Shop Manual D155AX-6

BULLDOZER

SEN00596-04

D155AX-6SERIAL NUMBERS 80001 and up

D155AX-6 1

SEN00598-04

BULLDOZER1SHOP MANUAL

D155AX-6

Machine model Serial number

D155AX-6 80001 and up

00 Index and foreword 1IndexComposition of shop manual .......................................................................................................................... 2Table of contents............................................................................................................................................. 4

SEN00598-04 00 Index and foreword

2 D155AX-6

Composition of shop manual 1The 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:QQQQ: 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 accord-

ingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00596-04

00 Index and foreword SEN00597-04Index SEN00598-04 qForeword and general information SEN00599-01

01 Specification SEN00600-01Specification and technical data SEN00601-01

10 Structure, function and maintenance standard SEN00602-01Engine and cooling system SEN00603-00Power train, Part 1 SEN00604-01Power train, Part 2 SEN00605-01Undercarriage and frame SEN00606-01Hydraulic system SEN00607-01Work equipment SEN00608-01Cab and its attachments SEN00609-01Electrical system SEN00610-01

20 Standard value table SEN00611-01Standard service value table SEN00678-01

30 Testing and adjusting SEN00612-01Testing and adjusting, Part 1 SEN00679-01Testing and adjusting, Part 2 SEN00680-01Testing and adjusting, Part 3 SEN00681-01Testing and adjusting, Part 4 SEN00682-01

40 Troubleshooting SEN00613-01General information on troubleshooting SEN00851-00Troubleshooting by failure and error codes, Part 1 SEN00716-01Troubleshooting by failure and error codes, Part 2 SEN00717-01Troubleshooting by failure and error codes, Part 3 SEN00718-01Troubleshooting by failure and error codes, Part 4 SEN00719-01Troubleshooting by failure and error codes, Part 5 SEN00720-01Troubleshooting by failure and error codes, Part 6 SEN00721-01

00 Index and foreword SEN00598-04

D155AX-6 3

Troubleshooting by failure and error codes, Part 7 SEN00722-01Troubleshooting by failure and error codes, Part 8 SEN00723-01Troubleshooting of electrical system (E-mode) SEN00807-01Troubleshooting of hydraulic and mechanical system (H-mode) SEN00808-00Troubleshooting of engine (S-mode) SEN00852-01

50 Disassembly and assembly SEN00614-01General information on disassembly and assembly SEN01204-01 qEngine and cooling system SEN01205-01 qPower train, Part 1 SEN01206-00Power train, Part 2 SEN01207-00 QQQQPower train, Part 3 SEN02707-00 QQQQUndercarriage and frame SEN01208-00 QQQQHydraulic system SEN01209-00 QQQQWork equipment SEN01210-00 QQQQCab and its attachments SEN01211-00 QQQQElectrical system SEN02708-00 QQQQ

90 Diagrams and drawings SEN00615-03Hydraulic diagrams and drawings SEN00616-02Electrical diagrams and drawings SEN00617-03


4 D155AX-6

Table of contents 100 Index and foreword

Index SEN00598-04Composition of shop manual....................................................................................................... 2Table of contents ......................................................................................................................... 4

Foreword and general information SEN00599-01Safety notice................................................................................................................................ 2How to read the shop manual ..................................................................................................... 7Explanation of terms for maintenance standard.......................................................................... 9Handling electric equipment and hydraulic component............................................................... 11How to read electric wire code .................................................................................................... 23Precautions when carrying out operation .................................................................................... 26Method of disassembling and connecting push-pull type coupler ............................................... 29Standard tightening torque table ................................................................................................. 32Conversion table ......................................................................................................................... 36

01 SpecificationSpecification and technical data SEN00601-01

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

10 Structure, function and maintenance standardEngine and cooling system SEN00603-00

Engine and cooling system ......................................................................................................... 2Radiator, oil cooler ................................................................................................................... 2Engine mount........................................................................................................................... 5Cooling fan pump..................................................................................................................... 6Cooling fan motor .................................................................................................................... 14

Power train, Part 1 SEN00604-01Power train skeleton.................................................................................................................... 2Overall drawing of power train unit.............................................................................................. 4Power train hydraulic piping drawing........................................................................................... 6Damper, universal joint................................................................................................................ 8Torque converter, PTO ................................................................................................................ 10Torque converter control valve .................................................................................................... 19Lockup clutch ECMV, stator clutch ECMV................................................................................... 20Transmission control ................................................................................................................... 26Transmission ............................................................................................................................... 28Transmission ECMV.................................................................................................................... 44Main relief valve and torque converter relief valve ...................................................................... 50Lubrication relief valve................................................................................................................. 52Scavenging pump........................................................................................................................ 53Power train and steering lubrication pump.................................................................................. 54

Power train, Part 2 SEN00605-01HSS system................................................................................................................................. 2HSS motor................................................................................................................................... 4Hydraulic, HSS pump.................................................................................................................. 14Hydraulic oil cooler bypass valve ................................................................................................ 37Steering, brake control ................................................................................................................ 38Steering unit ................................................................................................................................ 40Brake control valve...................................................................................................................... 62Brake ECMV................................................................................................................................ 64


D155AX-6 5

Parking brake solenoid valve ...................................................................................................... 69Sudden stop prevention valve..................................................................................................... 71Final drive.................................................................................................................................... 73Sprocket ...................................................................................................................................... 78

Undercarriage and frame SEN00606-01Track frame ................................................................................................................................. 2Recoil spring ............................................................................................................................... 4Idler ............................................................................................................................................. 6Track roller .................................................................................................................................. 8Carrier roller ................................................................................................................................ 10Track shoe................................................................................................................................... 12Main frame .................................................................................................................................. 18Suspension ................................................................................................................................. 20

Hydraulic system SEN00607-01Work equipment hydraulic piping diagram .................................................................................. 2Work equipment control piping diagram...................................................................................... 5Work equipment control .............................................................................................................. 6Hydraulic tank and filter............................................................................................................... 8Accumulator ................................................................................................................................ 10PCCS lever ................................................................................................................................. 11Work equipment lock valve ......................................................................................................... 15Control valve ............................................................................................................................... 16Work equipment cylinder............................................................................................................. 52Piston valve................................................................................................................................. 54Quick drop valve ......................................................................................................................... 56Self pressure reducing valve....................................................................................................... 61

Work equipment SEN00608-01Cylinder stay ............................................................................................................................... 2Blade ........................................................................................................................................... 4Cutting edge, end bit ................................................................................................................... 6Ripper.......................................................................................................................................... 8

Cab and its attachments SEN00609-01Cab mount + ROPS pin............................................................................................................... 2ROPS cab ................................................................................................................................... 3Air conditioner ............................................................................................................................. 4

Electrical system SEN00610-01Engine control ............................................................................................................................. 2Engine control system................................................................................................................. 3Deceleration potentiometer ......................................................................................................... 4Monitor system............................................................................................................................ 6Sensors ....................................................................................................................................... 25Palm command control system ................................................................................................... 28KOMTRAX system ...................................................................................................................... 31

20 Standard value tableStandard service value table SEN00678-01

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

30 Testing and adjustingTesting and adjusting, Part 1 SEN00679-01

Testing and adjusting, Part 1....................................................................................................... 3Tools for testing, adjusting, and troubleshooting ..................................................................... 3Measuring engine speed ......................................................................................................... 5Measuring intake air pressure (boost pressure) ...................................................................... 7


6 D155AX-6

Measuring exhaust temperature .............................................................................................. 8Measuring exhaust gas color................................................................................................... 10Adjusting valve clearance ........................................................................................................ 11Measuring compression pressure............................................................................................ 12Measuring blow-by pressure.................................................................................................... 14Measuring engine oil pressure................................................................................................. 15Handling fuel system parts ...................................................................................................... 16Releasing residual pressure from fuel system......................................................................... 16Measuring fuel pressure .......................................................................................................... 17Measuring fuel return rate and fuel leakage ............................................................................ 18Bleeding air from fuel circuit .................................................................................................... 22Measuring fuel circuit for leakage ............................................................................................ 24Testing and adjusting alternator belt tension ........................................................................... 25Testing and adjusting air conditioner compressor belt tension ................................................ 26Measuring fan speed ............................................................................................................... 27Measuring fan circuit oil pressure ............................................................................................ 28Bleeding air from fan pump...................................................................................................... 29Adjusting fuel control dial and decelerator pedal ..................................................................... 30

Testing and adjusting, Part 2 SEN00680-01Testing and adjusting, Part 2 ....................................................................................................... 3

Measuring power train oil pressure.......................................................................................... 3Adjusting transmission output shaft speed sensor .................................................................. 11Simple test procedure for brake performance ......................................................................... 12Adjusting brake pedal .............................................................................................................. 13Adjusting parking brake lever .................................................................................................. 15Emergency escape method when power train has trouble...................................................... 17Adjusting idler clearance.......................................................................................................... 20Testing and adjusting track shoe tension................................................................................. 21Measuring and adjusting work equipment and HSS oil pressure ............................................ 22Measuring control circuit basic pressure ................................................................................. 26Measuring work equipment lock solenoid valve output pressure ............................................ 27Emergency operation method when work equipment has trouble........................................... 28Measuring ripper pin puller solenoid valve output pressure .................................................... 30Testing parts which cause hydraulic drift of blade and ripper .................................................. 31Measuring internal leakage of work equipment cylinder.......................................................... 32Releasing residual pressure from work equipment cylinder .................................................... 33Bleeding air from work equipment cylinder.............................................................................. 33Adjusting work equipment lock lever ....................................................................................... 34Adjusting blade ........................................................................................................................ 35Adjusting operator's cab .......................................................................................................... 37

Testing and adjusting, Part 3 SEN00681-01Testing and adjusting, Part 3 ....................................................................................................... 2

Special functions of machine monitor (EMMS) ........................................................................ 2Testing and adjusting, Part 4 SEN00682-01

Testing and adjusting, Part 4 ....................................................................................................... 2Handling of power supply circuit of engine controller .............................................................. 2Preparation work for troubleshooting of electrical system ....................................................... 3Pm Clinic.................................................................................................................................. 5

40 TroubleshootingGeneral information on troubleshooting SEN00851-00

General information on troubleshooting ...................................................................................... 2Points to remember when troubleshooting .............................................................................. 2Sequence of events in troubleshooting.................................................................................... 3Check before troubleshooting.................................................................................................. 4Classification and procedures for troubleshooting................................................................... 5Connector pin Nos. and connection table................................................................................ 8


D155AX-6 7

T-boxes and T-adapters table.................................................................................................. 31Troubleshooting by failure and error codes, Part 1 SEN00716-01

Troubleshooting by failure and error codes, Part 1 ..................................................................... 3Failure codes table .................................................................................................................. 3Before carrying out troubleshooting when failure code is displayed........................................ 10Information in troubleshooting table ........................................................................................ 14Failure code [1500L0] Transmission clutch: Abnormal............................................................ 16Failure code [15SAL1] Forward clutch: Fill high ...................................................................... 17Failure code [15SALH] Forward clutch: Fill low....................................................................... 18Failure code [15SBL1] Reverse clutch: Fill high...................................................................... 19Failure code [15SBLH] Reverse clutch: Fill low....................................................................... 20Failure code [15SEL1] Speed 1st clutch: Fill high ................................................................... 21Failure code [15SELH] Speed 1st clutch: Fill low .................................................................... 22Failure code [15SFL1] Speed 2nd clutch: Fill high .................................................................. 23Failure code [15SFLH] Speed 2nd clutch: Fill low ................................................................... 24Failure code [15SGL1] Speed 3rd clutch: Fill high .................................................................. 25Failure code [15SGLH] Speed 3rd clutch: Fill low ................................................................... 26Failure code [15SJL1] L/U: Fill high......................................................................................... 28Failure code [15SJLH] L/U: Fill low ......................................................................................... 30Failure code [2301L1] Right brake: Fill high ............................................................................ 32Failure code [2301LH] Right brake: Fill low............................................................................. 33Failure code [2302L1] Left brake: Fill high .............................................................................. 34Failure code [2302LH] Left brake: Fill low ............................................................................... 35Failure code [7RFAKA] ECM HOLD RELAY: Disconnection ................................................... 36Failure code [AA10NX] Air Cleaner Clogging.......................................................................... 38Failure code [AB00MA] Battery Charge Abnormal .................................................................. 40Failure code [B@BAZG] Eng Oil PressLow ............................................................................ 42Failure code [B@BCNS] Eng Water Overheat ........................................................................ 42Failure code [B@BCZK] Eng Water Level Low ....................................................................... 43Failure code [B@CENS] T/C Oil Overheat.............................................................................. 43Failure code [B@HANS] Hyd Oil Overheat ............................................................................. 44

Troubleshooting by failure and error codes, Part 2 SEN00717-01Troubleshooting by failure and error codes, Part 2 ..................................................................... 4

Failure code [CA111] EMC Critical Internal Failure ................................................................. 4Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................... 6Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 8Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 10Failure code [CA131] Throttle Sensor High Error.................................................................... 12Failure code [CA132] Throttle Sensor Low Error..................................................................... 14Failure code [CA135] Eng Oil Press Sensor High Error .......................................................... 16Failure code [CA141] Eng Oil Press Sensor Low Error........................................................... 18Failure code [CA144] Coolant Temp Sens High Error ............................................................. 20Failure code [CA145] Coolant Temp Sens Low Error.............................................................. 22Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 24Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 26Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 26Failure code [CA221] Ambient Press Sens High Error............................................................ 28Failure code [CA222] Ambient Press Sens Low Error............................................................. 30Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 32Failure code [CA234] Eng Overspeed..................................................................................... 34Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 36Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 38Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 39Failure code [CA271] PCV1 Short Error.................................................................................. 40Failure code [CA272] PCV1 Open Error.................................................................................. 41Failure code [CA273] PCV2 Short Error.................................................................................. 42Failure code [CA274] PCV2 Open Error.................................................................................. 43


8 D155AX-6

Failure code [CA322] Inj #1 (L#1) Open/Short Error ............................................................... 44Failure code [CA323] Inj #5 (L#5) Open/Short Error ............................................................... 45Failure code [CA324] Inj #3 (L#3) Open/Short Error ............................................................... 46Failure code [CA325] Inj #6 (L#6) Open/Short Error ............................................................... 47Failure code [CA331] Inj #2 (L#2) Open/Short Error ............................................................... 48Failure code [CA332] Inj #4 (L#4) Open/Short Error ............................................................... 49Failure code [CA342] Calibration Code Incompatibility ........................................................... 50Failure code [CA351] Injectors Drive Circuit Error................................................................... 52Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 54Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 56Failure code [CA441] Battery Voltage Low Error ..................................................................... 58Failure code [CA442] Battery Voltage High Error .................................................................... 58Failure code [CA449] Rail Press Very High Error .................................................................... 59Failure code [CA451] Rail Press Sensor High Error................................................................ 60Failure code [CA452] Rail Press Sensor Low Error................................................................. 62Failure code [CA553] Rail Press High Error ............................................................................ 62Failure code [CA554] Rail Press Sensor In Range Error......................................................... 63Failure code [CA559] Rail Press Low Error ............................................................................. 64Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 68


Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 3Failure code [CA757] All Continuous Data Lost Error ............................................................. 3Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 4Failure code [CA1228] EGR Valve Servo Error 1 .................................................................... 6Failure code [CA1625] EGR Valve Servo Error 2 .................................................................... 7Failure code [CA1626] BP Valve Sol Current High Error......................................................... 8Failure code [CA1627] BP Valve Sol Current Low Error.......................................................... 10Failure code [CA1628] Bypass Valve Servo Error 1 ............................................................... 11Failure code [CA1619] Bypass Valve Servo Error 2 ............................................................... 12Failure code [CA1631] BP Valve Pos Sens High Error............................................................ 14Failure code [CA1632] BP Valve Pos Sens Low Error ............................................................ 16Failure code [CA1633] KOMNET Datalink Timeout Error........................................................ 18Failure code [CA1642] EGR Inlet Press Sens Low Error ........................................................ 20Failure code [CA1653] EGR Inlet Press Sens High Error........................................................ 22Failure code [CA2185] Throt Sens Sup Volt High Error........................................................... 24Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 26Failure code [CA2249] Rail Press Very Low Error................................................................... 26Failure code [CA2271] EGR Valve Pos Sens High Error......................................................... 28Failure code [CA2272] EGR Valve Pos Sens Low Error ......................................................... 30Failure code [CA2351] EGR Valve Sol Current High Error...................................................... 32Failure code [CA2352] EGR Valve Sol Current Low Error....................................................... 34Failure code [CA2555] Grid Htr Relay Volt Low Error.............................................................. 35Failure code [CA2556] Grid Htr Relay Volt High Error............................................................. 36Failure code [D110KA] Battery relay: Disconnection ............................................................... 38Failure code [D110KB] Battery Relay: Drive Short Circuit ....................................................... 40Failure code [D130KA] Neutral relay: Disconnection............................................................... 42Failure code [D130KB] Neutral relay: Short circuit .................................................................. 44Failure code [D161KA] Back-up alarm relay: Disconnection ................................................... 46Failure code [D161KB] Back-up alarm relay: Short circuit....................................................... 48Failure code [D190KA] ACC signal relay: Disconnection ........................................................ 50Failure code [D190KB] ACC signal relay: Short circuit............................................................ 52Failure code [D5ZKKX] Throttle Dial: Out of normal range...................................................... 54Failure code [DAFRKR] CAN Disconnection (Monitor)............................................................ 56Failure code [DB2RKR] CAN Disconnection (Engine controller)............................................. 58Failure code [DB90KK] WE controller: Source voltage reduction............................................ 60Failure code [DB90KR] PT controller: Can communication lost .............................................. 62


D155AX-6 9


Failure code [DB90KT] WE controller: Abnormality in controller ............................................. 3Failure code [DB95KK] WE controller: Source voltage reduction............................................ 4Failure code [DB97KK] WE controller: Source voltage reduction............................................ 6Failure code [DB99KQ] WE controller: Type select signal ...................................................... 8Failure code [DB9RKR] WE controller: Can communication lost ............................................ 10Failure code [DBE0KK] PT controller: Source voltage reduction............................................. 12Failure code [DBE0KT] PT controller: Abnormality in controller .............................................. 14Failure code [DBE6KK] PT controller: Source voltage reduction............................................. 16Failure code [DBE7KK] PT controller: Source voltage reduction............................................. 18Failure code [DBE9KQ] PT controller: Type select signal ....................................................... 20Failure code [DD12KA] Shift up Sw: Disconnection ................................................................ 22Failure code [DD12KB] Shift up Sw: Short circuit.................................................................... 24Failure code [DD13KA] Shift down Sw: Disconnection ........................................................... 26Failure code [DD13KB] Shift down Sw: Short circuit ............................................................... 28Failure code [DD14KA] Parking lever Sw: Disconnection ....................................................... 30Failure code [DD14KB] Parking lever Sw: Short circuit ........................................................... 32Failure code [DDDDKA] Back up brake Sw: Disconnection .................................................... 34Failure code [DDDDKB] Back up brake Sw: Short circuit........................................................ 36Failure code [DDDDKX] Back up brake Sw: Signal mismatch ................................................ 38Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection.............................................. 40Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit ................................................. 42Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection .................................................. 44Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit ...................................................... 46Failure code [DDNLKA] Weq lock Sw: Disconnection ............................................................. 48Failure code [DDNLKB] Weq lock Sw: Short circuit................................................................. 50Failure code [DDTSL1] S/C: Fill high....................................................................................... 52Failure code [DDTSLH] S/C: Fill low ....................................................................................... 54


Failure code [DFA4KX] BL lever 1: Out of normal range......................................................... 3Failure code [DFA4KZ] BL lever: Disconnection or short circuit .............................................. 3Failure code [DFA4L8] BL lever: Signal mismatch .................................................................. 4Failure code [DFA5KA] BL lever 1: Disconnection .................................................................. 6Failure code [DFA5KB] BL lever 1: Short circuit ..................................................................... 8Failure code [DFA6KA] BL lever 2: Disconnection .................................................................. 10Failure code [DFA6KB] BL lever 2: Short circuit...................................................................... 12Failure code [DFA7KX] BT lever 1: Out of normal range......................................................... 14Failure code [DFA7KZ] BT lever: Disconnection or short circuit.............................................. 14Failure code [DFA7L8] BT lever: Signal mismatch .................................................................. 15Failure code [DFA8KA] BT lever 1: Disconnection .................................................................. 16Failure code [DFA8KB] BT lever 1: Short circuit...................................................................... 18Failure code [DFA9KA] BT lever 2: Disconnection .................................................................. 20Failure code [DFA9KB] BT lever 2: Short circuit...................................................................... 22Failure code [DFAAKX] RL lever 1: Out of normal range ........................................................ 24Failure code [DFAAKZ] RL lever: Disconnection or short circuit ............................................. 24Failure code [DFAAL8] RL lever: Signal mismatch.................................................................. 25Failure code [DFABKA] RL lever 1: Disconnection.................................................................. 26Failure code [DFABKB] RL lever 1: Short circuit ..................................................................... 28Failure code [DFACKA] RL lever 2: Disconnection ................................................................. 30Failure code [DFACKB] RL lever 2: Short circuit ..................................................................... 32Failure code [DFADKX] RL lever 1: Out of normal range ........................................................ 34Failure code [DFADKZ] RL lever: Disconnection or short circuit ............................................. 34Failure code [DFADL8] RL lever: Signal mismatch ................................................................. 35Failure code [DFAEKA] RL lever 1: Disconnection.................................................................. 36Failure code [DFAEKB] RL lever 1: Short circuit ..................................................................... 38Failure code [DFAFKA] RL lever 2: Disconnection.................................................................. 40


10 D155AX-6

Failure code [DFAFKB] RL lever 2: Short circuit...................................................................... 42Failure code [DGT1KA] T/C oil temp sensor: Abnormal .......................................................... 44Failure code [DGT1KX] T/C oil temp sensor: Abnormal .......................................................... 46Failure code [DH21KA] Weq pressure sensor: Disconnection ................................................ 48Failure code [DH21KB] Weq pressure sensor: Short circuit .................................................... 50Failure code [DHT5KA] T/C in-pressure sensor: Disconnection.............................................. 52Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ................................................. 54Failure code [DHT7KA] T/C out-pressure sensor: Disconnection ........................................... 56Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ............................................... 58Failure code [DK10KX] Fuel control Dial: Out of normal range ............................................... 60


Failure code [DK30KA] ST lever 1: Disconnection .................................................................. 4Failure code [DK30KB] ST lever 1: Short circuit...................................................................... 6Failure code [DK30KX] ST lever 1: Out of normal range......................................................... 8Failure code [DK30KZ] RL lever: Disconnection or short circuit.............................................. 8Failure code [DK30L8] ST lever: Signal mismatch .................................................................. 9Failure code [DK31KA] ST lever 2: Disconnection .................................................................. 10Failure code [DK31KB] ST lever 2: Short circuit...................................................................... 12Failure code [DK40KA] Brake potentiometer: Disconnection .................................................. 14Failure code [DK40KB] Brake potentiometer: Short circuit...................................................... 16Failure code [DK55KX] FR lever: Out of normal range............................................................ 18Failure code [DK55KZ] FR lever: Disconnection or short circuit.............................................. 18Failure code [DK55L8] FR lever: Signal mismatch .................................................................. 19Failure code [DK56KA] FR lever 1: Disconnection .................................................................. 20Failure code [DK56KB] FR lever 1: Short circuit...................................................................... 22Failure code [DK57KA] FR lever 2: Disconnection .................................................................. 24Failure code [DK57KB] FR lever 2: Short circuit...................................................................... 26Failure code [DKH1KA] Pitch angle sensor: Disconnection .................................................... 28Failure code [DKH1KB] Pitch angle sensor: Short circuit ........................................................ 30Failure code [DLT3KA] T/M out-speed sensor: Disconnection ................................................ 32Failure code [DLT3KB] T/M out-speed sensor: Abnormal ....................................................... 33Failure code [DW7BKA] Fan rev EPC: Disconnection............................................................. 34Failure code [DW7BKB] Fan rev EPC: Short circuit ................................................................ 35Failure code [DWN1KA] Hss EPC1: Disconnection ................................................................ 36Failure code [DWN1KB] Hss EPC1: Short circuit .................................................................... 37Failure code [DWN1KY] Hss EPC1: Short circuit .................................................................... 38Failure code [DWN2KA] Hss EPC2: Disconnection ................................................................ 39Failure code [DWN2KB] Hss EPC2: Short circuit .................................................................... 40Failure code [DWN2KY] Hss EPC2: Short circuit .................................................................... 41Failure code [DWN3KA] Ssp solenoid: Disconnection ............................................................ 42Failure code [DWN3KB] Ssp solenoid: Short circuit ................................................................ 44Failure code [DWN3KY] Ssp solenoid: Short circuit ................................................................ 46Failure code [DWN5KA] Fan pump solenoid: Disconnection .................................................. 48Failure code [DWN5KB] Fan pump solenoid: Short circuit ...................................................... 49Failure code [DXA0KA] TVC Sol.: Disconnection.................................................................... 50Failure code [DXA0KB] TVC Sol.: Short circuit ....................................................................... 51Failure code [DXA0KY] TVC Sol.: Short circuit ...................................................................... 52Failure code [DXH1KA] Lock-up ECMV: Disconnection .......................................................... 54Failure code [DXH1KB] Lock-up ECMV: Short circuit.............................................................. 56Failure code [DXH1KY] Lock-up ECMV: Short circuit.............................................................. 58Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................................ 60


Failure code [DXH4KB] 1st clutch ECMV: Short circuit ........................................................... 3Failure code [DXH4KY] 1st clutch ECMV: Short circuit ........................................................... 4Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...................................................... 5


D155AX-6 11

Failure code [DXH5KB] 2nd clutch ECMV: Short circuit.......................................................... 6Failure code [DXH5KY] 2nd clutch ECMV: Short circuit.......................................................... 7Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ....................................................... 8Failure code [DXH6KB] 3rd clutch ECMV: Short circuit........................................................... 9Failure code [DXH6KY] 3rd clutch ECMV: Short circuit........................................................... 10Failure code [DXH7KA] R clutch ECMV: Disconnection.......................................................... 11Failure code [DXH7KB] R clutch ECMV: Short circuit ............................................................. 12Failure code [DXH7KY] R clutch ECMV: Short circuit ............................................................. 13Failure code [DXH8KA] F clutch ECMV: Disconnection .......................................................... 14Failure code [DXH8KB] F clutch ECMV: Short circuit.............................................................. 15Failure code [DXH8KY] F clutch ECMV: Short circuit.............................................................. 16Failure code [DXHBKA] Right brake ECMV: Disconnection.................................................... 18Failure code [DXHBKB] Right brake ECMV: Short circuit ....................................................... 20Failure code [DXHBKY] Right brake ECMV: Short circuit ....................................................... 22Failure code [DXHCKA] Left brake ECMV: Disconnection ...................................................... 24Failure code [DXHCKB] Left brake ECMV: Short circuit.......................................................... 26Failure code [DXHCKY] Left brake ECMV: Short circuit.......................................................... 28Failure code [DXHRKA] Blade up EPC: Disconnection........................................................... 30Failure code [DXHRKB] Blade up EPC: Short circuit .............................................................. 31Failure code [DXHRKY] Blade up EPC: Short circuit .............................................................. 32Failure code [DXHSKA] Blade down EPC: Disconnection ...................................................... 33Failure code [DXHSKB] Blade down EPC: Short circuit .......................................................... 34Failure code [DXHSKY] Blade down EPC: Short circuit .......................................................... 35Failure code [DXHTKA] Blade left 1 EPC: Disconnection ....................................................... 36Failure code [DXHTKB] Blade left 1 EPC: Short circuit ........................................................... 37Failure code [DXHTKY] Blade left 1 EPC: Short circuit ........................................................... 38Failure code [DXHUKA] Blade right 1 EPC: Disconnection..................................................... 39Failure code [DXHUKB] Blade right 1 EPC: Short circuit ........................................................ 40Failure code [DXHUKY] Blade right 1 EPC: Short circuit ........................................................ 41Failure code [DXHWKA] Ripper up EPC: Disconnection ........................................................ 42Failure code [DXHWKB] Ripper up EPC: Short circuit ............................................................ 43Failure code [DXHWKY] Ripper up EPC: Short circuit ............................................................ 44Failure code [DXHXKA] Ripper down EPC: Disconnection..................................................... 45Failure code [DXHXKB] Ripper down EPC: Short circuit ........................................................ 46Failure code [DXHXKY] Ripper down EPC: Short circuit ........................................................ 47Failure code [DXHYKA] Ripper Tilt In EPC: Disconnection..................................................... 48Failure code [DXHYKB] Ripper Tilt In EPC: Short circuit ........................................................ 49Failure code [DXHYKY] Ripper Tilt In EPC: Short circuit ........................................................ 50Failure code [DXHZKA] Ripper Tilt Back EPC: Disconnection ................................................ 51Failure code [DXHZKB] Ripper Tilt Back EPC: Short circuit.................................................... 52Failure code [DXHZKY] Ripper Tilt Back EPC: Short circuit.................................................... 53Failure code [DXJ4KA] Weq lock Sol.: Disconnection............................................................. 54Failure code [DXJ4KB] Weq lock Sol.: Short circuit ................................................................ 55

Troubleshooting by failure and error codes, Part 8 SEN00723-01Troubleshooting by failure and error codes, Part 8.................................................................. 2Failure code [DXJ8KA] Blade left 2 EPC: Disconnection ........................................................ 2Failure code [DXJ8KB] Blade left 2 EPC: Short circuit ............................................................ 3Failure code [DXJ8KY] Blade left 2 EPC: Short circuit ............................................................ 4Failure code [DXJ9KA] Blade right 2 EPC: Disconnection ...................................................... 5Failure code [DXJ9KB] Blade right 2 EPC: Short circuit.......................................................... 6Failure code [DXJ9KY] Blade right 2 EPC: Short circuit.......................................................... 7Failure code [DXJAKA] Q-drop EPC: Disconnection............................................................... 8Failure code [DXJAKB] Q-drop EPC: Short circuit .................................................................. 10Failure code [DXJAKY] Q-drop EPC: Short circuit .................................................................. 12Failure code [DXJBKA] S/C ECMV: Disconnection ................................................................. 14Failure code [DXJBKB] S/C ECMV: Short circuit..................................................................... 16Failure code [DXJBKY] S/C ECMV: Short circuit..................................................................... 18


12 D155AX-6

Troubleshooting of electrical system (E-mode) SEN00807-01Troubleshooting of electrical system (E-mode) ........................................................................... 3

Before carrying out troubleshooting for electrical system........................................................ 3Information in troubleshooting table......................................................................................... 7E-1 When starting switch turned ON, machine monitor displays nothing ............................... 8E-2 When starting switch turned ON (before startingengine), basic check item lights up ...... 10E-3 Engine does not start (Engine does not turn)................................................................... 12E-4 Preheater does not operate ............................................................................................. 14E-5 Precaution item lights up while engine is running ............................................................ 18E-6 Emergency stop item lights up while engine is running ................................................... 20E-7 Engine coolant temperature gauge does not indicate normally ....................................... 22E-8 Fuel level gauge does not indicate normally .................................................................... 23E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally .................. 25E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally........................ 26E-11 Contents of display by machine monitor are different from applicable machine ............ 29E-12 Machine monitor does not display some items .............................................................. 29E-13 Function switch does not work ....................................................................................... 29E-14 Operation mode does not change.................................................................................. 30E-15 Gearshift mode does not change ................................................................................... 30E-16 Customize function does not operate normally .............................................................. 31E-17 Customize memory function does not normally ............................................................. 31E-18 Float mode does not change.......................................................................................... 32E-19 Alarm buzzer cannot be stopped ................................................................................... 32E-20 Air conditioner does not operate normally (including air conditioner fault history) ......... 33E-21 When starting switch is turned OFF, service meter is not displayed .............................. 46E-22 Machine monitor cannot be set in service mode............................................................ 46E-23 Ripper pin puller cylinder does not operate.................................................................... 48E-24 Backup alarm does not sound or does not stop............................................................. 50E-25 Headlamp, rear lamp, and ripper point lamp do not light up .......................................... 52E-26 Windshield wiper and window washer do not operate ................................................... 56E-27 KOMTRAX system does not operate normally .............................................................. 72

Troubleshooting of hydraulic and mechanical system (H-mode) SEN00808-00Troubleshooting of hydraulic and mechanical system (H-mode)................................................. 3

Information in troubleshooting table......................................................................................... 3H-1 Power is low (Drawbar pull is low) ................................................................................... 4H-2 Machine does not travel (at 2nd or 3rd gear speed) ........................................................ 5H-3 Machine does not start at any gear speed....................................................................... 6H-4 Machine can travel only forward or in reverse ................................................................. 7H-5 When gear speed or travel direction is changed, time lag is large .................................. 8H-6 Machine cannot be steered (Machine does not turn right or left)..................................... 9H-7 Steering speed or steering force is low............................................................................ 9H-8 Brake does not work ........................................................................................................ 10H-9 Power train oil is overheated............................................................................................ 11H-10 Abnormal sound comes out from around HSS pump or HSS motor.............................. 12H-11 Speed of all work equipment is low ................................................................................ 13H-12 No work equipment moves ............................................................................................ 14H-13 Blade lift speed or power is low ..................................................................................... 15H-14 Blade tilt speed or power is low ..................................................................................... 16H-15 Ripper lift speed or power is low .................................................................................... 17H-16 Ripper tilt speed or power is low .................................................................................... 18H-17 Hydraulic drift of blade lift is large .................................................................................. 18H-18 Hydraulic drift of blade tilt is large .................................................................................. 19H-19 Hydraulic drift of ripper lift is large.................................................................................. 19H-20 Ripper pin puller cylinder does not operate ................................................................... 20H-21 Blade does not pitch ..................................................................................................... 20H-22 Abnormal sound comes out from around work equipment pump .................................. 21


D155AX-6 13

Troubleshooting of engine (S-mode) SEN00852-01Troubleshooting of engine (S-mode)........................................................................................... 3

Method of using troubleshooting chart ................................................................................... 3S-1 Starting performance of engine is poor ........................................................................... 6S-2 Engine does not start ....................................................................................................... 8S-3 Engine does not pick up smoothly ................................................................................... 12S-4 Engine stops during operation ......................................................................................... 13S-5 Engine does not rotate smoothly ..................................................................................... 14S-6 Engine lack output (or lacks power)................................................................................. 15S-7 Exhaust gas is black (incomplete combustion) ................................................................ 16S-8 Oil consumption is excessive (or exhaust gas is blue) .................................................... 18S-9 Oil becomes dirty quickly ................................................................................................ 19S-10 Fuel consumption is excessive ...................................................................................... 20S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)............................. 21S-12 Oil pressure drops.......................................................................................................... 22S-13 Oil level rises (Entry of coolant or fuel) .......................................................................... 24S-14 Coolant temperature becomes too high (Overheating).................................................. 26S-15 Abnormal noise is made ................................................................................................ 27S-16 Vibration is excessive .................................................................................................... 28

50 Disassembly and assemblyGeneral information on disassembly and assembly SEN01204-01

How to read this manual ............................................................................................................. 2Coating materials list................................................................................................................... 4Special tool list ............................................................................................................................ 7Sketches of special tools............................................................................................................. 14

Engine and cooling system SEN01205-01Removal and installation of fuel supply pump assembly............................................................. 2Removal and installation of fuel injector assembly ..................................................................... 6Removal and installation of cylinder head assembly .................................................................. 11Removal and installation of radiator assembly............................................................................ 22Removal and installation of aftercooler assembly ....................................................................... 24Removal and installation of engine assembly ............................................................................. 26Removal and installation of engine hood assembly .................................................................... 30Removal and installation of engine front seal ............................................................................. 32Removal and installation of engine rear seal .............................................................................. 34Removal and installation of fuel tank assembly .......................................................................... 39Removal and installation of fan drive assembly .......................................................................... 40Removal and installation of fan motor assembly......................................................................... 41

Power train, Part 1 SEN01206-00Removal and installation of damper assembly............................................................................ 2Disassembly and assembly of damper assembly ....................................................................... 5Removal and installation of power train unit assembly ............................................................... 11Disconnection and connection of power train unit assembly ...................................................... 15

Power train, Part 2 SEN01207-00Disassembly and assembly of PTO assembly ............................................................................ 2Disassembly and assembly of torque converter assembly ......................................................... 9Disassembly and assembly of transmission assembly ............................................................... 19Disassembly and assembly of HSS case assembly ................................................................... 36Removal and installation of HSS motor assembly ...................................................................... 53

Power train, Part 3 SEN02707-00Removal and installation of final drive assembly ........................................................................ 2Disassembly and assembly of final drive assembly .................................................................... 4

Undercarriage and frame SEN01208-00Removal and installation of track frame assembly...................................................................... 3


14 D155AX-6

Removal and installation of idler assembly ................................................................................. 6Disassembly and assembly of idler assembly............................................................................. 7Removal and installation of recoil spring assembly..................................................................... 11Disassembly and assembly of recoil spring assembly ................................................................ 12Removal and installation of track roller ....................................................................................... 17Disassembly and assembly of track roller assembly................................................................... 19Removal and installation of No. 1 bogie assembly...................................................................... 22Removal and installation of No. 2, No, 3 and No. 4 bogie assemblies........................................ 28Disassembly and assembly of bogie assembly........................................................................... 34Removal and installation of carrier roller assembly..................................................................... 37Disassembly and assembly of carrier roller assembly ................................................................ 38Removal and installation of pivot shaft assembly........................................................................ 42Spreading and installation of track shoe assembly ..................................................................... 44General disassembly and assembly of track shoe ...................................................................... 47Disassembly and assembly of 1 link in field ................................................................................ 61Disassembly and assembly of master link .................................................................................. 65Removal and installation of equalizer bar assembly ................................................................... 68Disassembly and assembly of equalizer bar assembly............................................................... 70Removal and in4stallation of segment teeth ............................................................................... 72

Hydraulic system SEN01209-00Removal and installation of hydraulic tank assembly .................................................................. 2Removal and installation of hydraulic pump assembly................................................................ 4Disassembly and assembly of hydraulic cylinder assembly........................................................ 7

Work equipment SEN01210-00Removal and installation of blade assembly ............................................................................... 2Disassembly and assembly of multi-shank ripper ....................................................................... 4

Cab and its attachments SEN01211-00Removal and installation of operator's cab assembly ................................................................. 2Removal and installation of operator's cab glass (Stuck glass)................................................... 4Removal and installation of floor frame assembly....................................................................... 13

Electrical system SEN02708-00Removal and installation of air conditioner unit assembly........................................................... 2Removal and installation of engine controller assembly ............................................................. 4Removal and installation of power train controller assembly ...................................................... 5Removal and installation of work equipment controller assembly............................................... 5

90 Diagrams and drawingsHydraulic diagrams and drawings SEN00616-02

Power train hydraulic circuit diagram .......................................................................................... 3Hydraulic circuit diagram (1/2)..................................................................................................... 5Hydraulic circuit diagram (2/2)..................................................................................................... 7

Electrical diagrams and drawings SEN00617-03Electrical circuit diagram ............................................................................................................. 3Electrical circuit diagram for inside cab ....................................................................................... 5Connectors table and arrangement drawing ............................................................................... 7


D155AX-6 15

D155AX-6 1

SEN00599-01

BULLDOZER1SHOP MANUAL

D155AX-6

Machine model Serial number

D155AX-6 80001 and up

00 Index and foreword 1Foreword and general informationSafety notice ................................................................................................................................................... 2How to read the shop manual ......................................................................................................................... 7Explanation of terms for maintenance standard ............................................................................................. 9Handling electric equipment and hydraulic component .................................................................................11How to read electric wire code...................................................................................................................... 23Precautions when carrying out operation...................................................................................................... 26Method of disassembling and connecting push-pull type coupler................................................................. 29Standard tightening torque table ................................................................................................................... 32Conversion table ........................................................................................................................................... 36


2 D155AX-6

(Rev. 2007/02)Safety notice 1Important safety noticeProper service and repair are extremely important for safe machine operation. The service and repairtechniques 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 specificpurpose.To prevent injury to workers, the symbol kkkk is used to mark safety precautions in this manual. Thecautions accompanying these symbols should always be followed carefully. If any dangerous situa-tion arises or may possibly arise, first consider safety, and take the necessary actions to deal withthe situation.

1. General precautionsk Mistakes in operation are extremely

dangerous. Read the Operation andMaintenance Manual carefully beforeoperating the machine.

1) Before carrying out any greasing orrepairs, read all the safety plates stuck tothe machine. For the locations of thesafety plates and detailed explanation ofprecautions, see the Operation and Main-tenance Manual.

2) Decide a place in the repair workshop tokeep tools and removed parts. Alwayskeep the tools and parts in their correctplaces. Always keep the work area cleanand make sure that there is no dirt, water,or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke whileworking.

3) When carrying out any operation, alwayswear safety shoes and helmet. Do notwear loose work clothes, or clothes withbuttons missing.q Always wear safety glasses when hit-

ting 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 oper-ating procedure before starting. Alwaysinform your fellow workers before startingany step of the operation. Before startingwork, hang UNDER REPAIR warningsigns in the operator's compartment.

5) Only qualified workers must carry out workand operation which require license orqualification.

6) Keep all tools in good condition, learn thecorrect way to use them, and use theproper ones of them. Before starting work,thoroughly check the tools, machine, fork-lift, service car, etc.

7) If welding repairs are needed, alwayshave a trained and experienced weldercarry out the work. When carrying outweld ing work, always wear weldinggloves, apron, shielding goggles, cap andother clothes suited for welding work.

8) Before starting work, warm up your bodythoroughly to start work under good condi-tion.

2. Preparations for work1) Before adding oil or making any repairs,

park the machine on hard and levelground, and apply the parking brake andblock the wheels or tracks to prevent themachine from moving.

2) Before starting work, lower the workequipment (blade, ripper, bucket, etc.) tothe ground. If this is not possible, insertthe lock pin or use blocks to prevent thework equipment from falling. In addition,be sure to lock all the control levers andhang warning signs on them.

Safety points1 Good arrangement2 Correct work clothes3 Following work standard4 Making and checking signs

5 Prohibition of operation and handling by unlicensed workers6 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


D155AX-6 3

3) When disassembling or assembling, sup-port the machine with blocks, jacks, orstands before starting work.

4) Remove all mud and oil from the steps orother places used to get on and off themachine. Always use the handrails, lad-ders or steps when getting on or off themach ine. Never jump on or o ff themachine. If it is impossible to use thehandrails, ladders or steps, use a stand toprovide safe footing.

3. Precautions during work1) Before disconnecting or removing compo-

nents of the oil, water, or air circuits, firstrelease the pressure completely from thecircuit. When removing the oil filler cap, adrain plug, or an oil pressure pickup plug,loosen it slowly to prevent the oil fromspurting out.

2) The coolant and oil in the circuits are hotwhen the engine is stopped, so be carefulnot to get scalded. Wait for the oil andcoolant to cool before carrying out anywork on the oil or water circuits.

3) Before starting work, stop the engine.When working on or around a rotatingpart, in particular, stop the engine. Whenchecking the machine without stoppingthe engine (measuring oi l pressure,revolving speed, temperature, etc.), takeextreme care not to get rolled or caught inrotating parts or moving parts.

4) Before starting work, remove the leadsfrom the battery. Always remove the leadfrom the negative () terminal first.

5) When raising a heavy component (heavierthan 25 kg), use a hoist or crane. Beforestarting work, check that the slings (wireropes, chains, and hooks) are free fromdamage. Always use slings which haveample capacity and install them to properplaces. Operate the hoist or crane slowlyto prevent the component from hitting anyother part. Do not work with any part stillraised by the hoist or crane.

6) When removing a cover which is underinternal pressure or under pressure from aspring, always leave 2 bolts in diagonalpositions. Loosen those bolts graduallyand alternately to release the pressure,and then remove the cover.

7) When removing components, be carefulnot to break or damage the electrical wir-ing. Damaged wiring may cause electricalfires.

8) When removing piping, stop the fuel or oilfrom spilling out. If any fuel or oil dripsonto the floor, wipe it up immediately. Fuelor oil on the floor can cause you to slipand can even start fires.

9) As a general rule, do not use gasoline towash parts. Do not use it to clean electri-cal parts, in particular.

10) Be sure to assemble all parts again in theiroriginal places. Replace any damagedparts and parts which must not be reusedwith new parts. When installing hoses andwires, be sure that they will not be dam-aged by contact with other parts when themachine is operated.

11) When installing high pressure hoses,make sure that they are not twisted. Dam-aged tubes a re dangerous , so beextremely careful when installing tubes forhigh pressure circuits. In addition, checkthat connect ing parts are cor rect lyinstalled.

12) When assembling or installing parts,always tighten them to the specifiedtorques. When installing protective partssuch as guards, or parts which vibrate vio-lently or rotate at high speed, be particu-lar ly carefu l to check that they areinstalled correctly.

13) When aligning 2 holes, never insert yourfingers or hand. Be careful not to get yourfingers caught in a hole.

14) When measuring hydraulic pressure,check that the measuring tools are cor-rectly assembled.

15) Take care when removing or installing thetracks of track-type machines. Whenremoving the track, the track separatessuddenly, so never let anyone stand ateither end of the track.

16) If the engine is operated for a long time ina place which is not ventilated well, youmay suffer from gas poisoning. Accord-ingly, open the windows and doors to ven-tilate well.


4 D155AX-6

4. Precautions for sling work and makingsigns1) Only one appointed worker must make

signs and co-workers must communicatewith each other frequently. The appointedsign maker must make specified signsclearly at a place where he is seen wellfrom the operator's seat and where he cansee the working condition easily. The signmaker must always stand in front of theload 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 slingwork.

3) Keep putting on gloves during sling work.(Put on leather gloves, if available.)

4) Measure the weight of the load by the eyeand check its center of gravity.

5) Use proper sling according to the weightof the load and method of slinging. If toothick wire ropes are used to sling a lightload, 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 slipout of the rope. Install 2 or more wireropes symmetrically.

k Slinging with 1 rope may causeturning of the load during hoisting,untwisting of the rope, or slippingof the rope from its original wind-ing position on the load, which canresult in a dangerous accident.

7) Limit the hanging angle to 60, as a rule.Do not sling a heavy load with ropes form-ing a wide hanging angle from the hook.When hoisting a load with 2 or moreropes, the force subjected to each ropewill increase with the hanging angle. Thetable below shows the variation of allow-able load in kN {kg} when hoisting is madewith 2 ropes, each of which is allowed tosling up to 9.8 kN {1,000 kg} vertically, atvarious hanging angles. When the 2 ropessling a load vertically, up to 19.6 kN {2,000kg} of total weight can be suspended.This weight is reduced to 9.8 kN {1,000kg} when the 2 ropes make a hangingangle of 120. If the 2 ropes sling a 19.6kN {2,000 kg} load at a lifting angle of150, each of them is subjected to a forceas large as 39.2 kN {4,000 kg}.

8) When installing wire ropes to an angularload, apply pads to protect the wire ropes.If the load is slippery, apply proper mate-rial to prevent the wire rope from slipping.

9) Use the specified eyebolts and fix wireropes, chains, etc. to them with shackles,etc.

10) Apply wire ropes to the middle portion ofthe hook.q Slinging near the tip of the hook may

cause the rope to slip off the hookduring hoisting. The hook has themaximum strength at the middle por-tion.

11) Do not use twisted or kinked wire ropes.12) When lifting up a load, observe the follow-

ing.q Wind in the crane slowly until wire

ropes are stretched. When settlingthe wire ropes with the hand, do notgrasp them but press them fromabove. If you grasp them, your fingersmay be caught.

q After the wire ropes are stretched,stop the crane and check the condi-tion of the slung load, wire ropes, andpads.


D155AX-6 5

q If the load is unstable or the wire ropeor chains are twisted, lower the loadand lift it up again.

q Do not lift up the load slantingly.13) When lifting down a load, observe the fol-

lowing.q When lifting down a load, stop it tem-

porarily at 30 cm above the floor, andthen lower it slowly.

q Check that the load is stable, andthen remove the sling.

q Remove kinks and dirt from the wireropes and chains used for the slingwork, and put them in the specifiedplace.

5. Precautions for using mobile cranea Read the Operation and Maintenance

Manual of the crane carefully in advanceand operate the crane safely.

6. Precautions for using overhead hoist cranek When raising a heavy part (heavier

than 25 kg), use a hoist, etc. In Disas-sembly and assembly, the weight of apart heavier than 25 kg is indicatedafter the mark of 4444.

1) Before starting work, inspect the wireropes, brake, clutch, controller, rails, overwind stop device, electric shock preven-tion earth leakage breaker, crane collisionprevention device, and power applicationwarning 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 directionsof the control buttons without fail.

5) Do not sling a load slantingly. Do not movethe crane while the slung load is swinging.

6) Do not raise or lower a load while thecrane 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, andthen lift it up.

9) Consider the travel route in advance andlift up a load to a safe height.

10) Place the control switch on a positionwhere it will not be an obstacle to workand passage.

11) After operating the hoist, do not swing thecontrol switch.

12) Remember the position of the main switchso that you can turn off the power immedi-ately in an emergency.

13) If the hoist stops because of a power fail-ure, turn the power switch OFF. Whenturning on a switch which was turned OFFby the electric shock prevention earthleakage breaker, check that the devicesrelated to that switch are not in operationstate.

14) If you find an obstacle around the hoist,stop the operation.

15) After finishing the work, stop the hoist atthe specified position and raise the hookto at least 2 m above the floor. Do notleave the sling installed to the hook.

7. Selecting wire ropes1) Select adequate ropes depending on the

weight of parts to be hoisted, referring tothe table below.

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

Wire ropes(Standard Z twist ropes without galvanizing)

(JIS G3525, No. 6, Type 6X37-A)Nominal

diameter of rope Allowable load

mm kN ton10 8.8 0.912 12.7 1.314 17.3 1.716 22.6 2.318 28.6 2.920 35.3 3.625 55.3 5.630 79.6 8.140 141.6 14.450 221.6 22.660 318.3 32.4


6 D155AX-6

8. Precautions for disconnecting and con-necting hoses and tubes in air conditionercircuit1) Disconnection

k Collect the air conditioner refrigerant(R134a) from the air conditioner circuitin advance.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 (R134a) gets inyour eyes, you may lose your sight.Accordingly, when collecting or fillingit, you must be qualified for handlingthe refrigerant and put on protectivegoggles.

2) Connection1] When installing the air conditioner cir-

cuit hoses and tubes, take care thatdirt, dust, water, etc. will not enterthem.

2] When connecting the air conditionerhoses and tubes, check that O-rings(1) are fitted to their joints.

3] Check that each O-ring is not dam-aged or deteriorated.

4] When connecting the refrigerant pip-ing, apply compressor oil for refriger-ant

Shop Manual D155AX-6

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