D155ax 8

SEN06497-03
BULLDOZER
D155AX -8
SERIAL NUMBERS 100001 and up
00 INDEX AND FOREWORD
D155AX-8 00-1
INDEX 00 INDEX AND FOREWORD
INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-21
HOW TO READ THE SHOP MANUAL........................................................................................... 00-21
SAFETY NOTICE FOR OPERATION............................................................................................. 00-23
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-29
ACTION IF FIRE OCCURS............................................................................................................ 00-31
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-32
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-33
PRECAUTIONS FOR AdBlue/DEF ................................................................................................ 00-34
STORE AdBlue/DEF ...................................................................................................................... 00-35
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-36
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-38
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-44
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-47
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-48
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-49
METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL TYPE COUPLER .............. 00-50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-53
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-57
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-63
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-64
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-68
LIST OF ABBREVIATION .............................................................................................................. 00-71
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-76
CONVERSION TABLE ................................................................................................................... 00-83
01 SPECIFICATION....................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
SPECIFICATIONS .................................................................................................................................. 01-3
SPECIFICATION DRAWING............................................................................................................ 01-3
SPECIFICATIONS ........................................................................................................................... 01-5
WEIGHT TABLE ............................................................................................................................ 01-13
TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-16
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
UREA SCR SYSTEM.............................................................................................................................. 10-5
LAYOUT DRAWING OF UREA SCR SYSTEM ................................................................................ 10-5
UREA SCR SYSTEM DIAGRAM ..................................................................................................... 10-7
FUNCTION OF UREA SCR SYSTEM.............................................................................................. 10-8
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-23
BOOT-UP SYSTEM .............................................................................................................................. 10-32
SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-32
BATTERY DISCONNECT SWITCH ............................................................................................... 10-34
ENGINE SYSTEM ................................................................................................................................ 10-36
LAYOUT DRAWING OF ENGINE RELATED PARTS ..................................................................... 10-36
ENGINE CONTROL SYSTEM ....................................................................................................... 10-38
AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-41
COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-44
COOLING SYSTEM.............................................................................................................................. 10-64
LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-64
COMPONENT PARTS OF COOLING SYSTEM............................................................................. 10-66
CONTROL SYSTEM............................................................................................................................. 10-82
LAYOUT OF ELECTRICAL CONTROL SYSTEM .......................................................................... 10-82
00-2 D155AX-8
00 INDEX AND FOREWORD INDEX
PALM COMMAND CONTROL SYSTEM........................................................................................ 10-83

MACHINE MONITOR SYSTEM ..................................................................................................... 10-87
KOMTRAX SYSTEM...................................................................................................................... 10-90
COMPONENT PARTS OF CONTROL SYSTEM............................................................................ 10-91
HYDRAULIC SYSTEM.........................................................................................................................10-125
LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-125
CLSS ............................................................................................................................................10-126
COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-129
POWER TRAIN SYSTEM ....................................................................................................................10-188
LAYOUT OF POWER TRAIN SYSTEM ........................................................................................10-188
OPERATE POWER TRAIN SYSTEM............................................................................................10-191
TRANSMISSION, STEERING, AND BRAKE CONTROL ..............................................................10-193
HSS SYSTEM...............................................................................................................................10-196
CENTRALIZED PRESSURE PICKUP PORT................................................................................10-199
COMPONENT PARTS OF POWER TRAIN SYSTEM ...................................................................10-201
WORK EQUIPMENT SYSTEM ............................................................................................................10-282
WORK EQUIPMENT CONTROL ..................................................................................................10-282
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-287
UNDERCARRIAGE AND FRAME........................................................................................................10-304
MAIN FRAME ...............................................................................................................................10-304
SUSPENSION ..............................................................................................................................10-305
TRACK FRAME AND IDLER CUSHION .......................................................................................10-308
WORK EQUIPMENT............................................................................................................................10-310
STRUCTURE OF CYLINDER STAY .............................................................................................10-310
STRUCTURE OF BLADE .............................................................................................................10-311
STRUCTURE OF VARIABLE GIANT RIPPER ..............................................................................10-313
STRUCTURE OF VARIABLE FIXED MULTI-SHANK RIPPER......................................................10-314
CAB AND ITS ATTACHMENTS ...........................................................................................................10-315
ROPS CAB ...................................................................................................................................10-315
CAB MOUNT ................................................................................................................................10-316
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE: D155AX-8 .................................................................... 20-3
STANDARD VALUE TABLE FOR MACHINE........................................................................................... 20-8
STANDARD VALUE TABLE FOR MACHINE: D155AX-8 ................................................................. 20-8
STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-28
STANDARD VALUE TABLE FOR ELECTRICITY........................................................................... 20-28
30 TESTING AND ADJUSTING ..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................. 30-5
TOOLS FOR TESTING AND ADJUSTING....................................................................................... 30-5
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-12
ENGINE AND COOLING SYSTEM....................................................................................................... 30-14
TEST ENGINE SPEED .................................................................................................................. 30-14
TEST BOOST PRESSURE............................................................................................................ 30-18
TEST EXHAUST GAS TEMPERATURE ........................................................................................ 30-20
TEST EXHAUST GAS COLOR ...................................................................................................... 30-23
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-25
TEST COMPRESSION PRESSURE.............................................................................................. 30-28
TEST BLOWBY PRESSURE ......................................................................................................... 30-31
TEST ENGINE OIL PRESSURE .................................................................................................... 30-33
TEST EGR VALVE AND KVGT OIL PRESSURE ........................................................................... 30-35
TEST FUEL PRESSURE ............................................................................................................... 30-37
TEST FUEL RETURN RATE AND LEAKAGE................................................................................ 30-39
BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-44
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-46
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-48
D155AX-8 00-3
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-49

CLEAN FUEL DOSER ................................................................................................................... 30-50
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER.................................. 30-52
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-58
TEST SCR RELATED FUNCTIONS............................................................................................... 30-59
CLEAN AdBlue/DEF TANK ............................................................................................................ 30-82
ADJUST DECELERATOR PEDAL ................................................................................................. 30-88
POWER TRAIN..................................................................................................................................... 30-91
TEST POWER TRAIN OIL PRESSURE......................................................................................... 30-91
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR ...................................................30-102
TEST BRAKE PERFORMANCE SIMPLY .....................................................................................30-103
TEST AND ADJUST BRAKE PEDAL ............................................................................................30-104
ADJUST PARKING BRAKE LEVER..............................................................................................30-107
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL...30-109
ADJUSTING IDLER CLEARANCE................................................................................................30-113
TEST AND ADJUST TRACK TENSION........................................................................................30-115
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................30-116
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES .....................................30-117
TEST OIL PRESSURE OF CONTROL CIRCUIT ..........................................................................30-122
TEST WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE .............................30-124
TEST RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE ......................................30-126
CHECK COOLING FAN SPEED ...................................................................................................30-128
TEST COOLING FAN CIRCUIT OIL PRESSURE .........................................................................30-129
BLEED AIR FROM COOLING FAN PUMP ...................................................................................30-131
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-132
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER .......................................30-134
BLEED AIR FROM WORK EQUIPMENT CYLINDERS.................................................................30-136
OPERATION WHEN WORK EQUIPMENT IS NOT EFFECTIVE ..................................................30-137
WORK EQUIPMENT............................................................................................................................30-139
ADJUST WORK EQUIPMENT LOCK LEVER...............................................................................30-139
TEST AND ADJUST OPERATOR'S CAB......................................................................................30-141
ELECTRICAL SYSTEM .......................................................................................................................30-146
SETTING AND OPERATION OF MACHINE MONITOR................................................................30-146
METHOD FOR STARTING UP KOMTRAX ...................................................................................30-269
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-274
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER .....................................................30-275
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-276
TEST DIODES ..............................................................................................................................30-277
Pm CLINIC...........................................................................................................................................30-278
Pm CLINIC SERVICE ...................................................................................................................30-278
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-14
GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-14
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-15
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-28
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-30
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-32
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-34
PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-58
SYMPTOM AND TROUBLESHOOTING NUMBERS ..................................................................... 40-61
INFORMATION IN TROUBLESHOOTING TABLE ......................................................................... 40-64
CONNECTORS LIST AND LAYOUT.............................................................................................. 40-66
CONNECTOR PIN NUMBERS - CONNECTION TABLE................................................................ 40-82
T-BOXES AND T-ADAPTERS LIST ..............................................................................................40-121
00-4 D155AX-8
FUSE LOCATION TABLE .............................................................................................................40-127

PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE .....................................40-130
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135])..........................................................................................................................40-134
FAILURE CODES TABLE .............................................................................................................40-136
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-159
FAILURE CODE [1500L0] T/M Clutches Double Engagement ......................................................40-159
FAILURE CODE [15SAL1] ECMV Release Trouble (Forward) ......................................................40-160
FAILURE CODE [15SALH] ECMV Engage Trouble (Forward) ......................................................40-162
FAILURE CODE [15SBL1] ECMV Release Trouble (Reverse)......................................................40-164
FAILURE CODE [15SBLH] ECMV Engage Trouble (Reverse) ......................................................40-166
FAILURE CODE [15SEL1] ECMV Release Trouble (1st) ..............................................................40-168
FAILURE CODE [15SELH] ECMV Engage Trouble (1st) ..............................................................40-170
FAILURE CODE [15SFL1] ECMV Release Trouble (2nd) .............................................................40-172
FAILURE CODE [15SFLH] ECMV Engage Trouble (2nd) .............................................................40-174
FAILURE CODE [15SGL1] ECMV Release Trouble (3rd) .............................................................40-176
FAILURE CODE [15SGLH] ECMV Engage Trouble (3rd)..............................................................40-178
FAILURE CODE [15SJL1] ECMV Release Trouble (Lock Up Clutch)............................................40-180
FAILURE CODE [15SJLH] ECMV Engage Trouble (Lock Up Clutch)............................................40-182
FAILURE CODE [1800MW] P/T Clutch Slip ..................................................................................40-184
FAILURE CODE [2300NR] Brake Thermal Load Abnormality .......................................................40-185
FAILURE CODE [2301L1] ECMV Release Trouble (RH Brake) ....................................................40-186
FAILURE CODE [2301LH] ECMV Engage Trouble (RH Brake).....................................................40-188
FAILURE CODE [2302L1] ECMV Release Trouble (LH Brake) .....................................................40-190
FAILURE CODE [2302LH] ECMV Engage Trouble (LH Brake) .....................................................40-192
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit.....................40-194
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit .....................40-195
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit ................................40-196
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit ................................40-198
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit..........................................................40-200
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit..........................................................40-201
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit.....................................40-202
FAILURE CODE [879EMC] Ventilation Damper Malfunction .........................................................40-204
FAILURE CODE [879FMC] Air Mix Damper Malfunction...............................................................40-205
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range ................................40-206
FAILURE CODE [989L00] Engine Controller Lock Caution 1 ........................................................40-208
FAILURE CODE [989M00] Engine Controller Lock Caution 2 .......................................................40-209
FAILURE CODE [989N00] Engine Controller Lock Caution 3........................................................40-210
FAILURE CODE [A1U0N3] Hydrocarbon Desorb Request 1.........................................................40-211
FAILURE CODE [A1U0N4] Hydrocarbon Desorb Request 2.........................................................40-213
FAILURE CODE [AA10NX] Air Cleaner Clogging..........................................................................40-215
FAILURE CODE [AB00KE] Charge Voltage Low...........................................................................40-217
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) ....40-219
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) ...............................40-221
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) ................................................40-223
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) ...........................................40-224
FAILURE CODE [AS00R6] Temporary Recovery of Inducement...................................................40-227
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5...........................................................40-228
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning ............................................40-229
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning ...............................40-230
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution..............................................40-231
FAILURE CODE [B@BAZG] Engine Oil Pressure Low .................................................................40-232
FAILURE CODE [B@BCNS] Engine Coolant Overheat ................................................................40-233
FAILURE CODE [B@BCZK] Engine Coolant Level Low ...............................................................40-234
FAILURE CODE [B@CENS] Power Train Oil Overheat ................................................................40-236
FAILURE CODE [B@HANS] Hydraulic Oil Overheat ....................................................................40-237
D155AX-8 00-5
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error.........................................40-238

FAILURE CODE [CA122] Charge Air Pressure Sensor High Error................................................40-239
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error.................................................40-241
FAILURE CODE [CA131] Throttle Sensor High Error....................................................................40-243
FAILURE CODE [CA132] Throttle Sensor Low Error.....................................................................40-245
FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error ................................................40-247
FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error .................................................40-249
FAILURE CODE [CA144] Coolant Temperature Sensor High Error...............................................40-251
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error................................................40-253
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error ..........................................40-255
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...........................................40-258
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error ......................................................40-261
FAILURE CODE [CA221] Ambient Pressure Sensor High Error....................................................40-263
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error ....................................................40-265
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error .....................................................40-267
FAILURE CODE [CA234] Engine Overspeed................................................................................40-268
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error ...............................................40-269
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error .......................................40-271
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error ....................................................40-273
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error.....................................................40-275
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error ..............................................................40-277
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error ..............................................................40-279
FAILURE CODE [CA273] PCV 2 Short Circuit Error......................................................................40-280
FAILURE CODE [CA274] PCV 2 Open Circuit Error .....................................................................40-282
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error ....................40-283
FAILURE CODE [CA343] Engine Controller Internal Failure .........................................................40-295
FAILURE CODE [CA351] Injectors Drive Circuit Error...................................................................40-296
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error ......................................................40-297
FAILURE CODE [CA356] MAF Sensor High Error ........................................................................40-300
FAILURE CODE [CA357] MAF Sensor Low Error .........................................................................40-302
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error .....................................................40-305
FAILURE CODE [CA441] Power Voltage Low Error ......................................................................40-306
FAILURE CODE [CA442] Power Voltage High Error .....................................................................40-309
FAILURE CODE [CA449] Common Rail Pressure High Error 2 ....................................................40-310
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error ...........................................40-311
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error ............................................40-313
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error...................40-315
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error....................40-317
FAILURE CODE [CA553] Common Rail Pressure High Error 1 ....................................................40-319
FAILURE CODE [CA555] Crankcase Pressure High Error 2 .........................................................40-320
FAILURE CODE [CA556] Crankcase Pressure High Error 3 .........................................................40-321
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 .....................................................40-322
FAILURE CODE [CA595] Turbocharger Speed High Error 2.........................................................40-327
FAILURE CODE [CA687] Turbocharger Speed Low Error ............................................................40-328
FAILURE CODE [CA689] Engine NE Speed Sensor Error ............................................................40-330
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error ............................................40-332
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error.............................................40-334
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error ...................40-336
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error....................40-337
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error ..........................................40-338
FAILURE CODE [CA778] Engine Backup Speed Sensor Error .....................................................40-339
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error ............................................40-342
FAILURE CODE [CA1664] KDOC Abnormality .............................................................................40-343
00-6 D155AX-8
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error ....................................40-346
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3 ...........................................................40-347
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error .....................................40-348
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error .....................................40-349
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error........................................................40-350
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error...........................40-352
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error ...........................40-354
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error..................................40-356
FAILURE CODE [CA1691] Defective Regeneration ......................................................................40-357
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error.............................................40-360
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error ...................................................40-363
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error ....................................................40-364
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error .......................................................40-366
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error..............................40-369
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error ..........................40-371
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error ...............................40-372
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error ............................................40-373
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error .............................................40-376
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error..............................................40-379
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error...............................................40-381
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error ...................................40-384
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error ....................................40-387
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error ............................40-389
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error ...............................................40-393
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error .................................................40-395
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 ...............................................40-397
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2 ...............................................40-400
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error .......................................................40-405
FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error........................................................40-407
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error ................................................40-409
FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error............................................40-411
FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error.............................................40-413
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error.......................................40-415
FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error .....................................................40-416
FAILURE CODE [CA1977] Fuel Doser Open Circuit Error or Short Circuit Error ...........................40-419
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error ................................................40-422
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error .........................................40-425
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error ..........................................40-427
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 ...................................................40-429
FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error ...................................................40-430
FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error....................................................40-432
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error ...............................................40-435
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error................................................40-437
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error..............................................40-439
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error ..............................................40-441
FAILURE CODE [CA2357] EGR Valve Servo Error.......................................................................40-443
FAILURE CODE [CA2381] KVGT Position Sensor High Error.......................................................40-444
FAILURE CODE [CA2382] KVGT Position Sensor Low Error .......................................................40-446
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error .....................................................40-448
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error .....................................................40-450
FAILURE CODE [CA2387] KVGT Servo Error ..............................................................................40-452
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error .........................................40-453
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error .........................................40-456
FAILURE CODE [CA2637] KDOC Face Plugging .........................................................................40-458
FAILURE CODE [CA2639] Manual Stationary Regeneration Request ..........................................40-460
FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error .......................................................40-462
FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error........................................................40-464
FAILURE CODE [CA2741] Fuel Dozer Solenoid Valve Swap Error...............................................40-466
D155AX-8 00-7
FAILURE CODE [CA2765] Injector Trim Data Mismatch ...............................................................40-467

FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error.................................40-468
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable ..
..................................................................................................................................................40-474
FAILURE CODE [CA2878] Fuel Doser Solenoid 2 Servo Error .....................................................40-477
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1......................................................40-480
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error.........................40-483
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error...........................................40-485
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error............................................40-487
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error....................................40-489
FAILURE CODE [CA3142] SCR Temperature Sensor High Error..................................................40-493
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error ..................................................40-494
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error ..........................................40-495
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error .......................................40-497
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error ........................................40-498
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error ................................40-499
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2...................................................40-501
FAILURE CODE [CA3165] SCR Outlet Temperature High Error ...................................................40-507
FAILURE CODE [CA3167] Fuel Doser Degradation......................................................................40-509
FAILURE CODE [CA3229] SCR Temperature High Error..............................................................40-512
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration ..............................40-514
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error ...............................40-516
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration....................40-520
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error....................................40-522
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error ....................................40-525
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error .........................................................40-528
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error ...................................................40-531
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration ...................................40-534
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1..............................................40-538
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration ....................................40-541
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 ..............................................40-544
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2 ..............................................40-546
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2 ..............................................40-548
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error ........................................40-551
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error .......................................40-552
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error ................................40-553
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error .....................................40-556
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error ....................................40-557
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error .............................40-558
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error .....................................40-561
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error ......................................40-562
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error ..............................40-564
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error..............................................40-567
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error...............................................40-569
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)...................40-573
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error .............................................40-580
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error................................................40-583
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error ................................................40-585
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error...........................40-587
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error ...........................40-589
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error ............40-592
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction ........................................................40-595
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error .................................40-599
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error..................................40-601
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error .......................................40-603
00-8 D155AX-8
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error.......................................40-605

FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error..................................................40-607
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error ..................................................40-609
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1...................................................40-611
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error.............................40-617
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error.......................................40-619
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error ...........................40-621
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error ....................................40-623
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error...................................40-628
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error....................................40-634
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error ...............................40-637
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error..............................40-638
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error............................................40-639
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error .................................40-642
FAILURE CODE [CA3751] SCR Catalyst Degradation Error.........................................................40-645
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error .........................40-647
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 .............................................40-649
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1 .............................................40-652
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error...............................40-655
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error............................................................40-659
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error ...........................................40-661
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error .......................................40-665
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error ......................................40-667
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error.......................................40-669
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error .............................................40-671
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error ............................................40-674
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error...............................................40-676
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error ..........40-678
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error ..............................40-683
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error ..........................40-687
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error...........................40-690
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction ............................................................40-693
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error ..............40-695
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error ..................................40-696
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error ........40-697
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error .........40-700
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error 40-703
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error ............................40-706
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error .............................40-708
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error ....................40-710
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error .........................................40-712
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error .......................................40-715
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error ......................................................40-717
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error .................40-720
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error .................40-722
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error.............40-724
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error.................................40-727
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error .........40-730
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error............................................40-733
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error...........................40-737
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error ...........................40-740
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error...............................................................40-743
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error................40-747
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error ...........................40-748
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error .................................40-749
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error...........................................................40-750
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible......................................40-752
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error................................................40-755
D155AX-8 00-9
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller) ..................40-758
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error.....................................40-760
FAILURE CODE [CA5383] Ash Accumulation High Error..............................................................40-763
FAILURE CODE [D130KA] Neutral Safety Relay Open Circuit......................................................40-765
FAILURE CODE [D130KB] Neutral Safety Relay Short Circuit......................................................40-768
FAILURE CODE [D190KA] Engine Controller Accessory Signal Hold Relay Open Circuit ............40-770
FAILURE CODE [D190KB] Engine Controller Accessory Signal Hold Relay Short Circuit.............40-772
FAILURE CODE [D19JKZ] Personal Code Relay Open or Short ..................................................40-774
FAILURE CODE [D811MC] KOMTRAX Malfunction......................................................................40-777
FAILURE CODE [D862KA] GPS Antenna Open Circuit ................................................................40-778
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)...........................40-779
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) ...........................40-781
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX) .................................40-783
FAILURE CODE [DAF0MB] Monitor ROM Abnormality.................................................................40-784
FAILURE CODE [DAF0MC] Monitor Malfunction ..........................................................................40-785
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit ..................................................40-786
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor).......................................40-787
FAILURE CODE [DAFGMC] GPS Module Malfunction .................................................................40-788
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) ................................40-789
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) ................................40-791
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor) ......................................40-793
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) ............................................40-794
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)....................................40-795
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller) .......................40-796
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller) .......................40-802
FAILURE CODE [DB90KT] W/E Controller Internal Abnormality ...................................................40-808
FAILURE CODE [DB90MC] W/E Controller Malfunction ...............................................................40-809
FAILURE CODE [DB91KK] W/E Controller Source Voltage Low Error ..........................................40-810
FAILURE CODE [DB92KK] W/E Controller Solenoid Power Voltage Low Error.............................40-813
FAILURE CODE [DB95KK] W/E Controller 5V Sensor 0 Power Voltage Out of Range .................40-816
FAILURE CODE [DB97KK] W/E Controller 5V Sensor 1 Power Voltage Out of Range .................40-819
FAILURE CODE [DB99KQ] Model Selection Signal Mismatch (W/E Controller)............................40-821
FAILURE CODE [DB9LKA] System Operating Lamp Open Circuit (W/E Controller) .....................40-823
FAILURE CODE [DB9LKB] System Operating Lamp Short Circuit (W/E Controller) .....................40-825
FAILURE CODE [DB9QKR] CAN 2 Defective Communication (W/E Controller) ...........................40-827
FAILURE CODE [DB9RKR] CAN 1 Defective Communication (W/E Controller)............................40-828
FAILURE CODE [DBE0KT] P/T Controller Internal Abnormality ....................................................40-830
FAILURE CODE [DBE1KK] P/T Controller Source Voltage Low Error...........................................40-831
FAILURE CODE [DBE2KK] P/T Controller Solenoid Power Voltage Low Error .............................40-834
FAILURE CODE [DBE5KK] P/T Controller 5V Sensor 0 Power Voltage Out of Range ..................40-837
FAILURE CODE [DBE6KK] P/T Controller 24V Sensor Power Voltage Out of Range ...................40-839
FAILURE CODE [DBE9KQ] Model Selection Signal Mismatch (P/T Controller) ............................40-841
FAILURE CODE [DBELKA] System Operating Lamp Open Circuit (P/T Controller) ......................40-843
FAILURE CODE [DBELKB] System Operating Lamp Short Circuit (P/T Controller) ......................40-845
FAILURE CODE [DBEQKR] CAN 2 Defective Communication (P/T Controller) ............................40-847
FAILURE CODE [DBERKR] CAN 1 Defective Communication (P/T Controller) ............................40-848
FAILURE CODE [DD12KA] Shift Up SW Open Circuit ..................................................................40-850
FAILURE CODE [DD12KB] Shift Up SW Short Circuit ..................................................................40-852
FAILURE CODE [DD13KA] Shift Down SW Open Circuit..............................................................40-854
FAILURE CODE [DD13KB] Shift Down SW Short Circuit ..............................................................40-856
FAILURE CODE [DD14KA] Parking Brake Lever SW Open Circuit...............................................40-858
FAILURE CODE [DD14KB] Parking Brake Lever SW Short Circuit ...............................................40-861
FAILURE CODE [DDDDKA] Brake Pedal SW Open Circuit ..........................................................40-863
FAILURE CODE [DDDDKB] Brake Pedal SW Short Circuit...........................................................40-866
FAILURE CODE [DDDDKX] Brake Pedal SW Signal Mismatch ....................................................40-869
FAILURE CODE [DDKAKA] Blade Float SW Open Circuit ............................................................40-870
FAILURE CODE [DDKAKB] Blade Float SW Short Circuit ............................................................40-872
FAILURE CODE [DDKBKA] Blade Auto Pitch SW Open Circuit ....................................................40-874
00-10 D155AX-8
FAILURE CODE [DDKBKB] Blade Auto Pitch SW Short Circuit ....................................................40-876

FAILURE CODE [DDKCL4] Ripper Tilt In SW Signal Mismatch ....................................................40-878
FAILURE CODE [DDKEL4] Ripper Tilt Back SW Signal Mismatch................................................40-881
FAILURE CODE [DDN7L4] Blade Pitch Back SW Signal Mismatch ..............................................40-884
FAILURE CODE [DDN8L4] Blade Pitch Dump SW Signal Mismatch ............................................40-887
FAILURE CODE [DDNLKA] W/E Lock SW Open Circuit ...............................................................40-890
FAILURE CODE [DDNLKB] W/E Lock SW Short Circuit ...............................................................40-892
FAILURE CODE [DDTSL1] Stator Clutch Release Trouble ...........................................................40-894
FAILURE CODE [DDTSLH] Stator Clutch Engage Trouble ...........................................................40-896
FAILURE CODE [DFA4KX] Blade Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit .....
..................................................................................................................................................40-898
FAILURE CODE [DFA4KZ] Blade Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit......
..................................................................................................................................................40-899
FAILURE CODE [DFA4L8] Blade Lift Lever Potentiometer 1 or 2 Signal Abnormality ...................40-900
FAILURE CODE [DFA5KA] Blade Lift Lever Potentiometer 1 Open Circuit ...................................40-901
FAILURE CODE [DFA5KY] Blade Lift Lever Potentiometer 1 Hot Short Circuit .............................40-904
FAILURE CODE [DFA6KA] Blade Lift Lever Potentiometer 2 Open Circuit ...................................40-906
FAILURE CODE [DFA6KY] Blade Lift Lever Potentiometer 2 Hot Short Circuit .............................40-909
FAILURE CODE [DFA7KX] Blade Tilt Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit......
..................................................................................................................................................40-911
FAILURE CODE [DFA7KZ] Blade Tilt Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit......
..................................................................................................................................................40-912
FAILURE CODE [DFA7L8] Blade Tilt Lever Potentiometer 1 or 2 Signal Abnormality ...................40-913
FAILURE CODE [DFA8KA] Blade Tilt Lever Potentiometer 1 Open Circuit ...................................40-914
FAILURE CODE [DFA8KY] Blade Tilt Lever Potentiometer 1 Hot Short Circuit .............................40-917
FAILURE CODE [DFA9KA] Blade Tilt Lever Potentiometer 2 Open Circuit ...................................40-919
FAILURE CODE [DFA9KY] Blade Tilt Lever Potentiometer 2 Hot Short Circuit .............................40-922
FAILURE CODE [DFAAKX] Ripper Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit....
..................................................................................................................................................40-924
FAILURE CODE [DFAAKZ] Ripper Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit....
..................................................................................................................................................40-925
FAILURE CODE [DFAAL8] Ripper Lift Lever Potentiometer 1 or 2 Signal Abnormality .................40-926
FAILURE CODE [DFABKA] Ripper Lift Lever Potentiometer 1 Open Circuit .................................40-927
FAILURE CODE [DFABKY] Ripper Lift Lever Potentiometer 1 Hot Short Circuit ...........................40-930
FAILURE CODE [DFACKA] Ripper Lift Lever Potentiometer 2 Open Circuit .................................40-932
FAILURE CODE [DFACKY] Ripper Lift Lever Potentiometer 2 Hot Short Circuit ...........................40-935
FAILURE CODE [DGS1KA] Hydraulic Oil Temperature Sensor Open Circuit ................................40-937
FAILURE CODE [DGS1KX] Hydraulic Oil Temperature Sensor Input Signal Out of Range ...........40-939
FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit .........................................40-941
FAILURE CODE [DGT1KX] T/C Oil Temperature Sensor Input Signal Out of Range ....................40-944
FAILURE CODE [DH21KA] W/E Pump Pressure Sensor Open Circuit .........................................40-946
FAILURE CODE [DH21KY] W/E Pump Pressure Sensor Hot Short Circuit ...................................40-949
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit ...............................................40-951
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen ......................................40-953
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen .............................................40-954
FAILURE CODE [DHT5KA] T/C Inlet Pressure Sensor Open Circuit.............................................40-955
FAILURE CODE [DHT5KY] T/C Inlet Pressure Sensor Hot Short Circuit ......................................40-958
FAILURE CODE [DHT7KA] T/C Outlet Pressure Sensor Open Circuit ..........................................40-960
FAILURE CODE [DHT7KY] T/C Outlet Pressure Sensor Hot Short Circuit....................................40-963
FAILURE CODE [DK10KA] Fuel Control Dial Open Circuit ...........................................................40-965
FAILURE CODE [DK10KB] Fuel Control Dial Short Circuit............................................................40-968
FAILURE CODE [DK30KA] S/T Potentiometer 1 Open Circuit ......................................................40-970
FAILURE CODE [DK30KY] S/T Potentiometer 1 Hot Short Circuit ................................................40-973
FAILURE CODE [DK30KX] S/T Potentiometer 1 and 2 Open Circuit or Hot Short Circuit .............40-975
FAILURE CODE [DK30KZ] S/T Potentiometer 1 and 2 Open Circuit or Hot Short Circuit..............40-976
FAILURE CODE [DK30L8] S/T Potentiometer 1 or 2 Signal Abnormality ......................................40-977
FAILURE CODE [DK31KA] S/T Potentiometer 2 Open Circuit ......................................................40-978
FAILURE CODE [DK31KY] S/T Potentiometer 2 Hot Short Circuit ................................................40-981
D155AX-8 00-11
FAILURE CODE [DK40KA] Brake Pedal Potentiometer Open Circuit ...........................................40-983

FAILURE CODE [DK40KY] Brake Pedal Potentiometer Hot Short Circuit .....................................40-986
FAILURE CODE [DK55KX] F/R Potentiometer 1 and 2 Open Circuit or Hot Short Circuit .............40-988
FAILURE CODE [DK55KZ] F/R Potentiometer 1 and 2 Open Circuit or Hot Short Circuit .............40-989
FAILURE CODE [DK55L8] F/R Potentiometer 1 or 2 Signal Abnormality ......................................40-990
FAILURE CODE [DK56KA] F/R Potentiometer 1 Open Circuit ......................................................40-991
FAILURE CODE [DK56KY] F/R Potentiometer 1 Hot Short Circuit................................................40-994
FAILURE CODE [DK57KA] F/R Potentiometer 2 Open Circuit ......................................................40-996
FAILURE CODE [DK57KY] F/R Potentiometer 2 Hot Short Circuit................................................40-999
FAILURE CODE [DKH1KA] Inclination Angle Sensor Open Circuit .............................................40-1001
FAILURE CODE [DKH1KY] Inclination Angle Sensor Hot Short Circuit.......................................40-1004
FAILURE CODE [DLM3KA] Fan Speed Sensor Open Circuit......................................................40-1006
FAILURE CODE [DLM3KB] Fan Speed Sensor Short Circuit......................................................40-1008
FAILURE CODE [DLM3MB] Fan Speed Sensor Function Deterioration ......................................40-1009
FAILURE CODE [DLT3KA] T/M Output Speed Sensor Open Circuit ...........................................40-1010
FAILURE CODE [DLT3KB] T/M Output Speed Sensor Ground Fault ..........................................40-1012
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range ......................40-1014
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range ......................40-1015
FAILURE CODE [DV20KB] Back Alarm Buzzer Short Circuit......................................................40-1016
FAILURE CODE [DW7BKA] Fan Reverse Solenoid Open Circuit ...............................................40-1018
FAILURE CODE [DW7BKB] Fan Reverse Solenoid Short Circuit................................................40-1020
FAILURE CODE [DWN1KA] S/T Control Valve Right EPC Solenoid Open Circuit ......................40-1022
FAILURE CODE [DWN1KB] S/T Control Valve Right EPC Solenoid Short Circuit.......................40-1024
FAILURE CODE [DWN1KY] S/T Control Valve Right EPC Solenoid Hot Short Circuit ................40-1026
FAILURE CODE [DWN2KA] S/T Control Valve Left EPC Solenoid Open Circuit.........................40-1027
FAILURE CODE [DWN2KB] S/T Control Valve Left EPC Solenoid Short Circuit .........................40-1029
FAILURE CODE [DWN2KY] S/T Control Valve Left EPC Solenoid Hot Short Circuit...................40-1031
FAILURE CODE [DWN3KA] Sudden Stop Prevention Valve Solenoid Open Circuit....................40-1032
FAILURE CODE [DWN3KB] Sudden Stop Prevention Valve Solenoid Short Circuit....................40-1034
FAILURE CODE [DWN3KY] Sudden Stop Prevention Valve Solenoid Hot Short Circuit .............40-1036
FAILURE CODE [DWN5KA] Fan Control Solenoid 1 Open Circuit ..............................................40-1038
FAILURE CODE [DWN5KB] Fan Control Solenoid 1 Short Circuit ..............................................40-1040
FAILURE CODE [DWN5KY] Fan Control Solenoid 1 Hot Short Circuit........................................40-1042
FAILURE CODE [DXA2KA] HSS Pump TVC Solenoid 1 Open Circuit ........................................40-1044
FAILURE CODE [DXA2KB] HSS Pump TVC Solenoid 1 Short Circuit ........................................40-1046
FAILURE CODE [DXA2KY] HSS Pump TVC Solenoid 1 Hot Short Circuit..................................40-1048
FAILURE CODE [DXH1KA] Lockup Clutch ECMV Solenoid Open Circuit...................................40-1050
FAILURE CODE [DXH1KB] Lockup Clutch ECMV Solenoid Short Circuit ...................................40-1052
FAILURE CODE [DXH1KY] Lockup Clutch ECMV Solenoid Hot Short Circuit ............................40-1054
FAILURE CODE [DXH4KA] T/M 1st Clutch ECMV Solenoid Open Circuit ..................................40-1056
FAILURE CODE [DXH4KB] T/M 1st Clutch ECMV Solenoid Short Circuit...................................40-1058
FAILURE CODE [DXH4KY] T/M 1st Clutch ECMV Solenoid Hot Short Circuit ............................40-1060
FAILURE CODE [DXH5KA] T/M 2nd Clutch ECMV Solenoid Open Circuit .................................40-1062
FAILURE CODE [DXH5KB] T/M 2nd Clutch ECMV Solenoid Short Circuit .................................40-1064
FAILURE CODE [DXH5KY] T/M 2nd Clutch ECMV Solenoid Hot Short Circuit ...........................40-1066
FAILURE CODE [DXH6KA] T/M 3rd Clutch ECMV Solenoid Open Circuit ..................................40-1068
FAILURE CODE [DXH6KB] T/M 3rd Clutch ECMV Solenoid Short Circuit ..................................40-1070
FAILURE CODE [DXH6KY] T/M 3rd Clutch ECMV Solenoid Hot Short Circuit............................40-1071
FAILURE CODE [DXH7KA] T/M Reverse Clutch ECMV Solenoid Open Circuit ..........................40-1073
FAILURE CODE [DXH7KB] T/M Reverse Clutch ECMV Solenoid Short Circuit ..........................40-1075
FAILURE CODE [DXH7KY] T/M Reverse Clutch ECMV Solenoid Hot Short Circuit....................40-1077
FAILURE CODE [DXH8KA] T/M Forward Clutch ECMV Solenoid Open Circuit ..........................40-1079
FAILURE CODE [DXH8KB] T/M Forward Clutch ECMV Solenoid Short Circuit ..........................40-1081
FAILURE CODE [DXH8KY] T/M Forward Clutch ECMV Solenoid Hot Short Circuit ....................40-1083
FAILURE CODE [DXHBKA] Right Brake ECMV Solenoid Open Circuit ......................................40-1085
FAILURE CODE [DXHBKB] Right Brake ECMV Solenoid Short Circuit ......................................40-1087
FAILURE CODE [DXHBKY] Right Brake ECMV Solenoid Hot Short Circuit ................................40-1089
FAILURE CODE [DXHCKA] Left Brake ECMV Solenoid Open Circuit ........................................40-1091
00-12 D155AX-8
FAILURE CODE [DXHCKB] Left Brake ECMV Solenoid Short Circuit.........................................40-1093

FAILURE CODE [DXHCKY] Left Brake ECMV Solenoid Hot Short Circuit ..................................40-1095
FAILURE CODE [DXHRKA] Blade Lift Raise EPC Solenoid Open Circuit...................................40-1097
FAILURE CODE [DXHRKB] Blade Lift Raise EPC Solenoid Short Circuit ...................................40-1099
FAILURE CODE [DXHRKY] Blade Lift Raise EPC Solenoid Hot Short Circuit ............................40-1100
FAILURE CODE [DXHSKA] Blade Lift Lower EPC Solenoid Open Circuit ..................................40-1102
FAILURE CODE [DXHSKB] Blade Lift Lower EPC Solenoid Short Circuit...................................40-1104
FAILURE CODE [DXHSKY] Blade Lift Lower EPC Solenoid Hot Short Circuit ............................40-1105
FAILURE CODE [DXHTKA] Blade Tilt Right Head EPC Solenoid Open Circuit...........................40-1107
FAILURE CODE [DXHTKB] Blade Tilt Right Head EPC Solenoid Short Circuit ...........................40-1109
FAILURE CODE [DXHTKY] Blade Tilt Right Head EPC Solenoid Hot Short Circuit .................... 40-1111
FAILURE CODE [DXHUKA] Blade Tilt Right Bottom EPC Solenoid Open Circuit........................ 40-1113
FAILURE CODE [DXHUKB] Blade Tilt Right Bottom EPC Solenoid Short Circuit........................ 40-1115
FAILURE CODE [DXHUKY] Blade Tilt Right Bottom EPC Solenoid Hot Short Circuit ................. 40-1117
FAILURE CODE [DXHWKA] Ripper Lift Raise EPC Solenoid Open Circuit................................. 40-1119
FAILURE CODE [DXHWKB] Ripper Lift Raise EPC Solenoid Short Circuit.................................40-1121
FAILURE CODE [DXHWKY] Ripper Lift Raise EPC Solenoid Hot Short Circuit ..........................40-1122
FAILURE CODE [DXHXKA] Ripper Lift Lower EPC Solenoid Open Circuit .................................40-1124
FAILURE CODE [DXHXKB] Ripper Lift Lower EPC Solenoid Short Circuit .................................40-1126
FAILURE CODE [DXHXKY] Ripper Lift Lower EPC Solenoid Hot Short Circuit...........................40-1127
FAILURE CODE [DXHYKA] Ripper Tilt In EPC Solenoid Open Circuit........................................40-1129
FAILURE CODE [DXHYKB] Ripper Tilt In EPC Solenoid Short Circuit ........................................40-1131
FAILURE CODE [DXHYKY] Ripper Tilt In EPC Solenoid Hot Short Circuit..................................40-1132
FAILURE CODE [DXHZKA] Ripper Tilt Back EPC Solenoid Open Circuit ...................................40-1134
FAILURE CODE [DXHZKB] Ripper Tilt Back EPC Solenoid Short Circuit ...................................40-1136
FAILURE CODE [DXHZKY] Ripper Tilt Back EPC Solenoid Hot Short Circuit.............................40-1137
FAILURE CODE [DXJ4KA] W/E Lock Solenoid Open Circuit ......................................................40-1139
FAILURE CODE [DXJ4KB] W/E Lock Solenoid Short Circuit ......................................................40-1141
FAILURE CODE [DXJ8KA] Blade Tilt Left Bottom EPC Solenoid Open Circuit ...........................40-1142
FAILURE CODE [DXJ8KB] Blade Tilt Left Bottom EPC Solenoid Short Circuit ...........................40-1144
FAILURE CODE [DXJ8KY] Blade Tilt Left Bottom EPC Solenoid Hot Short Circuit .....................40-1146
FAILURE CODE [DXJ9KA] Blade Tilt Left Head EPC Solenoid Open Circuit ..............................40-1148
FAILURE CODE [DXJ9KB] Blade Tilt Left Head EPC Solenoid Short Circuit ..............................40-1150
FAILURE CODE [DXJ9KY] Blade Tilt Left Head EPC Solenoid Hot Short Circuit........................40-1152
FAILURE CODE [DXJAKA] Quick drop solenoid: Open ..............................................................40-1154
FAILURE CODE [DXJAKB] Quick Drop EPC Solenoid Short Circuit ...........................................40-1156
FAILURE CODE [DXJAKY] Quick Drop EPC Solenoid Hot Short Circuit.....................................40-1158
FAILURE CODE [DXJBKA] T/C Stator Clutch ECMV Solenoid Open Circuit ..............................40-1160
FAILURE CODE [DXJBKB] T/C Stator Clutch ECMV Solenoid Short Circuit...............................40-1162
FAILURE CODE [DXJBKY] T/C Stator Clutch ECMV Solenoid Hot Short Circuit ........................40-1164
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .........................................................40-1166
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ..............................................40-1166
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK........................................................40-1173
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ..................................................40-1176
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP..... 40-1178
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING................................................................................................................................40-1180
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIA-
TOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW .................................................40-1184
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.....
................................................................................................................................................40-1186
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ...............40-1187
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1189
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1190
E-11 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1191
D155AX-8 00-13
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1192
E-13 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERA-
TURE ......................................................................................................................................40-1193
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .....................................40-1194
E-15 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERA-
TURE ......................................................................................................................................40-1197
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE..
................................................................................................................................................40-1198
E-17 OPERATION MODE DOES NOT CHANGE........................................................................40-1199
E-18 OPERATION MODE DOES NOT CHANGE........................................................................40-1200
E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN..........40-1201
E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MA-
CHINE .....................................................................................................................................40-1202
E-21 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ......................40-1203
E-22 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING.......................40-1204
E-23 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
................................................................................................................................................40-1205
E-24 SERVICE MODE CANNOT BE SELECTED .......................................................................40-1206
E-25 HORN DOES NOT SOUND................................................................................................40-1207
E-26 HORN DOES NOT STOP SOUNDING...............................................................................40-1209
E-27 BACKUP ALARM DOES NOT SOUND ..............................................................................40-1210
E-28 BACKUP ALARM DOES NOT STOP SOUNDING..............................................................40-1211
E-29 HEADLAMP DOES NOT LIGHT UP ...................................................................................40-1212
E-30 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP..........................................40-1216
E-31 NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY ...................................40-1219
E-32 FRONT WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTERMITTENT
OPERATIONS) ........................................................................................................................40-1224
E-33 REAR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTERMITTENT
OPERATIONS) ........................................................................................................................40-1228
E-34 LEFT DOOR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTERMIT-
TENT OPERATIONS)..............................................................................................................40-1232
E-35 RIGHT DOOR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTER-
MITTENT OPERATIONS)........................................................................................................40-1236
E-36 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY .........................40-1240
E-37 FAN DOES NOT ROTATE IN REVERSE............................................................................40-1241
E-38 GEAR CANNOT BE SHIFTED ...........................................................................................40-1242
E-39 FRONT WASHER DOES NOT OPERATE..........................................................................40-1243
E-40 REAR WASHER DOES NOT OPERATE ............................................................................40-1246
E-41 LEFT DOOR WASHER DOES NOT OPERATE..................................................................40-1249
E-42 RIGHT DOOR WASHER DOES NOT OPERATE ...............................................................40-1252
E-43 RIPPER PIN PULLER DOES NOT WORK .........................................................................40-1255
E-44 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1257
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1258
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1258
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ..........................................40-1259
FAILURE MODE AND CAUSE TABLE........................................................................................40-1263
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) .........................................40-1271
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) .....................................40-1274
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS ...............................................40-1276
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR IN REVERSE .40-1279
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE ...........................40-1281
H-6 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR RIGHT)........40-1283
H-7 STEERING SPEED OR POWER IS INSUFFICIENT............................................................40-1285
H-8 BRAKE DOES NOT WORK..................................................................................................40-1287
H-9 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE ....................................40-1288
H-10 POWER TRAIN OIL OVERHEATS.....................................................................................40-1289
00-14 D155AX-8
H-11 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND HSS PUMP OR HSS
MOTOR ...................................................................................................................................40-1291
H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY ...............................................................40-1292
H-13 ALL WORK EQUIPMENTS DO NOT OPERATE ................................................................40-1294
H-14 BLADE LIFT SPEED OR POWER IS LOW ........................................................................40-1296
H-15 BLADE TILT SPEED OR POWER IS LOW ........................................................................40-1298
H-16 RIPPER LIFT SPEED OR POWER IS LOW.......................................................................40-1300
H-17 RIPPER TILT SPEED OR POWER IS LOW .......................................................................40-1302
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE ..........................................................40-1304
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE...........................................................40-1305
H-20 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE.........................................................40-1306
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE ................................................40-1307
H-22 BLADE PITCH CYLINDER DOES NOT OPERATE ............................................................40-1308
H-23 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ............................40-1309
H-24 UNUSUAL NOISE IS HEARD FROM AROUND FAN .........................................................40-1310
TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1311
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1311
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
................................................................................................................................................40-1312
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1313
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ........................................................................................................40-1314
S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1315
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1317
S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1319
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1321
S-8 ENGINE LACKS POWER.....................................................................................................40-1322
S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1324
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1326
S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1327
S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1328
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
................................................................................................................................................40-1329
S-14 OIL PRESSURE DROPS ...................................................................................................40-1330
S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1332
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1333
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1334
S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1335
S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1336
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1337
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1338
S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1340
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1341
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1342
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1344
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1345
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-8
HOW TO READ THIS MANUAL....................................................................................................... 50-8
COATING MATERIALS LIST............................................................................................................ 50-9
SPECIAL TOOLS LIST .................................................................................................................. 50-14
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-39
ENGINE AND COOLING SYSTEM....................................................................................................... 50-62
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-62
REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-70
REMOVE AND INSTALL FUEL DOSER ASSEMBLY .................................................................... 50-85
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-87
D155AX-8 00-15
REMOVE AND INSTALL EGR VALVE ASSEMBLY.......................................................................50-114

REMOVE AND INSTALL EGR COOLER ASSEMBLY...................................................................50-117
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY ..........................................................50-122
REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-125
REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-128
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-137
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-140
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY ......................................................50-144
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY ....................................................50-148
REMOVE AND INSTALL ENGINE ASSEMBLY.............................................................................50-151
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-165
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-171
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-177
REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-184
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-191
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-202
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-213
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-215
REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-217
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-225
REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-234
REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-242
REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-253
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-258
REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-266
REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-272
REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-279
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-291
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-294
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-297
POWER TRAIN....................................................................................................................................50-301
REMOVE AND INSTALL DAMPER ASSEMBLY ...........................................................................50-301
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY ............................................................50-306
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY ........................................................50-311
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY ................................50-321
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY ....................................................................50-333
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY .....................................50-344
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY.................................................50-358
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY ....................................................................50-382
REMOVAL AND INSTALLATION OF HSS MOTOR ......................................................................50-407
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY ....................................................................50-410
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-415
REMOVE AND INSTALL TRACK FRAME ASSEMBLY.................................................................50-435
REMOVE AND INSTALL IDLER ASSEMBLY................................................................................50-445
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-448
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY ..............................................................50-454
DISASSEMBLE AND ASSEMBLE RECOIL SPRING....................................................................50-455
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY ...............................................................50-462
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-466
REMOVE AND INSTALL NO. 1 BOGIE ASSEMBLY.....................................................................50-470
REMOVE AND INSTALL NO. 2, 3, 4 BOGIE ASSEMBLIES .........................................................50-479
DISASSEMBLE AND ASSEMBLE TRACK ROLLER BOGEY ASSEMBLY ...................................50-488
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY ...........................................................50-492
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................50-495
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY ...................................................................50-500
SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-503
DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERALLY ....................................50-508
00-16 D155AX-8
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD...............................50-521

DISASSEMBLE AND ASSEMBLE MASTER LINK........................................................................50-527
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY..............................................................50-531
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS................................................50-535
REMOVE AND INSTALL SPROCKET ..........................................................................................50-537
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-538
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY ..................50-541
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY ..
..................................................................................................................................................50-545
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY.......................................................50-549
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY........................................................50-554
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-556
WORK EQUIPMENT............................................................................................................................50-560
REMOVE AND INSTALL BLADE ASSEMBLY ..............................................................................50-560
DISASSEMBLE AND ASSEMBLE BLADE ASSEMBLY ................................................................50-565
DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER ASSEMBLY ..........................50-571
DISASSEMBLE AND ASSEMBLE GIANT RIPPER ASSEMBLY...................................................50-576
METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE LIFT CYLINDER ASSEMBLY ....50-582
METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE TILT CYLINDER ASSEMBLY.....50-589
METHOD FOR DISASSEMBLING AND ASSEMBLING RIPPER CYLINDER ASSEMBLY ...........50-595
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-602
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS) .................................50-621
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-628
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-641
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-643
ELECTRICAL SYSTEM .......................................................................................................................50-645
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-645
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY ........................................50-651
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY ................................50-654
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-657
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-660
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-663
REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-665
REMOVE AND INSTALL BATTERY RELAY..................................................................................50-669
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-682
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ENGINE AND COOLING SYSTEM......................................................................................................... 60-4
MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-4
MAINTENANCE STANDARD OF DAMPER..................................................................................... 60-6
MAINTENANCE STANDARD OF COOLING SYSTEM .................................................................... 60-8
MAINTENANCE STANDARD OF COOLING FAN PUMP............................................................... 60-10
MAINTENANCE STANDARD OF COOLING FAN MOTOR............................................................ 60-14
POWER TRAIN..................................................................................................................................... 60-16
MAINTENANCE STANDARD OF UNIVERSAL JOINT................................................................... 60-16
MAINTENANCE STANDARD OF POWER TRAIN MOUNT ........................................................... 60-17
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO ........................................... 60-19
MAINTENANCE STANDARD OF TORQUE CONVERTER CONTROL VALVE.............................. 60-26
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV ......................................................... 60-27
MAINTENANCE STANDARD OF STATOR CLUTCH ECMV.......................................................... 60-28
MAINTENANCE STANDARD OF TRANSMISSION ....................................................................... 60-29
MAINTENANCE STANDARD OF TRANSMISSION ECMV............................................................ 60-34
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE .
................................................................................................................................................... 60-35
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE ..................... 60-36
MAINTENANCE STANDARD OF BEVEL GEAR SHAFT, HSS, AND BRAKE................................ 60-37
D155AX-8 00-17
MAINTENANCE STANDARD OF BRAKE CONTROL VALVE........................................................ 60-43

MAINTENANCE STANDARD OF BRAKE ECMV........................................................................... 60-45
MAINTENANCE STANDARD OF BRAKE SOLENOID VALVE....................................................... 60-46
MAINTENANCE STANDARD OF SUDDEN STOP PREVENTION VALVE..................................... 60-47
MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-48
MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-51
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING......... 60-52
UNDERCARRIAGE AND FRAME......................................................................................................... 60-54
MAINTENANCE STANDARD OF MAIN FRAME............................................................................ 60-54
MAINTENANCE STANDARD OF SUSPENSION........................................................................... 60-56
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-58
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-60
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-62
MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-64
MAINTENANCE STANDARD OF TRACK SHOE (SEALED AND LUBRICATED TYPE) ................ 60-65
MAINTENANCE STANDARD OF TRACK SHOE (GREASE FILLING TYPE) ................................ 60-67
MAINTENANCE STANDARD OF SINGLE SHOE AND HEAVY DUTY SHOE ............................... 60-69
HYDRAULIC SYSTEM.......................................................................................................................... 60-70
MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-70
MAINTENANCE STANDARD OF SCAVENGING PUMP ............................................................... 60-71
MAINTENANCE STANDARD OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP.........
................................................................................................................................................... 60-72
MAINTENANCE STANDARD OF WORK EQUIPMENT AND HSS PUMP ..................................... 60-74
MAINTENANCE STANDARD OF PC-EPC VALVE......................................................................... 60-76
MAINTENANCE STANDARD OF HSS MOTOR............................................................................. 60-77
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-80
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE..................................... 60-94
MAINTENANCE STANDARD OF QUICK DROP VALVE................................................................ 60-97
WORK EQUIPMENT............................................................................................................................. 60-99
MAINTENANCE STANDARD OF CYLINDER STAY ...................................................................... 60-99
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT...................................................60-101
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT ...............................................60-103
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER ..........................................................60-104
MAINTENANCE STANDARD OF BLADE TILT CYLINDER ..........................................................60-105
MAINTENANCE STANDARD OF VARIABLE MULTI-SHANK RIPPER .........................................60-106
MAINTENANCE STANDARD OF VARIABLE GIANT RIPPER ......................................................60-108
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER.........................................................60-110
MAINTENANCE STANDARD OF RIPPER TILT CYLINDER ......................................................... 60-111
MAINTENANCE STANDARD OF CAB MOUNT............................................................................60-112
80 APPENDIX................................................................................................................................................ 80-1
CONTENTS ............................................................................................................................................ 80-2
AIR CONDITIONER SYSTEM ................................................................................................................ 80-4
PRECAUTIONS FOR REFRIGERANT ............................................................................................ 80-4
AIR CONDITIONER COMPONENT ................................................................................................. 80-5
SPECIFICATIONS OF AIR CONDITIONER ..................................................................................... 80-7
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................... 80-8
OUTLINE OF REFRIGERATION CYCLE ......................................................................................... 80-9
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .....................................................................80-11
AIR CONDITIONER UNIT...............................................................................................................80-11
COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-15
AIR CONDITIONER CONTROLLER.............................................................................................. 80-18
COMPRESSOR ............................................................................................................................. 80-19
CONDENSER ................................................................................................................................ 80-21
RECEIVER DRIER......................................................................................................................... 80-22
SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-23
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......
.......................................................................................................................................................... 80-25
00-18 D155AX-8
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-27
AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-29
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-30
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
.......................................................................................................................................................... 80-32
TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-40
METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-40
EXPLANATION FOR TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .............. 80-43
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR .......................................................................................................... 80-44
TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-45
METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-45
TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-46
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-46
TEST SUNLIGHT SENSOR.................................................................................................................. 80-47
METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-47
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT............................................................... 80-48
METHOD FOR TESTING (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT ......................... 80-48
TEST RELAYS...................................................................................................................................... 80-49
METHOD FOR TESTING RELAYS ................................................................................................ 80-49
AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-50
AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-52
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-55
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit............................. 80-58
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit ............................. 80-59
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit ........................................ 80-60
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit ........................................ 80-62
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit.................................................................. 80-64
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit.................................................................. 80-65
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit............................................. 80-66
FAILURE CODE [879EMC] Ventilation Damper Malfunction ................................................................. 80-68
FAILURE CODE [879FMC] Air Mix Damper Malfunction....................................................................... 80-69
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range ........................................ 80-70
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).
.......................................................................................................................................................... 80-72
A-2 TROUBLESHOOTING OF COMPRESSOR SYSTEM (AIR IS NOT COOLED) .............................. 80-74
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) ..................................................................................................................................... 80-78
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-80
TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-82
CONNECTION OF SERVICE TOOL ..................................................................................................... 80-84
METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-84
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS...................................................................................................................................... 80-86
HANDLE COMPRESSOR OIL .............................................................................................................. 80-88
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-3
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-3
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.......................................................................... 90-7
HYDRAULIC CIRCUIT DIAGRAM (1/2) ........................................................................................... 90-9
HYDRAULIC CIRCUIT DIAGRAM (2/2) ..........................................................................................90-11
ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-13
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-13
ELECTRICAL CIRCUIT DIAGRAM (1/16)...................................................................................... 90-17
D155AX-8 00-19

ELECTRICAL CIRCUIT DIAGRAM (10/16) .................................................................................... 90-35
INDEX..................................................................................................................................................................1
00-20 D155AX-8
00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL
FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE SHOP MANUAL
REMARK
• Some of the attachments and options described in this Shop Manual may not be available in some districts.
If they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without advance notice.
• Shop Manuals are available for "Machine part" and "Engine part". For the engine unit, see the Shop Manual
for the same model of the engine as the one which is mounted on the machine.
Composition of Shop Manual
This Shop Manual contains technical information necessary for services performed in workshops. It is divided
into the following chapters for the easy of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component by system. "Structure and function" is
helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
The standard values for new machine and failure criterion are described for testing and adjusting, and trouble-
shooting. Use the standard values table to check the standard values for testing and adjusting, and judge trou-
bles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes measuring tools and measuring methods for testing and adjusting, as well as the adjust-
ing method of each part. The standard values and repair limit for "Testing and adjusting" are described in
"Standard value table".
40 TROUBLESHOOTING
Troubleshooting of failure part and its remedy method on the occurrence of the failure are described. Trouble-
shooting is sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torque and quantity and
weight of the coating material, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
In this section, the maintenance standard value of each component is described. The maintenance standard
shows the criteria and remedies for disassembly and assembly.
80 APPENDIX
The structure and function, testing and adjusting, and troubleshooting for all of the other components or equip-
ment which cannot be separately classified are described together in the appendix.
90 CIRCUIT DIAGRAMS
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbol
Important safety and quality portions are marked with the following symbols so that Shop Manual is used effec-
tively.
D155AX-8 00-21
HOW TO READ THE SHOP MANUAL 00 INDEX AND FOREWORD
Symbol Item Remark

This signal word indicates an imminently hazardous situation which, if not
Danger
avoided, will result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not
Warning
avoided, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not
Caution avoided, may result in minor or moderate injury. It may also be used to
alert against unsafe practices that may cause property damage.
If precautions described are not observed, the machine may be damaged
NOTICE Notice
or the service life may be reduced.
REMARK Remark This word is used for information that is useful to know.
Weight of parts and components, and items in which you must pay atten-
Weight
tion to selection of wires and working posture for slinging work.
Tightening torque for portions which needs special care in assembly work
Tightening torque
are indicated.
Places to be coated with adhesive, grease, etc. in assembly work are indi-
Coat
cated.
Oil and coolant Places to supply oil, coolant, etc. and their quantities are indicated.
Places from where oil, coolant, etc. are drained and their quantities are in-
Drain
dicated.
Unit
• In this Shop Manual, the International System of units (SI) is used for measurement.
• For reference, units that have been used in the past are given in { }.
00-22 D155AX-8
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
SAFETY NOTICE FOR OPERATION

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require use of special tools designed by Komatsu for special purposes.
• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a haz-
ardous situation occurs or be anticipated during such work, be sure to keep safe first and take every neces-
sary measures.
Safety points
• Good arrangement
• Correct work clothes
• Observance of work standard
• Practice of making and checking signals
• Prohibition of operation and handling by unlicensed workers
• Safety check before starting work
• Wearing protective goggles (for cleaning or grinding work)
• Wearing shielding goggles and protectors (for welding work)
• Good physical condition and preparation
• Precautions against work which you are not used to or you are used to too much
General precautions
k Inappropriate handling causes an extreme danger. Read and understand what is described in the op-
eration and maintenance manual before operating the machine. Read and understand what is descri-
bed in this manual before starting the work.
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations
of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
• Locate a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in
their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on
the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
• Always wear the protective eyeglasses when hitting parts with a hammer.
• Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any operation with two or more workers, always agree on the operating procedure before
starting. Always inform your fellow workers before starting any step of the operation. Before starting work,
hang UNDER REPAIR warning tag in the operator's compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Before start-
ing work, thoroughly check the tools, machine, forklift truck, service car, etc.
• If welding repairs are needed, always have a trained and experienced welder perform the work. When per-
forming welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited
for welding work.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition
and at the provided place.
Precautions for preparatory work
• Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the park-
ing brake and chock the wheels or tracks to prevent the machine from moving.
D155AX-8 00-23
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD
• Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the
handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure your footing.
Precautions during work
• For the machine equipped with a battery disconnect switch, before starting the work, check that the system
operating lamp is turned OFF, and then turn the battery disconnect switch to the OFF(Q) position and re-
move the switch key. For machines without a battery disconnect switch, before starting the work, remove
the cables from the battery. Always remove the cable from the negative (-) terminal first.
• Before disconnecting or removing components of the oil or fuel or water or air circuits, first release the re-
maining pressure completely from the circuit. When removing the oil filter cap, a drain plug, or an oil pres-
sure pickup plug, loosen it slowly to prevent the oil from spurting out.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine is shut down, so be careful not to get scalded.
Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
• Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut
down the engine. When checking the machine without shutting down the engine (measuring oil pressure,
revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.
• When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check
that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from
hitting any other part. Do not work with any part still raised by the hoist or crane.
• When removing a part which is under internal pressure or under reaction force of a spring, always leave 2
bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then
remove the part.
• When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may
cause a fire.
• When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off
immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
• As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.
• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that connections of them are correct.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to
check that they are installed correctly.
• When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
• When measuring hydraulic pressure, check that the measuring tools are correctly installed.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place which is not ventilated well, you may suffer from
gas poisoning. Accordingly, open the windows and doors to ventilate the place well.
00-24 D155AX-8
Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, It may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.
REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2,000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 ° each rope is subjected to a
force as large as 39.2 kN 4000 kg.
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
D155AX-8 00-25
REMARK
Slinging near the tip of the hook may cause the rope to slip
off the hook during hoisting. The hook has the maximum
strength at the middle part.
• Do not use twisted or kinked wire ropes.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When slinging a heavy load (25 kg or heavier), use a hoist crane or similar device. The weight of a
part that is 25 kg or heavier is indicated with the symbol in Disassembly and assembly.
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the operat-
ing button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it will not be an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emergency.
• If the hoist stops because of a power failure, turn the main switch OFF. When turning on a switch after it is
turned OFF by the ground fault circuit interrupter, check that the devices related to that switch are not in
operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the
floor. Do not leave the sling installed to the hook.
00-26 D155AX-8
Selecting wire ropes

Select adequate ropes depending on the weight of the parts to be hoisted, referring to the table below
Wire rope (JIS G3525, 6 x 37 - Type A)
(Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope Allowable load
mm kN t
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
REMARK
The allowable load is one sixth (safety factor) of the breaking load of the rope to be used.
Precautions for disconnecting air conditioner piping
k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnect-
ing the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working
clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for connecting air conditioner piping
• When installing the hose for the air conditioner circuit, take care not to allow invasion of dirt, dusts and wa-
ter into the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to the O-ring.
REMARK
However, do not apply oil to the threaded part of a bolt, nut or union.
D155AX-8 00-27
Manufacturer Part name

DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (equivalent to PAG46)
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
REMARK
Example of fitting of O-ring
An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see "Others", "Precautions for discon-
nection and connection of air conditioner piping".
00-28 D155AX-8
00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE
PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
This machine is equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.
D155AX-8 00-29
PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD
• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.
00-30 D155AX-8
00 INDEX AND FOREWORD ACTION IF FIRE OCCURS
ACTION IF FIRE OCCURS

• Turn the starting switch to OFF position to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fume generated by a fire contains harmful materials which have a bad influence on a human body
when they are sucked.
Do not breathe a fume.
• After a fire, there may be harmful compounds left. If it touches your skin it may have a bad influence on
your body.
Be sure to wear rubber gloves when handle the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton-work-gloves, wear rubber gloves under them.
D155AX-8 00-31
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00 INDEX AND FOREWORD
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and AdBlue/DEF.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.
00-32 D155AX-8
00 INDEX AND FOREWORD ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

This machine conforms to either regulation of Tier4 Final (North America) or Stage IV (Europe).
This machine is equipped with the following two exhaust gas treatment systems:
• Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu-
rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
• Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas
into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction
between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen
oxides into nitrogen and water.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.
This solution will be represented as AdBlue/DEF throughout this manual.
About AdBlue/DEF
AdBlue/DEF is necessary for the urea SCR system. AdBlue/DEF is a colorless transparent 32.5% aqueous urea
solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical prod-
ucts, and fertilizer, etc.
If you add any additional additive agents or water to AdBlue/DEF and use it, the devices will not function proper-
ly, and conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
• In Europe, use AdBlue.
• In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).
The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification
Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade
mark of API (American Petroleum Institute).
D155AX-8 00-33
PRECAUTIONS FOR AdBlue/DEF 00 INDEX AND FOREWORD
PRECAUTIONS FOR AdBlue/DEF

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
AdBlue/DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material
which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations
require immediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to AdBlue/DEF to protect from solution splashing in your eyes.
Wear rubber gloves when you perform work handling AdBlue/DEF to avoid skin contact.
PRECAUTIONS FOR ADDING

Do not put fluid other than AdBlue/DEF into AdBlue/DEF tank. If diesel fuel or gasoline is added into the tank, it
can cause a fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of AdBlue/DEF tank of the machine, the ammonia vapor may escape. Keep your face
away from the filler port during opening or refilling.
PRECAUTIONS FOR STORING

If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up
its container for storage. When opening the container, perform it where there is good ventilation. For storage,
see “STORE AdBlue/DEF”.
Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not
exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum con-
tainer, toxic gas may develop and a chemical reaction may corrode the container.
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

AdBlue/DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base
of “Actions if fire occurs”.
If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left unattend-
ed and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical reac-
tions.
THE OTHER PRECAUTIONS

When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precau-
tions for disposing of waste materials”. It should be treated in the same way.
Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and
a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when
handling the fluid waste of AdBlue/DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.
00-34 D155AX-8
00 INDEX AND FOREWORD STORE AdBlue/DEF
STORE AdBlue/DEF
• If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal
up its container for storage. Only open containers in a well-ventilated area.
• Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do
not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or alumi-
num container, toxic gas may develop and a chemical reaction may corrode the container.
• AdBlue/DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above.
The relation between the upper limit of storage temperature and the storage period of AdBlue/DEF is
shown in the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

Handling AdBlue/DEF in cold weather
• AdBlue/DEF freezes at –11 °C.
AdBlue/DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank
may be affected. Add AdBlue/DEF to the specified amount for cold weather (below the level of when AdBl-
ue/DEF may freeze).
• In cold weather, keep AdBlue/DEF or the machine installed with AdBlue/DEF in the indoors where the tem-
perature is at –11 °C or higher to prevent AdBlue/DEF in the tank from freezing.
If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper-
ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze.
Drain AdBlue/DEF to prevent it from freezing.
D155AX-8 00-35
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

With the increase in pressure and precision of the hydraulic components, the most common cause of a failure is
dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when adding hydraulic
oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment
• Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or at places
where there is a lot of dust.
Disassembly and maintenance work in the field
• When disassembly or maintenance work is performed on
hydraulic components in the field, there is a danger of dust
entering the components. It is also difficult to check the
performance after repairs, so it is desirable to use unit ex-
change. Disassembly and maintenance of hydraulic com-
ponents should be performed in a specially prepared dust-
proof workshop, and the performance should be checked
with special test equipment.
Sealing of openings (prevention of flowing out of oil)

• Plug the openings of removed pipes and components (if
plug is not available, seal with the caps, tapes, vinyl bags,
etc.) to prevent foreign material from entering or oil from
flowing out. Never perform testing works under the condi-
tion that the openings are left as they are or plugged with
cloths. Foreign material or leaked oil may pollute the envi-
ronment. The waste oil must not be discarded randomly.
Hand it over to your customer for disposal, or dispose it by
yourself.
Preventing intrusion of foreign materials during refilling operations.

• Be careful not to mix any foreign materials in the hydraulic
oil while refilling. Always keep the oil filler port and the
area around it clean. Pumps and oil containers are also
need to be kept clean. Using an oil cleaning device is an
effective method to filter out the collected dirt during the
storage.
Replacing hydraulic oil while its temperature is high

• The warmer the oil is, the easier they flow. In addition, the sludge can also be drained out easily from the
circuit together with the oil. It is the best to change the oil when it is still warm. When changing the oil, the
old hydraulic oil must be drained out as much as possible. (Drain the oil not only from the hydraulic tank,
but also from the filter and the drain plug hole in the circuit.) Mixing the old and the new oil will shorten the
life of the hydraulic oil since the old oil contains contaminants and sludge.
00-36 D155AX-8
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
Flushing operations
• After disassembling and assembling the equipment, or
when changing the oil with new one, use flushing oil to re-
move the contaminants, sludge and old oil from the hy-
draulic circuit. Normally, flushing is performed twice. Flush-
ing oil is used to preform the first flushing. In the secon-
dary flushing, the specified hydraulic oil is used.
Cleaning operations
• after repairing the hydraulic equipment (pump, control
valve, etc.) or when running the machine, perform oil
cleaning to remove the sludge or contaminants in the hy-
draulic oil circuit. The oil cleaning device is an extremely
effective device which enables to remove the ultra fine (ap-
proximately 3 μm) particles that the filter built in the hy-
draulic equipment could not even remove.
D155AX-8 00-37
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and as-
sembly" of the components, observe the following general cautions.
Precautions for removal and disassembly work
• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any for-
eign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
k The part numbers of O-ring shown in the table indicate the temporary part number when disas-
sembling and transporting the machine.
k When disassembling the machine, check the part number by referring to the Parts Book and use
the appropriate parts according to the usage conditions.
Introduction of parts for the disassembly of the face seal type hoses and tubes
Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
00-38 D155AX-8
00 INDEX AND FOREWORD INGS
Introduction of parts for the disconnection of the taper seal type hoses and
tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
0202 07376-50210 07222-00210
0303 07376-50315 07222-00312
0404 07376-50422 07222-00414
0505 07376-50522 07222-00515
0606 07376-50628 07222-00616
1010 07376-51034 07222-01018
1212 07376-51234 07222-01219
1414 07376-51443 07222-01422
Introduction of parts for the disconnection of the split flange type hoses and
tubes
Shoe bolt pitch

Nomi Hose side Tube side
(mm)
nal O-ring (4) Bolt (5) Washer (6)
No. Split flange Sleeve head
a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
D155AX-8 00-39
Shoe bolt pitch

Nomi Hose side Tube side
(mm)
nal O-ring (4) Bolt (5) Washer (6)
No. Split flange Sleeve head
a b Flange (1)
(2) (3)
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645
Introduction of parts for the removal of O-ring boss type joint
Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
00-40 D155AX-8
Introduction of parts for the removal of taper pipe thread type joint
Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108
02 R1/4 07042-00211 07043-00211
03 R3/8 07042-00312 07043-00312
04 R1/2 07042-00415 07043-00415
06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222
14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026
Precautions for installation and assembly work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded
part.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding surface with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then con-
nect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
D155AX-8 00-41
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded part of each taper male screws
which receives pressure.
However, if the threaded part is difficult to degrease, you may use a seal tape.
• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing direc-
tion of the threads, seeing from the screw end and starting at the third thread.
k If the seal tape is wound counterclockwise, it becomes loose when screwed in and comes off or
its sealed tip is pushed outside causing oil leakage.
k When the hydraulic equipment such as cylinders, pumps and pipings which are removed for replace-
ment are assembled again and operated for the first time, be sure to bleed air from the hydraulic cir-
cuit according the following procedure.
1. Start the engine, and run it at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100 mm
before the stroke end 4 to 5 times.
3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke.
k After repair is finished, when operating the machine which has been stored for a long period, bleed
air from the hydraulic circuit according to the same procedure.
Precautions at the time of completing work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the cool-
ant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and
add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu rec-
ommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuild-
ing the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
• Before starting the engine, add AdBlue/DEF to the specified level.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
REMARK
For the tightening torques, see the "Disassembly and assembly".
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
Intake and exhaust suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for wa-
Cooling system ter leakage.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
Fuel system leakage.
00-42 D155AX-8
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
The exhaust equipment indicates as follows. (The applications or components of equipment are different de-
pending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• DOC muffler
• Muffler
• Exhaust pipe
• or their connection parts of the preceding components
Visually check the exhaust equipment and its installation portion for a crack and damage. If any part is dam-
aged, replace it.
Check the exhaust equipment and its mounting bolts, nuts, and clamps on the installation portion for looseness.
If any part is loosely installed, retighten the bolts.
Check of function of muffler in exhaust system
REMARK
The muffler in exhaust system indicates as follows. (The applications or components of equipment are different
depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• DOC muffler
• Muffler
• Exhaust pipe
• or their connection parts of the preceding components
Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and as-
sembly".
D155AX-8 00-43
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

To maintain the performance of the machine over a long period, and to prevent failures or troubles before they
occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed.
This section deals particularly with correct repair procedures for mechatronics components and is aimed at im-
proving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical
equipment".
Handling wiring harnesses and connectors
• Wiring harnesses consist of wires connecting one component to another component, connectors used for
connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the
wires.
• Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be
affected by the direct effects of rain water, heat, or vibration. Furthermore, during inspection and repair op-
erations, they are frequently removed and installed again, so they are likely to suffer deformation or dam-
age. For this reason, it is necessary to be extremely careful when handling the wiring harnesses.
• If AdBlue/DEF is spilled over wire harness and connectors, it may cause corrosion and defective contact.
Since AdBlue/DEF corrodes easily, be careful not to spill it over electrical equipment, wire harness and con-
nectors.
Main failures occurring in wiring harness

Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female connec-
tor,or because one or both of connectors are deformed or the
position is not correctly aligned, or because there is corrosion
or oxidization of the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and contact may
become normal) by connecting and disconnecting the connec-
tors approximately 10 times.
00-44 D155AX-8
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
Defective crimping or soldering of connectors

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the joining area may become loose, which may result
in a defective connection or breakage.
Disconnections in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, the
crimping of the connector may separate, or the soldering may
be damaged, or the wiring harness may be broken.
High-pressure water entering connector

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Accordingly, be careful not to spray water over the connector.
If connectors are water proof structured, intruded water is hard-
ly drained. Once water enters into connectors, water goes
through pins to cause short-circuit. Drying the drenched con-
nectors or take appropriate actions before providing electricity.
Entry of water, mud or dirt when disconnecting a con-
nector
If any water, mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the
connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a piece
of dry cloth or blow it with compressed air.
Oil, mud or dirt stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through, resulting in defec-
tive contact. If any oil or grease, mud or dirt is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air
and spray it with electrical contact restorer.
k When wiping the joint portion of the connector, be care-
ful not to apply excessive force or deform the pins.
D155AX-8 00-45
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD
k If there is oil or water in the compressed air, it causes the contacts to become dirtier. So, remove the
oil and water from the compressed air completely before cleaning the connector with the com-
pressed air.
00-46 D155AX-8
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conven-
tional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special
care to prevent entry of the foreign material when servicing the fuel system.
Avoid filter change or repairing the machine in rain or high winds, or at places where there is a lot of dust.
Sealing openings
Seal the openings of the pipes and components which are removed with the caps, tapes, vinyl bags, etc. to pre-
vent foreign material from entering. Never perform testing works under the condition that the openings are left
as they are or plugged with cloths, because foreign material may enter or environment may be polluted by the
oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dis-
pose it by yourself.
How to clean parts when dirt is stuck
If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
• Be sure to use the Komatsu genuine fuel filter cartridge.
• The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the con-
ventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the
filter employs a specially high performance of filter element. If a filter other than a Komatsu genuine filter is
used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Ko-
matsu fuel filters and install them following the procedures in the shop manual.
D155AX-8 00-47
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

The Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable mechanism)
than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a fail-
ure. Use special care to prevent entry of the foreign material when servicing the air intake system.
Avoid the repair work of the machine in rain or strong wind or at the places where there is a lot of dust.
Sealing openings
Seal the openings of removed pipes and components with the caps, tapes, vinyl bags, etc. to prevent foreign
material from entering. Never perform testing works when the openings are left as they are or plugged with
cloths.
00-48 D155AX-8
00 INDEX AND FOREWORD PRACTICAL USE OF KOMTRAX
PRACTICAL USE OF KOMTRAX

KOMTRAX system transmits various machine information by using the radio communication and KOMTRAX op-
erator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the KOMTRAX
system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX
• The working place of the machine can be checked in the map on personal computer.
• Operation information such as machine service meter, operating hours, amount of fuel consumption and
caution as well as failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice tool for the user and operator.
How to use KOMTRAX practically
With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replace-
ment work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.
How to operate KOMTRAX
For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual (For
Key Person)".
D155AX-8 00-49
METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL
TYPE COUPLER 00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL TYPE

COUPLER
REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out when the
hose is disconnected. Accordingly, prepare an oil container.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold adapter (1) and push hose joint (2) into mating adapt-
er (3). (Fig. 1)
REMARK
It can be pushed in by approximately 3.5mm.
Do not hold rubber cap part (4).
2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it "clicks" (Fig.
2)
3. Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3)
REMARK
Since some hydraulic oil flows out, prepare an oil contain-
er.
Connection
1. Hold hose adapter (1) or hose (5) and insert it in mating
adapter (3), aligning them with each other. (Fig. 4)
REMARK
Do not hold rubber cap part (4).
2. After inserting the hose fitting in the adapter on the other
side perfectly, pull it back to check the connecting condi-
tion (Fig. 5)
REMARK
When the hose fitting is pulled back, the rubber cap will
move toward the hose, however, it is not a problem.
00-50 D155AX-8
00 INDEX AND FOREWORD TYPE COUPLER

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (7) straight
until sliding prevention ring (6) contacts contact surface (a)
of the hexagonal part at the male end. (Fig. 6)
2. While holding the condition of step 1., turn lever (8) to the
right (clockwise). (Fig. 7)
3. While keeping the conditions of steps 1. and 2., pull out
whole body (7) to disconnect it. (Fig. 8)
Connection
Hold the tightening adapter part and push body (7) straight until
sliding prevention ring (6) contacts contact surface (a) of the
hexagonal part at the male end. (Fig. 9)
D155AX-8 00-51
TYPE COUPLER 00 INDEX AND FOREWORD

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (9) straight
until sliding prevention ring (8) contacts contact surface (b)
of the hexagonal part at the male end. (Fig. 10)
2. While holding the condition of step. 1, push cover (10)
straight until it contacts contact surface (b) of the hexago-
nal portion at the male end. (Fig. 11)
3. While keeping the conditions of steps 1. and 2., pull out
whole body (9) to disconnect it. (Fig. 12)
Connection
Hold the tightening adapter part and push body (9) straight until
sliding prevention ring (8) contacts contact surface (b) of the
hexagonal part at the male end. (Fig. 13)
00-52 D155AX-8
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

TORS
Disconnecting connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, hold the connectors.
For connectors held by a screw, loosen the screw fully,
then hold the male and female connectors in each hand
and pull them apart. For connectors which have a lock
stopper, press down the stopper with your thumb and pull
the connectors apart.
k Do not pull the connectors with one hand.
2. When removing from clips

• Both of the connector and clip have stoppers, which
are engaged with each other when the connector is
connected.
• When removing a connector from a clip, pull the con-
nector in a parallel direction to the clip for removing
stoppers.
k If the connector is pried up and down or to the
right or left, the housing may break.
3. Action to take after removing connectors

After removing the connector, cover it with the vinyl bag to
prevent entry of dust, dirt,oil or water in the contact portion.
k If the machine is left disassembled for a long time,
improper contact may occur. Make sure to perform
this.
Connecting connectors
1. Check the connector visually.
• Check that there is no oil, dirt or water stick to the connector pins (joint portion).
D155AX-8 00-53
NECTORS 00 INDEX AND FOREWORD
• Check that the connector pins are free from deformation, defective contact, corrosion, or damage.
• Check that external surfaces of the connectors are free from damage or breakage.
k If any oil, water, or dirt are stuck to the connector, wipe it off with a dry cloth. If any water is in-
side, warm the inside of the connector and wiring with a dryer, but be careful that the tempera-
ture does not become too hot as it will cause short circuits.
k If there is any damage or breakage, replace the connector.
2. Fix the connector securely.
Align the position of the connectors correctly to fit them se-
curely. For connectors with the lock stopper, push it in the
connector until the stopper "clicks" into position.
3. Correct the protrusion of the boot and misalignment of the

wiring harness
• For connectors fitted with the boot, correct any extru-
sion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to
its correct position.
k If the protrusion of the boot and misalignment
of the wiring harness cannot be fixed, remove
the clamp to adjust them.
• If the connector clamp is removed, be sure to return it
to its original position. And check that it is securely in-
stalled.
Drying wiring harness

REMARK
If the wiring harness gets dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam wash-
ing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If
water gets directly on the connector, do as follows.
00-54 D155AX-8
00 INDEX AND FOREWORD NECTORS
1. Disconnect the connector and wipe off the water with a dry
cloth.
k If the connector is to be blown with dry com-
pressed air, there is the risk that oil in the air may
cause defective contact, remove oil and water in
the air before starting air blow.
2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
k Hot air from a dryer can be used, but limit the time
of using a dryer to prevent the connector or related
parts from becoming too hot, as this will cause de-
formation or damage to the connector.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected and
perform a continuity test to check for any short circuits be-
tween pins caused by water.
REMARK
After the connector is completely dried, blow the contact
restorer and reassemble them.
D155AX-8 00-55
NECTORS 00 INDEX AND FOREWORD
Handling controller
k Electronic circuits for control including microcomput-
ers are assembled in the controller. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
k Do not leave things on the controller.
k Cover the connector portion of the controller with a
tape and a vinyl bag. Do not touch the connector con-
nected part.
k Do not leave the controller in a place where it is ex-
posed to rain.
k Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).
k Precautions when performing arc welding
When performing arc welding on the machine body,
disconnect all of the wiring harness connectors con-
nected to the controller. Fit an arc welding ground
close to the welding point.
Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
k If the starting switch is turned to ON position with the connectors disconnected, the failure
which is not related to the part which is actually failed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
k If there is any value change on the multimeter, there may be a defective contact in the circuit.
00-56 D155AX-8
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
00 INDEX AND FOREWORD CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

TOR
Method for disconnecting Deutsch connector
While pressing locks (a) and (b) from each side respectively,
pull out female connector (2).
Method for connecting Deutsch connector

1. Insert female connector (2) horizontally until it clicks (arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.
D155AX-8 00-57
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
TYPE CONNECTOR 00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE

CONNECTOR
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA-
TOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
In the case that even if lock (L2) is pressed, connector (1)
cannot be pulled out toward you unless part A floats, float
part A with a small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1) toward you.
Method for connecting slide lock type connector (FRAMATOME-3, FRAMA-

TOME-2)
Insert the connector securely until it "clicks".
Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).
00-58 D155AX-8
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR
2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located in the back of connector (1).
Method for connecting slide lock type connector (FRAMATOME-24)

D155AX-8 00-59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PULL 00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PULL
Method for disconnecting connector with lock to pull
Disconnect the connector (2) by pulling lock (B) (on the wiring
harness side) of connector (2) outward.
Method for connecting connector with lock to pull

00-60 D155AX-8
00 INDEX AND FOREWORD WITH LOCK TO PUSH

LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series
• 107 series
REMARK
If the lock is located on the underside, use flat-head screwdriv-
er [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.
Method for connecting connector with lock to push (BOSCH-3)

D155AX-8 00-61
WITH LOCK TO PUSH 00 INDEX AND FOREWORD
Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
Method for connecting connector with lock to push (AMP-3)

Method for disconnecting connector with lock to push (SUMITOMO-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull the connector straight up.
Method for connecting connector with lock to push (SUMITOMO-3)

Method for disconnecting connector with lock to push (SUMITOMO-4)

While pressing lock (C), pull out connector (4) in the direction
of the arrow.
Method for connecting connector with lock to push (SUMITOMO-4)

00-62 D155AX-8
00 INDEX AND FOREWORD WITH HOUSING TO ROTATE

HOUSING TO ROTATE
Method for disconnecting connector with housing to rotate
Turn housing (H1) in the direction of the arrow.
REMARK
Housing (H1) is left on the wiring harness side.
Method for connecting connector with housing to rotate

1. Insert the connector to the end while aligning its grove to the other.
2. Turn housing (H1) in the direction of the arrow until it
"clicks".
D155AX-8 00-63
HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODE

In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electrical wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated
on the diagram.)
Indicates size of wire by nominal No.
0.85
Sizes (Nominal Nos.) are shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.
AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material
of the coating.
(Table 1)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage For large current wiring
wire for auto- AV
mobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for auto- AVS
mobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1)
Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)
Heat-resistant General wiring for extremely

low-voltage Heat-resistant cross- cold weather specification
AEX -50 to +110
wire for auto- linked polyethylene Wiring at high-temperature
mobile place
00-64 D155AX-8
00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/0.1 30/0.1 11/0.3 50/0.1 16/0.3 37/0.2 26/0.3 58/0.2 41/0.3 65/0.3
7/0.32
Diameter of 8 8 2 8 2 6 2 6 2 2
strand
Conductor
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
( mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Coa
ting AV Standard - - - - - - - 4.6
D
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/ 127/0.8 169/0.8 217/0.8
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80
Diameter of 0 0 0
strand
Conductor
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
( mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coa
ting AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/round compres- 11/round com- 16/round com-
- - -
Diameter of sion pression pression
strand
Conductor
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
( mm2)
d (approx.) - 0.9 - 1.1 - 1.4
D155AX-8 00-65
HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Coa
ting CAVS Standard - 1.6 - 1.8 - 2.1
D
REMARK
"f" of nominal No. denotes "flexible".
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White
REMARK
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the
color of the marking.
Example) GW indicates that the background is "Green" and marking is "White".
00-66 D155AX-8
00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -
D155AX-8 00-67
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The MAINTENANCE STANDARD section shows the judgment criteria whether the equipment or parts should
be replaced or can be reused when the machine is disassembled for the maintenance. The following terms are
the descriptions of the judgment criteria.
Standard dimension and tolerance
• To be accurate, the finished dimension of a part is slightly different from one to another.
• To specify the finished dimension of a part, a standard dimension is set for the part and an allowable differ-
ence from that dimension is indicated.
• The dimension set as the standard is called the standard dimension and the range of difference from this
standard dimension is called the "tolerance".
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/
lower limit of tolerance)."
Example) 120 (-0.022 / -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is decided
by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0
00-68 D155AX-8
00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
Standard clearance and standard value

• The clearance made when new parts are assembled is
called the standard clearance, which is indicated by the
range from the minimum clearance to the maximum clear-
ance.
• When some parts are repaired, the clearance is generally
adjusted to the standard clearance.
• The values indicating performance and function of new
products or equivalent are called the "standard value",
which is indicated by a range or a target value.
• When some parts are repaired, the value of performance/
function is set to the standard value.
Standard interference
• When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller
than that of the shaft to be inserted, the difference between those diameters is called the "interference".
• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Sub-
tract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range
between (A) and (B) is the "standard interference".
• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the
interference is in the standard range.
Repair limit and allowable value or allowable dimension
• The dimension of parts changes due to the wear or deformation while they are used. When the dimension
charges exceeding certain valve, parts cannot be used any longer. This value is called the "repair limit".
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of products lower while they are used. A value with which the product can be
used without causing a problem is called the "allowable value" or "allowable dimension".
• A product whose dimension is out of the allowable value, must be repaired. However, since the allowable
values are generally estimated through various tests or experiences in most cases, the judgment must be
made in consideration of the operating condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those
parts cannot be used is called the "allowable clearance".
• If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference
• The allowable maximum interference between the hole of a part and the shaft of another part to be assem-
bled is called the "allowable interference".
• The allowable interference shows the repair limit of the part of smaller tolerance.
D155AX-8 00-69
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
• The parts whose interferences are out of the allowable interference must be replaced or repaired.
00-70 D155AX-8
00 INDEX AND FOREWORD LIST OF ABBREVIATION
LIST OF ABBREVIATION
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text (marked with ).
• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of the
manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*), or Explanation
tion
component/system)
Travel and brake When the tires skid (wheels stop rotating), the
ABS Anti-skid Brake System brakes are released, and when the wheels start
(HD, HM) to rotate, the brakes are applied again.
Automatic Idling Setting
AISS Engine This function automatically sets the idle speed.
System
Steering A lever is used to perform the steering operations
Advanced Joystick instead of a steering wheel. Moreover, it shifts
AJSS
Steering System (WA) gear and changes direction (FORWARD or RE-
VERSE).
Travel and brake When the accelerator pedal is released while the
Automatic Retarder Ac- machine is traveling downhill, this function auto-
ARAC
celerator Control (HD, HM) matically applies the retarder with a constant
braking force.
Travel and brake When the accelerator pedal is released while the
machine is traveling downhill, this function auto-
Automatic Retarder
ARSC matically applies the retarder to ensure that the
Speed Control (HD, HM) machine speed does not accelerate above the
speed set by the operator.
Travel and brake When the tires spin on soft ground surfaces, this
Automatic Spin Regula-
ASR function automatically uses the optimum braking
tor (HD, HM) force to drive both wheels.
A device that can be fixed onto a machine in or-
ATT Attachment Work equipment
der to enable it to do different jobs.
Brake When the retarder is not being used, this valve
Brake cooling oil control
BCV bypasses part of the brake cooling oil to reduce
valve (HD) the load on the hydraulic pump.
Communication and elec- One of communication standards that is used in
CAN Controller Area Network
tronic control the network on the machine
A regulator valve which is installed to KCCV ven-
Crankcase Depression
CDR Engine tilator. It is written as CDR valve and it is not
Regulator
used independently.
This system can simultaneously actuate multiple
Closed-center Load
CLSS Hydraulic system actuators regardless of the load (provides better
Sensing System
combined operation than OLSS).
Engine controller electronically controls supply
pump, common rail, and injector. This function
CRI Common Rail Injection Engine
maintains optimum fuel injection amount and fuel
injection timing.
D155AX-8 00-71
LIST OF ABBREVIATION 00 INDEX AND FOREWORD

Abbrevia-
tion
component/system)
Electronic control device uses the signals from
Electronic Control Mod- the sensors on the machine. This signal indicates
ECM Electronic control system
ule the optimum actuation to the actuators. (Same as
ECU)
Transmission Proportional electromagnetic valve that gradually
Electronic Control Mod-
ECMV increases oil pressure to engage clutch and re-
ulation Valve (D, HD, WA, etc) duces transmission shock.
Travel This system ensures smooth high-speed travel
Electronically Controlled
ECSS by absorbing vibration of machine during travel
Suspension System (WA) with hydraulic spring effect of accumulator.
Electronic control device uses the signals from
the sensors on the machine. This signal indicates
ECU Electronic Control Unit Electronic control system
the optimum actuation to the actuators. (Same as
ECM)
This function recirculates part of exhaust gas to
Exhaust Gas Recircula-
EGR Engine combustion chamber in order to reduce combus-
tion
tion temperature, controls emission of NOx.
This system allows data (filter, oil replacement in-
Equipment Manage- terval, malfunctions on machine, failure code,
EMMS Machine monitor
ment Monitoring System and failure history) from each sensor on the ma-
chine to be checked on the monitor.
Electromagnetic Propor- This mechanism allows actuators to be operated
EPC Hydraulic system
tional Control in proportion to the current supplied.
This structure protects the operator's head from
Falling Object Protective falling objects.
FOPS Cab and canopy
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication Global Positioning System: This system uses sat-
Global Positioning Sys-
GPS (KOMTRAX, KOMTRAX ellites to determine the current location on the
tem
Plus) earth.
Global Navigation Satellite System: This system

Global Navigation Satel-
GNSS Engine uses satellites such as GPS, GALILEO, etc. to
lite System
determine the current location on the earth.
Steering This function uses a combination of hydraulic
Hydrostatic Steering motor and bevel shaft to control difference in
HSS
System (D) travel speed of right and left tracks. Accordingly
machine can turn without using steering clutch.
Transmission This function uses a combination of hydraulic
Hydro Static Transmis-
HST pump and hydraulic motor to shift the speed
sion (D, WA) range steplessly without using gears.
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This valve is installed at inlet port of pump, and it
adjusts fuel intake amount in order to control fuel
IMA Inlet Metering Actuator Engine
discharged volume of supply pump. Same as
IMV
00-72 D155AX-8

Abbrevia-
tion
component/system)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This valve is installed at inlet port of pump, and it
adjusts fuel intake amount in order to control fuel
IMV Inlet Metering Valve Engine
discharged volume of supply pump. Same as
IMA
This mechanism separates oil in blowby gas and
Komatsu Closed Crank-
KCCV Engine returns it to the intake side to re-combust it there.
case Ventilation
It primarily consists of filters.
Komatsu Catalyzed This filter captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst is used for purifying exhaust gas.
Komatsu Diesel Oxida-
KDOC Engine It is built in to KDPF or assembled with the muf-
tion Catalyst
fler.
This component is used to purify the exhaust
Komatsu Diesel Particu- gas. KDOC (catalyst) and KCSF (filter to capture
KDPF Engine soot) are built-in it.
late Filter
It is installed in place of the conventional muffler.
Travel and brake This function recovers the drive force of the
wheels by braking automatically with the opti-
Komatsu Traction Con- mum force and at the same time activates the in-
KTCS
trol System (HM) ter-axle differential lock when the wheels idle
while the machine travels on the soft ground
road.
Komatsu Variable Ge- The turbocharger on which the cross-section
KVGT Engine
ometry Turbocharger area of the exhaust passage is made variable.
Image display equipment such as a monitor
LCD Liquid Crystal Display Machine monitor
which assembles in the liquid crystal element.
It refers to semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- One of communication standards that is used in
LIN
work tronic control the network on the machine
Function that detects differential pressure of
LS Load Sensing Hydraulic system pump and controls discharged volume corre-
sponding to load.
Low Voltage Differential Communication and elec- One of communication standards that is used in
LVDS
Signaling tronic control the network on the machine
This indicates engine intake air flow. It is not
used independently but it is used as combined
MAF Mass Air Flow Engine
with sensor. Mass air flow sensor can be called
as MAF sensor.
Service that allows transmission and reception of
Multimedia Messaging
MMS Communication short messages consisting of characters or voice
Service
or images between cell phones.
D155AX-8 00-73
LIST OF ABBREVIATION 00 INDEX AND FOREWORD

Abbrevia-
tion
component/system)
Characteristics of electrical or hydraulic circuits.
Electrical system, Hydraul-
NC Normally Closed Circuit is normally closed if it is not actuated, and
ic system
it opens when it is actuated.
Characteristics of electrical or hydraulic circuits.
Electrical system, Hydraul-
NO Normally Open Circuit is normally open if it is not actuated, and it
ic system
closes when it is actuated.
Open-center Load Hydraulic system that can operate multiple actua-
OLSS Hydraulic system
Sensing System tors at the same time, regardless of the load.
PC Pressure Compensation Hydraulic system A function used to correct oil pressure.
Steering System in which a controller instantly analyses
Palm command control data from each lever, pedal, and dial, and per-
PCCS
system (D) forms optimum electronic control of the engine
and transmission.
This valve is installed at inlet port of pump and it
PCV Pre-stroke Control Valve Engine adjusts fuel intake amount in order to control fuel
discharged volume of supply pump.
This system is used for controlling proportional
Proportional Pressure
PPC Hydraulic system pressure. It moves actuators in proportion to the
Control
oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Power Tilt and power Work equipment This function performs hydraulic control of the tilt
PTP
Pitch dozer (D) and pitch of the bulldozer blade.
If a machine rolls over, this structure protects the

operator with the seat belt fastened from being
Roll-Over Protective crushed. (Operator Protective structure when roll-
ROPS Cab and canopy
Structure ing over)
This performance is standardized as ISO 3471.
It is exhaust gas purifier using urea solution con-
verts nitrogen oxides (NOx) to harmless nitrogen
Selective Catalytic Re-
SCR Urea SCR system and water by oxidation-reduction reaction. It may
duction
also mentioned as exhaust gas purification cata-
lyst or part of the name of related devices.
Abbreviation for the "Le Systeme International d'
Le Systeme Internation-
Unites". It is the universal unit system and "a sin-
SI al d' Unites (Internation- Unit
gle unit for a single quantity" is the basic principle
al unit system)
applied.
It refers to an actuator consisting of a solenoid
SOL Solenoid Electrical system and an iron core that is moved by the magnetic
force when the solenoid is energized.
Solenoid valve that switches over direction of
TWV 2-Way Valve Hydraulic system
flow.
Variable Flow Turbo- Turbocharger of which exhaust passage is varia-
VFT Engine
charger ble.
*1: Code for applicable machine model
00-74 D155AX-8
D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
D155AX-8 00-75
STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD
STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for bolts and nuts
Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2)10
13
8 27 to 34 {2.8 to 3.5}
(*2)12
17
10 59 to 74 {6.0 to 7.5}
(*1,*2) 14
19
12 98 to 123 {10.0 to 12.5}
(*1,*2) 17
14 22 153 to 190 {15.5 to 19.5}
24
16 235 to 285 {23.5 to 29.5}
(*1) 22
18 27 320 to 400 {33 to 41}
20 30 455 to 565 {46.5 to 58}
22 32 610 to 765 {62.5 to 78}
24 36 785 to 980 {80 to 100}
27 41 1150 to 1440 {118 to 147}
30 46 1520 to 1910 {155 to 195}
33 50 1960 to 2450 {200 to 250}
36 55 2450 to 3040 {250 to 310}
39 60 2890 to 3630 {295 to 370}
*1: Split flange bolt

*2: Flanged bolt
REMARK
Tighten the flanged bolts marked with “7” on the head as shown in the following to the tightening torque shown
in the table below.
00-76 D155AX-8
00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE
Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1/ 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4-20UNC
5/ 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16-18UNC
3/ 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8-16UNC
7/ 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16-14UNC
1/ 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
2-13UNC
9/ 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16-12UNC
5/ 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8-11UNC
3/ -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
4
7/ 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
8-9UNC
1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}
D155AX-8 00-77
Type of bolt A B

11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}
11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}
11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}
Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table be-
low.
Type of bolt A B

1/ 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
4-28UNF
5/ 34.3 to 39.2 {3.5 to 4} 34.3 {3.5} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF
3/ 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8-24UNF
7/ 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
16-20UNF
1/ 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2-20UNF
9/ 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16-18UNF
5/ 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8-18UNF
3/ 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4-16UNF
7/ 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8-14UNF
1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}
11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}
11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}
11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}
Table of tightening torque for O-ring boss piping joints

REMARK
Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
00-78 D155AX-8
Thread di- Tightening torque ( Nm { kgm} )

Width across
Nominal No. ameter
flats ( mm) Range Target
( mm)
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies de-
03, 04 20 pending on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of con- 128 to 186 {13.0 to 19.0} 157 {16.0}
nector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

REMARK
Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.
Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
D155AX-8 00-79
Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown
in the following table.
• The table is applied to the threaded part coated with engine oil (wet threaded part).
Tightening torque ( Nm { kgm} ) Taper seal Face seal

Width
Nominal Thread root
across Nominal size -
No. of Thread size diameter　
flats Range Target threads per
hose ( mm) ( mm) (refer-
( mm) inch
ence)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ 17.5
16-16UN
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/ 20.6
16-16UN
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4

06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -
Table of tightening torque for face seal joints

REMARK
• The tightening torque table below applies to the seal joint (sleeve nut type)
• The table is applied to the threaded part coated with engine oil (wet threaded part).
00-80 D155AX-8
Tightening torque ( Nm { kgm} ) Face seal

Outside di- Width
ameter of across flats Thread root diam-
Nominal size -
pipe ( mm) ( mm) Range Target eter ( mm) (refer-
threads per inch
ence)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/ 14.3
16-18UN
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ -16UN 17.5

16
12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/ 20.6

16-16UN
15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4

22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 13/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
REMARK
Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series en-
gines to the torques shown in the following table.
Thread diameter ( mm) Tightening torque ( Nm { kgm} )
6 10 ± 2 {1.02 ± 0.20}
8 24 ± 4 {2.45 ± 0.41}
10 43 ± 6 {4.38 ± 0.61}
12 77 ± 12 {7.85 ± 1.22}
14 -
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
REMARK
Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to the
torque shown in the following table.
D155AX-8 00-81
Thread diameter ( mm) Tightening torque ( Nm { kgm} )

6 8 ± 2 {0.81 ± 0.20}
8 10 ± 2 {1.02 ± 0.20}
10 12 ± 2 {1.22 ± 0.20}
12 24 ± 4 {2.45 ± 0.41}
14 36 ± 5 {3.67 ± 0.51}
Tightening torque table for tapered screws on 102,107, and 114 series engines
(National taper pipe thread (NPT))
REMARK
Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and
114 series engines to the torques shown in the following table.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )
1/ 15 ± 2 {1.53 ± 0.20} 5 ± 1 {0.51 ± 0.10}
16
1/ 20 ± 2 {2.04 ± 0.20} 15 ± 2 {1.53 ± 0.20}

8
1/ 25 ± 3 {2.55 ± 0.31} 20 ± 2 {2.04 ± 0.20}

4
3/ 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31}

8
1/ 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41}

2
3/ 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51}

4
00-82 D155AX-8
00 INDEX AND FOREWORD CONVERSION TABLE
CONVERSION TABLE
Method of using the conversion table
The conversion table is provided to enable simple conversion of the numerical numbers between the different
units. For further details of the method of using the conversion table, see the examples given below.
Example) Method of using the conversion table to convert mma unit from mm millimeters to inches.
Convert 55 mm to ininches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line
from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from
millimeters to inches. Accordingly, 55 mm = 2.165 in.
Convert 550 mm to ininches
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left)
to get 55 mm.
2. Convert 55 mm to 2.165 in mm according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point
one place to the right) to restore the original value. This gives 550 mm = 21.65 in
mm to in
(B)
1 mm=0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.780 3.819 3.858 3.898
mm to in
1 mm=0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
D155AX-8 00-83
CONVERSION TABLE 00 INDEX AND FOREWORD
1 mm=0.03937 in
0 1 2 3 4 5 6 7 8 9
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
kg to lb
1 kg=2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
ℓ to U.S.Gal
1 ℓ=0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
ℓ to U.K.Gal
1 ℓ=0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
00-84 D155AX-8
1 ℓ=0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to lbft
1 kgm=7.233 lbft
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
kg/cm2 to lb/in2
1 kg/cm2=14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
D155AX-8 00-85
CONVERSION TABLE 00 INDEX AND FOREWORD
1 kg/cm2=14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa
is to see the number in the center column of the following table. The figures on the following table show the
temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
00-86 D155AX-8
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
D155AX-8 00-87
01 SPECIFICATION
D155AX-8 01-1
CONTENTS 01 SPECIFICATION
CONTENTS
SPECIFICATIONS ......................................................................................................................................... 01-3
SPECIFICATION DRAWING................................................................................................................... 01-3
SPECIFICATION DRAWING: D155AX-8.......................................................................................... 01-3
SPECIFICATIONS .................................................................................................................................. 01-5
SPECIFICATIONS: D155AX-8 ......................................................................................................... 01-5
WEIGHT TABLE ................................................................................................................................... 01-13
WEIGHT TABLE: D155AX-8 .......................................................................................................... 01-13
TABLE OF FUEL, COOLANT, AND LUBRICANTS ............................................................................... 01-16
01-2 D155AX-8
01 SPECIFICATION SPECIFICATION DRAWING
SPECIFICATIONS
SPECIFICATION DRAWING
SPECIFICATION DRAWING: D155AX-8
Item Unit D155AX-8

Machine weight kg 42200
Engine model - Komatsu SAA6D140E-7 diesel engine
Engine rated horsepower
• Gross [SAE J1995] (*1) 268 {360}/ 1900 {1900}
kW {HP}/
• ISO14396 268 {360}/ 1900 {1900}
min-1 {rpm}
• Net [ISO 9249/SAE J1349] (*2) 264 {354}/ 1900 {1900}
Overall length
A Sigma tilt dozer + ripper 8420
mm
Semi-U tilt dozer + ripper 8470
B Overall height (with ROPS) mm 3390
Overall width
C Sigma tilt dozer + ripper 4060
mm
Semi-U tilt dozer + ripper 4130
Travel speed
Forward
• [1st/2nd/3rd (Low)/3rd) 3.5/5.6/7.5/11.6
km/h
Reverse
• [1st/2nd/3rd (Low)/3rd) 4.3/6.8/9.2/14.0
Track shoe
• Type - Single grouser
• Width mm 560
*1: Shows the value of engine only (without cooling fan).

*2: Shows the value when cooling fan is rotating at minimum speed.
D155AX-8 01-3
SPECIFICATION DRAWING 01 SPECIFICATION
REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit while net denotes the value measured of an engine under the condition near-
ly the same as that when it is installed on a machine.
• Rated horsepower (net) when cooling fan is rotating at maximum speed is the following value.
239kW {320HP}/1900 min-1 {1900 rpm}
• Maximum gross horsepower of engine is the following value.
267kW {358HP}/1800 min-1 {1800 rpm}
01-4 D155AX-8
01 SPECIFICATION SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS: D155AX-8
Machine model Unit D155AX-8
Weight
Machine weight
• Bare tractor
• Reinforced type SIGMADOZER + variable 33100
type multi-shank ripper + ROPS cab + air
kg 42200
conditioner + 560 heavy duty shoe + side
cover 41800
• Semi-U dozer
Performance
Minimum turning radius (F1, the center of machine) m 2.1
Gradeability deg. 30
Stability (front, rear, right, and left) deg. 35
Travel speed
Forward
• 1st 3.5
• 2nd 5.6
km/h
• 3rd (Low) 7.5
• 3rd 11.6
Reverse
• 1st 4.3
• 2nd 6.8
km/h
• 3rd (Low) 9.2
• 3rd 14.0
Ground pressure
• Bare tractor 88.4 {0.90}
• Reinforced type SIGMADOZER + variable
type multi-shank ripper + ROPS cab + air kPa
112.7 {1.15}
conditioner + 560 heavy duty shoe + side {kg/cm2}
cover
• Semi-U dozer 111.7 {1.14}
Dimensions
Overall length
• Bare tractor
5105
• Semi-U tilt dozer + tractor
mm 6375
• SIGMA tilt dozer + variable type multi-shank
8420
ripper
Overall width
D155AX-8 01-5
SPECIFICATIONS 01 SPECIFICATION

• Bare tractor
2765
• Semi-U tilt dozer + tractor
mm 4130
• SIGMA tilt dozer + variable type multi-shank
4060
ripper
Overall height
• To the tip of exhaust pipe 3385
mm
• To the top end of ROPS cab 3390
Track gauge 2140
Length of track on ground 3275
Shoe width (standard) mm 560
Minimum ground clearance (to the bottom surface
500
of undercover)
Engine
Model - SAA6D140E-7
4-cycle, water-cooled, in-line, vertical, direct in-
Type - jection, water-cooled type turbocharger + after-
cooler + (EGR) cooler
No. of cylinders - bore x stroke mm 6-140 x 165
Total piston displacement ℓ {cc} 15.24 {15240}
Performance
Engine rated horsepower
• Gross [SAE J1995] (*1) 268 {360}/ 1900 {1900}
kW {HP}/
• ISO14396 268 {360}/ 1900 {1900}
min-1 {rpm}
• Net [ISO 9249/SAE J1349] (*2) 264 {354}/ 1900 {1900}
Nm {kgm}/
Max. torque (*1) 1834 {187}/ 1300 {1300}
min-1 {rpm}
Max. speed with no load 2100 (0/-50) {2100 (0/-50)}
min-1 {rpm}
Min. speed with no load 740 (+25/0) {740 (+25/0)}
g/kWh
Fuel consumption ratio at rated horsepower 215 {158}
{g/HPh}
Starting motor - 24 V, 11 kW
Alternator - 24 V, 90 A
Battery (*3) - 12 V, 136Ah x 2
Radiator core type - Rectangle corrugated fin
01-6 D155AX-8

*1: Shows the value of engine only (without cooling fan).
*2: Shows the value when cooling fan is rotating at minimum speed.
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit. While, net denotes the value measured of an engine under the condition essen-
tially the same as that when it is installed on a machine.
• Rated horsepower (net) when cooling fan is rotating at maximum speed is the following value.
239kW {320HP}/1900 min-1 {1900 rpm}
• Maximum gross horsepower of engine is the following value.
267kW {358HP}/1800 min-1 {1800 rpm}
Power train
Torque converter 3-elements 1-level 2-phases type
Planet gear type, multiple disc clutch type,
hydraulic actuation type,
Transmission lubricating oil gear pump pressurized sending

type,
3-level forward, 3-level reverse, electrical actua-
tion type
Spiral bevel gear type, lubricating oil gear pump
Bevel gear shaft
pressurized sending type
HSS unit
Differential planet gear type, hydraulic motor
• HSS drive type,
electric type, hydraulic actuation type
Wet type, multi plate disc type, spring pressuriz-
• Brake ing type,
hydraulic actuation type, foot operated type
1-level flat gear, 1-level type planet gear, splash
Final drive
lubrication type
Undercarriage
Suspension type Hard type, balancing support type
Carrier roller 2 (each side)
Track roller 7 (each side)
Assembling type, single grouser,
Track shoe (560 mm)
42 pieces on one side, pitch 228.6 mm
Hydraulic system
Work equipment and HSS pump
Type - Variable swash plate type
MPa
Rated discharged pressure 41.2 {420}
{kg/cm2}
Theoretical discharged volume cm3/rev 190
HSS MOTOR
D155AX-8 01-7

Type - Fixed swash plate type (KMF140)
Rated pressure cm3/rev 41.2 {420}
Rated flow rate ℓ/min 311
Power train pump + steering lubrication pump (tan-
dem)
Type - Gear type (SAR(3)100 + 40)
MPa
Maximum discharged pressure 2.9 {30}
{kg/cm2}
40.0 (Steering pump)
Theoretical discharged volume cm3/rev
100.5 (Power train pump)
Scavenging pump
Type - Gear type (SAR(4)140)
MPa
Maximum discharged pressure 2.9 {30}
{kg/cm2}
Theoretical discharged volume cm3/rev 142.0
Cooling fan pump
Type - Variable swash plate type (LPV75(64))
MPa
Fan drive pressure 18.6 {190}
{kg/cm2}
Theoretical discharged volume cm3/rev 64
Cooling fan motor
Type - Fixed swash plate type (LMF110(65))
MPa
Rated pressure 17.8 {182}
{kg/cm2}
Rated flow rate ℓ/min 94.4
Work equipment hydraulic system

Control valve
Type for variable multi-shank ripper
• For ripper tilt 1 + 1 + triple, spool type, hydraulic assist type,
• For ripper lift electronic control
• For blade lift　 + ripper tilt
• For blade tilt + ripper lift
• For steering + (blade lift, blade tilt, steering)
Blade lift cylinder common to SIGMA and semi-U

Type - Double-acting piston type
Cylinder bore mm 110
Outside diameter of piston rod mm 75
Piston stroke (maximum) mm 1465
Max. distance between pins mm 2083
Min. distance between pins mm 627.5
01-8 D155AX-8

SIGMADOZER blade tilt cylinder
Cylinder bore
• Single tilt 160
mm
• Dual Tilt 160
Outside diameter of piston rod
• Single tilt 90
mm
• Dual Tilt 90
Piston stroke (maximum)
• Single tilt 205
mm
• Dual Tilt 140
Max. distance between pins
• Single tilt 1435
mm
• Dual Tilt 1430
Min. distance between pins
mm
• Dual Tilt 1290
Semi-U dozer blade tilt cylinder
Cylinder bore
• Single tilt 160
mm
• Dual Tilt 160
Outside diameter of piston rod
• Single tilt 90
mm
• Dual Tilt 90
Piston stroke (maximum)
• Single tilt 210
mm
• Dual Tilt 140
Max. distance between pins
mm
• Dual Tilt 1430
Min. distance between pins
mm
• Dual Tilt 1290
SIGMADOZER blade, pitch cylinder
D155AX-8 01-9

Min. distance between pins mm 1290
Ripper lift cylinder
Ripper tilt cylinder
Hydraulic tank Box type (externally-installed type control valve)
Work equipment
• Blade
Hydraulic SIGMA tilt dozer
Type Hydraulic semi-U tilt dozer
Hydraulic U tilt dozer
Support types of blade Left: tilt cylinder type Right: brace type
SIGMA tilt dozer
Performance
• Maximum raising distance (from the
ground) mm 1315
• Maximum lowering distance (from the mm 680
ground) mm 870
• Max. tilt amount deg. ±5
• Variable amount of blade edge angle m3 9.4
• Capacity of blade (SAE)
Dimensions
• Blade width mm 4060
• Blade height mm 1880
• Blade edge angle deg. 50
Semi-U tilt dozer
Performance
01-10 D155AX-8

ground) mm 1315
ground) mm 880
Dimensions
Full-U dozer
Performance
ground) mm 1315
ground) mm 920
Dimensions
SIGMA tilt dozer + pitch
Performance
• Max. tilt amount mm 870
• Maximum pitch angle deg. 4
• Maximum pitch back angle deg. 4
Semi-U tilt dozer + pitch
Performance
Full-U dozer + pitch
Performance
• Ripper
Variable type multi-shank ripper
Performance
D155AX-8 01-11

• Max. digging depth mm 905
• Maximum raising distance mm 950
• Digging angle at the point deg. 30 to 70
Dimensions
mm
• Maximum width of beam 2320
Quantity of
• Shank position 2
holes
Variable giant ripper
Performance
• Max. digging depth mm 1240
• Maximum raising distance mm 950
• Digging angle at the point deg. 30 to 70
Dimensions
mm
• Maximum width of beam 1401
Quantity of
• Shank position 3
holes
01-12 D155AX-8
01 SPECIFICATION WEIGHT TABLE
WEIGHT TABLE
WEIGHT TABLE: D155AX-8
k This weight table is provided for your reference when handling or transporting the components.
k This weight table shows the dry weight.
Unit: kg
Machine model D155AX-8
Engine, damper assembly 2439
• Engine assembly
2285
(including KDPF, SCR Ass'y, and AdBlue/DEF mixing tube)
• Damper assembly 122
• Universal joint 18
• Parts installed to engine (wiring) 14
Radiator assembly:
364
(including built-in type oil cooler, hydraulic oil cooler, and condenser)
Fuel tank assembly
When it is empty 424
When it is full 962
Aftercooler 26
Power train unit assembly 2580
• Torque converter and PTO assembly 503
• Transmission assembly 634
• HSS assembly 931
• Brake control valve
6
(brake ECMV assembly 2 pieces, brake solenoid valve)
• Scavenging pump 20
• Steering lubrication pump, power train pump 25
• Work equipment and HSS pump 119
• HSS motor 67
• Cooling fan pump 43
Power train filter assembly 17
Cooling fan motor 35
Final drive assembly 1426 x 2
• Sprocket tooth (13 x 9) x 2
Main frame assembly 4812
Track group assembly (one side) 3940
• Track frame 1350
• Idler assembly 332
• Recoil spring assembly 517
• 1st bogie 165
• Track roller assembly (single flange) 91
D155AX-8 01-13
WEIGHT TABLE 01 SPECIFICATION
Unit: kg
• 2nd, 3rd, 4th bogie assembly 406 x 3
• Track roller assembly (single flange) 91 x 4
• Track roller assembly (double flange) 103 x 3
• Carrier roller assembly 48 x 2
Track shoe assembly
Wet type (560 mm) 2545 x 2
Left pivot shaft assembly 126
Right pivot shaft assembly
Dual Tilt specification 126
Single tilt specification 143
Equalizer bar assembly 247
Hydraulic tank assembly (including hydraulic oil filter) 123
Control valve
160
(blade lift + blade tilt + ripper lift + ripper tilt + steering)
Engine underguard 283
Transmission underguard 279
Operator's seat 55
SIGMA tilt dozer assembly 5771 (standard: 5079)
• Blade 3493 (standard: 3076)
• Straight frame 1805 (standard: 1530)
• Tilt brace 93 x 1
• Center brace 250 x 1
• Tilt cylinder assembly 130
SIGMA dual tilt dozer assembly 5855 (standard: 5164)
• Pitch cylinder assembly 134 x 2
Semi-U tilt dozer assembly 5773 (standard: 4992)
• Tilt brace 94 x 1
• Tilt cylinder assembly 132
Blade lift cylinder assembly 165 x 2
Multi-shank ripper assembly 3985
• Bracket, beam, arm 2644
• Shank 295 x 3
01-14 D155AX-8
01 SPECIFICATION WEIGHT TABLE
Unit: kg
• Lift cylinder assembly 186 x 1
• Tilt cylinder assembly 249 x 1
Giant ripper assembly 3260
• Bracket, beam, arm 2425
• Shank 361 x 1
• Lift cylinder assembly 186 x 1
• Tilt cylinder assembly 249 x 1
• Pin puller cylinder assembly 7
Cab, floor assembly (ROPS integrated) 1452
• Floor cover 36
• Rear cover 20
• Air conditioner unit assembly 10
Air conditioner compressor 7
D155AX-8 01-15
TABLE OF FUEL, COOLANT, AND LUBRICANTS 01 SPECIFICATION
TABLE OF FUEL, COOLANT, AND LUBRICANTS

For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual.
Unit: ℓ
Greasing points Specified capacity Refill capacity
Engine oil pan 45 37
Power train case 130 90
Damper case 1.5 1.5
Final drive case (each on right and left sides) 31 31
Hydraulic oil system (with blade and ripper) 250 95
Cooling system 104 -
Fuel tank 625 -
AdBlue/DEF tank 59 -
01-16 D155AX-8
10 STRUCTURE AND FUNCTION
D155AX-8 10-1
CONTENTS 10 STRUCTURE AND FUNCTION
CONTENTS
UREA SCR SYSTEM..................................................................................................................................... 10-5
LAYOUT DRAWING OF UREA SCR SYSTEM ....................................................................................... 10-5
UREA SCR SYSTEM DIAGRAM ............................................................................................................ 10-7
FUNCTION OF UREA SCR SYSTEM..................................................................................................... 10-8
FUNCTION OF AdBlue/DEF SYSTEM............................................................................................. 10-8
INDUCEMENT STRATEGY ............................................................................................................10-11
COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-23
AdBlue/DEF MIXING TUBE ........................................................................................................... 10-23
SCR ASSEMBLY ........................................................................................................................... 10-23
AdBlue/DEF TANK ......................................................................................................................... 10-26
AdBlue/DEF PUMP ........................................................................................................................ 10-28
AdBlue/DEF INJECTOR................................................................................................................. 10-29
AdBlue/DEF HOSE ........................................................................................................................ 10-30
AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-31
BOOT-UP SYSTEM ..................................................................................................................................... 10-32
SYSTEM OPERATING LAMP SYSTEM ............................................................................................... 10-32
SYSTEM OPERATING LAMP SYSTEM DIAGRAM ....................................................................... 10-32
FUNCTION OF SYSTEM OPERATING LAMP............................................................................... 10-32
BATTERY DISCONNECT SWITCH ...................................................................................................... 10-34
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH......................................................... 10-34
FUNCTION OF BATTERY DISCONNECT SWITCH ...................................................................... 10-34
ENGINE SYSTEM ....................................................................................................................................... 10-36
LAYOUT DRAWING OF ENGINE RELATED PARTS ............................................................................ 10-36
ENGINE CONTROL SYSTEM .............................................................................................................. 10-38
LAYOUT OF ENGINE CONTROL SYSTEM................................................................................... 10-38
ENGINE CONTROL SYSTEM DIAGRAM...................................................................................... 10-38
FUNCTION OF ENGINE CONTROL SYSTEM .............................................................................. 10-40
AUTOMATIC IDLE STOP SYSTEM ...................................................................................................... 10-41
SYSTEM OPERATING AUTOMATIC IDLE STOP SYSTEM DIAGRAM......................................... 10-41
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM DIAGRAM..................................................... 10-41
COMPONENT PARTS OF ENGINE SYSTEM ...................................................................................... 10-44
DAMPER ....................................................................................................................................... 10-44
KVGT ............................................................................................................................................. 10-45
EGR SYSTEM ............................................................................................................................... 10-49
EGR VALVE ................................................................................................................................... 10-51
EGR COOLER ............................................................................................................................... 10-53
KCCV SYSTEM ............................................................................................................................. 10-55
KCCV VENTILATOR ...................................................................................................................... 10-57
KDPF ............................................................................................................................................. 10-60
COOLING SYSTEM..................................................................................................................................... 10-64
LAYOUT DRAWING OF COOLING SYSTEM ....................................................................................... 10-64
SPECIFICATIONS OF COOLING SYSTEM................................................................................... 10-65
COMPONENT PARTS OF COOLING SYSTEM.................................................................................... 10-66
COOLING FAN PUMP ................................................................................................................... 10-66
COOLING FAN MOTOR ................................................................................................................ 10-74
HYDRAULIC OIL COOLER BYPASS VALVE ................................................................................. 10-81
CONTROL SYSTEM.................................................................................................................................... 10-82
LAYOUT OF ELECTRICAL CONTROL SYSTEM ................................................................................. 10-82
PALM COMMAND CONTROL SYSTEM............................................................................................... 10-83
PALM COMMAND CONTROL SYSTEM DIAGRAM ...................................................................... 10-83
MACHINE MONITOR SYSTEM ............................................................................................................ 10-87
MACHINE MONITOR SYSTEM DIAGRAM.................................................................................... 10-87
FUNCTION OF MACHINE MONITOR SYSTEM ............................................................................ 10-87
KOMTRAX SYSTEM............................................................................................................................. 10-90
KOMTRAX SYSTEM DIAGRAM .................................................................................................... 10-90
FUNCTION OF KOMTRAX SYSTEM ............................................................................................ 10-90
10-2 D155AX-8
10 STRUCTURE AND FUNCTION CONTENTS
COMPONENT PARTS OF CONTROL SYSTEM................................................................................... 10-91

MACHINE MONITOR..................................................................................................................... 10-91
KOMTRAX TERMINAL .................................................................................................................10-106
POWER TRAIN CONTROLLER....................................................................................................10-108
WORK EQUIPMENT CONTROLLER ...........................................................................................10-112
DECELERATOR PEDAL POTENTIOMETER ...............................................................................10-115
ENGINE CONTROLLER ...............................................................................................................10-117
FUEL FEED PUMP .......................................................................................................................10-123
FUEL FEED PUMP SWITCH ........................................................................................................10-124
HYDRAULIC SYSTEM................................................................................................................................10-125
LAYOUT DRAWING OF HYDRAULIC SYSTEM ..................................................................................10-125
CLSS ...................................................................................................................................................10-126
STRUCTURE OF CLSS................................................................................................................10-126
FUNCTION OF CLSS ...................................................................................................................10-127
COMPONENT PARTS OF HYDRAULIC SYSTEM ..............................................................................10-129
HYDRAULIC TANK .......................................................................................................................10-129
WORK EQUIPMENT AND HSS PUMP.........................................................................................10-130
LS VALVE .....................................................................................................................................10-135
PC VALVE.....................................................................................................................................10-140
PC-EPC VALVE ............................................................................................................................10-143
CONTROL VALVE ........................................................................................................................10-147
POWER TRAIN SYSTEM ...........................................................................................................................10-188
LAYOUT OF POWER TRAIN SYSTEM ...............................................................................................10-188
OPERATE POWER TRAIN SYSTEM...................................................................................................10-191
TRANSMISSION, STEERING, AND BRAKE CONTROL .....................................................................10-193
LAYOUT OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM PARTS .............10-193
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL .....................................10-194
HSS SYSTEM......................................................................................................................................10-196
HSS SYSTEM DIAGRAM .............................................................................................................10-196
FUNCTION OF HSS SYSTEM......................................................................................................10-197
CENTRALIZED PRESSURE PICKUP PORT.......................................................................................10-199
LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT ...........................................................10-199
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT.......................................................10-200
COMPONENT PARTS OF POWER TRAIN SYSTEM ..........................................................................10-201
UNIVERSAL JOINT ......................................................................................................................10-201
POWER TRAIN MOUNT...............................................................................................................10-202
TORQUE CONVERTER AND PTO...............................................................................................10-203
TORQUE CONVERTER CONTROL VALVE .................................................................................10-210
LOCKUP CLUTCH ECMV.............................................................................................................10-211
STATOR CLUTCH ECMV .............................................................................................................10-214
TRANSMISSION...........................................................................................................................10-218
TRANSMISSION ECMV ...............................................................................................................10-228
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE ...........................................10-235
TRANSMISSION LUBRICATION RELIEF VALVE .........................................................................10-237
BEVEL GEAR SHAFT, HSS, AND BRAKE ...................................................................................10-237
FINAL DRIVE................................................................................................................................10-264
SCAVENGING PUMP ...................................................................................................................10-267
STEERING LUBRICATION PUMP AND POWER TRAIN PUMP ..................................................10-268
HSS MOTOR ................................................................................................................................10-269
ELECTRIC LEVER........................................................................................................................10-277
WORK EQUIPMENT SYSTEM ...................................................................................................................10-282
WORK EQUIPMENT CONTROL .........................................................................................................10-282
LAYOUT OF WORK EQUIPMENT CONTROL..............................................................................10-282
WORK EQUIPMENT CONTROL FUNCTION ...............................................................................10-283
LAYOUT OF DUAL TILT DOZER ..................................................................................................10-284
LAYOUT OF VARIABLE MULTI-SHANK RIPPER .........................................................................10-285
LAYOUT OF VARIABLE GIANT RIPPER ......................................................................................10-286
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ..................................................................10-287
D155AX-8 10-3
CONTENTS 10 STRUCTURE AND FUNCTION
SELF-PRESSURE REDUCING VALVE ........................................................................................10-287

WORK EQUIPMENT LOCK SOLENOID VALVE ...........................................................................10-293
PILOT CIRCUIT ACCUMULATOR ................................................................................................10-295
QUICK DROP VALVE ...................................................................................................................10-296
PISTON VALVE.............................................................................................................................10-300
BLADE ELECTRIC LEVER ...........................................................................................................10-301
RIPPER ELECTRIC LEVER .........................................................................................................10-302
UNDERCARRIAGE AND FRAME...............................................................................................................10-304
MAIN FRAME ......................................................................................................................................10-304
STRUCTURE OF MAIN FRAME...................................................................................................10-304
SUSPENSION .....................................................................................................................................10-305
STRUCTURE OF SUSPENSION..................................................................................................10-305
FUNCTION OF SUSPENSION .....................................................................................................10-307
TRACK FRAME AND IDLER CUSHION ..............................................................................................10-308
STRUCTURE OF TRACK FRAME AND IDLER CUSHION...........................................................10-308
SPECIFICATIONS OF TRACK FRAME AND IDLER CUSHION ...................................................10-309
FUNCTION OF TRACK FRAME AND IDLER CUSHION ..............................................................10-309
WORK EQUIPMENT...................................................................................................................................10-310
STRUCTURE OF CYLINDER STAY ....................................................................................................10-310
STRUCTURE OF BLADE ....................................................................................................................10-311
STRUCTURE OF VARIABLE GIANT RIPPER .....................................................................................10-313
STRUCTURE OF VARIABLE FIXED MULTI-SHANK RIPPER.............................................................10-314
CAB AND ITS ATTACHMENTS ..................................................................................................................10-315
ROPS CAB ..........................................................................................................................................10-315
STRUCTURE OF ROPS CAB.......................................................................................................10-315
FUNCTION OF ROPS CAB ..........................................................................................................10-315
CAB MOUNT .......................................................................................................................................10-316
STRUCTURE OF CAB MOUNT....................................................................................................10-316
10-4 D155AX-8
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM

SCR
Abbreviation for Selective Catalytic Reduction
LAYOUT DRAWING OF UREA SCR SYSTEM
D155AX-8 10-5
LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
1: AdBlue/DEF mixing tube 13: Ammonia sensor

2: SCR assembly 14: SCR outlet temperature sensor
3: AdBlue/DEF suction hose 15: SCR outlet NOx sensor
4: AdBlue/DEF return hose 16: AdBlue/DEF tank heating valve
5: AdBlue/DEF tank breather 17: KDPF
6: Ambient temperature sensor 18: AdBlue/DEF injector cooling tank
7: AdBlue/DEF tank 19: AdBlue/DEF injector coolant hose
8: AdBlue/DEF tank sensor 20: Turbocharger outlet NOx sensor
9: AdBlue/DEF filler port 21: AdBlue/DEF tank coolant outlet hose
10: AdBlue/DEF pump 22: AdBlue/DEF tank coolant inlet hose
11: AdBlue/DEF pressure hose 23: AdBlue/DEF injector
12: SCR temperature sensor
10-6 D155AX-8
10 STRUCTURE AND FUNCTION UREA SCR SYSTEM DIAGRAM
UREA SCR SYSTEM DIAGRAM

1
4 7 8 17
2 5 6 15 18 19 20
9 16 26
3 A
11 12 13 B 21 23 24
10 27
14 22 25
28
29
34
36 31
A
B
35
38
39 37 32
33 30
A4D02950
A: Coolant inlet B: Coolant outlet

1: MAF sensor 21: Ammonia sensor
2: Engine 22: Ammonia sensor controller
3: Engine controller 23: SCR temperature sensor
4: KDPF assembly 24: SCR outlet temperature sensor
5: KDOC unit 25: SCR temperature sensor controller
6: KCSF unit 26: SCR outlet NOx sensor
7: KDPF differential pressure sensor 27: SCR outlet NOx sensor controller
8: KDPF outlet pressure sensor 28: Smart sensor
9: Turbocharger outlet NOx sensor 29: Ambient temperature sensor
10: Turbocharger outlet NOx sensor controller 30: AdBlue/DEF system
11: KDOC inlet temperature sensor 31: AdBlue/DEF tank heating valve
12: KDOC outlet temperature sensor 32: AdBlue/DEF tank
13: KDPF outlet temperature sensor 33: AdBlue/DEF tank sensor
14: KDPF temperature sensor controller 34: AdBlue/DEF suction line
15: AdBlue/DEF mixing tube 35: AdBlue/DEF return line
16: AdBlue/DEF injector 36: AdBlue/DEF pressure line
17: SCR assembly 37: AdBlue/DEF pump
18: Upstream SCR catalyst 38: AdBlue/DEF line heater relay
19: Downstream SCR catalyst 39: Machine monitor
20: Ammonia oxidation catalyst
D155AX-8 10-7
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF UREA SCR SYSTEM

5
CO N2
1 NOx H2O
HC CO2
6 7 8
2
4
3
A4P14896
1: Engine 5: AdBlue/DEF injector

2: Engine controller 6: KDPF
3: AdBlue/DEF pump 7: SCR catalyst
4: AdBlue/DEF tank 8: Ammonia oxidation catalyst
• Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless
nitrogen and water.
• By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and
the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.
FUNCTION OF AdBlue/DEF SYSTEM

1: AdBlue/DEF tank 5
2: AdBlue/DEF suction hose
6
3: AdBlue/DEF pump
4
3A: Flow control valve
3B: Pump
3C: AdBlue/DEF filter
3D: Pressure sensor 2
4: AdBlue/DEF return hose
1
5: AdBlue/DEF pressure hose
6: AdBlue/DEF injector 3A 3D
P
• AdBlue/DEF system consists of AdBlue/DEF tank (1),
3C
AdBlue/DEF hoses (2), (4), (5), AdBlue/DEF pump (3), and
AdBlue/DEF injector (6).
3B 3
• The AdBlue/DEF system is a part of the Komatsu Urea
SCR system and its function is to provide AdBlue/DEF into
the SCR Catalyst Assembly.
A4P14892
• However, the comprising devices, such as the AdBlue/DEF
pump, may not start functioning till certain conditions are
fulfilled.
• The AdBlue/DEF system has heating systems to thaw and prevent AdBlue/DEF from freezing because
AdBlue/DEF freezes at －11 °C.
10-8 D155AX-8
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM
Function of AdBlue/DEF injection system

• The AdBlue/DEF pump pressurizes AdBlue/DEF and delivers it into the AdBlue/DEF mixing tube through
the AdBlue/DEF injector.
• The amount of AdBlue/DEF injection is controlled by the Engine Controller.
• The amount of AdBlue/DEF injection is calculated based on the information of the turbocharger outlet NOx
sensor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the ammonia sensor, the
SCR outlet NOx sensor and the exhaust gas flow rate.
• AdBlue/DEF injection is also controlled by the system temperature because Urea SCR systems are not ef-
fective in low temperature. For the monitoring of the system temperature, the KDPF outlet temperature sen-
sor is used in addition to the SCR temperature sensors.
• If any abnormality is detected in any of the sensors that are used for the calculation of the amount of AdBl-
ue/DEF injection and the monitoring of the system temperature, the Engine Controller commands termina-
tion of AdBlue/DEF injection. When this occurs, alerts will be activated and failure codes will be registered.
• Some abnormalities may cause large amount of urea precipitation inside the AdBlue/DEF mixing tube and
result in deposit of urea on the inner surfaces. If it continues and urea deposit accumulates AdBlue/DEF
injection can be blocked at the AdBlue/DEF injector or the exhaust gas flow can be choked in the passag-
es.
Function of purge system
• The AdBlue/DEF purging is incorporated to purge remain- 5
ing AdBlue/DEF in the AdBlue/DEF injector, AdBlue/DEF
hoses and the AdBlue/DEF pump to prevent AdBlue/DEF 6
from solidifying inside by precipitation or freezing. 4
• The AdBlue/DEF purging is activated automatically when
the engine is shut down or the ambient temperature falls
so low that the heating systems is not capable of maintain-
ing fluidity of AdBlue/DEF.
2
• In the case of the AdBlue/DEF purging of the engine shut-
down, the purging operation continues several minutes af-
1
ter the engine stops. Once the purging operation com-
pletes, the Engine Controller shuts itself down automatical- 3A 3D
ly. P
NOTICE
3C
Do not turn the battery disconnect switch to the OFF posi-

3B 3
tion till the System Operating Lamp in the battery box goes
out. The System Operating Lamp will go out when the sys-
tem shuts itself down after the purging operation com-
pletes. A4P14893
Function of heating system

• The AdBlue/DEF heating system has two operation modes.
• One operation mode is “Thaw mode”.
• At engine start-up if the Engine Controller judges AdBlue/DEF is frozen, it automatically commands
heating the AdBlue/DEF injection system.
• The AdBlue/DEF pump and the AdBlue/DEF injector hold their operation till the Engine Controller judg-
es the completion of AdBlue/DEF thawing operation.
• The other operation mode is “Freeze Prevention mode”.
• While the machine is in operation if the Engine Controller judges AdBlue/DEF is likely to freeze, it auto-
matically commands heating the AdBlue/DEF system.
• While the heating is on during machine operation if the Engine Controller judges that cooling by the
ambient exceeds the heating capacity of the system, it automatically starts AdBlue/DEF purging and
D155AX-8 10-9
shuts down the operation of the AdBlue/DEF pump and the AdBlue/DEF injector. However, the heating
system is kept on as long as the machine is in operation.
• “Thaw mode” and “Freeze Prevention mode” are controlled by utilizing information by temperature sensors.
The temperature sensors used for the control of two modes are different and the temperature Freeze Pre-
vention modesensors utilized by the comprising devices are different. The following table shows which com-
prising device uses which heating system and which temperature sensors in relation to which operation
mode.
Heating system Thawing mode Freeze prevention mode
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
sensor sensor
AdBlue/DEF pressure hose
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor
10-10 D155AX-8
INDUCEMENT STRATEGY
• The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions
control system.
• Inducement strategy is a control action to ensure prompt correction of various failures in the engine emis-
sions control system. It requires actions to limit engine performance and defines required indication such as
warning lamps and messages, as well as alarms while the control actions are imposed. The warning steps
of Inducement are different between for North America and for European Union.
• The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information”
screen of the machine monitor.
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR NORTH AMERICA)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 5 levels from Warning, Escalated Warning, Mild Inducement, Se-
vere Inducement and Final Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank. Final Inducement starts at 1 hour after the start of Severe Inducement
if the machine continues its operation without adding AdBlue/DEF into the tank, and reduces the engine
speed to low idle and keeps it at low idle.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Amount of AdBl- Machine monitor Engine controller
ue/DEF remain-
Status (*1) ing in the tank AdBlue/DEF lev-
el caution lamp Tone of audible Activated failure Engine deration
(AdBlue/DEF alert code (*2)
level gauge) (Action level)
10%
CA3497
1 Warning (The bottom two No sound No deration
(AdBlue/DEF
gradations light
level low error 1)
on)
5%
(Within the gra- CA3498
Escalated
2 dation of the Triplet (AdBlue/DEF No deration
Warning
second from the level low error 2)
bottom )
2.5%
CA1673
Mild Induce- (The gradation Torque: over
3 Intermittently (AdBlue/DEF
ment of the end of the 25%
level low error 3)
bottom lights on)
D155AX-8 10-11

ue/DEF remain-
CA1673 Torque: over

0% 50%
Severe Induce- CA3547
4 (All gradations Continuously
ment (AdBlue/DEF and
lights off)
level low error 4) RPM: over 40%
CA1673
After 1 hour in CA3547
Final Induce- Engine speed is
5 Severe Induce- Continuously AS00ZK
ment fixed to low idle
ment
(AdBlue/DEF
level low error 5)
*1: The number means Inducement strategy status on “SCR Information” screen of the machine monitor.
*2: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the
rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR

SYSTEM DEVICES (FOR NORTH AMERICA)
• When any abnormality is found in the AdBlue/DEF quality or in the Urea SCR system tampering or fault,
AdBlue/DEF system caution lamp on the machine monitor lights up, the Audible alert sounds. If time has
elapsed after any abnormality is generated, not only the warning by AdBlue/DEF caution lamp on the ma-
chine monitor and Audible alert, but also an action level is displayed, Inducement strategy is activated and
then the engine output is reduced.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• For detailed information on the displayed failure codes, refer to Troubleshooting section, “Troubleshooting
points (Inducement failure code list)”.
Machine monitor Engine controller
Elapsed time AdBlue/DEF

Status (*1) system cau- Failure code for
(*4) Tone of audi- Failure code for Engine dera-
tion lamp Inducement
ble alert abnormality tion (*2)
strategy status
(Action level)
1 Warning 1 hour No sound CA3571 (*3) No indication No deration
10-12 D155AX-8

strategy status
(Action level)
AS00R2
Escalated (Warning 2
2 2 hours Triplet CA3571 (*3) No deration
Warning (SCR Device
Abnormality))
AS00R3
Mild Induce- (Inducement 1 Torque: over
3 3 hours Intermittently CA3571 (*3)
ment (SCR Device 25%
Abnormality))
Torque: over
AS00R4 50%
Severe In- (Inducement 2
4 4 hours Continuously CA3571 (*3) and
ducement (SCR Device
Abnormality)) RPM: over
40%
AS00R5
Engine speed
Final Induce- Until repair- (Inducement 3
5 Continuously CA3571 (*3) is fixed to low
ment ing (SCR Device idle
Abnormality))
rated speed.
*3: The failure code shown in the table is just an example of abnormalities that trigger Inducement under the catego-
ry of “Abnormalities in the Urea SCR system”.
*4: Elapsed time of each column describes an accumulated time advancing to the next inducement strategy from the
time when Warning to the Inducement starts. Final Inducement is not cleared till abnormality is repaired.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM (FOR NORTH AMERICA)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
steps are the same and 5, warning indications are different and engine power deration starts from that of
“Mild Inducement (Over 25% torque reduction)”. The following graph and table show how the Inducement
caused by abnormalities in KDPF advances from “Warning” to “Final Inducement”.
D155AX-8 10-13
• The codes in the KDPF abnormality category are CA4151, CA4158, CA4161, CA4162, CA4259, CA3319,
CA3321 and CA3322.
Elapsed time
Status (*1) Caution lamp Tone of audi- Failure code for Failure code for Engine dera-
(*4) Inducement
(Action level) ble alert abnormality
strategy status
tion (*2)
Torque: over
1 Warning 1 hour Continuously CA4151 (*3) No indication
25%
Escalated Torque: over

2 2 hours Triplet CA4151 (*3) AS00R2
Warning 25%
Mild Induce- Torque: over

3 3 hours Intermittently CA4151 (*3) AS00R3
ment 25%
Torque: over
50%
Severe In-
4 4 hours Continuously CA4151 (*3) AS00R4 and
ducement
RPM: over
40%
10-14 D155AX-8

Elapsed time
(*4) Inducement
strategy status
tion (*2)
Engine speed
Final Induce- Until repair-
5 Continuously CA4151 (*3) AS00R5 is fixed to low
ment ing
idle
rated speed.
time when Warning to the Inducement starts. Final Inducement is not cleared till abnormality is repaired.
FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR NORTH

AMERICA)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Mild Inducement” through
the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine pow-
er.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed, but “Temporary Restoration from Inducement” is turned off whenever the system advan-
ces to “Final Inducement” even if either 30 minutes or 3 operations are not used up. All the abnormalities of
the Urea SCR system need to be corrected to regain another restoration capability.
• If all the abnormalities of the Urea SCR system are not corrected when the system is in “Severe Induce-
ment”, the system advances to “Final Inducement” in 1 hour after “Severe Inducement” started and engine
speed will be fixed to low idle to disable practical machine operation.
• To activate Temporary Restoration, follow the procedures described below.
1. Press F6 while the “Standard” screen is displayed on the machine monitor. The “SCR Information”
screen shall show up with the pop-up window A in the bottom half and later the pop-up window B repla-
ces the window A.
2. Press F6 again while the “window B” is on. “Engine Power Recovery” window shall show up.
3. Press F6 again while the “Engine Power Recovery” window is on. Temporary Restoration from Induce-
ment starts and engine power deration is brought back to the level of “Mild Inducement”.
D155AX-8 10-15
NOTICE
The “SCR Information” screen is on only for 30 seconds. When the “Standard” screen is replaced by
the “SCR Information” screen by pressing F6, the “window A” first shows up and is on for the first 15
seconds. The “window B” replaces “window A” for the next 15 seconds, then the “window A” comes
back in the last 15 seconds, and the “SCR Information” screen will be replaced automatically by the
“Standard” screen unless F6 is pressed while the “window B” is on.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR NORTH AMERICA)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated and starts from “Severe Inducement”.
• The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not
corrected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final In-
ducement” and engine speed will be fixed to low idle to disable practical machine operation.
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR EUROPEAN UNION)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Induce-
ment, and Severe Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank. Final Inducement starts at 1 hour after the start of Severe Inducement
if the machine continues its operation without adding AdBlue/DEF into the tank, and reduces the engine
speed to low idle and keeps it at low idle.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
ue/DEF remain-
10%
CA3497
1 Warning (The bottom two No sound No deration
(AdBlue/DEF
gradations light
level low error 1)
on)
5%
(Within the gra- CA3498
Continuous
2 dation of the Triplet (AdBlue/DEF No deration
Warning
second from the level low error 2)
bottom )
10-16 D155AX-8

ue/DEF remain-
2.5%
CA1673
Low-Level In- (The gradation Torque: over
3 Intermittently (AdBlue/DEF
ducement of the end of the 25%
level low error 3)
bottom lights on)
CA1673 Torque: over

0% 50%
Severe Induce- CA3547
4 (All gradations Continuously
ment (AdBlue/DEF and
lights off)
level low error 4) RPM: over 40%
rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR

SYSTEM DEVICES (FOR EUROPEAN UNION)
• When any abnormality is found in the AdBlue/DEF quality or in the Urea SCR system tampering or fault,
SCR system caution lamp on the machine monitor lights up, the Audible alert sounds. If time has elapsed
after any abnormality is generated, not only the warning by AdBlue/DEF caution lamp on the machine moni-
tor and Audible alert, but also an action level is displayed, Inducement strategy is activated and then the
engine output is reduced.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• For detailed information on the displayed failure codes, refer to Troubleshooting section, “Troubleshooting
points (Inducement failure code list)”.

strategy status
(Action level)
1 Warning 5 hours No sound CA3571 (*3) No indication No deration
D155AX-8 10-17

strategy status
(Action level)
AS00R2
Continuous (Warning 2
2 10 hours Triplet CA3571 (*3) No deration
Warning (SCR Device
Abnormality))
AS00R3
Low-Level In- (Inducement 1 Torque: over
3 20 hours Intermittently CA3571 (*3)
ducement (SCR Device 25%
Abnormality))
Torque: over
AS00R4 50%
Severe In- Until repair- (Inducement 2
4 Continuously CA3571 (*3) and
ducement ing (SCR Device
Abnormality)) RPM: over
40%
rated speed.
time when Warning to the Inducement starts. Severe Inducement is not cleared till abnormality is repaired.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
“Warning (Over 25% torque reduction)”. The following table shows how the Inducement caused by abnor-
malities in KDPF advances from “Warning” to “Severe Inducement”.
• The codes in the KDPF abnormality category are CA4151, CA4158, CA4161, CA4162, CA4259, CA3319,
CA3321 and CA3322.
10-18 D155AX-8

Elapsed time
(*4) Inducement
strategy status
tion (*2)
Torque: over
1 Warning 5 hours No sound CA4151 (*3) No indication
25%
Continuous Torque: over

Warning 25%
Low-Level In- Torque: over

ducement 25%
Torque: over
50%
Severe In- Until repair-
4 Continuously CA4151 (*3) AS00R4 and
ducement ing
RPM: over
40%
*2: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
D155AX-8 10-19
*3: The failure code shown in the table is just an example of abnormalities that trigger Inducement under the
category of “Abnormalities in KDPF system”.
*4: Elapsed time of each column describes an accumulated time advancing to the next inducement strategy
from the time when Warning to the Inducement starts. Severe Inducement is not cleared till abnormality is re-
paired.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in EGR. Although the total
“Warning (Over 25% torque reduction)”. The following table shows how the Inducement caused by abnor-
malities in EGR advances from “Warning” to “Severe Inducement”.
• The codes in the EGR abnormality category are CA2271, CA2272, CA2357, CA2349 and CA2353.
Elapsed time
(*4) Inducement
strategy status
tion (*2)
Torque: over
1 Warning 5 hours No sound CA2271 (*3) No indication
25%
Continuous Torque: over

Warning 25%
Low-Level In- Torque: over

ducement 25%
10-20 D155AX-8

Elapsed time
(*4) Inducement
strategy status
tion (*2)
Torque: over
50%
Severe In- Until repair-
4 Continuously CA2271 (*3) AS00R4 and
ducement ing
RPM: over
40%
*2: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*3: The failure code shown in the table is just an example of abnormalities that trigger Inducement under the
category of “Abnormalities in EGR system”.
*4: Elapsed time of each column describes an accumulated time advancing to the next inducement strategy
from the time when Warning to the Inducement starts. Severe Inducement is not cleared till abnormality is re-
paired.
FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EURO-

PEAN UNION)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Low-Level Inducement”
through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full en-
gine power.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another re-
storation capability.
• To activate Temporary Restoration, follow the procedures described below.
1. Press F6 while the “Standard” screen is displayed on the machine monitor. The “SCR Information”
screen shall show up with the pop-up window A in the bottom half and later the pop-up window B repla-
ces the window A.
2. Press F6 again while the “window B” is on. “Engine Power Recovery” window shall show up.
3. Press F6 again while the “Engine Power Recovery” window is on. Temporary Restoration from Induce-
ment starts and engine power deration is brought back to the level of “Low-Level Inducement”.
NOTICE
The “SCR Information” screen is on only for 30 seconds. When the “Standard” screen is replaced by
the “SCR Information” screen by pressing F6, the “window A” first shows up and is on for the first 15
seconds. The “window B” replaces “window A” for the next 15 seconds, then the “window A” comes
back in the last 15 seconds, and the “SCR Information” screen will be replaced automatically by the
“Standard” screen unless F6 is pressed while the “window B” is on.
D155AX-8 10-21
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR EUROPEAN UNION)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated.
• Inducement in the recurrence resumes counting time at the time when the previous abnormalities were cor-
rected if the previous Inducement is in Warning, Continuous Warning or Low-Level Inducement. The alerts
resume the previous Inducement. If the time the previous abnormalities were corrected is in Severe Induce-
ment, Inducement in the recurrence starts from Low-Level Inducement but the remaining time to Severe In-
ducement is 1 hour or 2 hours depending on abnormalities. If the 1 hour or 2 hours are used up without
correcting the new abnormalities, Inducement will advance to Severe Inducement and engine power will be
derated heavily.
10-22 D155AX-8
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM

SCR
AdBlue/DEF MIXING TUBE

STRUCTURE OF AdBlue/DEF MIXING TUBE
REMARK
The shape is subject to machine models.
A: Exhaust gas inlet (from KDPF) B: Exhaust gas outlet (to SCR)
1: V clamp 4: AdBlue/DEF mixing tube (connector)
2: AdBlue/DEF injector 5: AdBlue/DEF mixing tube (tube)
3: Gasket for AdBlue/DEF injector
FUNCTION OF AdBlue/DEF MIXING TUBE

It mixes AdBlue/DEF injected from AdBlue/DEF injector with exhaust gas, and decomposes it to ammonia which
is needed to purge NOx from SCR assembly.
SCR ASSEMBLY
SCR
STRUCTURE OF SCR ASSEMBLY

REMARK
D155AX-8 10-23
COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
18
20
14 15 16 17 19
A4P15765
A: From AdBlue/DEF mixing tube B: To Exhaust pipe

1: Inlet unit 4: Ammonia sensor
2: Upstream SCR catalyst unit 5: SCR temperature sensor
3: Downstream SCR catalyst unit 6: Temperature sensor controller
10-24 D155AX-8
7: Sensor bracket 14: Rectifying plate

8: Sensor bracket band 15: Upstream SCR catalyst
9: Outlet unit 16: Downstream SCR catalyst
10: SCR outlet temperature sensor 17: Ammonia oxidation catalyst
11: SCR outlet NOx sensor 18: Catalyzer hold mat
12: Water drain port 19: Water dam
13: Hanger plate 20: water baffle
• SCR assembly consists of the following: The inlet unit (1) which introduces the exhaust gas and equalize
the distribution of flow speed, the upstream SCR catalyst unit (2) which stores upstream SCR catalyst, the
downstream SCR catalyst unit (3) which stores downstream SCR catalyst and ammonia oxidation catalyst,
the outlet unit (9) which discharges the exhaust gas and as well as prevents rainwater from entering
through outlet into downstream SCR catalyst unit (3).
• Ammonia oxidation catalyst (17) oxidizes ammonia to water and nitrogen with ammonia oxidation catalyst
(17) to prevent ammonia which is supplied to SCR assembly from being released out because SCR cata-
lyst (15),(16) cannot completely consume it.
• Each 1 piece of SCR temperature sensor (5), SCR outlet temperature sensor (10), ammonia sensor (4),
and SCR outlet NOx sensor (11) are installed. These sensors are usable for various troubleshootings, such
as they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly
functions or not.
• Rectifing plate (14) equalizes the distribution of exhaust gas flow speed.
• SCR catalysts(15),(16) use the ceramic honeycomb.
• The catalyzer holding mat (18) is made of a specific fiber and protects the ceramic catalyst against vibra-
tions by the engine and the machine body. It also restrains the temperature of outer periphery of SCR as-
sembly from becoming high caused by a heat transfer of the ceramics during operation.
• Water dam (19) is located at the upstream side of the outlet and prevents rainwater from entering into
downstream SCR catalyst unit (3).
• Water baffle (20) is located at the downstream side of the outlet and prevents rainwater at outlet from
splashing over the detection part of NOx sensor.
D155AX-8 10-25
AdBlue/DEF TANK
STRUCTURE OF AdBlue/DEF TANK
A: Coolant inlet D: From AdBlue/DEF pump

B: Coolant outlet E: To breather
C: To AdBlue/DEF pump
1: Cap 5: Sight gauge
2: Sensor flange assembly 6: AdBlue/DEF tank filter
3: AdBlue/DEF tank sensor 7: Drain plug
4: AdBlue/DEF tank
10-26 D155AX-8
AdBlue/DEF TANK SENSOR

STRUCTURE OF AdBlue/DEF TANK SENSOR
REMARK
1: Connector 3: Temperature sensing part

2: Concentration Sensing part 4: Level sensing part
FUNCTION OF AdBlue/DEF TANK SENSOR

• This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and
AdBlue/DEF temperature through CAN communication.
• AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.
D155AX-8 10-27
AdBlue/DEF PUMP
STRUCTURE OF AdBlue/DEF PUMP
A: Suction from AdBlue/DEF tank A B C
B: Return to AdBlue/DEF tank
2 3 4
C: Pressurized sending to AdBlue/DEF injector
1: AdBlue/DEF pump
2: AdBlue/DEF inlet connector
3: AdBlue/DEF backflow connector
4: AdBlue/DEF outlet connector
5: Electric connector
6: AdBlue/DEF filter cap
7: AdBlue/DEF filter (built-in)
5 1 6
7 A4P15768
• The followings are built-in: The filter to collect the dust in

AdBlue/DEF, the valve to switch the flow direction when
purging, and the heater to thaw AdBlue/DEF when it is fro-
zen.
• It purges AdBlue/DEF from AdBlue/DEF tank, pressurizes
it to 900 kPa {9.18 kg/cm2} , and sends it to AdBlue/DEF 2 3 4
injector.
• To prevent wrong connection of connectors, the backflow
connectors are white and can be distinguished from oth-
ers. The sizes of inlet connector and outlet connector are
different and they cannot be connected each other.
P
A4P14894
10-28 D155AX-8
AdBlue/DEF INJECTOR
STRUCTURE OF AdBlue/DEF INJECTOR
A: Pressurized sending from AdBlue/DEF pump
B: Flowing in coolant
C: Flowing out coolant
1: AdBlue/DEF injector
2: AdBlue/DEF inlet connector
3: Coolant inlet connector
4: Coolant outlet connector
5: Electric connector
FUNCTION OF AdBlue/DEF INJECTOR

• It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.
• The injection amount is controlled by the valve opening or closing time while the pressure is constant.
• It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.
OPERATION OF AdBlue/DEF INJECTOR

Principle of injection of the injector is described. Following fig- 1 2 3
ure shows the state of injection. 4
1. Engine controller sends the electrical signal controlled by
AdBlue/DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves
from injection port (1) to make opening state.
Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.
3. When the electrical signal is not sent, seal ball (2) closes
injection port (1) with spring force (3), so AdBlue/DEF is
not injected. A4P15772
D155AX-8 10-29
AdBlue/DEF HOSE
STRUCTURE OF AdBlue/DEF HOSE
1: Connector 5: Insulation tape

2: Housing 6: Heating wire
3: Coupling 7: Nylon tube
4: Corrugated tube
• It is used as AdBlue/DEF piping between AdBlue/DEF tank and AdBlue/DEF pump or between AdBlue/DEF
pump and AdBlue/DEF injector.
• The shape of the engaging portion between AdBlue/DEF tank and AdBlue/DEF pump or AdBlue/DEF injec-
tor pin is based on 3/8 inches or 5/16 inches of SAE J2044. It can be installed or removed by one touch.
• There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.
• There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one accord-
ing to the model and the part to use.
FUNCTION OF AdBlue/DEF HOSE

• In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It
heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube while machine is stopped.
• It also keeps temperature to prevent AdBlue/DEF from freezing again while machine is operated.
10-30 D155AX-8
AdBlue/DEF TANK HEATING VALVE

STRUCTURE OF AdBlue/DEF TANK HEATING VALVE
A: Engine coolant inlet B: Engine coolant outlet

1: Solenoid 5: Plunger
2: Solenoid core 6: Diaphragm
3: Solenoid coil 7: Valve
4: Spring
FUNCTION OF AdBlue/DEF TANK HEATING VALVE

• AdBlue/DEF tank heating valve thaws AdBlue/DEF tank, and opening/closing of the valve (7) is done by
solenoid (1).
• The opening position of valve is fixed and the control is only for opening/closing. When the solenoid valve
(1) is de-energized, the valve is closed.
• Diaphragm (6) prevents entering of engine coolant into solenoid valve (1).
OPERATION OF AdBlue/DEF TANK HEATING VALVE

1. When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (1)
which is directly connected to plunger (5).
2. When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down
by spring (4) and valve (7) is closed.
D155AX-8 10-31
SYSTEM OPERATING LAMP SYSTEM 10 STRUCTURE AND FUNCTION
BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
SYSTEM OPERATING LAMP SYSTEM DIAGRAM
1: Battery disconnect switch 6: Machine monitor

2: Battery 7: Engine controller
3: Circuit breaker 8: Power train controller
4: Fuse box 9: Work equipment controller
5: System operating lamp 10: KOMTRAX terminal
FUNCTION OF SYSTEM OPERATING LAMP

The operation state of each controller is checked by ON/OFF of the system operating lamp.
This lamp is lit while any controller is in operation. Accordingly, the operator must not shut off the battery power
circuit while this lamp is lit.
k Before shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and
check that the system operating lamp goes out, then turn the battery disconnect switch to “OFF”
position.
k If the battery disconnect switch is turned to “OFF” position (battery power supply circuit is OFF)
while the system operating lamp is lit, data loss error of controller may occur. Never operate the bat-
tery disconnect switch while the system operating lamp is lit.
REMARK
• The system operating lamp goes out in max. 6 minutes after the starting switch is turned to “OFF” position.
• The system operating lamp may sometimes light up while the starting switch is turned to “OFF” position be-
cause KOMTRAX terminal may maintain its communication under this condition.
ON and OFF of system operating lamp
• Voltage of 24 V is constantly applied to one side of system operating lamp (LED (Light Emitting Diode)).
• When any controller is in operation, the controller side outputs Low (0 V), and a current flows through the
diode and the system operating lamp lights up.
• When all controllers are stopped, the controller side outputs High (24 V), and no current flows through the
diode and the system operating lamp goes off.
• KOMTRAX terminal performs communication periodically even if the starting switch is kept in “OFF” posi-
tion, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication state and machine stop time. So the lamp can be lit as long as approximately 1 hour.
10-32 D155AX-8
10 STRUCTURE AND FUNCTION SYSTEM OPERATING LAMP SYSTEM
REMARK
• The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the minute
leakage of current and not an abnormal phenomenon.
• When you want to cut off the battery circuit for maintenance but the system operating lamp is kept lit, turn
the starting switch to “ON” position once, and then turn it to “OFF” position, and the lamp goes out in max. 6
minutes.
After the system operating lamp goes out, turn the battery disconnect switch immediately to “OFF” position.
• After the engine is stopped, AdBlue/DEF in AdBlue/DEF injector or AdBlue/DEF pump is automatically
sucked into AdBlue/DEF tank to prevent malfunction caused by freezing of AdBlue/DEF or deposition of
urea. Accordingly, the system operating lamp keeps lit for a while after the starting switch is turned to “OFF”
position, and this is normal.
D155AX-8 10-33
BATTERY DISCONNECT SWITCH 10 STRUCTURE AND FUNCTION
BATTERY DISCONNECT SWITCH

LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH
1: Battery disconnect switch 2: System operating lamp
FUNCTION OF BATTERY DISCONNECT SWITCH

(O): OFF position
(I): ON position
• Usually, battery disconnect switch (1) is used instead of
disconnecting the cable from the negative terminal of the
battery in the following cases.
• When storing the machine for a long period (1 month
or longer)
• When servicing or repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
• When battery disconnect switch (1) is turned to OFF position (the contact is opened), all the continuous
power supplies for the components, including the starting switch B terminal and controllers, are all cut out,
and the condition is the same as the condition when the battery is not connected. Accordingly, all of the
electrical system of the machine does not operate.
NOTICE
• Do not turn OFF battery disconnect switch (1) while the system operating lamp is lit.
If battery disconnect switch (1) is turned OFF while the system operating lamp is lit, the data in the
controller may be lost and the controller may be damaged seriously.
• Do not turn OFF battery disconnect switch (1) while the engine is running or immediately after the
engine is stopped.
If battery disconnect switch (1) is turned OFF while the alternator is generating power, the generated
current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may
cause serious damage to the electrical system, including the electric devices and controllers.
10-34 D155AX-8
10 STRUCTURE AND FUNCTION BATTERY DISCONNECT SWITCH
REMARK
• The system operating lamp lights up while the controller is in operation or AdBlue/DEF pump is in operation.
It lights up when KOMTRAX is performing communication, even if the starting switch is set to OFF position.
• If battery disconnect switch (1) is turned OFF for a long period, the machine monitor and the clock of the
radio may be initialized. In this case, re-setting is required.
D155AX-8 10-35
LAYOUT DRAWING OF ENGINE RELATED PARTS 10 STRUCTURE AND FUNCTION
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE RELATED PARTS
1: Air Cleaner 4: Fuel prefilter

2: SCR assembly 5: Fuel main filter
3: Engine oil filter 6: Drain plug
10-36 D155AX-8
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF ENGINE RELATED PARTS
7: Front engine mount 13: KDPF

8: Alternator 14: KCCV ventilator
9: Vibration damper 15: KVGT
10: Auto-tensioner 16: Starting motor
11: EGR cooler 17: Rear engine mount
12: Engine controller
D155AX-8 10-37
ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM

LAYOUT OF ENGINE CONTROL SYSTEM
1: Fuel supply pump 6: Fuel control dial

2: Starting motor 7: Power train controller
3: Decelerator potentiometer 8: Battery relay
4: Starting switch 9: Battery disconnect switch
5: Decelerator pedal 10: Battery
• The throttle signals of the fuel control dial are sent to the power train controller and processed together with
the 3rd throttle signal, and then sent as the throttle commands together with the throttle signals of the de-
celerator pedal to the engine controller.
• The engine controller controls the engine corresponding to the commands.
ENGINE CONTROL SYSTEM DIAGRAM

REMARK
The figure below shows the engine control system.
10-38 D155AX-8
10 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
D155AX-8 10-39
ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF ENGINE CONTROL SYSTEM
• The engine controller receives the fuel control dial signals of the 1st throttle, decelerator pedal signals of
the 2nd throttle, and 3rd throttle signals which are the control signals from the power train controller, and
then controls the fuel supply pump corresponding to the command signals of the lowest engine speed.
• The 3rd throttle control signals are deceleration in reverse travel, deceleration in neutral, etc.
• The power train controller calculates a proper engine speed from information of deceleration in reverse
travel, deceleration in neutral, etc., and sends it as the 3rd throttle signal to the engine controller.
• The information of the engine controller is shared with the other controllers through the network and used
for the optimum control of the engine and machine.
• Deceleration in reverse travel is the function that restricts the idle engine speed to adjust reverse speed to
the set speed when reverse slow mode is selected.
• Deceleration in neutral is a function to limit the high idle speed while the transmission is in neutral.
10-40 D155AX-8
10 STRUCTURE AND FUNCTION AUTOMATIC IDLE STOP SYSTEM
AUTOMATIC IDLE STOP SYSTEM

SYSTEM OPERATING AUTOMATIC IDLE STOP SYSTEM DIAGRAM
Input/output signal
a: CAN signal c: Lock lever signal
b: Various sensor signals
1: Work equipment lock lever 8: KOMTRAX terminal
2: Work equipment lock lever switch 9: Work equipment controller
3: Parking brake lever 10: Hydraulic oil temperature sensor
4: Parking brake lever switch 11: Coolant temperature sensor
5: Power train controller 12: Torque converter oil temperature sensor
6: Machine monitor 13: Engine
7: Engine controller
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM DIAGRAM

• When the auto idle stop function is enabled and the conditions for operation are satisfied, the engine is
stopped after the set time.
• The auto idle stop function stops the engine when the power train controller sends the engine stop signal to
the engine controller.
• When the engine is stopped by the auto idle stop function, if the remaining time of the auto idle stop is less
than 30 seconds, the engine speed is fixed to low idle.
• The operating time of the auto idle stop function can be set by the user menu or service menu on the ma-
chine monitor.
Operating condition of automatic idle stop system
The auto idle stop function starts when all of the following conditions are satisfied at the same time.
• Engine is running.
D155AX-8 10-41
AUTOMATIC IDLE STOP SYSTEM 10 STRUCTURE AND FUNCTION
• Parking brake lever is in “LOCK” position.

• Work equipment lock lever is in “LOCK” position.
• Engine automatic warm-up function is not in "Normal warm-up" mode.
• Engine coolant temperature is below 95 °C.
• Hydraulic oil temperature is below 95 °C.
• Torque converter oil temperature is below 120 °C.
• Hydraulic fan is not turning in reverse.
• After-treatment devices is not being regenerated.
• Auto idle stop time on machine monitor is not reset. (*1)
• Machine monitor is not in service mode.
• None of following failure codes is occurring.
*1: See "Setting time".
Corresponding failure codes are as follows.
Failure code Failure (displayed on screen)
B@BCNS Engine Coolant Overheat
B@HANS Hydraulic Oil Overheat
B@CENS T/C Oil Temperature Overheat
CA144 Coolant Temperature Sensor High Error
CA145 Coolant Temperature Sensor Low Error
D8AQKR CAN 2 Defective Communication (KOMTRAX)
DBERKR CAN 1 Defective Communication (P/T Controller)
DBEQKR CAN 2 Defective Communication (P/T Controller)
DB9RKR CAN 1 Defective Communication (W/E Controller)
DB9QKR CAN 2 Defective Communication (W/E Controller)
DAFQKR CAN 2 Defective Communication (Monitor)
DB2RKR CAN 1 Defective Communication (Engine Controller)
DB2QKR CAN 2 Defective Communication (Engine Controller)
DGT1KA T/C Oil Temperature Sensor Open Circuit
DGS1KA Hydraulic Oil Temperature Sensor Open Circuit
Setting time
The set time for the auto idle stop function is set in the following menus.
For setting of each menu, see Testing and adjusting.
Fixing auto idle stop time (service menu)

Setting Contents of setting
In Auto Idle Stop Timer Setting (user menu), operator can select OFF or minimum set time in auto
Variable
idle stop setting to maximum time of 60 minutes. (Default)
The auto idle stop function does not operate, and Auto Idle Stop Time Setting (user menu) is not
OFF
displayed.
Operator can select from the set time in Auto Idle Stop Timer Setting (user menu) to x minutes (set
Fix to x min.
time at left). (Cannot select OFF)
10-42 D155AX-8
10 STRUCTURE AND FUNCTION AUTOMATIC IDLE STOP SYSTEM
Auto Idle Stop Timer Setting (user menu)

Setting Contents of setting
OFF Auto idle stop function does not operate. (Default)
y min. Stop the engine at Y minutes (set time at left) after setting the lock lever to “LOCK” position.
NOTICE
When "Fix to x min." is selected in the “Auto Idle Stop Time Fixing” (service menu), the screen changes
to the operator screen automatically and the auto idle stop function operates 60 minutes after the lock
lever is set to LOCK position, even if the Service menu is being used.
When performing work with the Service menu, always check the set value of the auto idle stop function.
D155AX-8 10-43
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF ENGINE SYSTEM

DAMPER
STRUCTURE OF DAMPER
Structure drawing
1: Dipstick 6: Flywheel
2: Breather 7: Outer body
3: Cover 8: Rubber coupling
4: Universal joint 9: Inner body
5: Drain plug 10: Output shaft
10-44 D155AX-8
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM
11: Coupling
FUNCTION OF DAMPER
• The damper, decreases the torsional vibration caused by the change in engine torque and the impact tor-
que generated when accelerating suddenly or when performing heavy-duty digging. In this way, it acts to
protect the torque converter, transmission, and other parts of the power train.
• The damper uses a rubber coupling, so the vibration is absorbed by the damping effect of the rubber mate-
rial. Also, the damper has few component parts.
OPERATE DAMPER
The power from the engine is transmitted to outer body (2) through flywheel (1). The torsional vibration of the
engine is absorbed by rubber coupling (3). Then, the power is transmitted to inner body (4) and further transmit-
ted to the torque converter and transmission through universal joint (5).
KVGT
KVGT
Abbreviation for KOMATSU Variable Geometry Turbocharger
STRUCTURE OF KVGT
REMARK
D155AX-8 10-45
General view, sectional view
A: Intake air inlet C: Exhaust inlet

B: Intake air outlet D: Exhaust outlet
1: Blower housing 7: Nozzle ring
2: KVGT speed sensor 8: Push rod
3: Hydraulic actuator 9: Shaft
4: Turbine housing 10: Blower impeller
5: Plate 11: Turbine impeller
6: Vane 12. Piston
10-46 D155AX-8
FUNCTION OF KVGT
C: Blower impeller
T: Turbine impeller
1: Air Cleaner
2: KVGT
3: KDPF, AdBlue/DEF mixing tube, SCR assembly
4: EGR cooler
5: EGR valve
• The exhaust gas regulations are applied to the exhaust gas from the engine running at low speed, as well
as at high speed. To meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount
of fresh suction air)
• To attain high EGR ratio, turbine inlet pressure (P3) must be set higher than boost pressure (P2) (P3 > P2).
For this reason, the variable turbocharger (KVGT) is employed, in which the exhaust gas pressure acting
on turbine impeller (T) is adjustable.
Also, since the boost pressure increases more quickly, generation of particulate caused by lack of oxygen
during low-speed operation (rotation) is reduced.
• The shaft joined to turbine impeller (T) drives blower impeller (C) and sends much air to the cylinder for
combustion.
If KVGT (2) sends more air, the fuel injection rate can be increased, thus the engine output is increased.
In addition, the air cooled by aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel in-
jection rate can be increased and the engine output is increased.
NOTICE
Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual
when replacing oil or oil filter.
D155AX-8 10-47
OPERATE KVGT
1. The exhaust gas enters (C) of turbine housing (4) and flows out through portion (P) and (D). Portion (P) is
surrounded by plate (5) fixed to turbine housing, nozzle ring (7), and vanes (6).
The area of its passage is changed by sliding push rod (8) to the right or left.
2. Hydraulic actuator (3) moves piston (12) in the actuator up and down with the hydraulic pressure controlled
by EPC valve installed to the front cover, and slides push rod (8) to the right and left.
3. The exhaust gas flowing through vanes (6) rotates blower impeller (10) through shaft (9) joined to turbine
impeller (11). As the result, the blower impeller works as a compressor, and the intake air entering through
(A) is compressed and discharge through (B).
4. When the exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed is in low range),
push rod (8) slides to the right and narrows portion (P).
5. The exhaust gas acting on turbine impeller (11) increases, the turbocharger speed increases, and more air
(oxygen) is taken in.
KVGT speed sensor (2) detects the rotation of the turbocharger.
When nozzle ring is "closed"
1. During low speed operation (rotation), exhaust gas inlet
passage (P) is narrow (L1). (It is not fully closed, however.)
2. If the turbine inlet pressure increases while the nozzle ring
is closed, the turbine inflow speed increases, and accord-
ingly the turbocharger speed increases.
10-48 D155AX-8
When nozzle ring is "open"

1. During high speed operation (rotation), exhaust gas inlet
passage (P) is wide (L2).
2. As the engine speed increases and the turbine inlet pres-
sure (exhaust gas pressure) increases accordingly, ex-
haust gas inlet passage (P) is widened (L2) so that the ex-
haust gas acts on turbine impeller (11) efficiently.
REMARK
• Nozzle ring (7), vanes (6), and push rod (8) are made in
one unit, and it slides only and does not rotate.
• Hydraulic actuator (3) is equipped with KVGT position sen-
sor. KVGT position sensor is calibrated together with the
variable mechanism of KVGT and the result is written in the
memory in KVGT position sensor. Accordingly, if any of hy-
draulic actuator (3), KVGT position sensor, and KVGT unit
fails, whole KVGT must be replaced.
Operation of hydraulic actuator
1. Hydraulic actuator (6) is reciprocated by the oil pressure
controlled by EPC valve (8) installed to EGR valve (10).
2. The hydraulic pressure supplied by engine boost oil pump
(12) is used for this purpose.
3. The position of hydraulic actuator (6) is fed back to engine
controller by the signals from KVGT position sensor (5).
EGR SYSTEM
EGR
Abbreviation for Exhaust Gas Recirculation
LAYOUT DRAWING OF EGR SYSTEM

REMARK
D155AX-8 10-49
1: KVGT 5: Intake connector

2: Intake manifold 6: EGR cooler
3: Mixing connector 7: Exhaust manifold
4: EGR valve
FUNCTION OF EGR SYSTEM

• EGR valve (hydraulically driven) (4) controls the gas flow from the exhaust section to the intake section.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake section.
• EGR cooler (6) cools the exhaust gas.
Engine coolant is used to cool the exhaust gas.
• Mixing connector (3) returns the air from the air-cooled aftercooler and the exhaust gas from EGR valve to
the intake section.
• Always exhausts the clean gas by controlling EGR circuit based on information sent from sensor installed to
each part to obtain EGR rate according to the operating condition.
• Monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure from
occurring.
10-50 D155AX-8
CIRCUIT DIAGRAM OF EGR SYSTEM
C: Blower impeller T: Turbine impeller

1: Air cleaner 9: EGR valve lift sensor
2: KDPF, AdBlue/DEF mixing tube, SCR assembly 10: Exhaust manifold
3: Ambient pressure sensor 11: Engine boost oil pump
4: Aftercooler 12: Intake manifold

5: EGR cooler 13: Charge (boost) pressure and temperature sensor
6: EGR valve 14: Engine controller
7: Hydraulic actuator (power piston) 15: Mixing connector
8: EPC valve (for EGR valve)
OPERATION OF EGR SYSTEM

1. The engine controller outputs signals in order to open EGR valve (6) most properly in accordance with the
engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.
2. When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10) into
EGR cooler (5) through the EGR piping.
3. The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6), merges with the supply air in the
mixing connector (15), and flows into the air intake manifold (12).
EGR VALVE
EGR
D155AX-8 10-51
STRUCTURE OF EGR VALVE

Structure drawing
REMARK
A: EGR gas inlet (from EGR cooler) D: Servo drive oil outlet
B: EGR gas outlet (to intake manifold) E: KVGT control hydraulic outlet
C: Servo drive oil inlet F: KVGT drive pressure outlet
1: Valve 5: Spring
2: Spring 6: EGR valve lift sensor
3: Power piston 7: EPC valve (for EGR)
4: Spool 8: EPC valve (for KVGT)
Structure
• EGR valve consists of the EGR gas flow control mechanism and EPC valve.
• There are 2 EPC valves, one for the EGR valves control and one for the KVGT control.
10-52 D155AX-8
OPERATE EGR VALVE

1. The oil from the boost oil pump flows in port (C) of EGR
valve. 　The control pressure from EPC valve enters port
(E).
2. Spool (4) is moved to the right by the reaction force of
spring (5), and EGR valve (1) is closed by the reaction for
of spring (2). Accordingly, the exhaust gas from EGR cool-
er does not flow to the intake side.
3. To open EGR valve (1), the control pressure from EPC
valve enters port (E) first. The position of spool (4) is deter-
mined by the balance of the control pressure and spring
(5).
4. Since the hydraulic circuit of power piston (3) opens, the
oil from the engine boost oil pump flows through port (C) and pushes power piston (3) to the left.
5. The oil from the boost oil pump acts on power piston (3) and generates force (Fp).
6. When force (Fp) increases more than reaction force (Fs) of spring (2), EGR valve (1) opens and the ex-
haust gas flows to the intake side.
7. Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) is stop-
ped at a position determined by spool (4).
8. The engine controller controls the valve position by controlling the spool position with the control pressure
of EPC valve.
9. Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which is
in contact with power piston (3).
10. EGR valve lift sensor senses the displacement of spool (4).
EGR COOLER
EGR
STRUCTURE OF EGR COOLER

REMARK
D155AX-8 10-53
General view, sectional view
A: EGR gas inlet D: Coolant outlet

B: EGR gas outlet (to EGR valve) E: Air vent
C: Coolant inlet F: Air vent
1: Header plate 3: Inner fin
2: Flat tube 4: Case
OPERATE EGR COOLER

REMARK
10-54 D155AX-8
1. EGR gas enters through (A) and flows through flat tubes
(2) (11 pieces).
2. Coolant enters through (C), flows outside of flat tubes (2)
in the shell, and goes out through (D).
3. Flat tube (2) has inner fins (3), thus EGR gas is cooled effi-
ciently and discharged through EGR gas outlet (B).
KCCV SYSTEM
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
LAYOUT DRAWING OF KCCV SYSTEM

REMARK
D155AX-8 10-55
A: Blowby gas C: Removed engine oil (to engine oil pan)

B: Blowby gas from which engine oil is removed (to
KVGT)
1: CDR valve 3: Check valve
2: KVGT 4: KCCV ventilator
FUNCTION OF KCCV SYSTEM

• Blowby gas (A) was discharged into the atmosphere as it was in the past, but it is not allowed to do so
because of the strict emission regulations.
• Blowby gas (A) contains ingredients of the engine oil. If it is recirculated to KVGT (2) as it is, it causes the
following problems. To prevent this, a filter is installed to KCCV ventilator (4) to remove the engine oil.
• Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
• Abnormal combustion in engine
• Malfunction of each sensor caused by sticking engine oil
10-56 D155AX-8
OPERATION OF KCCV SYSTEM

Drawing on the left shows the conventional flow of blowby gas. Drawing on the right shows the flow of blowby
gas which is sucked in KCCV ventilator and recirculated.
A: Blowby gas C: Engine oil

B: Clean gas
1: Air cleaner 5: Breather
2: KVGT 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Cylinder block (crankcase)
1. This system removes engine oil (C) mixed into blowby gas (A) in cylinder block (4) by using the filter in
KCCV ventilator (6), and recirculate clean gas (B) to the air intake side of KVGT (2).
2. Separated engine oil (C) is drained to engine oil pan (7) through the check valve.
KCCV VENTILATOR
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
STRUCTURE OF KCCV VENTILATOR

REMARK
D155AX-8 10-57
General view and sectional view
A: Blowby gas inlet (engine breather) D: Coolant inlet

B: Blowby gas outlet (to KVGT intake side) E: Coolant outlet
C: Oil drain port (to engine oil pan)
1: Heater tube 5: Filter
2: Crankshaft case pressure sensor 6: Relief valve
3: Case 7: Impactor
4: CDR valve
Structure
• Filter (5) is classified by the working direction for filter replacement into the top load type (removed upward)
and bottom load type (removed downward).
• The top load type (removed upward) and bottom load type (removed downward) are different from each
other in the position of the Crankshaft case pressure sensor.
In the top load type (removed upward), the Crankshaft case pressure sensor is installed to the blowby gas
inlet piping.
In the bottom load type (removed downward), the Crankshaft case pressure sensor is installed to the top of
KCCV ventilator.
FUNCTION OF KCCV VENTILATOR

• If the blowby gas is returned to the intake side of KVGT and crank case pressure becomes negative, the
dust may be sucked in through crank seal.
To prevent this, the pressure inside the crankcase is controlled by CDR valve (2).
• Crankcase pressure may increases and oil leakage may occur if filter (5) of KCCV ventilator is clogged.
To prevent this, crankcase pressure sensor (3) detects the clogging of filter (6).
• Keep the KCCV ventilator warm with warmed-up engine coolant, and prevent clogging of blowby gas pas-
sage due to freeze.
10-58 D155AX-8
• Relief valve (3) is inside of case (1), and it operates when filter (5) is blocked to bypass the blowby gas and
protect both KCCV ventilator and the engine.
OPERATE KCCV VENTILATOR

REMARK
1. Blowby gas enters at valve (A). Large drops of oil mist (atomized engine oil) are removed from the blowby
gas when it flows through impactor (4) holes in filter (5).
2. Small oil mist is separated in filter (5).
3. Separated oil flows down in the filter to go through oil drain port (C) to the oil pan.
4. CDR valve operates by KVGT intake negative pressure to prevent generation of excessive crankcase neg-
ative pressure.
5. Blowby gas pressure (crankcase pressure) is detected by crankcase pressure sensor (2).
6. If the engine controller judges through detected value of crankcase pressure sensor (2) that the filter is
clogged, it displays failure code CA555, and if the pressure increases further, it displays failure code
CA556.
7. Relief valve (3) is inside of case (1) and it operates when filter (5) is blocked to protect both KCCV ventilator
and the engine.
CDR VALVE
CDR
Abbreviation for Crankcase Depression Regulator
D155AX-8 10-59
OPERATION OF CDR VALVE

1. Normally, diaphragm (1) is pushed up by spring (2), there-
fore the blowby gas flows from crankcase side (A) into
KVGT side (air intake side) (B).
2. As the intake air at KVGT side (air intake side) (B) increas-
es, pressure on crankcase side (P1) decreases.
3. The reaction force of spring (2) is overwhelmed by ambient
pressure (P2). Diaphragm (1) shuts the passage and tem-
porarily blocks the flow.
4. When the blowby gas accumulates in the crankcase, pres-
sure (P1) on the crankcase side increases, and it pushes
up diaphragm (1) again and blowby gas starts to flow.
KDPF
KDPF
Abbreviation for KOMATSU Diesel Particulate Filter
STRUCTURE OF KDPF
General view
REMARK
A: From KVGT C: Water drain

B: Exhaust
1: KCSF unit 4: KDOC inlet temperature sensor
2: Connector block box 5: KDOC unit
3: Inlet unit 6: KDPF differential pressure sensor port
10-60 D155AX-8
7: KDOC outlet temperature sensor 12: Hanger bracket

8: KDPF differential pressure sensor 13: Sensor bracket
9: KDPF differential pressure sensor port 14: Sensor bracket band
10: Outlet unit 15: Water drain port
11: KDPF outlet temperature sensor
Structure
• KDPF consists of inlet unit (3) to introduce the exhaust gas, KDOC unit (5) to store the oxidation catalyst,
KCSF unit (1) to store the soot collecting filter equipped with catalyst, and outlet unit (10) to discharge the
exhaust gas and prevent rainwater from entering through outlet into KCSF unit with the built-in “weir”.
• KDOC unit (5) consists of a ceramic honeycomb with oxidation catalyst. This ceramic honeycomb works to
properly perform the following 2 actions; Oxidize NO (nitrogen monoxide) into NO2 (nitrogen dioxide) and
burn the fuel injected during automatic regeneration and manual stationary regeneration (*1).
• This ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceram-
ics under the vibration condition of the engine and machine body.
• This mat also thermally insulates the periphery of KDPF from the ceramics which becomes high tempera-
ture during operation.
• KCSF unit (1) also consists of ceramic honeycomb with oxidation catalyst, similarly to KDOC unit (5). This
ceramic honeycomb captures soot.
• KDPF is equipped with 3 temperature sensors and 1 differential pressure sensor (1 unit made of KDPF dif-
ferential pressure sensor and KDPF outlet pressure sensor).
• These 3 temperature sensors are used to monitor the functions of KDOC and KCSF and troubleshoot vari-
ous items by combining the sensed temperatures.
• The differential pressure sensor detects the soot level accumulated in KCSF by detecting the pressure dif-
ference over KCSF. It is also used to troubleshoot many items, similarly to the temperature sensors.
*1: Soot purification (oxidation) treatment.
FUNCTION OF KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramics honeycomb
• KDPF purifies the exhaust gas by catching large amount of
chainlike soot or PM (Particulate Matter such as soot)
which is contained in the engine exhaust gas.
• KDOC (oxidation catalyst) (1) oxidizes (nitrogen monoxide)
contained in the exhaust gas into NO 2 (nitrogen dioxide),
and regenerates (*1) soot accumulated in KCSF(2).
• KCSF (2) captures soot.
• The amount of accumulated soot in KCSF (2) in operation
range where the temperature of exhaust gas is relatively
high state is naturally oxidized and burnt away by the ef-
fect of KDOC (oxidation catalyst) (1). (This is called “pas-
sive regeneration”)
REMARK
“Passive generation” cannot be performed if the light load
operation and low temperature state of the exhaust gas
continue. Accumulated soot is gradually increased.
D155AX-8 10-61
• Engine controller always monitors 2 soot accumulation values and compares them. One is presumed soot
accumulation based on the engine operating conditions, and the other is the calculated soot accumulation
based on the signal from the differential pressure sensor which is attached to KCSF (2).
• If the amount of accumulated soot and the temperature of engine exhaust gas exceed the specified level,
engine controller performs “automatic regeneration” to burn away (oxidation) the soot.
While performing automatic regeneration, the engine controller calculates the exhaust gas temperature at
KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust
gas. (This is called “exhaust gas temperature raise control”)
The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the fuel
doser installed at the turbocharger outlet part,and exhaust gas volume is controlled by KVGT.
The engine controller enhances the oxidation power in KDOC (1) by raising the temperature of engine ex-
haust gas automatically, and improves combustion efficiency of soot captured in KCSF (2).
REMARK
When regeneration function on the machine monitor is disabled, or outside air temperature is extremely
low, or continuous light load operation is carried out, relatively low exhaust temperature continues. In such
case, “automatic regeneration” is not performed and the amount of soot accumulation is increased.
• If “automatic regeneration” is not performed due to the excess amount of accumulated soot in KCSF (2),
perform “manual stationary regeneration” to burn (oxidation) the soot and reduce the amount of soot inside
KCSF (2).
REMARK
Excessive amount of the soot interferes the flow of exhaust gas to worsen fuel consumption and engine
combustion state. It may lead to other failures.
If the amount of soot increases further, “manual stationary regeneration” cannot be performed safely. This
will result in a KDPF failure and replacement is unavoidable. Make sure to follow the procedures in the Op-
eration and Maintenance Manual when performing “manual stationary regeneration”
*1: Soot purification (oxidation) treatment
TYPES OF REGENERATION FUNCTIONS

Regeneration means to purify (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF or
maintain the urea SCR system normal.
Natural regeneration
When the exhaust temperature of the engine is relatively high, the oxidation power of soot in the exhaust gas
components is increased by the catalysis of KDOC to oxidize (burn) the soot accumulated in KCSF naturally.
Active regeneration (engine exhaust temperature rise control + fuel dosing)
• Automatic regeneration
• When soot is accumulated more than a certain level or the urea SCR system makes a request to main-
tain itself normal, the engine enters the exhaust temperature rise control mode (*1) and performs fuel
dosing (*2) and starts regeneration automatically.
The automatic regeneration is also performed by the direction from the engine controller at a set time
after the previous regeneration, regardless of soot accumulation in KCSF.
*1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or KGVT.
*2: Fuel injection performed to accelerate regeneration by increasing the exhaust temperature.
• Manual stationary regeneration
• When the exhaust temperature does not reach a certain level, depending on the operating condition of
the machine, or when the operator disables regeneration, the automatic regeneration is not performed
and accumulated soot in KCSF increases. Also, when the automatic regeneration is performed upon
receiving a request from the urea SCR system, the exhaust temperature may not reach a certain level,
depending on the operating condition of the machine. In these cases, a request for the manual station-
ary regeneration request is displayed on the machine monitor, and the operator must perform regener-
ation by the operation on the machine monitor screen.
In addition, when the engine controller is replaced or ash in KCSF is washed, a serviceman performs
regeneration by the operation on the machine monitor screen (“active regeneration for service”).
10-62 D155AX-8
NOTICE
• For the procedure to start and stop the regeneration of KDPF, see the Operation and Maintenance
Manual for each machine.
• Always use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a
failure in KDPF.
• Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the speci-
fied one, it can clog KDPF quickly, and that can increase fuel consumption and cause a failure in
KDPF.
• Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally
and may have trouble.
• Do not give strong impacts to KDPF by standing on it, dropping it, or hitting it, etc. KDPF has ceram-
ic parts in it, and they may be broken by a strong impact.
• Even when soot is not accumulated much, the engine controller may start "automatic regeneration".
This is automatic regeneration to maintain the function of KDPF or urea SCR system normal, and is
not an abnormal operation. Automatic regeneration to maintain the function of urea SCR system nor-
mal or manual stationary regeneration takes approximately 1 hour.
• During the “automatic regeneration” and the “manual stationary regeneration”, KVGT operates auto-
matically and the engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and ac-
cordingly the exhaust sound changes. These phenomena are not abnormal.
• During the “automatic regeneration” and the “manual stationary regeneration”, especially at low
temperature, white smoke may be discharged through the exhaust pipe outlet for a short time. This
phenomenon is not abnormal. Be sure to perform regeneration in a well-ventilated area, since car-
bon monoxide may be generated.
• During the “automatic regeneration” and the “manual stationary regeneration”, the exhaust pipe
may smell different from usual. This is not abnormal phenomenon.
• During the “automatic regeneration” and the “manual stationary regeneration”, the temperature of
the exhaust pipe discharged from the exhaust gas may increase above 650 °C. To prevent a fire,
check that there is no combustibles around the exhaust pipe. Also, check that there is no person in
the blow-out direction of the exhaust gas and confirm the safety around the machine.
• KDPF has “KDPF dry operation” function to prevent excessive accumulation of unburnt fuel in KDPF
when operation is continued at relatively low temperature for long hours.
• This is a function that the engine controller increases the engine exhaust temperature automatically
and performs dry operation of KCSF when the set condition is satisfied. When the automatic dry op-
eration is insufficient for the treatment, manual stationary regeneration may be required.
• The standard temperature of KDPF is shown below.
KDOC Out (KDOC out- KDPF Out (KDPF out-
KDOC In (KDOC inlet
let temperature sen- let temperature sen-
temperature sensor)
sor) sor)
While regeneration is not per-
100 to 250 °C
formed (idling state)
While regeneration is performed
100 to 250 °C 400 to 550 °C
(thermal mode: 1000 rpm)
D155AX-8 10-63
LAYOUT DRAWING OF COOLING SYSTEM 10 STRUCTURE AND FUNCTION
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
A: Aftercooler inlet hose C: Power train oil cooler inlet

B: Aftercooler outlet hose D: Power train oil cooler outlet
1: Pressure valve 2: Water filler cap
10-64 D155AX-8
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF COOLING SYSTEM
3: Air bleeding hose 11: Hydraulic oil cooler bypass valve

4: Radiator assembly 12: Hydraulic oil cooler
5: Overflow hose 13: Aftercooler
6: Inlet hose 14: Cushion
7: Reservoir tank 15: Cooling fan motor
8: Cooling fan pump 16: Fan
9: Outlet hose 17: Drain valve
10: Inlet hose (for circulation at coolant temperature 18: Lower tank (with built-in power train oil cooler)
low level)
SPECIFICATIONS OF COOLING SYSTEM

Radiator
Type of core: Rectangular corrugated fin
Fin pitch: 8.0/2P
Heat dissipation area: 40.05x3 m2
Relief pressure of pressure valve: 0.09 MPa {0.9 kg/cm2}
Vacuum pressure of pressure valve: 0.005 MPa {0.05 kg/cm2}
The reservoir tank is installed inside the right mudguard.
Aftercooler
Type of core: Rectangular straight fin
Fin pitch: 8.0/2P
Heat dissipation area: 23.15 m2
Power train oil cooler
Type of core: PTO-OL
Type of inner fin: TF8-C
Cooling method: Built in lower tank
The power train oil cooler is built in the lower tank.
Hydraulic oil cooler
Type of core: Rectangular corrugated fin (8.0/2P)
Type of inner fin: TF6-C
Cooling method: Cooling with air
D155AX-8 10-65
COMPONENT PARTS OF COOLING SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF COOLING SYSTEM

COOLING FAN PUMP
STRUCTURE OF COOLING FAN PUMP
General view
10-66 D155AX-8
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF COOLING SYSTEM
P1: Pump discharge port PS: Pump suction port

PAEPC: EPC output pressure pickup plug TO: Drain port
PEPC: EPC valve source pressure input port
1: Servo valve 2: Breather
Sectional view
1: Shaft 7: Cylinder block

2: Oil seal 8: Valve plate
3: Case 9: Spring
4: Rocker cam 10: Servo piston
5: Shoe 11: Ball retainer
6: Piston 12: End cap
D155AX-8 10-67
Structure
• Cylinder block (7) is supported on shaft (1) by spline (A).

• Shaft (1) is supported by each bearing at the front and rear.
• The end of piston (6) is a concave sphere, and it is caulked to be combined with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Shoe (5) slides in a circular pattern as always being presses against the flat surface (B) of rocker cam (4).
• Rocker cam (4) slides and pivots on ball (11).
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while seal the pressurized oil.
The oil pressure is balanced properly on this surface.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
SPECIFICATIONS OF COOLING FAN PUMP

Model: LPV75(64)
Type: Variable displacement swash plate type piston pump
Theoretical discharged volume: 64 cm3/rev
Fan drive pressure: 18.6 MPa {190 kg/cm2}
Rated speed: 2300 rpm
10-68 D155AX-8
FUNCTIONS OF COOLING FAN PUMP

• This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic energy and
discharges pressurized oil corresponding to the load.
• It is possible to change the discharged volume by changing the swash plate angle.
OPERATE COOLING FAN PUMP

Discharged volume selection (swash plate angle selection)
1. Cylinder block (7) rotates together with shaft (1) and shoe
(5) slides on plane (A).
2. Rocker cam (4) pivots on ball retainer (13), and according-
ly angle (a) between center line (X) of rocker cam (4) and
the axial direction of cylinder block (7) changes.
(a): Swash plate angle
D155AX-8 10-69
Suction and discharge of pressurized oil

1. While angle (a) is made between center line (X) of rocker
cam (4) and the axis of cylinder block (7), plane (A) works
as a cam for shoe (5).
2. Piston (6) slides inside cylinder block (7) and a difference
is made between volumes (E) and (F) in cylinder block (7).
3. Amount of (F) minus (E) per piston (6) is suctioned and
discharged.
4. Oil is discharged while cylinder block (7) rotates and the
volume of chamber (E) decreases.
5. Pressurized oil is suctioned as the volume of chamber (F)
increases.
Condition where no pressurized oil is suctioned in or discharged (swash plate

angle = 0)
1. When center line (X) of rocker cam (4) matches the axis of
cylinder block (7) (the swash plate angle is zero), the dif-
ference between volumes (E) and (F) inside cylinder block
(7) is zero.
2. Suction and discharge of pressurized oil is not performed
in this stage. Namely pumping action is not performed.
(Angle of swash plate never become zero.)
3. The pump discharged volume is in proportion to the swash
plate angle.
10-70 D155AX-8
Control of discharged volume

1. The swash plate angle (a) increases, the difference be-
tween volumes (E) and (F) increases, and also pump dis-
charged volume (Q) increases.
2. Swash plate angle (a) is changed by servo piston (10).
3. Servo piston (10) moves in a linear reciprocating motion
corresponding to the signal pressure from the servo valve.
This linear motion is transmitted to rocker cam (4).
4. Rocker cam (4) supported on ball retainer (11) slides
around ball retainer (11).
D155AX-8 10-71
SERVO VALVE OF COOLING FAN PUMP

STRUCTURE OF SERVO VALVE OF COOLING FAN PUMP
P: EPC valve source pressure PH: Pump discharged volume pressure

PE: Control piston pressure T: Drain port
1: Plug 5: Spool
2: Lever 6: Piston
3: Retainer 7: Sleeve
4: Seat 8: Spring
10-72 D155AX-8
FUNCTION OF SERVO VALVE OF COOLING FAN PUMP

The servo valve controls current (i) input to EPC valve and
pump discharged volume (Q) so that their relation is as shown
in the figure.
OPERATE SERVO VALVE OF COOLING FAN PUMP
1. The output pressure of EPC valve enters piston chamber (C) and pushes piston (3).
2. Piston (3) pushes spool (2) and moves to a position where it is balanced with the spring.
3. Land (PE) of the servo piston pressure passage is connected to pump discharged pressure passage (PH)
through the notch of spool (2), so the pump discharged pressure is transmitted to servo piston (6).
4. When rocker cam (5) is pushed up by servo piston (6), positional feedback is provided, and lever (1) moves
in the direction to compress spring (4).
5. When spool (2) is pushed back, the pump discharge circuit and servo piston circuit are disconnected.
D155AX-8 10-73
6. The pressure in the servo piston chamber decreases, and rocker cam (5) returns in the direction of the
maximum swash plate angle.
7. These processes are repeated, and the swash plate is fixed to a position where EPC output pressure is
balanced with the force of spring (4).
8. When EPC output pressure increases, the swash plate angle decreases. When EPC output pressure de-
creases, the swash plate angle increases.
COOLING FAN MOTOR

STRUCTURE OF COOLING FAN MOTOR
General view
P: From fan pump TC: To hydraulic tank

T: To oil cooler
1: Cooling fan reverse solenoid valve 2: Cooling fan speed sensor
10-74 D155AX-8
Sectional view
1: Output shaft 10: Cooling fan speed sensor

2: Case 11: Suction valve spring
3: Thrust plate 12: Suction valve
4: Shoe 13: Cooling fan reverse solenoid valve
5: Piston assembly 14: Pilot valve
6: Cylinder block 15: Reversible valve spool
7: Valve plate 16: Safety valve
8: End cover 17: Reversible valve spring
9: Center spring
SPECIFICATIONS OF COOLING FAN MOTOR

Model: LMF110(65)
Capacity: 65.1 cm3/rev
Rated flow rate: 80.7 ℓ/min
Check valve cracking pressure: 78.5 kPa {0.8 kg/cm2}
Safety valve cracking pressure: 18.6 kPa {0.19 kg/cm2}
D155AX-8 10-75
FUNCTION OF COOLING FAN MOTOR

It is a swash plate type axial piston motor. It converts the energy of the pressurized oil sent from the cooling fan
pump into rotary motion.
OPERATE COOLING FAN MOTOR

1. The pressurized oil sent from the pump flows through
valve plate (7) into cylinder block (5).
2. During the stroke of piston (4), the pressurized oil flows to
only either side of (Y-Y) which is connecting the top dead
center and bottom dead center.
3. The pressurized oil which flows in either side of cylinder
block (5) pushes pistons (4) (4 pieces or 5 pieces).
Each piston generates force F1 [F1 kg = P kg/cm2 x
πD2/4 cm2].
This force acts on thrust plate (2).
4. Since thrust plate (2) is fixed at angle (a) to output shaft
(1), the force is divided into components (F2) and (F3).
5. Radial component (F3) of these components generates
torque (T = F3 x ri) against (Y-Y) which is connecting the
top dead center and bottom dead center.
6. The combined force [T = ∑ (F3 x ri)] of these torques ro-
tates cylinder block (5) through pistons (4).
7. This cylinder block (5) is coupled with output shaft (1) by
spline.
8. Output shaft (1) rotates and transmits the torque.
10-76 D155AX-8
SUCTION VALVE OF COOLING FAN MOTOR

FUNCTION OF SUCTION VALVE OF COOLING FAN MOTOR
When the pump stops turning, no pressurized oil flows into the
motor. Since the motor is turned by the inertial force, the pres-
sure on the motor outlet side increases. When inflow of the
pressurized oil from inlet port (P) stops, suction valve (1) draws
in the pressurized oil on the outlet side and supplies it to port
(MA) to compensate for insufficiency in pressurized oil and pre-
vent cavitation.
OPERATE SUCTION VALVE OF COOLING FAN MOTOR

When engine is started
1. The pressurized oil from the cooling fan pump is supplied
to port (P), and the pressure on (MA) side increases.
2. When starting torque occurs in the motor, the motor starts
rotation.
3. The pressurized oil on the motor outlet (MB) side returns
to the tank through port (T).
D155AX-8 10-77
When engine is stopped

1. When the engine is stopped, the input speed of the cooling fan pump becomes 0 rpm.
2. No pressurized oil is supplied from the cooling fan pump to
port (P).
3. No pressurized oil flows to (MA) side of the motor, and
then motor speed decreases gradually.
4. If the motor shaft is rotated by inertial force while inflow of
pressurized oil to port (P) is reduced, the pressurized oil
on the outlet side is supplied by suction valve (1) to (MA)
side to prevent cavitation.
REVERSIBLE VALVE OF COOLING FAN MOTOR

OPERATE REVERSIBLE VALVE OF COOLING FAN MOTOR
When cooling fan reverse solenoid valve is "de-energized"
1. When coil (1) is "de-energized", the pressurized oil from
the pump is stopped by spool (2).
2. Port (C) is connected to the tank circuit.
3. Spool (3) is pushed to the right by spring (4).
4. Port (MA) opens, the pressurized oil flows in, and the mo-
tor rotates forward (clockwise).
10-78 D155AX-8
When cooling fan reverse solenoid valve is "energized"

1. When coil (1) is "energized", spool (2) is switched.
2. The pressurized oil from the pump flows into port (C), and
then into spool chamber (D).
3. The pressurized oil in chamber (D) compresses spring (4).
4. Spool (3) moves to the left.
5. Port (MB) opens, the pressurized oil flows in, and the mo-
tor rotates in reverse (counterclockwise).
SAFETY VALVE OF COOLING FAN MOTOR

FUNCTION OF SAFETY VALVE OF COOLING FAN MOTOR
The pressure in motor port (P) may increase when the engine
is started, etc. Safety valve (1) is installed to protect the fan
system circuit in this case.
D155AX-8 10-79
OPERATE SAFETY VALVE OF COOLING FAN MOTOR

When the pressure in port (P) exceeds the cracking pressure of
safety valve (1), valve (2) of safety valve (1) opens to release
the pressurized oil into port (T). Occurrence of abnormally high
pressure in port (P) is prevented by this operation.
10-80 D155AX-8
HYDRAULIC OIL COOLER BYPASS VALVE

STRUCTURE OF HYDRAULIC OIL COOLER BYPASS VALVE
Structure drawing
A: Hydraulic oil cooler inlet B: To tank

1: Body 3: Spring
2: Valve
SPECIFICATIONS OF HYDRAULIC OIL COOLER BYPASS VALVE

Specified cracking pressure: 0.5 MPa {5.1 kg/cm2}
FUNCTION OF HYDRAULIC OIL COOLER BYPASS VALVE

This valve is installed in the oil cooler inlet circuit. If any abnormal pressure is generated in the oil flowing to the
oil cooler, this valve acts to return the oil directly to the hydraulic tank.
D155AX-8 10-81
LAYOUT OF ELECTRICAL CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
CONTROL SYSTEM
LAYOUT OF ELECTRICAL CONTROL SYSTEM
1: Machine monitor 4: Communication antenna

2: Work equipment controller 5: GPS antenna
3: KOMTRAX terminal 6: Power train controller
10-82 D155AX-8
10 STRUCTURE AND FUNCTION PALM COMMAND CONTROL SYSTEM
PALM COMMAND CONTROL SYSTEM

PALM COMMAND CONTROL SYSTEM DIAGRAM
1: Machine monitor 9: Torque converter

2: Brake pedal 10: Torque converter control valve
3: Joystick (steering, directional and gear shift lever) 11: Transmission
4: Engine controller 12: Transmission control valve
5: Power train controller 13: HSS unit
6: Engine speed sensor 14: Brake control valve
7: Transmission output shaft speed sensor 15: Control valve
8: Engine 16: Steering control valve
D155AX-8 10-83
PALM COMMAND CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF GEAR SHIFT MODE

Types of gear shift mode
There are Automatic Shift Mode and Manual Shift Mode in the
gear shift mode. These modes are changed to each other each
time gear shift mode switch (1) is pressed.
Automatic Shift Mode
• When a load is applied, the gear is shifted down automati-
cally. When the load is reduced, the gear is automatically
shifted up to the maximum usable gear speed automatical-
ly.
• The torque converter locks up corresponding to loads and
the gear is shifted up to the set maximum gear speed au-
tomatically. In this mode, low fuel consumption and high
working efficiency can be obtained.
Manual Shift Mode
• When a load is applied while the auto shift down is ON, the gear is shifted down automatically. When the
load is reduced, however, the gear is not shifted up automatically.
• While the auto shift down is OFF, the operator shifts the gear up and down manually.
• While the auto shift down is ON, the gear is automatically shifted down when a load is applied.
• While the auto shift down is OFF, the gear is not automatically shifted down even when a load is applied.
Gear shift method
By pressing UP switch (1) or DOWN switch (2) on the joystick
(steering, directional, and gear shift lever), the operator can
perform gear shift operations and presettings.
Method to display on screen

The gear shift mode is displayed on the gear speed display portion of the machine monitor as shown below.
1: Current gear speed
2: “AUTO” mark which indicates Automatic Shift Mode
3: Symbol of Automatic Shift Mode
4: Preset (gear speed at start) and maximum gear speed for
travel
10-84 D155AX-8
10 STRUCTURE AND FUNCTION PALM COMMAND CONTROL SYSTEM
Manual Shift Mode

1: Current gear speed
2: “MAN” mark which indicates Manual Shift Mode
3: Symbol of Manual Shift Mode
4: Preset (gear speed at start)
Preset setting with shift switch operation in neutral

The maximum gear speed for travel (Automatic Shift Mode) and the gear speed at start (Manual Shift Mode) are
preset by operating the shift switch in neutral.
REMARK
• When the starting switch is turned to “ON” position, the system is set to “F1-R1” of Automatic Shift Mode.
• When the gear shift mode is switched, “F1-R1” is selected as the default.
Setting maximum gear speed for travel
Manual Shift Mode

Setting gear speed at start
Method to change gear speed with the shift switch operation during travel
By pressing the UP switch or DOWN switch while the machine is traveling, the maximum gear speed during
travel (in Automatic Shift Mode) or the current gear speed (in Manual Shift Mode) can be changed.
Changing the maximum gear speed while the machine is traveling
When traveling forward The maximum gear speed can be set to F1 to F3.
When traveling in reverse The maximum gear speed can be set to R1 to R3.
Each time this switch is pressed, the maximum gear speed is shifted up to the
UP switch
next range.
D155AX-8 10-85
PALM COMMAND CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
Each time this switch is pressed, the maximum usable gear speed is shifted
DOWN switch
down to the next range.
Manual Shift Mode

Changing gear speed for travel
When traveling forward The current gear speed can be set to F1 to F3.
When traveling reverse The current gear speed can be set to R1 to R3.
Each time this switch is pressed, the maximum gear speed is shifted up to the
UP switch
next range.
Each time this switch is pressed, the maximum usable gear speed is shifted
DOWN switch
down to the next range.
Gear speed setting for starting or changing travel direction on slope

• To ensure safety, the machine may start in 2nd “2” according to its condition when starting on an uphill in
3rd (Low) “3L”.
• To ensure safety, the machine starts in 1st “1” according to its condition and the minimum engine speed is
increased instantaneously when the travel direction is changed while traveling downhill.
10-86 D155AX-8
10 STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEM DIAGRAM
Input/output signal b: CAN signal

a: Power supply c: Sensor signal and switch signal
1: Machine monitor 4: Work equipment controller
2: Battery 5: Engine controller
3: Power train controller 6: Sensors and switches
FUNCTION OF MACHINE MONITOR SYSTEM

• The machine monitor system monitors the machine condition with the sensors installed to various parts of
the machine and processes and displays the obtained information on the monitor panel quickly to notify the
operator of the machine condition.
• The contents displayed on the panel are roughly classified as follows.
• Alarm when the machine has trouble
• Machine state (coolant temperature, torque converter oil temperature, fuel level, hydraulic oil tempera-
ture, etc.)
• Failure code
• Current and voltage values of the sensors and solenoids.
• Display of camera image
D155AX-8 10-87
MACHINE MONITOR SYSTEM 10 STRUCTURE AND FUNCTION
• The switches on the machine monitor have functions to control the machine.
Display on machine monitor

Contents and conditions of processing Method Flow of signals
Display of travel direction and gear speed.
• F1, R3, etc. are notified by CAN signal corresponding to in- CAN
formation of power train controller.
Display of gauges of fuel level, engine coolant temperature, etc.
• Controller converts the sensor signals into gauge numbers CAN
and sends them to the machine monitor by CAN.
Display of failure
• When any failure occurs, the corresponding failure code is Each sensor, solenoid
notified to the machine monitor by CAN signal.
↓
• The command to sound the buzzer or to light up the cau-
Controller
tion lamp is notified as well corresponding to the contents
of failure. ↓
When normal Machine monitor
• Action level and failure code CAN
In abnormality record display mode

• Failure codes and
- service meter reading at the first occurrence,
- service meter reading at the last occurrence,
- number of past occurrences,
are displayed on the machine monitor.
Monitoring display
The communication conditions of each sensor, each solenoid, and
CAN signals are displayed. Each sensor, solenoid
• The item Nos. and device conditions are notified to the ma- CAN ↓
chine monitor by CAN. Controller
• The machine monitor displays the items and each value. ↓
Each item is selected by using the cursor switches and enter Machine monitor
CAN
switch.
10-88 D155AX-8
10 STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
Others
Pre-defined Monitoring
Self-define Monitoring
Abnormality Record
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
- -
Default
Diagnostic Tests
Adjustment
No-Injection Cranking
KOMTRAX Settings
Service Message
REMARK
For details of the operating method, see Testing and Adjusting, "Special functions of machine monitor (EMMS)".
D155AX-8 10-89
KOMTRAX SYSTEM 10 STRUCTURE AND FUNCTION
KOMTRAX SYSTEM
KOMTRAX SYSTEM DIAGRAM
KOMTRAX system consists of KOMTRAX terminal, communication antenna, and GPS antenna
FUNCTION OF KOMTRAX SYSTEM

• KOMTRAX system transmits various types of information on the machine. KOMTRAX administrator sees
the information in the office and supplies various services to the customers.
• KOMTRAX system can transmits the following information.
• Positional information
• Working information
• Alarm and failure information
• Fuel consumption information
• Maintenance information
• Machine working condition information
REMARK
To provide the services, you need to establish radio station for KOMTRAX separately.
10-90 D155AX-8
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM

MACHINE MONITOR
FUNCTION OF MACHINE MONITOR
• The machine monitor has the monitor display function, mode selection function, and function of switching
the electrical components, etc. It also has the built-in alarm buzzer.
• CPU (Central Processing Unit) is mounted inside, and it processes, displays, and outputs information.
• The machine monitor consists of the display and switch section. The display is LCD (Liquid Crystal Dis-
play), and the switch section consists of flat sheet switches.
• If there is abnormality in the machine monitor, controller, or wiring between the machine monitor and con-
troller, the display does not display normally.
REMARK
• One of the features of liquid crystal display is that there may be black spots (spots that do not light up) or
white spots (spots that stay lit) on the screen. When there are fewer than 10 black or white spots, this is not
a failure or a defect.
• The battery voltage may drop sharply when the engine is started, depending on the ambient temperature
and battery condition. In this case, the display may disappear for a while. This phenomenon is not abnormal.
• When the machine monitor is used continuously, blue bright spots may appear on the black background.
This phenomenon is not abnormal.
Since the background of the standard screen of the display is blue or white, blue bright spots do not become
a problem. (Since red, green, or blue lamps light up when the LCD displays white)
D155AX-8 10-91
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR

070-18P [CN-CM01]
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
3 GND (continuous power supply) -
4 GND (continuous power supply) -
5 External starting signal Input
6 Starting motor cut-off relay Output
7 Buzzer signal Output
8 System operating Input/Output
9 Lamp switch Input
10 Starting switch ACC signal Input
11 Starting switch C signal Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 Analog GND -
15 Fuel level sensor Input
16 Alternator R signal Input
17 (*1) -
18 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.

070-12P [CN-CM02]
1 Seat belt alarm switch Input
2 (*1) -
3 Radiator coolant level sensor Input
4 Air cleaner clogging sensor Input
5 (*1) -
6 (*1) -
7 CAN0 terminating resistor terminal -
8 CAN0_H (KOMNET/c) Input/Output
9 CAN0_L (KOMNET/c) Input/Output
10 CAN1 terminating resistor terminal -
11 CAN1_H (KOMNET/r) Input/Output
12 CAN1_L (KOMNET/r) Input/Output
10-92 D155AX-8
070-20P [CN-CM03]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -

070-8P [CN-CM04]
1 Power supply for camera (8 V) Output
2 Camera NTSC signal Input
3 (*1) -
4 (*1) -
5 GND (power supply for camera) -
6 (*1) -
7 (*1) -
8 GND (shield) -
D155AX-8 10-93
TYPES OF GAUGES AND METERS DISPLAYED ON MACHINE MONITOR

Gauge Item displayed Description Remarks
Temperature Gauge • Indicates corresponding tempera-
Range
(°C) range ture range.
W1 105 Red • Alarm buzzer sounds at 105 °C or
(*1) higher.
W2 102 Red
Engine coolant • If the color of the gauge range is
temperature W3 100 Green white, perform warm-up operation.
gauge W4 85 Green
W5 60 Green
W6 30 White
Range
P1 130 Red • Alarm buzzer sounds at 130 °C or
(*1) higher.
P2 120 Red
Power train oil • If the color of the gauge range is
temperature P3 118 Green white, perform warm-up operation.
gauge P4 90 Green
P5 50 Green
P6 0 White
Range
H1 105 Red • Alarm buzzer sounds at 105 °C or
(*1) higher.
H2 102 Red
Hydraulic oil • If the color of the gauge range is
temperature H3 98 Green white, perform warm-up operation
gauge H4 70 Green for the hydraulic components.
H5 20 Green
H6 0 White
Quantity (lit- Gauge • Indicates corresponding level
Range
ers) range range.
F1 560 Green
(*4) F2 460 Green
Fuel level F3 376 Green
gauge
F4 197 Green
F5 150 Green
F6 106 Red
10-94 D155AX-8

Gauge • Indicates corresponding engine
Range Speed (rpm)
range speed.
M1 3000 Red • If the engine speed exceeds
(*1, *2)
2625 rpm, the engine overrun
M2 2625 Red
monitor lights up.
Engine tachom- M3 2000 Green
eter
M4 1500 Green
M5 1000 Green
M6 500 Green
Travel • Indicates corresponding travel
Gauge
Range speed speed.
range
(km/h)
(*1, *2) M1 15 Green
Speedometer M2 10 Green
M3 5 Green
M4 0 Green
Pressure Gauge • Indicates corresponding pump
Range
(MPa) range discharged pressure of work
M1 50 Green equipment
(*1, *2)
M2 40 Green
Hydraulic pump
oil pressure M3 30 Green
gauge M4 20 Green
M5 10 Green
M6 0 Green
Pressure Gauge • Indicates corresponding engine oil
Range
(MPa) range pressure.
M1 0.7 Green
(*1, *2) M2 0.5 Green
Engine oil pres- M3 0.4 Green
sure gauge
M4 0.3 Green
M5 0.2 Green
M6 0 Red
Gauge • Indicates corresponding battery
Range Voltage (V)
range voltage.
M1 31 Red
(*1, *2) M2 30 Red
Battery voltage M3 25 Green
gauge
M4 20 Green
M5 15 Green
M6 0 Red
D155AX-8 10-95

Gauge • Indicates corresponding drawbar
Range Power (W)
range pull.
M1 1.0 Green
(*1, *2) M2 0.8 Green
Drawbar pull M3 0.6 Green
gauge
M4 0.4 Green
M5 0.2 Green
M6 0 Green
Gauge • Indicates drawbar pull by several
Range Power (W)
range seconds.
(*1, *2) M1 0.70 Red • Horizontal axis indicates time and
Load display vertical axis indicates drawbar
M2 0.24 White pull. (The latest information is indi-
cated on rightmost.)
Gauge • Indicates pitch angle by several
Range Angle (°)
range seconds.
20 (For- • Horizontal axis indicates time and
M1 Gray
ward) vertical axis indicates machine
(*1, *2) pitching angle. (The latest infor-
10 (For-
Body pitch dis- M2 Gray mation is indicated on rightmost.)
ward)
play
10 (Back-
M3 Gray
ward)
20 (Back-
M4 Gray
ward)
Segment Load level • Indicates instantaneous fuel con-
sumption (average of fuel con-
Light to me-
Green 1 to 8 sumption by 3 seconds) in 10
dium
(*3) steps.
(Displays when Fuel consumption
ECO gauge is selected from the items on En-
Orange 9, 10 Heavy ergy Saving Guidance → Configu-
rations → ECO Gauge Display of
the user menu.)
Segment Load level • Indicates instantaneous drawbar
pull (average of drawbar pull per 1
Light to me-
Green 1 to 8 minutes) in 10 levels.
(*3) dium
(Displays when Drawbar pull is
Drawbar pull selected from the items on Energy
gauge
Saving Guidance → Configura-
Orange 9, 10 Heavy
tions → ECO Gauge Display of
the user menu.)
• Indicates accumulated engine op-
erating hours (alternator is gener-
Service meter 00000.0 h to 99999.9 h ating).
(Changes to Clock when F4
switch is pressed.)
10-96 D155AX-8

• Displays Time.
(Changes to Service meter when
• 12-hour system display (AM/PM) F4 switch is pressed.)
Clock (When clock is displayed on the
• 24-hour system display multi gauge, the display changes
to Engine tachometer when F2
switch is pressed.)
• (Configurations can be switched
(*3) • 1 day by selecting another item in Ener-
Fuel consump- • Split gy Saving Guidance → Configura-
tion gauge • None tions → Average Fuel Consump-
tion Display on user menu.)
Gauge
Range Quantity (%)
range
A1 100 Green
A2 75 Green
AdBlue/DEF A3 50 Green Indicates corresponding level range.
level gauge
A4 25 Green
A5 10 Green
A6 2.5 Red
A7 0 Red
*1: The gauge pointer disappears if the gauge signal is not available due to an open circuit in the CAN commu-
nication line.
*2: This item is classified into multi gauge, and the display changes every time the F2 switch is pressed.
*3: Display can be switched by selecting another item in “Energy Saving Guidance” → “Configurations” on user
menu.
*4: The gauge pointer disappears if the fuel level signal is not available due to an open circuit in the fuel level
sensor.
TYPES OF CAUTION LAMPS DISPLAYED ON MACHINE MONITOR

Description
Monitor
Symbol Item displayed display Remarks
Action level
Range (back-
monitor
ground col-
or)
Lights up • The monitor background color
Min. 105 °C L02
(red) changes depending on the
Lights up temperature detected.
Min. 102 °C -
Engine coolant (red) • If the temperature detected is
temperature 105 °C or above, the alarm
buzzer sounds, the overheat
Lights up prevention system operates
Below 102 °C -
(blue) automatically, and the engine
speed decreases.
D155AX-8 10-97
Description
Monitor
Action level
Range (back-
monitor
ground col-
or)
Min. 130 °C L02
Min. 120 °C -
Power train oil (red) • If the temperature detected is
Below 120 °C -
speed decreases.
Min. 105 °C L02
Min. 102 °C -
Hydraulic oil (red) • If the temperature detected is
Below 102 °C -
speed decreases.
Lights up
Below 150 ℓ - • The monitor background color
(red)
Fuel level changes depending on the re-
Lights up maining fuel level.
Min. 150 ℓ -
(blue)
Lights up
Max. 0.09 % L04
(red)
• The monitor background color
Lights up
Max. 2.5 % L03 changes depending on the re-
AdBlue/DEF (red)
maining fuel level.
level Lights up
Max. 10 % - • Alarm buzzer sounds at 2.5 %
(red)
or lower.
Lights up
Above 10 % -
(blue)
When charge is
defective (charge Lights up • Monitor lights up and alarm
(*1) L03 buzzer sounds when abnor-
voltage < battery (red)
Battery charge voltage) mality is detected while engine
is running.
When normal Lights off -
When abnormal • Monitor lights up and alarm
(*1) Lights up
(below specified L03 buzzer sounds when abnor-
(red)
Engine oil pres- pressure) mality is detected while engine
sure
When normal Lights off - is running.
When abnormal (*3)
Lights up • Monitor lights up if abnormality
Air cleaner clog- (above specified
(yellow) L01 is detected while engine is
ging pressure)
running.
10-98 D155AX-8
Description
Monitor
Action level
Range (back-
monitor
ground col-
or)
When abnormal
(*1) Lights up • Monitor lights up if abnormality
(below specified L01
(yellow) is detected while engine is
Radiator coolant level)
level running.
When mainte- • The display changes depend-
Lights up
nance due time is - ing on how long it has elapsed
(red)
over since the maintenance due
Maintenance time was over.
due time warn- • After starting switch is turned
ing (*2) When main-
Lights up to ON position, monitor lights
tenance notice -
(yellow) up if condition for lighting it up
time is over
is satisfied, and then goes out
in 30 seconds.
When action lev- • Monitor lights up when an ab-
Lights up
el L04 or L03 is L04 or L03 normality is detected in ma-
(red)
detected chine system.
State of system
When action lev- Lights up (*3) • Alarm buzzer sounds when
el L01 is detected (yellow) L01 the background color is red.
Lights up
el L04 or L03 is L04 or L03 normality is detected in engine
(red)
Engine system detected system.
state
Lights up
el L04 or L03 is L04 or L03 normality is detected in work
(red)
Work equipment detected equipment system.
system state
Lights up
el L04 or L03 is L04 or L03 normality is detected in steer-
(red)
Steering system detected ing system.
state
Lights up
el L04 or L03 is L04 or L03 normality is detected in trans-
(red)
Transmission detected mission system.
system state
Lights up
el L04 or L03 is L04 or L03 normality is detected in brake
(red)
Brake system detected system.
state
D155AX-8 10-99
Description
Monitor
Action level
Range (back-
monitor
ground col-
or)
Lights up
el L04 or L03 is L04 or L03 normality is detected in the
(red)
Parking brake detected parking brake system.
system state
Lights up
el L04 or L03 is L03 normality is detected in fan
(red)
Fan control sys- detected control system.
tem state
Lights up
el L04 or L03 is L04 or L03 normality is detected in KDPF
(red)
KDPF system detected system.
state
When action lev- Lights up • Monitor lights up when soot is
L03
el L03 is detected (red) accumulated inside KDPF or
Accumulation of cleaning function is abnormal-
soot in KDPF When action lev- Lights up (*3) ly degraded.
el L01 is detected (yellow) L01 • Alarm buzzer sounds when
the background color is red.
• Monitor lights up and alarm

When engine Lights up
Engine overrun L02 buzzer sounds when engine
overruns (red)
overrun is detected.
When air condi- (*3) • Monitor lights up when an ab-

Air conditioner Lights up
tioner is abnor- normality is detected in air
state (yellow) L01
mal conditioner system.

Lights up
el L04 or L03 is L04 or L03 normality is detected in AdBl-
(red)
AdBlue/DEF detected ue/DEF system.
System State
el L01 is detected (yellow) L01 the background is red.
When action lev- Lights up
L04
el L04 is detected (red)
When action lev- Lights up • Monitor lamp lights up when
L03 an abnormality is detected in
Action level the machine. Alarm buzzer
When action lev- Lights up
L02 sounds when the monitor
background is red.
When action lev- Lights up (*3)
el L01 is detected (yellow) L01
10-100 D155AX-8
*1: This is included in the Check before starting items. After the staring switch is turned to ON position, the mon-
itor is lit for 2 seconds, and changes to the standard screen if no abnormality is found.
*2: The notice time can be changed in Service menu, “05 Maintenance Mode Setting” → “00 Maintenance Mode
Change” → “02 Maintenance Notice Time Setting”.
*3: These items light up for 2 seconds, and then go out.
TYPES OF PILOT LAMPS DISPLAYED ON MACHINE MONITOR

• Operates automatically
at low temperature.
(Lights up for approxi-
Automatic mately 40 sec. at maxi-
preheating mum.)
• Goes out after engine
is started.
Elapsed time
after turning
starting Monitor dis- Displays the operation state of pre-
Preheating
switch to play heating.
HEAT (pre-
heat)
Automatic
preheating 0 to 30 sec-
Lights up
onds
30 to 40 sec-
Flashes
onds
40 seconds
Lights off
or longer
Lights up: Lock

Work equip- Indicates state of work equipment
Flashes: When it is necessary to lock
ment lock lock lever.
Lights off: Free
Lights up: Lock

Indicates state of parking brake lev-
Parking brake Flashes: When it is necessary to lock
er.
Lights off: Free
Lights up: ON Indicates the operation status of air

Air conditioner
Lights off: OFF conditioner and blower.
Lights up: Not fastened Indicates whether seat belt is fas-

Seat belt
Lights off: Fastened tened.
Lights up: When engine is stopped Indicates the operation status of en-
Engine stopped
Lights off: While engine is running gine.
In fan rotating in Lights up: Cooling fan reverse rotation Indicates the rotating state of cool-
reverse Lights off: Cooling fan normal rotation ing fan.
D155AX-8 10-101
Lights up: During KDPF regeneration

KDPF regener-
Lights up: When KDPF regeneration is com- Indicates operation status of KDPF.
ation
pleted
Indicates disabling of regeneration

After-treatment Lights up: When after-treatment devices re-
of after-treatment devices.
devices regen- generation is stopped
eration is stop- When manual stationary regenera-
Lights off: When after-treatment devices re-
ped tion is necessary, KDPF soot accu-
generation is canceled.
mulation monitor lights up.
Message Lights up: There is unread message.

Displays the state of message.
(Unread) Lights off: No message.
Message
Lights up: There is already-read message
(No return mes- but return message for it is not sent yet. Displays the state of message.
sage, already-
Lights off: No message.
read message)
P: Heavy-duty operation Indicates the state of operating

Operating mode
E: Low-fuel consumption operation mode setting.
Reverse slow Lights up: ON Indicates setting state of reverse

mode monitor Lights off: OFF slow mode.
Lights up: Dual tilt mode Indicates setting state of dual tilt
Dual tilt mode
Lights out: Single tilt mode mode.
Blade float op- Lights up: Blade float is operated. Indicates the operation state of
eration Lights out: Blade float is not operated. blade float.
Blade fine con- Lights up: ON Indicates setting state of blade fine
trol mode Goes off: OFF control mode.
Lights up: ON Indicates setting and operation state

Auto-pitch
Lights off: OFF of blade auto-pitch.
Estimated time before AdBlue/DEF level

monitor lights up
AdBlue/DEF Indicates operable hours estimated
low level guid- 1 to 8 hours: There is approx. "x" h before from AdBlue/DEF level and latest
ance AdBlue/DEF refill alarm AdBlue/DEF consumption.
Less than 1 hour: AdBlue/DEF refill alarm
will be displayed soon
Blade slow- Lights up: ON Indicates setting state of blade slow

down Lights off: OFF down.
10-102 D155AX-8

• Excessive engine idling guidance
• Deterrence guidance of hydraulic re-
lief
• Economy Mode (recommended) guid- Displays the guidance to support op-
ECO guidance
ance eration of the machine.
• Overload prevention guidance
• Auto shift mode recommendation
guidance
Ripper auto-re- Lights up: ON Indicates setting state of ripper auto-

turn Lights off: OFF return.
Speed range
See "Palm command control system".
display
OPERATOR MODE FUNCTION OF MACHINE MONITOR

The information items in this mode are displayed ordinarily. The operator can display and set them by operating
the switches. Display and setting of some items need special operations of the switches.
Items available in the operator mode are as follows:
*1: The operator mode items are classified as follows.
A: Display from the time when the starting switch is turned to “ON” position to the time when display changes to
the standard screen, and display after starting switch is turned to “OFF” position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special operations of switches
*2: Display sequence from the time when the starting switch is turned to ON position to the time when the stand-
ard screen appears varies depending on the settings and conditions of the machine as follows:
U: When the engine start lock and operator ID No. input setting are enabled
V: When the engine start lock is enabled and the operator ID No. input setting is disabled
W: When the engine start lock is disabled and the operator ID No. input setting is enabled
X: When the engine start lock and operator ID No. input setting are disabled
Y: When any abnormality is detected by the check before starting
Z: When any maintenance item is detected to be near maintenance time or exceeded
REMARK
• For how to operate the operator mode functions, see the Operation and Maintenance Manual.
• For the operating method of the engine start lock function, see "Password setting and canceling manual".
D155AX-8 10-103
Category Display order (*2)

Item
(*1) U V W X Y Z
Display of KOMATSU logo 1 1 1 1 1 1
Display of password input 2 2 - - - -
Display of service person identification state 3 - 2 - - -
Display of operator ID input screen 4 - 3 - - -
Display of check before starting 5 3 4 2 2 2
A Display of warning after Check before starting - - - - 3 -
Display of maintenance due time over - - - - - 3
Display of check of preset 6 4 5 3 4 4
Display of standard screen 7 5 6 4 5 5
Display of engine shutdown secondary switch screen
Display of end screen
Selection of operation mode
Selection of gearshift mode
Selection of reverse slow mode
Customizing operation
Stop operation of alarm buzzer
Selection of multi gauge
Operation of air conditioner
Selection of dual tilt
Operation of camera mode display (for machines equipped with camera)
B
Operation to display clock and service meter
Check of maintenance information
Setting and display of user menu
• Energy Saving Guidance
• Machine Setting
• Aftertreatment Devices Regeneration
• SCR Information
• Maintenance
• Monitor Setting
• User Message (including KOMTRAX messages for user)
ECO Guidance Display
Machine Setting (Fan Reverse Mode)
Display of caution monitor
C
Display of after-treatment devices regeneration
Display of action level and failure code
Display of Low AdBlue/DEF Level Guidance
10-104 D155AX-8
Category Display order (*2)

Item
(*1) U V W X Y Z
Checking function of LCD (Liquid Crystal Display)
D Checking function of service meter
Function of usage limitation setting/change password
SERVICE MODE FUNCTION OF MACHINE MONITOR

These functions are not displayed normally. A technician can display and set them special operation of
switches. These functions are used for special settings, testing, adjusting, or troubleshooting.
Items available in the service mode are as follows:
REMARK
For operating method of the service mode functions, see "Service mode" in Testing and adjusting.
Pre-defined Monitoring
Self-define Monitoring
Mechanical Sys Abnormality Record
Abnormality Record
Electrical Sys Abnormality Record
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Key-on Mode
Unit
Default Camera
Float Buzzer
Auto Idle Stop Time Fixing
Cylinder Cutout Mode Operation
Active Regeneration for Service
KDPF Memory Reset
Diagnostic Tests SCR Service Test
Engine Controller Active Fault Clear
Ash in Soot Accumulation Correction
Reset Number of Abrupt Engine Stop by AIS
Input ID
Brake Pedal Potentio Initial Set
Inclination Sensor Initial Set
S/T Lever N Position Setting
IP Auto Compensation Setting
Adjustment
Blade Lift Lever N Position Adj
Blade Tilt Lever N Position Adj
Ripper Lift Lever N Position Adj
Control Brake Release Mode
Sudden Stop Prevent Valve Mode
D155AX-8 10-105
No-Injection Cranking
Terminal Status
KOMTRAX Setting Display GPS & Communication State
Modem Information
Service Message Display
KOMTRAX TERMINAL
STRUCTURE OF KOMTRAX TERMINAL
General view
Model: TC630/TC635
1: GPS antenna connection 3: Machine harness connection (070-12P)

2: Machine harness connection (070-18P) 4: Communication antenna connection
FUNCTION OF KOMTRAX TERMINAL

• This terminal uses the communication technology of cell phone.
• This terminal is a wireless communication equipment which transmits various machine information obtained
from the network signals and input signals, as well as the GPS position information.
The terminal can transmit the data via the communication antenna.
• The condition of this terminal can be checked on the “KOMTRAX Setting” screen in the service mode of the
machine monitor.
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• The terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its dis-
play section.
REMARK
• The countries in which TC630 and TC635 can be used respectively are different.
INPUT AND OUTPUT SIGNALS OF KOMTRAX TERMINAL

070-18P [CN-CK01]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
10-106 D155AX-8

7 (*1) -
8 (*1) -
9 (*1) -
10 CAN_H (KOMNET/c) Input/Output
11 CAN_H (KOMNET/c) Input/Output
12 (*1) -
13 (*1) -
14 External starting signal Input/Output
15 System operating lamp Output
16 (*1) -
17 (*1) -
18 (*1) -

070-12P [CN-CK02]
1 GND -
2 GND -
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
9 (*1) -
10 (*1) -
12 (*1) -
D155AX-8 10-107
POWER TRAIN CONTROLLER

STRUCTURE OF POWER TRAIN CONTROLLER
General view
POWER TRAIN CONTROLLER INPUT AND OUTPUT SIGNALS

DRC26-24P [CN-PTCN1]
1 (*1) -
2 Steering lever potentiometer (main) Input
3 Brake pedal potentiometer Input
4 GND (Analog) -
5 Brake pedal switch (NO) Input
6 Fuel control dial Input
7 Torque converter outlet oil pressure sensor Input
8 Pitch angle sensor Input
9 Torque converter oil temperature sensor Input
10 GND (signal) -
11 Brake pedal switch (NC) Input
13 Torque converter inlet oil pressure sensor Input
14 Directional lever potentiometer (sub) Input
10-108 D155AX-8

16 Sensor power supply (+24 V) Output
17 Parking brake limit switch (NO) Input
18 (*1) -
19 Steering lever potentiometer (sub) Input
20 Directional lever potentiometer (main) Input
21 GND (analog) -
22 Sensor power supply (5 V) Output
23 Parking brake limit switch (NC) Input
24 (*1) -

DRC26-40P(A) [CN-PTCN2]
1 (*1) -
2 Lockup clutch fill switch Input
3 (*1) -
4 RS232C RXD Input
5 Transmission forward clutch fill switch Input
6 Brake left fill switch Input
7 (*1) -
8 Neutral safety relay Output
9 Fan reverse solenoid Output
10 (*1) -
11 (*1) -
12 Stator clutch fill switch Input
13 (*1) -
14 RS232C TXD Output
15 Transmission 3rd clutch fill switch Input
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 (*1) -
22 CAN0_L (KOMNET/c) Input/Output
23 CAN1_L (KOMNET/r) Input/Output
25 Transmission 2nd clutch fill switch Input
26 (*1) -
D155AX-8 10-109

27 (*1) -
28 Backup alarm Output
29 GND (pulse) -
30 Transmission output shaft speed sensor Input
31 (*1) -
32 CAN0_H (KOMNET/c) Input/Output
33 CAN1_H (KOMNET/r) Input/Output
34 RS232C GND -
35 Transmission 1st clutch fill switch Input
36 Transmission reverse clutch fill switch Input
37 Brake right fill switch Input
38 (*1) -
39 GND (pulse) -
40 Fan speed sensor Input

DRC26-40P(B) [CN-PTCN3]
2 Power supply (24 V) Input
3 GND (solenoids common) -
4 Battery relay drive Output
5 Left steering EPC valve Output
6 (*1) -
7 Transmission 2nd clutch ECMV Output
8 Sudden stop prevention solenoid Output
9 Shift Down SW (NC) Input
10 Power train controller selection (GND) Input
13 GND (solenoid common) Input
14 ACC signal from starting switch Input
15 Right steering EPC valve Output
16 (*1) -
17 Transmission 3rd clutch ECMV Output
18 Transmission forward clutch ECMV Output
19 Shift down switch (NO) Input
20 Work equipment controller selection (OPEN) Input
21 GND (power supply) -
10-110 D155AX-8

23 GND (solenoid common) -
24 ACC signal from starting switch Input
25 Fan pump solenoid Output
26 Brake left ECMV Output
27 STATOR CLUTCH ECMV Output
28 Transmission reverse clutch ECMV Output
29 Shift up switch (NC) Input
30 Specification selection (reserve) Input
35 (*1) —
36 Brake right ECMV Output
37 Lockup clutch ECMV Output
38 Transmission 1st clutch ECMV Output
39 Shift up switch (NO) Input
D155AX-8 10-111
WORK EQUIPMENT CONTROLLER

STRUCTURE OF PUMP CONTROLLER
General view
INPUT AND OUTPUT SIGNALS OF WORK EQUIPMENT CONTROLLER

DRC26-24P [CN-WECN1]
1 Ripper lift lever potentiometer (sub) Input
2 Blade lift lever potentiometer (sub) Input
3 Oil pressure sensor of work equipment pump Input
4 GND (Analog) -
5 (*1) -
6 (*1) -
7 Ripper lift lever potentiometer (main) Input
8 Blade lift lever potentiometer (main) Input
9 (*1) -
10 GND (signal) -
11 (*1) -
12 (*1) -
13 Blade tilt lever potentiometer (sub) Input
14 Hydraulic oil temperature sensor Input
10-112 D155AX-8

17 Blade auto-pitch switch (NO) Input
19 Blade tilt lever potentiometer (main) Input
20 (*1) -
21 GND (Analog) -
23 Blade auto-pitch switch (NC) Input

2 Work equipment knob raise switch (NO) Input
3 Blade pitch back switch 1 (NO) Input
4 RS232C RXD Input
5 (*1) -
6 (*1) -
7 Blade pitch dump switch 1 (NO) Input
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 Blade pitch back switch 2 (NO) Input
13 Blade pitch dump switch 2 (NO) Input
14 RS232C TXD Output
15 (*1) -
16 (*1) -
17 Engine low idle signal Input
18 (*1) -
19 Work equipment lock Solenoid Output
20 (*1) -
21 Engine controller ACC hold relay Output
22 CAN0 L (KOMNET/c) Input/Output
23 CAN1 L (KOMNET/r) Input/Output
25 (*1) -
26 (*1) -
D155AX-8 10-113

27 Work equipment lock switch (NO) Input
28 (*1) -
29 GND (pulse) -
30 (*1) -
31 (*1) -
32 CAN0 H (KOMNET/c) Input/Output
33 CAN1 H (KOMNET/r) Input/Output
34 RS232C GND -
35 (*1) -
36 (*1) -
37 Work equipment lock switch (NC) Input
38 Work equipment knob raise switch (NC) Input
39 GND (pulse) -
40 (*1) -

4 (*1) -
5 Ripper tilt IN EPC Output
6 (*1) -
7 Blade lift RAISE EPC Output
8 TVC solenoid Output
9 Ripper tilt IN switch 1 (NO) Input
10 Power train controller selection (OPEN) Input
15 Ripper tilt BACK EPC Output
16 (*1) -
17 Blade lift LOWER EPC Output
18 (*1) -
19 Ripper tilt IN switch 2 (NO) Input
20 Work equipment controller selection (GND) Input
10-114 D155AX-8

25 (*1) -
26 Ripper RAISE EPC Output
27 Blade tilt RIGHT head EPC Output
28 Blade tilt LEFT head EPC Output
29 Ripper tilt BACK switch 1 (NO) Input
35 Quick drop solenoid Output
36 Ripper LOWER EPC Output
37 Blade tilt RIGHT bottom EPC Output
38 Blade tilt LEFT bottom EPC Output
39 Ripper tilt BACK switch 2 (NO) Input
DECELERATOR PEDAL POTENTIOMETER

STRUCTURE OF DECELERATOR PEDAL POTENTIOMETER
1: Connector 3: Body
2: Lever 4: Potentiometer
D155AX-8 10-115
5: Coupling 7: Stopper
6: Shaft
FUNCTION OF DECELERATOR PEDAL POTENTIOMETER
1: Connector 5: Coupling
2: Lever 6: Shaft
3: Body 7: Stopper
4: Potentiometer
• The decelerator pedal potentiometer is installed in the dashboard and connected to the decelerator pedal
through the linkage.
• When the decelerator pedal is operated, the throttle potentiometer shaft is rotated by the linkage and the
potentiometer resistance changes.
• Constant voltage is applied between pins (A) and (C) of the potentiometer and an electric signal is sent
through pin (A) to the engine controller corresponding with the position of the decelerator pedal.
10-116 D155AX-8
ENGINE CONTROLLER
STRUCTURE OF ENGINE CONTROLLER
General view
INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER

Delphi96Pin (J1 connector)
Pin No. Signal name Input/Output
Ground/Shield/
1 Injector #1 (-)
Return
Ground/Shield/
2 Injector #2 (-)
Return
Ground/Shield/
3 Injector #3 (-)
Return
4 (*1) -
5 Fuel doser (+) Output
6 Fuel doser solenoid valve 2 Output
7 Fuel feed pump Output
8 Fuel doser solenoid valve 1 Output
9 Sensor power supply relay Output
10 (*1) -
11 (*1) -
12 (*1) -
D155AX-8 10-117

13 EGR valve solenoid (+) Output
14 PCV2 (+) Output
15 (*1) -
Ground/Shield/
16 Turbocharger speed (-)
Return
17 Turbocharger speed (+) Input
18 Engine Bkup speed sensor Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 PCV1 (+) Output
PCV1 (-) Ground/Shield/
24
Return
25 Injector #1 (+) Output
28 (*1) -
Ground/Shield/
29 Fuel doser (-)
Return
Ground/Shield/
30 GND
Return
31 Engine NE speed sensor Input
32 Mass air flow (MAF) sensor Input
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 Dosing fuel pressure sensor Input
38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 (*1) -
43 (*1) -
44 Ambient pressure sensor Input
45 Charge pressure sensor Input
46 (*1) -
47 (*1) -
10-118 D155AX-8

Ground/Shield/
48 PCV2 (-)
Return
52 (*1) -
53 (*1) -
Ground/Shield/
54 GND
Return
Ground/Shield/
55 GND
Return
Ground/Shield/
56 GND
Return
Ground/Shield/
57 GND
Return
Ground/Shield/
58 GND
Return
59 (*1) -
60 (*1) -
61 Intake air temperature sensor Input
62 Charge temperature sensor Input
63 Crankcase pressure sensor Input
64 (*1) -
65 (*1) -
66 (*1) -
67 KVGT position sensor Input
68 (*1) -
69 (*1) -
70 Datalink3 (+) (KOMNET/r) Communication
71 (*1) -
72 (*1) -
Ground/Shield/
73 Injector #4 (-)
Return
Ground/Shield/
74 Injector #5 (-)
Return
Ground/Shield/
75 Injector #6 (-)
Return
Ground/Shield/
76 EGR valve solenoid (-)
Return
77 (*1) -
78 Sensor 5 V power supply Power supply
D155AX-8 10-119

83 Coolant temperature sensor Input
84 (*1) -
85 Engine oil pressure sensor Input
86 (*1) -
87 Common rail pressure sensor Input
88 EGR valve lift sensor Input
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 Datalink3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -

Delphi96Pin (J2 connector)
1 Power supply (+24 V, continuous) Power supply
Ground/Shield/
2 KVGT solenoid (-)
Return
3 AdBlue/DEF line heater relay 1 Output
4 (*1) -
5 ACC (Key SW) Input
6 AdBlue/DEF pump temperature sensor/ AdBlue/DEF pump driver Input/ Output
7 AdBlue/DEF line heater relay 2 Output
10 Throttle sensor Input
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 AdBlue/DEF pump pressure sensor Input
17 (*1) -
10-120 D155AX-8

18 (*1) -
19 (*1) -
20 (*1) -
21 Datalink4 (+) (Sensor controller) Communication
22 Datalink4 (+) (KOMNET/c) Communication
23 (*1) -
24 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
Ground/Shield/
32 GND
Return
Ground/Shield/
33 GND
Return
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 AdBlue/DEF line heater 2 Input
39 AdBlue/DEF line heater 1 Input
40 (*1) -
41 KDPF differential pressure sensor Input
42 KDPF outlet pressure sensor Input
43 (*1) -
44 (*1) -
45 Datalink4 (-) (Sensor controller) Communication
46 Datalink4 (-) (KOMNET/c) Communication
47 (*1) -
Ground/Shield/
49 Power GND
Return
Ground/Shield/
50 Power GND
Return
Ground/Shield/
51 Power GND
Return
Ground/Shield/
52 Power GND
Return
D155AX-8 10-121

Ground/Shield/
53 AdBlue/DEF injector (-)
Return
Ground/Shield/
54 GND
Return
55 (*1) -
56 Ambient temperature sensor Input
Ground/Shield/
57 GND
Return
58 (*1) -
59 (*1) -
60 (*1) -
Ground/Shield/
61 GND
Return
62 (*1) -
63 (*1) -
64 (*1) -
65 (*1) -
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
Ground/Shield/
73 Power GND
Return
74 (*1) -
75 Intake air heater relay Output
76 (*1) -
77 AdBlue/DEF injector (+) Output
78 (*1) -
79 AdBlue/DEF pump voltage Output
80 KVGT solenoid (+) Output
81 AdBlue/DEF FCV Output
82 AdBlue/DEF tank heating valve Output
83 AdBlue/DEF pump heater relay Output
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
10-122 D155AX-8

88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -
FUEL FEED PUMP

STRUCTURE OF FUEL FEED PUMP
General view
A: Fuel inlet B: Fuel outlet

1: Body 3: Bracket
2: Rubber 4: Connector
FUNCTION OF FUEL FEED PUMP

The fuel feed pump is controlled and driven by the engine controller or fuel feed pump switch in the following
cases.
• Increase the fuel pressure during fuel dosing process. (Controlled by engine controller)
• Bleed air from the fuel line (on engine side). (Controlled by fuel feed pump switch)
D155AX-8 10-123
FUEL FEED PUMP SWITCH

STRUCTURE OF FUEL FEED PUMP SWITCH
General view
1: Body 3: LED lamp

2: Toggle switch 4: Connector
FUNCTION OF FUEL FEED PUMP SWITCH

• This switch receives signals from the engine controller and drives the fuel feed pump.
• The fuel feed pump is driven to bleed air from the fuel line by operating the toggle switch, when the fuel
filter is replaced, etc.
Air in the fuel line is bled by driving the fuel feed pump for the set time of the built-in timer.
• When the starting switch is at OFF position, the fuel feed pump is driven in the following pattern; Pump is
driven (30 seconds) → Pump is stopped (10 seconds). After 10 cycles of this pattern, the pump is stopped
automatically.
10-124 D155AX-8
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
1: Control valve
2: Hydraulic tank
3: Work equipment and HSS pump
4: Hydraulic oil pressure sensor
5: Hydraulic oil temperature sensor
D155AX-8 10-125
CLSS 10 STRUCTURE AND FUNCTION
CLSS
CLSS
Abbreviation for Closed-center Load Sensing System
STRUCTURE OF CLSS
System diagram
FEATURES OF CLSS
• Fine controllability not influenced by load
• Control performance that allows digging even under fine control operation condition
• Easy combined operation ensured by the flow dividing performance that is determined by the opening
areas of spools during combined operations
• Energy saving by variable discharge pump control
Composition of CLSS
• CLSS consists of variable displacement piston pump, control valves, and respective actuators.
• The pump consists of the main pump, fixed throttle valve, PC valve, and LS valve.
10-126 D155AX-8
10 STRUCTURE AND FUNCTION CLSS
FUNCTION OF CLSS
Control of pump swash plate angle
The pump swash plate angle (pump discharged volume) is so
controlled that LS differential pressure (ΔPLS), which is the dif-
ferential pressure between pump discharge pressure (PP) and
control valve outlet LS pressure (PLS) (actuator load pressure),
is constant.
[LS differential pressure (∆PLS) = Pump discharge pressure
(PP) - LS pressure (PLS)]
The pump swash plate angle shifts toward the maximum posi-
tion if LS differential pressure (ΔPLS) is lower than the set
pressure of the LS valve (when the actuator load pressure is
high). The pump swash plate angle shifts toward the mini-
mum position if LS differential pressure is higher than the set
pressure (when the actuator load pressure is low).
LS differential pressure (∆PLS) and pump

swash plate angle
REMARK
See "HSS pump" for the explanation of the operation.
D155AX-8 10-127
CLSS 10 STRUCTURE AND FUNCTION
Pressure compensation control
• A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.
• When actuators are operated in combined operations, the pressure difference (ΔP) between the upstream
(inlet port) and downstream (outlet port) of the spool of each valve are kept the same by the pressure com-
pensation valve, regardless the size of the load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and (S2)
of each valve.
10-128 D155AX-8
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM

HYDRAULIC TANK
STRUCTURE OF HYDRAULIC TANK
1: Oil filler cap 7: Hydraulic oil filter element

2: Breather 8: Strainer
3: Hydraulic tank 9: Sight gauge
4: Cover 10: Drain valve
5: Bypass valve 11: Drain plug
6: Spring
SPECIFICATIONS OF HYDRAULIC TANK

Hydraulic tank
Tank total capacity (center of gauge): 142 ℓ
Tank total capacity: 95 ℓ
Breather
Set pressure of exhaust valve: 16.7±2.45 kPa {0.17±0.025 kg/cm2}
D155AX-8 10-129
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION
Set pressure of intake valve: 1.96±0.29 kPa {0.02±0.003 kg/cm2}

Hydraulic oil filter
Cracking pressure of pressure valve: 147±29.4 kPa {1.5±0.3 kg/cm2}
Filtering precision: β5≧3, β10≧8, β20≧75
Filtering area: 8000 cm2
Filtering oil flow: 550 ℓ/min
Strainer
Filter mesh size: 105 µ
Filtering area: 1850 cm2
HYDRAULIC TANK BREATHER

STRUCTURE OF HYDRAULIC TANK BREATHER
1: Nut
2: Cover
3: Filter element
4: Case
5: Valve assembly
6: Body
Prevention of negative pressure in tank
• Since the hydraulic tank is pressurized and sealed, if the
oil level in it decreases, negative pressure is generated in
it.
At this time, valve (5) is opened by the differential pressure between the tank pressure and the ambient
pressure, and outside air is sucked in to prevent generation of negative pressure in the tank.
(Set pressure of intake valve : 1.96±0.29 kPa {0.02±0.003 kg/cm2} )
Prevention of pressure rise in tank
• While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and
the temperature in the hydraulic tank rise corresponding to the operation of the hydraulic cylinders.
When the pressure in the tank exceeds the set pressure, valve assembly (5) is pushed up to release the
pressure in the tank and prevent pressure rise.
(Set pressure of exhaust valve : 16.7±2.45 kPa {0.17±0.025 kg/cm2} )
WORK EQUIPMENT AND HSS PUMP

HSS
Abbreviation for Hydrostatic Steering System
STRUCTURE OF WORK EQUIPMENT AND HSS PUMP

This pump consists of a variable displacement swash plate type piston pump, PC valve, LS valve, and EPC
valve.
10-130 D155AX-8
General view
IM: PC mode selector current PB: Pump discharged pressure input port
PA: Pump discharge port PD1: Case drain port
D155AX-8 10-131
PD2: Drain plug PLS: Load pressure input port

PEN: Control pressure pickup port PLSC: Load pressure pickup port
PEPC: EPC source pressure port PM: PC mode selector pressure pickup port
PEPCC: EPC source pressure pickup port PS: Pump suction port
1: Front pump 3: PC valve
2: LS valve 4: PC-EPC valve
Sectional view
1: Shaft 7: Cylinder block

2: Cradle 8: Valve plate
3: Case 9: End cap
4: Rocker cam 10: Servo piston
5: Shoe 11: PC valve
6: Piston
10-132 D155AX-8
Structure drawing
• Cylinder block (7) is supported on shaft (1) by spline (12).

• Shaft (1) is supported by each bearing (13).
• The end of piston (6) is a concave sphere, and it is caulked to be combined with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Shoe (5) slides in a circular pattern as always being presses against the flat surface (A) of rocker cam (4).
• Rocker cam (4) rocks on cylindrical surface (B) of cradle (2) fixed to the case. High-pressure oil is supplied
between them to form a static pressure bearing.
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while seal the pressurized oil.
• The oil pressure is balanced properly on this surface.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
SPECIFICATIONS OF WORK EQUIPMENT AND HSS PUMP

Model: HPV190
Type: Variable displacement swash plate type piston pump
Theoretical discharged volume : 427 ℓ/min(when engine speed is 2249 rpm)
Rated discharged pressure: 41.2 MPa {420 kg/cm2}
D155AX-8 10-133
Rated speed: 2250 (-50/0) rpm
FUNCTION OF WORK EQUIPMENT AND HSS PUMP

• This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic pressure and
discharges pressurized oil corresponding to the load.
• It is possible to change the discharged volume by changing the swash plate angle.
Operation of work equipment and HSS pump
1. Cylinder block (7) rotates together with shaft (1) and shoe
(5) slides on plane (A).
2. Rocker cam (4) moves along cylindrical surface (B). As a
result, angle (a) between center line (X) of rocker cam (4)
and the axis of cylinder block (7) changes.
3. Angle (a) is called the swash plate angle.
4. While angle (a) is made between center line (X) of rocker

cam (4) and the axis of cylinder block (7), plane (A) works
as a cam for shoe (5).
5. Pistons (6) slide inside cylinder block (7) and a difference
is made between volumes (E) and (F) in cylinder block (7).
6. Oil in amount of (F) minus (E) is sucked in and discharged
from each piston (6).
7. Oil is discharged while cylinder block (7) rotates and the
volume of chamber (E) decreases.
8. Pressurized oil is suctioned as the volume of chamber (F)
increases.
9. When center line (X) of rocker cam (4) matches the axis of
cylinder block (7) (the swash plate angle is 0), the differ-
ence between volumes (E) and (F) inside cylinder block (7)
is 0.
10. Suction and discharge of pressurized oil is not performed
in this stage. Namely pumping action is not performed.
(Actually, however, a zero swash plate angle never oc-
curs.)
10-134 D155AX-8
Control of discharged volume

1. When swash plate angle (a) is increased, the difference
between volumes (E) and (F) is increased, then dis-
charged volume (Q) is increased.
2. Swash plate angle (a) is changed by servo piston (10).
3. Servo piston (10) moves in a linear reciprocating motion
corresponding to the signal pressure from the PC valve
and LS valve.
4. This linear movement is transmitted to rocker cam (4)
through slider (14).
5. Rocker cam (4) supported on the cylindrical surface of cra-
dle (2) slides and pivots on that surface.
6. The area of servo piston (10) for receiving the pressure

are not identical on the right side and left side. Main pump
discharged pressure (self-pressure) (PP) is always trans-
mitted to the pressure chamber of the small diameter pis-
ton side.
7. Output pressure (PEN) of LS valve is supplied to the pres-
sure chamber on large diameter piston side.
8. The movement of servo piston (10) is controlled by the re-
lationship of pressure between small diameter piston side
(PP) and large diameter side (PEN) and by the ratio of the
area receiving the pressure between small diameter piston
and large diameter piston.
LS VALVE
LS
Abbreviation for Load Sensing
D155AX-8 10-135
STRUCTURE OF LS VALVE
Sectional view
PA: Pump port PP: Pump port

PDP: Drain port PPL: Control pressure input port
PLP: LS control pressure output port PSIG: Drain port
PLS: LS pressure input port
1: Sleeve 5: Seat
2: Piston 6: Sleeve
3: Spool 7: Plug
4: Spring 8: Lock nut
FUNCTION OF LS VALVE
• The LS (load sensing) valve detects the load of the actua-
tor and controls the pump discharged volume.
• This valve controls main pump discharged volume (Q) ac-
cording to differential pressure (ΔPLS) [= PP – PLS],
called the LS differential pressure (the difference between
main pump discharge pressure (PP) and control valve out-
let port pressure (PLS)).
• This valve receives pump discharge pressure (PP), pres-
sure (PLS) (called the LS pressure) coming from the con-
trol valve output.
• The relationship between LS differential pressure (ΔPLS)
[= (PP) - (PLS)], which is a differential pressure between
main pump discharge pressure (PP) and LS pressure (PLS) , and discharged volume (Q) is as shown in the
diagram.
10-136 D155AX-8
OPERATE LS VALVE
When control valve is in NEUTRAL position
1. The LS valve is a 3-way selector valve, and LS pressure (PLS) on the inlet of the control valve is transmit-
ted to spring chamber (B), and pump discharged pressure (PP) is transmitted to port (H) of sleeve (8).
2. Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharged
pressure (self pressure) (PP) determine the position of spool (6).
3. Before the engine is started, servo piston (10) is pushed to the right. (See the figure below.)
4. When the engine is started, if the control lever is in NEUTRAL position, LS (PLS) is 0 MPa {0 kg/cm2} . (It is
connected to the drain circuit through the control valve spool.)
5. Spool (6) is pushed to the right and port (C) and port (D) are connected.
6. Pump discharged pressure (PP) enters the large diameter piston side from port (K).
7. The same pump discharged pressure (PP) also enters port (J) on small diameter piston side.
D155AX-8 10-137
8. corresponding to the area difference of servo piston (10),

the servo piston is moved in the direction which makes the
swash plate angle minimum.
Operation in direction to increase pump discharged volume
1. When the difference between pump discharge pressure (PP) and LS pressure (PLS), or LS differential
pressure (∆PLS), decreases (for example, when the open area of the control valve increases and pump dis-
charge pressure (PP) decreases), the combined force of LS pressure (PLS) and force of spring (4) pushes
spool (6) to the left.
2. As spool (6) moves, port (D) is connected to port (E) and connected to PC valve.
3. PC valve is connected to the drain port, and the line between ports (D) and (K) is set to drain pressure (PT).
(The operation of PC valve is explained later.)
4. The pressure at the large piston diameter end of servo piston (10) becomes drain pressure (PT), and pump
discharged pressure (PP) is constantly transmitted to port (J) at the small piston diameter end. Accordingly,
10-138 D155AX-8
servo piston (10) is pushed to the left, and moves the swash plate in the direction to make the discharged
volume larger.
Operation in direction to increase pump discharged volume
1. When servo piston (10) moves to the right (in the direction to reduce the discharged volume) and LS differ-
ential pressure (∆PLS) increases (for example, when the open area of the control valve decreases and
pump discharge pressure (PP) increases), the force caused by pump discharge pressure (PP) pushes
spool (6) to the right.
2. As spool (6) moves, pump discharge pressure (PP) flows through port (C) to port (D), and then through port
(K) to the large diameter piston side.
3. Although pump discharge pressure (PP) is applied to port (J) on the small diameter piston side, servo pis-
ton (10) is pushed to the right by the area difference between the large diameter piston side and small di-
ameter piston side of servo piston (10). As the result, the swash plate angle becomes smaller.
D155AX-8 10-139
When servo piston is balanced
1. The pressure receiving area on the large diameter piston side is set as (A1), that on the small diameter
piston side as (A0), and the pressure entering the large diameter piston side as (PEN).
2. When the force exerted by pump discharged pressure (PP) of the LS valve is balanced with the combined
force exerted by LS pressure (PLS) and spring (4), and the relation becomes (A0) x (PP) = (A1) x (PEN),
servo piston (10) stops in that position.
3. The swash plate of the pump is held at the intermediate position. [The swash plate stops at a position
where the openings from port (D) to port (E) and from port (C) to port (D) of spool (6) are approximately
equal.]
4. At this point, the relationship between the both pressure receiving areas of servo piston (10) is (A0):
(A1)=3:5, so the pressure applied to the both piston ends when it is balanced becomes (PP):(PEN)≒5:3.
5. The force of spring (4) is adjusted so that spool (6) can be balanced at the specified center when (PP) -
(PLS) = 1.96 MPa {20 kg/cm2} .
PC VALVE
PC
Abbreviation for Pressure Compensation
10-140 D155AX-8
STRUCTURE OF PC VALVE
PA: Pump port PM: Mode selector pressure pilot port

PDP: Drain port PPL: Control pressure output port (to LS valve)
1: Wire ring 5: Spool
2: Cover 6: Pin
3: Seat 7: Servo piston assembly
4: Retainer 8: Plug
FUNCTION OF PC VALVE
• The EPC valve consists of the proportional solenoid and
the hydraulic valve.
• When signal current (i) from the controller is received, an
EPC output pressure proportional to the amperage of cur-
rent is generated and output to the PC valve.
D155AX-8 10-141
OPERATE PC VALVE
When signal current is zero (coil is de-energized)
1. When the signal current from the controller is not flowing
through coil (2), coil (2) is de-energized.
2. Spool (5) is pushed to the left by spring (4).
3. Port (P) is closed, and the pressurized oil from the self-
pressure reducing valve does not flow to PC valve.
4. The pressurized oil from PC valve is drained to the tank
through port (C) and port (T).
When signal current is minute (coil is energized)

1. When low signal current flows through coil (2), coil (2) is
energized and generates thrust to push plunger (7) to the
right.
2. Rod (6) pushes spool (5) to the right, and the pressurized
oil from port (P) flows to port (C).
3. The pressure at port (C) increases and the total of the
force applied to the surface of spool (5) and force exerted
by spring (4) becomes larger than the thrust of plunger (7).
4. Spool (5) is pushed to the left, and ports (P) and (C) are
disconnected.
5. Port (C) is connected to port (T).
6. Spool (5) moves to a position where the thrust of plunger
(7) becomes equal to the total of the pressure at port (C)
and the load of spring (4).
7. The circuit pressure between the EPC valve and the PC
valve is controlled in proportion to the amperage of the sig-
nal current.
10-142 D155AX-8
When signal current is maximum (coil is energized)

1. When signal current flows through coil (2), coil (2) is ener-
gized.
2. Since the signal current is maximum at this time, the thrust
of plunger (7) also becomes maximum.
4. The pressurized oil flows from port (P) to port (C) at the
maximum rate, and the circuit pressure between the EPC
valve and PC valve is maximized.
5. Since port (T) closes, the pressurized oil does not flow into
the tank.
PC-EPC VALVE
PC
Abbreviation for Pressure Compensation
EPC
Abbreviation for Electromagnetic Proportional Control
D155AX-8 10-143
STRUCTURE OF PC-EPC VALVE
C: To PC valve T: To tank
P: From self-pressure reducing valve
1: Connector 5: Spool
2: Coil 6: Rod
3: Body 7: Plunger
4: Spring
10-144 D155AX-8
FUNCTION OF PC-EPC VALVE

• The EPC valve consists of the proportional solenoid and
the hydraulic valve.
• When signal current (i) from the controller is received, an
EPC output pressure proportional to the amperage of cur-
rent is generated and output to the PC valve.
OPERATE PC-EPC VALVE

When signal current is zero (coil is de-energized)
1. When the signal current from the controller is not flowing
through coil (2), coil (2) is de-energized.
2. Spool (5) is pushed to the left by spring (4).
3. Port (P) is closed, and the pressurized oil from the self-
pressure reducing valve does not flow to PC valve.
4. The pressurized oil from PC valve is drained to the tank
through port (C) and port (T).
D155AX-8 10-145
When signal current is minute (coil is energized)

1. When low signal current flows through coil (2), coil (2) is
energized and generates thrust to push plunger (7) to the
right.
2. Rod (6) pushes spool (5) to the right, and the pressurized
oil from port (P) flows to port (C).
3. The pressure at port (C) increases and the total of the
force applied to the surface of spool (5) and force exerted
by spring (4) becomes larger than the thrust of plunger (7).
4. Spool (5) is pushed to the left, and ports (P) and (C) are
disconnected.
5. Port (C) is connected to port (T).
6. Spool (5) moves to a position where the thrust of plunger
(7) becomes equal to the total of the pressure at port (C)
and the load of spring (4).
7. The circuit pressure between the EPC valve and the PC
valve is controlled in proportion to the amperage of the sig-
nal current.
When signal current is maximum (coil is energized)

1. When signal current flows through coil (2), coil (2) is ener-
gized.
2. Since the signal current is maximum at this time, the thrust
of plunger (7) is also maximum.
4. The pressurized oil flows from port (P) to port (C) at the
maximum rate, and the circuit pressure between the EPC
valve and PC valve is maximized.
5. Since port (T) closes, the pressurized oil does not flow into
the tank.
10-146 D155AX-8
CONTROL VALVE
STRUCTURE OF CONTROL VALVE
REMARK
The following is the description of the 5-spool valve (single tilt specification) and 6-spool valve (dual tilt specifi-
cation).
General view
REMARK
The figure below shows the 5-spool valve (single tilt specification).
D155AX-8 10-147
A1: To HSS motor A5: To ripper tilt cylinder bottom

A2: To blade tilt cylinder head B1: To HSS motor
A3: To blade lift cylinder head B2: To blade tilt cylinder bottom
A4: To ripper lift cylinder head B3: To blade lift cylinder bottom
10-148 D155AX-8
B4: To ripper lift cylinder bottom IB5: Connector (from controller)

B5: To ripper tilt cylinder head IB5: Connector (from controller)
IA1: Connector (from controller) LS: To pump LS valve
IA2: Connector (from controller) P: Pump port
IA3: Connector (from controller) PC: Pump pressure pickup port plug
IA4: Connector (from controller) PLSC: LS pressure pickup port plug
IA5: Connector (from controller) PEPC1: EPC valve source pressure input port (from
IB1: Connector (from controller) self-pressure reducing valve)
IB2: Connector (from controller) PEPC2: EPC valve source pressure input port (from
self-pressure reducing valve)
IB3: Connector (from controller)
T: Drain port
TS: To tank
1: EPC valve
REMARK
The figure below shows the 6-spool valve (dual tilt specification).
D155AX-8 10-149
A1: To HSS motor A5: To ripper lift cylinder head

A2: To blade tilt cylinder head A6: To ripper tilt cylinder bottom
A3: To blade lift cylinder head B1: To HSS motor
A4: To blade tilt cylinder head B2: To blade tilt cylinder bottom
10-150 D155AX-8
B3: To blade lift cylinder bottom IB5: Connector (from controller)

B4: To blade tilt cylinder bottom IB6: Connector (from controller)
B5: To ripper lift cylinder bottom LS: To pump LS valve
B6: To ripper tilt cylinder head P: Pump port
IA1: Connector (from controller) PC: Pump pressure pickup port plug
IA2: Connector (from controller) PLSC: LS pressure pickup port plug
IA4: Connector (from controller) self-pressure reducing valve)
self-pressure reducing valve)
IA6: Connector (from controller)
T: Drain port
T: Drain port
T: Drain port
TS: To tank
1: EPC valve
Sectional view (1/7)
REMARK
D155AX-8 10-151
10-152 D155AX-8
REMARK
1: Steering spool 7: Valve block
2: Blade tilt spool 8: Valve block
3: Blade lift spool 9: Valve block (6-spool valve only)
4: Blade tilt (pitch) spool (6-spool valve only) 10: Valve body
5: Ripper lift spool 11: Steering priority valve
6: Ripper tilt spool 12: Load check valve
D155AX-8 10-153
13: Pressure compensation valve 14: Filter

REMARK
1: LS relief valve (for work equipment valve) 3: LS shuttle valve

2: LS check valve (for work equipment valve) 4: Preset check valve
10-154 D155AX-8

REMARK
1: LS relief valve (for work equipment valve) 3: LS shuttle valve

2: LS check valve (for work equipment valve) 4: Preset check valve
D155AX-8 10-155
1: Main relief valve 3: Unload valve

2: LS relief valve (for steering valve) 4: Suction valve
10-156 D155AX-8
1. EPC valve
2. Suction valve
D155AX-8 10-157
1: EPC valve 3: LS bypass valve

2: Suction valve
10-158 D155AX-8
REMARK
Apply section H-H to 6-spool valve only.
1: EPC valve 2: Suction valve
D155AX-8 10-159
HYDRAULIC CIRCUIT DIAGRAMS OF CONTROL VALVE AND NAMES OF

VALVES
1: EPC valve 3: Steering priority valve

2: Pressure compensation valve 4: Relief valve
10-160 D155AX-8
Set pressure: 40.2 MPa {410 kg/cm2} 8: Ripper lift valve

5: Unload valve 9: Blade pitch valve
Set pressure: 2.5 MPa {25 kg/cm2} 10: Blade lift valve
6: LS relief valve 11: Blade tilt valve
Set pressure: 37.2 MPa {379 kg/cm2} 12: Steering valve
7: Ripper tilt valve
UNLOAD VALVE OF CONTROL VALVE

FUNCTION OF UNLOAD VALVE OF CONTROL VALVE
When control valve is in NEUTRAL position
When main spool (1) is at “HOLD” position, it drains the excess oil discharged by the pump, and prevents the
pressure from being formed in the circuit from rising.
D155AX-8 10-161
OPERATE UNLOAD VALVE OF CONTROL VALVE

When main spool (1) is at “HOLD” position, it drains the excess oil discharged by the pump, and prevents the
pressure from being formed in the circuit from rising.
1. When main spool (1) is at “HOLD” position, the pump discharge pressure passes from chamber (A) through
orifice (4) to chamber (D). Chambers (C) and (C') are connected to the drain circuit.
2. When pressurized oil is supplied from the pump, the pressure in chamber (D) increases, and main spool (1)
is pushed to the right by the received pressure which is determined by the cross-sectional area of piston (3)
receiving the pressure.
3. When this received pressure becomes larger than the set force of spring (2), main spool (1) moves to the
right and connects chambers (A) and (B), so the oil from the pump is drained.
4. Therefore, main spool (1) is balanced at a position that matches the supply of oil from the pump.
5. Actually, the amount of oil supplied from the pump is small, so the pressure in the circuit is almost the same
as the set force of spring (2).
10-162 D155AX-8
FUNCTION OF OILFLOW CONTROL OF CONTROL VALVE

Use of the CLSS circuit (Closed Center Load Sensing System) makes it possible to control the oil flow by ad-
justing the area of opening of the spool driven by the EPC valve regardless of the load.
OPERATE OILFLOW CONTROL OF CONTROL VALVE

Use of the CLSS circuit (Closed Center Load Sensing System) makes it possible to control the oil flow by ad-
justing the area of opening of the spool driven by the EPC valve regardless of the load.
When steering valve is at HOLD position
1. When steering spool (1) is at “HOLD” position, the pump discharged pressure is transmitted from chamber
(A) of the steering priority valve through the notch in spool (3) of the steering priority valve, and passes
through chamber (B) to chamber (C) of steering spool.
2. Oil in chamber (G) of the steering priority valve is drained through chamber (H) to chamber (F) of the steer-
ing spool.
3. Since the pump discharged pressure is acting on the left end of spool (3) of the steering priority valve, it
compresses spring (4) and moves to the right to the maximum stroke position.
D155AX-8 10-163
4. In this condition, the area of the opening to steering spool (1) of the steering priority valve is at its minimum.
When steering valve is set for steering left
• ΔPLS = Differential pressure between ports (K) and (J) = 2.0 MPa {20 kg/cm2}

• ΔPLS’ = Differential pressure between ports (I) and (D)
• ΔPLS ≒ PLS'
10-164 D155AX-8
1. When PCCS lever is operated to “LEFT”, pilot pressure

(PI) acts on the right end of steering spool (1) through the
EPC valve.
2. When the pressure becomes greater than the set load of
spring (2), steering spool (1) moves to the left and is bal-
anced at a position that matches pilot pressure (PI).
3. Chambers (C) and (D) are connected, and the oil dis-
charged from the pump flows through ports (A), (B), (C)
and (D) to HSS motor (6).
4. At the same time, the load pressure in chamber (D) of the
steering spool is transmitted through LS orifice (5) and
chamber (H) to chamber (G) of steering priority valve, and
is further transmitted through LS circuit (O) to the LS valve
of the work equipment and HSS pump.
5. Since chamber (B) pressure ≒ chamber (C) pressure, and
chamber (G) pressure ≒ chamber (D) pressure, steering
priority valve spool (3) is controlled by the differential pres-
sure of steering spool (1) [chamber (C) pressure - cham-
ber (D) pressure] and balanced with spring (4).
6. If the oil flow is too large, the differential pressure of steer-
ing spool (1) becomes larger, so steering priority valve
spool (3) moves in the direction to throttle the oil flow.
7. On the other hand, if the oil flow is too small, steering pri-
ority valve spool (3) moves in the direction to increase the oil flow.
8. LS valve of the pump is controlled so that the differential pressure between pump discharged pressure (P)
and LS pressure (LS) [LS differential pressure: ΔPLS] remains constant, so a suitable amount of oil flows to
ensure that the loss of pressure at the control valve (ΔPLS’) is equal to ΔPLS.
9. The loss of pressure in the control valve is determined by the area of the opening of steering spool (1), so
the oil flow matches the opening of steering spool (1).
10. The return oil flow from HSS motor (6) is drained through chamber (E) and chamber (F).
D155AX-8 10-165
When blade lift valve, blade tilt valve, ripper lift valve, and ripper tilt valve of
work equipment valve is at HOLD position
The figure shows the blade lift valve and steering valve.
10-166 D155AX-8
1. When blade lift spool (1) is at “HOLD” position, the pump discharged pressure (unload pressure) is trans-
mitted to chambers (D) and (D').
2. The pressure is not formed in chambers (H) and (H'), so pressure compensation valve spool (3) and steer-
ing priority valve spool (4) are pressed to the right.
3. The pump discharged pressure is transmitted to chamber (C) of the pressure compensation valve through
chambers (A) and (B) of steering priority valve spool (4), and is further transmitted through chambers (D)
and (E) to chamber (F) of the blade lift spool.
4. In the same way as described in “Steering valve”, the position of pressure compensation valve spool (3) is
determined to match the opening of blade lift spool (1), and the oil flow is determined so that pressure loss
(ΔPLS) of the control valve becomes equal to the control differential pressure (ΔPLS') of the pump LS
valve.
D155AX-8 10-167
Meter-out control when blade moves down under its own weight (work equip-
ment lever in “LOWER”)
1. When the blade moves down under its own weight, the oil flow of return oil from blade lift cylinder is control-
led by the area of the opening of blade lift spool (1).
10-168 D155AX-8
2. When the port of blade lift spool (1) is opened by pilot pressure (PI), because of the weight of the blade, the
pressurized oil from the cylinder head side passes through ports (A), (B), (C) and (D), and is drained to the
tank.
3. The flow of return oil from the blade lift cylinder is throttled by the area of opening between ports (A) and (B)
of the blade lift spool, so the lowering speed is controlled.
4. The pressurized oil flowing from the blade lift cylinder head end passes from the drain circuit through suc-
tion valve (2) and is supplied to the bottom end of the blade lift cylinder.
5. The oil discharged from the pump passes through ports (A'), (B'), (C'), (D') and (E'), and is supplied to the
blade lift cylinder bottom.
D155AX-8 10-169
Meter-out control when blade moves down under its own weight (work equip-
ment lever in “FLOAT”)
When the blade lift valve is at “FLOAT”, the cylinder port and drain port are interconnected to put the circuit in a
no-load condition.
10-170 D155AX-8
1. When the blade lift valve is in “FLOAT” condition, the pump circuit and cylinder ports (A3) and (B3) are dis-
connected so that the other control valves can be operated.
2. When the work equipment control lever is set at “LOWER” position and “FLOAT” button is pressed, output
pressure (PA3) of the EPC valve becomes 3.4 MPa {35 kg/cm2} or more and blade lift spool (1) is moved to
the maximum stroke position.
3. Ports (A3) and (B3) and LS circuit (O) are all interconnected to the drain circuit, so there is no load on the
blade lift cylinder.
4. If the blade lift cylinder is driven by the weight of the blade, the pressurized oil entering from port (A3) flows
to ports (A), (B), (B') and (A'), while the rest of the pressurized oil flows through ports (C) and (D), and is
drained.
5. The oil flow is throttled by the area of opening of blade lift spool (1) between ports (A) and (B) to control the
cylinder speed.
6. The pump circuit chamber (E) and ports (A3) and (B3) are disconnected but pump discharged pressure (P)
is formed at chamber (E), so it is possible to carry out combined operations with other control valves.
FUNCTION OF CONTROL VALVE DURING HYDRAULIC RELIEF

Steering valve
REMARK
The figure shows the condition of steering LS relief valve (5) during hydraulic relief.
D155AX-8 10-171
• ΔP1 = ΔP3 + ΔP4 = Differential pressure between ports (M) and (E)
• ΔP2 = Differential pressure between ports (E) and (N)
• ΔP3 = Differential pressure between ports (M) and (B)
• ΔP4 = Differential pressure between ports (B) and (E)
10-172 D155AX-8
• ΔLS = ΔP1 + ΔP2 = Differential pressure between ports (M) and (N) = 2.0 MPa {20 kg/cm2}
• This valve sets the maximum pressure when HSS motor (7) is operated.
OPERATE CONTROL VALVE DURING HYDRAULIC RELIEF

When steering is in operation
REMARK
The figure shows the condition of steering LS relief valve (5) during hydraulic relief.
D155AX-8 10-173
• ΔP1 = ΔP3 + ΔP4 = Differential pressure between ports (M) and (E)
• ΔP2 = Differential pressure between ports (E) and (N)
• ΔP4 = Differential pressure between ports (B) and (E)
10-174 D155AX-8
This valve sets the maximum pressure when HSS motor (7) is operated.
1. If steering spool (1) is moved and the pressure of HSS motor (7) becomes higher, the poppet of steering LS
relief valve (5) will start to open and oil is drained from LS circuit (O). [Ports (E), (F), (G), (J), (K), and (L)]
2. As a result, there will be a drop in pressure in LS passage (O) starting from LS sensing hole (F), and ΔP2
will become larger.
3. For the same reason, if the pressure in chambers (H) and (I) drops, steering priority valve spool (2) will
push against spring (3) and move to the right, and will make the opening between chambers (B) and (C)
smaller, so the flow to chambers (B) and (C) will be throttled and ΔP4 will become larger.
4. Because of the pump swash plate control, the system circuit is balanced at a circuit pressure which makes
the pressure loss generated by the flow at steering LS relief valve (5), ΔP1 + ΔP2, equal to LS differential
pressure (ΔLS).
5. The pump LS valve detects the differential pressure generated by steering LS relief valve (5), and moves
the pump swash plate angle from the maximum to the minimum position. The pump swash plate is bal-
anced at a position where the LS differential pressure is 2.0 MPa {20 kg/cm2} .
6. When the pump is at the minimum swash plate angle (minimum oil flow), if the minimum oil flow is greater
than the [LS relief oil flow + leakage at any part], the pressure is confined in the pump circuit [between the
pump and chambers (A) and (B)], so the LS differential pressure rises.
7. If this differential pressure goes above the set pressure for unload valve (4), the unload valve is actuated to
relieve the excess oil flow and balance the circuit.
When blade lift, blade tilt, ripper lift and ripper tilt are operated
REMARK
The figure shows the condition when work equipment LS valve (5) is relieved at blade tilt stroke end.
D155AX-8 10-175
• ΔP1 = ΔP3 + ΔP4 = Differential pressure between ports (M) and (P)
• ΔP2 = Differential pressure between ports (P) and (N)
• ΔP4 = Differential pressure between ports (B) and (P)
10-176 D155AX-8
1. If blade tilt spool (1) is moved and the pressure of the blade tilt cylinder becomes higher, the poppet of work
equipment LS relief valve (5) will start to open and pressurized oil will be drained from LS circuit (O). [Ports
(E), (F), (G), (J), (K) and (L)]
2. As a result, there will be a drop in pressure in LS passage (O) starting from LS sensing hole (F), and ΔP2
will become larger.
3. For the same reason, if the pressure in chambers (H) and (I) drops, pressure compensation valve spool (2)
will push against spring (3) and move to the right, and will make the opening between chambers (B) and (C)
smaller, so the flow to chambers (B) and (C) will be throttled and ΔP4 will become larger.
4. Because of the pump swash plate control, the system circuit is balanced at a circuit pressure which makes
the pressure loss generated by the flow at work equipment LS relief valve (5), ΔP1 + ΔP2, equal to LS dif-
ferential pressure (ΔLS).
5. The pump LS valve detects the differential pressure generated by work equipment LS relief valve (5), and
moves the pump swash plate angle from the maximum to the minimum position. The pump swash plate is
balanced at a position where the LS differential pressure is 2.0 MPa {20 kg/cm2} .
6. When the pump is at the minimum swash plate angle (minimum oil flow), if the minimum oil flow is greater
than the (LS relief oil flow + leakage at any part), the pressure is confined in the pump circuit [between the
pump and chambers (A) and (B)], so the LS differential pressure rises.
7. If this differential pressure goes above the set pressure for unload valve (4), the unload valve is actuated to
relieve the excess oil flow and balance the circuit.
Combined operation of steering and blade tilt
REMARK
The figure shows LS relief valves (4) and (5) relieved when the steering is stalled and the blade tilt cylinder is at
the stroke end.
D155AX-8 10-177
• Δ = P - P2
• ΔPO = Differential pressure between ports (H) and (K)
• Pressure P2 = LSO + ΔPO
10-178 D155AX-8
• When steering spool (1) and blade tilt spool (2) are relieved at the same time, the pump discharged pres-
sure is separated by pressure compensation valve spool (3) in the blade tilt valve, and the port pressure is
maintained at a constant value.
1. If HSS motor (6) stalls, the load pressure increases and steering valve LS relief valve (4) operates to cut off
the system. (For details, see “At relief, Steering valve”.)
2. The pump discharged pressure (P) is maintained at 38.2 MPa {390 kg/cm2} at this time, and this is trans-
mitted to chamber (G) of the blade tilt valve.
3. When blade tilt spool (2) is operated and the load on the blade tilt valve is greater, LS relief valve (5) for
blade tilt valve is actuated, and drain oil flow (Q1) flows to LS circuit (O).
4. A differential pressure is generated on the right and left sides of pressure compensation valve spool (3) by
LS throttle (M) of blade tilt spool (2), and it moves the full stroke to the right.
5. The opening between chambers (D) and (E) is throttled to the minimum size (pump pressure separated).
6. Oil flow (Q1) is determined by pump discharged pressure (P) and the total pressure loss Δ (P - LSO) of
ports (C), (D), (E), (F), (G), (I), (J) and (K).
7. Furthermore, pressure (P2) [the pressure in chamber (H)] becomes the total (LSO + ΔPO) of the set pres-
sure of work equipment LS relief valve (5) and the circuit pressure loss of ports (H), (I), (J) and (K).
FUNCTION OF CONTROL VALVE DURING COMBINED OPERATION

Steering and work equipment valve
REMARK
The figure shows the condition when the steering and blade lift valve are operated at the same time.
D155AX-8 10-179
The steering valve is equipped with steering priority valve spool (3), so if the steering valve and the downstream
work equipment valve are operated at the same time, priority is given to the flow of oil to the steering valve, and
the rest of the volume of oil discharged from the pump goes to the work equipment valve.
10-180 D155AX-8
OPERATE CONTROL VALVE DURING COMBINED OPERATION

Combined operations of steering system and work equipment
REMARK
The figure shows the condition when the steering and blade lift valve are operated at the same time.
D155AX-8 10-181
The steering valve is equipped with steering priority valve spool (3), so if the steering valve and the downstream
work equipment valve are operated at the same time, priority is given to the flow of oil to the steering valve, and
the rest of the volume of oil discharged from the pump goes to the work equipment valve.
10-182 D155AX-8
1. When steering spool (1) is operated to the left by EPC

valve output pressure (PI), the oil flows into the HSS motor
and a differential pressure is generated between the inlet
and outlet of the steering spool and between chambers (C)
and (D).
2. Steering priority valve spool (3) is controlled by this differ-
ential pressure, and at the same time, the pump swash
plate angle is controlled at ΔPLS = 2.0 MPa {20 kg/cm2} ,
and the oil flow to the steering valve is determined.
3. For details, see “Control of oil flow, Steering valve”.
4. In this condition, if downstream work equipment blade lift
spool (2) is operated, the pump discharged pressure mo-
mentarily drops
5. At the same time, ΔPLS becomes smaller, so the pump swash plate tilts toward the maximum angle in or-
der to increase the oil flow by the amount which compensates the pressure drop.
6. The differential pressure between chambers (C) and (D) becomes smaller, and steering priority valve spool
(3) is moved to the left by the pressure in chamber (E) in the direction to throttle the opening to the work
equipment valve.
When pump swash plate does not reach maximum angle
1. When the maximum oil flow from the pump is greater than the sum of the flow demanded by the steering
valve and work equipment valve, an amount of oil that matches the opening of steering spool (1) flows to
the steering valve.
2. An amount of oil determined by the pump discharged pressure, the load pressure and the area of the spool
opening, flows to the work equipment valve.
When pump swash plate is at maximum angle
When steering valve load ≦ work equipment valve load
• An amount of oil that matches the opening of steering spool (1) flows to the steering valve, and the remain-
ing oil flows to the work equipment valve.
When steering valve load > work equipment valve load.
• Pump discharged pressure (P) is determined by the steering valve load, but in this condition, if the down-
stream work equipment valve where the load is smaller is operated, the difference in pressure causes the
oil to try to flow to the work equipment valve, so the pump discharged pressure drops.
• To ensure the flow of oil to the steering system, steering priority valve spool (3) increases the area of the
opening to the steering system, while at the same time reducing the area of the opening to the work equip-
ment.
• In this condition, the flow of oil is divided in proportion to the difference in pressure between differential
pressure (P) – (P1) and differential pressure (P) – (P2).
• The bigger (P1) – (P2) is, the smaller the flow of oil to the steering system becomes.
Combined operation of blade lift and blade tilt
REMARK
The figure shows the condition when the blade lift and blade tilt are operated at the same time.
D155AX-8 10-183
It consists of a parallel circuit, so when combined operations are carried out, the oil flow is divided correspond-
ing to the opening area of each spool.
1. When blade tilt spool (1) and blade lift spool (2) are at the “HOLD” position or are at “OPERATE”, steering
priority valve (3) is pressed to the right, and the area of the opening to the downstream section is at its max-
imum.
10-184 D155AX-8
2. Blade tilt spool (1) and blade lift spool (2) are actuated by EPC valve output pressures (PA2) and (PB3),
and each of them is balanced at a position that matches its own EPC valve output pressure.
When pressure (P2) ≦ pressure (P3)
Blade lift valve load pressure (P3) is transmitted to the pump LS valve through LS circuit (O).
When pump swash plate does not reach maximum angle
• When the maximum flow of oil from the pump is greater than the sum of the oil flow demanded by the blade
tilt valve and blade lift valve, an oil flow that matches the opening of the spool flows to both of the blade tilt
valve and blade lift valve.
When pump swash plate is at maximum angle
• When the maximum flow of oil from the pump is smaller than the sum of the oil flow demanded by the blade
tilt valve and blade lift valve, the flow of oil to the blade tilt valve and blade lift valve is divided corresponding
to differential pressure (PO) - (P2) and differential pressure (PO) - (P3).
• In other words, more oil flows to (P2) where the load is small.
REMARK
When the blade is raised and the blade tilt valve and blade lift valve are moved to “RAISE” position at the same
time, the blade tilt valve load pressure is smaller than the blade lift valve load pressure, so the flow of oil to the
blade tilt valve is given priority. In addition, the oil flow demanded by the blade tilt valve is smaller, so the condi-
tion is just as if priority was given to the oil flow for the blade tilt valve.
When pressure (P2) = pressure (P3)
(P) – (P2) ≒ (P) – (P3), so an oil flow proportional to the size of the spool opening of each spool is distributed.
OPERATE UNLOAD VALVE PRESET SYSTEM

REMARK
The figure shows the condition with preset check valve (3) open immediately after blade lift valve is operated.
D155AX-8 10-185
1. This improves the response of the system including the pressure compensation valve and pump swash
plate by sending the pilot pressure (EPC valve source pressure) to the LS circuit, and compensating the
rise of the LS circuit pressure.
10-186 D155AX-8
2. When blade lift valve spool (1) is at “HOLD” position, pilot pressure (P1) (source pressure of PPC valve) is
sent through preset check valve (3) to chamber (F) of the pressure compensation valve. This pressure is
called preset pressure (P2).
3. Unload pressure (P) is transmitted to chamber (B), but (P1) + (F0) > (P) [F0: load of spring (4)], so pressure
compensation spool (2) moves to the left and the size of the opening between chambers (A) and (B) be-
comes the maximum.
4. When blade lift spool (1) is switched, unload pressure (P) flows immediately through chambers (A), (B), (C),
(D) and (E) to the blade lift cylinder, so the pressure at the port starts to rise and the time lag becomes
smaller.
5. At the same time, preset pressure (P2) is transmitted to LS circuit (O), and the pressure in the LS circuit
rises.
6. Unload valve (7) closes, and oil flows further to the pump LS valve to improve the response of the pump
swash plate angle. This makes it possible to reduce the response time for giving the necessary oil flow.
D155AX-8 10-187
LAYOUT OF POWER TRAIN SYSTEM 10 STRUCTURE AND FUNCTION
POWER TRAIN SYSTEM

LAYOUT OF POWER TRAIN SYSTEM
10-188 D155AX-8
10 STRUCTURE AND FUNCTION LAYOUT OF POWER TRAIN SYSTEM
1: Universal joint 7: Centralized pressure pickup port

2: Torque converter and PTO 8: Torque converter control valve
3: Transmission 9: Transmission ECMV
4: Bevel gear shaft, HSS, and brake 10: Brake control valve
5: Final drive 11: Main relief valve and torque converter relief valve
6: Work equipment and HSS pump (HPV190) 12: Power train oil filter
D155AX-8 10-189
LAYOUT OF POWER TRAIN SYSTEM 10 STRUCTURE AND FUNCTION
13: Scavenging pump (SAR(4) 140) 17: Transmission output shaft speed sensor
14: Power train oil cooler (with built in radiator lower 18: Torque converter oil temperature sensor
tank) 19: Torque converter outlet oil pressure sensor
15: HSS motor (KMF140) 20: Torque converter inlet oil pressure sensor
16: Power train pump and steering lubrication pump
(SAR(3) 100 + 40)
10-190 D155AX-8
10 STRUCTURE AND FUNCTION OPERATE POWER TRAIN SYSTEM
OPERATE POWER TRAIN SYSTEM
• The power generated by the engine is transmitted from universal joint (1) to torque converter (2) after its
torsional vibrations have been reduced with damper.
• The power from the engine is transmitted through the oil by torque converter (2) to the transmission input
shaft (turbine shaft) corresponding with the change in load.
• Transmission (3) uses a combination of planetary gear mechanisms and hydraulic clutches to reduce the
speed and shift the gears (3 forward speeds and 3 reverse speeds). corresponding to the change in load, 2
clutches are selected and engaged to transmit the power from the bevel pinion at the rear end of the trans-
mission to bevel gear fixed to the bevel gear shaft.
• The power transmitted to the bevel gear shaft is then further transmitted to HSS (Hydrostatic Steering Sys-
tem) unit (4).
Work equipment and HSS pump (6) is driven by PTO (5), and the oil discharged from it drives HSS motor
(7).
The rotation of the pair of the HSS gears on the right and left is controlled by HSS motor (7). The turning
direction is controlled by generating a difference in speed on the right and left.
It is also possible to use the HSS mechanism to reverse the rotation to the right and left to perform the
counter-rotation turn.
• Brake (8)of HSS is used for braking the machine. Brake (8) is a wet, multiple disc clutch and spring boosted
type.
The power output from brake (8) is transmitted to final drive (9).
D155AX-8 10-191
OPERATE POWER TRAIN SYSTEM 10 STRUCTURE AND FUNCTION
• Final drive (9) consists of a single-stage spur gear and a single-stage planetary gear system. It reduces the
speed and rotates sprocket (10) to drive the track shoe and move the machine.
10-192 D155AX-8
10 STRUCTURE AND FUNCTION TRANSMISSION, STEERING, AND BRAKE CONTROL
TRANSMISSION, STEERING, AND BRAKE CONTROL

LAYOUT OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM
PARTS
General view
D155AX-8 10-193
TRANSMISSION, STEERING, AND BRAKE CONTROL 10 STRUCTURE AND FUNCTION
1: Parking brake lever 10: DOWN switch

2: Electric steering lever 11: UP switch
3: Joystick (steering, directional, and gear shift lever) 12: Rod
(PCCS lever) 13: Limit switch
4: Power train controller 14: Brake pedal
5: HSS motor 15: Brake pedal potentiometer
6: Brake control valve 16: Decelerator pedal potentiometer
7: Transmission control valve 17: Decelerator pedal
8: Machine pitch angle sensor
9: Parking lock switch
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL
10-194 D155AX-8
10 STRUCTURE AND FUNCTION TRANSMISSION, STEERING, AND BRAKE CONTROL
• The transmission and steering are controlled with joystick (steering, directional, and gear shift lever) (PCCS
lever) (5).
• The machine has a safety mechanism for starting engine. If parking brake lever (1) is not in LOCK position,
parking lock switch (9) does not operate and engine cannot be started.
• While parking brake lever (1) is in LOCK position, power train controller (4) does not send the signal of turn-
ing to the EPC valve of the control valve.
• Joystick (steering, directional and gear shift lever) (PCCS lever) (3) sends electric signals to power train
controller (4). Upon receiving these electric signals, power train controller (4) sends signals to EPC valve of
the control valve to change the discharge of the pump and control the HSS motor.
• When the operator depresses brake pedal (14), rod (12) operates potentiometer (15) to send the electric
signal to power train controller (4). Upon receiving this signal, power train controller (4) sends the signal to
the brake control valve to apply the brake.
• When brake pedal (14) moves near the stroke end, limit switch (13) turns ON and operates the brake.
D155AX-8 10-195
HSS SYSTEM 10 STRUCTURE AND FUNCTION
HSS SYSTEM
HSS
HSS SYSTEM DIAGRAM
1: Joystick (steering, directional, and gear shift lever) 4: Work equipment and HSS pump
(PCCS lever) 5: Engine
2: Power train controller 6: EPC valve
3: Control valve 7: Hydraulic tank
10-196 D155AX-8
10 STRUCTURE AND FUNCTION HSS SYSTEM
8: Sprocket 11: HSS open hydraulic circuit

9: Final drive 12: Servo valve
10: HSS motor 13: Engine controller
Input/output signal
A: Directional signal C: Engine control information
B: Steering signal D: CAN communication network
FUNCTION OF HSS SYSTEM

• HSS is an abbreviation for Hydrostatic Steering System.
Hydrostatic means fluid statics.
• As shown in the figure, the HSS system consists of one set of control valve (3), work equipment and HSS
pump (4), and HSS motor (10). With this system, the machine can turn by creating a difference between the
right and left track speeds without decreasing the travel speed.
• Power train controller (2) controls the rotation direction and speed of HSS motor (10) via EPC valve (6) of
control valve (3) corresponding to the tilting direction and angle of joystick (steering, directional, and gear
shift lever) (PCCS lever) (1).
• HSS motor (10) drives the planetary gear mechanism on the bevel gear shaft and creates a difference in
speed between right and left sprockets (8) to turn the machine.
• Power train controller (2) detects the engine speed and hydraulic pressure at each part to control the trans-
mission and control valve (3) so that the engine will not stall.
• Engine control information including the engine speed is exchanged through the CAN communication net-
work between engine controller (13) and power train controller (2).
D155AX-8 10-197
HSS SYSTEM 10 STRUCTURE AND FUNCTION
10-198 D155AX-8
10 STRUCTURE AND FUNCTION CENTRALIZED PRESSURE PICKUP PORT
CENTRALIZED PRESSURE PICKUP PORT

LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT
SC: Stator clutch oil pressure pickup port 3RD: 3rd clutch oil pressure pickup port
LU: Lockup clutch oil pressure pickup port 2ND: 2nd clutch oil pressure pick-up port
F: F clutch oil pressure pickup port RB: Right brake pressure pickup port
R: R clutch oil pressure pickup port LB: Left brake pressure pickup port
1ST: 1st clutch oil pressure pickup port TM: Transmission main relief pressure pickup port
D155AX-8 10-199
CENTRALIZED PRESSURE PICKUP PORT 10 STRUCTURE AND FUNCTION
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT

The serviceability is improved by centralizing the oil pressure pickup ports necessary to Pm clinic into step cover
at the right of the cab.
10-200 D155AX-8
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF POWER TRAIN SYSTEM
COMPONENT PARTS OF POWER TRAIN SYSTEM

UNIVERSAL JOINT
STRUCTURE OF UNIVERSAL JOINT
1: Spider 2: Yoke
FUNCTION OF UNIVERSAL JOINT

The universal joint transmits the power output from the damper to the torque converter, while absorbing impacts
and vibration from it.
D155AX-8 10-201
COMPONENT PARTS OF POWER TRAIN SYSTEM 10 STRUCTURE AND FUNCTION
POWER TRAIN MOUNT

STRUCTURE OF POWER TRAIN MOUNT
General view
1: Front mount 5: Plate

2: Rear mount 6: Seal
3: Cover 7: Coupling
4: Cage 8: Clamp
10-202 D155AX-8
FUNCTION OF POWER TRAIN MOUNT

The mounts are installed at 2 places in the front section and at 2 places in the rear section to secure the main
frame and power train.
TORQUE CONVERTER AND PTO

PTO
Abbreviation for Power Take Off
STRUCTURE OF TORQUE CONVERTER AND PTO

General view
D155AX-8 10-203
A: From power train pump D: From transmission case

B: To power train oil cooler E: To transmission case
C: From main relief valve F: From power train oil cooler
10-204 D155AX-8
Sectional view
D155AX-8 10-205
1: Work equipment and HSS pump mounting location

2: Cooling fan pump mounting location
3: Scavenging pump mounting location
4: Power train pump and steering lubrication pump mounting
location
5: Torque converter case
6: Coupling
7: Input shaft (number of teeth: 58)
8: PTO idler gear (number of teeth: 66)
9: PTO idler gear shaft
10: Lockup clutch housing
11: Turbine
12: Drive case
13: Race
14: Stator
15: Pump
16: Retainer
17: Stator clutch front housing
18: Pump shaft
19: Stator clutch rear housing
20: Stator shaft
21: Stator clutch hub
22: Stator clutch plate
23: Stator clutch disc
24: Stator clutch piston
25: Transmission input shaft
26: Lockup clutch plate
27: Lockup clutch disc
28: Lockup clutch piston
29: Turbine boss
30: PTO gear A (number of teeth: 49)
31: PTO gear B (number of teeth: 48)
32: Scavenging pump drive gear (number of teeth: 56)
33: Torque converter control valve
34: Power train oil strainer
35: Sleeve
Structure
• The torque converter is a 3-element, single stage, 2 phase type and is integrated with the transmission.
• The torque converter is equipped with a wet double disc clutch type torque converter lockup device and a
stator clutch in order to reduce fuel consumption, to increase the operating performance, and to reduce the
horsepower consumption by the engine.
• For higher efficiency of continuous light dozing and leveling operation, the torque converter is locked up
(pump (15) and turbine (11) are integrated into 1 unit) and the engine power is transferred directly to the
transmission input shaft (25).
10-206 D155AX-8
• When the torque converter is locked up, the oil is still supplied to the torque converter.
Accordingly, the oil flowing from pump (15) through turbine (11) to stator (14) is obstructed by the stator
blades and cannot flow in any determined direction. As a result, this oil resists the rotation of the pump and
turbine (it is stirred).
• To reduce the rotating resistance of pump (15) and turbine (11), the stator clutch is disengaged simultane-
ously with lockup of the torque converter so that stator (14) can rotate freely.
• As stator (14) is dragged and turned by pump (15) and turbine (11), the oil returns from the turbine to the
pump smoothly to reduce resistance.
• Conditions for lockup mode and torque converter mode
Torque converter output shaft speed

Lockup mode Torque converter mode
Forward 1st Min. 1313 rpm Max. 1262 rpm
Forward 2nd Min. 1899 rpm Max. 1876 rpm
Forward 3rd Min. 1366 rpm Max. 1355 rpm
Reverse 1st Min. 1244 rpm Max. 1216 rpm
Reverse 2nd Min. 1196 rpm Max. 1177 rpm
Reverse 3rd Min. 1622 rpm Max. 1613 rpm
• Pump (15) is integrated with coupling (6), input shaft (7), lockup clutch housing (10), and drive case (12),
and is rotated by the engine power.
• Turbine (11) is integrated with turbine boss (29) and transmission input shaft (25), and rotated by the medi-
um of the oil from pump (15).
• Stator (14) is integrated with stator shaft (20) and stator clutch hub (21), and fixed to torque converter case
(5) through the stator clutch unit.
• The lockup clutch unit consists of clutch plate (26) meshed with drive case (12), clutch disc (27) meshed
with turbine boss (29), and clutch piston (28) which slides inside clutch housing (10) integrated with drive
case (12).
• The stator clutch unit consists of clutch hub (21) connected to stator shaft (20) with spline, clutch disc (23)
meshed with clutch hub (21), clutch plate (22) supported by the pins on clutch front housing (17) and clutch
rear housing (19), and clutch piston (24) which slides inside clutch front housing (17).
Clutch front housing (17) is fixed to torque converter case (5) with sleeve (35).
• The PTO unit consists of input shaft (7), PTO idler gear (8), PTO gear A (30), PTO gear B (31) and scav-
enging pump drive gear (32).
D155AX-8 10-207
POWER TRANSMITTING ROUTE OF TORQUE CONVERTER

Sectional view When lockup clutch is “disengaged” and stator clutch is “engag-
ed”
Drive case (4) is disconnected from turbine boss (8) and tur-
bine (7) and the torque converter works as an ordinary torque
converter.
Engine power
↓
Damper
↓
Universal joint
↓
Coupling (1)
↓
Input shaft (2)
↓
Clutch housing (3), drive case (4), and pump (5) rotate together
↓
Oil is used as a medium
↓
Turbine (7) and turbine boss (8)
↓
Transmission input shaft (9)
If stator clutch (10) is “engaged”, torque converter case (11) and stator shaft (12) are connected to each other to
fix stator (13).
10-208 D155AX-8
Sectional view When lockup clutch is “engaged” and stator clutch is “disengag-
ed”
Drive case (4) is connected to turbine boss (8) and turbine (7),
and the torque converter is locked up.
Engine power
↓
Damper
↓
Universal joint
↓
Coupling (1)
↓
Input shaft (2)
↓
Clutch housing (3), drive case (4), and pump (5) rotate together
↓
Lockup clutch (6)
↓
Turbine boss (8)
↓
Transmission input shaft (9)
If stator clutch (10) is “disengaged”, torque converter case (11) and stator shaft (12) are disconnected, and sta-
tor (13) is drag-turned by pump (5) and turbine (7).
D155AX-8 10-209
TORQUE CONVERTER OIL FLOW

1. The oil flows through the main relief valve and its pressure
is reduced to below the set pressure by the torque convert-
er relief valve. It then flows in inlet port (A), goes through
the oil passages of torque converter case (1), stator clutch
front housing (2), pump shaft (3) and retainer (4), and
flows into pump (5).
2. The oil is given centrifugal force by pump (5) and flows in
turbine (6) to transfer its energy to turbine (6).
3. The oil from turbine (6) is sent to stator (7) and flows in
pump (5) again. A part of the oil, however, is sent to stator
(7) and through outlet port (B) to the power train oil cooler.
TORQUE CONVERTER CONTROL VALVE

STRUCTURE OF TORQUE CONVERTER CONTROL VALVE
A: From power train pump B: Stator clutch oil pressure pickup port (SC)
10-210 D155AX-8
C: Lockup clutch oil pressure pickup port (LC)

1: Torque converter oil filter 3: Lockup clutch ECMV
2: Stator clutch ECMV
FUNCTION OF TORQUE CONVERTER CONTROL VALVE

• The torque converter control valve consists of the ECMV's which control the lockup clutch and stator clutch
respectively.
• This valve locks the torque converter with the lockup clutch to reduce fuel consumption, to increase the op-
erating performance, and to reduce the horsepower consumption by the engine during low-load operation.
It also disengage the stator clutch to reduce the rotation resistance of the pump and turbine in the torque
converter.
LOCKUP CLUTCH ECMV

ECMV
Abbreviation for Electronic Control Modulation Valve
STRUCTURE OF LOCKUP CLUTCH ECMV

NOTICE
Do not disassemble this ECMV since it needs to be adjusted for maintaining the performance once as-
sembled.
A: To clutch T: Drain
P: From pump DR: Drain
D155AX-8 10-211
P1: Clutch oil pressure pickup port

1: Fill switch connector 5: Proportional solenoid
2: Proportional solenoid connector 6: Pressure control valve
3: Oil pressure pickup valve 7: Nameplate (*1)
4: Fill switch
*1:
Clutches engaged Stamp on name plate
Lockup E*******
Stator A*******
FUNCTION OF LOCKUP CLUTCH ECMV

• This valve is used to adjust the clutch oil pressure to the set pressure and select a clutch.
• Since the pressure application characteristics to the clutch is used for the modulation waveform, ECMV is
capable of connecting the lockup clutch smoothly, thereby reducing the shocks resulting from gear shift. In
addition, the above prevents the generation of peak torque in the power train. As a result, it provides a com-
fortable ride for the operator and increases the durability of the power train.
When torque converter mode changes to direct drive mode
When gear is shifted (in direct travel)
10-212 D155AX-8
OPERATE LOCKUP CLUTCH ECMV

Operation during travel in torque converter mode
1. When traveling in torque converter drive mode, current
does not blow to proportional solenoid (1).
2. Pressure control valve (3) drains the oil from clutch port (A)
through drain port (T), and lockup clutch is “disengaged”.
3. Fill switch (5) is turned “OFF” at this time, since no oil pres-
sure is applied to pressure detection valve (4).
Operation during travel in direct drive mode (when being filled)

When the travel mode is changed from the torque converter
drive mode to the direct drive mode, current flows in proportion-
al solenoid (1), the oil pressure force balanced with the sole-
noid force is applied to chamber (B), and it pushes pressure
control valve (3) to the left. As a result, pump port (P) and
clutch port (A) open. When the clutch is filled with oil, oil pres-
sure pickup port (4) actuates and fill switch (5) is turned “ON”.
D155AX-8 10-213
Operation during travel in direct drive mode (when pressure is adjusted)

1. If current flows in proportional solenoid (1), the solenoid
generates thrust in proportion to the current. This thrust of
the solenoid is balanced with the sum of the thrust gener-
ated by the oil pressure in clutch port and the reaction
force of pressure control valve spring (2), and then the
pressure is regulated.
2. While shifting gears, the lockup clutch oil pressure is re-
duced temporarily to reduce the shock when shifting gear.
Oil pressure at this time is controlled so that the lockup
piston pushing force balances with the inside pressure of
torque converter.
STATOR CLUTCH ECMV

ECMV
STRUCTURE OF STATOR CLUTCH ECMV

NOTICE
sembled.
10-214 D155AX-8
A: To clutch DR: Drain

P: From pump P1: Clutch oil pressure pickup port
T: Drain P2: Pilot oil pressure pickup port
4: Fill switch
*1:
Lockup E*******
Stator A*******
FUNCTION OF STATOR CLUTCH ECMV

• This valve is used to adjust the clutch oil pressure to the set pressure and select a clutch.
• It forms a modulation wave pattern, so the stator clutch is engaged smoothly to reduce the shock when
shifting gear. In addition, it prevents generation of peak torque in the power train.
As a result, the operator comfort improves and the power train durability increases.
D155AX-8 10-215
Clutch oil pressure when lockup drive mode travel is switched

to torque converter drive mode travel
OPERATE STATOR CLUTCH ECMV

Operation during travel in direct drive mode
1. When traveling in direct (lockup) drive mode, no current
flows to proportional solenoid (1).
2. Since pressure control valve (3) drains the oil from clutch
port (A) through drain port (T), the stator clutch is “disen-
gaged”.
3. Fill switch (5) is turned “OFF” at this time, since no oil pres-
10-216 D155AX-8
Operation during travel in torque converter mode (when being filled)

When the travel mode is changed from the direct drive mode to
the torque converter drive mode, current flows in proportional
solenoid (1), the oil pressure force balanced with the solenoid
force is applied to chamber (B), and it pushes pressure control
valve (3) to the left. As a result, pump port (P) and clutch port
(A) open. When the clutch is filled with oil, oil pressure pickup
port (4) actuates and fill switch (5) is turned “ON”.
Operation during travel in direct drive mode (when pressure is adjusted)

If current flows in proportional solenoid (1), the solenoid gener-
ates thrust in proportion to the current. This thrust of the sole-
noid is balanced with the sum of the thrust generated by the oil
pressure in clutch port and the reaction force of pressure con-
trol valve spring (2), and then the pressure is regulated.
D155AX-8 10-217
TRANSMISSION
STRUCTURE OF TRANSMISSION
General view
10-218 D155AX-8
A: 1st clutch oil pressure pickup port (1ST) K: To torque converter

B: 3rd clutch oil pressure pickup port (3RD) L: To scavenging pump
C: R clutch oil pressure pickup port (R) M: To torque converter case
D: 2nd clutch oil pressure pickup port (2ND) N: From torque converter case
E: F clutch oil pressure pickup port (F) P: To R clutch
F: From power train pump R: To 3rd clutch
G: To brake control valve S: To1st clutch
H: From steering case T: To 2nd clutch
J: From power train oil cooler U: To F clutch
D155AX-8 10-219
Sectional view
1: Transmission ECMV 8: R planetary pinion (number of teeth: 26)

2: Main relief valve and torque converter relief valve 9: R ring gear (number of internal teeth: 86)
3: Transmission case 10: F planetary pinion (number of teeth: 24)
4: Sleeve 11: F ring gear (number of internal teeth: 91)
5: Transmission input shaft 12: 3rd planetary pinion (number of teeth: 35)
6: Tie bolt 13: 3rd ring gear (number of internal teeth: 89)
7: R ring gear (hub) 14: 2nd planetary pinion (number of teeth: 31)
10-220 D155AX-8
15: 2nd ring gear (number of internal teeth: 91) 29: 3rd carrier
16: 1st ring gear (number of internal teeth: 91) 30: F clutch housing
17: 1st planetary pinion (number of teeth: 27) 31: F clutch piston
18: Transmission output shaft (3rd sun gear) (number 32: F carrier
of teeth: 19) 33: R clutch housing
19: 1st clutch housing 34: F sun gear (number of teeth: 44)
20: 1st clutch piston 35: R clutch piston
21: 1st sun gear (number of teeth: 37) 36: Washer spring
22: 1st carrier 37: Clutch plate
23: 2nd clutch housing 38: Clutch disc
24: 2nd clutch piston 39: Piston return spring
25: 2nd sun gear (number of teeth: 29) 40: R carrier
26: 2nd carrier 41: Front housing
27: 3rd clutch housing 42: R sun gear (number of teeth: 34)
28: 3rd clutch piston
Structure
• The transmission is a “forward 3-speed and reverse 3-speed” transmission which consists of the planetary
gear mechanism and the disc clutches.
• The transmission selects a single rotating direction and a single speed range by fixing the planetary gear
mechanism and 2 clutches out of 5 pairs of disc clutches hydraulically by using ECMV.
• The transmission transfers the power received by transmission input shaft (5) to output shaft (18) by chang-
ing the gear speed (forward 1st-3rd or reverse 1st-3rd) with any combination of the forward or reverse
clutch, and one of 3 speed clutches.
Number of plates and discs used

Clutch No. Number of plates Number of discs
R clutch 6 6
F clutch 6 7
3rd clutch 3 4
2nd clutch 3 4
1st clutch 2 3
Combinations of clutches for each speed range and reduction ratios

Speed range Clutches engaged Reduction ratio
Forward 1st F x 1st 1.705
Forward 2nd F x 2nd 1.151
Forward 3rd F x 3rd 0.540
NEUTRAL * -
Reverse 1st R x 1st 1.406
Reverse 2nd R x 2nd 0.949
Reverse 3rd R x 3rd 0.445
*: Any one of the 1st, 2nd and 3rd clutches is filled with low-pressure oil.
D155AX-8 10-221
DISC CLUTCH
STRUCTURE OF DISC CLUTCH
Sectional view
• The disc clutch consists of piston (2), plates (3), discs (4),
pin (5), and return spring (6) to fix ring gear (1).
• The internal teeth of disc (4) are engaged with outside
teeth of ring gear (1).
• Plate (3) and clutch housing (7) are assembled with pin
(5).
FUNCTION OF DISC CLUTCH

REMARK
The figure shows the case in which the “1st” gear is selected.
• When the joystick (steering, directional and gear shift lev-
er) (PCCS lever) is in “NEUTRAL” position, any one of the
1st, 2nd, and 3rd gear speed is selected.
• The piston chamber of the clutch corresponding to the se-
lected gear speed is filled with oil by electronically control-
ling the oil circuit of each clutch.
• When the joystick (PCCS lever) is shifted from “NEUTRAL”
position to “FORWARD” or “REVERSE” position, the pump
is required to supply oil enough to fill the piston chamber of
the forward or reverse clutch.
• When the gear speed is changed from “FORWARD 1st” to “FORWARD 2nd”, the pump is required to sup-
ply oil enough to press the plates and discs of the 2nd clutch since the forward clutch has been filled with
the oil.
• The time lag at shifting gears is reduced by controlling the oil circuit as explained above.
OPERATE DISC CLUTCH

Operation when clutch is “ON” (engaged)
1. The oil from ECMV is routed to the back of piston (2)
through oil passage of clutch housing (7) and pushes pis-
ton (2) leftward.
2. Piston (2) presses plates (3) against discs (4) to hold rota-
tion of discs (4) with the friction force between them.
3. Since inside teeth of disc (4) are engaged with outside
teeth of ring gear (1), the ring gear (1) is locked.
10-222 D155AX-8
Operation when clutch is “OFF” (disengaged)

1. When the supply of oil from ECMV is shut off, piston (2) is
returned rightward by the force of return spring (6).
2. This relieves the frictional force between plates (3) and
discs (4), making the ring gear (1) free.
POWER TRANSMITTING ROUTE OF TRANSMISSION

Forward 1st
Power from torque converter

↓
Input shaft (1)
↓
F clutch sun gear (2)
D155AX-8 10-223
↓
F clutch planetary pinion (3)
↓
F clutch carrier (10)
↓
3rd clutch carrier (11)
↓
3rd clutch planetary pinion (12) → → → →
↓ ↓
3rd clutch ring gear (13)
↓ ↓
2nd clutch carrier (14)
↓
2nd clutch planetary pinion (15) → → ↓
↓ ↓
2nd clutch ring gear (16)
↓ ↓
1st clutch carrier (17) ↓
↓
1st clutch planetary pinion (18) ↓
↓ ↓
1st clutch sun gear (20) 2nd clutch sun gear (21)
↓ ↓ ↓
Output shaft (22) ← ↓ ← ←
10-224 D155AX-8
Forward 2nd

↓
Input shaft (1)
↓
↓
↓
↓
↓
3rd clutch planetary pinion (12) → →
↓ ↓
↓ ↓
D155AX-8 10-225

↓ ↓
2nd clutch planetary pinion (15)
↓ ↓
2nd clutch sun gear (21)
↓ ↓
Output shaft (22) ← ←
Forward 3rd

↓
Input shaft (1)
↓
↓
↓
10-226 D155AX-8
↓
↓
3rd clutch planetary pinion (12)
↓
Output shaft (22)
Reverse 1st
R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are locked hydraulically.
↓
Input shaft (1)
↓
R clutch sun gear (5)
↓
R clutch planetary pinion (6)
↓
R clutch ring gear (9)
D155AX-8 10-227
(R clutch carrier (8) is locked with R clutch ring gear (7). Accordingly R clutch ring
gear (9) is reversed to input shaft (1))
↓
↓
↓
3rd clutch planetary pinion (12) → → → →
↓ ↓
↓ ↓
↓ ↓
2nd clutch planetary pinion (15) → ↓
↓ ↓ ↓
2nd clutch ring gear (16)
↓ ↓ ↓
1st clutch carrier (17)
↓ ↓ ↓
1st clutch planetary pinion (18)
↓ ↓ ↓
1st clutch sun gear (20) 2nd clutch sun gear (21)
↓ ↓ ↓
Output shaft (22) ← ← ← ←
TRANSMISSION ECMV
ECMV
STRUCTURE OF TRANSMISSION ECMV

NOTICE
sembled.
10-228 D155AX-8
General view
AF: To F clutch A1: To 1st clutch

AR: To R clutch A2: To 2nd clutch
D155AX-8 10-229
A3: To 3rd clutch PR: R clutch oil pressure pickup port

P: From power train pump P1: 1s clutch oil pressure pickup port
T: Drain P2: 2nd clutch oil pressure pickup port
Dr: Drain P3: 3rd clutch oil pressure pickup port
PF: F clutch oil pressure pickup port
1: 3rd clutch proportional solenoid 12: Connector for 1st clutch proportional solenoid
2: 1st clutch proportional solenoid 13: Connector for 3rd clutch fill switch
3: R clutch proportional solenoid 14: Connector for 3rd clutch proportional solenoid
4: F clutch proportional solenoid 15: Connector for R clutch proportional solenoid
5: 2nd clutch proportional solenoid 16: Connector for 2nd clutch fill switch
6: 3rd clutch fill switch 17: Connector for 2nd clutch proportional solenoid
7: 2nd clutch fill switch 18: Connector for F clutch proportional solenoid
8: 1st clutch fill switch 19: Connector for 1st clutch fill switch
9: R clutch fill switch 20: Connector for R clutch fill switch
10: F clutch fill switch 21: Connector for F clutch fill switch
11: Transmission oil filter
1: Fill switch 3: Body (upper)

2: Pressure control valve 4: Body (lower)
10-230 D155AX-8
5: Proportional solenoid 7: Oil pressure pickup valve

6: Filter 8: Sleeve
FUNCTION OF TRANSMISSION ECMV

ECMV is controlled by the command current sent from the con-
troller to the proportional solenoid and the fill switch output sig-
nal.
The relationship between the proportional solenoid command
current for ECMV, clutch input pressure, and fill switch output
signal is shown below.
Range A: Before shifting gear (oil is drained)
Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
REMARK
The logic is designed so that the controller does not recognize
completion of filling even if the fill switch is turned ON during
the triggering period (Range D).
• When gear is shifted with gear shift switch, the clutch discs
and plates are pressed by piston. If high pressure is sud-
denly applied, the piston suddenly engages the clutch,
causing sudden start of the machine and excessive shock.
• ECMV reduces a shock at the start of the machine by in-
creasing the oil pressure applied to the piston gradually to
set pressure, and allows the clutch to be smoothly “engaged”. It aims to increase durability of the power
train　system and enhances an operator comfort.
Function of pressure control valve
A proportional solenoid in this valve receives the current sent from the controller and this valve converts it to oil
pressure.
Function of proportional solenoid
The proportional solenoid generates thrust shown below corresponding to the command current from the con-
troller.
The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate a
hydraulic pressure as shown below. Thus, the oil flow and pressure is controlled by controlling the command
current to change the thrust and let the pressure control valve operate.
Proportional solenoid current and thrust characteristics
D155AX-8 10-231
Proportional solenoid thrust and oil pressure characteristics
Function of fill switch

• When the clutch is filled with oil, the fill switch is turned
“ON” by the pressure of the clutch. This signal allows the
oil pressure to build up.
• Outputs a signal (a fill signal) to the controller to notify that
filling is complete when the clutch is filled with oil.
• Keeps outputting the signals (fill signals) to the controller
to notify that the oil pressure is applied while oil pressure is
applied to the clutch.
Range A: Before shifting gear (oil is drained)
Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
REMARK
The logic is designed so that the controller does not recognize
completion of filling even if the fill switch is turned “ON” during
the triggering period (Range D).
10-232 D155AX-8
OPERATE TRANSMISSION ECMV

Operation before shifting of gear (when being drained)
1. While no current is flowing to the proportional solenoid (1),
pressure control valve (3) drains the oil from clutch port (A)
through drain port (T).
2. Fill switch (5) is turned “OFF” at this time since no oil pres-
Operation when being filled.

When current is supplied to proportional solenoid (1) with no oil
in the clutch, the force exerted by the oil pressure, that is equal
to the thrust of the solenoid, develops in chamber (B) and
pushes pressure control valve (3) to the right. As a result,
pump port (P) and clutch port (A) are opened and oil starts fill-
ing the clutch. When the clutch is filled with oil, pressure detec-
tion value (4) actuates to turn “ON” fill switch (5).
D155AX-8 10-233
Operation when adjusting the pressure

If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust
of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the reac-
tion force of pressure control valve spring (2), and then the pressure is regulated.
Table of ECMV operation
ECMV
F R 1st 2nd 3rd
N ○ ○ ○
F1 ○ ○
Speed range
F2 ○ ○
F3 ○ ○
R1 ○ ○
R2 ○ ○
R3 ○ ○
REMARK
When the directional lever is in N (NEUTRAL) position, the
speed clutch of the speed range selected by gear shift lever ac-
tivates.
10-234 D155AX-8
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE

STRUCTURE OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF
VALVE
General view
A: Drain (torque converter relief) E: To torque converter

B: Drain P1: Main relief oil pressure pickup port
C: From pump P8: Torque converter relief pressure pickup port
D: Drain
1: Body 4: Piston
2: Piston 5: Main relief valve
3: Torque converter relief valve
MAIN RELIEF VALVE

FUNCTION OF MAIN RELIEF VALVE
The main relief valve regulates the pressure in the transmission and parking brake hydraulic circuits to the set
pressure.
Set pressure (at engine rated speed) : 3.18±0.1 MPa {32.4±1.0 kg/cm2}
D155AX-8 10-235
OPERATE MAIN RELIEF VALVE

1. The oil from the hydraulic pump flows to port (C) through
the filter. Then it flows to chamber (F) through orifice (a) in
main relief valve (1).
2. When the oil pressure in the circuit exceeds the set pres-
sure, the oil in chamber (F) pushes piston (2) and the reac-
tion force of the piston pushes main relief valve (1) left-
ward to connect ports (C) and (E). Then, the oil from pump
flows through port (E) into the torque converter.
TORQUE CONVERTER RELIEF VALVE

FUNCTION OF TORQUE CONVERTER RELIEF VALVE
The torque converter relief valve maintains the torque converter inlet pressure below the set pressure to protect
the torque converter from abnormally high pressure.
Set pressure (cracking pressure) : 1.06±0.05 MPa {10.8±0.5 kg/cm2}
OPERATE TORQUE CONVERTER RELIEF VALVE

1. The oil relieved through the main relief valve flows through
port (E) into the torque converter. It also flows through ori-
fice (b) in torque converter relief valve (3) into chamber
(G).
2. When the oil pressure to the torque converter goes beyond
the set pressure, the oil conducted to chamber (G) pushes
piston (4) and the resulting pushing force pushes torque
converter relief valve (3) rightward. Then ports (E) and (A)
open.
Then, the oil in port (E) is drained through port (A).
10-236 D155AX-8
TRANSMISSION LUBRICATION RELIEF VALVE

STRUCTURE OF TRANSMISSION LUBRICATION RELIEF VALVE
A: From oil cooler C: Drain

B: Drain
1: Spring 3: R clutch housing
2: F clutch housing 4: Piston
SPECIFICATIONS OF TRANSMISSION LUBRICATION RELIEF VALVE

Normal pressure : 0.14±0.05 MPa {1.4 0.5 kg/cm2}
Cracking pressure : 0.30±0.03 MPa {3.0±0.3 kg/cm2}
FUNCTION OF TRANSMISSION LUBRICATION RELIEF VALVE

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

HSS
D155AX-8 10-237
STRUCTURE OF BEVEL GEAR SHAFT, HSS, AND BRAKE

General view
10-238 D155AX-8
A: To transmission case D: Left brake pressure pickup port (LB)

B: From scavenging pump and steering lubrication oil E: From pin puller solenoid valve (drain)
pump
C: Right brake pressure pickup port (RB)
D155AX-8 10-239
Sectional view
10-240 D155AX-8
1: Bevel gear speed sensor 5: Brake control valve

2: Drain plug 6: Output shaft
3: Drain valve 7: Case
4: HSS motor mounting location 8: Cylinder
D155AX-8 10-241
9: Brake spring 26: Bevel gear shaft bearing A

10: Brake piston 27: Shim A (for adjustment of bevel gear)
11: Brake plate 28: Retainer
12: Brake disc 29: Shim B (for adjustment of bevel gear)
13: Brake drum 30: Nut (for bevel gear shaft)
14: Brake hub 31: Spacer
15: Tube 32: Nut (for bevel pinion)
16: Bevel gear shaft 33: Cage
17: Bevel gear (number of teeth: 32) 34: Shim C (for adjustment of bevel pinion)
18: Gear A (number of external teeth: 45) 35: Bevel pinion bearing
19: Sun gear (number of teeth: 34) 36: Bevel pinion (number of teeth: 17)
20: Pinion shaft 37: Gear B (number of teeth: 16)
21: Planetary pinion (number of teeth: 35) 38: Shaft
22: Ring gear (number of internal teeth: 104) 39: HSS motor
23: Hub 40: Drive gear (number of teeth: 19)
24: Carrier 41: Gear D (number of teeth: 28)
25: Bevel gear shaft bearing B 42: Gear C (number of teeth: 16)
Bevel gear shaft
• The bevel gear shaft divides the power sent from the engine through the torque converter and transmission
shaft to the right and left at right angles while reducing the rotating speed through the meshed bevel pinion
(36) and bevel gear (17).
• The bevel pinion (36) and bevel gear (17) on the bevel gear shaft are the spiral bevel gear, and they are
splash lubricated by the oil from the steering lubrication pump and scavenging pump.
• The bevel gear shaft consists of bevel pinion (36), bearing (35) and cage (33) which support the bevel pin-
ion, bevel gear (17) which is meshed with the bevel pinion (31), bevel gear shaft (16), bearings (25) and
(26) which support the bevel gear shaft, and retainer (28).
HSS
• The HSS consists of the transfer section to invert the rotating direction of HSS motor (39) and transmit the
power to gear A (18) and the planetary section to adjust the input power from ring gear (22) and sun gear
(19) and output the power to carrier (24).
The steering direction of the machine is changed by stopping the rotation of HSS motor (39) or changing its
turning direction.
• The transfer section has a set of reduction spur gears and they are splash lubricated by the oil from the
steering lubrication pump and scavenging pump.
• The planetary section has the forced lubrication method by the oil from the steering lubrication pump and
scavenging pump.
• The transfer section consists of drive gear (40) splined to HSS motor (39), gear D (41) meshed with the
drive gear, gear C (42) meshed with gear D, gear B (37) coupled with shaft (38), gear A (18) supported by
bearing on the bevel gear shaft, and the steering case which supports those parts.
• The planetary section consists of sun gear (19), planetary pinion (21), pinion shaft (20), ring gear (22), hub
(23) meshed with bevel gear shaft (16) and ring gear (22), and carrier (24) coupled with brake hub (14).
Brake
• The brake is connected to the R.H. HSS and L.H. HSS, and restricts the power transmitted from those HSS
to the final drives to brake the machine.
• The brake is of wet multiple disc clutch type and spring-loaded type. Brake control valve (5) is actuated hy-
draulically by operating the brake pedal.
10-242 D155AX-8
• The brake employs the forced lubrication system, in which oil from the steering lubrication pump and scav-
enging pump flows to case (7) and brake drum (13) through the passage in the steering case, and further
flows to brake discs (12) and brake plates (11).
• When the engine is stopped, the steering brake is "applied" since the back pressure acting on the brake
piston (10) lowers, even the brake pedal is not depressed. However, the brake is "released" as the oil pres-
sure in the circuit goes up when the engine restarts, so the parking brake lever must be set to the LOCK
position.
• The brake consists of brake hub (14) coupled with carrier (24), brake discs (12) meshed with the brake hub,
brake drum (13), brake plates (11) whose periphery is coupled with brake drum (13), brake piston (10) and
brake spring (9) which presses brake discs and brake plates together, and cylinder (8), case (7), and output
shaft (6) which support those parts.
Brake drum (13) and case (7) are fixed to the steering case.
Output shaft (6) is connected to brake hub (14) by spline and held by spacer (31) in the axial direction.
HSS
HSS
D155AX-8 10-243
OPERATE HSS
Operation when steering is in “NEUTRAL” (straight-travel)
A: Transmission output
B: HSS motor output (0 rpm)
C: Left bevel gear shaft output (= A±0)
D: Right bevel gear shaft output (= A±0)
HSS motor rotating direction
NEU-
PCCS lever steering operation Turn LEFT Turn RIGHT
TRAL
PCCS lever direction switching op- NEU- NEU-
Any Forward Reverse Forward Reverse
eration TRAL (*) TRAL (*)
HSS motor rotating direction
STOP Left Left Right Right Right Left
viewed from left side of machine
10-244 D155AX-8
*: Counter-rotation turn
REMARK
When the PCCS lever is in “NEUTRAL”, HSS motor (7) is stopped.
Power from transmission
↓
Bevel pinion (1)
↓
Bevel gear (2)
↓
Bevel gear shaft (3)
↓
Hub (4)
↓
Ring gear (5)
↓
Planetary pinion (6)
↓
Carrier (15)
↓
Brake hub (16)
↓
Output shaft (17)
D155AX-8 10-245
Operation when steering “LEFT TURN” (forward travel)
*A: Transmission output

*B: HSS motor output
*C: Combined output
*1: Transmission output speed

*2: HSS motor output speed
*3: Left bevel gear shaft output speed (*1 - *2)
*4: Right bevel gear shaft output speed (*1 + *2)
REMARK
When the PCCS lever is set to “LEFT TURN” while it is in FORWARD, HSS motor (7) rotates counterclockwise,
viewed from the left side of the machine.
10-246 D155AX-8
Power from HSS motor (7)

(Counterclockwise when viewed
(forward)
from left side of machine)
↓ ↓
Bevel pinion (1) Drive gear (8)
↓ ↓
Bevel gear (2) Gear D (9) → Gear C (10)
↓ ↓ ↓
Bevel gear shaft (3) Shaft (11)
↓ ↓ ↓
Hub (4) Gear B (12)
↓ ↓ ↓
Left gear A (13) Right gear A (13)
Ring gear (5) (Counterclockwise when viewed (Clockwise when viewed from left
from left side of machine) side of machine)
↓ ↓ ↓
↓ Left sun gear (14) Right sun gear (14)
↓ ↓ ↓
Planetary pinion (6) ← ← ← ←
↓
Carrier (15)
↓
Brake hub (16)
↓
Output shaft (17)
D155AX-8 10-247
Operation when steering “LEFT TURN” (reverse travel)

*C: Combined output
*3: Left bevel gear shaft output speed (*1 - *2)
*4: Right bevel gear shaft output speed (*1 + *2)
REMARK
When the PCCS lever is set to “LEFT TURN” while it is in REVERSE, HSS motor (7) rotates clockwise, viewed
from the left side of the machine.
10-248 D155AX-8

(Clockwise when viewed from left
(reverse)
side of machine)
↓ ↓
↓ ↓
↓ ↓ ↓
Bevel gear shaft (3) ↓ Shaft (11)
↓ ↓ ↓
Hub (4) ↓ Gear B (12)
↓ ↓ ↓
Ring gear (5) (Clockwise when viewed from left (Counterclockwise when viewed
side of machine) from left side of machine)
↓ ↓ ↓
↓ ↓ ↓
↓
Carrier (15)
↓
Brake hub (16)
↓
Output shaft (17)
D155AX-8 10-249
Operation when steering “RIGHT TURN” (forward travel)

*C: Combined output
*3: Left bevel gear shaft output speed (*1 + *2)
*4: Right bevel gear shaft output speed (*1 - *2)
REMARK
When the PCCS lever is set to “RIGHT TURN” while it is in FORWARD, HSS motor (7) rotates clockwise,
10-250 D155AX-8

(Clockwise when viewed from left
(forward)
side of machine)
↓ ↓
↓ ↓
↓ ↓ ↓
↓ ↓ ↓
Hub (4) Gear B (12)
↓ ↓ ↓
Ring gear (5) (Clockwise when viewed from left (Counterclockwise when viewed
side of machine) from left side of machine)
↓ ↓ ↓
↓ ↓ ↓
↓
Carrier (15)
↓
Brake hub (16)
↓
Output shaft (17)
D155AX-8 10-251
Operation when steering “RIGHT TURN” (reverse travel)

*C: Combined output
*3: Left bevel gear shaft output speed (*1 + *2)
*4: Right bevel gear shaft output speed (*1 - *2)
REMARK
When the PCCS lever is set to “RIGHT TURN” while it is in REVERSE, HSS motor (7) rotates counterclockwise,
10-252 D155AX-8

(Counterclockwise when viewed
(reverse)
from left side of machine)
↓ ↓
↓ ↓
↓ ↓ ↓
↓ ↓ ↓
Hub (4) Gear B (12)
↓ ↓ ↓
Ring gear (5) (Counterclockwise when viewed (Clockwise when viewed from left
from left side of machine) side of machine)
↓ ↓ ↓
↓ ↓ ↓
↓
Carrier (15)
↓
Brake hub (16)
↓
Output shaft (17)
D155AX-8 10-253
BRAKE
OPERATE BRAKE
Operation when brake is “released”.
1. When the PCCS lever is in the “NEUTRAL” position and
the brake pedal is released, the maximum brake pressure
is applied to the back of brake piston (1) by the brake con-
trol valve.
2. As the oil pressure rises, brake piston (1) compresses
brake spring (2) and moves to the left to eliminate the
pressing force between discs (3) and plates (4).
3. The power transmitted from bevel gear shaft through HSS
to brake hub (6) is transmitted to output shaft (7), then to
the final drive.
When brake is “applied”.

1. When the brake pedal is depressed, the brake pressure
applied to the back of brake piston (1) starts to lower by
the brake control valve.
2. At this time, piston (1) is pushed back to the right by the
tension of braked spring (2), and it presses disc (3) and
plate (4) against brake drum (5). Brake drum (5) is fixed to
the steering case.
3. The power applied to brake hub (6) or output shaft (7) is
decreased since disc (3) and plate (4) are pressed.
4. The brake force can be adjusted by controlling the oil pres-
sure applied to the back side of brake piston (1) corre-
sponding to the stroke of the brake pedal.
10-254 D155AX-8
BRAKE CONTROL VALVE

STRUCTURE OF BRAKE CONTROL VALVE
General view
D155AX-8 10-255
P: From power train pump BPL: To lubrication of bevel pinion bearing

L: From scavenging pump and steering lubrication oil TFL: To lubrication of HSS transfer section
pump DLB: Drain (left brake)
PS: To pin puller solenoid valve DRB: Drain (right brake)
LB: To left brake DB: Drain (sudden stop prevention valve)
LL: To lubrication of left brake DBP: Drain (sudden stop prevention valve pilot)
RB: To right brake DPB: Drain (parking brake)
RL: To lubrication of right brake PLB: Left brake oil pressure pickup port
BSL: To lubrication of bevel gear shaft and planetary RRB: Right brake oil pressure pickup port
section bearing
1. Left brake ECMV 5. Brake solenoid valve
2. Right brake ECMV 6. Sudden stop prevention valve
3. Steering oil filter 7. Check valve
4. Valve seat
FUNCTION OF BRAKE CONTROL VALVE

• The brake control valve is installed on the valve seat of the steering case.
• The brake control valve consists of 2 brake ECMV's, brake solenoid valve, and sudden stop prevention
valve, and controls the brake.
• The brake control valve is in the circuit between the power train pump and brake piston, and consists of 2
sets of brake ECMV (right and left).
• The brake control valve sends the oil from the power train pump to the brake and controls the R.H. and L.H.
disc clutches.
• The controller sends signals to each ECMV corresponding to the right or left stroke of the joystick (steering,
directional and gear shift lever) (PCCS lever) to turn the machine gradually or sharply.
• When the brake pedal is depressed, the controller sends the command to the brake ECMV corresponding
to the pedal stroke to apply the R.H. and L.H. brakes to stop the machine.
• The brake is operated by controlling each ECMV and solenoid valve with the controller connected electri-
cally to PCCS lever and brake pedal.
• The sudden stop prevention valve is installed to prevent the machine from stopping suddenly when abnor-
mality occurs in the electrical system.
• When the parking brake lever is set in “LOCK” position, the controller sends the signal to the parking brake
solenoid valve to drain the oil between the R.H. and L.H. brake ECMVs and the brake piston to apply the
brake. The parking brake solenoid valve is connected electrically to the brake pedal, as well.
BRAKE ECMV
ECMV
10-256 D155AX-8
STRUCTURE OF BRAKE ECMV

NOTICE
sembled.
A: To brake T: Drain
P: From pump DR: Drain
S: To brake solenoid valve P1: Brake oil pressure pickup port
4: Fill switch
*1:
Brake R*******
FUNCTION OF BRAKE ECMV

The brake ECMV keeps the brake oil pressure to the set pressure and furthermore changes the circuit to the
piston chamber of brake.
D155AX-8 10-257
Function of pressure control valve

The proportional solenoid receives a current sent from the controller and this valve converts it into oil pressure.
Function of proportional solenoid
• The propulsion force is generated corresponding to the command current from the controller.
• The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate
a hydraulic pressure. Thus, the oil flow and pressure is controlled by controlling the command current to
change the thrust and let the pressure control valve operate.
Function of fill switch
• When the brake is filled with oil, the fill switch is turned “ON” by the pressure applied to the brake. This
signal allows the oil pressure to build up.
• At the moment when the brake is filled with oil, the fill switch outputs the signal (fill signal) to the controller
to notify the finishing of filling.
• While the oil pressure is applied to the brake, the fill switch outputs the signal (fill signal) to the controller to
notify the presence of the oil pressure.
OPERATE BRAKE ECMV

Operation when PCCS lever is in “NEUTRAL” position, brake pedal is “re-
leased”, and parking brake lever is in “FREE” position
(Machine “traveling straight”, R.H. and L.H. brakes “released”, parking brake “released”)
10-258 D155AX-8
1. When the joystick (steering, directional and gear shift lever (PCCS lever)) is in “NEUTRAL” position and the
brake pedal is “released”, proportional solenoid (1) of the brake ECMV is energized and pushes ball (2) to
the left and closes the sealing part.
2. The oil in port (P) of the brake ECMV flows in port (B) and pushes valve (3) to the left to connect port (P) to
port (A) and disconnect port (B) from port (DR). At this time, the oil flows in the port behind the brake piston.
As the oil pressure increases, the brake piston is pushed to the left to compress the brake spring, then the
brake is “released”.
3. When the parking brake lever is set in the “FREE” position, the parking brake solenoid valve is de-ener-
gized. Accordingly, the pilot pressure of brake ECMV port (S) remains.
Operation when PCCS lever is in “NEUTRAL” position, brake pedal is “de-
pressed”, and parking brake lever is in “FREE” position
(Machine “stopped”, R.H. and L.H. brakes “applied”, parking brake “released”)
1. When the brake pedal is depressed, proportional solenoids (1) of L.H. and R.H. brake ECMV are de-ener-
gized to open the sealing part of ball (2).
2. The controller outputs the command current to proportional solenoids (1) corresponding to the brake pedal
stroke.
3. Proportional solenoid (1) generates the propulsion force in proportion to the command current. This propul-
sion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pres-
sure port of the brake piston and the tension of spring (4), then the brake pressure is set up to adjust the
brake force.
D155AX-8 10-259
4. When the brake pedal is depressed fully, the brake pedal switch is turned “ON”, and the parking brake sole-
noid valve is energized to drain the pilot pressure of the brake ECMV port (S). This performs the same
function as when the parking brake lever is set to “LOCK” position.
BRAKE SOLENOID VALVE

STRUCTURE OF BRAKE SOLENOID VALVE
General view
P: From brake ECMV Dr: Drain

T: Drain
1: Parking brake lever solenoid valve 5: Coil (ON/OFF type)
2: Brake pedal solenoid valve 6: Push pin
3: Connector for parking brake lever solenoid valve 7: Spring
4: Connector for brake pedal solenoid valve 8: Spool
Solenoid valve 9: Body
10-260 D155AX-8
OPERATE BRAKE SOLENOID VALVE

When PCCS lever is in “NEUTRAL” position, brake pedal is “released”, and
parking brake lever is in “LOCK” position
(Machine is “parked”, R.H. and L.H. brakes are “in operation”, parking brake is “applied”)
1. When the parking brake lever is in “LOCK” position, the parking brake lever switch is turned “ON” and coil
(1) of the parking brake solenoid valve is energized.
2. Spool (3) is pushed to the right direction by push pin (2), then port (P) and (T) are opened to drain the pilot
pressure of the L.H. and R.H. brake ECMV.
3. The oil flown into the brake piston back pressure port is drained through the brake ECMV.
4. The oil pressure in the port behind the brake piston continues to decrease, then the brake is fully “applied”
and kept applied.
5. When the engine is restarted, as ports (P) and (T) are still opened, the brake is kept “applied”.
6. When the parking brake lever is in “FREE” position, the parking brake lever switch is turned “OFF” and coil
(1) of the parking brake solenoid valve is de-energized.
7. Spool (3) is moved to the left, and closes ports (P) and (T) to maintain the pilot pressure of the L.H. and
R.H. brake ECMV.
8. The oil pressure from the brake ECMV is applied to the back pressure port of the brake piston, and brake is
“released”.
D155AX-8 10-261
SUDDEN STOP PREVENTION VALVE

STRUCTURE OF SUDDEN STOP PREVENTION VALVE
General view
A: From power train pump dr1: Drain

B: From brake ECMV dr2: Drain
1: Sudden stop prevention valve 4: Valve
EPC valve 5: Ball
2: Coil (proportional type) 6: Spool
3: Push pin 7: Body
FUNCTION OF SUDDEN STOP PREVENTION VALVE

• The sudden stop prevention valve is installed to prevent the machine from stopping suddenly when an ab-
normality takes place in the electric system.
• Sudden stop prevention valve (1) is installed in the drain circuit of the brake ECMV so that the pressure of
port (DR) does not drop suddenly when brake ECMV coil (2) is de-energized, and consequently the sudden
braking can be avoided when coil (2) of brake ECMV is de-energized.
10-262 D155AX-8
OPERATE SUDDEN STOP PREVENTION VALVE
If an abnormality takes place in the electric system, also coil (3) of the sudden stop prevention valve (1) is de-
energized. Then, the oil in port (DR) is drained through orifice (a) so that the brake is applied gradually.
D155AX-8 10-263
FINAL DRIVE
STRUCTURE OF FINAL DRIVE
General view
• The final drive is a single reduction spur gear, single reduction planetary gear. The lubrication is of splash
type using the rotation of the gears.
The final drive can be removed and installed as a single unit.
• Floating seal (1) is installed to the rotating sliding surface of the sprocket to prevent the entry of dirt or sand
and to prevent leakage of lubricating oil.
10-264 D155AX-8
Sectional view
1: Floating seal 10: No. 1 pinion

2: Sun gear 11: Final drive case
3: Carrier 12: Bearing cage
4: Sprocket boss 13: No. 1 gear
5: Sprocket teeth 14: No. 1 gear hub
6: Cover 15: Shaft
7: Planetary gear 16: Wear guard
8: Ring gear 17: Pivot shaft
9: Cover
SPECIFICATIONS OF FINAL DRIVE

Reduction ratio: -(81/17) x ((17 + 67)/17) = -23.543
D155AX-8 10-265
POWER TRANSMISSION OF FINAL DRIVE
1. The power from the bevel gear shaft and steering clutch is transmitted to 1st pinion (10) to rotate 1st gear
(13) meshed with the 1st pinion and sun gear (2) meshed with the 1st gear.
2. The rotation of sun gear (2) is transmitted to planetary gear (7). Since ring gear (8) meshed with planetary
gear (7) is fixed to cover (6), planetary gear (7) rotates along ring gear (8) and revolves around sun gear
(2).
3. Then, the rotating force of sun gear (2) forms the rotating force of carrier (3), which supports planetary gear
(7), and is transmitted to sprocket boss (4) via shaft (15).
4. The rotating direction of carrier (3) is the same as that of sun gear (2).
The rotational force transmitted to sprocket boss (4) is further transmitted to sprocket teeth (5).
10-266 D155AX-8
SCAVENGING PUMP
STRUCTURE OF SCAVENGING PUMP
General view
A: From scavenging pump strainer B: To steering case
SPECIFICATIONS OF SCAVENGING PUMP

Type: Gear pump
Theoretical discharged volume: 142.0 cm3/rev
Max. discharged pressure: 2.94 MPa {30 kg/cm2}
Max. speed: 2200 rpm
FUNCTION OF SCAVENGING PUMP

• The scavenging pump is installed to the torque converter case and is driven by the power from the engine.
• The scavenging pump sucks oil from the bottom of the transmission case through a strainer and returns it
to the steering case.
D155AX-8 10-267
STEERING LUBRICATION PUMP AND POWER TRAIN PUMP

STRUCTURE OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP
General view
A: From power train oil strainer C: To power train oil filter

B: To steering case
1: Power train pump 2: Steering lubrication pump
SPECIFICATIONS OF STEERING LUBRICATION PUMP AND POWER TRAIN

PUMP
Steering lubrication pump
Model: SAR(3)40
Type: Gear pump
Power train pump
Model: SAR(3)100
Type: Gear pump
10-268 D155AX-8

FUNCTION OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP

• The steering lubricating pump and power train pump are installed to the torque converter case and is driven
by the power from the engine.
• The steering lubricating oil pump sucks oil from the bottom of the steering case through a strainer and
sends it to the steering lubricating oil circuit.
• The power train pump sucks oil from the bottom of the steering case through a strainer and sends it to the
power train control circuit.
HSS MOTOR
HSS
D155AX-8 10-269
STRUCTURE OF HSS MOTOR
PA: From control valve T: To tank

PB: From control valve
1: HSS motor 3: Counterbalance valve
2: Check valve 4: Safety valve
10-270 D155AX-8
1: Drive shaft 7: Cover

2: Motor case 8: Counterbalance valve spool
3: Piston 9: Check valve
4: Cylinder block 10: Spool
5: Valve plate 11: Safety valve
6: Housing
The motor consists of a fixed displacement bent axis type piston motor, counterbalance valve, check valve, and
safety valve.
D155AX-8 10-271
SPECIFICATIONS OF HSS MOTOR

Model: KMF140
Type: Fixed displacement bent axis type piston motor
Motor capacity: 141.1 cm3/rev
Rated pressure: 41.2 MPa {420 kg/cm2}
OPERATE HSS MOTOR

1. 7 pistons (3) are attached to the disc part of drive shaft (1)
with a manner just like a spherical joint. Each piston (3)
forms a specific angle with drive shaft (1), and stored in
cylinder block (4).
2. It is assumed that the shaft of the disc is supported to ena-
ble free rotation of the disc. When force (F) is applied to
the disc diagonally, force (F) is divided into vertical force to
the disc (F1) and circumferential force (F2). (F1) pushes
the disc to axis direction, and (F2) rotates the disc clock-
wise.
3. Instead, when force (F'), not force (F) is applied to the disc,
the force (F') is also divided into (F'1) and (F'2), and the
disc is rotated counterclockwise by force (F'2).
4. The pressurized oil sent from the main piston pump enters
the piston motor inlet port, and the oil pressure is applied
to the back of piston (3), and drive shaft (1) is rotated by
inclination (Q) of piston (3) and cylinder block (4).
COUNTERBALANCE VALVE AND CHECK VALVE OF HSS MOTOR

HSS
10-272 D155AX-8
FUNCTION OF COUNTERBALANCE VALVE AND CHECK VALVE OF HSS MOTOR

8: Counterbalance valve
9: Check valve
• When the steering is operated on a downhill slope, the
gravity force tends to make the current driving speed faster
than the speed by motor (engine) rotation.
• If the steering is operated while the engine is running at
low speed, the motor rotates under no load and machine
runs away. This may cause an extremely dangerous condi-
tion.
• These valves control the steering operation corresponding
with the engine speed (pump discharged volume) in order
to prevent such a dangerous condition.
OPERATE COUNTERBALANCE VALVE AND CHECK VALVE OF HSS MOTOR

During normal travel (flat ground and uphill ground)
1. When steering lever is operated, the pressurized oil from
the control valve is supplied to port (PA).
2. It pushes open check valve (9A), and flows from motor in-
let port (MA) to motor outlet port (MB).
3. The outlet port side of the motor is closed by check valve
(9B) and spool (8), so the pressure at the oil supply side
rises.
D155AX-8 10-273
4. The pressurized oil at the oil supply side flows from orifice
(E1) of spool (8) into chamber (S1).
5. When the pressure in chamber (S1) increases higher than
the reaction force of the spool selector pressure, spool (8)
is pushed to the right.
6. Motor outlet port (MB) and port (PB) are connected to the
outlet passage, and the motor outlet side opens and the
motor turns.
During downhill travel

1. If the machine runs away on a downhill, the motor runs idle
and the pressure on the motor inlet side decreases.
2. Through orifice (E1), the pressure in chamber (S1) drops.
3. When the pressure in chamber (S1) decreases lower than
the spool selector pressure, spool (8) is pushed back to
the left by the reaction force of springs (13) and (14), and
port (MB) on the outlet side is throttled.
4. The pressure on the motor outlet side increases and rotat-
ing resistance is generated in the motor, thus the machine
is prevented from running away.
5. Spool (8) moves to a position where the force caused by
the machine weight and the hydraulic force on the motor
inlet side are balanced with the pressure of motor outlet
port (MB).
6. In this way, it throttles the motor outlet port circuit and ena-
bles to steer at a speed that matches the volume of oil dis-
charged from the pump.
SAFETY VALVE OF HSS MOTOR

HSS
10-274 D155AX-8
FUNCTION OF SAFETY VALVE OF HSS MOTOR

11: Safety valve
• When the operation of the steering is finished, the outlet
and inlet circuits of the motor are closed. Since the motor
is turned by inertial force, the pressure on the motor outlet
side increases abnormally, and the motor or piping may be
damaged. The safety valve releases this abnormal pres-
sure into the motor inlet side to protect the devices from
damage.
• This safety valve releases abnormal pressure into inlet
side when either (MA) or (MB) becomes outlet side.
OPERATE SAFETY VALVE OF HSS MOTOR

When pressure in chamber (MB) increases (motor turns right)
1. When the operation of the steering is finished, the check
valve of the counterbalance valve closes chamber (MB) in
the outlet side circuit.
2. Since the motor continues rotation because of inertial
force, the pressure on the outlet (MB) side increases.
D155AX-8 10-275
3. When it exceeds the set pressure, force (F1) [circle area

difference between (D1) and (D2) x pressure] compresses
spring (2).
4. The pressurized oil moves poppet (1) to the left and flows
into chamber (MB) in the circuit on the opposite side.
When pressure in chamber (MA) increases (motor turns left)

1. When the operation of the steering is finished, the check
valve of the counterbalance valve closes chamber (MA) in
the outlet circuit.
2. Since the motor continues rotation because of inertial
force, the pressure on the outlet (MA) side increases.
10-276 D155AX-8
3. When it exceeds the set pressure, force (F2) [circle area

difference between (D1) and (D3) x pressure] compresses
spring (2).
4. The pressurized oil moves poppet (1) to the left and flows
into chamber (MB) in the circuit on the opposite side.
ELECTRIC LEVER
STRUCTURE OF ELECTRIC STEERING LEVER
NOTICE
Do not disassemble this lever since its output voltage characteristics and operating effort characteris-
tics need to be adjusted.
D155AX-8 10-277
Appearance and sectional view
10-278 D155AX-8
1: Boot 4: Bolt
2: Cover 5: Lever
3: O-ring 6: Connector
FEATURE OF ELECTRIC STEERING LEVER

Characteristics of operating effort
For blade and ripper
• The characteristics are as shown in the figure at right in all
of the backward, forward, right, and left directions.
• Free return (operating effort characteristics diagram)
D155AX-8 10-279
For steering
• Operations in forward and backward directions
The control lever is held at 3 positions of “FORWARD”,
“NEUTRAL”, and “REVERSE”.
• Operations of steering in right and left directions
Free return
10-280 D155AX-8
Output voltage characteristics

• This is installed to the L.H. control stand, and the control
lever is installed directly on it.
• The operation angle (stroke) of the control lever is detect-
ed by the potentiometer and is output in the form of a sig-
nal voltage to the power train controller.
• A potentiometer is installed to detect each of longitudinal
displacement and lateral displacement. Each potentiome-
ter outputs 2 signal voltages which are opposite in phase
as shown in the figure on the right.
D155AX-8 10-281
WORK EQUIPMENT CONTROL 10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM

WORK EQUIPMENT CONTROL
LAYOUT OF WORK EQUIPMENT CONTROL
10-282 D155AX-8
10 STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
1: Work equipment lock lever 7: Pilot filter

2: Electric blade control lever 8: Pilot circuit accumulator
3: Electric ripper control lever 9: Float button
4: Work equipment controller 10: Pitch switch
5: Work equipment lock solenoid valve 11: Tilt switch
6: Self-pressure reducing valve 12: Work equipment lock switch
WORK EQUIPMENT CONTROL FUNCTION
• The work equipment control employs an EPC method which uses an EPC valve to move each control valve
spool.
• Work equipment lock lever (1) is interconnected with work equipment lock switch (2). When it is at the
“FREE” position, the work equipment lock valve operates to open the work equipment control circuit.
D155AX-8 10-283
LAYOUT OF DUAL TILT DOZER
1: R.H. blade tilt cylinder 4: Control valve

2: R.H. blade lift cylinder 5: L.H. blade tilt cylinder
3: Quick drop valve 6: L.H. blade lift cylinder
10-284 D155AX-8
10 STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
LAYOUT OF VARIABLE MULTI-SHANK RIPPER
1: Control valve 3: Ripper lift cylinder

2: Branch block 4: Ripper tilt cylinder
D155AX-8 10-285
LAYOUT OF VARIABLE GIANT RIPPER
1: Control valve 4: Ripper tilt cylinder

2: Branch block 5: Pin puller cylinder
3: Ripper lift cylinder 6: Pin puller solenoid valve
10-286 D155AX-8
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

SELF-PRESSURE REDUCING VALVE
STRUCTURE OF SELF-PRESSURE REDUCING VALVE
T: To tank P2: To fan motor

P1: From pump PR: Supply to EPC valve, etc.
D155AX-8 10-287
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION
1: Valve (sequence valve) 6: Spring (main pressure reducing valve)

2: Spring 7: Valve (pressure reducing valve)
3: Screw 8: Spring (safety valve)
4: Poppet 9: Ball
5: Spring (pilot pressure reducing valve) 10: Filter
10-288 D155AX-8
FUNCTION OF SELF-PRESSURE REDUCING VALVE

This valve reduces the discharged pressure of the fan pump
and supplies it to the EPC valve, etc. as the control pressure.
D155AX-8 10-289
OPERATE SELF-PRESSURE REDUCING VALVE

When engine is stopped (When all oil pressures are low)
1. Spring (6) pushes poppet (5) to the seat, and the circuit between ports (PR) and (T) is closed.
2. Spring (7) pushes spool (8) to the left side, and the ports (P1) and (PR) are connected to each other.
3. Spring (3) pushes valve (2) up, and ports (P1) and (P2) are disconnected from each other.
10-290 D155AX-8
When load pressure (P2) is lower than output pressure (PR) of self-pressure re-
ducing valve
1. Spring (3) and the pressure (PR) [0 MPa {0 kg/cm2} when the engine is stopped] push valve (2) in the di-
rection to disconnect ports (P1) and (P2) from each other. When the hydraulic oil enters port (P1), the ex-
pression [pressure (P1) ≒ force of spring (3) + (area d x pressure (PR))] holds, and the self pressure reduc-
ing valve adjusts the opening between ports (P1) and (P2) so that pressure (P1) is maintained higher than
pressure (PR).
2. When pressure (PR) rises above the set pressure, poppet (5) opens and hydraulic oil flows from port (PR),
through hole (a) in spool (8) and the opening of poppet (5) to the tank port (T).
3. Therefore, differential pressure is developed across hole (a) in spool (8), and it moves spool (8) to discon-
nect ports (P1) and(PR) from each other. Thus, this valve uses the area of the opening to regulate pressure
(P1) to a certain level [set pressure] and supplies it as pressure (PR).
D155AX-8 10-291
Operation when load pressure (P2) is high
1. When load pressure (P2) rises due to digging or other operations, pump discharged volume increases and
pressure (P1) rises. When the expression [Force exerted by pressure (P1) > Force of spring (3) + Force
(area (d) x pressure (PR))] holds, and valve (2) moves downward to its stroke end. As a result, the opening
between the ports (P1) and (P2) increases, the passage resistance becomes smaller to reduce engine
horsepower loss.
2. When pressure (PR) rises above the set pressure, poppet (5) opens and hydraulic oil flows from port (PR),
through hole (a) in spool (8) and the opening of poppet (5) to the tank port (T).
3. Therefore, differential pressure is developed across hole (a) in spool (8), and it moves spool (8) to discon-
nect ports (P1) and(PR) from each other. Thus, this valve uses the area of the opening to regulate pressure
(P1) to a certain level [set pressure] and supplies it as pressure (PR).
10-292 D155AX-8
Operation when abnormally high pressure is generated
When pressure (PR) of the self-pressure reducing valve rises abnormally high, ball (10) separates from the seat
against the spring (9) to allow the oil to flow from port (PR) to port (T) so as to reduce the pressure (PR). As a
result, the equipment (EPC valve, etc.), to which the oil pressure is supplied, is protected from the abnormal
high pressure.
WORK EQUIPMENT LOCK SOLENOID VALVE

STRUCTURE OF WORK EQUIPMENT LOCK SOLENOID VALVE
Structure drawing
1: Solenoid 2: Body
D155AX-8 10-293
3: Spool
FUNCTION OF WORK EQUIPMENT LOCK SOLENOID VALVE

• The work equipment lock valve is installed between the source pressure valve and control valve in the work
equipment control circuit.
• When the work equipment lock lever is set in “FREE” position, the work equipment lock valve actuates
linked with work equipment lock switch to open the work equipment control circuit, then the work equipment
becomes operable.
OPERATE WORK EQUIPMENT LOCK SOLENOID VALVE
The solenoid is operated by the electric signal to move the spool. As a result, the circuit between port (A) con-
nected to the source pressure valve and port (B) connected to the control valve is opened.
10-294 D155AX-8
PILOT CIRCUIT ACCUMULATOR

STRUCTURE OF PILOT CIRCUIT ACCUMULATOR
1: Gas plug
2: Shell
3: Poppet
4: Holder
5: Bladder
6: Oil port
SPECIFICATIONS OF PILOT CIRCUIT ACCUMULATOR

Type of gas: Nitrogen gas
Gas volume: 500 cm3
Max. actuating pressure: 6.86 MPa {70 kg/cm2}
Min. actuating pressure: 0.69 MPa {7 kg/cm2}
FUNCTION OF PILOT CIRCUIT ACCUMULATOR

The accumulator is installed between the pressure reducing valve and the EPC valve.
Even if the engine is stopped with the work equipment still raised, the pressure of the nitrogen gas compressed
inside the accumulator sends the pilot pressure to the control valve to actuate it and enable the work equipment
to move down under its own weight.
OPERATE PILOT CIRCUIT ACCUMULATOR

1. After the engine is stopped, when the work equipment lev-
er is in NEUTRAL, chamber (A) inside the bladder is com-
pressed by the oil pressure in chamber (B).
2. When the work equipment lever is operated, the oil pres-
sure in chamber (B) goes 2.9 MPa {30 kg/cm2} or less.
Pressure of the nitrogen gas in chamber (A) expands the
bladder and the oil in chamber (B) acts as the pilot pres-
sure to actuate the control valve.
D155AX-8 10-295
QUICK DROP VALVE

STRUCTURE OF QUICK DROP VALVE
For blade lift cylinder
10-296 D155AX-8
IQDV: QDV selector current PP: EPC valve source pressure port (from self-pres-
PB1: To L.H. blade lift cylinder bottom sure reducing valve)
PB2: To R.H. blade lift cylinder bottom TS: Seal drain port
PH1: To L.H. blade lift cylinder head VB: From control valve blade “RAISE”
PH2: To R.H. blade lift cylinder head VH: From control valve blade “LOWER”
1: Body 4: Body
2: Main spool 5: Selector valve spool
3: Plate 6: EPC valve
FUNCTION OF NO CIRCUITING CONDITION OF QUICK DROP VALVE

• Fine control of lowering blade (Stroke of lever is 70 % and below.)
• QDV mode: OFF
• QDV = Quick Drop Valve

• The QDV is installed between the control valve and the blade lift cylinder.
D155AX-8 10-297
• When the blade control lever is set in “LOWER” position, the QDV prevents a vacuum on the cylinder bot-
tom side and shortens time lag before starting digging.
• The blade lowering speed is mostly decided by the pump discharged volume. However, it can be increased
by installing the quick drop valve.
• Since the QDV electronically controls the operation of the PCCS lever, the controller and EPC valve (QDV
is built-in), it is possible to select ON or OFF.
OPERATE QUICK DROP VALVE DURING NO CIRCUITING CONDITION

• Fine control of lowering blade (Stroke of lever is 70 % or less.)
• QDV mode: OFF
1. Since command current (X) from the controller to EPC valve is 0 A, main spool (1) is not switched.
2. The circuits between port (VH) and port (PH), between port (VB) and port (PB), are shut off.
3. The pressure oil of the lift cylinder head flows from port (VH) to tank (T) through the control valve.
OPERATE QUICK DROP VALVE DURING CIRCUITING CONDITION

Lowering blade (lever stroke 70 % or more)
10-298 D155AX-8
QDV mode: ON
1. 1,000 mA of command current (X) flows from the controller to EPC valve and the pilot pressure from the
EPC valve is transmitted to chamber (a) at the main spool.
2. Main spool (1) moves to the right and the circuits between port (VH) and port (PH)/port (VB) and port (PB),
get into circulating condition.
3. Most of the pressurized oil which has been flowing from port (PH) to port (VH), circulates and flows to port
(PB).
4. The pressurized oil which has been flowing to port (PB) merges with the pressure oil from port (VB) and
flows into the lift cylinder bottom.
5. The blade lowering speed is increased by the quantity of oil flowing into the lift cylinder bottom.
6. Thus, vacuum on the lift cylinder bottom is prevented.
OPERATIE FROM THE CIRCULATING CONDITION OF LOWERING BLADE TO

THE BLADE THRUSTING CONDITION OF QUICK DROP VALVE
• Lowering blade (lever stroke 70 % or more)
D155AX-8 10-299
• QDV mode: ON
1. If the blade is thrust against the ground under the circulating condition of blade lowering, the lift cylinder
bottom pressure rises.
2. When the lift cylinder bottom pressure becomes 3.43 MPa {35 kg/cm2} or more, selector valve spool (2)
moves to the left.
3. The pilot pressure from the EPC valve is blocked and pressure chamber (a) of main spool (1) is connected
to drain circuit (TS).
4. Main spool (1) moves to the left by the force of spring (3).
5. The lift cylinder bottom is connected to the circuit between port (PB) and port (VB), thus circuit becomes no
circulating condition (oil cannot flow from head to bottom) and blade can thrust against ground.
PISTON VALVE
FUNCTION OF PISTON VALVE FOR BLADE LIFT CYLINDER
The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches its stroke end, the
valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston.
10-300 D155AX-8
In addition the piston valve relieves the shock which occurs when the piston comes into contact with the cylinder
head or the bottom and serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape
from the cylinder before the piston reaches its stroke end.
OPERATE PISTON VALVE FOR BLADE LIFT CYLINDER

Operation when piston valve is closed
1. Pressurized oil from the work equipment pump acts on pis-
ton (2) and piston valve (3).
2. Then, piston valve (3) is pushed to the right and contacts
the tapered part of piston valve seat (4) to seal in the oil.
As a result, the pressure in the cylinder rises to move pis-
ton (2) to the right.
Operation when piston valve is open

1. Just before piston rod (1) reaches the end of its stroke, the
tip of valve (6) contacts the cylinder bottom, so valve (6)
and piston valve (3) stop at that position and do not move
further. Only piston (2) moves further.
2. The oil at the cylinder head which has been sealed in by
piston valve (3) escapes through piston valve seats (4)
and (5) at this time, and the pressure inside the cylinder
stops rising.
BLADE ELECTRIC LEVER

STRUCTURE OF ELECTRIC BLADE CONTROL LEVER
NOTICE
D155AX-8 10-301
1: Boot 3: Connector
2: Nut
RIPPER ELECTRIC LEVER

STRUCTURE OF ELECTRIC RIPPER CONTROL LEVER
NOTICE
10-302 D155AX-8
1: Boot 3: Connector
2: Ring 4: Plate
D155AX-8 10-303
MAIN FRAME 10 STRUCTURE AND FUNCTION
UNDERCARRIAGE AND FRAME

MAIN FRAME
STRUCTURE OF MAIN FRAME
General view
1: Main frame 2: Cap
10-304 D155AX-8
10 STRUCTURE AND FUNCTION SUSPENSION
SUSPENSION
STRUCTURE OF SUSPENSION
1: Equalizer bar 2: Pivot shaft assembly
D155AX-8 10-305
SUSPENSION 10 STRUCTURE AND FUNCTION
3: Cover 6: Pivot shaft

4: Thrust plate 7: Seal cage
5: Thrust plate
8: Seal 10: Center pin

9: Side pin
10-306 D155AX-8
10 STRUCTURE AND FUNCTION SUSPENSION
FUNCTION OF SUSPENSION
The front of the track frame rocks up and down by using the rear pivot shafts (3) as a fulcrum. Equalizer bar (1)
rocks by using center pin (2) as a fulcrum. The right and left track frames are connected by side pin (4).
D155AX-8 10-307
TRACK FRAME AND IDLER CUSHION 10 STRUCTURE AND FUNCTION
TRACK FRAME AND IDLER CUSHION

STRUCTURE OF TRACK FRAME AND IDLER CUSHION
1: Idler 4: Yoke
2: Track frame 5: Dust seal
3: Carrier roller 6: Bushing
10-308 D155AX-8
10 STRUCTURE AND FUNCTION TRACK FRAME AND IDLER CUSHION
7: Rod 12: Track roller

8: Wear ring 13: Track roller support guard
9: Recoil spring 14: Minor bogie
10: Lubricator 15: Major bogie
11: Sprocket cover guard 16: First bogie
SPECIFICATIONS OF TRACK FRAME AND IDLER CUSHION

Track roller flange type and bogie arrangement
1st: S (single)
2nd: D (double)
3rd: S (single)
4th: D (double)
5th: S (single)
6th: D (double)
7th: S (single)
FUNCTION OF TRACK FRAME AND IDLER CUSHION
• Track rollers (5) are mounted on the K-shaped bogies to increase the actual ground contact area of track
shoes on uneven ground, and increase the drawbar pull.
• The K-shaped bogies are equipped with rubber pads (6) to absorb the shocks from the ground surface.
• The idler cushion charges or discharges grease from lubricator (4) to move rod (2) forward or backward in
order to adjust the track tension. The recoil spring (3) acts to dampen any sudden shock brought to bear on
idler (1).
D155AX-8 10-309
STRUCTURE OF CYLINDER STAY 10 STRUCTURE AND FUNCTION
WORK EQUIPMENT
STRUCTURE OF CYLINDER STAY
General view
1: Yoke 4: Dust seal

2: Bushing 5: Grease nipple
3: Bushing
10-310 D155AX-8
10 STRUCTURE AND FUNCTION STRUCTURE OF BLADE
STRUCTURE OF BLADE
General view
REMARK
The figure shows SIGMADOZER with dual tilt specification.
1: Blade 6: L.H. tilt cylinder

2: Cutting edge 7: Center brace
3: End bit 8: Straight frame
4: Lift cylinder 9: Trunnion
5: R.H. tilt cylinder (*1)
D155AX-8 10-311
STRUCTURE OF BLADE 10 STRUCTURE AND FUNCTION
*1: The single tilt specification uses the brace.
10-312 D155AX-8
10 STRUCTURE AND FUNCTION STRUCTURE OF VARIABLE GIANT RIPPER
STRUCTURE OF VARIABLE GIANT RIPPER

General view
1: Tilt cylinder 4: Arm

2: Lift cylinder 5: Cab mount bracket
3: Shank 6: Beam
D155AX-8 10-313
STRUCTURE OF VARIABLE FIXED MULTI-SHANK RIPPER 10 STRUCTURE AND FUNCTION
STRUCTURE OF VARIABLE FIXED MULTI-SHANK RIPPER

General view
1: Tilt cylinder 4: Arm

2: Lift cylinder 5: Cab mount bracket
3: Shank 6: Beam
10-314 D155AX-8
10 STRUCTURE AND FUNCTION ROPS CAB
CAB AND ITS ATTACHMENTS

ROPS CAB
ROPS
Abbreviation for Roll-Over Protective Structure
STRUCTURE OF ROPS CAB

General view
1: Front window 4: Door

2: Front wiper 5: Rear wiper
3: ROPS (with built-in cab)
FUNCTION OF ROPS CAB

ROPS cab is to protect the operator wearing seat belt from being crushed when the machine rolls over.
D155AX-8 10-315
CAB MOUNT 10 STRUCTURE AND FUNCTION
CAB MOUNT
STRUCTURE OF CAB MOUNT
Structure drawing
1: Support 4: ROPS stopper

2: Damper mount (front) 5: ROPS pin
3: Damper mount (rear)
The mounts are installed at 2 places in the front section and at 2 places in the rear section to secure the floor
frame and the cab.
10-316 D155AX-8
20 STANDARD VALUE TABLE
D155AX-8 20-1
CONTENTS 20 STANDARD VALUE TABLE
CONTENTS
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-3
STANDARD VALUE TABLE FOR ENGINE: D155AX-8 ........................................................................... 20-3
STANDARD VALUE TABLE FOR MACHINE.................................................................................................. 20-8
STANDARD VALUE TABLE FOR MACHINE: D155AX-8 ........................................................................ 20-8
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-25
STANDARD VALUE TABLE FOR ELECTRICAL .......................................................................................... 20-28
STANDARD VALUE TABLE FOR ELECTRICITY.................................................................................. 20-28
20-2 D155AX-8
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: D155AX-8
STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE: D155AX-8
Performance
Engine SAA6D140E-7
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Engine coolant temperature: 60 to
100 °C
• Power train oil temperature: 70 to
120 °C
• Hydraulic oil temperature: 45 to
100 °C
Engine high idle
• Operating Mode: P (Power mode) rpm 2100 (0 / -100) 2100 (0 / -100)
speed (*1)
• Fuel control dial: MAX (High idle)
• Joystick (steering, directional, and
gear shift lever) (PCCS lever): NEU-
TRAL
• Adjustment ID: 0007 “Engine Decel-
erator Cutting”
100 °C
120 °C
Engine speed at 100 °C rpm 740 ± 25 740 ± 25
low idle (*1)
• Operating Mode: P (Power mode)
• Fuel control dial: MIN (Low idle)
TRAL
*1: Item that can be checked in monitoring function of machine monitor.
Air intake and exhaust system

Engine SAA6D140E-7
Standard value for
new machine
100 °C
120 °C kPa Min. 123 Min. 109
Boost pressure
• Hydraulic oil temperature: 45 to { mmHg} {Min. 925} {Min. 820}
100 °C
• Adjustment ID: 0530 “Stall Mode”
D155AX-8 20-3
STANDARD VALUE TABLE FOR ENGINE: D155AX-8 20 STANDARD VALUE TABLE

Engine SAA6D140E-7
Standard value for
new machine
100 °C
120 °C
Exhaust temper- • Hydraulic oil temperature: 45 to
100 °C °C Max. 670 Max. 700
ature
• Whole speed range ambient temper-
ature: (20 °C)
• Engine coolant tem- %
Max. 25 Max. 35
perature60 to 100 °C At sudden ac- (Bosch in-
celeration (Max. 2.5) (Max. 3.5)
• After keeping for 5 dex)
Exhaust gas col- seconds at normal
or condition Fuel control di-
Bosch in-
• Measured at meas- al: MAX (High Max. 1.0 Max. 2.0
dex
uring port of KDPF idle)
inlet piping
Engine coolant tempera- Intake valve 0.35 -

Valve clearance mm
ture: Normal temperature Exhaust valve 0.57 -
• Engine coolant tem- Fuel control di- Min. 1.43 Min. 1.43
perature: 60 to al: MAX (High
idle) {Min. 14.6} {Min. 14.6}
100 °C
• Power train oil tem-
perature: 70 to
EGR valve oil 120 °C
pressure and • Hydraulic oil temper- MPa
KVGT oil pres- ature: 45 to 100 °C Fuel control di- { kg/cm2}
sure Min. 1.18 Min. 1.18
• Operating Mode: P al: MIN (Low
idle) {Min. 12.0} {Min. 12.0}
(Power mode)
• Joystick (steering,
directional, and gear
shift lever) (PCCS
lever): NEUTRAL
Main body
Engine SAA6D140E-7
Standard value for
new machine
• Engine coolant temperature40 to
Compression 60 °C MPa Min. 4.1 Min. 2.8
pressure • Engine speed200 to 250 rpm(Refer- { kg/cm2} {Min. 42} {Min. 29}
ence)
20-4 D155AX-8

Engine SAA6D140E-7
Standard value for
new machine
100 °C
120 °C kPa Max. 2.94 Max. 3.92
Blowby pressure
• Hydraulic oil temperature: 45 to { mmH2O} {Max. 300} {Max. 400}
100 °C
Fuel system
Engine SAA6D140E-7
Standard value for
new machine
100 °C
120 °C
MPa 0.15 to 0.3 0.15 to 0.3
Fuel pressure 100 °C
{ kg/cm2} {1.5 to 3} {1.5 to 3}
TRAL
D155AX-8 20-5
STANDARD VALUE TABLE FOR ENGINE: D155AX-8 20 STANDARD VALUE TABLE

Engine SAA6D140E-7
Standard value for
new machine
• Engine coolant tem- Engine speed
perature: 60 to Max. 900 Max. 900
1500 rpm
100 °C
• Hydraulic oil temper-
ature: 45 to 100 °C
• Operating Mode: P
(Power mode)
• Fuel control dial:
MAX (High idle)
• Adjustment ID: 0530
Return rate from “Stall Mode”
cc/min
injector • Gear shift mode:
Manual gear shift 1400 rpm Max. 840 Max. 840
mode
• Preset mode: F3-R3
shift lever) (PCCS
lever): Forward
• Return rate in 1 mi-
nute at torque con-
verter stall
100 °C
100 °C
Leakage from • Adjustment ID: 0530 “Stall Mode”
pressure limiter • Gear shift mode: Manual gear shift cc/min Max. 10 Max. 10
valve mode
gear shift lever) (PCCS lever): For-
ward
• Leakage in 1 minute at torque con-
verter stall
20-6 D155AX-8
Lubrication system
Engine SAA6D140E-7
Standard value for
new machine
• Engine oil tempera- Fuel control di- Min. 0.34 Min. 0.21
ture: Min. 80 °C al: MAX (High
idle) {Min. 3.5} {Min. 2.1}
(Power mode)
Engine oil pres- shift lever) (PCCS MPa
sure lever): NEUTRAL Fuel control di- { kg/cm2} Min. 0.10 Min. 0.08
• Engine oil (*2) al: MIN (Low
idle) {Min. 1.0} {Min. 0.8}
EO10W30–LA
EO15W40–LA
EOS5W30–LA
EOS5W40–LA
Engine oil tem-
Whole speed range (inside oil pan) °C 90 to 110 Max. 120
perature
*2: KES diesel engine oil
D155AX-8 20-7
STANDARD VALUE TABLE FOR MACHINE: D155AX-8 20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE

STANDARD VALUE TABLE FOR MACHINE: D155AX-8
Engine speed
Engine SAA6D140E-7
Standard value for
new machine
100 °C
Engine speed 120 °C
when decelerator • Hydraulic oil temperature: 45 to rpm 1025 ± 25 1025 ± 25
pedal is de- 100 °C
pressed (*1)
• Decelerator pedal: Depress fully
100 °C
120 °C
Engine speed at • Hydraulic oil temperature: 45 to
high idle during 100 °C rpm 1875 ± 50 1875 ± 50
neutral decelera-
tion (*1) • Operating Mode: P (Power mode)
TRAL
100 °C
120 °C
100 °C
Engine speed • Operating Mode: P (Power mode)

with torque con- • Fuel control dial: MAX (High idle) rpm 1540 ± 50 Max. 1380
verter stalled (*1) • Adjustment ID: 0530 “Stall Mode”
• Gear shift mode: Manual gear shift
mode
ward
20-8 D155AX-8
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: D155AX-8

Engine SAA6D140E-7
Standard value for
new machine
100 °C
120 °C
100 °C
Engine speed at • Fuel control dial: MAX (High idle)
rpm 1512 ± 50 Max. 1357
full stall (*1) • Adjustment ID: 0530 “Stall Mode”
• Gear shift mode: Manual gear shift
mode
ward
• Ripper control lever: RAISE relief
*1: Item that can be checked by using monitoring function of machine monitor.
SCR
Engine SAA6D140E-7
Standard value for
new machine
AdBlue/DEF AdBlue/DEF Pump Pressure Up Test within
Pump Pressure approximately 200 seconds after starting kPa Min. 800 Min. 800
Up Test the test
AdBlue/DEF In-
AdBlue/DEF Injection Quantity Test Injec-
jection Quantity mℓ 100(+7/-26) 100(+7/-26)
tion amount after the test
Test
AdBlue/DEF Line AdBlue/DEF Line Heater Relay 1 Test with-
Heater Relay 1 in approximately 900 seconds after starting V 24.5 ± 1.5 24.5 ± 1.5
Test the test
AdBlue/DEF Line AdBlue/DEF Line Heater Relay 2 Test with-
Heater Relay 2 in approximately 900 seconds after starting V 24.5 ± 1.5 24.5 ± 1.5
Test the test
AdBlue/DEF AdBlue/DEF Pump Heater Relay Test with-
Pump Heater in approximately 900 seconds after starting V 24.5 ± 1.5 24.5 ± 1.5
Relay Test the test
AdBlue/DEF AdBlue/DEF Tank Heater Valve Test within
Tank Heater approximately 900 seconds after starting V 24.5 ± 1.5 24.5 ± 1.5
Valve Test the test
D155AX-8 20-9

Engine SAA6D140E-7
Standard value for
new machine
AdBlue/DEF
SCR Denitration Efficiency Injection Test 1 (Normality) 1 (Normality)
SCR Denitration Result
Testmonitor display after -
Efficiency Test
the test SCR Efficiency
1 (Normality) 1 (Normality)
Test Result
Cooling fan
Engine SAA6D140E-7
Standard value for
new machine
100 °C
Cooling fan
• Fuel control dial: MAX (High idle) rpm 1450 ± 25 1450 ± 25
speed
• Adjustment ID: 1005 (Fan 100%
Mode)
100 °C
Cooling fan cir- MPa Max. 20.58 Max. 20.58
cuit oil pressure { kg/cm2} Max. {210} Max. {210}
• Adjustment ID: 1005 (Fan 100%
Mode)
Travel of control lever and pedal

Engine SAA6D140E-7
Standard value for
new machine
Joystick (steer- N to FOR-
30 ± 5 30 ± 5
ing, directional, WARD
and gear shift
lever) (PCCS N to RE-
lever): Forward • Engine stopped 30 ± 5 30 ± 5
VERSE
and reverse mm
• Measuring point:
Joystick (steer- Center of lever grip N to LEFT 40 ± 5 40 ± 5
ing, directional,
and gear shift
lever) (PCCS N to RIGHT 40 ± 5 40 ± 5
lever): Steering
Decelerator ped- • Engine stopped

mm 50 ± 15 50 ± 15
al • Measuring point: Center of pedal
• Fuel control dial: Full stroke 80 ± 10 80 ± 10
MIN (Low idle)
Brake pedal Until oil pres- mm
• Measuring point: sure becomes 52.5 ± 6.7 52.5 ± 6.7
Center of pedal zero
20-10 D155AX-8

Engine SAA6D140E-7
Standard value for
new machine
N to RAISE 60 ± 10 60 ± 10
• Engine stopped N to LOWER 60 ± 10 60 ± 10
Blade control
• Measuring point: mm
lever N to LEFT tilt 53 ± 10 53 ± 10
Center of lever knob
N to RIGHT tilt 53 ± 10 53 ± 10
• Engine stopped N to RAISE 30 ± 5 30 ± 5
Ripper control
lever N to LOWER 30 ± 5 30 ± 5
Center of lever knob
• Engine stopped N to tilt IN 4±1 4±1
Ripper control
switch N to tilt BACK 4±1 4±1
Center of switch
Operating effort of control lever and pedal

Engine SAA6D140E-7
Standard value for
new machine
Joystick (steer- N to FOR- 56.9±6.9 56.9 ± 6.9
ing, directional, WARD {5.8 ± 0.7} {5.8 ± 0.7}
and gear shift N
lever) (PCCS { kg} 56.9 ± 6.9 56.9 ± 6.9
N to RE-
lever): Forward • Engine stopped VERSE {5.8 ± 0.7} {5.8 ± 0.7}
and reverse
• Measuring point:
Joystick (steer- Center of lever grip 25.5±4.9 25.5 ± 4.9
N to LEFT
ing, directional, N {2.6 ± 0.5} {2.6 ± 0.5}
and gear shift
lever) (PCCS { kg} 28.4 ± 4.9 28.4 ± 4.9
N to RIGHT
lever): Steering {2.9 ± 0.5} {2.9 ± 0.5}
Decelerator ped- • Engine stopped N 49.0±9.8 49.0 ± 9.8

al • Measuring point: Center of pedal { kg} {5.0 ± 1.0} {5.0 ± 1.0}
Depressing ef- 93 93
• Fuel control dial: fort at starting {9.5} {9.5}
MIN (Low idle) N
Brake pedal Depressing ef-
• Measuring point: fort to depress { kg} 431.2 ± 117.6 431.2 ± 117.6
Center of pedal fully to the {44 ± 12} {44 ± 12}
stroke end.
D155AX-8 20-11

Engine SAA6D140E-7
Standard value for
new machine
36.3±7.8 36.3 ± 7.8
N to RAISE
{3.7 ± 0.8} {3.7 ± 0.8}
40.2 ± 7.8 40.2±7.8
• Engine stopped N to LOWER
Blade control N {4.1 ± 0.8} {4.1 ± 0.8}
lever • Measuring point:
{ kg} 29.4 ± 5.9 29.4 ± 5.9
Center of lever knob N to LEFT tilt
{3.0 ± 0.6} {3.0 ± 0.6}
N to RIGHT tilt 29.4 ± 5.9 29.4 ± 5.9
{3.0 ± 0.6} {3.0 ± 0.6}
Blade control • Engine stopped N

LOWER to 9.8±2.9 9.8 ± 2.9
lever FLOAT but- • Measuring point: { kg}
FLOAT {1.0 ± 0.3} {1.0 ± 0.3}
ton Center of button
28.4 ± 4.9 28.4 ± 4.9
• Engine stopped N to RAISE
Ripper control N {2.9 ± 0.5} {2.9 ± 0.5}
lever • Measuring point:
{ kg} 31.4 ± 4.9 31.4 ± 4.9
Center of lever knob N to LOWER
{3.2 ± 0.5} {3.2 ± 0.5}
4.9 ± 2.5 4.9 ± 2.5
• Engine stopped N to tilt IN
Ripper control N {0.5 ± 0.25} {0.5 ± 0.25}
switch • Measuring point:
{ kg} 4.9 ± 2.5 4.9±2.5
Center of switch N to tilt BACK
{0.5 ± 0.25} {0.5 ± 0.25}
Power train oil pressure

Engine SAA6D140E-7
Standard value for
new machine
• Engine coolant tem- Fuel control di- 2.99 to 3.38 Min. 2.79
idle) {30.5 to 34.5} {Min. 28.5}
100 °C
perature: 70 to 80 °C
Transmission • Hydraulic oil temper- MPa
main relief pres- ature: 45 to 100 °C
sure (TM) Fuel control di- { kg/cm2} 2.81 to 3.11 Min. 2.62
(Power mode) idle) {28.7 to 31.7} {Min. 26.7}
shift lever) (PCCS
lever): NEUTRAL
20-12 D155AX-8

Engine SAA6D140E-7
Standard value for
new machine
100 °C
80 °C
100 °C
Torque converter • Operating Mode: P (Power mode) MPa 1.42 ± 0.15 1.32 ± 0.15
lockup clutch
pressure (LU) • Fuel control dial: MAX (High idle) { kg/cm2} {14.5 ± 1.5} {13.5 ± 1.5}
ward (idle rotation)
• Gear shift mode: Automatic gear
shift
• Engine coolant tem- Fuel control di- 2.55 to 2.94 2.55 to 2.94
idle) {26.0 to 30.0} {26.0 to 30.0}
100 °C
Torque converter ature: 45 to 100 °C
MPa
stator clutch • Operating Mode: P
pressure (SC) Fuel control di- { kg/cm2} 2.55 to 2.94 2.55 to 2.94
(Power mode)
al: MIN (Low
• Joystick (steering, idle) {26.0 to 30.0} {26.0 to 30.0}
shift lever) (PCCS
lever): NEUTRAL
• During neutral decel-
eration operation
idle) {27.0 to 31.0} {Min. 24.5}
100 °C
Transmission for- • Hydraulic oil temper-
MPa
ward clutch pres- ature: 45 to 100 °C
sure (F) Fuel control di- { kg/cm2} 2.55 to 2.94 Min. 2.26
al: MIN (Low
(Power mode) {26.0 to 30.0} Min. {23.0}
idle)
• Gear shift mode:
Manual gear shift
(F3)
D155AX-8 20-13

Engine SAA6D140E-7
Standard value for
new machine
idle) {28.0 to 32.0} {Min. 26.5}
100 °C
Transmission re- • Hydraulic oil temper-
MPa
verse clutch ature: 45 to 100 °C
pressure (R) Fuel control di- { kg/cm2} 2.60 to 2.99 Min. 2.45
al: MIN (Low
(Power mode) {26.5 to 30.5} {Min. 25.0}
idle)
Manual gear shift
(R3)
idle) {31.0 to 34.0} {Min. 29.0}
100 °C
Transmission 1st • Hydraulic oil temper-
MPa
clutch pressure ature: 45 to 100 °C
(1ST) Fuel control di- { kg/cm2} 2.81 to 3.11 Min. 2.62
al: MIN (Low
(Power mode) {28.7 to 31.7} {Min. 26.7}
idle)
Manual gear shift
(F1)
idle) {37.5 to 31.5} {Min. 26.0}
100 °C
Transmission • Hydraulic oil temper-
MPa
2nd clutch pres- ature: 45 to 100 °C
sure (2ND) Fuel control di- { kg/cm2} 2.55 to 2.94 Min. 2.40
al: MIN (Low
(Power mode) {26.0 to 30.0} {Min. 24.5}
idle)
Manual gear shift
(F2)
20-14 D155AX-8

Engine SAA6D140E-7
Standard value for
new machine
idle) {31.0 to 34.0} {Min. 29.0}
100 °C
Transmission 3rd • Hydraulic oil temper-
MPa
clutch pressure ature: 45 to 100 °C
(3RD) Fuel control di- { kg/cm2} 2.81 to 3.11 Min. 2.62
al: MIN (Low
(Power mode) {28.7 to 31.7} {Min. 26.7}
idle)
Manual gear shift
(F3)
• Engine coolant tem- Fuel control di- 3.14 ± 0.20 Min. 2.16
idle) {32.0 ± 2.0} {Min. 22.0}
100 °C
Right brake pres- MPa
sure (RB) Fuel control di- { kg/cm2}
ature: 45 to 100 °C 3.14 ± 0.20 Min. 2.16
al: MIN (Low
• Operating Mode: P idle) {32.0 ± 2.0} {Min. 22.0}
(Power mode)
• Parking brake lever:
FREE position
• Engine coolant tem- Fuel control di- 3.14 ± 0.20 Min. 2.16
idle) {32.0 ± 2.0} {Min. 22.0}
100 °C
Left brake pres- MPa
sure (LB) Fuel control di- { kg/cm2}
ature: 45 to 100 °C 3.14 ± 0.20 Min. 2.16
al: MIN (Low
• Operating Mode: P idle) {32.0 ± 2.0} {Min. 22.0}
(Power mode)
• Parking brake lever:
FREE position
D155AX-8 20-15

Engine SAA6D140E-7
Standard value for
new machine
• Engine coolant tem- Fuel control di- Max. 1.0 Max. 1.0
idle) Max. {10.0} Max. {10.0}
100 °C
Torque converter • Hydraulic oil temper- MPa
inlet pressure ature: 45 to 100 °C
(*1) Fuel control di- { kg/cm2} 0.05 to 0.49 0.05 to 0.49
(Power mode) idle) {0.5 to 5.0} {0.5 to 5.0}
shift lever) (PCCS
lever): NEUTRAL
• Engine coolant tem- Fuel control di- 0.29 to 0.69 0.29 to 0.69
idle) {3.0 to 7.0} {3.0 to 7.0}
100 °C
Torque converter • Hydraulic oil temper- MPa
outlet pressure ature: 45 to 100 °C
(*1) Fuel control di- { kg/cm2} 0.05 to 0.29 0.05 to 0.29
(Power mode) idle) {0.5 to 3.0} {0.5 to 3.0}
shift lever) (PCCS
lever): NEUTRAL
100 °C
80 °C
Transmission lu- • Hydraulic oil temperature: 45 to
MPa 0.10 to 0.25 0.10 to 0.25
bricating oil pres- 100 °C
sure (reference) { kg/cm2} {1.0 to 2.5} {1.0 to 2.5}
TRAL
*1: Item that can be checked in monitoring function of machine monitor.
20-16 D155AX-8
Power train performance

Engine SAA6D140E-7
Standard value for
new machine
• Level ground F1 3.5 ± 0.2 3.5 ± 0.2
• Engine coolant tem- F2 5.6 ± 0.3 5.6 ± 0.3
perature: 60 to
F3L 7.5 ± 0.4 7.5 ± 0.4
100 °C
• Power train oil tem- F3 11.6 ± 0.6 11.6 ± 0.6
perature: 70 to R1 4.3 ± 0.3 4.3 ± 0.3
120 °C
R2 6.8 ± 0.4 6.8 ± 0.4
(Power mode) R3L 9.2 ± 0.5 9.2 ± 0.5
Travel speed • Fuel control dial: km/h
MAX (High idle)
Manual gear shift
mode
R3 14.0 ± 0.7 14.0 ± 0.7
• Run up distance: 15
to 30 m
• Measurement dis-
tance: 20 m (con-
verted into km/h)
Work equipment and HSS oil pressures

Engine SAA6D140E-7
Standard value for
new machine
100 °C
120 °C
MPa 2.45 (+1.37 / 0) 2.45 (+1.37 / 0)
Unload pressure 100 °C
{ kg/cm2} 25 (+14 / 0) 25 (+14 / 0)
TRAL
D155AX-8 20-17

Engine SAA6D140E-7
Standard value for
new machine
Blade lift relief • Engine coolant temperature: 60 to 27.5 ± 1.5 27.5 ± 1.5
pressure 100 °C {280 ± 15} {280 ± 15}
120 °C
MPa
Blade lift LS re- 100 °C { kg/cm2} 25.0 ± 0.98 25.0 ± 0.98
lief pressure • Operating Mode: P (Power mode) {255 ± 10} {255 ± 10}
• Blade control lever: Lift RAISE
Blade tilt relief • Engine coolant temperature: 60 to 27.5 ± 1.5 27.5 ± 1.5
pressure 100 °C {280 ± 15} {280 ± 15}
120 °C
MPa
Blade tilt LS re- 100 °C { kg/cm2} 25.0 ± 0.98 25.0 ± 0.98
• Blade control lever: Tilt RAISE
Ripper lift relief • Engine coolant temperature: 60 to 27.5±1.5 27.5 ± 1.5
pressure 100 °C {280 ± 15} {280 ± 15}
120 °C
MPa
Ripper lift LS re- 100 °C { kg/cm2} 25.0 ± 0.98 25.0 ± 0.98
• Ripper control lever: RAISE
Ripper tilt relief • Engine coolant temperature: 60 to 27.5 ± 1.5 27.5 ± 1.5
pressure 100 °C {280 ± 15} {280 ± 15}
120 °C
MPa
Ripper tilt LS re- 100 °C { kg/cm2} 25.0 ± 0.98 25.0 ± 0.98
• Tilt control switch: Tilt IN
20-18 D155AX-8

Engine SAA6D140E-7
Standard value for
new machine
HSS relief pres- • Engine coolant temperature: 60 to 38.2 to 41.7 38.2 to 41.7
sure (left side) 100 °C {390 to 425} {390 to 425}
120 °C
MPa
100 °C
HSS LS relief { kg/cm2} 36.2 to 38.1 36.2 to 38.1
pressure (left • Operating Mode: P (Power mode)
side) {369 to 389} {369 to 389}
gear shift lever) (PCCS lever): turn
left
HSS relief pres- • Engine coolant temperature: 60 to 38.2 to 41.7 38.2 to 41.7
sure (right side) 100 °C {390 to 425} {390 to 425}
120 °C
MPa
100 °C
HSS LS relief { kg/cm2} 36.2 to 38.1 36.2 to 38.1
pressure (right • Operating Mode: P (Power mode)
side) {369 to 389} {369 to 389}
gear shift lever) (PCCS lever): turn
right
100 °C
120 °C
Control circuit oil • Hydraulic oil temperature: 45 to MPa Min. 2.50 Min. 2.50
pressure 100 °C
{ kg/cm2} {Min. 25.5} {Min. 25.5}
• Blade control lever: NEUTRAL
• Ripper control lever: NEUTRAL
100 °C
120 °C
EPC valve out- • Hydraulic oil temperature: 45 to
put pressure of MPa 3.72 to 4.12 Min. 3.43
100 °C
control valve { kg/cm2} {38 to 42} {Min. 35}
(reference) • Operating Mode: P (Power mode)
• Joystick (steering, directional and
gear shift lever) (PCCS lever): At
each stroke ends
D155AX-8 20-19

Engine SAA6D140E-7
Standard value for
new machine
• Engine coolant tem- Lever position:
0 0
perature: 60 to LOCK
100 °C
Output pressure perature: 70 to
of work equip- 120 °C MPa
ment lock sole- • Hydraulic oil temper- { kg/cm2} Min. 2.50 Min. 2.50
noid valve ature: 45 to 100 °C FREE position
{Min. 25.5} (*2) {Min. 25.5} (*2)
(Power mode)
MAX (High idle)
Pulling out on
pin puller cyl- 2.99 to 3.38 Min. 2.79
• Engine coolant tem- inder head {30.5 to 34.5} (*3) {Min. 28.5} (*3)
perature: 60 to side
100 °C
Pushing in on
• Power train oil tem- pin puller cyl- 0 0
perature: 70 to inder head {0} {0}
Ripper pin puller 120 °C side MPa
solenoid valve
• Hydraulic oil temper- Pulling out on { kg/cm2}
outlet pressure
ature: 45 to 100 °C pin puller cyl- 0 0
• Operating Mode: P inder bottom {0} {0}
(Power mode) side
• Fuel control dial: Pushing in on
MAX (High idle) pin puller cyl- 2.99 to 3.38 Min. 2.79
inder bottom {30.5 to 34.5} (*3) {Min. 28.5} (*3)
side
*2: Same as control circuit oil pressure.

*3: It is the same as brake pressures on the right and left (RB and LB).
20-20 D155AX-8
Work equipment speed

Engine SAA6D140E-7
Standard value for
new machine
100 °C
• No load on blade
Blade RAISE 3.0 to 4.0 3.0 to 4.0
• Time required to move blade be-
tween ground level and rising end
• See STANDARD VALUE TABLE,
“MACHINE POSTURE AND PRO-
CEDURE FOR MEASURING PER-
FORMANCE”, "Fig. 1".
Sec.
100 °C
• No load on blade
Blade LOWER 1.2 to 1.9 1.2 to 1.9
• Time required to move blade be-
• Hydraulic oil temper- Single tilt
ature: 45 to 100 °C (SIGMA doz- 1.3 to 2.3 Max. 3.1
er)
(Power mode) Single tilt
1.8 to 2.8 Max. 3.1
• Fuel control dial: (semi-U dozer)
MAX (High idle) Dual tilt (SIG-
1.1 to 2.1 Max. 3.1
• No load on blade MA dozer)
• Time required to
Blade LEFT tilt move blade between Sec.
right tilt end and left
tilt end
• See STANDARD Dual tilt (semi-
VALUE TABLE, “MA- U dozer) 1.1 to 2.1 Max. 3.1
CHINE POSTURE
AND PROCEDURE
FOR MEASURING
PERFORMANCE”,
"Fig. 2".
D155AX-8 20-21

Engine SAA6D140E-7
Standard value for
new machine
• Hydraulic oil temper- Single tilt
ature: 45 to 100 °C (SIGMA doz- 1.3 to 2.3 Max. 3.1
er)
(Power mode) Single tilt
1.8 to 2.8 Max. 3.1
• Fuel control dial: (semi-U dozer)
MAX (High idle) Dual tilt (SIG-
1.1 to 2.1 Max. 3.1
• No load on blade MA dozer)
• Time required to
Blade right tilt move blade between Sec.
left tilt end and right
tilt end
• See STANDARD Dual tilt (semi-
VALUE TABLE, “MA- U dozer) 1.1 to 2.1 Max. 3.1
CHINE POSTURE
AND PROCEDURE
FOR MEASURING
PERFORMANCE”,
"Fig. 2".
100 °C
• No load on ripper (lowest shank
Ripper Raise hole) Sec. 1.5 to 2.5 Max. 4.0
• Time required to move ripper be-
• See STANDARD VALUE TABLE
100 °C
• No load on ripper (lowest shank
Ripper LOWER hole) Sec. 1.3 to 2.3 Max. 3.5
• 2. Time required to move ripper be-
tween rising end and ground level
20-22 D155AX-8

Engine SAA6D140E-7
Standard value for
new machine
100 °C
• No load on ripper
Ripper tilt IN Sec. 4.5 to 5.5 Max. 6.2
tween tilt back end and tilt in end
100 °C
• No load on ripper
Ripper tilt back Sec. 3.7 to 4.7 Max. 6.1
tween tilt in end and tilt out end
Operation time lag

Engine SAA6D140E-7
Standard value for
new machine
100 °C
Blade • Blade control lever: Full stroke Sec. Max. 1.7 Max. 2.5
• Start lowering operation at blade

max. raising position and measure
time from when blade reaches
ground until idler rises
D155AX-8 20-23

Engine SAA6D140E-7
Standard value for
new machine
100 °C
Ripper • Ripper control lever: Full stroke Sec. Max. 1.5 Max. 1.5
• Start lowering operation at ripper

max. raising position and measure
time from when ripper reaches
ground until sprocket rises.
Hydraulic drift of work equipment

Engine SAA6D140E-7
Standard value for
new machine
100 °C
• Engine stopped
Hydraulic drift of • Reduction of blade bottom height (h)

in 15 min. mm Max. 150 Max. 200
lifted blade
100 °C
• Engine stopped
Hydraulic drift of • Reduction of idler center height (h)
machine lifted by in 5 min. mm Max. 50 Max. 70
blade
100 °C
• Engine stopped
Hydraulic drift of • Reduction of track shoe bottom
machine tilted by height (h) in 5 min. mm Max. 50 Max. 70
blade
20-24 D155AX-8

Engine SAA6D140E-7
Standard value for
new machine
100 °C
• Engine stopped
Hydraulic drift of • Reduction of sprocket center height
machine lifted by (h) in 5 min. mm Max. 30 Max. 40
ripper
Cylinder leakage
Engine SAA6D140E-7
Standard value for
new machine
Blade lift cylinder • Hydraulic oil temperature: 45 to Max. 3.0 Max. 12
Ripper lift cylin- 100 °C
Max. 2.7 Max. 11
der • Fuel control dial: MAX (High idle) cc/min
Ripper tilt cylin- • Oil leakage for 1 minute while reliev-
ing cylinder to be measured Max. 2.7 Max. 11
der
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE

Fig. 1
Blade lifting speed
Fig. 2
Blade tilting speed
D155AX-8 20-25
Fig. 3
Ripper lifting speed
Fig. 4
Ripper tilting speed
Fig. 5
Hydraulic drift of lifted blade
Fig. 6
Hydraulic drift of machine lifted by blade
20-26 D155AX-8
Fig. 7
Hydraulic drift of machine tilted by blade
Fig. 8
Hydraulic drift of machine lifted by ripper
D155AX-8 20-27
STANDARD VALUE TABLE FOR ELECTRICITY 20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ELECTRICAL

STANDARD VALUE TABLE FOR ELECTRICITY
Controller
Equipment name Procedure, measuring location, criteria, and remarks
1. Starting switch: OFF
2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector J2.
4. Turn the battery disconnect switch to ON position.
Continu- 5.
Measure voltage with starting switch at OFF position and when starting engine.
Engine ous pow-
controller er supply Between J2 (1) and (73) 20 to 30 V
voltage
Between J2 (25) and (49) 20 to 30 V
Voltage Between J2 (26) and (50) 20 to 30 V
2. Turn battery disconnect switch to OFF position.
Continu-
3. Insert T-adapter into connector PTCN3.
ous pow-
er supply 4. Turn battery disconnect switch to ON position.
voltage
Between PTCN3 (1) and (21), (31) 20 to 30 V
Voltage
Between PTCN3 (11) and (32), (33) 20 to 30 V
Power train 1. Starting switch: OFF
controller
Solenoid 3. Insert T-adapter into connector PTCN3.
power 4. Turn battery disconnect switch to ON position.
supply
voltage Between PTCN3 (2) and (21) 20 to 30 V
Voltage Between PTCN3 (12) and (31) 20 to 30 V
Between PTCN3 (22) and (32) 20 to 30 V
Continu-
3. Insert T-adapter into connector WECN3.
ous pow-
er supply 4. Turn battery disconnect switch to ON position.
voltage
Between WECN3 (1) and each of (21) and (31) 20 to 30 V
Voltage
Work
equipment 1. Starting switch: OFF
controller 2. Turn battery disconnect switch to OFF position.
Solenoid 3. Insert T-adapter into connector WECN3.
power 4. Turn battery disconnect switch to ON position.
supply
voltage Between WECN3 (2) and (21) 20 to 30 V
Voltage Between WECN3 (12) and (31) 20 to 30 V
Between WECN3 (22) and (32) 20 to 30 V
20-28 D155AX-8
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ELECTRICITY

Continu- 3. Insert T-adapter into connector CM01.
Machine ous pow- 4. Turn the battery disconnect switch to ON position.
monitor er supply
voltage 5. Starting switch: ON
Between CM01 (1) and (3) 20 to 30 V
Voltage
Engine control
2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
EGR valve solenoid
Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between EGR-SOL (male) (1) and ground Min. 1 MΩ
2. Disconnect connector VGT-SOL, and connect T-adapter to male side.
KVGT solenoid
Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between VGT-SOL (male) (1) and ground Min. 1 MΩ
2. Disconnect connector UDM and connect socket to male side.
AdBlue/DEF injector
11.4 to
Resistance Between UDM (male) (1) and (2) 20 °C
12.6 Ω
2. Insert T-adapter into connector J1 or PIM.
Charge (Boost) pres-
3. Starting switch: ON
sure sensor
Between J1 (45) and (54), or between PIM
Voltage Sensor output 0.3 to 4.7 V
(3) and (2)
2. Disconnect connector DCL, and connect T-adapter to male side.
Approxi-
Between DCL (male) (B) and (C)
mately 2 kΩ
Throttle sensor
0.2 to
Resistance Between DCL (male) (A) and (C)
1.8 kΩ
0.2 to
Between DCL (male) (B) and (A)
1.8 kΩ
2. Insert T-adapter into connector J1 or POIL.
Engine oil pressure
sensor
Between J1 (85) and (54), or between POIL
(3) and (2)
D155AX-8 20-29

2. Disconnect connector TWTR and connect socket to male side.
0 °C 30 to 37 kΩ
9.3 to
25 °C
10.7 kΩ
Coolant temperature Between TWTR (male) (A) and (B) 3.2 to

50 °C
sensor 3.8 kΩ
Coolant temperature characteristics
Resistance 1.0 to
80 °C
1.3 kΩ
700 to
95 °C
800 Ω
All coolant tem-
Between TWTR (male) (B) and ground Min. 1 MΩ
perature range
2. Disconnect connector TIM and connect socket to male side.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
0 °C 29 to 36 kΩ
Charge temperature
sensor Between TIM (male) (A) and (B) 7.3 to
30 °C
Resistance 8.8 kΩ
Charge thermal characteristics
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
2. Insert T-adapter into connector J1 and PAMB.
Ambient pressure sen-
sor
Between J1 (44) and (54), or between
PAMB (3) and (2)
20-30 D155AX-8

2. Disconnect connector ATC and connect socket to male side.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
0 °C 29 to 36 kΩ
Ambient temperature
sensor 7.3 to
30 °C
Resistance Between ATC (male) (A) and (B) 8.8 kΩ
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
2. Insert T-adapter into connector PFUEL or J1.
Common rail pressure
sensor
Between PFUEL (female) (2) and (1), or
between J1 (42) and (58)
Crankcase pressure 2. Insert T-adapter into connector PCCV.
sensor 3. Starting switch: ON
Voltage Between PCCV3 (3) and (2) Sensor output 0.3 to 4.7 V
2. Disconnect connector VGT REV. and connect T-adapter to female side.
KVGT speed sensor
600 to
Resistance Between VGT REV. (female) (1) and (2)
160 Ω
2. Disconnect connector MAF, and connect T-adapter to male side.
-30 °C 25 to 28 Ω
5.5 to
0 °C
6.1 kΩ
Mass air flow (MAF)
sensor 1.9 to
Between MAF (male) (3) and (4) 25 °C
Resistance 2.1 kΩ
40 °C 1.1 to 1.2 Ω
180 to
100 °C
185 kΩ
Between MAF (male) (3) and ground Entire area Min. 1 MΩ
KDPF differential pres- 2. Insert T-adapter into connector PDPF.
sure sensor 3. Starting switch: ON
Voltage Between PDPF (2) and (1) Sensor output 0.5 to 4.5 V
D155AX-8 20-31

2. Insert T-adapter into connector J1 or SEGR.
EGR valve lift sensor
Voltage Between J1 (88) and (57), or between SEGR (3) and (2) 1.0 to 4.0 V
2. Insert T-adapter into connector J1 or SVGT.
KVGT position sensor
Voltage Between J1 (67) and (57), or between SVGT (C) and (B) 1.0 to 4.0 V
2. Insert T-adapter into connector J2 or DSM.
AdBlue/DEF pump
pressure sensor
Between J2 (female) (16) and (32), or be- 0.25 to
Voltage Sensor output
tween DSM (female) (3) and (4) 4.75 V
Machine control
2. Disconnect connector FAR1, and connect T-adapter to male side.
Fan reverse solenoid
Between FAR1 (male) (1) and (2) 34 to 44 Ω
Resistance
Between FAR1 (male) (1) and ground Min. 1 MΩ
2. Disconnect connector HSR, and connect T-adapter to male side.
S/T control valve right
solenoid 4.5 to
Between HSR (male) (1) and (2)
Resistance 14.5 Ω
Between HSR (male) (1) and ground Min. 1 MΩ
2. Disconnect connector HSL, and connect T-adapter to male side.
S/T control valve left
solenoid 4.5 to
Between HSL (male) (1) and (2)
Resistance 14.5 Ω
Between HSL (male) (1) and ground Min. 1 MΩ
2. Disconnect connector FAC, and connect T-adapter to male side.
Fan control solenoid 1
Between FAC (male) (1) and (2) 2 to 12 Ω
Resistance
Between FAC (male) (1) and ground Min. 1 MΩ
2. Disconnect connector TVC and connect T-adapter to male side.
Work equipment, HSS
pump solenoid Between TVC (male) (1) and (2) 2 to 12 Ω
Resistance
Between TVC (male) (1) and ground Min. 1 MΩ
20-32 D155AX-8

2. Disconnect connector SLUC, and connect T-adapter to male side.
Lockup clutch ECMV
solenoid Between SLUC (male) (1) and (2) 3 to 13 Ω
Resistance
Between SLUC (male) (1) and ground Min. 1 MΩ
2. Disconnect connector S1T, and connect T-adapter to male side.
Transmission 1st
clutch ECMV solenoid Between S1T (male) (1) and (2) 3 to 13 Ω
Resistance
Between S1T (male) (1) and ground Min. 1 MΩ
Transmission 2nd
Resistance
Transmission 3rd
Resistance
2. Disconnect connector SRT, and connect T-adapter to male side.
Transmission Reverse
clutch ECMV solenoid Between SRT (male) (1) and (2) 3 to 13 Ω
Resistance
Between SRT (male) (1) and ground Min. 1 MΩ
2. Disconnect connector SFT, and connect T-adapter to male side.
Transmission Forward
clutch ECMV solenoid Between SFT (male) (1) and (2) 3 to 13 Ω
Resistance
Between SFT (male) (1) and ground Min. 1 MΩ
2. Disconnect connector SBRR, and connect T-adapter to male side.
Right steering brake
ECMV solenoid Between SBRR (male) (1) and (2) 3 to 13 Ω
Resistance
Between SBRR (male) (1) and ground Min. 1 MΩ
2. Disconnect connector SBRL and connect T-adapter to male side.
Left steering brake
ECMV solenoid Between SBRL (male) (1) and (2) 3 to 13 Ω
Resistance
Between SBRL (male) (1) and ground Min. 1 MΩ
2. Disconnect connector WEP1, and connect T-adapter to male side.
Blade lift up EPC sole-
noid 4.5 to
Between WEP1 (male) (1) and (2)
Resistance 14.5 Ω
Between WEP1 (male) (1) and ground Min. 1 MΩ
D155AX-8 20-33

Blade lift up EPC sole-
noid 4.5 to
Between WEP2 (male) (1) and (2)
Resistance 14.5 Ω
Blade tilt left head
EPC solenoid Between WEP3 (male) (1) and (2) 2 to 12 Ω
Resistance
Blade tilt left bottom
Resistance
Blade tilt right head
Resistance
Blade tilt right bottom
Resistance
Ripper RAISE EPC
solenoid Between WEP7 (male) (1) and (2) 2 to 12 Ω
Resistance
Ripper LOWER EPC
solenoid Between WEP8 (male) (1) and (2) 2 to 12 Ω
Resistance
Ripper tilt in EPC sole-
noid Between WEP9 (male) (1) and (2) 2 to 12 Ω
Resistance
2. Disconnect connector WEPA, and connect T-adapter to male side.
Ripper tilt back EPC
solenoid Between WEPA (male) (1) and (2) 2 to 12 Ω
Resistance
Between WEPA (male) (1) and ground Min. 1 MΩ
20-34 D155AX-8

2. Disconnect connector WLK, and connect T-adapter to male side.
Work equipment lock
solenoid Between WLK (male) (1) and (2) 34 to 44 Ω
Resistance
Between WLK (male) (1) and ground Min. 1 MΩ
2. Disconnect connector QDP, and connect T-adapter to male side.
Quick drop solenoid 4.5 to
Between QDP (male) (1) and (2)
Resistance 14.5 Ω
Between QDP (male) (1) and ground Min. 1 MΩ
2. Disconnect connector SSTC, and connect T-adapter to male side.
Stator clutch ECMV
solenoid Between SSTC (male) (1) and (2) 3 to 13 Ω
Resistance
Between SSTC (male) (1) and ground Min. 1 MΩ
2. Disconnect connector HDT and connect T-adapter to male side.
Approxi-
25 °C mately
42 kΩ
Approxi-
Hydraulic oil tempera- 30 °C mately
ture sensor Between HDT (male) (1) and (2) 35 kΩ
Resistance (Oil temperature sensor thermal character-
istics) Approxi-
80 °C mately
6.5 kΩ
Approxi-
100 °C mately
3.7 kΩ
2. Disconnect connector TCT, and connect T-adapter to male side.
Approxi-
25 °C mately
42 kΩ
T/C oil temperature Approxi-

(P/L oil temperature) 30 °C mately
Between TCT (male) (1) and (2) 35 kΩ
sensor
Resistance (Oil temperature sensor thermal character-
istics) Approxi-
80 °C mately
6.5 kΩ
Approxi-
100 °C mately
3.7 kΩ
Oil pressure sensor of 2. Insert T-adapter into connector HHP.
work equipment pump 3. Starting switch: ON
Resistance Between HHP (male) (1) and (2) 0.5 to 4.5 V
D155AX-8 20-35

2. Disconnect connector AF1, and connect T-adapter to male side.
3. Start the engine.
Air cleaner clogging When air
sensor cleaner is nor- Max. 1 Ω
Resistance Between AF1 (male) (1) and (2) mal
Air cleaner is
Min. 1 MΩ
clogged
Torque converter inlet 2. Insert T-adapter into connector TIP.
pressure sensor 3. Starting switch: ON
Voltage Between TIP1 (female) (2) and (1) 0.5 to 4.5 V
Torque converter out- 2. Insert T-adapter into connector TOP.
let pressure sensor 3. Starting switch: ON
Voltage Between TOP (female) (2) and (1) 0.5 to 4.5 V
2. Insert T-adapter into connector TLV1.
Steering potentiometer
1
0.96 to
Voltage Between TLV1 (female) (7) and (8)
4.04 V
Steering potentiometer
2
0.96 to
4.04 V
2. Disconnect connector BRK, and connect T-adapter to male side.
3. Depress brake pedal to perform troubleshooting.
Brake pedal potenti- Approxi-
Between BRK (male) (C) and (A)
ometer mately 5 kΩ
Resistance Between BRK (male) (A) and (B) 0.25 to 5 kΩ

Between BRK (male) (B) and (C) 0.25 to 5 kΩ
Between BRK (male) (B) and ground Min. 1 MΩ
Directional potentiom-
eter 1
1.39 to
Voltage Between TLV1 (3) and (1)
3.61 V
20-36 D155AX-8

Directional potentiom-
eter 2
1.39 to
3.61 V
2. Insert T-adapter into connector PT1.
Pitch angle sensor 3. Starting switch: ON
0.24 to
Voltage Between PT1 (B) and (A)
4.76 V
2. Disconnect connector BVRV, and connect T-adapter to male side.
Transmission output Approxi-
shaft speed sensor Between BVRV (male) (1) and (2) mately
Resistance 560 Ω
Between BVRV (male) (1) and ground Min. 1 MΩ
Machine monitor
3. Insert T-adapter into connector CM01.
Battery charge
5. Start engine and perform troubleshooting at engine speed medium or higher
Voltage Between CM01 (16) and (3) 20 to 30 V
4. Disconnect HT/A terminal of heater relay.
Preheating k Prevent current from flowing through heater when starting switch is turned to
HEAT position
6. Turn starting switch to HEAT position.
D155AX-8 20-37
30 TESTING AND ADJUSTING
D155AX-8 30-1
CONTENTS 30 TESTING AND ADJUSTING
CONTENTS
RELATED INFORMATION ON TESTING AND ADJUSTING ......................................................................... 30-5
TOOLS FOR TESTING AND ADJUSTING.............................................................................................. 30-5
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ...................................................................... 30-12
ENGINE AND COOLING SYSTEM.............................................................................................................. 30-14
TEST ENGINE SPEED ......................................................................................................................... 30-14
METHOD FOR TESTING ENGINE SPEED ................................................................................... 30-14
TEST BOOST PRESSURE................................................................................................................... 30-18
METHOD FOR TESTING BOOST PRESSURE............................................................................. 30-18
TEST EXHAUST GAS TEMPERATURE ............................................................................................... 30-20
METHOD FOR TESTING EXHAUST GAS TEMPERATURE ......................................................... 30-20
TEST EXHAUST GAS COLOR ............................................................................................................. 30-23
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER .................... 30-23
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER ...................................... 30-24
TEST AND ADJUST VALVE CLEARANCE ........................................................................................... 30-25
METHOD FOR TESTING VALVE CLEARANCE ............................................................................ 30-25
METHOD FOR ADJUSTING VALVE CLEARANCE ....................................................................... 30-26
TEST COMPRESSION PRESSURE..................................................................................................... 30-28
METHOD FOR TESTING COMPRESSION PRESSURE............................................................... 30-28
TEST BLOWBY PRESSURE ................................................................................................................ 30-31
METHOD FOR TESTING BLOWBY PRESSURE .......................................................................... 30-31
TEST ENGINE OIL PRESSURE ........................................................................................................... 30-33
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR ............................ 30-33
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL .................................... 30-33
TEST EGR VALVE AND KVGT OIL PRESSURE .................................................................................. 30-35
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE ............................................ 30-35
TEST FUEL PRESSURE ...................................................................................................................... 30-37
METHOD FOR TESTING FUEL PRESSURE ................................................................................ 30-37
TEST FUEL RETURN RATE AND LEAKAGE....................................................................................... 30-39
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE................................................. 30-40
BLEED AIR FROM FUEL SYSTEM ...................................................................................................... 30-44
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM ................................................................ 30-44
TEST FUEL CIRCUIT FOR LEAKAGE ................................................................................................. 30-46
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE ........................................................... 30-46
HANDLE CYLINDER CUT-OUT MODE OPERATION........................................................................... 30-48
HANDLE NO-INJECTION CRANKING OPERATION ............................................................................ 30-49
CLEAN FUEL DOSER .......................................................................................................................... 30-50
METHOD FOR CLEANING FUEL DOSER .................................................................................... 30-50
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER......................................... 30-52
METHOD FOR WRITING INJECTOR COMPENSATION VALUE .................................................. 30-52
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ....................... 30-58
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROL-
LER ............................................................................................................................................ 30-58
TEST SCR RELATED FUNCTIONS...................................................................................................... 30-59
TEST AdBlue/DEF PUMP RAISED PRESSURE ........................................................................... 30-62
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR ....................................................... 30-64
TEST AdBlue/DEF LINE HEATER RELAY 1 .................................................................................. 30-67
TEST AdBlue/DEF LINE HEATER RELAY 2 .................................................................................. 30-70
TEST AdBlue/DEF PUMP HEATER RELAY................................................................................... 30-73
TEST AdBlue/DEF TANK HEATER VALVE .................................................................................... 30-76
TEST DENITRATION EFFICIENCY OF SCR................................................................................. 30-79
CLEAN AdBlue/DEF TANK ................................................................................................................... 30-82
METHOD FOR CLEANING AdBlue/DEF TANK ............................................................................. 30-83
ADJUST DECELERATOR PEDAL ........................................................................................................ 30-88
METHOD FOR ADJUSTING DECELERATOR PEDAL .................................................................. 30-88
POWER TRAIN............................................................................................................................................ 30-91
TEST POWER TRAIN OIL PRESSURE................................................................................................ 30-91
30-2 D155AX-8
30 TESTING AND ADJUSTING CONTENTS
METHOD FOR TESTING POWER TRAIN OIL PRESSURE.......................................................... 30-92

ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR ..........................................................30-102
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR ....................30-102
TEST BRAKE PERFORMANCE SIMPLY ............................................................................................30-103
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY.......................................................30-103
TEST AND ADJUST BRAKE PEDAL ...................................................................................................30-104
METHOD FOR TESTING BRAKE PEDAL ....................................................................................30-104
METHOD FOR ADJUSTING BRAKE PEDAL ...............................................................................30-104
ADJUST PARKING BRAKE LEVER.....................................................................................................30-107
METHOD FOR ADJUSTING PARKING BRAKE LEVER...............................................................30-107
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL..........30-109
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM
..................................................................................................................................................30-109
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RELEASE SYSTEM ...
..................................................................................................................................................30-110
UNDERCARRIAGE AND FRAME...............................................................................................................30-113
ADJUSTING IDLER CLEARANCE.......................................................................................................30-113
METHOD FOR ADJUSTING IDLER CLEARANCE .......................................................................30-113
TEST AND ADJUST TRACK TENSION...............................................................................................30-115
METHOD FOR TESTING TRACK TENSION ................................................................................30-115
METHOD FOR ADJUSTING TRACK TENSION ...........................................................................30-115
HYDRAULIC SYSTEM................................................................................................................................30-116
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM...................................................30-116
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT ...............30-116
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES ............................................30-117
METHOD FOR TESTING WORK EQUIPMENT AND HSS OIL PRESSURES..............................30-117
METHOD FOR ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURES.........................30-120
TEST OIL PRESSURE OF CONTROL CIRCUIT .................................................................................30-122
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT ...........................................30-122
TEST WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE ....................................30-124
METHOD FOR TESTING WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE .........
..................................................................................................................................................30-124
TEST RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE .............................................30-126
METHOD FOR TESTING RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE .......30-126
CHECK COOLING FAN SPEED ..........................................................................................................30-128
METHOD FOR CHECKING COOLING FAN SPEED ....................................................................30-128
TEST COOLING FAN CIRCUIT OIL PRESSURE ................................................................................30-129
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE ..........................................30-129
BLEED AIR FROM COOLING FAN PUMP ..........................................................................................30-131
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP ....................................................30-131
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.......................................30-132
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER.....
..................................................................................................................................................30-132
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER .....
..................................................................................................................................................30-132
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER ...
..................................................................................................................................................30-133
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER ..............................................30-134
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER ........30-134
BLEED AIR FROM WORK EQUIPMENT CYLINDERS........................................................................30-136
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS..................................30-136
OPERATION WHEN WORK EQUIPMENT IS NOT EFFECTIVE .........................................................30-137
METHOD FOR OPERATING WHEN WORK EQUIPMENT IS NOT EFFECTIVE..........................30-137
WORK EQUIPMENT...................................................................................................................................30-139
ADJUST WORK EQUIPMENT LOCK LEVER......................................................................................30-139
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER................................................30-139
CAB AND ITS ATTACHMENTS ..................................................................................................................30-141
TEST AND ADJUST OPERATOR'S CAB.............................................................................................30-141
D155AX-8 30-3
CONTENTS 30 TESTING AND ADJUSTING
METHOD FOR TESTING OPERATOR'S CAB..............................................................................30-141

METHOD FOR ADJUSTING OPERATOR'S CAB .........................................................................30-144
ELECTRICAL SYSTEM ..............................................................................................................................30-146
SETTING AND OPERATION OF MACHINE MONITOR.......................................................................30-146
OPERATOR MODE .....................................................................................................................30-149
SERVICE MODE...........................................................................................................................30-153
METHOD FOR STARTING UP KOMTRAX ..........................................................................................30-269
ADJUST REARVIEW CAMERA ANGLE ..............................................................................................30-274
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-274
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER ............................................................30-275
HANDLE BATTERY DISCONNECT SWITCH ......................................................................................30-276
TEST DIODES .....................................................................................................................................30-277
METHOD FOR TESTING DIODE USING DIGITAL TESTER ........................................................30-277
METHOD FOR TESTING DIODE USING ANALOG TESTER.......................................................30-277
Pm CLINIC..................................................................................................................................................30-278
Pm CLINIC SERVICE ..........................................................................................................................30-278
Pm CLINIC CHECK SHEET..........................................................................................................30-279
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE .................................................................30-295
30-4 D155AX-8
30 TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING

TOOLS FOR TESTING AND ADJUSTING
Tools for testing boost pressure
Symbol Part No. Part name Q'ty Remarks
- 799-201-2202 Boost gauge kit 1
A 1 799-401-2311 Gauge 1 Pressure range: -101 to 199.5 kPa
2 799-101-5160 Nipple 1 R1/8
- 799-401-2301 Pm kit 1
B
1 790-261-1130 Coupling 1
Tools for testing exhaust gas temperature

- 799-101-1502 Digital thermometer 1
A 1 79A-262-1910 Meter 1
2 6215-11-8180 Sensor 1
Tools for testing exhaust gas color

A 799-201-9002 Handy smoke checker 1
Commercially
- Smoke meter 1
available
B
Commercially
1 Probe 1
available
Tools for testing valve clearance

Commercially
A Feeler gauge 1
available
Tools for testing compression pressure

A 795-502-1590 Compression gauge 1
B 795-471-1330 Adapter 1
C 6261-71-6150 Gasket 1
Tools for testing blowby pressure

- 799-201-1506 Blowby checker 1 Pressure range: 10 kPa
1 799-201-1591 Gauge 1
A
2 799-201-1511 Tool 1
3 799-201-1571 Tube 1
Commercially
B Plug 1 Hose inside diameter: 24 mm
available
D155AX-8 30-5
TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING

Commercially Outside diameter of hose fitting part:
C Cap 2
available 28.1 mm
Tools for testing engine oil pressure

- 799-101-5002 Hydraulic tester 1
A 1 790-301-1190 Nipple 1 R1/4 → Rc1/8
2 799-101-5160 Nipple 1 R1/8
B 799-401-2320 Gauge 1 Pressure range1 MPa
C 799-101-5210 Quick nipple 1 R1/4
Tools for testing EGR valve and KVGT oil pressure

A 1 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
2 799-101-5160 Nipple 1 R1/8
B 791T-601-2220 Elbow 1 R1/8 → Rc1/8
Tools for testing fuel pressure

A
1 799-101-5160 Nipple 1
B 799-401-2320 Gauge 1 Pressure range: 1 MPa
C 795T-471-2010 Adapter 1 Size: M8 x 1.25 mm → Rc1/8
Tools for testing fuel return rate and leakage

A 6164-81-5750 Joint 1
B 6164-81-5790 Joint 1
Commercially
C Hose 1 Inside diameter: Approximately : 9 mm
available
Commercially
D Hose 1 Inside diameter: Approximately : 12 mm
available
Commercially
E Measuring cylinder 1
available
Commercially
F Stopwatch 1
available
G 07206-31214 Joint bolt 1
Commercially
H Cap nut 1 M14 x 1.5 mm
available
J 07376-70315 Plug 1
Commercially
K Hose 1 Inside diameter: Approximately : 16 mm
available
30-6 D155AX-8

Commercially
L Oil pan 1 Approximately 20 ℓ
available
Tools for testing fuel system for leakage

Commercially Developer for dye penetrant (color
A 1
available checker)
Tools for writing compensation values of injector and controller

Commercially
A Laptop computer 1 Windows 8 (32 bit)
available
B Cu3886388 INSITE ver. 8.0.2 1
C 795-799-5732 INLINE 5 Kit 1
Commercially
D available tool or Cable (USB) 1
795-799-5742
E 795-799-5721 Cable 1
F 799-601-4510 Cable (12P) 1
Tools for testing injection amount from AdBlue/DEF injector

A 799-601-4340 Socket 1
Commercially
B Multimeter 1
available
Commercially
C Measuring cylinder 1 Capacity: Approximately 200 to 500 mℓ
available
Tools for testing AdBlue/DEF line heater relay 1

A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available
Tools for testing AdBlue/DEF line heater relay 2

A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available
Tools for testing AdBlue/DEF pump heater relay

A 799-601-9130 T-adapter 1
D155AX-8 30-7

B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available
Tools for testing AdBlue/DEF tank heater valve

A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available
Tools for testing cleaning of AdBlue/DEF tank

Commercially Size: 450 mm (width) x 300 mm (depth) x
A Oil pan 1
available 130 mm (height), made of stainless steel
Commercially
- Remote breather hose 1
available
Commercially ASOH Co., LTD ASOH CICCOLO:
B 1 Valve 1
available CY-2208 or equivalent
Commercially Approximately 2 m, TOYOX TOYOSILI-
2 Hose 1
available CONE: TSI-8 or equivalent
Size: Approximately550 mm (width) x ap-
Commercially
C Wooden block 2 proximately180 mm (depth) x approxi-
available
mately100 mm (height)
Commercially Diameter: Approximately130 m, Height:
D Funnel 1
available Approximately200 mm or less
Length: Approximately2 m, made of poly-
Commercially
E Hose 1 propylene (diameter should be matched
available
to funnel for connection)
Commercially
F Polyethylene container 3 20 ℓ, made of polyethylene
available
Commercially
G AdBlue/DEF 1 For flushing: 30 ℓ
available
Tools for testing power train oil pressure

A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-2320 Gauge 1 Pressure range: 1 MPa
D 799-101-5220 Nipple 1 Size: M10x1.25 mm
E 07002-11023 O-ring 1
30-8 D155AX-8
Tools for testing brake pedal

A 79A-264-0091 Push-pull scale 1 Load: 0 to 490 N{0 to 50 kg}
Tools for releasing parking brake

- 790-190-1601 Pump assembly 1
A 1 790-190-1510 Volume pump 1
2 790-190-2500 Hose 1
B 02789-00315 Cap nut 1
C 19M-06-32820 Switch assembly 1
D 17A-06-41411 Wiring harness 1
E 7824-66-6430 Resistance 1
F 7827-10-1520 Resistance 1
Tools for adjusting idler clearance

Commercially
A Feeler gauge 1
available
Tools for testing track tension

L shape steel bar which has less deflec-
A - Steel rod 1
tion
Tools for testing work equipment and HSS oil pressures

1 799-101-5130 Gauge 1 Pressure range: 6 MPa
A
C 799-101-5220 Nipple 2 Size: M10x1.25 mm
D 07002-11023 O-ring 2
Tools for testing control circuit source pressure

2 799-101-5160 Nipple 1 R1/8
C 799-401-3200 Adapter 1 Size: 03
D155AX-8 30-9
Tools for testing work equipment lock solenoid valve outlet pressure
2 799-101-5160 Nipple 1 R1/8
C 799-401-3200 Adapter 1 Size: 03
Tools for testing ripper pin puller solenoid valve outlet pressure
2 799-101-5160 Nipple 2 R1/8
C 799-401-3200 Adapter 2 Size: 03
Tools for testing cooling fan circuit oil pressure

A
C 799-401-2950 Adapter 1 Size: 06
D 799-101-5220 Nipple 1 Size: M10x1.25 mm
E 07002-11023 O-ring 1
Air bleeding tools for cooling fan pump

Commercially
A Hose 1
available
Tools for testing internal oil leakage of work equipment cylinder

Commercially
A Measuring cylinder 1
available
B 07376-70422 Plug 1 Size: 04
C 02896-11012 O-ring 1 Size: 04
D 07378-11000 Flange 1 Size: 10
E 07000-13032 O-ring 1 Size: 10
Operation tools when work equipment is not effective

A 17A-06-41421 Wiring harness 1
30-10 D155AX-8
Tools for testing operator's cab

Commercially Transparent, approximately 6 m in outside
A Vinyl hose 1
available diameter and 3 m in length
Commercially
B Tape 1
available
Commercially
C Sealing tape 1
available
D155AX-8 30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Elbow
Adapter
30-12 D155AX-8
30 TESTING AND ADJUSTING SKETCH OF TOOLS FOR TESTING AND ADJUSTING
Adapter
D155AX-8 30-13
TEST ENGINE SPEED 30 TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM

TEST ENGINE SPEED
k Place the machine on a level ground, lower the work equipment to the ground, stop the engine, and
set the parking brake lever and work equipment lock lever to LOCK position.
Check this item under the following conditions.
• Coolant temperature: 60 to 100 °C
• Power train oil temperature: 70 to 120 °C
• Hydraulic oil temperature: 45 to 100 °C
• Operating mode: P (Power mode)
• Gear shift mode: Test can be performed in either auto or manual mode.
For testing of engine speed to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING ENGINE SPEED

Check the engine speed with the monitoring function of the machine monitor.
Testing engine high idle speed

1. Display the screen of Adjustment ID “0007”. For details,
see “Setting and operating machine monitor”.
Adjustment ID: 0007 “Engine decelerator cutting”
REMARK
When the transmission is in neutral, high idle speed is lim-
ited (by the neutral deceleration function). Be sure to dis-
play Adjustment ID “0007” to disable the limiting.
2. Shift the joystick (steering, directional and gearshift lever)
(PCCS lever), blade control lever, and ripper control lever
in their NEUTRAL position.
3. Start the engine with fuel control dial set in MIN (Low idle) position.
REMARK
The parking brake lever and work equipment lock lever can be tested in LOCK position.
4. Check the engine speed when fuel control dial is set in MAX (High idle) position.
For standard values, see Standard value table, “Standard value table for engine”.
Testing engine low idle speed

If the aftertreatment devices regeneration is displayed, perform the measurement after aftertreatment devices
regeneration is finished.When aftertreatment devices regeneration is finished, aftertreatment devices regenera-
tion pilot lamp goes off.
1. Select “Engine Speed” on “Pre-defined Monitoring”(01/22)
or from Monitoring Selection Menu to display. For details,
Monitoring code: 01002 “Engine Speed”
The drawing is an example of a “Pre-defined Monitoring”
(01/22) screen displayed.
30-14 D155AX-8
30 TESTING AND ADJUSTING TEST ENGINE SPEED
The drawing is an example of a Monitoring code: 01002

“Engine Speed” screen displayed.
3. Start the engine with fuel control dial set in MIN (Low idle)
position.
REMARK
The parking brake lever and work equipment lock lever
can be tested in LOCK position.
4. Check that the fuel dial is set at MIN (Low idle) position, and measure the engine speed.
Testing engine speed when decelerator pedal is depressed

Monitoring code: 01002 “Engine Speed”

position.
REMARK
4. Set the fuel control dial to MAX (High idle) position.
5. Measure the engine speed with the decelerator pedal depressed to its stroke end.
Testing engine high idle speed during neutral deceleration

D155AX-8 30-15
TEST ENGINE SPEED 30 TESTING AND ADJUSTING

position.
REMARK
4. Measure the engine speed when fuel control dial is set in MAX (High idle) position.
Testing engine speed with torque converter stalled

Adjustment ID: 0530 “Stall mode”
Preset (gear speed at moving off) can be set to “F3-R3”
only when “Stall mode” is enabled. Be sure to display the
Adjustment ID “0530” screen.
2. Set preset (gear speed at moving off) to “F3-R3” with up

switch (3) or down switch (4) on joystick (steering, direc-
tional and gear shift lever) (PCCS lever).
3. Select “P-MANUAL SFT MODE” with shift mode selector
switch (2).
position.
5. With the brake pedal depressed securely and the parking

brake lever in FREE position, set joystick (steering, direc-
tional and gear shift lever) (PCCS lever) directional selec-
tion in FORWARD position.
REMARK
Maintain steering at neutral.
Check that “F3” is displayed in the gear speed display sec-
tion (at the right bottom of the screen).
6. Depress the decelerator pedal and set the fuel control dial
at MAX (High idle) position.
7. Return the decelerator pedal slowly to stall the torque converter.
k Keep the brake pedal securely depressed and keep your right foot on the decelerator pedal for
safety until the work is finished.
8. Immediately after the “Power train oil temperature” indicates 118 to 120 °C, return the joystick (steering, di-
rectional and gear shift lever) (PCCS lever) directional selection to NEUTRAL position.
9. Repeat above steps 6. to 8. 3 times.
30-16 D155AX-8
30 TESTING AND ADJUSTING TEST ENGINE SPEED
10. Perform steps 6. to 7. again and check the engine speed when “Power train oil temperature” indicates 118
to 120 °C.
11. Immediately after finishing testing, return the joystick (steering, directional and gear shift lever) (PCCS lev-
er) directional selection to NEUTRAL position and set the fuel control dial at MAX (High idle) position to
lower the power train oil temperature.
Testing engine speed at full stall (torque converter stall + work equipment relief)

switch (2).
4. Start the engine, and set the fuel control dial to MIN (Low
idle) position.
5. Place the work equipment lock lever in FREE position and
operate the ripper control lever to move the ripper lift cylin-
der to the raise stroke end.
REMARK
8. Return the decelerator pedal slowly to stall the torque converter.
9. Immediately after the “Power train oil temperature” indicates 118 to 120 °C, return the joystick (steering, di-
rectional and gear shift lever) (PCCS lever) directional selection to NEUTRAL position.
10. Repeat above steps 7. to 9. three times.
11. Perform steps 7. to 8. again, and perform ripper RAISE relief by using the ripper control lever.
12. Check the engine speed when “Power train oil temperature” indicates 118 to 120 °C.
D155AX-8 30-17
TEST BOOST PRESSURE 30 TESTING AND ADJUSTING
TEST BOOST PRESSURE

Tools for testing boost pressure
- 799-201-2202 Boost gauge kit 1
A 1 799-401-2311 Gauge 1 Pressure range: -101 to 199.5 kPa
2 799-101-5160 Nipple 1 R1/8
- 799-401-2301 Pm kit 1
B
1 790-261-1130 Coupling 1
• Engine coolant temperature: 60 to 100 °C
For testing of boost pressure to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING BOOST PRESSURE

1. Open the cover on the left side of the machine.
2. Remove pressure pickup plug (1) on the side of the air in-
take connector.
30-18 D155AX-8
30 TESTING AND ADJUSTING TEST BOOST PRESSURE
3. Install nipple A2 of boost gauge kit A, and connect gauge

A1.
4. Run the engine at middle or higher speed and drain oil
from the hose.
REMARK
• Insert the hose connector into the gauge halfway to
open the self-seal on the hose side repeatedly, and the
oil will be purged.
• If Pm kit B is available, use oil draining coupling B in it.
• If oil is left in the hose, the gauge does not work. Ac-
cordingly, be sure to bleed the oil.
5. Measure the boost pressure when the torque converter

stalls.
REMARK
• To stall the torque converter, display Adjustment ID:
0530 screen.
• For the procedure for stalling the torque converter, see
“METHOD FOR TESTING ENGINE SPEED”.
• Normally, the boost pressure should be tested while
the engine is running at the rated horsepower. In the
field, however, an approximate value can be obtained
by stalling the torque converter.
After finishing the test, remove the testing tools and restore the machine.
D155AX-8 30-19
TEST EXHAUST GAS TEMPERATURE 30 TESTING AND ADJUSTING
TEST EXHAUST GAS TEMPERATURE

Testing tools for exhaust gas temperature
- 799-101-1502 Digital thermometer 1
A 1 79A-262-1910 Meter 1
2 6215-11-8180 Sensor 1
k Install or remove the testing tools after the exhaust manifold temperature has lowered.
For testing of exhaust gas temperature to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING EXHAUST GAS TEMPERATURE

1. Open the cover on the right side of the machine, and remove cover (1).
2. Disconnect coolant hose (3) and connector (4), and then
remove cover (2).
REMARK
For details of removal of cover (2), see Disassembly and
assembly, “REMOVE AND INSTALL STARTER ASSEM-
BLY”.
3. Remove cover (5).
30-20 D155AX-8
30 TESTING AND ADJUSTING TEST EXHAUST GAS TEMPERATURE
4. Remove inspection plug (6) from the exhaust manifold.
5. Install sensor A2 of digital thermometer A and connect it to

meter A1.
REMARK
Clamp the wiring harness of the digital thermometer so
that it does not touch a hot part during measurement.
6. Measure the exhaust gas temperature.
• Procedure for measuring maximum value in trouble-
shooting
REMARK
• Operate the machine actually and measure the
maximum exhaust temperature.
• Use the digital temperature gauge in the PEAK
mode.
• As the exhaust gas temperature differs greatly de-
pending on the ambient temperature (intake air
temperature of the engine), correct the value by
using the following formula if an abnormal value is
recorded.
Corrected value [ °C] = Measured value + 2 x (20 -
Ambient temperature)
• A procedure of measuring exhaust temperature periodically for preventive maintenance services (Pm
clinic)
NOTICE
If the torque converter is stalled simply, the torque converter oil is overheated before the ex-
haust temperature is stabilized. Accordingly, measure according to the following procedure.
1) Display the screen of Adjustment ID “0530”. For de-
tails, see “SETTING AND OPERATION OF MACHINE
MONITOR”.
Preset (gear speed at moving off) can be set to “F3-
R3” only when “Stall mode” is enabled. Be sure to dis-
play the Adjustment ID “0530” screen.
D155AX-8 30-21
TEST EXHAUST GAS TEMPERATURE 30 TESTING AND ADJUSTING
2) Set preset (gear speed at moving off) to “F3-R3” with

up switch (3) or down switch (4) on joystick (steering,
directional and gear shift lever) (PCCS lever).
3) Select “P-MANUAL SFT MODE” with shift mode se-
lector switch (2).
4) Start the engine with fuel control dial set in MIN (Low
idle) position.
5) Place the work equipment lock lever in FREE position
and operate the ripper control lever to move the ripper
lift cylinder to the raise stroke end.
6) With the brake pedal depressed securely and the
parking brake lever in FREE position, set joystick
(steering, directional and gear shift lever) (PCCS lev-
er) directional selection in FORWARD position.
Hold its steering section at neutral.
Check that “F3” is displayed in the gear speed display
section (at the right bottom of the screen).
7) Depress the decelerator pedal and set the fuel control
dial at MAX (High idle) position.
8) Return the decelerator pedal slowly, stall the torque

converter, relieve the ripper raise circuit, and raise the
exhaust temperature to approximately 650 °C (Condi-
tion (a) in the figure).
k Keep the brake pedal securely depressed and
keep your right foot on the decelerator pedal
for safety until the work is finished.
9) Discontinue only the ripper raise relief, and let the ex-
haust temperature decrease by torque converter stall
only (condition (b) in the figure).
REMARK
If the exhaust temperature does not go down but ris-
es, make the set temperature at step 8 higher.
10) Read the exhaust temperature when it has lowered and stabilized (Condition (c) in the figure).
NOTICE
When the “power train oil temperature” reaches approximately 120 °C, immediately return the
joystick (steering, directional and gear shift lever) (PCCS lever) directional selection to NEU-
TRAL position and set the fuel control dial at MAX (High idle) position to lower the power train
oil temperature.
30-22 D155AX-8
30 TESTING AND ADJUSTING TEST EXHAUST GAS COLOR
TEST EXHAUST GAS COLOR

Testing tools for exhaust gas color
A 799-201-9002 Handy smoke checker 1
Commercially
- Smoke meter 1
available
B
Commercially
1 Probe 1
available
k Be careful not to touch any hot part when installing or removing the testing tools.
k Be careful not to burn yourself when the aftertreatment devices regeneration is performed since high
temperature exhaust gas is spouted from the inspection port. Be sure to perform “Regeneration Dis-
able” operation of aftertreatment devices with machine monitor before testing(For the detail of “Re-
generation Disable” of aftertreatment devices, see “Operation and Maintenance Manual”).
• After keeping for 5 seconds at normal condition
For testing of exhaust gas color to perform troubleshooting or Pm Clinic, refer to this section.
If an air source and a electric power source are not available in the field, use handy smoke checker A. When
recording official data, etc., use smoke meter B.
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER

1. Open the cover on the right side of the machine.
3. Remove plug (2).
D155AX-8 30-23
TEST EXHAUST GAS COLOR 30 TESTING AND ADJUSTING
4. Fit a sheet of filter paper to handy smoke checker A.

5. Insert the exhaust gas intake pipe of handy smoke checker
A into port (a) for removed plug (2).
position.
7. Accelerate the engine sharply or run it with fuel control dial
at MAX (High idle), and collect the exhaust gas to the filter
paper by operating the handle of smoke checker A.
8. Remove the filter paper and compare it with the attached
scale for judgment.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
3 Plug (a):
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug (a):
Seizure prevention compound (LC-G)
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER

1. Insert probe B1 of smoke meter B into port (a) for removed
plug (2), and fix it to the exhaust pipe with the clip.
REMARK
Limit the supplied air pressure to 1.5 MPa {15 kg/cm2} or
lower.
2. Check that the power switch of smoke meter B is OFF, and
connect the power cable to the receptacle.
3. Loosen the cap nut of the suction pump, and place the fil-
ter paper.
REMARK
Place the filter paper securely so that the exhaust gas
does not leak.
4. Turn ON the power switch of smoke meter B.
position.
6. Accelerate the engine sharply or run it with fuel control dial
at MAX (High idle), and collect the exhaust gas to the filter
paper by depressing pedal switch B2 of smoke meter B.
7. Place the contaminated filter paper on the clean filter pa-
per (at least 10 sheets) in the filter paper holder and read
the indicated value.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.
3 Plug (2):
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug (2):
30-24 D155AX-8
30 TESTING AND ADJUSTING TEST AND ADJUST VALVE CLEARANCE
TEST AND ADJUST VALVE CLEARANCE

Testing tools for valve clearance
Commercially
A Feeler gauge 1
available
Engine coolant temperature: Normal temperature
For testing and adjusting of valve clearance to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING VALVE CLEARANCE

1. Remove the engine hood assembly and "KDPF and SCR" assembly. For details, see Disassembly and as-
sembly, “REMOVE AND INSTALL ENGINE HOOD ASSEMBLY” and “REMOVE AND INSTALL KDPF, SCR
ASSEMBLY”.
2. Remove the underguard. For details, see Disassembly and assembly, “REMOVE AND INSTALL ENGINE
ASSEMBLY”.
3. Remove breather (1) and cylinder head cover (2).
4. Remove water pump drive shaft cover (3).

REMARK
Remove cover (3) to crank the machine by rotating the wa-
ter pump drive shaft.
5. Rotate the crankshaft in the normal direction to set No. 1

cylinder with the piston to the compression top dead center
by matching “1.6 TOP” stamping mark (a) of the damper to
pointer (4).
REMARK
• Turn the crankshaft by turning hexagonal portion (b) of
the water pump drive shaft end.
• At the compression top dead center, the rocker arm of
No.1 cylinder can be moved by valve clearance with
hands. If the rocker arm does not move, cylinder is not
at the compression top dead center, so rotate the gear
further 1 turn.
D155AX-8 30-25
TEST AND ADJUST VALVE CLEARANCE 30 TESTING AND ADJUSTING
6. While the No. 1 cylinder is at the compression top dead

center, check the valve clearance marked with ● in the fol-
lowing figure.
REMARK
Insert feeler gauge A into the clearance between rocker
arm (5) and crosshead (6) to check the valve clearance.
7. Rotate the crankshaft in the normal direction by 1 turn and
check the valve clearance of the remaining valves marked
with ○.
8. After finishing the adjustment of No. 1 cylinder, rotate the
crankshaft forward by 120 ° at one time to align “TOP”
stamp line of each cylinder number to pointer (4), and test
the valve clearance of each cylinder in the sequence of the
firing order.
REMARK
Firing order: 1-5-3-6-2-4
METHOD FOR ADJUSTING VALVE CLEARANCE

After testing, adjust the valve clearance according to the following procedure, if necessary.
1. Set the checked cylinder to the compression top dead cen-
ter.
REMARK
• Turn the crankshaft by turning hexagonal portion (b) of
the water pump drive shaft end.
• At the compression top dead center, the rocker arm of
the checked cylinder can be moved by valve clearance
with hands. If the rocker arm does not move, cylinder is
not at the compression top dead center, so rotate the
gear further 1 turn.
30-26 D155AX-8
30 TESTING AND ADJUSTING TEST AND ADJUST VALVE CLEARANCE
2. Loosen lock nut (8) with adjustment screw (7) fixed.

3. Insert feeler gauge A in the clearance between rocker arm
(5) and crosshead (6) and adjust the valve clearance with
adjustment screw (7).
REMARK
Turn the adjustment screw (7), and adjust adjustment
screw (7) with feeler gauge inserted so that the feeler
gauge can move lightly.
4. Tighten lock nut (8) with adjustment screw (7) fixed.
3 Rocker arm assembly mounting bolt:
53 to 64.7 Nm {5.4 to 6.5 kgm}
5. Check the valve clearance again after tightening the lock
nut.
D155AX-8 30-27
TEST COMPRESSION PRESSURE 30 TESTING AND ADJUSTING
TEST COMPRESSION PRESSURE

Testing tools for compression pressure
A 795-502-1590 Compression gauge 1
B 795-471-1330 Adapter 1
C 6261-71-6150 Gasket 1
k Turn the battery disconnect switch to OFF position, and remove the key.
k When testing the compression pressure, be careful not to burn yourself by touching the exhaust
manifold, KDPF, SCR, or AdBlue/DEF mixing piping, or get caught in a rotating part.
• Engine speed: 200 to 250 rpm (Reference)
For testing of compression pressure to perform troubleshooting or Pm Clinic, or periodic maintenance, refer to
this section.
METHOD FOR TESTING COMPRESSION PRESSURE

1. Remove the engine hood assembly and "KDPF and SCR" assembly. For details, see Disassembly and as-
sembly, “REMOVE AND INSTALL ENGINE HOOD ASSEMBLY” and “REMOVE AND INSTALL KDPF, SCR
ASSEMBLY”.
2. Remove the underguard. For details, see Disassembly and assembly, “REMOVE AND INSTALL ENGINE
HOOD ASSEMBLY”.
3. Remove cylinder head cover (1) of the cylinder to be
checked. For details, see Disassembly and assembly, “RE-
MOVE AND INSTALL INJECTOR ASSEMBLY”.
4. Set the cylinders to check to the compression top dead
center. For details, see “METHOD FOR TESTING VALVE
CLEARANCE”.
30-28 D155AX-8
30 TESTING AND ADJUSTING TEST COMPRESSION PRESSURE
5. Remove rocker arm assembly (2).

6. Disconnect fuel high-pressure tube (3) and wiring harness
(4).
7. Remove injector (5) and injector wiring harness.
REMARK
• Disconnect the terminal of the injector harness on in-
jector (5) side and the bracket on the rocker housing
side, and then remove harness (4) from injector (5).
(Loosen the 2 terminal nuts alternately.)
• Pass a wire under the fuel path projected sideways and
pull up the injector (Do not pry the injector top up).
8. Fit gasket C to the end of adapter B.
9. Insert adapter B into the injector mounting hole and con-
nect compression gauge A.
REMARK
Apply a small amount of engine oil to the connecting por-
tion of adapter B and compression gauge A to prevent air
leakage.
10. Fix adapter B with the injector holder.
3 Injector holder mounting bolt:
59.0 to 74.0 Nm {6.0 to 7.5 kgm}
11. Install rocker arm assembly (2).
3 Rocker arm assembly (2) mounting bolt:
93 to 103 Nm {9.5 to 10.5 kgm}
12. Adjust the valve clearance. For details of the procedure,
see “METHOD FOR ADJUSTING VALVE CLEARANCE”.
13. Turn the battery disconnect switch to ON position, then
turn the starting switch to ON position.
14. Set the machine monitor to “No-Injection Cranking” . For
details, see “SETTING AND OPERATION OF MACHINE
MONITOR”.
15. Measure the compression pressure when the engine is
cranked by the starting motor.
REMARK
Read the compression pressure when the pointer of gauge
is stabilized.
Method for installing injector and high pressure fuel tube

Before installing the injector, replace the gasket and O-ring with new ones.
D155AX-8 30-29
TEST COMPRESSION PRESSURE 30 TESTING AND ADJUSTING
1. Push in injector (11) with the hand to assemble holder (12)

lightly.
2. Tighten bolt (13) and washer (14) lightly.
3. Apply engine oil to the spherical portion of washer (14).
4. Tighten sleeve nut (15) of the fuel high-pressure tube light-
ly.
5. Tighten bolt (13) to the specified torque.
3 Bolt(13):
59.0 to 74.0 Nm {6.0 to 7.5 Nm}
6. Tighten sleeve nut (15) to the specified torque.
3 Sleeve nut(15):
39.2 to 44.1 Nm {4 to 4.5 kgm}
Method for installing injector harness

1. Install the injector harness to the rocker arm housing and fix the connector side with the plate.
2. Fix the intermediate clamp with the clip.
3. Tighten the nut on the injector side.
3 Nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
REMARK
Eliminate slack of the injector harness and press it against the injector so that it will not interfere with the
rocker arm. (Tighten the nuts alternately.)
4. Secure the clamp and spacer with the bolt.
3 Rocker arm assembly mounting bolt:
93 to 103 Nm {9.5 to 10.5 kgm}
5. Adjust the valve clearance. For details, see “METHOD FOR ADJUSTING VALVE CLEARANCE”.
30-30 D155AX-8
30 TESTING AND ADJUSTING TEST BLOWBY PRESSURE
TEST BLOWBY PRESSURE

Testing tools for blowby pressure
- 799-201-1506 Blowby checker 1 Pressure range: 10 kPa
1 799-201-1591 Gauge 1
A
2 799-201-1511 Tool 1
3 799-201-1571 Tube 1
Commercially
B Plug 1 Hose inside diameter: 24 mm
available
Commercially Outside diameter of hose fitting portion:
C Cap 2
available 28.1 mm
For testing of blowby pressure to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING BLOWBY PRESSURE

1. Open the cover on the right side of the machine.
2. Remove the clamps and disconnect KCCV (1) blowby gas
inlet side hoses (2) and outlet side hose (3).
D155AX-8 30-31
TEST BLOWBY PRESSURE 30 TESTING AND ADJUSTING
3. Put caps C to the inlet side and outlet side of the blowby
gas, and install plug B to the outlet hose.
4. Insert tool A2 of blowby checker A into KCCV inlet hose
(2), and connect gauge A1 to tube A3.
5. Measure the blowby pressure when the torque converter
stalls.
REMARK
• To stall the torque converter, display Adjustment ID:
0530 screen.
• For the procedure for stalling the torque converter, see
“METHOD FOR TESTING ENGINE SPEED”.
• Normally, the blowby pressure should be measured
while the engine is operated at the rated horsepower.
In the field, however, an approximate value can be ob-
tained by stalling the torque converter.
• If rated horsepower operation or torque converter stall-
ing is not possible, measure with the fuel control dial at
MAX position (High idle). In this case, approximately
80 %of blowby pressure at the rated horsepower is ob-
tained.
• Blowby pressure varies greatly with the condition of the
engine. Therefore, if the value by the test is considered
unusual, make a check for excessive oil consumption,
bad color of exhaust gas, early oil deterioration, early
oil contamination, etc., which are related to improper
blowby pressure.
30-32 D155AX-8
30 TESTING AND ADJUSTING TEST ENGINE OIL PRESSURE
TEST ENGINE OIL PRESSURE

Tools for testing engine oil pressure
A 1 790-301-1190 Nipple 1 R1/4 → Rc1/8
2 799-101-5160 Nipple 1 R1/8
B 799-401-2320 Gauge 1 Pressure range 1 MPa
C 799-101-5210 Quick nipple 1 R1/4
• Engine oil temperature Min.: 80 °C
For testing of engine oil pressure to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR

REMARK
If a failure code is displayed, troubleshoot it.
2. Select “Engine Oil Pressure Sensor” on “Pre-defined Moni-
toring” or from Monitoring Selection Menu. For details, see
“SETTING AND OPERATION OF MACHINE MONITOR”.
Monitoring code: 37200 “Engine Oil Pressure Sensor”
3. Start the engine, and measure the engine oil pressure
when fuel control dial is at MAX (High idle) and MIN (Low
idle) positions.
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL

1. Open covers (1) and (2) on the right side of the machine.
D155AX-8 30-33
TEST ENGINE OIL PRESSURE 30 TESTING AND ADJUSTING
3. Remove engine oil pressure pickup plug (4) of the cylinder

block.
4. Install nipples A1 and A2 of hydraulic tester A and connect

them to gauge B.
REMARK
Since the plug hole size is Rc1/4, you may use quick nip-
ples C instead of nipples A1 and A2.
position.
6. Measure the engine oil pressure when fuel control dial is at
MAX (High idle) and MIN (Low idle) positions.
30-34 D155AX-8
30 TESTING AND ADJUSTING TEST EGR VALVE AND KVGT OIL PRESSURE
TEST EGR VALVE AND KVGT OIL PRESSURE

Tools for testing EGR valve and KVGT oil pressure
A 1 799-101-5140 Gauge 1 Pressure rang: 2.5 MPa
2 799-101-5160 Nipple 1 R1/8
B 791T-601-2220 Elbow 1 R1/8 → Rc1/8
For testing of EGR valve and KVGT to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE

2. Remove oil pressure pickup plug (1) of the tube.
3. Install elbow B and nipple A2 of hydraulic tester A and

connect it to gauge A1.
3 Elbow B and nipple A2:
59 to 98 Nm {6.0 to 10.0 kgm}
position.
5. Measure EGR valve pressure and KVGT pressure when
fuel control dial is at MAX (High idle) and MIN (Low idle)
positions.
D155AX-8 30-35
TEST EGR VALVE AND KVGT OIL PRESSURE 30 TESTING AND ADJUSTING
3 Plug (1):
59 to 98 Nm {6.0 to 10.0 kgm}
30-36 D155AX-8
30 TESTING AND ADJUSTING TEST FUEL PRESSURE
TEST FUEL PRESSURE

Tools for testing fuel pressure
A
1 799-101-5160 Nipple 1
B 799-401-2320 Gauge 1 Pressure range: 1 MPa
C 795T-471-2010 Adapter 1 Size: M8 x 1.25 mm → Rc1/8
k Check of the high-pressure circuit connecting the supply pump, the common rail, and the injector
cannot be performed due to the extremely high pressure generated there.
k Measure the fuel pressure only in the low-pressure circuit from the feed pump through the fuel filter
to the supply pump.
k Before testing the fuel system or removing/installing the tools, wait at least 30 seconds after stop-
ping the engine until the remaining pressure in the fuel circuit is released. (Do not start the work im-
mediately after the engine is stopped since remaining pressure is still in the circuit.)
For testing of fuel pressure to perform troubleshooting or Pm Clinic, or periodic maintenance, refer to this sec-
tion.
METHOD FOR TESTING FUEL PRESSURE

2. Remove plug (1) and install adapter C.
3 Adapter C:
7.84 to 9.8 Nm {0.8 to 1.0 kgm}
D155AX-8 30-37
TEST FUEL PRESSURE 30 TESTING AND ADJUSTING
3. Install nipple A1 of hydraulic tester A to adapter C, and

connect it to gauge B.
position.
5. Measure the fuel pressure when fuel control dial is set in
MAX (High idle) position.
3 Plug (1):
7.84 to 9.8 Nm {0.8 to 1.0 kgm}
30-38 D155AX-8
30 TESTING AND ADJUSTING TEST FUEL RETURN RATE AND LEAKAGE
TEST FUEL RETURN RATE AND LEAKAGE

Testing tools for fuel return rate and leakage
A 6164-81-5750 Joint 1
B 6164-81-5790 Joint 1
Commercially
C Hose 1 Inside diameter: Approximately 9 mm
available
Commercially
D Hose 1 Inside diameter: Approximately 12 mm
available
Commercially
E Measuring cylinder 1
available
Commercially
F Stopwatch 1
available
G 07206-31214 Joint bolt 1
Commercially
H Cap nut 1 M14 x 1.5 mm
available
J 07376-70315 Plug 1
Commercially
K Hose 1 Inside diameter: Approximately 16 mm
available
Commercially
L Oil pan 1 Approximately 20 ℓ
available
k Wait for 30 seconds at least after stopping the engine until the remaining pressure in the fuel circuit
is released. Then perform removing or installing the testing tools. (Do not start the work immediately
after the engine is stopped since remaining pressure is still in the circuit and the fuel may spout
out.)
For testing of fuel return rate and leakage to perform troubleshooting or Pm Clinic, or periodic maintenance, re-
fer to this section.
D155AX-8 30-39
TEST FUEL RETURN RATE AND LEAKAGE 30 TESTING AND ADJUSTING
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE

The figure shows the flow of fuel and measuring positions.
A: Measuring position of leakage from pressure limiter B: Measuring position of return rate from injector
valve
Testing leakage from pressure limiter valve

1. Open covers (1) and (2) on the right side of the machine.
3. Remove clamps (4) and (5), remove joint bolt (6), and re-
move tubes (7) and (8).
30-40 D155AX-8
4. Fit the gaskets to both ends of joint A, tighten joint bolt G,

and install hose D to joint A.
3 Joint bolt G:
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
REMARK
Prepare oil pan L of approximately 20 ℓ to catch the fuel
flowing out of hose D.
5. Install joint B, fuel tube (8), and cap nut H to removed joint
bolt (6), and install hose C to joint B.
3 Joint bolt (6):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
6. Arrange the route of hose C so that it does not sag, and
put its end in measuring cylinder E.

see “SETTING AND OPERATION OF MACHINE MONI-
TOR”.

switch (2).
position.
D155AX-8 30-41
TEST FUEL RETURN RATE AND LEAKAGE 30 TESTING AND ADJUSTING
13. Return the decelerator pedal slowly to stall the torque con-
verter.
14. After the engine speed is stabilized, measure the leakage amount for 1 minute with measuring cylinder E.
REMARK
You may test for 20 seconds and judge by multiplying the result by 3.
After finishing testing, stop the engine.
Testing fuel return rate from injector

While you are measuring the fuel return rate from the injector, keep the hose on the pressure limiter side con-
nected and keep its end in oil pan L.
1. Disconnect return hose (12) from return block (11) and
connect hose K.
REMARK
• Block the return hose by using plug J, and fix it to the
fuel tank.
• Bind the connecting part of hose K with a wire, etc. to
prevent it from coming off.
2. Arrange the route of hose K so that it does not sag, and

put its end in measuring cylinder E.
30-42 D155AX-8

TOR”.

switch (2).
position.

9. Return the decelerator pedal slowly to stall the torque con-
verter.
10. After the engine speed is stabilized, measure the return rate for 1 minute with measuring cylinder E.
REMARK
• For the procedure for stalling the torque converter, see “METHOD FOR TESTING ENGINE SPEED”.
• You may test for 20 seconds and judge by multiplying the result by 3.
• If the “No-pressure error in supply pump” occurs, the engine speed may not rise. In this case, record the
engine speed during the test, as well.
3 Joint bolt (6) :
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
D155AX-8 30-43
BLEED AIR FROM FUEL SYSTEM 30 TESTING AND ADJUSTING
BLEED AIR FROM FUEL SYSTEM

k Clean the engine and the parts around it, and degrease them in advance so that you can check it
easily for fuel leakage.
k Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the
engine is running, it presents a serious danger that could result in a fire.
k When the fuel circuit is tested or any component is removed from or installed to it, check for fuel
leakage according to the following procedure.
For bleeding air to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM

In the following cases, bleed air according to this procedure.
• When the fuel filter is replaced
• When run out of fuel occurs
• When starting the engine for the first time after replacing fuel piping or supply pump
1. Turn the starting switch to ON position and check that the
fuel level caution lamp is lit in blue.
REMARK
If the fuel level caution lamp is lit in any color other than
blue, the fuel level is low. In this case, add fuel.
2. Turn the starting switch to OFF position.
3. Check that fuel supply valve (1) at the bottom of the fuel
tank is opened.
REMARK
When fuel supply valve (1) is opened, its lever is in OPEN
position as shown in the figure.
30-44 D155AX-8
30 TESTING AND ADJUSTING BLEED AIR FROM FUEL SYSTEM
4. Open the cover on the left side of the machine and turn
fuel feed pump switch (3) to the ON position.
REMARK
• The fuel feed pump switch (3) has a timer in it. After
switch (3) is turned ON, the fuel feed pump repeats ac-
tuates and stops automatically 10 times.
• The fuel feed pump stops while lamp (2) is flashing, but
this is not an error.
• If switch (3) is turned to OFF position while lamp (2) is
flashing, lamp (2) goes out and the fuel feed pump
stops.
Lamp (3) flashes and the fuel feed pump operates.
5. After the specified time (approximately 6 minutes 30 sec-
onds), lamp (2) goes out and the fuel feed pump stops au-
tomatically.
When the fuel filter alone is replaced, the bleeding air is
completed.
6. When fuel in the fuel circuit is lost in the cases as fuel is
run out or the fuel piping or supply pump is replaced, set
switch (3) to ON position again immediately after the fuel
feed pump stops automatically.
7. When lamp (2) goes out, air bleeding is completed.
8. Start the engine by cranking it with the starting motor.
NOTICE
Do not operate the starting motor continuously for 20 seconds or more.
REMARK
The air in the high-pressure circuit is bled automatically by cranking the engine.
If the engine does not start, there may be defective air bleeding in the low-pressure circuit. In this case, try
to start the engine again according to the following procedure.
1) Set switch (3) for the fuel feed pump to ON position.
2) Rotate the engine with the starting motor to start it while the fuel feed pump is in operation.
If the engine does not start, wait for approximately 2 minutes, and then repeat steps 1) and 2).
9. After the engine starts, run it with the fuel control dial at MIN (Low idle) for approximately 5 minutes to bleed
all air from the fuel circuit.
D155AX-8 30-45
TEST FUEL CIRCUIT FOR LEAKAGE 30 TESTING AND ADJUSTING
TEST FUEL CIRCUIT FOR LEAKAGE

Testing tools for leakage in fuel system
Commercially Developer for dye penetrant (color
A 1
available checker)
k Fuel leakage may result in a fire during engine is running since very high pressure is generated in
the high-pressure circuit of the fuel system. If check of the fuel circuit or removal of the component
is performed, check it for fuel leakage according to the following procedure.
Clean the engine and the parts around it, and degrease them in advance so that you can check it easily for fuel
leakage.
For testing of fuel system for leakage to perform troubleshooting or Pm Clinic, or periodic maintenance, refer to
this section.
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE

Testing method of fuel circuit for leakage at engine stopped
2. Run the engine with fuel control dial at MIN (Low idle), and stop it after the engine automatic warm-up func-
tion is canceled automatically and engine speed is stabilized.
REMARK
• Turn the fuel control dial to MAX (High idle), the engine automatic warm-up function is canceled.
• For the condition of canceling the engine automatic warm-up function, see Structure and function, “En-
gine automatic warm-up system”.
3. Spray color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4. Check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 1 again.
Testing method of fuel circuit for leakage at engine low idle

REMARK
4. Start the engine, and set the fuel control dial to MIN (Low idle).
5. Stop the engine and check the fuel piping and component for fuel leakage.
sprayed.
Testing method of fuel circuit for leakage at engine high idle

30-46 D155AX-8
30 TESTING AND ADJUSTING TEST FUEL CIRCUIT FOR LEAKAGE
REMARK
4. Start the engine, and set the fuel control dial to MAX (High idle).
sprayed.
Method for testing leakage from fuel system at torque converter stall
REMARK
5. Stall the torque converter and apply a load to the engine. For details, see “METHOD FOR TESTING EN-
GINE SPEED”.
sprayed.
D155AX-8 30-47
HANDLE CYLINDER CUT-OUT MODE OPERATION 30 TESTING AND ADJUSTING
HANDLE CYLINDER CUT-OUT MODE OPERATION

The cylinder cutout mode operation means to run the engine with the fuel injectors of one or more cylinders
disabled electrically to reduce the number of active cylinders. The purposes and effects of cylinder cutout mode
operation are as follows.
• Cylinder cutout mode operation is used to find out a cylinder which does not output power normally (or,
combustion in it is abnormal).
• If the engine speed and output do not change from the normal operation (all-cylinder operation) when a cyl-
inder is cutout with the cylinder cutout mode operation, that cylinder has a failure.
The possible failures are as follows.
• Compression gas leakage from cylinder head gasket area
• Defective injection
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating system)
• Defective electrical system
• The injector of each cylinder is separately controlled electronically in the common rail fuel injection system,
so the cylinder cutout test can be performed easily by the simple operations of the switches compared with
the mechanical fuel injection system. So, the defective cylinder can be found out easily.
30-48 D155AX-8
30 TESTING AND ADJUSTING HANDLE NO-INJECTION CRANKING OPERATION
HANDLE NO-INJECTION CRANKING OPERATION

No-injection cranking operation means to crank the engine by using the starting motor while disabling injection
in all cylinders electrically. The purpose and effect of this operation are as follows.
No-injection cranking is performed to lubricate the engine parts and to protect them from seizure. It is performed
before the engine is started after the machine or engine has been stored for a long period.
D155AX-8 30-49
CLEAN FUEL DOSER 30 TESTING AND ADJUSTING
CLEAN FUEL DOSER

k Place the machine on a level ground, lower the work equipment to the ground in a stable posture, set
the lock lever to LOCK position, and stop the engine.
k Install or remove the cleaning devices after the exhaust manifold and pipe temperature has lowered.
For cleaning of fuel doser to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR CLEANING FUEL DOSER

1. Remove fuel doser (1). For details, see Disassembly and
assembly, “REMOVE AND INSTALL FUEL DOSER AS-
SEMBLY”.
REMARK
Fuel hose (2) does not need to be disconnected in this
section.
2. Soak cloth (15) with sufficient volume of diesel fuel, and

press it against the accumulated soot (14) at the fuel doser
injection port end for the diesel oil to permeate the soot.
3. After the diesel oil permeates the soot, wipe off the soot
(14) with cloth (15).
30-50 D155AX-8
30 TESTING AND ADJUSTING CLEAN FUEL DOSER
4. Brush the injection port end to remove the soot at the in-
jection port by using nylon brush (16).
Eliminate soot completely from the injection port by using
nylon brush (16) and cloth (15).
NOTICE
• Use a nylon brush for cleaning. Do not use a wire
brush because it may damage the injection port.
• Use diesel fuel for cleaning. Do not use other sol-
vents.
Injection port end after cleaning

Cleaning is completed (no soot remaining at injection port
(A))
Cleaning is insufficient (soot remaining at injection port (B))
After finishing the cleaning, restore the machine.

After installing the fuel doser assembly, run the engine for approximately 3 minutes with fuel control dial at MIN
(Low idle). Then stop the engine and check the water and fuel circuits of fuel doser for leakage.
D155AX-8 30-51
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROL-
LER 30 TESTING AND ADJUSTING
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER

Tools for writing compensation values of injector and controller
Commercially
A Laptop computer 1 Windows 8 (32bit)
available
B Cu3886388 INSITE ver. 8.0.2 1
C 795-799-5732 INLINE 5 Kit 1
Commercially
D available or Cable (USB) 1
795-799-5742
E 795-799-5721 Cable 1
F 799-601-4510 Cable (12P) 1
NOTICE
If a problem (shutdown or open circuit) occurs in the personal computer or cables, a serious error may
occur in the engine controller. Be careful when connecting the cables
To install INSITE to a personal computer, insert DVD-ROM software, and operate the personal computer ac-
cording to the displayed menus.
When connecting the INSITE system to the engine controller, do not interrupt the battery power supply to the
engine controller. A power loss breaks the connection with the INSITE system.
Check if the replacement record of the injector and engine controller are written in the maintenance note, etc.,
and note the information such as injector compensation value, etc. if there is a replacement record.
For writing the information to controller when the injector is replaced for troubleshooting, Pm clinic, or periodic
maintenance, etc. refer to this section.
METHOD FOR WRITING INJECTOR COMPENSATION VALUE

1. Write the injector compensation values to maintenance note, etc.
• When the injector is replaced, record the No. of injec-
tor to be replaced and compensation values written on
the new injector.
Read the letters on the injector top surface from left to
right, starting with the top line.
30-52 D155AX-8
30 TESTING AND ADJUSTING LER
• Record the No. of injector to be replaced and

compensation values written on the new injector.
• Read the letters on the injector top surface from
left to right, starting with the top line.
• When the engine controller is replaced, write the injec-

tor compensation value written on the old engine con-
troller to the new engine controller.
a: String of characters
b: QR code
• When the engine controller is replaced, inconsistency
may result between the data recorded on the sheet on
the back of the controller and that recorded in the reg-
ister when replacement of an injector or engine con-
troller was done before. In such case, you must use
the compensation character strings contained in the
maintenance record information or import the compen-
sation value information described on the top face of every injector installed on the cylinders, in the
same way as you did in the above when you replaced the injector.
2. When replacing the injector, clear the values on the compensation values sheet on the back of the engine
controller.
1) Clear the former data characters of the replaced injector on the compensation values sheet that is pro-
vided on the back of the controller. (Add strike-through.)
2) Note the former data of the replaced injector in the maintenance register.
3. Check that the starting switch is turned to OFF position and the operating lamp is off.
REMARK
When connecting and disconnecting the personal computer, be sure to turn the starting switch to OFF posi-
tion.
4. Connect INLINE 5 kit C and cable F to personal computer
A, and then connect these to service connector (SRV).
D155AX-8 30-53
Service connector (SRV) is installed to the rear left of the

operator's seat.
5. Start the personal computer.

6. Turn the starting switch to ON position to supply power from the battery to the engine controller.
7. Double-click the icon shown in the figure.
8. Establish communication with the engine controller according to the following procedure.
1) Check that display (a) is “INLINE5 USB (J1939) Con-
nection”, and Select “Connect to ECM”.
2) Check that display (b) is “None”, and select “Connect”.

When the illustration in connection state display (e)
stops moving, the connection with the engine control-
ler is completed.
30-54 D155AX-8
c: Connection-in-process screen
d: Screen after the connection is complete (illustration
does not move)
e: Communication status is displayed (illustration
moves during communication)
REMARK
While the illustration moves, communication with the
engine controller is in progress. Check that the illustra-
tion does not move at all, and then proceed to next
step.
9. Write the data of injector compensation values according to the following procedure.
1) Select screen (f) “Advanced ECM Data”.
2) Select screen (g) “Highpressure Common Rail Injector

Setup”.
3) Input new data to screen (h) “New Barcode”.

REMARK
• When the injector is replaced, input the injector
compensation value of new injector, and when the
engine controller is replaced, input the all injector
compensation values written on the old engine
controller to the new engine controller.
• Input the compensation values referring the main-
tenance note, etc.
NOTICE
If the compensation values are not correctly writ-
ten, an engine trouble can result.
D155AX-8 30-55
10. After inputting the injector compensation values to screen

(j), select screen (k) “Apply”.

12. Select screen (m) “OK”.
The data processing screen is displayed, and processing

is completed in approximately 30 seconds.
13. After data handling is completed, turn the starting switch to ON position.
14. Select screen (n) “OK”.
30-56 D155AX-8
15. Writing complete screen (p) is displayed again, select

“OK”.
16. When “success” is displayed on screen (r), data writing is

finished correctly, then proceed to next step.
If screen (s) is displayed, data writing is not finished cor-

rectly, repeat from injector compensation value input
screen again.
REMARK
When the engine controller is replaced, input compensa-
tion value may differ from the actual compensation value
although there is no replacement record in the mainte-
nance note, etc. Accordingly, if the data is not written cor-
rectly, read the all injector compensation values directly
and input them.
17. Select screen (t) “Disconnect from ECM”, and shut off the
communication with the engine controller.
After finishing the writing, restore the machine.

Turn the starting switch to OFF position, then turn the starting switch to ON position again to make sure that an
error is not present on the machine monitor.
REMARK
If failure code ([CA2765]: “Injector Trim Data Mismatch ”) is displayed, troubleshoot [CA2765].
D155AX-8 30-57
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE
CONTROLLER 30 TESTING AND ADJUSTING
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CON-

TROLLER
k Check that there is no person or combustible material around the machine (particularly in the direc-
tion of the exhaust gas flows).
• When starting the engine, ash contained in engine oil accumulates in KCSF and increases filter differential
pressure.
• Since filter differential pressure is used for calculation of soot accumulation in the engine controller, in-
crease amount of differential pressure by ash needs to be corrected.
• Correction amount of filter differential pressure increased by ash is calculated in the engine controller as
“Soot Correction by Ash Influence”.
• When engine controller is replaced with the new one, “Soot Correction by Ash Influence” becomes default
value, 0 g/ ℓ.
• When engine controller is replaced with the new one, perform applicable operation to obtain correct “Soot
Correction by Ash Influence”.
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO EN-

GINE CONTROLLER
Perform the applicable operation according to the following procedure.
• When only the engine controller is replaced.
Perform “Ash in Soot Accumulation Correction”. For detail, see “SETTING AND OPERATION OF MA-
CHINE MONITOR”.
• When both of engine controller and KCSF are replaced,
REMARK
the value of “Soot Correction by Ash Influence” and Ash Accumulationaccumulated in KCSF become 0 g/ ℓ,
“Ash in Soot Accumulation Correction” needs not to be performed.
Perform applicable operation. For details, see TROUBLESHOOTING, “Precautions for KDPF (KCSF,
KDOC) cleaning and change”.
30-58 D155AX-8
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS
TEST SCR RELATED FUNCTIONS

For testing of SCR related function to perform troubleshooting or Pm Clinic, refer to this section.
Type of SCR Service Test

Code Item Purpose Reference page
AdBlue/DEF This is a function to actuate AdBlue/DEF pump sin-
TEST AdBlue/DEF PUMP
01 Pump Pressure gly, and to check for damage of AdBlue/DEF hose
RAISED PRESSURE (30-62)
Up Test and failure in AdBlue/DEF pump.
This is a function to check AdBlue/DEF injector for TEST INJECTION AMOUNT
AdBlue/DEF Injec-
02 failure by increasing AdBlue/DEF pump pressure FROM AdBlue/DEF INJECTOR
tion Quantity Test
and injecting a certain amount of it. (30-64)
AdBlue/DEF Line
This is a function to actuate AdBlue/DEF line heater TEST AdBlue/DEF LINE HEAT-
03 Heater Relay 1
1 at any timing, and to check electrical action. ER RELAY 1 (30-67)
Test
AdBlue/DEF Line
This is a function to actuate AdBlue/DEF line heater TEST AdBlue/DEF LINE HEAT-
04 Heater Relay 2
2 at any timing, and to check electrical action. ER RELAY 2 (30-70)
Test
AdBlue/DEF
This is a function to actuate AdBlue/DEF pump heat- TEST AdBlue/DEF PUMP
05 Pump Heater Re-
er at any timing, and to check electrical action. HEATER RELAY (30-73)
lay Test
AdBlue/DEF Tank This is a function to actuate AdBlue/DEF tank heater TEST AdBlue/DEF TANK HEAT-
06
Heater Valve Test valve at any timing, and to check electrical action. ER VALVE (30-76)
SCR Denitration This is a function to check performance of TEST DENITRATION EFFI-
07
Efficiency Test AdBlue/DEF injection and catalyzer if necessary. CIENCY OF SCR (30-79)
Test State Category

Test State(a) Content
0 Waiting for execution of test (Test can be started by pressing START TEST switch).
1 Test is under preparation.
When nor-
5 Abnormality is judged after performing the test.
mal
10 Test is being performed.
20 Test is completed successfully.
11 to 18 Test is being performed but it is paused by external factor.
When abnor-
30 to 41 Test cannot be performed or cannot be continued.
mal
100 Key OFF/ECU shut down is necessary.
(a): Test State
D155AX-8 30-59
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING
Test state parameter list

Test State Content Details Required action
Regeneration disable state of af-
Wait for the start (de-
0 tertreatment devices regeneration Press the start test switch to start the test.
fault)
by machine monitor
AdBlue/DEF pump
Being changed to “Test State”
1 pressure is being in- Wait for “Test State to ”become “10”.
“10”
creased.
It is on the following state de-
pending on the contents.
• Being pressure-fed by
AdBlue/DEF pump
• AdBlue/DEF is being inject-
ed. • Check the items to be performed dur-
ing the test.
• The operation of energiza-
10 Being tested • For “SCR Denitration Efficiency Test”
tion cycle at a fixed time af-
ter specific time passes. or “Ash in Soot Accumulation Correc-
tion” test, wait for the test to finish.
• SCR Denitration Efficiency
Test is being performed.
• “Ash in Soot Accumulation
Correction” is being per-
formed.
Pressure drop of
Pressure drops (only when the
AdBlue/DEF pump is
AdBlue/DEF pump is pressure- Perform troubleshooting for the failure code
5 detected (failure code
fed) while the display of “Test [CA3574]. For details, see “Troubleshooting”.
[CA3574] is dis-
State” is “10”.
played)
• If “Please turn the key off.” is dis-
played, turn the starting switch to OFF
position, and shut down the engine
• AdBlue/DEF is being controller. (*1)
Test has been finish- purged.
20 • If “STOP” is displayed, press the cor-
ed. • Heater energizing has responding switch to return the test to
been completed. initial state.
Other than the above, the state automatically
returns to initial state.
• Wait for AdBlue/DEF purge to finish.
After the display of “Test State”
Purging (energizing • AdBlue/DEF is being
changes to “1”, the test restarts auto-
temporarily stops) or purged.
11 matically.
test cannot be per- • A particular error is being
formed. • If a specific error is displayed, see
displayed.
"Troubleshooting" and perform trouble-
shooting for the failure code.
AdBlue/DEF tank or
AdBlue/DEF tank temperature ex- Wait for AdBlue/DEF tank temperature or
AdBlue/DEF pump is
ceeds 70 °C or AdBlue/DEF AdBlue/DEF pump temperature to be low-
12 at high temperature
pump temperature exceeds upper ered. After the display of “Test State”
(energizing temporari-
limit. changes to “1”, the test restarts automatically.
ly stops)
SCR temperature is 450 °C and In “SCR Denitration Efficiency Test”, it is dis-
SCR temperature is above, or 250 °C and below (tem- played at switching of step, so wait for few
14
out of specified range perature range is set by each test minutes. After the display of “Test State”
level) changes to “1”, the test restarts automatically.
30-60 D155AX-8

Under the condition described on the left,
Exhaust gas flow rate Exhaust gas flow rate is 650 g/ “SCR Denitration Efficiency Test” can not be
15 is out of specified sec. and above or 50 g/sec. and performed. Perform the troubleshooting for
range below. the failure code. For details, see “Trouble-
shooting”.
• Turbo outlet NOx concen- Under the condition described on the left,
NOx value at turbo- tration: Max. 100 ppm “SCR Denitration Efficiency Test” can not be
16 charger outlet is out performed. Perform the troubleshooting for
of specified range • NOx sensor at turbocharg- the failure code. For details, see “Trouble-
er outlet is unmeasurable shooting”.
Injection of
The failure code is being dis- Perform the troubleshooting for the failure
17 AdBlue/DEF is pro-
played. code. For details, see “Troubleshooting”.
hibited
• Ambient temperature is In “SCR Denitration Efficiency Test”, it is dis-
Ambient temperature -30 °C and below played at switching of step, so wait for few
and ambient pressure
18 • Ambient pressure is 60 kPa minutes. Perform the troubleshooting for the
are out of specified
range and below or 160 kPa and failure code. For details, see “Troubleshoot-
above ing”.
• Set the lock lever in LOCK position.

Machine state is un-
30 Safety of machine is not secured. • Set the fuel control dial in MIN posi-
safe.
tion.
Fuel level has drop- Fuel low level caution is dis-
31 Refill with fuel.
ped. played.
The error is being displayed to
Test can not be per- Perform the troubleshooting for the failure
32 prohibit the regeneration of after-
formed (1) code. For details, see “Troubleshooting”.
treatment devices regeneration
Within 20 seconds af- Within 20 seconds after starting Start the engine, wait for 20 seconds or more,
33
ter starting engine engine and then restart the test.
The engine is stopped. Start the engine, and then restart the test.
Test can not be per-
34 Perform the troubleshooting for the failure
formed (2) Specified error is being displayed.
code. For details, see “Troubleshooting”.
Fuel control dial is not in MIN po- Lower the engine speed, and then restart the
Test can not be per- sition test.
35
formed (3) AdBlue/DEF tank temperature is Start the engine, thaw the AdBlue/DEF, and
-1 °C and below then restart the test.
A particular error is being dis- Perform the troubleshooting for the failure
Test can not be per- played. code. For details, see “Troubleshooting”.
36
formed (4) The AdBlue/DEF level is 10 % Refill with AdBlue/DEF, and then restart the
and below. test.
• Engine operation is unsta-
ble. Set the engine at low idle, and then restart
Test can not be per- • Immediately after starting, the test.
37
formed (5) etc.
AdBlue/DEF pump pressure does Perform the troubleshooting for the failure
not increase. code. For details, see “Troubleshooting”.
Test can not be per- A particular error is being dis- Perform the troubleshooting for the failure
39
formed (6) played. code. For details, see “Troubleshooting”.
D155AX-8 30-61

Engine control gover-
Set the engine at low idle, and then restart
40 nor state is not con- Engine control is unstable.
the test.
formable.
Test can not be per- Overheat or oil pressure low error Perform the troubleshooting for the failure
41
formed (7) is being displayed code. For details, see “Troubleshooting”.
• Engine is running.
Key OFF/ECU shut
down is necessary or • Regeneration temperature Shut down the engine controller for resetting
100 does not rise, and time has the key. (*1)
specified regenera-
tion time over been elapsed more than
specified time.
*1: Shut down of engine controller will be completed when system operating lamp goes out 1 to 6 minutes after
the starting switch is turned to OFF position.
TEST AdBlue/DEF PUMP RAISED PRESSURE

NOTICE
When the KOMNET communication error occurs within 1 second which the engine controller can not
detect, the test may be continued although the machine monitor does not continue the test (standard
screen). In that case, turn the starting switch to OFF position once, and then system operating lamp
goes out, and the engine controller shuts down to reset the test.
AdBlue/DEF Pump Pressure Up Test can actuate AdBlue/DEF pump singly, and can check for damage of AdBl-
ue/DEF hose and trouble in AdBlue/DEF pump.
For testing of AdBlue/DEF hose or AdBlue/DEF pump to perform troubleshooting or Pm Clinic, refer to this sec-
tion.
METHOD FOR TESTING AdBlue/DEF PUMP RAISED PRESSURE

1. Check that the system operating lamp is off, and then turn the starting switch to ON position.
k Do not perform this test while engine is running for the safety reasons.
2. Check that AdBlue/DEF level is higher than level (a) of the
sight gauge of AdBlue/DEF tank.
REMARK
When AdBlue/DEF level is below level (a), the
AdBlue/DEF level is low. Refill AdBlue/DEF.
3. Select “AdBlue/DEF Pump Pressure Up Test” by referring

“SETTING AND OPERATION OF MACHINE MONITOR”.
30-62 D155AX-8
4. Check that “0” of “Test State” is flashing.

REMARK
Flashing of “0” indicates “Waiting for the start (default)”,
and test can be performed. Screen other than “0” is dis-
played, follow “Parameter list of Test State”.
5. Press F1 to start “AdBlue/DEF Pump Pressure Up Test”.
F1: Starts “AdBlue/DEF Pump Pressure Up Test”.
F2: Stops “AdBlue/DEF Pump Pressure Up Test”. (When
“STOP” is displayed.)
F5: Returns the screen to “SCR Service Test” screen.
NOTICE
“Test State” does not change to “10” and test does not
start even if F1 is pressed, turn starting switch to OFF
position once, and repeat the testing procedure from
step 1.
REMARK
• Display of “Test State” changes to flashing of “10”, and
value of “AdBlue/DEF Pump Pressure” increases.
While the pressure is increasing, display of “Remaining
Permitted Test Time” is counted down from “1800 to 0
sec”, and when it reaches to “0 sec”, the test will be fin-
ished automatically.
• When the display of “Test State” is “11” to “41”, follow
“Parameter list of test state”.
• When the value of “AdBlue/DEF Pump Pressure” ex-
ceeds “900 kPa” within 1800 seconds of “Remaining
Permitted Test Time”, AdBlue/DEF pump and
AdBlue/DEF supply line are normal. Press F2 to com-
plete the test.
• If the value of “AdBlue/DEF Pump Pressure” does not increase, check each part of AdBlue/DEF supply
line for leakage, or check by sound and vibration that AdBlue/DEF pump operates. However, check for
AdBlue/DEF leakage and check the operation of AdBlue/DEF pump before “Remaining Permitted Test
Time” becomes “0sec”.
• If the value of “AdBlue/DEF Pump Pressure” does not exceeds 800 kPa after approximately 200 sec-
onds are elapsed, AdBlue/DEF stops operation automatically and failure code [CA1682] is displayed. If
the failure code is displayed, perform troubleshooting.
6. When the display of “Test State” changes from flashing of
“20” to flashing of “0”, press F5.
REMARK
• The display of “20” of “Test State” indicates that AdBl-
ue/DEF purge is in progress, and it starts automatically
and stops in 5 minutes at maximum.
• The display of “0” of “Test State” indicates “Wait for the
start (default)”, and is ready for test again.
D155AX-8 30-63
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR

Tools for testing injection amount from AdBlue/DEF injector
A 799-601-4340 Socket 1
Commercially
B Multimeter 1
available
Commercially
C Measuring cylinder 1 Capacity: Approximately 500 mℓ
available
k Place the machine on a level ground, lower the work equipment completely to the ground, stop the
engine, and set the parking brake lever and work equipment lock lever to LOCK position.
k For handling of AdBlue/DEF, see Operation and Maintenance Manual, “PRECAUTIONS FOR AdBlue/
DEF”.
k When holding AdBlue/DEF injector with your hands, be sure to put on safety glasses and rubber
gloves.
NOTICE
• When KOMNET communication error occurs within 1 second which the engine controller can not de-
tect, the test may be continued although the machine monitor does not continue the test (standard
• If the testing of this item is performed without removing AdBlue/DEF injector, it may cause a failure.
Be sure to remove AdBlue/DEF injector before starting the testing.
AdBlue/DEF injection quantity test is the function that checks if AdBlue/DEF injector has any failure by increas-
ing AdBlue/DEF pump pressure and injecting a certain amount of AdBlue/DEF.
For testing of AdBlue/DEF injector to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING INJECTION AMOUNT FROM AdBlue/DEF INJECTOR

1. After checking that the system operating lamp is off, turn the battery disconnect switch to OFF position, and
remove the key.
2. Remove cover (1) and guard (2).
30-64 D155AX-8
3. Check that there is neither crack nor dissolution on AdBl-

ue/DEF injector (4).
4. Disconnect connector (UDM), connect socket A, and

measure the resistance value.
REMARK
• The resistance value becomes high when it is at high
temperature. Cool it down completely, and perform the
measurement.
• Measure the resistance between pin 1 and pin 2.
“STANDARD VALUE TABLE FOR ELECTRICITY”.
5. After finishing the measurement, remove measuring instru-
ment, and connect connector (UDM).
6. Disconnect engine coolant hoses (3) (2 pieces), and remove AdBlue/DEF injector (4).
REMARK
• Be sure that coolant does not splash to SCR assembly when disconnect engine coolant hose (3).
• If the crystal of AdBlue/DEF is adhered at the tip of AdBlue/DEF injector (3), wipe it off with clean cloth.
• If the crystal of AdBlue/DEF is stuck and it is difficult to wipe it off, soak new AdBlue/DEF to cloth which
is not dirty, and wipe crystal off with it. Or, wipe crystal off by using distilled water or deionized water
instead of AdBlue/DEF.
7. Securely place resin measuring cylinder C on the stable
place.
8. Set AdBlue/DEF injector (4) to take the AdBlue/DEF inject-
ed from AdBlue/DEF injector (4) into the resin measuring
cylinder C securely.
9. Check that the system operating lamp is off, and turn the
starting switch to ON position.
REMARK
When AdBlue/DEF level is below level (a), the
AdBlue/DEF level is low. Refill AdBlue/DEF.
10. Turn the starting switch to ON position.
k Do not perform this test while engine is running for
the safety reasons.
D155AX-8 30-65
11. Select “AdBlue/DEF Injection Quantity Test” by referring

“SET AND OPERATE MACHINE MONITOR”.

REMARK
13. Press F1 to start “AdBlue/DEF Injection Quantity Test”.
F1: Starts “AdBlue/DEF Injection Quantity Test”.
(AdBlue/DEF is injected from AdBlue/DEF injector.)
F2: Stops “AdBlue/DEF Injection Quantity Test”. (When
NOTICE
• “Test State” does not change to “10” and test does
not start even if F1 is pressed, turn starting switch
to OFF position once, and repeat the testing proce-
dure from step 10.
• Press F2 to stop performing AdBlue/DEF injection.
(When F2 is pressed, the display of “Test State”
changes to the flashing of “20”.
• If you turn starting switch to OFF position by mis-
take during the test, do not turn starting switch to
ON position immediately, but check that system
operating lamp is off, and turn starting switch to
ON position again after engine controller shuts
down.
• When the KOMNET communication error occurs
within 1 second which the engine controller can
not detect, the test may be continued although the
machine monitor does not continue the test (stand-
ard screen). In that case, turn the starting switch to
OFF position once, and then system operating
lamp goes out, and the engine controller shuts
down to reset the test.
30-66 D155AX-8
REMARK
• The display of “Test State” changes to the flashing of “10”, and as AdBlue/DEF pump pressure increas-
es, the value of “AdBlue/DEF Pump Pressure” increases.
• When the display of Test State is “Test State” to “41”, follow “Parameter list of test state”.
• When the display of Remaining Permitted Test Time becomes “0:00 min:sec”, injection is completed. At
that time, AdBlue/DEF purge action starts automatically, and the display of “Test State” changes to the
flashing of “20”.
• AdBlue/DEF purge action is finished in 5 minutes, display of “Test State” changes to the flashing of “0”,
and injection test of AdBlue/DEF injector is completed.
• Since the display of “Final Accumulated Quantity” is the target value, it does not change from
“100.0 mℓ”.
• If the value of “AdBlue/DEF Pump Pressure” does not increase, check each part of AdBlue/DEF supply
line for leakage, or check by sound and vibration that AdBlue/DEF pump operates.
• After approximately 200 seconds are elapsed, if the value of “AdBlue/DEF Pump Pressure” does not
exceeds 800 kPa, AdBlue/DEF stops operation automatically and failure code [CA1682] appears. If the
failure code is displayed, perform troubleshooting.
14. When the display of Remaining Permitted Test Time becomes “0:00 min：sec” and injection is completed,
measure the amount of AdBlue/DEF collected in measuring cylinder.
REMARK
If it is out of the standard value, replace the AdBlue/DEF injector. For replacing of AdBlue/DEF injector, see
Disassembly and assembly, “Installation and removal of AdBlue/DEF injector”.
For the standard value, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
REMARK
3 Mounting bolt:
Be sure to replace the gasket with a new one.
6 to 8 Nm {0.6 to 0.8 kgm}
2 Seizure prevention compound:
TEST AdBlue/DEF LINE HEATER RELAY 1

Testing tools for AdBlue/DEF line heater relay 1
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available
NOTICE
“AdBlue/DEF Line Heater Relay 1 Test” function can actuate AdBlue/DEF line heater relay 1 at any timing, and
can check electrical action.
D155AX-8 30-67
For testing of AdBlue/DEF suction and return circuit heater relay to perform troubleshooting or Pm Clinic, refer
to this section.
METHOD FOR TESTING AdBlue/DEF LINE HEATER RELAY 1

remove the key.
2. Open cover (1) on the left side of the machine.
3. Disconnect the connector to be tested.

When testing the suction line and return circuit heater relay
of AdBlue/DEF: Connector (CN-UHA)
4. Connect T-adapter A and T-adapter box B, and prepare

multimeter C.
REMARK
Measure the voltage between pin 1 and pin 2.
5. Check that the system operating lamp is off, and then turn
the battery disconnect switch to ON position.
the safety reasons.
30-68 D155AX-8
7. Select “AdBlue/DEF Line Heater Relay 1 Test” by referring


REMARK
9. Press F1 to start “AdBlue/DEF Line Heater Relay 1 Test”.
F1: Starts “AdBlue/DEF Line Heater Relay 1 Test”.
F2: Stops “AdBlue/DEF Line Heater Relay 1 Test”. (When
NOTICE
dure from step 5.
take during test, do not turn starting switch to ON
position immediately. Check that system operating
lamp is off, and turn starting switch to ON position
again after engine controller shuts down.
REMARK
• Display of “Test State” changes to flashing of “10”, and display of “Remaining Time to Start Test” is
counted down from “60” to “0 sec”, and when it reaches to “0 sec”, the power is supplied automatically.
• When the display of “Test State” is “11” to “41”, follow “Parameter list of test state”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, “Line Heater 1 Command” is “ON”
and voltage will be outputted to the heater relay.
• The test stops automatically in the elapsed time of 16 minutes after F1 is pressed.
10. Measure the voltage between pin 1 and pin 2.
D155AX-8 30-69
REMARK
• If an abnormality occurs during measurement, failure codes [CA3713], [CA5115], [CA3562], and
[CA3563] are displayed. If these failure codes are displayed, perform troubleshooting.
• If 24.5±1.5 V is measured within 900 seconds of “Remaining Permitted Test Time”, you can finish the
measurement by pressing F2.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
11. When the voltage of 24.5±1.5 V is measured, press F2.
The display of “Test State” returns to flashing of “0”.
REMARK
When disconnecting connector, always turn the battery disconnect switch to OFF position.
TEST AdBlue/DEF LINE HEATER RELAY 2

Testing tools for AdBlue/DEF line heater relay 2
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available
NOTICE
“AdBlue/DEF Line Heater Relay 2 Test” function can actuate AdBlue/DEF line heater relay 2 at any timing, and
can check electrical action.
For testing of AdBlue/DEF pressure circuit heater relay to perform troubleshooting or Pm Clinic, refer to this sec-
tion.
METHOD FOR TESTING AdBlue/DEF LINE HEATER RELAY 2

remove the key.
30-70 D155AX-8

When the testing pressure line heater relay of AdBlue/
DEF: Connector (CN-URH2)
REMARK
AdBlue/DEF pressure circuit heater relay can be tested by connector (CN-UHC).
the multimeter.
REMARK
the safety reasons.
7. Select “AdBlue/DEF Line Heater Relay 2 Test” by referring

D155AX-8 30-71

REMARK
9. Press F1 to start “AdBlue/DEF Line Heater Relay 2 Test”.
F1: Starts “AdBlue/DEF Line Heater Relay 2 Test”.
F2: Stops “AdBlue/DEF Line Heater Relay 2 Test”. (When
NOTICE
dure from step 5.
ON position immediately. Check that system oper-
ating lamp is off, and turn starting switch to ON po-
sition again after engine controller shuts down.
REMARK
counted down from “60” to “0 sec”, and when it reaches to “0 sec”, the power is supplied automatically.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, “Line Heater 2 Command” is “ON”
and voltage will be outputted.
• The test stops automatically in the elapsed time of 16 minutes after F1 is pressed.
REMARK
• If an abnormality occurs during measurement, failure codes [CA3713], [CA5115], [CA3562], and
[CA3563] are displayed. If these failure codes are displayed, perform troubleshooting.
30-72 D155AX-8

The display of “Test State” changes to flashing of “0”.
REMARK
TEST AdBlue/DEF PUMP HEATER RELAY

Tools for testing AdBlue/DEF pump heater relay
A 799-601-9130 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available
NOTICE
• When the KOMNET communication error occurs within 1 second which the engine controller can not
• In this pump heater relay test, when the starting switch is turned to OFF position while testing (ener-
gizing), and turned to ON position again before system operating lamp goes out, then energizing re-
starts. If, by mistake, the starting switch is turned to ON position while testing (energizing) without
waiting that system lamp goes out, immediately turn the starting switch to OFF position regardless
of the display of machine monitor, and wait the system operating lamp goes out.
“AdBlue/DEF Pump Heater Relay Test” function can actuate AdBlue/DEF pump heater at any timing, and can
check electrical action.
For testing of AdBlue/DEF pump heater relay to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING AdBlue/DEF PUMP HEATER RELAY

remove the key.
2. Remove L.H. step cover (1).
D155AX-8 30-73

When the testing pressure line heater relay of AdBlue/
DEF: Connector (CN-UHR1)

the multimeter.
REMARK
the safety reasons.
7. Select “AdBlue/DEF Pump Heater Relay Test” by referring

30-74 D155AX-8

REMARK
9. Press F1 to start “AdBlue/DEF Pump Heater Relay Test”.
F1: Starts “AdBlue/DEF Pump Heater Relay Test”.
F2: Stops “AdBlue/DEF Pump Heater Relay Test”. (When
NOTICE
dure from step 5.
REMARK
counted down from “60” to “0 sec”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, voltage will be outputted.
• The relay operates for 900 seconds at maximum, and the remaining operable time is displayed as “Re-
maining Permitted Test Time”. However, it stops operation automatically if the temperature of the pump
reaches the upper limit to protect pump heater. It re-starts operation automatically when the temperature
of the pump drops, and then turns ON and OFF repeatedly.
• Perform measuring while energization is not repeated ON/OFF to obtain the stable voltage.
• When energization is repeated ON/OFF, press F2, and stop the test until pump temperature drops.
• When the sum of (Remaining time to start test 1 minute + Heater operating time) exceeds 15 minutes
after F1 is pressed, the test stops automatically.
• This check can be also performed by the following method; When the AdBlue/DEF pump temperature is
below 45ｰC, perform “AdBlue/DEF Pump Heater Relay Test”.Abnormality of the pump can be checked
when “AdBlue/DEF Pump Temperature” rises more than 5ｰC.
REMARK
• If an abnormality occurs during measurement, failure codes [CA4115], [CA4156], and [CA4169] are dis-
played. If these failure codes are displayed, perform troubleshooting.
D155AX-8 30-75
REMARK
AdBlue/DEF purge action starts automatically, and the dis-
play of “Test State” changes to the flashing of “20”.
REMARK
TEST AdBlue/DEF TANK HEATER VALVE

Testing tools for AdBlue/DEF tank heater valve
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available
NOTICE
“AdBlue/DEF Tank Heater Valve Test” function can actuate AdBlue/DEF tank heater at any timing, and can
check electrical action.
For testing of AdBlue/DEF tank heater valve relay to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING AdBlue/DEF TANK HEATER VALVE

remove the key.
2. Open cover (1) on the left side of the machine.
30-76 D155AX-8

When testing pressure line heater relay of AdBlue/DEF:
Connector (CN-UHV2)

the multimeter.
REMARK
7. Select “AdBlue/DEF Tank Heater Valve Test” by referring

D155AX-8 30-77

REMARK
played, follow “Parameter list of test state”.
9. Press F1 to start “AdBlue/DEF Tank Heater Valve Test”.
F1: Starts “AdBlue/DEF Tank Heater Valve Test”.
F2: Stops “AdBlue/DEF Tank Heater Valve Test”. (When
NOTICE
dure from step 5.
REMARK
counted down from “60” to “0 sec”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, voltage will be outputted.
• The valve operates for 900 seconds at maximum, and the remaining operable time is displayed as “Re-
maining Permitted Test Time”.
• After pressing F1, (“Remaining Time to Start Test”1 minute + the heater drive time) the test stops auto-
matically after 16 minutes (cumulative time). Sometimes heater valve does not operate continuously,
check “Remaining Time to Start Test” and “Remaining Time to Complete Test” on the machine monitor
for the heater drive cumulative time.
REMARK
• If an abnormality occurs during measurement, failure codes [CA1683] and [CA1684] are displayed. If
these failure codes are displayed, perform troubleshooting.
test by pressing F2.
• If AdBlue/DEF tank temperature rises too high because of this test, AdBlue/DEF may be deteriorated or
toxic ammonia (NH 3) odor is generated at refilling port. Observe the description in “Operation and Main-
tenance Manual”, “PRECAUTIONS FOR AdBlue/DEF”.
30-78 D155AX-8

The display of “Test State” changes to flashing of “0”.
REMARK
TEST DENITRATION EFFICIENCY OF SCR

k Check that there is no person or combustible material around the machine (particularly in the direc-
tion of the exhaust gas flow).
NOTICE
For testing of AdBlue/DEF injection performance and catalyst efficiency to perform troubleshooting or Pm Clinic,
refer to this section.
METHOD FOR TESTING DENITRATION EFFICIENCY OF SCR

1. Check that AdBlue/DEF level is higher than level (a') of the sight gauge of AdBlue/DEF tank.
2. Turning the starting switch to ON position, check that the
system operating lamp is off, and check gauges for the re-
maining fuel.
REMARK
• “SCR Denitration Efficiency Test” uses fuel and AdBl-
ue/DEF, and it takes approximately 90 minutes at maxi-
mum. Therefore, it is necessary to check the minimum
remaining amount for each.
• If the fuel and AdBlue/DEF are less than minimum
amount shown below, be sure to refill with them.
Gauge Minimum amount (gauge position)
Fuel level gauge (a) position and above
Sight gauge of AdBlue/DEF tank (a') position and above
3. Start the engine, and set the fuel control dial to MIN (Low idle) position.
D155AX-8 30-79
4. Select “SCR Denitration Efficiency Test” by referring “SET

AND OPERATE MACHINE MONITOR”.

REMARK
played, follow “Parameter list of test state”.
6. Press F1 to start “SCR Denitration Efficiency Test”.
F1: Starts “SCR Denitration Efficiency Test”.
F2: Stops “SCR Denitration Efficiency Test”. (When
“STOP” is displayed)
NOTICE
to OFF position once, and repeat the procedure
from step 1.
• When the test is stopped by pressing F2, “0” of
“Test State” flashes, but you can not restart the
test by pressing F1. To restart the test, turn the
starting switch to OFF position once. System oper-
ating lamp goes out, and engine controller shuts
down, and test is reset.
ON position immediately, but check that system
operating lamp is off, and turn starting switch to
ON position again after engine controller shuts
down.
30-80 D155AX-8
REMARK
• The display of “Test State” changes to the flashing of “10”, and “SCR Denitration Efficiency Test” starts.
• “SCR Denitration Efficiency Test” will be normally completed in approximately 30 minutes, however it
may take approximately 90 minutes at maximum depending on the test state.
• When the display of “Test State” changes from flashing of “10” to flashing of “20”, the test is completed.
• “Test State” becomes “14” temporarily at the half way of the test, this state means the temperature is in
transition and it is not abnormal, so continue the test. (The display changes to “10” in a few minutes.)
• Press F2 to stop performing the test, and to return to the standard screen. (When F2 is pressed, the
display of “Test State” changes to the flashing of “20”.)
7. When “20” of “Test State” flashes, check the state of “AdBl-
ue/DEF Injection Test Result” and “SCR Efficiency Test
Result”.
REMARK
When “1” is displayed, the test result is judged as normal,
when “0” is displayed it is judged as abnormal. When “0” is
displayed, perform step 7 and the failure code is displayed.
Test Test result (indication on monitor)
AdBlue/DEF in-
jection perform- 1 0 1 0
ance
SCR catalyst
1 1 0 0
performance
Failure code to
- [CA3755] [CA3751] [CA3755]
be displayed
8. Turn the starting switch to OFF position once, and then
turn it to ON position.
• If a failure code [CA3751] or [CA3755] is displayed, perform troubleshooting.

• After finishing the test, remove the testing tools and restore the machine.
D155AX-8 30-81
CLEAN AdBlue/DEF TANK 30 TESTING AND ADJUSTING
CLEAN AdBlue/DEF TANK

Testing tools for cleaning of AdBlue/DEF tank
Commercially Size: 450 mm (width) x 300 mm (depth) ×
A Oil pan 1
available 130 mm (height), made of stainless steel
Commercially
- Remote breather hose 1
available
Commercially ASOH Co., LTD ASOH CICCOLO:
B 1 Valve 1
available CY-2208 or equivalent
Commercially Approximately 2 m, TOYOXTOYOSILI-
2 Hose 1
available CONE: TSI-8 or equivalent
Size: Approximately 550 mm (width) x ap-
Commercially
C Wooden block 2 proximately 180 mm (depth) x approxi-
available
mately 100 mm (height)
Commercially Diameter: Approximately 130 m, hight:
D Funnel 1
available approximately 200 mm or less
Length: Approximately 2 m, made of poly-
Commercially
E Hose 1 propylene (with diameter for connection to
available
funnel)
Commercially
F Polyethylene container 3 20 ℓ, made of polyethylene
available
Commercially
G AdBlue/DEF 1 For flushing: 30 ℓ
available
k For handling of AdBlue/DEF, see Operation and Maintenance Manual, “Precautions for AdBlue/DEF”.
k When holding AdBlue/DEF injector with your hands, be sure to put on safety glasses and rubber
gloves.
For cleaning AdBlue/DEF tank to perform troubleshooting or Pm Clinic, refer to this section.
30-82 D155AX-8
30 TESTING AND ADJUSTING CLEAN AdBlue/DEF TANK
METHOD FOR CLEANING AdBlue/DEF TANK

1. Connect valve B1 to hose B2, and funnel D to hose E.
REMARK
Remote breather hose B, which connects valve B1 and
hose B2, is used to adjust the drain rate of AdBlue/DEF.
2. Stop the machine so that oil pan A is placed stably on the

track shoe and shoe grouser (1) is not just under the drain
port of AdBlue/DEF.
REMARK
Place wooden block C used later on the track shoe.
4. Place oil pan A stably on the track shoe.

k Toxic gas or corroded material may be generated
by a chemical reaction if an iron or aluminum con-
tainer is used to catch the draining fluid waste of
AdBlue/DEF from the machine. Use a container
made of resin (PP, PE) or stainless steel to catch
the draining fluid waste of AdBlue/DEF.
5. Drain the AdBlue/DEF in AdBlue/DEF tank according to

the following procedure.
1) Check that cap (3) of AdBlue/DEF tank is closed se-
curely.
REMARK
If cap (3) is not closed completely, close it securely.
D155AX-8 30-83
2) Disconnect breather hose (4) from AdBlue/DEF tank

(5), and connect remote breather hose B.
3) Open valve B1 of remote breather hose B.

REMARK
Valve B1 does not need to be opened fully.
4) Select “AdBlue/DEF Pump Pressure Up Test” by refer-

ring “SETTING AND OPERATION OF MACHINE
MONITOR”.
REMARK
By performing “AdBlue/DEF Pump Pressure Up Test”,
foreign matter stuck to AdBlue/DEF tank strainer can
be dropped inside the tank. Injection of AdBlue/DEF
injector is not executed.
5) On “AdBlue/DEF Pump Pressure Up Test” screen,

check that “0” is flashing in “Test State”.
REMARK
Flashing of “0” indicates “Waiting for the start (de-
fault)”, and test can be performed. Screen other than
“0” is displayed, follow “Parameter list of test state”.
6) Press F1 to start “AdBlue/DEF Pump Pressure Up
Test”.
F1: Starts “AdBlue/DEF Pump Pressure Up Test”.
F2: Stops “AdBlue/DEF Pump Pressure Up Test”.
(When “STOP” is displayed.)
30-84 D155AX-8

REMARK
AdBlue/DEF pump operates.
7) When the value of “AdBlue/DEF Pump Pressure” ex-
ceeds “800 kPa”, press F2.
REMARK
• When the value of “AdBlue/DEF Pump Pressure”
exceeds “800 kPa”, the display of “Test State”
changes to flashing of “10”.
• At this point, 1st “AdBlue/DEF Pump Pressure Up
Test” is completed. Perform 3 times in total.
8) Repeat above steps 5) to 7) 2 times.
9) Close valve B1 of remote breather hose B securely.
10) Loosen drain plug (6) by 6 turns and drain

AdBlue/DEF into oil pan A.
REMARK
There is a slit (a) at threaded part of drain plug (6) so
that AdBlue/DEF is not drained too much and splash-
ed.
11) After the draining rate decreases in 3 to 4 minutes, re-
move drain plug (6).
REMARK
The draining rate decreases in approximately 1.8 ℓ.
D155AX-8 30-85
12) In approximately 10 seconds after drain plug (6) is re-

moved, the draining rate starts increasing and de-
creasing alternatively. When it decreases, replace oil
pan A with funnel D connected with hose E.
REMARK
Put the end of hose E in polyethylene container F
placed on the ground.
13) Fix funnel D by holding it between wooden blocks C.
14) Fully open valve B1 of remote breather hose B.

15) When polyethylene container F is almost filled up with
AdBlue, close valve B1 of remote breather hose B se-
curely.
16) In approximately 10 seconds after valve B1 is closed,
the draining rate starts increasing and decreasing al-
ternatively. When it decreases, move hose E to empty
polyethylene container F.
REMARK
The draining rate decreases in approximately 0.9 ℓ.
17) Repeat steps 14) to 16). When the AdBlue/DEF tank becomes empty, install drain plug (6) securely.
6. Clean the AdBlue/DEF tank according to the following procedure.
30-86 D155AX-8
1) Check that drain plug (6) is closed securely.

2) Refill the AdBlue/DEF tank with new AdBlue/DEF.
5 AdBlue/DEF tank:
30 ℓ
3) Repeat steps 10) to 16) of procedure 5, and drain
AdBlue/DEF.
6 AdBlue/DEF tank:
30 ℓ
Cleaning of the AdBlue/DEF tank is completed.
7. Refill the AdBlue/DEF tank with AdBlue/DEF according to the following procedure.
1) Check that drain plug (6) is closed securely.
2) Install cover (2).
3) Disconnect remote breather hose B from AdBlue/DEF

tank (5).
4) Connect breather hose (4) to AdBlue/DEF tank (5).

5) Refill the AdBlue/DEF tank with new AdBlue/DEF.
5 AdBlue/DEF tank:
60 ℓ
NOTICE
AdBlue/DEF freezes at -11 °C. Refill with
AdBlue/DEF to lowest level under an environment
with -11 °C or below. See Operation and Mainte-
nance Manual, “How to check AdBlue/DEF
amount, refill”
Check the refilling amount of AdBlue/DEF through sight gauge.
D155AX-8 30-87
ADJUST DECELERATOR PEDAL 30 TESTING AND ADJUSTING
ADJUST DECELERATOR PEDAL

Outline of fuel control system
DIAL: Fuel control dial
PEDAL: Decelerator pedal
ROD: Decelerator pedal rod
POTENTIO: Decelerator pedal potentiometer
ENG-ECU: Engine controller
P/T-ECU: Power train controller
ENGINE: Engine (CRI device)
[KOMNET]: KOMNET communication circuit (3rd throttle sig-
nal)
As speed command signals, the following signals are input to the engine controller.
1: Fuel control dial potentiometer signal
2: Decelerator pedal potentiometer signal
3. 3rd throttle signal (power train controller)
• The engine controller controls the fuel control system of the engine (CRI system) corresponding to the low-
est engine speed signal among those input signals.
• The decelerator pedal speed and high idle speed are adjusted with the linkage of the decelerator pedal.
For adjusting of the decelerator pedal to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR ADJUSTING DECELERATOR PEDAL

The figure is a structural view for adjustment.
1: Decelerator pedal 2: Stopper pin
30-88 D155AX-8
30 TESTING AND ADJUSTING ADJUST DECELERATOR PEDAL
3: Stopper pin
Adjusting method of engine high idle speed

Check that the engine high idle speed is normal. For details, see “METHOD FOR TESTING ENGINE SPEED”.
If the engine high idle speed is abnormal, adjust it according to the following procedure.
1. Remove cover (4) under the dashboard.
2. Adjust installed dimension (b) of stopper bolt (3).

• When engine high idle speed is 2100 rpm or higher:
Decrease the engine high idle speed to below
1900 rpm with stopper bolt (3) to eliminate the play of
decelerator pedal (1), and then adjust installed dimen-
sion (b) of stopper bolt (3) to set the engine high idle
speed to the standard value.
• When engine high idle speed is 2050 rpm or lower:
Adjust installed dimension (b) of stopper bolt (3) until
the engine high idle speed reaches the standard val-
ue.
REMARK
Standard installed dimension (b) of stopper bolt (3): 36.0 mm
After adjusting, check that the engine high idle speed is in the standard range.
Adjusting method of engine speed when decelerator pedal is depressed

If the engine speed is abnormal when the decelerator pedal is depressed, adjust it according to the following
procedure.
D155AX-8 30-89
ADJUST DECELERATOR PEDAL 30 TESTING AND ADJUSTING
2. Adjust installed dimension (a) of stopper bolt (2).

REMARK
Standard installed dimension (a) of stopper bolt (2):
38.0 mm
After adjusting, measure the engine idle speed when the decelerator pedal is depressed, and check that it is in
the standard range.
30-90 D155AX-8
30 TESTING AND ADJUSTING TEST POWER TRAIN OIL PRESSURE
POWER TRAIN
TEST POWER TRAIN OIL PRESSURE
Testing tools for power train oil pressure
― 799-101-5002 Hydraulic tester 1
2 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
C 799-401-2320 Gauge 1 Pressure range: 1 MPa
D 799-101-5220 Nipple 1 Size: M10 x 1.25 mm
E 07002-11023 O-ring 1
List of oil pressure pick up nipples and gauges to be used

Pressure pickup
Oil pressure to be measured Gauge ( MPa)
port nipple (*1)
TM Transmission main relief pressure 6
LU Torque converter lockup clutch pressure 2.5
SC Torque converter stator clutch pressure 6
F Transmission forward clutch pressure 6
R Transmission reverse clutch pressure 6
1st Transmission 1st clutch pressure 6
2nd Transmission 2nd clutch pressure 6
3rd Transmission 3rd clutch pressure 6
RB Steering right brake pressure 6
LB Steering left brake pressure 6
― Torque converter inlet pressure Machine monitor (*2)
― Torque converter outlet pressure Machine monitor (*2)
*1: Marked on pickup port (centralized pressure pickup port block).

*2: Since the inlet pressure and outlet pressure of the torque converter are checked with the monitoring function
of the machine monitor, no nipple is installed at the pickup port (centralized pressure pickup port block).
D155AX-8 30-91
TEST POWER TRAIN OIL PRESSURE 30 TESTING AND ADJUSTING
Refer to this section when it is necessary to test the power train

during troubleshooting or Pm Clinic, etc.
METHOD FOR TESTING POWER TRAIN OIL PRESSURE

Testing transmission main relief pressure (TM)
1. The power train oil pressure pickup port (centralized pressure pickup port block) is installed inside right step
cover. Remove that cover when measuring the power train oil pressure.
2. Connect gauge A1 of hydraulic tester A to oil pressure
pickup port TM nipple.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
3. Start the engine and set the joystick (steering, directional
and gear shift lever) (PCCS lever) in NEUTRAL position.
REMARK
The test can also be performed with the parking brake lev-
er set in LOCK position.
4. Measure the main relief pressures when fuel control dial is
in MIN (Low idle) and MAX (High idle) positions.
For standard values, see Standard value table, “Standard
value table for machine”.
Testing torque converter lockup clutch pressure (LU)

30-92 D155AX-8

pickup port LU nipple.
REMARK
place of gauge A2.
3. Start the engine, raise the machine to the height which al-
lows the track to run idle off ground by using blade and rip-
per.
k After raising the machine, set the work equipment
lock lever to LOCK position.
D155AX-8 30-93
4. Set the gear shift mode and preset as follows with the gear
shift mode selector switch (2), up switch (3) or down switch
(4).
Gear shift mode: Automatic gear shift
Preset: “F1-R1”
5. Select “T/M Fill Sw Input2” on Monitoring Selection Menu
to display. For details, see “Setting and operating machine
monitor”.
6. Move joystick (steering, directional and gear shift lever)
(PCCS) travel direction to FORWARD to run the track idle
off ground.
Monitoring code: 31520 “T/M Fill Sw Input2”
k Be careful not to get caught by rotating part of
track during testing.
REMARK
Hold the steering side of it at neutral.
7. Set the fuel control dial at MAX (High idle) position and
measure the lockup clutch pressure when “L/U” of monitor-
ing item turns “ON”.
Testing torque converter stator clutch pressure (SC)

30-94 D155AX-8

pickup port SC nipple.
REMARK
place of gauge A1.
REMARK
4. Measure the torque converter stator clutch pressure when
fuel control dial is in MIN (Low idle) and MAX (High idle)
positions.
Testing transmission forward clutch pressure (F)

pickup port F nipple.
REMARK
place of gauge A1.
3. Start the engine and set the parking brake lever to FREE
position.
D155AX-8 30-95
(4).
Gear shift mode: Manual gear shift
Preset: “F2-R2”
5. Set the joystick (steering, directional and gear shift lever)

(PCCS lever) travel direction to FORWARD with the brake
pedal depressed, and shift up the gear to the 3rd gear
speed with the up switch (3).
REMARK
Check that “F3” is displayed in the gear speed display.
6. Measure the transmission forward clutch pressure when
fuel control dial is in MIN (Low idle) and MAX (High idle)
positions.
k Since the torque converter is stalled, keep depressing the brake pedal securely and keep your
right foot on the decelerator pedal for safety until the work is finished.
For standard values, see Standard value table, “Standard value table for machine”.
Testing transmission reverse clutch pressure (R)

pickup port R nipple.
REMARK
place of gauge A1.
position.
30-96 D155AX-8
(4).
Preset: “F2-R2”

(PCCS lever) travel direction to REVERSE with the brake
pedal depressed, and shift up the gear to the 3rd gear
speed with up switch (3).
REMARK
6. Measure the transmission reverse clutch pressure when
fuel control dial is in MAX (High idle) and MIN (Low idle)
positions.
Testing transmission 1st clutch pressure (1ST)

pickup port 1ST nipple.
REMARK
place of gauge A1.
position.
D155AX-8 30-97
(4).
Preset: “F1-R1”

pedal depressed.
REMARK
tion.
6. Measure the transmission 1st clutch pressure when fuel
control dial is in MIN (Low idle) position.
k Since the torque converter is stalled, keep depress-
ing the brake pedal securely and keep your right
foot on the decelerator pedal for safety until the
work is finished.
k Do not set the fuel control dial to MAX position
(High idle) during the test.
Testing transmission 2nd clutch pressure (2ND)

pickup port 2nd nipple.
REMARK
place of gauge A1.
position.
30-98 D155AX-8
(4).
Preset: “F2-R2”

pedal depressed.
REMARK
tion.
6. Measure the transmission 2nd clutch pressure when fuel
work is finished.
Testing transmission 3rd clutch pressure (3RD)

pickup port 3RD nipple.
REMARK
place of gauge A1.
position.
D155AX-8 30-99
(4).
Preset: “F2-R2”
5. With the brake pedal depressed, set the joystick (steering,

directional and gear shift lever) (PCCS lever) travel direc-
tion to FORWARD and shift up the gear to the 3rd gear
speed.
REMARK
6. Measure the transmission 3rd clutch pressure when fuel
work is finished.
Testing steering right brake pressure (RB)

pickup port RB nipple.
REMARK
place of gauge A1.
position.
4. Measure the steering right brake pressure when fuel con-
trol dial is in MAX (High idle) and MIN (Low idle) positions.
REMARK
In addition to the preceding test, check that the oil pres-
sure becomes 0 MPa when the brake pedal is depressed
or the parking brake lever is set to LOCK position.
30-100 D155AX-8
Testing steering left brake pressure (LB)

pickup port LB nipple.
REMARK
place of gauge A1.
position.
4. Measure the steering left brake pressure when fuel control
dial is in MAX (High idle) and MIN (Low idle) positions.
REMARK
In addition to the preceding test, check that the oil pres-
sure becomes 0 MPa when the brake pedal is depressed
or the parking brake lever is set to LOCK position.
Testing torque converter inlet pressure and outlet pressure

1. Display the following monitoring items. For details, see
“Setting and operating machine monitor”.
• Monitoring code: 32601 “T/C Inlet Pressure”
• Monitoring code: 32603 “T/C Outlet Pressure”
REMARK
3. Measure the torque converter inlet pressure and outlet
pressure when fuel control dial is in MAX (High idle) and
MIN (Low idle) positions.
D155AX-8 30-101
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 30 TESTING AND ADJUSTING
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR

For adjusting of the transmission output shaft speed sensor to perform troubleshooting or Pm Clinic, refer to this
section.
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR

1. Remove the fuel tank. For details, see Disassembly and
assembly, “Removal and installation of fuel tank”.
4 Fuel tank:
960 kg (when full)
2. Remove transmission output shaft speed sensor (1) and
check the sensor end is free from iron dust or flaw, and
then install it.
3. Tighten transmission output shaft speed sensor (1) until its

end touches the tooth tip of bevel gear (2).
2 Thread portion:
Liquid gasket (LG-5)
4. Return transmission output shaft speed sensor (1) by 1/2
to 1 turn.
REMARK
At this time, clearance (a) between transmission output
shaft speed sensor (1) and the tooth tip of bevel gear (2) is
0.75 to 1.5 mm.
5. While fixing transmission output shaft speed sensor (1),
tighten nut (3).
3 Nut:
49.0 to 68.6 Nm {5 to 7 kgm}
After finishing the adjustment, restore the machine.
Method for checking transmission output shaft speed sensor after adjusting it
1. Start the engine with fuel control dial set in MIN position (Low idle).
2. Select “T/M Output Speed” on “Pre-defined Monitoring ”
(10/22) or from Monitoring Selection Menu to display. For
details, see “SETTING AND OPERATION OF MACHINE
MONITOR”.
Monitoring code: 31400 “T/M Output Speed”
“T/M Output Speed” screen displayed.
3. Drive the machine actually or run the track idle off the
ground, and check that the transmission speed is dis-
played normally.
30-102 D155AX-8
30 TESTING AND ADJUSTING TEST BRAKE PERFORMANCE SIMPLY
TEST BRAKE PERFORMANCE SIMPLY

For testing of brake performance to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY

1. Start the engine on a level place, and set the blade and
ripper in the travel posture.
2. Set the parking brake lever to FREE position.
(4).
NOTICE
If this test is carried out in the 1st gear position, the
brake is overloaded. Accordingly, be sure to select
preset “F2-R2” so that the gear speed is set to 2nd
when the machine starts.
Preset: “F2-R2”
pedal depressed.
Hold its steering section at neutral.
tion.
at MAX position　(High idle).
6. Release the decelerator pedal slowly. Check that the ma-
chine does not start when your right foot leaves the decel-
erator pedal.
D155AX-8 30-103
TEST AND ADJUST BRAKE PEDAL 30 TESTING AND ADJUSTING
TEST AND ADJUST BRAKE PEDAL

Testing tools for brake pedal
A 79A-264-0091 Push-pull scale 1 Load: 0 to 490 N {0 to 50 kg}
For adjusting of the brake pedal to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING BRAKE PEDAL

Method for testing depressing effort of brake pedal
1. Start the engine with fuel control dial set in MIN position (Low idle).
2. Depress brake pedal (1) with your foot and check that it
operates smoothly.
3. Check the depressing force of the brake pedal to start the
operation of the brake by using push-pull scale A.
“STANDARD VALUE TABLE FOR MACHINE”.
4. Check the depressing force of brake pedal (1) at its stroke
end by using push-pull scale A.
“STANDARD VALUE TABLE FOR MACHINE”.
METHOD FOR ADJUSTING BRAKE PEDAL

30-104 D155AX-8
30 TESTING AND ADJUSTING TEST AND ADJUST BRAKE PEDAL
1: Brake pedal 5: Brake limit switch

2: Stopper pin 6: Double nut
3: Rod 7: Nut
4: Return spring
Method for adjusting depressing effort of brake pedal

2. Loosen nut (7).

3. With brake pedal (1) released, turn double nut (6) and ad-
just the installed dimension of return spring (4).
REMARK
• Turn the 2 nuts of double nut (6) together. Do not turn
each of them singly.
• Adjustment dimension of rod (installed dimension of re-
turn spring) (d): 92±0.5 mm
• Assembled dimension of rod (e): 127 mm
4. Tighten nut (7).
After adjusting, check again that the depressing effort of the brake pedal is within the standard range.
Adjustment method of brake potentiometer


TOR”.
Adjustment ID: 0005“Brake Pedal Potentio Initial Set”
D155AX-8 30-105
TEST AND ADJUST BRAKE PEDAL 30 TESTING AND ADJUSTING
3. Adjust installed dimension (b) of stopper (2) so that dimen-

sion (a) is 77 mm.
REMARK
• Dimension (b) = 36 mm (reference value)
• Standard dimension (c) of rod (3) = 120 mm (reference
value)
4. With brake pedal (1) released, adjust installed dimension
(b) of stopper (2) so that the brake pedal potentiometer
voltage is within the specified range shown below.
“BRAKE PEDAL VOLTAGE”: 2500±50 mV
5. Make the power train controller recognize the zero point of the brake pedal potentiometer. For details, see
“Adjustment ID: 0005 (Brake Pedal Potentio Initial Set)”.
Adjustment method of brake limit switch


TOR”.
Adjustment ID: 0005 “Brake Pedal Potentio Initial Set”
3. Depress brake pedal (1). When the brake pedal potentiom-
eter voltage enters the range below, fix brake pedal (1).
“BRAKE PEDAL VOLTAGE”: 3940 to 4150 mV
4. Adjust the installed position of brake limit switch (5) so that

the parking brake pilot monitor is turned ON at the position
where brake pedal (1) is fixed.
5. After adjusting the installed position, release brake pedal
(1) slowly and check that the parking brake pilot monitor is
turned OFF when the voltage is out of the range below.
“BRAKE PEDAL VOLTAGE”: 3940 to 4150 mV
30-106 D155AX-8
30 TESTING AND ADJUSTING ADJUST PARKING BRAKE LEVER
ADJUST PARKING BRAKE LEVER

For adjusting of the parking brake lever to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR ADJUSTING PARKING BRAKE LEVER

1: Panel 6: Cover
2: Grip 7: Console box
3: Air conditioner duct 8: Lever assembly
4: Cover 9: Limit switch
5: Panel 10: Parking brake lever
1. Remove panel (1), grip (2), air conditioner duct (3), and cover (4). For details, see Disassembly and assem-
bly.
REMARK
Remove panel (5), cover (6), and console box (7) as well, if necessary.
2. Assembly lever assembly (8) and adjust the operation of limit switch (9).
REMARK
When lever is set up: Limit switch is OFF
When lever is set down: Limit switch is ON
Operating stroke of limit switch: 2.8 mm
Check of brake oil pressure

Check that the brake oil pressures (steering RIGHT brake pressure (RB) and steering LEFT brake pressure
(LB)) are within the standard range when parking brake lever (10) is set to FREE position or LOCK position. For
details, see “METHOD FOR TESTING POWER TRAIN OIL PRESSURE”.
D155AX-8 30-107
ADJUST PARKING BRAKE LEVER 30 TESTING AND ADJUSTING
Check of limit switch

Check the operating condition of the parking brake lever limit switch.
1. Select and display “P/T Controller SW Input 1” on Monitor-
ing Code Selection Menu. For details, see “SETTING AND
OPERATION OF MACHINE MONITOR”.
Monitoring code: 40905 “P/T Controller SW Input 1”
2. Check that the signal of limit switch (9) is input normally
when parking brake lever (3) is set to FREE position or
LOCK position.
• FREE position
“Parking Brake Lock SW NC”: “ON”
“Parking Brake Lock SW NO”: “OFF”
• LOCK position
“Parking Brake Lock SW NC”: “OFF”
“Parking Brake Lock SW NO”: “ON”
30-108 D155AX-8
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE
30 TESTING AND ADJUSTING DOES NOT TRAVEL

DOES NOT TRAVEL
Tools for releasing parking brake
- 790-190-1601 Pump assembly 1
A 1 790-190-1510 Volume pump 1
2 790-190-2500 Hose 1
B 02789-00315 Cap nut 1
C 19M-06-32820 Switch assembly 1
D 17A-06-41411 Wiring harness 1
E 7824-66-6430 Resistance 1
F 7827-10-1520 Resistance 1
When the parking brake is not released and the machine does not move, you can move it according to the fol-
lowing procedure.
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE

RELEASE SYSTEM
If the engine cannot be started and the parking brake cannot be released, move the machine according to the
following procedure.
REMARK
When you can start the engine, see “METHOD FOR MOVING THE MACHINE BY ELECTRICITY”.
1. Assemble pump assembly A.
2. Install volume pump A1 of pump assembly A to the outside

of the operator’s cab.
D155AX-8 30-109
DOES NOT TRAVEL 30 TESTING AND ADJUSTING
3. Remove the rear cover under the fuel tank and disconnect
supply hose (2) of the ripper pin puller solenoid valve (1).
4. Connect hose A2 of pump assembly A.
REMARK
• Use the nipple of face seal type on the pump assembly
A side, since hose (2) of face seal type is used on the
machine side.
• Block solenoid valve (1) side with cap nut B.
5. Turn the starting switch ON and set the parking brake lever
in the FREE position.
6. Operate volume pump A1 to raise the brake releasing oil pressure to the initial pressure.
Initial pressure: Approximately 2.74 MPa {Approximately 28 kg/cm2}
REMARK
• Since an accumulator is installed in the circuit, the handle must be operated 30 to 50 times to raise the
oil pressure.
• If the oil pressure does not rise above a certain level, the relief valve may be set to low pressure. In this
case, adjust the set pressure of the relief valve.
7. Tow the machine to a safe place.
REMARK
• The brake releasing oil pressure lowers gradually because of internal leakage and the brake is applied
again approximately one minute after. Therefore, work quickly.
• When the brake release oil pressure drops to approximately 1.57 MPa {approximately 16 kg/cm2}, the
brake is applied. In such a case, increase the brake release oil pressure to its initial level by operating
the volume pump again.
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RE-
LEASE SYSTEM
When any trouble occurs in the electrical system of the power train control (forward and reverse travels, gear
speed, steering) and the machine does not move, move the machine according to the following procedure.
k Do not turn the starting switch to ON position or start the engine until switch accessory C and wiring
harness D are prepared.
REMARK
• You can perform this procedure only when you can start the engine.
• When you cannot start the engine, see “METHOD FOR MOVING THE MACHINE BY OIL PRESSURE”.
30-110 D155AX-8
30 TESTING AND ADJUSTING DOES NOT TRAVEL
1. Connect switch assembly C and resistors E and F to wiring

harness D.
k To prevent the machine from moving suddenly, set
all the gear speeds of switch assembly C to OFF
position, and set the directional switch to P posi-
tion.
2. Remove the battery cover and AdBlue/DEF tank. For de-
tails, see Disassembly and assembly, “REMOVE AND IN-
STALL AdBlue/DEF TANK ASSEMBLY”.
3. Connect wiring harness D to connector PL1.

REMARK
• The male housing and female housing of connector
PL1 are fixed with screw.
• Connect wiring harness D to both male side and fe-
male side of connector PL1.
4. Install the battery cover and AdBlue/DEF tank. For details,
see Disassembly and assembly, “REMOVE AND INSTALL
AdBlue/DEF TANK ASSEMBLY”.
5. Remove cover (3) on the front side of the L.H. console
box.
6. Disconnect connector NSF of the neutral safety relay, and

directly connect pins No. 3 and No. 5 of the connector on
the wiring harness side.
D155AX-8 30-111
DOES NOT TRAVEL 30 TESTING AND ADJUSTING
k Start the engine with this method only when the machine needs to be moved for the safety. In
any other case where the engine does not start, always perform troubleshooting and repair the
failed parts, and then start the engine.
k When the engine is started with this method, the neutral safety relay function does not work.
Therefore, before starting the engine, set the parking brake lever to LOCK position and all joy-
stick (steering, directional and gear shift lever) (PCCS lever) functions to NEUTRAL position.
REMARK
• Direct connection circuit: No. 3 and No. 5 of connector NSF (female)
• If connector PL1 is disconnected, a model selection error occurs and accordingly the neutral safety re-
lay is not driven. The above step is required to prevent this trouble.
7. Start the engine and set the parking brake lever to FREE position.
8. Operate switch assembly C and move the machine to a
safe place.
REMARK
The gear speed switch has an electric circuit that gives pri-
ority to operation of the low speed switch.
After moving the machine, remove the devices and return the removed parts to their original position.
REMARK
As for connector PL1, make sure the seal at the joint is not protruding or missing, and then tighten the screw to
3 Screw:
the specified torque.
2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
30-112 D155AX-8
30 TESTING AND ADJUSTING ADJUSTING IDLER CLEARANCE
UNDERCARRIAGE AND FRAME

ADJUSTING IDLER CLEARANCE
Adjusting tools for idler clearance
Commercially
A Feeler gauge 1
available
For adjusting of the idler clearance to perform troubleshooting or Pm Clinic, refer to this section.
When the R.H., L.H., upper, and lower guide plates are worn and the idler runs out sideway or tilts, adjust the
guide plates according to the following procedure.
METHOD FOR ADJUSTING IDLER CLEARANCE

1: Cover 5: Guide plate

2: Guide plate 6: Guide plate
3: Bolt 7: Guide plate
4: Shim 8: Guide plate
Adjustment in lateral direction

1. Travel 1 to 2 m on a level ground, and then stop.
D155AX-8 30-113
ADJUSTING IDLER CLEARANCE 30 TESTING AND ADJUSTING
2. Remove covers (1) (2 pieces).
3. Measure clearance (a) at 2 places between the track

frame and guide plate (2).
If clearance (a) is 4 mm or more, adjust it by loosening
bolts (3) and reducing shims (4).
k Do not loosen bolts (3) more than 3 turns. If you ig-
nore this, guide plate (2) falls.
REMARK
• Standard clearance (a) on each side: 0.5 to 1.0 mm
• The adjustable limit of the clearance is 6 mm on each
side.
Adjustment in vertical direction

Measure clearance (b) at 2 places between the guide plates (5)
and (6).
The clearance in the vertical direction cannot be adjusted with
shims. If clearance (b) is 8 mm or more, replace upper and low-
er guide plates (5), (6), (7), and (8) with new ones.
REMARK
Guide plates (5), (7), and (8) are welded.
30-114 D155AX-8
30 TESTING AND ADJUSTING TEST AND ADJUST TRACK TENSION
TEST AND ADJUST TRACK TENSION

Testing tools for track tension
L shape steel bar which has less deflec-
A - Steel rod 1
tion
If track becomes loose, refer to this section for testing and adjusting.
METHOD FOR TESTING TRACK TENSION

1. Move the machine forward slowly on a level ground, then
stop it.
REMARK
• Do not use brake pedal to stop the machine, set joy-
stick (steering, directional and gear shift lever) (PCCS
lever) in NEUTRAL position to stop the machine.
• Perform test with tracks stopped at a position where
pin (3) does not come above carrier roller (1).
2. Place straight steel bar A between the idler (4) and front
carrier roller (1), and measure maximum clearance (a) be-
tween the bottom of the steel bar and track shoe grouser
(2).
Standard maximum clearance (a) is 30 to 40 mm.
METHOD FOR ADJUSTING TRACK TENSION

If the track tension is abnormal, adjust it according to the following procedure.
In the following cases, remove cover (2) and adjust the track
tension.
• When the tension is too high:
Loosen plug (3) to discharge the grease.
k Do not loosen the plug more than one turn, be-
cause the plug may fly out due to the high internal
pressure of the grease.
3 Plug (3):
59 to 88 Nm {6 to 9 kgm}
• When the tension is low:
Pump in grease through grease fitting (4).
To adjust the tension precisely, drive the machine slowly forward and reverse, and test the tension again after
the tracks are settled.
D155AX-8 30-115
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30 TESTING AND ADJUSTING
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
For releasing the remaining pressure from hydraulic system to perform troubleshooting or Pm Clinic, refer to this
section.
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIR-

CUIT
When disconnecting the piping between the control valve and the work equipment cylinder, release the remain-
ing pressure in the circuit according to the following procedure.
1. Loosen hydraulic tank cap (1) gradually to release the re-
maining pressure in the tank.
2. Turn the starting switch to ON position and set the work
equipment lock lever in FREE position.
3. Operate the blade control lever and ripper control lever in
all directions.
The remaining pressure in the accumulator is all released
with several times of lever operation.
position.
5. Run the engine for approximately 10 seconds with the fuel control dial set to MIN (Low idle) position to
charge the accumulator, and then stop the engine.
6. Repeat above Steps 2. to 4. several times.
Remaining pressure will be completely released from the piping.
30-116 D155AX-8
30 TESTING AND ADJUSTING TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES

Testing tools for work equipment and HSS oil pressures
A
C 799-101-5220 Nipple 2 Size: M10×1.25 mm
D 07002-11023 O-ring 2
Test this item under the following conditions.
Unload pressure, work equipment pressure, and HSS oil pressure can also be tested by using “Self-define Mon-
itoring” function of the machine monitor.
For testing and adjusting of work equipment and HSS oil pressures to perform troubleshooting or Pm Clinic, re-
fer to this section.
METHOD FOR TESTING WORK EQUIPMENT AND HSS OIL PRESSURES

Testing unload pressure
1. Remove the control valve cover.
4 Control valve cover:

25 kg
2. Remove work equipment oil pressure pickup plug P of the
control valve.
D155AX-8 30-117
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES 30 TESTING AND ADJUSTING
3. Install nipple C and connect it to gauge A1 of hydraulic

tester A.
REMARK
place of gauge A1.
4. Start the engine and place the blade control lever and rip-
per control lever in their NEUTRAL position.
REMARK
The test can also be performed with the work equipment
lock lever set in LOCK position.
k Do not operate the work equipment or steering with
the pressure gauge installed. Otherwise, the gauge
may break.
5. Measure the unload pressure when fuel control dial is set
in MAX (High idle) position.
Testing work equipment oil pressure


25 kg
2. Remove work equipment oil pressure pickup plug P and
LS pressure pickup plug LS of the control valve.
3. Install nipple C to each measuring port and connect them

to gauge A2 of hydraulic tester A.
4. Start the engine and set the work equipment lock lever in
FREE position.
30-118 D155AX-8
6. Operate the blade control lever and ripper control lever to

relieve each cylinder at a stroke end, and measure the
work equipment relief pressure and work equipment LS re-
lief pressure.
k Do not operate the steering with the pressure
gauge installed. Otherwise, the gauge may break.
REMARK
P side is the work equipment relief pressure, and LS side
is the work equipment LS relief pressure.
Testing HSS oil pressure


25 kg
2. Remove work equipment oil pressure pickup plug P and
LS pressure pickup plug LS of the control valve.
REMARK
Measuring point of HSS oil pressure is the same as the
measuring port of work equipment oil pressure.
3. Install nipple C to each measuring port and connect them

to gauge A3 of hydraulic tester A.
4. Start the engine, set the parking brake lever to FREE posi-
tion, and keep depressing the brake pedal.
6. Operate the steering of joystick (steering, directional and
gear shift lever) (PCCS lever) toward left or right to relief
the steering, then measure the HSS relief pressure and
HSS LS relief pressure.
k Since the steering circuit is relieved, keep depress-
work is finished.
REMARK
P side is HSS relief pressure, and LS side is HSS LS relief
pressure.
D155AX-8 30-119
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES 30 TESTING AND ADJUSTING
Testing with machine monitor

The monitoring function can measure only the pressures on the mark P side of the control valve (unload pres-
sure, work equipment relief pressure, and HSS relief pressure) and cannot measure the pressures on the LS
marked side (work equipment LS relief pressure and HSS LS relief pressure).
1. Display the following monitoring items. For details, see
“Setting and operating machine monitor”.
Monitoring code: “70700 Hydraulic Oil Pump Pressure 1”
2. Start the engine and measure each oil pressure.
REMARK
The testing conditions for each oil pressure are the same
as those for each measurement taken with a gauge in the
preceding steps.
For standard values, see “Standard value table for ma-
chine”.
METHOD FOR ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURES

Adjusting unload pressure
The unload pressure cannot be adjusted.
Adjusting work equipment oil pressure

If the work equipment oil pressure is not normal, adjust LS relief valve (3) for the work equipment according to
the following procedure.
REMARK
The figure shows the 5-spool valve for the single tilt specifica-
tion (The dual tilt specification has the 6-spool valve).
1. While fixing adjustment nut (4), loosen lock nut (5).

2. Turn adjustment nut (4) to adjust the pressure.
When the adjustment nut is
• turned clockwise, the pressure is increased.
• turned counterclockwise, the pressure is decreased.
REMARK
Quantity of adjustment per turn of adjustment nut: Ap-
proximately 19.6 MPa {Approximately 200 kg/cm2}
3. While fixing adjustment nut (4), tighten lock nut (5).
3 Locknut (5):
39 to 49 Nm {4 to 5 kgm}
When the adjustment if finished, test work equipment oil pressure again. For details, see “Testing work equip-
ment oil pressure”.
Adjusting HSS oil pressure

If the HSS oil pressure is not normal, adjust LS relief valve (6) for HSS according to the following procedure.
30-120 D155AX-8
REMARK
The figure shows the 5-spool valve for the single tilt specifica-
tion (The dual tilt specification has the 6-spool valve).
1. Loosen lock nut (8) with adjustment screw (7) fixed.

2. Turn adjustment screw (7) to adjust oil pressure.
When the adjustment screw is
• turned clockwise, the pressure is increased.
• turned counterclockwise, the pressure is decreased.
REMARK
Pressure adjustment for one turn of adjustment
screw: Approximately 15.1 MPa {Approximately
154 kg/cm2}
3. Tighten lock nut (8) with adjustment screw (7) fixed.
3 Locknut (8):
68.6 to 78.5 Nm {7 to 8 kgm}
When the adjustment if finished, test HSS oil pressure again. For details, see “Testing HSS oil pressure”.
D155AX-8 30-121
TEST OIL PRESSURE OF CONTROL CIRCUIT 30 TESTING AND ADJUSTING
TEST OIL PRESSURE OF CONTROL CIRCUIT

Testing tools for control circuit source pressure
2 799-101-5160 Nipple 1 R1/8
C 799-401-3200 Adapter 1 Size: 03
The control circuit oil pressure is the pressure reduced by the self-pressure reducing valve in the fan circuit. It is
used commonly for the control valve EPC valve (steering, blade, and ripper), HSS circuit charge, fan pump con-
trol, and blade lift cylinder quick drop EPC valve.
• Blade control lever: NEUTRAL position
• Ripper control lever: NEUTRAL position
For testing and adjusting of control circuit source pressure to perform troubleshooting or Pm Clinic, refer to this
section.
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT

1. Remove the right step cover.
2. Disconnect accumulator inlet hose (1).
3. Install adapter C and connect the disconnected hose

again.
4. Install nipple A2 of hydraulic tester A and connect it to
gauge A1.
REMARK
place of gauge A1.
30-122 D155AX-8
30 TESTING AND ADJUSTING TEST OIL PRESSURE OF CONTROL CIRCUIT
5. Place the blade control lever and ripper control lever in

their NEUTRAL position.
REMARK
The test can also be performed with the work equipment
lock lever set in LOCK position.
position.
7. Measure the control circuit oil pressure when fuel control
dial is set in MAX (High idle) position.
D155AX-8 30-123
TEST WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRES-
SURE 30 TESTING AND ADJUSTING
TEST WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE

Testing tools for work equipment lock solenoid valve outlet pressure
― 799-101-5002 Hydraulic tester 1
2 799-101-5160 Nipple 1 R1/8
C 799-401-3200 Adapter 1 Size: 03
Refer to this section when it is necessary to test the work equipment lock solenoid valve during troubleshooting
or Pm Clinic, etc.
METHOD FOR TESTING WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT

PRESSURE

25 kg
2. Disconnect control valve inlet hose (1).
30-124 D155AX-8
TEST WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRES-
30 TESTING AND ADJUSTING SURE

again.
4. Install nipple A2 of hydraulic tester A and connect gauge
A1.
REMARK
place of gauge A1.
position.
7. Move the work equipment lock lever to LOCK position and
FREE position, and measure the solenoid valve output
pressure in each position.
D155AX-8 30-125
TEST RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE 30 TESTING AND ADJUSTING
TEST RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE

Testing tools for ripper pin puller solenoid valve outlet pressure
2 799-101-5160 Nipple 2 R1/8
C 799-401-3200 Adapter 2 Size: 03
For testing of ripper pin puller solenoid valve outlet pressure to perform troubleshooting or Pm Clinic, periodic
maintenance, refer to this section.
METHOD FOR TESTING RIPPER PIN PULLER SOLENOID VALVE OUTPUT

PRESSURE
1. Disconnect hoses (1) to (2).
Hose (1): Pin puller cylinder head side
Hose (2): Pin puller cylinder bottom side
30-126 D155AX-8
30 TESTING AND ADJUSTING TEST RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE

again.
3. Install nipple A2 of hydraulic tester A and connect it to
gauge A1.
REMARK
place of gauge A1.
position.
6. Measure the pin puller solenoid valve outlet pressure when

the pin puller switch is at PULL position (a) and PUSH po-
sition (b).
For standard values, see “STANDARD VALUE TABLE
FOR MACHINE”.
D155AX-8 30-127
CHECK COOLING FAN SPEED 30 TESTING AND ADJUSTING
CHECK COOLING FAN SPEED

Hydraulic oil temperature: 45 to 100 °C
For checking cooling fan speed to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR CHECKING COOLING FAN SPEED

2. Warm up the machine sufficiently and keep the hydraulic oil temperature in the specified range.
REMARK
The cooling fan speed varies if the hydraulic oil temperature is 40 °C or lower.
TOR”.
Adjustment ID: 1005 “Fan 100% mode”
REMARK
• The function is effective once “Fan 100 % mode”
screen appears, and controls the cooling fan speed at
the maximum speed (approximately 100 %).
• The “Fan 100 % mode” becomes ineffective when F5 is
pressed and the screen returns to “Input ID” screen.
4. Measure the fan speed when fuel control dial is set in MAX
(High idle) position.
30-128 D155AX-8
30 TESTING AND ADJUSTING TEST COOLING FAN CIRCUIT OIL PRESSURE
TEST COOLING FAN CIRCUIT OIL PRESSURE

Testing tools for cooling fan circuit oil pressure
A
C 799-401-2950 Adapter 1 Size: 06
D 799-101-5220 Nipple 1 Size: M10×1.25 mm
E 07002-11023 O-ring 1
For checking cooling fan circuit oil pressure to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE

1. Open radiator mask (1).
2. Disconnect supply hose (2) from the fan motor.
D155AX-8 30-129
TEST COOLING FAN CIRCUIT OIL PRESSURE 30 TESTING AND ADJUSTING
3. Install adapter C and connect disconnected hose (2)

again.
4. Install nipple D and connect it to gauge A1.
REMARK
place of gauge A1.
5. Turn the starting switch to ON position, display the screen

of Adjustment ID "1005". For details, see “SETTING AND
OPERATION OF MACHINE MONITOR”.
REMARK
• The function is effective once “Fan 100 % mode”
screen appears, and controls the cooling fan speed to
approximately 100% of the maximum speed.
• The cooling fan speed varies if the hydraulic oil temper-
ature is 40 °C or lower.
• The “Fan 100 % mode” becomes ineffective when F5 is
pressed and the screen returns to “Input ID” screen.
7. Measure the cooling fan circuit oil pressure when the fuel control dial is set in MAX (High idle) position.
30-130 D155AX-8
30 TESTING AND ADJUSTING BLEED AIR FROM COOLING FAN PUMP
BLEED AIR FROM COOLING FAN PUMP

Air bleeding tools for cooling fan pump
Commercially
A Hose 1
available
For bleeding air from the cooling fan pump to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP

If the cooling fan pump was removed and installed or its piping is disconnected and connected, bleed air from
the fan pump case according to the following procedure.
1. Check that the oil level in the hydraulic tank is normal.
2. Remove L.H. step cover (1).
3. Loosen air bleeder (2), connect air bleeding hose A, and

leave them for 15 minutes.
4. After 15 minutes, start the engine with fuel control dial set
in MIN position (Low idle).
5. When hydraulic oil containing no bubbles starts to flow out
of air bleeder (2), tighten air bleeder (2).
3 Air bleeder:
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
D155AX-8 30-131
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-
MENT 30 TESTING AND ADJUSTING
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT

When the work equipment drifts hydraulically, it is possible to judge if the cause is on the cylinder packing side
or on the control valve side.
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE

LIFT CYLINDER
1. Raise the front of the machine by bracing the blade, and
stop the engine.
REMARK
Do not extend the blade lift cylinder to the stroke end,
since it is equipped with the piston valve.
3. Operate the lift control side of the blade control lever in the
direction to extend the cylinder, and check the movement
of the cylinder.
• When the lowering speed is increased: The cylinder
packing is defective.
• No change: The control valve is defective.
REMARK
If the pressure in the accumulator decreases, set the fuel control dial to MIN (Low idle) position and start
the engine, and run it for approximately 10 seconds to increase the pressure in the accumulator.
The following are the reasons why the lowering speed is increased by the above operation when the cylin-
der packing causes the hydraulic drift.
• When the machine is set in the above posture (where the holding pressure is applied to the bottom
side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less
than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the
oil flowing in from the bottom side.
• As the internal pressure on the head side increases, both pressures come to balance at a certain level
of pressure (depending on leakage), and the lowering speed becomes slow.
• If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the
bottom side is closed by the check valve at this time), the oil in the head side flows in the drain circuit.
As a result, the pressure is imbalanced and the lowering speed is increased.
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE

TILT CYLINDER
1. Extend the tilt cylinder rod fully, then push the blade
against the ground to raise the left side of the machine,
and stop the engine.
3. Operate the lift control side of the blade control lever in the
direction to extend the cylinder, and check the movement
of the cylinder.
30-132 D155AX-8
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-
30 TESTING AND ADJUSTING MENT
REMARK
If the pressure in the accumulator decreases, set the fuel control dial to MIN (Low idle) position and start
the engine, and run it for approximately 10 seconds to increase the pressure in the accumulator.
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER

LIFT CYLINDER
1. Raise the rear of the machine by bracing the ripper, and
stop the engine.
3. Operate the ripper control lever in the direction to extend
the cylinder, and check the movement of the cylinder.
REMARK
If the pressure in the accumulator decreases, set the fuel
control dial to MIN (Low idle) position and start the engine,
and run it for approximately 10 seconds to increase the
pressure in the accumulator.
D155AX-8 30-133
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 30 TESTING AND ADJUSTING
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER

Testing tools for internal leakage of work equipment cylinder
Commercially
A Measuring cylinder 1
available
B 07376-70422 Plug 1 Size: 04
C 02896-11012 O-ring 1 Size: 04
D 07379-01044 Flange 1 Size: 10
E 07000-13032 O-ring 1 Size: 10
Since the blade lift cylinder has a piston valve, the internal leakage cannot be measured.
For testing of internal leakage of the work equipment cylinder to perform troubleshooting or Pm Clinic, or period-
ic maintenance, refer to this section.
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYL-

INDER
1. Release the remaining pressure in the hydraulic cylinder circuit referring to “METHOD FOR RELEASING
REMAINING PRESSURE FROM HYDRAULIC CIRCUIT”.
3. Extend the cylinder to be tested to the stroke end and set the machine in the testing posture.
• Operate the blade tilt cylinder and tilt the blade fully to the left.
• Pull out the shank pin, operate the ripper lift cylinder, and lower the ripper fully.
• Operate the ripper tilt cylinder and tilt the ripper (IN) fully to the front.
30-134 D155AX-8
30 TESTING AND ADJUSTING TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER
4. Disconnect head side hoses (1), (2), and (3) of the cylinder
to be checked and block the control valve side by using
plugs or flanges.
k Be careful not to disconnect the hoses on the bot-
tom side.
REMARK
When working on the hoses of the blade tilt cylinder, re-
move the piping cover of the frame.
• Block hose (1) of the blade tilt cylinder by using plug
B.
• Block hose (2) of the ripper lift cylinder by using flange
D.
• Block hose (3) of the ripper tilt cylinder by using flange
D.
5. Turn the fuel control dial to MAX (High idle) position, and
apply relief pressure to the cylinder bottom side.
• Operate the blade tilt cylinder and tilt the blade to the
left.
• Operate the blade ripper lift cylinder and lower the rip-
per.
• Operate the ripper tilt cylinder and tilt the ripper (IN) to
the front.
6. After 30 seconds, measure the leakage from the cylinder
in 1 minute by using measuring cylinder A.
D155AX-8 30-135
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 30 TESTING AND ADJUSTING
BLEED AIR FROM WORK EQUIPMENT CYLINDERS

For bleeding air from the work equipment to perform troubleshooting or Pm Clinic, refer to this section.
If the work equipment cylinder was removed and installed or its piping is disconnected and connected, bleed air
from its circuit according to the following procedure.
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS

1. Check that the oil level in the hydraulic tank is normal.
3. Start the engine and run it at low idle for approximately 5 minutes.
4. While keeping the fuel control dial at MIN position (Low idle), extend and retract the cylinder to bleed air for
approximately 5 minutes.
REMARK
Stop the piston rod approximately 100 mm before each stroke end, and never relieve the circuit.
5. Set the fuel control dial to MAX position (High idle) and perform the operation of step 4.
6. Set the fuel control dial to MIN position (Low idle), extend and retract the cylinder to each stroke end, and
relieve the circuit.
After stopping the engine, wait for approximately 1 hour. Then, if the hydraulic oil level is improper, add new oil
or drain the excessive oil.
30-136 D155AX-8
30 TESTING AND ADJUSTING OPERATION WHEN WORK EQUIPMENT IS NOT EFFECTIVE
OPERATION WHEN WORK EQUIPMENT IS NOT EFFECTIVE

Operation tools when work equipment is not effective
A 17A-06-41421 Wiring harness 1
k Do not turn the starting switch to ON position or start the engine until wiring harness A is prepared.
If the blade or ripper does not operate because of a trouble in the work equipment controller, perform operation
according to the following procedure.
METHOD FOR OPERATING WHEN WORK EQUIPMENT IS NOT EFFECTIVE

1. Install wiring harness A inside the operator's cab and
check the destination of each connector.
WLK: To work equipment lock solenoid under floor
WEPW: To power supply connector above control valve
WEPX: To EPC solenoid above control valve
WEPY: To EPC solenoid above control valve
REMARK
A connector No. label is stick to wiring harness A.
2. Remove the floor cover from the front of the operator's
seat.
4 Floor cover:
20 kg
3. Disconnect connector WLK of the work equipment lock
solenoid valve and connect connector WLK of wiring har-
ness A to the male side.

25 kg
5. Remove the plug of connector WEPW for the power sup-

ply above the control valve and connect connector WEPW
of wiring harness A to the female side.
D155AX-8 30-137
OPERATION WHEN WORK EQUIPMENT IS NOT EFFECTIVE 30 TESTING AND ADJUSTING
6. Disconnect connectors WEP1 to WEPA for the EPC sole-

noid above the control valve and connect connectors
WEPX and WEPY of wiring harness A to the male side.
k Do not connect wiring harness A to the connectors
for HSS (HSL and HSR).
REMARK
• Disconnect only the connectors for the coupled opera-
tions (2 pieces), and connect the connectors on wiring
harness A side to them.
• Check the operating direction of the switch and the
connector No. again when connecting the connectors.
• “List of connectors to be connected” is for dual tilt spec-
ifications. Single tilt specification does not have WEP5
and WEP6.
List of connectors to be connected

Connectors on machine side
Component and moving direction Connector No. Band color
RAISE WEP1 Green
Blade lift
LOWER WEP2 Green, black
RETRACT WEP3 Brown
Blade tilt LEFT
EXTEND WEP4 Brown, black
RETRACT WEP5 Blue
For blade tilt RIGHT
EXTEND WEP6 Blue, black
RAISE WEP7 Yellow
Ripper lift
LOWER WEP8 Yellow, black
IN WEP9 Red
Ripper tilt
BACK WEPA Red, black
Connectors on wiring harness A side
Component and moving direction Connector No. Band color
UP WEPX -
Lift
DOWN WEPY -
7. Check that the switch is in the neutral position.
k If the switch is not in the neutral position, the work
equipment may move unexpectedly when the en-
gine is started. Accordingly, be sure to check that
the switch is in the neutral position.
8. Start the engine, and set the fuel control dial to MIN posi-
tion (Low idle).
9. Operate the switch of wiring harness A to move the work
equipment.
k You cannot control the work equipment finely with
the switch. Accordingly, always run the engine at
low idle when operating the work equipment.
After operating the work equipment, remove the devices used and return the removed parts to their original po-
sition.
30-138 D155AX-8
30 TESTING AND ADJUSTING ADJUST WORK EQUIPMENT LOCK LEVER
WORK EQUIPMENT
ADJUST WORK EQUIPMENT LOCK LEVER
For adjusting of the work equipment lock lever to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER

1: Work equipment lock lever 3: Lever

2: Limit switch
1. Set work equipment lock lever (1) in LOCK position.
2. Install limit switch (2) so that it is set to sliding surface (d) of lever (3).
REMARK
Set the roller of the limit switch lightly, and do not stroke it.
3. Set work equipment lock lever (1) to FREE position, and check that limit switch (2) operates normally.
Stroke of limit switch: 2.5 to 3 mm
D155AX-8 30-139
ADJUST WORK EQUIPMENT LOCK LEVER 30 TESTING AND ADJUSTING
4. Check the operating condition of the work equipment lever

limit switch.
1) Select and display “Blade Knob SW Input 1” on Moni-
toring Code Selection Menu. For details, see “SET-
TING AND OPERATION OF MACHINE MONITOR”.
Monitoring code: 70302 “Blade Knob SW Input 1”
2) Check that the signal of limit switch (2) is input nor-
mally when work equipment lever (3) is set to FREE
position or LOCK position.
• FREE position
“Work equipment lock NC”: “ON”
“Work equipment lock NO”: “OFF”
• LOCK position
“Work equipment lock NC”: “OFF”
“Work equipment lock NO”: “ON”
30-140 D155AX-8
30 TESTING AND ADJUSTING TEST AND ADJUST OPERATOR'S CAB
CAB AND ITS ATTACHMENTS

TEST AND ADJUST OPERATOR'S CAB
Testing tools for operator's cab
Commercially Transparent, outside diameter: 6 mm,
A Vinyl hose 1
available length: Approximately 3 m
Commercially
B Tape 1
available
Commercially
C Sealing tape 1
available
For testing adjusting of the cab and door, refer to this section.
METHOD FOR TESTING OPERATOR'S CAB

Method for testing pressure in cab
• Fan speed: Fan 100 % mode
• FRESH/RECIRC air changeover setting: FRESH
• Air conditioner fan setting: High (FULL)
1. Fix the indoor side end of hose A to the top of the seat back with tape B.
2. Remove bolt (2) at the rear of L.H. console box (1), insert
the opposite end of the hose into the bolt hole, and pull it
out from inside of the battery cover on the left side of the
cab.
REMARK
Bolt (2) is the ground terminal of the wiring harness.
3. Seal the clearance between the hole of bolt (2) and hose A
with tape B.
4. Tighten terminal for GND having been removed in step 2
(at the rear of the machine) together with bolt (4) (at the
front of the machine).
REMARK
• This is a temporary measure to form the electrical circuit. The air conditioner does not operate, unless
this measure is taken.
• Bolt (4) is the ground terminal of the wiring harness.
D155AX-8 30-141
TEST AND ADJUST OPERATOR'S CAB 30 TESTING AND ADJUSTING
5. Pour water into hose A to approximately a half, and bend

the hose into a shape of letter U.
6. Fix hose A to outside of the cab with tape B, and match
the water levels in hose A with each other.
position.

TOR”.
9. Set the fuel control dial to MAX (High idle) position, and
measure water level difference (c) in hose A.
a: Inside of cab (pressurized)
b: Outside of cab (ambient pressure)
c: Measured value (internal pressure of cab)
Criterion: Measured value ≧ 68.6 Pa {7 mmH2O}
If the measured value is out of the standard range, check for clearance in the portions in the cab where the
wiring harness is laid through, sealed portions of the optional mounting holes, etc.
Method of testing door lock (damper rubber)

1. Stick sealing tape C to the damper rubber (6) contact sur-
face of door (5).
REMARK
Stick sealing tape C to 2 places each on the right and left
sides.
2. Open and close door (5) 2 to 3 times.
3. Check the contact portions of sealing tape C and cab.
• No adjustment is required if the sealing tape C and
cab are in light contact when the door is closed.
• Adjustment is required if the sealing tape C and cab
are not in contact at all or in contact so strongly that
the sealing tape is pealed off.
30-142 D155AX-8
Method of adjusting door lock (latch and striker)

Move door (5) in the closing direction and check the engage-
ment condition of latch (8) and striker (9).
REMARK
Measure distance (f) between center (d) of latch (8) and center
(e) of striker (9) from direction A.
• Normal: No adjustment is required if distance (f) is 0.5 mm
or less.
• Abnormal: Adjustment is required if distance (f) is larger
than 0.5 mm.
Method for testing open lock (latch and striker)

1. Move door in the opening direction and check the engage-
ment condition of latch (11) and striker (10).
REMARK
Check the relationship between latch (11) and striker (10)
from direction B.
2. Check that striker (10) is not leaning from center (g) of

latch (11).
3. Check if center (h) of striker (10) deviates from center (g)
of latch (11).
• Normal: No adjustment is required if deviation is
0.5 mm or less.
• Abnormal: Adjustment is required if deviation is larger
than 0.5 mm.
Method for testing open lock (stopper rubber)

1. While the door is locked open, shake the door back and forth and check for backlash.
• Normal: No adjustment is required, if there is not backlash.
• Abnormal: Adjustment is required, if there is backlash.
2. Check if the operating effort of the unlock lever is heavy.
• Normal: No adjustment is required, if the operating effort of the unlock lever is not heavy.
D155AX-8 30-143
TEST AND ADJUST OPERATOR'S CAB 30 TESTING AND ADJUSTING
• Abnormal: Adjustment is required, if the operating effort of the unlock lever is heavy.
METHOD FOR ADJUSTING OPERATOR'S CAB

Adjustment of door lock (damper rubber)
Check the relationship between the cab and door (damper rubber portion) while the door is closed. If it is abnor-
mal, adjust it.
1. Loosen the mounting bolts of damper rubber (6).
REMARK
You can remove and install the shim without removing the
mounting bolt.
2. Increase or decrease shim (7) under damper rubber (6)
and adjust the damper rubber (6) to the proper height.
Adjustment of door lock (latch and striker)

Check the relationship between the cab and door (latch and striker) while the door is closed. If it is abnormal,
adjust it.
1. Lightly tighten the mounting bolts of striker (9), open and
close door (5) 2 to 3 times in order to align latch (8) with
striker (9).
2. Check engagement of latch (8) and striker (9).
3. Tighten the mounting bolts of striker (9) to the specified
torque.
4. Open and close door (5) and check that it is locked and
unlocked smoothly.
REMARK
• If the door is not unlocked smoothly (the operating ef-
fort of the knob is heavy), adjust again from step 1.
• Operating effort of knob: 53.9 ± 19.6 N {5.5 ± 2 kg}
5. Apply grease to latch (8).
2 Latch:
Grease (G2-LI)
REMARK
If the grease on the latch dries up, the operating effort of
the knob increases. To prevent this, apply grease suffi-
ciently.
Adjustment of open lock (latch and striker)

Check the relationship between the cab and door (latch and striker) while the door is locked open. If it is abnor-
mal, adjust it.
30-144 D155AX-8
1. Loosen the mounting bolts of striker (10).

2. Set striker (10) upright and tighten the mounting bolts.
Adjustment of open lock (stopper rubber)

Check the relationship between the cab and door (stopper rubber) while the door is locked open. If it is abnor-
mal, adjust it.
1. Loosen the upper lock nut of stopper rubber (12).
2. Loosen the lower lock nut of stopper rubber (13).

3. Repair the trouble by adjusting the heights of stopper rub-
bers (12) and (13).
REMARK
• If there is play, protrude (heighten) the stopper rubber
until the play is eliminated.
• If the door is not locked easily or the operating effort of
the unlock lever is heavy, return (lower) the stopper
rubber to a degree that the door has no play.
4. While fixing stopper rubbers (12) and (13), tighten the lock
nuts.
D155AX-8 30-145
SETTING AND OPERATION OF MACHINE MONITOR 30 TESTING AND ADJUSTING
ELECTRICAL SYSTEM
SETTING AND OPERATION OF MACHINE MONITOR
Upper part of machine monitor (multi-information display part)

(a): Multi-information display
30-146 D155AX-8
30 TESTING AND ADJUSTING SETTING AND OPERATION OF MACHINE MONITOR
REMARK
Depending on ambient temperature and condition of battery, battery voltage may drop suddenly and machine
monitor display disappears when engine is started. But this phenomenon does not mean that machine monitor
is defective.
Upper part of machine monitor (switch part)
F1: Function switch F1
REMARK
• The function of each function switch is indicated by the icon on the screen of the multi-information display
(a).
• If the icon for a function switch is not displayed, that function switch is not working.
Lower part of machine monitor (switch part)
1: Operating mode selector switch/Numeral 1 input switch
2: Gear shift mode selector switch/Numeral 2 input switch
3: Customize switch/Numeral 3 input switch
4: Buzzer cancel switch/Numeral 4 input switch
5: Work equipment automation switch/Numeral 5 input switch
6: Reverse slow mode switch/Numeral 6 input switch
7: Air conditioner switch (fan speed raise switch)/Numeral 7 input switch
8: Air conditioner switch (temperature setting raise switch)/Numeral 8 input switch
9: Air conditioner switch (auto switch)/Numeral 9 input switch
0: Air conditioner switch (temperature setting lower switch)/Numeral 0 input switch
Switch without number: Air conditioner switch (fan speed lower switch)
REMARK
• Each switch has the function indicated by the icon and the function of inputting a numeral.
• The machine monitor automatically judges which function of each switch is currently enabled according to
the screen display of the multi-information display (a).
Operator mode and service mode of machine monitor
Machine monitor has operator mode and service mode. Various information is displayed on multi-information
display (a).
Some information are displayed automatically according to the configuration of the machine monitor and the
others are displayed according to the operation with switches.
• Operator mode
The information items in this mode are ordinarily displayed. The operator can display and set them by the
operation with switches. (Display and setting of some items need special operation of switches.)
For details, see Operation and Maintenance Manual.
Operator mode
Display of KOMATSU logo
Display of password input
Display of "Check before starting"
D155AX-8 30-147
Operator mode
Display of warning after "Check before starting"
Display of maintenance due time over
Display of check of preset
Display of standard screen
Display of AdBlue/DEF gauge low level warning
Display of end screen
Display of engine shutdown secondary switch operation
Selection of Operating mode
Selection of gear shift mode
Selection of reverse slow mode
Operation of customizing
Selection of customize memory
Operation to cancel alarm buzzer
Operation of air conditioner
Selection of dual tilt (dual tilt specification)
Operation to display camera mode
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode (including KOMTRAX messages for users)
Display of ECO guidance
Operation of machine setting (fan reverse mode)
Display of alarm monitor
Display of aftertreatment devices regeneration
Display of SCR information
Display function of action level and failure code
Following functions become operational by performing special operations.
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN (30-149)
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN (30-149)
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) (30-150)
CHECKING FUNCTION OF SERVICE METER (30-151)
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD (30-151)
• Service mode
The information items in this mode are not ordinarily displayed. Technicians can change display and set-
tings by operating the switches specially. This mode is used for testing, adjusting, or troubleshooting.
Service mode
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION (30-155)
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION (30-161)
METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYSTEMS) (30-171)
30-148 D155AX-8
Service mode
METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS) (30-173)
METHOD FOR CONFIRMING MAINTENANCE RECORD (30-176)
METHOD FOR OPERATING MAINTENANCE MODE SETTING (30-177)
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING (30-181)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (KEY-ON MODE) (30-181)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (UNIT) (30-182)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (CAMERA) (30-183)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (FLOAT BUZZER) (30-187)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (AUTO IDLE STOP TIMER FIXING) (30-188)
METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION) (30-189)
METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE) (30-191)
METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET) (30-193)
METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST) (30-194)
METHOD FOR OPERATING TESTING MENU (ENGINE STOP AdBlue/DEF INJ OVERHEAT COUNT RESET)
(30-197)
METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER ACTIVE FAULT CLEAR) (30-195)
METHOD FOR OPERATING TESTING MENU (ASH IN SOOT ACCUMULATION CORRECTION) (30-195)
METHOD FOR OPERATING TESTING MENU (RESET NUMBER OF ABRUPT ENGINE STOP BY AIS) (30-197)
VARIOUS SETTINGS OF MACHINE (30-198)
METHOD FOR PERFORMING NO INJECTION CRANKING (30-264)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS) (30-265)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS) (30-266)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS) (30-267)
METHOD FOR DISPLAYING SERVICE MESSAGE (30-267)
OPERATOR MODE
Only item which needs special operation of operator mode is shown.
For details of contents and operations of each function and display, see “Structure and function ”, or the “Opera-
tion and Maintenance Manual”.
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN

When the operator identification function is enabled, turn the
starting switch to ON position while pressing the numeral input
key 4, and the following technician identification state screen is
displayed for 2 seconds.
REMARK
The purpose of the display function of technician identification
status screen is to distinguish the operating state by technician
(maintenance work, etc.) and operating state by operator when
the customer controls operating state by operator, fuel con-
sumption, machine trouble by using operator ID function.
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN

After displaying the technician identification state screen, the operator ID input screen
D155AX-8 30-149
• The screen shown in the figure is displayed only when the

operator ID No. input setting is enabled.
• Before performing checking and adjusting, check in ad-
vance that the input setting of ID of the operator identifica-
tion function has already been set by the customer.
• When the customer has done the ID input setting with
SKIP, press F1 after displaying the technician identification
state screen, and the engine can be started.
• When the customer has done the ID input setting without
SKIP, the engine cannot be started unless the registered
ID is provided for the technician to use, from a person in
charge of the machine on the customer side.
• When turning the starting switch to ON position, input ID,
press F6 or F1, and the screen changes to check before
starting screen without switch operation. Confirm that it is
not necessary to identify the technician beforehand by ask-
ing administrator of the machine.
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)

While the standard screen is displayed, if the numeral input
switches or function switches are operated in the following
manner, the entire LCD screen turns white.
Switch operations (simultaneously): 4 + F2
• When finishing the operation of the switches, release F2
first.
• If there is a display error in the LCD, only that part is indi-
cated in black.
• An LCD panel, as one of its characteristics, sometimes
shows black spots (spots that remain unlit) and bright
spots (spots that do not go off).
If the number of the bright points and black points does not
exceed 10, the LCD panel is not faulty or defective.
• To return to the former screen, press any one of the func-
tion switches.
30-150 D155AX-8
CHECKING FUNCTION OF SERVICE METER

When checking the service meter with the starting switch in
OFF position, operate the numeral input switches as follows to
display only the service meter section.
Operate the switches (simultaneously): 4 + 1
REMARK
• There is some time lag in start of the LCD, so hold down
the switches until the service meter is displayed.
• If you release one of the switches, the monitor goes off.
• After the machine monitor is used continuously over a long
period of time, blue points (points that remain lit) may ap-
pear on this screen. It does not indicate that the LCD panel
is faulty or defective.
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE

PASSWORD
On the machine monitor, a password can be set as a user limitation setting. If the password has been set, a
password enter screen is displayed for resetting of maintenance items.
Perform the Usage Limitation Setting and Change Password functions according to the following procedure.
1. While the standard screen is displayed, perform the follow-
ing operation with the numeral input switches.
Switch operation (While pressing 4, press other switches
in order): 4 + 5 → 5 → 5
REMARK
This switch operation is available in 10 minutes after the
starting switch is turned to ON position.
D155AX-8 30-151
2. On “Usage Limitation Password” screen, input the current

password with the numeral input switches and enter it with
the function switch.
F5: Clears inputted numbers/Returns the screen to the
standard screen.
F6: Enters inputted password.
REMARK
• Default password: 000000
• When the inputted password is correct, the screen
changes to the next screen.
• When the inputted password is incorrect, a message to
request inputting the password again is displayed.
• The password for the usage limitation and the engine
start lock password are the same in default setting.
3. On “Usage Limitation Setting” screen, select a setting with
the function switch.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Cancels the selection and returns the screen to the
previous screen.
F6: Enters the selection.
4. On “Usage Limitation ON/OFF” screen, select a setting

with the function switch.
OFF: Password enter screen is not displayed.
ON: Displays the password enter screen for resetting of
maintenance items.
F5: Cancels the selection and returns the screen to the
previous screen.
5. On “Usage Limitation New Password Input” screen, input a
new password with the numeral input switches and enter it
• F5: Clears inputted numbers/Returns the screen to the
previous screen.
• F6: Enters inputted password.
REMARK
• Default password: 000000
• When the inputted password is correct, the screen
changes to the next screen.
• When the inputted password is incorrect, a message to
request inputting the password again is displayed.
• Set a new password of 4 to 6 digits (If it has only 3 or
less digits or has 7 or more digits, it is not accepted).
30-152 D155AX-8
6. On “Usage Limitation New Password Input”, input a new

password again with the numeral input switches and enter
it with the function switch.
F5: Clears the inputted numbers/Returns the screen to the
standard screen.
F6: Enters the inputted password.
REMARK
If the input password is different from the one inputted be-
fore, a message to request inputting again is displayed.
“Usage Limitation Setting”screen is displayed after the

screen to notify the completion of setting, and the pass-
word has been changed successfully.
SERVICE MODE
METHOD FOR OPERATING SERVICE MODE
To change the mode of the machine monitor to the service mode from the operator mode, perform the following
operation.
This operation is always required when you use the service mode.
1. While the standard screen is displayed, perform the follow-
ing operation with the numeral input switches.
Switch operation (While pressing 4, press other switches
in order): 4 + 1 → 2 → 3
REMARK
Switching operation is effective only while the standard
screen is displayed.
D155AX-8 30-153
2. When “Service Menu” screen is displayed, the service

mode is selected. Select a service menu you use with the
function switches or numeral input switches.
F5: Returns the screen to the standard screen (operator
mode).
REMARK
• Input a code (2-digit) with the numeral input switches to
directly select the menu, and then press F6 to enter the
selection.
• Items with 2-digit codes are the menus displayed on
“Service Menu” screen. The items on the right are the
menus on the next hierarchy.
The following shows the items selectable with “Service Menu” (including some items which need special
switching operations).
The menu items which can be selected in "Service Menu".

Code Item Reference page
METHOD FOR CHECKING PRE-DEFINED MONITORING
01 Pre-defined Monitoring
INFORMATION (30-155)
METHOD FOR CHECKING SELF-DEFINE MONITORING
02 Self-define Monitoring
INFORMATION (30-161)
Mechanical Sys Abnormali- METHOD FOR CONFIRMING ABNORMALITY RECORD
Abnormality ty Record (MECHANICAL SYSTEMS) (30-171)
03
Record Electrical Sys Abnormality METHOD FOR CONFIRMING ABNORMALITY RECORD
Record (ELECTRICAL SYSTEMS) (30-173)
METHOD FOR CONFIRMING MAINTENANCE RECORD
04 Maintenance Record
(30-176)
METHOD FOR OPERATING MAINTENANCE MODE SET-
05 Maintenance Mode Setting
TING (30-177)
METHOD FOR OPERATING PHONE NUMBER ENTRY
06 Phone Number Entry
SETTING (30-181)
METHOD FOR SETTING WITH DEFAULT SETTING MENU
Key-on mode
(KEY-ON MODE) (30-181)
Unit
(UNIT) (30-182)
07 Default Camera setting
(CAMERA) (30-183)
Float buzzer
(FLOAT BUZZER) (30-187)
Auto Idle Stop Time Fixing
(AUTO IDLE STOP TIMER FIXING) (30-188)
30-154 D155AX-8
Code Item Reference page

Cylinder Cutout Mode Op- METHOD FOR OPERATING TESTING MENU (CYLINDER
eration CUT-OUT OPERATION) (30-189)
Active Regeneration for METHOD FOR OPERATING TESTING MENU (REGENER-
Service ATION FOR SERVICE) (30-191)
METHOD FOR OPERATING TESTING MENU (KDPF MEM-
KDPF Memory Reset
ORY RESET) (30-193)
METHOD FOR OPERATING TESTING MENU (SCR SERV-
SCR Service Test
ICE TEST) (30-194)
Diagnostic
08 Engine Controller Active METHOD FOR SETTING WITH TESTING MENU (ENGINE
Tests
Fault Clear CONTROLLER ACTIVE FAULT CLEAR) (30-195)
Ash in Soot Accumulation METHOD FOR OPERATING TESTING MENU (ASH IN
Correction SOOT ACCUMULATION CORRECTION) (30-195)
Reset Number of Abrupt METHOD FOR OPERATING TESTING MENU (RESET
Engine Stop by AIS NUMBER OF ABRUPT ENGINE STOP BY AIS) (30-197)
METHOD FOR OPERATING TESTING MENU (ENGINE
Engine Stop at AdBlue/DEF
STOP AdBlue/DEF INJ OVERHEAT COUNT RESET)
Inj Overheat Count Reset
(30-197)
09 Adjustment VARIOUS SETTINGS OF MACHINE (30-198)
METHOD FOR PERFORMING NO INJECTION CRANKING
10 No-Injection Cranking
(30-264)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TER-
Terminal Status
MINAL STATUS) (30-265)
KOMTRAX GPS & Communication METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS
11
Settings State AND COMMUNICATION STATUS) (30-266)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MO-
Modem Information
DEM STATUS) (30-267)
12 Service Message METHOD FOR DISPLAYING SERVICE MESSAGE (30-267)
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION

The machine monitor can monitor the condition of the machine in real time by receiving signals from switches,
sensors, and actuators installed to various parts of the machine and the information from the controllers which is
controlling switches, etc.
In “Pre-defined Monitoring”, frequently used monitoring items in daily work are selected beforehand.
1. Select “Pre-defined Monitoring” on “Service Menu” screen.
D155AX-8 30-155
2. On “Pre-defined Monitoring”, select an item to be set by

using the function switches.
F1: Moves the screen to next page (screen).
F2: Returns the screen to previous page (screen).
F4: Selects hold or releasing hold (When Hold is selected,
“HOLD” part is hatched.)
F5: Returns the screen to “Service Menu” screen.
REMARK
For the items not displayed in “Pre-defined Monitoring”,
you can freely select and check from “Self-define Monitor-
ing” items.
TABLE OF PRE-DEFINED MONITORING ITEMS

Pre-defined Monitoring (01/22) Machine basics (1)
Unit Applicable
No. ID Item name
SI Metric Imperial component
1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C °F ENG
3 37200 Engine Oil Pressure Sensor kPa kg/cm2 psi ENG
4 18400 Intake Temperature °C °C °F ENG
5 30100 T/C Oil Temperature °C °C °F P/T
6 04413 Hydraulic Oil Temperature °C °C °F W/E

Unit Applicable
No. ID Item name

2 03204 Battery Power Supply V V V ENG
3 04300 Battery Charge Voltage V V V MON

Unit Applicable
No. ID Item name

2 32601 T/C Inlet Pressure MPa kg/cm2 psi P/T
3 32603 T/C Outlet Pressure MPa kg/cm2 psi P/T
4 70704 Hydraulic Oil Pump Pressure 1 MPa kg/cm2 psi W/E
Pre-defined Monitoring (04/22) Cooling fan

Unit Applicable
No. ID Item name

2 04107 Coolant Temperature r/min rpm rpm ENG
30-156 D155AX-8
Unit Applicable
No. ID Item name

4 30100 T/C Oil Temperature °C °C °F P/T
5 10007 Fan Speed r/min rpm rpm P/T
6 31624 Fan Pump EPC Solenoid Current mA mA mA P/T
Pre-defined Monitoring (05/22) Fuel injection

Unit Applicable
No. ID Item name

2 47300 KDOC 1 Inlet Temperature °C °C °F KDPF
3 36400 Rail Pressure kPa kg/cm2 psi ENG
4 36200 Rail Pressure Command kPa kg/cm2 psi ENG

5 17201 PCV Close Timing (TDC Standard) CA CA CA ENG
Pre-defined Monitoring (06/22) EGR, KVGT

Unit Applicable
No. ID Item name

2 48100 Turbocharger Speed r/min rpm rpm ENG
3 18100 EGR Valve Position mm mm in ENG
4 48600 EGR Solenoid Current mA mA mA ENG
5 48700 KVGT Position mm mm in ENG
6 48800 KVGT Solenoid Current mA mA mA ENG
Pre-defined Monitoring (07/22) Engine temperature

Unit Applicable
No. ID Item name

5 18500 Charge Temperature °C °C °F ENG
Pre-defined Monitoring (08/22) Intake temperature

Unit Applicable
No. ID Item name

3 37400 Ambient Pressure kPa kg/cm2 psi ENG
D155AX-8 30-157
Unit Applicable
No. ID Item name
4 36500 Charge Pressure kPa kg/cm2 psi ENG

6 48200 MAF kg/min kg/min lb/min ENG
Pre-defined Monitoring (09/22) KDPF

Unit Applicable
No. ID Item name
1 47000 KDPF Outlet Pressure kPa kg/cm2 psi KDPF
2 47100 KDPF Differential Pressure kPa kg/cm2 psi KDPF

3 47200 KDPF 1 Outlet Temperature °C °C °F KDPF
5 47400 KDOC 1 Outlet Temperature °C °C °F KDPF
6 47600 Dosing Fuel Pressure kPa kg/cm2 psi KDPF
Pre-defined Monitoring (10/22) Transmission clutch

Unit Applicable
No. ID Item name
1 31622 T/M Forward Clutch ECMV Current mA mA mA P/T

2 31616 T/M Reverse Clutch ECMV Current mA mA mA P/T
3 31612 T/M 1st Clutch ECMV Current mA mA mA P/T
4 31613 T/M 2nd Clutch ECMV Current mA mA mA P/T
5 31614 T/M 3rd Clutch ECMV Current mA mA mA P/T
6 31400 T/M Output Speed r/min rpm rpm P/T
Pre-defined Monitoring (11/22) Steering clutch

Unit Applicable
No. ID Item name
1 50600 Left HSS EPC Solenoid Current mA mA mA P/T

2 50601 Right HSS EPC Solenoid Current mA mA mA P/T
3 31619 Left Brake ECMV Current mA mA mA P/T
4 31618 Right Brake ECMV Current mA mA mA P/T
5 50400 Brake Pedal Potentiometer Volt mV mV mV P/T
Pre-defined Monitoring (12/22) Blade

Unit Applicable
No. ID Item name
1 71001 Blade Lift Cyl Head EPC Sol Cur mA mA mA W/E

2 71003 Blade Lift Cyl Btm EPC Sol Cur mA mA mA W/E
3 71005 LH Blade Tilt Cyl Head EPC Sol mA mA mA W/E
30-158 D155AX-8
Unit Applicable
No. ID Item name
4 71007 LH Blade Tilt Cyl Bottom EPC Sol mA mA mA W/E

Pre-defined Monitoring (13/22) Ripper

Unit Applicable
No. ID Item name
Ripper Lift Cylinder Head EPC Solenoid

1 71101 mA mA mA W/E
Current
Ripper Lift Cylinder Bottom EPC Sole-
2 71103 mA mA mA W/E
noid Current
3 71105 Ripper tilt in EPC current mA mA mA W/E
4 71107 Ripper tilt back EPC current mA mA mA W/E
Pre-defined Monitoring (14/22) Operation basics

Unit Applicable
No. ID Item name

2 18600 Inject Fueling Command mg/st mg/st mg/st ENG
3 19200 Exhaust Gas Flow Rate kL/h kL/h kgal/h SCR
5 19300 SCR Temperature °C °C °F SCR
6 19302 SCR Outlet Temperature °C °C °F SCR
Pre-defined Monitoring (15/22) AdBlue/DEF injector

Unit Applicable
No. ID Item name
1 47200 KDPF 1 Outlet Temperature °C °C KDPF KDPF

2 19304 AdBlue/DEF Pump State - - - SCR
3 19120 AdBlue/DEF Injection Quantity ml/sec ml/sec gal/sec SCR
4 19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
5 19202 Turbo Outlet NOx Corrected ppm ppm ppm SCR
6 19209 SCR Outlet NOx Corrected ppm ppm ppm SCR
Pre-defined Monitoring (16/22) AdBlue/DEF pump

Unit Applicable
No. ID Item name
D155AX-8 30-159
Unit Applicable
No. ID Item name
2 19108 AdBlue/DEF Pump Pressure kPa kg/cm2 psi SCR

3 19109 AdBlue/DEF Pump PressSensor Volt V V V SCR
5 19136 AdBlue/DEF Pump Temperature °C °C °F SCR
6 19114 AdBlue/DEF Reverting Valve Cmd - - - SCR
Pre-defined Monitoring (17/22) SCR sensor

Unit Applicable
No. ID Item name

2 19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
3 19202 Turbo Outlet NOx Corrected ppm ppm ppm SCR
4 19209 SCR Outlet NOx Corrected ppm ppm ppm SCR
5 19203 Turbo Outlet NOx Sensor State - - - SCR
6 19210 SCR Outlet NOx Sensor State - - - SCR
Pre-defined Monitoring (18/22) AdBlue/DEF tank sensor

Unit Applicable
No. ID Item name
1 19100 AdBlue/DEF Concentration % % % SCR

2 19110 AdBlue/DEF Level % % % SCR
3 19111 AdBlue/DEF Level Corrected % % % SCR
4 19115 AdBlue/DEF Temperature in Tank °C °C °F SCR
5 19400 Ambient Temperature °C °C °F SCR
6 19305 AdBlue/DEF Tank Heating State - - - SCR
Pre-defined Monitoring (19/22) AdBlue/DEF tank unfreeze control

Unit Applicable
No. ID Item name
1 19305 AdBlue/DEF Tank Heating State - - - SCR

2 19102 AdBlue/DEF Tank HtrValve Command - - - SCR
Pre-defined Monitoring (20/22) AdBlue/DEF pump unfreeze control

Unit Applicable
No. ID Item name
1 19107 AdBlue/DEF Pump Heater 1 Command - - - SCR

2 19309 AdBlue/DEF Pump Heater State - - - SCR
30-160 D155AX-8
Unit Applicable
No. ID Item name
3 19136 AdBlue/DEF Pump Temperature °C °C °F SCR

6 03204 Battery Power Supply V V V ENG
Pre-defined Monitoring (21/22) AdBlue/DEF hose unfreeze control

Unit Applicable
No. ID Item name
1 19306 AdBlue/DEF Line Heater 1 State - - - SCR

2 19106 AdBlue/DEF Line Heater 1 Command - - - SCR
3 19307 AdBlue/DEF Line Heater 2 State - - - SCR
4 19135 AdBlue/DEF Line Heater 2 Command - - - SCR
Pre-defined Monitoring (22/22) Operating environment

Unit Applicable
No. ID Item name
1 37400 Ambient Pressure kPa kg/cm2 psi ENG

METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION

The machine monitor can monitor the condition of the machine in real time by receiving signals from switches,
sensors, and actuators installed to various parts of the machine and the information from the controllers which is
controlling switches, etc.
“Self-define Monitoring” is used to select a desired monitoring item.
1. Select “Monitoring” on “Service Menu” screen.
D155AX-8 30-161
2. On“Monitoring Selection Menu” screen, select items to be

monitored by using the function switches or numeral input
switches.
F1: Moves the selection leftward.
F2: Moves the selection rightward.
F5: Clears input numbers/Returns the screen to “Service
Menu” screen.
REMARK
• For the setting of the monitoring, each time function switch F2 is pressed, sequential switching among
“ENG”→“KDPF”→“SCR”→“P/T”→“W/E”→“MON”→“ENG” takes place in this order. (Press F1 to reverse
the order.)
• For the selection with function switches, select an applicable equipment with F1 or F2, and select an
item with F3 or F4, and then enter it with F6.
• For the selection with numeral input switches, enter a 5-digit code, and the item of that code is selected
directly, and then enter it with F6.
• If the color of the box displaying the selected item's monitoring code changes from yellow to red, the
selection of the item of that box is entered.
• 6 monitoring items at maximum can be selected at the same time. However, it may not be possible to
set up to 6 items depending on the display pattern of the selected items.
3. After selecting monitoring items, execute monitoring with
the function switch or numeral input switch.
REMARK
• Execution with function switch: Double click or press
F6 long (for approximately 2 seconds).
• Execution with numeral input switch: Input “99999” and
press F6.
• If monitoring items are selected up to the limit number,
monitoring is executed automatically.
• When monitoring only two items, select them and con-
firm with F6. If F6 is pressed once more at this time,
monitoring is executed.
4. On “Monitoring” screen, perform the necessary operation
of the machine and check the monitoring information.
“Monitoring” screen displays the following information.
a: Monitoring information
b: Operating mode
c: Gear speed display (travel gear speed, gear shift mode,
preset mode)
d: Coolant temperature
e: Hydraulic oil temperature
f: Power train oil temperature
REMARK
• Monitoring information is indicated by value, ON/OFF, or special display.
• The unit of display can be selected from among “SI”, “metric”, and “Imperial” in “Default” screen from
“Service Menu”.
30-162 D155AX-8
5. Regarding monitoring information, the screen displaying

real-time data can be held or released by using function
switches.
F4: Selects hold or releasing hold (If Hold is selected,
F5: Returns the screen to “Monitoring Selection” menu
screen.
6. To change the setting of the operating mode (engine oper-

ation mode) or working/travel mode (gear shift mode) dur-
ing monitoring, operate the corresponding switch under the
current condition to turn on the applicable mode.
REMARK
If the setting is changed during monitoring, the new setting
is held even after the screen returns to the ordinary screen
after monitoring is finished.
A selected monitoring item can be saved or deleted by us-

ing function switches.
F1: “MEMORY” Saves a monitoring item.
F2: “CLEAR” Clears a monitoring item.
REMARK
• When a monitoring item is saved, a confirmation
screen appears asking whether the saved item should
be displayed or not when “Self-define Monitoring” is se-
lected again.
• When an item is saved, it can be displayed as many
times as required unless it is cleared.
• If another item is saved while having the previous item
saved, the previously saved item is overwritten by the
latest one.
TABLE OF SELF-DEFINE MONITORING

Unit (Default: SI) Applicable
Code No. Monitoring item (display on screen) Remarks
00201 Machine ID - ENG

01002 Engine Speed r/min rpm rpm ENG
04107 Coolant Temperature °C °C °F ENG
03204 Battery Power Supply V V V ENG
32720 Engine Oil Pressure Sensor ON/OFF ENG
D155AX-8 30-163

36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG

18400 Intake Temperature °C °C °F ENG
18500 Charge Temperature °C °C °F ENG
Display of abso-
lute value (in-
36500 Charge Pressure kPa kg/cm2 psi ENG
cluding ambient
pressure)
48100 Turbocharger Speed r/min rpm rpm ENG
48200 MAF kg/min kg/min lb/min ENG
48400 Crankcase Pressure kPa mmAq psi ENG
18100 EGR Valve Position mm mm in ENG
48600 EGR Solenoid Current mA mA mA ENG
48500 EGR Orifice Temperature °C °C °F ENG
48501 EGR Orifice Temp Sensor Voltage V V V ENG
48700 KVGT Position mm mm in ENG
48800 KVGT Solenoid Current mA mA mA ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
04105 Coolant Temperature Sensor Volt V V V ENG
37201 Engine Oil Pressure Sensor Volt V V V ENG
37401 Ambient Pressure Sensor Voltage V V V ENG
18401 Intake Temperature Sensor Volt V V V ENG
18501 Charge Temperature Sensor Volt V V V ENG
36501 Charge Pressure Sensor Voltage V V V ENG
36401 Rail Pressure Sensor Voltage V V V ENG
48401 Crankcase Pressure Sensor Volt V V V ENG
18101 EGR Valve Position Sensor Volt V V V ENG
48701 KVGT Position Sensor Voltage V V V ENG
17201 PCV Close Timing (TDC Standard) CA CA CA ENG
17500 Engine Power Mode Selection - ENG
48900 Engine Operation Mode - ENG
31701 Decelerator Pedal Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Pressure Command MPa kg/cm2 psi ENG
37300 Instantaneous Fuel Consumption (*1) l/h l/h l/h ENG
20216 Engine Controller Build Version - ENG
30-164 D155AX-8

20217 Engine Con Calibration Data Ver - ENG

18900 Engine Con Internal Temperature °C °C °F ENG
20400 Engine Controller S/N - ENG
31703 Decel Pedal Position Sensor Volt V V V ENG
38200 Engine State - ENG
38300 OFC Limit Inject Fueling mg/st mg/st mg/st ENG
47000 KDPF Outlet Pressure kPa kg/cm2 psi KDPF
47001 KDPF Outlet Pressure Sensor Volt V V V KDPF
47100 KDPF Differential Pressure kPa kg/cm2 psi KDPF
47101 KDPF Diff Pressure Sensor Volt V V V KDPF
47300 KDOC 1 Inlet Temperature °C °C °F KDPF
47400 KDOC 1 Outlet Temperature °C °C °F KDPF
47200 KDPF 1 Outlet Temperature °C °C °F KDPF
47500 Dosing Instant Fuel Consumption l/h l/h gal/h KDPF
47600 Dosing Fuel Pressure kPa kg/cm2 psi KDPF
47601 Dosing Fuel Pressure Sensor Volt V V V KDPF
47700 Soot Accumulation g/L g/L g/gal KDPF
47802 Soot Correction by Ash Influence g/L g/L g/gal KDPF
19100 AdBlue/DEF Concentration % % % SCR
19200 Exhaust Gas Flow Rate kL/h kL/h kgal/h SCR
19201 Turbo Outlet NOx Concentration ppm ppm ppm SCR
19202 Turbo Outlet NOx Concentration Corrected ppm ppm ppm SCR
0: Unmeasurable
19203 Turbo Outlet NOx Sensor State - - - SCR 1: Being meas-
ured
19204 SCR NH3 Concentration ppm ppm ppm SCR
19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
0: Unstable
19206 SCR NH3 Sensor Stability State - - - SCR 1: Stable
2: Error
0: Unmeasurable
19207 SCR NH3 Sensor State - - - SCR 1: Being meas-
ured
19208 SCR Outlet NOx Concentration ppm ppm ppm SCR
SCR Outlet NOx Concentration (compensa-
19209 ppm ppm ppm SCR
tion value)
0: Unmeasurable
19210 SCR Outlet NOx Sensor State - - - SCR 1: Being meas-
ured
D155AX-8 30-165

0: CLOSED
19102 AdBlue/DEF Tank HtrValve Command - - - SCR
1: OPEN
19103 AdBlue/DEF Level Low Error 1 % % % SCR
0: OFF
19106 AdBlue/DEF Line Heater 1 Command - - - SCR
1: ON
0: OFF
19107 AdBlue/DEF Pump Heater 1 Command - - - SCR
1: ON
19108 AdBlue/DEF Pump Pressure kPa kg/cm2 psi SCR
19109 AdBlue/DEF Pump Press Sensor Volt V V V SCR
19110 AdBlue/DEF Level % % % SCR
19111 AdBlue/DEF Corrected % % % SCR
0: CLOSED
19114 AdBlue/DEF Reverting Valve Cmd - - - SCR
1: OPEN
19300 SCR Temperature °C °C °F SCR
19302 SCR Outlet Temperature °C °C °F SCR
0: Initial state
1: Stop injection
19304 AdBlue/DEF Pump State - - - SCR 2: Pressure-fed
3: Being injected
4: Being purged
1: Being thawed
2: Being kept
19305 AdBlue/DEF Tank Heating State - - - SCR
warm
3: OFF
1: Being thawed
2: Being kept
19306 AdBlue/DEF Line Heater 1 State - - - SCR
warm
3: OFF
1: Being thawed
2: Being kept
19307 AdBlue/DEF Line Heater 2 State - - - SCR
warm
3: OFF
0: OFF
1: Being thawed
19309 AdBlue/DEF Pump Heater State - - - SCR 2: Being kept
warm
3: OFF
19115 AdBlue/DEF Temperature in Tank °C °C °F SCR
19119 Total AdBlue/DEF Injection Qty L L gal SCR
30-166 D155AX-8

19120 AdBlue/DEF Injection Quantity ml/sec ml/sec gal/sec SCR

19400 Ambient Temperature °C °C °F SCR
19401 Ambient Temperature Sensor Volt V V V SCR
19130 AdBlue/DEF Key off Refill Count - - - SCR
19133 Engine Room Temperature °C °C °F SCR
19134 Engine Room Temp Sensor Voltage V V V SCR
0: OFF
19135 AdBlue/DEF Line Heater 2 Command - - - SCR
1: ON
19136 AdBlue/DEF Pump Temperature °C °C °F SCR
19137 Total AdBlue/DEF Heating Time h h h SCR
20242 P/T Controller Assembly P/N - P/T
20243 P/T Controller Program P/N - P/T
20404 P/T Controller S/N - P/T
32900 Machine Pitch Angle deg. deg. deg. P/T
60100 Machine Pitch Angle Sensor Volt mV mV mV P/T
03000 Fuel Dial Sensor Voltage mV mV mV P/T
03001 Fuel Dial Throttle % % % P/T
30100 T/C Oil Temperature °C °C °F P/T
30101 T/C Oil Temperature Sens Voltage mV mV mV P/T
32601 T/C Inlet Pressure MPa kg/cm2 psi P/T
32602 T/C Inlet Pressure Sens Voltage mV mV mV P/T
32603 T/C Outlet Pressure MPa kg/cm2 psi P/T
32604 T/C Outlet Pressure Sens Voltage mV mV mV P/T
50200 T/M Lever Potentiometer1 Voltage mV mV mV P/T
50201 T/M Lever Potentiometer2 Voltage mV mV mV P/T
50300 S/T Lever Potentiometer1 Voltage mV mV mV P/T
50301 S/T Lever Potentiometer2 Voltage mV mV mV P/T
50400 Brake Pedal Potentiometer Volt mV mV mV P/T
31400 T/M Output Speed r/min rpm rpm P/T
70200 T/M Output Speed Sensor Voltage mV mV mV P/T
Forward Fill SW ON/OFF P/T
Reverse Fill SW ON/OFF P/T
40906 T/M Fill Sw Input1 1st Fill SW ON/OFF P/T
2nd Fill SW ON/OFF P/T
3rd Fill SW ON/OFF P/T
T/M Fill SW Input Lockup Fill SW ON/OFF P/T

31520
2 S/T Clutch Fill SW ON/OFF P/T
D155AX-8 30-167

Left Brake Fill SW ON/OFF P/T

31521 S/T Fill SW Input
Right Brake Fill SW ON/OFF P/T
Shift Up SW NC ON/OFF P/T
Shift Up SW NO ON/OFF P/T
Shift Down SW NC ON/OFF P/T
P/T Controller SW Shift Down SW NO ON/OFF P/T
40905
Input 1
Parking Brake Lock SW
ON/OFF P/T
NC
Parking Brake Lock SW
ON/OFF P/T
NO
P/T Controller SW C Signal ON/OFF P/T

40912
Input 2 R Signal ON/OFF P/T
P/T Controller SW Brake Pedal SW NC ON/OFF P/T

40984
Input 3 Brake Pedal SW NO ON/OFF P/T
31622 T/M Forward Clutch ECMV Current mA mA mA P/T
31616 T/M Reverse Clutch ECMV Current mA mA mA P/T
31612 T/M 1st Clutch ECMV Current mA mA mA P/T
31613 T/M 2nd Clutch ECMV Current mA mA mA P/T
31614 T/M 3rd Clutch ECMV Current mA mA mA P/T
31642 Lockup ECMV Current mA mA mA P/T
90700 S/T Clutch ECMV Current mA mA mA P/T
31619 Left Brake ECMV Current mA mA mA P/T
31618 Right Brake ECMV Current mA mA mA P/T
50600 Left HSS EPC Solenoid Current mA mA mA P/T
50601 Right HSS EPC Solenoid Current mA mA mA P/T
31628 Sudden Stop Prevention Valve Cur mA mA mA P/T
P/T Controller SW Backup Alarm ON/OFF P/T

40909
Output Neutral Safety ON/OFF P/T
40001 Theoretical Travel Speed km/h km/h mile/h P/T
60000 Theoretical Traction W W W P/T
10000 Fan Speed command r/min rpm rpm P/T
10007 Fan Speed r/min rpm rpm P/T
10013 Fan Speed Sensor Voltage V V V P/T
31624 Fan Pump EPC Solenoid Current mA mA mA P/T
20244 W/E Controller Ass'y P/N string string string W/E
20245 W/E Controller Program P/N string string string W/E
20405 W/E Controller S/N string string string W/E
70704 Hydraulic Oil Pump Pressure 1 MPa kg/cm2 psi W/E
30-168 D155AX-8

70705 Hyd Oil Pump Pressure1 Sens Volt mV mV mV W/E

04413 Hydraulic Oil Temperature °C °C °F W/E
04414 Hydraulic Oil Temp Sensor Volt V V V W/E
73400 Blade Lift Lever 1 Potentiometer Voltage mV mV mV W/E
73401 Blade Lift Lever Potentiometer 2 Voltage mV mV mV W/E
73500 Blade Tilt Lever Potentio 1 Volt mV mV mV W/E
73501 Blade Tilt Lever Potentio 2 Volt mV mV mV W/E
73700 Ripper Lift Lever Potentio1 Volt mV mV mV W/E
73701 Ripper Lift Lever Potentio2 Volt mV mV mV W/E
Engine Low Idle ON/OFF W/E
W/E Controller
40981 R Signal ON/OFF W/E
SW Input 1
C Signal ON/OFF W/E
W/E Lock SW NC ON/OFF W/E
Blade Knob SW W/E Lock SW NO ON/OFF W/E

70302
Input 1 Float SW NC ON/OFF W/E
Float SW NO ON/OFF W/E
Pitch Dump SW 1 NO ON/OFF W/E
Pitch Dump SW 2 NO ON/OFF W/E
Blade Knob SW Pitch Back SW 1 NO ON/OFF W/E

70303
Input 2 Pitch Back SW 2 NO ON/OFF W/E
Auto Pitch SW NC ON/OFF W/E
Auto Pitch SW NO ON/OFF W/E
Tilt In SW 1 NO ON/OFF W/E
Ripper Knob Sw Tilt In SW 2 NO ON/OFF W/E

70307
Input Tilt Back SW 1 NO ON/OFF W/E
Tilt Back SW 2 NO ON/OFF W/E
01353 Pump TVC Solenoid Current mA mA mA W/E
71001 Blade Lift Cyl Head EPC Sol Cur mA mA mA W/E
71003 Blade Lift Cyl Btm EPC Sol Cur mA mA mA W/E
71005 LH Blade Tilt Cyl Head EPC Sol mA mA mA W/E
71007 LH Blade Tilt Cyl Bottom EPC Sol mA mA mA W/E
90800 RH Blade Tilt Cyl Head EPC Sol mA mA mA W/E
90801 RH Blade Tilt Cyl Bottom EPC Sol mA mA mA W/E
71101 Ripper Lift Cyl Head EPC Sol mA mA mA W/E
71103 Ripper Lift Cyl Bottom EPC Sol mA mA mA W/E
71105 Ripper Tilt In EPC Sol Current mA mA mA W/E
71107 Ripper Tilt Back EPC Sol Current mA mA mA W/E
90900 Quick Drop Solenoid Current mA mA mA W/E
D155AX-8 30-169

60601 Battery Relay Drive Voltage mV mV mV W/E

W/E Controller
40983 Engine Hold ON/OFF W/E
SW Output
04300 Battery Charge Voltage V V V MON
04200 Fuel Level Sensor Voltage V V V MON
Key SW ON/OFF MON
Start ON/OFF MON
04500 Monitor Input 1 Preheat ON/OFF MON
Light ON/OFF MON
Engine Coolant Level ON/OFF MON
Air Cleaner ON/OFF MON
04501 Monitor Input 2
Battery Charge Voltage ON/OFF MON
Engine Shutdown 2nd
ON/OFF MON
04502 Monitor Input 3 SW
Seat Belt SW ON/OFF MON
F1 ON/OFF MON
F2 ON/OFF MON
Monitor Function F3 ON/OFF MON

04503
SW F4 ON/OFF MON
F5 ON/OFF MON
F6 ON/OFF MON
SW1 ON/OFF MON
SW2 ON/OFF MON
Monitor 1st & 2nd SW3 ON/OFF MON

04504
Row SW SW4 ON/OFF MON
SW5 ON/OFF MON
SW6 ON/OFF MON
SW7 ON/OFF MON
SW8 ON/OFF MON
Monitor 3rd & 4th SW9 ON/OFF MON

04505
Row SW SW10 ON/OFF MON
SW11 ON/OFF MON
SW12 ON/OFF MON
SW13 ON/OFF MON
Monitor 5th Row
04506 SW14 ON/OFF MON
SW
SW15 ON/OFF MON
00500 Monitor Model Code - MON
20227 Monitor Assembly P/N - MON
30-170 D155AX-8

20402 Monitor S/N - MON

20228 Monitor Program P/N - MON
20221 Monitor Program Version - MON
55300 A/C Compressor State ON/OFF MON
55000 A/C Fresh Air Temp Code - MON
55100 A/C Recirc Air Temp Code - MON
55200 A/C Mode Data (Monitor) - MON
55201 A/C Mode Data (A/C ECU) - MON
20260 KOMTRAX Assembly P/N - MON
20418 KOMTRAX S/N - MON
20261 KOMTRAX Program P/N - MON
20273 KOMTRAX Program Version - MON
20262 ID Key Controller Assembly P/N - MON
20419 ID Key Controller S/N - MON
20263 ID Key Controller Program P/N - MON
*1: Instantaneous fuel consumption (Code No: 37300) is the theoretical fuel consumption ratio. (Since it is a the-
oretical value, it is slightly different from the actual fuel consumption ratio).
• Listing order in table
The monitoring items are listed in the order of the display on “Monitoring Selection Menu” screen.
• Unit
The display unit can be set to “SI”, “Metric”, or “Imperial” as required (select a desired unit from “Unit” of
“Default” in “Service Menu”).
“mg/st” in the display unit is an abbreviation for milligram/stroke.
• Applicable component
“ENG”: The engine controller detects the monitoring information.
“KDPF”: The engine controller detects the monitoring information of KDPF.
“SCR”: The engine controller detects the monitoring information of SCR.
“P/T”: The power train controller detects monitoring information.
“W/E”: The work equipment controller detects monitoring information.
“MON”: The machine monitor detects the monitoring information.
ABNORMALITY RECORD MENU

METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYS-
TEMS)
The machine monitor logs the past and currently occurring failures classifying them into the mechanical system
abnormality and electrical system abnormality.
To check the mechanical system abnormality record, perform the following procedures.
For the failure code list, see “Failure code list”for troubleshooting.
D155AX-8 30-171
1. Select “Abnormality Record” on “Service Menu” screen.
2. On “Abnormality Record ”screen, select “Mechanical Sys

Abnormality Record” with the function switches or numeral
input switches.
F3: Moves the selection downward
F4: Moves the selection upward
F6: Enters the selection
REMARK
Input a code (2-digit) with the numeral input switches to di-
rectly select the item, and then press F6 to enter the selec-
tion.
3. On “Mechanical Sys Abnormality Record” screen, the fol-
lowing information is displayed.
a: Occurrence order of abnormalities from latest one/ Total
number of records
b: Failure code
c: Detail of failure
d: Number of occurrences (displayable range: 0 to 65535
times)
e: Service meter reading at the first occurrence
f: Service meter reading at the last occurrence
F1: Moves the selection to next page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F2: Moves the selection to previous page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F5: Returns the screen to “Abnormality Record” screen.
F6: Display of contents of failure is scrolled from right to left again
30-172 D155AX-8
REMARK
• If no abnormality is recorded, “No Abnormality Record” is displayed.
• In the mechanical systems abnormality record screen, up to 50 cases currently stored are displayed.
• If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and
that at the last occurrence are the same. When the latest service meter reading is recovered, the value
at the recovery time is displayed, thus the above readings may not be the same.
• If “E” is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not
confirmed.
• For all of the failure codes that the machine monitor can record, see “Troubleshooting”, “Failure code
list”.
• If the characters in the failure are many, the character strings display is scrolled.
• The contents of an abnormality record of the mechanical system cannot be deleted.
METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS)

The machine monitor logs the past and currently occurring failures classifying them into the mechanical system
abnormality and electrical system abnormality.
To check the electrical system abnormality record, perform the following procedures.
For all of the failure codes that the machine monitor can record, see “Troubleshooting”, “Failure code list”.
1. Display “Abnormality Record” on “Service Menu” screen.
2. On “Abnormality Record”screen, select “Electrical Sys Ab-

normality Record” with the function switches or numeral in-
put switches.
F6: Enters the selection
REMARK
rectly select the item, and then press F6 to enter the selec-
tion.
3. On “Electrical Sys Abnormality Record” screen, the follow-
ing information is displayed.
a: Occurrence order of abnormalities from latest one/ Total
number of records
b: Failure code
c: Detail of failure
d: Number of occurrences (displayable range: 0 to 65535
times)
e: Service meter reading at the first occurrence
D155AX-8 30-173
f: Service meter reading at the last occurrence

F1: Moves the selection to next page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F2: Moves the selection to previous page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F5: Returns the screen to “Abnormality Record” screen
F6: Display of contents of failure is scrolled to left again
REMARK
• If no abnormality is recorded, “No Abnormality Record” is displayed.
• On the electrical systems abnormality record screen, up to 20 cases currently stored are displayed. If
the number of abnormality records increases to 21 or beyond, the latest occurrence code is displayed
and the oldest one is deleted.
• If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and
that at the last occurrence are the same.
• If “E” is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not
confirmed.
• For all of the failure codes that the machine monitor can record, see “Troubleshooting”, “Failure code
list”.
• If the characters in the failure are many, the character strings display is scrolled.
4. While “Electrical Sys Abnormality Record” screen is dis-
played, perform the following operation by using the nu-
meral input switches.
1) Switch operation (While pressing 4, press other

switches in order): 4 + 1 → 2 → 3
30-174 D155AX-8
2) Check that the display on the screen becomes the

clear mode, then clear the individual information one
by one or all together by using the function switches.
REMARK
If deleting mode is ON, “CLEAR” is displayed in F2.
F2: Executes the deletion of all the abnormality re-
cords
F5: Returns the screen to “Abnormality Record” screen
F6: Executes the deletion of the selected abnormality records
REMARK
• To delete a selected abnormality record, select the abnormality record with F3 or F4, and then
press F6 to execute the deletion of abnormality record.
• To clear all abnormality records together, press F2, and then all the records are deleted regardless
of the selection.
• If “E” is displayed on the left of a failure code, the clearing operation is accepted but the item is not
cleared.
3) On “Electrical Systems Abnormality Record Reset” screen, operate the function switches.
F5: Returns the screen to “Electrical Sys Abnormality Record” (clear mode)
F6: Executes clearing
REMARK
• This is the screen when a selected abnormality re-
cord is going to be deleted.
• This is the screen when all the abnormality records

are going to be deleted.
4) If the screen to notify completion of clearing is displayed and then “Electrical Sys Abnormality Record”
screen (clear mode) is displayed, the clearing of the abnormality record is complete.
D155AX-8 30-175
REMARK
• This is the screen when the deletion of a selected
abnormality record is completed.
• This is the screen when the deletion of all the ab-

normality record is completed.
METHOD FOR CONFIRMING MAINTENANCE RECORD

The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and
checked by the following operations.
When the maintenance is performed, if the data are reset in the operator mode, the number of the times of
maintenance is recorded here.
1. Select “Maintenance Record” on “Service Menu” screen.
2. On “Maintenance Record” screen, select an item to be

checked with the function switches or numeral input
switches.
F1: Moves the selection to next page (screen).
F2: Moves the selection to previous page (screen).
REMARK
rectly select the item.
30-176 D155AX-8
The following items can be selected on Maintenance Record.

Code Item
49 Air Cleaner Clean and Change
60 Coolant Change
41 Fuel Prefilter Change
01 Engine Oil Change
02 Engine Oil Filter Change
20 P/T Oil Filter Change
03 Fuel Main Filter Change
05 Hydraulic Tank Breather Change
19 P/T Oil Change
70 P/T Case Breather Change
30 Hydraulic Oil Pilot Filter Change
44 Fuel Tank Breather Change
59 AdBlue/DEF Tank Breather Change
04 Hydraulic Oil Filter Change
07 Damper Case Oil Check and Change
08 Final Drive Case Oil Change
10 Hydraulic Oil Change
47 KCCV Filter Change
58 AdBlue/DEF Filter Change
48 KDPF Filter Cleaning
52 Fuel Doser Cleaning
67 AdBlue/DEF Tank Washing
Items displayed on “Maintenance Record” screen
a: Maintenance items
b: Number of replacements up to now
c: Service meter reading (SMR) at the last replacement
METHOD FOR OPERATING MAINTENANCE MODE SETTING

The actuating condition of the maintenance function in the operator mode can be set and changed by this me-
nus.
• To enable or disable the function
• To change the replacement interval setting (by item)
• To initialize all of the replacement interval setting.
D155AX-8 30-177
1. Select “Maintenance Mode Setting” on “Service Menu”

screen.
2. On “Maintenance Mode Setting” screen, select an item to

be changed with the function switches or numeral input
switches.
F1: Moves the selection to next page (screen).
F2: Moves the selection to previous page (screen).
REMARK
Input a code (2-digit) with the numeral input switches to directly select the item, and then press F6 to enter
the selection.
The following items can be selected on the Maintenance Mode Settingscreen.

Code Item
00 Maintenance Mode Change
49 Air Cleaner Cleaning or Change Interval
60 Coolant Change Interval
41 Fuel Pre Filter Change Interval
01 Engine Oil Change Interval
02 Engine Oil Filter Change Interval
20 P/T Oil Filter Change Interval
03 Fuel Main Filter Change Interval
05 Hydraulic Oil Tank Breather Change Interval
19 P/T Oil Change Interval
70 P/T Case Breather Change Interval
30 Hydraulic Oil Pilot Filter Change Interval
44 Fuel Tank Breather Change Interval
04 Hydraulic Oil Filter Change Interval
07 Damper Case Oil Check or Change Interval
08 Final Drive Case Oil Change Interval
10 Hydraulic Oil Change Interval
99 All Default Value
30-178 D155AX-8
3. The screen is shifted by selecting “Maintenance Mode On/

Off” in “Maintenance Mode Change”, and perform the set-
ting with the function switches.
“ON”: Functions of all maintenance items become effective
in operator mode.
“OFF”: Functions of all maintenance items become ineffec-
tive in operator mode
F5: Cancels the selection and returns the screen to “Main-
tenance Mode Change” screen
REMARK
This setting overrides the ON/OFF setting of each item after this change of setting is entered once.
4. The screen is shifted by selecting “Maintenance Notice
Time Setting”, perform the setting with the function
switches.
“Default”: Maintenance notice time being set on the ma-
chine monitor (Recommended by the manufacturer and
not changeable).
“Set”: Maintenance notice time that can be freely set in the
range from 10 to 200 hours. Maintenance reminder func-
tion works according to this set time in operator mode
(the time can be increased or decreased in multiples of
10 hours).
F3: Decreases the set value
F4: Increases the set value
F5: Cancels contents of setting before entry and returns
the screen to “Maintenance Mode Change” screen.
F6: Enters the setting and returns the screen to “Mainte-
nance Mode Change” screen
REMARK
• The setting becomes effective after you enter it with F6
and return the screen to “Maintenance Mode Setting”
screen with F5.
• If the value of an item which is set to “ON” is changed
after one operating hour or more from the setup, the
change is recognized as a reset operation.
5. The screen is shifted by selecting “On or Off Setting” of
each maintenance item, perform the setting with the func-
tion switches.
“ON”: Function of the particular maintenance item be-
comes effective in operator mode.
“OFF”: Function of the particular maintenance item be-
comes ineffective in operator mode.
F3: Moves the set value downward.
F4: Moves the set value upward.
F5: Cancels the selection and returns the screen to "Main-
tenance Mode Change" screen.
D155AX-8 30-179
F6: Enters the selection and returns the screen to "Maintenance Mode Change" screen.
6. The screen is shifted by selecting “set value” of each main-
tenance item, perform the setting with the function
switches.
“Default”: Maintenance set time set on the machine moni-
tor (Recommended by the manufacturer and not
changeable).
“Set”: Maintenance notice time that can be freely set.
Maintenance reminder function works according to this
set time in operator mode (the time can be increased or
decreased in multiples of 25 hours).
F3: Decreases the set value
F4: Increases the set value
the screen to “Maintenance Mode Change” screen.
F6: Enters the setting and returns to each maintenance
item screen.
REMARK
• The setting becomes effective after you enter it with F6
and return the screen to “Maintenance Mode Setting”
screen with F5.
• If the value of an item which is set to “ON” is changed
after one operating hour or more from the setup, the
change is recognized as a reset operation.
NOTICE
Maintenance notice time can be set at “Set” in “Air Cleaner Cleaning Interval or Change Interval”.
However, perform the cleaning or replacement of the air cleaner element when air cleaner clogging
“Air cleaner clogging monitor” lights up.
7. The screen is shifted by selecting “All Default Value”, per-
form the setting with the function switches.
If this item is executed, the set values of all the mainte-
nance items return to the default values.
F5: Returns the screen to “Maintenance Mode Setting”
screen.
F6: Executes initialization.
REMARK
Press F6, and the initialization completion screen is dis-
played after a short while. “Maintenance Mode Setting”
screen is displayed after that, and initialization is complet-
ed.
30-180 D155AX-8
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING

The telephone number, which is displayed together with “Current Abnormality” in the operator mode, can be in-
put and changed according to the following procedure.
If a telephone number is not input with this function, no telephone number is displayed in Operator mode.
1. Select “Phone Number Entry” on “Service Menu” screen.
2. On “Phone Number Entry” screen, register the phone num-

ber or change it.
F2: Deletes all input digits.
F3: Moves the input position to the next left place (if not
blank).
F4: Moves the input position to the next right place (if not
blank).
F5: Resets input digit/ Returns the screen to “Service
Menu” screen.
F6: Validates the entry.
REMARK
• Up to 14 digits can be input from the left. Leave the
surplus places without inputting.
• If an inputted numeral is wrong, move the cursor (or-
ange background) to that digit and overwrite it with the
correct numeral.
• No telephone number is displayed in the operator
mode when F6 is pressed without inputting any digit,
since there is no information of telephone number.
DEFAULT MENU
METHOD FOR SETTING WITH DEFAULT SETTING MENU (KEY-ON MODE)
Default menu is used to check or change default values of the machine monitor and machine.
Key-on Mode is used to set the operating mode to be selected automatically when the starting switch is turned
to ON position.
D155AX-8 30-181
1. Select “Default” on “Service Menu” screen.
2. On “Default” screen, select “Key-on Mode” with the func-

tion switches or numeral input switches.
REMARK
• Method of selecting is similar to “Service Menu”
screen.
• The following operating modes can be set by this func-
tion.
“Operating mode”: “Power”/“Economy”
“Auto-pitch”: “Auto Pitch OFF”/ “Auto Pitch Digging Posi-
tion Set”/ “Auto Pitch Mode”
“Auto-pitch Reverse Synchronization”: “ON”/“OFF”
“Ripper Auto Return”: “Ripper Auto Return OFF”/ “Ripper Auto Return Lift”/ “Ripper Auto Return Lift or Tilt”/
“Full Ripper Auto Return Lift and Tilt”
“Blade Fine Control”: “ON”/“OFF”
“Blade Lower Speed”: “ON”/“OFF”
3. On “Key-on Mode” screen, select the mode to be set with
the function switches.
“Mode at Previous Key-off”: Uses the last mode in previous
operation when starting switch is turned ON
“Default (All Off)”: Default mode settings (Operating mode
P: P, other items: OFF) are displayed when starting
switch is turned to ON position.
F5: Cancels the selection and returns the screen to “De-
fault” screen
F6: Enters the selection and returns the screen to “Default” screen.
REMARK
Default value at shipment is “Mode at Previous Key-off”.
METHOD FOR SETTING WITH DEFAULT SETTING MENU (UNIT)

The unit selecting function is used to select the unit of the data to be displayed in monitoring, etc.
30-182 D155AX-8
2. On “Default” screen, select “Unit” with the function

switches or numeral input switches.
REMARK
Method of selecting is similar to “Service Menu” screen.
3. On “Unit” screen, select the unit to be set with the function

switches.
F5: Cancels the selection and returns the screen to “De-
fault” screen.
F6: Enters the selection and returns the screen to “Default”
screen.
REMARK
Default value at the shipment is "SI Unit".
METHOD FOR SETTING WITH DEFAULT SETTING MENU (CAMERA)

Camera setting function is used for the setting of camera when the camera is installed or removed.
D155AX-8 30-183
2. Selecting a “Service Menu”.

On “Default” screen, select “Camera” with function
REMARK
3. On “Camera” setting screen, select the item “Camera 1”

with function switches.
Not Use: Camera is not used.
Use: Camera is used.
the screen to “Default” screen.
REMARK
• “Camera 2” or “Camera 3” cannot be connected to this
model. It is unnecessary to perform setting for “Camera
2” and “Camera 3”. These items for “Camera 2” and
“Camera 3” setting are displayed but do not perform
the setting.
• The image captured by the camera is displayed as a
reverse image (as same as a mirror image). It cannot
be switched to normal image (as same as direct view).
• Default value of “Camera” at shipment is “Not Use”.
• Enter each selected item with F6. The setting becomes
effective after returning the screen to “Default” screen
with F5.
• Unless the setting is normally done with this function
when the camera is connected, the camera icon is not
displayed above F3 in the operator mode. Accordingly,
camera image will not be available.
30-184 D155AX-8
4. Selecting items for “Guide Line Position Set”.

1) On “Guide Line Position Set”, select items to be set.
REMARK
• This is not displayed if “Not used” is selected for
“Camera 1” setting.
• For "Configurations" of the guide line, use "Guide
Line Display Mode" in the operator mode.
• OFF, outline, center line, and outline + center line
are available for the guide line.
screen.
• When it is not yet set, “Guide Line Position Setting
Fix” items are displayed.
2) After “Guide Line Position Setting” screen is displayed, select adjustment points and the center line
with function switches as follows.
D155AX-8 30-185
Points selecting screen

F1: Moves the selected point downward.
F2: Moves the selected point upward.
F3: Moves the selected point or center line leftward.
F4: Moves the selected point or center line rightward.
F5: Returns the screen to “Guide Line Position Set”
screen.
F6: Enters the position.
Center line selecting screen

F3: Moves the selected point or center line leftward.
F4: Moves the selected point or center line rightward.
F5: Returns the screen to “Guide Line Position Set”
screen.
F6: Enters the position.
3) On “Guide Line Position Setting Fix”, operate function

switches to enter the setting of each point.
F5: Cancels the setting and returns the screen to
“Guide Line Position Set” screen.
F6: Enters the setting.
30-186 D155AX-8
REMARK
• If “Guide Line Position Setting Fix” is not performed, configurations for the guide line cannot be
done in user mode.
• It is not set at shipment. Set it when installing the camera.
Initializing camera setting

To initialize the camera setting, perform the following procedure.
1. Displaying “Camera Setting Initialization” screen
REMARK
• If the camera is not installed, it is not displayed.
• If the camera setting is initialized, the camera becomes
unset state.
2. On the initialization confirmation screen, select an item

with function switches to execute initialization.
F5: Cancels the setting and returns the screen to “Cam-
era” screen.
F6: Executes initialization
REMARK
Press F6, and “Initialization completed.” screen is dis-
played to indicate the completion of initialization.
METHOD FOR SETTING WITH DEFAULT SETTING MENU (FLOAT BUZZER)

Float buzzer function is to set "Use"/"Not Use" of buzzer sound when the blade is placed in float or released.
D155AX-8 30-187
2. On “Default” screen, select “Float Buzzer” with the function

REMARK
3. On “Float Buzzer” screen, select the mode to be set with

the function switches.
F5: Cancels the selection and returns the display to “De-
fault” screen
F6: Enters the selection and returns the screen to “Default”
screen.
REMARK
Default value at shipment of “Float Buzzer” at shipment is
“Use”.
METHOD FOR SETTING WITH DEFAULT SETTING MENU (AUTO IDLE STOP TIM-
ER FIXING)
Auto idle stop time fixing function is used to set the time which is selectable with “Auto Idle Stop Timer Setting”
in the operator mode.
30-188 D155AX-8
2. On “Default” screen, select “Auto Idle Stop Time Fixing”

with the function switches or numeral input switches.
3. On “Auto Idle Stop Time Fixing” screen, select a setting

“Flexible”: Selection from OFF to 60 minutes is available.
OFF: Auto Idle Stop function is not used.
x-minute fixing: OFF or, longer time than the selected time
is not available.
the screen to “Default” screen.
F6: Enters the selection and returns the screen to “Default” screen.
REMARK
When this setting is “OFF”, Auto Idle Stop does not operate. Auto Idle Stop Time Setting in the operator
mode is disabled.
DIAGNOSTIC TESTS MENU

METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION)
Diagnostic Tests menu is used to perform various checks or resetting of the machine monitor and the machine.
Cylinder cutout mode operation means to run the engine with one or more fuel injectors disabled electrically to
reduce the number of effective cylinders. This operation is used to identify a cylinder that does not output power
normally (combustion in it is abnormal).
1. Select “Diagnostic Tests” on “Service Menu” screen.
D155AX-8 30-189
2. On “Diagnostic Tests” screen, select “Cylinder Cutout

Mode Operation” with the function switches or numeral in-
put switches.
REMARK
3. On “Cylinder Cutout Mode Operation” screen, select a cyl-

inder to be cut out with the function switches.
F1: Moves the selection leftward.
F2: Moves the selection rightward.
F4: Selects hold or releasing hold (When Hold is selected,
F5: Returns the screen to Diagnostic Test screen.
REMARK
• This operation can be performed while the engine is
running.
• If background (a) of the selected cylinder number be-
comes white after you press F6, the cylinder is cutout.
• If the machine monitor cuts out a cylinder but the en-
gine controller cannot cutout that cylinder, the back-
ground (a) of the cylinder number becomes yellow.
• One or more cylinders can be cutout.
• Holding displayed data
If F4 is pressed during the cylinder cutout operation,
the displayed information is newly held (b) (The real-
time information is kept displayed on the left side).
While the data is held, if F4 is pressed, the data hold-
ing function is reset.
The holding function is available for a cylinder, regard-
less of whether it is cutout or not.
If a normally operating cylinder is cut out, the following
phenomena occur. If the engine is running at near high
idle, however, the engine speed may not lower for the rea-
son of engine control. In this case, lower the engine speed with the fuel control dial and judge by increase
of the injection rate command.
• Engine speed lowers.
• Fuel Inject Command (quantity) increases.
4. When changing a cylinder to be cutout or when cylinder cutout operation is finished, select a cutout cylinder
to be reset with the function switches.
30-190 D155AX-8
REMARK
• This operation can be performed while the engine is running.
• When F6 is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset.
• If the machine monitor releases a cutout cylinder but the engine controller cannot release the cutout cyl-
inder, the background (a) of the cylinder number becomes red.
• The cutout cylinder mode operation is not automatically released after the screen returns to the operator
mode. Accordingly, be sure to perform the releasing operation after the cylinder cutout mode operation
is finished.
METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)

Active regeneration for service means to the method of burning soot by performing aftertreatment devices re-
generation, regardless of the soot accumulation.
2. On “Diagnostic Tests” screen, select “Active Regeneration

for Service” by using the function switches or numeral in-
put switches.
REMARK
screen.
• While the Aftertreatment devices regeneration state is
in Manual Stationary Regeneration or stopped, “Active
Regeneration for Service” cannot be selected.
3. When “Active Regeneration for Service” screen is dis-

played, the following information are displayed corre-
sponding to the Aftertreatment devices regeneration condi-
tion. Set the Aftertreatment devices regeneration accord-
ing to the given messages.
a: Soot accumulation level
b: Aftertreatment devices regeneration state
c: Selectable items
d: Message
D155AX-8 30-191
1) Select “Manual Stationary Regeneration” on “Active

Regeneration for Service” screen.
F5: Returns the screen to “Diagnostic Test” screen.
F6: Executes manual stationary regeneration.
REMARK
• The screen changes to “Monitoring Selection
Menu” screen which enables monitoring of ma-
chine information during active regeneration by
performing the following switch operation during
Active Regeneration for Service.
• Switch operation (While pressing 4, press other
switches in order): 4 + 1 → 2 → 3
Press F5 on “Self-define Monitoring” screen to re-
turn the screen to “Active Regeneration for Serv-
ice” screen.
• For the monitoring operation, see “Self-define
Monitoring” of “SETTING AND OPERATION OF MACHINE MONITOR”.
• “Active Regeneration for Service” can be performed only when the parking brake lever and work
equipment lock lever are in their LOCK position and the fuel control dial is in the MIN (Low idle)
position.
• Before performing “Manual Stationary Regeneration”, make sure the surrounding environment is
safe, no people and no combustibles are in the area. When you have to move the machine again
for the sake of security, move it to a safe place and repeat the operation from the start.
• “Active Regeneration for Service” stops automatically after 40 minutes. However, if the regeneration
is started when the soot accumulation is above 4 g/ ℓ and if the soot accumulation is above 1.9 g/ ℓ
after 40 minutes, it automatically switches to “Manual Stationary Regeneration” and continues until
the soot accumulation decreases to 1.9 g/ ℓ.
2) After the active regeneration for service is complete,
“Regeneration completed.” is displayed on the screen.
3) If F6 is pressed during manual stationary regenera-

tion, “Stop manual stationary regeneration?” is dis-
played on the screen. Enter the stop with the function
switch.
• F5: Does not stop regeneration (manual station-
ary regeneration is continued)
• F6: Stops regeneration.
30-192 D155AX-8
METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET)

Testing menu is used to check the machine or to reset the settings of machine monitor.
“KDPF Memory Reset” means to reset the KDPF information saved in the machine. Refer to this section to reset
the information when the KDPF is cleaned and replaced, or when the fuel doser is replaced.
2. On “Diagnostic Tests” screen, select “KDPF Memory Re-

set” with the function switches or numeral input switches.
REMARK
Selecting method is the same as on “Service Menu”
screen.
3. Select the item to be reset on “KDPF Memory Reset”

screen.
F3: Moves the selection mark downward.
F4: Moves the selection mark upward.
F5: Returns the screen to check screen.
4. When “Do you want to reset?” is displayed, enter the reset

by using the function switches.
F5: Returns the screen to previous screen.
F6: Executes resetting.
When resetting is finished successfully, “Resetting is com-
pleted” is displayed on the screen. If resetting is finished
unsuccessfully, “Resetting failed” is displayed on the
screen.
• Perform resetting of “KDPF Change” after replacing
KDPF.
• Perform resetting of “KDPF Cleaning” after cleaning
KDPF.
• Perform the“KDOC Change”reset after replacing or cleaning the KDOC.
• Perform the “Fuel Doser Cleaning” after the fuel doser is cleaned.
D155AX-8 30-193
METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST)

In case of failure of devices related to SCR, you can select the test items according to the procedures in this
section.
2. On “Diagnostic Tests”screen, select “SCR Service Test”

3. On “SCR Service Test” screen is displayed, select the item

to be performed.
F3: Moves the selection mark downward.
F4: Moves the selection mark upward.
F5: Returns the screen to “Diagnostic Tests” screen.
REMARK
You may enter a 2-digit code by using the numeral input
switches to select the item of that code.
The selectable items are indicated in table of “SCR Service Test”.
SCR Service Test

Code Item
01 AdBlue/DEF Pump Pressure Rising Test
02 AdBlue/DEF Injecting Rate Test
03 AdBlue/DEF Line Heater Relay 1 Test
04 AdBlue/DEF Line Heater Relay 2 Test
05 AdBlue/DEF Pump Heater Relay Test
06 AdBlue/DEF Tank Heater Valve Test
07 SCR Denitration Efficiency Test
Test the items listed in table of “SCR Service Test”. For details, see “TEST SCR RELATED FUNCTIONS”,
30-194 D155AX-8
METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER ACTIVE

FAULT CLEAR)
Active failure codes related In Range Error detected by engine controller can be cleared on the machine monitor
for this model.
The failure codes listed in “Table of failure code for inducement” of TROUBLESHOOTING, “PROCEDURE FOR
TESTING AND TROUBLESHOOTING” can not be cleared by “Engine Controller Active Fault Clear”.
2. On “Diagnostic Tests”screen, select “Engine Controller Ac-

tive Fault Clear” with the function switches or numeral in-
put switches.
3. After “Engine Controller Active Fault Clear” screen is dis-

played, select the item to be performed by using the func-
tion switches.
F6: Executes clearing.
METHOD FOR OPERATING TESTING MENU (ASH IN SOOT ACCUMULATION

CORRECTION)
You can correct the ash accumulation quantity in the soot accumulation according to the procedures in this sec-
tion.
D155AX-8 30-195
2. On “Diagnostic Tests”screen, select “Ash in Soot Accumu-

lation Correction” with the function switches or numeral in-
put switches.
3. Start the engine, and set the fuel control dial to MIN (Low
idle) position.
4. Check that “0” of “Test State” is blinking.

When “0” is blinking, you can perform the test.
For display of “Test State”, see “TEST SCR RELATED
FUNCTIONS”.
5. Start the correction by pressing F1.

REMARK
• The display of “Test State” changes to blinking of “10”,
and correction of ash accumulation quantity in soot ac-
cumulation is started.
• Correction of ash accumulation quantity in soot accu-
mulation is completed in approximately 2 hours.
6. When 20 of “Test State” is blinking, turn the starting switch

to OFF position.
REMARK
By turning the starting switch to OFF once, the correction
value is written in the engine controller.
30-196 D155AX-8
METHOD FOR OPERATING TESTING MENU (RESET NUMBER OF ABRUPT EN-

GINE STOP BY AIS)
Though this item is displayed Diagnostic Tests menu, it is unnecessary to perform “Reset number of abrupt en-
gine stops by AIS”. It is because the engine speed is lowered first and then stopped, auto idle stop will not
cause abrupt engine stops since Auto idle stop is not executed immediately at high engine speeds on this ma-
chine.
METHOD FOR OPERATING TESTING MENU (ENGINE STOP AdBlue/DEF INJ

OVERHEAT COUNT RESET)
NOTICE
When performing this item, see TROUBLESHOOTING, Failure code [AS10NT] “AdBlue/DEF Injector
Overheat Caution” or Failure code [AS10KM] “AdBlue/DEF Injector Overheat Warning”, and instruct an
operator about operation.
This function is used to reset the number saved in the machine, the number which engine stop performed when
the temperature of exhaust gas and coolant is high.
You can perform “Engine Stop at AdBlue/DEF Inj Overheat Count Reset” according to the procedures in this
section.
2. After “Diagnostic Tests” screen is displayed, input “95” by

using the numeral input switches and press F6.
3. After “Engine Stop at AdBlue/DEF Inj Overheat Count Re-

set” screen is displayed, select the item to be executed.
F6: Executes resetting.
D155AX-8 30-197
4. After executing resetting, press F6 and return the display

to “Diagnostic Tests” screen.
ADJUSTMENT MENU
VARIOUS SETTINGS OF MACHINE
Perform the adjustment of each machine setting with adjustment menu or Adjustment ID.
To perform each adjustment, select the adjustment item according to two following procedures.
When selecting adjustment items from adjustment menu:

• The following figure is an example of an adjustment menu
“Brake Pedal Potentio Initial Set” screen displayed.
• Functions allocated to the function switches F3 to F6 vary
depending on the adjustment items.
• For details of how to operate the adjustment items, refer to
the explanation for each Adjustment menu.
When selecting adjustment items from adjustment ID:

• The figure shows an example of Adjustment ID “0002”.
• The “000”, “00”, and “0” of the first 3 digits of Adjustment
ID must be input. However, those numbers are not dis-
played in “Adjustment” screen.
• Functions allocated to the function switches F3 to F6 vary
depending on the adjustment items.
• For details of how to operate the adjustment items, refer to
the explanation for each Adjustment ID.
ADJUSTMENT ITEMS TABLE

NOTICE
After completion of assembling the machine or during the controller replacement, be sure to perform
the adjustment marked with (*) in its “code” column or “Adjustment ID” column.
Adjustment item table to be selected from“Adjustment menu”

Code Adjustment item Remarks Reference page
METHOD FOR ADJUSTING WITH
Makes the power train controller recog-
Brake Pedal Potentio ADJUSTMENT MENU (BRAKE
02 (*) nize the zero point of the brake pedal
Initial Set PEDAL POTENTIO INITIAL SET)
potentiometer.
(30-203)
30-198 D155AX-8
Code Adjustment item Remarks Reference page

Makes the power train controller recog- METHOD FOR ADJUSTING WITH
Setting Pitch Angle nize the zero point of the pitch angle ADJUSTMENT MENU (SETTING
03 (*)
Sensor Standard Value sensor, and corrects the installation dif- PITCH ANGLE SENSOR STAND-
ference. ARD VALUE) (30-204)
S/T Lever Neutral Posi- ADJUSTMENT MMENU (S/T LEV-
04 (*) nize the zero point of the steering po-
tion Set ER NEUTRAL POSITION SET)
tentiometer.
(30-205)
IP Automatic Correction, Makes the power train controller recog- ADJUSTMENT MENU (IP AUTO-
05 (*) Trigger Initial Learning nize the transmission condition auto- MATIC CORRECTION, TRIGGER
Setting matically. INITIAL LEARNING SETTING)
(30-206)
Makes the work equipment controller METHOD FOR ADJUSTING WITH
Blade Lift Lever Neutral recognize the neutral position of the lift ADJUSTMENT MENU (BLADE LIFT
06 (*)
Position Adjustment potentiometer of the blade control lev- LEVER NEUTRAL POSITION AD-
er. JUSTMENT) (30-207)
Blade Tilt Lever Neutral recognize the neutral position of the tilt ADJUSTMENT MENU (BLADE TILT
07 (*)
Position Adjustment potentiometer of the blade control lev- LEVER NEUTRAL POSITION AD-
er. JUSTMENT) (30-208)
Ripper Lift Lever Neutral recognize the neutral position of the lift ADJUSTMENT MENU (RIPPER
08 (*)
Position Adjustment potentiometer of the ripper control lev- LIFT LEVER NEUTRAL POSITION
er. ADJUSTMENT) (30-209)
Control Brake Release Releases the control brake (R.H. and
09 ADJUSTMENT MENU (CONTROL
Mode L.H. brake ECMV).
BRAKE RELEASE MODE) (30-210)
Stops the sudden stop prevention sole-
Sudden Stop Prevent ADJUSTMENT MENU (SUDDEN
10 noid valve and control brake (R.H. and
Valve Operation Mode STOP PREVENT VALVE OPERA-
L.H. brake ECMV).
TION MODE) (30-211)
Adjustment item table to be selected from“Adjustment ID”

Adjustment
Adjustment item Remarks Reference page
ID
Performs the initial settings of the METHOD FOR PERFORMING
Power Train Controller specification code and initializes the WITH ADJUSTMENT ID: 0002
0002 (*)
Initialization controller internal memory (adjustment (POWER TRAIN CONTROLLER IN-
value). ITIALIZATION) (30-212)
METHOD FOR PERFORMING
Brake Pedal Potentio WITH ADJUSTMENT ID: 0005
0005 (*) nize the zero point of the brake pedal
Initial Set (BRAKE PEDAL POTENTIO INI-
potentiometer.
TIAL SET) (30-213)
Brake Pedal Stroke End ADJUSTMENT ID: 0006 (BRAKE
0006 nize the potentiometer value at the full
Setting PEDAL STROKE END SETTING)
stroke of the brake pedal.
(30-214)
Engine Decelerator Cut- Releases the neutral deceleration WITH ADJUSTMENT ID: 0007 (EN-
0007
ting function. GINE DECELERATOR CUTTING)
(30-216)
D155AX-8 30-199
Adjustment
ID
Makes the power train controller recog- METHOD FOR PERFORMING
Setting Pitch Angle nize the zero point of the pitch angle WITH ADJUSTMENT ID: 0009
0009 (*)
Sensor Standard Value sensor, and corrects the installation dif- (SETTING PITCH ANGLE SENSOR
ference. STANDARD VALUE) (30-217)
Controls the cooling fan speed to the
0010 Fan 70% Mode WITH ADJUSTMENT ID: 0010 (FAN
maximum speed (approximately 70 %).
70% MODE) (30-218)
Performs the initial settings of the METHOD FOR PERFORMING
Work Equipment Con- specification code and initializes the WITH ADJUSTMENT ID: 0031
0031 (*)
troller Initialization controller internal memory (adjustment (WORK EQUIPMENT CONTROL-
value). LER INITIALIZATION) (30-219)
This is the recommended mode of the
0530 Stall Mode WITH ADJUSTMENT ID: 0530
torque converter stall.
(STALL MODE) (30-220)
Sets the cooling fan speed to approxi-
1005 Fan 100% Mode WITH ADJUSTMENT ID: 1005 (FAN
mately 100 %.
100% MODE) (30-222)
S/T Lever N Position
1012 (*) nize the zero point of the steering po- WITH ADJUSTMENT ID: 1012 (S/T
Set
tentiometer. LEVER N POSITION SET) (30-223)
1013 S/T Lever Left Full Set nize the L.H. maximum position of the WITH ADJUSTMENT ID: 1013 (S/T
steering potentiometer. LEVER LEFT FULL SET) (30-224)
1014 S/T Lever Right Full Set nize the R.H. maximum position of the WITH ADJUSTMENT ID: 1014 (S/T
steering potentiometer. LEVER RIGHT FULL SET) (30-225)
Displays the continuous power supply METHOD FOR PERFORMING
Power Train Controller voltage and switched power supply WITH ADJUSTMENT ID: 2021
2021
Voltage Check Mode voltage that are supplied to the power (POWER TRAIN CONTROLLER
train controller. VOLTAGE CHECK MODE) (30-227)
Displays the continuous power supply
Work Equipment Con- WITH ADJUSTMENT ID: 2022
voltage and switched power supply
2022 troller Voltage Check (WORK EQUIPMENT CONTROL-
voltage that are supplied to the work
Mode LER VOLTAGE CHECK MODE)
equipment controller.
(30-228)
HSS Minimum Current Adjusts the swing radius at the start of WITH ADJUSTMENT ID: 2222 (HSS
2222
Value Setting Mode steering. MINIMUM CURRENT VALUE SET-
TING MODE) (30-229)
Reverse Slow (R1) Set- WITH ADJUSTMENT ID: 6001 (RE-
6001
ting VERSE SLOW (R1) SETTING)
(30-230)
Reverse Slow (R2) Set- Finely adjusts the reverse speed when WITH ADJUSTMENT ID: 6002 (RE-
6002
ting the Reverse Slow mode is ON. VERSE SLOW (R2) SETTING)
(30-231)
Reverse Slow (R3) Set- WITH ADJUSTMENT ID: 6003 (RE-
6003
ting VERSE SLOW (R3) SETTING)
(30-233)
30-200 D155AX-8
Adjustment
ID
IP Automatic Correction, Makes the power train controller recog- WITH ADJUSTMENT ID: 7842 (IP
7842 (*) Trigger Initial Learning nize the transmission condition auto- AUTOMATIC CORRECTION, TRIG-
Setting matically. GER INITIAL LEARNING SETTING)
(30-234)
nize manually if the auto recognition
WITH ADJUSTMENT ID: 7843
Transmission Clutch IP cannot be performed in Adjustment ID
7843 (TRANSMISSION CLUTCH IP
Manual Initial Correction “7842” or “Adjustment menu (IP Auto-
MANUAL INITIAL CORRECTION)
matic Correction, Trigger Initial Learn-
(30-236)
ing Setting)”.
Checks the compensation information METHOD FOR PERFORMING
7845 IP Learning Display in Adjustment ID “7842” and Adjust- WITH ADJUSTMENT ID: 7845 (IP
ment ID “7843”. LEARNING DISPLAY) (30-237)
Makes the power train controller com-
pensate manually if the auto compen-
Transmission Clutch Fill WITH ADJUSTMENT ID: 7847
sation cannot be performed in Adjust-
7847 Time Manual Initial Cor- (TRANSMISSION CLUTCH FILL
ment ID “7842” or “Adjustment menu
rection TIME MANUAL INITIAL CORREC-
(IP Automatic Correction, Trigger Initial
TION) (30-238)
Learning Setting)”.
Makes the work equipment controller METHOD FOR PERFORMING
Blade Lift Lever Neutral recognize the neutral position of the lift WITH ADJUSTMENT ID: 8000
8000 (*)
Position Adjustment potentiometer of the blade control lev- (BLADE LIFT LEVER NEUTRAL
er. POSITION ADJUSTMENT) (30-239)
Makes the work equipment controller
Blade Lift Lever Raise recognize the maximum RAISE posi-
8001 (BLADE LIFT LEVER RAISE
Stroke End Adjustment tion of the lift potentiometer of the
STROKE END ADJUSTMENT)
blade control lever.
(30-241)
Makes the work equipment controller
Blade Lift Lever Lower recognize the LOWER position of the
8002 (BLADE LIFT LEVER LOWER
Stroke End Adjustment lift potentiometer of the blade control
STROKE END ADJUSTMENT)
lever.
(30-242)
Blade Tilt Lever Neutral recognize the neutral position of the tilt WITH ADJUSTMENT ID: 8003
8003 (*)
Position Adjustment potentiometer of the blade control lev- (BLADE TILT LEVER NEUTRAL
er. POSITION ADJUSTMENT) (30-243)
Blade Tilt Lever Right
recognize the R.H. maximum position WITH ADJUSTMENT ID: 8004
8004 Most Position Adjust-
of the tilt potentiometer of the blade (BLADE TILT LEVER RIGHTMOST
ment
control lever. POSITION ADJUSTMENT) (30-244)
Blade Tilt Lever Left
recognize the L.H. maximum position WITH ADJUSTMENT ID: 8005
8005 Most Position Adjust-
of the tilt potentiometer of the blade (BLADE TILT LEVER LEFTMOST
ment
control lever. POSITION ADJUSTMENT) (30-246)
Ripper Lift Lever Neutral recognize the neutral position of the lift WITH ADJUSTMENT ID: 8006 (RIP-
8006 (*)
Position Adjustment potentiometer of the ripper control lev- PER LIFT LEVER NEUTRAL POSI-
er. TION ADJUSTMENT) (30-247)
D155AX-8 30-201
Adjustment
ID
Ripper Lift Lever RAISE recognize the maximum RAISE posi- WITH ADJUSTMENT ID: 8007 (RIP-
8007
Stroke End Adjustment tion of the lift potentiometer of the rip- PER LIFT LEVER RAISE STROKE
per control lever. END ADJUSTMENT) (30-248)
Ripper Lift lever LOW-
recognize the maximum LOWER posi- WITH ADJUSTMENT ID: 8008 (RIP-
8008 ER stroke end Adjust-
tion of the lift potentiometer of the rip- PER LIFT LEVER LOWER STROKE
ment
per control lever. END ADJUSTMENT) (30-249)
Blade Lift RAISE Cur- WITH ADJUSTMENT ID: 8020
8020
rent Value Correction (BLADE LIFT RAISE CURRENT
VALUE CORRECTION) (30-250)
Blade Lift LOWER Cur- WITH ADJUSTMENT ID: 8021
8021
rent Value Correction (BLADE LIFT LOWER CURRENT
Adjusts the sensitivity on the lift control METHOD FOR PERFORMING
Blade Lift RAISE Cur- side of the blade control lever. WITH ADJUSTMENT ID: 8022
8022 rent Value Correction (BLADE LIFT RAISE CURRENT
(Fine Control Mode VALUE CORRECTION (FINE CON-
TROL MODE)) (30-253)
Blade Lift LOWER Cur- WITH ADJUSTMENT ID: 8023
8023 rent Value Correction (BLADE LIFT LOWER CURRENT
(Fine Control Mode) VALUE CORRECTION (FINE CON-
TROL MODE)) (30-254)
Blade Tilt LEFT Current WITH ADJUSTMENT ID: 8024
8024
Value Correction (BLADE TILT LEFT CURRENT VAL-
Adjusts the sensitivity on the tilt control UE CORRECTION) (30-255)
side of the blade control lever. METHOD FOR PERFORMING
Blade Tilt RIGHT Cur- WITH ADJUSTMENT ID: 8025
8025
rent Value Correction (BLADE TILT RIGHT CURRENT
Blade Lift Lower Current Adjusts the blade LOWER speed dur- WITH ADJUSTMENT ID: 8030
8030
Value Correction ing Blade Lower Speed mode. (BLADE LIFT LOWER CURRENT
Control Brake Release Releases the control brake (R.H. and WITH ADJUSTMENT ID: 9995
9995
Mode L.H. brake ECMV). (CONTROL BRAKE RELEASE
MODE) (30-259)
Stops the sudden stop prevention sole-
Sudden Stop Prevent WITH ADJUSTMENT ID: 9996
9996 noid valve and control brake (R.H. and
Valve Operation Mode (SUDDEN STOP PREVENT VALVE
L.H. brake ECMV).
OPERATION MODE) (30-260)
9997 High Idle Cut Mode Restricts the high idle engine speed. WITH ADJUSTMENT ID: 9997
(HIGH IDLE CUT MODE) (30-262)
30-202 D155AX-8
Adjustment
ID
Max. Speed Range Set- Restricts the maximum gear speed of WITH ADJUSTMENT ID: 9998
9998
ting Mode the transmission. (MAX. SPEED RANGE SETTING
MODE) (30-263)
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (BRAKE PEDAL POTEN-

TIO INITIAL SET)
By “Brake Pedal Potentio Initial Set”, the power train controller recognizes the zero point of the brake pedal po-
tentiometer.
When the power train controller or brake pedal potentiometer has been replaced, or when brake pedal linkage
has been disconnected or connected, be sure to perform this adjustment.
1. Select “Adjustment” on “Service Menu” screen.
2. On “Adjustment” menu screen, select “Brake Pedal Poten-

tio Initial Set” with function switches or numeral input
switches.
F5: Cancels the adjustment and returns the screen to
“Service Menu” screen.
F6: Enters the selected adjustment items and moves the
screen to the next “Adjustment” screen.
REMARK
• For details of adjustment items, see “ADJUSTMENT
ITEMS TABLE”.
• Adjustment item can be selected similarly to “Service
Menu” screen.
3. On “Adjustment” screen, perform adjustment of “Brake
Pedal Potentio Initial Set” with function switches.
F3: Not used.
F4: Not used.
F5: Returns the screen to the adjustment item selection
screen.
F6: Saves the compensation value.
1) Hold the brake pedal at the neutral position (not de-
pressed).
2) Press F6, and check that warning buzzer sounds.
D155AX-8 30-203
REMARK
• This adjustment does not change the displayed values other than the adjustment value.
• After the adjustment is completed, this saved compensation values are effective even while the
starting switch is turned to OFF position.
• By Brake Pedal Potentio Initial Set, the braking performance is not adjusted.
• When performing the adjustment with “Adjustment ID: 0005 (Brake Pedal Potentio Initial Set)”, see
“METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0005 (BRAKE PEDAL POTENTIO INI-
TIAL SET)”.
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (SETTING PITCH ANGLE

SENSOR STANDARD VALUE)
By “Setting Pitch Angle Sensor Standard Value”, the power train controller recognizes the zero point of the pitch
angle sensor, and corrects the installation error.
When the power train controller was replaced, or when pitch angle sensor was removed, installed, or replaced,
be sure to perform this adjustment.
2. On “Adjustment” menu screen, select “Inclination Sensor

Initial Set” with function switches or numeral input
switches.
REMARK
ITEMS TABLE”.
• Adjustment item can be selected similarly to“Service
Menu” screen.
3. On “Adjustment” screen, perform adjustment of “Setting
Pitch Angle Sensor Standard Value” with function
switches.
F3: Not used.
F4: Not used.
screen.
1) Check that the machine remains horizontal.
30-204 D155AX-8

REMARK
• By performing this adjustment, the display item “Machine Pitch Angle” changes to 0.0 deg.
• By performing this adjustment, the saved compensation values are effective even while the starting
switch is turned to OFF position.
• When performing the adjustment with “Adjustment ID: 0009 (Setting Pitch Angle Sensor Standard
Value)”, see “METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0009 (SETTING PITCH AN-
GLE SENSOR STANDARD VALUE)”.
METHOD FOR ADJUSTING WITH ADJUSTMENT MMENU (S/T LEVER NEUTRAL

POSITION SET)
By “S/T Lever Neutral Position Set”, the power train controller recognizes the neutral position of the steering po-
tentiometer of the joystick (steering, directional and gear shift lever) (PCCS lever).
When the power train controller or joystick (steering, directional and gear shift lever) (PCCS lever) was re-
placed, be sure to perform this adjustment.
2. On “Adjustment” menu screen, select “S/T Lever N Posi-

tion Setting” with function switches or numeral input
switches.
REMARK
ITEMS TABLE”.
Menu” screen.
3. On “Adjustment” screen, perform adjustment of “S/T Lever
Neutral Position Set” with function switches.
F3: Not used.
F4: Not used.
screen.
1) Hold the joystick (steering, directional and gear shift
lever) (PCCS lever) at the neutral position.
D155AX-8 30-205

REMARK
• “S/T Lever Neutral Position Set”, does not adjust the steering performance.
• When performing the adjustment with the “Adjustment ID: 1012 (S/T Lever N Position Set)”, see
“Method for adjustment with Adjustment ID: 1012 (S/T Lever N Position Set)”.
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (IP AUTOMATIC COR-

RECTION, TRIGGER INITIAL LEARNING SETTING)
By “IP Automatic Correction, Trigger Initial Learning Setting”, the power train controller recognizes the mechani-
cal condition of the transmission.
Perform this adjustment item under the following conditions.
• “Engine Speed” : 1700 to 1950 rpm
• “T/C (P/L) Oil Temperature” : 65 to 85 °C
• Parking brake lever: LOCK position.
When the power train controller or transmission was replaced, be sure to perform this adjustment.
2. On “Adjustment” menu screen, select “IP Auto Compensa-

tion Setting” with function switches or numeral input
switches.
REMARK
ITEMS TABLE”.
Menu” screen.
30-206 D155AX-8
3. On “Adjustment”screen, perform adjustment of “IP Auto-

matic Correction, Trigger Initial Learning Setting” with func-
tion switches.
F3: Not used.
F4: Not used.
screen.
F6: Starts auto calibration.
REMARK
The machine does not work during the correction.
1) Start the engine, warm it up sufficiently, and hold the power train oil temperature within the range of
conditions.
2) Hold the engine speed within the range of conditions by using the fuel control dial.
3) Press F6 to start the automatic compensation work, and check that “1/11” is newly displayed on the
screen.
4) When “11/11” appears on the screen, press F6 and check that the warning buzzer sounds.
REMARK
• When performing the adjustment with “Adjustment ID: 7842 (IP Automatic Correction, Trigger Initial
Learning Setting)”, see “METHOD FOR PERFORMING WITH ADJUSTMENT ID: 7842 (IP AUTO-
MATIC CORRECTION, TRIGGER INITIAL LEARNING SETTING)”.　
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (BLADE LIFT LEVER

NEUTRAL POSITION ADJUSTMENT)
By “Blade Lift Lever Neutral Position Adjustment”, the work equipment controller recognizes the neutral position
of the lift potentiometer of the blade control lever.
When the work equipment controller or blade control lever was replaced, be sure to perform this adjustment.
2. On “Adjustment” menu screen, select “Blade Lift Lever N

Position Adj” with function switches or numeral input
switches.
screen to the selected “Adjustment” screen.
D155AX-8 30-207
REMARK
• For details of adjustment items, see “ADJUSTMENT ITEMS TABLE”.
• Adjustment item can be selected similarly to “Service Menu” screen.
3. On “Adjustment” screen, perform adjustment of “Blade Lift
Lever Neutral Position Adjustment” with function switches.
F3: Not used.
F4: Not used.
screen.
1) Hold the blade control lever at the neutral position.
REMARK
• By “Blade Lift Lever Neutral Position Adjustment”, the sensitivity of the blade control lever is not ad-
justed. To adjust the sensitivity of the blade control lever on the lift side, perform Adjustment IDs:
8020 to 8023.
• When performing the adjustment with the “Adjustment ID 8000 (Blade Lift Lever Neutral Position
Adjustment)”, see “METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8000 (BLADE LIFT
LEVER NEUTRAL POSITION ADJUSTMENT)”.
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (BLADE TILT LEVER

By “Blade Tilt Lever Neutral Position Adjustment”, the work equipment controller recognizes the neutral position
of the tilt potentiometer of the blade control lever.
2. On “Adjustment” menu screen, select “Blade Tilt Lever N

switches.
30-208 D155AX-8
REMARK
3. On “Adjustment” screen, perform adjustment of “Blade Tilt
F3: Not used.
F4: Not used.
screen.
REMARK
• By “Blade Tilt Lever Neutral Position Adjustment”, the sensitivity of the blade control lever is not ad-
justed. To adjust the sensitivity of the blade control lever on the tilt side, perform Adjustment ID:
8024 and Adjustment ID: 8025.
• When performing the adjustment with the “Adjustment ID 8003 (Blade Tilt Lever Neutral Position
Adjustment)”, see “METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8003 (BLADE TILT
LEVER NEUTRAL POSITION ADJUSTMENT)”.
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (RIPPER LIFT LEVER

By “Ripper Lift Lever Neutral Position Adjustment”, the work equipment controller recognizes the neutral position
of the lift potentiometer of the ripper control lever.
2. On “Adjustment” menu screen, select “Ripper Lift Lever N

switches.
D155AX-8 30-209
REMARK
3. On “Adjustment” screen, perform the adjustment of “Ripper
Lift Lever Neutral Position Adjustment” with function
switches.
F3: Not used.
F4: Not used.
screen.
1) Hold the ripper control lever at the neutral position.
REMARK
• By “Ripper Lift Lever Neutral Position Adjustment”, the sensitivity of the ripper control lever is not adjust-
ed.
• When performing the adjustment with “Adjustment ID: 8006 (Ripper Lift Lever Neutral Position Adjust-
ment)”, see “METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8006 (RIPPER LIFT LEVER
NEUTRAL POSITION ADJUSTMENT”.
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (CONTROL BRAKE RE-

LEASE MODE)
“Control Brake Release Mode” opens the control brake (R.H. and L.H. brake ECMV) to check the operation of
the backup brake (brake pedal solenoid valve).
Perform this adjustment as required when testing, adjusting, troubleshooting, etc.
2. On “Adjustment” menu screen, select “Control Brake Re-

lease Mode” with function switches or numeral input
switches.
30-210 D155AX-8
REMARK
When the “Control Brake Release Mode” appears, hold the
control brake (R.H. and L.H. brake ECMV) open.
F3: Not used.
F4: Not used.
F5: Returns the screen to the adjustment item selection screen.
F6: Not used.
REMARK
• If the joystick (steering, directional and gear shift lever)
(PCCS lever) is not at NEUTRAL position and the machine
is not stopped, the control brake (R.H. and L.H. brake
ECMV) is not held open.
• This adjustment becomes ineffective when pressing F5 and
returning the screen to the adjustment item selection
screen.
• When performing the adjustment with “Adjustment ID: 9995
(Control Brake Release Mode)”, see “METHOD FOR PER-
FORMING WITH ADJUSTMENT ID: 9995 (CONTROL
BRAKE RELEASE MODE)”.
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (SUDDEN STOP PRE-

VENT VALVE OPERATION MODE)
“Sudden Stop Prevent Valve Mode” stops the sudden stop prevention solenoid valve and control brake (R.H.
and L.H. brake ECMV), and checks the operation of the sudden stop prevention valve.
2. On “Adjustment” menu screen, select “Sudden Stop Pre-

vent Valve Mode” with function switches or numeral input
switches.
D155AX-8 30-211
REMARK
When “Sudden Stop Prevent Valve Operation Mode” screen
appears, the sudden stop solenoid valve and control brake
(R.H. and L.H. brake ECMV) are stopped.
F3: Not used.
F4: Not used.
F5: Returns the screen to the adjustment item selection screen.
F6: Not used.
REMARK
• Sudden stop prevention solenoid valve and control brake
(R.H. and L.H. brake ECMV) are not stopped if the joystick
(steering, directional and gear shift lever) (PCCS lever) is
not at NEUTRAL position and the machine is not stopped.
returning the screen to the adjustment item selection
screen.
• When performing the adjustment with “Adjustment ID: 9996
(Sudden Stop Prevent Operation Valve Mode)”, see
“METHOD FOR PERFORMING WITH ADJUSTMENT ID:
9996 (SUDDEN STOP PREVENT VALVE OPERATION
MODE)”.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0002 (POWER TRAIN

CONTROLLER INITIALIZATION)
“Power train controller initialization” initializes the recognized specification code, and also initializes the set value
of the memory inside the controller.
When the power train controller was replaced, be sure to perform this adjustment.
2. On “Adjustment” menu, select “Input ID” to be set.

F6: Enters the selection and moves the screen to the next
“Adjustment” screen.
30-212 D155AX-8
3. On “Input ID” screen, directly input Adjustment ID “0002”

with the numeral input switches.
F5: Returns the screen to “Adjustment” screen.
F6: Enters input Adjustment ID.
REMARK
• For details of Adjustment ID and adjustment items, see
“ADJUSTMENT ITEMS TABLE”.
• When the input Adjustment ID is incorrect, “Incorrect
ID” appears, and the screen next to “Input ID” does not
appear (you can input Adjustment ID again when this
screen is displayed).
4. On “Adjustment” screen, perform adjustment of “Power
Train Controller Initialization” with function switches.
F3: Not used.
F4: Not used.
F5: Returns the screen to “Input ID” screen.
F6: Saves the setting.
1) Press F6, and check that alarm buzzer sounds.
2) Check that the specification code of “MEMORY CODE
SET MODE” has changed from “1×1” to “111”.
REMARK
• If the specification code “111” of “MEMORY CODE SET
MODE”does not appear, the wiring harness of the work
equipment controller or the work equipment controller
main unit may be defective.
• In this adjustment, the memorized setting values are
effective even when the starting switch is turned to
OFF position after the adjustment is completed.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0005 (BRAKE PEDAL PO-
TENTIO INITIAL SET)
By “Brake Pedal Potentio Initial Set”, the power train controller recognizes the zero point of the brake pedal po-
tentiometer.
When the power train controller or brake pedal potentiometer has been replaced, or when brake pedal linkage
has been disconnected or connected, be sure to perform this adjustment.
D155AX-8 30-213


REMARK
4. On “Adjustment” screen, perform adjustment of “Brake
Pedal Potentio Initial Set” with function switches.
F3: Not used.
F4: Not used.
1) Hold the brake pedal at the neutral position (not de-
pressed).
REMARK
• This adjustment does not change the displayed
values other than the adjustment value.
• By performing this adjustment, the saved compen-
sation values are effective even while the starting
• By “Brake Pedal Potentio Initial Set”, the braking
performance is not adjusted.
• When performing the adjustment with the “Adjust-
ment menu (Brake Pedal Potentio Initial Set)”, see
“METHOD FOR ADJUSTING WITH ADJUST-
MENT MENU (BRAKE PEDAL POTENTIO INI-
TIAL SET)”.
METHOD FOR ADJUSTING WITH ADJUSTMENT ID: 0006 (BRAKE PEDAL

STROKE END SETTING)
By “Brake pedal stroke end setting”, the power train controller recognizes the potentiometer value at the full
stroke of the brake pedal.
Use this adjustment as necessary for operation.
30-214 D155AX-8


REMARK
4. On "Adjustment" screen, perform adjustment of “Brake
Pedal Stroke End Setting” with function switches.
F3: Not used.
F4: Not used.
F6: Saves the adjustment value.
1) Depress the brake pedal to the full stroke, and hold it.
REMARK
• By this adjustment, the displayed values other
than the adjustment value do not change.
• “Brake Pedal Stroke End Setting” does not adjust
the braking performance.
D155AX-8 30-215
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0007 (ENGINE DECELER-

ATOR CUTTING)
“Engine Decelerator Cutting” stops the engine neutral deceleration function.
This is used when checking the high idle speed of the basic engine.


REMARK
When “Engine Decelerator Cutting” screen appears, the neutral
deceleration function becomes ineffective, and restriction of
high idle engine speed at the transmission neutral is canceled.
F3: Not used.
F4: Not used.
F6: Not used.
REMARK
In this adjustment, the engine deceleration cutting function is
ineffective and the neutral deceleration function is effective
when pressing F5 and returning to “Input ID” screen.
30-216 D155AX-8
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0009 (SETTING PITCH AN-
GLE SENSOR STANDARD VALUE)
By “Setting Pitch Angle Sensor Standard Value”, the power train controller recognizes the zero point of the pitch
angle sensor, and corrects the installation error.
When the power train controller was replaced, or when pitch angle sensor was removed, installed, or replaced,
be sure to perform this adjustment.


REMARK
4. On "Adjustment" screen, perform adjustment of “Setting
Pitch Angle Sensor Standard Value” with function switches
F3: Not used.
F4: Not used.
1) Check that the machine remains horizontal.
D155AX-8 30-217
REMARK
• By performing this adjustment, the display item “BODY PITCH ANGLE” changes to 0.0 deg.
• When performing the adjustment with the “Adjustment menu (Setting Pitch Angle Sensor Standard
Value)”, see “METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (SETTING PITCH ANGLE
SENSOR STANDARD VALUE)”.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0010 (FAN 70% MODE)
“Fan 70% Mode” forcibly sets the cooling fan speed to approximately 70%.


REMARK
30-218 D155AX-8
When “Fan 70% Mode ”screen appears, the cooling fan speed
is controlled to the maximum speed (approximately 70 %).
F3: Decreases the adjustment value “FAN 70% SPEED
MODE”.
F4: Increases the adjustment value “FAN 70% SPEED MODE”.
F6: Not used.
REMARK
This adjustment is ineffective and the cooling fan speed restric-
tion is canceled when pressing F5 and returning to “Input ID”
screen.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0031 (WORK EQUIPMENT

CONTROLLER INITIALIZATION)
“Work Equipment Controller Initialization” initializes the specification code recognized by the work equipment
controller, and also initializes the set value of the memory inside the controller.
When the work equipment controller was replaced, be sure to perform this adjustment.


REMARK
appear (you can input Adjustment ID again with the nu-
meral input switches when this screen is displayed).
D155AX-8 30-219
4. On "Adjustment" screen, perform adjustment of “Work

Equipment Controller Initialization” with function switches.
F3: Not used.
F4: Not used.
F6: Saves the setting.
2) Check that the specification code of “MEMORY CODE
SET MODE” has changed from “2×2” to “222”.
REMARK
• If the specification code “222” does not appear, the
wiring harness of the work equipment controller or
the work equipment controller main unit may be
defective.
• In this adjustment, the memorized setting values
are effective even when the starting switch is
turned to OFF position after the adjustment is
completed.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 0530 (STALL MODE)

Hydraulic oil temperature Min. : 45 °C to 100 °C
To perform the torque converter stall, the stall mode automatically sets the fan speed to 100 % mode and allows
“F3-R3” to be set as the preset (moving-off gear speed).
REMARK
In the Stall mode, the torque converter stall is not performed automatically. Securely control the lever and pedal
at the torque converter stall. For the procedure for the torque converter stall, see "TEST ENGINE SPEED".

30-220 D155AX-8

REMARK
4. On “Adjustment” screen, perform setting of gear speed
and mode with function switches.
F3: Not used.
F4: Not used.
F6: Not used.
1) Set preset (moving-off gear speed) to “F3-R3” with up

switch (3) and down switch (4) of the joystick (steer-
ing, directional and gear shift lever) (PCCS lever).
REMARK
Only when this Adjustment ID is effective, you can set
the preset (moving-off gear speed) to “F3-R3”.
2) Select “P-MANUAL SFT MODE” with gear shift mode
selector switch (2).
REMARK
Mode setting information in screen
“P-AUTO SFT MODE”: Operating Mode is P (Power mode) and Gear Shift Mode is the automatic gear
shift.
“E-AUTO SFT MODE”: Operating Mode is E (Economy mode) and Gear Shift Mode is the automatic
gear shift.
“P-MANUAL SFT MODE”: Operating Mode is P (Power mode) and Gear Shift Mode is the manual gear
shift.
“E-MANUAL SFT MODE”: Operating Mode is E (Economy mode) and Gear Shift Mode is the manual
gear shift.
3) Start the engine, warm it up sufficiently, and hold the hydraulic oil temperature within the range of con-
ditions.
REMARK
4) Stall the torque converter. For details, see “TEST ENGINE SPEED”.
REMARK
This adjustment becomes ineffective when pressing F5 and returning the screen to “Input ID”.
D155AX-8 30-221
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 1005 (FAN 100% MODE)
“Fan 100% Mode” forcibly sets the cooling fan speed to approximately 100 % and the adjustment value of the
maximum speed.
Hydraulic oil temperature Min. : 45 °C to 100 °C
1. Start the engine, warm it up sufficiently, and hold the hydraulic oil temperature within the range of condi-
tions.
REMARK


REMARK
30-222 D155AX-8
5. On “Adjustment” screen, perform setting of “Fan 100%

Mode” with function switches.
F3: Decreases the adjustment value “FAN 100% SPEED
MODE”.
F4: Increases the adjustment value “FAN 100% SPEED
MODE”.
1) To change the adjustment value, press F3 or F4 to in-
crease or decrease the adjustment value.
2) Press F6 to fix the adjustment value, and check that
the warning buzzer sounds.
REMARK
• The function is effective once “Fan 100% Mode” screen appears, and controls the cooling fan
speed at the maximum speed (100 %).
• This adjustment becomes ineffective by pressing F5 and returning to “Input ID” screen. However,
the saved adjustment value is effective.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 1012 (S/T LEVER N POSI-
TION SET)
By “S/T Lever N Position Set”, the power train controller recognizes the neutral position of the steering potenti-
ometer of the joystick (steering, directional and gear shift lever) (PCCS lever).
When the power train controller or joystick (steering, directional and gear shift lever) (PCCS lever) was re-
placed, be sure to perform this adjustment.

D155AX-8 30-223

REMARK
4. On "Adjustment" screen, perform adjustment of “S/T Lever
N Position Set” with function switches.
F3: Not used.
F4: Not used.
1) Hold the joystick (steering, directional and gear shift
lever) (PCCS lever) at the neutral position.
REMARK
• By this adjustment, the displayed values other than the adjustment value do not change.
• By “S/T Lever N Position Set”, the steering performance is not adjusted.
• When performing the adjustment with the “Adjustment menu (S/T Lever Neutral Position Setting)”,
see “METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (S/T LEVER NEUTRAL POSITION
SET)”.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 1013 (S/T LEVER LEFT
FULL SET)
By “S/T Lever LEFT Full Set”, the power train controller recognizes the left maximum position of the steering
potentiometer of the joystick (steering, directional and gear shift lever) (PCCS lever).
30-224 D155AX-8


REMARK
Left Full Set” with function switches.
F3: Not used.
F4: Not used.
1) Hold the steering side of the joystick (steering, direc-
tional and gear shift lever) (PCCS lever) at the left
maximum position (stroke end).
REMARK
• By “S/T Lever LEFT Full Set”, the steering performance is not adjusted.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 1014 (S/T LEVER RIGHT
FULL SET)
By “S/T Lever RIGHT Full Set”, the power train controller recognizes the right maximum position of the steering
potentiometer of the joystick (steering, directional and gear shift lever) (PCCS lever).
D155AX-8 30-225


REMARK
Right Full Set” with function switches.
F3: Not used.
F4: Not used.
1) Hold the steering side of the joystick (steering, direc-
tional and gear shift lever) (PCCS lever) at the right
maximum position (stroke end).
REMARK
• By “S/T Lever RIGHT Full Set”, the steering performance is not adjusted.
30-226 D155AX-8
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 2021 (POWER TRAIN

CONTROLLER VOLTAGE CHECK MODE)
“Power Train Controller Voltage Check Mode” displays the continuous power supply voltage and switched power
supply voltage that are supplied to the power train controller.


REMARK
The “Power Train Controller Voltage Check Mode” screen ap-
pears. Check the voltage value.
F3: Not used.
F4: Not used.
F6: Not used
REMARK
Information displayed on the screen
“PT CONTROLLER UNSWITCHED POWER”: Continuous
power supply voltage
“PT CONTROLLER SWITCHED POWER”: Switched power supply voltage
D155AX-8 30-227
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 2022 (WORK EQUIPMENT

CONTROLLER VOLTAGE CHECK MODE)
“Work Equipment Controller Voltage Check Mode” displays the continuous power supply voltage and switched
power supply voltage that are supplied to the work equipment controller.


REMARK
The “Work Equipment Controller Voltage Check Mode” screen
appears. Check the voltage value.
F3: Not used.
F4: Not used.
F6: Not used.
REMARK
Information displayed on the screen
“WE CONTROLLER UNSWITCHED POWER”: Continuous
power supply voltage
“WE CONTROLLER SWITCHED POWER”: Switched power supply voltage
30-228 D155AX-8
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 2222 (HSS MINIMUM CUR-
RENT VALUE SETTING MODE)
“HSS Minimum Current Value Setting Mode” adjusts swing radius at the start of steering if the feeling of the start
if steering is different between right and left.


REMARK
4. On "Adjustment" screen, perform adjustment of “HSS Mini-
mum Current Value Setting Mode” with function switches.
F3: Not used.
F4: Not used.
1) Set the parking brake lever to FREE position.
2) Operate the joystick (steering, directional and gear
shift lever) (PCCS lever) toward the right or left gradu-
ally, and hold it at the position where the current value
to be set is displayed.
D155AX-8 30-229
REMARK
• When operating the joystick (steering, directional and gear shift lever) (PCCS lever) toward left, the
current value becomes negative.
• When operating the joystick (steering, directional and gear shift lever) (PCCS lever) toward right,
the current value becomes positive.
REMARK
• By pressing F6 when the joystick (steering, directional and gear shift lever) (PCCS lever) is at NEU-
TRAL position, the value returns to the factory default.
• The current value ( mA) varies within the range from -450 (left end) to 450 (right end).
• When the set current value increases in positive or negative direction, the swing radius decreases
at stat of steering operation (swings more quickly).
• Steering operation during adjustment wok is not necessary. However, perform steering operation
after the adjustment, and check that there is no problem in the actual swing.
• The figure shows an example when the current
value to be adjusted is reduced and the swing ra-
dius is decreased for the left steering.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 6001 (REVERSE SLOW

(R1) SETTING)
By the “Reverse Slow (R1) Setting”, set the travel speed applied in travel at R1 gear speed when Reverse Slow
mode is ON.

30-230 D155AX-8

by using the numeral input switches.
REMARK
4. On “Adjustment” screen, perform adjustment of “Reverse
Slow (R1) Setting” with function switches.
F3: Decreases the adjustment value
F4: Increases the adjustment value
1) Press F3 or F4 to increase or decrease the adjust-
ment value.
REMARK
• Information displayed on the screen
For the travel speed, the value 10 times as large
as the actual travel speed with the reverse travel
speed restricted is displayed. The adjustment val-
ue increases or decreases by 1 (by 0.1 km/h but
by 1 km/h for the values displayed on the machine
monitor).
• The restricted travel speed at factory default is
4.0 km/h, and the value displayed on the machine
monitor is “40 km/h” (10 times larger).
• If the value has already been adjusted, the adjust-
ed value is displayed. If the value is within the al-
lowable range, further adjustment can be per-
formed.
REMARK
• Travel operation is not required during the adjustment work. However, perform the travel operation
at R1 with the Reverse Slow mode ON after completion of the adjustment, and check that there is
no problem in the actual travel speed.

(R2) SETTING)
mode is ON.
D155AX-8 30-231


REMARK
ment value.
30-232 D155AX-8
REMARK
For the travel speed, the value 10 times as large as the actual travel speed with the reverse travel
speed restricted is displayed. The adjustment value increases or decreases by 1 (by 0.1 km/h but
by 1 km/h for the values displayed on the machine monitor).
• The restricted travel speed at factory default is 6.0 km/h, and the value displayed on the machine
• If the value has already been adjusted, the adjusted value is displayed. If the value is within the
allowable range, further adjustment can be performed.
REMARK

(R3) SETTING)
mode is ON.

D155AX-8 30-233

REMARK
ment value.
REMARK
For the travel speed, the value 10 times as large
as the actual travel speed with the reverse travel
speed restricted is displayed. The adjustment val-
ue increases or decreases by 1 (by 0.1 km/h but
by 1 km/h for the values displayed on the machine
monitor).
• The restricted travel speed at factory default is
12.0 km/h, and the value displayed on the machine
• If the value has already been adjusted, the adjust-
ed value is displayed. If the value is within the al-
lowable range, further adjustment can be per-
formed.
REMARK
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 7842 (IP AUTOMATIC

CORRECTION, TRIGGER INITIAL LEARNING SETTING)
By “IP Automatic Correction, Trigger Initial Learning Setting”, the power train controller recognizes the mechani-
• “Engine Speed” : 1700 to 1950 rpm
• “T/C (P/L) Oil Temperature” : 65 to 85 °C
• Parking brake lever: LOCK position.
30-234 D155AX-8
When the power train controller or transmission was replaced, be sure to perform this adjustment.


REMARK
4. On “Adjustment” screen, perform adjustment of “IP Auto-
matic Correction, Trigger Initial Learning Setting” with func-
tion switches.
F3: Not used.
F4: Not used.
F6: Starts auto calibration.
REMARK
The machine does not operate during the adjustment
work.
1) Start the engine, warm it up sufficiently, and hold the power train oil temperature within the range of
conditions.
2) Hold the engine speed within the range of conditions with the fuel control dial.
3) Press F6 to start the automatic compensation work, and check that “1/11” is newly displayed on the
screen.
4) When “11/11” appears on the screen, press F6 and check that the warning buzzer sounds.
D155AX-8 30-235
REMARK
• When performing the adjustment with the “Adjustment menu (IP Automatic Correction, Trigger Ini-
tial Learning Setting)”, see “METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (IP AUTO-
MATIC CORRECTION, TRIGGER INITIAL LEARNING SETTING)”.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 7843 (TRANSMISSION

CLUTCH IP MANUAL INITIAL CORRECTION)
By “Transmission Clutch IP Manual Initial Correction”, the power train controller recognizes the mechanical con-
dition of the transmission.
If the auto correction cannot be performed in “IP Automatic Correction, Trigger Initial Learning Setting” (Adjust-
ment ID 7842), the correction is performed manually.


REMARK
30-236 D155AX-8
4. On “Adjustment” screen, perform adjustment of “Transmis-

sion Clutch IP Manual Initial Correction” with function
switches.
REMARK
• Press F1 and F2 simultaneously, all the compensation
values are cleared to zero, and warning buzzer
sounds.
• The machine does not operate during the adjustment
work.
1) Select the clutch to be manually corrected with up
switch (1) or down switch (2) of the joystick (steering,
directional and gear shift lever) (PCCS lever).
ment value.
REMARK
By performing this adjustment, the saved compensa-
tion values are effective even while the starting switch
is turned to OFF position.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 7845 (IP LEARNING DIS-
PLAY)
By “IP Learning Display”, correction information of “IP Automatic Correction, Trigger Initial Learning Setting” (Ad-
justment menu or Adjustment ID: 7842) or “Transmission Clutch IP Manual Initial Correction” (Adjustment ID:
7843) can be checked.

D155AX-8 30-237

REMARK
The “IP Learning Display ”appears. The correction information
can be checked.
F3: Switches the display.
F4: Switches the display.
F6: Not used.
REMARK
This adjustment becomes ineffective when pressing F5 and re-
turning the screen to “Input ID”.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 7847 (TRANSMISSION

CLUTCH FILL TIME MANUAL INITIAL CORRECTION)
By “Transmission Clutch Fill Time Manual Initial Correction”, the power train controller recognizes the mechani-
If the auto correction cannot be performed in “IP Automatic Correction, Trigger Initial Learning Setting” (Adjust-
ment ID: 7842 or Adjustment menu), the correction is performed manually.

30-238 D155AX-8

REMARK
4. On “Adjustment” screen, perform adjustment of “Transmis-
sion Clutch Fill Time Manual Initial Correction” with func-
tion switches.
REMARK
• Press F1 and F2 simultaneously, all the compensation
values are cleared to zero, and warning buzzer
sounds.
• The machine does not operate during the adjustment
work.
1) Select the clutch to be manually corrected with up
switch (1) and down switch (2) of the joystick (steer-
ing, directional and gear shift lever) (PCCS lever).
ment value.
REMARK
The value displayed when the clutch is selected is the
correction information automatically or manually set
previously.
REMARK
By performing this adjustment, the saved compensation values are effective even while the starting
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8000 (BLADE LIFT LEVER
By “Blade Lift Lever Neutral Position Adjustment”, the work equipment controller recognizes the neutral position
of the lift potentiometer if the blade control lever.
D155AX-8 30-239


REMARK
F3: Not used.
F4: Not used.
30-240 D155AX-8
REMARK
• By “Blade Lift Lever Neutral Position Adjustment”, the sensitivity of the blade control lever is not ad-
justed. To adjust the sensitivity of the blade control lever on the lift side, perform Adjustment IDs:
8020 to 8023.
• When performing the adjustment with the “Adjustment menu (Blade Lift Lever Neutral Position Ad-
justment)”, see “METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (BLADE LIFT LEVER
NEUTRAL POSITION ADJUSTMENT)”.
RAISE STROKE END ADJUSTMENT)
By “Blade Lift Lever RAISE Stroke End Adjustment”, the work equipment controller recognizes the maximum
RAISE position of the lift potentiometer of the blade control lever.


REMARK
D155AX-8 30-241

Lever RAISE Stroke End Adjustment” with function
switches.
F3: Not used.
F4: Not used.
1) Hold the lift control side of the blade control lever at
the RAISE stroke end position.
REMARK
• By “Blade Lift Lever RAISE Stroke End Adjustment”, the sensitivity of the blade control lever is not
adjusted. To adjust the sensitivity of the blade control lever on the lift side, perform Adjustment IDs:
8020 to 8023.
LOWER STROKE END ADJUSTMENT)
By “Blade Lift Lever LOWER Stroke End Adjustment”, the work equipment controller recognizes the maximum
LOWER position of the lift potentiometer of the blade control lever.

30-242 D155AX-8

REMARK
Lever LOWER Stroke End Adjustment” with function
switches.
F3: Not used.
F4: Not used.
1) Hold the lift control side of the blade control lever at
the LOWER stroke end position.
REMARK
• By “Blade Lift Lever LOWER Stroke End Adjustment”, the sensitivity of the blade control lever is not
adjusted. To adjust the sensitivity of the blade control lever on the lift side, perform Adjustment IDs:
8020 to 8023.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8003 (BLADE TILT LEVER
By “Blade Tilt Lever Neutral Position Adjustment”, the work equipment controller recognizes the neutral position
of the tilt potentiometer if the blade control lever.
D155AX-8 30-243


REMARK
F3: Not used.
F4: Not used.
REMARK
• By “Blade Tilt Lever Neutral Position Adjustment”,
the sensitivity of the blade control lever is not ad-
justed. To adjust the sensitivity of the blade control
lever on the tilt side, perform Adjustment ID: 8024
and Adjustment ID: 8025.
• When performing the adjustment with the Adjust-
ment menu (Blade Tilt Lever Neutral Position Ad-
justment), see “METHOD FOR ADJUSTING WITH
ADJUSTMENT MENU (BLADE TILT LEVER NEU-
TRAL POSITION ADJUSTMENT)”.
RIGHTMOST POSITION ADJUSTMENT)
By “Blade Tilt Lever Rightmost Position Adjustment”, the work equipment controller recognizes the right maxi-
mum position of the tilt potentiometer of the blade control lever.
30-244 D155AX-8


REMARK
Lever Rightmost Position Adjustment” with function
switches.
F3: Not used.
F4: Not used.
1) Hold the tilt control side of the blade control lever at
the right stroke end position.
REMARK
• By “Blade Tilt Lever Rightmost Position Adjustment”, the sensitivity of the blade control lever is not
adjusted. To adjust the sensitivity of the blade control lever on the tilt side, perform Adjustment ID:
D155AX-8 30-245
LEFTMOST POSITION ADJUSTMENT)
By “Blade Tilt Lever Leftmost Position Adjustment”, the work equipment controller recognizes the left maximum
position of the tilt potentiometer of the blade control lever.


REMARK
Lever Leftmost Position Adjustment” with function
switches.
F3: Not used.
F4: Not used.
1) Hold the tilt control side of the blade control lever at
the left stroke end position.
30-246 D155AX-8
REMARK
• By “Blade Tilt Lever Leftmost Position Adjustment”, the sensitivity of the blade control lever is not
adjusted. To adjust the sensitivity of the blade control lever on the tilt side, perform Adjustment ID:
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8006 (RIPPER LIFT LEV-
ER NEUTRAL POSITION ADJUSTMENT)
By “Ripper Lift Lever Neutral Position Adjustment”, the work equipment controller recognizes the neutral position
of the lift potentiometer if the ripper control lever.


REMARK
D155AX-8 30-247
4. On “Adjustment” screen, perform adjustment of “Ripper Lift

F3: Not used.
F4: Not used.
1) Hold the ripper control lever at the neutral position.
REMARK
• By “Ripper Lift Lever Neutral Position Adjustment”,
the sensitivity of the ripper control lever is not ad-
justed.
• When performing the adjustment with the Adjust-
ment menu (Ripper Lift Lever Neutral Position Ad-
justment), see “METHOD FOR ADJUSTING WITH
ADJUSTMENT MENU (RIPPER LIFT LEVER
NEUTRAL POSITION ADJUSTMENT)”.
ER RAISE STROKE END ADJUSTMENT)
By “Ripper Lift Lever RAISE Stroke End Adjustment”, the work equipment controller recognizes the maximum
RAISE position of the lift potentiometer of the ripper control lever.

30-248 D155AX-8

REMARK
Lever RAISE Stroke End Adjustment” with function
switches.
F3: Not used.
F4: Not used.
1) Hold the lift control side of the ripper control lever at
the RAISE stroke end position.
REMARK
• By “Ripper Lift Lever RAISE Stroke End Adjustment”, the sensitivity of the ripper control lever is not
adjusted.
ER LOWER STROKE END ADJUSTMENT)
By “Ripper Lift Lever LOWER Stroke End Adjustment”, the work equipment controller recognizes the maximum
LOWER position of the lift potentiometer of the ripper control lever.
D155AX-8 30-249


REMARK
Lever LOWER Stroke End Adjustment” with function
switches.
F3: Not used.
F4: Not used.
1) Hold the lift control side of the ripper control lever at
the LOWER stroke end position.
REMARK
• By “Ripper Lift Lever LOWER Stroke End Adjustment”, the sensitivity of the ripper control lever is
not adjusted.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8020 (BLADE LIFT RAISE
CURRENT VALUE CORRECTION)
By “Blade Lift RAISE Current Value Correction”, the sensitivity of start of blade movement is adjusted when op-
erating the blade control lever in the lift RAISE direction with Blade Fine Control OFF.
30-250 D155AX-8


REMARK
RAISE Current Value Correction” with function switches.
F3: Decreases the adjustment value “Current Offset”.
F4: Increases the adjustment value “Current Offset”.
ment value.
REMARK
If the value has already been adjusted, the adjusted
value is displayed. You can adjust the value as many
times as desired.
D155AX-8 30-251
REMARK
• Blade operation during adjustment wok is not necessary. However, perform blade lift RAISE opera-
tion after the adjustment, and check that there is no problem in the actual operation sensitivity.
(Turn Blade Fine Control to OFF before checking.)
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8021 (BLADE LIFT LOW-
ER CURRENT VALUE CORRECTION)
By “Blade Lift LOWER Current Value Correction”, the sensitivity of start of blade movement is adjusted when
operating the blade control lever in the lift LOWER direction with Blade Fine Control OFF.


REMARK
30-252 D155AX-8

LOWER Current Value Correction” with function switches.
F4: Increases the adjustment value Current Offset.
ment value.
REMARK
times as desired.
REMARK
• Blade operation during adjustment wok is not necessary. However, perform blade lift LOWER oper-
ation after the adjustment, and check that there is no problem in the actual operation sensitivity.
(Turn Blade Fine Control to OFF before checking.)
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8022 (BLADE LIFT RAISE
CURRENT VALUE CORRECTION (FINE CONTROL MODE))
By “Blade Lift RAISE Current Value Correction (Fine Control Mode)”, the sensitivity of start of blade movement
is adjusted when operating the blade control lever in the lift RAISE direction with Blade Fine Control ON.

D155AX-8 30-253

REMARK
RAISE Current Value Correction (Fine Control Mode)” with
function switches.
ment value.
REMARK
times as desired.
REMARK
• Blade operation during adjustment wok is not necessary. However, perform blade lift RAISE opera-
tion after the adjustment, and check that there is no problem in the actual operation sensitivity.
(Turn Blade Fine Control to ON before checking.)
ER CURRENT VALUE CORRECTION (FINE CONTROL MODE))
By “Blade Lift LOWER Current Value Correction (Fine Control Mode)”, the sensitivity of start of blade movement
is adjusted when operating the blade control lever in the lift LOWER direction with Blade Fine Control ON.
30-254 D155AX-8


REMARK
LOWER Current Value Correction (Fine Control Mode)”
with function switches.
ment value.
REMARK
times as desired.
REMARK
• Blade operation during adjustment wok is not necessary. However, perform blade lift LOWER oper-
ation after the adjustment, and check that there is no problem in the actual operation sensitivity.
(Turn Blade Fine Control to ON before checking.)
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8024 (BLADE TILT LEFT
By “Blade Tilt LEFT Current Value Correction”, the sensitivity of start of blade movement is adjusted when oper-
ating the blade control lever in the tilt left direction.
D155AX-8 30-255


REMARK
LEFT Current Value Correction” with function switches.
ment value.
REMARK
times as desired.
30-256 D155AX-8
REMARK
• Blade operation during adjustment wok is not necessary. However, operate the blade tilt left after
the adjustment, and check that there is no problem in the actual operation sensitivity.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 8025 (BLADE TILT RIGHT
By “Blade Tilt RIGHT Current Value Correction”, the sensitivity of start of blade movement is adjusted when op-
erating the blade control lever in the tilt right direction.


REMARK
D155AX-8 30-257

RIGHT Current Value Correction” with function switches.
ment value.
REMARK
times as desired.
REMARK
• Blade operation during adjustment wok is not necessary. However, operate the blade tilt right after
the adjustment, and check that there is no problem in the actual operation sensitivity.
ER CURRENT VALUE CORRECTION)
“Blade Lift LOWER Current Value Correction” restricts and lowers the blade LOWER EPC command current to
limit the travel speed when Blade Lower Speed mode is ON.

30-258 D155AX-8

REMARK
LOWER Current Value Correction” with function switches.
F3: Decreases the adjustment value by 5.
F4: Increases the adjustment value by 5.
1) To change the adjustment value, press F3 or F4 to in-
crease or decrease the adjustment value.
REMARK
value is displayed. If the value is within the allowable
range, further adjustment can be performed.
2) To change the adjustment value, press F6 to check that the warning buzzer sounds.
REMARK
By performing this adjustment, the saved compensation values are effective even while the starting
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 9995 (CONTROL BRAKE

RELEASE MODE)
“Control Brake Release Mode” opens the control brake (R.H. and L.H. brake ECMV) to check the operation of
the backup brake (brake pedal solenoid valve).
D155AX-8 30-259


REMARK
When the “Control Brake Release Mode” appears, hold the
control brake (R.H. and L.H. brake ECMV) open.
F3: Not used.
F4: Not used.
F6: Not used.
REMARK
• If the joystick (steering, directional and gear shift lever)
(PCCS lever) is not at NEUTRAL position and the machine
is not stopped, the control brake (R.H. and L.H. brake
ECMV) is not held open.
returning the screen to “Input ID”.
• When performing the adjustment with the “Adjustment
menu (Control Brake Release Mode)”, see “METHOD FOR
ADJUSTING WITH ADJUSTMENT MENU (CONTROL
BRAKE RELEASE MODE)”.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 9996 (SUDDEN STOP

PREVENT VALVE OPERATION MODE)
“Sudden Stop Prevent Valve Operation Mode” stops the sudden stop prevention solenoid valve and control
brake (R.H. and L.H. brake ECMV), and checks the operation of the sudden stop prevention valve.
30-260 D155AX-8


REMARK
When “Sudden Stop Prevent Valve Operation Mode” screen
appears, the sudden stop solenoid valve and control brake
(R.H. and L.H. brake ECMV) are stopped.
F3: Not used.
F4: Not used.
F6: Not used.
REMARK
• Sudden stop prevention solenoid valve and control brake
(R.H. and L.H. brake ECMV) are not stopped if the joystick
(steering, directional and gear shift lever) (PCCS lever) is
not at NEUTRAL position and the machine is not stopped.
returning the screen to “Input ID”.
• When performing the adjustment with the “Adjustment
menu (Sudden Stop Prevent Valve Operation Mode)”, see
“METHOD FOR ADJUSTING WITH ADJUSTMENT MENU
(SUDDEN STOP PREVENT VALVE OPERATION MODE)”.
D155AX-8 30-261
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 9997 (HIGH IDLE CUT
MODE)
“High Idle Cut Mode” restricts the high idle speed.


REMARK
4. On “Adjustment” screen, perform adjustment of “High Idle
Cut Mode” with function switches.
F3: Decreases the adjustment value “HIGH IDLE RPM
SET MODE”.
F4: Increases the adjustment value “HIGH IDLE RPM SET
MODE”.
ment value.
REMARK
The adjustment value increases or decreases by
50 rpm.
30-262 D155AX-8

REMARK
• To cancel the restriction of the high idle speed, set the adjustment value to the originally-set high
idle speed 2100 rpm.
METHOD FOR PERFORMING WITH ADJUSTMENT ID: 9998 (MAX. SPEED

RANGE SETTING MODE)
“Max. Speed Range Setting Mode” restricts the maximum gear speed of the transmission.


REMARK
appear (you can input Adjustment ID again with the nu-
meral input switches when this screen is displayed).
D155AX-8 30-263
4. On “Adjustment” screen, perform adjustment of “Max.

Speed Range Setting Mode” with function switches.
F3: Decreases the adjustment value “MAX SHIFT”.
F4: Increases the adjustment value “MAX SHIFT”.
1) Press F3 or F4 to select the adjustment value.
REMARK
The restricted gear speed is effective both in Automat-
ic Shift Mode and Manual Shift Mode.
3) Turn the starting switch to OFF position, and then turn the starting switch to ON position again.
REMARK
• The adjusted setting is effective after turning the starting switch to ON position again.
• To clear the maximum gear speed restriction, set the adjustment value to the maximum gear speed
(3RD) (factory default).
METHOD FOR PERFORMING NO INJECTION CRANKING

If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient
lubrication with oil. To prevent this, the machine has a function to crank the engine without injecting fuel to lubri-
cate the engine before starting it.
Setting of No-Injection cranking to be performed while the engine is stopped.
Even if the operator tries to perform the No-Injection cranking while the engine is running, the message “Engine
is operating” is displayed and the No-Injection cranking does not become effective.
This function can be selected even when the engine is running.
However, if you execute No-Injection cranking, a message
“Please turn the key off once” is displayed on the screen.
Even if the confirmation screen is displayed and No-Injection

cranking is operated, the function does not become effective in
the following cases. Turn the starting switch OFF once to oper-
ate.
• The communication between the machine monitor and en-
gine controller is not normal.
• An engine start operation has been performed before the
message “No-injection cranking is possible” is displayed.
30-264 D155AX-8
1. Select “No-Injection Cranking” on “Service Menu” screen.
2. When “No-Injection Cranking” screen is displayed, confir-

mation for the execution of No-Injection cranking is dis-
played. Select the action with the function switch.
F5: Does not implement (returns the screen to “Service
Menu”).
F6: Executes.
3. If No-Injection cranking (no fuel injection on every cylinder)

is enabled, a message “No-injection cranking is possible”
is displayed on the screen. Crank the engine with the start-
ing motor.
NOTICE
Do not crank the engine for 20 seconds or longer to
protect the starting motor.
REMARK
While the screen is changing to the screen as shown in the
figure, the screen of “Getting Ready” is displayed.
4. After the cranking is completed, turn the starting switch to OFF position.
You cannot change the screen described above to another screen.
KOMTRAX SETTINGS MENU

METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS)
On “KOMTRAX setting display” screen, select “Terminal Status” with the function switches or numeral input
switches.
"“Terminal Status”" is used to check the setting condition of the KOMTRAX terminal.
1. Select “KOMTRAX Settings” on “Service Menu” screen.
D155AX-8 30-265
2. On “KOMTRAX Settings”screen, select “Terminal Status”

REMARK
3. On “Terminal Status” screen, the following items are dis-

played.
Terminal Type: Model name of the KOMTRAX communica-
tion modem
KOMTRAX Communication Inspection: State of radio sta-
tion establishment
GMT time: Greenwich Mean Time (add 9 hours to it for Ja-
pan time)
F5: Returns the screen to “KOMTRAX Settings” screen
METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION

STATUS)
The setting and operating state of KOMTRAX can be checked by using “KOMTRAX Settings” screen.
“GPS & Communication State” is used to check the positioning and communication state of the KOMTRAX ter-
minal.
2. On “KOMTRAX Settings” screen, select “GPS & Communi-

cation State” with the function switches or numeral input
switches.
REMARK
30-266 D155AX-8
3. On “GPS & Communication State” screen, the following

items are displayed.
Positioning: GPS positioning state
Communication: Communication environment and connec-
tion state of the communication modem
Number of message not yet sent: Number of mails that are
saved on the machine monitor and have not yet been
transmitted
F5: Returns the screen to “KOMTRAX Settings” screen
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS)

The setting and operating state of KOMTRAX can be checked by using the menu of “KOMTRAX Settings”.
“Modem Information” is used to check the phone number and IMSI of the KOMTRAX communication modem.
2. On “KOMTRAX Settings”screen, select “Modem Informa-

tion” with the function switches or numeral input switches.
REMARK
3. Display the phone number and IMSI.

F5: Returns the screen to “KOMTRAX settings” screen.
METHOD FOR DISPLAYING SERVICE MESSAGE

Special messages for the technician sent from the KOMTRAX base station (a distributor, etc.) can be checked
with this function.
D155AX-8 30-267
If a received message includes a setting operation, a return mail can be sent by using the numeral input
switches as well.
1. Select “Service Message” on “Service Menu” screen.
2. Displaying message
• Displaying message (read only)
If there is a message, its contents are displayed. If
there is no message, “No message.” is displayed.
F5: Returns the screen to “Service Menu” screen
REMARK
• This message is different from that sent to the op-
erator with the machine monitor in the operator
mode.
• Since this message is special for the technician,
the message monitor is not displayed as it is dis-
played in the operator mode.
• Display of message (with return mail function)
If a message provides the Numeric Input line under
the text, input a proper number by using the numeral
input switches and enter it by using the function
switch, and the information is returned to the KOM-
TRAX base station.
F5: Returns the screen to “KOMTRAX Settings”
screen
F6: Enters and sends the input value.
REMARK
• This message is different from that sent to the op-
erator in the operator mode.
• Since this message is special for the technician,
the message monitor is not displayed as it is dis-
played in the operator mode.
30-268 D155AX-8
30 TESTING AND ADJUSTING METHOD FOR STARTING UP KOMTRAX
METHOD FOR STARTING UP KOMTRAX

Method for starting-up KOMTRAX
Observe the following when using KOMTRAX.
1. KOMTRAX key person performs “Machine Registration” by using KOMTRAX client PC.
2. Perform “KOMTRAX Communication Inspection”.
• For operation procedures, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.
When KOMTRAX terminal is replaced.

Observe the following when replacing KOMTRAX terminal and using it again.
1. Our technician provides a new terminal, and records the part number and serial number.
2. Our technician replaces the terminal, and perform “KOMTRAX Communication Inspection”. Our technician
notifies KOMTRAX key person of the completion of inspection work and new terminal information.
3. KOMTRAX key person performs “Terminal Replacement” by using KOMTRAX client PC.
4. KOMTRAX key person fills in required items on “Terminal Replacement Sheet”, and send it by email to
KOMTRAX support center via KOMTRAX administrator in the subsidiary.
• For details, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.
KOMTRAX Communication Inspection on machine side

• KOMTRAX Communication Inspection must be done to check whether normal communication is available
from the terminal when the KOMTRAX terminal is replaced or started up.
• By performing this inspection, KOMTRAX starts communication.
• GPS and data communication are checked during the KOMTRAX Communication Inspection. Accordingly,
it is preferable to place the machine under the open sky where radio wave from the satellite is not blocked.
The opening inspection may not be completed when the machine is placed indoor where radio wave from
the satellite is blocked.
1. Check the machine for KOMTRAX Communication Inspection
Observe the following when checking if KOMTRAX Communication Inspection is to be performed or not.
1) On “Service Menu” screen, select “KOMTRAX Set-
tings” with function switches or numeral input
switches.
D155AX-8 30-269
METHOD FOR STARTING UP KOMTRAX 30 TESTING AND ADJUSTING
2) On “KOMTRAX Settings” screen, select “Terminal Sta-

tus” with the function switches or numeral input
switches.
3) On “Terminal Status” screen, check the state of “KOM-

TRAX Communication Inspection”.
If “KOMTRAX Communication Not Open” is displayed
on the state of “KOMTRAX Communication Inspec-
tion”, Perform step 2. If “Already Open” is displayed,
KOMTRAX Communication Inspection is not needed.
2. KOMTRAX Communication Inspection
Observe the following when performing KOMTRAX Com-
munication Inspection.
1) On “Service Menu” screen, select “KOMTRAX Set-

tings” with function switches or numeral input
switches.
2) On “KOMTRAX Settings” screen, select “GPS & Com-

munication State” with the function switches or numer-
al input switches.
30-270 D155AX-8
3) After “GPS & Communication State” screen is dis-

played, press the numerical switches in order while
pressing 4 as 4 + 1 → 2 → 3.
4) After “Are you sure you want to inspect?” is displayed,

execute the inspection with the function switch.
F5: Returns the screen to “GPS & Communication
State” screen
F6: Executes KOMTRAX Communication Inspection.
5) The screen displays the state of KOMTRAX Commu-

nication inspection. Check on this screen that all item
are “OK”.
“Modem”: “OK” is displayed when communication area
is confirmed.
“GPS”: “OK” is displayed when it acquires GPS data.
“Transmission”: “OK” is displayed when it transmits
data correctly.
“Inspection State”: When all items of “Modem”, “GPS”,
and “Transmission” are “OK”, “OK” is displayed on
“Inspection State”.
• It takes 90 seconds to 15 minutes for all items to be “OK”.
• While waiting for all items to be “OK”, operation such as turning the starting switch to OFF position
or starting the engine will not be a problem.
If there is nothing abnormal, KOMTRAX Communication Inspection finishes automatically. Select
“KOMTRAX Settings” → “Terminal Status” of “Service Menu” to make sure that “Already Open” is
indicated for the item in “KOMTRAX Communication Inspection”.
• KOMTRAX Communication Inspection may not be completed when the machine is placed indoor
where radio wave from the satellite is blocked.
D155AX-8 30-271
METHOD FOR STARTING UP KOMTRAX 30 TESTING AND ADJUSTING
6) When all items are “OK”, “KOMTRAX Communication

Opened.” screen automatically displayed.
Press Enter switch. “GPS & Communication State” ap-
pears, and the KOMTRAX Communication Inspection
for machine side is completed.
Other than the above, perform step 3.
3. Troubleshooting when KOMTRAX Communication Inspec-
tion is finished unsuccessfully
• If any of 1) to 5) in step 2 is finished unsuccessfully,
perform inspection from 1) in step 2.
• If 6) in step 2 is finished unsuccessfully, following
problems are suspected.
Troubleshooting when the failure occurs

Phenomenon Cause Required action
GPS does not be- Something on the cab blocks off GPS sat- Remove the obstacle on the cab.
come OK. ellites acquisition.
GPS antenna cable is not connected to Check for the connection. If the connection is loose,
the machine monitor, or they are loose. secure it.
Modem does not The mobile phone is out of communication Check for state of in/out communication range with
become OK. range. your mobile phone.
If it is out of communication range, move into com-
munication reception range and perform inspection.
Communication antenna cable is not con- Check for the connection. If the connection is loose,
nected to the KOMTRAX terminal, or they secure it.
are loose.
KOMTRAX terminal is not connected to Check for the connection. If the connection is loose,
machine side wiring harness, or they are secure it.
loose.
4. After troubleshooting, perform 1) in step 2 again.
30-272 D155AX-8
When the problems are not solved, contact your KOMTRAX support center.
D155AX-8 30-273
ADJUST REARVIEW CAMERA ANGLE 30 TESTING AND ADJUSTING
ADJUST REARVIEW CAMERA ANGLE

k Always adjust the camera before starting work. If it is not adjusted properly, you cannot secure the
visibility and a serious personal injury or death may result.
ADJUST REARVIEW CAMERA ANGLE

2. If the image displayed on the machine monitor is out of po-

sition, loosen mounting bolts (3) (3 places) of rearview
camera (2) and adjust angle (A).
REMARK
• Set angle (A) to 42 ° as standard.
• Adjust so that the range from sprocket center (a) to
machine rear end (b) is displayed on the machine mon-
itor.
• Dimension (c): 3790 mm (reference value)
3. Tighten mounting bolts (3).
30-274 D155AX-8
30 TESTING AND ADJUSTING HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER

k Before connecting the wiring harness connector, be sure to completely remove sand, dust, water,
etc., inside the connector on the controller side.
Disconnecting or connecting work of the connector between the engine controller and the engine must be per-
formed only when the starting switch and battery disconnect switch are in OFF position and the system operat-
ing lamp is off.
Measure it while a T-adapter is inserted into or connected to the connector between the engine controller and
engine for diagnosis.
REMARK
You may turn the starting switch to OFF or ON position but do not turn it to START position.
D155AX-8 30-275
HANDLE BATTERY DISCONNECT SWITCH 30 TESTING AND ADJUSTING
HANDLE BATTERY DISCONNECT SWITCH

k A hazard can result if an unauthorized person turns
switch key (1) to ON position carelessly.
NOTICE
When turning the battery disconnect switch to OFF posi-
tion, always remove the switch key.
• The operating condition of each controller can be checked
with the system operating lamp (2) to prevent the abnor-
mal end of the disconnection of the battery power supply
circuit while the controllers are in operation.
• Before shutting off the battery power supply circuit, turn the
starting switch to OFF position, and check that the system operating lamp goes out, then turn the battery
disconnect switch to OFF position.
• If the battery disconnect switch is turned to OFF position (battery power supply circuit is OFF) while the sys-
tem operating lamp is lit, data loss error of controller may occur. Never operate the battery disconnect
switch while the system operating lamp is lit.
• The system operating lamp goes out in max. 6 minutes after the starting switch is turned to OFF position.
• The system operating lamp may sometimes light up while the starting switch is turned to OFF position be-
cause KOMTRAX terminal may maintain its communication under this condition.
• Even if the system operating lamp is off, it may seem to be lit slightly because of a very little current inside
the controller. This phenomenon does not indicate abnormality.
• The KOMTRAX terminal performs communication periodically during the starting switch is in OFF posi-
tion, thus it repeats starting and stopping.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including
the communication state and machine stop time. It may be lit for a maximum of approximately 1 hour.
• When you want to open the battery circuit for maintenance but the system operating lamp is lit, turn the
starting switch to ON position once, turn it to OFF position, and then the lamp goes out in 6 minutes. After
system operating lamp goes out, turn the battery disconnect switch to OFF position immediately.
30-276 D155AX-8
30 TESTING AND ADJUSTING TEST DIODES
TEST DIODES
Test the diode array (8-pin) and the single diode (2-pin) accord-
ing to the following procedure.
The continuity directions of the diode array are as shown in the
figure.
REMARK
The continuity direction of the single diode is indicated on the
surface of the diode.
METHOD FOR TESTING DIODE USING DIGITAL TESTER

1. Select the screen to the diode range to check the dis-
played values.
REMARK
When an ordinary circuit multimeter is used, the voltage of
the internal battery is indicated.
2. Apply the red (+) lead of the multimeter to the anode (P)
side of the diode and apply the black (-) lead to the cath-
ode (N) side, and check the indicated value.
3. Evaluate the condition of the diode by the indicated value.
Indicated value does not change: No continuity (defective)
Indicated value changes: Continuity (normal) (*)
In the case of a silicon diode, a value in the range between 460 to 600 mV is indicated.
METHOD FOR TESTING DIODE USING ANALOG TESTER

1. Selects the screen for resistance range.
2. Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the
cathode (N) side, and check that the pointer moves.
3. Apply the red (+) lead of the multimeter to the cathode (N) side of the diode and apply the black (-) lead to
the anode (P) side, and check that the pointer moves.
4. Evaluate the condition of the diode by the movement of the pointer.
Result of movement of the pointer
Judgment
Step 2 Step 3
Normal (however, the movement of
the pointer (resistance) varies by type
Moves Does not move
of tester, or selection of measuring
range).
Moves Moves Defective (internal short circuit)
Does not move Does not move Defective (internal open circuit)
D155AX-8 30-277
Pm CLINIC SERVICE 30 TESTING AND ADJUSTING
Pm CLINIC
Pm CLINIC SERVICE
Model Serial No. Service meter
□D155AX-8 h
User name Date of inspection Inspector
Specifications
Front attachment Rear attachment Shoe width
□ SIGMA dozer □ Multi–shank ripper □560 mm □(　　　 )
□ Semi-U dozer □ Variable giant ripper □610 mm
□ Full-U dozer □ Counter weight ( kg) □660 mm
□ □ □710 mm
Operating condition
Quarry, mining Construction Type of soil Contents of operation
□ Construction, civil engi- %
□ Coal □ Rock □ Dozing
neering %
□ Gold □ Gravel □ Side cutting
□ Road %
□ Limestone □ Sand □ Ripping
□ Tunnel %
□ □ Clay □ Travel
□
Check of oil and coolant levels

□ Engine coolant When necessary
□ Engine oil level □ Damper case oil level □ Final drive oil level
□ Hydraulic oil level □ Power train oil level □
Ambient temperature Altitude
°C m
Operator's comment
Result of visual inspection
Abnormality record in mechanical systems Abnormality record in electrical systems

AA10NX Times/First time h/Latest h Times/First time h/Latest h
AB00MA Times/First time h/Latest h Times/First time h/Latest h
B@BAZG Times/First time h/Latest h Times/First time h/Latest h
B@BCNS Times/First time h/Latest h Times/First time h/Latest h
B@BCZK Times/First time h/Latest h Times/First time h/Latest h
B@CENS Times/First time h/Latest h Times/First time h/Latest h
30-278 D155AX-8
30 TESTING AND ADJUSTING Pm CLINIC SERVICE
Abnormality record in mechanical systems Abnormality record in electrical systems

B@HANS Times/First time h/Latest h Times/First time h/Latest h
CA234 Times/First time h/Latest h Times/First time h/Latest h
Max. range of engine coolant temperature gauge

Coolant temperature Color of monitor
Coolant temperature
gauge level light (a)
W1 105 °C
Red
W2 102 °C
W3 100 °C
W4 85 °C Green
W5 60 °C
W6 30 °C White
Max. range of power train oil temperature gauge

Oil temperature lev- Power train oil tem- Color of monitor
el perature light (a)
P1 130 °C
Red
P2 120 °C
P3 118 °C
P4 90 °C Green
P5 50 °C
P6 0 °C White
Pm CLINIC CHECK SHEET

D155AX-8
NOTICE
Perform the checks after sufficient warm-up operation of the engine.
Model Serial No. Service meter User name Date of inspection Inspector
D155AX-8
D155AX-8 30-279
Engine
Engine SAA6D140E-7
Standard val- Meas- No
Goo
Item Testing conditions Unit ue for new Repair limit ured val- goo
d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
100 °C
Engine
• Operating Mode: P (Power
speed at
mode) rpm 2000 to 2100 2000 to 2100
high idle
(*1) • Fuel control dial: MAX (High
idle)
• Joystick (steering, directional,
and gear shift lever) (PCCS lev-
er): NEUTRAL
• Adjustment ID: 0007 “Engine
Decelerator Cutting”
to 100 °C
to 120 °C
Engine 100 °C
speed at rpm 715 to 765 715 to 765
low idle (*1) • Operating Mode: P (Power
mode)
er): NEUTRAL
to 100 °C
to 120 °C
Engine • Hydraulic oil temperature: 45 to
speed when 100 °C
decelerator rpm 1000 to 1050 1000 to 1050
pedal is de- • Operating Mode: P (Power
pressed (*1) mode)
• Fuel control dial: MAX (High
idle)
• Decelerator pedal: Depress the
pedal fully.
30-280 D155AX-8

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 120 °C
Engine • Hydraulic oil temperature: 45 to
speed at 100 °C
high idle
• Operating Mode: P (Power rpm 1825 to 1925 1825 to 1925
during neu-
tral deceler- mode)
ation (*1) • Fuel control dial: MAX (High
idle)
er): NEUTRAL
to 100 °C
to 120 °C
100 °C
Engine mode)
speed with
torque con- rpm 1490 to 1590 Max. 1380
idle)
verter stal-
led (*1) • Adjustment ID: 0530 “Stall
Mode”
• Gear shift mode: Manual gear
shift mode
er): Forward
D155AX-8 30-281

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 120 °C
100 °C
mode)
Engine idle)
speed at full rpm 1462 to 1562 Max. 1357
stall (*1) • Adjustment ID: 0530 “Stall
Mode”
shift mode
er): Forward
• Ripper control lever: RAISE re-
lief
• Engine oil tempera- Fuel control Min. 0.34 Min. 0.21
ture: Min. 80 °C dial: MAX
(High idle) {Min. 3.5} {Min. 2.1}
(Power mode)
directional, and
Engine oil gear shift lever) MPa
pressure (PCCS lever):
Fuel control { kg/cm2} Min. 0.10 Min. 0.08
NEUTRAL
dial: MIN
• Engine oil (*2) (Low idle) {Min. 1.0} {Min. 0.8}
EO10W30–LA
EO15W40–LA
EOS5W30–LA
EOS5W40–LA
30-282 D155AX-8

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 120 °C
Blowby kPa Max. 2.94 Max. 3.92
100 °C
pressure { mmH2O} {Max. 300} {Max. 400}
mode)
• Adjustment ID: 0530 “Stall
Mode”
• KCCV circuit disconnected
to 100 °C
to 120 °C
Boost pres- • Hydraulic oil temperature: 45 to kPa Min. 123 Min. 109
sure 100 °C { mmHg} {Min. 925} {Min. 820}
mode)
• Adjustment ID: 0530 “Stall
Mode”
to 100 °C
to 120 °C
Exhaust 100 °C
°C Max. 670 Max. 700
temperature • Operating Mode: P (Power
mode)
• At torque converter stall (Adjust-
ment ID: 0530 "Stall Mode")
• Whole speed range ambient
temperature: (20 °C)
*2: KES diesel engine oil
D155AX-8 30-283
Cooling fan
Engine SAA6D140E-7
Goo
d
machine ue d
100 °C
Cooling fan • Fuel control dial: MAX (High
rpm 1425 to 1475 1425 to 1475
speed idle)
• Adjustment ID: 1005 (Fan
100% Mode)
100 °C
Cooling fan MPa Max. 20.58 Max. 20.58
circuit oil
idle) { kg/cm2} Max. {210} Max. {210}
pressure
• Adjustment ID: 1005 (Fan
100% Mode)
Power train
Engine SAA6D140E-7
Goo
d
machine ue d
• Engine coolant Fuel control Max. 1.0 Max. 1.0
temperature: 60 to dial: MAX
(High idle) Max. {10.0} Max. {10.0}
100 °C
perature: 70 to
80 °C
Torque con- • Hydraulic oil tem-
verter inlet perature: 45 to MPa
pressure 100 °C Fuel control { kg/cm2}
(*1) 0.05 to 0.49 0.05 to 0.49
• Operating Mode: P dial: MIN {0.5 to 5.0} {0.5 to 5.0}
(Power mode) (Low idle)
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL
30-284 D155AX-8

Engine SAA6D140E-7
Goo
d
machine ue d
• Engine coolant Fuel control 0.29 to 0.69 0.29 to 0.69
(High idle) {3.0 to 7.0} {3.0 to 7.0}
100 °C
perature: 70 to
80 °C
Torque con- • Hydraulic oil tem-
verter outlet perature: 45 to MPa
pressure 100 °C Fuel control { kg/cm2}
(*1) 0.05 to 0.29 0.05 to 0.29
• Operating Mode: P dial: MIN
(Low idle) {0.5 to 3.0} {0.5 to 3.0}
(Power mode)
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL
to 100 °C
to 80 °C
100 °C
Torque con- • Operating Mode: P (Power
verter lock- mode) MPa 1.27 to 1.57 1.17 to 1.47
up clutch
pressure • Fuel control dial: MAX (High { kg/cm2} {13 to 16} {12 to 15}
(LU) idle)
er): Forward (idle rotation)
• Gear shift mode: Automatic
gear shift
D155AX-8 30-285

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 80 °C
100 °C
Torque con-
• Operating Mode: P (Power MPa 2.55 to 2.94 2.55 to 2.94
verter stator
mode)
clutch pres- { kg/cm2} {26.0 to 30.0} {26.0 to 30.0}
sure (SC) • Fuel control dial: MAX (High
idle)
er): NEUTRAL
• During neutral deceleration op-
eration
to 100 °C
to 80 °C
Transmis- 100 °C
sion main MPa 2.99 to 3.38 Min. 2.79
relief pres- • Operating Mode: P (Power
{ kg/cm2} {30.5 to 34.5} {Min. 28.5}
sure (TM) mode)
idle)
er): NEUTRAL
to 100 °C
to 80 °C
Transmis- 100 °C
sion forward MPa 26.5 to 3.04 Min. 2.40
clutch pres- { kg/cm2} {27.0 to 31.0} {Min. 24.5}
sure (F)
mode)
idle)
shift (F3)
30-286 D155AX-8

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 80 °C
Transmis- 100 °C
sion reverse MPa 2.74 to 3.14 Min. 2.60
clutch pres- { kg/cm2} {28.0 to 32.0} {Min. 26.5}
sure (R)
mode)
idle)
shift (R3)
to 100 °C
to 80 °C
Transmis- • Hydraulic oil temperature: 45 to

sion 1st 100 °C MPa 2.81 to 3.11 Min. 2.62
clutch pres- • Operating Mode: P (Power { kg/cm2} {28.7 to 31.7} {Min. 26.7}
sure (1ST) mode)
shift (F1)
to 100 °C
to 80 °C

sion 2nd 100 °C MPa 2.55 to 2.94 Min. 2.40
sure (2ND) mode)
shift (F2)
D155AX-8 30-287

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 80 °C

sion 3rd 100 °C MPa 2.81 to 3.11 Min. 2.62
sure (3RD) mode)
shift (F3)
• Engine coolant Fuel control 2.94 to 3.34 Min. 2.16
(High idle) {30.0 to 34.0} {Min. 22.0}
100 °C
perature: 70 to
Right brake 80 °C
MPa
pressure • Hydraulic oil tem-
(RB) perature: 45 to Fuel control { kg/cm2} 2.94 to 3.34 Min. 2.16
100 °C dial: MIN
(Low idle) {30.0 to 34.0} {Min. 22.0}
(Power mode)
• Parking brake lev-
er: FREE position
• Engine coolant Fuel control 2.94 to 3.34 Min. 2.16
(High idle) {30.0 to 34.0} {Min. 22.0}
100 °C
perature: 70 to
Left brake 80 °C
MPa
pressure • Hydraulic oil tem-
(LB) perature: 45 to Fuel control { kg/cm2} 2.94 to 3.34 Min. 2.16
100 °C dial: MIN
(Low idle) {30.0 to 34.0} {Min. 22.0}
(Power mode)
• Parking brake lev-
er: FREE position
30-288 D155AX-8

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 120 °C
100 °C
Brake per-
• Fuel control dial: MAX (High - Machine must not move
formance
idle)
mode)
shift (F2)
Work equipment and HSS oil pressures

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 120 °C
100 °C
Unload MPa 2.45 to 3.82 2.45 to 3.82
pressure • Operating Mode: P (Power
{ kg/cm2} {25 to 39} {25 to 39}
mode)
idle)
er): NEUTRAL
D155AX-8 30-289

Engine SAA6D140E-7
Goo
d
machine ue d
Blade lift re- • Engine coolant temperature: 60 26.0 to 29.0 26.0 to 29.0
lief pressure to 100 °C {265 to 295} {265 to 295}
to 120 °C
MPa
100 °C 24.02 to 24.02 to
Blade lift LS { kg/cm2}
relief pres- • Operating Mode: P (Power 25.98 25.98
sure mode) {245 to 265} {245 to 265}
idle)
• Blade control lever: Lift RAISE
Blade tilt re- • Engine coolant temperature: 60 26.0 to 29.0 26.0 to 29.0
lief pressure to 100 °C {265 to 295} {265 to 295}
to 120 °C
MPa
100 °C 24.02 to 24.02 to
Blade tilt LS { kg/cm2}
relief pres- • Operating Mode: P (Power 25.98 25.98
sure mode) {245 to 265} {245 to 265}
idle)
• Blade control lever: Tilt
Ripper lift • Engine coolant temperature: 60 26.0 to 29.0 26.0 to 29.0
relief pres- to 100 °C
sure {265 to 295} {265 to 295}
to 120 °C
MPa
100 °C
Ripper lift { kg/cm2} 24.02 to 24.02 to
• Operating Mode: P (Power 25.98 25.98
LS relief
mode)
pressure {245 to 265} {245 to 265}
idle)
• Ripper control lever: RAISE
30-290 D155AX-8

Engine SAA6D140E-7
Goo
d
machine ue d
Ripper tilt • Engine coolant temperature: 60 26.0 to 29.0 26.0 to 29.0
relief pres- to 100 °C
sure {265 to 295} {265 to 295}
to 120 °C
MPa
100 °C
Ripper tilt { kg/cm2} 24.02 to 24.02 to
• Operating Mode: P (Power 25.98 25.98
LS relief
mode)
pressure {245 to 265} {245 to 265}
idle)
• Tilt control switch: Tilt IN
HSS relief • Engine coolant temperature: 60 38.2 to 41.7 38.2 to 41.7
pressure to 100 °C
(left side) {390 to 425} {390 to 425}
to 120 °C
100 °C
MPa
HSS LS re- { kg/cm2}
mode) 36.2 to 38.1 36.2 to 38.1
lief pressure
(left side) • Fuel control dial: MAX (High {369 to 389} {369 to 389}
idle)
er): turn left
HSS relief • Engine coolant temperature: 60 38.2 to 41.7 38.2 to 41.7
pressure to 100 °C
(right side) {390 to 425} {390 to 425}
to 120 °C
100 °C
MPa
HSS LS re- { kg/cm2}
mode) 36.2 to 38.1 36.2 to 38.1
lief pressure
(right side) • Fuel control dial: MAX (High {369 to 389} {369 to 389}
idle)
er): turn right
D155AX-8 30-291

Engine SAA6D140E-7
Goo
d
machine ue d
to 100 °C
to 120 °C
100 °C
Control cir- MPa Min. 2.50 Min. 2.50
cuit oil pres-
mode) { kg/cm2} {Min. 25.5} {Min. 25.5}
sure
idle)
• Blade control lever: NEUTRAL
position
• Ripper control lever: NEUTRAL
position
Work equipment speed

Engine SAA6D140E-7
Goo
d
machine ue d
100 °C
mode)
idle)
Blade • No load on blade Sec. 3.0 to 4.0 3.0 to 4.0
RAISE
• Time required to move blade
between ground level and rising
end
• See “Standard value table”,
“Machine posture and measure-
ment posture for measuring per-
formance” , “Fig. 1”.
30-292 D155AX-8

Engine SAA6D140E-7
Goo
d
machine ue d
• Hydraulic oil tem- Single tilt
perature: 45 to (SIGMA 1.3 to 2.3 Max. 3.1
100 °C dozer)
• Operating Mode: P Single tilt
(Power mode) (semi-U 1.8 to 2.8 Max. 3.1
dozer)
MAX (High idle) Dual tilt
• No load on blade (SIGMA 1.1 to 2.1 Max. 3.1
dozer)
Blade LEFT • Time required to
Sec.
tilt move blade be-
tween righ tilt end
and t left tilt end
• See “Standard val- Dual tilt
ue table” , “Ma- (semi-U 1.1 to 2.1 Max. 3.1
chine posture and dozer)
measurement pos-
ture for measuring
performance”, “Fig.
2”.
100 °C
mode)
idle)
Ripper • No load on ripper (lowest shank

hole) Sec. 1.3 to 2.3 Max. 3.5
LOWER
• Time required to move ripper
between rising end and ground
level
formance”, “Fig. 3”.
D155AX-8 30-293

Engine SAA6D140E-7
Goo
d
machine ue d
100 °C
mode)
idle)
Ripper tilt IN • No load on ripper Sec. 4.5 to 5.5 Max. 6.2
• Time required to move ripper
between tilt out end and tilt in
end
Hydraulic drift of work equipment

Engine SAA6D140E-7
Goo
d
machine ue d
100 °C
• Engine stopped
Hydraulic • Reduction of blade bottom
drift of lifted height (h) in 15 min. mm Max. 150 Max. 200
blade
100 °C
• Engine stopped
Hydraulic
drift of ma- • Reduction of sprocket center
height (h) in 5 min. mm Max. 30 Max. 40
chine lifted
by ripper • See “Standard value table”,
formance”, “Fig. 8”".
30-294 D155AX-8
Final drive
Engine SAA6D140E-7
Goo
d
machine ue d
• Engine stopped There must be no excessive
Final drive -
• Visual check of drain plug metal particles
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE

Model Serial No. Service meter User name Date of inspection Inspector
D155AX-8 /　　　/
Bushing
Engine SAA6D140E-7
No
Goo
Item Testing conditions Measurement result goo
d
d
Bushing Left side of machine

Measure just after work
temperature Right side of machine
Left side of machine
REMARK
Symbols to be entered in drawing
H: Hot (You cannot keep touching, very hot, min. 50 °C)
W: Warm (Level of tepid water, warmer than link, approximately 35 °C)
C: Normal temperature (Same temperature as link)
Right side of machine
D155AX-8 30-295
REMARK
Symbols to be entered in drawing
H: Hot (You cannot keep touching, very hot, min. 50 °C)
W: Warm (Level of tepid water, warmer than link, approximately 35 °C)
C: Normal temperature (Same temperature as link)
Track link
Engine SAA6D140E-7
Unit Pin No. Meas- No
Allowable Goo
Item Testing conditions urement goo
clearance d
result d
Left side of
1.4 (one side)
machine
Opening of Measure opening of

mm
track link track link (a)
Right side
1.4 (one side)
of machine
30-296 D155AX-8
D155AX-8 30-297
40 TROUBLESHOOTING
D155AX-8 40-1
CONTENTS 40 TROUBLESHOOTING
CONTENTS
RELATED INFORMATION ON TROUBLESHOOTING ................................................................................ 40-14
GENERAL TROUBLESHOOTING POINTS .......................................................................................... 40-14
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM................................................................. 40-15
SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................ 40-28
CHECKS BEFORE TROUBLESHOOTING ........................................................................................... 40-30
CHECKS BEFORE TROUBLESHOOTING ........................................................................................... 40-32
WALK-AROUND CHECK............................................................................................................... 40-32
TESTING IN ACCORDANCE WITH TESTING PROCEDURE.............................................................. 40-34
FUEL - CHECK LEVEL AND TYPE ............................................................................................... 40-34
FUEL - CHECK FOR FOREIGN MATERIAL .................................................................................. 40-34
CHECK AdBule/DEF LEVEL AND TYPE ....................................................................................... 40-35
FUEL PREFILTER - CHECK .......................................................................................................... 40-35
MAIN FILTER - CHECK ................................................................................................................. 40-37
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE...................................................................... 40-38
RESERVOIR TANK - CHECK COOLANT LEVEL .......................................................................... 40-39
AIR CLEANER - CHECK FOR CLOGGING ................................................................................... 40-40
OUTER ELEMENT - CLEAN.......................................................................................................... 40-41
REPLACE ELEMENT .................................................................................................................... 40-42
CHECK HYDRAULIC OIL LEVEL .................................................................................................. 40-43
CHECK HYDRAULIC OIL STRAINER ........................................................................................... 40-44
CHECK HYDRAULIC FILTER ........................................................................................................ 40-45
CHECK OIL LEVEL IN POWER TRAIN CASE............................................................................... 40-46
CHECK POWER TRAIN STRAINER ............................................................................................. 40-47
CHECK POWER TRAIN FILTER ................................................................................................... 40-48
CHECK OIL LEVEL IN DAMPER CASE ........................................................................................ 40-49
CHECK OIL LEVEL IN FINAL DRIVE CASE.................................................................................. 40-50
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod ....................................................... 40-51
PROCEDURE FOR TESTING AND TROUBLESHOOTING ................................................................. 40-58
SYMPTOM AND TROUBLESHOOTING NUMBERS ............................................................................ 40-61
INFORMATION IN TROUBLESHOOTING TABLE ................................................................................ 40-64
CONNECTORS LIST AND LAYOUT..................................................................................................... 40-66
CONNECTOR PIN NUMBERS - CONNECTION TABLE....................................................................... 40-82
T-BOXES AND T-ADAPTERS LIST .....................................................................................................40-121
FUSE LOCATION TABLE ....................................................................................................................40-127
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE ............................................40-130
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135]).................................................................................................................................40-134
FAILURE CODES TABLE ....................................................................................................................40-136
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) ............................................................40-159
FAILURE CODE [1500L0] T/M Clutches Double Engagement .............................................................40-159
FAILURE CODE [15SAL1] ECMV Release Trouble (Forward) .............................................................40-160
FAILURE CODE [15SALH] ECMV Engage Trouble (Forward) .............................................................40-162
FAILURE CODE [15SBL1] ECMV Release Trouble (Reverse).............................................................40-164
FAILURE CODE [15SBLH] ECMV Engage Trouble (Reverse) .............................................................40-166
FAILURE CODE [15SEL1] ECMV Release Trouble (1st) .....................................................................40-168
FAILURE CODE [15SELH] ECMV Engage Trouble (1st) .....................................................................40-170
FAILURE CODE [15SFL1] ECMV Release Trouble (2nd) ....................................................................40-172
FAILURE CODE [15SFLH] ECMV Engage Trouble (2nd) ....................................................................40-174
FAILURE CODE [15SGL1] ECMV Release Trouble (3rd) ....................................................................40-176
FAILURE CODE [15SGLH] ECMV Engage Trouble (3rd).....................................................................40-178
FAILURE CODE [15SJL1] ECMV Release Trouble (Lock Up Clutch)...................................................40-180
FAILURE CODE [15SJLH] ECMV Engage Trouble (Lock Up Clutch)...................................................40-182
FAILURE CODE [1800MW] P/T Clutch Slip .........................................................................................40-184
FAILURE CODE [2300NR] Brake Thermal Load Abnormality ..............................................................40-185
FAILURE CODE [2301L1] ECMV Release Trouble (RH Brake) ...........................................................40-186
FAILURE CODE [2301LH] ECMV Engage Trouble (RH Brake)............................................................40-188
40-2 D155AX-8
40 TROUBLESHOOTING CONTENTS
FAILURE CODE [2302L1] ECMV Release Trouble (LH Brake) ............................................................40-190

FAILURE CODE [2302LH] ECMV Engage Trouble (LH Brake) ............................................................40-192
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit............................40-194
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit ............................40-195
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit .......................................40-196
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit .......................................40-198
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit.................................................................40-200
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit.................................................................40-201
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit............................................40-202
FAILURE CODE [879EMC] Ventilation Damper Malfunction ................................................................40-204
FAILURE CODE [879FMC] Air Mix Damper Malfunction......................................................................40-205
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range .......................................40-206
FAILURE CODE [989L00] Engine Controller Lock Caution 1 ...............................................................40-208
FAILURE CODE [989M00] Engine Controller Lock Caution 2 ..............................................................40-209
FAILURE CODE [989N00] Engine Controller Lock Caution 3...............................................................40-210
FAILURE CODE [A1U0N3] Hydrocarbon Desorb Request 1................................................................40-211
FAILURE CODE [A1U0N4] Hydrocarbon Desorb Request 2................................................................40-213
FAILURE CODE [AA10NX] Air Cleaner Clogging.................................................................................40-215
FAILURE CODE [AB00KE] Charge Voltage Low..................................................................................40-217
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) ...........40-219
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) ......................................40-221
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) .......................................................40-223
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) ..................................................40-224
FAILURE CODE [AS00R6] Temporary Recovery of Inducement..........................................................40-227
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5..................................................................40-228
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning ...................................................40-229
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning ......................................40-230
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution.....................................................40-231
FAILURE CODE [B@BAZG] Engine Oil Pressure Low ........................................................................40-232
FAILURE CODE [B@BCNS] Engine Coolant Overheat .......................................................................40-233
FAILURE CODE [B@BCZK] Engine Coolant Level Low ......................................................................40-234
FAILURE CODE [B@CENS] Power Train Oil Overheat .......................................................................40-236
FAILURE CODE [B@HANS] Hydraulic Oil Overheat ...........................................................................40-237
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error................................................40-238
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error.......................................................40-239
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error........................................................40-241
FAILURE CODE [CA131] Throttle Sensor High Error...........................................................................40-243
FAILURE CODE [CA132] Throttle Sensor Low Error............................................................................40-245
FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error .......................................................40-247
FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error ........................................................40-249
FAILURE CODE [CA144] Coolant Temperature Sensor High Error......................................................40-251
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error.......................................................40-253
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error .................................................40-255
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error..................................................40-258
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error .............................................................40-261
FAILURE CODE [CA221] Ambient Pressure Sensor High Error...........................................................40-263
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error ...........................................................40-265
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error ............................................................40-267
FAILURE CODE [CA234] Engine Overspeed.......................................................................................40-268
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error ......................................................40-269
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error ..............................................40-271
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error ...........................................................40-273
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error............................................................40-275
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error .....................................................................40-277
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error .....................................................................40-279
FAILURE CODE [CA273] PCV 2 Short Circuit Error.............................................................................40-280
D155AX-8 40-3
FAILURE CODE [CA274] PCV 2 Open Circuit Error ............................................................................40-282

FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error ...........................40-283
FAILURE CODE [CA343] Engine Controller Internal Failure ................................................................40-295
FAILURE CODE [CA351] Injectors Drive Circuit Error..........................................................................40-296
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error .............................................................40-297
FAILURE CODE [CA356] MAF Sensor High Error ...............................................................................40-300
FAILURE CODE [CA357] MAF Sensor Low Error ................................................................................40-302
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error ............................................................40-305
FAILURE CODE [CA441] Power Voltage Low Error .............................................................................40-306
FAILURE CODE [CA442] Power Voltage High Error ............................................................................40-309
FAILURE CODE [CA449] Common Rail Pressure High Error 2 ...........................................................40-310
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error ..................................................40-311
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error ...................................................40-313
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error..........................40-315
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error...........................40-317
FAILURE CODE [CA553] Common Rail Pressure High Error 1 ...........................................................40-319
FAILURE CODE [CA555] Crankcase Pressure High Error 2 ................................................................40-320
FAILURE CODE [CA556] Crankcase Pressure High Error 3 ................................................................40-321
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 ............................................................40-322
FAILURE CODE [CA595] Turbocharger Speed High Error 2................................................................40-327
FAILURE CODE [CA687] Turbocharger Speed Low Error ...................................................................40-328
FAILURE CODE [CA689] Engine NE Speed Sensor Error ...................................................................40-330
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error ...................................................40-332
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error....................................................40-334
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error ..........................40-336
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error...........................40-337
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error .................................................40-338
FAILURE CODE [CA778] Engine Backup Speed Sensor Error ............................................................40-339
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error ...................................................40-342
FAILURE CODE [CA1664] KDOC Abnormality ....................................................................................40-343
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error ...........................................40-346
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3 ..................................................................40-347
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error ............................................40-348
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error ............................................40-349
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error...............................................................40-350
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error..................................40-352
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error ..................................40-354
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error.........................................40-356
FAILURE CODE [CA1691] Defective Regeneration .............................................................................40-357
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error....................................................40-360
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error ..........................................................40-363
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error ...........................................................40-364
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error ..............................................................40-366
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error.....................................40-369
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error .................................40-371
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error ......................................40-372
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error ...................................................40-373
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error ....................................................40-376
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error.....................................................40-379
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error......................................................40-381
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error ..........................................40-384
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error ...........................................40-387
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error ...................................40-389
40-4 D155AX-8
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error ......................................................40-393
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error ........................................................40-395
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 ......................................................40-397
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2 ......................................................40-400
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error ..............................................................40-405
FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error...............................................................40-407
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error .......................................................40-409
FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error...................................................40-411
FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error....................................................40-413
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error..............................................40-415
FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error ............................................................40-416
FAILURE CODE [CA1977] Fuel Doser Open Circuit Error or Short Circuit Error ..................................40-419
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error .......................................................40-422
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error ................................................40-425
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error .................................................40-427
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 ..........................................................40-429
FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error ..........................................................40-430
FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error...........................................................40-432
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error ......................................................40-435
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error.......................................................40-437
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error.....................................................40-439
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error .....................................................40-441
FAILURE CODE [CA2357] EGR Valve Servo Error..............................................................................40-443
FAILURE CODE [CA2381] KVGT Position Sensor High Error..............................................................40-444
FAILURE CODE [CA2382] KVGT Position Sensor Low Error ..............................................................40-446
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error ............................................................40-448
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error ............................................................40-450
FAILURE CODE [CA2387] KVGT Servo Error .....................................................................................40-452
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error ................................................40-453
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error ................................................40-456
FAILURE CODE [CA2637] KDOC Face Plugging ................................................................................40-458
FAILURE CODE [CA2639] Manual Stationary Regeneration Request .................................................40-460
FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error ..............................................................40-462
FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error...............................................................40-464
FAILURE CODE [CA2741] Fuel Dozer Solenoid Valve Swap Error......................................................40-466
FAILURE CODE [CA2765] Injector Trim Data Mismatch ......................................................................40-467
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error........................................40-468
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable .........
.........................................................................................................................................................40-474
FAILURE CODE [CA2878] Fuel Doser Solenoid 2 Servo Error ............................................................40-477
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1.............................................................40-480
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error................................40-483
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error..................................................40-485
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error...................................................40-487
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error...........................................40-489
FAILURE CODE [CA3142] SCR Temperature Sensor High Error.........................................................40-493
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error .........................................................40-494
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error .................................................40-495
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error ..............................................40-497
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error ...............................................40-498
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error .......................................40-499
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2..........................................................40-501
FAILURE CODE [CA3165] SCR Outlet Temperature High Error ..........................................................40-507
FAILURE CODE [CA3167] Fuel Doser Degradation.............................................................................40-509
FAILURE CODE [CA3229] SCR Temperature High Error.....................................................................40-512
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration .....................................40-514
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error ......................................40-516
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration...........................40-520
D155AX-8 40-5
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error...........................................40-522

FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error ...........................................40-525
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error ................................................................40-528
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error ..........................................................40-531
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration ..........................................40-534
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1.....................................................40-538
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration ...........................................40-541
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 .....................................................40-544
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2 .....................................................40-546
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2 .....................................................40-548
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error ...............................................40-551
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error ..............................................40-552
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error .......................................40-553
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error ............................................40-556
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error ...........................................40-557
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error ....................................40-558
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error ............................................40-561
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error .............................................40-562
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error .....................................40-564
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error.....................................................40-567
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error......................................................40-569
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)..........................40-573
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error ....................................................40-580
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error.......................................................40-583
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error .......................................................40-585
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error..................................40-587
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error ..................................40-589
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error ...................40-592
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction ...............................................................40-595
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error ........................................40-599
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error.........................................40-601
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error ..............................................40-603
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error..............................................40-605
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error.........................................................40-607
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error .........................................................40-609
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1..........................................................40-611
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error....................................40-617
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error..............................................40-619
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error ..................................40-621
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error ...........................................40-623
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error..........................................40-628
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error...........................................40-634
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error ......................................40-637
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error.....................................40-638
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error...................................................40-639
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error ........................................40-642
FAILURE CODE [CA3751] SCR Catalyst Degradation Error................................................................40-645
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error ................................40-647
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 ....................................................40-649
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1 ....................................................40-652
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error......................................40-655
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error...................................................................40-659
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error ..................................................40-661
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error ..............................................40-665
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error .............................................40-667
40-6 D155AX-8
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error..............................................40-669
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error ....................................................40-671
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error ...................................................40-674
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error......................................................40-676
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error .................40-678
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error .....................................40-683
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error .................................40-687
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error..................................40-690
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction ...................................................................40-693
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error .....................40-695
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error .........................................40-696
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error ...............40-697
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error ................40-700
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error .......40-703
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error ...................................40-706
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error ....................................40-708
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error ...........................40-710
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error ................................................40-712
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error ..............................................40-715
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error .............................................................40-717
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error ........................40-720
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error ........................40-722
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error....................40-724
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error........................................40-727
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error ................40-730
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error...................................................40-733
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error..................................40-737
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error ..................................40-740
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error......................................................................40-743
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error.......................40-747
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error ..................................40-748
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error ........................................40-749
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error..................................................................40-750
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible.............................................40-752
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error.......................................................40-755
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller) .........................40-758
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error............................................40-760
FAILURE CODE [CA5383] Ash Accumulation High Error.....................................................................40-763
FAILURE CODE [D130KA] Neutral Safety Relay Open Circuit.............................................................40-765
FAILURE CODE [D130KB] Neutral Safety Relay Short Circuit.............................................................40-768
FAILURE CODE [D190KA] Engine Controller Accessory Signal Hold Relay Open Circuit ...................40-770
FAILURE CODE [D190KB] Engine Controller Accessory Signal Hold Relay Short Circuit....................40-772
FAILURE CODE [D19JKZ] Personal Code Relay Open or Short .........................................................40-774
FAILURE CODE [D811MC] KOMTRAX Malfunction.............................................................................40-777
FAILURE CODE [D862KA] GPS Antenna Open Circuit .......................................................................40-778
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)..................................40-779
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) ..................................40-781
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX) ........................................40-783
FAILURE CODE [DAF0MB] Monitor ROM Abnormality........................................................................40-784
FAILURE CODE [DAF0MC] Monitor Malfunction .................................................................................40-785
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit .........................................................40-786
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor)..............................................40-787
FAILURE CODE [DAFGMC] GPS Module Malfunction ........................................................................40-788
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) .......................................40-789
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) .......................................40-791
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor) .............................................40-793
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) ...................................................40-794
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)...........................................40-795
D155AX-8 40-7
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller) ..............................40-796

FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller) ..............................40-802
FAILURE CODE [DB90KT] W/E Controller Internal Abnormality ..........................................................40-808
FAILURE CODE [DB90MC] W/E Controller Malfunction ......................................................................40-809
FAILURE CODE [DB91KK] W/E Controller Source Voltage Low Error .................................................40-810
FAILURE CODE [DB92KK] W/E Controller Solenoid Power Voltage Low Error....................................40-813
FAILURE CODE [DB95KK] W/E Controller 5V Sensor 0 Power Voltage Out of Range ........................40-816
FAILURE CODE [DB97KK] W/E Controller 5V Sensor 1 Power Voltage Out of Range ........................40-819
FAILURE CODE [DB99KQ] Model Selection Signal Mismatch (W/E Controller)...................................40-821
FAILURE CODE [DB9LKA] System Operating Lamp Open Circuit (W/E Controller) ............................40-823
FAILURE CODE [DB9LKB] System Operating Lamp Short Circuit (W/E Controller) ............................40-825
FAILURE CODE [DB9QKR] CAN 2 Defective Communication (W/E Controller) ..................................40-827
FAILURE CODE [DB9RKR] CAN 1 Defective Communication (W/E Controller)...................................40-828
FAILURE CODE [DBE0KT] P/T Controller Internal Abnormality ...........................................................40-830
FAILURE CODE [DBE1KK] P/T Controller Source Voltage Low Error..................................................40-831
FAILURE CODE [DBE2KK] P/T Controller Solenoid Power Voltage Low Error ....................................40-834
FAILURE CODE [DBE5KK] P/T Controller 5V Sensor 0 Power Voltage Out of Range .........................40-837
FAILURE CODE [DBE6KK] P/T Controller 24V Sensor Power Voltage Out of Range ..........................40-839
FAILURE CODE [DBE9KQ] Model Selection Signal Mismatch (P/T Controller) ...................................40-841
FAILURE CODE [DBELKA] System Operating Lamp Open Circuit (P/T Controller) .............................40-843
FAILURE CODE [DBELKB] System Operating Lamp Short Circuit (P/T Controller) .............................40-845
FAILURE CODE [DBEQKR] CAN 2 Defective Communication (P/T Controller) ...................................40-847
FAILURE CODE [DBERKR] CAN 1 Defective Communication (P/T Controller) ...................................40-848
FAILURE CODE [DD12KA] Shift Up SW Open Circuit .........................................................................40-850
FAILURE CODE [DD12KB] Shift Up SW Short Circuit .........................................................................40-852
FAILURE CODE [DD13KA] Shift Down SW Open Circuit.....................................................................40-854
FAILURE CODE [DD13KB] Shift Down SW Short Circuit .....................................................................40-856
FAILURE CODE [DD14KA] Parking Brake Lever SW Open Circuit......................................................40-858
FAILURE CODE [DD14KB] Parking Brake Lever SW Short Circuit ......................................................40-861
FAILURE CODE [DDDDKA] Brake Pedal SW Open Circuit .................................................................40-863
FAILURE CODE [DDDDKB] Brake Pedal SW Short Circuit..................................................................40-866
FAILURE CODE [DDDDKX] Brake Pedal SW Signal Mismatch ...........................................................40-869
FAILURE CODE [DDKAKA] Blade Float SW Open Circuit ...................................................................40-870
FAILURE CODE [DDKAKB] Blade Float SW Short Circuit ...................................................................40-872
FAILURE CODE [DDKBKA] Blade Auto Pitch SW Open Circuit ...........................................................40-874
FAILURE CODE [DDKBKB] Blade Auto Pitch SW Short Circuit ...........................................................40-876
FAILURE CODE [DDKCL4] Ripper Tilt In SW Signal Mismatch ...........................................................40-878
FAILURE CODE [DDKEL4] Ripper Tilt Back SW Signal Mismatch.......................................................40-881
FAILURE CODE [DDN7L4] Blade Pitch Back SW Signal Mismatch .....................................................40-884
FAILURE CODE [DDN8L4] Blade Pitch Dump SW Signal Mismatch ...................................................40-887
FAILURE CODE [DDNLKA] W/E Lock SW Open Circuit ......................................................................40-890
FAILURE CODE [DDNLKB] W/E Lock SW Short Circuit ......................................................................40-892
FAILURE CODE [DDTSL1] Stator Clutch Release Trouble ..................................................................40-894
FAILURE CODE [DDTSLH] Stator Clutch Engage Trouble ..................................................................40-896
FAILURE CODE [DFA4KX] Blade Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit .40-898
FAILURE CODE [DFA4KZ] Blade Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit..40-899
FAILURE CODE [DFA4L8] Blade Lift Lever Potentiometer 1 or 2 Signal Abnormality ..........................40-900
FAILURE CODE [DFA5KA] Blade Lift Lever Potentiometer 1 Open Circuit ..........................................40-901
FAILURE CODE [DFA5KY] Blade Lift Lever Potentiometer 1 Hot Short Circuit ....................................40-904
FAILURE CODE [DFA6KA] Blade Lift Lever Potentiometer 2 Open Circuit ..........................................40-906
FAILURE CODE [DFA6KY] Blade Lift Lever Potentiometer 2 Hot Short Circuit ....................................40-909
FAILURE CODE [DFA7KX] Blade Tilt Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit..40-911
FAILURE CODE [DFA7KZ] Blade Tilt Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit..40-912
FAILURE CODE [DFA7L8] Blade Tilt Lever Potentiometer 1 or 2 Signal Abnormality ..........................40-913
FAILURE CODE [DFA8KA] Blade Tilt Lever Potentiometer 1 Open Circuit ..........................................40-914
FAILURE CODE [DFA8KY] Blade Tilt Lever Potentiometer 1 Hot Short Circuit ....................................40-917
FAILURE CODE [DFA9KA] Blade Tilt Lever Potentiometer 2 Open Circuit ..........................................40-919
FAILURE CODE [DFA9KY] Blade Tilt Lever Potentiometer 2 Hot Short Circuit ....................................40-922
40-8 D155AX-8
FAILURE CODE [DFAAKX] Ripper Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit40-924
FAILURE CODE [DFAAKZ] Ripper Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Circuit 40-925
FAILURE CODE [DFAAL8] Ripper Lift Lever Potentiometer 1 or 2 Signal Abnormality ........................40-926
FAILURE CODE [DFABKA] Ripper Lift Lever Potentiometer 1 Open Circuit ........................................40-927
FAILURE CODE [DFABKY] Ripper Lift Lever Potentiometer 1 Hot Short Circuit ..................................40-930
FAILURE CODE [DFACKA] Ripper Lift Lever Potentiometer 2 Open Circuit ........................................40-932
FAILURE CODE [DFACKY] Ripper Lift Lever Potentiometer 2 Hot Short Circuit ..................................40-935
FAILURE CODE [DGS1KA] Hydraulic Oil Temperature Sensor Open Circuit .......................................40-937
FAILURE CODE [DGS1KX] Hydraulic Oil Temperature Sensor Input Signal Out of Range ..................40-939
FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit ................................................40-941
FAILURE CODE [DGT1KX] T/C Oil Temperature Sensor Input Signal Out of Range ...........................40-944
FAILURE CODE [DH21KA] W/E Pump Pressure Sensor Open Circuit ................................................40-946
FAILURE CODE [DH21KY] W/E Pump Pressure Sensor Hot Short Circuit ..........................................40-949
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit ......................................................40-951
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen .............................................40-953
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen ....................................................40-954
FAILURE CODE [DHT5KA] T/C Inlet Pressure Sensor Open Circuit....................................................40-955
FAILURE CODE [DHT5KY] T/C Inlet Pressure Sensor Hot Short Circuit .............................................40-958
FAILURE CODE [DHT7KA] T/C Outlet Pressure Sensor Open Circuit .................................................40-960
FAILURE CODE [DHT7KY] T/C Outlet Pressure Sensor Hot Short Circuit...........................................40-963
FAILURE CODE [DK10KA] Fuel Control Dial Open Circuit ..................................................................40-965
FAILURE CODE [DK10KB] Fuel Control Dial Short Circuit...................................................................40-968
FAILURE CODE [DK30KA] S/T Potentiometer 1 Open Circuit .............................................................40-970
FAILURE CODE [DK30KY] S/T Potentiometer 1 Hot Short Circuit .......................................................40-973
FAILURE CODE [DK30KX] S/T Potentiometer 1 and 2 Open Circuit or Hot Short Circuit ....................40-975
FAILURE CODE [DK30KZ] S/T Potentiometer 1 and 2 Open Circuit or Hot Short Circuit.....................40-976
FAILURE CODE [DK30L8] S/T Potentiometer 1 or 2 Signal Abnormality .............................................40-977
FAILURE CODE [DK31KA] S/T Potentiometer 2 Open Circuit .............................................................40-978
FAILURE CODE [DK31KY] S/T Potentiometer 2 Hot Short Circuit .......................................................40-981
FAILURE CODE [DK40KA] Brake Pedal Potentiometer Open Circuit ..................................................40-983
FAILURE CODE [DK40KY] Brake Pedal Potentiometer Hot Short Circuit ............................................40-986
FAILURE CODE [DK55KX] F/R Potentiometer 1 and 2 Open Circuit or Hot Short Circuit ....................40-988
FAILURE CODE [DK55KZ] F/R Potentiometer 1 and 2 Open Circuit or Hot Short Circuit ....................40-989
FAILURE CODE [DK55L8] F/R Potentiometer 1 or 2 Signal Abnormality .............................................40-990
FAILURE CODE [DK56KA] F/R Potentiometer 1 Open Circuit .............................................................40-991
FAILURE CODE [DK56KY] F/R Potentiometer 1 Hot Short Circuit.......................................................40-994
FAILURE CODE [DK57KA] F/R Potentiometer 2 Open Circuit .............................................................40-996
FAILURE CODE [DK57KY] F/R Potentiometer 2 Hot Short Circuit.......................................................40-999
FAILURE CODE [DKH1KA] Inclination Angle Sensor Open Circuit ....................................................40-1001
FAILURE CODE [DKH1KY] Inclination Angle Sensor Hot Short Circuit..............................................40-1004
FAILURE CODE [DLM3KA] Fan Speed Sensor Open Circuit.............................................................40-1006
FAILURE CODE [DLM3KB] Fan Speed Sensor Short Circuit.............................................................40-1008
FAILURE CODE [DLM3MB] Fan Speed Sensor Function Deterioration .............................................40-1009
FAILURE CODE [DLT3KA] T/M Output Speed Sensor Open Circuit ..................................................40-1010
FAILURE CODE [DLT3KB] T/M Output Speed Sensor Ground Fault .................................................40-1012
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range .............................40-1014
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range .............................40-1015
FAILURE CODE [DV20KB] Back Alarm Buzzer Short Circuit.............................................................40-1016
FAILURE CODE [DW7BKA] Fan Reverse Solenoid Open Circuit ......................................................40-1018
FAILURE CODE [DW7BKB] Fan Reverse Solenoid Short Circuit.......................................................40-1020
FAILURE CODE [DWN1KA] S/T Control Valve Right EPC Solenoid Open Circuit .............................40-1022
FAILURE CODE [DWN1KB] S/T Control Valve Right EPC Solenoid Short Circuit..............................40-1024
FAILURE CODE [DWN1KY] S/T Control Valve Right EPC Solenoid Hot Short Circuit .......................40-1026
FAILURE CODE [DWN2KA] S/T Control Valve Left EPC Solenoid Open Circuit................................40-1027
FAILURE CODE [DWN2KB] S/T Control Valve Left EPC Solenoid Short Circuit ................................40-1029
FAILURE CODE [DWN2KY] S/T Control Valve Left EPC Solenoid Hot Short Circuit..........................40-1031
FAILURE CODE [DWN3KA] Sudden Stop Prevention Valve Solenoid Open Circuit...........................40-1032
FAILURE CODE [DWN3KB] Sudden Stop Prevention Valve Solenoid Short Circuit...........................40-1034
D155AX-8 40-9
FAILURE CODE [DWN3KY] Sudden Stop Prevention Valve Solenoid Hot Short Circuit ....................40-1036
FAILURE CODE [DWN5KA] Fan Control Solenoid 1 Open Circuit .....................................................40-1038
FAILURE CODE [DWN5KB] Fan Control Solenoid 1 Short Circuit .....................................................40-1040
FAILURE CODE [DWN5KY] Fan Control Solenoid 1 Hot Short Circuit...............................................40-1042
FAILURE CODE [DXA2KA] HSS Pump TVC Solenoid 1 Open Circuit ...............................................40-1044
FAILURE CODE [DXA2KB] HSS Pump TVC Solenoid 1 Short Circuit ...............................................40-1046
FAILURE CODE [DXA2KY] HSS Pump TVC Solenoid 1 Hot Short Circuit.........................................40-1048
FAILURE CODE [DXH1KA] Lockup Clutch ECMV Solenoid Open Circuit..........................................40-1050
FAILURE CODE [DXH1KB] Lockup Clutch ECMV Solenoid Short Circuit ..........................................40-1052
FAILURE CODE [DXH1KY] Lockup Clutch ECMV Solenoid Hot Short Circuit ...................................40-1054
FAILURE CODE [DXH4KA] T/M 1st Clutch ECMV Solenoid Open Circuit .........................................40-1056
FAILURE CODE [DXH4KB] T/M 1st Clutch ECMV Solenoid Short Circuit..........................................40-1058
FAILURE CODE [DXH4KY] T/M 1st Clutch ECMV Solenoid Hot Short Circuit ...................................40-1060
FAILURE CODE [DXH5KA] T/M 2nd Clutch ECMV Solenoid Open Circuit ........................................40-1062
FAILURE CODE [DXH5KB] T/M 2nd Clutch ECMV Solenoid Short Circuit ........................................40-1064
FAILURE CODE [DXH5KY] T/M 2nd Clutch ECMV Solenoid Hot Short Circuit ..................................40-1066
FAILURE CODE [DXH6KA] T/M 3rd Clutch ECMV Solenoid Open Circuit .........................................40-1068
FAILURE CODE [DXH6KB] T/M 3rd Clutch ECMV Solenoid Short Circuit .........................................40-1070
FAILURE CODE [DXH6KY] T/M 3rd Clutch ECMV Solenoid Hot Short Circuit...................................40-1071
FAILURE CODE [DXH7KA] T/M Reverse Clutch ECMV Solenoid Open Circuit .................................40-1073
FAILURE CODE [DXH7KB] T/M Reverse Clutch ECMV Solenoid Short Circuit .................................40-1075
FAILURE CODE [DXH7KY] T/M Reverse Clutch ECMV Solenoid Hot Short Circuit...........................40-1077
FAILURE CODE [DXH8KA] T/M Forward Clutch ECMV Solenoid Open Circuit .................................40-1079
FAILURE CODE [DXH8KB] T/M Forward Clutch ECMV Solenoid Short Circuit .................................40-1081
FAILURE CODE [DXH8KY] T/M Forward Clutch ECMV Solenoid Hot Short Circuit ...........................40-1083
FAILURE CODE [DXHBKA] Right Brake ECMV Solenoid Open Circuit .............................................40-1085
FAILURE CODE [DXHBKB] Right Brake ECMV Solenoid Short Circuit .............................................40-1087
FAILURE CODE [DXHBKY] Right Brake ECMV Solenoid Hot Short Circuit .......................................40-1089
FAILURE CODE [DXHCKA] Left Brake ECMV Solenoid Open Circuit ...............................................40-1091
FAILURE CODE [DXHCKB] Left Brake ECMV Solenoid Short Circuit................................................40-1093
FAILURE CODE [DXHCKY] Left Brake ECMV Solenoid Hot Short Circuit .........................................40-1095
FAILURE CODE [DXHRKA] Blade Lift Raise EPC Solenoid Open Circuit..........................................40-1097
FAILURE CODE [DXHRKB] Blade Lift Raise EPC Solenoid Short Circuit ..........................................40-1099
FAILURE CODE [DXHRKY] Blade Lift Raise EPC Solenoid Hot Short Circuit ...................................40-1100
FAILURE CODE [DXHSKA] Blade Lift Lower EPC Solenoid Open Circuit .........................................40-1102
FAILURE CODE [DXHSKB] Blade Lift Lower EPC Solenoid Short Circuit..........................................40-1104
FAILURE CODE [DXHSKY] Blade Lift Lower EPC Solenoid Hot Short Circuit ...................................40-1105
FAILURE CODE [DXHTKA] Blade Tilt Right Head EPC Solenoid Open Circuit..................................40-1107
FAILURE CODE [DXHTKB] Blade Tilt Right Head EPC Solenoid Short Circuit ..................................40-1109
FAILURE CODE [DXHTKY] Blade Tilt Right Head EPC Solenoid Hot Short Circuit ........................... 40-1111
FAILURE CODE [DXHUKA] Blade Tilt Right Bottom EPC Solenoid Open Circuit............................... 40-1113
FAILURE CODE [DXHUKB] Blade Tilt Right Bottom EPC Solenoid Short Circuit............................... 40-1115
FAILURE CODE [DXHUKY] Blade Tilt Right Bottom EPC Solenoid Hot Short Circuit ........................ 40-1117
FAILURE CODE [DXHWKA] Ripper Lift Raise EPC Solenoid Open Circuit........................................ 40-1119
FAILURE CODE [DXHWKB] Ripper Lift Raise EPC Solenoid Short Circuit........................................40-1121
FAILURE CODE [DXHWKY] Ripper Lift Raise EPC Solenoid Hot Short Circuit .................................40-1122
FAILURE CODE [DXHXKA] Ripper Lift Lower EPC Solenoid Open Circuit ........................................40-1124
FAILURE CODE [DXHXKB] Ripper Lift Lower EPC Solenoid Short Circuit ........................................40-1126
FAILURE CODE [DXHXKY] Ripper Lift Lower EPC Solenoid Hot Short Circuit..................................40-1127
FAILURE CODE [DXHYKA] Ripper Tilt In EPC Solenoid Open Circuit...............................................40-1129
FAILURE CODE [DXHYKB] Ripper Tilt In EPC Solenoid Short Circuit ...............................................40-1131
FAILURE CODE [DXHYKY] Ripper Tilt In EPC Solenoid Hot Short Circuit.........................................40-1132
FAILURE CODE [DXHZKA] Ripper Tilt Back EPC Solenoid Open Circuit ..........................................40-1134
FAILURE CODE [DXHZKB] Ripper Tilt Back EPC Solenoid Short Circuit ..........................................40-1136
FAILURE CODE [DXHZKY] Ripper Tilt Back EPC Solenoid Hot Short Circuit....................................40-1137
FAILURE CODE [DXJ4KA] W/E Lock Solenoid Open Circuit .............................................................40-1139
FAILURE CODE [DXJ4KB] W/E Lock Solenoid Short Circuit .............................................................40-1141
FAILURE CODE [DXJ8KA] Blade Tilt Left Bottom EPC Solenoid Open Circuit ..................................40-1142
40-10 D155AX-8
FAILURE CODE [DXJ8KB] Blade Tilt Left Bottom EPC Solenoid Short Circuit ..................................40-1144
FAILURE CODE [DXJ8KY] Blade Tilt Left Bottom EPC Solenoid Hot Short Circuit ............................40-1146
FAILURE CODE [DXJ9KA] Blade Tilt Left Head EPC Solenoid Open Circuit .....................................40-1148
FAILURE CODE [DXJ9KB] Blade Tilt Left Head EPC Solenoid Short Circuit .....................................40-1150
FAILURE CODE [DXJ9KY] Blade Tilt Left Head EPC Solenoid Hot Short Circuit...............................40-1152
FAILURE CODE [DXJAKA] Quick drop solenoid: Open .....................................................................40-1154
FAILURE CODE [DXJAKB] Quick Drop EPC Solenoid Short Circuit ..................................................40-1156
FAILURE CODE [DXJAKY] Quick Drop EPC Solenoid Hot Short Circuit............................................40-1158
FAILURE CODE [DXJBKA] T/C Stator Clutch ECMV Solenoid Open Circuit .....................................40-1160
FAILURE CODE [DXJBKB] T/C Stator Clutch ECMV Solenoid Short Circuit......................................40-1162
FAILURE CODE [DXJBKY] T/C Stator Clutch ECMV Solenoid Hot Short Circuit ...............................40-1164
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................40-1166
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .....................................................40-1166
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...............................................................40-1173
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .........................................................40-1176
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP............40-1178
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTH-
ING.................................................................................................................................................40-1180
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR
COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW.................................................................40-1184
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING40-1186
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ......................40-1187
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....
.......................................................................................................................................................40-1189
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......40-1190
E-11 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ..
.......................................................................................................................................................40-1191
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ......
.......................................................................................................................................................40-1192
E-13 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE ....
.......................................................................................................................................................40-1193
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL ............................................40-1194
E-15 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE ....
.......................................................................................................................................................40-1197
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE.........
.......................................................................................................................................................40-1198
E-17 OPERATION MODE DOES NOT CHANGE...............................................................................40-1199
E-18 OPERATION MODE DOES NOT CHANGE...............................................................................40-1200
E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN.................40-1201
E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE ....
.......................................................................................................................................................40-1202
E-21 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .............................40-1203
E-22 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING..............................40-1204
E-23 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...40-1205
E-24 SERVICE MODE CANNOT BE SELECTED ..............................................................................40-1206
E-25 HORN DOES NOT SOUND.......................................................................................................40-1207
E-26 HORN DOES NOT STOP SOUNDING......................................................................................40-1209
E-27 BACKUP ALARM DOES NOT SOUND .....................................................................................40-1210
E-28 BACKUP ALARM DOES NOT STOP SOUNDING.....................................................................40-1211
E-29 HEADLAMP DOES NOT LIGHT UP ..........................................................................................40-1212
E-30 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP.................................................40-1216
E-31 NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY ..........................................40-1219
E-32 FRONT WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTERMITTENT OP-
ERATIONS) ....................................................................................................................................40-1224
E-33 REAR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTERMITTENT OP-
ERATIONS) ....................................................................................................................................40-1228
E-34 LEFT DOOR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTERMITTENT
OPERATIONS) ...............................................................................................................................40-1232
D155AX-8 40-11
E-35 RIGHT DOOR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTERMIT-
TENT OPERATIONS).....................................................................................................................40-1236
E-36 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY ................................40-1240
E-37 FAN DOES NOT ROTATE IN REVERSE...................................................................................40-1241
E-38 GEAR CANNOT BE SHIFTED ..................................................................................................40-1242
E-39 FRONT WASHER DOES NOT OPERATE.................................................................................40-1243
E-40 REAR WASHER DOES NOT OPERATE ...................................................................................40-1246
E-41 LEFT DOOR WASHER DOES NOT OPERATE.........................................................................40-1249
E-42 RIGHT DOOR WASHER DOES NOT OPERATE ......................................................................40-1252
E-43 RIPPER PIN PULLER DOES NOT WORK ................................................................................40-1255
E-44 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ........................................................40-1257
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) ............................40-1258
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)......................................40-1258
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS .................................................40-1259
FAILURE MODE AND CAUSE TABLE...............................................................................................40-1263
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) ................................................40-1271
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) ............................................40-1274
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS ......................................................40-1276
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR IN REVERSE ........40-1279
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE ..................................40-1281
H-6 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR RIGHT)...............40-1283
H-7 STEERING SPEED OR POWER IS INSUFFICIENT...................................................................40-1285
H-8 BRAKE DOES NOT WORK.........................................................................................................40-1287
H-9 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE ...........................................40-1288
H-10 POWER TRAIN OIL OVERHEATS............................................................................................40-1289
H-11 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND HSS PUMP OR HSS MO-
TOR................................................................................................................................................40-1291
H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY ......................................................................40-1292
H-13 ALL WORK EQUIPMENTS DO NOT OPERATE .......................................................................40-1294
H-14 BLADE LIFT SPEED OR POWER IS LOW ...............................................................................40-1296
H-15 BLADE TILT SPEED OR POWER IS LOW ...............................................................................40-1298
H-16 RIPPER LIFT SPEED OR POWER IS LOW..............................................................................40-1300
H-17 RIPPER TILT SPEED OR POWER IS LOW ..............................................................................40-1302
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE .................................................................40-1304
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE..................................................................40-1305
H-20 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE................................................................40-1306
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE .......................................................40-1307
H-22 BLADE PITCH CYLINDER DOES NOT OPERATE ...................................................................40-1308
H-23 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ...................................40-1309
H-24 UNUSUAL NOISE IS HEARD FROM AROUND FAN ................................................................40-1310
TROUBLESHOOTING OF ENGINE (S-MODE) ........................................................................................40-1311
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)......................................40-1311
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.40-1312
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT ........................................................40-1313
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT
DOES NOT START) .......................................................................................................................40-1314
S-4 ENGINE STARTABILITY IS POOR..............................................................................................40-1315
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ...............................................................................40-1317
S-6 ENGINE STOPS DURING OPERATION .....................................................................................40-1319
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ...............................................................................40-1321
S-8 ENGINE LACKS POWER............................................................................................................40-1322
S-9 KDPF GETS CLOGGED IN A SHORT TIME ...............................................................................40-1324
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .........................................................................40-1326
S-11 OIL BECOMES CONTAMINATED QUICKLY .............................................................................40-1327
S-12 FUEL CONSUMPTION IS EXCESSIVE ....................................................................................40-1328
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .40-1329
S-14 OIL PRESSURE DROPS ..........................................................................................................40-1330
S-15 FUEL MIXES INTO ENGINE OIL...............................................................................................40-1332
40-12 D155AX-8
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .............................................................................40-1333

S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ...........................................40-1334
S-18 UNUSUAL NOISE IS HEARD....................................................................................................40-1335
S-19 VIBRATION IS EXCESSIVE ......................................................................................................40-1336
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT........................................................................40-1337
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .......................................................40-1338
S-22 ACTIVE REGENERATION TAKES TIME...................................................................................40-1340
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.....................................40-1341
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ..........................................................................40-1342
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .................................................................40-1344
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)................................40-1345
D155AX-8 40-13
GENERAL TROUBLESHOOTING POINTS 40 TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING

GENERAL TROUBLESHOOTING POINTS
k If you remove the radiator cap while the engine is still hot, hot coolant may spout out and can scald
you. Wait until the engine cools down.
k Take extreme care not to touch a hot portion or not to be wound in a turning portion.
k Before removing a plug or a cap of a portion where oil pressure, hydraulic pressure, or air pressure
is applied, release the internal pressure first, then connect the measuring tool securely.
k Park the machine on a level place and check the frame lock bar, chocks, parking brake, etc.
k When working in a group, make signs and allow only the persons concerned to approach the ma-
chine.
k When disconnecting wiring, remove the key and turn the battery disconnect switch to OFF position.
• Troubleshooting means to investigate the root cause of a failure, repair immediately, and prevent recur-
rence of the failure.
• One important thing when you perform troubleshooting is to understand the structure and operation.
• A shortcut to efficient troubleshooting is to have an interview with the operator and set up an aim of trouble-
shooting.
• If you disassembly the machine hastily when it has a failure, you may disassemble unrelated portions and
may not be able to find the cause. As a result, the costs of the man-hours, parts, oil, or grease may in-
crease, and you may lose the confidence of the users and operators. Accordingly, sufficient advance check
and proper procedure are necessary for troubleshooting.
1. Ask users or operators the following questions.
1) Have any other problems occurred apart from the problem that has been reported?
2) Is there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
2. Perform the following checks before troubleshooting.
1) Check the machine for a symptom of abnormality.
2) Perform the Check before starting items.
3) Check the other check items.
4) Check other maintenance matters which can be checked externally and are considered to be necessa-
ry.
3. Check the degree of the trouble by yourself and judge if it is a real failure or it is a problem of handling or
operation.
When reproducing the trouble phenomenon by operating the machine, do not perform check or measure-
ment that can increase the failure.
4. Use the results of the investigation and inspection to narrow down the probable causes of the failure, then
use the troubleshooting flow chart (matrix) to locate the failure exactly.
The basic troubleshooting procedure is as follows.
• Start from the simple points.
• Start from the most likely points.
• Investigate other related parts or information.
5. If the root cause is not corrected, a similar failure may occur again even if the apparent failure has been
repaired. Always find out the cause of a failure first and remove the root cause of each failure.
40-14 D155AX-8
40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

The following are troubleshooting related cautions and changes, which have resulted from the newly installed of
the U rea SCR system to Tier4 Final specification.
Engine controller shut down
• When the starting switch is turned to the OFF position, the engine controller starts the end processing. After
the end processing is completed, the action of turning off the engine controller's power is referred to as
“Engine controller shut down”.
• On machines with the Urea SCR system, the engine controller's end processing now includes purging of
AdBlue/DEF from devices or hoses to the tank, which results in increase of the time required for completing
the end processing from approximately current 2 minutes max. 6 minutes. (Described as 2 to 6 minutes in
the description of “Troubleshooting by failure code”).
• If the starting switch is turned OFF and ON before the engine controller is shut down, the information in the
engine controller which should be updated will not be updated, and the troubleshooting of the device may
not function properly. If this happens, it becomes necessary to shut down the engine controller. Completion
of engine controller shut down can be confirmed when the system operating lamp goes out.
Loaded Diagnostics Operation To Confirm Failure Correction and Loaded Diag-
nostics Operation To Clear Failure Code in the troubleshooting procedure
k Since the aftertreatment devices and their temperature sensor, pressure sensor, NOx sensor, ammo-
nia sensor, AdBlue/DEF injector, etc. are heated to a high temperature after “Loaded Diagnostics Op-
eration To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”,
take care not to get burned. Perform troubleshooting or repair after letting the devices cool down.
1. Tips
• The engine controller monitors the operation of engine related components (including aftertreatment
devices), and displays a failure code on the monitor when an abnormality is detected, and clears the
failure code after the failure is corrected. The monitored items include: sensors, actuators, electric wir-
ing, catalyzer, etc.
• The engine controller clears the failure code when it performs troubleshooting and the failure is correct-
ed. However, the failure code may be cleared when the engine controller is shut down even if the fail-
ure still exists. It may be necessary to apply load to the engine to activate the troubleshooting. Open
circuits and short circuits can be diagnosed by turning the starting switch to ON position after complet-
ing the repair. The engine controller determines if the failure, and displays a failure code on the monitor
when an abnormality is detected.
• However, the engine controller may not activate troubleshooting of the aftertreatment devices or other
functions if the exhaust gas temperature or flow rate is below the specified value. “Loaded Diagnostics
Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”
should always be performed after the repair. These operations mean to run the engine, and rev up or
load the engine to meet the conditions for activating troubleshooting.
2. Loaded Diagnostics Operation To Confirm Failure Correction
• This operation is performed to confirm if a failure is corrected when the failure code is already cleared
(described later) or has been cleared before the failure was corrected.
• After the repair is completed, run the engine and the machine until the exhaust gas temperature and
flow rate exceed the specified value. Let the engine controller to activate troubleshooting of the after-
treatment devices to determine if the failure is corrected. If the failure is corrected, the failure code will
not be displayed.
D155AX-8 40-15
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40 TROUBLESHOOTING
REMARK
• For failure codes that require “Loaded Diagnostics Operation To Confirm Failure Correction” or “Loaded
Diagnostics Operation To Clear Failure Code” after repairing, a “Notice” mark is described in the related
information column of each failure code description, and the procedure will be given at the end of each
failure code description.
• When performing “Loaded Diagnostics Operation To Confirm Failure Correction” or “Loaded Diagnostics
Operation To Clear Failure Code”, confirm that the level of AdBlue/DEF and fuel in the tank are enough
to perform. To check the level of AdBlue/DEF and fuel, see to Testing and adjusting chapter, “SETTING
AND OPERATING MACHINE MONITOR”, “SERVICE MODE”, “METHOD FOR OPERATING TESTING
MENU (SCR SERVICE TEST)”.
3. Loaded Diagnostics Operation To Clear Failure Code
• This operation is performed to clear a failure code which is not cleared by turning the starting switch to
ON position after the failure is corrected.
• After the repair is completed, run the engine and the machine until the exhaust gas temperature and
flow rate exceed the specified value. Let the engine controller to activate troubleshooting of the after-
treatment devices to determine if the failure is corrected. If the failure is corrected, the displayed failure
code will go out.
4. SCR Service Test
• This is a function for determining whether there is a failure in the Urea SCR system. Perform this test
from the machine monitor.
REMARK
If instructed to perform a “SCR Service Test” in the troubleshooting procedure or somewhere else, see Test-
ing and adjusting chapter, “SETTING AND OPERATING MACHINE MONITOR”, “SERVICE MODE”,
“METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST)” and perform “SCR Service Test”.
Clearing Failure Code
“Clearing failure code” refers to manually deleting an “active” failure code from the engine controller. The follow-
ing two “Clearing Failure Code” functions have been added for Tier4 Final specification.
1. Engine Controller Active Fault Clear
• It is now possible to clear the failure code from the machine monitor without using INSITE.
• This function is provided as a means to perform troubleshooting when operating conditions for normally
activating the troubleshooting cannot be met after the cause of the failure is repaired. If the machine
can be operated, always clear failure codes by performing “Loaded Diagnostics Operation To Confirm
Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”.
• For details, refer to Testing and adjusting chapter “SETTING AND OPERATING MACHINE MONITOR”,
“SERVICE MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.However, if a failure code that relates to the “Inducement strategies” is displayed
(see separated list of failure code), failure codes will not be able to be cleared by this function.
• In this case, the failure code is cleared by using the “Engine Controller Active Fault Clear”, described
below, or by using INSITE.
2. Engine Controller Inducement Fault Clear
• This is a function for clearing failure code caused by the Urea SCR system “Inducement”.
• For the failure code relating to the “Inducement strategy” of the Urea SCR system, which cannot be
cleared by “Engine Controller Active Fault Clear”, these can now be cleared from the machine monitor
by using a one-time password issued by Komatsu. Also, INSITE can be used for clearing.
In case failure codes cannot be cleared
• The relevant failure code may not be able to clear due to derated engine power caused by “Inducement
strategy”, environmental conditions or other functional restrictions. Details and the measures to be taken
are as shown below.
40-16 D155AX-8
Case 1 ： Derated engine power caused by “Inducement strategy”

• The failure code may not be able to be cleared because it is a failure code caused by an “Inducement strat-
egy”, which derates the engine power. (Detail of “Inducement strategy”, see Structure and function chapter
“UREA SCR SYSTEM”.)
• Failure codes, which are caused by “Inducement strategy”, and be cleared by turning the starting switch to
ON position or operating the engine at low idle, are cleared in the same manner as before.
• However, some failure codes caused by “Inducement strategy” and require “Loaded Diagnostics Operation
To Clear Failure Code” may not let the machine move to activate troubleshooting. (The “Inducement status”
advances to derate engine power.) For the applicable codes, see separate sheet. Applicable codes are also
identified at their descriptions of “Troubleshooting by failure code”.
• Measures to be taken:
When the repair is completed, perform “Engine Con Inducement Fault Clear” and then “Loaded Diagnostics
Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code” to con-
firm that the failure code is cleared.
Case 2： Environmental conditions
• Depending on environmental conditions (altitude, ambient temperature and etc.) when performing “Loaded
Diagnostics Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure
Code”, or when AdBlue/DEF anti-freeze control is activated, the failure code may not be able to be cleared.
(Applicable codes are identified by including the conditions that prevent clearing in “Related information” of
each “Troubleshooting by failure code”.)
1. When the repair is completed, perform “Loaded Diagnostics Operation To Confirm Failure Correction”
or “Loaded Diagnostics Operation To Clear Failure Code” under appropriate environmental conditions.
(See the description of each “Troubleshooting by failure code”.)
2. If the measure mentioned above is difficult to take after the repair is completed, perform “Engine Con-
troller Active Fault Clear”, or “Engine Con Inducement Fault Clear” and then confirm that the failure
code is cleared.
• Examples:
• Some failure codes cannot be cleared under certain environmental conditions (altitude, ambient tem-
perature, etc.)
1. Some failure codes cannot be cleared at high altitudes (ambient pressure 80 kPa or less).
2. Some failure codes cannot be cleared at low temperatures (ambient temperature -7 °C or below).
3. Some failure codes indicate failures only when AdBlue/DEF antifreeze control is activated.
4. Some failure codes do not indicate a failure when AdBlue/DEF antifreeze control is activated.
• Code cannot be cleared because AdBlue/DEF pump stops or AdBlue/DEF injection stops
• Condition that stops the AdBlue/DEF pump or AdBlue/DEF injection is shown below.
1. Ambient temperature: -24 °C or below
2. Unfreeze control activated
Case 3： Functional restrictions caused by other failures
• The failure code may not be able to clear due to functional restrictions (Regeneration control stops, Stops
AdBlue/DEF injection, etc.) caused by other failures. Operation and procedure required for clearing the
code are given under “Troubleshooting by each failure code”.
By following the clearing procedure, clear the failure code.
• Examples:
1. The failure code cannot be cleared because an abnormal high voltage, abnormal low voltage, or com-
munication error (open or short circuit) of failure code is displayed for a related component.
D155AX-8 40-17
2. The failure code cannot be cleared because correct values are not input from a sensor (a failure code
for a related sensor is displayed).
3. The failure code cannot be cleared because a failure code that disables auto regeneration or manual
stationary regeneration of the aftertreatment devices is displayed.
4. The failure code cannot be cleared because a failure code that stops the AdBlue/DEF pump or disa-
bles AdBlue/DEF injection is displayed.
How to identify the failure code to be repaired
Among failure codes displayed on “Abnormality Record” screen of the machine monitor, identify failure codes
that have following conditions as a code to be repaired
1. Failure codes displayed with “E” (“E” is displayed on the left of failure code. See the following figure.)
• Check the “Abnormality Record” screen and identify all failure codes that “E” is currently displayed as a
code to be repaired.
• The failure codes are displayed in the upper row from the “E” on the “Abnormality Record” screen.
2. Failure codes displayed without “E” and their service meter reading (SMR) at last occurrence (at previous
working time, etc.) become the most recent time.
• The failure codes that have detected records most recently and are displayed without “E” may be in the
state that their abnormalities are not cleared (*1). Due to that, check the description of “Troubleshoot-
ing by failure code” and identify them as a code to be repaired.
• The failure codes are displayed on “Abnormality Record” screen in ascending order. (See the following
figure.)
*1: It corresponds to a failure code that is cleared by turning the starting switch to OFF position, or by stop-
ping the engine though the repair is not completed. Due to this kind of failure code, the failure code to be
repaired is not determined only by the existence of “E”. (Failure C pattern in the following REMARK “Dis-
play of “E” on the “Abnormality record” screen”.)
1: Area where “E” is displayed
2: Area where the most recent SMR is displayed
REMARK
Display of “E” on the “abnormality record” screen
1. Transition of “E” displayed with failure code has a following pattern.
The table is shown the display of “E” on “Abnormality Record” screen of the machine monitor when turning
the starting switch to O N position after turning the starting switch to OFF position and shutting down the
engine controller.
Occurrence of failure code (with or without “E”)
Transition Before re- Determination of the repair completion
pattern pair (under After repair Remarks
failure)
The “E” is not displayed To determine if the repair is completed suc-
Failure A “E” No display after the repair is complet- cessfully enables to turn the starting switch to
ed. ON position.
40-18 D155AX-8
It is necessary to perform “Loaded Diagnos-

The “E” doses not go out
tics Operation To Clear Failure Code” to de-
Failure B “E” “E” only by the repair is com-
termine if the repair is completed successful-
pleted.
ly.
• See the most recent SMR on “Abnor-
mality Record” screen and determine if
it is to be repaired because only the
Once the engine controller “E” cannot determine if the failure is
shuts down, the “E” goes cleared.
Failure C No display No display
out even if the repair is not
completed. • It is necessary to perform “Loaded Di-
agnostics Operation To Confirm Fail-
ure Correction” to determine if the re-
pair is completed successfully.
2. Unless clearing the “E” of failure code, a number of occurrences increase every time when turning the start-
ing switch to ON position.
D155AX-8 40-19
Troubleshooting Flow
40-20 D155AX-8
D155AX-8 40-21
40-22 D155AX-8
List of failure codes related to Inducement

• “●” mark shown in the following list means failure codes related to Inducement in each territory.
• When activating Inducement strategy, the following failure code is displayed with one of “AdBlue/DEF level
Low Error”, or “Urea SCR system devices abnormality” on “Current Abnormality” screen of the machine
monitor.
• “Urea SCR system devices abnormality” is displayed as Urea SCR System Abnormality on the “Abnormal-
ity Record” screen.
North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
Detail of failure DEF DEF
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
AS00ZK AdBlue/DEF Level Low Error 5 ● - - -
CA249 Ambient Air Temp Sensor High Error - - - ●
CA256 Ambient Air Temp Sensor Low Error - - - ●
CA1669 AdBlue/DEF Level Sensor Voltage High Error - - - ●
CA1673 AdBlue/DEF Level Low Error 3 ● - ● -
CA1677 AdBlue/DEF Temperature Sensor Low Error - - - ●
CA1678 AdBlue/DEF Temperature Sensor High Error - - - ●
CA1682 AdBlue/DEF Pump Priming Error - ● - ●
CA1683 AdBlue/DEF Tank Heating Valve Voltage High Error - ● - ●
CA1684 AdBlue/DEF Tank Heating Valve Voltage Low Error - ● - ●
CA1686 AdBlue/DEF Quality Sensor Voltage High Error - - - ●
CA1714 AdBlue/DEF Quality Sensor Out of Calibration Error - - - ●
CA1715 AdBlue/DEF Quality Sensor Internal Circuit Error - - - ●
CA1885 Turbo Outlet NOx Sensor Circuit Error - - - ●
CA1887 SCR Outlet NOx Sensor Circuit Error - - - ●
CA2271 EGR Valve Position Sensor High Error - - - ●
CA2272 EGR Valve Position Sensor Low Error - - - ●
CA2349 EGR Valve Solenoid Open Circuit Error - - - ●
CA2353 EGR Valve Solenoid Short Circuit Error - - - ●
CA2357 EGR Valve Servo Error - - - ●
CA2771 SCR Outlet NOx Sensor Datalink Timeout Error - ● - ●
CA2976 AdBlue/DEF Pump Temperature Sensor Signal Error - ● - ●
CA3142 SCR Temperature Sensor High Error - ● - ●
CA3143 SCR Temperature Sensor Low Error - ● - ●
CA3144 SCR Temperature Sensor In Range Error - ● - ●
CA3146 SCR Outlet Temperature Sensor High Error - ● - ●
CA3147 SCR Outlet Temperature Sensor Low Error - ● - ●
CA3148 SCR Outlet Temperature Sensor In Range Error - ● - ●
D155AX-8 40-23
North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
CA3151 SCR Catalyst Efficiency Low Error 2 - ● - ●
CA3165 SCR Outlet Temperature High Error - ● - ●
CA3229 SCR Temperature High Error - ● - ●
CA3231 SCR Temperature High Error - Non Regeneration - ● - ●
CA3232 Turbo Outlet NOx Sensor Datalink Timeout Error - ● - ●
CA3235 SCR Outlet Temperature High Error - Non Regeneration - ● - ●
CA3319 KDPF Outlet Temperature Sensor High Error - ● - ●
CA3321 KDPF Outlet Temperature Sensor Low Error - ● - ●
CA3322 KDPF Outlet Temperature Sensor In Range Error - ● - ●
CA3543 AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) - ● - -
CA3545 SCR Outlet NOx Sensor Unstable Error - - - ●
CA3558 AdBlue/DEF Pump Voltage High Error - ● - ●
CA3559 AdBlue/DEF Pump Voltage Low Error - ● - ●
CA3563 AdBlue/DEF LineHeater Relay 1 Voltage Low Error - ● - ●
CA3567 AdBlue/DEF Injector Open Circuit Error or Short Circuit Error - ● - ●
CA3568 AdBlue/DEF Injector Malfunction - ● - ●
CA3571 AdBlue/DEF Pump Pressure Sensor High Error - ● - ●
CA3572 AdBlue/DEF Pump Pressure Sensor Low Error - ● - ●
CA3574 AdBlue/DEF Pump Pressure Too Low Error - ● - ●
CA3575 AdBlue/DEF Pump Pressure Too High Error - ● - ●
CA3577 AdBlue/DEF FCV Voltage High Error - ● - ●
CA3578 AdBlue/DEF FCV Voltage Low Error - ● - ●
CA3583 SCR Outlet NOx Sensor Heater Warming up Error - - - ●
CA3596 AdBlue/DEF Pump Pressure Unstable Error - ● - ●
CA3649 Turbo Outlet NOx Sensor Heater Warming up Error - - - ●
CA3681 SCR Outlet NOx Sensor Power Voltage Error - - - ●
CA3682 Turbo Outlet NOx Sensor Power Voltage Error - - - ●
CA3717 SCR Outlet NOx Sensor Voltage Mismatch Error - - - ●
CA3718 Turbo Outlet NOx Sensor Voltage Mismatch Error - - - ●
CA3725 Turbo Outlet NOx Sensor Unstable Error - - - ●
CA3866 AdBlue/DEF Low Concentration Error 2 - - - ●
40-24 D155AX-8
North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
CA3868 AdBlue/DEF Tank Sensor Datalink Timeout Error - ● - ●
CA3899 SCR NH3 Sensor Circuit Error - - - ●
CA3911 SCR NH3 Sensor Datalink Timeout Error - ● - ●
CA3912 SCR NH3 Sensor Heater Warming up Error - - - ●
CA3932 SCR NH3 Sensor Heater Voltage High Error - - - ●
CA3933 SCR NH3 Sensor Heater Voltage Low Error - - - ●
CA3934 SCR NH3 Sensor Power Interrupt Error - - - ●
CA3935 SCR NH3 Sensor Trim Resistance Error - - - ●
CA3936 SCR NH3 Sensor Internal Circuit Error - - - ●
CA4151 KDOC and KDPF Temperature Sensor Datalink Timeout Error - ● - ●
CA4152 SCR Temperature Sensor Datalink Timeout Error - ● - ●
CA4155 AdBlue/DEF Pump Heater Relay Voltage High Error - ● - ●
CA4158 KDOC and KDPF Temperature Sensor Internal Circuit Error - ● - ●
CA4159 SCR Temperature Sensor Internal Circuit Error - ● - ●
KDOC and KDPF Temperature Sensor ECU Voltage High Er-
CA4161 - ● - ●
ror
KDOC and KDPF Temperature Sensor ECU Voltage Low Er-
CA4162 - ● - ●
ror
CA4164 SCR Temperature Sensor ECU Voltage High Error - ● - ●
CA4165 SCR Temperature Sensor ECU Voltage Low Error - ● - ●
CA4259 KDOC and KDPF Temperature Sensor Power Interrupt Error - ● - ●
CA4261 SCR Temperature Sensor Power Interrupt Error - ● - ●
CA4461 AdBlue/DEF LineHeater Relay 2 Voltage Low Error - ● - ●
CA4731 AdBlue/DEF Temperature Sensor Transmission Data Error - - - ●
CA4732 AdBlue/DEF Level Sensor Transmission Data Error - - - ●
CA4739 AdBlue/DEF Level Sensor Internal Circuit Error - - - ●
CA4769 AdBlue/DEF Level Measurement Impossible - ● - ●
CA4842 AdBlue/DEF High Concentration Error - - - ●
D155AX-8 40-25
List of failure codes that are related to Inducement and cannot be cleared at engine power deration
Failure
Detail of failure North America EU
code
CA1885 Turbo Outlet NOx Sensor Circuit Error - ●
CA1887 SCR Outlet NOx Sensor Circuit Error - ●
CA3144 SCR Temperature Sensor In Range Error ● ●
CA3148 SCR Outlet Temperature Sensor In Range Error ● ●
CA3151 SCR Catalyst Efficiency Low Error 2 ● ●
CA3322 KDPF Outlet Temperature Sensor In Range Error ● ●
CA3543 AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) ● -
CA3545 SCR Outlet NOx Sensor Unstable Error - ●
CA3547 AdBlue/DEF Level Low Error 4 ● ●
CA3568 AdBlue/DEF Injector Malfunction ● ●
CA3583 SCR Outlet NOx Sensor Heater Warming up Error - ●
CA3649 Turbo Outlet NOx Sensor Heater Warming up Error - ●
CA3681 SCR Outlet NOx Sensor Power Voltage Error - ●
CA3682 Turbo Outlet NOx Sensor Power Voltage Error - ●
CA3725 Turbo Outlet NOx Sensor Unstable Error - ●
CA3899 SCR NH3 Sensor Circuit Error - ●
CA3912 SCR NH3 Sensor Heater Warming up Error - ●
CA3932 SCR NH3 Sensor Heater Voltage High Error - ●
CA3933 SCR NH3 Sensor Heater Voltage Low Error - ●
CA3934 SCR NH3 Sensor Power Interrupt Error - ●
CA3935 SCR NH3 Sensor Trim Resistance Error - ●
CA3936 SCR NH3 Sensor Internal Circuit Error - ●
40-26 D155AX-8
List of failure codes is related to Inducement and cannot be cleared when freezing AdBlue/DEF (All terri-
tory)
Failure Detail of failure
code
CA1673 AdBlue/DEF Level Low Error 3
CA1682 AdBlue/DEF Pump Priming Error
CA3547 AdBlue/DEF Level Low Error 4
CA3567 AdBlue/DEF Injector Open Circuit Error or Short Circuit Error
CA3574 AdBlue/DEF Pump Pressure Too Low Error
CA3575 AdBlue/DEF Pump Pressure Too High Error
CA3578 AdBlue/DEF FCV Voltage Low Error
CA3596 AdBlue/DEF Pump Pressure Unstable Error
CA3866 AdBlue/DEF Low Concentration Error 2
CA4277 AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error
CA4768 Fuel in AdBlue/DEF Tank Error
CA4769 AdBlue/DEF Level Measurement Impossible
CA4842 AdBlue/DEF High Concentration Error
D155AX-8 40-27
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40 TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
40-28 D155AX-8
40 TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
D155AX-8 40-29
CHECKS BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Engine, lubricating oil, coolant, and AdBlue/DEF
No. Item Criteria Remedy
1 Check for unusual noise and smell - Repair
2 Check of engine for dirt - Remove
3 Check of engine for water leakage - Repair
4 Check of engine for oil leakage - Repair
5 Check of fuel line for leakage - Repair
6 Check of radiator for clogging - Remove
7 Check of AdBlue/DEF line for leakage - Repair
Check around the aftertreatment device for exhaust gas
8 - Repair
leakage
9 Check of fuel level and type - Add fuel
10 Check of foreign material in fuel - Clean and drain
11 Check of AdBlue/DEF level and type - Refilling with oil
12 Check of fuel prefilter - Replacement
13 Check of fuel filter - Replacement
14 Check of engine oil level (in oil pan) and type Between H and L Add engine oil
15 Check of coolant level (in sub tank) Between H and L Refilling with coolant
Clogging is not indicat-
Cleaning or replace-
16 Check of air cleaner for clogging ed on the machine mon-
ment
itor
Hydraulic and mechanical equipment

1 Check for unusual noise and smell - Repair
2 Check for oil leakage - Repair
3 Check of hydraulic oil level Between H and L Refilling with oil
4 Check of hydraulic oil strainer -
ment
5 Check of hydraulic oil filter - Replacement
6 Check of power train case oil level Between H and L Refilling with oil
7 Check of power train pump strainer - Clean and drain
8 Check of transmission filter and torque converter - Clean and drain
9 Check of damper case oil level Between H and L Refilling with oil
10 Check of final drive case oil level Between H and L Refilling with oil
11 Bleeding air - Bleeding air
Electric equipment
1 Check of battery terminal for looseness and corrosion - Retighten or replace
2 Check of alternator terminal for looseness and corrosion - Retighten or replace
40-30 D155AX-8
40 TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

Check of starting motor terminal for looseness and corro-
3 - Retighten or replace
sion
4 Check of battery voltage (with engine stopped) 20 to 30 V Charge or replacement
5 Check of battery electrolyte level Between H and L Refill or replacement
Check of wiring harness for discoloration, burnt areas and
6 - Replacement or repair
cover peeling
Check for coming off of wiring harness clamp and sagging
7 - Repair
of wiring harness
8 Check of grounding - Repair
9 Check for loose connector and damaged lock - Replacement or repair
Check of connector pin for corrosion, bends and deforma-
10 - Replacement or repair
tion
Drying, cleaning or re-
11 Check of connector for water and foreign material -
placement
12 Check of wiring harness for open or short circuit - Replacement or repair
13 Check of fuse for blowing out and corrosion - Replacement
Push in the reset but-
14 Check of circuit breaker -
ton
Check of alternator voltage (when engine speed is medium 27.5 to 29.5 V after few
15 Replacement
or higher) minutes of operation
Check of battery relay operation sound (when starting
16 - Replacement
switch is turned to ON or OFF position)
Exterior
1 Check of undercarriage - Repair
2 Check of handrails and steps - Repair
3 Check of mirrors - Cleaning or repair
Interior
1 Check of gauges and monitors -
ment
2 Check of seat belt - Repair
D155AX-8 40-31
CHECKS BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

WALK-AROUND CHECK
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of
oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, wiring harnesses for play, and accumulation of dust in places that reach
high temperatures.
k Accumulated combustibles around hot engine parts such as exhaust pipes, aftertreatment devices,
turbocharger, etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly
and repair any failures.
• Check for unusual noise and smell
Check for unusual sounds or smells.
If the machine is operated under the unusual sounds or smells, the cause of it may damage the machine,
so stop the operation immediately once you recognize it.
• Check around engine and removal of dirt
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.)
on hot engine parts such as the exhaust pipes, after-treatment devices, turbocharger, etc.
• Check of engine for water leakage
Check for coolant leakage from cooling system. If any abnormality is found, repair it.
• Check of engine for oil leakage
Check for oil leakage from engine. If any abnormality is found, repair it.
• Check of fuel line for leakage
Check for fuel leakage, check hoses and pipes for damage. If any abnormality is found, repair it.
• Check of radiator and removal of dirt
Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the radiator.
If any, remove them.
For removal of dirt from the radiator, see the Operation and Maintenance Manual, “Cleaning and testing of
radiator fins, oil cooler fins, aftercooler fins”.
• Check of AdBlue/DEF line for leakage
Check for oil leakage from AdBlue/DEF tank, pump, injector, hose or connection parts. If any abnormality is
found, repair it.
• Check around the aftertreatment device for exhaust gas leakage
Check the following parts and repair them if any abnormality is found. Pipes which connects turbocharger
and KDPF, exhaust gas leakage (soot attached) from the connection part of KDPF, pipes which connects
KDPF and SCR and exhaust gas leakage (urea deposit attached) from the connection part of SCR.
• Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage, and hoses for breakage, wear, and clearance. If any abnor-
mality is found, repair it.
• Check of hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage
Check for oil leaks. If any abnormality is found, repair it.
• Check around batteries and dirt removal
Check for any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the batteries. If any, re-
move them.
• Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers
If any abnormality is found, repair it.
• Check of handrails and steps for abnormality and looseness of bolts
If any abnormality is found, repair it and tighten any loose bolts.
• Check and clean rearview mirrors
Check rearview mirror for abnormality. If any, repair it.
Clean the mirror surface and adjust the mirror angle so that the rear of the machine can be seen from the
operator's seat.
40-32 D155AX-8
40 TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
• Check of gauges and monitors for abnormality

Check gauges and monitors in the operator's cab for abnormality. If any abnormality is found, replace it with
a new one.
Clean up the surfaces.
• Check of seat belt and mounting hardware
Check the hook, the lock, and hook mounting part for damage. If any abnormality is found, repair it.
D155AX-8 40-33
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE

FUEL - CHECK LEVEL AND TYPE
k Fuel is highly flammable and dangerous. Keep fire away.
k When adding fuel, be careful not to overflow it.
k Wipe off any spilled fuel. If fuel spills over soil or sand, remove all the fuel and soil or sand together.
1. Turn the engine starting switch to ON position and check
the fuel level with the fuel gauge (1) on the monitor panel.
After checking, turn the switch back to OFF position.
2. If fuel level is low, open fuel filler cap (F) of fuel tank, and
add fuel through filler port to the level enough for checking.
REMARK
If breather (1) of element is clogged, the pressure in the
tank decreases and fuel may not be supplied. To prevent
this, clean the breather hole.
FUEL - CHECK FOR FOREIGN MATERIAL

1. Prepare a container below drain hose (1) to receive fuel.
2. Turn drain valve (2) to “OPEN” position (O) to discharge
the sediment and water in the bottom together with the
fuel.
3. When only the clean fuel flows out, turn drain valve (2) to
close position S.
40-34 D155AX-8
40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE
CHECK AdBule/DEF LEVEL AND TYPE

k Do not pour anything besides AdBlue/DEF to the AdBlue/DEF tank. Pouring especially diesel oil or
gasoline can cause fires. Furthermore, toxic gas may develop by pouring additive.
k When opening the AdBlue/DEF tank cap, harmful ammonia gas may be exhausted from the tank.
Keep your face away from the filler port while opening the tank cap or refiling.
k Foreign matter mixed in AdBlue/DEF results in a short service life of AdBlue/DEF injector and AdBl-
ue/DEF pump.
Before removing the filler port cap, clean foreign matter around the cap. Refiling nozzle also needs
to be cleaned before the refiling.
k If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left
unattended, toxic gas or corrosive substance may be produced by chemical reactions.
k AdBlue/DEF may cause inflammation if it touches your skin.contaminated clothing or shoes must be
removed immediately and to wash off with water or warm water.
Use a soap and rinse your skin. If there may be pain or change in the skin appearance, consult your
doctor immediately.
k Do not force yourself to vomit if you have swallowed AdBlue/DEF accidentally. Wash your mouth out
and consult your doctor immediately.
k If AdBlue/DEF splash in the eyes, immediately flash your eye with clean water for a few minutes and
consult your doctor.
1. Turn the starting switch to “ON” position, and check AdBl-
ue/DEF with level gauge (A) on the monitor panel.
After checking, turn the switch back to “OFF” position.
2. If AdBlue/DEF level is low, open up the cover (1) on the

left side of machine body and turn the filler port (2) cap
counterclockwise. Add AdBlue/DEF from the filler port by
checking the sight gauge (3) until the amount required for
the test.
FUEL PREFILTER - CHECK

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k High pressure is generated inside the engine fuel piping system when the engine is running. Stop
the engine and wait at least 30 seconds until the inner pressure is released and then replace the fil-
ter.
k Keep fire away.
D155AX-8 40-35
NOTICE
• Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filtering properties.
Be sure to use Komatsu genuine parts when replacing.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine
fuel filter cartridge is used, foreign materials may enter and problem may occur in the injection sys-
tem. Do no use substitute parts.
• During testing or maintenance of the fuel system, be sure that any foreign material does not enter
the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean
fuel.
• Prepare a container to receive oil.
• Prepare a filter wrench.
1. Set supply valve (1) of the fuel tank to "Close" position S.
2. Open the side cover, and remove the mudguard cover.

3. Place a container to receive drained oil under prefilter car-
tridge (2).
4. Turn filter cartridge (2) counterclockwise by using the filter
wrench, and remove it.
REMARK
Check that the drain plug on the bottom of the transparent
cup is tightened securely.
5. Clean the filter bracket and thinly apply oil to the packing
surface of filter cartridge.
REMARK
Do not fill the new filter cartridge with fuel.
6. Remove cap A in the center, and then install it to the filter
bracket
7. Install prefilter cartridge.
REMARK
• When installing it, tighten it by 3/4 turns after the O-ring
came in touch with the sealing surface of filter bracket.
• If the prefilter cartridge is fastened too much, the O-ring
will be damaged and this leads to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from gaps
of the packing. Therefore, be sure to observe the fas-
tening angle.
Perform “Main filter check”.
40-36 D155AX-8
MAIN FILTER - CHECK

k High pressure is generated inside the engine fuel piping system when the engine is running. Stop
the engine and wait at least 30 seconds until the inner pressure is released and then replace the fil-
ter.
k Keep fire away.
NOTICE
• Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filtering properties.
Komatsu recommends Komatsu genuine parts when replacing.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine
fuel filter cartridge is used, foreign materials may enter and problem may occur in the injection sys-
tem. Do no use substitute parts.
• During testing or maintenance of the fuel system, be sure that any foreign material does not enter
the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean
fuel.
• Prepare a container to receive oil.
• Prepare a filter wrench.
1. Set supply valve (1) of the fuel tank to CLOSE (S) position.
2. Open the side cover, and remove the mudguard cover.

3. Turn filter cartridge (2) counterclockwise by using the filter
wrench, and remove it.
4. Clean the filter bracket and thinly apply oil to the packing
surface of filter cartridge.
REMARK
Do not fill the new filter cartridge with fuel.
5. Remove cap A in the center, and then install it to the filter

bracket
6. Install filter cartridge.
REMARK
• When installing it, tighten it by 3/4 turns after the O-ring
came in touch with the sealing surface of filter bracket.
• If the filter cartridge is fastened too much, the O-ring
will be damaged and this leads to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from gaps
of the packing. Therefore, be sure to observe the fas-
tening angle.
D155AX-8 40-37
7. Set valve (1) at the fuel tank bottom to OPEN (O) position.
8. Bleed air. For details, see TESTING AND ADJUSTING, “Bleeding air from fuel system”.
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until all parts have cooled down before starting the work.
REMARK
• When checking the oil level after the engine has been operated, wait at least 15 minutes after stopping the
engine.
• If the machine is at an angle, make it level before checking.
1. Stop the engine.
2. Open the side cover.
3. Pull out dipstick (G) and wipe the oil off with a cloth.
4. Check the oil level using the side with the stamped mark
“ENGINE STOPPED” of the dipstick G. The level is appro-
priate if it is between the embossed marks H and L.
5. If the oil level is above H, remove the bottom cover of the

machine body and place a container for drained oil right
below it.
40-38 D155AX-8
6. Remove drain plug (1).

7. Loosen drain valve (2) gradually with care not to get
splashed with drained oil, and drain oil.
REMARK
Be careful not loosen the drain valve (2) too much, other-
wise stopper pin in the valve will be deformed.
3 Drain plug (1):
68.6±9.81 Nm {7±1 kgm}
3 Drain valve (2):
63.7±14.7 Nm {6.5±1.5 kgm}
8. Recheck the hydraulic oil level.
9. If the oil is at the correct level, tighten the oil filler cap securely and close the engine hood.
RESERVOIR TANK - CHECK COOLANT LEVEL

k The radiator cap does not need to be opened for standard checks. When checking the coolant level,
check it in reservoir tank when the engine is cooled down.
k Immediately after the engine is stopped, the coolant is still very hot and the pressure is accumulated
in the radiator.
If the cap is opened under these conditions, you may be scalded. If you need to remove the radiator
cap, wait until the temperature drops before you do. Then turn the cap slowly to release the pressure
and remove it with care.
1. Open the cover (1) on the right side of the machine and
check that coolant level is between FULL and LOW marks
of reservoir tank (2).
D155AX-8 40-39
2. Coolant leakage may be suspected if the reservoir tank is

empty. If any abnormality is found in the check for leakage,
repair it immediately. IF no abnormality is found, check the
level of the coolant in the radiator. If it is low, open the cov-
er (3) and radiator filler cap (4) to add coolant. Check that
coolant level is above the bottom surface of the strainer
(5).
3. Refill the reservoir tank with coolant through the filler port
(6) up to FULL level.
AIR CLEANER - CHECK FOR CLOGGING

k When using compressed air for cleaning, put on personal protective items such as protective eye-
glasses, gloves, dust mask, etc. to protect yourself from dirt that will fly out.
k When removing the outer element from the air cleaner body, do not forcibly pull it out, otherwise it
can be dangerous.
k When working in high places or on poor footing, be careful not to fall because of the reaction when
pulling out the outer element.
Clean the air cleaner element if the internal yellow piston is
overlapped with the outer red zone (A) of dust indicator (1). Af-
ter cleaning, press reset button (2) to release.
40-40 D155AX-8
REMARK
• Do not clean the element until the yellow piston of dust indicator (1) overlaps with the outer red zone (A).
If the element is cleaned frequently before the yellow piston of dust indicator (1) is overlapped with the outer
red zone (A), the air cleaner will not deliver the optimum performance, and the cleaning effect will decrease.
• Inspection, cleaning or servicing while the engine is running allows entry of dusts and can damage the en-
gine since dusts attached to the element drop into the inner cylinder element more frequently during the
cleaning process. Be sure to clean after stopping the engine.
OUTER ELEMENT - CLEAN

• Before and after cleaning, be careful not to leave or store the element being exposed to the direct sunlight.
• Even when the number of cleanings of the outer element is 6, it must be replaced along with the inner ele-
ment if dust indicator (1) lights up prematurely after cleaning.
1. Open the door on the left side of the engine and disengage
hook (2) at 6 positions to remove cover (3).
2. When removing outer element (4), hold it and pull it out

while gently moving it up and down, right and left.
NOTICE
• Never remove inner element (5). If it is removed,
dirt will enter and can cause an engine trouble.
• Do not use a screwdriver or other tool.
• After removing outer element (4), check that the in-
ner element is not disengaged or inclined. If it is in-
clined, push it into the end straight with the hand.
3. After removing outer element (4), cover inner element (5)
with a clean cloth or tape to protect from dusts.
4. Clean dusts in inside and on cover (3) of air cleaner body
(6) by using a clean cloth or brush.
NOTICE
Never tap or hit the element against any other object
when cleaning it.
5. Blow dry compressed air (Max. 196 kPa {2 kg/cm2} ) from
the inside of the outer element along the pleats.
6. Then blow it from outside along the pleats, and finally blow
it from the inside again.
After clearing the element, throw light on its inside by using
a light bulb to check it. If it has a small hole or thin part, re-
place it.
7. Remove the cover of cloth or tape attached to inner ele-
ment (6).
8. Check the seal of the cleaned or new element for adhesion of dusts and oil and wipe them off, if any.
D155AX-8 40-41
REMARK
Do not use the element if its pleats or gasket or seal are damaged.
9. Push the outer element straight backward into the air
cleaner body with your hands while moving it up and
down, right and left.
When installing the air cleaner element, set it in such that
its cylinder bottom (side without a hole) B and C come to
cover (3) side.
REMARK
If they are installed in the opposite direction, serious trou-
bles including damage on the air cleaner elements and en-
gine may occur.
10. Align cover (3) with the element.
11. Lock the tip of hook (2) on the protrusion of the air cleaner
body.
12. Install hooks (2) in the diagonal positions (top and bottom,
or right and left), and lock them.
13. After installing cover (3), check that there is no clearance
between the air cleaner body and cover (3). If any, install
the cover again.
REPLACE ELEMENT
1. Referring to “CLEANING OF OUTER ELEMENT”, remove
outer element (4).
2. Remove inner element (5), and immediately install new in-
ner element (5) to air cleaner body (6).
REMARK
Do not clean and reuse the inner element. When replacing
the outer element, replace the inner element with new one
at the same time.
3. When installing the air cleaner element, set it in such that

its cylinder bottom (side without a hole) (B) comes to cover
(3) side.
REMARK
• If they are installed in the opposite direction, serious
troubles including damage on the air cleaner elements
and engine may occur.
• If the outer element and cover are installed when the
inner element is not securely installed, the outer ele-
ment can be damaged. Be sure to install it securely.
4. Push the outer element straight backward into the air
cleaner body with your hands while moving it up and down, right and left.
40-42 D155AX-8
5. When installing the air cleaner element, direct its bottom (C) (having no hole) toward cover (3).
REMARK
If they are installed in the opposite direction, serious troubles including damage on the air cleaner elements
and engine may occur.
6. Replace O-ring (7) of cover (3) with a new one.
7. Referring to “CLEANING OF OUTER ELEMENT”, install
cover (3).
8. Replace the seal of cover (3) with a new one.
CHECK HYDRAULIC OIL LEVEL

k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
k If oil is added to above the H mark, stop the engine and remove the drain plug (P) after the hydraulic
oil has cooled down. Loosen drain plug (1), and drain the excess oil.
1. Place the machine on a level ground, set the work equip-
ment in the same posture as the figure before stopping the
engine.
(SIGMA dozer)
Set the blade (a) on the ground to have the same length of
tilt cylinder as the length shown in the following table.
Set the ripper (b) pin to the lowest position and adjust the
length of each cylinders to the length shown in the follow-
ing table.
Reference
Item Dimension (mm)
Blade (DUAL) Tilt cylinder length 1360
Tilt cylinder length 1360
Blade (SINGLE)
Brace 1360
Lift cylinder length 1477
Ripper (VGR, VMR)
(Semi-U dozer, U dozer)

Set the blade (a) on the ground to have the same length of tilt cylinder as the length shown in the following
table.
Set the ripper (b) pin to the lowest position and adjust the length of each cylinders to the length shown in
the following table.
D155AX-8 40-43
Reference
Item Dimension (mm)
Blade (DUAL) Tilt cylinder length 1374
Blade (SINGLE)
Brace 1374
2. Stop the engine and wait for approximately 5 minutes, then

check that the oil level is between H and L marks on sight
gauge (G).
REMARK
Do not add oil above H line. It can damage the hydraulic
circuit or allow spurt of oil.
3. If the oil level is below line L, add oil through oil filter port
(F).
REMARK
If the machine is at an angle, make it level before check-
ing.
CHECK HYDRAULIC OIL STRAINER

1. Stop the engine and remove oil filler cap (F) of the hydraul-
ic tank to release the internal pressure.
2. Remove bolts (1) and remove cover (2).
When removing the bolts, keep pressing down the cover
(2) since it may jump out by inner spring.
40-44 D155AX-8
3. Pull the rod (3) up, and remove the strainer (4).
4. Remove dirt stuck to strainer (4) and clean the strainer in
cleaning oil. If strainer (4) is damaged, replace it with a
new one.
5. Insert and set strainer (4) in the tank.
6. While pressing down the spring with the projection at the
bottom of cover (2), and install the bolts.
Tighten the mounting bolts.
CHECK HYDRAULIC FILTER

1. Lower the work equipment on a level and firm ground, set
it in the posture securely as shown below, and stop the en-
gine.
2. Remove oil filler cap (F) of the hydraulic tank to release
the internal pressure.
3. Prepare oil container to receive oil.
4. Remove the drain plug (P) on the bottom of the tank, loos-
en drain valve (1), and drain oil.
REMARK
When loosening the drain plug (P), be careful not to get
splashed with drained oil.
5. After draining oil, close drain plug (P) and tighten drain
valve (1).
6. Remove bolt (2) first, and remove cover (3).

When removing the bolts, keep pressing down the cover
since it may jump out by spring (4).
7. Remove spring (4) and valve (5) , and then take out ele-
ment (6).
NOTICE
Check the bottom of the filter case for dirt or other ma-
terial, and remove any if found. At that time, take ex-
treme care for any dirt or other material not to drop in-
to the hydraulic tank.
8. Clean the inside of the case and removed parts in order to install new element.
9. After setting valve (5) and spring (4) on the element. Set cover (3) by using mounting bolts while being
pressed by the hand.
10. Tighten the mounting bolts.
11. Fill the tank with refill capacity of oil through oil filler port (F), then install the cap.
D155AX-8 40-45
12. To bleed air, run the engine at low idle speed for 10 minutes.
13. Stop the engine and check the amount of oil is within a specified level.
CHECK OIL LEVEL IN POWER TRAIN CASE

k If the machine is at an angle, make it level before checking.
k Oil level cannot be measured correctly since oil level rises while engine is stopped. Measure the oil
level on HOT side of gauge G with engine at high idle if the check is performed during operation or
after operation.
1. Start the engine, set the fuel control dial to low idle MIN, keep the engine at low idle speed for approximate-
ly 3 to 5 minutes.
REMARK
Perform the following procedure while engine is not stopped.
2. Pull out dipstick G and wipe the oil off with a cloth.
3. Insert dipstick G fully into the guide.
4. Pull out dipstick G and check the oil level. If the oil level is
between H and L on “HOT IDLE” embossed side of the
dipstick G, it is appropriate.
5. If the oil does not reach the L mark on “HOT IDLE” em-
bossed side of the dipstick G, remove the cap of oil filler F
and add oil through it. When adding oil, remove dipstick G.
6. If oil level is above H, open inspection cover (1), and drain

oil.
40-46 D155AX-8
Remove the drain plug (1), loosen drain valve (2), and
drain oil.
REMARK
• When loosening the drain plug (1), be careful not to get
splashed with drained oil.
• When draining oil, place an oil container under drain
port.
7. After checking the oil level and adding oil, install oil level
gauge G and oil filler cap F.
CHECK POWER TRAIN STRAINER

1. Add specified amount of oil through oil filler port F.
2. After refilling it with oil, confirm that oil is refilled to the
specified level according to “CHECK OF OIL LEVEL OF
POWER TRAIN CASE”.
3. Remove the cover (3) on the under cover on rear bottom

of the machine.
k The undercover is heavy. Never try to open or
close the undercover when you are directly under
it. When removing bolts, perform the work from the
rear of the undercover so that you can easily get
out of the way.
k When removing bolts, be careful not to be hit by
the falling undercover.
D155AX-8 40-47
4. Remove drain plug P2, and drain oil accumulated inside

the pipe.
6 Power train oil:

Approximately. 4 ℓ
5. Loosen mounting bolt (4) of power train strainer, and re-

move cover (5).
6. Remove spring (6), and remove strainer (7).
7. Remove any dirt stuck to the strainer (7) and wash it in
diesel oil or flushing oil. Clean the case interior and the re-
moved parts as well.
8. Loosen bolt (8) of scavenging pump strainer, and remove
cover (9).
9. Take strainer (10) out, and wash it with diesel fuel or flush-
ing oil.
After finishing the check and cleaning, return parts to original position.
CHECK POWER TRAIN FILTER

k Oil may spurt out when accumulated pressure in the filter is high. Depress the brake pedal several
times for releasing the pressure before opening the filter case, and lock the brake pedal.
40-48 D155AX-8
2. Remove mounting bolt of filter (2), and remove cover (3).

3. Take the element out, clean inside the case and parts re-
moved, and replace it with a new one.
k Komatsu recommends using Komatsu genuine ele-
ment.
4. Return the cover (1) to the place where it was installed
originally.
CHECK OIL LEVEL IN DAMPER CASE

k Place the machine on a level ground, stop the engine, and start the checking.
1. Open the engine side cover on the left side of the machine.
2. Pull out dipstick G and wipe the oil off with a cloth.
3. Insert dipstick G into dipstick pipe again, and check the oil
level.
4. Check that the oil level is between 2 embossed marks H
and L of the dipstick G. If the oil level is below L, refill it
with oil.
D155AX-8 40-49
5. If the oil level is above H, remove the under cover on the

bottom of the machine, remove the drain plug P to drain
oil. Recheck the oil level.
CHECK OIL LEVEL IN FINAL DRIVE CASE

k The oil is very hot immediately after the machine is moved. Start the work when the oil has cooled
down.
1. Place the machine on a level place.
2. Remove oil plug (1), and check that oil level is near the
bottom line of the plug hole.
3. If oil is insufficient, remove plug (3), refill it with engine oil
until engine oil flows out from oil level plug (2).
40-50 D155AX-8
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod

Check of battery terminal for looseness and corrosion
1. Open covers (1) and (2) on the left side of the machine,
and check terminal of battery A for looseness and corro-
sion.
Check of alternator terminal for looseness and corrosion

2. Open left engine side cover, and check terminal of battery
B and R for breakage, looseness and corrosion.
D155AX-8 40-51
Check of starting motor terminal for looseness and corrosion

3. Open right engine side cover, and check terminal of bat-
tery B and C for breakage, looseness and corrosion.
Check of battery voltage (with engine stopped)

4. Check the battery voltage by using the battery tester while the engine is stopped.
Check of battery electrolyte level
5. Check the battery electrolyte level according to the following procedure.
k Battery electrolyte level must be checked before operating the machine.
k Do not use the battery while its electrolyte level is below LOWER LEVEL. If it is used under that
condition, its inside becomes deteriorate, its service life is shortened, and it may lead to an ex-
plosion.
k Since the battery produces combustible gas that can explode, do not bring any open flame near
it.
k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or
skin. If it does, wash it away with water and contact your doctor.
NOTICE
• Do not add the electrolyte to the battery exceeding UPPER LEVEL line. If the electrolyte level is
too high, it may leak and cause damage to the paint surface or corrode other parts.
• To avoid freezing, add the purified water (such as a commercial battery fluid) before starting the
work in the next day.
• When checking the electrolyte level through the side face of the battery
1) Wipe and clean the battery surface, especially
around the battery level lines with a wet cloth, and
check to see that the battery fluid is between the
UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.)
lines.
k Do not clean the battery with a dry cloth
since static electricity may cause an explo-
sion.
2) If the battery fluid drops below the center position

between the UPPER LEVEL and LOWER LEVEL
lines, remove vinyl sheet (1) on top of the battery.
Immediately remove the cap (2) and add purified
water (such as a commercial battery fluid) imme-
diately until the fluid reaches the UPPER LEVEL.
3) After adding the purified water, tighten the cap se-
curely.
40-52 D155AX-8
NOTICE
If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a
syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a large amount of water.
• When electrolyte level cannot be checked through the side face of the battery
1) Remove the vinyl sheet ① to remove the cap (2).
(described previously)
2) Look into filler port (3) and check the surface of
fluid. If the fluid level is below sleeve (4), always
add the purified water (such as a commercial bat-
tery fluid) until it reaches the bottom of sleeve (the
UPPER LEVEL).
• (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
• (B) Low: Since the electrolyte level does not
reach the sleeve bottom, the shape of the electrode plates will appear straight.
3) After adding fluid, tighten cap (1).
NOTICE
If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a
syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a large amount of water.
Check of wiring harness for discoloration, burn and cover peeling
6. Check the wiring harness and cables for discoloration and burn.
k If discolored or burnt, the circuit may be shorted or grounded.
• Check the wiring harnesses and cables for damage and peeling of the covers.
• If any abnormality is found, repair or replace the wiring harness or cables.
Check for coming off of wiring harness clamp and sagging of wiring harness
7. Check wiring harness for sagging and looseness due to
coming off of harness clamp
REMARK
In particular, carefully check around the hot and movable
parts. Refix the harnesses if clamps are disconnected.
Check of grounding
D155AX-8 40-53
REMARK
Take special care of ground terminals for looseness and corrosion.
8. Check the connection of ground terminal (1) of engine con-
troller EC.
9. Check the connection of floor ground (2) on the left side of

underfloor.
Check for loose connector and damaged lock

10. Check the connection of male and female connectors by
pulling them by hand.
11. If the connection is loose, secure it.
12. Check the connectors for unlocking, and check the lock
and connector housing for cracking.
13. Check lock screw L of controller CNT for looseness.

REMARK
Use a hexagonal wrench with 4 mm width across flats.
Check of connector pin for corrosion, bends and deformation

14. Disconnect the connectors, and check their pins for corrosion, bending, sinking than other pins, and exten-
sion of female pins.
• If pins are defective, repair or replace them.
40-54 D155AX-8
• If the pins are not shiny, apply contact restorer to them and connect and disconnect the connectors
several times to shine them. (If the pins do not become shiny, connect and disconnect the connectors
10 times)
Check of connector for water and foreign material
15. Disconnect connectors, and check them for entering of wa-
ter or foreign material inside the connector.
REMARK
If there is entering of water or foreign material inside con-
nector, the seals may be damaged. Check the seals for
damage.
• If the seal is defective, repair or replace it.

• Dry the inside of the connector with a dryer.
• Wipe and remove any foreign material inside connec-

tor with a cloth or others, and blow the air to clean the
connector.
Check of wiring harness for open or short circuit

16. Check the connection (crimped part) between connector pins and wiring harness.
17. If it is open as shown as A, repair or replace the wiring har-
ness or cables.
18. Visually check wiring harnesses for peeling of harness
covers and the pins for contact with adjacent pins due to
defective crimping.
D155AX-8 40-55
Check of fuse for blowing out and corrosion

19. If a fuse is corroded and coated with white powder, or
there is any play between the fuse and fuse holder, re-
place the fuse.
REMARK
• Make sure to turn off the power supply (starting switch
is OFF) before performing replacement of the fuse.
• Fuse holders are located under the front left and over-
head of the operator's seat.
• Replace each fuse with the same capacity ones.
• Open the inspection cover A, and fuse box (1) to (3)
are seen.
• Fuse box (2) is overhead of operator's seat.
Check of circuit breaker

20. Check the circuit breaker.
REMARK
• Do not press and hold the circuit breaker reset button (There is a possibility of fire).
• Circuit breaker can be used repeatedly to prevent breakage of electrical parts and wiring by shutting the
electrical circuit when excessive electric current occurs.
21. Check the circuit breaker in each circuit.
REMARK
• If the circuit breaker trips, the reset button (1) pops out.
• Check all circuit breakers that reset button (1) is not
popped up.
• If the reset button (1) pops up soon after turning start-
ing switch on with reset button pushed, check the elec-
trical circuit because the excessive electric current is
still flowing.
• Push the reset button (1) having been popped up to
restore the shut electrical circuit.
40-56 D155AX-8
22. Check the main power supply of circuit breaker according

to the following procedure.
1) Turn the starting switch to OFF position.
2) Open the battery room cover on the front left side of
machine.
3) Check the circuit breakers A to C.
4) Push reset buttons A to C of circuit breaker in order.
REMARK
• Operation effort of reset button is heavier when the
electrical circuit is shut compared to it of normal
state.
• The height of reset button remains the same even
when the state of the circuit changes to shut or to
open.
Check of alternator voltage (when engine speed is medium or higher)
23. Open the engine hood.
24. Connect the positive (+) lead of the multimeter to alternator
terminal (B) and connect the negative (-) lead to the chas-
sis ground.
25. Start the engine and warm it up, and measure the voltage
while running the engine at a medium or a higher speed.
• If the voltage is abnormal, repair or replace the alter-
nator.
Check of battery relay operation sound

26. Open the battery cover.
27. Turn the starting switch to the ON and OFF positions, and check whether the battery relay operation sound
is heard or not.
• If the operation sound is not heard, check the related circuits, referring to the description of trouble-
shooting for “E-1” described in the E mode troubleshooting.
• If the relating circuit is normal, replace the battery relay.
D155AX-8 40-57
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 TROUBLESHOOTING
PROCEDURE FOR TESTING AND TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Display of code Troubleshooting by failure code
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine
If a symptom which is assumed to be a failure occurs on the machine, go to the corresponding troubleshooting
section.
• If action level and failure code are displayed on the standard screen of the machine monitor, perform the
troubleshooting for the corresponding [Display of code] corresponding to the displayed failure code.
REMARK
If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order. Note
down all the codes.
• If action level and failure code are not displayed on the standard screen of the machine monitor, check me-
chanical system failure code and electrical system failure code with abnormality record function of the ma-
chine monitor.
• If a failure code is displayed, perform troubleshooting for the corresponding [Display of code] corre-
sponding to the failure code.
• If an electrical system failure code is displayed, delete all the codes once and reproduce them, and
then see if the failure is still detected.
REMARK
A failure code of the mechanical system cannot be deleted.
• If no failure code is found in the abnormality record, a failure that the machine cannot find out by itself may
have occurred in the electrical system or hydraulic and mechanical system.
In this case, check a symptom which is assumed to be a failure again and select the same phenomenon
from the table of “Symptom and troubleshooting numbers”, and then perform troubleshooting corresponding
to that phenomenon in the [E mode], [H mode] or [S mode].
After repairing the failure, clear all the failure codes in the electrical system abnormality record according to the
following procedures.
40-58 D155AX-8
40 TROUBLESHOOTING PROCEDURE FOR TESTING AND TROUBLESHOOTING
1. While pressing numeric key [4] on the panel switch at the

standard screen, press [1]→[2]→[3] in order, then “Service
Menu” screen appears.
2. On “Service Menu”screen, press switch [F3] twice in the
panel switch section, and select “03 Abnormality Record”.
3. Press switch [F6] in the panel switch section to enter the

selection, and go to the “Abnormality Record” screen.
4. Press switch F6 in the panel switch section to enter the se-

lection, and go to the “Mechanical Systems abnormality re-
cord” screen.
5. Move down by pressing the F3 switch on the panel switch
to see if the next failure code is displayed and note down
all of the failure codes.
REMARK
A failure code of the mechanical system cannot be delet-
ed.
6. Press switch F5 in the panel switch section to return the
screen to the “Abnormality Record” screen.
D155AX-8 40-59
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 TROUBLESHOOTING
7. Go to the “Electrical Sys Abnormality Record” similarly to

steps 2 and 3.
8. Move down by pressing the F3 switch on the panel switch
to see if the next failure code is displayed and note down
all of the failure codes.
REMARK
“E” on the left of a failure code indicates that the failure
code is “Active” (the failure remains or restoration to nor-
mal has not been checked). A failure code having no “E”
on its left is a “Non-active” one. Since it disappears at the
following clear step, be sure to note it down.
9. While pressing numerical key [4] on the panel switch, press [1]→[2]→[3] in order to go to the “Clear mode”.
(Same as 1)
10. Press F2 switch (CLEAR) on the panel switch.
11. Press F6 key on the panel switch to clear all failure codes.
screen to the “Electrical Sys Abnormality Record” screen.
Check if failure codes are still displayed and write down, if
any.
screen to the “Abnormality Record” screen.
40-60 D155AX-8
40 TROUBLESHOOTING SYMPTOM AND TROUBLESHOOTING NUMBERS
SYMPTOM AND TROUBLESHOOTING NUMBERS

Troubleshooting
No. Symptom of failure
Index
User code, failure code
Action level is displayed on the machine monitor. Press function switch [F5] to
1
display the "Occurred error list"
Perform troubleshooting
2 Failure code is displayed on mechanical system abnormality record for failure code
3 Failure code is displayed on electrical system abnormality record
Symptom related to engine
4 Engine does not start (engine does not crank) E-1, S-1
5 Engine does not crank when starting switch is turned to “START” position. E-1, S-1
6 Engine cranks but no exhaust gas comes out S-2
Fuel is being injected but engine does not start (misfiring: engine cranks but does
7 S-3
not start)
8 Engine startability is poor S-4
9 Engine does not pick-up smoothly S-5
10 Engine stops during operation S-6, H-2
11 Engine runs rough or is unstable S-7
12 Engine lacks power S-8
13 Exhaust gas color is black (KDPF becomes clogged soon) S-9
14 Engine oil consumption is excessive S-10
15 Oil becomes contaminated early S-11
16 Fuel consumption is excessive S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Engine oil pressure drops S-14
19 Fuel mixes into engine oil S-15
20 Water mixes into engine oil (milky) S-16
21 Coolant temperature rises too high (overheating) S-17
22 Unusual noise is heard S-18
23 Vibration is excessive S-19
24 Air cannot be bled from fuel circuit S-20
25 Active regeneration is executed frequently S-21
26 Active regeneration takes time S-22
27 White smoke is exhausted during active regeneration S-23
28 Consumption of AdBlue/DEF is excessive S-24
29 There is unusual smell (irritating odor) S-25
30 Foreign matters enter AdBlue/DEF (AdBlue/DEF increases) S-26
31 Manual preheating system does not work E-2
32 Automatic preheating system does not work E-3
33 While preheating is working, preheating monitor does not light up E-4
D155AX-8 40-61
SYMPTOM AND TROUBLESHOOTING NUMBERS 40 TROUBLESHOOTING
Troubleshooting
Index
Power train
34 Machine lacks power (insufficient drawbar pull) H-1
35 Machine does not travel (at 2nd or 3rd gear speed) H-2
36 Machine does not move off at all gear speeds H-3
37 Machine travels only in one direction, either forward or in reverse H-4
38 Large time lag is in gear shifting or directional change H-5
39 Machine cannot be steered (machine does not turn left or right) H-6
40 Steering speed or power is insufficient H-7
41 Brake does not work H-8
42 Torque converter lockup clutch does not engage H-9
43 Power train oil overheats H-10
44 Unusual noise is heard from around HSS pump or HSS motor H-11
45 Gear cannot be shifted E-43
Symptom related to work equipment
46 All work equipments operate slowly H-12
47 All work equipment do not operate H-13
48 Blade lift speed or power is low H-14
49 Blade tilt speed or power is low H-15
50 Ripper lift speed or power is low H-16
51 Ripper tilt speed or power is low H-17
52 Hydraulic drift of lifted blade is large H-18
53 Hydraulic drift of tilted blade is large H-19
54 Hydraulic drift of lifted ripper is large H-20
55 Ripper pin puller cylinder does not operate H-21
56 Blade pitch cylinder does not operate H-22
58 Ripper pin puller does not work E-40
Symptom related to machine monitor
59 When starting switch is turned to ON position, machine monitor displays nothing E-5
When starting switch is turned to ON position (with engine stopped), radiator cool-
60 E-6
ant level monitor lights up in yellow
61 Air cleaner clogging monitor lights up in yellow while engine is running E-7
62 Charge level monitor lights up in red while engine is running E-8
63 Coolant temperature monitor lights up in red while engine is running E-9
64 Engine oil pressure monitor lights up in red while engine is running E-10
65 Power train oil temperature monitor lights up in red while engine is running E-11
66 Hydraulic oil temperature monitor lights up in red while engine is running E-12
67 Engine coolant temperature gauge does not indicate correct temperature E-13
68 Fuel level gauge does not indicate correct level E-14
40-62 D155AX-8
40 TROUBLESHOOTING SYMPTOM AND TROUBLESHOOTING NUMBERS
Troubleshooting
Index
69 Power train oil temperature gauge does not indicate correct temperature E-15
70 Hydraulic oil temperature gauge does not indicate correct temperature E-16
71 Operation mode does not change E-17
72 Operation mode does not change E-18
73 Operating customize switch does not display customize screen E-19
74 Modifying setting on customize screen does not change setting of machine E-20
75 Some areas of machine monitor screen are not displayed E-21
76 Alarm buzzer does not sound or does not stop sounding E-22
77 Service meter is not displayed while starting switch is in OFF position E-23
78 Service mode cannot be selected E-24
“PROCEDURE FOR
Air conditioner does not operate normally (including failure codes related to air TESTING AND TROU-
79
conditioner) BLESHOOTING” in
Chapter 80
Others
80 Horn does not sound E-25
81 Horn does not stop sounding E-26
82 Backup alarm does not sound E-27
83 Backup alarm does not stop sounding E-28
84 Headlamp does not light up E-29
85 Rear lamp and ripper point lamp do not light up E-30
86 No wiper operates continuously or intermittently E-31
Front wiper does not operate (failed in both continuous and intermittent opera-
87 E-32
tions)
Rear wiper does not operate (failed in both continuous and intermittent opera-
88 E-33
tions)
89 Left door wiper does not operate (failure continuous and intermittent operations) E-34
Right door wiper does not operate (failed in both continuous and intermittent op-
90 E-35
erations)
91 Front washer does not operate E-36
92 Rear washer does not operate E-37
93 Left door washer does not operate E-38
94 Right door washer does not operate E-39
95 Fan does not rotate in reverse E-41
96 Fuel feed pump does not operate or stop automatically E-42
97 KOMTRAX system does not operate normally E-44
98 Fan speed is abnormal (too high or low, or fan does not rotate) H-23
99 Unusual noise is heard from around fan H-24
D155AX-8 40-63
INFORMATION IN TROUBLESHOOTING TABLE 40 TROUBLESHOOTING
INFORMATION IN TROUBLESHOOTING TABLE

(Rev. 2011/12)
The following types of information are described in the troubleshooting list and related circuit diagram. Fully un-
derstand the description and perform troubleshooting.
Action level Failure code
Display on Display on Failure name displayed on "Abnormality Record" screen of the machine
Failure
machine machine monitor
monitor monitor
Details of
Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by the ma-
controller chine monitor or controller
Problem on A problem that appears as a failure on the lift truck as a result of an action (shown above) that is per-
machine formed by the machine monitor or controller.
Related in-
Information related to the occurred failure and its troubleshooting
formation
No. Cause Procedure, measuring location, criteria, and remarks

1 Defective --- Contents of description
Open or short circuit • Procedure
2
in wiring harness • Measuring point
Open circuit in wiring "Between A and B" denotes measuring values such as voltage and resistance
harness between A and B.
3 "Between A and ground" means the measurement of voltage, resistance or
(wire breakage or de-
others between place A and the place which has a continuity with chassis
fective contact of con-
nector) frame such as unpainted hexagonal head bolt or bolt hole which has no rust,
etc.
Ground fault in wiring
• Criteria to judge probable causes (standard value), remarks
harness
4 How to use troubleshooting sheet
(contact with ground
circuit) • Perform troubleshooting procedures in following order.
5 Hot short circuit • If the check result does not meet the criteria, the probable cause described on
the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific instruction, pro-
ceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been corrected.
Failures in wiring harness
• Open circuit
When the wiring and the internal circuit of the connector are not connected
with each other, and there is no continuity
Short circuit in wiring
6 • Ground fault
harness
A wiring harness not to be connected to the GND (ground) circuit comes into
contact with the GND (ground) circuit or chassis accidentally.
• Hot short circuit
A wiring harness not to be connected to the power circuit comes into contact
with the power circuit accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with one of
another wire. (Defective insulation in connector or others)
40-64 D155AX-8
40 TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE

Precautions for troubleshooting
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless otherwise speci-
fied.
• When (male) or (female) is not indicated with a connector number, disconnect
the connector, and insert T-adapters to both sides of male and female.
• When (male) or (female) is indicated with a connector number, disconnect the
connector, and connect T-adapter to the indicated side of connector.
7 Defective controller • "Male and female" means male and female of connector pins, not connector
housings.
• Male and female of connector pins and housing in DT series, etc, are opposite
to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wiring harness indicated first.
• Connect the negative (-) lead to a pin or wiring harness indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to troubleshooting
• The circuit diagram contains the connector No., pin No., and connector color related to the failure.
• “/” is used in the connector No. in the following 2 cases.
• Abbreviation (3 letters in many cases)
Example) T/C: Abbreviation for Torque Converter
• Male side and female side have different connector Nos.
Example) BREAK OUT / E24
• The circuit diagram contains the destination or source of the branch line in a wiring harness.
• Arrow (↔): Approximate installation position on the machine
NO: Normally Open
NC: Normally Closed
• Signal names such as GND and 24 V are included in addition to connector numbers at junctions, etc. in
circuit diagrams.
• Except for GND and 24 V, a signal name indicated at a junction, etc. shows that the wire is connected to
another junction or controller at where the same signal name is indicated.
D155AX-8 40-65
CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING
CONNECTORS LIST AND LAYOUT

Number
Connector No. Connector type Location Address
of pins
A/C DT 2 Air conditioner compressor D-1
AC01 YAZAKI 10 Air conditioner unit U-6
AC02 YAZAKI 4 Air conditioner unit U-6
AC04 ― 5 Compressor relay U-7
AC05 ― 4 Triple pressure switch K-3
AC06 ― 4 Capacitor motor relay 1 U-9
AC07 ― 4 Capacitor motor relay 2 V-9
AC08 ― 10 Capacitor motor relay 3 U-9
AC11 DT 4 Intermediate connector AB-7
ACS DT 2 Diode D-1
ADB DT 2 Additional buzzer (if equipped) M-2
ADH SWP 6 Additional heater switch M-5
ADH1 ― 5 Additional heater relay 1 X-8
ADH2 ― 5 Additional heater relay 2 X-8
AF1 DT 2 Air cleaner clogging sensor B-1
AL/B Terminal 1 Alternator terminal B C-1
AL/R Terminal 1 Alternator terminal R D-1
ASUS DT 2 Air suspension seat V-1
AUX0 Terminal 1 External power supply W-2
B-RES DT 3 Terminating resistor (120 Ω) AO-7
B105HL Terminal 1 Circuit breaker 105 A J-8
B105HS Terminal 1 Circuit breaker 105 A J-9
B105L Terminal 1 Circuit breaker 105 A K-9
B105S Terminal 1 Circuit breaker 105 A L-8
B60L Terminal 1 Circuit breaker 60 A L-8
B60S Terminal 1 Circuit breaker 60 A L-9
BCD DT 2 Diode X-6
BCD2 DT 2 Diode W-6
BCR ― 5 BR cut-off relay U-9
BFS ― 3 Blade float switch (Single tilt Knob) ―
BKAL DT 2 Backup alarm C-9
BKSW DT 3 Brake pedal switch O-1
BNSW DT 12 Blade pitch switch Q-9
BRB Terminal 1 Battery relay J-8
BRC Terminal 1 Battery relay L-7
BRE Terminal 1 Battery relay J-7
BRK DT 3 Brake pedal potentiometer O-1
40-66 D155AX-8
40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT
Number
of pins
BVRV DT 2 Transmission bevel reverse rotation sensor AJ-8
CB01 DT 6 Intermediate connector AC-9
CB02 M 2 Speaker (L.H.) AB-9
CB04 M 2 Speaker (R.H.) AC-9
CB07 YAZAKI 9 Radio AA-6
CB08 M 3 Accessory20 A AA-6
CB10 ― 2 Circuit breaker, U-8
CB11 SWP 6 Wiper intermittent switch Z-5
CB12 SWP 6 Rear wiper switch Y-5
CB13 SWP 6 Right wiper switch Y-5
CB14 SWP 6 Front wiper switch Y-5
CB15 SWP 6 Left wiper switch Y-5
CB16 KES-1 2 Room lamp Z-8
CB17 DT 4 Intermediate connector Y-2
CB23 DT 6 Front wiper motor Z-9
CB24 DT 4 Intermediate connector AB-1
CB25 YAZAKI 4 Additional lamp relay AD-2
CB26 ― 11 Front and rear wiper intermittent unit AC-1
CB27 ― 11 Right and left wiper intermittent unit AC-2
CB28 Terminal 2 Circuit breaker, 5 A U-8
CB31 Terminal 2 Circuit breaker, 30 A V-9
CB33 ― 6 Additional lamp switch Z-6
CB34 ― 6 Revolving warning lamp switch Z-6
CB37 DT 6 Rear wiper motor AB-9
CB9 Terminal 2 Circuit breaker, 30 A V-9
CBACC_1 DT 2 Accessory socket 1 W-9
D155AX-8 40-67
Number
of pins
CBACC_2 DT 2 Accessory socket 2 X-9
CBBCN DT 2 Revolving warning lamp Z-9
CBCIG YAZAKI 2 Cigarette lighter X-9
CBCV1 DT 6 DC converter AD-3
CBFL DT 2 Additional LH-side head lamp Y-9
CBFR DT 2 Additional RH-side head lamp AA-9
CBRL DT 2 Additional LH-side rear lamp AA-7
CBRR DT 2 Additional RH-side rear lamp AD-9
CBWL DT 4 L/D wiper motor AA-1
CBWR DT 4 R/D wiper motor Y-3
CK01 070 18 KOMTRAX terminal R-9
CK02 070 12 KOMTRAX terminal R-9
CM01 070 18 Machine monitor N-1
CM02 070 12 Machine monitor N-1
CM04 MITSUMI 8 Machine monitor M-3
CMR1 DT 4 Rear view camera AD-7
CN1 DT 2 njector #1 AK-6
CN4 DT 2 njector #4 AL-5
CN5 DT 2 njector #5 AO-7
CN6 DT 2 njector #6 AO-8
CTE DT 3 CAN terminating resistor (120 Ω) E-1
CTN DT 3 CAN terminating resistor (120 Ω) A-6
CTN2 DT 3 CAN terminating resistor (120 Ω) C-7
DCL DT 3 Decelerator pedal potentiometer M-2
DIA2 DT 3 Fuel control dial T-9
DIAL DT 3 Intermediate connector S-1
DOSER DT 2 HC dosing solenoid AL-9
DPFJ TYCO 4 DPF temperature sensor B-6
DPNL DT 2 Diode ―
DSM TYCO 12 Intermediate connector H-1
DSOV1 DT 2 Shut off valve solenoid #1 AN-9
DSOV2 DT 2 Shut off valve solenoid #2 AM-9
EFP DT 2 Electric fuel feed pump E-1
EG1 DT 12 Intermediate connector E-8
EG2 DT 12 Intermediate connector F-1
EG3 DT 12 Intermediate connector E-1
40-68 D155AX-8
Number
of pins
EG6 DT 12 Intermediate connector D-8
EGPW DTP 2 Intermediate connector X-4
EGR-SOL DT 2 EGR valve solenoid AK-9
EHL FURUKAWA 5 Engine hold relay V-6
EPP DT 12 Fuel feed and dozing pump timer A-5
ESD DT 3 Engine local option X-6
F105 DTHD 1 Intermediate connector X-3
F1T DT 2 1st clutch ECMV fill switch AF-9
F2T DT 2 2nd clutch ECMV fill switch AE-7
F3T DT 2 3rd clutch ECMV fill switch AE-8
F60 DTHD 1 Intermediate connector X-3
FAC DT 2 Fan pump control valve AF-5
FAR1 DT 2 Fan reverse solenoid A-1
FAR2 DT 2 Fan reverse rotation sensor A-1
FBRL DT 2 LH-side brake ECMV fill switch AJ-9
FBRR DT 2 RH-side brake ECMV fill switch AJ-9
FDK/FD1 DRC-70B/A 70 Intermediate connector W-9
FFT DT 2 F clutch ECMV fill switch AG-9
FLSW SWP 6 Headlamp switch P-1
FLUC DT 2 Torque converter lockup clutch ECMV fill switch AE-1
FLV DT 2 Fuel level sensor K-1
FRT DT 2 Reverse clutch ECMV fill switch AG-9
FSTC DT 2 Torque converter stator clutch ECMV fill switch AF-1
FTK DT 6 Intermediate connector J-7
G SUMITOMO 3 G sensor AM-5
G-RES DT 2 Fuel supply pump pull-up resistor AO-9
GND Terminal 1 Ground (fender) J-1
GND03 Terminal 1 Ground (ROPS) L-8
GND06 Terminal 1 Ground (fender) H-1
GND07 Terminal 1 Ground (Bulkhead) F-9
GND09 Terminal 1 Ground D-1
GND11 Terminal 1 Ground (floor) X-2
GND12 Terminal 1 Ground (floor) X-2
GND20 Terminal 1 Ground E-1
GND21 Terminal 1 Ground (fender) C-7
GND23 Terminal 1 Ground C-1
D155AX-8 40-69
Number
of pins
GND25 Terminal 1 Ground A-2
GNDC1 Terminal 1 Ground (floor) AA-6
GNDC2 Terminal 1 Ground (floor) AB-6
GNDC3 Terminal 1 Ground AA-8
GNDC4 Terminal 1 Ground AB-9
GNDC5 Terminal 1 Ground X-4
HDT DT 2 Hydraulic oil temperature sensor AE-4
HEAT1 DT 2 Intermediate connector V-1
HEAT2 DT 2 Intermediate connector R-1
HHP DT 3 Hydraulic oil pressure sensor AE-4
HNR Relay 5 Horn relay S-1
HNSW DT 2 Horn switch Q-9
HORN YAZAKI 2 Horn A-1
HSL DT 2 Left HSSEPC M-7
HSR DT 2 Right HSSEPC O-9
HSS DT 6 Intermediate connector AF-6
Terminal C of electrical intake air heater (ribbon
HT Terminal 1 L-7
heater) relay
Terminal A of electrical intake air heater (ribbon
HT/A Terminal 1 K-7
heater) relay
Terminal B of electrical intake air heater (ribbon
HT/B Terminal 1 L-7
heater) relay
HTD DT 2 Diode F-1
INJ DT 12 Intermediate connector AP-4
J1 DRC-96 96 Engine controller AO-6
J1939 DT 3 CAN_C AO-8
J2 DRC-60 96 Engine controller AO-6
JC01 ― 8 Joint connector AP-2
JC02 ― 12 Joint connector AP-2
JM03 ― 3 Joint connector ―
KEY DT 6 Starting switch M-3
40-70 D155AX-8
Number
of pins
KEY0 070 14 ID Key controller M-1
LBU DT 2 System operating lamp K-6
LHD DT 3 Intermediate connector A-4
LHDL DT 2 LH-side headlamp A-2
LHDR DT 2 RH-side headlamp A-4
LMD1 DT 2 Diode N-1
LMD2 DT 2 Diode N-1
LMFL FURUKAWA 5 LH-side headlamp relay U-7
LMFR FURUKAWA 5 RH-side headlamp relay U-7
LMRE FURUKAWA 5 Rear lamp relay U-7
LREL DT 2 LH-side rear lamp J-8
LRER DT 2 RH-side rear lamp H-9
LRP2 DT 2 Ripper point lamp C-9
M01A MOLEX 3 Radio Z-6
M01B YAZAKI 3 Intermediate connector X-5
M01C ― 3 AUX jack U-7
MAF FRAMATOME 4 Mass airflow sensor A-3
NE FRAMATOME 3 Ne speed sensor AP-1
NH3 TYCO 4 NH3 sensor E-1
NOX1 TYCO 4 NOx Sensor （turbocharger Outlet） A-5
NOX2 TYCO 4 NOx Sensor （SCR Outlet） D-1
NSF FURUKAWA 5 Neutral safety relay V-7
OEM DRC-70A 70 Intermediate connector AN-1
OPPW DT 2 External power supply X-6
OPSW SWP 6 Optional switch Q-1
OPT FURUKAWA 5 Optional relay X-9
PAMB FRAMATOME 3 Ambient pressure sensor AP-5
PBD DT 2 Diode W-6
PBS DT 2 Pedal brake solenoid valve AI-9
PCCV FRAMATOME 3 Crankcase pressure sensor AO-6
PCV1 SUMITOMO 2 Supply pump #1 AL-5
PCV2 SUMITOMO 2 Supply pump #2 AM-5
PDOSER FRAMATOME 3 HC dozing pressure sensor AN-9
PDPF FRAMATOME 4 DPF pressure sensor A-6
PFUEL AMP 3 Common rail pressure sensor AN-5
PHR FURUKAWA 5 Pre-heater relay U-7
PIM CANNON 4 Boost pressure sensor AP-3
PKD DT 2 Diode X-6
D155AX-8 40-71
Number
of pins
PKS DT 2 Parking brake solenoid AI-9
PKSW DT 3 Parking lock switch W-1
PL1 DRC-70A 70 Intermediate connector W-6
PL1F DRC-70A 70 Intermediate connector ―
PL1M DRC-70A 70 Intermediate connector ―
PLSW DT 2 Pin puller switch R-9
PNL 24-31 31 Intermediate connector ―
POIL AMP 3 Engine oil pressure sensor AN-5
PPL DT 2 Pin puller solenoid valve B-9
PRT1 DT 12 Intermediate connector D-8
PRT2 DT 6 Intermediate connector D-8
PSL FURUKAWA 5 Personal lock relay S-1
PT1 DT 3 Pitch angle sensor B-7
PTCN1 DRC26-24 24 Power train controller U-1
PTCN2 DRC26-40A 40 Power train controller U-1
PTCN3 DRC26-40B 40 Power train controller V-1
PUMP DT 12 Intermediate connector AE-6
QDP DT 2 Blade quick drop solenoid A-2
RDG DT 12 Intermediate connector A-4
RHT Terminal 1 Electrical intake air heater (ribbon heater) C-1
RLSW SWP 6 Rear lamp switch P-1
RNSW DT 6 Ripper tilt switch R-9
RSD DT 2 Diode W-6
S1T DT 2 1st clutch ECMV solenoid AE-9
S2T DT 2 2nd clutch ECMV solenoid AE-7
S3T DT 2 3rd clutch ECMV solenoid AE-8
SBC DT 2 Seat belt alarm switch X-7
SBRL DT 2 LH-side brake ECMV solenoid AJ-9
SBRR DT 2 RH-side brake ECMV solenoid AJ-8
SCRJ TYCO 4 SCR temperature sensor C-7
SEGR DT 4 EGR valve position sensor AO-5
SESW SWP 6 Engine stop secondary switch M-4
SFT DT 2 F clutch ECMV solenoid AF-7
SFTD YAZAKI 3 Shift down switch S-9
SFTU YAZAKI 3 Shift up switch S-9
SLS 050 2 Sunlight sensor O-1
SLUC DT 2 Torque converter lockup clutch ECMV solenoid AF-1
SRT DT 2 R clutch ECMV solenoid AE-8
40-72 D155AX-8
Number
of pins
SRV DT 12 Service connector X-7
SSP DT 2 Sudden stop prevention valve AH-9
SSR DT 12 Sensor power supply relay E-1
SSTC DT 2 Torque converter stator clutch ECMV solenoid AG-1
ST DT 2 Starting motor C-1
ST/B Terminal 1 Starter B terminal C-1
SVGT FRAMATOME 3 VGT valve position sensor AP-5
SW Terminal 1 Battery relay K-7
TCT DT 2 Torque converter oil temperature sensor AI-1
TIM PACKARD 2 Boost temperature sensor AP-3
TIP DT 3 Torque converter inlet pressure sensor AI-2
TL3 DT 6 Intermediate connector T-1
TLV1 DT 8 Lever assembly T-1
TMV 24-23 23 Intermediate connector AH-6
TOA YAZAKI 2 Outdoor temperature sensor K-9
TOP DT 3 Torque converter outlet pressure sensor AH-1
TPS DT 4 Intermediate connector X-5
TPS1 DT 12 Intermediate connector X-6
TRL Terminal 1 Terminal F-9
TRS Terminal 1 Terminal F-9
TVC DT 2 Pump TVC solenoid AF-5
TWTR PACKARD 2 Coolant temperature sensor AP-2
UDM BCK 2 AdBlue/DEF Injector B-7
AdBlue/DEF line heater (on low-temperature
UHA DT 2 G-1
pressure, intake, and purge)
AdBlue/DEF line heater (high-temperature pres-
UHC DT 2 H-1
sure side)
UHR1 DT 12 AdBlue/DEF line heater relay G-1
UHR2 DT 6 AdBlue/DEF line heater relay F-9
UHV1 DT 2 AdBlue/DEF tank heater valve ―
UHV2 DT 2 Intermediate connector I-1
UREA DT 4 AdBlue/DEF sensor I-1
URH2 DT 2 AdBlue/DEF heater E-9
VGT REV DT 2 VGTspeed sensor AO-5
VGT-SOL DT 2 VGTsolenoid AK-8
WECN1 DRC26-24 24 Work equipment controller R-1
WECN2 DRC26-40A 40 Work equipment controller Q-1
WECN3 DRC26-40B 40 Work equipment controller Q-1
WELK DT 3 Work equipment lock switch Q-9
D155AX-8 40-73
Number
of pins
WEP1 DT 2 Blade lift-up EPC N-9
WEP2 DT 2 Blade lift-down EPC N-8
WEP3 DT 2 LH-side blade tilt head EPC N-8
WEP4 DT 2 LH-side blade tilt bottom EPC N-8
WEP5 DT 2 RH-side blade tilt head EPC O-9
WEP6 DT 2 RH-side blade tilt bottom EPC N-8
WEP7 DT 2 Ripper lift-up EPC O-9
WEP8 DT 2 Ripper lift-down EPC M-8
WEP9 DT 2 Ripper tilt in EPC O-9
WEPA DT 2 Ripper tilt back EPC M-8
WEPW DT 3 Intermediate connector M-7
WEPX DT 2 Work equipment EPC X ―
WEPY DT 2 Work equipment EPC Y ―
WL1 DT 2 Intermediate connector B-1
WL2 DT 2 Intermediate connector A-3
WLK DT 2 Work equipment lock solenoid AG-5
WLV1 DT 2 Blade lever assembly Q-9
WLV2 DT 2 Ripper lever assembly P-9
WPNL DT 2 Diode ―
WSFR YAZAKI 2 Front washer tank K-2
WSH1 DT 6 Intermediate connector K-5
WSLH YAZAKI 2 LH-side washer tank K-4
WSRH YAZAKI 2 RH-side washer tank K-4
WSRR YAZAKI 2 Rear washer tank K-3
40-74 D155AX-8
1/7
D155AX-8 40-75
2/7
40-76 D155AX-8
3/7
D155AX-8 40-77
4/7
40-78 D155AX-8
5/7
D155AX-8 40-79
6/7
40-80 D155AX-8
7/7
D155AX-8 40-81
CONNECTOR PIN NUMBERS - CONNECTION TABLE 40 TROUBLESHOOTING
CONNECTOR PIN NUMBERS - CONNECTION TABLE

(Rev.2014.06)
The male or female is for pin, and the convex or concave is for fitting (housing).
40-82 D155AX-8
40 TROUBLESHOOTING CONNECTOR PIN NUMBERS - CONNECTION TABLE
D155AX-8 40-83
40-84 D155AX-8
D155AX-8 40-85
40-86 D155AX-8
D155AX-8 40-87
40-88 D155AX-8
D155AX-8 40-89
40-90 D155AX-8
D155AX-8 40-91
40-92 D155AX-8
D155AX-8 40-93
40-94 D155AX-8
D155AX-8 40-95
40-96 D155AX-8
D155AX-8 40-97
40-98 D155AX-8
D155AX-8 40-99
40-100 D155AX-8
D155AX-8 40-101
40-102 D155AX-8
D155AX-8 40-103
40-104 D155AX-8
D155AX-8 40-105
40-106 D155AX-8
D155AX-8 40-107
40-108 D155AX-8
D155AX-8 40-109
40-110 D155AX-8
D155AX-8 40-111
40-112 D155AX-8
D155AX-8 40-113
40-114 D155AX-8
D155AX-8 40-115
40-116 D155AX-8
D155AX-8 40-117
40-118 D155AX-8
D155AX-8 40-119
*:No.1 and 7 pin in male pin side do not exist.
40-120 D155AX-8
40 TROUBLESHOOTING T-BOXES AND T-ADAPTERS LIST
T-BOXES AND T-ADAPTERS LIST

(Rev.2012.09)
The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of har-
ness checker assemblies are listed in the horizontal line.
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name ID marking
799-601-2600 T-box (for ECONO) 21 ● ● ● ● ●

799-601-3100 T-box (for MS) 37 ●
799-601-3200 T-box (for MS) 37 ●
799-601-3380 Plate for MS (14 pins) ●
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P ●
799-601-3470 Case ●
799-601-2710 Adapter for MIC 5 MIC-5P ● ● ●
799-601-2720 Adapter for MIC 13 MIC-13P ● ● ●
799-601-2730 Adapter for MIC 17 MIC-17P ● ● ● ● ● ●
799-601-2740 Adapter for MIC 21 MIC-21P ● ● ● ● ● ●
799-601-2950 Adapter for MIC 9 MIC-9P ● ● ● ●
ECONO
799-601-2750 Adapter for ECONO 2 ● ●
2P
ECONO
3P
ECONO
4P
ECONO
8P
ECONO
12P
799-601-2810 Adapter for DLI 8 DLI-8P ● ●
D155AX-8 40-121
T-BOXES AND T-ADAPTERS LIST 40 TROUBLESHOOTING
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Extension cable (ECONO ECONO

799-601-2840 12 ● ● ●
type) 12P
799-601-2850 Case ●
799-601-4350 T-box (for DRC60, ECONO) 60 ●
799-601-4360 Case ●
799-601-7010 Adapter for X (T-adapter) 1 ● ●
799-601-7020 Adapter for X 2 X2P ● ● ● ●
799-601-7030 Adapter for X 3 X3P ● ● ● ●
799-601-7040 Adapter for X 4 X4P ● ● ● ●
799-601-7050 Adapter for SWP 6 SW6P ● ● ●
799-601-7060 Adapter for SWP 8 SW8P ● ● ●
799-601-7310 Adapter for SWP 12 SW12P ●
799-601-7070 Adapter for SWP 14 SW14P ● ●
799-601-7320 Adapter for SWP 16 SW16P ●
799-601-7080 Adapter for M (T-adapter) 1 ● ●
799-601-7090 Adapter for M 2 M2P ● ● ● ●
799-601-7110 Adapter for M 3 M3P ● ● ● ●
799-601-7120 Adapter for M 4 M4P ● ● ● ●
799-601-7130 Adapter for M 6 M6P ● ● ● ●
799-601-7340 Adapter for M 8 M8P ●
799-601-7140 Adapter for S 8 S8P ● ● ● ●
799-601-7150 Adapter for S (white) 10 S10P ● ● ● ●
799-601-7160 Adapter for S (blue) 12 S12P ● ● ●
799-601-7170 Adapter for S (blue) 16 S16P ● ● ● ●
799-601-7330 Adapter for S (white) 16 S16PW ●
799-601-7350 Adapter for S (white) 12 S12PW ●
799-601-7180 Adapter for AMP040 8 A8P ●
799-601-7190 Adapter for AMP040 12 A12P ● ●
799-601-7210 Adapter for AMP040 16 A16P ● ● ● ●
799-601-7220 Adapter for AMP040 20 A20P ● ● ● ●
799-601-7230 Short socket adapter for X 2 ● ● ● ●
799-601-7240 Case ● ●
799-601-7270 Case ●
799-601-7510 Adapter for 070 10 07-10 ●
799-601-7520 Adapter for 070 12 07-12 ●
40-122 D155AX-8
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601-7530 Adapter for 070 14 07-14 ●

799-601-7540 Adapter for 070 18 07-18 ●
799-601-7550 Adapter for 070 20 07-20 ●
799-601-7360 Adapter for relay 5 REL-5P ●
799-601-7370 Adapter for relay 6 REL-6P ●
799-601-7380 Adapter for JFC 2 ●
799-601-9010 Adapter for DTM 2 DTM2 ● ●
799-601-9020 Adapter for DT 2 DT2 ● ● ● ●
799-601-9030 Adapter for DT 3 DT3 ● ●
799-601-9040 Adapter for DT 4 DT4 ● ● ● ●
799-601-9050 Adapter for DT 6 DT6 ● ●
799-601-9060 Adapter for DT (gray) 8 DT8GR ● ●
799-601-9070 Adapter for DT (black) 8 DT8B ● ●
799-601-9080 Adapter for DT (green) 8 DT8G ● ●
799-601-9090 Adapter for DT (brown) 8 DT8BR ● ●
799-601-9110 Adapter for DT (gray) 12 DT12GR ● ●
799-601-9120 Adapter for DT (black) 12 DT12B ● ●
799-601-9130 Adapter for DT (green) 12 DT12G ● ●
799-601-9140 Adapter for DT (brown) 12 DT12BR ● ●
799-601-9210 Adapter for HD30-18 8 D18-8 ● ●
799-601-9220 Adapter for HD30-18 14 D18-14 ● ●
799-601-9230 Adapter for HD30-18 20 D18-20 ● ●
799-601-9240 Adapter for HD30-18 21 D18-21 ● ●
799-601-9250 Adapter for HD30-24 9 D24-9 ● ●
799-601-9260 Adapter for HD30-24 16 D24-16 ● ●
799-601-9270 Adapter for HD30-24 21 D24-21 ● ●
799-601-9280 Adapter for HD30-24 23 D24-23 ● ●
799-601-9290 Adapter for HD30-24 31 D24-31 ● ●
799-601-9310 Plate for HD30 (24 pins) ● ● ●
799-601-9320 T-box (for ECONO) 24 ● ● ●
799-601-9330 Case ●
799-601-9340 Case ●
799-601-9350 Adapter for DRC 40 DRC-40 ●
799-601-9360 Adapter for DRC 24 DRC-24 ●
799-601-9410* Socket for engine (CRI-T2) 2 G ●
D155AX-8 40-123
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Adapter for engine (CRI-T2)

Adapter PFUEL for engine
799-601-9420 3 A3 ● ●
(CRI-T3)
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* Socket PCV for engine (CRI- 2 P ● ●
T3)
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 ●
795-799-5520* Socket for engine (HPI-T2) 2 S ●
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C ● ●
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* Socket TIM for engine (CRI- 2 A ● ●
T3)
795-799-5460 Cable for engine (HPI-T2) 3 ●
Adapter PIM for engine (140-
799-601-4110 4 ITT3N ● ●
T3)
Adapter NE, CAM for engine
799-601-4130 3 FCIN ● ●
(CRI-T3)
799-601-4140 3 FCIG ● ●
Ambient pressure
Adapter POIL for engine
799-601-4150 3 FCIB ● ●
(CRI-T3)
799-601-4160 2 4160 ● ●
Oil pressure switch
Adapter PEVA for engine
799-601-4180 3 4180 ● ●
(CRI-T3)
799-601-4190* 3 1, 2, 3L ● ●
Common rail pressure
799-601-4230* 4 1, 2, 3, 4C ● ●
Intake pressure/temperature
Socket PAMB for engine
799-601-4240* 3 1, 2, 3A ● ●
(CRI-T3)
Socket PIM for engine (CRI-
799-601-4250* 3 1, 2, 3B ● ●
T3)
Socket G for engine (CRI-
799-601-4330* 3 1, 2, 3G ● ●
T3)
40-124 D155AX-8
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201

799-601-4340* 2 2, PA ● ●
Pump actuator
799-601-4380* (95) 4 1, 2, 3, 4T ●
Intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 ● ●
799-601-4211 Adapter for controller (ENG) 50 DRC50 ●
799-601-4220 Adapter for controller (ENG) 60 DRC60 ●
Socket for controller
799-601-4390* 60 ●
(95ENG)
799-601-4280* Box for controller (PUMP) 121 ●
799-601-9720 Adapter for controller (HST) 16 HST16A ●
799-601-9710 Adapter for controller (HST) 16 HST16B ●
799-601-9730 Adapter for controller (HST) 26 HST26A ●
Multi-adapter for DT 2 to 4, 2, 3,
799-601-9890 ●
DTM 2 pins 4
*: These are not T-adapters but sockets.
D155AX-8 40-125
T-adapter kit
Number of pins
Non-kit part
799-A65-4600
799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 ●

KDPF differential pressure sensor
799T-601-4611 4 799T-601-4611 ●
short socket adapter
KDPF outlet pressure sensor short
799T-601-4670 4 799T-601-4670 ●
socket adapter
799T-601-4680 KDPF dummy temperature sensor 4 799T-601-4680 ●
40-126 D155AX-8
40 TROUBLESHOOTING FUSE LOCATION TABLE
FUSE LOCATION TABLE

Connection table of circuit breaker and fuse box
REMARK
• This connection table shows the circuit breaker, fuse box and the devices which receive the power from the
fuse box (A switched power supply is the power which is supplied while the starting switch is in ON position
and an unswitched power supply is the power which is supplied while the starting switch is in OFF and ON
positions).
• When performing troubleshooting related to the electrical system, the breaker and fuse should be checked if
the power is supplied normally.
Circuit breaker CB1 to 10, 28 to 31
Power supply
Capacity of
breaker (type of Breaker No. Destination of power
breaker
power supplies)
CB1 20 A Power train controller power supply
CB2 20 A Work equipment controller power supply
CB3 20 A Air conditioner
CB105 (main
CB4 20 A Headlamp
power supply)
CB5 20 A Rear lamp
CB8 20 A (if equipped)
CB10 20 A Additional heater
CB28 5 A Compressor
CB29 20 A Condenser motor 1
CB105
CB30 20 A Condenser motor 2
CB31 30 A Cab main power
CB6 20 A Starting switch
CB60 (cab con-
tinuous power CB7 20 A Continuous power supply
supply)
CB9 30 A Engine controller power supply
CB105H (main
- 105 A Engine ribbon heater
power supply)
Fuse box l (FS11 (input side), FS12 (output side))

Power supply
breaker (type of Fuse No. Fuse capacity Destination of power
power supplies)
1 5 A Brake pedal switch
2 20 A Operator's cab
CB60 (cab con-
tinuous power 3 20 A Air conditioner continuous power supply
supply)
7 20 A System operating lamp
11 20 A Smart sensor relay 1
12 10 A Smart sensor relay 3
13 15 A Fuel feed pump power supply
CB60
15 20 A AdBlue/DEF heater
16 10 A AdBlue/DEF SUPPLY MODULE
D155AX-8 40-127
FUSE LOCATION TABLE 40 TROUBLESHOOTING
Power supply
breaker (type of Fuse No. Fuse capacity Destination of power
power supplies)
4 10 A Horn power supply
CB105 (main
5 5 A Parking brake switch
power supply)
6 20 A Pin puller
8 5 A Engine controller (ACC signal)
Air conditioner compressor relay, Air conditioner compressor
Starting switch 9 5 A
controller power supply
(ACC)
10 20 A Optional power supply
19 15 A Service connector (ACC)
Positions of the circuit breaker CB60, CB105, CB105H (inside of the battery
room)
Circuit breaker CB1 to CB10
Fuse box l position (inside of the cab)
40-128 D155AX-8
40 TROUBLESHOOTING FUSE LOCATION TABLE
Fuse box ll
Power supply
fuse (type of Fuse No. Fuse capacity Destination of power
power supply)
CB60 (cab con-
tinuous power 1 10 A Accessory power supply, Radio
supply)
2 20 A Additional lamp switch, Rotary lamp switch
3 20 A Accessory power supply
CB105 (main
4 20 A Radio, Room lamp,Cigarette lighter, Intermittent wiper switch
power supply)
5 10 A Front wiper, Rear wiper
6 10 A Right door wiper, Left door wiper
Fuse box ll position (inside of the operator's cab)
D155AX-8 40-129
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE 40 TROUBLESHOOTING
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE

k Be careful not get burned as the temperature of KDPF and KDOC rises up over 500 °C.
Related information
Soot accumulation amount of KCSF in KDPF is classified into 8 levels. Current soot accumulation level can be
checked in the “active regeneration for service” screen by displaying the “Diagnostic Tests” screen from the
service menu of machine monitor.
• If the soot accumulation level is 4 or 5, the failure code [CA2639] is displayed.
• If the soot accumulation level is 6 or 7, the failure code [CA1921] is displayed.
• If the soot accumulation level is 8, the failure code [CA1922] is displayed.
• If soot accumulation level is 8, KDPF is completely clogged with soot and inspection, cleaning or
change is required.
• Manual stationary regeneration can be performed up to soot accumulation level 7, and soot of KCSF
can be removed by burning it.
• When soot accumulation level is 4 to 7, manual stationary regeneration can also be performed from the
user mode.
Method of manual stationary regeneration from “active regeneration for service”
• When soot accumulation level is Max. 3, manual stationary regeneration can be performed only from “ac-
tive regeneration for service”.
2. Secure machine safety.
3. Display “Diagnostic Tests” screen from service menu of machine monitor, open “active regeneration for
service”, and perform “Manual Stationary Regeneration”.
• Time required for manual stationary regeneration varies depending on soot accumulation amount in KCSF.
Rough guide is described below.
Soot accumulation level 4: Approx. 40 minutes to 1 hour
Soot accumulation level 5: Approx. 1 hour to 2 hours
• Method of resetting KDPF (KCSF) cleaning
Display “Diagnostic Tests” screen from service menu of machine monitor, open “KDPF Memory Reset”,
and perform “KDPF Cleaning” (resetting KDPF cleaning).
• Method of resetting KDPF (KCSF) change
and perform “KDPF Change” (resetting KDPF change).
• When KCSF of KDPF has been changed, be sure to perform Manual Stationary Regeneration from “active
regeneration for service” and remove humidity, etc. in KCSF after resetting “KDPF Cleaning” and“KDPF
Change”.
• Method of resetting KDOC Change
and perform “KDOC Change” (resetting KDOC Change).
• If KDOC of KDPF is changed, Manual Stationary Regeneration is not necessary though resetting “KDOC
Change” is performed.
When KCSF is cleaned or changed
• In regular cleaning at 4500H
1. Check the soot accumulation level and, if soot accumulation level is displayed, Choose “Manual Sta-
tionary Regeneration” for service by “Active Regeneration for Service” screen on the monitor until the
level becomes zero.
2. Stop the engine, and remove KDPF and KCSF after piping around the engine are cooled down.
3. Clean KCSF using the ASH cleaning equipment placed in a specific maintenance plant, etc. (to clean
and reuse the removed KCSF).
40-130 D155AX-8
40 TROUBLESHOOTING PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE
4. Install the cleaned KCSF into the machine (to clean and reuse the removed KCSF).
5. Install an alternative KCSF into the machine (to change with a new KCSF).
6. Turn the starting switch to ON position and perform “KDPF Cleaning” reset from the KDPF reset
screen.
7. Perform “KDPF Change” reset from the KDPF reset screen.
If “KDPF Change” reset is performed, the change in () is reflected. (“Soot Correction by Ash Influence”
is changed to 0 g/ℓ.)
8. Start the engine and run it at low idle to warm up.
9. Choose “Manual Stationary Regeneration” for service by “Active Regeneration for Service” screen on
the monitor.
• When any crack or damage is found in test
1. Stop the engine, and remove KDPF and KCSF after piping around the engine are cooled down.
2. Install an alternative KCSF (new one or used one).
3. Turn the starting switch to ON position and perform KDPF cleaning reset from the KDPF reset screen.
4. Perform KDPF change reset from the KDPF reset screen.
5. Start the engine and run it at low idle to warm up.
6. Choose “Manual Stationary Regeneration” for service by “Active Regeneration for Service” screen on
the monitor.
• When KDPF Soot Accumulation High Error 2 [CA1922] is displayed
1. Stop the machine and make sure in the machine monitor that the failure code [CA1922] is displayed.
2. Check the records for appeared failure codes “[CA2639]: Manual Stationary Regeneration Request”,
“[CA1921]: KDPF Soot Accumulation High Error 1”, and “[CA1922]: KDPF Soot Accumulation High Er-
ror 2”.
<Case1> When removing KDPF and replacing KCSF
KCSF must be removed by removing KDPF when the below conditions are satisfied since the soot ac-
cumulation exceeds the limit which the regeneration can be performed.
“Time from appearance of [CA2639]: Manual Stationary Regeneration Request” (L01) to “[CA1921]:
KDPF Soot Accumulation High Error 1” (L03) ≥ 360 sec (KOMTRAX records) or ≥ 0.1 h (monitor Ab-
normality Record screen)
And time from appearance of “[CA1921]: KDPF Soot Accumulation High Error 1” (L03) to “[CA1922]:
KDPF Soot Accumulation High Error 2” (L04) ≥ 360 sec (KOMTRAX records) or ≥ 0.1 h (monitor Ab-
normality Record screen)
[Details of work]
Case1-1] Stop the engine, and remove KCSF after piping around the engine are cooled down.
Case1-2] Install an alternative KCSF (new one or used one).
Case1-3] Turn the starting switch ON and perform KDPF cleaning reset from the KDPF reset screen.
If KDPF cleaning reset is performed, the change in ( ) is reflected. (Soot accumulation: 9 g/ℓ → 8.1 g/ℓ,
Action level: L04 → L03, Failure code: [CA1922] → [CA1921])
Case1-4] Perform KDPF change reset from the KDPF reset screen.
If KDPF change reset is performed, the change in () is reflected. (“Soot Correction by Ash Influence” is
changed to 0 g/ℓ.)
Case 1-5] Start the engine and run it at low idle to warm up.
Case1-6] Choose “Manual Stationary Regeneration” for service by “Active Regeneration for Service”
screen on the monitor. (In this case, active regeneration for service may continue for approximately 2
hours. )
Case 1-7] When Active Regeneration for Service is complete, check that failure codes ([CA1922],
[CA1921], [CA2639]) are not displayed.
<Case2> If active regeneration for service is performed (KDPF need not be removed)
If the following conditions are met, it means that soot is not accumulated actually (equivalent to 9 g/ℓ)
and only the differential pressure has increased due to clogging caused by uneven soot accumulation.
Therefore, the actual soot accumulation is not high enough to cause abnormal combustion even when
active regeneration is performed, so choose “Manual Stationary Regeneration” for service by “Active
D155AX-8 40-131
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE 40 TROUBLESHOOTING
Regeneration for Service” screen on the monitor without changing KCSF and it is possible to continue
to use KCSF after decreasing soot.
• Make sure that there is no abnormality in the sensor system in troubleshooting and, if either of the
following conditions is met, perform the work.
• Time from appearance of “[CA2639]: Manual Stationary Regeneration Request” (L01) to
“[CA1921]: KDPF Soot Accumulation High Error 1” (L03) < 360 sec (KOMTRAX records) or < 0.1 h
(monitor Abnormality Record screen)
• Time from appearance of “[CA1921]: KDPF Soot Accumulation High Error 1” (L03) to “[CA1922]:
KDPF Soot Accumulation High Error 2” (L04) < 360 sec (KOMTRAX records) or < 0.1 h (monitor
Abnormality Record screen)
[Details of work]
Case 2-1] Start the engine and run it at low idle to warm up. From the KDPF reset screen, perform
resetting “KDPF Cleaning” after KDPF cleaning.
If “KDPF Cleaning” reset is performed, the change in ( ) is reflected. (Soot accumulation: 9 g/ℓ → 8.1
g/ℓ, Action level: L04 → L03, Failure code: [CA1922] → [CA1921])
NOTICE
<Case 2> To choose “Manual Stationary Regeneration” for service by “Active Regeneration for
Service” screen on the monitor (without removal of KDPF), do not perform KDPF change reset.
If KDPF change reset is performed, “Soot Correction by Ash Influence” calculated in the engine
controller is changed to 0 g/ℓ and is different from the accumulation value of ash accumulated
in KDPF actually.
If “Soot Correction by Ash Influence” should be changed to 0 g/ℓ after KDPF change reset, it
would be necessary to perform “Service mode” and “METHOD FOR SETTING WITH TESTING
MENU (ASH IN SOOT ACCUMULATION CORRECTION)” of “SETTING AND OPERATION OF MA-
CHINE MONITOR” in "TESTING AND ADJUSTING".
screen on the monitor. (In this case, active regeneration for service may continue for approximately 2
hours.)
Case 1-7] When Active Regeneration for Service is complete, check that failure codes ([CA1922],
[CA1921], [CA2639]) are not displayed.
• When Ash Accumulation High Error [CA5383] is displayed
See Troubleshooting failure code [CA5383] for check and, if the estimated cause is “Ash Accumulation
High”, perform the same work as that in “When KCSF is cleaned or changed” and “In regular cleaning at
4500H ”described in the precautions of this part.
When KDOC is cleaned or changed
• When any crack or damage is found in test
1. If any crack or damage is confirmed in KDOC, change KDOC.
2. Perform “KDPF Change” reset from the KDPF reset screen.
• When Defective Regeneration [CA1691] is displayed
1. Stop the machine and make sure in the machine monitor that the failure code [CA1691] is displayed.
([CA2637] may appear at the same time.)
2. Check the exhaust gas color of the engine.
3. Stop the engine, and remove KDOC and confirm the existence of crack and damage after piping
around the engine are cooled down.
<Case1> If there is any crack or damage in KDOC
Case1-1] Replace KDOC.
Case1-2] Perform “KDOC Change” reset from the KDPF reset screen.
<Case2> If there is no crack nor damage in KDOC
Case2-1] Clean KDOC and install it again.
Case1-2] Perform “KDCO Change” reset from the KDPF reset screen.
screen on the monitor for 40 minutes twice. (Fuel is injected at the time of regeneration)
40-132 D155AX-8
40 TROUBLESHOOTING PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE
*To choose “Manual Stationary Regeneration” for service by “Active Regeneration for Service” screen
on the monitor in succession, stop the engine.
REMARK
After turning starting switch to OFF position, engine controller performs AdBlue/DEF purging (for Max.
6 minutes) and then stops. To restart engine, wait until system operating lamp goes off after turning
starting switch to OFF position, and then turn starting switch to ON position.
Case 2-4] If failure code “[CA2637]: KDOC Face Plugging” is displayed after active regeneration for
service is complete, the catalyst performance of KDOC is deteriorated. Replace KDOC with a new one.
D155AX-8 40-133
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR
(FOR FAILURE CODES [CA1883] AND [CA3135]) 40 TROUBLESHOOTING
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR

FAILURE CODES [CA1883] AND [CA3135])
NOTICE
The KDPF differential pressure sensor and the KDPF outlet pressure sensor use the same connector.
Contained in kit part No. 799-A65-4600.
Short socket adapter for KDPF differential pressure used in failure code [CA1883]
40-134 D155AX-8
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR
40 TROUBLESHOOTING (FOR FAILURE CODES [CA1883] AND [CA3135])
Short socket adapter for KDPF outlet pressure used in failure code [CA3135]
D155AX-8 40-135
FAILURE CODES TABLE 40 TROUBLESHOOTING
FAILURE CODES TABLE

Failure Applicable Action Category of
Failure (Displayed on screen) Remarks
code component level history
FAILURE CODE [1500L0] T/M Clutches Double En- Electrical
1500L0 PT L03
gagement (40-159) System
FAILURE CODE [15SAL1] ECMV Release Trouble Electrical
15SAL1 PT L03
(Forward) (40-160) System
FAILURE CODE [15SALH] ECMV Engage Trouble Electrical
15SALH PT L03
(Forward) (40-162) System
FAILURE CODE [15SBL1] ECMV Release Trouble Electrical
15SBL1 PT L03
(Reverse) (40-164) System
FAILURE CODE [15SBLH] ECMV Engage Trouble Electrical
15SBLH PT L03
(Reverse) (40-166) System
FAILURE CODE [15SEL1] ECMV Release Trouble Electrical
15SEL1 PT L03
(1st) (40-168) System
FAILURE CODE [15SELH] ECMV Engage Trouble Electrical
15SELH PT L03
(1st) (40-170) System
FAILURE CODE [15SFL1] ECMV Release Trouble Electrical
15SFL1 PT L03
(2nd) (40-172) System
FAILURE CODE [15SFLH] ECMV Engage Trouble Electrical
15SFLH PT L03
(2nd) (40-174) System
FAILURE CODE [15SGL1] ECMV Release Trouble Electrical
15SGL1 PT L03
(3rd) (40-176) System
FAILURE CODE [15SGLH] ECMV Engage Trouble Electrical
15SGLH PT L03
(3rd) (40-178) System
FAILURE CODE [15SJL1] ECMV Release Trouble Electrical
15SJL1 PT L03
(Lock Up Clutch) (40-180) System
FAILURE CODE [15SJLH] ECMV Engage Trouble Electrical
15SJLH PT L03
(Lock Up Clutch) (40-182) System
FAILURE CODE [1800MW] P/T Clutch Slip Electrical
1800MW PT L03
(40-184) System
FAILURE CODE [2300NR] Brake Thermal Load Ab- Mechanical
2300NR PT -
normality (40-185) System
FAILURE CODE [2301L1] ECMV Release Trouble Electrical
2301L1 PT L04
(RH Brake) (40-186) System
FAILURE CODE [2301LH] ECMV Engage Trouble Electrical
2301LH PT L04
(RH Brake) (40-188) System
FAILURE CODE [2302L1] ECMV Release Trouble Electrical
2302L1 PT L04
(LH Brake) (40-190) System
FAILURE CODE [2302LH] ECMV Engage Trouble Electrical
2302LH PT L04
(LH Brake) (40-192) System
FAILURE CODE [879AKA] A/C Recirculation Air Electrical
879AKA MON -
Temperature Sensor Open Circuit (40-194) System
FAILURE CODE [879AKB] A/C Recirculation Air Electrical
879AKB MON -
Temperature Sensor Short Circuit (40-195) System
FAILURE CODE [879BKA] A/C Fresh Air Tempera- Electrical
879BKA MON -
ture Sensor Open Circuit (40-196) System
40-136 D155AX-8
40 TROUBLESHOOTING FAILURE CODES TABLE

FAILURE CODE [879BKB] A/C Fresh Air Tempera- Electrical
879BKB MON -
ture Sensor Short Circuit (40-198) System
FAILURE CODE [879CKA] Ventilating Sensor Open Electrical
879CKA MON -
Circuit (40-200) System
FAILURE CODE [879CKB] Ventilating Sensor Short Electrical
879CKB MON -
FAILURE CODE [879DKZ] Sunlight Sensor Open Electrical
879DKZ MON -
Circuit or Short Circuit (40-202) System
FAILURE CODE [879EMC] Ventilation Damper Mal- Electrical
879EMC MON L01
function (40-204) System
FAILURE CODE [879FMC] Air Mix Damper Mal- Electrical
879FMC MON L01
FAILURE CODE [879GKX] Refrigerant Pressure In- Electrical
879GKX MON L01
put Signal Out of Range (40-206) System
FAILURE CODE [989L00] Engine Controller Lock Electrical
989L00 MON -
Caution 1 (40-208) System
FAILURE CODE [989M00] Engine Controller Lock Electrical
989M00 MON -
FAILURE CODE [989N00] Engine Controller Lock Electrical
989N00 MON -
FAILURE CODE [A1U0N3] Hydrocarbon Desorb Electrical
A1U0N3 ENG L01
Request 1 (40-211) System
FAILURE CODE [A1U0N4] Hydrocarbon Desorb Electrical
A1U0N4 ENG L03
Request 2 (40-213) System
FAILURE CODE [AA10NX] Air Cleaner Clogging Mechanical
AA10NX MON L01
(40-215) System
FAILURE CODE [AB00KE] Charge Voltage Low Mechanical
AB00KE MON L03
(40-217) System
FAILURE CODE [AQ10N3] Manual Stationary Re-
Electrical
AQ10N3 generation Request (KDOC Face Plugging) ENG L01
System
(40-219)
FAILURE CODE [AS00N3] Manual Stationary Re- Electrical
AS00N3 ENG L01
generation Request (SCR) (40-221) System
FAILURE CODE [AS00R2] Warning 2 (SCR Device Electrical
AS00R2 ENG L01
Abnormality) (40-223) System
FAILURE CODE [AS00R3] Inducement 1 (SCR De- Electrical
AS00R3 ENG L03
vice Abnormality) (40-224) System
AS00R4 ENG L04
AS00R5 ENG L04
FAILURE CODE [AS00R6] Temporary Recovery of Electrical
AS00R6 ENG -
Inducement (40-227) System
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Electrical
AS00ZK ENG L04
Error 5 (40-228) System
D155AX-8 40-137

FAILURE CODE [AS10KM] AdBlue/DEF Injector Mechanical
AS10KM MON L01
Overheat Warning (40-229) System
FAILURE CODE [AS10NR] AdBlue/DEF Injector Electrical
AS10NR ENG -
High Temperature Warning (40-230) System
FAILURE CODE [AS10NT] AdBlue/DEF Injector Mechanical
AS10NT MON -
Overheat Caution (40-231) System
FAILURE CODE [B@BAZG] Engine Oil Pressure Mechanical
B@BAZG ENG L03
Low (40-232) System
FAILURE CODE [B@BCNS] Engine Coolant Over- Mechanical
B@BCNS ENG L02
heat (40-233) System
FAILURE CODE [B@BCZK] Engine Coolant Level Mechanical
B@BCZK MON L01
Low (40-234) System
FAILURE CODE [B@CENS] Power Train Oil Over- Mechanical
B@CENS PT L02
heat (40-236) System
FAILURE CODE [B@HANS] Hydraulic Oil Overheat Mechanical
B@HANS WE L02
(40-237) System
FAILURE CODE [CA115] Engine NE and Backup Electrical
CA115 ENG L04
Speed Sensor Error (40-238) System
FAILURE CODE [CA122] Charge Air Pressure Sen- Electrical
CA122 ENG L03
sor High Error (40-239) System
FAILURE CODE [CA123] Charge Air Pressure Sen- Electrical
CA123 ENG L03
sor Low Error (40-241) System
FAILURE CODE [CA131] Throttle Sensor High Er- Electrical
CA131 ENG L03
ror (40-243) System
FAILURE CODE [CA132] Throttle Sensor Low Error Electrical
CA132 ENG L03
(40-245) System
FAILURE CODE [CA135] Engine Oil Pressure Sen- Electrical
CA135 ENG L01
FAILURE CODE [CA141] Engine Oil Pressure Sen- Electrical
CA141 ENG L01
FAILURE CODE [CA144] Coolant Temperature Electrical
CA144 ENG L01
Sensor High Error (40-251) System
FAILURE CODE [CA145] Coolant Temperature Electrical
CA145 ENG L01
Sensor Low Error (40-253) System
FAILURE CODE [CA153] Charge Air Temperature Electrical
CA153 ENG L03
FAILURE CODE [CA154] Charge Air Temperature Electrical
CA154 ENG L03
FAILURE CODE [CA187] Sensor 2 Supply Voltage Electrical
CA187 ENG L03
Low Error (40-261) System
FAILURE CODE [CA221] Ambient Pressure Sensor Electrical
CA221 ENG L03
High Error (40-263) System
FAILURE CODE [CA222] Ambient Pressure Sensor Electrical
CA222 ENG L03
CA227 ENG L03
40-138 D155AX-8

FAILURE CODE [CA234] Engine Overspeed Mechanical
CA234 ENG L02
(40-268) System
FAILURE CODE [CA238] NE Speed Sensor Supply Electrical
CA238 ENG L01
Voltage Error (40-269) System
FAILURE CODE [CA239] NE Speed Sensor Supply Electrical
CA239 ENG L01
Voltage High Error (40-271) System
FAILURE CODE [CA249] Ambient Air Temp Sensor Electrical
CA249 ENG L01
FAILURE CODE [CA256] Ambient Air Temp Sensor Electrical
CA256 ENG L01
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Electrical
CA271 ENG L03
Error (40-277) System
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Electrical
CA272 ENG L03
FAILURE CODE [CA273] PCV 2 Short Circuit Error Electrical
CA273 ENG L03
(40-280) System
FAILURE CODE [CA274] PCV 2 Open Circuit Error Electrical
CA274 ENG L03
(40-282) System
FAILURE CODE [CA322] Injector #1 (L#1) Open Electrical
CA322 ENG L03
Circuit Error or Short Circuit Error (40-283) System
CA323 ENG L03
CA324 ENG L03
CA325 ENG L03
CA331 ENG L03
CA332 ENG L03
FAILURE CODE [CA343] Engine Controller Internal Electrical
CA343 ENG L04
Failure (40-295) System
FAILURE CODE [CA351] Injectors Drive Circuit Er- Electrical
CA351 ENG L03
ror (40-296) System
CA352 ENG L03
FAILURE CODE [CA356] MAF Sensor High Error Electrical
CA356 ENG L03
(40-300) System
FAILURE CODE [CA357] MAF Sensor Low Error Electrical
CA357 ENG L03
(40-302) System
CA386 ENG L03
FAILURE CODE [CA441] Power Voltage Low Error Electrical
CA441 ENG L04
(40-306) System
FAILURE CODE [CA442] Power Voltage High Error Electrical
CA442 ENG L04
(40-309) System
D155AX-8 40-139

FAILURE CODE [CA449] Common Rail Pressure Electrical
CA449 ENG L03
High Error 2 (40-310) System
CA451 ENG L03
CA452 ENG L03
CA515 ENG L03
Sensor Supply Voltage High Error (40-315) System
CA516 ENG L03
Sensor Supply Voltage Low Error (40-317) System
CA553 ENG L01
High Error 1 (40-319) System
FAILURE CODE [CA555] Crankcase Pressure High Electrical
CA555 ENG L01
FAILURE CODE [CA556] Crankcase Pressure High Electrical
CA556 ENG L03
CA559 ENG L01
Low Error 1 (40-322) System
FAILURE CODE [CA595] Turbocharger Speed High Electrical
CA595 ENG L01
FAILURE CODE [CA687] Turbocharger Speed Low Electrical
CA687 ENG L01
FAILURE CODE [CA689] Engine NE Speed Sensor Electrical
CA689 ENG L01
FAILURE CODE [CA691] Intake Air Temperature Electrical
CA691 ENG L01
FAILURE CODE [CA692] Intake Air Temperature Electrical
CA692 ENG L01
CA697 ENG L01
Temperature Sensor High Error (40-336) System
CA698 ENG L01
Temperature Sensor Low Error (40-337) System
FAILURE CODE [CA731] Engine Backup Speed Electrical
CA731 ENG L01
Sensor Phase Error (40-338) System
FAILURE CODE [CA778] Engine Backup Speed Electrical
CA778 ENG L01
Sensor Error (40-339) System
FAILURE CODE [CA1117] Engine Controller Partial Electrical
CA1117 ENG L04
Data Lost Error (40-342) System
FAILURE CODE [CA1664] KDOC Abnormality Electrical
CA1664 ENG L03
(40-343) System
FAILURE CODE [CA1669] AdBlue/DEF Level Sen- Electrical
CA1669 ENG L01
sor Voltage High Error (40-346) System
FAILURE CODE [CA1673] AdBlue/DEF Level Low Electrical
CA1673 ENG L03
FAILURE CODE [CA1677] AdBlue/DEF Tempera- Electrical
CA1677 ENG L01
ture Sensor Low Error (40-348) System
40-140 D155AX-8

CA1678 ENG L01
ture Sensor High Error (40-349) System
FAILURE CODE [CA1682] AdBlue/DEF Pump Pri- Electrical
CA1682 ENG L01
ming Error (40-350) System
FAILURE CODE [CA1683] AdBlue/DEF Tank Heat- Electrical
CA1683 ENG L01
ing Valve Voltage High Error (40-352) System
CA1684 ENG L01
ing Valve Voltage Low Error (40-354) System
FAILURE CODE [CA1686] AdBlue/DEF Quality Electrical
CA1686 ENG L01
Sensor Voltage High Error (40-356) System
FAILURE CODE [CA1691] Defective Regeneration Electrical
CA1691 ENG L03
(40-357) System
FAILURE CODE [CA1694] SCR Outlet NOx Sensor Electrical
CA1694 ENG L01
In Range Error (40-360) System
CA1695 ENG L03
CA1696 ENG L03
FAILURE CODE [CA1712] AdBlue/DEF Tank Thaw- Electrical
CA1712 ENG L01
ing Error (40-366) System
CA1713 ENG L01
er Valve Open Stuck Error (40-369) System
CA1714 ENG L01
Sensor Out of Calibration Error (40-371) System
CA1715 ENG L01
Sensor Internal Circuit Error (40-372) System
FAILURE CODE [CA1776] Sensor Supply Relay Electrical
CA1776 ENG L01
FAILURE CODE [CA1777] Sensor Supply Relay Electrical
CA1777 ENG L01
Voltage Low Error (40-376) System
FAILURE CODE [CA1843] Crankcase Pressure Electrical
CA1843 ENG L01
CA1844 ENG L01
FAILURE CODE [CA1879] KDPF Differential Pres- Electrical
CA1879 ENG L03
sure Sensor High Error (40-384) System
CA1881 ENG L03
sure Sensor Low Error (40-387) System
CA1883 ENG L03
sure Sensor In Range Error (40-389) System
FAILURE CODE [CA1885] Turbo Outlet NOx Sen- Electrical
CA1885 ENG L01
sor Circuit Error (40-393) System
CA1887 ENG L01
Circuit Error (40-395) System
FAILURE CODE [CA1921] KDPF Soot Accumula- Electrical
CA1921 ENG L03
tion High Error 1 (40-397) System
D155AX-8 40-141

FAILURE CODE [CA1922] KDPF Soot Accumula- Electrical
CA1922 ENG L04
tion High Error 2 (40-400) System
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 Electrical
CA1923 ENG L03
CA1924 ENG L03
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Electrical
CA1925 ENG L03
Range Error (40-409) System
FAILURE CODE [CA1927] Dosing Fuel Pressure Electrical
CA1927 ENG L01
CA1928 ENG L01
CA1942 ENG L01
Sensor In Range Error (40-415) System
CA1963 ENG L03
Servo Error (40-416) System
FAILURE CODE [CA1977] Fuel Doser Open Circuit Electrical
CA1977 ENG L03
Error or Short Circuit Error (40-419) System
CA1993 ENG L03
sure Low Error (40-422) System
FAILURE CODE [CA2185] Throttle Sensor Supply Electrical
CA2185 ENG L03
FAILURE CODE [CA2186] Throttle Sensor Supply Electrical
CA2186 ENG L03
CA2249 ENG L03
FAILURE CODE [CA2265] Fuel Feed Pump Open Electrical
CA2265 ENG L01
FAILURE CODE [CA2266] Fuel Feed Pump Short Electrical
CA2266 ENG L01
FAILURE CODE [CA2271] EGR Valve Position Electrical
CA2271 ENG L03
FAILURE CODE [CA2272] EGR Valve Position Electrical
CA2272 ENG L03
FAILURE CODE [CA2349] EGR Valve Solenoid Electrical
CA2349 ENG L03
Open Circuit Error (40-439) System
FAILURE CODE [CA2353] EGR Valve Solenoid Electrical
CA2353 ENG L03
Short Circuit Error (40-441) System
FAILURE CODE [CA2357] EGR Valve Servo Error Electrical
CA2357 ENG L03
(40-443) System
FAILURE CODE [CA2381] KVGT Position Sensor Electrical
CA2381 ENG L03
FAILURE CODE [CA2382] KVGT Position Sensor Electrical
CA2382 ENG L03
FAILURE CODE [CA2383] KVGT Solenoid Open Electrical
CA2383 ENG L03
40-142 D155AX-8

FAILURE CODE [CA2386] KVGT Solenoid Short Electrical
CA2386 ENG L03
FAILURE CODE [CA2387] KVGT Servo Error Electrical
CA2387 ENG L03
(40-452) System
FAILURE CODE [CA2555] Intake Air Heater Relay Electrical
CA2555 ENG L01
Open Circuit Error (40-453) System
FAILURE CODE [CA2556] Intake Air Heater Relay Electrical
CA2556 ENG L01
Short Circuit Error (40-456) System
FAILURE CODE [CA2637] KDOC Face Plugging Electrical
CA2637 ENG L01
(40-458) System
FAILURE CODE [CA2639] Manual Stationary Re- Electrical
CA2639 ENG L01
generation Request (40-460) System
CA2732 ENG L03
CA2733 ENG L03
FAILURE CODE [CA2741] Fuel Dozer Solenoid Electrical
CA2741 ENG L03
Valve Swap Error (40-466) System
FAILURE CODE [CA2765] Injector Trim Data Mis- Electrical
CA2765 ENG L01
match (40-467) System
CA2771 ENG L01
Datalink Timeout Error (40-468) System
FAILURE CODE [CA2777] Manual Stationary Re-
Electrical
CA2777 generation Request but KDPF Regeneration Disa- ENG -
System
ble (40-474)
CA2878 ENG L03
Servo Error (40-477) System
CA2881 ENG L03
FAILURE CODE [CA2976] AdBlue/DEF Pump Tem- Electrical
CA2976 ENG L01
perature Sensor Signal Error (40-483) System
FAILURE CODE [CA3133] KDPF Outlet Pressure Electrical
CA3133 ENG L03
CA3134 ENG L03
CA3135 ENG L03
FAILURE CODE [CA3142] SCR Temperature Sen- Electrical
CA3142 ENG L01
CA3143 ENG L01
CA3144 ENG L01
sor In Range Error (40-495) System
FAILURE CODE [CA3146] SCR Outlet Temperature Electrical
CA3146 ENG L01
D155AX-8 40-143

CA3147 ENG L01
CA3148 ENG L01
FAILURE CODE [CA3151] SCR Catalyst Efficiency Electrical
CA3151 ENG L01
CA3165 ENG L03
FAILURE CODE [CA3167] Fuel Doser Degradation Electrical
CA3167 ENG -
(40-509) System
FAILURE CODE [CA3229] SCR Temperature High Electrical
CA3229 ENG L03
FAILURE CODE [CA3231] SCR Temperature High Electrical
CA3231 ENG L03
Error - Non Regeneration (40-514) System
CA3232 ENG L01
sor Datalink Timeout Error (40-516) System
CA3235 ENG L03
High Error - Non Regeneration (40-520) System
FAILURE CODE [CA3239] AdBlue/DEF Line Heater Electrical
CA3239 ENG L01
2 Voltage High Error (40-522) System
CA3241 ENG L01
2 Voltage Low Error (40-525) System
CA3242 ENG L01
ing Error (40-528) System
FAILURE CODE [CA3251] KDOC Inlet Temperature Electrical
CA3251 ENG L03
FAILURE CODE [CA3253] KDOC Temperature Er- Electrical
CA3253 ENG L03
ror - Non Regeneration (40-534) System
FAILURE CODE [CA3254] KDOC Outlet Tempera- Electrical
CA3254 ENG L01
ture High Error 1 (40-538) System
FAILURE CODE [CA3255] KDPF Temperature Er- Electrical
CA3255 ENG L03
ror - Non Regeneration (40-541) System
FAILURE CODE [CA3256] KDPF Outlet Tempera- Electrical
CA3256 ENG L01
CA3311 ENG L03
CA3312 ENG L03
CA3313 ENG L03
CA3314 ENG L03
CA3315 ENG L03
CA3316 ENG L03
40-144 D155AX-8

CA3317 ENG L03
CA3318 ENG L03
ture Sensor In Range Error (40-558) System
CA3319 ENG L03
CA3321 ENG L03
CA3322 ENG L03
ture Sensor In Range Error (40-564) System
FAILURE CODE [CA3419] MAF Sensor Supply Electrical
CA3419 ENG L03
FAILURE CODE [CA3421] MAF Sensor Supply Electrical
CA3421 ENG L03
CA3497 ENG -
CA3498 ENG -
FAILURE CODE [CA3543] AdBlue/DEF Quality Er- Electrical
CA3543 ENG L01
ror (SCR Catalyst Efficiency Low) (40-573) System
FAILURE CODE [CA3543] AdBlue/DEF Quality Er- Electrical
CA3543 ENG L01
ror (SCR Catalyst Efficiency Low) (40-573) System
CA3545 ENG L01
Unstable Error (40-580) System
CA3547 ENG L04
FAILURE CODE [CA3558] AdBlue/DEF Pump Volt- Electrical
CA3558 ENG L01
age High Error (40-583) System
FAILURE CODE [CA3559] AdBlue/DEF Pump Volt- Electrical
CA3559 ENG L01
age Low Error (40-585) System
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Electrical
CA3562 ENG L01
Relay 1 Voltage High Error (40-587) System
CA3563 ENG L01
Relay 1 Voltage Low Error (40-589) System
FAILURE CODE [CA3567] AdBlue/DEF Injector Electrical
CA3567 ENG L01
Open Circuit Error or Short Circuit Error (40-592) System
FAILURE CODE [CA3568] AdBlue/DEF Injector Electrical
CA3568 ENG L01
Malfunction (40-595) System
FAILURE CODE [CA3571] AdBlue/DEF Pump Electrical
CA3571 ENG L01
Pressure Sensor High Error (40-599) System
CA3572 ENG L01
Pressure Sensor Low Error (40-601) System
CA3574 ENG L01
Pressure Too Low Error (40-603) System
CA3575 ENG L01
Pressure Too High Error (40-605) System
D155AX-8 40-145

FAILURE CODE [CA3577] AdBlue/DEF FCV Volt- Electrical
CA3577 ENG L01
age High Error (40-607) System
FAILURE CODE [CA3578] AdBlue/DEF FCV Volt- Electrical
CA3578 ENG L01
age Low Error (40-609) System
FAILURE CODE [CA3582] SCR Catalyst Efficiency Electrical
CA3582 ENG -
CA3583 ENG L01
Heater Warming up Error (40-617) System
CA3596 ENG L01
Pressure Unstable Error (40-619) System
CA3649 ENG L01
sor Heater Warming up Error (40-621) System
CA3681 ENG L01
Power Voltage Error (40-623) System
CA3682 ENG L01
sor Power Voltage Error (40-628) System
CA3713 ENG L01
1 Voltage High Error (40-634) System
CA3717 ENG L01
Voltage Mismatch Error (40-637) System
CA3718 ENG L01
sor Voltage Mismatch Error (40-638) System
CA3725 ENG L01
sor Unstable Error (40-639) System
CA3748 ENG L01
sor Stuck In Range Error (40-642) System
FAILURE CODE [CA3751] SCR Catalyst Degrada- Electrical
CA3751 ENG L03
tion Error (40-645) System
FAILURE CODE [CA3755] AdBlue/DEF Dosing Electrical
CA3755 ENG L03
Performance Degradation Error (40-647) System
FAILURE CODE [CA3866] AdBlue/DEF Low Con- Electrical
CA3866 ENG L01
centration Error 2 (40-649) System
FAILURE CODE [CA3867] AdBlue/DEF Low Con- Electrical
CA3867 ENG -
centration Error 1 (40-652) System
FAILURE CODE [CA3868] AdBlue/DEF Tank Sen- Electrical
CA3868 ENG L01
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Electrical
CA3899 ENG L01
FAILURE CODE [CA3911] SCR NH3 Sensor Data- Electrical
CA3911 ENG L01
link Timeout Error (40-661) System
FAILURE CODE [CA3912] SCR NH3 Sensor Heat- Electrical
CA3912 ENG L01
er Warming up Error (40-665) System
CA3932 ENG L01
er Voltage High Error (40-667) System
CA3933 ENG L01
er Voltage Low Error (40-669) System
40-146 D155AX-8

FAILURE CODE [CA3934] SCR NH3 Sensor Power Electrical
CA3934 ENG L01
Interrupt Error (40-671) System
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Electrical
CA3935 ENG L01
Resistance Error (40-674) System
FAILURE CODE [CA3936] SCR NH3 Sensor Inter- Electrical
CA3936 ENG L01
nal Circuit Error (40-676) System
FAILURE CODE [CA4151] KDOC and KDPF Tem- Electrical
CA4151 ENG L01
perature Sensor Datalink Timeout Error (40-678) System
CA4152 ENG L01
CA4155 ENG L01
Heater Relay Voltage High Error (40-687) System
CA4156 ENG L01
Heater Relay Voltage Low Error (40-690) System
FAILURE CODE [CA4157] AdBlue/DEF FCV Mal- Electrical
CA4157 ENG L01
CA4158 ENG L01
perature Sensor Internal Circuit Error (40-695) System
CA4159 ENG L01
sor Internal Circuit Error (40-696) System
CA4161 ENG L01
perature Sensor ECU Voltage High Error (40-697) System
CA4162 ENG L01
perature Sensor ECU Voltage Low Error (40-700) System
FAILURE CODE [CA4163] KDOC and KDPF Tem-
Electrical
CA4163 perature Sensor ECU Over Temperature Error ENG L01
System
(40-703)
CA4164 ENG L01
sor ECU Voltage High Error (40-706) System
CA4165 ENG L01
sor ECU Voltage Low Error (40-708) System
CA4166 ENG L01
sor ECU High Temperature Error (40-710) System
CA4168 ENG L01
Heater ON Stuck Error (40-712) System
CA4169 ENG L01
Heater OFF Stuck Error (40-715) System
CA4171 ENG L01
Thawing Error (40-717) System
CA4249 ENG L01
perature Sensor 1 In Range Error (40-720) System
CA4251 ENG L01
perature Sensor 2 In Range Error (40-722) System
CA4259 ENG L01
perature Sensor Power Interrupt Error (40-724) System
D155AX-8 40-147

CA4261 ENG L01
sor Power Interrupt Error (40-727) System
CA4277 ENG L01
Sensor Liquid Distinction Impossible Error (40-730) System
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Electrical
CA4281 ENG L01
Response Error (40-733) System
CA4459 ENG L01
Relay 2 Voltage High Error (40-737) System
CA4461 ENG L01
Relay 2 Voltage Low Error (40-740) System
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Electrical
CA4658 ENG -
CA4731 ENG L01
ture Sensor Transmission Data Error (40-747) System
CA4732 ENG L01
sor Transmission Data Error (40-748) System
CA4739 ENG L01
sor Internal Circuit Error (40-749) System
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Electrical
CA4768 ENG L03
Tank Error (40-750) System
FAILURE CODE [CA4769] AdBlue/DEF Level Electrical
CA4769 ENG L01
Measurement Impossible (40-752) System
FAILURE CODE [CA4842] AdBlue/DEF High Con- Electrical
CA4842 ENG L01
centration Error (40-755) System
FAILURE CODE [CA4952] System Operating Lamp Electrical
CA4952 ENG -
Short Circuit (Engine Controller) (40-758) System
CA5115 ENG L01
1 Voltage Low Error (40-760) System
FAILURE CODE [CA5383] Ash Accumulation High Electrical
CA5383 ENG -
FAILURE CODE [D130KA] Neutral Safety Relay Electrical
D130KA PT L01
Open Circuit (40-765) System
FAILURE CODE [D130KB] Neutral Safety Relay Electrical
D130KB PT L01
Short Circuit (40-768) System
FAILURE CODE [D190KA] Engine Controller Ac- Electrical
D190KA WE -
cessory Signal Hold Relay Open Circuit (40-770) System
FAILURE CODE [D190KB] Engine Controller Ac- Electrical
D190KB WE -
cessory Signal Hold Relay Short Circuit (40-772) System
FAILURE CODE [D19JKZ] Personal Code Relay Electrical
D19JKZ MON L03
Open or Short (40-774) System
FAILURE CODE [D811MC] KOMTRAX Malfunction Electrical
D811MC KOMTRAX -
(40-777) System
FAILURE CODE [D862KA] GPS Antenna Open Cir- Electrical
D862KA KOMTRAX -
cuit (40-778) System
FAILURE CODE [D8ALKA] System Operating Lamp Electrical
D8ALKA KOMTRAX -
Open Circuit (KOMTRAX) (40-779) System
40-148 D155AX-8

FAILURE CODE [D8ALKB] System Operating Lamp Electrical
D8ALKB KOMTRAX -
Short Circuit (KOMTRAX) (40-781) System
FAILURE CODE [D8AQKR] CAN 2 Defective Com- Electrical
D8AQKR MON -
munication (KOMTRAX) (40-783) System
FAILURE CODE [DAF0MB] Monitor ROM Abnor- Electrical
DAF0MB MON -
mality (40-784) System
FAILURE CODE [DAF0MC] Monitor Malfunction Electrical
DAF0MC MON -
(40-785) System
FAILURE CODE [DAF8KB] Camera Power Supply Electrical
DAF8KB MON L03
FAILURE CODE [DAF9KQ] Model Selection Signal Electrical
DAF9KQ MON L03
Mismatch (Monitor) (40-787) System
FAILURE CODE [DAFGMC] GPS Module Malfunc- Electrical
DAFGMC KOMTRAX -
tion (40-788) System
FAILURE CODE [DAFLKA] System Operating Electrical
DAFLKA MON -
Lamp Open Circuit (Monitor) (40-789) System
FAILURE CODE [DAFLKB] System Operating Electrical
DAFLKB MON -
Lamp Short Circuit (Monitor) (40-791) System
FAILURE CODE [DAFQKR] CAN 2 Defective Com- Electrical
DAFQKR KOMTRAX -
munication (Monitor) (40-793) System
FAILURE CODE [DAZ9KQ] Model Selection Signal Electrical
DAZ9KQ MON -
Mismatch (A/C) (40-794) System
FAILURE CODE [DAZQKR] CAN 2 Defective Com- Electrical
DAZQKR MON L01
munication (A/C ECU) (40-795) System
FAILURE CODE [DB2QKR] CAN 2 Defective Com- Electrical
DB2QKR MON L03
munication (Engine Controller) (40-796) System
FAILURE CODE [DB2RKR] CAN 1 Defective Com- Electrical
DB2RKR MON L03
munication (Engine Controller) (40-802) System
FAILURE CODE [DB90KT] W/E Controller Internal Electrical
DB90KT WE L01
Abnormality (40-808) System
FAILURE CODE [DB90MC] W/E Controller Mal- Electrical
DB90MC WE -
FAILURE CODE [DB91KK] W/E Controller Source Electrical
DB91KK WE L04
FAILURE CODE [DB92KK] W/E Controller Solenoid Electrical
DB92KK WE L04
Power Voltage Low Error (40-813) System
FAILURE CODE [DB95KK] W/E Controller 5V Sen- Electrical
DB95KK WE L03
sor 0 Power Voltage Out of Range (40-816) System
FAILURE CODE [DB97KK] W/E Controller 5V Sen- Electrical
DB97KK WE L01
FAILURE CODE [DB99KQ] Model Selection Signal Electrical
DB99KQ WE L04
Mismatch (W/E Controller) (40-821) System
FAILURE CODE [DB9LKA] System Operating Lamp Electrical
DB9LKA WE -
Open Circuit (W/E Controller) (40-823) System
FAILURE CODE [DB9LKB] System Operating Lamp Electrical
DB9LKB WE -
Short Circuit (W/E Controller) (40-825) System
D155AX-8 40-149

FAILURE CODE [DB9QKR] CAN 2 Defective Com- Electrical
DB9QKR MON L03
munication (W/E Controller) (40-827) System
FAILURE CODE [DB9RKR] CAN 1 Defective Com- Electrical
DB9RKR MON L03
munication (W/E Controller) (40-828) System
FAILURE CODE [DBE0KT] P/T Controller Internal Electrical
DBE0KT PT L01
Abnormality (40-830) System
FAILURE CODE [DBE1KK] P/T Controller Source Electrical
DBE1KK PT L04
FAILURE CODE [DBE2KK] P/T Controller Solenoid Electrical
DBE2KK PT L04
Power Voltage Low Error (40-834) System
FAILURE CODE [DBE5KK] P/T Controller 5V Sen- Electrical
DBE5KK PT L03
FAILURE CODE [DBE6KK] P/T Controller 24V Sen- Electrical
DBE6KK PT L03
sor Power Voltage Out of Range (40-839) System
FAILURE CODE [DBE9KQ] Model Selection Signal Electrical
DBE9KQ PT L04
Mismatch (P/T Controller) (40-841) System
FAILURE CODE [DBELKA] System Operating Electrical
DBELKA PT -
Lamp Open Circuit (P/T Controller) (40-843) System
FAILURE CODE [DBELKB] System Operating Electrical
DBELKB PT -
Lamp Short Circuit (P/T Controller) (40-845) System
FAILURE CODE [DBEQKR] CAN 2 Defective Com- Electrical
DBEQKR MON L03
munication (P/T Controller) (40-847) System
FAILURE CODE [DBERKR] CAN 1 Defective Com- Electrical
DBERKR WE L03
FAILURE CODE [DBERKR] CAN 1 Defective Com- Electrical
DBERKR MON L03
FAILURE CODE [DD12KA] Shift Up SW Open Cir- Electrical
DD12KA PT L03
FAILURE CODE [DD12KB] Shift Up SW Short Cir- Electrical
DD12KB PT L03
FAILURE CODE [DD13KA] Shift Down SW Open Electrical
DD13KA PT L03
FAILURE CODE [DD13KB] Shift Down SW Short Electrical
DD13KB PT L03
FAILURE CODE [DD14KA] Parking Brake Lever Electrical
DD14KA PT L03
SW Open Circuit (40-858) System
FAILURE CODE [DD14KB] Parking Brake Lever Electrical
DD14KB PT L03
SW Short Circuit (40-861) System
FAILURE CODE [DDDDKA] Brake Pedal SW Open Electrical
DDDDKA PT L03
FAILURE CODE [DDDDKB] Brake Pedal SW Short Electrical
DDDDKB PT L03
FAILURE CODE [DDDDKX] Brake Pedal SW Signal Electrical
DDDDKX PT L03
Mismatch (40-869) System
FAILURE CODE [DDKAKA] Blade Float SW Open Electrical
DDKAKA WE L01
40-150 D155AX-8

FAILURE CODE [DDKAKB] Blade Float SW Short Electrical
DDKAKB WE L01
FAILURE CODE [DDKBKA] Blade Auto Pitch SW Electrical
DDKBKA WE L01
FAILURE CODE [DDKBKA] Blade Auto Pitch SW Electrical
DDKBKA WE L01
FAILURE CODE [DDKBKB] Blade Auto Pitch SW Electrical
DDKBKB WE L01
FAILURE CODE [DDKBKB] Blade Auto Pitch SW Electrical
DDKBKB WE L01
FAILURE CODE [DDKCL4] Ripper Tilt In SW Signal Electrical
DDKCL4 WE L01
Mismatch (40-878) System
FAILURE CODE [DDKEL4] Ripper Tilt Back SW Electrical
DDKEL4 WE L01
Signal Mismatch (40-881) System
FAILURE CODE [DDN7L4] Blade Pitch Back SW Electrical
DDN7L4 WE L01
FAILURE CODE [DDN8L4] Blade Pitch Dump SW Electrical
DDN8L4 WE L01
FAILURE CODE [DDNLKA] W/E Lock SW Open Electrical
DDNLKA WE L03
FAILURE CODE [DDNLKB] W/E Lock SW Short Electrical
DDNLKB WE L03
FAILURE CODE [DDTSL1] Stator Clutch Release Electrical
DDTSL1 PT L03
Trouble (40-894) System
FAILURE CODE [DDTSLH] Stator Clutch Engage Electrical
DDTSLH PT L03
Trouble (40-896) System
FAILURE CODE [DFA4KX] Blade Lift Lever Potenti-
Electrical
DFA4KX ometer 1 and 2 Open Circuit or Hot Short Circuit WE L01
System
(40-898)
FAILURE CODE [DFA4KZ] Blade Lift Lever Potenti-
Electrical
DFA4KZ ometer 1 and 2 Open Circuit or Hot Short Circuit WE L01
System
(40-899)
FAILURE CODE [DFA4L8] Blade Lift Lever Potenti- Electrical
DFA4L8 WE L01
ometer 1 or 2 Signal Abnormality (40-900) System
FAILURE CODE [DFA5KA] Blade Lift Lever Potenti- Electrical
DFA5KA WE L01
ometer 1 Open Circuit (40-901) System
FAILURE CODE [DFA5KY] Blade Lift Lever Potenti- Electrical
DFA5KY WE L01
ometer 1 Hot Short Circuit (40-904) System
FAILURE CODE [DFA6KA] Blade Lift Lever Potenti- Electrical
DFA6KA WE L01
FAILURE CODE [DFA6KY] Blade Lift Lever Potenti- Electrical
DFA6KY WE L01
FAILURE CODE [DFA7KX] Blade Tilt Lever Potenti-
Electrical
DFA7KX ometer 1 and 2 Open Circuit or Hot Short Circuit WE L01
System
(40-911)
D155AX-8 40-151

FAILURE CODE [DFA7KZ] Blade Tilt Lever Potenti-
Electrical
DFA7KZ ometer 1 and 2 Open Circuit or Hot Short Circuit WE L01
System
(40-912)
FAILURE CODE [DFA7L8] Blade Tilt Lever Potenti- Electrical
DFA7L8 WE L01
ometer 1 or 2 Signal Abnormality (40-913) System
FAILURE CODE [DFA8KA] Blade Tilt Lever Potenti- Electrical
DFA8KA WE L01
FAILURE CODE [DFA8KY] Blade Tilt Lever Potenti- Electrical
DFA8KY WE L01
FAILURE CODE [DFA9KA] Blade Tilt Lever Potenti- Electrical
DFA9KA WE L01
FAILURE CODE [DFA9KY] Blade Tilt Lever Potenti- Electrical
DFA9KY WE L01
FAILURE CODE [DFAAKX] Ripper Lift Lever Poten-
Electrical
DFAAKX tiometer 1 and 2 Open Circuit or Hot Short Circuit WE L01
System
(40-924)
FAILURE CODE [DFAAKZ] Ripper Lift Lever Poten-
Electrical
DFAAKZ tiometer 1 and 2 Open Circuit or Hot Short Circuit WE L01
System
(40-925)
FAILURE CODE [DFAAL8] Ripper Lift Lever Poten- Electrical
DFAAL8 WE L01
tiometer 1 or 2 Signal Abnormality (40-926) System
FAILURE CODE [DFABKA] Ripper Lift Lever Poten- Electrical
DFABKA WE L01
tiometer 1 Open Circuit (40-927) System
FAILURE CODE [DFABKY] Ripper Lift Lever Poten- Electrical
DFABKY WE L01
tiometer 1 Hot Short Circuit (40-930) System
FAILURE CODE [DFACKA] Ripper Lift Lever Poten- Electrical
DFACKA WE L01
tiometer 2 Open Circuit (40-932) System
FAILURE CODE [DFACKY] Ripper Lift Lever Poten- Electrical
DFACKY WE L01
tiometer 2 Hot Short Circuit (40-935) System
FAILURE CODE [DGS1KA] Hydraulic Oil Tempera- Electrical
DGS1KA WE L01
ture Sensor Open Circuit (40-937) System
FAILURE CODE [DGS1KX] Hydraulic Oil Tempera- Electrical
DGS1KX WE L01
ture Sensor Input Signal Out of Range (40-939) System
FAILURE CODE [DGT1KA] T/C Oil Temperature Electrical
DGT1KA PT L01
Sensor Open Circuit (40-941) System
FAILURE CODE [DGT1KX] T/C Oil Temperature Electrical
DGT1KX PT L01
Sensor Input Signal Out of Range (40-944) System
FAILURE CODE [DH21KA] W/E Pump Pressure Electrical
DH21KA WE L01
FAILURE CODE [DH21KY] W/E Pump Pressure Electrical
DH21KY WE L01
Sensor Hot Short Circuit (40-949) System
FAILURE CODE [DHA4KA] Air Cleaner Clog Sen- Electrical
DHA4KA MON L01
sor Open Circuit (40-951) System
FAILURE CODE [DHAAMA] KDPF Differential Electrical
DHAAMA ENG -
Pressure Sensor Frozen (40-953) System
FAILURE CODE [DHACMA] KDPF Outlet Pressure Electrical
DHACMA ENG -
Sensor Frozen (40-954) System
40-152 D155AX-8

FAILURE CODE [DHT5KA] T/C Inlet Pressure Sen- Electrical
DHT5KA PT L03
FAILURE CODE [DHT5KY] T/C Inlet Pressure Sen- Electrical
DHT5KY PT L03
sor Hot Short Circuit (40-958) System
FAILURE CODE [DHT7KA] T/C Outlet Pressure Electrical
DHT7KA PT L03
FAILURE CODE [DHT7KY] T/C Outlet Pressure Electrical
DHT7KY PT L03
Sensor Hot Short Circuit (40-963) System
FAILURE CODE [DK10KA] Fuel Control Dial Open Electrical
DK10KA PT L03
FAILURE CODE [DK10KB] Fuel Control Dial Short Electrical
DK10KB PT L03
FAILURE CODE [DK30KA] S/T Potentiometer 1 Electrical
DK30KA PT L03
FAILURE CODE [DK30KX] S/T Potentiometer 1 Electrical
DK30KX PT L04
and 2 Open Circuit or Hot Short Circuit (40-975) System
FAILURE CODE [DK30KY] S/T Potentiometer 1 Hot Electrical
DK30KY PT L03
FAILURE CODE [DK30KZ] S/T Potentiometer 1 and Electrical
DK30KZ PT L04
2 Open Circuit or Hot Short Circuit (40-976) System
FAILURE CODE [DK30L8] S/T Potentiometer 1 or 2 Electrical
DK30L8 PT L03
Signal Abnormality (40-977) System
FAILURE CODE [DK31KA] S/T Potentiometer 2 Electrical
DK31KA PT L03
FAILURE CODE [DK31KY] S/T Potentiometer 2 Hot Electrical
DK31KY PT L03
FAILURE CODE [DK40KA] Brake Pedal Potentiom- Electrical
DK40KA PT L01
eter Open Circuit (40-983) System
FAILURE CODE [DK40KY] Brake Pedal Potentiom- Electrical
DK40KY PT L01
eter Hot Short Circuit (40-986) System
FAILURE CODE [DK55KX] F/R Potentiometer 1 Electrical
DK55KX PT L04
FAILURE CODE [DK55KZ] F/R Potentiometer 1 Electrical
DK55KZ PT L04
FAILURE CODE [DK55L8] F/R Potentiometer 1 or 2 Electrical
DK55L8 PT L03
Signal Abnormality (40-990) System
FAILURE CODE [DK56KA] F/R Potentiometer 1 Electrical
DK56KA PT L03
FAILURE CODE [DK56KY] F/R Potentiometer 1 Hot Electrical
DK56KY PT L03
FAILURE CODE [DK57KA] F/R Potentiometer 2 Electrical
DK57KA PT L03
FAILURE CODE [DK57KY] F/R Potentiometer 2 Hot Electrical
DK57KY PT L03
FAILURE CODE [DKH1KA] Inclination Angle Sen- Electrical
DKH1KA PT L03
D155AX-8 40-153

FAILURE CODE [DKH1KY] Inclination Angle Sen- Electrical
DKH1KY PT L03
sor Hot Short Circuit (40-1004) System
FAILURE CODE [DLM3KA] Fan Speed Sensor Electrical
DLM3KA PT L01
FAILURE CODE [DLM3MB] Fan Speed Sensor Electrical
DLM3MB PT L01
Function Deterioration (40-1009) System
FAILURE CODE [DLT3KA] T/M Output Speed Sen- Electrical
DLT3KA PT L03
FAILURE CODE [DLT3KB] T/M Output Speed Sen- Electrical
DLT3KB PT L03
sor Ground Fault (40-1012) System
FAILURE CODE [DR21KX] Camera 2 Picture Re- Electrical
DR21KX MON L01
verse Drive Input Out of Range (40-1014) System
FAILURE CODE [DR31KX] Camera 3 Picture Re- Electrical
DR31KX MON L01
verse Drive Input Out of Range (40-1015) System
FAILURE CODE [DV20KB] Back Alarm Buzzer Electrical
DV20KB PT L01
FAILURE CODE [DW7BKA] Fan Reverse Solenoid Electrical
DW7BKA PT L01
FAILURE CODE [DW7BKB] Fan Reverse Solenoid Electrical
DW7BKB PT L01
FAILURE CODE [DWN1KA] S/T Control Valve Electrical
DWN1KA PT L03
Right EPC Solenoid Open Circuit (40-1022) System
FAILURE CODE [DWN1KB] S/T Control Valve Electrical
DWN1KB PT L03
Right EPC Solenoid Short Circuit (40-1024) System
FAILURE CODE [DWN1KY] S/T Control Valve Electrical
DWN1KY PT L04
Right EPC Solenoid Hot Short Circuit (40-1026) System
FAILURE CODE [DWN2KA] S/T Control Valve Left Electrical
DWN2KA PT L03
EPC Solenoid Open Circuit (40-1027) System
FAILURE CODE [DWN2KB] S/T Control Valve Left Electrical
DWN2KB PT L03
EPC Solenoid Short Circuit (40-1029) System
FAILURE CODE [DWN2KY] S/T Control Valve Left Electrical
DWN2KY PT L04
EPC Solenoid Hot Short Circuit (40-1031) System
FAILURE CODE [DWN3KA] Sudden Stop Preven- Electrical
DWN3KA PT L04
tion Valve Solenoid Open Circuit (40-1032) System
FAILURE CODE [DWN3KB] Sudden Stop Preven- Electrical
DWN3KB PT L04
tion Valve Solenoid Short Circuit (40-1034) System
FAILURE CODE [DWN3KY] Sudden Stop Preven- Electrical
DWN3KY PT L04
tion Valve Solenoid Hot Short Circuit (40-1036) System
FAILURE CODE [DWN5KA] Fan Control Solenoid 1 Electrical
DWN5KA PT L03
FAILURE CODE [DWN5KB] Fan Control Solenoid 1 Electrical
DWN5KB PT L03
FAILURE CODE [DWN5KY] Fan Control Solenoid 1 Electrical
DWN5KY PT L01
Hot Short Circuit (40-1042) System
FAILURE CODE [DXA2KA] HSS Pump TVC Sole- Electrical
DXA2KA WE L01
noid 1 Open Circuit (40-1044) System
40-154 D155AX-8

FAILURE CODE [DXA2KB] HSS Pump TVC Sole- Electrical
DXA2KB WE L01
noid 1 Short Circuit (40-1046) System
FAILURE CODE [DXA2KY] HSS Pump TVC Sole- Electrical
DXA2KY WE L01
noid 1 Hot Short Circuit (40-1048) System
FAILURE CODE [DXH1KA] Lockup Clutch ECMV Electrical
DXH1KA PT L03
Solenoid Open Circuit (40-1050) System
FAILURE CODE [DXH1KB] Lockup Clutch ECMV Electrical
DXH1KB PT L03
Solenoid Short Circuit (40-1052) System
FAILURE CODE [DXH1KY] Lockup Clutch ECMV Electrical
DXH1KY PT L03
Solenoid Hot Short Circuit (40-1054) System
FAILURE CODE [DXH4KA] T/M 1st Clutch ECMV Electrical
DXH4KA PT L03
FAILURE CODE [DXH4KB] T/M 1st Clutch ECMV Electrical
DXH4KB PT L03
FAILURE CODE [DXH4KY] T/M 1st Clutch ECMV Electrical
DXH4KY PT L03
FAILURE CODE [DXH5KA] T/M 2nd Clutch ECMV Electrical
DXH5KA PT L03
FAILURE CODE [DXH5KB] T/M 2nd Clutch ECMV Electrical
DXH5KB PT L03
FAILURE CODE [DXH5KY] T/M 2nd Clutch ECMV Electrical
DXH5KY PT L03
FAILURE CODE [DXH6KA] T/M 3rd Clutch ECMV Electrical
DXH6KA PT L03
FAILURE CODE [DXH6KB] T/M 3rd Clutch ECMV Electrical
DXH6KB PT L03
FAILURE CODE [DXH6KY] T/M 3rd Clutch ECMV Electrical
DXH6KY PT L03
FAILURE CODE [DXH7KA] T/M Reverse Clutch Electrical
DXH7KA PT L03
ECMV Solenoid Open Circuit (40-1073) System
FAILURE CODE [DXH7KB] T/M Reverse Clutch Electrical
DXH7KB PT L03
ECMV Solenoid Short Circuit (40-1075) System
FAILURE CODE [DXH7KY] T/M Reverse Clutch Electrical
DXH7KY PT L04
ECMV Solenoid Hot Short Circuit (40-1077) System
FAILURE CODE [DXH8KA] T/M Forward Clutch Electrical
DXH8KA PT L03
FAILURE CODE [DXH8KB] T/M Forward Clutch Electrical
DXH8KB PT L03
FAILURE CODE [DXH8KY] T/M Forward Clutch Electrical
DXH8KY PT L04
FAILURE CODE [DXHBKA] Right Brake ECMV Sol- Electrical
DXHBKA PT L04
enoid Open Circuit (40-1085) System
FAILURE CODE [DXHBKB] Right Brake ECMV Sol- Electrical
DXHBKB PT L04
enoid Short Circuit (40-1087) System
FAILURE CODE [DXHBKY] Right Brake ECMV Sol- Electrical
DXHBKY PT L04
enoid Hot Short Circuit (40-1089) System
D155AX-8 40-155

FAILURE CODE [DXHCKA] Left Brake ECMV Sole- Electrical
DXHCKA PT L04
noid Open Circuit (40-1091) System
FAILURE CODE [DXHCKB] Left Brake ECMV Sole- Electrical
DXHCKB PT L04
noid Short Circuit (40-1093) System
FAILURE CODE [DXHCKY] Left Brake ECMV Sole- Electrical
DXHCKY PT L04
noid Hot Short Circuit (40-1095) System
FAILURE CODE [DXHRKA] Blade Lift Raise EPC Electrical
DXHRKA WE L01
FAILURE CODE [DXHRKB] Blade Lift Raise EPC Electrical
DXHRKB WE L01
FAILURE CODE [DXHRKY] Blade Lift Raise EPC Electrical
DXHRKY WE L03
FAILURE CODE [DXHSKA] Blade Lift Lower EPC Electrical
DXHSKA WE L01
FAILURE CODE [DXHSKB] Blade Lift Lower EPC Electrical
DXHSKB WE L01
FAILURE CODE [DXHSKY] Blade Lift Lower EPC Electrical
DXHSKY WE L03
FAILURE CODE [DXHTKA] Blade Tilt Right Head Electrical
DXHTKA WE L01
FAILURE CODE [DXHTKB] Blade Tilt Right Head Electrical
DXHTKB WE L01
FAILURE CODE [DXHTKY] Blade Tilt Right Head Electrical
DXHTKY WE L03
FAILURE CODE [DXHUKA] Blade Tilt Right Bottom Electrical
DXHUKA WE L01
FAILURE CODE [DXHUKB] Blade Tilt Right Bottom Electrical
DXHUKB WE L01
FAILURE CODE [DXHUKY] Blade Tilt Right Bottom Electrical
DXHUKY WE L03
FAILURE CODE [DXHWKA] Ripper Lift Raise EPC Electrical
DXHWKA WE L01
FAILURE CODE [DXHWKB] Ripper Lift Raise EPC Electrical
DXHWKB WE L01
FAILURE CODE [DXHWKY] Ripper Lift Raise EPC Electrical
DXHWKY WE L03
FAILURE CODE [DXHXKA] Ripper Lift Lower EPC Electrical
DXHXKA WE L01
FAILURE CODE [DXHXKB] Ripper Lift Lower EPC Electrical
DXHXKB WE L01
FAILURE CODE [DXHXKY] Ripper Lift Lower EPC Electrical
DXHXKY WE L03
FAILURE CODE [DXHYKA] Ripper Tilt In EPC Sol- Electrical
DXHYKA WE L01
enoid Open Circuit (40-1129) System
FAILURE CODE [DXHYKB] Ripper Tilt In EPC Sol- Electrical
DXHYKB WE L01
enoid Short Circuit (40-1131) System
40-156 D155AX-8

FAILURE CODE [DXHYKY] Ripper Tilt In EPC Sol- Electrical
DXHYKY WE L03
enoid Hot Short Circuit (40-1132) System
FAILURE CODE [DXHZKA] Ripper Tilt Back EPC Electrical
DXHZKA WE L01
FAILURE CODE [DXHZKB] Ripper Tilt Back EPC Electrical
DXHZKB WE L01
FAILURE CODE [DXHZKY] Ripper Tilt Back EPC Electrical
DXHZKY WE L03
FAILURE CODE [DXJ4KA] W/E Lock Solenoid Electrical
DXJ4KA WE L03
FAILURE CODE [DXJ4KB] W/E Lock Solenoid Electrical
DXJ4KB WE L03
FAILURE CODE [DXJ8KA] Blade Tilt Left Bottom Electrical
DXJ8KA WE L01
FAILURE CODE [DXJ8KB] Blade Tilt Left Bottom Electrical
DXJ8KB WE L01
FAILURE CODE [DXJ8KY] Blade Tilt Left Bottom Electrical
DXJ8KY WE L03
FAILURE CODE [DXJ9KA] Blade Tilt Left Head Electrical
DXJ9KA WE L01
FAILURE CODE [DXJ9KB] Blade Tilt Left Head Electrical
DXJ9KB WE L01
FAILURE CODE [DXJ9KY] Blade Tilt Left Head Electrical
DXJ9KY WE L03
FAILURE CODE [DXJAKA] Quick drop solenoid: Electrical
DXJAKA WE L01
Open (40-1154) System
FAILURE CODE [DXJAKB] Quick Drop EPC Sole- Electrical
DXJAKB WE L01
noid Short Circuit (40-1156) System
FAILURE CODE [DXJAKY] Quick Drop EPC Sole- Electrical
DXJAKY WE L01
noid Hot Short Circuit (40-1158) System
FAILURE CODE [DXJBKA] T/C Stator Clutch Electrical
DXJBKA PT L03
FAILURE CODE [DXJBKB] T/C Stator Clutch Electrical
DXJBKB PT L03
FAILURE CODE [DXJBKY] T/C Stator Clutch Electrical
DXJBKY PT L03
• In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
• A component in charge means a controller or the machine monitor that is in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PT: Power train controller
WE: Work equipment controller
KOMTRAX: KOMTRAX terminal
D155AX-8 40-157
• The failure codes that do not have numbers in the action code columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
• The "Category of record" shows the abnormality record into which the failure is classified, the electrical sys-
tem or mechanical system, when it is recorded in the abnormality record of the service menu. For details,
see "Troubleshooting by failure code (Display of code)".
40-158 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [1500L0] T/M Clutches Double Engagement
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF

CODE)
FAILURE CODE [1500L0] T/M Clutches Double Engagement
Action level Failure code Transmission Clutches Double Engagement (Power train controller
Failure
L03 1500L0 system)
• The following codes appeared simultaneously among failure codes related to transmission
clutch (gear speed restricted).
(1) Either one of [DXH4KA] or [DXH4KB], and either one of [DXH5KA] or [DXH5KB]
• The following codes appeared simultaneously among failure codes related to transmission
clutch (travel failure).
(2) Either one of [DXH8KA] or [DXH8KB], and either one of [DXH7KA] and [DXH7KB]
(3) Either one of [DXH6KA] or [DXH6KB], either one of [DXH5KA] or [DXH5KB] and either
Details of
one of [DXH4KA] or [DXH4KB].
failure
(4) [15SALH] and 15SBLH]
(5) Either one of [15SAL1] or [DXH8KY], and either one of [15SBL1] or [DXH7KY]
(6) [15SELH], [15SFLH] and [15SGLH]
(7) Either one of [15SEL1] or [DXH4KY], and either one of [15SFL1] or [DXH5KY].
(8) Either one of [15SEL1] or [DXH4KY], and either one of [15SGL1] or [DXH6KY]
(9) Either one of [15SFL1] or [DXH5KY], and either one of [15SGL1] or [DXH6KY].
Action of
• Controls operations of engine and transmission.
controller
• Auto shift down function does not operate.
• Once machine stops, engine speed is restricted to medium speed (half).
Phenomenon
• Once machine stops, travel can be performed only at the smallest gear speed that can be
on machine
operated.
• Automatic transmission function does not work.
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start engine and perform travel.
No. Cause Procedure, measuring location, criteria and remarks

If other failure codes are also displayed, perform troubleshooting for them.
Defective transmission [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1],

1 [15SFLH], [15SGL1], [15SGLH], [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB],
clutch system
[DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA], [DXH8KB], [DXH4KY],
[DXH5KY], [DXH6KY], [DXH7KY], [DXH8KY]
D155AX-8 40-159
FAILURE CODE [15SAL1] ECMV Release Trouble (Forward) 40 TROUBLESHOOTING
FAILURE CODE [15SAL1] ECMV Release Trouble (Forward)

Failure ECMV Release Trouble (Forward) (Power train controller system)
L03 15SAL1
Details of • Fill switch signal is ON even when output to solenoid circuit of transmission F clutch
failure ECMV is stopped.
Action of • Set to N (NEUTRAL) during R (REVERSE) operation (double engagement prevention).
controller • Controls operations of engine and transmission.
Phenomenon
• Once machine stops, travel is restricted to F1.
on machine
• Fill switch signal status (ON/OFF) of F clutch ECMV can be checked by monitoring func-
tion. (Code: 40906 Transmission fill switch input 1)
• After repairing, check if the failure code is cleared by the following procedure.
Related Procedure: Start engine and perform travel in N (NEUTRAL).
information • Seat (Approx. 50), remove cover under seat.
• First, check for any failure such as clogged power train oil filter.
• Next, check that clutch pressure is normal. For details, see Testing and adjusting "Testing
power train oil pressure".

1. Turn starting switch to OFF position.
Defective F clutch ECMV
1 fill switch (internal short 2. Disconnect connector FFT, and connect T-adapter to male side.
circuit)
Resistance Between FFT (male) (1) and ground (fill switch OFF) Min. 1 MΩ
2. Disconnect connector FFT.
3. Start engine.
2 harness or defective
power train controller If failure code [15SAL1] is still displayed, wiring harness has ground fault or power
train controller is defective (If failure code [15SAL1] goes out, Ｆ clutch fill switch is
defective).
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness
3 2. Disconnect connectors PTCN2 and FFT, and connect T-adapters to either
(contact with ground cir- female side.
cuit)
Between ground and PTCN2 (female) (5) or FFT (fe-
Resistance Min. 1 MΩ
male) (1)
40-160 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SAL1] ECMV Release Trouble (Forward)

If any failure is found by check on Cause 2 and failure code is still displayed after
above checks on Cause 3, power train controller is defective.
• Reference
3. Start engine.
REMARK
Defective power train Keep joystick (steering, directional, and gear shift lever) in N.
4
controller Voltage Between PTCN2 (5) and ground 7 to 11 V
3. Start engine.
4. While depressing brake, operate joystick (steering, directional, and gear
shift lever) to perform troubleshooting.
Between PTCN2 (5) and
Voltage F1/F2/F3 Max. 1 V
ground
Circuit diagram related to travel forward clutch ECMV
D155AX-8 40-161
FAILURE CODE [15SALH] ECMV Engage Trouble (Forward) 40 TROUBLESHOOTING
FAILURE CODE [15SALH] ECMV Engage Trouble (Forward)

Failure ECMV Engage Trouble (Forward) (Power train controller system)
L03 15SALH
Details of • Fill switch signal is OFF even when outputting to solenoid circuit of transmission F clutch
failure ECMV.
Action of • Set to N (NEUTRAL) during F (FORWARD) operation (defective engagement prevention).
Phenomenon
• Once machine stops, travel is restricted to R1.
on machine
• Fill switch signal status (ON/OFF) of F clutch ECMV can be checked by monitoring func-
Related Procedure: Start engine and perform travel F (FORWARD).
information • Seat (Approx. 50), remove cover under seat.
• Next, check that clutch pressure is normal. For details, see Testing and adjusting “Testing
power train oil pressure”.

2. Disconnect connector FFT, and connect T-adapter to male side.
REMARK
Hold the joystick (steering, directional and gear shift lever) at N.
Defective F clutch ECMV Resistance Between FFT (male) (1) and ground Min. 1 MΩ
1 fill switch (cannot turn
ON)
2. Disconnect connector FFT, and connect T-adapter to male side.
4. With the brake depressed, manipulate the joystick (steering, directional
and gear shift lever) for check.
Between FFT (male) (1)
Resistance F1/F2/F3 Max. 1 Ω
and ground
Open circuit in wiring har-
ness 2. Disconnect connectors PTCN2 and FFT, and connect T-adapters to each
2
(Wire breakage or defec- female side.
tive contact of connector) Resistance Between PTCN2 (female) (5) and FFT (female) (1) Max. 1 Ω
40-162 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SALH] ECMV Engage Trouble (Forward)

Reference
3. Start engine.
REMARK
Keep joystick (steering, directional, and gear shift lever) in N.
Defective power train Voltage Between PTCN2 (5) and ground 7 to 11 V
3
controller
3. Start engine.
ground
Circuit diagram related to travel forward clutch ECMV
D155AX-8 40-163
FAILURE CODE [15SBL1] ECMV Release Trouble (Reverse) 40 TROUBLESHOOTING
FAILURE CODE [15SBL1] ECMV Release Trouble (Reverse)

Failure ECMV Release Trouble (Reverse) (Power train controller system)
L03 15SBL1
Details of • Fill switch signal is ON even when output to solenoid circuit of transmission R clutch
Action of • Set to N (NEUTRAL) during F (FORWARD) operation (double engagement prevention).
Phenomenon
• Once machine stops, travel is restricted to R1.
on machine
• Fill switch signal status (ON/OFF) of R clutch ECMV can be checked by monitoring func-
information • Seat (Approx. 50 kg), remove cover under seat.

Defective R clutch ECMV
1 fill switch (internal short 2. Disconnect connector FRT, and connect T-adapter to male side.
circuit)
Resistance Between FRT (male) (1) and ground (fill switch OFF) Min. 1 MΩ
2. Disconnect connector FRT.
3. Start engine.
power train controller If failure code [15SBL1] is still displayed, wiring harness has ground fault or power
train controller is defective (If failure code [15SBL1] goes out, R clutch fill switch is
defective).
quired.
3 harness (contact with 2. Disconnect connectors PTCN2 and FRT, and connect T-adapter to either
ground circuit) female side.
Between ground and PTCN2 (female) (36) or FRT (fe-
male) (1)
40-164 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SBL1] ECMV Release Trouble (Reverse)

• Reference
3. Start engine.
REMARK
4
3. Start engine.
ground
Circuit diagram related to reverse clutch ECMV
D155AX-8 40-165
FAILURE CODE [15SBLH] ECMV Engage Trouble (Reverse) 40 TROUBLESHOOTING
FAILURE CODE [15SBLH] ECMV Engage Trouble (Reverse)

Failure ECMV Engage Trouble (Reverse) (Power train controller system)
L03 15SBLH
Details of • Fill switch signal is OFF even when outputting to solenoid circuit of transmission R clutch
failure ECMV.
Action of • Set to N (NEUTRAL) during R (REVERSE) operation (defective engagement prevention).
Phenomenon
• Once machine stops, travel is restricted to F1.
on machine
• Fill switch signal status (ON/OFF) of R clutch ECMV can be checked by monitoring func-
Related Procedure: Start engine and perform travel R (REVERSE).
• First, check for any failure such s clogged power train oil filter.

2. Disconnect connector FRT, and connect T-adapter to male side.
REMARK
Hold the joystick (steering, directional and gear shift lever) at N.
Defective R clutch ECMV Resistance Between FRT (male) (1) and ground Min. 1 MΩ
1 fill switch (cannot turn
ON)
2. Disconnect connector FRT, and connect T-adapter to male side.
4. With the brake depressed, manipulate the joystick (steering, directional
and gear shift lever) for check.
Between FRT (male) (1)
Resistance F1/F2/F3 Max. 1 Ω
and ground
Open circuit in wiring har- 2. Disconnect connectors PTCN2 and FRT, and connect T-adapters to each
2 ness (wire breakage or
female side.
defective contact)
Resistance Between PTCN2 (female) (36) and FRT (female) (1) Max. 1 Ω
40-166 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SBLH] ECMV Engage Trouble (Reverse)

3. Start engine.
REMARK
Voltage Between PTCN2 (36) and ground 7 to 11 V
Defective power train
3
controller 1. Turn starting switch to OFF position.
3. Start engine.
ground
Circuit diagram related to reverse clutch ECMV
D155AX-8 40-167
FAILURE CODE [15SEL1] ECMV Release Trouble (1st) 40 TROUBLESHOOTING
FAILURE CODE [15SEL1] ECMV Release Trouble (1st)

Failure ECMV Release Trouble (1st) (Power train controller system)
L03 15SEL1
Details of • Fill switch signal is ON even when output to solenoid circuit of transmission 1st clutch
Action of
controller
Phenomenon
• Once machine stops, travel is restricted to F1 and R1.
on machine
• Fill switch signal status (ON/OFF) of 1st clutch ECMV can be checked by monitoring func-
1st clutch ECMV fill 1. Turn starting switch to OFF position.

1 switch 2. Disconnect connector F1T, and connect T-adapter to male side.
(Internal short circuit) Resistance Between F1T (male) (1) and ground (fill switch OFF) Min. 1 MΩ
2. Disconnect connector F1T
3. Start engine.
power train controller If failure code [15SEL1] is still displayed, wiring harness has ground fault or power
train controller is defective (If failure code [15SEL1] goes out, 1st clutch fill switch is
defective).
quired.
3 harness (contact with 2. Disconnect connectors PTCN2 and F1T, and connect T-adapter to either
Between ground and PTCN2 (female) (35) or F1T (fe-
male) (1)
40-168 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SEL1] ECMV Release Trouble (1st)

If “any failure is found by check on Cause 2” and “failure code is still displayed after
above checks on Cause 3”, power train controller is defective.
• Reference
3. Start engine.
REMARK
4
3. Start engine.
Voltage F1/R1 Max. 1 V
ground
Circuit diagram related to 1st Clutch ECMV
D155AX-8 40-169
FAILURE CODE [15SELH] ECMV Engage Trouble (1st) 40 TROUBLESHOOTING
FAILURE CODE [15SELH] ECMV Engage Trouble (1st)

Failure ECMV Engage Trouble (1st) (Power train controller system)
L03 15SELH
Details of • Fill switch signal is OFF even when outputting to solenoid circuit of transmission 1st clutch
failure ECMV.
Action of
controller
Phenomenon
on machine
• Fill switch signal status (ON/OFF) of 1st clutch ECMV can be checked by monitoring func-
Related Procedure: Start engine and perform F1 or R1 travel.

2. Disconnect connector F1T, and connect T-adapter to male side.
3. Start engine.
REMARK
Joystick (steering, directional and gear shift lever) is in NEUTARL.
1st clutch ECMV fill Resistance Between F1T (male) (1) and ground Min. 1 MΩ
1 switch
(It is not turned to ON)
3. Start engine.
4. Perform troubleshooting by operating joystick (steering, directional and
gear shift lever) while depressing the brake pedal.
Between F1T (male) (1)
Resistance F1/R1 Max. 1 Ω
and ground
Open circuit in wiring har- 2. Disconnect connectors PTCN2 and F1T, and connect T-adapters to each
female side.
defective contact)
Resistance Between PTCN2 (female) (35) and F1T (female) (1) Max. 1 Ω
40-170 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SELH] ECMV Engage Trouble (1st)

3. Start engine.
REMARK
3
3. Start engine.
ground
Circuit diagram related to 1st Clutch ECMV
D155AX-8 40-171
FAILURE CODE [15SFL1] ECMV Release Trouble (2nd) 40 TROUBLESHOOTING
FAILURE CODE [15SFL1] ECMV Release Trouble (2nd)

Failure ECMV Release Trouble (2nd) (Power train controller system)
L03 15SFL1
Details of • Fill switch signal is ON even when output to solenoid circuit of transmission 2nd clutch
Action of
controller
Phenomenon
on machine
• Fill switch signal status (ON/OFF) of 2nd clutch ECMV can be checked by monitoring
function. (Code: 40906 Transmission fill switch input 1)

2nd clutch ECMV fill
1 switch (Internal short cir- 2. Disconnect connector F2T, and connect T-adapter to male side.
cuit)
Resistance Between F2T (male) (1) and ground (fill switch OFF) Min. 1 MΩ
2. Disconnect connector F2T
3. Start engine.
power train controller If failure code [15SFL1] is still displayed, wiring harness has ground fault or power
train controller is defective (If failure code [15SFL1] goes out, 2nd clutch fill switch
is defective).
quired.
harness
3 2. Disconnect connectors PTCN2 and F2T, and connect T-adapter to either
cuit)
male) (1)
40-172 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SFL1] ECMV Release Trouble (2nd)

• Reference
3. Start engine.
REMARK
4
3. Start engine.
ground
Circuit diagram related to 2nd Clutch ECMV
D155AX-8 40-173
FAILURE CODE [15SFLH] ECMV Engage Trouble (2nd) 40 TROUBLESHOOTING
FAILURE CODE [15SFLH] ECMV Engage Trouble (2nd)

Failure ECMV Engage Trouble (2nd) (Power train controller system)
L03 15SFLH
Details of • Fill switch signal is OFF even when outputting to solenoid circuit of transmission 2nd
failure clutch ECMV.
Action of
controller
Phenomenon
on machine

3. Start engine.
REMARK
2nd clutch ECMV fill Resistance Between F2T (male) (1) and ground Min. 1 MΩ
1 switch (It is not turned to
ON)
3. Start engine.
and ground
ness 2. Disconnect connectors PTCN2 and F2T, and connect T-adapters to each
2
tive contact of connector) Resistance Between PTCN2 (female) (25) and F2T (female) (1) Max. 1 Ω
40-174 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SFLH] ECMV Engage Trouble (2nd)

3. Start engine.
REMARK
3
3. Start engine.
ground
Circuit diagram related to 2nd Clutch ECMV
D155AX-8 40-175
FAILURE CODE [15SGL1] ECMV Release Trouble (3rd) 40 TROUBLESHOOTING
FAILURE CODE [15SGL1] ECMV Release Trouble (3rd)

Failure ECMV Release Trouble (3rd) (Power train controller system)
L03 15SGL1
Details of • Fill switch signal is ON even when output to solenoid circuit of transmission 3rd clutch
Action of
controller
Phenomenon
on machine
• Signal status (Connect/Disconnect) of 3rd clutch ECMV fill switch can be checked by mon-
itoring function. (Code: 40906 Transmission fill switch input 1)
3rd clutch ECMV fill 1. Turn starting switch to OFF position.

1 switch 2. Disconnect connector F3T, and connect T-adapter to male side.
(Internal short circuit) Resistance Between F3T (male) (1) and ground (fill switch OFF) Min. 1 MΩ
2. Disconnect connector F3T.
3. Start engine.
power train controller If failure code [15SGL1] is still displayed, wiring harness has ground fault or power
train controller is defective (If failure code [15SGL1] goes out, 3rd clutch fill switch
is defective).
quired.
harness
3 2. Disconnect connectors PTCN2 and F3T, and connect T-adapter to either
cuit)
male) (1)
40-176 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SGL1] ECMV Release Trouble (3rd)

• Reference
3. Start engine.
REMARK
4
3. Start engine.
ground
Circuit diagram related to 3rd Clutch ECMV
D155AX-8 40-177
FAILURE CODE [15SGLH] ECMV Engage Trouble (3rd) 40 TROUBLESHOOTING
FAILURE CODE [15SGLH] ECMV Engage Trouble (3rd)

Failure ECMV Engage Trouble (3rd) (Power train controller system)
L03 15SGLH
Details of • Fill switch signal is OFF even when outputting to solenoid circuit of transmission 3rd clutch
failure ECMV.
Action of
controller
Phenomenon
on machine
information • Seat (Approx.50 kg), remove cover under seat.

3. Start engine.
REMARK
3rd clutch ECMV fill Resistance Between F3T (male) (1) and ground Min. 1 MΩ
1 switch
(It is not turned to ON)
3. Start engine.
and ground
ness 2. Disconnect connectors PTCN2 and F3T, and connect T-adapters to each
2
tive contact of connector) Resistance Between PTCN2 (female) (15) and F3T (female) (1) Max. 1 Ω
40-178 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SGLH] ECMV Engage Trouble (3rd)

3. Start engine.
REMARK
3
3. Start engine.
ground
Circuit diagram related to 3rd Clutch ECMV
D155AX-8 40-179
FAILURE CODE [15SJL1] ECMV Release Trouble (Lock Up Clutch) 40 TROUBLESHOOTING
FAILURE CODE [15SJL1] ECMV Release Trouble (Lock Up Clutch)

Action level Failure code ECMV Release Trouble (Lock Up Clutch) (Power train controller sys-
Failure
L03 15SJL1 tem)
Details of • Fill switch signal is ON even when output to solenoid circuit of torque converter lockup
failure clutch ECMV is stopped.
Action of
• Forbids lockup.
controller
• Engine may stall during travel operation.
• Lockup function of torque converter does not operate.
Phenomenon
on machine
• Fill switch signal status of lockup clutch ECMV can be checked by monitoring function.
(Code: 31520 Transmission fill switch input 2)
Related Procedure: Start engine and perform travel R (REVERSE) (automatic gear shift mode).

Lockup clutch ECMV fill
2. Disconnect connector FLUC, and connect T-adapter to male side.
1 switch
(internal short circuit) Between FLUC (male) (1) and ground (Turn fill switch
to OFF position.)
2. Disconnect connector FLUC.
3. Start engine.
2 harness or defective REMARK
power train controller Keep joystick (steering, directional, and gear shift lever) in N.
If failure code [15SJL1] is still displayed, wiring harness has ground fault or power
train controller is defective (If failure code [15SJL1] goes out, lockup clutch fill
switch is defective).
quired.
harness
3 2. Disconnect connectors PTCN2 and FLUC, and connect T-adapter to either
cuit)
Between ground and PTCN2 (female) (2) or FLUC (fe-
male) (1)
40-180 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SJL1] ECMV Release Trouble (Lock Up Clutch)

• Reference
3. Start engine.
REMARK
Defective power train 1. Turn starting switch to OFF position.
4
controller 2. Insert T-adapter into connector PTCN2.
3. Start engine.
4. Raise tracks off the ground.
5. Travel (in automatic gear shift mode) in R1 (reverse) and operate lockup to
perform troubleshooting.
REMARK
See “Testing and adjusting, Testing power train oil pressure”, (4) “Testing torque
converter lockup clutch pressure” (LU).
Voltage R1 Max. 1 V
ground
Circuit diagram related to lockup clutch ECMV solenoid
D155AX-8 40-181
FAILURE CODE [15SJLH] ECMV Engage Trouble (Lock Up Clutch) 40 TROUBLESHOOTING
FAILURE CODE [15SJLH] ECMV Engage Trouble (Lock Up Clutch)

Action level Failure code ECMV Engage Trouble (Lock Up Clutch) (Power train controller sys-
Failure
L03 15SJLH tem)
Details of • Fill switch signal is OFF even when outputting to solenoid circuit of torque converter lock-
failure up clutch ECMV.
Action of
• Forbids lockup.
controller
• Lockup function of torque converter does not operate.
Phenomenon • Once machine stops, engine speed is restricted to medium speed (half).
on machine • Once machine stops, travel is restricted to F1 and R1.
• Fill switch signal status of lockup clutch ECMV can be checked by monitoring function.
(Code: 31520 Transmission fill switch input 2)
Related Procedure: Start engine and perform travel R (REVERSE) (automatic gear shift mode).

2. Disconnect connector FLUC, and connect T-adapter to male side.
3. Start engine.
Lockup clutch ECMV fill
5. Perform R1 travel (automatic gear shift mode), and then perform trouble-
switch
1 shooting while operating lockup.
(Do not turn to ON posi-
tion.) REMARK
For details, see "6) Testing torque converter oil lockup clutch pressure (LU) in
Testing and adjusting "Testing power train oil pressure".
Between FLUC (male) (1) and ground (Turn fill switch
Resistance Max. 1 Ω
to ON position.)
ness 2. Disconnect connectors PTCN2 and FLUC, and connect T-adapters to
2
(Wire breakage or defec- each female side.
tive contact of connector) Resistance Between PTCN2 (female) (2) and FLUC (female) (1) Max. 1 Ω
40-182 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [15SJLH] ECMV Engage Trouble (Lock Up Clutch)

If failure code is still displayed after above checks, power train controller is defec-
tive.
• Reference
3. Start engine.
REMARK
3
3. Start engine.
5. Travel (in automatic gear shift mode) in R1 (reverse) and operate lockup to
perform troubleshooting.
REMARK
See “Testing and adjusting, Testing power train oil pressure”, (4) “Testing torque
converter lockup clutch pressure” (LU).
Voltage R1 Max. 1 V
ground
Circuit diagram related to lockup clutch ECMV solenoid
D155AX-8 40-183
FAILURE CODE [1800MW] P/T Clutch Slip 40 TROUBLESHOOTING
FAILURE CODE [1800MW] P/T Clutch Slip

Failure Power Train Clutch Slip (Power train controller system)
L03 1800MW
Details of There is no harmonization between detected values of engine speed and transmission output speed
failure during torque converter lockup.
Action of
Controls operations of engine and transmission.
controller
Phenomenon
• Once machine stops, travel speed is restricted to F1 and R1.
on machine
• Engine speed status and transmission output speed status can be checked by monitoring
function. Code: 01002 engine speed, Code: 31400 transmission output speed (torque con-
Related
verter speed)
information
Procedure: Start engine and perform travel R (REVERSE) (automatic gear shift mode).

Slipping of power train Since slipping of clutch is detected, investigate cause, inspect damage of machine,
1 clutch (when system is and repair.
normal)
Defective engine Ne If failure code [CA689] or [CA778] is displayed, perform troubleshooting for the
2
speed sensor system code first.
Defective transmission If failure codes [DLT3KA] or [DLT3KB] is displayed, perform troubleshooting these
3
speed sensor system first.
Defective power train Since this is an internal failure, troubleshooting cannot be performed.
4
controller
40-184 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [2300NR] Brake Thermal Load Abnormality
FAILURE CODE [2300NR] Brake Thermal Load Abnormality

Failure Brake Thermal Load Abnormality (Power train controller system)
- 2300NR
Details of Power train controller judges abnormal heat from brake based on angle of inclination, travel speed,
failure duration of brake pedal operation, etc.
Action of
None in particular
controller
Phenomenon
-
on machine
Related
-
information

Improper brake operation Downhill travel is continued with brake pedal depressed.
1
when traveling downhill
Defective power train When operation for Cause 1 is not performed
2
controller
D155AX-8 40-185
FAILURE CODE [2301L1] ECMV Release Trouble (RH Brake) 40 TROUBLESHOOTING
FAILURE CODE [2301L1] ECMV Release Trouble (RH Brake)

Failure ECMV Release Trouble (RH Brake) (Power train controller system)
L04 2301L1
Details of Fill switch signal is ON even when output to solenoid circuit of R.H. steering brake ECMV is stop-
failure ped.
Action of • Restricts of engine, transmission, and brake operations.

controller • Operates sudden stop prevention valve.
on machine • Once machine stops, no travel operation cannot be performed.
• Fill switch signal status (ON/OFF) of R.H. steering brake ECMV can be checked by moni-
toring function. (Code: 31521 Steering fill switch input)
Related Procedure: Start engine.

Defective fill switch of
right steering brake 2. Turn starting switch to OFF position.
1
ECMV (internal short cir-
Between FBRR (male) (1) and ground (Turn fill switch
cuit) Resistance Min. 1 MΩ
to OFF position.)
2. Disconnect connector FBRR.
Ground fault in wiring 3. Start engine.
power train controller If failure code [2301L1] is displayed again, ground fault in wiring harness is detect-
ed or power train controller is defective.
If failure code [2301L1] is cleared, fill switch of right steering brake is defective.
NOTICE
If failure code is still displayed after above checks on cause 2, this check
is not required.
3 harness (contact with
ground circuit) 2. Disconnect connectors PTCN2 and FBRR, and connect T-adapter to either
female side.
Between ground and PTCN2 (female) (37) or FBRR
(female) (1)
40-186 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [2301L1] ECMV Release Trouble (RH Brake)

• Reference
3. Start engine.
4. Parking brake released
REMARK
4 Keep joystick (steering, directional, and gear shift lever) in N.
controller
Voltage Between PTCN2 (37) and ground Max. 1 V
3. Start engine.
5. Perform troubleshooting while depressing brake.
Circuit diagram related to right steering brake ECMV
D155AX-8 40-187
FAILURE CODE [2301LH] ECMV Engage Trouble (RH Brake) 40 TROUBLESHOOTING
FAILURE CODE [2301LH] ECMV Engage Trouble (RH Brake)

Failure ECMV Engage Trouble (RH Brake) (Power train controller system)
L04 2301LH
Details of
Fill switch signal is OFF even when outputting to solenoid circuit of R.H. steering brake ECMV.
failure
• Fill switch signal status (ON/OFF) of R.H. steering brake ECMV can be checked by moni-
toring function. (Code: 31521 Steering fill switch input)
Related Procedure: Start engine and release parking brake.

2. Disconnect connector FBRR, and connect T-adapter to male side.
Defective fill switch of 2. Disconnect connector FBRR, and connect T-adapter to male side.
right steering brake 3. Start engine.
1
ECMV (Do not turn to ON
position.) 4. Joystick (steering, directional and gear shift lever) is in NEUTARL.
5. Release parking brake.
Between FBRR (male) (1) and ground Min. 1 MΩ
Resistance
Between FBRR (male) (1) and ground Max. 1 Ω
Open circuit in wiring har- 2. Disconnect connectors PTCN2 and FBRR, and connect T-adapters to
each female side.
defective contact)
Resistance Between PTCN2 (female) (37) and FBRR (female) (1) Max. 1 Ω
40-188 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [2301LH] ECMV Engage Trouble (RH Brake)

3. Start engine.
REMARK
3 Voltage Between PTCN2 (37) and ground Max. 1 V
controller
3. Start engine.
Circuit diagram related to right steering brake ECMV
D155AX-8 40-189
FAILURE CODE [2302L1] ECMV Release Trouble (LH Brake) 40 TROUBLESHOOTING
FAILURE CODE [2302L1] ECMV Release Trouble (LH Brake)

Failure ECMV Release Trouble (LH Brake) (Power train controller system)
L04 2302L1
Details of Fill switch signal is ON even when output to solenoid circuit of L.H. steering brake clutch ECMV is
failure stopped.

• Fill switch signal status (ON/OFF) of L.H. steering brake clutch ECMV can be checked by
monitoring function. (Code: 31521 Steering fill switch input)

Defective left steering
1 brake ECMV fill switch 2. Turn starting switch to OFF position.
(internal short circuit)
Resistance Between FBRL (male) (1) and ground (fill switch OFF) Min. 1 MΩ
2. Disconnect connector FBRL.
Ground fault of wiring 3. Start engine.
power train controller If failure code [2302L1] is still displayed, wiring harness may be grounded or power
train controller is defective.
If failure code [2302L1] disappears, left steering brake fill switch is defective.
NOTICE
is not required.
ground circuit) 2. Disconnect connectors PTCN2 and FBRL, and connect T-adapter to either
female side.
Between ground and PTCN2 (female) (6) or FBRL (fe-
male) (1)
40-190 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [2302L1] ECMV Release Trouble (LH Brake)

• Reference
3. Start engine.
REMARK
4 Keep joystick (steering, directional, and gear shift lever) in N.
controller
3. Start engine.
Circuit diagram related to left steering brake ECMV
D155AX-8 40-191
FAILURE CODE [2302LH] ECMV Engage Trouble (LH Brake) 40 TROUBLESHOOTING
FAILURE CODE [2302LH] ECMV Engage Trouble (LH Brake)

Failure ECMV Engage Trouble (LH Brake) (Power train controller system)
L04 2302LH
Details of Fill switch signal is OFF even when outputting to solenoid circuit of L.H. steering brake clutch
failure ECMV.

• Fill switch signal status (ON/OFF) of L.H. steering brake clutch ECMV can be checked by
monitoring function. (Code: 31521 Steering fill switch input)
Related Procedure: Start engine and release parking brake lever.

2. Disconnect connector FBRL and connect T-adapter to male side.
2. Disconnect connector FBRL and connect T-adapter to male side.
1 brake ECMV fill switch (It 3. Start engine.
does not turn ON) 4. Put joystick (steering, directional and gear shift lever) in NEUTRAL.
5. Release parking brake.
Between FBRL (male) (1) and ground Min. 1 MΩ
Resistance
Between FBRL (male) (1) and ground Max. 1 Ω
ness (wire breakage or 2. Disconnect connectors PTCN2 and FBRL, and connect T-adapters to each
2
defective contact of con- female side.
nector)
Resistance Between PTCN2 (female) (6) or FBRL (female) (1) Max. 1 Ω
40-192 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [2302LH] ECMV Engage Trouble (LH Brake)

3. Start engine.
REMARK
3 Voltage Between PTCN2 (6) and ground Max. 1 V
controller
3. Start engine.
Circuit diagram related to left steering brake ECMV
D155AX-8 40-193
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor
Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open

Circuit
Action level Failure code Air Conditioner Recirculation Air Temperature Sensor Open Circuit
Failure
- 879AKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in recirculation air temperature sensor.
failure
Air conditioner controller transmits open circuit information of recirculation air temperature sensor to
Action of
machine monitor by CAN communication.
controller
Stops air conditioner when in automatic air conditioner mode.
Since air conditioner recirculation air temperature sensor has open circuit, automatic air conditioner
Phenomenon
does not operate.
on machine
(Air conditioner can be operated in manual mode.)
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in “SERV-
information ICE MODE” of machine monitor.
• Since connector of air conditioner recirculation air temperature sensor cannot be checked
when it is mounted on machine, troubleshooting cannot be performed.

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner controller may be defective. (In case of an internal defect, trouble-
2
unit shooting is impossible as an assembly. Replace whole assembly.)
40-194 D155AX-8
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor
40 TROUBLESHOOTING Short Circuit
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short

Circuit
Action level Failure code Air Conditioner Recirculation Air Temperature Sensor Short Circuit
Failure
- 879AKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in recirculation air temperature sensor.
failure
Air conditioner controller transmits short circuit information of recirculation air temperature sensor to
Action of
machine monitor by CAN communication.
controller
Stops air conditioner when in automatic air conditioner mode.
Since air conditioner recirculation air temperature sensor has short circuit, automatic air conditioner
Phenomenon
does not operate.
on machine
(Air conditioner can be operated in manual mode)
Related • Check if this failure code is displayed on electrical system failure record screen in “SERV-
information ICE MODE” of machine monitor.
• Since connector of air conditioner recirculation air temperature sensor cannot be checked
when it is mounted on machine, troubleshooting cannot be performed.

controller
2
D155AX-8 40-195
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open
Circuit 40 TROUBLESHOOTING
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit
Action level Failure code Air Conditioner Fresh Air Temperature Sensor Open Circuit
Failure
- 879BKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in outside air temperature sensor.
failure
Air conditioner controller transmits open circuit information of outside air temperature sensor to ma-
Action of chine monitor by CAN communication.
controller Ignores data of outside air temperature sensor and continues control of air conditioner in automatic
air conditioner mode.
Since air conditioner outside air temperature sensor has open circuit, outside air temperature is not
Phenomenon
considered in automatic air conditioner mode.
on machine
(Air conditioner is not affected in manual mode.)
• Check if this failure code is displayed on electrical system failure record screen in service
mode of machine monitor.
Related • For each connector, see “Installation locations of air conditioner parts and arrangement of
connectors”.
information
• Since air conditioner controller connector ACECU has no T-adapter and has small pins,
perform troubleshooting by using intermediate connector (although intermediate connector
has no T-adapter either, it has large pins).
• When replacing air conditioner harness between air conditioner controller connector ACE-
CU and intermediate connector, replace air conditioner unit.

2. Disconnect connector T0A.
Defective fresh air tem-
1
perature sensor Approxi-
Between T0A (male) (1)
Resistance 25 °C mately.
and (2)
1.7 kΩ
2. Disconnect connector AC01.
Open or short circuit in
2
wiring harness Approxi-
Between AC01 (female)
(3) and (4)
1.7 kΩ
quired.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or
3 2. Disconnect connectors T0A and AC01.
defective contact of con-
nector) Between AC01 (female) (3) and T0A (female) (2) Max. 1 Ω
Resistance
Between AC01 (female) (4) and T0A (female) (1) Max. 1 Ω
If failure code is still displayed after above checks, air conditioner controller is de-
4 fective. (In case of an internal defect, troubleshooting is impossible as an assembly.
controller
Replace whole assembly.)
If failure code is still displayed after above checks, air conditioner unit may be de-
unit
40-196 D155AX-8
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open
40 TROUBLESHOOTING Circuit
Circuit diagram related to air conditioner fresh air temperature sensor
D155AX-8 40-197
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit
Action level Failure code Air Conditioner Fresh Air Temperature Sensor Short Circuit
Failure
- 879BKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in outside air temperature sensor.
failure
Air conditioner controller transmits short circuit information of outside air temperature sensor to ma-
Action of chine monitor by CAN communication.
controller Ignores data of outside air temperature sensor and continues control of air conditioner in automatic
air conditioner mode.
Since air conditioner outside air temperature sensor has short circuit, outside air temperature is not
Phenomenon
considered in automatic air conditioner mode.
on machine
Related • For each connector, see “Installation locations of air conditioner parts and arrangement of
connectors”.
information
• Since air conditioner controller connector ACECU has no T-adapter and has small pins,

2. Disconnect connector T0A.
Defective fresh air tem-
1
perature sensor Approxi-
Between T0A (male) (1)
and (2)
1.7 kΩ
2. Disconnect connector AC01.
2
wiring harness Approxi-
Between AC01 (female)
(3) and (4)
1.7 kΩ
quired.
Short circuit in wiring har- 1. Turn starting switch to OFF position.
3
ness 2. Disconnect connectors T0A and AC01.
Between AC01 (female) (3) and (4), or between T0A

(female) (1) and (2)
Ground fault in wiring 2. Disconnect connectors T0A and AC01.
4
harness
Between ground and AC01 (female) (3) or T0A (fe-
male) (2)
40-198 D155AX-8
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short

controller
unit
Circuit diagram related to air conditioner fresh air temperature sensor
D155AX-8 40-199
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit

Action level Failure code Ventilating sensor Open Circuit
Failure
- 879CKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in evaporator temperature (frost) sensor.
failure
Air conditioner controller transmits open circuit information of evaporator temperature (frost) sensor
Action of
to machine monitor by CAN communication.
controller
Stops air conditioner.
Phenomenon
Air conditioner does not operate because of open circuit in evaporator temperature (frost) sensor.
on machine
Related • Check if this failure code is displayed on electrical system failure record screen in service
information mode of machine monitor.
• Since connector of air conditioner evaporator temperature (frost) sensor cannot be
checked when it is mounted on machine, troubleshooting cannot be performed.

controller
2
40-200 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [879CKB] Ventilating Sensor Short Circuit
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit

Action level Failure code Ventilating sensor Short Circuit
Failure
- 879CKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in evaporator temperature (frost) sensor.
failure
• Air conditioner controller transmits short circuit information of evaporator temperature
Action of
(frost) sensor to machine monitor by CAN communication.
controller
• Stops air conditioner.
Phenomenon
Air conditioner does not operate because of short circuit in evaporator temperature (frost) sensor.
on machine
• Since connector of air conditioner evaporator temperature (frost) sensor cannot be
checked when it is mounted on machine, troubleshooting cannot be performed.

controller
2
D155AX-8 40-201
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Cir-
cuit 40 TROUBLESHOOTING
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit

Action level Failure code Sunlight Sensor Open Circuit or Short Circuit
Failure
- 879DKZ (Machine monitor system)
Details of
Air conditioner controller detects open or short circuit in sunlight sensor.
failure
Air conditioner controller transmits open or short circuit information of sunlight sensor to machine
Action of monitor by CAN communication.
controller Ignores data of sunlight sensor and continues control of air conditioner in automatic air conditioner
mode.
Since air conditioner sunlight sensor has open or short circuit, sunlight intensity is not considered in
Phenomenon
automatic air conditioner mode.
on machine
• For each connector, see 80 APPENDIX, “Installation locations of air conditioner parts and
Related arrangement of connectors”.
information • Since air conditioner controller connector ACECU has no T-adapter and has small pins,
• T-adapter is not provided for connectors of sunlight sensor.

See 80 APPENDIX, “Testing sunlight sensor”.
Approx.
Direct sunlight
0.55 V
1 Defective sunlight sensor Between sunlight sensor Approx.
Voltage Cloudy
terminals 0.45 V
Approx.
Indoor
0.4 V
See 80 APPENDIX, “TEST SUNLIGHT SENSOR”.
ness (wire breakage or 2. Disconnect connector SLS.
2
nector) Between SLS (female) (1) and AC01 (female) (1) Max. 1 Ω
Resistance
Between SLS (female) (2) and AC01 (female) (2) Max. 1 Ω
controller
unit
40-202 D155AX-8
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Cir-
40 TROUBLESHOOTING cuit
Circuit diagram related to sunlight sensor
D155AX-8 40-203
FAILURE CODE [879EMC] Ventilation Damper Malfunction 40 TROUBLESHOOTING
FAILURE CODE [879EMC] Ventilation Damper Malfunction

Action level Failure code Ventilation Damper Malfunction
Failure
L01 879EMC (Machine monitor system)
Details of Air conditioner controller detects no rotation of vent selector (mode) damper servomotor, judging
failure from potentiometer voltage of servomotor.
Action of Air conditioner controller transmits abnormality of vent selector (mode) damper to machine monitor
controller by CAN communication.
Phenomenon
Vent (mode) cannot be selected, but air conditioner operates.
on machine
• Since connector of vent selector (mode) damper servomotor cannot be checked when it is
mounted on machine, troubleshooting cannot be performed.

controller
2
40-204 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [879FMC] Air Mix Damper Malfunction
FAILURE CODE [879FMC] Air Mix Damper Malfunction

Action level Failure code Air Mix Damper Malfunction
Failure
L01 879FMC (Machine monitor system)
Details of Air conditioner controller detects no rotation of air mix (temperature regulator) damper servomotor,
failure judging from potentiometer voltage of servomotor.
Action of Air conditioner controller transmits abnormality of air mix damper to machine monitor by CAN com-
controller munication.
Phenomenon
Air conditioner does not operate since temperature cannot be regulated.
on machine
• Since connector of air mix damper servomotor cannot be checked when it is mounted on
machine, troubleshooting cannot be performed.

controller
2
D155AX-8 40-205
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of
Range 40 TROUBLESHOOTING
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range

Action level Failure code Refrigerant Pressure Input Signal Out of Range
Failure
L01 879GKX (Machine monitor system)
Details of
Air conditioner controller detected that triple pressure switch is OFF (abnormal).
failure
Air conditioner controller transmits abnormality information of refrigerant pressure to machine moni-
Action of tor by CAN communication.
controller Air conditioner controller turns OFF compressor clutch relay since refrigerant pressure is abnormal.
(Air conditioner compressor stops)
Phenomenon
Air conditioner does not function (in cooling mode).
on machine
Related • For each connector, see "Layout drawing of parts and connectors".
information • Since air conditioner controller connector ACECU has no T-adapter and has small pins,

See “TESTING (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT”.
Defective refrigerant (tri-
1
ple) pressure switch k Before replacing triple pressure switch, collect refrigerant. See “PRE-
CAUTIONS FOR REFRIGERANT”.
2. Disconnect connectors AC01 and AC05.
2
defective contact of con- Between AC05 (female) (1) and AC01 (female) (5) Max. 1 Ω
nector) Resistance
Between AC05 (female) (2) and ground Max. 1 Ω
controller
unit
40-206 D155AX-8
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of
40 TROUBLESHOOTING Range
Circuit diagram related to refrigerant (triple) pressure switch
D155AX-8 40-207
FAILURE CODE [989L00] Engine Controller Lock Caution 1 40 TROUBLESHOOTING
FAILURE CODE [989L00] Engine Controller Lock Caution 1

Action level Failure code Engine Controller Lock Caution 1
Failure
－ 989L00 (Machine monitor system)
Details of
Engine controller lock up is detected (Factor 1).
failure
Action of ma- • None in particular

chine monitor • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Engine does not start.
on machine
• If the failure code is displayed after replacing the machine monitor, user password needs
Related to be changed back to the previous one.
information • After repairing, check if the failure code is cleared by the following procedure.

Machine monitor re- This failure may occur due to machine monitor replacement.
1
placed
40-208 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [989M00] Engine Controller Lock Caution 2
FAILURE CODE [989M00] Engine Controller Lock Caution 2

Failure
－ 989M00 (Machine monitor system)
Details of
Machine monitor detects engine controller lock (Factor 2).
failure

Phenomenon
on machine
• If the failure code is displayed after replacing the machine monitor, user password needs
Related to be changed back to the previous one.

Machine monitor re- This failure may occur due to machine monitor replacement.
1
placed
If this failure code is displayed even when machine monitor is not replaced, failure
Defective machine moni-
2 in machine monitor may occur. (Because this is an internal defect, troubleshooting
tor
cannot be performed.)
D155AX-8 40-209
FAILURE CODE [989N00] Engine Controller Lock Caution 3 40 TROUBLESHOOTING
FAILURE CODE [989N00] Engine Controller Lock Caution 3

Failure
－ 989N00 (Machine monitor system)
Details of
Machine monitor detects engine controller lock (Factor 3).
failure
Action of ma- • Tries automatic recovery.

Phenomenon
on machine
After repairing, check if the failure code is cleared by the following procedure.
Related
Procedure: Failure code cannot be reproduced since machine recovers when cause of failure disap-
information
pears.

Defective engine control- If this repeatedly occurs, engine controller may be defective. (In case of an internal
1
ler defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
40-210 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [A1U0N3] Hydrocarbon Desorb Request 1
FAILURE CODE [A1U0N3] Hydrocarbon Desorb Request 1

Action level Failure code Hydrocarbon Desorb Request 1
Failure
L01 A1U0N3 (Engine controller system)
Details of Unburned fuel remains in KDPF because engine has been running at low idle speed or low load for
failure a long time.
Action of Requests an operator to perform manual stationary regeneration (fuel drying). Or informs manual
controller stationary regeneration (fuel drying) is in progress.
Phenomenon Same phenomenon as automatic regeneration occurs. (When the machine is in a safe condition,
on machine machine controls the engine speed to stay up around 1000 rpm.)
Temperature in KDPF outlet temperature sensor can be checked by monitoring function.

(Code: 47200 (°C))
k KDPF and KDOC become hot (Min. 500 °C). Be careful not to get burned.
• Temperature detected by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature detected by KDOC outlet temperature sensor can be checked with monitor-
ing function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring func-
tion. (Code: 47201 (V))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration is performed due to the guidance of monitor display-
ing failure code [A1U0N3] or [A1U0N4], fuel dosing is disabled. Accordingly, each temper-
Related ature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to approximately 250 to
information 400 °C.
• When manual stationary regeneration except above is in progress, KDOC inlet tempera-
ture is approximately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet tem-
perature are 450 to 600 °C.
• If there is a significant difference between KDOC inlet temperature and KDOC outlet tem-
perature when KDPF is completely cooled or engine is running at engine low idle speed
(without regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet
temperature sensor, whichever is suspected to be defective, judging from KDPF outlet
temperature.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
REMARK
Turn ON the starting switch and check this failure code is cleared.

Manual stationary regen- Follow the instruction on the monitor to perform manual stationary regeneration.
1 eration performed (to dry
If this failure code is cleared after this, repair work is complete.
KDPF)
D155AX-8 40-211
FAILURE CODE [A1U0N3] Hydrocarbon Desorb Request 1 40 TROUBLESHOOTING

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. Turn starting switch to ON position.
2
connector
If this failure code is cleared, wiring harness connector is defective.
NOTICE
If this failure code is displayed, perform the following checks:
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform troubleshoot-
3
temperature sensor ing for [CA3313], [CA3314] or [CA3315].
After temperature is cooled down sufficiently, run engine at low idle and check if
Defective KDOC inlet temperature differences between the KDOC inlet temperature and the KDOC outlet
4
temperature sensor temperature, or KDPF outlet temperature is not large. If it is large difference, try to
change KDOC inlet temperature sensor.
If the KDOC inlet temperature is approximately 250 °C or below during manual sta-
tionary regeneration and if the KVGT solenoid current remains approximately
5 Defective KVGT
1000 mA even when several hours have passed and the manual stationary regen-
eration does not complete, the KVGT is defective.
Turn starting switch to ON position.
Defective engine control- If this failure code is still displayed and no failure is found by preceding checks, en-
6
ler gine controller is defective. (In case of an internal defect, troubleshooting is impos-
sible as an assembly. Replace whole assembly.)
40-212 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [A1U0N4] Hydrocarbon Desorb Request 2
FAILURE CODE [A1U0N4] Hydrocarbon Desorb Request 2

Action level Failure code Hydrocarbon Desorb Request 2
Failure
L03 A1U0N4 (Engine controller system)
Details of Unburned fuel remains in KDPF because engine has been running at low idle speed or low load for
failure a long time.
Action of Requests an operator to perform manual stationary regeneration (fuel drying). Or informs manual
controller stationary regeneration (fuel drying) is in progress.
Phenomenon Same phenomenon as automatic regeneration occurs. (When the machine is in a safe condition,
on machine machine controls the engine speed to stay up around 1000 rpm.)
• Temperature detected by KDPF outlet temperature sensor can be checked with monitoring
difference between these temperatures are approximately 10 °C. (KDOC inlet temperature
> KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration is performed due to the guidance of monitor display-
ing failure code [A1U0N3] or [A1U0N4], fuel dosing is disabled. Accordingly, each temper-
ature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to approximately 250 to
400 °C.
Related
• When manual stationary regeneration except above is in progress, KDOC inlet tempera-
information
ture is approximately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet tem-
perature are approximately 450 to 600 °C.
• If there is a significant difference between KDOC inlet temperature and KDOC outlet tem-
perature when KDPF is completely cooled or engine is running at engine low idle speed
(without regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet
temperature sensor, whichever is suspected to be defective, judging from KDPF outlet
temperature.
REMARK
Turn ON the starting switch and check this failure code and failure code [A1U0N3] is not dis-
played.

Manual stationary regen- Follow the instruction on the monitor to perform manual stationary regeneration.
1 eration performed (to dry
If this failure code is cleared after this, repair work is complete.
KDPF)
D155AX-8 40-213
FAILURE CODE [A1U0N4] Hydrocarbon Desorb Request 2 40 TROUBLESHOOTING

2
connector
NOTICE
If this failure code is displayed, perform the following checks:
3
4
5 Defective KVGT
6
40-214 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [AA10NX] Air Cleaner Clogging
FAILURE CODE [AA10NX] Air Cleaner Clogging

Failure Air Cleaner Clogging (machine monitor system)
L01 AA10NX
Details of Air cleaner clogging switch signal voltage is not 1 V or less while engine is running, and machine
failure monitor detects clogging of air cleaner (open of sensor contacts).
Action of ma-
Displays air cleaner clogging monitor in yellow on machine monitor.
chine monitor
Phenomenon
If machine is used as it is, engine may be damaged.
on machine
• Input (ON/OFF) from air cleaner clogging switch can be checked with monitoring function
Related (Code: 04501 Monitor input 2).
Procedure: Start engine.

Clogged air cleaner Air cleaner may be clogged. Check it for clogging and then clean or replace if clog-
1 (when system works ged.
properly)
2. Disconnect connector AF1 and connect T-adapter to male side.
3. Start engine.
Air cleaner suction resistance
Defective air cleaner
*1: Max.-3,430 Pa {Max.-350 mmH2O}
2 clogging switch (internal
open circuit) *2: -7,470±490 Pa {-762 ±50 mmH2O}
When air cleaner is nor-
Max.1 Ω
Between AF1(male)(1) mal *1
Resistance
and (2) When air cleaner is clog-
Max.1 MΩ
ged *2
Open circuit in wiring har- 2. Disconnect connectors CM02 and AF1, and insert T-adapters into each fe-
ness (wire breakage or male side.
3
nector) Between CM02 (female) (4) and AF1 (female) (1) Max. 1 Ω
Resistance
Between AF1 (female) (2) and ground Max. 1 Ω
If failure code is still displayed after above checks, machine monitor is defective. (In
case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
Reference
Defective machine moni- 2. Insert T-adapters into connectors CM01 and CM02.
4
tor
3. Start engine.
Max. 1 V
Between CM02 (4) and mal
Voltage
CM01 (3) When air cleaner is clog-
Min. 10 V
ged
D155AX-8 40-215
FAILURE CODE [AA10NX] Air Cleaner Clogging 40 TROUBLESHOOTING
CIRCUIT DIAGRAM (AIR CLEANER CLOGGING SENSOR)
40-216 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [AB00KE] Charge Voltage Low
FAILURE CODE [AB00KE] Charge Voltage Low

Failure Charge Voltage Low (Machine monitor system)
L03 AB00KE
Details of While engine is running, voltage from alternator drops, and machine monitor detects charge voltage
failure low
Action of ma-
Displays the charge level monitor in red on machine monitor.
chine monitor
Phenomenon
If machine continues to be operated, battery may not be charged.
on machine
• Battery power supply can be checked with monitoring function. (Code: 04300 battery
Related charge voltage)

Defective charging by al- 2. Insert T-adapter into connector CM01.
1 ternator (when system 3. Start engine and perform troubleshooting while running engine at medium
works properly) speed or higher.
Voltage Between CM01 (16) and (3) 26 to 30.5 V
If failure code is still displayed after above checks on cause 1, charge level monitor
Defective charge level
2 system may be defective. Perform “Charge level monitor lights up while engine is
monitor system
running” in E mode.
D155AX-8 40-217
FAILURE CODE [AB00KE] Charge Voltage Low 40 TROUBLESHOOTING
CIRCUIT DIAGRAM (BATTERY CHARGE)
40-218 D155AX-8
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request
40 TROUBLESHOOTING (KDOC Face Plugging)

(KDOC Face Plugging)
Action level Failure code Manual Stationary Regeneration Request
Failure (KDOC Face Plugging)
L01 AQ10N3
(Engine controller system)
The Manual Stationary Regeneration Request (KDOC) requires the user to perform “manual station-
ary regeneration” to recover the efficiency effectively because the efficiency of KDOC (catalyst ac-
Detail of fail-
tion) (The soot in KCSF does not burn normally because the KDOC inlet temperature in regenera-
ure
tion is normally approximately 250 to 400 °C and the KDOC outlet temperature is normally approxi-
mately 450 to 600 °C but the KDOC outlet temperature does not rise).
Action of • EGR valve closed.
controller • Fuel dosing stops.
Phenomenon
• None
on machine
k KDOC and KDPF become hot (Min. 500 °C). Be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked with monitoring function
(Code: 47300(°C))
• Temperature in KDOC outlet temperature sensor can be checked with monitoring function
(Code: 47400(°C))
• Temperature in KDPF outlet temperature sensor can be checked with monitoring function
(Code: 47200(°C))
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
lamp goes off after turning starting switch to OFF position, and then turn starting switch to
ON position.
Related • All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
information during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
ence is approximately 10 °C (KDOC inlet temperature > KDOC outlet temperature > KDPF
outlet temperature).
• During manual stationary regeneration, KDOC inlet temperature is approximately 250 to
400 °C, and both KDOC outlet temperature and KDPF outlet temperature are approxi-
mately 450 to 600 °C.
• The manual stationary regeneration (KDOC Face Plugging) does not perform fuel dozing
to recover the KDOC efficiently, so all of KDOC inlet temperature, KDOC outlet tempera-
ture, and KDPF outlet temperature become approximately 250 to 400 °C.
• The failure code [CA2637] is displayed while this failure code is displayed.
How to perform manual stationary regeneration
2. From service menu of machine monitor, display “Diagnostic Tests” screen, open “02 Active
Regeneration for Service”, and then perform “Manual Stationary Regeneration”.
REMARK
The manual stationary regeneration time of the Manual Stationary Regeneration Request (KDOC
Face Plugging) is approximately one and a half hours.
D155AX-8 40-219
(KDOC Face Plugging) 40 TROUBLESHOOTING

If this failure code is displayed on the machine monitor for several hours after man-
Defective engine control- ual stationary regeneration has been performed, engine controller is defective. (In
1
ler case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
40-220 D155AX-8
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request
40 TROUBLESHOOTING (SCR)
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)

Action level Failure code Manual Stationary Regeneration Request (SCR)
Failure
L01 AS00N3 (Engine controller systems)
Manual Stationary Regeneration Request (SCR) requires the user to perform “manual stationary re-
Detail of fail-
generation” to clear urea deposit effectively when the efficiency (catalyst action) of KDOC decreas-
ure
es or the KDOC outlet temperature in regeneration does not rise.
Action of
• Normal operation
controller
Phenomenon
None
on machine
k Since KDPF and KDOC are heated to 500 °C or above, be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked with monitoring function
(Code: 47300(°C))
• Temperature in KDOC outlet temperature sensor can be checked with monitoring function
(Code: 47400(°C))
• Temperature in KDPF outlet temperature sensor can be checked with monitoring function
(Code: 47200(°C))
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY”.
ON position.
• All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
Related during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
information
• During manual stationary regeneration (SCR), KDOC inlet temperature is approximately
250 to 400 °C, and both KDOC outlet temperature and KDPF outlet temperature are ap-
proximately 350 to 600 °C to clear urea deposit.
• Even if regeneration is not implemented normally, the failure code [AS00N3] may disap-
pear.
• The failure code [CA3568], [CA3582] may be displayed while this failure code is displayed.
Regeneration for Service”, and then perform “Manual Stationary Regeneration”.
REMARK
The manual stationary regeneration time of the Manual Stationary Regeneration Request (SCR) is
approximately an hour.
D155AX-8 40-221
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request
(SCR) 40 TROUBLESHOOTING

1
2 Defective KVGT
Defective engine control- If failure code is still displayed after above checks, any internal parts in the engine
3
ler controller is defective.
40-222 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)

Action level Failure code Warning 2 (SCR Device Abnormality)
Failure
L01 AS00R2 (Engine controller system)
• A certain time has passed since an abnormality of SCR System occurs.

Detail of fail-
ure • An abnormality of SCR system has occurred again within a certain time since abnormality
repair of SCR system. (EU specification)
Action of • The information related to this failure code is displayed on the monitor screen.
controller • Inducement status advances to the next status with more engine deration.
Phenomenon
The engine power deration after a certain time.
on machine
Related
This failure code is detected during engine operation.
information

Failure codes of SCR system abnormality are displayed. Perform troubleshooting
1 SCR system abnormality
for them.
Engine system abnormal- If any other failure codes than SCR system abnormality are displayed, perform
2
ity troubleshooting for them.
D155AX-8 40-223
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) 40 TROUBLESHOOTING
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)

Action level Failure code Inducement 1 (SCR Device Abnormality)
Failure
• A certain time has passed since AS00R2 occurs.

Detail of fail-
repair of SCR system. (EU Specification)
• The information related to this failure code is displayed on the monitor screen.
Action of
• Engine power deration
controller
• AS00R4 occurs and operates with engine speed is fixed significantly after a certain time.
Phenomenon • Engine power deration
on machine • The engine output reduces heavily after a certain time.
• This failure code is detected during engine operation.
Related • If this failure code displays after SCR system abnormality is repaired and the engine con-
troller is shut down, run the engine for 1 minute to clear the failure code.
information
• After this failure code is cleared, engine power deration continues until the starting switch

for them.
2
40-224 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)

Failure
• A certain time has passed since AS00R3 occurs.

Detail of fail-
repair of SCR system. (EU Specification)
Action of • Controls engine output significantly for operation.
controller • AS00R5 occurs and operates with engine speed is fixed at low idle speed after a certain
time.
Phenomenon • Engine output reduces heavily.
on machine • Engine speed is fixed at low idle speed.
• From the machine monitor, it is possible to perform a temporary restoration from induce-
ment to clear engine output low temporarily.
Related
• If this failure code displays after SCR system abnormality is repaired and the engine con-
information

for them.
2
D155AX-8 40-225
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality) 40 TROUBLESHOOTING

Failure
Detail of fail-
Engine power deration.
ure
Action of • Engine power deration for operation.
controller • Neither Manual Stationary Regeneration nor Active Regeneration for Service can be per-
formed.
Phenomenon
• Engine speed is fixed at low idle speed.
on machine
Related • If this failure code displays after SCR system abnormality is repaired and the engine con-
information

for them.
2
40-226 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [AS00R6] Temporary Recovery of Inducement
FAILURE CODE [AS00R6] Temporary Recovery of Inducement

Action level Failure code Temporary Recovery of Inducement
Failure
- AS00R6 (Engine controller system)
Detail of fail- • Temporary recovery of inducement is implemented from the machine monitor while engine
ure deration.
Action of • Restore engine power temporarily
controller • The information related to this failure code is displayed on the monitor screen.
Phenomenon
• Engine power recovered temporarily.
on machine
• This failure code is not failure but caution to display that temporary restoration from in-
ducement has been performed on Abnormality Record screen and KOMTRAX on the ma-
Related
chine monitor.
information
• After performing “Temporary restoration from inducement”, “E” of this failure code that is
active currently is displayed for 20 second on the “Abnormality record” screen.
D155AX-8 40-227
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5 40 TROUBLESHOOTING
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5

Action level Failure code AdBlue/DEF Level Low Error 5
Failure
L04 AS00ZK (Engine controller system)
Detail of fail-
AdBlue/DEF tank level lowers and a certain time has passed since failure code [CA3574] occurs.
ure
Action of • Engine power deration for operation.
controller • Neither Manual Stationary Regeneration nor Active Regeneration for Service can be per-
formed.
Phenomenon
Engine speed is fixed at low idle.
on machine
• The AdBlue/DEF level has been equivalent to or lower than 0.0 % for an hour.
information

2. Check the sight gauge to confirm that there is sufficient amount of
AdBlue/DEF in the AdBlue/DEF tank.
1 Low AdBlue/DEF level 3. Refill AdBlue/DEF if the level is low.
4. Turn starting switch to ON position.
If this failure code is cleared, AdBlue/DEF has been insufficient.
1. Check the sensor connector for contamination and damage.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
3
40-228 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning

Action level Failure code AdBlue/DEF Injector Overheat Warning
Failure
L01 AS10KM (Machine monitor system)
Detail of fail- Engine stops over 150 times under the condition of engine and aftertreatment devices with high
ure temperature
Action of
Displays the caution symbol of AdBlue/DEF Injector Overheat Warning on the machine monitor.
controller
Phenomenon
Defective injection of AdBlue/DEF may occur when engine starts operation again
on machine
• On the Pre-defined Monitoring screen, troubleshooting for the engine aftertreatment relat-
ed items is used (the figures below denote monitoring codes).
47000 KDPF Outlet Pressure
Related
47100 KDPF Differential Pressure
information
47200 KDPF 1 Outlet Temperature
47300 KDOC 1 Inlet Temperature
47400 KDOC 1 Outlet Temperature

　
1 Defective operation Instruct an operator about performing running at low idle approximately 5 minutes
before stopping the engine.
D155AX-8 40-229
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature
Warning 40 TROUBLESHOOTING
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning

Action level Failure code AdBlue/DEF Injector High Temperature Warning
Failure
— AS10NR (Engine controller system)
Detail of fail- The temperature of the AdBlue/DEF injector may become so high that it is damaged, so the output
ure is limited.
Action of
• Changes to output limitation
controller
Phenomenon
on machine
• This may occur if a heavy load operation is performed for a long time during AdBlue/DEF
thawing.
• This may occur if a heavy load operation is performed for a long time when an error relat-
ed to SCR system occurs.
• If the engine coolant temperature is high, the cooling capability of the AdBlue/DEF injector
Related is degraded and a warning may appear.
information • If the ambient temperature sensor and engine room temperature sensor shows different
values (values much lower than the actual temperature), unnecessary thawing control is
applied and a warning may appear.
• This failure code is a warning for equipment protection and does not indicate any failures.
• Both failure code and output limitation are cleared by turning OFF and ON the starting
switch.

Occurrence of an error Confirm if an error that stops AdBlue/DEF injection is displayed.
related to SCR compo- If displayed, perform a cancellation process.
1
nents (error that stops
AdBlue/DEF injection)
Rising coolant tempera- Check the radiator condition if:

ture • the radiator shutter prevents the coolant from working properly, or
2
(degraded radiator capa- • the radiator is clogged.
bility) Correct so that the radiator cooling capability works sufficiently.
Defective ambient tem-
3 If the temperature sensed by ambient temperature sensor is significantly low com-
perature sensor
pared to the actual temperature, the ambient temperature sensor is defective.
2. Open the pump side cover and wait for 5 minutes.
Defective engine room
4
temperature sensor If the temperature sensed by engine room temperature sensor is significantly low
compared to the actual temperature, the engine room temperature sensor is defec-
tive.
If failure code is still displayed after above checks, engine controller may be defec-
Defective engine control-
5 tive. Replace engine controller. (In case of an internal defect, troubleshooting is im-
ler
possible as an assembly. Replace whole assembly.)
40-230 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution

Action level Failure code AdBlue/DEF Injector Overheat Caution
Failure
- AS10NT (Machine monitor system)
• Engine stops over 150 times under the condition of engine aftertreatment devices with
Details of high temperature. Engine may have been stopped without sufficient running at low idle
speed. Failure does not occur at once, but if it is repeated, it slowly damages AdBlue/DEF
failure injector. AdBlue/DEF injector will be damaged eventually, and it may cause defective injec-
tion or leakage of AdBlue/DEF.
Action of
None in particular (No error is displayed on the machine monitor.)
controller
Phenomenon
Defective injection of AdBlue/DEF may occur when engine starts operation again.
on machine
• On the Pre-defined Monitoring screen, aftertreatment devices related for engine are used
(the numbers below denote monitoring codes).
47000 KDPF Outlet Pressure
Related
information
47200 KDPF 1 Outlet Temperature
47300 KDOC 1 Inlet Temperature
47400 KDOC 1 Outlet Temperature

　
1 Defective operation Instruct an operator about performing running at low idle approximately 5 minutes
before stopping the engine.
D155AX-8 40-231
FAILURE CODE [B@BAZG] Engine Oil Pressure Low 40 TROUBLESHOOTING
FAILURE CODE [B@BAZG] Engine Oil Pressure Low

Action level Failure code Engine Oil Pressure Low
Failure
L03 B@BAZG (Engine controller system)
Detail of fail- Signal voltage from engine oil pressure switch becomes GND while engine is running, and engine
ure controller detects engine oil pressure abnormality.
Action of • Lights up engine oil pressure monitor in red on machine monitor.
controller • Engine power deration.
Phenomenon
Engine power deration
on machine
• If machine is used as it is, engine may be seized.
• Signal voltage of engine oil pressure switch is input to engine controller that transmits the
information to machine monitor through CAN communication system.
Related
• See failure code [CA435] for troubleshooting of engine oil pressure switch while engine is
information
running.

1. Since engine oil pressure drop is sensed, check engine oil pressure.
Low engine oil pressure 2. Perform troubleshooting “Oil pressure drops”.
1 (when system works
properly) 3. In the case of excessive consumption of engine oil, perform troubleshoot-
ing “Engine oil consumption is excessive”.
If failure code is still displayed after above checks on cause 1, engine oil pressure
sensor system may be defective. Perform troubleshooting for failure codes [CA135]
Defective engine oil pres- and [CA141].
2
sure sensor system
switch system may be defective. Perform troubleshooting for failure code [CA435].
40-232 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [B@BCNS] Engine Coolant Overheat
FAILURE CODE [B@BCNS] Engine Coolant Overheat

Action level Failure code Engine Coolant Overheat
Failure
L02 B@BCNS (Engine controller system)
Details of Engine controller determines engine coolant temperature overheat when voltage from engine cool-
failure ant temperature sensor drops while engine is running.
Action of • Lights up engine coolant temperature monitor in red on machine monitor.

controller • Engine power deration
Phenomenon • If machine is used as it is, engine may be seized.
on machine • Engine power deration
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function (Code: 04107 En-
information gine coolant temperature)

Overheat of engine cool- Engine water may overheat. Check coolant temperature and remove cause of fail-
1 ant (when system works ure if engine water overheats.
properly)
Defective engine coolant If failure code is still displayed after above checks on cause 1, engine coolant tem-
2 temperature sensor sys- perature sensor system may be defective. Perform troubleshooting for failure codes
tem [CA144] and [CA145].
D155AX-8 40-233
FAILURE CODE [B@BCZK] Engine Coolant Level Low 40 TROUBLESHOOTING
FAILURE CODE [B@BCZK] Engine Coolant Level Low

Failure Eng Water Level Low
L01 B@BCZK
Details of Signal circuit of radiator coolant level switch is "OPEN" (disconnected from GND) when the engine
failure is stopped.
Action of ma-
None in particular
chine monitor
Phenomenon
Machine is used when coolant level is low, engine may overheat.
on machine
• Operation of radiator coolant level switch can be becked with (Code: 04500).
Related
information

Check whether radiator coolant level is normal.
1 Low radiator coolant level

NOTICE
If radiator coolant level is lowered, check periphery of engine and radia-
tor for leakage before refilling.
1. Since the float may be stuck by clogging of dirt, check and clean the cool-
ant level sensor directly.
Defective radiator coolant 3. Disconnect connector WLV, and connect T-adapter to male side.
2
level sensor
Radiator coolant level is
Between WLV (male) (1) Max. 1 Ω
Resistance normal.
and ground
Low radiator coolant level Min. 1 MΩ
2. Disconnect connectors CM02 and WLV, and connect T-adapters to each
3 ness (wire breakage or female side.
defective contact) Between CM02 (female) (3) and WLV (female) (1) Max. 1 Ω
Resistance
Between WLV (female) (2) and ground Max. 1 Ω
2. Connect T-adapter to connector CM01,CM02.
Defective machine moni- 3. Turn starting switch to ON position.
4
tor Radiator coolant level is
CM02 (female) (3) to Max. 1 V
Voltage normal.
CM01 (female) (3)
Low radiator coolant level Min. 10 V
40-234 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [B@BCZK] Engine Coolant Level Low
Circuit diagram related to radiator coolant level switch
D155AX-8 40-235
FAILURE CODE [B@CENS] Power Train Oil Overheat 40 TROUBLESHOOTING
FAILURE CODE [B@CENS] Power Train Oil Overheat

Failure Power Train Oil Overheat (Power train controller system)
L02 B@CENS
Details of Signal voltage from torque converter oil temperature sensor drops and power train controller detects
failure power train oil overheat.
Action of
Displays power train oil temperature monitor in red.
controller
Phenomenon
Power train equipment may be damaged if not performing troubleshooting.
on machine
• Power train controller enters signal voltage of torque converter oil temperature sensor and
transmits related information to machine monitor by CAN communication.
• Torque converter oil temperature can be checked by monitoring function. (Code: 30100
Related
torque converter oil temperature)
information
• Torque converter oil temperature is regarded as power train oil temperature.

Overheating of torque Torque converter (power train) oil may be overheating. If overheating is detected,
converter (power train) oil repair cause of failure.
1
(when system works
properly)
If failure code is still displayed after above checks on cause 1, torque converter oil
Failure of torque convert-
2 temperature sensor system may be defective. Perform troubleshooting for
er oil temperature sensor
[DGT1KA] or [DGT1KX].
40-236 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [B@HANS] Hydraulic Oil Overheat
FAILURE CODE [B@HANS] Hydraulic Oil Overheat

Action level Failure code Hydraulic Oil Overheat
Failure
L02 B@HANS (Work equipment controller system)
Details of Work equipment controller detects overheating of hydraulic oil temperature by voltage drop of hy-
failure draulic oil temperature sensor while engine is running.
Action of
Displays hydraulic oil temperature monitor on machine monitor in red.
controller
Phenomenon
If machine is used as it is, work equipment and HSS circuit may be damaged.
on machine
• Signal voltage from hydraulic oil temperature sensor is input to work equipment controller
and then data is transmitted to machine monitor through CAN communication system.
Related • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401: Hy-
information draulic Oil Temperature)

Overheating of hydraulic Hydraulic oil may overheat. Check hydraulic oil temperature, and remove cause of
1 oil (when system is nor- failure if hydraulic oil overheats.
mal)
If failure code is still displayed after above checks on cause 1, hydraulic oil temper-
Defective hydraulic oil
ature gauge system may be defective. Perform troubleshooting for failure code
2 temperature gauge sys-
[DGS1KA], [DGS1KX] or for “Hydraulic oil temperature gauge does not display nor-
tem
mally” in E-mode.
D155AX-8 40-237
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error 40 TROUBLESHOOTING
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error

Action level Failure code Engine NE and Backup Speed Sensor Error (Engine controller sys-
Failure
L04 CA115 tem)
Details of
Errors occur simultaneously in signal circuits of Ne speed sensor and Bkup speed sensor.
failure
Action of
Stops engine.
controller
Phenomenon • Stopped engine cannot be started.
on machine • Running engine stops.
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start engine.

Defective Ne speed sen- Perform troubleshooting for failure code [CA689].
1
sor system
Defective Bkup speed Perform troubleshooting for failure code [CA778].
2
sensor system
3
40-238 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA122] Charge Air Pressure Sensor High Error
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error

Failure Charge Air Pressure Sensor High Error (Engine controller system)
L03 CA122
Details of
High voltage occurs in signal circuit of charge pressure sensor (boost pressure sensor).
failure
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2} ) for operation.
Action of • EGR valve closes and fully opens KVGT.
• Regeneration control stops.
Phenomenon • Engine acceleration performance is poor.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
monitoring function. (Code: 36501 (V))
• Pressure (boost pressure) by charge pressure sensor (boost pressure sensor) can be
checked by monitoring function. (Code: 36500 (kPa))
Related
information
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
Defective sensor power If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
2
supply system first.
2. Disconnect connector PIM.
If failure code changes from [CA122] to [CA123], charge pressure (boost pressure)
sensor is defective.
Defective charge (boost) Reference
3
pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1 or PIM.
Between J1 (45) and (54),
Voltage or between PIM (3) and Sensor output 0.3 to 4.7 V
(2)
ness (ground line break- 2. Disconnect connectors J1 and PIM, and connect T-adapters to each fe-
4
age or defective contact male side.
of connector)
Resistance Between J1 (female) (54) and PIM (female) (2) Max. 1 Ω
D155AX-8 40-239
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error 40 TROUBLESHOOTING

Short circuit in wiring har- 2. Disconnect connectors J1 and PIM, and connect T-adapter to female side
5
ness of J1.
Resistance Between J1 (female) (45) and (78) Min. 1 MΩ
2. Disconnect connector PIM and connect T-adapter to female side, or insert
Hot short circuit in wiring T-adapter into connector J1.
6
harness 3. Turn starting switch to ON position (with connector PIM disconnected).
Between PIM (3) and (2), or between J1 (female) (45)
Voltage Max. 1 V
and (54)
ler
Circuit diagram related to charge air pressure sensor
40-240 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error

Failure Charge Air Pressure Sensor Low Error (Engine controller system)
L03 CA123
Details of
Low voltage occurs in signal circuit of charge pressure sensor (boost pressure sensor).
failure
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2} ) for operation.
Phenomenon • Engine acceleration performance is poor.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
monitoring function. (Code: 36501 (V))
• Pressure (boost pressure) by charge pressure sensor (boost pressure sensor) can be
checked by monitoring function. (Code: 36500 (kPa))
information Procedure: Turn starting switch to ON position.
• This failure code is displayed if sensor connector is disconnected.
code is cleared).

1
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
first.
Defective power supply 1. Turn starting switch to OFF position.
system of charge pres- 2.
2 Disconnect connector PIM and connect T-adapter to female side.
sure sensor (boost pres-
sure sensor) 3. Switch ON
Between PIM (female) (1) 4.75 to
Voltage Power supply input
and (2) 5.25 V
2. Disconnect connectors J1 and PIM, and connect T-adapters to each fe-
male side.
3
defective contact of con- Between J1 (female) (78) and PIM (female) (1) Max. 1 Ω
nector)
Resistance Between J1 (female) (45) and PIM (female) (3) Max. 1 Ω
Between J1 (female) (54) and PIM (female) (2) Max. 1 Ω
D155AX-8 40-241
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error 40 TROUBLESHOOTING

2. Disconnect connectors J1 and PIM, and connect T-adapter to either fe-
Short circuit in wiring har-
4 male side.
ness
Between J1 (female) (45) and (54), or between PIM
1. Turn starting switch to OFF position to perform troubleshooting.
Ground fault in wiring 2. Disconnect connectors J1 and PIM, and connect T-adapter to either fe-
5 harness (contact with male side.
ground circuit)
Between ground and J1 (female) (45) or PIM (female)
(3)
If failure code is still displayed after above checks on causes 1 to 5 and any failure
is found by checks on cause 6, sensor is defective.
Defective charge (boost) 2. Insert T-adapter into connector J1 or PIM.
6
pressure sensor 3. Turn starting switch to ON position.
Voltage or between PIM (3) and Sensor output 0.3 to 4.7 V
(2)
7
Circuit diagram related to charge air pressure sensor
40-242 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA131] Throttle Sensor High Error
FAILURE CODE [CA131] Throttle Sensor High Error

Action level Failure code Throttle Sensor High Error
Failure
L03 CA131 (Engine controller system)
Details of
High voltage occurs in signal circuit of decelerator pedal (throttle sensor).
failure
Action of
Operates at fixed value of decelerator pedal (throttle sensor).
controller
Phenomenon
Engine speed cannot be controlled by decelerator pedal (throttle sensor).
on machine
• Signal voltage of decelerator pedal (throttle sensor) can be checked by monitoring func-
Related tion. (Code: 31703)
Procedure: Turn starting switch to ON position and operate decelerator pedal.

1. Perform checkup referring to descriptions of wiring harness and connec-
tors in “c Electric equipment” of “Checks before troubleshooting” in “Gener-
Defective wiring harness al information on troubleshooting”.
1
Defective throttle sensor If failure code [CA2185] is also displayed, perform troubleshooting these first.
2
power supply system
Approx.
Defective decelerator 2 kΩ
3
pedal (throttle sensor)
0.2 to
1.8 kΩ
0.2 to
1.8 kΩ
2. Disconnect connector J2, and connect T-adapter to female side.
Open or short circuit in Approx.
4 Between J2 (female) (9) and (33)
wiring harness 2 kΩ
Resistance
0.2 to
Between J2 (female) (10) and (33)
1.8 kΩ
1. If failure code is still displayed after above checks on cause 4, this check is
not required.
5 3. Disconnect connectors J2 and DCL, and connect T-adapter to either fe-
ness
male side.
Between J2 (female) (9) and (10) or DCL (female) (A)
and (B)
D155AX-8 40-243
FAILURE CODE [CA131] Throttle Sensor High Error 40 TROUBLESHOOTING

Hot short circuit in wiring 2. Disconnect connector DCL and connect T-adapter to female side.
6
harness 3. Turn starting switch to ON position.
Voltage Between DCL (female) (A) and ground Max. 1 V
If failure code is still displayed after above checks, any internal parts in the engine
controller is defective.
Reference
7 4. Depress the decelerator pedal and perform troubleshooting.
ler
4.75 to
Between J2 (9) and (33) Power supply
5.25 V
Depress the decelerator Approx.
Voltage
pedal. 3.5 V
Between J2 (10) and (33)
Release the decelerator
Approx. 2 V
pedal.
Circuit diagram related to throttle sensor
40-244 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA132] Throttle Sensor Low Error
FAILURE CODE [CA132] Throttle Sensor Low Error

Failure Throttle Sensor Low Error (Engine controller system)
L03 CA132
Details of
Low voltage occurs in signal circuit of decelerator pedal (throttle sensor).
failure
Action of
Operates at fixed value of decelerator pedal (throttle sensor).
controller
Phenomenon
Engine speed cannot be controlled by decelerator pedal (throttle sensor).
on machine
• Signal voltage of decelerator pedal (throttle sensor) can be checked by monitoring func-
Related tion. (Code: 31703)
Procedure: Turn starting switch to ON position and operate decelerator pedal.

1
Defective throttle sensor If failure code [CA2185] is also displayed, perform troubleshooting these first.
2
power supply system
Approx.
Defective decelerator 2 kΩ
3
pedal (throttle sensor)
0.2 to
1.8 kΩ
0.2 to
1.8 kΩ
Open or short circuit in Approx.
wiring harness 2 kΩ
Resistance
0.2 to
1.8 kΩ
not required.
3. Disconnect connectors J2 and DCL, and connect T-adapters to each fe-
5 male side.
nector) Between J2 (female) (9) and DCL (female) (B) Max. 1 Ω
Resistance Between J2 (female) (10) and DCL (female) (A) Max. 1 Ω
Between J2 (female) (33) and DCL (female) (C) Max. 1 Ω
D155AX-8 40-245
FAILURE CODE [CA132] Throttle Sensor Low Error 40 TROUBLESHOOTING

not required.
6 3. Disconnect connectors J2 and DCL, and connect T-adapter to either fe-
ness
male side.
Between J2 (female) (33) and (10) or DCL (female) (A)
and (C)
Ground fault in wiring 2. Disconnect connectors J2 and DCL, and connect T-adapter to either fe-
ground circuit)
Between J2 (female) (10) or DCL (female) (A) and
ground
Reference
8 4. Depress the decelerator pedal and perform troubleshooting.
ler
4.75 to
Between J2 (9) and (33) Power supply
5.25 V
Depress the decelerator Approx.
Voltage
pedal. 3.5 V
Between J2 (10) and (33)
Release the decelerator
Approx. 2 V
pedal.
40-246 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error
FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error

Failure Engine Oil Pressure Sensor High Error (Engine controller system)
L01 CA135
Details of
High voltage occurs in signal circuit of engine oil pressure sensor.
failure
Action of
Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2} ) for operation.
controller
Phenomenon
on machine
• Signal voltage from engine oil pressure sensor can be checked by monitoring function.
(Code: 37201 (V))
Related • Oil pressure by engine oil pressure sensor can be checked by monitoring function. (Code:
information 37200 (kPa))

1
Defective engine oil pres- If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
2 sure sensor power sup- first.
ply system
2. Disconnect connector POIL.
If failure code changes from [CA135] to [CA141], engine oil pressure sensor is de-
fective.
Defective engine oil pres-
3 1. Turn starting switch to OFF position.
sure sensor
2. Insert T-adapter into connector J1 or POIL.
Voltage or between POIL (3) and Sensor output 0.3 to 4.7 V
(2)
ness (wire breakage or 2. Disconnect connectors J1 and POIL, and connect T-adapters to each fe-
4
defective contact of con- male side.
nector)
Resistance Between J1 (female) (54) and POIL (female) (2) Max. 1 Ω
2. Disconnect connectors J1 and POIL, and connect T-adapter to either fe-
5 male side.
ness
Between J1 (female) (85) and (78), or between POIL
D155AX-8 40-247
FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error 40 TROUBLESHOOTING

2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL, or insert T-adapter
Hot short circuit in wiring
6 into connector J1.
harness
4. Turn starting switch to ON position (with connector POIL disconnected).
Between J1 (85) and (54), or between POIL (female)
Voltage Max. 1 V
(3) and (2)
7
Circuit diagram related to engine oil pressure sensor
40-248 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error
FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error

Failure Engine Oil Pressure Sensor Low Error (Engine controller system)
L01 CA141
Details of
Low voltage occurs in signal circuit of engine oil pressure sensor.
failure
Action of
Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2} ) for operation.
controller
Phenomenon
on machine
• Signal voltage from engine oil pressure sensor can be checked by monitoring function.
(Code: 37201 (V))
Related • Oil pressure by engine oil pressure sensor can be checked by monitoring function. (Code:

1
first.
2 sure sensor power sup- 2. Disconnect connector POIL and connect T-adapter to female side.
ply system 3. Turn starting switch to ON position.
Between POIL (female) 4.75 to
(1) and (2) 5.25 V
2. Disconnect connectors J1 and POIL, and connect T-adapters to each fe-
male side.
If power supply input in check on cause 2 is normal,
Open circuit in wiring har- this check is not required. Max. 1 Ω
3 Between J1 (female) (78) and POIL (female) (1)
nector) If power supply input in check on cause 2 is normal,
Resistance
this check is not required. Max. 1 Ω
Between J1 (female) (54) and POIL (female) (2)
Between J1 (female) (85) and POIL (female) (3) (sen-
Max. 1 Ω
sor output)
Ground fault in wiring 2. Disconnect connectors J1 and POIL, and connect T-adapter to either fe-
ground circuit)
Between J1 (female) (85) and ground, or between
POIL (female) (3) and ground
D155AX-8 40-249
FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error 40 TROUBLESHOOTING

2. Disconnect connectors J1 and POIL, and connect T-adapter to either fe-
5 male side.
ness
Between J1 (female) (85) and (54), or between POIL
Defective engine oil pres- 2. Insert T-adapter into connector J1 or POIL.
6
sure sensor 3. Turn starting switch to ON position.
Voltage or between POIL (3) and Sensor output 0.3 to 4.7 V
(2)
7
Circuit diagram related to engine oil pressure sensor
40-250 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA144] Coolant Temperature Sensor High Error
FAILURE CODE [CA144] Coolant Temperature Sensor High Error

Failure Coolant Temperature Sensor High Error (Engine controller system)
L01 CA144
Details of
High voltage occurs in signal circuit of engine coolant temperature sensor.
failure
Action of
Sets coolant temperature to fixed value for operation.
controller
Phenomenon • Engine startability becomes poor in low temperature.
on machine • Overheat prevention function does not operate.
• Signal voltage from engine coolant temperature sensor can be checked by monitoring
function. (Code: 04105 (V))
• Temperature in engine oil coolant sensor can be checked by monitoring function. (Code:
04107 (°C))
Related Procedure: Turn starting switch to ON position.
information • This failure code is displayed when temperature sensor connector is disconnected.
• Because female connector alone is provided in “Socket” for troubleshooting for this sen-
sor, socket cannot be connected to female connector on wiring harness side of sensor and
check for wire breakage cannot be performed (T-adapter is not provided).
k Do not work at high coolant temperature, when testing and replacing coolant temper-
ature sensor.

1
REMARK
Regard coolant temperature sensor as normal if its resistance is 700 Ω to 37 kΩ
when coolant temperature is min. 0 °C.
0 °C 30 to 37 kΩ
9.3 to
Defective coolant tem- 25 °C
2 REMARK 10.7 kΩ
perature sensor
Coolant temperature 3.2 to
50 °C
characteristics 3.8 kΩ
Resistance between TWTR (male) (A) 1.0 to
80 °C
and (B) 1.3 kΩ
700 to
95 °C
800 Ω
Between TWTR (male) (B) All coolant temperature
Min. 1 MΩ
and ground range
D155AX-8 40-251
FAILURE CODE [CA144] Coolant Temperature Sensor High Error 40 TROUBLESHOOTING

REMARK
3 Use coolant temperature sensor resistance charac-
wiring harness
Resistance teristics table for check on cause 2 as criteria for re- 700 Ω to
sistance 37 kΩ
between J1 (female) (83) and (54) (coolant tempera-
ture: Min. 0 °C).
2. Disconnect connector TWTR.
Hot short circuit in wiring 3.
4 Insert T-adapter into connector J1.
harness
Voltage Between J1 (83) and (54) Max. 5.25 V
2. Disconnect connectors J1 and TWTR, and connect T-adapter to female
5 side of J1.
ness
Between J1 (female) (83) and each pin other than pin No continui-
Continuity
(83) ty
6
Electrical circuit diagram related to coolant temperature sensor
40-252 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA145] Coolant Temperature Sensor Low Error
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error

Failure Coolant Temperature Sensor Low Error (Engine controller system)
L01 CA145
Details of
Low voltage occurs in signal circuit of engine coolant temperature sensor.
failure
Action of
Sets coolant temperature to fixed value for operation.
controller
on machine • Overheat prevention function does not operate.
• Signal voltage from engine coolant temperature sensor can be checked by monitoring
function. (Code: 04105 (V))
• Temperature in engine oil coolant sensor can be checked by monitoring function. (Code:
04107 (°C))
• When temperature sensor connector is removed, failure code for High Error [CA144] is
displayed instead of this failure code.
k Do not work at high coolant temperature, when testing and replacing coolant temper-
ature sensor.

1
REMARK
Regard coolant temperature sensor as normal if its resistance is 700 Ω to 37 kΩ
when coolant temperature is min. 0 °C.
0 °C 30 to 37 kΩ
9.3 to
Defective coolant tem- 25 °C
2 REMARK 10.7 kΩ
perature sensor
Coolant temperature 3.2 to
50 °C
characteristics 3.8 kΩ
Resistance between TWTR (male) (A) 1.0 to
80 °C
and (B) 1.3 kΩ
700 to
95 °C
800 Ω
Between TWTR (male) (B) All coolant temperature
Min. 1 MΩ
and ground range
D155AX-8 40-253
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error 40 TROUBLESHOOTING

REMARK
3 Use coolant temperature sensor resistance charac-
ness
Resistance teristics table for check on cause 2 as criteria for re- 700 Ω to
sistance 37 kΩ
between J1 (female) (83) and (54) (coolant tempera-
ture: Min. 0 °C).
Ground fault in wiring 2. Disconnect connectors J1 and TWTR, and connect T-adapter to female
side of J1.
ground circuit)
Resistance Between J1 (female) (83) and ground Min. 1 MΩ
5
Electrical circuit diagram related to coolant temperature sensor
40-254 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA153] Charge Air Temperature Sensor High Error
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error

Action level Failure code Charge Air Temperature Sensor High Error (Engine controller sys-
Failure
L03 CA153 tem)
Details of
High voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Sets charge temperature (boost temperature) to fixed value (70 °C) for operation.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked by monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))
Related
• Because female connector alone is provided in "Socket" for troubleshooting for this sen-
information
• This failure code is displayed when temperature sensor connector is disconnected.
code is cleared).

1
D155AX-8 40-255
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error 40 TROUBLESHOOTING

REMARK
Regard charge temperature sensor as normal if its resistance is 280 Ω to 382 kΩ.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
Defective charge temper-
2
ature sensor 0 °C 29 to 36 kΩ
Between TIM (male) (A)
and (B) 7.3 to
30 °C
Resistance 8.8 kΩ
Charge thermal character-
istics 2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
Open or short circuit in REMARK

3
wiring harness Use charge temperature sensor resistance charac- 280 Ω to
Resistance teristics table for check on cause 2 as criteria for re- 382 kΩ
sistance
between J1 (female) (62) and (54).
Hot short circuit in wiring 2. Disconnect connector TIM.
4
harness 3. Insert T-adapter into connector J1.
2. Disconnect connectors J1 and TIM, and connect T-adapter to female side
5 of J1.
ness
Continuity
(62) ty
6
40-256 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA153] Charge Air Temperature Sensor High Error
Circuit diagram related to charge temperature sensor
D155AX-8 40-257
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error

Failure Charge Air Temperature Sensor Low Error (Engine controller system)
L03 CA154
Details of
Low voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Sets charge temperature (boost temperature) to fixed value (70 °C) for operation.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked by monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))
information
• When temperature sensor connector is removed, failure code for High Error [CA153] is
displayed instead of this failure code.
code is cleared).

1
40-258 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error

REMARK
Regard charge temperature sensor as normal if its resistance is 280 Ω to 382 kΩ.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
Defective charge temper- REMARK 0 °C 29 to 36 kΩ

2
ature sensor Charge thermal charac- 7.3 to
30 °C
teristics 8.8 kΩ
Resistance between TIM (male) (A) 2.3 to
60 °C
and (B) 2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
Between TIM (male) (B)
All range Min. 1 MΩ
and ground
Short circuit in wiring har- REMARK

3
ness Use charge temperature sensor resistance charac- 280 Ω to
Resistance teristics table for check on cause 2 as criteria for re- 382 kΩ
sistance
between J1 (female) (62) and (54).
4 harness (contact with 2. Disconnect connector J1, and connect T-adapter to female side.
ground circuit)
5
D155AX-8 40-259
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error 40 TROUBLESHOOTING
Circuit diagram related to charge temperature sensor
40-260 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error

Action level Failure code Sensor 2 Supply Voltage Low Error
Failure
Details of
Low voltage occurs in sensor 2 supply (5 V) circuit.
failure
• Ignores signals from EGR valve lift sensor and KVGT position sensor, and fixes values be-
fore detecting error for operation.
Action of
• Ignores signal from doser fuel pressure sensor, and fixes values before detecting error for
controller operation.
• Engine power deration.
Phenomenon
on machine
Related
information
ure code is cleared (note that the control is not released right after the failure code is
cleared).

1
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is cleared, disconnected sensor or engine wiring harness is de-
fective.
Defective sensor or wir- REMARK
2
ing harness
Other failure codes are also displayed. This is because connector is discon-
nected. Ignore all failure codes except for [CA187].
Dosing fuel pressure sensor PDOSER
EGR valve lift sensor SEGR
Connector
KVGT position sensor SVGT
Engine wiring harness J1
2. Disconnect connector J1, and connect T-adapter to male side.
3. Turn starting switch ON with connector J1 disconnected.
If no failure is found by this check, perform troubleshooting again from cause 1 be-
3 fore replacing the engine controller.
ler
4.75 to
Voltage Between J1 (male) (78) and (54)
5.25 V
D155AX-8 40-261
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error 40 TROUBLESHOOTING
Circuit diagram related to sensor 2 supply circuit
40-262 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA221] Ambient Pressure Sensor High Error
FAILURE CODE [CA221] Ambient Pressure Sensor High Error

Action level Failure code Ambient Pressure Sensor High Error
Failure
Detail of fail-
High voltage occurs in signal circuit of ambient pressure sensor.
ure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
• Stops KDPF regeneration control.
Phenomenon
on machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))

1
Defective ambient pres- If failure code [CA352] or [CA386] is displayed, perform troubleshooting these first.
2 sure sensor power sup-
ply system
2. Disconnect connector PAMB.
If failure code [CA221] changes to [CA222], sensor is defective.
Defective ambient pres- Reference

sure sensor
2. Insert T-adapter into connector J1 and PAMB.
Voltage or between PAMB (3) and Sensor output 0.3 to 4.7 V
(2)
ness (wire breakage of 2. Disconnect connectors J1 and PAMB and connect T-adapters to each fe-
4
ground line or defective male side.
contact of connector)
Resistance Between J1 (female) (54) and PAMB (female) (2) Max. 1 Ω
D155AX-8 40-263
FAILURE CODE [CA221] Ambient Pressure Sensor High Error 40 TROUBLESHOOTING

2. Disconnect connectors J1 and PAMB, and connect T-adapter to either fe-
5 male side.
ness
Between J1 (female) (78) and (44), or between PAMB
Hot short circuit in wiring 2. Disconnect connector PAMB, and connect T-adapter to female side.
6
Voltage Between PAMB (female) (3) and (2) Max. 1 V
7
CIRCUIT DIAGRAM (AMBIENT PRESSURE SENSOR)
40-264 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA222] Ambient Pressure Sensor Low Error
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error

Action level Failure code Ambient Pressure Sensor Low Error
Failure
Details of
Low voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa) for operation.
Phenomenon
on machine
• Signal voltage sensed by ambient pressure sensor can be checked with monitoring func-
tion. (Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
code is cleared).

1
If failure code [CA352] or [CA386] is displayed, perform troubleshooting these first.
Defective ambient pres- 2. Disconnect connector PAMB, and connect T-adapter to female side.
2 sure sensor power sup-
ply system 3. Switch ON
Between PAMB (female) 4.75 to
Voltage Turn power supply ON.
(1) and (2) 5.25 V
2. Disconnect connectors PAMB and J1, and connect T-adapter to either fe-
3 male side.
ness
Between J1 (female) (44) and (54), or between PAMB
Ground fault in wiring 2. Disconnect connectors PAMB and J1, and connect T-adapter to either fe-
ground circuit)
Between ground and J1 (female) (44) or PAMB (fe-
male) (3)
D155AX-8 40-265
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error 40 TROUBLESHOOTING

2. Disconnect connectors PAMB and J1 and connect T-adapters to each fe-
male side.
5
ness Between J1 (female) (44) and PAMB (female) (3) Max. 1 Ω
Resistance Between J1 (female) (54) and PAMB (female) (2) Max. 1 Ω
Between J1 (female) (78) and PAMB (female) (1) Max. 1 Ω
2. Insert T-adapter into connector J1 or PAMB.
Defective ambient pres- 3. Turn starting switch to ON position.
6
sure sensor
Voltage or between PAMB (3) and Sensor output 0.3 to 4.7 V
(2)
7
CIRCUIT DIAGRAM (AMBIENT PRESSURE SENSOR)
40-266 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error

Action level Failure code Sensor 2 Supply Voltage High Error
Failure
Details of
High voltage occurs in sensor 2 supply (5 V) circuit.
failure
• Ignores signals from EGR valve lift sensor and KVGT position sensor, and fixes values be-
fore detecting error for operation.
Action of
• Ignores signal from doser fuel pressure sensor, and fixes values before detecting error for
controller operation.
Phenomenon
on machine
Related
information
cleared).

Defective sensor power Perform troubleshooting for failure code [CA187].
1
supply 2 system
D155AX-8 40-267
FAILURE CODE [CA234] Engine Overspeed 40 TROUBLESHOOTING
FAILURE CODE [CA234] Engine Overspeed

Action level Failure code Engine Overspeed
Failure
Details of
Engine speed exceeds operating range.
failure
Action of
Restricts fuel injection rate until speed is lowered within operating range.
controller
Phenomenon
Engine speed varies.
on machine
• Engine speed can be checked with monitoring function. (Code: 01002 (rpm))
Related
information
Procedure: Start engine and run at high idle speed.

1 Improper fuel is used. Fuel used may be improper. Check it.
Defective relevant sys- If other failure codes are also displayed, perform troubleshooting for them.
2
tem
Method of using machine may be improper, so instruct operator on how to use ma-
3 Improper machine usage
chine properly.
If failure code is still displayed after above checks on causes 1 to 2, engine control-
4 ler is defective. (In case of an internal defect, troubleshooting is impossible as an
ler
assembly. Replace whole assembly.)
40-268 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error

Action level Failure code NE Speed Sensor Supply Voltage Error
Failure
Details of
Error occurs in NE speed sensor power supply (5 V) circuit.
failure
Action of
Controls by Bkup speed sensor signal.
controller
Phenomenon • Running engine stops (when Bkup (G) speed sensor is also defective).
on machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).

1
connector 2. Start the engine.
2. Disconnect following connectors one by one and turn starting switch to ON po-
sition each time.
3. Each time troubleshooting is finished at one connector , return to step 1.
and troubleshoot next connector.
Defective sensor or wir- If this code is cleared, disconnected sensor or engine wiring harness is defective.
2 REMARK
ing harness
Many of other failure codes are displayed at the same time. This is because of
connector being disconnected. So ignore other codes than this failure code
[CA238].
NE speed sensor NE
Connector
3. Turn starting switch ON with engine wiring harness disconnected.
3 4.75 to
ler Voltage Between J1 (male) (79) and (55)
5.25 V
D155AX-8 40-269
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error 40 TROUBLESHOOTING
CIRCUIT DIAGRAM (Ne SPEED SENSOR)
40-270 D155AX-8
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Er-
40 TROUBLESHOOTING ror
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error

Action level Failure code NE Speed Sensor Supply Voltage High Error (Engine controller sys-
Failure
L01 CA239 tem)
Details of
High voltage occurs in power supply (5 V) circuit of Ne speed sensor.
failure
Action of
Controls by Bkup speed sensor signal.
controller
Phenomenon • Running engine stops (when Bkup (G) speed sensor is also defective).
on machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).

1
Defective NE speed sen- 2. Disconnect connector NE.
2
sor 3. Turn starting switch to ON position.
If this code is cleared, disconnected sensor or engine wiring harness is defective.
2. Disconnect connector J1.
3 Defective wiring harness If this failure code is cleared, wiring harness is defective.
REMARK
Many of other failure codes are displayed at the same time. This is because of
connector being disconnected. So ignore other codes than this failure code
[CA239].
3. Turn starting switch ON with engine wiring harness disconnected.
4 4.75 to
ler Voltage Between J1 (male) (79) and (55)
5.25 V
D155AX-8 40-271
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Er-
ror 40 TROUBLESHOOTING
40-272 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA249] Ambient Air Temp Sensor High Error
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error

Action level Failure code Ambient Air Temp Sensor High Error
Failure
Detail of fail-
High voltage occurs in signal circuit of ambient temperature sensor.
ure
• Operates substituting the ambient temperature with the intake temperature.
Action of (If there are any abnormalities in the intake air temperature sensor, operates with the am-
controller bient temperature set to the default value (25 °C))
• Advances to Inducement strategy. (EU Specification)
• AdBlue/DEF line stops thawing.
Phenomenon • At low temperature, because the AdBlue/DEF injection becomes improper, the NOx emis-
on machine sion increases.
• Engine power deration according to inducement strategy. (EU Specification)
• This failure code is displayed when ambient temperature sensor connector is disconnect-
Related ed.

1
If this failure code is cleared, the wiring harness connector is defective.
2. Disconnect connector P65, and connect T-adapter to male side.
REMARK
If a resistance value of the ambient temperature sensor ranges from 280 Ω to
382 kΩ, the ambient temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
Defective ambient tem- 109 kΩ
2
perature sensor
0 °C 29 to 36 kΩ
7.3 to
Between P65 (male) (A) 30 °C
Resistance 8.8 kΩ
and (B)
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
D155AX-8 40-273
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error 40 TROUBLESHOOTING

REMARK
3 Use ambient temperature sensor resistance characteristics table for check on
wiring harness
cause 2 as a resistance value.
280 Ω to
Resistance Between J2 (female) (56) and (32)
382 kΩ
Hot short circuit in wiring 2. Insert T-adapter into connector J2.
4
5
Circuit diagram related to ambient air temperature sensor
40-274 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error

Action level Failure code Ambient Air Temp Sensor Low Error
Failure
Detail of fail-
Low voltage occurs in signal circuit of ambient temperature sensor.
ure
• Operates substituting the ambient temperature with the intake temperature.
Action of (If there are any abnormalities in the intake air temperature sensor, operates with the am-
controller bient temperature set to the default value (25 °C))
Phenomenon • At low temperature, because the AdBlue/DEF injection becomes improper, the NOx emis-
on machine sion increases.
• Engine power deration according to inducement strategy. (EU Specification)

1
If this failure code is cleared, the wiring harness connector is defective.
2. Disconnect connector ATC, and connect T-adapter to male side.
REMARK
If a resistance value of the ambient temperature sensor ranges from 280 Ω to
382 kΩ, the ambient temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
Defective ambient tem-
2 0 °C 29 to 36 kΩ
perature sensor
7.3 to
Between ATC (male) (A) 30 °C
8.8 kΩ
Resistance and (B)
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
Between ATC (male) (B) and ground Min. 1 MΩ
D155AX-8 40-275
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error 40 TROUBLESHOOTING

REMARK
3 Use ambient temperature sensor resistance characteristics table for check on
wiring harness
cause 2 as a resistance value.
280 Ω to
382 kΩ
Ground fault in wiring 2. Disconnect connectors J2 and ATC, and connect T-adapter to female side
4
harness of J2.
5
Circuit diagram related to ambient air temperature sensor
40-276 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error

Action level Failure code IMV/PCV 1 Short Circuit Error
Failure
Details of
Short circuit is detected in supply pump PCV1 circuit.
failure
Action of
Stops PCV1 drive.
controller
Phenomenon • Engine output drops.
on machine • Engine startability is poor.
• While engine is running normally, approx. 24 V of pulse voltage is supplied to PCV1 (1).
Because it is pulse voltage, it cannot be measured by using multimeter.
Related • If ground fault or hot short circuit is detected in line on minus side when starting switch is
information in ON position. Failure codes [CA271] and [CA273] appear simultaneously.

1. Check according to sections related to wiring harnesses and connectors in
“TROUBLESHOOTING-RELATED INFORMATION”, “CHECKS BEFORE
Defective wiring harness TROUBLESHOOTING”, “c Electrical equipment”.
1
connector 2. Start engine.
If this failure code goes out, wiring harness connector is defective.
Defective supply pump 2. Disconnect connector PCV1, and connect socket to male side.
2 PCV1 (internal short cir-
cuit) Resistance Between PCV1 (male) (1) and (2) 2.3 to 5.3 Ω
Resistance Between PCV1 (male) (1) and ground Min. 1 MΩ
Short circuit in wiring har- 2.
3 Disconnect connector J1, and connect T-adapter to female side.
ness
Resistance Between J1 (female) (23) and (24) (PCV1 resistance) 2.3 to 5.3 Ω
2. Disconnect connectors J1 and PCV1, and connect T-adapter to female
4 harness (contact with side of J1.
ground circuit) Between J1 (female) (23) and ground Min. 1 MΩ
Resistance
Between J1 (female) (24) and ground Min. 1 MΩ
5
Voltage Between J1 (24) and ground Max. 1 V
6
D155AX-8 40-277
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error 40 TROUBLESHOOTING
Circuit diagram related to IMV/PCV1
40-278 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error

Action level Failure code IMV/PCV 1 Open Circuit Error
Failure
L03 CA272 (Engine controller systems)
Details of
Wire breakage is detected in supply pump PCV1 circuit.
failure
Action of
None in particular
controller
Phenomenon • Engine output lowers.
on machine • Engine startability is poor.
Related • While engine is running normally, approx. 24 V of pulse voltage is supplied to PCV (1). Be-
cause it is pulse voltage, it cannot be measured by using multimeter.
information
• Because female connector alone is provided in “Socket” for troubleshooting for this sen-

1
Defective supply pump
2 PCV1 (internal short cir- 2. Disconnect connector PCV1, and connect socket to male side.
cuit)
Resistance Between PCV1 (male) (1) and (2) 2.3 to 5.3 Ω
Open or short circuit in 2.
wiring harness
4
Circuit diagram related to IMV/PCV1
D155AX-8 40-279
FAILURE CODE [CA273] PCV 2 Short Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA273] PCV 2 Short Circuit Error

Failure PCV 2 Short Circuit Error (Engine controller system)
L03 CA273
Details of
Short circuit is detected in supply pump PCV2 circuit.
failure
Action of
Stops PCV2 drive.
controller
Phenomenon • Engine power deration.
on machine • Engine startability becomes poor.
Related • While engine is running normally, approx. 24 V of pulse voltage is supplied to PCV2 (1).
information Because it is pulse voltage, it cannot be measured by using multimeter.
• If ground fault or hot short circuit is detected in line on minus side when starting switch is
in ON position. Failure codes [CA271] and [CA273] appear simultaneously.

1
Defective supply pump 2. Disconnect connector PCV2, and connect T-adapter to male side.
2 PCV2 (internal short cir-
cuit) Between PCV2 (male) (1) and (2) 2.3 to 5.3 Ω
Resistance
Between PCV2 (male) (1) and ground Min. 1 MΩ
ness
2. Disconnect connectors J1 and PCV2, and connect T-adapter to female
4 harness (contact with side of J1.
Resistance
5
6
40-280 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA273] PCV 2 Short Circuit Error
CIRCUIT DIAGRAM (FUEL SUPPLY PUMP PCV2)
D155AX-8 40-281
FAILURE CODE [CA274] PCV 2 Open Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA274] PCV 2 Open Circuit Error

Action level Failure code PCV 2 Open Circuit Error
Failure
Details of
Open circuit is detected in supply pump PCV2 circuit.
failure
Action of
None in particular
controller
Phenomenon • Engine power deration.
on machine • Engine startability becomes poor.
Related • While engine is running normally, approx. 24 V of pulse voltage is supplied to PCV2 (1).
Because it is pulse voltage, it cannot be measured by using multimeter.
information
• Because female connector alone is provided in "Socket" for troubleshooting for this sen-

1
Defective supply pump
2 PCV2 (internal open cir- 2. Disconnect connector PCV2, and connect T-adapter to male side.
cuit)
Resistance Between PCV2 (male) (1) and (2) 2.3 to 5.3 Ω
wiring harness
4
CIRCUIT DIAGRAM (FUEL SUPPLY PUMP PCV2)
40-282 D155AX-8
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short
40 TROUBLESHOOTING Circuit Error
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Cir-
cuit Error
Action level Failure code Injector #1 (L#1) Open Circuit Error or Short Circuit Error (Engine
Failure
L03 CA322 controller system)
Details of
Open or short circuit is detected in #1 injector circuit.
failure
Action of
None in particular
controller
on machine • Engine does not run stably.
Related • While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
information tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
• If ground fault or hot short circuit is detected, failure codes [CA322], [CA331] and [CA324]
appear simultaneously.

1
2. Disconnect connector CN1, and connect T-adapter to male side.
2 Defective injector #1
Between CN1 (male) (1) and (2) 0.4 to 1.1 Ω
Resistance
Between CN1 (male) (1) and ground Min. 1 MΩ
Open circuit or ground
3
fault in wiring harness Between J1 (female) (25) and (1) 0.4 to 1.1 Ω
Resistance
quired.
ness (wire breakage or 2. Disconnect connectors J1 and CN1, and connect T-adapter to each female
4
defective contact of con- side.
nector)
Between J1 (female) (25) and CN1 (female) (1) Max. 1 Ω
Resistance
D155AX-8 40-283
Circuit Error 40 TROUBLESHOOTING

quired.
Ground fault in wiring 2. Disconnect connectors J1 and CN1, and connect T-adapter to each female
5 harness (contact with side.
ground circuit) Between ground and J1 (female) (25) or CN1 (female)
Min. 1 MΩ
(1)
Resistance
Between ground and J1 (female) (1) or CN1 (female)
Min. 1 MΩ
(2)
2. Disconnect connectors J1 and CN1, and connect T-adapter to female side
of J1.
Short circuit in wiring har- No continui-

6 Between J1 (female) (25) and each pin other than pin
ness ty (no sound
(25)
is heard)
Continuity
No continui-
Between J1 (female) (1) and each pin other than pin
ty (no sound
(1)
is heard)
2. Insert T-adapter to connector J1.
Hot short circuit in wiring Voltage Between J1 (25) and ground Max. 6 V
7
harness
If measured voltage is abnormal, disconnect connector CN1 and measure the volt-
age at the same point again.
If the abnormality persists, a positive (+) line is defective.
If the voltage is restored back to a normal range, a negative (-) line is defective.
Defective another cylin- When failure code for abnormality in multiple injectors is displayed, perform trouble-
8 der's injector or wiring shooting these first.
harness
9
Circuit diagram related to injector #1
40-284 D155AX-8
cuit Error
Failure
Details of
failure
Action of
None in particular
controller
Related • If ground fault or hot short circuit is detected, failure codes [CA323], [CA325] and [CA332]
information appear simultaneously.
• While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.

1
Resistance
3
Resistance
quired.
4
nector)
Resistance
D155AX-8 40-285

quired.
Ground fault in wiring 2. Disconnect connectors J1 and CN5, and connect T-adapter to each female
Min. 1 MΩ
(1)
Resistance
Min. 1 MΩ
(2)
of J1.

ness ty (no sound
(50)
is heard)
Continuity
No continui-
ty (no sound
(74)
is heard)
7
harness
harness
9
40-286 D155AX-8
cuit Error
Failure
Details of
failure
Action of
None in particular
controller
Procedure: Start engine

1
Resistance
3
Resistance
quired.
4
nector)
Resistance
D155AX-8 40-287

quired.
Ground fault in wiring 2. Disconnect connectors J1 and CN3, and connect T-adapter to either fe-
Min. 1 MΩ
(1)
Resistance
Min. 1 MΩ
(2)
of J1.

ness ty (no sound
(27)
is heard)
Continuity
No continui-
ty (no sound
(3)
is heard)
7
harness
harness
9
40-288 D155AX-8
cuit Error
Failure
Details of
failure
Action of
None in particular
controller

1
Resistance
3
Resistance
quired.
4
nector)
Resistance
D155AX-8 40-289

quired.
Min. 1 MΩ
(1)
Resistance
Min. 1 MΩ
(2)
of J1.

ness ty (no sound
(51)
is heard)
Continuity
No continui-
ty (no sound
(75)
is heard)
7
harness
harness
9
40-290 D155AX-8
cuit Error
Failure
Details of
failure
Action of
None in particular
controller

1
Resistance
3
Resistance
quired.
4
nector)
Resistance
D155AX-8 40-291

quired.
Min. 1 MΩ
(1)
Resistance
Min. 1 MΩ
(2)
of J1.

ness ty (no sound
(26)
is heard)
Continuity
No continui-
ty (no sound
(2)
is heard)
7
harness
harness
9
40-292 D155AX-8
cuit Error
Failure
Details of
failure
Action of
None in particular
controller
Related • While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
information tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
• If ground fault or hot short circuit is detected, failure codes [CA323], [CA325] and [CA332]
appear simultaneously.

1
Resistance
3
Resistance
quired.
4
nector)
Resistance
D155AX-8 40-293

quired.
Min. 1 MΩ
(1)
Resistance
Min. 1 MΩ
(2)
of J1.

ness ty (no sound
(49)
is heard)
Continuity
No continui-
ty (no sound
(73)
is heard)
7
harness
harness
9
40-294 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA343] Engine Controller Internal Failure
FAILURE CODE [CA343] Engine Controller Internal Failure

Failure Engine Controller Internal Failure (Engine controller system)
L04 CA343
Details of
Internal defect is detected in engine controller.
failure
Action of
None in particular
controller
Phenomenon Engine runs normally. However, engine may be stopped during operation or stopped engine may
on machine not be started.
• Battery voltage of engine controller can be checked by monitoring function. (Code: 03203)
Related
information

Defective engine control- Perform troubleshooting for failure code [CA441].
1
ler system
D155AX-8 40-295
FAILURE CODE [CA351] Injectors Drive Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA351] Injectors Drive Circuit Error

Failure Injectors Drive Circuit Error (Engine controller system)
L03 CA351
Details of
Error occurs in injector drive circuit
failure
Action of
Restricts engine output for operation (restricts common rail pressure).
controller
Phenomenon
on machine
information Procedure: Start engine.

Defective relevant sys- If other failure codes (for injector system) are also displayed, perform troubleshoot-
1
tem ing for them.
2
ler system
40-296 D155AX-8

Failure
Details of
Low voltage occurs in sensor power supply 1 (5 V) circuit.
failure
• Ignores signal from Bkup speed sensor, and operates by NE speed sensor signal.
• Ignores signal from engine oil pressure sensor, and fixes oil pressure value to (250 kPa
{2.5 kg/cm2} ) for operation.
• Ignores signal from ambient pressure sensor, and fixes ambient pressure value to
(52.44 kPa {0.53 kg/cm2} ) for operation.
Action of • Ignores signal from charge (boost) pressure sensor, and fixes charge (boost) pressure val-
controller ue to (400 kPa {4.1 kg/cm2} ) for operation.
• Ignores signal from crankcase pressure sensor, and fixes crankcase pressure value to
(0 kPa {0 kg/cm2} ) for operation.
• EGR valve closes.
Phenomenon
on machine
Related
information
cleared).

1
D155AX-8 40-297

position each time.
If this failure code is cleared, disconnected sensor or engine wiring harness is de-
fective.
REMARK
Defective sensor or wir- Other failure codes are also displayed. This is because connector is discon-
2
ing harness nected. Ignore all failure codes except for [CA352].
Bkup speed sensor G
Oil pressure sensor POIL
Charge (Boost) pressure sensor PIM
Connector
Ambient pressure sensor PAMB
Crankcase pressure sensor PCCV
3. Turn starting switch ON with connector J1 disconnected.
ler
4.75 to
5.25 V
40-298 D155AX-8
Circuit diagram related to sensor 1 supply circuit
D155AX-8 40-299
FAILURE CODE [CA356] MAF Sensor High Error 40 TROUBLESHOOTING
FAILURE CODE [CA356] MAF Sensor High Error

Failure MAF Sensor High Error (Engine controller system)
L03 CA356
Details of
High frequency input error is detected in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) for operation.
Phenomenon
on machine
• Because sensor output is approx. 5 V of pulse waveform, it is not measured by using mul-
timeter.
• Mass air flow sensor and intake air temperature sensor are provided as a unit.
code is cleared).

tors in “c Electric equipment ”of “CHECKS BEFORE TROUBLESHOOT-
Defective wiring harness ING” in “RELATED INFORMATION ON TROUBLESHOOTING”.
1
Defective sensor power If failure code [CA3419] or [CA3421] are displayed at the same time, perform trou-
2
supply system bleshooting these first.
2. Disconnect connector MAF.
Defective mass air flow
sensor (internal defect)
If this failure code changes to failure code [CA357], mass air flow sensor is defec-
tive.
1. Perform preparation when starting switch is in OFF position.
2. Disconnect connector MAF and connect T-adapter to female side.
Defective sensor power
supply system
Between MAF (female) (2) Approx.
Voltage Power supply
and (3) 12 V
40-300 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA356] MAF Sensor High Error

quired.
2. Disconnect connectors J1 and MAF, and connect T-adapters to each fe-
ness (wire breakage of
5 male side.
ground line or defective
contact of connector) REMARK
Open circuit in GND line.
Resistance Between J1 (female) (56) and MAF (female) (3) Max. 1 Ω
2. Disconnect connectors J1 and MAF, and connect T-adapters to female
6 side of J1.
ness
Between J1 (female) (32) and each pin other than J1 No continui-
Continuity
(32) pin. ty
7
CIRCUIT DIAGRAM (MASS AIR FLOW SENSOR)
D155AX-8 40-301
FAILURE CODE [CA357] MAF Sensor Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA357] MAF Sensor Low Error

Failure Mass Air Flow Sensor Low Error (Engine controller system)
L03 CA357
Details of
Low frequency input error is detected in signal circuit of mass air flow sensor.
failure
• Sets mass air flow sensor to fixed value (10 kg/min) for operation.
Phenomenon
on machine
• Because sensor output is approximately. 5 V of pulse waveform, it is not measured by us-
ing multimeter.
• This failure code and failure code [CA691] are displayed simultaneously if sensor connec-
Related tor is removed.
code is cleared).

1
Defective sensor power If failure code [CA3419] or [CA3421] are displayed at the same time, perform trou-
2
supply system bleshooting these first.
Defective mass air flow 2. Replace mass air flow sensor.
3
sensor (internal defect) 3. Turn starting switch to ON position.
If this failure code is cleared, originally-provided mass air flow sensor is defective.
2. Disconnect connector MAF and connect T-adapter to female side.
supply system
Between MAF (female) (2) Approx.
and (3) 12 V
40-302 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA357] MAF Sensor Low Error

2. Disconnect connectors J1 and MAF, and connect T-adapter to either fe-
male side.
Open circuit in wiring har- If failure code is still displayed after above checks on
ness (wire breakage or cause 4, this check is not required. Max. 1 Ω
5
defective contact of con- Between J1 (female) (80) and MAF (female) (2)
nector)
Resistance If failure code is still displayed after above checks on
cause 4, this check is not required. Max. 1 Ω
Between J1 (female) (56) and MAF (female) (3)
Between J1 (female) (32) and MAF (female) (1) Max. 1 Ω
Ground fault in wiring 2. Disconnect connectors J1 and MAF, and connect T-adapter to either fe-
ground circuit)
Between ground and J1 (female) (32) or MAF (female)
(1)
7 side of J1.
ness
Continuity
(32) pin. ty
Hot short circuit in wiring 2. Disconnect connector MAF and connect T-adapter to female side.
8
Voltage Between MAF (female) (1) and (3) Max. 1 V
9
D155AX-8 40-303
FAILURE CODE [CA357] MAF Sensor Low Error 40 TROUBLESHOOTING
40-304 D155AX-8

Failure Sensor 1 Supply Voltage High Error (Engine controller system)
L03 CA386
Details of
High voltage occurs in sensor power supply 1 (5 V) circuit.
failure
• Ignores signal from Bkup speed sensor, and operates by NE speed sensor signal.
• Ignores signal from engine pressure sensor, and fixes oil pressure value to (250 kPa
{2.5 kg/cm2} ) for operation.
• Ignores signal from ambient pressure sensor, and fixes ambient pressure value to
(52.44 kPa {0.53 kg/cm2} ) for operation.
Action of • Ignores signal from charge (boost) pressure sensor, and fixes charge (boost) pressure val-
controller ue to (400 kPa {4.1 kg/cm2} ) for operation.
• Ignores signal from crankcase pressure sensor, and fixes crankcase pressure value to
(0 kPa {0 kg/cm2} ) for operation.
• EGR valve closes.
Phenomenon • Engine power deration is canceled by turning starting switch to OFF position after this fail-
on machine ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

1
supply 1 system
D155AX-8 40-305
FAILURE CODE [CA441] Power Voltage Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA441] Power Voltage Low Error

Action level Failure code Power Voltage Low Error
Failure
Detail of fail-
Low voltage occurs in power supply circuit of controller.
ure
Action of
Operates at fixed value (approximately 6.0 V) of battery voltage.
controller
Related
information
Procedure: Turn engine starting switch to ON position.

Loose or corroded bat- Battery terminal may be loose or corroded. Check it directly.
1
tery terminal
Loose terminal or partial 1. Turn starting switch to OFF position.

2
open circuit at terminal Check terminals of the alternator, battery, ground terminal (GND20), etc.
3
1. Perform troubleshooting with starting switch at OFF position and when starting
4 Improper battery voltage engine.
Voltage Between battery (+) and (-). 20 to 30 V
2. Insert T-adapter into connector EG2.
5 Defective alternator 3. Start engine and perform troubleshooting while running engine at medium
speed or higher.
Voltage Between EG2 (2) and ground 26 to 30.5 V
40-306 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA441] Power Voltage Low Error

Reference
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
3. Turn battery disconnect switch to ON position.
6 4. Measure voltage with starting switch at OFF position and when starting en-
ler
gine.
Voltage Between J2 (26) and (51) 20 to 30 V
CIRCUIT DIAGRAM (ENGINE CONTROLLER POWER SUPPLY)
D155AX-8 40-307
FAILURE CODE [CA441] Power Voltage Low Error 40 TROUBLESHOOTING
40-308 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA442] Power Voltage High Error
FAILURE CODE [CA442] Power Voltage High Error

Action level Failure code Power Voltage High Error
Failure
Details of
High voltage (Min. 36 V) occurs in power supply circuit of controller.
failure
Action of
Operates at fixed value approximately 36 V of battery voltage.
controller
Related
information

1
ler power supply system
D155AX-8 40-309
FAILURE CODE [CA449] Common Rail Pressure High Error 2 40 TROUBLESHOOTING
FAILURE CODE [CA449] Common Rail Pressure High Error 2

Action level Failure code Common Rail Pressure High Error 2
Failure
Details of
High pressure error (exceeding specified maximum level) has occurred in common rail pressure.
failure
Action of • Restricts engine output for operation.
controller • Restricts common rail pressure.
Phenomenon
on machine
• Signal voltage from common rail pressure sensor can be checked by monitoring function.
(Code: 36401 (V))
Related • Common rail pressure in common rail pressure sensor can be checked by monitoring
information function. (Code: 36400 (MPa))

Defective common rail Perform troubleshooting for failure code [CA553].
1
pressure sensor system
40-310 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA451] Common Rail Pressure Sensor High Error
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error

Action level Failure code Common Rail Pressure Sensor High Error
Failure
Details of
High voltage occurs in signal circuit of common rail pressure sensor.
failure
Phenomenon
on machine
(Code: 36401 (V))
• Common rail pressure in common rail pressure sensor can be checked by monitoring
Related
function. (Code: 36400 (MPa))
information
• This failure code is displayed if connector of common rail pressure sensor is disconnected.

1. See descriptions of wiring harness and connectors in “c: Electrical equipment”
in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION
Defective wiring harness ON TROUBLESHOOTING”, and check it.
1
If this failure code is cleared, harness connector is defective.
first.
Defective common rail
2 pressure sensor power 2. Disconnect connector PFUEL and connect T-adapter to female side.
supply system 3. Turn starting switch to ON position.
Between PFUEL (female) 4.75 to
(1) and (3) 5.25 V
2. Disconnect connectors PFUEL and J1, and connect T-adapters to each fe-
male side of connectors.
If power supply input is normal in check on cause 2,
3 Between J1(female)(82) and PFUEL(female)(1)
nector) If power supply input is normal in check on cause 2,
Resistance
Between J1(female)(58) and PFUEL(female)(3)
Between J1(female)(87) and PFUEL(female)(2) (sen-
Max. 1 Ω
sor output)
Short circuit in wiring har- 2. Disconnect connectors PFUEL and J1, and connect T-adapter to either fe-
4
ness male side.
Resistance Between J1(female)(82) and (87) or PFUEL(2) and (1) Min. 1 MΩ
D155AX-8 40-311
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error 40 TROUBLESHOOTING

2. Disconnect connector PFUEL.
3. Disconnect connector PFUEL, and connect T-adapter to female side or in-
sert T-adapters into connector
harness
REMARK
Pin (87) of J1 is connected to 5 V circuit via resistor inside engine controller.
Voltage Between PFUEL(female)(2) and (3) or J1(87) and (58) Approx. 5 V
Defective common rail 2. Insert T-adapter into connector PFUEL or J1.
6
Between PFUEL (female)
Voltage (2) and (3), or between J1 Sensor output 0.2 to 4.6 V
(87) and (58)
7
Circuit diagram related to common rail pressure sensor
40-312 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error

Action level Failure code Common Rail Pressure Sensor Low Error
Failure
Details of
Low voltage occurs in signal circuit of common rail pressure sensor.
failure
Action of • Engine power deration.
Phenomenon
on machine
(Code: 36401 (V))
Related function. (Code: 36400 (MPa))
• If temperature sensor connector is removed even in normal condition, failure code for High
Error [CA451] is displayed instead of this failure code.

1
first.
2 pressure sensor power 2. Disconnect connector PFUEL and connect T-adapter to female side.
Between PFUEL (female) 4.75 to
(1) and (3) 5.25 V
If failure code [CA452] changes to [CA451], sensor is defective.
Reference
pressure sensor
2. Insert T-adapter into connector PFUEL or J1.
Between PFUEL (2) and
Voltage (3), or between J1 (87) Sensor output 0.2 to 4.6 V
and (58)
D155AX-8 40-313
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error 40 TROUBLESHOOTING

ness (5 V line breakage 2. Disconnect connectors J1 and PAMB and connect T-adapters to each fe-
4
or defective contact of male side.
connector)
Resistance Between J1(female)(82) and PFUEL(female)(1) Max. 1 Ω
Ground fault in wiring 2. Disconnect connectors J1 and PFUEL, and connect T-adapter to either fe-
ground circuit)
Between PFUEL(female)(2) or J1(female)(87) and
ground
2. Disconnect connectors J1 and PFUEL, and connect T-adapter to either fe-
6 male side.
ness
Between PFUEL(female)(2) and (3) or J1(female)(87)
and (58)
7
40-314 D155AX-8
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Volt-
40 TROUBLESHOOTING age High Error
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage

High Error
Action level Failure code Common Rail Pressure Sensor Supply Voltage High Error (Engine
Failure
Details of
High voltage occurs in power supply (5 V) of common rail pressure sensor.
failure
Action of • Engine power deration
Phenomenon
on machine

1
2 pressure sensor (internal If this failure code is cleared any more, sensor is defective.
defect)
REMARK
Other failure codes are displayed at the same time. This happens because the
connector is disconnected. So ignore other codes besides this failure code.
2. Disconnect connectors J1.
If this failure code does not appear, wiring harness may be defective.
3 Defective wiring harness
Perform following troubleshooting.
REMARK
Other failure codes (many codes) are also displayed. They are generated be-
cause of disconnection of connector. Ignore failure codes other than this code.
quired.
Hot short circuit in wiring 2. Disconnect connector PFUEL, and connect T-adapter to female side
4 of connector.
harness
4.75 and
Voltage Between PFUEL(female)(1) and (3)
5.25 V
D155AX-8 40-315
age High Error 40 TROUBLESHOOTING

ler
4.7 to
5.25 V
40-316 D155AX-8
40 TROUBLESHOOTING age Low Error
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage

Low Error
Action level Failure code Common Rail Pressure Sensor Supply Voltage Low Error (Engine
Failure
Details of
Low voltage occurs in power supply (5 V) of common rail pressure sensor.
failure
Phenomenon
on machine

1
2 pressure sensor (internal If this failure code is cleared any more, sensor is defective.
defect)
REMARK
Other failure codes are displayed at the same time. This happens because the
connector is disconnected. So ignore other codes besides this failure code.
2. Disconnect connectors J1.
If this failure code does not appear, wiring harness may be defective.
Perform following troubleshooting.
REMARK
Other failure codes (many codes) are also displayed. They are generated be-
cause of disconnection of connector. Ignore failure codes other than this code.
quired.
4 harness (contact with 2. Disconnect connectors J1 and PFUEL, and connect T-adapter to either fe-
ground circuit) male side.
Between J1(female)(82) or PFUEL(female)(1) and
ground
D155AX-8 40-317
age Low Error 40 TROUBLESHOOTING

quired.
5 2. Disconnect connectors J1 and PFUEL, and connect T-adapter to either fe-
ness
male side.
Between J1(female)(58) and (82) or PFUEL(female)(1)
and (2)
ler
4.7 to
5.25 V
40-318 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA553] Common Rail Pressure High Error 1
FAILURE CODE [CA553] Common Rail Pressure High Error 1

Failure Common Rail Pressure High Error 1 (Engine controller system)
L01 CA553
Details of
Common rail pressure high error 1 (indicated pressure is higher than that which is assumed)
failure
Action of
None in particular
controller
Phenomenon
on machine
(Code: 36401 (V))

1
tem
Defective electrical sys- Since common rail pressure sensor may have electrical defect, perform trouble-
3 tem of common rail pres- shooting for following failure codes. [CA451], [CA452]
sure sensor
Defective mechanical Common rail pressure sensor may have mechanical trouble. Check it.
4 system of common rail
pressure sensor
Overflow valve spring may be broken, seat may be worn, and ball may be stuck.
5 Defective overflow valve
Check them.
6 Clogged overflow piping Overflow piping may be clogged. Check it.
7 Defective pressure limiter Pressure limiter may be defective mechanically. Check it.
D155AX-8 40-319
FAILURE CODE [CA555] Crankcase Pressure High Error 2 40 TROUBLESHOOTING
FAILURE CODE [CA555] Crankcase Pressure High Error 2

Action level Failure code Crankcase Pressure High Error 2
Failure
Details of
High pressure error (level 1) in crankcase is detected.
failure
Action of
None in particular
controller
Phenomenon
on machine
• Signal voltage from crankcase pressure sensor can be checked by monitoring function.
(Code: 48401 (V))
• Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
Related
48400 (kPa))
information
• This failure code is cleared when failure code [CA1942] is displayed.

1 Clogged KCCV filter Replace the KCCV filter.
If an error persists after replacement of the KCCV filter and emulsions are detected
Blocked KCCV gas pip-
2 inside KCCV, blocked emulsions may be suspected in KCCV blow by gas piping.
ing
Perform troubleshooting for coolant leakage.
Defective crankcase Crankcase pressure sensor system may be defective. Perform troubleshooting for
3
pressure sensor failure codes [CA1843] and [CA1844].
The error does not disappear after replacing KCCV filter, and “Crankcase Pressure
High Error 1” or “Crankcase Pressure High Error 2” is also displayed, piston ring
4 Increase of blowby gas may be worn or broken, or oil from KVGT may be leaked, valve guide and stem
seal may be worn or damaged. Perform troubleshooting “TROUBLESHOOTING
OF ENGINE (S MODE)”, “Engine oil consumption is excessive”.
40-320 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA556] Crankcase Pressure High Error 3
FAILURE CODE [CA556] Crankcase Pressure High Error 3

Failure Crankcase Pressure High Error 3 (Engine controller system)
L03 CA556
Details of
High pressure error (level 2) in crankcase is detected.
failure
Action of
controller
on machine • Oil may leak from seals or gauge.
(Code: 48401 (V))
Related
48400 (kPa))
information
• This failure code is cleared when failure code [CA1942] is displayed.

ing
3
D155AX-8 40-321
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 40 TROUBLESHOOTING
FAILURE CODE [CA559] Common Rail Pressure Low Error 1

Action level Failure code Common Rail Pressure Low Error 1
Failure
Details of
No-pressure error (level 1) is detected in supply pump.
failure
Action of
None in particular
controller
Phenomenon • Engine does not start. Or startability is poor.
on machine • Engine power deration.
Related function. (Code: 36400 (MPa))

Defective relevant sys- If another failure code is displayed, perform troubleshooting these first.
1
tem
REMARK
For details of troubleshooting, see Note 1.
REMARK
For check of fuel pressure in low-pressure circuit, see “ TESTING AND AD-
JUSTING”,“TEST FUEL PRESSURE”.
Defective low pressure Fuel pres-

3 sure in low-
circuit component
pressure cir-
cuit (with
engine run-
0.15 to 0.3 MPa {1.5 to 3.0 kg/cm2}
ning at high
idle or under
load equiva-
lent to rated
load)
Clogging of filter and See “Note 2” for contents of failure.
4
strainer
Defective electrical sys- Supply pump may have electrical defect. Perform troubleshooting for following fail-
5
tem of supply pump ure codes; [CA271], [CA272], [CA273], and [CA274]
Defective common rail Common rail pressure sensor may be defective. Check wiring harness for break-
6
pressure sensor age.
For details of testing pressure limiter leakage amount, see “ TESTING AND AD-
JUSTING” “TEST FUEL RETURN RATE AND LEAKAGE”.
Pressure
limiter leak-
7 Defective pressure limiter age amount
(rated oper- Max. 10 cc/min
ation or
equivalent
(stall load))
40-322 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA559] Common Rail Pressure Low Error 1

For check of limit return rate (spill) from injector, see “ TESTING AND ADJUST-
ING”, “TEST FUEL RETURN RATE AND LEAKAGE”.
1600 rpm 960 cc/min
8 Defective injector 1700 rpm 1020 cc/min

Limit return
Speed at operation equiv-
rate (spill) 1800 rpm 1080 cc/min
alent to rating (stall load)
from injector
1900 rpm 1140 cc/min
2000 rpm 1200 cc/min
If failure code is still displayed after above checks on Causes 1 to 8, supply pump
9 Defective supply pump
may be defective.
Test method of low-pressure circuit devices

<Using method of check sheet>
Perform the above troubleshooting and record its details in the attached “Check sheet for low rail pressure er-
ror”.
Note 1: Check low-pressure fuel circuit parts for following items.
• Remaining quantity of fuel
• Clogging of fuel tank breather
• Sticking, wear, or clogged filter of feed pump
• Leakage from or clogging of low-pressure fuel piping
• Malfunction of bypass valve, installation of wrong parts (See next fig.)
• Clogged fuel filter
• Fuel mixed into oil pan (fuel leakage inside head cover)
Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
D155AX-8 40-323
Overflow valve (1): Spring is seen through both holes.

Bypass valve (2): Spring is seen through hole on nut side.
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace filters and strainers according to the following procedure.
Gauze filter: Disassemble and check. If clogged, clean.
Strainer on upstream side of gauze filter: If gauze filter is clogged, clean upstream strainer as well.
Fuel filter: Failure is not solved by performing the work in 1) and 2) above, replace the fuel filter.
Check sheet for low rail pressure error

Model Work No.
Model and serial No. Date inspected
Engine SAA6D140E-7 Service meter
Engine serial No. Name of worker
No
Go
A. Visual check go
od
od
1 Fuel leakage to outside
2 Clogged fuel tank breather
40-324 D155AX-8
No
Go
B. Check with machine monitor (02 Failure record, 01 Monitoring, 09 Cylinder Cutout mode operation go
od
od
3 Check of failure code
Check of monitoring information
Standard value No
Measured Go
Code Item displayed Testing conditions ISO unit (reference val- go
value od
ue) od
Low idle r/min 740 (+25 / 0)
01002 Engine speed High idle r/min 2100 (0 / -50)
Torque converter stall r/min 1540
Low idle % 0
31701 Throttle position
High idle % 100
Inject Fueling
18600 Command Torque converter stall mg/st - - -
4 (Unit of weight)
Rail Pressure
36200 Torque converter stall MPa -
Command
Common rail pres-
36400 Torque converter stall MPa -
sure
Low idle CA - - -
Final injection tim-
36300 High idle CA - - -
ing command
Torque converter stall CA - - -
36500 Charge pressure Torque converter stall kPa - - -
Coolant tempera-
04107 Low idle °C - - -
ture
14200 Fuel temperature Low idle °C - - -
Check of Cylinder Cutout Mode Operation (engine speed)
Standard value No
Func- Measured Go
Cutout cylinder Testing conditions ISO unit (reference val- go
tion value od
ue) od
No. 1 cylinder Low idle r/min - - -
5 Set No. 2 cylinder Low idle r/min - - -
cutout
to No. 3 cylinder Low idle r/min - - -
each No. 4 cylinder Low idle r/min - - -
cylin-
der No. 5 cylinder Low idle r/min - - -
No. 6 cylinder Low idle r/min - - -
Standard value No
Measured Go
C. Check of fuel circuit pressure Testing conditions Unit (reference val- go
value od
ue) od
High idle or under load equiv- MPa 0.15 to 0.3
Leakage from pressure lim-
6 alent to rated operation (at
iter {kg/cm2} {1.5 to 3.0}
stall)
D155AX-8 40-325
No
Go
D. Check of strainer and filter go
od
od
7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
Standard value No
E. Check of leakage and return Measured Go
Testing conditions Unit (reference val- go
rate value od
ue) od
Leakage from pressure lim- Load equivalent to rating (at
11 cc/min Max. 10
iter stall)
Torque converter stall: 1600
cc/min 960
rpm
cc/min 1020 Speed:
rpm
12 Return rate from injector cc/min 1080
rpm
cc/min 1140 Return rate:
rpm
cc/min 1200
rpm
40-326 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA595] Turbocharger Speed High Error 2
FAILURE CODE [CA595] Turbocharger Speed High Error 2

Failure Turbocharger Speed High Error 2 (Engine controller system)
L01 CA595
Details of
High speed error in turbocharger speed is detected.
failure
Action of
Sets turbocharger speed to fixed value (130000 (rpm)) for operation.
controller
Phenomenon
on machine
• Turbocharger speed in turbocharger speed sensor can be checked by monitoring function.
(Code: 48100 (rpm))
Related
• Because sensor output is pulse waveform, it is not measured by using multimeter.
information

Increase of turbocharger Since turbocharger speed may increase, check it.
1
speed
2 Defective turbocharger Turbocharger may have a failure. Check it.
Defective turbocharger If no failure is found in cause 1, the turbocharger speed sensor system may be de-
3
speed sensor fective. Perform troubleshooting for failure code [CA687].
D155AX-8 40-327
FAILURE CODE [CA687] Turbocharger Speed Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA687] Turbocharger Speed Low Error

Action level Failure code Turbocharger Speed Low Error
Failure
Details of
Low speed occurs in turbocharger speed.
failure
Action of
Sets turbocharger speed to fixed value (130000 (rpm)) for operation.
controller
Phenomenon
on machine
• Because sensor output is pulse waveform, it is not measured by using multimeter.
• Turbocharger speed in turbocharger speed sensor can be checked by monitoring function.
Related (Code: 48100 (rpm))
information • This failure code is displayed if KVGT speed sensor connector is disconnected.
Procedure: Start engine and sets engine speed to 1200 rpm or higher.

1 Defective turbocharger Turbocharger may have a failure. Check it.
2
connector 2. Run engine at high idle.
Defective KVGT speed 2. Disconnect connector VGT REV. and connect T-adapter to female side.
3
600 to
Resistance Between VGT REV. (female) (1) and (2)
1600 Ω
Open circuit and short 1. Turn starting switch to OFF position.
circuit in wiring harness 2. Disconnect connector J1, and connect T-adapter to female side.
4 (short circuit, wire break-
age or defective contact 600 to
of connector) 1600 Ω
quired.
Open circuit in wiring har- 2. Disconnect connectors J1 and VGT REV., and connect T-adapters to each
5
ness female side.
Between J1 (female) (17) and VGT REV. (female) (1) Max. 1 Ω
Resistance
Between J1 (female) (16) and VGT REV. (female) (2) Max. 1 Ω
2. Disconnect connectors J1 and VGT REV., and connect T-adapter to either
6 female side.
ness
Between J1 (female) (17) and (16), or between VGT
REV. (female) (1) and (2)
40-328 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA687] Turbocharger Speed Low Error

2. Disconnect connectors J1 and VGT REV., and connect T-adapter to either
Ground fault in wiring female side.
7 harness (contact with Between ground and J1 (female) (17) or VGT REV. (fe-
ground circuit) Resistance Min. 1 MΩ
male) (1)
Between ground and J1 (female) (16) or VGT REV. (fe-
male) (2)
Hot short circuit in wiring 2. Disconnect connector J1, and connect T-adapter to female side.
8
Voltage Between J1 (female) (17) and ground Max. 1 V
Defective sensor installa- Defective turbocharger speed sensor (looseness) or defective parts for speed de-
9 tion or defective parts for tection (KVGT internal parts) (including deformation by heat) may be suspected.
speed detection Check it.
10
CIRCUIT DIAGRAM (TURBO SPEED SENSOR)
D155AX-8 40-329
FAILURE CODE [CA689] Engine NE Speed Sensor Error 40 TROUBLESHOOTING
FAILURE CODE [CA689] Engine NE Speed Sensor Error

Failure Engine NE Speed Sensor Error (Engine controller system)
L01 CA689
Details of
Error occurs in the signal from engine Ne speed sensor.
failure
Action of
Operates by Bkup speed sensor signal.
controller
Phenomenon • Running engine stops (when Bkup speed sensor is also defective).
on machine • Stopped engine cannot be started (when Bkup speed sensor is also defective).
• Because internal speed sensor consists of hole sensor and electronic circuit instead of
Related coil, whether speed sensor is normal or not cannot be determined even if resistance of
information speed sensor is measured by using multimeter.
• Because speed sensor output is 5 V of pulse voltage, it cannot be measured by using mul-
timeter.
• Speed sensor detects holes of flywheel and calculates engine speed.

1
Defective NE speed sen- If failure code [CA238] or [CA239] is displayed, perform troubleshooting for the
2
sor power supply system code first.
Engine NE speed sensor Engine NE speed sensor may be broken or installed improperly (loosened). Check
3 broken or installed im- it.
properly (loosened)
Improper installation of Flywheel may be installed defectively (loosened). Check it.
4
flywheel
2. Disconnect connector NE, and connect T-adapter to female side.
Defective NE speed sen-
sor power supply system
Between NE (female) (1) 4.75 to
and (2) 5.25 V
2. Disconnect connectors J1 and NE, and connect T-adapters to each female
side.
6
defective contact of con- Between J1 (female) (79) and NE (female) (1)
nector)
Between J1 (female) (55) and NE (female) (2)
Between J1 (female) (31) and NE (female) (3) Max. 1 Ω
40-330 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA689] Engine NE Speed Sensor Error

2. Disconnect connectors J1 and NE, and connect T-adapter to either female
side.
7 Between J1 (female) (79) and (31), or between NE (fe-
ness Min. 1 MΩ
male) (1) and (3)
Resistance
Between J1 (female) (55) and (31), or between NE (fe-
Min. 1 MΩ
male) (2) and (3)
Ground fault in wiring 2. Disconnect connectors J1 and NE, and connect T-adapter to either female
ground circuit)
Between ground and J1 (female) (31) or NE (female)
(3)
Hot short circuit in wiring 2. Disconnect connector NE, and connect T-adapter to female side.
9
Voltage Between NE (female) (3) and ground Max. 1 V
If failure code is still displayed after above checks, the engine Ne speed sensor
Defective engine NE
10 may be defective. (In case of an internal defect, troubleshooting is impossible as an
speed sensor
11
Function of Ne (crankshaft) speed sensor

Ne speed sensor detects places (A) where there are no bores
(H)on the flywheel (1) and the engine controller calculates the
engine speed and the phase.
D155AX-8 40-331
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error 40 TROUBLESHOOTING
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error

Failure Intake Air Temperature Sensor High Error (Engine controller system)
L01 CA691
Details of
High voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of
Sets intake air temperature to fixed value (25 °C) for operation.
controller
Phenomenon
on machine
Related • This failure code and failure code [CA357] are displayed simultaneously if sensor connec-
tor is removed.
information

1
-30 °C 25 to 28 kΩ
5.5 to
0 °C
Between MAF (male) (3) 6.1 kΩ
and (4) 1.9 to
Defective mass air flow 25 °C
2 Characteristic of intake 2.1 kΩ
Resistance temperature - resistance 1.1 to
value 40 °C
1.2 kΩ
180 to
100 °C
185 Ω
Between MAF (male) (3)
Entire area Min. 1 MΩ
and ground (sensor body)
Open circuit and short
circuit in wiring harness REMARK
3 (short circuit, wire break- Use intake temperature sensor resistance characteristics table for check on
age or defective contact
cause 2 as an air intake temperature resistance value.
of connector)
180 Ω to
28 kΩ
40-332 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA691] Intake Air Temperature Sensor High Error

4 3. Insert T-adapter into connector J1, or connect T-adapter to female side of
harness
MAF.
Voltage Between J1 (61) and (56) or MAF (female) (1) and (3). Max. 5.25 V
5 side of J1.
ness
Continuity
(61) pin. ty
6
D155AX-8 40-333
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error

Failure Intake Air Temperature Sensor Low Error (Engine controller system)
L01 CA692
Details of
Low voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of
Sets intake air temperature to fixed value (25 °C) for operation.
controller
Phenomenon
on machine
Related
information

1
If this failure code changes to failure code [CA691]. intake air temperature sensor is
defective.
Reference
Defective intake air tem- -30 °C 25 to 28 kΩ
2 perature sensor (internal
defect) 5.5 to
0 °C
Between MAF (male) (3) 6.1 kΩ
and (4) 1.9 to
25 °C
Characteristic of intake 2.1 kΩ
Resistance temperature - resistance 1.1 to
value 40 °C
1.2 kΩ
180 to
100 °C
185 Ω
Between MAF (male) (3)
Entire area Min. 1 MΩ
and ground (sensor body)
circuit in wiring harness REMARK
3 (short circuit, wire break- Use intake temperature sensor resistance characteristics table for check on
age or defective contact
cause 2 as an air intake temperature resistance value.
of connector)
180 Ω to
28 kΩ
40-334 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error

ground circuit)
(4)
5 side of J1.
ness
Continuity
(61) pin. ty
6
D155AX-8 40-335
FAILURE CODE [CA697] Engine Controller Internal Temperature
Sensor High Error 40 TROUBLESHOOTING
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor

High Error
Action level Failure code Engine Controller Internal Temperature Sensor High Error
Failure
Details of
High voltage error occurs in signal circuit of engine controller internal temperature sensor.
failure
Action of
None in particular
controller
Phenomenon
on machine
• Temperature detected by engine controller internal temperature sensor can be checked
Related with monitoring function. (Code: 18900 (°C))

Improper use of control- Check that controller is not used in high temperature environment.
1
ler
2
40-336 D155AX-8
FAILURE CODE [CA698] Engine Controller Internal Temperature
40 TROUBLESHOOTING Sensor Low Error
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor

Low Error
Action level Failure code Engine Controller Internal Temperature Sensor Low Error
Failure
Details of
Low voltage error occurs in signal circuit of engine controller internal temperature sensor.
failure
Action of
None in particular
controller
Phenomenon
on machine
• Temperature detected by engine controller internal temperature sensor can be checked
Related with monitoring function. (Code: 18900 (°C))

Improper use of control- Check that controller is not used in low temperature environment.
1
ler
2
D155AX-8 40-337
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error 40 TROUBLESHOOTING
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error

Action level Failure code Engine Backup Speed Sensor Phase Error
Failure
Details of Engine controller detects phase error by signal from engine Bkup speed sensor. (Compared with
failure signal from Ne speed sensor, phase does not fit.)
Action of
Controls by Ne speed sensor signal.
controller
Phenomenon • Running engine stops (when Ne speed sensor is also defective).
on machine • Stopped engine cannot be started (when Ne speed sensor is also defective).
information • For replacing Bkup speed sensor, replace fuel supply pump (For details, see “DISASSEM-
BLY AND ASSEMBLY” “REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY”.

Defective engine Ne Engine Ne speed sensor may be defective. Perform troubleshooting for failure code
1
speed sensor system [CA689].
Defective engine Bkup Engine Bkup speed sensor may be defective. Perform troubleshooting for failure
2
speed sensor circuit code [CA778].
Defective installation of Check that supply pump shaft is installed at correct angle. See DISASSEMBLY
3
supply pump AND ASSEMBLY, “REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY”.
40-338 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA778] Engine Backup Speed Sensor Error
FAILURE CODE [CA778] Engine Backup Speed Sensor Error

Action level Failure code Engine Backup Speed Sensor Error
Failure
Details of
Error is detected in engine Bkup speed sensor circuit.
failure
Action of
Operates by Ne speed sensor signal.
controller
• Running engine stops (when Ne speed sensor is also defective).
Phenomenon
• Stopped engine cannot be started (when Ne speed sensor is also defective).
on machine
• Engine startability is deteriorated (when Ne speed sensor is normal).
• For replacing Bkup speed sensor, replace fuel supply pump (For details, see “DISASSEM-
BLY AND ASSEMBLY” “REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY”).
Related
• Because internal speed sensor consists of electronic circuit instead of coil, whether speed
information
sensor is normal or not cannot be determined even if resistance of speed sensor is meas-
ured by using multimeter.
• Because speed sensor output is 5 V of pulse voltage, it cannot be measured by using mul-
timeter.

1
2
Damage or improper in- Engine Bkup speed sensor may be damaged or incorrectly (loosely) installed.
3 stallation (loose) of en- Check it directly.
gine Bkup speed sensor
Defective resistor (G- 2.
4 Disconnect connector G-RES and connect T-adapters to male side.
RES)
Resistance Between G-RES (male) (1) and (2) 620 Ω
Defective engine Bkup 2.
Disconnect connector G and connect T-adapters to female side.
5 speed sensor power sup- 3. Turn starting switch to ON position.
ply system
Between G (female) (1) 4.75 to
and (2) 5.25 V
2. Disconnect connectors J1 and G, and connect T-adapter to the female
6 wiring harness
side of connector J1.
(resistor RES line)
Resistance Between J1(female) (9) and (60) 620 Ω
D155AX-8 40-339
FAILURE CODE [CA778] Engine Backup Speed Sensor Error 40 TROUBLESHOOTING

2. Disconnect connectors J1 ,G and G-RES, and connect T-adapters to each
female side.
Open circuit in wiring har- If power supply voltage in check on cause 5 is normal,
ness this check is not required. Max.1 Ω
7
(wire breakage or defec- Between J1 (female) (78) and G (female) (1)
tive contact of connector) Resistance If power supply voltage in check on cause 5 is normal,
this check is not required. Max.1 Ω
Between J1 (female) (54) and G (female) (2)
Between J1 (female) (18) and G (female) (3) Max.1 Ω
2. Disconnect connectors J1, G, and G-RES, and connect T-adapters to fe-
male side of J1 or G.
8 Between J1 (female) (78) and (18), or between G (fe-
ness Min.1 MΩ
male) (1) and (3)
Resistance
Between J1 (female) (54) and (18), or between G (fe-
Min.1 MΩ
male) (2) and (3)
harness 2. Disconnect connectors J1 and G, and connect T-adapters to either female
9
(contact with ground cir- side.
cuit) Resistance Between ground and J1 (female) (18) or G (female) (3) Min.1 MΩ
2. Disconnect connectors G and G-RES, and connect T-adapters to female
Hot short circuit in wiring side of G.
10
harness
3. Turn starting switch to ON position (with connector PIM disconnected).
Voltage Between G (female) (3) and ground Max.1 V
If failure code is still displayed after above checks, engine Bkup speed sensor is
Defective engine Bkup
11 defective. (In case of an internal defect, troubleshooting is impossible as an assem-
speed sensor
bly. Replace whole assembly.)
12
40-340 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA778] Engine Backup Speed Sensor Error
Circuit diagram (engine Bkup speed sensor)
D155AX-8 40-341
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error 40 TROUBLESHOOTING
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error

Action level Failure code Engine Controller Partial Data Lost Error
Failure
Details of
Internal defect is detected in controller.
failure
Action of
None in particular
controller
• Engine runs normally. However, engine may be stopped during operation or stopped en-
Phenomenon
gine may not be started.
on machine
• Engine controller cannot memorize internal data correctly.
• Engine controller internal data (related to KDPF, AdBlue/DEF Level, etc.) may be lost. Ap-
propriate remedy must be performed after resetting error.
Related • This error code appears when power supply is disconnected by battery disconnect switch,
etc. before engine controller is normally exited.
information
NOTICE
Remedy after resetting error
See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR SETTING TESTING
(ACTIVE REGENERATION FOR SERVICE)” in “SETTING AND OPERATION OF MACHINE
MONITOR” to perform “Active Regeneration for Service”.

Defective power supply Since the power supply circuit may be defective, perform troubleshooting for failure
1
circuit system code [CA441].
Improper operation of Battery disconnect switch may be operated improperly.
2
battery disconnect switch
3
40-342 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1664] KDOC Abnormality
FAILURE CODE [CA1664] KDOC Abnormality

Action level Failure code KDOC Abnormality
Failure
Details of During regeneration, KDOC inlet temperature sensor and KDOC outlet temperature sensor indicate
failure similar values (temperature difference is approximately within 10°C).
• EGR valve closed.

controller • Regeneration control stops.
• Fuel dosing stops.
Phenomenon
on machine
k
The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
low idle speed (KDPF regeneration is not executed) are 100 to 250 °C, and difference be-
tween these temperatures is approximately 10 °C. (KDOC inlet temperature > KDOC out-
let temperature > KDPF outlet temperature)
• When manual stationary regeneration is in progress, KDOC inlet temperature is 250 to
400 °C, and KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
Related • As to procedure for accessing KDPF temperature sensor, see “50 Disassembly and as-
information sembly”, “Removal and installation of KDPF assembly” and “Disassembly and assembly of
KDPF assembly”.
• Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is
retracted (for up to 6 minutes). So when you restart engine, wait until the system operating
lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• Before performing “Loaded Diagnostics Operation To Confirm Failure Correction”,
firstly “Setting and operating machine monitor”, Service mode, Testing menu (En-
gine Controller Active Fault Clear) to be performed to clearer this failure code.
D155AX-8 40-343
FAILURE CODE [CA1664] KDOC Abnormality 40 TROUBLESHOOTING

1
Defective KDOC outlet If failure code [CA3316], [CA3317] or [CA3318] is displayed, perform troubleshoot-
2
1. Check if KDPF is attached to the exhaust system.
3 Defective KDOC
2. Check if KDOC is attached to KDPF.
4
Loaded Diagnostics Operation To Clear Failure Code

Perform the following operation to confirm the completion of the repair:
1. Turn the starting switch from OFF to ON.
2. Start the engine and run it at low idle speed for approximately 1 minute.
3. Display KDOC inlet and outlet temperatures with monitoring function.
NOTICE
KDOC inlet temperature of 250 °C or more is a requirement for clearing the failure code.
4. Perform continuously the blade RAISE relief for 15 minutes with fuel control dial at MAX position.
If the failure code is cleared after steps 1 to 4 are implemented, repair work is complete.
REMARK
• Every failure code is cleared by executing “Reset All Faults” command by using service tool “INSITE”.
• See “INSITE” Operation Manual for working with “INSITE”.
40-344 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1664] KDOC Abnormality
Circuit diagram related to KDOC temperature sensor
D155AX-8 40-345
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Er-
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error

Action level Failure code AdBlue/DEF Level Sensor Voltage High Error
Failure
Detail of fail-
Failure of AdBlue/DEF level sensor (Piezoelectric element for level measurement is open)
ure
Action of
Advances to Inducement strategy. (EU Specification)
controller
Phenomenon • Failure to measure AdBlue/DEF level.
on machine • Engine power deration according to inducement strategy. (EU Specification)
• The AdBlue/DEF level sensor is one of the AdBlue/DEF tank sensors integrated with the
AdBlue/DEF temperature sensor and AdBlue/DEF quality sensor performs CAN communi-
cation with the engine controller.
Related
• If the engine controller receives open-circuit information of Piezoelectric element for level
information measurement, this failure code is displayed.

1
tank sensor
3
40-346 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3

Failure
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank level becomes 2.5 % or less)
ure
Action of
controller
Phenomenon
on machine
• The failure codes of AdBlue/DEF level low are as follows:
When AdBlue/DEF level is 10 % or less [CA3497]
When AdBlue/DEF level is 2.5 % or less [CA1673]
Related
When AdBlue/DEF level is 0.0 %or less [CA3547]
information
• After this failure code is cleared, Engine power deration continues until the starting switch

tank sensor
3
D155AX-8 40-347
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Er-
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error

Action level Failure code AdBlue/DEF Temperature Sensor Low Error
Failure
Detail of fail- Failure of AdBlue/DEF temperature sensor (Short circuit of thermistor for temperature measure-
ure ment)
Action of
controller
• The AdBlue/DEF temperature sensor is one of the AdBlue/DEF tank sensors integrated
with the AdBlue/DEF level sensor and AdBlue/DEF quality sensor performs CAN commu-
nication with the engine controller.
Related
• If the thermistor for temperature measurement shorts, this failure code is sent to the en-
information gine controller via CAN communication and displayed.

1
tank sensor
3
40-348 D155AX-8
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Er-
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error

Action level Failure code AdBlue/DEF Temperature Sensor High Error
Failure
Detail of fail- Failure of AdBlue/DEF temperature sensor (Open circuit of thermistor for temperature measure-
ure ment)
Action of
controller
• The AdBlue/DEF temperature sensor is one of the AdBlue/DEF tank sensors integrated
with the AdBlue/DEF level sensor and AdBlue/DEF quality sensor performs CAN commu-
nication with the engine controller.
Related
• If the thermistor for temperature measurement is open, this failure code is sent to the en-
information gine controller via CAN communication and displayed.

1
tank sensor
3
D155AX-8 40-349
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error 40 TROUBLESHOOTING
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error

Action level Failure code AdBlue/DEF Pump Priming Error
Failure
Detail of fail- The pressure cannot be raised for preparation of AdBlue/DEF injection due to damage, clogging,
ure etc. of the AdBlue/DEF pump or hose.
Action of • AdBlue/DEF pump stop
controller • Advances to Inducement strategy.
Phenomenon • NOx emission increases
on machine • Engine power deration according to inducement strategy.
• The engine controller does not display this failure code during thawing control of the AdBl-
ue/DEF supply system (AdBlue/DEF injection is disabled, which disables judgment).
• Make sure that the value of the following 4 states are other than 1 (thawing) 3 minutes af-
ter the engine is started. (It is not possible to troubleshoot this failure until thawing control
is completed.)
• The state of each heater is 1: Thawing, 2: Warming, or 0: OFF.
Enter the following numbers directly and confirm the values on the monitoring code
screen.
19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF suction and purge line heater state
19307 AdBlue/DEF pressure line heater state
19308 AdBlue/DEF pump heater state
• This failure code is cleared on the AdBlue/DEF pump “Pre-defined Monitoring” screen if
Related the AdBlue/DEF pump pressure rises to around 900 kPa.
information • The associated values can be confirmed on the following screen. (The values can also be
confirmed on the monitoring code screen by entering the numbers directly.)
• The “Pre-defined Monitoring” screen. (The following numbers are the monitoring codes)
AdBlue/DEF pump diagnosis
19304 AdBlue/DEF pump state
19108 AdBlue/DEF Pump Pressure
19136 AdBlue/DEF Pump Temperature
19109 AdBlue/DEF Pump Pressure Sensor Voltage
19120 AdBlue/DEF Injection Quantity
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared. (This failure
code is not cleared by only turning ON the starting switch again.)

Defective AdBlue/DEF If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] is displayed on the
1
pump system abnormality record screen, perform troubleshooting these first.
Open circuit or short cir- If failure code [CA3713] or [CA5115] is displayed on the abnormality record screen,
2 cuit in AdBlue/DEF line perform troubleshooting these first.
heater 1
Defective AdBlue/DEF If failure code [CA2976] is also displayed, perform checks on causes 2 and after in
3 pump temperature sen- troubleshooting for this failure code.
sor system
40-350 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error

Defective AdBlue/DEF If failure code [CA1669] or [CA3868] or [CA4732] or [CA4739] or [CA4769] is dis-
4
level sensor system played, perform troubleshooting these first.
If failure code [CA1673] or [CA3497] or [CA3498] or [CA3547] is displayed, trouble-
shoot for those codes first.
5 Low AdBlue/DEF level
If the level is low, replenish AdBlue/DEF until it can be seen in the sight gauge, and
then “Loaded Diagnostics Operation To Clear Failure Code”.
If crystallized AdBlue/DEF is adhered to the surrounding of hose, tank, pump, or
engine compartment, it shows AdBlue/DEF may be leaking. Refer to “TESTING
Damaged AdBlue/DEF AND ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”,
6 hose, AdBlue/DEF leak- “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)” to per-
age at connection form AdBlue/DEF Pump Pressure Up Test and find the location of the AdBlue/DEF
leak.
Replace parts as necessary.
Check the AdBlue/DEF suction hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
7 frozen AdBlue/DEF. Blow air or send AdBlue/DEF through each AdBlue/DEF hose,
suction hose
and repair or replace the hose if clogged.
Check the AdBlue/DEF tank for entry of foreign material. Check the AdBlue/DEF
Clogged AdBlue/DEF
8 tank strainer for clogging. Repair or replace the part if any abnormality is found.
tank strainer
Use AdBlue/DEF for cleaning.
1. Remove the flange from the AdBlue/DEF tank.
2. Check if a suction tube in the AdBlue/DEF tank is torn apart.
Suction tube clogged or 3. see “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
9 torn apart in the CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
AdBlue/DEF tank TESTING MENU (SCR SERVICE TEST)” to perform “AdBlue/DEF Pump
Pressure Up Test” to check if AdBlue/DEF is not leaking from the suction tube
in the AdBlue/DEF tank visually.
If the interval specified in the Operation and Maintenance Manual has elapsed
since the last time the AdBlue/DEF pump filter was replaced, or foreign material
Clogged AdBlue/DEF
10 was found in the check for AdBlue/DEF tank strainer, replace the AdBlue/DEF
pump filter
pump filter. (Refer to “METHOD FOR REPLACING AdBlue/DEF FILTER” in the Op-
eration and Maintenance Manual)
Defective AdBlue/DEF If the cause is not determined by above checks, replace the AdBlue/DEF pump.
11
pump
ler
Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to the OFF position, and shut down the engine controller.
2. Turn starting switch to ON position, and start the engine.
3. Run the engine at low idle speed.
4. Check if monitoring code 19108 “Diesel Exhaust Fluid Line Pressure” rises up around 900 kPa within 5 mi-
nutes.
5. After ensuring the above 4., and after 3 minutes, check if this failure code is cleared after 3 minutes.
REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.
D155AX-8 40-351
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage
High Error 40 TROUBLESHOOTING
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Er-
ror
Action level Failure code AdBlue/DEF Tank Heating Valve Voltage High Error
Failure
Detail of fail-
High voltage error is detected in signal circuit of AdBlue/DEF tank heating valve.
ure
Action of
Advances to Inducement strategy.
controller
Phenomenon • Failure to thaw AdBlue/DEF.
• This failure code is displayed when AdBlue/DEF tank heating valve connector is discon-
nected.
• AdBlue/DEF tank heating valve is driven when AdBlue/DEF is thawed and engine starts
Related with the temperature of engine coolant 45 °C or below.
information • AdBlue/DEF tank heating value can also be driven at “AdBlue/DEF tank heater valve test”.
• This failure code is detected only when AdBlue/DEF tank heating value stops.

Defective wiring harness
1 2.
connector Start engine (engine coolant temperature: Max. 45 °C) or perform
“AdBlue/DEF tank heater valve test”.
Defective AdBlue/DEF 2.
2 Disconnect connector UHV1, and connect T-adapter to male side.
tank heating valve
Resistance Between UHV1 (male) (1) and (2) 15 to 30 Ω
Open or short circuit in Between J2 (female) (82) and (57)
3
wiring harness
Resistance REMARK 15 to 30 Ω
The resistance value is the same as the value for an
AdBlue/DEF tank heating valve
1. If failure code is still displayed after above checks on cause 3, this check is not
required.
ness (wire breakage or 3. Disconnect connectors J2 and UHV1 and connect T-adapters to each fe-
4
nector)
Between J2 (female) (82) and UHV1 (female) (1) Max. 1 Ω
Resistance
Between J2 (female) (57) and UHV (female) (2) Max. 1 Ω
40-352 D155AX-8
40 TROUBLESHOOTING High Error

Hot short circuit in wiring 2. Disconnect connector UHV1, and connect T-adapter to female side.
5
harness 3. Turn starting switch ON position (with the valve disconnected).
Voltage Between UHV1 (female) (1) and (2) Max. 4.5 V
2. Disconnect connectors J2 and UHV1, and connect T-adapter to female
side of J2.
6
ness
Measure it with continuity range of multimeter.
No continui-
Continuity ty (no sound
(82)
is heard)
7
Circuit diagram related to AdBlue/DEF tank heating valve
D155AX-8 40-353
Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Er-
ror
Action level Failure code AdBlue/DEF Tank Heating Valve Voltage Low Error
Failure
Detail of fail-
Low voltage error is detected in signal circuit of AdBlue/DEF tank heating valve.
ure
Action of
controller
Phenomenon • Failure to thaw AdBlue/DEF.
• The AdBlue/DEF tank heating valve operates when thawing the AdBlue/DEF and when
starting the engine while the temperature of the engine coolant is 45 °C or below.
• The AdBlue/DEF tank heating valve also operates when an “AdBlue/DEF Tank Heater
Valve Test” is implemented.
Related
• This failure code is detected only when the AdBlue/DEF tank heating valve is driven.
information
Procedure: Start engine (Engine coolant temperature: 45 °C or below), “Service mode”
and “Testing menu (SCR service test) - Operate” of “Setting and operating machine moni-
tor” to perform “AdBlue/DEF tank heater valve test”.

1 2.
connector Start engine (engine coolant temperature: Max. 45 °C) or perform
“AdBlue/DEF tank heater valve test”.
2 Disconnect connector UHV1, and connect T-adapter to male side.
tank heating valve
Resistance Between UHV1 (male) (1) and (2) 15 to 30 Ω
Open or short circuit in Between J2 (female) (82) and (57)
3
wiring harness
The resistance value is the same as the value for an
AdBlue/DEF tank heating valve
Ground fault in wiring 2. Disconnect connectors J2 and UHV1, and connect T-adapter to either fe-
ground circuit)
Between J2 (female) (82) or UHV1 (female) (1) and
ground
40-354 D155AX-8
40 TROUBLESHOOTING Low Error

2. Disconnect connectors J2 and UHV1, and connect T-adapter to female
side of J2.
5
ness
No continui-
(82)
is heard)
6
Circuit diagram related to AdBlue/DEF tank heating valve
D155AX-8 40-355
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High
Error 40 TROUBLESHOOTING
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error

Action level Failure code AdBlue/DEF Quality Sensor Voltage High Error
Failure
Detail of fail-
Failure of AdBlue/DEF quality sensor (Piezoelectric element for quality measurement is open)
ure
Action of
controller
Phenomenon • The AdBlue/DEF quality cannot be measured.
• The AdBlue/DEF quality sensor is one of the AdBlue/DEF tank sensors integrated with the
AdBlue/DEF level sensor and AdBlue/DEF temperature sensor performs CAN communi-
Related
• If the engine controller receives open-circuit information of Piezoelectric element for quali-
information ty measurement, this failure code is displayed.

1
tank sensor
3
40-356 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1691] Defective Regeneration
FAILURE CODE [CA1691] Defective Regeneration

Action level Failure code Defective Regeneration
Failure
L03 CA1691 (Engine controller systems)
Details of KDOC efficiency (catalyzer function) is lowered. (Because KDOC outlet temperature does not rise
compared with KDOC inlet temperature: 250 to 400 °C as normal, KDOC outlet temperature: 450 to
failure 600 °C as normal during regeneration.)
Action of
controller
Phenomenon
on machine
D155AX-8 40-357
FAILURE CODE [CA1691] Defective Regeneration 40 TROUBLESHOOTING
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
low idle speed (KDPF regeneration is not executed) are 100 to 250 °C, and difference be-
tween these temperatures is approximately 10 °C. (KDOC inlet temperature > KDOC out-
let temperature > KDPF outlet temperature)
• During manual stationary regeneration (normal), KDOC inlet temperature is 250 to 400 °C,
and both KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
• When dosing fuel does not blow out (KDOC drying) during manual stationary regenera-
tion, all of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet tempera-
ture are 250 to 400 °C.
Related
• Test exhaust gas color. For details, see “TESTING AND ADJUSTING”, “TEST EXHAUST
information
GAS COLOR”.
• Failure code [CA2637] may be also displayed. However, perform troubleshooting for this
failure code.
• When soot accumulation is at level 3 or lower, manual stationary regeneration can be per-
formed only from active regeneration for service.
• Procedure of performing the manual stationary regeneration from the "active regeneration
for service".
1. Start engine.
2. Make sure that machine is in safe condition.
3. Display Testing screen from Service Menu screen of machine monitor, open Active
Regeneration for Service, and perform Manual Stationary Regeneration (manual sta-
tionary regeneration finishes in approximately 40 minutes).
• Confirmation method of repair completion: For checking repair completion, start engine
and perform manual stationary regeneration if KDOC is not replaced. (See cause 5.)
NOTICE
• Confirmation of repair completion is not necessary if KDOC is replacecd.
• When KDOC in KDPF is changed, perform reset procedure for KDOC change and
then finish repair.

When KDPF cooled down sufficiently or there are significant differences between
Defective KDOC outlet
1 the KDOC outlet temperature and the KDOC inlet temperature or KDPF outlet tem-
temperature sensor
perature at idle (non-regeneration), change the KDPF temperature sensor.
Suddenly accelerate the engine from low idle to high idle two times, and then keep
the engine running at high idle for 5 seconds.
NOTICE
Defective exhaust gas
2 • If an excess black smoke is seen at high idle during acceleration, per-
color
form “S-9 KDPF GETS CLOGGED IN A SHORT TIME”.
• Even excessive black smoke is exhausted during engine acceleration,
if it is not at engine high idle, it is not defective.
40-358 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1691] Defective Regeneration
k Perform after KDPF and KDOC cooled down sufficiently.

1. Remove KDPF.
2. Remove KDOC.
Defective KDOC (stain, 3. Blow air from KDOC outlet and remove stains on ceramic surface inside
3 crack, damage on KDOC KDOC.
surface) 4. Check if the ceramic inside KDOC has cracks.
KDOC is defective if any cracks are found in KDOC (change KDOC).
NOTICE
Perform the following whether or not KDOC is changed:
1. Attach KDOC and KDPF.
3. On the Service screen of the machine monitor, display “Diagnostic Tests”
screen, open 03 “KDPF Memory Reset”, and perform 03 “KDOC Change”
(Reset after KDOC change).
NOTICE
Reset after KDOC
4 • Failure codes [CA1691] and [CA2637] are cleared when reset after
change
KDOC change is performed. At this point, a corrective action which is
effective when the failure code is displayed and is taken for dozing
fuel which is not injected is reset.
• Check that reset after KDOC change is complete successfully (by re-
set count). If not, perform troubleshooting again.
• If KDOC is changed, troubleshooting is complete without performing
manual stationary regeneration.
NOTICE
Perform if KDOC is not changed:
2. Take notes on the temperature in initial state and during manual stationary
regeneration from the KDOC inlet temperature sensor and the KDPF outlet
temperature sensor to check if the KDOC outlet temperature sensor is nor-
mal (see Related information).
3. Perform manual stationary regeneration (see Related information).
Defective KDOC (de- 4. Turn starting switch to OFF position.
5 graded catalyst action of
KDOC) 5. Start the engine and perform manual stationary regeneration (to check if
failure code [CA2637] is displayed).
NOTICE
• Troubleshooting is complete after making sure that the failure code is
cleared.
• If failure code [CA2637] is displayed after manual stationary regenera-
tion is complete, KDOC is defective (catalyst action of KDOC is de-
graded. Change KDOC).
• Perform cause 4 again when KDOC is changed.
D155AX-8 40-359
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error 40 TROUBLESHOOTING
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error

Action level Failure code SCR Outlet NOx Sensor In Range Error
Failure
Detail of fail- The value of the NOx sensor of the SCR outlet is abnormal compared with the turbocharger outlet
ure NOx emission value
Action of
None in particular
controller
Phenomenon
NOx emission increases.
on machine
k SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
ambient temperature is not high.
• If the SCR outlet NOx sensor probe is disconnected from the exhaust pipe or loosened,
this failure code may appear.
• The SCR outlet NOx sensor and turbocharger outlet NOx sensor are not serviceable,
Related therefore, replace the sensor if it is defective.
information NOTICE
• For this failure code, after investigating the cause of the problem and completing the
repair, perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
make sure repair is completed. (This failure code is not cleared by only turning ON
the starting switch.)
• If the failure code of active regeneration prohibition or that of AdBlue/DEF injection
prohibition appears, the failure cannot be cleared. Clear the corresponding failure
codes first

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], [CA3718], [CA3725], or
outlet NOx sensor sys- [CA3748] is displayed, perform troubleshooting for these failure codes first.
tem
1
(Open circuit, internal de-
fect, defective sensor
heater)
Defective SCR outlet If failure code [CA1887], [CA2771], [CA3545], [CA3583], [CA3681], or [CA3717] is
NOx sensor system displayed, perform troubleshooting for these failure codes first.
2 (Open circuit, internal de-
heater)
Urea deposit is accumu- 1. Perform “Loaded Diagnostics Operation To Clear Failure Code” to sublime
lated in the AdBlue/DEF urea deposit.
3 mixing tube but it is re- 2. Repair is completed if the failure code is cleared after performing “Loaded
movable by application of Diagnostics Operation To Clear Failure Code” (urea deposit has been re-
the thermal load. moved by sublimation).
Defective connection be- Check if the SCR outlet NOx sensor probe is installed securely.
tween the SCR outlet
4
NOx sensor probe and
an exhaust pipe
40-360 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error

1. Check if urea deposits are accumulated in the AdBlue/DEF mixing tube and
the AdBlue/DEF injector mount.
Accumulation of urea de- 2.
If deposits are accumulated, remove the AdBlue/DEF mixing tube to remove
5 posits in AdBlue/DEF
deposits and clean the tube.
mixing tube
3. Check if urea deposits are accumulated in the SCR inlet case. If accumulated,
perform the next item.
1. If urea deposit is accumulated inside the SCR inlet case, remove the urea
Accumulated urea de- deposit as much as possible.
6
posit in SCR assembly
2. Repair AdBlue/DEF mixing tube back to normal.
1. Refer to “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF
MACHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING
WITH TESTING MENU (SCR SERVICE TEST)” to perform an
“AdBlue/DEF INJECTOR INJECTION AMOUNT TEST” to judge the injec-
tor.
2. If the AdBlue/DEF injection amount test results are within the values speci-
Abnormal injection from fied in “TESTING AND ADJUSTING”, it is OK. Proceed to step 4.
7
AdBlue/DEF injector
3. If the AdBlue/DEF injection amount is out of the range specified in “Testing
and adjusting”, replace the AdBlue/DEF injector.
4. When the repair is completed, repeat “Loaded Diagnostics Operation To
Clear Failure Code” the system two times (repeat the operation two times
to ensure AdBlue/DEF to be sublimed, in case it has flown into the catalyst
(Required time: approximately 2 hours)).
Defective SCR outlet If no failure is found by the above checks, the SCR outlet NOx sensor is defective
8
NOx sensor (NOx sensor measurement probe is clogged with urea deposit)
If no failure is found by preceding checks, the turbocharger outlet NOx sensor may
Defective turbocharger
9 be defective. (Abnormality in the turbocharger outlet NOx sensor due to adverse ef-
outlet NOx sensor
fects of sulfur content)
ler

1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at low idle speed safely.
4. See “TESTING AND ADJUSTING”, “Service mode” and “Test menu (SCR Service Test)” in “Setting and op-
eration of machine monitor” to implement “SCR Denitration Efficiency Test” (maximum duration of the re-
moval efficiency is 1.5 hours).
5. The test condition on the monitor changes from “0” to “10”, then to “20”. (“14” may become temporarily due
to temperature transition).
6. When the test is completed after the test condition on the monitor is displayed as “20”, stop the engine and
shut down the engine controller (wait for a few minutes after the shutdown, then the starting switch to OFF
position).
7. Turn the starting switch to the ON position again.
D155AX-8 40-361
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error 40 TROUBLESHOOTING
REMARK
40-362 D155AX-8

Action level Failure code Sensor 5 Supply Voltage High Error
Failure
Details of High voltage error is detected in 5 V power supply of the KDPF differential pressure sensor, KDPF
failure outlet pressure sensor and, AdBlue/DEF pump pressure sensor.
• Operates at estimated value of KDPF outlet pressure sensor. (Operation may be per-
formed at 0 kPa {0 kg/cm2} .)
• Operates at estimated value of KDPF differential pressure sensor. (Operation may be per-
Action of formed at 0 kPa.)
controller • Operates at fixed value (1300 kPa) of AdBlue/DEF pump pressure.
Phenomenon
on machine
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).

Defective sensor 5 power Perform troubleshooting for failure code [CA1696].
1
supply system
D155AX-8 40-363

Failure
Detail of fail- Low voltage error is detected in 5 V power supply of the KDPF differential pressure sensor, KDPF
ure outlet pressure sensor and, AdBlue/DEF pump pressure sensor.
• Operates at estimated value of KDPF outlet pressure sensor. (Operation may be per-
formed at 0 kPa {0 kg/cm2} .)
• Operates at estimated value of KDPF differential pressure sensor. (Operation may be per-
Action of formed at 0 kPa {0 kg/cm2} .)
controller • Operates at fixed value (-100 kPa) of AdBlue/DEF pump pressure.
• Closes EGR valve.
• Controls engine output for operation.
• Stops regeneration control.
Phenomenon
on machine
unit.
information
code is cleared).

1
position each time.
If this failure code is cleared, disconnected sensor is defective.
Defective sensor or wir-
2
ing harness REMARK
Other failure codes are also displayed. This is because the connector is dis-
connected. Ignore all failure codes except.
KDPF differential pressure (outlet pressure) sensor PDPF
Connector
AdBlue/DEF pump pressure sensor DSM
Ground fault in wiring 2. Disconnect connectors J2, PDPF, and DSM, and connect T-adapter to ei-
3 harness (contact with ther female side.
ground circuit)
Between ground and J2 (female) (8) or PDPF (female)
(4)
40-364 D155AX-8

2. Disconnect connectors J2, PDPF, and DSM, and connect T-adapter to fe-
4 male side of J2.
ness
(8)
2. Disconnect connector PDPF.
3. Insert T-adapter into conditioner J2, or connect T-adapter to female side of
connector PDPF.
ler
4.75 to
Voltage Between J2 (8) and (32) or PDPF(female) (4) and (1)
5.25 V
Circuit diagram related to KDPF differential pressure and KDPF outlet pressure
sensor
D155AX-8 40-365
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error 40 TROUBLESHOOTING
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error

Action level Failure code AdBlue/DEF Tank Thawing Error
Failure
Detail of fail- Thawing of the AdBlue/DEF tank cannot be completed due to failure of the AdBlue/DEF tank heat-
ure ing valve, failure of the engine coolant circuit, etc.
Action of
None in particular
controller
Phenomenon
NOx emission increases
on machine
• The engine controller judges whether this failure code is displayed only during thawing
control of the AdBlue/DEF tank (The value of 19305 AdBlue/DEF Tank Heating State is
“1”).
• 19305 AdBlue/DEF Tank Heating State, 1: Thawing, 2: Warming, or 0: OFF.
• The Pre-defined Monitoring screen uses the AdBlue/DEF tank thawing control diagnosis.
(The following numbers are the monitoring codes)
• AdBlue/DEF injector diagnosis
Related 19102 AdBlue/DEF Tank HtrValve Command
information 19115 AdBlue/DEF Temperature in Tank
4107 Coolant Temperature
19400 Ambient Temperature
19133 Engine Room Temperature
NOTICE
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure this failure code is not re-
displayed. (Turning the starting switch to ON position does not confirm the completion of re-
pair.)

Defective AdBlue/DEF If failure code [CA1683] or [CA1684] is displayed on the abnormality record screen,
1 tank heating valve sys- perform troubleshooting these first.
tem
2 tank temperature sensor perform troubleshooting these first.
system
40-366 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error

See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OPERA-
TION MACHINE MONITOR”, “METHOD FOR SETTING WITH TESTING MENU
(SCR SERVICE TEST)” to perform an “AdBlue/DEF TANK HEATER RELAY TEST”
and check if the AdBlue/DEF tank heater valve is driven normally.
Confirm that the AdBlue/DEF tank heating valve operates in response to 19102
“AdBlue/DEF Tank HtrValve Command” (switches between 0 and 1).
1. Remove the coolant hose from the outlet side of the AdBlue/DEF tank heating
valve, and plug the removed hose.
3. Perform an “AdBlue/DEF TANK HEATER RELAY TEST” to drive the
AdBlue/DEF tank heating valve.
Mechanical failure of
4. Make sure that coolant flows out in response to valve open and close com-
3 AdBlue/DEF tank heating
valve mands.
REMARK
If coolant flows out in response to valve operation, the AdBlue/DEF tank
heating valve is normal.
If coolant does not flow out:
Increase the temperature of the inlet side coolant hose to make sure that the cool-
ant flows out.
1. If coolant flows out from the inlet side coolant hose, replace the AdBlue/DEF
tank heating valve.
2. If coolant does not flow out from the inlet side coolant hose, clogging of the
coolant circuit is suspected.
Check if the engine coolant circuit in the engine or AdBlue/DEF tank is leaking or
Clogged engine coolant clogged. In addition check if the engine coolant level is appropriate. If there are
4
circuit and trapped air some problems, repair the relevant portions. Bleed air from the engine coolant
again.
Perform “Loaded Diagnostics Operation To Confirm Failure Correction”. If the AdBl-
5 ue/DEF tank temperature does not rise correctly, replace the AdBlue/DEF tank sen-
tank temperature sensor
sor.
6
Loaded Diagnostics Operation To Confirm Failure Correction

Check if the repair has been completed with the following procedure：
3. Check monitoring code 19115 “AdBlue/DEF Temperature in Tank” on the “Troubleshooting Pre-defined
Monitoring” screen.
1) In case, monitoring code 19115 “AdBlue/DEF Temperature in Tank” is less than 1 °C.
1] Check if monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is issued (from 0 to
1) ,and perform warm-up operation.
When monitoring code 04107 “Coolant temperature” becomes 0 °C or more during warm-up oper-
ation, monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is issued ( from 0 to 1).
2] Keep warm-up operation and that monitoring code 04107 “Coolant temperature” is 20 °C or more.
3] Confirmation will be completed if the AdBlue/DEF tank temperature becomes 4 °C or more within
an hour after the “AdBlue/DEF Tank HtrValve Command” is issued. If it becomes 4 °C or less, re-
turn to troubleshooting.
D155AX-8 40-367
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error 40 TROUBLESHOOTING
2) In case, monitoring code 19115 “AdBlue/DEF Temperature in Tank” is 1 °C or more.

1] Perform warm-up operation, and raise the monitoring code 04107 “Coolant temperature” to the de-
gree over 20 °C added to the ambient temperature.
2] See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in
“SETTING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF tank heater re-
lay test”.
3] When monitoring code 04107 “Coolant temperature” is less than the ambient temperature added
to 20 °C during “AdBlue/DEF tank heater relay test”, perform warm-up operation together with
“AdBlue/DEF tank heater relay test” again.
4] Confirmation will be completed if the AdBlue/DEF temperature in Tank becomes 5 °C or above
within an hour after starting the AdBlue/DEF tank heater relay test. If it becomes 5 °C or less, re-
4. After the repair is completed, see “CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING” to
clear the failure code and make sure that the failure code has been cleared from the Abnormality Record
screen.
40-368 D155AX-8
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck
40 TROUBLESHOOTING Error
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Er-
ror
Action level Failure code AdBlue/DEF Tank Heater Valve Open Stuck Error
Failure
Detail of fail-
The AdBlue/DEF tank heating valve is open at all times.
ure
Action of
None in particular
controller
Phenomenon
AdBlue/DEF in the AdBlue/DEF tank may deteriorate quickly because the temperature is high.
on machine
ue/DEF tank.
• The Pre-defined Monitoring screen uses the AdBlue/DEF tank thawing control diagnosis.
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure repair
is completed. (This failure code is not cleared by only turning ON the starting switch.)

tem
system
D155AX-8 40-369
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck

See Testing and adjusting, “service modes” of “setting and operating machine mon-
itor”, “operating method of testing menu (SCR service test)” to perform an
“AdBlue/DEF tank heater relay test” and check if the AdBlue/DEF tank heater valve
is driven normally.
3 AdBlue/DEF tank heating 3. Perform an “AdBlue/DEF tank heater relay test” to drive the AdBlue/DEF tank
valve heating valve.
4. Confirm that coolant flows out in response to valve open and close commands.
If coolant flows out regardless of valve open and close commands, replace the
REMARK
• If coolant flows out in response to valve operation, the AdBlue/DEF
tank heating valve is normal.
• If coolant flows out, AdBlue/DEF tank heating valve is defective. So re-
place AdBlue/DEF tank heating valve.
sor.
5

3. Check if monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is not issued (0) on the Pre-De-
fined Monitoring screen.
4. Start the engine and check the monitoring code 19115 “AdBlue/DEF tank temperature”.
5. Raise monitoring code 04107 “Coolant temperature” to the degree over 10 °C or more than AdBlue/DEF
tank temperature.
6. Check again if the monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is not issued (0) on the
Pre-Defined Monitoring screen.
7. Check if monitoring code 19115 “AdBlue/DEF tank temperature” is 1 °C or less after a lapse of 5 minutes
after starting the engine.
screen.
REMARK
If the monitoring code 19115 “AdBlue/DEF tank temperature” is 2 °C or more, return to troubleshooting.
40-370 D155AX-8
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibra-
40 TROUBLESHOOTING tion Error
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration

Error
Action level Failure code AdBlue/DEF Quality Sensor Out of Calibration Error
Failure
Detail of fail-
AdBlue/DEF quality sensor transmission data is abnormal
ure
Action of
controller
Phenomenon • The AdBlue/DEF quality data cannot be measured.
Related
• If the AdBlue/DEF tank sensor is changed without installing genuine spare parts, this fail-
information ure code is displayed.

1
tank sensor
3
D155AX-8 40-371
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Cir-
cuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Er-

ror
Action level Failure code AdBlue/DEF Quality Sensor Internal Circuit Error
Failure
Detail of fail-
Failure of AdBlue/DEF quality sensor (Abnormality in the circuit for quality measurement)
ure
Action of
controller
Phenomenon • The AdBlue/DEF quality data cannot be measured.
Related
• If the engine controller receives information that the circuit for quality measurement is ab-
information normal, this failure code is displayed.

1
tank sensor
3
40-372 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error

Action level Failure code Sensor Supply Relay Voltage High Error
Failure
Detail of fail-
A high voltage error occurs in sensor power supply relay circuit.
ure
Action of
None in particular
controller
Phenomenon
on machine
• This failure code is displayed if the connector is removed when the sensor power supply
relay is turned OFF.
• Note that sensor power supply relay connector is energized even if starting switch is
turned to OFF position.
• This failure code is detected until the sensor power supply relay is turned OFF, during
which the engine controller shuts down since starting switch is turned to OFF position.
• This failure code is not detected when starting switch is at ON position and not displayed
Related on the monitor standard screen. Check the detection on "Abnormality Record" screen.
information • Troubleshooting of this failure code covers circuits from engine controller through sensor
power supply relay to ground.
NOTICE
• If the failure code is displayed, perform investigation of the cause, perform repair,
clear “Electrical Sys Abnormality Record”, turn starting switch off, and shut down
the engine controller. (See “PROCEDURE FOR TROUBLESHOOTING” in this chap-
ter.) Turn starting switch to ON position again and check "Abnormality Record"
screen. If this failure code is not logged, the repair is completed.

3. Perform deletion of “Electrical Sys Abnormality Record” in “SERVICE
Defective wiring harness MODE” of machine monitor.
1
connector
4. Turn the starting switch to OFF position, and shut down the engine control-
ler.
If this failure code is not logged on Abnormality Record screen, wiring harness con-
nector is defective.
D155AX-8 40-373
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error 40 TROUBLESHOOTING

2. Check that system operating lamp does not light up, and then turn battery
3. Disconnect relay connector SSR, and connect T-adapter to female side.
Voltage Between SSR (female) (5) and (4) Min. 22 V
ness (wire breakage or REMARK
2
If failure code still displays after above checks, this check is not required.
nector)
3. Disconnect connectors J1 and SSR and connect T-adapters to each fe-
male side.
Between J1 (female) (9) and SSR (female) (5) Max. 1 Ω
Resistance
Between SSR (female) (4) and ground Max. 1 Ω
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective sensor power 3. Disconnect connector SSR, and replace sensor power supply relay.
3
supply relay
4. Turn the battery disconnect switch ON.
If this failure code is cleared, the original sensor power supply relay is defective.
4
40-374 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error
Circuit diagram related to sensor power supply relay circuit
D155AX-8 40-375
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error

Action level Failure code Sensor Supply Relay Voltage Low Error
Failure
Detail of fail-
Low voltage error occurs in sensor power supply relay circuit.
ure
Action of
None in particular
controller
Phenomenon
on machine
• Be careful that voltage is applied to the connector of the sensor power supply relay even if
the starting switch is OFF.
Related • Troubleshooting of this failure code covers circuits from engine controller through sensor
information power supply relay to ground.

ment” in “Checks before troubleshooting” of “Related information on trou-
Defective wiring harness bleshooting”, and check it.
1
Defective circuit breaker If circuit breaker is tripped, circuit probably has ground fault.
2
CB9
Check if fuses No. 11 and 12 in fuse box F01 are blown.
Defective fuses No. 11
3 REMARK
and 12 in fuse box F01
If blown, perform troubleshooting for ground fault in wiring harness.
4
supply relay
40-376 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error
REMARK
If failure code still displays after above checks, this check is not required.
Open circuit in wiring har- 3. Disconnect connectors J1 and SSR and connect T-adapters to each fe-
5
defective contact of con- 4. Remove fuses No. 11 and 12 from fuse box F01.
nector)
Between J1 (female) (9) and SSR (female) (5) Max. 1 Ω
Between SSR (female) (4) and ground Max. 1 Ω
Resistance Between fuse box F01-11 and SSR (female) (1) Max. 1 Ω
Between fuse box F01-11 and SSR (female) (2) Max. 1 Ω
Between fuse box F01-12 and SSR (female) (3) Max. 1 Ω
Ground fault in wiring disconnect switch to OFF position.
6 harness (contact with 3. Disconnect connectors J1 and SSR and connect T-adapters to each fe-
GND circuit) male side.
Between J1 (female) (9) or SSR (female) (5) and
ground
7
D155AX-8 40-377
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error 40 TROUBLESHOOTING
Circuit diagram related to sensor power supply relay circuit
40-378 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error

Failure Crankcase Pressure Sensor High Error (Engine controller system)
L01 CA1843
Details of
High voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of
Sets crankcase pressure to fixed value. (approximately 0 kPa)
controller
Phenomenon
on machine
(Code: 48401 (V))
Related • Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
information 48400 (MPa))

1
2
Defective crankcase 2.Disconnect connector PCCV.
3 pressure sensor (internal 3. Turn starting switch to ON position.
defect)
If failure code [CA1843] changes to [CA1844], crankcase pressure sensor is defec-
tive.
ness (ground line break- 2. Disconnect connectors J1 and PCCV, and connect T-adapters to each fe-
4
age or defective contact male side.
of connector)
Resistance Between J1 (female) (54) and PCCV (female) (2) Max. 1 Ω
2. Disconnect connectors J1 and PCCV, and connect T-adapter to either fe-
5 male side.
ness
Between J1 (female) (63) and (78), or between PCCV
Hot short circuit in wiring 2. Disconnect connector PCCV and connect T-adapter to female side.
6
Voltage Between PCCV (female) (3) and (2) Max. 1 V
D155AX-8 40-379
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error 40 TROUBLESHOOTING

Reference
Defective engine control- 1. Turn starting switch to OFF position.
7
ler
Voltage Between J1 (63) and (54) Sensor output 0.3 to 4.7 V
Circuit diagram related to crankcase pressure sensor
40-380 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error

Action level Failure code Crankcase Pressure Sensor Low Error
Failure
Details of
Low voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of
Sets crankcase pressure to fixed value. (approximately 0 kPa)
controller
Phenomenon
on machine
(Code: 48401 (V))
Related • Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
information 48400 (MPa))

1
first.
Defective sensor power 2.
2 Disconnect connector PCCV and connect T-adapter to female side.
supply system
Between PCCV (female) 4.75 to
(1) and (2) 5.25 V
2. Disconnect connectors J1 and PCCV, and connect T-adapters to each fe-
male side.
NOTICE
If there is any abnormality in wiring harness, disconnect connector OEM and
check similarly to see if abnormality is in engine harness or in chassis har-
ness.
3
defective contact of con- If failure code is still displayed after above checks on
nector) cause 2, this check is not required. Max. 1 Ω
Between J1 (female) (78) and PCCV (female) (1)
Between J1 (female) (54) and PCCV (female) (2)
Between J1 (female) (63) and PCCV (female) (3) Max. 1 Ω
D155AX-8 40-381
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error 40 TROUBLESHOOTING

2. Disconnect connectors J1 and PCCV, and connect T-adapters to each fe-
male side.
Ground fault in wiring NOTICE
If there is any abnormality in wiring harness, disconnect connector OEM and
ground circuit)
check similarly to see if abnormality is in engine harness or in chassis har-
ness.
Between ground and J1 (female) (63) or PCCV (fe-
male) (3)
2. Disconnect connectors J1 and PCCV, and connect T-adapter to either fe-
5 male side.
ness
Between J1 (female) (63) and (54), or between PCCV
Defective crankcase 2. Insert T-adapters into connector PCCV.
6 pressure sensor (internal
defect)
Voltage Between PCCV(3) and (2) Sensor output 0.3 to 4.7 V
Reference
7
ler
Voltage Between J1 (63) and (54) Sensor output 0.3 to 4.7 V
40-382 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error
Circuit diagram related to crankcase pressure sensor
D155AX-8 40-383
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error

Action level Failure code KDPF Differential Pressure Sensor High Error (Engine controller sys-
Failure
L03 CA1879 tem)
Details of
High voltage error is detected in signal circuit of KDPF differential pressure sensor.
failure
• Operates at estimated value of KDPF differential pressure sensor. (If other failure code al-
so appears, operation may be performed at 0 kPa.)
Action of
• EGR valve closes and KVGT opens fully.
controller
Phenomenon
on machine
k KDPF becomes hot (Min. 500 °C). Be careful not to get burned.

unit.
• If failure code [CA3133] is displayed instead of failure code [CA1695], wire breakage (de-
fective contact of connector) of GND line is highly possible.
Related • Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
tion. (Code: 47101 (V))
information
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring

1
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
[CA1695] or [CA1696] first.
2 Disconnect connector PDPF and connect T-adapter to female side.
supply system
4.75 to
Voltage Between PDPF (female) (4) and (1)
5.25 V
40-384 D155AX-8

If this failure code is changed to [CA1881], the KDPF differential pressure sensor is
Defective KDPF differen- defective.
3
tial pressure sensor
NOTICE
• If this failure code is displayed, the wiring harness or engine control-
ler is defective.
• Ignore other failure codes displayed.
quired.
4
GND line or defective 2. Disconnect connectors J2 and PDPF, and connect T-adapters to each fe-
contact of connector) male side.
Resistance Between J2 (female) (32) and PDPF (female) (1) Max. 1 Ω
2. Disconnect connectors J2 and PDPF, and connect T-adapter to female
Short circuit in wiring har- side of J2.
5
ness
No continui-
(41)
is heard)
3. Connect T-adapter to female side of connector PDPF, or insert T-adapter
6 to connector J2.
harness
4. Turn starting switch to ON position (with connector PDPF disconnected).
Between J2 (female) (41) and (32), or between PDPF
Voltage Max. 1 V
7
D155AX-8 40-385
Circuit diagram related to KDPF differential pressure sensor
40-386 D155AX-8
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Er-
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error

Action level Failure code KDPF Differential Pressure Sensor Low Error
Failure
Details of
Low voltage error is detected in signal circuit of KDPF differential pressure sensor.
failure
Action of
• EGR valve closes and KVGT opens fully.
controller
Phenomenon
on machine

unit.
• If failure code [CA3134] is also displayed instead of failure code [CA1696], it is highly pos-
sible that sensor connector is removed or wire breakage (defective contact of connector)
occurs in 5 V line.
Related
• Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
information
tion. (Code: 47101 (V))

1
supply system
4.75 to
5.25 V
D155AX-8 40-387
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Er-

2. Disconnect connectors J2 and PDPF, and connect T-adapters to each fe-
male side.
3
defective contact of con- Between J2 (female) (32) and PDPF (female) (1)
nector)
Between J2 (female) (8) and PDPF (female) (4)
Between J2 (female) (41) and PDPF (female) (2) Max. 1 Ω
Ground fault in wiring 2. Disconnect connectors J2 and PDPF, and connect T-adapter to either fe-
ground circuit)
Between ground and J2 (female) (41) or PDPF (fe-
male) (2)
5
ness
No continui-
(41)
is heard)
Defective KDPF differen- 2. Insert T-adapter into connector PDPF.
6
tial pressure sensor 3. Turn starting switch to ON position.
Voltage Between PDPF (2) and (1) 0.5 to 4.5 V
7
40-388 D155AX-8
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In
40 TROUBLESHOOTING Range Error
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Er-

ror
Action level Failure code KDPF Differential Pressure Sensor In Range Error
Failure
Details of Signal voltage from KDPF differential pressure sensor does not show correct value. (Signal voltage
failure is within use range.)
Phenomenon
on machine

• KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated.
tion. (Code: 47101 (V))
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• Temperature in torque converter oil temperature sensor can be checked by monitoring
Use “Short socket adapter: 799T-601-4611”.
Related • For details of access to KDPF differential pressure sensor, wiring harness and tube, see
information “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEM-
BLY” and “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
ON position.
• “Loaded Diagnostics Operation To Clear Failure Code”.
NOTICE
again.)
• This failure code is cleared by performing operations indicated in TESTING AND AD-
JUSTING, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE MODE”,
“METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER ACTIVE
FAULT CLEAR)”.
D155AX-8 40-389
Range Error 40 TROUBLESHOOTING

1. Remove KDPF differential pressure sensor tube.
2. Clean and unclog the KDPF differential pressure sensor tube.
3. Check the KDPF differential pressure sensor tube for cracks or damages.
4. Securely connect both ends of the tube and install the KDPF differential
pressure sensor tube.
Defective KDPF differen-
1 Reference
tial pressure sensor tube
How to check clogged KDPF differential pressure sensor tube
2. Monitor the differential pressure by using KDPF differential pressure sen-
sor on Self-define Monitoring screen of the machine monitor.
Code 47100(kPa) 0 ± 3( kPa)
Improper installation of See “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEMBLY AND AS-
2
KDPF SEMBLY” in Chapter 50 for repair.
supply system
4.75 to
5.25 V
Defective wiring harness ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
4
connector FORMATION ON TROUBLESHOOTING”, and check and repair defects, if
any.
If failure code [CA1881] is cleared, the wiring harness or engine controller is defec-
tive.
Check on cause 4 again.
REMARK
Ignore other failure codes displayed.
Defective wiring harness 1. Turn starting switch to OFF position.
5
or engine controller
2. Disconnect connector PDPF and connect short socket adapter to female side.
Connect 5 V to the signal line. (short-circuit pins (4) and (2) of connector
PDPF.)
tive.
REMARK
40-390 D155AX-8
NOTICE
6 If failure codes [CA1881] and [CA1879] are displayed after checks on cause 4,
tial pressure sensor
the KDPF differential pressure sensor is defective.
7 controller is defective. (In case of an internal defect, troubleshooting is impossible
ler
as an assembly. Replace whole assembly.)

k Park the machine on a level ground.
1. Turn starting switch to ON position and leave it there for 1 minute (in order to allow engine controller to de-
termine drift of voltage when starting switch key is turned to ON position).
4. After warm-up operation, perform torque converter stall operation continuously for 40 seconds with fuel
control dial at MAX (high idle) position.
Torque converter stall operation
1) Use a manual gear shift mode in P mode.
2) On the “Service Menu” screen of the machine monitor, select “Adjustment”.
3) Enter 0350 “Stall mode” as an ID on the “Adjustment” screen.
4) Use a shift up (UP) switch on the PCCS lever to set preset mode display to [F3-R3].
The preset mode display (on the lower right of the screen) can be set to [F3-R3] only when the stall
mode is selected in the “Adjustment” function.
5) With the brake pedal depressed securely and the parking brake lever in FREE position, set the direc-
tion of the PCCS lever to FORWARD position.
NOTICE
• Make sure [F3] is displayed in a gear range display (on the lower right of the screen) before
proceeding to the next step.
• Hold the steering at NEUTRAL position.
6) Depress the decelerator pedal and set the fuel control dial at High idle (MAX) position.
7) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle.
k With the brake pedal depressed securely, place your right foot on the decelerator pedal for
safety until the work is completed.
8) As soon as torque converter (power train) oil temperature (T/C (P/L) oil temperature) indicates 118 °C,
reset the PCCS lever to NEUTRAL position.
NOTICE
• Take care not to overheat the oil of work equipment.
• Temperature indicated at the top of the green range on the power train oil temperature
gauge is approximately 118 to 120 °C.
9) If the failure code is cleared, repair work is complete.
5. If the failure code is not cleared, repeat the preceding step 4 for three times.
If the failure code is cleared, repair work is completed.
REMARK
D155AX-8 40-391
40-392 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error

Action level Failure code Turbocharger Outlet NOx Sensor Circuit Error
Failure
Detail of fail- The turbocharger outlet NOx sensor does not display any values due to an internal circuit error of
ure the turbocharger outlet NOx sensor.
Action of
Advances to Inducement strategy (EU Specification)
controller
Phenomenon • The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
on machine • Engine power deration (EU Specification)
k The turbo outlet, KDPF, sensor fitting piping, and sensor probe become hot (Min.
500 °C). Be careful not to get burn injury.
• The turbocharger outlet NOx sensor performs CAN communication with the engine con-
troller.
• The turbocharger outlet NOx sensor operates when KDOC inlet temperature is 150 °C or
more (19203 turbocharger outlet NOx sensor measurement state is "1").
• The turbocharger outlet NOx sensor does not operate when KDOC inlet temperature is
150 °C or lower, and correct value is not displayed.
• “Pre-defined” screen uses the engine operation state diagnosis, SCR catalyst, NOx sen-
sor, and ammonia sensor diagnosis.
• Engine operation state diagnosis
01002 Engine speed
19200 Exhaust gas flow rate
Related
47300 KDOC Inlet Temperature
information
19300 SCR Temperature
19302 SCR Outlet Temperature
• SCR catalyst, NOx sensor, ammonia sensor diagnosis.
19203 Turbo Outlet NOx Sensor State
19210 SCR Outlet NOx Sensor State
19202 Turbo Outlet Concentration Corrected
19209 SCR Outlet NOx Corrected
19205 Ammonia Concentration Corrected
NOTICE
For this failure code, after investigating the cause of the problem and completing the re-
pair, perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make
sure repair is completed. (This failure code is not cleared by only turning ON the start-
ing switch.)

CAN communication sys- If failure code [CA3232] is displayed, perform troubleshooting for [CA3232] first.
1
tem error
Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
2
supply system [CA1776] or [CA1777] first.
D155AX-8 40-393
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error 40 TROUBLESHOOTING

If failure code is still displayed after above checks, the turbocharger outlet NOx
sensor may be defective.
Defective turbocharger 2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3
outlet NOx sensor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
4

For the machine equipped with Inducement strategy for European Union, clear this failure code by Engine Con-
troller Inducement Fault Clear before 1. (EU Specification)
3. Run the engine at high idle safely to raise the exhaust gas temperature. (Keep the engine speed so that
monitoring code 47300 “KDOC Inlet Temperature” becomes 150 °C or higher. Check that monitoring code
19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1.)
4. Repair is completed if failure code is cleared after 3 minutes has passed.
REMARK
If the turbocharger outlet NOx sensor does not activate (that is, 19203 “Turbo Outlet NOx Sensor State” remains
as 0), return to troubleshooting.
40-394 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error

Action level Failure code SCR Outlet NOx Sensor Circuit Error
Failure
Detail of fail- The SCR outlet NOx sensor does not display any values due to an internal circuit error of the SCR
ure outlet NOx sensor.
Action of • Drive at the default NOx emission value (0 ppm)
controller • Advances to Inducement strategy. (EU Specification)
on machine • The engine power deration according to inducement strategy. (EU Specification)
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min.
400 °C). Be careful not to get burned.
• The SCR outlet NOx sensor is a smart sensor which performs CAN communication with
the engine controller together with the other sensors.
• The SCR outlet NOx sensor operates when SCR outlet temperature is 150 °C or more
(19210 SCR outlet NOx sensor measurement state is "1").
• The SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °C or
lower, and correct value is not displayed.
• “Pre-defined Monitoring” screen uses the engine operation state diagnosis, SCR catalyst,
NOx sensor, and ammonia sensor diagnosis.
01002 Engine speed
Related 19200 Exhaust gas flow rate
information 47300 KDOC Inlet Temperature
NOTICE
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure repair
is completed. (This failure code is not cleared by only turning ON the starting switch.)

Defective CAN communi- If failure code [CA2771] is displayed, perform troubleshooting for [CA2771] first.
1
cation system
2
D155AX-8 40-395
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error 40 TROUBLESHOOTING

If no failure is found by preceding checks, the SCR outlet NOx sensor is defective.
2. Replace the SCR outlet NOx sensor.
Defective SCR outlet
NOx sensor
4

3. Run the engine at high idle speed safely to raise the exhaust gas temperature. (Keep the engine speed so
that monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or higher. Check that monitoring
code 19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
REMARK
If the SCR outlet NOx sensor does not activate (that is, 19210 “SCR Outlet NOx Sensor State” remains as 0),
return to troubleshooting.
40-396 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1

Action level Failure code KDPF Soot Accumulation High Error 1
Failure
Details of This failure code requests users to perform “Manual stationary regeneration” immediately, because
KDPF soot accumulation level is 6 or 7 and it means a large amount of soot is accumulated in
failure KCSF (If soot accumulation level is 8, KDPF must be replaced.)
• EGR valve closes and fully opens KVGT.
Action of
• Controls output for operation.
controller
• Disables automatic regeneration but enables manual stationary regeneration.
Phenomenon
on machine
D155AX-8 40-397
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 40 TROUBLESHOOTING
k Since KDOC and KDPF are heated to 500 °C or above, be careful not to get burned.
tion. (Code: 47101 (V))
• When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
proximately 450 to 550 °C.
Related GAS COLOR”.
information • Soot accumulation amount in KDPF is classified into 8 levels. Current soot accumulation
level can be checked in 02 Active Regeneration for Service screen of machine monitor.
• Manual stationary regeneration downs soot accumulation level 7 from level 8 by removing
soot.
• If soot accumulation level is 8, failure code [CA1922] is displayed. At this time, KDPF is
completely clogged with soot and inspection, cleaning or replacement is required.
• If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for these failure codes first.
• If failure code [CA1922] is originally displayed, failure code changes from [CA1922] to
[CA1921] in troubleshooting process. In this case, see failure code [CA1922].
code is cleared).
Time required for the manual stationary regeneration depends on the accumulated soot in KCSF,
however, it is estimated as follows.
• If soot accumulation is level 4: Approximately 40 minutes to 1 hour
• If soot accumulation is level 5: Approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: Approximately 2 to 3 hours
• If soot accumulation is level 8: Manual stationary regeneration cannot be performed.
Cause for excessive soot accumulation
40-398 D155AX-8
1. Engine runs in light load area where exhaust gas temperature is high enough to burn soot
in KDPF.
• Low gas temperature at entering into KDPF cause a large amount of soot to be accu-
mulated.
• To protect KDPF from soot accumulation, it is necessary to run the engine under high
load.
2. There is an engine failure generating excessive black smoke.
Related
3. The function of disable regeneration is set from monitor.
information
• Regeneration is set not to perform automatically even if soot is accumulated. It is re-
quired to cancel regeneration disable and perform regeneration at safe place.
Method of canceling regeneration disable
• Select Cancel of Regeneration Disable from Aftertreatment Devices Regeneration screen
of user menu, and perform it. (For details, see “PROCEDURE FOR CANCEL OF AFTER-
TREATMENT DEVICES REGENERATION DISABLE SETTING” of “HANDLE Komatsu
Diesel Particulate Filter (KDPF)” of “Handling” in Operation and Maintenance Manual.)

1. Check that regeneration disable is not set on machine monitor. (Cancel the
regeneration disable if it is set.)
3. Secure the safety of the machine.
4. Perform “manual stationary regeneration” in user mode.
Defective accumulation When the manual stationary regeneration is completed successfully, the repair
1 is completed.
of soot in KDPF (KCSF)
If the regeneration is not completed after 3 hours, perform troubleshooting for
[CA2639].
5. Check that the failure code is cleared after manual stationary regeneration
is complete.
6. If failure code [CA1921] or [CA2639] is displayed after manual stationary
regeneration is complete, perform check on cause 2.
• If failure code [CA1921], or [CA2639] is displayed after manual stationary
regeneration is complete, perform the following:
• See “TEST EXHAUST GAS COLOR” section in “Chapter 30 TESTING
AND ADJUSTING” for checking the exhaust gas color.
• Perform regeneration disable on the machine monitor to check the exhaust
gas color.
Defective exhaust gas 1. Suddenly accelerate the engine from low idle to high idle two times, and then
2
color keep the engine running at high idle for 5 seconds.
If an excess black smoke is seen at high idle during acceleration, perform
“KDPF GETS CLOGGED IN A SHORT TIME” of S mode.
Even excessive black smoke is exhausted during engine acceleration, if it is
not at engine high idle, it is not defective.
2. To finish the exhaust gas color check, cancel the regeneration disable.
3. Make sure that the failure code is cleared.
D155AX-8 40-399
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2

Action level Failure code KDPF Soot Accumulation High Error 2
Failure
Details of • If soot accumulation is level 8：Manual stationary regeneration cannot be performed.

failure • Engine must be stopped immediately and perform diagnostic test and maintenance.
Action of
• Controls output for operation.
controller
• Disables automatic regeneration and manual stationary regeneration.
Phenomenon
on machine
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
tion. (Code: 47101 (V))
Related • When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
information mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
GAS COLOR”.
code is cleared).
• Soot accumulation amount in KDPF is classified into 8 levels. Current soot accumulation
level can be checked in 02 Active Regeneration for Service screen of machine monitor.
• Manual stationary regeneration downs soot accumulation level 7 from level 8 by removing
soot.
• If soot accumulation level is 8, failure code [CA1922] is displayed. At this time, KDPF is
completely clogged with soot and inspection, cleaning or replacement is required.
40-400 D155AX-8
Cause for excessive soot accumulation
1. Engine runs in light load area where exhaust gas temperature is high enough to burn soot
in KDPF.
• Low gas temperature at entering into KDPF cause a large amount of soot to be accu-
mulated.
• To protect KDPF from soot accumulation, it is necessary to run the engine under high
load.
2. There is an engine failure generating excessive black smoke.
3. The function of disable regeneration is set from monitor.
• Regeneration is set not to perform automatically even if soot is accumulated. Cancel
regeneration disable at safe place.
Method of canceling regeneration disable
Select Cancel of Regeneration Disable from Aftertreatment devices regeneration screen of user
Related menu, and perform it. (For details, see “PROCEDURE FOR CANCEL OF AFTERTREATMENT DE-
information VICES REGENERATION DISABLE SETTING” of “HANDLE Komatsu Diesel Particulate Filter
(KDPF)” of “Handling” in Operation and Maintenance Manual.)
Method of performing active regeneration for service
When soot accumulation is at level 3 or lower, manual stationary regeneration can be performed on-
ly from Active Regeneration for Service.
1. Start engine.
2. Make sure that machine is in a safe condition.
3. From service menu of machine monitor, display Diagnostic Tests screen, open Active Re-
generation for Service, and then perform Manual Stationary Regeneration.
Method of resetting KDPF cleaning
Display Testing screen from service menu of machine monitor, open KDPF Memory Reset, and per-
form KDPF cleaning (resetting KDPF cleaning).
Method of resetting KDPF change
Display Testing screen from service menu of machine monitor, open KDPF Memory Reset, and per-
form KDPF change (resetting KDPF change).
Removing humidity in KCSF
When KCSF of KDPF has been replaced, be sure to perform Manual Stationary Regeneration from
Active Regeneration for Service and remove humidity, etc. in KCSF after resetting KDPF cleaning
and KDPF change.
Increased accumulation 1. Check that regeneration disable is not set on machine monitor. (Cancel the
1 of soot due to regenera- regeneration disable if it is set.)
tion disable 2. Cancel regeneration disable and perform cause 2 and subsequent causes.
D155AX-8 40-401

Check records for appeared failure codes.
2. ON the Abnormality Record screen of the machine monitor, check records
for appeared failure codes CA2639, CA1921, and CA1922.
Period between CA2639 and CA1921 ≧ 360sec. (KOMTRAX Record) or ≧ 0.1h
(Monitor Record screen) and period between CA1921 and CA1922 ≧ 360sec.
(KOMTRAX Record) or ≧ 0.1h (Monitor Record screen)
[When the above condition is met]
REMARK
Because accumulated soot amount is high, KDPF regeneration cannot be per-
formed.
1. Change KCSF or KDPF.
2. Turn the starting switch to ON and perform “KDPF Cleaning” reset (see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”).
Make sure that failure code [CA1922] changed to [CA1921].
If failure code [CA1922] persists, check the operation procedure for “KDPF
Defective KDPF (KCSF)
2 Memory Reset”, then perform “KDPF Cleaning” Reset again.
(change KCSF)
3. Perform Reset after “KDPF Change” (see “PRECAUTIONS FOR KDPF
(KCSF, KDOC) CLEANING AND CHANGE”).
4. Perform checks on causes 4 to 7.
7. Perform “Active Regeneration for Service” to remove humidity, etc. in KCSF.
When the manual stationary regeneration is finished correctly, the repair is
completed.
[CA2639].
Check that the failure code is cleared after manual stationary regeneration is
complete.
If failure code [CA1922], [CA1921] or [CA2639] is displayed after manual sta-
tionary regeneration is complete, perform checks on cause 8.
[When the above condition is NOT met]
Actual accumulation of soot is less than the indicated value. Perform checks on
cause 3.
40-402 D155AX-8

If the actual accumulation of soot is less than the the indicated value on the ma-
chine monitor:
1. Perform checks on causes 4 to 7.
2. Turn the starting switch to ON and perform “KDPF Cleaning” reset (see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”).
Make sure that failure code [CA1922] changed to [CA1921].
If failure code [CA1922] persists, check the operation procedure for “KDPF
Memory Reset” Reset, then perform “KDPF Cleaning” Reset again.(see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”)
NOTICE
Do not perform “KDOC Change”(resetting KDOC Change) if KCSF or
Defective KDPF (KCSF) KDOC is not changed.
3 (abnormal accumulation
of soot) 3. Start the engine.
5. Perform “manual stationary regeneration” in user mode.
When the manual stationary regeneration is finished correctly, the repair is
completed.
If failure code [CA1922] is displayed again within 1 hour after starting the man-
ual stationary regeneration, perform steps 2 and 3 again.
[CA2639].
Check that the failure code is cleared after manual stationary regeneration is
complete.
If failure code [CA1922], [CA1921] or [CA2639] is displayed after manual sta-
tionary regeneration is complete, perform checks on cause 8.
4
5
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform troubleshoot-
6
2. Monitor the differential pressure by using KDPF differential pressure sensor on
Self-define Monitoring screen of the machine monitor.
Code 47100 ( kPa) 0±3 kPa
NOTICE
Perform the following when differential pressure is not within the above
7 tial pressure sensor (in-
range:
cluding the sensor tube)
Perform this when the KDPF differential pressure sensor tube is not clogged.
3. Check “Short circuit in wiring harness” for failure code [CA1881] or
[CA1879] (change the KDPF differential pressure sensor if no short circuit
is found).
D155AX-8 40-403

gas color.
8
40-404 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error

Failure Fuel Doser Solenoid 1 High Error (Engine controller system)
L03 CA1923
Details of
Abnormal high voltage occurs in fuel doser solenoid valve 1(shut off valve).
failure
Action of
Regeneration control stops.
controller
Phenomenon • Automatic regeneration is not performed.
on machine • Manual stationary regeneration cannot be performed.
k Exhaust connector and KDPF become hot (Min. 500 °C). Be careful not to get burn injury.
• If failure code [CA2732] is also displayed, it is highly possible that wire breakage of GND
line occurs.
Related
• This failure code is displayed if sensor connector DSOV1 is removed.
information
• See failure code [CA1925].

1
Defective dosing fuel sol-
2 enoid valve 1 (shut-off 2. Disconnect connector DSOV1, and connect T-adapter to male side.
valve)
Resistance Between DSOV1 (male) (2) and (1) 4 to 6 Ω
wiring harness
Resistance Between J1 (female) (8) and (30) 4 to 6 Ω
quired.
ness (wire breakage of 2. Disconnect connectors J1 and DSOV1 and connect T-adapters to each fe-
4
Between J1 (female) (8) and DSOV1 (female) (1) Max. 1 Ω
Resistance
Hot short circuit in wiring 2. Disconnect connector DSOV1, and connect T-adapter to female side.
5
Voltage Between DSOV1 (female) (1) and (2) Max. 4.7 V
D155AX-8 40-405
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error 40 TROUBLESHOOTING

1. Start the engine, and run it at low idle, and leave it for approximately 1 mi-
nute.
Defective engine control- 2. If other failure codes are displayed, perform troubleshooting for them.
6
ler
If this failure code is still displayed and no failure is found by preceding checks, en-
gine controller is defective. (In case of an internal defect, troubleshooting is impos-
Circuit diagram related to dosing fuel solenoid valve
40-406 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error
FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error

Failure Fuel Doser Solenoid 1 Low Error (Engine controller system)
L03 CA1924
Details of
Abnormal low voltage occurs in fuel doser solenoid valve 1(shut off valve).
failure
Action of
controller
• If connector DSOV1 is disconnected, failure code [CA1923] is displayed.
Related • See failure code [CA1925].
information • This failure code is cleared after implementing fuel doser solenoid valve 1drive again turn-
ing the starting switch from OFF to ON after abnormality repair.

1
Defective dosing fuel sol- 2. Disconnect connector DSOV1, and connect T-adapter to male side.
2 enoid valve 1 (shut-off
valve) Between DSOV1 (male) (2) and (1) 4 to 6 Ω
Resistance
Between DSOV1 (male) (1) and ground (DSOV body) Min. 1 MΩ
wiring harness
Ground fault in wiring 2. Disconnect connectors J1 and DSOV1, and connect T-adapter to either fe-
ground circuit)
Between ground (frame) and J1 (female) (9) or DSOV1
(female) (1)
2. Disconnect connectors J1 and DSOV1, and connect T-adapter to female
5
ness
No continui-
(8)
is heard)
Defective dosing fuel sol- Replace dosing fuel solenoid valve 1 (shut-off valve).
valve)
D155AX-8 40-407
FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error 40 TROUBLESHOOTING

nute.
7
ler
Diagram related to fuel doser

A: From refueling pump
B: Fuel return
C: To fuel supply pump
D: From cooling plate of the engine controller
JB: Fuel tube joint bolt
PDOSER: Dosing fuel pressure sensor connector
DSOV1: Dosing fuel solenoid valve 1 (shut-off valve) connector
DSOV2: Dosing fuel solenoid valve 2 (drain valve) connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor
Circuit diagram related to dosing fuel solenoid valve
40-408 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error

Failure Fuel Doser Solenoid 1 In Range Error (Engine controller system)
L03 CA1925
Details of Fuel doser solenoid valve 1 does not operate correctly. (Dosing fuel pressure is not sufficiently low-
failure ered due to half-open valve that must be originally closed on fuel inlet side.)
Action of
controller
• Defective fuel doser solenoid valve 1 (shut off valve) indicated by this code is determined
according to fuel pressure that changes with solenoid valve operation.
• Therefore, fuel pressure sensor must be checked.
• Engine controller tests and checks fuel pressure when turning starting switch to ON posi-
tion.
• Signal voltage from dosing fuel pressure sensor can be checked by monitoring function.
Related (Code: 47601 (V))
information • Pressure in dosing fuel pressure sensor can be checked by monitoring function. (Code:
47600 (kPa))
• Ambient pressure in ambient pressure sensor can be checked by monitoring function.
(Code: 37400 (kPa))
Procedure: Start engine and observe for 3 minutes.
[Method of clearing failure code]
Turn starting switch from OFF to ON position to start engine. Run engine at low idle speed for ap-
proximately 3 minutes, repair is completed when this failure code is canceled.

1
2. Disconnect fuel supply line (2) from fuel doser (1).
Defective doser fuel
pressure sensor
If the dosing fuel pressure is clearly different from ambient pressure, the dosing fuel
pressure sensor is defective (See related information).
REMARK
Doser fuel pressure should read atmospheric pressure.
D155AX-8 40-409
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error 40 TROUBLESHOOTING

3. Disconnect connector DSOV1.
4. Connect disconnected connector DSOV1 to new SOV.
REMARK
Defective doser fuel shut If connector DSOV1 has open circuit, failure code [CA1923] is displayed
3
off valve
and pressure test (to check fuel dosing system) is not performed, and fuel
pump is not driven.
6. Start engine.
If fuel leaks through fuel connector going to fuel supply line (2), fuel doser solenoid
valve 1 (shut off valve) (3) is defective.
1. Start the engine, and leave it for approximately 3 minutes.
2. If this failure code are displayed, perform troubleshooting for Related infor-
Defective engine control- mation, “Method of clearing failure code”.
4
ler

B: Fuel return
1. Fuel doser
2. Fuel supply line
40-410 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error
FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error

Failure Dosing Fuel Pressure Sensor High Error (Engine controller system)
L01 CA1927
Details of
Sensor voltage from dosing fuel pressure sensor is higher than threshold value.
failure
Action of
controller
(Code: 47600 (V))
Related • Pressure in dosing fuel pressure sensor can be checked by monitoring function. (Code:
Procedure: Turn starting switch to ON position and observe for 1 minute. (Due to 01,
check by abnormality record screen.)

1
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for those
codes first.
2 pressure sensor power 2. Disconnect connector PDOSER and connect T-adapter to female side.
4.75 to
Voltage Between PDOSER (female) (1) and (2)
5.25 V
2. Disconnect connector PDOSER.
Defective doser fuel If failure code [CA1927] changes to [CA1928], dosing fuel pressure sensor is de-
3
pressure sensor fective.
If failure code [CA1927] does not change to [CA1928], wiring harness or engine
Open circuit in wiring har- 2. Disconnect connectors J1 and PDOSER, and connect T-adapters to each
ness (wire breakage or female side.
4
defective contact of con- If failure code is still displayed after above checks on
nector)
Resistance cause 2, this check is not required. Max. 1 Ω
Between J1 (female) (57) and PDOSER (female) (2)
D155AX-8 40-411
FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error 40 TROUBLESHOOTING

2. Disconnect connectors J1 and PDOSER, and connect T-adapter to female
5
ness
No continui-
(57)
is heard)
2. Disconnect connector PDOSER.
3. Connect T-adapter to female side of connector PDOSER, or insert T-
Hot short circuit in wiring adapter into connector J1.
6
harness 4. Turn starting switch to ON position (with connector PDOSER disconnect-
ed).
Between J1 (female) (37) and (57), or between PDOS-
Voltage Max. 1 V
ER (female) (3) and (2)
Start the engine, and run it at low idle, and leave it for approximately 1 minute.
7
CIRCUIT DIAGRAM (DOSING FUEL PRESSURE SENSOR)
40-412 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error
FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error

Failure Dosing Fuel Pressure Sensor Low Error (Engine controller system)
L01 CA1928
Details of
Sensor voltage from dosing fuel pressure sensor is lower than threshold value.
failure
Action of
controller
(Code: 47600 (V))
Related • Pressure in dosing fuel pressure sensor can be checked by monitoring function. (Code:
47601 (kPa))
information
Procedure: Turn starting switch to ON position and observe for 1 minute. (Due to 01,
check by abnormality record screen.)

1
codes first.
2 pressure sensor power 2. Disconnect connector PDOSER and connect T-adapter to female side.
4.75 to
Voltage Between PDOSER (female) (1) and (2)
5.25 V
Defective doser fuel 2. Insert T-adapter into connector PDOSER.
3
Voltage Between PDOSER (3) and (2) 0.5 to 4.5 V
D155AX-8 40-413
FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error 40 TROUBLESHOOTING

2. Disconnect connectors J1 and PDOSER, and connect T-adapters to each
female side.
4
defective contact of con- Between J1 (female) (81) and PDOSER (female) (1)
nector)
Between J1 (female) (37) and PDOSER (female) (2)
Between J1 (female) (57) and PDOSER (female) (3) Max. 1 Ω
2. Disconnect connectors J1 and PDOSER, and connect T-adapter to female
5
ness
No continui-
(57)
is heard)
Ground fault in wiring 2. Disconnect connectors J1 and PDOSER, and connect T-adapter to either
6 harness (contact with female side.
ground circuit)
Between ground and J1 (female) (37) or PDOSER (fe-
male) (3)
7
CIRCUIT DIAGRAM (DOSING FUEL PRESSURE SENSOR)
40-414 D155AX-8
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Er-
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error

Action level Failure code Crankcase Pressure Sensor In Range Error
Failure
Details of
For output from crankcase pressure sensor, value out of normal range is displayed.
failure
Action of
None in particular
controller
Phenomenon
on machine
(Code: 48401 (V))
Related 48400 (MPa))
• This code appears if sensor value is not abnormal when turning starting switch to ON posi-
tion.

1
ing
D155AX-8 40-415
FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error 40 TROUBLESHOOTING
FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error

Failure Fuel Doser Solenoid 1 Servo Error (Engine controller system)
L03 CA1963
Details of Pressure in dosing fuel pressure sensor is lower than threshold value even when fuel doser sole-
failure noid valve 1 (shut off valve) is ON.
Action of
controller
(Code: 47601 (V))
• Pressure in dosing fuel pressure sensor can be checked by monitoring function. (Code:
47600 (kPa))
Related • Ambient pressure in ambient pressure sensor can be checked by monitoring function.
information (Code: 37400 (kPa))
Procedure: Start engine and observe for 3 minutes.
Method of clearing failure code
Turn starting switch from OFF to ON position to start engine. Run engine at low idle speed for ap-
proximately 3 minutes, repair is completed when this failure code is canceled.

1
Defective dosing fuel sol- If failure code [CA1923], [CA1924], or [CA1925] is displayed, perform troubleshoot-
2 enoid valve 1 (shut-off ing for [CA1923], [CA1924], or [CA1925] first.
valve)
Defective dosing fuel sol- If failure code [CA2732] or [CA2733] is displayed, perform troubleshooting for
3 enoid valve 2 (drain [CA2732] or [CA2733] first.
valve) system
Defective doser fuel If failure code [CA1927] or [CA1928] is displayed, perform troubleshooting for
4
pressure sensor system [CA1927] or [CA1928] first.
Defective fuel supply If failure code [CA559] is also displayed, perform troubleshooting for [CA559] first.
5
pump system
40-416 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error

2. See Fuse location table, check if fuse for fuel feed pump is blown.
Defective fuel feed pump 3. Loosen fuel tube joint bolt (JB).
6
system 4. Tilt switch for the fuel feed pump to ON position while the starting switch is in
OFF position.
(Fuel may spurt out. So be careful.)
To finish checking, turn the starting switch to ON position, or tilt switch for the
fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB) of fuel tube, fuel feed pump is defective.
7 Clogged fuel filter Check fuel filter for clogging.
4. See Related information, and display dosing fuel pressure and ambient
Defective doser fuel pressure on the machine monitor at the same time.
8
pressure sensor
pressure sensor is defective.
REMARK
Defective dosing fuel sol- Replace dosing fuel solenoid valve 1 (shut-off valve).
valve)
10
ler
D155AX-8 40-417

B: Fuel return
1. Fuel doser
2. Fuel supply line
40-418 D155AX-8
FAILURE CODE [CA1977] Fuel Doser Open Circuit Error or Short Cir-
40 TROUBLESHOOTING cuit Error
FAILURE CODE [CA1977] Fuel Doser Open Circuit Error or Short Circuit
Error
Action level Failure code Fuel Doser Open Circuit Error or Short Circuit Error (Engine control-
Failure
L03 CA1977 ler system)
Details of
Short circuit or wire breakage is detected in fuel doser circuit.
failure
Action of
controller
Phenomenon • Automatic regeneration is disabled.
on machine • Manual stationary regeneration is disabled.
k
Since exhaust connector and KDPF are heated to 500 °C or above, be careful not to get
burn injury.
(Code: 47600 (V))
• Pressure in dosing fuel pressure sensor can be checked by monitoring function. (Code:
47601 (kPa))
Procedure: Turn starting switch to ON position and observe for 1 minute.
Related • Turn starting switch to OFF position, perform AdBlue/DEF purging (Max. 6 minutes), and
perform shutdown. Then, regeneration control stop is canceled.
information
NOTICE
• This failure code requires“ Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform a
“Loaded Diagnostics Operation To Clear Failure Code” to make sure the failure code
is cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

1
2. Disconnect connector DOSER, and connect T-adapter to male side.
Defective fuel doser (in-
2 Between DOSER (male) (1) and (2) 0.5 to 2 Ω
jector)
Resistance Between DOSER (male) (1) and ground (fuel doser
Min. 1 MΩ
body)
D155AX-8 40-419
cuit Error 40 TROUBLESHOOTING

Open or short circuit in 2. Disconnect connector J1, and connect T-adapter to female side.
3
wiring harness Between J1 (female) (5) and (29)
Resistance 0.5 to 2 Ω
Resistance value is the same as the value of injector
quired.
ness (wire breakage or 2. Disconnect connectors J1 and DOSER and connect T-adapters to each fe-
4
nector)
Between J1 (female) (5) and DOSER (female) (1) Max. 1 Ω
Resistance
Between J1 (female) (29) and DOSER (female) (2) Max. 1 Ω
Ground fault in wiring 2. Disconnect connectors J1 and DOSER, and connect T-adapter to either
ground circuit)
Between ground (frame) and J1 (female) (5) or DOS-
ER (female) (1)
2. Disconnect connectors J1 and DOSER, and connect T-adapter to female
Short circuit in wiring har- side of J1 .
6
ness
No continui-
(5)
is heard)
Hot short circuit in wiring 2. Disconnect connector DOSER, and connect T-adapter to female side.
7
harness 3. Turn starting switch ON (with connector DOSER disconnected).
Resistance Between ground and DOSER (female) (2) 3 V
8

3. Start the engine, and perform active regeneration for service.
4. When failure code [CA1977] is cleared, stop the active regeneration for service.
40-420 D155AX-8
40 TROUBLESHOOTING cuit Error
Circuit diagram related to fuel doser (injector)
D155AX-8 40-421
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error

Action level Failure code KDPF Differential Pressure Low Error
Failure
Details of
Sensor voltage from KDPF differential pressure sensor is lower than threshold value.
failure
Phenomenon
on machine

tion. (Code: 47101 (V))
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• For details of access to KDPF differential pressure sensor, wiring harness and tube, see
“Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEM-
Related BLY” and “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
information • After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ON position.
code is cleared).
NOTICE
• This failure code requires “ Loaded Diagnostics Operation To Confirm Failure Cor-
rection”. After investigating the cause of the problem and completing the repair, per-
form “ Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
the failure code is cleared.

Defective KDPF differen- If failure code [CA1879], [CA1881] or [CA1883] is displayed, perform troubleshoot-
1 tial pressure sensor sys- ing for [CA1879], [CA1881] or [CA1883].
tem
40-422 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA1993] KDPF Differential Pressure Low Error

1. Turn the starting switch to OFF position, then turn the starting switch to ON
again.
2. Check if a failure code other than [CA1993] is displayed.
3. Start the engine and suddenly accelerate it from low idle to high idle two
times, then keep the engine running at high idle for 5 seconds. At this
point, check the color of exhaust gas at the exhaust pipe section during
2 KCSF failure 1 sudden acceleration and high idle.
4. If black smoke comes out of the exhaust pipe after performing 3., KCSF is
defective. Check KCSF for existence, damages or contamination by for-
eign materials. Repair it if necessary.
NOTICE
Perform checks on cause 3 and subsequent causes if no black smoke is de-
tected.
Check if:
1. the KDPF differential pressure sensor tube is present,
2. the KDPF differential pressure sensor tube is not connected improperly,
3 3. the removed KDPF differential pressure sensor tube for clogging, cracks,
or damages, or
4. the both ends of the KDPF differential pressure sensor tube is not loose.
1. If this failure code is displayed again after preceding procedures are imple-
mented, remove KDPF, then remove KCSF, and check filters for existence,
damages or contamination by foreign materials. Repair it if necessary.
4 KCSF failure 2 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
3. Perform repair again from cause 1 if this failure code is displayed again af-
ter “Loaded Diagnostics Operation To Confirm Failure Correction” has
been performed.
5

2. Perform “Engine Controller Active Fault Clear ” to clear this failure code from “SERVICE MODE” on the ma-
chine monitor.
5. After warm-up operation, perform torque converter stall operation for continuously 40 seconds or longer
with fuel control dial at High idle (MAX) position.
D155AX-8 40-423
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error 40 TROUBLESHOOTING
NOTICE
6) Depress the decelerator pedal and set the fuel control dial at High idle (MAX) position.
7) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle.
NOTICE
• Take care not to overheat the oil of work equipment.
• Temperature indicated at the top of the green range on the power train oil temperature is ap-
9) If the failure code is cleared, repair work is completed.
REMARK
40-424 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error

Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Details of
High voltage is detected in throttle sensor power supply (5 V) circuit.
failure
Action of Signal from decelerator pedal (throttle sensor) is ignored, and engine controller runs at fixed value
controller by decelerator pedal position.
Phenomenon
Engine speed cannot be controlled by decelerator pedal.
on machine

1
2. Disconnect connector DCL, and turn starting switch to ON position.
Defective throttle sensor If this failure code is cleared, throttle sensor is defective.
2
(decelerator pedal) NOTICE
Other failure codes are displayed as well. This is because the connector
is disconnected. Ignore failure codes besides this failure code [CA2185].
2. Disconnect connectors J2 and DCL, and connect T-adapters to female
3 side of J2.
ness
Between J2 (female) (9) and each pin besides J2 (fe- No continui-
Continuity
male) (9) pin. ty
ler
D155AX-8 40-425
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error 40 TROUBLESHOOTING
40-426 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error

Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Details of
Low voltage is detected in throttle sensor power supply (5 V) circuit.
failure
Action of Signal from decelerator pedal (throttle sensor) is ignored, and engine controller runs at fixed value
controller by decelerator pedal position.
Phenomenon
Engine speed cannot be controlled by decelerator pedal.
on machine

1
2. Disconnect connector DCL, and turn starting switch to ON position.
Defective throttle sensor If this failure code is cleared, throttle sensor is defective.
2
(decelerator pedal) NOTICE
Other failure codes are displayed as well. This is because the connector
is disconnected. Ignore failure codes besides this failure code [CA2186].
Ground fault in wiring 2. Disconnect connectors J2 and DCL, and connect T-adapter to either fe-
ground circuit)
Between J2 (female) (9) or DCL (female) (B) and
ground
2. Insert T-adapters into connector J2, or connect T-adapter to female side of
connector DCL.
ler
4.75 to
Voltage Between J2 (9) and (33) or DCL (female) (B) and (C)
5.25 V
controller is defective. (In case of an internal defect, troubleshooting is impossible
D155AX-8 40-427
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error 40 TROUBLESHOOTING
40-428 D155AX-8
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2

Failure Common Rail Pressure Low Error 2 (Engine controller system)
L03 CA2249
Details of No-pressure error is detected in supply pump. (Pressure lower than specified pressure continues for
failure a long time: Level 2.)

Phenomenon
on machine
(Code: 36401 (V))

Supply pump pressure Perform troubleshooting for failure code [CA559].
1
low error
D155AX-8 40-429
FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error

Failure Fuel Feed Pump Open Circuit Error (Engine controller system)
L01 CA2265
Detail of fail-
Fuel feed pump drive signal circuit is open (when controller drives pump time switch).
ure
Action of
None in particular
controller
Phenomenon • Startability is poor when air bleeding is used
on machine • KDPF regeneration does not work.
Related
• Troubleshooting for this failure code covers circuits from the engine controller to the fuel
information feed pump switch timer.
• This failure code is detected only when the feed pump is OFF.

1
Open circuit in wiring har- 2. Disconnect connectors J1 and EPP and connect T-adapters to each fe-
2
nector) Between J1 (female) (7) and EPP (female) (5) Max. 1 Ω
Resistance
Between ground and EPP (female) (10) Max. 1 Ω
Hot short circuit in wiring 2. Insert T-adapter into connector EPP.
3
Voltage Between EPP (5) and (10) Max. 1 V
If failure code is still displayed after above checks, engine controller or switch timer
is defective. (In case of an internal defect, troubleshooting is impossible as an as-
sembly. Replace whole assembly.)
Reference
Fuel feed pump operates at pressure test when the engine just starts.
1. Turn starting switch to OFF position, and shut down the engine controller.
4
ler or switch timer. 3. Turn starting switch to ON position.
4. Start up the engine. (switch timer is actuated immediately after starting the
engine.)
When switch timer is actu-
20 to 30 V
ated
Voltage Between J1 (7) and (30)
When switch timer is not
Max. 1 V
actuated
40-430 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error
CIRCUIT DIAGRAM (ELECTRIC FUEL FEED PUMP SWITCH)
D155AX-8 40-431
FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error

Action level Failure code Fuel Feed Pump Short Circuit Error
Failure
Detail of fail-
Fuel feed pump drive signal circuit shorts (when controller drives pump time switch).
ure
Action of
None in particular
controller
Phenomenon • Startability is poor when air bleeding is used
on machine • KDPF regeneration does not work.
Related 2. Start engine.
information • Troubleshooting for this failure code covers circuits from the engine controller to the fuel
feed pump switch timer.
• This failure code is detected only when the feed pump is ON.

1
2. Disconnect connector EPP.
Defective pump timer 4.
2 Start engine.
switch
If this failure code [CA2266] disappears, pump timer switch is defective.
REMARK
Since connector is disconnected, ignore all the other failure codes except this one.
Ground fault in wiring 2. Disconnect connectors J1 and EPP, and connect T-adapter to either fe-
ground circuit)
Between ground and J1 (female) (7) or EPP (female)
(5)
40-432 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error

If failure code is still displayed after above checks, engine controller or switch timer
is defective. (In case of an internal defect, troubleshooting is impossible as an as-
Reference
Fuel feed pump operates at pressure test when the engine just starts.
4
ler or switch timer. 3. Turn starting switch to ON position.
4. Start up the engine. (switch timer is actuated immediately after starting the
engine.)
When switch timer is actu-
20 to 30 V
ated
Voltage Between J1 (7) and (30)
When switch timer is not
Max. 1 V
actuated
D155AX-8 40-433
FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error 40 TROUBLESHOOTING
CIRCUIT DIAGRAM (ELECTRIC FUEL FEED PUMP SWITCH)
40-434 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2271] EGR Valve Position Sensor High Error
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error

Action level Failure code EGR Valve Position Sensor High Error
Failure
Detail of fail-
High voltage occurs in signal circuit of EGR valve position sensor.
ure
on machine • Engine power deration according to inducement strategy. (EU Specification).
• Signal voltage from EGR valve position sensor can be checked with monitoring function.
(Code: 18101 (V))
• EGR valve position (mm) sensed by EGR valve position sensor can be checked with mon-
Related itoring function. (Code: 18100 (mm))
information • Engine power deration is canceled when the failure code is cleared and the starting switch

1
Defective sensor power If failure code [CA187] or [CA227] is displayed, perform troubleshooting for those
2
supply system codes first.
Defective EGR valve lift 2. Disconnect connector SEGR.
3
sensor (internal defect) 3. Turn starting switch ON (with connector SEGR disconnected).
If failure code [CA2271] changes to [CA2272], the sensor is defective.
ness (wire breakage of 2. Disconnect connectors J1 and SEGR, and connect T-adapters to each fe-
4
GND line or defective male side.
Resistance Between J1 (female) (57) and SEGR (female) (2) Max. 1 Ω
2. Disconnect connectors J1 and SEGR, and connect T-adapter to either fe-
Short circuit in wiring har- male side.
5
ness
Between J1 (female) (81) and (88) or between SEGR
Resistance (female) (1) and (3) or between SEGR (female) (1) and Min. 1 MΩ
(4)
D155AX-8 40-435
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error 40 TROUBLESHOOTING

Hot short circuit in wiring 2. Disconnect connector SEGR and connect T-adapter to female side.
6
harness 3. Turn starting switch ON (with connector SEGR disconnected).
Voltage Between SEGR (female) (3) or (4) and (2) Max. 1 V
Reference
7
ler
Voltage Between J1 (88) and (57) 1.0 to 4.0 V
CIRCUIT DIAGRAM (EGR VALVE LIFT SENSOR)
40-436 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error

Action level Failure code EGR Valve Position Sensor Low Error
Failure
Detail of fail-
Low voltage occurs in signal circuit of EGR valve position sensor.
ure
on machine • Engine power deration according to inducement strategy. (EU Specification).
• Signal voltage from EGR valve position sensor can be checked with monitoring function.
(Code: 18101 (V))
• EGR valve position (mm) sensed by EGR valve position sensor can be checked with mon-
itoring function. (Code: 18100 (mm))
Related
information

1
codes first.
2 Disconnect connector SEGR and connect T-adapter to female side.
supply system
Between SEGR (female) 4.75 to
(1) and (2) 5.25 V
2. Disconnect connectors SEGR and J1, and connect T-adapters to each fe-
male side.
If power supply voltage in check on cause 2 is normal,
3 Between J1 (female) (81) and SEGR (female) (1)
nector) If power supply voltage in check on cause 2 is normal,
Resistance
Between J1 (female) (57) and SEGR (female) (2)
Between J2 (female) (88) and each of SEGR (female)
Max. 1 Ω
(3) and (4) (sensor output)
D155AX-8 40-437
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error 40 TROUBLESHOOTING

Ground fault in wiring 2. Disconnect connectors J1 and SEGR, and connect T-adapter to either fe-
ground circuit)
Between ground and J1 (female) (88) or SEGR (fe-
male) (3)
2. Disconnect connectors J1 and SEGR, and connect T-adapter to either fe-
5 male side.
ness
Between J1 (female) (88) and (57), or between SEGR
If no failure is found in causes 1 through 5 but found in cause 6, the sensor is de-
fective.
Defective EGR valve lift 2.
6 Insert T-adapter into connector J1 or SEGR.
sensor
Between J1 (88) and (57), or between SEGR (3) and
Voltage 1.0 to 4.0 V
(2)
7
CIRCUIT DIAGRAM (EGR VALVE LIFT SENSOR)
40-438 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error

Failure EGR Valve Solenoid Open Circuit Error (Engine controller system)
L03 CA2349
Detail of fail-
Open circuit occurs in EGR valve solenoid drive circuit.
ure
on machine • Engine output is reduced based on inducement strategy. (EU Specification).
• Signal current to EGR valve solenoid can be checked with monitoring function. (Code:
48600 (mA))
Related • Engine power deration is canceled when the failure code is cleared and the starting switch
information is turned OFF (not canceled only by deactivation of the failure code).

1
Defective EGR valve sol-
2 enoid　(internal open cir- 2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
cuit)
Resistance Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
Open or short circuit in NOTICE
3
wiring harness
If resistance is 1 MΩ or higher, wiring harness has open circuit. If resistance
is 1 Ω or below, wiring harness has short circuit.
If failure code is still displayed after above checks on Cause 3, this check is not re-
quired.
ness (wire breakage or 2. Disconnect connectors J1 and EGR-SOL, and connect T-adapters to each
4
nector)
Between J1 (female) (13) and EGR-SOL (female) (1) Max. 1 Ω
Resistance
Between J1 (female) (76) and EGR-SOL (female) (2) Max. 1 Ω
2. Disconnect connectors J1 and EGR-SOL, and connect T-adapter to either
5 female side.
ness
Between J1 (female) (13) and (76), or between EGR-
SOL (female) (1) and (2)
D155AX-8 40-439
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error 40 TROUBLESHOOTING

2. Disconnect connectors J1 and EGR-SOL, and connect T-adapter to either
6 harness (contact with Between ground and J1 (female) (13) or EGR-SOL (fe-
ground circuit) Min. 1 MΩ
male) (1)
Resistance
Between ground and J1 (female) (76) or EGR-SOL (fe-
Min. 1 MΩ
male) (2)
7
CIRCUIT DIAGRAM (EGR VALVE SOLENOID)
40-440 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error

Failure EGR Valve Solenoid Short Circuit Error (Engine controller system)
L03 CA2353
Detail of fail-
Short circuit occurs in EGR valve solenoid drive circuit.
ure
• Signal current to EGR valve solenoid can be checked with monitoring function. (Code:
48600 (mA))

1
Defective EGR valve sol- 2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
2 enoid　(internal open cir-
cuit) Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between EGR-SOL (male) (1) and ground Min. 1 MΩ
2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
3. Turn starting switch ON (with connector EGR-SOL disconnected).
3
harness REMARK
hot short circuit in negative line
Voltage Between EGR-SOL (female) (2) and ground Max. 3 V
4
D155AX-8 40-441
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error 40 TROUBLESHOOTING
CIRCUIT DIAGRAM (EGR VALVE SOLENOID)
40-442 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2357] EGR Valve Servo Error
FAILURE CODE [CA2357] EGR Valve Servo Error

Action level Failure code EGR Valve Servo Error
Failure
Details of EGR valve malfunctions. (Responsing value from EGR position sensor is different from the value of
failure EGR valve opening command.)

Phenomenon • Engine output is reduced based on inducement strategy (EU Specification).
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Position (mm))

1
tem
For testing of EGR valve drive pressure, see “TESTING AND ADJUSTING”, “TEST
Defective EGR valve EGR VALVE AND KVGT DRIVING OIL PRESSURE”.
2
driving oil pressure
If EGR valve drive pressure is abnormal, perform checks on causes 3 and 4.
• For check of engine oil pressure, see “TESTING AND ADJUSTING”,
Defective engine oil pres- “TEST ENGINE OIL PRESSURE”.
3 sure system (main cir-
cuit) • If engine oil pressure is not normal, perform troubleshooting (S mode).
(Engine oil pressure drops)
Defective EGR valve oil Oil pump and relief valve for EGR valve circuit may be defective. Check them.
4
pump
Defective hydraulic pip- Hydraulic piping for EGR valve circuit may be defective. Check it.
5
ing for EGR valve
Defective hydraulic return Hydraulic return piping for EGR valve circuit may be defective. Check it.
6
piping for EGR valve
• EGR valve may have mechanical trouble. Check it.
7 Defective EGR valve • Check especially that there is no foreign material in oil inlet and outlet of
EGR valve.
Defective EGR valve lift Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
sensor
If failure code is still displayed after above checks on causes 1 to 8, engine control-
9 ler is defective. (In case of an internal defect, troubleshooting is impossible as an
ler
D155AX-8 40-443
FAILURE CODE [CA2381] KVGT Position Sensor High Error 40 TROUBLESHOOTING
FAILURE CODE [CA2381] KVGT Position Sensor High Error

Action level Failure code KVGT Position Sensor High Error
Failure
Details of
High voltage is generated in KVGT position sensor signal circuit.
failure
Action of
controller
Phenomenon
on machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
• Position (mm) detected by KVGT position sensor can be checked with monitoring function.
Related (Code: 48700 (mm))

1
2
Defective KVGT position 2. Disconnect connector SVGT.
3
sensor (internal defect) 3. Turn starting switch ON (with connector SVGT disconnected).
If failure code [CA2381] changes to [CA2382], the sensor is defective.
ness (wire breakage of 2. Disconnect connectors J1 and SVGT, and connect T-adapters to each fe-
4
GND line or defective male side.
Resistance Between J1 (female) (57) and SVGT (female) (B) Max. 1 Ω
2. Disconnect connectors J1 and SVGT, and connect T-adapter to either fe-
5 male side.
ness
Between J1 (female) (67) and (81), or between SVGT
(female) (A) and (C)
Hot short circuit in wiring 2. Disconnect connector SVGT and connect T-adapter to female side.
6
harness 3. Turn starting switch ON (with connector SVGT disconnected).
Voltage Between SVGT (female) (C) and (B) Max. 1 V
40-444 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2381] KVGT Position Sensor High Error

Reference
7
ler
Voltage Between J1 (67) and (57) 1.0 to 4.0 V
CIRCUIT DIAGRAM (KVGT POSITION SENSOR)
D155AX-8 40-445
FAILURE CODE [CA2382] KVGT Position Sensor Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA2382] KVGT Position Sensor Low Error

Action level Failure code KVGT Position Sensor Low Error
Failure
Detail of fail-
Low voltage is generated in KVGT position sensor signal circuit.
ure
Action of
controller
Phenomenon
on machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
• Position (mm) detected by KVGT position sensor can be checked with monitoring function.
(Code: 48700 (mm))
Related • Engine power deration is canceled by turning starting switch to OFF position after this fail-
information ure code is cleared (note that the engine power deration is not canceled right after the fail-
ure code is cleared).

1
first.
2 Disconnect connector SVGT and connect T-adapter to female side.
supply system
Between SVGT (female) 4.75 to
(A) and (B) 5.25 V
2. Disconnect connectors SVGT and J1, and connect T-adapters to each fe-
male side.
If power supply voltage in check on cause 2 is normal,
3 Between J1 (female) (81) and SVGT (female) (A)
nector) If power supply voltage in check on cause 2 is normal,
Resistance
Between J1 (female) (57) and SVGT (female) (B)
Between J1 (female) (67) and SVGT (female) (C) (sen-
Max. 1 Ω
sor output)
40-446 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2382] KVGT Position Sensor Low Error

Ground fault in wiring 2. Disconnect connectors J1 and SVGT, and connect T-adapter to either fe-
ground circuit)
Between ground and J1 (female) (67) or SVGT (fe-
male) (C)
2. Disconnect connectors J1 and SVGT, and connect T-adapter to either fe-
5 male side.
ness
Between J1 (female) (67) and (57), or between SVGT
(female) (B) and (C)
If no failure is found in causes 1 through 5 but found in cause 6, the sensor is de-
fective.
Defective KVGT position 2. Insert T-adapter into connector J1 or SVGT.
6
sensor
Between J1 (67) and (57), or between SVGT (C) and
Voltage 1.0 to 4.0 V
(B)
7
CIRCUIT DIAGRAM (KVGT POSITION SENSOR)
D155AX-8 40-447
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error

Action level Failure code KVGT Solenoid Open Circuit Error
Failure
Detail of fail-
Open circuit occurs in KVGT solenoid drive circuit.
ure
Action of
controller
Phenomenon
on machine
• Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48600
(mA))

1
Defective KVGT sole-
2 noid　(internal open cir- 2. Disconnect connector VGT-SOL, and connect T-adapter to male side.
cuit)
Resistance Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
3
wiring harness If resistance is 1 MΩ or higher, wiring harness has open circuit. If resistance is
1Ω or below, wiring harness has short circuit.
quired.
ness (wire breakage or 2. Disconnect connectors J2 and VGT-SOL, and connect T-adapters to each
4
nector)
Between J2 (female) (80) and VGT-SOL (female) (1) Max. 1 Ω
Resistance
Between J2 (female) (2) and VGT-SOL (female) (2) Max. 1 Ω
2. Disconnect connectors J2 and VGT-SOL, and connect T-adapter to either
5 female side.
ness
Between J2 (female) (80) and (2), or between VGT-
SOL (female) (1) and (2)
40-448 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error

2. Disconnect connectors J2 and VGT-SOL, and connect T-adapter to each
6 harness (contact with Between ground and J2 (female) (80) or VGT-SOL (fe-
male) (1)
Resistance
Between ground and J2 (female) (2) or VGT-SOL (fe-
Min. 1 MΩ
male) (2)
7
CIRCUIT DIAGRAM (KVGT VALVE SOLENOID)
D155AX-8 40-449
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error

Failure KVGT Solenoid Short Circuit Error (Engine controller system)
L03 CA2386
Detail of fail-
Short circuit occurs in KVGT solenoid drive circuit.
ure
Action of
controller
Phenomenon
on machine
• Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48600
(mA))

1
Defective KVGT sole- 2. Disconnect connector VGT-SOL, and connect T-adapter to male side.
2 noid　(internal short cir-
cuit) Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between VGT-SOL (male) (1) and ground Min. 1 MΩ
2. Disconnect connector VGT-SOL and connect T-adapter to female side.
3. Turn starting switch ON (with connector VGT-SOL disconnected).
3
harness REMARK
hot short circuit in negative line
Voltage Between VGT-SOL (female) (2) and ground Max. 3 V
4
40-450 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error
CIRCUIT DIAGRAM (KVGT VALVE SOLENOID)
D155AX-8 40-451
FAILURE CODE [CA2387] KVGT Servo Error 40 TROUBLESHOOTING
FAILURE CODE [CA2387] KVGT Servo Error

Action level Failure code KVGT Servo Error
Failure
Detail of fail- KVGT servo error occurs. (Response from KVGT position sensor differs from KVGT opening com-
ure mand value.)
Action of
controller
Phenomenon
on machine
Related is turned OFF (not canceled only by deactivation of the failure code).

1
tem
For testing of KVGT drive pressure, see “TESTING AND ADJUSTING”, “TEST
Insufficient KVGT drive EGR VALVE AND KVGT DRIVING OIL PRESSURE”.
2
pressure
If KVGT drive pressure is abnormal, perform checks on causes 3, 4 and 5.
• For check of engine oil pressure, see “TESTING AND ADJUSTING”,
Defective engine oil pres- “TEST ENGINE OIL PRESSURE”.
3 sure system (main cir-
cuit) • If engine oil pressure is not normal, perform troubleshooting (S mode).
(Engine oil pressure drops)
4 Defective KVGT oil pump Oil pump and relief valve for KVGT valve circuit may be defective. Check them.
Defective hydraulic pip- Hydraulic piping for KVGT circuit may be defective. Check it.
5
ing for KVGT
Defective hydraulic return Hydraulic return piping for KVGT circuit may be defective. Check it.
6
piping for KVGT
KVGT may have a mechanical failure. Check it.
Also check that there is no foreign material in oil inlet of KVGT servo.
7 Defective KVGT If KDOC inlet temperature: approximately 250°C or below and KVGT solenoid cur-
rent: approximately 1000 mA are kept after active regeneration for service, KVGT is
defective (See failure code CA2639 because approximate manual stationary regen-
eration time depends on the soot level estimation).
Defective KVGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
8
sensor
9
40-452 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error
Action level Failure code Intake Air Heater Relay Open Circuit Error
Failure
Detail of fail-
Open circuit is detected in preheat relay drive circuit (primary circuit).
ure
Action of
None in particular
controller
Phenomenon Intake air heater does not work in auto preheating mode (resulting in degraded startability and emis-
on machine sion of white smoke at low temperatures).
• The heater relay operation conditions depend on the machine model.

• Troubleshooting of this failure code covers circuits from engine controller to primary (coil)
Related circuit of pre-heater relay.
information • This failure code is detected only when the relay is OFF.
Procedure: Turn starting switch to ON position (Coolant temperature: Min. -4 °C)

2. Turn starting switch to ON position. (engine coolant: -4 °C or above)
1 1. See descriptions of wiring harness and connectors in “c. METHOD FOR
connector
CHECKING ELECTRIC EQUIPMENT” in “CHECKS BEFORE TROUBLE-
SHOOTING” of “RELATED INFORMATION ON TROUBLESHOOTING”,
and check it.
2. Disconnect relay PHR, and connect T-adapter to male side.
200 to
Resistance Between PHR (male) (1) and (2)
400 Ω
Defective preheating re-
2
lay PHR 1. Turn starting switch to OFF position.
2. Replace relay PHR with another one.
3. Turn starting switch to ON position (coolant temperature: Max. -5 °C).
If this failure code is cleared, original preheating relay PHR is defective.
Open or short circuit in 2. Disconnect connector ECM J2, and connect T-adapter to female side.
3
wiring harness Between ECM J2 (female) (75) and (61) 200 to
Resistance
Relay PHR coil resistance 400 Ω
D155AX-8 40-453
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error 40 TROUBLESHOOTING

quired.
Open circuit in wiring har- 2. Disconnect connector ECM J2 and relay PHR, and connect T-adapter to
4
ness female side.
Between ECM J2 (female) (75) and PHR (female) (1) Max. 10 Ω
Resistance
Between ECM J2 (female) (61) and PHR (female) (2) Max. 10 Ω
Perform under conditions under which no preheating takes place (engine coolant:
-4 °C or above).
5 2. Insert T-adapter into connector J2.
harness
Voltage Between J2 (75) and (61) Max. 1 V
6
40-454 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error
CIRCUIT DIAGRAM (INTAKE AIR HEATER RELAY)
D155AX-8 40-455
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error
Action level Failure code Intake Air Heater Relay Short Circuit Error
Failure
Detail of fail-
Short circuit is detected in intake heater relay drive circuit (primary circuit).
ure
Action of
None in particular
controller
Phenomenon Intake air heater does not work in auto preheating mode (resulting in degraded startability and emis-
on machine sion of white smoke at low temperatures).
• The heater relay operation conditions depend on the machine model.

• Troubleshooting of this failure code covers circuits from engine controller to primary (coil)
Related circuit of pre-heater relay.
information • This failure code is detected only when the relay is ON.
Procedure: Turn starting switch to ON position (Coolant temperature: Max. -5 °C)

1
connector 2. Starting switch ON (Engine coolant: -5 °C or below).
2. Disconnect relay PHR, and connect T-adapter to male side.
200 to
Resistance Between PHR (male) (1) and (2)
400 Ω
Defective preheating re-
2
lay PHR 1. Turn starting switch to OFF position.
2. Replace relay PHR with another one.
3. Turn starting switch to ON position (coolant temperature: Max. -5 °C).
If this failure code is cleared, original preheating relay PHR is defective.
Ground fault in wiring 2. Disconnect connectors ECM J2 and relay PHR, and connect T-adapter to
3 harness (contact with either female side.
ground circuit)
Between ground and ECM J2 (female) (75) or PHR (fe-
Resistance Min. 100 kΩ
male) (1)
2. Disconnect connectors ECM J2 and relay PHR, and connect T-adapter to
4 female side of ECM J2.
ness
Between ECM J2 (female) (75) and each pin other No continui-
Continuity
than pin (75) ty
5
40-456 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error
CIRCUIT DIAGRAM (INTAKE AIR HEATER RELAY)
D155AX-8 40-457
FAILURE CODE [CA2637] KDOC Face Plugging 40 TROUBLESHOOTING
FAILURE CODE [CA2637] KDOC Face Plugging

Action level Failure code KDOC Face Plugging
Failure
KDOC face is plugged.
1. The KDOC surface is contaminated due to the operating conditions, and the catalytic effi-
Details of
ciency has dropped (clean the DOC).
failure
2. Deteriorated KDOC due to high temperature, dropped efficiency due to deposit, or drop-
ped efficiency due to damage (Replace KDOC with a new or used one.)
Phenomenon
None
on machine
k Since temperature of the turbocharger exhaust connector, KDOC and KDPF exceeds
500°C, be careful not to get burned.
When KDOC in KDPF is changed, perform reset procedure for KDOC change and then finish repair.
Procedure of performing the manual stationary regeneration from the "active regeneration for serv-
ice".
When soot accumulation is at level 3 or lower, manual stationary regeneration can be performed on-
ly from Active Regeneration for Service.
1. Start engine.
2. Make sure that machine is in safe condition.
Related generation for Service, and then perform “Manual Stationary Regeneration”.
information When operation efficiency of KDOC is decreasing, failure code [AQ10N3] may appear after failure
code [CA2637] is displayed repeatedly. If operation efficiency of KDOC is low, failure code [CA1691]
of regeneration ineffective may appear.
For check of the exhaust gas color, see “30 TESTING AND ADJUSTING”, “TEST EXHAUST GAS
COLOR”.
[Method of clearing failure code]
Start the engine, perform warm-up operation, and operate the machine in normal work for approxi-
mately 3 hours. (The time required for clearing codes will be reduced by high exhaust temperature
conditions.)
NOTICE
Operate the machine approximately 3 hours and check that this failure code is cleared.

1 Defective KVGT If failure code [CA238*] is displayed, perform troubleshooting for the code first.
If failure code [CA227*] or [CA23**] is displayed, perform troubleshooting for those
2 Defective EGR valve
codes first.
1. Remove turbocharger exhaust connector
2. Check inside of turbocharger exhaust connector for adhesion of oil and
3 fuel.
exhaust connector
If there is any, perform troubleshooting for failure codes [CA227*], [CA23**], etc.
which are related to EGR valve and KVGT.
Defective exhaust con- Check the exhaust system between the turbocharger and KDPF for damages in
4
nector or duct to KDPF connectors or ducts or loose connections.
40-458 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2637] KDOC Face Plugging

1. Suddenly accelerate the engine from low idle to high idle two times, and
then keep the engine running at high idle for 5 seconds.
If an excess black smoke is seen at high idle during acceleration, perform “S-9
Defective exhaust gas KDPF GETS CLOGGED IN A SHORT TIME”.
5
color
REMARK
1. Remove KDPF.
2. Remove KDOC.
NOTICE
6 Defective KDOC • Check if KDOC has any cracks (change KDOC if any).
• Check if KDOC inlet surface is clogged with soot 50 % or more (Clean-
ing of KDOC).
• Perform cause 7 when KDOC is changed, and perform causes 7 and 8
when it is cleaned.
1. Attach KDOC and KDPF.
3. On the Service screen of the machine monitor, display “Diagnostic Tests”
screen, open 03 “KDPF Memory Reset”, and perform 03 “KDOC Change”
Reset after KDOC (Reset after KDOC change).
7
change NOTICE
• Check that reset after KDOC change is complete successfully (by re-
set count). If not, perform troubleshooting again.
• If KDOC is changed, troubleshooting is complete without performing
manual stationary regeneration.
1. Perform manual stationary regeneration from active regeneration for serv-
ice.
3. Perform manual stationary regeneration from active regeneration for serv-
Manual stationary regen- ice again (to confirm the completion of the repair).
8
eration performed
NOTICE
If failure code [CA2637] is displayed after performing active regeneration for
service, KDOC's efficiency is degraded. Change KDOC and perform the reset
after KDOC change (see cause 7).
D155AX-8 40-459
FAILURE CODE [CA2639] Manual Stationary Regeneration Request 40 TROUBLESHOOTING
FAILURE CODE [CA2639] Manual Stationary Regeneration Request

Failure Manual Stationary Regeneration Request (Engine controller system)
L01 CA2639
The "Manual Stationary Regeneration Request" prompts operator to forcibly perform "Manual Sta-
Details of tionary Regeneration", which is more effective to remove soot, because soot accumulation in the
failure KCSF of KDPF has exceeded the level for automatic regeneration.
Soot accumulation reaches level 4 or 5.
Action of
Normal control
controller
Phenomenon
None in particular
on machine
NOTICE
• If this failure code [CA2639] is displayed, perform manual stationary regeneration.
• This failure code is displayed during Manual Stationary Regeneration, but it is nor-
mal.
• If this failure code is still displayed after several hours have passed after the manual
stationary regeneration, perform the following troubleshooting procedures.
k Since KDOC and KDPF are heated to 500 °C or above, be careful not to get burn injury.
• If KDOC inlet temperature is below approximately 250 °C, fuel dosing is disabled, so ac-
tually regeneration does not start when engine controller started manual stationary regen-
eration.
• KVGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
Related • Temperature detected by KDOC outlet temperature sensor can be checked with monitor-
information ing function. (Code: 47400 (°C))
• When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
• For check of the exhaust gas color, see “30 TESTING AND ADJUSTING”, “TEST EX-
HAUST GAS COLOR”.
40-460 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2639] Manual Stationary Regeneration Request
• How to perform manual stationary regeneration

1. Start engine.
2. Make sure that machine is in a safe condition.
generation for Service, and then perform Manual Stationary Regeneration.
• Switch operation during manual stationary regeneration: By pressing "1", "2", "3" in order
while numeral input switch [4] is pressed, the screen changes to Monitoring.
Related
information
• If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting these first.
Increased accumulation 1. Check that regeneration disable is not set on machine monitor. (Cancel the
1 of soot due to regenera- regeneration disable if it is set.)
tion disable 2. Cancel regeneration disable and perform cause 2 and subsequent causes.
2
Also check that there is no foreign material in oil inlet of KVGT servo.
3 Defective KVGT If KDOC inlet temperature: approximately 250°C or below and KVGT solenoid cur-
rent: approximately 1000 mA are kept after active regeneration for service, KVGT is
defective (See failure code CA2639 because approximate manual stationary regen-
eration time depends on the soot level estimation).
Defective KDPF (KDOC, Perform troubleshooting for “S-22 ACTIVE REGENERATION TAKES TIME” of S
4
or KCSF) mode.
gas color.
5
6
D155AX-8 40-461
FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error 40 TROUBLESHOOTING
FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error

Action level Failure code Fuel Doser Solenoid 2 High Error
Failure
Detail of fail-
Abnormal high voltage occurs in fuel doser solenoid valve 2 (drain valve).
ure
Action of
controller
k Since exhaust connector and KDPF are heated to 500°C or above, be careful not to
get burn injury.
• If failure code [CA1923] is also displayed, the ground line may have open circuit.
Related
• If connector DSOV2 is disconnected, this failure code is displayed.
information
• See failure code [CA1963].

1
2 enoid valve 2 (drain 2. Disconnect connector DSOV2, and connect T-adapter to male side.
valve)
Resistance Between DSOV2 (male) (2) and (1) 4 to 6 Ω
wiring harness
Resistance Resistance is the same as resistance of dosing fuel 4 to 6 Ω
solenoid valve 2.
quired.
ness (wire breakage of 2. Disconnect connectors J1 and DSOV2 and connect T-adapters to each fe-
4
Resistance
Hot short circuit in wiring 2. Disconnect connector DSOV2, and connect T-adapter to female side.
5
Voltage Between DSOV2 (female) (1) and (2) Max. 4.7 V
40-462 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error

nute.
6
ler
Circuit diagram related to dosing fuel solenoid valve 2
D155AX-8 40-463
FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error

Action level Failure code Dosing Fuel Solenoid Valve 2 Low Error
Failure
Detail of fail-
Abnormal low voltage occurs in fuel doser solenoid valve 2 (drain valve).
ure
Action of
controller
k Since exhaust connector and KDPF are heated to 500°C or above, be careful not to
get burn injury.
• If sensor connector DSV2 is disconnected, failure code [CA2732] is displayed.
Related • See failure code [CA1963].
information • This failure code is cleared after turning the starting switch OFF, turning the starting switch
ON, and performing driving dosing fuel solenoid valve 2.

1
2. Disconnect connector DSOV2, and connect T-adapter to male side.
2 enoid valve 2 (drain Between (1) and DSOV2 (male) (2) 4 to 6 Ω
valve)
Resistance Between DSOV2 (male) (1) and ground (dosing fuel
Min. 1 MΩ
solenoid 2 body)
wiring harness
Resistance Resistance is the same as resistance of dosing fuel 4 to 6 Ω
solenoid valve 2.
Ground fault in wiring 2. Disconnect connectors J1 and DSOV2, and connect T-adapter to either fe-
ground circuit)
Between ground (frame) and J1 (female) (6) or DSOV2
(female) (1)
2. Disconnect connectors J1 and DSOV2, and connect T-adapter to female
5
ness
No continui-
(6)
is heard)
40-464 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error

Defective dosing fuel sol- Replace dosing fuel solenoid valve 2 (drain valve).
6 enoid valve 2 (drain
valve)
nute.
7
ler
D155AX-8 40-465
FAILURE CODE [CA2741] Fuel Dozer Solenoid Valve Swap Error 40 TROUBLESHOOTING
FAILURE CODE [CA2741] Fuel Dozer Solenoid Valve Swap Error

Action level Failure code Dosing Fuel Solenoid Valve Swap Error
Failure
Detail of fail- Fuel Doser solenoid valve 1 (shut-off valve) and fuel doser solenoid valve 2 (drain valve) are con-
ure nected reversely.
Action of
controller
• Method of clearing failure code
Related Turn the starting switch from OFF to ON and start the engine. When this failure code is
information cleared after running the engine at low idle speed for approximately 3 minutes, the repair
is completed.
REMARK
Since exhaust connector and KDPF are heated to 500 °C or above, be careful not to get burn injury.

Reverse connection of Check connectors DSOV1 and DSOV2.
1
wiring harness connector

B: Fuel return
1. Fuel doser
2. Fuel supply line
40-466 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2765] Injector Trim Data Mismatch
FAILURE CODE [CA2765] Injector Trim Data Mismatch

Action level Failure code Injector Trim Data Mismatch
Failure
Details of • The data of the injector trim entered into the engine controller is not correct.
failure • The same injector trim data was input in multiple injectors.
Action of
controller
Phenomenon Engine controller is unable to grasp inherent variation in injector. AS a result, machine discharge
on machine unclean exhaust gas.

Since input value of injector trim data may be incorrect, check the input value.
Incorrect input of injector When replacing injector, perform injector trim. For details, see Chapter 30 “TEST-
1
trim data ING AND ADJUSTING”, “WRITE INJECTOR COMPENSATION VALUE TO EN-
GINE CONTROLLER”.
1. When multiple injectors that have the same injector trim data are installed, re-
place only applicable injector.
(When 2 injectors have overlapped data, replace one of them.)
Input of the same injector
2 2. After replacing, check that there is no overlapped data among the trim data of
trim data
all injectors, and input injector trim data again.
(See chapter 30, “WRITE INJECTOR COMPENSATION VALUE TO ENGINE
CONTROLLER”.)
D155AX-8 40-467
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error
Action level Failure code SCR Outlet NOx Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller does not receive SCR outlet NOx sensor data due to a communication error
ure with the SCR outlet NOx sensor.
Action of • Runs the controller using the default NOx emission value (0 ppm).
• NOx emission increases
Phenomenon
• Engine output is reduced based on inducement strategy.
on machine
• SCR outlet NOx concentration detection error
k The turbocharger outlet, the sensor installation piping, KDPF, and KDOC become hot
(Min. 500 °C). Be careful not to get burned.
k SCR assembly, the sensor installation piping, and the sensor probe become hot
• SCR outlet NOx sensor is a smart sensor which communicates with the engine controller
via CAN along with other sensors.
• This failure code is displayed if the sensor connector or a smart sensor (power supply) re-
lay connector is removed.
• CAN communication failure codes related to engine sensors include [CA2771], [CA3232],
[CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are displayed, a
defect in any of the 6 sensors, a defective smart sensor power supply relay/relay system
or a ground fault or short circuit or hot short circuit in wiring harness (CAN communication
line) can be suspected.
Related
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
information
using multimeter.
• AdBlue/DEF tank sensor consists of the AdBlue/DEF level sensor, AdBlue/DEF tempera-
ture sensor, and AdBlue/DEF quality sensor and is integrated into one sensor controller
which provides CAN communication with the engine controller.
• The KDPF temperature sensor consists of the KDOC inlet temperature sensor, the KDOC
outlet temperature sensor, and the KDPF outlet temperature sensor and is integrated into
one sensor controller which provides CAN communication with the engine controller.
• For replacement of the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
• The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
• For replacement of the SCR temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“DISASSEMBLE AND ASSEMBLE SCR TEMPERATURE SENSOR”.

1. See descriptions of wiring harness and connectors in “C Electrical equip-
1
connector
40-468 D155AX-8

Defective smart sensor disconnect switch to OFF position.
2 power supply relay sys- 3. Disconnect relay connector SSR, and connect T-adapter to female side.
tem
6. Perform troubleshooting for failure code [CA1776] if a failure is found.
Voltage Between SSR (female) (5) and (4) Min. 22 V
3. Disconnect connectors DPFJ, NOX1, NH3, SCRJ, NOX2, and UREA.
4. Insert T-adapter into connector SSR.
Defective sensor power 6. Turn starting switch to ON position.
3
supply relay
Between SSR (6) and (4) Min. 22 V
Voltage
If all 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed
4 2. Disconnect turbocharger outlet NOx sensor (NOX1).
outlet NOx sensor
Displaying less than 6 failure codes indicates the disconnected sensor is defective.
5 2. Disconnect SCR outlet NOx sensor (NOX2).
NOx sensor
Defective SCR tempera-
6 2. Disconnect SCR temperature sensor (SCRJ).
ture sensor
D155AX-8 40-469

Defective ammonia sen-
7 2. Disconnect an ammonia sensor (NH3).
sor
If all of 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed.
Defective KDPF temper- 2. Disconnect KDPF temperature sensor (DPFJ).
8
ature sensor
If any of these 6 codes disappeared, the sensor which has been disconnected is
defective.
If all 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151] and
Defective AdBlue/DEF 2. Disconnect AdBlue/DEF tank sensor (UREA).
9
tank sensor
If the number of displayed failure codes decrease from 6, the disconnected sensor
is defective.
2. Disconnect connector CTN2 and CTN and connect T-adapter to male side.
Defective CAN terminat- Approxi.
10 Between CTN2 (male) (A) and (B)
ing resistor 120 Ω
Resistance
Approxi.
Between CTN (male) (A) and (B)
120 Ω
• Communication line
As CAN terminating resistors of 120 ohm are connected in parallel, therefore, when
circuit resistance is measured at connector of CAN communication, if combined re-
sistance is 60 ohm, there is no open circuit.
Open circuit and short 2. Check that system operating lamp does not light up, and then turn battery
circuit in wiring harness disconnect switch to OFF position.
11
(broken or short-circuited
3. Disconnect connectors J2 and NOX2 and connect T-adapters to each fe-
communication line)
male side.
Approx.
Between NOX2 (female) (3) and (2)
60 Ω
Resistance
Approx.
60 Ω
40-470 D155AX-8

• Power line
2. Disconnect connector NOX2 and connect T-adapter to female side.
ness (wire breakage or Voltage Between NOX2 (female) (1) and (4) Min. 22 V
12 defective contact of con- If no failure is found by above results, this check is not required.
nector) (broken power 1. Turn starting switch to OFF position.
line)
2. Disconnect connectors SSR and NOX2 and connect T-adapters to each
female side.
Between SSR (female) (12) and NOX2 (female) (1) Max. 1 Ω
Resistance
Between NOX2 (female) (4) and ground Max. 1 Ω
If failure code is still displayed after above checks on cause 11, this check is not
required.
Open circuit in wiring har- 3.
Disconnect connectors J2, NOX2, CTN2, and CTN, and connect T-adapt-
ers to each female side.
13 defective contact of con-
nector) (broken commu- Between J2 (female) (21) and NOX2 (female) (3) Max. 1 Ω
nication line)
Between J2 (female) (45) and NOX2 (female) (2) Max. 1 Ω
Between CTN2 (female) (A) and NOX2 (female) (3) Max. 1 Ω
Resistance
Between CTN2 (female) (B) and NOX2 (female) (2) Max. 1 Ω
Between CTN (female) (A) and NOX2 (female) (3) Max. 1 Ω
Between CTN (female) (B) and NOX2 (female) (2) Max. 1 Ω
If no failure (no open circuit) is found by check on cause 11, measure resistance at
any one place in Hi line and Lo line.
3. Disconnect all related connectors, and connect T-adapter to the female
Ground fault in wiring side of the connector to be measured.
Between ground and any of J2 (female) (21), CTN2
ground circuit)
(female) (A), CTN (female) (A), NOX1 (female) (3),
Min. 1 MΩ
NH3 (female) (2), DPFJ (female) (3), SCRJ (female)
(3), NOX2 (female) (3), and UREA (female) (2).
Resistance
(female) (B), CTN (female) (B), NOX1 (female) (2),
Min. 1 MΩ
D155AX-8 40-471

any one place in Hi line and Lo line.
3. Insert T-adapter into one of the related connectors.
Hot short circuit in wiring 4. Set battery disconnect switch to ON position.
15
Between ground and any of J2 (21), CTN2 (A), CTN
(A), NOX1 (3), NH3 (2), DPFJ (3), SCRJ (3), NOX2 1 to 4 V
(3), and UREA (2).
Voltage
Between ground and any of J2 (45), CTN2 (B), CTN
(B), NOX1 (2), NH3 (3), DPFJ (2), SCRJ (2), NOX2 1 to 4 V
(2), and UREA (3).
16 2. Disconnect SCR outlet NOx sensor (NOX2).
NOx sensor
17
40-472 D155AX-8
Circuit diagram related to SCR system CAN communication
D155AX-8 40-473
but KDPF Regeneration Disable 40 TROUBLESHOOTING
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but

KDPF Regeneration Disable
Action level Failure code Manual Stationary Regeneration Request but KDPF Regeneration
Failure Disable
― CA2777 (Engine controller system)
• The Manual Stationary Regeneration Request prompts operator to forcibly perform "Man-
ual Stationary Regeneration", which is more effective to remove soot, because soot accu-
Detail of fail- mulation in the KCSF of KDPF has exceeded the level for automatic regeneration. Howev-
ure er, the operator is pressing Regeneration Disable, so regeneration is disabled.
• Soot accumulation reaches level 4 or 5.
Action of
None in particular
controller
Phenomenon
None in particular
on machine
40-474 D155AX-8
40 TROUBLESHOOTING but KDPF Regeneration Disable
k If KDOC and KDPF becomes hot (Min. 500 °C). Be careful not to get burn injury.
REMARK
If manual stationary regeneration is started when KDOC inlet temperature is below approximately
250 °C°C, fuel dosing is disabled, so actually regeneration does not start.
(Code: 47300 (°C))
• KVGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
(Code: 47400 (°C))
(Code: 47200 (°C))
• The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature can
also be confirmed from the Pre-defined Monitoring screen.
• All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
Related
information
2. Secure machine safety.
Regeneration for Service”, clear regeneration disable, and then perform “Manual Station-
ary Regeneration”.
Time required for manual stationary regeneration varies depending on soot accumulation amount in
KCSF. Rough guide is described below.
REMARK
• If this failure code is still displayed after several hours have passed after the manual sta-
tionary regeneration, perform the following troubleshooting procedures.
• If other failure code is also displayed (including manual stationary regeneration), perform
troubleshooting these first.
• This failure code is not a failure but an information to identify the failure.
• If this failure codes frequently appears, ask operator to perform "Cancel of Regeneration
Disable" and to execute manual stationary regeneration after full safety around the ma-
chine is secured and check that there is not a person or combustible around the machine.
D155AX-8 40-475
but KDPF Regeneration Disable 40 TROUBLESHOOTING

If the failure code is not cleared after Cancel of Regeneration Disable from the ma-
1 chine monitor, the engine controller may be defective (In case of an internal defect,
ler
troubleshooting is impossible as an assembly. Replace whole assembly.)
40-476 D155AX-8
FAILURE CODE [CA2878] Fuel Doser Solenoid 2 Servo Error

Failure Fuel Doser Solenoid 2 Servo Error (Engine controller system)
L03 CA2878
At the pressure test immediately after engine start, fuel doser solenoid valve2 (DSOV2, drain valve)
ON/OFF command does not match with the estimated fuel pressure detected by the dosing fuel
pressure sensor.
Detail of fail- 1. When Open DSOV1 Valve and Close DSOV2 Valve commands are given, the dosing fuel
ure
pressure detected by dosing fuel pressure sensor does not increase sufficiently.
2. When Close DSOV1 Valve and Open DSOV2 Valve commands are given, the dosing fuel
pressure detected by dosing fuel pressure sensor does not decrease sufficiently.
Action of
controller
k
burn injury.
• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47601 (V))
• Pressure detected by dosing fuel pressure sensor can be checked with monitoring func-
tion. (Code: 47600 (kPa))
Related
• Ambient pressure detected by ambient pressure sensor can be checked with monitoring
information
Procedure: Start engine. (Observe for 3 minutes.)
[Method of clearing failure codes]
Turn the starting switch from OFF to ON and start the engine. When this failure code is cleared after
running the engine at low idle speed for approximately 3 minutes, the repair is completed.

1
2 Defective fuel system Perform “TESTING AND ADJUSTING”, “TEST ENGINE OIL PRESSURE”.
valve)
valve) system
5
D155AX-8 40-477

2. Disconnect connectors DSOV1 and DSOV2.
3. Replace dosing fuel solenoid valve 1 with dosing fuel solenoid valve 2.
REMARK
valve) Do not replace connector DSOV1 with DSOV2.
If failure code changes to [CA1963], original dosing fuel solenoid valve 2 (drain
valve) is defective.
7 Clogged fuel return tube Check fuel return tube for clogging by removing fuel return tube.
Defective fuel shut off Check fuel connector of fuel shut off manifold for clogging by removing fuel tube.
8
manifold
4. See Related information, and display dosing fuel pressure and ambient
Defective doser fuel pressure at the same time.
9
pressure sensor
pressure sensor is defective.
REMARK
10
ler
40-478 D155AX-8

B: Fuel return
1. Fuel doser
2. Fuel supply line
D155AX-8 40-479
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1 40 TROUBLESHOOTING
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1

Failure Dosing Fuel Pressure Low Error 1 (Engine controller system)
L03 CA2881
Detail of fail- Pressure detected by dosing fuel pressure sensor during dosing is below the threshold value (the
ure fuel pressure is low).
Action of
• Above measures can be canceled by “turning the starting switch from OFF to ON” after
controller
failure code is displayed.
k
burn injury.
(Code: 47600 (V))
Related retracted (for up to 6 minutes). So when you restart engine, wait until the system operating
information lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
NOTICE
is cleared. (This failure code is not cleared by only turning ON the starting switch
again.)

1
valve)
valve) system
4
Defective fuel supply If failure code [CA559] is displayed, perform troubleshooting these first.
5
pump system
40-480 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1

2. Loosen fuel tube joint bolt (JB).
Defective fuel feed pump 3. Tilt switch for the fuel feed pump to ON position while the starting switch is in
6
system OFF position.
(Fuel may spurt out. So be careful.)
To finish checking, turn the starting switch to ON position, or tilt switch for the
fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB) of fuel tube, fuel feed pump is defective.
7 Clogged fuel filter Check fuel filter for clogging.
8 Defective fuel system Perform “TESTING AND ADJUSTING”, “TEST FUEL PRESSURE”.
Clogged fuel supply tube Check fuel supply tube and its joint bolt (JB).
9 and fuel leakage from
connectors
Defective fuel shut off Check fuel connector of fuel shut off manifold for clogging by removing fuel tube.
10
manifold
11 If the dosing fuel pressure is clearly different from ambient pressure, the dosing fuel
pressure sensor
pressure sensor is defective (See related information).
REMARK
Defective dosing fuel sol- Replace dosing fuel solenoid valve 2 (drain valve).
valve)
13
Operation for clearing failure code

(Make sure that this failure code is not displayed.)
2. Start the engine and run it at low idle speed for about 1 minute.
3. See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (Active Regeneration for Serv-
ice)” in “SETTING AND OPERATION OF MACHINE MONITOR” to perform“Active Regeneration for Serv-
ice”.
NOTICE
• If the failure code is cleared during regeneration for service, repair is complete.
REMARK
D155AX-8 40-481
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1 40 TROUBLESHOOTING

B: Fuel return
1. Fuel doser
2. Fuel supply line
40-482 D155AX-8
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor
40 TROUBLESHOOTING Signal Error
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal

Error
Action level Failure code AdBlue/DEF Pump Temperature Sensor Signal Error
Failure
Detail of fail-
Power supply, wiring harness, or sensor for AdBlue/DEF pump temperature is defective.
ure
Action of • The last normal value of AdBlue/DEF pump temperature is valid.
• AdBlue/DEF thawing defective.
Phenomenon
• NOx emission increases in low temperature due to defective AdBlue/DEF pump thawing.
on machine
• This failure code is displayed when AdBlue/DEF pump connector is disconnected.
Related • Because sensor output is approximately 10 V of pulse waveform, it is not measured by us-
ing multimeter.
information

Defective power supply If failure code [CA3558] or [CA3559] is displayed, perform troubleshooting for
system of AdBlue/DEF [CA3558] or [CA3559] first.
1
pump temperature sen-
sor
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
Defective wiring harness “RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
2
2. Disconnect connectors J2 and DSM, and connect T-adapter to either fe-
male side.
3
defective contact of con- Between J2 (female) (54) and DSM (female) (8) Max. 1 Ω
nector)
Resistance Between J2 (female) (79) and DSM (female) (9) Max. 1 Ω
Between J2 (female) (6) and DSM (female) (10) Max. 1 Ω
male side.
Between J2 (female) (6) and (54), or between DSM
Short circuit in wiring har- Min. 1 MΩ
4 (female) (10) and (8)
ness
Min. 1 MΩ
D155AX-8 40-483
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor
Signal Error 40 TROUBLESHOOTING

Ground fault in wiring 2. Disconnect connectors J2 and DSM, and connect T-adapter to either fe-
GND circuit)
Between J2 (female) (6) or DSM (female) (10) and
ground
Hot short circuit in wiring 2. Disconnect connector DSM, and connect T-adapter to female side.
6
Voltage Between DSM (female) (10) and (8) Max. 1 V
Defective AdBlue/DEF If no failure is found by preceding checks, AdBlue/DEF pump temperature sensor
7 pump temperature sen- may be defective. (In case of an internal defect, troubleshooting is impossible as an
sor (internal defect) assembly. Replace whole assembly.)
ler
Circuit diagram related to AdBlue/DEF pump temperature sensor
40-484 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error

Action level Failure code KDPF Outlet Pressure Sensor High Error
Failure
Detail of fail-
High voltage is generated in signal circuit of KDPF outlet pressure sensor.
ure
Action of Sets KDPF differential pressure sensor value to an estimated value (gauge pressure) and continues
controller operation (operates at 0 kPa (gauge pressure) if other failure codes appear at the same time).
Phenomenon
on machine
k Since KDPF is heated to 500 °C or above, be careful not to get burned.

• If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, ground
line probably has open circuit (defective contact of connector).
Related • Signal voltage from KDPF outlet pressure sensor can be checked by monitoring function.
information (Code: 47001 (V))
• Differential pressure detected by KDPF outlet pressure sensor can be checked by monitor-
ing function. (Code: 47000 (kPa))

1
supply system
4.75 to
5.25 V
Defective KDPF outlet • If this failure code is changed to [CA3134], the KDPF outlet pressure sen-
3
pressure sensor sor is defective.
• If this failure code is displayed, the wiring harness or engine controller is
defective.
• Ignore other failure codes displayed.
D155AX-8 40-485
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error 40 TROUBLESHOOTING

quired.
4
GND line or defective 2. Disconnect connectors J2 and PDPF, and connect T-adapters to each fe-
contact of connector) male side.
Resistance Between J2 (female) (32) and PDPF (female) (1) Max. 1 Ω
5
ness
No continui-
(42)
is heard)
Hot short circuit in wiring 3. Connect T-adapter to female side of connector PDPF, or insert T-adapter
6 harness (Contact with 24 to connector J2.
V circuit) 4. Turn starting switch to ON position (with connector PDPF disconnected).
Between J2 (female) (42) and (32), or between PDPF
Voltage Max. 1 V
7
Circuit diagram related to KDPF outlet pressure sensor
40-486 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error

Action level Failure code KDPF Outlet Pressure Sensor Low Error
Failure
Detail of fail-
Low voltage is generated in signal circuit of KDPF outlet pressure sensor.
ure
Action of Sets KDPF outlet pressure sensor value to an estimated value (gauge pressure) and continues op-
controller eration (operates at 0 kPa (gauge pressure) if other failure codes appear at the same time).
Phenomenon
None
on machine
k Since KDPF is heated to 500 °C or above, be careful not to get burned.

• If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
connector is probably disconnected or 5 V line probably has open circuit (defective contact
of connector).
Related • This failure code is displayed if sensor connector is disconnected.
information • Signal voltage from KDPF outlet pressure sensor can be checked by monitoring function.
(Code: 47001 (V))
• Differential pressure detected by KDPF outlet pressure sensor can be checked by monitor-
ing function. (Code: 47000 (kPa))

1
supply system
4.75 to
5.25 V
2. Disconnect connectors J2 and PDPF, and connect T-adapters to each fe-
male side.
3
defective contact of con- Between J2 (female) (32) and PDPF (female) (1)
nector)
Between J2 (female) (8) and PDPF (female) (4)
Between J2 (female) (41) and PDPF (female) (2) Max. 1 Ω
D155AX-8 40-487
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error 40 TROUBLESHOOTING

Ground fault in wiring 2. Disconnect connectors J2 and PDPF, and connect T-adapter to either fe-
ground circuit)
Between ground and J2 (female) (42) or PDPF (fe-
male) (3)
5
ness
No continui-
(42)
is heard)
Defective KDPF outlet 2. Insert T-adapter into connector PDPF.
6
Voltage Between PDPF (3) and (1) 0.5 to 4.5 V
7
40-488 D155AX-8
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Er-
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error

Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
Details of Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
failure (Signal voltage is within "operating" range.)
Action of
Sets KDPF outlet pressure at estimated value (gauge pressure) and allows engine to run.
controller
Phenomenon
None
on machine
k
burned.
• KDPF differential pressure sensed by KDPF differential pressure sensor can be checked
by monitoring function. (Code: 47100 (kPa))
• Signal voltage from KDPF outlet pressure sensor can be checked by monitoring function.
(Code: 47001 (V))
• Outlet pressure sensed by KDPF outlet pressure sensor can be checked by monitoring
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related REMARK
information Use “Short-circuit connector: 799T-601-4670”(its wiring is not identical with that of "Shortcircuit
connector: 799-601-4611).
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
position.
NOTICE
is cleared again.
• Before　performing “Loaded Diagnostics Operation To Confirm Failure Correction”,
firstly Setting and operating machine monitor, Service mode, Service mode (Engine
Controller Active Fault Clear) to be performed to clearer this failure code.
D155AX-8 40-489

3. Check the KDPF differential pressure sensor tube for cracks or damages.
4. Securely connect both ends of the tube and install the KDPF differential
pressure sensor tube.
1 Reference
How to check clogged KDPF differential pressure sensor tube
2. Monitor the outlet pressure by using KDPF outlet pressure sensor on Self-
define Monitoring screen of the machine monitor.
Code 47000(kPa) 0 ± 3( kPa)
supply system
4.75 to
5.25 V
Defective wiring harness ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
3
connector FORMATION ON TROUBLESHOOTING”, and check and repair defects, if
any.
tive.
REMARK
REMARK
Defective wiring harness 2. Disconnect connector PDPF and connect short socket adapter to female
4
or engine controller side.
REMARK
Connect 5 V to the signal line. (short-circuit pins (4) and (3) of connector
PDPF.)
tive.
REMARK
REMARK
40-490 D155AX-8

Defective KDPF outlet If failure codes [CA3134] and [CA3133] are displayed after checks on defective wir-
5
pressure sensor ing harness or engine controller, the KDPF outlet pressure sensor is defective.
6

3. Start the engine and keep the engine running for approximately 1 minute at low idle speed.
4. After warm-up operation, perform torque converter stall operation for continuously 40 seconds or longer
with fuel control dial at High idle (MAX) position.
NOTICE
6) Depress the decelerator pedal and set the fuel control dial at (MAX) position to run the engine at high
idle.
7) Return the decelerator pedal slowly to stall the torque converter with the fuel control dial at (MAX) posi-
tion.
NOTICE
• Be careful care not to overheat torque converter oil.
• Temperature indicated at the top of the green range on the power train oil temperature is
approximately 118 to 120 °C.
5. If the failure code is not cleared, perform above 4 for three times. If the failure code is cleared, repair work
is complete.
REMARK
D155AX-8 40-491
40-492 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3142] SCR Temperature Sensor High Error
FAILURE CODE [CA3142] SCR Temperature Sensor High Error

Action level Failure code SCR Temperature Sensor High Error
Failure
Detail of fail- Open circuit at wire (+) side or hot short circuit or abnormal sensor circuit of SCR temperature sen-
ure sor probe.
• Because the SCR temperature is not detected be detected, substitute the SCR outlet tem-
perature for the SCR temperature and run the engine (if the SCR outlet temperature sen-
Action of sor also has an error, use the last normal value).
• AdBlue/DEF injection stops.
• SCR temperature detection error
Phenomenon
on machine
k
SCR assembly, the sensor installation piping, and the sensor probe become hot (Min.
• Open circuit or hot short circuit in the sensor measuring section or probe (+) is sent to the
engine controller via CAN communication, and this failure code is displayed.
Related • The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
information one sensor controller which provides CAN communication with the engine controller.
• For replacement of the SCR temperature sensor, see Disassembly and assembly, “Re-
moval and installation of SCR assembly”.

2. Replace SCR temperature sensor.
1 ture sensor (internal de- 3. Turn starting switch to ON position.
fect) If this failure code is cleared, the original SCR temperature sensor is defective. (In
whole assembly.)
2
D155AX-8 40-493
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error

Action level Failure code SCR Temperature Sensor Low Error
Failure
Detail of fail-
Ground fault in SCR temperature sensor measuring section or probe (+)
ure
• As the SCR temperature cannot be detected, substitute the SCR outlet temperature for
the SCR temperature and run the engine (if the SCR outlet temperature sensor also has
Action of an error, use the latest normal value).
• AdBlue/DEF injection stops.
Phenomenon • NOx emission increases.
k SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
sensor controller which provides CAN communication with the engine controller.
Related • Ground fault in the sensor measuring section or probe (+) is sent to the engine controller
information via CAN communication, and this failure code is displayed.
• For the replacement procedure of the SCR temperature sensor, see "Disassembly and as-
sembly," “Removal and installation of SCR assembly”.

whole assembly.)
2
40-494 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error

Action level Failure code SCR Temperature Sensor In Range Error
Failure
Detail of fail- Temperature difference between SCR temperature sensor and SCR outlet temperature sensor is
ure not the same as the expected value.
Action of • Advances to Inducement strategy.
controller • AdBlue/DEF injection stops.
k Since KDPF, KDOC, and SCR are heated to 500 °C or above, be careful not to get burned.
• For the replacement procedure of the SCR temperature sensor, see “Disassembly and as-
sembly”, “Removal and installation of SCR temperature sensor”.
ON position.
• The temperature detected by the SCR temperature sensor can be confirmed from the Pre-
defined Monitoring screen.
• Use engine operation state diagnosis, AdBlue/DEF level, or AdBlue/DEF quality sensor di-
agnosis on the Pre-defined Monitoring screen. (The following numbers are the monitoring
codes)
01002 Engine speed
• Troubleshooting for AdBlue/DEF level and AdBlue/DEF quality sensors
19100 AdBlue/DEF Concentration
19110 AdBlue/DEF Level
19111 AdBlue/DEF Level Corrected
19115 AdBlue/DEF Temperature in Tank
NOTICE
pair, perform a “Loaded Diagnostics Operation To Confirm Failure Correction” to make
sure that the failure code is cleared. (Repair completion cannot be judged without rais-
ing the exhaust temperature even if this failure code is cleared by turning ON the start-
ing switch)
D155AX-8 40-495
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error 40 TROUBLESHOOTING

Defective SCR tempera- If failure code [CA3142] or [CA3143] is displayed, perform troubleshooting for
ture sensor (internal [CA3142] or [CA3143].
1
open or short circuit to
ground)
1. If failure code [CA3251] is displayed, perform troubleshooting for
[CA3251].
Defective KDPF system
2. If failure code [CA3253], [CA3254], or [CA3311] is displayed, perform trou-
2 (Abnormal exhaust gas bleshooting for [CA3253], [CA3254], or [CA3311].
temperature to SCR)
bleshooting for [CA3255], [CA3256], or [CA3312].
Defective SCR tempera- See “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL
3 ture sensor (installation SCR ASSEMBLY” and fix installation error, if any.
error)
2. If failure code [CA4277] is displayed or failure code [CA4277] is logged on
the abnormality record screen, perform troubleshooting these first.
3. Check the “AdBlue/DEF concentration” on the troubleshooting assistance
Improper AdBlue/DEF screen (normal value: 29 to 36 %).
4
quality
4. If a failure is found by above checks, it may be contaminated. Replace the
AdBlue/DEF in the tank.
5. Replace the AdBlue/DEF injector.
1. If the failure code persists after the above checks, replace the SCR tem-
Defective SCR tempera- perature sensor.
5 ture sensor (internal de- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
fect)
If the failure code is cleared, the SCR temperature sensor may be defective.
6

REMARK
If this failure code is displayed during “Loaded Diagnostics Operation To Confirm Failure Correction” return to
troubleshooting.
1. Clear this failure code by Engine Controller Inducement Fault Clear.
4. Run the engine at low idle speed for approximately 1 minute.
5. After warm-up operation, set fuel control dial to MAX position, and the operation mode to P.
6. Run the engine at high idle speed for 15 minutes.
7. If this failure code is cleared, repair is completed.
REMARK
Every failure code is cleared by executing “Reset All Faults” command by using service tool “INSITE”.
40-496 D155AX-8
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Er-
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error

Action level Failure code SCR Outlet Temperature Sensor High Error
Failure
Detail of fail- Sensor circuit in SCR outlet temperature sensor measuring section or probe (+) is open circuit or
ure hot short-circuit.
controller • AdBlue/DEF injection stops
Related • Open circuit or hot short circuit in the sensor measuring section or probe (+) is sent to the
information engine controller via CAN communication, and this failure code is displayed.
• For the replacement procedure of the SCR outlet temperature sensor, see "Disassembly
and assembly," “Disassembly and assembly of SCR temperature sensor”.

temperature sensor
If this failure code is cleared, the original sensor is defective. (Troubleshooting of
sensor is impossible.)
2
D155AX-8 40-497
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error

Action level Failure code SCR Outlet Temperature Sensor Low Error
Failure
Detail of fail-
Ground fault in SCR outlet temperature sensor measuring section or probe (+)
ure
400 °C). be careful not to get burned.
information via CAN communication, and this failure code is displayed.
• For the replacement procedure of the SCR outlet temperature sensor, see “Disassembly
and assembly”, “Disassembly and assembly of SCR temperature sensor”.

temperature sensor
If this failure code is cleared, the original sensor is defective. (Troubleshooting of
sensor is impossible.)
2
40-498 D155AX-8
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error

Action level Failure code SCR Outlet Temperature Sensor In Range Error
Failure
Detail of fail- Temperature difference between SCR temperature sensor and SCR outlet temperature sensor is
ure not the same as the expected value.
k Since KDPF, KDOC, and SCR are heated to 500 °C or above, be careful not to get
burned.
• For the replacement procedure of the SCR outlet temperature sensor, see “Disassembly
and assembly”, “Removal and installation of SCR temperature sensor”.
ON position.
codes)
01002 Engine speed
information
• AdBlue/DEF level, AdBlue/DEF quantity sensor diagnosis
NOTICE
ing switch)

Defective SCR outlet If failure code [CA3146] or [CA3147] is displayed, perform troubleshooting for
1
temperature sensor [CA3146] or [CA3147].
D155AX-8 40-499
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range

[CA3251].
temperature to SCR)
error or malfunction)
3. Confirm the “AdBlue/DEF concentration” on the Pre-defined Monitoring
4
quality 4. If failure code is still displayed after above checks, it may be contaminated.
Replace the AdBlue/DEF in the tank.
6. Perform the “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”.
Defective SCR outlet perature sensor.
5 temperature sensor (in- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
ternal defect)
6

REMARK
troubleshooting.
1. Clear this failure code by Engine Controller Inducement Fault Clear.
5. After warm-up operation, set fuel control dial to MAX position, and the operation mode to P.
REMARK
Every failure code is cleared by executing “Reset All Faults” command by using service tool “INSITE”.
40-500 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2

Action level Failure code SCR Catalyst Efficiency Low Error 2
Failure
Detail of fail-
The SCR catalyst efficiency has been low (20 % or less).
ure
Action of • AdBlue/DEF injection stops.
k The turbocharger outlet, KDPF, sensor fitting piping, and sensor probe become hot
k The AdBlue/DEF mixing piping, SCR assembly, sensor fitting piping, and sensor
probe become hot (Min. 400 °C). Be careful not to get burned.
k Be careful that AdBlue/DEF leaks when removing AdBlue/DEF mixing piping or AdBl-
ue/DEF injector.
• Due to Engine controller is shut down, the AdBlue/DEF injection activates once. However
If another error is detected, injection stops again.
• This failure code [CA3151] is displayed approximately one hour later after the engine con-
Related troller performs the Automatic Regeneration. The Automatic Regeneration is activated
information when the failure code [CA3582] (catalytic efficiency is lower than 70%) is displayed.
• Make sure the failure code [CA3582] is not displayed when confirming the completion of
repair.
• If the ambient pressure is 80 kPa or less and the ambient temperature is -7 °C or less, the
engine controller does not troubleshoot this failure code (Under this condition, performimg
“Loaded Diagnostics Operation To Clear Failure Code” does not clear this failure code).
Confirm on the “Pre-defined Monitoring” screen.
• When AdBlue/DEF injection stops at Active Regeneration is activated, the engine control-
ler does not troubleshoot this failure code (Under this condition, performimg “Loaded Diag-
nostics Operation To Clear Failure Code” does not clear this failure code).
• For the procedure to remove and change the AdBlue/DEF injector, see “Disassembly and
assembly of AdBlue/DEF injector”.
D155AX-8 40-501
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2 40 TROUBLESHOOTING
• On the “Pre-defined Monitoring”screen, these 4 diagnosis are displayed. Engine operation

state diagnosis, environment state diagnosis, SCR catalyst and NOx sensor and ammonia
sensor diagnosis, AdBlue/DEF level and AdBlue/DEF quality sensor diagnosis. (The fol-
lowing numbers are the displayed monitoring codes)
01002 Engine speed
• Environmental state diagnosis
37400 Ambient Pressure
18400 Intake Temperature
Related 19203 Turbo Outlet NOx Sensor State
information 19210 SCR Outlet NOx Sensor State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, perform
“Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared. (Repair completion cannot be judged without raising the exhaust tem-
perature even if this failure code is cleared by turning ON the starting switch)

tem
1
heater)
40-502 D155AX-8

heater)
Defective SCR tempera- If failure code [CA3142] or [CA3143] or [CA3144] or [CA3146] or [CA3147] or
ture sensor system [CA3148] or [CA3165] or [CA3229] or [CA3231] or [CA3235] or [CA4152] or
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] is displayed, perform troubleshoot-
fect) ing for these failure codes first.
Defective ammonia sen- If failure code [CA3899], [CA3911], [CA3912], [CA3932], [CA3933], [CA3934],
sor system [CA3935], [CA3936] or [CA4281] is displayed, perform troubleshooting for these
4 (Open circuit, internal de- failure codes first.
heater)
1. If failure code [CA4658] or [CA3568] is displayed, or failure code [CA4658] or
[CA3568] is displayed on the service meter display of the abnormality record
within 2 hours, perform “Loaded Diagnostics Operation To Confirm Failure
Correction”, check if failure code [CA3151], [CA3543], or [CA3582] is dis-
played.
Clogged AdBlue/DEF in-
5 2. If 19205 “Ammonia concentration (compensation value)” indicates a normal
jector
value (5 to 100 ppm) and the failure code is cleared, the repair is completed
(“Loaded Diagnostics Operation To Confirm Failure Correction” has resolved
the clogging problem and the machine has restored normal operation).
3. If the ammonia concentration indicates an abnormal value or either failure
code [CA3151], [CA3543], or [CA3582] is displayed, proceed to the next step.
1. Visually check the piping from the KDPF outlet to the SCR outlet for damage
or defective connection.
Defective mixing tube
6 2. Visually check for white crystallized AdBlue/DEF deposits on the surrounding
(exhaust gas leakage) area.
3. If defective connections or damages are found, fix or replace parts.
leak.
D155AX-8 40-503

1. Check the mounting of the AdBlue/DEF quality sensor is secured and the
wiring harness connections are not loosen Repair if any abnormality is
found.
3. Check if failure code [CA3866] or [CA3867] is displayed.
4. Read 19100 “AdBlue/DEF concentration” on the display and confirm that
the concentration is appropriate (Min. 25 %).
5. If failure code [CA3866] or [CA3867] is displayed and the 19100
Improper AdBlue/DEF
8 “AdBlue/DEF concentration” reading is inappropriate, drain the
quality
AdBlue /DEF tank, clean the tank, and refill with genuine AdBlue/DEF.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
check if this failure code is not cleared.
7. If the 19205 “Ammonia concentration (compensation value)” reading is
normal (5 to 100 ppm) and the failure code is not redisplayed, the repair is
completed.
8. If the ammonia concentration indicates an abnormal value or this failure
code recurs, proceed to the next step.
1. See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR
SETTING WITH TESTING MENU (SCR SERVICE TEST)” of “SETTING AND
OPERATION OF MACHINE MONITOR”, and perform an “SCR Denitration Ef-
ficiency Test”.
2. If the “SCR Denitration Efficiency Test” has not been completed successfully,
proceed to cause 10.
3. If failure code [CA1694], [CA3751], or [CA3755] is displayed after the “SCR
Defective urea SCR sys- Denitration Efficiency Test”, perform troubleshooting for relevant failure code
tem first.
9 (inspection with SCR RE- 4. After the failure code in the above 3 is cleared, perform “Loaded Diagnostics
MOVAL EFFICIENCY Operation To Clear Failure Code” to check if this failure code is not cleared.
TEST)
5. If 19205 “Ammonia concentration (compensation value)” indicates a normal
value (5 to 100 ppm) and the failure code is cleared, the repair is completed.
6. If the ammonia concentration indicates an abnormal value or this failure code
is not cleared, proceed to cause 13.
7. Even if the SCR REMOVAL EFFICIENCY TEST has been completed success-
fully and any of failure code [CA1694], [CA3751], or [CA3755] is not displayed,
1. Refer to “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
TESTING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Injection
Quantity Test” to judge the injector.
2. From the test results, confirm that the AdBlue/DEF injection amount is within
the values specified in “TESTING AND ADJUSTING”.
3. If the AdBlue/DEF injection amount is out of the range specified in “TESTING
Defective AdBlue/DEF in-
10 AND ADJUSTING”, replace the AdBlue/DEF injector.
jector
4. If the AdBlue/DEF injector has been replaced, perform the “AdBlue/DEF Injec-
tion Quantity Test” again. After confirming that the AdBlue/DEF injection
amount is within the range specified in “TESTING AND ADJUSTING”, proceed
to the next cause. (The purpose of this test for two times is to check accumu-
lated urea deposits in the AdBlue/DEF mixing tube )
5. Proceed to the next troubleshooting, even if the “AdBlue/DEF Injection Quanti-
ty Test” results were normal.
40-504 D155AX-8

mixing tube
12
If failure code is still displayed after above checks, the intake system may be defec-
tive.
(Offset/drift due to the deteriorated and aged MAF sensor, distorted intake system,
damaged rectifier)
1. Check for a defective air intake pipe and repair or replace any damaged or
Defective air intake sys- defective rectifier, if any.
13
tem 2. Replace mass air flow (MAF) sensor.
4. If 19205 “ammonia concentration (compensation value)” shows an normal
value (5 to 100ppm) and the failure code is cleared again, the repair has
been completed
If failure code is still displayed after above checks, the ammonia sensor may be de-
fective.
(Offset/drift due to the deteriorated and aged ammonia sensor)
1. Replace the ammonia sensor.
2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”,
14 then check if this failure code or failure code [CA3582] is displayed.
sor
3. If 19205 “Ammonia concentration (compensation value)” indicates a nor-
mal value (5 to 100 ppm) and the failure code is cleared, the repair is com-
pleted.
code is not cleared, proceed to the next step.
15

(Make sure that this failure code and failure code [CA3582] are cleared after this procedure.)
1. Clear this failure code by “Engine Controller Inducement Fault Clear”.
4. Run the engine at low idle speed (with no load) for approximately 1 minute.
5. After warm-up operation, set the fuel control dial to MAX.
6. Stalling torque converter operation continuously with fuel control dial at MAX position for approximately 20
seconds.
D155AX-8 40-505

REMARK
NOTICE
6) Depress the decelerator pedal and set the fuel control dial at MAX position to run the engine at high
idle speed.
7) Return the decelerator pedal slowly to stall torque converter with the fuel control dial at MAX position.
k Depressing the brake pedal securely, and place your right foot on the decelerator pedal dur-
ing stalling torque converter process for safety reason.
REMARK
• Temperature indicated at the top of the green range on the power train oil temperature is approxi-
• Pay attention not to get overheating of torque converter oil.
7. Run the engine at high idle speed for approximately 20 seconds.
8. Repeat steps 6 and 7 for up to 20 times, so that SCR temperature becomes 250 °C or more.
9. Run the engine at high idle speed and blade raise relief for 10 minutes.
10. Check that turbocharger outlet NOx emission value is 120 (ppm) or more.
11. Repeat from 5. to 7. for 20 times to get both SCR temperature and Nox emission value are obtained at the
same time.
REMARK
• If this failure code and failure code [CA3582] are cleared, repair is completed.
• If turbocharger outlet NOx emission value is less than 120 (ppm), return to troubleshooting.
• If this failure code or failure code [CA3582] is not cleared, return to troubleshooting.
40-506 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3165] SCR Outlet Temperature High Error
FAILURE CODE [CA3165] SCR Outlet Temperature High Error

Action level Failure code SCR Outlet Temperature High Error
Failure
Detail of fail-
The SCR outlet temperature has been high.
ure
ON position.
• The temperature detected by the SCR outlet temperature sensor can be confirmed from
the “Pre-defined Monitoring” screen.
agnosis on the “Pre-defined Monitoring” screen. (The following numbers are the monitor-
ing codes)
• If regeneration is not performed, the failure code [CA3235] may appear as well.
01002 Engine speed
Related
information
NOTICE
ing switch)
D155AX-8 40-507
FAILURE CODE [CA3165] SCR Outlet Temperature High Error 40 TROUBLESHOOTING

1
[CA3251].
temperature to SCR)
4
tion”.
ternal defect)
6

REMARK
troubleshooting.
2. Turn the starting switch to the ON position, and check the failure code is cleared. If this failure code is dis-
played, return to troubleshooting.
3. Start engine.
4. Run the engine at low idle speed for 10 minutes.
40-508 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3167] Fuel Doser Degradation
FAILURE CODE [CA3167] Fuel Doser Degradation

Action level Failure code Fuel Doser Degradation
Failure
- CA3167 (Engine controller system)
Details of • Fuel doser is deteriorated.

failure • The injection port of fuel doser is clogged.
Action of
None
controller
Phenomenon It takes time to perform automatic regeneration. (KDOC outlet temperature does not rise easily and
on machine it takes much time to burn the soot.)
k
The temperature of exhaust connector and KDPF becomes hot (Min. 500 °C). Be careful
not to get burn injury.
(Code: 47601 (V))
• For the cleaning method of the fuel doser, see “Chapter 30 TESTING AND ADJUSTING”
“PROCEDURES FOR CLEANING FUEL DOSER”.
• Since this failure code has no action level, it is not displayed in the user screen of the ma-
chine monitor. This failure code is displayed on service screen in machine monitor and
KOMTRAX.
Related ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
information
ON position.
NOTICE
• If this failure code is displayed, the injection amount of fuel doser is corrected. After
completion of the repair work, information on the corrected doser injection amount
must be reset, therefore, be sure to reset the fuel doser information after the repair.
Not resetting fuel doser information may damage KCSF.
• After checking the cause of failure, performing the repair, and performing “fuel dos-
er information reset” are completed, this failure code is completed. When fuel doser
is replaced, perform “fuel doser information reset”, and the repair is completed.
This failure code is not cleared by fuel doser information reset. After the next auto-
matic regeneration is finished, the failure code is canceled.
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER
ACTIVE FAULT CLEAR)”.

See descriptions of wiring harness and connectors in “c: Electrical equipment” in
1 “CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
connector
TROUBLESHOOTING”, and check it.
2
D155AX-8 40-509
FAILURE CODE [CA3167] Fuel Doser Degradation 40 TROUBLESHOOTING

valve)
valve) system
Defective fuel doser sys- If failure code [CA1977] is displayed, perform troubleshooting for [CA1977] first.
5
tem
6
enoid valve system ing for [CA1963], [CA2878], or [CA2881] first.
2. Remove fuel doser (1) from exhaust connector.
Clogged fuel doser injec- 3.
7 Clean fuel doser.
tion port
REMARK
See Related information for cleaning method of fuel doser.
2. Remove fuel doser (1) from exhaust connector.
3. Install fuel doser instead of exhaust connector
REMARK
to prevent exhaust gas leakage from fuel doser mounting hole part.
8 Defective fuel doser
5. Perform “Regeneration Disable”.
6. Start engine.
7. Run it at low idle, and wait for 2 minutes.
If there is fuel leakage from the tip of fuel doser (1), fuel doser is defective.
1. Perform fuel doser information reset.
2. If this failure code is displayed again after preceding procedures are imple-
Defective fuel doser sys-
9 mented, doser fuel block body may be clogged with foreign material. So
tem
replace doser fuel block body.
After replacing, perform “How to reset fuel doser information”.
Defective engine control- If this failure code is displayed again after preceding procedures are implemented,
10
ler engine controller is defective.
How to reset fuel doser information

1. Turn starting switch to ON position (with engine stopped).
2. On the Service Menu of the machine monitor, perform “04 Fuel Doser Cleaning” from “KDPF Memory Re-
set”.
• If this failure code is displayed, the injection amount of fuel doser is corrected. After completion of the repair
work, information on the corrected doser injection amount must be reset, therefore, be sure to reset the fuel
doser information after the repair.
• Otherwise, KCSF may be damaged.
REMARK
40-510 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3167] Fuel Doser Degradation

B: Fuel return
1. Fuel doser
2. Fuel supply line
D155AX-8 40-511
FAILURE CODE [CA3229] SCR Temperature High Error 40 TROUBLESHOOTING
FAILURE CODE [CA3229] SCR Temperature High Error

Action level Failure code SCR Temperature High Error
Failure
Detail of fail-
The SCR temperature is been high (800 °C or more).
ure
ON position.
• If regeneration is not implemented, the failure code [CA3231] may be displayed.
codes)
01002 Engine speed
Related
information
NOTICE
ing switch)
40-512 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3229] SCR Temperature High Error

1
ground)
[CA3251].
temperature to SCR)
error)
4
quality
fect)
6

REMARK
If this failure code is displayed during “Loaded Diagnostics Operation To Confirm Failure Correction”, return to
troubleshooting.
D155AX-8 40-513
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regen-
eration 40 TROUBLESHOOTING
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration

Action level Failure code SCR Temperature High Error - Non Regeneration
Failure
Detail of fail- The SCR temperature remains at high level (800 °C or more) when active regeneration is not per-
ure formed.
k Since KDPF, KDOC, and SCR are heated to 500 °C or above, be careful not to get burned
ON position.
codes)
01002 Engine speed
Related
information
NOTICE
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure that
the failure code is cleared. (Repair completion cannot be judged without raising the exhaust
temperature even if this failure code is cleared by turning ON the starting switch)

1
ground)
40-514 D155AX-8
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regen-
40 TROUBLESHOOTING eration

[CA3251].
temperature to SCR)
error)
4
quality
fect)
ler

REMARK
troubleshooting.
D155AX-8 40-515
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error
Action level Failure code Turbocharger Outlet NOx Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller cannot receive the data of the turbocharger outlet NOx sensor due to error of
ure communication with the turbocharger outlet NOx sensor.
Action of
controller
• The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
Phenomenon
• Engine power deration according to inducement strategy.
on machine
• Turbocharger Outlet NOx Concentration undetectable
k The turbocharger outlet, sensor fitting piping, KDPF, and KDOC become hot (Min.
• The turbocharger outlet NOx sensor is a smart sensor which performs CAN communica-
tion with the engine controller together with the other sensors.
Related • If the sensor connector or smart sensor (power supply) relay connector is disconnected,
this failure code is displayed.
information
• The failure codes of the CAN communication related to the engine sensor are [CA2771],
[CA3232], [CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are
displayed, the cause may be defect of any of the 6 sensors, defective smart sensor power
supply relay, defective relay system, or ground fault, short circuit, or hot short circuit of the
harness (CAN communication line).
using multimeter.

Defective wiring harness Perform checks on causes 1 to 10 for failure code [CA2771].
1
connector
40-516 D155AX-8

3. Disconnect connectors J2 and NOX1 and connect T-adapters to each fe-
circuit in wiring harness
2 male side.
communication line) REMARK
0 Ω indicates short circuit. In the case of other than 0 Ω, proceed to the next diag-
nosis
Approx.
Between NOX1 (female) (3) and (2)
60 Ω
Resistance
Approx.
60 Ω
• Power line
ness (wire breakage or Voltage Between NOX1 (female) (1) and (4) Min. 22 V
line)
female side.
Resistance
quired.
Disconnect connectors J2, NOX1, CTN2, and CTN, and connect T-adapt-
nector) (broken commu- Between J2 (female) (21) and NOX1 (female) (3) Max. 1 Ω
nication line)
Between J2 (female) (45) and NOX1 (female) (2) Max. 1 Ω
Between CTN2 (female) (A) and NOX1 (female) (3) Max. 1 Ω
Resistance
Between CTN2 (female) (B) and NOX1 (female) (2) Max. 1 Ω
Between CTN (female) (A) and NOX1 (female) (3) Max. 1 Ω
Between CTN (female) (B) and NOX1 (female) (2) Max. 1 Ω
D155AX-8 40-517

If failure code (no open circuit) is still displayed after above checks in cause 2,
measure resistance at any one place in Hi line and Lo line.
ground circuit)
Min. 1 MΩ
Resistance
Min. 1 MΩ
6
(3), and UREA (2).
Voltage
(2), and UREA (1).
2. Replace the turbocharger outlet NOx sensor (NOX1).
outlet NOx sensor
ler
40-518 D155AX-8
D155AX-8 40-519
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non
Regeneration 40 TROUBLESHOOTING
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Re-
generation
Action level Failure code SCR Outlet Temperature High Error - Non Regeneration
Failure
Detail of fail-
SCR outlet temperature remains at high level when active regeneration is not performed.
ure
on machine • Engine output is reduced based on inducement strategy.
• For replacement of the SCR temperature sensor, see Disassembly and assembly, “Re-
moval and installation of SCR temperature sensor”.
ON position.
• On the “Pre-defined Monitoring” screen troubleshooting for the engine operation state,
AdBlue/DEF level and AdBlue/DEF quality sensors are used (the figures below denote
monitoring codes).
• The temperature detected by the SCR outlet temperature sensor can be confirmed from
the “Pre-defined Monitoring” screen.
• Engine operation state troubleshooting
01002 Engine Speed
Related 19200 Exhaust Gas Flow Rate
NOTICE
40-520 D155AX-8
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non
40 TROUBLESHOOTING Regeneration

1
[CA3251].
temperature to SCR)
4
tion”.
ternal defect)
ler

REMARK
troubleshooting.
3. Start engine.
D155AX-8 40-521
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Er-
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error

Action level Failure code AdBlue/DEF Line Heater 2 Voltage High Error
Failure
Detail of fail- High voltage error is detected in signal circuit of AdBlue/DEF line heater 2 (on high-temperature
ure pressure).
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing.
on machine NOx emission increases.
• The AdBlue/DEF line heater 2 operates in AdBlue/DEF supply system thawing, warning,
or implementation of AdBlue/DEF line heater relay 2 test.
• The AdBlue/DEF line heater 2 is operated by the AdBlue/DEF line heater relay 2 in the
AdBlue/DEF heater relay.
Related
• This failure code is detected only when the AdBlue/DEF line heater 2 is OFF.
information
• If the connectors of all heaters connected to the AdBlue/DEF line heater 2 are disconnect-
ed, this failure code is displayed.

1
Defective AdBlue/DEF 3. Disconnect connector UHR1 and UHR2 and replace AdBlue/DEF heater
2 relay.
heater relay
If this failure code is cleared, the AdBlue/DEF heater relay is defective.
Open circuit or short cir-
cuit in wiring harness REMARK
3
(line heater relay input
Resistance value is the internal resistance value of the heater relay mentioned
side)
above.
Resistance Between J2 (female) (38) and ground 10 to 30 kΩ
If failure code is still displayed after above checks, this check is not required.
Open circuit in wiring har- 2. Disconnect connectors J2 and UHR1 and connect T-adapters to each fe-
4 male side.
ness
Between J2 (female) (38) and UHR1 (female) (9) Max. 1 Ω
Resistance
Between UHR1 (female) (12) and ground Max. 1 Ω
40-522 D155AX-8

Hot short circuit in wiring 2. Disconnect connector UHR1, and connect T-adapter to female side.
5 harness (contact with 24 3. Turn starting switch to ON position (with connector UHR1 disconnected).
V circuit)
Approxi-
Voltage Between UHR (female) (9) and (12)
mately 5 V
6 Disconnect connector URH2, and connect T-adapter to male side.
line heater
Resistance Between URH2 (male) (1) and (2) 5 to 40 Ω
Open circuit or short cir- 2. Disconnect connector UHR1 and connect T-adapter to female side.
cuit in wiring harness
7 REMARK
(line heater relay output
side) Resistance is possessed by above-mentioned AdBlue/DEF line heater.
Resistance Between UHR (female) (4) and (12) 5 to 40 Ω
8
D155AX-8 40-523
Circuit diagram related to AdBlue/DEF line heater
40-524 D155AX-8
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Er-
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error

Action level Failure code AdBlue/DEF Line Heater 2 Voltage Low Error
Failure
Detail of fail- Low voltage error is detected in signal circuit of AdBlue/DEF line heater 2 (on high-temperature
ure pressure).
Action of
None in particular
controller
Related AdBlue/DEF heater relay.
information • This failure code is detected only when the AdBlue/DEF line heater 2 is ON.
Procedure: Starting the engine at low temperature (engine room temperature of 12 °C or
less) or implementing AdBlue/DEF line heater relay 2 test

Defective wiring harness 2. Perform the “AdBlue/DEF Line Heater Relay 2 Test” by staring the engine
1
connector in low ambient temperature (12 °C or below), or by referring “SERVICE
MODE” of setting and operating machine monitor, “METHOD FOR OPER-
ATING TESTING MENU (SCR SERVICE TEST)”.
2 relay.
heater relay
3
side)
above.
D155AX-8 40-525

2. Disconnect connectors J2, UHR1, and URH2, and connect T-adapter to ei-
Ground fault in wiring ther female side.
4 harness (contact with Between J2 (female) (38) or UHR1 (female) (9) and
ground
Resistance
Between ground and UHR1 (female) (4) or URH2 (fe-
Min. 1 MΩ
male) (1)
5 Disconnect connector URH2, and connect T-adapter to male side.
line heater
Resistance Between URH2 (male) (1) and (2) 5 to 40 Ω
Open circuit or short cir- 2. Disconnect connector UHR1 and connect T-adapter to female side.
6 REMARK
side) Resistance is possessed by above-mentioned AdBlue/DEF line heater.
Resistance Between UHR (female) (4) and (12) 5 to 40 Ω
7
40-526 D155AX-8
D155AX-8 40-527
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error 40 TROUBLESHOOTING
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error

Action level Failure code AdBlue/DEF Tank Heating Error
Failure
AdBlue/DEF tank heating valve or engine coolant circuit, or both are clogging.
Detail of fail-
ure (The temperature of the AdBlue/DEF tank does not rise though the engine controller turns ON (“1”)
19102 “AdBlue/DEF Tank HtrValve Command” and opens the AdBlue/DEF tank heating valve.)
Action of
None in particular
controller
Phenomenon • AdBlue/DEF line stops thawing.
on machine • NOx emission increases.
• The engine controller judges whether this failure code is displayed only during thawing
control of the AdBlue/DEF tank (The value of 19305 AdBlue/DEF Tank Heating State is
“1”).
• The “Pre-defined Monitoring” screen uses the AdBlue/DEF tank thawing control diagnosis.
• AdBlue/DEF tank thawing control diagnosis
NOTICE
pair.)

tem
system
40-528 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error

See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OPERA-
TION MACHINE MONITOR”, “METHOD FOR SETTING WITH TESTING MENU
(SCR SERVICE TEST)” to perform an “AdBlue/DEF TANK HEATER RELAY TEST”
and check if the AdBlue/DEF tank heater valve is driven normally.
3. Perform an “AdBlue/DEF TANK HEATER RELAY TEST” to drive the
4. Make sure that coolant flows out in response to valve open and close com-
3 AdBlue/DEF tank heating
valve mands.
REMARK
If coolant flows out in response to valve operation, the AdBlue/DEF tank
heating valve is normal.
If coolant does not flow out:
Increase the temperature of the inlet side coolant hose to make sure that the cool-
ant flows out.
1. If coolant flows out from the inlet side coolant hose, replace the AdBlue/DEF
tank heating valve.
2. If coolant does not flow out from the inlet side coolant hose, clogging of the
coolant circuit is suspected.
• Check if the engine coolant circuit in the engine or AdBlue/DEF tank is
Failure of engine coolant leaking or clogged.
4
circuit • Also check whether amount of engine coolant is appropriate. If there are
some problems, repair the relevant portions.
sor.
6

3. Check monitoring code 19115 “AdBlue/DEF Temperature in Tank” on the “Troubleshooting Pre-defined
Monitoring” screen.
1) In case, monitoring code 19115 “AdBlue/DEF Temperature in Tank” is less than 1 °C.
1] Check if monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is issued (from 0 to
1) ,and perform warm-up operation.
When monitoring code 04107 “Coolant temperature” becomes 0 °C or more during warm-up oper-
ation, monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is issued ( from 0 to 1).
2] Keep warm-up operation and that monitoring code 04107 “Coolant temperature” is 20 °C or more.
3] Confirmation will be completed if the AdBlue/DEF tank temperature becomes 4 °C or more within
an hour after the “AdBlue/DEF Tank HtrValve Command” is issued. If it becomes 4 °C or less, re-
D155AX-8 40-529
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error 40 TROUBLESHOOTING
2) In case, monitoring code 19115 “AdBlue/DEF Temperature in Tank” is 1 °C or more.

1] Perform warm-up operation, and raise the monitoring code 04107 “Coolant temperature” to the de-
gree over 20 °C added to the ambient temperature.
2] See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in
“SETTING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF tank heater re-
lay test”.
3] When monitoring code 04107 “Coolant temperature” is less than the ambient temperature added
to 20 °C during “AdBlue/DEF tank heater relay test”, perform warm-up operation together with
“AdBlue/DEF tank heater relay test” again.
4] Confirmation will be completed if the AdBlue/DEF temperature in Tank becomes 5 °C or above
within an hour after starting the AdBlue/DEF tank heater relay test. If it becomes 5 °C or less, re-
screen.
40-530 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3251] KDOC Inlet Temperature High Error
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error

Failure KDOC Inlet Temperature High Error (Engine controller system)
L03 CA3251
Details of
KDOC inlet temperature remains at high level.
failure
Phenomenon
on machine
k
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to compen-
Related sate for torque drop, causing high exhaust temperature.
information • As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
position.
code is cleared).
NOTICE
again.)
D155AX-8 40-531
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error 40 TROUBLESHOOTING

1
2
enoid valve 1 [CA1925] or [CA1963] first.
Defective air intake sys- Check intake system hoses, clamps, and tubes for damage and loosening. Repair
3
tem as necessary (repair air intake leakage).
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
4 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
fuel.
Oil leakage to turbo-
5 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
6 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
KDOC inlet temperature
7 INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
sensor installation error
ASSEMBLY”. Repair as necessary.
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
8
ature sensor replace KDPF temperature sensor.
Defective engine control- If this failure code is kept displayed, or is displayed again after above checks are
9
ler performed, engine controller is defective.

NOTICE
If the failure code is cleared, repair work is completed.
• Every failure code is cleared by executing “Reset All Faults” command by using service tool
“INSITE”.
40-532 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3251] KDOC Inlet Temperature High Error
D155AX-8 40-533
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regenera-
tion 40 TROUBLESHOOTING
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration

Action level Failure code KDOC Temperature Error - Non Regeneration (Engine controller sys-
Failure
L03 CA3253 tem)
Details of The temperature sensor reading at the KDOC inlet remains high even though active regeneration is
failure not activated.

Phenomenon
on machine
40-534 D155AX-8
40 TROUBLESHOOTING tion
k
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• If the engine runs with poor combustion, (poor fuel spray due to troubles in the fuel injec-
tors is one of the examples of root causes but not limited to it), large amount of unburnt
fuel slips out with the exhaust gas and will be trapped in the aftertreatment system. The
trapped unburnt fuel can start burning in the aftertreatment system once the exhaust gas
becomes hot and it can keep burning.
sate for torque drop, causing high exhaust temperature.
Related ASSEMBLE KDPF ASSEMBLY”.
information • Engine controller does not shut itself down immediately after turning the starting switch to
the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
lamp in the battery box goes out even if quick re-start becomes necessary.
• Engine power deration will be restored only after the following two conditions are met.
(1) Run “Loaded Diagnostics Operation To Clear failure Code” record in Engine controller.
Both Action Level “L03” in the Standard screen and the pop-up window of the failure de-
scription in the Current Abnormality screen shall go out if the failure is corrected.
(2) the starting switch shall be turned to the OFF position.
NOTICE
again.)

Defective KDOC inlet Perform checks on causes 1 to 7 for failure code [CA3251].
1
temperature sensor
Defective KDOC outlet Perform checks on causes 1 and 8 for failure code [CA3254].
2
temperature sensor
D155AX-8 40-535

1. Remove KDPF.
2. Remove KDOC.
NOTICE
• Check if KDOC has any cracks (change KDOC if any).
3 Defective KDOC • If KDOC of KDPF is changed, perform the reset after KDOC change,
then troubleshooting is complete without performing manual station-
ary regeneration.
(See cause 7 for failure code [CA2637].)
• Check if KDOC inlet surface is clogged with soot 50 % or more.
(Cleaning of KDOC)
4
5

2. Start the engine and run it at low idle speed for 15 minutes.
If the failure code is cleared, repair work is complete. Otherwise, perform the following:
NOTICE
If failure code is not cleared after preceding steps 1 and 2 are performed, following temperature re-
quirements are included in clearing condition. Steps 4 and 5 are required to satisfy temperature re-
quirements.
• KDOC inlet temperature 200 °C or above
• KDOC outlet temperature 200 °C or above
3. Display KDOC inlet and outlet temperatures with monitoring function.
4. Perform continuously the blade RAISE relief for 15 minutes with fuel control dial at MAX (high idle) position.
5. When the KDOC inlet temperature or KDOC outlet temperature does not exceed 200 °C, perform “Loaded
Diagnostics Operation To Clear failure Code” [CA1883].
6. If the failure code is cleared, repair work is completed.
REMARK
40-536 D155AX-8
D155AX-8 40-537
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1 40 TROUBLESHOOTING
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1

Failure KDOC Outlet Temperature High Error 1(Engine controller system)
L01 CA3254
Details of
KDOC outlet temperature remains at high level.
failure
Action of
None
controller
Phenomenon
None
on machine
k
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related 2. Cylinders other than disabled cylinder may increase their fuel injection in order to compen-
information sate for torque drop, causing high exhaust temperature.
• Engine controller does not shut itself down immediately after turning the starting switch to
lamp in the battery box goes out even if quick restart becomes necessary.
NOTICE
again.)
40-538 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1

1
2
3
fuel.
tor
1. Remove KDPF.
2. Remove KDOC.
NOTICE
• Check if KDOC has any cracks (change KDOC if any).
7 Defective KDOC • If KDOC of KDPF is changed, perform the reset after KDOC change,
then troubleshooting is complete without performing manual station-
ary regeneration.
(See cause 7 for failure code [CA2637].)
• Check if KDOC inlet surface is clogged with soot 50 % or more.
(Cleaning of KDOC)
KDOC outlet temperature
9
10

2. Start the engine and run it at low idle speed for about 1 minute.
3. Choose manual stationary regeneration for service by Active regeneration for service screen on the moni-
tor.
4. End active regeneration for service.
D155AX-8 40-539
NOTICE
• Perform active regeneration for service for 15 minutes and more from its start.
• If the failure code is cleared when active regeneration for service is ended, repair is completed.
“INSITE”.
40-540 D155AX-8
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regenera-
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration

Action level Failure code KDPF Temperature Error - Non Regeneration (Engine controller sys-
Failure
L03 CA3255 tem)
Details of
KDPF outlet temperature remains at high level when active regeneration is not performed.
failure
Phenomenon
on machine
k
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
information ASSEMBLE KDPF ASSEMBLY”.
NOTICE
again.)
D155AX-8 40-541

1
2
fuel.
tor
KDPF outlet temperature
7
8

2. Start the engine and run it at low idle speed for 15 minutes.
If the failure code is cleared, repair work is complete. Otherwise, perform the following:
NOTICE
If failure code is not cleared after preceding steps 1 and 2 are performed, following temperature re-
quirements are included in clearing condition. Steps 4 and 5 are required to satisfy temperature re-
quirements.
• KDOC outlet temperature 200 °C or above
• KDPF outlet temperature 200 °C or above
3. Display KDOC outlet temperature and KDPF outlet temperature with monitoring function.
4. Perform continuously the blade RAISE relief for 15 minutes with fuel control dial at MAX (high idle) position.
5. When the KDOC outlet temperature or KDPF outlet temperature does not exceed 200 °C, perform “Loaded
Diagnostics Operation To Clear failure Code” [CA1883].
6. If the failure code is cleared, repair work is complete.
REMARK
40-542 D155AX-8
D155AX-8 40-543
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 40 TROUBLESHOOTING
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1

Action level Failure code KDPF Outlet Temperature High Error 1
Failure
Details of
The SCR outlet temperature has been in a high temperature state
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
information
compensate for torque drop, causing high exhaust temperature.
ON position.
NOTICE
cleared.

1
40-544 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1

Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
fuel.
tor
7
8

4. Choose manual stationary regeneration for service by Active regeneration for service screen on the moni-
tor.
5. End active regeneration for service.
NOTICE
• Perform active regeneration for service for 15 minutes minimum from its start.
• After active regeneration for service is ended and if failure code is cleared, repair is completed.
“INSITE”.
• See “INSITE” operation manual to use “INSITE”.
D155AX-8 40-545
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2

Action level Failure code KDOC Outlet Temperature High Error 2
Failure
Details of
KDOC outlet temperature remains at very high level.
failure
Phenomenon
on machine
k
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
information purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, per-
form a “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure

1
2
3
40-546 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2

fuel.
tor
8
9

NOTICE
• The failure code is cleared once when starting switch is turned from OFF position to ON posi-
tion. Check that cleared failure code is not generated again when engine runs at low idle speed.
2. Start the engine and run it at low idle speed without load for 2 minutes.
NOTICE
If this failure code is displayed when starting switch is turned to ON position but engine is not start-
ed, perform troubleshooting for following failure codes, too, after finishing troubleshooting and re-
pair for this code.
• [CA3316] KDOC Outlet Temperature Sensor Low Error
• [CA3317] KDOC Outlet Temperature Sensor High Error
D155AX-8 40-547
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2

Action level Failure code KDPF Outlet Temperature High Error 2
Failure
Details of
KDPF outlet temperature remains at very high level.
failure
• Fuel dosing stops..
Phenomenon
on machine
40-548 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2
k
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related
sate for torque drop, causing high exhaust temperature.
information
NOTICE
form “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
the failure code is cleared again.

1
2
3
D155AX-8 40-549

fuel.
tor
8
9

NOTICE
• The failure code is cleared once when starting switch is turned from OFF position to ON posi-
tion. Check that cleared failure code is not generated again when engine runs at low idle speed.
2. Start the engine and run it at low idle speed without load for 2 minutes.
NOTICE
If this failure code is displayed when starting switch is turned to ON position but engine is not start-
ed, perform troubleshooting for following failure codes as well after finishing troubleshooting and
repair for this code.
• [CA3319] KDPF Outlet Temperature Sensor Low Error
• [CA3321] KDPF Outlet Temperature Sensor High Error
40-550 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error

Action level Failure code KDOC Inlet Temperature Sensor Low Error
Failure
Details of
Ground fault in KDOC inlet temperature sensor measuring section or probe (+)
failure
• As the KDOC inlet temperature cannot be detected, substitute the KDOC outlet tempera-
ture for the KDOC inlet temperature and run the engine (if the KDOC outlet temperature
sensor also has an error, use a fixed value (250 °C).
Phenomenon • Defective forcible regeneration control
on machine • KDPF Soot Accumulation High
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over 500 °C.
• Ground fault in the sensor measuring section or probe (+) is sent to the engine controller
via CAN communication, and this failure code is displayed.
code is cleared).

1
3. Replace KDPF temperature sensor.
Defective KDOC inlet
temperature sensor
If this failure code is cleared, the original KDOC inlet temperature sensor is defec-
tive. (In case of an internal defect, troubleshooting is impossible as an assembly.
3
D155AX-8 40-551
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Er-
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error

Action level Failure code KDOC Inlet Temperature Sensor High Error
Failure
Detail of fail- Open circuit, hot short-circuit, or sensor circuit error in KDOC inlet temperature sensor measuring
ure section or probe (+)
• As the KDOC inlet temperature cannot be detected, substitute the KDOC outlet tempera-
ture for the KDOC inlet temperature and run the engine (if the KDOC outlet temperature
sensor also has an error, use a fixed value (250 °C)).
• Fuel dosing stops
Phenomenon Defective forcible regeneration control
on machine KDPF Soot Accumulation High
k Be careful not get burned as the temperature of KDPF and KDOC rises up over
500 °C.
Related
information
“Chapter 50 Disassembly and assembly”, "“Removal and installation of KDPF assembly”"
and "“Disassembly and assembly of KDPF assembly”".
ure code is cleared (note the engine power deration is not canceled only by the failure
code is cleared).

Defective KDOC inlet Perform troubleshooting for failure code [CA3313].
1 temperature sensor sys-
tem
40-552 D155AX-8
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error

Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
Difference between temperature sensed by KDOC inlet temperature sensor and that by KDOC out-
Details of
let temperature sensor differs from expected value.
failure
(Signal voltage is within input range.)
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine. (If failure is de-
tected in KDOC outlet temperature sensor, too, controller takes it that KDOC inlet temper-
ature is at default value (250 °C) and allows engine to run.)
Phenomenon
on machine
k
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related • Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is
information lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
code is cleared).
NOTICE
the failure code is cleared again.
D155AX-8 40-553

Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for those
1
temperature sensor codes.
2
3
fuel.
tor
KDOC inlet temperature
Defective KDPF temper- 2. If the failure code displays after performing the preceding troubleshooting,
8
ature sensor replace the KDPF temperature sensor.
9

1. Clear this failure code by Engine Controller Inducement Fault Clear from the “Service mode” of the machine
monitor.
3. Start the engine and run the engine at low idle speed for approximately 1 minute.
4. Set the fuel control dial to MAX position, stall torque converter continuously for approximately 40 seconds.
How to stall torque converter
1) Select P mode to operate gear shift lever in manual
2) On the “Service Menu” screen of the machine monitor, select “Adjustment” screen.
4) Set the preset mode display to [F3-R3] by shift up switch (UP) of PCCS lever.
The Preset mode display (lower right on the screen) can be set to [F3-R3] only when “Stall mode” is
selected on the “Adjustment” screen.
40-554 D155AX-8
5) Make sure to depress the brake pedal firmly, and put the parking brake lever in FREE position, set the
direction of the PCCS lever to FORWARD position.
NOTICE
idle speed.
Depressing the brake pedal securely, and place your right foot on the decelerator pedal during stalling
torque converter process for safety reason.
move the PCCS lever to NEUTRAL position.
NOTICE
• Pay attention not to get overheating of hydraulic oil temperature.
5. Repeat 4. For approximately 25 minutes continuously, paying attention not to get overheating of hydraulic
oil temperature.
6. If the failure code is cleared, repair is completed.
REMARK
D155AX-8 40-555
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Er-
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error

Action level Failure code KDOC Outlet Temperature Sensor Low Error
Failure
Detail of fail-
Ground fault in KDOC outlet temperature sensor measuring section or probe (+)
ure
• As the KDOC outlet temperature cannot be detected, substitute the KDOC inlet tempera-
ture for the KDOC outlet temperature and run the engine (if the KDOC inlet temperature
sensor also has an error, use a fixed value (250 °C).
• NOx emission increases.
information
code is cleared).

1
Defective KDOC outlet
temperature sensor
If this failure code is cleared, the original KDOC outlet temperature sensor is defec-
3
40-556 D155AX-8
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Er-
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error

Action level Failure code KDOC Outlet Temperature Sensor High Error
Failure
Detail of fail- Open circuit, hot short-circuit, or sensor circuit error in KDOC outlet temperature sensor measuring
ure section or probe (+).
• As the KDOC outlet temperature cannot be detected, substitute the KDOC inlet tempera-
ture for the KDOC outlet temperature and run the engine (if the KDOC inlet temperature
sensor also has an error, use a fixed value (250 °C)).
• NOx emission increases because AdBlue/DEF injection is disabled.
Phenomenon • Defective forcible regeneration control.
on machine • KDPF Soot Accumulation High.
information “Chapter 50 Disassembly and assembly”, “Removal and installation of KDPF assembly”
and “Disassembly and assembly of KDPF assembly”.
ure code is cleared (note the engine power deration is not canceled only by the failure
code is cleared).

Defective KDOC outlet Perform troubleshooting for failure code [CA3316].
tem
D155AX-8 40-557
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Er-

ror
Action level Failure code KDOC Outlet Temperature Sensor In Range Error
Failure
Details of The difference between the temperature sensed by KDOC outlet temperature sensor and the tem-
failure perature sensed by KDOC inlet temperature sensor differs from the expected value.
• Substitute the KDOC inlet temperature for the KDOC outlet temperature, and run the en-
gine (if the KDOC inlet temperature sensor also has an error, use the KDOC outlet tem-
perature (250ºC) as a default value).
Phenomenon
on machine
(Code: 47300 (ºC))
(Code: 47400 (ºC))
(Code: 47200 (ºC))
• As to procedure for accessing KDPF temperature sensor, see "50 DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY" and "REMOVE AND INSTALL KDPF ASSEMBLY".
Related
information OFF position and Engine controller keeps working until the purging is completed. The
code is cleared).
NOTICE

Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform troubleshooting for those
1
40-558 D155AX-8

2
3
fuel.
tor
8
9

monitor.
4. Set the fuel control dial to MAX position, stall torque converter continuously for approximately 40 seconds.
D155AX-8 40-559
NOTICE
idle speed.
NOTICE
oil temperature.
REMARK
40-560 D155AX-8
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Er-
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error

Action level Failure code KDPF Outlet Temperature Sensor High Error
Failure
Detail of fail- Open circuit, hot short-circuit, or sensor circuit error in KDPF outlet temperature sensor measuring
ure section or probe (+)
• Substitute the KDOC outlet temperature for the KDPF outlet temperature and run the en-
gine (if the KDOC outlet temperature sensor also has an error, use the default value of the
KDPF outlet temperature (250 °C)).
controller • EGR valve closed.
• Advances to Inducement strategy.
code is cleared).

Defective KDPF outlet Perform troubleshooting for failure code [CA3321].
tem
D155AX-8 40-561
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Er-
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error

Action level Failure code KDPF Outlet Temperature Sensor Low Error
Failure
Detail of fail-
Ground fault in KDPF outlet temperature sensor measuring section or probe (+)
ure
• Substitute the KDOC outlet temperature for the KDPF outlet temperature and run the en-
gine (if the KDOC outlet temperature sensor also has an error, use the default value of the
KDPF outlet temperature (250 °C).
• Ground fault in the sensor measuring section or probe (+) is sent to the engine controller
code is cleared).

1
Defective KDPF outlet
temperature sensor
If this failure code is cleared, the original KDPF outlet temperature sensor is defec-
40-562 D155AX-8
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Er-

3 controller is defective. (In case of an internal defect, troubleshooting is impossible
ler
D155AX-8 40-563
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error

Action level Failure code KDPF Outlet Temperature Sensor In Range Error (Engine controller
Failure
L03 CA3322 system)
Details of Temperature sensed by KDPF outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
Action of
controller
Phenomenon Engine power deration
on machine Engine power deration according to Inducement strategy.
k
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• As to procedure for accessing KDPF temperature sensor, see “50 Disassembly and as-
sembly”, “Removal and installation of KDPF assembly” and “Disassembly and assembly of
KDPF assembly”.
Related
information
NOTICE
• This failure code “Loaded Diagnostics Operation To Confirm Failure Correction”. Af-
ed Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared again.
• Engine power deration is canceled by turning starting switch to OFF position after
this failure code is cleared (note that the engine power deration is not canceled only
by the failure code is cleared).

Defective KDPF outlet If failure code [CA3319] or [CA3321] is displayed, perform troubleshooting for those
1
2
40-564 D155AX-8

3
fuel.
tor
8
9

monitor.
2. Turn starting switch from OFF position to ON position.
4. Set the fuel control dial at MAX position, stall torque converter continuously for approximately 40 seconds.
D155AX-8 40-565
NOTICE
idle speed.
NOTICE
oil temperature.
REMARK
40-566 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error

Action level Failure code Mass Air Flow Sensor Supply Voltage High Error
Failure
Details of
High voltage occurs in mass air flow sensor power supply (12 V) circuit.
failure
• Sets MAF sensor at fixed value (10 kg/min) and runs engine.
• Stops KDPF regeneration control.
Phenomenon
on machine

1
Defective sensor (internal
2 If this failure code is cleared, MAF sensor is defective.
defect)
REMARK
Many other failure codes appear at same time because of disconnected con-
nector. Ignore failure codes other than this.
REMARK
Defective engine control- fore replacing the engine controller.
4
ler
Approx.
12 V
tive. Replace engine controller. (In case of an internal defect, troubleshooting is im-
D155AX-8 40-567
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error 40 TROUBLESHOOTING
Circuit diagram related to mass air flow sensor
40-568 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error

Action level Failure code Mass Air Flow Sensor Supply Voltage Low Error
Failure
Details of
Low voltage appears in mass air flow sensor power supply (12 V) circuit.
failure
• Sets MAF sensor at fixed value (10 kg/min) and runs engine.
Phenomenon
on machine

1
Defective MAF sensor
2 If this failure code is cleared, MAF sensor is defective.
(internal defect)
REMARK
REMARK
4 side of J1.
ness
Between J1 (female) (80) and (56) or MAF (female) (2)
and (3).
D155AX-8 40-569
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error 40 TROUBLESHOOTING

ground circuit)
(2)
Defective engine control- fore replacing the engine controller.
6
ler
Approx.
12 V
Circuit diagram related to mass air flow sensor
40-570 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1

Failure
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank capacity becomes 10 % or less)
ure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
Related
information
• CA3498 is displayed if usage is continued without refilling AdBlue/DEF and the
AdBlue/DEF level becomes 5 % or less.

tank sensor
3
D155AX-8 40-571
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2 40 TROUBLESHOOTING

Failure
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank capacity becomes 5 % or less)
ure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
Related
information
• CA1673 is displayed and engine output is limited significantly if usage is continued without
refilling AdBlue/DEF and the AdBlue/DEF level becomes 2.5 % or less.

tank sensor
3
40-572 D155AX-8
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst
40 TROUBLESHOOTING Efficiency Low)
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Effi-

ciency Low)
Action level Failure code AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)
Failure
Detail of fail- • The SCR catalyst efficiency is poor (65 % or less) after AdBlue/DEF refilling with coolant.
ure • It is likely that the AdBlue/DEF quality is abnormal.
Action of
controller
Phenomenon • The NOx emission likely to have increased.
D155AX-8 40-573
Efficiency Low) 40 TROUBLESHOOTING
ue/DEF injector.
• This failure code [CA3543] is displayed after the engine controller implements “clearing
active regeneration (approximately one hour) of urea deposit accumulation” when the fail-
ure code [CA3582] is displayed.
• Make sure the failure code [CA3582] is not displayed when confirming the completion of
repair.
• If the ambient pressure is 80 kPa or less and the ambient temperature is -7 °C or less, the
Confirm on the Pre-defined Monitoring screen.
Related nostics Operation To Clear Failure Code” does not clear this failure code).
information • For the procedure to remove and change the AdBlue/DEF injector, see “Disassembly and
• On the “Pre-defined Monitoring”screen, these 4 diagnosis are displayed. Engine operation
01002 Engine speed
40-574 D155AX-8

Related
information
NOTICE

tem
1
heater)
heater)
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] or [CA4261] is displayed, perform
fect) troubleshooting for these failure codes first.
heater)
D155AX-8 40-575

found.
Improper AdBlue/DEF
quality
completed.
played.
jector
(“Loaded Diagnostics Operation To Confirm Failure Correction” has resolved
the clogging problem and the machine has restored normal operation).
leak.
40-576 D155AX-8

ficiency Test”.
tem first.
TEST)
jector
mixing tube
12
D155AX-8 40-577

tive.
damaged rectifier)
13
4. If 19205 “ammonia concentration (compensation value)” shows an normal
value (5 to 100ppm) and the failure code is cleared again, the repair has
been completed
fective.
sor
pleted.
15

(Make sure that this failure code and failure code [CA3582] are cleared after this procedure.)
1. Clear this failure code by “Engine Controller Inducement Fault Clear”.
4. Run the engine at low idle speed (with no load) for approximately 1 minute.
5. After warm-up operation, set the fuel control dial to MAX.
6. Stalling torque converter operation continuously with fuel control dial at MAX position for approximately 20
seconds.
REMARK
40-578 D155AX-8
NOTICE
idle speed.
REMARK
8. Repeat steps 6 and 7 for up to 20 times, so that SCR temperature becomes 250 °C or more.
9. Run the engine at high idle speed and blade raise relief for 10 minutes.
10. Check that turbocharger outlet NOx emission value is 120 (ppm) or more.
11. Repeat from 5. to 7. for 20 times to get both SCR temperature and Nox emission value are obtained at the
same time.
REMARK
• If this failure code and failure code [CA3582] are cleared, repair is completed.
• If turbocharger outlet NOx emission value is less than 120 (ppm), return to troubleshooting.
• If this failure code or failure code [CA3582] is not cleared, return to troubleshooting.
D155AX-8 40-579
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error 40 TROUBLESHOOTING
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error

Action level Failure code SCR Outlet NOx Sensor Unstable Error
Failure
Detail of fail-
The SCR outlet NOx sensor does not become measurable status.
ure
k The KDPF, sensor fitting piping, and sensor probe become hot (Min. 500 °C). Be care-
ful not to get burned.
• The SCR outlet NOx sensor operates when 19302 SCR outlet temperature is 150 °C or
more (19210 SCR outlet NOx sensor measurement state is “1”).
• The SCR outlet NOx sensor does not operate when SCR outlet temperature is (150 °C or
• Pre-defined Monitoring screen uses the engine operation state diagnosis, SCR catalyst,
NOx sensor, and ammonia sensor diagnosis.
01002 Engine speed
Related
information
NOTICE
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the
failure code is cleared. (This failure code is not cleared by only turning ON the starting
switch.)

Defective SCR outlet If failure code [CA1887] or [CA3583] or [CA3681] or [CA3717] is displayed, perform
1
NOx sensor system troubleshooting for these failure codes first.
40-580 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error

SCR outlet NOx sensor Check if the SCR outlet NOx sensor probe is installed securely.
2
installation error
NOx sensor
ler

3. Run the engine at high idle speed safely to raise the exhaust gas temperature and SCR catalyst tempera-
ture. (Keep the engine speed so that monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or
higher. Check that monitoring code 19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
REMARK
D155AX-8 40-581
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4 40 TROUBLESHOOTING

Failure
Detail of fail-
The AdBlue/DEF tank level lowers. (The tank capacity becomes 0.0 % or less)
ure
Action of • The information related to this failure code is displayed on the monitor screen.
controller • Engine power is derated heavily.
Phenomenon
Engine output reduces heavily.
on machine
Related When AdBlue/DEF level is 0.0 % or less [CA3547]
information • From the machine monitor, it is possible to perform a temporary restoration from induce-
ment to clear engine output low temporarily.
• If the machine continues to operate without adding, AS00ZK is displayed and engine out-
put for operation is limited to low idle.

tank sensor
3
40-582 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error

Action level Failure code AdBlue/DEF Pump Voltage High Error
Failure
Detail of fail-
High voltage error occurs in the AdBlue/DEF pump drive circuit.
ure
• AdBlue/DEF pump stops.
Action of
• AdBlue/DEF purging stops.
controller
• If the starting switch is turned ON while the AdBlue/DEF pump connector is removed, this
failure code is displayed.
• The AdBlue/DEF pump operates120 seconds after starting the engine, or it operates, after
Related starting the engine, if not in AdBlue/DEF thawing process, when the KDPF outlet tempera-
information ture becomes over 150 °C, or when AdBlue/DEF pump pressure raising test is implement-
ed.
Procedure: Turn starting switch to ON position or operate the AdBlue/DEF pump.

“RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
1
connector 3. See “SERVICE MODE” and “METHOD FOR SETTING WITH TESTING
MENU (SCR SERVICE TEST)” of SETTING AND OPERATION OF MA-
CHINE MONITOR, and perform an AdBlue/DEF Pump Pressure Up Test.
Open circuit in wiring har- 2. Disconnect connectors J2 and DSM, and connect T-adapter to either fe-
2
nector) Between J2 (female) (54) and DSM (female) (8) Max. 1 Ω
Resistance
2. Disconnect connectors J2 and DSM, and connect T-adapter to female side
of J2.

3 Between J2 (female) (6) and each pin other than (6) ty (no sound
ness
is heard)
Resistance
No continui-
Between J2 (female) (79) and each pin other than (79) ty (no sound
is heard)
If failure code is still displayed after above checks, AdBlue/DEF pump may be de-
pump
5
D155AX-8 40-583
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error 40 TROUBLESHOOTING
Circuit diagram related to AdBlue/DEF pump
40-584 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error

Action level Failure code AdBlue/DEF Pump Voltage Low Error
Failure
Detail of fail-
Low voltage error occurs in the AdBlue/DEF pump drive circuit.
ure
• AdBlue/DEF pump stops.
Action of
• AdBlue/DEF purging stops.
controller
• If the AdBlue/DEF pump connector is removed while the starting switch is ON, this failure
code is displayed.
• The AdBlue/DEF pump operates 120 seconds after starting the engine, or it operates, af-
Related ter starting the engine, if not in AdBlue/DEF thawing process, when the KDPF outlet tem-
information perature becomes over 150 °C, or when AdBlue/DEF pump pressure raising test is imple-
mented.
Procedure: Turn starting switch to ON position or operate the AdBlue/DEF pump.

1
2. Disconnect connectors J2 and DSM and connect T-adapters to each fe-
Open circuit in wiring har- male side.
2
ness
Resistance
male side.
3 Between J2 (female) (6) and (54), or between DSM
ness Min. 1 Ω
Resistance
Min. 1 Ω
D155AX-8 40-585
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error 40 TROUBLESHOOTING

Ground fault in wiring male side.
4 harness (contact with Between J2 (female) (6) or DSM (female) (10) and
GND circuit) Min. 1 Ω
ground
Resistance
Min. 1 Ω
ground
If failure code is still displayed after above checks, AdBlue/DEF pump may be de-
pump
6
Circuit diagram related to AdBlue/DEF pump
40-586 D155AX-8
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Er-

ror
Action level Failure code AdBlue/DEF LineHeater Relay 1 Voltage High Error
Failure
Detail of fail-
High voltage error occurs in the AdBlue/DEF line heater relay 1 circuit.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF line stops thawing.
on machine • NOx emission increases
• The AdBlue/DEF line heater relay 1 operates in AdBlue/DEF supply system thawing,
warning, or implementation of AdBlue/DEF line heater relay 1 test.
• The AdBlue/DEF line heater relay 1 is built in the AdBlue/DEF heater relay.
• Troubleshooting of this failure code covers circuits from engine controller through
Related AdBlue/DEF heater relay to power supply.
information • This failure code is detected only when the AdBlue/DEF line heater relay 1 is ON.
Procedure: Starting the engine at low temperature (ambient temperature of 5 °C or less) or
see “Service mode” and “Testing menu (SCR service test) - Operate” of Setting and oper-
ating machine monitor to perform “AdBlue/DEF line heater relay 1 test”.

1
2
harness 3. Turn starting switch to ON position (with connector UHR1 disconnected).
Voltage Between UHR (female) (10) and (12) Max. 3 V
3. Disconnect connector UHR1 and UHR2 and replace AdBlue/DEF heater
relay.
3 4. Turn the battery disconnect switch to ON position.
heater relay
5. Perform the “AdBlue/DEF Line Heater Relay 1 Test” by staring the engine
in low ambient temperature (5 °C or below), or by referring “SERVICE
D155AX-8 40-587

ler
40-588 D155AX-8
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Er-

ror
Action level Failure code AdBlue/DEF LineHeater Relay 1 Voltage Low Error
Failure
Detail of fail-
Low voltage error occurs in the AdBlue/DEF line heater relay 1 circuit.
ure
Action of
controller
Phenomenon
on machine
• This failure code is displayed if connector of AdBlue/DEF heater relay is removed while
the AdBlue/DEF line heater relay 1 is OFF.
• The AdBlue/DEF line heater relay 1 operates in AdBlue/DEF supply system thawing,
warning, or implementation of AdBlue/DEF line heater relay 1 test.
Related • The AdBlue/DEF line heater relay 1 is built in the AdBlue/DEF heater relay.
information • Troubleshooting of this failure code covers circuits from engine controller through
AdBlue/DEF heater relay to power supply.
• This failure code is detected only when the AdBlue/DEF line heater relay 1 is OFF.

1
Check if fuse No. 15 in fuse box F01 is blown.
Defective fuse No. 15 in
2 REMARK
fuse box F01
3 ness (sensor relay power 3. Disconnect connector UHR2, and connect T-adapter to female side.
supply side) 4. Turn the battery disconnect switch to ON position.
Voltage Between ground and UHR2 (female) (1) or (2) Min. 22 V
Open circuit in wiring har- 2. Turn the battery disconnect switch to OFF position.
4 ness (line heater relay
drive signal side) 3. Disconnect connectors J2 and UHR1 and connect T-adapters to each fe-
male side.
Resistance Between J2 (female) (3) and UHR1 (female) (10) Max. 1 Ω
D155AX-8 40-589

3. Disconnect connectors J2 and UHR1, and connect T-adapter to either fe-
Between J2 (female) (3) or UHR1 (female) (10) and
ground
Short circuit in wiring har- 3. Disconnect connectors J2 and UHR1, and connect T-adapter to female
6
ness side of J2.
Continuity
(3) ty
7 relay.
heater relay
ler
40-590 D155AX-8
D155AX-8 40-591
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or
Short Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short

Circuit Error
Action level Failure code AdBlue/DEF Injector Open Circuit Error or Short Circuit Error
Failure
Detail of fail-
Short or open circuit is detected in the AdBlue/DEF injector circuit.
ure
• AdBlue/DEF pump stop
Action of
• AdBlue/DEF injection stops
controller
k The AdBlue/DEF injector become hot (Min. 400 °C). Be careful not to get burned.
• This failure code is displayed when the AdBlue/DEF injection stops due to connector dis-
connection.
• Short circuit is detected in both ends of the connector between (+) and (-) and this failure
code is displayed when AdBlue/DEF injection stops.
• The voltage between the female terminals is 20 V or more when the AdBlue/DEF injector
connector is disconnected and the starting switch is turned ON, so the hot short circuit of
the harness cannot be checked.
• The AdBlue/DEF injector is activated for AdBlue/DEF injection and when AdBlue/DEF
purging.
• This failure code is cleared after repairing, and turning the starting switch from OFF to ON
position to activate AdBlue/DEF injection.
• The AdBlue/DEF pump stops under the following three conditions:
1. The ambient temperature is -24 °C or less.
2. AdBlue/DEF thawing
3. When the failure code of the AdBlue/DEF pump stoppage or the AdBlue/DEF injection
Related
stoppage is displayed.
information
If the AdBlue/DEF injector does not activate be driven due to any of the above-mentioned
functions, clear the failure code from the monitor after investigating the cause and make
sure that it is not displayed when discrimination is impossible (when AdBlue/DEF injection
stops).
• The Pre-defined Monitoring screen. (The following numbers are the monitoring codes)
• AdBlue/DEF pump diagnosis
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After com-
pleting the repair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make
sure the failure code is cleared if any failure parts are detected. (This failure code is not
cleared by turning ON the starting switch.)
40-592 D155AX-8
40 TROUBLESHOOTING Short Circuit Error

1
connector 2. Perform “Loaded Diagnostics Operation To Clear Failure Code”.
Defective AdBlue/DEF in- 2. Disconnect connector UDM and connect socket to male side.
2
jector
Between UDM (male) (1) 11.4 to
Resistance 20 °C
and (2) 12.6 Ω
3
wiring harness
The resistance is the same as AdBlue/DEF injector.
Between J2 (female) (77) 11.4 to
Resistance 20 °C
and (53) 12.6 Ω
2. Disconnect connectors J2 and UDM, and connect T-adapter to female side
Short circuit in wiring har- of connector J2.
4
ness
No continui-
(77)
is heard)
2. Disconnect connectors J2 and UDM, and connect T-adapter to female side
5 harness (contact with of connector J2.
Resistance
2. Disconnect connector UDM.
6 harness (hot short circuit 3. Insert T-adapter into connector J2.
in negative line) 4. Turn starting switch to ON position (with injector disconnected).

3. Check if AdBlue/DEF pump pressure is around 900 kPa after running the engine at low idle speed (with no
load) for 2 minutes.
REMARK
D155AX-8 40-593
Short Circuit Error 40 TROUBLESHOOTING
Circuit diagram related to AdBlue/DEF injector
40-594 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction

Action level Failure code AdBlue/DEF Injector Malfunction
Failure
Detail of fail- The AdBlue/DEF injector or AdBlue/DEF pressure hose is clogged or the AdBlue/DEF injector noz-
ure zle is sticking open.
controller • The AdBlue/DEF pump stops.
D155AX-8 40-595
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction 40 TROUBLESHOOTING
k The AdBlue/DEF injector becomes hot (Min. 400 °C). Be careful not to get burned.
ue/DEF supply system (because the AdBlue/DEF injection is disabled, which disables
judgment).
• Make sure that the value of the following 4 states are other than 1 (Thawing) 3 minutes
after the engine is started. (It is not possible to troubleshoot this failure until thawing con-
trol is completed.)
screen.
• The Pre-defined Monitoring screen uses the AdBlue/DEF injector diagnosis and
AdBlue/DEF pump diagnosis. (The following numbers are the monitoring codes)
Related
19202 Turbo Outlet NOx Concentration Corrected
information
47200 KDPF outlet temperature
NOTICE
code is cleared. (This failure code is not cleared by only turning ON the starting switch.)

1
Defective AdBlue/DEF in- If failure code [CA3567] is displayed on the abnormality record screen, perform
2
jector system troubleshooting these first.
40-596 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction

See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR SET-
TING WITH TESTING MENU (SCR SERVICE TEST)” in “SETTING AND OPERA-
TION OF MACHINE MONITOR” to perform “AdBlue/DEF Injector Rate Test”.
Case 1: AdBlue/DEF injection stops
The AdBlue/DEF injector or the AdBlue/DEF pressure hose may be clogged. Pro-
ceed to cause 4 to determine the cause of the failure.
Failure of the Case 2: AdBlue/DEF injection continues for more than 2 seconds without stoppage
3 1. The AdBlue/DEF injector nozzle remains open and stucked. Replace with
AdBlue/DEF injector
a new one.
2. To remove the accumulated deposits of AdBlue/DEF in SCR, see “SET-
TING AND OPERATION OF MACHINE MONITOR” of “SERVICE MODE”,
and “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)” to perform “Active Regeneration for Service” for 3 times (Refer-
ence: Approximately 2 hours is required in total (40 minutes per opera-
tion))
1. Prepare a container at the injector to receive drained AdBlue/DEF.
2. Remove the hose at AdBlue/DEF injector to allow AdBlue/DEF to drain.
3. See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OP-
ERATION OF MACHINE MONITOR”, “METHOD FOR SETTING WITH TEST-
ING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Pump Pres-
sure Up Test”.
4. If AdBlue/DEF flows out from the AdBlue/DEF pressure hose while the AdBl-
Clogged AdBlue/DEF ue/DEF pump pressure does not reach 900 kPa, there is no clogging in the
4
pressure hose AdBlue/DEF pressure hose.
5. The AdBlue/DEF injector is clogged. Replace it.
6. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in the
AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
Failure code [CA1682] may be displayed if the pressure does not rise within 3
minutes while performing the “AdBlue/DEF Pump Pressure Up Test”.
If failure code is still displayed after above checks, the AdBlue/DEF injector may
have been temporarily clogged but is now normal.
5 jector
Perform “Loaded Diagnostics Operation To Confirm Failure Correction”. If this fail-
(temporarily clogged)
ure code is cleared, repair is completed.
6

1. Perform “Engine Controller Inducement Fault Clear” to cancel engine power deration when inducement
strategy is activated.
3. Start the engine and warm it up.
ice)” in “SETTING AND OPERATION OF MACHINE MONITOR” to perform “Active Regeneration for Serv-
ice”.
5. Operate at least 10 minutes after the KDPF outlet temperature exceeded 300 °C.
D155AX-8 40-597
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction 40 TROUBLESHOOTING
6. Stop the service regeneration (make sure monitoring code 19108 “AdBlue/DEF pump pressure” is around
900 kPa).
7. Turn the fuel control dial to MAX position, and run the engine at high idle under no load for 2 minutes.
8. Perform torque converter stall operation as described below with fuel control dial at MAX position for 1 mi-
nute. (At this time, if the value of ammonia concentration is not within 10 to 500(ppm), return to trouble-
shooting).
1) Select P mode to operate gear shift lever in manual.
4) Set preset mode display to [F3-R3] by shift up (UP) switch on the PCCS lever.
The preset mode display (on the lower right of the screen) can be set to [F3-R3] only when “Stall
Mode” is selected in the “Adjustment” screen.
5) Make sure to depress the brake pedal firmly and the parking brake lever in FREE position, set the di-
rection of the PCCS lever to FORWARD position.
NOTICE
6) Depress the decelerator pedal and set the fuel control dial at MAX position.
7) Return the decelerator pedal slowly to stall the torque converter with the fuel control dial at MAX posi-
tion.
NOTICE
• Pay attention not to overheat of hydraulic oil temperature .
9. Repeat above steps 7 and 8 again.
11. Repeat the above steps 7, 8, 9, 10, 7, 8 and 9 again.
12. If this failure code is cleared, and active regeneration is not started, repair is completed.
REMARK
• If this failure code is displayed and active regeneration is started, return to troubleshooting.
• If active regeneration is started during “Loaded Diagnostics Operation To Confirm Failure Correction”, restart
troubleshooting after shutting down the engine controller.
• If active regeneration does not stop, press regeneration disable button to stop active regeneration and then
restart troubleshooting.
40-598 D155AX-8
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error

Action level Failure code AdBlue/DEF Pump Pressure Sensor High Error
Failure
Detail of fail-
High voltage error is detected in signal circuit of AdBlue/DEF pump pressure sensor.
ure
Operates at fixed value (1300 kPa) of AdBlue/DEF pump pressure.
Action of AdBlue/DEF pump stop
controller AdBlue/DEF purging stops
Phenomenon NOx emission increases
on machine Engine power deration according to inducement strategy.
• AdBlue/DEF pump pressure sensor is built in the AdBlue/DEF pump.
Related • If AdBlue/DEF pump pressure sensor is defective, see "Disassembly and assembly,"
“Changing AdBlue/DEF pump” to change the AdBlue/DEF itself.
information

1
Defective power supply If failure code [CA1695] or [CA1696] is also displayed, perform troubleshooting
2 system of AdBlue/DEF these first.
pump pressure sensor
2. Disconnect connector DSM.
pressure sensor
If the displayed failure code changes from [CA3571] to [CA3572], the AdBlue/DEF
pump pressure sensor is defective.
Open circuit in wiring har- 2. Disconnect connectors J2 and DSM and connect T-adapters to each fe-
4
nector) Open circuit in GND line
Short circuit in wiring har- 2. Disconnect connectors J2 and DSM, and connect T-adapter to female side
5
ness of J2.
D155AX-8 40-599
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High

2. Disconnect connector DSM, and connect T-adapter to female side or insert
Hot short circuit in wiring T-adapter to connector J2.
6
Between DSM (female) (3) and (4), or between J2 (16)
Voltage Max. 1 V
and (32)
7
Circuit diagram related to AdBlue/DEF pump pressure sensor
40-600 D155AX-8
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error

Action level Failure code AdBlue/DEF Pump Pressure Sensor Low Error
Failure
Detail of fail-
Low voltage error is detected in signal circuit of AdBlue/DEF pump pressure sensor.
ure
Operates at fixed value (-100 kPa) of AdBlue/DEF pump pressure.
Action of AdBlue/DEF pump stop
controller AdBlue/DEF purging stops
• This failure code is displayed when AdBlue/DEF pump connector is disconnected.
• AdBlue/DEF pump pressure sensor is built in the AdBlue/DEF pump.
Related • If AdBlue/DEF pump pressure sensor is defective, see "Disassembly and assembly,"
information “Changing AdBlue/DEF pump” to change the AdBlue/DEF itself.

1
If failure code [CA1695] or [CA1696] is also displayed, perform troubleshooting
these first.
Defective power supply
2 system of AdBlue/DEF 2. Disconnect connector DSM, and connect T-adapter to female side.
pump pressure sensor 3. Turn starting switch to ON position.
Between DSM (female) (2) 4.75 to
and (4) 5.25 V
2. Disconnect connectors J2 and DSM and connect T-adapters to each fe-
male side.
3
defective contact of con- Between J2 (female) (16) and DSM (female) (3) Max. 1 Ω
nector)
ness
Ground fault in wiring 2. Disconnect DSM, and connect T-adapter to female side or insert T-adapter
to connector J2.
ground circuit)
Resistance Between DSM (female) (3) or J2 (16) and ground Min. 1 MΩ
D155AX-8 40-601
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low

2. Insert T-adapter into connector J2 or DSM.
Defective AdBlue/DEF 3. Turn starting switch to ON position.
6
pressure sensor
Between J2 (female) (16)
0.25 to
Voltage and (32), or between DSM Sensor output
4.75 V
7
Circuit diagram related to AdBlue/DEF pump pressure sensor
40-602 D155AX-8
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Er-
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error

Action level Failure code AdBlue/DEF Pump Pressure Too Low Error
Failure
Detail of fail- Failure of the AdBlue/DEF pump, or clogging or rupture of the AdBlue/DEF channel from the AdBl-
ure ue/DEF tank filter to the AdBlue/DEF pump.
Action of • Raise the AdBlue/DEF pump pressure again.
Phenomenon • AdBlue/DEF injection becomes insufficient and NOx emission increases.
after the engine is started. (This failure cannot be repaired until thawing control is complet-
ed)
• The state of each heater is 1: Thawing, 2: Warming, or 0: OFF. (Enter the numbers directly
and confirm the values on the monitoring code screen.)
• This failure code is cleared if the AdBlue/DEF pump pressure rises to around 900 kPa on
Related the AdBlue/DEF pump “Pre-defined Monitoring screen”.
information • The “Pre-defined Monitoring screen” uses the AdBlue/DEF pump diagnosis. (The following
numbers are the monitoring codes)
NOTICE
This failure code requires Loaded Diagnostics Operation To Clear Failure Code. After investi-
gating the cause of the problem and completing the repair, perform a “Loaded Diagnostics
Operation To Clear Failure Code” to make sure the failure code is cleared.(This failure code
is not cleared by only turning starting switch to ON position.)

1
heater 1
Defective AdBlue/DEF If failure code [CA2976] is also displayed, perform checks on causes 2 and after in
3 pump temperature sen- troubleshooting for this failure code.
sor system
Defective AdBlue/DEF If failure code [CA1669] or [CA3868] or [CA4732] or [CA4739] or [CA4769] is dis-
4
level sensor system played, perform troubleshooting these first.
D155AX-8 40-603
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Er-

If failure code [CA1673] or [CA3497] or [CA3498] or [CA3547] is displayed, trouble-
shoot for those codes first.
5 Low AdBlue/DEF level
If the level is low, replenish AdBlue/DEF until it can be seen in the sight gauge, and
then “Loaded Diagnostics Operation To Clear Failure Code”.
leak.
Check the AdBlue/DEF suction hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
suction hose
Check the AdBlue/DEF tank for entry of foreign material. Check the AdBlue/DEF
Clogged AdBlue/DEF
8 tank strainer for clogging. Repair or replace the part if any abnormality is found.
tank strainer
Use AdBlue/DEF for cleaning.
1. Remove the flange from the AdBlue/DEF tank.
2. Check if a suction tube in the AdBlue/DEF tank is torn apart.
Suction tube clogged or 3. see “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
9 torn apart in the CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
AdBlue/DEF tank TESTING MENU (SCR SERVICE TEST)” to perform “AdBlue/DEF Pump
Pressure Up Test” to check if AdBlue/DEF is not leaking from the suction tube
in the AdBlue/DEF tank visually.
If the interval specified in the Operation and Maintenance Manual has elapsed
since the last time the AdBlue/DEF pump filter was replaced, or foreign material
Clogged AdBlue/DEF
10 was found in the check for AdBlue/DEF tank strainer, replace the AdBlue/DEF
pump filter
pump filter. (Refer to “METHOD FOR REPLACING AdBlue/DEF FILTER” in the Op-
eration and Maintenance Manual)
11
pump
12

4. Check if monitoring code 19108 “AdBlue/DEF pump pressure” rises up around 900 kPa within 5 minutes.
REMARK
40-604 D155AX-8
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Er-
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error

Action level Failure code AdBlue/DEF Pump Pressure Too High Error
Failure
AdBlue/DEF injector or AdBlue/DEF pressure hose is clogged, AdBlue/DEF pump fails,
Detail of fail-
AdBlue/DEF line from AdBlue/DEF tank filter to AdBlue/DEF pump is clogged, or AdBlue/DEF leaks
ure
because of breakage.
Action of • Stops AdBlue/DEF pump.
• Engine controller does not display this failure code during thawing control of AdBlue/DEF
feed system (since AdBlue/DEF cannot be injected and accordingly correct judgment is
not made).
• Check that values of following 4 states are not “1” (Thawing), 3 minutes after engine is
started (You cannot repair this failure until thawing control is completed).
• State of each heater is 1: Thawing control, 2: Heating, or 3 or 0: OFF (Input numbers di-
rectly on monitoring code screen, and check value.)
19305 SCR Tank Heating State
19306 SCR Line1 Heating State
• If AdBlue pump pressure on AdBlue/DEF pump “Pre-defined Monitoring” screen increases
to near 900 kPa, this code is not displayed.
Related
• For above reason, run engine at low idle speed for 5 minutes, and then check that repair is
information completed.
• The “Pre-defined Monitoring” screen, use AdBlue/DEF Pump Diagnosis. (Following num-
bers are monitoring codes.)
19304 SCR PumpState
19108 Diesel Exhaust Fluid Line Pressure
19136 AdBlue/DEF pump temperature
19109 Diesel Exhaust Fluid Line Pressure Sensor Voltage
19120 Diesel Exhaust Fluid Injection Rate
NOTICE
After inspecting cause of failure and performing repair, perform “Loaded Diagnostics Opera-
tion To Clear Failure Code”, and check that this failure code is canceled. (Display of this fail-
ure code is not canceled by simply turning starting switch to ON position)

1
heater 1
Check the AdBlue/DEF purging hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
purging hose
D155AX-8 40-605
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Er-

4
pump pressure sensor
5

4. Check if monitoring code 19108 “AdBlue/DEF pump pressure” rises up around 900 kPa within 5 minutes.
REMARK
40-606 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error

Failure AdBlue/DEF FCV Voltage High Error (Engine controller system)
L01 CA3577
Detail of fail-
High voltage error occurs in signal circuit of FCV (purge valve) in AdBlue/DEF pump.
ure
Stops AdBlue/DEF pump.
Action of
Stops AdBlue/DEF purge.
controller
Limits use.
Since AdBlue/DEF pump is stopped and AdBlue/DEF cannot be injected, released quantity of NOx
Phenomenon
increases.
on machine
Since AdBlue/DEF cannot be purged, AdBlue/DEF in AdBlue/DEF line may freeze.
• AdBlue/DEF FCV is built in AdBlue/DEF pump.
• If connector DSM is disconnected, this failure code is displayed.
• AdBlue/DEF FCV operates during AdBlue/DEF purge.
Related • AdBlue/DEF FCV operates at end of AdBlue/DEF pump pressure raising test.
information • After error is repaired, when starting switch is turned from OFF position to ON position and
AdBlue/DEF FCV is driven again, this failure code is canceled.
• If AdBlue/DEF FCV is defective, replace AdBlue/DEF pump assembly. For details, see
Disassembly and assembly, “Replacement of AdBlue/DEF pump”.

1
Defective AdBlue/DEF 2. Disconnect connector DSM, and connect T-adapter to female side.
2
FCV
Between DSM (male) (11)
Resistance Temperature 23±5 °C 21.1±3 Ω
and (12)
3
wiring harness
The resistance value is the same as the AdBlue/DEF FCV value
and (57)
REMARK
quired.
ness (wire breakage or 1. Turn starting switch to OFF position.
4
defective contact of con- 2. Disconnect connectors J2 and DSM and connect T-adapters to each fe-
nector) male side.
Resistance
D155AX-8 40-607
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error 40 TROUBLESHOOTING

Hot short circuit in wiring 2. Disconnect connector DSM, and connect T-adapter to female side.
5 harness (contact with 24
3. Turn starting switch ON position (with the valve disconnected).
V circuit)
of J2.
6
ness
No continui-
Resistance Between J2 (female) (81) and each pin other than (81) ty (no sound
is heard)
7
Circuit diagram related to AdBlue/DEF FCV
40-608 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error

Action level Failure code AdBlue/DEF FCV Voltage Low Error
Failure
Detail of fail-
Low voltage error is detected in signal circuit of FCV (valve for purge) of AdBlue/DEF pump.
ure
AdBlue/DEF pump stop
Action of
AdBlue/DEF purge stop
controller
• AdBlue/DEF FCV is built in the AdBlue/DEF pump.
• Short circuit is detected in both ends of the connector between (+) and (-) and this failure
code is displayed when driving the AdBlue/DEF FCV.
• This failure code is cleared after implementing AdBlue/DEF FCV drive again turning the
starting switch from OFF to ON after abnormality repair.
• AdBlue/DEF FCV operated at the time of AdBlue/DEF purge.
Related
• AdBlue/DEF FCV operates at the end when implementing a AdBlue/DEF pump pressure
information
raise test.
• If AdBlue/DEF FCV is defective, see “DISASSEMBLY AND ASSEMBLY”, “Changing AdBl-
ue/DEF pump” to change the AdBlue/DEF itself.
• This failure code is detected only when the AdBlue/DEF FCV operates.
Procedure: Operating AdBlue/DEF FCV

1
2
wiring harness
The resistance value is the same as the AdBlue/DEF FCV value
and (57)
D155AX-8 40-609
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error 40 TROUBLESHOOTING

of J2.
3
ness
No continui-
Resistance Between J2 (female) (81) and each pin other than (81) ty (no sound
is heard)
Ground fault in wiring 2. Disconnect connectors J2 and DSM, and connect T-adapter to either fe-
ground circuit)
ground
Defective AdBlue/DEF 2. Disconnect connector DSM, and connect T-adapter to female side.
5
FCV
Between DSM (male) (11)
and (12)
6
Circuit diagram related to AdBlue/DEF FCV
40-610 D155AX-8
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1

Action level Failure code SCR Catalyst Efficiency Low Error 1
Failure
Detail of fail-
The SCR catalyst efficiency remains low (70 % or less).
ure
Action of • The engine controller performs clearing active regeneration (approximately one hour) of
controller urea deposit accumulation in repair limit.
Phenomenon • The clearing active regeneration (approximately one hour) of urea deposit accumulation is
on machine performed automatically.
k Be careful of the attachment of AdBlue/DEF because AdBlue/DEF leaks when remov-
ing AdBlue/DEF mixing piping or AdBlue/DEF injector.
• The failure state is not cleared after performing clearing active regeneration of urea depos-
it accumulation. Start clearing active regeneration of urea deposit accumulation again
when performing repair limit again 20 or more minutes after.
• After the previous active regeneration (clearing of soot, time management, urea deposit
accumulation), do not start active regeneration of urea deposit accumulation if any failures
Related occur within 20 minutes.
information • If the ambient pressure is 80 kPa or less and the ambient temperature is -7 °C or less, the
Confirm on the Pre-defined Monitoring screen.
nostics Operation To Clear Failure Code” does not clear this failure code). Confirm on the
Pre-defined Monitoring screen.
• For the procedure to remove and change the AdBlue/DEF injector, see “REMOVE AND
INSTALL AdBlue/DEF INJECTOR”.
• The cause of this failure code is cleared after accumulation of urea deposit is resolved by
active regeneration. Troubleshooting is not necessary.
• If active regeneration is performed frequently after the active regeneration which is auto-
matically performed is normally finished, identify the cause according to the following pro-
cedure.
D155AX-8 40-611
• On the Pre-defined Monitoring screen, these 4 diagnosis are displayed. Engine operation
01002 Engine speed
Related
information
19202 AFT Intake NOx Corrected
19205 AFT NH3 Sensor Corrected
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.
(This failure code is not cleared by only turning ON the starting switch again.)

tem
1
heater)
40-612 D155AX-8

heater)
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] is displayed, perform troubleshoot-
fect) ing for these failure codes first.
heater)
played.
jector
(Loaded Diagnostics Operation To Confirm Failure Correction has resolved the
clogging problem and the machine has restored normal operation).
leak.
D155AX-8 40-613

found.
Improper AdBlue/DEF
quality
completed.
ficiency Test”.
tem first.
TEST)
jector
40-614 D155AX-8

mixing tube
12
tive.
damaged rectifier)
13
pleted.
fective.
sor
pleted.
ler

(Make sure that this failure code is cleared after this procedure.)
4. Stalling torque converter operation continuously with fuel control dial at MAX positionfor approximately 20
seconds.
D155AX-8 40-615
REMARK
NOTICE
idle speed.
tion.
REMARK
6. Repeat steps 4 and 5 for up to 20 times, so that SCR temperature becomes 250 °C or above.
7. Run the engine at high idle speed and blade raise relief until the failure code is cleared (Max. 10 minutes).
REMARK
Pay attention not to get overheating of power train and hydraulic oil.
8. Make sure that SCR Temperature is 250 °C or above and Turbo Outlet NOx emission value is 120 ppm or
more on Predefined Monitoring screen.
REMARK
If the failure is cleared, the repair is completed.
9. Operate the following, if the temperature, turbocharger outlet, and NOx emission value condition are not ful-
filled.
10. Stalling torque converter continuously with fuel control dial at MAX position for approximately 20 seconds.
12. Repeat 10 to 11 until the failure code is canceled (Max. 20 times).
REMARK
Pay attention not to get overheating of power train oil and hydraulic oil. (If it is likely to be overheated, ex-
tend the time of running the engine at high idle speed.)
REMARK
If the failure is cleared, the repair is completed.
13. After this failure code is cleared, repair is completed.
In case this failure code is displayed:
1. Display the SCR temperature and ammonia concentration on the Troubleshooting screen.
2. Perform operation so that the SCR temperature is kept 250 °C or above.
3. A normal value of ammonia concentration ranges from 5 to 100(ppm). If 0(ppm) is shown consistently or
100(ppm) or above is shown, return to troubleshooting because the repair is not completed.
40-616 D155AX-8
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming
40 TROUBLESHOOTING up Error
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Er-
ror
Action level Failure code SCR Outlet NOx Sensor Heater Warming up Error
Failure
Detail of fail- There is an abnormality in the heater part of the SCR outlet NOx sensor. (It is not heated or the
ure temperature cannot be kept)
• The SCR outlet NOx sensor operates when 19302 SCR outlet temperature is 150 °C or
more (19210 SCR outlet NOx sensor measurement state is “1”).
• The SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °C or
• The Pre-defined Monitoring screen uses the engine operation state diagnosis, SCR cata-
lyst, NOx sensor, and ammonia sensor diagnosis.
01002 Engine speed
Related
information
NOTICE
sure the failure code is cleared. (This failure code is not cleared by only turning ON the
starting switch.)

1
cation system
D155AX-8 40-617
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming
up Error 40 TROUBLESHOOTING

2
Defective SCR outlet If failure code [CA1887] or [CA3681] or [CA3717] is displayed, perform trouble-
NOx sensor system shooting for these failure codes first.
heater)
NOx sensor
ler

3. Run the engine at high idle speed safely to raise the exhaust gas temperature and SCR catalyst tempera-
ture. (Keep the engine speed so that monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or
higher. Check that monitoring code 19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
REMARK
40-618 D155AX-8
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Er-
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error

Action level Failure code AdBlue/DEF Pump Pressure Unstable Error
Failure
Detail of fail- A failure of the AdBlue/DEF pump pressure sensor, clogging of each AdBlue/DEF hose, or
ure AdBlue/DEF pump is found.
Action of • Raise the AdBlue/DEF pump pressure.
Phenomenon • Engine power deration according to inducement strategy.
after the engine is started. (This failure cannot be repaired until thawing control is complet-
ed)
• The state of each heater is 1: Thawing, 2: Warming, or 0: OFF. (Enter the numbers directly
and confirm the values on the monitoring code screen.)
• 19305 AdBlue/DEF Tank Heating State
• This failure code is cleared if the AdBlue/DEF pump pressure rises to around 900 kPa on
Related the AdBlue/DEF pump “Pre-defined Monitoring screen”.
information • The “Pre-defined Monitoring screen” uses the AdBlue/DEF pump diagnosis. (The following
numbers are the monitoring codes)
NOTICE
This failure code requires Loaded Diagnostics Operation To Clear Failure Code. After investi-
gating the cause of the problem and completing the repair, perform a “Loaded Diagnostics
Operation To Clear Failure Code” to make sure the failure code is cleared.(This failure code
is not cleared by only turning starting switch to ON position.)

If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] or [CA4169] or
1 [CA4171] or [CA4249] or [CA4251] is displayed on the abnormality record screen,
pump system
perform troubleshooting these first.
AdBlue/DEF pump pres- Perform checks on causes 1 to 3 for failure code [CA3575]. (This failure code may
2
sure raise be displayed with “[CA3575] AdBlue/DEF pump pressure high error”.)
AdBlue/DEF pump pres- Perform checks on causes 1 to 10 for failure code [CA3574]. (This failure code may
3
sure drop be displayed in place of “[CA3574] AdBlue/DEF pump pressure low error”.)
Defective AdBlue/DEF AdBlue/DEF pump pressure sensor in AdBlue/DEF pump may be defective. Re-
4
pressure sensor place the AdBlue/DEF pump.
D155AX-8 40-619
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Er-

ler

3. Check if monitoring code 19108 “AdBlue/DEF Pump Pressure” is 900±100 kPa within 5 minutes after start-
ing the engine.
REMARK
40-620 D155AX-8
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming
40 TROUBLESHOOTING up Error
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Er-
ror
Action level Failure code Turbocharger Outlet NOx Sensor Heater Warming up Error
Failure
Detail of fail- There is an abnormality in the heater part of the turbocharger outlet NOx sensor. (It is not heated or
ure the temperature cannot be kept)
Action of
controller
• The turbocharger outlet NOx sensor operates when 47300 “KDOC inlet temperature” is
150 °C or more (19203 “turbocharger outlet NOx sensor measurement state” is “1”).
• Use engine operation state diagnosis, SCR catalyst, NOx sensor, and ammonia sensor di-
ing codes)
Related 01002 Engine speed
information 19200 Exhaust gas flow rate
NOTICE
switch.)
D155AX-8 40-621
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming
up Error 40 TROUBLESHOOTING

1
tem error
2
Defective turbocharger If failure code [CA1885] or [CA3682] or [CA3718] is displayed, perform trouble-
outlet NOx sensor sys- shooting for these failure codes first.
3 tem
(internal circuit abnormal-
ity)
(Offset/drift due to sulfur-poisoned turbocharger outlet NOx sensor)
Defective turbocharger 1. Turn starting switch to OFF position.
4
outlet NOx sensor
2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
ler

that monitoring code 47300 “KDOC Inlet Temperature” becomes 150 °C or higher. Check that monitoring
code 19210 “Turbo Outlet NOx Sensor State” changes from 0 to 1.)
REMARK
40-622 D155AX-8
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Er-
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error
Action level Failure code SCR Outlet NOx Sensor Power Voltage Error
Failure
Detail of fail- The value of the SCR outlet NOx sensor cannot be measured due to a supply voltage error of the
ure SCR outlet NOx sensor.
• The SCR outlet NOx sensor operates when 19302 “SCR outlet temperature” is 150 °C or
more (19210 “SCR outlet NOx sensor measurement state” is “1”).
• The SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °Cor
ing codes)
Related 01002 Engine speed
information 19200 Exhaust gas flow rate
NOTICE
starting switch.)

1
D155AX-8 40-623

2
cation system
See descriptions of wiring harness and connectors in “C Electrical equipment” in
connector
• Power line
Open cCauseircuit in wir- If no failure is found by this check, perform checks on causes 8 and after.
ing harness (wire break-
Voltage Between NOX2 (female) (1) and (4) Min. 22 V
4 age or defective contact
of connector) (broken If no failure is found by above results, this check is not required.
power line) 1. Turn starting switch to OFF position.
female side.
Resistance
speed or higher.
7
supply relay
NOx sensor
ler
40-624 D155AX-8

that monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or higher. Check that monitoring
code 19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
REMARK
D155AX-8 40-625
40-626 D155AX-8
D155AX-8 40-627
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error
Action level Failure code Turbocharger Outlet NOx Sensor Power Voltage Error
Failure
Detail of fail- The turbocharger outlet NOx sensor does not display any values due to a supply voltage error of the
ure turbocharger outlet NOx sensor.
Action of
controller
40-628 D155AX-8
• The engine controller refers to the fluctuation of the KDPF differential pressure sensor and
KDPF outlet pressure sensor to judge the error of this failure code only when the exhaust
gas pressure is stable.
unit.
ing codes)
Related
•
information
01002 Engine speed
NOTICE
switch.)

1
2
cation system
See descriptions of wiring harness and connectors in “C Electrical equipment” in
connector
D155AX-8 40-629

• Power line
Open cCauseircuit in wir- If no failure is found by this check, perform checks on causes 8 and after.
ing harness (wire break-
Voltage Between NOX1 (female) (1) and (4) Min. 22 V
4 age or defective contact
of connector) (broken If no failure is found by above results, this check is not required.
power line) 1. Turn starting switch to OFF position.
female side.
Resistance
speed or higher.
7
supply relay
8
outlet NOx sensor
ler

40-630 D155AX-8

REMARK
D155AX-8 40-631
40-632 D155AX-8
D155AX-8 40-633
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error

Action level Failure code AdBlue/DEF Line Heater 1 Voltage High Error
Failure
Detail of fail- High voltage error is detected in signal circuit of AdBlue/DEF line heater 1 (on low-temperature
ure pressure, intake, and purge).
Action of
None in particular
controller
AdBlue/DEF heater relay.
Related
• This failure code is detected only when the AdBlue/DEF line heater 1 is OFF.
information
• If the connectors of all heaters connected to the AdBlue/DEF line heater 1 are disconnect-
ed, this failure code is displayed.

1
2 relay.
heater relay
3
side)
above.
ness (wire breakage or 2. Disconnect connectors J2 and UHR1 and connect T-adapters to each fe-
4 male side.
nector) Between J2 (female) (39) and UHR1 (female) (8) Max. 1 Ω
Resistance
Between UHR1 (female) (12) and ground Max. 1 Ω
40-634 D155AX-8

2. Disconnect connector UHR1, and connect T-adapter to female side.
5 3. Turn starting switch to ON position (with connector UHR1 disconnected).
harness
Approxi-
Voltage Between UHR (female) (8) and (12)
mately 5 V
2. Disconnect connectors UHC, and UHA, and connect T-adapters to each
Defective AdBlue/DEF male side.
6
line heater
Between UHC (male) (1) and (2) 5 to 40 Ω
Resistance
Between UHA (male) (1) and (2) 5 to 40 Ω
Open circuit or short cir- REMARK
7 Resistance value is the internal resistance value of the heater relay mentioned
side) above.
Between UHR1 (female) (5) and (12) 5 to 40 Ω
Resistance
ler
D155AX-8 40-635
40-636 D155AX-8
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error
Action level Failure code SCR Outlet NOx Sensor Voltage Mismatch Error
Failure
Detail of fail- The engine controller voltage setting and SCR outlet NOx sensor voltage specifications are not con-
ure sistent. (The sensor part numbers are different)
Related ambient temperature is not high.
information • A sensor different from genuine spare parts may have been installed when changing this
sensor.

1
cation system
2
2. Check the Part No. of the NOx sensor.
Defective SCR outlet 3. Replace the SCR outlet NOx sensor.
3
NOx sensor
If this failure code is cleared, the SCR outlet NOx sensor is defective.
4
D155AX-8 40-637
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mis-
match Error 40 TROUBLESHOOTING
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Er-
ror
Action level Failure code Turbocharger Outlet NOx Sensor Voltage Mismatch Error
Failure
Detail of fail- ne controller voltage setting and turbocharger outlet NOx sensor voltage specifications are not con-
ure sistent. (The sensor part numbers are different)
Action of
controller
Related ambient temperature is not high.
information • A sensor different from genuine spare parts may have been installed when changing this
sensor.

1
tem error
2
2. Check the Part No. of the NOx sensor.
Defective turbocharger 3. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3
outlet NOx sensor 4. Turn starting switch to ON position.
4
40-638 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error

Action level Failure code Turbocharger Outlet NOx Sensor Unstable Error
Failure
Detail of fail-
The turbocharger NOx sensor does not become measurable status.
ure
Action of
controller
D155AX-8 40-639
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error 40 TROUBLESHOOTING
• The engine controller refers to the fluctuation of KDPF differential pressure sensor and
KDPF outlet pressure sensor to judge the error of this failure code only when the exhaust
gas pressure is stable.
unit.
Related ing codes)
information • Engine operation state diagnosis
01002 Engine speed
NOTICE
pair, perform a “Loaded Diagnostics Operation To Confirm Failure Correction” to make
starting switch.)

1
tem error
Defective KDPF differen- If failure code [CA1879] or [CA1881] or [CA1883] is displayed, perform trouble-
2 tial pressure sensor sys- shooting for these failure codes first.
tem
Defective KDPF outlet If failure code [CA3133] or [CA3134] or [CA3135] is displayed, perform trouble-
3
pressure sensor system shooting for these failure codes first.
40-640 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error

Defective turbocharger If failure code [CA1885], [CA3649], [CA3682], and [CA3718] is displayed, perform
4 outlet NOx sensor sys- troubleshooting for these failure codes first.
tem
Defective turbocharger Check if the turbocharger outlet NOx sensor is installed securely.
5 outlet NOx sensor instal-
lation error
6
outlet NOx sensor
ler

REMARK
D155AX-8 40-641
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error
Action level Failure code Turbocharger Outlet NOx Sensor Stuck In Range Error
Failure
Detail of fail- The NOx emission value of the engine output does not change regardless of the change in the en-
ure gine operation state.
Action of
controller
Phenomenon
The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
on machine
• The turbocharger outlet NOx sensor operates when 47300 KDOC inlet temperature is
150 °C or more (19203 turbocharger outlet NOx sensor measurement state is “1”).
• The KDPF temperature sensor is composed of the KDOC inlet temperature sensor, the
KDOC outlet temperature sensor, and the KDPF outlet temperature sensor and provides
CAN communication with the engine controller integrated into one sensor controller.
• For the replacement procedure of the KDPF temperature sensor, see “DISASSEMBLY
AND ASSEMBLY”, “REMOVE AND INSTALL SCR ASSEMBLY”.
• The Pre-defined Monitoring screen uses the engine operation state diagnosis, SCR cata-
lyst, NOx sensor, and ammonia sensor diagnosis.
01002 Engine speed
NOTICE
pair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure the
switch.)
40-642 D155AX-8

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], or [CA3718] is displayed,
outlet NOx sensor sys- perform troubleshooting for these failure codes first.
tem
1
heater)
2. Check if the turbocharger outlet NOx sensor is disconnected from the exhaust
Turbocharger outlet NOx
2 pipe or loose.
3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
1. If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform trou-
bleshooting for [CA3313], [CA3314] or [CA3315] first.
Defective KDOC inlet 2. If the KDOC inlet temperature does not rise up to 150 °C during “Loaded
3 temperature sensor sys- Diagnostics Operation To Clear Failure Code”, replace the KDPF tempera-
tem ture sensor.
3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
Defective turbocharger sensor may be defective.
outlet NOx sensor 1. Turn starting switch to OFF position.
4
(Clogged sensor due to 2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
soot, etc.)
3. Perform “Loaded Diagnostics Operation To Clear Failure Code”.
5

3. Run the engine at high idle safely to raise the exhaust gas temperature. (Keep the engine speed so that
monitoring code 47300 “KDOC inlet temperature” is 150 °C or above.)
4. After the procedure in 3., check if the turbocharger outlet NOx sensor activates within 3 minutes (OK as far
as 19203 “Turbo Outlet NOx Sensor State” changes from “0” to “1”)
5. Perform torque converter stall operation as described below with fuel control dial at MAX position for ap-
proximately 20 seconds.
REMARK
D155AX-8 40-643
NOTICE
idle.
tion.
REMARK
• Be careful about overheating of torque converter oil.
6. Run the engine at low idle speed or high idle speed (with no load) for 30 seconds.
7. Repeat the above steps 5 and 6 up to 20 times until this failure code is cleared.
REMARK
If this failure code is not cleared, return to troubleshooting.
40-644 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3751] SCR Catalyst Degradation Error
FAILURE CODE [CA3751] SCR Catalyst Degradation Error

Action level Failure code SCR Catalyst Degradation Error
Failure
Detail of fail-
Denitration efficiency does not increase though the AdBlue/DEF injection amount is sufficient.
ure
Action of
None in particular
controller
Phenomenon It is possible that the NOx emission increases due to insufficient denitration efficiency, and ammonia
on machine is discharged.
k The temperature of aftertreatment devices such as SCR assembly and AdBlue/DEF

mixing piping becomes high (Min. 400 °C). Be careful not to get burned.
k Be careful of the attachment of AdBlue/DEF because AdBlue/DEF leaks when remov-
ing AdBlue/DEF mixing piping or AdBlue/DEF injector.
REMARK
• This failure code occurs only in the “SCR Denitration Efficiency Test” implemented to locate
Related the failure points when a failure code such as [CA3151], [CA3543], and [CA3582] is dis-
information played.
• The SCR catalyst cannot be replaced alone. (SCR A'ssy needs to be changed)
NOTICE
• For this failure code, after investigating the cause of the problem and completing the
repair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure
the failure code is cleared. (This failure code is not cleared by only turning ON the
starting switch.)

Defective SCR catalyst 1. Deterioration, dissolution, or damage of SCR catalyst can be suspected.
1 (Deterioration, dissolu- Replace the SCR assembly.
tion, damage) 2. Perform “Loaded Diagnostics Operation To Clear failure Code”.
2

2. Turn the starting switch to ON position, and start engine.
3. Run the engine at low speed idle safely.
4. See “TESTING AND ADJUSTING”, “Service mode” and “Test menu (SCR Service Test)” in “SETTING AND
OPERATION OF MACHINE MONITOR” to perform “SCR removal efficiency test” (maximum duration of the
removal efficiency: 1.5 h).
5. The test condition on the monitor changes from “0” to “10”, then to “20”. (“14” may be shown temporarily
due to temperature transition)
6. When the test is completed after the test condition on the monitor shows “20”, stop the engine and shut
down the engine controller (wait for a few minutes after the shutdown, then the starting switch to OFF posi-
tion).
7. Turn the starting switch to the ON position again to check if this failure code is cleared. If the failure code is
cleared, repair work is completed.
D155AX-8 40-645
FAILURE CODE [CA3751] SCR Catalyst Degradation Error 40 TROUBLESHOOTING
REMARK
40-646 D155AX-8
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degra-
40 TROUBLESHOOTING dation Error
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation

Error
Action level Failure code AdBlue/DEF Dosing Performance Degradation Error
Failure
Detail of fail-
Actual AdBlue/DEF dosing performance is less than that which is indicated.
ure
Action of
None in particular
controller
Phenomenon
The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
on machine
ue/DEF injector.
• This failure code occurs only in the “SCR Denitration Efficiency Test”(denitration efficiency
test time is up to 1.5 hours) implemented to locate the failure points when a failure code
Related such as [CA3151], [CA3543], and [CA3582] is displayed.
information • For the procedure to remove and change the AdBlue/DEF injector, see “Disassembly and
NOTICE
pair, perform a “Loaded Diagnostics Operation To Clear Failure Code” to make sure the
failure code is cleared. (This failure code is not cleared by turning ON the starting
switch.)

2. Remove the AdBlue/DEF injector.
3. Refer to “Testing and adjusting”, “SETTING AND OPERATION OF MA-
1 CHINE MONITOR”, “Service mode”, “Operation method of testing menu
jector
(SCR Service Test)” to perform an “AdBlue/DEF injector injection amount
test” to judge the injector.
3. See Testing and adjusting, “service modes” of “setting and operating ma-
chine monitor”, “operating method of testing menu (SCR service test)” to
Clogged AdBlue/DEF perform an “AdBlue/DEF pump pressure rising test”.
2
supply line 4. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in
the AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
minutes while performing the “AdBlue/DEF pump pressure rising test”.
D155AX-8 40-647
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degra-
dation Error 40 TROUBLESHOOTING

3
outlet NOx sensor
4. Performing “Loaded Diagnostics Operation To Clear Failure Code”.
(Offset/drift due to sulfur-poisoned SCR outlet NOx sensor)
Defective SCR outlet 1. Turn starting switch to OFF position.
4
NOx sensor 2. Replace the SCR outlet NOx sensor.
tive.
damaged rectifier)
Defective air intake sys- 1. Check for a defective air intake pipe and repair or replace any damaged or
5
tem defective rectifier, if any.
2. Replace mass air flow (MAF) sensor.
6

2. Turn the starting switch to ON position, and start engine.
3. Run the engine at low speed idle safely.
4. See “TESTING AND ADJUSTING”, “Service mode” and “Test menu (SCR Service Test)” in “SETTING AND
OPERATION OF MACHINE MONITOR” to perform “SCR removal efficiency test” (maximum duration of the
removal efficiency: 1.5 h).
5. The test condition on the monitor changes from “0” to “10”, then to “20”. (“14” may be shown temporarily
due to temperature transition)
6. When the test is completed after the test condition on the monitor shows “20”, stop the engine and shut
down the engine controller (wait for a few minutes after the shutdown, then the starting switch to OFF posi-
tion).
7. Turn the starting switch to the ON position again to check if this failure code is cleared. If the failure code is
cleared, repair work is completed.
REMARK
40-648 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2

Action level Failure code AdBlue/DEF Low Concentration Error 2
Failure
Detail of fail-
The more NOx emission increases, the lower concentration AdBlue/DEF gets.
ure
• Advances to Inducement strategy (EU Specification).
Action of
• AdBlue/DEF injection stops (EU Specification).
controller
• AdBlue/DEF pump stops (EU Specification).
Phenomenon • Engine power deration according to inducement strategy (EU Specification).
on machine • AdBlue/DEF injection stops.
• If SCR efficiency is degraded due to lowered AdBlue/DEF concentration, failure code
[CA3582] SCR Catalyst Efficiency Low Error 1 may be displayed.
• A surface in AdBlue/DEF fluctuates more in work on slopes or travel on uneven ground,
possibly disabling to detect the correct level or concentration.
• If AdBlue/DEF level monitor is illuminated in red or a warning on the concentration ap-
pears, move to a flat place as soon as possible and refill AdBlue/DEF. If this phenomenon
persists, refill AdBlue/DEF extra in AdBlue/DEF tank.
• If AdBlue/DEF tank temperature is 0 °C or below, the engine controller does not trouble-
shoot this failure code (“Loaded Diagnostics Operation To Clear Failure Code” does not
clear this failure code).
• Make sure that AdBlue/DEF tank temperature is 0 °C or above on the Pre-defined Monitor-
ing screen before troubleshooting this failure code.
• When AdBlue/DEF tank level is 0 %, the engine controller does not troubleshoot this fail-
ure code (“Loaded Diagnostics Operation To Clear Failure Code” does not clear this failure
code).
• Make sure that AdBlue/DEF tank temperature is 20 % or above on the Pre-defined Moni-
toring screen before troubleshooting this failure code.
Related • For draining and cleaning procedures of AdBlue/DEF tank, see Testing and adjusting,
information
“AdBlue/DEF Tank Washing”.
• For the replacement procedure of AdBlue/DEF level sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF level sensor”.
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF level and
AdBlue/DEF quality sensors are used (the figures below denote monitoring codes).
NOTICE
agnostics Operation To Clear Failure Code” to make sure that the failure code is
cleared.
D155AX-8 40-649
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 40 TROUBLESHOOTING

1. If failure code [CA1669] or [CA1677] or [CA1678] or [CA1686] or [CA1714]
or [CA1715] or [CA3868] or [CA4277] or [CA4731] or [CA4732] or
Defective AdBlue/DEF [CA4739] or [CA4768] or [CA4769] is displayed, perform troubleshooting
1 these first.
tank sensor system
2. If troubleshooting has been performed, carry out “Loaded Diagnostics Op-
eration To Clear Failure Code” topics.
1. Check that the “AdBlue/DEF concentration” displayed on the Pre-defined
Monitoring screen is in the normal range (29 to 36 %).
2. If the “AdBlue/DEF concentration” is normal, perform “Loaded Diagnostics
Operation To Clear Failure Code”.
3. If the “AdBlue/DEF concentration” falls outside of this range, use a porta-
Low AdBlue/DEF con-
ble concentration meter to recheck the concentration. If the concentration
2 centration (entrained wa-
still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
ter, etc.)
from the tank and refill with fresh AdBlue/DEF.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the portable concentration meter reading is in the range of 31.5 to
33.5 %, proceed to the next troubleshooting.
1. Drain more than 1 ℓ of AdBlue/DEF to check that it is not contaminated
with foreign material, etc.
2. If the drained AdBlue/DEF is contaminated, drain all of the AdBlue/DEF
and refill with fresh AdBlue/DEF.
Contaminated 3. If it is heavily contaminated with sand, dirt, etc., clean the AdBlue/DEF
3
AdBlue/DEF tank.
5. If the “AdBlue/DEF concentration” is out of the normal range, proceed to
the next troubleshooting.
1. Remove the AdBlue/DEF level sensor to gain access to the “AdBlue/DEF
concentration” sensing part (end of sensor).
2. Wipe the “AdBlue/DEF concentration” sensing part with a dry, clean cloth.
Foreign matter adhered Install the AdBlue/DEF level sensor.
4 to the sensing part of the 3. If the “AdBlue/DEF concentration” displayed on the Pre-defined Monitoring
AdBlue/DEF tank sensor screen falls in the range of 29 to 36 %, perform “Loaded Diagnostics Oper-
ation To Clear Failure Code” topics to complete the repair.
4. If the “AdBlue/DEF concentration” falls outside of this range, proceed to
2. If the “AdBlue/DEF concentration” displayed on the Pre-defined Monitoring
screen falls in the range of 29 to 36%, perform “Loaded Diagnostics Oper-
5 tank sensor (internal de-
fect)
1. Replace the engine controller.
Defective engine control- 2. If “AdBlue/DEF concentration” ranges from 29 to 36 % on the Trouble-
6
ler shooting Pre-defined Monitoring screen, perform “Loaded Diagnostics Op-
eration To Clear Failure Code” and repair is completed.
40-650 D155AX-8

3. Display monitoring code 19115 “AdBlue/DEF Temperature in Tank” on the Troubleshooting Pre-defined
Monitoring screen.
4. Stand by with the lever and pedal of the machine not operated.
Standby time depends on the initial value of the AdBlue/DEF Temperature in tank as follows:
• When the value is 0 °C or below, run the engine and wait for 0 °C or above in tank temperature (about
60 minutes).
• When the value ranges from 0 to 5 °C, stand by for 30 minutes(engine may be either started or not).
• When the value is 5 °C or above, stand by for 10 minutes(engine may be either started or not).
D155AX-8 40-651
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1

Action level Failure code AdBlue/DEF Low Concentration Error 1
Failure
Detail of fail-
AdBlue/DEF low concentration (25 % or below) is detected.
ure
Action of
None in particular
controller
Phenomenon
AdBlue/DEF is consumed largely
on machine
No error is displayed on the machine monitor.
A surface in AdBlue/DEF fluctuates more in work on slopes or travel on uneven ground, possibly
disabling to detect the correct level or concentration.
If AdBlue/DEF level monitor is illuminated in red or a warning on the concentration appears, move to
a flat place as soon as possible and refill AdBlue/DEF. If this phenomenon persists, refill
AdBlue/DEF extra in AdBlue/DEF tank.
• Make sure that AdBlue/DEF tank temperature is 0 °C or above on the “Pre-defined Moni-
toring” screen before troubleshooting this failure code.
• When AdBlue/DEF level is 0 %, the engine controller does not troubleshoot this failure
code (“Loaded Diagnostics Operation To Clear Failure Code” does not clear this failure
code).
• Make sure that AdBlue/DEF tank temperature is 20 % or above on the “Pre-defined Moni-
Related • For draining and cleaning procedures of AdBlue/DEF tank, see Testing and adjusting,
“CLEAN AdBlue/DEF TANK”.
information
• For the replacement procedure of AdBlue/DEF/level sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF/level sensor”.
• On the “Pre-defined Monitoring” screen troubleshooting for AdBlue/DEF level and
AdBlue/DEF quality sensors are used.
NOTICE
40-652 D155AX-8

1 these first.
tank sensor system
Low AdBlue/DEF con-
ble concentration meter to recheck the concentration. If the concentration
2 centration (entrained wa-
still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
ter, etc.)
3
AdBlue/DEF tank.
fect)
6
D155AX-8 40-653

Monitoring screen.
Standby time depends on the initial value of the AdBlue/DEF Temperature in tank as follows:
• When the value is 0 °C or below, run the engine and wait for 0 °C or above in tank temperature (about
60 minutes).
• When the value ranges from 0 to 5 °C, stand by for 30 minutes(engine may be either started or not).
• When the value is 5 °C or above, stand by for 10 minutes(engine may be either started or not).
40-654 D155AX-8
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error

Action level Failure code AdBlue/DEF Tank Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller cannot receive the data of the AdBlue/DEF tank sensor due to error of com-
ure munication with the AdBlue/DEF tank sensor.
Action of
controller
• The AdBlue/DEF level, quality, and temperature cannot be measured.
Phenomenon
• The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
on machine
• The AdBlue/DEF tank is a smart sensor which performs CAN communication with the en-
gine controller together with the other sensors.
• If the sensor connector or smart sensor (power supply) relay connector is disconnected,
this failure code is displayed.
• The failure codes of the CAN communication related to the engine sensor are [CA2771],
[CA3232], [CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are
displayed, the cause may be defective smart sensor power supply relay, defective relay
Related system, or ground fault, short circuit, or hot short circuit of the harness (CAN communica-
information tion line).
using multimeter.
• The AdBlue/DEF tank sensor is composed of the AdBlue/DEF level sensor, AdBlue/DEF
temperature sensor, and AdBlue/DEF quality sensor and provides CAN communication
with the engine controller integrated into one sensor controller.

1
connector
2
3. Disconnect connectors J2 and UREA, and connect T-adapters to each fe-
communication line)
male side.
Approx.
Between UREA (female) (2) and (1)
60 Ω
Resistance
Approx.
60 Ω
D155AX-8 40-655

• Power line
2. Disconnect connector UREA and connect T-adapter to female side.
ness (wire breakage or Voltage Between UREA (female) (4) and (3) Min. 22 V
line)
2. Disconnect connectors SSR and UREA and connect T-adapters to each
female side.
Between SSR (female) (11) and UREA (female) (4) Max. 1 Ω
Resistance
Between UREA (female) (3) and ground Max. 1 Ω
quired.
Disconnect connectors J2, UREA , CTN2, and CTN, and connect T-adapt-
nector) (broken commu- Between J2 (female) (21) and UREA (female) (2) Max. 1 Ω
nication line)
Between J2 (female) (45) and UREA (female) (1) Max. 1 Ω
Between CTN2 (female) (A) and UREA(female) (2) Max. 1 Ω
Resistance
Between CTN2 (female) (B) and UREA (female) (1) Max. 1 Ω
Between CTN (female) (A) and UREA (female) (2) Max. 1 Ω
Between CTN (female) (B) and UREA (female) (1) Max. 1 Ω
ground circuit)
Min. 1 MΩ
Resistance
Min. 1 MΩ
40-656 D155AX-8

6
(3), and UREA (2).
Voltage
(2), and UREA (1).
2. Replace AdBlue/DEF tank sensor (UREA).
Defective AdBlue/DEF 3. Turn starting switch to ON position.
7
tank sensor
If this failure code is cleared, the original sensor was defective. (In case of an inter-
nal defect, troubleshooting is impossible as an assembly. Replace whole assem-
bly.)
ler
D155AX-8 40-657
40-658 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error

Action level Failure code SCR NH3 Sensor Circuit Error
Failure
Detail of fail-
Ammonia sensor controller detected an ammonia sensor circuit error.
ure
Action of • Uses AdBlue/DEF injection control without using the ammonia sensor.
controller • Advances to Inducement strategy. (EU Specification).
k
SCR assembly, the sensor installation piping, and the sensor probe become hot (400 °C).
Be careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the ambi-
ent temperature is not high.
• If the ammonia sensor controller detects a circuit error of the ammonia sensor, the error is
sent to the engine controller via CAN communication, and this failure code is displayed.
• This failure code is displayed when a connector at the sensor probe is removed during the
machine operation. In this case, failure code [CA3935] is displayed when setting the start-
ing switch to ON position.
• If the exhaust temperature is 150 °C or below, this sensor does not detect any value (The
sensor does not work by only setting the starting switch to ON position even if the sensor
is normal).
Related
• On the “Pre-defined Monitoring” screen troubleshooting for the engine operation state are
information used (the figures below denote monitoring codes).
Engine operation state troubleshooting
01002 Engine Speed
19200 Exhaust Gas Flow Rate
NOTICE
agnostics Operation To Confirm Failure Correction” to make sure that the failure code is
cleared.

1
connector 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code persists after the above checks, the sensor may be defective.
Defective ammonia sen- 2. Replace the ammonia sensor.
2
sor
If the failure code is cleared, the original ammonia sensor may be defective.
D155AX-8 40-659
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error 40 TROUBLESHOOTING

1. Perform the above checks and “Loaded Diagnostics Operation To Confirm
Failure Correction”.
2. If this failure code is displayed in above diagnosis, replace an ammonia sensor
Defective ammonia sen- controller.
3
sor controller
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.
4

3. Run the engine at high idle speed to raise the exhaust gas temperature. (Keep the engine speed so that
monitoring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is cleared after 1 minute.
REMARK
40-660 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error

Action level Failure code SCR NH3 Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller does not receive ammonia sensor data due to a communication error with the
ure ammonia sensor.
• The ammonia sensor is separated from the sensor controller and communicated via CAN
with the engine controller along with other sensors.
• This failure code is displayed if the sensor controller's connector or a smart sensor (power
Related supply) relay connector is disconnected.
information • CAN communication failure codes related to engine sensors include [CA2771], [CA3232],
defect in any of the 6 sensors, a defective smart sensor power supply relay/relay system,
or a ground fault, short circuit, or hot short circuit in wiring harness (CAN communication
line) can be suspected.
using multimeter.

1
connector
2
communication line) 3. Disconnect connectors J2 and NH3 and connect T-adapters to each fe-
male side.
Approx.
Between NH3 (female) (2) and (3)
60 Ω
Resistance
Approx.
60 Ω
D155AX-8 40-661
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error 40 TROUBLESHOOTING

• Power line
2. Disconnect connector NH3, and connect T-adapter to female side.
ness (wire breakage or Voltage Between NH3 (female) (1) and (4) Min. 22 V
line)
2. Disconnect connectors SSR, and NH3 and connect T-adapters to each fe-
male side.
Between SSR (female) (7) and NH3 (female) (1) Max. 1 Ω
Resistance
Between NH3 (female) (4) and ground Max. 1 Ω
quired.
Disconnect connectors J2, NH3, CTN2, and CTN, and connect T-adapters
to each female side.
nector) (broken commu- Between J2 (female) (21) and NH3 (female) (2) Max. 1 Ω
nication line)
Between J2 (female) (45) and NH3 (female) (3) Max. 1 Ω
Between CTN2 (female) (A) and NH3 (female) (2) Max. 1 Ω
Resistance
Between CTN2 (female) (B) and NH3 (female) (3) Max. 1 Ω
Between CTN (female) (A) and NH3 (female) (2) Max. 1 Ω
Between CTN (female) (B) and NH3 (female) (3) Max. 1 Ω
ground circuit)
Min. 1 MΩ
Resistance
Min. 1 MΩ
40-662 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error

6
(3), and UREA (2).
Voltage
(2), and UREA (1).
2. Replace the ammonia sensor (NH3).
sor
ler
D155AX-8 40-663
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error 40 TROUBLESHOOTING
40-664 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error

Action level Failure code SCR NH3 Sensor Heater Warming up Error
Failure
Detail of fail-
Temperature control of the ammonia sensor is not working correctly.
ure
controller • Advances to Inducement strategy (EU Specification).
on machine • Engine output is reduced based on inducement strategy (EU Specification).
k
SCR assembly, the sensor installation piping, and the sensor probe become hot (min.
• On the Pre-defined Monitoring screen troubleshooting for the engine operation state is
used (the figures below denote monitoring codes).
Related
information 01002 Engine Speed
NOTICE
cleared.

Defective ammonia sen- If failure code [CA3899], [CA3911], [CA3932], [CA3933], [CA3934], [CA3935] or
sor system [CA3936] is displayed, perform troubleshooting for these failure codes first.
heater)
2
3
sor
D155AX-8 40-665
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error 40 TROUBLESHOOTING

2. If this failure code is displayed in above diagnosis, replace an ammonia
Defective ammonia sen- sensor controller.
4
sor controller 3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
tive.
5

REMARK
40-666 D155AX-8
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Er-
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error
Action level Failure code SCR NH3 Sensor Heater Voltage High Error
Failure
Detail of fail-
The ammonia sensor controller is determined as having excessive heater control voltage.
ure
k
SCR Ass'y, the sensor installation piping, and the sensor probe become hot (Min. 400 °C).
Be careful not to get burned.
Related
NOTICE
cleared.

1
2
sor
3
tive.
D155AX-8 40-667
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Er-

4

REMARK
40-668 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error
Action level Failure code SCR NH3 Sensor Heater Voltage Low Error
Failure
Detail of fail-
The ammonia sensor controller is determined as having heater control under-voltage.
ure
k
Related
NOTICE
cleared.

1
2
sor
3
tive.
D155AX-8 40-669
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error 40 TROUBLESHOOTING

4

REMARK
40-670 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error

Action level Failure code SCR NH3 Sensor Power Interrupt Error
Failure
Detail of fail-
A momentary power failure is detected in the ammonia sensor.
ure
k
• Momentary power failure is mostly caused by defective contact. Perform visual check a
torn harness coating.
• To detect an incomplete wire breakage, sway the wiring harness as much as possible at
the resistance measurement to check if the resistance can change or not.
• If the exhaust temperature is 150 °C or below, this sensor does not detect any value (The
sensor does not work by only setting the starting switch to ON position even if the sensor
is normal).
Related • On the “Pre-defined Monitoring” screen troubleshooting for the engine operation state are
information used (the figures below denote monitoring codes).
01002 Engine Speed
NOTICE
cleared.

1
supply relay system
Defective sensor power 3. Insert T-adapter into connector SSR.
2 supply relay (defective in- 4.
Disconnect connector NH3.
ternal circuit)
Voltage Between SSR (7) and (4) Min. 22 V
D155AX-8 40-671
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error 40 TROUBLESHOOTING

Open circuit in wiring har- 2. Disconnect connector NH3 and connect T-adapter to female side.
3
ness 3. Turn starting switch to ON position.
Voltage Between NH3 (female) (1) and (4) Min. 22 V
1. Perform the above checks and “Loaded Diagnostics Operation To Confirm
Failure Correction”.
2. If this failure code is displayed in above diagnosis, replace an ammonia sensor
Defective ammonia sen- controller.
4
sor controller
tive.
1. If the failure code persists after the above checks, replace the engine con-
troller.
5 2.
ler Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code disappeared, the engine controller may be defective.
1. If the failure code persists after the above checks, replace the engine harness.
6 Defective engine harness 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the engine harness may be defective.

REMARK
40-672 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error
CIRCUIT DIAGRAM (AMMONIA SENSOR)
D155AX-8 40-673
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error 40 TROUBLESHOOTING
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error

Action level Failure code SCR NH3 Sensor Trim Resistance Error
Failure
Detail of fail-
The ammonia sensor controller fails to catch a resistance value of the trim attached to the probe.
ure
k
• This failure code is displayed if the sensor connector is disconnected when setting the
starting switch to ON position.
Related
information
01002 Engine Speed
NOTICE
cleared.

1
2
sor
40-674 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error

3
tive.
4

REMARK
D155AX-8 40-675
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error 40 TROUBLESHOOTING
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error

Action level Failure code SCR NH3 Sensor Internal Circuit Error
Failure
Detail of fail-
The ammonia sensor controller fails.
ure
k
• Internal failure of the sensor controller itself
Related Engine operation state troubleshooting
NOTICE
cleared.

1
2
tive.
3

40-676 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error

REMARK
D155AX-8 40-677
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Da-
talink Timeout Error 40 TROUBLESHOOTING
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink

Timeout Error
Action level Failure code KDOC and KDPF Temperature Sensor Datalink Timeout Error
Failure
• The engine controller does not receive data from KDOC inlet temperature sensor, KDOC
outlet temperature sensor, and KDPF outlet temperature sensor due to a communication
Detail of fail- error with KDPF temperature sensor.
ure • This occurs when information on the KDOC inlet temperature sensor, the KDOC outlet
temperature sensor, and the KDPF outlet temperature sensor cannot be received for a
certain amount of time.
• Run the engine by using the default value of the KDOC inlet temperature, KDOC outlet
temperature, and the KDPF outlet temperature (250 °C).
Action of • AdBlue/DEF injection stops
• Defective forcible regeneration control
Phenomenon • KDPF Soot Accumulation High
on machine • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detec-
tion error
40-678 D155AX-8
40 TROUBLESHOOTING talink Timeout Error
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over
500 °C.
k The turbocharger outlet, the sensor installation piping, KDPF, and KDOC become hot
Related or a ground fault, short circuit, or hot short circuit in wiring harness (CAN communication
information line) can be suspected.
using multimeter.
code is cleared).

1
connector
2
3. Disconnect connectors J2 and DPFJ and connect T-adapters to each fe-
communication line)
male side.
Approx.
Between DPFJ (female) (3) and (2)
60 Ω
Resistance
Approx.
60 Ω
D155AX-8 40-679

• Power line
2. Disconnect connector DPFJ and connect T-adapter to female side.
ness (wire breakage or Voltage Between DPFJ (female) (4) and (1) Min. 22 V
line)
2. Disconnect connectors SSR, and DPFJ and connect T-adapters to each
female side.
Between SSR (female) (8) and DPFJ (female) (4) Max. 1 Ω
Resistance
Between DPFJ (female) (1) and ground Max. 1 Ω
quired.
Disconnect connectors J2, DPFJ, CTN2, and CTN, and connect T-adapt-
nector) (broken commu- Between J2 (female) (21) and DPFJ (female) (3) Max. 1 Ω
nication line)
Between J2 (female) (45) and DPFJ (female) (2) Max. 1 Ω
Between CTN2 (female) (A) and DPFJ (female) (3) Max. 1 Ω
Resistance
Between CTN2 (female) (B) and DPFJ (female) (2) Max. 1 Ω
Between CTN (female) (A) and DPFJ (female) (3) Max. 1 Ω
Between CTN (female) (B) and DPFJ (female) (2) Max. 1 Ω
ground circuit)
Min. 1 MΩ
Resistance
Min. 1 MΩ
40-680 D155AX-8
40 TROUBLESHOOTING talink Timeout Error

6
(3), and UREA (2).
Voltage
(2), and UREA (1).
Defective KDPF temper-
ature sensor
ler
D155AX-8 40-681
40-682 D155AX-8
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error

Action level Failure code SCR Temperature Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller does not receive SCR temperature sensor data due to a communication error
ure with the SCR temperature sensor.
• Stops AdBlue/DEF injection.
Action of • Runs the SCR temperature sensor and the SCR outlet temperature sensor using the last
controller normal values.
Phenomenon
on machine
• SCR temperature and SCR outlet temperature detection error
k
or a ground fault, short circuit, or hot short circuit in wiring harness (CAN communication
Related line) can be suspected.
information • Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• For replacement of the SCR temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“DISASSEMBLE AND ASSEMBLE SCR TEMPERATURE SENSOR”.

1
connector
2
communication line) 3. Disconnect connectors J2 and SCRJ and connect T-adapters to each fe-
male side.
Approx.
Between SCRJ (female) (3) and (2)
60 Ω
Resistance
Approx.
60 Ω
D155AX-8 40-683

• Power line
2. Disconnect connector SCRJ and connect T-adapter to female side.
ness (wire breakage or Voltage Between SCRJ (female) (4) and (1) Min. 22 V
line)
2. Disconnect connectors SSR and SCRJ and connect T-adapters to each fe-
male side.
Between SSR (female) (9) and SCRJ (female) (4) Max. 1 Ω
Resistance
Between SCRJ (female) (1) and ground Max. 1 Ω
quired.
Disconnect connectors J2, SCRJ, CTN2, and CTN, and connect T-adapt-
nector) (broken commu- Between J2 (female) (21) and SCRJ (female) (3) Max. 1 Ω
nication line)
Between J2 (female) (45) and SCRJ (female) (2) Max. 1 Ω
Between CTN2 (female) (A) and SCRJ (female) (3) Max. 1 Ω
Resistance
Between CTN2 (female) (B) and SCRJ (female) (2) Max. 1 Ω
Between CTN (female) (A) and SCRJ (female) (3) Max. 1 Ω
Between CTN (female) (B) and SCRJ (female) (2) Max. 1 Ω
ground circuit)
Min. 1 MΩ
Resistance
Min. 1 MΩ
40-684 D155AX-8

6
(3), and UREA (2).
Voltage
(2), and UREA (1).
2. Replace SCR temperature sensor (SCRJ).
ture sensor
ler
D155AX-8 40-685
40-686 D155AX-8
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High

Error
Action level Failure code AdBlue/DEF Pump Heater Relay Voltage High Error
Failure
Detail of fail-
A high voltage error is detected in AdBlue/DEF pump heater relay circuit.
ure
Action of
controller
Phenomenon
• AdBlue/DEF thawing defective.
on machine
• AdBlue/DEF pump heater relay is driven at AdBlue/DEF supply system thawing/thermal
insulation or an AdBlue/DEF pump heater relay test.
• AdBlue/DEF pump heater relay is integrated in the AdBlue/DEF heater relay.
Related
AdBlue/DEF heater relay to ground.
information
• This failure code is detected only when the AdBlue/DEF pump heater relay is turned OFF.
• This failure code is displayed if the connector is removed.

ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. See “service modes” of “setting and operating machine monitor”, “operating
1
connector method of testing menu (SCR service test)” to perform an “AdBlue/DEF pump
heater relay test”.
Open circuit in wiring har- 2. Disconnect connectors J2 and DSM and connect T-adapters to each female
ness (wire breakage or side.
2
nector) Between UHR1 (female) (12) and ground Max. 1 Ω
Resistance
Hot short circuit in wiring 2. Disconnect connector UHR1 and connect T-adapter to female side.
3
Voltage Between UHR1 (female) (3) and (12) Max. 4.5 V
D155AX-8 40-687

Defective AdBlue/DEF 3. Disconnect connector UHR1 and UHR2, and replace AdBlue/DEF heater
4 relay.
heater relay
ler
40-688 D155AX-8
Electrical circuit diagram related to AdBlue/DEF heater relay
D155AX-8 40-689
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Er-
ror
Action level Failure code AdBlue/DEF Pump Heater Relay Voltage Low Error
Failure
Detail of fail-
A low voltage error is detected in AdBlue/DEF pump heater relay circuit.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF thawing defective.
• AdBlue/DEF pump heater relay is driven at AdBlue/DEF supply system thawing/thermal
insulation or “a AdBlue/DEF pump heater relay test”.
• AdBlue/DEF pump heater relay is integrated in the AdBlue/DEF heater relay.
Related AdBlue/DEF heater relay to ground.
information • This failure code is detected only when the AdBlue/DEF pump heater relay is turned ON.
Procedure: Start the engine in low temperature (ambient temperature of 5 °C or below) or
see “service modes” of “setting and operating machine monitor”, and “explanation of oper-
ating method of testing menu (SCR service test)” to perform “AdBlue/DEF pump heater re-
lay test”.

ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. See “service modes” of “setting and operating machine monitor”, “operating
1
connector method of testing menu (SCR service test)” to perform an “AdBlue/DEF pump
heater relay test”.
2 REMARK
fuse box F01
Open circuit in wiring har- 2. Disconnect connectors J2 and DSM and connect T-adapters to each female
ness (wire breakage or side.
3
nector) Between UHR1 (female) (12) and ground Max. 1 Ω
Resistance
2. Disconnect connectors J2 and UHR1, and connect T-adapter to either female
harness
4 side.
(Contact with ground cir-
cuit) Between ground and J2 (female) (83) or UHR1 (fe-
male) (3)
40-690 D155AX-8

Defective AdBlue/DEF 3. Disconnect connector UHR1 and UHR2, and replace AdBlue/DEF heater
5 relay.
heater relay
ler
D155AX-8 40-691
Electrical circuit diagram related to AdBlue/DEF heater relay
40-692 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction

Action level Failure code AdBlue/DEF FCV Malfunction
Failure
Detail of fail-
A FCV (valve for purge) valve inside the AdBlue/DEF pump may be defective.
ure
Action of
AdBlue/DEF intake is inhibited.
controller
Phenomenon
Pump may break when it is frozen and it may result in failure of AdBlue/DEF injection.
on machine
• The engine controller does not display this failure code when controlling thawing of the
AdBlue/DEF supply system (because AdBlue/DEF injection is disabled and no judgment
cannot be made).
• 3 minutes after engine started, make sure that the value of the following 4 state is other
than 1 (Thawing). (This failure cannot be repaired until thawing control is complete.)
• State of each heater is either 1: Thawing 2: Heating 3 or 0: OFF. (Check the value by en-
tering a figure directly on the monitoring code screen).
19306 AdBlue/DEF intake return line heater state
19309 AdBlue/DEF Pump Heater State
• The Pre-defined Monitoring screen troubleshooting for AdBlue/DEF pump and aftertreat-
ment system are used (the figures below denote monitoring codes).
• Troubleshooting for AdBlue/DEF pump
19304 AdBlue/DEF Pump State
Related
information
19109 AdBlue/DEF Pump PressSensor Volt
• Aftertreatment system
47000 KDPF outlet differential pressure
47200 KDPF outlet temperature 1
47300 KDOC inlet temperature 1
47400 KDOC outlet temperature 1
19305 Dosing Fuel Pressure
NOTICE
After inspecting cause of failure and performing repair, perform “Loaded Diagnostics Opera-
tion To Clear Failure Code”, and check that this failure code is canceled. (Display of this fail-
ure code is not canceled by simply turning starting switch to ON position)

If failure code [CA2976] or [CA3558] or [CA3559] or [CA3571] or [CA3572] or
1 [CA3577] or [CA3578] is displayed on the abnormality record screen, perform trou-
pump system
bleshooting these first.
2
pump
D155AX-8 40-693
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction 40 TROUBLESHOOTING

3

ice)” in “SETTING AND OPERATION OF MACHINE MONITOR” to perform “Manual Stationary Regenera-
tion”.
4. Check monitoring code 47200 “KDPF outlet temperature” exceeds 300 °C and monitoring code 19108
“AdBlue/DEF pump pressure” is around 900 kPa on the Pre-defined Monitoring screen.
REMARK
For judgment criteria of this troubleshooting, it is necessary to raise exhaust gas temperature by using man-
ual stationary regeneration for KDPF outlet temperature to be 300 °C or more.
5. Stop “Manual Stationary Regeneration”.
6. Turn the starting switch OFF while the KDPF outlet temperature is 300 °C or more and stop the engine.
REMARK
If the KDPF outlet temperature is 400 °C or more, do not stop the engine to protect devices.
7. Shut down the engine controller, and turning the starting switch ON position.
REMARK
40-694 D155AX-8
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor In-
40 TROUBLESHOOTING ternal Circuit Error
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal

Circuit Error
Action level Failure code KDOC and KDPF Temperature Sensor Internal Circuit Error
Failure
Detail of fail- An abnormality was detected in any of the sensor circuits: KDOC inlet temperature sensor, KDOC
ure outlet temperature sensor, and KDPF outlet temperature sensor.
• Operate with the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature set to the default value (250 °C).
on machine • Any of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
ture cannot be detected.
• The KDPF temperature sensor is composed of the KDOC inlet temperature sensor, the
KDOC outlet temperature sensor, and the KDPF outlet temperature sensor and provides
CAN communication with the engine controller integrated into one sensor controller.
Related • For the replacement procedure of the KDPF temperature sensor, see “DISASSEMBLY
AND ASSEMBLY”, “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
information
code is cleared).

1
connector
ature sensor
ler
D155AX-8 40-695
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error

Action level Failure code SCR Temperature Sensor Internal Circuit Error
Failure
Detail of fail- An abnormality is detected in either of the sensor circuits: SCR temperature sensor and SCR outlet
ure temperature sensor.
• The SCR temperature sensor and SCR outlet temperature sensor operate at the latest
Action of normal value.
• Defective detection of SCR temperature or SCR outlet temperature
Phenomenon
on machine
k
The SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
Related sensor controller which provides CAN communication with the engine controller.
information • For the replacement procedure of the SCR temperature sensor, see “Disassembly and as-

1
connector
whole assembly.)
ler
40-696 D155AX-8
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU
40 TROUBLESHOOTING Voltage High Error
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Volt-
age High Error
Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage High Error
Failure
Detail of fail-
A battery high voltage error is detected in the KDPF temperature sensor controller.
ure
• Run the engine by using the fixed value of the KDOC inlet temperature, KDOC outlet tem-
perature, and the KDPF outlet temperature (250 °C).
Phenomenon • KDPF accumulated soot level is high
on machine • All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
Related • For replacement of the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY,
information
code is cleared).

1
connector
D155AX-8 40-697
Voltage High Error 40 TROUBLESHOOTING

1. Check that system operating lamp is not lit, and then turn the battery discon-
nect switch to OFF position.
3. Disconnect connector SSR and connect T-adapter to female side.
2 High battery voltage
Between SSR (female) (1) and (4) 22 to 30 V
Voltage Between SSR (female) (2) and (4) 22 to 30 V
ature sensor
ler
40-698 D155AX-8
40 TROUBLESHOOTING Voltage High Error
Circuit diagram related to KDOC/KDPF temperature sensor
D155AX-8 40-699
Voltage Low Error 40 TROUBLESHOOTING
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Volt-
age Low Error
Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage Low Error
Failure
Detail of fail-
A battery low voltage error is detected in the KDPF temperature sensor controller.
ure
• Run the engine by using the fixed value of the KDOC inlet temperature, KDOC outlet tem-
perature, and the KDPF outlet temperature (250 °C).
on machine • All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
Related
information
code is cleared).

1
connector
ature sensor
40-700 D155AX-8
40 TROUBLESHOOTING Voltage Low Error

3 Low battery voltage
ler
D155AX-8 40-701
Voltage Low Error 40 TROUBLESHOOTING
40-702 D155AX-8
40 TROUBLESHOOTING Over Temperature Error
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over
Temperature Error
Action level Failure code KDOC and KDPF Temperature Sensor ECU Over Temperature Error
Failure
Detail of fail-
KDOC/KDPF temperature sensor controller temperature high error
ure
Action of
None in particular
controller
Phenomenon
• All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
on machine
• For replacement of the KDPF temperature sensor, see Disassembly and assembly, “Dis-
Related assembly and assembly of KDPF assembly”.
information NOTICE
ing switch)

Exhaust gas leakage Check if the temperature sensor controller environmental temperature is extraordi-
1 (high environmental tem- nary high (150 °C or above).
perature)
Defective KDPF temper- 3. Turn starting switch to ON position.
2
ature sensor 4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
ler

REMARK
troubleshooting.
D155AX-8 40-703
Over Temperature Error 40 TROUBLESHOOTING

40-704 D155AX-8
40 TROUBLESHOOTING Over Temperature Error
D155AX-8 40-705
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Er-
ror
Action level Failure code SCR Temperature Sensor ECU Voltage High Error
Failure
Detail of fail-
High voltage error is detected in power supply voltage of SCR temperature sensor controller.
ure
• The SCR temperature and SCR outlet temperature are the latest normal value for opera-
Action of tion.
• Defective detection of SCR temperature and SCR outlet temperature
Phenomenon
on machine
k
information • For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.

1
connector
2 High battery voltage
whole assembly.)
ler
40-706 D155AX-8
Electrical circuit diagram related to SCR temperature sensor
D155AX-8 40-707
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Er-
ror
Action level Failure code SCR Temperature Sensor ECU Voltage Low Error
Failure
Detail of fail-
Low voltage error is detected in power supply voltage of SCR temperature sensor controller.
ure
• The SCR temperature and SCR outlet temperature are the latest normal value for opera-
Action of tion.
Phenomenon
on machine
k
information • For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.

1
connector
2 Low battery voltage
whole assembly.)
ler
40-708 D155AX-8
D155AX-8 40-709
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Tem-
perature Error 40 TROUBLESHOOTING
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Tempera-

ture Error
Action level Failure code SCR Temperature Sensor ECU High Temperature Error
Failure
Detail of fail- High temperature error is detected in SCR temperature sensor controller.
ure (Min. 150 °C)
Action of
None in particular
controller
Phenomenon
on machine
k
• For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
Related ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.
information NOTICE
ing switch)

Exhaust gas leakage Check if the temperature sensor controller environmental temperature is extraordi-
1 (high environmental tem- nary high (150 °C or above).
perature)
Defective SCR tempera- 3. Turn starting switch to ON position.
2 ture sensor (internal de-
fect) 4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
ler

REMARK
troubleshooting.
40-710 D155AX-8
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Tem-
40 TROUBLESHOOTING perature Error

D155AX-8 40-711
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error 40 TROUBLESHOOTING
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error

Action level Failure code AdBlue/DEF Pump Heater ON Stuck Error
Failure
Detail of fail- • A pump drive in AdBlue/DEF heater relay is working unnecessarily.

ure • AdBlue/DEF heater relay (pump heater relay) may be defective.
Action of
None in particular
controller
Phenomenon
AdBlue/DEF pump is defective.
on machine
• This failure code may be displayed when there is a hot heat source around the
AdBlue/DEF pump.
• If the initial temperature of 19136 AdBlue/DEF Pump Temperature is found to exceed
42 °C from this troubleshooting, the “Loaded Diagnostics Operation To Confirm Failure
Correctionis” not available repair result cannot be judged.
• When it is not in normal low temperature, 19309 AdBlue/DEF Pump Heater State stays as
“0”. (1: Thawing 2: Heating 3 or 0: OFF)
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF pump thawing con-
trol is used (the figures below denote monitoring codes).
• Troubleshooting for AdBlue/DEF pump thawing control
Related 19107 AdBlue/DEF Pump Heater Control Command
information 19309 AdBlue/DEF Pump Heater State
03203 Battery Power Supply
NOTICE
pair.)

Defective AdBlue/DEF Perform troubleshooting for failure code [CA3558] or [CA3559] or [CA2976].
1
pump system
Defective AdBlue/DEF Perform troubleshooting for failure codes [CA4155] and [CA4156].
2 pump heater relay sys-
tem
Check for ambient temperature of 5 °C or above (condition under which
AdBlue/DEF pump heater is not working).
3 2. Disconnect connector DSM and connect T-adapter to female side.
harness
ler
40-712 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error

1. Turn starting switch to ON position (Do not start the engine).
2. Check if monitoring code 19136 “AdBlue/DEF Pump Temperature” is 42 °C or less and 19107“AdBlue/DEF
Pump Heater 1 Command” is “0” on the Pre-defined Monitoring screen.
3. Wait for 10 minutes.
4. If the AdBlue/DEF Pump Temperature rises 12 °C or less after the starting switch is turned to ON, repair will
be completed.
screen.
REMARK
If the AdBlue/DEF Pump Temperature rises up to 12 °C or more after the starting switch is turned to ON, return
to troubleshooting.
D155AX-8 40-713
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error 40 TROUBLESHOOTING
Electrical circuit diagram related to AdBlue/DEF pump heater
40-714 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error

Action level Failure code AdBlue/DEF Pump Heater OFF Stuck Error
Failure
Detail of fail-
AdBlue/DEF pump thawing is not complete.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF pump thawing con-
trol is used.
• 19309 “AdBlue/DEF Pump Heater State”, 1: Thawing 2: Heating 3 or 0: OFF
(the figures below denote monitoring codes).
Troubleshooting for AdBlue/DEF pump thawing control
19107 AdBlue/DEF Pump Heater Control Command
Related 03203 Battery Power Supply
information NOTICE
agnostics Operation To Confirm Failure Correction” to check if the repair is completed.
(Clearing the failure code does not determine the completion of repair.)
(This failure code is not cleared by starting switch at ON position or “AdBlue/DEF pump
heater relay drive test” only.)
• If “AdBlue/DEF pump temperature ” is 45 °C or higher when starting switch is turned
to ON position, “Loaded Diagnostics Operation To Confirm Failure Correction” can-
not determine if the repair is completed successfully, therefore, wait until
“AdBlue/DEF pump temperature” becomes 45 °C or lower.
• In addition, if “AdBlue/DEF pump temperature ” is 55 °C or higher, “AdBlue/DEF
pump heater relay drive test” in “Loaded Diagnostics Operation To Confirm Failure
Correction” is disabled.

1
pump system
tem
Defective AdBlue/DEF 2. If the AdBlue/DEF pump temperature does not rise by at least 5 °C during
3
pump heater the test, replace the AdBlue/DEF pump.
ler
D155AX-8 40-715
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error 40 TROUBLESHOOTING

2. Check if monitoring code 19136 “AdBlue/DEF pump temperature” is 45 °C or below (If not, wait until moni-
toring code 19136 “AdBlue/DEF pump temperature” falls down to below 45 °C).
3. See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in “SET-
TING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF Pump Heater Relay Test”.
4. When monitoring code 19136 “AdBlue/DEF pump temperature” rises 5 °C or more from the start of testing,
repair is completed.
screen.
REMARK
When AdBlue/DEF pump temperature rises 4 °C or less from the start of testing, return to troubleshooting.
40-716 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error

Action level Failure code AdBlue/DEF Pump Thawing Error
Failure
Detail of fail-
AdBlue/DEF pump thawing is not complete.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed.
• 19309 AdBlue/DEF Pump Heater State, 1: Thawing 2: Heating 3 or 0: OFF
Related NOTICE
information After investigating the cause of the problem and completing the repair, perform “Loaded Di-
• If “AdBlue/DEF pump temperature ” is 45 °C or higher when starting switch is turned
• In addition, if “AdBlue/DEF pump temperature” is 55 °C or higher, “AdBlue/DEF

1
pump system
tem
3 REMARK
fuse box F01
Open or short circuit in 2. Disconnect connectors J2 and UHR1 and connect T-adapters to each female
4 side.
wiring harness
Resistance Between J2 (female) (54) and UHR1 (female) (2) 4 to 40 Ω
D155AX-8 40-717
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error 40 TROUBLESHOOTING

5
pump heater the test, replace the AdBlue/DEF pump.
ler

screen.
REMARK
40-718 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error
D155AX-8 40-719
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1
In Range Error 40 TROUBLESHOOTING
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In

Range Error
Action level Failure code AdBlue/DEF Pump Temperature Sensor 1 In Range Error
Failure
Detail of fail-
AdBlue/DEF pump temperature sensor 1 response is poor.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed.
Related NOTICE
• If “AdBlue/DEF pump temperature” is 45 °C or higher when starting switch is turned

1
pump system
tem
3 pump temperature sen-
the test, replace the AdBlue/DEF pump.
sor
ler
40-720 D155AX-8
40 TROUBLESHOOTING In Range Error

screen.
REMARK
D155AX-8 40-721
In Range Error 40 TROUBLESHOOTING
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In

Range Error
Action level Failure code AdBlue/DEF Pump Temperature Sensor 2 In Range Error
Failure
Detail of fail-
AdBlue/DEF pump temperature sensor 2 response is poor.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed
Related NOTICE
• If “AdBlue/DEF pump temperature” is 45 °C or higher when starting switch is turned

1
pump system
tem
3 pump temperature sen-
the test, replace the AdBlue/DEF pump.
sor
ler
40-722 D155AX-8
40 TROUBLESHOOTING In Range Error

3. See "TESTING AND ADJUSTING", “Special functions of machine monitor”, “Testing”, “SCR Service Test” to
perform “AdBlue/DEF pump heater relay drive test”.
4. Continue the test approximately for 15 minutes.
5. When on the screen displaying "Test State", Test State parameter “10” and “12” are blinking alternately ,
screen.
REMARK
If Test State does not change to “12”, return to troubleshooting.
D155AX-8 40-723
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor
Power Interrupt Error 40 TROUBLESHOOTING
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power In-
terrupt Error
Action level Failure code KDOC and KDPF Temperature Sensor Power Interrupt Error
Failure
Detail of fail- KDPF temperature sensor interrupt power failure error (12 open circuits are detected in the power
ure supply line in 60 seconds.)
Normal control
• Default value of the KDOC inlet temperature, KDOC outlet temperature, and the KDPF
outlet temperature (250 °C).
Action of
controller
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detec-
tion error
Phenomenon • Defective regeneration control
• KDPF accumulated soot level is high
• Mostly, momentary power failure is caused by defective contact and visually check a torn
harness coating and check for defective contact at the connector.
the resistance measurement to check if the resistance can change or not.
Related • Note that sensor power supply relay connector is energized even if starting switch is
information turned to OFF position.
• For replacement of the KDPF temperature sensor, see Disassembly and assembly, “Dis-
assembly and assembly of KDPF assembly”.
Procedure: Start engine and travel (vibrate the machine).
code is cleared).

1
supply relay system
40-724 D155AX-8
40 TROUBLESHOOTING Power Interrupt Error

3. Insert T-adapter into connector SSR.
2 4.
supply relay Disconnect connector DPFJ.
Open circuit in wiring har- 2. Disconnect connector DPFJ, and connect T-adapter to female side.
3
Voltage Between DPFJ (female) (4) and (1) Min. 22 V
Defective KDPF temper- If failure code is still displayed after above checks, KDPF temperature sensor may
4 ature sensor (defective be defective. (In case of an internal defect, troubleshooting is impossible as an as-
internal circuit) sembly. Replace whole assembly.)
ler
If there is no abnormality in above diagnosis, defective contact of harness is a pos-
sibility (Replace harness).
D155AX-8 40-725
Power Interrupt Error 40 TROUBLESHOOTING
40-726 D155AX-8
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error

Action level Failure code SCR Temperature Sensor Power Interrupt Error
Failure
Detail of fail- Interrupted power failure error in SCR temperature sensor is detected. (12 open circuits are detect-
ure ed in the power supply line in 60 seconds.)
• Holds the SCR temperature and the SCR outlet temperature using the last normal values.
Action of
controller
• SCR temperature and SCR outlet temperature have detection errors.
Phenomenon
on machine
• Mostly, momentary power failure is caused by defective contact and visually check a torn
harness coating and check for defective contact at the connector.
Related the resistance measurement to check if the resistance can change or not.
information • The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
• Note that smart sensor relay connector is energized even if starting switch is turned to
OFF position.
• For replacement of the SCR outlet temperature sensor, see Disassembly and assembly,
“Removal and installation of SCR temperature sensor”.
Procedure: Start engine and travel (vibrate the machine).

1
supply relay system
Defective sensor power 3. Insert T-adapter into connector SSR.
2 supply relay (defective in- 4.
Disconnect connector SCRJ.
ternal circuit)
Open circuit in wiring har- 2. Disconnect connector SCRJ, and connect T-adapter to female side.
3
Voltage Between SCRJ (female) (4) and (1) Min. 22 V
Defective SCR tempera- If failure code is still displayed after above checks, SCR temperature sensor may
4 ture sensor (internal de- be defective. (In case of an internal defect, troubleshooting is impossible as an as-
fect) sembly. Replace whole assembly.)
D155AX-8 40-727

ler
If the failure code persists even after replacing the engine controller, defective con-
tact of harness is a possibility (Replace harness).
40-728 D155AX-8
D155AX-8 40-729
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinc-
tion Impossible Error 40 TROUBLESHOOTING
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction

Impossible Error
Action level Failure code AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error
Failure
Detail of fail-
AdBlue/DEF sensor stays in disabling to measure the sensor quality.
ure
Action of
None in particular
controller
Phenomenon
Quality of AdBlue/DEF cannot be measured.
on machine
• AdBlue/DEF quality sensor is one of AdBlue/DEF tank sensors and is integrated with
AdBlue/DEF level sensor and AdBlue/DEF temperature sensor, providing CAN communi-
• When the AdBlue/DEF quality sensor cannot recognize liquid, AdBlue/DEF concentration
on the monitor shows the last value.
• Make sure that AdBlue/DEF tank temperature is 0 °C or above on the “Pre-defined Moni-
code).
• Make sure that AdBlue/DEF tank temperature is 20 % or above on the “Pre-defined Moni-
• For draining and cleaning procedures of AdBlue/DEF tank, see Testing and adjusting,
Related “AdBlue/DEF Tank Washing”.
information • For the replacement procedure of AdBlue/DEF/level sensor, see Disassembly and assem-
NOTICE
40-730 D155AX-8
40 TROUBLESHOOTING tion Impossible Error

1 these first.
tank sensor system
1. Check that the value of AdBlue/DEF level is displayed correctly with moni-
toring function.
REMARK
If AdBlue/DEF is empty and AdBlue/DEF level sensor cannot be sensed, 7 %
is displayed as the AdBlue/DEF level (compensation value).
2 Low AdBlue/DEF amount
2. When AdBlue/DEF is empty, refill AdBlue/DEF.
3. After finishing the work, perform “Loaded Diagnostics Operation To Clear
Failure Code” and the repair is completed.
4. If this failure code is displayed even if AdBlue/DEF level is displayed cor-
rectly, proceed to the next troubleshooting.
3
AdBlue/DEF tank.
fect)
Defective engine control- 2.
6 Perform “Loaded Diagnostics Operation To Clear Failure Code”.
ler
3. If this failure code is displayed, perform troubleshooting again.

D155AX-8 40-731
tion Impossible Error 40 TROUBLESHOOTING

3. Wait for 30 minutes. (It is not necessary to start the engine.)
40-732 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error

Action level Failure code SCR NH3 Sensor Stuck Response Error
Failure
Detail of fail-
Ammonia concentration in ammonia sensor changes slow.
ure
Action of
Uses AdBlue/DEF injection control without using the ammonia sensor.
controller
Phenomenon
NOx emission increases
on machine
(min. 400 °C). Be careful not to get burned.
• This failure code is displayed when ammonia sensor value cannot be detected; a sensor
probe is not attached to the exhaust pipe.
• This failure occurs also when AdBlue/DEF injector is clogged, and when CA3582 or
CA3568 or CA4658 is displayed, repair these codes first.
• If AdBlue/DEF injector is clogged when outside air temperature is -5 °C or below, this error
may appear solely.
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF injector and the en-
gine operation state are used (the figures below denote monitoring codes).
• Troubleshooting for AdBlue/DEF injector
Related 19120 AdBlue/DEF Injection Quantity
information 19205 ammonia concentration (compensation value)
19202 Turbo Outlet NOx Corrected
47200 KDPF Outlet Temperature
01002 Engine Speed
NOTICE
(This failure code is not cleared by only turning starting switch to ON position.)

Defective AdBlue/DEF in- If failure code [CA3568] or [CA4658] is displayed, perform troubleshooting for the
1
jector system code first.
2 Defective SCR catalyst If failure code [CA3582] is displayed, perform troubleshooting for the code first.
D155AX-8 40-733
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error 40 TROUBLESHOOTING

Defective ammonia sen- 2. Check if the ammonia sensor probe is correctly installed on SCR catalyst and
3 sor is not loose.
(improper installation) 3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
Low AdBlue/DEF con-
4 2. If the “AdBlue/DEF concentration” is out of the normal range, replace the
centration
AdBlue/DEF in the AdBlue/DEF tank, and perform “Loaded Diagnostics
1. Start engine.
2. When SCR temperature is 200 °C or higher on the Pre-defined Monitoring
screen, check for ammonia concentration.
Clogged AdBlue/DEF in- 1) If ammonia concentration indicates approximately 5 to 150(ppm), perform
5 jector “Loaded Diagnostics Operation To Clear Failure Code” because a clogged
AdBlue/DEF injector failure is cleared. (AdBlue/DEF injector is not clogged
anymore.)
2) If ammonia concentration stays at 0ppm, perform “Testing and adjusting”,
“SPECIAL FUNCTIONS OF MACHINE MONITOR”, “Testing”, “Active Re-
generation for Service”. (Clogged AdBlue/DEF injector)
6
sor
7
sor controller 3. Performing “Loaded Diagnostics Operation To Clear Failure Code”.
tive.
8
outlet NOx sensor
tive.
damaged rectifier)
Defective air intake sys- 1. Check for a defective air intake pipe and repair or replace any damaged or
9
tem defective rectifier, if any.
2. Replace mass air flow (MAF) sensor.
40-734 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error

1. If the failure code persists after the above checks, replace the engine con-
troller.
10 2.
ler Performing “Loaded Diagnostics Operation To Clear Failure Code”.
If the failure code disappeared, the engine controller may be defective.

4. Stalling torque converter continuously with fuel control dial at MAX position for approximately 20 seconds.
REMARK
NOTICE
idle speed.
REMARK
5. Check if monitoring code 19300 “SCR Temperature” is 290 °C or more and monitoring code 19202 “Turbo
Outlet NOx Corrected” is 120 ppm or more on the Troubleshooting Pre-defined Monitoring screen.
6. Run the engine at high idle (with no load) for 30 seconds.
7. Check if monitoring code 19300 “SCR Temperature” is about 250 °C on the Troubleshooting Pre-defined
Monitoring screen.
8. Repeat the above steps from 4. to 7. up to max. 20 times.
9. Repeat high idle run under no load for 5 minutes and blade raise relief for 3 minutes for 5 times.
D155AX-8 40-735
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error 40 TROUBLESHOOTING
REMARK
• If this failure code is not cleared, return to troubleshooting.
40-736 D155AX-8
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Er-

ror
Action level Failure code AdBlue/DEF LineHeater Relay 2 Voltage High Error
Failure
Detail of fail-
A high voltage error occurs in AdBlue/DEF line heater relay 2 circuit.
ure
Action of
None in particular
controller
• AdBlue/DEF line heater relay 2 is driven at AdBlue/DEF supply system thawing/thermal in-
sulation or “AdBlue/DEF line heater relay 2 test”.
• AdBlue/DEF line heater relay 2 is integrated in the AdBlue/DEF heater relay.
AdBlue/DEF heater relay to power supply.
Related
• This failure code is detected only when the AdBlue/DEF line heater 2 is turned ON.
information
Procedure: Start the engine in low temperature (engine room temperature of 12 °C or be-
low) or perform “AdBlue/DEF line heater relay 2 test”.
• (See “service modes” of “setting and operating machine monitor”, and “explanation of op-
erating method of testing menu (SCR service test”.)

1
If this failure code is displayed, wiring harness connector is defective.
2
harness 4. Turn the battery disconnect switch to ON position.
5. Turn starting switch to ON position (with connector UHR1 disconnected).
Voltage Between UHR (female) (11) and (12) Max. 3 V
D155AX-8 40-737

3. Disconnect connector UHR1 and UHR2 and replace AdBlue/DEF heater
relay.
Defective AdBlue/DEF 4. Turn the battery disconnect switch to ON position.
3
heater relay 5. Turn the starting switch to ON position.
6. Perform the “AdBlue/DEF Line Heater Relay 2 Test” by staring the engine
in low ambient temperature (12 °C or below), or by referring “SERVICE
ler
40-738 D155AX-8
D155AX-8 40-739
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Er-

ror
Action level Failure code AdBlue/DEF line heater relay 2 voltage low error
Failure
Detail of fail-
A low voltage error occurs in AdBlue/DEF line heater relay 2 circuit.
ure
Action of
Advances to Inducement strategy
controller
AdBlue/DEF line stops thawing.
Phenomenon
on machine
Engine output is reduced based on inducement strategy.
• AdBlue/DEF line heater relay 2 is driven at AdBlue/DEF supply system thawing/thermal in-
sulation or “AdBlue/DEF Line Heater Relay 2 Test”.
• AdBlue/DEF line heater relay 2 is integrated in the AdBlue/DEF heater relay.
Related AdBlue/DEF heater relay to power supply.
information • This failure code is detected only when the AdBlue/DEF line heater relay 2 is turned OFF.
• This failure code is displayed if connector UHR1 is disconnected when AdBlue/DEF line
heater 2 is turned OFF.

1
2 REMARK
fuse box F01
3 ness (sensor relay power 3. Disconnect connector UHR2, and connect T-adapter to female side.
supply side) 4. Turn the battery disconnect switch to ON position.
Voltage Between ground and UHR2 (female) (1) or (2) Min. 22 V
Open circuit in wiring har- 2. Turn the battery disconnect switch to OFF position.
4 ness (line heater relay
drive signal side) 3. Disconnect connectors J2 and UHR1 and connect T-adapters to each fe-
male side.
Resistance Between J2 (female) (7) and UHR1 (female) (11) Max. 1 Ω
40-740 D155AX-8

3. Disconnect connectors J2 and UHR1, and connect T-adapter to either fe-
Between J2 (female) (7) or UHR1 (female) (11) and
ground
Short circuit in wiring har- 3. Disconnect connectors J2 and UHR1, and connect T-adapter to female
6
ness side of J2.
Continuity
(7) ty
7 relay.
heater relay
8
D155AX-8 40-741
40-742 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error

Action level Failure code AdBlue/DEF Flow Low Error
Failure
Detail of fail-
Clogged AdBlue/DEF injector and AdBlue/DEF pressure hose
ure
Action of
• None in particular
controller
Phenomenon
on machine
D155AX-8 40-743
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error 40 TROUBLESHOOTING
k The AdBlue/DEF injector becomes hot (Min. 400 °C). Be careful not to get burned.
• This failure code is displayed together with failure codes whose possible cause is clogging
of AdBlue/DEF hose. These are the failure codes to identify the position where failure is
occurring, and they need not to be treated individually.
• If failure codes CA3151 and CA3568 appear together and these failure codes alone still
appear after finishing the repair, identify the cause according to the following procedure.
ue/DEF supply system (because the AdBlue/DEF injection is disabled, which disables
judgment).
• Make sure that the value of the following four states are other than 1 (Thawing) 3 minutes
after the engine is started. (It is not possible to troubleshoot this failure until thawing con-
trol is completed)
screen.
Related
• The “Pre-defined Monitoring” screen uses the AdBlue/DEF injector diagnosis and
information AdBlue/DEF pump diagnosis. (The following numbers are the monitoring codes)
19205 AFT NH3 Sensor Corrected
19202 Turbo Outlet NOx Corrected
47200 KDPF Outlet Temperature
19109 AdBlue/DEF Pump PressSensor Volt
NOTICE
investigating the cause of the problem and completing the repair, perform a “Loaded Di-
(This failure code is not cleared by only turning starting switch to ON position.)

1. Start the engine, run it with low idle.
2. At approximately 2 minutes after the starting of the engine, check that
19108 AdBlue/DEF pump pressure is kept around 900 kPa.
Reset of judgment condi- 3. Check that 19120 AdBlue/DEF Injection Quantity is “0”.
1
tions If it is still injected (the injection quantity is not “0”), wait for the injection to
stop.
4. Wait 3 minutes after AdBlue/DEF Injection Quantity becomes “0”.
40-744 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error

2
Defective AdBlue/DEF in- If failure code [CA3567] is displayed on the abnormality record screen, perform
3
jector system troubleshooting these first.
See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR SET-
TING WITH TESTING MENU (SCR SERVICE TEST)” in “SETTING AND OPERA-
TION OF MACHINE MONITOR” to perform “AdBlue/DEF Injector Rate Test”.
Case 1: AdBlue/DEF injection stops
The AdBlue/DEF injector or the AdBlue/DEF pressure hose may be clogged. Pro-
ceed to cause 5 to determine the cause of the failure.
Failure of the Case 2: AdBlue/DEF injection continues for more than 2 seconds without stoppage
4 1. The AdBlue/DEF injector nozzle remains open and stucked. Replace with
AdBlue/DEF injector
a new one.
2. To remove the accumulated deposits of AdBlue/DEF in SCR, see “SET-
TING AND OPERATION OF MACHINE MONITOR” of “SERVICE MODE”,
and “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)” to perform “Active Regeneration for Service” for 3 times (Refer-
ence: Approximately 2 hours is required in total (40 minutes per opera-
tion))
3. See Testing and adjusting, “service modes” of “setting and operating machine
monitor”, “operating method of testing menu (SCR service test)” to perform an
“AdBlue/DEF pump pressure rising test”.
4. If AdBlue/DEF flows out from the AdBlue/DEF pressure hose while the AdBl-
Clogged AdBlue/DEF ue/DEF pump pressure does not reach 900 kPa, there is no clogging in the
5
pressure hose AdBlue/DEF pressure hose.
5. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in the
AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
minutes while performing the “AdBlue/DEF pump pressure rising test”.
If failure code is still displayed after above checks, the AdBlue/DEF injector may
have been temporarily clogged but is now normal.
6 jector
Perform “Loaded Diagnostics Operation To Clear Failure Code”. If this failure code
is cleared, repair is completed.
7

2. Start the engine and warm it up.
3. Check if monitoring code 19108 “AdBlue/DEF pump pressure” is around 900 kPa.
4. Turn the fuel control dial to MAX position, and run the engine at high idle speed under no load for 20 sec-
onds.
5. Perform torque converter stall operation for continuously 20 seconds or longer with fuel control dial at MAX
position.
D155AX-8 40-745
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error 40 TROUBLESHOOTING

1) Select P mode to operate gear shift lever in manual.
4) Set preset mode display to [F3-R3] by shift up (UP) switch on the PCCS lever.
The preset mode display (on the lower right of the screen) can be set to [F3-R3] only when “Stall
Mode” is selected in the “Adjustment” screen.
5) Make sure to depress the brake pedal firmly and the parking brake lever in FREE position, set the di-
rection of the PCCS lever to FORWARD position.
NOTICE
idle speed.
tion.
NOTICE
• Pay attention not to overheat of hydraulic oil temperature.
6. Repeat above steps 4 and 5 for 20 times.
REMARK
• If this failure code is cleared during or after the operation (not displayed), repair work is completed.
• If this failure code is not cleared, return to troubleshooting.
40-746 D155AX-8
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Trans-
40 TROUBLESHOOTING mission Data Error
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission

Data Error
Action level Failure code AdBlue/DEF Temperature Sensor Transmission Data Error
Failure
Detail of fail-
Temperature data sent by AdBlue/DEF sensor is abnormal.
ure
Action of
Advances to Inducement strategy. (EU Specification).
controller
Phenomenon • AdBlue/DEF temperature cannot be measured.
• AdBlue/DEF level sensor is one of AdBlue/DEF tank sensors and is integrated with AdBl-
ue/DEF temperature sensor and AdBlue/DEF quality sensor, providing CAN communica-
Related tion with the engine controller.
information • This failure code is displayed unless an approved sensor is installed.

1
tank sensor
3
D155AX-8 40-747
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission
Data Error 40 TROUBLESHOOTING
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data

Error
Action level Failure code AdBlue/DEF Level Sensor Transmission Data Error
Failure
Detail of fail-
Level data sent by AdBlue/DEF sensor is abnormal.
ure
Action of
controller
Phenomenon • AdBlue/DEF level cannot be measured.
Related tion with the engine controller.
information • This failure code is displayed unless an approved sensor is installed.

1
tank sensor
3
40-748 D155AX-8
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error

Action level Failure code AdBlue/DEF Level Sensor Internal Circuit Error
Failure
Detail of fail-
AdBlue/DEF level sensor is defective (an error is detected in level measurement circuit)
ure
Action of
controller
Phenomenon AdBlue/DEF level cannot be measured.
on machine Engine output is reduced based on inducement strategy. (EU Specification).
tion with the engine controller.
Related
• This failure code is displayed when the engine controller receives information stating the
information level measurement circuit is abnormal.

1
tank sensor
3
D155AX-8 40-749
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error 40 TROUBLESHOOTING
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error

Action level Failure code Fuel in AdBlue/DEF Tank Error
Failure
Detail of fail-
AdBlue/DEF tank is contaminated with diesel fuel.
ure
• Stops AdBlue/DEF injection.
Action of
• Stops AdBlue/DEF pump.
controller
code).
Related
information “AdBlue/DEF Tank Washing”.
• For the replacement procedure of AdBlue/DEF/level sensor, see Disassembly and assem-
code is cleared).
NOTICE

or [CA3868] or [CA4731] or [CA4732] or [CA4768] is displayed, perform
Defective AdBlue/DEF troubleshooting these first.
1
tank sensor system
1. Drain total amount of the AdBlue/DEF to check that it is not contaminated
with diesel fuel. (Drain total amount of the AdBlue/DEF, since diesel fuel is
lighter than urea solution.)
AdBlue/DEF tank is con-
2 taminated with diesel 2. If it is contaminated with diesel fuel, clean AdBlue/DEF tank.
fuel. 3. After refill with the new AdBlue/DEF, perform “Loaded Diagnostics Opera-
tion To Clear Failure Code”.
4. If this failure code is displayed, proceed to the next troubleshooting.
40-750 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error

fect)
Defective engine control- 2.
4 Perform “Loaded Diagnostics Operation To Clear Failure Code”.
ler
3. If this failure code is displayed, perform troubleshooting again.

3. Wait for 10 minutes. (Do not start the engine)
4. After the deactivation of this failure code, diesel fuel may remain, so test and replace the SCR system
(pump, hose, etc.).
D155AX-8 40-751
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossi-
ble 40 TROUBLESHOOTING
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible

Action level Failure code AdBlue/DEF Level Measurement Impossible
Failure
Detail of fail-
AdBlue/DEF level sensor stays in disabling to measure AdBlue/DEF level.
ure
Action of
controller
• AdBlue/DEF level cannot be measured.
Phenomenon
• AdBlue/DEF level on the monitor changes.
on machine
• Displayed when AdBlue/DEF tank is completely empty.
• Contaminated sensing part or a failure in the sensor can be suspected as a cause other
than empty AdBlue/DEF tank.
• This failure code cannot be cleared if AdBlue/DEF tank temperature is 0 °C or lower.
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF level and quality
sensors is used.
• Troubleshooting for AdBlue/DEF level and quality sensors
Related 19110 AdBlue/DEF Level
information 19111 AdBlue/DEF Level Corrected
NOTICE
agnostics Operation To Clear Failure Code” to make sure that the failure code is
cleared .
40-752 D155AX-8
40 TROUBLESHOOTING ble

3. If there is no AdBlue/DEF, or AdBlue/DEF level is low.
1) Refill with AdBlue/DEF.
2) Turn starting switch to OFF position.
3) If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code”and repair is
completed.
AdBlue/DEF tank remain- 4) If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
1
ing amount check mains changed even after AdBlue/DEF has been refilled, proceed to cause
2.
4. If AdBlue/DEF level is normal
1) Turn starting switch to OFF position.
2) If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
mains changed even after AdBlue/DEF has been refilled, proceed to cause
2.
3) If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code”and repair is
completed.
1. Turn starting switch OFF, and confirm the following.
1) There is no foreign material such as dirt in AdBlue/DEF tank.
2) There is not a problem in quality and concentration of AdBlue/DEF.
3) There is no foreign material such as dirt attached to AdBlue/DEF sensor.
4) AdBlue/DEF float is not stuck.
2. Repair, or replace to solve if any of these failures are found.
Check inside conditions
2
of AdBlue/DEF tank 3. Turn starting switch to ON position.
4. If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code” and repair
is completed.
5. If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
mains changed even after performing remedy for these, proceed to cause
3.
• Check the sensor connector for contamination and damage.
• Make sure that DEF tank contains 15 % or more of AdBlue/DEF.
Defective AdBlue/DEF 2. Replace the AdBlue/DEF tank sensor.
3
tank sensor
4. If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code” and repair is
completed.
ler

D155AX-8 40-753
ble 40 TROUBLESHOOTING
Monitoring screen.
Standby time depends on the initial value of the AdBlue/DEF temperature in tank as follows:
• When the value is 0 °C or below, run the engine and wait for 2 hours after the temperature in tank rises
up to 0 °C or above.
• When the value ranges from 0 to 5 °C, stand by for 60 minutes.
• When the value is 5 °C or above, stand by for 30 minutes.
40-754 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error

Action level Failure code AdBlue/DEF High Concentration Error
Failure
Detail of fail-
AdBlue/DEF concentration is high (40 % or higher)
ure
• Advances to Inducement strategy. (EU Specification).
Action of
• Stops AdBlue/DEF injection (EU Specification).
controller
• Stops AdBlue/DEF pump. (EU Specification).
Phenomenon
Engine output is reduced based on inducement strategy. (EU Specification).
on machine
AdBlue/DEF level changes with machine operation on the slop or travel on even ground, possibly
disabling to detect the correct level or concentration.
If AdBlue/DEF level monitor is illuminated in red or a warning on the concentration appears, move to
a flat place as soon as possible and refill AdBlue/DEF. If this phenomenon persists, refill
AdBlue/DEF extra in AdBlue/DEF tank.
code).
“AdBlue/DEF Tank Washing”.
Related
information • For the replacement procedure of AdBlue/DEF level sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF level sensor”.
NOTICE
This failure code denotes requires “Loaded Diagnostics Operation To Clear Failure
Code”. After investigating the cause of the problem and completing the repair, perform
“Loaded Diagnostics Operation To Clear Failure Code” to make sure that the failure
code is cleared.
D155AX-8 40-755
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error 40 TROUBLESHOOTING

1 these first.
tank sensor system
High AdBlue/DEF con- ble concentration meter to recheck the concentration. If the concentration
2
centration still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
3
AdBlue/DEF tank.
fect)
6
40-756 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error

Monitoring screen.
Standby time depends on the initial value of the AdBlue/DEF temperature in tank as follows:
• When the value is 0 °C or below, run the engine and wait for 2 hours after the temperature in tank rises
up to 0 °C or above.
• When the value ranges from 0 to 5 °C, stand by for 60 minutes.
• When the value is 5 °C or above, stand by for 30 minutes.
D155AX-8 40-757
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (En-
gine Controller) 40 TROUBLESHOOTING
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine

Controller)
Action level Failure code System Operating Lamp Short Circuit (Engine Controller)
Failure
Detail of fail- Engine controller determines that system operating lamp circuit shorts because voltage of output
ure circuit does not become Low level while engine controller outputs current to system operating lamp.
Action of
Stops driving system operating lamp.
controller
Phenomenon While system operating lamp is lit, battery disconnect switch must not be turned to OFF position.
Turning battery disconnect switch to OFF position when the lamp is lit may destroy memory data
on machine stored in engine controller, each controller and machine monitor.
• Although engine controller is not able to light up system operating lamp, no trouble will re-
sult unless battery disconnect switch is turned to OFF position.
Related
• When controller lights up system operating lamp, output circuit voltage is at low level.
information

1
2. Remove fuse No. 7 in fuse box F01.
2 3. Disconnect connectors PTCN3, WECN3, KEY 0, CK01, CM01, CK01, J2,
ness
and LBU, and connect T-adapter to female side of connector LBU.
Resistance Between LBU (female) (1) and (2) Min. 1 MΩ
Hot short circuit in wiring 2. Disconnect connector LBU, and connect T-adapter to female side.
3
harness 3. Turn starting switch to ON position .
Voltage Between LBU (female) (2) and ground Max. 1 V
ler
40-758 D155AX-8
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (En-
40 TROUBLESHOOTING gine Controller)
Circuit diagram related to system operating lamp
D155AX-8 40-759
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error

Action level Failure code AdBlue/DEF Line Heater 1 Voltage Low Error
Failure
Detail of fail- A low voltage error occurs in AdBlue/DEF line heater 1 ( low-temperature pressure, intake and re-
ure turn side) signal circuit.
Action of
None in particular
controller
• AdBlue/DEF line heater 1 is driven at AdBlue/DEF supply system thawing/thermal insula-
tion or “AdBlue/DEF line heater relay 1 test”.
• AdBlue/DEF line heater 1 is driven by AdBlue/DEF line heater relay 1 inside AdBlue/DEF
heater relay.
Related • This failure code is detected only when the AdBlue/DEF line heater 1 is turned ON.
Procedure: Start the engine in low temperature (ambient temperature of 5 °C or below) or
see “service modes” of “setting and operating machine monitor”, and “explanation of oper-
ating method of testing menu (SCR service test)” to perform “AdBlue/DEF line heater relay
1 test”.

1
2 relay.
heater relay
3
side)
above.
40-760 D155AX-8

2. Disconnect connectors J2, UHR1, UHC, and UHB, and connect T-adapter
to either female side.
Ground fault in wiring Between J2 (female) (39) or UHR1 (female) (8) and
Min. 1 MΩ
4 harness (contact with ground
ground circuit)
Between ground and UHR1 (female) (5) or UHB (fe-
male) (1)
Between ground and UHR1 (female) (6) or UHC (fe-
Min. 1 MΩ
male) (1)
2. Disconnect connectors UHC, and UHA, and connect T-adapters to each
Defective AdBlue/DEF male side.
5
line heater
Between UHC (male) (1) and (2) 5 to 40 Ω
Resistance
Between UHA (male) (1) and (2) 5 to 40 Ω
Open circuit or short cir- REMARK
6 Resistance value is the internal resistance value of the heater relay mentioned
side) above.
Resistance
ler
D155AX-8 40-761
40-762 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [CA5383] Ash Accumulation High Error
FAILURE CODE [CA5383] Ash Accumulation High Error

Action level Failure code Ash Accumulation High Error
Failure
— CA5383 (Engine controller system)
Detail of fail-
Ash accumulation in KDPF is high and ash accumulated in KDPF needs to be cleaned.
ure
Action of
None in particular
controller
Phenomenon
KCSF may be damaged.
on machine
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• Ash accumulation in KDPF is high and ash accumulated in KDPF needs to be cleaned.
• As to procedure for accessing KDPF temperature sensor, see “50 Disassembly and as-
sembly”, “Removal and installation of KDPF assembly”.
Related ON position.
information • See Testing and adjusting, “service modes” of “setting and operating machine monitor”
and “setting method of testing menu (ash in soot accumulation correction)” to check ash
accumulation.
• This failure code is displayed when ash accumulation reaches the upper limit of its allowa-
ble amount.
• When the ash accumulation reaches the upper limit, KDPF is experiencing very high pres-
sure loss and ash cleaning is required.
• For resetting KDPF cleaning and KDPF change, see Testing and adjusting, “service
modes” of “setting and operating machine monitor” and “setting method of testing menu
(KDPF memory reset)”.
• This failure code is cleared on the user screen of the machine monitor but is displayed on
“Abnormality Record”screen and in service mode of the machine monitor and KOMTRAX.
NOTICE
• When this failure code is displayed, troubleshoot causes 1 and 2, then make sure to
perform ash cleaning in cause 3.
• After ash cleaning, reset KDPF cleaning and KDPF change.
• Otherwise, KCSF may be damaged.

Defective KDPF differen- If failure code [CA1879] or [CA1881] or [CA1883] is displayed, perform trouble-
1
tial pressure sensor shooting for [CA1879] or [CA1881] or [CA1883] first.
D155AX-8 40-763
FAILURE CODE [CA5383] Ash Accumulation High Error 40 TROUBLESHOOTING

Defective KDPF (KDOC, Perform troubleshooting for 1 through 11 in “S-21 Active regeneration is executed
2
or KCSF) frequently” in S mode.
NOTICE
• Be sure to perform:
1. Remove KDPF and flush ash accumulated in KDPF (see Related informa-
tion).
Excessive ash accumula-
tion
3. Perform Reset after KDPF cleaning (see Related information).
4. Perform Reset after KDPF change (see Related information).
5. Make sure that ash accumulation is 0 on the monitor (see Related informa-
tion).
ler
40-764 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [D130KA] Neutral Safety Relay Open Circuit
FAILURE CODE [D130KA] Neutral Safety Relay Open Circuit

Failure Neutral Safety Relay Open Circuit (Power train controller system)
L01 D130KA
Detail of fail- When controller drives primary circuit (coil side) of neutral safety relay, no current flows through cir-
ure cuit.
Action of ma-
Stops driving primary circuit (coil side) of neutral safety relay.
chine monitor
Phenomenon
on machine
• Output to primary (coil) circuit of neutral safety relay can be checked with monitoring func-
tion. (Code 40909: P/T SW Output)
Procedure: Turn starting switch to ON position and operate parking brake lever to LOCK
Related
position.
information
• This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but
not on secondary circuit (contact side).
• When PTCN2 (8) pin is shorted to ground, engine starts in any gear speed including neu-
tral gear speed.

Defective neutral safety 2. Disconnect connector NSF, and connect T-adapter to male side.
1 relay (internal open or
short circuit) 200 to
Resistance Between NSF (male) (1) and (2)
400 Ω
2. Disconnect connector PTCN2 and connect T-adapter to female side.

REMARK
2
wiring harness If resistance is 1 MΩ or more, wiring harness has open circuit. If it is below 1 Ω, wir-
ing harness has short circuit.
200 to
Resistance Between PTCN2 (female) (8) and ground
400 Ω
REMARK
If failure code is still displayed after above checks on Cause 2, this check is not
required.
2. Disconnect connectors PTCN2 and NSF, and connect T-adapters to each
defective contact)
female side.
Between PTCN2 (female) (8) and NSF (female) (1) Max. 1 Ω
Resistance
Between NSF (female) (2) and ground Max. 1 Ω
Hot short circuit in wiring 2. Disconnect connector NSF and connect T-adapter to female side.
V circuit)
Voltage Between NSF (female) (1) and ground Max. 4.5 V
D155AX-8 40-765
FAILURE CODE [D130KA] Neutral Safety Relay Open Circuit 40 TROUBLESHOOTING

tive.
• Reference
Defective power train 2. Insert T-adapter into connector PTCN2.
5
controller 3. Turn starting switch to ON position.
4. Operate parking brake to perform troubleshooting.
Between PTCN2 (8) and Free Max. 4.5 V

Voltage
ground LOCK 20 to 30 V
40-766 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [D130KA] Neutral Safety Relay Open Circuit
Circuit diagram related to neutral safety relay
D155AX-8 40-767
FAILURE CODE [D130KB] Neutral Safety Relay Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [D130KB] Neutral Safety Relay Short Circuit

Failure Neutral Safety Relay Short Circuit (Power train controller system)
L01 D130KB
Detail of fail- When controller drives primary circuit (coil side) of neutral safety relay, abnormal current flows
ure through circuit.
Action of ma-
Stops driving primary circuit (coil side) of neutral safety relay.
chine monitor
Phenomenon
on machine
• Output to primary (coil) circuit of neutral safety relay can be checked with monitoring func-
tion. (Code 40909: P/T SW Output)
Procedure: Turn starting switch to ON position and operate parking brake lever to LOCK
information position.
• This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but
not on secondary circuit (contact side).

2. Disconnect connector NSF, and connect T-adapter to male side.
Defective neutral safety
1 relay (internal open or 200 to
short circuit) Between NSF (male) (1) and (2)
Resistance 400 Ω
Between NSF (female) (1) and ground Min. 1 MΩ

REMARK
2
wiring harness If resistance is 1 MΩ or more, wiring harness has open circuit. If it is below 1 Ω, wir-
200 to
Resistance Between PTCN2 (female) (8) and ground
400 Ω
2. Disconnect connectors PTCN2 and NSF, and connect T-adapters to fe-
Ground fault in wiring male side or PTCN2.
ground circuit)
Between ground and PTCN2 (female) (8) or NSF (fe-
male) (1)
tive.
• Reference
4
Between PTCN2 (8) and Free Max. 4.5 V

Voltage
ground LOCK 20 to 30 V
40-768 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [D130KB] Neutral Safety Relay Short Circuit
Circuit diagram related to neutral safety relay
D155AX-8 40-769
FAILURE CODE [D190KA] Engine Controller Accessory Signal Hold
Relay Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [D190KA] Engine Controller Accessory Signal Hold Relay

Open Circuit
Action level Failure code Engine Controller Accessory Signal Hold Relay Open Circuit (Work
Failure
L01 D190KA equipment controller system)
Detail of fail- No voltage is supplied when circuit is disconnected from ground terminal in primary (coil) circuit of
ure engine hold relay.
Action of
Disconnects primary (coil) circuit of engine hold relay from ground terminal.
controller
Phenomenon • Turbocharger timer function does not operate (when turbocharger timer is installed).
on machine • No particular problems that affect the machine (when turbocharger timer is not installed).
• Output signal to primary (coil) circuit of engine hold relay can be checked with monitoring
function.
information • This failure code detects failure in primary (coil) circuit of engine hold relay, but does not
detects failure in secondary (contact) circuit.
• When WECN2 (21) pin is shorted to ground, engine does not stop after starting switch is
turned to OFF position.

Defective engine hold re- 2.
Disconnect connector EHL, and connect T-adapter to male side.
1 lay (internal open or short
circuit) 200 to
Resistance Between EHL (male) (1) and (2)
400 Ω
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to each
female side.
2
wiring harness
If resistance is 1 MΩ or higher, wiring harness has open circuit. If resistance is 1 Ω
or below, wiring harness has short circuit.
200 to
Resistance Between KEY (female) (5) and WECN2 (female) (21)
400 Ω
quired.
ness (wire breakage or 2. Disconnect connectors WECN2, EHL, and KEY, and connect T-adapters to
3
defective contact of con- each female side.
nector)
Between WECN2 (female) (21) and EHL (female) (2) Max. 1 Ω
Resistance
Between KEY (female) (5) and EHL (female) (1) Max. 1 Ω
Ground fault in wiring 2. Disconnect connectors WECN2 and EHL, and connect T-adapters to each
ground circuit)
Between ground and EHL (female) (2) or WECN2 (fe-
male) (21)
Defective work equip- If failure code is still displayed after above checks, work equipment controller is de-
5
ment controller fective.
40-770 D155AX-8
FAILURE CODE [D190KA] Engine Controller Accessory Signal Hold
40 TROUBLESHOOTING Relay Open Circuit
Circuit diagram related to engine acc signal hold relay
D155AX-8 40-771
FAILURE CODE [D190KB] Engine Controller Accessory Signal Hold
Relay Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [D190KB] Engine Controller Accessory Signal Hold Relay

Short Circuit
Action level Failure code Engine Controller Accessory Signal Hold Relay Short Circuit (Work
Failure
L01 D190KB equipment controller system)
Detail of fail-
Unusual current flows in primary (coil) circuit of engine hold relay when circuit is grounded.
ure
Action of
Disconnects primary (coil) circuit of engine hold relay from ground terminal.
controller
Phenomenon • Turbocharger timer function does not operate (when turbocharger timer is installed).
on machine • No particular problems that affect the machine (when turbocharger timer is not installed).
• Output signal to primary (coil) circuit of engine hold relay can be checked with monitoring
function.
• This failure code detects failure in primary (coil) circuit of engine hold relay, but does not
detects failure in secondary (contact) circuit.

Defective engine hold re- 2.
Disconnect connector EHL, and connect T-adapter to male side.
1 lay (internal open or short
circuit) 200 to
Resistance Between EHL (male) (1) and (2)
400 Ω
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to each
female side.
2
wiring harness
200 to
Resistance Between KEY (female) (5) and WECN2 (female) (21)
400 Ω
Hot short circuit in wiring 2. Disconnect connectors WECN2 and EHL, and connect T-adapters to fe-
3 harness (contact with 24 male side of WECN2.
V circuit) 3. Turn starting switch to ON position.
Voltage Between WECN2 (female) (21) and ground Max. 1 V
4
40-772 D155AX-8
FAILURE CODE [D190KB] Engine Controller Accessory Signal Hold
40 TROUBLESHOOTING Relay Short Circuit
Circuit diagram related to engine acc signal hold relay
D155AX-8 40-773
FAILURE CODE [D19JKZ] Personal Code Relay Open or Short 40 TROUBLESHOOTING
FAILURE CODE [D19JKZ] Personal Code Relay Open or Short

Failure Personal Code Relay Open or Short (Machine monitor system)
L03 D19JKZ
Detail of fail-
Open error or short circuit occurs in primary (coil) circuit of personal code relay.
ure
• None in particular (when open error occurred)
• Stops driving personal code relay (when short circuit occurred).
Action of ma- • If cause of failure disappears, machine becomes normal by itself (when open error occur-
chine monitor red).
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when short circuit occurred).
Phenomenon
on machine
• This failure code is displayed only when engine lock function is enabled.
Related Procedure: Turn starting switch to ON position (when open circuit occurred). Failure code
information cannot be reproduced on the machine (when short circuit occurred).
• Troubleshooting for this failure code covers circuit from circuit breaker CB1, through pri-
mary (coil) circuit of personal code relay PSL, to machine monitor.

Defective circuit breaker If circuit breaker is tripped, circuit probably has ground fault, etc.
1
CB1 or CB105
2. Disconnect relay PSL, and connect T-adapter to male side.
200 to
Resistance Between PSL (male) (1) and (2)
600 Ω
Personal Code Relay
2
PSL Abnormality 1. Turn starting switch to OFF position.
2. Replace relay PSL with preheating relay PHR.
If this failure code is cleared, original personal code relay PSL is defective.
2. Disconnect connectors CM01, PL1, and PTCN3, and connect T-adapter to
Open or short circuit or female side of CM01.
3 ground fault in wiring har-
ness 200 to
Between CB1 (2) and CM01 (female) (6)
Resistance 600 Ω
Between ground and CB1 (2) or CM01 (female) (6) Max. 1 Ω
NOTICE
is not required.
4
ness 2. Disconnect connector CM01 and relay PSL, and connect T-adapters to
each female side.
Between CB1 (2) and PSL (female) (1) Max. 1 Ω
Resistance
Between PSL (female) (2) and CM01 (female) (6) Max. 1 Ω
40-774 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [D19JKZ] Personal Code Relay Open or Short
NOTICE
is not required.
5 2. Disconnect connectors CM01 and relay PSL, and connect T-adapter to ei-
harness
ther female side.
Between PSL (female) (1) and ground Max. 1 Ω
Resistance Between ground and PSL (female) (2) or CM01 (fe-
Max. 1 Ω
male) (6)
2. Disconnect connector CM01 and relay PSL, and connect T-adapter to fe-
male side of CM01.
6
ness
Check with multimeter in continuity mode.
No continui-
Between CM01 (female) (6) and each pin other than
Continuity ty (No
(6)
sound)
Defective machine moni- If failure code is still displayed after above checks, machine monitor is defective.
7
tor (Because this is an internal defect, troubleshooting cannot be performed.)
D155AX-8 40-775
FAILURE CODE [D19JKZ] Personal Code Relay Open or Short 40 TROUBLESHOOTING
Circuit diagram related to personal code relay
40-776 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [D811MC] KOMTRAX Malfunction
FAILURE CODE [D811MC] KOMTRAX Malfunction

Failure KOMTRAX Malfunction (KOMTRAX system)
- D811MC
Details of
KOMTRAX Error
failure
Action of
controller
Phenomenon
KOMTRAX system does not operate normally.
on machine

Defective KOMTRAX (In case of an internal defect, troubleshooting is impossible
1 KOMTRAX Error
D155AX-8 40-777
FAILURE CODE [D862KA] GPS Antenna Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [D862KA] GPS Antenna Open Circuit

Action level Failure code GPS Antenna Open Circuit
Failure
- D862KA (KOMTRAX system)
Details of
Open circuit occurs in GPS antenna circuit.
failure

Phenomenon
GPS positioning system does not work.
on machine

Defective GPS antenna GPS antenna may be defective, or antenna cable may have open or short circuit,
1
or antenna cable or poor contact at terminal area (GPS).
Figure of structure
40-778 D155AX-8
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit
40 TROUBLESHOOTING (KOMTRAX)
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOM-

TRAX)
Action level Failure code System Operating Lamp Open Circuit (KOMTRAX)
Failure
― D8ALKA (KOMTRAX system)
KOMTRAX terminal determines that output circuit to system operating lamp is open because volt-
Details of age of output circuit remains at approximately 5 V or below for approximately 3 seconds after start-
failure ing switch is turned to ON position, during which KOMTRAX terminal does not drive system operat-
ing lamp.
• Does not turn system operating lamp ON.
Action of
controller
Phenomenon While system operating lamp lights up, battery disconnect switch must not be set to OFF position.
Setting battery disconnect switch to OFF position may destroy data stored in KOMTRAX terminal
on machine memory.
• Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
Related
result unless battery disconnect switch is set to OFF position.
information
• When controller lights up system operating lamp, output circuit voltage is at Low level.
• Since no controller drives system operating lamp for approx. 3 seconds after starting
switch is turned to ON position, open circuit can be detected.

Defective fuse 7 in fuse If fuse is blown out, circuit probably has ground fault.
1
box F01
2
CB6 or CB30
2. Turn battery disconnect switch OFF.
Open circuit in wiring har- 3. Disconnect connectors CK01 and LBU, and connect T-adapters to each
3
nector) Between CK01 (female) (15) and LBU (female) (2) Max. 1 Ω
Resistance Between LBU (female) (1) and battery relay terminal
Max. 1 Ω
BRB
If no failure is found by preceding checks, KOMTRAX terminal is defective. (In case
Defective KOMTRAX ter-
4 of an internal defect, troubleshooting is impossible as an assembly. Replace whole
minal
assembly.)
D155AX-8 40-779
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit
(KOMTRAX) 40 TROUBLESHOOTING
40-780 D155AX-8
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit
40 TROUBLESHOOTING (KOMTRAX)
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOM-

TRAX)
Action level Failure code System Operating Lamp Short Circuit (KOMTRAX)
Failure
- D8ALKB (KOMTRAX system)
Details of KOMTRAX terminal determines that system operating lamp circuit shorts because voltage of output
circuit does not become low level while KOMTRAX terminal outputs current to system operating
failure lamp.
• Stops driving system operating lamp.
Action of
controller
Phenomenon While system operating lamp lights up, battery disconnect switch must not be turned OFF. Turning
on machine battery disconnect switch OFF may destroy data stored in KOMTRAX terminal memory.
Related
• Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
information result unless battery disconnect switch is turned to OFF position.

3. Disconnect connector LBU.
4. Disconnect connectors PTCN3, CK01, CM01, WECN3 and EGC3, and
connect T-adapters to each female side.
Between PTCN3 (female) (34) and each pin other than No continui-
pin (34) ty
Between CK01 (female) (15) and each pin other than No continui-
pin (15) ty
Short circuit in wiring har- Between CM01 (female) (8) and every pin other than No continui-
1 Continuity
ness pin (8) ty
Between WECN3 (female) (34) and each pin other No continui-
than pin (34) ty
Between EGC3 (female) (9) and each pin other than No continui-
pin (9) ty
3. Remove fuse No. 15 in fuse box FS11.
4. Disconnect connectors PTCN3, WECN3, CK01, CM01, EGC3, and LBU,
and connect T-adapter to female side of LBU.
2
CB6 or CB30
If no failure is found by preceding checks, KOMTRAX terminal is defective. (In case
minal
assembly.)
D155AX-8 40-781
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit
(KOMTRAX) 40 TROUBLESHOOTING
40-782 D155AX-8
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOM-
40 TROUBLESHOOTING TRAX)
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX)

Action level Failure code CAN 2 Defective Communication (KOMTRAX) (Detected by machine
Failure
- D8AQKR monitor) (Machine monitor system)
Details of
Machine monitor does not recognize KOMTRAX over CAN communication-2 line (KOMNET/c).
failure
Action of ma-
None
chine monitor
Phenomenon
None
on machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• 5 different failure codes, [DBEQKR], [DB2QKR], [DB9QKR], [D8AQKR] and [DAZQKR] are
used for defective CAN communication by CAN2 when it is detected by machine monitor.
When all of these 5 failure codes are displayed, ground fault, short circuit or hot short in
wiring harness (CAN communication line) can be suspected. Since air conditioner is also
Related operated through CAN communication, you must, in such case, check on air conditioner
screen whether air conditioner is operable (ON/OFF and air flow of air conditioner).
information
REMARK
Air conditioner can be controlled even when failure code is displayed on screen. If air condi-
tioner is controlled, wiring harness (CAN communication line) does not have ground fault, short
circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
using multimeter.

Defective fuse 7 in fuse 2.
1 Remove fuse 15 in fuse box FS11.
box F01
If fuse is blown out, circuit probably has ground fault.
Defective power supply Perform troubleshooting for “E-44” of E mode.
2
to KOMTRAX terminal
Defective CAN communi- Perform checks on causes 5 to 10 in troubleshooting for failure code [DB2QKR].
3
cation 2 system
If no failure is found by the above checks, KOMTRAX terminal is defective. (In case
minal
assembly.)
5
D155AX-8 40-783
FAILURE CODE [DAF0MB] Monitor ROM Abnormality 40 TROUBLESHOOTING
FAILURE CODE [DAF0MB] Monitor ROM Abnormality

Failure Monitor ROM Abnormality (machine monitor system)
- DAF0MB
Details of
Machine monitor program is rewritten (program error).
failure
Action of
controller
Phenomenon • Machine monitor display is unreliable.
on machine • It can neither transmit the data to controllers nor receive the data from them.

Defective machine moni- Defective machine monitor (Because this is an internal defect, troubleshooting can-
1
tor not be performed.)
40-784 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DAF0MC] Monitor Malfunction
FAILURE CODE [DAF0MC] Monitor Malfunction

Action level Failure code Monitor Malfunction
Failure
- DAF0MC (Machine monitor system)
Detail of fail-
Machine monitor malfunctions.
ure
Action of
controller
Phenomenon • Indication of machine monitor is unreliable.
on machine • Machine monitor is incapable of normally exchanging data with controllers.

1
D155AX-8 40-785
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit

Action level Failure code Camera Power Supply Short Circuit
Failure
L03 DAF8KB (Machine monitor system)
Detail of fail- Output power supply voltage (rating: 8 V) from rear view monitor to camera is 10 V and above when
ure no current is outputted.
• Stops output power supply voltage to rear view camera.
Action of
controller
Phenomenon
Camera image is not displayed on rear view monitor screen.
on machine

2. Disconnect connector CMR1 of rearview camera, and turn starting switch
Defective rearview cam-
1 to ON position. If the failure code is cleared after disconnecting rearview
era (internal short circuit)
camera to perform operation of reproducing procedure, internal defect of
rearview camera is detected.
Defective rearview moni- 2. Disconnect connector CM04, and connect T-adapter to male side.
2
tor 3. Turn starting switch to ON position.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
2. Disconnect connector CMR1 and connect T-adapter to female side.
3 harness (contact with 24 3. Turn starting switch to ON position.
V circuit) (Disconnect rear view camera and check that it is normal, in advance.)
Voltage Between CM04 (female) (1) and (8) Max. 10 V
Circuit diagram related to camera power supply
40-786 D155AX-8
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Moni-
40 TROUBLESHOOTING tor)
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor)

Action level Failure code Model Selection Signal Mismatch (Monitor)
Failure
L03 DAF9KQ (Machine monitor system)
Details of Program in machine monitor and the model programmed in power train controller are incompatible
failure (Part number is wrong in machine monitor or in power train controller if it is replaced.)
Action of
controller
Phenomenon
Machine does not operate normally.
on machine
• Assembly part number of power train controller program can be checked with monitoring
function. (Code: 20242)
Related • Assembly part number of machine monitor program can be checked with monitoring func-
information tion. (Code: 20227)

Display assembly part number by monitoring function, and check that displayed
Defective machine moni- number is same as the one in Parts Book.
1
tor
Defective machine monitor (Programmed machine model is different.)
Display assembly part No. with monitoring function and check if it is same as part
Defective power train No. in parts catalog.
2
controller
Defective power train controller (Programmed model is different)
D155AX-8 40-787
FAILURE CODE [DAFGMC] GPS Module Malfunction 40 TROUBLESHOOTING
FAILURE CODE [DAFGMC] GPS Module Malfunction

Action level Failure code GPS Module Malfunction
Failure
- DAFGMC (KOMTRAX system)
Details of No position data is sent from GPS module (inside of machine monitor) to KOMTRAX communica-
failure tion modem more than 50 seconds since the startup of KOMTRAX.
Action of • None in particular

controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
on machine
After repairing, check if the failure code is cleared by the following procedure.
Related
Procedure: Turn starting switch to ON position. (Wait for more than 50 seconds after the switch is
information
turned ON.)

Defective machine moni- GPS module of machine monitor may be defective. (Because this is an internal de-
1
tor fect, troubleshooting cannot be performed.)
40-788 D155AX-8
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit
40 TROUBLESHOOTING (Monitor)
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)

Action level Failure code System Operating Lamp Open Circuit (Monitor)
Failure
- DAFLKA (Machine monitor system)
Machine monitor determines that system operating lamp circuit is open because voltage of output
Detail of fail-
circuit remains at approximately 5 V or less for approximately 3 seconds after starting switch is
ure
turned to ON position, during which machine monitor outputs no current to system operating lamp.
Action of
controller
Phenomenon
Machine monitor is not able to light up system operating lamp.
on machine
• Although machine monitor is not able to light up system operating lamp, no trouble will re-
sult unless battery disconnect switch is turned to OFF position.
Related • When controller lights up system operating lamp, output circuit voltage is at low level.
information • Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
position. Turning battery disconnect switch to OFF position may destroy data stored in ma-
chine monitor memory.

1
box F01
2
CB6 or CB30
Open circuit in wiring har- 3. Disconnect connectors CM01 and LBU, and connect T-adapters to each
3
nector) Between CM01 (female) (8) and LBU (female) (2) Max. 1 Ω
Max. 1 Ω
BRB
Defective machine moni- If no failure is found by preceding checks, machine monitor is defective. (Because
4
tor this is an internal defect, troubleshooting cannot be performed.)
D155AX-8 40-789
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit
(Monitor) 40 TROUBLESHOOTING
40-790 D155AX-8
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit
40 TROUBLESHOOTING (Monitor)
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor)

Action level Failure code System Operating Lamp Short Circuit (Monitor)
Failure
- DAFLKB (Machine monitor system)
Detail of fail- Machine monitor determines that system operating lamp circuit shorts because voltage of output cir-
ure cuit does not become low level while machine monitor outputs current to system operating lamp.
Action of
controller
Phenomenon
Machine monitor is not able to light up system operating lamp.
on machine
• Although machine monitor is not able to light up system operating lamp, no trouble will re-
Related sult unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
position. Turning battery disconnect switch to OFF position may destroy data stored in ma-
chine monitor memory.

3. Remove fuse No. 15 in fuse box FS11.
4. Disconnect connectors PTCN3, WECN3, CK01, CM01, J2, and LBU, and
connect T-adapter to female side of LBU.
4. Disconnect connectors PTCN3, CK01, CM01, WECN3 and J2, and con-
Short circuit in wiring har- nect T-adapters to each female side.
1
ness
pin (34) ty
pin (15) ty
Between CM01 (female) (8) and every pin other than No continui-
Continuity
pin (8) ty
than pin (34) ty
(48) ty
2
CB6 or CB30
3
D155AX-8 40-791
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit
(Monitor) 40 TROUBLESHOOTING
40-792 D155AX-8
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Moni-
40 TROUBLESHOOTING tor)
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)

Action level Failure code CAN 2 Defective Communication (Monitor)
Failure
- DAFQKR (KOMTRAX system)
Detail of fail-
KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.
ure
Action of
controller
Phenomenon
KOMTRAX system may not function normally.
on machine
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Related Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
information not displayed on machine monitor and it can be observed only through KOMTRAX sys-
tem.
using multimeter.

Defective power supply Perform troubleshooting for E mode "E-5".
1
to machine monitor
Defective CAN communi- Perform checks on cause 5 and subsequent causes in troubleshooting for failure
2
cation code [DB2QKR].
D155AX-8 40-793
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) 40 TROUBLESHOOTING
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C)

Action level Failure code Model Selection Signal Mismatch (Air conditioner)
Failure
- DAZ9KQ (Machine monitor system)
Details of Model in machine monitor program is different from that in air conditioner controller program (re-
failure placed machine monitor or air conditioner controller is wrong in part No.)
Action of
controller
Phenomenon
Air conditioner may not function normally.
on machine
• Model code specified by air conditioner controller program cannot be checked with moni-
toring function.
• Model code of machine monitor program can be checked with monitoring function (Code:
00500).
Related • Air conditioner control data (model and series) of machine monitor can be checked with
monitoring function (Code: 55200).
information
• Control data of air conditioner controller (model and series names) can be checked with
monitoring function (Code: 55201). (If control data is 09H (indicating medium-sized bull-
dozer), it is correct.)

Defective machine moni- Defective machine monitor (Programmed machine model is different.)
1
tor
Defective air conditioner Defective air conditioner controller (Wrong machine model is programmed.)
2
controller
40-794 D155AX-8
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C
40 TROUBLESHOOTING ECU)
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)

Action level Failure code CAN 2 Defective Communication (Air conditioner)(Engine cotoroller
Failure system)
L01 DAZQKR (detected by machine monitor) (Machine monitor)
Details of Machine monitor cannot recognize air conditioner controller on CAN2 communication line (KOM-
failure NET/c).
Action of • Retains information when the failure occurred.

• Failure codes to be generated by air conditioner controller are not displayed.
Phenomenon • Monitoring data related to air conditioner controller are not updated.
on machine • Air conditioner cannot be controlled. (Air does not blow out)
• Air conditioner operation screen of machine monitor is not displayed properly.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 5 different failure codes, [D8AQKR], [DAZQKR], [DB2QKR], [DB9QKR], and [DBEQKR]
Related are used for defective CAN communication by CAN2, which are detected by machine
information monitor. When all of these 5 failure codes are displayed, ground fault, short circuit or hot
short circuit in wiring harness (CAN communication circuit) are the possible causes.
• Each controller and machine monitor are continuously supplied with power from battery
even while starting switch is OFF.
• Signal of active CAN communication line is pulse voltage. It cannot be measured by using
multimeter.

Defective power supply Perform Chapter 80 “Troubleshooting for electrical system”.
1 to air conditioner control-
ler
Defective CAN2 commu- Perform checks on causes 4 to 9 for failure code [DB2QKR].
2
nication system
controller
4
D155AX-8 40-795
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine
Controller) 40 TROUBLESHOOTING
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Con-

troller)
Action level Failure code CAN 2 Defective Communication (Engine Controller) (Detected by
Failure
L03 DB2QKR machine monitor) (Machine monitor system)
Details of Machine monitor does not recognize the engine controller through CAN2 communication line (KOM-
failure NET/c).
Action of • Communication information is not updated.

• Failure codes to be generated by engine controller are not displayed.
Phenomenon • Monitoring data for which engine controller is responsible is not updated.
on machine • KDPF manual regeneration is not available.
• Cylinder cutout mode and no-injection cranking are not available.
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller is probably defective (cause
2).
• 5 different failure codes, [D8AQKR], [DAZQKR], [DB2QKR], [DB9QKR] and [DBEQKR] are
used for defective CAN communication by CAN2 when it is detected by machine monitor.
When all of these 5 failure codes are displayed, ground fault, short circuit or hot short in
wiring harness (CAN communication line) can be suspected. Since air conditioner is also
operated through CAN communication, you must, in such case, check on air conditioner
Related
screen whether air conditioner is operable (ON/OFF and air flow of air conditioner).
information
REMARK
tioner is controlled, wiring harness (CAN communication line) does not have ground fault, short
circuit, or hot short circuit.
using multimeter.
REMARK
If fuse - 19 in fuse box F01 is blown out, the machine monitor displays nothing.

Defective circuit breaker Check circuit breaker CB9 (30 A). (If it is tripped, engine controller probably has
1
CB9 (30 A) short circuit.)
If circuit breaker is not tripped, this check is not required.
Defective engine control- 2. Disconnect connector J2, and connect T-adapter to male side.
2
ler
Between J2 (male) (25) and (49) Min. 10 Ω
Resistance
Between J2 (male) (27) and (51) Min. 10 Ω
40-796 D155AX-8
40 TROUBLESHOOTING Controller)
REMARK
Check ground terminal GND20 for looseness and rust.
2. Disconnect connector J2 and connect T-adapter to female side.
Defective power supply 3. Turn starting switch to ON position.
3
to engine controller
REMARK
If abnormal, perform troubleshooting for [CA441].
Between J2 (female) (25) and (49) 20 to 30 V
Voltage
Between J2 (female) (27) and (51) 20 to 30 V
Defective fuse 8 in fuse If fuse is blown out, engine controller has probably has short circuit in it.
4
box F01
Defective CAN terminat- 2. Disconnect connectors CM02 and CTE, and connect T-adapter to male
ing resistor side.
5
(internal open or short
Between CTE (male) (A) and (B) 120 ± 12 Ω
circuit) Resistance
Between CM02 (male) (7) and (9) 120 ± 12 Ω
D155AX-8 40-797

• CAN communication line
REMARK
CAN terminating resistor of 120 Ω is also located in machine monitor. That is, two
CAN terminating resistors of 120 Ω are connected in parallel. When circuit resist-
ance is measured at connector of controller other than machine monitor, if com-
bined resistance is 60 Ω, wiring harness does not have open circuit.
OFF position.
2. Disconnect only connectors to be measured and connect T-adapter to fe-
male side.
REMARK
If short circuit is found (resistance between 2 terminals is 1 Ω or less), disconnect
all CAN communication connectors of every controller and check whether short cir-
cuit occurs between wiring harnesses or inside controller.
Open or short circuit in Approxi-
6
wiring harness Between CM02 (female) (8) and (9) mately
120 Ω
Approxi-
mately 60 Ω
Approxi-
Between WECN2 (female) (32) and (22)
mately 60 Ω
Approxi-
Resistance Between PTCN2 (female) (32) and (22)
mately 60 Ω
Approxi-
Between AC01 (female) (9) and (10)
mately 60 Ω
Approxi-
Between CK01 (female) (10) and (11)
mately 60 Ω
Approxi-
Between CTE (female) (A) and (B) mately
120 Ω
40-798 D155AX-8

• ACC signal of starting switch (start of CAN communication is not recog-
nized)
OFF position.
2. Disconnect connectors to be measured and insert T-adapters.
3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Between WECN3 (14) (24) and (21) 20 to 30 V
Voltage
Between PTCN3 (14) (24) and (21) 20 to 30 V
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
quired.
Open circuit in wiring har- 1. Turn starting switch to OFF position, and turn battery disconnect switch to
ness OFF position.
7
(wire breakage or defec- 2. Disconnect related connectors, and connect T-adapter to each female side
tive contact of connector) connector to be measured.
Between CM02 (female) (7) and CM02 (female) (8) Max. 1 Ω
Between CM02 (female) (8) and PTCN2 (female) (32) Max. 1 Ω
Between CM02 (female) (8) and J2 (female) (22) Max. 1 Ω
Between CM02 (female) (8) and WECN2 (female) (32) Max. 1 Ω
Resistance Between CM02 (female) (9) and WECN2 (female) (22) Max. 1 Ω
Between CM02 (female) (8) and AC01 (female) (9) Max. 1 Ω
Between CM02 (female) (9) and AC01 (female) (10) Max. 1 Ω
Between CM02 (female) (8) and CK01 (female) (10) Max. 1 Ω
Between CM02 (female) (9) and CK01 (female) (11) Max. 1 Ω
Between J2 (female) (22) and CTE (female) (A) Max. 1 Ω
Between J2 (female) (23) and CTE (female) (B) Max. 1 Ω
any one place in each case.
OFF position.
Ground fault in wiring 2. Disconnect all related connectors, and connect T-adapter to female side
harness connector to be measured.
8
(contact with ground cir- Between ground and any of CM02 (female) (8),
cuit) PTCN2 (female) (32), CK01 (female) (10), AC01 (fe- Min. 1 MΩ
male) (9), J2 (female) (22), and WECN2 (female) (32)
Resistance
Between ground and any of CM02 (female) (9),
PTCN2 (female) (22), CK01 (female) (11), AC01 (fe- Min. 1 MΩ
male) (10), J2 (female) (23), and WECN2 (female) (22)
D155AX-8 40-799

any one place in each case.
OFF position.
2. Disconnect one of the related connectors, and insert T-adapter to the con-
nector.
Short circuit or hot short
9 circuit in wiring harness 4. Turn starting switch to ON position.
(contact with 24 V circuit) REMARK
Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication, so re-
gard wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and any of CM02 (8), PTCN2 (32),
1 to 4 V
CK01 (10), J2 (22), and WECN2 (32)
Voltage
Between ground and any of CM02 (9), PTCN2 (22),
1 to 4 V
CK01 (11), J2 (23), and WECN2 (22)
• If all five of [D8AQKR], [DAZQKR], [DB2QKR], [DB9QKR], and [DBEQKR]
failure codes are displayed:
REMARK
To identify defective controller, repeat following steps 1. to 3. to disconnect con-
trollers one by one from CAN communication line .
1. Turn starting switch to OFF position, and set battery disconnect switch to
Defective engine control- OFF position.
ler, work equipment con-
2. Disconnect each CAN communication connector one by one in order en-
troller, transmission con-
10 gine controller connector J2, work equipment controller connector
troller, air conditioner
controller, machine moni- WECN2, power train controller connector PTCN2, air conditioner controller
tor, KOMTRAX terminal connector AC01, KOMTRAX terminal connector CK01, and machine moni-
tor connector CM02.
3. Set battery disconnect switch to ON position, turn starting switch to ON po-
sition, then perform troubleshooting.
4. Return to step 1 to check next connector.
Has the number of displayed failure co- If YES, disconnected controller is defec-
des decreased from five? tive.
11
12
40-800 D155AX-8
CIRCUIT DIAGRAM (CAN2 COMMUNICATION)
D155AX-8 40-801
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Con-

troller)
Action level Failure code CAN 1 Defective Communication (Engine controller sysstem)(Detect-
Failure
L03 DB2RKR ed by machine monitor) (Machine monitor system)
Details of
Machine monitor does not recognize engine controller over CAN communication-1 line (KOMNET/r).
failure
Action of • Hides pointer of engine coolant temperature gauge from screen.
controller • Moves pointer of engine speed meter to zero point.
• Information to be obtained from engine controller is not displayed and special functions
that need information do not work. Or received data are not updated.
Phenomenon
• Engine cannot be controlled.
on machine
• Engine speed and coolant temperature cannot be detected.
• Engine coolant temperature gauge pointer goes off on machine monitor screen.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller may be defective (cause 1).
• For CAN communication error over CAN communication-1 line, monitor controller can
Related generate failure codes [DB2RKR], [DB9RKR], and [DBERKR].
information • CAN1 terminating resistor is located in machine controller on operator's cab side and con-
nector "B_RES" is located on engine side ("B_RES" is not in CAN communication-1 circuit
(KOMNET/r). It is led from connector "J1").
• Since each controller is connected directly to battery, it is supplied with power even after
starting switch is turned to OFF position.
using multimeter.

Defective engine control- Perform checks on causes 1 to 4 in troubleshooting for failure code [DB2QKR].
1
ler system
2. Disconnect connectors CM02 and B_RES, and connect T-adapter to male
Defective CAN terminat-
2 ing resistor (internal open side.
or short circuit) Between B_RES (male) (A) and (B) 120 ± 12 Ω
Resistance
Between CM02 (male) (10) and (12) 120 ± 12 Ω
40-802 D155AX-8

• CAN communication line
REMARK
CAN terminating resistor of 120 Ω is also located in machine monitor. That is, 2
CAN terminating resistors of 120 Ω are connected in parallel. When circuit resist-
ance is measured at connector of controller other than machine monitor, if com-
bined resistance is 60 Ω, wiring harness does not have open circuit.
OFF position.
2. Disconnect connectors CM02, WECN2, PTCN2, J1, and B_RES one by
one, and connect T-adapters to each female side.
REMARK
If short circuit is found (resistance between 2 terminals is 1 Ω or less), disconnect
Open or short circuit in all CAN communication connectors of every controller, and check whether short cir-
3
wiring harness cuit occurs between wiring harnesses or inside controller.
Approxi-
Between CM02 (female) (11) and (12) mately
120 Ω
Approxi-
Between PTCN2 (female) (33) and (23)
mately 60 Ω
Approxi-
Resistance Between WECN2 (female) (33) and (23)
mately 60 Ω
Approxi-
Between RES2 (female) (A) and (B) mately
120 Ω
Approxi-
mately 60 Ω
D155AX-8 40-803

• ACC signal of starting switch (start of CAN communication is not recog-
nized)
OFF position.
2. Disconnect connectors CM01, PTCN3, WECN3 and J2 and insert T-adapt-
ers.
ON position.
Between CM01 (10), (13), and (3) 20 to 30 V
Between EGC3 (5) and (49) 20 to 30 V
Voltage
Between WECN3 (14), (24) and (21) 20 to 30 V
Between PTCN3 (14) (24) and (21) 20 to 30 V
REMARK
Open circuit in wiring har- If failure code is still displayed after above checks on cause 3, this check is not
ness
4 required.
(wire breakage or defec- 1.
Turn starting switch to OFF position, and turn battery disconnect switch to
tive contact of connector)
OFF position.
2. Disconnect connectors CM02, PTCN2, WECN2, J1, and B_RES and con-
nect T-adapters to each female side.
Between CM02 (female) (11) and WECN2 (female)
Max. 1 Ω
(33)
Between CM02 (female) (12) and WECN2 (female)
(23)
Between J2 (female) (70) and B_RES (female) (B) Max. 1 Ω
Between J2 (female) (94) and B_RES (female) (A) Max. 1 Ω
OFF position.
2. Disconnect connectors CM02, WECN2, PTCN2, J1, B_RES and connect
T-adapter to either female side.
Ground fault in wiring Between ground and any of WECN2 (female) (33),
harness PTCN2 (female) (33), CM02 (female) (10), (11) and J1 Min. 1 MΩ
5 (female) (94).
(contact with ground cir-
cuit) Between DCL (female) (A) and ground Min. 1 MΩ
Resistance
Between ground and any of WECN2 (female)(23),
PTCN2 (female) (23), CM02 (female) (12) and J1(fe- Min. 1 MΩ
male) (70)
Between B_RES (female) (B) and ground Min. 1 MΩ
40-804 D155AX-8
REMARK
If no failure (no open circuit) is found by check on cause 3, measure resistance
at any one place in each case.
OFF position.
2. Disconnect either of connectors CM02, WECN2, PTCN2 and B_RES, and
connect T-adapter to female side.
Short circuit or hot short
6 circuit in wiring harness REMARK
(contact with 24 V circuit) Not measured in J1
REMARK
CAN H and CAN L is 2.5 ± 1 V including during communication, so regard it as
normal if measured voltage is 1 to 4 V.
WECN2 (female) (33), PTCN2 (female) (33), and 1 to 4 V
B_RES (female) (A).
Voltage
WECN2 (female) (33), PTCN2 (female) (23), and 1 to 4 V
B_RES (female) (B).
• When failure code [DBERKR] is also displayed
REMARK
Disconnect controllers from CAN communication one by one to see which is
defective, power train controller or engine controller.
Defective power train OFF position.
7
controller 2. Disconnect power train controller (connector PTCN2).
3. Turn battery disconnect switch ON, then turn starting switch to ON posi-
tion.
Does either of displayed failure codes If YES, power train controller is defec-
[DBERKR] and [DB2RKR] for CAN1 tive.
communication go out?
• When failure code [DB9RKR] is also displayed
REMARK
Disconnect work equipment controller and engine controller one by one from
CAN communication line to determine which controller is defective.
Defective work equip- OFF position.
8
ment controller 2. Disconnect work equipment controller (connector WECN2).
ON position.
Does number of CAN1 communication If YES, work equipment controller is de-
failure codes decrease from those on fective.
[DB9RKR] and [DB2RKR]?
D155AX-8 40-805

• If failure code [DBERKR] or [DB9RKR] is displayed simultaneously
Disconnect work equipment controller, power train controller, and engine controller
one by one from CAN communication line to determine which controller is defec-
tive.
Defective engine control- OFF position.
9
ler 2. Disconnect engine controller (connector J1).
3. Turn battery disconnect switch to ON position, and turn the starting switch
to ON position.
Does number of CAN1 communication If YES, engine controller is defective.
failure codes decrease from those on
[DBERKR], [DB9RKR] and [DB2RKR]?
10
11
40-806 D155AX-8
Circuit diagram related to CAN communication 1
D155AX-8 40-807
FAILURE CODE [DB90KT] W/E Controller Internal Abnormality 40 TROUBLESHOOTING
FAILURE CODE [DB90KT] W/E Controller Internal Abnormality

Action level Failure code Work Equipment Controller Internal Abnormality
Failure
L01 DB90KT (Work equipment controller system)
Details of
• Information in ROM (non-volatile memory) in work equipment controller is abnormal.
failure
Action of
• Sets internal adjustment values to default values.
controller
Phenomenon • Operation feeling of work equipment may become bad.
on machine • Adjustment function of machine monitor may operate abnormally.

Use “Adjustment” function in service mode to initialize work equipment controller.
Defective adjustment of Perform operation of reproducing this failure code. If mark E of failure code is
1 work equipment control- cleared at this time, work equipment controller is normal.
ler
• Adjustment code: 0031 (Initial setting of work equipment controller)
In case of an internal defect, troubleshooting is impossible as an assembly. Re-
Defective work equip-
2 place whole assembly. (If there is no visible failure on machine, controller may be
ment controller
used as it is.)
40-808 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DB90MC] W/E Controller Malfunction
FAILURE CODE [DB90MC] W/E Controller Malfunction

Action level Failure code Work Equipment Controller Malfunction
Failure
- DB90MC (Work equipment controller system)
Details of
• Reset and restart CPU of work equipment controller is reset and restarted.
failure
Action of
• Reset and restart CPU of work equipment controller is reset and restarted.
controller
Phenomenon • KOMTRAX system does not operate normally.
on machine • Machine returns to state when starting switch is turned ON.

Defective work equip- Work equipment controller may be defective. (In case of an internal defect, trouble-
1
ment controller shooting is impossible as an assembly. Replace whole assembly.)
D155AX-8 40-809
FAILURE CODE [DB91KK] W/E Controller Source Voltage Low Error 40 TROUBLESHOOTING
FAILURE CODE [DB91KK] W/E Controller Source Voltage Low Error

Action level Failure code Work Equipment Controller Source Voltage Low Error
Failure
L01 DB91KK (Work equipment controller system)
Details of
• Battery direct power supply voltage of work equipment controller is below 17 V.
failure
Action of
• Restricts operation of engine, transmission, brake, and work equipment.
controller
• Monitor panel may display abnormally.
Phenomenon • Relay and solenoids may not be driven, and system may operate abnormally.
on machine • Once machine stops, engine speed is restricted to medium (half) speed.
• Once machine stops, it cannot travel at all.
• Power supply voltage of work equipment controller can be checked with adjusting function.
Related (Code: 2022 Work equipment controller voltage check mode)

Defective circuit breaker If circuit breaker is tripped, circuit probably has ground fault, etc. In this case, per-
1
(CB30) form check on cause 6 first.
Loose terminal or open 1. Turn starting switch to OFF position.

2
circuit in terminal Check terminals of battery relay, battery, etc.
3. Disconnect connectors WECN3 and connect T-adapter to female side.
4
fault in wiring harness REMARK
If voltage is 0 V, wiring harness has open-circuit or ground fault.
Between WECN3 (female) (1) and (21), (31) 20 to 30 V
Voltage
Between WECN3 (female) (11) and (32), (33) 20 to 30 V
40-810 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DB91KK] W/E Controller Source Voltage Low Error
REMARK
required.
3. If fuse is blown out, replace it.
ness (wire breakage or 4. If circuit breaker is tripped, reset it.
5
defective contact of con- 5. Disconnect connector WECN3 and connect T-adapter to female side.
nector)
Between ground and each of WECN3 (female) (21),
(31), (32), and (33)
Max. 1 Ω
REMARK
Resistance
Check terminal GND11 for looseness and rust.
Between battery positive terminal (+) and WECN3 (fe-
Max. 1 Ω
male) (1) and (11)
REMARK
required.
Ground fault in wiring 2. Turn battery disconnect switch to OFF position.
6 harness (contact with 3. If fuse is blown out, replace it.
ground circuit)
4. If circuit breaker is tripped, reset it.
Between WECN3 (female) (1) to (21) and (31) Min. 1 MΩ
Resistance
Between WECN3 (female) (11) to (32) and (33) Min. 1 MΩ
If failure code is still displayed after above checks, work equipment controller is de-
fective.
• Reference
Defective work equip- 2. Turn battery disconnect switch to OFF position.
7
ment controller 3. Insert T-adapter into connector WECN3.
Voltage
D155AX-8 40-811
FAILURE CODE [DB91KK] W/E Controller Source Voltage Low Error 40 TROUBLESHOOTING
Circuit diagram related to work equipment controller power supply
40-812 D155AX-8
FAILURE CODE [DB92KK] W/E Controller Solenoid Power Voltage
FAILURE CODE [DB92KK] W/E Controller Solenoid Power Voltage Low Er-
ror
Action level Failure code Work Equipment Controller Solenoid Power Voltage Low Error
Failure
Detail of fail- • Power supply voltage (power supplied through the battery relay) for work equipment con-
ure troller loads (relays and solenoids) is 17 V or lower.
Action of
• Restricts operations of engine, transmission, brake, and work equipment.
controller
• Relay and solenoid may not be actuated and system may not operate properly.
Phenomenon
• Once machine stops, engine speed is restricted to medium (half) speed.
on machine
• Once machine stops, it becomes unable to travel at all.
• Power supply voltage of work equipment controller can be checked with adjusting function.
Related (Code: 2022 Work equipment controller supply voltage check mode)

Defective circuit breaker If circuit breaker CB2 or CB105 is tripped, circuit probably has ground fault, etc. In
1
CB2 or CB105 this case, perform check on cause 6 first.

2
Defective wiring harness 4. Turn battery disconnect switch to OFF position.
4 or work equipment con- 5. Turn starting switch to ON position.
troller
Voltage Between WECN3 (12) and (31) 20 to 30 V
D155AX-8 40-813
REMARK
required.
2. Turn battery disconnect switch to ON position (to prevent short circuit during
Open circuit in wiring har- work).
ness (wire breakage or 3. Disconnect connector WECN3 and connect T-adapter to female side.
5
nector) Between ground and each of WECN3 (female) (21),
(31), (32), and (33)
Max. 1 Ω
REMARK
Resistance
Check terminal GND for looseness and rust.
Between ground and each of WECN3 (female) (2),
Max. 1 Ω
(12) and (22)
REMARK
required.
6 harness (contact with 2. Turn the battery disconnect switch to OFF position (to prevent short circuit dur-
ground circuit) ing work).
3. If circuit breaker is tripped, reset it.
4. Disconnect connector WECN3.
Resistance Between terminal BRC and ground Min. 1 MΩ
7
40-814 D155AX-8
Circuit diagram related to work equipment controller power supply
D155AX-8 40-815
FAILURE CODE [DB95KK] W/E Controller 5V Sensor 0 Power Voltage
Out of Range 40 TROUBLESHOOTING
FAILURE CODE [DB95KK] W/E Controller 5V Sensor 0 Power Voltage Out

of Range
Action level Failure code Work Equipment Controller 5V Sensor 0 Power Voltage Out of
Failure Range
• Voltage of 5 V power supply circuit for work equipment controller sensor is below 4.5 V or
Details of
above 5.5 V.
failure
• Unusual current flows in 5 V power supply circuit for work equipment controller sensor.
Action of • Stops outputting of 5 V power supply circuit for work equipment controller sensor.
controller • Restricts operation of engine and transmission.
• System may not operate normally.
Phenomenon • Automatic gear shift system does not work.
• Once machine stops, gear speed is restricted to F1 and R2.

2. Disconnect connectors of the following levers, and turn starting switch to ON
position.
REMARK
Because defective connectors are disconnected from disconnected lever when
Defective blade control this failure code is cleared, other failure code is displayed.
1
lever (internal defect)
REMARK
However, ignore failure codes other than this failure code.
DB95KK
Connector WLV1 Blade control lever does not
disappear.
2. Disconnect connectors of the following levers, and turn starting switch to ON
position.
REMARK
Because defective connectors are disconnected from disconnected lever when
Defective ripper control this failure code is cleared, other failure code is displayed.
2
lever (internal defect)
REMARK
However, ignore failure codes other than this failure code.
DB95KK
Connector WLV2 Ripper control lever does not
disappear.
Ground fault in wiring 2. Disconnect connectors WECN1, WLV1, and WLV2, and connect T-adapter to
3 harness (contact with either female side.
ground circuit)
Between ground and WECN1 (22), WLV1 (4), WLV1
(8), or WLV2 (4)
40-816 D155AX-8
40 TROUBLESHOOTING Out of Range

2. Disconnect connectors WLV1 and WLV2, and connect T-adapters to female
side.
ness
Between ground and WLV1 (female) (4) and (1) or be-
Voltage tween WLV1 (female) (8) to WLV2 (female) (4) and 4.5 to 5.5 V
ground
fective.
Reference
5 3.
ment controller Turn starting switch to ON position.
REMARK
Since 24 V power is supplied to connector WECN1, 5 V cannot be checked when
the connector WECN1 is disconnected.
Voltage Between WECN1 (22) and (21) 4.5 to 5.5 V
D155AX-8 40-817
Circuit diagram related to work equipment controller sensor 5 V power supply
40-818 D155AX-8
FAILURE CODE [DB97KK] W/E Controller 5V Sensor 1 Power Voltage Out

of Range
Action level Failure code Work Equipment Controller 5V Sensor 1 Power Voltage Out of
Failure
L01 DB97KK Range
• Voltage of 5 V power supply voltage circuit for work equipment controller sensor is below
Details of 4.5 V or above 5.5 V.
failure • Unusual current flows in 5 V power supply voltage circuit for work equipment controller
sensor.
Action of
• Stops outputting of 5 V power supply circuit when abnormal current flows.
controller
Phenomenon • Work equipment pump oil pressure is not monitored correctly (It does not affect machine
on machine behavior in particular).

2. Disconnect connector HHP.
Defective hydraulic pump
• If this failure code is cleared, disconnected hydraulic pump pressure sen-
1 pressure sensor (internal
sor is defective.
defect)
REMARK
Other failure codes are displayed as well. This is because connector is discon-
nected. Ignore failure codes other than [DB97KK].
Ground fault in wiring 2. Disconnect connectors WECN2 and HHP, and connect T-adapter to either fe-
ground circuit)
Between ground and WECN2 (female) (1) or HHP (fe-
male) (B)
Short circuit in wiring har- 2. Disconnect connector HHP and connect T-adapter to female side.
3
Voltage Between HHP (female) (B) and (A) 4.5 to 5.5 V
fective.
Reference
2. Insert T-adapters into connectors WECN1 and WECN2.
4 3.
ment controller Turn starting switch to ON position.
REMARK
Since 24 V power is supplied to connector WECN1, 5 V output cannot be checked
with connector WECN1 disconnected.
Voltage Between WECN2 (1) and WECN1 (21) 4.5 to 5.5 V
D155AX-8 40-819
Circuit diagram related to work equipment controller 5 V sensor power supply
40-820 D155AX-8
FAILURE CODE [DB99KQ] Model Selection Signal Mismatch (W/E
FAILURE CODE [DB99KQ] Model Selection Signal Mismatch (W/E Control-

ler)
Action level Failure code Model Selection Signal Mismatch
Failure
L04 DB99KQ (Work equipment controller system)
Detail of fail- • Specification set in work equipment controller does not agree with specification set in
ure memory. (Initialization of work equipment controller is not performed.)
Action of • Stops all work equipment controller outputs.
controller • Restricts operations of engine, transmission, brake, and work equipment.
• Machine does not move at all.
Phenomenon • Automatic gear shift function does not work.

Use “Adjustment” function in service mode to initialize work equipment controller.
Defective adjustment of Perform operation of reproducing this failure code. If mark E of failure code is
1 work equipment control- cleared at this time, work equipment controller is normal.
ler
• Adjustment code: 0031 (Initial setting of work equipment controller)
2. Disconnect connector WECN3 and connect T-adapter to female side.
Between WECN3 (female) (10) and ground Min. 1 MΩ
ness (wire breakage or Between WECN3 (female) (20) and ground Max. 1 Ω
2
defective contact of con- Between WECN3 (female) (21) and ground Max. 1 Ω
nector) Resistance
Between WECN3 (female) (31) and ground Max. 1 Ω
If failure code is still displayed after above checks, work equipment controller may
3 be defective. (In case of an internal defect, troubleshooting is impossible as an as-
ment controller
D155AX-8 40-821
FAILURE CODE [DB99KQ] Model Selection Signal Mismatch (W/E
Circuit diagram related to we controller work equipment controller model selec-

tion
40-822 D155AX-8
FAILURE CODE [DB9LKA] System Operating Lamp Open Circuit
40 TROUBLESHOOTING (W/E Controller)
FAILURE CODE [DB9LKA] System Operating Lamp Open Circuit (W/E

Controller)
Action level Failure code System Operating Lamp Open Circuit (Work equipment controller
Failure
DB9LKA system)
The work equipment controller has detected an open circuit because the output line voltage of sys-
Detail of fail-
tem operating lamp is approximately 5 V or less when the work equipment controller does not out-
ure
put the voltage for approximately 3 seconds after the starting switch has turned ON.
Action of
controller
Turning battery disconnect switch to OFF position may destroy data stored in work equipment con-
on machine troller memory.
• Although work equipment controller is not able to light up system operating lamp, no trou-
Related
ble will result unless battery disconnect switch is turned to OFF position.
information
• Since no controller drives system operating lamp for approximately 3 seconds after start-

1
box F01
2
CB6 or CB30
Open circuit in wiring har- 3. Disconnect connectors WECN3 and LBU, and connect T-adapters to each
3
nector) Between WECN3 (female) (34) and LBU (female) (2) Max. 1 Ω
Max. 1 Ω
(BRB)
ment controller
D155AX-8 40-823
FAILURE CODE [DB9LKA] System Operating Lamp Open Circuit
(W/E Controller) 40 TROUBLESHOOTING
40-824 D155AX-8
FAILURE CODE [DB9LKB] System Operating Lamp Short Circuit
40 TROUBLESHOOTING (W/E Controller)
FAILURE CODE [DB9LKB] System Operating Lamp Short Circuit (W/E

Controller)
Action level Failure code System Operating Lamp Short Circuit (Work equipment controller
Failure
DB9LKB system)
Work equipment controller determines that output circuit to system operating lamp shorts because
Detail of fail-
voltage of output circuit does not become Low level while work equipment controller drives system
ure
operating lamp.
Action of
controller
Turning battery disconnect switch to OFF position may destroy data stored in work equipment con-
on machine troller memory.
Related
• Although work equipment controller is not able to light up system operating lamp, no trou-
information ble will result unless battery disconnect switch is turned to OFF position.

3. Remove fuse 15 in fuse box FS11.
4. Disconnect connectors PTCN3, CK01, CM01, WECN3, and EGC3, and
Short circuit in wiring har- connect T-adapters to each female side.
1
ness
5. Turn battery disconnect switch ON.
(34) ty
(15) ty
Between CM01 (female) (8) and each pin other than No continui-
Continuity
(8) ty
than (34) ty
(9) ty
ment controller
D155AX-8 40-825
FAILURE CODE [DB9LKB] System Operating Lamp Short Circuit
(W/E Controller) 40 TROUBLESHOOTING
40-826 D155AX-8
FAILURE CODE [DB9QKR] CAN 2 Defective Communication (W/E
FAILURE CODE [DB9QKR] CAN 2 Defective Communication (W/E Control-

ler)
Action level Failure code CAN 2 Defective Communication (Work equipment controller system)
Failure
L03 DB9QKR (detected by machine monitor) (Machine monitor)
Details of Machine monitor does not recognize work equipment controller on CAN2 communication line (KOM-
failure NET/cr).
Action of • Does not update communication information of CAN2.

• Failure codes related to work equipment controller are not displayed.
Phenomenon
• Each data of monitoring code is not updated.
on machine
• Adjustment function is not available.
troller.
• There are 5 different failure codes, [D8AQKR], [DAZQKR], [DB2QKR], [DB9QKR], and
[DBEQKR] which are used for defective CAN communication by CAN2 when it is detected
by machine monitor. When all of these 5 failure codes are displayed, ground fault, short
circuit or hot short in wiring harness (CAN communication circuit) are the possible causes.
In such case, check whether air conditioner is operable (ON/OFF and air flow of air condi-
Related tioner) with air conditioner screen since air conditioner is also operated through CAN com-
information munication.
REMARK
tioner is controlled, there is no possibility of ground fault, short circuit, or hot short circuit occur-
ring in wiring harness (CAN communication line).
multimeter.

Defective power supply Perform troubleshooting for failure code [DB91KK].
1 to work equipment con-
troller
2
cation 2 system
ment controller
4
D155AX-8 40-827
FAILURE CODE [DB9RKR] CAN 1 Defective Communication (W/E
FAILURE CODE [DB9RKR] CAN 1 Defective Communication (W/E Control-

ler)
Action level Failure code CAN 1 Defective Communication (Work equipment controller system)
Failure
L03 DB9RKR (detected by machine monitor) (Machine monitor)
Details of Machine monitor does not recognize work equipment controller on CAN1 communication line (KOM-
failure NET/r).
Action of • Does not update Communication information of CAN1.

• Information and failure code to be obtained from work equipment controller are not dis-
Phenomenon played. Update of received data is stopped.
on machine • Hydraulic oil temperature gauge pointer disappears.
troller.
• Machine monitor uses failure codes [DB9RKR] and [DBERKR] to indicate failures in CAN
communication on CAN 1 line. When failure code [DB9RKR] or [DBERKR] is displayed si-
multaneously on screen, a ground fault, short circuit, or hot short circuit in wiring harness
Related
(CAN communication line) are the possible causes.
information
• CAN1 terminating resistors are located in machine monitor on operator's cab side and
connector "RES2" is located on engine side (CAN communication 1 circuit (KOMNET/r) is
not provided. It is connected to connector "J2").
• Each controller is continuously supplied with power from battery even while starting switch
is OFF.
multimeter.

Defective power supply Perform troubleshooting for failure code [DB91KK].
1 system to work equip-
ment controller
Defective CAN communi- Perform checks on causes 2 to 9 in troubleshooting for failure code [DB2RKR].
2
cation 1 system
ment controller
4
40-828 D155AX-8
FAILURE CODE [DB9RKR] CAN 1 Defective Communication (W/E
D155AX-8 40-829
FAILURE CODE [DBE0KT] P/T Controller Internal Abnormality 40 TROUBLESHOOTING
FAILURE CODE [DBE0KT] P/T Controller Internal Abnormality

Action level Failure code Power Train Controller Internal Abnormality
Failure
L01 DBE0KT (Power train controller system)
Detail of fail-
• Information in ROM (non-volatile memory) in power train controller is abnormal.
ure
Action of
• Sets internal adjustment values to defaults.
controller
Phenomenon • Operator's feeling at transmission gear shift may become uncomfortable.
on machine • Adjusting function by power train controller may not operate properly.

Perform reproducing method in “Adjustment” function in service mode. If failure
code mark E goes out, system is normal.
Defective adjustment of
1
power train controller REMARK
Adjustment code: 0002 “Power train controller initialization”
In case of an internal defect, troubleshooting is impossible as an assembly. Re-
2 place whole assembly. (If there is no visible failure on machine, controller may be
controller
used as it is.)
40-830 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DBE1KK] P/T Controller Source Voltage Low Error
FAILURE CODE [DBE1KK] P/T Controller Source Voltage Low Error

Action level Failure code Power Train Controller Source Voltage Low Error
Failure
L04 DBE1KK (Power train controller system)
Detail of fail- • Power supply (power supply directly connected to battery) voltage for power train control-
ure ler is 17 V or lower.
Action of
• Restricts operations of engine, transmission, and brake.
controller
• Machine monitor may not display correctly.
Phenomenon • Relay and solenoid may not be actuated and system may not operate properly.
• Power supply voltage of power train controller can be checked with adjusting function.
Related (Code: 2021: Power train controller voltage check mode)

1
(CB30 or CB7) this case, perform check on cause 6 first.

2
4
wiring harness REMARK
If voltage is 0 V, it has open circuit or ground fault.
Between PTCN3 (female) (1) and (21) or (31) 20 to 30 V
Voltage
Between PTCN3 (female) (11) and (32) or (33) 20 to 30 V
D155AX-8 40-831
FAILURE CODE [DBE1KK] P/T Controller Source Voltage Low Error 40 TROUBLESHOOTING
REMARK
required.
3. If a fuse is blown out, replace it.
ness (wire breakage or 4. If a circuit breaker is tripped, reset the circuit breaker.
5
defective contact of con- 5. Disconnect connector PTCN3 and connect T-adapter to female side.
nector)
Between ground and each of PTCN3 (female) (21),
(31), (32) and (33)
Max. 1 Ω
REMARK
Resistance
Between each of PTCN3 (female) (1) and (11) and bat-
Max. 1 Ω
tery positive terminal (+)
REMARK
required.
6 harness (contact with 3. If a fuse is blown out, replace it.
ground circuit)
4. If a circuit breaker is tripped, reset the circuit breaker.
Between PTCN3 (female) (1) and (21) or (31) Min. 1 MΩ
Resistance
Between PTCN3 (female) (11) and (32) or (33) Min. 1 MΩ
tive.
• Reference
Defective power train 2. Turn battery disconnect switch to OFF position.
7
Between PTCN3 (1) and and (21), (31) 20 to 30 V
Voltage
Between PTCN3 (female) (11) and and (32), (33) 20 to 30 V
40-832 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DBE1KK] P/T Controller Source Voltage Low Error
Circuit diagram related to power train controller power source
D155AX-8 40-833
FAILURE CODE [DBE2KK] P/T Controller Solenoid Power Voltage
FAILURE CODE [DBE2KK] P/T Controller Solenoid Power Voltage Low Er-
ror
Action level Failure code Power Train Controller Solenoid Power Voltage Low Error
Failure
Details of
• Power voltage for power train controller loads (relays and solenoids) is 17 V or lower.
failure
Action of
• Restrict the operation of the engine, transmission, and brake.
controller
• Relays and solenoids are not driven and the system does not work correctly.
Phenomenon
• Once the machine stops, engine speed is restricted to medium (half) speed.
on machine
• Once the machine stops, it does not travel at all.
• Power supply voltage of power train controller can be checked with adjusting function.
(Code: 2021 Power train controller voltage check mode)
Related
• If the battery relay does not turn ON, see E-1 in E-mode.
information

1
CB1 or CB105 this case, perform check on cause 6 first.

2
or power train controller
Voltage Between PTCN3 (12) and (31) 20 to 30 V
40-834 D155AX-8
REMARK
required.
2. Turn the battery disconnect switch to OFF position (to prevent short circuit dur-
Open circuit in wiring har- ing work).
ness (wire breakage or 3. Disconnect connector PTCN3 and connect T-adapter to female side.
5
nector) Between ground and each of PTCN3 (female) (21),
(31), (32) and (33)
Max. 1 Ω
REMARK
Resistance
Between BRC and each of PTCN3 (female) (2), (12),
Max. 1 Ω
and (22)
REMARK
required.
ground circuit) 2. Turn the battery disconnect switch to OFF position (to prevent short circuit dur-
ing work).
Resistance Between BRC terminal and ground Min. 1 MΩ
Defective power train If failure code is still displayed after above checks, power train controller is defec-
7
controller tive.
D155AX-8 40-835
Circuit diagram related to power train controller power source
40-836 D155AX-8
FAILURE CODE [DBE5KK] P/T Controller 5V Sensor 0 Power Voltage
FAILURE CODE [DBE5KK] P/T Controller 5V Sensor 0 Power Voltage Out

of Range
Action level Failure code Power Train Controller 5 V Sensor 0 Power Voltage Out of Range
Failure
• Voltage of 5 V power supply (0) from power train controller to sensors is below 4.5 V or
Detail of fail- above 5.5 V.
ure
• Unusual current flows in 5 V power supply (0) circuit for power train controller sensors.
Action of • Stops output of 5 V power supply (0), if unusual current flows.
• System may not function normally.
• Once machine is stopped, selectable gear speeds are restricted to F1 and R1.

2. Disconnect following connectors one by one in order and turn starting switch
ON each time.
• If this code goes out, disconnected device is defective.
Defective fuel control di-
al, brake pedal, or joy- REMARK
1
stick (steering, directional Other failure codes are displayed (many) at the same time. This happens be-
and gear shift lever) cause the connector is disconnected. Ignore failure codes other than
[DBE5KK].
Fuel control dial DIAL
Connector joystick (steering, directional and gear shift lever) TLV1
Brake pedal BRK
Defective power train 2. Disconnect connector PTCN1 and connect T-adapter to male side.
2
Voltage Between PTCN1 (male) (22) and (21) 4.5 to 5.5 V
Ground fault in wiring 2. Disconnect connectors PTCN1, DIAL, TLV1, and BRK, and connect T-
3 harness (contact with adapter to either female side.
ground circuit)
Between ground and PTCN1 (female) (22), TLV1 (fe-
male) (4), (5), BRK (C), or DIAL (female) (A)
2. Disconnect connectors PTCN1, DIAL, TLV1, and BRK, and connect T-
Hot short circuit in wiring adapter to either female side.
V circuit)
Between TLV1 (female) (4) and (1), between TLV1 (fe-
Voltage male) (5) and (8), between BRK (C) and (A), or be- 4.5 to 5.5 V
tween DIAL (female) (A) and (C)
D155AX-8 40-837
FAILURE CODE [DBE5KK] P/T Controller 5V Sensor 0 Power Voltage
Circuit diagram related to power train controller 5V power supply
40-838 D155AX-8
FAILURE CODE [DBE6KK] P/T Controller 24V Sensor Power Voltage
FAILURE CODE [DBE6KK] P/T Controller 24V Sensor Power Voltage Out of
Range
Action level Failure code Power Train Controller 24 V Sensor Power Voltage Out of Range
Failure
• Voltage of 24 V power supply circuit from power train controller to sensors is below 12 V or
Detail of fail- above 30 V.
ure
• Unusual current flows in 24 V power supply circuit for power train controller sensors.
Action of • Stops output of 24 V power supply if unusual voltage flows.
• System may not function normally.

2. Disconnect following connectors one by one in order and turn starting switch
ON each time.
Defective pitch angle
sensor, torque converter • If this code goes out, disconnected sensor is defective.
input pressure sensor, or REMARK
1
torque converter output
pressure sensor (internal Other failure codes are also displayed. This is caused by that connectors are
defect) disconnected. Ignore all of displayed failure codes other than [DBE6KK].
Pitch angle sensor PT1
Connector Torque converter input pressure sensor TIP
Torque converter output pressure sensor TOP
Defective power train 2. Disconnect connector PTCN1 and connect T-adapter to male side.
2
Voltage Between PTCN1 (male) (16) and (21) 20 to 30 V
2. Disconnect connectors PTCN1, PT1, TIP, and TOP, and connect T-adapter to
harness
3 either female side.
cuit) Between ground and PTCN1 (female) (16), TIP(B),
and TOP(B) or PT1 (female) (C)
2. Disconnect connectors PT1, TIP, and TOP, and connect T-adapter to either fe-
4
Between TIP (B) and (A), TOP (B) and (A) or PT1 (fe-
Voltage 20 to 30 V
male) (C) and (A)
D155AX-8 40-839
FAILURE CODE [DBE6KK] P/T Controller 24V Sensor Power Voltage
Circuit diagram related to power train controller 24V power supply
40-840 D155AX-8
FAILURE CODE [DBE9KQ] Model Selection Signal Mismatch (P/T
FAILURE CODE [DBE9KQ] Model Selection Signal Mismatch (P/T Control-

ler)
Action level Failure code Model Selection Signal Mismatch (Power train controller)
Failure
L04 DBE9KQ (Power train controller system)
Detail of fail- Specification set in power train controller does not agree with specification set in memory (Initializa-
ure tion of power train controller is not performed).
Action of • Stops all of outputs of power train controller.
• Machine does not move at all.
Phenomenon
on machine

Perform reproducing method in “Adjustment” function in service mode. If failure
code mark E goes out, system is normal.
Defective adjustment of
1
power train controller REMARK
Adjustment code: 0002 “Power train controller initialization”
2. Disconnect connector PTCN3 and connect T-adapter.
Open circuit in wiring har- Between PTCN3 (female) (10) and ground Max. 1 Ω
2 Between PTCN3 (female) (21) and ground Max. 1 Ω
nector) Resistance Between PTCN3 (female) (31) and ground Max. 1 Ω
Between PTCN3 (female) (32) and ground Max. 1 Ω
Between PTCN3 (female) (33) and ground Max. 1 Ω
If failure code is still displayed after above checks, power train controller may be
controller
D155AX-8 40-841
FAILURE CODE [DBE9KQ] Model Selection Signal Mismatch (P/T
Circuit diagram related to power train controller model selection
40-842 D155AX-8
FAILURE CODE [DBELKA] System Operating Lamp Open Circuit
40 TROUBLESHOOTING (P/T Controller)
FAILURE CODE [DBELKA] System Operating Lamp Open Circuit (P/T Con-
troller)
Action level Failure code System Operating Lamp Open Circuit (Power train controller)
Failure
- DBELKA (Power train controller system)
Power train controller determines that system operating lamp circuit is open because voltage of out-
Details of put circuit remains at approximately 5 V or below for approximately 3 seconds after starting switch is
failure turned to ON position, during which power train controller outputs no current to system operating
lamp.
Action of
controller
Phenomenon System operating lamp indicates period during which battery disconnect switch must not be turned
to OFF position. Turning battery disconnect switch to OFF position may destroy memory data in
on machine power train controller.
• Although power train controller is not able to light up system operating lamp, no trouble will
Related
result unless battery disconnect switch is turned to OFF position.
information
• Since no controller drives system operating lamp for approximately 3 seconds after start-

1
box F01
2
CB6 or CB30
Open circuit in wiring har- 3. Disconnect connectors PTCN3 and LBU, and connect T-adapters to each
3
nector) Between PTCN3 (female) (34) and LBU (female) (2) Max. 1 Ω
Max. 1 Ω
(BRB)
controller
D155AX-8 40-843
FAILURE CODE [DBELKA] System Operating Lamp Open Circuit
(P/T Controller) 40 TROUBLESHOOTING
40-844 D155AX-8
FAILURE CODE [DBELKB] System Operating Lamp Short Circuit
40 TROUBLESHOOTING (P/T Controller)
FAILURE CODE [DBELKB] System Operating Lamp Short Circuit (P/T Con-
troller)
Action level Failure code System Operating Lamp Short Circuit (Power train controller)
Failure
- DBELKB (Power train controller system)
Detail of fail- Power train controller detects short circuit because output from power train controller to system op-
ure erating lamp does not make output voltage low.
Action of
controller
Phenomenon System operating lamp indicates period during which battery disconnect switch must not be turned
to OFF position. Turning battery disconnect switch to OFF position may destroy memory data in
on machine power train controller.
• Although power train controller is not able to light up system operating lamp, no trouble will
result unless battery disconnect switch is turned to OFF position.
Related
information

4. Disconnect connectors PTCN3, CK01, CM01, WECN3, and EGC3, and
Short circuit in wiring har- connect T-adapters to each female side.
1
ness
(34) ty
(15) ty
Between CM01 (female) (8) and each pin other than No continui-
Continuity
(8) ty
than (34) ty
(9) ty
controller
D155AX-8 40-845
FAILURE CODE [DBELKB] System Operating Lamp Short Circuit
(P/T Controller) 40 TROUBLESHOOTING
40-846 D155AX-8
FAILURE CODE [DBEQKR] CAN 2 Defective Communication (P/T
FAILURE CODE [DBEQKR] CAN 2 Defective Communication (P/T Control-

ler)
Action level Failure code CAN 2 Defective Communication (Power train controller) (detected
Failure
L03 DBEQKR by machine monitor) (Machine monitor)
Details of Machine monitor does not recognize power train controller on CAN2 communication line
failure (KOMNET/c).
Action of • Does not update communication information of CAN2.

• Failure codes to be generated by air conditioner controller are not displayed.
Phenomenon
• Each data of monitoring code is not updated.
on machine
troller.
• There are 5 different failure codes of [D8AQKR], [DAZQKR], [DB2QKR], [DB9QKR], and
[DBEQKR] which are used for defective CAN communication by CAN2 when it is detected
by machine monitor. When all of these 5 failure codes are displayed, ground fault, short
circuit or hot short in wiring harness (CAN communication circuit) are the possible causes.
In such case, check whether air conditioner is operable (ON/OFF and air flow of air condi-
Related tioner) with air conditioner screen since air conditioner is also operated through CAN com-
information munication.
REMARK
tioner is controllable, there is no possibility of ground fault, short circuit, or hot short circuit oc-
curring in wiring harness (CAN communication line).
multimeter.

Defective electric power Perform troubleshooting for failure code [DBE1KK].
1 supply to power train
controller
2
cation 2 system
controller
4
D155AX-8 40-847
FAILURE CODE [DBERKR] CAN 1 Defective Communication (P/T
FAILURE CODE [DBERKR] CAN 1 Defective Communication (P/T Control-

ler)
Action level Failure code CAN 1 Defective Communication (Power train controller) (detected
Failure
L03 DBERKR by machine monitor) (Machine monitor system)
Details of Machine monitor does not recognize power train controller on CAN1 communication line
failure (KOMNET/r).
Action of • Does not update Communication information of CAN1.

• Information and failure code to be obtained from work equipment controller are not dis-
Phenomenon played. Update of received data is stopped.
on machine • Pointer for power train oil temperature (torque converter) disappears.
troller.
• Machine monitor uses failure codes [DB9RKR] and [DBERKR] to indicate failures in CAN
communication on CAN 1 line. When failure code [DB9RKR] or [DBERKR] is displayed si-
multaneously on screen, a ground fault, short circuit, or hot short circuit in wiring harness
Related
(CAN communication line) are the possible causes.
information
• CAN1 terminating resistors are located in machine monitor on operator's cab side and
connector "RES2" is located on engine side (CAN communication 1 circuit (KOMNET/r) is
not provided. It is connected to connector "J2").
• Each controller is continuously supplied with power from battery even while starting switch
is OFF.
multimeter.

Defective electric power Perform troubleshooting for [DBE1KK].
1 supply to power train
controller
Defective CAN communi- Perform checks on causes 2 to 9 in troubleshooting for failure code [DB2RKR].
2
cation 1 system
3
controller
40-848 D155AX-8
FAILURE CODE [DBERKR] CAN 1 Defective Communication (P/T
D155AX-8 40-849
FAILURE CODE [DD12KA] Shift Up SW Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DD12KA] Shift Up SW Open Circuit

Action level Failure code Shift Up SW Open Circuit
Failure
L03 DD12KA (Power train controller system)
Details of NO(Normally Open) and NC(Normally Closed) lines of shift up switch circuit becomes open (switch:
failure OFF) simultaneously.
Action of
Assumes that shift up switch is not pressed.
controller
Phenomenon
Upshifting is disabled.
on machine
• NO line is for detecting operation, and NC line is for detecting errors.
• State of shift up switch signal can be checked with monitoring function. (Code: 40905 P/T
Controller SW Input 1)
Related
information
Procedure: Turn starting switch to ON position and operate shift up switch.
• Since no T-adapter is provided for connector SFTU, troubleshooting is not performed on
the female side.

2. Disconnect connector SFTU.
3. Turn shift up switch ON and OFF to perform troubleshooting.
REMARK
Defective shift up switch “Switch OFF”: Release, “Switch ON”: Press
1
(internal open circuit)
Between SFTU (male) (3) Switch OFF Max. 1 Ω
and (2) Switch ON Min. 1 MΩ
Resistance
Between SFTU (male) (1) Switch OFF Min. 1 MΩ
and (2) Switch ON Max. 1 Ω
3. Insert T-adapter into connector TL3.
REMARK
Open circuit or hot short
2 • If voltage is 0 V, wiring harness has open circuit. If it is 24 V, wiring harness
has hot short circuit.
• Voltage of approximately 9 V is applied to “NO” and “NC” signal circuits
through resistor in power train controller.
Between TL3 (1) and (2) 7 to 11 V
Voltage
40-850 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DD12KA] Shift Up SW Open Circuit

2. Disconnect connectors PTCN1 and PTCN3, and connect T-adapters to each
female side.
Open circuit in wiring har- 3. Turn shift up switch ON and OFF to perform troubleshooting.
ness (wire breakage or Between PTCN3 (female)
3
defective contact of con- (29) and PTCN1 (female) Switch OFF Max. 1 Ω
nector) (4)
Resistance
Between PTCN3 (female)
(39) and PTCN1 (female) Switch ON Max. 1 Ω
(4)
tive.
• Reference
2. Insert T-adapters into connector PTCN1 and PTCN3.
4. Turn shift up switch ON/OFF to perform troubleshooting.
4 REMARK
controller
Voltage of approximately 9 V V is applied to pin (29) of PTCN3 and pin (39) of
PTCN3 through resistor in power train controller.
Between PTCN3 (29) and Switch OFF Max. 1 V

PTCN1 (4) Switch ON 7 to 11 V
Voltage
Between PTCN3 (39) and Switch OFF 7 to 11 V
PTCN1 (4) Switch ON Max. 1 V
Circuit diagram related to shift up switch and shift down switch
D155AX-8 40-851
FAILURE CODE [DD12KB] Shift Up SW Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DD12KB] Shift Up SW Short Circuit

Action level Failure code Shift Up SW Short Circuit
Failure
L03 DD12KB (Power train controller system)
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of shift up switch circuit becomes 0 V (switch:
ure ON) simultaneously.
Action of
Assumes that shift up switch is not pressed.
controller
Phenomenon
Upshifting is disabled.
on machine
• State of shift up switch signal can be checked with monitoring function. (Code: 40905 P/T
SW Input 1)
Related
information
Procedure: Turn starting switch to ON position and operate shift up switch.
the female side.

3. Turn shift up switch ON and OFF to perform troubleshooting.
REMARK
Defective shift up switch “Switch OFF”: Release, “Switch ON”: Press
1
Between SFTU (male) (3) Switch OFF Max. 1 Ω
Resistance
Between SFTU (male) (1) Switch OFF Min. 1 MΩ
2. Disconnect connectors PTCN3 and SFTU, and connect T-adapter to female
2 harness (contact with side of PTCN3.
ground circuit) Between PTCN3 (female) (39) and ground Min. 1 MΩ
Resistance
Between PTCN3 (female) (29) and ground Min. 1 MΩ
side of PTCN3.
REMARK
Short circuit in wiring har- Check by using multimeter in continuity mode.

3
ness No continui-
Between PTCN3 (female) (29) and each pin other than
ty (no sound
(29)
is heard)
Continuity
No continui-
ty (no sound
(39)
is heard)
40-852 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DD12KB] Shift Up SW Short Circuit

tive.
• Reference
4 REMARK
controller

Voltage
D155AX-8 40-853
FAILURE CODE [DD13KA] Shift Down SW Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DD13KA] Shift Down SW Open Circuit

Action level Failure code Shift Down SW Open Circuit
Failure
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of downshift switch circuit becomes open
ure (switch: OFF) simultaneously.
Action of
Assumes that downshift switch is not pressed.
controller
Phenomenon
Downshift is disabled.
on machine
• State of downshift switch signal can be checked with monitoring function. (Code: 40905
P/T SW Input 1)
Related
information
Procedure: Turn starting switch to ON position and operate downshift switch.
the female side.

2. Disconnect connector TL3, and connect T-adapter to male side.
3. Turn shift down switch ON and OFF to perform troubleshooting.
REMARK
Defective shift down
1 switch (internal open cir- “Switch OFF”: Release, “Switch ON”: Press
cuit) Switch OFF Max. 1 Ω
Between TL3 (male) (5)
Resistance
Between TL3 (male) (4) Switch OFF Min. 1 MΩ
3. Insert T-adapter into connector TL3.
REMARK
• Voltage of approximately 9 V is applied to “NO” and “NC” signal circuits
Voltage
2. Disconnect connectors PTCN1, PTCN3, and SFTD, and connect T-adapters to
Open circuit in wiring har- each female side.
3 Between PTCN3 (female) (19) and SFTD (male) (1) Max. 1 Ω
nector)
Resistance Between PTCN1 (female) (4) and SFTD (male) (2) Max. 1 Ω
Between PTCN3 (female) (9) and SFTD (male) (3) Max. 1 Ω
40-854 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DD13KA] Shift Down SW Open Circuit

tive.
• Reference
4 REMARK
controller

Voltage
D155AX-8 40-855
FAILURE CODE [DD13KB] Shift Down SW Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DD13KB] Shift Down SW Short Circuit

Action level Failure code Shift Down SW Short Circuit
Failure
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of downshift switch circuit becomes 0 V (switch:
ure ON) simultaneously.
Action of
Assumes that downshift switch is not pressed.
controller
Phenomenon
Downshift is disabled.
on machine
• State of downshift switch signal can be checked with monitoring function. (Code: 40905
P/T SW Input 1)
Related
information
Procedure: Turn starting switch to ON position and operate downshift switch.
the female side.

2. Disconnect connector TL3, and connect T-adapter to male side.
3. Turn shift down switch ON and OFF to perform troubleshooting.
REMARK
Defective shift down
cuit) Switch OFF Max. 1 Ω
Between TL3 (male) (5)
Resistance
Between TL3 (male) (4) Switch OFF Min. 1 MΩ
Resistance
side of PTCN3.
REMARK

3
ness No continui-
ty (no sound
(9)
is heard)
Continuity
No continui-
ty (no sound
(19)
is heard)
40-856 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DD13KB] Shift Down SW Short Circuit

tive.
• Reference
4 REMARK
controller

Voltage
D155AX-8 40-857
FAILURE CODE [DD14KA] Parking Brake Lever SW Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DD14KA] Parking Brake Lever SW Open Circuit

Action level Failure code Parking Brake Lever SW Open Circuit
Failure
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of parking brake lever switch circuit becomes
ure open (switch: OFF) simultaneously.
Action of • Assumes that parking brake lever is in released position.
• Automatic gear shift function does not work.
Phenomenon • Once machine stops, engine speed is restricted to medium (half) speed.
on machine • Once machine stops, selectable gear speeds are restricted to F1 and R1.
• Engine cannot start.
• NC line is for detecting operation, and NO line is for detecting errors.
• State of parking brake lever switch signal can be checked with monitoring function.
Related (Code: 40905 P/T SW Input 1)
Procedure: Turn starting switch to ON position and operate parking brake lever.
• When parking brake lever is in released position, parking brake lever switch is ON.

2. Disconnect connector PKSW, and connect T-adapter to male side.
Defective parking brake
1 lever switch (internal Between PKSW (male) (A) Lever: LOCK Min. 1 MΩ
open circuit) and (B) Lever: FREE Max. 1 Ω
Resistance
Between PKSW (male) (A) Lever: LOCK Max. 1 Ω
and (C) Lever: FREE Min. 1 MΩ
2. Disconnect connector PKSW and connect T-adapter to female side.
REMARK
Open circuit or hot short • If voltage is 0 V, wiring harness has open circuit. If it is 24 V, wiring harness
2
circuit in wiring harness has hot short circuit.
• Voltage of approximately 9 V is applied to signal lines NO and NC through
a resistor in power train controller.
Between PKSW (female) (B) and (A) 7 to 11 V
Voltage
Between PKSW (female) (C) and (A) 7 to 11 V
40-858 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DD14KA] Parking Brake Lever SW Open Circuit
REMARK
required.
3 ness (wire breakage or 2. Disconnect connectors PTCN1 and PKSW, and connect T-adapters to each fe-
defective contact) male side.
Between PTCN1 (female) (17) and PKSW (female) (C) Max. 1 Ω
Resistance Between PTCN1 (female) (23) and PKSW (female) (B) Max. 1 Ω
Between PKSW (female) (A) and ground Max. 1 Ω
tive.
• Reference
4 REMARK
controller
Voltage of approximately 9 V V is applied to pin (23) of PTCN1 in power train con-
troller.
Between PTCN1 (23) and Lever: LOCK 7 to 11 V

ground Lever: FREE Max. 1 V
Voltage
Between PTCN1 (17) and Lever: LOCK Max. 1 V
ground Lever: FREE 7 to 11 V
D155AX-8 40-859
FAILURE CODE [DD14KA] Parking Brake Lever SW Open Circuit 40 TROUBLESHOOTING
Circuit diagram related to parking brake lever switch and solenoid valve
40-860 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DD14KB] Parking Brake Lever SW Short Circuit
FAILURE CODE [DD14KB] Parking Brake Lever SW Short Circuit

Action level Failure code Parking Brake Lever SW Short Circuit
Failure
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of parking brake lever switch circuit becomes
ure 0 V (switch: ON) simultaneously.
Action of • Assumes that parking brake lever is in released position.
• Engine cannot start.
• State of parking brake lever switch signal can be checked with monitoring function.
Procedure: Turn starting switch to ON position and operate parking brake lever.
• When parking brake lever is in released position, parking brake lever switch is ON.

2. Disconnect connector PKSW, and connect T-adapter to male side.
Defective parking brake
1 lever switch (internal Between PKSW (male) (A) Lever: LOCK Min. 1 MΩ
open circuit) and (B) Lever: FREE Max. 1 Ω
Resistance
Between PKSW (male) (A) Lever: LOCK Max. 1 Ω
and (C) Lever: FREE Min. 1 MΩ
2. Disconnect connectors PTCN1 and PKSW, and connect T-adapter to either fe-
Ground fault in wiring male side.
2 harness (contact with Between ground and PKSW (female) (B) or PTCN1
(female) (17)
Resistance
Between ground and PKSW (female) (C) or PTCN1
Min. 1 MΩ
(female) (23)
2. Disconnect connectors PTCN1 and PKSW, and connect T-adapter to female
side of PTCN1.
REMARK
Short circuit in wiring har- Check with multimeter in continuity mode.

3
ness No continui-
ty (No
(17)
sound)
Continuity
No continui-
ty (No
(23)
sound)
D155AX-8 40-861
FAILURE CODE [DD14KB] Parking Brake Lever SW Short Circuit 40 TROUBLESHOOTING

tive.
• Reference
4 REMARK
controller
Voltage of approximately 9 V V is applied to pin (23) of PTCN1 in power train con-
troller.
Between PTCN1 (23) and Lever: LOCK 7 to 11 V

ground Lever: FREE Max. 1 V
Voltage
Between PTCN1 (17) and Lever: LOCK Max. 1 V
ground Lever: FREE 7 to 11 V
Circuit diagram related to parking brake lever switch and solenoid valve
40-862 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDDDKA] Brake Pedal SW Open Circuit
FAILURE CODE [DDDDKA] Brake Pedal SW Open Circuit

Action level Failure code Brake Pedal SW Open Circuit
Failure
L03 DDDDKA (Power train controller system)
Detail of fail-
Signals of 2 lines for brake pedal switch circuit are turned OFF (OPEN) at the same time.
ure
Action of • Assumes that brake pedal is not depressed.
Phenomenon
• Once machine stops, selectable gear speeds are restricted to F1 and R1.
on machine
• Out of signals of 2 lines, NO is used for detecting operation and NC is used for detecting
error.
• State of brake pedal switch signal can be checked with monitoring function.
Procedure: Turn starting switch to ON position and operate brake pedal.
*NO: Normally Open
*NC: Normally Closed

2. Disconnect connector BKSW, and connect T-adapter to male side.
3. Turn brake pedal switch ON/OFF to perform troubleshooting (Depress/release
brake pedal).
Defective brake pedal REMARK

cuit)
Between BKSW (male) (A) Pedal released Max. 1 Ω
and (B) Pedal depressed Min. 1 MΩ
Resistance
Between BKSW (male) (A) Pedal released Min. 1 MΩ
and (C) Pedal depressed Max. 1 Ω
2. Connect T-adapter to connector BKSW.
REMARK
2
• Voltage of approximately 9 V is applied to signal lines NO and NC through
a resistor in power train controller.
Between BKSW (female) (B) and (A) 7 to 11 V
Voltage
Between BKSW (female) (C) and (A) 7 to 11 V
D155AX-8 40-863
FAILURE CODE [DDDDKA] Brake Pedal SW Open Circuit 40 TROUBLESHOOTING

2. Disconnect connectors PTCN1 and PTCN3, and connect T-adapters to each
female side.
Open circuit in wiring har- 3. Turn shift up switch ON/OFF to perform troubleshooting.
defective contact) Between PTCN1 (female)
Switch released Max. 1 Ω
(11) and PTCN3 (23)
Resistance
Switch depressed Max. 1 Ω
(5) and PTCN3 (23)
tive.
• Reference
4. Turn brake pedal switch ON/OFF to perform troubleshooting.
4 REMARK
controller
Between PTCN1 (5) and Switch released Max. 1 V

PTCN3 (23) Switch depressed 7 to 11 V
Voltage
Between PTCN1 (11) and Switch released 7 to 11 V
PTCN3 (23) Switch depressed Max. 1 V
40-864 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDDDKA] Brake Pedal SW Open Circuit
Circuit diagram related to parking brake pedal switch and solenoid valve
D155AX-8 40-865
FAILURE CODE [DDDDKB] Brake Pedal SW Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DDDDKB] Brake Pedal SW Short Circuit

Action level Failure code Brake Pedal SW Short Circuit
Failure
L03 DDDDKB (Power train controller system)
Detail of fail-
Signals of 2 lines for brake pedal switch circuit are turned ON (CLOSE) at the same time.
ure
Action of • Assumes that brake pedal is not depressed.
Phenomenon
on machine
• Out of signals of 2 lines, NO is used for detecting operation and NC is used for detecting
error.
• State of brake pedal switch signal can be checked with monitoring function.
*NO: Normally Open
*NC: Normally Closed

2. Disconnect connector BKSW, and connect T-adapter to male side.
3. Turn brake pedal switch ON/OFF to perform troubleshooting (Depress/release
brake pedal).
Defective brake pedal REMARK

cuit)
Between BKSW (male) (A) Pedal released Max. 1 Ω
and (B) Pedal depressed Min. 1 MΩ
Resistance
Between BKSW (male) (A) Pedal released Min. 1 MΩ
and (C) Pedal depressed Max. 1 Ω
2. Disconnect connectors PTCN1 and BKSW, and connect T-adapter to female
Resistance
40-866 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDDDKB] Brake Pedal SW Short Circuit

2. Disconnect connectors PTCN1 and BKSW, and connect T-adapter to female
side of PTCN1.
REMARK

3
ness No continui-
ty (No
(11)
sound)
Continuity
No continui-
ty (No
(5)
sound)
tive.
• Reference
4. Turn brake pedal switch ON/OFF to perform troubleshooting.
4 REMARK
controller
Between PTCN1 (5) and Switch released Max. 1 V

PTCN3 (23) Switch depressed 7 to 11 V
Voltage
Between PTCN1 (11) and Switch released 7 to 11 V
PTCN3 (23) Switch depressed Max. 1 V
D155AX-8 40-867
FAILURE CODE [DDDDKB] Brake Pedal SW Short Circuit 40 TROUBLESHOOTING
Circuit diagram related to parking brake pedal switch and solenoid valve
40-868 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDDDKX] Brake Pedal SW Signal Mismatch
FAILURE CODE [DDDDKX] Brake Pedal SW Signal Mismatch

Action level Failure code Brake Pedal SW Signal Mismatch
Failure
L03 DDDDKX (Power train controller system)
Detail of fail-
Brake pedal potentiometer signals do not agree with brake pedal switch signals.
ure
Action of
Restricts operation of engine and transmission.
controller
• Backup brake may not operate.
• State of brake pedal potentiometer signal can be checked with monitoring function.
Related (Code: 50400 Brake Pedal Potentio)

Defective brake pedal If [DDDDKA] or [DDDDKB] is also displayed, perform troubleshooting these first.
1
switch system
Adjust brake pedal and perform reproducing method. If failure code mark E goes
Defective adjustment of out, system is normal.
2
brake pedal switch
Testing and adjusting item: Adjustment of brake pedal
If failure code is still displayed after above checkss on causes 1 and 2, power train
3 controller may be defective. (In case of an internal defect, troubleshooting is impos-
controller
D155AX-8 40-869
FAILURE CODE [DDKAKA] Blade Float SW Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DDKAKA] Blade Float SW Open Circuit

Action level Failure code Blade Float SW Open Circuit
Failure
L01 DDKAKA (Work equipment controller system)
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of blade float switch circuit becomes open
Action of
Assumes that blade float switch is not pressed.
controller
Phenomenon
Blade float control is disabled.
on machine
Related • State of blade float switch signal can be checked with monitoring function.
(Code: 70300 Blade knob switch 1)
information
Procedure: Turn starting switch to ON position and operate blade float switch.

2. Disconnect connector BNSW.
3. Turn blade FLOAT switch to ON and OFF positions, and perform trouble-
shooting.
REMARK
Turn switch to OFF: Release, Turn switch to ON: Press
1 of blade FLOAT switch Turn switch to OFF posi-
Max. 1 Ω
(internal open circuit) Between BNSW (male) (3) tion.
and (4) Turn switch to ON posi-
Min. 1 MΩ
tion.
Resistance
Turn switch to OFF posi-
Min. 1 MΩ
Between BNSW (male) (3) tion.
Max. 1 Ω
tion.
3. Connect T-adapter to connector BNSW.
REMARK
Open circuit or hot short • If voltage is 0 V, open circuit occurs. If voltage is 24 V, hot short circuit oc-
2
circuit in wiring harness curs.
• In work equipment controller, approx. 9 V of voltage is applied to signal
lines of “NO” and “NC” via resistance.
• Ignore failure codes other than DDKAKA
Between BNSW (3) and (4) 7 to 11 V
Voltage
40-870 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDKAKA] Blade Float SW Open Circuit

2. Disconnect connectors WECN1and WECN2, and connect T-adapters to
each female side.
Open circuit in wiring har- shooting.
Between WECN2 (female)
defective contact) Turn switch to OFF posi-
(38) and WECN1 (female) Max. 1 Ω
tion.
(4)
Resistance
Turn switch to ON posi-
(2) and WECN1 (female) Max. 1 Ω
tion.
(4)
fective.
Reference
2. Insert T-adapters to connectors WECN1 and WECN2.
4. Turn on and off blade float switch to perform troubleshooting.
4
ment controller REMARK
Voltage of approximately 9 V is applied to WECN2 pin (38) and WECN2 pin (2)
through resistor in work equipment controller.
Between WECN2 (38) and Switch: OFF Max. 1 V

WECN1 (4) Switch: ON 7 to 11 V
Voltage
Between WECN2 (2) and Switch: OFF 7 to 11 V
WECN1 (4) Switch: ON Max. 1 V
Circuit diagram related to blade FLOAT switch
D155AX-8 40-871
FAILURE CODE [DDKAKB] Blade Float SW Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DDKAKB] Blade Float SW Short Circuit

Action level Failure code Blade Float SW Short Circuit
Failure
L01 DDKAKB (Work equipment controller system)
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of blade float switch circuit becomes 0 V
ure (switch: ON) simultaneously.
Action of
Assumes that blade float switch is not pressed.
controller
Phenomenon
Blade float control is disabled.
on machine
Related • State of blade float switch signal can be checked with monitoring function.
(Code: 70300 Blade knob switch 1)
information
Procedure: Turn starting switch to ON position and operate blade float switch.

shooting.
REMARK
Turn switch to OFF: Release, Turn switch to ON: Press
1 of blade FLOAT switch Turn switch to OFF posi-
Max. 1 Ω
(internal open circuit) Between BNSW (male) (3) tion.
Min. 1 MΩ
tion.
Resistance
Turn switch to OFF posi-
Min. 1 MΩ
Between BNSW (male) (3) tion.
Max. 1 Ω
tion.
2. Disconnect connectors WECN2 and BNSW, and connect T-adapter to fe-
2 harness (contact with male side of WECN2.
ground circuit) Between WECN2 (female) (38) and ground Min. 1 MΩ
Resistance
40-872 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDKAKB] Blade Float SW Short Circuit

male side of WECN2.
REMARK
Short circuit in wiring har- Investigate it by continuity mode of tester.
3
ness No continui-
Between WECN2 (female) (38) and each pin other
ty (no
than WECN2 (38).
sound)
Continuity
No continui-
Between WECN2 (female) (2) and each pin other than
ty (no
WECN2 (2).
sound)
fective.
Reference
4

WECN1 (4) Switch: ON 7 to 11 V
Voltage
WECN1 (4) Switch: ON Max. 1 V
Circuit diagram related to blade FLOAT switch
D155AX-8 40-873
FAILURE CODE [DDKBKA] Blade Auto Pitch SW Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DDKBKA] Blade Auto Pitch SW Open Circuit

Action level Failure code Blade Auto Pitch SW Open Circuit
Failure
L01 DDKBKA (Work equipment controller system)
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of blade auto pitch switch circuit becomes open
Action of
Assumes that blade auto pitch switch is not pressed.
controller
Phenomenon
Blade auto pitch control is disabled.
on machine
Related • State of blade auto pitch switch signal can be checked with monitoring function.
(Code: 70306 Blade knob switch input 2)
information
Procedure: Turn starting switch to ON position and operate blade auto pitch switch.

3. Turn blade auto pitch switch ON/OFF to perform troubleshooting.
Defective blade auto REMARK

1 pitch switch harness Switch OFF: Release, Switch ON: Press
(Internal open circuit) Switch: OFF Max. 1 Ω
Between BNSW (1) and
(3) Switch: ON Min. 1 MΩ
Resistance
Between BNSW (2) and Switch: OFF Min. 1 MΩ
(3) Switch: ON Max. 1 Ω
REMARK
2
• Voltage of approximately 9 V V is applied to signal lines "NO" and "NC" in
work equipment controller.
• Ignore all displayed failure codes other than DDKBKA.
Voltage
40-874 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDKBKA] Blade Auto Pitch SW Open Circuit

Turn blade auto pitch switch ON/OFF to perform troubleshooting.
ness
3 Between WECN1 (female)
(Wire breakage or defec- Switch: OFF Max. 1 Ω
tive contact of connector) (23) and (4)
Resistance
Switch: ON Max. 1 Ω
(17) and (4)
fective.
Reference
2. Connect T-adapter to connector PA02.
4 REMARK
ment controller

(4) Switch: ON 7 to 11 V
Voltage
(4) Switch: ON Max. 1 V
Circuit diagram related to blade auto-pitch switch
D155AX-8 40-875
FAILURE CODE [DDKBKB] Blade Auto Pitch SW Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DDKBKB] Blade Auto Pitch SW Short Circuit

Action level Failure code Blade Auto Pitch SW Short Circuit
Failure
L01 DDKBKB (Work equipment controller system)
Detail of fail- NO(Normally Open) and NC(Normally Closed) lines of blade auto pitch switch circuit becomes 0 V
ure (switch: ON) simultaneously.
Action of
Assumes that blade auto pitch switch is not pressed.
controller
Phenomenon
Blade auto pitch control is disabled.
on machine
• NO* line is for detecting operation, and NC* line is for detecting errors.
Related • State of blade auto pitch switch signal can be checked with monitoring function.
information
Procedure: Turn starting switch to ON position and operate blade auto pitch switch.

3. Turn blade auto pitch switch ON/OFF to perform troubleshooting.
Defective blade auto REMARK

1 pitch switch harness Switch OFF: Release, Switch ON: Press
(Internal open circuit) Switch: OFF Max. 1 Ω
Between BNSW (1) and
(3) Switch: ON Min. 1 MΩ
Resistance
Between BNSW (2) and Switch: OFF Min. 1 MΩ
(3) Switch: ON Max. 1 Ω
2. Disconnect connectors WECN1 and BNSW, and connect T-adapter to female
Ground fault in wiring side of WECN1.
2
harness
Resistance
male side of WECN1.
REMARK
Short circuit in wiring har- Check it by using multimeter in continuity mode.
3
ness No continui-
ty (no sound
than (23)
is heard)
Continuity
No continui-
ty (no sound
than (17)
is heard)
40-876 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDKBKB] Blade Auto Pitch SW Short Circuit

fective.
Reference
2. Connect T-adapter to connector PA02.
4 REMARK
ment controller

(4) Switch: ON 7 to 11 V
Voltage
(4) Switch: ON Max. 1 V
Circuit diagram related to blade auto-pitch switch
D155AX-8 40-877
FAILURE CODE [DDKCL4] Ripper Tilt In SW Signal Mismatch 40 TROUBLESHOOTING
FAILURE CODE [DDKCL4] Ripper Tilt In SW Signal Mismatch

Action level Failure code Ripper Tilt In SW Signal Mismatch
Failure
L01 DDKCL4 (Work equipment controller system)
Detail of fail-
Signals of 2 NO* circuits of ripper tilt-in lever disagree with each other.
ure
Action of
Assumes that ripper tilt in lever is in neutral.
controller
Phenomenon
Ripper tilt in control is disabled.
on machine
• State of ripper tilt in lever signal can be checked with monitoring function.
(Code: 70307 Ripper knob switch input)
information Procedure: Turn starting switch to ON position and operate ripper control lever (in tilt in
direction).
*NO: Normally Open

2. Disconnect connector RNSW, and connect T-adapter to male side.
3. Operate ripper tilt lever (in tilt-in direction) and perform troubleshooting.
1 of ripper tilt in lever Between RNSW (male) (1) Free Min. 1 MΩ
(Internal open circuit) and (3) Tilt IN Max. 1 Ω
Resistance
Between RNSW (male) (2) Free Min. 1 MΩ
and (3) Tilt IN Max. 1 Ω
2. Disconnect connector RNSW.
3. Connect T-adapter to connector RNSW.
REMARK
• In work equipment controller, approximately. 9 V of voltage is applied to 2-
line signal line of “NO” via resistance.
Between RNSW (female) (1) and (3) 7 to 11 V
Voltage
40-878 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDKCL4] Ripper Tilt In SW Signal Mismatch
REMARK
quired.
Open circuit in wiring har- 2. Disconnect connectors WECN1, WECN3 and RNSW, and connect T-adapters
ness to each female side.
3
(Wire breakage or defec-
Between WECN3 (female) (9) and RNSW (female) (2) Max. 1 Ω
Resistance Between WECN3 (female) (19) and RNSW (female)
Max. 1 Ω
(1)
Between WECN1 (female) (4) and RNSW (male) (3) Max. 1 Ω
harness 2. Disconnect connectors WECN1 and connect T-adapter to female side.
4
(contact with ground cir- Between WECN3 (female) (9) and ground Min. 1 MΩ
cuit) Resistance
2. Disconnect connector WECN3, and connect T-adapter to female side of
WECN3.
REMARK

5
ness No continui-
ty (no sound
(9)
is heard)
Continuity
No continui-
ty (no sound
than (19)
is heard)
fective.
• Reference
4. Operate ripper tilt lever (in tilt-IN direction) to perform troubleshooting.
6 REMARK
ment controller
Voltage of approximately 9 V is applied to WECN3 pin (9) and pin (19) through re-
sistor in work equipment controller.
Between WECN3 (9) and Free 7 to 11 V

WECN1 (4) Tilt IN Max. 1 V
Voltage
D155AX-8 40-879
FAILURE CODE [DDKCL4] Ripper Tilt In SW Signal Mismatch 40 TROUBLESHOOTING
Circuit diagram related to ripper tilt lever
40-880 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDKEL4] Ripper Tilt Back SW Signal Mismatch
FAILURE CODE [DDKEL4] Ripper Tilt Back SW Signal Mismatch

Action level Failure code Ripper Tilt Back SW Signal Mismatch
Failure
L01 DDKEL4 (Work equipment controller system)
Detail of fail-
Signals of 2 NO(Normally Open) circuits of ripper tilt-back lever disagree with each other.
ure
Action of
Assumes that ripper tilt back lever is in neutral.
controller
Phenomenon
Ripper tilt back control is disabled.
on machine
• State of ripper tilt back lever signal can be checked with monitoring function.
(Code: 70307 Ripper knob switch input)
Related
information
Procedure: Turn starting switch to ON position and operate ripper control lever (in tilt back
direction).

2. Disconnect connector RNSW, and connect T-adapter to male side.
3. Operate ripper tilt lever (in tilt-back direction) and perform troubleshooting.
1 of ripper tilt back lever Between RNSW (male) (4) FREE Min. 1 MΩ
(internal open circuit) and (3) Tilt back Max. 1 Ω
Resistance
Between RNSW (male) (5) FREE Min. 1 MΩ
and (3) Tilt back Max. 1 Ω
2. Disconnect connector RNSW.
3. Connect T-adapter to connector RNSW.
REMARK
2 If voltage is 0 V, open circuit occurs. If voltage is 24 V, hot short circuit occurs.
REMARK
In work equipment controller, approx. 9 V of voltage is applied to 2-line signal line of
“NO” via resistance.
Voltage
quired.
2. Disconnect connectors WECN1, WECN3 and RNSW, and connect T-
adapters to each female side.
defective contact) Between WECN3 (female) (29) and RNSW (female)
Max. 1 Ω
(5)
Resistance
Between WECN3 (female) (39) and RNSW (male) (4) Max. 1 Ω
D155AX-8 40-881
FAILURE CODE [DDKEL4] Ripper Tilt Back SW Signal Mismatch 40 TROUBLESHOOTING

Ground fault in wiring 2. Disconnect connector WECN3 and connect T-adapter to female side.
Resistance
2. Disconnect connectors WECN3 and RNSW, and connect T-adapter to fe-
male side of WECN3.
REMARK
Short circuit in wiring har- Investigate it by continuity mode of tester.
5
ness No continui-
ty (no
than WECN3 (29).
sound)
Continuity
No continui-
ty (no
than WECN3 (39).
sound)
fective.
• Reference
4. Operate ripper tilt lever (in tilt-back direction) to perform troubleshooting.
6 REMARK
ment controller

Voltage
40-882 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDKEL4] Ripper Tilt Back SW Signal Mismatch
Circuit diagram related to ripper tilt lever
D155AX-8 40-883
FAILURE CODE [DDN7L4] Blade Pitch Back SW Signal Mismatch 40 TROUBLESHOOTING
FAILURE CODE [DDN7L4] Blade Pitch Back SW Signal Mismatch

Action level Failure code Blade Pitch Back SW Signal Mismatch
Failure
L01 DDN7L4 (Work equipment controller system)
Detail of fail- • Signals of 2 NO(Normally Open) circuits of blade pitch-back lever disagree with each oth-
ure er.
Action of
• Assumes that blade pitch back lever is in neutral.
controller
Phenomenon
• Blade pitch back control is disabled.
on machine
• State of blade pitch back lever signal can be checked with monitoring function.
Related
information
Procedure: Turn starting switch to ON position and operate blade lever (in pitch back di-
rection).

2. Disconnect connector BNSW, and connect T-adapter to male side.
3. Operate blade pitch lever (in pitch back direction) to perform troubleshoot-
ing.
Blade pitch back lever REMARK
1 harness
“Switch OFF”: Release, “Switch ON”: Press
(Internal open circuit)
Between BNSW (male) FREE Min. 1 MΩ
(11) and (9) Pitch back Max. 1 Ω
Resistance
Between BNSW (male) FREE Min. 1 MΩ
(10) and (9) Pitch back Max. 1 Ω
REMARK
Open circuit or hot short If voltage is 0 V, wiring harness has open circuit. If it is 24 V, wiring harness has hot
2
circuit in wiring harness short circuit
.
REMARK
Voltage of approximately 9 V is applied to 2 signal lines of “NO”.
Voltage
40-884 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDN7L4] Blade Pitch Back SW Signal Mismatch
REMARK
required.
2. Disconnect connectors WECN1, WECN2, and BNSW, and connect T-
ness
3 adapters to each female side.
tive contact of connector) Between WECN2 (female) (3) and BNSW (female)
Max. 1 Ω
(10)
Resistance Between WECN1 (female) (4) and BNSW (female) (9) Max. 1 Ω
Between WECN2 (female) (12) and BNSW (female)
Max. 1 Ω
(11)
Ground fault in wiring 2. Disconnect connectors WECN2, and connect T-adapter to female side of
harness WECN2.
4
cuit) Resistance
male side of WECN2.
REMARK
5
ness No continui-
ty (No
(3)
sound)
Continuity
No continui-
ty (No
than (12)
sound)
fective.
• Reference
4. Operate blade pitch lever (in pitch-back direction) to perform troubleshoot-
Defective work equip- ing.
6

WECN1 (4) Pitch BACK Max. 1 V
Voltage
WECN1 (4) Pitch BACK Max. 1 V
D155AX-8 40-885
FAILURE CODE [DDN7L4] Blade Pitch Back SW Signal Mismatch 40 TROUBLESHOOTING
Circuit diagram related to blade pitch back lever
40-886 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDN8L4] Blade Pitch Dump SW Signal Mismatch
FAILURE CODE [DDN8L4] Blade Pitch Dump SW Signal Mismatch

Action level Failure code Blade Pitch Dump SW Signal Mismatch
Failure
L01 DDN8L4 (Work equipment controller system)
Detail of fail- • Signals of 2 NO(Normally Open) circuits of blade pitch-dump lever disagree with each oth-
ure er.
Action of
• Assumes that blade pitch dump lever is in neutral.
controller
Phenomenon
• Blade pitch dump control is disabled.
on machine
• State of blade pitch dump lever signal can be checked with monitoring function.
Related
information
Procedure: Turn starting switch to ON position and operate blade lever (in pitch dump di-
rection).

2. Disconnect connector BNSW and connect T-adapter to male side.
3. Operate blade pitch lever (in pitch-back direction) to perform troubleshoot-
ing.
Defective wiring harness REMARK
1 of blade pitch-dump lever “Switch OFF”: Release, “Switch ON”: Presse
Between BNSW (male) (7) Free Min. 1 MΩ
and (9) Pitch DUMP Max. 1 Ω
Resistance
Between BNSW (male) (8) Free Min. 1 MΩ
and (9) Pitch DUMP Max. 1 Ω
REMARK
Open circuit or hot short If voltage is 0 V, wiring harness has open circuit, if it is 24 V, wiring harness has hot
2
circuit in wiring harness short circuit.
REMARK
A voltage of approximately 9 V is applied to 2 signal wires of “NO” through resist-
ance in the work equipment controller.
Voltage
D155AX-8 40-887
FAILURE CODE [DDN8L4] Blade Pitch Dump SW Signal Mismatch 40 TROUBLESHOOTING

quired.
Open circuit in wiring har- 2. Disconnect connectors WECN1, WECN2, and WELK, and connect T-
ness (wire breakage or adapters to each female side.
3
Between WECN2 (female) (13) and BNSW (female)
nector) Max. 1 Ω
(7)
Resistance
Between WECN1 (female) (4) and BNSW (female) (9) Max. 1 Ω
Between WECN2 (female) (7) and BNSW (female) (8) Max. 1 Ω
2. Disconnect connector WECN2, and connect T-adapter to female side of
4 harness (contact with WECN2.
Resistance
male side of WECN2.
REMARK
Short circuit in wiring har- Check it by using multimeter in continuity mode.
5
ness No continui-
ty (no
than (13).
sound)
Continuity
No continui-
Between WECN2 (female) (7) and each pins other
ty (no
than (7).
sound)
fective.
• Reference
4. Operate blade pitch lever (in pitch-dump direction) to perform trouble-
Defective work equip- shooting.
6

WECN1 (4) Pitch DUMP Max. 1 V
Voltage
WECN1 (4) Pitch DUMP Max. 1 V
40-888 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDN8L4] Blade Pitch Dump SW Signal Mismatch
Circuit diagram related to blade pitch back lever
D155AX-8 40-889
FAILURE CODE [DDNLKA] W/E Lock SW Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DDNLKA] W/E Lock SW Open Circuit

Action level Failure code Work Equipment Lock SW Open Circuit
Failure
L03 DDNLKA (Work equipment controller system)
Detail of fail- • NO(Normally Open) and NC(Normally Close) lines of work equipment lock lever switch cir-
ure cuit becomes open (switch: OFF) simultaneously.
Action of • Assumes that work equipment lock lever is in LOCK position.
Phenomenon
on machine
• Work equipment control is disabled.
• Engine does not start.
• State of work equipment lock lever switch signal can be checked with monitoring function.
Related
information
Procedure: Turn starting switch to ON position and operate work equipment lock lever.
• When work equipment lock lever is in LOCK position, the work equipment lock lever
switch is ON (diagram indicates LOCK state).

2. Disconnect connector WELK and connect T-adapter to male side.
3. Operate work equipment lock lever to perform troubleshooting.
1 ment lock lever switch Between WELK (male) (A) LOCK Min. 1 MΩ
(internal open circuit) and (B) Free Max. 1 Ω
Resistance
Between WELK (male) (A) LOCK Max. 1 Ω
and (C) Free Min. 1 MΩ
REMARK
Open circuit or hot short If voltage is 0 V an open circuit exists, if 24 V a hot short circuit exists.
2
REMARK
A voltage of approximately 9 V is applied to “NO” and “NC” signal wires through a
resistor in the work equipment controller.
Between WELK (female) (B) and (A) 7 to 11 V
Voltage
Between WELK (female) (C) and (A) 7 to 11 V
40-890 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDNLKA] W/E Lock SW Open Circuit

quired.
Open circuit in wiring har- 2. Disconnect connectors WECN1, WECN2, and WELK, and connect T-
ness (wire breakage or adapters to each female side.
3
Between WECN1 (female) (10) and WELK (female) (A) Max. 1 Ω
nector)
Between WECN2 (female) (37) and WELK (female) (B) Max. 1 Ω
Resistance
Between WECN2 (female) (27) and WELK (female)
Max. 1 Ω
(C)
fective.
• Reference
4 REMARK
ment controller

WECN1 (10) LOCK Max. 1 V
Voltage
Circuit diagram related to work equipment lock switch
D155AX-8 40-891
FAILURE CODE [DDNLKB] W/E Lock SW Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DDNLKB] W/E Lock SW Short Circuit

Action level Failure code Work Equipment Lock SW Short Circuit
Failure
L03 DDNLKB (Work equipment controller system)
Detail of fail- • NO(Normally Open) and NC(Normally Close) lines of work equipment lock lever switch cir-
ure cuit becomes 0 V (switch: ON) simultaneously.
Action of • Assumes that work equipment lock lever is in LOCK position.
Phenomenon
on machine
• Work equipment control is disabled.
• Engine does not start.
• State of work equipment lock lever switch signal can be checked with monitoring function.
Related
information
Procedure: Turn starting switch to ON position and operate work equipment lock lever.
• When work equipment lock lever is in LOCK position, the work equipment lock lever
switch is ON (diagram indicates LOCK state).

1 ment lock lever switch Between WELK (male) (A) LOCK Min. 1 MΩ
(internal open circuit) and (B) Free Max. 1 Ω
Resistance
Between WELK (male) (A) LOCK Max. 1 Ω
and (C) Free Min. 1 MΩ
2. Disconnect connectors WECN1, WECN2, and WELK, and connect T-
Ground fault in wiring adapter to any female side.
2 harness (contact with Between ground and WELK (female) (B) or WECN2
(female) (37)
Resistance
Between ground and WELK (female) (C) or WECN2
Min. 1 MΩ
(female) (27)
40-892 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDNLKB] W/E Lock SW Short Circuit

2. Disconnect connectors WECN2 and WELK, and connect T-adapter to fe-
male side of WECN2.
REMARK
3
ness No continui-
ty (no sound
than (27)
is heard)
Continuity
No continui-
ty (no sound
than (37)
is heard)
fective.
• Reference
4 REMARK
ment controller

Voltage
Circuit diagram related to work equipment lock switch
D155AX-8 40-893
FAILURE CODE [DDTSL1] Stator Clutch Release Trouble 40 TROUBLESHOOTING
FAILURE CODE [DDTSL1] Stator Clutch Release Trouble

Failure Stator Clutch Release Trouble (Power train controller system)
L03 DDTSL1
Detail of fail- While controller stops driving torque converter stator clutch ECMV solenoid, fill switch signal re-
ure mains ON.
Action of
None in particular
controller
• In some cases, sufficient travel torque may not be obtained.
• Signal state (ON/OFF) of stator clutch ECMV fill switch can be checked with monitoring
function. (Code: 31520 T/M Fill SW Input2)
information • Remove operator's seat and cover under seat.
• First, check for defects such as clogged power train oil filter.
• Then, check that clutch pressure is normal by referring to Testing and adjusting, "Testing

quired.
harness
1 2. Disconnect connectors PTCN2 and FSTC, and connect T-adapter to either
cuit)
Between ground and PTCN2 (female) (12) or FSTC
(female) (1)
2. Disconnect connector FSTC.
REMARK
power train controller Keep PCCS lever in N.
If failure code [DDTSL1] is displayed again, ground fault in wiring harness is detect-
ed or power train controller is defective.
(If failure code [DDTSL1] is cleared, stator clutch fill switch is defective
Defective fill switch of 2. Disconnect connector FSTC, and connect T-adapter to male side.
3 stator clutch ECMV (in-
ternal short circuit) Between FSTC (male) (1) and ground (with fill switch
OFF)
40-894 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDTSL1] Stator Clutch Release Trouble

• Reference
controller
3. Start engine.
REMARK
Keep PCCS lever in N.
Circuit diagram (stator clutch oil pressure)
D155AX-8 40-895
FAILURE CODE [DDTSLH] Stator Clutch Engage Trouble 40 TROUBLESHOOTING
FAILURE CODE [DDTSLH] Stator Clutch Engage Trouble

Failure Stator Clutch Engage Trouble (Power train controller system)
L03 DDTSLH
Detail of fail-
While controller drives torque converter stator clutch ECMV solenoid, fill switch signal remains OFF.
ure
Action of
None in particular
controller
• In some cases, sufficient travel torque may not be obtained.
• Signal state (ON/OFF) of stator clutch ECMV fill switch can be checked with monitoring
function. (Code: 31520 T/M Fill SW Input2)
information • Remove operator's seat and cover under seat.
• First, check for defects such as clogged power train oil filter.
• Then, check that clutch pressure is normal by referring to Testing and adjusting, "Testing

Defective fill switch of 2.
Disconnect connector FSTC, and connect T-adapter to male side.
1 stator clutch ECMV (does 3. Start engine.
not turn ON)
Between FSTC (male) (1) and ground (with fill switch
ON)
Open circuit in wiring har- 2. Disconnect connectors PTCN2 and FSTC, and connect T-adapters to
each female side.
defective contact)
Resistance Between PTCN2 (female) (12) and FSTC (female) (1) Max. 1 Ω
tive.
• Reference
controller
3. Start engine.
REMARK
Keep PCCS lever in N.
40-896 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DDTSLH] Stator Clutch Engage Trouble
Circuit diagram (stator clutch oil pressure)
D155AX-8 40-897
FAILURE CODE [DFA4KX] Blade Lift Lever Potentiometer 1 and 2
Open Circuit or Hot Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DFA4KX] Blade Lift Lever Potentiometer 1 and 2 Open

Circuit or Hot Short Circuit
Action level Failure code Blade Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Cir-
Failure cuit
L01 DFA4KX (Work equipment controller system)
Detail of fail- In blade lift lever potentiometer 1 and 2 systems, either failure code [DFA5KA] or [DFA5KY] is dis-
ure played with failure code [DFA6KA] or [DFA6KY] at the same time.
Action of
Assumes that blade lift lever is in neutral.
controller
Phenomenon
Blade lift control is disabled.
on machine
• State of blade lift lever potentiometer signal can be checked with monitoring function.
Related (Code: 73400 Blade Lift Lever 1 Potentio) (Code: 73401 Blade Lift Lever 2 Potentio)
Procedure: Turn starting switch to ON position and operate blade lever (lifting).

Blade lift potentiometer Perform troubleshooting for failure codes [DFA5KA], [DFA5KY], [DFA6KA] and
1
mulfunction [DFA6KY].
40-898 D155AX-8
FAILURE CODE [DFA4KZ] Blade Lift Lever Potentiometer 1 and 2
40 TROUBLESHOOTING Open Circuit or Hot Short Circuit
FAILURE CODE [DFA4KZ] Blade Lift Lever Potentiometer 1 and 2 Open

Action level Failure code Blade Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short Cir-
Failure cuit
L01 DFA4KZ (Work equipment controller system)
In blade lift lever potentiometer 1 and 2 systems, only one side is abnormal when starting switch is
Detail of fail-
in ON position, and then either failure code [DFA5KA] or [DFA5KY] is displayed with failure code
ure
[DFA6KA] or [DFA6KY] at the same time.
Action of
Assumes that blade lift lever is in neutral.
controller
Phenomenon
Blade lift control is disabled.
on machine

1
D155AX-8 40-899
FAILURE CODE [DFA4L8] Blade Lift Lever Potentiometer 1 or 2 Sig-
nal Abnormality 40 TROUBLESHOOTING
FAILURE CODE [DFA4L8] Blade Lift Lever Potentiometer 1 or 2 Signal Ab-

normality
Action level Failure code Blade Lift Lever Potentiometer 1 or 2 Signal Abnormality (Work
Failure
L01 DFA4L8 equipment controller system)
Detail of fail- In blade lift lever potentiometer 1 and 2 systems, total of both signal voltages is 4.41 V or lower, or
ure 5.59 V or higher.
Action of
Continues control with signal of normal one of blade lift lever potentiometer 1 and 2 systems.
controller
Phenomenon
None
on machine

1
40-900 D155AX-8
FAILURE CODE [DFA5KA] Blade Lift Lever Potentiometer 1 Open
FAILURE CODE [DFA5KA] Blade Lift Lever Potentiometer 1 Open Circuit

Action level Failure code Blade Lift Lever Potentiometer 1 Open Circuit (Work equipment con-
Failure
L01 DFA5KA troller system)
Detail of fail-
Signal voltage of blade lift lever potentiometer system 1 is 0.5 V or lower.
ure
Action of
Continues control with signal from blade lift lever potentiometer system 2.
controller
Phenomenon
None
on machine
• Signal voltage of blade lift lever potentiometer 1 can be checked with monitoring function.
Related (Code: 73400)

If failure code [DB95KK] is also displayed, perform troubleshooting these first.
2. Disconnect connector WLV1 and connect T-adapter to female side.
Defective 5 V sensor 3. Turn starting switch to ON position.
1
power supply system
REMARK
If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between WLV1 (female) (4) and (1) 4.5 to 5.5 V
2. Insert T-adapter into connector WLV1.
4. Operate blade control lever (in lilt direction) to perform troubleshooting.
Defective blade lift lever
potentiometer 1 (internal REMARK
2
short circuit) or ground When power supply voltage is normal and sensor output voltage is abnormal (be-
fault low 0.5), distinction from ground fault is not clear. In this case, go to Cause 4.
If failure code is still displayed after above checks on Cause 4, blade lilt lever po-
tentiometer 1 is defective.
0.96 to
Voltage Between WLV1 (female) (3) and (1)
4.04 V
D155AX-8 40-901

2. Disconnect connectors WECN1 and WLV1, and connect T-adapters to
each female side.
REMARK
If power supply voltage is normal check on Cause 1, Max. 1 Ω
Open circuit in wiring har- this check is not required.
Between WECN1 (female) (22) and WLV1 (female) (4)
defective contact)
Resistance REMARK
this check is not required.
Between WECN1 (female) (2) and WLV1 (female) (2) Max. 1 Ω
REMARK
required.
2. Disconnect connectors WECN1 and WLV1, and connect T-adapter to ei-
ground circuit) ther female side.
Between WECN1 (female) (8) and (21) or between
Min. 1 MΩ
WLV1 (female) (1) and (8)
Resistance
Between WECN1 (female) (8) and ground or between
Min. 1 MΩ
WLV1 (female) (3) and ground
fective.
• Reference
Defective work equip- 2. Insert T-adapter into connector WECN1.
5
ment controller
4. Operate blade control lever (in lift direction) to perform troubleshooting.
0.96 to
Voltage Between WECN1 (8) and (21)
4.04 V
40-902 D155AX-8
Circuit diagram related to blade lift lever
D155AX-8 40-903
FAILURE CODE [DFA5KY] Blade Lift Lever Potentiometer 1 Hot
Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DFA5KY] Blade Lift Lever Potentiometer 1 Hot Short Cir-
cuit
Action level Failure code Blade Lift Lever1 Potentiometer 1 Hot Short Circuit
Failure
L01 DFA5KY (Work equipment controller system)
Detail of fail-
• Signal voltage of blade lift lever potentiometer system 1 is 4.5 V or higher.
ure
Action of
• Continues control with signal from blade lift lever potentiometer system 2.
controller
Phenomenon
• None
on machine
Related (Code: 73400 Blade Lift Lever 1 Potentio Volt)

Defective 5 V sensor If failure code [DB95KK] is also displayed, perform troubleshooting these first.
1
power supply system
2. Disconnect connector WLV1.
If failure code [DFA5KY] goes out, blade lift lever potentiometer is defective.
potentiometer 1 (internal
2 (If this failure code is still displayed, wiring harness or work equipment controller is
short circuit) or ground
fault defective.)
REMARK
Since connector WLV1 is disconnected, many other failure codes appear. Ig-
nore all of them other than [DFA5KY].
Hot short circuit in wiring 2. Disconnect connector WLV1 and connect T-adapter to female side.
3
Voltage Between WLV1 (female) (3) and (4) or ground Max. 1 V
2. Disconnect connectors WECN1 and WLV1, and connect T-adapter to fe-
male side of WECN1.
4
ness
No continui-
Continuity ty (No
(8)
sound)
40-904 D155AX-8

fective.
• Reference
5
ment controller
0.96 to
4.04 V
D155AX-8 40-905
FAILURE CODE [DFA6KA] Blade Lift Lever Potentiometer 2 Open Circuit

Action level Failure code Blade Lift Lever Potentiometer 2 Open Circuit
Failure
L01 DFA6KA (Work equipment controller system)
Detail of fail-
• Signal voltage of blade lift lever potentiometer system 2 is 0.5 V or lower.
ure
Action of
controller
Phenomenon
• None
on machine
Related (Code: 73400 Blade Lift Lever 2 Potentio)

1
power supply system
REMARK
4. Operate blade control lever (in lilt direction) to perform troubleshooting.
2
open circuit) or ground When power supply voltage is normal and sensor output voltage is abnormal (be-
If failure code is still displayed after above checks on Cause 4, blade lilt lever po-
0.96 to
4.04 V
40-906 D155AX-8

each female side.
REMARK
If the power supply voltage in check on Cause 1 is Max. 1 Ω
Open circuit in wiring har- normal, this check is not required.
defective contact)
Resistance REMARK
normal, this check is not required.
REMARK
required.
Min. 1 MΩ
Resistance
Min. 1 MΩ
fective.
• Reference
5
ment controller
0.96 to
4.04 V
D155AX-8 40-907
40-908 D155AX-8
FAILURE CODE [DFA6KY] Blade Lift Lever Potentiometer 2 Hot Short Cir-
cuit
Action level Failure code Blade Lift Lever Potentiometer 2 Hot Short Circuit
Failure
Detail of fail-
• Signal voltage of blade lift lever potentiometer system 2 is 4.5 V or higher.
ure
Action of
controller
Phenomenon
• None
on machine
Related (Code: 734001 Blade Lift Lever 2 Potentio)

1
power supply system
If failure code [DFA6KY] goes out, blade lift lever potentiometer is defective.
2 (If this failure code is still displayed, wiring harness or work equipment controller is
fault defective.)
REMARK
3
male side of WECN1.
4
ness
No continui-
Continuity ty (No
(2)
sound)
D155AX-8 40-909

fective.
• Reference
5
ment controller
0.96 to
4.04 V
40-910 D155AX-8
FAILURE CODE [DFA7KX] Blade Tilt Lever Potentiometer 1 and 2
FAILURE CODE [DFA7KX] Blade Tilt Lever Potentiometer 1 and 2 Open

Action level Failure code Blade Tilt Lever Potentiometer 1 and 2 Open Circuit or Hot Short Cir-
Failure
L01 DFA7KX cuit (Work equipment controller system)
Detail of fail- In blade tilt lever potentiometer 1 and 2 systems, either failure code [DFA8KA] or [DFA8KY] is dis-
ure played with failure code [DFA9KA] or [DFA9KY] at the same time.
Action of
Assumes that blade tilt lever is in neutral.
controller
Phenomenon
Blade tilt control is disabled.
on machine
• State of blade tilt lever potentiometer signal can be checked with monitoring function.
Related (Code: 73500 Blade Tilt Lever 1 Potentio) (Code: 73501 Blade Tilt Lever 2 Potentio)
Procedure: Turn starting switch to ON position and operate blade lever (tilting).

Defective blade tilt lever Perform troubleshooting for failure codes [DFABKA], [DFA8KY], [DFA9KA] and
1
potentiometer [DFA9KY].
D155AX-8 40-911
FAILURE CODE [DFA7KZ] Blade Tilt Lever Potentiometer 1 and 2
FAILURE CODE [DFA7KZ] Blade Tilt Lever Potentiometer 1 and 2 Open

Action level Failure code Blade Tilt Lever Potentiometer 1 and 2 Open Circuit or Hot Short Cir-
Failure
L01 DFA7KZ cuit (Work equipment controller system)
In blade tilt lever potentiometer 1 and 2 systems, only one side is abnormal when starting switch is
Detail of fail-
in ON position, and then either failure code [DFA8KA] or [DFA8KY] is displayed with failure code
ure
[DFA9KA] or [DFA9KY] at the same time.
Action of
Assumes that blade tilt lever is in neutral.
controller
Phenomenon
Blade tilt control is disabled.
on machine
Related (Code: 73500 Blade Tilt Lever 1 Potentio) (Code: 73501 Blade Tilt Lever 2 Potentio)

1
40-912 D155AX-8
FAILURE CODE [DFA7L8] Blade Tilt Lever Potentiometer 1 or 2 Sig-
40 TROUBLESHOOTING nal Abnormality
FAILURE CODE [DFA7L8] Blade Tilt Lever Potentiometer 1 or 2 Signal Ab-

normality
Action level Failure code Blade Tilt Lever Potentiometer 1 or 2 Signal Abnormality (Work
Failure
L01 DFA7L8 equipment controller system)
Details of In blade tilt lever potentiometer 1 and 2 systems, total of both signal voltages is 4.41 V or lower, or
failure 5.59 V or higher.
Action of
Continues control with signal of normal one of blade tilt lever potentiometer 1 and 2 systems.
controller
Phenomenon
None
on machine
Related (Code: 73500 Blade Tilt Lever 1 Potentio) (Code: 73501 Blade Tilt Lever B Potentio)

1
D155AX-8 40-913
FAILURE CODE [DFA8KA] Blade Tilt Lever Potentiometer 1 Open
FAILURE CODE [DFA8KA] Blade Tilt Lever Potentiometer 1 Open Circuit

Action level Failure code Blade Tilt Lever Potentiometer 1 Open Circuit (Work equipment con-
Failure
L01 DFA8KA troller system)
Details of
Signal voltage of blade tilt lever potentiometer 1 system is below 0.5 V.
failure
Action of
Continues control by using signal voltage of blade tilt lever potentiometer 2 system.
controller
Phenomenon
None
on machine
• Signal voltage of blade tilt lever potentiometer 1 can be checked with monitoring function
(Code: 73500 Blade tilt lever 1 potentiometer voltage)
Related
information
Procedure: Turn starting switch to ON position and operate blade control lever (in tilting
direction).

1
power supply system
REMARK
4. Operate blade control lever (in tilt direction) to perform troubleshooting.
Defective blade tilt lever REMARK
2 When power supply voltage is normal and sensor output voltage is abnormal
open circuit) or ground
fault (below 0.5 V), distinction from ground fault is not clear. In this case, go to
Cause 4.
If failure code is still displayed after above checks on Cause 4, blade lever tilt po-
0.96 to
4.04 V
40-914 D155AX-8

each female side.
REMARK
defective contact)
Resistance REMARK
REMARK
required.
Min. 1 MΩ
Resistance
Min. 1 MΩ
fective.
• Reference
5
ment controller
0.96 to
4.04 V
D155AX-8 40-915
Circuit diagram related to blade tilt lever potentiometer
40-916 D155AX-8
FAILURE CODE [DFA8KY] Blade Tilt Lever Potentiometer 1 Hot Short
FAILURE CODE [DFA8KY] Blade Tilt Lever Potentiometer 1 Hot Short Cir-
cuit
Action level Failure code Blade Tilt Lever Potentiometer 1 Hot Short Circuit (Work equipment
Failure
L01 DFA8KY controller system)
Detail of fail-
Signal voltage of blade tilt lever potentiometer system 1 is 4.5 V or above.
ure
Action of
Continues blade control with signal from blade tilt lever potentiometer system 2.
controller
Phenomenon
None
on machine
• Voltage of blade tilt lever potentiometer 1 signal can be checked with monitoring function.
Related (Code: 73500 Blade Tilt Lever 1 Potentio)

Defective blade tilt lever
potentiometer 1 (internal If failure code [DFA8KY] goes out, blade tilt lever potentiometer is defective (If this
1 failure code is still displayed, wiring harness or work equipment controller is defec-
fault tive).
REMARK
2
male side of WECN1.
3
ness
No continui-
Continuity ty (No
than (19)
sound)
D155AX-8 40-917

fective.
• Reference
4
ment controller
0.96 to
4.04 V
5
power supply system
40-918 D155AX-8
FAILURE CODE [DFA9KA] Blade Tilt Lever Potentiometer 2 Open Circuit

Action level Failure code Blade Tilt Lever Potentiometer 2 Open Circuit
Failure
L01 DFA9KA (Work equipment controller system)
Detail of fail-
• Signal voltage of blade tilt lever potentiometer system 2 is 0.5 V or lower.
ure
Action of
• Continues blade control with signal from blade tilt lever potentiometer system 1.
controller
Phenomenon
• None
on machine
• Signal voltage of blade tilt lever potentiometer 2 can be checked with monitoring function.
Related (Code: 73501 Blade Tilt Lever 2 Potentio Volt)

1
power supply system
REMARK
Defective blade tilt lever
2
open circuit) or ground When power supply voltage is normal and sensor output voltage is abnormal (be-
If failure code is still displayed after above checks on Cause 4, blade tilt lever po-
0.96 to
4.04 V
D155AX-8 40-919

each female side.
REMARK
defective contact)
Resistance REMARK
REMARK
required.
Min. 1 MΩ
Resistance
Min. 1 MΩ
fective.
• Reference
5
ment controller
0.96 to
4.04 V
40-920 D155AX-8
D155AX-8 40-921
FAILURE CODE [DFA9KY] Blade Tilt Lever Potentiometer 2 Hot Short Cir-
cuit
Action level Failure code Blade Tilt Lever Potentiometer 2 Hot Short Circuit
Failure
Detail of fail-
• Signal voltage of blade tilt lever potentiometer system 2 is 4.5 V or lower.
ure
Action of
• Continues blade control with signal from blade tilt lever potentiometer system 1.
controller
Phenomenon
• None
on machine
• Signal voltage of blade tilt lever potentiometer 2 can be checked with monitoring function.
Related (Code: 73501 Blade Tilt Lever 2 Potentio Volt)

1
power supply system
Defective blade tilt lever If failure code [DFA9KY] goes out, blade tilt lever potentiometer is defective.
potentiometer 2 (internal (If this failure code is displayed again, wiring harness or work equipment controller
2
short circuit) or ground is defective)
fault
REMARK
Since connector WLV1 is cleared, multiple failure codes appear. Ignore them,
except [DFA9KY]
.
3
male side of WECN1.
4
ness
No continui-
Continuity ty (No
than (13)
sound)
40-922 D155AX-8

fective.
• Reference
5
ment controller
0.96 to
4.04 V
D155AX-8 40-923
FAILURE CODE [DFAAKX] Ripper Lift Lever Potentiometer 1 and 2
FAILURE CODE [DFAAKX] Ripper Lift Lever Potentiometer 1 and 2 Open

Action level Failure code Ripper Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short
Failure
L01 DFAAKX Circuit (Work equipment controller system)
Detail of fail- In ripper lift lever potentiometer 1 and 2 systems, either failure code [DFABKA] or [DFABKY] is dis-
ure played with failure code [DFACKA] or [DFACKY] at the same time.
Action of
Assumes that ripper lift lever is in neutral.
controller
Phenomenon
Ripper lift control is disabled.
on machine
• State of ripper lift lever potentiometer signal can be checked with monitoring function.
Related (Code: 73700 Ripper Lift Lever 1 Potentio) (Code: 73701 Ripper Lift Lever 2 Potentio)
Procedure: Turn starting switch to ON position and operate ripper control lever (lifting).

Defective ripper lift lever Perform troubleshooting for failure codes [DFABKA], [DFABKY], [DFACKA] and
1
potentiometer [DFACKY].
40-924 D155AX-8
FAILURE CODE [DFAAKZ] Ripper Lift Lever Potentiometer 1 and 2
FAILURE CODE [DFAAKZ] Ripper Lift Lever Potentiometer 1 and 2 Open

Action level Failure code Ripper Lift Lever Potentiometer 1 and 2 Open Circuit or Hot Short
Failure
L01 DFAAKZ Circuit (Work equipment controller system)
In ripper lift lever potentiometer 1 and 2 systems, only one side is abnormal when starting switch is
Detail of fail-
in ON position, and then either failure code [DFABKA] or [DFABKY] is displayed with failure code
ure
[DFACKA] or [DFACKY] at the same time.
Action of
Assumes that ripper lift lever is in neutral.
controller
Phenomenon
Ripper lift control is disabled.
on machine

1
D155AX-8 40-925
FAILURE CODE [DFAAL8] Ripper Lift Lever Potentiometer 1 or 2 Sig-
nal Abnormality 40 TROUBLESHOOTING
FAILURE CODE [DFAAL8] Ripper Lift Lever Potentiometer 1 or 2 Signal

Abnormality
Action level Failure code Ripper Lift Lever Potentiometer 1 or 2 Signal Abnormality (Work
Failure
L01 DFAAL8 equipment controller system)
Detail of fail- In ripper lift lever potentiometer 1 and 2 systems, total of both signal voltages is 4.41 V or lower, or
ure 5.59 V or higher.
Action of
Continues control with signal of normal one of ripper lift lever potentiometer 1 and 2 systems.
controller
Phenomenon
None
on machine

1
40-926 D155AX-8
FAILURE CODE [DFABKA] Ripper Lift Lever Potentiometer 1 Open
FAILURE CODE [DFABKA] Ripper Lift Lever Potentiometer 1 Open Circuit

Action level Failure code Ripper Lift Lever Potentiometer 1 Open Circuit (Work equipment con-
Failure
L01 DFABKA troller system)
Detail of fail-
Signal voltage of ripper lift lever potentiometer system 1 is 0.5 V or lower.
ure
Action of
Continues control with signal from ripper lift lever potentiometer system 2.
controller
Phenomenon
on machine
• Voltage of ripper lift lever potentiometer 1 signal can be checked with monitoring function.
Related (Code: 73700 Ripper Lift Lever 1 Potentio)

1
power supply system
REMARK
2. Insert T-adapter into connector WLV2 side.
4. Operate ripper control lever (in lift direction) and perform troubleshooting.
Defective ripper lift lever REMARK
2 If battery voltage is normal but sensor output voltage is abnormal (Max. 0.5 V), it is
short circuit or ground
fault) difficult to judge whether cause of failure is wire breakage or short circuit. Proceed
to cause 4.
If failure code is still displayed after above checks on cause 4, ripper lift lever po-
Max. 0.96 to
4.04 V
D155AX-8 40-927

1. 1. Turn starting switch to OFF position.
2. 2. Disconnect connectors WECN1 and WLV2 and connect T-adapters to
each female side.
REMARK
If battery voltage is normal in cause 1, this check is Max. 1 Ω
Open circuit in wiring har- not required.
defective contact)
Resistance REMARK
If battery voltage is normal in cause 1, this check is Max. 1 Ω
not required.
REMARK
required.
1. 1. Turn starting switch to OFF position.
2. 2. Disconnect connectors WECN1 and WLV2 and connect T-adapter to ei-
Between WECN1 (female) (7) and (21) or WLV2 (fe-
Min. 1 MΩ
male) (1) and (3)
Resistance
Between WECN1 (female) (7) and ground or WLV2
Min. 1 MΩ
(female) (3) and ground
fective.
• Reference
5
ment controller
0.96 to
4.04 V
40-928 D155AX-8
Circuit diagram related to ripper lift lever potentiometer
D155AX-8 40-929
FAILURE CODE [DFABKY] Ripper Lift Lever Potentiometer 1 Hot
FAILURE CODE [DFABKY] Ripper Lift Lever Potentiometer 1 Hot Short Cir-
cuit
Action level Failure code Ripper Lift Lever Potentiometer 1 Hot Short Circuit
Failure
L01 DFABKY (Work equipment controller system)
Detail of fail-
• Signal voltage of ripper lift lever potentiometer system 1 is 4.5 V or higher.
ure
Action of
• Continues control with signal from ripper lift lever potentiometer system 2.
controller
Phenomenon
• None
on machine
• Signal voltage of ripper lift lever potentiometer 1 can be checked with monitoring function.
Related (Code: 73700 Ripper Lift Lever 1 Potentio Volt)

1
power supply system
Defective ripper lift lever
potentiometer 1 (internal If failure code [DFABKY] does not appear, ripper lift lever potentiometer is defective
2 (if this failure code remains, wiring harness or work equipment controller is defec-
short circuit or ground
fault) tive).
REMARK
Many other failure codes appear because of disconnected connector WLV2. Ig-
nore failure codes other than [DFABKY].
3
2. Disconnect connectors WECN1 and WLV2, and connect T-adapters to fe-
male side of WECN1.
4
ness
Investigate it by continuity mode of tester.
No continui-
Continuity ty (no
WECN1 (7).
sound)
40-930 D155AX-8
FAILURE CODE [DFABKY] Ripper Lift Lever Potentiometer 1 Hot

fective.
• Reference
5
ment controller
0.96 to
4.04 V
D155AX-8 40-931
FAILURE CODE [DFACKA] Ripper Lift Lever Potentiometer 2 Open
FAILURE CODE [DFACKA] Ripper Lift Lever Potentiometer 2 Open Circuit

Action level Failure code Ripper Lift Lever Potentiometer 2 Open Circuit
Failure
L01 DFACKA (Work equipment controller system)
Detail of fail-
• Signal voltage of ripper lift lever potentiometer system 2 is 0.5 V or lower.
ure
Action of
controller
Phenomenon
on machine

1
power supply system
REMARK
Defective ripper lift lever REMARK
2 If battery voltage is normal but sensor output voltage is abnormal (Max. 0.5 V), it is
fault difficult to judge whether cause of failure is wire breakage or short circuit. Proceed
to cause 4.
If failure code is still displayed after above checks on cause 4, ripper lift lever po-
Between WLV2 (female) 0.96 to
Voltage Sensor output
(2) and (1) 4.04 V
each female side.
If battery voltage is normal in cause 1, this check is not
Open circuit in wiring har- required. Max. 1 Ω
defective contact)
Resistance If battery voltage is normal in cause 1, this check is not
required. Max. 1 Ω
40-932 D155AX-8

quired.
ground circuit) Between WECN1 (female) (1) and (21) or WLV2 (fe-
Min. 1 MΩ
male) (1) and (2)
Resistance
Between WECN1 (female) (1) and ground or WLV2
Min. 1 MΩ
(female) (2) and ground
fective.
• Reference
5
ment controller
0.96 to
4.04 V
D155AX-8 40-933
40-934 D155AX-8
FAILURE CODE [DFACKY] Ripper Lift Lever Potentiometer 2 Hot
FAILURE CODE [DFACKY] Ripper Lift Lever Potentiometer 2 Hot Short Cir-
cuit
Action level Failure code Ripper Lift Lever Potentiometer 2 Hot Short Circuit
Failure
L01 DFACKY (Work equipment controller system)
Detail of fail-
• Signal voltage of ripper lift lever potentiometer system 2 is 4.5 V or higher.
ure
Action of
controller
Phenomenon
• None
on machine

1
power supply system
Defective ripper lift lever
potentiometer 2 (internal If failure code [DFACKY] does not appear, ripper lift lever potentiometer is defective
2 (if this failure code remains, wiring harness or work equipment controller is defec-
fault tive).
REMARK
Many other failure codes appear because of disconnected connector WLV2. Ig-
nore failure codes besides [DFACKY].
3
2. Disconnect connectors WECN1 and WLV2, and connect T-adapters to fe-
male side of WECN1.
4
ness
No continui-
Continuity ty (no
WECN1 (1).
sound)
D155AX-8 40-935
FAILURE CODE [DFACKY] Ripper Lift Lever Potentiometer 2 Hot

fective.
• Reference
5
ment controller
0.96 to
4.04 V
40-936 D155AX-8
FAILURE CODE [DGS1KA] Hydraulic Oil Temperature Sensor Open
FAILURE CODE [DGS1KA] Hydraulic Oil Temperature Sensor Open Circuit

Action level Failure code Hydraulic Oil Temperature Sensor Open Circuit (Work equipment
Failure
L01 DGS1KA controller system)
Detail of fail-
Hydraulic oil temperature sensor signal is out of normal range.
ure
Action of
None in particular
controller
Phenomenon • Fan speed is restricted to half speed.
on machine • Hydraulic oil temperature is not displayed correctly on monitor panel.
• Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraul-
Related ic Oil Temperature)
Procedure: Turn starting switch to ON position or start engine.

2. Disconnect connector HDT and connect T-adapter to male side.
Approx.
Defective hydraulic oil 25 °C
Between HDT (male) (1) 42 kΩ
temperature sensor sys-
tem and (2) Approx.
1 30 °C
REMARK 35 kΩ
(internal open or short Resistance
circuit) Temperature-Resistance 80 °C Approx.
characteristics of oil tem- 6.5 kΩ
perature sensor Approx.
100 °C
3.7 kΩ
2. Disconnect connector HDT and connect T-adapter to female side.
REMARK
Open circuit, short circuit,
2 ground fault, or hot short • If voltage is 0 V, wiring harness has open circuit, ground fault, or short cir-
circuit in wiring harness cuit, and if voltage is 24 V, wiring harness has hot short circuit.
• Voltage of approximately 5 V is applied to temperature sensor signal cir-
cuits through resistor in work equipment controller.
Approxi-
Voltage Between HDT (female) (1) and (2)
mately. 5 V
D155AX-8 40-937
FAILURE CODE [DGS1KA] Hydraulic Oil Temperature Sensor Open
NOTICE
is not required.
3
wiring harness
• Resistance accords with thermal characteristics table in cause 1.
• If resistance is 1 MΩ or higher, wiring harness has open circuit. If resistance
is 1 Ω or below, wiring harness has short circuit.
Approxi-
Resistance Between WECN1 (female) (14) and (21) mately 3.7
to 90 kΩ
NOTICE
If failure code is still displayed after above checks on cause 2 or 3, this
check is not required.
4
defective contact of con- 2. Disconnect connectors WECN1 and HDT, and connect T-adapters to each
nector) female side.
Between WECN1 (female) (14) and HDT (female) (1) Max. 1 Ω
Resistance
Between WECN1 (female) (21) and HDT (female) (2) Max. 1 Ω
2. Disconnect connectors WECN1 and HDT, and connect T-adapter to fe-
male side of WECN1.
5
ness
Check it by using multimeter in continuity mode.
No continui-
than (14)
is heard)
6
Circuit diagram related to hydraulic oil temperature sensor
40-938 D155AX-8
FAILURE CODE [DGS1KX] Hydraulic Oil Temperature Sensor Input
40 TROUBLESHOOTING Signal Out of Range
FAILURE CODE [DGS1KX] Hydraulic Oil Temperature Sensor Input Signal

Out of Range
Action level Failure code Hydraulic Oil Temperature Sensor Input Signal Out of Range (Work
Failure
L01 DGS1KX equipment controller system)
Detail of fail-
Hydraulic oil temperature sensor signal is out of normal range.
ure
Action of
None in particular
controller
Phenomenon • Fan speed is restricted to half speed.
on machine • Hydraulic oil temperature is not displayed correctly on monitor panel.
• Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraul-
Related ic Oil Temperature)

Defective hydraulic oil 2. Disconnect connector HDT.
temperature sensor (in- 3. Turn starting switch to ON position.
1
ternal open circuit or
short circuit) If failure code [DGS1KX] disappears and [DGS1KA] for open circuit appears, hy-
draulic oil temperature sensor is defective. (If failure code [DGS1KX] is still dis-
played, wiring harness or work equipment controller is defective.)
Ground fault in wiring 2. Disconnect connectors WECN1 and HDT, and connect T-adapter to either
ground circuit)
Between ground and WECN1 (female) (14) or HDT (fe-
male) (1)
2. Disconnect connectors WECN1 and HDT, and connect T-adapter to fe-
male side of WECN1.
3
ness
No continui-
than (14)
is heard)
4
D155AX-8 40-939
FAILURE CODE [DGS1KX] Hydraulic Oil Temperature Sensor Input
Signal Out of Range 40 TROUBLESHOOTING
Circuit diagram related to hydraulic oil temperature sensor
40-940 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit
FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit

Action level Failure code Torque Converter Oil Temperature Sensor Open Circuit (power train
Failure
L01 DGT1KA controller system)
Detail of fail- • Torque converter oil temperature (power train oil temperature) sensor signal is out of nor-
ure mal range.
Action of
controller
• Power train oil temperature gauge may not indicate correct temperature.
Phenomenon
• Fan speed is restricted to half speed.
on machine
• Gear shift shock of transmission is large.
• Torque converter oil temperature stands for power train oil temperature.
Related • Torque converter oil temperature can be checked with monitoring function. (Code: 30100
T/C Oil Temperature)
information

2. Disconnect connector TCT, and connect T-adapter to male side.
Approxi-
25 °C
Defective T/C oil temper- mately 42 Ω
Between TCT (male) (1)
ature (P/L oil tempera- Approxi-
1 and (2) 30 °C
ture) sensor (internal mately 35 Ω
open or short circuit) Resistance REMARK
Approxi-
Thermal characteristics 80 °C
mately 6.5 Ω
of oil temperature sensor
Approxi-
100 °C
mately 3.7 Ω
2. Disconnect connector TCT and connect T-adapter to female side.
REMARK
2 ground fault, or hot short • If voltage is 0 V, wiring harness has open circuit, ground fault, or short cir-
circuit in wiring harness cuit, and if voltage is 24 V, wiring harness has hot short circuit.
• Voltage of approximately 5 V is applied to signal line of temperature sensor
Approxi-
Voltage Between TCT (female) (1) and (2)
mately. 5 V
D155AX-8 40-941
FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit 40 TROUBLESHOOTING

quired.
REMARK
3 • Resistance values are same as temperature characteristics of Cause 1.
wiring harness
• If resistance is 1 MΩ or more, wiring harness has open circuit. If it is below
1 Ω, wiring harness has short circuit.
Approxi-
Resistance Between PTCN1 (female) (9) and (21) mately 3.7
to 90 kΩ
If failure code is still displayed after above checks on cause 2 or 3, this check is not
required.
2. Disconnect connectors PTCN1 and TCT, and connect T-adapters to each
defective contact) female side.
Between PTCN1 (female) (9) and TCT (female) (1) Max. 1 Ω
Resistance
Between PTCN1 (female) (21) and TCT (female) (2) Max. 1 Ω
2. Disconnect connectors PTCN1 and TCT, and connect T-adapter to female
side of PTCN1.
5
ness
No continui-
Continuity ty (no
(9)
sound)
6
controller tive.
40-942 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit
Circuit diagram related to torque converter oil temperature (P/L oil temperature)
sensor
D155AX-8 40-943
FAILURE CODE [DGT1KX] T/C Oil Temperature Sensor Input Signal
FAILURE CODE [DGT1KX] T/C Oil Temperature Sensor Input Signal Out of
Range
Action level Failure code Torque Converter Oil Temperature Sensor Input Signal Out of Range
Failure
L01 DGT1KX (Power train controller system)
Detail of fail-
• Torque converter oil temperature sensor signal is out of normal range.
ure
Action of
controller
• Power train oil temperature gauge may not indicate correct temperature.
Phenomenon
• Fan speed is restricted to half speed.
on machine
• Torque converter oil temperature stands for power train oil temperature.
Related • See failure code [DGT1KA] for Temperature-Resistance characteristics table of oil temper-
ature sensor.
information
• Even when system works properly, failure code [DGT1KA] is displayed if sensor connector
is disconnected and starting switch is turned to ON position.

Defective T/C oil temper- 2. Disconnect connector TCT.
ature (P/L oil tempera- 3. Turn starting switch to ON position.
1
ture) sensor (internal
open or short circuit) If failure code [DGT1KX] goes out and [DGT1KA] for open circuit is displayed, tor-
que converter oil temperature sensor is defective. If failure code [DGT1KX] is still
displayed, wiring harness or power train controller is defective.
Ground fault in wiring 2. Disconnect connectors PTCN1 and TCT, and connect T-adapter to either
ground circuit)
Between ground and PTCN1 (female) (9) or TCT (fe-
male) (1)
2. Disconnect connectors PTCN1 and TCT, and connect T-adapter to female
side of PTCN1.
3
ness
No continui-
Continuity ty (no
(9)
sound)
4
controller tive.
40-944 D155AX-8
FAILURE CODE [DGT1KX] T/C Oil Temperature Sensor Input Signal
Circuit diagram related to torque converter oil temperature (P/L oil temperature)
sensor
D155AX-8 40-945
FAILURE CODE [DH21KA] W/E Pump Pressure Sensor Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DH21KA] W/E Pump Pressure Sensor Open Circuit

Action level Failure code Work Equipment Pump Pressure Sensor Open Circuit (Work equip-
Failure
L01 DH21KA ment controller system)
Detail of fail-
Signal voltage of work equipment pump pressure sensor is 0.2 V or lower.
ure
Action of
None in particular
controller
Phenomenon
Oil pressure of work equipment pump cannot be monitored.
on machine
• Signal voltage of work equipment pump oil pressure sensor can be checked with monitor-
Related ing function. (Code: 70701 Hydraulic Pressure Sensor1)

If failure code [DB97KK] is also displayed, perform troubleshooting for that failure
code first.
2. Disconnect connector HHP and connect T-adapter to female side.
Defective 5 V sensor
power supply system
REMARK
2. Insert T-adapter into connector HHP.
Defective work equip- REMARK
ment pump oil pressure If power supply voltage is normal and sensor output voltage is abnormal (0.5 V
2
sensor (internal defect) or lower), it cannot be determined whether ground fault or defective sensor is
or ground fault
the cause. In this case, go to check on cause 4.
• If failure code is still displayed after above checks on cause 4, work equip-
ment pump pressure sensor is defective.
Voltage Between HHP (C) and (A) Sensor output 0.5 to 4.5 V
40-946 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DH21KA] W/E Pump Pressure Sensor Open Circuit

2. Disconnect connectors WECN1, WECN2 and HHP, and connect T-adapt-
NOTICE
If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 Ω
Open circuit in wiring har- • Between WECN1 (female) (21) and HHP (fe-
ness (wire breakage or male) (A)
3
nector) NOTICE
Resistance
If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 Ω
• Between WECN2 (female) (1) and HHP (fe-
male) (B)
• Between WECN1 (female) (3) and HHP (fe-
Max. 1 Ω
male) (C)
NOTICE
is not required.
2. Disconnect connectors WECN1 and HHP, and connect T-adapter to either
Between WECN1 (female) (3) and (21), or between
Min. 1 MΩ
HHP (female) (C) and (A)
Resistance
Between ground and WECN1 (female) (3) or HHP (fe-
Min. 1 MΩ
male) (C)
fective.
Reference
Defective work equip- 1. Turn starting switch to OFF position.
5
ment controller
D155AX-8 40-947
FAILURE CODE [DH21KA] W/E Pump Pressure Sensor Open Circuit 40 TROUBLESHOOTING
Circuit diagram related to work equipment pump oil pressure
40-948 D155AX-8
FAILURE CODE [DH21KY] W/E Pump Pressure Sensor Hot Short Cir-
FAILURE CODE [DH21KY] W/E Pump Pressure Sensor Hot Short Circuit
Action level Failure code Work Equipment Pump Pressure Sensor Hot Short Circuit (Work
Failure
L01 DH21KB equipment controller system)
Detail of fail-
Signal voltage of work equipment pump pressure sensor is 4.8 V or above.
ure
Action of
None in particular
controller
Phenomenon
Oil pressure of work equipment pump cannot be monitored.
on machine
• Signal voltage of work equipment pump oil pressure sensor can be checked with monitor-
ing function. (Code: 70701 Hydraulic Pressure Sensor1)
• Even when system works properly, failure code [DH21KA] is displayed if work equipment
oil pressure sensor connector is disconnected and starting switch is turned to ON position.

If failure code [DB97KK] is also displayed, perform troubleshooting for that failure
code first.
2. Disconnect connector HHP and connect T-adapter to female side.
Defective 5 V sensor
power supply system
REMARK
Defective work equip- 2. Disconnect connector HHP.
ment pump oil pressure 3. Turn starting switch to ON position.
2
or ground fault If failure code [DH21KB] disappears and [DH21KA] for open circuit appears, work
equipment pump oil pressure sensor is defective. (If failure code [DH21KB] is still
displayed, wiring harness or power train controller is defective.)
Hot short circuit in wiring 2. Disconnect connector HHP and connect T-adapter to female side.
3 harness (Contact with 24
V circuit)
Voltage Between HHP (female) (C) and (A) or ground Max. 1 V
2. Disconnect connectors WECN1 and HHP, and connect T-adapter to fe-
male side of WECN1.
4
ness
Check by using multimeter in continuity mode.
No continui-
(3)
is heard)
D155AX-8 40-949
FAILURE CODE [DH21KY] W/E Pump Pressure Sensor Hot Short Cir-

fective.
Reference
5
ment controller
Circuit diagram related to work equipment pump oil pressure
40-950 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit

Action level Failure code Air Cleaner Clog Sensor Open Circuit
Failure
L01 DHA4KA (Machine monitor system)
Machine monitor determines that air cleaner clogging sensor circuit is open (open of sensor con-
Detail of fail-
tacts) because signal voltage from air cleaner clogging switch is not 1 V or below when starting
ure
switch is turned to ON position.
Action of
Displays air cleaner clogging monitor in yellow on machine monitor.
controller
Phenomenon If machine is used as it is, clogging of air cleaner cannot be detected correctly, inducing damage to
on machine engine.
• Input signal (ON/OFF) from air cleaner clogging sensor can be checked with monitoring
Related function (Code: 04501 Monitor Input 2).

properly)
2. Disconnect connector AF1 and connect T-adapter to male side.
3. Start engine.
Air cleaner suction resistance
Defective air cleaner
*1: Max.-3,430 Pa {Max.-350 mmH2O}
2 clogging switch (internal
open circuit) *2: -7,470±490 Pa {-762 ±50 mmH2O}
Max.1 Ω
Between AF1(male)(1) mal *1
Resistance
and (2) When air cleaner is clog-
Max.1 MΩ
ged *2
Open circuit in wiring har- 2. Disconnect connectors CM02 and AF1, and insert T-adapters into each fe-
3
nector) Between CM02 (female) (4) and AF1 (female) (1) Max. 1 Ω
Resistance
Between AF1 (female) (2) and ground Max. 1 Ω
If failure code is still displayed after above checks, machine monitor is defective. (In
whole assembly.)
Reference
4 2. Insert T-adapters into connectors CM01 and CM02.
tor
Between CM02 (4) and Max. 1 V
Voltage mal
CM01 (3)
Air cleaner is clogged Max. 10 V
D155AX-8 40-951
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit 40 TROUBLESHOOTING
CIRCUIT DIAGRAM (AIR CLEANER CLOGGING SENSOR)
40-952 D155AX-8
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Fro-
40 TROUBLESHOOTING zen
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen

Action level Failure code KDPF Differential Pressure Sensor Frozen
Failure
- DHAAMA (Engine controller system)
Signal voltage from KDPF differential pressure sensor does not show a correct value when ambient
Detail of fail-
temperature is low because of frozen KDPF differential pressure sensor. (Signal voltage is within
ure
"normal" or "operating" range.)
Action of
controller
Phenomenon
None in particular
on machine
k Since KDOC and KDPF are heated to 500 °C or be careful not to get burned.
• The cause of this failure code is solved after freeze is solved. Troubleshooting is not nec-
essary.
• If the ambient temperature is not at freezing point of the sensor when this failure code is
displayed on abnormality record, identify the cause according to the following procedures.
unit.
tion. (Code: 47101 (V))
Related (Code: 47300 (°C))
information • Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
(Code: 47200 (°C))
Chapter 50 “DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEM-
BLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY”.
ON position.

Defective KDPF differen- If failure code [CA1883] is displayed on the abnormality record screen, perform
1
tial pressure sensor tube troubleshooting for failure code [CA1883] first.
Ambient temperature Check the installation of the ambient temperature sensor.
2
Defective engine room Check the installation of the engine room temperature sensor.
3
temperature sensor
If this failure code displays when the ambient temperature is high, the engine con-
4 troller is defective. (In case of an internal defect, troubleshooting is impossible as
ler
D155AX-8 40-953
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen 40 TROUBLESHOOTING
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen

Action level Failure code KDPF Outlet Pressure Sensor Frozen
Failure
- DHACMA (Engine controller system)
Signal voltage from KDPF outlet pressure sensor does not show a correct value when ambient tem-
Detail of fail-
perature is low because of KDPF outlet pressure sensor frozen. (Signal voltage is within "normal" or
ure
"operating" range.)
Action of
controller
Phenomenon
None in particular
on machine
• The cause of this failure code is solved after freeze is solved. Troubleshooting is not nec-
essary.
• If the ambient temperature is not freezing point when this failure code is displayed on ab-
normality record, identify the cause according to the following procedures.
unit.
• Signal voltage from KDPF outlet pressure sensor can be checked by monitoring function.
(Code: 47001 (V))
• Pressure in KDPF outlet pressure sensor can be checked by monitoring function. (Code:
47000 (kPa))
Related (Code: 47300 (°C))
information • Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
(Code: 47200 (°C))
Chapter 50 “DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEM-
BLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for Max. 6 minutes) and then stops. To restart engine, wait until system operating lamp
goes off after turning starting switch to OFF position, and then turn starting switch to ON
position.

Defective KDPF differen- If failure code [CA3135] is displayed on the abnormality record screen, perform
1
tial pressure sensor tube troubleshooting for failure code [CA3135] first.
Ambient temperature Check the installation of the ambient temperature sensor.
2
Defective engine room Check the installation of the engine room temperature sensor.
3
temperature sensor
If this failure code displays when the ambient temperature is high, the engine con-
4 troller is defective. (In case of an internal defect, troubleshooting is impossible as
ler
40-954 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DHT5KA] T/C Inlet Pressure Sensor Open Circuit
FAILURE CODE [DHT5KA] T/C Inlet Pressure Sensor Open Circuit

Action level Failure code Torque Converter Inlet Pressure Sensor Open Circuit (power train
Failure
L03 DHT5KA controller system)
Detail of fail-
Signal voltage of torque converter inlet pressure sensor is 0.2 V or lower.
ure
Action of
None in particular
controller
Phenomenon
on machine
• Inlet pressure of torque converter cannot be monitored.
• Signal voltage from torque converter inlet oil pressure sensor can be checked with moni-
Related toring function. (Code: 32602 T/C In-Pressure Sensor Volt)

If failure code [DBE6KK] is also displayed, perform troubleshooting these first.
Defective sensor 24 V 2. Disconnect connector TIP and connect T-adapter to female side.
1
power supply system 3. Turn starting switch to ON position.
If power supply voltage is abnormal, go to Cause 3.
Voltage Between TIP (female) (B) and (A) 20 to 30 V
2. Insert T-adapter into connector TIP.
Defective torque convert-
er inlet pressure sensor REMARK
2
(internal defect or ground When power supply voltage is normal and sensor output voltage is abnormal
fault) (below 0.5), distinction from ground fault is not clear. In this case, go to Cause
4. If failure code is still displayed after above checks on Cause 4, torque con-
verter inlet oil pressure sensor sensor is defective.
Voltage Between TIP (female) (C) and (A) 0.5 to 4.5 V
D155AX-8 40-955
FAILURE CODE [DHT5KA] T/C Inlet Pressure Sensor Open Circuit 40 TROUBLESHOOTING

2. Disconnect connectors PTCN1 and TIP, and connect T-adapters to each
female side.
REMARK
ness (wire breakage or this check is not required.
3
defective contact of con- Between PTCN1 (female) (16) and TIP (female) (B)
nector)
Resistance REMARK
Between PTCN1 (female) (21) and TIP (female) (A)
Between PTCN1 (female) (13) and TIP (female) (Ｃ) Max. 1 Ω
REMARK
required.
2. Disconnect connectors PTCN1 and TIP, and connect T-adapter to either
Between PTCN1 (female) (13) and (21) or between
Min. 1 MΩ
TIP (female) (C) and (A)
Resistance
Between PTCN1 (female) (13) and ground or between
Min. 1 MΩ
TIP (female) (C) and ground
tive.
• Reference
5
Voltage Between PTCN1 (13) and (21) 0.5 to 4.5 V
40-956 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DHT5KA] T/C Inlet Pressure Sensor Open Circuit
Circuit diagram related to torque converter inlet oil pressure sensor
D155AX-8 40-957
FAILURE CODE [DHT5KY] T/C Inlet Pressure Sensor Hot Short Cir-
FAILURE CODE [DHT5KY] T/C Inlet Pressure Sensor Hot Short Circuit
Action level Failure code Torque Converter Inlet Pressure Sensor Hot Short Circuit (power
Failure
L03 DHT5KB train controller system)
Detail of fail-
Signal voltage of torque converter inlet pressure sensor is 4.7 V or above.
ure
Action of
None in particular
controller
Phenomenon
on machine
• Inlet pressure of torque converter cannot be monitored.
• Signal voltage from torque converter inlet oil pressure sensor can be checked with moni-
toring function. (Code: 32602 T/C In-Pressure Sensor Volt)
information
• Even when system works properly, failure code [DHT5KA] is displayed if torque converter
inlet oil pressure sensor connector is disconnected and starting switch is turned to ON po-
sition.

Defective sensor 24 V 2. Disconnect connector TIP and connect T-adapter to female side.
1
Voltage Between TIP (female) (B) and (A) 20 to 30 V
Defective torque convert- 2. Disconnect connector TIP.
er inlet pressure sensor 3. Turn starting switch to ON position.
2
(internal defect or ground
fault) If failure code [DHT5KY] goes out, torque converter inlet oil pressure sensor is de-
fective. (If failure code [DHT5KY] is still displayed, wiring harness or power train
controller is defective.)
Hot short circuit in wiring 2. Disconnect connector TIP and connect T-adapter to female side.
3
Voltage Between TIP (female) (C) and (A) or ground Max. 1 V
2. Disconnect connectors PTCN1 and TIP, and connect T-adapter to female
side of PTCN1.
4
ness
No continui-
Voltage ty (No
(13)
sound)
40-958 D155AX-8
FAILURE CODE [DHT5KY] T/C Inlet Pressure Sensor Hot Short Cir-

tive.
• Reference
5
Circuit diagram related to torque converter inlet oil pressure sensor
D155AX-8 40-959
FAILURE CODE [DHT7KA] T/C Outlet Pressure Sensor Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DHT7KA] T/C Outlet Pressure Sensor Open Circuit

Action level Failure code Torque Converter Outlet Pressure Sensor Open Circuit
Failure
L03 DHT7KA (Power train controller system)
Detail of fail-
Signal voltage of torque converter outlet pressure sensor is 0.2 V or lower.
ure
Action of
None in particular
controller
Phenomenon
on machine
• Outlet pressure of torque converter cannot be monitored.
• Signal voltage from torque converter outlet oil pressure sensor can be checked with moni-
Related toring function. (Code: 32604 T/C Outlet Pressure Sensor Volt)

Defective sensor 24 V 2. Disconnect connector TOP and connect T-adapter to female side.
1
Voltage Between TOP (female) (B) and (A) 20 to 30 V
2. Insert T-adapter into connector TOP.
Defective torque convert- REMARK
er outlet pressure sensor
2 When power supply voltage is normal and sensor output voltage is abnormal
fault) (below 0.5), distinction from ground fault is not clear. In this case, go to Cause
4. If failure code is still displayed after above checks on Cause 4, torque con-
verter outlet oil pressure sensor sensor is defective.
Between TOP (female) (C)
and (A)
40-960 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DHT7KA] T/C Outlet Pressure Sensor Open Circuit

2. Disconnect connectors PTCN1 and TOP, and connect T-adapters to each
female side.
REMARK
ness (wire breakage or this check is not required.
3
defective contact of con- Between PTCN1 (female) (16) and TOP (female) (B)
nector)
Resistance REMARK
Between PTCN1 (female) (21) and TOP (female) (A)
Between PTCN1 (female) (7) and TOP (female) (C) Max. 1 Ω
REMARK
required.
2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to either
Min. 1 MΩ
TOP (female) (C) and (A)
Resistance
Disconnect connectors PTCN1 and TOP, and connect
Min. 1 MΩ
T-adapter to either female side.
tive.
• Reference
5
controller
D155AX-8 40-961
FAILURE CODE [DHT7KA] T/C Outlet Pressure Sensor Open Circuit 40 TROUBLESHOOTING
Circuit diagram related to torque converter outlet pressure sensor
40-962 D155AX-8
FAILURE CODE [DHT7KY] T/C Outlet Pressure Sensor Hot Short Cir-
FAILURE CODE [DHT7KY] T/C Outlet Pressure Sensor Hot Short Circuit
Action level Failure code Torque Converter Outlet Pressure Sensor Hot Short Circuit
Failure
L03 DHT7KB (Power train controller system)
Detail of fail-
Signal voltage of torque converter outlet pressure sensor is 4.7 V or above.
ure
Action of
None in particular
controller
Phenomenon
on machine
• Outlet pressure of torque converter cannot be monitored.
• Signal voltage from torque converter outlet oil pressure sensor can be checked with moni-
toring function. (Code: 32604 T/C Outlet Pressure Sensor Volt)
information
• Even when system works properly, failure code [DHT7KA] is displayed if torque converter
outlet oil pressure sensor connector is disconnected and starting switch is turned to ON
position.

Defective sensor 24 V 2. Disconnect connector TOP and connect T-adapter to female side.
1
Voltage Between TOP (female) (B) and (A) 20 to 30 V
Defective torque convert- 2. Disconnect connector TOP.
er outlet pressure sensor 3. Turn starting switch to ON position.
2
fault) If failure code [DHT7KY] goes out, torque converter outlet oil pressure sensor is de-
fective. (If failure code [DHT7KY] is still displayed, wiring harness or power train
controller is defective.)
Hot short circuit in wiring 2. Disconnect connector TOP and connect T-adapter to female side.
3
Voltage Between TOP (female) (C) and (A) or ground Max. 1 V
2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female
side of PTCN1.
4
ness
No continui-
Continuity ty (No
(7)
sound)
D155AX-8 40-963
FAILURE CODE [DHT7KY] T/C Outlet Pressure Sensor Hot Short Cir-

tive.
• Reference
5
controller
Circuit diagram related to torque converter outlet pressure sensor
40-964 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK10KA] Fuel Control Dial Open Circuit
FAILURE CODE [DK10KA] Fuel Control Dial Open Circuit

Failure Fuel Control Dial Open Circuit (power train controller system)
L03 DK10KA
Detail of fail-
Signal voltage of fuel control dial circuit is 0.5 V or lower.
ure
Action of • Continues engine control by using signal from decelerator pedal potentiometer.
Phenomenon
on machine
• Input voltage from fuel control dial can be checked with monitoring function. (Code: 03000
Related Fuel control dial voltage)

Defective sensor 5 V 2. Disconnect connector DIA2 and connect T-adapter to female side.
1
If power supply voltage is abnormal, proceed to check on cause 3.
Voltage Between DIA2 (female) (A) and (C) 4.5 to 5.5 V
2. Disconnect connector DIA2, and connect T-adapter to male side.
3. Operate fuel control dial and perform troubleshooting.
Approx.
Defective fuel control dial Between DIA2 (male) (A) and (C)
5 kΩ
2 (internal open circuit or
ground fault) 0.5 to
Between DIA2 (male) (B) and (C)
Resistance 4.5 kΩ
0.5 to
Between DIA2 (male) (A) and (B)
4.5 kΩ
Between ground and DIA2 (male) (B) Min. 1 MΩ
2. Disconnect connectors PTCN1, TLV1 and BRK, and connect T-adapter to
female side of PTCN1.
REMARK
• Resistance accords with table in cause 2.
3 • If resistance is Min. 1 MΩ, it has open circuit. If resistance is Max. 1 Ω, it
wiring harness
has short circuit.
Approx.
5 kΩ
Resistance
0.5 to
4.5 kΩ
D155AX-8 40-965
FAILURE CODE [DK10KA] Fuel Control Dial Open Circuit 40 TROUBLESHOOTING

2. Disconnect connectors PTCN1 and DIA2 and connect T-adapters to each
female side.
If no failure is found in power supply by check on
cause 1 or check on cause 3, this check is not re-
quired. Max. 1 Ω
ness (wire breakage or Between PTCN1 (female) (22) and DIA2 (female) (A)
4
defective contact of con- If no failure is found in power supply by check on
nector) cause 1 or check on cause 3, this check is not re-
Resistance
quired. Max. 1 Ω
Between PTCN1 (female) (21) and DIA2 (female) (C)

If failure code is still displayed after above checks on
Between PTCN1 (female) (6) and DIA2 (female) (B)
quired.
2. Disconnect connectors PTCN1, DIA2, BRK, and TLV1, and connect T-
5 harness (contact with adapter to either female side.
ground circuit) Between PTCN1 (female) (6) and (21), or between
Min. 1 MΩ
DIA2 (female) (B) and (C)
Resistance
Between ground and PTCN1 (female) (6), or between
Min. 1 MΩ
ground and DIA2 (female) (B)
tive.
• Reference
6 2. Insert T-adapter into connector PTCN1.
controller
4. Turn fuel control dial to perform troubleshooting.
40-966 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK10KA] Fuel Control Dial Open Circuit
Circuit diagram related to fuel control dial
D155AX-8 40-967
FAILURE CODE [DK10KB] Fuel Control Dial Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DK10KB] Fuel Control Dial Short Circuit

Failure Fuel Control Dial Short Circuit (power train controller system)
L03 DK10KB
Detail of fail-
Signal voltage of fuel control dial circuit is 4.5 V or above.
ure
Action of • Continues engine control by using signal from decelerator pedal potentiometer.
Phenomenon
on machine
• Input voltage from fuel control dial can be checked with monitoring function. (Code: 03000
Related Fuel control dial voltage)

Defective sensor 5 V 2. Disconnect connector DIA2 and connect T-adapter to female side.
1
Voltage Between DIA2 (female) (A) and (C) 4.5 to 5.5 V
2. Disconnect connector DIA2, and connect T-adapter to male side.
3. Operate fuel control dial and perform troubleshooting.
Defective fuel control dial Approx.
2 (internal open circuit or Between DIA2 (male) (A) and (C)
5 kΩ
ground fault)
0.5 to
Resistance Between DIA2 (male) (B) and (C)
4.5 kΩ
0.5 to
Between DIA2 (male) (A) and (B)
4.5 kΩ
Hot short circuit in wiring 2. Disconnect connector DIA2, and connect T-adapter to female side.
3
Voltage Between DIA2 (female) (B) and (C) or ground Max. 1 V
2. Disconnect connectors PTCN1 and DIA2, and connect T-adapter to female
side of connector PTCN1.
4
ness
No continui-
(6)
is heard)
40-968 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK10KB] Fuel Control Dial Short Circuit

tive.
• Reference
controller
4. Turn fuel control dial to perform troubleshooting.
Circuit diagram related to fuel control dial
D155AX-8 40-969
FAILURE CODE [DK30KA] S/T Potentiometer 1 Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DK30KA] S/T Potentiometer 1 Open Circuit

Failure Steering Potentiometer 1 Open Circuit (power train controller system)
L03 DK30KA
Detail of fail-
Signal voltage of steering lever potentiometer 1 (S/T lever 1) is 0.5 V or lower.
ure
Action of • Continues control by using signal from steering lever potentiometer 2 (S/T lever 2).
Phenomenon
on machine
• Signal voltage of steering lever potentiometer 1 signal can be checked with monitoring
function. (Code: 50300 S/T Lever1 Potentio)
Related
information
Procedure: Turn starting switch to ON position and Operate PCCS lever (in steering direc-
tion)

Defective sensor 5 V 2. Disconnect connector TLV1 and connect T-adapter to female side.
1
Voltage Between TLV1 (female) (5) and (8) 4.5 to 5.5 V
REMARK
Defective steering poten- If power supply voltage is normal and sensor output voltage is abnormal (0.5 V
2 tiometer 1 (internal open
or lower), it cannot be determined whether ground fault or defective sensor is
circuit) or ground fault
If failure code is still displayed after above checks on cause 4, steering potentiome-
ter 1 is defective.
0.96 to
4.04 V
40-970 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK30KA] S/T Potentiometer 1 Open Circuit

2. Disconnect connectors PTCN1 and TLV1, and connect T-adapters to each
female side.
REMARK
If power supply voltage in check on cause 1 is nor- Max. 1 Ω
ness (wire breakage or mal, this check is not required.
3
defective contact of con- Between PTCN1 (female) (22) and TLV1 (female) (5)
nector)
Resistance REMARK
mal, this check is not required.
Between PTCN1 (female) (21) and TLV1 (female) (8)
Between PTCN1 (female) (2) and TLV1 (female) (7) Max. 1 Ω
REMARK
required.
2. Disconnect connectors PTCN1 and TLV1, and connect T-adapter to either
Between PTCN1 (female) (2) and (21), or between
Min. 1 MΩ
TLV1 (female) (7) and (8)
Resistance
Between ground and PTCN1 (female) (2) or TLV1 (fe-
Min. 1 MΩ
male) (7)
tive.
• Reference
5
controller
4. Operate PCCS lever for steering to perform troubleshooting.
0.96 to
Voltage Between PTCN1 (2) and (21)
4.04 V
D155AX-8 40-971
Circuit diagram related to steering potentiometer
40-972 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK30KY] S/T Potentiometer 1 Hot Short Circuit
FAILURE CODE [DK30KY] S/T Potentiometer 1 Hot Short Circuit

Action level Failure code Steering Potentiometer 1 Hot Short Circuit (power train controller
Failure
L03 DK30KB system)
Detail of fail-
Signal voltage of steering lever potentiometer 1 (S/T lever 1) is 4.5 V or higher.
ure
Phenomenon
on machine
Related function. (Code: 50300 S/T Lever1 Potentio)

Defective sensor 5 V If failure code [DBE5KK] is also displayed, perform troubleshooting these first.
1
power supply system
2. Disconnect connector TLV1.
Defective steering poten-
2 tiometer 1 (internal open If failure code [DK30KY] disappears, steering potentiometer is defective. (If this fail-
circuit) or ground fault ure code is still displayed, wiring harness or power train controller is defective.)
REMARK
Since connector TLV1 is disconnected, many failure codes appear. Ignore fail-
ure codes other than [DK30KY].
Hot short circuit in wiring 2. Disconnect connector TLV1 and connect T-adapter to female side.
3
Voltage Between TLV1 (female) (7) and (8) or ground Max. 1 V
2. Disconnect connectors PTCN1 and TLV1, and connect T-adapters to fe-
Short circuit in wiring har- male side of connector PTCN1.
4
ness
No continui-
(2)
is heard)
tive.
• Reference
5
controller
0.96 to
4.04 V
D155AX-8 40-973
FAILURE CODE [DK30KY] S/T Potentiometer 1 Hot Short Circuit 40 TROUBLESHOOTING
40-974 D155AX-8
FAILURE CODE [DK30KX] S/T Potentiometer 1 and 2 Open Circuit or
40 TROUBLESHOOTING Hot Short Circuit
FAILURE CODE [DK30KX] S/T Potentiometer 1 and 2 Open Circuit or Hot

Short Circuit
Action level Failure code Steering Potentiometer 1 and 2 Open Circuit or Hot Short Circuit
Failure
L04 DK30KX (power train controller system)
Detail of fail- In steering lever steering potentiometer 1 (ST lever 1) and 2 (ST lever 2), either failure code
ure [DK30KA] or [DK30KB] is displayed with failure code [DK31KA] or [DK31KB] at the same time.
Action of
controller
on machine • Once machine stops, it becomes unable to travel at all.
• Signal voltage of steering lever potentiometer can be checked with monitoring function.
(Code: 50300 S/T Lever1 Potentio) (Code: 50301 S/T Lever2 Potentio)
Related
information
tion)

Failure of steering poten- Perform troubleshooting for failure codes [DK30KA], [DK30KY], [DK31KA], and
1
tiometer system [DK31KY].
D155AX-8 40-975
FAILURE CODE [DK30KZ] S/T Potentiometer 1 and 2 Open Circuit or
Hot Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DK30KZ] S/T Potentiometer 1 and 2 Open Circuit or Hot

Short Circuit
Action level Failure code Steering Potentiometer 1 and 2 Open Circuit or Hot Short Circuit
Failure
L04 DK30KZ (power train controller system)
In steering lever steering potentiometer 1 (ST lever 1) and 2 (ST lever 2), only one side is abnormal
Detail of fail-
when starting switch is in ON position, and then either failure code [DK30KA] or [DK30KB] is dis-
ure
played with failure code [DK31KA] or [DK31KB] at the same time.
Action of
controller
Phenomenon
on machine
Related
information
Procedure: Turn starting switch to ON position and operate PCCS lever (in steering direc-
tion)

1
40-976 D155AX-8
FAILURE CODE [DK30L8] S/T Potentiometer 1 or 2 Signal Abnormali-
40 TROUBLESHOOTING ty
FAILURE CODE [DK30L8] S/T Potentiometer 1 or 2 Signal Abnormality

Action level Failure code Steering Potentiometer 1 or 2 Signal Abnormality (power train con-
Failure
L03 DK30L8 troller system)
Detail of fail- Sum of signal voltages of steering lever steering potentiometers 1 (ST lever 1) and 2 (ST lever 2) is
ure 4.41 V or lower, or 5.59 V or higher.
• Continues steering control by using signal from steering lever potentiometer 1 (ST lever 1)
Action of
or 2 (ST lever 2) whichever is normal.
controller
• Restricts operation of engine and transmission.
Phenomenon
on machine
Related
information
tion)

1
D155AX-8 40-977
FAILURE CODE [DK31KA] S/T Potentiometer 2 Open Circuit

Failure Steering Potentiometer 2 Open Circuit (power train controller system)
L03 DK31KA
Detail of fail-
Signal voltage of steering lever potentiometer 2 (S/T lever 2) is 0.5 V or lower.
ure
Phenomenon
on machine
function. (Code: 50301 S/T Lever2 Potentio)
Related
information
Procedure: Turn starting switch to ON position and operate PCCS lever (in steering direc-
tion))

1
REMARK
Defective steering poten- If power supply voltage is normal and sensor output voltage is abnormal (0.5 V
2 tiometer 2 (internal open
circuit) or ground fault
If failure code is still displayed after above checks on cause 4, steering potentiome-
ter 2 is defective.
0.96 to
4.04 V
40-978 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK31KA] S/T Potentiometer 2 Open Circuit

female side.
REMARK
Open circuit in wiring har- mal, this check is not required.
defective contact)
Resistance REMARK
REMARK
required.
Min. 1 MΩ
Resistance
Min. 1 MΩ
male) (6)
tive.
Reference
5
controller
0.96 to
4.04 V
D155AX-8 40-979
40-980 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK31KY] S/T Potentiometer 2 Hot Short Circuit
FAILURE CODE [DK31KY] S/T Potentiometer 2 Hot Short Circuit

Action level Failure code Steering Potentiometer 2 Hot Short Circuit (power train controller
Failure
L03 DK31KY system)
Detail of fail-
Signal voltage of steering lever potentiometer 2 (S/T lever 2) is 4.5 V or higher.
ure
Phenomenon
on machine
Related function. (Code: 50301 S/T Lever2 Potentio)

1
power supply system
Defective steering poten-
2 tiometer 2 (internal open If failure code [DK31KY] disappears, steering potentiometer is defective. (If this fail-
circuit) or ground fault ure code is still displayed, wiring harness or power train controller is defective.)
REMARK
3
2. Disconnect connectors PTCN1 and TLV1, and connect T-adapters to fe-
male side of connector PTCN1.
4
ness
No continui-
(19)
is heard)
D155AX-8 40-981
FAILURE CODE [DK31KY] S/T Potentiometer 2 Hot Short Circuit 40 TROUBLESHOOTING

tive.
Reference
5
controller
0.96 to
4.04 V
40-982 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK40KA] Brake Pedal Potentiometer Open Circuit
FAILURE CODE [DK40KA] Brake Pedal Potentiometer Open Circuit

Action level Failure code Brake Pedal Potentiometer Open Circuit (power train controller sys-
Failure
L03 DK40KA tem)
Detail of fail-
Signal voltage of brake pedal potentiometer is 0.5 V or lower.
ure
Action of
controller
Phenomenon
• selectable gear speeds are restricted to F1 and R1.
on machine
• Once machine stops, engine speed is restricted to half (medium) speed.
• Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related (Code: 50400 Brake Pedal Potentiometer Volt)

Defective sensor 5 V 2. Disconnect connector BRK and connect T-adapter to female side.
1
Voltage Between BRK (female) (C) and (A) 4.5 to 5.5 V
Defective brake pedal Approxi-
2 potentiometer (internal Between BRK (male) (C) and (A)
mately 5 kΩ
open or short circuit)
Resistance Between BRK (male) (A) and (B) 0.25 to 5 kΩ
Between BRK (male) (B) and ground Min. 1 MΩ
2. Disconnect connectors PTCN1, TLV1, and DIA2, and connect T-adapter to
female side of PTCN1.
REMARK
3 If resistance is 1 MΩ or more, wiring harness has open circuit. If it is below 1 Ω, wir-
wiring harness
Approx.
Resistance 5 kΩ
Between PTCN1 (female) (3) and (21) 0.25 to 5 kΩ
D155AX-8 40-983
FAILURE CODE [DK40KA] Brake Pedal Potentiometer Open Circuit 40 TROUBLESHOOTING

2. Disconnect connectors PTCN1 and BRK, and connect T-adapters to each
female side.
If power supply voltage in check on Cause 1 is normal
or failure code is still displayed after above checks on
Cause 3, this check is not required. Max. 1 Ω
Open circuit in wiring har- Between PTCN1 (female) (21) and BRK (female) (A)
defective contact) If power supply voltage in check on Cause 1 is normal
Resistance or failure code is still displayed after above checks on
Between PTCN1 (female) (22) and BRK (female) (C)

If failure code is still displayed after above checks on
Between PTCN1 (female) (3) and BRK (female) (B)
tive.
• Reference
controller
40-984 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK40KA] Brake Pedal Potentiometer Open Circuit
Circuit diagram related to brake pedal potentiometer
D155AX-8 40-985
FAILURE CODE [DK40KY] Brake Pedal Potentiometer Hot Short Cir-
FAILURE CODE [DK40KY] Brake Pedal Potentiometer Hot Short Circuit

Action level Failure code Brake Pedal Potentiometer Hot Short Circuit
Failure
L01 DK40KY (power train controller system)
Detail of fail-
Signal voltage of brake pedal potentiometer is 4.8 V or higher.
ure
Action of
controller
Phenomenon
• selectable gear speeds are restricted to F1 and R1.
on machine
• Once machine stops, engine speed is restricted to half (medium) speed.
• Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related (Code: 50400 Brake Pedal Potentiometer Volt)

Defective sensor 5 V 2. Disconnect connector BRK and connect T-adapter to female side.
1
Voltage Between BRK (female) (C) and (A) 4.5 to 5.5 V
Defective brake pedal
2 potentiometer (internal Approxi-
open or short circuit) Between BRK (male) (C) and (A)
mately 5 kΩ
Resistance
Between BRK (male) (A) and (B) 0.25 to 5 kΩ
2. Disconnect connectors PTCN1 and BRK, and connect T-adapter to female
side of PTCN1.
Hot short circuit in wiring REMARK
3
harness
(Continuity) (3) and each pin other No continuity (No sound)
than (3)
Short circuit in wiring har- 2. Disconnect connector BRK and connect T-adapter to female side.
4
Voltage Between BRK (female) (B) and (A) or ground Max. 1 V
40-986 D155AX-8
FAILURE CODE [DK40KY] Brake Pedal Potentiometer Hot Short Cir-

tive.
• Reference
controller
Circuit diagram related to brake pedal potentiometer
D155AX-8 40-987
FAILURE CODE [DK55KX] F/R Potentiometer 1 and 2 Open Circuit or
FAILURE CODE [DK55KX] F/R Potentiometer 1 and 2 Open Circuit or Hot

Short Circuit
Action level Failure code F/R Potentiometer 1 and 2 Open Circuit or Hot Short Circuit
Failure
L04 DK55KX (power train controller system)
Detail of fail- In travel lever potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), either failure code [DK56KA] or
ure [DK56KY] is displayed with failure code [DK57KA] or [DK57KY] are displayed at the same time.
Action of
controller
Phenomenon
on machine
• Signal voltage of travel lever potentiometer can be checked with monitoring function.
(Code: 50200 T/M Lever Potentiometer1 Voltage) (Code: 50201 T/M Lever Potentiometer2
Related
Voltage)
information
Procedure: Turn starting switch to ON position and operate PCCS lever (in F-R direction).

Failure of travel lever po- Perform troubleshooting for failure codes [DK56KA], [DK56KY], [DK57KA], and
1
tentio system [DK57KY].
40-988 D155AX-8
FAILURE CODE [DK55KZ] F/R Potentiometer 1 and 2 Open Circuit or
FAILURE CODE [DK55KZ] F/R Potentiometer 1 and 2 Open Circuit or Hot

Short Circuit
Action level Failure code F/R Potentiometer 1 and 2 Open Circuit or Hot Short Circuit
Failure
L04 DK55KZ (power train controller system)
In travel lever potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), when starting switch is turned to ON
Detail of fail-
position, only one side malfunctions and then either failure code [DK56KA] or [DK56KY] is displayed
ure
with failure code [DK57KA] or [DK57KY] at the same time.
Action of
controller
Phenomenon
on machine
• (Code: 50200 T/M Lever Potentiometer1 Voltage)
Related
information

1
D155AX-8 40-989
FAILURE CODE [DK55L8] F/R Potentiometer 1 or 2 Signal Abnormal-
ity 40 TROUBLESHOOTING
FAILURE CODE [DK55L8] F/R Potentiometer 1 or 2 Signal Abnormality

Action level Failure code F/R Potentiometer 1 or 2 Signal Abnormality (power train controller
Failure
L03 DK55L8 system)
Detail of fail- Sum of signal voltages of travel lever potentiometers 1 (F/R lever 3) and 2 (F/R lever 4) is 4.41 V or
ure lower, or 5.59 V or higher.
• Continues travel control by using signal from PCCS lever F-R potentiometer 1 (F/R lever
Action of
3) or 2 (F/R lever 4) whichever is normal.
controller
Phenomenon
on machine
Related
information

1
40-990 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK56KA] F/R Potentiometer 1 Open Circuit
FAILURE CODE [DK56KA] F/R Potentiometer 1 Open Circuit

Failure F/R Potentiometer 1 Open Circuit (power train controller system)
L03 DK56KA
Detail of fail-
Signal voltage of travel lever potentiometer 1 (F/R lever 3) is 0.5 V or lower.
ure
Action of • Continues control by using signal from travel lever potentiometer 2 (F/R lever 4).
Phenomenon
on machine
• Signal voltage of travel lever potentiometer 1 can be checked with monitoring function.
Related • (Code: 50200 T/M Lever Potentiometer1 Voltage)

1
Defective travel lever po- REMARK
tentiometer 3 (internal
2 If power supply voltage is normal and sensor output voltage is abnormal (below
open circuit or ground
fault) 0.5 V), internal disconnection and ground fault cannot be identified. In this
case, go to cause 4. If check result of cause 4 is normal, travel lever potentiom-
eter 1 is defective.
1.39 to
3.61 V
female side.
Open circuit in wiring har- If power supply voltage in check on cause 1 is normal,
ness (wire breakage or this check is not required. Max. 1 Ω
3
nector)
Resistance If power supply voltage in check on cause 1 is normal,
D155AX-8 40-991
FAILURE CODE [DK56KA] F/R Potentiometer 1 Open Circuit 40 TROUBLESHOOTING

quired.
ground circuit) Between PTCN1 (female) (20) and (21), or between
Min. 1 MΩ
Resistance
Min. 1 MΩ
male) (3)
tive.
• Reference
5
4. Operate PCCS lever (forward and reverse travel) to perform troubleshoot-
ing.
1.39 to
4.76 V
40-992 D155AX-8
Circuit diagram related to travel lever potentiometer
D155AX-8 40-993
FAILURE CODE [DK56KY] F/R Potentiometer 1 Hot Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DK56KY] F/R Potentiometer 1 Hot Short Circuit

Failure F/R Potentiometer 1 Hot Short Circuit (power train controller system)
L03 DK56KY
Detail of fail-
ure
Phenomenon
on machine
• Signal voltage of lever potentiometer 1 can be checked with monitoring function. (Code:
Related 50200 T/M Lever Potentiometer1 Voltage)

1
power supply system
Defective travel lever po-
tentiometer 1 (internal If failure code [DK56KY] disappears, travel lever potentiometer is defective. (If this
2
short circuit or ground failure code is still displayed, wiring harness or power train controller is defective.)
fault)
REMARK
3
2. Disconnect connectors PTCN1 and TLV1, and connect T-adapter to fe-
male side of PTCN1.
4
ness
No continui-
(20)
is heard)
40-994 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK56KY] F/R Potentiometer 1 Hot Short Circuit

tive.
• Reference
5
ing.
1.39 to
4.76 V
D155AX-8 40-995
FAILURE CODE [DK57KA] F/R Potentiometer 2 Open Circuit

Failure F/R Potentiometer 2 Open Circuit (power train controller system)
L03 DK57KA
Detail of fail-
ure
Phenomenon
on machine
Related 50201 T/M Lever Potentiometer2 Voltage)

1
Defective travel lever po- REMARK
tentiometer 4 (internal If power supply voltage is normal and sensor output voltage is abnormal (0.5 V
2
open circuit or ground
fault)
When test result for cause 4 is normal, travel lever potentiometer 2 is defective.
1.39 to
3.61 V
2. Disconnect connectors PTCN1 and TLV1 and connect T-adapters to each
female side.
REMARK
ness (wire breakage or mal, this check is not required.
3
nector)
Resistance REMARK
40-996 D155AX-8
REMARK
required.
Between PTCN (female) (14) and (21), or between
Min. 1 MΩ
Resistance
Between ground and PTCN (female) (14), or between
Min. 1 MΩ
ground and TLV1 (female) (2)
tive.
• Reference
5
ing.
1.39 to
3.61 V
D155AX-8 40-997
40-998 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DK57KY] F/R Potentiometer 2 Hot Short Circuit
FAILURE CODE [DK57KY] F/R Potentiometer 2 Hot Short Circuit

Failure F/R Potentiometer 2 Hot Short Circuit (power train controller system)
L03 DK57KY
Details of
Signal voltage of travel lever potentiometer 2 (F/R lever 4) is 4.5 V and above.
failure
Action of • Continues control corresponding to signals from travel lever potentiometer 1 (F/R lever 3).
controller • Restricts engine and transmission operations.
• Automatic transmission system does not work.
Phenomenon
on machine
• Once machine stops, selectable travel is restricted to F1 and R1.
Related 50201 T/M lever potentiometer 2 voltage)

1
power supply system
Defective travel lever po-
tentiometer 4 (internal If failure code [DK57KB] disappears, travel lever potentiometer is defective. (If this
2
open circuit or ground failure code is still displayed, wiring harness or power train controller is defective.)
fault)
REMARK
ure codes other than [DK57KB]
Hot short circuit in wiring 2. Disconnect connector TLV1, and connect T-adapter to female side.
3
2. Disconnect connectors PTCN1 and TLV1, and connect T-adapter to fe-
4
ness
No continui-
(14)
is heard)
D155AX-8 40-999
FAILURE CODE [DK57KY] F/R Potentiometer 2 Hot Short Circuit 40 TROUBLESHOOTING

tive.
• Reference
5
ing.
1.39 to
3.61 V
40-1000 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DKH1KA] Inclination Angle Sensor Open Circuit
FAILURE CODE [DKH1KA] Inclination Angle Sensor Open Circuit

Failure Inclination Angle Sensor Open Circuit (power train controller system)
L03 DKH1KA
Detail of fail-
Signal voltage of pitch angle sensor is 0.15 V or lower.
ure
Action of • Cannot sense pitch angle of machine.
• Shifting shocks occur when traveling on slopes.
• Signal from pitch angle sensor signal can be checked with monitoring function.
(Code: 60100 Machine Pitch Angle Sensor Volt)
• Even when system works properly, this failure code is displayed if sensor connector is dis-
connected.

Defective sensor 24 V 2. Disconnect connector PT1 and connect T-adapter to female side.
1
Voltage Between PT1 (female) (C) and (A) 20 to 30 V
2. Insert T-adapter into connector PT1.
REMARK
Defective pitch angle
2 sensor (internal defect or If power supply voltage is normal and sensor output voltage is abnormal (0.5 V
ground fault) or lower), it cannot be determined whether ground fault or defective sensor is
the cause. In this case, proceed to cause 4.
If cause 4 is normal, pitch angle sensor is defective.
0.24 to
Voltage Between PT1 (B) and (A)
4.76 V
D155AX-8 40-1001
FAILURE CODE [DKH1KA] Inclination Angle Sensor Open Circuit 40 TROUBLESHOOTING

2. Disconnect connectors OTCN1 and PT1, and connect T-adapters to each fe-
male side.
REMARK
If power supply voltage in check on cause 1 is nor-
Open circuit in wiring har- mal, this check is not required. Max. 1 Ω
ness
3 REMARK
Between PTCN1 (female) (16) and PT1 (C)
tive contact of connector) Resistance
REMARK
Between PTCN1 (female) (21) and PT1 (A)
Between PTCN1 (female) (8) and PT1 (B) Max. 1 Ω
REMARK
If power supply voltage in check on cause 1 is normal, this check is not re-
quired.
harness 2. Disconnect connectors OTCN 1 and PT1, and connect T-adapter to either fe-
4
(Contact with ground cir- male side.
cuit)
Between PTCN1 (female) (8) and (21) or PT1 (female)
Min. 1 MΩ
(B) and (A)
Resistance
Between PTCN1 (female) (8) and ground or PT1 (fe-
Min. 1 MΩ
male) (B) and ground
tive.
• Reference
5 2.
controller Insert T-adapter into connector PTCN1.
0.24 to
4.76 V
40-1002 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DKH1KA] Inclination Angle Sensor Open Circuit
CIRCUIT DIAGRAM (PITCH ANGLE SENSOR)
D155AX-8 40-1003
FAILURE CODE [DKH1KY] Inclination Angle Sensor Hot Short Cir-
FAILURE CODE [DKH1KY] Inclination Angle Sensor Hot Short Circuit

Action level Failure code Inclination Angle Sensor Hot Short Circuit
Failure
L03 DKH1KY (power train controller system)
Detail of fail-
Signal voltage of pitch angle sensor is 4.85 V or above.
ure
Action of • Cannot sense pitch angle of machine.
• Shifting shocks occur when traveling on slopes.
• Signal from pitch angle sensor signal can be checked with monitoring function.
(Code: 60100 Machine Pitch Angle Sensor Volt)
• Even when system works properly, failure code [DKH1KA] is displayed if pitch angle sen-
sor connector is disconnected and starting switch is turned to ON position.

Defective sensor 24 V 2. Disconnect connector PT1 and connect T-adapter to female side.
1
Voltage Between PT1 (female) (C) and (A) 20 to 30 V
2. Disconnect connector PT1.
Defective pitch angle 3. Turn starting switch to ON position.
2 sensor
If failure code [DKH1KY] is cleared and failure code for wire breakage [DKH1KA] is
(Internal defect) displayed, pitch angle sensor is defective.
(If failure code [DKH1KY] is displayed again, wiring harness or power train control-
ler is defective.)
Hot short circuit in wiring 2. Disconnect connector PT1 and connect T-adapter to female side.
3
Voltage Between PT1 (female) (B) and ground Max. 1 V
2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to fe-
4
ness
Check by using multimeter in continuity mode of tester.
No continui-
Continuity ty (no
(8)
sound)
40-1004 D155AX-8
FAILURE CODE [DKH1KY] Inclination Angle Sensor Hot Short Cir-

tive.
• Reference
5 2.
controller Insert T-adapter into connector PTCN1.
0.24 to
4.76 V
CIRCUIT DIAGRAM (PITCH ANGLE SENSOR)
D155AX-8 40-1005
FAILURE CODE [DLM3KA] Fan Speed Sensor Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DLM3KA] Fan Speed Sensor Open Circuit

Action level Failure code Fan Speed Sensor Open Circuit
Failure
L01 DLM3KA (power train controller system)
Detail of fail-
No signal is input from fan speed sensor.
ure
Action of • Recognizes that fan speed is 0 rpm.
controller • Does not perform PID control.
Phenomenon • Fan speed cannot be monitored.
on machine • Fan control is disabled.
• Fan speed can be checked with monitoring function.
Related (Code: 10007 Fan Speed)

Defective fan speed sen- 2. Disconnect connector FAR2 and connect T-adapter to male side.
sor
1 Approxi-
(internal open or short Between FAR2 (male) (1) and (2)
Resistance mately 2 kΩ
circuit)
2. Disconnect connector PTCN2, and connect T-adapter to female side.
REMARK
2 If resistance is 1 MΩ or more, wiring harness has open circuit. If it is below 1 Ω,
wiring harness
wiring harness has short circuit.
Approxi-
mately 2 kΩ
quired.
ness 2. Disconnect connectors PTCN2 and FAR2, and connect T-adapter to each
3
Between PTCN2 (female) (39) and FAR (2) Max. 1 Ω
Resistance
Between PTCN2 (female) (40) and FAR (1) Max. 1 Ω
Hot short circuit in wiring 2. Disconnect connector FAR2, and connect T-adapter to female side.
4
Voltage Between FAR2 (female) (1) and (2) 3 to 4 V
controller
40-1006 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DLM3KA] Fan Speed Sensor Open Circuit
Circuit diagram related to fan speed sensor
D155AX-8 40-1007
FAILURE CODE [DLM3KB] Fan Speed Sensor Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DLM3KB] Fan Speed Sensor Short Circuit

Action level Failure code Fan Speed Sensor Function Deterioration
Failure
L01 DLM3KB (power train controller system)
Detail of fail- Difference between fan speed value specified by power train controller and actual fan speed sensed
ure by fan speed sensor exceeds 100 rpm.
Action of
• power train controller does not perform PID operation on fan.
controller
Phenomenon
on machine
• Fan speed value specified by power train controller can be checked with monitoring func-
tion.
(Code: 10000 Fan Speed command)
Related
• Fan speed sensed by fan speed sensor can be checked with monitoring function.
information
(Code: 10007 Fan Speed)
This failure code can be generated under conditions that fan solenoid system is normal
and fan speed sensor is also normal (they are electrically normal).

Defective hydraulic sys- Perform Testing and adjusting, “TEST COOLING FAN CIRCUIT OIL PRESSURE”.
1
tem
40-1008 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DLM3MB] Fan Speed Sensor Function Deterioration
FAILURE CODE [DLM3MB] Fan Speed Sensor Function Deterioration

Action level Failure code Fan Speed Sensor Function Deterioration
Failure
L01 DLM3MB (Power train controller system)
Detail of fail- Difference between fan speed value specified by power train controller and actual speed sensed by
ure fan speed sensor exceeds 100 rpm.
Action of
Does not perform PID control on fan.
controller
Phenomenon
Fan speed control does not function normally.
on machine
• Fan speed specified by power train controller can be checked with monitoring function.
(Code: 10000)
• Fan speed sensed by fan speed sensor can be checked with monitoring function. (Code:
Related 10007)
information • This code is conditioned that fan solenoid is normal and fan speed sensor is also normal
(it means normal electrically).

Defective hydraulic fan Perform “TESTING AND ADJUSTING”, “METHOD FOR TESTING OIL PRES-
1
hydraulic circuit SURE IN FAN PUMP CIRCUIT”
D155AX-8 40-1009
FAILURE CODE [DLT3KA] T/M Output Speed Sensor Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DLT3KA] T/M Output Speed Sensor Open Circuit

Action level Failure code Transmission Output Speed Sensor Open Circuit (power train con-
Failure
L03 DLT3KA troller system)
Detail of fail-
No signal is output from transmission output speed sensor.
ure
Action of
• Recognizes that transmission output speed is 0 rpm.
controller
Phenomenon
on machine
• Traction force cannot be calculated.
• Once machine stops, gear shift mode is restricted to manual gear shift mode.
• Transmission output speed can be checked with monitoring function.
(Code: 31400 T/M Out Speed)
Related
information
Procedure: Turn starting switch to ON position and travel (drive machine or run tracks in
the air with machine body put on stands).

Defective transmission 2. Disconnect connector BVRV, and connect T-adapter to male side.
level (output) speed sen-
1 sor Approxi-
Between BVRV (male) (1) and (2) mately
(internal open or short Resistance 560 Ω
circuit)
REMARK
Open or short circuit in If resistance is 1 Ｍ Ω or higher, wiring harness has open circuit. If resistance is
2
wiring harness 1Ω or below, wiring harness has short circuit.
Approxi-
Resistance Between PTCN2 (female) (29) and (30) mately
560 Ω
REMARK
Open circuit in wiring har- required.
ness 1. Turn starting switch to OFF position.
3
(Wire breakage or defec- 2. Disconnect connectors PTCN2 and BVRV, and connect T-adapter to each fe-
tive contact of connector) male side.
Between PTCN2 (female) (29) and BVRV (female) (2) Max. 1 Ω
Resistance
Between PTCN2 (female) (30) and BVRV (female) (1) Max. 1 Ω
Hot short circuit in wiring 2. Disconnect connector BVRV, and connect T-adapter to female side.
4
Voltage Between BVRV (female) (1) and (2) 3 to 4 V
40-1010 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DLT3KA] T/M Output Speed Sensor Open Circuit

controller
Circuit diagram related to transmission output shaft speed sensor
D155AX-8 40-1011
FAILURE CODE [DLT3KB] T/M Output Speed Sensor Ground Fault 40 TROUBLESHOOTING
FAILURE CODE [DLT3KB] T/M Output Speed Sensor Ground Fault

Action level Failure code Transmission Output Speed Sensor Ground Fault (power train con-
Failure
L03 DLT3KB troller system)
Detail of fail-
No signal is output from transmission output speed sensor.
ure
Action of
• Recognizes that transmission output speed is 0 rpm.
controller
Phenomenon
on machine
• Traction force cannot be calculated.
• Once machine stops, gear shift mode is restricted to manual gear shift mode.
• Transmission output speed can be checked with monitoring function.
(Code: 31400 T/M Out Speed)
Related
information
Procedure: Turn starting switch to ON position and travel (drive machine or run tracks in
the air with machine body put on stands).

Defective transmission 2. Disconnect connector BVRV, and connect T-adapter to male side.
level (output) speed sen-
1 sor Approxi-
Between BVRV (male) (1) and (2) mately
(internal open or short Resistance 560 Ω
circuit)
REMARK
Open or short circuit in If resistance is 1 Ｍ Ω or higher, wiring harness has open circuit. If resistance is
2
wiring harness 1Ω or below, wiring harness has short circuit.
Approxi-
Resistance Between PTCN2 (female) (29) and (30) mately
560 Ω
2. Disconnect connectors PTCN2 and BVRV, and connect T-adapter to either fe-
harness
3 male side.
cuit) Between ground and PTCN2 (female) (30) or BVRV
(female) (1)
controller
40-1012 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DLT3KB] T/M Output Speed Sensor Ground Fault
Circuit diagram related to transmission output shaft speed sensor
D155AX-8 40-1013
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out
of Range 40 TROUBLESHOOTING
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of

Range
Action level Failure code Camera 2 Picture Reverse Drive Input Out of Range
Failure
L01 DR21KX (Machine monitor system)
Details of
failure
Action of
controller
Phenomenon
on machine
• This failure code does not relate to this machine because it is not equipped with camera 2.
Related This failure code is provided in case where camera 2 is installed in future.
information • If this failure code is displayed, clear failure code by referring to “Classification and proce-
dures for troubleshooting”.
40-1014 D155AX-8
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out
40 TROUBLESHOOTING of Range
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of

Range
Action level Failure code Camera 3 Picture Reverse Drive Input Out of Range
Failure
L01 DR31KX (Machine monitor system)
Details of
failure
Action of
controller
Phenomenon
on machine
• This failure code does not relate to this machine because it is not equipped with camera 3.
Related This failure code is provided in case where camera 3 is installed in future.
information • If this failure code is displayed, clear failure code by referring to “Classification and proce-
dures for troubleshooting”.
D155AX-8 40-1015
FAILURE CODE [DV20KB] Back Alarm Buzzer Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DV20KB] Back Alarm Buzzer Short Circuit

Action level Failure code Back Alarm Buzzer Short Circuit
Failure
L01 DV20KB (power train controller system)
Details of
When a power is output to backup alarm circuit, abnormal current flows.
failure
• Stops driving the backup alarm circuit.
Action of
controller
is set to OFF position.
Phenomenon
Back-up alarm does not sound.
on machine
• Output signal to back-up alarm can be checked with monitoring function.
Related (Code: 40909 P/T Controller SW Output)
Procedure: Turn starting switch to ON position and operate travel lever (reverse).

2. Disconnect connector BKAL, and connect T-adapter to female side.
Defective back-up alarm 4. Perform reverse travel operation.
1
(Internal defect) If the following voltage is normal but backup alarm does not sound, backup alarm is
defective.
k Never enter under the machine when operating travel lever.
Voltage Between BKAL (female) (1) and (2) 20 to 30 V
2. Disconnect connectors PTCN2 and BKAL, and connect T-adapter to either fe-
harness
2 male side.
cuit) Between ground and BKAL (female) (1) or PTCN2 (fe-
male) (28)
2. Insert T-adapter into connector BKAL.
Defective power train 4. Perform troubleshooting by control of travel lever.
3
controller
k Never enter under the machine when operating travel lever.
Travel lever: Neutral Max. 1 V
Voltage Between BKAL (1) and (2)
Travel lever: Reverse 20 to 30 V
40-1016 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DV20KB] Back Alarm Buzzer Short Circuit
CIRCUIT DIAGRAM (BACK-UP ALARM)
D155AX-8 40-1017
FAILURE CODE [DW7BKA] Fan Reverse Solenoid Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DW7BKA] Fan Reverse Solenoid Open Circuit

Action level Failure code Fan Reverse Solenoid Open Circuit
Failure
L01 DW7BKA (Power train controller system)
Details of
When controller drives fan reverse solenoid, no current flows through circuit.
failure
Action of
Stops driving fan reverse solenoid.
controller
Phenomenon
Fan reverse function cannot be used.
on machine
• Output condition to fan reverse solenoid can be checked with monitoring function.
Procedure: Turn starting switch to ON position and select fan reverse mode.

Defective fan reverse sol-
1 enoid (internal open cir- 2. Disconnect connector FAR1, and connect T-adapter to male side.
cuit)
Resistance Between FAR1 (male) (1) and (2) 34 to 44 Ω
Open circuit, short circuit, 2. Disconnect connector FAR1 and connect T-adapter to female side.
ground fault, hot short 3. Turn starting switch to ON position.
2 circuit of wiring harness,
or defective power train 4. Shake the wiring harness by hand while measuring the voltage. If the volt-
controller age becomes 0 V while shaking, wiring harness has open circuit.
Voltage Between FAR1 (female) (1) and (2) Max. 4.5 V
2. Disconnect connector PTCN3 and PTCN2, and connect T-adapter to fe-
male side.
3 REMARK
wiring harness
If resistance value is Min. 1 MΩ, wiring harness has open circuit. If resistance value
is Max. 1 Ω, wiring harness has short circuit.
Resistance Between PTCN2 (female) (9) and PTCN3 (female) (3) 34 to 44 Ω
quired.
ness (wire breakage or 2. Disconnect connectors PTCN3, PTCN2, and FAR1, and connect T-adapt-
4
defective contact of con- ers to each female side.
nector)
Between PTCN2 (female) (9) and FAR1 (female) (1) Max. 1 Ω
Resistance
Between PTCN3 (female) (3) and FAR1 (female) (2) Max. 1 Ω
Hot short circuit in wiring 2. Disconnect connector FAR1 and connect T-adapter to female side.
5
Resistance Between FAR1 (female) (1) and ground Max. 4.5 Ω
controller
40-1018 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DW7BKA] Fan Reverse Solenoid Open Circuit
Circuit diagram related to fan reverse solenoid
D155AX-8 40-1019
FAILURE CODE [DW7BKB] Fan Reverse Solenoid Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DW7BKB] Fan Reverse Solenoid Short Circuit

Action level Failure code Fan Reverse Solenoid Short Circuit
Failure
L01 DW7BKB (Power train controller system)
Details of
When controller drives fan reverse solenoid, abnormal current flows through circuit.
failure
Action of
Stops driving fan reverse solenoid.
controller
Phenomenon
Fan reverse function cannot be used.
on machine
• Output condition to fan reverse solenoid can be checked with monitoring function.
Procedure: Turn starting switch to ON position and select fan reverse mode.

Defective fan reverse sol- 2. Disconnect connector FAR1, and connect T-adapter to male side.
1 enoid (internal open cir-
cuit) Between FAR1 (male) (1) and (2) 34 to 44 Ω
Resistance
Ground fault in wiring 2. Disconnect connectors PTCN3, PTCN2, and FAR1, and connect T-adapter
2 harness (contact with to any female side.
ground circuit)
Between ground and PTCN2 (female) (9) or FAR1 (fe-
male) (1)
2. Disconnect connectors PTCN3, PTCN2, and FAR1, and connect T-adapter
3 to any female side.
ness
Between PTCN2 (female) (9) and PTCN3 (female) (3)
or between FAR1 (female) (1) and (2)
controller
40-1020 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DW7BKB] Fan Reverse Solenoid Short Circuit
Circuit diagram related to fan reverse solenoid
D155AX-8 40-1021
FAILURE CODE [DWN1KA] S/T Control Valve Right EPC Solenoid
FAILURE CODE [DWN1KA] S/T Control Valve Right EPC Solenoid Open
Circuit
Action level Failure code Steering Control Valve Right EPC Solenoid Open Circuit (power train
Failure
L03 DWN1KA controller system)
Details of
When controller drives HSS right EPC solenoid, no current flows through circuit.
failure
Action of • Stops driving HSS right EPC solenoid.
Phenomenon
on machine
• Right turn cannot be performed.
• Output condition to HSS right EPC solenoid can be checked with monitoring function.
(Code: 50601 Right HSS EPC Solenoid Current (F/B))
Related
information
Procedure: Turn starting switch to ON position and operate steering lever (to steer to
right).

Defective HSS right EPC 2.
Disconnect connector HSR, and connect T-adapter to male side.
1 solenoid　(internal open
circuit) 4.5 to
Resistance Between HSR (male) (1) and (2)
14.5 Ω
Open circuit, short circuit, 2. Disconnect connector HSR and connect T-adapter to female side.
Voltage Between HSR (female) (1) and (2) Max. 4.5 V

REMARK
3
wiring harness If resistance value is Min. 1 MΩ, wiring harness has open circuit. If resistance value
4.5 to
14.5 Ω
quired.
ness (wire breakage or 2. Disconnect connectors PTCN3 and HSR, and connect T-adapters to each
4
nector)
Between PTCN3 (female) (23) and HSR (female) (2) Max. 1 Ω
Resistance
Between PTCN3 (female) (15) and HSR (female) (1) Max. 1 Ω
controller
40-1022 D155AX-8
FAILURE CODE [DWN1KA] S/T Control Valve Right EPC Solenoid
40 TROUBLESHOOTING Open Circuit
Circuit diagram related to HSS right EPC solenoid
D155AX-8 40-1023
FAILURE CODE [DWN1KB] S/T Control Valve Right EPC Solenoid
FAILURE CODE [DWN1KB] S/T Control Valve Right EPC Solenoid Short
Circuit
Action level Failure code Steering Control Valve Right EPC Solenoid Short Circuit (power train
Failure
L03 DWN1KB controller system)
Details of
When controller drives HSS right EPC solenoid, unusual current flows through circuit.
failure
Phenomenon
on machine
• Right turn cannot be performed.
(Code: 50601 Right HSS EPC Solenoid Current (F/B))
Related
information
Procedure: Turn starting switch to ON position and operate steering lever (to steer to
right).

2. Disconnect connector HSR, and connect T-adapter to male side.
Defective HSS right EPC
1 solenoid　(internal open 4.5 to
circuit) Between HSR (male) (1) and (2)
Resistance 14.5 Ω
Between HSR (male) (1) and ground Min. 1 MΩ
Ground fault in wiring 2. Disconnect connectors PTCN3 and HSR, and connect T-adapter to either
ground circuit)
Between ground and PTCN3 (female) (15) or HSR (fe-
male) (1)
2. Disconnect connectors PTCN3 and HSR, and connect T-adapter to either
3 female side.
ness
HSR (female) (1) and (2)
controller
40-1024 D155AX-8
FAILURE CODE [DWN1KB] S/T Control Valve Right EPC Solenoid
D155AX-8 40-1025
FAILURE CODE [DWN1KY] S/T Control Valve Right EPC Solenoid
FAILURE CODE [DWN1KY] S/T Control Valve Right EPC Solenoid Hot
Short Circuit
Action level Failure code Steering Control Valve Right EPC Solenoid Hot Short Circuit (power
Failure
L04 DWN1KY train controller system)
Details of
Current flows constantly to HSS right EPC solenoid circuit.
failure
Phenomenon
on machine
• Keeps turning to the right.
Related (Code: 50601 Right HSS EPC Solenoid Current (F/B))

Hot short circuit in wiring 2. Disconnect connector HSR and connect T-adapter to female side.
1
Voltage Between HSR (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and HSR, and connect T-adapter to female
side of PTCN3.
2
ness
No continui-
(15)
is heard)
controller
40-1026 D155AX-8
FAILURE CODE [DWN2KA] S/T Control Valve Left EPC Solenoid
FAILURE CODE [DWN2KA] S/T Control Valve Left EPC Solenoid Open Cir-
cuit
Action level Failure code Steering Control Valve Left EPC Solenoid Open Circuit (power train
Failure
Details of
When controller drives HSS left EPC solenoid, no current flows through circuit.
failure
Action of • Stops driving HSS left EPC solenoid.
Phenomenon
on machine
• Left turn cannot be performed.
• Output condition to HSS left EPC solenoid can be checked with monitoring function.
Related (Code: 50600 Left HSS EPC Solenoid Current(F/B))
Procedure: Turn starting switch to ON position and operate steering lever (to steer to left).

Defective HSS left EPC 2. Disconnect connector HSL, and connect T-adapter to male side.
1 solenoid　(internal open
circuit) 4.5 to
Resistance Between HSL (male) (1) and (2)
14.5 Ω
Open circuit, short circuit, 2. Disconnect connector HSL and connect T-adapter to female side.
Voltage Between HSL (female) (1) and (2) Max. 4.5 V

REMARK
3
4.5 to
14.5 Ω
If failure code is still displayed after above checks on open or short circuit in wiring
harness, this check is not required.
ness (wire breakage or 2. Disconnect connectors PTCN3 and HSL, and connect T-adapters to each
4
nector)
Between PTCN3 (female) (5) and HSL (female) (1) Max. 1 Ω
Resistance
Between PTCN3 (female) (23) and HSL (female) (2) Max. 1 Ω
controller
D155AX-8 40-1027
FAILURE CODE [DWN2KA] S/T Control Valve Left EPC Solenoid
Circuit diagram related to HSS left EPC solenoid
40-1028 D155AX-8
FAILURE CODE [DWN2KB] S/T Control Valve Left EPC Solenoid
FAILURE CODE [DWN2KB] S/T Control Valve Left EPC Solenoid Short Cir-
cuit
Action level Failure code Steering Control Valve Left EPC Solenoid Short Circuit (power train
Failure
Details of
When controller drives HSS left EPC solenoid, unusual current flows through circuit.
failure
Phenomenon
on machine
• Left turn cannot be performed.
Procedure: Turn starting switch to ON position and operate steering lever (to steer to left).

2. Disconnect connector HSL, and connect T-adapter to male side.
Defective HSS left EPC
1 solenoid　(internal open 4.5 to
circuit) Between HSL (male) (1) and (2)
Resistance 14.5 Ω
Between HSL (male) (1) and ground Min. 1 MΩ
Ground fault in wiring 2. Disconnect connectors PTCN3 and HSL, and connect T-adapter to either
ground circuit)
Between ground and PTCN3 (female) (5) or HSL (fe-
male) (1)
2. Disconnect connectors PTCN3 and HSL, and connect T-adapter to either
3 female side.
ness
Between PTCN3 (female) (5) and (23) or between HSL
controller
D155AX-8 40-1029
FAILURE CODE [DWN2KB] S/T Control Valve Left EPC Solenoid
40-1030 D155AX-8
FAILURE CODE [DWN2KY] S/T Control Valve Left EPC Solenoid Hot
FAILURE CODE [DWN2KY] S/T Control Valve Left EPC Solenoid Hot Short
Circuit
Action level Failure code Steering Control Valve Left EPC Solenoid Hot Short Circuit (power
Failure
Details of
Current flows constantly to HSS left EPC solenoid circuit.
failure
Phenomenon
on machine
• Machine keeps trning to left.

Hot short circuit in wiring 2. Disconnect connector HSL and connect T-adapter to female side.
1
Voltage Between HSL (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and HSL, and connect T-adapter to female
Short circuit in wiring har- side of PTCN3.
2
ness
No continui-
(5)
is heard)
controller
D155AX-8 40-1031
FAILURE CODE [DWN3KA] Sudden Stop Prevention Valve Solenoid
FAILURE CODE [DWN3KA] Sudden Stop Prevention Valve Solenoid Open

Circuit
Action level Failure code Sudden Stop Prevention Valve Solenoid Open Circuit (Power train
Failure
Details of
No current flows when outputting to sudden stop prevention solenoid circuit.
failure
Action of • Stops driving the sudden stop prevention solenoid circuit.
controller • Restricts of engine, transmission, and brake operations.
Phenomenon
on machine
• Once machine stops, no travel operation cannot be performed.
• Condition of output to sudden stop prevention solenoid can be checked by monitoring
Related function. (Code: 31628 S.S.P Solenoid)

Defective sudden stop
1 prevention solenoid (in- 2. Disconnect connector SSP, and connect T-adapter to male side.
ternal open circuit)
Resistance Between SSP (male) (1) and (2) 5 to 15 Ω
Open circuit, short circuit, 2. Disconnect connector SSP and connect T-adapter to female side.
Voltage Between SSP (female) (1) and (2) Max. 4.5 V
3
wiring harness
Resistance Between PTCN3 (female) (8) and (13) 5 to 15 Ω
quired.
ness (wire breakage or 2. Disconnect connectors PTCN3 and SSP, and connect T-adapters to each
4
nector)
Between PTCN3 (female) (8) and SSP (female) (1) Max. 1 Ω
Resistance
Between PTCN3 (female) (13) and SSP (female) (2) Max. 1 Ω
controller
40-1032 D155AX-8
FAILURE CODE [DWN3KA] Sudden Stop Prevention Valve Solenoid
CIRCUIT DIAGRAM (SUDDEN STOP PREVENTION SOLENOID)
D155AX-8 40-1033
FAILURE CODE [DWN3KB] Sudden Stop Prevention Valve Solenoid
FAILURE CODE [DWN3KB] Sudden Stop Prevention Valve Solenoid Short

Circuit
Action level Failure code Sudden Stop Prevention Valve Solenoid Short Circuit (Power train
Failure
Details of
Abnormal current flows in the sudden stop prevention solenoid circuit when the circuit is driven.
failure
Action of • Stops driving the sudden stop prevention solenoid circuit.
controller • Restricts of engine, transmission, and brake operations.
Phenomenon
on machine
• Once machine stops, no travel operation cannot be performed.
• Condition of output to sudden stop prevention solenoid can be checked by monitoring
Related function. (Code: 31628 S.S.P Solenoid)

Defective sudden stop 2. Disconnect connector SSP, and connect T-adapter to male side.
1 prevention solenoid (in-
ternal open circuit) Between SSP (male) (1) and (2) 5 to 15 Ω
Resistance
Between SSP (male) (1) and ground Min. 1 MΩ
Ground fault in wiring 2. Disconnect connectors PTCN3 and SSP, and connect T-adapter to either
ground circuit)
Between ground and PTCN3 (female) (8) or SSP (fe-
male) (1)
2. Disconnect connectors PTCN3 and SSP, and connect T-adapter to either
3 female side.
ness
Between PTCN3 (female) (8) and (13) or SSP (female)
(1) and (2)
controller
40-1034 D155AX-8
FAILURE CODE [DWN3KB] Sudden Stop Prevention Valve Solenoid
D155AX-8 40-1035
FAILURE CODE [DWN3KY] Sudden Stop Prevention Valve Solenoid
FAILURE CODE [DWN3KY] Sudden Stop Prevention Valve Solenoid Hot

Short Circuit
Action level Failure code Sudden Stop Prevention Valve Solenoid Hot Short Circuit (power
Failure
Detail of fail-
Current flows constantly to S.S.P. solenoid circuit.
ure
Action of • Stops driving S.S.P. solenoid.
controller • Restricts operations of engine, transmission, and brake.
• Sudden stop prevention function does not work.
• Output condition to S.S.P. solenoid can be checked with monitoring function. (Code:
Related 31628 Sudden Stop Prevention Valve Cur)

Defective sudden stop 2. Disconnect connector SSP, and connect T-adapter to male side.
1 prevention solenoid (in-
ternal short circuit) Between SSP (male) (1) and (2) 5 to 15 Ω
Resistance
Between SSP (male) (1) and ground Min. 1 MΩ
Hot short circuit in wiring 2. Disconnect connector SSP and connect T-adapter to female side.
2
Voltage Between SSP (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and SSP, and connect T-adapters to fe-
male side of PTCN3.
3
ness
No continui-
(8)
is heard)
controller
40-1036 D155AX-8
FAILURE CODE [DWN3KY] Sudden Stop Prevention Valve Solenoid
D155AX-8 40-1037
FAILURE CODE [DWN5KA] Fan Control Solenoid 1 Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DWN5KA] Fan Control Solenoid 1 Open Circuit

Action level Failure code Fan Control Solenoid 1 Open Circuit (Work equipment controller sys-
Failure
L03 DWN5KA tem)
Details of
No output current flows into fan pump EPC solenoid 1 circuit.
failure
Action of
Stops driving fan pump EPC solenoid 1 circuit.
controller
• Output of fan pump remains at its maximum.
• Outputting stat to fan pump EPC solenoid 1 can be checked with monitoring function
Related (Code: 31624 Fan Pump Solenoid Current (F/B).

Defective fan pump sole-
1 noid 1 (internal open cir- 2. Disconnect connector FAC, and connect T-adapter to male side.
cuit)
Resistance Between FAC (male) (1) and (2) 2 to 12 Ω
Open circuit, short circuit, 2. Disconnect connector FAC and connect T-adapter to female side.
Voltage Between FAC (female) (1) and (2) Max. 4.5 V
3
wiring harness
quired.
ness (wire breakage or 2. Disconnect connectors PTCN3 and FAC, and connect T-adapters to each
4
nector)
Between PTCN3 (female) (3) and FAC (female) (2) Max. 1 Ω
Resistance
Between PTCN3 (female) (25) and FAC (female) (1) Max. 1 Ω
controller
40-1038 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DWN5KA] Fan Control Solenoid 1 Open Circuit
Circuit diagram related to fan control solenoid 1
D155AX-8 40-1039
FAILURE CODE [DWN5KB] Fan Control Solenoid 1 Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DWN5KB] Fan Control Solenoid 1 Short Circuit

Action level Failure code Fan Control Solenoid 1 Short Circuit (Work equipment controller sys-
Failure
L03 DWN5KB tem)
Details of
When controller drives fan pump EPC solenoid 1, unusual current flows through circuit.
failure
Action of
controller
• Output of fan pump remains at its maximum.
• Output condition to fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 31624 Fan Pump Solenoid Current (F/B))

Defective fan pump sole- 2. Disconnect connector FAC, and connect T-adapter to male side.
1 noid 1 (internal open cir-
cuit) Between FAC (male) (1) and (2) 2 to 12 Ω
Resistance
Ground fault in wiring 2. Disconnect connectors PTCN3 and FAC, and connect T-adapter to either
ground circuit)
Between ground and PTCN3 (female) (25) or FAC (fe-
male) (1)
2. Disconnect connectors PTCN3 and FAC, and connect T-adapter to either
3 female side.
ness
Between PTCN3 (female) (3) and (25) or FAC (female)
(1) and (2)
controller
40-1040 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DWN5KB] Fan Control Solenoid 1 Short Circuit
D155AX-8 40-1041
FAILURE CODE [DWN5KY] Fan Control Solenoid 1 Hot Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DWN5KY] Fan Control Solenoid 1 Hot Short Circuit

Action level Failure code Fan Control Solenoid 1 Hot Short Circuit (Work equipment controller
Failure
L01 DWN5KY system)
Details of
Current flows constantly to fan pump EPC solenoid 1 circuit.
failure
Action of
controller
Phenomenon • Output of fan pump remains at its minimum.
on machine • Machine easily overheats.
• Output condition to fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 31624 Fan Pump Solenoid Current (F/B))

Defective fan pump sole- 2. Disconnect connector FAC, and connect T-adapter to male side.
1 noid 1 (internal open cir-
cuit) Between FAC (male) (1) and (2) 2 to 12 Ω
Resistance
Hot short circuit in wiring 2. Disconnect connector FAC and connect T-adapter to female side.
2
Voltage Between FAC (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and FAC, and connect T-adapter to female
side of PTCN3.
REMARK
No continui-
(25)
is heard)
2. Disconnect connectors FAC, PTCN1, PTCN2, and PTCN3, and connect T-
Short circuit in wiring har- adapters to female side of PTCN1, PTCN2, and PTCN3.
3
ness
REMARK
No continui-
Between PTCN3 (female) (25) and each pin of PTCN1
ty (no sound
(female)
is heard)
No continui-
(female)
is heard)
No continui-
ty (no sound
(female)
is heard)
40-1042 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DWN5KY] Fan Control Solenoid 1 Hot Short Circuit

controller
D155AX-8 40-1043
FAILURE CODE [DXA2KA] HSS Pump TVC Solenoid 1 Open Circuit 40 TROUBLESHOOTING
FAILURE CODE [DXA2KA] HSS Pump TVC Solenoid 1 Open Circuit

Action level Failure code HSS Pump TVC Solenoid 1 Open Circuit (Work equipment controller
Failure
L01 DXA2KA system)
Detail of fail- When controller drives TVC solenoid of work equipment and HSS pump, no current flows through
ure circuit.
Action of
Stops driving TVC solenoid of work equipment and HSS pump.
controller
Phenomenon
If load is applied to engine running at low speed, engine stops.
on machine
• Output condition to TVC solenoid of work equipment and HSS pump can be checked with
Related monitoring function. (Code: 01300 TVC Solenoid (F/B))

ment and HSS pump sol- 2.
1 Disconnect connector TVC and connect T-adapter to male side.
enoid (internal open cir-
cuit) Resistance Between TVC (male) (1) and (2) 2 to 12 Ω
Open circuit, short circuit, 2. Disconnect connector TVC and connect T-adapter to female side.
or defective work equip- 4. Shake the wiring harness by hand while measuring the voltage. If the volt-
ment controller age becomes 0 V while shaking, wiring harness has open circuit.
Voltage Between TVC (female) (1) and (2) Max. 4.5 V
3
wiring harness
Resistance Between WECN3 (female) (3) and (8) 2 to 12 Ω
quired.
ness (wire breakage or 2. Disconnect connectors WECN3 and TVC, and connect T-adapters to each
4
nector)
Between WECN3 (female) (3) and TVC (female) (2) Max. 1 Ω
Resistance
Between WECN3 (female) (8) and TVC (female) (1) Max. 1 Ω
ment controller
40-1044 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXA2KA] HSS Pump TVC Solenoid 1 Open Circuit
Circuit diagram related to work equipment HSS pump TVC solenoid 1
D155AX-8 40-1045
FAILURE CODE [DXA2KB] HSS Pump TVC Solenoid 1 Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DXA2KB] HSS Pump TVC Solenoid 1 Short Circuit

Action level Failure code HSS Pump TVC Solenoid 1 Short Circuit (Work equipment controller
Failure
L01 DXA2KB system)
Detail of fail- When controller drives TVC solenoid of work equipment and HSS pump, unusual current flows
Action of
controller
Phenomenon
If load is applied to engine running at low speed, engine stops.
on machine
Related monitoring function. (Code: 01300 Pump TVC Solenoid Current (F/B))

ment and HSS pump sol-
1
enoid (internal open cir- Between TVC (male) (1) and (2) 2 to 12 Ω
cuit) Resistance
Ground fault in wiring 2. Disconnect connectors WECN3 and TVC, and connect T-adapter to either
ground circuit)
Between ground and WECN3 (female) (8) or TVC (fe-
male) (1)
2. Disconnect connectors WECN3 and TVC, and connect T-adapter to either
3 female side.
ness
TVC (female) (1) and (2)
ment controller
40-1046 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXA2KB] HSS Pump TVC Solenoid 1 Short Circuit
D155AX-8 40-1047
FAILURE CODE [DXA2KY] HSS Pump TVC Solenoid 1 Hot Short Cir-
FAILURE CODE [DXA2KY] HSS Pump TVC Solenoid 1 Hot Short Circuit
Action level Failure code HSS Pump TVC Solenoid 1 Hot Short Circuit (Work equipment con-
Failure
L01 DXA2KY troller system)
Detail of fail-
Current flows constantly to TVC solenoid circuit of work equipment and HSS pump.
ure
Action of
controller
Phenomenon
Work equipment speed may decrease.
on machine
Related monitoring function. (Code: Pump TVC Solenoid Current (F/B))

ment and HSS pump sol-
1
enoid (internal open cir- Between TVC (male) (1) and (2) 2 to 12 Ω
cuit) Resistance
Hot short circuit in wiring 2. Disconnect connector TVC and connect T-adapter to female side.
2
Voltage Between TVC (female) (1) and (2) Max. 4.5 V
2. Disconnect connectors WECN3 and TVC, and connect T-adapter to fe-
male side of WECN3.
3
ness
No continui-
(8)
is heard)
ment controller
40-1048 D155AX-8
FAILURE CODE [DXA2KY] HSS Pump TVC Solenoid 1 Hot Short Cir-
D155AX-8 40-1049
FAILURE CODE [DXH1KA] Lockup Clutch ECMV Solenoid Open Cir-
FAILURE CODE [DXH1KA] Lockup Clutch ECMV Solenoid Open Circuit

Action level Failure code Lockup Clutch ECMV Solenoid Open Circuit (power train controller
Failure
L03 DXH1KA system)
Detail of fail- When controller drives torque converter lockup clutch ECMV solenoid, no current flows through cir-
ure cuit.
Action of
Stops driving torque converter lockup clutch ECMV solenoid.
controller
• Torque converter lockup clutch does not engage.
• Output condition to lockup clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31642 Lockup ECMV Current (F/B))
Procedure: Start engine and travel in reverse (automatic gear shift mode).

Defective lockup solenoid 2.
1 Disconnect connector SLUC, and connect T-adapter to male side.
Resistance Between SLUC (male) (1) and (2) 3 to 13 Ω
Open circuit, short circuit, 2. Disconnect connector SLUC and connect T-adapter to female side.
Voltage Between SLUC (female) (1) and (2) Max. 4.5 V
3
wiring harness
quired.
ness 2. Disconnect connectors PTCN3 and SLUC, and connect T-adapters to
4
Between PTCN3 (female) (23) and SLUC (female) (2) Max. 1 Ω
Resistance
Between PTCN3 (female) (37) and SLUC (female) (1) Max. 1 Ω
controller
40-1050 D155AX-8
FAILURE CODE [DXH1KA] Lockup Clutch ECMV Solenoid Open Cir-
Circuit diagram related to torque converter lockup clutch ECMV
D155AX-8 40-1051
FAILURE CODE [DXH1KB] Lockup Clutch ECMV Solenoid Short Cir-
FAILURE CODE [DXH1KB] Lockup Clutch ECMV Solenoid Short Circuit

Failure Lockup Clutch ECMV Solenoid Short Circuit (Power train controller)
L03 DXH1KB
Details of Unusual current flows in the torque converter lockup clutch ECMV solenoid circuit when the circuit is
failure driven.
Action of
Unusual current flows in the solenoid circuit for torque converter lockup clutch ECMV.
controller
• Torque converter lockup function does not operate.
on machine • Once machine stops, travel speed is restricted to F1 and R1.
• Condition of output to the lockup clutch ECMV solenoid can be checked with monitoring
Related function (Code: 31 L/U ECMV(F/B))
Procedure: Sstart engine + Travel REVERSE (automatic gear shift mode)

2. Disconnect connector SLUC, and connect T-adapter to male side.
Defective lockup solenoid
1
(internal open circuit) Between SLUC (male) (1) and (2) 3 to 13 Ω
Resistance
Between SLUC (male) (1) and ground Min. 1 MΩ
2. Disconnect connectors PTCN3 and SLUC, and connect T-adapter to either
harness
2 female side.
cuit) Between ground and PTCN3 (female) (37) or SLUC
(female) (1)
2. Disconnect connectors PTCN3 and SLUC, and connect T-adapter to either
3 female side.
ness
Between PTCN3 (female) (23) and ground or SLUC
controller
40-1052 D155AX-8
FAILURE CODE [DXH1KB] Lockup Clutch ECMV Solenoid Short Cir-
D155AX-8 40-1053
FAILURE CODE [DXH1KY] Lockup Clutch ECMV Solenoid Hot Short
FAILURE CODE [DXH1KY] Lockup Clutch ECMV Solenoid Hot Short Cir-
cuit
Action level Failure code Lockup Clutch ECMV Solenoid Hot Short Circuit (power train control-
Failure
L03 DXH1KY ler system)
Detail of fail-
Current flows constantly to torque converter lockup clutch ECMV solenoid circuit.
ure
Action of • Stops driving torque converter lockup clutch ECMV solenoid.
• Torque converter lockup clutch remains engaged.
• Engine may stop during travel.
Phenomenon
on machine
• Output condition to lockup clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31642 Lockup ECMV Current (F/B))

Hot short circuit in wiring 2. Disconnect connector SLUC and connect T-adapter to female side.
1
Voltage Between SLUC (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and SLUC, and connect T-adapters to fe-
male side of PTCN3.
REMARK
No continui-
Continuity ty (no
(37).
sound)
2 2.
ness Disconnect connectors PTCN1 to 3 and SLUC, and connect T-adapters to
female sides of PTCN1 to 3.
REMARK
No continui-
Between each pin of PTCN3 (female) (37) to PTCN1
ty (no
(female).
sound)
Continuity
No continui-
ty (no
(female).
sound)
controller
40-1054 D155AX-8
FAILURE CODE [DXH1KY] Lockup Clutch ECMV Solenoid Hot Short
D155AX-8 40-1055
FAILURE CODE [DXH4KA] T/M 1st Clutch ECMV Solenoid Open Cir-
FAILURE CODE [DXH4KA] T/M 1st Clutch ECMV Solenoid Open Circuit
Action level Failure code Transmission 1st Clutch ECMV Solenoid Open Circuit (power train
Failure
L03 DXH4KA controller system)
Detail of fail- • When controller drives transmission 1st clutch ECMV solenoid, no current flows through
ure circuit.
Action of • Stops driving transmission 1st clutch ECMV solenoid.
Phenomenon
on machine
• Once machine is stopped, selectable gear speeds is restricted to F2 and R2.
• Output condition to 1st clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31612 T/M 1st Clutch ECMV Current (F/B))
Procedure: Start engine and drive machine in F1 or R1.

Defective 1st clutch
1 ECMV solenoid (Internal 2. Disconnect connector S1T, and connect T-adapter to male side.
open circuit)
Resistance Between S1T (male) (1) and (2) 3 to 13 Ω
Open circuit, short circuit, 2. Disconnect connector S1T, and connect T-adapter to female side.
Voltage Between S1T (female) (1) and (2) Max. 4.5 V
3
wiring harness
If resistance value is Min. 1 MΩ, wiring circuit has open circuit. If resistance value is
Max. 1 Ω, wiring harness has short circuit.
quired.
ness (wire breakage or 2. Disconnect connectors PTCN3 and S1T, and connect T-adapters to each
4
nector)
Between PTCN3 (female) (38) and S1T (female) (1) Max. 1 Ω
Resistance
controller
40-1056 D155AX-8
FAILURE CODE [DXH4KA] T/M 1st Clutch ECMV Solenoid Open Cir-
Circuit diagram related to transmission 1st clutch ECMV solenoid
D155AX-8 40-1057
FAILURE CODE [DXH4KB] T/M 1st Clutch ECMV Solenoid Short Cir-
FAILURE CODE [DXH4KB] T/M 1st Clutch ECMV Solenoid Short Circuit
Action level Failure code Transmission 1st Clutch ECMV Solenoid Short Circuit (power train
Failure
L03 DXH4KB controller system)
Detail of fail- • When controller drives transmission 1st clutch ECMV solenoid, unusual current flows
Phenomenon
on machine

Defective 1st clutch 2. Disconnect connector S1T, and connect T-adapter to male side.
1 ECMV solenoid (Internal
short circuit) Between S1T (male) (1) and (2) 3 to 13 Ω
Resistance
Ground fault in wiring 2. Disconnect connectors PTCN3 and S1T, and connect T-adapter to either
ground circuit)
Between ground and PTCN3 (female) (38) or S1T (fe-
male) (1)
2. Disconnect connectors PTCN3 and S1T, and connect T-adapter to either
3 female side.
ness
Between PTCN3 (female) (23) and (38) or S1T (fe-
male) (1) and (2)
controller
40-1058 D155AX-8
FAILURE CODE [DXH4KB] T/M 1st Clutch ECMV Solenoid Short Cir-
D155AX-8 40-1059
FAILURE CODE [DXH4KY] T/M 1st Clutch ECMV Solenoid Hot Short
FAILURE CODE [DXH4KY] T/M 1st Clutch ECMV Solenoid Hot Short Cir-
cuit
Action level Failure code Transmission 1st Clutch ECMV Solenoid Hot Short Circuit
Failure
L03 DXH4KY (power train controller system)
Detail of fail- • When controller drives transmission 1st clutch ECMV solenoid, current flows constantly
Phenomenon
on machine

Hot short circuit in wiring 2. Disconnect connector S1T, and connect T-adapter to female side.
1
Voltage Between S1T (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and S1T, and connect T-adapter to female side
of PTCN3.
REMARK
No continui-
(38)
is heard)
2 2. Disconnect connectors PTCN1 to 3 and S1T, and connect T-adapters to fe-
ness
male sides of PTCN3.
REMARK
No continui-
ty (no sound
(female).
is heard)
Continuity
No continui-
ty (no sound
(female).
is heard)
controller
40-1060 D155AX-8
FAILURE CODE [DXH4KY] T/M 1st Clutch ECMV Solenoid Hot Short
D155AX-8 40-1061
FAILURE CODE [DXH5KA] T/M 2nd Clutch ECMV Solenoid Open Cir-
FAILURE CODE [DXH5KA] T/M 2nd Clutch ECMV Solenoid Open Circuit
Action level Failure code Transmission 2nd Clutch ECMV Solenoid Open Circuit
Failure
L03 DXH5KA (Power train controller system)
Details of • No current flows when outputting the current to solenoid circuit of transmission 2nd clutch
failure ECMV.
Action of • Unusual current flows in the solenoid circuit for transmission 2nd clutch ECMV.
Phenomenon
on machine
• Condition of output to solenoid of 2nd clutch ECMV can be checked by monitoring func-
tion.
Related
(Code: 31613 2nd ECMV output current (F/M))
information
Procedure: Start engine and perform F2 or R2 travel.

Defective solenoid of 2nd
1 clutch ECMV (internal 2. Disconnect connector S2T, and connect T-adapter to male side.
open circuit)
Open circuit, short circuit, 2. Disconnect connector S2T and connect T-adapter to female side.
2. Disconnect connector PTCN3, and connect T-adapter to male side.
3
wiring harness
REMARK
required.
4
defective contact of con- 2. Disconnect connectors PTCN3 and S2T, and connect T-adapters to each fe-
nector) male side.
Resistance
controller
40-1062 D155AX-8
FAILURE CODE [DXH5KA] T/M 2nd Clutch ECMV Solenoid Open Cir-
Circuit diagram related to transmission 2nd clutch ECMV solenoid
D155AX-8 40-1063
FAILURE CODE [DXH5KB] T/M 2nd Clutch ECMV Solenoid Short Cir-
FAILURE CODE [DXH5KB] T/M 2nd Clutch ECMV Solenoid Short Circuit
Action level Failure code Transmission 2nd Clutch ECMV Solenoid Short Circuit
Failure
L03 DXH5KB (Power train controller system)
Details of • Abnormal current flows when outputting to solenoid circuit of transmission 2nd clutch
failure ECMV.
Action of • Stops driving transmission 2nd clutch ECMV solenoid.
controller • Restricts operations of engine and transmission.
Phenomenon
on machine
• Once machine stops, gear speed is restricted to F1 and R2.
tion.
Related
information
Procedure: Start engine and perform F2 or R2 travel.

Defective solenoid of 2nd 2. Disconnect connector S2T, and connect T-adapter to male side.
1 clutch ECMV (internal
Resistance
harness
2 female side.
cuit) Between ground and PTCN3 (female) (7) or S2T (fe-
male) (1)
3 female side.
ness
Between PTCN3 (female) (3) and (7) or between S2T
controller
40-1064 D155AX-8
FAILURE CODE [DXH5KB] T/M 2nd Clutch ECMV Solenoid Short Cir-
D155AX-8 40-1065
FAILURE CODE [DXH5KY] T/M 2nd Clutch ECMV Solenoid Hot Short
FAILURE CODE [DXH5KY] T/M 2nd Clutch ECMV Solenoid Hot Short Cir-
cuit
Action level Failure code Transmission 2nd Clutch ECMV Solenoid Hot Short Circuit (Power
Failure
L03 DXH5KY train controller system)
Details of • Current flows constantly when outputting to solenoid circuit of transmission 2nd clutch
failure ECMV.
Action of • Unusual current flows in the solenoid circuit for transmission 2nd clutch ECMV.
Phenomenon
on machine
tion.
Related
information

Hot short circuit in wiring 2. Disconnect connector PTCN3 and connect T-adapter to female side.
1
2. Disconnect connectors PTCN3 and S2T, and connect T-adapter to female
side of PTCN3.
REMARK
No continui-
(7)
is heard)
2 2.
ness Disconnect connectors PTCN1 to 3 and S2T, and connect T-adapters to
female side of PTCN1 to 3.
REMARK
No continui-
ty (no sound
(female)
is heard)
Continuity
No continui-
ty (no sound
(female)
is heard)
controller
40-1066 D155AX-8
FAILURE CODE [DXH5KY] T/M 2nd Clutch ECMV Solenoid Hot Short
D155AX-8 40-1067
FAILURE CODE [DXH6KA] T/M 3rd Clutch ECMV Solenoid Open Cir-
FAILURE CODE [DXH6KA] T/M 3rd Clutch ECMV Solenoid Open Circuit
Action level Failure code Transmission 3rd Clutch ECMV Solenoid Open Circuit (power train
Failure
L03 DXH6KA controller system)
Detail of fail- • When controller drives transmission 3rd clutch ECMV solenoid, no current flows through
ure circuit.
Action of • Stops driving transmission 3rd clutch ECMV solenoid.
Phenomenon
on machine
• Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31614 T/M 3rd Clutch ECMV Current (F/B))

Defective solenoid of 3rd
1 clutch ECMV (internal 2. Disconnect connector S3T, and connect T-adapter to male side.
open circuit)
Open circuit, short circuit, 2. Disconnect connector S3T and connect T-adapter to female side.
2. Disconnect connector PTCN3, and connect T-adapter to male side.
3
wiring harness
quired.
ness 2. Disconnect connectors PTCN3 and S3T, and connect T-adapters to each
4
Resistance
controller
40-1068 D155AX-8
FAILURE CODE [DXH6KA] T/M 3rd Clutch ECMV Solenoid Open Cir-
Circuit diagram related to transmission 3rd clutch ECMV solenoid
D155AX-8 40-1069
FAILURE CODE [DXH6KB] T/M 3rd Clutch ECMV Solenoid Short Cir-
FAILURE CODE [DXH6KB] T/M 3rd Clutch ECMV Solenoid Short Circuit
Action level Failure code Transmission 3rd Clutch ECMV Solenoid Short Circuit (power train
Failure
L03 DXH6KB controller system)
Detail of fail- • When controller drives transmission 3rd clutch ECMV solenoid, unusual current flows
Phenomenon
on machine

Defective solenoid of 3rd 2. Disconnect connector S3T, and connect T-adapter to male side.
Resistance
harness
2 female side.
cuit) Between ground and PTCN3 (female) (7) or S3T (fe-
male) (1)
3 female side.
ness
Between PTCN3 (female) (13) and (17) or S3T (fe-
male) (1) and (2)
controller
40-1070 D155AX-8
FAILURE CODE [DXH6KY] T/M 3rd Clutch ECMV Solenoid Hot Short
FAILURE CODE [DXH6KY] T/M 3rd Clutch ECMV Solenoid Hot Short Cir-
cuit
Action level Failure code Transmission 3rd Clutch ECMV Solenoid Hot Short Circuit (power
Failure
L03 DXH6KY train controller system)
Detail of fail- • When controller drives transmission 3rd clutch ECMV solenoid, current flows constantly
Phenomenon
on machine

Hot short circuit in wiring 2. Disconnect connector S3T and connect T-adapter to female side.
1
2. Disconnect connectors PTCN3 and S3T, and connect T-adapter to female
side of PTCN3.
REMARK
No continui-
(17)
is heard)
2 2.
ness Disconnect connectors PTCN1 to 3 and S3T, and connect T-adapters to
REMARK
No continui-
ty (no sound
(female)
is heard)
Continuity
No continui-
ty (no sound
(female)
is heard)
controller
D155AX-8 40-1071
FAILURE CODE [DXH6KY] T/M 3rd Clutch ECMV Solenoid Hot Short
40-1072 D155AX-8
FAILURE CODE [DXH7KA] T/M Reverse Clutch ECMV Solenoid Open
FAILURE CODE [DXH7KA] T/M Reverse Clutch ECMV Solenoid Open Cir-
cuit
Action level Failure code Transmission Reverse Clutch ECMV Solenoid Open Circuit (power
Failure
L03 DXH7KA train controller system)
Detail of fail- • When controller drives transmission R clutch ECMV solenoid, no current flows through cir-
ure cuit.
Action of
controller
Phenomenon
on machine
• Once machine stops, selectable gear speed is restricted to F1.
• Output condition to R clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31616 T/M Reverse Clutch ECMV Current (F/B))
Procedure: Start engine and travel in reverse.

Defective R clutch ECMV
1 solenoid (internal open 2. Disconnect connector SRT, and connect T-adapter to male side.
circuit)
Resistance Between SRT (male) (1) and (2) 1 to 13 Ω
Open circuit, short circuit, 2. Disconnect connector SRT and connect T-adapter to female side.
Voltage Between SRT (female) (1) and (2) Max. 4.5 V
3
wiring harness
quired.
ness 2. Disconnect connectors PTCN3 and SRT, and connect T-adapters to each
4
Between PTCN3 (female) (28) and SRT (female) (1) Max. 1 Ω
Resistance
Between PTCN3 (female) (3) and SRT (female) (2) Max. 1 Ω
controller
D155AX-8 40-1073
FAILURE CODE [DXH7KA] T/M Reverse Clutch ECMV Solenoid Open
Circuit diagram related to transmission reverse clutch ECMV solenoid
40-1074 D155AX-8
FAILURE CODE [DXH7KB] T/M Reverse Clutch ECMV Solenoid Short
FAILURE CODE [DXH7KB] T/M Reverse Clutch ECMV Solenoid Short Cir-
cuit
Action level Failure code Transmission Reverse Clutch ECMV Solenoid Short Circuit (power
Failure
L03 DXH7KB train controller system)
Detail of fail- • When controller drives transmission R clutch ECMV solenoid, unusual current flows
Action of
controller
Phenomenon
on machine
Procedure: Start engine and travel in reverse.

Defective R clutch ECMV 2. Disconnect connector SRT, and connect T-adapter to male side.
1 solenoid (internal short
circuit) Between SRT (male) (1) and (2) 3 to 13 Ω
Resistance
Between SRT (male) (1) and ground Min. 1 MΩ
2. Disconnect connectors PTCN3 and SRT, and connect T-adapter to either
harness
2 female side.
cuit) Between ground and PTCN3 (female) (28) or SRT (fe-
male) (1)
2. Disconnect connectors PTCN3 and SRT, and connect T-adapter to either
3 female side.
ness
Between PTCN3 (female) (3) and (28) or between SRT
controller
D155AX-8 40-1075
FAILURE CODE [DXH7KB] T/M Reverse Clutch ECMV Solenoid Short
40-1076 D155AX-8
FAILURE CODE [DXH7KY] T/M Reverse Clutch ECMV Solenoid Hot
FAILURE CODE [DXH7KY] T/M Reverse Clutch ECMV Solenoid Hot Short
Circuit
Action level Failure code Transmission Reverse Clutch ECMV Solenoid Hot Short Circuit
Failure
Detail of fail- • When controller drives transmission R clutch ECMV solenoid, current constantly flows
Action of
controller
Phenomenon
on machine

Hot short circuit in wiring 2. Disconnect connector SRT and connect T-adapter to female side.
1
Voltage Between SRT (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and SRT, and connect T-adapter to female
side of PTCN3.
REMARK
No continui-
(28)
is heard)
2 2.
ness Disconnect connectors PTCN1 to 3 and SRT, and connect T-adapters to
REMARK
No continui-
ty (no sound
(female)
is heard)
Continuity
No continui-
ty (no sound
(female)
is heard)
controller
D155AX-8 40-1077
FAILURE CODE [DXH7KY] T/M Reverse Clutch ECMV Solenoid Hot
40-1078 D155AX-8
FAILURE CODE [DXH8KA] T/M Forward Clutch ECMV Solenoid Open
FAILURE CODE [DXH8KA] T/M Forward Clutch ECMV Solenoid Open Cir-
cuit
Action level Failure code Transmission Forward Clutch ECMV Solenoid Open Circuit
Failure
L03 DXH8KA (power train controller system)
Detail of fail- • When controller drives transmission F clutch ECMV solenoid, no current flows through cir-
ure cuit.
Action of • Stops driving transmission F clutch ECMV solenoid.
controller Restricts operation of engine and transmission.
Phenomenon
on machine
• Once machine stops, selectable gear speed is restricted to R1.
• Output condition to F clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31622 T/M Forward Clutch ECMV Current (F/B))
Procedure: Start engine and travel forward.

Defective solenoid of F
1 clutch ECMV (internal 2. Disconnect connector SFT, and connect T-adapter to male side.
open circuit)
Resistance Between SFT (male) (1) and (2) 3 to 13 Ω
Open circuit, short circuit, 2. Disconnect connector WECN3 and connect T-adapter to female side.
Voltage Between SFT (female) (1) and (2) Max. 4.5 V
3
wiring harness
quired.
ness 2. Disconnect connectors PTCN3 and SFT, and connect T-adapters to each
4
Between PTCN3 (female) (18) and SFT (female) (1) Max. 1 Ω
Resistance
Between PTCN3 (female) (13) and SFT (female) (2) Max. 1 Ω
controller
D155AX-8 40-1079
FAILURE CODE [DXH8KA] T/M Forward Clutch ECMV Solenoid Open
Circuit diagram related to transmission forward clutch ECMV solenoid
40-1080 D155AX-8
FAILURE CODE [DXH8KB] T/M Forward Clutch ECMV Solenoid Short
FAILURE CODE [DXH8KB] T/M Forward Clutch ECMV Solenoid Short Cir-
cuit
Action level Failure code Transmission Forward Clutch ECMV Solenoid Short Circuit
Failure
L03 DXH8KB (power train controller system)
Detail of fail- • When controller drives transmission F clutch ECMV solenoid, unusual current flows
Phenomenon
on machine
Procedure: Start engine and travel forward.

Defective solenoid of F 2. Disconnect connector SFT, and connect T-adapter to male side.
short circuit) Between SFT (male) (1) and (2) 3 to 13 Ω
Resistance
Between SFT (male) (1) and ground Min. 1 MΩ
2. Disconnect connectors PTCN3 and SFT, and connect T-adapter to either
harness
2 female side.
cuit) Between ground and PTCN3 (female) (18) or SFT (fe-
male) (1)
2. Disconnect connectors PTCN3 and SFT, and connect T-adapter to either
3 female side.
ness
Between PTCN3 (female) (13) and (18) or SFT (fe-
male) (1) and (2)
controller
D155AX-8 40-1081
FAILURE CODE [DXH8KB] T/M Forward Clutch ECMV Solenoid Short
40-1082 D155AX-8
FAILURE CODE [DXH8KY] T/M Forward Clutch ECMV Solenoid Hot
FAILURE CODE [DXH8KY] T/M Forward Clutch ECMV Solenoid Hot Short
Circuit
Action level Failure code Transmission Forward Clutch ECMV Solenoid Hot Short Circuit
Failure
Detail of fail- • When controller drives transmission F clutch ECMV solenoid, current constantly flows
Phenomenon
on machine

Hot short circuit in wiring 2. Disconnect connector SFT and connect T-adapter to female side.
1
Voltage Between SFT (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and SFT, and connect T-adapter to female
side of PTCN3.
REMARK
No continui-
Short circuit in wiring har- Between PTCN3 (female) (18) and each pin other than
2 ty (no sound
ness (18)
is heard)
No continui-
(female).
is heard)
No continui-
ty (no sound
(female).
is heard)
controller
D155AX-8 40-1083
FAILURE CODE [DXH8KY] T/M Forward Clutch ECMV Solenoid Hot
40-1084 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXHBKA] Right Brake ECMV Solenoid Open Circuit
FAILURE CODE [DXHBKA] Right Brake ECMV Solenoid Open Circuit

Action level Failure code Right Brake ECMV Solenoid Short Circuit (power train controller sys-
Failure
L04 DXHBKA tem)
Detail of fail-
When controller drives right steering brake ECMV solenoid no current flows through circuit.
ure
• Stops driving right steering brake ECMV solenoid.
Action of
controller
• Activates sudden stop prevention valve.
• Right brake stays on.
Phenomenon
on machine
• Output condition (current) to right steering brake ECMV solenoid can be checked with
Related monitoring function. (Code: 31618 Right Brake ECMV Current (F/B)).
Procedure: Turn starting switch to ON position and release parking brake lever.

Defective right steering
1 brake ECMV solenoid 2. Disconnect connector SBRR, and connect T-adapter to male side.
Resistance Between SBRR (male) (1) and (2) 3 to 13 Ω
Open circuit, short circuit, 2. Disconnect connector SBRR and connect T-adapter to female side.
Voltage Between SBRR (female) (1) and (2) Max. 4.5 V
3
wiring harness
quired.
ness (wire breakage or 2. Disconnect connectors PTCN3 and SBRR, and connect T-adapters to
4
nector)
Between PTCN3 (female) (36) and SBRR (female) (1) Max. 1 Ω
Resistance
Between PTCN3 (female) (13) and SBRR (female) (2) Max. 1 Ω
controller
D155AX-8 40-1085
FAILURE CODE [DXHBKA] Right Brake ECMV Solenoid Open Circuit 40 TROUBLESHOOTING
Circuit diagram related to right steering brake ECMV solenoid
40-1086 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXHBKB] Right Brake ECMV Solenoid Short Circuit
FAILURE CODE [DXHBKB] Right Brake ECMV Solenoid Short Circuit

Action level Failure code Right Brake ECMV Solenoid Short Circuit (power train controller sys-
Failure
L04 DXHBKB tem)
Detail of fail-
When controller drives right steering brake ECMV solenoid, unusual current flows through circuit.
ure
Action of
controller
• Right brake stays on.
Phenomenon
on machine

Defective right steering 2. Disconnect connector SBRR, and connect T-adapter to male side.
1 brake ECMV solenoid
(internal short circuit) Between SBRR (male) (1) and (2) 3 to 13 Ω
Resistance
Between SBRR (male) (1) and ground Min. 1 MΩ
Ground fault in wiring 2. Disconnect connectors PTCN3 and SBRR, and connect T-adapter to ei-
ground circuit)
Between ground and PTCN3 (female) (36) or SBRR
(female) (1)
2. Disconnect connectors PTCN3 and SBRR, and connect T-adapter to ei-
3 ther female side.
ness
Between PTCN3 (female) (13) and (36), or SBRR (fe-
male) (1) and (2)
controller
D155AX-8 40-1087
FAILURE CODE [DXHBKB] Right Brake ECMV Solenoid Short Circuit 40 TROUBLESHOOTING
40-1088 D155AX-8
FAILURE CODE [DXHBKY] Right Brake ECMV Solenoid Hot Short
FAILURE CODE [DXHBKY] Right Brake ECMV Solenoid Hot Short Circuit
Action level Failure code Right Brake ECMV Solenoid Hot Short Circuit (power train controller
Failure
L04 DXHBKY system)
Detail of fail-
Current flows constantly to right steering brake ECMV solenoid circuit.
ure
Action of
controller
• Right brake does not work.
Phenomenon
on machine

Hot short circuit in wiring 2. Disconnect connector SBRR and connect T-adapter to female side.
1
Voltage Between SBRR (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and SBRR, and connect T-adapters to fe-
male side of PTCN3.
REMARK
No continui-
Continuity ty (no
(36).
sound)
2 2.
ness Disconnect connectors PTCN1 to 3 and SBRR, and connect T-adapters to
REMARK
No continui-
ty (no
(female).
sound)
Continuity
No continui-
ty (no
(female).
sound)
controller
D155AX-8 40-1089
FAILURE CODE [DXHBKY] Right Brake ECMV Solenoid Hot Short
40-1090 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXHCKA] Left Brake ECMV Solenoid Open Circuit
FAILURE CODE [DXHCKA] Left Brake ECMV Solenoid Open Circuit

Action level Failure code Left Brake ECMV Solenoid Open Circuit (power train controller sys-
Failure
L04 DXHCKA tem)
Detail of fail-
When controller drives left steering brake ECMV solenoid, no current flows through circuit.
ure
• Stops driving left steering brake ECMV solenoid.
Action of
controller
• Left brake stays on.
Phenomenon
on machine
• Output condition (current) to left steering brake ECMV solenoid can be checked with moni-
Related toring function. (Code: 31619 Left Brake ECMV Current (F/B)).

1 brake ECMV solenoid 2. Disconnect connector SBRL and connect T-adapter to male side.
Resistance Between SBRL (male) (1) and (2) 3 to 13 Ω
Open circuit, short circuit, 2. Disconnect connector HSR and connect T-adapter to female side.
Voltage Between HSR (female) (1) and (2) Max. 4.5 V
3
wiring harness
quired.
ness (wire breakage or 2. Disconnect connectors PTCN3 and SBRL, and connect T-adapters to
4
nector)
Between PTCN3 (female) (26) and SBRL (female) (1) Max. 1 Ω
Resistance
Between PTCN3 (female) (13) and SBRL (female) (2) Max. 1 Ω
controller
D155AX-8 40-1091
FAILURE CODE [DXHCKA] Left Brake ECMV Solenoid Open Circuit 40 TROUBLESHOOTING
Circuit diagram related to left steering brake ECMV solenoid
40-1092 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXHCKB] Left Brake ECMV Solenoid Short Circuit
FAILURE CODE [DXHCKB] Left Brake ECMV Solenoid Short Circuit

Action level Failure code Left Brake ECMV Solenoid Short Circuit (power train controller sys-
Failure
L04 DXHCKB tem)
Detail of fail-
When controller drives left steering brake ECMV solenoid, no current flows through circuit.
ure
Action of
controller
• Left brake stays on.
Phenomenon
on machine

Defective left steering 2. Disconnect connector SBRL and connect T-adapter to male side.
1 brake ECMV solenoid
(internal open circuit) Between SBRL (male) (1) and (2) 3 to 13 Ω
Resistance
Between SBRL (male) (1) and ground Min. 1 MΩ
Ground fault in wiring 2. Disconnect connectors PTCN3 and SBRL, and connect T-adapter to either
ground circuit)
Between ground and PTCN3 (female) (26) or SBRL
(female) (1)
2. Disconnect connectors PTCN3 and SLB, and connect T-adapter to either
3 female side.
ness
SBRL (female) (1) and (2)
controller
D155AX-8 40-1093
FAILURE CODE [DXHCKB] Left Brake ECMV Solenoid Short Circuit 40 TROUBLESHOOTING
40-1094 D155AX-8
FAILURE CODE [DXHCKY] Left Brake ECMV Solenoid Hot Short Cir-
FAILURE CODE [DXHCKY] Left Brake ECMV Solenoid Hot Short Circuit
Action level Failure code Left Brake ECMV Solenoid Hot Short Circuit (power train controller
Failure
L04 DXHCKY system)
Detail of fail-
When controller drives left steering brake ECMV solenoid, current flows through circuit.
ure
Action of
controller
• Left brake does not work.
Phenomenon
on machine

Hot short circuit in wiring 2. Disconnect connector SBRL and connect T-adapter to female side.
1
Voltage Between SBRL (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and SBRL, and connect T-adapter to fe-
male side of PTCN3.
REMARK
No continui-
(26)
is heard)
2 2.
ness Disconnect connectors PTCN1 to 3 and SBRL, and connect T-adapters to
REMARK
No continui-
ty (no sound
(female)
is heard)
Continuity
No continui-
ty (no sound
(female)
is heard)
controller
D155AX-8 40-1095
FAILURE CODE [DXHCKY] Left Brake ECMV Solenoid Hot Short Cir-
40-1096 D155AX-8
FAILURE CODE [DXHRKA] Blade Lift Raise EPC Solenoid Open Cir-
FAILURE CODE [DXHRKA] Blade Lift Raise EPC Solenoid Open Circuit
Action level Failure code Blade Lift Raise EPC Solenoid Open Circuit (Work equipment con-
Failure
L01 DXHRKA troller system)
Detail of fail-
When controller drives blade lift RAISE EPC solenoid, no current flows through circuit.
ure
Action of
Stops driving blade lift RAISE EPC solenoid.
controller
Phenomenon
Blade lift cannot be raised.
on machine
• Output condition to blade lift RAISE EPC solenoid can be checked with monitoring func-
Related tion. (Code: 71001 Blade Lift Cyl Head EPC Sol Cur (F/B))
Procedure: Turn starting switch to ON position, and operate blade control lever (raising).

Defective blade lift 2. Disconnect connector WEP1, and connect T-adapter to male side.
1 RAISE EPC solenoid (in-
ternal open circuit) 4.5 to
Resistance Between WEP1 (male) (1) and (2)
14.5 Ω
Open circuit, short circuit, 2. Disconnect connector WEP1 and connect T-adapter to female side.
Voltage Between WEP1 (female) (1) and (2) Max. 4.5 V

REMARK
3
4.5 to
14.5 Ω
quired.
ness (wire breakage or 2. Disconnect connectors WECN3 and WEP1, and connect T-adapters to
4
nector)
Between WECN3 (female) (7) and WEP1 (female) (1) Max. 1 Ω
Resistance
5
D155AX-8 40-1097
FAILURE CODE [DXHRKA] Blade Lift Raise EPC Solenoid Open Cir-
Circuit diagram related to blade lift up EPC solenoid
40-1098 D155AX-8
FAILURE CODE [DXHRKB] Blade Lift Raise EPC Solenoid Short Cir-
FAILURE CODE [DXHRKB] Blade Lift Raise EPC Solenoid Short Circuit
Action level Failure code Blade Lift Raise EPC Solenoid Open Circuit (Work equipment con-
Failure
L01 DXHRKB troller system)
Detail of fail-
When controller drives blade lift RAISE EPC solenoid, unusual current flows through circuit.
ure
Action of
Stops driving blade lift RAISE EPC solenoid.
controller
Phenomenon
Blade lift cannot be raised.
on machine
Procedure: Turn starting switch to ON position, and operate blade control lever (raising).

Ground fault in wiring 2. Disconnect connectors WECN3 and WEP1, and connect T-adapter to ei-
ground circuit)
Between ground and WECN3 (female) (7) or WEP1
(female) (1)
2. Disconnect connectors WECN3 and WEP1, and connect T-adapter to ei-
2 ther female side.
ness
WEP1 (female) (1) and (2)
ment controller
Defective blade lift
4 RAISE EPC solenoid (in- 4.5 to
ternal open circuit) Between WEP1 (male) (1) and (2)
Resistance 14.5 Ω
D155AX-8 40-1099
FAILURE CODE [DXHRKY] Blade Lift Raise EPC Solenoid Hot Short
FAILURE CODE [DXHRKY] Blade Lift Raise EPC Solenoid Hot Short Cir-
cuit
Action level Failure code Blade Lift Raise EPC Solenoid Hot Short Circuit (Work equipment
Failure
L03 DXHRKY controller system)
Detail of fail-
Current always flows to blade lift RAISE EPC solenoid circuit.
ure
Action of • Current always flows to blade lift RAISE EPC solenoid circuit.
• Blade lift continues to be raised.

Defective blade lift
1 RAISE EPC solenoid (in- 4.5 to
ternal short circuit) Between WEP1 (male) (1) and (2)
Resistance 14.5 Ω
Hot short circuit in wiring 2. Disconnect connector WEP1 and connect T-adapter to female side.
2
2. Disconnect connectors WECN3 and WEP1, and connect T-adapter to fe-
male side of WECN3.
3
ness
No continui-
(7)
is heard)
ment controller
40-1100 D155AX-8
FAILURE CODE [DXHRKY] Blade Lift Raise EPC Solenoid Hot Short
D155AX-8 40-1101
FAILURE CODE [DXHSKA] Blade Lift Lower EPC Solenoid Open Cir-
FAILURE CODE [DXHSKA] Blade Lift Lower EPC Solenoid Open Circuit
Action level Failure code Blade Lift Lower EPC Solenoid Open Circuit (Work equipment con-
Failure
L01 DXHSKA troller system)
Detail of fail-
When controller drives blade lift LOWER EPC solenoid, no current flows through circuit.
ure
Action of
Stops driving blade lift LOWER EPC solenoid.
controller
Phenomenon
Blade lift cannot be lowered.
on machine
• Output condition to blade lift LOWER EPC solenoid can be checked with monitoring func-
tion. (Code: 71003 Blade Lift Cyl Btm EPC Sol Cur (F/B))
Related
information
Procedure: Turn starting switch to ON position, and operate blade control lever (lowering
down).

Defective blade lift LOW- 2.
Disconnect connector WEP2, and connect T-adapter to male side.
1 ER EPC solenoid (inter-
nal open circuit) 4.5 to
Resistance Between WEP2 (male) (1) and (2)
14.5 Ω
controller age becomes 0 V while shaking, wiring harness is open.

REMARK
3
wiring harness If resistance value is Min. 1 MΩ, open circuit occurs. If resistance value is Max.
1 Ω, short circuit occurs.
4.5 to
14.5 Ω
REMARK
required.
4
defective contact of con- 2. Disconnect connectors WECN3 and WEP2, and connect T-adapters to
nector) each female side.
Resistance
5
40-1102 D155AX-8
FAILURE CODE [DXHSKA] Blade Lift Lower EPC Solenoid Open Cir-
Circuit diagram related to blade lift down EPC solenoid
D155AX-8 40-1103
FAILURE CODE [DXHSKB] Blade Lift Lower EPC Solenoid Short Cir-
FAILURE CODE [DXHSKB] Blade Lift Lower EPC Solenoid Short Circuit
Action level Failure code Blade Lift Lower EPC Solenoid Short Circuit (Work equipment con-
Failure
L01 DXHSKB troller system)
Detail of fail-
When controller drives blade lift LOWER EPC solenoid, unusual current flows through circuit.
ure
Action of
Stops driving blade lift LOWER EPC solenoid.
controller
Phenomenon
Blade lift cannot be lowered.
on machine
tion. (Code: 71003 Blade Lift Cyl Btm EPC Sol Cur (F/B))
Related
information
Procedure: Turn starting switch to ON position, and operate blade control lever (lowering
down).

ground circuit)
(female) (1)
2 ther female side.
ness
ment controller
Defective blade lift LOW-
4 ER EPC solenoid (inter- 4.5 to
nal open circuit) Between WEP2 (male) (1) and (2)
Resistance 14.5 Ω
40-1104 D155AX-8
FAILURE CODE [DXHSKY] Blade Lift Lower EPC Solenoid Hot Short
FAILURE CODE [DXHSKY] Blade Lift Lower EPC Solenoid Hot Short Cir-
cuit
Action level Failure code Blade Lift Lower EPC Solenoid Hot Short Circuit (Work equipment
Failure
L03 DXHSKY controller system)
Detail of fail-
Current flows constantly to blade lift LOWER EPC solenoid circuit.
ure
Action of • Stops driving blade lift LOWER EPC solenoid.
• Blade lift continues to be lowered.
Related tion. (Code: 71003 Blade Lift Cyl Btm EPC Sol Cur (F/B))

Defective blade lift LOW-
1 ER EPC solenoid (inter- 4.5 to
nal short circuit) Between WEP2 (male) (1) and (2)
Resistance 14.5 Ω
2
male side of WECN3.
3
ness
No continui-
than (17)
is heard)
ment controller
D155AX-8 40-1105
FAILURE CODE [DXHSKY] Blade Lift Lower EPC Solenoid Hot Short
40-1106 D155AX-8
FAILURE CODE [DXHTKA] Blade Tilt Right Head EPC Solenoid Open
FAILURE CODE [DXHTKA] Blade Tilt Right Head EPC Solenoid Open Cir-
cuit
Action level Failure code Blade Tilt Right Head EPC Solenoid Open Circuit (Work equipment
Failure
L01 DXHTKA controller system)
Detail of fail-
When controller drives blade tilt right head EPC solenoid, no current flows through circuit.
ure
Action of
Stops driving blade tilt right head EPC solenoid.
controller
Phenomenon
Right cylinder for blade tilt or pitch cannot be retracted.
on machine
• Output condition to blade tilt right head EPC solenoid can be checked with monitoring
function. (Code: 90800 RH Blade Tilt Cyl Head EPC Sol (F/B))
Related
information
Procedure: Turn starting switch to ON position and operate blade control lever (reverse
pitch).

Defective blade tilt R.H.
1 head EPC solenoid (in- 2. Disconnect connector WEP5, and connect T-adapter to male side.
Resistance Between WEP5 (male) (1) and (2) 2 to 12 Ω
3
wiring harness
quired.
4
nector)
Resistance
ment controller
D155AX-8 40-1107
FAILURE CODE [DXHTKA] Blade Tilt Right Head EPC Solenoid Open
Circuit diagram related to blade tilt right head EPC solenoid
40-1108 D155AX-8
FAILURE CODE [DXHTKB] Blade Tilt Right Head EPC Solenoid Short
FAILURE CODE [DXHTKB] Blade Tilt Right Head EPC Solenoid Short Cir-
cuit
Action level Failure code Blade Tilt Right Head EPC Solenoid Short Circuit (Work equipment
Failure
L01 DXHTKB controller system)
Detail of fail-
When controller drives blade tilt right head EPC solenoid, unusual current flows through circuit.
ure
Action of
Stops driving blade tilt right head EPC solenoid.
controller
Phenomenon
Right cylinder for blade tilt or pitch cannot be retracted.
on machine
function. (Code: 90800 RH Blade Tilt Cyl Head EPC Sol (F/B))
Related
information
Procedure: Turn starting switch to ON position and operate blade control lever (reverse
pitch).

Defective blade tilt R.H. 2. Disconnect connector WEP5, and connect T-adapter to male side.
1 head EPC solenoid (in-
ternal open circuit) Between WEP5 (male) (1) and (2) 2 to 12 Ω
Resistance
ground circuit)
(female) (1)
3 ther female side.
ness
ment controller
D155AX-8 40-1109
FAILURE CODE [DXHTKB] Blade Tilt Right Head EPC Solenoid Short
40-1110 D155AX-8
FAILURE CODE [DXHTKY] Blade Tilt Right Head EPC Solenoid Hot
FAILURE CODE [DXHTKY] Blade Tilt Right Head EPC Solenoid Hot Short
Circuit
Action level Failure code Blade Tilt Right Head EPC Solenoid Hot Short Circuit (Work equip-
Failure
L03 DXHTKY ment controller system)
Detail of fail-
Current flows constantly to blade tilt right head EPC solenoid circuit.
ure
Action of • Stops driving blade tilt right head EPC solenoid.
• Right cylinder for blade tilt or pitch continues to be retracted.
Related function. (Code: 90800 RH Blade Tilt Cyl Head EPC Sol (F/B))

ternal hot short circuit) Between WEP5 (male) (1) and (2) 2 to 12 Ω
Resistance
2
2. Disconnect connectors WECN3 and WEP5, and connect T-adapters to fe-
male side of WECN3.
3
ness
No continui-
than (27)
is heard)
ment controller
D155AX-8 40-1111
FAILURE CODE [DXHTKY] Blade Tilt Right Head EPC Solenoid Hot
40-1112 D155AX-8
FAILURE CODE [DXHUKA] Blade Tilt Right Bottom EPC Solenoid
FAILURE CODE [DXHUKA] Blade Tilt Right Bottom EPC Solenoid Open
Circuit
Action level Failure code Blade Tilt Right Bottom EPC Solenoid Open Circuit (Work equipment
Failure
L01 DXHUKA controller system)
Details of
When controller drives blade tilt right bottom EPC solenoid, no current flows through circuit.
failure
Action of
Stops driving blade tilt right bottom EPC solenoid circuit.
controller
Phenomenon
Right cylinder for blade tilt or pitch cannot be extended.
on machine
• Output condition to blade tilt right bottom EPC solenoid can be checked with monitoring
function. (Code: 90801 RH Blade Tilt Cyl Bottom EPC Sol (F/B))
Related
information
Procedure: Turn starting switch to ON position and operate blade control lever (forward
pitch).

Defective blade tilt R.H.
1 bottom EPC solenoid (in- 2. Disconnect connector WEP6, and connect T-adapter to male side.
3
wiring harness
quired.
4
nector)
Resistance
ment controller
D155AX-8 40-1113
FAILURE CODE [DXHUKA] Blade Tilt Right Bottom EPC Solenoid
CIRCUIT DIAGRAM (BLADE TILT RI)GHT BOTTOM EPC SOLENOID
40-1114 D155AX-8
FAILURE CODE [DXHUKB] Blade Tilt Right Bottom EPC Solenoid
FAILURE CODE [DXHUKB] Blade Tilt Right Bottom EPC Solenoid Short
Circuit
Action level Failure code Blade Tilt Right Bottom EPC Solenoid Short Circuit (Work equipment
Failure
L01 DXHUKB controller system)
Detail of fail-
When controller drives blade tilt right bottom EPC solenoid, no current flows through circuit.
ure
Action of
Stops driving blade tilt right bottom EPC solenoid circuit.
controller
Phenomenon
Right cylinder for blade tilt or pitch cannot be extended.
on machine
function. (Code: 90801 RH Blade Tilt Cyl Bottom EPC Sol (F/B))
Related
information
pitch).

1 bottom EPC solenoid (in-
Resistance
ground circuit)
(female) (1)
3 ther female side.
ness
ment controller
D155AX-8 40-1115
FAILURE CODE [DXHUKB] Blade Tilt Right Bottom EPC Solenoid
40-1116 D155AX-8
FAILURE CODE [DXHUKY] Blade Tilt Right Bottom EPC Solenoid
FAILURE CODE [DXHUKY] Blade Tilt Right Bottom EPC Solenoid Hot
Short Circuit
Action level Failure code Blade Tilt Right Bottom EPC Solenoid Hot Short Circuit (Work equip-
Failure
L03 DXHUKY ment controller system)
Detail of fail-
Current flows constantly to blade tilt right bottom EPC solenoid circuit.
ure
Action of • Stops driving blade tilt right bottom EPC solenoid circuit.
• Right cylinder for blade tilt or pitch continues to be extended.
on machine • Once machine is stopped, selectable gear speeds are restricted to F1 and R1.
Related function. (Code: 90801 RH Blade Tilt Cyl Bottom EPC Sol (F/B))

ternal short circuit) Between WEP6 (male) (1) and (2) 2 to 12 Ω
Resistance
2
male side of WECN3.
3
ness
No continui-
than (37)
is heard)
ment controller
D155AX-8 40-1117
FAILURE CODE [DXHUKY] Blade Tilt Right Bottom EPC Solenoid
40-1118 D155AX-8
FAILURE CODE [DXHWKA] Ripper Lift Raise EPC Solenoid Open
FAILURE CODE [DXHWKA] Ripper Lift Raise EPC Solenoid Open Circuit
Action level Failure code Ripper Lift Raise EPC Solenoid Open Circuit (Work equipment con-
Failure
L01 DXHWKA troller system)
Detail of fail-
When controller drives ripper RAISE EPC solenoid, no current flows through circuit.
ure
Action of
Stops driving ripper RAISE EPC solenoid.
controller
Phenomenon
Ripper cannot be raised.
on machine
• Output condition to ripper RAISE EPC solenoid can be checked with monitoring function.
Related (Code: 71101 Ripper Lift Cyl Head EPC Sol (F/B))
Procedure: Turn starting switch to ON position, and operate ripper control lever (raising).

Defective ripper RAISE
1 EPC solenoid (internal 2. Disconnect connector WEP7, and connect T-adapter to male side.
open circuit)
3
wiring harness
Resistance Between WECN3 (female) (3) and (26) 2 to 12 MΩ
quired.
4
nector)
Resistance
ment controller
D155AX-8 40-1119
FAILURE CODE [DXHWKA] Ripper Lift Raise EPC Solenoid Open
Circuit diagram related to ripper RAISE EPC solenoid
40-1120 D155AX-8
FAILURE CODE [DXHWKB] Ripper Lift Raise EPC Solenoid Short
FAILURE CODE [DXHWKB] Ripper Lift Raise EPC Solenoid Short Circuit
Action level Failure code Ripper Lift Raise EPC Solenoid Short Circuit (Work equipment con-
Failure
L01 DXHWKB troller)
Details of
Unusual current flows in the ripper lift RAISE EPC solenoid circuit when the circuit is driven.
failure
Action of
Stops driving the ripper lift RAISE EPC solenoid circuit.
controller
Phenomenon
Ripper lift RAISE operation cannot be performed.
on machine
• Condition of output to the ripper lift RAISE EPC solenoid can be checked with monitoring
Related function (Code: 71101 Ripper Raise EPC(F/B))
Procedure: Turn starting switch to ON position + Ripper control lever operation (RAISE)

Defective ripper RAISE 2. Disconnect connector WEP7, and connect T-adapter to male side.
1 EPC solenoid (internal
open circuit) Between WEP7 (male) (1) and (2) 2 to 12 Ω
Resistance
ground circuit)
(female) (1)
3 ther female side.
ness
Between WECN3 (female) (3) and (26) or WEP7 (fe-
male) (1) and (2)
ment controller
D155AX-8 40-1121
FAILURE CODE [DXHWKY] Ripper Lift Raise EPC Solenoid Hot Short
FAILURE CODE [DXHWKY] Ripper Lift Raise EPC Solenoid Hot Short Cir-
cuit
Action level Failure code Ripper Lift Raise EPC Solenoid Hot Short Circuit (Work equipment
Failure
L03 DXHWKY controller)
Details of
Current continuously flows in the ripper lift RAISE EPC solenoid circuit.
failure
Action of • Stops driving the ripper lift RAISE EPC solenoid circuit.
• Ripper lift RAISE operation keeps operating.
• Condition of output to the ripper lift RAISE EPC solenoid can be checked with monitoring
Related function (Code: 71101 Ripper Raise EPC(F/B))

Defective ripper RAISE 2. Disconnect connector WEP7, and connect T-adapter to male side.
short circuit) Between WEP7 (male) (1) and (2) 2 to 12 Ω
Resistance
2
male side of WECN3.
3
ness
No continui-
Continuity ty (no
than (26).
sound)
ment controller
40-1122 D155AX-8
FAILURE CODE [DXHWKY] Ripper Lift Raise EPC Solenoid Hot Short
D155AX-8 40-1123
FAILURE CODE [DXHXKA] Ripper Lift Lower EPC Solenoid Open
FAILURE CODE [DXHXKA] Ripper Lift Lower EPC Solenoid Open Circuit
Action level Failure code Ripper Lift Lower EPC Solenoid Open Circuit (Work equipment con-
Failure
L01 DXHXKA troller)
Details of
No current flows in the ripper lift LOWER EPC solenoid circuit when the circuit is driven.
failure
Action of
Stops driving the ripper lift LOWER EPC solenoid circuit.
controller
Phenomenon
Ripper lift LOWER operation cannot be performed.
on machine
• Condition of output to the ripper lift LOWER EPC solenoid can be checked with monitoring
Related function (Code: 71103 Ripper Down EPC(F/B))
Procedure: Turn starting switch to ON position and ripper lever operation (LOWER).

Defective ripper LOWER
open circuit)
3
wiring harness
quired.
4
nector)
Resistance
ment controller
40-1124 D155AX-8
FAILURE CODE [DXHXKA] Ripper Lift Lower EPC Solenoid Open
Circuit diagram related to ripper LOWER EPC solenoid
D155AX-8 40-1125
FAILURE CODE [DXHXKB] Ripper Lift Lower EPC Solenoid Short
FAILURE CODE [DXHXKB] Ripper Lift Lower EPC Solenoid Short Circuit
Action level Failure code Ripper Lift Lower EPC Solenoid Short Circuit (Work equipment con-
Failure
L01 DXHXKB troller)
Details of
Unusual current flows in the ripper lift LOWER EPC solenoid circuit when the circuit is driven.
failure
Action of
Stops driving the ripper lift LOWER EPC solenoid circuit.
controller
Phenomenon
Ripper lift LOWER operation cannot be performed.
on machine
Procedure: Turn starting switch to ON position and ripper lever operation (LOWER).

Defective ripper LOWER 2. Disconnect connector WEP8, and connect T-adapter to male side.
Resistance
ground circuit)
(female) (1)
3 ther female side.
ness
male) (1) and (2)
ment controller
40-1126 D155AX-8
FAILURE CODE [DXHXKY] Ripper Lift Lower EPC Solenoid Hot Short
FAILURE CODE [DXHXKY] Ripper Lift Lower EPC Solenoid Hot Short Cir-
cuit
Action level Failure code Ripper Lift Lower EPC Solenoid Hot Short Circuit (Work equipment
Failure
L03 DXHXKY controller)
Details of
Current continuously flows in the ripper lift LOWER EPC solenoid circuit.
failure
Action of • Stops driving the ripper lift LOWER EPC solenoid circuit.
• Ripper lift LOWER operation keeps operating.

Defective ripper LOWER 2. Disconnect connector WEP8, and connect T-adapter to male side.
Resistance
2
male side of WECN3.
3
ness
No continui-
Continuity ty (no
than (36).
sound)
ment controller
D155AX-8 40-1127
FAILURE CODE [DXHXKY] Ripper Lift Lower EPC Solenoid Hot Short
40-1128 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXHYKA] Ripper Tilt In EPC Solenoid Open Circuit
FAILURE CODE [DXHYKA] Ripper Tilt In EPC Solenoid Open Circuit

Failure Ripper Tilt In EPC Solenoid Open Circuit (Work equipment controller)
L01 DXHYKA
Details of
No current flows in the ripper tilt IN EPC solenoid circuit when the circuit is driven.
failure
Action of
Stops driving the ripper tilt IN EPC solenoid circuit.
controller
Phenomenon
Ripper tilt IN operation cannot be performed.
on machine
• Condition of output to the ripper tilt IN EPC solenoid can be checked with monitoring func-
Related tion (Code: 71105 Ripper Tilt In EPC(F/B))
Procedure: Turn starting switch to ON position and ripper lever operation (Tilt IN)

Defective ripper tilt in
open circuit)
3
wiring harness
quired.
4
nector)
Resistance
ment controller
D155AX-8 40-1129
FAILURE CODE [DXHYKA] Ripper Tilt In EPC Solenoid Open Circuit 40 TROUBLESHOOTING
Circuit diagram related to ripper tilt in EPC solenoid
40-1130 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXHYKB] Ripper Tilt In EPC Solenoid Short Circuit
FAILURE CODE [DXHYKB] Ripper Tilt In EPC Solenoid Short Circuit

Failure Ripper Tilt In EPC Solenoid Short Circuit (Work equipment controller)
L01 DXHYKB
Details of
Unusual current flows in the ripper tilt IN EPC solenoid circuit when the circuit is driven.
failure
Action of
Stops driving the ripper tilt IN EPC solenoid circuit.
controller
Phenomenon
Ripper tilt IN operation cannot be performed.
on machine
Procedure: Turn starting switch to ON position and ripper lever operation (Tilt IN)

Defective ripper tilt in 2. Disconnect connector WEP9, and connect T-adapter to male side.
Resistance
ground circuit)
(female) (1)
3 ther female side.
ness
male) (1) and (2)
ment controller
D155AX-8 40-1131
FAILURE CODE [DXHYKY] Ripper Tilt In EPC Solenoid Hot Short Cir-
FAILURE CODE [DXHYKY] Ripper Tilt In EPC Solenoid Hot Short Circuit
Action level Failure code Ripper Tilt In EPC Solenoid Hot Short Circuit (Work equipment con-
Failure
L03 DXHXKY troller)
Details of
Current continuously flows in the ripper tilt IN EPC solenoid circuit.
failure
Action of • Stops driving the ripper tilt IN EPC solenoid circuit.
• Ripper tilt IN operation keeps operating.

Defective ripper tilt in 2. Disconnect connector WEP9, and connect T-adapter to male side.
Resistance
2
male side of WECN3.
3
ness
No continui-
Continuity ty (no
than (15).
sound)
ment controller
40-1132 D155AX-8
FAILURE CODE [DXHYKY] Ripper Tilt In EPC Solenoid Hot Short Cir-
D155AX-8 40-1133
FAILURE CODE [DXHZKA] Ripper Tilt Back EPC Solenoid Open Cir-
FAILURE CODE [DXHZKA] Ripper Tilt Back EPC Solenoid Open Circuit
Action level Failure code Ripper Tilt Back EPC Solenoid Open Circuit (Work equipment con-
Failure
L01 DXHZKA troller)
Details of
No current flows in the ripper tilt BACK EPC solenoid circuit when the circuit is driven.
failure
Action of
Stops driving the ripper tilt BACK EPC solenoid circuit.
controller
Phenomenon
Ripper tilt BACK operation cannot be performed.
on machine
• Condition of output to the ripper tilt BACK EPC solenoid can be checked with monitoring
Related function (Code: 71107 Ripper Tilt Back EPC(F/B))
Procedure: Turn starting switch to ON position and ripper lever operation (Tilt BACK)

Defective ripper tilt back
1 EPC solenoid (internal 2. Disconnect connector WEPA, and connect T-adapter to male side.
open circuit)
Resistance Between WEPA (male) (1) and (2) 2 to 12 Ω
Open circuit, short circuit, 2. Disconnect connector WEPA and connect T-adapter to female side.
Voltage Between WEPA (female) (1) and (2) Max. 4.5 V
3
wiring harness
quired.
ness (wire breakage or 2. Disconnect connectors WECN3 and WEPA, and connect T-adapters to
4
nector)
Between WECN3 (female) (15) and WEPA (female) (1) Max. 1 Ω
Resistance
Between WECN3 (female) (13) and WEPA (female) (2) Max. 1 Ω
ment controller
40-1134 D155AX-8
FAILURE CODE [DXHZKA] Ripper Tilt Back EPC Solenoid Open Cir-
Circuit diagram related to ripper tilt back EPC solenoid
D155AX-8 40-1135
FAILURE CODE [DXHZKB] Ripper Tilt Back EPC Solenoid Short Cir-
FAILURE CODE [DXHZKB] Ripper Tilt Back EPC Solenoid Short Circuit
Action level Failure code Ripper Tilt Back EPC Solenoid Short Circuit (Work equipment con-
Failure
L01 DXHZKB troller)
Details of
Unusual current flows in the ripper tilt BACK EPC solenoid circuit when the circuit is driven.
failure
Action of
Stops driving the ripper tilt BACK EPC solenoid circuit.
controller
Phenomenon
Ripper tilt BACK operation cannot be performed.
on machine
Procedure: Turn starting switch to ON position and ripper lever operation (Tilt BACK)

Defective ripper tilt back 2. Disconnect connector WEPA, and connect T-adapter to male side.
open circuit) Between WEPA (male) (1) and (2) 2 to 12 Ω
Resistance
Ground fault in wiring 2. Disconnect connectors WECN3 and WEPA, and connect T-adapter to ei-
ground circuit)
Between ground and WECN3 (female) (15) or WEPA
(female) (1)
2. Disconnect connectors WECN3 and WEPA, and connect T-adapter to ei-
3 ther female side.
ness
Between WECN3 (female) (13) and (15) or WEPA (fe-
male) (1) and (2)
ment controller
40-1136 D155AX-8
FAILURE CODE [DXHZKY] Ripper Tilt Back EPC Solenoid Hot Short
FAILURE CODE [DXHZKY] Ripper Tilt Back EPC Solenoid Hot Short Cir-
cuit
Action level Failure code Ripper Tilt Back EPC Solenoid Hot Short Circuit (Work equipment
Failure
L03 DXHZKY controller)
Details of
Current continuously flows in the ripper tilt BACK EPC solenoid circuit.
failure
Action of • Stops driving the ripper tilt BACK EPC solenoid circuit.
• Ripper tilt BACK operation keeps operating.

Defective ripper tilt back 2. Disconnect connector WEPA, and connect T-adapter to male side.
open circuit) Between WEPA (male) (1) and (2) 2 to 12 Ω
Resistance
Hot short circuit in wiring 2. Disconnect connector WEPA and connect T-adapter to female side.
2
Voltage Between WEPA (female) (1) and (2) Max. 4.5 V
2. Disconnect connectors WECN3 and WEPA, and connect T-adapter to fe-
male side of WECN3.
3
ness
No continui-
Continuity ty (no
than (15).
sound)
ment controller
D155AX-8 40-1137
FAILURE CODE [DXHZKY] Ripper Tilt Back EPC Solenoid Hot Short
40-1138 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXJ4KA] W/E Lock Solenoid Open Circuit
FAILURE CODE [DXJ4KA] W/E Lock Solenoid Open Circuit

Action level Failure code Work Equipment Lock Solenoid Open Circuit (Work equipment con-
Failure
L03 DXJ4KA troller system)
Detail of fail-
• When controller drives work equipment lock solenoid, no current flows through circuit.
ure
Action of
• Stops driving work equipment lock solenoid.
controller
• Blade and ripper cannot be operated.
Phenomenon
on machine
Procedure: Turn starting switch to ON position and operate work equipment lock lever
information (FREE).

1 ment lock solenoid 2. Disconnect connector WLK and connect T-adapter to male side.
(internal open circuit) Resistance Between WLK (male) (1) and (2) 34 to 44 Ω
Open circuit, short circuit, 2. Disconnect connector WLK and connect T-adapter to female side.
Voltage Between WLK (female) (1) and (2) Max. 4.5 V
2. Disconnect connectors WECN3 and WECN2, and connect T-adapters to
each female side.
3
wiring harness
Between WECN3 (female) (19) and each of WECN (2)
Resistance 34 to 44 Ω
and (3)
quired.
ness 2. Disconnect connectors WECN2, WECP3, and WLK, and connect T-adapt-
4
(Wire breakage or defec- ers to each female side.
Between WECN2 (female) (19) and WLK (female) (1) Max. 1 Ω
Resistance
Between WECN2 (female) (3) and WLK (female) (2) Max. 1 Ω
ment controller
D155AX-8 40-1139
FAILURE CODE [DXJ4KA] W/E Lock Solenoid Open Circuit 40 TROUBLESHOOTING
Circuit diagram related to work equipment lock lever solenoid
40-1140 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXJ4KB] W/E Lock Solenoid Short Circuit
FAILURE CODE [DXJ4KB] W/E Lock Solenoid Short Circuit

Action level Failure code Work Equipment Lock Solenoid Short Circuit (Work equipment con-
Failure
L03 DXJ4KB troller system)
Details of
• When controller drives work equipment lock solenoid, no current flows through circuit.
failure
Action of
• Stops driving work equipment lock solenoid.
controller
• Blade and ripper cannot be operated.
Phenomenon
on machine
Procedure: Turn starting switch to ON position and operate work equipment lock lever
information (FREE).

Defective work equip- 2. Disconnect connector WLK and connect T-adapter to male side.
1 ment lock solenoid (inter-
nal open circuit) Between WLK (male) (1) and (2) 34 to 44 Ω
Resistance
Between WLK (male) (1) and ground Min. 1 MΩ
2. Disconnect connectors WECN2, WECN3, and WLK, and connect T-adapt-
harness
2 er to any female side.
cuit) Between ground and WECN2 (female) (19) or WLK
(female) (1)
2. Disconnect connectors WECN2, WECN3, and WLK, and connect T-adapt-
3 er to any female side.
ness
Between WECN2 (female) (19) and WECN3 (female)
(3), or between WLK (female) (1) and (2)
ment controller
Circuit diagram related to work equipment lock lever solenoid
D155AX-8 40-1141
FAILURE CODE [DXJ8KA] Blade Tilt Left Bottom EPC Solenoid Open
FAILURE CODE [DXJ8KA] Blade Tilt Left Bottom EPC Solenoid Open Cir-
cuit
Failure Blade Tilt Left Bottom EPC Solenoid Open Circuit
L01 DXJ8KA
Detail of fail-
• When controller drives blade tilt left bottom EPC solenoid, no current flows through circuit.
ure
Action of
• Stops driving blade tilt left bottom EPC solenoid.
controller
Phenomenon
• Left cylinder for blade tilt or pitch cannot be extended.
on machine
• Output condition to blade tilt left bottom EPC solenoid can be checked with monitoring
function.
Related (Code: 71007 LH Blade Tilt Cyl Bottom EPC Sol (F/B))
pitch).

Defective blade tilt L.H.
1 bottom EPC solenoid (in- 2. Disconnect connector WEP4, and connect T-adapter to male side.
2. Disconnect connector WECN3 and connect T-adapter to male side.
3
quired.
ness 2. Disconnect connectors WECN3 and WEP4, and connect T-adapters to each
4
Between WECN (female) (23) and WEP4 (female) (2) Max. 1 Ω
Resistance
Between WECN (female) (38) and WEP4 (female) (1) Max. 1 Ω
ment controller
40-1142 D155AX-8
FAILURE CODE [DXJ8KA] Blade Tilt Left Bottom EPC Solenoid Open
Circuit diagram related to blade tilt left bottom EPC solenoid
D155AX-8 40-1143
FAILURE CODE [DXJ8KB] Blade Tilt Left Bottom EPC Solenoid Short
FAILURE CODE [DXJ8KB] Blade Tilt Left Bottom EPC Solenoid Short Cir-
cuit
Failure Blade Tilt Left Bottom EPC Solenoid Short Circuit
L01 DXJ8KB
Detail of fail- • When controller drives blade tilt left bottom EPC solenoid, unusual current flows through
ure circuit.
Action of
controller
Phenomenon
• Left cylinder for blade tilt or pitch cannot be extended.
on machine
function.
Related (Code: 71007 LH Blade Tilt Cyl Bottom EPC Sol (F/B))
pitch).

Defective blade tilt L.H. 2. Disconnect connector WEP4, and connect T-adapter to male side.
Resistance
2. Disconnect connectors WECN3 and WEP4, and connect T-adapter to either
harness
2 female side.
cuit) Between ground and WECN3 (female) (38) or WEP4
(female) (1)
2. Disconnect connectors WECN3 and WEP4, and connect T-adapter to either
Short circuit in wiring har- female side.
3
ness
ment controller
40-1144 D155AX-8
FAILURE CODE [DXJ8KB] Blade Tilt Left Bottom EPC Solenoid Short
D155AX-8 40-1145
FAILURE CODE [DXJ8KY] Blade Tilt Left Bottom EPC Solenoid Hot
FAILURE CODE [DXJ8KY] Blade Tilt Left Bottom EPC Solenoid Hot Short
Circuit
Failure Blade Tilt Left Bottom EPC Solenoid Hot Short Circuit
L03 DXJ8KY
Detail of fail-
• When controller drives blade tilt left bottom EPC solenoid, no current flows through circuit.
ure
Action of
controller
• Left cylinder for blade tilt or pitch continues to be retracted.
on machine • Once machine is stopped, selectable gear speeds are restricted to F1 and R1.
function.
Related
(Code: 71007 LH Blade Tilt Cyl Bottom EPC Sol (F/B))
information

Resistance
2
2. Disconnect connectors WECN3 and WEP4, and connect T-adapter to female
side of WECN3.
3
ness Check it by using multimeter in continuity mode.
No continui-
Between WECN (female) (38) and each pin other than
(38)
is heard)
ment controller
40-1146 D155AX-8
FAILURE CODE [DXJ8KY] Blade Tilt Left Bottom EPC Solenoid Hot
D155AX-8 40-1147
FAILURE CODE [DXJ9KA] Blade Tilt Left Head EPC Solenoid Open
FAILURE CODE [DXJ9KA] Blade Tilt Left Head EPC Solenoid Open Circuit
Action level Failure code Blade Tilt Left Head EPC Solenoid Open Circuit
Failure
L01 DXJ9KA (Power train controller system)
Details of
• No output current flows into blade tilt L.H. head EPC solenoid circuit.
failure
Action of
• Stops outputting to blade tilt L.H. head EPC solenoid circuit.
controller
Phenomenon
• L.H. cylinder for blade TILT or PITCH operation cannot be retracted.
on machine
• Output state to blade tilt L.H. head EPC solenoid can be checked with monitoring function.
Related (Code: 72005 L.H. cylinder head EPC current 2 (F/B))
Procedure: Turn starting switch to ON position and operate blade control lever (in reverse
pitch direction).

Defective blade tilt L.H.
1 head EPC solenoid (in- 2. Disconnect connector WEP3, and connect T-adapter to male side.
2. Disconnect connector WEP3 and connect T-adapter to female side.
3
wiring harness If resistance is 1 MΩ or more, wiring harness has open circuit. If it is below 1 Ω,
wiring harness has short circuit.
Resistance Between WEP3 (female) (23) and (28) 2 to 12 Ω
quired.
ness 2. Disconnect connectors WECN3 and WEP3, and connect T-adapters to
4
Resistance
ment controller
40-1148 D155AX-8
FAILURE CODE [DXJ9KA] Blade Tilt Left Head EPC Solenoid Open
Circuit diagram related to blade tilt left head EPC solenoid
D155AX-8 40-1149
FAILURE CODE [DXJ9KB] Blade Tilt Left Head EPC Solenoid Short
FAILURE CODE [DXJ9KB] Blade Tilt Left Head EPC Solenoid Short Circuit
Action level Failure code Blade Tilt Left Head EPC Solenoid Short Circuit
Failure
L01 DXJ9KB (Power train controller system)
Details of
• Abnormal output current flows into blade tilt L.H. head EPC solenoid circuit.
failure
Action of
controller
Phenomenon
• L.H. cylinder for blade TILT or PITCH operation cannot be retracted.
on machine
Procedure: Turn starting switch to ON position and operate blade control lever (in reverse
pitch direction).

Resistance
harness
2 ther female side.
cuit) Between ground and WECN3 (female) (28) or WEP3
(female) (1)
3 ther female side.
ness
ment controller
40-1150 D155AX-8
FAILURE CODE [DXJ9KB] Blade Tilt Left Head EPC Solenoid Short
D155AX-8 40-1151
FAILURE CODE [DXJ9KY] Blade Tilt Left Head EPC Solenoid Hot
FAILURE CODE [DXJ9KY] Blade Tilt Left Head EPC Solenoid Hot Short
Circuit
Action level Failure code Blade Tilt Left Head EPC Solenoid Hot Short Circuit
Failure
L1 DXJ9KY (Power train controller system)
Details of
• Output current continuously flows into blade tilt L.H. head EPC solenoid circuit.
failure
Action of
controller
• Left cylinder for blade tilt or pitch continues to be retracted.

ternal short circuit) Between WEP (male) (1) and (2) 2 to 12 Ω
Resistance
Between WEP (male) (1) and ground Min. 1 MΩ
Hot short circuit in wiring 2. Disconnect connector WECN3 and WEP3, and connect T-adapter to female
2 side.
harness
male side of WECN3.
3
ness
No continui-
than (28)
is heard)
ment controller
40-1152 D155AX-8
FAILURE CODE [DXJ9KY] Blade Tilt Left Head EPC Solenoid Hot
D155AX-8 40-1153
FAILURE CODE [DXJAKA] Quick drop solenoid: Open 40 TROUBLESHOOTING
FAILURE CODE [DXJAKA] Quick drop solenoid: Open

Action level Failure code Quick Drop EPC Solenoid Open Circuit
Failure
L01 DXJAKA (Work equipment controller system)
Details of
• No output current flows into blade quick drop EPC solenoid circuit.
failure
Action of
• Stops outputting to blade quick drop EPC solenoid circuit.
controller
Phenomenon
• Blade quick drop function does not operate.
on machine
• Output state to blade quick drop EPC solenoid can be checked with monitoring function.
Related (Code: 90900 Quick drop solenoid current (F/B))
Procedure: Turn starting switch to ON position and operate blade lever (LOWER).

Defective quick drop sol-
2. Disconnect connector QDP, and connect T-adapter to male side.
1 enoid
(Internal open circuit) 4.5 to
Resistance Between QDP (male) (1) and (2)
14.5 Ω
Open circuit, short circuit, 2. Disconnect connector QDP and connect T-adapter to female side.
Voltage Max. 4.5 V

REMARK
3
4.5 to
14.5 Ω
quired.
ness 2. Disconnect connectors WECN3 (female) and QDP, and connect T-adapt-
4
(Wire breakage or defec- ers to each female side.
Between WECN3 (female) (23) and QDP (female) (2) Max. 1 Ω
Resistance
Between WECN3 (female) (35) and QDP (female) (1) Max. 1 Ω
ment controller
40-1154 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXJAKA] Quick drop solenoid: Open
Circuit diagram related to blade quick drop EPC solenoid
D155AX-8 40-1155
FAILURE CODE [DXJAKB] Quick Drop EPC Solenoid Short Circuit 40 TROUBLESHOOTING
FAILURE CODE [DXJAKB] Quick Drop EPC Solenoid Short Circuit

Action level Failure code Quick Drop EPC Solenoid Short Circuit
Failure
L01 DXJAKB (Work equipment controller system)
Details of
• Abnormal output current flows into blade quick drop EPC solenoid circuit.
failure
Action of
controller
Phenomenon
• Blade quick drop function does not operate.
on machine
Procedure: Turn starting switch to ON position and operate blade lever (LOWER).

Defective quick drop sol- 2. Disconnect connector QDP, and connect T-adapter to male side.
1 enoid 4.5 to
(Internal open circuit) Resistance 14.5 Ω
2. Disconnect connectors WECN3 and QDP, and connect T-adapter to either
harness
2 female side.
cuit) Between ground and WECN3 (female) (35) or QDP
(female) (1)
2. Disconnect connectors WECN3 and QDP, and connect T-adapter to either
3 female side.
ness
QDP (female) (1) and (2)
ment controller
40-1156 D155AX-8
40 TROUBLESHOOTING FAILURE CODE [DXJAKB] Quick Drop EPC Solenoid Short Circuit
D155AX-8 40-1157
FAILURE CODE [DXJAKY] Quick Drop EPC Solenoid Hot Short Cir-
FAILURE CODE [DXJAKY] Quick Drop EPC Solenoid Hot Short Circuit
Action level Failure code Quick Drop EPC Solenoid Hot Short Circuit
Failure
L01 DXJAKY (Work equipment controller system)
Details of
• Output current constantly flows into blade quick drop EPC solenoid circuit.
failure
Action of
controller
Phenomenon
• Blade quick drop function cannot be turned OFF.
on machine

Defective quick drop sol- 2. Disconnect connector QDP, and connect T-adapter to male side.
1 enoid 4.5 to
(Internal short circuit) Resistance 14.5 Ω
Hot short circuit in wiring 2. Disconnect connector QDP and connect T-adapter to female side.
2
Voltage Between QDP (female) (1) and (2) Max. 4.5 V
2. Disconnect connectors WECN3 and QDP, and connect T-adapter to fe-
male side of QDP.
3
ness
No continui-
than (35)
is heard)
ment controller
40-1158 D155AX-8
FAILURE CODE [DXJAKY] Quick Drop EPC Solenoid Hot Short Cir-
D155AX-8 40-1159
FAILURE CODE [DXJBKA] T/C Stator Clutch ECMV Solenoid Open
FAILURE CODE [DXJBKA] T/C Stator Clutch ECMV Solenoid Open Circuit
Action level Failure code Torque Converter Stator Clutch ECMV Solenoid Open Circuit
Failure
L03 DXBKA (Power train controller system)
Detail of fail-
• No output current flows into solenoid circuit of stator clutch ECMV.
ure
Action of • Stops outputting to solenoid circuit of stator clutch ECMV.
• Engine speed may not be transferred normally.
on machine • Once machine stops, gear speed is restricted to F1 and R2.
• Automatic gear shift system does not work.
• Output state to solenoid of stator clutch ECMV can be checked with monitoring function.
Related (Code: 90700 S/C ECMV output current (F/B))
Procedure: Start engine and travel.

Defective solenoid of sta-
1 tor clutch ECMV (internal 2. Disconnect connector SSTC, and connect T-adapter to male side.
open circuit)
Resistance Between SSTC (male) (1) and (2) 3 to 13 Ω
Open circuit, short circuit, 2. Disconnect connector SSTC and connect T-adapter to female side.
Voltage Between SSTC (female) (1) and (2) Max. 4.5 V
3
wiring harness
quired.
ness 2. Disconnect connectors PTCN3 and SSTC, and connect T-adapters to
4
Between PTCN3 (female) (27) and SSTC (female) (1) Max. 1 Ω
Resistance
Between PTCN3 (female) (3) and SSTC (female) (2) Max. 1 Ω
controller
40-1160 D155AX-8
FAILURE CODE [DXJBKA] T/C Stator Clutch ECMV Solenoid Open
Circuit diagram related to torque converter stator clutch ECMV solenoid
D155AX-8 40-1161
FAILURE CODE [DXJBKB] T/C Stator Clutch ECMV Solenoid Short
FAILURE CODE [DXJBKB] T/C Stator Clutch ECMV Solenoid Short Circuit
Action level Failure code Torque Converter Stator Clutch ECMV Solenoid Short Circuit
Failure
L03 DXBKB (Power train controller system)
Detail of fail-
• Abnormal output current flows into solenoid circuit of stator clutch ECMV.
ure
Procedure: Start engine and travel.

Defective solenoid of sta- 2. Disconnect connector SSTC, and connect T-adapter to male side.
1 tor clutch ECMV (internal
short circuit) Between SSTC (male) (1) and (2) 3 to 13 Ω
Resistance
Between SSTC (male) (1) and ground Min. 1 MΩ
Ground fault in wiring 2. Disconnect connectors PTCN3 and SSTC, and connect T-adapter to either
ground circuit)
Between ground and PTCN3 (female) (27) or SSTC
(female) (1)
2. Disconnect connectors PTCN3 and SSTC, and connect T-adapter to either fe-
3
ness
SSTC (female) (1) and (2)
controller
40-1162 D155AX-8
FAILURE CODE [DXJBKB] T/C Stator Clutch ECMV Solenoid Short
D155AX-8 40-1163
FAILURE CODE [DXJBKY] T/C Stator Clutch ECMV Solenoid Hot
FAILURE CODE [DXJBKY] T/C Stator Clutch ECMV Solenoid Hot Short Cir-
cuit
Action level Failure code Torque Converter Stator Clutch ECMV Solenoid Hot Short Circuit
Failure
L03 DXBKY (Power train controller system)
Detail of fail-
• Output current constantly flows into solenoid circuit of stator clutch ECMV.
ure

Hot short circuit in wiring 2.
1 Disconnect connector SSTC and connect T-adapter to female side.
harness
Voltage Between SSTC (female) (1) and ground Max. 4.5 V
2. Disconnect connectors PTCN3 and SSTC, and connect T-adapter to fe-
male side of PTCN3.
REMARK
No continui-
(27).
is heard)
Short circuit in wiring har- 1. Turn starting switch to OFF position.
2
ness
2. Disconnect connectors PTCN1 to 3 and SSTC, and connect T-adapters to
REMARK
No continui-
ty (no sound
PTCN1 (female)
is heard)
Continuity
No continui-
ty (no sound
PTCN1 (female)
is heard)
controller
40-1164 D155AX-8
FAILURE CODE [DXJBKY] T/C Stator Clutch ECMV Solenoid Hot
D155AX-8 40-1165
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-

MODE)
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
Failure Engine does not start (engine doe snot crank)
• Since the engine start circuit has the neutral safety function, the engine does not start un-
less the work equipment lock lever and parking brake lever are in LOCK position and the
travel lever is in NEUTRAL position.
• Since KOMTRAX has starting lock function, engine does not start unless starting lock is
canceled.
• Before performing troubleshooting, check that no relevant failure code is displayed (If fail-
Related ure code [D19JKZ], [D130KA], [D130KB], [D190KA], [D190KB], [DD14KA], or [DD14KB] is
information displayed, perform troubleshooting these first).
• If failure symptom is "Battery relay operation sound is not heard" when starting switch is
turned to ON position, perform troubleshooting for E-1 as well.
• If failure symptom "Machine monitor does not light up" appears while starting switch is
turned to ON position, main power supply system may be defective. Perform troubleshoot-
ing for E-5 (lines of circuit breakers CB30 and CB6).
• If engine does not stop, replace engine hold relay.
REMARK
Loose terminal or open Turn starting switch to OFF position.
1
circuit in terminal
Check terminals of starting motor, alternator, battery relay, circuit breaker, ground
GND, GND03, etc.
Between battery relay terminal BRE and ground
REMARK
Contact between battery As ground, select unpainted portion of frame or non-
2
relay and frame (ground) Resistance rusted metallic part (plated bolt), etc. Max. 1 Ω
REMARK
Looseness or rust of terminal
GND03
Be ready with starting switch at OFF position, then perform troubleshooting without
turning starting switch to ON position.
Insufficient battery ca-
3
pacity Battery voltage (2 cells) Min. 24 V
Gravity of battery (1 piece) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated with failure
4 code [DB2QKR] and [DB2RKR. If this code appears, perform troubleshooting for
ler system
causes 1 to 4 of [DB2QKR] first.
• If failure code [CA2265] or [CA2266] is displayed, perform troubleshooting
5 Defective fuel feed pump for [CA2265] or [CA2266] first.
• See E-42, and check the lamp of fuel feed pump, etc.
40-1166 D155AX-8
40 TROUBLESHOOTING E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)

2. Operate parking lever to perform troubleshooting.
Defective parking lever
6 switch (internal defect, Other than
Display of FREE position
defective adjustment) “P”
“P” on moni-
tor panel Display of
LOCK position
“P”
ment lock lever switch Other than
7 FREE position
(internal defect or im- Display of “P”
proper adjustment) “P” on moni-
tor panel Display of
LOCK position
“P”
Defective fuse No. 19 in If fuse is burnt out, circuit may have ground fault. (See check on Cause 13.)
8
fuse box F01
1. Turn starting switch to ON position (connect ACC).
Defective battery relay
9 REMARK
system
If turn-ON sound of battery relay is not heard, go to Cause 21.
1. Turn starting switch to OFF position and remove fuse No. 19 in fuse box
Defective fuse No. 19 in F01.
10 fuse box F01 or defective 2.
Turn starting switch to ON position (connect ACC).
wiring harness
Voltage Between fuse box F01-19 and ground 20 to 30 V
2. Remove fuse No. 8 (5 A) in fuse box F01 (to prevent engine from starting
during check).
Defective starting switch, 3. Insert T-adapter into connector ST.
neutral safety relay NSF,
11 personal lock relay PSL, 4. Turn starting switch to START position and hold it (two persons required
battery relay, or wiring for this check).
harness Voltage Between ST (1) and ground 20 to 30 V
REMARK
If voltage is abnormal, go to check on cause 15.
REMARK
If failure code is still displayed after above checks on cause 10, this check is
not required.
Open circuit in wiring har- 1. Turn the starting switch to OFF position and turn the battery disconnect
ness 1 (wire breakage or switch to OFF position (to prevent short circuit during check).
12
defective contact of con- 2.
Disconnect connector KEY and connect T-adapter to female side.
nector)
3. Disconnect fuse No. 19 of fuse box F01.
Between battery (+) terminal and KEY (female) (5) Max. 1 Ω
Resistance
Between KEY (female) (1) and F01-19 Max. 1 Ω
D155AX-8 40-1167
REMARK
not required.
Ground fault in wiring 1. Turn starting switch to OFF position, and turn battery disconnect switch to
13 harness 1 (contact with OFF position.
ground circuit)
2. Disconnect fuses No. 9, No. 15 and No. 19 of fuse box F01.
Between battery (+) terminal and ground Max. 1 Ω
Resistance
Between F01-19 and ground Min. 1 MΩ
REMARK
not required.
OFF position.
2. Disconnect connector KEY, and connect T-adapter to male side.
3. After troubleshooting, turn starting switch to ON/START position and per-
form troubleshooting again.
Turn starting switch to
Min. 1 MΩ
Defective starting switch Between KEY (male) (1) OFF position.
14
(internal open circuit) and (5) Turn starting switch to ON
Max. 1 Ω
position.
Min. 1 MΩ
Between KEY (male) (4) OFF position.
Resistance
and (5) Turn starting switch to ON
Max. 1 Ω
position.
Min. 1 MΩ
and (5) Turn starting switch to
Max. 1 Ω
START position.
REMARK
If failure code is still displayed after above checks on Cause 11, this check is
not required.
Defective neutral safety
15 relay (internal open cir- 1. Turn starting switch to OFF position.
cuit) 2. Replace neutral safety relay (NSF) with another relay.
3. Start engine.
If engine starts, original neutral safety relay (NSF) is defective.
REMARK
not required.
Defective personal code
16 relay (internal open or 1. Turn starting switch to OFF position.
short circuit) 2. Replace personal lock relay (PSL) with another relay.
3. Start engine.
If engine starts, original personal lock relay is defective.
40-1168 D155AX-8
REMARK
When engine does not stop
Defective engine hold re-
17 2. Turn battery disconnect switch to OFF position.
lay
3. Replace engine hold relay (EHL) with another relay (Example: PHR).
If engine stops, original engine hold relay (EHL) is defective.
2. Remove connector RSD and connect T-adapter to diode.
Defective diode RSD (in- REMARK

18 ternal open circuit or Measure it with diode range of multimeter.
short circuit)
No continui-
Between RSD (male) (1) (+) and (2) (-)
Continuity ty
Between RSD (male) (2) (+) and (1) (-) Continuity
Defective alternator (in-
19 Between terminal AL/R
ternal short circuit) Voltage Input for generation Max. 1 V
and ground
during check).
3. Insert T-adapter into connector ST.
4. Turn starting switch to START position to perform troubleshooting.
Defective starting motor
20 Between starting motor
(internal defect) Power supply 20 to 30 V
terminal B and ground
Between ST (1) and
Voltage Input for starting 20 to 30 V
ground
Between ST (2) and
Input for charging Max. 1 V
ground
Battery relay
2. Disconnect connector KEY and connect T-adapter to female side.
Resistance Between SW terminal and KEY (female) (4) Max. 1 Ω
Battery relay
Open circuit in battery re- 2. Turn starting switch to ON position.
21
lay harness
REMARK
Check where 24 V power is reached to, and locate open section.
Between KEY (4) and ground 20 to 30 V
Between BRB terminal and ground 20 to 30 V
Voltage
Between SW terminal and ground 20 to 30 V
Between BRC terminal and ground 20 to 30 V
D155AX-8 40-1169

Alternator and starting motor
during check).
4. Insert T-adapters into connectors KEY, NSF, PSL, and ST.
6. Turn starting switch to START position to perform troubleshooting.
Open circuit in wiring har- REMARK
ness 2 (wire breakage or Check where 24 V power is reached to, and locate open section.
22
nector) Between KEY (3) and ground 20 to 30 V
Between NSF (1) and ground 20 to 30 V
Voltage
Between PSL (4) and ground 20 to 30 V
Between ST (1) and ground 20 to 30 V
Between alternator terminal B and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
If fuse or fusible link is burnt out, replace it.
3. Disconnect connectors KEY, NSF, PLS, and CM01.
4. Connect T-adapters to each female side of KEY, NSF, PSL, and CM01.
Between KEY (female) (3) and NSF (female) (3) Max. 1 Ω
Open circuit in fuse cir- Between NSF (female) (5) and PSL (female) (3) Max. 1 Ω
23
cuit Between PSL (female) (4) and starting motor safety re-
Max. 1 Ω
lay terminal S
Between alternator B and starting motor B Max. 1 Ω
Resistance
Between starting motor B and battery relay BRC Max. 1 Ω
Between alternator AL/R (terminal R) and starting mo-
Max. 1 Ω
tor safety relay terminal R
Between alternator AL/R and RSD (female) (2) Max. 1 Ω
Between RSD (female) (1) and KEY (female) (4) Max. 1 Ω
Defective battery relay If only voltage at terminal BRC is abnormal in check on Cause 21 related to battery
24
(does not turn ON) relay, battery relay is defective.
40-1170 D155AX-8

3. Disconnect connectors KEY, EHL, NSF, PSL, ST, CM01, PTCN1, WECN1,
and CK02.
4. Connect T-adapters to each female side of connectors KEY, NSF and PSL.
Ground fault in wiring 5. Remove fuse No. 19 in fuse box F01.
25 harness 2 (contact with Between ground and KEY (female) (3) or NSF (female)
(3)
Between ground and NSF (female) (5) or PSL (female)
Min. 1 MΩ
Resistance (3)
Between ground and PSL (female) (4) or ST (female)
Min. 1 MΩ
(1)
Between PSL (female) (2) and ground Min. 1 MΩ
2.
Hot short circuit in wiring Disconnect terminal AL/R
26 harness (Contact with 24 3. Turn starting switch to ON position.
V circuit)
Between terminal AL/R (wiring harness side) and
Voltage Max. 1 V
ground
D155AX-8 40-1171
Circuit diagram related to engine starting circuit
40-1172 D155AX-8
40 TROUBLESHOOTING E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK

Failure Manual preheating system does not work.
REMARK
This troubleshooting describes procedures to be followed when manual preheating does not
function to heat the ribbon heater mounting section.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either
preheating works, preheating monitor lights up. (When only preheating monitor does not
light up, perform troubleshooting for failure "While preheating is working, preheating moni-
Related tor does not light up").
information • If failure symptom "Machine monitor displays nothing" or "Battery relay does not make op-
erating sound" appears when starting switch is turned to ON position, main electric power
supply system may be defective. In these cases, perform troubleshooting for E-5 and E-1
first respectively.
• The machine monitor does not light up when circuit breaker CB6 or CB30 is tripped.
• Before performing troubleshooting, check that no preheat-related failure code is displayed.
(If failure code [CA153], [CA154], [CA2555], or [CA2556] is displayed, perform trouble-
shooting for those codes first.)

Defective circuit breaker If circuit breaker CB105H is tripped, circuit probably has ground fault. In this case,
1
CB105H perform check on cause 8 first.
Looseness of terminal 1. Turn starting switch to OFF position.
2 and wire breakage at ter-
minal part Check for terminals of heater relay, battery relay, ribbon heater, etc.

2. Disconnect connector CM01 and KEY, and connect T-adapter to female
side of KEY.
Between KEY (female) (2) and ground (heater relay Approx.
Resistance
coil resistance) 20 Ω
Secondary side
Open or short circuit in Between HT/A (input terminal on contact side of heater
3 Voltage 20 to 30 V
wiring harness relay) and ground
Primary side
2. Disconnect HT/B terminal of heater relay.
3. Turn the starting switch to the HEAT position (R1 connected)
REMARK
To perform checks without passing an electric current when starting switch is in
HEAT position
Voltage Between heater relay HT terminal and ground 20 to 30 V
D155AX-8 40-1173
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40 TROUBLESHOOTING
REMARK
If no failure is found in primary side by check on cause 3, this check is not re-
quired.
Defective diode HTD (in- 2. Disconnect connector HTD, and connect T-adapter to diode.
4 ternal open circuit or
short circuit) REMARK
Measure it with diode range of multimeter.
No continui-
Between HTD (male) (1) (+) and (2) (-)
Continuity ty
Between HTD (male) (2) (+) and (1) (-) Continuity
REMARK
If no failure is found in primary side by check on cause 3, this check is not re-
quired.
2. Turn disconnect switch to OFF position.
5 Defective starting switch
4. Turn starting switch to OFF and the HEAT positions to perform trouble-
shooting.
OFF Min. 1 MΩ
Resistance KEY (male) (2) to (5)
HEAT Max. 1 Ω
Defective ribbon heater 2.
6 Disconnect HT/B terminal.
Continuity Between HT/B wiring harness and ground Continuity
Defective heater relay If failure code is still displayed after above checks on cause 3 and heater relay op-
7 (does not turn ON) (ter- eration sound is not heard, the heater relay is defective.
minal HT/B)
REMARK
required.
Ground fault in wiring 2. Turn the battery disconnect switch to OFF position.
8 harness (contact with 3. Disconnect connector KEY, CM01, HTD, terminal HT, HT/A, and BRC ter-
ground circuit)
minal.
Between heater relay HT terminal (wiring harness side)
Min. 1 MΩ
and ground
Resistance
Between HT/A (input terminal on contact side of heater
Min. 1 MΩ
relay) and ground
40-1174 D155AX-8
40 TROUBLESHOOTING E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK
CIRCUIT DIAGRAM (ENGINE PREHEATING SYSTEM)
D155AX-8 40-1175
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40 TROUBLESHOOTING
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK

Failure Automatic preheating system does not work.
• Automatic preheating starts when the engine coolant temperature is -5°C and below (Mon-
itoring code of engine coolant temperature: 04107)
• If the automatic preheating does not work, check if manual preheating works first.
Related
• Engine controller checks primary (coil) side of preheat relay (connector PHR) and gener-
information
ates failure code [CA2555] or [CA2556] if it is defective.
• Engine controller generates failure code [CA144] or [CA145] if the engine coolant temper-
ature sensor is defective.

Defective fuse No. 6 in If fuse No. 6 in fuse box F01 is blown out, the circuit probably has ground fault. In
1
fuse box F01 this case, perform check on cause 5 first.
2. Replace preheating relay (connector PHR) with, for example, rear lamp re-
Defective preheating relay (connector: LMRE).
2 lay PHR (internal open or
short circuit)
If automatic preheating function operates when engine coolant temperature is -5°C
or below, preheating relay is defective.
2. Disconnect connector J2 and connect T-adapter to female side.
REMARK
If resistance value is Min. 1, open circuit occurs. If resistance value is Max. 1, short
3 circuit occurs.
fault in wiring harness
REMARK
Coil resistance of preheating relay
200 to
400 Ω
2. Disconnect connectors PHR and CM01, and connect T-adapters to female
side of PHR.
4 ness (wire breakage or 3. Remove fuse No. 6 in fuse box F01.
defective contact)
Between PHR (female) (3) and F01 - 6 Max. 1 Ω
Resistance Between PHR (female) (5) and HT terminal of heater
Max. 1 Ω
relay
If fuse is not burnt out, this check is not required.
Ground fault in wiring 2. Disconnect connectors PHR, HEAT, PLSW and ASUS, and connect T-
adapters to female side of PHR.
ground circuit)
Resistance Between PHR (female) (3) and ground Min. 1 MΩ
2. Disconnect connectors J2 and relay PHR, and connect T-adapter to either
6 female side.
harness
Between ground and J2 (female) (75) or PHR (female)
(1)
40-1176 D155AX-8
40 TROUBLESHOOTING E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK
D155AX-8 40-1177
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR
DOES NOT LIGHT UP 40 TROUBLESHOOTING
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES

NOT LIGHT UP
Failure While preheating is working, preheating monitor does not light up.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either
Related
preheating works, preheating monitor lights up.
information
• Check that manual preheating function works normally in advance.

2. Disconnect connectors KEY, CM01 and PHR, and connect T-adapters to
1 ness (wire breakage or each female side.
defective contact) Between KEY (female) (2) and CM01 (female) (12) Max. 1 Ω
Resistance
Between PHR (female) (5) and CM01 (female) (12) Max. 1 Ω
If failure code is still displayed after above checks, machine monitor is defective.
Reference
Defective machine moni- 3. Disconnect HT/B terminal of heater relay.
2
tor 4. Turn starting switch to HEAT position.
REMARK
To perform checks without passing an electric current when starting switch is in
HEAT position
40-1178 D155AX-8
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR
40 TROUBLESHOOTING DOES NOT LIGHT UP
D155AX-8 40-1179
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MA-
CHINE MONITOR DISPLAYS NOTHING 40 TROUBLESHOOTING
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE

MONITOR DISPLAYS NOTHING
Failure When starting switch is turned to ON position, machine monitor displays nothing.
• When starting switch is turned to ON position, machine monitor displays KOMATSU logo,
password input screen (if set), check preset setting screen, and standard screen in order.
Related • Battery voltage may drop sharply when engine is started, depending on ambient tempera-
information ture and battery condition. In this case, machine monitor display may disappear for a
while. This phenomenon is not abnormal.
• Check that battery disconnect switch is in ON position.

Omission of turning bat- Turn starting switch to OFF position, and check that battery disconnect switch is
1 tery disconnect switch turned ON.
ON

2
circuit in terminal Check terminals of battery relay, circuit breaker, etc.
If circuit breaker is tripped, circuit probably has ground fault.
Defective circuit breaker
3 • If CB30 or CB6 is tripped, see cause 8.
CB30, CB6, or CB7
• If CB7 is tripped, see cause 12.
Defective fuse No. 19 in If fuse is burnt out, circuit may have ground fault. (See check on Causes 8 and 12.)
4
fuse box F01
1. Turn starting switch to OFF position, and turn battery disconnect switch
OFF.
2. Remove fuses No. 9 and No. 19 in fuse box F01.
Defective starting switch,
5
wiring harness, or battery 4. Turn starting switch to ON position.
Voltage Between fuse box F01-19 (input terminal) and ground 20 to 30 V
REMARK
If voltage is normal, go to check on cause 9.
Be ready with starting switch at OFF position, then perform troubleshooting without
turning starting switch to ON position.
Insufficient battery ca-
6
pacity Battery voltage (2 cells) Min. 24 V
Gravity of battery (1 piece) Min. 1.26
40-1180 D155AX-8
40 TROUBLESHOOTING CHINE MONITOR DISPLAYS NOTHING
REMARK
required.
OFF position.
2. Disconnect fuse No. 19 in fuse box F01.
ness 1 (wire breakage or 3. Turn starting switch to ON position with battery disconnect switch at OFF
7
defective contact of con- position.
nector)
Between battery (-) terminal and ground Max. 1 Ω
Between battery (+) terminal and F01-19 Max. 1 Ω
Resistance Between terminal B30L and CB7 (1) Max. 1 Ω
Between terminal B30L and CB6 (1) Max. 1 Ω
Between CB6 (2) and F01-19 Max. 1 Ω
REMARK
If failure code is still displayed after above checks on causes 3 and 4, this
check is not required.
Ground fault in wiring OFF position.
8 harness 1 (contact with 2. Disconnect fuses No. 9, No. 15 and No. 19 in fuse box F01 and connector
ground circuit)
CM01.
Between battery (+) terminal and ground Max. 1 Ω
Resistance Between F01-19 and ground Min. 1 MΩ
Between F01-19 and ground Min. 1 MΩ
1. Turn starting switch to OFF position, and turn battery disconnect switch
OFF.
Defective wiring harness, 3. Turn battery disconnect switch ON, and turn starting switch to ON position
9 starting switch, or ma- (connect ACC).
chine monitor
Between CM01 (10) and (4) (ACC line) 20 to 30 V
REMARK
If (ACC line) in check on cause 9 is normal, this check is not required.
Defective starting switch
10 3. Turn starting switch to ON position and perform troubleshooting again.
Min. 1 MΩ
Resistance
and (5) Turn starting switch to ON
Max. 1 Ω
position.
D155AX-8 40-1181
CHINE MONITOR DISPLAYS NOTHING 40 TROUBLESHOOTING
REMARK
required.
1. Turn starting switch to OFF position, and set battery battery disconnect
switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors KEY and CM01.
ness 2 (wire breakage or 3. Connect T-adapters to each female side of connectors KEY and CM01.
11
nector) Between battery (+) terminal and each of CM01 (fe-
Max. 1 Ω
male) (1) and (2)
Between ground (GND11) and each of CM01 (female)
(3) and (4)
Between battery (+) terminal and KEY (female) (5) Max. 1 Ω
Between KEY (female) (1) and CM01 (female) (10) Max. 1 Ω
REMARK
required.
OFF position.
Ground fault in wiring 2. Disconnect fuses No. 8, 9, and 10 in fuse box F01, and disconnect con-
12 harness 2 (contact with
nectors KEY, CM01, PTCN3, WECN3, and EPP.
ground circuit)
3. Connect T-adapters to each female side of connectors KEY and CM01.
Between ground and each of CM01 (female) (1) and
Min. 1 MΩ
(2)
Resistance
Between ground and KEY (female) (1) or CM01 (fe-
Min. 1 MΩ
male) (10)
13
40-1182 D155AX-8
40 TROUBLESHOOTING CHINE MONITOR DISPLAYS NOTHING
Circuit diagram related to monitor power supply
D155AX-8 40-1183
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH
ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS
UP IN YELLOW 40 TROUBLESHOOTING
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH EN-

GINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN
YELLOW
Failure When starting switch is turned to ON position, machine monitor displays nothing.
• When starting switch is turned to ON position, machine monitor displays KOMATSU logo,
password input screen (if set), check preset setting screen, and standard screen in order.
Related • Battery voltage may drop sharply when engine is started, depending on ambient tempera-
information ture and battery condition. In this case, machine monitor display may disappear for a
while. This phenomenon is not abnormal.
• Check that battery disconnect switch is in ON position.

Low radiator coolant level Because radiator coolant level may be lowered, check and refill with coolant if level
1
(when system is normal) is lowered.
2. Disconnect connector WLV, and connect T-adapter to male side.
Defective coolant level
2
sensor (internal defect) Between FULL and LOW Max. 1 Ω
Between WLV (male) (1)
Resistance
and (2) Max. LOW Min. 1 MΩ
2. Disconnect connector CM02 and connect T-adapter to female side.
3 ness (wire breakage or REMARK
defective contact)
Refill with coolant.
Resistance Between CM02 (female) (3) and WLV (female) (1) Max. 1 Ω
Reference
Defective machine moni- 2. Insert T-adapter into connector CM02.
4
tor
Between CM02 (female) Between FULL and LOW Max. 1 V

Voltage
(3) and ground Max. LOW Min. 7 V
40-1184 D155AX-8
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH
ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS
40 TROUBLESHOOTING UP IN YELLOW
Circuit diagram related to radiator coolant level
D155AX-8 40-1185
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW
WHILE ENGINE IS RUNNING 40 TROUBLESHOOTING
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE

ENGINE IS RUNNING
Failure Air cleaner clogging monitor lights up in yellow while engine is running.
Related Signal from air cleaner clogging switch can be checked with monitoring function (Code: 04501
information "Monitor input 2").

properly)
Defective air cleaner Perform troubleshooting for failure code [AA10NX].
2
clogging switch system
40-1186 D155AX-8
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE
40 TROUBLESHOOTING IS RUNNING
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS

RUNNING
Failure Charge level monitor lights up in red while engine is running.
Related
Generated signal condition of alternator can be checked with monitoring function (Code: 04300)
information

1
circuit in terminal Check terminals of the alternator, etc.
Defective alternator (in- 2. Start engine and perform troubleshooting while running engine at medium
2
sufficient generation) speed or higher.
Voltage Between terminal AL/R and ground 20 to 30 V
2. Remove connector RSD and connect T-adapter to diode.
Defective diode RSD (in- REMARK

3 ternal open circuit or Measure it with diode range of multimeter.
short circuit)
No continui-
Between RSD (male) (1) (+) and (2) (-)
Continuity ty
Between RSD (male) (2) (+) and (1) (-) Continuity
2. Disconnect the battery ground cable.
Open circuit in wiring har- 3. Disconnect connectors CM01 and RSD, and connect T-adapter to female
ness (wire breakage or side of CM01.
4
4. Disconnect terminal AL/R
nector)
Between CM01 (female) (16) and AL/R Max. 1 Ω
Resistance
Between alternator terminal E and ground Max. 1 Ω
Ground fault in wiring 3. Disconnect connectors CM01, RSD, PTCN1, WECN1 and ST, and con-
nect T-adapter to female side of CM01.
ground circuit)
4. Disconnect terminal AL/R
Resistance Between CM01 (female) (16) and ground Min. 1 MΩ
Reference
2. Disconnect battery ground.
6 3. Insert T-adapter into connector CM01.
tor
4. Connect battery ground.
5. Start engine and perform troubleshooting at engine speed medium or high-
er
D155AX-8 40-1187
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE
IS RUNNING 40 TROUBLESHOOTING
40-1188 D155AX-8
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN
40 TROUBLESHOOTING RED WHILE ENGINE IS RUNNING
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED

WHILE ENGINE IS RUNNING
Failure Engine coolant temperature monitor lights up in red while engine is running.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
Related
transmitted to machine monitor through CAN communication system.
information
• Engine coolant temperature can be checked with monitoring function (Code: 04107)

Overheat of engine cool- Engine coolant may overheat. Check coolant temperature and remove cause of
1 ant (when system works failure if coolant overheats.
properly)
Defective machine moni- If no failure can be found in causes 1 and 2, machine monitor is defective. (Be-
3
tor cause this is an internal defect, troubleshooting cannot be performed.)
D155AX-8 40-1189
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE
ENGINE IS RUNNING 40 TROUBLESHOOTING
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE EN-

GINE IS RUNNING
Failure Engine oil pressure monitor lights up while engine is running.
• Engine oil pressure can be checked with monitoring function.
Related
• Information of engine oil pressure sensor is input to engine controller, and then it is trans-
information
mitted from engine controller to machine monitor through CAN communication system.

Low engine oil pressure Engine oil pressure may drops. Check it and remove cause of failure if oil pressure
1 (when system works is low.
properly)
2 sensor system may be defective. Perform troubleshooting for failure codes [CA135]
sure system
and [CA141].
3
40-1190 D155AX-8
E-11 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN
40 TROUBLESHOOTING RED WHILE ENGINE IS RUNNING
E-11 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED

Failure Power train oil temperature monitor lights up in red while engine is running.
• Torque converter oil temperature is used as power train oil temperature.
• Signal voltage of torque converter oil temperature sensor is input to power train controller,
Related
and its information is transfered by CAN communication to machine monitor.
information
• Torque converter (power train) oil temperature can be checked with monitoring function.
• (Code: 30100 T/C (P/L) oil temperature)

Overheating of power Power train oil may be overheating. If overheating is detected, repair cause of fail-
1 train oil (when system ure.
works properly)
3
D155AX-8 40-1191
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED
WHILE ENGINE IS RUNNING 40 TROUBLESHOOTING
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED

Failure Hydraulic oil temperature monitor lights up in red while engine is running.
• Signal voltage of hydraulic oil temperature sensor is input to pump controller that transmits
Related infor- information to machine monitor through CAN communication system.
mation • Hydraulic oil temperature can be checked with monitoring function.
• (Code: 04401)

Overheating of hydraulic Hydraulic oil may overheat. Check hydraulic oil temperature, and remove cause of
1 oil (when system is nor- failure if hydraulic oil overheats.
mal)
Defective hydraulic oil If failure code is still displayed after above checks on cause 1, hydraulic oil temper-
2 temperature sensor sys- ature sensor system or machine monitor may be defective. Perform troubleshooting
tem for failure codes [DGS1KA] and [DGS1KX].
3
40-1192 D155AX-8
E-13 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDI-
40 TROUBLESHOOTING CATE CORRECT TEMPERATURE
E-13 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE

CORRECT TEMPERATURE
1. While coolant temperature is rising normally, it does not rise from white range (C).
2. While coolant temperature is stabilized normally, it rises to red range (H).
Failure 3. Coolant temperature is different from indication of engine coolant temperature gauge.
4. Indication of engine coolant temperature gauge is different from indication of coolant tem-
perature monitor.
• Signal of coolant temperature sensor is input to engine controller, and then it is transmitted
Related to machine monitor through communication system.
information • Engine coolant temperature can be checked with monitoring function (Code: 04107 En-
gine coolant temperature)

If no failure is found check on cause 1, machine monitor is defective. (Because this
is an internal defect, troubleshooting cannot be performed.)
Reference:
Perform troubleshooting when starting switch is in ON position and engine is run-
ning.
Engine coolant tempera- Coolant temperature
Red
ture: 105 °C gauge level: 6
Defective machine moni- Red
2 ture: 102 °C gauge level: 5
tor
Color of Blue
monitor light
(a) Engine coolant tempera- Coolant temperature
Blue
Blue
Blue
Engine coolant temperature gauge and monitor
D155AX-8 40-1193
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 40 TROUBLESHOOTING
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL

1. Fuel level gauge does not indicate correct level.
Failure 2. Indication of fuel gauge is different from actual fuel level.
3. Indication of fuel gauge does not accord with indication of fuel level monitor.
Related Input signal (voltage signal) from fuel level sensor can be checked with monitoring function. (Code:
information 04200 fuel level sensor voltage)

2. Disconnect connector FLV, and connect T-adapter to male side.
Between FLV (female) (1) Fuel gauge: FULL Approx. 4 Ω
Defective fuel level sen- and (2)
1 sor (internal open or
short circuit) REMARK Approx.
Resistance Fuel gauge: EMPTY
Fuel level sensor charac- 85 Ω
teristics
Between ground and FLV (male) (2) Max. 1 Ω
2. Disconnect connector FLV, and connect T-adapter to female side.
REMARK
2 ground fault, or hot short • If voltage is 0 V, it has open circuit or ground fault. If voltage is 24 V, it has
circuit in wiring harness hot short circuit.
• Voltage of approximately 3.3 V is applied to fuel level sensor signal circuits
through resistor in machine monitor.
Approx.
Voltage Between FLV (female) (1) and (2)
3.3 V
quired.
2. Disconnect connector CM01 and connect T-adapter to female side.
3
wiring harness
• Resistance accords with fuel level sensor characteristics table in cause 1.
• If resistance is Min. 1 MΩ, it has open circuit. If resistance is Max. 1 Ω, it
has short circuit.
Resistance Between CM01 (female) (15) and (14) 4 to 85 Ω
required.
ness (wire breakage or 2. Disconnect connectors CM01 and FLV and connect T-adapters to each fe-
4
nector)
Between CM01 (female) (15) and FLV (female) (1) Max. 1 Ω
Resistance
Between CM01 (female) (14) and FLV (female) (2) Max. 1 Ω
40-1194 D155AX-8
40 TROUBLESHOOTING E-14 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL

quired.
5 harness (contact with 2. Disconnect connectors CM01 and FLV, and connect T-adapter to either fe-
Between ground and CM01 (female) (15) or FLV (fe-
male) (1)
2. Disconnect connectors CM01 and FLV, and connect T-adapter to female
Short circuit in wiring har- side of CM01.
6
ness
No continui-
Between CM01 (female) (15) and each pin other than
(15)
is heard)
(Because this is an internal defect, troubleshooting cannot be performed.)
Reference:
ning.
Defective machine moni- Fuel level: 560 Fuel gauge level: 6 Blue
7
tor Fuel level: 460 Fuel gauge level: 5 Blue
Color of Fuel level: 376 Fuel gauge level: 4 Blue
monitor light
(a) Fuel level: 197 Fuel gauge level: 3 Blue
Fuel level: 150 Fuel gauge level: 2 Red
Fuel level: Min. 106 Fuel gauge level: 1 Red
Circuit diagram related to fuel level sensor
D155AX-8 40-1195
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 40 TROUBLESHOOTING
Fuel level monitor
40-1196 D155AX-8
E-15 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDI-
40 TROUBLESHOOTING CATE CORRECT TEMPERATURE
E-15 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE

CORRECT TEMPERATURE
1. While power train oil temperature is increasing normally, gauge does not read higher than
white range (C).
2. While power train oil temperature is stabilized normally, gauge reads red range (H).
Failure
3. Power train oil temperature does not match to display of power train oil temperature.
4. Power train oil temperature gauge does not match to display of power train oil temperature
monitor.
• Torque converter oil temperature is used as power train oil temperature.
Related • Signal voltage of torque converter oil temperature sensor is input to power train controller,
and its information is transfered by CAN communication to machine monitor.
information
• Torque converter (power train) oil temperature can be checked with monitoring function
(Code: 30100 T/C (P/L) oil temperature).

Reference:
ning.
Power train oil tempera- Power train oil tempera-
Red
ture: 130 °C ture gauge level: 6
2 ture: 120 °C ture gauge level: 5
tor
Color of Blue
monitor light
(a) Power train oil tempera- Power train oil tempera-
Blue
Blue
Blue
POWER TRAIN OIL TEMPERATURE GAUGE AND POWER TRAIN OIL TEMPERA-
TURE MONITOR
D155AX-8 40-1197
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE
CORRECT TEMPERATURE 40 TROUBLESHOOTING
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE COR-

RECT TEMPERATURE
1. While hydraulic oil temperature is rising normally, it does not rise from white range (C).
2. While hydraulic oil temperature is stabilized normally, it rises to red range (H).
Failure 3. Hydraulic oil temperature is different from indication of hydraulic oil temperature gauge.
4. Indication of hydraulic oil temperature gauge is different from indication of hydraulic oil
temperature monitor.
• Signal voltage from hydraulic oil temperature sensor is input to work equipment controller
Related and then data is transmitted to machine monitor through CAN communication system.
information • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 "Hy-
draulic Oil Temperature")

Defective hydraulic oil If failure code is still displayed after above checks on cause 1, hydraulic oil temper-
1 temperature sensor sys- ature sensor system or machine monitor may be defective. Perform troubleshooting
tem for failure codes [DGS1KA] and [DGS1KX].
• Reference
ning.
Hydraulic oil temperature Hydraulic oil temperature:
Red
level: 6 105°C
2 level: 5 102°C
tor
Color when Blue
level: 4 98°C
monitor
lights up Hydraulic oil temperature Hydraulic oil temperature:
Blue
level: 3 70°C
Blue
level: 2 20°C
Blue
level: 1 0°C
HYDRAULIC OIL TEMPERATURE GAUGE AND HYDRAULIC OIL TEMPERATURE

MONITOR
40-1198 D155AX-8
40 TROUBLESHOOTING E-17 OPERATION MODE DOES NOT CHANGE
E-17 OPERATION MODE DOES NOT CHANGE

1. Operation mode switch cannot switch the operation mode monitor.
Failure
2. Engine output does not change after the operation mode has been changed.
Related • Before performing troubleshooting, check that no related failure code is displayed.
(If failure code [DBERKR] or [DB2RKR] is displayed, perform troubleshooting for those co-
information des first.)

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)
If engine output is changed when turning operation mode switch, engine controller
is normal.
Engine controller may be defective. (In case of an internal defect, troubleshooting is
Defective engine control- impossible as an assembly. Replace whole assembly.)
2
ler
D155AX-8 40-1199
E-18 OPERATION MODE DOES NOT CHANGE 40 TROUBLESHOOTING
E-18 OPERATION MODE DOES NOT CHANGE

1. Gear shift mode switch cannot switch the gear shift mode display section.
Failure
2. Changing the gear shift mode does not change the power train gear shift setting.
Related • Before performing troubleshooting, check that no related failure code is displayed.
(If failure code [DBEQKR], [DBERKR], [DK40KA], [DK40KY], [DLT3KA], or [DLT3KB] is
information displayed, perform troubleshooting for those codes first.)

1
Defective power train Power train controller may be defective. (In case of an internal defect, troubleshoot-
2
controller ing is impossible as an assembly. Replace whole assembly.)
40-1200 D155AX-8
E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUS-
40 TROUBLESHOOTING TOMIZE SCREEN
E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE

SCREEN
Failure Operating customize switch does not display customize screen.
Related
information

1
D155AX-8 40-1201
E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT
CHANGE SETTING OF MACHINE 40 TROUBLESHOOTING
E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE

SETTING OF MACHINE
Failure Modifying setting on customize screen does not change setting of machine.
Related
information

Defective engine control- Engine controller, power train controller, or work equipment controller may be de-
ler, power train controller, fective. (In case of an internal defect, troubleshooting is impossible as an assembly.
1
or work equipment con- Replace whole assembly.)
troller
2
40-1202 D155AX-8
E-21 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DIS-
40 TROUBLESHOOTING PLAYED
E-21 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DIS-

PLAYED
Failure • Some areas of machine monitor screen are not displayed.
Related • One of the features of liquid crystal display panels is that there may be black spots (spots
that do not light up) or white spots (spots that stay lit) on the screen. When there are fewer
information than 10 black or white spots, this is not a failure or a defect.
Defective machine moni- Perform troubleshooting when starting switch is in ON position.

tor When all the lights of liquid crystal display panel is on (entirely white) by the follow-
1
(Liquid crystal display ing switch operation, machine monitor is normal.
panel part) • Switch operation: [4]+[F2] (Press them simultaneously.)
Defective machine moni- If no failure is found check on cause 1, machine monitor is defective. (Because this
2
tor is an internal defect, troubleshooting cannot be performed.)
D155AX-8 40-1203
E-22 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP
SOUNDING 40 TROUBLESHOOTING
E-22 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUND-
ING
Failure • Alarm buzzer does not sound or does not stop sounding.
Related
information

1
Defective power train Power train controller may be defective. (In case of an internal defect, troubleshoot-
2
controller ing is impossible as an assembly. Replace whole assembly.)
Defective work equip- Work equipment controller may be defective. (In case of an internal defect, trouble-
3
ment controller shooting is impossible as an assembly. Replace whole assembly.)
40-1204 D155AX-8
E-23 SERVICE METER IS NOT DISPLAYED, WHILE STARTING
40 TROUBLESHOOTING SWITCH IS IN OFF POSITION
E-23 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS

IN OFF POSITION
Failure Service meter is not displayed while starting switch is in OFF position.
Related • The following switch operation with the starting switch set to OFF position displays a serv-
ice meter in the upper middle of the screen.
information Operation of switches: [4]+[1] (pressed simultaneously)

When starting switch is turned to ON position, if machine monitor displays nothing,
Defective backup power
1 backup power supply system may be defective. Perform troubleshooting for “E-3
supply system
When starting switch is turned to ON position, machine monitor displays nothing”.
Defective machine moni- If no failure is found check on cause 1, machine monitor is defective. (Because this
2
tor is an internal defect, troubleshooting cannot be performed.)
D155AX-8 40-1205
E-24 SERVICE MODE CANNOT BE SELECTED 40 TROUBLESHOOTING
E-24 SERVICE MODE CANNOT BE SELECTED

Failure Service mode cannot be selected.
Related • Service mode is enabled with the following switch operation:

Operation of switches: [4] + [1]→[2]→[3] (While pressing [4], press [1], [2] and [3] in this
information order.)

1
40-1206 D155AX-8
40 TROUBLESHOOTING E-25 HORN DOES NOT SOUND
E-25 HORN DOES NOT SOUND

Failure Horn does not sound.
Related
information

If fuse F01-4 is blown out, the circuit probably has ground fault. In this case, per-
1 Defective fuse F01-4
form check on cause 8 first.
2. Disconnect horn switch terminal (no polarity).
2 Defective horn switch 3. Turn horn switch to ON and OFF positions, and perform troubleshooting.
OFF Min. 1 MΩ
Resistance
ON Max. 1 Ω
2. Replace horn relay (HRN) with another relay.
3 Defective horn relay 3. Turn the battery disconnect switch ON.
4. Turn horn switch ON.
If horn sounds, original horn relay is defective.
2. Disconnect connector LHD and connect T-adapter to female side.
4 Defective wiring harness 3. Turn battery disconnect switch to ON position.
Voltage Between LHD (female) (C) and ground 20 to 30 V
Open circuit in in wiring 2. Remove fuse F01-4.
5
harness or horn 3. Turn horn switch ON.
Continuity Between F01-4 and ground Continuity
6 Open circuit in horn 2. Disconnect connector LHD.
Continuity Between LHD(male)(C) and ground Continuity
Open circuit in wiring har- 　If any failure is found by check on Cause 5 and failure code is still displayed after
7 ness (wire breakage or above checks on Cause 6, wiring harness has open circuit.
defective contact)
REMARK
If fuse is not burnt out, this check is not required.
8 harness (contact with 2. Insert T-adapter into LHD.
ground circuit) 3. Remove fuse F01-4.
Resistance Between LHD (C) and ground Min. 1 MΩ
Defective horn (internal If failure code is still displayed after above checks, horn may be defective.
9
defect)
D155AX-8 40-1207
E-25 HORN DOES NOT SOUND 40 TROUBLESHOOTING
Circuit diagram related to horn
40-1208 D155AX-8
40 TROUBLESHOOTING E-26 HORN DOES NOT STOP SOUNDING
E-26 HORN DOES NOT STOP SOUNDING

Failure Horn does not stop sounding.
Related
information

2. Disconnect horn switch terminal (no polarity).
1 Defective horn switch 3. Turn horn switch to ON and OFF positions, and perform troubleshooting.
OFF Min. 1 MΩ
Resistance
ON Max. 1 Ω
Hot short circuit in wiring 2. Insert T-adapter into LHD.
V circuit)
Voltage Between LHN (C) and ground Max. 1 V
Defective horn (internal If failure code is still displayed after above checks, horn may be defective.
3
defect)
Circuit diagram related to horn
D155AX-8 40-1209
E-27 BACKUP ALARM DOES NOT SOUND 40 TROUBLESHOOTING
E-27 BACKUP ALARM DOES NOT SOUND

Failure Backup alarm does not sound.
Related
If ground fault occurs in backup alarm circuit, failure code [DV20KB] is displayed.
information

2. Disconnect connector BKAL and connect T-adapter to female side.
1 Defective wiring harness 4. Perform reverse travel operation.
k When traveling machine, do not measure under it.
Voltage Between BKAL (1) and (2) 20 to 30 V
REMARK
required.
ness 1. Turn starting switch to OFF position.
2
(wire breakage or defec- 2. Disconnect connectors PTCN2 and BKAL, and connect T-adapters to each
tive contact) female side.
Between PTCN2 (female) (28) and BKAL (female) (1) Max. 1 Ω
Resistance
Between BKAL (female) (2) and ground Max. 1 Ω
2. Disconnect connectors PTCN2 and BKAL, and connect T-adapter to either fe-
harness
3 male side.
cuit) Between ground and BKAL (female) (1) or PTCN2 (fe-
male) (28)
Defective back-up alarm If failure code is still displayed after above checks, backup alarm may be defective.
4
(Internal defect)
40-1210 D155AX-8
40 TROUBLESHOOTING E-28 BACKUP ALARM DOES NOT STOP SOUNDING
E-28 BACKUP ALARM DOES NOT STOP SOUNDING

Failure Backup alarm does not stop sounding.
Related
information

2. Disconnect connector BKAL and connect T-adapter to female side.
1 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) Between BKAL (female) (1) and (2) Max. 1 V
Voltage
Between BKAL (female) (1) and ground Max. 1 V
Defective back-up alarm If failure code is still displayed after above checks, backup alarm may be defective.
2
(Internal defect)
D155AX-8 40-1211
E-29 HEADLAMP DOES NOT LIGHT UP 40 TROUBLESHOOTING
E-29 HEADLAMP DOES NOT LIGHT UP

Failure Headlamp does not light up.
Related • If a harness shared between a headlamp switch, diode, and right and left headlamps is
defective, both right and left headlamps do not light up (if either of the headlamps lights
information up, checking the cause of these failures is not required).

1 Defective headlamp Since headlamp may be defective, check its bulb for breakage.
2
CB4
3 Defective fuse (F01-19) If fuse is blown, circuit may have ground fault, etc.
2. Replace headlamp relay for the side that does not light up (connector: LMFL or
LMFR) with preheating relay (connector: PHR).
Defective headlamp relay 3. Turn starting switch to ON position.
4 (LMFL or LMFR) (internal Failure code [CA2555] is displayed on machine monitor when preheat relay is
open or short circuit) removed. Ignore it in this case.
4. Turn on headlamp switch.
If headlamp switch lights up, original headlamp relay is defective.
2. Disconnect connector FLSW and connect T-adapter to male side.
3. Turn ON and OFF headlamp switch and perform troubleshooting.
REMARK
Defective headlamp Headlamp switch has ON positions on both sides.
5
switch Between FLSW (male) (5)
and (6) or between (4) and Headlamp: OFF Min. 1 MΩ
(5)
Resistance
Between FLSW (male) (5)
and (6) or between (4) and Headlamp: ON Max. 1 Ω
(5)
2. Remove connectors LMD1 and LMD2, and connect T-adapter to diode.
REMARK
Defective diode (LMD1 or Measure it with diode range of multimeter.
LMD2) No continui-
6 Between LMD1 (male) (1) (+) and (2) (-)
(internal open or short ty
circuit)
Between LMD1 (male) (2) (+) and (1) (-) Continuity
Continuity
No continui-
Between LMD2 (male) (1) (+) and (2) (-)
ty
Between LMD2 (male) (2) (+) and (1) (-) Continuity
40-1212 D155AX-8
40 TROUBLESHOOTING E-29 HEADLAMP DOES NOT LIGHT UP
REMARK
Check to find from which point the voltage is abnormal to help locate the defec-
tive point in warning harness.
2. Disconnect connectors LHDR and LHDL, and connect T-adapters to each
female side.
Between LHDL (female) (1) and (2) 20 to 30 V
Voltage
Between LHDR (female) (1) and (2) 20 to 30 V
REMARK
Open or short circuit in 2. Disconnect connectors LMFL and LMFR, and connect T-adapters to each
7
wiring harness female side.
Between LMFL (female) (1) and (2) 20 to 30 V
Between LMFL (female) (3) and (2) 20 to 30 V
Voltage
Between LMFR (female) (1) and (2) 20 to 30 V
Between LMFR (female) (3) and (2) 20 to 30 V
REMARK
2. Disconnect connector FLSW and connect T-adapter to female side.
Voltage Between FLSW (female) (5) and (2) 20 to 30 V
D155AX-8 40-1213
E-29 HEADLAMP DOES NOT LIGHT UP 40 TROUBLESHOOTING
REMARK
required.
2. Remove fuse F01-19.
3. Disconnect connectors FLSW, LMD1, LMD2, LMFL, LMFR, LHDR, LHDL,
KEY and F105, and connect T-adapters to each female side.
Between LHDR (male) (2) and ground Max. 1 Ω
Between LHDL (male) (2) and ground Max. 1 Ω
Between LHDR (female) (1) and LMFR (female) (5) Max. 1 Ω
Open circuit in wiring har- Between LHDL (female) (1) and LMFL (female) (5) Max. 1 Ω
ness
8 Between LMFL (female) (1) and LMD1 (female) (1) Max. 1 Ω
(wire breakage or defec-
tive contact of connector) Between LMD1 (female) (1) and LMD2 (female) (1) Max. 1 Ω
Between LMFL (female) (2) and ground Max. 1 Ω
Resistance Between LMFL (female) (3) and F105 (female) (1) Max. 1 Ω
Between LMFL (female) (1) and LMFR (female) (1) Max. 1 Ω
Between FLSW (female) (6) and LMD2 (female) (2) Max. 1 Ω
Between FLSW (female) (4) and LMD1 (female) (2) Max. 1 Ω
Between FLSW (female) (5) and KEY (female) (1) Max. 1 Ω
Between FLSW (female) (2) and ground Max. 1 Ω
REMARK
required.
1. Turn the starting switch to ON position and turn it OFF immediately.
REMARK
Ground fault in wiring Close circuit breaker CB4 (to reproduce ground fault).
harness 2. Remove fuse F01-19.
9
(contact with ground cir- 3. Disconnect connectors LMD1, LMD2, LMFL, LHDR and LHDL, and con-
cuit)
nect T-adapter to female side of LMFL.
Between LMFL (female) (1) and ground Min. 1 MΩ
Between LMFL (female) (3) and ground (** Only when
Resistance circuit breaker is operated, resistance value is 1 MΩ of Min. 1 MΩ
standard value.
Between LMFL (female) (5) and ground Min. 1 MΩ
40-1214 D155AX-8
40 TROUBLESHOOTING E-29 HEADLAMP DOES NOT LIGHT UP
Circuit diagram related to headlamp and rear lamp
D155AX-8 40-1215
E-30 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP 40 TROUBLESHOOTING
E-30 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP

Failure Rear lamp and ripper point lamp do not light up.
• If a harness shared between a fuse, rear lamp relay, rear lamp switch and ripper point
lamp is defective, both the rear lamp and ripper point lamp do not light up (if either of the
Related rear lamp or the ripper point lamp lights up, checking the cause of these failures is not re-
quired).
information
REMARK
Connector LREL of the rear lamp and connector LRP2 of the ripper point lamp are optional.

Defective rear lamp Since the rear lamp may be defective, check its bulb for breakage.
1
(burned-out bulb)
Defective ripper point Because ripper point lamp may be defective, check for burned-out bulb.
2 lamp
(burned-out bulb)
Defective circuit breaker If circuit breaker is tripped, circuit probably has ground fault, etc.
3
CB5
If fuse is burnt out, circuit may have ground fault, etc.
4 Defective fuse (F01-19) REMARK
If fuse is not burnt out, front lamp does not light up either.
2. Replace relay (connector LMRE) with preheat relay (connector PHR).
Failure cause of rear
lamp relay REMARK
5
(Internal open or short Failure code [CA2555] is displayed on machine monitor if preheat relay
circuit) (PHR) is removed. Ignore it in this case.
4. Turn on rear lamp switch.
If rear lamp lights up, original rear lamp relay is defective.
2. Disconnect connector RLSW and connect T-adapter to male side.
3. Turn ON and OFF rear lamp switch to perform troubleshooting.
Defective rear lamp
6 Between RLSW (male) (5)
switch OFF 1 MΩ
and (6)
Resistance
Between RLSW (male) (5)
ON 1 Ω
and (6)
Between LRER (female) (1) and (2) 20 to 30 V

Between LREL (female) (1) and (2) (* only for option
20 to 30 V
Voltage machine)
Open circuit or ground Between LRP2 (female) (1) and (2) (* only for option
7 20 to 30 V
fault in wiring harness machine)
Between LMRE (female) (1) and (2) 20 to 30 V
Voltage
Between LMRE (female) (3) and (2) 20 to 30 V
Voltage Between RLSW (female) (5) and (2) 20 to 30 V
40-1216 D155AX-8
40 TROUBLESHOOTING E-30 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP
REMARK
required.
2. Disconnect connectors F105, RLSW, LMRE, LRER, LREL (* only for op-
tion machine), LRP2 (* only for option machine), and KEY, and connect T-
adapters to each female side.
Between LRER (female) (2) and ground Max. 1 Ω
Between LRER (female) (1) and LMRE (female) (5) Max. 1 Ω
Between LMRE (female) (1) and RLSW (female) (1) or
Open circuit in wiring har- Max. 1 Ω
(5)
ness
8 Between LMRE (female) (2) and ground Max. 1 Ω
(open circuit or defective
contact) Between LMRE (female) (3) and F105 (male) (1) Max. 1 Ω
Between RLSW (female) (3) and KEY (female) (1) Max. 1 Ω
Resistance Between RLSW (female) (2) and ground Max. 1 Ω
Between LREL (female) (2) and ground (* only for op-
Max. 1 Ω
tion machine)
Between LRP2 (female) (2) and ground (* only for op-
Max. 1 Ω
tion machine)
Between LREL (female) (1) and LMRE (female) (5) (*
Max. 1 Ω
only for option machine)
Between LRP2 (female) (1) and LMRE (female) (* only
Max. 1 Ω
for option machine)
REMARK
required.
1. Turn starting switch to ON position, and then turn starting switch to OFF
position immediately.
REMARK
Ground fault in wiring Operate circuit breaker CB5 (reproduce ground fault).
harness 2. Remove fuse F01-19.
9
(Contact with ground cir- 3. Disconnect connectors LMRE, LRER, LRP2 (* only for option machine)
cuit)
and LREL (* only for option machine), and connect T-adapter to female
side of LMRE.
Between LMRE (female) (1) and ground Min. 1 MΩ
Between LMRE (female) (3) and ground (** Only when
Resistance circuit breaker is operated, resistance value is 1 of Min. 1 MΩ
standard value.
Between LMRE (female) (5) and ground Min. 1 MΩ
D155AX-8 40-1217
E-30 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP 40 TROUBLESHOOTING
Circuit diagram related to headlamp and rear lamp ripper point lamp
40-1218 D155AX-8
40 TROUBLESHOOTING E-31 NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY
E-31 NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY

Failure No wiper operates continuously or intermittently.
• If one of the windshield wipers can work, checking circuit breaker CB31 and fuse 4 in fuse
box FS51 is not required.
• 24 V power is supplied to wiper intermittent units CB26 and CB27 continuously or intermit-
tently from the wiper intermittent switch.
• T-adapter is not provided to the connector of wiper intermittent units CB26 and CB27
(check without a T-adapter).
• Wiper intermittent units CB26 and CB27 have two wiper intermittent circuits respectively.
Description of pins on the wiper intermittent unit
(1):GND1
Related
(2):Relay output 1 (power supply 1 to wiper motor)
information
(3):Continuous 24 V input
(4):Intermittent 24 V input
(6):24 V common input
(7):24 V pulse input 2 from wiper motor
(9):GND2
• Check an open circuit in wiring harness in Pins 1, 2, 3, 4, 6, and 9 of the wiper intermittent
unit in this troubleshooting because there are no T-adapters.

If any of fuses at is blown out, the circuit probably has ground fault. In this case,
perform check on cause 4 first.
Defective fuse No. 4, 5, • If fuse 4 in fuse box FS51 is defective, no wiper operates.
1
or 6 in fuse box FS51. • If fuse 5 in fuse box is defective, front and rear wipers do not operate.
• If fuse 6 in fuse box is defective, R.H. door wiper and L.H. door wipers do
not operate.
2. Disconnect connector CB11, and connect T-adapter to male side.
3. Turn intermittent switch to ON and OFF positions, and perform trouble-
shooting.
Defective wiper intermit-
2 OFF Max. 1 Ω
tent switch Between CB11 (male) (3)
and (4) ON Min. 1 MΩ
Resistance
Between CB11 (male) (5) OFF Max. 1 Ω
and (6) ON Min. 1 MΩ
D155AX-8 40-1219
E-31 NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY 40 TROUBLESHOOTING

If any wiper operates, this check is not required.
Voltage Between fuse box B3 terminal and ground 20 to 30 V

If any wiper operates, this check is not required.
2. Disconnect connector CB11, and connect T-adapter to female side.
Between CB11 (female) (4) or (5) and terminal of fuse
4 of fuse box FS51
• Wiper intermittent unit
2. Disconnect connector CB11 to CB15, CB23 and CB24, and connect T-
adapter to female side.
REMARK
There are many diodes in internal circuit. Pay attention to tester polarity.
REMARK
If “OFF” is not displayed for resistance value in multimeter, this means that
3 ness (wire breakage or open circuit does not occur.
defective contact) Check for open circuit in 1 and 3 pins of CB26. Be-
1 to 50 MΩ
tween CB11 (female) (3) (+) and CB14 (female) (3) (-)
Check for open circuit of 4 and 9 pins of CB26. Be-
1 to 50 MΩ
Resistance
1 to 50 MΩ
1 to 50 MΩ
• Wiper intermittent unit
2. Insert T-adapters into connectors CB23 and CB24.
4. Turn front and left wiper switches to ON position.
5. Turn intermittent switch to OFF position.
20 to 30 V
tween CB23 (6) and ground
Voltage
20 to 30 V
tween CB24 (3) and ground
40-1220 D155AX-8

required.
2. Remove fuses 4 to 6 in fuse box FS51.
3. Disconnect connectors CB11, CB17, CB23, CB24, CB26, CB27 and CB37.
Ground fault in wiring Between fuse box B3 terminal and ground Min. 1 MΩ
ground circuit) Between terminal of fuse 4 in fuse box and ground Min. 1 MΩ
Between terminal of fuse 5 in fuse box and ground Min. 1 MΩ
Resistance
Between terminal of fuse 6 in fuse box and ground Min. 1 MΩ
Between CB11 (female) (3) and ground Min. 1 MΩ
D155AX-8 40-1221
E-31 NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY 40 TROUBLESHOOTING
Circuit diagram related to wiper
40-1222 D155AX-8
D155AX-8 40-1223
E-32 FRONT WIPER DOES NOT OPERATE (FAILED IN BOTH CON-
TINUOUS AND INTERMITTENT OPERATIONS) 40 TROUBLESHOOTING
E-32 FRONT WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINU-

OUS AND INTERMITTENT OPERATIONS)
Failure Front wiper does not operate (failed in both continuous and intermittent operations).
• See E-mode in “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY“ if a
rear windshield wiper does not work either.
• The wiper motor is driven by the power supplied from front and rear wiper intermittent unit
CB26 even during continuous operation.
• The wiper motor detects a stop position and pulses 24 V voltage from the fuse.
• The wiper motor is driven by 24 V voltage pulse interchanged with front and rear wiper in-
termittent unit CB26 during intermittent operation.
• Pins which are associated with this failure in wiper intermittent unit CB 26 are as follows.
Related 1. (1):GND1
information
2. (2):Relay output 1 (power supply 1 to wiper motor)
3. (3):Continuous (24 V) input
4. (4):Intermittent (24 V) input
5. (6):24 V common input
6. (8):24 V pulse input 1 from wiper motor
• Check an open circuit in wiring harness in pins 2 and 8 of wiper intermittent unit CB26 in
this troubleshooting. See E-mode in “NO WIPER OPERATES CONTINUOUSLY OR IN-
TERMITTENTLY“ for an open circuit in other pins.

Defective front wiper mo- 2.
1 Disconnect connector CB23, and connect T-adapter to male side.
tor (internal open circuit)
Continuity Between CB23 (6) and (1) Continuity
REMARK
Check that right and left door wipers operate.
2. Disconnect connectors CB26 and 27, and switch wiper intermittent units.
Defective front and rear 3. Turn starting switch to ON position.
2 (F, R) wiper intermittent
unit (internal open circuit) 4. Turn front wiper switch to ON position.
If front wiper is normal, originally provided front and rear wiper intermittent unit is
defective.
Reference: Between CB26 (male) (2) and (8) Max. 1 Ω
Resistance
Reference: Between CB26 (male) (2) and (6) Min. 1 MΩ
Defective front wiper 4. Turn switch to ON and OFF positions, and perform troubleshooting.
3
switch
Between CB14 (male) (2)
OFF Min. 1 MΩ
and (3)
Resistance
ON Max. 1 Ω
and (3)
40-1224 D155AX-8
40 TROUBLESHOOTING TINUOUS AND INTERMITTENT OPERATIONS)

• Ground
2. Disconnect connector CB14 and connect T-adapter to female side.
Resistance Between CB14 (female) (2) and ground Max. 1 Ω
• Wiper motor power from fuse
Voltage Between CB23 (3) and (1) 20 to 30 V
Open circuit in wiring har- 2. Remove fuse 5 in fuse box FS51.
defective contact)
REMARK
If no failure is found in wiper motor power supply,
Between CB23 (female) (3) and terminal of fuse 5 of
fuse box FS51
Resistance REMARK
If no failure is found in wiper motor power supply, Max. 1 Ω
Between CB23 (female) (1) and ground
Max. 1 Ω
tween CB23 (female) (2) and (6)
2. Disconnect connector CB23 and CB26, and connect T-adapter to female
ground circuit) Between CB23 (female) (2) and ground Min. 1 MΩ
Resistance
If failure code is still displayed after above checks, front wiper motor is defective.
• Reference
2. Insert T-adapter into connector CB23.
Defective front wiper mo-
6 tor (failure in stop posi- 4. Turn front wiper switch to ON position.
tion detection)
REMARK
Voltage is applied when operating windshield wiper (GND at wiper stop position
and during wiper intermittent).
Between CB23 (2) and (1) 20 to 30 V
Voltage
D155AX-8 40-1225
TINUOUS AND INTERMITTENT OPERATIONS) 40 TROUBLESHOOTING
40-1226 D155AX-8
40 TROUBLESHOOTING TINUOUS AND INTERMITTENT OPERATIONS)
D155AX-8 40-1227
E-33 REAR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTIN-
UOUS AND INTERMITTENT OPERATIONS) 40 TROUBLESHOOTING
E-33 REAR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS

AND INTERMITTENT OPERATIONS)
Failure Rear wiper does not operate (failed in both continuous and intermittent operations).
• See E-mode in “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY“ if a
front windshield wiper does not work either.
• The wiper motor is driven by the power supplied from front and rear wiper intermittent unit
CB26 even during continuous operation.
• The wiper motor detects a stop position and pulses 24 V voltage from the fuse.
• The wiper motor is driven by 24 V voltage pulse interchanged with front and rear wiper in-
termittent unit CB26 during intermittent operation.
• Pins which are associated with this failure in wiper intermittent unit CB 26 are as follows.
Related
(3): Continuous 24 V input
information
(4): Intermittent 24 V input
(5): Relay output 2 (power supply 2 to wiper motor)
(6): 24 V common input
(7): 24 V pulse input 2 from wiper motor
(9): GND2
• Check an open circuit in wiring harness in pins 5 and 7 of wiper intermittent unit CB26 in
this troubleshooting. See E-mode in “NO WIPER OPERATES CONTINUOUSLY OR IN-
TERMITTENTLY“ for an open circuit in other pins.

Defective rear wiper mo- 2.
1 Disconnect connector CB37, and connect T-adapter to male side.
tor (internal open circuit)
REMARK
Check that right and left door wipers operate.
2. Disconnect connectors CB26 and 27, and switch wiper intermittent units.
Defective front and rear 3. Turn starting switch to ON position.
2 (F, R) wiper intermittent
unit (internal open circuit) 4. Turn rear wiper switch to ON position.
If rear wiper is normal, originally provided front and rear wiper intermittent unit is
defective.
Resistance
Defective rear wiper 4. Turn switch to ON and OFF positions, and perform troubleshooting.
3
switch
OFF Min. 1 MΩ
and (3)
Resistance
ON Max. 1 Ω
and (3)
40-1228 D155AX-8
40 TROUBLESHOOTING UOUS AND INTERMITTENT OPERATIONS)

• Ground
Open circuit in wiring har- 2. Remove fuse 5 in fuse box.
4 ness (wire breakage or 3. Disconnect connector CB37 and connect T-adapter to female side.
defective contact)
REMARK
fuse box
Resistance REMARK
Check for open circuit of 5 and 7 pins of CB26.
Max. 1 Ω
Between CB37 (female) (4) and (3)
Resistance
If failure code is still displayed after above checks, rear wiper motor is defective.
• Reference
Defective rear wiper mo-
6 tor (failure in stop posi- 4. Turn rear wiper switch to ON position.
tion detection) REMARK
Voltage
D155AX-8 40-1229
UOUS AND INTERMITTENT OPERATIONS) 40 TROUBLESHOOTING
40-1230 D155AX-8
40 TROUBLESHOOTING UOUS AND INTERMITTENT OPERATIONS)
D155AX-8 40-1231
E-34 LEFT DOOR WIPER DOES NOT OPERATE (FAILED IN BOTH
CONTINUOUS AND INTERMITTENT OPERATIONS) 40 TROUBLESHOOTING
E-34 LEFT DOOR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTIN-
UOUS AND INTERMITTENT OPERATIONS)
Failure Left door wiper does not operate (failure continuous and intermittent operations).
• If right door wiper does not operate either, see E-mode in “NO WIPER OPERATES CON-
TINUOUSLY OR INTERMITTENTLY“.
• Left door wiper motor is driven by power supplied from L.H. and R.H. door wiper intermit-
tent unit CB27 even in continuous operation mode.
• Wiper motor detects stop position and converts 24 V voltage supplied from fuse into pulse
voltage.
• In intermittent operation mode, wiper motor operates while exchanging 24 V pulses with
L.H. and R.H. door wiper intermittent unit CB27.
Related • Following pins on wiper intermittent unit CB27 are associated with this troubleshooting.
information (1):GND1
(3):Continuous (24 V) input
(4):Intermittent (24 V) input
(6):Common 24 V input
In this troubleshooting, open circuit in wiring harnesses connected to pins 2 and 8 on wiper intermit-
tent unit CB27 are checked. See E-mode in “NO WIPER OPERATES CONTINUOUSLY OR INTER-
MITTENTLY“ for an open circuit in other pins.

Defective left door wiper
1 motor (internal open cir- 2. Disconnect connector CB24 and connect T-adapter to male side.
cuit)
REMARK
Check that front and rear wipers operate normally.
2. Disconnect connectors CB26 and 27, and interchange wiper intermittent
units with each other.
Defective L.H. and R.H.
2 door wiper intermittent 3. Turn starting switch to ON position.
unit (internal open circuit) 4. Turn on left door wiper switch.
If left door wiper operates normally, original L.H. and R.H. door wiper intermittent
unit is defective.
Resistance
Defective left door wiper 4. Turn on and off switch to perform troubleshooting.
3
switch
OFF Min. 1 MΩ
and (3)
Resistance
ON Max. 1 Ω
and (3)
40-1232 D155AX-8
40 TROUBLESHOOTING CONTINUOUS AND INTERMITTENT OPERATIONS)

• Ground
ness (wire breakage or 2. Remove fuse 6 of fuse box.
4
defective contact of con- 3. Disconnect connector CB24 and connect T-adapter to female side.
nector)
REMARK
If failure code is still displayed after above checks
on wiper motor power, this check is not required. Max. 1 Ω
Between CB24 (female) (4) and fuse 6 terminal of fuse
box
Resistance REMARK
If failure code is still displayed after above checks Max. 1 Ω
on wiper motor power, this check is not required.
Check of open circuit in wiring harness connecting pins
Max. 1 Ω
2 and 8 on CB27 between CB24 (female) (2) and (3)
Ground fault in wiring 2. Disconnect connectors CB24 and CB27, connect T-adapter to female side.
ground circuit) Between CB24(female)(2) and ground Min. 1 MΩ
Resistance
Between CB24(female)(3) and ground Min. 1 MΩ
If failure code is still displayed after above checks, left door wiper motor is defec-
tive.
• Reference
Defective left door wiper 3. Turn starting switch to ON position.
6 motor (failure in stop po- 4. Turn on left door wiper switch.
sition detection)
REMARK
Voltage
D155AX-8 40-1233
40-1234 D155AX-8
D155AX-8 40-1235
E-35 RIGHT DOOR WIPER DOES NOT OPERATE (FAILED IN BOTH
E-35 RIGHT DOOR WIPER DOES NOT OPERATE (FAILED IN BOTH CON-
TINUOUS AND INTERMITTENT OPERATIONS)
Failure Right door wiper does not operate (failed in both continuous and intermittent operations).
• If left door wiper does not operate, see E-mode in “NO WIPER OPERATES CONTINU-
OUSLY OR INTERMITTENTLY“.
• Power is supplied from right door (LH, RH) wiper intermittent unit CB27 and wiper motor
operates even in continuous operation.
• Wiper motor detects stop position and performs pulsing of 24 V voltage from fuse.
• Left door and right door (LH, RH) wiper intermittent unit CB27 and 24 V voltage pulse is
received/delivered and wiper motor operates in intermittent operation.
• Pins related to this failure in wiper intermittent unit CB27 are described below.
Related
(3):Continuous 24 V input
information
(4):Intermittent 24 V input
(6):24 V common input
(9):GND2
• In this troubleshooting, open circuit in wiring harness of 5 and 7 pins of wiper intermittent
unit CB27 is checked. For open circuit in other pins, see E-mode in “NO WIPER OPER-
ATES CONTINUOUSLY OR INTERMITTENTLY“.

Defective right door wiper
1 motor (internal open cir- 2. Disconnect connector CB17, and connect T-adapter to male side.
cuit)
REMARK
Check that front and rear wipers operate normally.
2. Disconnect connectors CB26 and 27, and interchange wiper intermittent
units with each other.
Defective L.H. and R.H.
2 door wiper intermittent 3. Turn starting switch to ON position.
unit (internal open circuit) 4. Turn on right door wiper switch.
If right door wiper operates normally, original L.H. and R.H. door wiper intermittent
unit is defective.
Resistance
Defective right door wiper 4. Turn switch to ON and OFF positions, and perform troubleshooting.
3
switch
OFF Min. 1 MΩ
and (3)
Resistance
ON Max. 1 Ω
and (3)
40-1236 D155AX-8

• Ground
Open circuit in wiring har- 2. Remove fuse 6 in fuse box.
4 ness (wire breakage or 3. Disconnect connector CB17 and connect T-adapter to female side.
defective contact)
REMARK
fuse box
Resistance REMARK
Check for wire breakage of 5 and 7 pins of CB27.
Max. 1 Ω
Between CB17 (female) (2) and (3)
Resistance
If failure code is still displayed after above checks, right door wiper motor is defec-
tive.
• Reference
Defective right door wiper 3. Turn starting switch to ON position.
6 motor (failure in stop po- 4. Turn right door wiper switch to ON position.
sition detection)
REMARK
Voltage
D155AX-8 40-1237
40-1238 D155AX-8
D155AX-8 40-1239
E-36 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATI-
CALLY 40 TROUBLESHOOTING
E-36 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY

Failure Fuel feed pump does not operate or stop automatically.
Related
information

Insufficient battery Check the battery for charge level since battery charge level may be low.
1
charge
Defective circuit breaker If circuit breaker is tripped, circuit probably has ground fault, etc. In this case, per-
2
(CB30) form check on cause 6 first.
2. Disconnect connector EPP, and connect T-adapter to female side.
ness (wire breakage or Voltage Between EPP (3) and (10) 20 to 30 V
3
Turn battery disconnect switch to OFF position. (for continuous power sup-
nector)
ply)
2. Disconnect connector EPP, and connect T-adapter to female side.
Resistance Between ground and EPP (female) (10) Max. 1 Ω
1. Turn battery disconnect switch to OFF position. (for continuous power sup-
ply)
Ground fault in wiring 2. Disconnect connector EPP, and connect T-adapter to female side.
4 harness (contact with 3. Remove fuse No. 12 from fuse box FS11.
ground circuit)
Between ground and EPP (female) (1) Min. 1 MΩ
Resistance
Between ground and EPP (female) (3) Min. 1 MΩ
2. Disconnect connector EPP and connect T-adapter to female side.
5 Defective priming pump 3. Turn battery disconnect switch ON.
4. Turn priming pump switch ON.
Voltage Between EPP (1) and (12) 20 to 30 V
Lamp flashes but outputting is stopped in approximately 5 seconds.
Overloaded priming
6 If pump is overloaded, power is turned OFF automatically to protect circuit (Priming
pump
pump switch is reset automatically).
Malfunction of fuel feed If fuel feed pump does not stop automatically, fuel feed pump switch may be defec-
pump switch (malfunction tive.
7
or it does not stop auto- (Turn toggle switch to OFF position, and stop pump rotation. Then, replace switch.)
matically).
2. Disconnect connector EFP, and connect T-adapter to male side.
Internal defect of priming
8 Between EFP (male) (1) and (2) 1 to 3 Ω
pump
Resistance Between EFP (male) (1) and pump body Min. 1 MΩ
Between EFP (male) (2) and pump body Min. 1 MΩ
40-1240 D155AX-8
40 TROUBLESHOOTING E-37 FAN DOES NOT ROTATE IN REVERSE
E-37 FAN DOES NOT ROTATE IN REVERSE

Failure Fan does not rotate in reverse.
Related
See "Fan Reverse" in Structure, Operation, Machine monitor.
information

Defective fan reverse sol- Perform troubleshooting for failure codes [DW7BKA] and [DW7BKB].
1
enoid
Circuit diagram related to fan
D155AX-8 40-1241
E-38 GEAR CANNOT BE SHIFTED 40 TROUBLESHOOTING
E-38 GEAR CANNOT BE SHIFTED

Failure Shift operation is not available (shift switch operation does not work).
Related
information
REMARK
When no failure code related to shift control switch is displayed
Hold down shift control switch for 10 seconds or more. If any of following failure co-
Shift up switch and shift des is displayed at this time, perform troubleshooting for that failure code.
1 [DD12KA], [DD12KB], [DD13KA], [DD13KB]
down switch
REMARK
When failure code related to shift control switch is displayed
Perform troubleshooting for displayed failure code.
Internal defect of trans- Transmission clutch may have internal defect. Check it.
2
mission clutch
40-1242 D155AX-8
40 TROUBLESHOOTING E-39 FRONT WASHER DOES NOT OPERATE
E-39 FRONT WASHER DOES NOT OPERATE

Failure Front washer does not operate.
• See E-mode in “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY“ or
Related “FRONT WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTER-
information MITTENT OPERATIONS)“ if the windshield wiper does not work either.
• T-adapter is not provided to the connector of a washer motor (check without a T-adapter).
REMARK
Check that rear washer fluid comes out.
Defective front washer
1 motor (internal open cir- 2. Switch connectors WSFR and WSRR.
cuit) 3. Turn starting switch to ON position.
4. Turn front washer switch to ON position.
If rear washer fluid comes out, originally provided front washer motor is defective.
Defective front wiper 4. Turn switch to ON and OFF positions, and perform troubleshooting.
2
switch
OFF Min. 1 MΩ
and (6)
Resistance
ON Max. 1 Ω
and (6)
Continuity Between CB14 (female) (6) and ground Continuity
defective contact) 2. Remove fuse 5 in fuse box.
fuse box
2. Remove fuse 5 in fuse box.
Ground fault in wiring 3. Disconnect connector CB14 and WSFR, and connect T-adapter to female
4 harness (contact with side of CB14.
ground circuit)
Resistance
D155AX-8 40-1243
E-39 FRONT WASHER DOES NOT OPERATE 40 TROUBLESHOOTING
Circuit diagram related to windshield washer
40-1244 D155AX-8
40 TROUBLESHOOTING E-39 FRONT WASHER DOES NOT OPERATE
D155AX-8 40-1245
E-40 REAR WASHER DOES NOT OPERATE 40 TROUBLESHOOTING
E-40 REAR WASHER DOES NOT OPERATE

Failure Rear washer does not operate.
• SeeE-mode in “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY“ or
Related “REAR WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTER-
REMARK
Check that front washer fluid comes out.
Defective rear washer
1 motor (internal open cir- 2. Switch connectors WSFR and WSRR.
cuit) 3. Turn starting switch to ON position.
4. Turn rear washer switch to ON position.
If front washer fluid comes out, originally provided rear washer motor is defective.
Defective rear wiper 4. Turn switch to ON and OFF positions, and perform troubleshooting.
2
switch
OFF Min. 1 MΩ
and (6)
Resistance
ON Max. 1 Ω
and (6)
fuse box
Ground fault in wiring 3. Disconnect connector CB12 and WSRR, and connect T-adapter to female
ground circuit)
Resistance
40-1246 D155AX-8
40 TROUBLESHOOTING E-40 REAR WASHER DOES NOT OPERATE
D155AX-8 40-1247
E-40 REAR WASHER DOES NOT OPERATE 40 TROUBLESHOOTING
40-1248 D155AX-8
40 TROUBLESHOOTING E-41 LEFT DOOR WASHER DOES NOT OPERATE
E-41 LEFT DOOR WASHER DOES NOT OPERATE

Failure Left door washer does not operate.
Related “LEFT DOOR WIPER DOES NOT OPERATE. (FAILED IN BOTH CONTINUOUS AND IN-
information TERMITTENT OPERATIONS)“ if the windshield wiper does not work either.
REMARK
Check that right door washer fluid flows.
Defective left door wash-
1 er motor (internal open 2. Interchange connectors WSLH and WSRH.
circuit) 3. Turn starting switch to ON position.
4. Turn left door washer switch to ON position.
If fluid of right door washer flows, original left door washer motor is defective.
Defective left door wiper 4. Turn on and off switch to perform troubleshooting.
2
switch
OFF Min. 1 MΩ
and (6)
Resistance
ON Max. 1 Ω
and (6)
3
Remove fuse 6 of fuse box.
nector)
Between CB15 (female) (5) and fuse terminal 6 of fuse

box
2. Remove fuse 6 of fuse box.
Ground fault in wiring 3. Disconnect connectors CB15 and WSLH, and connect T-adapter to female
ground circuit)
Resistance
D155AX-8 40-1249
E-41 LEFT DOOR WASHER DOES NOT OPERATE 40 TROUBLESHOOTING
40-1250 D155AX-8
40 TROUBLESHOOTING E-41 LEFT DOOR WASHER DOES NOT OPERATE
D155AX-8 40-1251
E-42 RIGHT DOOR WASHER DOES NOT OPERATE 40 TROUBLESHOOTING
E-42 RIGHT DOOR WASHER DOES NOT OPERATE

Failure Right door washer does not operate.
Related “RIGHT WIPER DOES NOT OPERATE (FAILED IN BOTH CONTINUOUS AND INTER-
REMARK
Check that left door washer fluid comes out.
Defective right door
2. Switch connector WSLH and WSRH.
1 washer motor (internal
open circuit) 3. Turn starting switch to ON position.
4. Turn right door washer switch to ON position.
If left door washer fluid comes out, originally provided right door washer motor is
defective.
Defective right door wiper 4. Turn switch to ON and OFF positions, and perform troubleshooting.
2
switch
OFF Min. 1 MΩ
and (6)
Resistance
ON Max. 1 Ω
and (6)
fuse box
Ground fault in wiring 3. Disconnect connector CB13 and WSRH, and connect T-adapter to female
ground circuit)
Resistance
40-1252 D155AX-8
40 TROUBLESHOOTING E-42 RIGHT DOOR WASHER DOES NOT OPERATE
D155AX-8 40-1253
E-42 RIGHT DOOR WASHER DOES NOT OPERATE 40 TROUBLESHOOTING
40-1254 D155AX-8
40 TROUBLESHOOTING E-43 RIPPER PIN PULLER DOES NOT WORK
E-43 RIPPER PIN PULLER DOES NOT WORK

Failure Ripper pin puller cylinder does not operate.
Related
information

If fuse F01-6 is blown out, the circuit probably has ground fault. In this case, per-
1 Defective fuse F01-6
form check on cause 6 first.
2. Disconnect connector PPL, and connect T-adapter to male side.
Defective pin puller
2
switch (internal defect) Between PPL (male) (1) and (2) 10 to 40 Ω
Resistance
Between PPL (male) (1) and ground Min. 1 MΩ
2. Disconnect connector PPL, and connect T-adapter to male side.
Defective pin puller sole-
3
noid (internal defect) Between PPL (male) (1) and (2) 10 to 40 Ω
Resistance
Between PPL (male) (1) and ground Min. 1 MΩ
2. Disconnect connectors ASUS, PHR and HEAT1.
3. Remove fuse F01-6.
Open or short circuit in 4. Turn pin puller switch to ON position (retracting).
4
wiring harness
Between fuse F01-6 terminal and ground
Pin puller solenoid resistance
REMARK
required.
Open circuit in wiring har- 2. Remove fuse F01-6.
5
ness 3. Disconnect connectors PLSW and PPL, and connect T-adapters to each
female side.
Between PPL (female) (2) and ground Max. 1 Ω
Resistance Between PPL (female) (1) and PLSW (female) (2) Max. 1 Ω
Between fuse F01-6 and PLSW (female) (1) Max. 1 Ω
REMARK
required.
6 harness (contact with 2. Remove fuse F01-6.
ground circuit) 3. Disconnect connectors PLSW and PPL, and connect T-adapters to female
side of PLSW.
Between PPL (female) (1) and PLSW (female) (1) Min. 1 MΩ
Resistance
Between PLSW (female) (1) and ground Min. 1 MΩ
D155AX-8 40-1255
E-43 RIPPER PIN PULLER DOES NOT WORK 40 TROUBLESHOOTING

2. Disconnect connector PPL and connect T-adapter to female side.
V circuit) 4. Turn pin puller switch to OFF position (pushing out).
Voltage Between PPL (female) (1) and (2) Max. 1 V
Circuit diagram related to ripper pin puller cylinder
40-1256 D155AX-8
40 TROUBLESHOOTING E-44 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
E-44 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY

Failure KOMTRAX system does not operate normally.
• Perform following troubleshooting if administrator of KOMTRAX system requests to check
whether failure occurs in system on machine.
• Even when KOMTRAX system is defective, no problem appears on machine.
Related • All troubleshooting can be checked on the service menu of the machine monitor.
information • For checking of Terminal Status, see Testing and adjusting, “METHOD FOR CONFIRM-
ING KOMTRAX SETTINGS (TERMINAL STATUS)”.
• For checking of GPS & Communication State, see Testing adjusting, “METHOD FOR
CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS)”.

2. Display Terminal Status screen.
1 Transmitting error 1
Monitoring display Check item: KOMTRAX State of radio station es-
Communication tablishment
2. Display GPS & Communication Status screen.
N ###.##.## (Latitude)
Defective GPS position-
2 Monitoring display Check item: Positioning E ###.##.## (Longitude)
ing
Positioning in Progress
If the latitude and longitude are not displayed within 5 minutes in an open-sky area,
call the KOMTRAX service hot-line for advice.
Monitoring display Check item: Communica- Communication reception
Defective communication tion range level 1 to communi-
3
environment cation reception range lev-
el 3
Contact KOMTRAX service hot-line if communication reception range is not within
level 1 to 3.
4 Transmitting error 2
Monitoring display Check item: Number of 0 to 9 (normally 0)
message(s) not yet sent
D155AX-8 40-1257
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H
MODE) 40 TROUBLESHOOTING
TROUBLESHOOTING FOR HYDRAULIC AND MECHANI-

CAL SYSTEMS (H MODE)
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)
(Rev. 2014/04)
The following information is summarized in the troubleshooting table. Before performing troubleshooting, under-
stand that information fully.
Failure Failure symptom that appears on machine
Related infor-
Information on occurred failure or troubleshooting
mation

1
2 <Contents of description>
Probable cause of failure
3 (Each number is serial num- • Criteria to determine probable causes
ber, not priority sequence.) • Remarks for determination of probable cause
4
5
40-1258 D155AX-8
40 TROUBLESHOOTING SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS
D155AX-8 40-1259
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 40 TROUBLESHOOTING
This system diagram shows simplified overall hydraulic circuit diagram and is intended to be used as reference
material for troubleshooting of hydraulic and mechanical systems.
40-1260 D155AX-8
40 TROUBLESHOOTING SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS
System chart of power train system
D155AX-8 40-1261
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 40 TROUBLESHOOTING
40-1262 D155AX-8
40 TROUBLESHOOTING FAILURE MODE AND CAUSE TABLE
FAILURE MODE AND CAUSE TABLE

Component causing failure Power train
Failure
Power train pump

Torque converter
Torque converter relief valve
Transmission
Last chance filter

Power train pump main relief valve
Transmission clutch valve (ECMV)
Transmission clutch
Lockup clutch, stator clutch
Machine lacks power (insufficient drawbar pull). ○ ○ ○ ○ ○ ○ ○ ○
MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED). ○ ○ ○ ○ ○ ○ ○
MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS. ○ ○ ○ ○ ○ ○ ○
MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR
○ ○ ○ ○ ○
IN REVERSE.
Power train system
LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE. ○ ○ ○ ○ ○ ○

MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR
RIGHT)
STEERING SPEED OR POWER IS INSUFFICIENT.
BRAKE DOES NOT WORK ○
TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE ○ ○ ○ ○ ○ ○
POWER TRAIN OIL OVERHEATS ○ ○ ○ ○ ○ ○
UNUSUAL NOISE IS HEARD FROM AROUND HSS PUMP OR HSS MO-
TOR.
ALL WORK EQUIPMENTS OPERATE SLOWLY.
ALL WORK EQUIPMENT DO NOT OPERATE.
BLADE LIFT SPEED OR POWER IS LOW.
H-00 BLADE TILT SPEED OR POWER IS LOW

RIPPER LIFT SPEED OR POWER IS LOW.
RIPPER TILT SPEED OR POWER IS LOW.
HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE.
HYDRAULIC DRIFT OF TILTED BLADE IS LARGE.
HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE.
RIPPER PIN PULLER CYLINDER DOES NOT OPERATE. ○
BLADE PITCH CYLINDER DOES NOT OPERATE.
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT PUMP.
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)
FAN SYSTEM
UNUSUAL NOISE IS HEARD FROM AROUND FAN.
D155AX-8 40-1263
FAILURE MODE AND CAUSE TABLE 40 TROUBLESHOOTING
Component causing failure Brake

Failure
Brake (drags or slips)

Brake valve
Brake pedal limit switch
Brake pedal linkage
Brake piston seal

Parking brake solenoid valve
Parking brake lever linkage
Brake disc and plate

Machine lacks power (insufficient drawbar pull). ○ ○ ○ ○
MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED). ○ ○ ○ ○
MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS. ○ ○ ○ ○
IN REVERSE.
Power train system
LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE. ○

MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR
RIGHT)
BRAKE DOES NOT WORK ○ ○ ○ ○
TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE
POWER TRAIN OIL OVERHEATS ○
TOR.
BLADE LIFT SPEED OR POWER IS LOW.

RIPPER LIFT SPEED OR POWER IS LOW.
RIPPER TILT SPEED OR POWER IS LOW.
RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT PUMP.
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)
FAN SYSTEM
40-1264 D155AX-8
Component causing failure Pump and motor
Engine
Hydraulic tank strainer
Pump suction piping
Exterior components around fan

Failure
PTO
Work equipment and HSS pump
Fan pump
HSS motor (including relief valve)
Fan motor (including relief valve)

Machine lacks power (insufficient drawbar pull). ○ ○ ○
MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED).
MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS. ○ ○
○ ○
IN REVERSE.
Power train system
LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE. ○ ○

MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT
○ ○ ○ ○
OR RIGHT)
STEERING SPEED OR POWER IS INSUFFICIENT. ○
BRAKE DOES NOT WORK ○
POWER TRAIN OIL OVERHEATS ○ ○ ○
○ ○ ○ ○
TOR.
ALL WORK EQUIPMENTS OPERATE SLOWLY. ○ ○ ○ ○ ○
ALL WORK EQUIPMENT DO NOT OPERATE. ○ ○ ○ ○ ○
BLADE LIFT SPEED OR POWER IS LOW. ○ ○ ○
H-00 BLADE TILT SPEED OR POWER IS LOW ○ ○ ○

RIPPER LIFT SPEED OR POWER IS LOW. ○ ○ ○
RIPPER TILT SPEED OR POWER IS LOW. ○ ○ ○
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT
○ ○ ○
PUMP.
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ○ ○ ○ ○
FAN SYSTEM
UNUSUAL NOISE IS HEARD FROM AROUND FAN. ○
D155AX-8 40-1265
Component causing failure Hydraulic system

Failure
Self-pressure reducing valve
Unload valve
EPC valve
EPC lock valve
LS relief valve
PC valve
LS valve
Suction valve
Divider valve (for work equipment and HSS pump)
Work equipment and HSS main relief valve)
HSS control valve (spool)

Machine lacks power (insufficient drawbar pull).
MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED).
MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS.
MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FOR-
WARD OR IN REVERSE.
Power train system
LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL

CHANGE.
MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN
○ ○ ○
LEFT OR RIGHT)
STEERING SPEED OR POWER IS INSUFFICIENT. ○ ○ ○ ○ ○ ○ ○
BRAKE DOES NOT WORK
POWER TRAIN OIL OVERHEATS
UNUSUAL NOISE IS HEARD FROM AROUND HSS PUMP OR HSS
MOTOR.
ALL WORK EQUIPMENTS OPERATE SLOWLY. ○ ○ ○ ○ ○ ○
ALL WORK EQUIPMENT DO NOT OPERATE. ○ ○ ○ ○
BLADE LIFT SPEED OR POWER IS LOW. ○ ○ ○ ○ ○ ○ ○
BLADE TILT SPEED OR POWER IS LOW ○ ○ ○ ○ ○ ○

RIPPER LIFT SPEED OR POWER IS LOW. ○ ○ ○ ○ ○ ○
RIPPER TILT SPEED OR POWER IS LOW. ○ ○ ○ ○ ○ ○
BLADE PITCH CYLINDER DOES NOT OPERATE. ○ ○
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT
○
PUMP.
40-1266 D155AX-8
FAN SYSTEM
Failure
D155AX-8
ARY)
40 TROUBLESHOOTING
Component causing failure

FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATION-
Self-pressure reducing valve

Divider valve (for work equipment and HSS pump)
Unload valve
Work equipment and HSS main relief valve)
EPC valve
EPC lock valve
LS relief valve
Hydraulic system
PC valve
LS valve
Suction valve
HSS control valve (spool)
40-1267
FAILURE MODE AND CAUSE TABLE

Failure
Blade lift cylinder
Blade tilt cylinder
Blade pitch cylinder

Pin puller cylinder
Pin puller solenoid valve
Blade lift control valve (spool and pressure compensation valve)
Blade tilt control valve (spool and pressure compensation valve)
Blade pitch control valve (spool and pressure compensation valve)
Ripper lift control valve (spool and pressure compensation valve)
Ripper tilt control valve (spool and pressure compensation valve)

Machine lacks power (insufficient drawbar pull).
MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR
SPEED).
MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS.
MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FOR-
WARD OR IN REVERSE.
Power train system
LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL

CHANGE.
MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN
LEFT OR RIGHT)
BRAKE DOES NOT WORK
POWER TRAIN OIL OVERHEATS
UNUSUAL NOISE IS HEARD FROM AROUND HSS PUMP OR
HSS MOTOR.
40-1268 D155AX-8

Failure
Blade lift cylinder
Blade tilt cylinder
Blade pitch cylinder

Pin puller cylinder
Pin puller solenoid valve
Blade lift control valve (spool and pressure compensation valve)
Blade tilt control valve (spool and pressure compensation valve)
Blade pitch control valve (spool and pressure compensation valve)
Ripper lift control valve (spool and pressure compensation valve)
Ripper tilt control valve (spool and pressure compensation valve)

BLADE LIFT SPEED OR POWER IS LOW. ○ ○
BLADE TILT SPEED OR POWER IS LOW ○ ○

RIPPER LIFT SPEED OR POWER IS LOW. ○ ○
RIPPER TILT SPEED OR POWER IS LOW. ○ ○
HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE. ○ ○
HYDRAULIC DRIFT OF TILTED BLADE IS LARGE. ○ ○
HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE. ○ ○
RIPPER PIN PULLER CYLINDER DOES NOT OPERATE. ○ ○
BLADE PITCH CYLINDER DOES NOT OPERATE. ○ ○
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIP-
MENT PUMP.
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATION-
FAN SYSTEM
ARY)
D155AX-8 40-1269
(*)
Clutches engaged
F R 1st 2nd 3rd
F1 ○ ○
F2 ○ ○
Speed range
F3 ○ ○
R1 ○ ○
R2 ○ ○
R3 ○ ○
40-1270 D155AX-8
40 TROUBLESHOOTING H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL)
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL)

Failure Machine lacks power (insufficient drawbar pull).
• Check that power train oil amount is appropriate.
• Check if the torque converter stall speed is within the standard value (F3 stall speed:
1,380 rpm)
• If failure codes are displayed, perform troubleshooting for them first. (15SAL1, 15SBL1,
Related
15SEL1, 15SFL1, 15SGL1)
information
• Make sure that the parking brake is released.
• Torque converter oil pressure can be checked with monitoring function. (Monitoring code:
32601 (inlet pressure), 32603 (outlet pressure))
• Engine speed can be checked with monitoring function. (Monitoring code: 01002)

Defective power train Check strainer for clogging.
1
pump strainer
Air sucked into power Check of suction piping for crack and looseness.
2
train pump suction side
Be ready with engine stopped, then perform troubleshooting with engine at low idle
and high idle.
Min.
2.62 MPa
Low idle
{26.7
Main relief kg/cm2}
Engine speed
pressure Min.
Defective power train 2.79 MPa
3 High idle
pump main relief valve {28.5
kg/cm2}
Check that free length of spring and number of shims are normal and spool moves
smoothly.
• Free length of spring (large): 122 mm
• Number shims: 6
• Free length of spring (small): 108 mm
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Max.
Torque con-
1.0 MPa
verter inlet PCCS lever NEUTRAL
{10.0
oil pressure
kg/cm2}
0.29 to
Defective torque convert- Torque con- 0.69 MPa
4 verter outlet PCCS lever NEUTRAL
er relief valve {3.0 to
oil pressure
7.0 kg/cm2}
If oil pressure is not decreased by adjustment, check main relief valve for malfunc-
tion (fatigued spring), internal defect (defective valve seat), etc.
NOTICE
If torque converter outlet pressure is low, oil cooler may be broken.
Check radiator coolant for mixing of oil.
D155AX-8 40-1271
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) 40 TROUBLESHOOTING

Defective torque convert- idle.
5
er
Stall speed PCCS lever Stall in F3 1,380 rpm
Be ready with engine stopped, then perform troubleshooting with engine at low idle.
REMARK
Gear speed clutch is operated by combined 2 clutches. Check combination
with Table 1.
Min.
F clutch
2.25 MPa
ECMV out- PCCS lever F3 stalled
{23.0
put pressure
kg/cm2}
Min.
R clutch
2.45 MPa
ECMV out- PCCS lever R3 stalled
{25.0
put pressure
6
Defective transmission kg/cm2}
clutch valve (ECMV)
Min.
1st clutch
2.62 MPa
{26.7
put pressure
kg/cm2}
Min.
2nd clutch
2.40 MPa
{24.5
put pressure
kg/cm2}
Min.
3rd clutch
2.62 MPa
{26.7
put pressure
kg/cm2}
If failure code is still displayed after above checks on cause 3 and clutch oil pres-
7 Clogged last chance filter
sure is low or “0”, check last chance filter for clogging.
• If oil pressure is found low by check on cause 7, oil may be leaking
Defective transmission through seal ring of clutch.
8
clutch • If oil pressure is found normal by check on cause 7, clutch may be slip-
ping.
• When oil pressure during check on cause 3 is abnormal but main relief
Defective power train valve is normal, disconnect power train pump outlet hose, crank engine,
9 and see if oil flows out.
pump
• Check line filter for sticking foreign material such as metal chips.
REMARK
Be ready with engine stopped, then perform troubleshooting with engine at
10 Defective brake valve
high idle.
2.16 MPa
Brake pres- Parking brake lever in
Brake pedal OFF {22.0
sure FREE
kg/cm2}
40-1272 D155AX-8
40 TROUBLESHOOTING H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL)

Parking 0 MPa
ON
brake sole- {0 kg/cm2}
Malfunction of parking noid valve Parking brake switch 2.16 MPa
11
brake solenoid valve inlet pres- OFF {22.0
sure kg/cm2}
If oil pressure is low when parking brake switch is turned OFF, check if solenoid
valve spool is stuck.
Be ready with engine stopped, then perform troubleshooting in adjustment mode
(ID: 9995, Electric brake constant open mode) with engine at low idle.
0 MPa
Malfunction of brake ped- Brake pedal ON
12 {0 kg/cm2}
al solenoid valve solenoid
Brake pedal switch 2.16 MPa
valve inlet
pressure OFF {22.0
kg/cm2}
Internal defect of trans- If no failure is found by checks on causes 1 to 12, transmission may have internal
13
mission defect. Check magnet plug for metallic matter.
If failure code still displays after above checks on causes 1 to 13, engine perform-
14 Defective engine system ance may lower. Perform troubleshooting by referring to “S mode” troubleshooting,
“S-6”.
Clutches engaged
table1
F R 1st 2nd 3rd
F1 ● ●
F2 ● ●
F3 ● ●
Speed range
R1 ● ●
R2 ● ●
R3 ● ●
D155AX-8 40-1273
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) 40 TROUBLESHOOTING
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED)
Failure Machine does not travel (at 2nd or 3rd gear speed).
15SFL1, 15SGL1)
Related
information

and high idle.
Min.
2.62 MPa
Low idle
{26.7
Main relief kg/cm2}
Engine speed
pressure Min.
1 High idle
kg/cm2}
smoothly.
• Number shims: 6
idle.
Max.
Torque con-
1.0 MPa
{10.0
oil pressure
kg/cm2}
0.29 to
oil pressure
7.0 kg/cm2}
NOTICE
Internal defect of torque idle.
3
converter
40-1274 D155AX-8
40 TROUBLESHOOTING H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED)

Min.
2nd clutch
2.55 MPa
{26.0
Defective transmission put pressure
4 kg/cm2}
clutch valve (ECMV)
Min.
3rd clutch
2.84 MPa
{29.0
put pressure
kg/cm2}
6
ping.
Parking 0 MPa
ON
7
brake solenoid valve inlet pres- OFF {22.0
sure kg/cm2}
0 MPa
8 {0 kg/cm2}
valve inlet
pressure OFF {22.0
kg/cm2}
Move to level ground and start engine to perform troubleshooting.
Malfunction (dragging) of
9 If machine does not move at low idle in F2, brake is dragging. Perform trouble-
brake
shooting for "H-8 Brake does not operate".
10
D155AX-8 40-1275
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS 40 TROUBLESHOOTING
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS

Failure Machine does not move off at all gear speeds.
15SEL1, 15SFL1, 15SGL1)
Related
information

1
pump strainer
2
and high idle.
Min.
2.62 MPa
Low idle
{26.7
Main relief kg/cm2}
Engine speed
pressure Min.
3 High idle
kg/cm2}
smoothly.
• Number shims: 6
idle.
Max.
Torque con-
1.0 MPa
{10.0
oil pressure
kg/cm2}
0.29 to
oil pressure
7.0 kg/cm2}
NOTICE
5
er
40-1276 D155AX-8
40 TROUBLESHOOTING H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS

REMARK
with Table 1.
Min.
F clutch
2.25 MPa
{23.0
put pressure
kg/cm2}
Min.
R clutch
2.45 MPa
{25.0
put pressure
6
clutch valve (ECMV)
Min.
1st clutch
2.62 MPa
{26.7
put pressure
kg/cm2}
Min.
2nd clutch
2.40 MPa
{24.5
put pressure
kg/cm2}
Min.
3rd clutch
2.62 MPa
{26.7
put pressure
kg/cm2}
8
ping.
pump
REMARK
high idle.
10 Defective brake valve 2.16 MPa
Brake pres- Parking brake lever in
S/T brake pedal OFF {22.0
sure FREE
kg/cm2}
If brake pressure is abnormal, perform troubleshooting for "H-8 Brake does not op-
erate".
D155AX-8 40-1277
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS 40 TROUBLESHOOTING

Parking 0 MPa
ON
11
brake solenoid valve outlet pres- OFF {22.0
sure kg/cm2}
0 MPa
12 {0 kg/cm2}
valve inlet
pressure OFF {22.0
kg/cm2}
13
40-1278 D155AX-8
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FOR-
40 TROUBLESHOOTING WARD OR IN REVERSE
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR

IN REVERSE
Failure Machine travels only in one direction, either forward or in reverse.
• Check that oil level in power train is normal before performing troubleshooting.
• If failure codes are displayed, perform troubleshooting for them first. (15SAL1, 15SALH,
Related 15SBL1, 15SBLH, DXH7KA, DXH8KA)
information • Make sure that the parking brake is released.

1
pump strainer
2
and high idle.
Min.
2.62 MPa
Low idle
{26.7
Main relief kg/cm2}
Engine speed
pressure Min.
3 High idle
kg/cm2}
smoothly.
• Number shims: 6
idle.
Min.
Output pres- 2.40 MPa
PCCS lever F3 stalled
Defective transmission sure {24.5
4
clutch valve (ECMV) kg/cm2}
Min.
R clutch
2.60 MPa
{26.5
put pressure
kg/cm2}
If failure code is still displayed after above checks on cause 3 and F and R clutch
oil pressure is low or “0”, check last chance filter for clogging.
through seal ring of clutch.
6 Defective F or R clutch
• If oil pressure is found normal by check on cause 5, clutch may be slip-
ping.
D155AX-8 40-1279
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FOR-
WARD OR IN REVERSE 40 TROUBLESHOOTING

pump
40-1280 D155AX-8
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL
40 TROUBLESHOOTING CHANGE
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE

Failure Large time lag is in gear shifting or directional change.
Related
information
15SEL1, 15SFL1, 15SGL1, 15SHL1)

Defective power train When transmission oil temperature is low, if unusual noise is heard from power
1
pump strainer train pump or transmission filter, check strainer for clogging.
2
and high idle.
Min.
2.62 MPa
Low idle
{26.7
Main relief kg/cm2}
Engine speed
pressure Min.
3 High idle
kg/cm2}
smoothly.
• Number shims: 6
REMARK
with Table 1.
Min.
F clutch
2.25 MPa
{23.0
put pressure
kg/cm2}
Min.
R clutch
2.45 MPa
{25.0
put pressure
4
clutch valve (ECMV)
Min.
1st clutch
2.62 MPa
{26.7
put pressure
kg/cm2}
Min.
2nd clutch
2.40 MPa
{24.5
put pressure
kg/cm2}
Min.
3rd clutch
2.62 MPa
{26.7
put pressure
kg/cm2}
D155AX-8 40-1281
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL
CHANGE 40 TROUBLESHOOTING

If failure code is still displayed after above checks on cause 3 and lockup oil pres-
Move to level ground and start engine to perform troubleshooting.
If machine does not move at low idle in F2, brake is dragging. Perform trouble-
Malfunction of Parking shooting for "H-8 Brake does not operate".
6
Brake (Dragging) REMARK
If oil pressure is low in all gear speeds and time lag is large in all gear speeds
during check on Cause 5, parking brake piston seal may be defective.
7
ping.
pump
9
mission defect.
40-1282 D155AX-8
H-6 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN
40 TROUBLESHOOTING LEFT OR RIGHT)
H-6 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT

OR RIGHT)
Failure Machine cannot be steered (machine does not turn left or right)
• Check that oil level in hydraulic tank is normal.
Related • If failure codes are displayed, perform troubleshooting for them first. (DXHBKA, DXHCKA)
information • HSS (steering) pump pressure can be checked with monitoring function. (monitoring code:
70700)

If work equipment or cooling fan also malfunctions when the machine does not turn
1 Defective PTO
to either side, PTO may be defective.
Air sucked in on suction Check suction piping for cracks, looseness, etc.
2
side of HSS pump
Defective HSS pump Check strainer for clogging.
3
strainer
REMARK
high idle.
2.45
Defective unload valve of Unload (+1.37/0)
4
steering valve valve relief All control levers NEUTRAL MPa {25
pressure (+14/0)
kg/cm2}
When work equipment control lever is operated, if work equipment oil pressure
does not increase, unload valve may be kept open.
REMARK
high idle.
Improper set pressure or Min.
5 malfunction of self-pres- Control cir-
2.50 MPa
sure reducing valve cuit source All control levers NEUTRAL
{25.5
pressure
kg/cm2}
Relief valve of self-pressure reducing valve cannot be adjusted on-board. Replace
the assembly if out of standards.
While oil pressure is judged normal by check on cause 5, if oil pressure does not
Defective spool of steer- increase when machine is steered, steering spool may be malfunctioning.
6
ing valve
Check if spool is stuck.
REMARK
high idle.
Defective steering main 24.5
7 Steering (+1.23/-2.45
relief valve
main relief Steering Steering relief ) MPa {250
pressure (+12.5/-25)
kg/cm2}
When relief pressure is abnormal, adjust main relief valve pressure.
D155AX-8 40-1283
H-6 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN
LEFT OR RIGHT) 40 TROUBLESHOOTING

When low relief pressure is detected on right and left sides by check on cause 7
Defective overload relief but main relief valve is normal, overload relief valve of HSS motor may be abnor-
8 mal.
valve
This is unadjustable on actual machine. Replace assembly.
If measured pressure is unusual in check on cause 7 and main relief valve is nor-
mal, disconnect steering pump outlet hose, crank engine, and check that oil flows
9 Defective HSS pump out.
Check if the return filter and the suction strainer have such foreign materials as
metal strips.
Unusual noise comes If unusual noise comes from around HSS peripheral equipment, perform trouble-
10 from around HSS periph- shooting as described in "H-11 UNUSUAL NOISE IS HEARD FROM AROUND
eral equipment. HSS PUMP OR HSS MOTOR".
40-1284 D155AX-8
40 TROUBLESHOOTING H-7 STEERING SPEED OR POWER IS INSUFFICIENT
H-7 STEERING SPEED OR POWER IS INSUFFICIENT

Failure Steering speed or power is insufficient.
Related • If failure codes are displayed, perform troubleshooting for them first. (DK30KX, DK30KZ,
DK30L8)
information
• HSS (steering) pump pressure can be checked with monitoring function. (monitoring code:
70700)

1
side of HSS pump
REMARK
high idle.
Defective unload valve of
2 2.45
steering valve
Unload (+1.37/0)
valve relief All control levers NEUTRAL MPa {25
pressure (+14/0)
kg/cm2}
REMARK
high idle.
2.50 MPa
{25.5
pressure
kg/cm2}
REMARK
Defective steering main
high idle.
4
relief valve 38.2 to
Steering
41.7 MPa
main relief R.H. and L.H. steering Brake pedal depressed
{390 to
pressure
425 kg/cm2}
When low relief pressure is detected on right and left sides by check on cause 4
Defective overload relief but main relief valve is normal, overload relief valve of HSS motor may be abnor-
5 mal.
valve
This is unadjustable on actual machine. Replace assembly.
REMARK
Defective steering LS re-
high idle.
6
lief valve 36.2 to
Steering LS
38.1 MPa
relief pres- Right and left steering Depress the brake pedal
{369 to
sure
389 kg/cm2}
D155AX-8 40-1285
H-7 STEERING SPEED OR POWER IS INSUFFICIENT 40 TROUBLESHOOTING

If turning speed when steering operation is performed while blade lift cylinder is hy-
Defective divider valve draulically relieved is same as that when only steering operation is performed, di-
7 for work equipment and vider valve may malfunction.
HSS
Check divider valve spool for sticking.
Defective adjustment and Check for stuck PC valve spool and presence of deformed springs and change
8
malfunction of PC valve them if they are defective.
Defective adjustment and Check for stuck LS valve spool and presence of deformed springs and change
9
malfunction of LS valve them if they are defective.
Unusual noise comes If unusual noise comes from around HSS peripheral equipment, perform trouble-
10 from around HSS periph- shooting as described in "H-11 UNUSUAL NOISE IS HEARD FROM AROUND
eral equipment. HSS PUMP OR HSS MOTOR".
40-1286 D155AX-8
40 TROUBLESHOOTING H-8 BRAKE DOES NOT WORK
H-8 BRAKE DOES NOT WORK

Failure Brake does not work
Related
• If failure codes are displayed, perform troubleshooting for them first. (DK40KA, DXHBKA,
information
DXHCKA)

1
Oil leakage from valve Check piping between solenoid valve and brake valve (L/H) for oil leakage.
2 circuit of pin puller sole-
noid valve (OPT)
and high idle.
Min.
2.62 MPa
Low idle
{26.7
Main relief kg/cm2}
Engine speed
pressure Min.
3 High idle
kg/cm2}
smoothly.
• Number shims: 6
REMARK
high idle.
Malfunction of brake 3.19 ±
4 0.2 MPa
valve L.H. or R.H. brake pedal Released
Brake pres- {32.5 ±
sure 2 kg/cm2}
0 MPa
L.H. or R.H. brake pedal Depressed
{0 kg/cm2}
Improper adjustment of If any failure is found by check on cause 3, brake pedal limit switch may be adjust-
5
brake pedal limit switch ed defectively. Adjust it.
If any failure is found by check on cause 3, brake seal may be defective. Check it
6 Defective brake seal
for scratch, etc.
Defective brake disc and Brake disc and plate may slip or be worn. Check them.
7
plate
D155AX-8 40-1287
H-9 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 40 TROUBLESHOOTING
H-9 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE

Failure Torque converter lockup clutch does not engage
• Before performing troubleshooting, check that power train oil level is normal.
Related • If failure codes are displayed, perform troubleshooting for related failure code first
(DXH1KA, DXH1KB, DXH1KY).
information
• ON/OFF state of lockup clutch fill switch can be also checked with monitor (Monitoring
code: 31520).

and high idle.
Min.
2.62 MPa
Low idle
{26.7
Main relief kg/cm2}
Engine speed
pressure Min.
1 High idle
kg/cm2}
smoothly.
• Number shims: 6
REMARK
high idle.
1.12 to
Lockup
Malfunction of torque Jack up machine with 1.52 MPa
clutch
converter lockup clutch blade and ripper, and set Travel in F3. {12.0 to
2 ECMV out-
or stator clutch valve in F3. 15.0 kg/cm2
put pressure
(ECMV) }
2.60 to
Stator clutch Jack up machine with 2.99 MPa
ECMV out- blade and ripper, and set Travel in F3. {26.5 to
put pressure in F3. 30.5 kg/cm2
}
• If oil pressure is low in check on Cause 3, clutch seal ring may be leaking.
Defective lockup or stator
4 • If failure code is still displayed after above checks on Cause 3, clutch may
clutch
be slipping.
Defective power train valve is normal, power train pump may be defective.
5
pump
REMARK
Internal defect of torque Be ready with engine stopped, then perform troubleshooting with engine at
6
converter high idle.
40-1288 D155AX-8
40 TROUBLESHOOTING H-10 POWER TRAIN OIL OVERHEATS
H-10 POWER TRAIN OIL OVERHEATS

Failure Power train oil overheats
• Check that power train oil level is proper.
• Check that parking brake is released securely.
• Measure torque converter oil temperature and check it with monitored temperature or see
if it matches to oil temperature sensor (Monitoring code: 30100). (If not, perform trouble-
Related
shooting for “Power train oil temperature gauge does not indicated normally”.)
information
• Torque converter oil pressure can be also checked with monitor (Monitoring code: 32601
(Inlet pressure), 32602 (Output pressure)).
• Check that radiator is not clogged.
• Engine speed can be also checked with monitor (monitoring code: 01002).

1
pump strainer
2
and high idle.
Min.
2.62 MPa
Low idle
{26.7
Main relief kg/cm2}
Engine speed
pressure Min.
3 High idle
kg/cm2}
smoothly.
• Number shims: 6
REMARK
2,000 rpm.
Max.
Torque con-
1.0 MPa
{10.0
oil pressure
kg/cm2}
Defective torque convert- 0.29 to
4 Torque con-
er relief valve 0.69 MPa
verter outlet PCCS lever NEUTRAL
{3.0 to
oil pressure
7.0 kg/cm2}
If oil pressure is not decreased by adjustment, check relief valve for malfunction
(fatigued spring), internal defect (defective valve seat), etc.
NOTICE
D155AX-8 40-1289
H-10 POWER TRAIN OIL OVERHEATS 40 TROUBLESHOOTING

5
er
REMARK
with Table 1.
Min.
F clutch
2.25 MPa
{23.0
put pressure
kg/cm2}
Min.
R clutch
2.45 MPa
{25.0
put pressure
6
clutch valve (ECMV)
Min.
1st clutch
2.62 MPa
{26.7
put pressure
kg/cm2}
Min.
2nd clutch
2.40 MPa
{24.5
put pressure
kg/cm2}
Min.
3rd clutch
2.62 MPa
{26.7
put pressure
kg/cm2}
Defective gear speed through seal ring of clutch.
7
clutch
• If oil pressure is found high by check on cause 6, clutch may be slipping.
REMARK
Start engine to perform troubleshooting.
Malfunction (dragging) of 1. Raise machine off ground by using blade and ripper.
8
brake
2. Set gear speed to F3 with engine speed at low idle.
3. If track shoe does not turn, brake is dragging. Perform troubleshooting for
"H-8 Brake does not operate".
REMARK
Malfunction (slip) of
9 Start engine to perform troubleshooting.
brake
Stall in F3. If machine does not stop completely, brake is slipping.
10
mission defect.
If failure code still displays after above checks on causes 1 to 10, engine perform-
11 Defective engine system ance may lower. Perform troubleshooting by referring to “S mode” troubleshooting,
“S-14”.
40-1290 D155AX-8
H-11 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIP-
40 TROUBLESHOOTING MENT AND HSS PUMP OR HSS MOTOR
H-11 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT

AND HSS PUMP OR HSS MOTOR
Failure Unusual noise is heard from around Work equipment and HSS pump or HSS motor.
Related • Check that oil level in hydraulic tank is appropriate.
information • HSS pump is also used as work equipment.

1 Inappropriate oil Check for inappropriate oil used.
Clogged hydraulic oil Check strainer for clogging.
2
tank strainer
Air sucked in suction cir- Check suction piping for cracks, looseness, etc.
3
cuit
REMARK
Improper adjustment or
malfunction of main relief
high idle.
4
valve (set pressure is too Work equip-
high) 27.5 ± 1.5
ment main
Blade pitch cylinder Relief MPa {280 ±
relief pres-
15 kg/cm2}
sure
Internal defect of HSS HSS pump may have internal defect. Check it.
5
pump
Internal defect of HSS Internal defect of the HSS motor is suspected. Check it.
6
motor
D155AX-8 40-1291
H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY 40 TROUBLESHOOTING
H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY

Failure All work equipments operate slowly.
• If any failure code is displayed, perform troubleshooting these first (DXA2KB or DXA3KB).
Related
• Check that engine high idle speed is normal on the monitor. (Monitoring code: 01002)
information
• Work equipment pump pressure can also be checked on monitor. (Monitoring code:
70700)

1 Defective PTO If the radiator fan malfunctions and the blade does not rise, PTO may be defective.
2
strainer
3
side of HSS pump
Defective line filter in Check if the line filter is not clogged.
4 EPC valve control circuit
(installed at 2 locations)
REMARK
high idle.
5
work equipment valve 2.45(+1.37/
Unload
Work equipment control 0) MPa
valve relief NEUTRAL
levers {25(+14/0)
pressure
kg/cm2}
REMARK
high idle.
Defective work equip- 27.5 ±
6 Work equip-
ment main relief valve 1.5 MPa
ment relief Blade cylinder Relief
{280 ±
pressure
15 kg/cm2}
If relief pressure does not rise to approx. 2.4 MPa {25 kg/cm2} and above after
main relief valve is adjusted, unload valve may remain opened.
REMARK
high idle.
7 Defective LS relief valve
25.0 ±
Work equip-
0.98 MPa
ment LS re- Blade cylinder Relief
{255 ±
lief pressure
10 kg/cm2}
40-1292 D155AX-8
40 TROUBLESHOOTING H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY
REMARK
high idle.
2.50 MPa
{25.5
pressure
kg/cm2}
If measured pressure is unusual in check on cause 7 and self-pressure reducing
9 Defective fan pump
valve is normal, fan pump may be defective.
Improper adjustment or Check PC valve for sticking of spool and fatigue of spring. If any failure is found,
10
malfunction of PC valve replace it.
Improper adjustment or Check LS valve for sticking of spool and fatigue of spring. If any failure is found,
11
malfunction of LS valve replace it.
If measured pressure by check on cause 6 is unusual and main relief valve is nor-
12 Defective HSS pump mal, disconnect work equipment pump outlet hose, crank engine, and check wheth-
er oil flows out.
D155AX-8 40-1293
H-13 ALL WORK EQUIPMENTS DO NOT OPERATE 40 TROUBLESHOOTING
H-13 ALL WORK EQUIPMENTS DO NOT OPERATE

Failure All work equipment do not operate.
Related • If any failure code is displayed, perform troubleshooting these first (DXJ4KA or DXJ4KB).
information • Work equipment pump pressure can also be checked on monitor. (Monitoring code:
70700)

1 Defective PTO If the radiator fan malfunctions and the blade does not rise, PTO may be defective.
2
strainer
3
side of HSS pump
Defective line filter in Check if the line filter is not clogged.
4 EPC valve control circuit
(installed at 2 locations)
REMARK
high idle.
5
Unload
levers {25(+14/0)
pressure
kg/cm2}
REMARK
high idle.
Defective work equip- 27.5 ±
6 Work equip-
ment main relief valve 1.5 MPa
ment relief Blade cylinder Relief
{280 ±
pressure
15 kg/cm2}
REMARK
high idle.
2.50 MPa
{25.5
pressure
kg/cm2}
REMARK
high idle.
8 Defective LS relief valve
25.0 ±
Work equip-
0.98 MPa
ment LS re- Blade cylinder Relief
{255 ±
lief pressure
10 kg/cm2}
40-1294 D155AX-8
40 TROUBLESHOOTING H-13 ALL WORK EQUIPMENTS DO NOT OPERATE

If measured pressure is unusual in check on cause 7 and self-pressure reducing
9 Defective fan pump
valve is normal, fan pump may be defective.
REMARK
high idle.
Malfunction of work Min. 0 MPa
10 equipment lock solenoid LOCK
{0 kg/cm2}
valve Output pres-
sure of sole- Work equipment lock lever Min.
noid valve 2.50 MPa
Free
{2.50
kg/cm2}
If measured pressure by check on cause 6 is unusual and main relief valve is nor-
11 Defective HSS pump mal, disconnect work equipment pump outlet hose, crank engine, and check wheth-
er oil flows out.
D155AX-8 40-1295
H-14 BLADE LIFT SPEED OR POWER IS LOW 40 TROUBLESHOOTING
H-14 BLADE LIFT SPEED OR POWER IS LOW

Failure Blade lift speed or power is low
• Check that hydraulic oil level is proper.
• If failure codes are displayed, perform troubleshooting for related failure code first
(DXA2KA, DXA2KB, DXA2KY, DXA3KA, DXA3KB, DXA3KY).
Related • Check that blade is not modified.
information • Work equipment pump pressure can be also checked with monitoring function. (monitoring
code: 70700)
• If hydraulic drift of blade lift is also large, perform troubleshooting for "H-18 Hydraulic drift
of blade lift is large" first.

Defective strainer of work Check strainer for clogging.
1
equipment pump
2 side of work equipment
pump
REMARK
high idle.
2.50 MPa
{25.5
pressure
kg/cm2}
REMARK
Defective operation of
high idle.
4
EPC valve for blade lift EPC valve
output pres- 3.43 MPa
Blade lift control lever Lifting control
sure (refer- {35 kg/cm2}
ence)
REMARK
high idle.
5
Unload
levers {25(+14/0)
pressure
kg/cm2}
40-1296 D155AX-8
40 TROUBLESHOOTING H-14 BLADE LIFT SPEED OR POWER IS LOW
REMARK
high idle.
Defective work equip- Work equip- 27.5 ±
6 ment main 1.5 MPa
ment main relief valve Blade lift cylinder Relief
relief pres- {280 ±
sure 15 kg/cm2}
If failure code is still displayed after above checks on causes 3 and 6 but main cir-
Defective operation of cuit oil pressure is not higher than relief pressure of unload valve during blade
7 blade lift control valve RAISE operation, operation of work equipment spool may be defective.
spool
Check spool for sticking.
Defective operation of Ripper operates normally and blade rises with no-load ripper. However, blade pres-
blade lift control valve sure compensation valve may be defective if blade cannot rise when load is applied
8
pressure compensation to ripper.
valve
Because operation of suction valve of blade control valve may be defective, check
Defective operation of it for damage, etc.
9 blade lift control valve
(suction valve) * Switch suction valve of blade control valve to that of ripper lift or ripper lift control
valve, and determine based on change of phenomenon.
Check for stuck LS valve spool and fatigue of spring. If anything wrong is found,
10 Malfunction of PC valve
replace it.
11 Malfunction of LS valve
replace it.
REMARK
Defective blade lift cylin- high idle.
12
der
When relief pressure is low, disconnect hydraulic hose on blade lift cylinder head
side and relieve cylinder at its stroke end. If oil flows out from cylinder side, cylinder
piston ring is defective.
If measured oil pressure is unusual in check on cause 6 and main relief valve is
Defective work equip- normal, work equipment pump may be defective.
13
ment pump If pump is defective, check for similar symptom in ripper operation and blade tilt op-
eration.
D155AX-8 40-1297
H-15 BLADE TILT SPEED OR POWER IS LOW 40 TROUBLESHOOTING

Failure Blade tilt speed or power is low.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DXA2KA, DXA2KB, DXA2KY, DXA3KA, DXA3KB, or DXA3KY)
• Check that blade is not modified.
Related • Check that engine high idle speed is normal with monitoring function. (Monitoring code:
information 01002)
• Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 70700)
• When hydraulic drift of tilted blade is also large, perform troubleshooting for “H-19 Hy-
draulic drift of tilted blade is large”first.

1
equipment pump
pump
REMARK
high idle.
2.50 MPa
{25.5
pressure
kg/cm2}
REMARK
high idle.
4
EPC valve for blade tilt EPC valve
output pres- 3.43 MPa
Blade tilt control lever Tilting control
ence)
REMARK
high idle.
5
Unload
levers {25(+14/0)
pressure
kg/cm2}
40-1298 D155AX-8
40 TROUBLESHOOTING H-15 BLADE TILT SPEED OR POWER IS LOW

REMARK
Defective work equip- Be ready with engine stopped, then perform troubleshooting with engine at
6 high idle.
ment main relief valve
Work equip- 27.5 ±
ment main 1.5 MPa
Blade tilt cylinder Relief
sure 15 kg/cm2}
When no failure is found by checks on causes 3 and 6, if main circuit oil pressure
Malfunction of blade tilt does not exceed unload valve relief pressure when boom is tilted, work equipment
7 spool may be malfunctioning.
control valve spool
Check if spool is stuck.
Defective operation of If ripper operates normally and tilt system operates normally when no load is ap-
blade tilt control valve plied to ripper but operates abnormally when ripper is loaded, blade pressure com-
8
pressure compensation pensation valve may be defective.
valve
replace it.
replace it.
REMARK
Defective blade tilt cylin- high idle.
11
der
When relief pressure is low, disconnect hydraulic hose on blade tilt cylinder head
side and relieve cylinder at its stroke end. If oil flows out from cylinder side, cylinder
piston ring is defective.
If measured oil pressure is unusual in check on cause 6 and main relief valve is
Defective work equip- normal, work equipment pump may be defective.
12
ment pump
If pump is defective, check for similar symptom in ripper operation.
D155AX-8 40-1299
H-16 RIPPER LIFT SPEED OR POWER IS LOW 40 TROUBLESHOOTING
H-16 RIPPER LIFT SPEED OR POWER IS LOW

Failure Ripper lift speed or power is low.
• Check that oil level in hydraulic tank is appropriate.
• If failure codes are displayed, perform troubleshooting for them first. (DXA2KA, DXA2KB,
DXA2KY, DXA3KA, DXA3KB, DXA3KY)
Related • Check if the ripper is modified.
information • Work equipment pump pressure is checked with monitoring function. (Monitoring code:
70700)
• When hydraulic drift of lifted ripper is also large, perform troubleshooting for "H-20 HY-
DRAULIC DRIFT OF LIFTED RIPPER IS LARGE" first.

1
equipment pump
pump
REMARK
high idle.
2.50 MPa
{25.5
pressure
kg/cm2}
REMARK
high idle.
4
EPC valve for ripper lift EPC valve Ripper lift control lever Lift operation 3.43 MPa
output pres- {35 kg/cm2}
sure (refer-
ence)
REMARK
high idle.
5
Unload
levers {25(+14/0)
pressure
kg/cm2}
40-1300 D155AX-8
40 TROUBLESHOOTING H-16 RIPPER LIFT SPEED OR POWER IS LOW
REMARK
high idle.
6 ment main 1.5 MPa
ment main relief valve Ripper lift cylinder Relief
sure 15 kg/cm2}
Defective operation of cuit oil pressure is not higher than relief pressure of unload valve during ripper lift
7 ripper lift control valve operation, operation of work equipment spool may be defective.
spool
Defective operation of Blade lift operates normally and ripper lift operates normally with no-load blade lift.
8 ripper control valve pres- However, ripper lift pressure compensation valve may be defective if ripper lift oper-
sure compensation valve ates abnormally when load is applied to blade lift.
replace it.
replace it.
REMARK
Defective ripper lift cylin- high idle.
11
der
If measured relief oil pressure is low, disconnect hydraulic hose at the ripper lift cyl-
inder head side. If oil flows out from cylinder when cylinder is stalled at its stroke
end, cylinder piston ring is defective.
• If measured oil pressure is unusual in check on cause 6 and main relief
Defective work equip- valve is normal, work equipment pump may be defective.
12
ment pump To determine whether work equipment pump is defective, check for similar symp-
tom in blade operation.
D155AX-8 40-1301
H-17 RIPPER TILT SPEED OR POWER IS LOW 40 TROUBLESHOOTING
H-17 RIPPER TILT SPEED OR POWER IS LOW

Failure Ripper tilt speed or power is low.
• Check that oil level in hydraulic tank is appropriate.
• If failure codes are displayed, perform troubleshooting for them first. (DXA2KA, DXA2KB,
Related DXA2KY, DXA3KA, DXA3KB, DXA3KY)
information • Check if the ripper is modified.
• Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 70700)

1
equipment pump
pump
REMARK
high idle.
2.50 MPa
{25.5
pressure
kg/cm2}
EPC valve output pressure (reference)
Be ready
with engine
Defective operation of stopped,
4 then per- 3.43 MPa
EPC valve for ripper tilt Ripper tilt control lever Tilting control
form trou- {35 kg/cm2}
bleshooting
with engine
at high idle.
REMARK
high idle.
5
Unload
levers {25(+14/0)
pressure
kg/cm2}
REMARK
high idle.
6 ment main 1.5 MPa
ment main relief valve Ripper tilt cylinder Relief
sure 15 kg/cm2}
40-1302 D155AX-8
40 TROUBLESHOOTING H-17 RIPPER TILT SPEED OR POWER IS LOW

Defective operation of cuit oil pressure is not higher than relief pressure of unload valve during ripper tilt
7 ripper tilt control valve operation, operation of work equipment spool may be defective.
spool
Defective operation of Blade lift operates normally and ripper lift operates normally with no-load blade lift.
8 ripper control valve pres- However, ripper lift pressure compensation valve may be defective if ripper lift oper-
sure compensation valve ates abnormally when load is applied to blade lift.
replace it.
replace it.
REMARK
Defective ripper tilt cylin- high idle.
11
der
If hydraulic hose on ripper tilt cylinder head side is disconnected when relief oil
pressure is low and oil leaks from cylinder side by relief operation at stroke end,
piston ring of cylinder is defective.
• If measured oil pressure is unusual in check on cause 6 and main relief
Defective work equip- valve is normal, work equipment pump may be defective.
12
ment pump To determine whether work equipment pump is defective, check for similar symp-
tom in blade operation.
D155AX-8 40-1303
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 40 TROUBLESHOOTING
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE

Failure Hydraulic drift of lifted blade is large.
Related • Check if the blade is modified.
information • Make sure that a work equipment circuit has no oil (fuel) leakage before troubleshooting.

If hydraulic drift becomes larger by troubleshooting according to the following pro-
cedure, seal of blade lift control valve spool is defective.
Defective blade lift con- 1. Push the ground surface by blade lift, and push up front of machine.
1
trol valve (spool) seal 2. Stop engine and turn starting switch to ON position.
3. Move blade control lever to “Lift LOWER” side, and check whether ma-
chine is lowered.
REMARK
Extend blade lift cylinder to stroke end (push up forward) and stop engine to
Defective blade lift cylin-
2 perform troubleshooting.
der
Disconnect hydraulic hose on blade lift cylinder side. If oil flows out of cylinder, cyl-
inder piston ring is defective.
40-1304 D155AX-8
40 TROUBLESHOOTING H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE

Failure Hydraulic drift of tilted blade is large.
Related • Check if the blade is modified.

cedure, seal of blade lift control valve spool is defective.
Defective blade lift con- 1. Push the ground surface by blade lift, and push up front of machine.
1
3. Move blade control lever to “Lift LOWER” side, and check whether ma-
chine is lowered.
idle.
Defective blade tilt cylin-
2 Leakage
der
from cylin- Tilt LEFT operation Relief cylinder 12 cc/min
der
D155AX-8 40-1305
H-20 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE 40 TROUBLESHOOTING
H-20 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE

Failure Hydraulic drift of lifted ripper is large.
Related • Check if the ripper is modified.

cedure, seal of ripper lift control valve spool is defective.
Defective ripper lift con- 1. Push the ground surface by ripper lift, and push up rear of machine.
1
3. Move ripper control lever to “Lift LOWER” side, and check whether ma-
chine is lowered.
Be ready with engine started, then perform troubleshooting with engine at high idle.
Defective ripper lift cylin- Leakage
2
der from cylin- Ripper lift cylinder LOWER relief 11 cc/min
der
40-1306 D155AX-8
40 TROUBLESHOOTING H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE

Failure Ripper pin puller cylinder does not operate.
Related
information

and high idle.
2.62 MPa
Low idle {26.7
Main relief kg/cm2}
Engine speed
pressure 2.79 MPa
Defective adjustment or
1 malfunction of transmis- High idle {28.5
sion main relief valve kg/cm2}
Check that free length of springs and number of shims are normal and that spool
moves smoothly.
• Free length of large spring: 122 mm
• Number of shims: 6 pcs.
• Free length of small spring: 108 mm
idle.
2.79 MPa
Malfunction of pin puller Push {28.5
2 Output pres-
solenoid valve kg/cm2}
sure of sole- Pin puller switch
noid valve 2.79 MPa
Pull {28.5
kg/cm2}
REMARK
Defective pin puller cylin- high idle.
3
der
When oil pressure is low in check on Cause 2, disconnect hydraulic hose on pin
puller cylinder head side and relieve at stroke end. If oil flows out from cylinder
side, cylinder piston ring is defective.
D155AX-8 40-1307
H-22 BLADE PITCH CYLINDER DOES NOT OPERATE 40 TROUBLESHOOTING
H-22 BLADE PITCH CYLINDER DOES NOT OPERATE

Failure Blade pitch cylinder does not operate.
• If failure codes are displayed, perform troubleshooting for them first. (DDKBKA, DDKBKB,
Related DDN7L4, DDN8L4)
information • Blade knob (pitch) switch input state can be checked with monitoring function. (Monitoring
code: 70306)
REMARK
high idle.
2.50 MPa
{25.5
pressure
kg/cm2}
REMARK
high idle.
2 blade pitch control valve EPC valve
spool output pres- 3.43 MPa
Blade pitch control switch ON
ence)
Check spool for scratch, etc.
REMARK
high idle.
Improper adjustment or Work equip-
3 malfunction of main relief ment main 27.5 ± 1.5
valve Blade pitch cylinder Relief MPa {280 ±
relief pres-
15 kg/cm2}
sure
REMARK
4 Defective pitch cylinder
high idle.
When relief pressure is low, disconnect hydraulic hose on blade pitch cylinder head
side and relieve cylinder at its extension stroke end. If oil flows out from cylinder
side, cylinder piston ring is defective.
40-1308 D155AX-8
H-23 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATION-
40 TROUBLESHOOTING ARY)
H-23 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)

Failure Fan rotation is abnormal (such as excessive noise or vibration of fan, or overheating)
• When engine is started for first time after hydraulic oil replacement, fan may temporarily
rotates at higher speed, but this is normal.
• Check that oil level in hydraulic tank is appropriate before performing troubleshooting.
Related
• If failure codes are displayed, perform troubleshooting for them first. (DWN5KA, DWN5KB,
information DWN5KY, DLM3MB)
• Radiator Fan Speed can be checked with monitoring function. (Monitoring code: 10007)
REMARK
If engine speed is not sufficiently high, perform troubleshooting for “S-5 Rota-
tion is unstable”.
REMARK
1 Defective engine speed Start engine and perform check.
740 to
Engine: Low idle
Engine 765 rpm
speed 2050 to
Engine: High idle
2100 rpm
2 Defective PTO (fan drive) PTO fan drive may be defective.
Check with engine speed at high idle
3 Defective fan speed Hydraulic oil temperature: Fan adjustment mode: 1425 to
Fan speed
Within operating range 100 % 1475 rpm
idle.
Malfunction of fan motor
4 Fan motor 20.58 MPa
(relief valve) Hydraulic oil temperature: Fan adjustment mode:
circuit pres- {210 kg/cm2
Within operating range 100%
sure }
If specified pressure is not obtained by adjusting relief valve in check on Cause 4,
5 Defective fan pump fan pump may have internal defect.
Check self-pressure reducing valve inlet strainer for metallic particles.
Internal defect of fan mo- If failure code is still displayed after above checks on Causes 1 to 5, fan motor may
6
tor have internal defect.
D155AX-8 40-1309
H-24 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40 TROUBLESHOOTING
H-24 UNUSUAL NOISE IS HEARD FROM AROUND FAN

Failure Unusual noise is heard from around fan.
Related
information

Looseness of installation Check if mounting portions of fan and fan motor are loose and have play.
1
of fan and fan motor
2 Interference with shroud Check fan for interference with shroud.
Internal defect of fan mo- If failure code is still displayed after above checks on Causes 1 and 2, fan motor
3
tor may have internal defect.
40-1310 D155AX-8
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S
40 TROUBLESHOOTING MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)

INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)
(Rev. 2014/04)
The following information is summarized in the troubleshooting table. Before performing troubleshooting, under-
stand that information fully.
Failure Failure symptom that appears on engine
Related infor-
Information on occurred failure or troubleshooting
mation
Cause Point to check, remarks Remedy

1
<Contents of description>
2 Probable cause of failure
• Contents of check to deter-
(Each number is serial • Actions to eliminate probable
3 mine probable causes
number, not priority se- cause of failure
4 quence.) • Remarks for determination of
probable cause
5
1.Gauze filter for feed pump

This figure shows the location of gauze filter (1) for the feed pump explained in this manual.
D155AX-8 40-1311
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS
TURNED TO START POSITION 40 TROUBLESHOOTING
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO

START POSITION
Failure Engine does not crank when starting switch is turned to "START" position
• See E-mode in "ENGINE DOES NOT START (ENGINE DOES NOT CRANK)" for electri-
Related
cal system troubleshooting
information
• If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy

When starting switch is turned to START, starting mo- Perform troubleshooting
tor pinion does not pop out. for "ENGINE DOES NOT
Defective starting circuit
1 START (ENGINE DOES
wiring system
NOT CRANK)" and take
remedies.
• Starting motor pinion makes grating noise
(When starting switch is turned to START posi-
tion, starting motor pinion pops out).
• Starting motor pinion comes off halfway (When
Perform troubleshooting
starting switch is turned to START position,
for "ENGINE DOES NOT
Defective starting motor starting motor pinion pops out).
2 START (ENGINE DOES
(safety relay portion) • Starting motor makes flapping sound and does NOT CRANK)" and take
not turn (When starting switch is turned to remedies.
START position, starting motor pinion pro-
trudes) (Reference: “Flapping sound” means
sound made when starting motor pinion pops in
and out)
If starting motor pinion makes grating noise and the
Breakage of flywheel ring Replace if the item is bro-
3 starting motor does not turn, visually check the fly-
gear ken
wheel ring gear.
Disconnect the inlet and outlet gas piping of EGR cool-
er to check if water containing coolant is draining.
A crack on the EGR cool- After EGR cooler replace-
4 er (Reference: coolant REMARK ment, drain the water in
contained in exhaust) the engine cylinder.
Moisture in exhaust gas may be condensed, but this
is not a failure. Check if it is coolant or not.
40-1312 D155AX-8
40 TROUBLESHOOTING S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT

Failure Engine cranks but no exhaust gas comes out.
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

1 Fuel level is low. If fuel tank is checked, it is empty. Refueling
Fuel tank cap air bleeding hole is clogged. Flush air breather hole in
Clogging fuel tank cap air
2 fuel tank cap surrounding
bleeding hole
area.
Clogged fuel filter ele- Check used hours of fuel filter element. If it is used Fuel filter element replace-
3
ment over specified time, fuel filter element may be clogged. ment
Foreign materials are If drain fuel from fuel tank, rust or water comes out.
4 Fuel replacement
mixed into fuel.
When performing bleeding air from the fuel system, air • Perform air bleeding
Air mixed in fuel piping comes out. (For details, see Testing and adjusting, operation
5 “Bleeding air from fuel system”).
system • Correct or replace
fuel piping
Leakage from fuel piping Fuel leaks from fuel piping. (For details, see Testing Correct or replace fuel pip-
6
system and adjusting, “Test fuel circuit for leakage”). ing related parts
Check leakage from common rail pressure limiter. For
details, see Testing and adjusting, “Testing fuel deliv-
ery, return rate, and leakage”.
7 Defective common rail Common rail replacement
REMARK
Leakage from common rail pressure limiter is
10 cc/min or less, and common rail is normal.
NOTICE
Be sure to check for above “Defective common
rail”.
Check common rail pressure with machine monitor. If it
8 Defective supply pump does not increase even during cranking, supply pump Supply pump replacement
is defective.
REMARK
Common rail pressure can be checked with monitor-
ing function (Code: 36400 (MPa)).
Priming pump has no or heavy resistance to operation. Priming pump replace-
9 Defective priming pump
ment
Clogged feed pump Clogged gauze filter Gauze filter cleaning or re-
10
gauze filter placement
When common rail pressure (code: 36400 “Common Loosen common rail side
Defective air bleeding
rail pressure”) is checked on monitor, pressure does of injection pipe and high-
11 from common rail or in-
not drop after stopping (Pressure does not drop, if air pressure pipe mounting
jection pipe
is left). nuts to bleed air.
D155AX-8 40-1313
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MIS-
FIRING: ENGINE CRANKS BUT DOES NOT START) 40 TROUBLESHOOTING
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIR-
ING: ENGINE CRANKS BUT DOES NOT START)
Failure Fuel is being injected but engine does not start (misfiring: engine cranks but does not start).
Related
information

Gravity of electrolyte and voltage of battery are low. Filling of battery electro-
1 Defective battery
lyte
bleeding hole
area.
4
5 Fuel replacement
mixed into fuel.
fuel piping
7
Priming pump has no or heavy resistance to operation. Priming pump replace-
8 Defective priming pump
ment
9
Clogged air cleaner ele- Air cleaner dust indicator is at caution level. Air cleaner element check
10
ment and cleaning
• Installation part of intake air heater is not
warmed during preheat operation.
Defective intake air heat- Intake air heater replace-
11 • Engine preheating monitor does not operate
er ment
normally during preheat operation or when it is
low temperature.
• Check valve clearance (Reference: See Testing
and adjusting, “Testing and adjusting valve
Worn valve, rocker arm, clearance”). Valve or rocker arm re-
12
etc. placement
• When engine is operated, unusual noise is
heard from around cylinder head.
Check compression pressure (Reference: See “TEST-
Piston ring and piston re-
13 Defective piston ring ING AND ADJUSTING”, “Testing compression pres-
placement
sure”).
Perform cylinder cutout mode operation to identify cyl-
Defective injector (clog-
inder that does not change in speed (see “TESTING
14 ged injector, defective Replace injector.
AND ADJUSTING”, “HANDLING CYLINDER CUTOUT
spray)
MODE OPERATION”).
Defective engine control- In case of an internal defect, troubleshooting is impos- Engine controller replace-
15
ler sible as an assembly. Replace whole assembly. ment
40-1314 D155AX-8
40 TROUBLESHOOTING S-4 ENGINE STARTABILITY IS POOR
S-4 ENGINE STARTABILITY IS POOR

Failure Engine startability is poor.
Related • Common rail fuel injection system (CRI) controls fuel injection timing electronically. Even
information when start operation is performed, engine does not start until crankshaft is rotated at least
twice. This is not abnormal.

Gravity of electrolyte and voltage of battery are low. Filling of battery electro-
1 Defective battery
lyte
• Unspecified fuel is used.
• It does not use a fuel that meets the tempera-
Use recommended fuel
ture. (Reference: It starts at warm weather, but
3 Unspecified fuel is used. described in Operation
engine startability is poor at cold weather.)
and Maintenance Manual.
• Deposited wax (milky) is found in clear bowl of
fuel prefilter.
bleeding hole
area.
5
6 Fuel replacement
mixed into fuel.
fuel piping
8
REMARK
NOTICE
rail”.
is defective.
REMARK
11
D155AX-8 40-1315
S-4 ENGINE STARTABILITY IS POOR 40 TROUBLESHOOTING

12
ment and cleaning
• Installation part of intake air heater is not
warmed during preheat operation.
Defective intake air heat- Intake air heater replace-
13 • Engine preheating monitor does not operate
er ment
normally during preheat operation or when it is
low temperature.
Disconnect the inlet and outlet gas piping of EGR cool-
er to check if water containing coolant is draining.
A crack on the EGR cool- After EGR cooler replace-
14 er (Reference: coolant REMARK ment, drain the water in
contained in exhaust) the engine cylinder.
Moisture in exhaust gas may be condensed, but this
is not a failure. Check if it is coolant or not.
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
15 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).
16
• Measure compression pressure (See Standard
value table). (Reference: See Testing and ad-
Defective contact of justing, “Testing compression pressure”.) Valve or valve seat repair
17
valve and valve seat • Check valve clearance (Reference: See Testing or replacement
clearance”).
• Make exhaust gas color measuring hole before
KDPF, and check exhaust gas through it (Refer-
ence: See “TESTING AND ADJUSTING”,
“Checking exhaust gas color”). Piston ring and piston re-
18 Defective piston ring
• Measure compression pressure (See standard placement
value table). (Reference: See “TESTING AND
ADJUSTING”, “Testing compression pressure”.)
• Check piston ring and piston ring groove.
40-1316 D155AX-8
40 TROUBLESHOOTING S-5 ENGINE DOES NOT PICK UP SMOOTHLY
S-5 ENGINE DOES NOT PICK UP SMOOTHLY

Failure Engine does not pick-up smoothly.
Related
information

bleeding hole
area.
3
4 Fuel replacement
mixed into fuel.
fuel piping
6
REMARK
NOTICE
rail”.
is defective.
REMARK
9
When crankcase pressure high error (failure code:
CA555) is still displayed even after KCCV filter is re- Perform troubleshooting
Crankcase pressure high
10 placed, blowby pressure is probably high (see Testing for cause 11 and subse-
error
and adjusting, “Testing blowby pressure”). In this case, quent causes.
KVGT may be seized or damaged.
D155AX-8 40-1317
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40 TROUBLESHOOTING

• Unusual noise is heard from KVGT.
KVGT seizure and dam-
12 • Check if KVGT shaft can rotate (by manually KVGT replacement
age
moving the KVGT's blade axially and vertically).
Defective valve clear- Valve clearance adjust-
13 • Check valve clearance (Reference: See Testing ment
ance
clearance”).
14
clearance”).
16
40-1318 D155AX-8
40 TROUBLESHOOTING S-6 ENGINE STOPS DURING OPERATION
S-6 ENGINE STOPS DURING OPERATION

Failure Engine stops during operation.
Related
information

bleeding hole
area.
3
4 Fuel replacement
mixed into fuel.
fuel piping
6
7
See Testing and adjusting, “Testing fuel discharge rate, Supply pump and pres-
return rate, and leakage” sure limiter replacement
Defective air intake hose Visually check for damages of air intake hose.
Air intake hose replace-
9 (air cleaner to KVGT in-
ment
let)
Defective air intake mani- Check for internal damages of air intake manifold. Air intake manifold re-
10
fold placement
Defective boost piping Air comes out of boost piping.
and connection (between Boost piping repair or re-
11
KVGT outlet and intake placement
manifold)
Defective exhaust pipe Check exhaust pipes for damage and exhaust gas
Exhaust piping replace-
12 (between exhaust mani- leakage (Check heat insulation cover and soot on heat
ment
fold and KDPF inlet) insulation plate)
Broken valve or rocker Check valve and rocker arm (when stops with unusual Valve or rocker arm re-
13
arm noise). placement
• Oil drained from oil pan contains metallic pow-
Breakage or seizure of der.
Piston and connecting rod
14 piston and connecting • Remove oil pan and check piston and connect- replacement
rod ing rod (Reference: Stopping with unusual
noise or stopping caused by overheating)
• Metal particles are contained in oil drained from
Breakage or seizure of oil pan. Crankshaft main bearing
15
crankshaft main bearing • Remove oil pan and check crankshaft main replacement
bearing.
Defective engine control- Check power supply wiring of engine controller. (Refer- Correct engine controller
16
ler power supply wiring ence: See Troubleshooting, Failure code [CA343].) power supply wiring
D155AX-8 40-1319
S-6 ENGINE STOPS DURING OPERATION 40 TROUBLESHOOTING

Check starting switch wiring. Perform troubleshooting
Defective starting switch for “Engine does not start
17
wiring (engine does not crank)”
and take remedies.
Malfunction of hydraulic H-mode: See “Machine lacks power (insufficient draw- Diagnose and take rem-
18
system bar pull)” edies for H mode
40-1320 D155AX-8
40 TROUBLESHOOTING S-7 ENGINE RUNS ROUGH OR IS UNSTABLE
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE

Failure Engine runs rough or is unstable.
Related
information

bleeding hole
area.
3
4 Fuel replacement
mixed into fuel.
fuel piping
6
Check boost system (between KVGT outlet and after-
Leakage from boost sys- Boost piping repair or re-
7 cooler, aftercooler and between aftercooler and air in-
tem placement
take manifold) for leakage.
8
Replace a sensor, and check if it operates normally
Defective mass air flow Mass air flow and temper-
9 (failure code may be displayed due to dust attached to
and temperature sensor ature sensor replacement
sensor).
D155AX-8 40-1321
S-8 ENGINE LACKS POWER 40 TROUBLESHOOTING
S-8 ENGINE LACKS POWER

Failure Engine lacks power.
Related
information

bleeding hole
area.
3
4 Fuel replacement
mixed into fuel.
fuel piping
6
See Testing and adjusting, “Testing fuel discharge rate, Supply pump and pres-
return rate, and leakage” sure limiter replacement
8
9
ment and cleaning
Check air cleaner and rectifying wire net for deforma- Air cleaner repair or re-
10 Defective air cleaner
tion. placement
Defective air intake hose Visually check for damages of air intake hose.
Air intake hose replace-
11 (air cleaner to KVGT in-
ment
let)
Defective air intake mani- Check for internal damages of air intake manifold. Air intake manifold re-
12
fold placement
13
manifold)
Defective installation of Air leakage through mounting portion of charge pres- Repair installation of
14
charge pressure sensor sure sensor charge pressure sensor
ment
Gas leakage from EGR Gas leaking from EGR piping.
16 Replace EGR piping
piping
Check of air intake/ Measure boost pressure (Reference: See Testing and
exhaust system (KVGT adjusting, “Testing boost pressure”).
Defective parts repair and
17 outlet, air intake mani-
replacement
fold/exhaust manifold,
and KDPF inlet)
40-1322 D155AX-8
40 TROUBLESHOOTING S-8 ENGINE LACKS POWER

age
Open a bore for measuring the exhaust gas color in
front of KDPF and check the exhaust gas coming out
Excessive soot load in KDPF cleaning or replace-
19 of the bore. (See STANDARD VALUE TABLE) (Refer-
KDPF ment
ence: See “TEST EXHAUST GAS COLOR” section in
“TESTING AND ADJUSTING”.)
Check KDPF for clogging - discharge pressure in front KDPF cleaning or replace-
20 Defective KDPF
of KDPF ment
ance
clearance”).
23
24
clearance”).
Clogged KCCV filter ele- If KCCV filter element is removed, a large quantity of Replace KCCV filter ele-
26
ment oil is found attached to it. ment.
D155AX-8 40-1323
S-9 KDPF GETS CLOGGED IN A SHORT TIME 40 TROUBLESHOOTING
S-9 KDPF GETS CLOGGED IN A SHORT TIME

Failure KDPF gets clogged in a short times
Related
information

Unspecified fuel is used. Use recommended fuel
2 Fuel replacement
mixed into fuel.
Check air cleaner and rectifying wire net for deforma- Air cleaner repair or re-
3 Defective air cleaner
tion. placement
ment
Defective installation of Air leakage through mounting portion of charge pres-
Repair installation of
5 charge (boost) pressure sure sensor
charge pressure sensor
sensor
6
manifold)
Check KDPF for clogging - discharge pressure in front KDPF cleaning or replace-
7 Defective KDPF
of KDPF ment
Gas leakage from EGR Gas leaking from EGR piping.
piping
age
When checking fuel return rate, fuel return rate is ex-
Defective fuel return pip- Fuel return piping repair or
11 cessive. (Reference: See Testing and adjusting, “Test-
ing replacement
ing fuel return rate and leakage”.)
Replace a sensor, and check if it operates normally
Defective mass air flow Mass air flow and temper-
12 (failure code may be displayed due to dust attached to
and temperature sensor ature sensor replacement
sensor).
ance
clearance”).
40-1324 D155AX-8
40 TROUBLESHOOTING S-9 KDPF GETS CLOGGED IN A SHORT TIME

14
clearance”).
D155AX-8 40-1325
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40 TROUBLESHOOTING
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE

Failure Engine oil consumption is excessive
Related
information

Dust intake from air in- If air intake piping between air cleaner and engine is Air intake piping cleaning
1
take system removed, dust enters in piping. or replacement
• Measured blowby pressure is above standard
value.
• After KCCV filter element is replaced, blowby
Breakage or wear of pis- Piston ring replacement or
2 pressure is still high.
ton ring repair
• Measure compression pressure (See standard
Oil leakage from KCCV Check for oil leakage from KCCV oil return piping. Oil piping repair or re-
3
oil return piping. placement
4 Oil leakage out of engine Check for oil leakage. Oil leakage part repair
Check for oil leakage from oil filter. Oil filter re installation or
5 Oil leakage from oil filter
replacement
Oil leakage from oil pip- Check for oil leakage from oil piping Oil piping repair or re-
6
ing placement
Oil leakage from oil drain Check oil leakage from oil drain plug.
7 Retighten oil drain plug
plug
Check for oil leakage from oil pan. Oil pan repair or replace-
8 Oil leakage from oil pan
ment
Oil leakage from cylinder Check for oil leakage from cylinder head. Cylinder head repair or re-
9
head placement
Wear of damage of rear Oil in clutch chamber or damper chamber on mounted Rear oil seal repair or re-
10
oil seal machine side is increased. placement
• Inlet/outlet of blower and outlet of turbine in
KVGT have oil stains.
11 Oil leakage from KVGT KVGT replacement
• Check if KVGT shaft can rotate (by manually
• Oil is mixed in coolant.
• Remove and check oil cooler. Check outside for
Oil leakage from oil cool-
12 oil leakage. Oil cooler replacement
er
• Check oil cooler for leakage by air pressure
test.
Oil leakage from EGR Outlet port is stained with oil after the EGR valve is dis-
13 EGR valve replacement
valve system connected.
• Check valve guide and stem seal.
Wear or damage of valve • Remove cylinder head and check guide internal Valve guide and stem seal
14
guide or stem seal surface and stem seal for damage (Reference: replacement
See Maintenance standard).
40-1326 D155AX-8
40 TROUBLESHOOTING S-11 OIL BECOMES CONTAMINATED QUICKLY
S-11 OIL BECOMES CONTAMINATED QUICKLY

Failure Oil becomes contaminated quickly
Related
information

Oil out of specification is used Use recommended oil de-
Use of oil out of specifi-
2 scribed in Operation and
cation
Maintenance Manual.
Check exhaust gas color in front of KDPF. (See stand-
Perform troubleshooting of
Exhaust gas color in front ard value table.) (Reference: See Testing and adjust-
3 "exhaust gas color is
of KDPF is black. ing, “Exhaust gas color”). (Exhaust gas color in front of
black"
KDPF is black.)
1. Measured blowby pressure is higher than
standard value.
4 Much blowby gas Perform following checks.
2. Blowby pressure is still high after KCCV filter el-
ement is replaced.
Check if KVGT shaft is not loose when rotated (by
Defective seal on turbine
5 manually moving the KVGT's blade axially and vertical- KVGT replacement
side of KVGT
ly).
• Disconnect the EGR valve to check a stem
Wear in the EGR valve seal, guide, and system.
6 EGR valve replacement
guide • Outlet port is stained with oil after the EGR
valve is disconnected.
Check for high oil level (If oil is added too much, it be- Lower oil level to appropri-
7 Addition of too much oil
comes high temperature and is deteriorated rapidly). ate level.
Visually check oil cooler element for dirt (temperature Oil cooler element repair
8 Dirt on oil cooler element
rise caused by dirt of oil cooler element) or replacement
• Measured blowby pressure is above standard
value.
• After KCCV filter element is replaced, blowby
Breakage or wear of pis- Piston ring replacement or
9 pressure is still high.
ton ring repair
• Measure compression pressure (See standard
• Check valve guide and stem seal.
Wear or damage of valve • Remove cylinder head and check guide internal Valve guide and stem seal
10
guide or stem seal surface and stem seal for damage (Reference: replacement
See Maintenance standard).
D155AX-8 40-1327
S-12 FUEL CONSUMPTION IS EXCESSIVE 40 TROUBLESHOOTING
S-12 FUEL CONSUMPTION IS EXCESSIVE

Failure Fuel consumption is excessive.
Related
information

Leakage from injector (Reference: See “TESTING • Replace injector.
AND ADJUSTING”,“Testing fuel discharge, return and
Much leakage from injec- leakage”). • Excessive dust may
1 be in fuel. Confirm
tor
quality control of
fuel.
Clogged fuel return pip- Check fuel return piping for clogging (injection amount Fuel return piping repair or
2
ing increases for clogged fuel return piping). replacement
Fuel leakage from inside • Check if oil level is increasing.

4 Defective parts repair
of cylinder head • Check if there is smell of diesel fuel.
• Check if oil level is increasing or there is smell
Fuel leakage atfeed of diesel fuel. Feed pump oil seal re-
5
pump oil seal part placement
• Check feed pump oil seal.
6 External fuel leakage Check for fuel leakage to outside of engine. Defective parts repair
Fuel leakage from fuel Check of fuel leakage of fuel doser part
7 Fuel doser replacement
doser
• Unspecified fuel filter is used. • Use recommended
• Procedures described in Operation and Mainte- fuel described in Op-
nance Manual are not observed when replacing eration and Mainte-
fuel filter. nance Manual.
Fuel is contaminated with
8 • Observe procedures
dust
for replacing fuel fil-
ter described in Op-
eration and Mainte-
nance Manual.
Fuel leakage from fuel Check for fuel leakage to outside of fuel feed pump Fuel feed pump replace-
9
feed pump ment
40-1328 D155AX-8
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOL-
40 TROUBLESHOOTING ANT LEVEL GOES DOWN)
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT

LEVEL GOES DOWN)
Failure Oil is in coolant (or coolant spurts back or coolant level goes down)
Related
information

Engine oil is increasing and milky. Perform troubleshooting of
1 Engine oil is milky. "water mixes into engine
oil (milky)"
Breakage of oil cooler el- Check oil cooler element. Oil cooler element re-
2
ement placement
• There are many bubbles in radiator and coolant
Breakage of cylinder blows back. Cylinder head replace-
3
head • Disassemble engine and check cylinder head ment
for abnormality by pressure test.
• Many bubbles and blow-back are found in radi-
ator. Cylinder head gasket re-
4 Breakage of head gasket
• Disassemble and inspect engine. Check cylin- placement
der head gasket for failure.
Cracking or hole caused • Engine oil is increasing and milky.

Cylinder block replace-
5 by pitting in cylinder • Disassemble engine and check inside of cylin- ment
block der block for cracking or hole caused by pitting.
D155AX-8 40-1329
S-14 OIL PRESSURE DROPS 40 TROUBLESHOOTING
S-14 OIL PRESSURE DROPS

Failure Engine oil pressure drops.
Related
• Check if machine is operated on slopes steeper than angle specified in Operation and
information
Maintenance Manual.

Oil level in oil pan is insufficient.
1 Insufficient oil in oil pan Oil pressure monitor indicates low oil pressure on Oil refiling
slopes.
Check oil pressure sensor, wiring harness, and con- Oil pressure sensor, wiring
Defective oil pressure
2 nectors harness, and connectors
sensor or wiring harness
replacement
• Perform oil analysis and check for mixing of oil If oil is mixed into fuel,
perform troubleshooting of
3 Fuel mixed in oil • Oil smells of diesel fuel.
"fuel mixes into engine oil
(milky)"
• Perform oil analysis and check for mixing of wa- If oil is mixed into water,
ter perform troubleshooting of
4 Water mixed in oil
"water mixes into engine
• Oil is milky.
oil (milky)"
• Check oil filter.
(Reference: Oil filter is used for more than specified
5 Clogged oil filter Oil filter replacement
period, oil is deteriorated badly, etc.)
• Oil filter may be blocked by water.
6 Clogged oil strainer Check oil strainer. Oil strainer cleaning
Flattened or clogged hy- Hydraulic piping is flattened or clogged. Hydraulic piping replace-
7
draulic piping ment
• Check oil pump (for wear or breakage of gear)
8 Defective oil pump Oil pump replacement
• Oil pump is heavy in turning or has play.
Check whether the valve spring is deformed and dam-
9 Defective regulator valve Regulator valve exchange
aged
Defective oil pump relief Valve and spring of oil pump relief valve are weakening Oil pump relief valve ex-
10
valve and damaged. change
Cracking in oil pump suc- Check around oil pump suction piping (for cracking ing Oil pump suction piping
11
tion piping piping). replacement
Defective seal between Check sealing portion.
12 oil pump and oil pump Seal replacement
suction piping
Check boost oil pump. Boost oil pump replace-
13 Defective boost oil pump
ment
Defective boost oil pump Check valve and spring of boost oil pump relief valve Boost oil pump relief valve
14
relief valve for fatigue and damage. replacement
Leakage from EGR hy- Check EGR hydraulic piping. EGR hydraulic piping re-
15
draulic piping placement
• Check main journal bearing.
Wear of main journal Bearing of main journal re-
16 • Metal particles are contained in oil drained from placement
bearing
oil pan.
40-1330 D155AX-8
40 TROUBLESHOOTING S-14 OIL PRESSURE DROPS

• Check pin journal bearing.
Wear of pin journal bear- Bearing of pin journal re-
17 • Oil drained from oil pan contains metallic pow-
ing placement
der.
Breakage or removal of Check of piston cooling nozzle Piston cooling nozzle re-
18
piston cooling nozzle placement
D155AX-8 40-1331
S-15 FUEL MIXES INTO ENGINE OIL 40 TROUBLESHOOTING
S-15 FUEL MIXES INTO ENGINE OIL

Failure Fuel mixes into engine oil (There is smell of diluted diesel fuel).
Related
information

Fuel leakage from injec- Check injector and O-ring. Injector and O-ring re-
2
tor or O-ring (spill circuit) placement
Defective seal between Check of seal between injector and inspection pipe,
injector and inspection check of injection pipe for cracking
3 Repair or replacement
pipe, or cracked injection
pipe
Internal defect of supply Replace supply pump, and check if mixing of fuel is
4 Supply pump replacement
pump prevented.
40-1332 D155AX-8
40 TROUBLESHOOTING S-16 WATER MIXES INTO ENGINE OIL (MILKY)
S-16 WATER MIXES INTO ENGINE OIL (MILKY)

Failure Water mixes into engine oil (milky)
• If oil mixes into coolant, perform troubleshooting for "Oil mixes into coolant".
• If any failure code is displayed, perform troubleshooting for that code.
Related If engine is started and stopped frequently when ambient temperature is low, water vapor in blowby
information gas may condense and cause milky oil or emulsified matter may stick because of KCCV. This is not
abnormal, as long as there is no coolant leakage.
If coolant level lowers rapidly and coolant leakage is suspected, perform following troubleshooting.

• Water containing coolant is draining after dis-
connecting the inlet and outlet gas piping of
EGR cooler (check if it is antifreeze because it
may be condensed water).
A crack on the EGR cool-
1 (Reference: A crack in the EGR cooler, if any, may be EGR cooler replacement
er
caused by lowered coolant level in the coolant system.
Check if there is no water leakage from the piping of
the coolant system or radiator when the replacing the
EGR cooler.)
• Check oil cooler element and O-ring
Breakage of oil cooler el- Oil cooler element and O-
2 • Leakage form oil cooler is detected by pressure ring replacement
ement or O-ring
test.
Leakage through water Check water pump mechanical seal for leakage Mechanical sealed part of
3
pump mechanical seal water pump replacement
Clogged water pump Check water pump drain hole. Water pump drain hole
4
drain hole cleaning
Breakage of cylinder Disassemble engine and check cylinder head and Cylinder head and head
5
head or head gasket head gasket gasket replacement
Cracking or hole caused • Engine oil is increasing and milky.

Cylinder block replace-
6 by pitting in cylinder • Disassemble engine and check inside of cylin- ment
block der block for cracking or hole caused by pitting.
D155AX-8 40-1333
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40 TROUBLESHOOTING
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)

Failure Coolant temperature rises too high (overheating)
Related
information

1 Clogged radiator core Check for clogging of radiator core and crushing of fin. Cleaning of radiator core
Thermostat does not open at cracking temperature.
2 Malfunction of thermostat REMARK Thermostat replacement

Cracking temperature of thermostat: 76.5 ± 2 °C (Full
open temperature: 90 °C)
The error is detected in coolant temperature gauge Coolant temperature sen-
Defective coolant tem-
3 system, but measured coolant temperature in radiator sor, monitor or wiring har-
perature gauge
is normal. ness replacement
Fuel injection amount is excessive. Perform troubleshooting
Increase of fuel injection
4 for “Fuel consumption is
amount
excessive”
5 Low coolant level Check coolant level for decrease. Refilling with coolant
Check coolant piping for coolant leakage. Coolant piping replace-
6 Coolant leakage
ment
Visually check water pump (check of water leakage
7 Broken water pump through shaft seal, breakage of impeller, breakage of Water pump replacement
shaft)
Overheat due to increase Check for defective mass air flow and temperature
in EGR ratio (EGR sensor.
amount against fresh air
Mass air flow and temper-
8 intake amount) caused
ature sensor replacement
by defective mass air
flow and temperature
sensor
Overheat caused by in- Check air cleaner and rectifying wire net for deforma-
crease of EGR ratio tion.
Air cleaner repair or re-
9 (quantity of EGR to fresh
placement
intake air) caused by de-
formation of air cleaner
Defective cylinder head Check if there are many bubbles in radiator and if cool- Reform troubleshooting in
10
or head gasket ant blows back. "Oil is mixed in coolant".
40-1334 D155AX-8
40 TROUBLESHOOTING S-18 UNUSUAL NOISE IS HEARD
S-18 UNUSUAL NOISE IS HEARD

Failure Unusual noise is heard.
• Check place of sound source, inside or outside, then perform troubleshooting.
• While engine is not warmed up sufficiently, it is operated in low-temperature mode and it
Related generates a little larger sound. This is not abnormal.
information • When engine is accelerated, it is set in acceleration mode and it generates a little larger
sound for approximately 3 to 5 seconds. This is not abnormal.

• Gas leakage from following parts; between cyl-
inder head and exhaust manifold, piping be-
Gas leakage from each tween exhaust manifold and KVGT, piping be- Problematic portions re-
1 tween KVGT outlet and KDPF
part of the piping pair or replacement
• Gas leakage from EGR piping or air intake pip-
ing
Vibration of exhaust pip- Confirm the presence of vibration by visual check Check and retighten pip-
2
ing and exhaust bellows ing fixed bracket
Seizure, damage, and Check if KVGT shaft can rotate (by manually moving
3 unusual noise from the KVGT's blade axially and vertically). KVGT replacement
KVGT
Check internal KDPF. KDPF cleaning or replace-
4 KDPF broken internally
ment
Defective valve clear- Check valve clearance (Reference: See Testing and Valve clearance adjust-
6
ance adjusting, “Testing and adjusting valve clearance”). ment
Seizure of pin bushing, Check inside of oil pan for metallic powder.
Damaged parts repair or
7 front bearing, or main
replacement
bearing
1. If metal particles are found in oil pan or oil filter,
overhaul engine and check piston rings and cyl-
Worn piston ring or cylin- inder liners. Replace piston ring or cyl-
8
der liner 2. Measure pressure (See Standard value table) inder liner.
(Reference: See Testing and adjusting, “Testing
compression pressure”)
Broken valve or rocker Overhaul engine and check valve and rocker arm Valve or rocker arm re-
9
arm parts. placement
Broken peripheral parts Overhaul engine and inspect idler gear parts.
10 Idler gear replacement
of idler gear
D155AX-8 40-1335
S-19 VIBRATION IS EXCESSIVE 40 TROUBLESHOOTING
S-19 VIBRATION IS EXCESSIVE

Failure Vibration is excessive.
• If unusual noise is heard and vibration is excessive, perform troubleshooting for "Unusual
Related
noise is heard" as well.
information

Loose engine mounting Visually check engine mounting bolts for looseness
Retighten bolts or cush-
1 bolts or defective cush- and cushions for cracks and hardening.
ions replacement
ions
Worn faucet joint portion Check for worn faucet joint portion of front support
2 Replace front support
of front support trunnion trunnion
Breakage of vibration Visually check the vibration damper for damage or de- Vibration damper replace-
3
damper terioration. ment
Abnormality of output Check output shaft and damper for internal damage.
Defective parts replace-
4 shaft and inside of damp-
ment
er
Misalignment and facial Measure misalignment and facial runout at connection
runout at connection of of engine output side. Defective parts replace-
5
engine output side is out ment
of standard range.
Wear of main bearing If metallic powder is found in oil pan and oil filler, disas-
Damaged parts repair and
7 and connecting rod bear- semble engine and check it.
replacement
ing
Broken valve or rocker If there is metallic powder in oil pan or oil filter, open Damaged parts repair and
8
arm head cover and check valve and rocker arm. replacement
If metal particles are found in oil pan or oil filter, over- Camshaft bushings re-
9 Worn camshaft bushing
haul engine and check camshaft bushings. placement
40-1336 D155AX-8
40 TROUBLESHOOTING S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT

Failure Air cannot be bled from fuel circuit.
Related
information

Defective charge of bat- Even if fuel feed pump switch is turned to ON position,
2 Charge battery
tery pump operation does not make sound.
Looseness of fuel prefil- Check for loosened fuel prefilter drain valve (Air mixed
3 Close drain valve
ter drain valve for loosened fuel prefilter drain valve).
4
When performing bleeding air from the fuel system, air
Air mixed in fuel piping
5 comes out. (For details, see Testing and adjusting,
system
“Bleeding air from fuel system”).
6
When fuel feed pump switch is turned ON, voltage is Fuel feed pump replace-
7 Malfunction of feed pump
applied to fuel feed pump, but pump does not operate. ment
Malfunction of fuel feed No voltage is supplied to fuel feed pump when fuel Electric fuel feed pump
8
pump switch feed pump switch is in ON. The lamp does not light up. switch replacement
Defective wiring harness Testing wiring harness
for fuel feed pump and Wiring harness replace-
9
wiring harness for fuel ment
feed pump
D155AX-8 40-1337
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 40 TROUBLESHOOTING
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY

Failure Active regeneration is executed frequently.
Related
information

Unless heavy-duty operation is performed, soot is ac- Choose “Manual Station-
cumulated because the exhaust gas temperature does ary Regeneration” for
not rise. service by “Active Regen-
Engine run at a medium eration for Service” screen
1
speed for prolonged time. on the monitor and carry
out complete combustion
of soot to remove it com-
pletely.
Make hole before KDPF to measure exhaust gas color
and check exhaust gas through it (See Standard value
table). Perform troubleshooting
2 Bad exhaust gas color
for “Exhaust gas is black”
(Reference: See Testing and adjusting, “Testing ex-
haust gas color”)
Blocked KDOC when ex- If regeneration frequently is not improved after a cor-
3 haust gas color is defec- rective action for cause 2, KDOC is blocked. KDOC cleaning
tive
Oil out of specification is used Use recommended oil de-
Use of oil out of specifi-
4 scribed in Operation and
cation
Maintenance Manual.
Blocked KCSF by the If regeneration frequently is not improved after a cor- KCSF cleaning and re-
5
use of non-designated oil rective action for cause 4, KCSF is blocked. plecement
Check for lowering of coolant level. Perform troubleshooting of
Coolant leakage to ex-
6 "water mixes into engine
haust system
oil (milky)"
Clogging of KCSF by Check for clogging at KCSF inlet.
KCSF cleaning and re-
7 coolant leakage to ex-
plecement
haust system
Check whether urea deposit is accumulated in the • Cleaning inside
Urea deposit (white de- AdBlue/DEF mixing tube. AdBlue/DEF mixing
posit) is accumulated in tube
9
the AdBlue/DEF mixing
tube. • Perform service re-
generation.
• Perform AdBlue/DEF injector injection amount
Defective AdBlue/DEF in- test and detect any leakage. Replacement of
10
jector • Perform troubleshooting for failure code AdBlue/DEF injector
[CA3568] and [CA3582].
Deteriorated KDOC by KDOC deterioration due to high volume of sulfur (If re-
11 the use of non-designat- generation frequently is not improved after a corrective KDOC replacement
ed fuel action for causes 1 to 10, KDOC is deteriorated).
40-1338 D155AX-8
40 TROUBLESHOOTING S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY

If frequency of regeneration is not improved even after Perform “Service modes”
having taken the action of causes 1 to 11, ash accumu- and “Inspection menu
lation to KDPF is actually large. (Ash in Soot Accumulation
Actual ash accumulation
12 Correction)” of “Setting of
in KDPF is large.
Machine Monitor” of
TESTING AND ADJUST-
ING.
If regeneration frequency is not improved after a cor-
13 Blocked KDOC KDOC cleaning
rective action for causes 1 to 12, KDOC is blocked.
14 Damaged KDOC Check for damaged KDOC. KDOC replacement
D155AX-8 40-1339
S-22 ACTIVE REGENERATION TAKES TIME 40 TROUBLESHOOTING
S-22 ACTIVE REGENERATION TAKES TIME

Failure Active regeneration takes time.
Related
• Since the time required for manual stationary regeneration depends on the accumulated
information
soot level, see failure code CA2639.

If KDOC inlet temperature: approximately 250 °C or Replace KVGT assembly
Defective operation of below and KVGT solenoid current: approximately (including hydraulic actua-
1 1000 mA are kept after active regeneration for service,
KVGT tor and KVGT position
KVGT is defective (See failure code CA2639 because sensor)
approximate manual stationary regeneration time de-
pends on the soot level estimation).
Make hole before KDPF to measure exhaust gas color
and check exhaust gas through it (See Standard value
table). Perform troubleshooting
2 Bad exhaust gas color
for “Exhaust gas is black”
(Reference: See Testing and adjusting, “Testing ex-
haust gas color”)
Defective regeneration Check of fuel doser
3 for soot accumulation of Fuel doser cleaning
fuel doser
Blocked KDOC when ex- If regeneration frequently is not improved after a cor-
4 haust gas color is defec- rective action for cause 2, KDOC is blocked. KDOC cleaning
tive
haust system
oil (milky)"
Blocked KCSF caused by Check for clogged KCSF.
6 coolant leakage to ex- KCSF cleaning
haust system
8
generation.
• Perform AdBlue/DEF injector injection amount
Defective AdBlue/DEF in- test and detect any leakage. Replacement of
9
jector • Perform troubleshooting for failure code AdBlue/DEF injector
[CA3568] and [CA3582].
Deteriorated KDOC by KDOC deterioration due to high volume of sulfur (If re-
10 the use of non-designat- generation time is not improved after a corrective ac- KDOC replacement
ed fuel tion for causes 1 to 9, KDOC is deteriorated).
If regeneration time is not improved after a corrective
action for causes 1 to 10, KDOC is blocked.
40-1340 D155AX-8
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERA-
40 TROUBLESHOOTING TION
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION

Failure White smoke is exhausted during active regeneration.
• White smoke may be discharged for a short time just after the engine is started or during
Related
the regeneration in the cold season, but this is not trouble.
information

haust system
oil (milky)"
Blocked KDOC caused If white smoke emission is not improved after a correc-
KDOC cleaning and re-
2 by coolant leakage to ex- tive action for cause 1, KDOC is blocked.
placement
haust system
Deteriorated KDOC by KDOC deterioration due to high volume of sulfur (If
4 the use of non-designat- white smoke emission is not improved after a correc- KDOC replacement
ed fuel tive action for causes 1 to 3, KDOC is deteriorated).
If white smoke emission is not improved after a correc-
tive action for causes 1 to 4, KDOC is blocked.
7 Damaged KCSF Check for damaged KCSF. KCSF replecement
Check that AdBlue/DEF in the tank is not colored in • Replacement of
blue (Confirm that coolant is not mixed in). heating pipe
• Cleaning of
AdBlue/DEF hose
• Replacement of
Coolant enters into AdBl- AdBlue/DEF pump
8
ue/DEF tank • Replacement of
AdBlue/DEF injector
• Cleaning inside
AdBlue/DEF mixing
tube
• SCR replacement
D155AX-8 40-1341
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 40 TROUBLESHOOTING
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE

Failure Consumption of AdBlue/DEF is excessive.
Related
information

Check that concentration of AdBlue/DEF in the tank is Replace AdBlue/DEF in
Usage of AdBlue/DEF
not lower than the standard concentration. (The speci- the AdBlue/DEF tank with
1 which is not up to stand-
fied AdBlue/DEF ammonia concentration is 32.5 %). a product with the stand-
ard
ard concentration.
• Check AdBlue/DEF hose (check if there is any
Defective AdBlue/DEF place where AdBlue/DEF is leaking). Replacement of
2
hose • Perform AdBlue/DEF pump pressure up test to AdBlue/DEF hose
specify the place where it is leaking.
Defective AdBlue/DEF Check AdBlue/DEF pump. (Check that no AdBlue/DEF Replacement of
3
pump leaks from the connecting part.) AdBlue/DEF pump
Defective AdBlue/DEF Check for AdBlue/DEF leakage from AdBlue/DEF tank. Replacement of
4
tank AdBlue/DEF tank
• Check for AdBlue/DEF injector related failure
code.
Defective AdBlue/DEF in- Replacement of
5 • Perform AdBlue/DEF Injection quantity test.
jector AdBlue/DEF injector
• Perform troubleshooting for failure code
[CA3568].
• Check for oil leakage from ammonia sensor
mounting part Repair and replacement of
6 • Check for breakage in appearance the installation part of the
sor
• Perform troubleshooting for failure code ammonia sensor
[CA4281].
• Check that there is no gas leakage from mount-
ing part of SCR outlet NOx sensor.
Repair and replacement of
Defective SCR outlet • Check that there is no damage on the appear-
7 the installation part of the
NOx sensor ance.
SCR outlet NOx sensor
[CA1694].
ing part of KDPF temperature sensor.
Defective KDPF temper- • Check that there is no damage on the appear-
ature sensor ance.
KDPF temperature sensor
[CA3322].
ing part of SCR temperature sensor.
Defective SCR tempera- • Check that there is no damage on the appear-
ture sensor ance.
SCR temperature sensor
[CA3151].
40-1342 D155AX-8
40 TROUBLESHOOTING S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE

Change sensor and check that consumption of Replacement of mass air
Defective mass air flow
10 AdBlue/DEF is normal. (Failure code may not be dis- flow and temperature sen-
and temperature sensor
played because of attachment of dust on the sensor.) sor
Gas leakage from EGR Gas is leaking from EGR piping.
piping
The aftercooler outlet Clogging of the aftercooler core (Aftercooler outlet tem-
temperature is high (The perature: Max. 50 °C) Cleaning of the aftercooler
12
intake manifold tempera- core
ture is high).
13
generation.
Check that AdBlue/DEF mixing tube is not damaged,
Defective AdBlue/DEF and that exhaust gas is not leaked. (Check that no Replacement of
14
mixing tube urea deposit is accumulated on AdBlue/DEF mixing AdBlue/DEF mixing tube
tube surface)
• Check that SCR catalyst is not damaged and
the performance is not deteriorated.
15 Defective SCR catalyst SCR catalytic exchange
[CA3151].
D155AX-8 40-1343
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 40 TROUBLESHOOTING
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)

Failure There is unusual smell (irritating odor).
Related
information

• Perform AdBlue/DEF injection rate test.
Abnormal injection from Replacement of
1 • Perform troubleshooting for failure code
AdBlue/DEF injector AdBlue/DEF injector
[CA3568].
2
the AdBlue/DEF m

D155ax 8

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SEN06497-03

PALM COMMAND CONTROL SYSTEM........................................................................................ 10-83

HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-49

FUSE LOCATION TABLE .............................................................................................................40-127

FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error.........................................40-238

FAILURE CODE [CA2765] Injector Trim Data Mismatch ...............................................................40-467

FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error.......................................40-605

FAILURE CODE [DDKBKB] Blade Auto Pitch SW Short Circuit ....................................................40-876

FAILURE CODE [DK40KA] Brake Pedal Potentiometer Open Circuit ...........................................40-983

FAILURE CODE [DXHCKB] Left Brake ECMV Solenoid Short Circuit.........................................40-1093

REMOVE AND INSTALL EGR VALVE ASSEMBLY.......................................................................50-114

DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD...............................50-521

MAINTENANCE STANDARD OF BRAKE CONTROL VALVE........................................................ 60-43

ELECTRICAL CIRCUIT DIAGRAM (5/16)...................................................................................... 90-25

FOREWORD, SAFETY, BASIC INFORMATION

Symbol Item Remark

SAFETY NOTICE FOR OPERATION

Precautions for slinging work and making signals

Selecting wire ropes

Manufacturer Part name

PRECAUTIONS TO PREVENT FIRE

ACTION IF FIRE OCCURS

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

PRECAUTIONS FOR AdBlue/DEF

PRECAUTIONS FOR ADDING

PRECAUTIONS FOR STORING

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

THE OTHER PRECAUTIONS

*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Sealing of openings (prevention of flowing out of oil)

Preventing intrusion of foreign materials during refilling operations.

Replacing hydraulic oil while its temperature is high

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

Hose side Pipe joint side

Hose side Pipe joint side

Shoe bolt pitch

Shoe bolt pitch

Introduction of parts for the removal of O-ring boss type joint

Nominal No. Plug (1) O-ring (2)

Nominal Plug (1)

02 R1/4 07042-00211 07043-00211

03 R3/8 07042-00312 07043-00312

04 R1/2 07042-00415 07043-00415

06 R3/4 07042-00617 07043-00617

14 R11/2 07042-01422 07043-01422

Precautions for installation and assembly work

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

Main failures occurring in wiring harness

Defective crimping or soldering of connectors

High-pressure water entering connector

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

PRACTICAL USE OF KOMTRAX

METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL TYPE

METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE

METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

2. When removing from clips

3. Action to take after removing connectors

3. Correct the protrusion of the boot and misalignment of the