Komatsu D155AX-5 User Manual

SEBM016205

1

-

MACHINE MODEL SERIAL NUMBER

D155AX-5 70001 and up

This shop manual may contain attachments and optional equipment that are not available in your

•

area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.

D155AX-5 mounts the SA6D140E-2 or SA6D140E-3 engine.

•

For details of the engine, see the 6D140-2 or 140-3 Series Engine Shop Manual.

C 2001 1
All Rights Reserved
Printed in Japan 04-01(03)

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CONTENTS

No. of page

01 GENERAL ..............................................................................01-1

10 STRUCTURE AND FUNCTION ............................................10-1

20 TESTING AND ADJUSTING................................................20-1

30 DISASSEMBLY AND ASSEMBLY .......................................30-1

40 MAINTENANCE STANDARD...............................................40-1

90 OTHERS ................................................................................90-1

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(Blank page)

30

DISASSEMBLY AND ASSEMBLY

Method of using manual ............................ 30- 3

Precautions when carring out operation ... 30- 5

Special tool list............................................. 30- 7

Special tool sketch ....................................... 30-17

STARTING MOTOR

Removal and Installation ...................... 30-26

ALTERNATOR

Removal and Installation ...................... 30-27

ENGINE OIL COOLER CORE

Removal and Installation ...................... 30-28

FUEL INJECTION PUMP

Removal .................................................. 30-29

Installation .............................................. 30-30

WATER PUMP

Removal and Installation ...................... 30-31

TURBOCHARGER

Removal and Installation ...................... 30-32

NOZZLE HOLDER

Removal and Installation ...................... 30-33

FUEL INJECTOR

Removal and Installation ................... 30-33-1

ENGINE FRONT SEAL

Removal .................................................. 30-34

Installation .............................................. 30-35

ENGINE REAR SEAL

Removal .................................................. 30-37

Installation .............................................. 30-38

CYLINDER HEAD

Removal .................................................. 30-42

Installation .............................................. 30-47

THERMOSTAT

Removal and Installation ...................... 30-49

AIR CONDITIONER COMPRESSOR

Removal .................................................. 30-50

Installation .............................................. 30-51

AIR CONDITIONER CONDENSER

Removal and Installation ...................... 30-52

FUEL TANK

Removal and Installation ...................... 30-53

RADIATOR

Removal .................................................. 30-54

Installation .............................................. 30-56

RADIATOR, OIL COOLER, GUARD

Removal .................................................. 30-57

Installation .............................................. 30-59

FAN DRIVE

Removal .................................................. 30-60

Installation .............................................. 30-61

HYDRAULIC COOLER

Removal and Installation ...................... 30-62

ENGINE

Removal .................................................. 30-63

Installation .............................................. 30-65

DAMPER

Removal .................................................. 30-66

Installation .............................................. 30-67

Disassembly ........................................... 30-68

Assembly ................................................ 30-71

POWER TRAIN UNIT

Removal .................................................. 30-75

Installation .............................................. 30-79

Separation .............................................. 30-80

Connection ............................................. 30-84

PTO

Disassembly ........................................... 30-85

Assembly ................................................ 30-89

TORQUE CONVERTER

Disassembly ........................................... 30-94

Assembly ................................................ 30-97

TORQFLOW TRANSMISSION

Disassembly ......................................... 30-100

Assembly .............................................. 30-109

HSS CASE

Disassembly ......................................... 30-120

Assembly .............................................. 30-129

HYDRAULIC PUMP

Removal ................................................ 30-142

Installation ............................................ 30-146

HSS PUMP

Disassembly ...................................... 30-146-1

Assembly ........................................... 30-146-8

HSS MOTOR

Removal and Installation .................... 30-147

POWER TRAIN MAIN RELIEF VALVE

Removal and Installation .................... 30-148

Disassembly and Assembly ............... 30-149

HSS, PPC CHARGE VALVE

Removal and Installation .................... 30-150

HSS, PCC CHARGEING VALVE

Disassembly ......................................... 30-151

Assembly .............................................. 30-152

TRANSMISSION CONTROL VALVE

Removal ................................................ 30-153

Installation ............................................ 30-154

Disassembly and Assembly ............... 30-155

30-1D155AX-5

5

BRAKE VALVE

Removal and Installation .................... 30-157

Disassembly and Assembly ............... 30-158

FINAL DRIVE

Removal ................................................ 30-160

Installation ............................................ 30-162

Disassembly ......................................... 30-163

Assembly .............................................. 30-168

TRACK FRAME

Removal ................................................ 30-174

Installation ............................................ 30-176

IDLER ASSEMBLY

Removal ................................................ 30-177

Installation ............................................ 30-178

Disassembly ......................................... 30-179

Assembly .............................................. 30-181

RECOIL SPRING

Removal and Installation .................... 30-184

Disassembly ......................................... 30-185

Assembly .............................................. 30-190

TRACK ROLLER

Removal ................................................ 30-194

Installation ............................................ 30-195

Disassembly ......................................... 30-196

Assembly .............................................. 30-199

BOGIE

Removal ................................................ 30-202

Installation ............................................ 30-204

Disassembly ......................................... 30-205

Assembly .............................................. 30-209

CARRIER ROLLER

Removal and Installation ................... 30-213

Disassembly ......................................... 30-214

Assembly .............................................. 30-216

TRACK SHOE

Checking before removal ................... 30-219

Removal (normal) ................................ 30-219

Removal (when there is abnorma-

lity inside track frame) ................. 30-220

Installation ............................................ 30-221

Overall disassembly ............................ 30-222

Overall assembly ................................. 30-227

Press-fitting jig dimention table for

link press .............................................. 30-241

ONE LINK

Disassembly ......................................... 30-242

Assembly .............................................. 30-244

MASTER LINK

Disassembly ......................................... 30-246

Assembly .............................................. 30-248

PIVOT SHAFT

Removal and Installation .................... 30-251

EQUALIZER BAR

Removal ................................................ 30-252

Installation ............................................ 30-253

EQUALIZER BAR SIDE BUSHING

Removal and Installation .................... 30-254

SEGMENT TEETH

Removal and Installation .................... 30-255

HYDRAULIC TANK

Removal and Installation .................... 30-256

MAIN CONTROL VALVE

Removal ................................................ 30-257

Installation ............................................ 30-258

Disassembly ......................................... 30-259

Assembly .............................................. 30-262

HSS OIL COOLER BYPASS VALVE

Removal and Installation .................... 30-266

Disassembly, assembly of HMT

oil cooler bypass valve ....................... 30-267

BLADE PPC VALVE

Removal ................................................ 30-268

Installation ............................................ 30-269

RIPPER PPC VALVE

Removal ................................................ 30-270

Installation ............................................ 30-271

BLADE PPC VALVE

Disassembly ......................................... 30-272

Assembly .............................................. 30-273

BLADE LIFT CYLINDER

Removal and Installation .................... 30-275

BLADE TILT CYLINDER

Removal and Installation .................... 30-276

RIPPER LIFT CYLINDER

Removal and Installation .................... 30-277

RIPPER TILT CYLINDER

Removal and Installation .................... 30-278

HYDRAULIC CYLINDER

Disassembly ......................................... 30-279

Assembly .............................................. 30-282

BLADE

Removal ................................................ 30-286

Installation ............................................ 30-287

Disassembly ......................................... 30-288

Assembly .............................................. 30-290

MULTI-SHANK RIPPER

Disassembly ......................................... 30-292

Assembly .............................................. 30-294

ROPS GUARD

Removal and Installation .................... 30-296

OPERATOR CAB

Removal and Installation .................... 30-297

HOOD

Removal and Installation .................... 30-298

FLOOR FRAME

Removal ................................................ 30-299

Installation ............................................ 30-304

DASHBOARD

Removal ................................................ 30-305

Installation ............................................ 30-306

MONITOR

Removal and Installation .................... 30-307

HSS CONTROLLER

Removal and Installation .................... 30-308

30-2

1

D155AX-5

DISASSEMBLY AND ASSEMBLY

P Sleeve

SPECIAL TOOL SKETCH

02

01

SYM.

30°

3

+0.4

+0.2

ø190.7

ø180±0.2

ø175

C0.5

STKM16A 1

PLATE

PART NAME MATERIAL

S400P

80

30°

R1

60

1 2.7

QTY/SET

17.7

MASS
(kg)

465.5±0.2

ø190 x t10TUBE

t22

REMARKES

)2

)1

C2

C2

+0.4

ø178

+0.2

ø210

C1

8

HEAT TREATMENT

PART NAME QTY

20

DDD00866

MATERIAL

- - -

SLEEVE 1

SEE DWG

7 9 1 T - 6 5 0 - 2 1 1 0

P Plate

C1

22

C1

2-20 D R I L L S

200

102

HEAT TREATMENT

- - -

PART NAME QTY

PLATE 1

7 9 1 T - 6 5 0 - 2 1 2 0

DDD00867

MATERIAL

SS400P

D155AX-5

30-25

1

DISASSEMBLY AND ASSEMBLY

STARTING MOTOR

REMOVAL OF STARTING
MOTOR ASSEMBLY

 Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Open engine right side cover (top) and remove
cover (bottom).

2. Disconnect 3 starting motor wires (1) and 1 wir­ing connector (2).

3. Remove 3 bolts, then remove starting motor
assembly (3).

INSTALLATION OF STARTING
MOTOR ASSEMBLY

• Carry out installation in the reverse order to

removal.

Serial 70001 – 75000

2

1

DED00001

Serial No. 75001 and up

1

3

DED00002

30-26

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF ALTERNATOR
ASSEMBLY

 Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Open engine right side cover (top) and remove
cover (bottom).

2. Disconnect alternator wiring (1) and (2).

3. Loosen locknut (3), then turn adjustment nut (4)

to loosen tension of V-belt (5).

4. Remove bolts (6) and (7), then remove alterna­tor assembly (8) together with belt cover. 1
e Remove the V-belt from the pulley when re-

moving the alternator assembly.

ALTERNATOR

Serial No. 70001-75000

1

2

DED00003

Serial No. 75001 and up

INSTALLATION OF
ALTERNATOR ASSEMBLY

• Carry out installation in the reverse order to

removal.

1

e After installing the alternator, adjust the belt

tension. For details, see TESTING AND AD­JUSTING, TESTING AND ADJUSTING AL­TERNATOR BELT TENSION.

8

6

5

3

4

7

DED00004

D155AX-5

30-27

5

5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF ENGINE OIL
COOLER CORE ASSEMBLY

e Drain coolant.

ENGINE OIL COOLER

Serial No. 70001 – 75000

6

1. Remove wiring clamp (1).

2. Remove muffler water drain tube (2).

3. Remove adiabatic plate (3).

4. Disconnect turbocharger lubrication tube (4) at

turbocharger end, then move it towards rear.

5. Disconnect connector (5).

6. Remove oil cooler assembly (6).

7. Remove core assembly (8) from cover (7).

1

4

2

Serial No. 75001 and up

3

1

5

DED00005

INSTALLATION OF ENGINE OIL
COOLER CORE ASSEMBLY

• Carry out installation in the reverse order to

removal.

• Refilling with water

Add water through water filler to the specified
level.
e Run the engine to circulate the water through

the system. Then check the water level again.

78

DDD00006

30-28

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

DED00009

9

10

REMOVAL OF FUEL INJECTION
PUMP ASSEMBLY

Serial No. 70001 – 75000

1. Close valve of fuel supply piping.

2. Rotate crankshaft in normal direction and align

match mark of fuel injection pump.
fl This makes it easier to check the compres-

sion top dead center position of the No. 1
cylinder when installing the fuel injection
pump.

3. Open engine left side cover (top) and remove
cover (bottom).

4. Disconnect fuel control rod (1), and fuel hoses
(2), (3), (4), and (5). 1

FUEL INJECTION PUMP

7

5. Remove boost compensator tube (19).

6. Disconnect fuel hose (6) and tube (7).

7. Remove coupling cover (8).

8. Remove lubrication tubes (9) and (10).

9. Disconnect 6 delivery tubes (11). 2

6

8

DED00008

D155AX-5

11

DED00010

30-29

5

5

DISASSEMBLY AND ASSEMBLY

10. Loosen tightening bolt (12) at drive shaft end,

and remove 4 pump mounting bolts (13).

11. Remove fuel injection pump assembly (14) to-

gether with coupling. 3

FUEL INJECTION PUMP

12

13

DED00011

14

INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to

removal.

1

e Adjust the linkage. For details, see TEST-

ING AND ADJUSTING, ADJUSTING FUEL
CONTROL LINKAGE.

2

3 Sleeve nut: 123.5 ± 1.0 Nm {2.4 ± 0.1 kgm}

3

e Install the fuel injection pump as follows.

1) After installing pump assembly, align
damper (I,J) marks (15) and pointer (16)
correctly.

2) Loosen bolt of coupling (18) to align
match mark (17) of injection pump.

13

18

17

13

DED00012

16

15

DED00013

30-30

5

DED00014

D155AX-5

DISASSEMBLY AND ASSEMBLY

3

4

5

DED00016

REMOVAL OF WATER PUMP
ASSEMBLY

1. Drain coolant.

2. Using an adjustable wrench, push tension pul-

ley (2) of fan belt (1), and remove fan belt.

3. Loosen locknut (3), then loosen adjustment nut

(4), and remove V-belt (5). 1

WATER PUMP

1

4. Remove connectors (6) and (7).

5. Remove pulley (8).

6. Remove water pump assembly (9).

INSTALLATION OF WATER
PUMP ASSEMBLY

• Carry out installation in the reverse order to

removal.

2

DED00015

Serial No. 70001 – 75000

Serial No. 75001 and up

1

e After installing the V-belt, adjust the belt ten-

sion. For details, see TESTING AND AD­JUSTING, TESTING AND ADJUSTING AL­TERNATOR BELT TENSION.

• Refilling with water

Add water through water filler to the specified
level.
e Run the engine to circulate the water through

the system. Then check the water level again.

8

D155AX-5

DED00018

30-31

1

5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF
TURBOCHARGER ASSEMBLY

Serial No. 70001 - 75000

1. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM­BLY.

2. Remove adiabatic covers (2) and (3).

3. Disconnect tube (4) and hose (5), then lift off air

cleaner assembly (6).

4 Air cleaner assembly: 35 kg

4. Disconnect lubrication hose (7) and drain tube

(8). 1

5. Remove turbocharger assembly (9). 2

TURBOCHARGER

INSTALLATION OF
TURBOCHARGER ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to

removal.

1

3 Hose mounting bolt:

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

2

3 Turbocharger mounting bolt:

49.0 ± 9.8 Nm {5 ± 1 kgm}

6

5

4

DBD00026

7

8

DED00021

30-32

5

9

DED00020

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF
TURBOCHARGER ASSEMBLY

Serial No. 75001 and up

1. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM­BLY.

2. Remove adiabatic covers (1) and (2).

3. Disconnect tube (3) and hose (4), then lift off air

cleaner assembly (5).

4 Air cleaner assembly: 35 kg

4. Disconnect lubrication hose (6) and drain tube

(7). 1

5. Remove turbocharger assembly (8). 2

TURBOCHARGER

INSTALLATION OF
TURBOCHARGER ASSEMBLY

Serial No. 75001 and up

• Carry out installation in the reverse order to

removal.

1

3 Hose mounting bolt:

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

2

3 Turbocharger mounting bolt:

49.0 ± 9.8 Nm {5 ± 1 kgm}

D155AX-5

30-32-1

5

30-32-2 (Blank Page)

D155AX-5

DISASSEMBLY AND ASSEMBLY

1

2

DBD00413

3

4

5

DBD00414

3

4

5

6

DBD00415

REMOVAL OF NOZZLE
HOLDER ASSEMBLY

Serial No. 70001 – 75000

1. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM­BLY.

2. Remove cylinder head cover (1). 1

e For No. 4 and 5 cylinders, remove the air

cleaner assembly and air supply connector.

3. Disconnect delivery tube (2). 2

4. Loosen locknut (3), and remove connector (4).

3

5. Remove holder (5). 4

6. Using tool A, remove nozzle holder assembly

(6). 5

NOZZLE HOLDER

INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to

removal.

1

3 Cylinder head cover mounting bolt:

24.5 ± 4.9 Nm {2.5 ± 0.5 kgm}

2

3 Delivery tube sleeve nut:

23.5 ± 0.98 Nm {2.4 ± 0.1 kgm}

3

3 Connector:

31.9 ± 2.5 Nm {3.25 ± 0.25 kgm}

3 Locknut: 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}

4

3 Holder mounting bolt:

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

5

e When assembling the nozzle holder, clean

the nozzle holder mount and check that there
is no dirt or dust inside the sleeve before
assembling.
Tighten the mounting bolts uniformly in turn
to prevent excessive tightening on one side.

A

6

DBD00416

D155AX-5

30-33

5

5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF FUEL INJECTOR
ASSEMBLY

Serial No. 75001 and up

1. Remove hood assembly. For details, see RE-

MOVAL OF HOOD ASSEMBLY.

2. Remove common rail high-pressure pipe (1).

1

3. Disconnect wiring connector (2).
fl Insert a flat-head screwdriver in the slit of

the connector to press the stopper and dis­connect the connector.

FUEL INJECTOR

4. Remove cylinder head cover (3). 2

fl For Nos. 4 and 5, remove the air cleaner

assembly and air intake connector.

5. Remove mounting bolts and rocker arm (4).
fl Loosen locknut (5) and then loosen adjust-

ment screw (6) by 2 - 3 turns so that an
excessive force will not be applied to the
push rod when the rocker arm is installed.

3

6. Remove 2 nuts (7) of solenoid valve above fuel

injector. 4

7. Pull out spring clamp (8) and disconnect clamp

(9).

8. Remove mounting bolts (12) of holder (11) of

connector (having an O-ring) (10) and to remove
holder, then insert connector (10) to remove it.

4

30-33-1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

9. Remove holder (13) of fuel injector, then remove

injector assembly (14). 5
fl Do not hold the solenoid of the injector with

priers, etc. to remove the injector.

INSTALLATION OF FUEL
INJECTOR ASSEMBLY

Serial No. 75001 and up

• Carry out installation in the reverse order to

removal.

FUEL INJECTOR

1

3 High-pressure pipe sleeve nut:

39.2 ± 7.4 Nm {4.0 ± 5.0 kgm}

fl If there is any slit "b" or pit "c" on the taper

sealing part (Part "a": The part of 2 mm from
the end) of the high-pressure pipe joint or if
part "d" (Tape seal end: Part of 2 mm from
the end) has level difference that is felt with
a nail (or if part "d" is fatigued) and the fuel
may leak, replace the high-pressure pipe.

2

3 Cylinder head mounting bolt:

29.4 ± 34.3 Nm {3.0 ± 3.5 kgm}

3

fl When tightening the mounting bolts, check

that the ball of the adjustment screw is fit­ted to the socket of the push rod.

3 Rock arm mounting bolt:

93 ± 103 Nm {9.5 ± 10.5 kgm}

fl Adjust the valve clearance. For details, see

ADJUSTING VALVE CLEARANCE.

D155AX-5

30-33-2

5

DISASSEMBLY AND ASSEMBLY

4

fl Method of installing wiring harness.

1) Fit O-ring (15).

2) Install cap (16).

3) Tighten nut (14).

4) Secure clamp with bolt (18).

3 Terminal nut:

1.8 ± 2.2 Nm {0.18 ± 0.22 kgm}

fl Eliminate the slack of the wiring harness and

press it against the injector body.

5

fl Method of installing fuel injector.

1) Install fuel injector assembly (14) and holder
(13) to the cylinder head temporarily.

2) Tighten mounting bolt (19) of holder (13)

temporarily.

3) Tighten sleeve (20) temporarily.

4) Tighten holder mounting bolt (19) se
curely.

5) Tighten sleeve (20) securely.

fl Apply engine oil to the spherical part of the

spherical washer.

ENGINE REAR SEAL

3 Holder mounting bolt:

58.8 ± 73.5 Nm {6.0 ± 7.5 kgm}

30-33-3

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

DAD00046

Make mark with punch

fl After installing the flywheel, use tool 1 to

measure the face runout and radial runout.
fl Face runout: Max. 0.30 mm
fl Radial runout: Max. 0.30 mm

ENGINE REAR SEAL

D155AX-5

30-41

1

DISASSEMBLY AND ASSEMBLY

REMOVAL OF CYLINDER HEAD
ASSEMBLY

Serial No. 70001 – 75000

 Disconnect the cable from the negative (-) ter-

minal of the battery.

1. Drain coolant.

2. Close fuel supply valve.

3. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM­BLY.

4. Remove engine side covers (left, right).

5. Remove adiabatic covers (2) and (3).

6. Disconnect tube (4) and hose (5), and lift off air

cleaner assembly (6).

4 Air cleaner assembly : 35 kg

CYLINDER HEAD

6

7. Remove tube (7), then lift off muffler assembly
(8).

4 Muffler assembly : 45 kg

8. Remove bracket (9).

9. Disconnect turbocharger lubrication hose (10)

and return tube (11). 1

5

10

4

DBD00026

8

7

DBD00027

9

30-42

5

11

DBD00028

D155AX-5

DISASSEMBLY AND ASSEMBLY

DBD00041

i !8 !9o r!4 !5t !0 @2 @3!1

u!7 @0w q!3 !6y e@1 @4!2

DAD00042

@2 !8 !4 !0 y w e

u

!1

!5 !9 @3

@1 !7 !3 o t q r i !2 !6 @0 @4

INSTALLATION OF CYLINDER
HEAD ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to

removal.

1

3 Mounting bolt : 66.2 ± 7.4 Nm

{6.75 ± 0.75 kgm}

2

fl Tighten the bolts in the order 1 - 3 as

shown in the diagram on the right, then
tighten in the order 4 - N.

3 Exhaust manifold mounting bolt :

1st step : 29.4 ± 4.9 Nm

{3.0 ± 0.5 kgm}
2nd step : 66.2 ± 7.4 Nm
{6.75 ± 0.75 kgm}

3

3 Joint bolt : 29.4 ± 4.9 Nm

{1.15 ± 0.15 kgm)

4

fl Install the hoses without twisting or interfer-

ence.

3 Joint bolt : 29.4 ± 4.9 Nm

{3.0 ± 0.5 kgm}

5

fl Tighten the bolts in the order of 1 - N as

shown in the diagram on the right.

3 Intake manifold mounting bolt :

1st step : 29.4 ± 4.9 Nm

{3.0 ± 0.5 kgm}
2nd step : 66.2 ± 7.4 Nm
{6.75 ± 0.75 kgm}

6

3 Intake connector mounting bolt :

49.0 ± 9.8 Nm {5 ± 1 kgm}

7

3 Joint bolt : 8.8 ± 1.0 Nm
{0.9 ± 0.1 kgm}

8

3 Delivery tube sleeve nut :

23.5 ± 1.0 Nm {2.4 ± 0.1 kgm}

9

3 Head cover mounting bolt :

24.5 ± 9.8 Nm {2.5 ± 1.0 kgm}

0

fl Clean the mounting bolt oil holes before in-

stalling.

fl Check that the ball of the adjustment screw

is fitted properly into the socket of the push

CYLINDER HEAD

rod.

fl Adjust the valve clearance.

For details, see TESTING AND ADJUST­ING, ADJUSTING VALVE CLEARANCE.
3 Rocker arm assembly :

98 ± 4.9 Nm {10 ± 0.5 kgm}

3 Locknut :

48.0 ± 2.9 Nm {4.9 ± 0.3 kgm}

A

fl Adjust the crosshead as follows.

1) Loosen locknut, then turn adjustment
screw back.

2) Press top of crosshead lightly and
tighten adjustment screw.

3) When adjustment screw contacts
valve stem, screw in a further 20°.

4) Tighten locknut to hold in position.

3 Locknut : 58.8 ± 5.9 Nm
{6.0 ± 0.6 kgm}

B

3 Locknut : 39.2 ± 4.9 Nm

{4.0 ± 0.5 kgm}

D155AX-5

30-47

5

DISASSEMBLY AND ASSEMBLY

C

3 Connector : 31.9 ± 2.5 Nm

{3.25 ± 0.25 kgm}

D

3 Holder mounting bolt : 66.2 ± 7.4 Nm

{6.75 ± 0.75 kgm}

CYLINDER HEAD

2

3

6

E

fl Check that there is no dirt or dust on the

cylinder head mounting surface or inside the
cylinder.

fl When installing the gasket, check that the

grommet does not come out.

fl Coat the bolt thread and seat face completely

with molybdenum disulphide (LM-P).

fl Tighten the cylinder head mounting bolts in

the order given in the diagram.
2 Cylinder head mounting bolt :

Anti-friction compound (LM-P)

3 Cylinder head mounting bolt :

1st step : Tighten to 147 ± 9.8 Nm

{15 ± 1 kgm}

2nd step : Tighten to 215.6 ± 4.9 Nm

{22 ± 0.5 kgm}

3rd step : 1) When using tool B

• Using an angle tightening
wrench, tighten bolt 90° .

2) When not using tool B

• Make marks on bolt and fly­wheel with a felt pen, then
tighten bolt 90°.

+30°

0

5

1

Make marks on
cylinder head and bolt

4

7

DAD00043

B

DBD00044

+30

90°

0

fl Tighten bolt 7 to 66.2 ± 7.4 Nm {6.75 ± 0.75

kgm} one time.

fl After tightening, make one punch mark on

the bolt head to indicate the number of times
it has been tightened.

• If any bolt already has five punch marks,
do not reuse it. Replace it with a new
bolt.

• Refilling with water

• Add water through water filler to the speci-

fied level.

fl Run the engine to circulate the water through

the system. Then check the water level
again.

30-48

1

DAD00045

Make mark with punch

DAD00046

D155AX-5

DISASSEMBLY AND ASSEMBLY

1

2

3

DBD00421

REMOVAL OF THERMOSTAT
ASSEMBLY

1. Drain coolant.

2. Remove alternator assembly.

For details, see REMOVAL OF ALTERNATOR AS­SEMBLY.

3. Disconnect radiator inlet hose (1).

4. Disconnect bypass tube (2).

5. Remove cover (3).

6. Remove 2 thermostats (4).

THERMOSTAT

INSTALLATION OF
THERMOSTAT ASSEMBLY

• Carry out installation in the reverse order to

removal.

• Refilling with water

Add water through water filler to the specified
level.
fl Run the engine to circulate the water through

the system. Then check the water level
again.

4

4

DBD00422

D155AX-5

30-49

1

DISASSEMBLY AND ASSEMBLY

REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY

AIR CONDITIONER COMPRESSOR

Serial No. 70001 – 75000

 Using tool X, collect freon gas (R134a).

1. Open engine left side cover (top) and remove
cover (bottom).

2. Remove wiring connector (1).

3. Disconnect hoses (2) and (3). 1

fl Fit blind plugs to prevent dirt or water from

entering the hoses.

4. Loosen 4 mounting bolts (4).

5. Remove V-belt cover (5).

6. Loosen adjustment bolt (6) and remove.

7. Remove mounting bolts (4), remove V-belt (7)

from pulley, then remove compressor assembly
(8). 2

123

4

DBD00423

Serial No. 70001 – 75000

6

5

Serial No. 70001 – 75000

4

7

Serial No. 75001 and up

DBD00424

8

DBD00425

30-50

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

3

DED00438

4

5

DED00439

REMOVAL OF ENGINE
ASSEMBLY

Serial No. 70001 – 75000

 Disconnect the cable from the negative (–) ter-

minal of the battery.

fl Close the supply valve of the fuel tank.

1. Remove radiator, oil cooler, guard assembly.
For details, see REMOVAL OF RADIATOR, OIL
COOLER, GUARD ASSEMBLY.

2. Disconnect starting motor wiring (1).

3. Disconnect engine speed sensor connectors (2)

(CN009, CN010).

ENGINE

1

DED00436

4. Disconnect wiring connector (3) (CN101).

5. Disconnect 2 air conditioner hoses (4). 1

fl Loosen the sleeve nut slightly, and release

the air conditioner gas (R134a) completely
before disconnecting the hose.

fl Fit blind plugs to prevent dirt or water from

entering the hoses.

fl Disconnect at the air conditioner end, then

remove all the clamps from the floor frame
and move towards the engine.

6. Disconnect 2 heater hoses (5).
fl Disconnect at the air conditioner end, then

move towards the engine.

2

DED00437

D155AX-5

30-63

5

DISASSEMBLY AND ASSEMBLY

DED00441

10

7. Disconnect fuel supply hose (6).

8. Disconnect fuel return hose (7).

ENGINE

9. Disconnect fuel control rod (8).

10. Disconnect ground wiring (9).

11. Disconnect universal joint (10) at damper end.

12. Remove front mount bolts (11) and rear mount

bolts (12). 2

11

8

9

7

6

DED00440

12

13. Move engine assembly (13) towards front of
machine, and lift off gradually.
fl Be careful not to damage the wiring or hoses

when removing the engine assembly.

4 Engine assembly : 1,750 kg

30-64

1

DDD00442

13

DED00443

D155AX-5

DISASSEMBLY AND ASSEMBLY

Serial No. 75001 and up

¤ Disconnect the cable from the negative (-) ter-

minal of the battery.
fl Close the fuel feed valve.

1. Remove radiator and oil cooler and guard as­sembly. For details, see REMOVAL OF RADIA­TOR AND OIL COOLER AND GUARD ASSEM­BLY.

2. Disconnect starting motor wiring (1).

3. Disconnect wiring connector (2).

ENGINE

4. Disconnect 2 air conditioner house (3). 1

fl Loosen the sleeve nut of each hose a little to

discharge the all air conditioner refrigerant
(R134a), then disconnect the hose.

fl Plug the hoses to prevent dirt, water, etc.

from entering them.

fl Remove the all clamps on the floor frame

and move the hoses toward the engine.

5. Disconnect 2 heater hoese (4).

6. Disconnect air conditioner wiring connector (5).

7. Disconnect fuel hoses (6), (7), and (8).

D155AX-5

30-64-1

5

DISASSEMBLY AND ASSEMBLY

8. Disconnect ground wire (9).

9. Disconnect universal joint (10) from damper.

ENGINE

10. Remove front mounting bolts (11) and rear

mounting bolts (12). 2

11. Moving engine assembly (13) to front of ma­chine body, lift it off gradually.

fl After removing the engine assembly, take

care not to damage the wires, hoses, etc.

4 Engine assembly : 1,750 kg

30-64-2

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF POWER TRAIN
UNIT ASSEMBLY

Serial No. 70001 – 75000

¤ Park the machine on level ground, lower the

work equipment completely to the ground, then
disconnect the cable from the negative (-) termi­nal of the battery.

1. Drain oil

6 Hydraulic tank : Approx. 97 ¬
6 Power train case: Approx. 60 ¬

2. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.

POWER TRAIN UNIT

3. Open bottom plate at bottom of power train

unit.

4. Remove cover (1) at bottom of fuel tank.

5. Close lever (2) of fuel valve.

6. Disconnect hose (3) leading to priming pump.

7. Disconnect fuel return hoses (4) and (5).

8. Disconnect fuel level sensor wiring connector

(6) (CN422).

9. Lift off fuel tank assembly (7).

fl Sling at three points and use a lever block at

the center to keep the tank horizontal.

fl Move the tank to the rear, and when it clears

the floor frame, raise the rear of the tank
slightly with the lever block. (Do this to
avoid interference with the ripper hoses.)

4 Fuel tank assembly (when full) : 760 kg

10. Disconnect engine speed sensor wiring connec-

tor (8).

11. Disconnect suction tube (9) of 3-spool pump

(HSS lubrication, torque converter, transmission
charge).
fl Remove the cover at the top of the pump.

D155AX-5

30-75

5

DISASSEMBLY AND ASSEMBLY

12. Remove suspension rod (10).

13. Remove top cover of centralized pressure detec-

tion port, then remove centralized pressure de­tection block (11) from frame.

POWER TRAIN UNIT

14. Disconnect hose (12) between hydraulic pump

and control valve.

15. Disconnect wiring connector (13) (HHP).

16. Remove suction tube (14).

fl Be careful not to damage the gasket of the

joint.

17. Disconnect hose (15) between cooler bypass
valve and hydraulic tank.

18. Disconnect hose (16) between charge relief valve
and hydraulic tank.

19. Remove power train oil supply pipe (17).

20. Disconnect power train dipstick tube (18) from

case, and move towards right side of chassis.

30-76

1

D155AX-5

DISASSEMBLY AND ASSEMBLY

33. Lift off power train unit assembly (34). 5

fl Check that the wiring and piping has all been

removed, then lift off the power train unit
assembly.

4 Power train unit assembly : 2800 kg

INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY

POWER TRAIN UNIT

Serial No. 70001 – 75000

• Carry out installation in the reverse order to
removal.

1

3 Universal joint mounting bolt :

110.3 ± 22.1 Nm {11.3 ± 2.3 kgm}

2

3 Mount cap mounting bolt :

277.5 ± 32.4 Nm {28.3 ± 3.3 kgm}

3

fl Clamp the protruding portion of the cou-

pling seal, then assemble the clamp thread
so that it is parallel to the cap mount seat
surface.

4

3 Front mount mounting bolt :

926.8 ± 103.0 Nm {94.5 ± 10.5 kgm}

5

fl When assembling the power train assem-

bly, be extremely careful not to damage seal
(32).

• Refilling with oil (Hydraulic tank. power train
case.)

Add engine oil through oil filler to the specified
level.
fl Run the engine to circulate the oil through

the system. Then check the oil level again.

5 Hydraulic tank : Approx. 97 ¬
5 Power train case : Approx. 60 ¬

D155AX-5

30-79

5

1

DISASSEMBLY AND ASSEMBLY

SEPARATION OF POWER
TRAIN UNIT ASSEMBLY

• Drain oil

Before setting the power train unit assembly on
the block, drain the oil from the PTO case.

1. Raise power train unit assembly (1) and set on

block 1.

4 Power train unit assembly : 2800 kg

2. Disconnect 3 hoses (2) connected to cooler by-

pass valve.

3. Disconnect HSS pump connecting hose (3).

4. Remove cooler bypass valve assembly (4) to-

gether with bracket.

POWER TRAIN UNIT

5. Disconnect 5 charge relief valve connecting

hoses (5).

6. Disconnect wiring connector (6) (CN406).

7. Remove charge relief valve (7).

8. Disconnect pressure detection hoses (8) and (9),

and remove reducing pressure valve hose (10).

1

fl Disconnect the transmission modulation

pressure detection hose.

10

8

9

DBD00927

30-80

1

D155AX-5

DISASSEMBLY AND ASSEMBLY

DLD01003

18

19

DLD01005

21

22

108

4) Remove brake drum (12) together with disc

and plate.

HSS CASE

12

DKD01001

5) Remove plate (13), disc (15), spring (16), and

plate (14) from brake drum.

6) Remove mounting bolts, then remove car-

rier assembly (19) from hub (18).

7) Remove gear assembly (20) from hub as-

sembly (18).

14

16

18

13

15

DKD01002

20

8) Remove ring (21), then remove ring gear

(22) from gear (108).

9) Remove snap ring (23), and pull out shaft

(24).

D155AX-5

23

DLD01004

24

DLD01006

30-121

1

5

DISASSEMBLY AND ASSEMBLY

E2

DLD01010

39

10) Remove planetary gear (25), bearing (26),
thrust washer (27), shaft (24), and ball (28).

HSS CASE

25

11) Remove snap ring (31), then remove stop­per (32) from hub (18).

26

27

32

31

24

28

DLD01007

18

DKD01008

2. Bevel pinion assembly

1) Using guide bolts 3 and forcing screws re­move bevel pinion assembly (33) and shim
(34).

fl Check the number and thickness of the

shims, and keep in a safe place.

2) Disassembly of bevel pinion assembly
i) Remove bolts (35), (36) and pin (37).

Serial No. 75001 –

ii) Hold with press to prevent pinion from

moving, then use tool E2 to remove
locknut (39).

iii) Using push tool 5, remove bevel pinion

(40) from cage (41).

34

r

41

e

33

DLD01009

t

40

30-122

5

DKD01011

D155AX-5

DISASSEMBLY AND ASSEMBLY

iv) Remove bearing (42).
v) Remove outer races (43) and (107) from

cage (41).

42

DLD01012

43

HSS CASE

107

41

DLD01013

vi) Remove bearing (109) from bevel pinion

(40).

3. Sun gear

Remove sun gear (45).
fl Remove the sun gear on the opposite side

in the same way.

4. Gear

1) Remove snap ring (47), then remove spacer
(48).

40

45

109

DLD01014

47

48

2) Using gear puller 6, remove gear (49).

D155AX-5

y

DLD01015

DLD01016

49

DLD01017

30-123

5

DISASSEMBLY AND ASSEMBLY

DLD01021

57

58

HSS CASE

fl Only inner race (50) of bearing (55) will re-

main.

fl Remove the gear on the opposite side in the

same way.

5. Valve seat

1) Pull out 2 brake circuit tubes (51) and 3 lu­brication tubes (52), then remove.

2) Remove valve seat (53).

51

52

49

55

51

50

DKD01018

52

53

51

DKD01019

6. Lubrication tubes, dipstick tube, suction tube

1) Remove lubrication tubes (52) and (56).

2) Remove lubrication tubes (57) and (58).

3) Remove dipstick tube (59) and suction tube
(60).

52

56

DLD01020

59

30-124

5

1

60

DLD01022

D155AX-5

DISASSEMBLY AND ASSEMBLY

• Serial No. 75001 –

vi) Turn the nut unit the phase of any one

of the pin insertion holes of the nut (8
places) is matched to that of any one of
the pin insertion holes of the pinion shaft
(5 places). (Returning angle: 0 - 9°)

vii) Insert pin (37) in the above holes. Fit

plate (36) and tighten bolts (35).

2 Bolt : Thread tightener (LT-2)
3 Bolt : 11.8 - 14.7 Nm

{1.2 - 1.5 kgm}

2) Using guide bolt 3, assemble shim (34) and

install bevel pinion assembly (33).
fl There are three types of shim:

0.1, 0.2, 0.5 mm

HSS CASE

y

6. Adjusting tooth contact, backlash

1) Adjusting backlash

Put the probe of dial gauge 6 at right an­gles in contact with the tip of the bevel gear
teeth. Hold the bevel pinion in position, and
read the measurement when the bevel gear
is moved forward and backward.
fl Standard value for backlash :

fl Measure at least three points on oppo-

site sides.

• If the result of the inspection shows that
the correct backlash is not being ob­tained, adjust as follows.

fl Adjust the shim thickness at the left cage.

• If backlash is too small
Loosen mounting bolt of cage and re­move shim.

• If backlash is too large
Loosen mounting bolt of cage and add
shim.

DBD00156

0.25 - 0.33 mm

Front

A

DAD00157

D155AX-5

Front

B

DAD00158

30-135

1

5

DISASSEMBLY AND ASSEMBLY

HSS CASE

2) Adjusting tooth contact
Testing

i) Coat the tooth face of the bevel pinion lightly

with red lead (minium). Rotate the bevel
gear forward and backward and inspect the
pattern left on the teeth.

ii) Tooth contact should be checked as follows

(from tip of teeth of bevel pinion).
a) Center of tooth contact: 20 - 40 % of

tooth width (from small end)

b) Width of tooth contact: 30 - 50 % of tooth

width

c) Center of tooth contact: 35 - 65 % of

tooth height (from root of tooth)

d) Width of tooth contact: 60 - 80 % of tooth

height
In addition, there should be no strong con­tact at the addendum or dedendum (tip or
root of the gear teeth) or at the big and
small ends.
fl If the gears are adjusted to this pattern,

the tooth contact will be correct when

load is applied.

Big
end

Root of tooth

Big end

Tip of tooth

Small end

DBD00159

b

a

c

d

Small
end

Adjustment

If the result of the inspection shows that the
correct tooth contact is not being obtained, ad­just again as follows.
i) If bevel pinion is too far from center line of

bevel gear.
Contact is at the small end of the convex
tooth face of the bevel gear and at the big
end of the concave tooth face.

• Correct the tooth contact as follows.
Adjust the thickness of the shims at the bevel
pinion to move the bevel pinion in direction

A.

Move the bevel gear in direction B, then
check the tooth contact pattern and back­lash again.

ii) If bevel pinion is too close to center line of

bevel gear.
Contact is at the big end of the convex tooth
face of the bevel gear and the small end of
the concave tooth face.

• Correct the tooth contact as follows.
Adjust the thickness of the shims at the bevel
pinion to move the bevel pinion in direction

B.

Move the bevel gear in direction A, then
check the tooth contact pattern and back­lash again.

DBD00160

B

A

DBD00161

B

A

DBD00162

30-136

1

D155AX-5

DISASSEMBLY AND ASSEMBLY

4

DKD01083

107

108

109

DAD02453

iii) Using eyebolts 1, align bolt hole with

hub and brake drum, then install brake
cover assembly (5).
fl Tighten the mounting bolts tempo-

rarily.

fl The force of the spring is applied, so

tighten the hexagon socket head
bolts uniformly.

iv) Using push tool, press fit inner race (4).
v) Install plate (3) and flange (2).

3 Flange: 58.8 - 73.6 Nm

{6 - 7.5 kgm}

vi) Fully tighten bolts temporarily tightened

in Step iii).

3 Mounting bolt: 98.1 - 122.6 Nm

{10 ± 12.5 kgm}

HSS CASE

q

5

DLD00999

23

• Installation of brake, carrier assembly

1) Angle steering case assembly approx. 15°
so that tool E1 is perpendicular to ground
surface.

2) Using tool E1, install brake, carrier assembly
(1).

3 Mounting bolt: 98.1 - 122.6 Nm

{10 - 12.5 kgm}

fl Assemble the brake, carrier assembly on

the opposite side in the same way.

fl When cover (109) of the rear surface on

HSS case (107) has been removed, in­stall new gasket (108).

2 Gasket (apply to both surfaces):

Gasket sealant (LG-1)

DLD01255

E1

1

DLD00997

D155AX-5

30-141

1

DISASSEMBLY AND ASSEMBLY

REMOVAL OF HYDRAULIC
PUMP ASSEMBLY

¤ Park the machine on level ground, lower the

work equipment completely to the ground, then
disconnect the cable from the negative (–) ter­minal of the battery.

1. Drain hydraulic oil and power train oil.

6 Hydraulic oil : Approx. 97 ¬
6 Power train case : Approx. 60 ¬

2. Remove cab.
For details, see REMOVAL OF CAB ASSEMBLY.

3. Lift off operator’s seat assembly (1).

4 Operator’s seat : 54 kg

HYDRAULIC PUMP

Serial No. 70001 – 75000

4. Remove floor frame left and right side covers
(2).

5. Remove floor mat, then remove cover (3).

Serial No. 75001 and up

30-142

1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

6. Disconnect acceleration rod (4) from yoke.

7. Disconnect deceleration rod (5) from yoke.

8. Disconnect brake rod (6).

fl Loosen locknut (7), and turn joint (8) to dis-

connect.
Joint (8) has a reverse thread.

9. Remove floor assembly (9).

HYDRAULIC PUMP

4 Floor assembly: 26 kg

A. Removal of hydraulic pump assembly

1) Disconnect hose (1) leading to work equip­ment control valve.

2) Disconnect wiring connector (2) (HHP).

3) Disconnect suction tube joints (3) and (4).

4) Remove 4 mounting bolts (5), then remove
tube (6).

5) Remove mounting bolts, then remove hy­draulic pump assembly (7).

4 Hydraulic pump assembly : 19 kg

D155AX-5

30-143

1

5

DISASSEMBLY AND ASSEMBLY

B. Removal of 3-spool pump assembly (HSS lubri-

cation + torque converter, transmission charge
+ torque converter charge pump)

1) Remove cover (1).

2) Disconnect HSS motor and brake lubrication
tube (2).

3) Disconnect suction tube (3) from power train
case.

4) Disconnect transmission filter hose (4).

HYDRAULIC PUMP

5) Disconnect filter bypass valve hose (5).
fl It is difficult to disconnect the hose at

the pump end.

6) Remove mounting bolts, then lift off 3-spool
pump assembly (6).
fl Remove together with hose (5).

4 3-spool pump assembly : 24 kg

30-144

1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

C. Removal of HSS pump assembly

1) Disconnect HSS and PPC charge valve hose
(1).

2) Disconnect cooler bypass valve hose (2).

3) Disconnect charge filter hose (3).

4) Disconnect solenoid wiring connector (4)

(PUP.A).

5) Disconnect cooler bypass valve hose (5).

6) Disconnect HSS motor hoses (6) and (7).

7) Disconnect charge relief valve hose (8).

HYDRAULIC PUMP

8) Disconnect engine speed sensor wiring con-

nector (9) (CN010).

9) Disconnect solenoid wiring connector (10)

(PUP.B).

10) Remove mounting bolts, then lift off HSS

pump assembly (10).

4 HSS pump assembly : 116 kg

D155AX-5

30-145

1

5

DISASSEMBLY AND ASSEMBLY

D. Removal of charge + scavenging pump assembly

1) Disconnect charge filter hose (1).
fl It is difficult to disconnect the hose at

the pump end.

2) Disconnect power train case suction tube (2).

3) Disconnect suction hydraulic tank tube (3).

HYDRAULIC PUMP

4) Lift off charge + scavenging pump assembly
(4).
fl Raise, then move slowly towards the en-

gine, and lower gradually from clearance.

4 Charge + scavenging pump assembly :

30 kg

INSTALLATION OF HYDRAULIC
PUMP ASSEMBLY

• Carry out installation in the reverse order to
removal.

• Refilling oil

5 Hydraulic oil : Approx. 97 ¬
5 Power train case : Approx. 60 ¬

• Bleeding air

Bleed the air from the pumps and power train.
For details, see TESTING AND ADJUSTING,
Bleeding air.

30-146

1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

HSS, PPC CHARGING VALVE

DISASSEMBLY OF HSS, PPC CHARGING VALVE ASSEMBLY

12

13

20

16

15

19

5

21

18

22

17

14

1

3

4

11

7

10

9

8

6

2

23

DKD01197

1. Remove plug (1), then remove springs (3) and
(4) from valve body (2).

2. Remove plug (5), then remove spool assembly
(6).

3. Remove valve (8), spring (9), valve (10), and
shim (11) from spool (7).

4. Remove plug (12), then remove spring (13).

5. Remove plug (14), then remove spool assembly

(15).

6. Remove valve (17), spring (18), and valve (19)
from spool (16).

7. Remove plug (20), then remove spring (21) and
valve (22).

8. Remove plug (23).

D155AX-5

30-151

1

5

DISASSEMBLY AND ASSEMBLY

HSS, PPC CHARGING VALVE

ASSEMBLY OF HSS, PPC CHARGING VALVE ASSEMBLY

12

13

20

16

15

19

14

21

22

1

17

18

11

7

10

9

8

6

5

2

23

4

3

DKD01197

fl Clean all parts, and check for dirt or dam-

age. Coat the sliding surfaces of all parts
with engine oil before installing.

1. Tighten plug (23).

2. Assemble valve (22) and spring (21) to valve

body (2), and tighten plug (20).

3. Assemble valve (19), spring (18), and valve
(17) to spool (16).

4. Assemble spool assembly (15) to valve body
(2), and tighten plug (14).

3 Plug : 63.7 ± 14.7 Nm {6.5 ± 1.5 kgm}

5. Assemble spring (13) and tighten plug (12).

3 Plug : 68.6 ± 9.8 Nm {7 ± 1 kgm}

6. Assemble valve (10), spring (9), valve (8),

and shim (11) to spool (7).
fl Check the number and thickness of the

shims, then assemble.
Shim thickness: 0.5 mm
No. of shims: 4

7. Assemble spool assembly (6) to valve body
(2) and tighten plug (5).

3 Plug : 68.6 ± 9.8 Nm {7 ± 1 kgm}

8. Assemble springs (4) and (3), and tighten

plug (1).

3 Plug : 68.6 ± 9.8 Nm {7 ± 1 kgm}

30-152

1

5

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY

¤ Park the machine on level ground, lower the

work equipment completely to the ground, then
disconnect the cable from the negative (–) ter­minal of the battery.

1. Remove operator’s seat and floor plate.
For details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY.

2. Disconnect hose brackets (1) and (2) from trans­mission case cover.

3. Disconnect speed control cable (3), and remove
bracket from case cover.
fl Do not disconnect the cable from the bracket.

TRANSMISSION CONTROL VALVE

4. Disconnect directional control cable (4), and re-

move bracket from case cover.
fl Do not disconnect the cable from the bracket.

5. Disconnect transmission modulation pressure
detection hose (5).

6. Disconnect wiring connector of gear speed de­tection limit switch (5-1).

• Serial No. Only 75001 and up

7. Disconnect backup alarm limit switch wiring con­nector (6) (CN251), and remove limit switch (7).

8. Using forcing screws, remove transmission cover
(8). 1

9. Disconnect hose (9) coming from charge pump,
and remove plate (10).

10. Remove sleeve (11), then remove block (12).

D155AX-5

30-153

1

5

DISASSEMBLY AND ASSEMBLY

10. Remove sleeves (13) and (14). 2

11. Remove block (15), then remove sleeve (16).

3

12. Remove mounting bolts, then remove transmis-

sion control valve assembly (17). 4

INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY

• Carry out installation in the reverse order to
removal.

TRANSMISSION CONTROL VALVE

1

fl Look through the inspection window in the

cover to check that the lever and yoke are
meshed, then tighten the mounting bolts.

fl When installing the cover, tap with a plastic

hammer. If the dowel pin portion is not
inserted, remove the cover, correct the mesh­ing of the lever and yoke, then install again.

23

2 Sleeve : Grease (G2-LI)

4

3 Transmission control valve mounting bolt :

49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}

30-154

1

D155AX-5

DISASSEMBLY AND ASSEMBLY

INSTALLATION OF BLADE PPC
VALVE ASSEMBLY

• Carry out installation in the reverse order to
removal.

1 2 3

e The connection position for the pump hose,

drain hose, and PPC hose are distinguished
by color bands at the caulking portion for
the hoses, so check the colors when con­necting.

4

e Set the PPC valve in the mounting direction

shown in the diagram on the right when
installing.
(The diagram on the right shows the PPC
valve as seen from the top of the panel.)

Front of
machine

P4

BLADE PPC VALVE

T

P2

(View of valve from above)

P1

P

P3

DAD00788

• Refilling with oil (hydraulic tank)

Add engine oil through oil filler to the specified
level.
e Run the engine to circulate the oil through

the system. Then check the oil level again.

D155AX-5

30-269

1

1

DISASSEMBLY AND ASSEMBLY

REMOVAL OF RIPPER PPC
VALVE ASSEMBLY

 Fully lower work equipment to the ground. Re-

lease the remaining pressure in the circuit. For
details, see TESTING AND ADJUSTING, RELEAS­ING REMAINING PRESSURE IN HYDRAULIC CIR­CUIT. Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank.

1. Remove operator’ seat, remove 1 cover on in­side right, then remove side cover on right side
of chassis.

4 Operator’s seat: 50 kg

2. Remove cover (1).

e Disconnect the horn switch connector

(CN262) at the same time.

RIPPER PPC VALVE

3. Loosen lock bolt of lever (2), and pull out lever

(2) together with boot.

4. Remove lever guide.
Serial No. Only 75001 and up

5. Disconnect pump hose (4). 1

6. Disconnect drain hose (5). 2

7. Disconnect PPC hose (6). 3

7. Remove ripper PPC valve assembly (7). 4

4

5

6

6

DBD00791

30-270

1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

5

5

6

DED01133

6

DED01134

7

8

9

REMOVAL OF OPERATOR CAB
ASSEMBLY

OPERATOR CAB

Serial No. 70001 – 75000

 Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Remove ROPS guard.
For details, see REMOVAL OF ROPS GUARD.

2. Open left side cover.

3. Disconnect connectors (1) (CN360), (2) (CN-

CAB1), and (3) (CN-CAB2).

4. Disconnect 4 washer hoses (4). 1

5. Remove step (5), then remove cover (6).

6. Remove garnishes (7), (8), and (9).

7. Remove 19 mounting bolts, then lift off opera-

tor cab assembly (10).

4 Operator cab assembly: 290 kg

2

3

4

1

DED01132

INSTALLATION OF OPERATOR
CAB ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to
removal.

1

e Match the color bands and connect the

washer hoses.

10

DED01135

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1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF HOOD
ASSEMBLY

HOOD

1. Remove exhaust pipe (1).

2. Remove partition (2), then remove rubber seal.

3. Loosen clamp (3) and disconnect connector (4)

from hood end.

4. Lift off hood assembly (5).

4 Hood assembly: 90 kg

INSTALLATION OF HOOD
ASSEMBLY

• Carry out installation in the reverse order to
removal.

1

DED00795

2

DED00796

3

4

DED00797

5

DED00798

30-298

1

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF FLOOR FRAME
ASSEMBLY

Serial No. 70001 – 75000

¤ Park the machine on level ground, lower the

work equipment completely to the ground, then
disconnect the cable from the negative (-) termi­nal of the battery.

1. Remove operator cab assembly.
For details, see REMOVAL OF OPERATOR CAB
ASSEMBLY.

2. Lift off operator’s seat (1).

4 Operator’s seat : 54 kg

3. Remove floor plate (2).

FLOOR FRAME

4. Disconnect deceleration rod (3).

5. Remove left armrest (4) and right armrest (5).

6. Remove right side covers (6) and (7).

7. Remove left side covers (8) and (9).

8. Disconnect engine wiring connector (10) (CN101).

9. Disconnect monitor wiring connector (11)

(CN214).

10. Disconnect panel lighting wiring connector (12)
(CN215).

D155AX-5

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1

5

DISASSEMBLY AND ASSEMBLY

11. Disconnect air conditioner hoses (13). 1

fl Using tool X, collect new freon gas (R134a).

12. Remove bracket (14), and move receiver tank
(15) towards outside.

13. Disconnect 2 heater hoses (16).
fl Close the heater hose valve at the engine

end.

fl Fit blind plugs after disconnecting.

14. Loosen bellows hose clamp (17), and discon­nect bellows hose from engine hood.

15. Remove 2 covers (18).

FLOOR FRAME

16. Open cover (19), remove cleaner cover (20) and

filter, then remove cover (19).

17. Remove covers (21) and (22), and install eyebolts.

30-300

1

D155AX-5

DISASSEMBLY AND ASSEMBLY

35. Disconnect speed control cable (48), and remove
bracket (49) from transmission case.

36. Disconnect directional selector control cable (50),
and remove bracket (51) from transmission case.

37. Disconnect parking brake cable (52) from brake
valve, and remove bracket (53) from HSS case.

38. Disconnect brake control rod (54) from brake
valve.
fl After disconnecting the cable and rod, tie

them to the floor frame.

FLOOR FRAME

39. Remove 8 front mount bolts (55).

40. Remove 8 suspension mounting bolts (56).

D155AX-5

30-303

1

DISASSEMBLY AND ASSEMBLY

41. Lift off floor frame assembly (57).

4 Floor frame assembly : 230 kg

fl Control with a lever block to avoid interfer-

ence when removing.

INSTALLATION OF FLOOR
FRAME ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to
removal.

1

fl Install the hoses without twisting or interfer-

ence.

fl Install the air conditioner circuit hoses care-

fully to prevent dirt, dust, or water from get­ting inside the hoses.

fl Check that there are O-rings at the piping

connection of the air conditioner hoses, and
coat the O-rings thoroughly with compres­sor oil before connecting.

FLOOR FRAME

2

fl The positions for connecting the PPC hoses

are distinguished by color bands at the quick
coupler, so check the colors when installing.

30-304

1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF DASHBOARD
ASSEMBLY

Serial No. 70001 – 75000

¤ Park the machine on level ground, lower the

work equipment completely to the ground, then
disconnect the cable from the negative (–) ter­minal of the battery.

1. Remove operator’s cab assembly.
For details, see REMOVAL OF OPERATOR’S CAB
ASSEMBLY.

2. Disconnect engine wiring connector (1) (CN101).

3. Disconnect monitor wiring connector (2) (CN214).

4. Disconnect panel lighting wiring connector (3)

(CN215).

5. Disconnect air conditioner hoses (4). 1
fl Using tool X, collect freon gas (R134a).

6. Remove bracket (5), and move receiver tank to­wards outside.

7. Disconnect 2 heater hoses (6).
fl Close the heater hose valve at the engine

end.

fl After disconnecting, fit with blind plugs.

8. Loosen bellows hose clamp (7), and disconnect
bellows hose from engine hood.

DASHBOARD

9. Remove 2 covers (8).

10. Open cover (9), remove cleaner cover (10) and

filter, then remove cover (9).

88

DED01138

9

10

D155AX-5

DED01139

30-305

1

5

DISASSEMBLY AND ASSEMBLY

11. Remove covers (11) and (12), and install eyebolts.

12. Remove mounting bolts, then lift off dashboard

assembly (13).

DASHBOARD

11

12

DED01140

4 Dashboard assembly : 85 kg

INSTALLATION OF
DASHBOARD ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to
removal.

1

fl Install the hoses without twisting or interfer-

ence.

fl Install the air conditioner circuit hoses care-

fully to prevent dirt, dust, or water from get­ting inside the hoses.

fl Check that there are O-rings at the piping

connection of the air conditioner hoses, and
coat the O-rings thoroughly with compres­sor oil before connecting.

• Charging with air conditioner gas

Using tool X, charge air conditioner circuit with
new freon gas (R134a).

13

DED01141

30-306

1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

1

DED01117

1

2

DED01118

REMOVAL OF MONITOR
ASSEMBLY

 Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Remove mounting bolts and open monitor as­sembly (1).

2. Disconnect connectors (2) (CN-P1 and CN-P2),
and remove monitor assembly (1).

• Serial No. 70001 – 75000

3. Disconnect connectors (T01, CN4, CN1, CN2),
and remove monitor assembly (1).

• Serial No. 75001 –

MONITOR

Serial No. 70001 – 75000

Serial No. 70001 – 75000

INSTALLATION OF MONITOR
ASSEMBLY

• Carry out installation in the reverse order to
removal.

Serial No. 75001 and up

D155AX-5

30-307

1

5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF HSS
CONTROLLER ASSEMBLY

Serial No. 70001 – 75000

¤ Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Remove cover (1) at rear of operator’s seat.

2. Disconnect steering neutral adjustment switch

wiring connector (2) (CN-CSW).

3. Disconnect HSS controller wiring connectors (3)
(CN-1), (4) (CN-2H1), and (5) (CN-2H2).

4. Remove mounting bolts, then remove HSS con­troller assembly (6).

HSS CONTROLLER

INSTALLATION OF HSS
CONTROLLER ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to
removal.

30-308

1

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF HSS
CONTROLLER ASSEMBLY

Serial No. 75001 and up

¤ Disconnect the cable from the negative (–) ter-

minal of the battery

1. Remove cover (1) from rear of operator's seat.

2. Disconnect HSS controller wiring connector (2)

(CN-ST1), (3) (CN-ST2), and (4) (CN-ST3.)

3. Remove mounting bolts and HSS controller as­sembly (5).

INSTALLATION OF HSS
CONTROLLER ASSEMBLY

HSS CONTROLLER

Serial No. 75001 and up

• Carry out installation in the reverse order to re-

moval.

D155AX-5

30-309

5

5