sun gear Carrier Sprocket boss Sprocket teeth Cover Planetary gear Ring gear Cover

No.1 pinion Final drive case Bearing cage No.1 gear No.1 gear hub Shaft Wear guard Pivot shaft

Unit: mm No.

Check item

Criteria

Remedy

Standard clearance

Clearance limit

0.25 – 0.77

0.77

18

Backlash between No.1 pinion and No.1 gear

19

Backlash between sun gear and planetary gear

0.20 – 0.55

0.55

20

Backlash between planetary gear and ring gear

0.22 – 0.71

0.71

21

Outside diameter of No.1 pinion oil seal contact surface

22

Thickness of thrust collar of inner body roller bearing

23

Clearance between outer diameter of planet gear shaft and inner diameter of carrier hole. (Small diameter)

24

Clearance between outer diameter of planet gear shaft and inner diameter of carrier hole.(Large diameter)

25

Standard shim thickness for No.1 pinion bearing cage

26

Wear of wear guard

D155A-6

Replace

Standard size

Tolerance

Repair limit

95

–0.087 –0.087

94.913

23 Standard size

Repair or replace

22.95 Tolerance

Shaft

Hole

Standard clearance

Clearance limit

68.262

–0.015 –0.034

–0.009 –0.039

- 0.024 – + 0.025

(Max. Replace clearance) + 0.025

90

–0.036 –0.058

–0.066 –0.101

- 0.065 – - 0.008

2

– 0.008

Adjust

Standard size

Repair limit

67

21

Repair or replace

47

SEN02863-00


Path of power transmission

q

48

The power from the bevel gear shaft and steering clutch is transmitted to 1st pinion (10) to rotate 1st gear (13) meshed with the 1st pinion and sun gear (2) meshed with the 1st gear. The rotation of sun gear (2) is transmitted to planetary gear (7). Since ring gear (8) meshed with the planetary gear is fixed to cover (6), the planetary gear (7) rotates along the ring gear (8) and revolves around the sun gear (2).

Then, the rotating force of sun gear (2) forms the rotating force of carrier (3), which supports the planetary gear (7), via shaft (15), and is transmitted to sprocket boss (4). The rotating direction of carrier (3) is the same with sun gear (2). The rotational force transmitted to sprocket boss (4) is further transmitted to sprocket teeth (5).

D155A-6


D155A-6

SEN02863-00

49

SEN02863-00


Sprocket

1

Unit: mm No.

Check item

1

Wear of sprocket tooth tip

2

Wear of sprocket tooth root

3 4

50

Criteria Standard clearance

Remedy Repair limit

351

339

21.7

15.5

Wear of width of sprocket tooth tip

83

75

Wear of width of sprocket tooth root

105

95

Rebuid or replace

D155A-6


SEN02863-00

Sprocket tooth shape of full scale

D155A-6

51

SEN02863-00




52

D155A-6

SEN02864-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Undercarriage and frame Track frame ..................................................................................................................................................... 2 Recoil spring ................................................................................................................................................... 4 Idler ................................................................................................................................................................. 6 Track roller ...................................................................................................................................................... 8 Carrier roller .................................................................................................................................................. 10 Track shoe .................................................................................................................................................... 12 Main frame .................................................................................................................................................... 18 Suspension ................................................................................................................................................... 20

D155A-6

1

SEN02864-00


Track frame

1. 2. 3. 4. 5. 6. 7. 8.

Equalizer bar Pivot shaft Idler Track frame Carrier roller Sprocket Sprocket cover guard Track roller

1

Outline q The track rollers are mounted on an K-shaped bogie. This increases the actual ground contact area between the track shoes and the ground on rough surfaces, and helps increase the drawbar pull. q The K-shaped bogies are equipped with rubber pads to absorb the shock from the ground surface. Track roller, bogie Track roller flange type arrangement 1st

2nd

3rd

4th

5th

6th

7th

S

D

D

D

D

D

S

D: Double S: Single

2

D155A-6


SEN02864-00

Unit: mm No.

4

Check item

Deformation of track frame

D155A-6

Criteria

Remedy

Item

Repair limit

Curvature

7 (over length of 3,000)

Twisting

3 (over length of 300)

Dents (pipe portion)

12

Correct or replace

3

SEN02864-00

Recoil spring

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

4

Yoke Dust seal Rod Recoil spring Wear ring Lubricator Nut Housing Cylinder Holder Bushing


1

Outline q Recoil spring (4) is used to adjust the track tension by pumping in or releasing grease from lubricator (6) to move rod (3) forward or backward. The recoil spring also acts to dampen any sudden shock brought to bear on the idler.

D155A-6


SEN02864-00

Unit: mm No. 1

11

Check item

Criteria

Press-fitting force for idler yoke Clearance between rod and bushing

392 kN {40 ton} Standard size 110

Tolerance

Recoil spring

D155A-6

Adjust

Shaft

Hole

Standard clearance

Clearance limit

–0.036 –0.090

+0.277 +0.062

0.098 – 0.367

1.0

Standard size 4

Remedy

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

734

597

298 kN {30,388 kg}

687

274 kN {27,900 kg}

Replace

5

SEN02864-00

Idler

6


1

D155A-6


SEN02864-00

Unit: mm No.

C

heck item


Remedy Repair limit

1

Outer diameter of protrusion

850

—

2

Outer diameter of tread

800

781

3

Depth of tread

25

34.5

4

Thickness of tread

21

11.5

5

Overall width

245

—

6

Width of tread

62

—

7

Clearance between shaft and bushing

Tolerance

Standard size 85

8

Interference between idler and bushing

Shaft

Hole

Standard clearance

Clearance limit

–0.210 –0.260

+0.255 +0.220

0.430 – 0.515

—

Tolerance

Standard size 135

Shaft

Hole

+0.130 +0.080

+0.100 –0.050

Standard size 9

Shaft flange width 20

10

Play of shaft in axial direction

D155A-6

Rebuild or replace

Standard Interference interference limit 0.02 – 0.18

Replace bushing

—

Repair limit

–0 –0.05

—

Replace

0.49 – 0.72

7

SEN02864-00

Track roller

8


1

D155A-6


SEN02864-00

Unit: mm No.

C

heck item

Criteria

Remedy

Standard size

Repair limit

298

—

282

—

1

Outer diameter of flange (outside flange)

2

Outer diameter of flange (inside flange)

3


255

230

4

Thickness of tread

60

47.5

5

Overall width

294

—

6

Width of tread (single flange)

64

—

7

Width of tread (double flange)

62

—

8

Flange width (outside of double flange)

25

—

9

Flange width (inside of double flange)

22

—

10

Shaft flange width

20

—

11

Clearance between shaft and bushing

Standard size 85

12

Interference between bushing and roller

Standard size 135

13

End play

D155A-6

Tolerance Shaft

Hole

Standard clearance

–0.210 –0.260

+0.255 +0.220

0.430 – 0.515

Tolerance Shaft

Hole

+0.130 +0.080

+0.063 –0.020

Rebuild or replace

Clearance limit —

Standard Interference interference limit 0.017 – 0.150

Standard size

Clearance limit

0.5 – 0.75

—

Replace bushing

Replace

— Adjust or replace

9

SEN02864-00

Carrier roller

10


1

D155A-6


SEN02864-00

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

1

Outer diameter of flange

220

—

2


190

167

3

Width of tread

63

—

4

Thickness of tread

37.5

26

5

Width of flange

6

7

Interference between shaft and ring

Clearance between shaft and support

21 Standard size 70 Standard size 68

8

Play of roller in axial direction

D155A-6

Rebuild or replace

— Tolerance Shaft

Hole

+0.166 +0.120

+0.030 +0.030

Tolerance Shaft

Hole

–0.2 –0.2

+0.300 +0.030

Standard interference 0.090 – 0.166 Standard clearance

Replace

0 – 0.5

Standard clearance 0.010 – 0.230

11

SEN02864-00


Track shoe

1

Dry type

a

12

P portion shows the link of bushing press fitting end. D155A-6


SEN02864-00

Unit: mm No. 1

2

Check item

Bushing outside diameter Thickness of bushing metal

4

Link height

5

Thickness of link metal (bushing press-fitting portion)

6

Shoe bolt

Interference between bushing and link

Remedy

Standard size

Repair limit

228.9

231.9 (Heavy-duty areas) 233.9 (Standard areas)

Link pitch

3

7

Criteria

When turned

Standard size

Normal load

Impact load

81

75.0

77.0

15.8

9.8

11.8

Standard size

Repair limit

144

128

45.5

29.5

Tightening torque (Nm {kgm})

Additional tightening angle (deg.)

590 ± 60 {60 ± 6}

120 ± 10

Standard size

Tolerance

Reverse or replace

Repair or replace

Retighten

Standard interference

Shaft

Hole

77.0

+0.404 +0.304

+0.074 +0.074

0.230 – 0.404

8a

Interference between regular pin and link

48.5

+0.484 +0.334

–0.038 –0.100

0.372 – 0.584

8b

Interference between master pin and link

48.5

+0.230 +0.200

–0.038 –0.100

0.238 – 0.330

Adjust or replace

Standard clearance 9

Clearance between links

D155A-6

One side

Both side

1.4

2.8

13

SEN02864-00


Sealed and lubricated track

a

14

P portion shows the link of bushing press fitting end.

D155A-6


SEN02864-00

Unit: mm No. 1

2 3

Check item

Thickness of bushing metal Link height

5

Thickness of link metal (bushing press-fitting portion) a. Regular link b. Master link

7

8

Repair limit

228.9

Bushing outside diameter

Shoe bolt

Remedy

Standard size

Link pitch

4

6

Criteria

Interference between bushing and link Interference between regular pin and link

231.9 When turned

Standard size

Normal load

Impact load

81

72.5

75.0

15.8

7.3

9.8

Standard size

Repair limit

144

128

45.5

29.5

Tightening torque (Nm {kgm})

Additional tightening angle (deg.)

590 ± 60 {60 ± 6}

120 ± 10

590 ± 60 {60 ± 6}

180 ± 10 Tolerance

Standard size

Reverse or replace

Repair or replace

Retighten

Standard interference

Shaft

Hole

77.0

+0.404 +0.304

+0.074 +0.074

0.230 – 0.404

48.5

+0.484 +0.334

–0.038 –0.100

0.372 – 0.584

Adjust or replace

Standard clearance 9

Clearance between links

D155A-6

One side

Both side

1.4

2.8

15

SEN02864-00


Single shoe, heavy duty shoe

Unit: mm No. 1

2

16

Check item

Criteria

Remedy

Standard size

Repair limit

single

80

30

heavy duty

80

30

Overall height single of shoe heavy duty

97

47

99

49

Height of grouser

Repair or replace

D155A-6


D155A-6

SEN02864-00

17

SEN02864-00

Main frame

18


1

D155A-6


1. 2. 3. 4. 5. 6. 7. 8.

SEN02864-00

Main frame Cage Clamp Cover Seal Coupling Cap Plate Unit: mm

No.

9

10

Check item Clearance between equalizer bar shaft and bushing Press-fitting force for equalizer bar shaft mounting bushing

D155A-6

Criteria Standard size 95

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

–0.036 –0.090

+0.213 +0.129

0.165 – 0.303

1.0

29.42 – 68.65 kN {3 – 7 ton}

Replace

Adjust

19

SEN02864-00

Suspension

20


1

D155A-6


1. 2. 3. 4. 5.

SEN02864-00

6. 7. 8. 10. 11.

Equalizer bar Pivot shaft assembly Cover Thrust plate Thrust plate

Pivot shaft Seal cage Seal Side pin Center pin Unit: mm

No.

Check item

9

Press-fitting force for side pin bushing

12

Press-fitting force for center pin bushing

13

Clearance between center pin and bushing

14

Clearance between side pin and bushing

15

Interference between side pin boss and bushing

16

17

18

Interference between pivot shaft and seal stopper ring Clearance between pivot shaft and bushing (outer) Clearance between pivot shaft and bushing (inner)

Criteria

Remedy

27.46 – 64.7 kN {2.8 – 6.6 ton} — 47.07 – 131.41 kN {4.8 – 13.4 ton} Tolerance

Standard size

Shaft

Hole

Standard clearance

Clearance limit

95

–0.036 –0.090

+0.279 +0.213

0.249 – 0.369

1.0

70

–0.030 –0.060

+0.046 +0.046

0.030 – 0.106

1.0

Standard size

Tolerance

Standard Interference interference limit

Shaft

Hole

130

+0.033 +0.015

–0.028 –0.068

0.043 – 0.101

—

179

+0.083 +0.043

–0.053 –0.093

0.096 – 0.176

—

Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

148

–0.145 –0.208

+0.099 +0.035

0.180 – 0.307

1.0

175

–0.145 –0.208

+0.095 +0.025

0.170 – 0.303

1.0

Replace bushing

Outline q The front of the track frame rocks up and down using the rear pivot shafts (6) as a fulcrum. Equalizer bar (1) rocks using center pin (11) as a fulcrum. The left and right track frames are connected by side pin (10). D155A-6

21

SEN02864-00




22

D155A-6

SEN02865-02


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

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

D155A-6

1

SEN02865-02


Work equipment hydraulic piping diagram

1

Semi U-dozer

1. 2. 3. 4.

2

Blade tilt cylinder R.H. blade lift cylinder Accumulator Control valve

5. 6. 7. 8.

Hydraulic tank Hydraulic pump L.H. blade lift cylinder Oil cooler

D155A-6


SEN02865-02

Multi-shank ripper

1. 2. 3. 4.

Control valve Divider block Ripper lift cylinder Ripper tilt cylinder

D155A-6

3

SEN02865-02


Giant ripper

1. 2. 3. 4. 5. 6.

4

Control valve Divider block Ripper lift cylinder Pin puller cylinder Ripper tilt cylinder Pin puller solenoid valve

D155A-6


D155A-6

SEN02865-02

5

SEN02865-02


Work equipment control piping diagram

1

Blade, ripper control Serial No.: 85001 – 85024

1. 2.

6

Accumulator Control valve

3. 4.

Work equipment lock valve Self pressure reducing valve

D155A-6


SEN02865-02

Serial No.: 85025 and up

1. 2. 3.

Accumulator Control valve Work equipment lock valve

D155A-6

4. 5.

Self pressure reducing valve Filter

7

SEN02865-02


Work equipment control

1

3 4 2 1 5

M

N

AJG00278

8

D155A-6


1. 2. 3. 4. 5.

SEN02865-02

Work equipment lock lever Blade PPC valve Ripper PPC valve Work equipment lock switch Control valve

Lever positions A : Blade HOLD B : Blade LOWER B + C :Blade FLOAT D : Blade RAISE E : Blade LEFT TILT F : Blade RIGHT TILT G : Ripper HOLD H : Ripper RAISE J : Ripper LOWER K : Ripper DECREASE TIP ANGLE (with variable ripper) L : Ripper INCREASE TIP ANGLE (with variable ripper) M : FREE N : LOCK Outline q The work equipment control employs a PPC system which uses a PPC valve to move the spools of the control valve.

D155A-6

9

SEN02865-02


Hydraulic tank and filter

1. 2. 3. 4. 5. 6.

10

Pressure valve Drain valve Drain plug Cover Cover Hydraulic tank

1

7. 8. 9. 10. 11. 12.

Strainer Suction valve Spring Hydraulic filter element Oil filler cap Sight gauge

D155A-6


SEN02865-02

Specified value Tank capacity Hydraulic tank

Breather

Level inside tank

(l)

125

Hi

(l)

95

Center

(l)

85

Low

(l)

75

16.7 ± 2.5 Cracking pressure (kPa {kg/cm2}) {0.17±0.025} 2 ± 0.3 Vacuum valve actuating pressure (kPa {kg/cm2}) {0.02±0.003} Cracking pressure (kPa {kg/cm2})

Hydraulic filter

Mesh size

(µ m)

20/10/5

Filtering area

(cm2)

13,600

Filtering oil flow Strainer

D155A-6

147 ± 29.4 {1.5±0.31}

(l/min)

550

Mesh size

(µ m)

105

Filtering area

(cm2)

1,850

11

SEN02865-02

Accumulator For EPC valve


1

Function q The accumulator is installed between the redusing valve and the EPC valve. Even if the engine is started with the work equipment still raised, the pressure of the nitrogen gas compressed inside the accumulator sends the pilot pressure to the control valve to actuate it and enable the work equipment to move down under its own weight. Operation After the engine is stopped, when the EPC valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B). q When the EPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30 kg/cm2}, and the pressure of the nitrogen gas in chamber (A) expands the bladder, so the oil in chamber (B) acts as the pilot pressure and actuates the main control valve. q

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: 3.14 MPa {32 kg/cm2} Min. actuation pressure: 1.18 MPa {12 kg/cm2}

12

D155A-6


PPC valve

SEN02865-02

1

Blade PPC valve

P: From self pressure reducing valve P1: To blade lift valve (LOWER, FLOAT) P2: To blade lift valve (RAISE)

D155A-6

P3: To blade tilt valve (LEFT TILT) P4: To blade tilt valve (RIGHT TILT) T: To tank

13

SEN02865-02

1. 2. 3. 4. 5.

14

Spool Piston Disc Nut (For connecting lever) Joint


6. 7. 8. 9.

Plate Retainer Body Filter

D155A-6


SEN02865-02

Unit: mm No.

Check item


10

Metering spring (For ports P3 and P4)

Remedy Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

26.53 x 8.15

24.9

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

11

Centering spring (For ports P3 and P4)

48.57 x 15.5

32.5

107.9 N {11 kg}

—

86.3 N {8.8 kg}

12

Metering spring (For port P2)

26.3 x 8.15

24.1

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

13

Centering spring (For port P2)

43.2 x 15.5

34

78.5 N {8 kg}

—

62.8 N {6.4 kg}

14

Centering spring (For port P1)

34.0 x 15.5

31.9

94 N {9.6 kg}

—

75.3 N {7.68 kg}

15

Metering spring (For port P1)

29.27 x 8.15

25.4

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

D155A-6

Replace spring If damaged or deformed.

15

SEN02865-02

Operation 1. When in neutral 1) For lifting blade q Ports (A) and (B) of the blade lift valve of thecontrol valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).

16


2) q

For tilting blade Ports (C) and (D) of the blade tilt valve of the control valve and ports (P3) and (P4) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).

D155A-6


2. q

q

q

q

q

q

q

SEN02865-02

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

D155A-6

17

SEN02865-02

3. q

q

q

q

18

When in fine control (When control lever is returned) If disc (3) begins to return, the force of centering spring (14) and the pressure in port (P1) push up spool (1). As a result, fine control hole (f) is connected to drain chamber (D) and the oil in port (P1) is released. If the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (15) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f’) of the valve which is not in operation and then flows through port (P2) into port (A).


4. q

q

q

When lever is operated to stroke end If disc (3) pushes down piston (2) and retainer (7) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and pushes the control valve spool. The oil returning from port (A) flows through port (P2) and fine control (f’) into drain chamber (D).

D155A-6


5. q

q

q q

q

q q

When blade is “floated” If piston (2) on the “LOWER” side of port (P1) is pushed down by disc (3), ball (18) touches projection (a) of the piston in the middle of the stroke (The detent starts to operate). If piston (2) is pushed in further, ball (18) pushes up collar (17) supported on detent spring (16) and escapes out to go over projection (a) of the piston. At this time, piston (2') on the opposite side is pushed up by spring (19). As a result, the oil in chamber (F) flows through (b) and (c) to chamber (E) and piston (2') follows disc (3). Since passage (d) is connected to port (P1), almost the same pressure is applied to passage (d) and port (P1). Chamber (E) is normally connected to drain chamber (D). If ball (18) goes over projection (a) of the piston, passage (d) and chamber (E) are connected and the oil starts flowing. At this time, the control valve moves to the “FLOAT” position and the blade is floated. Since piston (2') is pushed up by the pressure in chamber (E), the “FLOAT” state is kept even if the lever is released.

D155A-6

SEN02865-02

6. q

q

When “FLOAT” state of blade is reset Disc (3) is pushed down with a force larger than the oil pressure in chamber (E) to return from the “FLOAT” position. As a result, chamber (E) is disconnected from passage (d) and connected to the drain chamber. Accordingly, the oil pressure in chamber (E) is lost and the “FLOAT” state is reset.

19

SEN02865-02


Ripper PPC valve

P P1 P2 P3 P4 T

20

: From self pressure reducing valve : To ripper tilt valve (OUT) : To ripper tilt valve (IN) : To ripper lift valve (LOWER) : To ripper lift valve (RAISE) : To tank

D155A-6


D155A-6

SEN02865-02

21

SEN02865-02

22


D155A-6


1. 2. 3. 4. 5. 6. 7. 8. 9.

SEN02865-02

Spool Piston Disc Nut (for connecting lever) Joint Plate Retainer Body Filter

Unit: mm No.

Check item

Criteria

Remedy

Standard size Centering spring 10 (For ports P3 and P4)

11

Centering spring (For ports P1 and P2)

12 Metering spring

D155A-6

Repair limit

Free length × Outside diameter

Installed length

Installed load

Free length

Installed load

50.35 × 15.5

34

55.9 N {5.7 kg}

—

44.7 N {4.56 kg}

50.05 × 15.5

34

71.4 N {7.28 kg}

—

57.1 N {5.8 kg}

26.53 × 8.15

24.9

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

Replace spring if damaged or deformed.

23

SEN02865-02

Operation 1. When in neutral q Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).

2. q

q

q

q

24


q

q

Since metering spring (2) is compressed in proportion to the stroke of the control lever, the pressure in port (P1) rises in proportion to the stroke of the control lever. Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the pressure in port (P1)] is balanced with the force of the control valve spool return spring.

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

D155A-6


3. q

q

q

q

When in fine control (When control lever is returned) If disc (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). As a result, fine control hole (f) is connected to drain chamber (D) and the oil in port (P1) is released. If the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (2) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f') of the valve which is not in operation and then flows through port (P2) into chamber (B).

D155A-6

SEN02865-02

4. q

q

q

When lever is operated to stroke end If disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into chamber (A) and pushes the control valve spool. The oil returning from chamber (B) flows through port (P2) and fine control (f') into drain chamber (D).

25

SEN02865-02

Work equipment lock valve

1. 2. 3.


1

Solenoid Body Spool

Outline q The work equipment lock valve is installed between the basic pressure valve and control valve in the work equipment control circuit. If the work equipment lock lever is set in the FREE position, the work equipment lock switch operates and the work equipment lock valve opens the work equipment control circuit so that the operator can operate the work equipment. Operation q The solenoid is operated by the electric signal to move the spool. As a result, the circuit between port (A) connected to the basic pressure valve and port (B) connected to the control valve is opened.

26

D155A-6


D155A-6

SEN02865-02

27

SEN02865-02

Control valve


1

General view

28

D155A-6


SEN02865-02

A: Pump pressure pick-up port A1: To blade tilt cylinder head A2: To blade lift cylinder head A3: To ripper lift cylinder head A4: To ripper tilt cylinder bottom B: LS pressure pick-up port B1: To blade tilt cylinder bottom B2: To blade lift cylinder bottom B3: To ripper lift cylinder bottom B4: To ripper tilt cylinder head C: PPC main pressure port LS: To pump LS valve P: From pump PA1: From blade PPC valve PA2: From blade PPC valve PA3: From ripper PPC valve PA4: From ripper PPC valve PB1: From blade PPC valve PB2: From blade PPC valve PB3: From ripper PPC valve PB4: From ripper PPC valve T: To tank

D155A-6

29

SEN02865-02


Sectional view (1/3)

30

D155A-6


1. 2. 3. 4.

SEN02865-02

5. 6. 7. 8.

Valve block Ripper tilt spool Ripper lift spool Blade lift spool

Blade tilt spool Valve body Load check valve Pressure compensation valve Unit: mm

No.

Check item


Remedy Repair limit


Installed length

Installed load

Free length

Installed load

76.3 x 30

68.5

224N {22.8kg}

—

178N {18.2kg}

10 Spool return spring

51.7 x 31.3

50

140N {14.3kg}

—

112N {11.4kg}

11 Spool return spring

54.7 x 36.5

33.5

217N {22.1kg}

—

174N {17.7kg}

12 Load check valve spring

20.8 x 12.2

13.5

12.7N {1.3kg}

—

9.8N {1.0kg}

86.7 x 30

66

193N {19.63kg}

—

154N {15.7kg}

9

Spool return spring

13 Unload valve spring

D155A-6

If damaged or deformed, replace spring

31

SEN02865-02


(2/3)

32

D155A-6


1. 2. 3.

LS check valve Main relief valve LS relief valve

SEN02865-02

4. 5. 6.

Unload valve Suction valve Check valve (built in spool) Unit: mm

No.

Check item


7

Suction valve spring

D155A-6

Remedy Repair limit


Installed length

Installed load

Free length

Installed load

64.9 x 12.5

56

6.37N {0.65kg}

—

5.1N {0.52kg}


33

SEN02865-02


(3/3)

34

D155A-6


SEN02865-02

1. Suction valve 2. Preset check valve 3. LS bypass valve Unit: mm No.

Check item


4

Suction valve spring

D155A-6

Remedy Repair limit


Installed length

Installed load

Free length

Installed load

46.8 x 7.5

40.6

5.49N {0.56kg}

—

4.41N {0.45kg}


35

SEN02865-02


Operation of control valve

Function q When the main spool is at the HOLD position, it drains the excess oil discharged by the pump, and prevents the pressure from being formed in the circuit from rising. q Use of the CLSS circuit (Closed Center Load Sensing System) makes it possible to control the oil flow by adjusting the area of opening of the spool driven by the PPC valve, regardless of the load.

q

When (FO) becomes larger than set load (FS) of spring (2), the spool moves to the right and connects the passage between chamber (A) and chamber (B), so the oil from the pump is drained. Therefore, spool (1) is balanced at a position that matches the supply of oil from the pump. Actually, the amount of oil supplied from the pump is small, so the pressure in the circuit is almost the same as the set load of spring (2).

Operation of unload valve q When the main spool is at the HOLD position, the pump pressure passes from chamber (A) through oriffice (4) to chamber (D). Chambers (C) and (C') are connected to the drain circuit. q When oil is supplied from the pump, the pressure in chamber (D) rises, and spool (1) is pushed to the right by pressure (FO) which is determined by the cross-sectional area of piston (3) receiving the pressure.

36

D155A-6


SEN02865-02

Control of oil flow 1. a

At HOLD The diagram shows blade right tilt cylinder circut

Operation q When the spool is at the HOLD position, the pump pressure is sent from chamber (A) through the notch in spool (3) of the pressure compensation valve, and passes through chamber (B) to chamber (C). Chamber (G) is drained through chamber (H) to chamber (F). When this happens, the pump pressure is acting on the left end of spool (3) of the pressure compensation valve, so it pushes against the

D155A-6

load of spring (4) and moves to the right to the maximum stroke position. In this condition, the area of the opening to spool (1) of the blade tilt valve is at its minimum.

37

SEN02865-02

2.

At blade right tilt

Operation q When the tilt lever is operated to right tilt, pilot pressure (PB1) acts on the right end of spool (1) through the PPC valve, and when the pressure becomes greater than the set load of spring (2), the spool starts to move to the left. It is balanced at a position corresponding to PPC output pressure (PB1).

38


q q q

PLS = differential pressure between ports (K) and (J) = 1.96 MPa {20kg/cm2} PLS' = differential pressure between ports (I) and (D) PLS C PLS'

D155A-6


q

q

Chamber (C) and chamber (D) are connected, and the oil from the pump flows through ports (A), (B), (C), and (D) to tilt cylinder (6). At the same time, the load pressure in chamber (D) passes through LS orifice (5) and chamber (H), and is sent to chamber (G). It is also sent from the LS circuit (O) to pump servo valve (7). The condition of the pressure of spool (3) is chamber (B) pressure C chamber (C) pressure, and chamber (G) pressure C chamber (D) pressure, so spool (3) is controlled by the differential pressure of spool (1) (chamber (C) pressure – Chamber (D) pressure), and balances with spring (4). In other words, if the oil flow is too large, the differential pressure of spool (1) becomes larger, so spool (3) moves in the direction to throttle the oil flow; on the other hand, if the oil flow is too small, spool (3) moves in the direction to increase the oil flow.

D155A-6

SEN02865-02

q

q

In addition, pump servo valve (7) is controlled so that the differential pressure between pump pressure (P) and LS pressure (LS) (LS differential pressure: ( PLS) remains constant, so a suitable amount of oil flows to ensure that the loss of pressure at the control valve ( PLS') is equal to ( PLS). The loss of pressure in the control valve is determined by the area of the opening of the main spool, so the oil flow matches the opening of the spool. The return oil flow from the tilt cylinder passes through chamber (E) and chamber (F), and is drained.

39

SEN02865-02

3.

40


Meter-out control when blade moves down under its own weight (work equipment lever at LOWER)

D155A-6


SEN02865-02

Operation q In the case where the blade falls owing to the weight of the blade, the return flow from a cylinder is controlled according to the opening area of main spool (1). q

Oil flows from the suction valve (2) to a cylinder so that it prevents the circuit from being evacuated.

q

When a spool port opens with PPC output pressure at (PA2), oil on the cylinder head side passes through ports (A), (B) and (D) and then drains into the tank owing to the weight of the blade. At this time, the opening area between ports (A) and (B) squeezes the return flow from a lift cylinder in order to control the drop speed. In the case where the blade falls owing to the weight of the blade, oil on the cylinder head side passes through a drain circuit and the suction valve (2) and then it is supplied to the cylinder bottom side. At the same time, the output flow from the pump passes through ports (A1), (B1), (C1), (D1) and (E1) and then it is supplied to the cylinder bottom side.

q

D155A-6

41

SEN02865-02

4.

42


Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)

D155A-6


SEN02865-02

Operation q When the lift valve is at FLOAT, the cylinder port and drain port are connected to put the circuit in a no-load condition. q When the lift valve is in the FLOAT condition, the pump passage and cylinder ports (A3) and (B3) are separated so that the other control valves can be operated. q When the work equipment control lever is at t h e F L O AT p o s i t i o n , i f p r e s s u r e ( PA 3 ) becomes 3.4 MPa (35 kg/cm 2 ) or more, lift spool (1) is moved to the maximum stroke position. q In this condition, ports (A3) and (B3) and the LS passage (O) are all connected to the drain circuit, so there is no load on the lift cylinder. q If the cylinder is driven by the weight of the blade, the oil entering from (A3) flows to ports (A), (B), (B1) and (A1), while the rest of the oil flows through port (D), and is drained. The oil from suction valve (9) flows to port (B3). When this happens, the oil flow is throttled by the area of opening between ports (A) and (B) of spool (1), and the cylinder speed is controlled. q The pump circuit chamber (E) and ports (A3) and (B3) are separated, and pump pressure (P) is formed, so it is possible to carry out compound operations with other control valves.

D155A-6

43

SEN02865-02

5. a

q q q

44


At relief (Blade lift, blade tilt, ripper lift, ripper tilt) The diagram shows the condition at relief for work equipment LS relief valve (5) with blade tilt stroke end.

P1 = P3 + P4 = Differential pressure between ports (M) and (P) P2 = Differential pressure between ports (P) and (N) P3 = Differential pressure between ports (M) and (B)

q q

P4 = Differential pressure between ports (B) and (P) LS = P1 + P2 = Differential pressure between ports (M) and (N) = 1.96 MPa {20 kg/ cm2}

D155A-6


SEN02865-02

Operation q If blade tilt valve (1) is moved, and the pressure of tilt cylinder (8) becomes higher, work equipment LS relief valve (5) will crack and oil will be drained from LS circuit (O). (Ports (P), (F), (G), (J), and (K)). As a result, there will be a drop in pressure in LS passage (O) starting from LS sensing hole (F), and ( P2) will become larger. q For the same reason, if the pressure in chamber (I) and (H) drops, spool (2) will push against spring (3) and move to the right, and will make the opening between chambers (B) and (C) smaller, so the flow between chambers (B) and (C) will be throttled and ( P4) will become larger. q Because of the pump swash plate control, the system circuit is balanced at a circuit pressure which makes the pressure loss generated by the flow at work equipment LS relief valve (5) ( P1) + ( P2) equal to LS differential pressure ( LS). When this happens, pump LS valve (6) detects the differential pressure generated by LS relief valve (5), and moves the pump swash plate from the maximum to the minimum position where the LS differential pressure is 1.96 MPa {20 kg/cm2}. q When the pump is at the minimum swash plate angle (minimum oil flow), if the minimum oil flow is greater than the LS relief oil flow + leakage at any part, the pressure is confined in the pump circuit (the pump and chambers (A) and chamber (B) through pressure compensation valve (7)), so the LS differential pressure rises. If this differential pressure goes above the set pressure for unload valve (4), the unload valve is actuated to relieve the excess oil flow and balance the circuit.

D155A-6

45

SEN02865-02

6. a

46


Compound operation of work equipment valve The diagram shows the condition when the blade lift and tilt valves are operated at the same time.

D155A-6


q

It consists of a parallel circuit, so when compound operations are carried out, the oil flow is divided according to the size of each spool opening.

q

Tilt spool (1) and lift spool (2) are actuated by PPC valve output pressure (PA1) and (PB2), and each is balanced at a position that matches its own pilot pressure.

1)

When pump pressure (P2) Z (P3) Lift valve load pressure (P3) is sent to pump LS valve (4) through LS passage (O).

q

SEN02865-02

(1) When pump swash plate does not reach maximum angle q When the maximum flow of oil from the pump is greater than the total of the oil flow demanded by the tilt valve and lift valve, an oil flow that matches the opening of the spool flows to both the tilt valve and lift valve. (2) When pump swash plate is at maximum angle q When the maximum flow of oil from the pump is smaller than the total of the oil flow demanded by the tilt valve and lift valve, the flow of oil to the tilt valve and lift valve is divided according to differential pressure (PO) – (P2) and differential pressure (PO) – (P3). In other words, more oil flows to (P2) where the load is small. q

2) q

In cases where the blade is raised in the air and the tilt valve and lift valve (for raise) are operated at the same time, the tilt valve load pressure is smaller than the lift valve load pressure, so the flow of oil to the tilt valve is given priority. In addition, the oil flow demanded by the tilt valve is smaller, so the condition is just as if priority was given to the oil flow for the tilt valve.

When pump pressure (P2) = pump pressure (P3) (P) – (P2) C (P) – (P3), so an oil flow proportional to the size of the spool opening is distributed to each spool.

D155A-6

47

SEN02865-02

7. a

48


Unload valve preset system The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is operated.

D155A-6


q

This improves the response of the system including the pump swash plate and pressure compensation valve by sending the pilot pressure (basic pressure of PPC valve) to the LS circuit, and compensating the rise of the LS circuit pressure.

q

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

q

When spool (1) is switched, unload pressure (P) flows immediately through chamber (A), (B), (C), (D), and (E) to lift cylinder (8), so the pressure at the port starts to rise and the time lag becomes smaller.

q

At the same time, preset pressure (P2) is supplied to LS circuit (O) by the timing of the spool, and the pressure in the LS circuit rises. Because of this, unload valve (7) closes, and oil is sent further to pump LS valve (6) to improve the response of the pump swash plate angle. This makes it possible to reduce the response time for giving the necessary oil flow. Check valve (5) is built in the spool to prevent preset pressure (P2) from venting in force from the cylinder port.

q

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

D155A-6

SEN02865-02

49

SEN02865-02

Work equipment cylinder


1

Blade lift cylinder

Blade tilt cylinder

Ripper cylinder

a

50

The piping of the lift cylinder and tilt cylinder of the variable multi-shank ripper is different from the above.

D155A-6


SEN02865-02

Unit: mm No.

Check item


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

75

-0.030 -0.076

+0.279 +0.065

0.095 – 0.355

0.666

90

-0.036 -0.090

+0.270 +0.061

0.097 – 0.330

0.695

100

-0.036 -0.090

+0.257 +0.047

0.105 – 0.375

0.675

Ripper TILT

110

-0.036 -0.090

+0.261 +0.047

0.105 – 0.375

0.675

2

Clearance between piston rod support shaft and blade ball portion

Blade LIFT

85

—

+0.3 +0.3

—

1.0

3

Clearance between cylinder support shaft and bushing

Blade LIFT

85

-0.100 -0.174

—

0.100 – 0.228

0.5

4

Clearance between piston rod spherical surface and cap

Blade TILT

115

-0.200 -0.300

—

—

—

60

-0.030 -0.050

+0.174 +0.100

0.130 – 0.224

1.0

5

Blade TILT Clearance between cylinder bottom sup- Ripper port shaft and bush- LIFT ing Ripper TILT

90

-0.036 -0.090

+0.207 +0.120

0.156 – 0.297

1.0

100

-0.036 -0.090

+0.201 +0.119

0.156 – 0.291

1.0

Ripper LIFT

90

-0.036 -0.090

+0.207 +0.120

0.156 – 0.297

1.0

Ripper TILT

100

-0.036 -0.090

+0.201 +0.119

0.156 – 0.291

1.0

Blade LIFT

1

6

Clearance between piston rod and bush- Blade TILT ing Ripper LIFT

Clearance between cylinder rod support shaft and bushing

D155A-6

Replace

51

SEN02865-02

Piston valve


1

For blade lift cylinder Outline q The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches its stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston. When the blade is tilted, the blade is subject to a tortional force owing to the uneven position of the pistons in the two cylinders; that is the piston on one side is still moving while the piston on the other side has reached its stroke end. The piston valves are installed to prevent the tortional force from occurring. When one of the pistons reaches its stroke end, its piston valve opens to relieve the oil pressure. In addition the piston valve relieves the shock which occurs when the piston comes into contact with the cylinder head or the bottom and serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape from the cylinder before the piston reaches its stroke end.

2.

Piston valve OPEN Just before piston rod (1) reaches the end of its stroke, the tip of valve (6) contacts the cylinder bottom, so valve (6) and piston valve (3) stop at that position and do not move further. Only piston (2) moves further. When this happens, the oil at the cylinder head, which was sealed by piston valve (3), escapes from piston valve seats (4) and (5), and the pressure inside the cylinder stops rising.

Operation 1. Piston valve CLOSED Pressurized oil from the hydraulic pump acts on piston (2) and piston valve (3). The piston valve (3) is pushed in the direction of the arrow until piston valve seat (4) comes into snug contact with the tapered section, thereby, this causing the pressure in the cylinder to rise and moving piston (2) in the direction of the arrow.

52

D155A-6


D155A-6

SEN02865-02

53

SEN02865-02

Quick drop valve


1

(Blade lift cylinder) Structure The quick drop valve consists of valve body (1), spool (2), check valve (3), and spring (4). The quick drop valve serves to increase the blade lowering speed and to reduce the occurrence of vacuum when the blade is lowering, thereby shortening the time lag before digging is started. The blade lowering speed, which is generally determined by the pump discharge, can be made faster with the quick drop valve.

2.

1. 2. 3. 4.

Valve body Spool Check valve Spring

Operation 1. Start of lowering When the blade lever is operated to LOWER, the oil from the control valve enters the cylinder bottom through port (A) and pushes the piston. In the meantime, the oil in the cylinder head is pushed out into the piston, enters valve port (B), and flows into the tank from port (C).

54

While lowering Pressurized oil from the cylinder head flows into port (C) through port (B). At this time, the oil flow is restricted by an orifice (a) provided along the way, causing a differential pressure before and after the orifice. When the differential pressure becomes greater than the force of spring (4), it compresses the spring and moves spool (2) and check valve (3) to the right. When the spool and the check valve have moved, part of the oil flowing from the cylinder head to tank enters the passage to the cylinder bottom together with the oil from the control valve. Thus, the blade lowering speed increases in accordance with the amount of oil that flows to the bottom of the cylinder and reduces the formation of vacuum at the bottom of the cylinder.

D155A-6


Self pressure reducing valve

T: P1: P2: PR:

SEN02865-02

1

To hydraulic tank From cooling fan pump To cooling fan motor Supply to PPC valve and EPC valve

D155A-6

55

SEN02865-02

1. 2. 3. 4.


5. 6.

Sequence valve Valve Filter Screw

Poppet Ball

Unit: mm No.

Check item

Criteria

Remedy

Standard size 7

Valve return spring

Free length Installation x outer length diameter

Repair limit Installation load

Free length

Installation load

70.9 x 18

56

250 N {25.5 kg}

—

200 N {20.4 kg}

8

Ball return spring

16.1 x 7.8

13.4

61.8 N {6.3 kg}

—

49.0 N {5.0 kg}

9

Valve return spring

19.2 x 7.2

16.1

19.6 N {2.0 kg}

—

15.7 N {1.6 kg}

56


D155A-6


SEN02865-02

Operation At engine stop (total low pressure)

q

q

q

Spring (6) pushes the poppet (5) to the seat, and the circuit between ports (PR) and (T) is closed. Spring (7) pushes valve (8) to the left side, and the circuit between port (P1) and port (PR) is open. Spring (3) pushes the valve (2) to the upper side, and the circuit between ports (P1) and (P2) is closed.

Function The self pressure reducing valves reduce the discharge pressure of the fan pump and supplies it to the PPC valve, the EPC valve, etc. as the control pressure.

q

D155A-6

57

SEN02865-02


2.

When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve.

q

The spring (3) and the (PR) pressure (0 MPa {0 kg/cm2} at the time of engine stop) pushes the valve (2) in the direction to close the circuit between the ports (P1) and (P2). When the hydraulic oil enters the (P1) port, the expression ((P1) pressure Spring (7) force + (ø(d) area x (PR) pressure)) holds, and the self pressure reducing valve will adjust the openings of the ports (P1) and (P2) so that the (P1) pressure can be maintained higher than the (PR) pressure. When the (PR) pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil flows through the route from the (PR) port, the hole a in the spool (8), the poppet (5) opening to the tank port (T).

q

58

q

Therefore, there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port (P1) and the (PR) opening. Then, the (P1) pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the (PR) pressure.

D155A-6


3.

At raise of load pressure P2

q

When the load pressure (P2) rises due to digging or other operations, the pump delivery will increase and the (P1) pressure will rise. Then, the expression ((P1) pressure > Spring (7) force + ( (d) area x (PR) pressure)) will hold, and the valve (2) will move to the right side till the stroke end. As a result, the opening between the ports (P1) and (P2) will increase, the passage resistance will become smaller to reduce engine loss horsepower.

D155A-6

SEN02865-02

q

q

When the (PR) pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil will flow through the route from the (PR) port, the hole (a) in the spool (8), the poppet (5) opening to the tank port (T). Therefore, there will occur a differential pressure around the hold (a) in the spool (8) and the spool will move in the direction to close the port (P1) and the (PR) opening. Then, the (P1) pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the (PR) pressure.

59

SEN02865-02

4.

At occurrence of abnormal high pressure

q

When the (PR) pressure of the self pressure reducing valve rises abnormally high, the ball (10) will separate from the seat against the spring (9) force to flow the hydraulic oil to the output ports (PR) (T) so as to reduce the (PR) pressure. Then, the equipment (PPC valve, etc.), to which the oil pressure is supplied, is protected from the abnormal high pressure.

60


D155A-6


D155A-6

SEN02865-02

61

SEN02865-02




62

D155A-6

SEN02866-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Work equipment Cylinder stay ................................................................................................................................................... 2 Blade............................................................................................................................................................... 4 Cutting edge, end bit....................................................................................................................................... 6 Ripper ............................................................................................................................................................. 8

D155A-6

1

SEN02866-00

Cylinder stay

1. 2. 3. 4. 5.

2


1

Yoke Dust seal Bushing Bushing Grease nipple

D155A-6


SEN02866-00

Unit: mm No.

6

Check item Clearance between cylinder yoke and bushing


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

125

–0.172 –0.235

+0.063 +0.046

0.172 – 0.298

—

7

Clearance between cylinder yoke and bushing

100

–0.170 –0.224

+0.054 +0.046

0.170 – 0.278

—

8

Clearance between bushing of cylinder support shaft and yoke

110

–0.172 –0.035

+0.054 +0.046

0– 0.089

0.5

D155A-6

Replace

3

SEN02866-00

Blade


1

Sigma-tilt dozer, semi-U blade

4

D155A-6


SEN02866-00

Sigma-tilt, semi-U blade common parts mark Unit: mm No.

1

Check item Clearance between brace and pin


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

60

–0.3 –0.5

+0.174 +0.100

0.4 – 0.674

2

2

Clearance between brace pin and bracket

60

–0.3 –0.5

+0.5 +0.2

0.5 – 1.0

2

3

Clearance between brace spherical surface and cap

115

–0.2 –0.3

+0.3 +0.6

0.2 – 0.6

1

4

Clearance between brace pin and bracket

90

–0.3 –0.5

+0.3 +0.1

0.4 – 0.8

2

5

Clearance between brace pin and brace

90

–0.3 –0.5

+0.5 +0.3

0.6 – 1.0

2

6

Clearance between joint and blade bracket

140

–0.2 –0.7

+0.5 +0.3

0.5 – 1.2

2

7

Clearance between frame pin and joint

70

–0.5 –0.6

+0.3 +0.6

0.5 – 0.9

3

8

Clearance between blade bracket pin and blade bracket

70

–0.5 –0.6

+0.3 +0.6

0.5 – 0.9

3

9

Clearance between blade bracket pin and joint

70

–0.5 –0.6

+0.3 +0.6

0.5 – 0.9

3

10

Clearance between center brace spherical surface and cap

165

–0.2 –0.3

+0.3 +0.6

0.2 – 0.6

1

11

Clearance between trunnion spherical surface and cap (Left)

160

–0.5 –1.0

+0.5 +0.0

0.5 – 1.5

8

12

Clearance between trunnion spherical surface and cap (Right)

195

–0.5 –1.0

+0.5 +0.0

D155A-6

Replace

Adjust shims or replace

Replace

Adjust shims or replace

Replace 0.5 – 1.5

8

5

SEN02866-00


Cutting edge, end bit

1

For semi-U blade

Unit: mm No.

Check item


Remedy Repair limit

1

Height of outside of end bit

315

235

2

Width of end bit

540

440

3

Height of inside of end bit

254

215

4

Height of cutting edge

254

215 (175 to turning)

6

Replace

Turn or replace

D155A-6


SEN02866-00

For sigma-tilt blade

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

330

260 (215 to turning)

300

235

1

Height of cutting edge

2

Height of outside of end bit

3

Height of inside of end bit

330

260

4

Width of end bit

640

500

D155A-6

Turn or replace Replace

7

SEN02866-00

Ripper


1

Variable multi-shank ripper

8

D155A-6


SEN02866-00

Unit: mm No.

Check item

Criteria

Remedy

Shaft

Hole

Standard clearance

Clearance limit

110

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.5

110

–0.036 –0.090

+0.529 +0.463

0.499 – 0.619

1.5

100

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.5

Clearance between tilt cylinder mounting pin and bushing

100

–0.036 –0.090

+0.201 +0.119

0.155 – 0.291

1.5

Clearance between lift cylinder 5,11 mounting pin and mounting bracket or beam bracket

90

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.5

Clearance between lift cylinder 6,12 mounting pin and shank bushing

90

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.5

Clearance between arm 1,7 mounting pin and mounting bracket or beam bracket 2,8

Clearance between arm mounting pin and bushing

Clearance between tilt cylin3,9 der mounting pin and mounting bracket or beam bracket 4,10

Standard size

Tolerance

13

Clearance between shank mounting pin and shank holder

Shaft 80 Hole 82

+0.300 –0.300

+0.300 –0.300

1.400 – 2.600

10.0

14

Clearance between shank mounting pin and shank hole

Shaft 80 Hole 88

+0.300 –0.300

+1.000 –1.000

3.700 – 6.300

15.0

15

Wear of point

16

Wear of protector

D155A-6

Standard size

Repair limit

335

225

115

90

Replace

9

SEN02866-00


Variable giant ripper

10

D155A-6


SEN02866-00

Unit: mm No.

Check item

Criteria

Remedy

Shaft

Hole

Standard clearance

Clearance limit

110

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.5

110

–0.036 –0.090

+0.529 +0.463

0.499 – 0.619

1.5

100

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.5

Clearance between tilt cylinder mounting pin and bushing

100

–0.036 –0.090

+0.201 +0.119

0.155 – 0.291

1.5

Clearance between lift cylinder 5,11 mounting pin and mounting bracket or beam bracket

90

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.5

Clearance between lift cylinder 6,12 mounting pin and shank bushing

90

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.5

Clearance between arm 1,7 mounting pin and mounting bracket or beam bracket 2,8

Clearance between arm mounting pin and bushing

Clearance between tilt cylin3,9 der mounting pin and mounting bracket or beam bracket 4,10

Standard size

Tolerance

13

Clearance between shank mounting pin and shank holder

Shaft 75 Hole 77

+0.300 –0.300

+0.300 –0.300

1.400 – 2.600

10.0

14

Clearance between shank mounting pin and shank hole

Shaft 75 Hole 80

+0.300 –0.300

+1.000 –1.000

3.700 – 6.300

15.0

15

Wear of point

16

Wear of protector

D155A-6

Standard size

Repair limit

335

225

115

90

Replace

11

SEN02866-00




12

D155A-6

SEN02867-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

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

D155A-6

1

SEN02867-00

Cab mount + ROPS pin


1

Cab spec.

1. 2. 3. 4. 5.

2

Support Damper mount (front) Damper mount (rear) ROPS pin (front) ROPS pin (rear)

Outline q Viscous mounts are installed at two places at the front and two places at the rear to secure the floor frame and cab. q An oil-filled damper mount is used to absorb the vibration. q The ROPS pins are installed to 2 places each at the front and rear sections to fix the ROPS (built in the cab) when the machine rolls over.

D155A-6


ROPS cab

SEN02867-00

1

Cab assembly

1. 2. 3. 4. 5.

Front wiper Front glass Rear wiper Door ROPS sub (built in CAB)

D155A-6

3

SEN02867-00

ROPS floor


1

Cab less spec.

1.

4

ROPS floor

D155A-6


SEN02867-00

Air conditioner

1

Air conditioner piping

1. 2. 3. 4. 5. 6. 7. 8. 9.

Condenser Hot water return piping Hot water pick-up piping Front window defroster Side window defroster Air outlet for face Air outlet for center Air outlet for rear Air conditioner unit

D155A-6

10. 11. 12. 13. 14. 15.

Air outlet for foot Receiver tank Refrigerant piping Valve (hot water outlet) Air conditioner compressor Valve (hot water inlet)

A: B:

Fresh air Recirculated air

5

SEN02867-00




6

D155A-6

SEN02868-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Electrical system Engine control ................................................................................................................................................. 2 Engine control system..................................................................................................................................... 3 Deceleration potentiometer............................................................................................................................. 4 Monitor system................................................................................................................................................ 6 Sensors......................................................................................................................................................... 25 Palm command control system..................................................................................................................... 28 KOMTRAX system........................................................................................................................................ 31

D155A-6

1

SEN02868-01


Engine control

1. 2. 3. 4. 5. 6. 7. 8. 9.

2

Decelerator pedal Decelerator potentiometer Starter switch Fuel control dial Battery relay Battery Power train controller Starter Fuel supply pump

1

Outline The throttle signals of the fuel control dial are sent to the power train controller and processed together with the 3rd throttle signal, and then sent as the throttle commands together with the throttle signals of the decelerator pedal to the engine throttle controller. The engine throttle controller controls the engine according to the commands.

q

D155A-6


SEN02868-01

Engine control system

Outline q The engine throttle controller receives the fuel control dial signal of the 1st throttle, decelerator pedal signal of the 2nd throttle, and 3rd throttle signal which is the control signal from the power train controller, and then controls the fuel supply pump according to the command signal having the lowest engine speed. The control signals of the 3rd throttle are as follows. (1) Auto deceleration (F3, R3, F2, R2) (2) Neutral deceleration q The power train controller calculates a proper engine speed from information items (1), (2), etc. and sends it as the 3rd throttle signal to the engine throttle controller.

D155A-6

1

q

q

q

The information of the engine throttle controller is possessed jointly by the other controllers through the network and used for the optimum control of the engine and machine body. The auto deceleration is a function of setting the engine speed low temporarily when the travel direction is changed from F3, R3, F2, and R2 (to protect the transmission clutch). The neutral deceleration is a function of limiting the high idle speed when the transmission is set in neutral.

3

SEN02868-01

Deceleration potentiometer

1. 2. 3. 4. 5. 6. 7.

4

Connector Lever Body Potentiometer Cuppling Shaft Stopper


1

Outline q The deceleration potentiometer is installed to the inside of the dashboard and connected to the decelerator pedal by linkage. q If the decelerator pedal is pressed, it rotates the throttle potentiometer shaft through the linkage and the potentiometer resistance changes. Constant voltage is applied between pins (A) and (C) of the potentiometer and a voltage signal is sent through pin (B) to the engine controller according to the position of the decelerator pedal.

D155A-6


D155A-6

SEN02868-01

5

SEN02868-01


Monitor system

q

6

The monitor system monitors the machine condition with the sensors installed to various parts of the machine and processes and displays the obtained information on the panel quickly to notify the operator of the machine condition. The main display sections and functions of the panel are as follows. 1) Monitor unit which turns on the alarm when the machine has a trouble. 2) Gauge unit which constantly displays the machine condition (coolant temperature, torque converter oil temperature, fuel level, etc.) 3) Function of displaying error codes. 4) Function of monitoring the current and voltage of the sensors and solenoids,

1

q

The CPU (Central Processing Unit) in the monitor panel displays and outputs various information items processed by the power train controller. The display unit is LCD (Liquid Crystal Display)

D155A-6


SEN02868-01

Processing in machine monitor (Common to all specifications) Display of machine monitor Contents and conditions of processing 1. Display of travel direction and gear speed. • F1, R3, etc. are notified by CAN according to information of power train controller.

Method

Flow of signals

CAN

2. Display of gauges of fuel level, engine coolant temperature, etc. • Controller converts the sensor signals into gauge CAN numbers and sends them to the machine monitor by CAN. 3. Display of trouble • When the machine has a trouble, the corresponding failure code is notified to the machine monitor by CAN. • Which one should be turned on, the buzzer or the caution lamp, is notified, too. 1) In normal state User code, service code CAN 2) In trouble history display mode The service code (6-digit code) and the following items are displayed • Time after first occurrence • Time after latest occurrence • Number of past occurrences The machine monitor displays the code.

Each sensor/solenoid-controllermachine monitor

Display of monitoring condition Contents and conditions of processing

Method

1. The communication conditions of each sensor, each solenoid, and CAN are displayed. • The item Nos. and device conditions are notified to CAN the machine monitor by CAN. • The machine monitor displays the items and each value.

Flow of signals

Each sensor-controller-machine monitor

2. Each items is selected by using the cursor switches and CAN confirmation switch.

Other items 01 02 03 04 05 06 07 08 09 10 11 12 13 88 89

a

Contents and conditions of processing Monitoring Trouble history Maintenance history Maintenance mode change Telephone number set Default Adjustment PM clinic Reduced cylinders mode operation No injection cranking Fuel consumption display — Service message display Screen adjustment a —

Method

Flow of signals

–

–

See testing and adjusting, special functions of machine monitor.

D155A-6

7

SEN02868-01


Machine monitor

Outline q The machine monitor has the functions to display various items and the functions to select modes and electric parts. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The monitor display employs an LCD (Liquid Crystal Display). The switches are flat sheet switches.

8

Precautions on the machine monitor display q The liquid crystal display panel may have black spots (which do not light up) or bright spots (which stay on). Products having 10 or less black or bright spots conform the product specification; such the condition is quite normal. q Battery voltage may suddenly drop at enginestart due to ambient temperature or the condition of the battery. The machine monitor display may temporarily disappear if it happens; it is quite normal. q Continuous operation of the machine monitor may display blue bright spots on the screen having a black background; it is quite normal. The screen normally displayed on the monitor has a blue or white background. For this reason, blue spots will not cause any problem (since the liquid crystal lights up red, blue, and green spots when displaying white).

D155A-6


Input and output signals

Input/ output 1 Battery power (+24V constantly) Input 2 Battery power (+24V constantly) Input 3 Battery power GND — 4 Battery power GND — Input/ 5 Wake-up Output 6 Relay output Output 7 Chassis signal GND — 8 Hydraulic oil pressure — 9 Fuel level Input 10 NC(*) — 11 Charge amount Input 12 Chassis analog signal GND — 13 Light switch Input 14 Key switch (ACC) Input 15 Key switch (C) Input 16 Preheating Input 17 NC(*) — 18 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Signal name

CN-CM02 Input/ output 1 NC(*) — 2 NC(*) — 3 Coolant level sensor Input 4 NC(*) — 5 NC(*) — 6 NC(*) — 7 Chassis signal GND — 8 CAN terminating resistance — Input/ 9 CAN_H Output Input/ 10 CAN_L Output 11 NC(*) — 12 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.

CN-CM03 Pin No.

CN-CM01 Pin No.

SEN02868-01

Signal name

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Input/ output RS232C CD for communication terminal Input RS232C RXD for communication terminal Input RS232C SG for communication terminal — Signal name

Signal GND for communication terminal — control Communication terminal selection signal Input RS232C RTS for communication terminal Output RS232C TXD for communication terminal Output RS232C DTR for communication terminal Output RS232C DTR for communication terminal Input RS232C CTS for communication terminal RS232C RI for communication terminal Power GND for communication terminal Input CH1 for communication terminal status Output for communication terminal power control Output CH1 for communication terminal control Output CH2 for communication terminal control Input CH2 for communication terminal status Electric power supply for communication terminal

Input Input — Input Output Output Output Input Output

CN-CM04 Input/ output 1 NC(*) — 2 NC(*) — 3 NC(*) — 4 NC(*) — 5 NC(*) — 6 NC(*) — 7 NC(*) — 8 NC(*) — 9 NC(*) — 10 NC(*) — 11 NC(*) — 12 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.

Signal name

CN-CM05 Pin No. 1 2 3 4 5 6 7 8

D155A-6

Input/ output Electric power supply for camera Output Camera NTSC signal input 1 Input Camera NTSC signal input 2 Input Camera NTSC signal input 3 Input Electric power supply GND for camera — Camera signal GND1 — Camera signal GND2 — Camera signal GND3 — Signal name

9

SEN02868-01


Monitor control, display portion

1. 2. 3. 4. 5. 6. 7. 8.

10

Gear shift mode selector switch Buzzer cancel switch Working mode selector switch Engine coolant temperature Multi gauge Pilot display Service meter, clock Hydraulic mode display

9. 10. 11. 12. 13. 14. 15.

Fuel level Travel gear speed gear shift mode preset Guidance icon Function switch Custom switch Custom memory switch Air conditioner switch

D155A-6


D155A-6

SEN02868-01

11

SEN02868-01


Machine monitor display

Check

Display category

Symbol

Display item

Displays when engine is stopped and starting switch is ON Display when normal: OFF Display when abnormal: ON

Below low level

Engine oil pressure

When sensor is abnormal Display when normal: OFF or when wiring harness is Display when abnormal: ON disconnected

Battery charge

Displays when starting switch is ON and engine is running When charge is defective Display when normal: OFF Display when abnormal: ON CAUTION lamp flashes

Engine oil pressure

Below 49.0kPa {0.5kg/cm2}

Radiator coolant level

Below low level

Caution

Torque converter oil temperature

Pilot

Display method

Radiator coolant level

Engine coolant temperature

12

Display range

When at highest level on engine coolant temperature gauge Above 102°C: Symbol ON Above 105°C: Symbol ON + buzzer When at highest level on engine coolant temperature gauge Above 120°C: Symbol ON Above 130°C: Symbol ON + buzzer

Hydraulic oil temperature

Above 100°C: Symbol ON Above 110°C: Symbol ON + buzzer

Maintenance

When replacement time of filter or oil has been passed

Preheating

When preheating

Displays when starting switch is ON and engine is running Display when normal: OFF Display when abnormal: ON Alarm buzzer sounds

Lights according to required time determined by engine controller based. It also lights at the time of manual preheat by setting starting switch at preheat position (turning it counterclockwise).

D155A-6


Display category

Symbol

Display item

SEN02868-01

Display range

Display method


Gauges


Indicative applicable temperature


Fuel level

Service meter (Hours meter)

D155A-6

Indicative applicable level

From 0 to 99999

Actuated when the engine is rotating

13

SEN02868-01


Gauge

The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot be obtained due to disconnection of CAN. Gauge

Engine coolant temperature (°C)

Power train oil temperature (°C)

Hydraulic oil temperature (°C)

Fuel level (l)

14

Range A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 C1 C2 C3 C4 C5 C6 D1 D2 D3 D4 D5 D6

Temperature or volume 105 102 100 85 60 30 130 120 118 90 50 0 110 100 98 70 20 0 565 425 310 220 150 75

Indicator

Buzzer sound

Red Red Off Off Off White Red Red Off Off Off White Red Red Off Off Off White Off Off Off Off Off Red

Q

Q

Q

D155A-6


Battery voltage

Machine speed

1. 0 km/h 2. 5 km/h

3. 10 km/h 4. 15 km/h

4. 30 MPa 5. 40 MPa 6. 50 MPa

D155A-6

4. 25 V 5. 30 V 6. 31 V

1. 500 rpm 2. 1,000 rpm 3. 1,500 rpm

4. 2,000 rpm 5. 2,500 rpm 6. 3,000 rpm

Drawbar pull

Engine oil pressure

1. 0.0 MPa 2. 0.2 MPa 3. 0.3 MPa

1. 0 V 2. 17 V 3. 20 V Engine speed

Hydraulic oil pressure

1. 0 MPa 2. 10 MPa 3. 20 MPa

SEN02868-01

4. 0.4 MPa 5. 0.5 MPa 6. 0.7 MPa

1. 0 W 2. 0.2 W 3. 0.4 W

4. 0.6 W 5. 0.8 W 6. 1.0 W

15

SEN02868-01


Guidance icon and function switch The function switches differ depending on the screen display. Each guidance icon shows the function of the switch below it. Switches with no guidance icon are disabled. The functions shown by the guidance icons are as shown in the table below. Symbol

16

Switch

Item

Function

F6

Enter

Enters selected/set item.

F5

Return

Returns to previous screen.

F4

Select service meter/clock

Selects service meter and clock alternately.

F5

Select maintenance screen

Selects maintenance screen.

F6

Select user mode screen

Selects user mode screen.

F3

Select item

Selects item on left side (Selects right end item after left end item).

F4

Select item

Selects item on right side (Selects left end item after right end item).

F3

Select item

Selects item on lower side (Selects top item after bottom item)/Resets holding of monitoring.

F4

Select item

Selects item on upper side (Selects bottom item after top item)/Holds monitoring.

F1

Select item

Selects page on lower side (Selects top page after bottom page).

F2

Select item

Selects page on upper side (Selects bottom page after top page).

F2

Return to default setting

Returns selected item to default setting. (Used for adjustment of screen.)

F1

Start

Starts operation. (Used to start measurement of split fuel consumption on fuel consumption display screen.)

F1

Stop

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

F1/F2

Clear

Clears selected/displayed item

F1

Set

Executes setting.

F2

Change multi gauge

Change of multi gauge items

D155A-6


SEN02868-01

Air conditioner control switch To operate the air conditioner, use the air conditioner control switches.

Service meter/time selector function 9a : Specifies airflow 9b : Specifies temperature 9c : AUTO 9d : A/C 9e : Switches among air blowing modes 9f : Switches between inside air and outside air 9g : OFF 9a to 9c : Enables entered information simultaneously with switching to the air conditioner control screen below. 9d to 9f : Switches to the air conditioner control screen below. Another pressing switches among modes. 9g : Turns OFF the air conditioner function without switching to the air conditioner screen.

q

Pressing F4 on the normal screen when the service meter is displayed in the top center of the screen switches the display to the time, and doing so when the time is displayed switches the display to the service meter.

If you do no operation at least 5 sec. with the air conditioner control screen displayed, the window returns to the normal window. a When communication with the air conditioner is disconnected, or “spurting-out damper”, “A/M damper”, or “refrigerant” has a problem, the following screen appears.

D155A-6

17

SEN02868-01


Maintenance function q

Pressing F5 on the normal screen switches to the maintenance screen.

F5 : Cancels the reset to return to the maintenance table screen. F6 : Resets the remaining time to return to the normal screen. No operation at least 30 sec. : Returns to the normal screen. q

No.

F1 : Displays the next page. Displays the top page when the last page is displayed. F2 : Displays the previous page. Displays the last page when the top page is displayed. F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Returns to the normal screen. F6 : Switches to the maintenance time reset screen. No operation at least 30 sec. : Returns to the normal screen. q

q

18

If the remaining time on the maintenance table screen is less than 30 hours, the relevant items are highlighted in yellow, and if 0 hours, they are done in red. On the maintenance time reset screen, reset the remaining time for the selected item to return to the default.

The table below shows the maintenance items and replacement intervals. The time remaining to maintenance is reduced as the machine is operated. Item

01 Engine oil 02 Engine oil filter 03 Fuel main filter 41 Fuel pre filter 04 Hydraulic filter 06 Corrosion resistor 07 Damper case oil 08 Final drive case oil 10 Hydraulic oil 19 P/L oil 20 P/L oil filter *: If equipped (To be determined) P/L: Power train q

Replacement interval (Hours) 500 500 1000 500 2000 1000(*) 2000 1000 2000 1000 500

The content of the caution display differs according to the remaining time. The relationship is as shown in the table below. Display

Condition Remaining time for mainteNone nance for all items is more than 30 hours. There is one or more items Notice display (black symwith less than 30-hour bol displayed on yellow remaining time for maintebackground) nance. There is one or more items Warning display (white with less than 0-hour symbol displayed on red remaining time for maintebackground) nance.

D155A-6


q

To reset the maintenance time carelessly, it is locked by the password.

SEN02868-01

User mode q q

q q

a

1

Pressing F6 on the normal screen enters the user mode, switching to the user menu screen. In user mode, you can specify items relating to the machine monitor and machine shown below. Utility screen select Multi gauge select Screen adjustment Clock adjustment Language setting Message display Fan reverse mode

The default password is “000000”. Enabling the password lock on an attachmentequipped machine locks the attachment setting screen at the same time. For information on changing the maintenance password, see “Maintenance password change function” in the Testing and adjusting section.

F3 : F4 : F5 : F6 :

Selects (highlights) an item one down. Selects (highlights) an item one up. Returns to the normal screen. Switches to the setting screen for the selected item. No operation at least 30 sec. : Returns to the normal screen. (In user mode, no switch operation at least 30 sec. returns to the previous screen.)

Utility screen select q

q

D155A-6

If utility screen select is selected with switch F6, (1) Standard Display, (2) Load Display, or (3) Body Pitch Display can be selected. Select an item with switch F3 or F4 and confirm that item with switch F6.

19

SEN02868-01


Multi gauge select On this screen, the gauges displayed at the center can be selected. Select an item with switch F3 or F4 and confirm that item with switch F6.

q q

Standard display The normal screen is selected.

q

Load display q The horizontal axis indicates the time and the vertical axis indicates the traction force. The operation should be carried out in the green range. q The graph on the screen is updated and scrolled to the left at intervals of several seconds.

The following items can be selected.

q

No.

Selected item

Remarks

1

Power train oil Temperature

With caution

2

HYD oil temperature

With caution

3

Vehicle Speed

4

HYD Pressure

5

ENG Oil Pressure

6

Battery Voltage

—

7

Engine Speed

—

8

Traction Force

—

9

Clock

—

— — With caution

10 ENG coolant temperature For Utility Screen Select 11 Fuel

For Utility Screen Select

Body Pitch Display q The horizontal axis indicates the time and the vertical axis indicates the pitch angle of the body. q The graph on the screen is updated and scrolled to the left at intervals of several seconds.

20

D155A-6


Screen adjustment q

q

q q

Selecting the Screen adjustment from the user menu and pressing F6 switches to the screen adjustment screen. From this menu, you can adjust the brightness, contrast, and luminance of the machine monitor screen. When the light switch is in Night mode ON, the night mode screen is adjustable. When the light switch is in Daytime mode ON or OFF, the daytime mode screen is adjustable.

F2 : Returns all adjusted values to the defaults. F3 : Decreases the value indicated by the indicator one graduation left. F4 : Increases the value indicated by the indicator one graduation right. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. F6 : Confirms the changes and moves to the next item. q

q

SEN02868-01

F6 : Moves to the setup items of the selected (highlighted) item. q q

The adjustment methods for the camera screen and normal screen are the same. The background when adjusting the camera screen is the No. 1 camera image.

F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. F6 : Moves to the setup items of the selected (highlighted) item.

Clock adjustment q

q

Selecting the Clock adjustment from the user menu and pressing F6 switches to the clock adjustment screen. On this screen, you can change the setting of the time displayed on the normal screen.

For a camera-equipped machine, the brightness, contrast, and illuminance of the camera screen are also adjustable. For a camera-equipped machine, selecting Sc reen adjus tment fro m the us er menu switches to the screen for selecting a screen you want to adjust.

1)

F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. D155A-6

Time setting Set the clock time. If the time setting item is not highlighted, press F6 to highlight it. The time display part is highlighted. F3 : Advances the clock one hour. F4 : Sets the clock back one hour. F5 : Cancels changes you made before confirming them with F6 to return to the user menu. F6 : Confirms the changes and moves to minute setting.

21

SEN02868-01


The minute display part is highlighted. F3 : Advances the clock one min. F4 : Set the clock back one min. F5 : Cancels changes you made before confirming them with F6 to return to the use menu. F6 : Confirms the changes and moves to the 12/24 display mode. 2)

3)

12/24 display mode Specify time display to 12-hour display (AM/PM) or 24-hour display. If the item of 12/24 display mode is not highlighted, press F6 to highlight it. F3 : Moves to the item one right. F4 : Moves to the item one left. F5 : Cancels the changes to return to the user menu. F6 : Confirms the changes and moves to summer time. Summer time Selecting ON for this sets the time forward one hour. Setting OFF returns to the ordinary time. F3 : Moves to the item one right. F4 : Moves to the item one left. F5 : Cancels changes you made before confirming them with F6 to return to the user menu screen. F6 : Confirms the changes and moves to the time setting. a

F3 : F4 : F5 : F6 :

Selects (highlights) an item one down. Selects (highlights) an item one up. Cancels the changes to return to the user menu. Cancels the changes to return to the user menu.

Message display q

q q

For a KOMTRAX-equipped machine, you can view notification from the sales representative. When there is a message, the message monitor appears on the upper left of the normal screen. The lighting green monitor indicates that there are messages to be read. The lighting blue monitor appears when you have not sent replies yet after opening messages which accept replies.

Summer time (daylight saving time) is a system to lead a life according to the one-hour advanced time in order to make efficient use of daylight time.

Language setting q

q

22

Selecting the Language from the user menu screen and pressing F6 switches to the language setting screen. From this menu, you can change the language to be displayed on the monitor. Available languages are as follows. English, Japanese, Chinese, French, Spanish, Portuguese, Italian, German, Russian, and Turkish

D155A-6


q

Press F6 to enter user mode and select “Message display” and you can view (open) the messages.

SEN02868-01

Fan reverse mode q q

q q

In this mode, the fan is driven in reverse to clean the radiator core. While the starting switch is OFF, select an item with switch F3 or F4 and confirm that item with switch F6. While screen (A) is displayed, press switch F6, and the fan is ready to run in reverse. While screen (B) is displayed, start the engine.

F6 : Returns to the user mode screen. q

q

q q

q

Under messages that accept replies, “Value to be entered with 10-key: [ ]” appears.If it appears, enter the selected item number provided in the message using the switches of the machine monitor, and press F6. “Do you want to transmit the entered value?” appears under the message. Press F6 and the entered value will be sent.

Messages will be deleted when their validity expire or a new message is received. When no message has not been received, “No message” appears at the blue part of the top of the screen. Separately from the message display for users above, the service menu is provided with message display for service.

D155A-6

Precautions for using fan reverse mode a q In this mode, the fan cannot be reversed while the engine is running. q When running the fan in reverse, set the travel lock in the LOCK position. q While the fan is running in reverse, the machine cannot travel. q When resetting the reverse running, turn the starting switch OFF to stop the engine. q When using this mode, warm up the engine sufficiently. If the engine is not warmed up, air may not be supplied sufficiently.

23

SEN02868-01

Service meter check function q

If you continuously pressing auto-deceleration switch (1) and buzzer cancel switch (2) at the same time when setting the starting switch to the OFF position, the service meter will appear on the screen in 3 to 5 sec.

q

When these switches are released, the LCD goes out. Continuous operation of the machine monitor may display blue bright spots on this screen; it is quite normal.

a

24


Display LCD check function q

Continuously pressing the buzzer cancel switch (1) and F2 at the same time on the password input screen or normal screen causes the entire LCD to light in white. Release F2 and buzzer cancel switch in order. If any part of the display is black, the LCD is broken.

q

Pressing any function switch returns to the previous screen.

D155A-6


SEN02868-01

Sensors Type of sensor

1 Sensor method

When normal

When abnormal

Contact

OFF

ON

Resistance

—

—


Resistance

—

—


Resistance

—

—

Contact

ON

OFF

Fuel level

Resistance

—

—

Engine speed sensor

Resistance

—

—

Bevel gear speed sensor

Resistance

—

—

Pitch angle sensor

Resistance

—

—

Engine oil pressure Engine coolant temperature

Coolant level

Engine oil pressure sensor

1. 2. 3.

Plug Contact ring Contact

4. 5. 6.

Diaphragm Spring Terminal

4. 5. 6.

Tube Wire Connector

Engine coolant temperature sensor Torque converter oil temperature sensor Hydraulic oil temperature sensor

1. 2. 3.

Thermistor Body Tube

D155A-6

25

SEN02868-01


Coolant level sensor

1. 2. 3.

Float Sensor Tube

4. 5.

Wire Connector

Fuel level sensor

1. 2. 3. 4. 5. 6. 7.

26

Connector Float Arm Body Spring Contact Spacer

Function The fuel sensor is installed to the side face of the fuel tank. The float moves up and down according go the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level.

q

D155A-6


SEN02868-01

Engine speed sensor Bevel gear speed sensor

1. 2. 3.

Magnet Terminal Case

4. 5.

Boots Connector

3. 4.

Wire Connector

Pitch angle sensor

1. 2.

Body Tube

D155A-6

27

SEN02868-01

Palm command control system

1. 2. 3. 4. 5. 6. 7. 8.

28


1

Machine monitor (Multi-information) Preset mode switch Engine throttle controller Power train controller Engine speed sensor Transmission control valve Steering control valve Transmission output shaft speed sensor

D155A-6


SEN02868-01

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

Gear shift operation q Set a gear by pressing (a) or (b) of the steering/directional/gearshift lever. (a) Shift-up switch (b) Shift-down switch Display of screen The gearshift mode is displayed in the gearshift mode display section of the monitor panel as shown below. A: Auto gearshift mode 1. Gear speed used currently 2. Preset (gear speed at start) and maximum gear speed during travel 3. Mark of AUTO (which indicates auto gearshift mode) 4. Mark of Dozing (which indicates auto gearshift mode) B: Manual gearshift mode 5. Gear speed used currently 6. Preset (gear speed at start) 7. Mark of Ripping (which indicates manual gearshift mode)

D155A-6

29

SEN02868-01

Setting preset with shift switches in neutral q Set the preset (gear speed at start) and the maximum gear speed during travel (for only the auto gearshift mode) with the gearshift switches in neutral. A: Auto gearshift mode 2. Setting preset (gear speed at start) and maximum gear speed during travel)


Changing gear speed with gearshift switches during travel q The maximum gear speed during travel (in the auto gearshift mode) or the gear speed used during travel (in the manual gearshift mode) can be changed with the gearshift switches while the machine is traveling. A: Auto gearshift mode 2. Changing maximum speed during travel During forward travel: The maximum gear speed can be set to F1 – F3. During reverse travel: The maximum gear speed can be set to R1 – R3. Shift-up switch: Each time this switch is pressed, the maximum gear speed is heightened to the next range. Shift-down switch: Each time this switch is pressed, the maximum gear speed is lowered to the next range.

B: Manual gearshift mode 6. Setting preset (gear speed at start)

B: Manual gearshift mode 5. Changing maximum speed during travel During forward travel: The maximum gear speed can be set to F1 – F3. During reverse travel: The maximum gear speed can be set to R1 – R3. Shift-up switch: Each time this switch is pressed, the maximum gear speed is heightened to the next range. Shift-down switch: Each time this switch is pressed, the maximum gear speed is lowered to the next range.

a

30

When the starting switch is turned ON, the auto gearshift mode ([F1 – R1]) is set. When the gearshift mode is changed, [F1 – R1] is selected initially.

D155A-6


KOMTRAX system

q

q

q

a

SEN02868-01

1

The KOMTRAX system consists of a KOMTRAX terminal, communication antenna, machine monitor, and GPS antenna. This system transmits various kinds of machine information wirelessly. Persons to operate the KOMTRAX can refer to the information at office to provide various kinds of services for customers. Information transmittable from the KOMTRAX system includes the following. 1. Operation map 2. Service meter 3. Position information 4. Error history and others. To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.

D155A-6

31

SEN02868-01

KOMTRAX terminal


1

TH300

1. 2. 3.

Communication antenna connection Connector A (14 poles) Connector B (10 poles)

Outline q The KOMTRAX terminal is a wireless communication device to transmit various kinds of machine information or GPS position information the monitor obtains from network signals or input signals in the machine. The terminal can transmit information via the communication antenna.

Input and output signals Connector A Pin No. A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 A-11 A-12 A-13 A-14

Signal name Power (12V) NC(*1) NC(*1) Electric power supply switching NC(*1) NC(*1) GND GND NC(*1) NC(*1) NC(*1) NC(*1) NC(*1) NC(*1)

Input/ output Input — — Output — — — — — — — — — —

Connector B Input/ output B-1 Serial signal DCD Output B-2 Serial signal RXD Output B-3 Serial signal TXD Input B-4 Serial signal DTR Input B-5 Serial signal SGND — B-6 Serial signal DSR Output B-7 NC(*1) — B-8 NC(*1) — B-9 NC(*1) — B-10 NC(*1) — *1: Never connect to NC or malfunctions or failures will occur. Pin No.

32

Signal name

D155A-6


D155A-6

SEN02868-01

33

SEN02868-01




34

D155A-6

SEN03199-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up

20 Standard value table

1

Standard service value table Standard value table for engine ...................................................................................................................... 2 Standard value table for machine ................................................................................................................... 3

D155A-6

1

SEN03199-00


Standard value table for engine

Category

Item

Speed

1

Machine model

D155A-6

Engine

SAA6D140E-5 Unit

Standard value for new machine

Service limit value

High idle

rpm

2,100 (0/-50)

2,100 (0/-50)

Low idle

rpm

740 (+40/0)

740 (+40/0)

Rated speed

rpm

1,900

1,900

kPa {mmHg}

Min. 85 {Min. 640}

72 {540}

°C

670

720

% (Bosch index)

Max. 30 (Max. 3.0)

40 {4.0}

(Bosch index)

Max. 1.0

2.0

Intake valve

mm

0.35

—

Exhaust valve

mm

0.57

—

Min. 4.1 {Min. 42}

2.8 {29}

200 – 250

200 – 250

Max. 2.94 {Max. 300}

3.92 {400}

MPa {kg/cm2}

Min. 0.34 {Min. 3.5}

0.21 {2.1}

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.08 {0.8}

Measurement condition

• Engine coolant temperature: Within operating range

• Engine coolant temperature: Within operating range Intake air pressure • Power train oil temperature: Within (Boost pressure) operating range • Torque converter: Stalled Exhaust temperature

Exhaust gas color

Engine

Valve clearance

Compression pressure

Blow-by pressure

• Whole speed range (Outside temperature: 20°C) At sharp acceleration • Engine coolant (Low idle o temperature: Within High idle) operating range High idle

• Normal temperature Compression MPa pressure {kg/cm2} Engine rpm speed • Engine coolant temperature: Within operating range kPa • Power train oil temperature: Within {mmH2O} operating range • Torque converter: Stalled • Engine oil temperature: 40 – 60°C

• SAE0W30EOS, SAE5W40EOS, High idle SAE10W30DH, Engine oil pressure SAE15W40DH SAE30DH Oil • Engine oil temperature: Low idle Min. 80 °C

2

Oil temperature

• Whole speed range (In oil pan)

°C

90 – 110

120

Alternator belt tension

• Between water pump pulley – alternator pulley • Deflection under finger pressure of 98 N {10 kg}

mm

13 – 16

13 – 16

• Between compressor pulley – fan Air compressor belt pulley tension • Deflection under finger pressure of 59 N {6 kg}

mm

Approx. 10

Approx. 10

D155A-6


SEN03199-00

Standard value table for machine

1

Machine model

Cooling fan

Engine speed

Category

Item

D155A-6 Unit


Service limit value

rpm

875 ± 25

875 ± 25

rpm

1,875 ± 50

1,875 ± 50

rpm

1,665 ± 50

1,450

rpm

1,630 ± 50

1,395

rpm

—

—

rpm

1,100 ± 5 %

1,100 ± 5 %

30 ± 5

30 ± 5

30 ± 5

30 ± 5

40 ± 5

40 ± 5

40 ± 5

40 ± 5

mm

50 ± 10

50 ± 10

All stroke

mm

79 ± 10

79 ± 10

Stroke to 0 of oil pressure

mm

54 ± 4

54 ± 4


• Engine coolant temperature: Within operating range Decelerator pedal • Power train oil temperature: Within speed operating range • Hydraulic oil temperature: Within operating range • Engine: High idle Auto deceleration • Decelerator pedal speed: Press pedal speed • Auto deceleration speed: Set all levers in neutral • Engine coolant temperature: Within operating range Torque converter • Power train oil temperature: Within stall speed operating range • Hydraulic oil temperature: Within operating range • Engine: High idle Torque converter • Select P mode stall speed + Work • Torque converter stall speed: F3 equipment relief • Torque converter stall speed + Work speed equipment relief speed: F3 + Ripper raise • Hydraulic oil temperature: Within operating range Min. speed • Fan: Set in 100% mode • Engine: Low idle Fan motor speed • Hydraulic oil temperature: Within operating range Max. speed • Fan: Set in 100% mode • Engine: High idle

• Hydraulic oil temperature: Within operating range MPa • Fan: Set in 100% mode {kg/cm2} • Engine: High idle No mm Forward Forward/ Reverse travel No mm Reverse • Stop engine • Center of lever grip N o Left mm Steering N o Right mm

PCCS lever

Stroke of control lever/pedal

Fan pump circuit pressure

Decelerator pedal

• Stop engine • Center of pedal

Brake pedal

• Engine: Low idle • Center of pedal

D155A-6

3

SEN03199-00


Machine model Item

Blade control lever

Operating effort of control lever/pedal

Unit


Service limit value

N o Raise

mm

60 ± 10

72 ± 10

N o Lower

mm

60 ± 10

72 ± 10

N o Left tilt

mm

53 ± 10

53 ± 10

mm

53 ± 10

53 ± 10

N o Raise

mm

77 ± 10

75 ± 10

N o Lower

mm

77 ± 10

75 ± 10

N o In

mm

79 ± 10

80 ± 10

N o Out

mm

79 ± 10

80 ± 10

No

Forward

N {kg}

56.9 ± 6.9 {5.8 ± 0.7}

56.9 ± 6.9 {5.8 ± 0.7}

Reverse

N {kg}

50.1 ± 6.9 {5.2 ± 0.7}

50.1 ± 6.9 {5.2 ± 0.7}

N o Left

N {kg}

24.5 ± 4.9 {2.5 ± 0.5}

24.5 ± 4.9 {2.5 ± 0.5}

N o Right

N {kg} N {kg} N {kg} N {kg}

27.5 ± 4.9 {2.8 ± 0.5} 49.0 ± 9.8 {5.0 ± 1.0} 411.6 ± 78.4 {42.0 ± 8.0} 39.2 ± 5.9 {4.0 ± 0.6}

27.5 ± 4.9 {2.8 ± 0.5} 49.0 ± 9.8 {5.0 ± 1.0} 411.6 ± 78.4 {42.0 ± 8.0} 39.2 ± 5.9 {4.0 ± 0.6}

N o Lower

N {kg}

39.2 ± 9.8 {4.0 ± 1.0}

39.2 ± 9.8 {4.0 ± 1.0}

Lower o Float

N {kg}

82 ± 9.8 {8.4 ± 1.0}

82 ± 9.8 {8.4 ± 1.0}

N o Left tilt

N {kg} N {kg} N {kg} N {kg}

28.4 ± 5.9 {2.9 ± 0.6} 28.4 ± 5.9 {2.9 ± 0.6} 19.6 ± 4.9 {2.0 ± 0.5} 19.6 ± 4.9 {2.0 ± 0.5}

28.4 ± 5.9 {2.9 ± 0.6} 28.4 ± 5.9 {2.9 ± 0.6} 19.6 ± 4.9 {2.0 ± 0.5} 19.6 ± 4.9 {2.0 ± 0.5}

N o In

N {kg}

24.5 ± 4.9 {2.5 ± 0.5}

24.5 ± 4.9 {2.5 ± 0.5}

N o Out

N {kg}

24.5 ± 4.9 {2.5 ± 0.5}

24.5 ± 4.9 {2.5 ± 0.5}


• Stop engine • Center of lever knob

No

Ripper control lever

PCCS lever

Stroke of control lever/pedal

Category

D155A-6


Forward/ Reverse travel

No • Stop engine • Center of lever grip

Right tilt

Steering

Decelerator pedal Brake pedal

• • • •

Stop engine Center of pedal Engine: Low idle Center of pedal N o Raise

• Stop engine Blade control lever • Center of lever knob • Lower o Float

No

Right tilt

N o Raise

Ripper control lever

4


N o Lower

D155A-6


SEN03199-00

Machine model Category

Item Torque converter inlet pressure

Torque converter outlet pressure

D155A-6

MPa {kg/cm2} MPa {kg/cm2}

Standard value for new machine 0.05 – 0.49 {0.5 – 5.0} Max. 1.0 {Max. 10.0}

MPa {kg/cm2}

0.05 – 0.29 {0.5 – 3.0}

0.05 – 0.29 {0.5 – 3.0}

MPa {kg/cm2}

0.29 – 0.69 {3.0 – 7.0}

0.29 – 0.69 {3.0 – 7.0}

MPa {kg/cm2}

2.81 – 3.11 {28.7 – 31.7}

Min. 2.62 {Min. 26.7}

MPa {kg/cm2}

3.04 – 3.33 {31.0 – 34.0}

Min. 2.84 {Min. 29.0}

Low idle

MPa {kg/cm2}

2.55 – 2.94 {26.0 – 30.0}

Min. 2.35 {Min. 24.0}

High idle

MPa {kg/cm2}

2.65 – 3.04 {27.0 – 31.0}

Min. 2.45 {Min. 25.0}

MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2}

2.60 – 2.99 {26.5 – 30.5} 2.74 – 3.14 {28.0 – 32.0} 2.81 – 3.11 {28.7 – 31.7} 3.04 – 3.33 {31.0 – 34.0}

Min. 2.40 {Min. 24.5} Min. 2.55 {Min. 26.0} Min. 2.62 {Min. 26.7} Min. 2.84 {Min. 29.0}

MPa {kg/cm2}

2.55 – 2.94 {26.0 – 30.0}

Min. 2.35 {Min. 24.0}

MPa {kg/cm2}

2.70 – 3.09 {27.5 – 31.5}

Min. 2.50 {Min. 25.5}

MPa {kg/cm2} MPa {kg/cm2}

2.81 – 3.11 {28.7 – 31.7} 3.04 – 3.33 {31.0 – 34.0}

Min. 2.62 {Min. 26.7} Min. 2.84 {Min. 29.0}

MPa {kg/cm2}

0.098 – 0.25 {1.0 – 2.5}

0.098 – 0.25 {1.0 – 2.5}

MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2}

3.04 – 3.33 {31.0 – 34.0} 3.04 – 3.33 {31.0 – 34.0} 3.04 – 3.33 {31.0 – 34.0}

3.04 – 3.33 {31.0 – 34.0} 3.04 – 3.33 {31.0 – 34.0} 3.04 – 3.33 {31.0 – 34.0}

High idle

MPa {kg/cm2}

3.04 – 3.33 {31.0 – 34.0}

3.04 – 3.33 {31.0 – 34.0}

Low idle

MPa {kg/cm2}

2.3 – 2.6 {23.5 – 26.5}

2.3 – 2.6 {23.5 – 26.5}

MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2}

2.3 – 2.6 {23.5 – 26.5} 2.3 – 2.6 {23.6 – 26.5} 2.3 – 2.6 {23.6 – 26.5}

2.3 – 2.6 {23.5 – 26.5} 2.3 – 2.6 {23.6 – 26.5} 2.3 – 2.6 {23.6 – 26.5}

Measurement condition Low idle • Power train oil temperature: Within operating High idle range • PCCS lever: Neutral Low idle • Display by monitoring High idle

• Power train oil temperature: Within operating Low idle range Transmission main • PCCS lever: Neutral relief pressure (Main relief pressure) High idle • Brake pedal: Press (Other than above) Transmission F clutch pressure (When operating N1 o F1)

Power train oil pressure

Transmission R clutch pressure (When operating N1 o R1) Transmission 1st clutch pressure (When operating N1 o F1) Transmission 2nd clutch pressure (When operating N1 o F2)

Low idle High idle • Power train oil temper- Low idle ature: Within operating range High idle • PCCS lever: Neutral (Main relief pressure) Low idle • Brake pedal: Press (Other than above) High idle

Transmission 3rd clutch pressure (When operating F2 o F3) Transmission lubricating oil pressure (Reference) Steering right brake • Power train oil pressure temperature: Within operating range • PCCS lever: Neutral Steering left brake • Brake pedal: Release pressure • Power train oil temperature: Within operating range • Gear speed: N • PCCS lever: Right stroke end Steering left clutch • PCCS lever: Left pressure stroke end Steering right clutch pressure

D155A-6

Low idle High idle High idle Low idle High idle Low idle

High idle Low idle High idle

Unit

Service limit value 0.05 – 0.49 {0.5 – 5.0} Max. 1.0 {Max. 10.0}

5

SEN03199-00


Machine model

Power train performance

Category

D155A-6 Unit


Service limit value

F1

km/h

3.8 ± 0.2

3.8 ± 0.2

F2

km/h

7.5 ± 0.4

7.5 ± 0.4

F3L

km/h

7.5 ± 0.4

7.5 ± 0.4

F3

km/h

11.6 ± 0.6

11.6 ± 0.6

R1

km/h

4.6 ± 0.2

4.6 ± 0.2

R2

km/h

6.8 ± 0.4

6.8 ± 0.4

R3L

km/h

9.2 ± 0.5

9.2 ± 0.5

R3

km/h

14.0 ± 0.7

14.0 ± 0.7

MPa {kg/cm2}

—

—

MPa {kg/cm2}

2.45 (+1.37/0)

2.45 (+1.37/0)

{25 (+14/0)}

{25 (+14/0)}

MPa {kg/cm2}

27.5 ± 1.5 {280 ± 15}

27.5 ± 1.5 {280 ± 15}

MPa • Hydraulic oil temperature: Within {kg/cm2} operating range Ripper lift relief MPa • Engine: High idle pressure {kg/cm2} • Cylinder of measured circuit: Ripper tilt relief MPa Stroke end pressure {kg/cm2} Work equipment LS MPa relief pressure {kg/cm2} • Hydraulic oil temperature: Within Control circuit basic operating range MPa pressure • Engine: High idle {kg/cm2} • All levers: Set in neutral

27.5 ± 1.5 {280 ± 15}

27.5 ± 1.5 {280 ± 15}

27.5 ± 1.5 {280 ± 15}

27.5 ± 1.5 {280 ± 15}

27.5 ± 1.5 {280 ± 15} 25.0 ± 0.98 {255 ± 10}

27.5 ± 1.5 {280 ± 15} 25.0 ± 0.98 {255 ± 10}

Item

Travel speed

Unload pressure

Measurement condition • Flat ground • Engine coolant temperature: Within operating range • Power train oil temperature: Within operating range • Select manual gearshift mode • Engine: High idle • Approach run: 10 – 30 m • Measuring distance: 20 m (Converted into km/h)

• Hydraulic oil temperaLow idle ture: Within operating range • All levers: High idle Set in neutral

Work equipment oil pressure

Blade lift relief pressure Blade tilt relief pressure

6

Work equipment speed

Work equipment

• Hydraulic oil temperature: Within Control valve PPC operating range valve output • Engine: High idle pressure • Lever of measured circuit: Stroke end

Blade lift

• Hydraulic oil temperature: Within operating range Raise • Engine: High idle • Select P mode • Apply no load to blade. • Measure time required to move blade from ground level to raise Lower stroke end • For measuring posture, see Fig. 1

3.97 (+0.49/0)

3.78 – 4.46

{40.5 (+5/0)}

{38.5 – 45.5}

MPa {kg/cm2}

3.82 – 4.12 {39 – 42}

3.53 {36}

sec

3.0 – 4.0

3.0 – 4.0

sec

1.0 – 1.7

1.0 – 1.7

D155A-6


SEN03199-00

Machine model Category

Item

Work equipment


Blade tilt

Ripper lift

Ripper tilt

Time lag

Blade

Ripper

D155A-6

Measurement condition • Hydraulic oil temperature: Within Left tilt operating range • Engine: High idle • Select P mode • Apply no load to blade • Measure time required to move blade from left tilt end to right tilt end Right tilt • For measuring posture, see Fig. 2 • Hydraulic oil temperature: Within operating range Raise • Engine: High idle • Select P mode • Apply no load to ripper (Shank hole: Lowest) • Measure time required to move ripper from ground level to raise Lower end • For measuring posture, see Fig. 3 • Hydraulic oil temperature: Within operating range Tilt in • Engine: High idle • Select P mode • Apply no load to ripper • Measure time required to move ripper from tilt in end to tilt back end Tilt back • For measuring posture, see Fig. 4 • Hydraulic oil temperature: Within operating range • Engine: Low idle • Select P mode. • Blade control lever: Set to stroke end • Lower blade from max. rising position and measure time after blade comes in contact with ground until idler is lifted • Hydraulic oil temperature: Within operating range • Engine: Low idle • Select P mode • Ripper control lever: Set to stroke end • Lower ripper from max. rising position and measure time after ripper comes in contact with ground until sprocket is lifted

D155A-6 Unit


Service limit value

sec

1.8 – 2.8

3.1

sec

1.8 – 2.8

3.1

sec

2.5 – 3.5

4.0

sec

2.5 – 3.5

4.0

sec

4.5 – 5.5

6.2

sec

3.3 – 4.3

5.7

sec

Max. 1.7

2.5

sec

Max. 1.5

1.5

7

SEN03199-00


Machine model

8

Unit


Service limit value

mm

Max. 150/15 minutes

200/15 minutes

mm

Max. 50/5 minutes

70/5 minutes

• Hydraulic oil temperature: Within operating range Hydraulic drift • Stop engine of machine • Measure reduction of idler center tilted by blade height h in 5 minutes • For measuring posture, see Fig. 7

mm

Max. 50/5 minutes

70/5 minutes

• Hydraulic oil temperature: Within operating range Hydraulic drift • Stop engine of machine • Measure reduction of sprocket center lifted by ripper height h in 5 minutes • For measuring posture, see Fig. 8

mm

Max. 50/5 minutes

70/5 minutes

cc/min

Max. 3.0

12

cc/min

Max. 2.7

11

cc/min

Max. 2.7

11

Hydraulic drift of work equipment

Item

Leakage from cylinder

Work equipment

Category

D155A-6


• Hydraulic oil temperature: Within operating range Hydraulic drift • Stop engine of lifted blade • Measure reduction of blade bottom height h in 15 minutes • For measuring posture, see Fig. 5 • Hydraulic oil temperature: Within operating range Hydraulic drift • Stop engine of machine • Measure reduction of idler center lifted by blade height h in 5 minutes • For measuring posture, see Fig. 6

Blade lift cylinder Ripper lift cylinder Ripper tilt cylinder

• Hydraulic oil temperature: Within operating range • Engine: High idle • Measure leakage from relieved cylinder in 1 minute

D155A-6


SEN03199-00

Postures and procedures for measuring performance Fig. 1: Blade lift speed

Fig. 4: Ripper tilt speed

Fig. 2: Blade tilt speed

Fig. 5: Hydraulic drift of lifted blade

Fig. 3: Ripper lift speed

Fig. 6: Hydraulic drift of machine lifted by blade

D155A-6

9

SEN03199-00


Fig. 7: Hydraulic drift of machine tilted by blade

Fig. 8: Hydraulic drift of machine lifted by ripper

10

D155A-6


D155A-6

SEN03199-00

11

SEN03199-00




12

D155A-6

SEN03200-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up

30 Testing and adjusting

1

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

D155A-6

1

SEN03200-01


Testing and adjusting alternator belt tension................................................................................................. 29 Testing and adjusting air conditioner compressor belt tension...................................................................... 30 Measuring fan speed..................................................................................................................................... 31 Measuring fan circuit oil pressure ................................................................................................................. 32 Bleeding air from fan pump ........................................................................................................................... 33 Bleeding air from work equipment pump....................................................................................................... 34 Adjusting fuel control dial and decelerator pedal .......................................................................................... 35

2

D155A-6


SEN03200-01

Testing and adjusting item

Symbol

Measuring intake air pressure (boost pressure)

A

Measuring exhaust temperature

B

Measuring exhaust gas color Adjusting valve clearance Measuring compression pressure

2

D

799-201-2202 Boost gauge kit

1

– 101 – 200 kPa {– 760 – 1,500 mmHg}

799-401-2220 Hose

1 Straight type quick coupler

799-101-1502 Digital thermometer

1 – 99.9 – 1,299°C

Part name

E

1

Commercially Smoke meter available

1

Commercially Thickness gauge available

1

1 795-502-1590 Compression gauge

Air intake: 0.35 mm, Exhaust: 0.57 mm

1 0 – 7.0 MPa {0 – 70 kg/cm2} 1

6261-71-6150 Gasket

1

799-201-1504 Blow-by checker

1 0 – 5 kPa {0 – 500 mmH2O}

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 6.0, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 60 MPa {600 kg/cm2}

2 799-401-2320 Hydraulic tester

1

Pressure gauge: 1.0 MPa {10 kg/cm2}


1



1


1

Pressure gauge: 1.0 MPa {10 kg/cm2}

F

1 G

1 Measuring fuel pressure

Bosch index: 0 – 9

795-471-1330 Adapter

2

Measuring blow-by pressure

Measuring engine oil pressure

Remarks

Part No.

1 799-201-9001 Handy smoke checker C

1

Q'ty

Tools for testing, adjusting, and troubleshooting

H

2 799-401-2320 Hydraulic tester 3

795T-471-2010 Adapter

1

07005-00812 Gasket

1

For 140E-5 engine

8 × 1.25 mm o R1/8

1 6151-51-8490 Spacer

1 Inside diameter: 14 mm

2 6206-71-1770 Joint

1 Inside diameter of joint: 10 mm

3

Commercially Hose available

1 ø5 mm × 2 – 3 m

Measuring fuel return rate J 4 and fuel leakage

Commercially Hose available

1 ø15 mm × 2 – 3 m

5

Commercially Measuring cylinder available

1

6

Commercially Stopwatch available

1

795-205-1100 Tachometer kit

1 6.0 – 99999.9 rpm


1



1


Measuring fan speed

K

1 Measuring fan circuit pressure

L

2 799-401-3400 Adapter 3

D155A-6

799-101-5220 Nipple 07002-11023 O-ring

1 Size: 05 1 Size: 10 × 1.25 mm

3


Measuring power train oil pressure


Symbol

Measuring and adjusting work equipment oil pressure

N 1

P


1



1


Part name

79A-264-0091 Push-pull scale

1 0 – 490 N {0 – 50 kg}

19M-06-32820 Switch assembly

1

17A-06-41410 Wiring harness

1

2 790-190-1601 Pump assembly

1


1



1


1 Q 2

Measuring control circuit basic pressure

Remarks

Part No.

M

Adjusting brake pedal Emergency escape method when power train has trouble

Q'ty

SEN03200-01

799-101-5220 Nipple

2

07002-11023 O-ring

2


1



1


799-401-3200 Adapter

1

02896-11009 O-ring

1


1


1


1 R 2

1 Testing work equipment lock solenoid valve output S 790-261-1204 Digital hydraulic tester pressure 791T-643-1010 Elbow 2 07002-11423 O-ring

T 2 3

1 Measuring ripper pin puller solenoid valve output U pressure 2

Size: 03

1 1


1



1


799-401-3100 Adapter

1

02896-11008 O-ring

1

799-401-3200 Adapter

1

02896-11009 O-ring

1


1



1


799-401-3200 Adapter

1

02896-11009 O-ring

1

1 PPC valve output pressure

Size: 10 × 1.25 mm

Size: 02 Size: 03

Size: 03

Measuring internal leakage of work equipment cylinder

V

Commercially Measuring cylinder available

1

Measuring coolant temperature and oil temperature

—

799-101-1502 Digital thermometer

1 – 99.9 – 1,299°C

4

D155A-6


SEN03200-01

Symbol

Part No.

Part name

Q'ty


Remarks


1 0 – 294 N {0 – 30 kg}


1 0 – 490 N {0 – 50 kg}

—

Commercially Ruler available

1

Measuring work equipment speed

—

Commercially Stopwatch available

1

Measuring voltage and resistance

—

Commercially Circuit tester available

1

Testing operating effort and pressing force

—

Measuring stroke and hydraulic drift

799-601-4101 or T-adapter assembly 799-601-4201

Engine related controller, sensor and actuator diagnosis

mashine related controller and sensors/wiring harnesses diagnosis

—

—

799-601-4350 • T-box

For DRC60 • ECONO*² (Max 60P) 1 (Does not include in assembly No.799-601-4201)

795-799-5530 • Socket

For engine (CRI-T3) coolant temperature sensor (PACKARD 2P) For engine (CRI-T3) fuel temperature 1 sensor (PACKARD 2P) For engine (CRI-T3) oil temperature sensor (PACKARD 2P)

795-799-5540 • Socket

1

For engine (CRI-T3) boost temperature sensor (PACKARD 2P)

799-601-4240 • Socket

1

For engine (CRI-T3) ambient pressure sensor (AMP 3P)

799-601-4110 • Socket

1

For engine (CRI-T3) boost pressure sensor (SUMITOMO 3P)

799-601-4330 • Socket

1

For engine (CRI-T3) G (Bkup) sensor (SUMITOMO 3P)

799-601-9430 • Socket

For engine (CRI-T3) supply pump 1 PCV1 • supply pump PCV sensor (SUMITOMO 3P)

799-601-4130 • T-adapter

1

For engine (CRI-T3) NE sensor (FRAMATOME 3P)

799-601-4150 • T-adapter

1

For engine (CRI-T3) oil pressure sensor (FRAMATOME 3P)

799-601-9420 • T-adapter

1

For engine (CRI-T3) common rail pressure sensor (AMP 3P)

799-601-4211 • T-adapter

For engine controller (DRC26-50P) 1 (Does not include in assembly No. 799-601-4201)

799-601-4220 • T-adapter

For engine controller DRC26-60P 1 (Does not include in assembly No. 799-601-4201)

799-601-4260 • T-adapter

For engine controller (DTP-4P) 1 (Include in assembly No. 799-6019000 and 799-601-9100, too)

799-601-9040 • T-adapter

For DT 4P 1 (Include in assembly No. 799-6019000 and 799-601-9200, too)

799-601-9020 • T-adapter

For DT 2P 1 (Include in assembly No. 799-6019000 and 799-601-9200, too)

799-601-9000 or 799-601-9100 T-adapter assembly or 799-601-9300 799-601-9200 • T-box

D155A-6

1 For ECONO*¹ (Max 24P)

5



Symbol

Part No.

Part name

Q'ty

SEN03200-01

Remarks

799-601-4101 T-adapter assembly 799-601-4350 • T-box

1 For DRC60 • ECONO*² (Max 60P)

799-601-7000 or 799-601-7100 or T-adapter assembly 799-601-7400 or 799-601-8000 799-601-2600 • T-box

For ECONO*³ (Max 21P) 1 (Does not include in assembly No. 799-601-7000.)

799-601-7210 • T-adapter

1 For AMP040 16P

799-601-7220 • T-adapter

1 For AMP040 20P

799-601-7110 • T-adapter

1 For M 3P

799-601-7050 • T-adapter

1

For SWP 6P (Does not include in assembly No. 799-601-8000.)

799-601-7500 T-adapter assembly

mashine related controller and sensors/wiring harnesses diagnosis

—

799-601-7510 • T-adapter

1 For AMP070 10P

799-601-7520 • T-adapter

1 For AMP070 12P

799-601-7530 • T-adapter

1 For AMP070 14P

799-601-7540 • T-adapter

1 For AMP070 18P

799-601-7550 • T-adapter

1 For AMP070 20P

799-601-9000 or T-adapter assembly 799-601-9200 799-601-9040 • T-adapter

For DT 4P 1 (Include in assembly No. 799-6014101 and 799-601-4201, too.)

799-601-9020 • T-adapter

1 For DT 2P

799-601-9030 • T-adapter

1 For DT 3P

799-601-9050 • T-adapter

1 For DT 6P

799-601-9060 • T-adapter

1 For DT 8P

799-601-9070 • T-adapter

1 For DT 8P

799-601-9110 • T-adapter

1 For DT 12P (Gray)

799-601-9120 • T-adapter

1 For DT 12P (Black)

799-601-9130 • T-adapter

1 For DT 12P (Green)

799-601-9140 • T-adapter

1 For DT 12P (Brown)

799-601-9280 • T-adapter 799-601-9290 • T-adapter

1 For HD36 24-24P 1 For HD36 24-31P (Does not include in assembly No.799-601-9200.) (Include in assembly No. 799-6019100, too.)

799-601-9300 T-adapter assembly

6

799-601-9360 • T-adapter

1 For pump controller (DRC26-24P)

799-601-9350 • T-adapter

1 For pump controller (DRC26-40P)

D155A-6


Sketches of special tools

SEN03200-01

1

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. H3 Adapter

S2 Elbow

D155A-6

7

SEN03200-01

Measuring engine speed k

a

1.

1

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the engine speed under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range q Working mode: P mode q Gearshift mode: Either Auto or Manual Preparation work Measure the engine speed with the Adjustment function in the service mode of the machine monitor. a For the operating method of the machine monitor, see Special functions of machine monitor (EMMS). 1) Measuring low idle speed, decelerator pedal speed, auto-deceleration speed, torque converter stall speed, and torque converter stall speed + work equipment relief speed (full stall speed): q Adjustment code: 0530 (Stall mode) a When stalling the torque converter for a purpose other than measuring the engine speed, be sure to use this adjustment code, too.

2)

8


Measuring high idle speed: q Adjustment code: 0007 (Reset engine deceleration) a Only when this code is selected, the engine can be operated and tested with the auto-decelerator reset.

2.

Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position.

3.

Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position. a When measuring the high idle speed, be sure to select adjustment code [0007] (If adjustment code [0530] is selected, the auto-deceleration speed is measured).

4.

Measuring decelerator pedal speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral, press the decelerator pedal to the stroke end, and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position.

5.

Measuring auto-deceleration speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed.

D155A-6

30 Testing and adjusting a

6.

7.

SEN03200-01 a

The parking brake lever and work equipment lock lever may be kept in the LOCK position.

Measuring torque converter stall speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. 3) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering system in neutral. 4) Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. 5) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 6) Just after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120 °C, return the direction of PCCS lever to neutral. a The top of the green range of the power train oil temperature gauge indicates about 118 – 120 °C. 7) Repeat above steps 3) – 6) 3 times. 8) Perform steps 3) – 5) again and measure the engine speed about 5 seconds after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120 °C. a Immediately after finishing measurement, return the direction of PCCS lever to neutral and lower the power train oil temperature with the engine at high idle.

3)

4)

5) 6) k

7)

8) 9)

The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. Set the work equipment lock lever in the free position and operate the ripper control lever to set the ripper lift cylinder to the raise stroke end. While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering system in neutral. Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. Just after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120 °C, return the direction of PCCS lever to neutral. a The top of the green range of the power train oil temperature gauge indicates about 118 – 120 °C. Repeat above steps 4) – 7) 3 times. Perform steps 4) – 6) again, operate the ripper control lever to relieve the ripper raise system, and measure the engine speed about 5 seconds after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120 °C. a Immediately after finishing measurement, return the direction of PCCS lever to neutral and lower the power train oil temperature with the engine at high idle.

Measuring torque converter stall + work equipment relief speed (Full stall speed) 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3].

D155A-6

9

SEN03200-01


Measuring intake air pressure (boost pressure) a

4.

Run the engine at a medium or higher speed and drain the oil from the test hose. a Insert the connecting parts of the gauge and hose about a half and open the selfseal on the hose side repeatedly, and the oil will be drained. a If Pm kit (A) is available, you may drain the oil by using the oil draining coupling (790-261-1130) in that kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil.

5.

Turn the starting switch ON and set the machine monitor to Adjustment function of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see Special functions of machine monitor (EMMS).

6.

While running the engine at high idle, stall the torque converter and measure the intake air pressure (boost pressure). a For the procedure for stalling the torque converter, see Measuring engine speed. a Normally, the intake air pressure (boost pressure) should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter.

1

Measuring instruments for intake air pressure (boost pressure)

Symbol A k

k

a

Part No. 799-201-2202 799-401-2220

Part name Boost gauge kit Hose

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Be careful not to touch any hot part of the engine when removing or installing the measuring tools. Measure the intake air pressure (boost pressure) under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range

1.

Open the engine left side cover.

2.

Remove intake air pressure pickup plug (1) from the rear of the air intake connector.

3.

10

Install nipple [1] of boost gauge kit A and connect gauge [2].

D155A-6


7.

SEN03200-01

After finishing measurement, remove the measuring instruments and return the removed parts. q Remove the gasket sealant sticking to the threaded part of the removed plug with a wire brush, apply adhesive or gasket sealant to it, and install it. 2 Plug: LT-2 or LG-5 3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm} (Air intake connector made of FC) 6.9 – 14.7 Nm {0.7 – 1.5 kgm} (Air intake connector made of Al l)

D155A-6

11

SEN03200-01


Measuring exhaust temperature 1 a

Measuring instruments for exhaust temperature

Symbol

Part No.

B

799-101-1502

k

k

a

Part name Digital thermometer

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Install and remove the measuring instruments after the exhaust manifold is cooled. Measure the exhaust temperature under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range

1.

Open the engine right side cover and right mudguard.

2.

Remove 1 exhaust temperature pickup plug (1) from the exhaust manifold. a You may measure the exhaust temperature at either front or rear plug.

3.

12

Install sensor [1] of digital thermometer B and connect them to meter [2]. a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part during measurement.

4.

When measuring maximum exhaust temperature for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. a Use the PEAK mode of the thermometer. a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. q Corrected value [°C] = Measured value + 2 × (20 – Outside air temperature)

5.

Procedure for measuring exhaust temperature periodically for preventive maintenance (Pm clinic) a If the torque converter is stalled simply, the torque converter oil is overheated before the exhaust temperature is stabilized. Accordingly, measure according to the following procedure. 1) Turn the starting switch ON and set the machine monitor to Adjustment function of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see Special functions of machine monitor (EMMS). D155A-6


2) 3)

4)

5)

6) 7)

SEN03200-01

8)

Start the engine and set the fuel control dial in the low idle (MIN) position. Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. Set the work equipment lock lever in the free position and operate the ripper control lever to set the ripper lift cylinder to the raise stroke end. While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering system in neutral. Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. Return the decelerator pedal slowly to stall the torque converter and relieve the ripper raise system to raise the exhaust temperature to about 650 °C (Condition (a) in the figure) with the engine at high idle. k

9)

k

a

Just after the power train oil temperature (T/C TEMPERAT URE) reaches about 120 °C, return the direction of PCCS lever to neutral and lower the power train oil temperature with the engine at high idle. The border between the green range and red range of the power train oil temperature gauge indicates about 120 °C.

Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.

6.

D155A-6

Under the condition of step 7), stop relieving the ripper raise system and lower the exhaust temperature by only stalling the torque converter (Condition (b) in the figure). a If the exhaust temperature does not lower but rises, set the temperature high in step 7). After the exhaust temperature is lowered and stabilized, measure the exhaust temperature (Condition (c) in the figure).

After finishing measurement, remove the measuring instruments and return the removed parts. q Clean the threaded part of the removed plug, apply anti-seizure compound to it, and tighten it. 2 Plug: Anti-seizure compound (LC-G) 3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}

13

SEN03200-01


Measuring exhaust gas color a

Measuring instruments for exhaust gas color

Symbol C k

k

a

a

1.

1

Part No.

Part name

1

799-201-9001

Handy smoke checker

2

Commercially available

Smoke meter

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Be careful not to touch any hot part of the engine when removing or installing the measuring tools. If an air source and an electric power source are not available in the field, use handy smoke checker C1. When recording official data, use smoke meter C2. Measure the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range Measuring with handy smoke checker C1 1) Stick a sheet of filter paper to smoke checker C1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Start the engine. 4) Accelerate the engine suddenly or run it at high idle and operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas.

2)

3)

4)

5)

6) 7)

5) 6)

2.

14

Remove the filter paper and compare it with the attached scale. After finishing measurement, remove the measuring instrument and return the removed parts.

Measuring with smoke meter C2 1) Insert probe [1] of smoke meter C2 in the outlet of exhaust pipe (1) and fix it to the exhaust pipe with a clip.

8)

9)

Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter C2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm²}. Connect the power cable to a receptacle of AC 100 V. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn power switch of smoke meter C2 ON.

Start the engine. Accelerate the engine suddenly or run it at high idle and press the accelerator pedal of smoke meter C2 and collect the exhaust gas into the filter paper. Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing measurement, remove the measuring instrument and return the removed parts.

D155A-6


SEN03200-01

Adjusting valve clearance a

Measuring instruments for valve clearance

Symbol

Part No.

D


k

a

1.

Part name Thickness gauge

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Adjust the valve clearance under the following condition. q Engine coolant temperature: Normal temperature Remove the engine hood assembly and air cleaner together. 4

2.

1

Engine hood assembly: 170 kg

5.

6.

Remove all cylinder head covers (1).

7.

3.

Remove the inspection plate on the right of the radiator guard.

4.

Rotate the crankshaft forward to bring the stamped "1.6TOP" line (a) of the damper to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Rotate the crankshaft with the hexagonal part at the end of the water pump drive shaft. a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn. a Eliminate the slack of the injector wiring harness and press it against the injector body so that it will not interfere with the rocker arm. Tighten the nuts alternately.

D155A-6

8.

9.

While fixing adjustment screw (3), loosen locknut (4). a After setting the No. 1 cylinder to the compression top dead center, adjust the valve clearance of the No. 1 cylinder. Insert thickness gauge D in the clearance between rocker arm (5) and cross head (6) and adjust the valve clearance with adjustment screw (3). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the thickness gauge lightly. a Valve clearance Intake valve : 0.35 mm Exhaust valve: 0.57 mm While fixing adjustment screw (3), tighten locknut (4). 3 Locknut: 45.1 – 51.0 Nm {4.6 – 5.2 kgm} a After tightening the locknut, check the valve clearance again.

After adjusting the No. 1 cylinder, rotate the crankshaft forward by 120 ° to set the stamped TOP line of each cylinder to pointer (2) according to the firing order and adjust the valve clearance. q Firing order: 1–5–3–6–2–4 After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

15

SEN03200-01


Measuring compression pressure1 a

Measuring tools for compression pressure

Symbol 1 E k

a

a

1.

2

Part No. 795-502-1590

Compression gauge

795-471-1330

Adapter

6261-71-6150

Gasket

Remove the engine hood assembly and air cleaner together.

5.

Install adapter E2 to the mounting hole on the injector and connect compression gauge E1. a Be sure to fit the gasket to the injector end. a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily.

6.

Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a See Adjusting valve clearance.

Engine hood assembly: 170 kg

Remove cylinder head cover (1) of the cylinder to measure the compression pressure.

3.

Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a For the procedure for bringing each cylinder to the compression top dead center, see Adjusting valve clearance.

4.

Disconnect fuel high-pressure tube (3) and injector wiring harness (4) and remove injector (5) and wiring harness.

16

a

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure under the following conditions. q Engine oil temperature: 40 – 60 °C

4

2.

Part name

Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and r em o v e th e i n j ec t o r wi r i ng h ar ne s s (Loosen the 2 terminal nuts alternately). Pass a wire under the fuel path projected sideways and pull up the injector (Do not pry the injector top up).

D155A-6


7.

Set the engine in the no-injection cranking mode with the machine monitor. a See Testing and adjusting (Part 3), "Noinjection cranking".

8.

Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. q Monitoring code: 01002 Engine Speed a For the operating method, see Special functions of machine monitor (EMMS). a Be sure to replace the copper gasket and O-ring with new ones before installing the injector.

SEN03200-01

2)

Tighten bolt (13) and washer (14) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily. 4) Tighten bolt (13) permanently. 3 Bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 5) Tighten sleeve nut (15) permanently. 3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}

a 1) 2) 3) 4)

a

9.

Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized. a When measuring the compression pressure, check that the engine speed is in the range of the measurement condition.

Install the injector wiring harness according to the following procedure. Install the injector wiring harness to the rocker arm housing and fix the connector side with the plate. Fix the intermediate clamp with the clip. Tighten the nut on the injector side. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} Secure the clamp and spacer with the bolt. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} Adjust the valve clearance. For details, see Adjusting valve clearance. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 kgm {3.0 – 3.5 kgm}

10. After finishing measurement, remove the measuring instruments and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. a Before installing the injector, replace the copper gasket and O-ring with new ones. 1) Push in injector (11) with the hand to assemble holder (12) temporarily. D155A-6

17

SEN03200-01


Measuring blow-by pressure a

Part No.

F

799-201-1504

k

Part name Blow-by checker

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the blow-by pressure under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range

1.

Open the engine left side cover and left mudguard.

2.

Install nozzle [1] and hose [2] of blow-by checker F to the end of breather hose (1) and connect them to gauge [3].

3.

While running the engine at high idle, stall the torque converter and measure the blow-by pressure. a For the procedure for stalling the torque converter, see Measuring engine speed. a Normally, the blow-by pressure should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter. a If it is impossible to run the engine at the rated output or stall the torque converter, measure while the engine is running at high idle. The value obtained in this case is about 80% of the blow-by pressure at the rated output. a The blow-by pressure may vary largely with the engine condition. If the measured

18

value is judged abnormal, check for increase of oil consumption, bad exhaust gas color, deterioration of oil, high deterioration speed of oil, etc. which are related to the abnormal blow-by pressure.

Measuring instrument for blow-by pressure

Symbol

a

1

4.

After finishing measurement, remove the measuring instruments and return the removed parts.

D155A-6


SEN03200-01

Measuring engine oil pressure a

1 2

k

a

4.

Run the engine at low idle and high idle and measure the engine oil pressure.

5.

After finishing measurement, remove the measuring instruments and return the removed parts. q Remove the gasket sealant sticking to the threaded part of the removed plug with a wire brush, apply adhesive or gasket sealant to it, and install it. 2 Plug: LT-2 or LG-5 3 Plug: 16.7 – 37.2 Nm {1.7 – 3.8 kgm}

Measuring instruments for engine oil pressure

Symbol G

1

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range

1.

Open the engine left side cover and left mudguard.

2.

Remove engine oil pressure pickup plug (1) from the cylinder block.

3.

Install nipples [1] and [2] of hydraulic tester G1 and connect them to hydraulic tester G2. a Since the size of the plug hole is R1/4, quick nipples (799-101-5210) may be used instead of nipples [1] and [2].

D155A-6

19

SEN03200-01

Handling fuel system parts a

a

a

20


1

Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter. Precaution for connecting fuel spill circuit hose The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If the engine is started while the spill circuit hose is blocked, the spill circuit pressure increases abnormally and the injector may be damaged.

Releasing residual pressure from fuel system 1 a

a

a

k

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at for least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)

D155A-6


SEN03200-01

Measuring fuel pressure a

1 2 3 k

a k

3.

Measuring instruments for fuel pressure

Symbol

H

1

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-401-2320

Hydraulic tester

Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal. Engine speed

Fuel pressure

High idle

0.15 – 0.3 MPa {1.5 – 3 kg/cm²}

795T-471-2010 Adapter 07005-00812

Gasket

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel filter to the supply pump. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured.

1.

Open the engine left side cover and remove fuel pressure pickup plug (1) from the top of the fuel filter.

2.

Install adapter H3 and elbow [1] and nipple [2] of hydraulic tester H1 and connect them to hydraulic tester H2.

D155A-6

4.

After finishing measurement, remove the measuring instruments and return the removed parts. 3 Plug: 7.84 – 9.8 Nm {0.8 – 1.0 kgm}

21

SEN03200-01


Measuring fuel return rate and fuel leakage

a

Measuring instruments for return rate and fuel leakage

Symbol

J

a k

22

1

Part No.

Part name

1

6151-51-8490

Spacer

2

6206-71-1770

Joint

3

Commercially available Hose

4

Commercially available Hose

5

Commercially available Measuring cylinder

6

Commercially available Stopwatch

Prepare an oil pan of about 20 l to receive the fuel flowing out during the test. Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.

D155A-6


1.

SEN03200-01

5)

Preparation work 1) Open the engine left side cover and left mudguard. 2) Remove tube (3) between supply pump (1) and common rail (2). a In the figure, 1 oil filter is removed temporarily from the common rail side. a Disconnect both ends of the tube, loosen the clamp, and move the tube to the opposite side of the cylinder block.

2.

3)

Insert spacer J1 on supply pump (1) side and tighten the removed joint bolt again. a Connect the return pipe to the fuel tank again, too. a Be sure to fit the gaskets to both ends of the spacer.

4)

Insert joint J2 on common rail (2) side and tighten the removed joint bolt again. a In the figure, 1 oil filter is removed temporarily from the common rail side. a Be sure to fit the gaskets to both ends of the joint.

D155A-6

Connect test hose J3 to the end of joint J2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for measuring the leakage from the pressure limiter.

Testing leakage from pressure limiter 1) Lay test hose J3 so that it will not slacken and put its end in the oil pan. 2) Turn the starting switch ON and make the machine monitor display the "Adjustment" function in the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".

23

SEN03200-01

3)

4) 3.

24


Run the engine at high idle and stall the torque converter. After the engine speed is stabilized, measure the leakage in 1 minute with measuring cylinder J5. a For the procedure for stalling the torque converter, see Measuring torque converter stall speed. a You may measure the leakage for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following range, it is normal. Engine speed

Leakage (cc/min)

Torque converter stall

Max. 10

After finishing measurement, stop the engine.

Testing return rate from injector a Keep the hose on the pressure limiter side connected and keep its end in the oil pan while measuring the return rate from the injector. 1) Disconnect return hose (5) of return block (4) and connect test hose J4. a Stop the return hose with a plug, etc. and fix it to the fuel tank. Plug: 07376-70315 a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off.

2)

Lay test hose J4 so that it will not slacken and put its end in the oil pan.

3)

Turn the starting switch ON set the machine monitor to Adjusting function of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".

D155A-6


4)

Run the engine at high idle and stall the torque converter. After the engine speed is stabilized, measure the return rate in 1 minute with measuring cylinder J5. a For the procedure for stalling the torque converter, see Measuring engine speed. a You may measure the return rate for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the measurement. a If the return rate (spill) from the injector is in the following range, it is normal. Torque converter stall speed (rpm)

5) 4.

SEN03200-01

Limit of return rate (spill) (cc/min)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1.200

After finishing measurement, stop the engine.

Work after finishing measurement After finishing all measurement, remove the measuring instruments and return the removed parts. 3 Common rail pressure limiter joint bolt: 17.7 – 22.6 Nm {1.8 – 2.3 kgm} 3 Supply pump overflow joint bolt: 14.8 – 19.6 Nm {1.5 – 2.0 kgm}

D155A-6

25

SEN03200-01

Bleeding air from fuel circuit a

a


Bleed air from the fuel circuit in the following cases according to this procedure. q When the fuel filter is replaced q When fuel is used up q When the engine is started for the first time after the fuel piping or supply pump is replaced If the fuel filter was replaced, do not fill the main filter and prefilter with the fuel.

1.

Turn the starting switch to the "OFF" position.

2.

Check that the fuel valve on the fuel tank side is open.

3.

Open the left side cover of the engine and set air bleeding piping lever (1) in the vertical position to open the valve of the circuit.

4.

Turn "ON" switch (3) of electric priming pump timer (2) installed to the side of the air cleaner. a The electric priming pump operates and lamp (4) blinks.

a

26

a

1

a k

The electric priming pump stops while the lamp is blinking. This phenomenon is not abnormal, however. If the switch is turned "OFF" position while the lamp is blinking, the lamp goes off and the electric priming pump stops. While the electric priming pump is in operation, pressure is applied to the fuel circuit. Do not loosen the air bleeding plug at this time, since the fuel may spout out.

5.

After the specified time (approx. 7 minutes), lamp (4) goes off and the electric priming pump stops automatically. a If only the fuel filter was replaced, the air bleeding work is completed now.

6.

If the fuel was used up or the fuel piping or supply pump was replaced and there is not fuel in the fuel circuit, turn switch (3) "ON" again after the electric priming pump stops automatically.

7.

When lamp (4) goes off, the air bleeding work is completed.

8.

Set air bleeding piping lever (1) in the horizontal position to stop the valve of the circuit.

The electric priming pump has a timer in it to start and stop itself automatically (See the following figure).

D155A-6


9.

SEN03200-01

Start the engine with the starting motor. a Do not operate the starting motor continuously for more than 20 seconds. q Run the engine at low idle for about 5 minutes to bleed all air from the fuel circuit. q After stopping the engine, check that the air bleeding valve is closed.

10. If the engine does not start, start it according to the following procedure. k When starting the engine, check that there is no person around the engine. a Perform the following procedure with the air bleeding valve closed. (Do not open the air bleeding valve after step 7.) a If the engine does not start, wait for at least 2 minutes before trying to start again. 1) Turn the electric priming pump switch "ON". 2) While the electric priming pump is operating, start the engine. q If the engine does not start, repeat the above operation. a Do not operate the starting motor continuously for more than 20 seconds. a If the engine does not start, wait for at least 2 minutes before trying to start again. 3) After the engine starts, keep it running for at least 5 minutes to bleed all air from the fuel circuit. 4) Stop the engine and check that the air bleeding valve is closed. 5) From now on, start the engine as usual.

D155A-6

27

SEN03200-01

Measuring fuel circuit for leakage1 k

a a

Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing and installing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.

1.

Spray color checker (developer) over the joints of the fuel supply pump, common rail, fuel injector, and high-pressure piping.

2.

Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.

3.

Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.

4.

Run the engine at low idle.

5.


6.

Run the engine at high idle.

7.


8.

Run the engine at high idle and load it. a Relieve the ripper circuit by raising the ripper.

28


9.

Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. a If no fuel leakage is detected, inspection is completed.

D155A-6


Testing and adjusting alternator belt tension 1 k

SEN03200-01

6.

Install belt cover (1) with the 2 mounting bolts. a Check for breakage of the pulleys, wear of the V-grooves, contact of the belts and Vgrooves, and contact of the belt covers and rotating parts. a If the belt is lengthened to the adjustment limit, cut, or cracked, replace it with new one. a If the V-belt is replaced, adjust its tension again after 1 operating hour. a After tightening the bolts, check that the belt tension is normal according to the above procedure.

7.

After testing and adjusting, return the removed parts.

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.

Testing 1. Open the engine right side cover and remove the inspection plate on the right of the radiator guard. 2.

Press the intermediate point of the belt between alternator pulley and water pump pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 98 N {Approx. 10 kg} a Deflection (a): 13 – 16 mm

Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.

Remove the 2 mounting bolts and belt cover (1). a Remove the belt cover only when replacing the belt.

2.

Loosen 2 mounting bolts (3) of alternator (2), and then loosen lock bolt (4) of the adjustment rod.

3.

Loosen locknut (5) of the adjustment rod and move alternator (2) with adjustment nut (6) to adjust the tension of the belt.

4.

While fixing adjustment nut (6), tighten locknut (5).

5.

Tighten locknut (4) of the adjustment rod and 2 mounting bolts (3) of alternator (2).

D155A-6

29

SEN03200-01

Testing and adjusting air conditioner compressor belt tension k


1

After tightening the bolts, check that the belt tension is normal according to the above procedure.

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.

Testing 1. Open the engine left side cover and left mudguard. 2.

Press the intermediate point of the belt between the supply pump pulley and compressor pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 59 N {Approx. 6 kg} a Deflection (a): 10 mm

5.

After testing and adjusting, return the removed parts.

Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.

Loosen 4 bracket mounting bolts (1).

2.

Loosen locknut (2) and move compressor (4) and bracket as a unit with adjustment bolt (3) to adjust the belt tension.

3.

While fixing adjustment nut (3), tighten locknut (2).

4.

Tighten 4 bracket mounting bolts (1). a Check for breakage of the pulleys, wear of the V-grooves, contact of the belts and Vgrooves, and contact of the belt covers and rotating parts. a If the belt is lengthened to the adjustment limit, cut, or cracked, replace it with new one. a If the V-belt is replaced, adjust its tension again after 1 operating hour.

30

D155A-6


SEN03200-01

Measuring fan speed a

Measuring instrument for fan speed

Symbol

Part No.

K

795-205-1100

k

a

1.

Part name

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the fan motor speed under the following condition. q Hydraulic oil temperature: Within operating range Open the radiator mask and remove the fan net. Stick 1 reflection tape [1] of tachometer kit K to fan (1)

3.

Set probe [2] to the reflection tape with stand [3] and connect it to tachometer [4]. k

a

5.

If this adjustment code is displayed, the fan speed is kept at 100% speed in accordance with the engine speed, regardless of the state of the machine.

Tachometer kit

2.

4.

a

1

6.

While running the engine at low idle and high idle, measure the fan speed

7.


Take care that the probe will not interfere with the fan. Rotate the fan with the hand and check that the probe can sense the rotation of the reflection tape.

Close the radiator mask. k

Before starting the engine, be sure to close the radiator mask. Do not start the engine while the radiator mask is open.

Start the engine and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 1005 (Fan 100% mode) a For the operating method, see "Special functions of machine monitor (EMMS)".

D155A-6

31

SEN03200-01


Measuring fan circuit oil pressure1 a

Measuring instruments for fan circuit oil pressure

Symbol 1 L

2 3

k

a

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-401-3400

Adapter (05)

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the fan circuit oil pressure under the following condition. q Hydraulic oil temperature: Within operating range

1.

Open the radiator mask and remove the fan net.

2.

Disconnect supply hose (1) of the fan motor.

3.

Install adapter L2 and connect the disconnected hose again.

4.

Install nipple L3 and connect it to oil pressure gauge [2]. a When using an analog oil pressure gauge, use one of 39.2 MPa {400 kg/cm²}.

32

5.

6.

Close the radiator mask. k

Before starting the engine, be sure to close the radiator mask. Do not start the engine while the radiator mask is open.

Start the engine and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 1005 (Fan 100% mode) a For the operating method, see "Special functions of machine monitor (EMMS)". a If this adjustment code is displayed, the fan speed is kept at 100% speed in accordance with the engine speed, regardless of the state of the machine.

D155A-6


7.

While running the engine at high idle, measure the fan circuit oil pressure.

SEN03200-01

Bleeding air from fan pump a

a

8.

1

If the fan pump is removed and installed or its piping is disconnected and connected, bleed air from the fan pump case according to the following procedure. Before starting the following work, check that the hydraulic oil level is normal.

1.

Remove the left step cover.

2.

Loosen air bleeder (1) and leave it for 15 minutes.

3.

After 15 minutes, start the engine and run it at low idle.

4.

After oil flows out of air bleeder (1), tighten air bleeder (1) and stop the engine. 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}


D155A-6

33

SEN03200-01


Bleeding air from work equipment pump 1 a

a

If the work equipment pump is removed and installed or its piping is disconnected and connected, bleed air from the work equipment pump case according to the following procedure. Before starting the following work, check that the hydraulic oil level is normal.

1.

Remove the right step cover.

2.

Loosen air bleeder (1) and leave it for 15 minutes.

3.

After 15 minutes, start the engine and run it at low idle.

4.

After oil flows out of air bleeder (1), tighten air bleeder (1) and stop the engine. 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

34

D155A-6


SEN03200-01

Adjusting fuel control dial and decelerator pedal

k

1.

1

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Outline of fuel control system The following signals are input as rotation command signals to the engine controller. 1) Fuel control dial potentiometer signal 2) Decelerator pedal potentiometer signal 3) 3rd throttle signal (Power train controller) q The engine controller controls the fuel control system of the engine (CRI system) according to the one of the above input signals which indicates the lowest engine speed. q Adjust the decelerator pedal speed and high idle speed with the decelerator pedal linkage. q

D155A-6

DIAL: Fuel control dial PEDAL: Decelerator pedal ROD: Decelerator pedal rod POTENTIO: Decelerator pedal potentiometer ENG-ECU: Engine controller P/T-ECU: Power train controller ENGINE: Engine unit (CRI devices) [KOMNET]: KOMNET communication circuit (3rd throttle signal)

35

SEN03200-01

2.

Preparation work 1) Remove the right cover of the dashboard and the right foot rest as a unit. 2) Start the engine and set the machine monitor to Adjusting function of the service mode. q Adjustment code: 0007 (Engine decelerator cut) a For the operating method, see "Special functions of machine monitor (EMMS)".

3.

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

4.

Adjusting high idle speed With the fuel control dial in the high idle position (MAX), release decelerator pedal (1) and check that the high idle speed is normal. q High idle speed: 2,050 ± 50 rpm a If the high idle speed is abnormal, adjust it according to the following procedure. q When the engine speed is above 1,950 rpm: Lower the engine speed below 1,900 rpm temporarily with stopper bolt (3) to eliminate the play of the decelerator pedal, and then adjust the engine speed to the high idle. q When the engine speed is below 1,950 rpm: Adjust the engine speed to the high idle speed with stopper bolt (3). q Standard installed dimension (b) of stopper bolt: 34.8 mm

36


5.

Work after adjustment After finishing all adjustment, return the removed parts.

D155A-6


D155A-6

SEN03200-01

37

SEN03200-01




38

D155A-6

SEN03201-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Testing and adjusting, Part 2 Measuring power train oil pressure................................................................................................................. 3 Adjusting transmission output shaft speed sensor.........................................................................................11 Simple test procedure for brake performance............................................................................................... 12 Adjusting brake pedal ................................................................................................................................... 13 Adjusting parking brake lever........................................................................................................................ 15 Emergency escape method when power train has trouble ........................................................................... 17 Adjusting idler clearance............................................................................................................................... 20 Testing and adjusting track shoe tension ...................................................................................................... 22 Measuring and adjusting work equipment oil pressure................................................................................. 23 Measuring control circuit basic pressure....................................................................................................... 26 Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure) ..................... 27 Measuring PPC valve output pressure ......................................................................................................... 28 Adjusting play of work equipment PPC valve ............................................................................................... 30 Measuring ripper pin puller solenoid valve output pressure.......................................................................... 31 Testing parts which cause hydraulic drift of blade and ripper........................................................................ 32 Measuring internal leakage of work equipment cylinder ............................................................................... 33

D155A-6

1

SEN03201-00


Releasing residual pressure from work equipment cylinder.......................................................................... 34 Bleeding air from work equipment cylinder ................................................................................................... 34 Adjusting work equipment lock lever............................................................................................................. 35 Adjusting blade.............................................................................................................................................. 36 Adjusting operator's cab................................................................................................................................ 38

2

D155A-6


SEN03201-00

Measuring power train oil pressure a

1

Measuring instruments for power train oil pressure

Symbol M k

a

a

a

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the power train oil pressure under the following condition. q Power train oil temperature: Within operating range Since the power trail oil pressure pickup plugs (centralized pressure pickup section) are installed inside the right step cover, remove that cover when measuring the power train oil pressure. Pressure pickup plugs and gauges to be used

No. Stamp 1

TM

2

RC

3

LC

4

F

5

R

6

1ST

7

2ND

8

3RD

9

RB

10

LB

11

IN

12

OUT

D155A-6

Oil pressure to be measured

Transmission main relief pressure Steering right clutch pressure Steering left clutch pressure Transmission forward clutch pressure Transmission reverse clutch pressure Transmission 1st clutch pressure Transmission 2nd clutch pressure Transmission 3rd clutch pressure Steering right brake pressure Steering left brake pressure Torque converter inlet pressure Torque converter outlet pressure

Oil pressure gauge (MPa {kg/cm²}) 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 6.0 {60} 2.5 {25} 2.5 {25}

3

SEN03201-00

1.

Measuring transmission main relief pressure (TM) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (1). a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.

2)

3)

4)

Start the engine and set the PCCS lever in the fully neutral position. a The parking brake lever may be set in the LOCK position. While running the engine at low idle and high idle, measure the main relief pressure.


2.

Measuring right steering clutch pressure (RC) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure measurement nipple (2). a Use a 6.0 MPa {60 kg/cm²} oil pressure gauge.

2) 3)

4)

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

4

Start the engine and set the parking lever to the FREE position. Operate the PCCS lever steering fully to the right. a Set the direction to the neutral position. Measure the oil pressure with the engine at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever steering is returned to neutral.

After completing the measurement, remove the measuring equipment and set to the original condition.

D155A-6


3.

Measuring left steering clutch pressure (LC) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure measurement nipple (3). a Use a 6.0 MPa {60 kg/cm²} oil pressure gauge.

2) 3)

4)

Start the engine and set the parking lever to the FREE position. Operate the PCCS lever steering fully to the left. a Set the direction to the neutral position. Measure the oil pressure with the engine at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever steering is returned to neutral.

SEN03201-00

4.

Measuring transmission forward clutch pressure (F) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (4). a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/ cm²}.

2) 3)

4)

5)

Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2 While pressing the brake pedal, set the direction of PCCS lever in the forward position and shift up the gear to the 3rd gear speed with the shiftup switch. a Keep the steering system in neutral. a Check that [F3] is displayed in the gear speed display section. While running the engine at high idle, measure the forward clutch pressure. k

5)

D155A-6

Since the torque converter is stalled, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.


5

SEN03201-00

6)

5.



Measuring transmission reverse clutch pressure (R) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (5). a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/ cm²}.

6)

2) 3)

4)

5)

Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2 While pressing the brake pedal, set the direction of PCCS lever in the reverse position and shift up the gear to the 3rd gear speed with the shiftup switch. q Keep the steering system in neutral. q Check that [R3] is displayed in the gear speed display section. While running the engine at high idle, measure the reverse clutch pressure. k

6



D155A-6


6.

SEN03201-00

Measuring transmission 1st clutch pressure (1ST) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (6). a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/ cm²}.

6)

7. 2) 3)

4)

5)

Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F1-R1 While pressing the brake pedal, set the direction of PCCS lever in the forward position. a Keep the steering system in neutral. a Check that [F1] is displayed in the gear speed display section. While running the engine at low idle, measure the 1st clutch pressure. k

k

Since the torque converter is stalled, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. Do not increase the engine speed to high idle during measurement.

Measuring transmission 2nd clutch pressure (2ND) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (7). a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/ cm²}.

2) 3)

4)

D155A-6


Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2 While pressing the brake pedal, set the direction of PCCS lever in the forward position. a Keep the steering system in neutral. a Check that [F2] is displayed in the gear speed display section.

7

SEN03201-00

5)

While running the engine at low idle, measure the 2nd clutch pressure. k

k



4)

5)

While pressing the brake pedal, set the direction of PCCS lever in the forward position and shift up the gear to the 3rd gear speed with the shiftup switch. a Keep the steering system in neutral. a Check that [F3] is displayed in the gear speed display section. While running the engine at low idle, measure the 3rd clutch pressure. k

k

6)

8.

3)

8


Measuring transmission 3rd clutch pressure (3RD) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (8). a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/ cm²}.

2)


6)


Start the engine and set the parking brake lever in the FREE position. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2

D155A-6


9.

Measuring steering right brake pressure (RB) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (9). a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/ cm²}.

2) 3)

Start the engine and set the parking brake lever in the FREE position. While running the engine at low idle and high idle, measure the right brake pressure. a During measurement, check that the oil pressure lowers to 0 when the brake pedal is pressed or the parking brake lever is set in the LOCK position.

SEN03201-00

10. Measuring steering left brake pressure (LB) 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (10). a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/ cm²}.

2) 3)

4) 4)

D155A-6


Start the engine and set the parking brake lever in the FREE position. While running the engine at low idle and high idle, measure the left brake pressure. a During measurement, check that the oil pressure lowers to 0 when the brake pedal is pressed or the parking brake lever is set in the LOCK position.


9

SEN03201-00

11. Measuring torque converter inlet pressure 1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure measurement nipple (11). a Use a 2.5 MPa {25 kg/cm²} oil pressure gauge.


12. Measuring torque converter outlet pressure 1) Connect hydraulic tester M to oil pressure measurement nipple (12). a Use a 2.5 MPa {25 kg/cm²} oil pressure gauge.

2) 2) 3)

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

3)

4) 4)

10


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


D155A-6


Adjusting transmission output shaft speed sensor k

1.

SEN03201-00

Remove the fuel tank and transmission output shaft speed sensor (1). a

Fuel tank: 950 kg (when full)

Before adjusting the transmission output shaft speed sensor, remove it and check that its tip is free from steel chips and flaws, and then reinstall it.

2.

Screw in sensor (1) until its tip touches the tooth tip of bevel gear (2). 2 Threads: Gasket sealant (LG-5)

3.

Return sensor (1) by the specified angle. a Returning angle of sensor: 1/2 – 1 turn a Adjust clearance (a) between the sensor tip and gear tooth tip to 0.75 – 1.5 mm.

4.

While fixing sensor (1), tighten nut (3). 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}

D155A-6

After finishing adjustment, return the removed parts.

6.

Start the engine, set the machine monitor to Monitoring function of the service mode, and check that the transmission speed is indicated normally. a Monitoring code: 31400 T/M Out Speed a For the operating method, see Special functions of machine monitor (EMMS). a To rotate the transmission output shaft, drive the machine actually or run the track idle.

1

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position.

4

5.

11

SEN03201-00

Simple test procedure for brake performance 1 k

a

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Carry out the simple performance test of the brake under the following condition. q Power train oil temperature: Within operating range

1.

Set the blade and ripper in the travel position on a level place.

2.

Run the engine and set the parking brake lever in the FREE position.

3.

Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift (Ripping) q Preset range: F2-R2

4.

While pressing the brake pedal, set the direction of PCCS lever in the forward position. k

a a 5.

12


6.

Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idle speed. k


If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd gear speed. Check that [F2] is displayed in the gear speed display section. Keep the steering system in neutral.

Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position.

D155A-6


SEN03201-00

Adjusting brake pedal

a

Adjusting tool for brake pedal

Symbol N k

a a

1.

1

Part No.

Part name


Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Tighten the locknut of the rod securely and bend the cotter pin securely. When adjusting the brake pedal, remove the left cover of the dashboard and left foot rest as a unit. Adjusting brake potentiometer 1) Turn the starting switch ON and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 0005 (Brake pedal potentiometer initial correction) a For the operating method, see "Special functions of machine monitor (EMMS)".

D155A-6

2)

3)

4)

Adjust installed dimension (b) of stopper (2) so that dimension (a) will be 80 mm. q Dimension (b) = 35.5 mm (Reference value) Adjust installed dimension (b) of stopper (2) so that the brake pedal potentiometer voltage will be the specified voltage when brake pedal (1) is released. q Brake pedal voltage: 2,500 ± 50 mV Referring to "Special functions of machine monitor (EMMS), Service mode 07, Adjustment (Adjustment ID: 0005)", perform initial correction of the brake pedal potentiometer.

13

SEN03201-00

2.

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

3.

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

4.

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

5.

Work after finishing adjustment After finishing adjustment, return the removed parts.

14


D155A-6


SEN03201-00

Adjusting parking brake lever

k

a a

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Tighten the locknut of the rod securely and bend the cotter pin securely. Remove the lever cover in the cab.

1.

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

2.

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

D155A-6

1

q

Brake oil pressure (At high idle) Parking brake lever

Oil pressure

FREE position

2.75 ± 0.29 MPa {28.0 ± 3.0 kg/cm²}

LOCK position

0 MPa {0 kg/cm²}

15

SEN03201-00

3.

Checking limit switch 1) Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. a Monitoring code: 40905 T/M Sw Input 1 a For the operating method, see "Special functions of machine monitor (EMMS)".

2)

16


Check that the limit switch signal is input normally when parking brake lever (3) is set in the FREE position and LOCK position. q FREE position: Travel lock NC OFF, Travel lock NO ON q LOCK position: Travel lock NC ON, Travel lock NO OFF

D155A-6


SEN03201-00

Emergency escape method when power train has trouble 1 a

Tools for emergency escape

Symbol P

1 2

1.

Part No.

Part name

19M-06-32820 Switch assembly 17A-06-41410 Wiring harness 790-190-1601

Pump assembly

Emergency escape method with switch box (Using P1) a If the machine cannot be moved because of a trouble in the electric system of the power train control unit (travel direction, gear speed, steering), escape according to the following procedure. a The engine must be startable for the following procedure. a If the engine cannot be started, see Emergency escape method with brake releasing device (Using P2). k Do not turn the starting switch ON or start the engine before preparing the switch assembly and wiring harness P1 completely. 1) Connect wiring harness [2] to switch assembly [1] of emergency escape device P1. k

2)

D155A-6

Set the all gear speed switches of switch assembly [1] in the OFF position and set the directional switch in the P position to prevent the machine from starting suddenly.

3)

Disconnect neutral safety relay NSF (2) and connect pins No. 3 and No. 5 of the connector on the wiring harness side. a Direct coupling circuit: NSF (female) No. 3 io No. 5 a If connector PL1 is disconnected, a model selection error is made and neutral safety relay NSF is not driven. The above operation is performed to prevent this. k If the engine is started by this method, the neutral safety function d o e s n o t w o r k . A c c o r d i n g l y, before starting the engine, set the parking brake lever in the LOCK position and set the PCCS lever in the fully neutral position. k Start the engine by this method only in an emergency. If the engine does not start in another case, be sure to carry out troubleshooting and repair the trouble.

Open the left fender inspection cover and connect wiring harness [2] to connector PL1 (1). a The male housing and female housing of connector PL1 are fixed with screws. a Connect the wiring harness to both male side and female side of connector PL1.

17

SEN03201-00

4) 5)

6)

2.

18

Start the engine and set the parking brake lever in the FREE position. Operate switch assembly [1] and move the machine to a safe place. a The gear speed switch is so made that the switch on the lower gear speed will be operated first.


2)

Install volume pump [3] of pump assembly P2 to the outside of the operator's cab.

3)

Remove the fuel tank under rear cover and disconnect supply hose (3) of the pin puller solenoid valve.

4)

Connect end hose [4] of pump assembly P2 to the hose side. a Since the hose on the machine side is face seal type, use a nipple of face seal type on the pump assembly P2 side. a Stop the solenoid valve side with a cap nut, etc. Cap nut: 02789-00315

5)

Turn the starting switch ON and set the parking brake lever in the FREE position.

After moving the machine, remove the instruments used and return the removed parts. a Check that the seal at the joint of connector PL1 is not projected or removed and then tighten the screws to the specified torque. 3 Screw of connector PL1: 2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}

Escape method with brake releasing device (Using P2) a If the engine cannot be started and the parking brake cannot be released, escape according to the following procedure. 1) Assemble pump assembly P2.

D155A-6


6)

7)

D155A-6

SEN03201-00

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

19

SEN03201-00

Adjusting idler clearance

a

If the lateral guide, vertical guide, or guide plate of the idler is worn and the idler runs out sideways or slants, adjust the idler clearance according to the following procedure.

1.

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

20


1

D155A-6


2.

Adjusting in vertical directions 1) Measure clearance (B) between support (3) and guide plate (4) and clearance (C) between vertical guide (5) and wear plate (6). 2) If the total of clearances (B) + (C) is 5 mm or wider, pull out shim (7) and add it to shim (8) to adjust the clearance to the following range. Clearances (B) + (C): 2 mm a When normal, clearance (C) = 0 mm.

SEN03201-00

(7) Tighten bolts (1). 3 Bolt: 662 – 829 Nm {67.5 – 84.5 kgm} a This part can be adjusted to 6 mm.

Adjustment procedure 1] To grasp the adjustment quantity, measure clearance (B) and let it be x. Adjusting quantity: x – 2 mm a

2]

3] a

4]

5] a

6]

D155A-6

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

Pull up vertical guide (5) with a bar etc. to reduce clearance (C) to 0 and pull out shim (7) for the adjusting quantity measure in step 1]. Add shim (7) pulled out to shim (8). (Right, left, inside, and outside, 8 places in total) Check that the total number of shims (7) and (8) in each place is the same as the total number before the adjustment. If the number of the shims is changed, the internal spring does not function normally. After adjusting, tighten spring holding bolts (9).

21

SEN03201-00


Testing and adjusting track shoe tension 1 k

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position.

Testing 1. Drive the machine slowly on a level place, then stop it. a Do not apply the brake when stopping. 2.

Place straight steel bar (1) between the idler and front carrier roller and measure maximum clearance (a) between the bottom of the steel bar and shoe grouser. a For the above measurement, use an Lshaped steel which will be deflected less. q Standard max. clearance (a): 20 – 30 mm

4.

After finishing adjustment, return the removed parts.

Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. 1.

Remove cover (2).

2.

When the tension is too high Loosen plug (3) to discharge the grease. k

3.

22

Since the high-pressure grease may spout out, do not loosen the plug more than 1 turn. 3 Plug: 59 – 88 Nm {6 – 9 kgm}

When tension is low Add grease through grease fitting (4). a If the track shoe is not tensed well, drive the machine forward and in reverse slowly.

D155A-6


SEN03201-00

Measuring and adjusting work equipment oil pressure a

Measuring and adjusting instruments for work equipment oil pressure

Symbol 1 Q 2 k

a

1

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. When measuring and adjusting the work equipment oil pressure, remove the control valve cover. 4

3)

Run the engine at high idle and set the blade control lever and ripper control lever in neutral and measure the unload pressure. a The work equipment lock lever may be set in the LOCK position. k Do not operate the work equipment or steer the machine with the oil pressure gauge of 6.0 MPa {60 kg/ cm²} installed. If you do so, the oil pressure gauge will be broken.

4)

After finishing measurement, remove the measuring instrument and return the removed parts.

Control valve cover: 25 kg

Measuring a Measure the work equipment under the following condition. q Hydraulic oil temperature: Within operating range a The unload pressure, work equipment oil pressure can be checked with the monitoring function of the service mode of the machine monitor (See 4). 1.

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

2.

2)

D155A-6

Measuring work equipment oil pressure 1) Remove P oil pressure pickup plug (1) and LS oil pressure pickup plug (2) from the control valve.

Install nipple Q2 and connect it to oil pressure gauge [1] of hydraulic tester Q1. a When using an analog oil pressure gauge, use one of 6.0 MPa {60 kg/ cm²}.

23

SEN03201-00

2)

Install nipples Q2 and connect them to oil pressure gauges [1] of hydraulic tester Q1. a When using analog oil pressure gauges, use ones of 40 MPa {400 kg/ cm²}.

3)

Start the engine and set the work equipment lock lever in the FREE position. Run the engine at high idle, operate the blade control lever and ripper control lever to relieve each cylinder at a stroke end, and measure the work equipment relief pressure and work equipment LS relief pressure. a The work equipment relief pressure is measured on the P-stamp side and the work equipment LS relief pressure is measured on the LS-stamp side. k Do not steer the machine with the oil pressure gauge of 40 MPa {400 kg/cm²} installed. If you do so, the oil pressure gauge will be broken.

4)

5)

24


3.

Measuring with machine monitor 1) Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. q Monitoring code: 70700 Hydraulic Pump Pressure 1 a For the operating method, see Special functions of machine monitor (EMMS).

2)

Start the engine and measure each oil pressure. a The measuring condition of each oil pressure is the same with 1 – 3 above. a Only the oil pressures on the P-stamp side (unload pr essure and work equipment relief pressure) can be measured with the monitoring function. The oil pressures on the LSstamp side (work equipment and LS relief pressure) cannot be measured.


D155A-6


Adjusting 1. Adjusting unload pressure a The unload pressure cannot be adjusted. 2.

SEN03201-00

3)

While fixing adjustment nut (4), tighten locknut (5). 3 Locknut: 39 – 49 Nm {4 – 5 kgm}

4)

After finishing measurement, check the work equipment oil pressure according to the above measuring method.

Adjusting work equipment oil pressure a If the work equipment oil pressure is abnormal, adjust it with work equipment LS relief valve (3) according to the following procedure.

1) 2)

D155A-6

While fixing adjustment nut (4), loosen locknut (5). Adjust the pressure by rotating adjustment nut (4). a If the adjustment nut is q rotated to the right, the pressure is heightened. q rotated to the left, the pressure is lowered. a Quantity of adjustment per turn of adjustment nut: Approx. 19.6 MPa {Approx. 200 kg/cm²}

25

SEN03201-00


Measuring control circuit basic pressure 1 a

Measuring instruments for control circuit basic pressure

Symbol 1 R 2

a

k

a

1.

Part No.

Part name

799-101-5002

Hydraulic tester

709-261-1204


799-401-3200

Adapter (03)

02896-11009

O-ring

The control circuit basic pressure is the pressure lowered by the self-pressure reducing valve of the fan circuit. It is used commonly for the fan pump control and PPC valve. Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the control circuit basic pressure under the following condition. q Hydraulic oil temperature: Within operating range

Run the engine at high idle, set the blade control lever and ripper control lever in neutral, and measure the control circuit basic pressure. a The work equipment lock lever may be set in the LOCK position.

5.


a

The control circuit basic pressure cannot be adjusted.

Remove the centralized pressure pickup block top cover of the right fender of the machine.

2.

Install adapter R2 and connect the disconnected hose again.

3.

Install nipple [1] of hydraulic tester R1 and connect it to oil pressure gauge [2]. a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/cm²}.

26

4.

D155A-6


SEN03201-00

Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure) 1 a

Measuring instruments for work equipment lock solenoid valve output pressure

Symbol 1 S 2 k

a

1.

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


791T-643-1010 Elbow 07002-11423

O-ring

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the work equipment lock solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range

4.

Run the engine at high idle, set the work equipment lock lever in the LOCK position and FREE position, and measure the solenoid valve output. a If the output pressure is as follows, the operation of the work equipment lock solenoid valve is normal. Work equipment lock lever

Output pressure

LOCK position

0 MPa {0 kg/cm²}

FREE position

Same as control circuit basic pressure (See standard value table)

Remove the control valve cover. 4


2.

Disconnect hose (1), replace elbow (2) with adapter S2, and connect hose (1) again.

3.

Install nipple [1] of hydraulic tester S1 to tool S2 and connect oil pressure gauge [2] of 6.0 MPa {60 kg/cm2}.

5.

D155A-6


27

SEN03201-00


Measuring PPC valve output pressure a

1 2 3 k

a a

6.

After finishing measurement, remove the measuring tools and return the removed parts.

1

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-401-3100

Adapter (02)

02896-11008

O-ring

799-401-3200

Adapter (03)

02896-11009

O-ring

Stop the machine on a flat ground, lower the work equipment to the ground, and set the parking brake lever and safety lock lever in the lock position. Before measuring the PPC valve output pressure, check that the basic pressure of the control circuit is normal. Measure the PPC valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range

1.

Remove the main control valve cover.

2.

Disconnect PPC valve output pressure hose (1) and install pressure pickup adapter (T2, T3). a For the circuit to be measured, see the figure on the next page.

3.

Install nipple [1] of hydraulic tester T1 and connect oil pressure gauge [2].

4.

Start the engine and set the safety lock lever in the free position.

28

Run the engine at high idle, operate the control lever of the circuit to be measured, and measure the oil pressure. a Measure the oil pressure with the control lever at the stroke end. a Measure the oil pressure on the blade lowering side with the control lever at the float position.

Measuring tools for PPC valve output pressure

Symbol

T

5.

D155A-6


1. 2. 3. 4. 5.

Main valve Self-pressure reducing valve PPC lock valve Blade PPC valve Ripper PPC valve

D155A-6

SEN03201-00

A. B. C. D. E. F. G. H.

Blade right tilt Blade lower Ripper lower Ripper tilt back Ripper tilt in Ripper tilt raise Blade raise Blade left tilt

29

SEN03201-00


Adjusting play of work equipment PPC valve 1 a a

q

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

1.

Remove boot (1).

2.

Loosen locknut (2) and turn disc (3) to adjust the play. a Do not move the piston at this time.

3.

Fix disc (3) and tighten locknut (2). 3 Locknut: 93.1 – 112.7 Nm {9.5 – 11.5 kgm}

4.

Install boot (1).

30

D155A-6


SEN03201-00

Measuring ripper pin puller solenoid valve output pressure 1 a

Measuring instruments for ripper pin puller solenoid valve output pressure

Symbol 1 U 2 k

a

1.

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-401-3200

Adapter (03)

02896-11009

O-ring

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the ripper pin puller solenoid valve output pressure under the following condition. q Power train oil temperature: Within operating range

4.

Run the engine at high idle, set the pin puller switch in the pull-out position and push-in position, and measure the solenoid valve output pressure at each position. a If the output pressure is as follows, the operation of the ripper pin puller solenoid valve is normal. Tested Pin puller hose switch

Remove the undercover of the fuel tank and disconnect ripper pin puller solenoid valve hose (1) or (2). q Hose (1): Pin puller cylinder head side q Hose (2): Pin puller cylinder bottom side

(1)

(2)

2.

Install adapter U2 and connect the disconnected hose again.

3.

Install nipple [1] of hydraulic tester U1 and connect oil pressure gauge [2]. a When using an analog oil pressure gauge, use one of 5.9 MPa {60 kg/cm²}.

D155A-6

5.

Output pressure

Pull-out

Same as transmission main relief pressure (See standard value table)

Push-in

0 MPa {0 kg/cm²}

Pull-out

0 MPa {0 kg/cm²}

Push-in

Same as transmission main relief pressure (See standard value table)


31

SEN03201-00

Testing parts which cause hydraulic drift of blade and ripper


1

a

If the blade or ripper drifts hydraulically, check to see if the cause is on the cylinder packing side or control valve side according to the following procedure.

1.

Set the cylinders to be tested in the following positions and stop the engine. 1) Blade lift cylinder Brace the blade to raise the front side of the machine body. a Since the blade lift cylinder is equipped with a piston valve, do not extend it to the stroke end.

32

2)

Blade tilt cylinder Extract the tilt cylinder to the stroke end and brace the blade to push up the left side of the machine body.

3)

Ripper lift cylinder Brace the ripper to push up the rear side of the machine body.

2.

Turn the starting switch ON and set the work equipment lock lever in the FREE position.

3.

Extend the cylinder to be tested with the corresponding lever and check its movement. q If the lowering speed is increased, the cylinder packing is defective. q If the lowering speed does not change, the control valve is defective. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator.

[Reference] Reason why the lowering speed is increased when the cylinder packing is the cause of the hydraulic drift: 1. If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. 2. As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), then the lowering speed is lowered. 3. If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.

D155A-6


SEN03201-00

Measuring internal leakage of work equipment cylinder a

Part No.

V


k

a

1.

2.

1

q

Measuring instruments for internal leakage of work equipment cylinder

Symbol

a

q

Part name Measuring cylinder

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Since the blade lift cylinder is equipped with a piston valve, its internal leakage cannot be measured. Measure the internal leakage of work equipment cylinder under the following condition. q Hydraulic oil temperature: Within operating range Extend the cylinder to be measured to the stroke end and set the machine in the measuring position. 1) Blade tilt cylinder Tilt the blade to the left end. 2) Ripper lift cylinder Pull out the shank pin and lower the ripper to the end. 3) Ripper tilt cylinder Tilt the ripper forward (in) to the end. k Release the residual pressure from the cylinder circuit. For details, see Releasing residual pressure from work equipment cylinder. Disconnect hoses (1), (2), and (3) on the head side of the tested cylinder and stop the hose side with a plug or a flange. a When working on the blade tilt cylinder hoses, remove the hose cover of the frame. k Take care not to disconnect the hoses on the bottom side. q Hose (1): Blade tilt cylinder Plug: 07376-70422 (Size #04) O-ring: 02896-11012 (Size #04)

D155A-6

Hose (2): Ripper lift cylinder Hose (3): Ripper tilt cylinder Head: 07378-11000 (Size #10) O-ring: 07000-13032 (Size #10)

3.

Run the engine at high idle and apply the relief pressure to the cylinder bottom side. q Blade tilt cylinder: Operate to tilt blade to left. q Ripper lift cylinder: Operate to lower ripper. q Ripper Tilt cylinder: Operate to tilt ripper forward (in).

4.

After 30 second, measure leakage in 1 minute with measuring cylinder V.

5.

After finishing measurement, return the removed parts. a Bleed air from the cylinder circuit. For details, see Bleeding air from work equipment cylinder.

33

SEN03201-00


Releasing residual pressure from work equipment cylinder 1

Bleeding air from work equipment cylinder 1

a

a

k

1.

When disconnecting the piping between the control valve and work equipment cylinder, release the residual pressure from the circuit according to the following procedure. Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position.

1.

Run the engine at low idle for about 5 minutes.

2.

While running the engine at low idle, extend and retract the cylinder to be bled 4 – 5 times. a Move the piston rod to about 100 mm before the stroke end and never relieve the oil.

3.

While running the engine at high idle, carry out the operation in step 2.

4.

While running the engine at low idle, move the cylinder to the stroke end to relieve the oil.

Loosen oil filler cap (1) of the hydraulic tank gradually to release the residual pressure from the tank.

2.

Turn the starting switch ON and set the work equipment lock lever in the FREE position.

3.

Operate the blade control lever and ripper control lever to each direction. a If the control lever is operated 2 – 3 times, the residual pressure in the accumulator is released.

4.

Run the engine at low idle for about 10 seconds to increase the pressure in the accumulator, then stop it.

5.

Repeat steps 2 – 4 above 2 – 3 times.

34

a

If the work equipment cylinder is removed and installed or its piping is disconnected and connected, bleed air from its circuit according to the following procedure. Before performing the following operation, check that the hydraulic oil level is normal.

D155A-6


SEN03201-00

Adjusting work equipment lock lever

k

a a

1

a a

Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Tighten the locknut of the rod securely and bend the cotter pin securely. When adjusting the work equipment lock lever, remove the control valve cover. 4


1.

Set work equipment lock lever (1) in the LOCK position.

2.

Set and install limit switch (2) to sliding surface (a) of lever (1). a Just set the roller of the limit switch to the sliding surface. Do not move it.

3.

Set work equipment lock lever (1) in the FREE position and check that limit switch (2) operates normally. q Stroke of limit switch: 2.5 – 3 mm

4.

Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode.

D155A-6

Monitoring code: 70300 Blade Sw Input For the operating method, see Special functions of machine monitor (EMMS).

5.

Check that the limit switch signal is input normally when work equipment lock lever (1) is set in the FREE position and LOCK position. q FREE position: Work equipment lock NC OFF, Work equipment lock NO ON q LOCK position: Work equipment lock NC ON, Work equipment lock NO OFF

35

SEN03201-00


Adjusting blade

a a 1.

1

If the blade is removed and installed or disassembled and reassemble, adjust it according to the following procedure. The above figure shows the blade of the dual tilt specification. Adjusting shims for assembly 1) Adjust the shim of tilting section (1) (1 place). a After reassembling the tilting section, supply grease to it. 2 Tilting section: Grease (G2-LI)

Adjusted point

Adjusted clearance

Standard clearance

Standard shim thickness

1

a

See note.

4 mm

a

36

Adjust the shim so that the play of the ball in the axial direction will be less than 1 mm and the ball can rotate smoothly.

D155A-6


2)

SEN03201-00

Adjust the shim of center section (2) (2 places). a After reassembling the center section, supply grease to it. 2 Center section: Grease (G2-LI)

Adjusted point

Adjusted clearance

Standard clearance


2

b

See note.

4 mm

a

3)

Adjusting blade tilt distance (Single tilt specification) 1) Adjust installed dimension (d) of brace (4) with the handle.

Dimension d

2) Adjust the shim so that the play of the ball in the axial direction will be less than 1 mm and the ball can rotate smoothly.

Dimension

blade 1,292 mm

Semi-U blade

Full-U blade

1,372 mm

1,372 mm

Measure right and left tilt distances (e1) and (e2). blade

Semi-U blade

Full-U blade

e1

565 mm

570 mm

583 mm

e2

565 mm

570 mm

583 mm

Adjust the shim of lifting section (3) (2 places).

Adjusted point

Adjusted clearance

Standard clearance


3

c

Max. 1 mm

4 mm

D155A-6

2.

3)

If both tilt distances are not the same, adjust installed dimension (d) of brace (4) according to the following procedure. q e1 > e2: Increase installed dimension (d) slightly. q e1 < e2: Decrease installed dimension (d) slightly.

37

SEN03201-00

Adjusting operator's cab


1

a

If the operator's cab is removed and installed or disassembled and transported and assembled in the field, test and adjust it according to the following procedure.

1.

Measuring internal pressure of cab a Criterion Criterion: Measured value X 88.2 Pa {9 mmH2O} a Measurement condition q Engine speed: High idle q Fan speed: Fan 100% mode q EXTERNAL/INTERNAL air changeover switch: EXTERNAL position q Air conditioner fan switch: High (FULL) 1) Prepare a transparent vinyl hose. q Outside diameter: 6 mm, Length: 3,000 mm 2) Secure the inside end of the hose to the top of the seatback with a tape. 3) Remove 1 bolt (1) under the left console box. Pass the other end of the hose through the bolt hole and take it out of the top of battery cover (2) on the left side of the cab.

4) 5) 6)

38

Seal the clearance between the hole of bolt (1) and hose [1] with tape (3). Pour water in the hose up to about half and bend the hose in a U-shape. Secure hose [1] to the outside of the cab and set the water level in the vinyl hose out of the cab to that in the cab.

2.

7)

Start the engine and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 1005 (Fan 100% mode) a For the operating method, see Special functions of machine monitor (EMMS).

8)

Run the engine at high idle and measure water level difference (c) in hose [1]. q (a): Inside of cab (Pressurized) q (b): Out of cab (Ambient pressure) q (c): Measured value (Internal pressure of cab) a If the measured value (internal pressure of the cab) is lower than the standard value, check the seals of the h o l e s fo r w i r i n g h a r n e s s e s a n d optional parts in the cab.

Checking searing performance 1) Close all the openings (doors and windows) of the cab. 2) Splash water around the hatched part of the cab at the rate of about 19 l/min for 10 minutes. a At this time, it is not necessary to splash pressurized water. 3) Splash water horizontally from a hose over the contact portions of seal (4) between the cab and floor frame.

D155A-6


4)

SEN03201-00

4)

Check around the dashboard carefully for water leakage. a If water leaks, caulk the leaking part and check again.

5)

3.

Testing and adjusting door lock (damper rubber) a Close the door and check the relationship between the operator's cab and door (damper rubber portions). If there is any abnormality, adjust it. 1) Stick adhesive tape [2] to the contact face of damper rubber (6) of door (5). a Check both sides, 2 places on each side. 2) Open and close door (5) 2 – 3 times. 3) Check the contact portions of adhesive tape [2] and operator's cab. q Normal: When the door is closed, the damper rubber comes in contact lightly (No adjustment is required). q Abnormal: When the door is closed, the damper rubber does not come in contact or comes in contact so strongly that the adhesive tape is removed (Adjustment is required).

4.

Testing and adjusting door lock (latch and striker) a Close the door and check the relationship between the operator's cab and door (latch and striker). If there is any abnormality, adjust it. 1) Move door (5) in the closing direction and check the engaging condition of latch (8) and striker (9). a Check quantity of misalignment (f) between center of latch (d) and center of striker (e) from the direction of (A). q Normal: Quantity of misalignment (f) is 0.5 mm or less.

2)

3) 4)

D155A-6

Loosen the mounting bolts of damper rubber (6). a You can remove and install the shims without removing the mounting bolts. Increase or decrease shims (7) under damper rubber (6) to adjust the height of damper rubber (6) properly.

Tighten the mounting bolts of striker (9) temporarily. Then, open and close door (5) 2 – 3 times to align latch (8) with striker (9). Check the engagement of latch (8) and striker (9). Tighten the mounting bolts of striker (9) securely.

39

SEN03201-00

5)

6)

Open and close door (5) and check that it is locked and unlocked smoothly. a If the door is not locked or unlocked smoothly (the operating effort of the knob is large), repeat adjustment from the first. a Operating effort of door knob: 49 ± 19.6 N {5 ± 2 kg} Apply grease to latch (8). a If the latch dries up, the operating e ff o r t o f t h e k n ob i s i n c r ea s e d . Accordingly, apply sufficient grease to the latch. 2 Latch: Grease (G2-LI)


2) 3)

4) 5)

5.

40

Check that striker (10) is not leaning against or from center (g) of latch (11). Check that striker (10) is aligned with center (h) of latch (11). q Normal: Quantity of misalignment is 0.5 mm or less.

Loosen the mounting bolts of striker (10). While setting striker (10) upright, tighten the mounting bolts.

Testing and adjusting open lock (latch and striker) a Check the relationship between the operator's cab and door (latch and striker) while the door is locked open. If there is any fault, adjust the open lock. 1) Check the relationship between the open lock latch and striker from the direction of (B). a Move the door in the opening direction and check the engagement of the latch and striker.

D155A-6


6.

SEN03201-00

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

4)

Loosen the locknut of stopper rubber (13) (lower one).

5)

Adjust the height of stopper rubbers (12) and (13) according to the trouble. a If there is play, project (heighten) the stopper rubber until the play is eliminated. a If the door is not locked easily or the unlock lever is heavy, return (lower) the stopper rubber in the range that the door does not have play. While fixing stopper rubbers (12) and (13), tighten the locknuts.

6)

D155A-6

41

SEN03201-00




42

D155A-6

SEN03202-02


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Testing and adjusting, Part 3 Special functions of machine monitor (EMMS) ............................................................................................... 2

D155A-6

1

SEN03202-02

Special functions of machine monitor (EMMS)


1

Air conditioner specification

2

D155A-6


Heater specification

SEN03202-02

Upper section of machine monitor (Display section) (a): Multi-display a The figure shows an example of display of symbols and gauges in the ordinary display mode (The contents of display depend on the condition of the machine and operating method). a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper section of machine monitor (Switch section) [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower section of machine monitor (Switch section) [1]: Numeral 1 input switch/Operation mode selector switch [2]: Numeral 2 input switch/Gearshift mode selector switch [3]: Numeral 3 input switch/Customize switch [4]: Numeral 4 input switch/Buzzer cancel switch [5]: Numeral 5 input switch [6]: Numeral 6 input switch/Customize memory switch [7]: Numeral 7 input switch/Air conditioner or heater switch [8]: Numeral 8 input switch/Air conditioner or heater switch [9]: Numeral 9 input switch/Air conditioner or heater switch [0]: Numeral 0 input switch/Air conditioner or heater switch Switch having no numerals: Air conditioner or heater switch a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multidisplay (a). a The difference between the air conditioner specification and heater specification is only the functions of the switches in this section.

D155A-6

3

SEN03202-02


t Ordinary functions and special functions of machine monitor The machine monitor has the ordinary functions and special functions and displays information of various types on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special functions: Service mode The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting. Operator mode (Outline) A Display of KOMATSU logo

Page

Page

Service mode

5p 5p

15 p

01 Monitoring

16 p Mechanical system "Abnormality Record"

A Display of screen to input password

6p

A Display of check before starting

6p

A Display of warning after check before starting

6p

A Display of ending of maintenance interval

6p

03 Maintenance Record

30 p

A Display of check of preset

7p

04 Maintenance Mode Change

31 p

A Display of ordinary screen

7p

05 Phone Number Entry

33 p

02 Abnormal- Electrical system "Abnormality ity Record Record"

21 p 22 p

A Display of end screen

7p

Key-on Mode

34 p

B Selection of operation mode

7p

Setting of unit

35 p

B Selection of gearshift mode

8p

o 06 Default

Setting of maintenance password

36 p

Special operations

Air conditioner "Abnormality Record"/ 29 p Heater "Abnormality Record"

B Customizing operation

8p

B Operation of customize memory

8p

B Operation of air conditioner/heater

8p

Operation to display camera mode (if camera is installed)

9p

B

Setting of camera

37 p

Setting of ECO display

38 p

07 Adjustment

39 p

08 Pm Clinic

53 p

B Operation to display clock and service meter

9p

09 Cylinder Cut-Out

54 p

B Check of maintenance information

10 p

10 No Injection

55 p

10 p

11 Fuel Consumption

56 p

C Display of caution monitor

11 p

C Display of action code and failure code

11 p

Terminal Status 12 KOMTRAX GPS & Communication Status Settings Modem S/N

58 p

13 Service Message

60 p

B

Setting and display of user mode (including KOMTRAX messages for user)

O (Special operations) D

Function of checking display of LCD (Liquid Crystal Display)

13 p

D Function of checking service meter

13 p

D Function of changing maintenance password

14 p

57 p 59 p

a

Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch

4

D155A-6

30 Testing and adjusting t a

a

SEN03202-02

Operator mode (Outline) Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see "the Structure, function and maintenance standard, or Operation and Maintenance Manual". The following are the displays or functions of the operator mode explained in this section (including some items which need special operations). Display pattern a

b

c

d

Display of KOMATSU logo

1

1

1

1

Display of screen to input password

2

–

–

–

Display of check before starting

3

2

2

2

Display of warning after check before starting

–

–

3

–

Display of ending of maintenance inter– val

–

–

3

Display of check of preset

4

4

4

4

Display of ordinary screen

5

4

5

5

a

Display pattern of operator mode The contents of display from the time when starting switch is turned ON to the time when screen changes to ordinary screen depends on the setting and condition of the machine. a: When engine start lock is set effective b: When engine start lock is set ineffective c: When there is abnormal item in checkbefore-starting items d: When there is maintenance item which is not maintained after specified interval

Display of KOMATSU logo When the s tarting switch is turned ON, the KOMATSU logo is displayed for 2 seconds. After the KOMATSU logo is displayed for 2 seconds, the screen changes to "Display of screen to input password" or "Display of check before starting".

Display of end screen Selection of operation mode Selection of gearshift mode Customizing operation Operation of customize memory Operation to cancel alarm buzzer Operation of air conditioner/heater Operation to display camera mode (if camera is installed) Operation to display clock and service meter Check of maintenance information Setting and display of user mode (including KOMTRAX messages for user)

a a

The following screen may be displayed instead of the above "Display of screen to input password screen". If this screen is displayed, call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy.

Display of caution monitor Display of action code and failure code O (Special operations) Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing maintenance password

D155A-6

5

SEN03202-02

Display of screen to input password After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is set effective. a If the password is input normally, the screen changes to "Display of check before starting". a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another.

Display of check before starting When the screen changes to the check-beforestarting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to "Display of warning after check before starting" or "Display of ending of maintenance interval". a If no abnormality is detected by the check before starting, the screen changes to "Display of check of preset". a The monitors (3 pieces) displayed on the screen are the items under the check before starting.

6


Display of warning after check before starting If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the radiator coolant level monitor (a) is warning of low radiator coolant level.

Display of ending of maintenance interval When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is effective. The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval. a Set or change the maintenance function in the service mode.

D155A-6


Display of check of preset If the check before starting is finished normally, the screen to check the preset (gear speed at start) is displayed for 2 seconds. a After display of check of preset is finished, the sc re en ch anges to "Di spl ay of ordi nary screen".

Display of ordinary screen If the machine monitor starts normally, the ordinary screen is displayed. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]). a Power train oil temperature gauge (b) is displayed on the multi-gauge section (It is turned ON and OFF with the user mode function or [F2]). a ECO gauge (c) is displayed at the right end of the screen (It is turned ON and OFF in the service mode).

D155A-6

SEN03202-02

Display of end screen When the starting switch is turned OFF, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen, depending on the message display function of KOMTRAX.

Selection of operation mode While the ordinary screen is displayed, press the operation mode selector switch, and the operation mode monitor (a) changes. a Each time the switch is pressed, the operation mode changes between [P (Power)] and [E (Economy)].

7

SEN03202-02

Selection of gearshift mode While the ordinary screen is displayed, press the gearshift mode selector switch, and the gearshift mode monitor (a) in the gear speed display section changes. a Each time the switch is pressed, the gearshift mode changes between [Dozing (Automatic gearshift)] and [Ripping (Manual gearshift)]. a If dozing (automatic gearshift) is selected, AUTO symbol (b) is displayed in the gear speed display section.

Customizing operation While the ordinary screen is displayed, press the customize switch, and you can change the setting of the machine. a If the customize memory switch is operated while the above screen is displayed, up to 5 settings can be saved.


Operation of customize memory While the ordinary screen is displayed, press the customize memory switch, and you can select the recorded setting of customization.

Operation of air conditioner/heater While the ordinary screen is displayed, press the air conditioner switch or heater switch, and the Airconditioner Adjustment screen or Heater Adjustment screen is displayed. a While the Air-conditioner Adjustment screen or Heater Adjustment screen is displayed, if you do not touch any switch for 5 seconds, the screen changes to the ordinary screen. a Air conditioner specification

a

8

Heater specification

D155A-6


Operation to display camera mode (if camera is installed) When a camera is installed, if [F3] is pressed, the multi-display changes to the camera image. a Set the connection of the camera in the service mode.

a

a a

a a

a

Up to 3 cameras can be connected. If the camera mode is selected, however, only the image of camera 1 is always displayed.

SEN03202-02

Operation to display clock and service meter While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and clock alternately. a When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the summer time with the user mode function. a Display of service meter

a

Display of clock

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

D155A-6

9

SEN03202-02


Check of maintenance information While the maintenance monitor or ordinary screen is displayed, press [F5], and the maintenance table screen is displayed.

Setting and display of user mode (including KOMTRAX messages for user) While the ordinary screen is displayed, press [F6], and the user menu screen is displayed.

a

a

To reset the time left after finishing maintenance, more operations are necessary.

There are following items in the user menu. Utility Screen Select Multi Gage Select Screen Adjustment Clock Adjustment Language Message display Hydraulic fan reversing

[KOMTRAX message] q There are 2 types of KOMTRAX message; one is for the user and the other is for the service. q For user: A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is displayed on the ordinary screen. To see the contents of the message, operate "Message display" in the above user menu.

10

D155A-6


q

For service: A message transmitted from the KOMTRAX base station for the service. Even if it is received, nothing is displayed on the ordinary screen. To see the contents of the message, operate "KOMTRAX message display" in the service menu.

Display of caution monitor If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen, the caution monitor is displayed large for a moment and then displayed at (a) in the screen. a On the camera mode screen, the caution monitor blinks at the left upper of the screen when the caution is generated.

D155A-6

SEN03202-02

Display of action code and failure code If an abnormality which displays an action code and a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed. (a) : Action code (3 digits) (b) : Failure code (5 or 6 digits) (c) : Telephone mark (d) : Telephone No. a This screen is displayed only when an abnormality (failure code) for which an action code is set occurs. a The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the fault history in the service mode, check the details in the service mode.

11

SEN03202-02 a


Remedies given by displayed action codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual)

Action code

Method of indicating trouble

Examples of trouble

Remedy given to operator to take

E01

• Action code and failure code are • Backup alarm does not sound. displayed. • Fan speed is kept at maximum.

• Although all or a part of automatic function stops, machine can be operated. • Ask your Komatsu distributor for repair.

E02

• Gear is not shifted up or down. • Action code and failure code are • Engine boost pressure is abnormal. displayed. • Exhaust gas color is bad when • Alarm buzzer sounds. temperature is low.

• If operator stops and restarts engine, machine can be operated without limiting any function. Operator must take care, however. • Ask your Komatsu distributor for repair.

E03

• Engine coolant temperature sensor is abnormal. • Action code and failure code are • Usable gear speeds are limited. displayed. • Move machine to safe place. • Engine speed does not rise to • Telephone No. is displayed (if • Ask your Komatsu distributor for maximum. set). repair. • Gearshift shock is increased. • Alarm buzzer sounds. • Steering performance lowers. • Braking shock is increased.

E04

• Action code and failure code are displayed. • Engine cannot be controlled. • Telephone No. is displayed (if • Machine cannot travel. set). • Machine stops. • Alarm buzzer sounds.

12

• Stop machine immediately. • Ask your Komatsu distributor for repair.

D155A-6


Function of checking display of LCD (Liquid Crystal Display) While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. a The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the function switch.

D155A-6

SEN03202-02

Function of checking service meter To check the service meter while the starting switch is turned OFF, operate the numeral input switches as follows. At this time, only the service meter section displays. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD, hold down the switches until the LCD displays normally. a After the machine monitor is used continuously, blue points (points which do not go off) may be seen on this screen. This phenomenon does not indicate a failure or a defect.

13

SEN03202-02


Function of changing maintenance password When changing the maintenance password used for the maintenance setting function, follow these procedures. 1.

2.

3.

14

q

While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [5] o [5] o [5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned on.

q

Set a new password of 4 – 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). [F5]: Delete input numeral/Return to ordinary screen [F6]: Confirm input numeral

4.

After the "New Password" screen is displayed again, input a new password again with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.

5.

If the screen to notify completion of setting is displayed and then the ordinary screen is displayed, the password is changed successfully.

After the "Password" screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to input the password again is displayed.

After the "New Password" screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. D155A-6


SEN03202-02

t Service mode To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1.

a

You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].

a

The items which can be selected in the service menu are as follows.

Check of display of screen and operation of switches While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3]

01 Monitoring Mechanical system "Abnormality Record" 02 Abnormality Record

Electrical system "Abnormality Record" Air conditioner "Abnormality Record"/ Heater "Abnormality Record"

a

This operation of the switches is accepted only while the ordinary screen is displayed.

03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Setting of unit 06 Default

Setting of maintenance password Setting of camera Setting of ECO display

07 Adjustment 08 PM CLINIC 09 Cylinder Cut-Out 10 No Injection 11 Fuel Consumption

2.

Selection of service menu When the "Service Menu" screen is displayed, the service mode is selected. Select a service menu you use with the function switches or numeral input switches. q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary screen (operator mode) q [F6]: Confirm selection

D155A-6

12 KOMTRAX Settings

Terminal Status GPS & Communication Status Modem S/N

13 Service Message

a

Items with 2-digit codes are the menus displayed on the Service menu screen. The items on their right are the menus on the next hierarchy.

15

SEN03202-02


Monitoring The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc. 1.

Selecting menu Select "01 Monitoring" on the "Service Menu" screen.

3.

2.

16

Selecting monitoring items After the "Monitoring" screen is displayed, select items to be monitored with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Delete input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items.

Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and confirm with [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.

D155A-6


4.

Executing monitoring After the "Monitoring" screen is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be set to SI unit, metric unit, or inch unit with the Default function in the service mode.

5.

Holding monitoring information The monitoring information can be held and holding is reset with the function switches. q [F3]: Reset holding q [F4]: Hold information (displayed data) q [F5]: Return to monitoring selection menu screen

D155A-6

SEN03202-02

6.

Changing machine setting mode To change the setting of the "P/E Mode", "Fan Rev." mode, or "Working" mode during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to return to the monitoring information screen. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the ordinary screen after monitoring is finished.

17

SEN03202-02


Monitoring items list Code No.

Monitoring item (Display on screen)

Unit (Initial setting: ISO) ISO

meter

inch

Component in charge

50300 S/T Lever 1 Potentio

mV

mV

mV

P/T

50301 S/T Lever 2 Potentio

mV

mV

mV

P/T

50400 Brake Pedal Potentio

mV

mV

mV

P/T

31619 Brake LH ECMV(F/B)

mA

mA

mA

P/T

31618 Brake RH ECMV(F/B)

mA

mA

mA

P/T

90600 S/T Clutch LH ECMV(F/B)

mA

mA

mA

P/T

90601 S/T Clutch RH ECMV(F/B)

mA

mA

mA

P/T

31628 S.S.P Solenoid

mA

mA

mA

P/T

°

°

°

P/T

60100 Pitch Angle Sensor

mV

mV

mV

P/T

60500 ENG Hold Relay

mV

mV

mV

P/T

60600 BR Hold Relay

mV

mV

mV

P/T

50000 Fuel Dial Throttle

%

%

%

P/T

03000 Fuel Dial Sensor

mV

mV

mV

P/T

32900 Pitch Angle

31521 S/T Fill Sw Input

BL (Left brake fill sw)

ON • OFF

P/T

CL (Left clutch fill sw)

ON • OFF

P/T

CR (Right clutch fill sw)

ON • OFF

P/T

BR (Right brake fill sw)

ON • OFF

P/T

50200 T/M Lever 1 Potentio

mV

mV

mV

P/T

50201 T/M Lever 2 Potentio

mV

mV

mV

P/T

31622 T/M Clutch F ECMV(F/B)

mA

mA

mA

P/T

31616 T/M Clutch R ECMV(F/B)

mA

mA

mA

P/T

31602 T/M Clutch 1st ECMV(F/B)

mA

mA

mA

P/T

31603 T/M Clutch 2nd ECMV(F/B)

mA

mA

mA

P/T

31604 T/M Clutch 3rd ECMV(F/B)

mA

mA

mA

P/T

C

C

F

P/T

31400 T/M Out Speed

r/min

rpm

rpm

P/T

50900 T/M Lock Relay

mV

mV

mV

P/T

40001 Vehicle Speed

km/h

km/h

MP/h

P/T

60000 Traction

W

W

W

P/T

70200 T/M Out Speed Sensor

mV

mV

mV

P/T

70400 Back Alarm Relay

mV

mV

mV

P/T

31624 Fan Pump Solenoid(F/B)

mA

mA

mA

P/T

r/min

rpm

rpm

P/T

30100 T/C Oil Temperature

10000 Fan Speed

40905 T/M Sw Input 1

18

SUNC (Gear shift up sw)

ON • OFF

P/T

SUNO (Gear shift up sw)

ON • OFF

P/T

SDNC (Gear shift down sw)

ON • OFF

P/T

Remarks

D155A-6


Code No.


40905 T/M Sw Input 1

T/M Fill Sw 40906 Input 1

31520

T/M Fill Sw Input 2

40909 T/M Output 1

SEN03202-02


meter

inch

Component in charge

SDNO (Gear shift down sw)

ON • OFF

P/T

PNC (Parking brake lever sw)

ON • OFF

P/T

PNO (Parking brake lever sw)

ON • OFF

P/T

F (F clutch fill sw)

ON • OFF

P/T

R (R clutch fill sw)

ON • OFF

P/T

1st (1st clutch fill sw)

ON • OFF

P/T

2nd (2nd clutch fill sw)

ON • OFF

P/T

3rd (3rd clutch fill sw)

ON • OFF

P/T

L/U( Lock-up clutch fill sw)

ON • OFF

P/T

S/C (Stator clutch fill sw)

ON • OFF

P/T

Brly (Back Alarm relay)

ON • OFF

P/T

Prly (Parking lock relay)

ON • OFF

P/T

Fres (Fan reverse solenoid)

ON • OFF

P/T

70700 Hydraulic Pump Pressure 1

MPa

kg/cm²

psi

P/T

70701 Hydraulic Pressure Sensor 1

mV

mV

mV

P/T

20227 Monitor Ass’y P/N

—

MON

20402 Monitor Serial No

—

MON

20228 Monitor Prog P/N

—

MON

20242 P/T Con Ass’y P/N

—

P/T

20404 P/T Con Serial No

—

P/T

20243 P/T Con Prog P/N

—

P/T

04200 Fuel Level Sensor Volt

V

V

V

MON

04300 Battery Charge Volt

V

V

V

MON

04401 Hyd Oil Temperature

C

C

F

MON

04002 Hyd Temp Sens Volt

V

V

V

MON

18900 ECM Internal Temp

C

C

F

ENG

37200 Engine Oil Pressure

kPa

kg/cm²

psi

ENG

00201 Machine ID

—

ENG

20216 ECM Build Version

—

ENG

20217 ECM Calibration Data Ver

—

ENG

20400 ECM Serial No

—

ENG

01002 Engine Speed

r/min

rpm

rpm

ENG

36700 Engine Torque Ratio

%

%

%

ENG

31701 Throttle Position

%

%

%

ENG

03001 Throttle Pos Sens Volt

mV

mV

mV

ENG

17500 Engine Power Mode

D155A-6

—

Remarks

ENG

19

SEN03202-02



meter

inch

Component in charge

MPa

kg/cm²

psi

ENG

V

V

V

ENG

MPa

kg/cm²

psi

ENG

CA

CA

CA

ENG

04107 Coolant Temperature

C

C

F

ENG

01405 Coolant Temp Sens Volt

V

V

V

ENG

kPa

kg/cm²

psi

ENG

V

V

V

ENG

kPa

kg/cm²

psi

ENG

36501 Charge Press Sens Volt

V

V

V

ENG

03203 Battery Power Supply

V

V

V

ENG

37300 Fuel Rate

l/h

l/h

gal/h

ENG

31706 Final Throttle Position

%

%

%

ENG

18500 Charge Temperature

C

C

F

ENG

18501 Charge Temp Sens Volt

V

V

V

ENG

18600 Inject Fueling Command

mg/st

mg/st

mg/st

ENG

17201 PCV Close Timing

CA

CA

CA

ENG

18700 Engine Output Torque

Nm

kgm

lhft

ENG

37201 Eng Oil Press Sens Volt

V

V

V

ENG

14200 Fuel Temperature

C

C

F

ENG

14201 Fuel Temp Sens Volt

V

V

V

ENG

Code No.


36400 Rail Pressure 36401 Rail Pressure Sens Volt 36200 Rail Press Command 36300 Injection Timing Command

37400 Ambient Pressure 37401 Ambient Press Sens Volt 36500 Charge Pressure-Abs

40912 P/T Sw Input

40910 P/T Sw Input 2

40915 P/T Output

a a

a

20

R-sig

ON • OFF

P/T

Acc

ON • OFF

P/T

Eng S

ON • OFF

P/T

Eng L

ON • OFF

P/T

Eng Sd

ON • OFF

P/T

WL-NO (Work equipment lock Sw)

ON • OFF

P/T

WL-NC (Work equipment lock Sw)

ON • OFF

P/T

W-LOK (Work equipment lock SOL)

ON • OFF

P/T

Remarks

Indication by absolute value (including ambient pressure)

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


"Abnormality Record" (Mechanical system "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the mechanical system "Abnormality Record", perform the following procedures. 1.

Selecting menu Select "02 Abnormality Record" on the "Service Menu" screen.

2.

Selecting sub menu After the "Abnormality Record" screen is displayed, select "01 Mechanical Systems" with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. If the heater specification is selected, "03 Heater Abnormality Record" is displayed.

D155A-6

SEN03202-02

3.

Information displayed on "Abnormality Record" screen On the "Mechanical Systems" screen, the following information is displayed. (a): Occurrence order of abnormality from latest one/Total number of records (b): Failure code (c): Contents of trouble (d): Number of occurrence time (e): Service meter reading at first occurrence (f): Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to "Abnormality Record" screen a If no "Abnormality Record" is recorded, "No Abnormality Record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table in "Abnormality Record (Electrical system Abnormality Record)".

4.

Deleting "Abnormality Record" The contents of the mechanical system "Abnormality Record" cannot be deleted.

21

SEN03202-02

"Abnormality Record" (Electrical system "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the electrical system "Abnormality Record", perform the following procedures. 1.

Selecting menu Select "02 Abnormality Record" on the "Service Menu" screen.

2.

Selecting sub menu After the "Abnormality Record" screen is displayed, select "02 Electrical Systems" with the function switches or numeral input switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. If the heater specification is selected, "03 Heater Abnormality Record" is displayed.

22


3.

Information displayed on "Abnormality Record" screen On the "Electrical Systems" screen, the following information is displayed. (a):Occurrence order of abnormality from latest one/Total number of records (b):Failure code (c): Contents of trouble (d):Number of occurrence time (e):Service meter reading at first occurrence (f): Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to "Abnormality Record" screen a If no "Abnormality Record" is recorded, "No Abnormality Record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table.

4.

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

D155A-6


SEN03202-02 a

2)

3)

D155A-6

Check that the screen is set in the delete mode, and then delete the items one by one or together with the function switches. a If the screen is set in the delete mode, [CLEAR] graphic mark is indicated at [F2]. q [F2]: Delete all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to "Abnormality Record" screen q [F6]: Delete selected item a To delete items one by one: Select the item to be deleted with [F3] or [F4] and press [F6]. a To delete all items together: Press [F2], and all the items are deleted, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the deleting operation is accepted but the information is not deleted.

4)

The following figure shows the screen displayed when the items are deleted one by one (which is a little different from the screen displayed when all the items are deleted together).

If the screen to notify completion of deletion is displayed and then the "Electrical Sys. Error Reset" (delete mode) screen is displayed, the deletion of the "Abnormality Record" is completed. a After a while, the screen returns to the "Electrical Sys. Error Reset" screen.

After the "Electrical Sys. Error Reset" screen is displayed, operate the function switches. q [F5]: Return to "Electrical Sys. Error Reset" screen (Delete mode) q [F6]: Execute deletion

23

SEN03202-02


Failure codes table Action code

Failure code

E03

1500L0

E03

Component in charge

Category of history

Transmission clutch: Abnormal

P/T

Electrical system

15SAL1

Forward clutch: Fill high

P/T

Electrical system

E03

15SALH

Forward clutch: Fill Low

P/T

Electrical system

E03

15SBL1

Reverse clutch: Fill high

P/T

Electrical system

E03

15SBLH

Reverse clutch: Fill Low

P/T

Electrical system

E03

15SEL1

Speed 1st clutch: Fill high

P/T

Electrical system

E03

15SELH

Speed 1st clutch: Fill Low

P/T

Electrical system

E03

15SFL1

Speed 2nd clutch: Fill high

P/T

Electrical system

E03

15SFLH

Speed 2nd clutch: Fill Low

P/T

Electrical system

E03

15SGL1

Speed 3rd clutch: Fill high

P/T

Electrical system

E03

15SGLH

Speed 3rd clutch: Fill Low

P/T

Electrical system

E04

2201L1

Right clutch: See the list

P/T

Electrical system

E04

2201LH


P/T

Electrical system

E04

2202L1

Left clutch: See the list

P/T

Electrical system

E04

2202LH


P/T

Electrical system

—

2300KM

Stall in 1st gear speed

P/T

Electrical system

E04

2301L1

Right brake: Fill high

P/T

Electrical system

E04

2301LH

Right brake: Fill low

P/T

Electrical system

E04

2302L1

Left brake: Fill high

P/T

Electrical system

E04

2302LH

Left brake: Fill low

P/T

Electrical system

—

7RFAKA

ECM HOLD RELAY: Disconnection

P/T

Electrical system

—

AA10NX

Air Cleaner Clogging

MON

Mechanical system

—

AB00MA

Battery Charge Abnormal

MON

Mechanical system

—

B@BAZG

Eng Oil Press Low

ENG

Mechanical system

—

B@BCNS

Eng Water Overheat

ENG

Mechanical system

—

B@BCZK

Eng Water Level Low

MON

Mechanical system

—

B@CENS

T/C Oil Overheat

P/T

Mechanical system

—

B@HANS

Hyd Oil Overheat

MON

Mechanical system

E04

CA111

EMC Critical Internal Failure

ENG

Electrical system

E04

CA115

Eng Ne and Bkup Speed Sens Error

ENG

Electrical system

E03

CA122

Chg (boost) Air Press Sensor High Error

ENG

Electrical system

E03

CA123

Chg (boost) Air Press Sensor Low Error

ENG

Electrical system

E03

CA131

Throttle Sensor High Error

ENG

Electrical system

E03

CA132

Throttle Sensor Low Error

ENG

Electrical system

E02

CA135

Eng Oil Press Sensor High Error

ENG

Electrical system

E02

CA141

Eng Oil Press Sensor Low Error

ENG

Electrical system

24

Trouble (Displayed on screen)

D155A-6


Action code

Failure code

E02

CA144

E02

SEN03202-02

Component in charge

Category of history

Coolant Temp Sens High Error

ENG

Electrical system

CA145

Coolant Temp Sens Low Error

ENG

Electrical system

E01

CA153

Chg (boost) Air Temp Sensor High Error

ENG

Electrical system

E01

CA154

Chg (boost) Air Temp Sensor Low Error

ENG

Electrical system

E03

CA187

Sens Supply 2 Volt Low Error

ENG

Electrical system

E03

CA221

Ambient Press Sens High Error

ENG

Electrical system

E03

CA222

Ambient Press Sens Low Error

ENG

Electrical system

E03

CA227

Sens Supply 2 Volt High Error

ENG

Electrical system

—

CA234

Eng Overspeed

ENG

Electrical system

E03

CA238

Ne Speed Sens Supply Volt Error

ENG

Electrical system

E01

CA263

Fuel Temp Sensor High Error

ENG

Electrical system

E01

CA265

Fuel Temp Sensor Low Error

ENG

Electrical system

E03

CA271

PCV1 Short Error

ENG

Electrical system

E03

CA272

PCV1 Open Error

ENG

Electrical system

E03

CA273

PCV2 Short Error

ENG

Electrical system

E03

CA274

PCV2 Open Error

ENG

Electrical system

E03

CA322

Inj #1 Open/Short Error

ENG

Electrical system

E03

CA323


ENG

Electrical system

E03

CA324


ENG

Electrical system

E03

CA325


ENG

Electrical system

E03

CA331


ENG

Electrical system

E03

CA332


ENG

Electrical system

E04

CA342

Calibration Code Incompatibility

ENG

Electrical system

E03

CA351

Injectors Drive Circuit Error

ENG

Electrical system

E03

CA352


ENG

Electrical system

E03

CA386


ENG

Electrical system

E04

CA441

Battery Voltage Low Error

ENG

Electrical system

E04

CA442

Battery Voltage High Error

ENG

Electrical system

E03

CA449

Rail Press Very High Error

ENG

Electrical system

E03

CA451

Rail Press Sensor High Error

ENG

Electrical system

E03

CA452

Rail Press Sensor Low Error

ENG

Electrical system

E02

CA553

Rail Press High Error

ENG

Electrical system

E03

CA554

Rail Press Sensor In Range Error

ENG

Electrical system

E02

CA559

Rail Press Low Error

ENG

Electrical system

E03

CA689

Eng Ne Speed Sensor Error

ENG

Electrical system

E03

CA731

Eng Bkup Speed Sens Phase Error

ENG

Electrical system

E04

CA757

All Continuous Data Lost Error

ENG

Electrical system

D155A-6


25

SEN03202-02

Action code

Failure code

E03

CA778

E03


Component in charge

Category of history

Eng Bkup Speed Sensor Error

ENG

Electrical system

CA1633

KOMNET Datalink Timeout Error

ENG

Electrical system

E03

CA2185

Throt Sens Sup Volt High Error

ENG

Electrical system

E03

CA2186

Throt Sens Sup Volt Low Error

ENG

Electrical system

E03

CA2249

Rail Press Very Low Error

ENG

Electrical system

E01

CA2555

Grid Htr Relay Volt Low Error

ENG

Electrical system

E01

CA2256

Grid Htr Relay Volt High Error

ENG

Electrical system

—

D110KA

Battery relay: Disconnection

P/T

Electrical system

—

D110KB

Battery Relay: Drive Short Circuit

P/T

Electrical system

E02

D130KA

Neutral relay: Disconnection

P/T

Electrical system

E02

D130KB

Neutral relay: Short circuit

P/T

Electrical system

E01

D161KA

Back-up alarm relay: Disconnection

P/T

Electrical system

E01

D161KB

Back-up alarm relay: Short circuit

P/T

Electrical system

—

D190KA

ACC signal relay: Disconnection

P/T

Electrical system

—

D190KB

ACC signal relay: Short circuit

P/T

Electrical system

E03

D5ZKKX

Throttle Dial: Out of normal range

P/T

Electrical system

E03

DAFRKR

CAN Disconnection (Monitor)

MON

Electrical system

E03

DB2RKR

CAN Disconnection (Engine controller)

ENG

Electrical system

E03

DB90KR

PT controller: Can communication lost

P/T

Electrical system

E03

DBE0KK

PT controller: Source voltage reduction

P/T

Electrical system

E01

DBE0KT

PT controller: Abnormality in controller

P/T

Electrical system

E02

DBE6KK


P/T

Electrical system

E02

DBE7KK


P/T

Electrical system

E04

DBE9KQ

PT controller: Type select signal

P/T

Electrical system

E02

DD12KA

Shift up Sw: Disconnection

P/T

Electrical system

E02

DD12KB

Shift up Sw: Short circuit

P/T

Electrical system

E02

DD13KA

Shift down Sw: Disconnection

P/T

Electrical system

E02

DD13KB

Shift down Sw: Short circuit

P/T

Electrical system

E03

DD14KA

Parking lever Sw: Disconnection

P/T

Electrical system

E03

DD14KB

Parking lever Sw: Short circuit

P/T

Electrical system

E02

DDDDKA

Back up brake Sw: Disconnection

P/T

Electrical system

E02

DDDDKB

Back up brake Sw: Short circuit

P/T

Electrical system

E02

DDDDKX

Back up brake Sw: Signal mismatch

P/T

Electrical system

E01

DGT1KA

T/C oil temp sensor: Abnormal

P/T

Electrical system

E01

DGT1KX

T/C oil temp sensor abnormal

P/T

Electrical system

—

DH21KA

Weq pressure sensor: Disconnection

P/T

Electrical system

—

DH21KB

Weq pressure sensor: Short circuit

P/T

Electrical system

26


D155A-6


Action code

Failure code

E03

DK10KX

E03

SEN03202-02

Component in charge

Category of history

Fuel control Dial: Out of normal range

P/T

Electrical system

DK30KA

ST lever 1: Disconnection

P/T

Electrical system

E03

DK30KB

ST lever 1: Short circuit

P/T

Electrical system

E04

DK30KX

ST lever 1: Out of normal range

P/T

Electrical system

E04

DK30KZ

ST lever: Disconnection or short circuit

P/T

Electrical system

E03

DK30L8

ST lever: Signal mismatch

P/T

Electrical system

E03

DK31KA


P/T

Electrical system

E03

DK31KB


P/T

Electrical system

E03

DK40KA

Brake potentiometer: Disconnection

P/T

Electrical system

E03

DK40KB

Brake potentiometer: Short circuit

P/T

Electrical system

E04

DK55KX

FR lever: Out of normal range

P/T

Electrical system

E04

DK55KZ

FR lever: Disconnection or short circuit

P/T

Electrical system

E03

DK55L8

FR lever: Signal mismatch

P/T

Electrical system

E03

DK56KA

FR lever 1: Disconnection

P/T

Electrical system

E03

DK56KB

FR lever 1: Short circuit

P/T

Electrical system

E03

DK57KA


P/T

Electrical system

E03

DK57KB


P/T

Electrical system

E03

DKH1KA

Pitch angle sensor: Disconnection

P/T

Electrical system

E03

DKH1KB

Pitch angle sensor: Short circuit

P/T

Electrical system

E01

DLT3KA

T/M out-speed sensor: Disconnection

P/T

Electrical system

E01

DLT3KB

T/M out-speed sensor: Abnormal

P/T

Electrical system

E01

DW7BKA

Fan rev EPC: Disconnection

P/T

Electrical system

E01

DW7BKB

Fan rev EPC: Short circuit

P/T

Electrical system

E04

DWN3KA

Ssp solenoid: Disconnection

P/T

Electrical system

E04

DWN3KB

Ssp solenoid: Short circuit

P/T

Electrical system

E04

DWN3KY

Ssp solenoid: Short circuit

P/T

Electrical system

E01

DWN5KA

Fan pump solenoid: Disconnection

P/T

Electrical system

E01

DWN5KB

Fan pump solenoid: Short circuit

P/T

Electrical system

E03

DXH4KA

1st clutch ECMV: Disconnection

P/T

Electrical system

E03

DXH4KB

1st clutch ECMV: Short circuit

P/T

Electrical system

E03

DXH4KY


P/T

Electrical system

E03

DXH5KA

2nd clutch ECMV: Disconnection

P/T

Electrical system

E03

DXH5KB

2nd clutch ECMV: Short circuit

P/T

Electrical system

E03

DXH5KY


P/T

Electrical system

E03

DXH6KA

3rd clutch ECMV: Disconnection

P/T

Electrical system

E03

DXH6KB

3rd clutch ECMV: Short circuit

P/T

Electrical system

E03

DXH6KY


P/T

Electrical system

D155A-6


27

SEN03202-02

Action code

Failure code

E03

DXH7KA

E03


Component in charge

Category of history

R clutch ECMV: Disconnection

P/T

Electrical system

DXH7KB

R clutch ECMV: Short circuit

P/T

Electrical system

E04

DXH7KY


P/T

Electrical system

E03

DXH8KA

F clutch ECMV: Disconnection

P/T

Electrical system

E03

DXH8KB

F clutch ECMV: Short circuit

P/T

Electrical system

E04

DXH8KY


P/T

Electrical system

E03

DXH9KA

Right clutch ECMV: Disconnection

P/T

Electrical system

E03

DXH9KB

Right clutch ECMV: Short circuit

P/T

Electrical system

E04

DXH9KY

Right clutch ECMV: Hot short

P/T

Electrical system

E03

DXHAKA

Left clutch ECMV: Disconnection

P/T

Electrical system

E03

DXHAKB

Left clutch ECMV: Short circuit

P/T

Electrical system

E04

DXHAKY

Left clutch ECMV: Hot short

P/T

Electrical system

E04

DXHBKA

Right brake ECMV: Disconnection

P/T

Electrical system

E04

DXHBKB

Right brake ECMV: Short circuit

P/T

Electrical system

E04

DXHBKY


P/T

Electrical system

E04

DXHCKA

Left brake ECMV: Disconnection

P/T

Electrical system

E04

DXHCKB

Left brake ECMV: Short circuit

P/T

Electrical system

E04

DXHCKY


P/T

Electrical system

E03

DXJ4KA

Weq lock Sol.: Disconnection

P/T

Electrical system

E03

DXJ4KB

Weq lock Sol.: Short circuit

P/T

Electrical system

a a

a

a

28


Entry order of items in table The items are entered in the order of their failure codes (incremental order). Action code Attached: If the failure code is detected, the action code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the fault. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the fault. Component in charge MON: The machine monitor is in charge of detection of fault. ENG: The engine controller is in charge of detection of fault. P/T: The power train controller is in charge of detection of fault. Category of record Mechanical equipment system: Fault information is recorded in the "Mechanical Systems". Electrical equipment system: Fault information is recorded in the "Electrical Systems" .

D155A-6


"Abnormality Record" (Air conditioner "Abnormality Record"/Heater "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the air conditioner "Abnormality Record" or heater "Abnormality Record", perform the following procedures. a All the following figures show the air conditioner specification. 1.

Selecting menu Select "02 Abnormality Record" on the Service menu screen.

2.

Selecting sub menu After the "Abnormality Record" screen is displayed, select "03 Air-conditioning System" or "03 Heater Abnormality Record" with the function switches or numeral input switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].

D155A-6

SEN03202-02

3.

Information displayed on "Abnormality Record" screen On the air conditioner "Abnormality Record" or heater "Abnormality Record" screen, the following information is displayed. (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) q [F2]: Delete "Abnormality Record" q [F5]: Return to "Abnormality Record" screen a If [E] is displayed on the left of a condition, the abnormality is still occurring or resetting of it has not been confirmed. a If "CAN Status" is displayed in Communication condition, communication cannot be carried out normally. Accordingly, the conditions of other items are turned OFF.

4.

Deleting "Abnormality Record" While the "Abnormality Record" screen is displayed, press [F2], and the number of occurrence time of fault is deleted. If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.

a

Heater specification In the heater specification, the display of "Air conditioner" is replaced with "Heater" and the items which are not related to the heater are not displayed.

29

SEN03202-02


Maintenance Record The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section.

01 Engine Oil Change

1.

07 Check and addition of damper case oil

02 Eng Oil Filter Change 03 Fuel Main Filter Change 41 Fuel Pre Filter Change 04 Hyd Oil Filter Change 06 Corrosion Resistor Change

Selecting menu Select "03 Maintenance Record" on the "Service Menu" screen.

08 Replacement interval of final drive case oil 10 Replacement of hydraulic oil 19 Replacement of power train oil 20 Replacement of power train oil filter

3.

2.

Selecting maintenance record item After the "Maintenance Record" screen is displayed, select an item to be checked with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.

a

30

Items displayed on Maintenance Record screen The following items are displayed. (a): Maintenance items (b): Number of times of change up to now (c): Service meter reading (SMR) at previous change

The following items can be selected in the maintenance record.

D155A-6


SEN03202-02

Maintenance Mode Change The operating condition for maintenance function in the operation mode can be set and changed with this menu. q Set function effective or ineffective q Change set change interval (by items) q Initialize all set change intervals

00 Maintenance Mode On/Off

1.

06 Replacement interval of corrosion resistor

Selecting menu Select "04 Maintenance Mode Change" on the Service menu screen.

01 Engine Oil Change Int 02 Eng Oil Filter Change Int 03 Fuel Main Filter Change Int 41 Fuel Pre Filter Change Int 04 Hyd Oil Filter Change Int 07 Check and replacement interval of damper case oil 08 Replacement interval of final drive case oil 10 Replacement interval of hydraulic oil 19 Replacement interval of power train oil 20 Replacement interval of power train oil filter 99 Use Default Value

3.

2.

Selecting sub menu After the "Maintenance Mode On/Off" screen is displayed, select an item to be monitored with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].

a

D155A-6

Contents of setting of ON/OFF of maintenance mode After selecting "00 Maintenance Mode On/Off", if the screen is displayed, set ON or OFF with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance mode screen q [F6]: Confirm selection and return to Maintenance mode screen a Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.

The following items can be selected on the "Maintenance Mode On/Off" screen.

31

SEN03202-02

4.

Contents of setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches.

q

q

q q q q q

q

a

32

Default: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). Set: Maintenance interval which can be set freely. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 50 hours). ON: Maintenance function of this item is set effective in operator mode. OFF: Maintenance function of this item is set ineffective in operator mode. [F3]: Select Reduce set value (Upper) or OFF (Lower). [F4]: Select Increase set value (Upper) or ON (Lower). [F5]: Cancel setting before confirmation and return to Maintenance Mode Change screen. [F6]: Confirm setting of upper or lower line. After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance Mode Change screen with [F5], the setting is effective.


5.

Function of All Default Value After selecting "99 Use Default Value", if the screen is displayed, set with the function switches.

a

q q

a

a

If this operation is executed, the set values of all the maintenance items are set to default values. [F5]: Return to Maintenance Mode Change screen [F6]: Execute default setting A while after [F6] is pressed, the default setting completion screen is displayed. Then, if the "Maintenance Mode Change" screen is displayed, default setting is completed. The default setting of the corrosion resistor is "OFF".

D155A-6


Phone Number Entry The phone No. displayed when the action code/failure code is displayed in the operator mode can be input and changed according to the following procedure. If a phone No. is not input with this function, no phone No. is displayed in the operator mode. 1.

Selecting menu Select "05 Phone Number Entry" on the "Service Menu" screen.

2.

Registering and changing telephone No. After the "Phone Number Entry" screen is displayed, register or change the phone No. q [F2]: Delete all input No. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Delete input digit/Return to service menu q [F6]: Confirm input

a a

D155A-6

SEN03202-02 a

If [F6] is pressed without inputting a digit, there is not information of phone No. Accordingly, no phone No. is displayed in the operator mode.

Up to 14 digits can be input from the left. Input nothing in the surplus positions. If one of the input digits is wrong, move to that digit (and its background changes to orange) and overwrite it with the correct digit.

33

SEN03202-02

Default setting (Key-on Mode) Check or change various settings related to the machine monitor and machine by default setting. The function of Key-on Mode is used to set the initial mode displayed on the machine monitor when the starting switch is turned ON. 1.

Selecting menu Select "06 Default" on the "Service Menu" screen.

2.

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

34


3.

Selecting mode After the "Key-on Mode" screen is displayed, select the mode to be set with the function switches. q Mode at previous key-OFF: Final mode in previous operation is displayed when starting switch is turned ON q Default Value (ALL OFF): Default setting of all mode items (Power: E, other 3 items: OFF) is displayed when starting switch is turned ON q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to default screen q [F6]: Confirm selection and return to default screen a When the machine is delivered, Default Value (All OFF).

D155A-6


SEN03202-02

Default setting (Setting of unit) Check or change various settings related to the machine monitor and machine by default setting. The unit selecting function is used to select the unit of the data displayed for monitoring, etc. 1.


2.

Selecting sub menu After the "Default" screen is displayed, select "02 Unit" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

3.

Selecting unit After the "Unit" screen is displayed, select the unit to be set with the function switches. q [F3]: Move to lower unit q [F4]: Move to upper unit q [F5]: Cancel selection and return to default screen q [F6]: Confirm selection and return to default screen a When the machine is delivered, the SI unit system is set.

D155A-6

35

SEN03202-02


Default setting (Setting of maintenance password) Check or change various settings related to the machine monitor and machine by default setting. The function of setting maintenance password is used to set the display of the password screen when the functions related to the maintenance are used in the operator mode. 1.

[F6]: Confirm selection and return to default screen


2.

Selecting sub menu After the "Default" screen is displayed, select "03 Maintenance Password" with the function switches or numeral input switches. a Select this item similarly to an item on the Service menu screen.

3.

Selecting Enable/Disable After the "Maintenance Password" screen is displayed, select the setting with the function switches. q Disable: Password screen is not displayed q Enable: Password screen is displayed q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Initialization screen

36

q

4.

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

5.

Changing maintenance password The password can be changed by operating the switches specially in the operator mode. a See "Function of changing maintenance password" in the operator mode. a Default password: [000000] a If the password setting is changed from "Enable" to "Disable", the password is reset to the default. a When "Enable" is set again, be sure to set a new password. a The maintenance password is different from the engine start lock password.

D155A-6


Default setting (Setting of camera) Check or change various settings related to the machine monitor and machine by default setting. The camera setting function is used to set default setting and removal of a camera. 1.

SEN03202-02

q q q q

a

Selecting menu Select "06 Default" on the "Service Menu" screen. a a

a a 2.

Selecting sub menu After the "Default" screen is displayed, select "04 Camera" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

3.

Selecting camera setting After the "Camera" screen is displayed, select the setting with the function switches. q OFF: Camera is not connected q Original image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor)

D155A-6

a

[F3]: Move to left item [F4]: Move to right item [F5]: Cancel setting before confirmation and return to Default screen [F6]: Confirm selection in each line After "Camera" screen is displayed, camera 1 can be always set. When 2 or more cameras are connected, if camera 1 is set, the screen changes to setting of camera 2 automatically. After confirming the setting of each line with [F6], return to the Default screen with [F5], and the setting is effective. If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. If 2 or more cameras are connected, be sure to set the use of them from camera 1 in order. The function of displaying 2 images simultaneously is effective when use of camera 1 and camera 2 is set. When a camera is installed, check that the displayed image is not inverted horizontally in the operator mode.

37

SEN03202-02

Default setting (Setting of ECO display) Check or change various settings related to the machine monitor and machine by initialization. The ECO display setting function is used to set the display of the ECO gauge. 1.

a

If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen.

a

Display of ECO gauge (a)


2.

Selecting sub menu After the "Default" screen is displayed, select "05 ECO Display" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

3.

Selecting display setting After the "ECO Display" screen is displayed, select the setting with the function switches. q ON: Display ECO q OFF: Do not display ECO q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel selection and return to default screen q [F6]: Confirm selection and return to default screen

38


D155A-6


SEN03202-02

Adjustment The operator can adjust various items related to the machine with the machine monitor. When using an adjustment item, select it according to the following procedure. 1.

Selecting menu Select "07 Adjustment" on the "Service Menu" screen.

3.

2.

Selecting adjustment item After the "Adjustment" screen is displayed, input the 4-digit adjustment ID of the adjustment item to be used with the numeral input switches. q [F5]: Cancel adjustment and return to Service menu screen q [F6]: Confirm input adjustment ID and go to Adjustment screen a For the adjustment ID's and their adjustment items, see the adjustment items table.

a

D155A-6

Displaying adjustment screen After the "Adjustment" screen for the adjustment ID is displayed, you can start adjustment. a In the figure, adjustment ID [0002] is selected and displayed as an example. a "000", "00", and "0" on the left of the adjustment ID must be filled but they are not displayed on the adjustment screen. a The functions given to function switches [F3] – [F6] depend on the adjustment item. a For the method of operating each adjustment item, see the explanation of its adjustment ID.

If the input adjustment ID is incorrect, the message of "No ready Adjustment" is displayed and the ID input screen does not change (Another ID can be input again with the numeral input switches while this screen is displayed).

39

SEN03202-02


Adjustment items table Adjustment ID

40

Adjustment item

Remarks

0002

Power train controller initialization

0005

Brake pedal potentiometer initial correction

0007

Engine decelerator cutting

0009

Pitch angle sensor initial correction

0010

Fan 70% mode

0530

Stall mode

0910

Load record check mode

1005

Fan 100% mode

1012

Steering lever neutral position adjustment

1013

Steering lever leftmost position adjustment

1014

Steering lever rightmost position adjustment

1015

Right brake oil pressure offset

1016

Left brake oil pressure offset

2021

Power train controller voltage check mode

6001

R1 reverse slow set speed

Fine adjustment of reverse slow mode

6002



6003



7842

Transmission clutch IP automatic initial correction

7843

Transmission clutch IP manual initial correction

7845

Transmission clutch IP learning display

9995

Control brake release mode

9996

Sudden stop prevent valve operation mode

9997

High idle cut mode

9998

Max. gear speed setting mode

Resetting auto-decelerating function

Recommended mode of torque converter stall

Control brake: Brake ECMV (Right and left)

D155A-6


Adjustment ID: 0002 (Power train controller initialization)

q

a

q

q

This adjustment code is used to initialize the specification code recognized by the power train controller and the set values of the memory in the controller. After the power train controller is replaced, be sure to carry out this adjustment once. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save setting Operating method: 1) Press [F6] and check that the alarm buzzer sounds. 2) Check that the displayed specification code [CODE] has changed from [5x5] to [555]. a If specification code [555] is not displayed, the controller wiring harness or the controller unit may be defective. a Even if this adjustment code is turned off, the setting is effective.

D155A-6

SEN03202-02

Adjustment ID: 0005 (Brake pedal potentiometer initial correction)

q

a

This adjustment code is used to make the power train controller recognize the zero point of the brake pedal potentiometer. After the power train controller or brake pedal potentiometer is replaced or the brake pedal linkage is disconnected and connected, be sure to carry out this adjustment once.

q

Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save corrected value

q

Operating method: 1) Check that the brake pedal is in the neutral position (it is not pressed at all) and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the correction is effective. a This adjustment code is used to make the controller recognize the zero point of the potentiometer. It is not used to adjust the braking force.

41

SEN03202-02

Adjustment ID: 0007 (Engine decelerator cutting)


Adjustment ID: 0009 (Pitch angle sensor initial correction)

This adjustment code is used to stop the autodeceleration function of the engine and check the high idle speed of the engine unit. The engine can be driven and tested with the auto-deceleration reset only while this adjustment code is selected. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

q

q

Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused

q

Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save corrected value

q

Operating method: When this adjustment code is displayed, its function is effective and the auto-deceleration function is stopped. a After this adjustment code is turned OFF, its function is ineffective.

q

Operating method: 1) Check that the machine is level. 2) Press [F6] and check that the alarm buzzer sounds. a If adjustment is carried out, displayed item [BODY PITCH ANGLE] changes to [0.0 °] (The other displayed items do not change). a Even if this adjustment code is turned off, the correction is effective.

q

a a

42

a

This adjustment code is used to make the power train controller recognize the zero point of the pitch angle sensor and to correct the installation error. After the power train controller is replaced or the pitch angle sensor is removed and installed or replaced, be sure to carry out this adjustment once.

D155A-6


Adjustment ID: 0010 (Fan 70% mode)

q

a

q

q

This adjustment code is used to set the cooling fan speed to about 70% forcibly. Use this adjustment code for testing, adjusting, or troubleshooting when necessary. Functions of function switches [F3]: Increase adjustment value [FAN 70% SPEED MODE] [F4]: Decrease adjustment value [FAN 70% SPEED MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused Operating method: When this adjustment code is displayed, its function is effective and the cooling fan speed is controlled to about 70% of the maximum speed. a After this adjustment code is turned OFF, its function is ineffective.

SEN03202-02

Adjustment ID: 0530 (Stall mode)

q

This adjustment code is used to set the fan speed in the 100% mode automatically and make it possible to set the preset (gear speed at start) to [F3-R3] to stall the torque converter. a The preset (gear speed at start) can be set to [F3-R3] only while this adjustment code is selected. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

q


q

Mode setting information within screen [P-AUTO SFT MODE]: Automatic gearshift in P mode [E-AUTO SFT MODE]: Automatic gearshift in E mode [P-MANUAL SFT MODE]: Manual gearshift in P mode [E-MANUAL SFT MODE]: Manual gearshift in E mode

q

Operating method: When this adjustment code is displayed, its function is effective and the preset (gear speed at start) is set to [F3-R3]. k

a

D155A-6

This adjustment code does not stall the t o r q u e c o n v e r t e r a u t o m a t i c a l l y. Accordingly, operate the levers and pedals securely when stalling the torque converter (For the procedure for stalling the torque converter, see Measuring engine speed). After this adjustment code is turned OFF, its function is ineffective.

43

SEN03202-02

Adjustment ID: 0910 (Load record check mode)

q

a

q

q

q

44

This adjustment code is used to check the load on the machine, odometer, and reverse odometer. Use this adjustment code for testing, adjusting, or troubleshooting when necessary. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused Mode setting information within screen [1000 rpm SMR]: Time displayed by service meter in which engine speed was above 1,000 rpm [ODO METER FORWARD]: Total forward travel distance [ODO METER REVERSE]: Total reverse travel distance Operating method: When this adjustment code is displayed, its function is effective and the load on the machine, odometer, and reverse odometer are displayed simultaneously. a The data cannot be reset. a After this adjustment code is turned OFF, its function is ineffective.


Adjustment ID: 1005 (Fan 100% mode)

q

a

This adjustment code is used to set the cooling fan speed to about 100% forcibly. It is also used to set the adjustment value of the maximum speed. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

q

Functions of function switches [F3]: Increase adjustment value [FAN 100% SPEED MODE] [F4]: Decrease adjustment value [FAN 100% SPEED MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value

q

Operating method: a When this adjustment code is displayed, its function is effective and the cooling fan speed is controlled to about 100% of the maximum speed. 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) When confirming the adjustment value, press [F6] and check that the alarm buzzer sounds. a After this adjustment code is turned OFF, its function is ineffective but the set adjustment value is effective.

D155A-6


Adjustment ID: 1012 (Steering lever neutral position adjustment)

SEN03202-02

Adjustment ID: 1013 (Steering lever leftmost position adjustment)

This adjustment code is used to make the power train controller recognize the neutral position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.

q

q

Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value

q


q

Operating method: 1) Check that the PCCS lever is in the neutral position of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the neutral position of the potentiometer. It is not used to adjust the steering force.

q

Operating method: 1) Operate the PCCS lever to the left stroke end of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the leftmost position of the potentiometer. It is not used to adjust the steering force.

q

a

D155A-6

a

This adjustment code is used to make the power train controller recognize the leftmost position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.

45

SEN03202-02

Adjustment ID: 1014 (Steering lever rightmost position adjustment)

q

a

q

q

46

This adjustment code is used to make the power train controller recognize the rightmost position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Operating method: 1) Operate the PCCS lever to the right stroke end of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the rightmost position of the potentiometer. It is not used to adjust the steering force.


Adjustment ID: 1015 (Right brake oil pressure offset)

q

a

This adjustment code is used to adjust the right brake oil pressure manually. Use this adjustment code for work when necessary.

q

Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value

q

Information displayed on screen The offset oil pressure is displayed and the adjustment value is increased or decreased by 0.1 kg/cm² (The value displayed on the screen is multiplied by 100). a The default adjustment value is 0 kg/cm². a The adjustment range is -3 – 3 kg/cm².

q

Operating method: 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a If the oil pressure has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to operate the brake during adjustment. After finishing adjustment, however, operate the brake and check that there is not a problem in the actual brake performance. a Even if this adjustment code is turned off, the adjustment is effective.

D155A-6


Adjustment ID: 1016 (Left brake oil pressure offset)

q

a

q

q

q

This adjustment code is used to adjust the left brake oil pressure manually. Use this adjustment code for work when necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Information displayed on screen The offset oil pressure is displayed and the adjustment value is increased or decreased by 0.1 kg/cm² (The value displayed on the screen is multiplied by 100). a The default adjustment value is 0 kg/cm². a The adjustment range is -3 – 3 kg/cm². Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a It is not necessary to operate the brake during adjustment. After finishing adjustment, however, operate the brake and check that there is not a problem in the actual brake performance. a If the oil pressure has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a Even if this adjustment code is turned off, the adjustment is effective.

D155A-6

SEN03202-02

Adjustment ID: 2021 (Power train controller voltage check mode)

q

a

This adjustment code is used to check the constant power supply voltage and switch power supply voltage applied to the power train controller. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

q


q

Information displayed on screen [PT CONTROLLER UNSWITCH POWER]: Constant power supply voltage [PT CONTROLLER ACC POWER]: Switch power supply voltage

q

Operating method: When this adjustment code is displayed, its function is effective and the constant power supply voltage and switch power supply voltage are displayed simultaneously. a After this adjustment code is turned OFF, its function is ineffective.

47

SEN03202-02

Adjustment ID: 6001 (R1 reverse slow set speed)



This adjustment code is used to adjust the engine speed applied to travel at gear speed R1 with the reverse slow mode ON. Use this adjustment code for work when necessary.

q

q


q


q

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

q

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

q

Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a If the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R1 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.

q

Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a If the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R2 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.

q

a

48

a

This adjustment code is used to adjust the engine speed applied to travel at gear speed R2 with the reverse slow mode ON. Use this adjustment code for work when necessary.

D155A-6



q

a

q

q

q

This adjustment code is used to adjust the engine speed applied to travel at gear speed R3 with the reverse slow mode ON. Use this adjustment code for work when necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Information displayed on screen The speed reduced from the high idle speed (2,050 rpm) is displayed and the adjustment value is increased or decreased by 50 rpm (The value displayed on the screen is multiplied by 1/10). a The default adjustment value is 300 rpm (Displayed value: 30). (Default setting: 2,050 – 300 = 1,850 rpm) Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a If the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R3 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.

D155A-6

SEN03202-02

Adjustment ID: 7842 (Transmission clutch IP automatic initial correction)

q

a

This adjustment code is used to make the power train controller recognize the mechanical condition of the transmission. After the power train controller or transmission is replaced, be sure to carry out this adjustment once.

q


q

Conditions for correction work 1) [ENGINE SPEED]: 1,700 – 1,950 rpm 2) [T/C TEMPERATURE]: 65 – 85 °C 3) Parking brake lever: LOCK position a When using this adjustment code, keep t he abo ve c ond iti ons ( In pa rti c ula r, increase the power train oil temperature sufficiently before starting adjustment).

q

Operating method: 1) Start the engine and keep its speed in the specified range of condition with the fuel control dial. 2) Press [F6] and start the correction work and check that [1ST CLUTCH] is displayed newly on the screen. 3) If [END OF TEACHING] is displayed on the screen, press [F6]. If the alarm buzzer sounds at this time, correction work is completed. a The machine does not move during the correction work. a Even if this adjustment code is turned off, the correction is effective.

49

SEN03202-02

Adjustment ID: 7843 (Transmission clutch IP manual initial correction)

q

a

q

This adjustment code is used to carry out correction manually when the correction is not carried out normally by the operation of IP automatic correction (Adjustment ID: 7842). Use this adjustment code after the IP correction work, if necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value a If [F2] is pressed while [F1] is pressed, all the correction values are set to 0.

q

Functions of shift-up and shift-down switches You can select a clutch to be corrected manually with the shift-up and shift-down switches.

q

Conditions for correction work Same as the conditions for IP automatic correction (Adjustment ID: 7842).

q

Operating method: 1) Start the engine and keep its speed in the specified range of condition with the fuel control dial. 2) Select a clutch to be corrected manually with the shift-up or shift-down switches. 3) Increase or decrease the adjustment value by pressing [F3] or [F4]. 4) Press [F6] and check that the alarm buzzer sounds. a The machine does not move during the correction work. a Even if this adjustment code is turned off, the correction is effective.

50


Adjustment ID: 7845 (Transmission clutch IP learning display)

q

a

This adjustment code is used to check the information of correction made by the operation of IP automatic correction (Adjustment ID: 7842) or IP manual correction (Adjustment ID: 7843). Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

q

Functions of function switches [F3]: Change display [F4]: Change display [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused

q

Operating method When this adjustment code is displayed, its function is effective and the correction information is displayed. a After this adjustment code is turned OFF, its function is ineffective.

D155A-6


Adjustment ID: 9995 (Control brake release mode)

SEN03202-02

Adjustment ID: 9996 (Sudden stop prevent valve operation mode)

This adjustment code is used to release the control brake (right and left brake ECMV) to check the operation of the backup brake (brake pedal solenoid valve). Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

q

q


q


q

Operating method When this adjustment code is displayed, its function is effective and the control brake (right and left brake ECMV) is kept released. a After this adjustment code is turned OFF, its function is ineffective.

q

Operating method When this adjustment code is displayed, its function is effective and the sudden stop prevent solenoid valve and right and left brake ECMV are kept stopped. a After this adjustment code is turned OFF, its function is ineffective.

q

a

D155A-6

a

This adjustment code is used to stop the sudden stop prevent solenoid valve and right and left brake ECMV to check the operation of the sudden stop prevent valve. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

51

SEN03202-02

Adjustment ID: 9997 (High idle cut mode)


Adjustment ID: 9998 (Max. gear speed setting mode)

q q

a

q

q

52

This adjustment code is used to limit the high idle speed. Use this adjustment code for work when necessary. Functions of function switches [F3]: Increase adjustment value [HIGH IDLE RPM SET MODE] [F4]: Decrease adjustment value [HIGH IDLE RPM SET MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a When resetting the limitation of the high idle speed, set the adjustment value to the original high idle speed (2,050 rpm). a Even if this adjustment code is turned off, the adjustment is effective.

q

a

This adjustment code is used to limit the maximum transmission gear speed. The limited gear speed is applied in both automatic gearshift mode and manual gearshift mode. Use this adjustment code for work when necessary.

q

Functions of function switches [F3]: Increase adjustment value [MAX SHIFT] [F4]: Decrease adjustment value [MAX SHIFT] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value

q

Operating method 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzzer sounds. a When resetting the limitation of the maximum gear speed, set the adjustment value to the maximum gear speed (3RD). a Even if this adjustment code is turned off, the adjustment is effective.

D155A-6


SEN03202-02

Pm Clinic The machine monitor can check the condition of the machine without connecting testing tools to assist the Pm Clinic and other periodic inspections. 1.

q

2nd screen

q

[F1]: Change screen [F2]: Change screen [F3]: Reset holding [F4]: Hold (displayed data) [F5]: Return to service menu screen

Selecting menu Select "08 PM CLINIC" on the Service menu screen.

q q q q

3. 2.

Information displayed on Pm Clinic screen The Pm Clinic function displays the following information on 2 pages. q 1st screen

D155A-6

Holding displayed information The displayed information can be held and released with [F3] and [F4].

53

SEN03202-02

Cylinder Cut-Out operation The operator can perform Cylinder Cut-Out operation with the machine monitor. Reduced cylinder mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1.

2.


3.

Resetting disabled cylinder When changing a cylinder to be disabled or when reduced cylinder mode operation is finished, select a disabled cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes light blue, the cylinder is reset. a If the machine monitor rests a disabled cylinder but the engine controller cannot reset that disabled cylinder, the background of the cylinder No. becomes red. a The reduced cylinder mode operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to perform the resetting operation after the reduced cylinder mode operation is finished.

4.

Function of holding displayed information If [F4] is pressed during the reduced cylinder mode operation, the displayed information is newly held (c) (The real-time information is kept displayed on the left side). a While the information is held, if [F3] is pressed, the holding function is reset. a The holding function is effective, regardless of setting of the reduced cylinder mode operation.

Selecting menu Select "09 Cylinder Cut-Out" on the "Service Menu" screen.

Selecting cylinder to be disabled After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be disabled with the function switches. q [F1]: Move selection mark (R) to left q [F2]: Move selection mark (R) to right q [F3]: Reset holding q [F4]: Hold q [F5]: Return to service menu screen q [F6]: Confirm selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is disabled. a If the machine monitor disables a cylinder but the engine controller cannot disable that cylinder, the background of the cylinder No. becomes yellow. a One or more cylinders can be disabled.

[Reference] If a normally operating cylinder is disabled, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) q If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command. q

54

D155A-6


SEN03202-02 a

Display of No Injection If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set the No Injection while the engine is stopped. 1.

2.

3.

Limit the cranking time to 20 seconds to protect the starting motor.

Selecting menu Select "10 No Injection" on the "Service Menu" screen.

Displaying check screen If the "No Injection" screen is displayed, the machine monitor asks the operator if no-injection cranking should be performed. Answer with the function switch. q [F5]: Do not perform (Return to Service menu screen) q [F6]: Perform a While the screen is changing to the following screen, the screen of "Communication between controllers is being checked" is displayed.

4.

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

5.

Prohibiting no-injection cranking If the operator tries to perform the no-injection cranking while the engine is running, the message that the engine is running is displayed and the no-injection cranking is not set effective. a This function can be selected even while the engine is running. If the no-injection cranking is performed, however, the message of "Engine is running" is displayed on the screen.

Starting no-injection cranking If no-injection cranking (Fuel injection in no cylinders) becomes effective, that is displayed on the screen. Under this condition, crank the engine with the starting motor. a While the screen is changing to the following screen, the screen of "Setting is being prepared" is displayed.

D155A-6

55

SEN03202-02

Display of Fuel Consumption This function calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicates it. 1.

Selecting menu Select "11 Fuel Consumption" on the "Service Menu" screen.

2.

Starting measurement After the screen of "Fuel Consumption" is displayed, start measurement with the function switches. q [F1]: Start q [F2]: Clear q [F5]: Return to Service menu screen a When the screen of "Fuel Consumption" is displayed, if a data is indicated, it is the data of the previous measurement. This data is not an obstacle to new measurement and can be deleted by pressing [F2]. a If [F1] is pressed, the data is displayed on the starting date and time side and measurement starts. a The display unit of the fuel changes according to the unit set with the initialization (unit setting) function. SI and meter: l/h, inch: gal/h

56


3.

Display and function during measurement Clock mark (a) flashes during measurement. a While the fuel consumption is being measured, the operator can work with the operator mode and other functions. Measurement is not finished until this screen is displayed again and [F1] is pressed (Even if the starting switch is turned OFF, this function is kept effective, although fuel consumption is measured only while the engine is running).

4.

Finishing measurement Press [F1], and measurement is finished and the data are displayed on the finishing date and time side.

5.

Displaying fuel consumption If the measurement is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.

D155A-6


Display of KOMTRAX Settings (Terminal Status) The setting condition and operating condition of KOMTRAX can be checked with "KOMTRAX Settings". Terminal Status is used to check the setting condition of the KOMTRAX terminal. 1.

Selecting menu Select "12 KOMTRAX Settings" on the "Service Menu" screen.

2.

Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "01 Terminal Status" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

3.

Contents of Terminal Status On the "Terminal Status" screen, the following items are displayed. q Terminal Type: Model name of KOMTRAX communication MODEM q KOMTRAX communication: Executing condition of KOMTRAX communication q GMT time: Greenwich Meant Time (+ 9 hours in Japan)

D155A-6

SEN03202-02

q

[F5]: Return to KOMTRAX Settings screen

57

SEN03202-02

Display of KOMTRAX Settings (GPS & Communication Status) The setting condition and operating condition of KOMTRAX can be checked with KOMTRAX Settings. Condition of positioning and communication is used to check the condition of positioning and communication of the KOMTRAX terminal. 1.


2.

Selecting sub menu After the Display of "KOMTRAX Settings" screen is displayed, select "02 GPS & Communication Status" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

58


3.

Contents of display of condition of positioning and communication On the screen of "GPS & Communication Status", the following items are displayed. q Positioning: Positioning condition of GPS q Communication: Communication environment of communication MODEM and connecting condi tion of c ommunication MODEM q Number of message not yet sent: Number of mails in machine monitor not yet sent q [F5]: Return to KOMTRAX Settings screen

D155A-6


SEN03202-02

Display of KOMTRAX Settings The setting condition and operating condition of KOMTRAX can be checked with KOMTRAX Settings. MODEM S/N is used to check the serial No. of the KOMTRAX communication MODEM. 1.


2.

Selecting sub menu After the Display of "KOMTRAX Settings" screen is displayed, select "03 Modem S/N" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

3.

Contents of display of MODEM S/N The serial No. of KOMTRAX communication MODEM is displayed. q [F5]: Return to KOMTRAX Settings screen

D155A-6

59

SEN03202-02

Display of Service Message Special messages for the serviceman sent from the KOMTRAX base station (a distributor, etc.) can be checked with this function. If there is setting in a message, a return mail can be sent by using numeral input switches. 1.

Operation to display menu Select "13 Service Message" on the "Service Menu" screen.

2.

Display of message (Read-only) If there is a message, its contents are displayed. If there is not a message, "No message" is displayed. q [F5]: Return to service menu screen a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.

3.

Display of message (with return mail function) If a box to enter a value with the numeral keys is displayed under the message, enter a proper number with the numeral input switches and function switches and confirm it, and the information is returned to the KOMTRAX base station. q [F5]: Return to service menu screen

60


q

a a

[F6]: Confirm and return input value This message is different from a message transmitted to the operator in the operator mode. Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.

D155A-6


D155A-6

SEN03202-02

61

SEN03202-02




62

D155A-6

SEN03203-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Testing and adjusting, Part 4 Handling of power supply circuit of engine controller...................................................................................... 2 Preparation work for troubleshooting of electrical system .............................................................................. 3 Pm Clinic......................................................................................................................................................... 5

D155A-6

1

SEN03203-00


Handling of power supply circuit of engine controller 1 1.

Before disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF.

2.

If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.

2

D155A-6


Preparation work for troubleshooting of electrical system

SEN03203-00

2.

1

a

When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller, power train controller, or work equipment controller, expose the related connectors according to the following procedure.

1.

Machine monitor 1) Remove the 4 mounting bolts each from covers (1) and (2) and remove those covers. 2) Remove the 4 mounting bolts each from covers (3) and (4) and remove those covers together with the foot rest. a The 2 bolts on the front window side of the foot rest are used as the cover mounting bolts, too. 3) Remove the 4 mounting bolts of machine monitor (5) and pull out machine monitor (5) and switch cover together toward the operator's seat.

4)

D155A-6

Engine controller 1) Open the left engine side cover and left mudguard. 2) Remove the mounting bolts and cover (6).

3)

Insert or connect troubleshooting T-adapters in or to connectors EGC1, EGC2, and EGC3 of engine controller (7). a Since connectors EGC1 and EGC2 are fixed with screws, loosen those screws before disconnecting. a When returning connectors EGC1 and EGC2, tighten the screws to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and CM03 of machine monitor (5). a AT11 is for the GPS antenna. a If a camera is installed, CM05 is also wired.

3

SEN03203-00

3.

4


Power train controller 1) Remove the inside lower cover of the left console. 2) Insert or connect troubleshooting T-adapters in or to connectors STC1, STC2, and STC3 of power train controller (8). a Since the connectors are fixed with screws, loosen those screws before disconnecting. a When returning the connectors, tighten the screws to the specified torque. 3 Screw: 2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}

D155A-6


SEN03203-00

Pm Clinic

1

Machine model

Serial No.

Service meter

D155A-6

h

User's name

Date of execution /

Inspector

/

Specifications Blade

Rear attachment

T blade T Semi-U blade T Full-U blade T

T Multi-shank ripper T Variable giant ripper T Counterweight ( T

Shoe width

T 560 mm T 610 mm T 660 mm T 710 mm

kg)

T

Working condition Construction

Quarry/Mining T Coal T Gold T Limestone

T Construction/Civil engineering T Road T Tunnel T

T

) Contents of work T Dozing T Side cutting T Ripping T Travel

Type of soil (Specific gravity: T Rock T Gravel T Sand T Clay

% % % %

Check of oil and coolant levels

T Engine coolant level T Engine oil level T Hydraulic oil level

When necessary T Damper case oil level T Power train oil level


Power train oil temperature

Max. range: Max. range: Following figure (Left) Following figure (Right) Operator's opinion

T Final drive oil level T

Ambient temperature Max.

°C/Min.

Altitude

°C

m

Result of visual inspection

Fault history of mechanical system

Fault history of electrical system

AA10NX

times/1st time

h/last

h

times/1st time

h/last

h

AB00MA

times/1st time

h/last

h

times/1st time

h/last

h

B@BAZG

times/1st time

h/last

h

times/1st time

h/last

h

B@BCNS

times/1st time

h/last

h

times/1st time

h/last

h

B@BCZK

times/1st time

h/last

h

times/1st time

h/last

h

B@CENS

times/1st time

h/last

h

times/1st time

h/last

h

B@HANS

times/1st time

h/last

h

times/1st time

h/last

h

CA234

times/1st time

h/last

h

times/1st time

h/last

h

D155A-6

5

SEN03203-00


Check positions/Method 1

6

D155A-6


SEN03203-00


D155A-6

7

SEN03203-00



8

D155A-6


SEN03203-00

Pm Clinic check sheet Machine model

Serial No.

Service meter

User's name

Date of execution

Inspector

D155A-6

Unit

Low idling

Engine

Without deceleration High (Adjustment: 0007) Engine speed idle Normal (Deceleration) Decelerator pedal

Boost pressure Exhaust temperature

2.

Service limit value

740 – 780

740 – 780

rpm

F3 stall

1,615 – 1,715

1,450

F3 stall + Ripper raise relieve

1,580 – 1,680

1,395

Min. 85 {Min. 640}

72 {540}

—

—

670

720

Max. 2.94 {Max. 300}

3.92 {400}

Min. 034 {Min. 3.5}

0.21 {2.1}

Min. 010 {Min. 1.0}

0.08 {0.8}


Service limit value

—

—

kPa {mmHg}

Ambient temperature F3 stall

°C kPa {mmH2O}

High idle Low idle

—

—

—

—

1,825 – 1,925 1,825 – 1,925 850 – 900

F3 stall

Measurement result

2,050 – 2,100 2,050 – 2,100

850 – 900

Blow-by presF3 stall sure Engine oil pressure


Rejected


Rejected

Item

Accepted

Engine

Accepted

1.

MPa {kg/cm²}

Cooling fan Item


Unit

Low idle Fan

Speed

Circuit pressure

D155A-6

Adjustment: High idle 1005 High idle

Measurement result

rpm 1,045 – 1,155 1,045 – 1,155 MPa {kg/cm²}

9

SEN03203-00

Transmission

Item

Max. 1.0 {Max. 10.0}

Max. 1.0 {Max. 10.0}

0.05 – 0.29 {0.5 – 3.0}

0.05 – 0.29 {0.5 – 3.0}

0.29 – 0.69 {3.0 – 7.0}

0.29 – 0.69 {3.0 – 7.0}


Service limit value

Low idle

2.81 – 3.11 {28.7 – 31.7}

Min. 2.62 {Min. 26.7}

High idle

3.04 – 3.33 {31.0 – 34.0}

Min. 2.84 {Min. 29.0}

2.55 – 2.94 {26.0 – 30.0}

Min. 2.35 {Min. 24.0}

2.60 – 2.99 {26.5 – 30.5}

Min. 2.40 {Min. 24.5}

Monitoring: 32601 High idle Low idle Monitoring: 32603 High idle


Unit

Gear speed: P/N

F clutch pressure

Gear speed: F3 Brake: Applied

Low idle

R clutch pressure

Gear speed: R3 Brake: Applied

Low idle

1st clutch pressure


Low idle

2.81 – 3.11 {28.7 – 31.7}

Min. 2.62 {Min. 26.7}

2nd clutch pressure


Low idle

2.60 – 2.89 {26.5 – 29.5}

Min. 2.40 {Min. 24.5}

3rd clutch pressure


Low idle

2.81 – 3.11 {28.7 – 31.7}

Min. 2.62 {Min. 26.7}


Service limit value

Low idle

2.46 – 3.04 {25.0 – 31.0}

2.16 {22.0}

High idle

2.46 – 3.04 {25.0 – 31.0}

2.16 {22.0}

Low idle

2.46 – 3.04 {25.0 – 31.0}

2.16 {22.0}

High idle

2.46 – 3.04 {25.0 – 31.0}

2.16 {22.0}


Right brake pressure

Gear speed: N Brake: Released

Left brake pressure

Gear speed: N Brake: Released

Brake F2 stall, high idle performance

MPa {kg/cm²}

Unit

MPa {kg/cm²}

2.3 – 2.6 {23.5 – 26.5}

2.3 – 2.6 {23.5 – 26.5}

2.3 – 2.6 {23.5 – 26.5}

Low idle

2.3 – 2.6 {23.5 – 26.5}

2.3 – 2.6 {23.5 – 26.5}

High idle

2.3 – 2.6 {23.5 – 26.5}

2.3 – 2.6 {23.5 – 26.5}

Low idle Gear speed: N PCCS lever: Right stroke end High idle

Left clutch pressure

Gear speed: N PCCS lever: Left stroke end

Measurement result

Measurement result

Machine must not move. 2.3 – 2.6 {23.5 – 26.5}

Right clutch pressure Clutch

10

MPa {kg/cm²}

Rejected

0.05 – 0.49 {0.5 – 5.0}

Main relief pressure

Item

Brake

0.05 – 0.49 {0.5 – 5.0}

Low idle

Measurement result

Rejected

Outlet pressure

Service limit value

Unit

Rejected

Inlet pressure



Accepted

Torque converter

Item

Accepted

Power train oil pressure k Measure each transmission clutch pressure only while the engine is running at low speed for safety.

Accepted

3.


D155A-6


Work equipment/HSS oil pressure

Item

Work equipment control lever: All levers in neutral

Work equipment relief pressure

Cylinder stroke Work equip- end relief ment LS relief pressure Control circuit basic pressure

Work equipment control lever: All levers in neutral

2.45 – 3.82 {25 – 39}

2.45 – 3.82 {25 – 39}

High idle

26.0 – 29.0 {265 – 295}

26.0 – 29.0 {265 – 295}

High idle

24.0 – 26.0 {245 – 265}

24.0 – 26.0 {245 – 265}

High idle

3.97 – 4.46 {40.5 – 45.5}

3.78 – 4.46 {38.5 – 45.5}


Service limit value

3.0 – 4.0

3.0 – 4.0

1.8 – 2.8

3.1

2.5 – 3.5

4.0

4.5 – 5.5

6.2

Unit


Service limit value

°C

—

—

mm

Max. 150

200

mm

Max. 50

70

Unit


Service limit value

MPa {kg/cm²}

Ripper lower

High idle

Ripper tilt in

High idle

sec

Rejected

High idle

Measurement result

Rejected

Blade left tilt

Measurement result

Accepted

High idle

Unit

Accepted



Blade raise

—

—

Hydraulic drift of work equipment

Hydraulic drift

Item


Hydraulic oil temperature Hydraulic drift of blade lift

Engine: Stopped Blade lift: 15 minutes Ripper lift: 5 minutes

Hydraulic drift of ripper lift

Final drive Item

FD

Final drive

D155A-6


Engine: Stopped

—

Measurement result

Rejected

7.

High idle

Measurement result

Work equipment speed Item

6.

Service limit value

Unit

Accepted

5.

Unload pressure



Rejected

Work equipment oil pressure Accepted

4.

SEN03203-00

There must not abnormally much metal dust.

11

SEN03203-00

8.

Repair record (Must be filled in) Date

12


Service meter

Repair record

Date

Service meter

/

/

h

/

/

h

/

/

h

/

/

h

/

/

h

/

/

h

/

/

h

/

/

h

/

/

h

/

/

h

Repair record

D155A-6


SEN03203-00

Pm Clinic undercarriage check sheet Machine model

Serial No.

Service meter

User's name

Date of execution

Inspector

D155A-6

1.

Bushing temperature Item


Measurement result

Accepted Rejected

Under- Bushing Measure just Left side of machine carriage temperature after work. Right side of machine

Left side of machine

a

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

Right side of machine

a

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

D155A-6

13

Item


Unit

Undercarriage

Left side of machine

Opening of track link

Measure dimension (a).

Clearance limit

Pin No.

Measurement result

Rejected


Accepted

SEN03203-00

1.4 (Each side)

mm

Right side of machine

1.4 (Each side)

Opening of track link (a)

14

D155A-6


D155A-6

SEN03203-00

15

SEN03203-00




16

D155A-6

SEN03204-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up

40 Troubleshooting

1

Failure code table and fuse locations Failure codes table.......................................................................................................................................... 2 Fuse locations................................................................................................................................................. 8

D155A-6

1

SEN03204-01

40 Troubleshooting

Failure codes table

1

Action code

Failure code

E03

1500L0

Transmission clutch: Abnormal

E03

15SAL1

Forward clutch: Fill high

E03

15SALH

Forward clutch: Fill Low

E03

15SBL1

Reverse clutch: Fill high

E03

15SBLH

Reverse clutch: Fill Low

E03

15SEL1

Speed 1st clutch: Fill high

E03

15SELH

Speed 1st clutch: Fill Low

E03

15SFL1

Speed 2nd clutch: Fill high

E03

15SFLH

Speed 2nd clutch: Fill Low

E03

15SGL1

Speed 3rd clutch: Fill high

E03

15SGLH

Speed 3rd clutch: Fill Low

E04

2201L1


E04

2201LH


E04

2202L1


E04

2202LH


–

2300KM

Stall in 1st gear speed

E04

2301L1

Right brake: Fill high

E04

2301LH

Right brake: Fill low

E04

2302L1

Left brake: Fill high

E04

2302LH

Left brake: Fill low

–

7RFAKA

ECM HOLD RELAY: Disconnection

–

AA10NX

Air Cleaner Clogging

–

AB00MA

Battery Charge Abnormal

–

B@BAZG Eng Oil Press Low

–

B@BCNS Eng Water Overheat

–

B@BCZK Eng Water Level Low

–

B@CENS T/C Oil Overheat

–

B@HANS Hyd Oil Overheat


E04

CA111

EMC Critical Internal Failure

E04

CA115

Eng Ne and Bkup Speed Sens Error

2

Component Category of in charge history Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Mechanical MON system Mechanical MON system Mechanical ENG system Mechanical ENG system Mechanical MON system Mechanical P/T system Mechanical MON system Electrical ENG system Electrical ENG system

Reference manual

Troubleshooting by failure code, Part 1 SEN03206-00

D155A-6

40 Troubleshooting

SEN03204-01

Action code

Failure code

E03

CA122

Chg (boost) Air Press Sensor High Error

E03

CA123

Chg (boost) Air Press Sensor Low Error

E03

CA131

Throttle Sensor High Error

E03

CA132

Throttle Sensor Low Error

E02

CA135

Eng Oil Press Sensor High Error

E02

CA141

Eng Oil Press Sensor Low Error

E02

CA144

Coolant Temp Sens High Error

E02

CA145

Coolant Temp Sens Low Error

E01

CA153

Chg (boost) Air Temp Sensor High Error

E01

CA154

Chg (boost) Air Temp Sensor Low Error

E03

CA187


E03

CA221

Ambient Press Sens High Error

E03

CA222

Ambient Press Sens Low Error

E03

CA227


–

CA234

Eng Overspeed

E03

CA238

Ne Speed Sens Supply Volt Error

E01

CA263

Fuel Temp Sensor High Error

E01

CA265

Fuel Temp Sensor Low Error

E03

CA271

PCV1 Short Error

E03

CA272

PCV1 Open Error

E03

CA273

PCV2 Short Error

E03

CA274

PCV2 Open Error

E03

CA322


E03

CA323


E03

CA324


E03

CA325


E03

CA331


E03

CA332


E04

CA342

Calibration Code Incompatibility

E03

CA351

Injectors Drive Circuit Error

E03

CA352


D155A-6


Component Category of in charge history Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system

Reference manual



3

SEN03204-01

40 Troubleshooting

Action code

Failure code

E03

CA386


E04

CA441

Battery Voltage Low Error

E04

CA442

Battery Voltage High Error

E03

CA449

Rail Press Very High Error

E03

CA451

Rail Press Sensor High Error

E03

CA452

Rail Press Sensor Low Error

E02

CA553

Rail Press High Error

E03

CA554

Rail Press Sensor In Range Error

E02

CA559

Rail Press Low Error

E03

CA689

Eng Ne Speed Sensor Error

E03

CA731

Eng Bkup Speed Sens Phase Error

E04

CA757

All Continuous Data Lost Error

E03

CA778

Eng Bkup Speed Sensor Error

E03

CA1633

KOMNET Datalink Timeout Error

E03

CA2185

Throt Sens Sup Volt High Error

E03

CA2186

Throt Sens Sup Volt Low Error

E03

CA2249

Rail Press Very Low Error

E01

CA2555

Grid Htr Relay Volt Low Error

E01

CA2256

Grid Htr Relay Volt High Error

–

D110KA

Battery relay: Disconnection

–

D110KB

Battery Relay: Drive Short Circuit

E02

D130KA

Neutral relay: Disconnection

E02

D130KB

Neutral relay: Short circuit

E01

D161KA

Back-up alarm relay: Disconnection

E01

D161KB

Back-up alarm relay: Short circuit

–

D190KA

ACC signal relay: Disconnection

–

D190KB

ACC signal relay: Short circuit

E03

D5ZKKX

Throttle Dial: Out of normal range

E03

DAFRKR CAN Disconnection (Monitor)

E03

DB2RKR

CAN Disconnection (Engine controller)

E03

DB90KR

PT controller: Can communication lost

4


Component Category of in charge history Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical MON system Electrical ENG system Electrical P/T system

Reference manual



D155A-6

40 Troubleshooting

SEN03204-01

Action code

Failure code

E03

DBE0KK


E01

DBE0KT

PT controller: Abnormality in controller

E02

DBE6KK


E02

DBE7KK


E04

DBE9KQ

PT controller: Type select signal

E02

DD12KA

Shift up Sw: Disconnection

E02

DD12KB

Shift up Sw: Short circuit

E02

DD13KA

Shift down Sw: Disconnection

E02

DD13KB

Shift down Sw: Short circuit

E03

DD14KA

Parking lever Sw: Disconnection

E03

DD14KB

Parking lever Sw: Short circuit

E02

DDDDKA Back up brake Sw: Disconnection

E02

DDDDKB Back up brake Sw: Short circuit

E02

DDDDKX Back up brake Sw: Signal mismatch

E01

DGT1KA

T/C oil temp sensor: Abnormal

E01

DGT1KX

T/C oil temp sensor abnormal

–

DH21KA

Weq pressure sensor: Disconnection

–

DH21KB

Weq pressure sensor: Short circuit

E03

DK10KX

Fuel control Dial: Out of normal range

E03

DK30KA


E03

DK30KB


E04

DK30KX

ST lever 1: Out of normal range

E04

DK30KZ

ST lever: Disconnection or short circuit

E03

DK30L8

ST lever: Signal mismatch

E03

DK31KA


E03

DK31KB


E03

DK40KA

Brake potentiometer: Disconnection

E03

DK40KB

Brake potentiometer: Short circuit

E04

DK55KX

FR lever: Out of normal range

E04

DK55KZ

FR lever: Disconnection or short circuit

E03

DK55L8

FR lever: Signal mismatch

D155A-6


Component Category of in charge history Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system

Reference manual


5

SEN03204-01

40 Troubleshooting

Action code

Failure code

E03

DK56KA


E03

DK56KB


E03

DK57KA


E03

DK57KB


E03

DKH1KA

Pitch angle sensor: Disconnection

E03

DKH1KB

Pitch angle sensor: Short circuit

E01

DLT3KA

T/M out-speed sensor: Disconnection

E01

DLT3KB

T/M out-speed sensor: Abnormal

E01

DW7BKA Fan rev EPC: Disconnection

E01

DW7BKB Fan rev EPC: Short circuit

E04

DWN3KA Ssp solenoid: Disconnection

E04

DWN3KB Ssp solenoid: Short circuit

E04

DWN3KY Ssp solenoid: Short circuit

E01

DWN5KA Fan pump solenoid: Disconnection

E01

DWN5KB Fan pump solenoid: Short circuit

E03

DXH4KA

1st clutch ECMV: Disconnection

E03

DXH4KB


E03

DXH4KY


E03

DXH5KA

2nd clutch ECMV: Disconnection

E03

DXH5KB


E03

DXH5KY


E03

DXH6KA

3rd clutch ECMV: Disconnection

E03

DXH6KB


E03

DXH6KY


E03

DXH7KA

R clutch ECMV: Disconnection

E03

DXH7KB


E04

DXH7KY


E03

DXH8KA

F clutch ECMV: Disconnection

E03

DXH8KB


E04

DXH8KY


E03

DXH9KA

Right clutch ECMV: Disconnection

6


Component Category of in charge history Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical W/E system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system

Reference manual Troubleshooting by failure code, Part 3 SEN03208-00


D155A-6

40 Troubleshooting

SEN03204-01

Action code

Failure code

E03

DXH9KB

Right clutch ECMV: Short circuit

E04

DXH9KY

Right clutch ECMV: Hot short

E03

DXHAKA Left clutch ECMV: Disconnection

E03

DXHAKB Left clutch ECMV: Short circuit

E04

DXHAKY

E04

DXHBKA Right brake ECMV: Disconnection

E04

DXHBKB Right brake ECMV: Short circuit

E04

DXHBKY

E04

DXHCKA Left brake ECMV: Disconnection

E04

DXHCKB Left brake ECMV: Short circuit

E04

DXHCKY


E03

DXJ4KA

Weq lock Sol.: Disconnection

E03

DXJ4KB

Weq lock Sol.: Short circuit

a a

a

a


Left clutch ECMV: Hot short


Component Category of in charge history Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system Electrical P/T system

Reference manual


Entry order of items in table The items are entered in the order of their failure codes (incremental order). Action code Attached: If the failure code is detected, the action code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the fault. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the fault. Component in charge MON: The machine monitor is in charge of detection of fault. ENG: The engine controller is in charge of detection of fault. P/T: The power train controller is in charge of detection of fault. Category of record Mechanical equipment system: Fault information is recorded in the "Mechanical Systems". Electrical equipment system: Fault information is recorded in the "Electrical Systems" .

D155A-6

7

SEN03204-01

40 Troubleshooting

Fuse locations

1

Connection table of circuit breakers and fuse boxes a This connection table shows the devices to which each power supply of the fuse box supplies power (An accessory power supply is a device which supplies power while the starting switch is in the ON position and an unswitched power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers and fuses to see if the power is supplied normally. Circuit breakers CB1 – CB9 Power circuit breaker Circuit (Type of power supply) breaker No.

CB105 (Accessory power supply)

CB30 (Unswitched power supply)

Circuit breaker capacity

CB9

20A

CB1

20A

CB2

20A

CB3

20A

Destination of power Optional power supply Power train controller Emergency power supply (For power train switch box) Work equipment controller Emergency power supply (For work equipment switch box) Air conditioner unit, blower motor, and compressor electromagnetic clutch

CB4

20A

Headlamp, additional headlamp

CB5

20A

Rear lamp, additional rear lamp, ripper point lamp

CB6

20A

CB7

20A

Starting switch Engine hold relay Machine monitor Power train controller Work equipment controller

CB8

30A

—

—

Power circuit breaker (Type of power supply)

Fuse No.

Fuel capacity


1

20A

Operator's cab power supply (To connection table of fuse box

2

5A

Backup alarm, backup alarm relay

3

20A


)

4

20A


)

5

5A

Engine controller (Signal ACC)

CB105H (Unswitched power supply)

Engine controller, Electric priming pump Engine electrical intake air heater

Fuse box FS1

CB105 (Accessory power supply) Starting switch (ACC)

8

Destination of power

)

D155A-6

40 Troubleshooting

SEN03204-01

Fuse box FS2 Power circuit breaker (Type of power supply)

Fuse No.

Fuel capacity


1

5A

Pedal brake solenoid valve

2

5A



Starting switch (ACC)

D155A-6


Engine electrical intake air heater 3

20A

Ripper pin puller solenoid valve

4

5A

Horn

5

20A

Optional power supply

Pneumatic suspension seat

9

SEN03204-01

40 Troubleshooting

Locations of circuit breakers CB30, CB105, and CB105H (In battery room)

Locations of circuit breakers CB1 – CB9 and fuse boxes FS1 and FS2 (In battery room)

10

D155A-6

40 Troubleshooting

SEN03204-01

Fuse box Power circuit fuse (Type of power supply) FS1-1 (Unswitched power supply) FS1-3 (Accessory power supply)

Fuse No.

Fuel capacity

Destination of power Radio

1

10A

12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter)

2

20A

3

20A

Additional light relay, additional light Rotary lamp 12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter) Radio

FS1-4 (Accessory power supply)

Location of fuse box

D155A-6

Room lamp

4

20A

5

10A

Front wiper, rear wiper

6

10A

Left wiper, right wiper

Cigarette lighter Windshield wiper (Via intermittent relay)

(In operator's cab)

11

SEN03204-01

40 Troubleshooting



12

D155A-6

SEN03205-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up

40 Troubleshooting

1

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

D155A-6

1

SEN03205-01

40 Troubleshooting

Points to remember when troubleshooting k k k k k k

1

Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

2.

3.

2

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.

4) 5)

Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered to be necessary.

4.

Confirming failure q Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.

5.

Troubleshooting q Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information.

6.

Measures to remove root cause of failure q Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

D155A-6

40 Troubleshooting

SEN03205-01

Sequence of events in troubleshooting

1

D155A-6

3

SEN03205-01

40 Troubleshooting

Check before troubleshooting Item 1. Check of level and type of fuel 2. Check of fuel for foreign matter

Lubricating oil/Coolant

Hydraulic/ Mechanical equipment

4

Criterion

Remedy

—

Add fuel

—

Clean and drain

3. Check of hydraulic oil level

Between H – L

Add oil

4. Check of damper case oil level

Between H – L

Add oil

5. Check of power train oil level

Between H – L

Add oil

6. Check of level and type of engine oil (in oil pan)

Between H – L

Add oil

7. Check of coolant level (in sub tank)

Between FULL - LOW

Add coolant

8. Check of dust indicator for clogging

Out of red range

Clean or replace

9. Check of brake pedal stroke

—

Adjust

1. Check for abnormal noise/smell

—

Repair

2. Check for oil leakage

—

Repair

3. Bleeding air

—

Bleed air

1. Check of battery terminals and wiring for looseness and corrosion

—

Retighten or replace

2. Check of alternator terminals and wiring for looseness and corrosion

—


3. Check of starting motor terminals and wiring for looseness and corrosion

—


4. Check of battery voltage (with engine stopped)

20 – 30 V

Charge or replace

Between H – L

Add or replace

6. Check of wires for discoloration, burn, and removal of cover

—

Repair or replace

7. Check for released wire clamp and drooping wire

—

Repair

8. Check of wires for wetness (Check connectors and terminals for wetness, in particular)

—

Dry

9. Check circuit breaker for turning OFF and fuse for disconnection and corrosion

—

Replace

10. Check of alternator voltage (while engine speed is at middle or higher)

After operating for several minutes: 27.5 – 29.5 V

Replace

11. Check of battery relay for operating sound (when starting switch is turned ON or OFF)

—

Replace

5. Check of electrolyte level Electrical equipment

1

D155A-6

40 Troubleshooting

SEN03205-01

Classification and procedures for troubleshooting

1

Classification for troubleshooting Type Display of code

Contents Troubleshooting by failure code

E mode

Troubleshooting for electrical system

H mode

Troubleshooting for hydraulic and mechanical system

S mode

Troubleshooting for engine

Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1.

Procedure for troubleshooting to be taken when action code and failure code are displayed on machine monitor: If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting for the corresponding "Display of code" according to the displayed failure code.

2.

When electrical system failure code or mechanical system failure code is recorded in fault history: If a action code and a failure code are not displayed on the machine monitor, check for a mechanical system failure code and an electrical system failure code with the fault history function of the machine monitor. If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" according to that code. a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is still detected. a A failure code of the mechanical system cannot be deleted. a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history function, carry out the corresponding troubleshooting in "E mode".

3.

When action code or failure code is not displayed and no failure code is recorded in fault history: If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".

D155A-6

5

SEN03205-01

40 Troubleshooting

Phenomena looking like troubles and troubleshooting Nos. Troubleshooting No.

Phenomena looking like troubles

Display of code

E mode

H mode

S mode

Phenomena related to action code/failure code 1 Action code and failure code are displayed on machine monitor 2

When fault history is checked, failure code is displayed in mechanical system fault history

3

When fault history is checked, failure code is displayed in electrical system fault history

4

When fault history is checked, failure code is displayed in air conditioner or heater fault history

According to displayed code

Phenomena related to engine 5 Starting performance of engine is poor 6 Engine does not start

S-1 E-3

S-2

7 Engine does not pick up smoothly

S-3

8 Engine stops during operation

S-4

9 Engine does not rotate smoothly

S-5

10 Engine lack output (or lacks power)

S-6

11 Exhaust gas is black (incomplete combustion)

S-7

12 Oil consumption is excessive (or exhaust gas is blue)

S-8

13 Oil becomes dirty quickly

S-9

14 Fuel consumption is excessive

S-10

15 Oil is in coolant (or coolant spurts back or coolant level goes down)

S-11

16 Oil pressure drops

S-12

17 Oil level rises (Entry of coolant or fuel)

S-13

18 Coolant temperature becomes too high (Overheating)

S-14

19 Abnormal noise is made

S-15

20 Vibration is excessive

S-16

21 Air cannot be bled from fuel circuit

S-17

22 Preheater does not operate

E-4 Phenomena related to power train

23 Power is low (Drawbar pull is low)

H-1

24 Machine does not travel (at 2nd or 3rd gear speed)

H-2

25 Machine does not start at any gear speed

H-3

26 Machine can travel only forward or in reverse

H-4

27 When gear speed or travel direction is changed, time lag is large

H-5

28 Steering is not possible

H-6

29 Steering is possible only on one side

H-7

30 Steering overrun occurs

H-8

31 Brake does not work

H-9

32 Power train oil is overheated

H-10 Phenomena related to work equipment

33 Speed of all work equipment is low

H-11

34 No work equipment moves

H-12

35 Blade lift speed or power is low

H-13

6

D155A-6

40 Troubleshooting

SEN03205-01

Troubleshooting No.

Phenomena looking like troubles

Display of code

E mode

H mode

36 Blade tilt speed or power is low

H-14

37 Ripper lift speed or power is low

H-15

38 Ripper tilt speed or power is low

H-16

39 Hydraulic drift of blade lift is large

H-17

40 Hydraulic drift of blade tilt is large

H-18

41 Hydraulic drift of ripper lift is large

H-19

42 Ripper pin puller cylinder does not operate

E-22

43 Abnormal sound comes out from around work equipment pump 44

S mode

H-20 H-21

Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats)

H-22

Phenomena related to machine monitor 45 When starting switch turned ON, machine monitor displays nothing 46

When starting switch turned ON (before startingengine), basic check item lights up

E-1 E-2

47 Precaution item lights up while engine is running

E-5

48 Emergency stop item lights up while engine is running

E-6

49 Engine coolant temperature gauge does not indicate normally

E-7

50 Fuel level gauge does not indicate normally

E-8

Power train oil temperature gauge (multi-gauge) does not indicate normally

E-9

52 Hydraulic temperature gauge (multi-gauge) does not indicate normally

E-10

51

53

Contents of display by machine monitor are different from applicable machine

E-11

54 Machine monitor does not display some items

E-12

55 Function switch does not work

E-13

56 Operation mode does not change

E-14

57 Gearshift mode does not change

E-15

58 Customize function does not operate normally

E-16

59 Customize memory function does not normally

E-17

60 Alarm buzzer cannot be stopped

E-18

61

Air conditioner does not operate normally (including air conditioner fault history)

E-19

62 When starting switch is turned OFF, service meter is not displayed

E-20

63 Machine monitor cannot be set in service mode

E-21

64 Ripper pin puller cylinder does not operate

E-22

65 Backup alarm does not sound or does not stop

E-23

66 Headlamp, rear lamp, and ripper point lamp do not light up

E-24

67 Windshield wiper and window washer do not operate

E-25

68 Fan does not reverse

E-27

69 Gear cannot be shifted

E-28 Other phenomena

70 KOMTRAX terminal does not operate normally

E-26

71 Electric priming pump does not operate or does not stop automatically

E-29

D155A-6

7

SEN03205-01

40 Troubleshooting

Information in troubleshooting table

1

a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Action code

Failure code

Display on Display on machine machine monimonitor tor Contents of trouble

Trouble

Trouble name displayed in fault history of machine monitor

Contents of trouble detected by machine monitor or controller

Action of Action taken by machine monitor or controller to protect system or devices when they detect machine monitrouble tor or controller Problem that appears on machine

Problem that appears on machine as result of action taken by machine monitor or controller (shown above)

Related information

Information related to detected trouble or troubleshooting

Cause

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment

1

2 Possible causes and standard value in normal state

8

• Disconnection Connector is connected defectively or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.

Possible causes of trouble (Given numbers are refer ence numbers, which do not (1) Method of indicating connector No. and handling of Tindicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of "male" and "female", 3 disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 4 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.

D155A-6

40 Troubleshooting

SEN03205-01

Related circuit diagram

This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (i o): Roughly shows the location on the machine.

D155A-6

9

SEN03205-01

Connection table for connector pin numbers a

10

40 Troubleshooting

(Rev. 2007.10) 1

The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

11

SEN03205-01

12

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

13

SEN03205-01

14

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

15

SEN03205-01

16

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

17

SEN03205-01

18

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

19

SEN03205-01

20

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

21

SEN03205-01

22

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

23

SEN03205-01

24

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

25

SEN03205-01

26

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

27

SEN03205-01

28

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

29

SEN03205-01

30

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

31

SEN03205-01

32

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

33

SEN03205-01

34

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

35

SEN03205-01

36

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

37

SEN03205-01

38

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

39

SEN03205-01

40

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

41

SEN03205-01

42

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

43

SEN03205-01

44

40 Troubleshooting

D155A-6

40 Troubleshooting

D155A-6

SEN03205-01

45

SEN03205-01

40 Troubleshooting

T-branch box and T-branch adapter table a

(Rev. 2008.02) 1

q

q

q q

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.

q

799-601-2600 T-box (for ECONO)

21

799-601-3100 T-box (for MS)

37

q

799-601-3200 T-box (for MS)

37

q q

799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)

24

MS-24P

q

799-601-3420 Adapter for BENDIX (MS)

24

MS-24P

q


17

MS-17P

q


17

MS-17P

q


5

MS-5P

q


10

MS-10P

q


5

MS-5S

q


17

MS-17P

q


19

MS-19P

q


14

MS-14P

q

799-601-2710 Adapter for MIC

5

MIC-5P

q q


13

MIC-13P

q q


17

MIC-17P

q q q


21

MIC-21P

q q q


9

MIC-9P

799-601-2750 Adapter for ECONO

2

ECONO2P

q q


3

ECONO3P

q q


4

ECONO4P

q q


8

ECONO8P

q q


12 ECONO12P q q

q

799-601-3470 Case

799-601-2810 Adapter for DLI

8

DLI-8P

q q


12

DLI-12P

q q


16

DLI-16P

q q

799-601-2840 Extension cable (ECONO type)

12 ECONO12P q q

q q q

q

q q

q

q q q

q

q

q

799-601-2850 Case 799-601-4350 T-box (for DRC60, ECONO)

q

q

60

q

799-601-4360 Case q

q

X2P

q q q

q

3

X3P

q q q

q

4

X4P

q q q

q

799-601-7050 Adapter for SWP

6

SW6P

q q q


8

SW8P

q q q


12

SW12P


14

SW14P


16

SW16P

799-601-7010 Adapter for X (T-adapter)

1

799-601-7020 Adapter for X

2

799-601-7030 Adapter for X 799-601-7040 Adapter for X

q q

q q

799-601-7080 Adapter for M (T-adapter)

1

—

q

q

799-601-7090 Adapter for M

2

M2P

q q q

q


3

M3P

q q q

q

46

D155A-6

40 Troubleshooting

SEN03205-01

q q q

q q

Out of kit

S8P

799-601-4201

8

799-601-4101

799-601-7140 Adapter for S

799-601-9300

q

799-601-9200

q q q

M8P

799-601-9100

M6P

8

799-601-9000

6


799-601-8000


799-601-7500

q

799-601-7400

q q q

799-601-7100

M4P

799-601-7000

4

799-601-2800


Part name

799-601-2700


Part No.

799-601-2500

Number of pins

T-adapter kit

q

799-601-7150 Adapter for S (White)

10

S10P

q q q

799-601-7160 Adapter for S (Blue)

12

S12P

q q q q q q

q

799-601-7170 Adapter for S (Blue)

16

S16P


16

S16PW


12

S12PW

799-601-7180 Adapter for AMP040

8

A8P

q


12

A12P

q

q


16

A16P

q q q

q


20

A20P

q q q

q

799-601-7230 Short connector for X

2

—

q q q

q

q q

q q

799-601-7240 Case

q

799-601-7270 Case 799-601-7510 Adapter for 070

10

07-10

q

799-601-7520 Adapter for 070

12

07-12

q

799-601-7530 Adapter for 070

14

07-14

q

799-601-7540 Adapter for 070

18

07-18

q

799-601-7550 Adapter for 070

20

07-20

q

799-601-7360 Adapter for relay

5

REL-5P

q

799-601-7370 Adapter for relay

6

REL-6P

q

799-601-7380 Adapter for JFC

2

—

q

799-601-9010 Adapter for DTM

2

DTM2

q

q

799-601-9020 Adapter for DT

2

DT2

q

q


3

DT3

q

q


4

DT4

q

q


6

DT6

q

q

799-601-9060 Adapter for DT (Gray)

8

DT8GR

q

q

799-601-9070 Adapter for DT (Black)

8

DT8B

q

q

799-601-9080 Adapter for DT (Green)

8

DT8G

q

q

799-601-9090 Adapter for DT (Brown)

8

DT8BR

q

q

799-601-9110 Adapter for DT (Gray)

12

DT12GR

q

q

799-601-9120 Adapter for DT (Black)

12

DT12B

q

q

799-601-9130 Adapter for DT (Green)

12

DT12G

q

q

799-601-9140 Adapter for DT (Brown)

12

DT12BR

q

q

799-601-9210 Adapter for HD30-18

8

D18-8

q q

799-601-9220 Adapter for HD30-18

14

D18-14

q q

799-601-9230 Adapter for HD30-18

20

D18-20

q q

799-601-9240 Adapter for HD30-18

21

D18-21

q q

799-601-9250 Adapter for HD30-24

9

D24-9

q q

799-601-9260 Adapter for HD30-24

16

D24-16

q q

799-601-9270 Adapter for HD30-24

21

D24-21

q q

799-601-9280 Adapter for HD30-24

23

D24-23

q q

799-601-9290 Adapter for HD30-24

31

D24-31

q q

799-601-9310 Plate for HD30 (24-pin)

D155A-6

q q

q q q q

q

47

799-601-9320 T-box (for ECONO)

q q

24

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800


799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

40 Troubleshooting

Number of pins

SEN03205-01

q

q

799-601-9330 Case

q

799-601-9340 Case 799-601-9350 Adapter for DRC

40

DRC-40

q q

799-601-9360 Adapter for DRC

24

DRC-24

799-601-9410* Socket for engine (CRI-T2)

2

G

Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Adapter for oil pressure

3

A3

q q

2

P

q q

799-601-9440* Socket for engine (CRI-T2)

3

1,2,3

q

795-799-5520* Socket for engine (HPI-T2)

2

S

q

Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor

2

C

q q

2

A

q q

795-799-5460 Cable for engine (HPI-T2)

3

—

q


3

—

q


3

—

q

799-601-9430*

795-799-5540*

Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV

Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM

q

799-601-4110 Adapter for engine (140-T3) PIM

4

ITT3N

q q

799-601-4130 Adapter for engine (CRI-T3) NE, CAM

3

FCIN

q q

Adapter for engine (CRI-T3) 799-601-4140 Atmosphere pressure

3

FCIG

q q

799-601-4150 Adapter for engine (CRI-T3) POIL

3

FCIB

q q

Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch

2

4160

q q

799-601-4180 Adapter for engine (CRI-T3) PEVA

3

4180

q q

Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure

3

1,2,3L

q q

4

1,2,3,4C

q q

799-601-4240* Socket for engine (CRI-T3) PAMB

3

1,2,3A

q q

799-601-4250* Socket for engine (CRI-T3) PIM

3

1,2,3B

q q

799-601-4330* Socket for engine (CRI-T3) G

3

1,2,3,G

q q

Socket for engine (CRI-T3) 799-601-4340* Pump actuator

2

2,PA

q q

4

1,2,3,4T

799-601-4230*

799-601-4380*

Socket for engine (CRI-T3) Air intake pressure/temperature

Socket for engine (CRI-T3)(95) Air intake pressure/temperature

q q q

799-601-4260 Adapter for controller (ENG)

4

DTP4


50

DRC50

q q


60

DRC60

799-601-4390* Socket for controller (95 ENG)

60

—

q

799-601-4280 Box for controller (PUMP)

121

—

q

799-601-9720 Adapter for controller (HST)

16

HST16A

q


16

HST16B

q


26

HST26A

q

799-601-9890 Multi-adapter for DT2-4 and DTM2

2, 3, 4

—

q

“*” Shows not T-adapter but socket.

48

D155A-6

40 Troubleshooting

SEN03205-01

.

D155A-6

49

SEN03205-01

40 Troubleshooting



50

D155A-6

SEN03206-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up

40 Troubleshooting

1

Troubleshooting by failure and error codes, Part 1 Failure code [1500L0] Transmission clutch: Abnormal ................................................................................... 3 Failure code [15SAL1] Forward clutch: Fill high ............................................................................................. 4 Failure code [15SALH] Forward clutch: Fill low .............................................................................................. 5 Failure code [15SBL1] Reverse clutch: Fill high ............................................................................................. 6 Failure code [15SBLH] Reverse clutch: Fill low .............................................................................................. 7 Failure code [15SEL1] Speed 1st clutch: Fill high........................................................................................... 8 Failure code [15SELH] Speed 1st clutch: Fill low ........................................................................................... 9 Failure code [15SFL1] Speed 2nd clutch: Fill high........................................................................................ 10 Failure code [15SFLH] Speed 2nd clutch: Fill low .........................................................................................11 Failure code [15SGL1] Speed 3rd clutch: Fill high........................................................................................ 12 Failure code [15SGLH] Speed 3rd clutch: Fill low......................................................................................... 13 Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON ... 14 Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF.. 16 Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON ..... 18

D155A-6

1

SEN03206-00

40 Troubleshooting

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

2

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [1500L0] Transmission clutch: Abnormal Action code E03

Contents of trouble

Action of controller Problem that appears on machine Related information

Failure code 1500L0

Trouble

1

Transmission clutch: Abnormal (Power train controller system)

• Among failure codes related to transmission clutch, 2 or more of following failure codes occurred similarly. 1) Either [DXH4KA] or [DXH4KB] 2) Either [DXH5KA] or [DXH5KB] 3) Either [DXH6KA] or [DXH6KB] • Among failure codes related to transmission clutch, following combinations of failure codes occurred similarly. 1) [15SAL1] and [15SBL1] 2) [15SALH] and [15SBLH] 3) 2 or all of [15SEL1], [15SFL1], and [15SGL1] 4) 2 or all of [15SELH], [15SFLH], and [15SGLH] • Limits operation of engine and transmission. • Auto-shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to specific gear speed. • Method of reproducing failure code: Start engine + Travel.

Cause Standard value in normal state/Remarks on troubleshooting Possible causes and standard If other failure codes are displayed, carry out troubleshooting for them. value in normal [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], state [15SGL1], [15SGLH], [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB]

D155A-6

3

SEN03206-00

40 Troubleshooting

Failure code [15SAL1] Forward clutch: Fill high Action code

Failure code

E03 Contents of trouble Action of controller Problem that appears on machine Related information

15SAL1

Trouble

1

Forward clutch: Fill high (Power train controller system)

• When output to transmission F clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON. • Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1. • State of F clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in neutral. Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.

1

Defective F clutch ECMV fill switch (Internal short circuit)

FFT (male) Between (1) – chassis ground

Possible causes and standard value in normal state

Ground fault in wiring har2 ness (Contact with GND circuit)

PCCS lever (Travel gear speed)

Resistance

N

Min. 1 Mz

F1, F2, F3

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC2 (female) (35) – FFT (female) (1) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3

Defective power train controller

STC2 Between (35) – chassis ground

4 Defective hydraulic system


Voltage

N

5 – 11 V

F1, F2, F3

Max. 1 V

If causes 1 – 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).

Circuit diagram related

4

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [15SALH] Forward clutch: Fill low Action code

Failure code

E03

15SALH

Trouble

1

Forward clutch: Fill low (Power train controller system)

Contents of trouble

• When output to transmission F clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.

Action of controller

• Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement). • Limits operation of engine and transmission.

Problem that appears on machine Related information

• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • State of F clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in forward position. Cause


Defective F clutch ECMV fill 1 switch (Internal disconnection)


FFT (male) Between (1) – chassis ground


Resistance

N

Min. 1 Mz

F1, F2, F3

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC2 (female) (35) ResisMax. 1 z nector) – FFT (female) (1) tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3





Voltage

N

5 – 11 V

F1, F2, F3

Max. 1 V



D155A-6

5

SEN03206-00

40 Troubleshooting

Failure code [15SBL1] Reverse clutch: Fill high Action code

Failure code


15SBL1

Trouble

1

Reverse clutch: Fill high (Power train controller system)

• When output to transmission R clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON. • Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • State of R clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in neutral. Cause


1

Defective R clutch ECMV fill switch (Internal short circuit)

FRT (male) Between (1) – chassis ground



Resistance

N

Min. 1 Mz

R1, R2, R3

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC2 (female) (25) Resiscuit) Min. 1 Mz – FRT (female) (1) and chassis ground tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3





Voltage

N

5 – 11 V

R1, R2, R3

Max. 1 V



6

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [15SBLH] Reverse clutch: Fill low Action code

Failure code

E03

15SBLH

Trouble

1

Reverse clutch: Fill low (Power train controller system)

Contents of trouble

• When output to transmission R clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF.


• Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement). • Limits operation of engine and transmission.


• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1. • State of R clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in reverse position. Cause


Defective R clutch ECMV fill 1 switch (Internal disconnection)


FRT (male) Between (1) – chassis ground


Resistance

N

Min. 1 Mz

R1, R2, R3

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC2 (female) (25) ResisMax. 1 z nector) – FRT (female) (1) tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3





Voltage

N

5 – 11 V

R1, R2, R3

Max. 1 V



D155A-6

7

SEN03206-00

40 Troubleshooting

Failure code [15SEL1] Speed 1st clutch: Fill high Action code

Failure code


15SEL1

Trouble

1

Speed 1st clutch: Fill high (Power train controller system)

• When output to transmission 1st clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of 1st clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in neutral. Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine, select manual gearshift mode, and carry out troubleshooting.

Defective 1st clutch ECMV 1 fill switch (Internal short circuit)


F1T (male) Between (1) – chassis ground


Resistance

Other than F1, N, or R1

Min. 1 Mz

F1, R1

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC3 (female) (19) Resiscuit) Min. 1 Mz – F1T (female) (1) and chassis ground tance a Prepare with starting switch OFF, then start engine, select manual gearshift mode, and carry out troubleshooting. 3





Voltage


5 – 11 V

F1, R1

Max. 1 V



8

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [15SELH] Speed 1st clutch: Fill low Action code

Failure code


15SELH

Trouble

1

Speed 1st clutch: Fill low (Power train controller system)

• When output to transmission 1st clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF. • Limits operation of engine and transmission. • Auto-shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2. • State of 1st clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in F1 or R1 position (in manual gearshift mode). Cause


Defective 1st clutch ECMV 1 fill switch (Internal disconnection)




Resistance


Min. 1 Mz

F1, R1

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC3 (female) (19) ResisMax. 1 z nector) – F1T (female) (1) tance a Prepare with starting switch OFF, then start engine, select manual gearshift mode, and carry out troubleshooting. 3





Voltage


5 – 11 V

F1, R1

Max. 1 V



D155A-6

9

SEN03206-00

40 Troubleshooting

Failure code [15SFL1] Speed 2nd clutch: Fill high Action code

Failure code


15SFL1

Trouble

1

Speed 2nd clutch: Fill high (Power train controller system)

• When output to transmission 2nd clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON. • Limits operation of engine and transmission. • Auto-shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2. • State of 2nd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in neutral. Cause


Defective 2nd clutch ECMV 1 fill switch (Internal short circuit)




Resistance


Min. 1 Mz

F2, R2

Max. 1 z






Voltage


5 – 11 V

F2, R2

Max. 1 V



10

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [15SFLH] Speed 2nd clutch: Fill low Action code

Failure code


15SFLH

Trouble

1

Speed 2nd clutch: Fill low (Power train controller system)

• When output to transmission 2nd clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of 2nd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in F2 or R2 position (in manual gearshift mode). Cause


Defective 2nd clutch ECMV 1 fill switch (Internal disconnection)




Resistance


Min. 1 Mz

F2, R2

Max. 1 z






Voltage


5 – 11 V

F2, R2

Max. 1 V



D155A-6

11

SEN03206-00

40 Troubleshooting

Failure code [15SGL1] Speed 3rd clutch: Fill high Action code

Failure code


15SGL1

Trouble

1

Speed 3rd clutch: Fill high (Power train controller system)

• When output to transmission 3rd clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON. • Limits operation of engine and transmission. • Auto-shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F3 and R3. • State of 3rd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in neutral. Cause


Defective 3rd clutch ECMV 1 fill switch (Internal short circuit)




Resistance


Min. 1 Mz

F3, R3

Max. 1 z






Voltage


5 – 11 V

F3, R3

Max. 1 V



12

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [15SGLH] Speed 3rd clutch: Fill low Action code

Failure code


15SGLH

Trouble

1

Speed 3rd clutch: Fill low (Power train controller system)

• When output to transmission 3rd clutch ECMV solenoid circuit is turned ON, fill switch signal is turned OFF. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of 3rd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine + Set transmission in F3 or R3 position (in manual gearshift mode). Cause


Defective 3rd clutch ECMV 1 fill switch (Internal disconnection)




Resistance


Min. 1 Mz

F3, R3

Max. 1 z






Voltage


5 – 11 V

F3, R3

Max. 1 V

If causes 1 - 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).


D155A-6

13

SEN03206-00

40 Troubleshooting

Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON 1 Action code

Failure code


2201L1

Trouble

• The fill switch signal is not set off at output stop of the right steering clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • Auto-shift down function does not work. • The input state (ON/OFF) from the right steering clutch fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing failure code: Engine start Cause Defective right steering 1 clutch fill switch (Internal short)


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. FCLR (male)

PCCS lever

Resistance

Between (1) – chassis ground

N (Neutral)

Min. 1 Mz

Right max. steering

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective harness grounding 2 (Contact with ground circuit) Wiring harness between STC2 (female) (3) – ResisMin. 1Mz FCLR (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start for troubleshooting. 3

4

14

When right steering clutch oil pressure command current is OFF, fill signal is ON (Power train controller system)


STC2

PCCS lever

Voltage


N (Neutral)

5 – 11 V

Right max. steering

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure sure system is assumed to be abnormal. Carry out the related trousystem bleshooting (H mode).

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

15

SEN03206-00

40 Troubleshooting

Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF 1 Action code

Failure code


2201LH

Trouble

• The fill switch signal is not set off at output to the right steering clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • Auto-shift down function does not work. • The input state (ON/OFF) from the right steering clutch fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever operate (right steering) Cause Defective right steering 1 clutch fill switch (Internal short)


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. FCLR (male)

PCCS lever

Resistance


N (Neutral)

Min. 1 Mz

Right max. steering

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC2 (female) (3) – ResisMax. 1 z nector) FCLR (female) (1) tance a Prepare with starting switch OFF. Engine start for troubleshooting. 3

4

16

When right steering clutch oil pressure command current is ON, fill signal is OFF (Power train controller system)


STC2

PCCS lever

Voltage


N (Neutral)

5 – 11 V

Right max. steering

Max. 1 V


D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

17

SEN03206-00

40 Troubleshooting

Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON 1 Action code

Failure code


2202L1

Trouble

• The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • Auto-shift down function does not work. • The input state (ON/OFF) from the left steering clutch fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing failure code: Engine start Cause Defective left steering clutch 1 fill switch (Internal short)


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. FCLL (male)

PCCS lever

Resistance


N (Neutral)

Min. 1 Mz

Left max. steering

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective harness grounding 2 (Contact with ground circuit) Wiring harness between STC2 (female) (13) ResisMin. 1 Mz – FCLL (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start for troubleshooting. 3

4

18

When left steering clutch oil pressure command current is OFF, fill signal is ON (Power train controller system)


STC2

PCCS lever

Voltage


N (Neutral)

5 – 11 V

Left max. steering

Max. 1 V


D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

19

SEN03206-00

40 Troubleshooting

Failure code [2202LH] When left steering clutch oil pressure command current is ON, fill signal is OFF 1 Action code

Failure code


2202LH

Trouble

• The fill switch signal is not set off at output to the left steering clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • Auto-shift down function does not work. • The input state (ON/OFF) from the left steering clutch fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever operate (left steering) Cause Defective left steering clutch 1 fill switch (Internal short)


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. FCLL (male)

PCCS lever

Resistance


N (Neutral)

Min. 1 Mz

Left max. steering

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC2 (female) (13) ResisMax. 1 z nector) – FCLL (female) (1) tance a Prepare with starting switch OFF. Engine start for troubleshooting. 3

4

20

When left steering clutch oil pressure command current is ON, fill signal is OFF (Power train controller system)


STC2

PCCS lever

Voltage


N (Neutral)

5 – 11 V

Left max. steering

Max. 1 V


D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

21

SEN03206-00

40 Troubleshooting

Failure code [2300KM] Stall in 1st gear speed Action code

Failure code

—

2300KM

Trouble

Contents of trouble Action of controller

Stall in 1st gear speed (Engine controller system) —

• Saves only history.

Problem that appears on machine

—

Related information

—


22

1

Cause

Standard value in normal state/Remarks on troubleshooting

1 Work prohibited by operator

—

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [2301L1] Right brake: Fill high Action code

Failure code


2301L1

Trouble

Right brake: Fill high (Power train controller system)

• When output to steering case right brake ECMV solenoid circuit is turned OFF, fill switch signal is turned ON. • Limits operation of engine, transmission, and brake. • Applies brake lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, machine cannot travel at all. • State of right brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 S/T Fill Sw Input) • Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate brake pedal (Press). Cause Defective right brake ECMV 1 fill switch (Internal short circuit)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshooting. FBRR (male)

Brake pedal

Resistance


Released

Max. 1 z

Pressed

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC2 (female) (38) Resiscuit) Min. 1 Mz – FBRR (female) (1) and chassis ground tance a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshooting. 3



STC2

Brake pedal

Voltage


Released

Max. 1 V

Pressed

5 – 11V



D155A-6

23

SEN03206-00

40 Troubleshooting

Failure code [2301LH] Right brake: Fill low Action code

Failure code


2301LH

Trouble

Right brake: Fill low (Power train controller system)

• When output to steering case right brake ECMV solenoid circuit is turned ON, fill switch signal is turned OFF. • Limits operation of engine, transmission, and brake. • Applies brake lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, machine cannot travel at all. • State of right brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 S/T Fill Sw Input) • Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate brake pedal (Press). Cause Defective right brake ECMV 1 fill switch (Internal short circuit)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshooting. FBRR (male)

Brake pedal

Resistance


Released

Max. 1 z

Pressed

Min. 1 Mz

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC2 (female) (38) ResisMax. 1 z nector) – FBRR (female) (1) tance a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshooting. 3



STC2

Brake pedal

Voltage


Released

Max. 1 V

Pressed

5 – 11 V



24

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [2302L1] Left brake: Fill high Action code

Failure code


2302L1

Trouble

1

Left brake: Fill high (Power train controller system)

• When output to steering case left brake ECMV solenoid circuit is turned OFF, fill switch signal is turned ON. • Limits operation of engine, transmission, and brake. • Applies brake lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, machine cannot travel at all. • State of left brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 S/T Fill Sw Input) • Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate brake pedal (Press). Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshooting.

1


Defective left brake ECMV fill switch (Internal short circuit)

FBRL (male)

Brake pedal

Resistance


Released

Max. 1 z

Pressed

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC2 (female) (2) Resiscuit) Min. 1 Mz – FBRL (female) (1) and chassis ground tance a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshooting. 3



STC2

Brake pedal

Voltage


Released

Max. 1 V

Pressed

5 – 11 V



D155A-6

25

SEN03206-00

40 Troubleshooting

Failure code [2302LH] Left brake: Fill low Action code

Failure code


2302LH

Trouble

1

Left brake: Fill low (Power train controller system)

• When output to steering case left brake ECMV solenoid circuit is turned ON, fill switch signal is turned OFF. • Limits operation of engine, transmission, and brake. • Applies brake lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, machine cannot travel at all. • State of left brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 S/T Fill Sw Input) • Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate brake pedal (Press). Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshooting.

1


Defective left brake ECMV fill switch (Internal short circuit)

FBRL (male)

Brake pedal

Resistance


Released

Max. 1 z

Pressed

Min. 1 Mz

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC2 (female) (2) ResisMax. 1 z nector) – FBRL (female) (1) tance a Prepare with starting switch OFF, then start engine, set parking brake lever in Free position, and carry out troubleshooting. 3



STC2

Brake pedal

Voltage


Released

Max. 1 V

Pressed

5 – 11 V



26

D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

27

SEN03206-00

40 Troubleshooting

Failure code [7RFAKA] ECM HOLD RELAY: Disconnection Action code

Failure code

—

7RFAKA

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

ECM HOLD RELAY: Disconnection (Power train controller system)

• When ground circuit of engine cut relay circuit is disconnected to turn output ON, no current flows. • None in particular. • When engine cut mechanism is installed, engine cannot be cut (stopped). • State of engine cut relay circuit signal can be checked with monitoring function. (Code: 40912 P/T Sw Input) • Method of reproducing failure code: Start engine. • This failure code detects abnormality on primary side (coil side) of engine cut relay but does not detect abnormality on secondary side (contact side). Cause

1

Defective engine cut relay (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ACT (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (19) 2 or defective contact in con- – ACT (female) (2) nector) Wiring harness between ACT (female) (1) – terminal 270.

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harWiring harness between STC2 (female) (19) 3 ness (Contact with GND cir- – ACT (female) (2) and chassis ground cuit) Wiring harness between ACT (female) (1), (3) – terminal 270, circuit branch end and chassis ground. Defective power train con4 troller

28

Resistance

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STC2

Voltage


20 – 30 V

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

29

SEN03206-00

40 Troubleshooting

Failure code [AA10NX] Air Cleaner Clogging Action code

Failure code

— Contents of trouble

AA10NX

Trouble

1

Air Cleaner Clogging (Machine monitor system)

• While engine was running, air cleaner clogging switch signal circuit detected clogging of air cleaner (opening of sensor contact).

Action of • None in particular. machine monitor Problem that appears on machine Related information

• If machine is used as it is, engine may be damaged. • Method of reproducing failure code: Start engine.

Cause 1

Clogged air cleaner (When system is normal)

Standard value in normal state/Remarks on troubleshooting a Air cleaner may be clogged. Check and clean or replace it. a Prepare with starting switch OFF, then start engine and carry out troubleshooting.

Defective air cleaner clog2 ging switch (Internal disconnection)


AF1 (male)

Between (1) – (2)

Air cleaner

Resistance

Normal (Intake air resistance: *1)

Max. 1 z

Clogged (Intake air resistance: *2)

Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (4) 3 or defective contact in con- – AF1 (female) (1) nector) Wiring harness between CM01 (female) (7), CM02 (female) (7) – AF1 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective power train con4 troller

CM02

Between (4) – (7)

Air cleaner

Voltage

Normal (Intake air resistance: *1)

Max. 1 V

Clogged (Intake air resistance: *2)

20 – 30 V

*1: Max. -3,430 Pa {-350 mmH2O} *2: -7,470 ± 490Pa {-762 ± 50 mmH2O}

30

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

31

SEN03206-00

40 Troubleshooting

Failure code [AB00MA] Battery Charge Abnormal Action code

Failure code

—

AB00MA

Contents of trouble

Trouble

1

Battery Charge Abnormal (Machine monitor system)

• While engine was running, alternator signal circuit detected that battery charge voltage was low.

Action of • Displays charge level monitor red on machine monitor. machine monitor Problem that appears on machine Related information

• If machine is used as it is, battery may not be charged. • Battery voltage can be checked with monitoring function. (Code: 03203 Battery Power Supply) • Method of reproducing failure code: Start engine. Cause


1

2

32

Defective charge by alternator (When system is normal)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. CM01

Engine

Voltage


Above medium speed

27.5 – 29.5 V

If cause 1 is not detected, charge level monitor system may be Defective charge level monidefective. Carry out "E-5 Caution item lights up while engine is tor system running" in E mode.

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

33

SEN03206-00

40 Troubleshooting

Failure code [B@BAZG] Eng Oil Press Low Action code

Failure code

— Contents of trouble Action of controller Problem that appears on machine Related information

B@BAZG

Trouble

Eng Oil Press Low (Engine controller system)

• While engine was running, engine oil pressure sensor signal circuit detected that engine oil pressure was abnormally low. • Displays engine oil pressure monitor red on machine monitor. • Continues operation with limited output (Limits injection rate and engine speed). • If machine is used as it is, engine may be seized. • Engine oil pressure sensor signal is input to engine controller and then transmitted to machine monitor through communication system. • Engine oil pressure can be checked with monitoring function. (Code: 37200 Engine Oil Pressure) • Method of reproducing failure code: Start engine. Cause


1


1

Low engine oil pressure (When system is normal)

2

If cause 1 is not detected, engine oil pressure sensor may be Defective engine oil pressure defective. Carry out troubleshooting for failure codes [CA135] and sensor system [CA141].

Check engine oil pressure. If it is low, remove cause.

Failure code [B@BCNS] Eng Water Overheat Action code

Failure code

—

B@BCNS


Trouble

34

Eng Water Overheat (Engine controller system)

• While engine was running, engine coolant temperature sensor signal circuit detected that engine coolant was overheated. • Displays engine coolant temperature monitor red on machine monitor. • If machine is used as it is, engine may be seized. • Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature) • Method of reproducing failure code: Start engine. Cause


1


1

Overheated engine coolant (When system is normal)

Check engine coolant for overheating. If it is overheated, remove cause.

2

Defective engine coolant temperature sensor system

If cause 1 is not detected, engine coolant temperature sensor may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].

D155A-6

40 Troubleshooting

SEN03206-00

Failure code [B@BCZK] Eng Water Level Low Action code

Failure code

— Contents of trouble

B@BCZK

Trouble

1

Eng Water Level Low (Machine controller system)

• While starting switch was ON (and engine was stopped) or engine was running, radiator coolant level switch signal circuit detected that radiator coolant level was low (sensor contact was open).

Action of • Displays radiator coolant level monitor red on machine monitor. machine monitor • Continues operation with limited output (Limits injection rate and engine speed). Problem that appears on machine Related information

• If machine is used as it is, engine may be overheated. • Method of reproducing failure code: Start engine.

Cause Possible causes and standard value in normal state


1

Low coolant level (When system is normal)

Check radiator sub tank for lowering of coolant level. If coolant level is low, add coolant.

2

Defective radiator coolant level monitor system

If cause 1 is not detected, radiator coolant level monitor may be defective. Carry out "E-2 Caution item lights up while starting switch is ON (and engine is stopped)" in E mode.

Failure code [B@CENS] T/C Oil Overheat Action code

Failure code

—

B@CENS


Trouble

D155A-6

T/C Oil Overheat (Power train controller system)

• While engine was running, torque converter oil temperature sensor signal circuit detected that power train oil was overheated. • Displays torque converter oil temperature monitor red on machine monitor. • If machine is used as it is, power train components may be damaged. • Torque converter oil temperature sensor signal is input to power train controller and then transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) • Method of reproducing failure code: Start engine. Cause


1


Overheated power train oil 1 (When system is normal)

Check power train oil for overheating. If it is overheated, remove cause.

Defective torque converter 2 oil temperature sensor system

If cause 1 is not detected, torque converter oil temperature sensor system may be defective. Carry out troubleshooting for failure code [DGT1KA] or [DGT1KX].

35

SEN03206-00

40 Troubleshooting

Failure code [B@HANS] Hyd Oil Overheat Action code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code B@HANS

Trouble

36

Hyd Oil Overheat (Machine monitor system)

• While engine was running, hydraulic oil temperature sensor signal circuit detected that hydraulic oil was overheated. • Displays hydraulic oil temperature monitor red on machine monitor. • If machine is used as it is, work equipment and HSS circuit components may be damaged. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature) • Method of reproducing failure code: Start engine. Cause


1


Overheated hydraulic oil 1 (When system is normal)

Check hydraulic oil for overheating. If it is overheated, remove cause.

Defective hydraulic oil tem2 perature gauge system

If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for "E-10 Hydraulic oil temperature gauge (Multi-gauge) does not indicated normally" in E mode.

D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

37

SEN03206-00

40 Troubleshooting

Failure code [CA111] EMC Critical Internal Failure Action code

Failure code

E04

CA111


Trouble

1

EMC Critical Internal Failure (Engine controller system)

• Trouble occurred in engine controller. • None in particular. • Engine runs normally but may stop during operation or may not be able to start. • Source voltage of engine controller can be checked with monitoring function. (Code: 03203 Battery Power Supply) Cause 1

Defective circuit breaker (CB30 or CB8)

Standard value in normal state/Remarks on troubleshooting If circuit breaker is turned OFF, circuit probably has ground fault. (See cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)

Wiring harness between EGC3 (female) (3), (4) – CB8 (2)

Resistance

Max. 1 z

Wiring harness between CB8 (1) – CB30 (B30S)

Resistance

Max. 1 z

Wiring harness between CB30 (B30L) – terminal BRB

Resistance

Max. 1 z

Wiring harness between EGC3 (female) (1), (2) – chassis ground (GND20)

Resistance

Max. 1 z



Wiring harness between EGC3 (female) (3), (4) – CB8 (2) and chassis ground Wiring harness between CB8 (1) – CB30 Ground fault in wiring har(B30S), circuit branch end and chassis 3 ness (Contact with GND cirground cuit) Wiring harness between CB30 (B30L) – terminal BRB and chassis ground Wiring harness between EGC3 (female) (1), (2) – chassis ground (GND20) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller

38

EGC3

Starting switch

Voltage

Between (3), (4) – (1), (2)

ON

20 – 30 V

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

39

SEN03206-00

40 Troubleshooting

Failure code [CA115] Eng Ne and Bkup Speed Sens Error Action code

Failure code

E04

CA115

Contents of trouble Action of controller Problem that appears on machine

Trouble

1

Eng Ne and Bkup Speed Sens Error (Engine controller system)

• Trouble occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously. • None in particular. • Engine cannot be started (if engine has been stopped). • Engine stops (if engine has been running).

Related information Cause


1

Defective Ne speed sensor system

Ne speed sensor system may be defective. Carry out troubleshooting for code [CA689].

2

Defective Bkup speed sensor system

Bkup speed sensor system may be defective. Carry out troubleshooting for code [CA778].

3

Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective sensor installation of sensor, internal trouble of flywheel, etc.)

4

Defective mount of Bkup speed sensor

5

Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defecconnection) of sensor tive connection (wrong connection).

6 Defective engine controller

40


Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal trouble of supply pump, etc.)

If causes 1 – 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

41

SEN03206-00

40 Troubleshooting

Failure code [CA122] Chg (boost) Air Press Sensor High Error Action code

Failure code

E03

CA122


Trouble

1

Chg (boost) Air Press Sensor High Error (Engine controller system)

• Signal voltage in charge pressure sensor circuit is abnormally high. • Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation. • Acceleration performance of engine lowers or black smoke is produced more during acceleration. • State of charge pressure sensor can be checked with monitoring function. (Code: 36500 Charge Pressure-Abs) Cause


Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting 1 ply system for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 2

Defective charge pressure sensor (Internal trouble)

PIM Between (1) – (3)

Voltage Power supply

4.75 – 5.25 V

Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)


Wiring harness between EGC1 (female) (37) – PIM (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) Ground fault in wiring har(37) – PIM (female) (1) and chassis ground 4 ness (Contact with GND cirWiring harness between EGC1 (female) cuit) (47) – PIM (female) (3) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (44) – PIM (female) (2) and chassis ground

Resistance

Min. 1 Mz


Short circuit in wiring har5 ness (with another wiring harness)

Wiring harness between EGC1 (female) (37) – PIM (female) (1) and between EGC1 (female) (47) – PIM (female) (3)

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (37) – PIM (female) (1) and between EGC1 (female) (44) – PIM (female) (2)

Resistance

Min. 1 Mz

Chassis ground between EGC1 (female) (47) – PIM (female) (3) and between EGC1 (female) (44) – PIM (female) (2)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller

EGC1 Between (37) – (47)

42


4.75 – 5.25 V

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

43

SEN03206-00

40 Troubleshooting

Failure code [CA123] Chg (boost) Air Press Sensor Low Error Action code

Failure code

E03

CA123

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

44

Trouble

1

Chg (boost) Air Press Sensor Low Error (Engine controller system)

• Signal voltage in charge pressure sensor circuit is abnormally low. • Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues • operation. • Acceleration performance of engine lowers or black smoke is produced more during acceleration. • State of charge pressure sensor can be checked with monitoring function. (Code: 36500 Charge Pressure-Abs) Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA122].

D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

45

SEN03206-00

40 Troubleshooting

Failure code [CA131] Throttle Sensor High Error Action code

Failure code

E03

CA131


Trouble

1

Throttle Sensor High Error (Engine controller system)

• Signal voltage in decelerator pedal potentiometer circuit is abnormally high. • Sets throttle position with fuel control dial signal and continues operation.


• State of decelerator pedal optimum operation range signal can be checked with monitoring function. (Code: 03001 Throttle Pos Sens Volt) Cause 1


Defective sensor power sup- If code [CA2185] or [CA2186] is indicated, carry out troubleshootply system ing for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

2

Defective fuel control dial (Internal trouble)

DCL (male)

Resistance

Between (B) – (C)

1.5 – 2.5 kz

Between (A) – (B)

0 – 3 kz

Between (A) – (C)

0 – 3 kz




Wiring harness between EGC2 (female) (9) – DCL (female) (A)

Resistance

Max. 1 z

Wiring harness between EGC2 (female) (22) – DCL (female) (B)

Resistance

Max. 1 z

Wiring harness between EGC2 (female) (23) – DCL (female) (C)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC2 (female) (9) Ground fault in wiring har– DCL (female) (A) and chassis ground 4 ness (Contact with GND cirWiring harness between EGC2 (female) cuit) (22) – DCL (female) (B) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EGC2 (female) (23) – DCL (female) (C) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller

46

EGC2

Voltage

Between (22) – (23)

Power supply

4.75 – 5.25 V

Between (9) – (23)

Signal

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

47

SEN03206-00

40 Troubleshooting

Failure code [CA132] Throttle Sensor Low Error Action code

Failure code

E03

CA132

Trouble

1

Throttle Sensor Low Error (Engine controller system)

Contents of trouble

• Signal voltage in decelerator pedal potentiometer circuit is abnormally low.


• Sets throttle position with fuel control dial signal and continues operation.

Problem that appears on machine Related information Possible causes and standard value in normal state

48

• State of decelerator pedal optimum operation range signal can be checked with monitoring function. (Code: 03001 Throttle Pos Sens Volt) Cause


D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

49

SEN03206-00

40 Troubleshooting

Failure code [CA135] Eng Oil Press Sensor High Error Action code

Failure code

E02

CA135


Trouble

1

Eng Oil Press Sensor High Error (Engine controller system)

• Signal voltage in engine oil pressure sensor circuit is abnormally high. • Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.


• State of engine oil pressure sensor can be checked with monitoring function. (Code: 37201 Eng Oil Press Sens Volt) Cause 1


Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting ply system for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.

2

Defective engine oil pressure sensor (Internal trouble)

POIL Between (1) – (2)


4.75 –5.25 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)


Wiring harness between EGC1 (female) (37) – POIL (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) Ground fault in wiring har(37) – POIL (female) (1) and chassis ground 4 ness (Contact with GND cirWiring harness between EGC1 (female) cuit) (47) – POIL (female) (2) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (13) – POIL (female) (3) and chassis ground

Resistance

Min. 1 Mz




Wiring harness between EGC1 (female) (37) – POIL (female) (1) and between EGC1 (female) (47) – POIL (female) (2)

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. EGC1 Between (37) – (47)

50


4.75 – 5.25 V

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

51

SEN03206-00

40 Troubleshooting

Failure code [CA141] Eng Oil Press Sensor Low Error Action code

Failure code

E02

CA141


Trouble

1

Eng Oil Press Sensor Low Error (Engine controller system)

• Signal voltage in engine oil pressure sensor circuit is abnormally low. • Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.


52

• State of engine oil pressure sensor can be checked with monitoring function. (Code: 37201 Eng Oil Press Sens Volt) Cause


D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

53

SEN03206-00

40 Troubleshooting

Failure code [CA144] Coolant Temp Sens High Error Action code

Failure code

E02

CA144


Trouble

1

Coolant Temp Sens High Error (Engine controller system)

• Signal voltage in engine coolant temperature sensor circuit is abnormally high. • Fixes engine coolant temperature (90°C) and continues operation. • Startability of engine lowers at low temperature. • State of engine coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant Temp Sens Volt) Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWTR (male)

Defective engine coolant 1 temperature sensor (Internal trouble)


Between (A) – (B)

Coolant temperature

Resistance

0°C

30 – 37 kz

25°C

9.3 – 10.7 kz

50°C

3.2 – 3.8 kz

80°C

1.0 – 1.3 kz

95°C

700 – 800 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) Resis2 Max. 1 z or defective contact in con- (15) – TWTR (female) (A) tance nector) Wiring harness between EGC1 (female) ResisMax. 1 z (38) – TWTR (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har3 ness (Contact with GND cir- Wiring harness between EGC1 (female) Resiscuit) Min. 1 Mz (15) – TWTR (female) (A) and chassis tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EGC1 (female) 4 Defective engine controller Between (15) – (38)

54

Coolant temperature

Resistance

0°C

30 – 37 kz

25°C

9.3 – 10.7 kz

50°C

3.2 – 3.8 kz

80°C

1.0 – 1.3 kz

95°C

700 – 800 z

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

55

SEN03206-00

40 Troubleshooting

Failure code [CA145] Coolant Temp Sens Low Error Action code

Failure code

E02

CA145


56

Trouble

1

Coolant Temp Sens Low Error (Engine controller system)

• Signal voltage in engine coolant temperature sensor circuit is abnormally low. • Fixes engine coolant temperature (90°C) and continues operation. • Startability of engine lowers at low temperature. • State of engine coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant Temp Sens Volt) Cause


D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

57

SEN03206-00

40 Troubleshooting

Failure code [CA153] Chg (boost) Air Temp Sensor High Error Action code

Failure code

E01

CA153


Trouble

1

Chg (boost) Air Temp Sensor High Error (Engine controller system)

• Signal voltage in charge temperature sensor circuit is abnormally high. • Fixes charge temperature (intake air temperature) (70°C) and continues operation. • Startability of engine lowers at low temperature. • State of charge temperature sensor signal can be checked with monitoring function. (Code: 18501 Charge Temp Sens Volt) Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TIM (male)

1

Defective charge temperature sensor (Internal trouble)

Between (A) – (B)

Between (A) – chassis ground


Intake air temperature

Resistance

0°C

29 – 36 kz

25°C

9 – 11 kz

40°C

4.9 – 5.8 kz

100°C

600 – 700 kz

All range

Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) 2 or defective contact in con- (23) – TIM (female) (A) nector) Wiring harness between EGC1 (female) (47) – TIM (female) (B)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between EGC1 (female) Resiscuit) Min. 1 Mz (23) – TIM (female) (A) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EGC1 (female) 4 Defective engine controller Between (23) – (47)

58

Intake air temperature

Resistance

0°C

29 – 36 kz

25°C

9 – 11 kz

40°C

4.9 – 5.8 kz

100°C

600 – 700 kz

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

59

SEN03206-00

40 Troubleshooting

Failure code [CA154] Chg (boost) Air Temp Sensor Low Error Action code

Failure code

E01

CA154


Trouble

1

Chg (boost) Air Temp Sensor Low Error (Engine controller system)

• Signal voltage in charge temperature sensor circuit is abnormally low. • Fixes charge temperature (intake air temperature) (70°C) and continues operation. • Startability of engine lowers at low temperature. • State of charge temperature sensor signal can be checked with monitoring function. (Code: 18501 Charge Temp Sens Volt)


Cause


Failure code [CA187] Sens Supply 2 Volt Low Error Action code

Failure code

E03

CA187


Trouble

1

Sens Supply 2 Volt Low Error (Engine controller system)

• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low. • • • •

Operates Bkup speed sensor with signals of Ne speed sensor. Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation. Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.

• Engine output drops.

Related information Possible causes and standard value in normal state

60

Cause


D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

61

SEN03206-00

40 Troubleshooting

Failure code [CA221] Ambient Press Sens High Error Action code

Failure code

E03

CA221


Trouble

1

Ambient Press Sens High Error (Engine controller system)

• Signal voltage in ambient pressure sensor circuit is abnormally high. • Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Engine output drops. • State of ambient pressure sensor signal can be checked with monitoring function. (Code: 37401 Ambient Press Sens Volt) Cause


Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting 1 ply system for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PAMB 2

Defective ambient pressure sensor (Internal trouble)

Voltage

Between (1) – (3)

Power supply

4.75 – 5.25 V

Between (2) – (3)

Signal

0.3 – 4.7 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)


Wiring harness between EGC1 (female) (37) – PAMB (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) (37) Ground fault in wiring har– PAMB (female) (1) and chassis ground 4 ness (Contact with GND cirWiring harness between EGC1 (female) (38) cuit) – PAMB (female) (3) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (3) – PAMB (female) (2) and chassis ground

Resistance

Min. 1 Mz



Wiring harness between EGC1 (female) (37) – PAMB (female) (1) and between EGC1 (female) (38) - PAMB (female) (3)

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (37) – PAMB (female) (1) and between EGC1 (female) (3) – PAMB (female) (2)

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (38) – PAMB (female) (3) and between EGC1 (female) (3) – PAMB (female) (2)

Resistance

Min. 1 Mz

a repare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller

62

EGC1

Voltage

Between (37) – (38)

4.75 – 5.25 V

Between (3) – (38)

0.3 – 4.7 V

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

63

SEN03206-00

40 Troubleshooting

Failure code [CA222] Ambient Press Sens Low Error Action code

Failure code

E03

CA222


64

Trouble

1

Ambient Press Sens Low Error (Engine controller system)

• Signal voltage in ambient pressure sensor circuit is abnormally low. • Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Engine output drops. • State of ambient pressure sensor signal can be checked with monitoring function. (Code: 37401 Ambient Press Sens Volt) Cause


D155A-6

40 Troubleshooting

D155A-6

SEN03206-00

65

SEN03206-00

40 Troubleshooting

Failure code [CA227] Sens Supply 2 Volt High Error Action code

Failure code

E03

CA227


Trouble

1

Sens Supply 2 Volt High Error (Engine controller system)

• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high. • • • •

Operates Bkup speed sensor with signals of Ne speed sensor. Sets oil pressure sensor to default value (250 kPa [2.55 kg/cm2}) and continues operation. Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Fixes charge (boost) pressure sensor value (400 kPa [4.1 kg/cm2}) and continues operation.

• Engine output drops.

Related information Cause 1 Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective sensor (Internal 2 trouble)


Disconnect devices at right in order. If "E" of failure code disappears when a device is disconnected, that device has trouble in it.

Bkup speed sensor

G connector

Oil pressure sensor

POIL connector

Ambient pressure sensor

PAMB connector

Charge pressure sensor

PIM connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) Resis3 Max. 1 z or defective contact in con- (37) – each sensor (female) tance nector) Wiring harness between EGC1 (female) ResisMax. 1 z (47) – each sensor (female) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) Ground fault in wiring har(37) – each sensor (female) and chassis 4 ness (Contact with GND cirground cuit) Wiring harness between EGC1 (female) (47) – each sensor (female) and chassis ground Short circuit in wiring har5 ness (with another wiring harness)


66

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) (37) – each sensor (female) and between EGC1 (female) (47) – each sensor (female)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. EGC1

Voltage

Between (37) – (47)

4.75 – 5.25 V

D155A-6

40 Troubleshooting

SEN03206-00


D155A-6

67

SEN03206-00

40 Troubleshooting



68

D155A-6

SEN03207-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up

40 Troubleshooting

1

Troubleshooting by failure and error codes, Part 2 Failure code [CA234] Eng Overspeed ............................................................................................................ 3 Failure code [CA238] Ne Speed Sens Supply Volt Error ................................................................................ 4 Failure code [CA263] Fuel Temp Sensor High Error....................................................................................... 6 Failure code [CA265] Fuel Temp Sensor Low Error ....................................................................................... 8 Failure code [CA271] PCV1 Short Error ......................................................................................................... 9 Failure code [CA272] PCV1 Open Error ....................................................................................................... 10 Failure code [CA273] PCV2 Short Error ........................................................................................................11 Failure code [CA274] PCV2 Open Error ....................................................................................................... 12 Failure code [CA322] Inj #1 Open/Short Error .............................................................................................. 14 Failure code [CA323] Inj #5 Open/Short Error .............................................................................................. 16 Failure code [CA324] Inj #3 Open/Short Error .............................................................................................. 18 Failure code [CA325] Inj #6 Open/Short Error .............................................................................................. 20 Failure code [CA331] Inj #2 Open/Short Error .............................................................................................. 22 Failure code [CA332] Inj #4 Open/Short Error .............................................................................................. 24

D155A-6

1

SEN03207-01

40 Troubleshooting

Failure code [CA342] Calibration Code Incompatibility ................................................................................. 26 Failure code [CA351] Injectors Drive Circuit Error ........................................................................................ 28 Failure code [CA352] Sense Supply 1 Volt Low Error................................................................................... 30 Failure code [CA386] Sense Supply 1 Volt High Error.................................................................................. 32 Failure code [CA441] Battery Voltage Low Error .......................................................................................... 34 Failure code [CA442] Battery Voltage High Error.......................................................................................... 34 Failure code [CA449] Rail Press Very High Error ......................................................................................... 35 Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 36 Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 38 Failure code [CA553] Rail Press High Error.................................................................................................. 38 Failure code [CA554] Rail Press Sensor In Range Error .............................................................................. 39 Failure code [CA559] Rail Press Low Error .................................................................................................. 40 Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 44 Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 46 Failure code [CA757] All Continuous Data Lost Error................................................................................... 46 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 48 Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 50 Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 52 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 54 Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 54 Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................... 55 Failure code [CA2556] Grid Htr Relay Volt High Error .................................................................................. 56 Failure code [D110KA] Battery relay: Disconnection .................................................................................... 58 Failure code [D110KB] Battery Relay: Drive Short Circuit ............................................................................ 60 Failure code [D130KA] Neutral relay: Disconnection .................................................................................... 62 Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 64 Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 66 Failure code [D161KB] Back-up alarm relay: Short circuit ............................................................................ 68 Failure code [D190KA] ACC signal relay: Disconnection.............................................................................. 70 Failure code [D190KB] ACC signal relay: Short circuit ................................................................................. 72

2

D155A-6

40 Troubleshooting

SEN03207-01

Failure code [CA234] Eng Overspeed Action code

Failure code

—

CA234


Trouble

D155A-6

Eng Overspeed (Engine controller system)

• Engine speed is above operating range. • Limits fuel injection rate until engine speed lowers to operating range. • Engine speed fluctuates. • Engine speed can be checked with monitoring function. (Code: 01002 Engine Speed) Cause


1


1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Improper way of use

Way of use of machine may be improper. Teach proper way of use to operator.



3

SEN03207-01

40 Troubleshooting

Failure code [CA238] Ne Speed Sens Supply Volt Error Action code

Failure code

E03

CA238


Trouble

1

Ne Speed Sens Supply Volt Error (Engine controller system)

• Trouble occurred in Ne speed sensor power supply (5 V) circuit. • Controls Ne speed sensor with signals of Bkup speed sensor. • Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

1

Defective Ne speed sensor (Internal trouble)


Engine Ne speed sensor

NE connector



Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) 2 or defective contact in con- (16) – NE (female) (1) nector) Wiring harness between EGC1 (female) (48) – NE (female) (2)

Max. 1 z

Resistance

Max. 1 z


Ground fault in wiring harWiring harness between EGC1 (female) 3 ness (Contact with GND cir(16) – NE (female) (1) and chassis ground cuit) Wiring harness between EGC1 (female) (48) – NE (female) (2) and chassis ground Short circuit in wiring har4 ness (with another wiring harness)


4

Resistance

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) (16) – NE (female) (1) and between EGC1 (female) (48) – NE (female) (2)

Resistance

Min. 1 Mz


Voltage

Between (16) – (48)

4.75 – 5.25 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

5

SEN03207-01

40 Troubleshooting

Failure code [CA263] Fuel Temp Sensor High Error Action code

Failure code

E01

CA263


Trouble

1

Fuel Temp Sensor High Error (Engine controller system)

• Signal voltage in fuel temperature sensor circuit is abnormally high. • Fixes fuel temperature (90 °C) and continues operation.


• State of fuel temperature sensor signal can be checked with monitoring function. (Code: 14201 Fuel Temp Sens Volt) Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TFUEL (male)

1

Defective fuel temperature sensor (Internal trouble) Between (A) – (B)


Fuel temperature

Resistance

0°C

30 – 37 kz

25°C

9.3 – 10.7 kz

50°C

3.2 – 3.8 kz

80°C

1.0 – 1.3 kz

95°C

700 – 800 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) Resis2 Max. 1 z or defective contact in con- (30) – TFUEL (female) (A) tance nector) Wiring harness between EGC1 (female) ResisMax. 1 z (47) – TFUEL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between EGC1 (female) (30) Resiscuit) Min. 1 Mz – TFUEL (female) (A) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EGC1 (female) 4 Defective engine controller Between (30) – (47)

6

Fuel temperature

Resistance

0°C

30 – 37 kz

25°C

9.3 – 10.7 kz

50°C

3.2 – 3.8 kz

80°C

1.0 – 1.3 kz

95°C

700 – 800 z

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

7

SEN03207-01

40 Troubleshooting

Failure code [CA265] Fuel Temp Sensor Low Error Action code

Failure code

E01

CA265


Trouble

1

Fuel Temp Sensor Low Error (Engine controller system)

• Signal voltage in fuel temperature sensor circuit is abnormally low. • Fixes fuel temperature (90°C) and continues operation.


8

Cause


D155A-6

40 Troubleshooting

SEN03207-01

Failure code [CA271] PCV1 Short Error Action code

Failure code

E03

CA271


Trouble

1

PCV1 Short Error (Engine controller system)

• There is short circuit in PCV1 circuit of supply pump. • None in particular.

Problem that appears on machine Related information Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

1

Defective supply pump PCV1 (Internal short circuit)

PCV1 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 z

Between (1), (2) – chassis ground

Min. 1 Mz



Ground fault in wiring harWiring harness between EGC1 (female) (4) 2 ness (Contact with GND cir– PCV1 (female) (1) and chassis ground cuit) Wiring harness between EGC1 (female) (5) – PCV1 (female) (2) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3

Hot short (Short circuit with Wiring harness between EGC1 (female) (4) 24V circuit) in wiring harness – PCV1 (female) (1) and chassis ground

Voltage

Max. 1 V

Wiring harness between EGC1 (female) (5) – PCV1 (female) (2) and chassis ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

EGC1 (female)

Resistance

Between (4) – (5)

2.3 – 5.3 z


Min. 1 Mz


D155A-6

9

SEN03207-01

40 Troubleshooting

Failure code [CA272] PCV1 Open Error Action code

Failure code

E03

CA272


Trouble

1

PCV1 Open Error (Engine controller system)

• There is disconnection in PCV1 circuit of supply pump. • None in particular.



Defective supply pump 1 PCV1 (Internal disconnection)

PCV1 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 z


Min. 1 Mz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) (4) 2 or defective contact in con- – PCV1 (female) (1) nector) Wiring harness between EGC1 (female) (5) – PCV1 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z



Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


EGC1 (female)

Resistance

Between (4) – (5)

2.3 – 5.3 z


Min. 1 Mz


10

D155A-6

40 Troubleshooting

SEN03207-01

Failure code [CA273] PCV2 Short Error Action code

Failure code

E03

CA273


Trouble

1

PCV2 Short Error (Engine controller system)

• There is short circuit in PCV2 circuit of supply pump. • None in particular.



1

Defective supply pump PCV2 (Internal short circuit)

PCV2 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 z


Min. 1 Mz




Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Hot short (Short circuit with Wiring harness between EGC1 (female) (9) 24V circuit) in wiring harness – PCV2 (female) (1) and chassis ground

Voltage

Max. 1 V

Wiring harness between EGC1 (female) (10) – PCV2 (female) (2) and chassis ground

Voltage

Max. 1 V


EGC1 (female)

Resistance

Between (9) – (10)

2.3 – 5.3 z


Min. 1 Mz


D155A-6

11

SEN03207-01

40 Troubleshooting

Failure code [CA274] PCV2 Open Error Action code

Failure code

E03

CA274


Trouble

1

PCV2 Open Error (Engine controller system)

• There is disconnection in PCV2 circuit of supply pump. • None in particular.



Defective supply pump 1 PCV2 (Internal disconnection)

PCV2 (male)

Resistance

Between (1) – (2)

2.3 – 5.3 z


Min. 1 Mz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) (9) 2 or defective contact in con- – PCV2 (female) (1) nector) Wiring harness between EGC1 (female) (10) – PCV2 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z



Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


EGC1 (female)

Resistance

Between (9) – (10)

2.3 – 5.3 z


Min. 1 Mz


12

D155A-6

40 Troubleshooting

D155A-6

SEN03207-01

13

SEN03207-01

40 Troubleshooting

Failure code [CA322] Inj #1 Open/Short Error Action code

Failure code

E03

CA322


Trouble

1

Inj #1 Open/Short Error (Engine controller system)

• There is disconnection or short circuit in injector #1 circuit. • None in particular. • Output drops. • Rotation is unstable.



1

Defective injector #1 (Internal trouble)

CN1 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) 2 or defective contact in con- (45) – CN1 (female) (1) nector) Wiring harness between EGC1 (female) (53) – CN1 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z


Ground fault in wiring harWiring harness between EGC1 (female) 3 ness (Contact with GND cir(45) – CN1 (female) (1) and chassis ground cuit) Wiring harness between EGC1 (female) (53) – CN1 (female) (2) and chassis ground 4

Defective another cylinder injector or wiring harness

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

If a failure code of troubles in multiple injectors is displayed, carry out troubleshooting for it. Carry out troubleshooting for a short circuit in circuit #2 or #3. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


14

EGC1 (female)

Resistance

Between (45) – (53)

0.4 – 1.1 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

15

SEN03207-01

40 Troubleshooting


Failure code

E03

CA323


Trouble

1





1


CN5 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z




Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



16

EGC1 (female)

Resistance

Between (46) – (60)

0.4 – 1.1 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

17

SEN03207-01

40 Troubleshooting


Failure code

E03

CA324


Trouble

1





1


CN3 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z




Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



18

EGC1 (female)

Resistance

Between (55) – (52)

0.4 – 1.1 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

19

SEN03207-01

40 Troubleshooting


Failure code

E03

CA325


Trouble

1





1


CN6 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z




Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



20

EGC1 (female)

Resistance

Between (57) – (59)

0.4 – 1.1 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

21

SEN03207-01

40 Troubleshooting


Failure code

E03

CA331


Trouble

1





1


CN2 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z




Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



22

EGC1 (female)

Resistance

Between (54) – (51)

0.4 – 1.1 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

23

SEN03207-01

40 Troubleshooting


Failure code

E03

CA332


Trouble

1





1


CN4 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z




Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



24

EGC1 (female)

Resistance

Between (56) – (58)

0.4 – 1.1 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

25

SEN03207-01

40 Troubleshooting

Failure code [CA342] Calibration Code Incompatibility Action code

Failure code

E04

CA342


Trouble

1

Calibration Code Incompatibility (Engine controller system)

• Incompatibility occurred in engine controller data. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start.


26

Cause


D155A-6

40 Troubleshooting

D155A-6

SEN03207-01

27

SEN03207-01

40 Troubleshooting

Failure code [CA351] Injectors Drive Circuit Error Action code

Failure code

E03

CA351


Trouble

1

Injectors Drive Circuit Error (Engine controller system)

• Trouble occurred in injector drive circuit. • Limits engine output and continues operation (Limits common rail pressure). • Engine output drops. • Source voltage of engine controller can be checked with monitoring function. (Code: 03203 Battery Power Supply) Cause 1 Defective related system 2

Defective circuit breaker (CB30 or CB8)

Standard value in normal state/Remarks on troubleshooting If another failure code (failure code of trouble in injector system) is indicated, carry out troubleshooting for it. If circuit breaker is turned OFF, circuit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC3 (female) (3), (4) – CB8 (2)

Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB8 (1) – CB30 3 or defective contact in con- (B30S) nector) Wiring harness between CB30 (B30L) – terminal BRB Wiring harness between EGC3 (female) (1), (2) – chassis ground (GND20)


Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC3 (female) (3), (4) – CB8 (2) and chassis ground Wiring harness between CB8 (1) – CB30 Ground fault in wiring har(B30S) or circuit branch end and chassis 4 ness (Contact with GND cirground cuit) Wiring harness between CB30 (B30L) – terminal BRB and chassis ground Wiring harness between EGC3 (female) (1), (2) – chassis ground (GND20) and chassis ground


28

Resistance

Resistance

Min. 1 Me

Resistance

Min. 1 Me

Resistance

Min. 1 Me

Resistance

Min. 1 Me


Voltage

Between (3), (4) – (1), (2)

20 – 30 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

29

SEN03207-01

40 Troubleshooting

Failure code [CA352] Sense Supply 1 Volt Low Error Action code

Failure code

E03

CA352


Trouble

1

Sense Supply 1 Volt Low Error (Engine controller system)

• Signal voltage in sensor power supply 1 (5 V) circuit of engine controller is abnormally low. • Limits common rail pressure sensor output and continues operation (Limits common rail pressure). • Engine output drops.


30

Cause


D155A-6

40 Troubleshooting

D155A-6

SEN03207-01

31

SEN03207-01

40 Troubleshooting

Failure code [CA386] Sense Supply 1 Volt High Error Action code

Failure code

E03

CA386


Trouble

1

Sense Supply 1 Volt High Error (Engine controller system)

• Signal voltage in sensor power supply (5 V) circuit is abnormally high. • Limits common rail pressure sensor output and continues operation (Limits common rail pressure). • Engine output drops.

Related information Cause 1 Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective sensor (Internal 2 trouble)

Disconnect devices at right in order. If “E” of failure code disapCommon rail prespears when a device sure sensor is disconnected, that device has trouble in it.

PFUEL connector



Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) 3 or defective contact in con- (33) – PFUEL (female) (1) nector) Wiring harness between EGC1 (female) (47) – PFUEL (female) (3)

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) Ground fault in wiring har(33) – PFUEL (female) (1) and chassis 4 ness (Contact with GND cirground cuit) Wiring harness between EGC1 (female) (47) – PFUEL (female) (3) and chassis ground Short circuit in wiring har5 ness (with another wiring harness)


32

Resistance

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) (33) – PFUEL (female) (1) and between EGC1 (female) (47) – PFUEL (female) (3)

Resistance

Min. 1 Mz


Voltage

Between (33) – (47)

4.75 – 5.25 z

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

33

SEN03207-01

40 Troubleshooting

Failure code [CA441] Battery Voltage Low Error Action code

Failure code

E04

CA441


Trouble

1

Battery Voltage Low Error (Engine controller system)

• Power supply circuit voltage of engine controller is abnormally low. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start. • Source voltage of engine controller can be checked with monitoring function. (Code: 03203 Battery Power Supply) Cause


Failure code [CA442] Battery Voltage High Error Action code

Failure code

E04

CA442


34

Trouble

1

Battery Voltage High Error (Engine controller system)

• Power supply circuit voltage of engine controller is abnormally low. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start. • Source voltage of engine controller can be checked with monitoring function. (Code: 03203 Battery Power Supply) Cause


D155A-6

40 Troubleshooting

SEN03207-01

Failure code [CA449] Rail Press Very High Error Action code

Failure code

E03

CA449


D155A-6

Trouble

1

Rail Press Very High Error (Engine controller system)

• Common rail pressure sensor circuit detected abnormally high pressure (level 2). • Limits engine output and continues operation (Limits common rail pressure). • Engine output drops. • Common rail pressure can be checked with monitoring function. (Code: 36400 Rail Pressure) Cause


35

SEN03207-01

40 Troubleshooting

Failure code [CA451] Rail Press Sensor High Error Action code

Failure code

E03

CA451


Trouble

1

Rail Press Sensor High Error (Engine controller system)

• Signal voltage in common rail pressure sensor circuit is abnormally high. • Limits engine output and continues operation (Limits common rail pressure). • Engine output drops. • State of common rail pressure sensor signal can be checked with monitoring function. (Code: 36401 Rail Pressure Sense Volt) Cause 1


Defective sensor power sup- If code [CA352] or [CA386] is indicated, carry out troubleshooting ply system for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PFUEL

Defective common rail pres2 sure sensor (Internal trouble)

Voltage

Between (1) – (3)

Power supply

4.75 – 5.25 V

Between (2) – (3)

Signal

0.26 – 4.6 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Possible causes and standard value in normal state

Wiring harness between EGC1 (female) (33) – PFUEL (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) (33) Ground fault in wiring har– PFUEL (female) (1) and chassis ground 4 ness (Contact with GND cirWiring harness between EGC1 (female) (25) cuit) – PFUEL (female) (2) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (47) – PFUEL (female) (3) and chassis ground

Resistance

Min. 1 Mz



36

Wiring harness between EGC1 (female) (33) – PFUEL (female) (1) and between EGC1 (female) (25) – PFUEL (female) (2)

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03207-01


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.


EGC1

Voltage

Between (33) – (47)

4.75 – 5.25 V

Between (25) – (47)

0.26 – 4.6 V


D155A-6

37

SEN03207-01

40 Troubleshooting

Failure code [CA452] Rail Press Sensor Low Error Action code

Failure code

E03

CA452


Trouble

1

Rail Press Sensor Low Error (Engine controller system)

• Signal voltage in common rail pressure sensor circuit is abnormally low. • Limits engine output and continues operation (Limits common rail pressure). • Engine output drops. • State of common rail pressure sensor signal can be checked with monitoring function. (Code: 36401 Rail Pressure Sense Volt)


Cause


Failure code [CA553] Rail Press High Error Action code

Failure code

E02

CA553


Trouble

38

Rail Press High Error (Engine controller system)

• Common rail pressure sensor circuit detected abnormally high pressure (level 1). • None in particular. • Engine output drops. • Common rail pressure can be checked with monitoring function. (Code: 36400 Rail Pressure) Cause


1




2 Use of improper fuel

Check fuel used directly (for high viscosity).

3

Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out common rail pressure sensor troubleshooting for failure code [CA451].

Defective mechanical system 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly. sor 5 Defective overflow valve

Check overflow valve directly for broken spring, worn seat, and stuck ball.

6 Clogging of overflow piping

Check overflow piping directly for clogging.

7 Defective pressure limiter

Check pressure limiter directly for mechanical defect.

D155A-6

40 Troubleshooting

SEN03207-01

Failure code [CA554] Rail Press Sensor In Range Error Action code

Failure code

E03

CA554


D155A-6

Trouble

1

Rail Press Sensor In Range Error (Engine controller system)

• In-range error occurred in common rail pressure sensor circuit. • Limits engine output and continues operation (Limits common rail pressure). • Engine output drops. • State of common rail pressure sensor signal can be checked with monitoring function. (Code: 36401 Rail Pressure Sense Volt) Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for Failure code [CA451].

39

SEN03207-01

40 Troubleshooting

Failure code [CA559] Rail Press Low Error Action code

Failure code

E02

CA559


Trouble

Rail Press Low Error (Engine controller system)

• Supply pump does not feed fuel (level 1). • Limits common rail pressure. • Engine output drops. • Common rail pressure can be checked with monitoring function. (Code: 36400 Rail Pressure) Cause




2 Use of improper fuel

Check fuel used directly for improper quality.

3

Defective low-pressure circuit device

4 Clogging of filter/strainer


1

a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjusting, Testing fuel pressure. Pressure in fuel low-pressure circuit (high idle)

0.15 – 0.3 M.P.O. {1.5 – 3.0 kg/am2}

a For contents of troubleshooting, see Note 2.

5

Defective electrical system of Supply pump PCV may have electric trouble. Carry out troublesupply pump PCV shooting for following codes; [CA271], [CA272], [CA273], [CA274].

6

Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor ness for damage. a For testing of leakage from pressure limiter, see Testing and adjusting, Measuring fuel return rate and fuel leakage.

7 Defective pressure limiter

Leakage from pressure limiter (Operation equivalent to rated operation (under stall load))

Max. 10 CD/min.

a For measuring of return (spill) limit from injector, see Testing and adjusting, Measuring fuel return rate and fuel leakage.

8 Defective injector

9 Defective supply pump

Speed in rated operation (stall load)

Return (Spill) limit from injector

1,600 wpm

960 CD/min.

1,700 wpm

1,020 cc/min

1,800 rpm

1,080 cc/min

1,900 rpm

1,140 cc/min

2,000 rpm

1,200 cc/min

If causes 1 – 8 are not detected, supply pump may be defective.

Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for rail pressure low error".

40

D155A-6

40 Troubleshooting

SEN03207-01

Note 1: When low-pressure circuit is defective, check the following: q Fuel level q Clogged fuel tank breather q Water separator/Prefilter filled with water q Clogged fuel filter q Clogged screen in water separator q Stuck or worn feed pump, clogged filter q Leaked or clogged low-pressure fuel pipe q Bypass valve malfunction, defective assembly of other parts (See Fig.1.) q Clogged fuel filter q Fuel in oil pan (fuel leakage in head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2): Spring is seen through hole on nut side. q Fuel inlet joint (3): Gauze filter is seen through both holes.

Note 2: Check, clean, and replace the filters and strainers according to the following procedure. q Fuel filter: Replace. (Replace both prefilter and main filter.) q Water separator: Disassemble and check. If screen (4) is clogged, clean it. (See Fig. 2.) q Gauze filter: Disassemble and check. Clean, if clogged. q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.

D155A-6

41

SEN03207-01

40 Troubleshooting

Check sheet for rail pressure low error Model Machine serial No.

Work No.

SAA6D140E-5

Service meter

#

Date of check

Engine Engine serial No.

D155A-6

#

/

/ h

Worker's name

A. Visual check

Good NG

1 Fuel leakage to outside 2 Clogging of fuel tank breather

B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG 3 Check of failure code

/

/

/

/

Check of monitoring information Code

Displayed item

Checking condition

ISO unit

Standard value (Reference value)

r/min

715 – 765

Low idle 01002 Engine speed

31706

Final accelerator position

Final fuel injection 18600 rate command (by weight) 4

Measured value

Good NG

High idle

r/min

1,825 – 1,925


r/min

1,560 – 1,660

Low idle

%

0

High idle

%

100

mg/st

—

—

—


36200

Final common rail Torque converter stall pressure command

MPa

—

—

—

36400

Common rail pressure

MPa

—

—

—

CA

—

—

—

Final injection tim36300 ing command

Torque converter stall Low idle High idle

CA

—

—

—


CA

—

—

—


kPa

—

—

—

°C

—

—

—

°C

—

—

—

ISO unit


No. 1 cylinder

r/min

—

—

—

No. 2 cylinder Reduce No. 3 cylinder each cylinder No. 4 cylinder No. 5 cylinder

r/min

—

—

—

r/min

—

—

—

r/min

—

—

—

r/min

—

—

—

No. 6 cylinder

r/min

—

—

—

36500

Chg (boost) pressure

04107

Engine coolant temLow idle perature

14200 Fuel temperature

Low idle

Check of reduced cylinder mode operation (Engine speed) Setting

5

42

Reduced cylinder

Checking condition

Measured value

Good NG

D155A-6

40 Troubleshooting

C. Check of fuel circuit pressure 6

Fuel low-pressure circuit pressure

SEN03207-01

Checking condition High idle

Unit


MPa {kg/cm2}

0.15 – 0.3 {1.5 – 3.0}

Measured value

D. Check of strainers and filters

Good NG

Good NG

7 Visual check of strainers 8 Visual check of gauze filter 9 Visual check of fuel filter 10 Visual check of bypass valve

E. Check of leakage and return rate 11

Leakage through pressure limiter

12 Return rate from injector

D155A-6

Unit


Torque converter stal

cc/min

Max. 10

Torque converter stall 1,600 rpm

cc/min

960


cc/min

1,020


cc/min

1,080


cc/min

1,140


cc/min

1,200

Checking condition

Measured value

Good NG

Speed: Leakage

43

SEN03207-01

40 Troubleshooting

Failure code [CA689] Eng Ne Speed Sensor Error Action code

Failure code

E03

CA689


Trouble

1

Eng Ne Speed Sensor Error (Engine controller system)

• Trouble occurred in engine Ne speed sensor circuit. • Operates with signals of Bkup speed sensor. • Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).

Related information Cause 1


Defective sensor power supIf code [CA238] is indicated, carry out troubleshooting for it first. ply system a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between EGC1 (female) (16) – NE (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) Ground fault in wiring har(16) – NE (female) (1) and chassis ground 3 ness (Contact with GND cirWiring harness between EGC1 (female) cuit) (48) – NE (female) (2) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (27) – NE (female) (3) and chassis ground

Resistance

Min. 1 Mz




Wiring harness between EGC1 (female) (16) – NE (female) (1) and between EGC1 (female) (48) – NE (female) (2)

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (16) – NE (female) (1) and between EGC1 (female) (48) – NE (female) (2)

Resistance

Min. 1 Mz

Chassis ground between EGC1 (female) (48) – NE (female) (2) and between EGC1 (female) (27) – NE (female) (3)

Resistance

Min. 1 Mz

Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for part defect. Defective engine Ne speed sensor

If causes 1 – 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)



6

44

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

45

SEN03207-01

40 Troubleshooting

Failure code [CA731] Eng Bkup Speed Sens Phase Error Action code

Failure code

E03

CA731

Trouble

Eng Bkup Speed Sens Phase Error (Engine controller system)

Contents of trouble

• Engine Bkup sensor circuit detected phase error.


• Controls with signals of engine Ne speed sensor.


1

• Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal).

Related information


Cause


1

Defective engine Ne speed sensor system

Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA689].

2

Defective engine Bkup speed sensor system

Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].

Failure code [CA757] All Continuous Data Lost Error Action code

Failure code

E04

CA757


Trouble

1

All Continuous Data Lost Error (Engine controller system)

• All data in engine controller are lost. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start.


46

Cause


D155A-6

40 Troubleshooting

D155A-6

SEN03207-01

47

SEN03207-01

40 Troubleshooting

Failure code [CA778] Eng Bkup Speed Sensor Error Action code

Failure code

E03

CA778


Trouble

1

Eng Bkup Speed Sensor Error (Engine controller system)

• Trouble occurred in engine Bkup speed sensor circuit. • Operates with signals of Ne speed sensor. • Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal).



Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting ply system for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between EGC1 (female) (37) – G (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC1 (female) Ground fault in wiring har(37) – G (female) (1) and chassis ground 3 ness (Contact with GND cirWiring harness between EGC1 (female) cuit) (47) – G (female) (2) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (26) – G (female) (3) and chassis ground

Resistance

Min. 1 Mz




Wiring harness between EGC1 (female) (37) – G (female) (1) and between EGC1 (female) (47) – G (female) (2)

Resistance

Min. 1 Mz

Wiring harness between EGC1 (female) (37) – G (female) (1) and between EGC1 (female) (26) – G (female) (3)

Resistance

Min. 1 Mz

Chassis ground between EGC1 (female) (47) – G (female) (2) and between EGC1 (female) (26) – G (female) (3)

Resistance

Min. 1 Mz

Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly part for defect. 6

Defective engine Bkup speed sensor


48

If causes 1 – 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

49

SEN03207-01

40 Troubleshooting

Failure code [CA1633] KOMNET Datalink Timeout Error Action code E03 Contents of trouble Action of controller

Failure code CA1633

Trouble

1

KOMNET Datalink Timeout Error (Engine controller system)

• Trouble occurred in KOMNET (CAN) communication circuit between engine controller and machine monitor, power train controller, and work equipment controller. • Operates in default mode or maintains condition when abnormality occurs.




Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) (32)

Resistance

Max. 1 z

Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22)

Resistance

Max. 1 z



Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) Ground fault in wiring har(32), ACCN (female) (17), SRV (male) (3) or 2 ness (Contact with GND cirCA1 (female) (A) and chassis ground cuit) Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) Hot short (Contact with GND (32), ACCN (female) (17), SRV (male) (3) 3 circuit) in wiring harness or CA1 (female) (A) and chassis ground Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground Defective CAN terminal 4 resistance (Internal disconnection or short circuit)


50

Resistance

Voltage

Max. 1 V

Voltage

Max. 1 V

Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CA1 (male)

Resistance

Between (A) – (B)

Approx. 120 z


D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

51

SEN03207-01

40 Troubleshooting

Failure code [CA2185] Throt Sens Sup Volt High Error Action code

Failure code

E03

CA2185


Trouble

1

Throt Sens Sup Volt High Error (Engine controller system)

• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high. • Sets throttle position with signal of fuel control dial and continues operation.




1

Defective fuel control dial (Internal trouble)


Decelerator pedal potentiometer

DCL connector



Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC2 (female) 2 or defective contact in con- (22) – DCL (female) (B) nector) Wiring harness between EGC2 (female) (23) – DCL (female) (C)

Max. 1 z

Resistance

Max. 1 z


Ground fault in wiring harWiring harness between EGC2 (female) 3 ness (Contact with GND cir(22) – DCL (female) (B) and chassis ground cuit) Wiring harness between EGC2 (female) (23) – DCL (female) (C) and chassis ground Short circuit in wiring har4 ness (with another wiring harness)


52

Resistance

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EGC2 (female) (22) – DCL (female) (B) and between EGC2 (female) (23) – DCL (female) (C)

Resistance

Min. 1 Mz


Voltage

Between (22) – (23)

4.75 – 5.25 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

53

SEN03207-01

40 Troubleshooting

Failure code [CA2186] Throt Sens Sup Volt Low Error Action code

Failure code

E03

CA2186


Trouble

1

Throt Sens Sup Volt Low Error (Engine controller system)

• Signal voltage in throttle sensor power supply (5 V) circuit of engine controller is abnormally low. • Sets throttle position with signal of fuel control dial and continues operation.




Failure code [CA2249] Rail Press Very Low Error Action code

Failure code

E03

CA2249


Trouble

1

Rail Press Very Low Error (Engine controller system)

• Very low pressure error (level 2) occurred in supply pump. • Limits common rail pressure. • Engine output drops.


54

Cause


D155A-6

40 Troubleshooting

SEN03207-01

Failure code [CA2555] Grid Htr Relay Volt Low Error Action code

Failure code

E01

CA2555


D155A-6

Trouble

1

Grid Htr Relay Volt Low Error (Engine controller system)

• There is disconnection in intake air heater relay circuit. • None in particular. • Engine does not start easily at low temperature. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature) Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA2556].

55

SEN03207-01

40 Troubleshooting

Failure code [CA2556] Grid Htr Relay Volt High Error Action code

Failure code

E01

CA2556


Trouble

1

Grid Htr Relay Volt High Error (Engine controller system)

• There is short circuit in intake air heater relay. • None in particular. • Engine does not start easily at low temperature. • Engine controller has automatic preheating function, which is turned ON when engine coolant temperature is below -5 °C (for up to 30 seconds). • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature) Cause

1

Defective intake air heater relay (Internal trouble)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PHR (male)

Resistance

Between (1) – (2)

200 – 400 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC2 (female) 2 or defective contact in con- (40) – PHR (female) (1) nector) Wiring harness between PHR (female) (2) – chassis ground (GND03)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between EGC2 (female) Resiscuit) Min. 1 Mz (40) – PHR (female) (1) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller

56

EGC2

Coolant temperature

Voltage


-5 °C or higher

Max. 1 V

Below -5 °C

20 – 30 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

57

SEN03207-01

40 Troubleshooting

Failure code [D110KA] Battery relay: Disconnection Action code

Failure code

–

D110KA


Trouble

1

Battery relay: Disconnection (Power train controller system)

• Turns signal to battery relay holding circuit, no current flows. • Turns signal to battery relay holding circuit OFF. • Problem may occur in writing data into ROM (non-volatile memory) of each controller. • tate of battery relay holding circuit signal can be checked with monitoring function. (Code: 60600 BR Hold Relay) • Method of reproducing failure code: Turn starting switch ON o OFF. Cause


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective battery relay (Inter1 nal disconnection) Battery relay Continuity Between terminals SW – BRE

There is continuity



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (4) 2 or defective contact in con- – terminal SW nector) Wiring harness between terminal BRE and chassis ground

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

3

4

58

Resistance

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between STC3 (female) (4) – terminal SW, terminal 260, terminal AL/R or circuit branch end and chassis ground


Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STC3

Starting switch

Voltage


OFF

Max. 1 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

59

SEN03207-01

40 Troubleshooting

Failure code [D110KB] Battery Relay: Drive Short Circuit Action code

Failure code

–

D110KB


Trouble

1

Battery Relay: Drive Short Circuit (Power train controller system)

• When signal was output to battery relay circuit, abnormal current flowed. • Turns signal to battery relay holding circuit OFF. • Problem may occur in writing data into ROM (non-volatile memory) of each controller. • State of battery relay holding circuit signal can be checked with monitoring function. (Code: 60600 BR Hold Relay) • Method of reproducing failure code: Turn starting switch ON o OFF. Cause


1


Battery relay

Continuity/Resistance

Between terminals SW – BRE

There is continuity

Between terminal SW – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between STC3 (female) (4) Resiscuit) Min. 1 Mz – terminal SW, terminal 260 or RSD tance (female) (1) and chassis ground

3

60

Defective battery relay (Internal short circuit)



Starting switch

Voltage


ON

20 – 30 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

61

SEN03207-01

40 Troubleshooting

Failure code [D130KA] Neutral relay: Disconnection Action code

Failure code

E02

D130KA


Trouble

Neutral relay: Disconnection (Power train controller system)

• When ground circuit of neutral safety relay circuit is disconnected, no current flows. • Turns output of neutral safety relay circuit OFF. • Engine cannot be started. • State of neutral safety relay circuit signal can be checked with monitoring function. (Code: 59099 T/M Lock Relay) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free). • This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not detect abnormality on secondary side (contact side). Cause 1 Defective fuse (FS2-5) Defective neutral safety relay 2 (Internal disconnection)


1

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. NSF (male)

Resistance

Between (1) – (2)

300 – 600 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (8) Resis3 Max. 1 z or defective contact in con- – NSF (female) (2) tance nector) Wiring harness between NSF (female) (1) – ResisMax. 1 z FS21 (5) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between STC2 (female) (8) 4 ness (Contact with GND cir- – NSF (female) (2) and chassis ground cuit) Wiring harness between NSF (female) (1) – FS21 (5) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


62


STC2

Parking brake lever

Voltage


Lock

Max. 1 V

Free

20 – 30 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

63

SEN03207-01

40 Troubleshooting

Failure code [D130KB] Neutral relay: Short circuit Action code

Failure code

E02

D130KB


Trouble

1

Neutral relay: Short circuit (Power train controller system)

• When ground circuit of neutral safety relay was disconnected, abnormal current flowed. • Turns output of neutral safety relay circuit OFF. • Engine cannot be started. • State of neutral safety relay circuit signal can be checked with monitoring function. (Code: 59099 T/M Lock Relay) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free). • This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not detect abnormality on secondary side (contact side). Cause


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective neutral safety relay 1 (Internal short circuit) NSF (male) Resistance 300 – 600 z

Between (1) – (2) Possible causes and standard value in normal state

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between STC2 (female) (8) Voltage Max. 1 V – NSF (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3

64


STC2

Parking brake lever

Voltage


Lock

Max. 1 V

Free

20 – 30 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

65

SEN03207-01

40 Troubleshooting

Failure code [D161KA] Back-up alarm relay: Disconnection Action code

Failure code

E01

D161KA


Trouble

Back-up alarm relay: Disconnection (Power train controller system)

• When ground circuit of back-up alarm relay circuit is disconnected, no current flows. • Turns output of back-up alarm relay circuit OFF. • Back-up alarm does not sound • State of back-up alarm relay circuit signal can be checked with monitoring function. (Code: 70400 Back Alarm Relay) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse). • This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not detect abnormality on secondary side (contact side). Cause 1 Defective fuse (FS1-2) Defective back-up alarm 2 relay (Internal disconnection)


1

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BKA (male)

Resistance

Between (1) – (2)

300 – 600 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (18) Resis3 Max. 1 z or defective contact in con- – BKA (female) (2) tance nector) Wiring harness between BKA (female) (1) – ResisMax. 1 z FS12 (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between STC2 (female) (18) 4 ness (Contact with GND cir- – BKA (female) (2) or circuit branch end and cuit) chassis ground Wiring harness between BKA (female) (1), (3) – FS12 (2) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz




66

PCCS lever (Directional)

Voltage

N

20 – 30 V

R (Reverse)

Max. 1 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

67

SEN03207-01

40 Troubleshooting

Failure code [D161KB] Back-up alarm relay: Short circuit Action code

Failure code

E01

D161KB


Trouble

Back-up alarm relay: Short circuit (Power train controller system)

• When ground circuit of back-up alarm relay was disconnected, abnormal current flowed. • Turns output of back-up alarm relay circuit OFF. • Back-up alarm does not sound. • State of back-up alarm relay circuit signal can be checked with monitoring function. (Code: 70400 Back Alarm Relay) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse) • This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not detect abnormality on secondary side (contact side). Cause

1


1

Defective back-up alarm relay (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BKA (male)

Resistance

Between (1) – (2)

300 – 600 z


2

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between STC2 (female) (18) – BKA (female) (2) or circuit branch end and chassis ground

Voltage

Max. 1 V




68

PCCS lever (Directional)

Voltage

N

20 – 30 V

R (Reverse)

Max. 1 V

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

69

SEN03207-01

40 Troubleshooting

Failure code [D190KA] ACC signal relay: Disconnection Action code

Failure code

–

D190KA


Trouble

1

ACC signal relay: Disconnection (Power train controller system)

• When ground circuit of ACC signal drive relay circuit is disconnected, no current flows. • Turns signal to ACC signal drive relay circuit OFF. • Turbo-timer function does not operate (if turbo-timer is installed). • Machine is not affected particularly (if turbo-timer is not installed). • State of ACC signal drive relay circuit signal can be checked with monitoring function. (Code: 60500 ENG Hold Relay) • Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed). • This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does not detect abnormality on secondary side (contact side). Cause

1

Defective ACC signal drive relay (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EHL (male)

Resistance

Between (1) – (2)

200 – 400 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (9) 2 or defective contact in con- – EHL (female) (2) nector) Wiring harness between EHL (female) (1) – branch point (J)

3

4

70

Resistance

Max. 1 z

Resistance

Max. 1 z


Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between STC2 (female) (9) – EHL (female) (2) and chassis ground Defective power train controller

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STC2 (female)

Resistance


200 – 400 z

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

71

SEN03207-01

40 Troubleshooting

Failure code [D190KB] ACC signal relay: Short circuit Action code

Failure code

–

D190KB


Trouble

• Turns output of ACC signal drive relay circuit OFF. • Turbo-timer function does not operate (if turbo-timer is installed). • Machine is not affected particularly (if turbo-timer is not installed). • State of ACC signal drive relay circuit signal can be checked with monitoring function. (Code: 60500 ENG Hold Relay) • Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed). • This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does not detect abnormality on secondary side (contact side).

1

Defective ACC signal drive relay (Short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EHL (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC2 (female) (9) Resiscuit) 1 Mz – EHL (female) (2) and chassis ground tance

3

72

ACC signal relay: Short circuit (Power train controller system)

• When ground circuit of ACC signal drive relay was disconnected, abnormal current flowed.

Cause


1



Resistance


200 – 400 z

D155A-6

40 Troubleshooting

SEN03207-01


D155A-6

73

SEN03207-01

40 Troubleshooting



74

D155A-6

SEN03208-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up

40 Troubleshooting

1

Troubleshooting by failure and error codes, Part 3 Failure code [D5ZKKX] Throttle Dial: Out of normal range............................................................................. 4 Failure code [DAFRKR] CAN Disconnection (Monitor) ................................................................................... 6 Failure code [DB2RKR] CAN Disconnection (Engine controller) .................................................................... 8 Failure code [DB90KR] PT controller: Can communication lost.................................................................... 10 Failure code [DBE0KK] PT controller: Source voltage reduction .................................................................. 12 Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 14 Failure code [DBE6KK] PT controller: Source voltage reduction .................................................................. 16 Failure code [DBE7KK] PT controller: Source voltage reduction .................................................................. 18 Failure code [DBE9KQ] PT controller: Type select signal............................................................................. 20 Failure code [DD12KA] Shift up Sw: Disconnection ..................................................................................... 22 Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 24 Failure code [DD13KA] Shift down Sw: Disconnection ................................................................................. 26 Failure code [DD13KB] Shift down Sw: Short circuit .................................................................................... 28 Failure code [DD14KA] Parking lever Sw: Disconnection............................................................................. 30

D155A-6

1

SEN03208-00

40 Troubleshooting

Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 32 Failure code [DDDDKA] Back up brake Sw: Disconnection.......................................................................... 34 Failure code [DDDDKB] Back up brake Sw: Short circuit ............................................................................. 36 Failure code [DDDDKX] Back up brake Sw: Signal mismatch...................................................................... 38 Failure code [DGT1KA] T/C oil temp sensor: Abnormal................................................................................ 40 Failure code [DGT1KX] T/C oil temp sensor: Abnormal................................................................................ 42 Failure code [DH21KA] Weq pressure sensor: Disconnection...................................................................... 44 Failure code [DH21KB] Weq pressure sensor: Short circuit ......................................................................... 46 Failure code [DK10KX] Fuel control Dial: Out of normal range..................................................................... 48 Failure code [DK30KA] ST lever 1: Disconnection........................................................................................ 50 Failure code [DK30KB] ST lever 1: Short circuit ........................................................................................... 52 Failure code [DK30KX] ST lever 1: Out of normal range .............................................................................. 54 Failure code [DK30KZ] RL lever: Disconnection or short circuit ................................................................... 54 Failure code [DK30L8] ST lever: Signal mismatch........................................................................................ 55 Failure code [DK31KA] ST lever 2: Disconnection........................................................................................ 56 Failure code [DK31KB] ST lever 2: Short circuit ........................................................................................... 58 Failure code [DK40KA] Brake potentiometer: Disconnection........................................................................ 60 Failure code [DK40KB] Brake potentiometer: Short circuit ........................................................................... 62 Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 64 Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 64 Failure code [DK55L8] FR lever: Signal mismatch ....................................................................................... 65 Failure code [DK56KA] FR lever 1: Disconnection ....................................................................................... 66 Failure code [DK56KB] FR lever 1: Short circuit ........................................................................................... 68

2

D155A-6

40 Troubleshooting

D155A-6

SEN03208-00

3

SEN03208-00

40 Troubleshooting

Failure code [D5ZKKX] Throttle Dial: Out of normal range Action code

Failure code

E03

D5ZKKX


Trouble

1

Throttle Dial: Out of normal range (Power train controller system)

• Signal voltage of fuel control dial is below 0.30 V or above 4.55 V. • Continues control with decelerator pedal potentiometer signal. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel Dial Sensor) • Method of reproducing failure code: Turn starting switch ON. Cause


Defective sensor 5V power 1 supply system

If failure code [DBE7KK] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective fuel control dial 2 (Internal disconnection or short circuit)

DIAL (male)

Resistance

Between (1) – (3)

4.0 – 6.0 kz

Between (1) – (2)

0.25 – 7.0 kz

Between (2) – (3)

0.25 – 7.0 kz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (22) 3 or defective contact in con- – DIAL (female) (1) nector) Wiring harness between STC1 (female) (1) –DIAL (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Contact with GND cirWiring harness between STC1 (female) (1) Resiscuit) Min. 1 Mz – DIAL (female) (2) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with GND 5 circuit) in wiring harness Wiring harness between STC1 (female) (1) Voltage Max. 1 V – DIAL (female) (2) and chassis ground

6

4



Voltage

Between (1) – (21)

0.30 – 4.33 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

5

SEN03208-00

40 Troubleshooting

Failure code [DAFRKR] CAN Disconnection (Monitor) Action code

Failure code


DAFRKR

Trouble

1

CAN Disconnection (Monitor) (Machine monitor system)

• Machine monitor cannot recognize engine controller, power train controller, or work equipment controller in CAN communication circuit. • Limits operation of engine and transmission. • System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Method of reproducing failure code: Turn starting switch ON.

Cause




Resistance

Max. 1 z


Resistance

Max. 1 z




Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) Hot short (Short circuit with (32), ACCN (female) (17), SRV (male) (3) or 3 24V circuit) in wiring harness CA1 (female) (A) and chassis ground

Voltage

Max. 1 V

Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground

Voltage

Max. 1 V

Defective CAN terminal 4 resistance (Internal disconnection or short circuit)

5

6

Resistance

Defective machine monitor or controller

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CA1 (male)

Resistance

Between (A) – (B)

Approx. 120 z

If causes 1 – 4 are not detected, machine monitor, engine controller, or power train controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

7

SEN03208-00

40 Troubleshooting

Failure code [DB2RKR] CAN Disconnection (Engine controller) Action code

Failure code

E03

DB2RKR


Trouble

1

CAN Disconnection (Engine controller) (Power train controller system)

• Power train controller cannot recognize engine controller in CAN communication circuit. • Limits operation of engine and transmission. • System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Method of reproducing failure code: Turn starting switch ON.

Cause




Resistance

Max. 1 z


Resistance

Max. 1 z




Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) Hot short (Contact with GND (32), ACCN (female) (17), SRV (male) (3) or 3 circuit) in wiring harness CA1 (female) (A) and chassis ground Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground Defective CAN terminal 4 resistance (Internal disconnection or short circuit)

8

Resistance

Voltage

Max. 1 V

Voltage

Max. 1 V


Resistance

Between (A) – (B)

Approx. 120 z

5

Defective engine controller or power train controller

If causes 1 – 4 are not detected, engine controller or power train controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

6

Defective engine controller power supply

As the engine controller power supply can be detective, carry out troubleshooting for "Failure code CA111".

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

9

SEN03208-00

40 Troubleshooting

Failure code [DB90KR] PT controller: Can communication lost Action code

Failure code


DB90KR

Trouble

1

PT controller: Can communication lost (Power train controller system)

• Power train controller cannot recognize machine monitor, engine controller or work equipment controller in CAN communication circuit. • Limits operation of engine and transmission. • System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Method of reproducing failure code: Turn starting switch ON.

Cause




Resistance

Max. 1 z


Resistance

Max. 1 z




Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), (9) – EGC2 (female) (46), STC2 (female) Hot short (Contact with GND (32), ACCN (female) (17), SRV (male) (3) or 3 circuit) in wiring harness CA1 (female) (A) and chassis ground Wiring harness between CM02 (female) (10) – EGC2 (female) (47), STC2 (female) (22), ACCN (female) (18), SRV (male) (10) or CA1 (female) (B) and chassis ground Defective CAN terminal 4 resistance (Internal disconnection or short circuit)

5

10

Resistance

Defective machine monitor or controller

Voltage

Max. 1 V

Voltage

Max. 1 V


Resistance

Between (A) – (B)

Approx. 120 z

If causes 1 – 4 are not detected, machine monitor, engine controller, or power train controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

11

SEN03208-00

40 Troubleshooting

Failure code [DBE0KK] PT controller: Source voltage reduction Action code

Failure code

E03

DBE0KK


Trouble

1

PT controller: Source voltage reduction (Power train controller system)

• Source voltage of work equipment controller is below 17 V. • Limits operation of engine and transmission. • • • •

Machine monitor may not display normally. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all.

• Source voltage of power train controller can be checked with adjusting function. (Code: 2121) • Method of reproducing failure code: Turn starting switch ON. Cause 1


Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault (CB1, CB7, CB30 or CB105) (See cause 3). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (1), (11) – CB7 (2)

Resistance

Max. 1 z

Wiring harness between CB7 (1) – CB30 (B30S)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between CB105 (B105L) – terminal BRC

Resistance

Max. 1 z

Wiring harness between STC3 (female) (21), (31), (32), (33) – chassis ground (GND11)

Resistance

Max. 1 z

Wiring harness between CB30 (B30L) – terDisconnection in wiring har- minal BRB ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC3 (female) (2), (12), (22) – CB1 (2) nector) Wiring harness between CB1 (1) – CB105 (B105S)


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (1), (11) – CB7 (2) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CB7 (1) – CB30 (B30S) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between CB1 (1) – CB105 (B105S) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CB105 (B105L) – terminal BRC and chassis ground

Resistance

Min. 1 Mz

Ground fault in wiring harWiring harness between CB30 (B30L) – ter3 ness (Contact with GND cirminal BRB and chassis ground cuit) Wiring harness between STC3 (female) (2), (12), (22) – CB1 (2) or PL1 (female) (68) and chassis ground

12

D155A-6

40 Troubleshooting

SEN03208-00

Cause



Defective power train con4 troller

STC3

Starting switch

Voltage

Between (1), (11) – (21), (31), (32), (33)

OFF

20 – 30 V

Between (2), (12), (22) – (21), (31), (32), (33)

ON

20 – 30 V


D155A-6

13

SEN03208-00

40 Troubleshooting

Failure code [DBE0KT] PT controller: Abnormality in controller Action code

Failure code

E01

DBE0KT


Trouble

• Sets internal adjustment values to default values. • Shifting feel of transmission may become bad. • Adjusting function may not operate normally. • Method of reproducing failure code: Turn starting switch ON.

Defective adjustment of 1 power train controller

2

14

PT controller: Abnormality in controller (Power train controller system)

• Information in ROM (non-volatile memory) of power train controller is abnormal.


1


Standard value in normal state/Remarks on troubleshooting Turn Adjustment function in service mode ON and perform operation of reproducing trouble. If "E" of failure code disappears at this time, system is normal. • Adjustment code: 0002 (Initialization of power train controller) Troubleshooting cannot be carried out since defect is in power train controller. (If there is not any visible trouble in machine, controller may be used as it is.)

D155A-6

40 Troubleshooting

D155A-6

SEN03208-00

15

SEN03208-00

40 Troubleshooting


Failure code

E02

DBE6KK


Trouble

1


• Voltage of 24V power supply circuit for power train controller sensors is below 17 V or above 30 V. • Abnormal current flowed in 24V power supply circuit for power train controller sensors. • Turns output of 24V power supply circuit OFF, if abnormal current flows. • Limits operation of engine and transmission. • System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Method of reproducing failure code: Turn starting switch ON.

Cause


Defective pitch angle sensor 1 or torque converter pressure Disconnect devices at right in order. If "E" of failure code disapsensor (Internal trouble) pears when a device is disconnected, that device has trouble in it. Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC1 (female) (16) Resiscuit) Min. 1 Mz – PT1 (female) (C) tance

3

16



Voltage

Between (16) – (21)

20 – 30 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

17

SEN03208-00

40 Troubleshooting


Failure code

E02

DBE7KK


Trouble

1


• Voltage of 5V power supply circuit for power train controller sensors is below 4.5 V or above 5.5 V. • Abnormal current flowed in 5V power supply circuit for power train controller sensors. • Turns output of 5V power supply circuit OFF, if abnormal current flows. • Limits operation of engine and transmission. • System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Method of reproducing failure code: Turn starting switch ON.

Cause


Disconnect devices Defective brake pedal poten- at right in order. If 1 tiometer, fuel control dial or "E" of failure code PCCS lever (Internal trouble) disappears when a device is disconnected, that device has trouble in it.

Brake pedal potentiometer

Connector BRK

Fuel control dial

Connector DIAL

PCCS lever

Connector TLV1

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC1 (female) (22) – BRK (female) (C) and chassis ground [Brake pedal potentiometer system]


Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between STC1 (female) (22) cuit) – DIAL (female) (1) and chassis ground [Fuel control dial system] Wiring harness between STC1 (female) (22) – TLV1 (female) (4), (5) and chassis ground [PCCS lever system]

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between STC1 (female) (22) – BRK (female) (C) and chassis ground [Brake pedal potentiometer system]

3

4

18

Voltage

Max. 1 V

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between STC1 (female) (22) – DIAL (female) (1) and chassis ground [Fuel control dial system]

Voltage

Max. 1 V

Wiring harness between STC1 (female) (22) – TLV1 (female) (4), (5) and chassis ground [PCCS lever system]

Voltage

Max. 1 V



Voltage

Between (22) – (21)

4.5 – 5.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

19

SEN03208-00

40 Troubleshooting

Failure code [DBE9KQ] PT controller: Type select signal Action code

Failure code

E04

DBE9KQ


PT controller: Type select signal (Power train controller system)

• Specification setting in power train controller does not match to specification setting signal (Power train controller cannot be recognized). • Turns all outputs of power train controller OFF. • Limits operation of engine and transmission. • Machine does not move at all. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all. • Method of reproducing failure code: Turn starting switch ON.

1


Trouble

1

Cause


Defective adjustment of power train controller

Turn Adjustment function in service mode ON and perform operation of reproducing trouble. If "E" of failure code disappears at this time, system is normal. • Adjustment code: 0002 (Initialization of power train controller)

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between STC3 (female) (40) ResisMax. 1 z nector) – chassis ground (GND11) tance

3



Voltage

Wiring harness between (40) – chassis ground

Max. 1 V


20

D155A-6

40 Troubleshooting

D155A-6

SEN03208-00

21

SEN03208-00

40 Troubleshooting

Failure code [DD12KA] Shift up Sw: Disconnection Action code

Failure code

E02

DD12KA


Trouble

1

Shift up Sw: Disconnection (Power train controller system)

• Signals of 2 systems of shift-up switch circuit are turned OFF (opened) simultaneously. • Recognizes that shift-up switch is not pressed. • Transmission gear cannot be shifted up. • Auto shift-down function does not operate. • "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of shift-up switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch. Cause


Defective shift-up switch 1 (Internal disconnection)

SFTU (male)

Shift-up switch OFF (Released)

ON (Pressed)

Resistance between (3) – (2)

Max. 1 z

Min. 1 Mz


Min. 1 Mz

Max. 1 z




Wiring harness between STC3 (female) (9) – SFTU (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Hot short (Short circuit with Wiring harness between STC3 (female) (9) 24V circuit) in wiring harness – SFTU (female) (1) and chassis ground

Voltage

Max. 1 V

Wiring harness between STC1 (female) (12) – SFTU (female) (3) and chassis ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STC1 ,STC3 4

22



ON (Pressed)

Voltage between STC1 (12) – STC1 (4)

Max. 1 V

5 – 11 V


5 – 11 V

Max. 1 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

23

SEN03208-00

40 Troubleshooting

Failure code [DD12KB] Shift up Sw: Short circuit Action code

Failure code

E02

DD12KB


Trouble

1

Shift up Sw: Short circuit (Power train controller system)

• Signals of 2 systems of shift-up switch circuit are turned ON (closed) simultaneously. • Recognizes that shift-up switch is not pressed. • Transmission gear cannot be shifted up. • Auto shift-down function does not operate. • "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of shift-up switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch. Cause


Defective shift-up switch 1 (Internal short circuit)


SFTU (male)


ON (Pressed)


Max. 1 z

Min. 1 Mz


Min. 1 Mz

Max. 1 z


Ground fault in wiring harWiring harness between STC3 (female) (9) 2 ness (Contact with GND cir– SFTU (female) (1) and chassis ground cuit) Wiring harness between STC1 (female) (12) – SFTU (female) (3) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


3

24


STC1 ,STC3


ON (Pressed)


Max. 1 V

5 – 11 V


5 – 11 V

Max. 1 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

25

SEN03208-00

40 Troubleshooting

Failure code [DD13KA] Shift down Sw: Disconnection Action code

Failure code

E02

DD13KA


Trouble

1

Shift down Sw: Disconnection (Power train controller system)

• Signals of 2 systems of shift-down switch circuit are turned OFF (opened) simultaneously. • Recognizes that shift-down switch is not pressed. • Transmission gear cannot be shifted down. • Auto shift-down function does not operate. • "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of shift-down switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch. Cause


Defective shift-down switch 1 (Internal disconnection)

SFTD (female)

Shift-down switch OFF (Released)

ON (Pressed)


Max. 1 z

Min. 1 Mz


Min. 1 Mz

Max. 1 z




Wiring harness between STC1 (female) (18) – SFTD (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Hot short (Short circuit with Wiring harness between STC1 (female) (18) 24V circuit) in wiring harness – SFTD (female) (1) and chassis ground

Voltage

Max. 1 V

Wiring harness between STC1 (female) (24) – SFTD (female) (3) and chassis ground

Voltage

Max. 1 V


4

26


STC1


ON (Pressed)

Voltage between (24) –- (4)

Max. 1 V

5 – 11 V

Voltage between (18) – (4)

5 – 11 V

Max. 1 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

27

SEN03208-00

40 Troubleshooting

Failure code [DD13KB] Shift down Sw: Short circuit Action code

Failure code

E02

DD13KB


Trouble

1

Shift down Sw: Short circuit (Power train controller system)

• Signals of 2 systems of shift-down switch circuit are turned ON (closed) simultaneously. • Recognizes that shift-down switch is not pressed. • Transmission gear cannot be shifted down. • Auto shift-down function does not operate. • "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of shift-down switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch. Cause


Defective shift-down switch 1 (Internal disconnection)


SFTD (female)


ON (Pressed)


Max. 1 z

Min. 1 Mz


Min. 1 Mz

Max. 1 z


Ground fault in wiring harWiring harness between STC1 (female) (18) 2 ness (Contact with GND cir– SFTD (female) (1) and chassis ground cuit) Wiring harness between STC1 (female) (24) – SFTD (female) (3) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


3

28


STC1


ON (Pressed)


Max. 1 V

5 – 11 V


5 – 11 V

Max. 1 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

29

SEN03208-00

40 Troubleshooting

Failure code [DD14KA] Parking lever Sw: Disconnection Action code

Failure code

E03

DD14KA


Trouble

1

Parking lever Sw: Disconnection (Power train controller system)

• Signals of 2 systems of parking brake lever switch circuit are turned OFF (opened) simultaneously. • Recognizes that parking brake lever is in FREE position. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of parking brake lever switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever. Cause 1 Defective fuse (FS2-5)

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

PKSW (male) Defective parking brake lever 2 switch (Internal disconnecResistance between tion) (A) – (B) Resistance between (A) – (C)

Parking brake lever FREE position

LOCK position

Max. 1 z

Min. 1 Mz

Min. 1 Mz

Max. 1 z




Wiring harness between FS22 (2) – PKSW (female) (A)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (23) – PKSW (female) (B)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (17) – PKSW (female) (C)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FS22 (2) – PKSW (female) (A) and chassis ground Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between STC1 (female) (23) cuit) – PKSW (female) (B) and chassis ground Wiring harness between STC1 (female) (17) – PKSW (female) (C), PKS (female) (1) or PKD (female) (1) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective power train con5 troller

30

STC1


LOCK position

Voltage between (23) – chassis ground

20 – 30 V

Max. 1 V


Max. 1 V

20 – 30 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

31

SEN03208-00

40 Troubleshooting

Failure code [DD14KB] Parking lever Sw: Short circuit Action code

Failure code

E03

DD14KB


Trouble

1

Parking lever Sw: Short circuit (Power train controller system)

• Signals of 2 systems of parking brake lever switch circuit are turned ON (closed) simultaneously. • Recognizes that parking brake lever is in FREE position. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of parking brake lever switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever. Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PKSW (male)

1

Defective parking brake lever switch (Internal short circuit) Resistance between (A) – (B) Resistance between (A) – (C)



LOCK position

Max. 1 z

Min. 1 Mz

Min. 1 Mz

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2

Wiring harness between STC1 (female) (23) Hot short (Short circuit with – PKSW (female) (B) and chassis ground 24V circuit) in wiring harness Wiring harness between STC1 (female) (17) – PKSW (female) (C), PKS (female) (1) or PKD (female) (1) and chassis ground

Voltage

Max. 1 V

Voltage

Max. 1 V


3

32


STC1


LOCK position


20 – 30 V

Max. 1 V


Max. 1 V

20 – 30 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

33

SEN03208-00

40 Troubleshooting

Failure code [DDDDKA] Back up brake Sw: Disconnection Action code

Failure code

E02

DDDDKA


Trouble

1

Back up brake Sw: Disconnection (Power train controller system)

• Signals of 2 systems of brake pedal switch circuit are turned OFF (opened) simultaneously. • Recognizes that brake pedal is not pressed. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of brake pedal switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input1) • Method of reproducing failure code: Turn starting switch ON + Operate brake pedal. Cause 1 Defective fuse (FS2-1)

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BKSW (male)

2

Defective brake pedal switch (Internal disconnection) Resistance between (A) – (B) Resistance between (A) – (C)

Brake pedal Released

Pressed

Max. 1 z

Min. 1 Mz

Min. 1 Mz

Max. 1 z




Wiring harness between FS22 (1) – BKSW (female) (A)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (11) – BKSW (female) (B)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (5) – BKSW (female) (C)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FS22 (1) – BKSW (female) (A) and chassis ground Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between STC1 (female) (11) cuit) – BKSW (female) (B) and chassis ground Wiring harness between STC1 (female) (5) – BKSW (female) (C), PBS (female) (1) or PBD (female) (1) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective power train con5 troller

34

STC1


Pressed


20 – 30 V

Max. 1 V


Max. 1 V

20 – 30 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

35

SEN03208-00

40 Troubleshooting

Failure code [DDDDKB] Back up brake Sw: Short circuit Action code

Failure code

E02

DDDDKB


Trouble

1

Back up brake Sw: Short circuit (Power train controller system)

• Signals of 2 systems of brake pedal switch circuit are turned ON (closed) simultaneously. • Recognizes that brake pedal is not pressed. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error. • State of brake pedal switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch ON + Operate brake pedal. Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BKSW (male)

1

Defective brake pedal switch (Internal disconnection) Resistance between (A) – (B) Resistance between (A) – (C)



Pressed

Max. 1 z

Min. 1 Mz

Min. 1 Mz

Max. 1 z


Wiring harness between STC1 (female) (11) Hot short (Short circuit with – BKSW (female) (B) and chassis ground 24V circuit) in wiring harness Wiring harness between STC1 (female) (5) – BKSW (female) (C), PBS (female) (1), or PBD (female) (1) and chassis ground

Voltage

Max. 1 V

Voltage

Max. 1 V


3

36


STC1


Pressed


20 – 30 V

Max. 1 V


Max. 1 V

20 – 30 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

37

SEN03208-00

40 Troubleshooting

Failure code [DDDDKX] Back up brake Sw: Signal mismatch Action code

Failure code

E02

DDDDKX


Trouble

• None in particular. • Backup brake may not operate. • State of brake pedal potentiometer signal can be checked with monitoring function. (Code: 50400 Brake Pedal Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.

1


Defective brake pedal switch If failure code [DDDDKA] or [DDDDKB] is also displayed, carry out system troubleshooting for it first.

Adjust brake pedal and perform operation of reproducing trouble. 2 Defective brake pedal switch If "E" of failure code disappears at this time, system is normal. • Testing and adjusting item: Adjusting brake pedal 3

38

Back up brake Sw: Signal mismatch (Power train controller system)

• Brake pedal potentiometer signal does not match to brake pedal switch signal.

Cause


1


If causes 1 – 2 are not detected, power train controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

D155A-6

40 Troubleshooting

D155A-6

SEN03208-00

39

SEN03208-00

40 Troubleshooting

Failure code [DGT1KA] T/C oil temp sensor: Abnormal Action code

Failure code

E01

DGT1KA


Trouble

1

T/C oil temp sensor: Abnormal (Power train controller system)

• Torque converter oil temperature sensor signal is out of normal range. • None in particular. • Power train oil temperature gauge may not indicate normally. • Torque converter oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause Defective torque converter oil temperature sensor (Inter1 nal short circuit or disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TCT (male)

Resistance

Between (1) – (2)

1 – 50 kz


Min. 1 Mz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (9) 2 or defective contact in con- – TCT (female) (1) nector) Wiring harness between STC1 (female) (21) – TCT (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between STC1 (female) (9) Resiscuit) Min. 1 Mz – TCT (female) (1) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between STC1 (female) (9) Voltage Max. 1 V – TCT (female) (1) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5

40


STC1 (female)

Resistance

Between (9) – (21)

1 – 50 kz


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

41

SEN03208-00

40 Troubleshooting

Failure code [DGT1KX] T/C oil temp sensor: Abnormal Action code

Failure code

E01

DGT1KX


Trouble

1

T/C oil temp sensor: Abnormal (Power train controller system)

• Torque converter oil temperature sensor signal is out of normal range. • None in particular. • Power train oil temperature gauge may not indicate normally. • Torque converter oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause Defective torque converter oil temperature sensor (Inter1 nal short circuit or disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TCT (male)

Resistance

Between (1) – (2)

1 – 50 kz


Min. 1 Mz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (9) 2 or defective contact in con- – TCT (female) (1) nector) Wiring harness between STC1 (female) (21) – TCT (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between STC1 (female) (9) Resiscuit) Min. 1 Mz – TCT (female) (1) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between STC1 (female) (9) Voltage Max. 1 V – TCT (female) (1) and chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5

42


STC1 (female)

Resistance

Between (9) – (21)

1 – 50 kz


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

43

SEN03208-00

40 Troubleshooting

Failure code [DH21KA] Weq pressure sensor: Disconnection Action code

Failure code

–

DH21KA


Trouble

1

Weq pressure sensor: Disconnection (Power train controller system)

• Signal voltage of work equipment pump oil pressure sensor is below 0.5 V. • None in particular. • Oil pressure of work equipment pump cannot be monitored. • State of work equipment pump oil pressure sensor can be checked with monitoring function. (Code: 70701 Hydraulic Pressure Sensor 1) • Method of reproducing failure code: Turn starting switch ON. Cause



If failure code [DB95KK] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.

Defective work equipment oil 2 pressure sensor (Internal trouble)

HHP

Voltage

Between (B) – (A)

Power supply

4.5 – 5.5 V

Between (C) – (A)

Signal

0.5 – 6.0 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)

Wiring harness between STC1 (female) (21) – HHP (female) (A)

Resistance

Max. 1 z

Wiring harness between STC3 (female) (34) – HHP (female) (B)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (20) – HHP (female) (C)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Contact with GND cirWiring harness between STC1 (female) (20) Resiscuit) Min. 1 Mz – HHP (female) (C) and chassis ground tance 5

44



D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

45

SEN03208-00

40 Troubleshooting

Failure code [DH21KB] Weq pressure sensor: Short circuit Action code

Failure code

–

DH21KB


Trouble

1

Weq pressure sensor: Short circuit (Power train controller system)

• Signal voltage of work equipment pump oil pressure sensor is below 6.0 V. • None in particular. • Oil pressure of work equipment pump cannot be monitored. • State of work equipment pump oil pressure sensor can be checked with monitoring function. (Code: 70701 Hydraulic Pressure Sensor 1) • Method of reproducing failure code: Turn starting switch ON. Cause



If failure code [DB95KK] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.


Defective work equipment oil 2 pressure sensor (Internal trouble)

HHP

Voltage

Between (B) – (A)

Power supply

4.5 – 5.5 V

Between (C) – (A)

Signal

0.5 – 6.0 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between STC1 (female) (20) Voltage Max. 1 V – HHP (female) (C) and chassis ground 4

46



D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

47

SEN03208-00

40 Troubleshooting

Failure code [DK10KX] Fuel control Dial: Out of normal range Action code

Failure code

E03

DK10KX


Trouble

1

Fuel control Dial: Out of normal range (Power train controller system)

• Signal voltage of fuel control dial is out of normal range. • Continues control with signal of decelerator pedal potentiometer. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of fuel control dial signal can be checked with monitoring function. (Code: 03000 Fuel Dial Sensor) • Method of reproducing failure code: Turn starting switch ON. Cause 1

Defective sensor 5V power supply system

Standard value in normal state/Remarks on troubleshooting If failure code [DBE7KK] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective fuel control dial 2 (Internal disconnection or short circuit)

DIAL (male)

Resistance

Between (1) – (3)

4.0 – 6.0 kz

Between (1) – (2)

0.25 – 7.0 kz

Between (2) – (3)

0.25 – 7.0 kz



Wiring harness between STC1 (female) (22) – DIAL (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between STC1 (female) (22) 4 ness (Contact with GND cir- – DIAL (female) (1) or circuit branch end cuit) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between STC1 (female) (1) – DIAL (female) (2) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between STC1 (female) (22) – DIAL (female) (1) or circuit branch end and chassis ground

Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between STC1 (female) (1) – DIAL (female) (2) and chassis ground

Wiring harness between STC1 (female) (21) – DIAL (female) (3) or circuit branch end and chassis ground

Voltage

Max. 1 V

Voltage

Max. 1 V

Voltage

Max. 1 V


48


STC1

Voltage

Between (22) – (21)

4.6 – 5.4 V

Between (1) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

49

SEN03208-00

40 Troubleshooting

Failure code [DK30KA] ST lever 1: Disconnection Action code

Failure code

E03

DK30KA

Trouble

1

ST lever1: Disconnection (Power train controller system)

Contents of trouble

• Signal voltage of PCCS lever steering potentiometer 1 system is below 0.5 V.


• Continues control with signal of PCCS lever steering potentiometer 2 system. • Limits operation of engine and transmission.


• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of PCCS lever steering potentiometer 1 signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering direction). Cause 1



Defective PCCS lever steer2 ing potentiometer 1 (Internal disconnection)

TLV1 (male)

PCCS lever

Between (5) – (8) Between (5) – (7)

3.2 kz ± 20% Neutral


Resistance 3.2 kz ± 20% 3.2 kz ± 20%


Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (22) 3 or defective contact in con- – TLV1 (female) (5) nector) Wiring harness between STC1 (female) (2) – TLV1 (female) (7)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Contact with GND cirWiring harness between STC1 (female) (2) Resiscuit) Min. 1 Mz – TLV1 (female) (7) and chassis ground tance Defective power train con5 troller

50


Voltage

Between (2) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

51

SEN03208-00

40 Troubleshooting

Failure code [DK30KB] ST lever 1: Short circuit Action code

Failure code

E03

DK30KB

Trouble

1

ST lever1: Short circuit (Power train controller system)

Contents of trouble

• Signal voltage of PCCS lever steering potentiometer 1 system is above 4.5 V.








Defective PCCS lever steer2 ing potentiometer 1 (Internal short circuit)

PCCS lever

Between (5) – (8) Between (5) – (7) Between (7) – (8)

Resistance 3.2 kz ± 20%

Neutral

3.2 kz ± 20% 3.2 kz ± 20%

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between STC1 (female) (2) Voltage Max. 1 V – TLV1 (female) (7) and chassis ground

4

52

TLV1 (male)



Voltage

Between (2) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

53

SEN03208-00

40 Troubleshooting

Failure code [DK30KX] ST lever 1: Out of normal range Action code E04 Contents of trouble Action of controller Problem that appears on machine Related information


Failure code DK30KX

Trouble

1

ST lever 1: Out of normal range (Power train controller system)

• In PCCS lever steering potentiometer 1 and 2 systems, either of failure codes [DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of PCCS lever steering potentiometer signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering direction). Cause


Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].

Failure code [DK30KZ] RL lever: Disconnection or short circuit Action code

Failure code

E04

DK30KZ



54

Trouble

1

ST lever: Disconnection or short circuit (Power train controller system)

• In PCCS lever steering potentiometer 1 and 2 systems, when starting switch is turned ON, only either side is abnormal and then either of failure codes [DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all. • State of PCCS lever steering potentiometer signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering direction). Cause



D155A-6

40 Troubleshooting

SEN03208-00

Failure code [DK30L8] ST lever: Signal mismatch Action code E03

Failure code DK30L8

Trouble

1

ST lever: Signal mismatch (Power train controller system)

Contents of trouble

• In PCCS lever steering potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V or above 5.59 V.


• Continues control with signal of normal one of PCCS lever steering potentiometer 1 and 2 systems. • Limits operation of engine and transmission.



D155A-6

• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of PCCS lever steering potentiometer signal can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering direction). Cause



55

SEN03208-00

40 Troubleshooting

Failure code [DK31KA] ST lever 2: Disconnection Action code

Failure code

E03

DK31KA

Trouble

1

ST lever 2: Disconnection (Power train controller system)

Contents of trouble

• Signal voltage of PCCS lever steering potentiometer 2 system is below 0.5 V.







Defective PCCS lever steer2 ing potentiometer 2 (Internal disconnection)

TLV1 (male)

PCCS lever




Resistance 3.2 kz ± 20% 3.2 kz ± 20%



Resistance

Max. 1 z

Resistance

Max. 1 z


56


Voltage

Between (19) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

57

SEN03208-00

40 Troubleshooting

Failure code [DK31KB] ST lever 2: Short circuit Action code

Failure code

E03

DK31KB

Trouble

1

ST lever 2: Short circuit (Power train controller system)

Contents of trouble

• Signal voltage of PCCS lever steering potentiometer 2 system is above 4.5 V.








Defective PCCS lever steer2 ing potentiometer 2 (Internal short circuit)

PCCS lever



Neutral

3.2 kz ± 20% 3.2 kz ± 20%


4

58

TLV1 (male)



Voltage

Between (19) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

59

SEN03208-00

40 Troubleshooting

Failure code [DK40KA] Brake potentiometer: Disconnection Action code

Failure code

E03

DK40KA


Trouble

1

Brake potentiometer: Disconnection (Power train controller system)

• Signal voltage of brake pedal potentiometer is below 0.5 V. • Cannot recognize brake pedal position. • Auto shift-down function may not operate normally. • State of brake pedal potentiometer signal can be checked with monitoring function. (Code: 50400 Brake Pedal Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate brake pedal. Cause




Defective brake pedal poten2 tiometer (Internal disconnection)

BRK (male)

Resistance

Between (C) – (A)

4.0 – 6.0 kz

Between (B) – (A)

0.25 – 7.0 kz

Between (B) – (C)

0.25 – 7.0 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state


Wiring harness between STC1 (female) (21) – BRK (female) (A)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (3) – BRK (female) (B)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (22) – BRK (female) (C)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between STC1 (female) (3) 4 ness (Contact with GND cir- – BRK (female) (B) and chassis ground cuit) Wiring harness between STC1 (female) (22) – BRK (female) (C) or circuit branch end and chassis ground Defective power train con5 troller

60

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Voltage

Between (3) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

61

SEN03208-00

40 Troubleshooting

Failure code [DK40KB] Brake potentiometer: Short circuit Action code

Failure code

E03

DK40KB


Trouble

1

Brake potentiometer: Short circuit (Power train controller system)

• Signal voltage of brake pedal potentiometer is above 4.5 V. • Cannot recognize brake pedal position. • Auto shift-down function may not operate normally. • State of brake pedal potentiometer signal can be checked with monitoring function. (Code: 50400 Brake Pedal Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate brake pedal. Cause




Defective brake pedal poten2 tiometer (Internal short circuit) Possible causes and standard value in normal state

Resistance

Between (C) – (A)

4.0 – 6.0 kz

Between (B) – (A)

0.25 – 7.0 kz

Between (B) – (C)

0.25 – 7.0 kz


Wiring harness between STC1 (female) (3) Hot short (Short circuit with – BRK (female) (B) and chassis ground 24V circuit) in wiring harness Wiring harness between STC1 (female) (22) – BRK (female) (C) or circuit branch end and chassis ground

Defective power train con4 troller

62

BRK (male)

Voltage

Max. 1 V

Voltage

Max. 1 V


Voltage

Between (3) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

63

SEN03208-00

40 Troubleshooting

Failure code [DK55KX] FR lever: Out of normal range Action code E04 Contents of trouble Action of controller Problem that appears on machine Related information


Failure code DK55KX

Trouble

1

FR lever 1: Out of normal range (Power train controller system)

• In PCCS lever F-R potentiometer 1 and 2 systems, either of failure codes [DK56KA] and [DK56KB] and either of failure codes [DK57KA] and [DK57KB] occurred simultaneously. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all. • State of PCCS lever F-R potentiometer signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction). Cause



Failure code [DK55KZ] FR lever: Disconnection or short circuit Action code

Failure code

E04

DK55KZ



64

Trouble

1

FR lever: Disconnection or short circuit (Power train controller system)

• In PCCS lever F-R potentiometer 1 and 2 systems, when starting switch is turned ON, only either side is abnormal and then either of failure codes [DK56KA] and [DK56KB] and either of failure codes [DK57KA] and [DK57KB] occurred simultaneously. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all. • State of PCCS lever F-R potentiometer signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction). Cause



D155A-6

40 Troubleshooting

SEN03208-00

Failure code [DK55L8] FR lever: Signal mismatch Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information


D155A-6

Failure code DK55L8

Trouble

1

FR lever: Signal mismatch (Power train controller system)

• In PCCS lever F-R potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V or above 5.59 V. • Continues control with signal of normal one of PCCS lever F-R potentiometer 1 and 2 systems. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of PCCS lever F-R potentiometer signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction). Cause



65

SEN03208-00

40 Troubleshooting

Failure code [DK56KA] FR lever 1: Disconnection Action code

Failure code

E03

DK56KA

Trouble

FR lever 1: Disconnection (Power train controller system)

Contents of trouble

• Signal voltage of PCCS lever F-R potentiometer 1 system is below 0.5 V.


• Continues control with signal of PCCS lever F-R potentiometer 2 system. • Limits operation of engine and transmission.


1

• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of PCCS lever F-R potentiometer 1 signal can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction). Cause 1



Defective PCCS lever F-R 2 potentiometer 1 (Internal disconnection)

TLV1 (male)

PCCS lever




Resistance 3.2 kz ± 20% 3.2 kz ± 20%



Resistance

Max. 1 z

Resistance

Max. 1 z


66


Voltage

Between (13) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

67

SEN03208-00

40 Troubleshooting

Failure code [DK56KB] FR lever 1: Short circuit Action code

Failure code

E03

DK56KB

Trouble

1

FR lever 1: Short circuit (Power train controller system)

Contents of trouble

• Signal voltage of PCCS lever F-R potentiometer 1 system is above 4.5 V.








Defective PCCS lever F-R 2 potentiometer 1 (Internal short circuit)

PCCS lever



Neutral

3.2 kz ± 20% 3.2 kz ± 20%


4

68

TLV1 (male)



Voltage

Between (13) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03208-00


D155A-6

69

SEN03208-00

40 Troubleshooting



70

D155A-6

SEN03209-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up

40 Troubleshooting

1

Troubleshooting by failure and error codes, Part 4 Failure code [DK57KA] FR lever 2: Disconnection ......................................................................................... 4 Failure code [DK57KB] FR lever 2: Short circuit............................................................................................. 6 Failure code [DKH1KA] Pitch angle sensor: Disconnection............................................................................ 8 Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................. 10 Failure code [DLT3KA] T/M out-speed sensor: Disconnection ..................................................................... 12 Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................ 13 Failure code [DW7BKA] Fan rev EPC: Disconnection.................................................................................. 14 Failure code [DW7BKB] Fan rev EPC: Short circuit ..................................................................................... 15 Failure code [DWN3KA] Ssp solenoid: Disconnection.................................................................................. 16 Failure code [DWN3KB] Ssp solenoid: Short circuit ..................................................................................... 18 Failure code [DWN3KY] Ssp solenoid: Short circuit ..................................................................................... 20 Failure code [DWN5KA] Fan pump solenoid: Disconnection........................................................................ 22 Failure code [DWN5KB] Fan pump solenoid: Short circuit ........................................................................... 23 Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................. 24

D155A-6

1

SEN03209-00

40 Troubleshooting

Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................................................. 25 Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................................................. 26 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection............................................................................ 27 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................................... 28 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................................... 29 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection............................................................................. 30 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 31 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit ................................................................................ 32 Failure code [DXH7KA] R clutch ECMV: Disconnection ............................................................................... 33 Failure code [DXH7KB] R clutch ECMV: Short circuit................................................................................... 34 Failure code [DXH7KY] R clutch ECMV: Short circuit................................................................................... 35 Failure code [DXH8KA] F clutch ECMV: Disconnection................................................................................ 36 Failure code [DXH8KB] F clutch ECMV: Short circuit ................................................................................... 37 Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................................... 38 Failure code [DXH9KA] Right steering clutch ECMV disconnection ............................................................. 40 Failure code [DXH9KB] Right steering clutch ECMV short circuit................................................................. 42 Failure code [DXH9KY] Right steering clutch ECMV hot short ..................................................................... 44 Failure code [DXHAKA] Left steering clutch ECMV disconnection ............................................................... 46 Failure code [DXHAKB] Left steering clutch ECMV short circuit................................................................... 48 Failure code [DXHAKY] Left steering clutch ECMV hot short ....................................................................... 50 Failure code [DXHBKA] Right brake ECMV: Disconnection ......................................................................... 52 Failure code [DXHBKB] Right brake ECMV: Short circuit ............................................................................. 54 Failure code [DXHBKY] Right brake ECMV: Short circuit ............................................................................. 56 Failure code [DXHCKA] Left brake ECMV: Disconnection............................................................................ 58 Failure code [DXHCKB] Left brake ECMV: Short circuit ............................................................................... 60 Failure code [DXHCKY] Left brake ECMV: Short circuit ............................................................................... 62 Failure code [DXJ4KA] Weq lock Sol.: Disconnection .................................................................................. 64 Failure code [DXJ4KB] Weq lock Sol.: Short circuit ...................................................................................... 65

2

D155A-6

40 Troubleshooting

D155A-6

SEN03209-00

3

SEN03209-00

40 Troubleshooting

Failure code [DK57KA] FR lever 2: Disconnection Action code

Failure code

E03

DK57KA

Trouble

FR lever 2: Disconnection (Power train controller system)

Contents of trouble

• Signal voltage of PCCS lever F-R potentiometer 2 system is below 0.5 V.




1




Defective PCCS lever F-R 2 potentiometer 2 (Internal disconnection)

TLV1 (male)

PCCS lever




Resistance 3.2 kz ± 20% 3.2 kz ± 20%



Resistance

Max. 1 z

Resistance

Max. 1 z


4


Voltage

Between (7) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

5

SEN03209-00

40 Troubleshooting

Failure code [DK57KB] FR lever 2: Short circuit Action code

Failure code

E03

DK57KB

Trouble

1

FR lever 2: Short circuit (Power train controller system)

Contents of trouble

• Signal voltage of PCCS lever F-R potentiometer 2 system is above 4.5 V.








Defective PCCS lever F-R 2 potentiometer 2 (Internal short circuit)

PCCS lever



Neutral

3.2 kz ± 20% 3.2 kz ± 20%


4

6

TLV1 (male)



Voltage

Between (7) – (21)

0.5 – 4.5 V

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

7

SEN03209-00

40 Troubleshooting

Failure code [DKH1KA] Pitch angle sensor: Disconnection Action code

Failure code

E03

DKH1KA


Trouble

1

Pitch angle sensor: Disconnection (Power train controller system)

• Signal voltage of pitch angle sensor is below 0.5 V. • Cannot sense pitch angle of machine. • Limits operation of engine and transmission. • Gearshift shock is made on slope or steering shock is made on level ground. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of pitch angle sensor signal can be checked with monitoring function. (Code: 60100 Pitch Angle Sensor) • Method of reproducing failure code: Turn starting switch ON. Cause


Defective sensor 24V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1 supply system ing for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PT1 2

Defective pitch angle sensor (Internal trouble)

Voltage

Between (C) – (A)

Power supply

20 – 30 V

Between (B) – (A)

Signal

0.15 – 4.85 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Possible causes and standard value in normal state


Wiring harness between STC1 (female) (21) – PT1 (female) (A)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (8) – PT1 (female) (B)

Resistance

Max. 1 z

Wiring harness between STC1 (female) (16) – PT1 (female) (C)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Contact with GND cirWiring harness between STC1 (female) (8) Resiscuit) Min. 1 Mz – PT1 (female) (B) and chassis ground tance 5

8



D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

9

SEN03209-00

40 Troubleshooting

Failure code [DKH1KB] Pitch angle sensor: Short circuit Action code

Failure code

E03

DKH1KB


Trouble

1

Pitch angle sensor: Short circuit (Power train controller system)

• Signal voltage of pitch angle sensor is above 4.85 V. • Cannot sense pitch angle of machine. • Limits operation of engine and transmission. • Gearshift shock is made on slope or steering shock is made on level ground. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • State of pitch angle sensor signal can be checked with monitoring function. (Code: 60100 Pitch Angle Sensor) • Method of reproducing failure code: Turn starting switch ON. Cause


Defective sensor 24V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1 supply system ing for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PT1 Possible causes and standard value in normal state

2

Defective pitch angle sensor (Internal trouble)

Voltage

Between (C) – (A)

Power supply

20 – 30 V

Between (B) – (A)

Signal

0.15 – 4.85 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between STC1 (female) (8) Voltage Max. 1 V – PT1 (female) (B) and chassis ground 4

10



D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

11

SEN03209-00

40 Troubleshooting

Failure code [DLT3KA] T/M out-speed sensor: Disconnection Action code

Failure code

E01

DLT3KA


Trouble

T/M out-speed sensor: Disconnection (Power train controller system)

• No signal is input from transmission bevel speed sensor. • Recognizes that transmission bevel speed is 0 rpm. • Transmission bevel speed cannot be monitored. • Traction force cannot be calculated. • Transmission bevel speed can be checked with monitoring function. (Code: 31400 T/M Out Speed) • Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no load). Cause Defective transmission bevel 1 speed sensor (Internal disconnection or short circuit)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BVRV (male)

Resistance

Between (1) – (2)

500 – 1,000 z


Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (30) 2 or defective contact in con- – BVRV (female) (1) nector) Wiring harness between STC2 (female) (29) – BVRV (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between STC2 (female) (30) Resiscuit) Min. 1 Mz – BVRV (female) (1) and chassis ground tance 4




12

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DLT3KB] T/M out-speed sensor: Abnormal Action code

Failure code

E01

DLT3KB


Trouble

T/M out-speed sensor: Abnormal (Power train controller system)

• No signal is input from transmission bevel speed sensor. • Recognizes that transmission bevel speed is 0 rpm. • Transmission bevel speed cannot be monitored. • Traction force cannot be calculated. • Transmission bevel speed can be checked with monitoring function. (Code: 31400 T/M Out Speed) • Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no load). Cause Defective transmission bevel 1 speed sensor (Internal disconnection or short circuit)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BVRV (male)

Resistance

Between (1) – (2)

500 – 1,000 z


Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (30) 2 or defective contact in con- – BVRV (female) (1) nector) Wiring harness between STC2 (female) (29) – BVRV (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between STC2 (female) (30) Resiscuit) Min. 1 Mz – BVRV (female) (1) and chassis ground tance 4




D155A-6

13

SEN03209-00

40 Troubleshooting

Failure code [DW7BKA] Fan rev EPC: Disconnection Action code

Failure code

E01

DW7BKA


Trouble

1

Fan rev EPC: Disconnection (Power train controller system)

• When signal is output to fan reverse solenoid circuit, no current flows. • Turns signal to fan reverse solenoid circuit OFF. • Fan reverse function cannot be used. • Operating condition of fan reverse solenoid can be checked with monitoring function. (Code: 40909 T/M Output 1) • Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode. Cause

1

Defective fan reverse solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FAR (male)

Resistance

Between (1) – (2)

34 – 44 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (18) 2 or defective contact in con- – FAR (female) (1) nector) Wiring harness between STC3 (female) (13) – FAR (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between STC3 (female) (18) Voltage Max. 1 V – FAR (female) (1) and chassis ground 4




14

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DW7BKB] Fan rev EPC: Short circuit Action code

Failure code

E01

DW7BKB


Trouble

1

Fan rev EPC: Short circuit (Power train controller system)

• When signal was output to fan reverse solenoid circuit, abnormal current flowed. • Turns signal to fan reverse solenoid circuit OFF. • Fan reverse function cannot be used. • Operating condition of fan reverse solenoid can be checked with monitoring function. (Code: 40909 T/M Output 1) • Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode. Cause


1


Defective fan reverse solenoid (Internal short circuit)

FAR (male)

Resistance

Between (1) – (2)

34 – 44 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC3 (female) (18) Resiscuit) Min. 1 Mz – FAR (female) (1) and chassis ground tance Short circuit in wiring har3 ness (with another wiring harness)

4


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (18) – FAR (female) (1) and between STC3 (female) (13) – FAR (female) (2)

Resistance

Min. 1 Mz



D155A-6

15

SEN03209-00

40 Troubleshooting

Failure code [DWN3KA] Ssp solenoid: Disconnection Action code

Failure code

E04

DWN3KA


Trouble

1

Ssp solenoid: Disconnection (Power train controller system)

• When signal is output to sudden stop prevent solenoid circuit, no current flows. • Limits operation of engine, transmission, and brake. • Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all. • Output to sudden stop prevent solenoid can be checked with monitoring function. (Code: 31628 SSP Solenoid) • Method of reproducing failure code: Turn starting switch ON. Cause Defective sudden stop pre1 vent solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SSP (male)

Resistance

Between (1) – (2)

3.5 – 12.5 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (7) 2 or defective contact in con- – SSP (female) (1) nector) Wiring harness between STC3 (female) (23) – SSP (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between STC3 (female) (7) Voltage Max. 1 V – SSP (female) (1) and chassis ground

4

16



Resistance

Between (7) – (23)

3.5 – 12.5 z

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

17

SEN03209-00

40 Troubleshooting

Failure code [DWN3KB] Ssp solenoid: Short circuit Action code

Failure code

E04

DWN3KB


Trouble

Ssp solenoid: Short circuit (Power train controller system)

• When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed. • Limits operation of engine, transmission, and brake. • Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all. • Output to sudden stop prevent solenoid can be checked with monitoring function. (Code: 31628 SSP Solenoid) • Method of reproducing failure code: Turn starting switch ON. Cause Defective sudden stop pre1 vent solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirResisWiring harness between STC3 (female) (7) cuit) Min. 1 Mz – SSP (female) (1) and chassis ground tance Short circuit in wiring har3 ness (with another wiring harness)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (7) – SSP (female) (1) and between STC3 (female) (23) – SSP (female) (2)

Resistance

Min. 1 Mz


18


STC3 (female)

Resistance

Between (7) – (23)

3.5 – 12.5 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

19

SEN03209-00

40 Troubleshooting

Failure code [DWN3KY] Ssp solenoid: Short circuit Action code

Failure code

E04

DWN3KY


Trouble

Ssp solenoid: Short circuit (Power train controller system)

• When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed. • Limits operation of engine, transmission, and brake. • Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all. • Output to sudden stop prevent solenoid can be checked with monitoring function. (Code: 31628 SSP Solenoid) • Method of reproducing failure code: Turn starting switch ON. Cause Defective sudden stop pre1 vent solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between STC3 (female) (7) Voltage Max. 1 V – SSP (female) (1) and chassis ground Short circuit in wiring har3 ness (with another wiring harness)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (7) – SSP (female) (1) and between STC3 (female) (23) – SSP (female) (2)

Resistance

Min. 1 Mz


20


STC3 (female)

Resistance

Between (7) – (23)

3.5 – 12.5 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

21

SEN03209-00

40 Troubleshooting

Failure code [DWN5KA] Fan pump solenoid: Disconnection Action code

Failure code

E01

DWN5KA


Trouble

1

Fan pump solenoid: Disconnection (Power train controller system)

• When signal is output to fan pump EPC solenoid circuit, no current flows. • Turns signal to fan pump EPC solenoid circuit OFF. • Fan speed is kept at maximum. • If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed. • Output to fan pump EPC solenoid can be checked with monitoring function. (Code: 31624 Fan pump Solenoid (F/B)) • Method of reproducing failure code: Turn starting switch ON. Cause Defective fan pump EPC 1 solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FAC (male)

Resistance

Between (1) – (2)

2 – 12 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (36) 2 or defective contact in con- – FAC (female) (1) nector) Wiring harness between STC3 (female) (23) – FAC (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between STC3 (female) (36) Voltage Max. 1 V – FAC (female) (1) end and chassis ground 4




22

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DWN5KB] Fan pump solenoid: Short circuit Action code

Failure code

E01

DWN5KB


Trouble

Fan pump solenoid: Short circuit (Power train controller system)

• When signal was output to fan pump EPC solenoid circuit, abnormal current flowed. • Turns signal to fan pump EPC solenoid circuit OFF. • Fan speed is kept at maximum. • If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed. • Output to fan pump EPC solenoid can be checked with monitoring function. (Code: 31624 Fan pump Solenoid (F/B)) • Method of reproducing failure code: Turn starting switch ON. Cause Defective fan pump EPC 1 solenoid (Internal short circuit)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FAC (male)

Resistance

Between (1) – (2)

2 – 12 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC3 (female) (36) Resiscuit) Min. 1 Mz – FAC (female) (1) and chassis ground tance Short circuit in wiring har3 ness (with another wiring harness)

4


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (36) – FAC (female) (1) and between STC3 (female) (23) – FAC (female) (2)

Resistance

Min. 1 Mz



D155A-6

23

SEN03209-00

40 Troubleshooting

Failure code [DXH4KA] 1st clutch ECMV: Disconnection Action code

Failure code

E03

DXH4KA

Contents of trouble

Trouble

1st clutch ECMV: Disconnection (Power train controller system)

• When signal is output to transmission 1st clutch ECMV solenoid circuit, no current flows.


• Turns signal to transmission 1st clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.


• Auto shift-down function does not operate. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2.

Related information

1

• Output to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602 T/M Clutch 1st ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F1 or R1. Cause

1

Defective 1st clutch ECMV solenoid

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S1T (male)

Resistance

Between (1) – (2)

3.5 – 12.5 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (6) 2 or defective contact in con- – S1T (female) (1) nector) Wiring harness between STC3 (female) (23) – S1T (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z


3

4

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between STC3 (female) (23) – S1T (female) (2) or circuit branch end and chassis ground Defective power train controller

Voltage

Max. 1 V



24

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DXH4KB] 1st clutch ECMV: Short circuit Action code

Failure code

E03

DXH4KB

Contents of trouble

Trouble

1st clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602 T/M Clutch 1st ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F1 or R1. Cause Defective 1st clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirResisWiring harness between STC3 (female) (6) cuit) Min. 1 Mz – S1T (female) (1) and chassis ground tance Short circuit in wiring har3 ness (with another wiring harness)

4


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (6) – S1T (female) (1) and between STC3 (female) (23) – S1T (female) (2)

Resistance

Min. 1 Mz



D155A-6

25

SEN03209-00

40 Troubleshooting

Failure code [DXH4KY] 1st clutch ECMV: Short circuit Action code

Failure code

E03

DXH4KY

Contents of trouble

Trouble

1st clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602 T/M Clutch 1st ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F1 or R1. Cause Defective 1st clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between STC3 (female) (6) Voltage Max. 1 V – S1T (female) (1) and chassis ground Short circuit in wiring har3 ness (with another wiring harness)

4



Resistance

Min. 1 Mz



26

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DXH5KA] 2nd clutch ECMV: Disconnection Action code

Failure code

E03

DXH5KA

Contents of trouble

Trouble

2nd clutch ECMV: Disconnection (Power train controller system)

• When signal is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.


• Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.



Related information

1

• Output to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603 T/M Clutch 2nd ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F2 or R2. Cause Defective 2nd clutch ECMV 1 solenoid (Internal disconnection)


Resistance

Between (1) – (2)

3.5 – 12.5 z




Resistance

Max. 1 z

Resistance

Max. 1 z


3

4


Voltage

Max. 1 V



D155A-6

27

SEN03209-00

40 Troubleshooting

Failure code [DXH5KB] 2nd clutch ECMV: Short circuit Action code

Failure code

E03

DXH5KB

Contents of trouble

Trouble

2nd clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603 T/M Clutch 2nd ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F2 or R2. Cause Defective 2nd clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz


4



Resistance

Min. 1 Mz



28

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DXH5KY] 2nd clutch ECMV: Short circuit Action code

Failure code

E03

DXH5KY

Contents of trouble

Trouble

2nd clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603 T/M Clutch 2nd ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F2 or R2. Cause Defective 2nd clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz


4



Resistance

Min. 1 Mz



D155A-6

29

SEN03209-00

40 Troubleshooting

Failure code [DXH6KA] 3rd clutch ECMV: Disconnection Action code

Failure code

E03

DXH6KA

Contents of trouble

Trouble

3rd clutch ECMV: Disconnection (Power train controller system)

• When signal is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.


• Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission.


• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.

Related information

1

• Output to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604 T/M Clutch 3rd ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F3 or R3. Cause Defective 3rd clutch ECMV 1 solenoid (Internal disconnection)


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z


3

4


Voltage

Max. 1 V



30

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DXH6KB] 3rd clutch ECMV: Short circuit Action code

Failure code

E03

DXH6KB

Contents of trouble

Trouble

3rd clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604 T/M Clutch 3rd ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F3 or R3. Cause Defective 3rd clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz


4



Resistance

Min. 1 Mz



D155A-6

31

SEN03209-00

40 Troubleshooting

Failure code [DXH6KY] 3rd clutch ECMV: Short circuit Action code

Failure code

E03

DXH6KY

Contents of trouble

Trouble

3rd clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604 T/M Clutch 3rd ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F3 or R3. Cause Defective 3rd clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz


4



Resistance

Min. 1 Mz



32

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DXH7KA] R clutch ECMV: Disconnection Action code

Failure code

E03

DXH7KA


Trouble

1

R clutch ECMV: Disconnection (Power train controller system)

• When signal is output to transmission R clutch ECMV solenoid circuit, no current flows. • Turns signal to transmission R clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1. • Output to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to R (Reverse). Cause Defective R clutch ECMV 1 solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRT (male)

Resistance

Between (1) – (2)

3.5 – 12.5 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (37) 2 or defective contact in con- – SRT (female) (1) nector) Wiring harness between STC3 (female) (13) – SRT (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z


3

4

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between STC3 (female) (13) – SRT (female) (2) or circuit branch end and chassis ground Defective power train controller

Voltage

Max. 1 V



D155A-6

33

SEN03209-00

40 Troubleshooting

Failure code [DXH7KB] R clutch ECMV: Short circuit Action code

Failure code

E03

DXH7KB


Trouble

R clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed. • Turns signal to transmission R clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1. • Output to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to R (Reverse). Cause Defective R clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirResisWiring harness between STC3 (female) (37) cuit) Min. 1 Mz – SRT (female) (1) and chassis ground tance Short circuit in wiring har3 ness (with another wiring harness)

4


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (37) – SRT (female) (1) and between STC3 (female) (13) – SRT (female) (2)

Resistance

Min. 1 Mz

If causes 1 - 3 are not detected, power train controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


34

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DXH7KY] R clutch ECMV: Short circuit Action code

Failure code

E04

DXH7KY


Trouble

R clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed. • Turns signal to transmission R clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1. • Output to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to R (Reverse). Cause Defective R clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between STC3 (female) (37) Voltage Max. 1 V – SRT (female) (1) and chassis ground Short circuit in wiring har3 ness (with another wiring harness)

4


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (37) – SRT (female) (1) and between STC3 (female) (13) – SRT (female) (2)

Resistance

Min. 1 Mz



D155A-6

35

SEN03209-00

40 Troubleshooting

Failure code [DXH8KA] F clutch ECMV: Disconnection Action code

Failure code

E03

DXH8KA


Trouble

1

F clutch ECMV: Disconnection (Power train controller system)

• When signal is output to transmission F clutch ECMV solenoid circuit, no current flows. • Turns signal to transmission F clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • Output to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F (Forward). Cause Defective F clutch ECMV 1 solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SFT (male)

Resistance

Between (1) – (2)

3.5 – 12.5 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (27) 2 or defective contact in con- – SFT (female) (1) nector) Wiring harness between STC3 (female) (13) – SFT (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z


3

4

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between STC3 (female) (13) – SFT (female) (2) or circuit branch end and chassis ground Defective power train controller

Voltage

Max. 1 V



36

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DXH8KB] F clutch ECMV: Short circuit Action code

Failure code

E03

DXH8KB


Trouble

F clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed. • Turns signal to transmission F clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • Output to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F (Forward). Cause Defective F clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirResisWiring harness between STC3 (female) (27) cuit) Min. 1 Mz – SFT (female) (1) and chassis ground tance Short circuit in wiring har3 ness (with another wiring harness)

4


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (27) – SFT (female) (1) and between STC3 (female) (13) – SFT (female) (2)

Resistance

Min. 1 Mz



D155A-6

37

SEN03209-00

40 Troubleshooting

Failure code [DXH8KY] F clutch ECMV: Short circuit Action code

Failure code

E04

DXH8KY


Trouble

F clutch ECMV: Short circuit (Power train controller system)

• When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed. • Turns signal to transmission F clutch ECMV solenoid circuit OFF. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • Output to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B)) • Method of reproducing failure code: Start engine + Set gear to F (Forward). Cause Defective F clutch ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between STC3 (female) (27) Voltage Max. 1 V – SFT (female) (1) and chassis ground Short circuit in wiring har3 ness (with another wiring harness)

4


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (27) – SFT (female) (1) and between STC3 (female) (13) – SFT (female) (2)

Resistance

Min. 1 Mz



38

D155A-6

40 Troubleshooting

D155A-6

SEN03209-00

39

SEN03209-00

40 Troubleshooting

Failure code [DXH9KA] Right steering clutch ECMV disconnection Action code

Failure code

E03

DXH9KA


Trouble

• Flashes caution lamp and turns on caution buzzer. • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to right. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Outputting to right steering clutch solenoid (Current) can be checked in real-time moniitoring mode. (Code 90601: Right steering clutch ECMV (E-POCV) command current, output current) • Method of reproducing failure code: Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to right).

Defective right steering 1 clutch solenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SCLR (male)

Resistance

Between (1) – (2)

5 – 15 z


Disconnection in wiring harness (Disconnection in Wiring harness between STC3 (female) (35) 2 wiring or defective contact in – SCLR (female) (1) connector) Wiring harness between STC3 (female) (3) – SCLR (female) (2) 3

40

Right steering clutch ECMV disconnection (Power train controller system)

• When signal is output to right steering clutch solenoid circuit, current does not flow.

Cause


1

Resistance

Max. 1 z

Resistance

Max. 1 z

If causes 1 and 2 are not detected, power train controller may be Defective power train controldefective. (Since trouble is in system, troubleshooting cannot be ler carried out.)

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

41

SEN03209-00

40 Troubleshooting

Failure code [DXH9KB] Right steering clutch ECMV short circuit Action code

Failure code

E03

DXH9KB


Trouble

Right steering clutch ECMV short circuit (Power train controller system)

• When signal was output to right steering clutch solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to right. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Outputting to right steering clutch solenoid (Current) can be checked in real-time moniitoring mode. (Code 90601: Right steering clutch ECMV (E-POCV) command current, output current) • Method of reproducing failure code: Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to right). Cause Defective right steering 1 clutch solenoid (Internal short circuit)



Resistance

Between (1) – (2)

5 – 15 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between Resis(Contact with ground circuit) STC3 (female) (35) – SCLR (female) (1) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring 3 harness (with another wiring Short circuit of wiring harness between STC3 (female) (35) – SCLR (female) (1) with harness) wiring harness between STC3 (female) (3) – SCLR (female) (2) 4

42

1

Resistance

Min. 1 Mz


D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

43

SEN03209-00

40 Troubleshooting

Failure code [DXH9KY] Right steering clutch ECMV hot short Action code

Failure code

E04

DXH9KY


Trouble

• Flashes caution lamp and turns on caution buzzer. • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to right. (R clutch cannot be disengaged.) • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more. • Outputting to right steering clutch solenoid (Current) can be checked in real-time moniitoring mode. (Code 90601: Right steering clutch ECMV (E-POCV) command current, output current) • Method of reproducing failure code: Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to right).

Defective right steering 1 clutch solenoid (Internal short circuit)


Resistance

Between (1) – (2)

5 – 15 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24 V circuit)

3

44

Right steering clutch ECMV hot short (Power train controller system)

• Some current always flows into right steering clutch solenoid circuit.

Cause


1

Short circuit of wiring harness between STC3 (female) (35) – SCLR (female) (1) with chassis ground

Voltage

Max. 1 V

Short circuit of wiring harness between STC3 (female) (3) – SCLR (female) (2) with chassis ground

Voltage

Max. 1 V


D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

45

SEN03209-00

40 Troubleshooting

Failure code [DXHAKA] Left steering clutch ECMV disconnection Action code

Failure code

E03

DXHAKA


Trouble

• Flashes caution lamp and turns on caution buzzer. • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to left. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Outputting to left steering clutch solenoid (Current) can be checked in real-time moniitoring mode. (Code 90600: Left steering clutch ECMV (E-POCV) command current, output current) • Method of reproducing failure code: Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to left).

Defective left steering clutch 1 solenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SCLL (male)

Resistance

Between (1) – (2)

5 – 15 z


Disconnection in wiring harness (Disconnection in Wiring harness between STC3 (female) (25) 2 wiring or defective contact in – SCLL (female) (1) connector) Wiring harness between STC3 (female) (3) – SCLL (female) (2) 3

46

Left steering clutch ECMV disconnection (Power train controller system)

• When signal is output to left steering clutch solenoid circuit, current does not flow.

Cause


1

Resistance

Max. 1 z

Resistance

Max. 1 z


D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

47

SEN03209-00

40 Troubleshooting

Failure code [DXHAKB] Left steering clutch ECMV short circuit Action code

Failure code

E03

DXHAKB


Trouble

Left steering clutch ECMV short circuit (Power train controller system)

• When signal was output to left steering clutch solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to left. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Outputting to left steering clutch solenoid (Current) can be checked in real-time moniitoring mode. (Code 90600: Left steering clutch ECMV (E-POCV) command current, output current) • Method of reproducing error code: Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to left). Cause Defective left steering clutch 1 solenoid (Internal short circuit)



Resistance

Between (1) – (2)

5 – 15 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between Resis(Contact with ground circuit) STC3 (female) (25) – SCLL (female) (1) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring 3 harness (with another wiring Short circuit of wiring harness between STC3 (female) (25) – SCLL (female) (1) with harness) wiring harness between STC3 (female) (3) – SCLL (female) (2) 4

48

1

Resistance

Min. 1 Mz

If causes 1 – 3 are not detected, power train controller may be Defective power train controldefective. (Since trouble is in system, troubleshooting cannot be ler carried out.)

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

49

SEN03209-00

40 Troubleshooting

Failure code [DXHAKY] Left steering clutch ECMV hot short Action code

Failure code

E04

DXHAKY


Trouble

• Flashes caution lamp and turns on caution buzzer. • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to left. (L clutch cannot be disengaged.) • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more. • Outputting to left steering clutch solenoid (Current) can be checked in real-time moniitoring mode. (Code 90600: Left steering clutch ECMV (E-POCV) command current, output current) • Method of reproducing failure code: Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to left).

Defective left steering clutch 1 solenoid (Internal short circuit)


Resistance

Between (1) – (2)

5 – 15 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24 V circuit)

3

50

Left steering clutch ECMV hot short (Power train controller system)

• Some current always flows into left steering clutch solenoid circuit, current does not flow.

Cause


1

Short circuit of wiring harness between STC3 (female) (25) – SCLL (female) (1) with chassis ground

Voltage

Max. 1 V

Short circuit of wiring harness between STC3 (female) (3) – SCLL (female) (2) with chassis ground

Voltage

Max. 1 V


D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

51

SEN03209-00

40 Troubleshooting

Failure code [DXHBKA] Right brake ECMV: Disconnection Action code

Failure code

E04

DXHBKA

Contents of trouble

Trouble

Right brake ECMV: Disconnection (Power train controller system)

• When signal is output to steering case right brake ECMV solenoid circuit, no current flows.


• Turns signal to steering case right brake ECMV solenoid circuit OFF. • Limits operation of engine and transmission.


• Brake is applied lightly during travel. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all.

Related information

1

• Output to right brake ECMV solenoid can be checked with monitoring function. (Code: 31618 Brake RH ECMV (F/B)) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free). Cause Defective right brake ECMV 1 solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SBRR (male)

Resistance

Between (1) – (2)

3.5 – 12.5 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (15) 2 or defective contact in con- – SBRR (female) (1) nector) Wiring harness between STC3 (female) (3) – SBRR (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between STC3 (female) (15) Voltage Max. 1 V – SBRR (female) (1) and chassis ground

4

52



Resistance

Between (15) – (3)

3.5 – 12.5 z

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

53

SEN03209-00

40 Troubleshooting

Failure code [DXHBKB] Right brake ECMV: Short circuit Action code

Failure code

E04 Contents of trouble

DXHBKB

Trouble

Right brake ECMV: Short circuit (Power train controller system)

• When signal was output to steering case right brake ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to right brake ECMV solenoid can be checked with monitoring function. (Code: 31618 Brake RH ECMV (F/B)) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free). Cause Defective right brake ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirResisWiring harness between STC3 (female) (15) cuit) Min. 1 Mz – SBRR (female) (1) and chassis ground tance Short circuit in wiring har3 ness (with another wiring harness)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (15) – SBRR (female) (1) and between STC3 (female) (3) – SBRR (female) (2)

Resistance

Min. 1 Mz


54


STC3 (female)

Resistance

Between (15) – (3)

3.5 – 12.5 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

55

SEN03209-00

40 Troubleshooting

Failure code [DXHBKY] Right brake ECMV: Short circuit Action code

Failure code

E04 Contents of trouble

DXHBKY

Trouble

Right brake ECMV: Short circuit (Power train controller system)

• When signal was output to steering case right brake ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to right brake ECMV solenoid can be checked with monitoring function. (Code: 31618 Brake RH ECMV (F/B)) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free). Cause Defective right brake ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between STC3 (female) (15) Voltage Max. 1 V – SBRR (female) (1) and chassis ground Short circuit in wiring har3 ness (with another wiring harness)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (15) – SBRR (female) (1) and between STC3 (female) (3) – SBRR (female) (2)

Resistance

Min. 1 Mz


56


STC3 (female)

Resistance

Between (15) – (3)

3.5 – 12.5 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

57

SEN03209-00

40 Troubleshooting

Failure code [DXHCKA] Left brake ECMV: Disconnection Action code

Failure code

E04

DXHCKA

Contents of trouble

Trouble

Left brake ECMV: Disconnection (Power train controller system)

• When signal is output to steering case left brake ECMV solenoid circuit, no current flows.


• Turns signal to steering case left brake ECMV solenoid circuit OFF. • Limits operation of engine and transmission.



Related information

1

• Output to left brake ECMV solenoid can be checked with monitoring function. (Code: 31619 Brake LH ECMV (F/B)) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free). Cause Defective left brake ECMV 1 solenoid (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SBRL (male)

Resistance

Between (1) – (2)

3.5 – 12.5 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (5) 2 or defective contact in con- – SBRL (female) (1) nector) Wiring harness between STC3 (female) (3) – SBRL (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness Wiring harness between STC3 (female) (5) Voltage Max. 1 V – SBRL (female) (1) and chassis ground

4

58



Resistance

Between (5) – (3)

3.5 – 12.5 z

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

59

SEN03209-00

40 Troubleshooting

Failure code [DXHCKB] Left brake ECMV: Short circuit Action code

Failure code

E04

DXHCKB

Contents of trouble

Trouble

Left brake ECMV: Short circuit (Power train controller system)

• When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to left brake ECMV solenoid can be checked with monitoring function. (Code: 31619 Brake LH ECMV (F/B)) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free). Cause Defective left brake ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirResisWiring harness between STC3 (female) (5) cuit) Min. 1 Mz – SBRL (female) (1) and chassis ground tance Short circuit in wiring har3 ness (with another wiring harness)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (5) – SBRL (female) (1) and between STC3 (female) (3) – SBRL (female) (2)

Resistance

Min. 1 Mz


60


STC3 (female)

Resistance

Between (5) – (3)

3.5 – 12.5 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

61

SEN03209-00

40 Troubleshooting

Failure code [DXHCKY] Left brake ECMV: Short circuit Action code

Failure code

E04

DXHCKY

Contents of trouble

Trouble

Left brake ECMV: Short circuit (Power train controller system)

• When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.





Related information

• Output to left brake ECMV solenoid can be checked with monitoring function. (Code: 31619 Brake LH ECMV (F/B)) • Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free). Cause Defective left brake ECMV 1 solenoid (Internal short circuit)


1


Resistance

Between (1) – (2)

3.5 – 12.5 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between STC3 (female) (5) Voltage Max. 1 V – SBRL (female) (1) and chassis ground Short circuit in wiring har3 ness (with another wiring harness)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STC3 (female) (5) – SBRL (female) (1) and between STC3 (female) (3) – SBRL (female) (2)

Resistance

Min. 1 Mz


62


STC3 (female)

Resistance

Between (5) – (3)

3.5 – 12.5 z


Min. 1 Mz

D155A-6

40 Troubleshooting

SEN03209-00


D155A-6

63

SEN03209-00

40 Troubleshooting

Failure code [DXJ4KA] Weq lock Sol.: Disconnection Action code

Failure code

E03

DXJ4KA


Trouble

Weq lock Sol.: Disconnection (Power train controller system)

• When signal is output to work equipment lock solenoid circuit, no current flows. • Turns signal to work equipment lock solenoid circuit OFF. • Blade and ripper cannot be operated. • Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever (Free). Cause Defective work equipment 1 lock solenoid (Internal disconnection)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. WLK (male)

Resistance

Between (1) – (2)

20 – 60 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (8) Resis2 Max. 1 z or defective contact in con- – WLK (female) (1) tance nector) Wiring harness between STC3 (female) (3) ResisMax. 1 z – WLK (female) (2) tance

3



Resistance

Between (8) – (3)

20 – 60 z


64

D155A-6

40 Troubleshooting

SEN03209-00

Failure code [DXJ4KB] Weq lock Sol.: Short circuit Action code

Failure code

E03

DXJ4KB


Trouble

Weq lock Sol.: Short circuit (Power train controller system)

• When signal was output to work equipment lock solenoid circuit, abnormal current flowed. • Turns signal to work equipment lock solenoid circuit OFF. • Blade and ripper cannot be operated. • Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever (Free). Cause Defective work equipment 1 lock solenoid (Internal short circuit)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. WLK (male)

Resistance

Between (1) – (2)

20 – 60 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Contact with GND cirWiring harness between STC3 (female) (8) Resiscuit) Min. 1 Mz – WLK (female) (1) and chassis ground tance

3


Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between STC3 (female) (8) – WLK (female) (1) and chassis ground

Voltage

Max. 1 V



STC3 (female)

Resistance

Between (8) – (3)

20 – 60 z


Min. 1 Mz


D155A-6

65

SEN03209-00

40 Troubleshooting



66

D155A-6

SEN03210-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up

40 Troubleshooting

1

Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting for electrical system ............................................................................... 3 Information in troubleshooting table................................................................................................................ 7 E-1 When starting switch turned ON, machine monitor displays nothing ....................................................... 8 E-2 When starting switch turned ON (before starting engine), basic check item lights up............................ 10 E-3 Engine does not start (Engine does not turn) ......................................................................................... 12 E-4 Preheater does not operate.................................................................................................................... 15 E-5 Precaution item lights up while engine is running .................................................................................. 18 E-6 Emergency stop item lights up while engine is running.......................................................................... 20 E-7 Engine coolant temperature gauge does not indicate normally ............................................................. 22 E-8 Fuel level gauge does not indicate normally .......................................................................................... 23 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 25 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 26 E-11 Contents of display by machine monitor are different from applicable machine................................... 28 E-12 Machine monitor does not display some items .................................................................................... 28

D155A-6

1

SEN03210-01

40 Troubleshooting

E-13 Function switch does not work ............................................................................................................. 28 E-14 Operation mode does not change ........................................................................................................ 29 E-15 Gearshift mode does not change ......................................................................................................... 29 E-16 Customize function does not operate normally .................................................................................... 30 E-17 Customize memory function does not normally.................................................................................... 30 E-18 Alarm buzzer cannot be stopped.......................................................................................................... 31 E-19 Air conditioner does not operate normally (including air conditioner fault history) ............................... 32 E-20 When starting switch is turned OFF, service meter is not displayed .................................................... 46 E-21 Machine monitor cannot be set in service mode .................................................................................. 46 E-22 Ripper pin puller cylinder does not operate .......................................................................................... 48 E-23 Backup alarm does not sound or does not stop ................................................................................... 50 E-24 Headlamp, rear lamp, and ripper point lamp do not light up................................................................. 52 E-25 Windshield wiper and window washer do not operate.......................................................................... 57 E-26 KOMTRAX terminal does not operate normally ................................................................................... 73 E-27 Fan does not reverse............................................................................................................................ 74 E-28 Gear cannot be shifted ......................................................................................................................... 76 E-29 Electric priming pump does not operate or does not stop automatically .............................................. 78

2

D155A-6

40 Troubleshooting

SEN03210-01

Before carrying out troubleshooting for electrical system

1

Connection table of circuit breakers and fuse boxes a This connection table shows the devices to which each power supply of the fuse box supplies power (An accessory power supply is a device which supplies power while the starting switch is in the ON position and an unswitched power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers and fuses to see if the power is supplied normally. Circuit breakers CB1 – CB9 Power circuit breaker Circuit (Type of power supply) breaker No.



Circuit breaker capacity

CB9

20A

CB1

20A

CB2

20A

CB3

20A

Destination of power Optional power supply Power train controller Emergency power supply (For power train switch box) Work equipment controller Emergency power supply (For work equipment switch box) Air conditioner unit, blower motor, and compressor electromagnetic clutch

CB4

20A

Headlamp, additional headlamp

CB5

20A

Rear lamp, additional rear lamp, ripper point lamp

CB6

20A

CB7

20A

Starting switch Engine hold relay Machine monitor Power train controller Work equipment controller

CB8

30A

—

—

Power circuit breaker (Type of power supply)

Fuse No.

Fuel capacity


1

20A


2

5A

Backup alarm, backup alarm relay

3

20A


)

4

20A


)

5

5A

Engine controller (Signal ACC)

CB105H (Unswitched power supply)

Engine controller, electric priming pump Engine electrical intake air heater

Fuse box FS1

CB105 (Accessory power supply) Starting switch (ACC)

D155A-6


)

3

SEN03210-01

40 Troubleshooting

Fuse box FS2 Power circuit breaker (Type of power supply)

Fuse No.

Fuel capacity


1

5A

Pedal brake solenoid valve

2

5A



Starting switch (ACC)

4


Engine electrical intake air heater 3

20A

Ripper pin puller solenoid valve

4

5A

Horn

5

20A

Optional power supply

Pneumatic suspension seat

D155A-6

40 Troubleshooting

SEN03210-01

Locations of circuit breakers CB30, CB105, and CB105H (In battery room)

Locations of circuit breakers CB1 – CB9 and fuse boxes FS1 and FS2 (In battery room)

D155A-6

5

SEN03210-01

40 Troubleshooting

Fuse box Power circuit fuse (Type of power supply) FS1-1 (Unswitched power supply) FS1-3 (Accessory power supply)

Fuse No.

Fuel capacity

Destination of power Radio

1

10A

12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter)

2

20A

3

20A

Additional light relay, additional light Rotary lamp 12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter) Radio

FS1-4 (Accessory power supply)

Location of fuse box

6

Room lamp

4

20A

5

10A

Front wiper, rear wiper

6

10A

Left wiper, right wiper

Cigarette lighter Windshield wiper (Via intermittent relay)

(In operator's cab)

D155A-6

40 Troubleshooting

SEN03210-01


1

a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information

Trouble which occurred in the machine Information related to detected trouble or troubleshooting Cause

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment

1

• Disconnection Connector is connected defectively or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.


Possible causes of trouble (Given numbers are refer ence numbers, which do (1) Method of indicating connector No. and handling of Tnot indicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. 3 • If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 4 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.

Related circuit diagram This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (i o): Roughly shows the location on the machine.

D155A-6

7

SEN03210-01

40 Troubleshooting

E-1 When starting switch turned ON, machine monitor displays nothing 1 Trouble

Related information

• When starting switch turned ON, machine monitor displays nothing. • When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input password (if set), screen of check before starting, screen to check setting of preset, and ordinary screen in order. • When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Cause


1 Low charge level of battery

Electrolyte specific gravity (1 piece)

Min. 24 V

Min. 1.26

2

Defective circuit breaker (CB30, CB6, or CB7)

3

Machine monitor connector may be connected wrongly. Check it Wrong connection of connecdirectly (Connection between connectors CM01 and CM02 and tor between connectors CM03 and CM04).


Battery voltage (2 pieces)

Defective starting switch (Internal disconnection)

If circuit breaker is turned OFF, circuit probably has ground fault. (See cause 6.)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Starting switch Between 250 – 270

Resistance ON

Wiring harness between battery (–) – chassis ground

Resistance

Max. 1 z

Wiring harness between battery (+) – terminal BRB – CB30 (B30L)

Resistance

Max. 1 z

Wiring harness between CB30 (B30S) – CB7 (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between CB30 (B30S) – CB6 (1)

Resistance

Max. 1 z

Wiring harness between CB6 (2) – terminal 250

Resistance

Max. 1 z

Wiring harness between terminal 270 – CM01 (female) (14)

Resistance

Max. 1 z

Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB7 (2) – CM01 5 or defective contact in con- (female) (1), (2) nector) Wiring harness between CM01 (female) (3), (4) – chassis ground (GND11)

8

Max. 1 z


D155A-6

40 Troubleshooting

SEN03210-01

Cause



Wiring harness between battery (+) – terminal BRB – CB30 (B30L) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CB30 (B30S) – CB7 (1) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between CB6 (2) – terminal 250 or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Wiring harness between terminal 270 – CM01 (female) (14) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CB7 (2) – CM01 Ground fault in wiring har(female) (1), (2) or circuit branch end and 6 ness (Contact with GND cir- chassis ground cuit) Wiring harness between CB30 (B30S) – CB6 (1) or circuit branch end and chassis ground

a Prepare with starting switch OFF, then hold starting switch OFF and ON and carry out troubleshooting in each case. 7 Defective machine monitor

CM01

Starting switch

Voltage

Between (1), (2) – (3) , (4)

OFF

20 – 30 V

Between (14) – (3), (4)

ON

20 – 30 V


D155A-6

9

SEN03210-01

40 Troubleshooting

E-2 When starting switch turned ON (before starting engine), basic check item lights up Trouble Related information

1

• When starting switch turned ON (before starting engine), basic check item lights up. • Basic check item is only lowering of radiator coolant level. Cause Lowering of radiator coolant 1 level (When system is normal)

Standard value in normal state/Remarks on troubleshooting Coolant level in radiator sub tank may be low. Check it and add coolant if necessary. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective radiator coolant 2 level switch (Internal disconnection)

WLV (male)


Sub tank coolant level

Resistance

Between FULL – LOW

Max. 1 z

Below LOW

Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (3) 3 or defective contact in con- – WLV (female) (1) nector) Wiring harness between CM01 (female) (7), CM02 (female) (7) – WLV (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective machine monitor

CM02 Between (3) – chassis ground

Sub tank coolant level

Voltage

Between FULL – LOW

Max. 1 V

Below LOW

20 – 30 V


10

D155A-6

40 Troubleshooting

D155A-6

SEN03210-01

11

SEN03210-01

40 Troubleshooting

E-3 Engine does not start (Engine does not turn) Trouble Related information

1

• Engine does not start (Engine does not turn). • Engine starting circuit has following 2 start lock mechanisms. 1) Start lock with password of machine monitor 2) Start lock with parking brake lever and work equipment lock lever Cause


1 Low charge level of battery

2


Battery voltage (2 pieces)

Electrolyte specific gravity (1 piece)

Min. 24 V

Min. 1.26

a Prepare with starting switch OFF, then keep starting switch OFF and turn it to START and carry out troubleshooting in each case. Starting switch Between 250 – 280

Resistance OFF

Min. 1 Mz

START

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting.

3

Defective neutral safety relay Replace neutral safety relay (Right No.) with another (Internal trouble) relay. If engine starts at this time, neutral safety relay is defective.

NSF

a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. Starting motor Defective starting motor 4 (Internal defect) Possible causes and standard value in normal state

Voltage

Between B – chassis ground

Battery power supply

20 –30 V

Between ST (2) – chassis ground

Starting signal

20 –30 V

Between ST (2) – chassis ground

Generation signal

Max. 13 V

If battery power supply, starting signal, and generation signal are normal but starting motor does not turn, starting motor is defective.

5

Defective alternator (Internal short circuit)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Alternator Between R – chassis ground

Generation signal

Voltage Max. 13 V


6

Disconnection in wiring harness (Disconnection in wiring Wiring harness between terminal 280 – NSF or defective contact in con- (female) (3) nector) Wiring harness between NSF (female) (5) – EG2 (8) – ST (female) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between terminal 280 – NSF Ground fault in wiring har7 ness (Contact with GND cir- (female) (3) or circuit branch end and chassis ground cuit)

Resistance

Min. 1 Mz

Wiring harness between NSF (female) (5) – EG2 (8) – ST (female) (1) and chassis ground

Resistance

Min. 1 Mz


8

12

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between terminal R – ST (female) (2) or circuit branch end and chassis ground

Voltage

Max. 1 V

D155A-6

40 Troubleshooting


SEN03210-01

Cause 9

Detective engine controller power supply

Standard value in normal state/Remarks on troubleshooting As the engine controller power supply can be detective, carry out troubleshooting for "Failure code CA111".


D155A-6

13

SEN03210-01

14

40 Troubleshooting

D155A-6

40 Troubleshooting

SEN03210-01

E-4 Preheater does not operate Trouble Related information

1

(1) When starting switch is turned to HEAT position, preheating monitor does not light up. • Preheater monitor lights up when starting switch is turned to HEAT. • If engine coolant temperature is below -5 °C, automatic warm-up system operates and preheating monitor lights up for up to 40 seconds. Cause

1


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. Starting switch Between 250 – 255


Resistance OFF

Min. 1 Mz

HEAT

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) ResisMax. 1 z nector) (16) – terminal 255 tance a Prepare with starting switch OFF, then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. 3 Defective machine monitor

D155A-6

CM01

Starting switch

Voltage


OFF

Max. 1 V

HEAT

20 – 30 V

15

SEN03210-01

40 Troubleshooting

Trouble

(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become warm.

Related information

• Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting for E-3 Engine does not start (Engine does not turn)). Cause 1

Defective circuit breaker (CB105H)

Standard value in normal state/Remarks on troubleshooting If circuit breaker is turned OFF, circuit probably has ground fault (See cause 5). a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to HEAT and carry out troubleshooting.

2

Defective heater relay (Internal disconnection)

Heater relay Between HT – chassis ground Between HT/B – chassis ground

Starting switch

Voltage 20 – 30 V

HEAT 20 – 30 V

a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to HEAT and carry out troubleshooting in each case. 3

Defective intake air heater (Internal disconnection)

RHT

Starting switc

Voltage

Between terminal – chassis ground

HEAT

20 – 30 V

If voltage is normal but heater mounting part does not become warm, intake air heater is defective.



Wiring harness between terminal 255 – terminal HT

Resistance

Max. 1 z

Wiring harness between terminal BRC – CB105H (B105HS)

Resistance

Max. 1 z

Wiring harness between CB105H (B105HL) – terminal HT/A

Resistance

Max. 1 z

Wiring harness between terminal HT/B – terminal RHT

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between terminal 255 – terminal HT or CM01 (female) (16) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between CB105H (B105HL) – terminal HT/A and chassis ground

Resistance

Min. 1 Mz

Wiring harness between terminal HT/B – terminal RHT and chassis ground

Resistance

Min. 1 Mz

Ground fault in wiring har5 ness (Contact with GND cir- Wiring harness between terminal BRC – CB105H (B105HS) and chassis ground cuit)

16

D155A-6

40 Troubleshooting

SEN03210-01


D155A-6

17

SEN03210-01

40 Troubleshooting

E-5 Precaution item lights up while engine is running Trouble Related information

• Precaution item lights up while engine is running. • Check item is only charge level monitor. • State of generation signal of alternator can be checked with monitoring function. (Code: 04300 Battery Charge Volt) Cause Defective generation by 1 alternator (when system is normal)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Alternator

Engine speed

Voltage

Between R – chassis ground

Medium or higher

20 – 30 V

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) (11) ResisMax. 1 z nector) – terminal R tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring har3 ness (Contact with GND cir- Wiring harness between CM01 (female) (11) cuit) – terminal R or circuit branch end and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective machine monitor

18

CM01

Engine

Voltage


Medium or higher

20 – 30 V

D155A-6

40 Troubleshooting

SEN03210-01


D155A-6

19

SEN03210-01

40 Troubleshooting

E-6 Emergency stop item lights up while engine is running Trouble Related information

(1) Engine coolant temperature monitor lights up. • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature) Cause


Trouble Related information


If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].

3 Defective machine monitor

If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

2

(2) Engine oil pressure monitor lights up. • Signals of engine oil pressure sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine oil pressure can be checked with monitoring function. (Code: 37200 Engine Oil Pressure)

Lowering of engine oil pres1 sure (when system is normal) 2

Related information


• Signals of torque converter oil temperature sensor are input to power train controller and then transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) Standard value in normal state/Remarks on troubleshooting

1

Overheating of power train oil (when system is normal)

2

If cause 1 is not detected, power train oil temperature sensor sysDefective power train oil temtem may be defective. Carry out troubleshooting for failure codes perature sensor system [DGT1KA] and [DGT1KX].


20

Engine oil pressure may be low. If it is low, remove cause.

(3) Power train oil temperature monitor lights up.

Cause



If cause 1 is not detected, engine oil pressure sensor system may Defective engine oil pressure be defective. Carry out troubleshooting for failure codes [CA135] sensor system and [CA141].


Trouble


Overheating of engine cool- Engine coolant may be overheated. If it is overheated, remove 1 ant (when system is normal) cause.

Cause


1

Power train oil may be overheated. If it is overheated, remove cause.


D155A-6

40 Troubleshooting


SEN03210-01

(4) Hydraulic oil temperature monitor lights up. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature) Cause


D155A-6

Overheating of hydraulic oil 1 (when system is normal) 2

Defective hydraulic oil temperature gauge system

Standard value in normal state/Remarks on troubleshooting Hydraulic oil may be overheated. If it is overheated, remove cause. If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge (Multi-gauge) does not display normally.

21

SEN03210-01

40 Troubleshooting

E-7 Engine coolant temperature gauge does not indicate normally

1

Trouble

(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C). (2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).

Related information

• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature)


Cause 1



Standard value in normal state/Remarks on troubleshooting Engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145]. If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

Trouble

(3) Display of coolant temperature gauge is different from actual engine coolant temperature. (4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor.

Related information

• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature) Cause

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.




Coolant temperature gauge level

105 °C

6

102 °C

5

100 °C

4

85 °C

3

60 °C

2

30 °C

1

Engine coolant temperature gauge and coolant temperature monitor

22

D155A-6

40 Troubleshooting

SEN03210-01

E-8 Fuel level gauge does not indicate normally Trouble Related nformation

1

(1) While fuel is added, fuel level gauge does not rise from red range (E). (2) While fuel level is low, fuel level gauge does not lower from green range top (F) • Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel Level Sensor Volt) Cause Defective fuel level sensor 1 (Internal disconnection or short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FLV (male) Between (1) – (2)

Fuel level

Resistance

FULL

Approx. 4 z

EMPTY

Approx. 85 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM01 (female) (9) 2 or defective contact in con- – FLV (female) (1) nector) Wiring harness between CM01 (female) (12) – FLV (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between CM01 (female) (9) Resiscuit) Min. 1 Mz – FLV (female) (1) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between CM01 (female) (9) Voltage Max. 1 V – FLV (female) (1) and chassis ground 5 Defective machine monitor

If causes 1 – 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


D155A-6

23

SEN03210-01


40 Troubleshooting

(3) Display of fuel level gauge is different from actual fuel level. (4) Display of fuel level gauge is different from display of fuel level monitor. • Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel Level Sensor Volt) Cause




Quantity of fuel

Reading of fuel level gauge

565 l

6

425 l

5

310 l

4

220 l

3

150 l

2

75 l

1

Fuel level gauge and fuel level monitor

24

D155A-6

40 Troubleshooting

SEN03210-01

E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally 1 Trouble

(1) While power train oil temperature is rising normally, temperature gauge does not rise from white range (C). (2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H).

Related information

• Signals of power train oil temperature sensor are input to power train controller and then transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) Cause



Power train oil temperature sensor system may be defective. Defective power train oil tem1 Carry out troubleshooting for failure codes [DGT1KA] and perature sensor system [DGT1KX]. 2 Defective machine monitor

If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

Trouble

(3) Display of power train temperature gauge is different from actual power train oil temperature. (4) Display of power train oil temperature gauge is different from display of power train oil temperature monitor.

Related information

• Signals of power train oil temperature sensor are input to power train controller and then transmitted to machine monitor through communication system. • Power train oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) Cause




Power train oil temperature

Power train oil temperature gauge level

130 °C

6

120 °C

5

118 °C

4

80 °C

3

50 °C

2

0 °C

1

Power train oil temperature gauge and power train oil temperature monitor

D155A-6

25

SEN03210-01

40 Troubleshooting

E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally Trouble Related information

(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C). (2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H). • Hydraulic temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature) Cause Defective hydraulic oil temperature sensor system 1 (Internal disconnection or short circuit)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. HDT (male)

Resistance

Between (1) – (2)

3.5 – 90 kz


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM01 (female) (8) Resis2 Max. 1 z or defective contact in con- – HDT (female) (1) tance nector) Wiring harness between CM01 (female) ResisMax. 1 z (12) – HDT (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Contact with GND cirWiring harness between CM01 (female) (8) Resiscuit) Min. 1 Mz – HDT (female) (1) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between CM01 (female) (8) Voltage Max. 1 V – HDT (female) (1) and chassis ground 5 Defective machine monitor



26

D155A-6

40 Troubleshooting


SEN03210-01

(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature) Cause





Reading of hydraulic oil temperature gauge

110 °C

6

100 °C

5

98 °C

4

70 °C

3

20 °C

2

0 °C

1

Hydraulic oil temperature gauge and hydraulic oil temperature monitor

D155A-6

27

SEN03210-01

40 Troubleshooting

E-11 Contents of display by machine monitor are different from applicable machine Trouble

1

• Contents of display by machine monitor are different from applicable machine.


Cause 1 Defective machine monitor

Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

E-12 Machine monitor does not display some items Trouble Related information

• Machine monitor does not display some items. • The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. Cause


1

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting.

1

Defective machine monitor (LCD panel)

When following switches are operated, if all LCD panel is lighted up (all surface becomes white), LCD panel is normal. • Operation of switches: [4] + [F2] (Press simultaneously)

2

Defective machine monitor (body)


E-13 Function switch does not work Trouble

1

• Function switch does not work.


28



D155A-6

40 Troubleshooting

SEN03210-01

E-14 Operation mode does not change Trouble

1

(1) When operation mode switch is operated, display of operation mode monitor does not change.






(2) When operation mode is changed, engine output is not changed. • Engine output mode recognized by engine controller can be checked with monitoring function. (Code: 17500 Engine Power Mode) Cause



Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


Engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

E-15 Gearshift mode does not change Trouble

1

(1) When gearshift mode switch is operated, display of speed mode section does not change.


Trouble



(2) When gearshift mode is changed, gearshift setting of power train is not changed.

Related information


D155A-6

Cause 1 Defective machine monitor 2


Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Power train controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

29

SEN03210-01

40 Troubleshooting

E-16 Customize function does not operate normally Trouble

1

(1) When customize switch is operated, customize screen is not displayed.


Trouble



(2) When setting is changed on customize screen, setting of machine is not changed.

Related information Cause Possible causes and standard value in normal state



Defective engine controller, Engine controller, power train controller may be defective. (Since 2 defective power train controltrouble is in system, troubleshooting cannot be carried out.) ler

E-17 Customize memory function does not normally Trouble

1

(1) When customize memory switch is operated, customize memory screen is not displayed.


Trouble



(2) When selection is changed on customize memory screen, setting of machine is not changed.

Related information Cause Possible causes and standard value in normal state

30



Defective engine controller, Engine controller, power train controller may be defective. (Since 2 defective power train controltrouble is in system, troubleshooting cannot be carried out.) ler

D155A-6

40 Troubleshooting

SEN03210-01

E-18 Alarm buzzer cannot be stopped Trouble

1

• Alarm buzzer cannot be stopped.


D155A-6



31

SEN03210-01

40 Troubleshooting

E-19 Air conditioner does not operate normally (including air conditioner fault history) Trouble

1

(1) When air conditioner switch is operated, air conditioner control screen is not displayed.


Trouble



(2) When air conditioner switch is operated, air conditioner does not operate at all.


Defective circuit breaker (CB3)

2 Defective fuse in unit

Standard value in normal state/Remarks on troubleshooting If circuit breaker is turned OFF, circuit probably has ground fault (See cause 4). If fuse in unit is broken, circuit in unit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB3 (2) – fuse in 3 or defective contact in con- unit - ACCN (wiring side) (6) nector) Wiring harness between ACCN (wiring side) (16) – chassis ground (GND12)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between CB3 (2) – fuse in Resiscuit) Min. 1 Mz unit – ACCN (wiring side) (6) or circuit tance branch end and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5

Defective air conditioner controller

ACCN (wiring side)

Voltage

Between (6) – (16)

20 – 30 V

If above voltage is normal, air conditioner controller may be defective. 6 Defective machine monitor

32


D155A-6

40 Troubleshooting

Trouble

SEN03210-01

(3) Air does not come out (Air flow is insufficient).


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side).

1

2

Defective blower relay (Internal disconnection)

Defective power transistor (Internal defect)

AC03 (male)

Resistance

Between (1) – (3)

140 – 340 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (contact side). AC03

Air conditioner switch

Voltage


Air blow position

20 – 30 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fan switch Operate between Low and Medium and High.

If air flow changes according to operation of fan switch, power transistor (ACPT) is normal.

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state

3 Defective blower motor (Internal defect)

ACBM (wiring side) Air conditioner switch Between (1) – (2)

Air blow position

Voltage 20 – 30 V

If above voltage is normal and blower motor does not revolve, blower motor (ACBM) is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CB3 (2) – fuse in unit - AC03 (female) (1)

Resistance

Max. 1 z

Wiring harness between AC03 (female) (3) – ACCN (wiring side) (36)

Resistance

Max. 1 z

Wiring harness between CB3 (2) – AC03 (female) (4)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between ACPT (wiring side) (1) – chassis ground (GND12)

Resistance

Max. 1 z

Wiring harness between ACPT (wiring side) (2) – ACCN (wiring side) (8)

Resistance

Max. 1 z

Wiring harness between ACPT (wiring side) (4) – ACCN (wiring side) (7)

Resistance

Max. 1 z

Disconnection in wiring harness (Disconnection in wiring Wiring harness between AC03 (female) (5) 4 or defective contact in con- – ACBM (wiring side) (1) nector) Wiring harness between ACBM (wiring side) (2) – ACPT (wiring side) (3)

D155A-6

33

SEN03210-01

40 Troubleshooting

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AC03 (female) (3) – ACCN (wiring side) (36) and chassis ground


Wiring harness between AC03 (female) (5) Ground fault in wiring har– ACBM (wiring side) (1) and chassis 5 ness (Contact with GND cirground cuit) Wiring harness between ACBM (wiring side) (2) – ACPT (wiring side) (3) and chassis ground Wiring harness between ACPT (wiring side) (2) – ACCN (wiring side) (8) and chassis ground

34

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

6

If causes 1 – 5 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)

7

If causes 1 – 5 are not detected, air conditioner system may be Defective air conditioner sysdefective. See Machine Component Volume, Shop Manual, Troutem bleshooting, Air conditioner, Troubleshooting.

D155A-6

40 Troubleshooting

Trouble

SEN03210-01

(4) Air is not cooled (Cooling performance is insufficient).


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side).

1

Defective compressor relay (Internal disconnection)

2 Defective internal air sensor


AC04 (male)

Resistance

Between (1) – (3)

140 – 340 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (contact side). AC04


Voltage


Cooling position

20 – 30 V

Internal air sensor may be defective. Carry out troubleshooting for "Abnormality in internal air sensor".

3

Defective high and low pres- High and low pressure switches may be defective. Carry out trousure switches bleshooting for "Abnormality in refrigerant".

4

Defective compressor clutch Compressor clutch may be defective. Check it directly. (Internal defect)

5

Defective compressor (InterCompressor may be defective. Check it directly. nal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CB3 (2) – fuse in unit – AC04 (female) (1)

Disconnection in wiring harness (Disconnection in wiring Wiring harness between AC04 (female) (3) 6 or defective contact in con- – ACCN (wiring side) (35) nector) Wiring harness between CB3 (2) – AC04 (female) (4) Wiring harness between AC04 (female) (2) – A/C (female) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z


D155A-6

Ground fault in wiring harWiring harness between AC04 (female) (3) 7 ness (Contact with GND cir- – ACCN (wiring side) (35) and chassis cuit) ground

Resistance

Min. 1 Mz

Wiring harness between AC04 (female) (2) – A/C (female) (1) and chassis ground

Resistance

Min. 1 Mz

8


9

If causes 1 – 7 are not detected, air conditioner system may be Defective air conditioner sysdefective. See Machine Component Volume, Shop Manual, Troutem bleshooting, "Air conditioner", Troubleshooting.

35

SEN03210-01

40 Troubleshooting

Trouble

(5) Air conditioner fault history: Communication condition "CAN disconnection", Communication condition "Abnormal"

Related information

• While abnormality in communication is being detected, "CAN disconnection" is displayed. • If abnormality in communication has been detected and reset, "Abnormality" is displayed. • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, condition of other items is not displayed. • Method of reproducing fault history: Turn starting switch ON. Cause


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between AC02 (female) (1) Resis1 Max. 1 z or defective contact in con- – CM02 (female) (8), (9) tance nector) Wiring harness between AC02 (female) (2) ResisMax. 1 z – CM02 (female) (10) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between AC02 (female) (1) – CM02 (female) (8), (9), EGC2 (female) Ground fault in wiring har(46), STC2 (female) (32), CA1 (female) (A), 2 ness (Contact with GND ciror SRV (female) (3) and chassis ground cuit) Wiring harness between AC02 (female) (2) – CM02 (female) (10), EGC2 (female) (47), STC2 (female) (22), CA1 (female) (B), or SRV (female) (10) and chassis ground

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between AC02 (female) (1) – CM02 (female) (8), (9), EGC2 (female) Hot short (Short circuit with (46), STC2 (female) (32), CA1 (female) (A), 3 24V circuit) in wiring harness or SRV (female) (3) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between AC02 (female) (2) – CM02 (female) (10), EGC2 (female) (47), STC2 (female) (22), CA1 (female) (B), or SRV (female) (10) and chassis ground

Resistance

Min. 1 Mz

Defective CAN terminal 4 resistance (Internal short circuit or disconnection)

5


Resistance

Between (A) – (B)

Approx. 120 z



36

Resistance


D155A-6

40 Troubleshooting




SEN03210-01

(6) Air conditioner fault history: Setting condition "Abnormality" • If setting of air conditioner controller model is different from setting of machine monitor model, "Abnormality" is displayed. • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing fault history: Turn starting switch ON. Cause 1


Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in troller system, troubleshooting cannot be carried out.)


Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

(7) Air conditioner fault history: Internal air sensor "Abnormality" • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause Defective internal air sensor 1 (Internal disconnection or short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ACPS (device side)

Resistance

Between (1) – (2)

300 z – 430 kz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACCN (wiring side) 2 or defective contact in con- (11) – ACPS (wiring side) (2) nector) Wiring harness between ACCN (wiring side) (27) – ACPS (wiring side) (1)

3

Short circuit in wiring harness (with GND circuit)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ACCN (wiring side) (11) – ACPS (wiring side) (2) and chassis ground

Resistance

Min. 1 Mz


4

5

D155A-6

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between ACCN (wiring side) (11) – ACPS (wiring side) (2) and chassis ground

Voltage

Max. 1 V


37

SEN03210-01

Trouble Related information Possible causes and standard value in normal state


40 Troubleshooting

(8) Air conditioner fault history: External air sensor "Unused" • External air sensor is not used in air conditioner system of this machine. • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Cause 1 Normal display

Standard value in normal state/Remarks on troubleshooting Since external air sensor is not used in air conditioner system of this machine, above display is normal.

(9) Air conditioner fault history: Air flow sensor "Abnormality" • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause Defective air flow sensor 1 (Internal disconnection or short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ACFS (device side)

Resistance

Between (1) – (2)

100 z – 115 kz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACCN (wiring side) 2 or defective contact in con- (12) – ACFS (wiring side) (2) nector) Wiring harness between ACCN (wiring side) (27) – ACFS (wiring side) (1)

3

Short circuit in wiring harness (with GND circuit)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ACCN (wiring side) (12) – ACFS (wiring side) (2) and chassis ground

Resistance

Min. 1 Mz


4

5

38

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between ACCN (wiring side) (12) – ACFS (wiring side) (2) and chassis ground

Voltage

Max. 1 V


D155A-6

40 Troubleshooting


SEN03210-01

(10) Air conditioner fault history: Daylight sensor "Abnormality" • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1

Defective daylight sensor (Internal defect)

Standard value in normal state/Remarks on troubleshooting Daylight sensor may be defective.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACCN (wiring side) Resis2 Max. 1 z or defective contact in con- (3) – SLS (female) (1) tance nector) Wiring harness between ACCN (wiring side) ResisMax. 1 z (15) – SLS (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state

Ground fault in wiring harWiring harness between ACCN (wiring side) 3 ness (Contact with GND cir- (3) – SLS (female) (1) or circuit branch end cuit) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between ACCN (wiring side) (15) – SLS (female) (2) and chassis ground

Resistance

Min. 1 Mz


5

D155A-6

Wiring harness between ACCN (wiring side) Hot short (Short circuit with (3) – SLS (female) (1) or circuit branch end 24V circuit) in wiring harness and chassis ground

Voltage

Max. 1 V

Wiring harness between ACCN (wiring side) (15) – SLS (female) (2) and chassis ground

Voltage

Max. 1 V


39

SEN03210-01


40 Troubleshooting

(11) Air conditioner fault history: Air outlet damper 1 "Abnormality" • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1


Defective air outlet servomoAir outlet servomotor may be defective. tor 1 (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ACB1 (wiring side) (1) – ACCN (wiring side) (3)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ACB1 (wiring side) (1) – ACCN (wiring side) (3) or circuit branch end and chassis ground Possible causes and standard value in normal state

Wiring harness between ACB1 (wiring side) Ground fault in wiring har(5) – ACCN (wiring side) (9) and chassis 3 ness (Contact with GND cirground cuit) Wiring harness between ACB1 (wiring side) (6) - ACCN (wiring side) (24) and chassis ground Wiring harness between ACB1 (wiring side) (7) – ACCN (wiring side) (23) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ACB1 (wiring side) (1) – ACCN (wiring side) (3) or circuit branch end and chassis ground

Voltage

Max. 1 V

Wiring harness between ACB1 (wiring side) Hot short (Short circuit with (5) – ACCN (wiring side) (9) and chassis 4 24V circuit) in wiring harness ground

Voltage

Max. 1 V

Wiring harness between ACB1 (wiring side) (6) – ACCN (wiring side) (24) and chassis ground

Voltage

Max. 1 V


Voltage

Max. 1 V

5

40


D155A-6

40 Troubleshooting


SEN03210-01

(12) Air conditioner fault history: Air outlet damper 2 "Abnormality" • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1


Defective air outlet servomoAir outlet servomotor may be defective. tor 2 (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ACB2 (wiring side) (1) – ACCN (wiring side) (3) or circuit branch end and chassis ground Possible causes and standard value in normal state

Wiring harness between ACB2 (wiring side) Ground fault in wiring har(5) – ACCN (wiring side) (9) and chassis 3 ness (Contact with GND cirground cuit) Wiring harness between ACB2 (wiring side) (6) - ACCN (wiring side) (24) and chassis ground Wiring harness between ACB2 (wiring side) (7) – ACCN (wiring side) (23) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ACB2 (wiring side) (1) – ACCN (wiring side) (3) or circuit branch end and chassis ground

Voltage

Max. 1 V

Wiring harness between ACB2 (wiring side) Hot short (Short circuit with (5) – ACCN (wiring side) (9) and chassis 4 24V circuit) in wiring harness ground

Voltage

Max. 1 V


Voltage

Max. 1 V


Voltage

Max. 1 V

5

D155A-6


41

SEN03210-01


40 Troubleshooting

(13) Air conditioner fault history: A/M damper "Abnormality" • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1


Defective air mix servomotor Air mix servomotor may be defective. (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ACSM (wiring side) (1) – ACCN (wiring side) (27)

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between ACSM (wiring side) (5) – ACCN(wiring side) (2)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ACSM (wiring side) (3) – ACCN (wiring side) (3) or circuit branch end and chassis ground Possible causes and standard value in normal state

Wiring harness between ACSM (wiring side) Ground fault in wiring har(5) – ACCN (wiring side) (2) and chassis 3 ness (Contact with GND cirground cuit) Wiring harness between ACSM (wiring side) (6) – ACCN (wiring side) (21) and chassis ground Wiring harness between ACSM (wiring side) (7) – ACCN (wiring side) (22) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between ACSM (wiring side) (3) – ACCN (wiring side) (3) or circuit branch end and chassis ground

Voltage

Max. 1 V

Wiring harness between ACSM (wiring side) Hot short (Short circuit with (5) – ACCN (wiring side) (2) and chassis 4 24V circuit) in wiring harness ground

Voltage

Max. 1 V

Wiring harness between ACSM (wiring side) (6) – ACCN (wiring side) (21) and chassis ground

Voltage

Max. 1 V

Wiring harness between ACSM (wiring side) (7) – ACCN (wiring side) (22) and chassis ground

Voltage

Max. 1 V

5

42


D155A-6

40 Troubleshooting


SEN03210-01

(14) Air conditioner fault history: Refrigerant "Abnormality" • If "CAN disconnection" is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1


Defective high and low pres2 sure switches (Internal disconnection)

Refrigerant (gas) may be insufficient. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. AC05 (male)

Resistance

Between (1) – (2)

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACCN (wiring side) Resis3 Max. 1 z or defective contact in con- (4) – AC05 (female) (1) tance nector) Wiring harness between AC05 (female) (2) ResisMax. 1 z – chassis ground (GND12) tance 4

D155A-6

Insufficient refrigerant (gas) (when system is normal)



43

SEN03210-01

40 Troubleshooting


44

D155A-6

40 Troubleshooting

D155A-6

SEN03210-01

45

SEN03210-01

40 Troubleshooting

E-20 When starting switch is turned OFF, service meter is not displayed Trouble Related information

• When starting switch is turned OFF, service meter is not displayed. • While starting switch is at OFF position, if following switches are operated, service meter is displayed at top center of screen. Operation of switches: [4] + [1] (Press simultaneously) Cause


1


When starting switch is turned ON, if machine monitor displays Defective backup power sup- nothing, backup power supply system may be defective. In this 1 ply system case, carry out troubleshooting for "E-1 When starting switch turned ON, machine monitor displays nothing". 2 Defective machine monitor


E-21 Machine monitor cannot be set in service mode Trouble Related information Possible causes and standard value in normal state

46

1

• Machine monitor cannot be set in service mode. • If following switches are operated, machine monitor is set in service mode. Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order) Cause 1 Defective machine monitor


D155A-6

40 Troubleshooting

D155A-6

SEN03210-01

47

SEN03210-01

40 Troubleshooting

E-22 Ripper pin puller cylinder does not operate Trouble

1

(1) When pin puller switch is pulled out, cylinder is not retracted. (2) When pin puller switch is pushed in, cylinder is not extended.

Related information Cause 1 Defective fuse(FS2-3)

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault (See cause 5). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

2 Defective pin puller switch

PLSW (male) Between (1) – (2)

Pin puller switch

Resistance

Pulled out

Max. 1 z

Pushed in

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pin puller solenoid

PPL (male)

Resistance

Between (1) – (2)

10 – 80 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state


Wiring harness between FS22 (3) – PLSW (female) (1)

Resistance

Max. 1 z

Wiring harness between PLSW (female) (2) – PPL (female) (1)

Resistance

Max. 1 z

Wiring harness between PLSW (female) (2) – chassis ground (GND03)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between FS22 (3) – PLSW 5 ness (Contact with GND cir- (female) (1) or circuit branch end and chascuit) sis ground

Resistance

Min. 1 Mz

Wiring harness between PLSW (female) (2) – PPL (female) (1) and chassis ground

Resistance

Min. 1 Mz


48

Wiring harness between FS22 (3) – PLSW Hot short (Short circuit with (female) (1) or circuit branch end and chas24V circuit) in wiring harness sis ground

Voltage

Max. 1 V

Wiring harness between PLSW (female) (2) – PPL (female) (1) and chassis ground

Voltage

Max. 1 V

D155A-6

40 Troubleshooting

SEN03210-01


D155A-6

49

SEN03210-01

40 Troubleshooting

E-23 Backup alarm does not sound or does not stop Trouble

1

• Backup alarm does not sound or does not stop.



Defective backup alarm relay Replace backup alarm relay (Right No.) with 1 (Internal disconnection or another relay. If backup alarm operates norshort circuit) mally at this time, backup alarm relay is defective.

BKA




Wiring harness between BKA (female) (3) – branch point (F)

Resistance

Max. 1 z

Wiring harness between BKA (female) (5) – BKAL (female) (1)

Resistance

Max. 1 z

Wiring harness between BKAL (female) (2) – chassis ground (GND03)

Resistance

Max. 1 z


Ground fault in wiring har3 ness (Contact with GND cir- Wiring harness between BKA (female) (5) – cuit) BKAL (female) (1) or circuit branch end and chassis ground

Resistance

Min. 1 Mz


4

5

50

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between BKA (female) (5) – BKAL (female) (1) or circuit branch end and chassis ground Defective backup alarm (Internal trouble)

Voltage

Max. 1 V

If causes 1 – 4 are not detected, backup alarm may be defective.

D155A-6

40 Troubleshooting

SEN03210-01


D155A-6

51

SEN03210-01

40 Troubleshooting

E-24 Headlamp, rear lamp, and ripper point lamp do not light up Trouble Related information

1

(1) Headlamp does not light up. • Only when headlamp switch is set in "Moon" mark position, screen brightness of machine monitor is changed for night. Cause


1


If circuit breaker is turned OFF, circuit probably has ground fault (See cause 8).

2

Defective headlamp (Broken Headlamp bulb and ground wire may be defective. Check them bulb, default grounding) directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective headlamp switch 3 (Internal disconnection)

FLSW (male)

Headlamp switch

Resistance

Between (5) – (4)

Moon mark

Max. 1 z


Neutral

Min. 1 Mz

Between (5) – (6)

Sun mark

Max. 1 z


Defective left headlamp relay Replace left headlamp relay (Right No.) with 4 (Internal disconnection or another relay. If left headlamp becomes short circuit) normal at this time, left headlamp relay is defective.

LMFL



Defective right headlamp 5 relay (Internal disconnection Replace right headlamp relay (Right No.) with another relay. If right headlamp or short circuit) becomes normal at this time, right headlamp relay is defective. Defective diode LMD1 or 6 LMD2 (Internal disconnection)

LMFR

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LMD1 (male), LMD2 (male)

Continuity

Between (2) – (1)

There is continuity



52

Wiring harness between terminal 270 – FLSW (female) (5)

Resistance

Max. 1 z

Wiring harness between FLSW (female) (4) – LMD1 (female) (2)

Resistance

Max. 1 z

Wiring harness between LMD1 (female) (1), LMD2 (female) (1) – LMFL (female) (1), LMFR (female) (1)

Resistance

Max. 1 z

Wiring harness between LMFL (female) (2), LMFR (female) (2) – chassis ground (GND03)

Resistance

Max. 1 z

Wiring harness between CB4 (2) – LMFL (female) (3), LMFR (female) (3)

Resistance

Max. 1 z

Wiring harness between LMFL (female) (5) – LHDL (female) (1)

Resistance

Max. 1 z

Wiring harness between LMFR (female) (5) – LHDR (female) (1)

Resistance

Max. 1 z

D155A-6

40 Troubleshooting

SEN03210-01

Cause



D155A-6

Wiring harness between terminal 270 – FLSW (female) (5) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Wiring harness between FLSW (female) (4), (3) – LMD1 (female) (2) or CM01 (female) (13) and chassis ground

Resistance

Min. 1 Mz

Ground fault in wiring harWiring harness between LMD1 (female) (1), 8 ness (Contact with GND cirLMD2 (female) (1) – LMFL (female) (1), cuit) LMFR (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CB4 (2) – LMFL (female) (3), LMFR (female) (3) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LMFL (female) (5) – LHDL (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LMFR (female) (5) – LHDR (female) (1) and chassis ground

Resistance

Min. 1 Mz

53

SEN03210-01

Trouble

40 Troubleshooting

(2) Rear lamp and ripper point lamp do not light up.



1


If circuit breaker is turned OFF, circuit probably has ground fault (See cause 8).

2

Defective rear lamp (Broken Rear lamp bulb and ground wire may be defective. Check them bulb, default grounding) directly.

Defective ripper point lamp (Broken bulb, default ground- Ripper point lamp bulb and ground wire may be defective. Check 3 ing) them directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4

Defective rear lamp switch (Internal disconnection)

RLSW (male) Between (5) – (6)

Defective rear lamp relay 5 (Internal disconnection or short circuit)


Rear lamp switch

Resistance

OFF

Min. 1 Mz

ON

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace rear lamp relay (Right No.) with another relay. If rear lamp becomes normal at this time, rear lamp relay is defective.

LMRE


Defective ripper point lamp 6 relay (Internal disconnection Replace ripper point lamp relay (Right No.) with another relay. If ripper point lamp or short circuit) becomes normal at this time, ripper point lamp relay is defective.

LMRP

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between terminal 270 – RLSW (female) (5)

Resistance

Max. 1 z

Wiring harness between RLSW (female) (6) – LMRE (female) (1), LMRP (female) (1)

Resistance

Max. 1 z

Wiring harness between LMRE (female) (2), LMRP (female) (2) – chassis ground (GND03)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between LREL (female) (2) – chassis ground (GND03)

Resistance

Max. 1 z

Wiring harness between LRER (female) (2) – chassis ground (GND03)

Resistance

Max. 1 z

Wiring harness between LMRP (female) (5) – LRP1 (female) (1)

Resistance

Max. 1 z

Disconnection in wiring harness (Disconnection in wiring 7 Wiring harness between CB5 (2) – LMRE or defective contact in con(female) (3), LMRP (female) (3) nector) Wiring harness between LMRE (female) (5) – LREL (female) (1), LRER (female) (1)

54

D155A-6

40 Troubleshooting

SEN03210-01

Cause



D155A-6

Wiring harness between terminal 270 – RLSW (female) (5) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Wiring harness between RLSW (female) (6), (1) – LMRE (female) (1), LMRP (female) (1) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between LMRE (female) (5) – LREL (female) (1), LRER (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between LMRP (female) (5) – LRP1 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Ground fault in wiring har8 ness (Contact with GND cirWiring harness between CB5 (2) – LMRE cuit) (female) (3), LMRP (female) (3) and chassis ground

55

SEN03210-01

40 Troubleshooting


56

D155A-6

40 Troubleshooting

SEN03210-01

E-25 Windshield wiper and window washer do not operate Trouble

1

(1) No windshield wipers and window washers do not operate.



Defective fuse (FS12 – 4 or

-4)

If fuse is broken, circuit probably has ground fault (See cause 3). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Disconnection in wiring harness (Disconnection in wiring Wiring harness between FS12 (4) – fuse 2 or defective contact in con- (B3) nector) Wiring harness between fuse (4) – CN11 (female) (5)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between FS12 (4) – fuse 3 ness (Contact with GND cir(B3) and chassis ground cuit) Wiring harness between fuse (4) – CN11 (female) (5) and chassis ground

D155A-6

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

57

SEN03210-01


40 Troubleshooting

(2) Front windshield wiper does not operate (Continuous operation is defective). • If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become defective. • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with front wiper switch ON and intermittent switch OFF. Cause 1 Defective fuse (

Standard value in normal state/Remarks on troubleshooting -5)

If fuse is broken, circuit probably has ground fault (See cause 7). a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

2

Defective front wiper motor (Internal trouble)

CN23

Front wiper switch

Voltage

Between (6) – (1)

ON

20 – 30 V

If voltage is normal but wiper does not operate, motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Defective front wiper switch (Internal disconnection)

CN14 (male) Between (2) – (3)


Defective front wiper inter4 mittent selector relay (Internal trouble)

Defective front wiper inter5 mittent relay (Internal trouble)

Front wiper switch

Resistance

OFF

Min. 1 Mz

ON

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace front wiper intermittent selector relay (Right No.) with another relay. If front wiper becomes normal at this time, intermittent selector relay is defective.

CN29

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace front wiper intermittent relay (Right No.) with another relay. If front wiper becomes normal at this time, intermittent relay is defective.

CN28

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse (5) – CN14 (female) (3), (5), CN28 (female) (3), or CN23 (female) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between CN28 (female) (5) – CN23 (female) (6)

Resistance

Max. 1 z

Wiring harness between CN28 (female) (6) – chassis ground (GND3)

Resistance

Max. 1 z

Disconnection in wiring harWiring harness between CN14 (female) (2) ness (Disconnection in wiring – CN29 (female) (3) 6 or defective contact in conWiring harness between CN29 (female) (4) nector) – CN28 (female) (4)

58

D155A-6

40 Troubleshooting

SEN03210-01

Cause



Trouble

Wiring harness between fuse (5) – CN14 (female) (3), (5), CN28 (female) (3), CN23 (female) (3), or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between CN29 (female) (4) – CN28 (female) (4) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Ground fault in wiring har7 ness (Contact with GND cirWiring harness between CN14 (female) (2) cuit) – CN29 (female) (3) and chassis ground

(3) Front windshield wiper does not operate intermittently. • Before carrying out troubleshooting, check that continuous operation is normal.

Related information

• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with front wiper switch and intermittent switch ON. • During intermittent operation, wiper stops for 5 seconds after each cycle of operation. Cause


1

Defective intermittent switch (Internal disconnection)


Defective front wiper inter2 mittent selector relay (Internal trouble)


Defective front wiper inter3 mittent relay (Internal trouble)

Intermittent switch

Resistance

OFF

Min. 1 Mz

ON

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace front wiper intermittent selector relay (Right No.) with another relay. If front wiper becomes normal at this time, intermittent selector relay is defective.

CN29

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace front wiper intermittent relay (Right No.) with another relay. If front wiper becomes normal at this time, intermittent relay is defective.

CN28



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


D155A-6

Ground fault in wiring harWiring harness between CN11 (female) (6) 5 ness (Contact with GND cir- – CN29 (female) (1) or circuit branch end cuit) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

59

SEN03210-01


40 Troubleshooting

(4) Rear windshield wiper does not operate (Continuous operation is defective). • If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become defective. • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with rear wiper switch ON and intermittent switch OFF. Cause 1 Defective fuse (



2

Defective rear wiper motor (Internal trouble)

CN37

Rear wiper switch

Voltage

Between (6) – (1)

ON

20 – 30 V

If voltage is normal but wiper does not operate, motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Defective rear wiper switch (Internal disconnection)


Rear wiper switch

Resistance

OFF

Min. 1 Mz

ON

Max. 1 z



Defective rear wiper intermitReplace rear wiper intermittent selector 4 tent selector relay (Internal relay (Right No.) with another relay. If rear trouble) wiper becomes normal at this time, intermittent selector relay is defective.

CN33


Defective rear wiper intermit- Replace rear wiper intermittent relay (Right tent relay (Internal trouble) No.) with another relay. If rear wiper becomes normal at this time, intermittent relay is defective.

CN32

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse (5) – CN12 (female) (3), (5), CN32 (female) (3), or CN37 (female) (6)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Disconnection in wiring harWiring harness between CN12 (female) (2) ness (Disconnection in wiring – CN33 (female) (3) 6 or defective contact in conWiring harness between CN33 (female) (4) nector) – CN32 (female) (4)

60

D155A-6

40 Troubleshooting

SEN03210-01

Cause



Trouble

Wiring harness between fuse (5) – CN12 (female) (3), (5), CN32 (female) (3), CN37 (female) (6), or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between CN33 (female) (4) –- CN32 (female) (4) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Ground fault in wiring har7 ness (Contact with GND cirWiring harness between CN12 (female) (2) cuit) – CN33 (female) (3) and chassis ground

(5) Rear windshield wiper does not operate intermittently. • Before carrying out troubleshooting, check that continuous operation is normal.

Related information

• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with rear wiper switch and intermittent switch ON. • During intermittent operation, wiper stops for 5 seconds after each cycle of operation. Cause


1



Intermittent switch

Resistance

OFF

Min. 1 Mz

ON

Max. 1 z


Defective rear wiper intermitReplace rear wiper intermittent selector 2 tent selector relay (Internal relay (Right No.) with another relay. If rear trouble) wiper becomes normal at this time, intermittent selector relay is defective.

CN33

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state

3

Defective rear wiper intermit- Replace rear wiper intermittent relay (Right tent relay (Internal trouble) No.) with another relay. If rear wiper becomes normal at this time, intermittent relay is defective.

CN32



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


D155A-6


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

61

SEN03210-01


40 Troubleshooting

(6) Right door wiper does not operate (Continuous operation is defective). • If fuse ( -6) is broken, operations of both right door wiper and left door wiper become defective. • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF. Cause 1 Defective fuse (



2

Defective right door wiper motor (Internal trouble)

CN17

Right door wiper switch

Voltage

Between (3) – (1)

ON

20 – 30 V

If voltage is normal but wiper does not operate, motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right door wiper 3 switch (Internal disconnection)

CN13 (male)


Resistance

OFF

Min. 1 Mz

ON

Max. 1 z

Between (2) – (3)

Defective right door wiper 4 intermittent selector relay (Internal trouble) Possible causes and standard value in normal state

Defective right door wiper 5 intermittent relay (Internal trouble)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace right door wiper intermittent selector relay (Right No.) with another relay. If right door wiper becomes normal at this time, intermittent selector relay is defective.

CN31

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace right door wiper intermittent relay (Right No.) with another relay. If right door wiper becomes normal at this time, intermittent relay is defective.

CN30


62

Wiring harness between fuse (6) – CN13 (female) (3), (5) or CN17 (female) (4)

Resistance

Max. 1 z

Wiring harness between fuse (female) (3)

(6) – CN30

Resistance

Max. 1 z

Disconnection in wiring har- Wiring harness between CN13 (female) (2) ness (Disconnection in wiring – CN31 (female) (3) 6 or defective contact in conWiring harness between CN31 (female) (4) nector) – CN30 (female) (4)

Resistance

Max. 1 z

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

D155A-6

40 Troubleshooting

SEN03210-01

Cause



D155A-6

Wiring harness between fuse (6) – CN13 (female) (3), (5), CN17 (female) (4), or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Wiring harness between fuse (6) – CN30 Ground fault in wiring har(female) (3) or circuit branch end and chas7 ness (Contact with GND cirsis ground cuit) Wiring harness between CN13 (female) (2) – CN31 (female) (3) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

63

SEN03210-01

Trouble

40 Troubleshooting

(7) Right door wiper does not operate intermittently. • Before carrying out troubleshooting, check that continuous operation is normal.

Related information

• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with right door wiper switch and intermittent switch ON. • During intermittent operation, wiper stops for 5 seconds after each cycle of operation. Cause


1



Defective right door wiper 2 intermittent selector relay (Internal trouble)


Defective right door wiper 3 intermittent relay (Internal trouble)

Intermittent switch

Resistance

OFF

Min. 1 Mz

ON

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace right door wiper intermittent selector relay (Right No.) with another relay. If right door wiper becomes normal at this time, intermittent selector relay is defective.

CN31

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace right door wiper intermittent relay (Right No.) with another relay. If right door wiper becomes normal at this time, intermittent relay is defective.

CN30



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


64


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

D155A-6

40 Troubleshooting


SEN03210-01

(8) Left door wiper does not operate (Continuous operation is defective). • If fuse (

-6) is broken, operations of both right door wiper and left door wiper become defective.

• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF. Cause 1 Defective fuse (



2

Defective left door wiper motor (Internal trouble)

CN24

Left door wiper switch

Voltage

Between (3) – (1)

ON

20 – 30 V

If voltage is normal but wiper does not operate, motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left door wiper 3 switch (Internal disconnection)

CN15 (male)


Resistance

OFF

Min. 1 Mz

ON

Max. 1 z

Between (2) – (3)

Defective left door wiper 4 intermittent selector relay (Internal trouble) Possible causes and standard value in normal state

Defective left door wiper 5 intermittent relay (Internal trouble)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace left door wiper intermittent selector relay (Right No.) with another relay. If left door wiper becomes normal at this time, intermittent selector relay is defective.

CN27

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace left door wiper intermittent relay (Right No.) with another relay. If left door wiper becomes normal at this time, intermittent relay is defective.

CN26

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (6) – CN15

Resistance

Max. 1 z

Wiring harness between fuse (6) – CN26 (female) (3) or CN24 (female) (4)

Resistance

Max. 1 z

Disconnection in wiring har- Wiring harness between CN15 (female) (2) ness (Disconnection in wiring – CN27 (female) (3) 6 or defective contact in conWiring harness between CN27 (female) (4) nector) – CN26 (female) (4)

Resistance

Max. 1 z

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between fuse (female) (3), (5)

D155A-6

65

SEN03210-01

40 Troubleshooting

Cause



66

Wiring harness between fuse (6) – CN15 (female) (3), (5) or circuit branch end and chassis ground

Resistance

Min. 1 Mz

Wiring harness between fuse (6) – CN26 Ground fault in wiring har(female) (3), CN24 (female) (4) or circuit 7 ness (Contact with GND cirbranch end and chassis ground cuit) Wiring harness between CN15 (female) (2) – CN27 (female) (3) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

D155A-6

40 Troubleshooting

Trouble

SEN03210-01

(9) Left door wiper does not operate intermittently. • Before carrying out troubleshooting, check that continuous operation is normal.

Related information

• If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective. • Carry out troubleshooting with left door wiper switch and intermittent switch ON. • During intermittent operation, wiper stops for 5 seconds after each cycle of operation. Cause


1



Defective left door wiper 2 intermittent selector relay (Internal trouble)


Defective left door wiper 3 intermittent relay (Internal trouble)

Intermittent switch

Resistance

OFF

Min. 1 Mz

ON

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace left door wiper intermittent selector relay (Right No.) with another relay. If left door wiper becomes normal at this time, intermittent selector relay is defective.

CN27

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace left door wiper intermittent relay (Right No.) with another relay. If left door wiper becomes normal at this time, intermittent relay is defective.

CN26



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


D155A-6


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

67

SEN03210-01


40 Troubleshooting

(10) Water does not come out from front window washer. • Before carrying out troubleshooting, check that windshield wiper operates normally. • If fuse ( -5) is broken, operations of both front window washer and rear window washer become defective. Cause 1 Defective fuse (



Defective front window 2 washer motor (Internal trouble)

WSH1

Front wiper switch

Voltage

Between (3) – (4)

ON (Wash position)

20 – 30 V

If voltage is normal but washer does not operate, motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Defective front wiper switch (Internal disconnection)



Front wiper switch

Resistance

OFF

Min. 1 Mz

ON (Wash position)

Max. 1 z


(5) – CN14

Resistance

Max. 1 z

Wiring harness between CN14 (female) (6) – WSH1 (female) (3)

Resistance

Max. 1 z

Wiring harness between WSH1 (female) (4) – chassis ground (GND06)

Resistance

Max. 1 z



68

Ground fault in wiring harWiring harness between fuse (5) – CN14 5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and cuit) chassis ground

Resistance

Min. 1 Mz

Wiring harness between CN14 (female) (6) – WSH1 (female) (3) and chassis ground

Resistance

Min. 1 Mz

D155A-6

40 Troubleshooting


SEN03210-01

(11) Water does not come out from rear window washer. • Before carrying out troubleshooting, check that windshield wiper operates normally. • If fuse ( -5) is broken, operations of both front window washer and rear window washer become defective. Cause 1 Defective fuse (



Defective rear window 2 washer motor (Internal trouble)

WSH2

Rear wiper switch

Voltage

Between (3) – (4)

ON (Wash position)

20 – 30 V

If voltage is normal but washer does not operate, motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Defective rear wiper switch (Internal disconnection)



Rear wiper switch

Resistance

OFF

Min. 1 Mz

ON (Wash position)

Max. 1 z


(5) – CN12

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z



D155A-6


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

69

SEN03210-01


40 Troubleshooting

(12) Water does not come out from right door washer. • Before carrying out troubleshooting, check that windshield wiper operates normally. • If fuse ( tive.

-6) is broken, operations of both right door washer and left door washer become defec-

Cause 1 Defective fuse (


If fuse is broken, circuit probably has ground fault (See cause 5). a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting

Defective right door washer 2 motor (Internal trouble)

WSH2


Voltage

Between (1) – (2)

ON (Wash position)

20 – 30 V

If voltage is normal but washer does not operate, motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Defective right door wiper 3 switch (Internal disconnection)

CN13 (male)

Between (5) – (6)


Resistance

OFF

Min. 1 Mz

ON (Wash position)

Max. 1 z


(6) – CN13

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z



70


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

D155A-6

40 Troubleshooting


SEN03210-01

(13) Water does not come out from left door washer. • Before carrying out troubleshooting, check that windshield wiper operates normally. • If fuse ( -6) is broken, operations of both right door washer and left door washer become defective. Cause 1 Defective fuse (



Defective left door washer 2 motor (Internal trouble)

WSH1


Voltage

Between (1) – (2)

ON (Wash position)

20 – 30 V

If voltage is normal but washer does not operate, motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Defective left door wiper 3 switch (Internal disconnection)

CN15 (male)

Between (5) – (6)


Resistance

OFF

Min. 1 Mz

ON (Wash position)

Max. 1 z


(6) – CN15

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z



D155A-6


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

71

SEN03210-01

40 Troubleshooting


72

D155A-6

40 Troubleshooting

SEN03210-01

E-26 KOMTRAX terminal does not operate normally Trouble Related information

1

• KOMTRAX terminal does not operate normally. • If KOMTRAX terminal administrator makes request for checking system on machine side for trouble, carry out following troubleshooting. • Even if KOMTRAX terminal has trouble, it does not particularly appear on machine. • Carry out all troubleshooting on service menu screen of machine monitor. Cause

1 Defective transmission 1

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and check "Setting condition of terminal" screen. Check item

Normal display

Communication start check

Completion

a Turn starting switch ON and check "Condition of positioning and communication" screen. Normal display

Positioning

E ###,##,##(Longitude)

N ###,##,##(Latitude)

2 Defective GPS Possible causes and standard value in normal state

Check item

In positioning If latitude and longitude are not displayed in 5 minutes on open ground, notify KOMTRAX service hot line. a Turn starting switch ON and check "Condition of positioning and communication" screen. 3

Defective communication environment

Check item

Normal display

Communication

Zone level 1 – Zone level 3

If zone level 1 – 3 is not displayed within communication zone of ORBCOMM, notify KOMTRAX service hot line.

4 Defective transmission 2

a Turn starting switch ON and check "Condition of positioning and communication" screen. Check item

Normal display

Number of items not transmitted

0 – 9 (Normally 0)

a Select "Setting condition of terminal" from "12 Display of KOMTRAX setting" in the service menu of the machine monitor.

D155A-6

a Select "Condition of positioning and communication" from "12 Display of KOMTRAX setting" in the service menu of the machine monitor.

73

SEN03210-01

40 Troubleshooting

E-27 Fan does not reverse Trouble Related information

1

• When fan is set in fan cleaning mode or fan reverse mode (if equipped), fan does not reverse. • If any switched is operated during reverse prohibition period, orange lamp blinks. • Orange lamp lights up in cleaning mode and reverse mode. Cause Abnormality in fan reverse 1 solenoid Operation of fan cleaning 2 switch in reverse prohibition period Operation of fan reverse 3 switch (if equipped) in reverse prohibition period

Standard value in normal state/Remarks on troubleshooting If failure code [DW7BKA], [DW7BKB] or [DW7BKY] is displayed, carry out troubleshooting for it first. If switch is operated after engine is started, fan does not reverse and orange lamp blinks. At this time, orange lamp indicated that switch operation is ineffective but does not indicate trouble. Turn key switch OFF to stop engine and turn battery relay OFF, and then set fan in fan cleaning or fan reverse mode again. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective fan cleaning switch (Internal disconnection)

FAN1 (male) Between (2) and (1)

Switch

Resistance

OFF

Min. 1 Mz

CLN position

Max. 1 z



FAN2 (male)

Switch

Resistance

OFF

Min. 1 Mz

Defective fan cleaning switch Between (1) and (3) (if equipped) (Internal disconnection)

CLN position

Min. 1 Mz

REV position

Max. 1 z

OFF

Min. 1 Mz

Between (4) and (3)

CLN position

Max. 1 z

REV position

Min. 1 Mz

[When standard cleaning switch is employed] Disconnection in wiring harness (Internal disconnection)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FAN1 (female) (1) and GND7

Resistance

Max. 1 z

Wiring harness between FAN1 (female) (2) and STCN2 (female) (38)

Resistance

Max. 1 z


5 [When optional reverse switch is employed] Disconnection in wiring harness (Internal disconnection)

Wiring harness between FAN2 (female) (3) and GND7

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

If causes 1 – 5 are not detected, steering controller may be defec6 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried out.)

74

D155A-6

40 Troubleshooting

SEN03210-01


D155A-6

75

SEN03210-01

40 Troubleshooting

E-28 Gear cannot be shifted Trouble

•

1

Gear cannot be shifted.


Standard value in normal state/Remarks on troubleshooting a When failure code related to gear shift operation switch is not displayed


Gear shift operation switch trouble • Shift-up switch 1 • Shift-down switch • Shift switch (Optional type lever)

Hold down shift operation switch for 10 seconds. If any of following failure codes is displayed at this time, carry out troubleshooting for it. [DD12KA], [DD12KB], [DD13KA], [DD13KB] a When failure code related to gear shift operation switch is displayed Carry out troubleshooting for displayed failure code.

2 Gear speed limit

If action code displays failure code [E03] or [E04], gear speed is limited. Carry out troubleshooting gear speed limit first.

3 Defect in transmission clutch Transmission clutch may have defect in it. Check it directly.

76

D155A-6

40 Troubleshooting

D155A-6

SEN03210-01

77

SEN03210-01

40 Troubleshooting

E-29 Electric priming pump does not operate or does not stop automatically Trouble

1

• Electric priming pump does not operate or does not stop automatically

Relative information Cause 1 Low battery charge level 2

Defective circuit breaker No. 10

Standard value in normal state/Remarks on troubleshooting Battery charge level may be low. Check battery directly. If circuit breaker No. 10 is turned OFF, circuit probably has ground fault. (Check cause No. 5)

Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it harness (Power supply and carry out troubleshooting (since power supply is unswitched). system) 3 (Disconnection in wiring or Voltage 20 – 30 V defective contact in con- Between EPP (1) – (2) nector) a Prepare with battery ground cable disconnected, then connect battery and turn electric priming pump ON and carry out troubleshooting.

Disconnection in wiring • Lamp blinks but stops in about 5 seconds. harness (Drive power supply sys- Between EFP (1) – (2) Voltage 20 – 30 V 4 tem) (Disconnection in wir- a Prepare with battery ground cable disconnected, then carry out ing or defective contact in troubleshooting without reconnecting (since power supply is connector) unswitched). Between EPP (female) (2) – ground Possible causes and standard value in normal state

Resistance

Max. 1 z

a Prepare with battery ground cable disconnected, then carry out troubleshooting without reconnecting (since power supply is unswitched). Wiring harness between EPP (female) (1) – Ground fault in wiring har- circuit breaker B30S and ground 5 ness (Contact with GND Wiring harness between EPP (female) (3) – circuit) EFP (female) (1) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EPP (female) (4) – EFP (female) (2) and ground

Resistance

Min. 1 Mz

Between EFP (female) (1) – (2)

Resistance

1–3z

a Prepare with battery ground cable disconnected, then connect battery and turn electric priming pump ON and carry out troubleshooting. Between EPP (3) – (4) Voltage 20 – 30 V Defective electric priming • Lamp blinks but output voltage is improper. 6 pump switch (Malfunction or automatic stop failure) • Results of troubleshooting steps 1 – 4 are normal and lamp does not blink. a When electric priming pump does not stop automatically, electric priming pump switch may be defective. (Turn toggle switch OFF to stop pump and then replace switch.) 7

• Lamp blinks but stops in about 5 seconds. Overload on electric prima If pump is overloaded, power supply is turned OFF automatically ing pump to protect circuit (Priming switch is reset automatically).

1 1 1

78

D155A-6

40 Troubleshooting

SEN03210-01

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with battery ground cable disconnected, then carry out troubleshooting without reconnecting (since power supply is unswitched).

Possible causes and standard Between EFP (male) (1) – (2) value in normal 8 Trouble in electric priming pump state Between EFP (male) (1) – pump body

Between EFP (male) (2) – pump body

Resistance

1–3z

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


D155A-6

79

SEN03210-01

40 Troubleshooting



80

D155A-6

SEN03211-00


D155A-6

Machine model

Serial number

D155A-6

85001 and up

40 Troubleshooting

1

Troubleshooting of hydraulic and mechanical system (H-mode) Information in troubleshooting table................................................................................................................ 3 H-1 Power is low (Drawbar pull is low) ........................................................................................................... 4 H-2 Machine does not travel (at 2nd or 3rd gear speed) ................................................................................ 5 H-3 Machine does not start at any gear speed ............................................................................................... 6 H-4 Machine can travel only forward or in reverse ......................................................................................... 7 H-5 When gear speed or travel direction is changed, time lag is large........................................................... 8 H-6 Steering is not possible ............................................................................................................................ 9 H-7 Steering is possible only on one side ..................................................................................................... 10 H-8 Steering overrun occurs ..........................................................................................................................11 H-9 Brake does not work .............................................................................................................................. 12 H-10 Power train oil is overheated................................................................................................................ 13 H-11 Speed of all work equipment is low ...................................................................................................... 14 H-12 No work equipment moves................................................................................................................... 15 H-13 Blade lift speed or power is low............................................................................................................ 16

D155A-6

1

SEN03211-00

40 Troubleshooting

H-14 Blade tilt speed or power is low............................................................................................................ 17 H-15 Ripper lift speed or power is low .......................................................................................................... 18 H-16 Ripper tilt speed or power is low .......................................................................................................... 19 H-17 Hydraulic drift of blade lift is large ........................................................................................................ 19 H-18 Hydraulic drift of blade tilt is large ........................................................................................................ 20 H-19 Hydraulic drift of ripper lift is large ........................................................................................................ 20 H-20 Ripper pin puller cylinder does not operate.......................................................................................... 21 H-21 Abnormal sound comes out from around work equipment pump......................................................... 22 H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats).............. 23

2

D155A-6

40 Troubleshooting

SEN03211-00


1

a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand that information fully. Trouble Related information

Trouble which occurred in the machine Information related to detected trouble or troubleshooting Cause


1


2

3

Possible causes of trouble (Given numbers are refer• Standard value in normal state to judge possible causes ence numbers, which do • Remarks on judgment not indicate priority)

4

D155A-6

3

SEN03211-00

40 Troubleshooting

H-1 Power is low (Drawbar pull is low) Trouble Related information

1

• Power is low (Drawbar pull is low). • Before carrying out troubleshooting, check that power train oil level is normal. Cause

1 Defective engine

2 Defective power train pump

Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. PCCS lever

Engine speed

F3 stall

1,450 rpm

Power train pump may be defective. Check it directly. Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting.

3 Trouble in torque converter

PCCS lever

Torque converter inlet pressure


Neutral

Max. 1.0 MPa {Max. 10.0 kg/cm2}

0.29 – 0.69 MPa {3.0 – 7.0 kg/cm2}

a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. PCCS lever Neutral Improper set pressure or 4 internal trouble of transmission main relief valve

Transmission main relief pressure TM

Min. 2.84 MPa {Min. 29.0 kg/cm2}

a Prepare with engine stopped, then keep engine stopped and carry out troubleshooting. Check directly that free length of spring and number of shims are normal and spool moves smoothly. • Free length of spring (large): 122 mm • Free length of spring (small): 108 mm • Number of shims: 6


a Prepare with engine stopped, then run engine at low idle and carry out troubleshooting.

5

Malfunction of transmission clutch valve (ECMV)

PCCS lever

Transmission clutch

Clutch pressure

F3 stall

F


R3 stall

R


F1 stall

1ST


F2 stall

2ND


F3 stall

3RD


Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 6 Defective brake valve

Parking brake lever

Steering brake

Brake oil pressure

Free

RB LB

2.16 MPa {22.0 kg/cm2}

Defective adjustment of If check result of cause 6 is abnormal, parking brake lever or brake 7 parking brake lever or brake pedal linkage is adjusted defectively. Check them directly. pedal linkage 8 Trouble in transmission

4

Transmission may have trouble in it. Check it directly.

D155A-6

40 Troubleshooting

SEN03211-00

H-2 Machine does not travel (at 2nd or 3rd gear speed) Trouble Related information

1

• Machine does not travel (at 2nd or 3rd gear speed). • Before carrying out troubleshooting, check that power train oil level is normal. • Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1). Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting.

1 Trouble in torque converter

PCCS lever



Neutral


0.29 – 0.69 MPa {3.0 – 7.0 kg/cm2}

a Prepare with engine stopped, then run engine at low idle and carry out troubleshooting. Possible causes and standard value in normal state

2


PCCS lever

Transmission clutch

Clutch pressure

F2 stall

2ND


F3 stall

3RD


3

Trouble in transmission clutch

Transmission clutch (2nd or 3rd gear speed) may have trouble in it. Check it directly.

4

Malfunction of parking brake Parking brake may be malfunctioning (Dragging). Check linkage (Dragging) and valves. a Move to level place, start engine, and check.

D155A-6

Malfunction of brake (Drag5 ging)

Run engine at low idle and set transmission in F2. If machine does not move at this time, brake is dragging. Carry out troubleshooting for "H-8 Brake does not work".

6 Trouble in transmission

Transmission may have trouble in it. Check it directly.

5

SEN03211-00

40 Troubleshooting

H-3 Machine does not start at any gear speed Trouble Related information

1

• Machine does not start at any gear speed. • Before carrying out troubleshooting, check that power train oil level is normal. Cause 1 Defective power train pump

Standard value in normal state/Remarks on troubleshooting Power train pump may be defective. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. PCCS lever Neutral

Improper set pressure or 2 internal trouble of transmission main relief valve



a Prepare with engine stopped, then keep engine stopped and carry out troubleshooting. Check directly that free length of spring and number of shims are normal and spool moves smoothly. • Free length of spring (large): 122 mm • Free length of spring (small): 108 mm • Number of shims: 6 a Prepare with engine stopped, then run engine at low idle and carry out troubleshooting (after checking transmission main relief pressure is normal).


3

4



PCCS lever

Transmission clutch

Clutch pressure

F3 stall

F


R3 stall

R


F1 stall

1ST


F2 stall

2ND


F3 stall

3RD


Transmission clutch (F or R) may have trouble in it. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting (after checking transmission main relief pressure is normal). Brake pedal

5 Malfunction of brake

Released Pressed

Steering brake RB LB

Brake pressure 2.16 MPa {22.0 kg/cm2} 0 MPa {0 kg/cm2}

If brake pressure is abnormal, carry out troubleshooting for "H-8 Brake does not work".

6

D155A-6

40 Troubleshooting

SEN03211-00

H-4 Machine can travel only forward or in reverse Trouble Related information

1

• Machine can travel only forward or in reverse. • Before carrying out troubleshooting, check that power train oil level is normal. Cause 1 Defective power train pump



TM


a Prepare with engine stopped, then keep engine stopped and carry out troubleshooting. Check directly that free length of spring and number of shims are normal and spool moves smoothly. • Free length of spring (large): 122 mm • Free length of spring (small): 108 mm • Number of shims: 6


a Prepare with engine stopped, then run engine at low idle and carry out troubleshooting (after checking transmission main relief pressure is normal). 3

D155A-6

Transmission main relief pressure


PCCS lever

Transmission clutch

Clutch pressure

F3 stall

F


R3 stall

R


4

Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch seal (F or R) may be defective. Check it directly.

5


Transmission clutch (F or R) may have trouble in it. Check it directly.

7

SEN03211-00

40 Troubleshooting

H-5 When gear speed or travel direction is changed, time lag is large 1 Trouble Related information

• When gear speed or travel direction is changed, time lag is large. • Before carrying out troubleshooting, check that power train oil level is normal. Cause 1 Defective power train pump





a Prepare with engine stopped, then keep engine stopped and carry out troubleshooting. Check directly that free length of spring and number of shims are normal and spool moves smoothly. • Free length of spring (large): 122 mm • Free length of spring (small): 108 mm • Number of shims: 6 a Prepare with engine stopped, then run engine at low idle and carry out troubleshooting (after checking transmission main relief pressure is normal).

Possible causes and standard value in normal state 3


PCCS lever

Transmission clutch

Clutch pressure

F3 stall

F


R3 stall

R


F1 stall

1ST


F2 stall

2ND


F3 stall

3RD


4

Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch seal (F or R) may be defective. Check it directly.

5


Transmission clutch may have trouble in it. Check it directly. a Move to level place, start engine, and check.

Malfunction of brake (Drag6 ging)

8

Run engine at low idle and set transmission in F2. If machine does not move at this time, brake is dragging. Carry out troubleshooting for "H-8 Brake does not work".

D155A-6

40 Troubleshooting

SEN03211-00

H-6 Steering is not possible Trouble Related information

1

• Steering is not possible. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting the engine, then drive the engine in low idle mode for troubleshooting.

1 Defective operation of brake Raise machine with blade and ripper, drive it in F3 (or R3), and steer it in direction in which machine cannot turn. If track shoe stops at this time, brake is defective. (Carry out troubleshooting for "H-9 Brake does not work".) a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting.


D155A-6

2

PCCS lever

Left stroke end

Right stroke end


2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}

0 MPa {0 kg/cm2}

0 MPa {0 kg/cm2}

2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}

Left brake pressure

0 MPa {0 kg/cm2}

3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}


3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}

0 MPa {0 kg/cm2}

Defective operation of steering clutch valve (ECMV) Right clutch pressure

3

Defective seal of steering clutch

When the cause 2 is not applicable, the clutch seal is supposed to be defective. Check it directly.

4

Internal defect of steering clutch

The inside of the steering clutch is supposed to be defective, check it directly.

5

Malfunction of steering Carry out troubleshooting related to steering potentiometer. potentiometer of travel lever

9

SEN03211-00

40 Troubleshooting

H-7 Steering is possible only on one side Trouble Related information

1

• Steering is possible only on one side. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause


1 Defective operation of brake Raise machine with blade and ripper, drive it in F3 (or R3), and steer it in direction in which machine cannot turn. If track shoe stops at this time, brake is defective. (Carry out troubleshooting for "H-9 Brake does not work".) a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting.


10

2

PCCS lever

Left stroke end

Right stroke end


2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}

0 MPa {0 kg/cm2}

0 MPa {0 kg/cm2}

2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}

Left brake pressure

0 MPa {0 kg/cm2}

3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}


3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}

0 MPa {0 kg/cm2}

Defective operation of steering clutch valve (ECMV) Right clutch pressure

3

Defective seal of steering clutch

When the cause 1 is not applicable, the clutch seal is supposed to be defective. Check it directly.

4

Internal defect of steering clutch

The inside of the steering clutch is supposed to be defective, check it directly.

5

Malfunction of steering Carry out troubleshooting related to steering potentiometer. potentiometer of travel lever

D155A-6

40 Troubleshooting

SEN03211-00

H-8 Steering overrun occurs Trouble Related information

• Steering overrun occurs. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause



1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for F3 travel (or R3 travel). If the track shoe stops, the brake is defective. (Execute the troubleshooting of “Brake does not work.”) 2

D155A-6

1

When the track shoe does not stop in the troubleshooting of the Defective operation of steercause 1, the steering clutch is defective. (Execute the troubleshooting clutch ing of “Steering is not possible.”)

11

SEN03211-00

40 Troubleshooting

H-9 Brake does not work Trouble Related information

1

• Brake does not work. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause

Standard value in normal state/Remarks on troubleshooting a Start the engine for troubleshooting.

1 Degradation of brake

2

Step on the brake pedal, shift the gear to F2 and drive the engine in high idle mode. When the machine moves, the brake performance is degraded.

Defective operation of brake The brake pedal and the brake valve are supposed not to work norpedal mally. Check them directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting.


12

3

PCCS lever

Left stroke end

Right stroke end


2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}

0 MPa {0 kg/cm2}

0 MPa {0 kg/cm2}

2.3 – 2.6 MPa {23.5 – 26.5 kg/cm2}

Left brake pressure

0 MPa {0 kg/cm2}

3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}


3.04 – 3.33 MPa {31.0 – 34.0 kg/cm2}

0 MPa {0 kg/cm2}

Defective operation of steering brake valve (ECMV) Right clutch pressure

4 Defective brake seal

When the brake seal is not normal in the troubleshooting of the cause 3, the brake seal is supposed to be defective. Check it directly.

5 Internal defect of brake

The inside of the brake is supposed to be defective. Check it directly.

D155A-6

40 Troubleshooting

SEN03211-00

H-10 Power train oil is overheated Trouble Related information

1

• Power train oil is overheated. • Before carrying out troubleshooting, check that power train oil level is normal. • Before carrying out troubleshooting, check that power train oil temperature gauge indicates actual oil temperature (If it does not, carry out troubleshooting for "E-9 Power train oil temperature gauge (Multi-gauge) does not indicate normally". • Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1). Cause 1 Defective engine 2

Defective power train pump or air in suction circuit

Standard value in normal state/Remarks on troubleshooting Engine cooling system may be defective or engine output may be increased. Carry out troubleshooting for engine unit (S mode). Power train pump may be defective or air is in suction circuit. Check them directly. a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting.

3 Trouble in torque converter Possible causes and standard value in normal state

4

Malfunction of transmission clutch (Slip)

PCCS lever



Neutral


0.29 – 0.69 MPa {3.0 – 7.0 kg/cm2}

Transmission clutch may be malfunctioning (slipping). Check it directly. a Start engine and check.

5

Malfunction of brake (Dragging)

1. Float machine above ground with blade and ripper. 2. Run engine at low idle and set transmission gear in F3 or R3. 3. If track shoe does not turn, brake is dragging. (Carry out troubleshooting for "H-9 Brake does not work".) a Start engine and check.

6 Malfunction of brake (Slip)

D155A-6

Stall machine at F3. If machine does not stop perfectly, brake is slipping.

13

SEN03211-00

40 Troubleshooting

H-11 Speed of all work equipment is low Trouble Related information

1

• Speed of all work equipment is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. Cause


1

Defective PTO (work equipment pump drive section)

Work equipment pump drive section of PTO may be defective. Check them directly.

2

Defective work equipment pump

Work equipment pump may be defective. Check them directly. a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting.

3 Malfunction of unload valve


Improper set pressure or 4 malfunction of main relief valve

PCCS lever Blade control lever Ripper control lever

Unload pressure

Neutral

2.45 (+1.37/0) MPa {25 (+14/0) kg/cm2}

a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting. Blade control lever


Raise relief

27.5 ± 1.5 MPa {280 ± 15 kg/cm2}

a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Improper set pressure or 5 malfunction of self-acting pressure reducing valve

14


Control circuit basic pressure

Neutral

3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}

6 Trouble in fan pump

If check result of cause 5 is abnormal, fan pump may have trouble in it. Check it directly.

7 Internal leak of PPC valve

If cause 5 is detected, oil may be leaking in PPC valve. Check PPC valve directly.

D155A-6

40 Troubleshooting

SEN03211-00

H-12 No work equipment moves Trouble Related information

1

• No work equipment moves. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. Cause


1

Defective PTO (work equipment pump drive section)

Work equipment pump drive section of PTO may be defective. Check them directly.

2

Defective work equipment pump

Work equipment pump may be defective. Check them directly. a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting.

3 Malfunction of unload valve


Improper set pressure or 4 malfunction of main relief valve


Unload pressure

Neutral

2.45 (+1.37/0) MPa {25 (+14/0) kg/cm2}

a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting. Blade control lever


Raise relief

27.5 ± 1.5 MPa {280 ± 15 kg/cm2}




Neutral

3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}

a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 6

D155A-6

Malfunction of work equipment lock solenoid valve

Work equipment lock lever

Solenoid valve output pressure

Lock

0 MPa {0 kg/cm2}

Free

3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}

15

SEN03211-00

40 Troubleshooting

H-13 Blade lift speed or power is low Trouble Related information

1

• Blade lift speed or power is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. • Check that blade has not been modified. • If hydraulic drift of blade lift is large, carry out troubleshooting for "H-17 Hydraulic drift of blade lift is large" first. Cause Improper set pressure or 1 malfunction of main relief valve

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting. Blade control lever Raise relief

Main relief pressure 27.5 ± 1.5 MPa {280 ± 15 kg/cm2}

a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Possible causes and standard value in normal state

Improper set pressure or 2 malfunction of self-acting pressure reducing valve

3



Neutral

3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}

Malfunction of blade lift con- Spool of blade lift control valve may be malfunctioning. Check it trol valve (spool) directly.

Suction valve of blade lift control valve may be malfunctioning. Check it directly. Malfunction of blade lift con4 * This suction valve can be checked by replacing it with suction trol valve (suction valve) valve of ripper lift or ripper tilt control valve and observing change of phenomenon. 5 Air in blade lift cylinder

16

Air may be in blade lift cylinder. Bleed air and then judge from change of phenomenon.

D155A-6

40 Troubleshooting

SEN03211-00

H-14 Blade tilt speed or power is low Trouble Related information

• Blade tilt speed or power is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. • Check that blade has not been modified. • If hydraulic drift of blade tilt is large, carry out troubleshooting for "H-18 Hydraulic drift of blade tilt is large" first. Cause Improper set pressure or 1 malfunction of main relief valve


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting. Blade control lever Left tilt relief



3



Neutral

3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}

Malfunction of blade tilt con- Spool of blade tilt control valve may be malfunctioning. Check it trol valve (spool) directly.

4 Air in blade tilt cylinder

D155A-6

1

Air may be in blade tilt cylinder. Bleed air and then judge from change of phenomenon.

17

SEN03211-00

40 Troubleshooting

H-15 Ripper lift speed or power is low Trouble Related information

1

• Ripper lift speed or power is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. • Check that ripper has not been modified. • If hydraulic drift of ripper lift is large, carry out troubleshooting for "H-19 Hydraulic drift of ripper lift is large" first. Cause Improper set pressure or 1 malfunction of main relief valve

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting. Ripper control lever Raise relief




3



Neutral

3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}

Malfunction of ripper lift con- Spool of ripper lift control valve may be malfunctioning. Check it trol valve (spool) directly.

Suction valve of ripper lift control valve may be malfunctioning. Check it directly. Malfunction of ripper lift con4 * This suction valve can be checked by replacing suction valves trol valve (suction valve) on head side and bottom side with each other and observing change of phenomenon. 5 Air in ripper lift cylinder

18

Air may be in ripper lift cylinder. Bleed air and then judge from change of phenomenon.

D155A-6

40 Troubleshooting

SEN03211-00

H-16 Ripper tilt speed or power is low Trouble Related information

1

• Ripper tilt speed or power is low. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. • Check that ripper has not been modified. Cause Improper set pressure or 1 malfunction of main relief valve

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch ON, then run engine at high idle and carry out troubleshooting. Ripper control lever Tilt-in relief




3



Neutral

3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}

Malfunction of ripper tilt con- Spool of ripper tilt control valve may be malfunctioning. Check it trol valve (spool) directly.

Suction valve of ripper tilt control valve may be malfunctioning. Check it directly. Malfunction of ripper tilt con4 * This suction valve can be checked by replacing suction valves trol valve (suction valve) on head side and bottom side with each other and observing change of phenomenon. 5 Air in ripper tilt cylinder

Air may be in ripper tilt cylinder. Bleed air and then judge from change of phenomenon.

H-17 Hydraulic drift of blade lift is large Trouble Related information

1

• Hydraulic drift of blade lift is large. • Check that blade has not been modified. • Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit. Cause

Standard value in normal state/Remarks on troubleshooting a Start engine and prepare, then stop engine and carry out troubleshooting.


Defective seal of blade lift 1 control valve (spool)

2

D155A-6

Defective seal of blade lift cylinder

Perform following procedure. If hydraulic drift is increased at this time, seal of blade lift control valve spool is defective. 1. Brace blade against ground by lifting operation to push up front part of machine. 2. Stop engine and then turn starting switch ON. 3. Set blade control lever in "Lower" position and check phenomenon. Seal of blade lift cylinder may be defective. Check it directly.

19

SEN03211-00

40 Troubleshooting

H-18 Hydraulic drift of blade tilt is large Trouble Related information

1

• Hydraulic drift of blade tilt is large. • Check that blade has not been modified. • Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit. Cause



1

Defective seal of blade tilt control valve (spool)

Defective seal of blade tilt 2 cylinder

Perform following procedure. If hydraulic drift is increased at this time, seal of blade tilt control valve spool is defective. 1. Brace blade against ground by tilting operation to push up front part of machine. 2. Stop engine and then turn starting switch ON. 3. Set blade control lever in "Tilt left" position and check phenomenon. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Blade tilt cylinder


Left tilt relief

12 cc/min

H-19 Hydraulic drift of ripper lift is large Trouble Related information

1

• Hydraulic drift of ripper lift is large. • Check that ripper has not been modified. • Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit. Cause



1

2

20

Defective seal of ripper lift control valve (spool)

Defective seal of ripper lift cylinder

Perform following procedure. If hydraulic drift is increased at this time, seal of ripper lift control valve spool is defective. 1. Brace ripper against ground by lifting operation to push up rear part of machine. 2. Stop engine and then turn starting switch ON. 3. Set ripper control lever in "Lower" position and check phenomenon. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Ripper lift cylinder


Lower relief

11 cc/min

D155A-6

40 Troubleshooting

SEN03211-00

H-20 Ripper pin puller cylinder does not operate

1

Giant ripper specification Trouble Related information

• Ripper pin puller cylinder does not operate. • Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1). Cause


Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.

1

Malfunction of pin puller solenoid

Pin puller switch

Check point

Pushed in

Cylinder bottom side

Pulled out

Cylinder head side

Solenoid output pressure Min. 2.84 MPa {Min. 29.0 kg/cm2}

2 Trouble in pin puller cylinder Pin puller cylinder has trouble in it. Check it directly.

D155A-6

21

SEN03211-00

40 Troubleshooting

H-21 Abnormal sound comes out from around work equipment pump 1 Trouble Related information

• Abnormal sound comes out from around work equipment pump. • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal. Cause 1 Use of improper oil


2

3 Air in suction circuit 4

22

Clogged hydraulic tank strainer

Trouble in work equipment pump

Standard value in normal state/Remarks on troubleshooting Oil used may be improper. Check it directly. Hydraulic tank strainer may be clogged. Check it directly. Suction circuit of work equipment pump may have sucked in air. Check it directly. Work equipment pump may have trouble in it.

D155A-6

40 Troubleshooting

SEN03211-00

H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats) Trouble Related information

1

• Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats). • Before starting troubleshooting, check that oil level in hydraulic tank is normal.

Cause

Standard value in normal state/Remarks on troubleshooting a Start engine and carry out troubleshooting.

1 Defective engine speed

Measurement conditions

Engine speed

Engine at low idle

740 + 40 0 rpm

Engine at high idle

2,100

0 - 50

rpm

If engine speed is not increased to specification, carry out troubleshooting for "S-5 Engine hunts". 2

Defective PTO (fan pump drive)

Fan pump drive of PTO may be defective. Check it directly. a Prepare with starting switch OFF, then run engine at high idle and carry out troubleshooting.


3

Defect in fan pump or fan motor


Fan pump EPC circuit basic pressure

—

3.78 – 4.46 MPa {38.5 – 45.5 kg/cm2}

a Prepare with starting switch OFF, then run engine at high idle and carry out troubleshooting. Measurement conditions

Fan drive circuit pressure

Fan 100% mode

15.7 ± 2.5 MPa {160 ± 25 kg/cm2}

a Prepare with starting switch OFF, then run engine at high idle and carry out troubleshooting.

4 Defective fan

D155A-6


Fan speed

Fan 100% mode

1,100 + 5% 0 rpm

Fan may be broken or may be installed defectively. Check it directly.

23

SEN03211-00

40 Troubleshooting



24

D155A-6

SEN03212-01


D155A-6

Machine model D155A-6

Serial number 85001 and up

40 Troubleshooting

1

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

D155A-6

1

SEN03212-01

40 Troubleshooting

S-16 Vibration is excessive ........................................................................................................................... 23 S-17 Air cannot be bled from fuel circuit ....................................................................................................... 24

2

D155A-6

40 Troubleshooting

SEN03212-01

Method of using troubleshooting chart Causes

A

Questions

1

2

3

4

1 2 3 4 5 6

B

C

Check items

7

Troubleshooting

The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. [Questions] Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. [Check items] Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the right. [Causes] Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. [Troubleshooting] Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable one by applying troubleshooting tools or direct inspection.

1

8 9 10 11 a b c d

Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w. E: Causes to be referred to for questions and check items Q : Causes related to questions and check items w : Causes highly probable among ones marked with Q a When narrowing the "causes", apply the items marked with w before those marked with Q. When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)

D155A-6

3

SEN03212-01

40 Troubleshooting

Exhaust gas color is black (incomplete combustion) Let us assume that a trouble of “Exhaust gas color is black” occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas color slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].

4

D155A-6

40 Troubleshooting

SEN03212-01

There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in the [Causes] sections. The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is explained according to Step 1 — Step 3 shown below.

D155A-6

5

SEN03212-01

40 Troubleshooting

S-1 Starting performance of engine is poor General causes why starting performance is poor q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel q Coolant in exhaust pipe a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however

1

Defective or deteriorated battery

Defective alternator (generator section)

Defective alternator (regulator section)

Defective intake air heater system

Defective injector

Stuck or seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter

Leaking or clogged fuel piping or entry of air

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder

Defective contact of valve and vale seat

Clogged air cleaner element

Causes

Confirm recent repair history

Questions

Starting performance

Operated for long period

E

E E

Became worse gradually

Q w w

Q Q

E w

Engine starts easily when warm

w

Q Q Q Q

Non-specified fuel is used Filters have not been replaced according to Operation and Maintenance Manual

w

w w Q Q w

Engine oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)

w

During operation, charge level monitor indicates abnormal charge (if monitor is installed)

w w w

Dust indicator is red (if it is installed)

w

Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping

w

Priming pump is too light or too heavy to operate

w Q Q

Q w

Check items

Starting motor cranks engine slowly While engine is rotated with starting motor

When air bleeding plug of fuel filter is removed, fuel does not flow out

w w w

When spill hose from injector is disconnected, little fuel spills

w

Immediately after engine is started, temperature of exhaust manifold of a cylinder is low

Q Q

Engine does not pick up smoothly and combustion is irregular

w Q w Q Q

Engine hunts (rotation is irregular)

w

Blow-by gas is excessive

q

Inspect air cleaner directly

q q

Compression pressure is low

q

When air is bled from fuel system, air comes out

q

Troubleshooting

Inspect fuel filter directly

q

Inspect feed pump gauze filter directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code

q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q

When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage of 20 – 30 V generated between alternator terminals B and E while engine is running at low idle?

q

Yes

q

No

q Replace

Replace

Replace

Replace

Replace

Clean

Clean

Correct

Clean

Replace

Correct

Remedy

Clean

Specific gravity of electrolyte and battery voltage are low

Replace

Degree of use of machine

*1: Displayed failure codes: [CA559] and [CA2249]

6

D155A-6

40 Troubleshooting

SEN03212-01

S-2 Engine does not start

1

a) Engine does not rotate General causes why engine does not rotate q Seized internal parts of engine o See "S-4 Engine stops during operation" q Water hammer caused by coolant which entered cylinder q Defective electrical system q Trouble in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine

Defective starting circuit wiring

Defective starting motor (motor section)

Defective starting motor (safety relay section)

Defective starting switch

Defective battery relay

Defective connection of battery terminal


Broken flywheel ring gear

Causes

E E


Q

When starting switch is Horn does not sound turned ON Horn volume is low

w

Battery electrolyte level is low

w Q

When starting switch is turned to START, starting pinion does not move out

Q

Speed of rotation is low

w

When starting switch is turned to START, start- Makes grating noise ing pinion moves out, Soon disengages again but Makes rattling noise and does not turn

Q

w

w

w

w w

q q


q

There is not voltage (20 – 30 V) between battery relay terminals B and E

q

When terminals B and C of starting switch are connected, engine starts

Turn starting switch OFF, connect cables, When terminals B and C at safety relay outlet are connected, engine turn starting switch ON, starts and carry out troubleshooting Even if terminals B and C at safety relay outlet are connected, engine does not start

Replace

Replace

Replace

q Replace

Remedy

q

Carry out troubleshooting on applicable machine side

Q w

—

Q

Replace

Check items

When starting switch is turned ON, no operating sound comes out from battery relay

Inspect flywheel ring gear directly Troubleshooting

w

w

Battery terminal is loose

D155A-6

Q

Replace


Correct

Questions


7

SEN03212-01

40 Troubleshooting

b) Engine rotates but no exhaust gas comes out General causes why engine rotates but no exhaust gas comes out q Fuel is not supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)

Defective fuel injector

Malfunction flow damper

Malfunction of overflow valve (Does not close)

Wrong connection of supply pump PCV

Defective supply pump PCV


Broken supply pump shaft or key

Clogged feed pump gauze filter Seized or abnormally worn feed pump

Clogged fuel filter



Insufficient fuel in tank

Use of improper fuel

Causes

E E E


w Q w w w

Exhaust gas suddenly stopped coming out (when starting again) Filters have not been replaced according to Operation and Maintenance Manual Fuel tank is empty

w

Air breather hole of fuel tank cap is clogged

Q w

There are rust and water in fuel drained from fuel tank w

Check items

There is not fuel in removed fuel filter

E

Q Q Q

Q Q

Fuel is leaking from fuel piping

w


w Q Q


Q

While engine is rotated with starting When spill hose from injector is disconnected, little fuel motor spills

E E Q

w

Q

w Q

Q

w w w w

Q

q q

q

q


q

Inspect fuel filter directly Troubleshooting

w w

q

Inspect feed pump gauze filter directly

q

Inspect feed pump directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2 Short/Open Error (*3)" indicated by code

q q q

Inspect overflow valve directly

q q Replace

Correct

Replace

Replace

Replace

Clean Replace

Replace

Correct

Correct

Add

Remedy

Replace

Engine can be started in reduced cylinder mode

Replace


Replace

Questions


*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA271] and [CA272] *3: Displayed failure codes [CA273] and [CA274]

8

D155A-6

40 Troubleshooting

SEN03212-01

c) Exhaust gas comes but engine does not start (fuel is injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel

Defective intake air heater system

Defective coolant temperature sensor or wiring harness


Clogged injector or defective spray



Clogged fuel filter

Leaking or clogged fuel system or entry of air


Use of improper fuel

Worn piston ring or cylinder liner

Worn dynamic valve system (Valve, rocker lever, etc.)


Causes


E

E E

w

Suddenly failed to start

E w

Q

Q Q

Non-specified fuel is used Filters have not been replaced according to Operation and Maintenance Manual

w

w w w

Engine oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)

w w

Dust indicator is red (if it is installed)

Q


w w

There are rust and water in fuel drained from fuel tank

w

There is not fuel in removed fuel filter Fuel is leaking from fuel piping

w


w Q Q w

Check items

Starting motor rotates engine slowly

w

When engine is rotated, abnormal sound comes out from around cylinder head While engine is rotated with starting motor,


Q

w

When spill hose from injector is disconnected, little fuel spills

w


q


q

Inspect dynamic valve system directly

q

Compression pressure is low Troubleshooting

w w

q


q


q

Inspect feed pump gauze filter directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code

q q

When injector unit is tested, spray condition is bad

q


q

Coolant temperature gauge does not indicate normally (if it is installed)

q Replace

Replace

Clean

Replace

Clean

Clean

Correct

Clean

Replace

Replace

Replace

Remedy

Clean

When starting switch is turned to HEAT, intake air heater mount does not become warm

Replace

Questions

Degree of use of machine Operated for long period

*1: Displayed failure codes [CA559] and [CA2249]

D155A-6

9

SEN03212-01

40 Troubleshooting

S-3 Engine does not pick up smoothly

1

General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel spray q Improper selection of fuel q Control by controller in derate mode (limiting injection rate (output) because of an error in electrical system)

Clogged injector or defective spray

Malfunction of flow damper (Large leakage from injector)



Clogged fuel filter




Seized turbocharger or interference of turbocharger

Improper valve clearance

Defective contact of valve and valve seat


Causes

E E


E w

Engine pick-up suddenly became worse

E E Q Q

Q w w w

Non-specified fuel is used

w

Filters have not been replaced according to Operation and Maintenance Manual

w

Oil must be added more frequently

w

Dust indicator is red (if indicator is installed)

w


w w

There are rust and water in fuel drained from fuel tank Fuel is leaking from fuel piping

w


w Q Q Q


Check items

Exhaust gas color

w

w

Blue under light load

w Q

Black

w

w

w

When engine is rotated, abnormal sound comes out from around cylinder head

w

When engine is rotated, interference sound comes out from around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied

Q

w w

Engine hunts (rotation is irregular)

Q

Q w

Q

w


q


q

Compression pressure is low Troubleshooting

w

w w

q q

Inspect valve clearance directly

q

Turbocharger is heavy to rotate with hand

q


q


q


q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

Replace

Clean

Clean

Correct

Clean

Replace

Replace

Adjust

Replace

Clean

Remedy

q q Correct


Replace

Questions



10

D155A-6

40 Troubleshooting

SEN03212-01

S-4 Engine stops during operation

1

General causes why engine stops during operation q Seized parts inside engine q Insufficient supply of fuel q Overheating q Trouble in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine

Broken auxiliary equipment (pump, compressor, etc.)

Trouble in drive devices on applicable machine side


w

Broken supply pump shaft or key

Q w Q w

Broken or seized feed pump


Clogged fuel filter

Leaking or clogged fuel piping



Broken or seized gear train

Broken or seized crankshaft bearing

Broken or seized piston or connecting rod

Broken dynamic valve system (valve, rocker arm, etc.)

Causes

Confirm recent repair history E E

Operated for long period w w w w

Questions

Made abnormal noise stopped suddenly Engine

w Q

Overheated and stopped

Q

Stopped slowly

w

Hunted and stopped

w Q

Q Q Q Q Q


Q Q Q

Filters have not been replaced according to Operation and Maintenance Manual

w w

Fuel level monitor indicates low level (if monitor is installed)

w

Fuel tank is empty

w w

Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping

w


w Q Q w w

Check items

There are rust and water in fuel drained from fuel tank w w

There are metal particles in oil drained from oil pan

Q Q

w w

Engine does not rotate at all When engine is rotated with hand

Q

w

Engine rotates in opposite direction

w

Engine moves by gear backlash

w w

Supply pump shaft does not turn

w

Engine rotates, but stops when load is applied to machine

q

Inspect piston and connecting rod directly

q

Inspect crankshaft bearing directly

q

Inspect gear train directly

q


q


q

Inspect feed pump directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code

q q

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Replace

Replace

Replace

Clean

Clean

Correct

Clean

Add

Replace

Replace

Replace

Replace

Remedy

q Replace

Troubleshooting

Carry out troubleshooting on applicable machine

q


—



D155A-6

11

SEN03212-01

40 Troubleshooting

S-5 Engine does not rotate smoothly

1

General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)

Defective Bkup speed sensor or wiring harness

Defective Ne speed sensor or wiring harness

Clogged injector or defective spray (dirt in injector)

Malfunction of flow damper (Large leakage from injector)

Clogged fuel filter





Low setting of low idle speed

Causes

Confirm recent repair history E E

Engine hunts

At a certain speed range

Q

Q Q

At low idle

w

Q Q Q Q Q Q Q Q

Even when speed is raised

Q Q

w

On slopes

Q Q w w

Filters have not been replaced according to Operation and Maintenance Manual w

Troubleshooting

Check items

Fuel tank is empty

w


Q Q

There are rust and water in fuel drained from fuel tank Fuel is leaking from fuel piping

w


w Q Q


q q


q

Inspect fuel filter directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q q

Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*1)" indicated by code

q Correct

Correct

Replace

Replace

Replace

Correct

Clean

Add

Remedy

Correct

Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*2)" indicated by code

Correct

Questions


*1: Displayed failure code [CA689] *2: Displayed failure code [CA778]

12

D155A-6

40 Troubleshooting

SEN03212-01

S-6 Engine lack output (or lacks power)

D155A-6

E E

Q

Q

Q Q Q Q

Q

Q Q Q Q

Defective fuel temperature sensor or wiring harness

Defective charge pressure sensor or wiring harness

Defective installation of charge pressure sensor (air leakage)


Defective drive of injector (signal or solenoid)

E

Clogged injector or defective spray (dirt in injector)

Q w

Q Q Q w w w w w w w w w w Q w w Q w

Q Q Q Q Q Q

w

w

q q q q q q q

Replace

Replace

Correct

Replace

Replace

Replace

Clean

Correct

q Clean

Replace

Adjust

Replace

Replace

Correct

Remedy


E Q

Inspect air cleaner directly q Inspect air intake piping directly q Boost pressure is low q q q Compression pressure is low q q Inspect valve clearance directly q Inspect fuel filter directly Inspect feed pump gauze filter directly Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Inspect boost pressure sensor mount directly Carry out troubleshooting according to "Chg Air Press Sensor High (Low) Error (*2)" indicated by code Carry out troubleshooting according to "Fuel Temp Sensor High (Low) Error (*3)" indicated by code

*1: Displayed failure code [CA559] and [CA2249] *2: Displayed failure code [CA122] and [CA123] *3: Displayed failure code [CA263] and [CA265]

Clogged fuel filter

Leaking or clogged fuel piping






E

Replace

Confirm recent repair history Degree of use of machine Operated for long period Suddenly Power was lost Gradually Non-specified fuel is used Filters have not been replaced according to Operation and Maintenance Manual Engine oil must be added more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Black Exhaust gas is Blue under light load Immediately after engine is started, temperature of exhaust manifold of a cylinder is low When engine is rotated, interference sound comes out from around turbocharger When engine is rotated, abnormal sound comes out from around cylinder head High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular Engine hunts (rotation is irregular) Blow-by gas is excessive

Air leakage from air intake piping


Causes

Clean

Troubleshooting

Check items

Questions

General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheating o See "S-14 Coolant temperature becomes too high (Overheating)" q Control by controller in derate mode (limiting injection rate (output) because of an error in electrical system)

1

13

SEN03212-01

40 Troubleshooting

S-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black q Insufficient intake of air q Excessive injection of fuel q Defective condition of fuel injection q Improper selection of fuel q Overheating o See "S-14 Coolant temperature becomes too high (Overheating)" q Control by controller in derate mode (limiting injection rate (output) because of an error in electrical system)

1 Defective coolant temperature sensor or wiring harness

Improper fuel injection pressure

Improper fuel injection timing

Clogged fuel spill piping (on cylinder head side)

Abnormally worn injector

Clogged or seized injector



Crushed or clogged muffler

Leakage of air between turbocharger and cylinder head





Causes


E


Questions

Exhaust gas color

E

E

w

Suddenly became black

w

Gradually became black

Q w


Q Q


w

Oil must be added more frequently Power was lost

E Q Q Q Q

w

Suddenly

Q w

Gradually

Dust indicator is red (if indicator is installed)

Q Q

Q

Q Q Q

w

Muffler is crushed

w

Air leaks between turbocharger and cylinder head or clamp is loosened

Q Q Q

Engine is operated in low-temperature mode at normal temperature

Check items


Q w w

When engine is rotated, interference sound comes out from around turbocharger

w

When engine is rotated, abnormal sound comes out from around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)

Q Q Q Q

Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular

w Q Q Q

Q Q w w


w

When spill hose from injector is disconnected, abnormally much fuel spills

q


q


q

Troubleshooting


q q


q

When muffler is removed, exhaust gas color improves Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code

q


q q q

Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by code

Adjust

Adjust

Correct

Replace

Replace

Replace

Replace

Replace

Correct

Adjust

Replace

Replace

Clean

Remedy

q Replace


*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA144] and [CA145]

14

D155A-6

40 Troubleshooting

SEN03212-01

S-8 Oil consumption is excessive (or exhaust gas is blue) General causes why oil consumption is excessive q Abnormal consumption of oil q Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) q External leakage of oil q Wear of parts in lubrication system

1 Oil leakage from oil pan, cylinder head, etc.

Oil leakage from oil drain plug

Oil leakage from oil piping

Oil leakage from oil filter

Oil leakage from oil cooler

Broken oil cooler

Worn or damaged rear oil seal


Broken piston ring

Clogged breather or breather hose

Oil leakage from EGR valve stem

Turbocharger Worn seal at blower end

Worn seal at turbocharger end

Worn or damaged valve (stem, guide, or seal)

Dust sucked in from intake system

Causes

E E E E


E w

Oil consumption suddenly increased Q


Q w

Q

Q Q w

Oil becomes dirty quickly

w w w w w

Outside of engine is dirty with oil w

There are loose piping clamps in intake system

w Q w

Inside of turbocharger exhaust outlet pipe is dirty with oil

w

There is oil in coolant w

Oil level in damper chamber is high Q

Exhaust gas is blue under light load

w w w

None q

There is dust in intake manifold

q

Inside of intake manifold is abnormally dirty

q q

Play of turbocharger shaft is excessive

q

Exhaust port of EGR valve is dirty with oil

q

Check breather and breather hose directly

q q


q

Inspect rear oil seal directly

q q

Leakage from oil cooler is detected by pressure test

D155A-6

Correct

Correct

Replace

Correct

Replace

Replace

Clean

Replace

Replace

Replace

Remedy

Correct

q q q q

Oil leaks out of engine Correct

Troubleshooting

w w

Q

Correct

Amount of blow-by gas

Q

Excessive

Correct

Check items

Inside of turbocharger intake outlet pipe is dirty with oil

Replace

Questions


15

SEN03212-01

40 Troubleshooting

S-9 Oil becomes dirty quickly

1

Exhaust gas color is bad

Q

Non-specified fuel is used Q

Engine oil must be added more frequently

w w Q


Q Q

Inside of exhaust pipe is dirty with oil

w

w w

Q

Comes out excessively

Q w

Q w

Does not come out at all q q

Exhaust port of EGR valve is dirty with oil

q q


See S-7

Blow-by gas

w

Black

q

Check breather and breather hose directly

q

Inspect oil cooler directly

q

Inspect oil filter directly

q

Spring of oil filter safety valve is hitched or broken

q Replace

Replace

Clean

Clean

Replace

Replace

Replace

Remedy

Replace

Inspect turbocharger lubrication drain tube directly

—

Exhaust gas is

w


Play of turbocharger shaft is excessive

16

Clogged turbocharger lubrication drain tube

E E E E


Engine oil temperature rises quickly Check items

Defective oil filter safety valve


Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is installed)

Troubleshooting

Clogged oil filter

Clogged oil cooler

Clogged breather or breather hose


Worn valve or valve guide

Worn EGR valve guide

Defective seal at turbocharger turbine end

Causes

Clean

Questions

General causes why oil becomes dirty quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Overload operation

D155A-6

40 Troubleshooting

SEN03212-01

S-10 Fuel consumption is excessive

1

General causes why fuel consumption is excessive q Leakage of fuel q Defective condition of fuel injection (fuel pressure or injection timing) q Excessive injection of fuel

Defective coolant temperature sensor or wiring harness

Improper fuel injection timing

Malfunction of injector

Defective spray by injector

Defective common rail pressure

Defective supply pump plunger

Defective feed pump oil seal

Fuel leakage from fuel filter, piping, etc.

Fuel leakage inside head cover

Causes

E E


Q

Gradually increased Q Q

Suddenly increased

w

There is external leakage of fuel from engine

w

Combustion is irregular w

w w


Q

Low idle speed is high

Q

Torque converter stall speed or pump relief speed is high Exhaust gas is

Q Q

Black

Q Q

Q

White

q

Remove head cover and inspect inside directly

q

Inspect feed pump oil seal directly

q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code

q


q

When spill hose from injector is disconnected, much fuel spills Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by code

q

Correct

Replace

Replace

Correct

Correct

Remedy

q Replace

q

Confirm with monitoring function on applicable machine side

Correct

Check items

Engine oil level rises and oil smells of diesel fuel

Troubleshooting

Q Q Q Q

Correct

Fuel consumption

E Q

Is large compared to other machines of same model

Replace

Questions


*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA144] and [CA145]

D155A-6

17

SEN03212-01

40 Troubleshooting

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)

1

General causes why oil is in coolant q Leakage in lubrication system q Leakage in cooling system

Broken hydraulic oil cooler or power train oil cooler on applicable machine side

Broken oil cooler core or O-ring

Insufficient protrusion of cylinder liner

Damaged cylinder liner O-ring or holes caused by pitting

Crack in cylinder block

Broken cylinder head or head gasket

Causes

E

Degree of use of machine Operated for long period Oil level

Q Q

w

There are excessive air bubbles in radiator and coolant spurts back

w w

Hydraulic oil or power train oil on applicable machine side is milky

w

When hydraulic oil or power train oil is drained, water flows out

w

q q

Inspect cylinder block and liner directly

q

Inspect cylinder liner directly

q Replace

Replace

Replace

Remedy

Replace


—

q

Leakage from cylinder head is detected by pressure test


Check items

Q

Q Q

Oil level has risen and oil is milky

18

Q

Q Q

Gradually increased

Hard water is used as coolant

Troubleshooting

E

Q

Suddenly increased

Replace

Questions


D155A-6

40 Troubleshooting

SEN03212-01

S-12 Oil pressure drops

1

General causes why oil pressure drops q Leakage from, clogging, or wear of lubrication system q Defective oil pressure control q Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed. q Deterioration of oil due to overheating

Defective oil pressure sensor or wiring harness

Leaking, crushed, or clogged hydraulic piping

Clogged oil filter

Defective oil pump relief valve

Defective oil pump

Clogged or broken pipe in oil pan

Clogged strainer in oil pan

Coolant or fuel in oil

Lack of oil in oil pan

Worn journal of bearing

Causes

E


E

E Q w

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q

Non-specified oil is used

Q w

Filters have not been replaced according to Operation and Maintenance Manual w

Indicates pressure drop at low idle Oil pressure monitor (if installed)

Q

Indicates pressure drop at low, high idle

Q

Indicates pressure drop on slopes

w

w w w Q w

w

Oil level in oil pan is low

w

Q

w

External hydraulic piping is leaking or crushed w

Oil is milky or smells of diesel oil There are metal particles in oil drained from oil pan

w

There are metal particles in oil drained from oil filter

w

There are metal particles in oil filter

q

Q

q q See S-13

Inspect oil pan strainer and pipe directly Oil pump is heavy to rotate or it has play Valve spring of oil pump relief valve is fatigued or damaged Inspect oil filter directly

q q q

Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)" indicated by code Correct

Adjust

Replace

Clean

Clean

—

Add

Remedy

q Replace

Troubleshooting

Check items

Sometimes indicates pressure drop Oil level monitor indicates oil lever drop (if monitor is installed)

Replace


Replace

Questions


*1: Displayed codes [CA135] and [CA141]

D155A-6

19

SEN03212-01

40 Troubleshooting

S-13 Oil level rises (Entry of coolant or fuel)

1

General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant"

E

E

w

Fuel consumption has increased Coolant must be added more frequently

Q

There is oil in coolant

Q

w w Q Q

w

w

Oil is milky

Q

When engine is started, water drops from muffler

Q

When radiator cap is removed and engine is run at low idle, abnormally many bubbles come out or coolant spurts back

w

w w Q

Q

Exhaust gas is white

Q w

Water pump drain hole (breather hole) is clogged

w

When water pump drain hole (breather hole) is cleaned, coolant flows out w

Oil level in damper chamber on applicable machine side is low

w

Oil level in hydraulic tank on applicable machine is low q


q

Troubleshooting

Remove and inspect head cover directly

q q

Inspect cylinder block and liner directly

q

Inspect rear oil seal directly

q


q

Remove and inspect water pump directly

q

Remove and inspect thermostat cover directly

q

Remove and inspect supply pump directly

q Replace

Correct

Replace

Replace

Correct

Replace

Replace

Correct

Remedy

Replace

Inspect seal of auxiliary equipment directly

20

Defective seal of auxiliary equipment (pump and compressor)

Defects in supply pump

Defective thermostat seat

Clogged water pump drain hole (breather hole) or defective seal

Broken oil cooler core or O-ring

Worn or damaged rear oil seal


Cracks inside cylinder block

E E


Oil smells of diesel fuel

Check items

Fuel leakage inside cylinder block


Replace

Questions


Causes

D155A-6

40 Troubleshooting

SEN03212-01

S-14 Coolant temperature becomes too high (Overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation or damage of fan) q Drop in heat dissipation efficiency q Trouble in coolant circulation system q Rise of oil temperature in power train o Carry out troubleshooting on applicable machine side

1 Rise of power train oil temperature on applicable machine side

Defective coolant temperature gauge

Malfunction of fan

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged or crushed radiator fins

Malfunction of thermostat

Broken water pump

Low coolant level

Clogged or broken oil cooler



Causes

E E

Degree of use of machine Operated for long period Overheating Coolant temperature gauge (if installed)

E E Q w

Occurred suddenly

Q

Rises quickly

Q

w w

Does not go down from red range w

Radiator coolant level monitor indicates low (if monitor is installed) w Q

Engine oil level has risen and oil is milky

w

Milky oil is floating on coolant w

There are many bubbles in radiator and coolant spurts back Check items

Q Q w w

Has continued at low level

When light applied to radiator core, no light passes through

w

Dirt and mud are accumulated in radiator shroud and undercover on applicable machine side

w

w

w

Coolant is leaking because of cracks in hose or loose clamps

w

Coolant flows out from radiator overflow hose Power train oil temperature enters red range faster than engine coolant temperature (if oil temperature gauge and coolant temperature gauge are installed)

w

q q

Inspect oil cooler directly

q

Temperature difference between upper and lower tanks of radiator is large

q

Thermostat does not open at cracking temperature

q

Temperature difference between upper and lower tanks of radiator is slight

q

Inspect radiator core directly

q

Cracking pressure of radiator cap is low

q

Inspect fan directly

q Correct

Replace

Correct

Correct

Replace

Replace

Add

Replace

Replace

Remedy

Replace

Coolant temperature is normal

Replace

Troubleshooting

Inspect cylinder liner directly

D155A-6


q


—

Questions


21

SEN03212-01

40 Troubleshooting

S-15 Abnormal noise is made

1

General causes why abnormal noise is made q Abnormality due to defective parts q Abnormal combustion q Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 5 seconds. This does not indicate abnormality, however

Improper fuel injection timing (Defective coolant temperature sensor)

Dirt caught in injector

Clogged or seized injector

Deformed cooling fan

Removed or seized gear train bushing

Improper gear train backlash

Excessive wear of piston ring or cylinder liner


Defective inside of muffler (Removal of bulkhead)

Broken dynamic valve system (valve, rocker lever, etc.)

Interference of turbocharger or seized turbocharger

Leakage of air between turbocharger and cylinder head

Causes

E

Degree of use of machine Operated for long period Abnormal noise

Q

Gradually increased

Q Q

Non-specified fuel is used w


w


w

w

Air leaks between turbocharger and cylinder head

w

When engine is rotated, interference sound comes out from around turbocharger

w

When engine is rotated, abnormal sound comes out from around cylinder head

w w

When engine is rotated, beat noise comes out from around muffler Check items

Q

Q Q

Suddenly increased

Immediately after engine is started, temperature of exhaust manifold of a cylinder is low Exhaust gas is

w Q w

Blue under light load Q w

Black

Q w

Engine does not pick up smoothly and combustion is irregular Q

Abnormal noise is loud when engine is accelerated

Q Q

w

Blow-by gas is excessive q


q


q

When muffler is removed, abnormal noise disappears Troubleshooting

Q

q


q


q q


q

Inspect fan directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q q

Abnormal noise comes out only at start of engine

q

22

Correct

Replace

Correct

Replace

Replace

Replace

Adjust

Replace

Correct

Replace

Remedy

Replace


Correct

Questions


D155A-6

40 Troubleshooting

SEN03212-01

S-16 Vibration is excessive

1

General causes why vibration is excessive q Defective parts (abnormal wear, breakage, etc.) q Misalignment between engine and applicable machine q Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for "S-15 Abnormal noise is made", too

Broken parts in damper on applicable machine side

Worn front support spigot joint

Misalignment between engine and devices on applicable machine side

Loose engine mounting bolts or broken cushions

Improper injection timing

Worn camshaft bushing

Improper gear train backlash

Worn main bearing or connecting rod bearing

Stuck dynamic valve system (valve, rocker lever, etc.)

Causes

E

E

E

E

Q

Q

Q

Q


Q

Q


w

w


w

w

Oil pressure is low at low idle

Q

Q

Degree of use of machine Operated for long period Vibration

Q

Suddenly increased Gradually increased

Q

Vibration occurs at medium speed Q

Vibration follows engine speed Exhaust gas is black

w


q

Q

Q Q Q Q

q

Inspect main bearing and connecting rod bearing directly Troubleshooting

Q

q


q

Inspect camshaft bushing directly

q


q

Inspect engine mounting bolts and cushions directly

q

Radial runout or facial runout is detected

q

Inspect front support spigot joint directly

q

D155A-6

Replace

Adjust

Replace

Adjust

Replace

Replace

Replace

Remedy

Replace

Inspect inside of damper directly

Replace

Check items

Questions


23

SEN03212-01

40 Troubleshooting

S-17 Air cannot be bled from fuel circuit

1

(After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but stalls.) General causes why air cannot be bled q Electric priming pump does not operate. q Fuel is not supplied or is supplied very little. q Fuel valve or air bleeding valve is not set properly. q Air bleeding piping is clogged. q Fuel return piping is clogged.

Low battery charge level

Clogged fuel filter

Clogged water separator screen

Defective wiring harness of electric priming pump

Malfunction of electric priming pump switch

Malfunction of electric priming pump

Clogged air bleeding piping

Leaking or clogged fuel piping or air in it

Clogged fuel tank cap breather hole

Improper setting of fuel valve (Closed)

Improper setting of air bleeding valve (Closed)

Low fuel level

Causes

EE


Q Q


w Q

Fuel tank is empty Fuel tank cap breather hole is clogged

w w

Check items

Fuel is leaking from fuel piping

w w

Switch lamp does not blink When electric priming pump switch is operated

w

Lamp blinks but pump operation sound is not heard Pump operation sound is heard but fuel does not flow out of hose soon

Q Q

w w w

Q Q

q

Air bleeding valve is closed

Troubleshooting

Q

w

Fuel valve (supply side) is closed

q

Fuel valve (return side) is closed

q

Water drain valve and air intake plug of water separator are loosened

q

Water drain valve of fuel prefilter is loosened

q q

There is flaw or dirt on sealing face of fuel prefilter or main filter

q

Check air bleeding piping and orifice directly (See Note 1)

q

Check fuel piping (supply side and return side) directly (for clogging and breakage)

q

Check electric priming pump directly

q q

Check electric priming system directly (See E-33 in E-mode)

q

Check water separator screen directly

q

24

Clean

Replace

Replace

Replace

Correct

Correct

Correct

Correct

Correct

Remedy

Add

Check fuel filter for clogging (Failure code CA559, Note 2)

Charge


Replace

Questions


D155A-6

40 Troubleshooting

SEN03212-01

Note 1: Check of air bleeding piping for clogging •

Remove joint bolt (1) and blow clean compressed air into hole [b] of the orifice to check for clogging.

D155A-6

25

SEN03212-01

40 Troubleshooting



26

D155A-6

SEN03366-01


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 General information on disassembly and assembly How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tool list ................................................................................................................................................ 7 Sketches of special tools .............................................................................................................................. 13

D155A-6

1

SEN03366-01

50 Disassembly and assembly

How to read this manual

1

1. Removal and installation of assemblies Special tools q Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts ).

* *** ****

a

2

General tools that are necessary for removal or installation are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described.

Removal The "Removal" section contains procedures and precautions for implementing the work, know how and the amount of oil or coolant to be drained. q Various symbols used in the "Removal" section are explained and listed below. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. [*1] : This mark shows that there are instructions or precautions for installing parts. 6 : This mark shows the amount of oil or coolant to be drained. 4 : Weight of part or component q

Installation q Except where otherwise instructed, installation of parts is done in the reverse order of removal. q Instructions and precautions for installing parts are shown with [*1] mark in the "Removal" section, identifying which step the instructions are intended for. q Marks shown in the "Installation" section stand for the following. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5

: Quantity of oil or coolant to be added

Sketches of special tools q Various special tools are illustrated for the convenience of local manufacture.

D155A-6


SEN03366-01

2. Disassembly and assembly of assemblies Special tools q Special tools which are deemed necessary for disassembly and assembly of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They respectively have a new part number. R : Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts ).

* *** ****

a

D155A-6

Disassembly In "Disassembly" section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant drained are described. q The meanings of the symbols used in "Disassembly" section are as follows. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. 6: Quantity of oil or coolant drained q

Assembly q In "Assembly" section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. q The meanings of the symbols used in "Assembly" section are as follows. k : Precautions related to safety in execution of work a: This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5

: Quantity of oil or coolant to be added

Sketches of special tools Various special tools are illustrated for the convenience of local manufacture.

q

General tools that are necessary for disassembly and assembly are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described.

3

SEN03366-01


Coating materials list

1 (Rev. 2007.06)

a a

The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this manual.

Category

Komatsu code

Part number

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.

Adhesive

LT-3 LT-4

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

ThreeBond 1735

Gasket sealant

790-129-9140

• Used to stick and seal metal, glass, and plastics.

Polyethylene • Used to seal plugs. container Tube

• Heat-resistant seal used to repair engines.

50 g

• Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.

790-129-9130

2g

Loctite 648-50

79A-129-9110

50 cc

LG-1

790-129-9010

200 g

790-129-9080

Can

• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods.

Aron-alpha 201

LG-5

1 kg

• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures. Tube

• Used to stick or seal gaskets and packings of power train case, etc.

• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-6

790-129-9020

200 g

Tube

• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.

LG-7

790-129-9070

1 kg

Tube

• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Tube

• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.

LG-8 ThreeBond 1207B

4

790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)

419-15-18131

100 g

D155A-6


Seizure prevention compound

Part number

Container


790-129-9310

200 g

Tube

• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.

LG-10 ThreeBond 1206E

790-129-9320

200 g

Tube

• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.

LG-11 ThreeBond 1121

790-129-9330

200 g

Tube

• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.

ThreeBond 1211

790-129-9090

100 g

Tube

• Gasket sealant used to repair engine.

Tube

• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.

—

Can

• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Various

Various

• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.

LM-P

LC-G NEVER-SEEZ

09940-00040

—

SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)

Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM

Grease

Q'ty

LG-9 ThreeBond 1206D

Molybdenum disulfide lubricant

Gasket sealant

CateKomatsu code gory

SEN03366-01

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)

Hyper White Grease G2-T, G0-T (*)

SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*) G2-S ThreeBond 1855

G2-U-S ENS grease

D155A-6

—

427-12-11871

200 g

• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like swing circle bearings, etc. and spline. 400 g x 20 container • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg

400 g 16 kg

200 g

2 kg

• Bellows-type container Can •

Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.

Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants.

Tube

• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.

Can

• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.

5

SEN03366-01

Part number

SUNSTAR PAINT PRIMER 580 SUPER

6

SUNSTAR PAINT PRIMER 435-95

Container


20 ml

Glass container

• Used as primer for cab side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

• Used as primer for glass side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

417-926-3910

22M-54-27230

• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)

SUNSTAR GLASS PRIMER 435-41

22M-54-27240

150 ml

Can

SUNSTAR SASH PRIMER GP-402

22M-54-27250

20 ml

Glass container

• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)

SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”

417-926-3910

320 ml

Polyethylene container

• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml


• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)

SUNSTAR PENGUINE SUPER 560

22M-54-27210

320 ml

Ecocart (Special container)

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml


SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml


• Used to seal front window. (Using limit: 6 months after date of manufacture)

Cartridge

• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)

GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220

333 ml

Adhesive for cab glass

Caulking material

Adhesive

Primer

SUNSTAR GLASS PRIMER 580 SUPER

Q'ty

Adhesive for cab glass

CateKomatsu code gory


• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)

D155A-6


SEN03366-01

Special tool list

1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured). a Necessity : t . . . . . . Cannot be substituted, should always be installed (used) : q . . . . . . Extremely useful if available, can be substituted with commercially available part a New/Remodel: N. . . . . . Tools newly developed for this model and given new part Nos.

Work item

Removal and installation of fuel supply pump assembly

Symbol

Part No.

Part name

1

795-630-5500

Standard puller

t 1

2 A 3

01010-81090

Bolt

t 2

01643-31032

Washer

t 2

4

790-331-1110

Wrench

q 1

Removal and installation of cylinder head assembly

795T-521-1111 Push tool 2 3

Bolt

t 3

01050-31635

Bolt

t 3

795-931-1100

Seal puller

t 1

C

Bolt

t 4

01643-31645

Washer

t 8

795T-421-1240 Push tool 5

8

Disassembly and assembly of damper assembly

F

Bolt

t 4

01643-31645

Washer

t 4

795T-521-1150 Push tool 01050-31635

Bolt

Disassembly and assemH bly of HSS case assembly

1

2

D155A-6

t 1

Installation of Engine front seal

Q Installation of Engine rear seal Q

Installation of Engine rear seal (Press fit of sleeve)

t 4 t 1

Q

Bolt

t 4

01643-31645

Washer

t 8

791-612-1100

Installer

t 1

790-101-4200

Puller (294 kN {30 ton})

t 1

790-101-1102

Hydraulic pump

t 1

791T-615-1310 • Plate

Tightening of cylinder head bolt

Q Installation of Engine front seal (Press fit of sleeve)

01050-31645

791T-615-1300 Puller assembly Disassembly and assem1 bly of transmission G assembly 2

t 1

01050-31645

795T-421-1250 Push tool 9

t 1

01050-31645

Nature of work and remarks

Separation of drive gear

t 1 R Q

01050-31655

795T-421-1270 Push tool 4 Removal and installation of engine front seal, rear seal

Necessity Q'ty New/Remodel Sketch

: R. . . . . . Tools remodeled from tools already available for other models and given upgraded part Nos. : Blank . . Tools already available for other models, usable without any modification a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See Sketches of special tools).

Installation of Engine rear seal

Press fitting of bearing

t 1 N 1 N Q Operation check of clutch piston 1

01010-82040

• Bolt

799-301-1600

Oil leak tester kit (A)

t 1

791-662-1110

Bracket

t 1

01010-31685

Bolt

t 1

01017-31620

Bolt

t 1

790-302-1500

Spanner kit

t 1

09003-09200

• Spanner

1

Removal and installation of brake and carrier assembly Removal and installation of nut (bevel pinion side)

7

Work item


Symbol

Removal and installation of final drive assembly

J

2

3

4

5

6

7

8

Part name

790-337-1032

Lifting tool

t 1

791-627-1320

Shackle

t 2

791T-627-1910 Plate

1

Disassembly and assemK bly of final drive assembly

Part No.


SEN03366-01


Removal and installation of t 1 N Q final drive assembly

01010-82080

Bolt

t 2

790-431-1031

Block

t 1

791-520-4140

Screw

t 2

790-101-2360

Plate

t 2

791-112-1180

Nut

t 2

790-101-2480

Adapter

t 2

791T-627-1920 Plate

t 1 N Q

790-101-2102

Puller

t 1

790-101-1102

Hydraulic pump

t 1

790-431-1031

Block

t 1

791-520-4140

Screw

t 1

791-112-1180

Nut

t 2

01643-32460

Washer

t 2

Pulling out of pinion shaft

791T-627-1940 Push tool

Pulling out and press fitting of sprocket and hub assemt 1 N Q bly t 1 N Q

790-101-2102

Puller

t 1

790-101-1102

Hydraulic pump

t 1

791-627-1280

Installer

t 1

790-101-5401

Push tool kit

t 1

790-101-5441

• Plate

1

790-101-5421

• Grip

1

01010-51240

• Bolt

1

791T-627-1930 Plate

Installation of floating seal

Press fitting of oil seal

t 1

790-101-5401

Push tool kit

790-101-5451

• Plate

1

790-101-5421

• Grip

1

01010-51240

• Bolt

1

791T-627-1950 Plate

t 1 N Q

791T-627-1960 Plate

t 1 N Q

790-201-1500

Push tool kit

t 1

790-201-1680

• Plate

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

791-520-4140

Screw

t 1

790-101-2420

Adapter

t 1

791-112-1180

Nut

t 1

01643-22460

Washer

t 1

792-785-1120

Plate

t 1




D155A-6

Work item

Symbol

Disassembly and assemK 7 bly of final drive assembly

Disassembly and assembly of idler assembly

1 L

SEN03366-01

Part No.

Part name



Push tool

t 1

790-101-2102

Puller

t 1

790-101-1102

Hydraulic pump

t 1

791-630-1220

Rod

t 2

790-101-2510

Block

t 1

790-101-2570

Washer

t 2

01580-01411

Nut

t 2

01643-31445

Washer

t 2

790-101-2102


t 1

791-830-1410



Press fitting of idler bushing

790-101-1102

Hydraulic pump

t 1

2

791-651-1510

Installer

t 1


3

791-601-1000

Oil pump

t 1

Refilling with oil

791-685-8006

Compressor

t 1

791-635-3160

Extension

t 1

Disassembly and assembly of recoil spring assem- M 2 bly

Compression of recoil spring

791T-630-2610 Spacer

t 1

790-101-1300

Cylinder

t 1

790-101-1102

Hydraulic pump

t 1

L 2

791-651-1510

Installer

t 1


1

790-102-1891

Nut wrench

t 1

Disassembly and assembly of carrier roller assem- R 2 bly 3

Removal and installation of nut

791-651-1510

Installer

t 1


Disassembly and assembly of track roller assembly

4

1

791T-630-1350 Spacer

t 1

Q Press fitting of ring

791-601-1000

Oil pump

t 1

Refilling with oil

791-675-9701

Remover and installer

t 1

791-101-4300

Cylinder (196 kN {20 ton}) t 1

791-101-4200


t 1

791-101-1102

Hydraulic pump

t 1

Disassembly and assembly of track shoe assembly

2 General disassembly and general assembly of track S 3 shoe assembly 4

791-932-1110

Plug push tool

t 1

Driving of plug (small)

791-660-7460

Pin brush

t 1

Cleaning of pin

791-432-1110

Plug push tool

t 1

Driving of plug (large)

5

791-632-1052

Installer

t 1

Insertion of link seal

6

790-701-3000

Seal checker

t 1

Check of oil supply and airtightness

7

791-601-1000

Oil pump

t 1

Refilling with oil

791-675-9581

Adapter

t 1

791-675-9590

Guide

t 1

01010-52460

Bolt

t 2

01010-51440

Bolt

t 2

Field disassembly and assembly of 1 link

D155A-6

T 1


9

Work item


Symbol

2

3

4

5

6 Field disassembly and assembly of 1 link

T 7

8

9

10

10

Part No.

Part name


SEN03366-01

790-101-1102

Pump

t 1

790-101-4300

Cylinder (1,470 kN {150 ton})

t 1

791-685-9510

Frame

t 1

791-685-9520

Frame

t 1

791-685-9530

Rod

t 1

791-685-9550

Nut

t 1

791-685-9560

Bolt

t 1

791-675-9570

Adapter

t 1

04530-12030

Eyebolt

t 1

790-101-1102

Pump

t 1

790-101-4300


t 1

791-685-9540

Rod

t 1

791-685-9550

Nut

t 3

791-675-5520

Guide

t 1

791-675-5530

Pusher

t 1

01010-51030

Bolt

t 1

791-685-9620

Extension

t 1

790-101-1102

Pump

t 1

790-101-4200


t 1

791-675-5542

Adapter

t 1

791-675-5571

Adapter

t 1

790-101-1102

Pump

t 1

790-101-4300


t 1

791-675-5580

Guide

t 1

791-685-9510

Frame

t 1

791-685-9520

Frame

t 1

791-685-9530

Rod

t 1

791-685-9540

Rod

t 1

791-685-9550

Nut

t 3

791-685-9560

Bolt

t 4

791-126-0150

Adapter

t 1

01010-51030

Bolt

t 1

791-685-9620

Extension

t 1

791-675-5542

Adapter

t 1

791-675-5560

Guide

t 1

790-101-1102

Pump

t 1

790-101-4300


t 1

791-675-5560

Guide

t 1

791-675-5542

Adapter

t 1


Disassembly of 1 link





Assembly of 1 link

Assembly of 1 link

Assembly of 1 link

Assembly of 1 link

D155A-6

Work item

Symbol

790-101-4200


t 1

791-670-3270

Guide

t 1

791-126-0150

Adapter

t 1

791-675-5560

Guide

t 1

791-675-9570

Adapter

t 1

01010-51030

Bolt

t 1

790-101-1102

Pump

t 1

790-101-4200


t 1

791-675-9701


t 1

790-101-1102

Pump

t 1

790-101-4200


t 1

790-101-4300


t 1


3

791-432-1110

Plug push tool

t 1

Driving of plug (large)

4

790-701-3000

Seal checker

t 1

Check of oil supply and airtightness

791-932-1110

Plug push tool

t 1

T

1

2

5

Removal and installation of equalizer bar assembly

Removal and installation of operator's cab (stuck glass)

V

W

X 1

1 Disassembly and assembly of hydraulic cylinder Y assembly 2

D155A-6


t 1

13

Removal and installation of pivot shaft assembly

Part name

Pump

12

Disassembly and assemU bly of master link

Part No.

790-101-1102

11

Field disassembly and assembly of 1 link

SEN03366-01



791T-650-2110 Sleeve

t 1

790-201-2770

t 1

Spacer

791T-650-2120 Plate

t 1

792-104-3940

Bolt

t 2

790-101-2510

Block

t 1

790-101-2570

Washer

t 2

01580-01613

Nut

t 1

790-105-2300

Jack assembly (196 kN {20 ton})

t 1

790-101-1102

Hydraulic pump

t 1

Assembly of 1 link Assembly of 1 link

Assembly of 1 link

Expansion of link

Driving of plug (small) Q Q

Press fitting of ring

791T-650-2130 Sleeve

t 1

Q

790-101-2420

Adapter

t 1

791-502-4140

Screw

t 1

790-101-2540

Washer

t 2

790-112-1180

Nut

t 2

790-101-4000


t 1

790-101-1102

Hydraulic pump

t 1

793-498-1210

Lifter (Suction cup)

t 2

Installation of window glass

790-502-1003

Cylinder repair stand

t 1

Disassembly and assembly of hydraulic cylinder

790-101-1102

Hydraulic pump

t 1

790-102-3802

Multi-wrench

t 1

Pulling out of center pin

Installation of round head (Blade lift)

11

Work item


Symbol

Part No.

790-201-1702

3

Disassembly and assem4 bly of hydraulic cylinder Y assembly

5

6

12

Part name

Push tool kit


SEN03366-01


t 1

Press fitting of bushing

790-201-1721

• Push tool

1

790-201-1821

• Push tool

1

Blade lift

790-201-1841

• Push tool

1

Blade tilt

790-201-1851

• Push tool

1

Ripper lift

790-201-1861

• Push tool

1

Ripper tilt

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1500

Push tool kit

790-201-1630

• Plate

1

Blade lift

790-201-1650

• Plate

1

Blade tilt

790-201-1660

• Plate

1

Ripper lift

790-201-1670

• Plate

1

Ripper tilt

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-720-1000

Expander

t 1

796-720-1670

Ring

t 1

07281-01279

Clamp

t 1

796-720-1690

Ring

t 1

07281-01919

Clamp

t 1

796-720-1720

Ring

t 1

07281-02429

Clamp

t 1

790-102-4300

Wrench

t 1

790-102-4310

Pin

t 2

t 1

Press fitting of dust seal

Press fitting of dust seal Installation of piston ring Blade lift Blade tilt Ripper lift Ripper tilt Removal and installation of screw-type piston

D155A-6


Sketches of special tools

SEN03366-01

1 Note) We will not be liable for any result of use of special tools manufactured according to the following drawings.

C2: Push tool

C4: Push tool

D155A-6

13

SEN03366-01


Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. C5: Push tool

C8: Push tool

14

D155A-6


SEN03366-01

Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. C9: Push tool

G1: Plate (791T-615-1310)

D155A-6

15

SEN03366-01


Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. Component of J: Plate (791T-627-1910)

K1: Plate (791-627-1920)

16

D155A-6


SEN03366-01

Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. Component of K2: Plate (791T-627-1930)

Component of K2: Push tool (791T-627-1940)

D155A-6

17

SEN03366-01


Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. Component of K5: Plate (791T-627-1950)

Component of K5: Plate (791T-627-1960)

18

D155A-6


SEN03366-01

Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. Component of M2: Spacer (791T-630-2610)

Component of V: Sleeve (791T-650-2110)

D155A-6

19

SEN03366-01


Note) We will not be liable for any result of use of special tools manufactured according to the following drawings. Component of V: Plate (791T-650-2120)

Component of W: Sleeve (791T-650-2130)

20

D155A-6


D155A-6

SEN03366-01

21

SEN03366-01




22

D155A-6

SEN03367-01


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Engine and cooling system Removal and installation of fuel supply pump assembly ................................................................................ 2 Removal and installation of fuel injector assembly ......................................................................................... 7 Removal and installation of cylinder head assembly .................................................................................... 13 Removal and installation of radiator assembly ............................................................................................. 24 Removal and installation of aftercooler assembly......................................................................................... 27 Removal and installation of engine assembly ............................................................................................... 30 Removal and installation of engine hood assembly ...................................................................................... 34 Removal and installation of engine front seal ............................................................................................... 36 Removal and installation of engine rear seal ................................................................................................ 40 Removal and installation of fuel tank assembly ............................................................................................ 45 Removal and installation of fan drive assembly ............................................................................................ 47 Removal and installation of fan motor assembly .......................................................................................... 48

D155A-6

1

SEN03367-01


Removal and installation of fuel supply pump assembly 1

3.

Remove the fuel filter and filter head assembly according to the following procedure. 1) Loosen joint (5) at the top of the fuel air bleeding tube. [*1] 2) Disconnect joint (6) at the bottom of the fuel air bleeding tube. [*2] 3) Disconnect fuel filter inlet tube (7) and fuel filter outlet tube (8) from the filter. [*3] 4) Remove clamp (9) of the engine oil level gauge guide. 5) Remove fuel filter and filter head assembly (10).

4.

Loosen mounting nut (11) of the engine oil level gauge guide. [*4]

1

795-630-5500

Standard puller

t 1

A 2

01010-81090

Bolt

t 2

3

01643-31032

Washer

t 2

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Removal k

1.

2.

2

Disconnect the cable from the negative (–) terminal of the battery. Open engine left side cover (1) and remove covers (2) and (3).

Open undercover (4). k

Using a floor jack, a wire rope, etc., open the undercover carefully.

D155A-6


5.

Disconnect the following wiring connectors. 1) Wiring fixing bracket mounting bolts (12) and (13). 2) Wiring connectors PCV1 (14), CPV2 (15) and backup sensor (16).

6.

Disconnect or remove the following tubes around the supply pump. 1) Remove tube clamp (17) between the pump and fuel filter. 2) Remove tube (18) between the pump and fuel filter. (This tube was disconnected from the fuel filter in step 3-3).) [*5] 3) Remove tube clip (19) between the feed pump and priming pump. 4) Disconnect tube (20) between the feed pump and priming pump. [*6] a Tube (21) is also clamped. 5) Remove tube (22) between the feed pump and cooling plate. [*7] a Tube (21) is removed, too. 6) Remove 2 fuel return tube clamps (23). [*8] 7) Remove fuel return tube clip (24). 8) Remove fuel return tubes (25) and (26). [*9] 9) Remove lubrication tube (27). [*10]

D155A-6

SEN03367-01

7.

Remove the high-pressure pipes according to the following procedure. 1) Remove the clamp and stay (28). 2) Remove the clamp and stay (29). 3) Remove the clamp and stay (30). 4) Remove 4 boots (31) (2 pieces each on the supply pump side and common rail side). [*11]

5)

Loosen sleeve nuts (32) (2 pieces on the common rail side) and (33) (2 pieces on the supply pump side) and remove highpressure pipes (34) and (35).

3

SEN03367-01

8.

Rotate crank shaft forward so that the middle position (a) of "2.5 TOP" stamp line of damper (36) and "3.4 TOP" stamp line aligns to the pointer (37). a Crank the crankshaft at hexagonal part (b) of water pump drive shaft tip.


12. Remove bracket (40), and loosen four mounting bolts (41). 13. Set tools A1, A2 and A3 on drive gear (42), and tighten the center bolt of tool A1 to remove drive gear (42) from the shaft (43). 14. Remove mounting bolts (41) and remove fuel supply pump assembly (44). a Keep tool A1, A2 and A3 set on drive gear (42) until fuel supply pump assembly is installed, for the drive gear falls off without the tools.

9.

Remove engine front cover (38).

10. Check that the mounting bolt hole (c) at the top of cover align to the forcing tap of drive gear. a If they are not aligned, rotate crankshaft one more turn. 11. Remove nut (39). [*12] a Take care not to drop into the case.

4

D155A-6


SEN03367-01

Installation

4.

Tighten permanently four mounting bolts (41).

1.

Set fuel supply pump assembly (44). a Before setting, check that key (d) of shaft aligns to the key slot (e) of drive gear.

5.

Tighten bracket (40) permanently. 3 Mounting bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

2.

Temporarily tighten four mounting bolts (41) and bracket (40) with fingers. 2 Mounting bolt: Liquid adhesive (LT-2)

6.

Temporarily tighten clamps (45), (46) and (47), and stays (28), (29) and (30), with fingers.

7.

Tighten clamps (45), (46) and (47) permanently. a Tighten clamps in the order of (45), (29) and (47). 3 Clamping bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm}

8.

Tighten stays (28), (29) and (30) permanently. a Tighten stays in the order of (28), (29) and (30).

9.

Carry out the subsequent procedure in the reverse order of removal.

3.

Set high pressure pipes (34) and (35), temporarily tighten sleeve nuts (32) and (33) with fingers and tighten permanently with the following torque. 3 Common rail side sleeve nut: 39.2 – 58.8 Nm {4 – 6 kgm} Supply pump side sleeve nut: 39.2 – 49 Nm {4 – 5 kgm}

D155A-6

5

SEN03367-01

Assembly [*1], [*2] 3 Fuel air bleeding tube joint bolt: (Air vent side and fuel filter head side) (5), (6): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} [*3], [*5] 3 Fuel tube joint bolt: Between fuel filter and supply pump (18): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} (Fuel filter side) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Supply pump side) Between fuel filter and supply pump (17): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} (Fuel filter side)


[*10]

3

Lubrication tube joint bolt: 7.9 – 12.7 Nm {0.8 – 1.3 kgm} (Supply pump side) 9.8 – 12.7 Nm {1.0 – 1.3 kgm} (Block side)

[*11] a Install covers (32) and (33) with the notch in the following direction. q Cover (32): Common rail side q Cover (33): Supply pump side [*12]

3

Nut (39): 176 – 196 Nm {18 – 20 kgm}

[*4]

3

Gauge guide mounting nut: 19.6 – 34.3 Nm {2 – 3.5 kgm}

[*6]

3

Tube joint bolt between feed pump and priming pump: 14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Feed pump side) 43 – 47 Nm {4.4 – 4.8 kgm} (Priming pump side)

[*7]

3

Tube joint bolt between feed pump and cooling plate: 14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Feed pump side) 43 – 47 Nm {4.4 – 4.8 kgm} (Cooling plate side)

[*8]

3

Fuel return tube clamp bolt: 9.8 ± 1 Nm {1.0 – 0.1 kgm}

[*9]

3

6

Fuel return tube joint bolt: Between supply pump and priming pump (25) 14.8 – 19.6 Nm {1.5 – 2.0 kgm} (Supply pump side) 19.6 – 29.4 Nm {2.0 – 3.0 kgm} (Priming pump side of (25)) Between supply pump and common rail (26) 17.7 – 22.6 Nm {1.8 – 2.3 kgm} (Common rail side)

D155A-6


SEN03367-01

Removal and installation of fuel injector assembly 1 Removal k

Disconnect the cable from the negative (–) terminal of the battery.

1.

Remove the engine hood. For details, see "Removal and installation of engine hood assembly".

2.

Remove the corrosion resistor assembly, fuel filter assembly, prefilter assembly and oil filter assembly according to the following procedure. 1) Corrosion resistor 1] Disconnect 2 corrosion resistor inlet/ outlet tubes (1). [*1] 2] Remove corrosion resistor bracket assembly (2). 2) Fuel filter 1] Remove oil level gauge guide clamp (3). 2] Loosen the upper joint bolt (on the air vent assembly side) of fuel air bleeding tube (4), remove the lower joint bolt, and disconnect fuel air bleeding t u be ( 4) f r o m f ue l fi l te r b r ac k e t assembly (5). [*2] 3] Disconnect 2 fuel filter inlet/outlet tubes (6). [*3] 4] Remove fuel filter bracket assembly (5). 3) Prefilter 1] Remove prefilter inlet hose (7) and outlet tube (8). [*4] 2] Remove prefilter bracket assembly (9). 4) Oil filter 1] Remove tube assembly (10) between the oil filter and cylinder block. [*5] 2] Remove oil filter bracket assembly (11). a a

D155A-6

3.

Remove high-pressure pipe clamp (12) between the common rail and supply pump and then remove stay (13).

4.

Remove common rail cover (14).

a

The following is the removal procedure for the No. 1 fuel injector assembly.

5.

Remove stay (15). a If bracket (16) is removed, you can work easily.

When removing the No. 1 fuel injector assembly, you do not need to remove the prefilter assembly. When removing one other than the No. 1 fuel injector assembly, you do not need to remove the corrosion resistor assembly and fuel filter assembly.

7

SEN03367-01

6.

Remove clamp (17).

7.

Remove boot (18).

8.

Loosen sleeve nut (19).

9.

Remove stays (20) – (23).


11. Rotate crankshaft forward, align damper "1.6TOP" stamp line (c) to pointer (P), and then set the No.1 cylinder to the compression top dead center. a Crank the crankshaft at hexagonal part (d) of water pump drive shaft tip.

12. Remove cover (25). [*7] 13. Remove mounting bolts (26) through (28), and remove rocker arm and rocker shaft assembly (29). [*8] a Loosen lock nut (31), and loosen adjustment screw (32) two or three turns to prevent excessive force applied to push rod (30), when installing rocker arm and rocker shaft assembly.

10. Remove cylinder head cover (24). [*6]

8

D155A-6


SEN03367-01

14. Loosen sleeve nut (33), and remove high pressure pipe (34) from injector. 15. Remove wiring harness clamping bolt (35) and clip (36). [*9] 16. Remove two wiring harness capture nuts (37) from fuel injector assembly. [*10] a Tighten nuts alternately. 17. Remove holder mounting bolt (38).

18. Set L type bar [1] under fuel injector assembly inlet connector (a), and remove slowly fuel injector assembly (39) with holder (40) using leverage action. a Do not pull out solenoid valve portion at the top of injector by pinching with pliers, etc.

D155A-6

9

SEN03367-01

Installation 1.

Install fuel injector assembly. 1) Check that no foreign material stays inside injector sleeve. 2) Install O-rings (41) and (42), and gasket (43) to injector. a Take care not to install O-ring to groove (b).

3) 4) 5)

10


6) 7)

Tighten bolts (38) to the specified torque. 3 Bolt (38): 58.8 – 73.5 Nm {6 – 7.5 kgm} Tighten sleeve nuts (33) and (19). 3 Sleeve nuts (33) and (19): 39.2 – 49 Nm {4 – 5 kgm}

Set fuel injector assembly (39) with holder (40) to cylinder head. Attach spherical washer (44) to bolt (38), and tighten temporarily bolt (38). 2 Spherical washer: Engine oil Tighten temporarily high pressure pipe sleeve nuts (33) and (19). k Install high pressure pipe after ch ecking the f ollo wings. If an abnormality takes place, it may cause fuel leakage, and replace high pressure pipe. q Check visually taper seal portion (a portion: within 2 mm from the tip) at the joint section for visible vertical slit scar (b) or patchy dent (c). q Check the difference at (d) portion (tip of taper seal portion: within 2 mm from the tip) for any catches on a finger nail (no fatigue).

D155A-6


2.

Install high pressure pipe clamp and stay. 1) Temporarily tighten high pressure pipe clamp, stay (23), clamping bolts (45) through (49), and stay mounting bolt, with fingers. 2) Tighten permanently high pressure pipe clamping bolt. 3 Clamping bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} 3) Tighten permanently stay mounting bolt. 4) Temporarily tighten high pressure pipe clamp, stay (22), clamping bolts (50) through (54), and stay mounting bolt, with fingers. 5) Install boot (18). a Install with the notch toward cylinder block side. 6) Install high pressure pipe clamp (17) and gate type frame (14) temporarily. 7) Tighten clamping bolt for high pressure pipe clamp (17) permanently. 3 Clamping bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} 8) Tighten gate type frame (14) permanently. 9) Tighten high pressure pipe clamp, stay (22) and clamping bolts (50) through (54), permanently. 3 Clamping bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} 10) Tighten permanently stay mounting bolt.

D155A-6

SEN03367-01

3.

Install the subsequent procedure in the reverse order of removal.

[*1]

3

Corrosion resistor tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} (Inlet and outlet)

[*2]

3

Fuel air bleeding tube joint bolt (Upper and lower): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

[*3]

3

Fuel filter tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} (Inlet and outlet)

[*4]

3

Prefilter inlet hose sleeve nut (7): 84 – 132 Nm {8.5 – 13.5 kgm} Prefilter outlet tube sleeve nut (8): (Bracket side) 84 – 132 Nm {8.5 – 13.5 kgm} (Tube side) 43 – 47 Nm {4.4 – 4.7 kgm}

[*5] Installation procedure for oil filter tube 1. Install tubes (55) and (56) temporarily to bracket (58) with clip (57). 2. Install flange (59) and tubes (55) and (56) temporarily. 3. Install the oil filter end of tubes (55) and (56) in the hole of the oil filter bracket and tighten bolts (60) temporarily. 4. Install flange (59) to the cylinder block temporarily with bolts (61). 5. Tighten bolts (60) on the oil filter side permanently. 6. Tighten bolts (61) of flange (59) permanently.

11

SEN03367-01

[*6]

3

Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

[*7] a Install with the notch downward. [*8] a When installing rocker arm and rocker shaft assembly (29), check the ball portion of adjustment screw (32) to be inserted securely into socket of push rod (30), and tighten mounting bolts. a As 3 mounting bolts are different each other, install them referring to the followings. q Mounting bolt (26): Stem length 120mm q Mounting bolt (27): Stem length 90 mm q Mounting bolt (28): Stem length 75.2 mm 3 Mounting bolts (26), (27) and (28): 93 – 103 Nm {9.5 – 10.5 kgm} a Adjust valve clearance referring to the section of Testing and adjusting, "Adjusting valve clearance".

12


[*9] [*10] a Install wiring harness according to the following procedure. a Eliminate the slack of the injector wiring harness and press it against the injector body so that it will not interfere with the rocker arm. Tighten the nuts alternately. 1) Install clip (36). 2) Tighten two capture nuts (37). a Tighten capture nuts alternately. 3 Capture nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} 3) Tighten wiring harness clamping bolt (35).

D155A-6


Removal and installation of cylinder head assembly

SEN03367-01

3.

1

Removal k


1.


2.

Remove the corrosion resistor assembly, fuel filter assembly, prefilter assembly and oil filter assembly according to the following procedure. 1) Corrosion resistor 1] Disconnect 2 corrosion resistor inlet/ outlet tubes (1). [*1] 2] Remove corrosion resistor bracket assembly (2). 2) Fuel filter 1] Remove oil level gauge guide clamp (3). 2] Loosen the upper joint bolt (on the air vent assembly side) of fuel air bleeding tube (4), remove the lower joint bolt, and disconnect fuel air bleeding t u be ( 4) f r o m f ue l fi l te r b r ac k e t assembly (5). [*2] 3] Disconnect 2 fuel filter inlet/outlet tubes (6). [*3] 4] Remove fuel filter bracket assembly (5). 3) Prefilter 1] Remove prefilter inlet hose (7) and outlet tube (8). [*4] 2] Remove prefilter bracket assembly (9). 4) Oil filter 1] Remove tube assembly (10) between the oil filter and cylinder block. [*5] 2] Remove oil filter bracket assembly (11).

D155A-6

Disconnect or remove the hoses according to the following procedure. 1) Remove priming pump cover (12). 2) Remove clips (13), (14) and (14a) and fuel return tube (15). [*6] 3) Remove clamps (16) and (17) and then remove fuel tube (18) between the fuel filter and supply pump. [*7]

13

SEN03367-01

4.

Disconnect wiring clips (19) and (20) and remove heater wiring connector RHT (21).

5.

Remove wiring clips (22) – (34) and move the wiring aside.


8.

Remove breather tube (40).

9.

Remove aftercooler outlet hose (41) and air intake connector (42) together. [*8]

10. Remove water tube (corrosion resistor outlet/ inlet tube) (43). 11. Remove venturi connector (44). 12. Remove housing (45).

6.

Remove stay (35), air vent assembly (36) and bracket (37) together.

7.

Remove brackets (38) and (39). 13. Disconnect fuel hose (46).

14

D155A-6


14. Remove clamp (47).

SEN03367-01

18. Remove 2 wiring harness clamps (54), upper and lower, at the rear of the air intake manifold.

15. Remove mounting bolts of bracket (48) and move bracket (48) breather (49) together.

16. Disconnect connectors TFUEL (50), TIM (51) and PIM (52).

19. Remove charge pressure sensor (55), plate (56) and bracket (57) together. a These parts must be removed to secure a space for loosening the turbocharger lubrication tube clamp.

17. Remove spill tube (53). [*9] 20. Remove 5 stays (58) of the high-pressure pipe clamps. [*10]

D155A-6

15

SEN03367-01

21. Remove high-pressure pipe clamp stays (59), (60), (61), (62) and (63). [*11]

22. Remove air intake manifold (64). [*12] 4

Air intake manifold: 50 kg

23. Remove the muffler according to the following procedure. 1) Remove heat insulation plate (65).

16


2)

Remove bracket (66).

3)

Remove 4 muffler mounting bolts (67) and lift off muffler (68). 4

Muffler: 55 kg

24. Remove the turbocharger assembly according to the following procedure. 1) Remove air connector (69). [*13] 2) Remove heat insulation plates (70), (71) and (72). 3) Remove bracket (73). 4) Remove muffler drain tube (74). 5) Remove water tube (75). 6) Remove the turbocharger-end mounting bolt of oil tube (76).

D155A-6


7)


8) 9)

Remove oil tube (78). [*14] Remove water tube (79).

10) Sling turbocharger and exhaust manifold assembly (80). 11) Remove 24 mounting bolts (81) and lift off tu rb o ch ar g er an d e x ha us t m an if ol d assembly (80). [*15] 4

Turbocharger and exhaust manifold assembly: 80 kg

SEN03367-01

25. Disconnect connectors CN1 (79), CN2 (80), CN3 (81), CN4 (82), CN5 (83) and CN6 (84), and move wiring harnesses (85) and (86). a To disconnect the connector, push in the (X) direction with a flat-head screwdriver [1] placed at the stepped portion (a) while pressing stopper (b).

26. Remove gate type frame (87) and clamp (88). [*16] 27. Remove spill tube (89). [*17] 28. Remove cover (90) and high pressure pipe (91) depending on the cylinder head assembly to be removed. [*18] [*19]

D155A-6

17

SEN03367-01

29. Remove water tube (92). [*20] 30. Remove cylinder head cover (93). [*21]

31. Rotate crankshaft forward, align damper "1.6TOP" stamp line (c) to pointer (P), and then set the No.1 cylinder to the compression top dead center. a Crank the crankshaft at hexagonal part (d) of water pump drive shaft tip.

18


32. Remove three mounting bolts (95) through (97), and remove rocker arm and rocker shaft assembly (98). a Loosen lock nut (100), and loosen adjustment screw (101) two or three turns to prevent excessive force applied to push rod (99), when installing rocker arm and rocker shaft assembly. [*22]

33. Remove fuel injector assembly. 1) Remove wiring harness clamping bolt (102) and clip (103). [*23] 2) Remove two wiring harness capture nuts (104) from fuel injector assembly. [*24] a Loosen nuts alternately. 3) Unscrew bolt (105) to remove holder (106). 4) Push connecter (107) into rocker housing, and remove injector wiring harness (108). [*25] a O-ring is installed in connector (107).

D155A-6


5) 6)

Remove mounting bolt (110) of holder. [*26] Set L type bar [2] under fuel injector assembly inlet connector (e), and remove slowly fuel injector assembly (111) with holder using leverage action. [*27] a Do not grip the solenoid valve at the top of the injector to pull off the injector.

34. Remove two push rods (99).

SEN03367-01

Installation 1.

Install cylinder head assembly. 1) Install cylinder head gasket (118). a Check that the mounting surface of cylinder head and the inside of cylinders are free from foreign material. a Check that the gasket is free from peeling or coming off of grommet.

2)

Check cylinder head mounting bolts for the following items, and if out of standard, replace mounting bolt without reusing it. q Bolt tightening should be 5 times or less. (The number of punch mark at the head of bolt should be 5 or less.) q Bolt under head length service limit (a) Short bolt:Less than 170.8 mm Long bolt: Less than 205.8 mm

35. Remove crosshead (113). 36. Remove three mounting bolts (114), three bolts (115) and auxiliary bolt (116), and remove cylinder head assembly (117).

D155A-6

19

SEN03367-01

3) 4)

5)

20

Install cylinder head assembly. Tighten each 3 mounting bolts (114) and (115) in order 1 through 6 as shown in the figure. 2 Mounting bolt: Lubricant with molybdenum disulfide (LM-P) 3 Mounting bolt 1st time: 137 – 157 Nm {14 – 16 kgm} 2nd time: 284 – 294 Nm {29.0 – 30.0 kgm} 3rd time: Retighten 90° (+30°/0) with tool A4. a When tool A4 is not available, put marks (a) and (b) to bolt and cylinder head, and retighten bolt 90° (+30°/0). Tighten auxiliary bolt (116) (tightening order: 7th) with the following torque. 3 Auxiliary bolt: 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}


2.

After installing cross head (113), make adjustment as follows. 1) Loosen lock nut (100), and loosen adjustment screw (101). 2) Lightly push cross head (113) contact surface (h) with rocker arm, and hold cross head to contact with push rod (99) side valve stem (119). 3) Screw slowly adjustment screw (101), and check the position where adjustment screw touches valve stem (120). 4) From the above condition, screw adjustment screw (101) 20°. 5) While holding adjustment screw (101) with a flat-head screwdriver, tighten locknut (100). 3 Locknut: 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}

D155A-6


3.

SEN03367-01

Install push rod (99). a Raise push rod slightly, and check that push rod is securely inserted in cam follower.

[*7]

3

4.

carry out the rest of installation in the reverse order of removal.

[*1]

3

Corrosion resistor tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*2]

3

Fuel air bleeding tube joint bolt (Upper and lower): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

[*3]

3

Fuel filter tube joint bolt (Inlet and outlet): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*4]

3 3

Prefilter inlet hose sleeve nut (7): 84 – 132 Nm {8.5 – 13.5 kgm} Prefilter outlet tube sleeve nut (8): (Bracket side) 84 – 132 Nm {8.5 – 13.5 kgm} (Tube side) 43 – 47 Nm {4.4 – 4.7 kgm}

Supply pump-end joint bolt of fuel tube between fuel filter and supply pump: 14.8 – 19.6 Nm {1.5 – 2.0 kgm}

[*8] [*13] a Replace the MIKALOR clamps with new ones. a Install each MIKALOR clamp according to the following procedure. 1) Set the hose to its original position. 2) Set the bridge (BR) under the bolt (BC) and reduce lapping area (b) over the band (BD) to a minimum of 5 mm. 3) Tighten bolt (BC). a Do not use an impact wrench. 2 Threaded part of bolt: Lubricating oil (THREEBOND, PANDO 18B) q When reusing the hose, install it to the clamp mark on it. 3 Bolt (BC): 25 ± 5 Nm {2.55 ± 0.5 kgm} q When using a new hose, tighten until dimension BDG is as follows. a Dimension BDG: 8 – 10 mm

[*5] Installation procedure for oil filter tube Install the oil filter tube according to [*5] in "Removal and installation of fuel injector assembly". [*6]

3

Fuel return tube joint bolts Upper joint bolt (15a): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Lower joint bolt (15b): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

D155A-6

21

SEN03367-01


[*9]

3 3

Joint bolt (53a): 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Joint bolt (53b): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

[*17]

3

[*10] [*11] [*16] [*19] a Install high pressure pipe, clamp, stay and gate type frame referring to the section, "Removal and installation of fuel injector assembly". [*12] a Tighten intake manifold (64) mounting bolts in the numerical order shown below. 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

Spill tube joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*18] a Install cover with the notch downward. [*20]

3

Water tube joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*21]

3

Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

[*14]

3

Oil tube cylinder block side joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*15] a Tighten exhaust manifold mounting bolts in the numerical order shown below. 2 Threads of mounting bolt: Lubricant with molybdenum disulfide (LM-P) 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

22

D155A-6


[*22] a When installing rocker arm and rocker shaft assembly (98), check the ball portion of adjustment screw (101) to be inserted securely into socket of push rod (99), and tighten mounting bolts. a As three mounting bolts are different each other, install them referring the followings. q Mounting bolt (95): Stem length 120 mm q Mounting bolt (96): Stem length 90 mm q Mounting bolt (97): Stem length 75.2 mm 3 Mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a Adjust valve clearance referring to the section of Testing and adjusting, "Adjusting valve clearance".

a

SEN03367-01

[*23] [*24] [*25] a Install injector wiring harness according to the following procedure. 1) Install O-ring to injector wiring harness (108). 2) Install injector wiring harness (108) in rocker housing, install holder (106) and tighten bolt (105). 3) Install clip (103). 4) Tighten two capture nuts (104). a Tighten capture nuts alternately. 3 Capture nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} 5) Install wiring harness clamping bolt (102).

[*26] [*27] a Install the fuel injector assembly referring to the section, "Removal and installation of fuel injector assembly". Eliminate the slack of the injector wiring harness and press it against the injector body so that it will not interfere with the rocker arm. Tighten the nuts alternately.

D155A-6

23

SEN03367-01

Removal and installation of radiator assembly


1

Removal k

1.

Disconnect the negative terminal (–) of the battery. Drain the coolant. 6

2.

Coolant: 82 l

Remove cover at the top of radiator, and disconnect connector LHD (1). 6.

Sling radiator assembly (12) and remove it. [*3] 4

3.

Remove cover (2). 4

Cover: 50 kg

4.

Disconnect hoses (3) through (7). [*1] a Remove mounting bolts for hoses (5) through (7), and disconnect hoses with tubes.

5.

Remove bracket (8) through (11). [*2] a Remove bracket (8) when removing left radiator assembly.

24

Radiator assembly: 25 kg

D155A-6


SEN03367-01

Installation q

Carry out installation in the reverse order of removal.

[*1] a Install hoses (5) and (7) with the red circle paint upward. 2 Tube flange: gasket sealant 3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm} a Tighten two parallel clamps for hose (6) with its bolt location rotated 180° each other. 2 Tube flange: gasket sealant 3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm} [*2] a Install radiator mounting brackets (9 – 11) and cushion (19) according to the following procedure. 1) Set plate (18), cushion (19) and brackets (9 – 11) on the mounting boss of radiator (12). At this time, fit brackets (9 – 11) to the mounting seat of upper tank (17). (You may tighten bracket mounting bolts (22) temporarily.) 2) Install collar (20) upside down (with the small diameter side up) and tighten mounting bolt (21). Compress cushion (19). (L1 o L2) 3) With mounting bolt (21) tightened, tighten mounting bolts (22) of brackets (9 – 11). 4) Once remove mounting bolt (21). 5) Install collar (20) again in the normal (with the small diameter side down). 6) Tighten mounting bolt (21). 7) Check clearance (L3) (approx. 7 mm).

D155A-6

25

SEN03367-01


[*3] a Set radiator assembly according to the following procedure. 1) Set rubber (13) with its stepped portion (a) downward. a Apply appropriate amount of grease to prevent drop down when lifted up. 2) Install O-ring (14). 2 O-ring periphery: Grease (G2-LI)

26

3)

Open radiator grill, remove fan net and install four cushions (15) to lower tank (16).

4)

Sling the radiator assembly and set it on the lower tank slowly. a Check visually the installation condition from the machine front.

D155A-6


Removal and installation of aftercooler assembly

SEN03367-01

1

4.

Remove four mounting bolts for tube (4). [*2]

5.

Remove brackets, (5), (6) and (7).

6.

Sling aftercooler assembly (8) and remove it.

Removal k

1.

Disconnect the negative terminal (–) of the battery. Remove cover at the top of radiator, and disconnect connector LHD (1).

4

2.

Remove cover (2). 4

3.

Aftercooler assembly: 35 kg

Cover: 50 kg

Disconnect the tube (3) from the lower part of the after cooler. [*1]

D155A-6

27

SEN03367-01

50 Disassembly and assembly a

Installation q


a

Check the charged air cooler mounting face for air leakage. If air leaks, replace the gasket, hose clamp and tube mounting bolts. (Apply LG-6 to the gasket mating face.)

1.

Remove the small hood sub-assembly (on the radiator) and the undercover at the front of the machine.

2.

Check the mounting faces (1) of the charged air cooler, duct and tube for air leakage. a Check for abnormal sound and spray soap water to check for air leakage. a Check for air leakage for 3 minutes while running the engine at full throttle.

3.

If air leaks, remove the engine upper hood, side cover, air cleaner and right and left mudguards.

4.

Remove lower duct and tube (2) and replace the gasket. 2 Charged air cooler flange and duct and tube flange: Gasket sealant (LG-6) a Spread gasket sealant (LG-6) on the narrow places of the flange with a spatula. Spread it thinly on the inside to prevent it from projecting into the duct or tube.

28

Assemble the duct and tube in 30 minutes after applying the gasket sealant.

5.

Assemble the charged air cooler, duct and tube so that the faces coated with LG-6 will be stuck to both sides of the new gasket. a When installing the duct and tube, take care not to misalign them. After assembling them, be sure to dry them for at least 2 hours. a Use new gasket, mounting bolts and washers. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

6.

Remove upper duct and tube (3) and replace the gasket. 2 Charged air cooler flange and duct and tube flange: Gasket sealant (LG-6) a Spread gasket sealant (LG-6) on the narrow places of the flange with a spatula. Spread it thinly on the inside to prevent it from projecting into the duct or tube. a Assemble the duct and tube in 30 minutes after applying the gasket sealant.

D155A-6


7.

SEN03367-01

Assemble the charged air cooler, duct and tube so that the faces coated with LG-6 will be stuck to both sides of the new gasket. a When installing the duct and tube, take care not to misalign them. After assembling them, be sure to dry them for at least 2 hours. a Use new gasket, mounting bolts and washers. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

[*1] [*2] a When loosened hose clamp, replace clamp with new one. a Install each MIKALOR clamp according to the following procedure. 1) Set the hose to its original position. 2) Set the bridge (BR) under the bolt (BC) and reduce lapping area (b) over the band (BD) to a minimum of 5 mm. 3) Tighten bolt (BC). a Do not use an impact wrench. 2 Threaded part of bolt: Lubricating oil (THREEBOND, PANDO 18B) q When reusing the hose, install it to the clamp mark on it. 3 Bolt (BC): 25 ± 5 Nm {2.55 ± 0.5 kgm} q When using a new hose, tighten until dimension BDG is as follows. a Dimension BDG: 8 – 10 mm

D155A-6

29

SEN03367-01

Removal and installation of engine assembly


k

k

k

6.

Remove stay (3).

7.

Remove the muffler according to the following procedure. 1) Remove heat insulation plate (4).

Disconnect the cable from the negative (–) terminal of the battery. Collect refrigerant (R134a) beforehand a Ask professional traders for collecting and filling the refrigerant (R134a). a Never release of the refrigerant (R134a) to the atmosphere. If the refrigerant (R134a) gets inside ones eyes, it may cause blindness. Therefore, make sure to wear protective glasses when collecting or filling the refrigerant. Collecting and filling work must be conducted by a qualified person. If you disconnect the heater hose and drain the coolant while the radiator coolant temperature is high, you may be scalded. Accordingly, wait until the coolant temperature decreases and then start the work.

1.

Recover the air conditioner refrigerant.

2.

Drain the coolant. 6

Coolant: 82 l

3.


4.

Open the undercover (1).

30

Remove air intake connector and air hose assembly (2). [*1]

1

Removal k

5.

k

2)

Remove bracket (5).

Using a floor jack, a wire rope, etc., open the undercover carefully.

D155A-6


3)

Remove 4 muffler mounting bolts (6) and lift off muffler (7). 4

SEN03367-01

12. Disconnect fuel hose (11) between the fuel tank and prefilter. [*2]

Muffler: 55 kg

13. Disconnect return hose (12). 8.

Remove the radiator assembly. For details, see "Removal and installation of radiator assembly".

9.

Remove the aftercooler assembly. For details, see "Removal and installation of aftercooler assembly".

10. Remove reservoir tank (8) and bracket (9) together.

14. Remove aftercooler tube (13). [*3]

11. Disconnect ground wire (10).

D155A-6

31

SEN03367-01

15. Remove heater hose (15).


22. Disconnect connectors AC05 (24), EG2 (25) and EG1 (26).

16. Lift off water tube (16). 23. Remove and move receiver tank (27).

17. Disconnect starting motor B-terminal ST/B (17).

24. Disconnect hose (28) from radiator lower tank. [*4]

18. Remove heater hose (18). 19. Remove 3 clamps (19) of the heater hose disconnected in step 15 and disconnect the hose from the engine.

25. Separate universal joint (29) at the engine side. [*5]

20. Remove the 2 hoses from each of air conditioner condenser (20) and oil cooler (21) and remove frame (22). 21. Remove frame (23).

32

D155A-6


SEN03367-01

26. Temporarily sling engine assembly.

Installation

27. Remove mounting bolts (30) and (31), four pcs.each. [*6]

q

Carry out installation in the reverse order to removal.

[*1] [*3] (MIKALOR clamp) a Use a new MIKALOR clamp. a Installation procedure of hose 1) Set the hose to the original position. 2) Set the bridge (BR) under the clamp bolt (BC) and lap it over band (BD) at least (b) reaches 5 mm. 3) Tighten the clamp. a Do not use an impact wrench. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO18B) 28. Sling engine assembly (32) and remove it. a Check all wires and pipes are removed. a Remove carefully to avoid any interference with the machine body.

q

When reusing the hose Install the clamp to the calmp mark made on the hose. 3 Clamp bolt (BC): 25 ± 5 Nm {2.55 ± 0.5 kgm}

q

When using a new hose Tighten until dimension (BDG) is 8 – 10 mm.

[*2]

3

Hose mounting sleeve nut: 84 – 132 Nm {8.5 – 13.5 kgm}

[*4]

3

Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}

[*5]

3

Universal joint mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

[*6]

3

D155A-6

Engine mounting bolt: 823.8 – 1,029 Nm {84 – 105 kgm}

33

SEN03367-01

Removal and installation of engine hood assembly


4.

1

4

Removal k

Remove cover (1).

2.

Open side cover (2) and remove covers (3) – (5). a Work on the opposite side similarly.

34

Front hood: 55 kg


1.

3.

Remove the 4 front hood mounting bolts and lift off front hood (7).

5.

Remove two mounting bolts (9) for tube (8).

6.

Remove hose (10). [*1]

Disconnect headlamp wiring connector CNLHD (6).

D155A-6


7.

Disconnect connector AF1 (11).

SEN03367-01

Installation q

Carry out installation in the reverse order to removal

[*1]

3

8.

Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}

Sling engine hood (12) and remove it. 4

D155A-6

Engine hood: 170 kg

35

SEN03367-01


Removal and installation of engine front seal

1

Sketch

Push tool

t 1 R Q

2 01050-31655

Bolt

t 3

01050-31635

Bolt

t 3

Seal puller

t 1

795T-521-1150

Push tool

t 1

01050-31635

Bolt

t 4

795T-521-1111

C

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

3 795-931-1100 8

Q

Removal 1.

Remove the radiator and oil cooler guard assembly.

2.

Remove damper (1) and flange (2).

Removal with tool C1 a Remove all the chips. a Take care in the removal not to damage front seal (3) installation position on front cover (4) and the seal contact face on crankshaft (5). a Before removing, slightly drive the front seal in once to free it from fixation. a When front seal (3) is fixed too hard to the front cover (4), carry out the following procedure. 1) Drill through a hole of approx. 3 mm dia. on front seal (3). 2) Replace the tip of tool C3 with the drill type one. 3) Insert the top end of tool C3 into the drilled hole, and remove the front seal by the impact of slide hammer (SH). (Apply the slide hammer evenly not to tilt the front seal.) a Remove the metal powders completely. a When the sleeve is attached, cut sleeve (6) using a gad and hammer to remove it. a Take care not to damage crankshaft (5).

q

3.

36

Tool C3

Remove front seal (3).

D155A-6


Installation a a

a a a a

1.

Check the seal by checking the wear of the shaft and replace it with the "standard seal" or "sleeved seal". If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 mmm) and does not have any flaw, install "standard seal A". In other cases, install "sleeved seal B". (7): Plastic inside cylinder which is also used as installation guide. (6): Sleeve. Do not remove installation guide (7) from front seal (3) before installing the front seal. Handle front seal (3) and sleeve (6) as an assembly and never separate them from each other.

Standard spare seal

SEN03367-01

Procedure for installing standard seal a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the front cover. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. a Never remove installation guide (7) of the replacement seal before installing the seal.

Sleeved seal

1)

D155A-6

Set large inside diameter side (b) of installation guide (7) to the end of crankshaft (5). a Take care not to mistake the direction of the plastic inside cylinder.

37

SEN03367-01

2) 3)

4)

Push in the metal ring of seal (3) evenly as if you are passing over the large diameter side of plastic inside cylinder (7). After pushing in the seal to a depth where it does not come off the front cover, remove plastic inside cylinder (7). a When removing the inside cylinder, take care not to damage the seal lip. Tighten tool C2 until the bolts (55 mm) reach the end.


2.

Procedure for installing sleeved seal a When installing the front seal, do not apply oil or grease to the shaft, inside cylinder surface of sleeve (6) and seal lip. 1) Set sleeve and front seal assembly (8) to tool C8 (for fitting the sleeved seal). 2 Sleeve inside cylinder surface (6): Gasket sealant (LG-7)

2) 5)

38

Tighten tool C2 with the bolts (35 mm) again to press fit seal (3) until the end of tool C2 reaches the end of crankshaft (5). a Seal driving distance (a) from crankshaft: 9.1 – 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.

Set the sleeve of the front seal assembly (8) to the end of crankshaft (5) and tighten the 3 bolts evenly to press fit sleeve and rear seal assembly (8) until the end of tool C8 (for press fitting the sleeved seal) reaches the end of crankshaft (5).

D155A-6


3) 4)

3.

4.

SEN03367-01

Remove tool C8 (for press fitting the sleeved seal) and install tool C2 (for press fitting the seal). Tighten the 3 bolts (35 mm) evenly to press fit sleeve and front seal assembly (8) until the end of tool C2 reaches the end of crankshaft (5) a Seal driving distance (a) from crankshaft: 9.1 – 10.1 mm a When press fitting the seal, take care not to damage the lip of the seal with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.

Install flange (2). 3

Flange mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}

Install damper (1).

D155A-6

39

SEN03367-01


Removal and installation of engine rear seal

t 1

Push tool

t 1

Bolt

t 4

01643-31645

Washer

t 8

795T-421-1240

Push tool

t 1

Bolt

t 4

01643-31645

Washer

t 4

795T-421-1250

Push tool

t 1

Bolt

t 4

Washer

t 8

795T-421-1270 4 01050-31645

5 01050-31645

9 01050-31645 01643-31645

While moving flywheel (2) toward this side, lift it off. k Since the socket part of the flywheel is shallow, it may fall suddenly. Take care not to catch your fingers in the flywheel. 4

Flywheel: 60 kg

Q

Q

Q

Removal 1.

Remove the engine assembly. For details, see "Removal and installation of engine assembly".

2.

Remove damper assembly (1). For details, see "Removal and installation of damper assembly".

40

4.

Sketch

New/Remodel

Q'ty

Seal puller

3 795-931-1100

C

Part name

Necessity

Part No.

Install eyebolt [1] to flywheel (2), sling flywheel (2), and remove bolts (3).

1

Special tools Symbol

3.

5.

Remove rear seal (4) according to the following procedure. a Measure the distance from the end of the housing. 1) Before pulling out rear seal (4), drive it in a little to separate it from housing (FWH).

D155A-6


2)

q

If the seal is sleeved, cut and remove sleeve (5) with a chisel and a hammer. a When cutting, take care extremely not to damage crankshaft (6). 3) Hitch the end of tool C3 to the metal ring of rear seal (4) and pull out the seal with impacts of slide hammer (SH). a Do not use a drill etc. since chips may enter the engine. a If chips were made, remove all of them. Tool C3

SEN03367-01

Installation a

a a a a

a

Check the wear of the shaft and select the "standard" or "sleeved" Teflon seal (Laydown lip seal) to replace the used seal. If the shaft is worn to the degree of luster (If the wear depth which you feel with your finger is less than 10 mm) and does not have any flaw, install "standard seal (A)". In other cases, install "sleeved seal (B)". (7): Plastic inside cylinder which is also used as installation guide. (5): Sleeve. Do not remove installation guide (7) from rear seal (4) before installing the rear seal. Handle rear seal (4) and sleeve (5) as an assembly and never separate them from each other.

q

Standard spare seal

a

Clean, degrease, and dry the contact surface of the seal to the flywheel housing side. Clean, degrease, and dry the seal lip surface (periphery of the crankshaft). Check that the end corners and lip sliding surface of the crankshaft and the housing are free from flaw, burr and rust.

q

Sleeved seal

Left: Standard seal, Right: Sleeved seal

a a

D155A-6

41

SEN03367-01

1.

4)

Procedure for installing standard seal a When installing rear seal (4), do not apply oil or grease to the shaft and seal lip. 1) Set large inside diameter side (b) of plastic inside cylinder (7) of rear seal (4) to the end of crankshaft (6). a Take care not to mistake the direction of the plastic inside cylinder.

2) 3)

42


Push in the metal ring of rear seal (4) evenly as if you are passing over the large diameter side of plastic inside cylinder (7). After pushing in rear seal (4) to a depth where it does not come off the housing, remove plastic inside cylinder (7). a When removing the inside cylinder, take care not to damage the seal lip.

2.

Tighten the 3 bolts evenly to press fit rear seal (4) until the end of tool C4 (for press fitting the seal) reaches the end of crankshaft (6). a Tighten tool C4 (for press fitting the s ea l) fi rs t w it hou t in s erti ng a ny washer until the bolts reach the end and then tighten with 2 washers inserted (in each bolt). a When press fitting the seal, take care not to damage the lip on the PTO side with the tool set etc. a After press fitting the seal, remove the red sealant layer from its periphery.

Procedure for installing sleeved seal a When installing the rear seal, do not apply oil or grease to the shaft and inside cylinder (C) and seal lip of the sleeve. 1) Set sleeve and rear seal assembly (8) to tool C5 (for fitting the sleeved seal). 2 Sleeve inside cylinder surface (C): Gasket sealant (LG-7)

D155A-6


2)

Set sleeve of the rear seal to the end of crankshaft (6) and tighten the 4 bolts of tool C5 evenly to press fit sleeve and rear seal assembly (8). a Tighten tool C5 (for press fitting the sleeved seal) with 1 washer inserted in each bolt until the bolts reach the end.

3)

Remove tool C5 (for press fitting the sleeved seal) and install tool C9 (for press fitting the seal). Tighten the 3 bolts evenly to press fit sleeve and rear seal assembly (8) until the end of tool C9 reaches the end of crankshaft (6). a Tighten the bolt of tool C9 (for press fitting the seal) without washer until it reaches, and then tighten the bolt using 2 washers (for each bolt). a After press fitting the seal, remove the red sealant layer from its periphery. a Rear seal driving depth: 13.2 ± 0.2 mm from end of crankshaft

4)

a

D155A-6

SEN03367-01

3.

Flywheel Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (2), install it to the crankshaft, and tighten bolts (3). a If there are 5 punch marks on a bolt, do not use that bolt but replace it. 2 Threaded part and seat of bolt: Engine oil SAE No. 30

a

Tighten the mounting bolts according to the following procedure. 3 Flywheel mounting bolts 1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm} 2nd time:1)When using tool A4 (See the tools list) Retighten each bolt by 90 (+30°/0) in the order of [1] – [8]. 2) When not using tool A4 Make marks on each bolt and flywheel withpaint,then retighten each bolt by 90 (+30°/0) in the order of [1] – [8].

When installing, set the dowel pin of the crankshaft to the dowel hole of the flywheel.

43

SEN03367-01

44

a

After tightening, make 1 punch mark (9) on each bolt head to indicate the number of tightening time.

a

After installing the flywheel, measure the facial runout and radial runout with tool [2]. a Radial runout: Max. 0.30 mm a Facial runout: Max. 0.30 mm

q

Carry out the following installation in the reverse order to removal.


D155A-6


Removal and installation of fuel tank assembly 1

SEN03367-01

4.

Remove cover (4).

5.

Remove fuel hoses (5), (6) and (7).

6.

Sling water separator storage box (8) and remove 5 mounting bolts (9).

7.

Lift off water separator storage box (8).

8.

Open the inspection cover and disconnect wiring harness connector (10).

Removal k


1.

Open the water separator inspection cover and turn the fuel drain lever (1) in the direction of (L) to drain the fuel.

2.

Remove line filter assembly (2).

3.

Remove pin puller drive hose mounting bracket (3). (Machine with giant ripper)

D155A-6

45

SEN03367-01

9.

Remove 6 fuel tank mounting bolts (11) on the right and left sides.


Installation q


10. Sling the fuel tank assembly, move it back about 100 mm, and disconnect hoses (12) and (13). v

11. Remove fuel tank assembly (14). 4

46

Fuel tank assembly: 410 kg (When empty) 915 kg (When full)

D155A-6


SEN03367-01

Removal and installation of fan drive assembly 1

4.

Disconnect wiring harness connector FAR (5) and remove wiring harness clamp.

Removal

5.

Disconnect fan motor hoses (6), (7) and (8). a Plug the hoses so that foreign matter will not enter them.

6.

Using eyebolts [1], sling fan drive assembly (9) and remove mounting bolts (10).

7.

Lift off fan drive assembly (9).

k

1.

Disconnect the cable from the negative (–) terminal of the battery. Drain the hydraulic oil. 6

2.

Hydraulic tank: Approx. 85 l

Remove 4 mounting bolts (1) and open mask (2).

4

3.

Fan drive assembly: 125 kg

Remove 4 mounting bolts (3) and remove guard (4).

Installation q


q

Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5

D155A-6


47

SEN03367-01

Removal and installation of fan motor assembly 1


Installation q

Removal


1.

Remove the fan motor assembly. For details, see "Removal and installation of fan drive assembly".

[*1] Be sure to align the hole of lock plate (1) by turning nut (2) in the tightening direction.

2.

Remove the mounting bolt and lock plate (1). [*1]

[*2]

3.

Remove nut (2). [*2]

4.

Using puller [1], remove fan (3).

5.

Remove 4 mounting bolts (4) and fan motor assembly (5). [*3] 4

48

3

Mounting nut (2): 441 – 539 Nm {45 – 55 kgm}

[*3] a Clean and degrease the fitting areas of the fan motor and fan.

Fan motor assembly: 40 kg

D155A-6


D155A-6

SEN03367-01

49

SEN03367-01




50

D155A-6

SEN03368-01


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Power train, Part 1 Removal and installation of damper assembly ............................................................................................... 2 Disassembly and assembly of damper assembly ........................................................................................... 5 Removal and installation of power train unit assembly ..................................................................................11 Disconnection and connection of power train unit assembly ........................................................................ 16

D155A-6

1

SEN03368-01

Removal and installation of damper assembly


9.

1

Removal 1.

Drain the oil in damper case. 6

Damper case: 1.5 l

2.

Remove floor frame assembly referring to the section, "Removal and installation of floor frame assembly".

3.

Remove work equipment and HSS pump assembly referring to the section, "Removal and installation of work equipment and HSS pump assembly".

4.

Remove the cooling fan pump assembly referring to the section, "Removal and installation of cooling fan pump assembly".

5.

Remove cover (1).

6.

Disconnect breather hose (2).

7.

Remove oil level gauge (3).

8.

Sling universal joint assembly (3) and remove it. [*1] 4

2

Remove mounting bolts for damper cover assembly (5), and install two guide bolts [1] diagonally. [*2]

10. Using forcing bolt [2], pull out damper cover assembly (5) so that the lifting tool can be applied, and then remove it. [*3] 4

Damper cover assembly: 60 kg

Universal joint assembly: 20 kg

D155A-6


11. Remove damper assembly. 1) Remove two mounting bolts for damper assembly (6), and set guide bolts [3]. [*4] 2) Remove the rest of mounting bolts, and pull out damper assembly using forcing bolt [4]. [*5] 3) Use eyebolt [5] to remove damper assembly (6). 4

Damper assembly: 60 kg

SEN03368-01

Installation q


[*1]

2 3

Universal joint mounting bolt: Liquid adhesive (LT-2) Universal joint mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

[*2] a Apply gasket sealant to damper cover, and tighten mounting bolts 2 to 3 minutes after application. 3 Damper cover mounting bolt: 98.1 – 122.6 Nm {10 – 12.5 kgm} [*3] a Install damper cover assembly according to the following procedure. 1) Degrease the spline portion "a" of shaft (7), apply dry lubricant A, and leave it 2 to 3 minutes. 2) Fill "b" portion of inner body (8) with about 80 g of lithium base extreme pressure grease with molybdenum disulphide B. A

Dry lubricant with molybdenum disulphide

Sumiko lubricant Rocol Dry Splay or equivalent

• Kyodo yushi Molylex No.2 or an equivalent Lithium base extreme • Showa Shell Sekiyu B pressure grease with Retinax AM or an equivmolybdenum disulphide alent • Nippon Oil Corporation Molytex or an equivalent

D155A-6

3

SEN03368-01

3)

Apply gasket sealant to the flange portion of damper cover assembly. a Apply it to the engine side also. a Apply it with the thickness 0.1 to 0.2 mm. 2 Damper cover mounting face: Gasket sealant (LG-6)

4)

Install the damper cover assembly to the engine.


[*4] [*5] 3 Damper mounting bolt: 98 – 122.6 Nm {10 – 12.5 kgm} q

Refilling with oil 5

3

4

Damper case: 1.5 l Drain plug: 58.5 – 78.5 Nm {6 – 8 kgm}

D155A-6


SEN03368-01

Disassembly and assembly of damper assembly

1

F

t 1

791-612-1100

Installer

790-101-4200

Puller t 1 (294 kN {30 ton})

790-101-1102

Hydraulic pump

D155A-6

Sketch

Part name

New/Remodel

Part number

Q'ty

Symbol

Necessity

Special tools

t 1

5

SEN03368-01


Disassembly

2)

Disassembly of damper cover assembly (1) 1.

Coupling Remove bolt (3) from cover (2), then remove holder (4) and coupling (5).

3.

2.

Bearing and oil seal 1) Remove oil seal (9) from cover (2), and pull out inner race (7-3) of bearing (7).

Shaft 1) Set damper cover assembly (1) to block [1], and remove shaft (6) by tapping it from output side with plastic hammer, etc. a Shaft (6) will be pulled out with inner race (7-1) of bearing (7) and oil seal (8).

2)

6

Remove collar (7-2) and O-ring of bearing (7) from shaft (6), and pull out inner race (7-1).

Remove outer races (7-4) and (7-5) of bearing (7) from cover (2).

D155A-6


SEN03368-01

Disassembly of damper assembly (10) 1. Unscrew bolt (11) to remove flange (12). 2.

Remove outer body (13), inner body (14) and cushion (15).

3.

Pull out plug (17) from flange (16). a This procedure applies only when replacing plug.

D155A-6

7

SEN03368-01


Assembly Assembly of damper assembly (10) 1.

8

Set flange (16) and outer body (13) to cylinder [1], matching their bolt holes, and install inner body (14). 2 Mating surface of flange and outer body: Gasket sealant (LG-6) 2 Outer body inner surface: Grease (G2-LI) 2 Cushion contact surface of inner body: Grease (G2-LI)

D155A-6


2.

SEN03368-01

Install cushion (15). a Apply grease (G2-LI) to entire surface of cushion. a After installing the cushion, fill clearances (a) (16 points) between inner body (14) and outer body (13) with grease of 30% amount of the space.

Assembly of damper cover assembly (1) 1. Press fit outer races (7-4) and (7-5) of bearing (7) to cover (2) using push tool [2].

3.

Install flange (12) and tighten bolts (11). 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

2.

4.

Press fit inner race (7-1) of bearing (7) to shaft (6) with tool F.

Fill (b) portion of inner body (14) with about 80 g of the following grease. 2 : Grease Grease

Supplier part name

• Kyodo yushi Molylex No.2 or an equivalent • Showa Shell Sekiyu Lithium base extreme Retinax AM or an pressure grease with equivalent molybdenum disulphide • Nippon Oil Corporation Molytex or an equivalent

D155A-6

9

SEN03368-01

3.

Install collar (7-2) and O-ring to shaft (6).

4.

Set cover (2) to shaft (6), and press fit bearing inner race (7-3) using tool F.

5.

Install oil seals (8) and (9) to cover (2). 2 Press fitting surface of oil seal: Gasket sealant (LG-5) 2 Oil seal lip surface: Grease (G2-LI) a Apply gasket sealant at oil seal surface thinly, and wipe off extra sealant.

10


6.

Install coupling (5) and holder (4), and tighten bolt (3). 3 Mounting bolt: 245.2 – 308.9 Nm {25 – 31.5 kgm}

D155A-6


Removal and installation of power train unit assembly 1

SEN03368-01

12. Remove clamps (14) and (15) and hoses (16) and (17).

Removal k

1.

Disconnect the cable from the negative (–) terminal of the battery. Drain the oil from the hydraulic tank and power train case. 6 6

2.

Hydraulic tank: 97 l Power train case: 97 l

Remove the cabin and floor frame assembly. For details, see "Removal and installation of cabin and floor frame assembly".

3.

Remove the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly".

4.

Remove oil level detection pipe (1).

5.

Remove oil filler pipe (3).

6.

Remove return hose (2).

7.

Remove stays (4) and (5).

8.

Disconnect hoses (6) and (7) from control valve (8).

13. Remove oil pressure pickup hose mounting bracket (18).

14. Remove accumulator and bracket assembly (19) and disconnect hose (20).

9.

Remove 2 clips (9) and hoses (10) and (11).

10. Remove work equipment pump suction tube (12). [*1] 11. Disconnect hose (13) from control valve.

D155A-6

11

SEN03368-01

15. Disconnect hose (21).


18. Remove clips (24) – (26). 19. Remove stay (27). 20. Move wiring and piping (28) toward the machine.

16. Disconnect hose (22) coming from the oil cooler.

21. Disconnect power train filter hoses (29) and (30). 22. Remove the 4 bracket mounting bolts (at the filter bottom) and remove filter and bracket assembly (31). 4

Power train filter assembly: 30 kg

17. Remove grease tube (23).

12

D155A-6


23. Remove 4 mounting bolts (32) on the engine side and disconnect universal joint (33). [*1] a After disconnecting the universal joint, push the yoke into the torque converter side to disconnect the universal joint completely.

SEN03368-01

27. Remove covers (38) on both sides of the steering case.

28. Remove cap (39). [*2] 29. Loosen coupling clamp (40) and move seal (41) out a little. [*3] 24. Remove pin puller hoses (34) and (35). 25. Remove pin puller line unit (36).

30. Remove final drive shaft cover (42). 26. Disconnect additional filter hoses (36) and (37).

D155A-6

13

SEN03368-01

31. Using eyebolt [1] (M10 x 1.5), pull out drive shaft (43). a Pull out the drive shaft until it comes off the spline on the steering case side. a If the drive shaft cannot be pulled out easily, raise the shoe grouser with a jack to a position where the drive shaft can be pulled out easily. a Pull out the drive shaft on the opposite side similarly.


33. Lift off power train assembly (45). [*5] a Check that all the wiring and piping are disconnected. a When lifting up the assembly, take care that it will not interfere with the machine. 4

Power train assembly: 2,500 kg

32. Remove 2 mounting bolts (44) each on the right and left sides of the power train assembly. [*4]

14

D155A-6


SEN03368-01

Installation q


[*1]

3

Universal joint mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

[*2]

3

Cap mounting bolt: 245.8 – 309 Nm {25 – 31.5 kgm}

[*3] a Clamp the seal ridge of the coupling securely and install the threaded part of the clamp so that it will be in parallel with the cap mounting seat. [*4]

3

Mount mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}

[*5] a When installing the power train unit assembly, take care not to damage seal (40). q

Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5 5

D155A-6

Hydraulic tank: 85 l Power train case: 90 l

15

SEN03368-01

Disconnection and connection of power train unit assembly 1


4.

Remove hoses (5) – (11).

5.


6.


7.

Remove block (18).

8.

Remove hose (19).

9.


Disconnection 1.

Set power train unit assembly (1) on block [1]. 4

Power train unit assembly: 2,500 kg

2.

Referring to circuit diagram collection "Electric circuit diagrams and connector location diagrams", disconnect all the connectors from the power train unit and remove all the wiring harnesses.

3.

Remove covers (2) and (3) and remove oil pressure pickup hose assembly (4). [*1] a Disconnect the 12 oil pressure pickup hoses from the power train unit.

16

D155A-6


10. Remove hoses (21) and (22).

SEN03368-01

16. Disconnect suction tube (30) from the fan pump.

11. Remove tube (23). 17. Remove work equipment pump suction tube mounting bolt (31) and lift off work equipment pump suction tube (28) and fan pump suction tube (30) together.

12. Remove hoses (24) and (25).

18. Remove work equipment pump assembly (32). 4

Work equipment pump assembly: 100 kg

13. Remove hose and tube assembly (26). 14. Remove tube (27). 15. Sling work equipment pump suction tube (28) and remove clamp (29).

D155A-6

17

SEN03368-01

19. Remove power train and lubricating oil pump assembly (33). 4


22. Remove coupling (36).

Power train and lubricating oil pump assembly: 25 kg

23. Remove right and left front mounts (48).

20. Remove cooling fan pump assembly (34). 4

Cooling fan pump assembly: 30 kg

24. Sling power train unit assembly (37) and set block [2]. 25. Remove the 18 mounting bolts and lift off steering case assembly. [*2] 21. Remove scavenging pump assembly (35). 4

18

4

Steering case assembly: 1,000 kg

Scavenging pump assembly: 20 kg

D155A-6


SEN03368-01

26. Set PTO and torque converter and transmission assembly (38) on block [3] with the PTO side up.

29. Remove pressure sensor block (43) and 2 sleeves (44). 27. Remove inside together.

strainer

and

block

(39)

28. Remove cover (40), spring (41) and magnet assembly (42).

D155A-6

19

SEN03368-01


30. Remove the 19 mounting bolts and lift off PTO assembly (45). [*3] 4

PTO assembly: 300 kg

31. Remove 10 torque converter assembly mounting bolts (46). [*4]

32. Sling torque converter assembly (47) and pull it out by using 2 forcing screws [4] (M12 x 1.75). 33. Lift off torque converter assembly (47).

20

D155A-6


SEN03368-01

Connection Carry out connection in the reverse order to disconnection.

q

[*1] a The oil pressure pickup hoses have color bands on their adapters. Referring to the table, connect those hoses to the power train unit. Symbol

Pressure pick up point

Band color

a

1st transmission clutch pressure

Red

b

3rd transmission clutch pressure

Yellow/ Black

c

Reverse transmission clutch pressure

Red/Blue

d

2nd transmission clutch pressure

White/ Yellow

e

Forward transmission clutch pressure

White/Blue

f

Transmission main relief pressure

No band

g


h


Yellow/ Black

i

Left brake pressure

White

j

Right clutch pressure

White/ Black

k


Black

l


Yellow

Blue/Black

[*2]

3

Steering case mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

[*3]

3

PTO assembly mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

[*4]

3

D155A-6

Torque converter mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

21

SEN03368-01




22

D155A-6

SEN03369-00


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Power train, Part 2 Disassembly and assembly of PTO assembly ................................................................................................ 2 Disassembly and assembly of torque converter assembly ............................................................................. 9 Disassembly and assembly of transmission assembly ................................................................................. 14 Disassembly and assembly of steering case assembly................................................................................ 31

D155A-6

1

SEN03369-00

Disassembly and assembly of PTO assembly


3)

While supporting cover (5) with block, push in gear (6) to separate it from the cover.

4)

Remove inner race (7) from gear (6).

5)

Remove snap ring (14) and remove bearing (8) from cover (5).

1

Disassembly 1.

Lubrication tube 1) Remove shaft lubrication tube (1).

2)

2.

2

Remove pump drive gear lubrication tube (2).

Work equipment and pump drive gear and cover assembly 1) Remove 4 mounting bolts (3) and set the guide bolt. 2) Tighten forcing screws into hole (a) to remove gear and cover assembly (4).

D155A-6


Remove bearing (40) from case (17).

4)

Remove inner race (41) from gear (13).

Cooling fan pump drive gear and cover assembly 1) Remove 6 mounting bolts (10) and set a guide bolt. 2) Tighten forcing screws into hole (c) to remove gear and cover assembly (11).

5)

Remove snap ring (14) and remove bearing (15) from cover (12).

6)

Remove case (17) from bearing (16).

6)

3.

SEN03369-00

3)

D155A-6

While supporting cover (12) with block [1], push in gear (13) to separate it from the cover.

3

SEN03369-00

4.


2)

Scavenging pump drive gear assembly 1) Remove snap ring (18). 2) Remove gear (19) by pushing it into the case.

3)

3)

Remove snap ring (20) and remove bearing (21) from the case.

Remove the mounting bolts and set guide bolt [2]. Using forcing screws [3], remove shaft (23). a Keep holding the gear in the case.

1]

2]

5.

Idler gear assembly 1) Remove the mounting bolt and plate (22).

6.

4

Remove bearing (25) and spacer (26) from gear (24). a When reusing the bearing and spacer, keep them so that they will be combined with the original outer race. Remove outer race (27) and snap ring (28) from gear (24).

Input shaft outer race Remove snap ring (29) and input shaft outer race (30).

D155A-6


Assembly a a a 1.

2.

SEN03369-00

1)

Install snap ring (28) to gear (24) and press fit outer race (27).

2)

Using 3 guide bolts [4], insert shaft (23) to the position shown in the figure. a If shaft (23) is inserted all the way, gear (24) cannot be installed. 2 O-ring: Grease (G2-LI)

3) 4)

Install bearing (25) to shaft (23). Install spacer (26).

Clean all the parts thoroughly and check them for dirt or damage before installing. After press fitting each bearing, drop 6 cc of TO30 or TO10 onto it and rotate it about 10 turns. Check that each snap ring is fitted to the groove. Input shaft outer race Press fit input shaft outer race (30) and install snap ring (29).

Idle gear assembly a Match the serial Nos. and match marks of the bearing, outer race and spacer at places [A] – [C] and use them as an assembly.

D155A-6

5

SEN03369-00

5) 6)

7)


Install gear (24). Install bearing (25) and tighten plate (22) with the bolt to press fit the bearing to the shaft. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245.0 – 308.7 Nm {25.0 – 31.5 kgm}

6

While holding the inner race side of the bearing with push tool [5], install drive gear (19).

3)

Install snap ring (18).

Fix shaft (23) with the mounting bolts.

4.

3.

2)

Cooling fan pump drive gear and cover assembly 1) Press fit bearing (16) to case (17).

Scavenging pump drive gear 1) Press fit bearing (21) to the case and install snap ring (20).

D155A-6


2)

Press fit bearing (15) to cover (12) and install snap ring (14).

3)

Press fit inner race (41) to gear (13).

SEN03369-00

5)

5.

4)

Work equipment and HST pump drive gear and cover assembly 1) Press fit bearing (40) to case (17).

Using the push tool, press fit gear (13) to cover (12).

2)

D155A-6

Install gear and cover assembly (11), meshing it with the idler gear. 2 O-ring: Grease (G2-LI) 2 Mounting bolt; Adhesive (LT-2) 3 Mounting bolt: 98.0 – 122.5 Nm {10.0 – 12.5 kgm}

Press fit bearing (8) to cover (5).

7

SEN03369-00

3)

Press fit inner race (7) to gear (6).

4)

Press fit bearing (7) and inner race (8) to gear (9).


6)

6.

5)

Lubrication tube 1) Install lubrication tube (2). 3 Joint bolt: 34.3 – 44.2 Nm {3.5 – 4.5 kgm}

Install gear and bearing assembly (6) to cover (5).

2)

8

Install gear and cover assembly (4) to the case. 2 O-ring: Grease (G2-LI) 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98.0 – 122.5 Nm {10.0 – 12.5 kgm}

Install lubrication tube (1). 3 Joint bolt: 34.3 – 44.2 Nm {3.5 – 4.5 kgm}

D155A-6


Disassembly and assembly of torque converter assembly

SEN03369-00

3.

1

Case 1) Remove snap ring (6). 2) Remove spacer (7).

Disassembly 1.

Input shaft 1) Remove 18 bolts (1) from input shaft (2). 2) Use eyebolt [1], and remove input shaft (2) from case and turbine assembly (3).

3)

2.

3)

Using puller [2] and plate [3] disconnect case assembly (8) and turbine (9).

4)

Remove bearing (11) from case (10).

Remove snap ring (4), then remove inner race (5).

Case, turbine assembly Remove 30 bolts (1a) from below, then use eyebolts [4], and remove case and turbine assembly (3).

D155A-6

9

SEN03369-00

4.

Stator and race assembly 1) Remove snap ring (12) and stator and race assembly (13).

2)

Remove 2 snap rings (14) and remove race (15) from stator (16).


5.

Pump 1) Remove snap ring (18) and spacer (19). 2) Remove pump assembly (21) from stator shaft assembly (20).

3) 4)

10

Remove 12 mounting bolts (22) and remove pump (24) from retainer (23). Remove snap ring (25) and remove bearing (26) from retainer (23).

D155A-6


SEN03369-00

Assembly

4)

a

5) 6)

a a

a 1.

Clean all the parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. After press fitting each bearing, drop 10 cc of TO30 or TO10 onto it and rotate it about 10 turns. When installing a bearing by expansion fit, drop 10 cc of TO30 or TO10 onto it and rotate it about 10 turns before freezing it in dry ice etc. Check that each snap ring is fitted to the groove. Pump 1) Press fit bearing (26) to retainer (23) and install snap ring (25). 2) Install retainer (23) to pump (24). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 58.8 – 73.6 Nm {6.0 – 7.5 kgm}

3)

D155A-6

Install seal ring (27) to stator shaft (20).

2.

Install pump assembly (21) to stator shaft assembly (20). Install spacer (19) and snap ring (18). Install snap ring (17) to the shaft.

Stator and race assembly 1) Install race (15) to stator (16) and install 2 snap rings (14).

2)

Install stator and race assembly (13) and snap ring (12).

11

SEN03369-00

3.

Case 1) Install bearing (11) to case (10).

2)

3) 4)

12

Using push tool [4], push inner race end of bearing, then install case assembly (8) to boss portion of turbine (9).


4.

Input shaft 1) Press fit inner race (5), and install snap ring (4).

2)

Install input shaft (2) to case and turbine assembly (3). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}

Install spacer (7). Install snap ring (6).

D155A-6


5.

SEN03369-00

Case, turbine assembly 1) Using eyebolts [1], align groove of case with drain plug, and install case and turbine assembly (1). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm} 2) Install drain plug. 3 Drain plug: 7.4 ± 1.5 Nm {0.75 ± 0.15 kgm}

D155A-6

13

SEN03369-00


Disassembly and assembly of transmission assembly

3)

Remove sleeve (3) and flanges (4) and (5).

4)

Remove control valve assembly (6).

1

791T-615-1300 Puller assembly 1 791T-615-1310 • Plate G 2

01010-82040

• Bolt

799-301-1600

Oil leak tester kit (A)

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

t 1 N 1 N Q 1 t 1

Disassembly a

Keep the removed discs and plates on a flat place so that they will not warp.

1.

Relief valve assembly Remove relief valve assembly (1).

3.

2.

14

Snap ring Remove snap ring (123) from output shaft (124). a Remove the snap ring at this time.

Control valve assembly 1) Remove cover assembly (2). 2) Remove the nut of wiring harness connector (2A) and push in the connector.

D155A-6


4.

Transmission case 1) Set the block with the torque converter side up. 2) Remove sleeve (7).

3)

5.

Using eyebolts [2], sling transmission case (8), remove 13 tie bolts (9) (used to clamp the transmission case, too), and remove case (8).

SEN03369-00

6.

Input shaft-front cover-No. 1 carrier assembly 1) Using sling bar [3], remove input shaftfront cover-No. 1 carrier assembly (11).

2)

Disassemble the input shaft-front coverNo. 1 carrier assembly according to the following procedure. 1] Remove snap ring (12), No. 2 sun gear (13) and snap ring (14). 2] Remove snap ring (15), No. 1 sun gear (16) and collar (17).

Tie bolts Remove 4 remaining tie bolts (9). 3] 4]

D155A-6

Remove snap rings (18) and (126). Drive out input shaft toward the torque converter and remove front cover (19).

15

SEN03369-00

5]

Remove snap ring (20) and drive out input shaft (21) toward the torque converter.

6] 7]

Remove collar (128). Remove snap ring (22) and No. 1 ring gear (23). Pull out shaft (24) and remove thrust washer (25), gear (26), bearing (27) and ball (28). a Take care not to lose the ball.

8]

7.

16

No. 1 disc, plate and spring 1) Remove spring (29). 2) Remove springs (30), discs (31) and plates (32).


8.

No. 1 housing assembly 1) Using eyebolts [4], remove No. 1 housing assembly (33). 2) Remove No. 1 piston (34) from the housing.

9.

Guide pin Remove guide pins (35).

10. No. 2 disc, plate and spring 1) Remove spring (36). 2) Remove springs (37), discs (38) and plates (39).

11. Remove through bolt guide (40), lubricating oil relief valve (41) and spring (130).

D155A-6


12. Snap ring Remove snap ring (125).

SEN03369-00

2] 3]

Remove spacer (47) from No. 2 carrier assembly (49). Pull out shaft (50) and remove thrust washer (51), gear (52), bearing (53) and ball (54). a Take care not to lose the ball.

13. No. 2 housing and No. 2 carrier assembly 1) Using eyebolts [5], remove No. 2 housing and No. 2 carrier assembly (42). 2) Remove No. 2 piston (43).

3)

D155A-6

Disassemble No. 2 housing and No. 2 carrier assembly according to the following procedure. 1] Remove snap ring [44] and pull out No. 2 carrier assembly (45) from No. 2 housing (46).

4]

Remove snap ring (55) and ring gear (56). a Push the snap ring inward with a pin (Diameter: Max. 3 mm) from outside to warp and remove it.

5]

Remove seal ring (57) and snap ring (58) from No. 2 housing (46) and remove bearing (59).

17

SEN03369-00

14. No. 3 disc, plate and spring 1) Remove springs (60). 2) Remove springs (61), discs (62) and plates (63).

15. No. 3 carrier assembly 1) Remove No. 3 carrier assembly (64).

2)

18


16. Output shaft and No. 4 sun gear 1) Pull out output shaft (73). 2) Remove snap ring (74) from the output shaft. 3) Remove No. 4 sun gear (75).

17. No. 4 carrier and No. 3 ring gear assembly 1) Remove No. 4 carrier and No. 3 ring gear assembly (76).

Disassemble No. 3 carrier assembly according to the following procedure. 1] Remove seal ring (65). 2] Pull out shaft (66). 3] Remove thrust washer (67), planetary gear (68), bearing (69) and ball (70). a Take care not to lose the ball. 4] Remove snap ring (71) and bearing (72).

D155A-6


2)

Disassemble the No. 4 carrier and No. 3 ring gear assembly according to the following procedure. 1] Remove snap ring (77) and ring gear (127). a Push the snap ring inward with a pin (Diameter: Max. 3 mm) from outside to warp and remove it. 2] Remove seal rings (78) and (79). 3] Drive in roll pin (80) to pull out shaft (80A). 4] Remove thrust washer (81), planetary gear (82) and bearing (83). 5] Remove snap ring (84) to remove bearing (85) and spacer (86) as an assembly. 6] Remove bearing (85) from spacer (86).

SEN03369-00

19. No. 4 disc, plate, spring and guide pin 1) Remove spring (89). 2) Remove springs (90), No. 4 discs (91) and plates (92). 3) Remove guide pin (93).

20. No. 5 carrier and No. 4 ring gear assembly 1) Remove mounting bolts (94). 2) Remove No. 5 carrier and No. 4 ring gear assembly (95).

18. No. 3 housing 1) Remove No. 3 housing (87). 2) Remove No. 3 piston (88).

3)

D155A-6

Disassemble No. 5 carrier and No. 4 ring gear assembly according to the following procedure. 1] Drive out shaft (96) to remove thrust washer (97), gear (98), bearing (99) and ball (100). a Take care not to lose the ball.

19

SEN03369-00

2]

Remove snap ring (101) and remove No. 4 ring gear (102) from carrier (103).

21. No. 5 sun gear Remove No. 5 sun gear (104).


23. No. 5 disc, plate and spring 1) Remove springs (107). 2) Remove discs (108), plates (109) and springs (110).

24. No. 5 ring gear Remove No. 5 ring gear (111). 25. No. 5 piston Remove No. 5 piston (112).

22. No. 4 housing assembly 1) Remove No. 4 housing assembly (105). 2) Remove No. 4 piston (106). 26. Cover assembly 1) Remove snap ring (113) and remove cover assembly (114) from output housing assembly (115).

20

D155A-6


2) 3)

Remove seal rings (116) and (117) from cover (118). Remove bearing (119) from cover (118).

SEN03369-00

Assembly q

a a a a

Precautions for assembly Clean all the parts thoroughly and check them for dirt or damage before installing. Coat the sliding surfaces of each part with engine oil before installing. When installing piston seal ring (a), direct the pressure receiving side (b) toward housing (c). When installing a metallic seal ring, apply grease (G2-LI) to it and fit it evenly.

27. Output housing 1) Remove snap ring (120) and remove bearing (121) and spacer (122) from output housing (123). 2) Remove bearing (121) from spacer (122).

1.

D155A-6

Output housing 1) Using the push tool, press fit bearing (121) to spacer (122).

21

SEN03369-00

2) 3)

2.

Cover assembly 1) Using the push tool, press fit bearing (119) to cover (118). 2) Install seal rings (117) and (116) to cover (118).

3)

4)

22

Using the push tool, press fit spacer (122) and bearing assembly (121) to output housing (123). Install snap ring (120).


3.

No. 5 piston Install No. 5 piston (112) to the output housing.

4.

No. 5 ring gear Install No. 5 ring gear (111).

5.

Guide pin Install guide pin (93).

6.

No. 5 disc, plate and spring 1) Install discs (108), plates (109) and springs (110). a Install the 3 discs and 2 plates. 2) 2) Install springs (107). a Free length of spring: 66 mm

Using the push tool, install cover assembly (114) to output housing assembly (115). a Press fit the inner race side of the bearing to install. Install snap ring (113).

D155A-6


7.

No. 4 housing assembly 1) Fit the seal ring and install No. 4 piston (106). 2) Install No. 4 housing assembly (105). a Check that the springs are fitted to the grooves.

8.

No. 5 carrier and No. 4 ring gear assembly 1) Assemble the No. 5 carrier and No. 4 ring gear assembly according to the following procedure. 1] Set No. 4 ring gear (102) to carrier (103) and install snap ring (101).

2]

3]

D155A-6

Install bearing (99) to gear (98). While fitting thrust washers (97) to both sides of them, set them to the carrier. Fit ball (100) and install shaft (96).

SEN03369-00

2)

9.

Using guide bolts, set No. 5 carrier and No. 4 ring gear assembly (95) and tighten mounting bolts (94). 2 Threaded part of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

No. 5 sun gear Install No. 5 sun gear (104).

10. No. 4 discs, plates and springs 1) Install No. 4 discs (91), plates (92) and springs (90). a Install the 4 discs and 3 plates. 2) Install springs (89). a Free length of spring: 70 mm

23

SEN03369-00


8]

11. No. 3 housing assembly 1) Fit the seal ring and install No. 3 piston (88). 2) Install No. 3 housing (87). a Check that the springs are fitted to the grooves.

2)

Set the No. 3 ring gear to No. 4 carrier and install snap ring (77). a Check that the snap ring is fitted to the groove.

Install No. 4 carrier and No. 3 ring gear assembly (76).

12. No. 4 carrier and No. 3 ring gear assembly 1) Assemble No. 4 carrier and No. 3 ring gear assembly according to the following procedure. 1] Using the push tool, press fit bearing (85) to spacer (86).

13. No. 4 sun gear Install No. 4 sun gear (75).

2] 3] 4]

5] 6] 7]

24

Using the push tool, press fit spacer (86) and bearing assembly (85) to the No. 4 carrier. Install snap ring (84). Install bearing (83) to planetary gear (82). While fitting thrust washers (81) to both sides of them, set them to the carrier. While setting the shaft pin hole to the carrier pin hole, install shaft (80A). Check that the pin holes are aligned and drive roll pin (80). Install seal rings (79) and (78).

14. Output shaft 1) Install snap ring (74) to the output shaft. 2) While setting output shaft (73) to the spline of the sun gear, push it in.

D155A-6


15. No. 3 carrier assembly 1) Assemble the No. 3 carrier assembly according to the following procedure. 1] Using the push tool, press fit bearing (72) to the carrier and install snap ring (71). 2] Install bearing (69) to planetary gear (68). While fitting thrust washers (67) to both sides of them, set them to the carrier. 3] Fit ball (70) and install shaft (66). 4] Install seal ring (65).

2)

Install No. 3 carrier assembly (64).

SEN03369-00

16. No. 3 discs, plates and springs 1) Install discs (62), plates (63) and springs (61). a Install the 4 discs and 3 plates. 2) Install springs (60). a Free length of spring: 70 mm

17. No. 2 housing and No. 2 carrier assembly 1) Assemble the No. 2 housing and No. 2 carrier assembly according to the following procedure. 1] Press fit bearing (59) to No. 2 housing (46) and install snap ring (58). 2] Install seal ring (57).

3]

D155A-6

Set No. 1 ring gear (56) and No. 2 carrier (45) and install snap ring (55).

25

SEN03369-00

4]

5]

6] 7]

Install No. 2 ring gear (48). Install spacer (47). a Direct the side of the cut inside toward the carrier.

8]

Install No. 2 housing (46) to No. 2 carrier assembly (45). a Press fit the inner race side of the housing bearing. Install snap ring (44).

9]

26

Install bearing (53) to gear (52). While fitting thrust washers (51) to both sides of them, set them to the carrier. Fit ball (54) and install shaft (50).


2)

3)

4)

Using eyebolts [5], install No. 2 housing and No. 2 carrier assembly (42). a Check that the springs are fitted to the grooves. Fit the seal ring and install No. 2 piston (43).

Install tool G1 to the inside groove of the No. 3 carrier, pull it up, and install snap ring (125).

18. Install through bolt guide (40), spring (130) and lubricating oil relief valve (41).

D155A-6


19. Guide pin Install guide pins (35).

SEN03369-00

3]

Set No. 1 ring gear (23) to No. 1 carrier and install snap ring (22).

4]

Press fit bearing (117) to input shaft (21). Install No. 1 carrier assembly (118) to input shaft (21) and install snap ring (18).

20. No. 2 discs, plates and springs 1) Install No. 2 discs (38), plates (39) and springs (37). a Install the 7 discs and 6 plates. 2) Install springs (36). a Free length of spring: 81.7 mm

5]

21. No. 1 housing assembly 1) Fit the seal ring and install No. 1 piston (34). 2) Using eyebolts [4], install No. 1 housing assembly (33), while aligning it with the No. 2 piston. a Press the housing to push in the dowel pins.

6] 7] 8]

Install collar (17). Install No. 1 sun gear (16) and snap ring (15). Install snap ring (14).

22. Input shaft and No. 1 carrier assembly 1) Assemble the input shaft and No. 1 carrier assembly according to the following procedure. 1] Install bearing (27) to gear (26). While fitting thrust washers (25) to both sides of them, set them to the carrier. 2] Fit ball (28) and install shaft (24).

D155A-6

27

SEN03369-00

9]

2)

Install No. 2 sun gear (13) and snap ring (12).

Sling input shaft and No. 1 carrier assembly (119) and install it, while meshing the No. 2 sun gear with No. 2 planetary gear.

23. No. 1 discs, plates and springs 1) Install collar (128). 2) Install No. 1 discs (31), plates (32) and spring (30). a Install 6 discs and 5 plates. 3) Install springs (29). a Free length of spring: 81.7 mm

28


24. Front cover 1) Install seal ring (121) to front cover (122).

2)

Using eyebolts [6], install front cover (122), while aligning it with the guide pins and springs. Press fit the inner race side of bearing (123) and install snap ring (24). a Check that the springs are fitted to the cover.

25. Tie bolts Install tie bolts (9) (4 pieces). (The 4 bolts marked with * in the attached drawing). 3 166.7 ± 9.8 Nm {17 ± 1 kgm}

D155A-6


SEN03369-00

26. Operation check of piston Using tool G2, check the operating condition and stroke of each piston. Piston

Standard stroke (mm)

No. 1

7.2

No. 2

7

No. 3

5

No. 4

5

No. 5

6

29. Snap ring Raise the case assembly and install snap ring (123) to output shaft (124).

30. Control valve assembly 1) Install control valve assembly (6). 3 Mounting bolt: 49.1 ± 4.9 Nm {5.0 ± 0.5 kgm}

27. Transmission case Fit the O-ring. Using eyebolts [2], install transmission case (8) and remaining 13 tie bolts (9). 3 Tie bolt: 166.7 ± 9.8 Nm {17 ± 1 kgm}

2)

Install flanges (4) and (5) and sleeve (3).

28. Sleeve Install sleeve (7).

D155A-6

29

SEN03369-00

3)


Install cover assembly (2). 2 Threaded part of mounting bolt: Gasket sealant (LG-1 or LG-5)

31. Main relief valve assembly Install main relief valve assembly (1). 3 Mounting bolt: 49.1 ± 4.9 Nm {5.0 ± 0.5 kgm}

30

D155A-6


SEN03369-00

Disassembly and assembly of steering case assembly

2.

Clutch, brake assembly 1) Angle the steering case assembly approx. 15° so that tool H1 is perpendicular to ground surface. 2) Remove mounting bolts, then using tool H1, remove clutch and brake assembly (2). a Do not remove the hexagon socket head bolt. a Remove the clutch and brake assembly on the other side in the same way.

q

EDisassembly of clutch, brake assembly 1) Disassembly of brake assembly i) Remove flange (3) and seal ring (4). ii) Remove plate (5).

1

1 H 2

791-662-1110

Bracket

t 1

01010-31685

Bolt

t 1

01017-31620

Bolt

t 1

790-302-1500

Spanner kit

t 1

09003-09200

• Spanner

1

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Disassembly 1.

Steering valve assembly, reducing valve Remove steering valve assembly (1).

D155A-6

31

SEN03369-00


ix) Using eyebolts, remove drum (12) together with disc and plate. x) Remove 6 discs (13), 5 plates (14), and 6 springs (15) from drum (12).

iii)

Loosen 4 hexagon socket head bolts uniformly and remove, then using eyebolts [1], remove cover (6). a The inner race of the bearing will come out. iv) Remove bearing (7) from cover (6).

2) v) Remove 2 brake springs (8). vi) Remove brake piston (9).

Disassembly of clutch assembly i) Remove mounting bolts, then remove cover (16). a The cover is being pushed by the clutch spring, so loosen the bolts uniformly. ii) Remove 5 discs (17) and 5 plates (18).

vii) Using puller [2], remove cage (10). a The outer race of the bearing will come out. viii) Remove 3 seal rings (11) from hub.

32

D155A-6


SEN03369-00

ix) Remove clutch spring (25). x) Remove clutch outer drum (26) from brake hub (27).

iii)

Remove snap ring (19), then remove inner drum (20). a Remove the snap ring from the ring groove, then fit it in the inner drum groove. iv) Remove snap ring (21).

xi) Remove bearing (28) from brake hub (27). xii) Remove snap ring (27) from brake hub, then remove stopper (30).

v)

Using puller [3], remove bearing (22) from inner drum (20). vi) Remove snap ring (19) from inner drum.

3. vii) Remove mounting bolts, then remove cage (23). viii) Remove clutch piston (24).

D155A-6

Pipes Remove 6 pipes (31). a When removing the pipes, be careful not to damage the O-rings.

33

SEN03369-00

4.

Lubrication tubes Remove 3 lubrication tubes (32).

5.

Case cover Remove cover (33).


8.

Bevel pinion assembly 1) Using guide bolts [4] and forcing screws [5], remove bevel pinion assembly (37) and shim (38). a Check the number and thickness of the shims, and keep in a safe place.

2)

6.

Suction tube, dipstick tube Remove suction tube (34) and dipstick tube (35).

7.

Lubrication tubes Remove left and right lubrication tubes (36).

Disassembly of bevel pinion assembly i) Hold with press to prevent pinion from moving, then use tool H2 to remove locknut (39). ii) Using push tool [6], remove bevel pinion (40) from cage (41).

iii) Remove bearing (42). iv) Remove outer races (43) and (44) from cage (41).

34

D155A-6


Remove bearing (45) from bevel pinion (40).

3)

Lift off bevel gear shaft, bevel gear assembly (49).

Bevel gear shaft, bevel gear assembly 1) Turn over steering case so that right cage is at top, then remove cage (46) and shim (47). a Check the number and thickness of the shims, and keep in a safe place.

4)

Disassembly of bevel gear shaft, bevel gear assembly i) Using puller [7], remove bearing (51) from bevel gear shaft (50). ii) Remove reamer bolt (52), then remove bevel gear (53) from bevel gear shaft (50).

v)

9.

SEN03369-00

2)

Lift off right cover (48). iii)

D155A-6

Using puller [8], remove bearing (54) from bevel gear shaft (50).

35

SEN03369-00

5)

Turn over steering case, then remove left cage (55) and shim (56). a Check the number and thickness of the shims, and keep in a safe place.


Assembly q

a a a a

6)

Remove outer race (57) from cage (55).

10. Nipple Remove nipple (58).

36

Precautions when assembling Clean all parts, and check for dirt or damage. After press fitting the bearing, apply 6 cc of EO10CD or EO30CD in drops, then rotate 10 times. Coat the sliding surfaces of all parts with engine oil before installing. Assemble the piston seal rings with the side receiving the pressure facing the housing, coat with grease (G2-LI) and install uniformly, taking care that they do not move to one side. a Fix the rotation seal ring in position with grease (G2-LI) and be extremely careful not to get it caught when assembling. Check that the snap ring is fitted securely in the groove.

1.

Nipple Install nipple (58).

2.

Bevel gear shaft, bevel gear assembly 1) Using push tool [9], press fit outer race (57) to cage (55).

D155A-6


2)

3)

Assemble shim (56) and install cage (55). a There are four types of shim: 0.05, 0.1, 0.2, 0.5 mm 3 Cage mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}

SEN03369-00

4)

Turn over steering case so that right side is at top, then install bevel gear shaft and bevel gear assembly (49).

5)

Raise right cover (48) and install. 3 Mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}

6)

Assemble shim (47) and install cage (46). a There are four types of shim: 0.05, 0.1, 0.2, 0.5 mm 3 Cage mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}

Assembly of bevel gear shaft, bevel gear assembly i) Set bevel gear (53) to bevel gear shaft (50), then fit reamer bolt (52) and tighten nut. 3 Nut: 245.2 ± 29.4 Nm {25 ± 3 kgm}

ii)

Using push tool [10], press fit bearing (54) to bevel gear shaft (50). iii) Using push tool [11], press fit bearing (51) to bevel gear shaft (50).

D155A-6

37

SEN03369-00

3.

Adjusting preload of bevel gear shaft 1) Adjust thickness of shims at cage to adjust turning torque of bevel gear shaft. a Turning torque (bevel pinion not meshed): 4.2 – 5.1 Nm {0.43 – 0.52 kgm} (At tip of bevel gear teeth: 22.6 – 26.5 N {2.3 – 2.7 kg}) a Rotate the bevel gear 2 – 3 times when measuring the turning torque.

4.

Bevel pinion assembly 1) Assemble bevel pinion as follows. i) Using push tool, press fit bearing (45) to bevel pinion (40).


iv) Press fit bearing (42) to cage (41) with press. v) Hold in press so that pinion does not move, then use tool H2 and tighten locknut (39). 2 Locknut: Thread tightener (LT-2) 3 Locknut: 779.6 ± 83.4 Nm {79.5 ± 8.5 kgm} a Rotate the cage when tightening.

2)

Using guide bolt [12], assemble shim (38) and install bevel pinion assembly (37). a There are four types of shim: 0.05, 0.1, 0.2, 0.5 mm

ii)

Using push tool, press fit outer races (44) and (43) to cage (41). iii) Put bevel pinion (40) on press stand, and set cage (41) in position.

38

D155A-6


5.

Adjustment of backlash and tooth contact 1) Adjustment of backlash Apply the probe of dial gauge [13] to the tooth tip at the end of the bevel gear perpendicularly. While fixing the bevel pinion, move the bevel gear forward and backward and read the dial gauge. a Standard backlash: 0.25 – 0.33 mm a Measure the backlash diagonally at 3 or more places. a Adjust the backlash by increasing or decreasing thickness of the right and left shims. Do not change the total thickness of both shims, however, so that the pre-load will not change. (If the thickness of the shim on one side is increased, decrease the thickness of the other side, and vice versa.) q When backlash is insufficient Decrease the thickness of the shim on the right side of the machine and increase the thickness on the left side by the same quantity. (Move the bevel gear in direction (A).)

D155A-6

SEN03369-00

q

2)

When backlash is too large Decrease the thickness of the shim on the left side of the machine and increase the thickness on the right side by the same quantity. (Move the bevel gear in direction (B).)

Adjustment of tooth contact Testing 1] Apply red lead thinly to the tooth surfaces of the bevel gear and turn the bevel gear in the forward and reverse directions, and then check the tooth contact pattern on the bevel gear.

39

SEN03369-00

2]

The tooth contact must be as follows. (The standard distance is measured from the tooth tip of the bevel pinion.) a) Center of tooth contact: 20 – 40% of face width (from small end) b) Width of tooth contact: 30 – 50% of face width c) Center of tooth contact: 35 – 65% of tooth depth d) Width of tooth contact: 60 – 80% of tooth depth Check that there is not a strong contact at tips (A), roots (B), small end (C) or large end (D). a If the bevel gear and bevel pinion are adjusted in this way, their teeth come in contact with each other correctly when they are loaded.


Adjustment If the tooth contact pattern is not proper, adjust the tooth contact according to the following procedure. 1) If the bevel pinion is too far from the center line of the bevel gear, the contact is at the small end of the bevel gear tooth faces curved outward and at the large end of the bevel gear tooth faces curved inward. q In this case, adjust the tooth contact according to the following procedure. Adjust the thickness of the shims on the bevel pinion side to move the bevel pinion in direction (A). Move the bevel gear in direction (B) and then check the tooth contact pattern and backlash again.

2)

q

a

40

If the bevel pinion is too close to the center line of the bevel gear, the contact is at the large end of the bevel gear tooth faces curved outward and the small end of the bevel gear tooth faces curved inward. In this case, adjust the tooth contact according to the following procedure. Adjust the thickness of the shims on the bevel pinion side to move the bevel pinion in direction (A). Move the bevel gear in direction (B), then check the tooth contact pattern and backlash again. Do not change the total thickness of the shims on the right and left sides.

D155A-6


3)

When adjustment is finished, tighten the mounting bolts of the cage and bevel pinion assembly to the specified torque. 2 Mounting bolts of cage and bevel pinion assembly: 98 – 122.5 Nm {10 – 12.5 kgm}

SEN03369-00

9.

Lubrication tubes Install 3 lubrication tubes (32).

10. Pipes Install 6 pipes (31).

6.

Lubrication tubes Install left and right lubrication tubes (36).

7.

Suction tube, dipstick tube Install suction tube (34) and dipstick tube (35).

11. Clutch, brake assembly Assembly of clutch, brake assembly 1) Assembly of clutch assembly i) Assemble stopper (30) to brake hub (27), and install snap ring (29). ii) Using push tool, press fit bearing (28) to brake hub. 8.

Case cover Install cover (33).

D155A-6

41

SEN03369-00


iii)

Install clutch outer drum (26) to brake hub (27). 3 Mounting bolt: 110.3 ± 12.3 Nm{11.25 ± 1.25 kgm} iv) Set clutch outer drum facing up, then assemble clutch spring (25).

ix) Press fit inner drum (20) to cage (23), then install snap ring (19) assembled to inner drum. a The outer race of bearing (22) (installed in Step 1) -viii)) is press fitted.

v) Assemble clutch piston (24). vi) Fit seal ring and install cage (23). 3 Mounting bolt: 110.3 ± 12.3 Nm{11.25 ± 1.25 kgm}

x)

Assemble plate (18) and disc (17). a Assemble the plate to the piston end. a Pistons: 5, Plates: 5 xi) Install cover (16). a The cover is being pushed by the clutch spring, so tighten the bolts uniformly. 3 Mounting bolt: 66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}

vii) Assemble snap ring (19) in groove of inner drum (20). viii) Press fit bearing (22) to inner drum (20), and install snap ring (21).

42

D155A-6


2)

Assembly of brake assembly i) Install 3 seal rings (11) to brake hub (27). ii) Install cage (10) to brake hub (27). a The outer race of the bearing is press fitted.

SEN03369-00

vii) Using push tool, press fit bearing (7) to cover (6).

viii) Install guide bolts [14] and [15] to brake piston (9) and brake cage (10). a Guide bolt [14] is for releasing the brake. iii)

Set brake outer drum (12) to clutch outer drum. iv) Assemble discs (13), plates (14), and springs (15). a Discs: 6, Plates: 5, Springs: 6

ix) Using eyebolts [1], align with guide bolts, and set cover (6) in position. x) Compress spring with bolt and press fit bearing (7) at same time. v)

Fit seal ring to brake cage and install brake piston (9). vi) assemble brake spring (8).

D155A-6

43

SEN03369-00

xi) Remove guide bolts and install plate (5). xii) Install seal ring (4) and flange (3). a Assemble the clutch and brake assembly on the opposite side in the same way. 3 Flange mounting bolt: 66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}


12. Steering valve, reducing valve Install steering valve (1). 3 Mounting bolt: 49.0 ± 4.9 Nm {5 ± 0.5 kgm}

a 3) 4)

44

Angle the steering case assembly approx. 15° so that tool H1 is perpendicular to ground surface. Using tool H1, install clutch and brake assembly (2). a Assemble the clutch brake assembly on the opposite side in the same way. 3 Mounting bolt: 110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}

When removing cover (61) of steering case (59) rear surface, install new gasket (60). 2 Gasket (apply to both sides): Gasket sealant (LG-1)

D155A-6


D155A-6

SEN03369-00

45

SEN03369-00




46

D155A-6

SEN03370-00


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Power train, Part 3 Removal and installation of final drive assembly ............................................................................................ 2 Disassembly and assembly of final drive assembly........................................................................................ 4

D155A-6

1

SEN03370-00


Removal and installation of final drive assembly 1

3.

Raising of machine k 1) Using a jack (686 kN {70 ton}) [2] and the ripper of the work equipment, raise the machine and set right and left support stands [1] under the steering case. 2) Set right and left support stands [3] under the main frame on the front side of the machine. a After setting support stands [1] and [3], set the hydraulic jack and ripper as auxiliary supports.

4.

Remove guards (3) and (4).

J

790-337-1032

Lifting tool

t 1

791-627-1320

Shackle

t 2

791T-627-1910 Plate 01010-82080

Bolt

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

t 1 N Q t 2

Removal 1.

Spread the track assembly. For details, see "Spreading and installation of track assembly".

2.

Remove 8 mounting bolts (2) on the inside of final drive assembly (1). [*1]

2

D155A-6


5.

Remove drive shaft cover (5).

SEN03370-00

8.

Using tool J, sling final drive assembly (1) and remove the remaining bolts. k First, loosen 1 bolt on each of both sides of the final drive so that the final drive will not jump out. Then, loosen all the bolts gradually to pull out the final drive assembly.

9.

Lift off final drive assembly (1). 4

6.

Final drive assembly: 1,400 kg

Pull out drive shaft (6). a Using forcing screws, pull out the drive shaft until the spline can be pulled out. a If the shaft cannot be pulled out, move the sprocket forward or backward to a position where the shaft can be pulled out.

Installation q


[*1], [*2] 3 Final drive mounting bolt: 1,150 – 1,440 Nm {118 – 147 kgm}

7.

Remove the upper mounting bolts of the final drive assembly and install tool J. [*2]

D155A-6

3

SEN03370-00


Disassembly and assembly of final drive assembly

Disassembly

1

1.

1

2

3

K

4

5

6

7

4

790-431-1031

Block

t 1

791-520-4140

Screw

t 2

790-101-2360

Plate

t 2

791-112-1180

Nut

t 2

790-101-2480

Adapter

t 2

6

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Draining oil Remove the drain plug to drain the oil in the final drive case.

791T-627-1920 Plate

t 1 N Q

790-101-2102

Puller

t 1

790-101-1102

Hydraulic pump

t 1

790-431-1031

Block

t 1

791-520-4140

Screw

t 1

791-112-1180

Nut

t 2

01643-32460

Washer

t 2

791T-627-1930 Plate

t 1 N Q

791T-627-1940 Push tool

t 1 N Q

790-101-2102

Puller

t 1

790-101-1102

Hydraulic pump

t 1

791-627-1280

Installer

t 1

790-101-5401

Push tool kit

t 1

790-101-5441

• Plate

1

790-101-5421

• Grip

1

01010-51240

• Bolt

1

Final drive case: Approx. 31 l

2.

Drive shaft Remove drive shaft (1).

3.

Shaft 1) Set the final drive assembly to the block. 2) Remove mounting bolts (2).

t 1

790-101-5401

Push tool kit

790-101-5451

• Plate

1

790-101-5421

• Grip

1

01010-51240

• Bolt

1

791T-627-1950 Plate

t 1 N Q

791T-627-1960 Plate

t 1 N Q

790-201-1500

Push tool kit

t 1

790-201-1680

• Plate

790-101-5021

• Grip

1

01010-50816

• Bolt

1

791-520-4140

Screw

t 1

790-101-2420

Adapter

t 1

791-112-1180

Nut

t 1

01643-22460

Washer

t 1

792-785-1120

Plate

t 1

791-830-1410

Push tool

t 1

790-101-2102

Puller

t 1

790-101-1102

Hydraulic pump

t 1

1

D155A-6


3)

4.

SEN03370-00

Using eyebolts [1], remove shaft (3).

4)

Remove floating seal (8) and bearing outer races (9) and (10). a Keep the floating seal in a safe place so that it will not be damaged.

5)

Reverse the sprocket hub assembly and remove 9 sprockets (11).

Sprocket hub assembly 1) Remove mounting bolts (4) and plate (5).

2) 3)

D155A-6

Using tool K1, pull out sprocket hub assembly (6). a Bearing (7) comes off, too. Using eyebolts [2], remove sprocket hub assembly (6).

5.

Wear guard Remove wear guard (12).

5

SEN03370-00

6.


6)

Cover assembly 1) Remove spacer (13). 2) Remove floating seal (14). a Keep the floating seal in a safe place so that it will not be damaged. 3) Remove mounting bolts (15).

7)

7. 4)

Carrier assembly 1) Using 3 eyebolts [5], remove carrier assembly (21).

Using eyebolts [3], sling cover assembly (16). Using 3 forcing screws [4], remove the cover assembly.

2) 5)

6

Reverse the cover assembly and remove 6 lock plates (19). Remove ring gear (20).

Remove bearing (17) and spacer (18).

Disassemble the carrier assembly according to the following procedure. 1] Remove bolts (22) and holders (23). 2] Pull out planetary gear shaft (24).

D155A-6


8.

3]

Remove planetary gear (25), bearings (26) and (27) and spacer (28) from the carrier.

4]

Remove bearing outer races (29) and (30) from the planetary gear.

SEN03370-00

9.

Holder Remove mounting bolt (33) and holder (34).

10. Gear 1) Remove the gear according to the following procedure. 1] Sling case-hub-case assembly (35) a little. 2] Push the shaft of case (36) to make a clearance between bearing (37) and case shaft. a Take care not to damage the bearing holding area on the pinion side.

Sun gear Remove thrust washer (31) and sun gear (32).

3] 4]

D155A-6

Remove mounting bolts (38). Using eyebolts [6], sling gear (39), and slant the hub to remove the gear.

7

SEN03370-00

11. Hub and case assembly 1) Using tool K2, remove hub assembly (40) and bearing (37).

2)

3)

8


4)

Remove collar (43) and remove bearing (44) from case (36).

5)

Remove sump plate (45) from case (36).

Using eyebolts [7], remove hub assembly (40).

Remove 2 bearing outer races (42) from hub (41).

12. Cage assembly 1) Remove the mounting bolts of cage assembly (46). Using forcing screws [8], remove the cage assembly from case (36).

D155A-6


2)

Remove outer race (48) and oil seal (49) from cage (47).

3)

Remove shims (50).

SEN03370-00

14. Outer race and oil seal Remove outer race (55) and oil seal (56) from case (36).

13. Gear assembly 1) Remove gear assembly (51). 2) Using puller [9], remove bearings (52) and (53) from gear (54).

D155A-6

9

SEN03370-00

Assembly a a

1.

2.

Gear assembly 1) Using the push tool [11], press fit bearings (52) and (53) to gear (54). q Bearing press fitting force: 6 – 17 kN {0.6 – 1.7 ton} 2) Install the drive shaft cover. 3) Install gear assembly (51).

3.

Cage assembly 1) Using tool K4, press fit oil seal (49) to cage (47). a When press fitting the oil seal, take care of its direction. a Apply gasket sealant thinly to the inside wall of the housing and wipe off projected part. 2 Oil seal lip: Grease (G2-LI) 2 Oil seal press fitting area: Gasket sealant (LG-5)

Clean all the parts thoroughly and check them for dirt or damage before installing. Coat the sliding surfaces of each part with engine oil before installing. Oil seal and outer race 1) Using tool K4, press fit oil seal (56) to case (36). a When press fitting the oil seal, take care of its direction. a Apply gasket sealant thinly to the inside wall of the housing and wipe off projected part. 2 Oil seal lip: Grease (G2-LI) 2 Oil seal press fitting area: Gasket sealant (LG-5)

2)

10


Using tool K5, press fit outer race (55) to case (36). q Outer race press fitting force: 1 – 13 kN {0.1 – 1.4 ton}

D155A-6


2)

Using tool K5, press fit bearing outer race (48) to cage (47). q Bearing press fitting force: 1 – 13 kN {0.1 – 1.4 ton}

3)

Fit the O-ring to cage assembly (46), install them, and adjust shim (50). a When installing the cage assembly, lower it gradually not to damage the oil seal lip.

4)

Adjustment of shim q Adjust the pinion bearing clearance according to the following procedure. 1] Tighten mounting bolts (D), (E), (G) and (H) of cage (40) evenly. 3 Mounting bolt: 20 Nm {2 kgm} 2] Using a thickness gauge, measure clearances (a) and (b) between cage (47) and case (36). 3] Referring to Table 1, determine quantity (c) of the shim from the total of clearances (a) and (b).

D155A-6

SEN03370-00

4]

Install determined shim (50) to the cage and tighten the 6 mounting bolts of cage (47) evenly. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

11

SEN03370-00


Table 1

4. Number of shims to be used

a + b (mm) Above

Below

t = 0.15

3.05

3.15

5

3.15

3.25

2

1

3.25

3.35

9

1

3.35

3.45

6

3.45

3.55

3

3.55

3.65

3.65

3.75

7

3.75

3.85

4

3.85

3.95

1

3.95

4.05

8

4.05

4.15

5

4.15

4.25

4.25

4.35

4.35

4.45

6

4.45

4.55

3

4.55

4.65

4.65

4.75

7

4.75

4.85

4

4.85

4.95

1

4.95

5.05

8

5.05

5.15

5

5.15

5.25

2

5.25

5.35

9

5.35

5.45

6

5.45

5.55

3

t = 0.5

1

1

t = 1.0

Total shim thickness (mm)

1

1.75

1

1.80 1.85

1

1.90

1

1.95

2

2.00

1

2.05

1

2.10

2

2.15

1

2.20

1

2.25

2

2

2.30

9

1

2.35

1

2.40

2

2.45

1

2

2.50

1

1

2.55

5.55

5.65

5.65

5.75

7

5.75

5.85

4

5.85

5.95

5.95

6.05

6.05

6.15

5

6.15

6.25

6.25

6.35

6.35

6.45

6

6.45

6.55

3

6.55

6.65

6.65

6.75

7

6.75

6.85

4

6.85

6.95

6.95

1

1

2

2.60

1

2

2.65

1

1

2.70

2

2.75

1

2

2.80

1

1

2.85

1

2

2.90

2

2.95

3

3.00

2

3.05

2

3.10

1

3

3.15

8

2

3.20

2

3.25

2

3

3.30

9

2

3.35

1

2

3.40

3

3.45

1

3

3.50

1

2

3.55

3

3.60

1

1

3

3.65

7.05

8

1

2

3.70

7.05

7.15

5

3

3.75

7.15

7.25

2

1

3

3.80

7.25

7.35

9

1

2

3.85

12

1

1

Hub and case assembly 1) Install oil sump plate (45) to case (36). a When installing the plate, press its surface against case faces (a) and (b). 2 Mounting bolt: Adhesive (LT-2)

2)

3)

Using tool K5, press fit bearing (44) to case (36). q Bearing press fitting force: 21 – 54 kN {2.1 – 5.5 ton} Install collar (43).

D155A-6


5.

SEN03370-00

4)

Using tool K5, press fit 2 bearing outer races (42) to hub (41). q Bearing press fitting force: 3 – 18 kN {0.3 – 1.8 ton}

2)

Tighten gear mounting bolts (38). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 230 – 289 Nm {23.5 – 29.5 kgm}

5)

Using eyebolts [7], set hub assembly (40) to the shaft.

3)

Using tool K7, press fit bearing (37) to case (36). q Bearing press fitting force: 21 – 54 kN {2.1 – 5.5 ton}

Gear 1) Using eyebolts [6], sling gear (39). While slanting the hub, set the gear to the hub.

D155A-6

6.

Holder Install holder (34) and tighten mounting bolt (35). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 230 – 289 Nm {23.5 – 29.5 kgm}

13

SEN03370-00

7.

Sun gear Install sun gear (32) and thrust washer (31).

8.

Carrier assembly a Since each planetary gear bearing is an assembly, assemble it from the inner race, outer race and spacer of the same identification mark. 1) Using tool K6, press fit bearing outer races (29) and (30) to the planetary gear. q Bearing press fitting force: 10 – 35 kN {1.0 – 3.6 ton}

2)

14


3)

Set the planetary gear assembly to the carrier and press fit shaft (24). a While aligning the holes of the bearing spacer, press fit the shaft gradually.

4)

Install holders (23) and tighten bolts (22). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 230 – 289 Nm {23.5 – 29.5 kgm}

5)

Using 3 eyebolts [4], install carrier assembly (21).

Install bearings (26) and (27) and spacer (28) to planetary gear (25).

D155A-6


9.

Cover assembly 1) Install ring gear (20) and 6 lock plates (19) and tighten the mounting bolts. 2 Mounting bolt: Adhesive (LT-2)

2) 3)

4)

D155A-6

SEN03370-00

5)

Using eyebolts [3], fit the O-ring to cover assembly (16) and install them to the case assembly. a The mating faces of the case and cover must be free from a dent, rust, oil, dirt and water. a Apply the gasket sealant all around the mating face (1 side) of the case without breakage. 2 Mating face of case: Gasket sealant (LG-7) a Tighten the bolts within 20 minutes after applying the gasket sealant.

6)

Tighten mounting bolts (15). 3 Mounting bolt: 455 – 565 Nm {46.5 – 58 kgm}

Install spacer (18). Using tool K3, press fit bearing (17). q Bearing press fitting force: 15 – 43 kN {1.5 – 4.4 ton}

Using tool K4, press fit floating seal (14). a Degrease and dry the O-ring and Oring contact surface before installing the floating seal. a After installing the floating seal, check that its tilt is 1 mm or less.

15

SEN03370-00

10. Wear guard Install wear guard (12). 3 Mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}

11. Sprocket hub assembly 1) Using tool K5, press fit bearing outer races (9) and (10). q Bearing press fitting force: 14 – 59 kN {1.5 – 4.4 ton}

2)

16


3)

Using tool K3, press fit floating seal (8). a Degrease and dry the O-ring and Oring contact surface before installing the floating seal. a After installing the floating seal, check that its tilt is 1 mm or less.

4)

Using eyebolts [2], install sprocket hub assembly (6) to the cover assembly. a Check that the sliding surface of the floating seal is free from dirt and apply engine oil thinly.

Install 9 sprockets (11) to the sprocket hub. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 1,176 ± 98 Nm {120 ± 10 kgm}

D155A-6


5)

SEN03370-00

2)

Using tool [10], press fit bearing (7). a While rotating the sprocket hub assembly, press fit the bearing. q Bearing press fitting force: 15 – 43 kN {1.5 – 4.4 ton}

Tighten mounting bolts (2). 3 Mounting bolt: 1,225 – 1,470 Nm {125 – 150 kgm}

13. Drive shaft Install drive shaft (1). 6)

Install plate (5) and tighten mounting bolts (4). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 2 30 – 289 Nm {23.5 – 29.5 kgm}

q

a

12. Shaft 1) Fit the O-ring to the sprocket hub assembly. Using eyebolts [1], install shaft (3).

Refilling with oil Tighten the drain plug and add oil through the oil filler. After installing the final drive assembly to the machine, check the oil level again.

5 3 3

D155A-6

Final drive case: Approx. 31 l Oil filler/Drain plug: 127 – 176 Nm {13 – 18 kgm} Oil level gauge plug: 58.8 – 76.4 Nm {6 – 8 kgm}

17

SEN03370-00




18

D155A-6

SEN03371-00


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Undercarriage and frame Removal and installation of track frame assembly.......................................................................................... 3 Removal and installation of idler assembly ..................................................................................................... 6 Disassembly and assembly of idler assembly ................................................................................................ 7 Removal and installation of recoil spring assembly .......................................................................................11 Disassembly and assembly of recoil spring assembly .................................................................................. 12 Removal and installation of track roller assembly ......................................................................................... 17 Disassembly and assembly of track roller assembly .................................................................................... 18 Removal and installation of carrier roller assembly ...................................................................................... 20 Disassembly and assembly of carrier roller assembly .................................................................................. 21 Removal and installation of pivot shaft assembly ......................................................................................... 25 Spreading and installation of track shoe assembly ....................................................................................... 27 General disassembly and assembly of track shoe........................................................................................ 30 Disassembly and assembly of 1 link in field.................................................................................................. 44 Disassembly and assembly of master link .................................................................................................... 48 Removal and installation of equalizer bar assembly ..................................................................................... 51 Disassembly and assembly of equalizer bar assembly ................................................................................ 53

D155A-6

1

SEN03371-00


Removal and installation of segment teeth ................................................................................................... 55

2

D155A-6


Removal and installation of track frame assembly 1

SEN03371-00

4.

Disconnection of equalizer bar 1) Sling track frame assembly, and 2 bolts (1) and remove cover (2) of equalizer bar. 2) Remove 2 bolts (3) and lock plate (4). 3) Remove equalizer bar side pin (5).

5.

Disconnection of track frame assembly 1) Remove cover mounting bolt and install guide bar [4]. 2) Remove remaining bolts, and disconnect cover (6).

Removal 1.

Remove blade assembly. For details, see "Removal and installation of blade assembly".

2.

Spread track shoe assembly. For details, see "Spreading and installation of track shoe assembly".

3.

Jacking up chassis machine according to the following procedure k 1) Using hydraulic jack (686 kN {70 ton}) [2] and ripper of machine, jack up machine and set stands [1] under steering case on left and right. 2) Set stands [3] on left and right under main frame at front of machine. 3) Set blocks under front of raised track frame to ensure safety during operation. a After setting stands [1] and [3], set the hydraulic jack and ripper again to act as extra support.

3)

D155A-6

Disconnect 4 hoses (7).

3

SEN03371-00

4)

Remove 2 mounting bolts (8) and remove washer (9).


6.

Lift off track frame assembly (14). [*2] a When lifting off the track frame assembly, take care extremely not to damage the seal surface. 4

5) 6) 7)

4

Remove seal (10). [*1] Remove 6 mounting bolts (11) and washer (12). Remove spacer (13)

7.

Track frame assembly: 3,960 kg

Remove seal (15) from pivot shaft (16). [*3]

D155A-6


Installation q


[*1] a Install seal (10) according to the following procedure. 1) Reverse seal (10) so that the molded letter (a) face will be on the inside. 2) With the seal reversed, insert the seal in washer (12). 3) Apply oil (EO-30) to face (b) of washer (9) at the shaft end. 4) Install washer (9) to the shaft end.

SEN03371-00

[*3] a Install seal (15) according to the following procedure. 1) Reverse seal (15) so that the molded letter (c) face will be on the inside. 2) With the seal reversed, insert seal (15) in pivot shaft (16). 3) Apply oil (EO-30) to face (d) of track frame assembly (14). 4) Install track frame assembly to the pivot shaft.

q

Refilling with oil (Pivot chamber) 5

Pivot chamber: 9 l (EO-30)

[*2] a When inserting the track frame assembly, take care extremely not to damage the seal surface.

D155A-6

5

SEN03371-00

Removal and installation of idler assembly 1 Removal 1.

Remove blade assembly. For details, see "Removal and installation of blade assembly"

2.

Spread track shoe assembly. For details, see "Spread and installation of track shoe assembly"

3.

Remove seat support bolt (1), and remove plate (2) and shim (3). [*1]

4.

Loosen support mounting bolts (4), and remove shim (5). [*2] 4

Installation q


[*1] a Standard thickness (Upper) (Tu): 8 mm a Standard thickness (Lower) (Te): 4 mm [*2] a Standard thickness (Ts): 6.5 mm 3 Mounting bolt: 662 – 829 Nm {67.5 – 84.5kgm} a Set clearance (Tc): 2.0 – 3.4 mm (Including endplay) a Endplay (Ep): 0.49 – 0.72 mm (Total of both side)

Idler assembly: 460 kg

5.

Remove 4 yoke mounting bolts (6), then sling idler assembly (7), and pull it out forward to remove.

6.

Remove spring seat and spring. a These parts are installed between support and track frame.

6


D155A-6


SEN03371-00

Disassembly and assembly of idler assembly

1

791-630-1220

Rod

t 2

790-101-2510

Block

t 1

790-101-2570

Washer

t 2

01580-01411

Nut

t 2

01643-31445

Washer

t 2

790-101-2102


790-101-1102

Hydraulic pump

t 1

2

791-651-1510

Installer

t 1

3

791-601-1000

Oil pump

t 1

1 L

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Disassembly 1.

Remove the oil drain plug to drain the oil. 6

2.

Idler: Approx. 390 – 450 cc

Set idler assembly (1) to blocks [1]. 4

Idler assembly: 500 kg

3.

Remove nut (2) and pull out bolt (3).

4.

Lift off support assembly (4). 4

Support assembly: 100kg

5.

Remove floating seal (5a) from bushing (6).

6.

Remove floating seal (5b) from support assembly (4).

7.

Remove 6 pieces of bolts (7) from bushing (6).

D155A-6

7

SEN03371-00

8.

Reverse the idler assembly (1) and set it to blocks [1]. 4

9.

Idler assembly: 400kg

Remove nut (8) and pull out bolt (9).


14. Using tool L1, remove shaft (14) and bushing (12). 15. Remove bushing (12) from shaft (14). a Do not remove inner bushing from outer bushing. [*1]

10. Lift off support assembly (10). 4

Support assembly: 100kg

11. Remove floating seal (11a) from bushing (12). 12. Remove floating seal (11b) from support assembly (10). 13. Remove 6 pieces of bolts (13) from bushing (12).

16. Reverse the idler assembly (1) and set it to blocks [1]. 17. Using push tool [2] and tool L1, remove bushing (6). a Do not remove inner bushing from outer bushing. [*2]

8

D155A-6


SEN03371-00

Assembly

6.

Tighten 6 pieces of bolts (7) to bushing (6).

a

Clean all the parts thoroughly and check them for dirt or damage.

7.

Using tool L2, install floating seal (5a) to bushing (6).

1.

Set idler (1) to blocks [1].

2.

Using plate [3] and tool L1, press fit bushing (12). a Bushing (12) is supplied with a set inner bushing and outer bushing.

8.

Using tool L2, install floating seal (5b) to support assembly (4).

3.

Tighten 6 pieces of bolts (13) to bushing (12).

4.

Reverse the idler assembly (1) and set it to blocks [1].

5.

Using tool L1, press fit shaft (14) and bushing (6).

D155A-6

9

SEN03371-00

9.


Assemble support assembly (4) to idler assembly (1).

10. Install bolt (3) and tighten nut (2).

11. Reverse the idler assembly (1) and set it to blocks [1]. 12. Assemble floating seal (11a),(11b) and support assembly (10) to idler assembly (1) as a same procedure step 7 to step 10. 13. Using tool L3, add oil to the specified level and tighten the plug. 6

10

Idler: 390 – 450 cc (GO140B)

D155A-6


Removal and installation of recoil spring assembly 1

SEN03371-00

Installation q


a

While checking the recoil spring assembly through the lubricator adjustment window, install in the track frame.

Removal 1.

Remove the idler assembly. For details, see "Removal and installation of idler assembly".

2.

Pull out the recoil spring assembly (1) forward to remove. 4

D155A-6

Recoil spring assembly: 450 kg

11

SEN03371-00


Disassembly and assembly of recoil spring assembly

3)

1

Using push tool [1], pull out piston (9) from yoke (8) with a press.

791-685-8006

Compressor

t 1

791-635-3160

Extension

t 1

M 2 791T-630-2610 Spacer

t 1

790-101-1300

Cylinder

t 1

790-101-1102

Hydraulic pump

t 1

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Q

q

Disassembly 1.

Remove yoke and piston assembly (2) from recoil spring assembly (1).

2.

Disassembly of yoke and piston assembly 1) Remove snap ring (3), packing (4) and ring (5). 2) Remove bolt (6) and plate (7).

12

3.

If cylinder (10) has not been broken and shaft end nut (11) has not come off, disassemble according to the following procedure.

Remove holder (13) from recoil spring case (12). k Never stand in front of or at the rear of the recoil spring assembly to avoid danger.

D155A-6


4.

5.

Disassembly of holder 1) Remove cover (15) from holder (14). 2) Remove seal (16) and bushing (17) from holder (14).

SEN03371-00

7.

Apply hydraulic pressure gradually to tool M2 to compress the spring and tighten nut (11) until spacer (19) comes off and then remove the spacer.

8.

Remove nut (11) and release the hydraulic oil gradually to release the spring tension.

9.

Remove recoil spring (20) and cylinder (10) from recoil spring case (12).

Remove the lock plate from cylinder (10) and remove lubricator (18).

10. Remove bushing (21) from cylinder (10). 11. Remove seal (22) and bushing (23) from recoil spring case (12).

6.

Set recoil spring assembly (1) to tool M2. k Set the spring securely since its installed load is heavy and dangerous. a Installed load of spring: 314 kN {32,000 kg}

D155A-6

13

SEN03371-00

q

k

1)

2)

3) 4)

14

If cylinder (10) has been broken or shaft end nut (11) has come off and the mounting bolt of holder (13) is removed, recoil spring (20) will jump out forward. In this case, disassemble according to the following procedure. Never stand in front of or at the rear of the recoil spring assembly to avoid danger until holder (13) and recoil spring case (12) are separated and the recoil spring is taken out and safety is confirmed.

Set recoil spring assembly (1) to tool M2. k Set the spring securely since its installed load is heavy and dangerous. a Installed load of spring: 314 kN {32,000 kg} Apply hydraulic oil gradually and fix recoil spring assembly (1).


Assembly 1.

Using the push tool, press fit bushing (23) to recoil spring case (12) and install seal (22). 2 Bushing: Grease (G2-LI)

2.

Using the push tool, press fit bushing (21) to cylinder (10). 2 Bushing: Grease (G2-LI)

3.

Temporarily install recoil spring (20) and cylinder (10) to recoil spring case (12) and set them to tool M2. 2 Inside of case and parts in case: Grease (Apply G2-LI to minimum thickness of 3 mm) k Set the spring securely since its installed load is heavy and dangerous. a Installed load of spring: 314 kN {32,000 kg} a When compressing the spring, align it by using lever block [2] etc. so that the threaded part will not be damaged. a Installed length of spring: 656 mm

Remove the mounting bolts of holder (13). Release the hydraulic oil gradually to release the spring tension.

D155A-6


4.

5.

Install nut (11) and spacer (19). a Eliminate the clearance between the nut and spacer. (Reference) If there is any clearance, the spring load is applied to the threaded part of the nut. The nut may be damaged and may not be able to be disassembled next time.

SEN03371-00

6.

Install lubricator (18) to cylinder (10) and install the lock plate. a Install the grease fitting at 45° ± 5° out.

7.

Assembly of holder 1) Using the push tool, press fit bushing (17) to holder (14) and install seal (16). 2 Bushing and oil seal: Grease (G2-LI) 2) Install cover (15) to holder (14).

8.

Install holder (13) to recoil spring case (12). 2 Mating faces of holder and case: Grease (G2-LI)

Release the hydraulic pressure gradually to release the spring tension completely and then remove recoil spring assembly (1) from tool M2.

D155A-6

15

SEN03371-00

9.


Assembly of yoke and piston assembly 1) Using the push tool and press, press fit piston (9) to yoke (8). q Yoke press fitting force: 392 kN {40 ton}

2) 3)

Install plate (7) and tighten bolt (6). a Check that the plate is not on the yoke. Install ring (5), packing (4) and snap ring (3). 2 Packing and ring: Grease (G2-LI)

10. Install yoke and piston assembly (2) to recoil spring assembly (1).

16

D155A-6


Removal and installation of track roller assembly 1

SEN03371-00

Installation q

Removal 1.

Remove track frame assembly. For details, see "Removal and installation of track frame"

2.

Reverse the track frame assembly (1).

3.

Remove 2 mounting bolts (2) and retainer (3). [*1]

4. 5.

Remove 4 mounting bolts (4) and guard (5). [*2] Remove 14 mounting bolts (6) and guard (7). [*3] 4


[*1]

2 3

Retainer mounting bolt: Adhesive (LT-2) Retainer mounting bolt: 445 – 565 Nm {46.5 – 58 kgm}

[*2]

2 3

Guard mounting bolt: Adhesive (LT-2) Guard mounting bolt: 445 – 565 Nm {46.5 – 58 kgm}

[*3]

2 3

Track roller guard: 145 kg

Guard mounting bolt : Adhesive (LT-2) Guard mounting bolt (side and upper): 784 – 981 Nm {80 –100kgm}

[*4]

2 3

6.

Track roller mounting bolt : Adhesive (LT-2) Track roller mounting bolt : 784 – 981 Nm {80 – 100kgm}

Remove 4 mounting bolts (8) and lift off track roller assembly (9). [*4] 4

Track roller (single flange): 115 kg

4

Track roller (double flange): 125 kg

D155A-6

17

SEN03371-00


Disassembly and assembly of track roller assembly

L 2

791-651-1510

Installer

Sketch

New/Remodel

Q'ty

Part name

Necessity

Part No.

Reverse track roller assembly (8) and set to press.

8.

Remove 6 bolts (9).

9.

Using press, push out shaft (10) and bushing (4).

1


7.

t 1

10. Remove bushing (11) from shaft (10). a Do not separate inner bushing and outer bushing. [*1]

Disassembly 1.

Remove plug and drain oil.

2.

Remove ring (1), then remove collar (2). a Remove collar (5) same as collar (2).

3.

Remove floating seal (3a) from bushing (4).

4.

Remove floating seal (3b) from collar (2).

5.

Remove floating seal (6a), (6b) same as procedure 3 and 4. 11. Reverse track roller assembly (8) and set to press. 12. Using push tool [1], push out bushing (11). a Do not separate inner bushing and outer bushing. [*2]

6.

18

Remove 6 bolts (7) from track roller (8).

D155A-6


Assembly 1.

Set track roller assembly (8) to press.

2.

Set bushing (4) to track roller (8) with o-ring.

3.

Using plate [2], press fit bushing (4) to track roller (8).

4.

Fix bushing(4) with 6 mounting bolts. 2 Mounting bolt : Molybdenum disulfide lubricant (LM-P) 3 Mounting bolt : 1st step : 735 ± 10 Nm {74 ± 1kgm} 2nd step(angle tightning): 90 ± 5°

5.

Reverse track roller assembly (8) and set to block [3].

6.

Sling shaft (10) and install it to bushing (4). a Do not damage inside of bushing.

SEN03371-00

9.

Fix bushing (11) with 6 bolts. 2 Mounting bolt : Molybdenum disulfide lubricant (LM-P) 3 Mounting bolt: 1st step : 735 ± 10 Nm {74 ± 1kgm} 2nd step(angle tightning): 90 ± 5°

10. Using tool L2, assemble floating seal (3a) to bushing (4). a Before installing the floating seal, roughly clean, degrease and dry the O-ring and floating seal contact surface (hatched areas). Take care that dirt will not stick to the floating seal contact surface. a After inserting the floating seal, check that Its tilt is 1 mm or less and projection (a) of the seal is 7 –11 mm.

11. PUsing tool L2, assemble floating seal (3a) to collar (9). 7.

Set bushing (11) to track roller assembly with o-ring.

8.

Using push tool [4], press fit bushin (11).

D155A-6

19

SEN03371-00

Removal and installation of carrier roller assembly


4.

1

Removal 1.

Pass rope [2] through the link hole and wind it onto carrier roller (3) and stretch it. Loosen the rope gradually to pull out carrier roller (3) from support (4). [*1] 4

Remove the track frame top cover and loosen lubricator (1) to lower the track tension. k Since the internal pressure of the recoil spring cylinder is very high, do not loosen the lubricator more than 1 turn. If the grease does not come out sufficiently after the lubricator is loosened, move the mach ine forward an d in reverse.

Carrier roller: 45 kg

Installation q

2.

Using hydraulic jacks [1], raise the track shoe.

3.

Remove mounting bolts (2).

[*1] When installing the carrier roller to the support, make clearance (a) shown in the figure. q Clearance (a): 1.2 mm 2 Support mounting bolt: Adhesive (LT-2) q

20


Adjust the track shoe assembly tension. For details, see Testing and adjusting, "Testing and adjusting track shoe assembly tension".

D155A-6


SEN03371-00

Disassembly and assembly of carrier roller assembly

1

5.

Using tool R1, remove nut (4).

6.

Using puller [2], remove the ring press fitting part. Using eyebolts, remove bearing (5) and roller (6) together.

7.

Remove outer race (7) from the roller.

8.

Using puller [3], remove ring (8) and the inner race of bearing (9) together.

9.

Remove floating seal (10) from ring (8).

R

1

790-102-1891

Nut wrench

t 1

2

791-651-1510

Installer

t 1

3 791T-630-1350 Spacer

t 1

4

t 1

791-601-1000

Oil pump

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Q

Disassembly 1.

Remove the plug to drain the oil. a While rotating the shaft, drain the oil. 6

Carrier roller: 570 – 680 cc

2.

Set carrier roller assembly (1) to block [1].

3.

Remove the mounting bolts and cover (2).

4.

Remove ring (3).

D155A-6

21

SEN03371-00


10. Using push tool [4], remove ring (11).

Assembly

11. Remove floating seal (12) from ring (11).

a

Clean all the parts thoroughly and check them for dirt or damage.

1.

Using push tool [5], press fit the inner race of bearing (9) to the shaft.

2.

Using push tool [6], press fit outer race (7) of the bearing to the roller.

3.

Set the inner races of roller (6) and bearing (5) to the shaft.

4.

Using push tool [7], press fit the inner race of bearing (5) to the shaft. a While rotating the roller, press fit the bearing until the roller becomes a little heavy to rotate.

22

D155A-6


5.

6.

Using tool R1, tighten nut (4) to "58.8 Nm {6 kgm}". a After tightening the nut, if the nut hole is not aligned with the shaft hole, align it by loosening it.

SEN03371-00

9.

Using tool R2, install floating seal (10) to ring (8).

10. Fit the O-ring and install ring (8) while setting it to the dowel pin.

Install ring (3).

11. Using tool R2, install floating seal (12) to ring (11). 7.

Fit the O-ring and install cover (2) and then tighten the mounting bolts. a Tighten the oil filler plug temporarily.

a

8.

Reverse roller (6) and add oil between the shaft and roller. 5

a

Refill capacity: 570 – 680 cc (GO140) a

D155A-6

Before installing the floating seal, thoroughly clean, degrease and dry the O-ring and O-ring contact surface (hatched areas). After inserting the floating seal, check that its tilt is 1 mm or less and projection (a) of the seal is 7 – 11 mm. Coat the sliding surfaces of the floating seal and take care that dirt will not stick to them.

23

SEN03371-00

12. Using tool R3, press fit ring (11). a Press fit the ring so that dimension (a) from the shaft end to the ring top will be 131.95 ± 0.2 mm.


14. After checking for air leakage, check again that the oil supplied in step 8 is still at a proper level. a Check of oil level Remove the oil filler plug, slant the carrier roller approx. 10°, and check the oil level. 15. Tighten the oil filler plug 3 Plug: 157.0 – 255.0 Nm {16.0 – 26.0 kgm}

13. Using tool R4, apply the standard pressure to the roller oil filler to check the seal for air leakage. a Standard pressure: 0.1 MPa {1 kg/cm2} a Check method Keep the standard pressure for 10 seconds and confirm that the gauge pointer does not lower.

24

D155A-6


SEN03371-00

Removal and installation of pivot shaft assembly 1

V

Sling pivot shaft assembly (3) and remove the mounting bolts. Using eyebolts [1], lift off pivot shaft assembly (3). [*2] 4

791T-650-2110 Sleeve

t 1

790-201-2770

t 1

Spacer

791T-650-2120 Plate

t 1

792-104-3940

Bolt

t 2

790-101-2510

Block

t 1

790-101-2570

Washer

t 2

01580-01613

Nut

t 1

790-105-2300

Jack assembly t 1 (196 kN {20 ton})

790-101-1102

Hydraulic pump

Pivot shaft assembly: 135 kg

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity


3.

Q Q

t 1

Removal 1.

Remove the track frame assembly. For details, see "Removal and installation of track frame assembly".

2.

Remove seal (1) and ring (2). [*1]

D155A-6

25

SEN03371-00


Installation q


[*1] a Install seal (1) according to the following procedure. 1) Reverse seal (1) so that the molded letter (a) face will be on the inside. 2) With seal (1) reversed, insert it in pivot shaft (3).

a

Using tool V, press fit ring (2). q Press fitting force: 8.8 – 22.5 kN {0.9 – 2.3 ton} q Ring press fitting dimension: 475.5 ± 1 mm

[*2]

2

3

26

Pivot shaft mounting bolt: Adhesive (LT-2) Pivot shaft mounting bolt: 784 – 981 Nm {80 – 100 kgm}

D155A-6


Spreading and installation of track shoe assembly

SEN03371-00

1

Check before spreading track shoe assembly k

k

1.

Since it may be very dangerous to spread the track shoe assembly, check the following items in advance. Do not loosen the lubricator more than 1 turn. If the grease does not come out sufficiently, move the machine forward and in reverse.

Spreading of track shoe assembly (Ordinary) a

If no abnormality is detected by "Check before spreading track shoe assembly", perform the following procedure.

1.

Set the master link in position. a Set master link (3) above the idler (a little after the center of the idler). a Set blocks [1] and [2] at the front of the idler and between the carrier rollers so that the mating part of the master link will not open until the master bolt is pulled out.

2.

Lower the track shoe tension. [*1] k Do not loosen lubricator (2) more than 1 turn. a If the track shoe tension is not lowered after the lubricator is loosened, move the machine forward and in reverse.

Remove cover (1) and loosen lubricator (2) of the adjustment cylinder to discharge the grease. k Do not loosen the lubricator more than 1 turn.

2.

After the shoe is loosened, perform "Spreading of track shoe assembly (Ordinary)".

3.

If the track shoe is not loosened by the above work, perform "Spreading of track shoe assembly (When track frame has internal trouble)". a The track frame may have an internal trouble (damage of the recoil spring or recoil spring set bolt, fall of the shaft end nut, etc.)

D155A-6

27

SEN03371-00

3.

4.

28

Remove track shoe (4). [*2] a Loosen the 4 bolts by 1 – 2 turns each and check that they rotate lightly, and then pull them out. Do not pull them out one by one without checking their looseness. a If the bolts are loosened forcibly while they are still tight, their threads and master link (3) may be damaged.

Sling the front end of the master link and move the machine slowly in reverse to spread track shoe assembly (5). a Length of track shoe: Approx. 10.5 m k Never stand in front of the idler to avoid danger.


Spreading of track shoe assembly (When track frame has internal trouble) a k

If any abnormality is detected by "Check before spreading track shoe assembly", perform the following procedure. If the track shoe is removed while the track frame has an internal trouble, it may spring back. Even if the track shoe is removed, the idler may jump out, and that can cause a serious accident. Accordingly, spread the track shoe according to the following procedure.

1.

Remove the work equipment. For details, see "Removal and installation of blade assembly".

2.

Lower the track shoe tension. [*1] k Do not loosen lubricator more than 1 turn. a If the track shoe tension is not lowered after the lubricator is loosened, move the machine forward and in reverse to discharge the grease. a Check that all the grease has been discharged.

3.

Move the machine slowly forward against large block [3] or a wall (or the blade of another machine of the similar size of the machine to be repaired, if available) to press the track shoe (4) on the idler side. When the recoil spring and track shoe are distorted, stop and apply the brake. At this time, set the master link (3) between the idler and front carrier roller. a For safe work, apply lever block [4] between the carrier roller support and link.

4.

Remove track shoe (4) and disconnect master link (3). [*2]

5.

Move the machine slowly in reverse to spread the track shoe.

D155A-6


SEN03371-00

Installation q

Carry out installation in the reverse order to expansion (ordinary).

[*1] a Adjust the track shoe tension. For details, see Testing and adjusting, "Testing and adjusting track shoe tension". [*2] a Tighten the shoe mounting bolts for the master link in the following order. 2 Shoe mounting bolt: Molybdenum disulfide grease (LM-P) 3 Shoe mounting bolt: 1st time: 590 ± 60 Nm {60 ± 6 kgm} 2nd time: Retighten by 180° ± 10° a Tighten all the 4 bolts with fingers until the master link mating faces are fitted. a If the bolts are tightened forcibly before the master link mating faces are fitted, their threads and master link may be damaged.

D155A-6

29

SEN03371-00


General disassembly and assembly of track shoe

1

a


791-101-4300

Cylinder t 1 (196 kN {20 ton})

791-101-4200


791-101-1102

Hydraulic pump

t 1

2

791-932-1110

Plug push tool

t 1

3

791-660-7460

Pin brush

t 1

Sketch

New/Remodel

Part name

791-675-9701

1

S

Part No.

Q'ty

Symbol

Necessity

Special tools

t 1

4

791-432-1110

Plug push tool

t 1

5

791-632-1052

Installer

t 1

6

790-701-3000

Seal checker

t 1

7

791-601-1000

Oil pump

t 1

For the general disassembly of the track shoe, see "Parts judgment guide, Undercarriage, Oil lubricated track" and "Parts judgment guide, Undercarriage, Reversing procedure for oil lubricated track".

General disassembly 1.

30

If it is obliged to cut a shoe nut with gas, keep the seal temperature below 80 °C to prevent thermal deterioration of the seal and take measures to prevent the spatters from entering through the clearances among the links.

Removal of shoe Sling the shoe assembly and set it with the shoe up on the floor and remove the shoe by using a shoe bolt impact wrench. a If a shoe bolt is not loosened after it is unscrewed by 1 turn (If its torque is not reduced to 0), loosen the other bolts first, and it will be removed smoothly. a If a shoe bolt is turned forcibly while its torque is not 0, it and link will adhere to each other and they will need to be repaired. a When moving the shoe assembly, take care not to damage the master link.

2.

Disassembly of link 1) Set the link assembly on a link press and hit it with a hammer so that the bushing will be fitted to the jaw. a If the link tread, outside of the bushing, etc. are worn, adjust the height of jaw [1] or guide plate and align disassembly jigs [2] and [3] with the pin and bushing so that the link hole will not be damaged during disassembly work. a If the disassembly jigs are not aligned well, the link hole may be damaged and the pin and bushing may be broken during disassembly work.

D155A-6


2)

3)

D155A-6

SEN03371-00

4)

Using tool S2, drive the small plug of the pin inward after the disassembly work so that the workplace will not become dirty.

Operate the left cylinder to pull out the pin and bushing from the left link simultaneously. a Check the pulling out force of the pin and bushing to see if press fitting force for them necessary for reversed reassembly is obtained.

3.

Return the right cylinder and take out the links, pins, bushings, and spacers on the right and left sides and feed the next 1 set of the link assembly to the jaw. a If the bushing ends and sealing surfaces are damaged, oil will leak. Accordingly, handle them carefully.

Inspection Check the parts for the following items to see if they can be used for an oil lubricated track or a grease lubricated track, then examine them generally and determine to use them for an oil lubricated track or a grease lubricated track. a For judgment of reuse of the parts, see "Parts judgment guide, Undercarriage, Oil lubricated track". 1) Check the parts visually for damage. If a part seems to be damaged, check it by dye penetrant test or magnaflux inspection. If it has any crack, it cannot be used again. Discard it.

Return the left cylinder and operate the right cylinder to pull out the pin and bushing from the right link simultaneously.

31

SEN03371-00

2)

a

32

Measure the outside diameters of the press fitting parts of the pin and bushing and the inside diameters of the pin and bushing fitting parts of the link with a micrometer and a cylinder gauge to see if the interference is larger than the limit. When using the pin, bushing, and link for an oil lubricated track, however, secure the standard interference between the pin and link. a If the interference is less than the limit, replace the parts with new ones. a For the dimensional criteria, see "Maintenance Standard".

Precautions for storage 1) Store the seal without removing it from the link so that the counterbore portion will not be rusted and take care not to damage the seal lip. 2) Apply rust-preventive oil to the pin and bushing fitting parts, shoe mating surface and master link mating surface of the link. 3) When storing, apply rust-preventive oil to all the surfaces of the pin, bushing and spacer. Take care not to damage the ends of the bushing in particular.


General assembly a

For the whole assembly of the track shoe, see "Parts judgment guide, Undercarriage, Reversing procedure for oil lubricated track".

When recycling for oil lubricated track 1. Preparation work 1) Cleaning of seal assembly Remove the seal assembly from the link and divide it into the seal ring (1) and load ring (2), and then clean them. a Since the seal ring and load ring are deteriorated easily by the cleaning liquid (trichloroethylene etc), clean them quickly. After cleaning them, wipe off the cleaning liquid from them.

2)

When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the nodules sticking to the press fitting parts with the grinder, too. a If the ends are worn and sharpened, they may scuff the press fitting parts and cause oil leakage.

D155A-6


3)

If the link, pin, bushing and spacer are dirty, clean them. Remove the nodules sticking to the link and bushing with the grinder. a Since these parts rust easily, clean them just before assembling. a Do not polish the bushing ends. If they are polished, oil may leak. If the large plug was pulled out, drive it in by using tool S4. a Clean the pin hole in advance by using tool S3.

4)

1] 2] 3]

D155A-6

Insert plug (3) through the plug insertion window into the guide hole. Push the bar with the hand and insert the plug until it stops. Push the plug with the bar to press the guide against pin (4). a Driving distance (a) from pin end: 10 ± 1 mm a If the chamfered part of the pin hole has been worn, chamfer it with a small-sized grinder (grindstone tip angle: 45° – 60°) so that the plug will not be damaged. a Coat the plug with GO90 and drive it with the small diameter end ahead.

SEN03371-00

5)

Installation of seal assembly Clean the counterbore portion (d) of the link carefully and push in the seal to the bottom by using tool S5. a If oil sticks to the counterbore portion of the link or seal assembly, the seal will turn and its sealing performance will lower. Accordingly, do not apply any oil. When inserting the seal in the counterbore portion, take care that oil not stick to the seal.

6)

Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. a For the standard dimensions, see "Dimensions table of press fitting jig of link press". a If the pin end (part P) or the sides of the link (parts Q and R) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on the right and left sides will be even.

33

SEN03371-00

7)

2.


Adjust the relief pressure of the link press so that the pressing force of the press will not exceed the standard value. a If the pressing force is too strong, the spacer will be pressed forcibly against the bushing. As a result, the spacer may be broken and it and bushing may be worn abnormally. a Final pressing force for pin and bushing: 862 kN {88 tons} Final pressing force C 1.8 x Average press fitting force (Adjust the relief pressure of the link press to set the final pressing force.)

Assembly of link 1) Apply oil (GO90) to the mating surfaces of the pin and bushing with a clean brush and assemble them, and then set them before the jaw of the link press. a When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press).

3)

4)

5) 2)

34

Set shoe mounting faces of the right and left master links on bushing side up and press fit the bushing. a At this time, use the master links on the pin side as supports. a Bushing press fitting force: 88 – 304 kN {9 – 31 ton}

Using the shoe bolt hole pitch gauge, press fit the master links until the distance between the shoe bolt holes of both links is the standard value. a Blow off all the steel chips caused by press fitting of the bushing with compressed air. Reverse the master links and check that they are press fitted in parallel.

Measure the projections of the bushing on the right and left sides with a depth gauge. a Adjust the press fitting jig of the link press so that the projections on the right and left sides will be even.

D155A-6


6)

SEN03371-00

Send the master links and set the next pin and bushing. a When reusing a pin, install it so that its side hole will be on the link tread side similarly to a new one. If it is not installed so, its strength may be lowered. Accordingly, indicate the direction of side hole (e) on the end face to prevent a mistake.

9)

7)

Using spacer [4] for fine adjustment, press fit the pin and bushing until the pin end is fitted to the bottom of the receiving jig. a Adjust the depth of the receiving jig hole so that the projections of the pin on the right and left sides will be even.

Set the right link and install the spacer to the pin. a Check that the seal surface and bushing end are free from dirt and apply oil (GO90) to them with a clean cloth or brush. a When installing the spacer, wipe it with a clean cloth.

10) Set the left link and install the spacer to the pin. a Apply oil similarly to the right link.

8)

D155A-6

Set the right jig on the receiving side and the left one on the pushing side and press fit the pin and bushing simultaneously. a If the pin and bushing have play when they are press fitted, the seal may come off the link. To prevent this, press fit smoothly. If the seal comes off the link, stop press fitting and set the seal to the link correctly, and then start press fitting again. a Press fitting force for pin and bushing: 343 – 490 kN {35 – 50 ton}

35

SEN03371-00

11) Set the left jig on the receiving side and the right one on the pushing side and press fit the left link. a When press fitting, take care that both seals and spacers will not come off. a Link press fitting force: 343 – 490 kN {35 – 50 ton}

12) Press fit until the link, spacer and bushing are fitted together. a Actually, you cannot see from outside if the above parts are fitted. Accordingly, control the hydraulic pressure of the link press. Set the relief pressure to a proper level and heighten the hydraulic pressure to that level. For setting of the relief pressure, see Preparation work. a Check that adjacent 2 links can turn around each other.

36


13) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes and check that the result is within the standard range. a If the distance between the shoe bolt holes is longer than the standard range, disassemble and check for abnormality, then press fit again. a If the distance between the shoe bolt holes is shorter than the standard range and the shoe cannot be installed, the spacer or bushing end may be worn more than repair limit. In this case, disassemble and replace the parts.

14) After each link is assembled, bleed air from the pin by using tool S6 and check the sealing performance. a Keep the degree of vacuum inside the pin at 91 – 95 kPa {680 – 710 mmHg} for 5 seconds and check that the pressure does not change. If the pressure changes, disassemble and check the seal. If the seal is free from abnormality, assemble again.

D155A-6


SEN03371-00

16) After supplying oil, drive in the small plug into the specified position, using tool S2. a Apply G090 around the small plug. a Drive in the small plug to the following depth. Driving depth from end: 7.5 ± 1 mm

15) Using tool S7, supply oil (G090) until the oil supply pressure rises to 196 – 294 kPa {2 – 3 kg/cm2}. a In a cold or very cold district, supply K OM AT SU genu ine oil ( 150- 0919270 for cold district or 195-3261990 for very cold district) having better low-temperature characteristics instead of G090. a If the oil pressure is heightened too much, it has bad effects on the seal. Take care.

17) Assemble the master link on the pin side at last. a Check that the master links on the right and left sides are press fitted in parallel. a

D155A-6

Determine oil level (a) as follows; supply oil (d) so that depth (L) of the hollow of pin hole (c) will be in the following range when the link is left with small plug side (b) up (with the link assembly on its side) for 30 minutes. Dimension (L): 35 – 65 mm

3.

Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. a When reusing (reversing) the bushing, set the worn outside face of the bushing to the shoe mounting side of the link (set the bushing with the worn outside surface up on the link press). 2 Shoe bolt: Molybdenum disulfide grease (LM-P) 3 Shoe bolt (Regular link) Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 120° ± 10°

37

SEN03371-00

2) 3)

4) 5)

When installing a 2-piece shoe, place the assembled 2-piece shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushingside master link (2) together and set them to each other by the mating faces. Place shoe (3) and fit the mating surfaces of the links. Check that master bolts (4) can be tightened easily with the fingers, then connect the links with the master bolts. 2 Master bolt: Molybdenum disulfide grease (LM-P) 3 Master bolt (Master link) Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 180° ± 10°


When recycling for grease lubricated track 1. Preparation work 1) Cleaning of seal assembly Remove the seal assembly from the link and divide it into the seal ring (1) and load ring (2), and then clean them. a Since the seal ring and load ring are deteriorated easily by the cleaning liquid, clean them quickly. After cleaning them, wipe off the cleaning liquid from them.

2)

a

38

When reusing the pin, chamfer its end corners carefully with a grinder so that it will be press fitted smoothly.

Tighten the bolts in the order of 1 – 4.

D155A-6


3)

Using tools S2 and S4, drive the large and small plugs (3) into the pin (4). 1] Insert each plug through the plug insertion window into the guide hole. a Apply oil to the plug. 2] Push the bar with the hand until the plug stops. 3] Push the plug with the bar to press the guide against the pin. 4] Drive in the bar with a hammer. a Driving distance (a) from pin end: Small plug: 7.5 ± 1 mm Large plug: 6.0 ± 2 mm a If the plugs were not pulled out of the pin when the shoe was disassembled, reuse them as they are.

4) 5)

D155A-6

SEN03371-00

6)

Installation of seal assembly Clean the counterbore portion (d) of the link carefully. Using tool S5, push in the seal to the bottom. a If grease sticks to the counterbore portion of the link or seal assembly, the seal will turn and its sealing performance will lower. Accordingly, do not apply any grease.

7)

Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. a For the standard dimensions, see "Dimensions table of press fitting jig of link press". a If the pin end (part P) or the sides of the link (parts Q and R) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on the right and left sides will be even.

If the outside of the pin, surfaces of the spacer, and ends and inside of the bushing are dirty, clean them. Apply grease to the outside of the pin and surfaces of the spacer.

39

SEN03371-00

2.

Assembly of link 1) Apply lithium grease (G2-LI) to the mating surfaces of the pin and bushing and assemble them, then set them before the jaw of the link press. a When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press).


3)

4)

5) 2)

40

Press fit the master links on both bushing sides to the bushing with the shoe fitting faces up. a At this time, use the master links on the pin side as supports. a Press fitting force for bushing: 88 – 304 kN {9 – 31 ton}

Using the shoe bolt hole pitch gauge, press fit the master links until the distance between the shoe bolt holes of both links is the standard value. a Blow off all the steel chips caused by press fitting of the bushing with compressed air. Reverse the master links and check that they are press fitted in parallel.

Measure the projections of the bushing on the right and left sides with a depth gauge. a Adjust the press fitting jig of the link press so that the projections on the right and left sides will be even.

D155A-6


6)

SEN03371-00

Send the master links and set the next pin and bushing. a When reusing a pin, install it so that its side hole will be on the link tread side similarly to a new one. If it is not installed so, its strength may be lowered. Accordingly, indicate the direction of the side hole on the end face to prevent a mistake. a If the outside of the pin is worn, install it so that the un-worn surface will be on the traction side. In this case, install the pin so that its side hole will be on the link tread side.

3.

7)

D155A-6

Set the right and left links and operate both pushing jigs to press fit the pin and bushing simultaneously. a If the pin and bushing have play when they are press fitted, the seal may come off the link. To prevent this, press fit smoothly. If the seal comes off the link, stop press fitting and set the seal to the link correctly, then start press fitting again. a Final pressing force for pin and bushing: 343 – 490 Nm {35 – 50 ton} Final pressing force C 1.8 x Average press fitting force (Adjust the relief pressure of the link press to set the final pressing force.)

8)

Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes. When the distance is in the standard range, stop press fitting.

9)

Assemble the master link on the pin side at last. a Check that the master links on the right and left sides are press fitted in parallel.

Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. a When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press). 2 Shoe bolt: Molybdenum disulfide grease (LM-P) 3 Shoe bolt (Regular link): Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 120° ± 10°

41

SEN03371-00

2) 3)

4) 5)

When installing the assembled 2-piece track shoes, place them on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushingside master link (2) together and set them to each other by the mating faces. Place shoe (3) and fit the mating surfaces of the links. Check that master bolts (4) can be tightened easily with the fingers, then connect the links with the master bolts. 2 Master bolt: Molybdenum disulfide grease (LM-P) 3 Master bolt (Master link) Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 180° ± 10°

a

42


Tighten the bolts in the order of 1 – 4.

D155A-6


SEN03371-00

Dimensions table of fitting jig of link press

Adjustment Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. a If the pin end (part P) or the sides of the link (parts Q and R) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on the right and left sides will be even. Unit: mm

Precaution 1. The link receiving faces of jaw (5) must be vertical. 2. Wear plate (6) should be replaceable.

Dimensions of jig

D155A-6

a

b

c

4.5

3.25

50.6

43

SEN03371-00


Disassembly and assembly of 1 link in field

1

1

2

3

T

4

5

6

7

44

791-675-5580

Guide

t 1

t 1

791-685-9510

Frame

t 1

t 2

791-685-9520

Frame

t 1

Bolt

t 2

791-685-9530

Rod

t 1

790-101-1102

Pump

t 1

791-685-9540

Rod

t 1

790-101-4300

Cylinder t 1 (1,470 kN {150 ton})

791-685-9550

Nut

t 3

Bolt

t 4

791-685-9510

Frame

t 1

791-685-9560

Adapter

t 1

Frame

t 1

791-126-0150

791-685-9520

Bolt

t 1

Rod

t 1

01010-51030

791-685-9530

Extension

t 1

Nut

t 1

791-685-9620

791-685-9550

Adapter

t 1

791-685-9560

Bolt

t 1

791-675-5542

Guide

t 1

Adapter

t 1

791-675-5560

791-675-9570

Pump

t 1

Eyebolt

t 1

790-101-1102

04530-12030 790-101-1102

Pump

t 1

790-101-4300


790-101-4300


791-675-5560

Guide

t 1

791-675-5542

Adapter

Rod

t 1

t 1

791-685-9540

790-101-1102

Pump

Nut

t 3

t 1

791-685-9550 791-675-5520

Guide

t 1

790-101-4200


t 1

791-675-5530

Pusher

t 1

12 791-670-3270

Guide

t 1

791-675-9581

Adapter

t 1

791-675-9590

Guide

01010-52460

Bolt

01010-51440

8

9

T

10

11

01010-51030

Bolt

t 1

791-126-0150

Adapter

t 1

791-685-9620

Extension

t 1

791-675-5560

Guide

t 1

790-101-1102

Pump

t 1

791-675-9570

Adapter

t 1

790-101-4200


t 1

01010-51030

Bolt

t 1

791-675-5542

Adapter

t 1

791-675-5571

Adapter

t 1

790-101-1102

Pump

t 1

790-101-4300


13

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

D155A-6


Disassembly of 1 link in field k Only how to use the tools is explained below. For details of disassembly and assembly, see "General disassembly (or assembly) of track shoe". 1.

2.

SEN03371-00

3.

Insert the rod of tool T4 from the cylinder side and install it with the nuts (2 pieces). Pass the rod through the hole of link (1) and install it.

4.

Set tool T5 (adapter, guide and pusher) and apply pressure to pull out pin (3). When the cylinder reaches the stroke end, insert tool T5 (extension) between the adapter and guide and repeat the work.

5.

Set tool T6 (294 kN {30 ton}) puller) and spacer [1] to the center of the roller tread of the link to be disassembled and apply hydraulic pressure to the puller to open and disconnect the link by 5 – 6 mm.

Using 2 bolts (2), install tool T1 (adapter, guide and bolt) to link (1). a The track bolts may be used as 2 bolts (2).

Assemble tool T2 (pump and cylinder of 150 ton) and tool T3 (frame, rod, adapter, 1 bolt and eyebolt) and sling them together and set them on the shoe.

D155A-6

45

SEN03371-00

Assembly of 1 link in field 1. Assemble the link sub-assembly. 1) Set tool T7 the link end face and press fit bushing (1). a Busing press fitting force: 88 – 304 kN {9 – 31 ton}

2)

2.

46


3.

Set link (4) on the opposite side and support it with tool T8 (guide).

4.

Set tools T9 and T10 as in the procedure for pulling out the pin. Using tool T9 (adapter, extension, guide, adapter and bolt) for (d) on the bushing side and tool T10 (extension, guide, adapter and bolt) for (c) on the pin side, press fit (d) and (c) alternately. a Pin press fitting force: 284 – 686 kN {29 – 70 ton} a Bushing press fitting force: 88 – 304 kN {9 – 31 ton}

5.

Using tool T11 (294 kN {30 ton} puller) as in the disassembly procedure, push open link (5) on the bushing side.

Set tool T7 to the end face of the link (on the pin side) and press fit pin (2). a Set the pin with its side hole (a) directed toward link tread (b). a Pin pressing force: 284 – 686 kN {29 – 70 ton}

Set the link to be connected to link sub-assembly (3).

D155A-6


6.

Set pin-side link (6) to bushing-side link (5) and connect them by tool T12 (guide), and then remove tool T11 (puller).

7.

Set tool T5 to pin (7). Using tool T13 (adapter, bolt and guide), press fit pin (7). 3 Pin press fitting hole of link: Gasket sealant (198-32-19890) Cylinder: (b), Frame side: (e) a Set the pin with its side hole directed toward the link tread. a Pin press fitting force: 284 – 686 kN {29 – 70 ton}

D155A-6

SEN03371-00

47

SEN03371-00


Disassembly and assembly of master link

2.

1

790-101-1102

Pump

t 1

790-101-4200


t 1

791-675-9701


t 1

790-101-1102

Pump

t 1

790-101-4200


t 1

790-101-4300


3

791-432-1110

Plug push tool

t 1

4

790-701-3000

Seal checker

t 1

5

791-932-1110

Plug push tool

t 1

1

U 2

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Disassembly a

1.

48

For the using method of tool U2, see "Disassembly in field". Removal of track shoe assembly Remove the track shoe assembly from the track frame. For details, see "Spreading and installation of track shoe assembly".

Removal of master link 1) Cutting and removal of master link on bushing side with gas Cut at (a) with gas and remove the hatched part. Pull out master links (5) and (6) by moving them up and down. Then, remove pins (8) and (9) from regular link (7) by pressing them up and down with the press. Special tool : 1. Gas cutting machine : 2. Tool U2

2)

Removal of master link on pin side Cut at (b) with gas and remove the hatched parts. Remove pin (10) from link (11) by pressing it down with the press, and then remove pin (10) and link (12) from bushing (13) simultaneously. Special tool : 1. Gas cutting machine : 2. Tool U2

D155A-6


SEN03371-00

Assembly a

1.

2.

2)

Set spacer (3) and seal assembly (4) to the counterbore of the link at the connecting section.

3)

Align the holes of the pin and bushing and connect by guide pin [2].

4)

Press fit pin (5) with tool U2 and install master link (1) on the bushing side. 2 Apply gasket sealant (198-32-19890) to the pin hole of the link. a Direct the side hole of the pin toward the link tread.

For the using method of U2, see "Assembly of 1 link in field". Assembly of link on bushing side 1) Press fit master link (1) on the bushing side to bushing (2) with the press. a When press fitting the right and left master links, take care extremely that they will be in parallel. a Do not damage the mating faces of the master links and end of the bushing. Unit: mm L1

169 ± 0.7

L2

219.8 ± 0.7

D1

27 drill hole

D2

24 x 2.0

Installation of link on bushing side 1) Push open the central part of the link tread with tool U1 as shown in the figure (Open the link tip by 10 mm). (a): 5 mm

D155A-6

49

SEN03371-00

5) 6)


2)

Install the shoe to the link at the connecting section. Drive in large plug (6) with tool U3, add oil with tool U4, and drive in small plug (7) with U5. a When press fitting the right and left master links, take care extremely that they will be in parallel (on the bushing side and pin side). a Do not damage the mating faces of the master links and end of the bushing. a Take care extremely that dirt or sand will not stick to the seal, spacer, ends of bushing and tap mating faces of the master link.

3)

4.

3.

50

Assembly of link on pin side 1) Set spacer (3) and seal assembly (4) to the counterbore of the master link.

Insert pin (9) in bushing (8), set master links (10) on the pin side from the right and left sides, and press fit them with tool U2. Drive in large plug (11) with tool U3, add oil with tool U4, and drive in small plug (12) with U5.

Connection of master link 1) Place the assembled 2-piece track shoes on a level place in 1 line with the shoe side up. 2) Pull pin-side master link (13) and bushingside master link (14) together and set them to each other by the mating faces. 3) Place the shoe and fit the mating surfaces of the links. 4) Check that the master bolts can be tightened easily with the fingers, and then connect the links with the master bolts. 2 Shoe bolt: Molybdenum disulfide grease (LM-P) 3 Shoe bolt (Master link) Initial torque: 590 ± 60 Nm {60 ± 6 kgm} Retightening angle: 180° ± 10°

D155A-6


SEN03371-00 a

Removal and installation of equalizer bar assembly

1

k

W

791T-650-2130 Sleeve

t 1

790-101-2420

Adapter

t 1

791-502-4140

Screw

t 1

790-101-2540

Washer

t 2

790-112-1180

Nut

t 2

790-101-4000


790-101-1102

Hydraulic pump

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Q

t 1

5.

Operate hydraulic jacks [2] slowly to lower the machine until the equalizer bar reaches the right and left track frames.

6

Disconnect grease hose (5).

7.

Remove lock plate (6).

Removal 1.

2.

Remove the engine undercover and power train undercover. 4

Engine undercover: 220 kg

4

Power train undercover: 270 kg

Repeat steps 3 and 4 to remove the pin on the opposite side. If the track frame assembly on the opposite side is floated before the pin is pulled out, support it on a block, etc.

Set a hydraulic jack under the center of the equalizer bar to raise the machine and set support stands [1] and hydraulic jacks [2] under the radiator guard.

3.

Remove 2 bolts (1) and cover (2). [*1]

4.

Remove lock plate (3) and side pin (4). [*2] a If the equalizer bar hole and track frame hole are not aligned, the pin cannot be removed easily. Accordingly, adjust the hanging height of the track frame properly.

D155A-6

51

SEN03371-00

8.

Sling equalizer bar assembly (7) with a crane and a chain block.


Installation q


[*1]

2 3

Threaded part of cover mounting bolt: Adhesive (LT-2) Cover mounting bolt: 784 – 981 Nm {80 – 100 kgm}

[*2]

k

9.

Using tool W, pull out center pin (8). [*3] k Do not operate the hydraulic device in front of or under the puller, but operate as far from the puller as possible.

When aligning the pin holes, never insert your fingers in them. a Before installing the side pin, adjust the height of the main frame with the hydraulic jacks to align the equalizer bar hole with the track frame hole. 2 Seal lip: Grease (G2-LI) [*3]

k

When aligning the pin holes, never insert your fingers in them. a Before installing the center pin, sling the equalizer bar to align the equalizer bar hole with the main frame hole. 2 Equalizer bar center bushing: Grease (G2-LI) [*4] Install the equalizer bar with the grease fitting side forward.

10. While operating the chain block and crane, remove equalizer bar assembly (7). [*4] 4 k

52

Equalizer bar assembly: 240 kg

Do not lower the machine after removing the equalizer bar assembly.

D155A-6


Disassembly and assembly of equalizer bar assembly

SEN03371-00

Assembly

1

1.

Center bushing Using the press, press fit center bushing (5) to equalizer bar (4). a Press fitting force for center bushing: 47.1 – 131.4 kN {4.8 – 13.4 ton} 2 Periphery of spherical bushing: Molybdenum disulfide grease (LM-P)

2.

Side bushing 1) Install ring (2) to one side of equalizer bar (4). 2) Using the press, press fit spherical bushing (3) to equalizer bar (4). a Press fitting force for spherical bushing: 27.4 – 64.7 kN {2.8 – 6.6 ton} 2 Periphery of spherical bushing: Molybdenum disulfide grease (LM-P)

Disassembly 1.

Remove the equalizer bar. For details, see "Removal and installation of equalizer bar assembly".

2.

Side bushing 1) Remove seal (1). 2) Remove ring (2).

3)

3.

Using tool [1], remove spherical bushing (3) from equalizer bar (4).

Center bushing Remove center bushing (5) from equalizer bar (4).

D155A-6

53

SEN03371-00

3) 4)

54


Install ring (2) on the opposite side. Using the press, press fit seal (1). a Press fitting force for seal: 6.9 – 18.6 kN {0.7 – 1.9 ton} a The metallic part of the seal must not project from the equalizer bar end.

D155A-6


Removal and installation of segment teeth

SEN03371-00

Installation

1

Removal 1.

Stop the machine in a position where the segment teeth can be removed easily (between the shoe and track frame).

2.

Remove the mounting bolts and segment teeth (1). [*1]

D155A-6

q


[*1] a When installing, press segment teeth (1) toward the center of sprocket hub (2) and tighten the nuts in the order of 1 o 2 o 3. 2 Threaded part of segment teeth mounting nut: Adhesive (LT-2) 3 Segment teeth mounting nut: 1,176 ± 98 Nm {120 ± 10 kgm}

55

SEN03371-00




56

D155A-6

SEN03372-00


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Hydraulic system Removal and installation of hydraulic tank assembly...................................................................................... 2 Removal and installation of hydraulic pump assembly ................................................................................... 4 Disassembly and assembly of hydraulic cylinder assembly ........................................................................... 7

D155A-6

1

SEN03372-00

Removal and installation of hydraulic tank assembly


1

Removal k

1.

Lower the work equipment to the ground and release the residual pressure in the piping, referring to Testing and adjusting, "Releasing residual pressure in hydraulic circuit". Then, loosen the hydraulic tank cap gradually to release the internal pressure of the hydraulic tank.

5.

Disconnect clamp of oil level gauge (3).

6.

Disconnect clamp of oil filler pipe (4).

7.

Disconnect hoses (5) – (8).

8.

Disconnect suction tube (9).

9.

Remove the 4 mounting bolts at the hydraulic tank bottom and lift off hydraulic tank assembly (10).

Drain the oil from the hydraulic tank. 6


2.

Remove the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly".

3.

Remove control valve cover (1).

4

4.

2

Hydraulic tank assembly: 100 kg

Disconnect hose (2) between the control valves from the hydraulic tank.

D155A-6


SEN03372-00

Installation q


q

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

q

Bleeding air Bleed air from each part. For details, see Testing and adjusting, "Bleeding air from each part".

D155A-6

3

SEN03372-00

Removal and installation of hydraulic pump assembly


1

2) 3)

Disconnect hoses (3), (4), (5) and (6). Disconnect accumulator (7) and hose together.

4) 5)

Disconnect hoses (8), (9) and (10). Remove block (11).

6)

Disconnect wiring harness connectors TVC (12), FAC (13) and HDT (14). Remove wiring harness bracket (15).

Removal k

k

1.

Lower the work equipment to the ground and release the residual pressure in the piping, referring to Testing and adjusting, "Releasing residual pressure in hydraulic circuit". Then, loosen the hydraulic tank cap gradually to release the internal pressure of the hydraulic tank. Disconnect the cable from the negative (–) terminal of the battery. Drain the oil from the hydraulic tank and power train case. 6 6

Hydraulic tank: Approx. 85 l Power train case: Approx. 90 l

2.

Remove the floor frame assembly. For details, see "Removal and installation of floor frame assembly". a Remove the floor frame assembly only when removing the work equipment and HSS pump assembly and power train and lubricating oil pump assembly.

q

Removal of work equipment pump assembly 1) Disconnect the centralized pressure pickup ports and block (1) together.

7)

4

D155A-6


8)

Disconnect suction tube (16). a Remove the suction tube mounting bolts on the fuel pump side, too.

SEN03372-00

q

Removal of power train and steering lubricating oil pump assembly 1) Disconnect tubes (1), (2) and (3). 2) Sling power train and steering lubricating oil pump assembly (4), remove 2 mounting bolts (5), and lift off pump assembly (4). 4

9)

Sling work equipment pump assembly (17), remove 2 mounting bolts (18), and lift off work equipment pump assembly (17). 4

Work equipment pump assembly: 110 kg q

D155A-6

Power train and steering lubricating oil pump assembly: 30 kg

Removal of cooling fan pump assembly 1) Remove the floor mat and cover. 2) Disconnect wiring harness connector FAC (1).

5

SEN03372-00

3) 4) 5)

Disconnect hoses (2), (3) and (4). Disconnect suction tube (5). Sling cooling fan pump assembly (6), remove 4 mounting bolts (7), and lift off cooling fan pump assembly (6). 4

q

Cooling fan pump assembly: 25 kg

Installation q


q

Refilling with oil (Hydraulic tank and power train case) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

q

Bleeding air Bleed air from each part. For details, see Testing and adjusting, "Bleeding air from each part".

Removal of scavenging pump assembly 1) Remove suction tube (1). 2) Disconnect outlet tube (2). 3) Remove the 2 mounting bolts and scavenging pump assembly (3). 4

6


Scavenging pump assembly: 20 kg

D155A-6


SEN03372-00

Disassembly and assembly of hydraulic cylinder assembly

Disassembly

1

1.

1 2

3

Y 4

5

6

790-502-1003

Cylinder repair stand

t 1

790-101-1102

Hydraulic pump

t 1

790-102-3802

Multi-wrench

t 1

790-201-1702

Push tool kit

t 1

790-201-1721

• Push tool

1

790-201-1821

• Push tool

1

790-201-1841

• Push tool

1

790-201-1851

• Push tool

1

790-201-1861

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1500

Push tool kit

790-201-1630

• Plate

1

790-201-1650

• Plate

1

790-201-1660

• Plate

1

790-201-1670

• Plate

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-720-1000

Expander

t 1

796-720-1670

Ring

t 1

Piston rod assembly Blade lift cylinder 1) Set cylinder assembly (1) to tool Y1. 2) Using the hydraulic pump or the power wrench and tool Y2, remove head assembly (2). 3) Pull piston rod assembly (3). a Put an oil pan under the cylinder to receive the oil.

q

t 1

07281-01279

Clamp

t 1

796-720-1690

Ring

t 1

07281-01919

Clamp

t 1

796-720-1720

Ring

t 1

07281-02429

Clamp

t 1

790-102-4300

Wrench

t 1

790-102-4310

Pin

t 2

D155A-6

2. Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Remove the tubes. a Blade lift cylinder and ripper cylinder

q

Blade tilt cylinder, ripper lift cylinder, and ripper tilt cylinder 1) Remove the mounting bolt assembly and disconnect head assembly (4). q Width across flats of blade tilt cylinder: 16 mm q Width across flats of ripper lift and tilt cylinders: 18 mm 2) Pull piston rod assembly (5). a Put an oil pan under the cylinder to receive the oil.

7

SEN03372-00

3.

Piston assembly Blade lift cylinder 1) Remove the mounting bolts and spacer (6) and pull out valve (7). 2) Pull out piston assembly (8). 3) Remove backup rings (9) and O-ring (10). 4) Remove retainer (11).


q

q

Ripper tilt cylinders 1) Remove the mounting bolts and spacer (16). 2) Pull out piston assembly (17). 3) Remove backup rings (18) and O-ring (19).

4) 5)

Disassembly of piston assembly 1] Remove wear rings (12). 2] Remove piston ring (13). a Do not remove seat (14) and valve (15) from the piston.

q

8

Disassembly of piston assembly 1] Remove wear rings (20). 2] Remove piston ring (21).

Ripper lift cylinder and ripper tilt cylinder 1) Set piston rod assembly (5) to tool Y1.

D155A-6


2)

SEN03372-00

Remove lock screw (22) of piston assembly (17). q Screw size: M12 x Pitch 1.75

4. a

Head assembly 1) Remove head assembly (2) or (4).

If screw (22) is crushed so much that it cannot be removed, tighten it and cut threads of the screw hole, and then remove it.

2)

D155A-6

3)

Using tool Y6, remove piston assembly (17) from piston rod (23).

4)

Disassembly of piston assembly 1] Remove backup ring and O-ring (24). 2] Remove wear ring (25). 3] Remove piston ring (26).

Disassembly of head assembly 1] Remove O-ring (27). (Blade lift cylinder only) 2] Remove O-ring (28) and backup ring (29). 3] Remove packing (30). 4] Remove ring (31). 5] Remove snap ring (32) and dust seal (33). 6] Remove snap ring (34) and bushing (35).

9

SEN03372-00

Assembly a

Apply engine oil to the sliding surface of each part. When assembling, take care not to damage the rod packing, dust seal and O-ring.

1.

Head assembly 1) Assembly of head assembly

1]


3]

Using tool Y4, install dust seal (33).

4]


5] 6] 7]

Install ring (31). Install packing (30). Install O-ring (28) and backup ring (29). Install O-ring (27). (Blade lift cylinder only)

Using tool Y3, press fit bushing (35).

8] 2]

10


D155A-6


2)

2.

4] 5]

Install head assembly (2) or (4) to the piston rod.

Piston assembly q Ripper lift cylinder and ripper tilt cylinder 1) Assembly of piston assembly 1] Using tool Y5, expand piston ring (26). a Set the piston ring to tool Y5 and turn the handle of the tool by 8 – 10 turns to expand the piston ring. 2] Remove piston ring (26) from tool Y5 and install it to the piston. 3] Using tool Y5, compress piston ring (26).

D155A-6

SEN03372-00

2)

Install wear ring (25). Install backup ring and O-ring (24). a Before installing the backup ring, warm it in water at 50 – 60 °C. a Apply grease to the O-ring and backup ring so that the backup ring will not open.

Install piston assembly (17) to piston rod (23) and set piston rod assembly (5) to tool Y1.

11

SEN03372-00

3)

When reusing piston rod (23) and pist o n a s s e m bl y ( 1 7 ) , i n s ta l l th e m according to the following procedure. a Remove burrs and fins from the threaded part with a file. a Clean the parts thoroughly and remove metal chips and dirt. 1] Using tool Y6, tighten piston assembly (17) into piston rod (23) until the screw holes are aligned.

2]

12


4)

When either or both of piston rod (23) and piston assembly (17) are new, install them according to the following procedure. 1] Using tool Y6, tighten piston assembly (17). 3 Piston assembly: 294 ± 29.4 Nm {30 ± 3.0 kgm} 2] Make 1 screw hole to install the screw. a Apply the drill to the groove in the threads between the piston and piston rod and cut threads horizontally. q Thread cutting dimensions (mm): Tap drill diameter: 10.3 Tap drill depth: 27 Tap size: 12 x 1.75 Tapping depth: 20 3] After making the screw hole, remove chips and dirt and clean thoroughly.

Install screw (22). a Before installing the screw, degrease and dry its threaded part thoroughly. a After installing the screw, bend 4 places around it. 2 Threaded part of screw: Adhesive (LOCTITE No. 262) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} a After installing the screw, bend 4 places around it.

D155A-6


4]

q

SEN03372-00

2)

Install screw (22). a Before installing the screw, degrease and dry it thoroughly. a After installing the screw, bend 4 places around it. 2 Threaded part: Adhesive (LOCTITE No. 262) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm}

3)

Blade tilt cylinder 1) Using tool Y5, install piston ring (21) and wear ring (20), similarly to steps 2-1)-1] – 4] above. q

D155A-6

Install O-ring (19) and backup ring (18) to the piston rod and then install piston assembly (17). a Before installing the backup ring, warm it in water at 50 – 60 °C. a Apply grease to the O-ring and backup ring so that the backup ring will not open. Fix with spacer (16) and tighten the mounting bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98.1 – 122.6 Nm {10 –12.5 kgm}

Blade lift cylinder 1) Using tool Y5, install piston ring (13) and wear ring (12), similarly to steps 2-1)-1] – 4] above.

13

SEN03372-00

2) 3)

4) 5)

3.

14

Install retainer (11). Fit O-ring (10) and install backup ring (9). a Before installing the backup ring, warm it in water at 50 – 60 °C. a Apply grease to the O-ring and backup ring so that the backup ring will not open. Install piston assembly (8). Install valve (7) to spacer (6) and install them with the mounting bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98.1 – 122.6 Nm {10 –12.5 kgm}


q

Blade tilt cylinder, ripper lift cylinder and ripper tilt cylinder 1) Install piston rod assembly (5) to the cylinder. 2 Sealing part: Grease (G2-LI) a Push in the piston rod to the stroke end. 2) Tighten head assembly (4) with the mounting bolts. 3 Mounting bolt: q Blade tilt (343 ± 34.3 Nm {35 ± 3.5 kgm}) q Ripper lift (343 ± 34.3 Nm {35 ± 3.5 kgm}) q Ripper tilt (490 ± 49 Nm {50 ± 5.5 kgm})

Piston rod assembly q Blade lift cylinder 1) Set cylinder (1) to tool Y1. 2) Install piston rod assembly (3) to the cylinder. 2 Sealing part: Grease (G2-LI) a Push in the piston rod to the stroke end. 3) Using tool Y2, tighten head assembly (2). 3 Head assembly: 932 ± 93.0 Nm {95 ± 9.5 kgm}

D155A-6


D155A-6

SEN03372-00

15

SEN03372-00




16

D155A-6

SEN03373-00


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Work equipment Removal and installation of blade assembly ................................................................................................... 2 Disassembly and assembly of multi-shank ripper ........................................................................................... 4

D155A-6

1

SEN03373-00


Removal and installation of blade assembly 1 Removal k

Lower the work equipment to a level place and set blocks [1] under the right and left straight frames securely.

1.

Remove cap (1) of the lift cylinder assembly. [*1] a Check the quantity and thickness of the shims.

2.

Sling lift cylinder assembly (2). Run the engine and retract the piston fully. Install the cylinder fixing device and fix the lift cylinder assembly to the radiator guard. a Bind the piston rod with wires etc. so that it will not come out. q Similarly, disconnect the cylinder on the opposite side from the blade. k Release the residual pressure in the piping, referring to Testing and adjusting, "Releasing residual pressure in hydraulic circuit". Then, loosen the hydraulic tank cap gradually to release the internal pressure of the hydraulic tank.

2

3.

Remove right and left covers (3).

4.

Disconnect hose (4). a Plug the hoses so that dirt will not enter the piping.

5.

Remove right and left trunnion caps (5).

6.

Remove blade assembly (6). [*2] a Run the engine and move the machine slowly in reverse to disconnect the blade assembly from the trunnion.

D155A-6


SEN03373-00

Installation q


[*1] a Adjust clearance (a) at the cap mating surfaces to the following range with the shim and check that the cylinder turns smoothly. q Standard clearance (a): 0.2 – 0.5 mm q Standard shim thickness: 4 mm a After installing the blade, adjust the blade tilting distance. For details, see Testing and adjusting, "Adjusting blade". q


[*2] a Adjust height (b) and width (c) of the right and left straight frames to the following values with blocks [1] etc. q Height (b) of trunnion: Approx. 636 mm q Width (c) of frame: Approx. 3,053 mm

D155A-6

3

SEN03373-00

Disassembly and assembly of multi-shank ripper


1

Disassembly a

Plug the disconnected pipings and hoses so that dirt will not enter them.

1.

Run the engine and set the ripper in the maximum raising and maximum tilt-in position.

2.

Sling shank (1), remove the lock pin to remove mounting pin (2), and lower shank (1) slowly to remove. 4

3.

4.

4

Shank: 270 kg

5.

Sling tilt cylinder assembly (5), remove the lock plate, and pull out pin (6) on the rod side. a Run the engine, retract the piston rod fully, and lower it to the arm. a Install the pin to the beam temporarily since it is used when the beam is removed. k Release the residual pressure in the piping, referring to Testing and adjusting, "Releasing residual pressure in hydraulic circuit". Then, loosen the hydraulic tank cap gradually to release the internal pressure of the hydraulic tank.

6.

Disconnect lift cylinder hose (7) and tilt cylinder hose (8) and move them toward the fuel tank.

Set support stands [1] under the beam, set block [2] under the arm, and lower the ripper assembly.

Sling lift cylinder assembly (3), remove the lock plate, and pull out pin (4) on the rod side. a Run the engine, retract the piston rod fully, and lower it to the arm.

D155A-6


7.

Sling lift cylinder assembly (3), remove the lock plate, pull out pin (9), and lift off lift cylinder assembly (3). 4

8.

SEN03373-00

Assembly 1.

Lift cylinder assembly: 190 kg

4

a

Sling tilt cylinder assembly (5), pull out pin (9), and lift off tilt cylinder assembly (5). 4

Sling beam (10), remove the lock plates, pull out right and left pins (11), and lift off beam (10). 4

Arm: 650 kg Set block [2] under the arm.

Tilt cylinder assembly: 260 kg

2. 9.

Sling arm (12), install right and left pins (13), and fix them with the lock plates.

Sling beam (10), install right and left pins (11), and fix them with the lock plates. 4

a

Beam: 1,250 kg Set support stands [1] under the beam.

Beam: 1,250 kg

10. Sling arm (12), remove the lock plates, pull out right and left pins (13), and lift off arm (12). 4

D155A-6

Arm: 650 kg

5

SEN03373-00

3.

Sling tilt cylinder assembly (5) and install pin (9).


7.

Sling lift cylinder assembly (3), run the engine, extend the piston rod, align the pin holes, install pin (4), and fix it with the lock plate.

8.

Run the engine and set the ripper in the maximum raising and maximum tilt-in position.

9.

Pass a wire through the shank mounting hole of the beam and sling shank (1). Install pin (2) and fix it with the lock pin.

4

a

4.

Tilt cylinder assembly: 260 kg After installing, lower the rod side to the arm.

Sling lift cylinder assembly (3), push in pin (9), and fix it with the lock plate. 4

a

Lift cylinder assembly: 190 kg After installing, lower the rod side to the arm.

4

5.

Connect tilt cylinder hose (8) and lift cylinder hose (7).

6.

Sling tilt cylinder assembly (5), run the engine, extend the piston rod, align the pin holes, install pin (6), and fix it with the lock plate.

6

Shank: 270 kg

D155A-6


SEN03373-00

10. Greasing After assembling, supply sufficient amount of grease to each pin. 2 Pin: Grease (G2-LI) q


D155A-6

7

SEN03373-00




8

D155A-6

SEN03375-00


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Cab and its attachments Removal and installation of operator's cab assembly ..................................................................................... 2 Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 4 Removal and installation of operator's cab and floor frame assembly.......................................................... 13

D155A-6

1

SEN03375-00

Removal and installation of operator's cab assembly


6.

Disconnect wiring harness connector DSH (9). [*2]

7.

Remove mounting bolts (10) at the bottom of the operator's cab. a Remove the bolts on the right and left side. [*3]

8.

Remove mounting bolts (11) in the operator's cab. a Remove the bolts on the right, left and rear side. [*4]

1

Removal k


1.

Remove cigarette lighter cover (1) and disconnect wiring harness connector ACC.

2.

Remove garnishes (2) – (4).

3.

Disconnect 4 window washer hoses (5). [*1]

4.

Disconnect wiring harness connectors CBPW (6) and WST (7).

5.

2

Remove cover (8).

D155A-6


9.

Lift off operator's cab assembly (12). 4

Operator's cab assembly: 400 kg

SEN03375-00

Installation q


[*1] a Connect the window washer hoses according to their band colors. Window washer hoses Red ................... Right door Blue................... Left door Black ................. Rear window No color band ... Front window [*2] a Before installing, check that seal rubber parts (brown, 2 pieces) are installed to the connector and they are not broken. 3 Connector mounting bolt: 2.83 ± 0.28 Nm {0.288 ± 0.028 kgm} [*3], [*4] 1) Tighten bolts (1) – (23) in the numeric order shown in the attached drawing.

a 3 Part marked with A (M16):

279 ± 27.9 Nm {28.5 ± 2.8 kgm} Part marked with * (M20): 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Part marked with a (M24): 294 ± 29.4 Nm {30.0 ± 3.0 kgm}

2)

D155A-6

Retighten bolts (1) – (21) (M20, M24) by 60 ° ± 10 °.

3

SEN03375-00


Removal and installation of operator's cab glass (Stuck glass)

*

4

Among the panes of window glass of the operator's cab, the 3 panes of (1) and (2) on both sides are stuck. In this section, the procedure for replacing the stuck glass is explained.

1

(1): Front window glass (2): Left door window glass : Right door window glass (3): Both-sided adhesive tape (4): Trim seal (5): Door handle

D155A-6


SEN03375-00

793-498-1210

Lifter (Suction cup)

(The following figure shows the operator's cab of a wheel loader.) Sketch

X 1

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

t 2

Removal *

Remove the window glass to be replaced according to the following procedure.

1.

Using seal cutter [1], cut the adhesive between broken window glass (6) and operator's cab (metal sheet) (7).

a a

If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4].

(The following figure shows the operator's cab of a wheel loader.)

a

D155A-6

If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it.

2.

Remove the window glass.

5

SEN03375-00

Installation 1.

Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator's cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfaces. (If the painted surfaces are scratched, adhesion will be lowered.)

(The following figure shows the operator's cab of a wheel loader.)

2.

6


3.

Stick both-sided adhesive tape (3) along the inside edges of the front window glass sticking section and both door window glass sticking sections. a Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before sticking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take care that the both-sided adhesive tape will not float at each corner of the window frame. a Do not lap the finishing end of both-sided adhesive tape (3) over the starting end but make clearance (a) of about 5 mm between them.

Remove oil, dust, dirt, etc. from the sticking surfaces of cab (7) and window glass (8) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry.

D155A-6


4.

Install trim seals (4) to both door window glasses (2).

a

D155A-6

Install each trim seal (4) so that its finishing end and starting end will be jointed at position (c) and dimension (b) between the corner and position (c) will be 90 mm.

SEN03375-00

5.

Position the new window glass. 1) Using tool X1, set the window glass to the sticking position. Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then adjust it evenly. a Position front window glass (1) from inside of operator's cab (7). Adjust it so that the difference between black coated part and the metal sheet of operator's cab (7) will be even on the right, left, upper, and lower sides. a When positioning each door window glass (2), align handle holes (d) of door (9) (on the glass side and door metal sheet side) first. Then, adjust the door window glass so that the positional relationship between it and door metal sheet will be even all around the window. 2)

After positioning the glasses, stick tapes [6] between front window glass (1) and operator's cab (7) and the right, left, and lower parts of each door window glass (2) and each door (9), and then draw positioning line (e).

3)

Cut the tapes between window glasses (1) and (2) and operator's cab (7) with a knife, and then remove the window glasses. a Do not remove the tapes left on the window glasses and operator's cab before installing the window glasses.

7

SEN03375-00

6.

1)

Break aluminum seal (11) of the outlet of adhesive cartridge (10) and install the nozzle.

2)

Cut the tip of the adhesive nozzle (12) so that dimensions (f) and (g) will be as follows. q Dimension (f) : 10 mm q Dimension (g): 15 mm

3)

Set adhesive cartridge (10) to caulking gun [7]. a An electric caulking gun is more efficient.

Apply adhesive. 2

a a a a a

8


Adhesive:Sikaflex 256HV manufactured by Sika Japan Do not use primer. The using limit of the adhesive is 6 months after the date of manufacture. Do not use the adhesive after this limit. Keep the adhesive in a dark place where the temperature is below 25°C. Never heat the adhesive higher than 30°C. When reusing the adhesive, remove the all hardened part from the nozzle tip.

D155A-6


4)

SEN03375-00 a

Remove release tape of the both-sided adhesive tape (3a) on the glass side.

a a

5)

Apply adhesive (13) to the outside of bothsided adhesive tape (3) of the operator's cab.

7.

D155A-6

Apply adhesive (13) to dimensions (h) and (j) of both-sided adhesive tape (3) of operator's cab (7). q Dimension (h): 10 mm q Dimension (j) : 15 mm Apply adhesive (13) higher than bothsided adhesive tape (3). Apply the adhesive evenly.

Install the front window glass. 1) Using tool X1, match front window glass (1) to line (e) on positioning tapes [6] drawn in step 5 and install it to operator's cab (7). a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking the window glass, press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly.

9

SEN03375-00

3) 4)


Mask front window glass (1) and operator's cab (7) with masking tapes [8]. Fill the clearance between front window glass (1) and operator's cab (7) with caulking material (14) all around the window. 2 Caulking material: SEKISUI SILICONE SEALANT a The usable period of the following caulking material is 6 months after the date of manufacture. Do not use the caulking material after its usable period.

8.

5)

10

After applying caulking material (14) to front window glass (1), form it with the fingers as shown in the following figure. a Use rubber spatula [9] to form the caulking material around the handrail, etc. where it is difficult to form with the fingers.

Install both door window glasses. 1) Using tool X1, match both door window glasses (2) to lines (e) on positioning tapes [6] drawn in step 5 and install them to both doors (9). a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking each window glass, press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of each window glass firmly.

D155A-6


SEN03375-00

If adhesive (13) is projected from the trim seals (4) of stuck door window glasses on both sides, remove it with rubber spatula [9].

9. 3)

Fill the clearance between each door window glass and trim in the range of dimension (k). i) Mask the range of dimension (k) of each door window glass. ii) Fill clearance (m) between each door window glass (2) and trim seal (4) with caulking material. a The usable period of the following caulking material is 6 months after the date of manufacture. Do not use the caulking material after its usable period. a Apply the caulking material to joint (c) of the trim seal, too. 2 Caulking material: SEKISUI SILICONE SEALANT

D155A-6

Fix the window glasses. 1) Using styrene foam blocks [10] and rubber bands [11], fix the front window glass to fit it completely. a You may use sealing tapes to fix the front window glass. (The figure shows the operator's cab of a hydraulic excavator.)

11

SEN03375-00

2)


Immediately after sticking both door window glasses, install door handles (5), and lock the doors to fix the glasses.

10. After installing the window glasses, remove the primer and adhesive from them and the operator's cab. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glasses, do not give an impact to them. 11. Protect the stuck window glasses. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20°C and humidity of 60%). 2) After applying the adhesive, wait for at least 24 hours, before operating the machine actually.

12

D155A-6


Removal and installation of operator's cab and floor frame assembly

SEN03375-00

3.

Disconnect 8 PPC hoses (2) – (9). a (Color code of each hoses) (2) Red (6) Black-red (3) Yellow (7) Black-yellow (4) Green (8) Black-green (5) Brown (9) Black-brown

4.

Disconnect 4 clamps (10) – (13).

5.

Open side cover (14), and remove covers (15) and (16). a Both side of left and right.

1

Removal k k

k

a a k

Disconnect the cable from the negative (–) terminal of the battery. In the case that you do not drain the coolant, if you disconnect the heater hose when the coolant temperature in the radiator is high, you may be scalded. In this case, wait until the coolant temperature lowers and then disconnect the heater hose. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.

1.

Remove fuel tank assembly. For details, see "Removal and installation of fuel tank assembly".

2.

Remove control valve cover (1).

D155A-6

13

SEN03375-00

6.

Disconnect air conditioner hoses (17) and (18).


10. Lift off battery top cover (23). 4

7.

Disconnect heater hoses (19) and (20).

8.

Disconnect battery cable (21).

9.

Remove 2 duct flange mounting bolts (22).

14

Cover: 75 kg

11. Disconnect and remove hose and flange (24) from flange (25).

12. Disconnect ground wire (26).

D155A-6


13. Disconnect 4 window washer hoses (27).

SEN03375-00

17. Remove mounting bolts (34) at the rear right and left of the floor frame. [*3]

14. Disconnect wiring harness (28). 18. Remove cover (35).

15. Disconnect wiring harness connectors FSB (29), PL1 (30), FD1 (31) and FD4 (32). [*1]

19. Sling pin (36), tighten the bolt to pull out pin (37), and lift off pin (36). 20. Remove the pin on the other side at the rear and the 2 pins at the front according to steps 15 and 16.

16. Remove bracket mounting bolts (33) in front of the floor frame. [*2]

21. Lift off operator's cab and floor frame assembly (38). a When removing, take care extremely that the floor frame assembly will not interfere with another part. 4

D155A-6

Floor frame assembly: 1,000 kg

15

SEN03375-00


Installation q


[*1] a Before installing, check that seal rubber parts (brown, 2 pieces) are installed to the connector and they are not broken. 3 Connector mounting bolt: 2.83 ± 0.28 Nm {0.288 ± 0.028 kgm} [*2], [*3] 3 Floor frame mounting bolts (19) and (20): 824 – 1,030 Nm {84 – 105 kgm} [*2]

3

Bracket mounting bolt (33): 153 – 190 Nm {15.5 – 19.5 kgm}

[*3]

3

16

Floor frame mounting bolt (34): 984 – 980 Nm {80 – 100 kgm}

D155A-6


D155A-6

SEN03375-00

17

SEN03375-00




18

D155A-6

SEN03376-00


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

50 Disassembly and assembly1 Electrical system Removal and installation of air conditioner unit assembly .............................................................................. 2 Removal and installation of engine controller assembly ................................................................................. 4 Removal and installation of power train controller assembly .......................................................................... 5 Removal and installation of KOMTRAX assembly .......................................................................................... 5

D155A-6

1

SEN03376-00

Removal and installation of air conditioner unit assembly


k

k

a a k

1.

2

Remove the cover at the right lower part of the operator's seat.

3.

Lift off operator's seat assembly (1).

1

Removal k

2.

Disconnect the cable from the negative (–) terminal of the battery. In the case that you do not drain the coolant, if you disconnect the heater hose when the coolant temperature in the radiator is high, you may be scalded. In this case, wait until the coolant temperature lowers and then disconnect the heater hose. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.

4

Operator's seat assembly: 55 kg

4.

Remove cover (2).

5.

Disconnect air conditioner hoses (3) and (4). [*1]

6.

Disconnect heater hoses (5) and (6).

Remove the operator's cab assembly. For details, see "Removal and installation of operator's cab".

D155A-6


7.

Remove the 4 mounting bolts of work equipment controller assembly (7) and disconnect the assembly.

SEN03376-00

10. Disconnect wiring harness connectors AC01 (10) and AC02 (11). 11. Disconnect wiring harness clamp (12) and move wiring harness (13) aside.

8.

Remove filter (8). 12. Disconnect 2 duct hoses (14). 13. Remove the 7 mounting bolts and air conditioner unit assembly (15).

9.

Remove cover (9).

Installation q


[*1] a When installing the air conditioner hoses, take care that dirt, dust, water, etc. will not enter them. a When installing each air conditioner pipe, check that the O-ring is fitted to it. a Check that the O-ring is not damaged or deteriorated. 2 O-ring: ND-OIL8 q Filling air conditioner with refrigerant Fill the air conditioner circuit with refrigerant (R134a).

D155A-6

3

SEN03376-00

Removal and installation of engine controller assembly


1.

Disconnect wiring harness connectors EGC1 (4), EGC2 (5) and EGC3 (6). [*1]

5.

Remove the engine controller assembly (7).

1

Removal k

4.

Disconnect the cable from the negative (–) terminal of the battery. Open the left engine side cover and lift off side cover assembly (1). 4

Side cover assembly: 40 kg

Installation q


[*1] 2.

Remove 2 oil filters (2).

3.

Remove cover (3).

4

3

Connector mounting screw: 2.82 Nm {0.288 kgm}

D155A-6


SEN03376-00

Removal and installation of power train controller assembly 1

Removal and installation of KOMTRAX assembly

Removal

Removal

k


1.

Remove the left lower cover of the operator's seat.

2.

Remove 4 mounting bolts (1) of the power train controller assembly.

3.

Move the controller, disconnect wiring harness connectors STC1 (2), STC2 (3) and STC3 (4), and remove power train controller assembly (5). [*1]

k

1


1.

Remove 4 mounting bolts (1), cover (2).

2.

Disconnect wire harness connector (4).

3.

Disconnect antenna cable (3).

4.

Remove 4 mounting bolts (5), and KOMTRAX assembly (6).

Installation Installation q

q



[*1]

3

Connector mounting screw: 2.82 Nm {0.288 kgm}

D155A-6

5

SEN03376-00




6

D155A-6

SEN04442-00


D155A-6

Machine Model

Serial Number

D155A-6

85001 and up

60 Air conditioner

1

Structure, function, testing, adjusting, and troubleshooting Structure and function ..................................................................................................................................... 3 Air conditioner component ....................................................................................................................... 3 Configuration and function of refrigerating cycle ..................................................................................... 4 Outline of refrigerating cycle .................................................................................................................... 5 Air conditioner unit ................................................................................................................................... 7 Functions of major components in the air conditioner unit ...................................................................... 9 Control plate ...........................................................................................................................................11 Compressor ........................................................................................................................................... 13 Condenser ............................................................................................................................................. 14 Receiver drier ........................................................................................................................................ 15 Testing, adjusting and troubleshooting.......................................................................................................... 17 Caution about refrigerant ....................................................................................................................... 17 Troubleshooting procedure .................................................................................................................... 18 Block diagram ........................................................................................................................................ 19

D155A-6

1

SEN04442-00

60 Air conditioner

Circuit diagram and arrangement of connector pins .............................................................................. 20 Detail of air conditioner unit ................................................................................................................... 22 Part and connector locations ................................................................................................................. 24 Testing air leakage (duct)....................................................................................................................... 31 Testing with self-diagnosis function........................................................................................................ 33 Testing temperature control ................................................................................................................... 36 Testing vent (mode) changeover............................................................................................................ 39 Testing Recirc/Fresh changeover .......................................................................................................... 42 Testing inner sensor............................................................................................................................... 44 Testing evaporator temperature sensor ................................................................................................. 45 Testing sunlight sensor .......................................................................................................................... 48 Testing (dual) pressure switch for refrigerant......................................................................................... 49 Testing relays and diodes ...................................................................................................................... 51 Troubleshooting chart 1 ......................................................................................................................... 53 Troubleshooting chart 2 ......................................................................................................................... 54 Troubleshooting for electrical system (E mode)..................................................................................... 57 E-1 Power supply system (Air conditioner does not operate)......................................................... 58 E-2 Compressor system (Air is not cooled) .................................................................................... 62 E-3 Blower motor system (No air comes out or air flow is abnormal) ............................................. 65 E-4 Temperature cannot be controlled............................................................................................ 70 E-5 Vent (mode) cannot be changed over ...................................................................................... 72 E-6 Recirc/Fresh air cannot be changed over ................................................................................ 74 Troubleshooting with gauge pressure .................................................................................................... 76 Connection of service tool...................................................................................................................... 78 Precautions for connecting air conditioner piping .................................................................................. 79 Handling of compressor oil .................................................................................................................... 80 1. Control of compressor oil .......................................................................................................... 80 2. Adding of compressor oil .......................................................................................................... 80 3. Compressor replacement.......................................................................................................... 81 4. Applying compressor oil for O-ring............................................................................................ 81

2

D155A-6

60 Air conditioner

SEN04442-00

Structure and function

1

Air conditioner component

1

1. 2. 3. 4. 5. 6. 7. 8. 9.

Condenser Hot water return piping Hot water piping Front window defroster Side window defroster Air outlet for face Air outlet for center Air outlet for rear Air conditioner unit

10. 11. 12. 13. 14. 15. 16.

Air outlet for foot Receiver drier Refrigerant piping Valve (hot water outlet) Air conditioner compressor Valve (hot water inlet) (Dual) pressure switch

A. B.

Fresh air filter Recirculated air filter

Specifications

D155A-6

Refrigerant

R134a

Refrigerant refilling level (g)

1200 ± 50

3

SEN04442-00

60 Air conditioner

Configuration and function of refrigerating cycle

1

Component Item Location

Function

Compressor

Condenser

Expansion valve

Evaporator

Engine compartment

Front of radiator

In operator’s cab (In air conditioner unit)

In operator’s cab (In air conditioner unit)

Circulates refrigerant gas and increases its temperature and pressure so that it can be liquefied easily in condenser.

Condenses refrigerant Lowers temperature and to discharge heat pressure of refrigerant absorbed in evaporator. liquid and gas for easy evaporation with throttle. Controls flow rate, too.

(Compression of refrig- (condensation of refrig- (Throttle of refrigerant) erant) erant) State of refrigerant

4

Gas o Gas Adiabatic compression

Gas o Liquid Constant pressure change

Liquid o Liquid and gas Adiabatic expansion

Evaporates refrigerant to absorb heat from (or cool) air around evaporator.

(Evaporation of refrigerant) Liquid and gas o Gas Constant pressure change

D155A-6

60 Air conditioner

Outline of refrigerating cycle

SEN04442-00

1

3.

Receiver drier The refrigerant liquefied in the condenser is reserved in the receiver drier temporarily so that it can be supplied to the evaporator according to the cooling load. A strainer and a drying agent are sealed in the receiver drier to remove “dirt” and “water” in the refrigerating cycle. If any water is in the refrigerating cycle, it is frozen in the small hole of the expansion valve and retards the flow of the refrigerant. It can cause a cooling trouble.

4.

Expansion (Expansion valve) The pressure of the refrigerant liquid is lowered by the restricting action [*1] of the expansion valve to a level at which the refrigerant is evaporated easily. The action to lower the pressure of the refrigerant to a level at which the refrigerant is evaporated easily before the refrigerant is sent to the evaporator is called expansion. The expansion valve which performs this action also controls the flow rate of the refrigerant. In other words, the quantity of the refrigerant liquid evaporated in the evaporator is decided by the quantity of heat to be removed (refrigeration load) at the specified evaporation temperature (evaporation pressure), and the expansion valve senses it and controls the refrigerant flow rate properly. [*1] Restricting action If there is a suddenly narrowed part in a pipe in which a liquid is flowing, there is resistance to the flow. Since the sectional area is increased suddenly through this part, the liquid expands suddenly and its pressure and temperature lower. No heat is exchanged between the inside and outside of the pipe during this action.

The refrigerating cycle performs the following four actions. The refrigerant is liquefied and gasified repeatedly while it is circulated in the cycle. 1.

2.

Compression (Compressor) The refrigerant gas is compressed by the compressor to the state where it can be liquefied easily at the normal temperature (ambient temperature). The refrigerant evaporated in the evaporator is sucked into the compressor. This action is performed to keep the refrigerant pressure in the evaporator low so that the refrigerant liquid can continue evaporation actively even if the ambient temperature is close to 0°C. The refrigerant gas sucked into the compressor is compressed in the cylinder and its pressure and temperature are so changed that is can be liquefied easily when it is cooled with the external air at the normal temperature. Condensation (Condenser) The refrigerant gas in the condenser is cooled to be liquefied with the external air. The refrigerant gas of high temperature and high pressure discharged from the compressor is cooled to be liquefied with the external air and then stored in the receiver drier. The heat discharged from the refrigerant of high temperature and high pressure discharged from the compressor is called the condensation heat, which is the total of the heat that the refrigerant absorbed from the operator’s cab through the evaporator (vaporization heat) and the work performed to compress the refrigerant (the value converted into heat). During condensation, the refrigerant gas and refrigerant liquid are mixed together in the condenser. While the refrigerant gas changes to the refrigerant liquid, the relationship between the pressure (condensation pressure) and temperature (condensation temperature) is kept constant. Reference: The pressure varies with the type of refrigerant and the condensation temperature.

D155A-6

5

SEN04442-00

5.

6

60 Air conditioner

Evaporation (Evaporator) The refrigerant changes from liquid to gas (superheated vapor) in the evaporator. The refrigerant mist in the evaporator evaporates actively. At this time, the refrigerant evaporates quickly, absorbing heat necessary for evaporation (latent heat of vaporization) from the air around the cooling fins (air in the operator’s cab). The cooled air is spread in the operator’s cab by the fan to lower the temperature in the operator’s cab. The refrigerant mist sent through the expansion valve and the evaporated refrigerant are mixed together in the evaporator. While the refrigerant liquid changes to the refrigerant gas, the relationship between the pressure (evaporation pressure) and temperature (evaporation temperature) is kept constant. If the pressure is set, the temperature is decided automatically. That is, the relationship between the above pressure and temperature is equal to the relationship between saturation pressure and saturation temperature. To evaporate the refrigerant at lower temperature, the pressure in the evaporator must be kept lower. Accordingly, the evaporated refrigerant is sucked into the compressor. The refrigerant circulates in the refrigerating cycle, repeating the above four actions, to move the heat from the operator’s cab where the temperature is low to the outside where the temperature is high. If the amount of the refrigerant is insufficient, all of the refrigerant is evaporated while it is passing through the evaporator and the evaporator capacity decreases. It can cause a cooling trouble. To the contrary, if the amount of the refrigerant is too much, a part of it is not evaporated in the evaporator and is absorbed in the compressor. As a result, the compressor compresses the liquid and may be broken.

D155A-6

60 Air conditioner

Air conditioner unit a

This air conditioner unit is auto temperature control type.

a

Inside temp. sensor is the same as inner (air temperature) sensor.

D155A-6

SEN04442-00

1

7

SEN04442-00

60 Air conditioner

Outline q The air conditioner unit consists of the evaporator, heater core and fan (blower) and generates cool air and hot air. q

Temperature control The machine monitor sends temperature setting data to the control amplifier (See “Control plate”) according to the temperature control switch operation. The control amplifier controls the air mix servomotor to adjust the angle of the cool door, hot door and sub hot door for temperature control.

q

Over-cooling (Freezing) prevention The evaporator temperature sensor senses evaporator temperature by the change of resistance. The control amplifier converts the change of resistance of the evaporator temperature sensor into a change of voltage and detects the evaporator temperature by the change of voltage. The control amplifier turns OFF the compressor clutch relay so that the evaporator will not be frozen.

q

Air flow adjustment The machine monitor sends air flow data to the control amplifier (described later) according to the air flow adjustment switch. The control amplifier controls the air flow with the power transistor.

q

Vent (mode) changeover The machine monitor sends mode data to the control amplifier according to the vent selector (mode) switch. The control amplifier controls the blowing out (mode) servomotor to adjust the angles of the foot door, defroster door, front door and rear door for vent changeover.

q

Automatic air conditioner The inner temperature sensor senses the room temperature by the change of resistance. The control amplifier converts the change of resistance of the inner temperature sensor into a change of voltage and detects the room temperature by the change of voltage. The control amplifier checks the inner air temperature sensor voltage so that the room temperature will be kept at the temperature set with the machine monitor.

a

The 5 A fuse for the air conditioner unit is installed to the wiring harness. The door is the same as the damper.

a

8

D155A-6

60 Air conditioner

Functions of major components in the air conditioner unit 1 q

Evaporator Evaporator fins are cooled by low-pressure, low-temperature refrigerant gas being sent from the expansion valve. Air from the blower motor is cooled and dehumidified when passing through the fins.

q

Heater core Fins of the heater core are heated by the hot water (cooling water) being sent from the engine. Air from the blower motor is heated as it passes through the fins.

q

Expansion valve This valve converts high-pressure, high-temperature liquid refrigerant coming from the receiver to low-pressure, low-temperature misty refrigerant through the throttling function. It controls the flow rate of the refrigerant by changing the level of throttling depending on the thermal load (temperature) in the operator's cab. As a result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in evaporator. 1) Structure The box-type expansion valve consists of the diaphragm, thermosensing rod, needle valve (ball), spring, etc. The outside of diaphragm (hatched part) is pre-enclosed with refrigerant gas. The spring is installed on the needle valve (ball) side of the thermosensing rod. The needle valve opening ratio is decided when the constant force of the spring to push the ball to the right is balanced with the force (Fg) of the refrigerant gas to push the thermosensing rod to the left through the diaphragm. As a result, the refrigerant flow rate to the evaporator is decided and the temperature is controlled.

D155A-6

SEN04442-00

2)

Operation The thermosensing rod senses the temperature of the refrigerant which passed the evaporator. The temperature at this time is conduc ted through the thermosensing rod to the refrigerant gas in the diaphragm chamber (hatched part). As the pre-enclosed refrigerant gas temperature changes, the gas pressure changes and pressing force (Fg) also changes. The thermosensing rod attached directly to the diaphragm so moves that the constant force of the spring to push the ball will be balanced with variable force (Fg) to adjust the needle valve opening ratio. A: When the evaporator outlet temperature is high (at start of cooling (air is not cooled yet)) The gas pressure in the diaphragm chamber increases and the gas volume increases. Pushing force (Fg) of the refrigerant gas increases and the thermosensing rod (ball) moves to the left and the need le v alv e opens wid e. Muc h refrigerant is supplied to the evaporator and the cooling capacity increases. B.

When the evaporator outlet temperature is low (during cooling (air is cooled already)) The gas pressure in the diaphragm chamber decreases and the gas volume decreases. Since pushing force (Fg) of the refrigerant gas is small, the thermosensing rod (ball) moves to the right and the needle valve is narrowed. Accordingly, refrigerant supply and the cooling capacity decrease.

9

SEN04442-00

q

Power transistor (PTR) It controls the blower motor speed by receiving signal current from the air conditioner control amplifier. (See “Control plate”.)

q

Servomotor

a

This servomotor is used for temperature control (AIR MIX) and blowing out (MODE).

1.

If the switch on the control panel is operated, the control amplifier supplies 24 V power across (6) and (7). (The rotation direction changes according to the polarities of the supplied power.)

10

60 Air conditioner

2.

There is a variable resistor in the servomotor and its resistance varies with the angle of the motor shaft. The control amplifier applies 5 V voltage to this variable resistor and judges the rotation angle of the motor by the potential difference (PT). When the door (damper) comes to the position set with each switch, the control amplifier stops supplying the power to the servomotor. a Do not apply the power directly to the motor terminal to drive the motor because the motor output shaft is damaged or the motor coil is broken.

3.

If the potential difference (PT) does not reach the voltage set for the servomotor control, the control amplifier notifies the error to the machine monitor. Then, the letters of “A/C Controller Error” are displayed red on the air conditioner operation screen of the machine monitor. a The Recirc/Fresh changeover servomotor does not have this potential difference (PT). Accordingly, it does not have the self-diagnosis function.

D155A-6

60 Air conditioner

Control plate

1.

SEN04442-00

1

Control amplifier (CNTAMP)

A/C U: Air conditioner unit AC01: Intermediate connector to air conditioner control amplifier (CNTAMP) (GND, sunlight sensor, pressure switch, connectors for relay) AC02: Intermediate connector to air conditioner control amplifier (CNTAMP) (24 V, CAN communication with machine monitor)

D155A-6

Functions of main component parts q Control amplifier (CNTAMP) (1) 1) Communicates with the machine monitor through CAN communication system and controls the air conditioner unit with the switch inputs related to the air conditioner. 2) Controls the three servomotors in the air conditioner unit to adjust the temperature, changeover the vent (mode), and changeover the recirculated air or fresh air. 3) Turns ON and OFF blower main relay (switch to blow air) and compressor clutch relay (switch to operate the compressor). See item 8 in “Part and connector locations”. a Control amplifier (CNTAMP) (1) controls compressor clutch relay on the basis of following three (input) data. 1] “A/C” switch or “AUTO” switch on the machine monitor 2] Evaporator temperature sensor 3] (Dual) pressure switch 4) Has the self-diagnosis function. If any abnormality is detected, the control amplifier notifies it to the machine monitor by the CAN communication. Then, the letters of “A/C Controller Error” are displayed red on the air conditioner operation screen of the machine monitor. 5) Adjusts the room temperature to the set temperature on the basis of the data of the sunlight sensor and inner air sensor in the automatic air conditioner mode.

11

SEN04442-00

60 Air conditioner

Input and output signals of control amplifier (CNTAMP) Connector on controller side: ACCN AMP 040-36PM Connector on wiring harness side: [1], [2] [1] AMP 040-16PF Pin No.

Symbol

[2] AMP 040-20PF Signal name

Symbol

17

CAN (+)

CAN communication +

Input/ Output

CAN communication –

Input/ Output

Signal name

—

2

A/M P

3

POT 5V

Servo potentiometer 5V power supply Output

18

CAN (–)

4

PRESS SW

(Dual) pressure switch (Refrigerant pressure)

19

R/F A

Output

5

—

Recirculated air and fresh air servo terminal A

6

+24 V

20

R/F B

Recirculated air and fresh air servo terminal B

Output

Input

21

A/M A

A/M servo terminal A

Output

Output

22

A/M B

A/M servo terminal B

8 9

A/M servo potentiometer voltage

— Power supply

Input Input — Input

BLOW F/B Blower feedback signal PTR B

—

Input and output

Pin No.

1

7

—

Input and output

Power transistor control signal

Blowing out (mode) servo MODE P potentiometer voltage —

Input

10

—

—

11

THI

12

THEVA

13

—

—

—

14

—

—

—

15

SS

16

GND

Inner air temperature sensor

Input

Evaporator temperature sensor

Input

Sunlight sensor

Input

GND

Input

MODE A Blowing out (mode) servo terminal A

Output

24

MODE B Blowing out (mode) servo terminal B

Output

25

—

—

26

—

—

27

GND S

28

—

—

—

29

—

—

—

30

—

—

—

31

—

—

—

32

—

—

—

33

—

—

—

34

—

—

35

CCRL

Sensor GND

q q q

— — Input

Compressor clutch relay

36 BLOW RL Blower main relay

12

Output

23

— Output Output

A/M: Air mix F/B: Feedback R/F: Recirculation/Fresh

D155A-6

60 Air conditioner

SEN04442-00

Compressor

1

A: Refrigerant inlet port from air conditioner unit B: Refrigerant outlet port to condenser C: Pulley D: Relief valve

Function Other than circulating the refrigerant, compressor compresses the refrigerant gas from the evaporator to a high-pressure, high-temperature misty refrigerant so that it may be easily regenerated (liquefied) at normal temperature. q The magnetic clutch in the compressor is engaged depending on the evaporator temperature and refrigerant pressure. If the magnetic clutch is engaged, the shaft in the compressor rotates to operate the compressor. q

Specifications

D155A-6

Piston capacity (cc/rev)

157.3

Allowable maximum speed (rpm)

6,000

Refrigerant oil used

Denso: ND-OIL8 (For R134a)

Refrigerant oil refilling volume (cc)

180

13

SEN04442-00

60 Air conditioner

Condenser

1.

Condenser

A: Refrigerant inlet from compressor B: Refrigerant outlet to receiver drier Function Condenser (1) q Condenser cools and liquefies the high-pressure, high-temperature misty refrigerant from the compressor. a

If the fins are crushed or clogged with dirt, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As a result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.

Specifications Fin pitch (mm)

4.0

Height × Width × Thickness

357 × 540 × 16

Max. pressure used (MPa {kg/cm2})

3.6 {36}

14

D155A-6

60 Air conditioner

SEN04442-00

Receiver drier

1

1. 2.

Receiver drier (Dual) pressure switch

A: B:

Refrigerant inlet from condenser Refrigerant outlet to air conditioner unit

q

SG: Sight glass Function Receiver drier (1) q It is used to store liquefied high-pressure, hightemperature misty refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. q It eliminates foreign substances in the circulation circuit and water content in the refrigerant by use of the built-in filter and desiccating agent. q Sight glass (1) allows inspection of the refrigerant flow. Even if 5 minutes elapsed after engine start up and turning ON of A/C switch, when bubbles are seen through sight glass (1), the amount of the refrigerant is insufficient. If the amount of the refrigerant is proper, no bubbles are seen there. a If there is no (or excessive) refrigerant in the refrigerating cycle, no bubbles are seen through sight glass (1), too.

(Dual) pressure switch (2) a Connector is AC05 If abnormally low or high pressure is generated in the refrigerant circulation circuit, the (dual) pressure switch is turned “OFF”. (it is normally turned “ON”.) When the (dual) pressure switch become “OFF”, the control amplifier turns the compressor clutch relay “OFF”. So the magnetic clutch of the compressor is disengaged and the devices related to the air conditioner are protected.

LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}

Specifications Weight of desiccating agent (g)

D155A-6

370

15

SEN04442-00

16

60 Air conditioner

D155A-6

60 Air conditioner

SEN04442-00

Testing, adjusting and troubleshooting Caution about refrigerant k

a a k

q

1

1

Collect the air conditioner refrigerant (R134a) from air conditioner circuit to before disconnecting air conditioner hose replace air conditioner unit, air conditioner compressor or receiver drier and so on. Ask a qualified shop for collecting, adding and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on protective goggles, gloves and working suits with long sleeves while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person. Refrigerant (R134a) filling up quantity: 1200 g ± 50 g

D155A-6

17

SEN04442-00

60 Air conditioner

The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function, you can inspect the operation of sensors and servomotors in the system. If a troubled section is detected, every part of that section must be inspected.

Troubleshooting procedure 1. 2.

3.

1

After basic check, find the troubled section according to the detected trouble of the air conditioner. Find the troubled section with the self-diagnosis function (See “Inspection with self-diagnosis”). If the air conditioner unit does not operate at all, check that the power supplied to the control amplifier is normal and that CAN communication between machine monitor and the control amplifier is normal. If any part of the air conditioner unit operates, the power supply and CAN communication do not need to be checked. After finding out the troubled section, inspect the component parts in that section and repair the troubled part.

Basic flow of troubleshooting Occurrence of trouble: Examination, confirmation of failure

Basic check

operate?

1. Battery voltage (24 V) 2. Tension of compressor belt 3. Oil stain at air conditioner hose joints (*2) 4. Abnormal sound check (*3) Compressor, blower motor and air conditioner hose (clamp) E-1 Power supply system (Air conditioner does not operate)

Inspection with self-diagnosis function (*1) and with each switch

Troubleshooting with troubleshooting chart 1

Troubleshooting with E mode

Troubleshooting with gauge pressure

Inspection with troubleshooting chart 2

*1: By error display or abnormal display on “Abnormality Record” screen on machine monitor. *2: If refrigerant leaks, recirculating compressor oil in the air conditioner circuit always leaks, too. *3: Start engine and then air conditioner switch ON.

18

D155A-6

60 Air conditioner

Block diagram a

SEN04442-00

1

This air conditioner unit is auto temperature control type.

D155A-6

19

SEN04442-00

Circuit diagram and arrangement of connector pins

20

60 Air conditioner

1

D155A-6

60 Air conditioner

a a

SEN04442-00

INSIDE TEMP. SENSOR means “Inner sensor” on “Abnormality Record” screen: “03 Air-conditioning System”. BLOWING OUT (MODE) SERVOMOTOR means BLOWING OUT (MODE) CHANGEOVER SERVOMOTOR.

D155A-6

21

SEN04442-00

Detail of air conditioner unit

22

60 Air conditioner

1

D155A-6

60 Air conditioner

D155A-6

SEN04442-00

23

SEN04442-00

Part and connector locations a

a 1.

2.

24

60 Air conditioner

1

3.

Remove foot duct (2).

4.

Remove cover (3).

There are a circuit breaker and a fuse. The circuit breaker is in the battery cover on the left side of the machine and the fuse is wound onto the wiring harness between the air conditioner unit and control amplifier. The air conditioner unit is at the rear of the operator seat. Open the battery cover on the left side of the machine. (See the fuse locations in Troubleshooting Volume.) q Circuit breaker CB3 (5th from left) (20 A): For power supply for air conditioner compressor and air conditioner unit (for all devices related to air conditioner) a If the reset button (RB) of the circuit breaker is projected, the circuit is turned OFF. In this case, push in the reset button (RB). If it is kept pushed in, the circuit is normal. If it is soon projected again, the circuit may have a ground fault etc. (See E-1.)

Remove recirculated air filter (1) from the rear of the operator seat.

D155A-6

60 Air conditioner

SEN04442-00

a

5.

State without cover (3) q A/C U: Air conditioner unit q CNTAMP: Control amplifier q [1] and [2]: Control amplifier connectors q AC01: Connector to air conditioner unit for GND, compressor, pressure switch, relay and sunlight sensor q AC02: Connector to air conditioner unit for 24 V power supply and CAN communication connector to monitor panel (Communication circuit common to engine controller and pump controller) Disconnect connectors AC01 and AC02.

6.

Disconnect clamp (4).

7.

Remove bracket (5). a Fu5A: Fuse 5 A is installed to the bracket bottom of wiring harness (H). For power supply for air conditioner unit (including primary side of relays for blower (fan) and air conditioner compressor) q Fuse part No. Fu5A: ND93950-05003 q [5]: Blowingout (Mode) servomotor connector q [6]: Temperature control (Air mix) servomotor connector

D155A-6

25

SEN04442-00

q q q q q q q

26

60 Air conditioner

[3]: Blower (Fan) motor connector [4]: Power transistor (PTR) connector [5]: Blowingout (Mode) servomotor connector [6]: Temperature control (Air mix) servomotor connector [7]: Recirc/Fresh changeover servomotor connector [8]: Recirculated air sensor connector [9]: Evaporator temperature sensor connector

D155A-6

60 Air conditioner

8.

9.

Relays and diodes The relays and diodes are at the left rear of the operator seat. q AC03: Blower main relay connector --- For turning fan motor ON/OFF q AC04: Compressor clutch relay connector --- For turning air conditioner compressor (clutch) ON/OFF q Diodes: ACD1 and ACD2 --- For cutting back electromotive force generated in the primary coils of the blower main relay and compressor clutch relay. For protection of control amplifier (CNTAMP) IF: Recirculated air filter

SEN04442-00

q q q

AC05: Pressure switch connector RD: Receiver drier SG: Sight glass

Pressure switch Open engine left cover (6) and remove covers (7) – (9).

D155A-6

27

SEN04442-00

60 Air conditioner

10. Air conditioner compressor q ACC: Air conditioner compressor q A/C: Air conditioner compressor connector q ACS: Diode connector of air conditioner compressor q GND09: Ground q A/C1: Intermediate connector of air conditioner compressor

28

D155A-6

60 Air conditioner

11. Sunlight sensor connector SLS and machine monitor connector CM02 (CAN communication connector) a If the machine monitor connector CM02 is disconnected, the engine controller and other controller(s) can not perform the CAN communication. Accordingly, failure code: [DAFRMC] is displayed. If the screen changes to the air conditioner operation screen at this time, “A/C Controller error” is displayed red. If the above error is not displayed, no check is necessary. Note: “A/C Controller error” on the air conditioner operation screen is also displayed when the vent cannot be changed, when the temperature control is abnormal or when the refrigerant pressure switch is turned OFF. (“A/C Controller error” display for “the refrigerant pressure switch is turned OFF” will be abolished in the future.) 1) Remove dashboard cover (10). 2) Disconnect sunlight sensor (S) connector (SLS).

3) 4)

D155A-6

SEN04442-00

5)

Float dashboard (14) and pull it out toward you. a Since the wiring harness is connected, pull out the dashboard slowly. q DSH: Intermediate connector of machine monitor a Connector DSH is DRC-70. Take care in handling it. See the next page.

6)

Disconnect the following connectors. q (15): KEY q (16): BKSW --- Red band q (17): DCL --- Blue band q (18): BRK --- Yellow band q (19): FLSW q (20): RLSW

Remove duct (11). Remove covers (12) and (13).

29

SEN04442-00

7)

Inspect connectors CM01, CM02, CM03 and GPS from the backside of dashboard (14). a CM02 and CM03 can be connected reversely. Take care. CM03 is green.

12. Intermediate connector 1) Open cover (21).

2) 3)

30

60 Air conditioner

q

How to disconnect connector DSH Disconnect the connector straight slowly and check the seal for breakage, peeling and sticking foreign matter. a If the seal is damaged, replace it.

q

How to connect connector DSH 1) Check that the seal is correctly installed to the plug. 2) Check that the key is positioned to be matched to the groove of the receptacle (key is not positioned oppositely). 3) Set the plug connector to the receptacle straight (since the seal is projected) and fit it a little, while check that the seal is not rolled up. 4) Tighten the hexagon bolt at the center of the connector by 2 – 3 turns. 5) Fit the plug connector to the end and adjust it so that the clearance between it and the fitted receptacle will be even when seen from each direction. 6) Tighten the lock bolt to the specified torque. 3 Hexagon lock bolt: 2.8 ± 0.3 Nm {0.28 ± 0.03 kgm} a If the lock bolt is tightened to strongly, it will be broken and cannot lock. Take care.

Disconnect battery ground cable. Inspect connectors FSB, FD1 and FD4.

D155A-6

60 Air conditioner

Testing air leakage (duct) 1.

2.

SEN04442-00

1

3.

Remove cover (3).

Remove recirculated air filter (1) from the rear of the operator seat.

4.

Remove cover (4).

5.

Ensure that the following are not removed. 1) Duct (5) 2) Front duct (FD) 3) Defroster duct (DD) q A/C U: Air conditioner unit q A1 and A2: Front blowingout route q C1, C2 and C3: Defroster blowingout route


D155A-6

31

SEN04442-00

6.

32

60 Air conditioner

For air leakage through the defroster blowingout route of C2 and C3, check each duct joint for air leakage in the defroster mode at the maximum air flow. a When air does not come out of only C2 (Air comes out of C1 and C3) 1) Remove duct (6). 2) Check to see if air comes out of (P) in the defroster mode at the maximum air flow. 3) If no air comes out of (P), inspect duct (7). 4) If air comes out of (P), remove dashboard (8), referring to “Part and connector locations”, Item 11. 5) Inspect duct (9).

D155A-6

60 Air conditioner

Testing with self-diagnosis function

SEN04442-00

1

Outline On the air conditioner operation screen of the machine monitor, the system performs self-diagnosis for the communication with the air conditioner unit, temperature control, vent (mode) changeover and refrigerant pressure with the pressure switch. If any of these items has trouble, “A/C Controller error” is displayed red to notify the trouble. a “A/C Controller error” display for “the refrigerant pressure switch is turned OFF” will be abolished in the future.

a

1.

While pressing numeral key [4] on the normal screen, press [1], [2] and [3] in order.

2.

On the service menu screen, press [F3] (R) once to select “02 Abnormality Record”.

3.

Press [F6] (

Once a problem is detected, its indication is not reset even if it becomes normal. The indication can be reset after the starting switch is turned OFF.

On the air conditioner “Abnormality Record” screen in the service mode of the machine monitor, the system performs self-diagnosis for various sensors, in addition to the above items, and displays “Error” red if any problem is detected. a The system does not have self-diagnosis function for the Recirc/Fresh changeover servomotor. q

Explanation of machine monitor operating procedure

) to confirm.

How to enter air conditioner “Abnormality Record” screen in service mode of machine monitor.

Outline of machine monitor operation Normal screen O While pressing [4], press [1], [2] and [3] in order. Service menu (Mode) O Press [F3] once. Press [F6]. 02 Abnormality Record O Press [F3] twice. Press [F6]. 03 Air-conditioning system “Abnormality Record” screen

D155A-6

33

SEN04442-00

60 Air conditioner

4.

On the “Abnormality Record” screen, press [F3] (R) twice to select “03 Air-conditioning System”.

5.

Press [F6] (

q

34

q

) to confirm.

Information displayed on Abnormality Record screen: “03 Air-conditioning System” screen (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) (d): If CAN status is abnormal in condition, CAN communication cannot be carried out normally but air conditioner unit is disconnected. Accordingly, the conditions (d) of other items are not displayed. (e): If [E] is displayed on the left of a condition, the abnormality is still occurring or clearing of it has not been confirmed. q [F2]: Clear “Abnormality Record” q [F5]: Return to “Abnormality Record” screen

Clearing “Abnormality Record” by machine monitor While the “Abnormality Record” screen is displayed, press [F2], and the number of occurrence time of abnormality is reset. If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.

Caution Inner Sensor means inside temperature sensor on “block diagram” or “circuit diagram”. “Ventilating Sensor is abnormal” means that evaporator temperature sensor is short circuit or disconnected. “Sunlight Sensor is abnormal” means that Sunlight Sensor is short circuit only. “Ventilation is abnormal” means servomotor for blowing out changeover (mode) damper does not rotate judging from the servomotor potentiometer voltage. a Damper is the same as door. “Air Mix is abnormal” means servomotor for Air Mix (temperature adjustment) damper does not rotate judging from the servomotor potentiometer voltage. “Refrigerant” means refrigerant pressure from (dual) pressure switch. Namely, “refrigerant is abnormal” means that (dual) pressure switch of refrigerant is OFF. 1.

CAN Status (communication) is abnormal The CAN communication between the machine monitor and air conditioner control amplifier (CNTAMP) is not carried out normally. a If failure code [DAFRMC] (Error of CAN communication with engine controller) is displayed, all the communication circuit is abnormal. In this case, see failure code [DAFRMC] in Chapter 40. If [DAFRMC] is not displayed, only the communication between control amplifier (CNTAMP) and machine monitor is abnormal. (Check connectors CN-N10, CN-AC01, [1] and [2] for disconnection. See “Part and connector locations” 2., 3., and 6. or see E-1.)

2.

Setting abnormal The software of the air conditioner amplifier does not match that of the monitor. Check the part numbers of those components.

D155A-6

60 Air conditioner

3.

Inner Sensor abnormal a Inner Sensor is the same as inside temperature sensor on “block diagram” or “circuit diagram”. a There is a Disconnection or a short circuit in the line between the control amplifier and Inside temperature sensor. a Action of air conditioner amplifier: The air conditioner amplifier controls with only the set temperature since the data of the Inside temperature sensor are not available. a Trouble: The air conditioner does not function automatically but functions when operated manually. a See “Testing Inner Sensor”.

4.

Ventilating Sensor abnormal a Ventilating Sensor is the same as evaporator temperature sensor. a There is a disconnection or a short circuit in the line between the control amplifier and evaporator temperature sensor. a Action of control amplifier: The control amplifier stops outputting to the compressor. a Trouble: The air conditioner does not work. (See “Testing evaporator temperature sensor”.)

5.

Sunlight Sensor abnormal There is a short circuit between the control amplifier and Sunlight Sensor. a Action of control amplifier: The control amplifier controls without the Sunlight Sensor. a Trouble: The automatic air conditioner does not work when the machine is exposed to the direct sunlight in the automatic air conditioner mode. a See “Testing sunlight sensor”.

SEN04442-00

6.

Ventilation is abnormal Servomotor for blowing out changeover (mode) damper does not rotate judging from the servomotor potentiometer voltage. a Damper is the same as door. a Trouble: Blowing out is not changed. a Action of control amplifier: The control amplifier stops outputting to the servomotor for blowing out changeover (mode). a Even if the link is disconnected and the damper does not rotate, the self-diagnosis system judges the damper normal since the servomotor potentiometer voltage changes normally. (For mechanical troubles, see “Testing vent (mode) changeover”.

7.

Air Mix is abnormal Servomotor for Air Mix (temperature adjustment) damper does not rotate judging from the servomotor potentiometer voltage. a Damper is the same as door. a Trouble: The temperature control system does not work. a Action of control amplifier: The control amplifier stops outputting to the air mix servomotor. a Even if the link is disconnected and the damper does not rotate, the self-diagnosis system judges the damper normal since the servomotor potentiometer voltage changes normally. (For mechanical troubles, see “Testing temperature control”.

8.

Refrigerant is abnormal (Dual) pressure switch signal for refrigerant is abnormal. Namely pressure switch for refrigerant is OFF. a Trouble: The air conditioner does not work. a Action of control amplifier: The control amplifier stops outputting to the compressor. k

a

D155A-6

When replacing the pressure switch, be sure to collect the refrigerant. See “Cautions about refrigerant”. See “Testing (dual) pressure switch for refrigerant”.

35

SEN04442-00

Testing temperature control

60 Air conditioner

1

2.


3.

Remove cover (3).

a

State with cover (3) removed q A/C U: Air conditioner unit q CNTAMP: Control amplifier

4.

Check contacts of connector [6] of the air mix servomotor (for disconnection).

Outline q Temperature is controlled by mixing ratio of the hot air from the heater and cooled air from the evaporator by changing the angles of the four doors (dampers) in the air mix section. The angle of each door (damper) is set changed by the air mix servomotor through plate (P1), lever 1 (L1) – lever 6 (L6) and rod (RODAM). Only rod (RODAM), lever 5 (L5) and lever 6 (L6) are seen from outside. (For the figure, see item 5.) a

a

a

1.

36

If lever 5 (L5) and lever 6 (L6) move smoothly between COOL MAX and HOT MAX, plate (P1) and lever 1 (L1) – lever 4 (L4) operate normally, too. Control amplifier (CNTAMP) control temperature is automatically based on inside temperature sensor. So to operate between COOL MAX and HOT MAX inside temperature sensor connector may have to be disconnected. To reset the self-diagnosis system (To clear the air conditioner error displayed on the air conditioner screen of the machine monitor), the starting switch must be turned OFF (While the self-diagnosis system is indicating a problem, no signals are output to the servomotor). Remove recirculated air filter (1) from the rear of the operator seat.

D155A-6

60 Air conditioner

5.

Check the rod (RODAM) for disconnection.

6.

Start the engine and turn the air conditioner power ON.

7.

Set the temperature to 18°C and 32°C on the air conditioner screen of the monitor and check visually that lever 5 (L5) and lever 6 (L6) move smoothly between COOL MAX and HOT MAX. a Figure is PC200-8 type, so duct is different from this type. a For COOL MAX and HOT MAX, see the right.

q

When Lever 5 (L5) and Lever 6 (L6) do not move between COOL MAX and HOT MAX. 1) Starting switch OFF. 2) Disconnect connector [8] under box assembly (11).

3)

D155A-6

SEN04442-00 a

Plate (P1), lever 1 (L1) – lever 4 (L4) are not seen from outside.

Retry steps 6 and 7. a After checking the operation and connect [8], confirm “Inner sensor is normal” on Abnormality Record screen: "03 Air-conditioning System" screen.

37

SEN04442-00

q

38

60 Air conditioner

When lever 5 (L5) and lever 6 (L6) do not move smoothly through the range shown in the figure 4)

Disconnect connectors [5] and [6] of the servomotor.

5)

Make match marks on servomotors (5) and (6) to show which connector has been connected to which servomotor. (The servomotor will be exchanged with each other later.)

6)

Remove servomotors (5) and (6).

7) a

Remove cover (7). Figure is PC200-8 type, so duct is different from this type.

8)

Rotate plate (P1) with the hand between COOL MAX and HOT MAX to see where lever 1 (L1) – lever 6 (L6) are hitched and then repair. a If the levers do not move smoothly, clean them and apply grease to the links. 2 Link: Molykote ® MH-62 Grease (Dow Corning Toray Co. Ltd.)

9)

When plate (P1) is rotated with the hand between COOL MAX and HOT MAX, if lever 1 (L1) – lever 6 (L6) move smoothly, the servomotor may have trouble. In this case, exchange servomotors (5) and (6) and operate them. a For electrical problems, see “E-4 Temperature cannot be controlled”.

D155A-6

60 Air conditioner

SEN04442-00

Testing vent (mode) changeover 1 Outline The vent (modes) are selected by changing the angles of the 4 internal doors (dampers). The angles of the doors (dampers) are changed by the servomotor through plate (P2), defroster rod (RODD), front face rod (RODF) and lever 7 (LEVER 7) – lever 12 (LEVER 12). Only defroster rod (RODD), front face rod (RODF), lever 7 (L7) and lever 8 (L8) are seen from outside. (For the figure, see item 5.) Visually check the positions of the levers and opening and closing operations of the doors (dampers) of the front face and rear face. The rear face door (damper) angle is changed by the servomotor through lever (L13) and rod (RODR). Since lever (L11) of the front face and lever (L13) and rod (RODR) of the rear face are not seen from outside, remove the duct and check the revolution of the door (damper) directly. a To reset the self-diagnosis system (To delete the air conditioner error displayed on the air conditioner screen of the machine monitor), the starting switch must be turned OFF (While the self-diagnosis system is indicating a trouble, no signals are output to the servomotor). 1.

Referring to “Testing temperature control, 1. – 3.,” remove recirculated filter (1), duct (2) and cover (3).

2.

Check contacts of connector [5] of the servomotor (for disconnection).

3.

Check the defroster rod (RODD) and foot rod (RODF) for disconnection.

4.


5.

Press the vent selector switch on the air conditioner screen of the monitor and check visually that lever 7 (L7) and lever 8 ( L8) move smoothly between the foot mode and defroster mode shown in the figure.

6.

Stop the engine.

7.

Remove rear face duct (RFD).

8.

Referring to “Testing for air leakage (ducts)”, remove the ducts in order from the one on the monitor side and remove front face duct (FFD).

D155A-6

39

SEN04442-00

60 Air conditioner

9.


10. Press the vent selector switch on the air conditioner screen of the monitor and check the opening and closing operations of the front face door and rear face door (damper).

q

When lever 7 (L7) and lever 8 (L8) do not move smoothly through the range shown in the figure or the front face door and rear face door (damper) do not open or close 1) 2)

3) 4)

40

Disconnect connectors [5] and [6] of the servomotor. Make match marks on servomotors (5) and (6) to show which servomotor has been installed. (The servomotor will be exchanged with each other later.) Remove servomotors (5) and (6). Remove cover (7). a Figure is PC200-8 type, so duct is different from this type.

D155A-6

60 Air conditioner

5)

a

Rotate plate (P2) with the hand to see where lever 7 (L7) – lever 12 (L12) are hitched and then repair. a If the levers do not move smoothly, clean them and apply grease to the links. 2 Link: Molykote ® MH-62 Grease (Dow Corning Toray Co. Ltd.) 6) When plate (P2) is rotated with the hand, if lever 7 (L7) – lever 12 (L12) move smoothly, the servomotor may have trouble. In this case, exchange servomotors (5) and (6) and operate them. a The figures of the foot mode and defroster mode are shown before. For electrical problem, see “E-5 Vent (mode) cannot be changed over”.

D155A-6

SEN04442-00 a

F. Face door position will change from “OPEN” to “Half” gradually when raising the setting temperature from 18°C to 32°C gradually.

41

SEN04442-00

Testing Recirc/Fresh changeover1 Outline Recirculated air or fresh air is selected by changing the door (damper) angle in the air conditioner unit with the servomotor. Check the opening and closing operations of the door (damper) visually. a The system does not have self-diagnosis function for the Recirc/Fresh changeover servomotor. 1.

Remove recirculation air filter from behind the operator seat.

2.


3.

Press the Recirc/Fresh selector switch on the air conditioner screen of the monitor and check visually that door (damper) (F/R D) opens and closes.

4.

When door (damper) (F/R D) does not open and close, check contacts of connector [7] of the servomotor (for disconnection), referring to “Testing temperature control, 1. –3.”, recirculated filter (1), duct (2) and cover (3).

a

42

60 Air conditioner

Reference q How to remove fresh air duct. 1. Remove duct (4).

For electric problems, see “E-6 Recirc/ Fresh cannot be changed over”.

D155A-6

60 Air conditioner

q

a

SEN04442-00

Method of replacing Recirc/Fresh changeover servomotor Remove fresh air duct in advance. 1) Disconnect connector [7]. (Explained before) 2) Disconnect inner sensor connector [8]. 3) Remove box assembly (11). 4) Remove the Recirc/Fresh changeover servomotor from box assembly (11).

D155A-6

43

SEN04442-00

Testing inner sensor a

q

q

60 Air conditioner

1

8.

Inner Sensor is the same as inside temperature sensor on “block diagram” or “circuit diagram”. If “Inner Sensor abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”), test the inner sensor. To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.

Check that the resistance between female connector [8] (2) (PB) (on the wiring harness side) and connector [1] (11) (PB) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.)

9.

Check that the resistance between female connector [8] (1) (BrR) (on the wiring harness side) and connector [2] (27) (BrR) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.)

1.

Referring to “Testing temperature control, 1. – 3.,” recirculated filter (1), duct (2) and cover (3).

2.

Check contacts of inner sensor connector [8] (for disconnection).

3.

Referring to “Testing Recirc/Fresh changeover door (damper)”, remove the fresh air duct.

4.

Referring to “Method of replacing Recirc/Fresh changeover servomotor”, remove box assembly (11).

5.

Resistance between terminals on sensor side of connector [8]: Normal value: 0°C ----- 1.6 kz 25°C --- 5 kz

6.

Disconnect connectors [1] and [2] from control amplifier (CNTAMP).

7.

Check that the female terminals (on the wiring harness side) of connector [8] are not shorted to each other. (If they are shorted, the wiring harness is defective.)

44

10. Connect all the connectors. 11. Turn the starting switch ON and carry out selfdiagnosis (“Abnormality Record” screen on the machine monitor: “03 Air-conditioning System”). If “Inner Sensor abnormal” is still displayed, replace the control amplifier.

D155A-6

60 Air conditioner

Testing evaporator temperature sensor 1 q

q

If “Ventilating Sensor abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”), test the evaporator temperature sensor. To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.

1.

Remove recirculated air filter (1), duct (2) and cover (3) according to Testing temperature control, 1 – 3.

2.

Disconnect connectors AC01 and AC02 from air conditioner unit (A/C U).

3.

Disconnect clamp (4).

4.

Remove control amplifier (CNTAMP) and its bracket together.

SEN04442-00

6.

Disconnect connector [9].

7.

Measure the resistance between the mate (female) of connector [9] and the terminal on the evaporator temperature sensor side. Normal value: 0°C ----- 4.8 kz 15°C --- 2.3 kz

a

8.

5.

Ensure contact of connector [9] along wiring harness (H). (Check for disconnection.)

D155A-6

If an error is detected by the self-diagnosis and evaporator temperature sensor is normal, control amplifier (CNTAMP) or the wiring harness is defective.

Disconnect connectors [1] and [2] from control amplifier (CNTAMP). (Connect connector [9].) Resistance between terminal (11) (PB) of connector [1] and (27) (BrR) of [2]: Normal value: 0°C ----- 4.8 kz 15°C --- 2.3 kz a If the result of 8. above is normal, control amplifier (CNTAMP) is defective. If the result of 8. above is abnormal, and the result of 7. is normal, the wiring harness is defective.

45

SEN04442-00 a

If the evaporator temperature sensor is defective, replace it according to the following procedure.

q

Replacing evaporator temperature sensor. Remove air conditioner unit assembly (A/C U). For details, see Shop Manual, Chapter 50, “Removal and installation of air conditioner unit assembly”.

1.

2.

Remove wiring harness. (For each connector, see the “Part and connector locations”.)

3.

Remove servomotors (2) and (3).

4.

Remove cover (4).

5.

Remove the link section. For details, see Shop Manual, Chapter 60, Structure and function, “Air conditioner unit”.

6.

Separate cases (5) and (6).

46

60 Air conditioner

D155A-6

60 Air conditioner

7.

Remove the evaporator.

8.

Remove the holder from part (P) and remove the evaporator temperature sensor.

SEN04442-00

Installation 1.

Install the evaporator temperature sensor to the position shown in the previous figure with the holder.

2.

Carry out the following installation in the reverse order to removal.

D155A-6

47

SEN04442-00

Testing sunlight sensor q

q

1.

2.

48

60 Air conditioner

1

If “Sunlight Sensor abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”), test sunlight sensor connector SLS. To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF. a A short circuit between the terminals of the sunlight sensor unit is a defect. Whether the sunlight sensor is normal cannot be checked by measuring resistance, etc., however. Accordingly, if the wiring is normal, presume the sunlight sensor to be abnormal and replace it. If “Sunlight Sensor abnormal” is still displayed, replace the control amplifier. Remove cover (10) and check connector SLS of sunlight sensor (S) on the rear side of the cover (for disconnection).

3.

Referring to “Testing temperature control, 1. – 3.,” recirculated filter (1), duct (2) and cover (3).

4.

Referring to “Testing evaporator temperature sensor item 1, 5.”, disconnect connector [1] from control amplifier (CNTAMP).

5.

Ensure that the terminals of female connector SLS (on the wiring harness side) are not shorted to each other. (If they are shorted, the wiring harness is defective.)

6.

Check that the resistance between female connector SLS (2) (L) (on the wiring harness side) and connector [1] (3) (YW) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.) a If the result of item 6 or item 7 is abnormal, check the contact of connector CN-AC01. (See “Part and connector locations.”)

7.

Check that the resistance between female connector SLS (1) (O) (on the wiring harness side) and connector [1] (15) (RB) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.)

8.

Connect all the connectors.

9.

Turn the starting switch ON and carry out selfdiagnosis (on the air conditioner fault history screen of the machine monitor). If “Sunlight Sensor abnormal” is still displayed, replace the control amplifier.

Disconnect SLS connector and measure voltage between male terminals on sunlight sensor (S) at voltage range of tester because the sensor (S) may be broken by measurement of resistance at resistance range of tester. q Approximate voltage of sunlight sensor unit 0.55 (V): direct sunlight 0.45 (V): cloudy 0.4 (V): in room

D155A-6

60 Air conditioner

Testing (dual) pressure switch for refrigerant 1 q

q

q

a

1.

If “Refrigerant abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”), test pressure switch connector AC05. To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF. The pressure switch unit is turned ON when the refrigerant pressure is normal and OFF when the refrigerant pressure is abnormal. The pressure switch unit may be OFF when ambient temperature below 0°C because the refrigerant pressure becomes down. The pressure switch unit is not defective but normal.

SEN04442-00

3.

Ensure that the terminals on the switch side of connector AC05 are shorted to each other (ON). (When they are not shorted (OFF), the pressure switch detects abnormal refrigerant pressure.) a When the pressure switch is OFF, connect a pressure gauge to the high pressure side of the air conditioner compressor and check the refrigerant pressure. See “Connection of service tool” and “Troubleshooting with gauge pressure.” a If refrigerant pressure is normal, the pressure switch is defective.

q

(Dual) pressure switch

Open engine left cover (1) and remove covers (2) – (4).

LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2} 2.

Disconnect pressure switch connector AC05. RD: Receiver drier SG: Sight glass

D155A-6

k

When replacing the pressure switch, be sure to collect the refrigerant.

49

SEN04442-00

q

50

60 Air conditioner

When the terminals on the switch side of connector AC05 are shorted (ON) (See E-2 for circuit) 1) Referring to “Testing temperature control, 1., 3.,” recirculated filter (1), duct (2) and cover (3). 2)

Disconnect connector [1] from control amplifier (CNTAMP).

3)

Check that the resistance between female connector AC05 (2) (B) (on the wiring harness side) and the ground is 1 z or below. (If not, the wiring harness is defective.)

4)

Check that the resistance between female connector AC05 (1) (G) (on the wiring harness side) and connector [1] (4) (GB) (on the wiring harness side) is 1 z or below. (If not, the wiring harness is defective.) a If the result of item 4) is abnormal, check the contact of connector CNAC01. (See “Part and connector locations.”)

5)

Connect all the connectors.

6)

Turn the starting switch ON and carry out self-diagnosis (“Abnormality Record” screen on machine monitor: “03 Air-conditioning System”). If “Refrigerant abnormal” is still displayed, replace the control amplifier.

D155A-6

60 Air conditioner

Testing relays and diodes a a

SEN04442-00

1

If the air conditioner compressor is normal (air is cooled) and air comes out, the relays are normal. Accordingly, skip these relay tests. Bring your ear to each relay to check its operation by sound.

There are two relays. q Blower main relay (connector AC03): Used to turn the fan motor ON/OFF. q Compressor clutch relay (connector AC04): Used to turn the air conditioner compressor (clutch) ON/OFF 1.

Check contacts of connectors AC03 and AC04 (for disconnection) from left behind of operator seat.

2.

Turn the starting switch ON (do not start the engine) and turn the main power of the air conditioner ON. If the blower-off relay is normal, it is turned ON. Check its click.

3.

If the air conditioner switch is turned ON at this time, the compressor relay is turned ON if it is normal. Check its click. a Control amplifier (CNTAMP) does not turn the compressor relay ON in the following cases. 1) When the evaporator temperature is below 3°C (depending on the input voltage from the evaporator temperature sensor). 2) When the pressure switch detects abnormality (it is turned OFF). a If the fan sound is too loud to hear the compressor relay sound, disconnect connector AC03 with the starting switch in the OFF position, and then check. IF: Recirculated air filter

D155A-6

q

Checking relay unit a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil actually.

Blower main relay (AC03) 1) The resistance of the coil between terminals (1) and (2) is 140 – 340 z. 2) While the voltage (DC20 – 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are disconnected from each other and terminals (3) and (5) are connected to each other. 3) While the voltage (DC20 – 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (4) are connected to each other and terminals (3) and (5) are disconnected from each other.

Compressor clutch relay (AC04) 1) The resistance of the coil between terminals (1) and (3) is 140 – 340 z. 2) Without voltage (DC20 – 30 V) applied between terminals (1) (+) and (3), terminals (2) and (4) are disconnected from each other. 3) With the voltage (DC20 – 30 V) applied between terminals (1) (+) and (3), terminals (2) and (4) are connected to each other.

51

SEN04442-00

q

52

60 Air conditioner

Testing diode units (ACD1) and (ACD2) (male) a Measure with a circuit tester in the diode range. a Test ACD2 similarly to ACD1. Between ACD1 (2) (+) and (1) (–): There is continuity. Between ACD1 (2) (–) and (1) (+): There is no continuity.

D155A-6

60 Air conditioner

Troubleshooting chart 1

SEN04442-00

1

a a 1.

The numbers in the boxes are the item numbers in the troubleshooting table. E-2, E-3 means Troubleshooting for electrical system (E mode). Cooling trouble

2.

Heating trouble

D155A-6

53

SEN04442-00

60 Air conditioner

Troubleshooting chart 2 1.

1

Blower fan motor does not revolve or its speed is different from set value. a See troubleshooting "E-3 Blower motor system (No air comes out or air flow is abnormal)" for troubleshooting for the electrical system. Possible cause

Check method

Defective BLOWER MAIN RELAY See “Testing relays and diodes”

Remedy Replace

Disconnection of wire or defective Check connector of blower fan motor for disconnec- Repair broken parts and conconnection tion. See E-3 and “Part and connector locations” nect correctly Defective blower motor

Check two lead wires of motor with circuit tester. If there is not continuity, motor is defective. See E-3 and “Part and connector locations”

Replace

Defective POWER TRANSISTOR Move fan switches in sequence and check fan speed. Replace (PTR) Defective diode (ACD1)

2.

Check diode (ACD1). See E-3 and “Testing relays and diodes”.

Replace

Blower fan motor is normal but air flow is insufficient. Possible cause

Check method

Remedy

Large duct resistance

Check duct for crushing and filter for clogging

Repair

Air leakage

See “Testing air leakage (duct)”

Repair or replace

Obstruction on suction side of evaporator

Check evaporator for stain and obstruction

Remove obstruction and clean

Defective evaporator temperature sensor, defective contact of evaporator temperature sensor or defective expansion valve

Evaporator is frozen. Check sensor clip. Check sensor for dirt. Check the frost on the hose near pressure switch (when freezing advances furthermore)

Repair or replace (Evaporator temperature sensor and expansion valve are in air conditioner unit)

Check method

Remedy

3.

Low/high pressure Possible cause

Collect refrigerant, then charge with proper quantity of refrigerant again

Excessive or insufficient refrigerant Insufficient refrigerant

If R-134a is used as refrigerant, its quantity cannot be checked through sight glass. Accordingly, check by connecting gauge manifold. Purpose of sight glass is to check refrigerant flow.

Collect refrigerant, then charge with proper quantity of refrigerant again

Overcharge with refrigerant

Judgment by pressure at inlet/ outlet of compressor

54

Repair leaking part, then charge with proper quantity of refrigerant again

Normal pressure range Low pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2} High pressure: Appox. 1.5 – 1.7 MPa {15 – 17 kg/cm2} These values are for following condition, however. Temperature in cab: 30 – 35°C Engine speed: Appox. 1500 rpm

See Troubleshooting with gauge pressure

D155A-6

60 Air conditioner

4.

SEN04442-00

Compressor does not revolve at all or its speed is low. a See "E-2 compressor system (Air is not cooled)" for troubleshooting for the electrical system.

Troubled part

Possible cause

Compressor belt Loosened compressor belt Trouble in compressor Compressor

Magnet clutch

Check method

Remedy

Vibration amplitude of belt is large Adjust tension Slip of belt

Repair or replace

Insufficient compressor oil or seizure Heating of compressor in the compressor

See "Handling compressor oil"

Low battery voltage

Slip of clutch

Charge battery

Disconnection or short circuit in coil

Inspect with circuit tester (10 – 20 z)

Replace

Disconnection in wiring or defective Check ground wire and connecconnection of ground wire tions

Repair

Relay

Defective compressor clutch relay

See “Testing relays and diodes.” Replace

Refrigerant pressure

Low/high pressure (Operation of pressure switch)



Pressure switch Defective pressure switch

See “Testing (dual) pressure switch for refrigerant” and E-2

Replace

Diode

Check diode (ACD2). See E-2 and “Testing relays and Replace diodes.”

5.

Defective diode (ACD2)

Blower fan motor is normal but air flow is insufficient. Possible cause

Check method

Remedy

Large duct resistance

Check duct for crushing and filter for clogging

Repair

Air leakage through duct joints

Check duct joints for defective duct seal and disconnection of duct

Repair

Clogging of heater core fins

Check heater core fins for clogging

Repair

6.

Check of hot water Possible cause

Check method

Remedy

Low engine coolant temperature

Warm up engine, and then check engine coolant temperature

Find out cause

Low engine coolant level

Check coolant level in radiator

Add coolant

Insufficient circulation of engine coolant

Check engine coolant piping for clogging (Hose, pipe, and core)

Bleed air and repair

Contrary connection of IN and OUT Check the destination of heater hoses heater hoses

7.

Repair

Fan rotation speed Possible cause

Fan rotation speed is low

D155A-6

Check method See "Checking and adjusting air conditioner compressor belt tension" in chapter 30 "Testing and adjusting" of shop manual.

Remedy Repair

55

SEN04442-00

8.

60 Air conditioner

Other items Possible cause

Check method

Temperature cannot be adjusted

See "Testing temperature control" and "Troubleshooting for electrical system, E-4"

Vent (mode) cannot be changed over

See "Testing vent (mode) changeover" and "Troubleshooting for electrical system, E-5"

Recirc/Fresh cannot be changed over

See "Testing Recirc/Fresh changeover" and "Troubleshooting for electrical system, E-6"

Excessive compressor oil

See "Handling compressor oil"

Water leakage into the cab

Clogging of drain hole

56

Remark

Common to cooling and heating

Cooling only

D155A-6

60 Air conditioner

SEN04442-00

Troubleshooting for electrical system (E mode) a

The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before troubleshooting, understand the information fully. Trouble Related information

Problem that appears on machine Information related to detected trouble or troubleshooting

Causes


a

1

Procedure/Standard (normal) value/Remarks on troubleshooting

• Standard (value) required for judgement (Normal state value) 1 Assumed causes for trouble • Remarks required for judgement (The order number indicates a serial number, not a priority sequence. Perform trouble- (1) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads shooting according to these as shown below unless otherwise specified. 2 numbers, however.) • Connect the plus (+) lead to pin or harness indicated in the front. • Connect the minus (–) lead to a pin or harness indicated in the rear. (2) Example of troubleshooting by inspection of multiple items 3 - defective a Normal in 1 but abnormal in 2 At this time “- defective” shown at left is applied

If a wiring harness is burnt, replace it.

q Disconnection in wiring The connector connection is defective or wiring harness is disconnected. q Ground fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit accidentally. q Hot short circuit A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit accidentally. q Short circuit A harness of an independent circuit abnormally comes into contact with one of another circuit. Related circuit diagram This is the excerpted circuit diagram related to troubleshooting q Connector No.: Indicates (Model – No. of pins) (Color). q See “Arrangement of connector pins” and “Arrangement of parts and connectors” q The circuit diagram shows the size and colors of wires. W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown a When there are 2 colors Example: WY: Yellow line on white background a The number before the wire color indicates the wire size. q N.C.: Normally closed (Normally turned ON) q [1], [2],··· are connector numbers. q Arrow (io): Roughly indicates mounting place on machine.

D155A-6

57

SEN04442-00

60 Air conditioner

E-1 Power supply system (Air conditioner does not operate) Problem Indication of problem on machine

Air conditioner does not operate due to power supply system failure. • “A/C Controller Error” is displayed red on air conditioner screen of machine monitor. • No air blows out (Blower motor does not rotate). • If failure code [DAFRMC] is displayed on machine monitor, see Chapter 40 Troubleshooting first and repair so that [DAFRMC] will not be displayed. a CAN communication is connected to machine monitor, engine controller, pump controller and air conditioner controller.

Related information

• “A/C Controller Error” is displayed on air conditioner operation screen of machine monitor in following cases. In E-1, 1), 2) and 3) of following cases are explained. 1) Power is not supplied to control amplifier. 2) Control amplifier is broken. 3) Control amplifier (CNTAMP) cannot communicate with machine monitor. 4) Blowing out door (damper) servomotor does not rotate. 5) Temperature control (AIRMIX) door (damper) servomotor does not rotate. 6) Refrigerant pressure is abnormal. • Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine monitor: “03 Air-conditioning System” and check to see if “CAN Status” is abnormal. Abnormality of “CAN Status” indicates that control amplifier at rear of air conditioner unit cannot communicate with machine monitor. “CAN Status” is indicated as abnormal in any case of 1), 2) and 3) above. • Referring to “Part and connector locations”, ensure the following. 1) Circuit breaker CB3 is not OFF (Its reset button is not projected). (It is ON, if normal.) 2) Fuse Fu5A is not broken. • Ground cable of air conditioner is grounded together with that of machine wiring harness for electrical equipment of machine. • For each connector and relay, see “Part and connector locations”. • If fuse is broken when A/C switch is pressed, see E-2. • T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a T-adapter is not prepared for other connectors. Causes


1

Between (16) (black) on wiring harness side of connector [1] – ground 2

58

Defective wiring harness (ground cable)

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect connector [1] from control amplifier and carry out troubleshooting without turning starting switch ON.

Circuit breaker CB3 is OFF, broken fuse

Resistance

Max. 1 z

1) Turn starting switch OFF. 2) Referring to “Part and connector locations”, check circuit breaker CB3 is not OFF (Its reset button is not projected) and check fuse Fu5A.

D155A-6

60 Air conditioner

SEN04442-00

Causes

Standard value in normal state/Remarks on troubleshooting a If fuse described in related information is broken, replace it. 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect connectors [1] and [2] from control amplifier. 4) Turn starting switch ON and carry out troubleshooting. Between (6) (red) – (16) (B) on wiring harness side of connector [1]

3 Defective wiring harness


Ground fault in wiring 4 harness (Contact with GND circuit)

5

D155A-6

Disconnection in wiring harness

Voltage

20 – 30 V

A

a If fuse is broken again in test A above, perform following procedure. (Replace broken fuse.) 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect control amplifier connector [1] and carry out troubleshooting without turning starting switch ON. a If fuse is broken again in test A above and results B and C below are normal, blower motor circuit may be cause of trouble. See E3. Between (6) (red) – (16) (black) wiring harness side of connector [1]

Resistance

Min. 1 Mz

B

Between (6) (red) on wiring harness side of connector [1] – ground

Resistance

Min. 1 Mz

C

a If fuse is broken again in test A for cause 3 and result of B or C is abnormal, identify wiring harness having ground fault. 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect connectors AC01, AC02 and [1]. 4) Connect T-adapter to wiring harness side of connector [1] and carry out troubleshooting without turning starting switch ON. a If result D or E below is abnormal: Short circuit in air conditioner wiring harness (on plate) a If result F or G below is abnormal: Short circuit in machine wiring harness Between (6) (red) – (16) (black) on wiring harness side of connector [1]

Resistance

Min. 1 Mz

D

Between (6) (red) on wiring harness side of connector [1] – ground

Resistance

Min. 1 Mz

E

Between connector AC02 (female) (4) – AC01 (female) (5) (black)

Resistance

Min. 1 Mz

F

Between connector AC01 (female) (4) (red) – (5) (black)

Resistance

Min. 1 Mz

G

a If fuse described in related information is not broken and test result A for cause 3 is abnormal, check with circuit diagram.

59

SEN04442-00

60 Air conditioner

Causes

Standard value in normal state/Remarks on troubleshooting a If CAN communication circuit has short circuit or ground fault, [DAFRMC] error is displayed. a Terminal resistors of about 120 z are in machine monitor and on engine. Since they are connected in parallel, combined resistance is about 60 z. 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect control amplifier connectors [1] and [2] and connect T-adapter to wiring harness side. 4) Carry out troubleshooting without turning starting switch ON.


Disconnection in CAN communication circuit 6 (Communication between control panel and control amplifier is defective)

Between connector [2] (17) – (18)

Approx. 60 z

H

a If result H above is abnormal, perform following procedure. a If result H above and J below are abnormal, operator cab wiring harness is abnormal. a If result H above is abnormal and J below is normal, air conditioner wiring harness (on plate) is abnormal. a Terminal resistors of about 120 z are in machine monitor and on engine. Since they are connected in parallel, combined resistance is about 60 z. 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect control amplifier connectors [1] and [2] and connect T-adapter to wiring harness side. 4) Carry out troubleshooting without turning starting switch ON. Between connector AC02 (female) (1) – (2)

60

Resistance

Resistance

Approx. 60 z

J

7 Defective control amplifier

When test results for causes 1, 2, result A for cause 3 and result H for cause 6 are normal, replace control amplifier.


When test results for causes 1 – 7 are normal, machine monitor is defective.

D155A-6

60 Air conditioner

SEN04442-00


D155A-6

61

SEN04442-00

60 Air conditioner

E-2 Compressor system (Air is not cooled) Problem

Air is not cooled due to compressor system failure.

Indication of problem on machine

• When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is not cooled as displayed on screen. • Air conditioner compressor does not operate. • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. Causes of this phenomenon are 1) – 6). For 1) – 5), see “Related information” in E-1.

Related information

In E-2, “6) Refrigerant pressure is abnormal” of “Related information” in E-1 is explained. • Referring to “Testing with self-diagnosis function”, display air conditioner fault history screen on machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is abnormal, compressor is not turned ON and air is not cooled consequently. a Abnormal refrigerant pressure indicates that “Signal (connector [1] (4)) from pressure switch is not grounded”. • Air conditioner may not be turned ON even when ambient temperature is below 5°C (Normal). • For each connector, see “Part and connector locations”. • T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a T-adapter is not prepared for other connectors. Causes

1 Defective pressure switch

Standard value in normal state/Remarks on troubleshooting a If “A/C Controller Error” is displayed red on air conditioner operation screen of machine monitor, perform following procedure. 1) Turn starting switch OFF. 2) Disconnect battery ground terminal. 3) Disconnect pressure switch connector P17 and carry out troubleshooting without turning starting switch ON. a Pressure switch may operate normally and turn off itself. Accordingly, if following is abnormal (if switch is turned OFF), install pressure gauge to low pressure side of air conditioner compressor and check refrigerant pressure. Between (1) – (2) on pressure switch side of connector AC05 k

Possible causes and standard value in normal state 2

Defective air conditioner compressor

Resistance

Max. 1 z

Before replacing pressure switch, collect refrigerant.

1) Turn starting switch OFF. 2) Disconnect connector A/C from air conditioner compressor and carry out troubleshooting without turning starting switch ON. a Ensure connection of air conditioner compressor ground cable and GND09. (See “Part and connector locations”.) Between (1) on air conditioner compressor side of connector A/C – ground (Air conditioner compressor coil resistance)

Resistance

Approx. 15 z

1) Turn starting switch OFF. 2) Disconnect connectors ACS, ACD2 and carry out troubleshooting without turning starting switch ON. a Test at diode range. 3 Defective Diode

62

Between ACS (male) (1) (+) – (2) (–)

There is no continuity

Between ACS (male) (1) (–) – (2) (+)

There is continuity

Between ACD2 (male) (1) (+) – (2) (–)


Between ACD2 (male) (1) (–) – (2) (+)

There is continuity

D155A-6

60 Air conditioner

SEN04442-00

Causes

4


Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors [1], AC04 and ACS and carry out troubleshooting without turning starting switch ON. a Ensure that test result for cause 1 is normal (pressure switch is turned ON) and that for cause 2 is normal (air conditioner compressor is normal) and that cause 3 is normal. Between connector [1] (4) – ground (Pressure switch is turned ON)

Resistance

Max. 1 z

Between connector AC04 (female) (2) – ground (Air conditioner compressor coil resistance)

Resistance

Approx. 15 z

Between connector ACS (male) (2) – ground

Resistance

Max. 1 z

• Referring to “Testing relays”, check sound made when compressor clutch relay is turned ON. a If blower sound is too large to hear operating sound of compressor clutch relay, turn starting switch OFF temporarily and disconnect connector R30.

Click is heard.

A

a If A above and B below are abnormal and C is normal (relay is normal), go to causes 7 and 8. 5


Defective compressor clutch 1) Turn starting switch OFF. 2) Disconnect connector AC04. relay (Does not turn ON) 3) Short (2) (white) and (4) (green) of connector AC04 (on wiring harness side) wire. (Turn compressor ON forcibly without using relay.) 4) Turn starting switch ON.

Air is cooled.

B

1) Turn starting switch OFF. 2) Disconnect connector AC04 and carry out troubleshooting without turning starting switch ON. Between AC04 (relay side) (1) – (3) (coil resistance)

Ground fault in wiring 6 harness (Contact with GND circuit)

Resistance

Approx. 140 – 340 z

C

a If fuse is not broken, skip troubleshooting. 1) Turn starting switch OFF. 2) Disconnect connector AC04 and carry out troubleshooting without turning starting switch ON. a Ensure that test result for cause is normal. Between (2) on machine wiring harness side of connector AC04 – ground (Air conditioner compressor coil resistance)

Resistance

Approx. 15 z

1) Turn starting switch OFF. 2) Disconnect connector AC04 and [2] and carry out troubleshooting Short circuit in wiring without turning starting switch ON. 7 harness (with another wiring a Ensure that test result for cause 2 is normal. harness) Between (3) – (1) on machine wiring harness ResisMin. 1 Mz side of connector AC04 tance 8



Check with circuit diagram. 1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter in wiring harness side. 3) Turn starting switch ON. 4) Display air conditioner operation screen on machine monitor and press A/C switch. Between connector [2] (35) – [1] (16)

10

D155A-6

Defective machine monitor (Defective switch)

Voltage

Max. 1 V

1) Turn starting switch ON. 2) Display air conditioner operation screen on machine monitor. Press A/C switch.

“A/C ON” is displayed.

63

SEN04442-00

60 Air conditioner


64

D155A-6

60 Air conditioner

SEN04442-00

E-3 Blower motor system (No air comes out or air flow is abnormal) Problem

No air comes out or air flow is abnormal due to blower motor system failure.


• LCD of machine monitor on air conditioner operation screen lights normally but air does not come out. • Air flow does not match fan switch setting on air conditioner operation screen.

Related information

• This trouble is not checked with self-diagnosis function. • If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. Possible causes for this trouble are as follows. 1) Compressor clutch relay is defective (Stuck closed). (See E-2, 5, A.) 2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air conditioner unit.) 3) Expansion valve is adjusted improperly. (Remove air conditioner unit and replace expansion valve.) • If air comes out, fuse and relay are normal and wiring harness is seldom abnormal. • If air comes out but its flow is abnormal in heating mode, replace power transistor first. • For each connector, relay, and power transistor, see “Part and connector locations”. • T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a T-adapter is not prepared for other connectors. Causes


1) Turn starting switch OFF. 2) Disconnect connector [3] and carry out troubleshooting without turning starting switch ON. 1 Defective blower (fan) motor Between wiring harness terminals on blower There is continuity motor side of connector [3] a If power transistor is normal, all of following are normal. Reverse is not always true, however (Transistor itself cannot be checked if transistor unit is removed). 1) Turn starting switch OFF. 2) Disconnect connector [4] and carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state 2 Defective power transistor

D155A-6

Between (2) (+) – (1) of connector [4] (male) (power transistor) (Internal fuse and resistor must not be broken) a If test result is abnormal, overcurrent has flowed. In this case, replace blower motor, too.

Approx. 11 kz

Between (3) – (4) of connector [4] (male) (power transistor) (Internal resistor must not be broken)

Approx. 2.2 kz

Between (1) (+) – (3) (–) of connector [4] (male) (power transistor)

There is continuity * Diode range

Between (3) (+) – (1) (–) of connector [4] (male) (power transistor)

There is no continuity * Diode range

65

SEN04442-00

60 Air conditioner

Causes

Standard value in normal state/Remarks on troubleshooting • Referring to “Testing relay”, check turn-on sound of blower main relay.

Click is heard.

A

a If test results A above and B below are abnormal and C is normal (relay is normal), go to causes 8-J and 10.

3

Defective blower main relay (Does not turn ON)

1) Turn starting switch OFF. 2) Disconnect connector AC03. 3) Short (3) (red/yellow) and (4) (red/blue) of connector AC03 (wiring harness side) with wire. (Turn blower ON forcibly without using relay.) 4) Turn starting switch ON. Operate fan on air conditioner operation screen.

Air comes out.

B

a If air does not come out even when blower is turned ON forcibly without using relay, cause is part other than relay. 1) Turn starting switch OFF. 2) Disconnect connector AC03 and carry out troubleshooting without turning starting switch ON. Between (1) – (2) of AC03 (relay side) (coil resistance)

4 Defective Diode Possible causes and standard value in normal state 5

Defective wiring harness (ground)

Resistance

Approx. 140 – 340 z

C

1) Turn starting switch OFF. 2) Disconnect connector ACD1 and carry out troubleshooting without turning starting switch ON. a Test at diode range. Between ACD1 (male) (1) (+) – (2) (–)


Between ACD1 (male) (1) (–) – (2) (+)

There is continuity

1) Turn starting switch OFF. 2) Disconnect connector [4] and carry out troubleshooting without turning starting switch ON. Between (1) (black) on wiring harness side of connector [4] – ground

Resistance

Max. 1 z

• Blower motor input voltage 1) Turn starting switch OFF. 2) Disconnect connector [3]. 3) Turn starting switch ON. 4) Press fan switch on air conditioner operation screen. (Air flow may be set to any position.) a If result is abnormal, go to causes 8-J and 10. Between (1) (red/yellow) on wiring harness side of connector [3] – ground

6

Check of input and output voltages

Voltage

Approx. 24 V

• Power transistor input voltage 1) Turn starting switch OFF. 2) Disconnect connector [4]. (Since no current flows to blower motor, blower motor does not rotate.) 3) Turn starting switch ON. 4) Press fan switch on air conditioner operation screen. (Air flow may be set to any position.) a If D below is abnormal, go to G below. a If E below is abnormal, go to causes (9) and (10). Between (2) (brown/black) – (1) (black) on wiring harness side of connector [4]

Voltage

Max. 2 V

D

Between (3) (black/blue) – (1) (black) on wiring harness side of connector [4]

Voltage

Approx. 24 V *1

E

*1: At blower main relay ON

66

D155A-6

60 Air conditioner

SEN04442-00

Causes

6

Check of input and output voltages

7 Defective blower (fan) motor


• Control amplifier 1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. 4) Press fan switch on air conditioner operation screen. (Air flow may be set to any position.) a If F below is abnormal, go to causes 7-J and 9. a If G below is abnormal, go to causes (9) and (10). Between (36) – (16) of connector [2]

Voltage

Max. 1 V

F

Between (8) – (16) of connector [1]

Voltage

Max. 2 V

G

When test results D for cause 6 are normal (voltage is normal but motor does not rotate), blower (fan) motor is defective. 1) Turn starting switch OFF. 2) Disconnect connectors AC03 and [1] and carry out troubleshooting without turning starting switch ON.

Short circuit in wiring 8 harness (with another wiring Between (2) – (1) on wiring harness side of connector AC03 harness) Between (6) – (7) on wiring harness side of connector [1] Ground fault in wiring 9 harness (Contact with GND circuit) 10



Defective machine monitor 12 (Defective switch)

D155A-6


Resistance Resistance

Min. 1 Mz

J

Min. 1 Mz

1) Turn starting switch OFF. 2) Disconnect connectors [1] and [4] and carry out troubleshooting without turning starting switch ON. Between (2) – (1) on wiring harness side of connector [4]

Resistance

Min. 1 Mz

Check with circuit diagram. Control amplifier is defective in following cases. 1) F for cause 6 is abnormal, J for cause 8 is normal, and cause 10 is normal. 2) G for cause 6 is abnormal and causes 9 and 10 are normal. 1) Turn starting switch ON. 2) Display air conditioner operation screen on machine monitor. Press fan switches from MIN to MAX.

LCD display of air flow changes from MIN to MAX.

67

SEN04442-00

60 Air conditioner


68

D155A-6

60 Air conditioner

D155A-6

SEN04442-00

69

SEN04442-00

60 Air conditioner

E-4 Temperature cannot be controlled Problem

Temperature cannot be controlled.


• “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-1.) • While air conditioner operation screen of machine monitor is displayed, temperature does not change even if temperature control switch is operated.

Related information

a Temperature control means “Air Mix” of cooled air and hot air. • Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine monitor: “03 Air-conditioning System” and check to see if “Air Mix is abnormal” and “Inner sensor is abnormal”. See “Testing inner sensor” when “Inner sensor is abnormal”. • Even if rod etc. is disconnected (See “Testing temperature control”), if current is supplied to air mix servomotor by operating switches and potentiometer in servomotor reaches normal voltage, selfdiagnosis function judges system normal. • Referring to “Testing temperature control”, check that there is not contact of connector [6] or mechanical trouble (removal or interference of link, etc.) • Air mix servomotor and air blowing out (mode) servomotor are same part number. Operating angle of temperature control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and blowing out (mode) servomotor to see if they are normal. • Air mix servomotor can be checked for trouble by connecting new servomotor to connector [6] and see if it operates normally. • For each connector, see “Part and connector locations”. • T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a Since T-adapter is not prepared for other connectors, check signals with control amplifier during operation. Causes

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector [6] and carry out troubleshooting without turning starting switch ON.

Between (6) – (7) of connector [6] (on servomotor side) (There must not be Defective air mix servomotor disconnection or short circuit) 1 (Unit test) Between (1) – (3) of connector [6] (on servomotor side) (There must not be disconnection or short circuit) Between (1) – (5) of connector [6] (on servomotor side) (There must not be disconnection or short circuit) Possible causes and standard value in normal state

70

Resistance

400 – 3000 z

Resistance

4 k – 8 kz

Resistance

4 k – 8 kz

1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. Between connector [1] (3) – [2] (27)

Voltage

5V

1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. 4) Set temperature control switch on air conditioner operation screen to COOL MAX. Defective air mix servomotor 5) Set temperature control switch on air conditioner operation screen to HOT MAX. 2 or defective air conditioner a Voltage appears across (21) and (22) of connector [2] for about 3 wiring harness seconds (only while door moves). a Voltage across connectors [1] (2) and [2] (27) changes for about 3 seconds (only while door moves) (It is stabilized after door stops). Between (21) (+) – (22) (–) of connector [2] a If temperature is changed from HOT MAX to COOL MAX, voltage polarities are reversed.

Voltage

Approx. 24 V

Between connector [1] (2) (+) – [2] (27) (–)

Voltage

Change below 5 V

D155A-6

60 Air conditioner

SEN04442-00

Causes 3 Possible causes and standard value in normal state

Defective air conditioner wiring harness


Defective machine monitor 5 (Defective switch)

Standard value in normal state/Remarks on troubleshooting a When test result for cause 1 is normal and that for cause 2 is abnormal, perform following procedure. Check with circuit diagram. a When test result for cause 1 is normal and that for cause 2 is abnormal and that for cause 3 is normal, control amplifier is defective. 1) Turn starting switch ON. 2) Display air conditioner operation screen on machine monitor. Press temperature control switch.

LCD display changes from 18 to 32 °C.


D155A-6

71

SEN04442-00

60 Air conditioner

E-5 Vent (mode) cannot be changed over Problem Indication of problem on machine

Vent (mode) cannot be changed over. • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-1.) • When vent selector switch on air conditioner operation screen of machine monitor is operated, vent does not change. • Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine monitor: “03 Air-conditioning System” and check to see if “Ventilating sensor is abnormal”. • Even if rod etc. is disconnected (See “Testing vent (mode) changeover”), if current is supplied to blowing out (mode) servomotor by operating switches and potentiometer in servomotor reaches normal voltage, self-diagnosis function judges system normal.

Related information

• Referring to “Testing vent (mode) changeover”, check that there is not contact of connector [5] or mechanical trouble (removal or interference of link, etc.) • Air mix servomotor and blowing out (mode) servomotor are same. Operating angle of temperature control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and blowing out (mode) servomotor to see if they are normal. • Blowing out servomotor can be checked for trouble by connecting new servomotor to connector [5] and see if it operates normally. • For each connector, see “Part and connector locations”. • T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a Since T-adapter is not prepared for other connectors, check signals with control amplifier during operation. Causes

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector [5] and carry out troubleshooting without turning starting switch ON.

Between (6) – (7) of connector [5] (on servomotor side) (There must not be Defective blowing out (mode) disconnection or short circuit) 1 servomotor (Unit test) Between (1) – (3) of connector [5] (on servomotor side) (There must not be disconnection or short circuit) Between (3) – (5) of connector [5] (on servomotor side) (There must not be disconnection or short circuit) Possible causes and standard value in normal state

72

Resistance

400 – 3000 z

Resistance

4 k – 8 kz

Resistance

4 k – 8 kz

1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. Between connector [1] (3) – [2] (27)

Voltage

5V

1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. 4) Set vent selector switch on air conditioner operation screen to FACE. Defective blowing out (mode) 5) Set vent selector switch on air conditioner operation screen to 2 servomotor or defective air DEFROST. conditioner wiring harness a Voltage appears across (24) and (23) of connector [2] for about 3 seconds (only while door moves). a Voltage across connectors [1] (9) and [2] (27) changes for about 3 seconds (only while door moves) (It is stabilized after door stops). Between (24) (+) – (23) (–) of connector [2] a If vent is changed from DEFROST to FACE, voltage polarities are reversed.

Voltage

Approx. 24 V

Between connector [1] (9) (+) – [2] (27) (–)

Voltage

Changes below 5 V

D155A-6

60 Air conditioner

SEN04442-00

Causes 3 Possible causes and standard value in normal state



Standard value in normal state/Remarks on troubleshooting a When test result for cause 1 is normal and that for cause 2 is abnormal, perform following procedure. Check with circuit diagram. a When test result for cause 1 is normal and that for cause 2 is abnormal and that for cause 3 is normal, control amplifier is defective. 1) Turn starting switch ON. 2) Display air conditioner operation screen on machine monitor.

5

Defective machine monitor (Defective switch)

Operate air outlet switch and change LCD display to FACE, FACE and REAR, FOOT, FACE and REAR, FOOT, FOOT and DEFRSOT, and DEFROST.

LCD display changes to each mode


D155A-6

73

SEN04442-00

60 Air conditioner

E-6 Recirc/Fresh air cannot be changed over Problem

Recirc/Fresh air cannot be changed over.


• When Recirc/Fresh selector switch of machine monitor is operated, recirculated or fresh air does not changeover (Recirc/Fresh changeover door (damper) does not rotate).

Related information

• Recirc/Fresh changeover is not checked with self-diagnosis function. • Referring to “Testing Recirc/Fresh changeover”, operate Recirc/Fresh selector switch and check that there is not mechanical trouble (removal or interference of link, etc.) in Recirc/Fresh changeover door. • Operating angle of Recirc/Fresh changeover servomotor is 90°. • For each connector, see “Part and connector locations”. • T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a Since T-adapter is not prepared for other connectors, check signals with control amplifier during operation. Causes

Defective Recirc/Fresh changeover servomotor 1 (Unit test) or defective air conditioner wiring harness

2


Standard value in normal state/Remarks on troubleshooting a Since connector [7] cannot be disconnected easily, test on control amplifier side. 1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and connect T-adapter to wiring harness side. 3) Carry out troubleshooting without turning starting switch ON. Between connector [1] (wiring harness side) (6) – connector [2] (wiring harness side) (19) (There must not be disconnection or short circuit)

Resistance

400 – 3000 z

Between connector [1] (wiring harness side) (6) – connector [2] (wiring harness side) (20) (There must not be disconnection or short circuit)

Resistance

400 – 3000 z

a When test result for cause 1 is abnormal, perform following procedure. Check with circuit diagram. 1) Turn starting switch OFF. 2) Disconnect connectors [1] and [2] and insert T-adapter. 3) Turn starting switch ON. 4) Set Recirc/Fresh selector switch on air conditioner operation screen to Recirc. 5) Set Recirc/Fresh selector switch on air conditioner operation screen to Fresh. a Voltage appears across connector [1] (6) and connector [2] (20) for about 3 seconds (only while door moves to Fresh position).


Defective control amplifier or Between connector [1] (6) (+) and connector Approx. Voltage 3 defective Recirc/Fresh [2] (20) (–) 24 V changeover servomotor See 1) – 3) above. 4) Set Recirc/Fresh selector switch on air conditioner operation screen to Fresh. 5) Set Recirc/Fresh selector switch on air conditioner operation screen to Recirc. a Voltage appears across connector [1] (6) and connector [2] (19) for about 3 seconds (only while door moves to Recirc position). Between connector [1] (6) (+) and connector [2] (19) (–) Defective Recirc/Fresh 4 changeover servomotor

74

Voltage

Approx. 24 V

a When test result for cause 1 is abnormal and that for cause 2 is normal, Recirc/Fresh changeover servomotor is defective. (If all test results for causes 1, 2 and 3 are normal, cause may be mechanical trouble such as hitch.)

D155A-6

60 Air conditioner

SEN04442-00

Causes Possible causes and standard value in normal state

5 Defective control amplifier Defective machine monitor 6 (Defective switch)

Standard value in normal state/Remarks on troubleshooting a When test results for causes 1 and 2 are normal and that for cause 3 is abnormal, control amplifier is defective. 1) Turn starting switch ON. 2) Display air conditioner operation screen on machine monitor. Press Recirc/Fresh selector switch.

Display of Recirc/ Fresh changes.


D155A-6

75

SEN04442-00

60 Air conditioner


1

Referring to “Connection of service tool”, carry out troubleshooting by reading the high and low gauge pressures of the cooling cycle.

a

The gauge pressure varies largely with the weather condition and operating condition of the machine. Take care.

Engine speed

Low idle


ON

Fan switch

Hl

High pressure is too high: Above approx. 2.5 MPa {25 kg/cm2} High pressure is too low: Below approx. 1 MPa {10 kg/cm2} Low pressure is too high: Above approx. 0.3 MPa {3 kg/cm2} Low pressure is too low: Below approx. 0.05 MPa {0.5 kg/cm2}

Set temperature

Full cool

q q q q

a

Item Atmospheric temperature

q

a

20 – 50°C

Dual pressure switch Normally "ON", abnormal pressure "OFF" for compressor.

(Dual) pressure switch on high pressure side protects air conditioner circuit with OFF: See right LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}

Indicated gauge pressure

Pressure is normal

Cause

Check method

Both high pressure and low pressure are too low

Remedy

Air conditioner cycle is operating normally. If there is any trouble (cooling trouble), there is another cause. High pressure: Approx. 1.5 – 1.7 MPa {15 – 17 kg/cm2} Low pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2} Insufficient refrigerant

Collect refrigerant, then fill Bubble can be seen in the up with proper quantity of sight glass (*1) refrigerant again (*2)

Clogging of receiver drier

There is a temperature difference between inlet and Replace outlet pipes of receiver drier. Tank is frosty

Clogging of expansion valve Expansion valve is frosty Gas leakage at heat sensing tube of expansion valve

Low pressure becomes vacDefective evaporator sensor uum or defective contact of sensor (removal of mounting clip)

(*2)

Clean or replace (*2)

Low pressure gauge becomes vacuum

Replace

Evaporator is frozen Air flow is down by freezing (At cool max. and HI speed of fan, later it becomes not to cold.)

Repair or replace Replace receiver drier Collect refrigerant, then fill up with proper quantity of refrigerant again (*2)

Piping between receiver drier and compressor is Clogging or flattening or pip- clogged or flattened. If ing clogged completely, low gauge pressure becomes vacuum

76

Condition value

(*2)

Clean or replace (*2)

D155A-6

60 Air conditioner

SEN04442-00

Indicated gauge pressure

Cause

Check method

Filling too much with refrigerConnect gauge manifold ant

Both high pressure and low pressure are too high

High pressure is too high and low pressure is too low

Remedy Collect refrigerant, then fill up with proper quantity of refrigerant again (*2)

Defective cooling of condenser

Stain of condenser, clogging Clean, repair fins, or repair or crushing of fins, or defec- or replace condenser tive revolution of cooling fan (*2)

Defective adjustment of expansion valve (Valve is opened too wide)

Bubble can be seen in the sight glass

Air in cycle

Bubble can be seen in the sight glass

Replace (*2) Evacuate and then fill up with proper quantity of refrigerant again (*2)

Clogging or flattening of pip- There is a remarkable tem- Clean inside of cycle or ing between compressor and perature difference between replace condenser before and after clogged part (*2)

Both high pressure and low Defective compressor (Com- pressure are balanced while High pressure is too low and Replace pression trouble of compres- compressor is in operation. low pressure is too high sor) Compressor has seized and is extremely hot. *1

(*2)

If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are stained with oil. Increase tightening of the joints or replace parts.

*2.

k

a

Sight glass (SG) is on the receiver drier (RD).

When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After replacing it, fill up the air conditioner system with refrigerant again.

D155A-6

77

SEN04442-00

60 Air conditioner

Connection of service tool Symbol X

a

Part No. 799-703-1200

1

Part name Service tool kit

Use the service tool kit for R134a.

Service tool kit 1. Gauge manifold 2. High pressure charging hose (red) 3. Low pressure charging hose (blue) 4. Quick joint (Hi) (Large diameter) 5. Quick joint (Lo) (Small diameter) a. The thread is rough. So be careful not to loosen.

78

Connect the gauge manifold, hoses and other service tools according to the following procedure. 1. 2. 3. 4.

Close the high-pressure valve (HI) and lowpressure valve (LO) of gauge manifold (1). Connect red charging hose (2) to the (HI) side and blue charging hose (3) to the (LO) side. Connect quick joints (4) and (5) to each hose. Connect the quick joints to the service valves of the high and low-pressure pipings.

D155A-6

60 Air conditioner

Precautions for connecting air conditioner piping q

q

q

q

SEN04442-00

1

When connecting the piping, apply compressor oil NDOIL-8 for R134a to the O-rings. (See item 4. in “Handling of compressor oil”) Do not apply oil to the threads of a bolt, nut or union, however. Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged. Push in each pipe to the stopper (until it clicks) and tighten the bolt or nut fully with your fingers. Be sure to use two wrenches to tighten each nut (Apply a torque wrench to the tightening side). Place one wrench and tighten the nut with the other wrench to the specified torque.

Refrigerant piping diagram

Table of tightening torque for refrigerant piping adapter and installation Screw size

D155A-6

Unit: Nm {kgm}

Tightening torque

M6 × 1.0

8 – 12 {0.8 – 1.2}

M16 × 1.5

12 – 15 {1.2 – 1.5}

M24 × 1.5

30 – 35 {3.1 – 3.6}

79

SEN04442-00

60 Air conditioner

Handling of compressor oil 1.

2.

80

1

Control of compressor oil (Denso: ND-OIL8: For R134a) Compressor oil does not need to be checked or added so frequently as engine oil. Insufficiency or excess of compressor oil can cause the following troubles. Condition

Contents

Insufficiency of oil

Lubrication trouble and seizure of compressor

Excess of oil

Cooling trouble (Excessive oil stick to parts and lower heat exchange performance)

Check compressor oil in the following cases, and then add new oil if necessary. q When much refrigerant is discharged because of leakage. q When the compressor is troubled and replaced. q When a cycle parts such as the air conditioner unit, condenser, receiver drier, evaporator unit, etc. is replaced. Quantity of oil to be added when cycle part is replaced Air conditioner part

Quantity to be added (cm3)

Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.

Air conditioner unit, evaporator

Approx. 40

Condenser

Approx. 40

Adding of compressor oil k Since refrigerant is dangerous and bad for environment, collect the refrigerant before disconnecting the air conditioner hose. See “Caution about refrigerant”. k If refrigerant gets in your eyes, you may lose your sight. (Put on protective goggles.) a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized. Be sure to use the specified oil for R134a (Denso: ND-OIL8) a Oil for R134a absorbs moisture very easily. Accordingly, fit the cap immediately after using oil to stop the atmosphere. Store the oil can in a dry and ventilated place. a Precautions for using oil Oil for R134a (Denso: ND-OIL8 in particular) may dissolve acrylic resin and polystyrene (excluding baked polystyrene paint film). Accordingly, do not stick oil to those plastics.

Receiver drier

Approx. 20

Hose (Compressor – Condenser)

Approx. 10

Hose (Condenser – Receiver)

Approx. 20

Each hose (Compressor – M24 joint – Cab)

Approx. 15

Hose (Cab – Receiver)

Approx. 10

D155A-6

60 Air conditioner

3.

Compressor replacement In case of compressor seizure or breakage. Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely. In this case, flush the air conditioner circuit and replace the compressor and receiver drier. The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new compressor with the oil of the specified quantity (180 cc) filled in it. q Other cases New compressor has 180 cc compressor oil in it. So drain excessive compressor oil before installing new compressor in the following. 1) Prepare an oil pan and drain oil from old compressor. 2) Measure the quantity of the drained oil with a graduated cylinder, and note the quantity or mark the level. q

3)

D155A-6

SEN04442-00

4.

Applying compressor oil for O-ring When connecting a pipe or hose, apply oil (Denso: ND-OIL8) to its O-ring to prevent refrigerant leakage. k When discarding a can which still has some oil in it, make a hole on it to discharge gas and oil.

Drain below-mentioned quantity of oil from new compressor. 180 cc – “the noted quantity”. EX. If drained oil quantity from removed compressor is 30cc, drain oil of 180 – 30 cc = 150 cc from new one.

81

SEN04442-00

60 Air conditioner



82

D155A-6

SEN02875-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up

90 Diagrams and drawings

1

Hydraulic diagrams and drawings Power train hydraulic circuit diagram .............................................................................................................. 3 Hydraulic circuit diagram Serial No.: 85001 – 85024...................................................................................... 5 Hydraulic circuit diagram Serial No.: 85025 and up........................................................................................ 7

D155A-6

1

SEN02875-01

2


D155A-6


Power train hydraulic circuit diagram

D155A-6

SEN02875-01

Power train hydraulic circuit diagram D155A-6

3

Hydraulic circuit diagram Serial No.: 85001 – 85024

D155A-6

Hydraulic circuit diagram D155A-6

1

SEN02875-01

5

Hydraulic circuit diagram Serial No.: 85025 and up

D155A-6

Hydraulic circuit diagram D155A-6

1

SEN02875-01

7


D155A-6

SEN02875-01

9

SEN02875-01




10

D155A-6

SEN02874-01


D155A-6

Machine model

Serial number

D155A-6

85001 and up


1

Electrical diagrams and drawings Electrical circuit diagram (Cab spec.) ............................................................................................................. 3 Electrical circuit diagram (Cab less spec.) ...................................................................................................... 5 Electrical circuit diagram for inside cab........................................................................................................... 7 Connectors table and arrangement drawing................................................................................................... 9

D155A-6

1

SEN02874-01

2


D155A-6

Electrical circuit diagram (Cab spec.)

Electrical circuit diagram (Cab spec.)

D155A-6

SEN02874-01

D155A-6

3

Electrical circuit diagram (Cab less spec.)

Electrical circuit diagram (Cab less spec.) D155A-6

SEN02874-01

D155A-6

5


Electrical circuit diagram for inside cab

D155A-6

SEN02874-01

Electrical circuit diagram for inside cab D155A-6

7

Connectors table and arrangement drawing D155A-6 Connector No.

Type of connector

Number of pin

250

Terminal

1

255

Terminal

1

Connectors table and arrangement drawing D155A-6 Address

Connector No.

Starting switch (Terminal B)

R-9

GND03

Terminal

6

Ground (ROPS)

M-5

Starting switch (Terminal R1)

R-8

GND06

Terminal

4

Ground (Fender)

J-1 G-1

Location

Type of connector

Number of pin

Location

Address

256

Terminal

1

Starting switch (Terminal R2)

R-8

GND07

Terminal

1

Ground (Bulkhead)

260

Terminal

1

Starting switch (Terminal BR)

R-8

GND08

Terminal

4

Ground (Guard) [Additional headlamp specification]

270

Terminal

1

Starting switch (Terminal ACC)

R-9

GND09

Terminal

1

Ground (Engine)

AE-2

280

Terminal

1

Starting switch (Terminal C)

R-9

GND11

Terminal

6

Ground (Floor)

AB-6

A/C

DT

2

Air conditioner compressor

AE-1

GND12

Terminal

6

Ground (Floor)

AB-6

—

A/C1

DT

2

Intermediate conncector

F-7, AG-8

GND20

Terminal

2

Ground (Engine)

AF-2

AC01

YAZAKI

8


K-8, AB-8

GND21

Terminal

1

Ground (electric air bleeding pump switch)

M-4

AC02

SUMITOMO4

4


K-9, AB-7

HDT

DT

2

Hydraulic oil temperature sensor

AI-2

AC03

Relay

5

Air conditioner blower relay

AB-5

HHP

DT

3

Work equipment and HSS pump pressure sensor

AI-4

AC04

Relay

4

Air conditioner compressor relay

AB-4

HNSW

DT

2

Horn switch

V-9

AC05

S090

2

Air conditioner gas pressure sensor

I-1

HRN

—

1

Horn

C-2

ACCN

040

36

Air conditioner controller

L-8

HT

Terminal

2

Heater relay (Terminal C)

A-5

ACD1

DT

2

Diode

AB-2

HT/A

Terminal

1

Heater relay (Terminal A)

B-5

ACD2

DT

2

Diode

AB-2

HT/B

Terminal

1

Heater relay (Terminal B)

A-4

AE-2

HTD

DT

2

Diode

D-8

INJ

DT

12

Intermediate connector (injector)

ACS

DT

2

Diode

ACT

Relay

5

Engine ACC signal cut relay

H-1 AG-3

AF1

DT

2

Air cleaner clogging switch (If equipped)

E-7

J1939

DT

3

Service connector

AF-8

AL/B

Terminal

1

Alternator terminal B

AC-4

JM01

—

5

Junction wiring harness

AH-4

AL/R

Terminal

1

Alternator terminal R

AC-5

JM02

—

6


AH-3

AT11

—

1

Machine monitor

F-8

JM03

—

4


AH-3

AT12

—

1

GPS antenna

I-9

JM04

—

4


AG-2

AT21

—

1

KOMTRAX communication module

H-8

JM05

—

3


AH-5

AT22

—

1

ORBCOMM antenna

I-9

JM08

—

6


AG-8

AUX0

—

1

Service connector

K-2

KEY

DT

6

Starting switch

R-6

B30L

Terminal

1

Circuit breaker (30A)

L-2

LHD

DT

2

Intermediate connector

C-3

B30S

Terminal

1


L-2

LHDL

DT

2

Left headlamp

C-3

B105HL

Terminal

1


M-3

LHDL1

DT

2

Additional left headlamp [Additional headlamp specification]

—

B105HS

Terminal

1


M-3

LHDL2

DT

2

Additional left headlamp [Additional headlamp specification]

— C-4

B105L

Terminal

1


L-2

LHDR

DT

2

Right headlamp

B105S

Terminal

1


L-2

LHDR1

DT

2

Additional right headlamp [Additional headlamp specification]

—

BKA

Relay

5

Backup alarm relay

A-8

LHDR2

DT

2

Additional right headlamp [Additional headlamp specification]

BKAL

DT

2

Backup alarm

M-5

LMD1

DT

2

Diode

Q-8

—

BKSW

DT

3

Brake pedal switch

P-6

LMD2

DT

2

Diode

Q-8

BRB

Terminal

1

Battery relay (Contact input terminal)

N-3

LMFL

Relay

5

Left headlamp relay

C-9

BRC

Terminal

3

Battery relay (Contact output terminal)

M-3

LMFR

Relay

5

Right headlamp relay

C-9

BRE

Terminal

1

Battery relay (Coil ground terminal)

N-1

LMRE

Relay

5

Rear lamp relay

A-9

BRK

DT

3

Brake pedal potentiometer

P-5

LMRP

Relay

5

Ripper lamp relay

D-7 M-7

BVRV

DT

2

Transmission bevel speed sensor

AK-6

LREL

DT

2

Left rear lamp

CA1

DT

3

CAN terminal resistance

AH-3

LRER

DT

2

Right rear lamp

I-9

CB1

—

1


C-6

LRP2

DT

3

Ripper lamp

M-6

CB2

—

1


C-6

NE

FRAMATONE

3

Engine Ne speed sensor

AH-4

CB3

—

1


C-6

NSF

Relay

5

Neutral safety relay

CB4

—

1


B-6

OPPW

DT

2


CB5

—

1


B-6

PAMB

FRAMATONE

4

Ambient pressure sensor

AH-3

CB6

—

1


B-6

PBD

DT

2

Diode

AB-6

CB7

—

1


B-6

PBS

DT

2

Pedal brake solenoid

AL-7

C-9 Z-9

CB8

—

1


A-6

PCV1

SUMITOMO

2

Supply pump #1

AD-2

CB9

—

1


D-6

PCV2

SUMITOMO

2

Supply pump #2

AD-2

CB30

—

2


L-2

PFUEL

AMP

3

Common rail pressure sensor

AF-2

CB105

—

2


L-3

PHR

Relay

5

Preheat relay

CB105H

—

2


M-3

PIM

CANNON

4

Charge pressure sensor

AH-6

B-9

CBPW

DTP

4


X-9

PKD

DT

2

Diode

AB-6

CK01

070

14


Y-9

PKS

DT

2

Parking brake solenoid

AL-6

CK02

070

10


Y-9

PKSW

DT

3

Parking brake lever switch

CM01

070

18

Machine monitor

R-6

PL1

DRC-70A

70


CM02

070

12

Machine monitor

R-5

PLSW

DT

2

Pin puller switch

W-9

CM03

070

18

Machine monitor

R-5

POIL

CANNON

4

Engine oil pressure sensor

AG-2

CM04

070

12

Machine monitor

—

PPL

DT

2

Pin puller solenoid valve

CM05

070

8

Machine monitor

—

PRT

DT-A

12


E-7

CN1

DT

2

Injecter #1

AC-4

PT1

DT

3

Pitch angle sensor

D-6

CN2

DT

2

Injecter #2

AC-5

RDG

DT-A

12


CN3

DT

2

Injecter #3

AD-7

RES

DT

2

Service connector

AG-7

CN4

DT

2

Injecter #4

AE-7

RHT

Terminal

1

Intake air heater (Ribbon heater)

AC-6

CN5

DT

2

Injecter #5

AE-7

RLSW

SWP

6

Rear lamp switch

CN6

DT

2

Injecter #6

AH-7

RSD

DT

2

Diode

DCL

DT

3

Decelerator pedal potentiometer

DIAL

M

3

Fuel control dial

DSH

DRC-70A

70


L-8, AB-5 AB-4, AN-7

M-4

C-5

P-4 AB-1

P-6

S1T

DT

2

Transmission 1st clutch ECMV (Solenoid)

AI-8

AB-8

S2T

DT

2

Transmission 2nd clutch ECMV (Solenoid)

AJ-7

P-2, V-1

DTS

DT

12

Intermediate connector (used when work equipment controller is installed)

E22

DT

6


AG-2

EFP

DT

2

Electric air bleeding pump

AF-2

EG1

DTP

2


H-1, AH-5

EG2

DT-B

12


H-1, AH-5

EGC1

DRC-60

60

Engine controller

AH-4

EGC2

DRC-50

50

Engine controller

AH-4

EGC3

DTP

4

Engine controller

AG-3

EGPW

DTP

2


L-3

EHL

Relay

5

Engine hold relay

D-9

Z-9

EPP

DT

6

Electric air bleeding pump switch

F-7

ESD

DT

3

Service connector (for engine option)

Z-9

F105

DTHD

1


K-2

F1T

DT

2

Transmission 1st clutch ECMV (Fill switch)

AJ-9

F2T

DT

2

Transmission 2nd clutch ECMV (Fill switch)

AJ-7

F3T

DT

2

Transmission 3rd clutch ECMV (Fill switch)

AI-8

F30

DTHD

1


L-3

FAC

DT

2

Fan pump control valve

AI-3

FAR

DT

2

Fan reverse solenoid valve

C-1

FBRL

DT

2

Left brake ECMV (Fill switch)

AL-7

FBRR

DT

2

Right brake ECMV (Fill switch)

AM-7

FCLL

DT

2

Left steering clutch ECMV (Fill switch)

AN-6

FCLR

DT

2

Right steering clutch ECMV (Fill switch)

AN-7

FD1

24-31

31


K-2, AB-4

FD2

DT-C

12


L-3

FD3

DT

6


M-3

FD4

24-31

31


J-2, AB-3

FFT

DT

2

Transmission F clutch ECMV (Fill switch)

FLSW

SWP

6

Headlamp switch

P-5

FLV

DT

2

Fuel level sensor

M-4

FRT

DT

2

Transmission R clutch ECMV (Fill switch)

AK-9

AK-9

FS11

—

5

Fuse box

A-8

FS12

—

5

Fuse box

A-7

FS21

—

5

Fuse box

A-7

FS22

—

5

Fuse box

FSB

24-21

21


FTK

DT

6


M-7

G

SUMITOMO

3

Engine Bkup speed sensor

AD-2

GND

Terminal

1

Ground (ROPS)

M-3

S3T

DT

2

Transmission 3rd clutch ECMV (Solenoid)

AI-8

SBRL

DT

2

Left brake ECMV (Solenoid)

AM-7

SBRR

DT

2

Right brake ECMV (Solenoid)

AM-7

SCLL

DT

2

Left steering clutch ECMV (Solenoid)

AN-6

SCLR

DT

2

Right steering clutch ECMV (Solenoid)

AN-7

SFT

DT

2

Transmission F clutch ECMV (Solenoid)

AJ-7

SFTD

—

3

Shift-down switch

X-1

SFTU

—

3

Shift-up switch

Y-1

SLS

050

2

Daylight sensor

P-7

SRT

DT

2

Transmission R clutch ECMV (Solenoid)

AI-8

SRV

DT-A

12

Service connector (for CAN communication)

W-9

SSP

DT

2

Sudden stop prevent valve

AK-6

ST

DT

2

Starting motor (Terminal R, S)

AC-3

ST/B

Terminal

1

Starting motor (Terminal B)

AD-7

STC1

DRC26-24

24

Power train controller

Z-1

STC2

DRC26-40A

40


Z-1

STC3

DRC26-40B

40


AA-1

SW

Terminal

1

Battery relay (Coil signal terminal)

TCT

DT

2

Torque converter oil temperature sensor

N-1 AM-2

TFUEL

PACKARD

2

Fuel temperature sensor

AH-7

TIM

PACKARD

2

Charge temperature sensor

AH-6

TLV1

DT-B

8

Steering/directional/gearshift lever (Potentiometer)

Y-1

TLV2

DT

6

Steering/directional/gearshift lever (Shift switch)

Y-1

TMV

24-23

23


AN-3

TWTR

PACKARD

2

Engine coolant temperature sensor

AF-8

WELK

DT

3

Work equipment lock lever switch

W-9

WLK

DT

2

Work equipment lock solenoid valve

AJ-6

WLV

DT

2

Radiator coolant level sensor

C-2

WSH

DT

4


X-9

WSH1

DT

6

Window washer tank (Front, left)

J-2

WSH2

DT

6

Window washer tank (Rear, right)

I-1

A-7 B-9, AB-4

SEN02874-01 D155A-6

9


D155A-6

SEN02874-01

11

SEN02874-01




12

D155A-6

Shop Manual D155-6

Recommend Documents