Komatsu D155AX-6 Dozer Bulldozer Service Repair Manual - 80001 and up

BULLDOZER SEN00596-14 D155AX -6 SERIAL NUMBERS 80001 and up

D155AX-6 1 SEN00598-14 BULLDOZER 1SHOP MANUAL D155AX-6 Machine model Serial number D155AX-6 80001 and up 00 Index and foreword 1 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

SEN00598-14 00 Index and foreword 2 D155AX-6 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 SEN00596-14 00 Index and foreword SEN00597-14 Index SEN00598-14 q Foreword and general information SEN00599-04 01 Specification SEN00600-05 Specification and technical data SEN00601-04 q 10 Structure, function and maintenance standard SEN00602-05 Engine and cooling system SEN00603-00 Power train, Part 1 SEN00604-01 Power train, Part 2 SEN00605-02 Undercarriage and frame SEN00606-01 Hydraulic system SEN00607-03 q Work equipment SEN00608-01 Cab and its attachments SEN00609-01 Electrical system SEN00610-03 20 Standard value table SEN00611-03 Standard service value table SEN00678-03 30 Testing and adjusting SEN00612-05 Testing and adjusting, Part 1 SEN00679-05 Testing and adjusting, Part 2 SEN00680-02 Testing and adjusting, Part 3 SEN00681-04 Testing and adjusting, Part 4 SEN00682-02 40 Troubleshooting SEN00613-06 Failure code table and fuse locations SEN04628-02 General information on troubleshooting SEN00851-02 Troubleshooting by failure and error codes, Part 1 SEN00716-02 Troubleshooting by failure and error codes, Part 2 SEN00717-03 Troubleshooting by failure and error codes, Part 3 SEN00718-04 Troubleshooting by failure and error codes, Part 4 SEN00719-01 Troubleshooting by failure and error codes, Part 5 SEN00720-02

00 Index and foreword SEN00598-14 D155AX-6 3 Troubleshooting by failure and error codes, Part 6 SEN00721-03 Troubleshooting by failure and error codes, Part 7 SEN00722-01 Troubleshooting by failure and error codes, Part 8 SEN00723-01 Troubleshooting of electrical system (E-mode) SEN00807-02 Troubleshooting of hydraulic and mechanical system (H-mode) SEN00808-02 Troubleshooting of engine (S-mode) SEN00852-02 50 Disassembly and assembly SEN00614-05 General information on disassembly and assembly SEN01204-04 Engine and cooling system SEN01205-05 q Power train, Part 1 SEN01206-03 q Power train, Part 2 SEN01207-03 q Power train, Part 3 SEN02707-01 Undercarriage and frame SEN01208-02 Hydraulic system SEN01209-02 q Work equipment SEN01210-01 Cab and its attachments SEN01211-02 Electrical system SEN02708-01 80 Air conditioner SEN04682-01 Structure, function, testing, adjusting, and troubleshooting SEN04683-01 90 Diagrams and drawings SEN00615-06 Hydraulic diagrams and drawings SEN00616-04 Electrical diagrams and drawings SEN00617-05

SEN00598-14 00 Index and foreword 4 D155AX-6 Table of contents 1 00 Index and foreword Index SEN00598-14 Composition of shop manual ....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN00599-04 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 SEN00601-04 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 SEN00603-00 Engine and cooling system ......................................................................................................... 2 Radiator, oil cooler ................................................................................................................... 2 Engine mount........................................................................................................................... 5 Cooling fan pump..................................................................................................................... 6 Cooling fan motor .................................................................................................................... 14 Power train, Part 1 SEN00604-01 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 Torque converter control valve .................................................................................................... 19 Lockup clutch ECMV, stator clutch ECMV................................................................................... 20 Transmission control ................................................................................................................... 26 Transmission ............................................................................................................................... 28 Transmission ECMV.................................................................................................................... 44 Main relief valve and torque converter relief valve ...................................................................... 50 Lubrication relief valve................................................................................................................. 52 Scavenging pump........................................................................................................................ 53 Power train and steering lubrication pump .................................................................................. 54 Power train, Part 2 SEN00605-02 HSS system................................................................................................................................. 2 HSS motor ................................................................................................................................... 4 Hydraulic, HSS pump .................................................................................................................. 14 Hydraulic oil cooler bypass valve ................................................................................................ 37 Steering, brake control ................................................................................................................ 38 Steering unit ................................................................................................................................ 40 Brake control valve ...................................................................................................................... 62

00 Index and foreword SEN00598-14 D155AX-6 5 Brake ECMV ............................................................................................................................... 64 Parking brake solenoid valve ...................................................................................................... 68 Sudden stop prevention valve ..................................................................................................... 70 Final drive.................................................................................................................................... 72 Sprocket ...................................................................................................................................... 78 Undercarriage and frame SEN00606-01 Track frame ................................................................................................................................. 2 Recoil spring ............................................................................................................................... 4 Idler ............................................................................................................................................. 6 Track roller .................................................................................................................................. 8 Carrier roller ................................................................................................................................ 10 Track shoe................................................................................................................................... 12 Main frame .................................................................................................................................. 18 Suspension ................................................................................................................................. 20 Hydraulic system SEN00607-03 Work equipment hydraulic piping diagram .................................................................................. 2 Work equipment control piping diagram...................................................................................... 5 Work equipment control .............................................................................................................. 8 Hydraulic tank and filter ............................................................................................................... 10 Accumulator ................................................................................................................................ 14 PCCS lever ................................................................................................................................. 15 Work equipment lock valve ......................................................................................................... 19 Control valve ............................................................................................................................... 20 Work equipment cylinder ............................................................................................................. 56 Piston valve ................................................................................................................................. 58 Quick drop valve ......................................................................................................................... 60 Self pressure reducing valve ....................................................................................................... 65 Work equipment SEN00608-01 Cylinder stay ............................................................................................................................... 2 Blade ........................................................................................................................................... 4 Cutting edge, end bit ................................................................................................................... 6 Ripper .......................................................................................................................................... 8 Cab and its attachments SEN00609-01 Cab mount + ROPS pin............................................................................................................... 2 ROPS cab ................................................................................................................................... 3 Air conditioner ............................................................................................................................. 4 Electrical system SEN00610-03 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 SEN00678-03 Standard value table for engine .................................................................................................. 2 Standard value table for machine ................................................................................................ 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN00679-05 Tools for testing, adjusting, and troubleshooting ......................................................................... 3 Measuring engine speed ............................................................................................................. 7 Measuring intake air pressure (boost pressure) .......................................................................... 9 Measuring exhaust temperature ................................................................................................. 10

SEN00598-14 00 Index and foreword 6 D155AX-6 Measuring exhaust gas color ...................................................................................................... 12 Adjusting valve clearance............................................................................................................ 13 Measuring compression pressure ............................................................................................... 14 Measuring blow-by pressure ....................................................................................................... 16 Measuring engine oil pressure .................................................................................................... 17 Testing EGR valve and bypass valve drive oil pressure.............................................................. 18 Handling fuel system parts .......................................................................................................... 19 Releasing residual pressure from fuel system ............................................................................ 19 Measuring fuel pressure .............................................................................................................. 20 Measuring fuel return rate and fuel leakage ................................................................................ 21 Bleeding air from fuel circuit ........................................................................................................ 25 Measuring fuel circuit for leakage................................................................................................ 27 Testing and adjusting alternator belt tension ............................................................................... 28 Testing and adjusting air conditioner compressor belt tension .................................................... 29 Measuring fan speed ................................................................................................................... 30 Measuring fan circuit oil pressure................................................................................................ 31 Bleeding air from fan pump ......................................................................................................... 32 Adjusting fuel control dial and decelerator pedal ......................................................................... 33 Testing and adjusting, Part 2 SEN00680-02 Testing and adjusting, Part 2 ....................................................................................................... 3 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 ................................................................................. 21 Measuring and adjusting work equipment and HSS oil pressure ............................................ 22 Measuring control circuit basic pressure ................................................................................. 26 Measuring work equipment lock solenoid valve output pressure ............................................ 27 Emergency operation method when work equipment has trouble ........................................... 28 Measuring ripper pin puller solenoid valve output pressure .................................................... 30 Testing parts which cause hydraulic drift of blade and ripper .................................................. 31 Measuring internal leakage of work equipment cylinder .......................................................... 32 Releasing residual pressure from work equipment cylinder .................................................... 33 Bleeding air from work equipment cylinder .............................................................................. 33 Adjusting work equipment lock lever ....................................................................................... 34 Adjusting blade ........................................................................................................................ 35 Adjusting operator's cab .......................................................................................................... 37 Testing and adjusting, Part 3 SEN00681-04 Special functions of machine monitor (EMMS)............................................................................ 2 Testing and adjusting, Part 4 SEN00682-02 Testing and adjusting, Part 4 ....................................................................................................... 2 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 SEN04628-02 Failure codes table ...................................................................................................................... 2 Fuse locations ............................................................................................................................. 9 Information in troubleshooting table ............................................................................................ 13 General information on troubleshooting SEN00851-02 Points to remember when troubleshooting .................................................................................. 2 Sequence of events in troubleshooting ....................................................................................... 3

00 Index and foreword SEN00598-14 D155AX-6 7 Check before troubleshooting ..................................................................................................... 4 Classification and procedures for troubleshooting ...................................................................... 5 Connection table for connector pin numbers .............................................................................. 8 T-branch box and T-branch adapter table ................................................................................... 44 Troubleshooting by failure and error codes, Part 1 SEN00716-02 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 [15SJL1] L/U: Fill high ............................................................................................ 14 Failure code [15SJLH] L/U: Fill low ............................................................................................. 16 Failure code [2301L1] Right brake: Fill high................................................................................ 18 Failure code [2301LH] Right brake: Fill low ................................................................................ 19 Failure code [2302L1] Left brake: Fill high .................................................................................. 20 Failure code [2302LH] Left brake: Fill low ................................................................................... 21 Failure code [7RFAKA] ECM HOLD RELAY: Disconnection ....................................................... 22 Failure code [AA10NX] Air Cleaner Clogging ............................................................................. 24 Failure code [AB00MA] Battery Charge Abnormal ...................................................................... 26 Failure code [B@BAZG] Eng Oil Press Low ............................................................................... 28 Failure code [B@BCNS] Eng Water Overheat ............................................................................ 28 Failure code [B@BCZK] Eng Water Level Low........................................................................... 29 Failure code [B@CENS] T/C Oil Overheat ................................................................................. 29 Failure code [B@HANS] Hyd Oil Overheat ................................................................................. 30 Troubleshooting by failure and error codes, Part 2 SEN00717-03 Failure code [CA111] EMC Critical Internal Failure ..................................................................... 4 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................ 6 Failure code [CA122] Chg Air Press Sensor High Error ............................................................. 8 Failure code [CA123] Chg Air Press Sensor Low Error .............................................................. 10 Failure code [CA131] Throttle Sensor High Error ....................................................................... 12 Failure code [CA132] Throttle Sensor Low Error ........................................................................ 14 Failure code [CA135] Eng Oil Press Sensor High Error .............................................................. 16 Failure code [CA141] Eng Oil Press Sensor Low Error .............................................................. 18 Failure code [CA144] Coolant Temp Sens High Error ................................................................. 20 Failure code [CA145] Coolant Temp Sens Low Error ................................................................. 22 Failure code [CA153] Chg Air Temp Sensor High Error .............................................................. 24 Failure code [CA154] Chg Air Temp Sensor Low Error ............................................................... 26 Failure code [CA187] Sens Supply 2 Volt Low Error ................................................................... 26 Failure code [CA221] Ambient Press Sens High Error ............................................................... 28 Failure code [CA222] Ambient Press Sens Low Error ................................................................ 30 Failure code [CA227] Sens Supply 2 Volt High Error .................................................................. 32 Failure code [CA234] Eng Overspeed ........................................................................................ 34 Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................ 36 Failure code [CA263] Fuel Temp Sensor High Error ................................................................... 38 Failure code [CA265] Fuel Temp Sensor Low Error .................................................................... 40 Failure code [CA271] PCV1 Short Error ..................................................................................... 41 Failure code [CA272] PCV1 Open Error ..................................................................................... 42 Failure code [CA273] PCV2 Short Error ..................................................................................... 43 Failure code [CA274] PCV2 Open Error ..................................................................................... 44 Failure code [CA322] Inj #1 (L#1) Open/Short Error ................................................................... 46 Failure code [CA323] Inj #5 (L#5) Open/Short Error ................................................................... 48

SEN00598-14 00 Index and foreword 8 D155AX-6 Failure code [CA324] Inj #3 (L#3) Open/Short Error ................................................................... 50 Failure code [CA325] Inj #6 (L#6) Open/Short Error ................................................................... 52 Failure code [CA331] Inj #2 (L#2) Open/Short Error ................................................................... 54 Failure code [CA332] Inj #4 (L#4) Open/Short Error ................................................................... 56 Failure code [CA342] Calibration Code Incompatibility ............................................................... 58 Failure code [CA351] Injectors Drive Circuit Error ...................................................................... 60 Failure code [CA352] Sens Supply 1 Volt Low Error ................................................................... 62 Failure code [CA386] Sens Supply 1 Volt High Error .................................................................. 64 Failure code [CA441] Battery Voltage Low Error ......................................................................... 66 Failure code [CA442] Battery Voltage High Error ........................................................................ 66 Failure code [CA449] Rail Press Very High Error ........................................................................ 67 Failure code [CA451] Rail Press Sensor High Error ................................................................... 68 Failure code [CA452] Rail Press Sensor Low Error .................................................................... 70 Failure code [CA553] Rail Press High Error ................................................................................ 70 Failure code [CA554] Rail Press Sensor In Range Error ............................................................ 71 Failure code [CA559] Rail Press Low Error................................................................................. 72 Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................... 76 Troubleshooting by failure and error codes, Part 3 SEN00718-04 Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................... 3 Failure code [CA757] All Continuous Data Lost Error ................................................................. 3 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 4 Failure code [CA1228] EGR Valve Servo Error 1........................................................................ 6 Failure code [CA1625] EGR Valve Servo Error 2........................................................................ 7 Failure code [CA1626] BP Valve Sol Current High Error ............................................................ 8 Failure code [CA1627] BP Valve Sol Current Low Error ............................................................. 10 Failure code [CA1628] Bypass Valve Servo Error 1 .................................................................... 11 Failure code [CA1619] Bypass Valve Servo Error 2 .................................................................... 12 Failure code [CA1631] BP Valve Pos Sens High Error ............................................................... 14 Failure code [CA1632] BP Valve Pos Sens Low Error ................................................................ 16 Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................... 18 Failure code [CA1642] EGR Inlet Press Sens Low Error ............................................................ 20 Failure code [CA1653] EGR Inlet Press Sens High Error ........................................................... 22 Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................. 24 Failure code [CA2186] Throt Sens Sup Volt Low Error ............................................................... 26 Failure code [CA2249] Rail Press Very Low Error ...................................................................... 26 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................ 28 Failure code [CA2272] EGR Valve Pos Sens Low Error ............................................................. 30 Failure code [CA2351] EGR Valve Sol Current High Error ......................................................... 32 Failure code [CA2352] EGR Valve Sol Current Low Error .......................................................... 34 Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................. 35 Failure code [CA2556] Grid Htr Relay Volt High Error ................................................................ 36 Failure code [D110KA] Battery relay: Disconnection................................................................... 38 Failure code [D110KB] Battery Relay: Drive Short Circuit ........................................................... 40 Failure code [D130KA] Neutral relay: Disconnection .................................................................. 42 Failure code [D130KB] Neutral relay: Short circuit ...................................................................... 44 Failure code [D161KA] Back-up alarm relay: Disconnection....................................................... 46 Failure code [D161KB] Back-up alarm relay: Short circuit .......................................................... 48 Failure code [D190KA] ACC signal relay: Disconnection ............................................................ 50 Failure code [D190KB] ACC signal relay: Short circuit ............................................................... 52 Failure code [D5ZKKX] Throttle Dial: Out of normal range ......................................................... 54 Failure code [DAFRKR] CAN Disconnection (Monitor) ............................................................... 56 Failure code [DB2RKR] CAN Disconnection (Engine controller) ................................................ 58 Failure code [DB90KK] WE controller: Source voltage reduction ............................................... 60 Failure code [DB90KR] PT controller: Can communication lost .................................................. 62 Troubleshooting by failure and error codes, Part 4 SEN00719-01 Troubleshooting by failure and error codes, Part 4 ..................................................................... 3 Failure code [DB90KT] WE controller: Abnormality in controller ............................................. 3

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Komatsu D155AX-6 Dozer Bulldozer Service Repair Manual - 80001 and up

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