D155ax-5 S Sebm016205 D155ax-5 0407
D155ax-5 S Sebm016205 D155ax-5 0407
D155ax-5 S Sebm016205 D155ax-5 0407
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.
C 2001 1
All Rights Reserved
D155AX-5
Printed in Japan 04-01(03) 00-1
5
CONTENTS
No. of page
00-2 D155AX-5
1
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40-22 90- 9 3
40-24 90-11 3
40-25 90-13 3
40-26 90-15 3
40-28 3 90-17 3
40-29 3 90-19 3
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D155AX-5 00-2-5
00-7
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00-2-6 (Blank page) D155AX-5
4
30 DISASSEMBLY AND ASSEMBLY
Method of using manual ............................ 30- 3 HYDRAULIC COOLER
Precautions when carring out operation ... 30- 5 Removal and Installation ...................... 30-62
Special tool list ............................................. 30- 7 ENGINE
Special tool sketch ....................................... 30-17 Removal .................................................. 30-63
STARTING MOTOR Installation .............................................. 30-65
Removal and Installation ...................... 30-26 DAMPER
ALTERNATOR Removal .................................................. 30-66
Removal and Installation ...................... 30-27 Installation .............................................. 30-67
ENGINE OIL COOLER CORE Disassembly ........................................... 30-68
Removal and Installation ...................... 30-28 Assembly ................................................ 30-71
FUEL INJECTION PUMP POWER TRAIN UNIT
Removal .................................................. 30-29 Removal .................................................. 30-75
Installation .............................................. 30-30 Installation .............................................. 30-79
WATER PUMP Separation .............................................. 30-80
Removal and Installation ...................... 30-31 Connection ............................................. 30-84
TURBOCHARGER PTO
Removal and Installation ...................... 30-32 Disassembly ........................................... 30-85
NOZZLE HOLDER Assembly ................................................ 30-89
Removal and Installation ...................... 30-33 TORQUE CONVERTER
FUEL INJECTOR Disassembly ........................................... 30-94
Removal and Installation ................... 30-33-1 Assembly ................................................ 30-97
ENGINE FRONT SEAL TORQFLOW TRANSMISSION
Removal .................................................. 30-34 Disassembly ......................................... 30-100
Installation .............................................. 30-35 Assembly .............................................. 30-109
ENGINE REAR SEAL HSS CASE
Removal .................................................. 30-37 Disassembly ......................................... 30-120
Installation .............................................. 30-38 Assembly .............................................. 30-129
CYLINDER HEAD HYDRAULIC PUMP
Removal .................................................. 30-42 Removal ................................................ 30-142
Installation .............................................. 30-47 Installation ............................................ 30-146
THERMOSTAT HSS PUMP
Removal and Installation ...................... 30-49 Disassembly ...................................... 30-146-1
AIR CONDITIONER COMPRESSOR Assembly ........................................... 30-146-8
Removal .................................................. 30-50 HSS MOTOR
Installation .............................................. 30-51 Removal and Installation .................... 30-147
AIR CONDITIONER CONDENSER POWER TRAIN MAIN RELIEF VALVE
Removal and Installation ...................... 30-52 Removal and Installation .................... 30-148
FUEL TANK Disassembly and Assembly ............... 30-149
Removal and Installation ...................... 30-53 HSS, PPC CHARGE VALVE
RADIATOR Removal and Installation .................... 30-150
Removal .................................................. 30-54 HSS, PCC CHARGEING VALVE
Installation .............................................. 30-56 Disassembly ......................................... 30-151
RADIATOR, OIL COOLER, GUARD Assembly .............................................. 30-152
Removal .................................................. 30-57 TRANSMISSION CONTROL VALVE
Installation .............................................. 30-59 Removal ................................................ 30-153
FAN DRIVE Installation ............................................ 30-154
Removal .................................................. 30-60 Disassembly and Assembly ............... 30-155
Installation .............................................. 30-61
D155AX-5 30-1
5
BRAKE VALVE SEGMENT TEETH
Removal and Installation .................... 30-157 Removal and Installation .................... 30-255
Disassembly and Assembly ............... 30-158 HYDRAULIC TANK
FINAL DRIVE Removal and Installation .................... 30-256
Removal ................................................ 30-160 MAIN CONTROL VALVE
Installation ............................................ 30-162 Removal ................................................ 30-257
Disassembly ......................................... 30-163 Installation ............................................ 30-258
Assembly .............................................. 30-168 Disassembly ......................................... 30-259
TRACK FRAME Assembly .............................................. 30-262
Removal ................................................ 30-174 HSS OIL COOLER BYPASS VALVE
Installation ............................................ 30-176 Removal and Installation .................... 30-266
IDLER ASSEMBLY Disassembly, assembly of HMT
Removal ................................................ 30-177 oil cooler bypass valve ....................... 30-267
Installation ............................................ 30-178 BLADE PPC VALVE
Disassembly ......................................... 30-179 Removal ................................................ 30-268
Assembly .............................................. 30-181 Installation ............................................ 30-269
RECOIL SPRING RIPPER PPC VALVE
Removal and Installation .................... 30-184 Removal ................................................ 30-270
Disassembly ......................................... 30-185 Installation ............................................ 30-271
Assembly .............................................. 30-190 BLADE PPC VALVE
TRACK ROLLER Disassembly ......................................... 30-272
Removal ................................................ 30-194 Assembly .............................................. 30-273
Installation ............................................ 30-195 BLADE LIFT CYLINDER
Disassembly ......................................... 30-196 Removal and Installation .................... 30-275
Assembly .............................................. 30-199 BLADE TILT CYLINDER
BOGIE Removal and Installation .................... 30-276
Removal ................................................ 30-202 RIPPER LIFT CYLINDER
Installation ............................................ 30-204 Removal and Installation .................... 30-277
Disassembly ......................................... 30-205 RIPPER TILT CYLINDER
Assembly .............................................. 30-209 Removal and Installation .................... 30-278
CARRIER ROLLER HYDRAULIC CYLINDER
Removal and Installation ................... 30-213 Disassembly ......................................... 30-279
Disassembly ......................................... 30-214 Assembly .............................................. 30-282
Assembly .............................................. 30-216 BLADE
TRACK SHOE Removal ................................................ 30-286
Checking before removal ................... 30-219 Installation ............................................ 30-287
Removal (normal) ................................ 30-219 Disassembly ......................................... 30-288
Removal (when there is abnorma- Assembly .............................................. 30-290
lity inside track frame) ................. 30-220 MULTI-SHANK RIPPER
Installation ............................................ 30-221 Disassembly ......................................... 30-292
Overall disassembly ............................ 30-222 Assembly .............................................. 30-294
Overall assembly ................................. 30-227 ROPS GUARD
Press-fitting jig dimention table for Removal and Installation .................... 30-296
link press .............................................. 30-241 OPERATOR CAB
ONE LINK Removal and Installation .................... 30-297
Disassembly ......................................... 30-242 HOOD
Assembly .............................................. 30-244 Removal and Installation .................... 30-298
MASTER LINK FLOOR FRAME
Disassembly ......................................... 30-246 Removal ................................................ 30-299
Assembly .............................................. 30-248 Installation ............................................ 30-304
PIVOT SHAFT DASHBOARD
Removal and Installation .................... 30-251 Removal ................................................ 30-305
EQUALIZER BAR Installation ............................................ 30-306
Removal ................................................ 30-252 MONITOR
Installation ............................................ 30-253 Removal and Installation .................... 30-307
EQUALIZER BAR SIDE BUSHING HSS CONTROLLER
Removal and Installation .................... 30-254 Removal and Installation .................... 30-308
30-2 D155AX-5
1
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL SKETCH
P Sleeve
)2 )1
30
30
C2
1800.2
3 C2
+0.4
175 +0.2
+0.4
+0.2
190.7
210
178
R1
C0.5 C1
8
80 60 20
465.50.2 DDD00866
P Plate
102
200
DDD00867
--- SS400P
D155AX-5 30-25
1
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
Serial 70001 75000
MOTOR ASSEMBLY
2
Disconnect the cable from the negative () ter-
minal of the battery.
INSTALLATION OF STARTING
MOTOR ASSEMBLY
Carry out installation in the reverse order to
removal.
3
DED00002
30-26 D155AX-5
5
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY Serial No. 70001-75000
2
DED00003
INSTALLATION OF
ALTERNATOR ASSEMBLY 8
Carry out installation in the reverse order to
removal. 6
1 5
e After installing the alternator, adjust the belt
tension. For details, see TESTING AND AD-
JUSTING, TESTING AND ADJUSTING AL- 3
TERNATOR BELT TENSION.
4 7 DED00004
D155AX-5 30-27
5
5
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
30-28 D155AX-5
5
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
8 DED00008
10
9 DED00009
11
DED00010
D155AX-5 30-29
5
5
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
12
13
DED00011
13 13
DED00012
INSTALLATION OF FUEL 16
INJECTION PUMP ASSEMBLY
Serial No. 70001 75000
Carry out installation in the reverse order to
removal. 15
1
e Adjust the linkage. For details, see TEST-
ING AND ADJUSTING, ADJUSTING FUEL
CONTROL LINKAGE.
DED00013
2
3 Sleeve nut: 123.5 1.0 Nm {2.4 0.1 kgm}
3
18 17
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.
DED00014
30-30 D155AX-5
5
DISASSEMBLY AND ASSEMBLY WATER PUMP
1
e After installing the V-belt, adjust the belt ten-
sion. For details, see TESTING AND AD-
JUSTING, TESTING AND ADJUSTING AL-
TERNATOR BELT TENSION.
8
DED00018
D155AX-5 30-31
1
5
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
Serial No. 70001 - 75000
1. Remove hood assembly.
For details, see REMOVAL OF HOOD ASSEM-
BLY.
3. Disconnect tube (4) and hose (5), then lift off air
cleaner assembly (6).
5
4
DBD00026
INSTALLATION OF
TURBOCHARGER ASSEMBLY
7
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}
8
2 DED00021
9
DED00020
30-32 D155AX-5
5
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
Serial No. 75001 and up
1. Remove hood assembly.
For details, see REMOVAL OF HOOD ASSEM-
BLY.
3. Disconnect tube (3) and hose (4), then lift off air
cleaner assembly (5).
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 NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
Serial No. 70001 75000
1. Remove hood assembly. 1
For details, see REMOVAL OF HOOD ASSEM-
BLY.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
DBD00414
4 A
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 6
is no dirt or dust inside the sleeve before
assembling.
Tighten the mounting bolts uniformly in turn
to prevent excessive tightening on one side.
DBD00416
D155AX-5 30-33
5
5
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
30-33-1 D155AX-5
5
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
INSTALLATION OF FUEL
INJECTOR ASSEMBLY
Serial No. 75001 and up
Carry out installation in the reverse order to
removal.
1
3 High-pressure pipe sleeve nut:
39.2 7.4 Nm {4.0 5.0 kgm}
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 fit-
ted to the socket of the push rod.
3 Rock arm mounting bolt:
93 103 Nm {9.5 10.5 kgm}
D155AX-5 30-33-2
5
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
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}
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.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
30-33-3 D155AX-5
5
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
DAD00046
D155AX-5 30-41
1
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
1. Drain coolant.
6. Disconnect tube (4) and hose (5), and lift off air
cleaner assembly (6).
6
4 Air cleaner assembly : 35 kg
5
4
DBD00026
4 Muffler assembly : 45 kg
7
DBD00027
11 DBD00028
30-42 D155AX-5
5
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
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 i !8 !9 o r!4 !5 t !0 @2 @3 !1
{6.75 0.75 kgm}
2
fl Tighten the bolts in the order 1 - 3 as u!7 @0 w q!3 !6 y e@1 @4 !2
shown in the diagram on the right, then
tighten in the order 4 - N.
3 Exhaust manifold mounting bolt : DBD00041
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 u !1 !5 !9 @3
@2 !8 !4 !0 y w e
fl Install the hoses without twisting or interfer-
ence.
3 Joint bolt : 29.4 4.9 Nm
@1 !7 !3 o t q r i !2 !6 @0 @4
{3.0 0.5 kgm}
5
fl Tighten the bolts in the order of 1 - N as
DAD00042
shown in the diagram on the right.
3 Intake manifold mounting bolt :
1st step : 29.4 4.9 Nm rod.
{3.0 0.5 kgm} fl Adjust the valve clearance.
2nd step : 66.2 7.4 Nm For details, see TESTING AND ADJUST-
{6.75 0.75 kgm} ING, ADJUSTING VALVE CLEARANCE.
6 3 Rocker arm assembly :
3 Intake connector mounting bolt : 98 4.9 Nm {10 0.5 kgm}
49.0 9.8 Nm {5 1 kgm} 3 Locknut :
7 48.0 2.9 Nm {4.9 0.3 kgm}
3 Joint bolt : 8.8 1.0 Nm A
{0.9 0.1 kgm} fl Adjust the crosshead as follows.
8 1) Loosen locknut, then turn adjustment
3 Delivery tube sleeve nut : screw back.
23.5 1.0 Nm {2.4 0.1 kgm} 2) Press top of crosshead lightly and
9 tighten adjustment screw.
3 Head cover mounting bolt : 3) When adjustment screw contacts
24.5 9.8 Nm {2.5 1.0 kgm} valve stem, screw in a further 20.
0 4) Tighten locknut to hold in position.
fl Clean the mounting bolt oil holes before in- 3 Locknut : 58.8 5.9 Nm
stalling. {6.0 0.6 kgm}
fl Check that the ball of the adjustment screw B
is fitted properly into the socket of the push 3 Locknut : 39.2 4.9 Nm
{4.0 0.5 kgm}
D155AX-5 30-47
5
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
C
3 Connector : 31.9 2.5 Nm
{3.25 0.25 kgm}
3 2
D 6
3 Holder mounting bolt : 66.2 7.4 Nm
{6.75 0.75 kgm}
E 5 4
fl Check that there is no dirt or dust on the 1
cylinder head mounting surface or inside the
cylinder.
fl When installing the gasket, check that the 7
DAD00043
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.
B
2 Cylinder head mounting bolt :
Anti-friction compound (LM-P)
3 Cylinder head mounting bolt :
DAD00046
30-48 D155AX-5
1
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1
1. Drain coolant.
4
INSTALLATION OF
THERMOSTAT ASSEMBLY
Carry out installation in the reverse order to
removal.
Refilling with water 4
Add water through water filler to the specified
level.
DBD00422
fl Run the engine to circulate the water through
the system. Then check the water level
again.
D155AX-5 30-49
1
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
Serial No. 70001 75000
ASSEMBLY
Using tool X, collect freon gas (R134a). 1 3
2
1. Open engine left side cover (top) and remove
cover (bottom).
DBD00424
7
DBD00425
30-50 D155AX-5
5
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
Serial No. 70001 75000
DED00437
DED00439
D155AX-5 30-63
5
DISASSEMBLY AND ASSEMBLY ENGINE
7 6 DED00440
10
DED00441
DDD00442
DED00443
30-64 D155AX-5
1
DISASSEMBLY AND ASSEMBLY ENGINE
D155AX-5 30-64-1
5
DISASSEMBLY AND ASSEMBLY ENGINE
30-64-2 D155AX-5
5
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
1. Drain oil
D155AX-5 30-75
5
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
30-76 D155AX-5
1
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
Serial No. 70001 75000
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).
D155AX-5 30-79
5
1
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
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.
8 9
DBD00927
30-80 D155AX-5
1
DISASSEMBLY AND ASSEMBLY HSS CASE
DKD01001
14
16 DKD01002
19
18
DLD01003 DLD01004
22 24
DLD01005 DLD01006
D155AX-5 30-121
1
5
DISASSEMBLY AND ASSEMBLY HSS CASE
28
27 DLD01007
31 18
DKD01008
33
r
DLD01009
30-122 D155AX-5
5
DISASSEMBLY AND ASSEMBLY HSS CASE
41
DLD01012 DLD01013
109
DLD01014
3. Sun gear
Remove sun gear (45).
fl Remove the sun gear on the opposite side
in the same way. 45
47
4. Gear
1) Remove snap ring (47), then remove spacer
(48). 48
DLD01015 DLD01016
DLD01017
D155AX-5 30-123
5
DISASSEMBLY AND ASSEMBLY HSS CASE
55
DKD01018
5. Valve seat
1) Pull out 2 brake circuit tubes (51) and 3 lu-
brication tubes (52), then remove. 51
52
2) Remove valve seat (53).
52 53
51
51 DKD01019
56
DLD01020
57 59
58 60
DLD01021 DLD01022
30-124 D155AX-5
5
1
DISASSEMBLY AND ASSEMBLY HSS CASE
Front
DAD00158
D155AX-5 30-135
1
5
DISASSEMBLY AND ASSEMBLY HSS CASE
DBD00160
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained, ad-
just 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 B
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. A
DBD00161
Move the bevel gear in direction B, then
check the tooth contact pattern and back-
lash 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. B
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 back- A
DBD00162
lash again.
30-136 D155AX-5
1
DISASSEMBLY AND ASSEMBLY HSS CASE
DLD00999
DKD01083 DLD01255
DLD00997
DAD02453
D155AX-5 30-141
1
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
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 () ter-
minal of the battery.
2. Remove cab.
For details, see REMOVAL OF CAB ASSEMBLY.
Serial No. 70001 75000
3. Lift off operators seat assembly (1).
4 Operators seat : 54 kg
30-142 D155AX-5
1
5
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
4 Floor assembly: 26 kg
D155AX-5 30-143
1
5
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
30-144 D155AX-5
1
5
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
D155AX-5 30-145
1
5
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
INSTALLATION OF HYDRAULIC
PUMP ASSEMBLY
Carry out installation in the reverse order to
removal.
Refilling oil
Bleeding air
Bleed the air from the pumps and power train.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-146 D155AX-5
1
5
DISASSEMBLY AND ASSEMBLY HSS, PPC CHARGING VALVE
20
14
21
22
1
15
17 3
18 4
19
16
13
11 2
12 7
10
9
8
6 23
DKD01197
5
D155AX-5 30-151
1
5
DISASSEMBLY AND ASSEMBLY HSS, PPC CHARGING VALVE
20
14
21
22
1
15
17 3
18 4
19
16
13
11 2
12 7
10
9
8
6 23
DKD01197
5
fl Clean all parts, and check for dirt or dam- 8. Assemble springs (4) and (3), and tighten
age. Coat the sliding surfaces of all parts plug (1).
with engine oil before installing. 3 Plug : 68.6 9.8 Nm {7 1 kgm}
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}
30-152 D155AX-5
1
5
5
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
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 () ter-
minal of the battery.
D155AX-5 30-153
1
5
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
Carry out installation in the reverse order to
removal.
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 mesh-
ing 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 D155AX-5
1
DISASSEMBLY AND ASSEMBLY BLADE PPC VALVE
1 2 3
Front of
machine
e The connection position for the pump hose,
drain hose, and PPC hose are distinguished P3
by color bands at the caulking portion for P4
the hoses, so check the colors when con-
necting. P1 (View of valve from above)
DAD00788
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.)
D155AX-5 30-269
1
DISASSEMBLY AND ASSEMBLY RIPPER PPC VALVE
4 Operators seat: 50 kg
6
6
DBD00791
30-270 D155AX-5
1
5
DISASSEMBLY AND ASSEMBLY OPERATOR CAB
DED01133
INSTALLATION OF OPERATOR
CAB ASSEMBLY 8 9
7
Serial No. 70001 75000
1
e Match the color bands and connect the
washer hoses.
DED01134
10
DED01135
D155AX-5 30-297
1
5
DISASSEMBLY AND ASSEMBLY HOOD
REMOVAL OF HOOD
ASSEMBLY
1. Remove exhaust pipe (1). 1
4 Hood assembly: 90 kg
DED00795
INSTALLATION OF HOOD
ASSEMBLY
Carry out installation in the reverse order to
removal.
DED00796
DED00797
DED00798
30-298 D155AX-5
1
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
4 Operators seat : 54 kg
D155AX-5 30-299
5
1
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
30-300 D155AX-5
1
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
D155AX-5 30-303
1
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
INSTALLATION OF FLOOR
FRAME ASSEMBLY
Serial No. 70001 75000
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 get-
ting 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 compres-
sor oil before connecting.
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 D155AX-5
1
5
DISASSEMBLY AND ASSEMBLY DASHBOARD
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 () ter-
minal of the battery.
1. Remove operators cab assembly.
For details, see REMOVAL OF OPERATORS CAB
ASSEMBLY.
8 8
DED01138
10
DED01139
D155AX-5 30-305
5
1
DISASSEMBLY AND ASSEMBLY DASHBOARD
11
12
DED01140
4 Dashboard assembly : 85 kg
13
INSTALLATION OF
DASHBOARD ASSEMBLY
Serial No. 70001 75000 DED01141
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 get-
ting 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 compres-
sor oil before connecting.
30-306 D155AX-5
1
5
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
Serial No. 70001 75000
ASSEMBLY
Disconnect the cable from the negative () ter-
minal of the battery.
1
1. Remove mounting bolts and open monitor as-
sembly (1).
1
INSTALLATION OF MONITOR
ASSEMBLY
2
Carry out installation in the reverse order to
removal.
DED01118
D155AX-5 30-307
1
5
DISASSEMBLY AND ASSEMBLY HSS CONTROLLER
REMOVAL OF HSS
CONTROLLER ASSEMBLY
Serial No. 70001 75000
INSTALLATION OF HSS
CONTROLLER ASSEMBLY
Serial No. 70001 75000
30-308 D155AX-5
1
5
DISASSEMBLY AND ASSEMBLY HSS CONTROLLER
REMOVAL OF HSS
CONTROLLER ASSEMBLY
Serial No. 75001 and up
Disconnect the cable from the negative () ter-
minal of the battery
INSTALLATION OF HSS
CONTROLLER ASSEMBLY
Serial No. 75001 and up
D155AX-5 30-309
5
5
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