D155axi-8 Sen06521-02 Disassembly & Assembly

SEN06521-02
BULLDOZER D155AXi -8
SERIAL NUMBERS 100040 and up
50 DISASSEMBLY AND ASSEMBLY
D155AXI-8 50-1
50 DISASSEMBLY AND ASSEM-
CONTENTS BLY
CONTENTS
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ................................................................. 50-8
HOW TO READ THIS MANUAL.............................................................................................................. 50-8
COATING MATERIALS LIST................................................................................................................. 50-10
SPECIAL TOOLS LIST ......................................................................................................................... 50-15
SKETCHES OF SPECIAL TOOLS ........................................................................................................ 50-42
ENGINE AND COOLING SYSTEM.............................................................................................................. 50-69
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY ......................................................................... 50-69
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY ............................................................. 50-69
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY ............................................................ 50-71
REMOVE AND INSTALL INJECTOR ASSEMBLY ................................................................................ 50-77
METHOD FOR REMOVING INJECTOR ASSEMBLY .................................................................... 50-77
METHOD FOR INSTALLING INJECTOR ASSEMBLY ................................................................... 50-82
REMOVE AND INSTALL FUEL DOSER ASSEMBLY ........................................................................... 50-92
METHOD FOR REMOVING FUEL DOSER ASSEMBLY ............................................................... 50-92
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY .............................................................. 50-93
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY ..................................................................... 50-94
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY ......................................................... 50-95
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .......................................................50-105
REMOVE AND INSTALL EGR VALVE ASSEMBLY..............................................................................50-121
METHOD FOR REMOVING EGR VALVE ASSEMBLY .................................................................50-121
METHOD FOR INSTALLING EGR VALVE ASSEMBLY ................................................................50-122
REMOVE AND INSTALL EGR COOLER ASSEMBLY..........................................................................50-124
METHOD FOR REMOVING EGR COOLER ASSEMBLY .............................................................50-124
METHOD FOR INSTALLING EGR COOLER ASSEMBLY ............................................................50-126
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .................................................................50-129
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY .....................................................50-129
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY ....................................................50-130
REMOVE AND INSTALL ALTERNATOR BELT ....................................................................................50-132
METHOD FOR REMOVING ALTERNATOR BELT ........................................................................50-132
METHOD FOR INSTALLING ALTERNATOR BELT .......................................................................50-133
REMOVE AND INSTALL RADIATOR ASSEMBLY ...............................................................................50-135
METHOD FOR REMOVING RADIATOR ASSEMBLY ...................................................................50-135
METHOD FOR INSTALLING RADIATOR ASSEMBLY ..................................................................50-138
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ......................................................50-144
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY ..........................................50-144
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .........................................50-145
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.......................................................................50-147
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY ..........................................................50-147
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .........................................................50-148
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY .............................................................50-151
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY .................................................50-151
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY ................................................50-153
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY ...........................................................50-155
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY...............................................50-155
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY..............................................50-156
REMOVE AND INSTALL ENGINE ASSEMBLY....................................................................................50-157
METHOD FOR REMOVING ENGINE ASSEMBLY .......................................................................50-157
METHOD FOR INSTALLING ENGINE ASSEMBLY ......................................................................50-164
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .........................................................................50-171
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .............................................................50-171
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL ............................................................50-173
REMOVE AND INSTALL ENGINE REAR OIL SEAL............................................................................50-177
METHOD FOR REMOVING ENGINE REAR OIL SEAL................................................................50-177
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...............................................................50-179
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY ........................................................................50-183
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY............................................................50-183
50-2 D155AXI-8
BLY CONTENTS
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...........................................................50-186

REMOVE AND INSTALL FUEL TANK ASSEMBLY ..............................................................................50-189
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY ......................................................50-189
METHOD FOR INSTALLING FUEL TANK ASSEMBLY.................................................................50-192
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ...................................................................50-196
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .......................................................50-196
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY ......................................................50-202
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.....................................50-207
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY ........................50-207
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .......................50-213
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .......................................................................50-218
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR ...........................................................50-218
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR ..........................................................50-218
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER ....................................................................50-220
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER ........................................................50-220
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .......................................................50-220
REMOVE AND INSTALL KDPF ASSEMBLY........................................................................................50-221
METHOD FOR REMOVING KDPF ASSEMBLY ...........................................................................50-221
METHOD FOR INSTALLING KDPF ASSEMBLY ..........................................................................50-224
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ...................................................................50-229
METHOD FOR DISASSEMBLING KDPF ASSEMBLY ..................................................................50-229
METHOD FOR ASSEMBLING KDPF ASSEMBLY........................................................................50-234
REMOVE AND INSTALL SCR ASSEMBLY..........................................................................................50-239
METHOD FOR REMOVING SCR ASSEMBLY .............................................................................50-239
METHOD FOR INSTALLING SCR ASSEMBLY ............................................................................50-242
REMOVE AND INSTALL KDPF, SCR ASSEMBLY...............................................................................50-247
METHOD FOR REMOVING KDPF, SCR ASSEMBLY ..................................................................50-247
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY .................................................................50-252
REMOVE AND INSTALL KCCV ASSEMBLY .......................................................................................50-259
METHOD FOR REMOVING KCCV ASSEMBLY ...........................................................................50-259
METHOD FOR INSTALLING KCCV ASSEMBLY ..........................................................................50-261
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .........................................................................50-264
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .............................................................50-264
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE ............................................................50-267
REMOVE AND INSTALL AdBlue/DEF INJECTOR ...............................................................................50-272
METHOD FOR REMOVING AdBlue/DEF INJECTOR...................................................................50-272
METHOD FOR INSTALLING AdBlue/DEF INJECTOR..................................................................50-275
REMOVE AND INSTALL AdBlue/DEF PUMP ......................................................................................50-278
METHOD FOR REMOVING AdBlue/DEF PUMP ..........................................................................50-278
METHOD FOR INSTALLING AdBlue/DEF PUMP .........................................................................50-282
REMOVE AND INSTALL AdBlue/DEF HOSE ......................................................................................50-286
METHOD FOR REMOVING AdBlue/DEF HOSE ..........................................................................50-286
METHOD FOR INSTALLING AdBlue/DEF HOSE .........................................................................50-292
REMOVE AND INSTALL AIR CLEANER ASSEMBLY..........................................................................50-298
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .............................................................50-298
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY ............................................................50-299
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .......................................50-301
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY ...........................50-301
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY..........................50-302
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ..........................................50-303
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY ..............................50-303
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY.............................50-304
POWER TRAIN...........................................................................................................................................50-307
REMOVE AND INSTALL DAMPER ASSEMBLY ..................................................................................50-307
METHOD FOR REMOVING DAMPER ASSEMBLY......................................................................50-307
METHOD FOR INSTALLING DAMPER ASSEMBLY.....................................................................50-309
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY ...................................................................50-312
METHOD FOR DISASSEMBLE DAMPER ASSEMBLY ................................................................50-313
D155AXI-8 50-3
CONTENTS BLY
METHOD FOR ASSEMBLING DAMPER ASSEMBLY ..................................................................50-314

REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY ...............................................................50-317
METHOD FOR REMOVING POWER TRAIN UNIT ASSEMBLY...................................................50-317
METHOD FOR INSTALLING POWER TRAIN UNIT ASSEMBLY..................................................50-322
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY .......................................50-327
METHOD FOR DISCONNECTING POWER TRAIN UNIT ASSEMBLY ........................................50-327
METHOD FOR CONNECTING POWER TRAIN UNIT ASSEMBLY ..............................................50-333
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY ...........................................................................50-339
METHOD FOR DISASSEMBLING PTO ASSEMBLY ....................................................................50-339
METHOD FOR ASSEMBLING PTO ASSEMBLY ..........................................................................50-343
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY ............................................50-350
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY .....................................50-350
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY ...........................................50-356
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY........................................................50-364
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY ................................................50-365
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY ................................................50-375
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY ...........................................................................50-388
METHOD FOR DISASSEMBLING HSS ASSEMBLY ....................................................................50-390
METHOD FOR ASSEMBLING HSS ASSEMBLY ..........................................................................50-399
REMOVAL AND INSTALLATION OF HSS MOTOR .............................................................................50-413
METHOD FOR REMOVING HSS MOTOR ASSEMBLY................................................................50-413
METHOD FOR INSTALLING HSS MOTOR ASSEMBLY ..............................................................50-414
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY ...........................................................................50-416
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ..........................50-416
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY ..............................................................50-418
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY.............................................................50-421
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY......................................................50-423
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY ...........................................................50-430
UNDERCARRIAGE AND FRAME...............................................................................................................50-441
REMOVE AND INSTALL TRACK FRAME ASSEMBLY........................................................................50-441
METHOD FOR REMOVING TRACK FRAME ASSEMBLY............................................................50-441
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY ..........................................................50-446
REMOVE AND INSTALL IDLER ASSEMBLY.......................................................................................50-451
METHOD FOR REMOVING IDLER ASSEMBLY ..........................................................................50-451
METHOD FOR INSTALLING IDLER ASSEMBLY .........................................................................50-452
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY ........................................................................50-454
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .................................................................50-454
METHOD FOR ASSEMBLING IDLER ASSEMBLY.......................................................................50-455
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY .....................................................................50-459
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY .........................................................50-459
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY ........................................................50-459
DISASSEMBLE AND ASSEMBLE RECOIL SPRING...........................................................................50-460
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ...................................50-460
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY .....................................................50-464
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY ......................................................................50-467
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY ..........................................................50-467
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY.........................................................50-469
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY .......................................................50-471
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY ................................................50-471
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY ......................................................50-472
REMOVE AND INSTALL NO. 1 BOGIE ASSEMBLY............................................................................50-475
METHOD FOR REMOVING NO. 1 BOGIE ASSEMBLY................................................................50-476
METHOD FOR INSTALLING NO. 1 BOGIE ASSEMBLY ..............................................................50-479
REMOVE AND INSTALL NO. 2, 3, 4 BOGIE ASSEMBLIES ................................................................50-484
METHOD FOR REMOVING NO. 2, 3, 4 BOGIE ASSEMBLIES ....................................................50-485
METHOD FOR INSTALLING NO. 2, 3, 4 BOGIE ASSEMBLIES ...................................................50-487
DISASSEMBLE AND ASSEMBLE TRACK ROLLER BOGEY ASSEMBLY ..........................................50-492
METHOD FOR DIS ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY..................................50-492
50-4 D155AXI-8
BLY CONTENTS
METHOD FOR ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY.........................................50-493

REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY ..................................................................50-495
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY ......................................................50-495
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY .....................................................50-496
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY ...................................................50-497
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY ............................................50-497
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY ..................................................50-499
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY ..........................................................................50-502
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY..............................................................50-502
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY.............................................................50-503
SEPARATION AND CONNECTION OF TRACK ASSEMBLY...............................................................50-504
METHOD FOR CHECKING BEFORE SEPARATION OF THE TRACK ASSEMBLY .....................50-504
METHOD FOR SEPARATING OF TRACK ASSEMBLY (NORMAL)..............................................50-504
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DE-
FECT)........................................................................................................................................50-505
METHOD FOR INSTALLING TRACK ASSEMBLY ........................................................................50-507
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY ..........................................................50-509
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY..................................................50-509
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY ................................................50-509
DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERALLY ...........................................50-510
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY .........................................50-510
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY ...............................................50-512
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY ............................50-525
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY .....................50-525
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY ...........................50-526
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD......................................50-535
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD ..............................50-536
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD ....................................50-537
DISASSEMBLE AND ASSEMBLE MASTER LINK...............................................................................50-540
METHOD FOR DISASSEMBLING MASTER LINK .......................................................................50-540
METHOD FOR ASSEMBLING MASTER LINK .............................................................................50-541
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY .....................................................................50-544
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY.........................................................50-544
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY........................................................50-546
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS.......................................................50-548
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS ...............................................50-548
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS .....................................................50-549
REMOVE AND INSTALL SPROCKET .................................................................................................50-550
METHOD FOR REMOVING SPROCKET .....................................................................................50-550
METHOD FOR INSTALLING SPROCKET ....................................................................................50-550
HYDRAULIC SYSTEM................................................................................................................................50-551
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...................................................................50-551
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY ......................................................50-551
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .....................................................50-552
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY .........................50-554
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY .............50-554
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY ............50-556
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY .........
.........................................................................................................................................................50-558
METHOD FOR REMOVING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEM-
BLY............................................................................................................................................50-558
METHOD FOR INSTALLING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEM-
BLY............................................................................................................................................50-560
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY ..............................................................50-562
METHOD FOR REMOVING COOLING FAN PUMP ASSEMBLY..................................................50-562
METHOD FOR INSTALLING COOLING FAN PUMP ASSEMBLY ................................................50-564
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY...............................................................50-566
METHOD FOR REMOVING SCAVENGING PUMP ASSEMBLY ..................................................50-566
D155AXI-8 50-5
CONTENTS BLY
METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY .................................................50-567

REMOVE AND INSTALL CONTROL VALVE ASSEMBLY ....................................................................50-568
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY........................................................50-568
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY.......................................................50-569
WORK EQUIPMENT...................................................................................................................................50-572
REMOVE AND INSTALL BLADE ASSEMBLY .....................................................................................50-572
METHOD FOR REMOVING BLADE ASSEMBLY .........................................................................50-572
METHOD FOR INSTALLING BLADE ASSEMBLY ........................................................................50-574
DISASSEMBLE AND ASSEMBLE BLADE ASSEMBLY .......................................................................50-577
METHOD FOR DISASSEMBLING BLADE ASSEMBLY................................................................50-577
METHOD FOR ASSEMBLING BLADE ASSEMBLY......................................................................50-580
DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER ASSEMBLY .................................50-583
METHOD FOR DISASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY ..........................50-583
METHOD FOR ASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY ................................50-585
DISASSEMBLE AND ASSEMBLE GIANT RIPPER ASSEMBLY..........................................................50-588
METHOD FOR DISASSEMBLING GIANT RIPPER ASSEMBLY ..................................................50-588
METHOD FOR ASSEMBLING GIANT RIPPER ASSEMBLY ........................................................50-591
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ..........................50-594
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ..............50-594
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY .............50-596
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ...........50-599
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ....50-600
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ..........50-605
METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE TILT CYLINDER ASSEMBLY............50-616
METHOD FOR DISASSEMBLING BLADE TILT CYLINDER ASSEMBLY .....................................50-616
METHOD FOR ASSEMBLING BLADE TILT CYLINDER ASSEMBLY ...........................................50-618
METHOD FOR DISASSEMBLING AND ASSEMBLING RIPPER CYLINDER ASSEMBLY ..................50-622
METHOD FOR DISASSEMBLING RIPPER CYLINDER ASSEMBLY ...........................................50-622
METHOD FOR ASSEMBLING RIPPER CYLINDER ASSEMBLY .................................................50-624
CAB AND ITS ATTACHMENTS ..................................................................................................................50-629
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ..................................................................50-629
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY ......................................................50-630
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY .....................................................50-640
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS) ........................................50-648
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS) ............................50-650
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)...........................50-650
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY ........................................................50-655
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY ............................................50-655
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY ...........................................50-661
REMOVE AND INSTALL OPERATOR'S SEAT ....................................................................................50-668
METHOD FOR REMOVING OPERATOR'S SEAT ........................................................................50-668
METHOD FOR INSTALLING OPERATOR'S SEAT .......................................................................50-669
REMOVE AND INSTALL SEAT BELT ..................................................................................................50-670
METHOD FOR REMOVING SEAT BELT ......................................................................................50-670
METHOD FOR INSTALLING SEAT BELT .....................................................................................50-671
ELECTRICAL SYSTEM ..............................................................................................................................50-672
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ..........................................................50-672
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY ..............................................50-672
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .............................................50-674
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY ...............................................50-678
METHOD FOR REMOVING POWER TRAIN CONTROLLER ASSEMBLY ...................................50-678
METHOD FOR INSTALLING POWER TRAIN CONTROLLER ASSEMBLY ..................................50-679
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY .......................................50-680
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY ...........................50-680
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY..........................50-680
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ...............................................................50-682
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY ...................................................50-682
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY ..................................................50-683
50-6 D155AXI-8
BLY CONTENTS
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .....................................50-685
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .........................50-685
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR ........................50-686
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR................................................50-688
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR....................................50-688
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...................................50-688
REMOVE AND INSTALL SCR TEMPERATURE SENSOR ..................................................................50-690
METHOD FOR REMOVING SCR TEMPERATURE SENSOR ......................................................50-690
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR .....................................................50-692
REMOVE AND INSTALL BATTERY RELAY.........................................................................................50-694
METHOD FOR REMOVING BATTERY RELAY ............................................................................50-694
METHOD FOR INSTALLING BATTERY RELAY ...........................................................................50-702
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY .............................................................50-707
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY.................................................50-707
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY................................................50-708
REMOVE AND INSTALL CONTROL BOX ...........................................................................................50-711
METHOD FOR REMOVING CONTROL BOX ...............................................................................50-711
METHOD FOR INSTALLING CONTROL BOX ..............................................................................50-712
REMOVE AND INSTALL GNSS RECEIVER........................................................................................50-713
METHOD FOR REMOVING GNSS RECEIVER............................................................................50-713
METHOD FOR INSTALLING GNSS RECEIVER ..........................................................................50-714
REMOVE AND INSTALL GNSS ANTENNA .........................................................................................50-715
METHOD FOR REMOVING GNSS ANTENNA.............................................................................50-715
METHOD FOR INSTALLING GNSS ANTENNA............................................................................50-716
REMOVE AND INSTALL IMU SENSOR ..............................................................................................50-721
METHOD FOR REMOVING IMU SENSOR ..................................................................................50-721
METHOD FOR INSTALLING IMU SENSOR .................................................................................50-723
D155AXI-8 50-7
HOW TO READ THIS MANUAL BLY
RELATED INFORMATION ON DISASSEMBLY AND AS-

SEMBLY
HOW TO READ THIS MANUAL
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 torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
Reading the special tools list
• The special tools required for removal and installation work are described in the list as symbols such as
A1, ..., X1. Part number, part name, necessity, and quantity are described.
• Details of the special tools are on “SPECIAL TOOLS LIST”. Details of sketches are on “SKETCHES OF
SPECIAL TOOLS”. Special tools required for a specified work is also described in each work procedures.
• The symbols used in the table of special tools indicate the following meanings.
■: Not substitutable, and work cannot be performed without the tool.
●: Very useful tools to use which can be substituted with commercially available tools.
Reading the work procedures
All the necessary information for the work procedure, the precautions and prior knowledge relating to the work
procedures is described step by step.
Reading the symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Oil and coolant
(*1)
Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.
*1:For places to supply oil, coolant, etc. and their quantities, see SPECIFICATIONS “TABLE OF FUEL, COOL-
ANT, AND LUBRICANTS”.
Reading the signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE NOTICE
or shortening of service life may occur.
50-8 D155AXI-8
BLY HOW TO READ THIS MANUAL
Symbol Item Remark

REMARK Remarks This signal word contains useful information to know.
Reading the unit

International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
D155AXI-8 50-9
COATING MATERIALS LIST BLY
COATING MATERIALS LIST

Coating materials which are not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cork plugs from falling off.
• Use for plastic (except polyethylene, pol-
20 g Polyethy- ypropylene, tetrafluoroethylene and vinyl
LT-1B 790-129-9050 (contained lene con- chloride), rubber, metal, and non-metal
2 pieces) tainer parts which require immediate and
strong adhesion.
• Features: Resistance to heat and chemi-
Polyethy- cals
LT-2 790-129-9180 50 g lene con-
tainer • Use to keep bolts and plugs from com-
ing loose and as sealant.
790-129-9060 Adhesive
Set of adhe- 1 kg • Use to bond and seal metal, glass and
LT-3 Pail
sive and hard- Hardener plastics.
ener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene con- • Use to seal plugs for blank holes.
tainer
Holts • Heat-resistant seal used to repair en-
790-129-9120 75 g Tube
MH705 gines
• Instantaneous adhesive
THREEBOND Polyethy-
• Curing time: From 5 sec. to 3 min.
790-129-9140 50 g lene con-
1735 tainer • Use to bond mainly metals, rubbers,
plastics, and woods.
• Instantaneous adhesive
Aron Alpha Polyethy- • Quick-curing type (max. strength is ob-

790-129-9130 2 g lene contained after 30 minutes)
201 tainer • Use to bond rubbers, plastics, and met-
als.
• General-purpose instantaneous adhe-
sive with excellent resistance to heat
Loctite
428-99-80070 20 cc Tube and impact
499
• Use for the bushing mounting faces of
axle supports.
Polyethy- • Features: Resistance to heat and chemi-

Loctite
79A-129-9110 50 cc lene con- cals
648-50 tainer • Use to bond high-temperature fit parts.
50-10 D155AXI-8
BLY COATING MATERIALS LIST
Liquid gasket
• Use to seal various threaded parts, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene con-
tainer • Use to seal taper plugs, elbows, and nip-
ples for hydraulic piping.
• Features: Silicon-based heat and cold-
resistant
LG-6 790-129-9160 200 g Tube • Use to seal flange surface and threaded
parts
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
THREEBOND 419-15-18131 100 g Tube and shock-resistant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the cir-
LG-9 cle gear top seal which is not clamped
THREEBOND 790-129-9310 200 g Tube by bolts, gaps in the weld which must be
1206D
caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when insert-
THREEBOND 790-129-9320 200 g Tube ing radiator hoses
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with solid

gaskets.
THREEBOND 790-129-9330 200 g Tube
• Use for covers of the transmission case
1121
and steering case etc.
THREEBOND
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted parts,
LM-P ― 200 g Tube and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S ― 190 g Pail
metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.
D155AXI-8 50-11
Seizure prevention compound

• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
― ― Pail
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust mani-
fold and the turbocharger, etc.
Grease
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
• Lithium grease with extreme pressure lu-
G0-LI (*) SY- Various Various brication performance, general purpose
*: For cold dis- GA-160CNLI type.
tricts SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.
Molybdenum Bellows-
• Caution: Do not use this grease for roll-
SYG2-400M 400 gx 10 ing bearings like swing circle bearings,
disulfide type con-
grease SYG2-400M-A 400 gx 20 tainer etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Pail • Caution: Use this grease for work equip-
ment pins only when installing them, but
do not use it afterwards.
Hyper white SYG2-400T-A
grease • Higher seizure resistance, heat resist-
SYG2-16CNT Bellows-
ance, and waterproof than molybdenum
G2-T SYG0-400T-A 400 g type con-
disulfide grease
G0-T(*) (*) 16 kg tainer
Pail
• Not so conspicuous on machine since
*: For cold dis- SYG0-16CNT color is white.
tricts (*)
Biogrease SYG2-400B
G2-B SYGA-16CNB
Bellows- • Since this grease is bacterially biode-
G2-BT (*) SYG2-400BT 400 g type con- gradable in short period, the impact on
*: For use at (*) tainer microorganisms, animals, and plants is
16 kg
high tempera- SY- Pail kept to the minimum.
ture and under GA-16CNBT
high load (*)
• Feature: Silicon-based grease with wider
G2-S operating temperature range and superi-
THREEBOND ― 200 g Tube or thermal oxidative stability to prevent
1855
deterioration of rubber and plastic.
• Use for oil seals of the transmission, etc.
50-12 D155AXI-8
BLY COATING MATERIALS LIST
• Feature: Urea (organic) grease with heat
resistance and long service life, inclu-
G2-U-SENS sion type.
427-12-11871 2 kg Pail
Grease • Use for rubber, bearing and oil seal in
damper.
• Caution: Do not mix with lithium grease.
Primer
Loctite Glass con- • Use to accelerate hardening of instanta-
428-99-80080 100 mℓ
712 tainer neous adhesive.
SUNSTAR
• Use as primer for cab side (Expira-
Paint Surface Glass con-
20 mℓ tion date: 4 months after its produc-
Primer 580 tainer
SUPER
tion date)
417-926-3910
SUNSTAR • Use as primer for glass side (Expira-
Glass con-
For adhered window glass
Glass Primer 20 mℓ tion date: 4 months after its produc-
tainer
580 SUPER tion date)
SUNSTAR • Use as primer for painted cab sheet
Glass con-
Paint Surface 22M-54-27230 20 mℓ metal surface (Expiration date: 4
tainer
Primer 435-95 months after its production date)
SUNSTAR • Use as primer for black ceramic-coat-
PRIMER ed glass surface and for hard poly-
22M-54-27240 150 mℓ Steel can
435-41 for carbonate-coated surface (Expiration
glass date: 4 days after its production date)
SUNSTAR • Use as primer for sash (alumite sur-
Glass con-
sash primer 22M-54-27250 20 mℓ face treatment) (Expiration date:4
tainer
GP-402 months after its production date)
Adhesive
• Use "S" as adhesive for glass in high
SUNSTAR
Polyethy- temperature months (during summer)
Penguin Seal
417-926-3910 320 mℓ lene con- and "W" in low temperature months
580 SUPER
tainer (during winter) (Expiration date:4
"S" or "W"
months after its production date)
Polyethy- • Use as adhesive for glass (Expiration
Sika Japan Si-
20Y-54-39850 310 mℓ lene con- date: 6 months after its production
kaflex 256HV
tainer date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Super 22M-54-27210 320 mℓ (special date: 6 months after its production
560 container) date)
D155AXI-8 50-13
Caulking material
SUNSTAR Polyethy- • Use to seal for joint between glasses

Penguin Seal 417-926-3920 320 mℓ lene con- (Expiration date: 4 months after its
No.2505 tainer production date)
Polyethy-
SEKISUI Sili- • Use to seal front window (Expiration
20Y-54-55130 333 mℓ lene con-
cone Sealant date: 6 months after its production)
tainer
GE TOSHIBA • Translucent white seal used for joint
SILICONES 22M-54-27220 333 mℓ Cartridge between glasses (Expiration date: 12
TOSSEAL381 months after its production date)
50-14 D155AXI-8
BLY SPECIAL TOOLS LIST
SPECIAL TOOLS LIST

How to read the tool list
• Part No.
Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
• Necessity:
■: Tools not substituted, must always be equipped.
●: Very useful tools which can be substituted with commercially available tools.
• New/Redesign:
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
• Sketch:
○: Tools marked with ○ in the sketch column have the sketches.
Sketches are introduced in “Sketches of special tools”, and all sketches of “79*T-***-***”are described.
Tools for removal and installation of supply pump assembly
New/Redesign
Necessity
Sketch
Symbol Part No. Part name Q'ty Remarks
A - Wrench type torque wrench ■ 1 Tightening of sleeve nut
Tools for removal and installation of injector assembly

New/Redesign
Necessity
Sketch
Q'ty
Symbol Part No. Part name Remarks

B - L-shaped bar ■ 1 Removal of injector assembly
Tools for removal and installation of cylinder head assembly

New/Redesign
Necessity
Sketch
Q'ty

Removal and installation of cylinder
C - Eyebolt ■ 2
head
D 790-331-1110 Wrench ● 1 Angle tightening of bolts
D155AXI-8 50-15
SPECIAL TOOLS LIST BLY
Tools for removal and installation of cooling fan drive assembly
New/Redesign
Necessity
Sketch
Q'ty
Removal and installation of cooling fan

A - Eyebolt ■ 1
drive assembly
Tools for removal and installation of cooling fan and fan motor assembly
New/Redesign
Necessity
Sketch
Q'ty
A 790-101-3501 Gear puller ● 1 Removal of cooling fan
Tools for removal and installation of engine front oil seal

New/Redesign
Necessity
Sketch
Q'ty
795T-521-1111 Push tool ■ 1 ○

A 01050-31655 Bolt ■ 3 Installation of engine front oil seal
01050-31635 Bolt ■ 3
B 795-931-1100 Puller ■ 1 Removal of engine front seal
795T-521-1150 Push tool ■ 1 ○
C Installation of engine front oil seal
01050-31635 Bolt ■ 4
Tools for removal and installation of engine rear oil seal

New/Redesign
Necessity
Sketch
Q'ty
A 795-931-1100 Seal puller ■ 1

795T-421-1270 Push tool ■ 1 ○
B 01050-31645 Bolt ■ 4
01643-31645 Washer ■ 8 Installation of engine rear oil seal
795T-421-1240 Push tool ■ 1 ○
C 01050-31645 Bolt ■ 4
01643-31645 Washer ■ 4
D 790-331-1110 Wrench ● 1 Removal of engine rear seal
50-16 D155AXI-8
New/Redesign
Necessity
Sketch
Q'ty
795T-421-1250 Push tool ■ 1 ○

E 01050-31645 Bolt ■ 4 Installation of engine rear oil seal
01643-31645 Washer ■ 8
F - Eyebolt ■ 1 Removal and installation of flywheel
Measurement of facial runout and radial
G - Dial gauge ■ 1
runout
Tools for removal and installation of AdBlue/DEF tank assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Oil pan ■ 1 N
- Remote breather hose ■ 1
B - Valve ■ 1
- Hose ■ 1
Draining AdBlue/DEF
C - Wooden block ■ 1
D - Funnel ■ 1
E - Hose ■ 1
F - Polyethylene container ■ 1
G - Vinyl gloves ■ 1
H 6540-71-2720 AdBlue/DEF pump cap kit ■ 1 Disconnection and connection of AdBl-
ue/DEF hose
AdBlue/DEF hose plug (3/8
J 600-919-5030 ■ 1
inch)
Tools for removal and installation of AdBlue/DEF tank sensor flange assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Oil pan ■ 1 N
B - Valve ■ 1
- Hose ■ 1
Draining AdBlue/DEF
D - Funnel ■ 1
E - Hose ■ 1
D155AXI-8 50-17
New/Redesign
Necessity
Sketch
Q'ty
ue/DEF hose
J 600-919-5030 ■ 1
inch)
Tools for removal and installation of KDPF assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Digital angle gauge ● 1 For measurement of KDPF outlet angle
Tools for disassembly and assembly of KDPF assembly New/Redesign

Necessity
Sketch
Q'ty
A - Block ■ 4 Fixing KDPF assembly

Removal and installation of KDPF as-
B - Lifting tool ■ 2
sembly
Removal and installation of sensor ta-
C - Long socket ■ 1
ble
D - Level gauge ■ 1 Assembly of KDPF assembly
Tools for removal and installation of SCR assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Digital angle gauge ■ 1 For measurement of SCR inlet angle
Tools for removal and installation of KDPF and SCR assembly

New/Redesign
Necessity
Sketch
Q'ty
Disconnection and connection of AdBl-

A - Vinyl gloves ● 1 N
ue/DEF hose
Cover for AdBlue/DEF injector Disconnection and connection of AdBl-
B 6540-71-1310 ■ 1 N
electric connector ue/DEF injector electric connector
50-18 D155AXI-8
New/Redesign
Necessity
Sketch
Q'ty
Plug (for 5/16 inch hose diame- Disconnection and connection of AdBl-
C 600-919-5050 ■ 1 N
ter) ue/DEF hose
6540-71-1720 AdBlue/DEF injector cap kit ■ 1 N Removal and installation of injector
1 Disconnection and connection of AdBl-
AdBlue/DEF side cap ■ 1 N
ue/DEF hose
D
2 Disconnection and connection of cool-
Coolant side cap ■ 2 N
ant hose
3 Injector side cap ■ 1 N Removal and installation of injector
Tools for removal and installation of AdBlue/DEF mixing tube
New/Redesign
Necessity
Sketch
Symbol Part No. Part name Q'ty Remarks
Removal and installation of

A 6540-71-2720 Injector cap kit ■ 1 N
AdBlue/DEF injector
Tools for removal and installation of AdBlue/DEF injector

New/Redesign
Necessity
Sketch
Q'ty

ue/DEF hose
B 6540-71-1310 ■ 1 N
C 600-919-5050 ■ 1 N
ter) ue/DEF hose
AdBlue/DEF side cap ■ 1 N
ue/DEF hose
D
2 Disconnection and connection of cool-
Coolant side cap ■ 2 N
ant hose
3 Injector side cap ■ 1 N Removal and installation of injector
D155AXI-8 50-19
Tools for removal and installation of AdBlue/DEF pump
New/Redesign
Necessity
Sketch
Q'ty
B 600-919-5030 ■ 1 N
ter) ue/DEF hose
C 6540-71-2720 AdBlue/DEF pump cap kit ■ 1 N
Tools for disconnection and connection of AdBlue/DEF hose
New/Redesign
Necessity
Sketch
Q'ty
B 6540-71-1720 AdBlue/DEF injector cap kit ■ 1 N
Plug (for 3/8 inch hose diame-
C 600-919-5030 ■ 1 N Disconnection and connection of AdBl-
ter)
ue/DEF hose
D 6540-71-2720 AdBlue/DEF pump cap kit ■ 1 N
E 600-919-5050 ■ 1 N
ter)
Tools for removal and installation of damper assembly

New/Redesign
Necessity
Sketch
Q'ty
A 790-201-3130 Guide bolt ■ 2 Removal and installation of damper

B 790-201-3250 Bolt ■ 2 cover
C 790-201-3120 Guide bolt ■ 2

Removal and installation of damper as-
D 790-201-3230 Bolt ■ 2
sembly
E - Eyebolt ■ 1
Tools for disassembly and disassembly of damper assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 2 Disassembly and assembly of damper

B - Cylinder ■ 2 assembly
C 793T-623-1170 Push tool ■ 2 ○ Assembly of damper cover assembly
50-20 D155AXI-8
New/Redesign
Necessity
Sketch
Q'ty
791-612-1100 Installer ■ 2
D 790-101-4200 Puller (294 kN 30 t) ■ 1 Press-fit of bearing
790-101-1102 Hydraulic pump ■ 1
Tools for removal and installation of power train unit assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Bolt (M10 x 1.5) ■ 1 Pulling-out of shaft
Tools for disconnection and connection of power train unit assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 2 Fixing of power train unit assembly
Tools for disassembly and assembly of PTO assembly

New/Redesign
Necessity
Sketch
Q'ty
Removal and installation of gear and

A 790-201-3130 Guide bolt ■ 3
cover assembly
B 790-201-3290 Bolt ■ 4 Pulling-out of bearing
C - Block ■ 2 Fixing of cover
D 790-201-2720 Spacer ■ 1
Pulling-out of gear
E 793T-615-1720 Spacer ■ 1 ○
F 793T-417-1310 Spacer ■ 1 ○ Pulling-out of bearing
G 790-201-3250 Bolt ■ 2 Pulling-out of shaft
H 793T-613-1340 Spacer ■ 1 ○
J 790-201-2730 Spacer ■ 1 Press-fit of bearing
K 792T-413-1120 Push tool ■ 1 ○
D155AXI-8 50-21
Tools for disassembly and assembly of torque converter assembly
New/Redesign
Necessity
Sketch
Q'ty
A 790-201-3260 Bolt ■ 2 Pulling-out of shaft

Removal and installation of drive case
B - Eyebolt ■ 2
and housing assembly
C 790-201-3240 Bolt ■ 2
Pulling-out and press-fit of bearing
D 790-201-2660 Plate ● 1
E 790-201-2860 Spacer ■ 1 Removal of pump assembly
F 793T-615-1710 Spacer ■ 1 ○ Pulling-out and press-fit of bearing
G 790-201-2780 Spacer ■ 1
Press-fit of bearing
H 790-201-2750 Spacer ■ 1
K - Block ■ 1 Fixing of turbine and gear
Tools for disassembly and assembly of transmission assembly

New/Redesign
Necessity
Sketch
Q'ty
791T-615-1300 Puller assembly ■ 1 ○

A 791T-615-1310 • Plate ■ 1 ○
Operation check of clutch piston
01010-82040 • Bolt ■ 1
B 799-301-1600 Oil leak tester kit (A) ■ 1
C 791T-615-1350 Push tool ■ 1 ○
791T-615-1320 Plate ■ 1 ○
D
01017-31620 Bolt ■ 4
Installation of snap ring
791T-615-1330 Plate ■ 2
E
01282-61230 Bolt ■ 4
F 791T-615-1340 Plate ■ 1 ○
G 793T-422-1220 Push tool ■ 1 ○
Pulling-out of bearing
H 796-430-1110 Push tool ■ 1
J 790-201-2660 Plate ● 1 Press-fit of bearing
K 793T-615-1730 Spacer ■ 1 ○ Installation of cover
L 790-201-3120 Guide bolt ■ 2 Installation of carrier and ring gear
Removal and installation of housing as-
M - Eyebolt ■ 2
sembly
Removal and installation of input shaft,
N - Sling bar ■ 1
front cover and No.1 carrier assembly
P 790-201-3230 Bolt ■ 2 Removal of cover
50-22 D155AXI-8
Tools for disassembly and assembly of HSS assembly
New/Redesign
Necessity
Sketch
Q'ty
791-622-1110 Bracket ■ 1
Removal and installation of brake and
A 01010-31685 Bolt ■ 1
carrier assembly
01017-31620 Bolt ■ 1
790-302-1500 Wrench kit ■ 1 Removal and installation of nut (bevel
B
09003-09200 • Wrench ■ 1 pinion side)

C
09003-08290 • Wrench ■ 1 gear side)
Removal and installation of bevel pinion

D 790-201-3130 Guide bolt ■ 2
assembly
E 791T-630-2410 Push tool ■ 1 ○ Removal of bevel pinion
F 790-101-3501 Gear puller ■ 1
G 790-201-1410 Plate ● 1 Removal of gear
H 790-101-3000 Push puller ● 1
790-101-2501 Push puller ■ 1
790-101-2510 • Block ■ 1
790-101-2520 • Screw ■ 1
791-112-1180 • Nut ■ 1
J 790-101-2540 • Washer ■ 1 Pulling-out of shaft
790-101-2550 • Leg ■ 2
790-101-2570 • Plate ■ 4
790-101-2560 • Nut ■ 2
790-101-2670 • Adapter ■ 2
K 790-201-2770 Spacer ■ 1
L 792T-415-1410 Push tool ■ 1 ○
M 792T-446-1150 Push tool ■ 1 ○
Press-fit of retainer assembly
N 793T-613-1380 Spacer ■ 1 ○
P 79A-264-0021 Push-pull scale ■ 1 Measurement of starting torque
Q 793T-417-1110 Push tool ■ 1 ○
R 792T-413-1120 Push tool ■ 1 ○
S 793T-417-1310 Spacer ■ 1 ○
T 792T-415-1420 Push tool ■ 1 ○
U 790-201-2780 Spacer ■ 1
V 796T-426-1410 Push tool ■ 1 ○
W 793T-222-1310 Plate ■ 1 ○
X 793T-417-1130 Push tool ■ 1 ○
D155AXI-8 50-23
New/Redesign
Necessity
Sketch
Q'ty
Y 796-426-1120 Push tool ■ 1 Press-fit of bushing

Z 790-201-3120 Guide bolt ■ 2 Installation of brake cover assembly
AA - Eyebolt ■ 2 Removal and installation of case
AB - Block ■ 2 Fixing of bevel gear
796-514-2000 Remover ● 1
AC Pulling-out of shaft
796-514-2130 Adapter ■ 1
Tools for removal and installation of final drive assembly
New/Redesign
Necessity
Sketch
Q'ty
790-337-1032 Lifting tool ■ 1

791-627-1320 Shackle ■ 2 Removal and installation of final drive
A
791T-627-1910 Plate ■ 1 ○ assembly
01010-82080 Bolt ■ 2
B - Blocking tool ■ 2
C - Hydraulic jack ■ 1 Support of machine
D - Blocking tool ■ 2
Tools for disassembly and assembly of final drive assembly

New/Redesign
Necessity
Sketch
Q'ty
790-431-1031 Block ■ 1
791-520-4140 Screw ■ 2
790-101-2360 Plate ■ 4
791-112-1180 Nut ■ 2
A Pulling-out of sprocket hub assembly
790-101-2480 Adapter ■ 2
791T-627-1920 Plate ■ 1
790-101-2102 Puller ■ 1
50-24 D155AXI-8
New/Redesign
Necessity
Sketch
Q'ty
790-431-1031 Block ■ 1
791-520-4140 Screw ■ 2
790-101-2360 Plate ■ 4
791-112-1180 Nut ■ 2
B Pulling-out of hub assembly
790-101-2420 Adapter ■ 2
796-430-1110 Push tool ■ 1
790-101-2102 Puller ■ 1
C 791-627-1280 Installer ■ 1 Press-fit of floating seal
790-101-5401 Push tool kit ■ 1
790-101-5441 • Plate ■ 1
D Press-fit of oil seal
790-101-5421 • Grip ■ 1
01010-51240 • Bolt ■ 1
790-101-5401 Push tool kit ■ 1
790-101-5451 • Plate 1
E
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-201-1500 Push tool kit ■ 1
790-201-1680 • Plate 1
F
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-520-4140 Screw ■ 1
790-101-2420 Adapter ■ 1
791-112-1180 Nut ■ 1
G 01643-22460 Washer ■ 1
793T-417-1130 Push tool ■ 1 ○
790-101-2102 Puller ■ 1 Press-fit of bearing
791T-627-1950 Plate ■ 1 ○
H 790-101-5421 Grip ■ 1
01010-51240 Bolt ■ 1
J 791T-627-1940 Push tool ■ 1 ○
D155AXI-8 50-25
New/Redesign
Necessity
Sketch
Q'ty
791T-627-1960 Plate ■ 1 ○
K 790-101-5421 Grip ■ 1
01010-51240 Bolt ■ 1
790-101-2510 Block ■ 1
790-201-3310 Bolt ■ 2
L 790-101-2570 Plate ■ 2
01580-01613 Nut ■ 2 Press-fit of bearing
01643-31645 Washer ■ 2
M 790-201-3340 Bolt ■ 2
N 790-201-3250 Bolt ■ 2
790-101-3000 Push puller ■ 1
P
790-201-2650 Plate ■ 1
Q 792T-415-1420 Push tool ■ 1 ○
Disassembly and assembly of final
R - Eyebolt ■ 2
drive assembly
S 792T-423-1320 Push tool ■ 1 ○ Press-fit of bearing
Tools for removal and installation of track frame assembly

New/Redesign
Necessity
Sketch
Q'ty
791T-130-1010 Bracket ■ 6 ○
A 01010-63060 Bolt ■ 12 Fixing of bogie assembly
01643-33080 Washer ■ 12
E - Eyebolt ■ 1 Removal and installation of track frame
F 791T-685-1410 Lifting tool ● 1 ○ assembly
G - Oil pan ■ 1 Receiving of oil
50-26 D155AXI-8
Tools for disassembly and assembly of idler assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 2 Fixing of idler assembly

B - Forcing screw ■ 2 Removal of retainer
791T-630-1230 Plate ■ 1
791-630-1220 Log ■ 2
790-101-2510 Block ■ 1
790-101-2570 Washer ■ 2
C Press-fit of idler bushing
01580-01411 Nut ■ 2
01643-31445 Washer ■ 2
790-101-2102 Puller (294 kN 30 t) ■ 1
D 796-670-1020 Installer ■ 1 Installation of floating seal
E 791-601-1000 Oil pump ■ 1 Refilling with oil
Tools for disassembly and assembly of recoil spring assembly

New/Redesign
Necessity
Sketch
Q'ty
A 790-201-2840 Spacer ■ 1 Pulling-out of piston

791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
B 791T-630-2610 Spacer ■ 1
Compression of recoil spring
790-101-1300 Cylinder ■ 1
C - Lever block ■ 1
Tools for removal and installation of track roller assembly

New/Redesign
Necessity
Sketch
Q'ty
791T-130-1010 Bracket ■ 6 ○
A 01010-63060 Bolt ■ 12
Fixing of bogie assembly
01643-33080 Washer ■ 12
B - Lever block ■ 1
D155AXI-8 50-27
Tools for disassembly and assembly of track roller assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1 Fixing of track roller

B 790-201-3250 Forcing screw ■ 2 Pulling-out of plate
C Removal and installation of shaft and
- Eyebolt ■ 2
retainer
Pulling-out and press-fit of shaft and
D 791T-630-1290 Plate ■ 1 ○
seal guide
E 791T-630-1330 Push tool ■ 1 ○ Press-fit of bushing
F 791-651-1510 Installer ■ 2 Installation of floating seal
G 791-601-1000 Oil pump ■ 1 Refilling with oil
Tools for removal and installation of 1st bogie assembly

New/Redesign
Necessity
Sketch
Q'ty
791T-130-1010 Bracket ■ 2 ○
01643-33080 Washer ■ 4
790-401-1700 Lifting tool ■ 1
B Removal and installation of track roller
790-401-1761 Adapter ■ 1
791-630-1360 Spacer ■ 1
790-101-2310 Block ■ 1
790-101-2360 Plate ■ 2
C 790-445-4130 Screw ■ 2 Pulling-out of shaft and ring
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN 50 t) ■ 1
790-201-2760 Spacer ■ 1
791-630-1370 Adapter ■ 1
790-434-1060 Screw ■ 2
D 01580-13024 Nut ■ 2 Pulling-out of ring
01643-33080 Washer ■ 1
709-101-4000 Puller (490 kN 50 t) ■ 1
E 796-230-1120 Installer ■ 1 Installation of floating seal
F 790-201-2650 Plate ■ 1 Press-fit of ring
50-28 D155AXI-8
New/Redesign
Necessity
Sketch
Q'ty
G 790-701-3000 Seal checker ■ 1 Check of floating seal airtightness

H 791-601-1000 Oil pump ■ 1 Refilling with oil
790-101-2310 Block ■ 1
790-445-4130 Screw ■ 2
796T-470-1130 Plate ■ 1 ○
J 790-101-2360 Plate ■ 2 Press-fit of cartridge pin assembly
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN 50 t) ■ 1
Pin hole alignment of track frame and
K 791T-630-1390 Guide ■ 1 ○
bogie
Tools for removal and installation of 2nd, 3rd, 4th bogie assembly New/Redesign
Necessity
Sketch
Q'ty
791T-130-1010 Bracket ■ 2 ○
01643-33080 Washer ■ 4
B - Block ■ 1 Removal and installation of bogie as-
C - Iron plate ■ 1 sembly
791-630-1360 Spacer ■ 1
790-101-2310 Block ■ 1
790-101-2360 Plate ■ 2
D 790-445-4130 Screw ■ 2 Pulling-out of shaft and ring
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN 50 t) ■ 1
790-201-2760 Spacer ■ 1
791-630-1370 Adapter ■ 1
790-434-1060 Screw ■ 2
E 01580-13024 Nut ■ 2 Pulling-out of ring
01643-33080 Washer ■ 1
709-101-4000 Puller (490 kN 50 t) ■ 1
D155AXI-8 50-29
New/Redesign
Necessity
Sketch
Q'ty
G 790-201-2650 Plate ■ 1 Press-fit of ring

H 790-701-3000 Seal checker ■ 1 Check of floating seal airtightness
J - Block ■ 1
K - Hydraulic jack ■ 1
Support of machine
L - Blocking tool ■ 2
M - Hydraulic jack ■ 2
N 791T-630-1390 Guide ■ 1 ○
bogie
790-101-2310 Block ■ 1
790-445-4130 Screw ■ 2
796T-470-1130 Plate ■ 1 ○
P 790-101-2360 Plate ■ 2 Press-fit of cartridge pin assembly
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN 50 t) ■ 1
Q 791-601-1000 Oil pump ■ 1 Refilling with oil
Removal and installation of bogie as-
R - Lever block ■ 1
sembly
Tools for disassembly and assembly of bogie assembly

New/Redesign
Necessity
Sketch
Q'ty
790-101-2310 Block ■ 1
790-445-4130 Screw ■ 2
796T-470-1130 Plate ■ 1 ○
A 790-101-2360 Plate ■ 2 Press-fit of cartridge pin assembly
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN 50 t) ■ 1
B 791-601-1000 Oil pump ■ 1 Refilling with oil
50-30 D155AXI-8
Tools for removal and installation of carrier roller assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Hydraulic jack ■ 2 Support of track shoe assembly

Removal and installation of carrier roller
B - Rope ■ 1
assembly
Tools for disassembly and assembly of carrier roller assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1 Fixing of carrier roller assembly

B 790-102-1891 Nut wrench ■ 1 Removal and installation of nut
790-101-2501 Push puller ■ 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
790-101-2540 • Washer 1
C Pulling-out of bearing and roller
790-101-2620 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2710 • Adapter 2
790-201-1410 Plate ■ 1
D 790-101-3000 Push puller ■ 1 Pulling-out of bearing and ring
E 793T-417-1130 Push tool ■ 1 ○ Pulling-out of ring
F 793T-417-1210 Push tool ■ 1 ○
G 793T-623-1170 Push tool ■ 1 ○
H 791-651-1510 Installer ■ 1 Installation of floating seal
J 791-601-1000 Oil pump ■ 1 Refilling with oil
K 791T-630-1350 Spacer ■ 1 ○ Press-fit of ring
Tools for removal and installation of pivot shaft assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Forcing screw ■ 2 Removal of pivot shaft assembly
D155AXI-8 50-31
New/Redesign
Necessity
Sketch
Q'ty
791T-650-2110 Sleeve ■ 1 ○
790-201-2770 Spacer ■ 1
791T-650-2120 Plate ■ 1 ○
792-104-3940 Bolt ■ 2
B 790-101-2510 Block ■ 1 Press-fit of ring
790-101-2570 Washer ■ 2
01580-01613 Nut ■ 1
790-105-2300 Jack assembly (196 kN 20 t) ■ 1
Tools for separation and connection of track shoe assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1
Separation and connection of track
B - Block ■ 1
shoe assembly
C - Block (large) ● 1
Tools for disassembly and assembly of track shoe assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Jaw ■ 1
791-675-9701 Remover, installer 1
Disassembly and assembly of track
790-101-4300 Cylinder (196 kN 20 t) ■ 1
B shoe assembly
790-101-4200 Cylinder (294 kN 30 t) ■ 1
C 791-932-1110 Plug push tool ■ 1 Driving-in of plug (small)
D 791-660-7460 Pin brush ■ 1 Cleaning of pin
E 791-432-1110 Plug push tool ■ 1 Driving-in of plug (small)
F 791-632-1052 Installer ■ 1 Insertion of link seal
G - Spacer ■ 1 Press-fit of pin and bushing
50-32 D155AXI-8
Tools for disassembly and assembly of PLUS type track assembly
New/Redesign
Necessity
Sketch
Q'ty
Installation of track link pin (for small

A 791-432-1110 Push tool ■ 1
plug)
B 790-701-3000 Checker ■ 1 Check of track link airtightness
C 791-601-1000 Oil pump ■ 1 Oil filling of track link
791T-132-1000 Push tool assembly ■ 1 〇
791T-132-1010 • Guide 1 〇
Installation of wedge ring (for large plug
D 791T-132-1020 • Holder 1 〇
side)
793T-B32-1030 • Bar 1 〇
01580-11210 • Nut 1
791T-132-1110 • Guide 1 〇
Installation of wedge ring (for small plug
E 791T-132-1020 • Holder 1 〇
side)
793T-B32-1030 • Bar 1 〇
01580-11210 • Nut 1
F 791T-432-2810 Push tool ■ 1 〇 Press-fit of oil seal
Scattering prevention of wedge ring cut
H - Thick cloth ■ 1
pieces
L - Jaw ■ 1 Adjustment of link press press-fitting jig
M - Wear plate ■ 1 Adjustment of link press press-fitting jig
Measurement of pin protrusion dimen-
N - Depth gauge ■ 1
sion
Measurement of distance between
P - Shoe bolt pitch gauge ■ 1
shoe bolt holes
D155AXI-8 50-33
Tools for disassembly and assembly of 1 track link in field
New/Redesign
Necessity
Sketch
Q'ty
791-675-9581 Adapter ■ 1
791-675-9590 Guide ■ 1
A
01010-52465 Bolt ■ 2
01010-51440 Bolt ■ 2
790-101-1102 Pump ■ 1
B
790-101-4300 Cylinder (1470 kN 150 t) ■ 1
791-685-9510 Frame ■ 1
791-685-9520 Frame ■ 1
791-685-9530 Rod ■ 1
791-685-9550 Nut ■ 1
791-685-9560 Bolt ■ 1
C
791-675-9570 Adapter ■ 1
04530-12030 Eyebolt ■ 1
01010-51030 Bolt ■ 1
790-101-1102 Pump ■ 1
790-101-4300 Cylinder (1470 kN 150 t) ■ 1
791-685-9540 Rod ■ 1 Disassembly of 1 link
D
791-685-9550 Nut ■ 3
791-675-5520 Guide ■ 1
E 791-675-5530 Pusher ■ 1
791-126-0150 Adapter ■ 1
790-101-1102 Pump ■ 1
F
790-101-4200 Puller (294 kN 30 t) ■ 1
791-675-5542 Adapter ■ 1
791-675-5571 Adapter ■ 1
G
790-101-1102 Pump ■ 1
790-101-4300 Cylinder (1470 kN 150 t) ■ 1
H 791-675-5580 Guide ■ 1
791-126-0150 Adapter ■ 1
791-685-9620 Extension ■ 1
J 791-675-5550 Guide ■ 1
791-675-5542 Adapter ■ 1
01010-51030 Bolt ■ 1
50-34 D155AXI-8
New/Redesign
Necessity
Sketch
Q'ty
K 791-670-3270 Guide ■ 1
791-126-0150 Adapter ■ 1
791-675-5560 Guide ■ 1
L
791-675-9570 Adapter ■ 1
01010-51030 Bolt ■ 1
791-685-9510 Frame ■ 1
791-685-9520 Frame ■ 1
791-685-9530 Rod ■ 1
791-685-9540 Rod ■ 1
Disassembly of 1 link
791-685-9550 Nut ■ 3
791-685-9560 Bolt ■ 4
M
791-126-0150 Adapter ■ 1
01010-51030 Bolt ■ 1
791-685-9620 Extension ■ 1
791-675-5571 Adapter ■ 1
791-675-5550 Guide ■ 1
791-675-9631 Adapter ■ 1
N - Spacer ■ 1
Tools for disassembly and assembly of master link

New/Redesign
Necessity
Sketch
Q'ty
791-675-9701 Remover, installer ■ 1

790-101-1102 Pump ■ 1 Disassembly and assembly of track
A
790-101-4200 Puller (294 kN 30 t) ■ 1 shoe assembly
790-101-4300 Cylinder (1470 kN 150 t) ■ 1

790-101-1102 Pump ■ 1
B Expansion of link
790-101-4200 Puller (294 kN 30 t) ■ 1
C - Guide pin ■ 1 Pin hole alignment of pin and bushing
D 791-432-1110 Plug push tool ■ 1 Driving-in of plug (large)
E 790-701-3000 Seal checker ■ 1 Check of floating seal airtightness
F 791-932-1110 Plug push tool ■ 1 Driving-in of plug (small)
D155AXI-8 50-35
Tools for removal and installation of equalizer bar assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Blocking tool ■ 2
Support of machine
B - Hydraulic jack ■ 2
791T-650-2130 Sleeve ■ 1 ○
790-101-2420 Adapter ■ 1
791-520-4140 Screw ■ 1
C 790-101-2540 Washer ■ 2 Pulling-out of center pin
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN 50 t) ■ 1
790-101-1102 Pump ■ 1
Tools for disassembly and assembly of equalizer bar assembly New/Redesign

Necessity
Sketch
Q'ty
A 794T-622-1610 Spacer ■ 1 ○ Pulling-out of bushing
Tools for removal and installation of blade assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1 Fixing of I-frame
Tools for disassembly and assembly of blade assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1 Fixing of blade

B - Block ■ 2 Fixing of I-frame
C - Block ■ 1 Fixing of center brace
50-36 D155AXI-8
Tools for disassembly and assembly of multi-shank ripper assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Blocking tool ■ 2 Fixing of beam

B - Block ■ 1 Fixing of arm
Tools for disassembly and assembly of giant ripper assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 2 Fixing of machine

B - Blocking tool ■ 2 Fixing of boom and arm
C - Block ■ 2 Fixing of arm
Tools for disassembly and assembly of stroke and reset sensing blade lift cylinder assembly
New/Redesign
Necessity
Sketch
Q'ty
790-502-1003 Cylinder repair stand ■ 1 Disassembly and assembly of hydraulic

A
790-101-1102 Hydraulic pump ■ 1 cylinder
B 790-102-3802 Multi-wrench ■ 1 Installation of round head (blade lift)

C - Rubber hammer ● 1
Removal of stroke sensor
D - Spatula ● 1
790-201-1500 Push tool kit ■ 1
790-201-1630 • Plate 1
E Press-fit of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1702 Push tool kit ■ 1
790-201-1821 • Push tool 1
F Press-fit of bushing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-720-1000 Expander ■ 1
796-720-1660 Ring ■ 1
G 07281-01159 Clamp ■ 1 Installation of piston ring
796-720-1690 Ring ■ 1
07281-01919 Clamp ■ 1
D155AXI-8 50-37
New/Redesign
Necessity
Sketch
Q'ty
For measurement of sensor installing

H - Digital angle gauge ■ 1
angle
Tools for disassembly and assembly of blade tilt cylinder assembly
New/Redesign
Necessity
Sketch
Q'ty
790-201-1702 Push tool kit ■ 1

790-201-1841 • Push tool 1
A Press-fit of bushing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit ■ 1
790-201-1650 • Push tool 1
B Press-fit of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-720-1000 Expander ■ 1
796-720-1660 Ring ■ 1
C 07281-01159 Clamp ■ 1 Installation of piston ring
796-720-1690 Ring ■ 1
07281-01919 Clamp ■ 1
Tools for disassembly and assembly of ripper cylinder assembly

New/Redesign
Necessity
Sketch
Q'ty

A
790-201-1702 Push tool kit ■ 1

790-201-1851 • Push tool ■ 1
B 790-201-1861 • Push tool ■ 1 Press-fit of bushing
790-101-5021 • Grip ■ 1
01010-50816 • Bolt ■ 1
50-38 D155AXI-8
New/Redesign
Necessity
Sketch
Q'ty
790-201-1500 Push tool kit ■ 1

790-201-1660 • Plate ■ 1
C 790-201-1670 • Plate ■ 1 Press-fit of dust seal
790-101-5021 • Grip ■ 1
01010-50816 • Grip ■ 1
790-720-1000 Expander ■ 1
796-720-1660 Ring ■ 1
D 07281-01159 Clamp ■ 1 Installation of piston ring
796-720-1690 Ring ■ 1
07281-01919 Clamp ■ 1
790-102-4300 Wrench ■ 1 Removal and installation of screwed-in
E
790-102-4310 Pin ■ 2 type piston
Tools for removal and installation of operator's cab assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Oil pan ■ 1 N
B - Valve ■ 1
- Hose ■ 1
Draining AdBlue/DEF
D - Funnel ■ 1
E - Hose ■ 1
ue/DEF hose
J 600-919-5030 ■ 1
inch)
D155AXI-8 50-39
Tools for removal and installation of operator's cab glass (adhered glass)
New/Redesign
Necessity
Sketch
Q'ty
A - Seal cutter ■ 1
B - Extra fine wire (piano wire, etc) ■ 1
C - Pliers ■ 1 Removal of window glass
D - Cutter knife ■ 1
E - Scraper ■ 1
F 793-498-1210 Lifter (suction cup) ■ 2
G - Caulking gun ■ 1
H - Tape ■ 1 Installation of window glass
J - Rubber band ■ 2
K - Styrene foam ■ 2
Tools for removal and installation of battery relay

New/Redesign
Necessity
Sketch
Q'ty
A - Oil pan ■ 1 N
B - Valve ■ 1
- Hose ■ 1
Draining AdBlue/DEF
D - Funnel ■ 1
E - Hose ■ 1
ue/DEF hose
J 600-919-5030 ■ 1
inch)
Tools for removal and installation of GNSS antenna

New/Redesign
Necessity
Sketch
Q'ty
Tightening the wire (made by ESCO,

A - Wire twisting pliers ■ 1 N
equivalent to EA534XC-150)
50-40 D155AXI-8
Tools for removal and installation of IMU sensor
New/Redesign
Necessity
Sketch
Q'ty
Tightening the wire (made by ESCO,

A - Wire twisting pliers ■ 1 N
equivalent to EA534XC-150)
B - Wrench ■ 1 N
Tightening the connector
C 791T-606-1110 Hook ■ 1 N
D155AXI-8 50-41
SKETCHES OF SPECIAL TOOLS BLY
SKETCHES OF SPECIAL TOOLS

k Komatsu does not take any responsibility for special tools manufactured according to these sketch-
es.
795T-521-1111: Push tool
795T-521-1150: Push tool
50-42 D155AXI-8
BLY SKETCHES OF SPECIAL TOOLS
795T-521-1270: Push tool
795T-521-1240: Push tool
D155AXI-8 50-43
795T-521-1250: Push tool
793T-623-1170: Push tool
50-44 D155AXI-8
793T-615-1720: Spacer
793T-417-1310: Spacer
D155AXI-8 50-45
793T-613-1340: Spacer
792T-413-1120: Push tool
50-46 D155AXI-8
793T-615-1710: Spacer
791T-615-1310: Plate
D155AXI-8 50-47
791T-615-1350: Push tool
791T-615-1320: Plate
50-48 D155AXI-8
791T-615-1330: Plate
791T-615-1340: Plate
D155AXI-8 50-49
793T-422-1220: Push tool
793T-615-1730: Spacer
50-50 D155AXI-8
791T-630-2410: Push tool
792T-415-1410: Push tool
D155AXI-8 50-51
792T-446-1150: Push tool
793T-613-1380: Spacer
50-52 D155AXI-8
793T-417-1110: Push tool
792T-415-1420: Push tool
D155AXI-8 50-53
795T-426-1410: Push tool
793T-222-1310: Plate
50-54 D155AXI-8
793T-417-1130: Push tool
791T-627-1910: Plate
D155AXI-8 50-55
791T-627-1920: Plate
791T-627-1950: Plate
50-56 D155AXI-8
791T-627-1940: Push tool
791T-627-1960: Plate
D155AXI-8 50-57
792T-423-1320: Push tool
791T-130-1010: Bracket
50-58 D155AXI-8
791T-685-1410: Lifting tool
791T-630-2610: Spacer
D155AXI-8 50-59
791T-630-1290: Plate
791T-630-1330: Push tool
50-60 D155AXI-8
796T-470-1130: Plate
791T-630-1390: Guide
D155AXI-8 50-61
793T-417-1210: Push tool
791T-650-2110: Sleeve
50-62 D155AXI-8
791T-650-2120: Plate
791T-132-1000: Push tool Assembly
D155AXI-8 50-63
791T-132-1010: Guide
791T-132-1020: Holder
50-64 D155AXI-8
791T-132-1100: Push tool Assembly
791T-132-1110: Guide
D155AXI-8 50-65
793T-B32-1030: Bar
791T-432-2810: Push tool
50-66 D155AXI-8
791T-650-2130: Sleeve
794T-622-1610: Spacer
D155AXI-8 50-67
791T-606-1110: Hook
50-68 D155AXI-8
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
ENGINE AND COOLING SYSTEM

REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
KDPF and Filter head, oil Fuel filter

Exterior
SCR assembly
Bracket, cover
filter assembly A
Fuel Supply pump

A high-pressure assembly
pipe
Tools for removal and installation of supply pump assembly
New/Redesign
Necessity
Sketch
Q'ty
k Park the machine on a level ground, and set parking brake lever to the LOCK position.
k Lower the work equipment to the ground, and set the work equipment lock lever to LOCK position.
k Turn the starting switch to OFF position to stop the engine.
k Turn the battery disconnect switch to OFF position, and remove the key.
k When removing and installing the fuel piping, take extreme care to prevent foreign material from en-
tering into the fuel piping. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel.
k Check the connector numbers and installed positions before disconnecting wiring and hoses, and
record them.
k When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring
and hoses by the clips and clamps. If the wiring and hoses may be damaged or deformed, remove
the clips and clamps before disconnecting them.
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY

Exterior
1. Close fuel valve lever (1).
D155AXI-8 50-69
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY
2. Support engine underguard (2) by using a lifting tool or

floor jack, remove the mounting bolts (12 pieces), and re-
move engine underguard (2).
4 Engine underguard (2):

270 kg
3. Remove engine hood assembly. For details, see “RE-
MOVE AND INSTALL ENGINE HOOD ASSEMBLY”.
KDPF and SCR assembly

4. Remove the KDPF and SCR assembly. For details, see “REMOVE AND INSTALL KDPF, SCR ASSEM-
BLY”.
5. Remove clamps (3) (4 pieces), and remove AdBlue/SCR
drain tube (4).
Bracket, cover
6. Remove piping clip (5).
7. Remove mounting bolts (3 pieces), and remove bracket
(6).
REMARK
• After removing bracket (6), move the air conditioner
hose aside so that it does not hinder the work.
8. Remove mounting bolts (2 pieces), and remove seat (7).
Filter head, oil filter

9. Remove piping clip (8) of the fuel return hose.
10. Remove piping clips (10), one each on oil tubes (9) (2
pieces).
11. Remove filter head (11) mounting bolts (2 pieces each)
and flange mounting bolts (4 pieces) on the cylinder block
head side, and then remove oil tubes (9) (2 pieces) togeth-
er with the flange as a unit.
12. Remove mounting bolts (6 pieces), and remove filter head
(11) and the oil filter as an assembly.
50-70 D155AXI-8
Fuel filter assembly

13. Disconnect fuel supply hose (12).
14. Disconnect fuel tube (13).
15. Remove mounting bolts (4 pieces) and remove fuel prefil-
ter assembly (14).
16. Remove the mounting bolts (3 pieces), and remove cover
(15).
17. Disconnect fuel tubes (16), (17), (18), (19), and (20).
18. Remove mounting bolts (4 pieces), and remove fuel filter
assembly (21).
19. Remove dipstick pipe (22).
20. Disconnect wiring connectors PCV1 (23), PCV2 (24) and G (25).
21. Disconnect EGR oil tubes (26) and (27).
Fuel high-pressure pipe
22. Remove fuel spray prevention caps (28a), (28b), (29a),
(29b) of fuel high-pressure pipes (28) and (29), loosen
sleeve nut, and remove fuel high-pressure pipes (28) and
(29).
REMARK
Loosen sleeve nut on common rail side as well.
23. Disconnect fuel tubes (30), (31), (32), and (33).
24. Disconnect oil tubes (34) and (35).
Supply pump assembly

25. Remove mounting bolts (36) (4 pieces), and remove sup-
ply pump assembly (37).
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY

NOTICE
• Do not bend the fuel high-pressure pipe to correct before installing.
• If the fuel high-pressure pipe has any defect, replace it with a new one since fuel may leak.
D155AXI-8 50-71
Check of fuel high-pressure pipe joints

1. Make sure with visual check that range of dimension (a)
starting from the taper seal tip end of the fuel high-pres-
sure pipe joint is free from longitudinal slits (b) or pits (c).
Dimension (a): 2 mm
2. Make sure that dimension (a) starting from the taper seal
tip end of the fuel high-pressure pipe joint is free from
steps (d) you can feel by your fingernail. (free from fati-
gue.)
Dimension (a): 2 mm
NOTICE
When removing and installing the fuel high-pressure
pipe, check for fuel leakage according to the following
procedure.
Procedure for checking for fuel leakage after connecting fuel high-pressure pipe
3. When removing and installing the fuel high-pressure pipe, check for fuel leakage according to the following
procedure.
1) Clean the engine and the parts around it, and degrease them in advance so that you can check it easi-
ly for fuel leakage.
2) Spray color checker (developer) over the joint of the fuel supply pump, common rail, fuel injector, and
fuel high-pressure pipe.
3) Check for fuel leakage from the fuel piping and devices under the following 4 conditions respectively.
NOTICE
If fuel leakage is found during the inspection, restart the inspection after the repairing work is
finished.
REMARK
Check for fuel leakage from the high-pressure circuit focusing on the area where the color checker is
sprayed.
1] After starting the engine, hold the engine speed at Max. 1000 rpm, stop the engine when the en-
gine speed is stabilized, and then check for fuel leakage.
2] After starting the engine, keep it running at low idle, and then check for fuel leakage.
3] After starting the engine, keep it running at high idle, and then check for fuel leakage.
4] After starting the engine, keep it running at high idle to apply load to the engine, and then check for
fuel leakage.
REMARK
When applying load to the engine, stall the torque converter or relieve the hydraulic pump.
50-72 D155AXI-8
Supply pump assembly

4. Install it so that the coupling of fuel supply pump assembly
(37) is aligned with missing teeth (A) of drive housing (38).
5. Install supply pump assembly (37), and install it with

mounting bolts (36) (4 pieces).
2 Mounting bolt (36):
Liquid adhesive (LT-2)

6. Install oil tubes (34) and (35).
3 Joint of oil tubes (34) and (35) (oil block side):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Joint of oil tube (34) (supply pump side):
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
3 Joint of oil tube (35) (drive housing side):
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
D155AXI-8 50-73
7. Install fuel tubes (30), (31), (32), and (33).

k If the fuel tube is installed incorrectly toward the
supply pump, the supply pump may be damaged.
3 Joint of fuel tubes (30), (31), (32) and (33) (supply
pump side):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
3 Joint of fuel tube (30) (fuel feed pump block side :
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3 Joint of fuel tube (31) (common rail side):
17.7 to 22.6 Nm {1.8 to 2.3 kgm}
3 Fuel tube (32) (fuel feed pump block side):
43 to 47 Nm {4.4 to 4.8 kgm}
3 Fuel tube (33) (cooling plate side):
24 to 27 Nm {2.4 to 2.7 kgm}
8. Install fuel high-pressure pipes (28) and (29), tighten
sleeve nut, and install fuel spray prevention caps (28a),
(28b), (29a), (29b) of fuel high-pressure pipes (28) and
(29).
REMARK
• Install the fuel spray prevention cap with the slit of the
cap on the common rail side facing downward and with
the slit of the cap on the supply pump side facing to the
cylinder block.
• Loosen the sleeve nuts of fuel high-pressure pipes (28)
and (29) once. Check that excessive force is not ap-
plied to fuel high-pressure pipes (28) and (29), and
tighten it to the specified torque by using tool A.
3 Sleeve nut of fuel high-pressure pipes (28) and (29):
39.2 to 44.1 Nm {4 to 4.5 kgm}
9. Install EGR oil tubes (26) and (27).
3 Joint of EGR oil tube (26) (EGR valve side):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3 EGR oil tube (26) (EGR oil pump side):
43 to 47 Nm {4.4 to 4.8 kgm}
3 Joint of EGR oil tube (27) (air vent block side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint of EGR oil tube (27) (EGR valve part):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3 Joint of EGR oil tube (27) (front cover side):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
10. Install wiring connectors PCV1 (23), PCV2 (24), and G (25).
11. Install dipstick pipe (22).
3 Dipstick pipe (22):
19.6 to 34.3 Nm {2 to 3.5 kgm}
12. Install fuel filter assembly (21), and tighten it with the mounting bolts (4 pieces).
13. Install fuel tubes (16), (17), (18), (19), and (20).
50-74 D155AXI-8
3 Joint of fuel tube (16):

7.8 to 9.8 Nm {0.8 to 1.0 kgm}
3 Joint of fuel tubes (17) and (18) (fuel filter side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint of fuel tube (17) (supply pump side):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
24 to 27 Nm {2.4 to 2.7 kgm}
3 Joint of fuel tubes (17) and (19) (fuel doser solenoid valve side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint of fuel tube (20) (fuel doser solenoid valve side):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Joint of fuel tubes (19) and (20) (fuel feed pump block side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
14. Tighten cover (15) with the mounting bolts (3 pieces).
15. Install fuel prefilter assembly (14), and tighten it with the mounting bolts (4 pieces).
16. Install fuel tube (13).
3 Fuel tube (13):
43 to 47 Nm {4.4 to 4.8 kgm}
17. Install fuel supply hose (12).
18. Tighten filter head (11) and oil filter with the mounting bolts
(6 pieces).
19. Install oil tubes (10) (2 pieces) and flange according to the
following procedure.
1) Insert oil tube (10) (oil filter side) into filter head (11),
and lightly tighten the flange to the cylinder block.
2) Tighten the mounting bolt on the oil filter side to the
specified torque, and then tighten the flange mounting
bolt on the cylinder block side to the specified torque.
REMARK
Fit O-rings to the mating faces of the cylinder head and
flange, and install them.
20. Tighten filter head (11) and oil tubes (10) (2 pieces) with the mounting bolts (2 pieces).
21. Install piping clips (9) (1 place each) to oil tubes (10) (2 pieces).
22. Install piping clip (8) of the fuel return hose.
Bracket, cover
23. Tighten sheet (7) with the mounting bolts (2 pieces).
24. Install bracket (6), and tighten it with the mounting bolts (3
pieces).
25. Install wiring clip (5).
D155AXI-8 50-75
26. Install AdBlue/SCR drain tube (4) with clamps (3) (4

pieces).

27. Install KDPF and SCR assembly. For details, see “REMOVE AND INSTALL KDPF, SCR ASSEMBLY”.
Exterior
28. Install the engine hood assembly. For details, see “REMOVE AND INSTALL ENGINE HOOD ASSEMBLY”.
29. Support engine underguard (2) by using lifting tool or floor
jack, remove the mounting bolts (12 pieces), and remove
engine underguard (2).

270 kg
30. Open fuel valve lever (1).
50-76 D155AXI-8
BLY REMOVE AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
record them.
METHOD FOR REMOVING INJECTOR ASSEMBLY

Exterior


270 kg
D155AXI-8 50-77
REMOVE AND INSTALL INJECTOR ASSEMBLY BLY
Engine, cooling
4. Remove the KDPF and SCR assembly. For details, see “REMOVE AND INSTALL KDPF, SCR ASSEM-
BLY”.
drain tube (4).
6. When removing the No. 1 fuel injector assembly, perform
the following 2 items.
1) Remove the hydraulic oil cooler assembly. For details,
see “REMOVE AND INSTALL HYDRAULIC OIL
COOLER ASSEMBLY”.
2) Remove the aftercooler assembly. For details, see
“REMOVE AND INSTALL AFTERCOOLER ASSEM-
BLY”.
Bracket, cover
(6).
REMARK
• After removing bracket (6), move the air conditioner
hose aside so that it does not hinder the work.
9. Remove mounting bolts (2 pieces), and remove seat (7).
10. Disconnect terminal TRS (8) and terminal TRL (9).

11. Remove wiring clips (10) and (11).
13. When removing No. 3 and No. 4 fuel injector assemblies,
remove 2 mounting bolts (2 pieces) and cover (12).

14. Remove piping clip (13) of the fuel return hose.
15. Remove piping clips (15), one each on 2 oil tubes (14) (2
pieces).
16. Remove mounting bolts (2 pieces), and disconnect oil
tubes (14) (2 pieces) from filter head (16).
17. Remove filter head (16) mounting bolts (2 pieces each)
side, and then remove oil tubes (14) (2 pieces) together
with the flange as a unit.
50-78 D155AXI-8

21. Remove mounting bolts (4 pieces), and remove fuel prefil-
ter assembly (18).
22. Remove the mounting bolts (3 pieces), and remove cover
(20).
assembly (26).
27. Disconnect EGR oil tubes (31) and (32).
Breather assembly
28. Cut wiring bands (33) (3 places), and remove wiring clips
(34) (2 places).
29. Disconnect wiring connector DOSER (35).
30. Remove wiring clamps (36) (2 places) and wiring clips (37)
(3 places).
(38).
(39).
(40).
34. When removing No.2 and No.3 fuel injector assembly, re-
move piping (41) between KCCV ventilators from the
breather, and remove breather assembly (42).
Fuel tube
35. Remove joint of fuel tube (43), and remove relief valve (44)
and fuel tube (43).
36. Remove the oil spray prevention cap installed on the
KVGT side of KVGT oil tubes (45) and (46), loosen the
sleeve nut, and remove KVGT oil tubes (45), (46), and
(47).
EGR cooler assembly:

37. When removing No.1 injector assembly, remove EGR cooler assembly. For details, see “REMOVE AND IN-
STALL EGR COOLER ASSEMBLY”.
D155AXI-8 50-79
Wiring harness, connector

38. Disconnect wiring connector INJ (48).
39. Disconnect wiring connectors CN1 (49), CN2 (50), CN3
(51), CN4 (52), CN5 (53), and CN6 (54) on the injector
side.
40. Remove wiring harness brackets (55) to (60), and remove
fuel injector relay wiring harness (61).

41. Remove the high-pressure clamp between common rails
from the fuel supply pump, and remove bracket (62) from
gate-type frame (63).
42. Remove high-pressure pipe clamp bolts (64) (7 pieces) be-
tween the fuel injectors from the common rail.
43. Remove mounting bolts (2 pieces), and remove gate-type
frame (63).
44. Loosen fuel high-pressure clamps (66) to (80) and stay re-
lated to high-pressure fuel pipes (65) (6 pieces).
REMARK
• Take extreme care not to damage or deform fuel high-
pressure pipe (65) when removing the fuel injector as-
sembly.
• High pressure pipe for No.1 injector:4 places (66), (67), (68), (69)
• High pressure pipe for No.2 injector: 3 places (70), (71), (72)
• High pressure pipe for No.3 injector: 2 places (70), (73)
• High pressure pipe for No.4 injector: 2 places (74), (75)
• High pressure pipe for No.5 injector: 3 places (74), (76), (77)
• High pressure pipe for No.6 injector:4 places (76), (78), (79), (80)
45. Remove fuel spray prevention caps (81) from high-pres-
sure fuel pipes (66) (6 pieces) between the common rail
and fuel injectors, and loosen the sleeve nuts.
REMARK
• Do not remove fuel spray prevention cap (81) of the
cylinder from which the fuel injector assembly is not re-
moved, and do not loosen the sleeve nut of fuel high-
pressure pipe (66).
50-80 D155AXI-8
Cylinder head cover

46. Remove mounting bolts (3 pieces), and remove each cylin-
der head cover (82).
REMARK
• Do not remove cylinder head cover (82) of the cylinder
from which the fuel injector assembly is not removed.
47. Remove mounting bolts (83) (3 pieces), and remove rock-

er arm and rocker shaft assembly (84).
48. Disconnect fuel high-pressure pipe (66) from the fuel injec-
tor assembly.
Injector assembly
49. Remove wiring clip bolt (87) and spring clamp (88).
50. Disconnect capture nuts (89) (2 pieces) from the fuel injec-
tor assembly.
REMARK
• Loosen capture nuts (89) alternately.
51. Remove the fuel injector assembly according to the follow-

ing procedure.
1) Record the cylinder number to which the injector is installed and the character string (M) printed on the
QR code tab (Q) as a set, and then remove the fuel injector assembly.
REMARK
• Check that all the character strings (M) have been recorded correctly.
• Do not remove QR code tab (Q) on the top of the fuel injector assembly.
• Be careful not to damage QR code tab (Q) on the top of the fuel injector assembly.
(Reference: The QR code and character string indicate the difference of compensation values for fuel
injection of the fuel injector that is specific to each fuel injector.)
D155AXI-8 50-81
(Reading order of character string (M))
2) Remove holder mounting bolt (90).

3) Insert tool B under inlet connector (e) of injector as-
sembly (91), and slowly remove fuel injector assembly
(91) together with the holder by prying.
REMARK
• Never grip the solenoid valve part at the top of the
injector assembly with pliers, etc. to pull out it.
METHOD FOR INSTALLING INJECTOR ASSEMBLY

Check of fuel high-pressure pipe joints
1. Check the connection parts of the fuel high-pressure pipe
while paying attention to the followings.
NOTICE
• Do not bend the fuel high-pressure pipe to correct
before installing.
• Check the following items and install the fuel high-
pressure pipe. If it has any defect, replace the high-
pressure pipe with a new one since fuel may leak.
• Visually check that taper seal part (a) of the con-
nection part (2 mm area from the tip-end) is free
from longitudinal slits (b) or spotty dents (c).
• Make sure that part (d) (end of taper seal: 2 mm
from the tip-end) is free from steps you can feel by
your fingernail (free from fatigue).
Check for fuel leakage
2. When removing and installing the fuel high-pressure piping, check for fuel leakage according to the follow-
ing procedure after assembling the engine.
REMARK
Clean the engine and the parts around it, and degrease them in advance so that you can check it easily for
fuel leakage.
1) Spray color checker (developer) to the supply pump, common rail, injectors, and joints of the high-pres-
sure piping.
2) Start the engine, keep its speed at1000 rpm or below, and stop it when the speed is stabilized.
3) Check the fuel piping and devices for fuel leakage.
50-82 D155AXI-8
REMARK
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 1) again.
4) Start the engine, and keep it running at low idle.
REMARK
sprayed.
6) Start the engine, and keep it running at high idle.
REMARK
sprayed.
8) Start the engine and keep it running at high idle, and apply a load to the engine.
REMARK
• When checking the engine for leakage as it is installed on the machine, stall the torque converter or
relieve the hydraulic pump.
REMARK
sprayed.
• If no fuel leakage is detected, the inspection process is complete.
Injector assembly
3. Install injector assembly (91) according to the following procedure.
REMARK
• Check that dirt, etc. is not attached to inside of the injector sleeve on the cylinder head side.
1) Install O-rings (92), (93), and gasket (94) to fuel injector (1).
REMARK
• Take care not to install O-ring (92) to groove (d).
2 O-rings (92) and (93):
Engine oil
2) Install holder (95) to fuel injector (1), and insert the fuel injector assembly to the injector sleeve on the
cylinder head side.
REMARK
• When reusing the fuel injector assembly and engine controller, check the cylinder numbers and
character strings (M) recorded during removal of the fuel injector assembly, and install the fuel in-
jector assembly to the corresponding cylinder.
• When replacing the fuel injector assembly or engine controller with new ones, check the cylinder
numbers and character strings (M) recorded in the engine controller assembly, and install the fuel
injector assembly to the corresponding cylinder.
• Check that the fuel injector assembly is fully and securely inserted.
D155AXI-8 50-83
3) Install the spherical washer (96) to holder mounting

bolt (90) and tighten holder (95) lightly.
2 Spherical washer (7):
Engine oil
REMARK
• Lightly tighten the sleeve nut of the fuel high-pres-
sure pipe, and then tighten holder mounting bolt
(90) to the specified torque.
3 Holder mounting bolt (90):
59±74 Nm {6±7.5 kgm}
REMARK
• Wash off dirt and dust attached on the parts near harness connectors, and remove them completely
to prevent them from entering connectors.
• Use clean engine oil when applying engine oil to O-rings and lubricated portions.
• When replacing the fuel injector assembly to a new one, write down the number of cylinder to which
a new injector assembly is installed and character string (M) listed on QR code tab (Q) at the top of
the injector as a set.
• Check that all the character strings (M) have been recorded correctly.
• When replacing the fuel injector assembly or engine controller assembly, write character string (M)
of the fuel injector assembly. For details, see TESTING AND ADJUSTING, “WRITE COMPENSA-
TION VALUE WHEN INJECTOR AND ENGINE CONTROLLER ARE REPLACED”.
• Be sure to write character string (M) written down in the cylinder number column of the cylinder to
which the injector assembly is installed.
• If character string (M) is not written correctly, the engine may not operate normally.
• (Reference: The QR code and character string indicate the difference of compensation values for
fuel injection of the fuel injector that is specific to each fuel injector.)
• (Reading order of character string (M))
4. Install the fuel injector wiring harness to the fuel injector
assembly according to the following procedure.
50-84 D155AXI-8
1) Eliminate the sag of the fuel injector wiring harness

and install it to the fuel injector assembly so that it will
not interfere with the rocker arm.
2) Install spring clamp (88).
3) Install capture nuts (89) (2 pieces).
REMARK
• Tighten capture nuts (89) alternately.
3 Capture nut (89):
2±0.2 Nm {0.2±0.02 kgm}
5. Install fuel high-pressure pipe (66) to the injector assembly.
6. Install rocker arm and rocker shaft assembly (84), and in-
stall it with mounting bolts (83) (3 pieces).
REMARK
• Loosen locknut (86), and loosen adjustment screw (87) 2 to 3 turns so that excessive force is not ap-
plied to push rod (85) when the rocker arm and rocker shaft assembly (84) is installed.
D155AXI-8 50-85
• Apply engine oil to part (e) of the crosshead and to

socket part (f) of push rod (85).
2 Part (e) of the crosshead, socket part (e) of push
rod (85):
Engine oil
REMARK
• When installing rocker arm and rocker shaft assembly
(84), check that the ball of adjustment screw (87) is se-
curely fitted in the socket part of push rod (85), and
then tighten mounting bolts (83a), (83b), and (83c).
• Note that mounting bolts (83a), (83b), and (83c) have
different sizes.
Mounting bolt (83a): Under head 120 mm
Mounting bolt (83b): Under head 90 mm
Mounting bolt (83c): Under head 75 mm
3 Mounting bolts (83a), (83b), (83c):
93 to 103 Nm {9.5 to 10.5 kgm}
REMARK
• Adjust the valve clearance. For details, see TESTING
AND ADJUSTING, “TEST AND ADJUST VALVE
CLEARANCE”.
Cylinder head cover
7. Install cylinder head covers (82), and tighten them with the
mounting bolts (3 pieces).
REMARK
• Fit the gasket to the cylinder head cover (82), and in-
stall it.
• Lightly tighten the mounting bolts at the front on the in-
take manifold side since wiring harness brackets (55)
to (60) are tightened together with the bolt.
50-86 D155AXI-8

8. Tighten the sleeve nuts of fuel high-pressure pipes (65) (6
pieces) between the common rail and fuel injector.
REMARK
• Loosen the sleeve nut of fuel high-pressure pipe (65)
once. Check that excessive force is not applied to fuel
high-pressure pipe (65), and tighten it to the specified
torque by using tool A.
• Check the O-ring for extrusion.
3 Sleeve nut of fuel high-pressure pipe (65):
39.2 to 44.1 Nm {4 to 4.5 kgm}
9. Install fuel high-pressure pipes (65) according to the fol-
lowing procedure.
1) Tighten the sleeve nuts of fuel high-pressure pipes (a)
to (f) to the specified torque.
3 Sleeve nut on fuel injector side:
39.2 to 44.1 Nm {4 to 4.5 kgm}
3 Sleeve nut on common rail side:
39.2 to 44.1 Nm {4 to 4.5 kgm}
2) Install fuel high-pressure pipe clamps (66) to (80) and
the stays loosely by hand.
3) Fasten fuel high-pressure pipe clamps (66) to (80) to
the specified torque.
3 Fuel high-pressure clamping bolt:
9.8 to 1 Nm {1.0 to 0.1 kgm}
4) Install fuel high-pressure pipe clamps (66) to (71) and
the stays loosely by hand.
5) Install bracket (62) and gate-type frame (63) loosely.
6) Tighten the bolts (7 pieces) of fuel high-pressure tube
clamp (64) to the specified torque.
3 Fuel high-pressure clamping bolt:
9.8±1 Nm {1.0±0.1 kgm}
7) Tighten gate-type frame (63) to the specified torque.
8) Fasten the stays of fuel high-pressure pipe clamps (72) to (80) to the specified torque.
9) Install fuel spray prevention caps (81).
REMARK
Install fuel spray prevention cap (81) with the slit of the cap on the fuel injector side facing downward
and with the slit of the cap on the common rail side facing to the cylinder block.
D155AXI-8 50-87
Wiring harness, connector

10. Install injector relay wiring harness (61), and install wiring
harness brackets (55) to (60).
11. Install wiring connectors CN1 (49), CN2 (50), CN3 (51),
CN4 (52), CN5 (53), and CN6 (54) on the injector side.
12. Install wiring connector INJ (48).

13. Install EGR cooler assembly. For details, see “REMOVE AND INSTALL EGR COOLER ASSEMBLY”.
KVGT oil tube
14. Install KVGT oil tubes (45), (46), and (47), tighten the
sleeve nut, and install the oil spray prevention cap that
was installed on the KVGT side of KVGT oil tubes (45) and
(46).
REMARK
• Direct downward the slits of fuel spray prevention caps
to be installed to KVGT joint.
3 Sleeve nut of KVGT oil tubes (45), (46), and (47):
24 to 27 Nm {2.4 to 2.7 kgm}
Fuel tube
15. Install fuel tube (43) and relief valve (44), and tighten them with the joint of fuel tube (43).
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3 Fuel tube (43) (fuel doser side):
15.3±0.5 Nm {1.56±0.05 kgm}
50-88 D155AXI-8
Breather assembly
16. Install breather assembly (42), and install piping (41) be-
tween KCCV ventilators to the breather.
3 Hose clamp of piping (41) between KCCV ventila-
tors:
4.4±0.49 Nm {0.45±0.05 kgm}
17. Install bracket (40), and install mounting bolts (2 pieces).
20. Install wiring clamps (36) (2 places) and wiring clips (37) (3
places).
21. Install wiring connector DOSER (35).
22. Install wiring clips (34) (2 places), and install wiring bands
(33) (3 places).

34.3 to 44.1 Nm {3.5 to 4.5 kgm}
43 to 47 Nm {4.4 to 4.8 kgm}
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
24. Install wiring connector PCV1 (28), PCV2 (29), and G (30).
19.6 to 34.3 Nm {2.0 to 3.5 kgm}
26. Install fuel filter assembly (26), and tighten it with the mounting bolts (4 pieces).
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
24 to 27 Nm {2.4 to 2.7 kgm}
D155AXI-8 50-89
3 Joint of fuel tubes (23) and (24) (fuel doser solenoid valve side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Joint of fuel tubes (24) and (25) (fuel feed pump block side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
28. Install cover (20), and tighten it with the mounting bolts (3 pieces).
29. Install fuel prefilter assembly (18), and tighten it with the mounting bolts (4 pieces).
3 Fuel tube (19):
43 to 47 Nm {4.4 to 4.8 kgm}
32. Install filter head (16) and oil filter by using installation
parts, and tighten them with the mounting bolts (6 pieces).
33. Install oil tubes (14) (2 pieces) and flange, and tighten
them with filter head (16) mounting bolts (2 pieces each)
side.
REMARK
• Fit O-rings to the mating faces of the cylinder head and
flange, and install them.
• Install oil tube and flange assembly according to the
following procedure.
1) Insert oil tube (14) (oil filter side) into filter head (16), and lightly tighten the flange to the cylinder block.
2) Tighten the mounting bolt on the oil filter side to the specified torque, and then tighten the flange
mounting bolt on the cylinder block side to the specified torque.
34. Install piping clips (15) (1 place each) to oil tubes (14) (2 pieces).
35. Install piping clip (13) of the fuel return hose.
Bracket
36. Install cover (12), and tighten it with the mounting bolts (2
pieces).
37. Install piping clip (11).
50-90 D155AXI-8
40. Tighten sheet (7) with the mounting bolts (2 pieces).

pieces).

pieces).
Engine, cooling
44. Install the aftercooler assembly. For details, see “REMOVE AND INSTALL AFTERCOOLER ASSEMBLY”.
45. Install the hydraulic oil cooler assembly. For details, see “REMOVE AND INSTALL HYDRAULIC OIL
COOLER ASSEMBLY”.
Exterior

270 kg
D155AXI-8 50-91
REMOVE AND INSTALL FUEL DOSER ASSEMBLY BLY
REMOVE AND INSTALL FUEL DOSER ASSEMBLY

METHOD FOR REMOVING FUEL DOSER ASSEMBLY

Cover
1. Open side covers (1) and (2) on the right of engine.
NOTICE
Check that it is securely fixed with the lock.
Fuel doser
2. Remove harness clamp (3).
3. Disconnect coolant tubes (4) and (5).
4. Remove bolt (6), and remove fuel doser (7).
50-92 D155AXI-8
BLY REMOVE AND INSTALL FUEL DOSER ASSEMBLY
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY

Fuel doser
1. Install heat insulator (8) to fuel doser (7).
2. Install fuel doser (7), and tighten it with bolt (6).
2 Bolt (6):
Seizure prevention compound (LC-G)
3 Bolt (6):
8.5 to 9.5 Nm {0.87 to 0.97 kgm}
NOTICE
• After tightening the bolts to the specified torque,
and tighten them alternately to the specified torque
again.
• For heat insulator (8), gasket (9), and bolt (6), use
new parts.
• Install gasket (9) with convex side of stepped por-
tion facing exhaust connector side.
• Install gasket (9) and heat insulator (8) carefully not
to fall off.
After tightening the bolts to the specified torque, and
tighten them alternately to the specified torque again.
3. Install coolant tubes (4) and (5).
3 Joint bolt of coolant tubes (4) and (5):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
4. Install wiring harness clamp (3).
Cover
5. Unlock the engine right side cover (1) and (2), and close
them.
D155AXI-8 50-93
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY BLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Tools for removal and installation of cylinder head assembly

New/Redesign
Necessity
Sketch
Q'ty

Removal and installation of cylinder
C - Eyebolt ■ 2
head
D 790-331-1110 Wrench ● 1 Angle tightening of bolts
record them.
50-94 D155AXI-8
BLY REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY

Exterior


270 kg
4. Remove KDPF and SCR assembly. For details, see “RE-
MOVE AND INSTALL KDPF, SCR ASSEMBLY”.
drain tube (4).
6. Remove the hydraulic oil cooler assembly. For details, see
“REMOVE AND INSTALL HYDRAULIC OIL COOLER AS-
SEMBLY”.
7. Remove the aftercooler assembly. For details, see “RE-
MOVE AND INSTALL AFTERCOOLER ASSEMBLY”.
Bracket, Cover
(6).
REMARK
• After removing bracket (6), move air conditioner hose
aside so that it does not hinder the work.
10. Remove mounting bolts (2 pieces) and seat (7).
D155AXI-8 50-95
Wiring
12. Remove wiring clips (10) and (11).
13. Remove mounting bolts (2 pieces), and remove cover (12).
Filter head, Oil filter

14. Remove piping clip (13) of fuel return hose.
15. Remove piping clips (15), one each on oil tubes (14) (2
pieces).
16. Remove mounting bolts (2 pieces) and disconnect oil
tubes (14) (2 pieces) from filter head (16).
17. Remove filter head (16) mounting bolts (2 pieces) and cyl-
inder block side flange mounting bolts (4 pieces), remove
oil tubes (14) (2 pieces), and the flange as a unit.
21. Remove mounting bolts (4 pieces), and remove fuel prefil-
ter assembly (18).
assembly (26).
27. Disconnect EGR oil tubes (31) to (32).
KCCV assembly
28. Remove KCCV assembly. For details, see “REMOVE AND INSTALL KCCV ASSEMBLY”.
50-96 D155AXI-8
Breather assembly
29. Cut wiring bands (33) (3 pieces), and remove wiring clips
(34) (2 pieces).
30. Disconnect wiring connector (35).
31. Remove wiring clamps (36) (2 pieces), and wiring clips
(37) (3 pieces).
(38).
(39).
(40).
35. Remove clamps (41a) (2 pieces) and remove piping (41)
and breather assembly (42) as a unit.
36. Remove clamps (41b).
37. Remove clamp (41c), and remove piping (41d).
Fuel tube
38. Remove joint of fuel tube (43), and remove relief valve (44)
and fuel tube (43).
39. Remove oil spray prevention cap installed to KVGT side of
KVGT oil tube (45) and (46), loosen sleeve nut, and re-
move KVGT oil tube (45), (46), and (47).
EGR cooler assembly

40. Remove EGR cooler assembly. For details, see “REMOVE AND INSTALL EGR COOLER ASSEMBLY”.
Connector
41. Disconnect wiring connector INJ (48).
42. Disconnect wiring connectors CN1 (49), CN2 (50), CN3
(51), CN4 (52), CN5 (53), and CN6 (54).
43. Remove wiring harness bracket (55) to (60), and injector
relay harness (61).
EGR valve
44. Remove EGR valve assembly. For details, see “REMOVE AND INSTALL EGR VALVE ASSEMBLY”.
D155AXI-8 50-97
Oil filler pipe

45. Remove mounting bolt (1 piece) and U-bolt (62) on cylin-
der block side, and remove oil filler pipe (63).
(64).
47. Remove mounting bolts (6 pieces), and remove oil filter
bracket (65).
REMARK
Remove wiring clip fixed to oil filter bracket (65).
bracket (66) and dosing fuel solenoid valve as a unit.
REMARK
Remove wiring clip fixed to fuel filter bracket (66).
Connector, Bracket
49. Remove mounting bolts (67) (3 pieces), and remove
bracket (68).
REMARK
Remove wiring clip fixed to bracket (68).
50. Disconnect wiring connectors PIM (69) and TIM (70).
Tube, Bracket
51. Remove clamps (71a) (5 places).
52. Remove Nox sensor (71).
53. Remove clamps (71b).
54. Remove mounting bolts (71c) (3 pieces), and remove
bracket (71d).

56. Remove clamps (72b) (2 pieces) and clamp (72c).
57. Remove mounting bolts (72d) (4 pieces), and remove
bracket (72e).
50-98 D155AXI-8
58. Remove piping clips (4 pieces), and remove KVGT lubrica-

tion oil tube (73a).
59. Remove fuel return tube (73b).
Air intake manifold

60. Remove connecting bolts (74b) (4 pieces) from air intake
manifold connector (74a).
Alternator
61. Remove the alternator belt. For details, see “REMOVE AND INSTALL ALTERNATOR BELT”.
62. Remove bolt (75b) connecting alternator (75a).
63. Remove mounting bolts (74) (6 pieces), and remove joint housing (74d) and air connector (74e) as a unit.
REMARK
Remove clamp stay mounting bolt of fuel high-pressure pipe for No. 1 injector.
64. Remove mounting bolts (74f) (3 pieces), and remove intake manifold connector (74a).
Hose, Bracket
65. Remove bracket (77a).
(77).
67. Loosen clamp of hose (76).
68. Remove clamp (78a) and joint bolt (78d).
69. Remove clamp (78c), and remove tube (78b).
70. Remove clamp (78e), and remove tube (78f).
71. Remove mounting bolts (78g) (3 pieces), and remove air
connector (78h).
72. Loosen clamp of hose (79).
73. Remove mounting bolts (2 pieces) of bracket (80) and re-
move bracket (80) and boost connector (81) as a unit.
74. Remove hose (79).
D155AXI-8 50-99
Exhaust elbow
76. Remove piping clip (1 place each), and remove coolant
tubes (83), (84), (85), and (86).
77. Remove piping clip (1 place), and remove KVGT lubrica-
tion oil tube (87).
79. Remove mounting bolts (4 pieces), and remove heat insu-
lation cover (89) and bracket (89a) together.
80. Remove mounting bolts (4 pieces), and remove heat insu-
lation cover (90) and bracket (90a) together.
82. Remove joint bolt (91b), and remove tube (91).
83. Remove clamp (92a).
84. Remove joint bolt (92b), and remove tube (92).
85. Remove mounting bolts (4 pieces), and remove exhaust

elbow (93a) and doser connector (93b) as a unit.
86. Remove mounting bolts (2 pieces), and remove exhaust
elbow mount bracket (93c).
KVGT assembly
87. Remove mounting bolts (4 pieces), sling KVGT assembly
(94), and remove it.
4 KVGT assembly (94):

45 kg
50-100 D155AXI-8
Exhaust manifold
(95).
(96).
90. Remove 2 mounting bolts to remove bracket (96a).
(96b).
(97).
93. Remove 2 mounting bolts to remove bracket (97a).
94. Remove mounting bolts (3 pieces), and remove bracket (97b).
95. Remove mounting bolts (98a) (4 pieces), and remove
bracket (98).
bracket (99).
bracket (100).
98. Remove joint bolt (101a), and remove tube (101).
99. Remove mounting bolts (24 pieces), sling exhaust mani-

fold (102) and remove it.
4 Exhaust manifold (102):

25 kg
D155AXI-8 50-101
Air intake manifold

100. Remove high-pressure pipe clamp from fuel supply pump,
and remove bracket (103) from gate type frame (104).
101. Remove high-pressure pipe clamp bolts (105) (7 pieces)
from between the common rail and fuel injector.
102. Remove mounting bolts (2 pieces), and remove gate type
frame (104).
103. Loosen fuel high-pressure pipe (106) (6 pieces) clamps
(140) to (157) and stays.
High-pressure pipes for No. 1 injector: (4 places) of (140),
(146), (147), and (149).
(148), and (150).
High-pressure pipes for No. 3 injector: (2 places) of (142)
and (150).
High-pressure pipes for No. 4 injector: (2 places) of (143)
and (151).
(151), and (153).
(152), (153), and (154).
104. Remove mounting bolts (20 pieces), sling intake manifold
REMARK
Take care not to damage fuel high-pressure pipes when
slinging air intake manifold (107) to remove.
4 Air intake manifold (107):

45 kg
Tube
105. Remove joints (5 pieces), and remove coolant tube (108).
106. Remove joints (5 pieces), and remove fuel return tube
(109).
50-102 D155AXI-8

107. Remove fuel spray prevention cap (110) from each fuel
high-pressure pipe (106) between the common rail and
fuel injectors, loosen the sleeve nuts, and remove fuel
high-pressure pipes (106) (6 pieces).
Cylinder head cover

108. Remove mounting bolts (3 pieces), and remove each cylin-
der head cover (111).
Rocker arm and rocker shaft assembly

109. Remove mounting bolts (112) (3 pieces), and remove rock-
er arm and rocker shaft assembly (113).
REMARK
Loosen locknut (115), and loosen adjustment screw (116)
2 to 3 turns so that excessive force is not applied to push
rod (114) when the rocker arm and rocker shaft assembly
(113) is installed.
110. Remove fuel high-pressure pipe (106) from injector as-
sembly.
Injector assembly
111. Remove wiring clip bolt (117) and spring clamp (118).
112. Remove capture nut (119) (2 pieces) from injector assem-
bly.
REMARK
Loosen capture nuts (119) alternately.
113. Remove the injector assembly according to the following
procedure.
D155AXI-8 50-103
1) Write down the cylinder number and the character

string (M) listed on the QR code tab (Q) as a set, and
remove the injector.
Reading order of character string (M)

REMARK
• After writing down the character string (M), check
that it is written correctly.
• Do not remove QR code tab (Q) attached to the
head of injector assembly.
• Do not damage QR code tab (Q) attached to the
head of injector assembly.
2) Remove holder mounting bolt (120).

3) Slowly remove injector assembly (121) and holder to-
gether by using leverage of tool B inserted under inlet
connector (e) of injector assembly (121).
REMARK
Do not pull out the solenoid valve part at the top of the
injector assembly with pliers, etc.
Push rod
114. Remove push rods (122) (2 pieces).
50-104 D155AXI-8
Crosshead
115. Remove crossheads (123).
Cylinder head assembly

116. Remove mounting bolts (124) (3 pieces), mounting bolts
(125) (3 pieces), and auxiliary bolt (126) (1 piece). Sling
cylinder head assembly (127) and remove it by using tool
C.
4 Cylinder head assembly (127):

25 kg
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY

k Do not bend the fuel high-pressure pipe for repair.
k Check the following items and install the fuel high-
pressure pipe. If it has any defect, replace the high-
pressure pipe with a new one since fuel may leak.
Visually check that taper seal part (a) of the connecting
part (2 mm area from the tip-end) is free from longitudi-
nal slits (b) or spotty dents (c).
Make sure that part (d) (end of taper seal: 2 mm area
from the tip-end) is free from steps you can feel by your
fingernail. ( free from fatigue.)
Method for checking for fuel leakage after connecting fuel high-pressure pipe
1. Check for leakage in the following cases.
NOTICE
When performing removal and installation, check for fuel leakage according to the following proce-
dure.
1) Clean the engine and the parts around it, and degrease them in advance so that you can check it easi-
ly for fuel leakage.
2) Spray color checker (developer) over the connecting part of the supply pump, common rail, fuel injec-
tor, and fuel high-pressure pipe.
3) Check fuel leakage from fuel pipings and devices.
NOTICE
Repair them when the fuel is leaking out and then start the check from the beginning.
REMARK
Check the high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
D155AXI-8 50-105
1) Start the engine, hold the engine speed Max. 1000 rpm, stop the engine once after engine speed be-
comes stable, and check for fuel leakage.
2) After starting the engine, run the engine at low idle, hold it, and check for fuel leakage.
3) After starting the engine, run the engine at high idle, hold it, apply load to the engine, and check for fuel
leakage.
REMARK
Apply load to the engine at torque converter stall or hydraulic pump relief.
2. Install the cylinder head assembly (127) according to the following procedure.
1) Check that the cylinder head mounting face and inside of the cylinders are free from dirt and foreign
material, and then set cylinder head gasket.
REMARK
Check that the grommet of cylinder head gasket (3) has no peeling or omission.
2) Do not reuse cylinder head mounting bolts (124) and
(125) when they are out of the following standard. Al-
ways replace it with the new one.
The number of tightening times becomes 6 times (5
punch marks) or more.
Stem length (a) of the bolt exceeds the allowable limit.
Long bolt (124): Min. 205.8 mm
Short bolt (125): Min. 170.8 mm
3) Sling cylinder head assembly (127) by using tool C, in-

stall it, and tighten the mounting bolts (124) (3 pieces)
and (125) (3 pieces) and auxiliary bolts (126) (1
piece).
2 Mounting bolts (124), (125), and auxiliary bolts
(126):
Molybdenum disulfide lubricant (LM-P)
4 Cylinder head assembly (127):

25 kg
50-106 D155AXI-8
4) Tighten mounting bolts (124), (125).

3 Mounting bolts (124), (125) (1st time):
137 to 157 Nm {14 to 16 kgm}
3 Mounting bolts (124), (125) (2nd time):
284 to 294 Nm {29.0 to 30.0 kgm}
3 Mounting bolt (124), (125) (3rd time):
90(+30/0) °
• When using tool D, retighten the bolt
90(+30/0) deg. in the order of (1) to (6) as
shown in the following figure.
• When not using tool D, put marks (f) on
the bolt and flywheel, and tighten the
bolts by 90 (+30/0) deg. in the order of (1)
to (6) shown in the following figure.
REMARK
• After tightening the bolt, put a punch mark (g) on
each bolt head to indicate the number of tighten-
ing.
• Do not put a punch mark when replacing a bolt
with a new one.
• Tighten the mounting bolts (124) and (125) in the
order of (1) to (6) shown in the above figure, and
tighten auxiliary bolts (126) in the order of (7)
shown in the above figure.
3 Auxiliary bolt (175):
66.6±7.4 Nm {6.8±0.8 kgm}
Crosshead
3. Adjust crosshead (123) according to the following proce-
dure.
1) Loosen the locknut, and loosen the adjustment screw.
2) While pressing the top of crosshead (123) lightly, and
screw in the adjustment screw.
3) After the adjustment screw touches the valve stem,
tighten it further by 20 deg.
4) Tighten lock nut (26) to the specified torque.
3 Locknut:
58.7±5.9 Nm {6±0.6 kgm}
D155AXI-8 50-107
Push rod
4. Install push rods (122) (2 pieces).
Injector assembly
5. Install injector assembly (121) according to the following procedure.
REMARK
Check that there is no dust or etc is attached to the inside the injector sleeve on the cylinder head side.
1) Install O-rings (130), (131), and gasket (132) to injec-
tor (121).
REMARK
Take care not to install O-ring (130) to groove (d).
2 O-rings (130) and (131):
Engine oil
2) Install holder (134) to fuel injector (121), and insert the
injector assembly into injector sleeve on cylinder
head.
REMARK
In case of reusing the injector assembly and engine controller, check the cylinder No. and character
string (M) which were written down when injector assembly was removed, and install the injector as-
sembly to the correspondent cylinder.
REMARK
In case of replacing the injector assembly and engine controller, check the cylinder No. and character
string (M) which were written down on the engine controller, and install the injector assembly to the cor-
respondent cylinder.
REMARK
Check that the injector assembly is inserted completely to the end.
3) Install the spherical washer (135) to holder mounting bolt (120), and tighten holder (134) lightly.
2 Spherical washer (135):
Engine oil
REMARK
Tighten the sleeve nut of fuel high-pressure pipe, and tighten holder mounting bolt (120) to the speci-
fied torque.
3 Holder mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
REMARK
Wash off dirt and dust attached on the parts near harness connectors, and remove them completely to pre-
vent them from entering connectors.
REMARK
Use clean engine oil when applying engine oil to O-rings and lubricated parts.
50-108 D155AXI-8
REMARK
In case of replacing the injector assembly with the new
one, write down the number of cylinder to be installed to
and character string (M) listed on QE code tab (Q) at the
top of the injector as a set.
(Reading order of character string (M))

REMARK
After writing down the character string (M), check that it is
written correctly.
REMARK
When injector assembly and engine controller is replaced,
see Testing and adjusting, “WRITE INJECTOR COMPEN-
SATION VALUE TO ENGINE CONTROLLER”, and write
character string (M) of injector assembly into engine con-
troller.
REMARK
Make sure to write character string (M) which was written
down on the corresponding cylinder No.
REMARK
If the character strings are not written correctly, the engine may not operate normally.
(Reference: The QR code and character string indicates the compensation value for fuel injection of the in-
jector, which is specific to each injector.)
6. Eliminate the sag of the fuel injector harness, and install it
to the injector assembly so that it will not interfere with the
rocker arm.
7. Install spring clamp (118).
8. Tighten capture nuts (119) (2 pieces) alternately.
9. Tighten capture nuts (119) alternately.
3 Capture nut (119):
2±0.2 Nm {0.2±0.02 kgm}
10. Wiring bolt (117).
Rocker arm and rocker shaft assembly
11. Install fuel high-pressure pipe (106) to injector assembly.
D155AXI-8 50-109
12. Tighten rocker arm and rocker shaft assembly (113) with
mounting bolt (112) (3 pieces).
REMARK
Loosen locknut (115), and loosen adjustment screw (116)
2 to 3 turns so that excessive force is not applied to push
rod (114) when the rocker arm and rocker shaft assembly
(113) is installed.
REMARK
Apply engine oil to (e) part of crosshead and socket part (f)
of push rod (114).
2 (e) part of crosshead and (f) part of push rod
(114):
Engine oil
REMARK
When installing rocker arm and rocker shaft assembly
(113), check that ball part of adjustment screw (116) fits in
the socket part of push rod (114), and tighten mounting
bolts (112a), (112b), and (112c).
REMARK
Note that mounting bolts (112a), (112b), and (112c) have
different dimensions
Mounting bolt (112a)stem length 120
Mounting bolt (112b)stem length 90
Mounting bolt (112c)stem length 75
3 Mounting bolt (112a), (112b), and (112c):
93 to 103 Nm {9.5 to 10.5 kgm}
REMARK
Adjust the valve clearance. For details, see Testing and
adjusting, “TEST AND ADJUST VALVE CLEARANCE”.
50-110 D155AXI-8
Cylinder head cover

13. Tighten cylinder head cover (111) with mounting bolt (3
pieces).
REMARK
Install gasket to cylinder head cover (111).
REMARK
Tighten mounting bolts in front of air intake manifold side
lightly since these are tightened together with harness
brackets (55) to (60).

14. Tighten fuel high-pressure pipe (106) with sleeve nut. In-
stall fuel spray prevention cap (110).
REMARK
Install fuel spray prevention cap (110) so that slit of fuel in-
jector side faces downward, and slit of common rail side
faces cylinder block.
REMARK
Check that the excess force is not applied to fuel high-
pressure pipe (106) by loosening the sleeve nut of fuel
high-pressure pipe (106) once, and tighten it by using tool
A to the specified torque.
15. Tighten the sleeve nut of high-pressure fuel pipe (106) to
3 Sleeve nut on fuel injector side:
39.2 to 44.1 Nm {4 to 4.5 kgm}
3 Sleeve nut on common rail side:
39.2 to 44.1 Nm {4 to 4.5 kgm}
1) Attach fuel high-pressure pipe clamp (140) to (154)
and stay loosely by hand.
REMARK
Attach air intake manifold connector (74a), joint hous-
ing (74d), and air connector (74e) to fuel high-pres-
sure pipe clamp (140), and install loosely.
2) Fasten fuel high-pressure pipe clamp (140) to (154) to
3 fuel high-pressure pipe clamp bolt:
9.8±1 Nm {1.0±0.1 kgm}
3) Fasten the stays of fuel high-pressure pipe clamp
(140) to (145) to the specified torque.
D155AXI-8 50-111
4) Install bracket (103) and gate type frame (104) loose-

ly.
5) Fasten fuel high-pressure pipe clamp bolts (105) (7
pieces) to the specified torque.
3 fuel high-pressure pipe clamp bolt (105):
9.8±1 Nm {1.0±0.1 kgm}
6) Tighten gate type frame (104) to the specified torque.
7) Fasten the stays of fuel high-pressure pipe clamp
(146) to (154) to the specified torque.
Tube
16. Tighten fuel return tube (109) with joint bolts (5 pieces).
3 Joint bolt of fuel return hose (109):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
17. Tighten coolant tube (108) with joint bolts (5 pieces).
3 Joint bolt of coolant tube (108):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Air intake manifold

18. Sling air intake manifold (107), install it, and tighten it with
4 Air intake manifold (107):

45 kg
REMARK
Replace the gasket on flange of air intake manifold (107)
with the new one, sling air intake manifold (107), and in-
stall it.
REMARK
Be careful not to damage fuel high-pressure pipes when
slinging air intake manifold (107) to install.
REMARK
Tighten air intake manifold mounting bolts in the order of
(1) to (20).
3 Air intake manifold mounting bolt:
58.8 to 73.5 Nm {6 to 7.5 kgm}
50-112 D155AXI-8
Exhaust manifold
19. Replace the gasket on flange of exhaust manifold(102)
with the new one, sling exhaust manifold (102), and install
it.
4 Exhaust manifold (102):

25 kg
20. Tighten the exhaust manifold mounting bolts (1) to (24).
1) Lightly tighten mounting bolts (3 pieces) in the order of

(1) to (3).
2) Lightly tighten the remaining mounting bolts (21
pieces) in the order of (4) to (24).
3) Tighten all the mounting bolt to the specified torque in
the order of (1) to (24).
2 Exhaust manifold mounting bolt (1) to (24):
3 Exhaust manifold mounting bolt:
58.8 to 73.5 Nm {6 to 7.5 kgm}
21. Temporarily assemble tube (101) with joint bolt (101a).
REMARK
Tighten tube (101) when installing EGR cooler.
22. Install bracket (100) with bolts (100a) (4 pieces).

25. Tighten brackets (97b) with mounting bolt (3 pieces).

26. Tighten brackets (97a) with mounting bolt (2 pieces).
27. Tighten brackets (97) with mounting bolt (3 pieces).
28. Tighten brackets (96b) with mounting bolt (2 pieces).
29. Tighten brackets (96a) with mounting bolt (2 pieces).
D155AXI-8 50-113
KVGT assembly
32. Sling KVGT cooler assembly (94), remove it, and tighten it
with mounting bolts (4 pieces).
4 KVGT assembly (94):

45 kg
2 KVGT assembly (94) mounting bolt:
3 KVGT assembly (94) mounting bolt:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
Exhaust elbow
33. Install exhaust elbow mount bracket (93c), and tighten it
with the mounting bolts (2 pieces).
2 Exhaust elbow mount bracket (93) mounting bolts:
34. Install exhaust elbow (93a) and doser connector (93b),
and tighten them with the mounting bolts (4 pieces).
2 Exhaust elbow (93a) mounting bolts:
35. Install tube (92) with joint bolt (92b).

3 Joint bolt (92b):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
36. Install clamp (92a).
37. Install tube (91) with joint bolt (91b).
3 Joint bolt (91b):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
38. Install clamps (91a) (2 places).
39. Tighten heat insulation cover (90) and bracket (90a) with
40. Tighten cover (88) with mounting bolts (4 pieces).
41. Install KVGT lubricating oil tube (87), and install wiring clip
(1 place).
REMARK
Attach gasket to the flange of KVGT lubrication oil tube
(87), and install it.
42. Tighten heat insulation cover (89) and bracket (89a) with
43. Install coolant tube (83), (84), (85), and (86), and install piping clip (1 place).
3 Coolant tube (83) (KCCV plate side):
24 to 27 Nm {2.4 to 2.7 kgm}
3 Joint of coolant tubes (84), (85), and (86):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
44. Tighten cover (82) with mounting bolts (4 pieces).
50-114 D155AXI-8
Hose, Bracket
45. Install hose (79).
46. Install bracket (80) and boost connector (81), and tighten
them with mounting bolts (2 pieces).
47. Tighten clamp of hose (79).
3 Clamp of hose (79):
10.5±0.5 Nm {1.07±0.05 kgm}
48. Install air connector (78h) with mounting bolts (78g) (3
pieces).
49. Fasten clamp of hose (76).
3 Clamp of hose (76):
8.8±0.5 Nm {0.9±0.05 kgm}
50. Install tube (78f), and install clamp (78e).
3 Clamp (78e):
3.3±0.49 Nm {0.34±0.05 kgm}
51. Install tube (78d) and then install joint bolt (78d) and clamp
(78c).
3 Joint bolt (78d):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Clamp (78c):
3.3±0.49 Nm {0.34±0.05 kgm}
53. Install bracket (77) with mounting bolts (4 pieces).
2 Mounting bolt of bracket (77):
54. Install bracket (77a).
Air intake manifold
55. Install air intake manifold (74a), and tighten it with mount-
ing bolts (3 pieces).
REMARK
Replace the gasket to be installed to the flange surface of
air intake manifold connector (74a) and air intake manifold
with a new one.
56. Install joint housing (74d) and air connector (74e), and
tighten them with mounting bolts (74c) (6 pieces).
REMARK
• Install clamp stay mounting bolt of fuel high-pressure
pipe for No. 1 injector.
• Replace the gasket to be installed to the flange surface
of joint housing (74d) and air intake manifold connector
(74a) with a new one.
Alternator
57. Install bolt (75b) connecting alternator (75a).
REMARK
Bolt (75b) connecting alternator (75a) can be installed from rear side of the machine.
58. Install the alternator belt. For details, see “REMOVE AND INSTALL ALTERNATOR BELT”.
D155AXI-8 50-115
59. Install bolts (74b) (4 pieces) connecting intake manifold connector (74a).
Tube, Bracket
60. Install fuel return tube (73b).
3 Joint of fuel return tube (73b) (cylinder block side):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Joint of fuel return tube (73b) (fuel return block
side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
61. Install KVGT lubricating oil tube (73a), and install wiring
clip (4 place).
REMARK
Attach gasket to the flange of KVGT side of KVGT lubrica-
tion oil tube (73a), and install it.
3 Joint of KVGT lubrication oil tube (73a) (cooling plate side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
62. Install bracket (72e) with the mounting bolts (72d) (4
pieces).
63. Install clamp (72c) and clamps (72c) (2 places).
65. Install bracket (71d) with the mounting bolts (71c) (3

pieces).
66. Install clamp (71b).
67. Install Nox sensor (71).
2 Threaded part of Nox sensor:
3 Nox sensor:
50±10 Nm {5.1±1 kgm}
Connector, Bracket
69. Install wiring connectors PIM (69) and TIM (70).
70. Install bracket (68) with the mounting bolts (67) (3 pieces).
50-116 D155AXI-8
Oil filler pipe

71. Install fuel filter bracket (66) and dosing fuel solenoid
valve, and tighten them with mounting bolts (6 pieces).
72. Install oil filter bracket (65), and tighten it with mounting
bolts (6 pieces).
73. Tighten brackets (64) with mounting bolts (2 pieces).
74. Install oil filler pipe (63), and tighten it with mounting bolt (1
pieces) and U-bolt (62) on the cylinder block side.
REMARK
Fit O-ring in insertion part of cam follower cover, and install
it.
3 U-bolt (62) nut:
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
EGR valve
75. Install EGR valve assembly. For details, see “REMOVE AND INSTALL EGR VALVE ASSEMBLY”.
Connector
76. Install injector relay harness (61), and install harness
brackets (55) to (60).
77. Install wiring connectors CN1 (49), CN2 (50), CN3 (51),
CN4 (52), CN5 (53), and CN6 (54).
78. Install wiring connector INJ (48).
EGR cooler assembly

79. Install EGR cooler assembly (50). For details, see “REMOVE AND INSTALL EGR COOLER ASSEMBLY”.
REMARK
Tighten tube (101) which is temporarily assembled in step 21.
Fuel tube
80. Tighten sleeve nuts of KVGT oil tubes (45), (46), and (47),
and install oil splash prevention caps.
REMARK
• Install the oil splash prevention cap to KVGT connect-
ing part so that the slit faces downward.
3 Sleeve nut of KVGT oil tubes (45), (46), and (47):
24 to 27 Nm {2.4 to 2.7 kgm}
81. Install relief valve (44) and fuel tube (43) with the joint of
fuel tube (43).
3 Joint of fuel tube (43) (dosing fuel solenoid valve side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3 Fuel tube (43) (fuel doser side):
15.3±0.5 Nm {1.56±0.05 kgm}
D155AXI-8 50-117
Breather assembly
82. Install breather assembly (42) and piping (41) as a unit.
84. Install piping (41d) and install clamp (41c).
3 Clamp (41c):
4.4±0.49 Nm {0.45±0.05 kgm}
85. Install clamp (41b).
86. Install bracket (40) with the mounting bolts (2 pieces).
89. Remove wiring clamps (36) (2 places) and wiring clips (37)
(3 places).
90. Install wiring connector DOSER (35).
91. Install wiring clips (34) (2 places), and install bands (33) (3
places).
KCCV assembly
92. Install KCCV assembly. For details, see “REMOVE AND INSTALL KCCV ASSEMBLY”.
3 Joint of coolant tube of KCCV assembly (KCCV assembly side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3 Joint of coolant outlet tube of KCCV assembly (cylinder block side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Clamp of coolant inlet tube of KCCV assembly (air connector side):
3.3±0.49 Nm {0.34±0.05 kgm}
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
43 to 47 Nm {4.4 to 4.8 kgm}
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
94. Connect the wiring connectors PCV1 (28), PCV2 (29) and G (30).
19.6 to 34.3 Nm {2.0 to 3.5 kgm}
96. Install fuel filter assembly (26), and tighten it with mounting bolts (4 pieces).
50-118 D155AXI-8

7.8 to 9.8 Nm {0.8 to 1.0 kgm}
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
24 to 27 Nm {2.4 to 2.7 kgm}
3 Joint of fuel tubes (23) and (24) (dosing fuel solenoid valve side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint of fuel tube (24) (dosing fuel solenoid valve side):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Joint of fuel tubes (24) and (25) (fuel feed pump side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
98. Install cover (20) with mounting bolts (3 pieces).
99. Install fuel prefilter assembly (18), and tighten it with mounting bolts (4 pieces).
3 Fuel tube (19):

43 to 47 Nm {4.4 to 4.8 kgm}
101. Connect fuel supply hose (17).
Filter head, Oil filter
102. Tighten filter head (16) and oil filter with mounting bolts (6
pieces).
103. Install oil tube (14) (2 pieces) and flange according to the
following procedures.
1) Insert oil filter side of oil tube (14) into filter head (16),
and lightly tighten the flange to cylinder block.
2) Tighten mounting bolts on oil filter side to the specified
torque, and tighten flange mounting bolts on cylinder
block side to the specified torque.
REMARK
Set O-ring to the contacting face of cylinder head and
flange.
104. Tighten filter head (16) and oil tube (14) (2 pieces) with mounting bolts (2 pieces).
105. Install piping clips (15), one each on oil tubes (14) (2 pieces).
Bracket
107. Install cover (12) and tighten it with mounting bolts (2
pieces).
108. Install piping clip (11).
D155AXI-8 50-119
111. Tighten seat (7) with mounting bolts (2 pieces).

pieces).

pieces).
Engine and cooling system

COOLER ASSEMBLY”.
Exterior
118. Install engine hood assembly. For details, see “REMOVE AND INSTALL ENGINE HOOD ASSEMBLY”.

270 kg
50-120 D155AXI-8
BLY REMOVE AND INSTALL EGR VALVE ASSEMBLY
REMOVE AND INSTALL EGR VALVE ASSEMBLY
record them.
METHOD FOR REMOVING EGR VALVE ASSEMBLY

Engine hood
1. Remove engine hood assembly. For details, see “REMOVE AND INSTALL ENGINE HOOD ASSEMBLY”.
2. Remove KDPF and SCR assembly. For details, see “REMOVE AND INSTALL KDPF, SCR ASSEMBLY”.
Connector
3. Disconnect solenoid connectors EGR-SOL (1), VGT-SOL
(2), and SEGR (4).
4. Separate band (3) (5 places).
NOTICE
Put the mark on the mounting positions of the bands.
Oil tube
5. Remove clamps (5), (6), and (7).
D155AXI-8 50-121
REMOVE AND INSTALL EGR VALVE ASSEMBLY BLY
6. Disconnect oil tubes (8), (9), (10), and (11).
EGR valve assembly

7. Remove mounting bolts (12) and (13).
8. Remove mounting bolt (14) (2 pieces) and mounting bolts
(15) (4 pieces), and remove EGR valve assembly (16).
METHOD FOR INSTALLING EGR VALVE ASSEMBLY

EGR valve assembly
1. Install EGR valve assembly (16) with mounting bolt (14) (2
pieces) and mounting bolts (15) (4 pieces).
2. Install mounting bolts (12) and (13).
Oil tube
3. Install oil tubes (8), (9), (10), and (11).
3 Oil tubes (10) and (11):
24 to 27 Nm {2.4 to 2.7 kgm}
3 Oil tube (9) (EGR valve side):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3 Oil tube (9) (air vent block side):
24.5 to 34.3 Nm {3.5 to 4.5 kgm}
3 Joint of tube (8):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
50-122 D155AXI-8
BLY REMOVE AND INSTALL EGR VALVE ASSEMBLY
4. Install clamps (5), (6), and (7).
Connector
5. Install band (3) (5 places) at positions marked during disassembly.
6. Install solenoid connectors EGR-SOL (1), VGT-SOL (2),
and SEGR (4).

Engine hood
D155AXI-8 50-123
REMOVE AND INSTALL EGR COOLER ASSEMBLY BLY
REMOVE AND INSTALL EGR COOLER ASSEMBLY
record them.
METHOD FOR REMOVING EGR COOLER ASSEMBLY

Draining coolant
1. Drain the coolant from the radiator.
6 Radiator:
103.5 ℓ
Engine hood
3. Remove KDPF and SCR assembly. For details, see “REMOVE AND INSTALL KDPF, SCR ASSEMBLY”.
Cooling
4. Remove the clamp, and remove air cleaner hose (1).
5. Disconnect tube (2).
6. Remove the clamp, and disconnect radiator upper hose
(3).
50-124 D155AXI-8
BLY REMOVE AND INSTALL EGR COOLER ASSEMBLY
Cover
7. Remove mounting bolts (4) (9 pieces), and remove heat in-
sulation cover (5).
sulation cover (7).

sulation cover bracket (9).
EGR connector
10. Remove mounting bolts (10) (4 pieces), and remove brack-
et (11).
11. Remove EGR valve side flange bolts (12) (4 pieces) and
EGR cooler side flange bolts (13) (8 pieces), and remove
EGR cooler outlet connector (14).
12. Remove mounting bolts (15) (4 pieces), and remove EGR

cooler inlet connector bracket (16).
13. Remove flange bolts (17) (4 pieces) on the exhaust mani-
fold side and flange bolts (18) (8 pieces) on the EGR cool-
er side, and then remove EGR cooler inlet connector as-
sembly (19).
D155AXI-8 50-125
Bracket
14. Remove mounting bolts (20) (4 pieces), and remove brack-
et (21).
15. Remove mounting bolts (22) (3 pieces), and disconnect
bracket (23).
REMARK
1 place of mounting bolt (22) of bracket (23) is tightened
together with spacer (24).
Tube
16. Remove clamps (25) (2 pieces) and joint bolt (26), and dis-
connect coolant tube (27).
17. Remove clamps (28) and joint bolt (29), and disconnect
coolant tube (30).

18. Remove mounting bolts (31) (2 pieces), and remove cool-
ant return tube (32).
19. Remove mounting bolts (33) (2 pieces), and remove cool-
ant supply tube (34).
20. Remove mounting bolts (35) (4 pieces), sling EGR cooler
assembly (36), and remove it.
4 EGR cooler assembly:

80 kg
METHOD FOR INSTALLING EGR COOLER ASSEMBLY

EGR cooler assembly
1. Sling EGR cooler assembly (36), and tighten it with mount-
ing bolts (35) (4 pieces) to install.
4 EGR cooler assembly:

80 kg
2. Install coolant supply tube (34) with mounting bolts (33) (2
pieces).
REMARK
Replace the gasket to be installed to the coolant tube
flange surface with a new one.
3. Install coolant return tube (32) with mounting bolts (31) (2 pieces).
REMARK
Replace the gasket to be installed to the coolant tube flange surface with a new one.
50-126 D155AXI-8
BLY REMOVE AND INSTALL EGR COOLER ASSEMBLY
Tube
4. Tighten coolant tube (30) with clamp (28) and joint bolts
(29).
5. Tighten coolant tube (27) with clamp (25) (2 pieces) and
joint bolts (26).
Bracket
REMARK
1 place of mounting bolt (22) of bracket (23) is tightened
together with spacer (24).
2 Bracket (23) mounting bolt (22) (exhaust elbow
mount bracket side):
EGR connector
8. Remove flange bolts (17) (4 pieces) on the exhaust mani-
fold side and flange bolts (18) (8 pieces) on the EGR cool-
er side, and then install EGR cooler inlet connector assem-
bly (19).
REMARK
EGR inlet connector assembly (19) with a new one.
9. Install EGR cooler inlet connector bracket (16) with the
10. Install EGR cooler outlet connector (14) with EGR valve
side flange bolts(12) (4 pieces) and EGR cooler side flange
bolts (13) (8 pieces).
REMARK
EGR outlet connector assembly (14) with a new one.
11. Install bracket (11) with mounting bolts (10) (4 pieces).
D155AXI-8 50-127
Cover
12. Install heat insulation cover bracket (9) with mounting bolts
(8) (4 pieces).
13. Install heat insulation cover (7) with mounting bolts (6) (5
pieces).
2 Heat insulation cover (7) mounting bolts (3 bolts on
EGR cooler side)::
14. Install heat insulation cover (5) with mounting bolts (4) (9
pieces).
Cooling
15. Install the clamp, and connect radiator upper hose (3).
3 Radiator upper hose (3) clamp:
8.8±0.5 Nm {0.9±0.05 kgm}
16. Install tubes (2).
17. Install air cleaner hose (1), and tighten it with the clamp.
3 Air cleaner hose (1) clamp:
8.8±0.5 Nm {0.9±0.05 kgm}

Engine hood
Refilling with coolant
20. Refill it with the coolant to the specified level through the coolant filler port. Run the engine to circulate the
coolant through system. Then check the coolant level again.
5 Radiator:
103.5 ℓ
50-128 D155AXI-8
BLY REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY

METHOD FOR REMOVING STARTING MOTOR ASSEMBLY

Cover
NOTICE
2. Disconnect connector WL2 (3).

3. Disconnect hose (4).
4. Remove cover (5).

5. Remove mudguard cover (6).
Starting motor assembly

6. Disconnect terminal B (7).
7. Remove wiring harness clamp (8), and disconnect connec-
tor (9).
8. Remove the mounting bolts (10a) (3 pieces), and remove
starting motor assembly (10).
D155AXI-8 50-129
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY BLY
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY

Starting motor assembly
1. Install gasket (11) to starting motor assembly (10).
REMARK
Be sure to replace the gasket with a new one.
2. Install starting motor assembly (10), and tighten it with the

mounting bolts (10a) (3 pieces).
3. Install connector (9), and install wiring harness clamp (8).
4. Install terminal B (7).
3 Mounting bolt of terminal B (7):
19.6 to 25.5 Nm {2 to 2.6 kgm}
Cover
5. Install mudguard cover (6).
6. Install cover (5).

8. Connect connector WL2 (3).
50-130 D155AXI-8
BLY REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
9. Unlock the engine right side cover (1) and (2), and close
them.
D155AXI-8 50-131
REMOVE AND INSTALL ALTERNATOR BELT BLY
REMOVE AND INSTALL ALTERNATOR BELT

METHOD FOR REMOVING ALTERNATOR BELT

Cover
1. Open side covers (1) and (2) on the left of engine.
NOTICE
Check that the locks are securely fixed.
2. Remove left mudguard cover (3).
3. Remove mounting bolts (4a) (4 pieces), and remove cover

(4).
Alternator belt
4. Loosen lock nut (5), fully tighten pressing bolt (6), push in
tension pulley (7), and loosen the tension of alternator belt
(8).
5. Remove alternator belt (8).
50-132 D155AXI-8
BLY REMOVE AND INSTALL ALTERNATOR BELT
METHOD FOR INSTALLING ALTERNATOR BELT

Alternator belt
1. Install alternator belt (8).
2. Apply tension to alternator belt with push belt (6) and ten-
sion pulley (7).
REMARK
Check that the belt fits in the pulley groove without any dis-
placement.
Cover
3. Install cover (4) with mounting bolts (4a).
4. Make sure that the head surface of push bolt (6) become
even with the end surface (a) of cover (4), and tighten it
with lock nut (5).
D155AXI-8 50-133
REMOVE AND INSTALL ALTERNATOR BELT BLY
5. Install left mudguard cover (3).

6. Unlock the engine side cover (1) and (2) on the left side,
and close them.
50-134 D155AXI-8
BLY REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL RADIATOR ASSEMBLY
k If you drain the radiator coolant when it is still hot, you may be scalded. Wait until the coolant tem-
perature drops before draining.
METHOD FOR REMOVING RADIATOR ASSEMBLY

Draining coolant
6 Radiator:
103.5 ℓ
Fan guard
2. Open front radiator mask (1).
3. Remove fan guard (2).
D155AXI-8 50-135
REMOVE AND INSTALL RADIATOR ASSEMBLY BLY
Smaller hood
5. Remove wiring harness (4) on the back side of cover (3).
6. Remove coolant filler port cover (5).
7. Disconnect connector LHDL (6).
8. Sling smaller hood (7), and remove it.
4 Smaller hood:
25 kg
50-136 D155AXI-8
Bracket
9. Remove bolts (8a) (2 pieces) (right and left).
10. Remove bolts (8b) (2 pieces) (right and left), and remove
brackets (9) (right and left).
Hose
11. Disconnect wiring connector RDG (10), and remove
clamps (11) (3 places).
12. Disconnect hoses (12) and (13).
REMARK
• When removing the R.H. radiator assembly, disconnect
hose (12).
• When removing the center radiator assembly, discon-
nect hose (13).
13. Disconnect tubes (14), (15), (16), and (17).

REMARK
• When removing the L.H. radiator assembly, disconnect
tube (14).
• When removing the center radiator assembly, discon-
nect tubes (15) and (17).
• When removing the R.H. radiator assembly, disconnect
tube (16).
• When disconnecting tube (17), remove bracket (18).
D155AXI-8 50-137
Bracket
14. Remove brackets (19) to (27).
k Be sure to keep either of right and left brackets (26)
and (27) installed. Otherwise, the cooler assembly
tilts toward the engine assembly side, and the oil
cooler core may be damaged since it contacts the
engine assembly.
REMARK
• When removing the L.H. radiator assembly, remove
brackets (19), (20), (21), and (26).
• When removing the center radiator assembly, remove
brackets (20), (21), (22), and (23).
• When removing the R.H. radiator assembly, remove
brackets (22), (23), (24), (25), and (27).
15. Sling radiator assembly (28), and remove it.
4 Radiator assembly (28):

20 kg
METHOD FOR INSTALLING RADIATOR ASSEMBLY

Radiator assembly
1. Install O-ring (37).
2 Outside perimeter of O-ring (37):
Grease (G2-LI)
50-138 D155AXI-8
2. Sling radiator assembly (28), lower it slowly,and install it to

lower tank (38).
REMARK
Visually check the installation status from the machine
front.
4 Radiator assembly (28):

20 kg
D155AXI-8 50-139
Bracket
3. Install plate (32), cushion (33), brackets (22), (23), (24),
and (25) respectively onto the boss for mounting radiator
assemblies (28).
REMARK
• Fit brackets(22), (23), (24), and (25) closely on the
mounting sheet of upper tank (31).
• You may also tighten bracket mounting bolt (36) lightly.
4. Install collar (34) facing reversely (smaller diameter side
faces upward), and tighten mounting bolt (35).
REMARK
Height of cushion (33) decreases from (L1) to (L2).
5. Tighten mounting bolts (36) of brackets (22), (23), (24),
and (25) with mounting bolt (35) tightened.
6. Remove mounting bolt (35), set collar (34) facing in the
normal direction (smaller diameter side faces downward),
and tighten mounting bolt (35) again.
7. Check clearance (L3).
Clearance (L3): Approximately 7 mm
Hose, tube
8. Install tubes (14), (15), (16), and (17).
REMARK
• When hoses (18), (19), and (20) were removed, install
tubes with red paint (a) facing upward.
• When fastening hose clamps (29) for hoses (18), (19),
and (20), fasten hose clamps (29) (2 pieces) with the
bolts whose positions are 180 ° apart from each other.
3 Hose clamp (29):
8.8±0.5 Nm {90±5 kgm}
50-140 D155AXI-8
9. Install hose clamp (29) to the position indicated in the fig-

ure.
Dimension (b): 6 mm
Dimension (c): 4 mm
Dimension (d): 2 mm
10. Replace tubes (14), (15), (16), (17), and gasket (30) be-
tween upper tanks with new ones.
2 Mating face of gasket (30):
Liquid gasket (LG-7)
11. Install hoses (12) and (13).

12. Connect wiring connector RDG (10), and install clamps
(11) (3 places).
D155AXI-8 50-141
Bracket
13. Install brackets (9) (right and left) with bolts (8b) (2 pieces)
(right and left).
14. Install bolts (8a) (2 pieces) (right and left).
Smaller hood
15. Sling smaller hood (7), and install it.
4 Smaller hood:
25 kg
16. Connect connector LHDL (6).
17. Install coolant filler port cover (5).
50-142 D155AXI-8
18. Install wiring harness (4) on the back side of cover (3).
Fan guard
20. Install fan guard (2).
21. Close right and left radiator masks (1).

22. Refill it with the coolant to the specified level through the coolant filler port. Run the engine to circulate the
coolant through system. Then check the coolant level again.
Radiator103.5 ℓ
D155AXI-8 50-143
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY BLY
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY

k If you drain the hydraulic oil when it is still hot, you may be scalded. Wait until the oil temperature
drops before draining.
k Loosen the cap of the hydraulic tank gradually,and release the pressure remaining inside the hy-
draulic tank.
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY

Cover
1. Sling engine underguard (1) by using lifting tools, hold it,
remove the mounting bolts (10 pieces) excluding the
hinge, and open engine underguard (1).

270 kg
3. Remove right and left side covers (2) and (3).
Draining hydraulic oil

4. Drain hydraulic oil from the hydraulic tank.
6 Hydraulic tank:
95 ℓ
Hose
5. Disconnect hydraulic oil cooler outlet hose (4).
NOTICE
In order to prevent oil from flowing out, install the
plugs to the hose and fitting.
50-144 D155AXI-8
BLY REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
6. Disconnect hydraulic oil cooler inlet hose (5).

NOTICE
In order to prevent oil from flowing out, install the
plugs to the hose and fitting.
Hydraulic oil cooler assembly

7. Remove the mounting bolts (4 pieces), and remove hy-
draulic oil cooler assembly (6).
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY

1. Install hydraulic oil cooler assembly (6), and tighten it with
the mounting bolts (4 pieces).
Hose
2. Install hydraulic oil cooler inlet port hose (5).
D155AXI-8 50-145
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY BLY
3. Install hydraulic oil cooler outlet hose (4).
Cover
4. Install right and left side covers (2) and (3).

close engine underguard (1), and tighten the mounting
bolts (10 pieces) excluding the hinge.

270 kg
Refilling with oil

6. Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the
system. Then check the oil level again.
5 Hydraulic tank:
95 ℓ
50-146 D155AXI-8
BLY REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY

Cover
remove the mounting bolts (10 pieces) excluding the
hinge, and open engine underguard (1).

270 kg
Engine hood
Hydraulic oil cooler
3. Remove the hydraulic oil cooler assembly. For details, see “REMOVE AND INSTALL HYDRAULIC OIL
COOLER ASSEMBLY”.
Hose
4. Disconnect radiator air bleeder hose (2).
5. Disconnect radiator upper hose (3).
D155AXI-8 50-147
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY BLY
6. Disconnect aftercooler outlet flange (4).
7. Disconnect aftercooler inlet flange (5).
Aftercooler assembly
8. Sling aftercooler assembly (6), hold it, and remove the af-
tercooler mounting bolts (3 pieces) on the lower side.
9. Remove mounting bolts (8) (4 pieces) for aftercooler
mounting bracket (7), sling aftercooler assembly (6) and
remove it.
4 Aftercooler assembly (6):

45 kg
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY

1. Sling aftercooler assembly (6), install it, and tighten it with
mounting bolt (8) (4 pieces) of aftercooler mount bracket
(7).
4 Aftercooler assembly (6):

45 kg
2. Sling aftercooler assembly (6), hold it, and tighten it with
the aftercooler mounting bolts (3 pieces) on the lower side.
50-148 D155AXI-8
BLY REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
Hose
3. Install aftercooler inlet flange (5).
REMARK
Replace O-ring to be installed to the mating face of after-
cooler inlet flange (5) with a new one.
REMARK
When the aftercooler inlet hose is replaced, fasten MIKA-
LOR clamps (2 pieces) with the bolts whose positions are
180 ° apart from each other.
4. Install MIKALOR clamp of aftercooler inlet flange (5) ac-
cording to the following procedure.
1) Set bridge (BR) under clamp fastening bolt (BC), and
adjust overlap (b) between the bridge and band (BD)
to Min. 5 mm.
2) Tighten fastening bolt (BC).
REMARK
Do not use an impact wrench.
2 Threaded portion of fastening bolt (BC):
Lubricating oil (ThreeBond PANDO 18B)
Size of clamp on aftercooler inlet clamp side
(BDG)13(0/-3) mm
5. Install MIKALOR clamp on the inlet aftercooler side to the
position indicated in the figure.
Dimension (g): 80 mm
Dimension (h): 5 mm
Dimension (i): 25 mm
Dimension (j): 8 mm
6. Install aftercooler outlet flange (4).

REMARK
Replace O-ring to be installed to the mating face of after-
cooler outlet flange (4) with a new one.
REMARK
When the aftercooler outlet hose is replaced, fasten MIKA-
LOR clamps (2 pieces) with the bolts whose positions are
180 ° apart from each other.
7. Install MIKALOR clamp of aftercooler outlet flange (4) ac-
D155AXI-8 50-149
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY BLY
1) Set bridge (BR) under clamp fastening bolt (BC), and

adjust overlap (b) between the bridge and band (BD)
to Min. 5 mm.
2) Tighten fastening bolt (BC).
REMARK
Do not use an impact wrench.
2 Threaded portion of fastening bolt (BC):
Lubricating oil (ThreeBond PANDO 18B)
Size of clamp on aftercooler outlet side
(BDG)28(0/-3) mm
8. Install MIKALOR clamp on the aftercooler outlet side to the
position indicated in the figure.
Dimension (c): 80 mm
Dimension (d): 5 mm
Dimension (e): 25 mm
Dimension (f): 8 mm
9. Install radiator upper hose (3).

3 Radiator upper hose (3) clamp :
8.8±0.5 Nm {0.9±0.05 kgm}
10. Install radiator air bleeder hose (2).
Engine hood
Hydraulic oil cooler
COOLER ASSEMBLY”.
Cover
close engine underguard (1), and install the mounting bolts
(10 pieces) excluding the hinge.

270 kg
50-150 D155AXI-8
BLY REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY
Tools for removal and installation of cooling fan drive assembly
New/Redesign
Necessity
Sketch
Q'ty
Removal and installation of cooling fan

A - Eyebolt ■ 1
drive assembly
draulic tank.
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY

Draining
6 Hydraulic tank:
95 ℓ
Fan guard
2. Open right and left radiator masks (1).
D155AXI-8 50-151
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY BLY
3. Remove fan guard (2).
4 Fan guard (2):

15 kg
Connector
4. Remove connector cover (3).
5. Disconnect wiring connectors FAR1 (4) and FAR2 (5), and

remove clip (6).
Hose
6. Disconnect hydraulic hoses (7), (8) and (9).
REMARK
In order to prevent oil from flowing out, install the plugs to
the hose and fitting.
50-152 D155AXI-8
BLY REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY
Cooling fan drive

7. Sling cooling fan drive assembly (10) by using tool A, and
hold it.
8. Remove mounting bolts (11) (3 upper bolts and 2 lower
bolts).
9. Sling cooling fan drive assembly (10) and remove it.
NOTICE
Remove cooling fan drive assembly (10) so that it does
not interfere with surrounding parts.
4 Cooling fan drive assembly (10):

145 kg
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY

Cooling fan drive
1. Sling cooling fan drive assembly (10), and install it.
NOTICE
Install cooling fan drive assembly (10) so that it does
not interfere with surrounding parts.
4 Cooling fan drive assembly (10):

145 kg
2. Install mounting bolts (11) (3 pieces on upper side and 2
pieces on lower side).
Hose
3. Install hydraulic hoses (7), (8) and (9).
Connector
4. Install wiring connectors FAR1 (4) and FAR2 (5) and install
clip (6).
D155AXI-8 50-153
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY BLY
5. Install connector cover (3).
Fan guard
6. Install fan guard (2).
4 Fan guard (2):

15 kg
7. Close right and left radiator masks (1).
Refilling with oil

8. Refill the hydraulic tank with oil to the specified level through the oil filler port. Start the engine to circulate
the oil through the piping, and check the oil level again. (For details, see “TABLE OF FUEL, COOLANT,
AND LUBRICANTS”.)
5 Hydraulic tank:
95 ℓ
50-154 D155AXI-8
BLY REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY

Tools for removal and installation of cooling fan and fan motor
New/Redesign
Necessity
Sketch
Q'ty
A 790-101-3501 Gear puller ● 1 Removal of cooling fan
draulic tank.
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY

Draining hydraulic oil
6 Drain amount:
95 ℓ
Cooling fan drive
2. Remove the cooling fan drive assembly. For details, see “REMOVE AND INSTALL COOLING FAN DRIVE
ASSEMBLY”.
Cooling fan and fan motor assembly
3. Remove mounting bolt (1) and lock plate (2).
4. Loosen mounting nut (3).
5. Disconnect fan (5) together with boss (4) from the fan mo-
tor shaft by using tool A.
NOTICE
To prevent boss (4) from popping out, turn mounting
nut (3) for 3 to 4 threads.
NOTICE
Do not remove boss (4) by tapping using a hammer.
6. Remove mounting nuts (3), and remove fan (5).
D155AXI-8 50-155
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY BLY
4 Fan (5):
45 kg
7. Remove mounting bolts (6) (4 pieces), and remove cooling
fan and fan motor assembly (7).
4 Cooling fan and fan motor assembly (7):

45 kg
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY

Cooling fan and fan motor assembly
1. Install cooling fan and fan motor assembly (7), and install
4 Cooling fan and fan motor assembly (7):

45 kg
2. Install fan (5) and boss (4).
4 Fan (5) :
45 kg
REMARK
Wipe off dust, etc. on the engaging portion between the
fan motor shaft and boss (4), and degrease it.
3. Tighten mounting nut (3).
3 Mounting nut (3):
441 to 539 Nm {45 to 55 kgm}
4. Tighten lock plate with mounting bolt (1).
REMARK
Be sure to rotate mounting nut (3) in the tightening direction for the hole alignment of lock plate (2).
Cooling fan drive
5. Install the cooling fan drive assembly. For details, see “REMOVE AND INSTALL COOLING FAN DRIVE
ASSEMBLY”.
Refilling with oil
6. Refill the hydraulic tank with oil to the specified level through the oil filler port. Start the engine to circulate
the oil through the piping, and check the oil level again. (For details, see “TABLE OF FUEL, COOLANT,
AND LUBRICANTS”.)
5 Hydraulic tank :
95 ℓ
50-156 D155AXI-8
BLY REMOVE AND INSTALL ENGINE ASSEMBLY
REMOVE AND INSTALL ENGINE ASSEMBLY
k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit.
k Ask a qualified person for collecting, adding and filling operations of the refrigerant (R134a).
k Never release the refrigerant (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.
record them.
METHOD FOR REMOVING ENGINE ASSEMBLY

Air conditioner gas
1. Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit.
REMARK
Refrigerant to be collected: 900±50 g
Draining
6 Radiator:
103.5 ℓ
6 Hydraulic tank:
95 ℓ
D155AXI-8 50-157
REMOVE AND INSTALL ENGINE ASSEMBLY BLY
Engine hood assembly

Cover

270 kg
7. Support power train underguard (3) by using a lifting tool

or floor jack, remove the mounting bolts (10 pieces), and
remove power train underguard (3).
4 Power train underguard (3):

290 kg
8. Disconnect the connector WL2 (4).

50-158 D155AXI-8
10. Remove bolts (6) (2 pieces), and remove mudguard cover

(7).
REMARK
Before removing bolt (6), remove grommet.
11. Remove bolts (8) (2 pieces), then remove cover (9).

12. Remove bolts (10) (2 pieces), and remove mudguard cov-
er (11).
13. Remove bolts (12) (3 pieces), then remove cover (13).
REMARK
Before removing bolts (8), (10) and (12), remove grommet.
14. Remove the back side of bolts (2 pieces), and remove cov-
er (14).
Cooling assembly
16. Remove bolts (17) (2 pieces), and disconnect hose (18).
17. Remove bolts (19) (2 pieces), and disconnect hose (20).
18. Remove clamps (21) (2 places) and clamp (22).

19. Remove bolts (23) (2 pieces), and disconnect tube (24).
D155AXI-8 50-159
21. Remove clamp (27), and air cleaner hose (28).

22. Remove clamp (29), and disconnect hose (30).
23. Remove clamp (31), and disconnect radiator inlet hose
(32).
24. Remove clamps (34) (7 places).

25. Disconnect the connector (35) from the clip.
26. Remove bolts (36) (4 pieces) to disconnect aftercooler in-

let flange (37).
27. Remove aftercooler outlet flange (40) with bolts (38) (4

pieces) and (39) (6 pieces).

29. Disconnect the connector (42) from the clip.
50-160 D155AXI-8
30. Remove bolts (43) (8 pieces) and open both sides of radia-
tor mask (44).
31. Remove mounting bolts (45) (6 pieces), and remove both

sides of fan guard (46).
32. Remove bolts (47) (4 pieces).
33. Sling cooling assembly (49) while holding it, remove both
sides of bolts (48) (4 pieces) to remove cooling assembly
(49).
4 Cooling assembly (49):

370 kg
Hose, Connector
34. Remove clamp (50).
35. Remove the clip, and remove heater hose (51).
36. Remove the clip (52), and remove heater hose (53).
37. Disconnect starting motor cable terminal ST/B (54).
D155AXI-8 50-161
38. Disconnect air conditioner hoses (55) (2 pieces).

NOTICE
Plug the hose to prevent dust and water from entering.
40. Disconnect the connector (57).

41. Remove bolts (58) (2 pieces), and remove seat (59).
42. Disconnect terminal TRL (60).
43. Remove clamp (61), and disconnect fuel return hose (62).
44. Disconnect the connectors EG3 (63), EG4 (64), EG5 (65)
and EG2 (66).
45. Disconnect fuel hose (67).
50-162 D155AXI-8
46. Disconnect engine ground terminal (68).
Universal joint
universal joint (71) from coupling (70) on the damper side.
Engine assembly
48. Remove rear engine mount bolts (72) from the right and
left sides.
49. Remove both sides of front engine mount bolt (73).
50. Install lifting tools to the slinging bracket, sling engine as-
sembly (74), and remove it.
NOTICE
Do not sling engine assembly (74) by tools other than
the slinging bracket.
4 Engine assembly (74):

2200 kg
D155AXI-8 50-163
METHOD FOR INSTALLING ENGINE ASSEMBLY

Engine assembly
1. Install lifting tools to the slinging bracket, sling engine as-
sembly (74) and install it.
NOTICE
Do not sling engine assembly (74) by tools other than
the slinging bracket.
4 Engine assembly (74):

2200 kg
2. Install both sides of front engine mounting bolts (73).

3 Mounting bolt:
785 to 980 Nm {80 to 100 kgm}
3. Install both sides of rear engine mounting bolts (72).

3 Mounting bolt:
785 to 980 Nm {80 to 100 kgm}
Universal joint
universal joint (71) from coupling (70) on the damper side.
Adhesive (LT-2)
98 to 123 Nm {10.0 to 12.5 kgm}
50-164 D155AXI-8
Hose, Connector
5. Connect engine ground terminal (68).
6. Connect the connectors EG3 (63), EG4 (64), EG5 (65) and
EG2 (66).
7. Connect the connectors EG3 (63), EG4 (64), EG5 (65) and
EG2 (66).
8. Install fuel return hose (62).
9. Install clamp (61).
10. Connect terminal TRL (60).
11. Connect the connector (57).

12. Install seat (59) with bolts (58) (2 pieces).
D155AXI-8 50-165
13. Connect fuel supply hose (56).

14. Install air conditioner hoses (55) (2 pieces).
2 O-ring and threaded portion:
Compressor oil (DENSO: ND-OIL8)
NOTICE
• Do not remove the plug from the fitting before con-
necting the pipe.
• Be careful that dirt, dust, water, etc. do not enter
the air conditioner piping.
• Check that the O-rings are fitted to the joints when
connecting the air conditioner piping.
• Check that the O-ring is not damaged or deteriorat-
ed.
3 Mounting bolt (M6x1.0):
8 to 12 Nm {0.81 to 1.22 kgm}
15. Connect starting motor cable terminal ST/B (54).
16. Install heater hose (53).
17. Install clip (52).
18. Fit heater hose (51), and install clip.
Cooling assembly
20. Sling cooling assembly (49) and install it with both sides of
4 Cooling assembly (49):

370 kg
21. Install bolts (47) (4 pieces).
50-166 D155AXI-8
22. Install both sides of fan guards (46) with mounting bolts
(45) (6 pieces).
23. Close both sides of radiator mask (44) and install it with
24. Install connector (42) to the clip.
25. Install clamps (41) (2 places).
26. Install aftercooler outlet flange (40) with bolts (38) (4

pieces) and (39) (6 pieces).
27. Install aftercooler inlet flange (37) with bolts (36) (4

pieces).
D155AXI-8 50-167
28. Install connector (35) to the clip.

30. Install radiator inlet hose (32) and tighten it with clamp
(31).
3 Hose clamp:
8.8±0.5 Nm {0.9±0.05 kgm}
31. Install hose (30) and clamp (29).
32. Install air cleaner hose (28), and tighten it with clamp (27).
3 Hose clamp:
8.8±0.5 Nm {0.9±0.05 kgm}
33. Install tube (26) with bolts (25) (2 pieces).

REMARK
Replace O-ring to be installed to the mating face of tubes
(24) and (26) with a new one.
35. Install clamps (21) (2 places) and clamp (22).
36. Install hose (20) with bolts (19) (2 pieces).

37. Install hose (18) with bolts (17) (2 pieces).
REMARK
Replace O-ring to be installed to the mating face of tubes
(18) and (20) with a new one.
Cover
39. Install cover (14) with back side of bolts (2 pieces).
50-168 D155AXI-8
40. Install cover (13) with bolts (12) (3 pieces).

41. Install mudguard cover (11) with bolts (10) (2 pieces).
REMARK
After installing bolts (8), (10) and (12), install grommet.
43. Install mudguard cover (7) with bolts (6) (2 pieces).

REMARK
After installing bolt (6), install grommet.
44. Connect the hose(5).

45. Connect the connector WL2 (4).
46. Support power train underguard (3) by using lifting tool or

floor jack. Install power train underguard (3) with the
4 Power train underguard (3):

290 kg

jack, and install engine underguard (2) with the mounting
bolts (12 pieces).

270 kg

D155AXI-8 50-169
Oil and coolant

50. Refill the hydraulic tank with Komatsu genuine oil to the
specified level through the oil filler port. Start the engine to
circulate the oil through the piping, and check the oil level
again. (For details, see STRUCTURE AND FUNCTION,
“TABLE OF FUEL, COOLANT, AND LUBRICANTS”.)
5 Hydraulic tank:
95 ℓ
51. Refill the radiator with coolant to the specified level
through the coolant filler port. Run the engine to circulate
the coolant. Then check the coolant level again. (For details, see Structure and function, “TABLE OF FUEL,
COOLANT, AND LUBRICANTS”.)
5 Radiator:
103.5 ℓ
Air conditioner gas
52. Refill the refrigerant (air conditioner gas: R134a) from the air conditioner circuit.
REMARK
50-170 D155AXI-8
BLY REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
Tools for removal and installation of engine front oil seal
New/Redesign
Necessity
Sketch
Q'ty
795T-521-1111 Push tool ■ 1 ○

A 01050-31655 Bolt ■ 3 Installation of engine front oil seal
01050-31635 Bolt ■ 3
B 795-931-1100 Puller ■ 1 Removal of engine front seal
795T-521-1150 Push tool ■ 1 ○
C Installation of engine front oil seal
01050-31635 Bolt ■ 4
METHOD FOR REMOVING ENGINE FRONT OIL SEAL

Underguard

270 kg

3. Remove the hydraulic oil cooler assembly. For details, see “REMOVE AND INSTALL HYDRAULIC OIL
COOLER ASSEMBLY”.
D155AXI-8 50-171
REMOVE AND INSTALL ENGINE FRONT OIL SEAL BLY
4. Remove the aftercooler assembly. For details, see “REMOVE AND INSTALL AFTERCOOLER ASSEM-
BLY”.
Alternator belt
Damper
6. Remove mounting bolts (4) (6 pieces), and remove crank
pulley (5) and vibration damper (6).
4 Vibration damper (6):

40 kg
Front seal
7. Remove mounting bolts (7) (6 pieces), and remove flange (8).
8. Slightly drive in front seal (9) once before removing front
seal (9), and separate stuck seal from front cover (10).
k For the sleeved seal, cut sleeve (12) and remove it
by using a chisel, hammer, etc.
k Be careful not to damage seal mounting portion of
front cover (10) and seal contact surface of crank-
shaft (11).
REMARK
If front seal (9) cannot be removed easily since it is stuck
to front cover (10). remove it according to the following
procedure.
1) Replace tip of tool B with the drill type, and drill holes of approximately 3 mm (a few places) on front
seal (9).
k After machining, remove chips securely.
2) Insert tip of tool B into the drilled hole, and remove the
front seal by using impact power of slide hammer (SH)
(perform this evenly for the front seal not to lean).
k Be careful not to damage crankshaft (11).
50-172 D155AXI-8
9. Remove front seal (9).
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL

Front seal
1. Check wear of crankshaft (11).
NOTICE
When the wear depth of the shaft is 10 μm or less and
the shaft is free from damages, etc., install “standard
seal (A)”. Other than this, install “sleeved seal (B)”.
(13): Inner plastic tube/installation guide
(12): Sleeve
2. Check that the end corner and the lip sliding surface of
crankshaft (11), and front cover (10) are free from a flaw,
burr, sharp edge, and rust before installing front seal (9).
3. When installing front seal (9), wipe off oil on crankshaft
(11) sufficiently.
NOTICE
Do not apply oil or grease to crankshaft (11) and seal lip surface (crankshaft surrounding area).
4. Install front seal (9).
• Standard seal
D155AXI-8 50-173
1) Apply larger inside diameter side (b) of plastic in-

ner tube/installation guide (13) to the end surface
of crankshaft (11).
NOTICE
• Never remove plastic inner tube/installa-
tion guide (13) of the standard seal until
front seal (9) is installed.
• Be careful not to install plastic inner tube/
installation guide (13) in the wrong direc-
tion.
2) Apply force to the metal ring of front seal (9)
evenly by hands, and push in plastic inner tube/
installation guide (13) like riding over the larger in-
side diameter side.
NOTICE
Evenly tap by using a plastic hammer to push
in it while taking care not to deform the metal
ring.
3) Pushing in plastic inner tube/installation guide

(13) so that front seal (9) does not fall off front
cover (10), and then remove plastic inner tube/
installation guide.
NOTICE
Be careful not to damage the seal lip surface
when removing plastic inner tube/installation
guide (13).
4) Install tool A, evenly tighten tool A mounting bolts

(35 mm) (3 pieces), and press-fit front seal (9) un-
til the end surface of tool A contacts the end sur-
face of crankshaft (11).
NOTICE
by the tool set when press-fitting front seal
(9).
Press-fitting dimension (a) of front oil seal (9)
from crank shaft (11): 9.1 to 10.1 mm
• Sleeved seal
50-174 D155AXI-8
1) Set sleeved seal assembly (14) on tool C (for

press-fitting sleeved seal).
NOTICE
Handle sleeve (12) and front seal (9) as a set
part. Never remove the sleeve.
2 Inner tube surface of sleeve (12):
2) Put sleeve (12) of sleeved seal assembly (14) on-

to the end surface of crankshaft (11).
3) Evenly tighten the tool C mounting bolts (3
pieces), and press-fit sleeved seal assembly (14)
until the end surface of tool C contacts the end
surface of crankshaft (11).
4) Remove tool C, and replace it with tool A.
5) Evenly tighten tool A mounting bolts (35 mm) (3

until the end surface of tool A contacts the end
NOTICE
by the tool set when press-fitting sleeved seal
assembly (14).
Press-fitting dimension (a) of sleeved seal assem-
bly (14) from crank shaft (11): 9.1 to 10.1 mm
5. After press-fitting front seal (9), remove the red sealant
layer from its outer periphery.
Damper
6. Install flange (8) with bolt (7).
7. Install crank pulley (5) and vibration damper (6) with bolt
(4).
4 Vibration damper (6):

40 kg
245 to 309 Nm {25.0 to 31.5 kgm}
Alternator belt
D155AXI-8 50-175

COOLER ASSEMBLY”.
Underguard
jack, and install engine underguard (1) with the mounting
bolts (12 pieces).

270 kg
50-176 D155AXI-8
BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL

Tools for removal and installation of engine rear oil seal
New/Redesign
Necessity
Sketch
Q'ty
A 795-931-1100 Seal puller ■ 1

795T-421-1270 Push tool ■ 1 ○
B 01050-31645 Bolt ■ 4
01643-31645 Washer ■ 8 Installation of engine rear oil seal
795T-421-1240 Push tool ■ 1 ○
C 01050-31645 Bolt ■ 4
01643-31645 Washer ■ 4
D 790-331-1110 Wrench ● 1 Removal of engine rear seal
795T-421-1250 Push tool ■ 1 ○
E 01050-31645 Bolt ■ 4 Installation of engine rear oil seal
01643-31645 Washer ■ 8
F - Eyebolt ■ 1 Removal and installation of flywheel
Measurement of facial runout and radial
G - Dial gauge ■ 1
runout
METHOD FOR REMOVING ENGINE REAR OIL SEAL

Engine assembly
1. Remove the engine assembly. For details, see “REMOVE AND INSTALL ENGINE ASSEMBLY”.
Damper assembly
2. Remove damper assembly (1). For details, see “REMOVE
AND INSTALL DAMPER ASSEMBLY”.
D155AXI-8 50-177
REMOVE AND INSTALL ENGINE REAR OIL SEAL BLY
Flywheel
3. Install tool F to flywheel (2), sling the flywheel, hold it, and
remove bolt (3).
4. Pull flywheel (2) forward gradually, sling it, and remove it.
NOTICE
Since the spigot joint portion of flywheel (2) is shallow,
the flywheel may fall off suddenly. Be careful not to get
your finger caught.
4 Flywheel (2):
60 kg
Rear seal
5. Measure the dimension from the end surface of flywheel
housing (5) before removing rear seal (4).
6. Slightly drive in rear seal (4) once before removing rear
seal (4), and separate stuck seal from flywheel housing
(5).
NOTICE
• For the sleeved seal, cut sleeve (6) and remove it
by using a chisel, hammer, etc.
• Be careful not to damage crankshaft (7).
7. Hook tip of tool A to the metal ring of rear seal (4), and re-
move it by using impact power of slide hammer (SH) (per-
form this evenly for the rear seal not to lean).
NOTICE
• Do not use a drill, etc. since chips may enter the
engine.
• If chips are created, remove them securely.
REMARK
• The seal type is single seal (dry in the flywheel hous-
ing).
• Depending on the conditions, either of “standard seal
(A)” or “sleeved seal (B)” is installed.
50-178 D155AXI-8
METHOD FOR INSTALLING ENGINE REAR OIL SEAL

Rear seal
1. Check wear of crankshaft (7).
NOTICE
When the wear depth of the shaft is 10 μm or less and
the shaft is free from damages, etc., install “standard
seal (A)”. Other than this, install “sleeved seal (B)”.
(8): Inner plastic tube/installation guide
(6): Sleeve
2. Clean, degrease, and dry the contact surface against fly-

wheel housing (5).
3. Check that the end corner and the lip sliding surface of
crankshaft (7), and flywheel housing (5) are free from a
flaw, burr, sharp edge, and rust before installing rear seal
(4).
4. When installing rear seal (4), wipe off oil on crankshaft (7)
sufficiently.
NOTICE
Do not apply oil or grease to crankshaft (7) and seal lip
surface (crankshaft surrounding area).
5. Install rear seal (4).
• Standard seal
1) Apply larger inside diameter side (b) of plastic in-
ner tube/installation guide (8) to the end surface
of crankshaft (7).
NOTICE
• Never remove plastic inner tube/installa-
tion guide (8) of the standard seal until rear
seal (4) is installed.
• Be careful not to install plastic inner tube/
installation guide (8) in the wrong direc-
tion.
2) Apply force to the metal ring of rear seal (4) even-
ly by hands, and push in plastic inner tube/installation guide (8) like riding over the larger inside
diameter side.
NOTICE
Evenly tap by using a plastic hammer to push in it while taking care not to deform the metal
ring.
D155AXI-8 50-179
3) Pushing in plastic inner tube/installation guide (8)

so that rear seal (4) does not fall off flywheel
housing (5), and then remove plastic inner tube/
installation guide.
NOTICE
when removing plastic inner tube/installation
guide (8).
4) Install tool B, evenly tighten tool B mounting bolts

(4 pieces), and press-fit rear seal (4) until the end
surface of tool B contacts the end surface of
crankshaft (7).
NOTICE
by the tool set when press-fitting rear seal (4).
REMARK
Tighten tool B mounting bolts without washers un-
til the bolts hit the bottom of the holes first, insert
washers (2 pieces), and then tighten the bolts.
• Sleeved seal
1) Set sleeved seal assembly (9) on tool C (for
press-fitting sleeved seal).
NOTICE
Handle sleeve (6) and rear seal (4) as a set
part. Never remove the sleeve.
2 Inner tube surface of sleeve (6):
2) Put sleeve (6) of sleeved seal assembly (9) onto

the end surface of crankshaft (7).
3) Evenly tighten the tool C mounting bolt (4 pieces),
and press-fit sleeved seal assembly (9) until the
end surface of tool C contacts the end surface of
crankshaft (7).
4) Remove tool C, and replace it with tool E.
50-180 D155AXI-8
5) Evenly tighten the tool E mounting bolts (3

until the end surface of tool E contacts the end
NOTICE
by the tool set when press-fitting sleeved seal
assembly (9).
REMARK
Tighten tool E mounting bolts without washers un-
til the bolts hit the bottom of the holes first, insert
washers (2 pieces), and then tighten the bolts.
Press-fitting depth of rear seal: From end surface of crankshaft (7) 13.2±0.2 mm
6. After press-fitting rear seal (4), remove the red sealant layer from its outer periphery.
Flywheel
7. Sling flywheel (2) by using tool F, install it to the crank-
shaft, and then tighten bolt (3).
NOTICE
The bolt which has 5 punch marks must be replaced
with a new one without being reused.
4 Flywheel (1):
60 kg
2 Threaded portion of bolt, seat surface:
Engine oil
8. Tighten the mounting bolt.
1) Tighten the bolt (1st time).
3 Flywheel mounting bolt:
118±4.9 Nm {12±0.5 kgm}
2) Tighten the bolt (2nd time) in order of (1) to (8) as
shown in the figure.
REMARK
When not using tool D, put marks (f) on the bolt and
flywheel, and then tighten the bolt (2nd time).
3 Flywheel mounting bolt:
90(+30/0) °
9. After tightening the bolt, put a punch mark (g) on each bolt
head to indicate the number of tightening.
REMARK
Do not put a punch mark when replacing the bolt with a
new one.
D155AXI-8 50-181
10. After installing the flywheel, measure the radial runout and
facial runout by using tool G.
Facial runout0.20 mm or less
Radial runout0.13 mm or less
Damper assembly
11. Install damper assembly (1). For details, see “REMOVE
AND INSTALL DAMPER ASSEMBLY”.
Engine assembly
12. Install the engine assembly. For details, see “REMOVE AND INSTALL ENGINE ASSEMBLY”.
50-182 D155AXI-8
BLY REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY

METHOD FOR REMOVING ENGINE HOOD ASSEMBLY

Smaller hood
2. Remove wiring harness (2) on the back side of cover (1).
3. Remove coolant filler port cover (3).
4. Disconnect connector LHD (4).
D155AXI-8 50-183
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY BLY
5. Remove smaller hood (5).
4 Smaller hood:
55 kg
Cover, connector
6. Disconnect connector RDG (6).

NOTICE
Check that they are securely fixed with the lock.
10. Remove covers (11) and (12).
11. Disconnect connectors PRT1 (13), EG6 (14), PRT2 (15).
50-184 D155AXI-8
12. Loosen clamp (16), and disconnect hose (17).

REMARK
• Cover the openings of disconnected hose and air
cleaner with vinyl, etc. to prevent dust from entering.
• Keep the opening covered with vinyl until just before
they are assembled.
NOTICE

15. Remove the grommet at the rear of the engine hood, and
remove mounting bolts (22) (2 pieces).
16. Remove mounting bolts (23) (2 pieces) at the front of the

engine hood, sling engine hood assembly (24), and re-
move it.
4 Engine hood assembly:

200 kg
REMARK
Remove the engine hood assembly together with the air
cleaner assembly as a unit.
D155AXI-8 50-185
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY

1. Sling engine hood assembly (24), set it, and install bolts
(23) (2 pieces) on the front side of the engine hood.
4 Engine hood assembly:

200 kg
REMARK
Install engine hood assembly together with air cleaner as-
sembly as a unit.
2. Install bolts (22) (2 pieces) on the rear side of the engine

hood, and install the grommet.
Cover, connector
3. Install covers (20) and (21).
4. Close engine left side covers (18) and (19).
50-186 D155AXI-8
5. Install hose (17) and fasten it with clamp (16).

3 Clamp:
8.8±0.5 Nm {0.9±0.05 kgm}
6. Connect connectors PRT1 (13), EG6 (14), and PRT2 (15).
8. Install the cover (10).

9. Close engine right side covers (8) and (9).

11. Connect connector RDG (6).
D155AXI-8 50-187
Smaller hood
12. Install smaller hood (5).
4 Smaller hood:
55 kg
13. Connect connector LHD (4).
14. Install coolant filler port cover (3).
15. Install wiring harness (2) on the back side of cover (1).
16. Install the cover (1).
50-188 D155AXI-8
BLY REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY

METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY

Battery cover
1. Open covers (1) and (2).
2. Remove connector (3) from battery cover (4).

4. Remove bolts (6) (2 pieces) and move bracket (7) aside so
that it does not hinder the work.
5. Disconnect washer hose (8).

8. Remove breather joint (12).

D155AXI-8 50-189
REMOVE AND INSTALL FUEL TANK ASSEMBLY BLY
12. Close cover (2), and remove it from parts (a) (3 places) of
battery cover (4) by using the nylon sling.
Hose
13. Remove bolts (16) (4 pieces), and remove fuel tank bottom
cover (17).

REMARK
In order to prevent fuel from flowing out, install the plugs to
50-190 D155AXI-8
16. Disconnect wiring connector FTK (20).

Receiver assembly
18. Remove bolts (22) (3 pieces), and move receiver assem-
bly (23) aside so that it does not hinder the work.
Fuel tank assembly

19. Disconnect fuel return hoses (24) (2 pieces).
REMARK
In order to prevent fuel from flowing out, install the plugs to
20. Remove bolts (25) (4 pieces), and remove bracket for sling
(26) (2 pieces).
21. Install bracket (26) to bracket mounting part (b) on right
and left sides by using bolts (25).
D155AXI-8 50-191
22. Remove mounting bolts (27) (8 pieces), sling fuel tank as-
sembly (28), and remove it.
4 Fuel tank assembly (28) (when the tank is empty):

420 kg
4 Fuel tank assembly (28) (when the tank is full):

950 kg
METHOD FOR INSTALLING FUEL TANK ASSEMBLY

Fuel tank assembly
1. Set cushion (30), (31), and boss (32) to frame (29).
2. Sling fuel tank assembly (28), hold it, set plate (33) to
mounting bolt (27) (8 pieces), and install fuel tank assem-
bly (28).
4 Fuel tank assembly (28) (when the tank is empty):

420 kg
4 Fuel tank assembly (28) (when the tank is full):

950 kg
3. Install fuel return hose (24) (2 pieces).
50-192 D155AXI-8
Receiver assembly
4. Install receiver assembly (23) with bolts (22) (3 pieces).
5. Connect wiring connector FTK (20).

Hose
9. Install fuel tank bottom cover (17) with bolts (16) (4

pieces).
D155AXI-8 50-193
Battery cover
10. Close cover (2), and install it to parts (a) (3 places) of bat-
tery cover (4) by using the nylon sling.
REMARK
Place it on the fender, and then slightly open cover (2) to
check the position.

14. Install breather joint (12).
3 breather joint (12):
51.0to 85.3 Nm {5.2 to 8.7 kgm}

Mounting bolt (9)34.3to 64.1 Nm {3.5to 6.5 kgm}
17. Connect washer hose (8).
50-194 D155AXI-8
18. Install bracket (7) with bolts (6) (2 pieces).

19. Install connector (3) to battery cover (4).
21. Close covers (1) and (2).

22. Check the fuel system for leakage. For details, see TEST-
ING AND ADJUSTING, “TEST FUEL CIRCUIT FOR
LEAKAGE”.
23. Bleed air from the fuel system. For details, see TESTING
AND ADJUSTING, “BLEEDING AIR FROM FUEL SYS-
TEM”.
D155AXI-8 50-195
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY BLY
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY
Tools for removal and installation of AdBlue/DEF tank assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Oil pan ■ 1 N
B - Valve ■ 1
- Hose ■ 1
Draining of AdBlue/DEF
D - Funnel ■ 1
E - Hose ■ 1
ue/DEF hose
J 600-919-5030 ■ 1
inch)
k Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING
AND ADJUSTING, “HANDLING BATTERY DISCONNECT SWITCH”.)
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY

Battery cover
50-196 D155AXI-8
BLY REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY
2. Disconnect connector (3) from battery cover (4).


8. Remove breather (12).

D155AXI-8 50-197
Draining from AdBlue/DEF tank

13. Remove bolts (16) (2 pieces), and remove cover (17).
14. Check that cap (18) is securely closed.
15. Place tool C on the track shoe for future use as described
in the following steps.
16. Prepare tool A under AdBlue/DEF tank.
REMARK
Toxic gas or corroded material may be generated by a
chemical reaction if an iron or aluminum container is used
to catch the draining AdBlue/DEF from the machine. Use a
container made of resin (PP, PE) or stainless steel to catch
the draining AdBlue/DEF.
17. Disconnect breather hose (19), and connect tool B.
50-198 D155AXI-8
REMARK
When connecting tool B, be sure to close valve B1 of tool
B.
18. Loosen drain plug (20) 6 turns, and drain AdBlue/DEF into
tool A.
6 AdBlue/DEF tank:
73 ℓ
NOTICE
When handling AdBlue/DEF, be sure to use tool G.
REMARK
There is a slit (a) at threaded portion of drain plug (20) so
that AdBlue/DEF is not drained too much and splashed.
19. After the draining rate decreases in 3 to 4 minutes, remove
drain plug (20).
REMARK
The guide until draining is weakened is approximately
1.8 ℓ.
D155AXI-8 50-199
20. After removing drain plug (20), draining amount increases

or decreases in approximately 10 seconds. Change tool A
to tool D at the timing of decreasing.
REMARK
Through tool E, insert tip of tool D into tool F that is placed
on the ground.
21. Pinch tool D by using tool C to fix it.
22. Fully open valve B1 of tool B.

23. When tool F is nearly fully filled, securely close valve B1 of
tool B.
24. After closing valve B1, draining amount increases or de-
creases in approximately 10 seconds. Change tool F to
tool E at the timing of decreasing.
REMARK
0.9 ℓ.
25. When AdBlue/DEF tank becomes empty, install drain plug
(20) securely.
3 Drain plug (20):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
50-200 D155AXI-8
Draining coolant
27. Loosen drain plug (22), and drain the coolant.
6 Radiator:
103.5 ℓ
Hose, Connector
29. Disconnect connector UHV2 (25).

31. Disconnect coolant outlet hose (27).
32. Disconnect coolant inlet hose (28).
35. Before removing AdBlue/DEF hoses (31) and (32), wash
their connections with clean tap water to remove the stick-
ing materials.
NOTICE
• When handling AdBlue/DEF, be sure to use tool G.
D155AXI-8 50-201
• After disconnecting AdBlue/DEF hose, install tool

H to the hose side and install tool J to the nipple
side to prevent leakage.
36. Pinch protruding portions (e) of clip with your fingers, and
the lock is released. While they are kept pinched, pull out
AdBlue/DEF hoses (31) and (32) in the opposite direction
to AdBlue/DEF tank side, and remove it.
AdBlue/DEF tank assembly

37. Remove bracket (33).
38. Remove nut (34), and remove holder (35).
39. Remove AdBlue/DEF tank assembly (36).
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY

50-202 D155AXI-8
NOTICE
1. Install AdBlue/DEF tank assembly (36).

2. Install holder (35) with nut (34).
3. Install bracket (33).
Hose, connector
4. Wash the connection of AdBlue/DEF hoses (31), (32), and
pin (m) with clean city water to remove the sticking materi-
als. Check the AdBlue/DEF hoses and pin (m) are not
damaged.
5. Insert connectors (n) of AdBlue/DEF hoses (31) and (32)
into pin (m) on the injector side until click sound is heard to
install them.
REMARK
When it is inserted until the convex part of pin (m) passes
the convex part inside the clip, it can be locked by the clip.
8. Install coolant inlet port hose (28).
9. Install coolant outlet hose (27).
11. Install breather hose (19).
12. Install connector UHV2 (25).
D155AXI-8 50-203
Battery cover
REMARK
check the position.

19. Install breather (12).
50-204 D155AXI-8


Refilling with AdBlue/DEF

26. Refill with AdBlue/DEF to the specified level through the filler port of the AdBlue/DEF tank.

28. Tighten drain plug (22).
D155AXI-8 50-205

the coolant. Then check the coolant level again.
5 Radiator:
103.5 ℓ
50-206 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE AS-
BLY SEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY

Tools for removal and installation of AdBlue/DEF tank sensor flange assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Oil pan ■ 1 N
B - Valve ■ 1
- Hose ■ 1
D - Funnel ■ 1
E - Hose ■ 1
ue/DEF hose
J 600-919-5030 ■ 1
inch)
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY

Battery cover

D155AXI-8 50-207
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE AS- 50 DISASSEMBLY AND ASSEM-
SEMBLY BLY


50-208 D155AXI-8
BLY SEMBLY

in the following steps.
REMARK
REMARK
B.
D155AXI-8 50-209
SEMBLY BLY
tool A.
6 AdBlue/DEF tank:
73 ℓ
NOTICE
REMARK
19. After the draining rate decreases in 3 to 4 minutes, remove
drain plug (20).
REMARK
1.8 ℓ.

REMARK
Through tool E, insert tip of tool D into tool F that is placed
on the ground.
50-210 D155AXI-8
BLY SEMBLY

23. When tool F is nearly fully filled, securely close valve B1 of
tool B.
creases in approximately 10 seconds. Change tool F to
tool E at the timing of decreasing.
REMARK
0.9 ℓ.
25. When AdBlue/DEF tank becomes empty, install drain plug
(20) securely.
3 Drain plug (20):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Draining coolant
6 Radiator:
103.5 ℓ
D155AXI-8 50-211
SEMBLY BLY
Hose, Connector
29. Disconnect connector UHV2 (25).

32. Disconnect coolant inlet hose (28).
35. Before removing AdBlue/DEF hoses (31) and (32), wash
their connections with clean tap water to remove the stick-
ing materials.
NOTICE
H to the hose side and install tool J to the nipple
side to prevent leakage.
AdBlue/DEF hoses (31) and (32) in the opposite direction
to AdBlue/DEF tank side, and remove it.
50-212 D155AXI-8
BLY SEMBLY
AdBlue/DEF tank sensor flange assembly

37. Remove bolts (33) (12 pieces), and remove AdBlue/DEF
tank sensor flange assembly (34).
NOTICE
Pull out tip (f) of AdBlue/DEF tank sensor flange as-
sembly (34) carefully not to interfere with the edge (g)
of the tank.
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY

D155AXI-8 50-213
SEMBLY BLY
NOTICE
1. Install O-rings (35) and (36), and install AdBlue/DEF tank

sensor (34).
NOTICE
• Use brand new O-rings (35) and (36).
• Check if tip (h) of AdBlue/DEF tank sensor (34) is
certainly inserted into tank groove bottom (j).
NOTICE
Install AdBlue/DEF tank sensor (34) according to the
following procedures to prevent O-rings (35) and (36)
from damaged, falling off, being caught, and twisted.
1) Apply distilled water for lubricating O-rings (35) and
(36).
2 O-rings (35) and (36):
Distilled water
REMARK
If any foreign material is mixed into AdBlue/DEF tank,
it may be the cause of the failure. Do not use grease,
lubricating oil or any lubricating substance.
2. Install AdBlue/DEF tank flange sensor assembly (34) with
9.5 to 10.5 Nm {0.97 to 1.07 kgm}
50-214 D155AXI-8
BLY SEMBLY
Hose, connector
3. Wash the connection of AdBlue/DEF hoses (31), (32), and
pin (m) with clean city water to remove the sticking materi-
als. Check the AdBlue/DEF hoses and pin (m) are not
damaged.
4. Insert connectors (n) of AdBlue/DEF hoses (31) and (32)
into pin (m) on the injector side until click sound is heard to
install them.
REMARK
When it is inserted until the convex part of pin (m) passes
11. Install connector UHV2 (25).
Battery cover
REMARK
check the position.
D155AXI-8 50-215
SEMBLY BLY




50-216 D155AXI-8
BLY SEMBLY


5 Radiator:
103.5 ℓ
D155AXI-8 50-217
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR BLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR

METHOD FOR REMOVING AdBlue/DEF TANK SENSOR
1. Remove AdBlue/DEF tank sensor flange assembly. For details, see “REMOVE AND INSTALL AdBlue/DEF
TANK SENSOR FLANGE ASSEMBLY”.
AdBlue/DEF tank sensor
3. Remove mounting bolts (2) (4 pieces), and remove AdBl-
ue/DEF tank sensor (3).
NOTICE
Pull out tip (a) of AdBlue/DEF tank sensor (3) carefully
not to interfere with edge (b) of AdBlue/DEF tank sen-
sor flange assembly.
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR

AdBlue/DEF tank sensor
REMARK
• Use a new O-ring.
• If any foreign material is mixed into AdBlue/DEF tank, it
may be the cause of the failure. Do not use grease, lu-
bricating oil or any lubricating substance.
• Apply distilled water to O-ring (4) for lubricating.
2 O-ring (4):
Distilled water
2. Install AdBlue/DEF sensor (3) with mounting bolt (2).
REMARK
• Do not turn AdBlue/DEF tank sensor (3) to prevent O-
ring (4) from falling off and twisting.
• To prevent O-ring (4) from biting into the sensor, press
the top of AdBlue/DEF tank sensor (3) by hands to seat
the flange on the mounting face.
3 Mounting bolt:
11.89 to 14.7 Nm{1.2 to 1.5 kgm}
50-218 D155AXI-8
BLY REMOVE AND INSTALL AdBlue/DEF TANK SENSOR

4. Install AdBlue/DEF tank sensor flange assembly. For details, see “REMOVE AND INSTALL AdBlue/DEF
D155AXI-8 50-219
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER BLY
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER

METHOD FOR REMOVING AdBlue/DEF TANK STRAINER
1. Remove AdBlue/DEF tank sensor flange assembly. For details, see “REMOVE AND INSTALL AdBlue/DEF
AdBlue/DEF tank strainer
2. Remove mounting bolts (1), and remove strainer (2).
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER

Strainer
REMARK
• Use a brand new O-ring.
• If any foreign material is mixed into AdBlue/DEF tank, it
may be the cause of the failure. Do not use grease, lu-
bricating oil or any lubricating substance.
• Apply distilled water for lubricating O-ring (3).
2 O-ring:
Distilled water
2. Install strainer (2) with mounting bolt (1).
3 Mounting bolt:
4.9 to 5.9 Nm{0.5 to 0.6 kgm}

3. Install AdBlue/DEF tank sensor flange assembly. For details, see “REMOVE AND INSTALL AdBlue/DEF
50-220 D155AXI-8
BLY REMOVE AND INSTALL KDPF ASSEMBLY
REMOVE AND INSTALL KDPF ASSEMBLY
Tools for removal and installation of KDPF assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Digital angle gauge ● 1 For measurement of KDPF outlet angle
k Since the KDPF is heated to 500 °C or above, be careful not to get burn injury.
k Wait until the temperature of KDPF to cool down before starting any work.
k Check that no combustible materials (dry leaves, twigs, etc.) accumulated around KDPF. If any dirt or
combustible materials are found, remove them.
k KDPF is fragile against shock such as falling, handle it with care, and never use damaged part.
k Manage the service life of KDPF by recording each history, and do not use KDPF that exceeds its
service life.
METHOD FOR REMOVING KDPF ASSEMBLY

AdBlue/DEF mixing tube
1. Remove AdBlue/DEF mixing tube (1). For details, see “RE-
MOVE AND INSTALL AdBlue/DEF MIXING TUBE”.
D155AXI-8 50-221
REMOVE AND INSTALL KDPF ASSEMBLY BLY
Wiring, Piping
2. Remove clamps (3) (7 pieces) of wiring harness (2).
3. Remove clamps (5) (10 pieces) of hose (4), and reposition
hose (5) out of the way.
4. Slide the lever (red) of connector PDPF (6) in the direction

of the arrow to unlock it.
5. Pull out DPF pressure sensor connector PDPF (6) in the

direction of the arrow while pushing the knob at the top of
the connector to disconnect it.
6. Slide the lever (yellow) on connector DPFJ (7) in the direc-

tion of the arrow to unlock it, and disconnect connector
DPFJ (7). (For details, see the following.)
50-222 D155AXI-8
1) Insert a flat-head screwdriver, etc. into the claw part

(b) of connector lever (yellow) (a), and unlock it.
2) Pinch lever (yellow) (a) with fingers, and slide it.
REMARK
Do not remove lever (yellow) (a).
3) Disconnect connector DPFJ (7) while pulling it in the
direction opposite to the sensor side.
7. Disconnect connectors PDPF (6) and DPFJ (7), and then

reposition wiring harness (2) out of the way.
Exhaust pipe
8. Remove mounting bolts (8) (4 pieces), and disconnect ex-
haust pipe (9) from KDPF assembly (10).
NOTICE
Take care not to deform the bellows part (f) of exhaust
pipe (9) having been disconnected.
KDPF assembly, Bracket

9. Install a lifting tool to slinging position (a) of KDPF assem-
bly (10), sling KDPF assembly (10) and bracket (11), and
hold them.
10. Remove mounting bolts (12) (4 pieces), sling KDPF as-
sembly (10) together with bracket (11) as a unit, and re-
move them.
4 KDPF assembly (10) and bracket (11):

110 kg
D155AXI-8 50-223
REMARK
Be careful not to lose dowel pins (13) (2 pieces) when removing bracket (11).
11. Place removed KDPF assembly (10) and bracket (11) on a stable place.
NOTICE
Block the hole to avoid entry of foreign material or damage to the exhaust pipe.
KDPF assembly angle measurement
12. Measure the mounting angle of KDPF assembly (10) to the
bracket by using tool A according to the following proce-
dure.
1) Measure angle (c) to reference plane (b) at the ex-
haust pipe outlet.
2) Record the measured angle as this will be used as the
reference at the time of installation.
U-bolt
13. Remove nuts (14) (4 pieces) and (15) (4 pieces), and re-
move U-bolt (16).
Bracket
14. Sling KDPF assembly (10) and hold it. Remove mounting
bolts (17) (4 pieces), and remove bracket (11) from KDPF
assembly (10).
4 KDPF assembly (10):

77 kg
METHOD FOR INSTALLING KDPF ASSEMBLY

Bracket
1. Sling KDPF assembly (10) by using a lifting tool, and set it
to bracket assembly (11).

77 kg
50-224 D155AXI-8
Installing U-bolts loosely

2. Install U-bolts (16) loosely with nuts (14) and (15).
Angle Adjusting of KDPF assembly

3. Adjust the mounting angle of KDPF assembly (10) to the
dure.
1) Place tool A on top surface (d) of KDPF assembly
(10), and adjust the angle to 0±0.5 °.
2) Adjust angle (c) to 30±0.5 ° against standard surface
(b) at the exhaust pipe outlet.
4. Install KDPF assembly (11) with bolts (17) (4 pieces).
Tightening U-bolts to specified torque

5. Tighten U-bolts (16) according to the following procedure.
1) Tighten nuts (15) (4 pieces) evenly.
3 Nut (15):
20.6 to 27.4 Nm {2.1 to 2.8 kgm}
3 Nut (14):
29.4 to 39.2 Nm {3.0 to 4.0 kgm}
3) Turn nuts (15) (4 pieces) slightly in the loosening di-
rection.
4) Make sure that dimension (e) from U-bolt (16) end to lower mounting nut (14) are even at both sides.
D155AXI-8 50-225
KDPF assembly, Bracket

6. Install a lifting tool to slinging position (a) of KDPF assem-
bly (10), sling KDPF assembly (10) together with bracket
(11) as a unit, and then decide the position with dowel pin
(13) to set the unit onto the base bracket.
REMARK
Apply liquid gasket to dowel pin (13).
2 Dowel pin (13):
4 KDPF assembly (10) and bracket (11):

110 kg
NOTICE
Avoid entry of foreign material or damage to the exhaust pipe.
7. Install KDPF assembly (10) and bracket (11) with mounting bolts (12) (4 pieces).
Exhaust pipe
8. Install gasket (9a) to exhaust pipe (9).
NOTICE
• Use a brand new gasket.
• Install gasket to make the downstream side of gas
flow (g) is convex (k) to gasket.
9. Install exhaust pipe (9) to KDPF assembly (10) with

NOTICE
Take care not to deform the bellows part (f) of exhaust
pipe (9) while performing work.
2 Mounting bolt threaded part:
78.5 to 88.3 Nm {8.0 to 9.0 kgm}
50-226 D155AXI-8
Wiring, Bracket
10. Install connector PDPF (6) and connector DPFJ (7) ac-
1) Slide the lever (red) in the direction of the arrow, insert
connector PDPF (6) with the lock released, and slide it
in the opposite direction of the arrow to lock it.
2) Slide the lever (yellow) in the direction of the arrow, in-

sert connector DPFJ (7) with the lock released, and
slide it in the opposite direction of the arrow to install
it. (For details, see the following.)
3) While keeping lever (yellow) (a) pulled up, insert con-

nector DPFJ (7) into sensor.
D155AXI-8 50-227
4) Push lever (yellow) (a) with your finger until the click
sound is heard, connector becomes locked.
11. Install hoses (4).

12. Install clamps (5) (10 pieces).
13. Install clamps (3) (7 pieces) of the wiring harness (2).

14. Install AdBlue/DEF mixing tube (1). For details, see “RE-
50-228 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY
Disassembly of KDPF assembly, Assembly tool
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 4 Fixing KDPF assembly

Removal and installation of DPF as-
B - Lifting tool ■ 2
sembly
Removal and installation of sensor ta-
C - Long socket ■ 1
ble
D - Level gauge ■ 1 Assembly of KDPF assembly
k Wear anti-dust masks since soot, ash, mat material, and metallic powder accumulated in the KDPF
may be inhaled when cleaning, replacing, and disposing KDPF.
k KDPF is fragile against shock such as falling, handle with care, and never use damaged part.
k Manage the service life of KDPF by recording each history, and do not use KDPF that exceeds its
service life.
k The band used to mount the KDPF is made of stainless steel and threaded portion may be damaged,
accordingly never use an impact wrench for removal and installation.
REMARK
• After cleaning and replacing KDPF, perform the work as shown below.
• Clean the KDPF itself and related parts and degrease them.
• After installing the assembly to the machine, start the engine and then check for oil leakage and soot
attached.
• When mounting bands or gaskets were removed, prepare brand new ones.
• For the tools to be used whose sizes are expressed in both units of mm and inch, use the general tools.
METHOD FOR DISASSEMBLING KDPF ASSEMBLY

Preparation
1. Prepare tool A of dimension in the right figure.
D155AXI-8 50-229
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY BLY
REMARK
• For details of tool A, see the following dimension draw-
ing.
Dimension (W): Approximately 500 mm
Dimension (H): Approximately 275 mm
Dimension (D): Approximately 100 mm
Dimension (A): Approximately 400 mm
2. Install tool B, sling KDPF assembly (1), and hold it.

3. Remove U-bolts (2) (2 pieces).
4. Remove bolts (3) (4 pieces), and remove KDPF assembly
(1) from bracket (4).
5. Set KDPF assembly (1) on tool A so that it does not touch
piping or band, and securely fix it.

75 kg
50-230 D155AXI-8
Marking
6. Mark at 3 points (e), (f), and (g) of each body connection in
the circumferential direction.
NOTICE
These marks are required to facilitate the angle adjust-
ment of KDPF inlet and outlet flanges securely in as-
sembly work.
(a): Connection of inlet (5) and KDOC (6) (3 points in the
circumferential direction)
(b): Connection of KDOC (6) and KCSF (7) (3 points in the
(b): Connection of KDOC (7) and outlet (8) (3 points in the
Temperature sensor
NOTICE
Put the marks to clamp installation positions.
D155AXI-8 50-231
8. Loosen mounting nuts (10) and (11), hold metal portions

(h) of KDOC inlet temperature sensor (12) and KDOC out-
let temperature sensor (13) by hand, and pull out them
straight in the direction of the arrow.
REMARK
KDOC inlet temperature sensor mounting nut (width
across flats): 17 mm
KDOC outlet temperature sensor mounting nut (width
9. Loosen mounting nuts (14), hold metal portion (h) of KDPF

outlet temperature sensor (15) by hand, and pull out it
straight in the direction of the arrow.
REMARK
KDPF outlet temperature sensor mounting nut (width
10. Remove bolts (16) (2 pieces), and remove temperature

sensor (17).
REMARK
Mounting bolt (width across flats): 10 mm
50-232 D155AXI-8
KDPF differential pressure sensor

11. Remove clamps (18) and (19).
REMARK
Clamp mounting bolt (width across flats): 14 mm
12. Pull out piping connectors (21) and (22) from differential
pressure sensor (20) while pushing portion (i) of the con-
nectors in the direction of the arrow.
13. Loosen mounting nuts (23) and (24), and pull out differen-
tial pressure sensor Hi piping (25) and differential pressure
sensor Lo piping (26) vertically.
Differential pressure sensor Hi piping mounting nut (width
across flats): 17.46 mm {11/16 in}
Differential pressure sensor Lo piping mounting nut (width
across flats): 15.88 mm {5/8 in}
14. Remove bolts (27) (2 pieces), and remove KDPF differen-

tial pressure sensor (20).
REMARK
Sensor table
15. Remove band (28) by using tool C, and remove sensor ta-
ble (29).
NOTICE
• Band (28) is made of stainless steel, accordingly
never use an impact wrench for tightening.
• Reuse of band (28) is not allowed. Discard it.
REMARK
Band (28) mounting nut (width across flats) : 11.1 mm
{7/16 in}
D155AXI-8 50-233
KDPF assembly
16. Remove mounting bolts (30) (12 pieces) of inlet (5) and
KDOC (6), mounting bolts (31) (13 pieces) of KDOC (6)
and KCSF (7), and mounting bolts (32) (12 pieces) of
KCSF (7) and outlet (8).
REMARK
Be careful that the length of the mounting bolt of the part
which has clamp (33), etc. is different from other bolts.
17. Install backup plate (34), and gasket (35).

18. Disconnect inlet (5), KDOC (6), KCSF (7), and outlet (8).
NOTICE
Be careful not to topple or drop each body.
METHOD FOR ASSEMBLING KDPF ASSEMBLY

KDPF assembly
1. Securely fix tool A which are used for disassembling the
bottom of each body.
2. Set inlet (5), KDOC (6), KCSF (7), and outlet (8).
3. Securely align the match mark positions (e), (f), and (g) (3
places in the circumferential direction) with connection of
each body during disassembly.
NOTICE
If they are assembled with match marks displaced, the
flanges of KDPF inlet and outlet are installed at wrong
angle causing defective installation of exhaust pipe at
its inlet and outlet.
4. Install brand new gasket (35) to the area between the bod-
ies.
50-234 D155AXI-8
5. Install backup plate (34) and clamp (33).

6. Install mounting bolts (30) (12 pieces) of inlet (5) and
KDOC (6), mounting bolts (31) (13 pieces) of KDOC (6)
and KCSF (7), and mounting bolts (32) (12 pieces) of
KCSF (7) and outlet (8).
2 Mounting bolt:
3 Mounting bolt:
59 to 74 Nm {6.0 to 7.6 kgm}
REMARK
j: Connection between inlet (5) and KDOC (6)
k: Connection between KDOC (6) and KCSF (7)
l: Connection between KCSF (7) and outlet (8)
• Installation position of backup plate
D155AXI-8 50-235
• Length of mounting bolt

*1: Bolt tightened together with clamp and backup
plate
Sensor table
7. Install sensor table (29) loosely with band (29) by using
tool C.
NOTICE
• Band (28) is made of stainless steel, accordingly
never use an impact wrench for tightening.
• Use a brand new band (28).
KDPF differential pressure sensor

8. Install KDPF differential pressure sensor (20) with bolts
(27) (2 pieces).
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
REMARK
9. Temporarily assemble differential pressure sensor Hi pip-

ing (25), differential pressure sensor Lo piping (26), and
clamps (18) and (19) (2 places).
10. Install piping connectors (21) and (22) to differential pres-
sure sensor (20).
REMARK
Check that “locking” sound is heard when piping connec-
tors (21) and (22) are inserted.
50-236 D155AXI-8
11. Position differential pressure sensor Hi piping (25) and differential pressure sensor Lo piping (26), and
check that they are not unnecessarily stressed.
12. Tighten band (28) to the specified torque.
3 Band (28) bolt:
6.3 to 8.3 Nm {0.64 to 0.85 kgm}
NOTICE
Do not use an impact wrench since band (28) is made
of stainless steel.
REMARK
Mounting nut (width across flats) of band (28): 11.1 mm
{7/16 in}
13. Tighten differential pressure sensor Lo piping mounting nut (24) to the specified torque.
3 Mounting nut (24):
13.6 to 19.0 Nm {1.39 to 1.94 kgm}
REMARK
Differential pressure sensor Lo piping mounting nut (width across flats): 15.88 mm {5/8 in}
14. Tighten differential pressure sensor Hi piping mounting nut (23) to the specified torque.
24.5 to 36.5 Nm {2.5 to 3.7 kgm}
REMARK
Differential pressure sensor Hi piping mounting nut (width across flats): 17.46 mm {11/16 in}
15. Loosen clamps (18) and (19) to the specified torque.
3 Clamp mounting bolts (18) and (19):
10.8 to 26.0 Nm {1.1 to 2.7 kgm}
REMARK
Clamp mounting bolt (width across flats): 14 mm
Temperature sensor
16. Install temperature sensor (17) with bolts (16) (2 pieces).
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
REMARK
17. Install KDPF outlet temperature sensor (15) with mounting

nut (14).
22 to 28 Nm {2.2 to 2.8 kgm}
REMARK
KDPF outlet temperature sensor mounting nut (width
D155AXI-8 50-237
18. Tighten KDOC inlet temperature sensor (12) and KDOC

outlet temperature sensor (13) with mounting nuts (10) and
(11).
22 to 28 Nm {2.2 to 2.8 kgm}
35 to 41 Nm {3.6 to 4.2 kgm}
REMARK
KDOC inlet temperature sensor mounting nut (width
KDOC outlet temperature sensor mounting nut (width
19. Align clamps (9) (7 places) with positions marked during
disassembly, and install them.
REMARK
For clip fixing position, use the dimensions in the right fig-
ure as a guide.
50-238 D155AXI-8
BLY REMOVE AND INSTALL SCR ASSEMBLY
REMOVE AND INSTALL SCR ASSEMBLY
Tools for removal and installation of SCR assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Digital angle gauge ■ 1 For measurement of SCR inlet angle
k Check that no combustible materials (dry leaves, twigs, etc.) accumulated around SCR. If any dirt or
combustible materials are found, remove them.
k Since SCR is fragile against shock such as falling, handle it with care, and never use damaged part.
METHOD FOR REMOVING SCR ASSEMBLY

1. Remove AdBlue/DEF mixing tube (1). For details, see “RE-
D155AXI-8 50-239
REMOVE AND INSTALL SCR ASSEMBLY BLY
Wiring, piping
2. Remove clamps (3) (5 pieces) of wiring harness (2).
3. Slide the lever (yellow) on connector NH3 (4), NOx2 (5),
and SCRJ (6) in the direction of the arrow to unlock it, and
disconnect connector NH3 (4), NOx2 (5), and SCRJ (6).
(For details, see the following.)

2) Pinch lever (yellow) (a) with your fingers and slide it.
REMARK
3) Disconnect connectors NH3 (4), NOx2 (5), and SCRJ
(6) while pulling them in the direction opposite to the
sensor side.
4. Disconnect connectors NH3 (4), NOx2 (5), and SCRJ (6),
and then reposition wiring harness (2) out of the way.
Exhaust pipe
5. Disconnect mounting bolts (7) (4 pieces), and disconnect
exhaust pipe (8) from SCR assembly (9).
50-240 D155AXI-8
Sensor
6. Remove clamps (10) (3 pieces), and remove NH3 sensor
(11).
7. Remove clamps (12) (3 pieces), and remove Nox sensor
(13).
REMARK
1 of clamps (12) is tightened together with spacer (12a).
SCR assembly, Bracket

8. Install the lifting tool to slinging position (a) of SCR assem-
bly (9), sling SCR assembly (9) and bracket (14), and hold
them.
9. Remove mounting bolts (15) (4 pieces), sling SCR assem-
bly (9) together with bracket (14) as a unit, and remove
them.
4 SCR assembly (9), bracket (14):

130 kg
10. Place SCR assembly (9) and bracket (14) which were re-
moved on a stable place.
NOTICE
Block the hole to avoid entry of foreign material or damage to the exhaust pipe.
SCR assembly angle measurement
11. Adjust the mounting angle of SCR assembly (9) to the
dure.
1) Measure angle (c) to reference plane (b) at the ex-
haust pipe outlet.
2) Record the measured angle as this will be used as the
reference at the time of installation.
D155AXI-8 50-241
U-bolt
12. Remove nuts (16) (4 pieces) and (17) (4 pieces), and re-
move U-bolt (18).
Bracket
13. Sling SCR assembly (9) and hold it. Remove mounting
bolts (19) (4 pieces), and disconnect bracket (14) from
SCR assembly (9).
4 SCR assembly (9):

94 kg
METHOD FOR INSTALLING SCR ASSEMBLY

Bracket
1. Sling SCR assembly (9) by using lifting tool, and set it to
bracket assembly (14).
4 SCR assembly (9):

94 kg
Installing U-bolts loosely

2. Install U-bolts (18) loosely with nuts (16) (4 pieces) and
(17) (4 pieces).
50-242 D155AXI-8
Adjusting SCR mounting angle

3. Adjust the mounting angle of SCR assembly (9) to the
dure.
1) Place tool A on top surface (d) of SCR assembly (9),
and adjust the angle to 0±0.5 °.
2) Adjust angle (c) to 40±0.5 ° against standard surface
(b) at the exhaust pipe outlet.
4. Install SCR assembly (9) with bolts (19) (4 pieces).
Tightening U-bolt to specified torque

5. Tighten U-bolt (18) according to the following procedure.
3 Nut:
20.6 to 27.4 Nm {2.1 to 2.8 kgm}
3 Nut:
29.4 to 39.2 Nm {3 to 4 kgm}
3) Turn nuts (17) (4 pieces) slightly in the loosening di-
rection.
4) Make sure that the dimension from U-bolt (18) end to lower mounting nut (16) are even at both sides.
SCR assembly, Bracket
6. Install the lifting tool to slinging position (a) of SCR assem-
bly (9), sling SCR assembly (9) together with bracket (14)
as a unit, and then set the unit onto the base bracket.
4 SCR assembly (9), bracket (14):

130 kg
NOTICE
Avoid entry of foreign material or damage to the ex-
haust pipe.
7. Install SCR assembly (9) and bracket (14) with mounting
D155AXI-8 50-243
Sensor
8. Install Nox sensor (13).
3 Nox sensor:
50±10 Nm {5.1±1.0 kgm}
REMARK
1 of clamps (12) is tightened together with spacer (12a).
10. Install NH3 sensor (11).
3 NH3 sensor (11):
50±10 Nm {5.1±1.0 kgm}
Exhaust pipe
12. Install exhaust pipe (8) to SCR assembly (9) with mounting
Wiring
13. Move wiring harness (2) closer to SCR assembly (9).
50-244 D155AXI-8
14. Slide the lever (yellow) in the direction of the arrow, insert
each connector NH3 (4), NOx2 (5), and SCRJ (6) with the
lock released, and slide it in the opposite direction of the
arrow to lock it. (For details, see the following.)

nectors NH3 (4), NOx2 (5), and SCRJ (6) into the sen-
sor side.
2) Push lever (yellow) (a) with your finger until the click
sound is heard, connector becomes locked.
15. Install wiring harness (2) with clamps (3) (5 pieces).
D155AXI-8 50-245

16. Install AdBlue/DEF mixing tube (1). For details, see “RE-
50-246 D155AXI-8
BLY REMOVE AND INSTALL KDPF, SCR ASSEMBLY
REMOVE AND INSTALL KDPF, SCR ASSEMBLY

Tools for removal and installation of KDPF and SCR assembly
New/Redesign
Necessity
Sketch
Q'ty

ue/DEF hose
B 6540-71-1310 ■ 1 N
C 600-919-5050 ■ 1 N
ter) ue/DEF hose
- • AdBlue/DEF side cap ■ 1 N
ue/DEF hose
D
2 Removal and installation of coolant
- • Coolant side cap ■ 2 N
hose
3 - • Injector side cap ■ 1 N Removal and installation of injector
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, and
set the lock lever to LOCK position, and then stop the engine.
k Stop the engine, turn the battery disconnect switch to OFF position, and remove the key. (For de-
tails, see TESTING AND ADJUSTING, “HANDLE BATTERY DISCONNECT SWITCH”.)
k Since KDPF and SCR assembly is heated to 500 °C or above, take care not to get burn injury.
k If KDPF and SCR assembly is hot, wait until it has cooled down before starting any work.
k Check that no combustible materials (dry leaves, twigs, etc.) accumulate around KDPF and
AdBlue/DEF mixing tube. If any dirt or combustible materials are found, remove them.
k Since KDPF, AdBlue/DEF mixing tube, and SCR is fragile against shock such as falling, handle it with
care, and never use damaged part.
METHOD FOR REMOVING KDPF, SCR ASSEMBLY

Engine hood
1. Remove the engine hood. For details, see “REMOVE AND INSTALL ENGINE HOOD ASSEMBLY”.
Wiring, hose
2. Remove clamps (3) (7 pieces) of wiring harness (2) on the
side of KDPF assembly (1).
3. Remove clamps (5) (10 pieces) of hose (4), and reposition
hose (4) out of the way.
D155AXI-8 50-247
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BLY
4. Slide the lever (red) of connector PDPF (6) in the direction

5. Pull out DPF pressure sensor connector PDPF (6) in the

direction of the arrow while pushing the knob at the top of
the connector to disconnect it.
6. Slide the lever (yellow) on connector DPFJ (7) in the direc-

tion of the arrow to unlock it, and disconnect connector
DPFJ (7). (For details, see the following.)

2) Slide lever (yellow) (a) while pinching it with your fin-
gers.
REMARK
3) Disconnect connector DPFJ (7) while pulling it in the
opposite direction to the sensor side.
50-248 D155AXI-8
7. Remove clamps (8) to (11).

NOTICE
• Be sure that coolant does not splash to KDPF and
SCR assembly when disconnecting hose (12).
• Install tool D2 to AdBlue/DEF injector side after dis-
connecting hose (12).
9. Before disconnecting AdBlue/DEF hose (13), wash their connections with clean tap water to remove the
sticking materials.
NOTICE
When handling AdBlue/DEF hose, be sure to use tool
A.
AdBlue/DEF hose (13) in the opposite direction to
AdBlue/DEF pump side, and remove it.
D155AXI-8 50-249
NOTICE
After disconnecting AdBlue/DEF hose (13), install tool
C to the hose side, and tool D1 to AdBlue/DEF injector
side to prevent AdBlue/DEF from leaking.
11. Disconnect AdBlue/DEF wiring connector UDM (14) ac-

1) Slide red lever (14a) toward lock release position (d)
until it clicks.
2) While pressing knob (b) with your finger, disconnect
AdBlue/DEF wiring connector UDM (14).
NOTICE
• After disconnecting AdBlue/DEF hose (13), discon-
nect AdBlue/DEF wiring connector UDM (14) (to
prevent AdBlue/DEF from sticking to the
AdBlue/DEF wiring connector).
• After disconnecting AdBlue/DEF wiring connector
UDM (14), install tool B to the electrical connectors
side of AdBlue/DEF injector (to prevent entry of the
foreign material).
12. Reposition wiring harness (2) out of the way.
13. Remove mounting bolts (24) (2 pieces), and reposition

tank (25) together with the bracket as a unit out of the way.
50-250 D155AXI-8
14. Remove clamps (16) (5 pieces) of wiring harness (2) on

the side of SCR assembly (15).
15. Slide the lever (yellow) on connector NH3 (17), NOx2 (18),
and SCRJ (19) in the direction of the arrow to unlock it,
and disconnect connector NH3 (17), NOx2 (18), and SCRJ
(19). (For details, see the following.)

gers.
REMARK
3) Disconnect connectors NH3 (17), NOx2 (18), and
SCRJ (19) while pulling them in the opposite direction
to the sensor side.
Exhaust pipe
16. Remove mounting bolts (20a) (4 pieces) and (20b) (4
pieces), and remove exhaust pipe.
NOTICE
Take care not to damage the bellows part (h) of ex-
haust pipe (21) while performing work.
D155AXI-8 50-251
17. Install lifting tools to slinging position (g) of KDPF assem-

bly (1) and to slinging position (f) of SCR assembly (15),
sling KDPF assembly (1) and SCR assembly (15) together
with base bracket (22) as a unit, and hold them.
18. Remove mounting bolts (23) (13 pieces), sling KDPF as-
sembly (1) and SCR assembly (15) together with bracket
(22) as a unit, and remove them.
4 bracket (22):
KDPF assembly (1), SCR assembly (15), base
350 kg
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY

1. Set slings to lifting position (g) of KDPF assembly (1) and
lifting position (f) of SCR assembly (15).
2. Sling KDPF assembly (1) and SCR assembly (15) together
with base bracket (22) as a unit of KDPF and SCR assem-
bly (26), and set them on the machine body.
4 KDPF and SCR assembly (26):

350 kg
3. Install KDPF and SCR assembly (26) with mounting bolts
(23) (13 pieces).
NOTICE
Set mounting bolts (23) to KDPF and SCR assembly
(26) while it is slung, and assemble KDPF and SCR as-
sembly (26).
98.1 to 123 Nm {10.0 to 12.5 kgm}
50-252 D155AXI-8
Exhaust pipe
4. Install gaskets (21a) (2 pieces) to exhaust pipe (21).
NOTICE
• Use a new gasket.
flow (j) is convex (k) to gasket.
5. Install exhaust pipe (21) with mounting bolts (20a) (4

pieces) and (20b) (4 pieces).
NOTICE
Take care not to damage the bellows part (h) of ex-
haust pipe (21) while performing work.
2 Mounting bolts (20a) and (20b):
3 Mounting bolt (20a):
78.5 to 88.3 Nm {8.0 to 9.0 kgm}
Wiring, hose
6. Move wiring harness (2) closer to SCR assembly (15).
7. Slide the lever (yellow) of each connector NH3 (17), NOx2
(18), and SCRJ (19) in the direction of the arrow, insert
connectors with the lock released, and slide it in the direc-
tion opposite to the arrow to lock it. (For details, see the
following.)
D155AXI-8 50-253

nectors NH3 (17), NOx2 (18), and SCRJ (19) into the
sensor side.
2) Push lever (yellow) (a) with finger until the click sound
is heard, then connector is locked.
8. Install wiring harness (2) with clamps (16) (5 pieces).
9. Remove tool B on the electrical connectors side of

AdBlue/DEF injector, draw wiring harness (2) near you,
and install wiring connector UDM (14) according to the fol-
lowing procedure.
1) Insert connector UDM (14) in arrow direction (e) until
the click sound is heard.
2) Slide red lever (14a) in arrow direction (e) until the
click sound is heard to lock it.
50-254 D155AXI-8
10. Install tank (25) together with the bracket as a unit with
D155AXI-8 50-255
11. Remove tool C on AdBlue/DEF hose side, and tool D1 on

AdBlue/DEF injector side, and install AdBlue/DEF hose
(13).
NOTICE
• When handling AdBlue/DEF, be sure to use tool A.
• After installing connector UDM (14), install
AdBlue/DEF hose (to prevent AdBlue/DEF from at-
taching to the wiring connector).
REMARK
• Clean connection of AdBlue/DEF hose (13) and AdBl-
ue/DEF injector pin thoroughly to prevent dust from
sticking to them. Also, check that there is no damage.
• Insert connector (n) of AdBlue/DEF hose (13) into pin
(m) of injector side until click sound is heard to install.
(Install the opposite side of AdBlue/DEF hose to the
joint side.)
• When it is inserted so that convex part of pin (m) pass-
es the convex part inside the clip, it can be locked by
the clip.
12. Remove tool D2, and install hose (12).
50-256 D155AXI-8
13. Install clamps (8) to (11).
14. Connect connector PDPF (6) and DPFJ (7) according to

the following procedure.
1) Slide the lever (red) in the direction of the arrow, insert
connector PDPF (6) with the lock released, and slide it
in the opposite direction of the arrow to lock it.
2) Slide the lever (yellow) in the direction of the arrow, in-

sert connector DPFJ (7) with the lock released, and
slide it in the opposite direction of the arrow to install
it. (For details, see the following.)

nector DPFJ (7) into sensor side
D155AXI-8 50-257
15. Pull in hose (4), and install hose (4) with clamps (5) (10
pieces).
16. Install wiring harness (2) to KDPF assembly (1) with
clamps (3) (7 pieces).
Engine hood
17. Install the engine hood. For details, see “REMOVE AND INSTALL ENGINE HOOD ASSEMBLY”.
50-258 D155AXI-8
BLY REMOVE AND INSTALL KCCV ASSEMBLY
REMOVE AND INSTALL KCCV ASSEMBLY

k After the engine is stopped, the parts are very hot. Wait until all parts are cooled down.
k If hoses are wrongly assembled, it may result in engine damage. So be careful sufficiently when as-
sembling hoses.
METHOD FOR REMOVING KCCV ASSEMBLY

Cover
1. Open engine right side covers (1) and (2), and secure
them by using the locks.
REMARK
2. Disconnect the connector WL2 (3).

D155AXI-8 50-259
REMOVE AND INSTALL KCCV ASSEMBLY BLY
Wiring
5. Disconnect the connector PCCV (7).
1) Slide the lever (red) of connector PCCV (7) in the di-

rection of the arrow to unlock it.
2) While pushing the knob on the top of the connector,

pull out the connector in the direction of the arrow, and
disconnect the connector PCCV (7).
Hose
6. Remove coolant inlet tube (11) of clamps (8) (2 places)
and hose clamp (9).
REMARK
Prepare oil container under the piping before starting the
work.
7. Remove joint bolt (10) and disconnect coolant inlet tube
(11).
8. Remove coolant outlet tube (15) of clamps (12) (2 places)
and hose clamp (13).
9. Remove joint bolt (14) and disconnect coolant outlet tube
(15).
10. Disconnect oil drain hose (16).
50-260 D155AXI-8
11. Remove clamps (17) (2 places) and disconnect blowby

gas outlet hose (18).
12. Remove clamps (19) (2 places) and disconnect blowby
gas inlet hose (20).
KCCV assembly
KCCV assembly (22).
METHOD FOR INSTALLING KCCV ASSEMBLY

KCCV assembly
1. Install KCCV assembly (22) with bolts (21) (4 pieces).
Hose
2. Install clamps (19) (2 places) and connect blowby gas inlet
hose (20).
3. Install clamps (17) (2 places) and connect blowby gas out-
let hose (18).
3 Mounting clamp of blowby gas hoses (20) and
(18):
4.4±0.49 Nm {0.45±0.05 kgm}
D155AXI-8 50-261
REMOVE AND INSTALL KCCV ASSEMBLY BLY
4. Install oil drain hose (16).

3 Mounting clamp of oil drain hose (16):
3.3±0.49 Nm {0.34±0.05 kgm}
5. Tighten coolant inlet tube (11) with joint bolt (10).
6. Tighten coolant inlet tube (11) of hose clamp (9) and install
clamps (8) (2 places).
7. Tighten coolant outlet tube (15) with joint bolt (14).
8. Tighten coolant outlet tube (15) of hose clamp (13) and in-
stall clamps (12) (2 places).
3 Coolant tubes (11) and (15) of joint bolts (10) and (14):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3 Hose clamps (9) and (13):
3.3±0.49 Nm {0.34±0.05 kgm}
9. When check valve (22) at the bottom of oil drain hose (16)
is removed, install check valve (22) with its black side (b)
downward.
(k): KCCV side (gray)
(b): Cylinder block side (black)
(e): Oil flow (from KCCV to cylinder block)
Wiring
10. Slide the lever (red) in the direction of the arrow, insert
connector PCCV (7) with the lock released, and slide it in
the opposite direction of the arrow to lock it.
NOTICE
Check that the connector is free from dust, and then
install it.
50-262 D155AXI-8
Cover

13. Install connector WL2 (3).
14. Unlock the engine right side covers (1) and (2), and close
them.
D155AXI-8 50-263
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE BLY
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE

Tools for removal and installation of AdBlue/DEF mixing tube
New/Redesign
Necessity
Sketch
Q'ty
Removal and installation of

A 6540-71-2720 Injector cap kit ■ 1 N
AdBlue/DEF injector
k Since AdBlue/DEF mixing tube is heated to 500 °C or above, take care not to get burn injury.
k If AdBlue/DEF mixing tube is hot, wait until it has cooled down before starting any work.
k Check that no combustible materials (dry leaves, twigs, etc.) accumulated around AdBlue/DEF mix-
ing tube. If any dirt or combustible materials are found, remove them.
k AdBlue/DEF mixing tube is fragile against shock such as falling, handle it with care, and never use
damaged part.
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE

Engine hood
50-264 D155AXI-8
BLY REMOVE AND INSTALL AdBlue/DEF MIXING TUBE

3. Remove mounting bolts (5) (3 pieces) and push
AdBlue/DEF injector (6) together with hoses (7),
AdBlue/DEF injector hose (8) and connector MB03 (9) out
of the way.
REMARK
Block the hole on AdBlue/DEF mixing tube side. (Hole di-
ameter: 19.8 in diameter mm)
4. After removing AdBlue/DEF injector (6), install tool A to
nozzle end (a).
REMARK
Protecting the nozzle end (a).
5. Remove mounting bolts (10a) (2 pieces) of bracket (10),

and push tank (11) together with the bracket (10) out of the
way.
U-bolt
6. Remove mounting nuts (12) (4 pieces) and washers (13)
(2 pieces), and remove U-bolt (14).
D155AXI-8 50-265

bracket (16).
8. Use a lifting tool and sling AdBlue/DEF mixing tube (17) to-
gether with connector and tube and keep holding it.
4 AdBlue/DEF mixing tube:

30 kg
9. Remove mounting bolts (18) (4 pieces each at front and
rear).
10. Sling AdBlue/DEF mixing tube (17) by using a lifting tool,
and remove it.
4 AdBlue/DEF mixing tube:

30 kg
bracket (20).
50-266 D155AXI-8
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE

Temporary assembly of AdBlue/DEF mixing tube
1. Put gasket (23) between connector (21) and tube (22), and
temporarily assemble AdBlue/DEF mixing tube with V-
clamp (24) according to the following procedure.
1) Tighten the nut (24a) of V-clamp (24) until it begins to
be tightened.
2) Loosen the nut (24a) of V-clamp (24) by 3 turns.
REMARK
• By this procedure, the misalignment can be avoid-
ed, and it can be rotated in the rotation direction.
• When installing gasket (23) and V-clamp (24), use
new parts.
2. Temporarily assemble bracket (20) with the mounting bolts

(19) (2 pieces).
D155AXI-8 50-267
3. Install gaskets (17a) (2 pieces) to AdBlue/DEF mixing tube

(17).
NOTICE
• Install a new gasket to the mating faces of the
KDPF assembly and the SCR assembly.
flow (c) is convex (d) to gasket and face the pro-
truding part (e) of gasket towards the inside.
4. Sling AdBlue/DEF mixing tube (17) by using a lifting tool,

and install it to KDPF assembly and SCR assembly.
4 AdBlue/DEF mixing tube (17):

30 kg
5. Apply seizure prevention compound to the thread part of
mounting bolts (18) (4 pieces each at the front and the
back), and lightly tighten mounting bolts (18) by hand.
2 Threaded portion of mounting bolt (18):
50-268 D155AXI-8
6. Fasten V-clamp (24) to the specified torque according to

1) Adjust the tightening angle of inlet and outlet angle (a)
of AdBlue/DEF mixing tube and V-clamp (24).
AdBlue/DEF mixing tube inlet and outlet angle (a)70 °
2) Adjust tightening angle (b) of V-clamp (24).
Tightening angle of V-clamp (b)50±5 °
3) Tighten nuts (24a) of V-clamp (24) to 5.5±1.0 Nm
{0.56±0.1 kgm} .
4) Hit V-clamp (24) from 180 ° opposite direction of bolt
(24b) by using a plastic hammer, etc. in the order of
(d) to (e) or (f) to (g) as shown in the following figure.
5) Tighten the nuts (24a) of V-clamp (24) to the specified
torque of 11.0±1.0 Nm {1.12±0.1 kgm} .
D155AXI-8 50-269
Assembly of AdBlue/DEF mixing tube

7. Temporarily assemble U-bolt (14) with washers (13) (2
pieces) and nuts (12) (4 pieces).
8. Tighten mixing tube (17) with mounting bolts (18) (4 pieces
each at the front and the back) to the specified torque.
78.5 to 88.3 Nm {8.0 to 9.0 kgm}
9. Tighten U-bolt (14) with nuts (12) (4 pieces) to the speci-
fied torque.
3 Mounting nut (12) (upper):
14.7 to 19.6 Nm {1.5 to 2.0 kgm}
3 Mounting nut (12) (lower):
29.4 to 34.3 Nm {3.0 to 3.5 kgm}
10. Fasten bracket (20) with mounting bolts (19) (2 pieces) to
98.1 to 123.0 Nm {10.0 to 12.5 kgm}
12. Remove tool A of AdBlue/DEF injector (6) nozzle end (a).

REMARK
Wash the nozzle end (a) with clean tap water to remove
the sticking materials.
50-270 D155AXI-8
13. Install AdBlue/DEF injector (6) according to the following

procedure.
NOTICE
Use a new gasket.
1) Apply seizure prevention compound LC-G to mounting
bolts (5).
2) Temporarily assemble gasket (6a) and mounting bolts
(5) (3 pieces) to AdBlue/DEF injector (6), and install
them to AdBlue/DEF mixing tube (17).
REMARK
• Before tightening mounting bolts (5), install them
so that no clearance is created between gasket
(6a) and AdBlue/DEF mixing tube (17) and be-
tween gasket (6a) and AdBlue/DEF injector (6).
• Install AdBlue/DEF injector (6) together with hose
(7), AdBlue/DEF injector hose (8), and connector
MB03 (9).
3) Tighten mounting bolt (5) to 5.88 to 7.85 Nm {0.6±0.8
kgm} in the order of a, b, and c.
4) Tighten mounting bolt (6) to 5.88 to 7.85 Nm
{0.6±0.8kgm} in the order of a, b, and c again.
NOTICE
• After tightening the mounting bolts to the
specified torque, tighten all the bolts to speci-
fied torque again.
• Be careful not to damage AdBlue/DEF inlet and
coolant inlet/outlet connector parts by hitting
them to the peripheral parts.
Engine hood
D155AXI-8 50-271
REMOVE AND INSTALL AdBlue/DEF INJECTOR BLY
REMOVE AND INSTALL AdBlue/DEF INJECTOR

Tools for removal and installation of AdBlue/DEF injector
New/Redesign
Necessity
Sketch
Q'ty

ue/DEF hose
B 6540-71-1310 ■ 1 N
C 600-919-5050 ■ 1 N
ter) ue/DEF hose
- • AdBlue/DEF side cap ■ 1 N
ue/DEF hose
D
2 Removal and installation of coolant
- • Coolant side cap ■ 2 N
hose
3 - • Injector side cap ■ 1 N Removal and installation of injector
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, and
METHOD FOR REMOVING AdBlue/DEF INJECTOR

Engine hood
Wiring, hose
50-272 D155AXI-8
BLY REMOVE AND INSTALL AdBlue/DEF INJECTOR

NOTICE
Make sure that coolant does not splash to KDPF and
SCR assembly when disconnect hose (3).
NOTICE
After disconnecting hose (3), install tool D2 to
AdBlue/DEF injector side.
4. Before removing AdBlue/DEF hose (4), wash their connec-
tions with clean tap water to remove the sticking materials.
AdBlue/DEF hose (4) in the opposite direction to
NOTICE
• When handling AdBlue/DEF hose, be sure to use
tool A.
C to the hose side, and tool D1 to AdBlue/DEF in-
jector side to prevent AdBlue/DEF from leaking.
D155AXI-8 50-273
6. Disconnect AdBlue/DEF wiring connector UDM (5) accord-

ing to the following procedure.
1) Slide red lever (10) toward lock release position (d)
until it clicks.
2) While pressing knob (b) with your finger, disconnect
AdBlue/DEF wiring connector UDM (5).
NOTICE
• After disconnecting AdBlue/DEF hose (4), discon-
nect AdBlue/DEF wiring connector UDM (5) (to pre-
vent AdBlue/DEF from sticking to the AdBlue/DEF
wiring connector).
• After disconnecting AdBlue/DEF wiring connector
UDM (5), install tool B to the electrical connectors
side of AdBlue/DEF injector (to prevent entry of the
foreign material).
AdBlue/DEF injector
7. Remove mounting bolts (6) (3 pieces), and remove AdBl-
ue/DEF injector (7).
REMARK
Block the hole on AdBlue/DEF mixing tube side. (Hole di-
ameter: diameter 21 mm)
8. After removing AdBlue/DEF injector (7), install tool D3 to

nozzle end (a).
REMARK
Protecting the nozzle end (a).
50-274 D155AXI-8
METHOD FOR INSTALLING AdBlue/DEF INJECTOR

AdBlue/DEF injector
1. Remove tool D3 of nozzle end (a) of AdBlue/DEF injector
(7).
2. Install AdBlue/DEF injector (7) according to the following

procedure.
NOTICE
Use a new gasket.
1) Apply seizure prevention compound LC-G to mounting
bolts (6).
2) Temporarily assemble gasket (8) and mounting bolts
(6) (3 pieces) to AdBlue/DEF injector (7), and install
them to AdBlue/DEF mixing tube (9).
REMARK
Before tightening mounting bolt (6), install them so
that no clearance is created between gasket (8) and
AdBlue/DEF mixing tube (9) and between gasket (8)
and AdBlue/DEF injector (7).
3) Tighten mounting bolt (6) to 5.88 to 7.85 Nm {0.6±0.8
kgm} in the order of a, b, and c.
4) Tighten mounting bolt (6) to 5.88 to 7.85 Nm
{0.6±0.8kgm} in the order of a, b, and c again.
NOTICE
• After tightening the mounting bolts to the
specified torque, tighten all the bolts to speci-
fied torque again.
• Be careful not to damage AdBlue/DEF inlet and
coolant inlet/outlet connector parts by hitting
them to the peripheral parts.
D155AXI-8 50-275
Wiring, hose
3. Remove tool B on the electrical connector side of
AdBlue/DEF injector, and connect wiring connector UDM
(5) according to the following procedure.
1) Insert connector UDM (5) in arrow direction (e) until
the click sound is heard.
2) Slide red lever (10) in arrow direction (e) until the click
sound is heard to lock it.
NOTICE
• After connecting wiring connector UDM (5), install
AdBlue/DEF hose (4). (This is to prevent
AdBlue/DEF from sticking to the wiring connector).
50-276 D155AXI-8
4. Remove tool C on AdBlue/DEF hose side, and tool D1 on

AdBlue/DEF injector side, and install AdBlue/DEF hose
(4).
REMARK
• Clean connection of AdBlue/DEF hose (4) and
AdBlue/DEF injector pin thoroughly to prevent dust
from sticking to them. Also, check that there is no dam-
age.
• Insert connector (m) of AdBlue/DEF hose (4) into pin
(k) of the injector until click sound is heard, and con-
nect it. (Connect the opposite side AdBlue/DEF hose to
the joint.)
• When it is inserted so that convex portion (n) of pin (k)
passes the convex portion inside the clip, it can be
locked by the clip.
5. Remove tool D2, and install hose (3).
6. Install clamps (1) and (2).
Engine hood
D155AXI-8 50-277
REMOVE AND INSTALL AdBlue/DEF PUMP BLY
REMOVE AND INSTALL AdBlue/DEF PUMP

Tools for removal and installation of AdBlue/DEF pump
New/Redesign
Necessity
Sketch
Q'ty
B 600-919-5030 ■ 2 N
ter) Disconnection and connection of AdBl-
Plug (for 5/16 inch hose diame- ue/DEF hose
C 600-919-5050 ■ 1 N
ter)
6540-71-2720 AdBlue/DEF pump/tank cap kit ■ 1 N
1 Between AdBlue/DEF pump and AdBl-
- AdBlue/DEF pump side cap ■ 1 N
ue/DEF injector (pressurized sending)
2 • Removal and installation of
AdBlue/DEF hose between
AdBlue/DEF pump and AdBlue/DEF
D tank (return)
- AdBlue/DEF pump side cap ■ 2 N
• Removal and installation of
AdBlue/DEF hose between
AdBlue/DEF pump and AdBlue/DEF
tank (suction)
3 AdBlue/DEF pump electric con- AdBlue/DEF pump electric connector
- ■ 1 N
nector cap cap
k Place the machine on a level ground, and set parking brake lever to LOCK position.
k Turn the starting switch to OFF position, and stop the engine.
AND ADJUSTING, “HANDLE BATTERY DISCONNECT SWITCH”.)
METHOD FOR REMOVING AdBlue/DEF PUMP

Battery cover
50-278 D155AXI-8
BLY REMOVE AND INSTALL AdBlue/DEF PUMP



D155AXI-8 50-279
AdBlue/DEF pump

15. Refer to the following procedure. Slide the lever (yellow)
(a) of connector DSM (19) in the direction of the arrow (f)
to unlock it, and disconnect connector DSM (19).

gers.
REMARK
3) Pull connector DSM (19) to the opposite direction to
the sensor side, and disconnect it.
50-280 D155AXI-8
16. Before removing AdBlue/DEF hoses (20), (21), and (22),

wash their connections with clean tap water to remove the
sticking materials.
NOTICE
• After disconnecting AdBlue/DEF hose, install tools

B and C to the hose side and install tools D1 and
D2 to the nipple side to prevent leakage.
17. Pinch protruding part (e) of clip with your fingers, and the
lock is released. While they are kept pinched, pull out
AdBlue/DEF hoses (20), (21), and (22) in the opposite di-
rection to AdBlue/DEF pump side, and remove them.
18. Remove bolts (23) (3 pieces), and remove AdBlue/DEF

pump (24).
D155AXI-8 50-281
METHOD FOR INSTALLING AdBlue/DEF PUMP

AdBlue/DEF pump
NOTICE
When handling AdBlue/DEF, use tool A.
1. Install AdBlue/DEF pump (24) with mounting bolt (23) (3

pieces).
15.2 to 2.3 Nm {1.5 to 2.3 kgm}
2. Slide the lever (yellow) (a) of connector DSM (19) in the di-
rection of arrow (f), insert it while the lock is released, slide
it in the opposite direction to that of the arrow, and connect
connector DSM (19) according to the following procedure.

nector DSM (19) into sensor side.
50-282 D155AXI-8
4. Remove tools B and C of AdBlue/DEF hoses (20), (21),

and (22), and tools D1 and D2 on AdBlue/DEF pump side,
then install AdBlue/DEF hoses (20), (21), and (22).
NOTICE
Be careful not to damage AdBlue/DEF pressure con-
nector part, intake connector part, and return connec-
tor part by hitting them to the peripheral parts. In addi-
tion, do not retighten them.
REMARK
• Clean the connection of AdBlue/DEF hoses (20), (21),
and (22) and AdBlue/DEF pump pin thoroughly, and
check that there is no dust or dirt or damage on them.
• Insert connectors (m) of AdBlue/DEF hoses (20), (21),
and (22) into each pin (k) of AdBlue/DEF pump until
click sound is heard, and install them. (Install the oppo-
site side AdBlue/DEF hose to the joint.)
• When it is inserted until convex part (n) of pin (k) pass-
es the convex part inside the clip, it can be locked by
the clip.
D155AXI-8 50-283
Battery cover
REMARK
check the position.


50-284 D155AXI-8


17. Refill with AdBlue/DEF to the specified level through the filler port of AdBlue/DEF tank.
D155AXI-8 50-285
REMOVE AND INSTALL AdBlue/DEF HOSE BLY
REMOVE AND INSTALL AdBlue/DEF HOSE

Tools for removal and installation of AdBlue/DEF hose
New/Redesign
Necessity
Sketch
Q'ty
B 6540-71-1720 AdBlue/DEF injector cap kit ■ 1 N
Plug (for 3/8 inch of hose diam-
C 600-919-5030 ■ 1 N Disconnection and connection of AdBl-
eter)
ue/DEF hose
D 6540-71-2720 AdBlue/DEF pump cap kit ■ 1 N
Plug (for 5/16 inch of hose di-
E 600-919-5050 ■ 1 N
ameter)
METHOD FOR REMOVING AdBlue/DEF HOSE

Battery cover

50-286 D155AXI-8
BLY REMOVE AND INSTALL AdBlue/DEF HOSE


4 Battery cover (4):

110 kg
D155AXI-8 50-287
Cover
15. Remove covers (18) to (21).
AdBlue/DEF hose
17. Wash the connections of AdBlue/DEF hose with clean city
water to remove the sticking materials before removing
AdBlue/DEF hose (23), and then remove AdBlue/DEF
hose (23) according to the following procedure.
NOTICE
When handling AdBlue/DEF hose, be sure to use tool
A.
18. Disconnect connector UHA (24a),UHC (24b).
50-288 D155AXI-8
AdBlue/DEF hose (23) in the opposite direction to the
AdBlue/DEF pump and AdBlue/DEF tank side, and re-
move AdBlue/DEF hose (23).
NOTICE
C on the hose side, and tool D on the AdBlue/DEF tank
and AdBlue/DEF pump side to prevent AdBlue/DEF
from leaking.
D155AXI-8 50-289
50-290 D155AXI-8
NOTICE
C on the hose side, and tool D on the AdBlue/DEF
pump side to prevent AdBlue/DEF from leaking.
23. Disconnect connector URH2(33).

D155AXI-8 50-291
NOTICE
E on the hose side, and tool B on the AdBlue/DEF
pump side to prevent AdBlue/DEF from leaking.
METHOD FOR INSTALLING AdBlue/DEF HOSE

AdBlue/DEF hose
1. When handling AdBlue/DEF hose, be sure to use tool A
and install AdBlue/DEF hose according to the following
procedure.
2. Remove tool E on AdBlue/DEF hose side and tool B on

AdBlue/DEF injector side, and then install AdBlue/DEF
hose (36).
50-292 D155AXI-8
3. Wash the connection of AdBlue/DEF hose (36) and pin (f)

with clean city water to remove the sticking materials.
Check the AdBlue/DEF hose and pin are not damaged.
4. Insert connector (g) of AdBlue/DEF hose (36) into pin (f) of
injector side until click sound is heard to install. (Install the
opposite side AdBlue/DEF hose to the joint.)
REMARK
When it is inserted so that convex part (h) of pin (f) passes
5. Install connector URH2 (33).
6. Install clamps (34) and (35).
7. Remove tool C on AdBlue/DEF hose side and tool D on

hose (32).
D155AXI-8 50-293

REMARK
50-294 D155AXI-8
11. Remove tool C on AdBlue/DEF hose side and tool D on

hose (23).
REMARK
14. Install connector UHA (24a), UHC (24b).
Cover
17. Install covers (18) to (21).
D155AXI-8 50-295
Battery cover
19. Close cover (2), and install it to parts (a) (3 places) of battery cover (4) by using the nylon sling.
4 Battery cover (4):

110 kg

50-296 D155AXI-8



D155AXI-8 50-297
REMOVE AND INSTALL AIR CLEANER ASSEMBLY BLY
REMOVE AND INSTALL AIR CLEANER ASSEMBLY

METHOD FOR REMOVING AIR CLEANER ASSEMBLY

Connector
2. Disconnect indicator hose (1).
3. Disconnect connector AF1 (2).
5. Remove clogging sensor (4).

7. Slide the lever (red) of connector MAF (6) in the direction
of the arrow to unlock.
50-298 D155AXI-8
BLY REMOVE AND INSTALL AIR CLEANER ASSEMBLY
8. While pressing the knob on the upper portion of the con-

nector, pull out the connector in the direction of the arrow.
Air cleaner assembly

9. Remove bolts (7) (4 pieces), and slowly remove bracket
(8) together with air cleaner assembly (9) as a unit.
REMARK
Removal of the air cleaner assembly must be performed
by 2 persons.
4 Air cleaner assembly:

30 kg
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY

Air cleaner assembly
1. Install air cleaner assembly (9) slowly together with brack-
et (8) with bolts (7) (4 pieces).
REMARK
Installation of the air cleaner assembly must be performed
by 2 persons.
4 Air cleaner assembly:

30 kg
D155AXI-8 50-299
REMOVE AND INSTALL AIR CLEANER ASSEMBLY BLY
Connector
2. Connect connector MAF (6).
3. Slide the connector lever (red) in the direction of the arrow
to lock.
5. Install clogging sensor (4).

7. Connect connector AF1 (2).
8. Install indicator hose (1).
3 Indicator hose joint nut:
17.6 Nm {1.8 kgm}

50-300 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEM-
BLY BLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY

k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit before disconnecting
the air conditioner hose.
refrigerant.
record them.
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY

Alternator belt
Hose, connector
2. Disconnect air conditioner hoses (1) and (2).
3. Disconnect ground cable (3), and disconnect connectors
A/C (4) and (5).
Air conditioner compressor

4. Remove mounting bolts (6) (8 pieces), and remove air con-
ditioner compressor assembly (7).
D155AXI-8 50-301
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY

Air conditioner compressor
1. Remove mounting bolts (6) (8 pieces), and install air condi-
tioner compressor assembly (7).
Mounting bolt (8)24.5 to 29.4 Nm {2.5 to 3.0 kgm}
Hose, connector
2. Install ground cable (3), connectors A/C (4) and (5).
3. Install air conditioner hoses (1) and (2).
REMARK
When connecting the air conditioner circuit piping, observe
the following:
• Do not remove the plug from the fitting before connect-
ing the pipe.
• Be careful that dirt, dust, water, etc. do not enter the air
conditioner piping.
• Check that the O-rings are fitted to the joints when con-
necting the air conditioner piping.
• Check that the O-ring is not damaged or deteriorated.
• When connecting air conditioner piping, apply compres-
sor oil for new refrigerant (R134a) to the O-rings and
threaded portions.
• When connecting the air conditioner pipes, tighten by
using 2 wrenches.
2 O-ring and threaded portion:
Screw size (M6 x 1.0) (width across flats: 10 mm)8 to
12 Nm {0.8 to 1.2 kgm}
Alternator belt
Refilling with refrigerant
5. Refill with refrigerant (air conditioner gas: R134a).
Filling quantity: 900 ± 50 g
50-302 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEM-
BLY BLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY

k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. If it touches your skins, you
may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working clothes
with long sleeves while you are collecting or filling the refrigerant.
record them.
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY

Air conditioner gas
REMARK
Refrigerant to be collected: 900 ± 50 g
Cover
2. Disconnect right and left connectors (1).
3. Remove cover (2) at the top of the condenser.
D155AXI-8 50-303
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY
Air conditioner condenser assembly

5. Disconnect connector (4).
7. Remove mounting bolt (8) on the bottom side.
8. Remove air conditioner condenser assembly (9).
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY
50-304 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEM-
BLY BLY
Air conditioner condenser assembly

1. Install air conditioner condenser assembly (9).
2. Install mounting bolt (8) on the bottom side.
3. Connect air conditioner hoses (5) and (6).

NOTICE
• When installing the hose for the air conditioner cir-
cuit, be careful not to let dirt, dusts and water go-
ing into the hose.
• Do not reuse an O-ring because it is deformed and
deteriorated if used once.
• When removing the O-rings, use a soft tool so that
the piping is not damaged.
ed.
• Apply compressor oil (DENSO: ND-OIL8) for refrig-
erant (R134a) to O-ring.
2 Threaded portion of air conditioner tube:
REMARK
When connecting the air conditioner pipes, tighten by using 2 wrenches.
3 Screw size(M22 x 1.5) (width across flats: 24 mm):
20 to 25 Nm {2.04 to 2.55 kgm}
3 Screw size(M16 x 1.5) (width across flats: 19 mm):
12 to 15 Nm {1.22 to 1.53 kgm}
4. Connect connector (4).
D155AXI-8 50-305
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY
Cover
6. Install cover (2) on the top side of the condenser.
7. Connect right and left connectors (1).
Air conditioner gas

8. Refill with refrigerant (air conditioner gas: R134a) through the air conditioner circuit.
REMARK
9. Refill with air conditioner compressor oil. For details, see “HANDLE COMPRESSOR OIL”.
50-306 D155AXI-8
BLY REMOVE AND INSTALL DAMPER ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL DAMPER ASSEMBLY
Tools for removal and installation of damper assembly
New/Redesign
Necessity
Sketch
Q'ty
A 790-201-3130 Guide bolt ■ 2 Removal and installation of damper as-

B 790-201-3250 Bolt ■ 2 sembly
C 790-201-3120 Guide bolt ■ 2

Removal and installation of damper as-
D 790-201-3230 Bolt ■ 2
sembly
E - Eyebolt ■ 1
METHOD FOR REMOVING DAMPER ASSEMBLY

Draining
1. Drain oil from the damper case.
6 Damper case:
1.5 ℓ
Operator's cab assembly
2. Remove the operator's cab assembly. For details, see “REMOVE AND INSTALL OPERATOR'S CAB AS-
SEMBLY”.
Work equipment pump and HSS pump assembly
3. Remove work equipment pump assembly and HSS pump assembly. For details, see “REMOVE AND IN-
STALL WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY”.
Cooling fan pump assembly
4. Remove the cooling fan pump assembly. For details, see “REMOVE AND INSTALL COOLING FAN PUMP
ASSEMBLY”.
D155AXI-8 50-307
REMOVE AND INSTALL DAMPER ASSEMBLY BLY
Suction tube
5. Remove suction tube (1).
Hose
6. Remove louver (2).
7. Disconnect breather hose (3).

Universal joint assembly

9. Sling universal joint assembly (5) and remove it.
4 Universal joint assembly (5):

20 kg
10. Pull out coupling (6) on the torque converter side.
50-308 D155AXI-8
Damper assembly
11. Remove the mounting bolts of damper cover assembly (7),
and install tool A diagonally.
12. By using tool B, pull out damper cover assembly (7) so
that the lifting tool can be hooked, and remove it.
4 Damper cover assembly (5):

60 kg
13. Remove mounting bolts (2 pieces) of damper assembly

(8), and set tool C.
14. Remove the remaining mounting bolts, and pull out them
by using tool D.
15. Install tool E, and remove damper assembly (8).
4 Damper assembly (8):

60 kg
METHOD FOR INSTALLING DAMPER ASSEMBLY

Damper assembly
1. Install tool E to damper assembly (8), sling and install it by
using tool C.
4 Damper assembly (8):

60 kg
3 Damper mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
D155AXI-8 50-309
REMOVE AND INSTALL DAMPER ASSEMBLY BLY
2. Degrease spline part (a) of shaft (9), apply dry lubricant,

and leave it for 2 or 3 minutes.
3. Fill portion (b) of inner body (10) with approximately 80 g
of lithium base extreme pressure grease with molybdenum
disulfide.
Part Dry lubricant with molybde- SUMICO ROCOL: Dry
(a) num disulfide spray or equivalent
Part Lithium base extreme pres- • KYODO YUSHI: Moly-
b sure grease with molybde- lex No.2 or equivalent
num disulfide
• Showa Shell: RETI-
NAX AM or equivalent
• Nippon Oil: Moritex or
equivalent
4. Apply liquid gasket to the flange of damper cover assem-
bly (7).
2 Damper cover mounting face:
REMARK
• Apply also to the engine side.
• Apply with the thickness of 0.1 to 0.2 mm.
5. After applying the liquid gasket to damper cover assembly
(7), sling damper cover assembly (7) by using tool A after
2 or 3 minutes, and install it.
3 Mounting bolt of damper cover assembly (7):
98 to 123 Nm {10.0 to 12.5 kgm}
Universal joint assembly

6. Install coupling (6) on the torque converter side.
7. Sling universal joint assembly (5), and install it.
4 Universal joint assembly (5):

20 kg
2 Universal joint mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
50-310 D155AXI-8
Hose
10. Refill with the oil specified by Komatsu to the specified lev-
el through the oil filler port of the damper case.
Damper case1.5 ℓ (For details. see "TABLE OF FUEL,
COOLANT, AND LUBRICANTS".)
3 Drain plug:
58.5 to 78.5 Nm {6 to 8 kgm}
11. Install louver (2).
Suction tube
12. Install suction tube (1).

13. Install the cooling fan pump assembly. For details, see “REMOVE AND INSTALL COOLING FAN PUMP
ASSEMBLY”.
14. Install work equipment HSS pump assembly. For details, see “REMOVE AND INSTALL WORK EQUIP-
MENT PUMP AND HSS PUMP ASSEMBLY”.
15. Install the operator's cab assembly. For details, see “REMOVE AND INSTALL OPERATOR'S CAB ASSEM-
BLY”.
16. Refilling the damper case with Komatsu genuine oil. (For details, see “TABLE OF FUEL, COOLANT, AND
LUBRICANTS”.)
5 Damper case:
1.5 ℓ
D155AXI-8 50-311
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY BLY
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY
Tools for disassembly and assembly of damper assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 2 Disassembly and assembly of damper

B - Cylinder ■ 2 assembly
C 793T-623-1170 Push tool ■ 2 ○ Assembly of damper assembly

791-612-1100 Installer ■ 2
D 790-101-4200 Puller (294 kN {30 t} ) ■ 1 Press fit of bearing
50-312 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY
METHOD FOR DISASSEMBLE DAMPER ASSEMBLY

Damper cover assembly
1. Remove bolt (3) from cover (2), and remove holder (4) and
coupling (5).
2. Set damper cover assembly (1) on tool A, remove shaft (6)

by tapping it from the output side by a plastic hammer.
REMARK
Shaft (6) is removed together with inner race (7a) of bear-
ing (7) and oil seal (8).
3. Remove collar (7b) of bearing (7) and O-ring (6a) from

shaft (6), and remove inner race (7a).
4. Remove oil seal (9) from cover (2), and remove inner race
(7c) from bearing (7).
D155AXI-8 50-313
5. Remove outer races (7d) and (7e) of bearing (7) from cov-
er (2).
Damper assembly
6. Remove bolt (11), and remove flange (12).
7. Remove outer body (13), inner body (14), and cushion
(15).
8. Pull out plug (17) from flange (16).
REMARK
Pull out plug (17) only when replacing plug (17).
METHOD FOR ASSEMBLING DAMPER ASSEMBLY

Damper assembly
1. Align the bolt holes of flange (16) with those of outer body
(13), set them on tool B, and install inner body (14) to it.
2 Mating surfaces of flange and outer body:
2 Inner surface of outer body:
Grease (G2-LI)
2 Contact surface of inner body cushion:
Grease (G2-LI)
2. Install cushion (15).

2 Entire surface of cushion:
Grease (G2-LI)
3. Fill 30% of the space of clearance (a) (16 places) between
inner body (14) and outer body (13) with grease.
2 30% of space of clearance (a) (16 places):
Grease (G2-LI)
50-314 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY
4. Install flange (12), and tighten bolt (11).

3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
5. Fill portion (b) of inner body (14) with approximately 80 g

of grease shown below.
2 Portion (b) of inner body (14):
Grease (See the following table.)
Grease Manufacturer name
Lithium base extreme pressure • KYODO YUSHI: Molylex
grease with molybdenum disul- No.2 or equivalent
fide
• Showa Shell: RETINAX
AM or equivalent
• Nippon Oil: Moritex or
equivalent
Damper cover assembly
6. By using tool C and press, press-fit outer races (7d) and
(7e) of bearing (7) to cover (2).
7. By using tool D, press-fit inner race (7a) of bearing (7) to

shaft (6).
D155AXI-8 50-315
8. Install collar (7b) and O-ring (6a) to shaft (6).
9. Place cover (2) on shaft (6), and press-fit bearing inner

race (7c) by using tool D.
10. Install oil seals (8) and (9) to cover (2).

2 Press-fitting surface of oil seal::
2 Oil seal lip surface:
Grease (G2-LI)
REMARK
Thinly apply liquid gasket on the oil seal surface and wipe
off any liquid gasket that is squeezed out.
11. Install coupling (5) and holder (4), and tighten bolt (3).
3 Mounting bolt:
245.2 to 308.9 Nm {25.0 to 31.5 kgm}
50-316 D155AXI-8
BLY REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY
Tools for removal and installation of power train unit assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Bolt (M10 x 1.5) ■ 1 Pulling-out of shaft
record them.
METHOD FOR REMOVING POWER TRAIN UNIT ASSEMBLY

Draining
1. Drain oil from the hydraulic tank and power train case.
6 Hydraulic tank:
95 ℓ
6 Power train case:

90 ℓ
SEMBLY”.
Piping, wiring
3. Remove dipstick pipe (1) and oil filler tube (2).
D155AXI-8 50-317
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY BLY
4. Remove clamp (4) of wiring harness (3), and move it aside

so that it does not hinder the work.
5. Remove clamp (5), and remove hose (6).
6. Remove clamp (7) of the hose between the control valve
and lock valve, and disconnect hoses (8) and (9).
and ripper block, and disconnect hoses (11) (4 pieces).
8. Remove hoses (12) (2 pieces) between the control valve

and lift tube.
and HSS motor, and disconnect hoses (15) (2 pieces).
11. Remove hoses (16) and (17).
12. Remove hoses (18) and (19) between the control valve
and the work equipment and HSS pump.

14. Remove centralized pressure pickup port block (21), and
move it aside so that it does not hinder the work.
50-318 D155AXI-8
15. Remove clamp (22) of the hose between the lock valve
and accumulator, and disconnect hoses (23) and (24).
Accumulator assembly
17. Remove accumulator assembly (26).
18. Remove clamp (28) of wiring harness (27), and move wir-
ing harness (27) aside so that it does not hinder the work.
19. Remove clamp (29), and disconnect hose (30).
D155AXI-8 50-319
Filter assembly
21. Remove hoses (33) (2 pieces) of filter assembly (32).
22. Remove clamp (34), and remove filter assembly (32).
23. Disconnect hose (35) on the bottom side of the front right
of the power train unit.
24. Disconnect hose (36) on the bottom side of the front left of
the power train unit.
Universal joint
25. Disconnect universal joint (37) on the torque converter
side.
REMARK
Push in the yoke on the torque converter side, and com-
pletely disconnect universal joint (37) and torque convert-
er.
Drive shaft
26. Remove covers (38) on both sides of the steering case.
50-320 D155AXI-8
27. Remove cap (38).

28. Loosen clamp (39), slightly slide seal (40) to the outside.
29. Remove covers (41) (right and left) of the final drive shaft.
30. By using tool A, pull out drive shafts (42) (right and left) to
the outside until the spline on the steering case side is
pulled out.
REMARK
If it is difficult to pull out the shaft, set the jack to the shoe
grouser to push up it, search the position where the shaft
is easily pulled out, and then pull out it.
Power train unit assembly

31. Remove mounting bolts (43) (4 pieces) on the front right
and left sides of the power train unit.
32. Sling power train unit assembly (44) and remove it.
NOTICE
• Check that all the wiring and piping are removed.
• When removing it, be careful not to interfere with
the machine main unit.
4 Power train unit assembly:

2400 kg
D155AXI-8 50-321
METHOD FOR INSTALLING POWER TRAIN UNIT ASSEMBLY

Power train unit assembly
1. Sling power train unit assembly (44), and set it.
NOTICE
• When setting it, be careful not to interfere with the
machine main unit.
• When installing the power train unit assembly, be
careful not to damage seal (40).
4 Power train unit assembly:

2400 kg
2. Install mounting bolts (43) (4 pieces) on the front right and

left sides of the power train unit.
3 Mount mounting bolt:
824 to 1030 Nm {84 to 105 kgm}
Drive shaft
3. Install drive shafts (42) (right and left).
4. Install covers (41) (right and left) of the final drive shaft.
50-322 D155AXI-8
5. Align seal (40), and fasten clamp (39).

NOTICE
Securely fasten clamp (39) at the sealing hump on the
coupling. Clamp threaded portion must be assembled
parallel to the cap mounting seat.
6. Install cap (38).
3 Mount cap mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
Universal joint
7. Install universal joint (37).
98 to 123 Nm {10.0 to 12.5 kgm}
Piping, wiring
8. Install hose (35) on the bottom side of the front right of the
power train unit.
9. Install hose (36) on the bottom side of the front left of the
power train unit.
Filter assembly
10. Install filter assembly (32).
D155AXI-8 50-323
12. Install hoses (33) (2 pieces) of filter assembly (32).

14. Fit hose (30), and install clamp (29).
15. Install clamp (28) of wiring harness (27).
Accumulator assembly
16. Install accumulator assembly (26).
18. Fit hoses (23) and (24) between the lock valve and accu-
mulator, and install clamp (22).
50-324 D155AXI-8
19. Install centralized pressure pickup port block (21).

21. Install hoses (18) and (19) between the control valve and
the work equipment and HSS pump.
23. Fit hoses (15) (2 pieces) between the control valve and
HSS motor, and install clamp (14).
25. Install hoses (12) (2 pieces) between the control valve and
lift tube.
26. Fit hoses (11) (4 pieces) between the control valve and rip-
per block, and install clamp (10).
27. Fit hoses (8) and (9) between the control valve and lock
valve, and install clamp (7).
28. Fit hose (6), and install clamp (5).
29. Install clamp (4) of wiring harness (3).
D155AXI-8 50-325
30. Install dipstick pipe (1) and oil filler tube (2).

BLY”.
Refilling with hydraulic oil
32. Refill with oil through the oil filler ports of the hydraulic tank and power train case to the specified level. Run
the engine to circulate the oil through the piping. Then check the oil level again. (For details. see "TABLE
OF FUEL, COOLANT, AND LUBRICANTS".)
5 Hydraulic tank:
95 ℓ
5 Power train case:

90 ℓ
50-326 D155AXI-8
50 DISASSEMBLY AND ASSEM- DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEM-
BLY BLY
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY
Tools for disconnection and connection of power train assembly

New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 2 Fixing power train unit assembly
METHOD FOR DISCONNECTING POWER TRAIN UNIT ASSEMBLY

Advance preparation
1. Set power train unit assembly (1) on tool A.
4 Power train unit assembly (1):

2400 kg
Connector
2. Disconnect all the connectors remove install the wiring
harness from the power train unit referring to Trouble-
shooting, “CONNECTOR LAYOUT DRAWING” and Circuit
diagrams, “ELECTRICAL CIRCUIT DIAGRAM”.
D155AXI-8 50-327
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY
Hose
3. Remove cover (2), and remove detection hose assembly (3).
REMARK
Disconnect power train unit side (10 places) of the detection hose.
5. Remove tube (5).

6. Remove work equipment pump and HSS pump assembly (6).
4 Work equipment pump and HSS pump assembly (6):

120 kg
7. Remove cooling fan pump assembly (7).
4 Cooling fan pump assembly (7):

45 kg
Scavenging pump assembly
8. Remove tubes (8) and (9), and remove scavenging pump
assembly (10).
4 Scavenging pump assembly (10):

20 kg
Power train pump and steering lubrication pump assembly

9. Remove tubes (11) and (12), and remove power train
pump and steering lubrication pump assembly (13).
4 sembly (13):
Power train pump and steering lubrication pump as-
30 kg
50-328 D155AXI-8
BLY BLY
10. Remove tube (14).
11. Remove coupling (15).
PTO, torque converter, and transmission assembly

12. Sling PTO, torque converter, and transmission assembly
(16), hold it, and remove the mounting bolts (18 pieces) to
disconnect it from HSS unit assembly (17).
4 (16):
1500 kg
13. Set PTO, torque converter, and transmission assembly

(16) to tool B with PTO side facing upward.
D155AXI-8 50-329
BLY BLY
14. Remove block (18) together with the internal strainer.
15. Remove cover (19), and remove spring (20) and magnet
assembly (21).
50-330 D155AXI-8
BLY BLY
16. Remove pressure sensor block (22), and then remove 2

sleeves (23).
D155AXI-8 50-331
BLY BLY
Torque converter valve assembly

18. Remove torque converter valve assembly (25) and 2
sleeves (26).
PTO assembly
19. Remove the mounting bolts (19 pieces), sling PTO assem-
bly (27), and remove it.
50-332 D155AXI-8
BLY BLY
Torque converter assembly

20. Sling torque converter assembly (28) and remove it.
REMARK
Remove the mounting bolt (under head: 90 mm, 10
pieces) marked with (b) in the figure only.
4 Torque converter assembly (28):

130 kg
METHOD FOR CONNECTING POWER TRAIN UNIT ASSEMBLY

Torque converter assembly
1. Sling torque converter assembly (28), and install it.
REMARK
Install the mounting bolt (under head: 90 mm, 10 pieces)
marked with (b) in the figure only.
4 Torque converter assembly (28):

130 kg
2 Torque converter assembly mounting bolt:
3 Torque converter assembly mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
D155AXI-8 50-333
BLY BLY
PTO assembly
2. Sling PTO assembly (27), and install it with the mounting
bolts (19 pieces).
3 PTO assembly mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
Torque converter valve assembly

3. Install sleeves (26) (2 pieces).
4. Install torque converter valve assembly (25).
50-334 D155AXI-8
BLY BLY
6. Install sleeves (23) (2 pieces).
7. Install pressure sensor block (22).
8. Install spring (20) and magnet assembly (21).
D155AXI-8 50-335
BLY BLY
10. Install block (18) together with the internal strainer.

11. Sling PTO, torque converter, and transmission assembly
(16), hold it, and connect it to HSS unit assembly (17) with
the mounting bolts (18 pieces).
4 (16):
1500 kg
3 Transmission case mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
12. Install coupling (15).
13. Install tube (14).
50-336 D155AXI-8
BLY BLY

14. Install power train pump and steering lubrication pump as-
sembly (13).
4 sembly (13):
30 kg
15. Install tubes (11) and (12).

16. Install scavenging pump assembly (10).

20 kg
17. Install tubes (8) and (9).

18. Install cooling fan pump assembly (7).
4 Cooling fan pump assembly (7):

45 kg

19. Install work equipment pump and HSS pump assembly (6).
4 Work equipment pump and HSS pump assembly (6):

120 kg
D155AXI-8 50-337
BLY BLY
21. Remove cover (2), and install detection hose assembly (3).
REMARK
Connect power train unit side (10 places) of the detection
hose.
Connector
22. Connect all the connectors and install the wiring harness from the power train unit referring to Troubleshoot-
ing, “CONNECTOR LAYOUT DRAWING” and Circuit diagrams, “ELECTRICAL CIRCUIT DIAGRAM”.
REMARK
Color band is attached to the detection hose fitting. Con-
nect the hose to the power train unit referring to the follow-
ing table.
Sym-
Detecting place Band colors
bol
a Torque converter lockup clutch pressure Yellow/Red
b Torque converter stator clutch pressure Yellow/Blue
c Transmission 1st clutch pressure Red
d Transmission 3rd clutch pressure Yellow/Black
e Transmission R clutch pressure Red/Blue
f Transmission 2nd clutch pressure White/Yellow
g Transmission F clutch pressure White/Blue
h Transmission main relief pressure Colorless
i Left brake pressure White
j Right brake pressure Yellow
50-338 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY
Tools for disassembly and assembly of PTO assembly
New/Redesign
Necessity
Sketch
Q'ty
Removal and installation of gear and

A 790-201-3130 Guide bolt ■ 3
cover assembly
B 790-201-3290 Bolt ■ 4 Pulling out of bearing
C - Block ■ 2 Fixing of cover
D 790-201-2720 Spacer ■ 1
Pulling out of gear
E 793T-615-1720 Spacer ■ 1 ○
F 793T-417-1310 Spacer ■ 1 ○ Pulling out of bearing
G 790-201-3250 Bolt ■ 2 Pulling out of shaft
H 793T-613-1340 Spacer ■ 1 ○
J 790-201-2730 Spacer ■ 1 Press fit of bearing
K 792T-413-1120 Push tool ■ 1 ○
METHOD FOR DISASSEMBLING PTO ASSEMBLY

Lubrication tube
1. Remove shaft lubrication tube (1).
D155AXI-8 50-339
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY BLY
2. Remove pump drive gear lubrication tube (2).
Work equipment, HSS pump drive gear, cover assembly

3. Remove mounting bolts (3) (2 pieces), and set tool A.
4. Tighten forcing screw into hole (a), and remove gear and
cover assembly (4).
5. Remove cover (5) from gear and bearing assembly (6).
6. Remove bearing (7), and inner race (8) from gear (9).
REMARK
Tighten bearing (7) by using tool B at tap (b) alternately,
and push it out.
50-340 D155AXI-8
7. Remove bearing (40) from case (17).
Cooling fan pump drive gear, cover assembly

8. Remove 6 mounting bolts (10), and set the guide bolts.
9. Tighten forcing screw into hole (c), and remove gear and
cover assembly (11).
10. Separate gear (13) from cover by push gear (13) in by us-
ing tool D while cover (12) is supported by tool C.
11. Remove inner race (41) from gear (13).
D155AXI-8 50-341
12. Remove snap ring (14), and remove bearing (15).
13. Remove bearing (16) from case (17).
Scavenging pump drive gear

14. Remove snap ring (18).
15. Push gear (19) into the case by using tool E.
16. Remove snap ring (20), and remove bearing (21) from the
case by using tool F.
50-342 D155AXI-8
Idler gear assembly

17. Remove the mounting bolt, and remove plate (22).
18. Remove the mounting bolt, and set tool A.

19. Remove shaft (23) by using tool G.
REMARK
Hold the gear in the case.
20. Remove bearing (25) and spacer (26) from gear (24).
REMARK
When storing, be careful not to change the combination of
bearing and outer race if they are to be reused.
21. Remove outer race (27) and snap ring (28) from gear (24).
Input shaft outer race

22. Remove snap ring (29), and remove outer race for input
shaft (30).
METHOD FOR ASSEMBLING PTO ASSEMBLY

REMARK
• Clean all parts, and check them for dirt or damage, and assemble.
• After press-fitting the bearing, drip at least 6 cc of power line oil (TO30 or TO10) to it and rotate it 10 turns.
• Check that snap ring is fitted to the groove completely.
D155AXI-8 50-343
Input shaft outer race

1. Press-fit outer race (30) for input shaft, and install snap
ring (29).
Idler gear assembly

2. Use bearing, outer race, and spacer as a unit by aligning
manufacturing number and mark at places [d] to [f] shown
in the figure.
3. Set snap ring (28) to gear (24), and press-fit outer race
(27).
4. Insert shaft (23) until it reaches to the position shown in

the figure by using tools A (3 pieces).
REMARK
If shaft (23) is inserted to the end, gear (24) cannot be in-
stalled.
2 O-ring:
Grease (G2-LI)
50-344 D155AXI-8
5. Install O-ring to shaft (23).

6. Install spacer (26).
7. Install gear (24).

8. Set bearing (25), tighten bolt of plate (22), and press-fit in-
to the shaft.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
245.0 to 308.7 Nm {25.0 to 31.5 kgm}
9. Fix shaft (23) with mounting bolts.
Scavenging pump drive gear

10. Press-fit bearing (21) by using tool K, and install snap ring
(20).
D155AXI-8 50-345
11. Press the inner race side of bearing by using tool F, and in-
stall drive gear (19).
12. Install snap ring (18).
Cooling fan pump drive gear, cover assembly

13. Press-fit bearing (16) into case (17).
14. Press-fit bearing (15) into cover (12), and install snap ring
(14).
50-346 D155AXI-8
15. Press-fit inner race (41) into gear (13).
16. Press-fit gear (13) into cover (12) by using tool J.
17. Install the gear and cover assembly (11) as engaging them
to the idler gear.
2 O-ring:
Grease (G2-LI)
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
Work equipment, HSS pump drive gear, cover assembly

18. Press-fit bearing (40) into case (17).
D155AXI-8 50-347
19. Press-fit bearing (7), and inner race (8) into gear (9).
20. Install the gear and bearing assembly (6) to cover (5).
21. Install the gear and cover assembly (4) to case.

2 O-ring:
Grease (G2-LI)
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
Lubrication tube
22. Install lubrication tube (2).
3 Joint bolt:
34.3 to 44.2 Nm {3.5 to 4.5 kgm}
50-348 D155AXI-8

3 Joint bolt:
34.3 to 44.2 Nm {3.5 to 4.5 kgm}
D155AXI-8 50-349
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY BLY
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY
Tools for disassembly and assembly of torque converter assembly
New/Redesign
Necessity
Sketch
Q'ty
A 790-201-3260 Bolt ■ 2 Pulling out of shaft

Removal and installation of drive case
B - Eyebolt ■ 2
and housing assembly
C 790-201-3240 Bolt ■ 2
Pulling out and press fit of bearing
D 790-201-2660 Plate ● 1
E 790-201-2860 Spacer ■ 1 Removal of pump assembly
F 793T-615-1710 Spacer ■ 1 ○ Pulling out and press fit of bearing
G 790-201-2780 Spacer ■ 1
Press fit of bearing
H 790-201-2750 Spacer ■ 1
K - Block ■ 1 Fixing of turbine and gear
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY

Input shaft
1. Remove the mounting bolts (18 pieces), and remove input
shaft (1) by using tool A.
50-350 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY
Drive case, housing assembly

3. Remove mounting bolts (57) (30 pieces) between the drive
case and pump, and remove drive case and housing as-
sembly (56) by using tool B.
Disassembly of drive case and housing assembly

4. Remove snap ring (4), and remove spacer (5).
5. Remove bearing (8) from the turbine side by using tools C

(2 pieces).
D155AXI-8 50-351
6. Remove the mounting bolts (30 pieces), and remove hous-

ing assembly (6) by using tool B.
7. Remove seal rings (7) (2 pieces) from housing (9).
Piston
8. Remove piston (10).
9. Remove seal rings (11) (2 pieces) from piston (10).
Disc, plate
10. Remove discs (12) (2 pieces) and plate (13).
50-352 D155AXI-8
Turbine, gear
11. Remove the turbine and gear (15).
Stator and race assembly

12. Remove snap ring (16), and remove stator and race as-
sembly (17).
13. Remove snap rings (18) (2 pieces), and remove race (19)
from stator (20).
D155AXI-8 50-353
Pump
15. Remove snap ring (22) and spacer (23).
16. By using tool D, remove pump assembly (25) from stator
shaft and clutch assembly (24).

pump (28) from retainer (27).
18. Remove snap ring (29), and remove bearing (30) from re-
tainer (27) by using tool E.
Stator clutch assembly

19. Gradually loosen mounting bolts (31) (3 pieces), and dis-
connect housing and shaft assembly (32).
20. Remove stator clutch piston (33).
21. Remove seal ring (34) from stator clutch piston (33).
22. Remove pins (35) (5 pieces) and springs (36) (10 pieces),
and remove stator clutch discs (37) (2 pieces) and stator
clutch plate (38) from housing (39).
50-354 D155AXI-8
Housing and shaft assembly

23. Remove mounting bolts (40) (6 pieces).
24. Remove shaft (41) by using tool C.
25. Remove seal ring (42), bushing (43), and sleeve (44) from
shaft (45).
26. Remove snap ring (46), and remove gear (47).
27. By using tool D and press, press the shaft, and remove
shaft and bearing assembly (48) from housing (49).
28. Remove snap ring (50) and spacer (51), and remove bear-
ing (52) from shaft (53) by using tool F.
D155AXI-8 50-355
29. Remove seal ring (54) from shaft (53).
30. Remove seal rings (55) from housing (49).
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY

REMARK
• Clean each part and check them for dirt or damage. Apply their sliding surface with engine oil before instal-
ling.
• After press-fitting the bearing, drip Min. 6 cc of TO30 or TO10, and rotate it approximately 10 turns.
• When installing the bearing by expansion fit, drip Min. 6 cc of TO30 or TO10 to the bearing and rotate the
bearing approximately 10 turns before cooling it in dry ice, etc.
• Check if the snap ring is fitted securely to the groove.
Stator clutch assembly
1. Press-fit bearing (52) to shaft (53) by using tool F.
50-356 D155AXI-8
2. Install spacer (51) and snap ring (50) to shaft (53).

3. Install seal ring (54) to shaft (53).
REMARK
Securely fix the seal ring with grease.
2 Seal ring (54):
Grease (G2-LI)
4. Press-fit shaft and bearing assembly (48) to housing (49)

by using tool D.
5. Install bushing (43) and sleeve (44) to shaft (45).

REMARK
Install them by expansion fit.
6. Install seal ring (42) to shaft (45).
REMARK
Securely fix the seal ring with grease.
2 Seal ring (42):
Grease (G2-LI)
7. Install shaft assembly (41) to housing (49) by using 6 bolts

(40).
58.8 to 73.6 Nm {6.0 to 7.5 kgm}
D155AXI-8 50-357
8. Reverse the housing assembly, fit gear (47), and install

snap ring (46).
9. Install seal rings (55) to housing (49).

REMARK
The seal ring has the installation direction. Install it in the
direction as shown in the figure.
2 Outside perimeter of seal ring:
Grease (G2-LI)
10. Install seal ring (33) to stator clutch piston (34).
REMARK
Grease (G2-LI)
11. Install stator clutch piston (34) to housing (49).
2 Seal ring contact surface:
Grease (G2-LI)
12. Install 5 pins (35).

13. Install stator clutch discs (37) (2 pieces) and stator clutch
plate (38).
50-358 D155AXI-8
14. Install springs (36) (10 pieces).
15. Place housing (39) and tighten mounting bolts (a) (3

pieces) from the lower side.
REMARK
Tighten mounting bolts (a) (3 pieces) gradually and evenly.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
16. Insert mounting bolts (b) (10 pieces) of the transmission
assembly and torque converter assembly before installing
the pump.
Pump
17. Press-fit bearing (30) to retainer (27) by using tool G, and
install snap ring (29).
18. Install retainer (27) to pump (28).
58.8 to 73.6 Nm {6.0 to 7.5 kgm}
D155AXI-8 50-359
19. By using tool E, install pump assembly (25) to stator shaft

and clutch assembly (24).
20. Install spacer (23) and snap ring (22).
Stator and race assembly

21. Attach snap ring (21) to the shaft.
22. Install race (19) to stator (20) and install snap rings (18) (2
pieces).
23. Install stator and race assembly (17), and install snap ring
(16).
50-360 D155AXI-8
Drive case, housing

24. Set turbine and gear (15) on tool K.
25. Place drive case (14) on turbine and gear (15).
26. Install discs (12) (2 pieces) and plate (13).
27. Install seal rings (11) (2 pieces) to piston (10).

REMARK
Grease (G2-LI)
D155AXI-8 50-361
28. Install piston (10).
29. Install seal rings (7) (2 pieces) to housing (9).

REMARK
Grease (G2-LI)
30. Sling housing assembly (6), and install it to the drive case.
REMARK
Lower the housing gradually while aligning the holes (3
places) in the top of piston with the projecting pins inside
the housing.
2 Mounting bolt:
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
31. Press-fit the inner race of bearing (8) by using tool H.
50-362 D155AXI-8
32. Fit spacer (5), and install snap ring (4).
33. Install drive case and housing assembly (56).

REMARK
Align pump plug (57) with the oil groove of the drive case,
and install it.
2 Mounting bolt:
3 Mounting bolt:
49.0 to 58.8 Nm {5.0 to 6.0 kgm}
3 Mounting bolt:
14.7 to 19.6 Nm {1.5 to 2.0 kgm}
Input shaft
34. Install bearing (3) and snap ring (2) by using tool H.
35. Install input shaft (1).

2 Mounting bolt:
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
D155AXI-8 50-363
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY BLY
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY
Input shaft,
Valve Transmission front cover, and No.1 disc, No.1 housing
assembly case No.1 carrier plate, spring assembly A
assembly
No.2 housing Disassembly of

No.2 disc, and No.2 No.2 housing No.3 disc, No.3 carrier
A plate, spring carrier and No.2 carrier plate, spring assembly B
assembly assembly
Disassembly No.4 carrier Disassembly

Output shaft, of No.4 carrier
B of No.3 carrier
No.4 sun gear
and No.3 ring
and No.3 ring
No.3 housing C
assembly gear assembly gear assembly
No.4 disc, No.5 carrier Disassembly

of No.5 carrier No.4 housing
C plate, spring, and No.4 ring
and No.4 ring
No.5 sun gear
assembly D
guide pin gear assembly gear assembly
No.5 disc, No.5 ring gear, Cover Output

D plate, spring piston assembly housing
Tools for disassembly and assembly of transmission assembly

New/Redesign
Necessity
Sketch
Q'ty
791T-615-1300 Puller assembly ■ 1 ○

A 791T-615-1310 • Plate ■ 1 ○
Operation check of clutch piston
01010-82040 • Bolt ■ 1
B 799-301-1600 Oil leak tester kit (A) ■ 1
C 791T-615-1350 Push tool ■ 1 ○
791T-615-1320 Plate ■ 1 ○
D
01017-31620 Bolt ■ 4
Installation of snap ring
791T-615-1330 Plate ■ 2
E
01282-61230 Bolt ■ 4
F 791T-615-1340 Plate ■ 1 ○
G 793T-422-1220 Push tool ■ 1 ○
Pulling out of bearing
H 796-430-1110 Push tool ■ 1
J 790-201-2660 Plate ● 1 Press fit of bearing
K 793T-615-1730 Spacer ■ 1 ○ Install cover
50-364 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY
New/Redesign
Necessity
Sketch
Q'ty
L 790-201-3120 Guide bolt ■ 2 Installation of carrier and ring gear

Removal and installation of housing as-
M - Eyebolt ■ 2
sembly
Removal and installation of input shaft,
N - Sling bar ■ 1
front cover and No.1 carrier assembly
P 790-201-3230 Bolt ■ 2 Removal of cover
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY

REMARK
Keep the removed disc and plate on a level place to prevent from distortion.
Valve assembly
1. Remove relief valve assembly (1).
2. Remove cover assembly (2).

3. Remove the nut of wiring harness connector (2A), and
push in the connector.
4. Remove sleeve (3), flange (4) and (5).
D155AXI-8 50-365
5. Remove control valve assembly (6).
Transmission case
6. Remove snap ring (123) from output shaft (124).
7. Direct the torque converter side upward, and set the block.
8. Remove sleeve (7).
9. Sling transmission case (8) by using tool M, remove tie

bolts (9) (13 pieces) (tightened together with transmission
case and front cover), and remove case (8).
50-366 D155AXI-8
10. Remove remaining tie bolts (9) (4 pieces).
Input shaft, front cover, and No.1 carrier assembly

11. Remove input shaft, front cover, and No. 1 carrier assem-
bly (11) by using tool N.
12. Remove snap ring (12), and remove No.2 sun gear (13)
and snap ring (14).
13. Remove snap ring (15), and remove No.1 sun gear (16)
and collar (17).
14. Remove snap rings (18) and (126).

15. Drive out carrier toward the transmission side by using tool
C, and remove front cover (19).
D155AXI-8 50-367
16. Remove snap ring (20), ad drive out input shaft (21) to-
ward the torque converter side, and remove it.
17. Remove bearing (20a) from input shaft (21) by using tool
G.
18. Remove collar (128).

19. Remove snap ring (22), and remove No.1 ring gear (23).
20. Pull out shaft (24), and remove thrust washer (25), gear
(26), bearing (27), and ball (28).
REMARK
Be careful not to lose the ball.
No.1 disc, plate, spring

21. Remove spring (29).
22. Remove spring (30), disc (31), and plate (32).
No.1 housing assembly

23. Remove No.1 housing assembly (33) by using tool M.
24. Remove No.1 piston (34) from the housing.
50-368 D155AXI-8
25. Remove guide pin (35).

28. Remove guide (40) for through bolt, lubricating oil relief
valve (41) and spring (126).
No.2 housing and No.2 carrier assembly

30. Remove No.2 housing and No.2 carrier assembly (42) by
using tool M.
31. Remove ring gear (42a), and No.2 piston (43).
D155AXI-8 50-369
Disassembly of No.2 housing and No.2 carrier assembly

32. Remove snap ring (44), and pull out No.2 carrier assembly
(45) from No.2 housing (46).
33. Remove spacer (47) from No.2 carrier assembly (49).

REMARK
35. Remove snap ring (55), and remove ring gear (56).
REMARK
Press from the outside with the pin (Max. φ3 mm) to bend
the snap ring, and remove it.
36. Remove seal ring (57) and snap ring (58) from No.2 hous-
ing (46), and remove bearing (59).
50-370 D155AXI-8

No.3 carrier assembly

39. Remove No.3 carrier assembly (64).
Disassembly of No.3 carrier assembly

40. Remove seal ring (65).
41. Pull out shaft (66).
42. Remove thrust washers (67), planetary gear (68), bearing
(69) and ball (70).
REMARK
Output shaft, No.4 sun gear

44. Remove output shaft (73).
45. Remove snap ring (74) from the output shaft.
46. Remove No.4 sun gear (75).
D155AXI-8 50-371
No.4 carrier and No.3 ring gear assembly

47. Remove No.4 carrier and No.3 ring gear assembly (76).
Disassembly of No.4 carrier and No.3 ring gear assembly

48. Remove snap ring (77), and remove ring gear (127).
REMARK
Press from the outside with the pin (Max. φ3 mm) to bend
the snap ring, and remove it.
49. Remove seal rings (78) and (79).
50. Drive in roll pin (80) inward, and pull out shaft (80A).
51. Remove thrust washers (81), planetary gear (82), and
bearing (83).
52. Remove snap ring (84), and remove bearing (85) and
spacer (86) as an assembly.
53. Remove bearing (85) from spacer (86) by using tool H.
No.3 housing
54. Remove No.3 housing (87).
55. Remove No.3 piston (88).
No.4 disc, plate, spring, guide pin

57. Remove spring (90), No.4 disc (91), and plate (92).
58. Remove guide pin (93).
50-372 D155AXI-8

59. Remove mounting bolt (94).
60. Remove No.5 carrier and No.4 ring gear assembly (95).
Disassembly of No.5 carrier and No.4 ring gear assembly

REMARK
62. Remove snap ring (101), and remove No.4 ring gear (102)
from carrier (103).
No.5 sun gear

63. Remove No.5 sun gear (104).
D155AXI-8 50-373

64. Remove No.4 housing assembly (105).

67. Remove disc (108), plate (109), and spring (110).
No.5 ring gear, piston

68. Remove No.5 ring gear (111).
Cover assembly
70. Remove snap ring (113), and remove cover assembly
(114) from output housing assembly (115) by using tool I.
50-374 D155AXI-8
71. Remove seal rings (116) and (117) from cover (118).
72. Remove bearing (119) from cover (118).
Output housing
73. Remove snap ring (120), and remove bearing (121) and
spacer (122) from output assembly (123).
74. Remove bearing (121) from spacer (122) by using tool H.
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY

REMARK
• Clean all parts ,check them for dirt or damage, and assem-
ble them.
• Apply engine oil (for details, see "TABLE OF FUEL, COOL-
ANT, AND LUBRICANTS") to the sliding surface of each
part before installing.
• In the stall seal ring (a) for piston with receiving side (b) fac-
ing housing (c) as shown in the figure.
• When installing the metal seal ring, apply grease (G2-LI),
and then install the rings uniformly without unevenness.
Output housing
1. By using tool J, press-fit bearing (121) to spacer (122).
D155AXI-8 50-375
2. Install spacer (122) and bearing (121) assembly to output

housing (123).
Cover assembly
4. Install bearing (119) to cover (118).
5. Install seal rings (117) and (116) to cover (118).
6. By using tool K, install cover assembly (114) to output

housing assembly (115).
REMARK
Press-fit the inner race side of the bearing to install it.
50-376 D155AXI-8
No.5 piston, ring gear

8. Install No.5 piston (112) to the output housing.
9. Install No.5 ring gear (111).

10. Install guide pin (93).
11. Install disc (108), plate (109), and spring (110).
REMARK
Discs (3 pieces) and Plates (2 pieces)
12. Install spring (107).
Free length of spring 66 mm

13. Fit the seal ring, and install No.4 piston (106).
14. Install No.4 housing assembly (105).
REMARK
Check that the spring is securely fitted to the groove.

15. Set No.4 ring gear (102) to carrier (103), and install snap
ring (101).
D155AXI-8 50-377
16. Install bearing (99) to gear (98), fit thrust washers (97) to
both sides, and set it to carrier.
17. Fit ball (100), and install shaft (96).
18. By using tool L, set No.5 carrier and No.4 ring gear assem-
bly (95), and tighten mounting bolt (94).
2 Mounting bolt threaded portion:
66.2 to 7.4 Nm {6.75 to 0.75 kgm}
No.5 sun gear

19. Install No.5 sun gear (104).

20. Install No.4 disc (91), plate (92), and spring (90).
REMARK
50-378 D155AXI-8

23. Install No.3 housing (87).
REMARK

24. By using tool J, press-fit bearing (85) to spacer (86).
25. Install spacer (86) and bearing (85) assembly to No.4 car-
rier.
27. Install bearing (83) to planetary gear (82), fit thrust wash-
ers (81) to both sides, and set it to the carrier.
28. Align the pin hole of the shaft with that of the carrier, and
install shaft (80A).
29. Check that the pin holes are aligned each other, and then
drive in roll pin (80).
30. Install seal rings (79) and (78).
31. Set No.3 ring gear to No.4 carrier, and install snap ring
(77).
REMARK
Check that the snap ring is securely fitted to the groove.
32. Install No.4 carrier and No.3 ring gear assembly (76).
D155AXI-8 50-379
Output shaft
33. Install No.4 sun gear (75).
34. Install snap ring (74) to the output shaft.
35. Push in output shaft (73) while aligning it with the spline of
the sun gear.
No.3 carrier assembly

36. Install bearing (72) and snap ring (71) to the carrier.
37. Install bearing (69) to planetary gear (68), fit thrust wash-
ers (67) to both sides, and set it to carrier.
39. Install seal ring (65).
40. Install No.3 carrier assembly (64).

REMARK
4 discs and 3 plates
50-380 D155AXI-8
No.2 housing and No.2 carrier assembly

43. Install bearing (59) and snap ring (58) to No.2 housing
(46).
44. Install seal ring (57).
45. Set No.1 ring gear (56) to No.2 carrier (45), and install
snap ring (55).
48. Install No.2 ring gear (48).

REMARK
Direct the side where the inside was cut toward the carrier
side.
D155AXI-8 50-381
50. Install No.2 carrier assembly (45) to No.2 housing (46).

REMARK
Press-fit the inner race side of the bearing of the housing.
52. Install No.2 housing and No.2 carrier assembly (42) by us-
ing tool M.
REMARK
53. Fit the seal ring, and install No.2 piston (43) and ring gear
(42a).
54. Install tool A to the inner groove of No.3 carrier, pull up it,
and install snap ring (125).
55. Install guide (40) for through bolt, spring (126) and lubricat-
ing oil relief valve (41).
50-382 D155AXI-8

56. Install guide pin (35).
REMARK
Free length of spring 81.7 mm

60. By using tool M, align No.1 housing assembly (33) with
No.2 piston, and install the assembly.
REMARK
Press the housing, and push in the dowel pin.
Input shaft, No.1 carrier assembly

63. Set No.1 ring gear (23) to No.1 carrier, and install snap
ring (22).
64. Install bearing (117) to input shaft (21).

65. Fit bearing (117) of input shaft (21) to No.1 carrier assem-
bly (118), and install snap ring (18).
D155AXI-8 50-383
66. Install collar (17).

67. Install No.1 sun gear (16), and install snap ring (15).
69. Install No.2 sun gear (13), and install snap ring (12).
70. Sling input shaft and No.1 carrier assembly (119), mesh
No.2 sun gear and No.1 planetary gear, and install it.

REMARK
Free length of spring 81.7 mm
50-384 D155AXI-8
Front cover
74. Install seal ring (121) to front cover (122).
75. Install bearing (122a) and snap ring (122b) to front cover
(122).
76. By using tool M, align the guide pin with the spring, and in-
stall front cover (122).
77. Install tie bolts (9) (4 pieces). (Bolts (4 pieces) marked with
* in the figure)
3 Tie bolt (9) (4 pieces marked with *):
166.7±9.8 Nm {17±1 kgm}
78. Tighten bolt (d), press the inner side of bearing (123) by
using tool F, pull up tools D and E, input groove (e), and
carrier (f) (hatched area) entirely by its reaction force, and
align them with the groove of snap ring (124).
REMARK
When bolt (d) is tightened firmly, install snap ring (124).
REMARK
Check that the spring is securely fitted to the cover.
D155AXI-8 50-385
Piston operational check

79. By using tool B, check the operating conditions and stroke
of pistons.
Piston Standard stroke (mm)
No.1 7.2
No.2 7
No.3 5
No.4 5
No.5 6
Transmission case
80. Fit O-ring, install transmission case (8) by using tool M, and install remaining tie bolts (9) (13 pieces).
3 Tie bolt (9):
166.7±9.8 Nm {17±1 kgm}
81. Install sleeve (7).
Valve assembly
82. Install control valve assembly (6).
3 Mounting bolt:
49.1±4.9 Nm {5.0±0.5 kgm}
50-386 D155AXI-8
83. Install flanges (4), (5) and sleeve (3).
84. Install cover assembly (2).

2 Mounting bolt threaded portion:
Liquid gasket (LG-1 or LG-5)
85. Install relief valve (1).

3 Mounting bolt:
49.1±4.9 Nm {5.0±0.5 kgm}
D155AXI-8 50-387
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY BLY
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY
Tools for disassembly and assembly of HSS assembly New/Redesign

Necessity
Sketch
Q'ty
791-622-1110 Bracket ■ 1
Removal and installation of brake and
A 01010-31685 Bolt ■ 1
carrier assembly
01017-31620 Bolt ■ 1
B
09003-09200 • Wrench ■ 1 pinion side)

C
09003-08290 • Wrench ■ 1 gear side)
Removal and installation of bevel pinion

D 790-201-3130 Guide bolt ■ 2
assembly
E 791T-630-2410 Push tool ■ 1 ○ Removal of bevel pinion assembly
F 790-101-3501 Gear puller ■ 1
G 790-201-1410 Plate ● 1 Removal of gear
H 790-101-3000 Push puller ● 1
50-388 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY
New/Redesign
Necessity
Sketch
Q'ty
790-101-2501 Push puller ■ 1

790-101-2510 • Block ■ 1
790-101-2520 • Screw ■ 1
791-112-1180 • Nut ■ 1
J 790-101-2540 • Washer ■ 1 Pulling out of shaft
790-101-2550 • Leg ■ 2
790-101-2570 • Plate ■ 4
790-101-2560 • Nut ■ 2
790-101-2670 • Adapter ■ 2
K 790-201-2770 Spacer ■ 1
L 792T-415-1410 Push tool ■ 1 ○
M 792T-446-1150 Push tool ■ 1 ○
Press fit of retainer assembly
N 793T-613-1380 Spacer ■ 1 ○
P 79A-264-0021 Push-pull scale ■ 1 Measurement of starting torque
Q 793T-417-1110 Push tool ■ 1 ○
R 792T-413-1120 Push tool ■ 1 ○
S 793T-417-1310 Spacer ■ 1 ○
T 792T-415-1420 Push tool ■ 1 ○
U 790-201-2780 Spacer ■ 1
V 796T-426-1410 Push tool ■ 1 ○
W 793T-222-1310 Plate ■ 1 ○
X 793T-417-1130 Push tool ■ 1 ○
Y 796-426-1120 Push tool ■ 1 Press fit of bushing
Z 790-201-3120 Guide bolt ■ 2 Installation of brake cover assembly
AA - Eyebolt ■ 2 Removal and installation of case
AB - Block ■ 2 Fixing of bevel gear
796-514-2000 Remover ● 1
AC Pulling out of shaft
796-514-2130 Adapter ■ 1
D155AXI-8 50-389
METHOD FOR DISASSEMBLING HSS ASSEMBLY

Brake and carrier assembly
1. Tilt HSS case assembly approximately 15 deg. so that tool
A is installed perpendicularly against the ground surface.
2. Remove the mounting bolt, and remove brake and carrier
assembly (1) by using tool A.
REMARK
Do not remove the hexagonal socket head bolt.
REMARK
Remove the brake and carrier assembly on the opposite
side according to the same procedure.
Disassembly of brake and carrier assembly
3. Remove flange (2) and plate (3).
4. Loosen the hexagonal socket head bolts evenly, and re-

move brake case (5) by using tool AA.
REMARK
Loosen the bolts evenly since they are pressed by the
brake spring.
REMARK
The outer bearing is remove d together with the cover as a
unit.
5. Remove space (6), brake piston (7), piston (8), and cylin-
der (9).
50-390 D155AXI-8
6. Remove brake drum (12) together with the disc and plate.
7. Remove disc (15), spring (16), and plate (14) from the
brake drum.
8. Remove the mounting bolt, and remove carrier assembly

(19) from hub (18).
9. Remove gear assembly (20) from hub assembly (18).
10. Remove ring (21), and remove ring gear (22) from bearing
(108).
11. Remove snap ring (23), and pull out shaft (24).
D155AXI-8 50-391
12. Remove planetary gear (25), bearing (26), thrust washer

(27), shaft (24), and ball (28).
13. Remove snap ring (31), and remove stopper (32) from hub
(18).
Bevel pinion assembly

14. By using tool D and forcing screw, remove bevel pinion as-
sembly (33) and shim (34).
REMARK
Check the thickness and number of shims, and store
shims.
15. Remove bolt (35), and remove plate (36) and pin (37).
16. Press and fix the pinion by using press , and remove lock
nut (39) by using tool B.
17. By using tool E, remove bevel pinion (40) from cage (41).
50-392 D155AXI-8
18. Remove bearing (42).

19. Remove outer race (43) and (107) from cage (41).
20. Remove bearing (109) from bevel pinion (40).
Gear
21. Remove sun gear (45).
REMARK
Remove the gear on the opposite side according to the
same procedure.
22. Remove snap ring (47), and remove spacer (48).
D155AXI-8 50-393
23. By using tools F and G, remove gear (49).

REMARK
For bearing (55), only inner race (50) remains.
REMARK
Remove the gear on the opposite side according to the
same procedure.
Valve seat
24. Pull out and remove brake circuit tubes (51) (2 pieces) and
lubrication tubes (52) (2 pieces).
25. Remove valve seat (53).
Lubrication tube, dipstick pipe, suction tube

26. Remove lubrication tubes (52) and (56).
50-394 D155AXI-8
27. Remove lubrication tubes (57) and (58).

28. Remove dipstick pipe (59) and suction tube (60).
Motor output gear

29. Remove flange (61) from case (62).
30. Remove flange and gear assembly (63).
31. By using tool H, remove gear assembly (65) from flange

(64).
32. Remove inner race (67) and bearing (68) from gear (66).
33. Remove bearing (69) from flange (61).
D155AXI-8 50-395
Right side carrier drive gear

34. Remove bolt (70), and remove plate (71) and gear (72).
35. Drive out shaft (73) by using a plastic hammer to remove

it.
36. Remove inner race (75) from bearing (74).

Intermediate gear
38. Remove the shaft mounting bolt.
39. By using tool AC, pull out shaft (76), and remove gear (77)
and bearing (78).
50-396 D155AXI-8
Bevel gear shaft and bevel gear assembly

40. Remove mounting bolt (85) of the left side retainer.
41. Remove mounting bolt (86) of the right side retainer.
42. Sling bevel gear shaft and bevel gear assembly (87) and
remove it by using tool AA.
REMARK
Check the thickness and number of shims of the left side
cage, and store shims.
Disassembly of bevel gear shaft and bevel gear assembly

43. Remove inner race (91) on the right side of shaft (92) by
using tool H.
REMARK
Remove inner race (91) on the left side of shaft (92) ac-
cording to the same procedure.
44. Remove right side retainer (89) from shaft (92).
45. Remove hexagonal socket head bolt (95), and remove

plate (93) and shims (94).
D155AXI-8 50-397
46. Remove nut (96) by using tool C.

47. Remove spacer (96a).
48. Pull out left side retainer (97) from shaft (92) by using tools
J and G.
49. Remove bearing (98) from retainer (97).
50. Remove nut (99), and remove bevel gear (100) from shaft
(92).
51. Remove bearing (101) from right side retainer (89).
50-398 D155AXI-8
METHOD FOR ASSEMBLING HSS ASSEMBLY

REMARK
• Clean all parts, check them for dirt or damage, and assem-
ble them.
• Drip engine oil to the rotating parts of the bearing (For de-
tails, see "TABLE OF FUEL, COOLANT, AND LUBRI-
CANTS".), and then rotate it a few times.
• Apply engine oil (for details, see "TABLE OF FUEL, COOL-
ANT, AND LUBRICANTS") to the sliding surface of each
part before installing.
• Direct the pressure receiving side of the piston seal ring to-
ward the housing, apply grease (G2-LI), and then install the
rings uniformly without unevenness.
• Fix the rotating seal ring with grease (G2-LI), install it while using care not to let it be caught.
• Check if the snap ring is fitted securely to the groove.
Bevel gear shaft and bevel gear assembly
1. By using tool K, press-fit bearings (101) and (74) to right
side retainer (89).
2. Install inner race (106) to shaft (92) by shrink fit.

REMARK
Shrink fit temperature: Approximately 30 minutes at 100°C
3. Set bevel gear (100) to shaft (92), and tighten nut (99).
3 Nut:
215.8 to 274.6 Nm {22.0 to 28.0 kgm}
4. Install the seal rings.
5. By using tool L, press-fit outer race (103), bearing (104),
spacer (105), bearing (104), and outer race (103) to left
side retainer (97) in order.
D155AXI-8 50-399
6. Fit plate (93), and lightly tighten it with hexagonal socket

head bolts (a few pieces).
7. Receive the bevel gear by using tool AB, and press-fit re-
tainer assembly (102) to the shaft by using tools M and N.
8. Install spacer (96a).
9. Fix the shaft, and tighten nut (96) by using tool C.

2 Nut (96):
Adhesive (LT-2)
3 Nut (96):
735.5 to 902.2 Nm {75.0 to 92.0 kgm}
REMARK
Remove the bolt from the area where the tool contacts the
hexagonal socket head bolt.
10. Lightly tighten the bolts (4 pieces), measure dimensions

(a) and (c) to obtain dimension (b), and then select a shim
as thick as dimension (b).
Shim thickness (b) = ((a) - (c)) - (0.1 to 0.2 mm)
11. Install selected shim (94), and tightening bolt (95).
50-400 D155AXI-8
12. Install right side retainer (89) to shaft (92).
13. Install inner race (91) to shaft (92) by shrink fit.

REMARK
Shrink fit temperature: Approximately 20 minutes at 100°C
REMARK
Install inner race (91) on the left side of shaft (92) accord-
ing to the same procedure.
14. Install left side retainer (88) and tool R.

15. Sling the right side retainer by using tool Z, hold it, align
tool D with the bolt hole, and then install bevel gear shaft
and bevel gear assembly (90) to the case.
16. Install shims to the left side retainer, and tighten mounting
bolts (85) and (86) of the right and left retainers.
REMARK
Shims are available in 3 types: 0.1, 0.2, 0.5 mm
REMARK
Loosen the mounting bolt of the left side retainer when ad-
justing the backlash and tooth contact. To check the start-
ing torque of the bevel gear shaft, tighten the bolt tempora-
rily.
D155AXI-8 50-401
17. Press the tip of the teeth of bevel gear (100) by using tool
P to measure the starting torque of the bevel gear shaft.
Starting torque: Max. 3.0 Nm {0.31 kgm} (Tip of bevel gear
teeth: Max. 19.6 Nm {2.0 kgm})
Intermediate gear
18. Install snap ring (83) and spacer (84) to gear (77), and
press-fit outer race (82) by using tool Q.
19. Install bearing (78) on the lower side, spacer (81), and
bearing (78) on the upper side.
20. Install gear assembly (79) to case (80), align shaft (76)
with the bolt hole, and install the shaft.
REMARK
Align the shaft with the bolt hole of the plate, and install it.
Right side carrier drive gear

21. By using tool R, press-fit bearing (74) to the case.
22. By using tool S, press-fit inner race (75) to shaft (73).
REMARK
Press-fit up to approximately 27 mm from the shaft sur-
face.
REMARK
Install the shaft only to one side.
50-402 D155AXI-8
23. Align shaft (73) with the bearing, and install it.
24. By using tool S, install inner race (75) to the position be-
tween the shaft and bearing.
REMARK
Hold down the shaft from the opposite side.
25. Fit gear (72) and plate (71), and tighten bolt (70).
98 to 123 Nm {10.0 to 12.5 kgm}
Lubrication tube, suction tube, dipstick pipe

26. Install suction tube (60) and dipstick pipe (59).
27. Install lubrication tubes (57) and (58).
3 Joint bolt :
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
D155AXI-8 50-403

3 Joint bolt :
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
Bevel pinion
29. Press-fit bearing (109) to bevel pinion (40) by using tool T.
30. Press-fit outer races (43) and (107) to cage (41) by using
tool U.
31. Place bevel pinion (40) on the press stand, and set cage
(41).
32. Press-fit bearing (42) to cage (41) by using tool V and

press.
2 Lock nut (39):
Adhesive (LT-2)
3 Locknut (39):
696.3 to 863.0 Nm {71 to 88 kgm}
REMARK
Tighten the nut while rotating the cage.
REMARK
After tightening the nut, check that the bevel pinion rotates
smoothly.
33. Press and fix the pinion by using the press, and tighten lock nut (39) by using tool B.
34. Rotate the nut until phase of pin insertion holes (8 places) of the nut aligns with phase of pin insertion holes
(5 places) of the pinion shaft at 1 place.
Returning angle: 0 to 9 deg.
50-404 D155AXI-8
35. Insert pin (37) to the preceding hole, fit plate (36), and tighten bolt (35).
2 Bolt (35):
Adhesive (LT-2)
3 Bolt (35):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
36. By using tool D, install shim (34), and install bevel pinion
assembly (33).
REMARK
Shims are available in 3 types: 0.1, 0.2, 0.5 mm
Backlash
37. Put the probe of the dial gauge to the tooth surface of the bevel gear end perpendicularly, fix the bevel pin-
ion, and read the graduations when moving the bevel gear back and forth.
REMARK
Backlash standard value: 0.25 to 0.33 mm
REMARK
Measure the backlash at diagonal 3 points or more.
• When backlash is smaller
Add the shim of the left side retainer. (Advance the
bevel gear in direction (d).)
• When backlash is larger

Reduce the shim of the left side retainer. (Advance the
bevel gear in direction (e).)
Check of tooth contact

38. Select 3 pieces of teeth so that circumference of bevel gear is divided into 3 evenly. Apply red lead thinly on
entire teeth surfaces on travel forward side and travel reverse side. Rotate the bevel gear more than 17
times in both direction of forward and reverse.
39. Transcribe the tooth contact mark on the bevel gear to transparent tape in order to check it by sticking it on
external form of the gear shown in the following figure.
D155AXI-8 50-405
(v): Concave surface

(w): Convex surface
(x): External form of gear
(y): External form of pinion
REMARK
• The tooth contact is as shown below.
(j): 12 to 25 mm
(k): 18 to 31 mm
(m): 1 to 6 mm
(n): 5 to 11 mm
Check that there are no marks of strong contact at
tooth tip (f), dedendum (g), small end (h) and large end
(i).
50-406 D155AXI-8
• The tooth contact that meets the following conditions is

not appropriate.
Width (aa) of tooth contact engaged at pinion tooth tip:
Max. 7 mm
Distance (ab) between pinion tooth tip and tooth con-
tact large end: Min. 3 mm
REMARK
If the adjustment is done in this way, correct tooth contact
is obtained when the load is applied.
Adjusting of tooth contact
40. If no right pattern of tooth contact is obtained as a result of measuring, adjust it according to the following
procedure.
41. When the bevel pinion is too far apart from the bevel gear
center line, the tooth contact pattern shows that small end
tooth surface is bent toward the outside of the bevel gear
and large end tooth surface is bent toward the inside.
REMARK
• Adjust the bevel pinion side shims, and advance the
bevel pinion in direction (r).
• Advance the bevel gear in direction (s), and check the
tooth contact patterns and backlash again.
42. When the bevel pinion is too close to the bevel gear center
line, the tooth contact pattern shows that large end tooth
surface is bent toward the outside of the bevel gear and
small end tooth surface is bent toward the inside.
REMARK
• Adjust the bevel pinion side shims, and advance the
bevel pinion in direction (t).
• Advance the bevel gear in direction (u), and check the
tooth contact patterns and backlash again.
43. At the time of completion of adjustment, tighten the mount-
ing bolts of the cage and bevel pinion assembly to the specified torque.
3 Mounting bolts of both cage and bevel pinion assembly:
98 to 123 Nm {10.0 to 12.5 kgm}
Motor output gear
44. Press-fit bearing (69) to flange (61) by using a push tool.
45. Press-fit inner race (67) and bearing (68) to gear (66) by
using a push tool.
D155AXI-8 50-407
46. Install flange (64) to gear assembly (65).
47. Install flange and gear assembly (63) to case (62).

48. Install flange (61).
Valve seat
50. Align valve seat (53) with installed lubrication tube (52),
and install the seat.
51. Install brake circuit tube (51).
50-408 D155AXI-8
Gear
52. By using tool V, press-fit inside bearing (55), snap ring
(54), and outside bearing (55) to gear (49).
53. Align gear (49) with the bevel gear shaft bearing, and in-
stall it.
54. By using tool X, press-fit inner race (50).

55. Fit spacer (48), and install snap ring (47).
Sun gear
56. Install thrust washer (46) to sun gear (45).
57. Install sun gear (45).

58. Install stopper (32) to hub (18), and install snap ring (31).
59. Install bushing (38).
60. By using tool L, press-fit inner race (37).
REMARK
Make 2 assemblies according to the same procedure.
D155AXI-8 50-409
Carrier assembly
64. Install sleeve (36) to carrier (35).
65. Install bushings (29) and (30) to gear (108) by using tool Y.
66. Set gear (108) to ring gear (22), fit ring (21), and install the
ring gear to the gear.
67. Install gear assembly (20) to hub (18).

68. Install carrier assembly (19) to hub (18).
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
69. Set brake drum (12) to hub assembly (18).

REMARK
5 discs and 4 plates (14)
50-410 D155AXI-8
71. By using tool K, press-fit bearing (17) to hub (9).

72. Install seal rings (13a) and (13b) to hub (9).
73. Install hub (9).

75. Install piston (8) and spring (7).
REMARK
Install the spring so that the outside perimeter opens.
Brake cover assembly

76. Press-fit bearing (11) to brake cover (10) by using tool K.
77. Install tool Z to hub (9).
78. By using tool AA, align the bolt hole of the hub with that of
the brake drum, and install brake cover (5).
REMARK
Lightly install the mounting bolt.
REMARK
Evenly tighten the hexagonal socket head bolts since
spring works.
79. By using tool L, press-fit inner race (4).
80. Install plate (3) and flange (2).
3 Flange (2):
58.8 to 73.6 Nm {6.0 to 7.5 kgm}
D155AXI-8 50-411
81. Tighten the bolts lightly tightened in steps 7 and 9 to the

specified torque.
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}

82. Tilt the steering case assembly approximately 15 deg. so
that tool A is perpendicular to the ground surface.
83. Install brake and carrier assembly (1) by using tool A.
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
REMARK
Install the brake and carrier assembly on the opposite side
according to the same procedure.
REMARK
When cover (109) on the rear surface of HSS case (107),
install a brand new gasket (108).
2 Gasket (applying to both sides):
50-412 D155AXI-8
BLY REMOVAL AND INSTALLATION OF HSS MOTOR
REMOVAL AND INSTALLATION OF HSS MOTOR

record them.
METHOD FOR REMOVING HSS MOTOR ASSEMBLY

Draining oil
1. Remove plug (1), loosen plug (2) and drain oil.
6 Hydraulic tank:
91.5 ℓ
Fuel tank assembly

2. Remove the fuel tank assembly. For details, see “REMOVE AND INSTALL FUEL TANK ASSEMBLY”.
Motor assembly
3. Disconnect main hoses (3) and (4).
4. Disconnect drain hose (5).
5. Disconnect pin puller cylinder hose (6).
D155AXI-8 50-413
REMOVAL AND INSTALLATION OF HSS MOTOR BLY
6. Sling motor assembly (7), hold it, remove mounting bolts

(8) (2 pieces) and remove the assembly.
4 Motor assembly:
75 kg
METHOD FOR INSTALLING HSS MOTOR ASSEMBLY

Motor assembly
1. Sling motor assembly (7), hold it and install it with mount-
ing bolts (8) (2 pieces).
4 Motor assembly:
75 kg
2. Install pin puller cylinder hose (6).
3. Install drain hose (5).

4. Install main hoses (3) and (4).
Fuel tank assembly

5. Install the fuel tank assembly. For details, see “REMOVE AND INSTALL FUEL TANK ASSEMBLY”.
50-414 D155AXI-8
BLY REMOVAL AND INSTALLATION OF HSS MOTOR
Refilling with oil (hydraulic tank)

6. Install plugs (1) and (2).
7. Refill with oil to the specified level through the oil filler port.
Run the engine to circulate the oil through the system.
Then, check the oil level again.
5 Hydraulic tank:
91.5 ℓ For details of oil level, see "TABLE OF FUEL,
COOLANT, AND LUBRICANTS".
D155AXI-8 50-415
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY BLY
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY

Tools for removal and installation of final drive assembly
New/Redesign
Necessity
Sketch
Q'ty
790-337-1032 Lifting tool ■ 1

791-627-1320 Shackle ■ 2
A Remove and install final drive assembly
791T-627-1910 Plate ■ 1 ○
01010-82080 Bolt ■ 2
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY

Track shoe assembly
1. Separate the track shoe assembly. For details, see “SEPA-
RATION AND CONNECTION OF TRACK ASSEMBLY”.
Final drive assembly

2. Remove the inside mounting bolts (2) (8 pieces) of final drive assembly (1).
3. Lift the rear of the machine by using the jack, crane or rip-
per, and set tools B on the right and left side under the
frame, and then lift the rear of the machine.
4 Machine rear weight:

Approximately 9.5 t
4. Set tool C at the center of the equalizer bar, lift the ma-
chine front, and set tools D on the right and left sides of
the equalizer bar.
REMARK
When slinging by using the crane, use the towing hook of
the undercover.
4 Machine front weight:

Approximately 9.5 t
50-416 D155AXI-8
BLY REMOVE AND INSTALL FINAL DRIVE ASSEMBLY
5. Set the block under the front of the lifted track frame, and
secure the safety during the work.
REMARK
After setting tool B and tool D, set the jack and ripper
again as a support.
6. Remove guards (3) and (4).
7. Remove drive shaft cover (5).
D155AXI-8 50-417
8. By using the forcing screw, pull out drive shaft (6) up to the
position where the spline is removed.
REMARK
If the shaft cannot be removed easily, move the sprocket
backward and forward to adjust the shaft to the position
where the shaft is removed.
9. Remove the mounting bolt at the top of the final drive as-
sembly, and install tool A to the assembly.
10. Sling final drive assembly (1) by using tool A, hold it, and
remove all the bolts installed to the machine.
REMARK
• To easily remove and install the joint parts, adjust it by
using lifting tools so that the joint is kept parallel.
• To prevent the final drive from jumping out, loosen the
mounting bolt (1 piece each) on the both sides of the
final drive. Loosen the bolt and remove it while pulling
out the final drive assembly.
11. Sling final drive assembly (1) and remove it.
4 Final drive assembly:

1400 kg
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY

Final drive assembly
1. Sling final drive assembly (1) by using tool A, and install it
to the machine with the mounting bolt.
4 Final drive assembly:

1400 kg
3 Mounting bolt:
1150 to 1440 Nm {118 to 147 kgm}
50-418 D155AXI-8
BLY REMOVE AND INSTALL FINAL DRIVE ASSEMBLY
2. Remove tool A, and install the original mounting bolt to the

place where the tool was installed.
3 Mounting bolt:
1150 to 1440 Nm {118 to 147 kgm}
3. Fit drive shaft (6) back to final drive assembly (1).

REMARK
If the shaft cannot be inserted easily, move the sprocket
backward and forward to adjust the position where the
shaft is inserted, and fit it back.
4. Install drive shaft cover (5).
5. Install guards (3) and (4).

D155AXI-8 50-419
7. Lift the machine front by using tool C that is set at the cen-
ter of the equalizer bar, and remove tools D that are set on
the right and left side of the equalizer bar.
REMARK
the undercover.

Approximately 9.5 t
per, and remove tool B, jacks and block that were set on
the right and left side under the frame.

Approximately 9.5 t
9. Lower the machine that was lifted by using the jack, crane
or ripper.
10. Remove mounting bolts (2) (8 pieces) inside final drive as-
sembly (1).
Track shoe assembly

11. Install the track shoe assembly. For details, see “SEPARATION AND CONNECTION OF TRACK ASSEM-
BLY”.
50-420 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
Tools for disassembly and assembly of final drive assembly

New/Redesign
Necessity
Sketch
Q'ty
790-431-1031 Block ■ 1
791-520-4140 Screw ■ 2
790-101-2360 Plate ■ 4
791-112-1180 Nut ■ 2
A Pulling out of sprocket hub assembly
790-101-2480 Adapter ■ 2
791T-627-1920 Plate ■ 1
790-101-2102 Puller ■ 1
790-431-1031 Block ■ 1
791-520-4140 Screw ■ 2
790-101-2360 Plate ■ 4
791-112-1180 Nut ■ 2
B Pulling out of hub assembly
790-101-2420 Adapter ■ 2
796-430-1110 Push tool ■ 1
790-101-2102 Puller ■ 1
C 791-627-1280 Installer ■ 1 Press fit of floating seal
790-101-5401 Push tool kit ■ 1
790-101-5441 • Plate ■ 1
D Press fit of oil seal
790-101-5421 • Grip ■ 1
01010-51240 • Bolt ■ 1
D155AXI-8 50-421
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY BLY
New/Redesign
Necessity
Sketch
Q'ty
790-101-5401 Push tool kit ■ 1

790-101-5451 • Plate 1
E
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-201-1500 Push tool kit ■ 1
790-201-1680 • Plate 1
F
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-520-4140 Screw ■ 1
790-101-2420 Adapter ■ 1
791-112-1180 Nut ■ 1
G 01643-22460 Washer ■ 1
793T-417-1130 Push tool ■ 1 ○
790-101-2102 Puller ■ 1 Press fit of bearing
791T-627-1950 Plate ■ 1 ○
H 790-101-5421 Grip ■ 1
01010-51240 Bolt ■ 1
J 791T-627-1940 Push tool ■ 1 ○
791T-627-1960 Plate ■ 1 ○
K 790-101-5421 Grip ■ 1
01010-51240 Bolt ■ 1
790-101-2510 Block ■ 1
790-201-3310 Bolt ■ 2
L 790-101-2570 Plate ■ 2
01580-01613 Nut ■ 2 Press fit of bearing
01643-31645 Washer ■ 2
M 790-201-3340 Bolt ■ 2
N 790-201-3250 Bolt ■ 2
790-101-3000 Push puller ■ 1
P
790-201-2650 Plate ■ 1
Q 792T-415-1420 Push tool ■ 1 ○
Disassembly and assembly of final
R - Eyebolt ■ 2
drive assembly
S 792T-423-1320 Push tool ■ 1 ○ Press fit of bearing
50-422 D155AXI-8
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY

Draining oil
1. Remove the drain plug, and drain the oil in the final drive case.
Final drive caseApproximately 31 ℓ
Shaft
2. Remove drive shaft (1).
3. Set the final drive assembly on the block.
5. Remove shaft (3) by using tool R.
Sprocket hub assembly

6. Remove mounting bolts (4), and remove plate (5).
D155AXI-8 50-423
7. Pull out sprocket hub assembly (6) by using tool A to re-

move it.
REMARK
Bearing (7) is removed simultaneously.
8. Remove sprocket hub assembly (6) by using tool R.
9. Remove floating seal (8), and remove bearing outer races

(9) and (10).
REMARK
Keep the floating seal in a safe place so that it is not dam-
aged.
10. Turn over the sprocket hub assembly and remove 9

sprockets (11).
Wear guard
11. Remove wear guard (12).
4 Wear guard:
60 kg
50-424 D155AXI-8
Cover assembly
12. Remove spacer (13).
13. Remove floating seal (14).
REMARK
Keep the floating seal in a safe place so that it is not dam-
aged.
15. Sling cover assembly (16) by using tool R, hold it, and re-
move the cover assembly by using tools M (3 pieces).
REMARK
To easily remove and install the joint parts, adjust it by us-
ing lifting tools so that the joint is kept parallel.
16. Remove bearing (17), and remove spacer (18).
17. Turn over the cover assembly and remove lock plates (19)
at 6 places.
18. Remove ring gear (20).
D155AXI-8 50-425
Carrier assembly
19. Remove carrier assembly (21) by using tool R (3 pieces).
20. Remove bolt (22), and remove holder (23).

21. Pull out planetary gear shaft (24).
22. Remove planetary gear (25), bearings (26), (27), and

spacer (28) from the carrier.
23. Remove bearing outer races (29) and (30) from the plane-
tary gear.
50-426 D155AXI-8
Gear
24. Remove sun gear (32) from thrust (31).
25. Remove mounting bolt (33), and remove holder (34).
26. Slightly sling case, hub, and case assembly (35).

27. Press the shaft of case (36) to secure the clearance be-
tween bearing (37) and case shaft.
REMARK
Be careful not to damage the holding portion of the bearing
on the pinion side.

29. Sling gear (39) by using tool R, and remove the hub.
REMARK
If it is difficult to remove the hub, slightly tilt it to the right or
left to remove it.
D155AXI-8 50-427
Hub assembly
30. Remove hub assembly (40) by using tool B.
32. Remove hub assembly (40) by using tool R.
33. Remove bearing outer races (42) (2 pieces) from hub (41).
Case assembly
34. Remove collar (43), and remove bearing (44) from case
(36).
50-428 D155AXI-8
35. Remove plate (45) from case (36).
Cage assembly
36. Remove the mounting bolts of case assembly (46), and re-
move the assembly from case (36) by using tool N.
37. Remove outer race (48) and oil seal (49) from cage (47).
38. Remove shim (50).
D155AXI-8 50-429
Gear assembly
39. Remove gear assembly (51).
40. Remove bearings (52) and (53) from gear (54) by using
tool P.
41. Remove outer race (55) and oil seal (56) from case (36).
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY

Perform the work according to the following procedure when assembling the final drive assembly.
• Clean all parts, and check them for dirt or damage, and assemble them.
• Apply engine oil (for details, see “TABLE OF FUEL, COOLANT, AND LUBRICANTS”.) to the sliding surface
of each part before installing.
1. Press-fit oil seal (56) to case (36) by using tool D.
REMARK
• When installing the oil seal, be careful of the installa-
tion direction.
• Apply liquid gasket lightly to the inner surface of the
housing hole, and wipe off any protruded liquid gasket.
2 Oil seal lip:
Grease (G2-LI)
2 Press-fitting portion of oil seal:
Case
2. Press-fit outer race (55) to case (36) by using tool H.
Outer race press-fitting force: 1 to 13 kN {0.1 to 1.4 t}
50-430 D155AXI-8
Gear assembly
3. Press-fit bearings (52) and (53) to gear (54) by using tool
Q.
Bearing press fitting force: 6 to 17 kN {0.6 to 1.7 t}
4. Install the drive shaft cover.
5. Install gear assembly (51).
Cage assembly
6. Press-fit oil seal (49) to cage (47) by using tool D.
REMARK
• When installing the oil seal, be careful of the installa-
tion direction.
• Apply liquid gasket lightly to the inner surface of the
housing hole, and wipe off any protruded liquid gasket.
2 Oil seal lip:
Grease (G2-LI)
2 Press-fitting portion of oil seal:
7. Press-fit outer race (48) to cage (47) by using tool H.
8. Install O-ring to cage assembly (46), and adjust shim (50).

REMARK
Lower the cage assembly gradually to prevent the oil seal
lip from being damaged, and install it.
9. Adjust the clearance of the pinion ring bearing according to
D155AXI-8 50-431
1) Tighten mounting bolts (D), (E), (G), and (H) of cage

(47) uniformly.
3 Mounting bolt:
20 Nm {2 kgm}
2) Use the feeler gauge to measure clearance (a) and (b)
between cage (47) and case (36) under this condition.
3) Decide the number of shims (c) based on total of
clearance (a) and (b) referring to Table1.
4) Install shims (50) to cage (47) and tighten the mount-
ing bolts (6 pieces) of the cage uniformly.
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
Table 1
(a) + (b) (mm) Number (c) of shims to be used Thickness of shims in to-
Min. Less than t = 0.15 t = 0.5 t = 1.0 tal (mm)
3.05 3.15 5 1 1.75

3.15 3.25 2 1 1 1.80
3.25 3.35 9 1 1.85
3.35 3.45 6 1 1.90
3.45 3.55 3 1 1 1.95
3.55 3.65 2 2.00
3.65 3.75 7 1 2.05
3.75 3.85 4 1 1 2.10
3.85 3.95 1 2 2.15
3.95 4.05 8 1 2.20
4.05 4.15 5 1 1 2.25
4.15 4.25 2 2 2.30
4.25 4.35 9 1 2.35
4.35 4.45 6 1 1 2.40
4.45 4.55 3 2 2.45
4.55 4.65 1 2 2.50
4.65 4.75 7 1 1 2.55
4.75 4.85 4 2 2.60
4.85 4.95 1 1 2 2.65
4.95 5.05 8 1 1 2.70
5.05 5.15 5 2 2.75
5.15 5.25 2 1 2 2.80
5.25 5.35 9 1 1 2.85
5.35 5.45 6 2 2.90
5.45 5.55 3 1 2 2.95
5.55 5.65 3 3.00
50-432 D155AXI-8
(a) + (b) (mm) Number (c) of shims to be used Thickness of shims in to-
Min. Less than t = 0.15 t = 0.5 t = 1.0 tal (mm)
5.65 5.75 7 2 3.05

5.75 5.85 4 1 2 3.10
5.85 5.95 1 3 3.15
5.95 6.05 8 2 3.20
6.05 6.15 5 1 2 3.25
6.15 6.25 2 3 3.30
6.25 6.35 9 2 3.35
6.35 6.45 6 1 2 3.40
6.45 6.55 3 3 3.45
6.55 6.65 1 3 3.50
6.65 6.75 7 1 2 3.55
6.75 6.85 4 3 3.60
6.85 6.95 1 1 3 3.65
6.95 7.05 8 1 2 3.70
7.05 7.15 5 3 3.75
7.15 7.25 2 1 3 3.80
7.25 7.35 9 1 2 3.85
Case assembly
10. Install plate (45) to case (36).
REMARK
Press surfaces (a) and (b) of the case respectively to in-
stall the plate.
2 Mounting bolt:
11. By using tool E, press-fit bearing (44) to case (36).
D155AXI-8 50-433
Hub assembly
13. Press-fit bearing outer races (42) (2 pieces) to hub (41) by
using tool E.
14. Set hub assembly (40) to the shaft by using tool R.
Gear
15. Sling gear (39) by using tool R, and set it to the hub.
REMARK
If it is difficult to set the gear, slightly tilt it to the right or left
to set it.
50-434 D155AXI-8
16. Tighten gear mounting bolts (38).

2 Mounting bolt:
3 Mounting bolt:
230 to 289 Nm {23.5 to 29.5 kgm}
17. By using tool G, press-fit bearing (37) to case (36).

18. Install holder (34), and tighten mounting bolt (33).

2 Mounting bolt:
3 Mounting bolt:
230 to 289 Nm {23.5 to 29.5 kgm}
19. Install sun gear (32) and thrust (31).
D155AXI-8 50-435
Bearing
20. Press-fit bearing outer races (29) and (30) to the planetary
gear by using tool F.
REMARK
The planetary gear bearing is an assembled part. Align the
identification marks of the inner race, outer race, and
spacer to assemble them.
21. Install bearings (26), (27), and spacer (28) to planetary

gear (25).
Carrier assembly
22. Set the carrier to the planetary gear, and press-fit shaft
(24).
REMARK
Align the hole of bearing with that of the spacer, and press-
fit the shaft gradually.
23. Install holder (23), and tighten bolt (22).

2 Mounting bolt:
3 Mounting bolt:
23 to 289 Nm {23.5 to 29.5 kgm}
50-436 D155AXI-8
24. Install carrier assembly (21) by using tool R (3 pieces).
Cover assembly
25. Install ring gear (20), install lock plates (19) (6 pieces), and
tighten the mounting bolts.
2 Mounting bolt:

27. Press-fit bearing (17) by using tool J.
28. Press-fit floating seal (14) by using tool C.

REMARK
• Degrease O-ring and contact surface of O-ring com-
pletely and dry them before installing.
• After installing the floating seal, check that its leaning is
1 mm or less.
D155AXI-8 50-437
29. By using tool R, install O-ring to cover assembly (16), and

install them to the case assembly.
REMARK
• Avoid the mating surfaces of the case and cover from
dent, rust, oil, grease, dirt, and water.
• Apply liquid gasket to entire circumference of the mat-
ing surface on the case side (one side) without gap.
• After applying liquid gasket, tighten the bolt within 20
seconds.
2 Case mating surface:
30. Tighten it with mounting bolts (15).
3 Mounting bolt:
455 to 565 Nm {46.5 to 58 kgm}
Wear guard
31. Install wear guard (12).
3 Mounting bolt:
824 to 1030 Nm {84 to 105 kgm}
Sprocket hub assembly

32. Press-fit bearing outer races (9) and (10) by using tool K.
50-438 D155AXI-8
33. Install sprockets (11) (9 pieces) to the sprocket hub.

2 Mounting bolt:
3 Mounting bolt:
1176±98 Nm {120±10 kgm}
34. Press-fit floating seal (8) by using tool C.

REMARK
• Degrease O-ring and contact surface of O-ring com-
pletely and dry them before installing.
• After installing the floating seal, check that its leaning is
1 mm or less.
35. Install sprocket hub assembly (6) to the cover assembly by

using tool R.
REMARK
Check the floating seal sliding surface for dirt, etc. and
lightly apply engine oil to it.
36. Press fit bearing (7) by using tool L.

REMARK
Press-fit it while rotating the sprocket hub assembly.
37. Install plate (5), and tighten it with mounting bolts (4).
2 Mounting bolt:
3 Mounting bolt:
230 to 289 Nm {23.5 to 29.5 kgm}
D155AXI-8 50-439
Shaft
38. Install O-ring to the sprocket hub assembly side, and in-
stall shaft (3) by using tool R.
39. Tighten mounting bolts (2).

3 Mounting bolt:
1225 to 1470 Nm {125 to 150 kgm}
40. Install drive shaft (1).

41. Tighten the drain plug of the final drive case, and refill with
oil (TO30) from the oil filler port.
5 Final drive case:

Approximately 31 ℓ
3 Oil filler and drain plug:
127 to 176 Nm {13 to 18 kgm}
3 Dipstick plug:
58.8 to 76.4 Nm {6 to 8 kgm}
50-440 D155AXI-8
BLY REMOVE AND INSTALL TRACK FRAME ASSEMBLY
UNDERCARRIAGE AND FRAME

REMOVE AND INSTALL TRACK FRAME ASSEMBLY
Tools for removal and installation of track frame assembly
New/Redesign
Necessity
Sketch
Q'ty
791T-130-1010 Bracket ■ 6 ○
A 01010-63060 Bolt ■ 12 Fixing bogie assembly
01643-33080 Washer ■ 12
E - Eyebolt ■ 1 Removal and installation of track frame
F 791T-685-1410 Lifting tool ● 1 ○ assembly
G - Container ■ 1 Receiving of oil
METHOD FOR REMOVING TRACK FRAME ASSEMBLY

Blade assembly
1. Remove the blade assembly. For details, see “REMOVE AND INSTALL BLADE ASSEMBLY”.
Separation of track shoe assembly
2. Separate the track shoe assembly. For details, see “SEPARATION AND CONNECTION OF TRACK AS-
SEMBLY”.
D155AXI-8 50-441
REMOVE AND INSTALL TRACK FRAME ASSEMBLY BLY
Preparation
3. Fix the bogie assembly by using tool A.
per, and set tools B on the right and left sides under the
frame, and then raise the rear of the machine.

Approximately 9500 kg
5. Set tool C at the center of the equalizer bar, lift the ma-
chine front, and set tools D on the right and left sides of
the equalizer bar.
REMARK
the engine underguard.

REMARK
After setting tool B and tool D, set the jack and ripper
again as a support.
7. Install tool E for slinging.
50-442 D155AXI-8
8. Sling track frame assembly (16) to be removed by using

lifting tools, and hold it.
REMARK
• To easily remove and install the joint parts, adjust it by
• Track frame assembly can be lifted straight without hit-
ting the step by using tool F.
Pin
9. Remove mounting bolts (1), and remove cover (2).
10. Remove mounting bolts (3) (2 pieces), and remove lock
plate (4).
11. Pull out pin (5).
REMARK
It is difficult to remove the pin if the holes of the equalizer
bar and track frame are not aligned each other. Adjust the
slinging height on the track frame side for removal.
Guard
12. Remove guard (6).
D155AXI-8 50-443
Hose
13. Remove the mounting bolt, and pull out cover (7).
REMARK
Prepare tool G for oil leakage from the hose.
REMARK
• Be careful that the hose is connected inside the cover.
• Prepare tool H since oil leaks from the pivot shaft case.
14. Disconnect hoses (8), (9), (10), and (11) that are connect-
ed inside the pulled out cover (7), and remove cover (7).
REMARK
Plug the hoses to prevent any dirt, dust and water from en-
tering.
15. Remove the mounting bolts (2 pieces) and washer (12).

16. Remove seal (13).
17. Remove the mounting bolts (6 pieces) and washer (14).
18. Remove spacer (15) from washer (14).
50-444 D155AXI-8
Track frame assembly

19. Sling track frame assembly (16) and remove it.
4 Track frame assembly:

3825 kg
REMARK
Be careful not to contact the step.
20. Remove seal (17) from pivot shaft (18).
D155AXI-8 50-445
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY

1. Reverse seal (17) so that the molded character (c) surface
of seal (17) faces inward.
2. Insert seal (17) into pivot shaft (18) with seal (17) re-
versed.
3. Apply engine oil to surface (d) of track frame assembly
(16).(For details, see “TABLE OF FUEL, COOLANT, AND
LUBRICANTS”.)
4. Sling track frame assembly (16) with the lifting tool, and in-
stall it to pivot shaft (18) and then to the machine.
4 Track frame assembly:

3825 kg
REMARK
• When inserting the track frame assembly, take extreme
care not to damage the seal surface.
• To easily remove and install the joint parts, adjust them
by using lifting tools so that the joint is kept parallel.
50-446 D155AXI-8
Hose
5. Install washer (14) to spacer (15).
6. Install the mounting bolts (6 pieces) to the installed washer
(14).
7. Reverse seal (13) so that the molded character (a) surface
8. Insert seal (13) into washer (14) with seal (13) reversed.
9. Apply engine oil to surface (b) of washer (12) at the shaft
end.(For details, see “TABLE OF FUEL, COOLANT, AND
LUBRICANTS”.)
10. Install washer (12) at the shaft end.
11. Install the mounting bolts (2 pieces) to the installed washer
(12).
D155AXI-8 50-447
12. Connect hoses (8), (9), (10), and (11) to cover (7), and in-
stall them to the track frame assembly.
REMARK
Prepare tool G for oil leakage from the hose.
13. Install cover (7) with the mounting bolt.
14. Tighten the drain plug of the pivot shaft case, and fill with
the engine oil through the oil filler port. (For details, see
“TABLE OF FUEL, COOLANT, AND LUBRICANTS”.)
5 Pivot shaft case:

Approximately 9 ℓ
Guard
15. Install guard (6).
50-448 D155AXI-8
Pin
16. Insert pin (5).
REMARK
It is difficult to insert the pin if the holes of the equalizer bar
and track frame are not aligned each other. Adjust the
slinging height on the track frame side for removal.
17. Install lock plate (4), and install mounting bolts (3) (2
pieces).
18. Install cover (2) and install mounting bolts (1).
2 Threaded portion of mounting bolt (1):
784 to 981 Nm {80 to 100 kgm}
19. Grease the pin from the grease nipple.
2 Pin:
Grease (G2-L1)
Recovery work
20. Place tool C at the center of the equalizer bar, lift the ma-
chine front, and remove tool D.
REMARK
• When slinging by using the crane, use the towing hook
of the engine underguard.
• As a support, slightly lift the machine rear by using the
ripper.
• Set the block under the front of the lifted track frame,
and secure the safety during the work.
per, and remove tool B under the frame.

D155AXI-8 50-449
22. Remove the jack, and remove tool A from the bogie as-
sembly.
Installation of track shoe assembly

BLY”.
Installation of blade assembly
24. Install the blade assembly. For details, see “REMOVE AND INSTALL BLADE ASSEMBLY”.
50-450 D155AXI-8
BLY REMOVE AND INSTALL IDLER ASSEMBLY
REMOVE AND INSTALL IDLER ASSEMBLY

METHOD FOR REMOVING IDLER ASSEMBLY

SEMBLY”.
NOTICE
For hazard prevention, never let anyone stand at front of the idler assembly.
Support
2. Remove side cover (1).
REMARK
Remove one each from inside and outside.
3. Loosen the support mounting bolt, remove shims, and re-

move support (2).
REMARK
• Check the number and thickness of the shims, and
keep them in a safe place.
• Remove one each from inside and outside.
D155AXI-8 50-451
REMOVE AND INSTALL IDLER ASSEMBLY BLY
Idler assembly
4. Loosen guide tension bolt (3).
REMARK
Loosen 2 pieces each on inside and outside.
5. Remove idler guide mounting bolt (4).
6. Sling idler assembly (5), pull it forward, and remove it.
4 Idler assembly:
350 kg
7. Remove spring seat (6), and remove tension spring (7).
REMARK
The preceding parts are assembled between the support
and track frame.
METHOD FOR INSTALLING IDLER ASSEMBLY

Idler assembly
1. Install tension spring (7) and spring sheet (6).
2. Sling idler assembly (5), and install it to the track frame.
4 Idler assembly:
350 kg
3. Install idler guide mounting bolt (4).
4. Tighten guide tension bolt (3).
50-452 D155AXI-8
BLY REMOVE AND INSTALL IDLER ASSEMBLY
Support
5. Fit shims, and install support (2).
REMARK
Place the idler assembly at the center of the track frame,
and adjust clearance (a) between the track frame and
guide plate by using shims.
Standard clearance (a): 0.5 to 1.0 mm Standard shim
thickness: 6 mm
6. Install side cover (1).

REMARK
Install one each to inside and outside.
Installation of track shoe assembly

BLY”.
D155AXI-8 50-453
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY BLY
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY

Tools for disassembly and assembly of idler assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 2 Fixing of idler assembly

B - Forcing screw ■ 2 Removal of retainer
791T-630-1230 Plate ■ 1
791-630-1220 Log ■ 2
790-101-2510 Block ■ 1
790-101-2570 Washer ■ 2
C Press fit of idler bushing
01580-01411 Nut ■ 2
01643-31445 Washer ■ 2
790-101-2102 Puller (294 kN {30 t} ) ■ 1
D 796-670-1020 Installer ■ 1 Installation of floating seal
E 791-601-1000 Oil pump ■ 1 Refilling with oil
METHOD FOR DISASSEMBLING IDLER ASSEMBLY

Draining
1. Remove the oil drain plug to drain the oil.
6 Idler:
670 to 730 cc
Retainer
2. Set idler assembly (1) on tool A.
3. Remove nut (2), and pull out bolt (3).
4. Remove support (4).
5. Remove ring (5).
6. Remove the mounting bolts, and retainer (6) by using tool

B.
7. Remove plate (7).
8. Reverse the idler assembly.
50-454 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
9. Remove nut (8) and bolt (9), and remove support (10).
10. Remove ring (11).
11. Remove retainer (12) by using tool B.

13. Sling shaft (14), and remove it.
Floating seal
14. Remove floating seals (15) from rings (5) and (11).
15. Remove floating seals (16) from retainers (6) and (12).
Bushing
16. Remove bushing (17) from idler (1).
METHOD FOR ASSEMBLING IDLER ASSEMBLY

Clean all parts, and check them for dirt or damage, and assemble the idler assembly.
D155AXI-8 50-455
Bushing
1. Set tool C to idler (1), and press-fit bushing (17).
REMARK
• Center the bushing by using a plastic hammer, etc.,
and then press-fit it.
• Press-fit the bushing so that dimension (a) between the
idler end surface and bushing upper surface is
16±0.5 mm.
Bushing press-fitting force: 16 to 92 kN {1.6 to 9.4 t}
Floating seal
2. Install floating seal (12) to retainers (5) and (9) by using
tool D.
REMARK
• Seal projection size (b) shown in figure (A) is 7 to
11 mm.
• After inserting, check that the seal tilt is 1 mm or less.
• Clean, completely degrease and dry the thick line area
(O-ring and contact surface of O-ring) shown in figure
(B) before installing the seal.
3. Install floating seal (11) to rings (8) and (4) by using tool D.
50-456 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
REMARK
• Seal projection size (b) shown in figure (A) is 7 to
11 mm.
• After inserting, check that the seal tilt is 1 mm or less.
• Clean, completely degrease and dry the thick line area
(O-ring and contact surface of O-ring) shown in figure
(B) before installing the seal.
Retainer
4. Set idler (1) to tool A.
5. Install plate (13), and install retainer (12).
6. Sling idler (1), reverse it, and set it to tool D.

7. Sling shaft (14), and install it to the idler.
REMARK
Install the idler while taking care not to damage the retain-
er mounting floating seal on the bottom side.
8. Install plate (7), and install retainer (6).
9. Press-fit ring (12) to the shaft by using push tool so that di-
mension (C) is secured.
REMARK
Apply engine oil thinly to the floating seal mating face (For
details. see "TABLE OF FUEL, COOLANT, AND LUBRI-
CANTS".) before installing the ring.
Ring press-fitting dimension (c): 80±0.2 mm
10. Reverse idler (1), and set it to tool A.

11. Press-fit ring (6) to the shaft by using push tool so that di-
mension (d) is secured.
REMARK
Apply engine oil thinly to the floating seal mating face (For
details. see "TABLE OF FUEL, COOLANT, AND LUBRI-
CANTS".) before installing the ring.
Ring press-fitting dimension (d): 80±0.2 mm
D155AXI-8 50-457
12. Install supports (4) and (10) to shaft (14), fit bolts (3) and
(9), and tighten nuts (2) and (8).
13. By using tool E, apply the standard pressure to the oil filler
port of the idler assembly to check for air leakage from the
seal.
REMARK
Apply the standard pressure for 10 seconds, and check
that the pointer of gauge does not drop down.
Standard pressure: 0.1 MPa {1 kg/cm2}
Refilling with oil

14. Fill the idler assembly with oil by using tool E.
5 Idler oil:
670 to 730 cc (GO140B)
15. After filling with oil, check that the oil is at the specified level.
REMARK
Remove the oil filler plug, tilt the idler assembly approxi-
mately 10 °, and check that oil is at the under surface of
the oil filler port.
16. Tighten the oil filler plug.
3 Oil filler plug:
160 to 255 Nm {16.0 to 26.0 kgm}
50-458 D155AXI-8
BLY REMOVE AND INSTALL RECOIL SPRING ASSEMBLY
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY

METHOD FOR REMOVING RECOIL SPRING ASSEMBLY

Idler assembly
1. Remove the idler assembly. For details, see “REMOVE AND INSTALL IDLER ASSEMBLY”.
Recoil spring assembly
2. Pull out recoil spring assembly (1) forward, and remove it.
4 Recoil spring assembly:

510 kg
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY

1. Insert recoil spring assembly (1) into the track frame.
REMARK
When installing the recoil spring assembly to the track
frame, check it through the lubricator adjustment window
while inserting it.
4 Recoil spring assembly:

510 kg
Idler assembly
2. Install the idler assembly. For details, see “REMOVE AND INSTALL IDLER ASSEMBLY”.
D155AXI-8 50-459
DISASSEMBLE AND ASSEMBLE RECOIL SPRING BLY
DISASSEMBLE AND ASSEMBLE RECOIL SPRING
Tools for disassembly and assembly of recoil spring assembly
New/Redesign
Necessity
Sketch
Q'ty
A 790-201-2840 Spacer ■ 1 Pulling out of piston

791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
B 791T-630-2610 Spacer ■ 1
Compression of recoil spring
790-101-1300 Cylinder ■ 1
C - Lever block ■ 1
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING

Yoke, piston assembly
1. Remove yoke and piston assembly (2) from recoil spring
assembly (1).
50-460 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE RECOIL SPRING
Disassembly of yoke and piston assembly

2. Remove snap ring (3), and remove packing (4) and ring
(5).
3. Remove bolt (6), and remove plate (7).
4. Pull out piston (9) from yoke (8) by using press and tool A.
5. Perform the following procedure depending on whether or

not cylinder (10) is broken or shaft end nut (11) is re-
moved.
6. Remove holder (13) from recoil spring case (12).

NOTICE
For hazard prevention, never let anyone stand at front
and rear of the recoil spring assembly.
D155AXI-8 50-461
Holder
7. Remove cover (15) from holder (14).
8. Remove seal (16) and bushing (17) from holder (14).
9. Remove the lock plate and lubricator (18) from cylinder

(10).

10. Set recoil spring assembly (1) on tool B.
NOTICE
Since the load at installed length of the spring is large
and dangerous, set the recoil spring assembly secure-
ly to the tool.
Load at installed length of spring: 314 kN {32,000 kg}
11. Apply oil pressure slowly by using tool B to compress the

spring, and tighten shaft end nut (11) until spacer (19) is
removed, and then remove the spacer.
12. Remove shaft end nut (11), and release the oil pressure
gradually to release the tension of the spring.
50-462 D155AXI-8
13. Remove recoil spring (20) and cylinder (10) from recoil
spring case (12).
14. Remove bushing (21) from cylinder (10).
15. Remove seal (22) and holder (23) from recoil spring case
(12).
When cylinder is broken and shaft end nut is remove

16. Remove the mounting bolt of holder (13) by using tool B.
NOTICE
• When the mounting bolt of holder (13) is removed,
recoil spring (20) jumps out to the front. Be sure to
use tool B to remove the bolt.
• Never let anyone stand at the front and rear of the
recoil spring assembly until holder (13) is discon-
nected from recoil spring case (12) and the recoil
spring is removed.
17. Set recoil spring assembly (1) on tool B.

NOTICE
ly to the tool.
18. Apply oil pressure slowly to fix recoil spring assembly (1).
(Do not compress the spring as possible.)
19. Remove the mounting bolt of holder (13).
20. Release the oil pressure gradually to release the tension of the spring.
D155AXI-8 50-463
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY

1. Press-fit bushing (23) to recoil spring case (12) by using a
push tool, and install seal (22).
2 Bushing:
Grease (G2-LI)
2. By using a push tool, press-fit bushing (21) to cylinder
(10).
2 Bushing:
Grease (G2-LI)
3. Inside of case and parts inside case Grease layer thick-

ness Min. 3 mm)
2 Inside of case and parts inside case:
Grease ((G2-LI)
4. Temporarily assemble recoil spring (20) and cylinder (10)
on recoil spring case (12), and set them on tool B.
NOTICE
ly to the tool.
REMARK
To protect the threaded portion from any damage when the spring is compressed, use chain tool C, etc. to
center the recoil spring and compress it.
Installed height of spring: 656 mm
5. Install shaft end nut (11), and install spacer (19).
REMARK
• Do not create clearance between the shaft end nut and
spacer when installing them.
• If the clearance is created, the threaded portion of the
shaft end nut is subject to the spring load, and the
screw may be damaged. (If the screw is damaged, the
assembly cannot be disassembled next time.)
6. Gradually release the oil pressure, loosen the spring ten-

sion completely, and remove recoil spring assembly (1)
from tool B.
50-464 D155AXI-8
7. Install lubricator (18) to cylinder (10), and install the lock

plate.
REMARK
Install the grease fitting so that it faces outside 45±5 °.
Holder
8. Press-fit bushing (17) to holder (14) by using a push tool,
and install seal (16).
2 Bushing, oil seal:
Grease (G2-LI)
9. Install cover (15) to holder (14).
10. Install holder (13) to recoil spring case (12).

2 Mating surfaces of holder and case:
Grease (G2-LI)
Yoke, piston assembly

11. Press fit piston (9) to yoke (8) by using a push tool.
Yoke press-fitting force: 392 kN{40 t}
D155AXI-8 50-465
12. Fit plate (7), and tighten bolt (6).

REMARK
Check that the plate is not displaced onto the yoke.
13. Install ring (5) and packing(4), and install snap ring (3).
2 Packing, ring:
Grease (G2-LI)
14. Install yoke and piston assembly (2) to recoil spring as-
sembly (1).
50-466 D155AXI-8
BLY REMOVE AND INSTALL TRACK ROLLER ASSEMBLY
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY

Tools for removal and installation of track roller assembly
New/Redesign
Necessity
Sketch
Q'ty
791T-130-1010 Bracket ■ 6 ○
A 01010-63060 Bolt ■ 12
Fixing bogie assembly
01643-33080 Washer ■ 12
B - Lever block ■ 1
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY

Track shoe
1. Remove upper cover (5) of the track frame, loosen lubrica-
tor (6) to degrease, and loosen the track tension.
k The internal pressure of the recoil spring cylinder
is high. Do not loosen lubricator (6) 1 turn or more.
REMARK
If the track tension is not loosened even by loosening the
lubricator, perform forward and reverse travel of the ma-
chine.
Preparation
2. Install tool A, and fix bogie assembly (1).
REMARK
Fix the bogie assembly corresponding to the position of
track roller assembly (2) to be removed referring to the fol-
lowing table.
Bogie assembly to be fixed by using the
Track roller assem- tool
bly to be removed
Installed bogie Related bogie
1st roller (*1) 2nd bogie
2nd roller 2nd bogie 1st bogie
3rd roller 2nd bogie 3rd bogie
4th roller 3rd bogie 2nd bogie
5th roller 3rd bogie 4th bogie
6th roller 4th bogie 3rd bogie
7th roller 4th bogie -
D155AXI-8 50-467
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY BLY
*1: Sling 1st bogie assembly (1) by using tool B, etc. and
fix it. For 1st bogie assembly (1), fixing tools cannot be
used.
REMARK
Mounting configuration of track roller assembly (2)
(S): Track roller assembly (single flange)
(D): Track roller assembly (double flange)
3. Operate the blade and ripper to lift the machine up to the
position where track roller assembly (2) is lifted from the
track shoe.
REMARK
Lower the engine speed, and slowly move the blade and
ripper.
Track roller assembly
4. Loosen the mounting bolts of roller cap (3).
REMARK
• Loosen the both bolts inside and outside.
• Do not remove the mounting bolt.
5. Operate the blade and ripper to lower the machine.
REMARK
ripper.
6. Remove the mounting bolts, and remove roller cap (3).
REMARK
The dowel pin is inserted. Be careful not to damage it.
position where track roller assembly (2) is separated from
the bogie.
8. Pull out track roller assembly (2) to the outside of the ma-
chine.
4 Track roller assembly (single flange):

95 kg
4 Track roller assembly (double flange):

110 kg
REMARK
Lower the engine speed, and slowly move the blade and ripper.
50-468 D155AXI-8
BLY REMOVE AND INSTALL TRACK ROLLER ASSEMBLY
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY

Preparation
1. Operate the blade and ripper to raise the machine to the position where track roller assembly (2) can be set
on the track shoe.
REMARK
2. Set track roller assembly (2) on the track shoe.
REMARK
Install track roller assembly (2) with the oil filler plug facing
outward.
3. Operate the blade and ripper, lower the machine to the po-
sition where roller cap (3) can be lightly tightened with the
roller cap mounting bolts.
REMARK
ripper.
4. Lightly tighten roller cap (3) with the roller cap mounting
bolt.
5. Align dowel pin (4) with the dowel pin hole of the track roll-
er, and tighten roller cap (3) with the roller cap mounting
bolt.
REMARK
Be careful not to break the dowel pin.
2 Roller cap mounting bolt:
662 to 829 Nm {67.5 to 84.5 kgm}
Recovery work
REMARK
D155AXI-8 50-469
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY BLY
7. Remove tool A that was fixing bogie assembly (1) and tool
B that was slinging 1st bogie assembly (1).
8. Remove upper cover (5) of the track frame, tighten lubrica-

tor (6) of the cylinder back to the original state, add
grease, and strain the track shoe.
9. Adjust the track tension. For details, see TESTING AND
ADJUSTING, “TEST AND ADJUST TRACK TENSION”.
50-470 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY

Tools for disassembly and assembly of track roller assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1 Fixing of track roller

B 790-201-3250 Forcing screw ■ 2 Pulling out of plate
C Removal and installation of shaft and
- Eyebolt ■ 2
retainer
Pulling out and press fit of shaft and
D 791T-630-1290 Plate ■ 1 ○
seal guide
E 791T-630-1330 Push tool ■ 1 ○ Press fit of bushing
G 791-601-1000 Oil pump ■ 1 Refilling with oil
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY

Draining
1. Remove the oil filler plug, and drain oil.
6 Track roller:
930 to 990 cc
Retainer
2. Set track roller (1) on tool A.
3. Remove the mounting bolt, and remove ring (2) together
with retainer (3) and plate (4) as a unit by using tool B.
4. Reverse the track roller assembly.
5. Remove the mounting bolt, and remove shaft (5) together
with retainer (3) as a unit by using tool C.
6. By using press, remove ring (6), retainer (7), plate (4) and
(8) from the shaft.
7. Remove rings (2) and (6) from the retainers (3) and (7).
D155AXI-8 50-471
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY BLY
Floating seal
8. Remove floating seal (9) from rings (2) and (6).
REMARK
Keep the floating seal not to damage it.
9. Remove floating seal (10) from retainers (3) and (7).
REMARK
Keep the floating seal not to damage it.
Bushing
10. Remove bushings (11) (2 pieces) from roller (12).
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY

Perform the work according to the following procedure when assembling the track roller assembly.
Clean each part, and check for dirt or damage.
Bushing
1. Set roller (12) on the press, press-fit it by using tool D so
that press-fitting dimension between roller end surface of
bushing (11) and bushing upper surface is (a).
REMARK
Center the bushing by using a plastic hammer, etc., and
then press-fit it.
(a): 18±1 mm
Bushing press-fitting force: 19 to 120 kN {2 to 12 t}
2. Set shaft (5) to the roller.
Floating seal, retainer
3. By using tool F, install floating seal (10) to retainers (3) and
(7).
REMARK
• When installing the floating seal, clean, degrease and
completely dry the contact faces of O-ring and floating
seal (hatched area). Be careful not to allow dirt and for-
eign matter to attach on the contact surface of the float-
ing seal.
• After inserting the floating seal, check that the tilt of the
seal is 1 mm or less and the projection dimension (a) of
the seal is in the range of 7 to 11 mm.
50-472 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
4. Fit O-ring, and install the roller to retainers (3), (7), plate (4) and (8).
REMARK
Check that the plate can be rotated smoothly by hand.
5. By using tool F, install floating seal (9) to seal guides (2)
and (6).
Press fitting force of ring: 39 to 69 kN {4 to 7 t}
REMARK
• When installing the floating seal, clean, degrease and
completely dry the contact faces of O-ring and floating
seal (hatched area). Be careful not to allow dirt and for-
eign matter to attach on the contact surface of the float-
ing seal.
seal is 1 mm or less and the projection dimension (a) of
the seal is in the range of 7 to 11 mm.
Ring
6. Press-fit ring (2) to the shaft by using tool E.
REMARK
• Press-fit the ring so that press-fitting dimension (c) be-
tween the shaft end and ring upper surface is as follow-
ing.
• Reverse the track roller assembly, and press-fit ring (6)
on the opposite side according to the same procedure.
Press-fitting dimension (c): 48.5±0.2 mm
Check for leakage

7. By using tool G, apply the standard pressure to the oil filler
port of the track roller assembly to check for air leakage
from the seal.
REMARK
Apply the standard pressure for 10 seconds, and check
that the pointer of gauge does not drop down.
Standard pressure: 0.1 MPa {1 kg/cm2}
Refilling with oil

8. Fill the track roller assembly with oil (GO140) by using tool G.
D155AXI-8 50-473
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY BLY
5 Track roller oil:

930 to 990 cc
9. After filling with oil, check that the oil is at the specified level.
REMARK
Remove the oil filler plug, tilt the track roller assembly ap-
proximately 10 °, and check that oil is at the under surface
of the oil filler port.
10. Tighten the oil filler plug.
3 Oil filler plug:
160 to 250 Nm {16 to 25 kgm}
50-474 D155AXI-8
BLY REMOVE AND INSTALL NO. 1 BOGIE ASSEMBLY
REMOVE AND INSTALL NO. 1 BOGIE ASSEMBLY
Tools for removal and installation of 1st bogie assembly
New/Redesign
Necessity
Sketch
Q'ty
791T-130-1010 Bracket ■ 2 ○
01643-33080 Washer ■ 4
790-401-1700 Lifting tool ■ 1
B Removal and installation of track roller
790-401-1761 Adapter ■ 1
791-630-1360 Spacer ■ 1
790-101-2310 Block ■ 1
790-101-2360 Plate ■ 2
C 790-445-4130 Screw ■ 2 Pulling-out of shaft and ring
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN {50 t} ) ■ 1
790-201-2760 Spacer ■ 1
791-630-1370 Adapter ■ 1
790-434-1060 Screw ■ 2
D 01580-13024 Nut ■ 2 Pulling-out of ring
01643-33080 Washer ■ 1
709-101-4000 Puller (490 kN {50 t} ) ■ 1
E 796-230-1120 Installer ■ 1 Installation of floating seal
F 790-201-2650 Plate ■ 1 Press fit of ring
G 790-701-3000 Seal checker ■ 1 Check of floating seal airtightness
H 791-601-1000 Oil pump ■ 1 Refilling with oil
D155AXI-8 50-475
REMOVE AND INSTALL NO. 1 BOGIE ASSEMBLY BLY
New/Redesign
Necessity
Sketch
Q'ty
790-101-2310 Block ■ 1
790-445-4130 Screw ■ 2
796T-470-1130 Plate ■ 1 ○
J 790-101-2360 Plate ■ 2 Press fit of cartridge pin assembly
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN {50 t} ) ■ 1
K 791T-630-1390 Guide ■ 1 ○
bogie
METHOD FOR REMOVING NO. 1 BOGIE ASSEMBLY

Undercover
1. Remove undercover.
REMARK
When removing the bogie assembly, remove the undercover in the way of works.
4 Engine undercover:
220 kg
4 Power train undercover:

270 kg
SEMBLY”.
Preparation
3. Fix 2nd bogie assembly by using tool A, and operate the
blade and ripper to lift the machine up to the position
where the track roller of 2nd bogie assembly (2) is lifted
from the track link.
NOTICE
Set the blocking tools and blocks under the front and
rear frames to prevent the machine from lowering.
50-476 D155AXI-8
4. Sling 1st bogie assembly (2) with wire and fix it to prevent
it from lowering.

5. Loosen the mounting bolts of roller cap (3) 20 mm.
REMARK
Loosen the both bolts inside and outside.
6. Tap the end surface of shaft (4) by using a hammer (plastic
hammer), and disconnect the track roller from the bogie.
REMARK
7. Set tool B, and remove roller cap (3).
8. Remove track roller assembly (5) by using tool B.

REMARK
Remove track roller assembly (5) while balancing it.
4 Track roller assembly (5):

95 kg
D155AXI-8 50-477
Shaft, ring
10. Set tool C.

11. Push shaft (7) by using tool C, and push out ring (8) to-
ward the opposite side.
REMARK
Pushing force (reference): 216 to 402 kN{22 to 41 t}
12. Remove floating seal (9) from the end surfaces of rings (8)
and (10).
REMARK
Keep the floating seals not to damage them.
50-478 D155AXI-8
13. Set pulling tool D, and pull out rings (10) and (11).
REMARK
Pulling-out force (reference): 216 to 402 kN{22 to 41 t}

15. Remove spacer (13) and floating seals (14) between rings
(10) and (11).
REMARK
16. Pull out the shaft and ring of the bogie on the opposite side
according to the same procedure as steps 9 to 15.
Bogie assembly
17. Sling 1st bogie (13), and pull out it toward the outside.
4 Bogie assembly:
60 kg
METHOD FOR INSTALLING NO. 1 BOGIE ASSEMBLY

Cartridge pin assembly
1. Press-fit shaft (7) to ring (8).
REMARK
Shaft (7) press fitting force: 1.96 to 15.68 kN{0.2 to 1.6 t}
2 Between shaft (7) and ring (8):
Molybdenum dioxide lubricant (LM-P)
D155AXI-8 50-479
2. Install floating seals (9) to rings (8) and (10), and install
floating seals (14) to the opposite side of ring (10) and ring
(11) by using tool E.
REMARK
• When installing floating seals (9) and (14), clean, de-
grease and completely dry the contact faces (hatched
area) of O-ring and floating seals (9) and (14).
• Take care that dirt dose not stick to the contact faces of
floating seals (9) and (14).
• After inserting floating seals (9) and (14), check that
the tilt of the seal is 1 mm or less and the projection di-
mension (a) of the seal is in the range of 3 to 5 mm.
3. Insert spacer (12) and ring (10) to shaft (7) and ring (8).
4. Install spacer (13) to ring (10), and press-fit ring (11) by us-
ing tool F.
REMARK
Press fitting force of ring (11): 3.9 to 48 kN{0.4 to 4.9 t}
5. Check the airtightness of the floating seal by using tool G.
50-480 D155AXI-8
6. Fill the cartridge pin assembly with oil to the specified level
by using tool H.
REMARK
Hydraulic pressure when filling: 0.49 MPa{5 kg/cm2}
5 Cartridge pin assembly:

50 to 60 cc (GO140) (81 to 95 % of full oil)
Bogie
7. Sling 1st bogie (13), and install it.
REMARK
Sling 1st bogie (13), insert it from the front, and then place
it on the mounting position.
8. Align the track frame with the pin hole of the bogie, and in-
sert guide tool K.
NOTICE
When aligning pin hole position, never insert your fin-
ger into the holes.
D155AXI-8 50-481
9. Insert cartridge pin assembly (15) into the pin hole.

REMARK
Insert the cartridge pin assembly with arrow (b) of the edge
surface facing upward (installed to the machine).
10. Press-fit cartridge pin assembly (15) by using tool J.
REMARK
• Push in the cartridge pin assembly by using cover (6).
• Push in the cartridge pin assembly up to machined sur-
face (c) of the track frame.
2 Pin periphery surface:
REMARK
Press-fitting force of cartridge pin assembly: 216 to
402 kN{22 to 41 t}
11. Press-fit the cartridge pin assembly on the opposite side
according to the same procedure as steps 9 and 10.

REMARK
Install to 2 places inside and outside.
50-482 D155AXI-8

13. Sling track roller assembly (5) by using tool B, and place it.
REMARK
• Place it so that the oil filler plug faces outside of the
machine.
• Place the track roller assembly while balancing it.
4 Track roller assembly:

95 kg
14. Lightly tighten roller cap (3) with the mounting bolt.
REMARK
15. Align it with the dowel pin hole, and tighten bolts (16).
662 to 829 Nm{67.5 to 84.5 kgm}
Track shoe assembly

BLY”.
17. Adjust the track tension. For details, see TESTING AND ADJUSTING, “TEST AND ADJUST TRACK TEN-
SION”.
D155AXI-8 50-483
REMOVE AND INSTALL NO. 2, 3, 4 BOGIE ASSEMBLIES BLY
REMOVE AND INSTALL NO. 2, 3, 4 BOGIE ASSEMBLIES
Tools for removal and installation of 2nd, 3rd, 4th bogie assembly
New/Redesign
Necessity
Sketch
Q'ty
791T-130-1010 Bracket ■ 2 ○
01643-33080 Washer ■ 4
B - Block ■ 1 Removal and installation of bogie as-
C - Iron plate ■ 1 sembly
791-630-1360 Spacer ■ 1
790-101-2310 Block ■ 1
790-101-2360 Plate ■ 2
D 790-445-4130 Screw ■ 2 Pulling-out of shaft and ring
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN {50 t} ) ■ 1
790-201-2760 Spacer ■ 1
791-630-1370 Adapter ■ 1
790-434-1060 Screw ■ 2
E 01580-13024 Nut ■ 2 Pulling-out of ring
01643-33080 Washer ■ 1
709-101-4000 Puller (490 kN {50 t} ) ■ 1
G 790-201-2650 Plate ■ 1 Press fit of ring
J - Block ■ 1
K - Hydraulic jack ■ 1
Support of machine
L - Blocking tool ■ 2
M - Hydraulic jack ■ 2
50-484 D155AXI-8
BLY REMOVE AND INSTALL NO. 2, 3, 4 BOGIE ASSEMBLIES
New/Redesign
Necessity
Sketch
Q'ty

N 791T-630-1390 Guide ■ 1 ○
bogie
790-101-2310 Block ■ 1
790-445-4130 Screw ■ 2
796T-470-1130 Plate ■ 1 ○
P 790-101-2360 Plate ■ 2 Press fit of cartridge pin assembly
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN {50 t} ) ■ 1
Q 791-601-1000 Oil pump ■ 1 Refilling with oil
Removal and installation of bogie as-
R - Lever block ■ 1
sembly
METHOD FOR REMOVING NO. 2, 3, 4 BOGIE ASSEMBLIES

Undercover
1. Remove undercover.
REMARK
When removing the bogie assembly, remove the undercover in the way of works.
4 Engine undercover:
220 kg
4 Power train undercover:

270 kg
SEMBLY”.
Preparation
3. Fix bogie assembly (1) by using tool A.
REMARK
Also remove the cover on the opposite side.
position where the track roller is lifted from the track link.
NOTICE
Set the blocks between the track roller and track link
to prevent the machine from lowering.
D155AXI-8 50-485
6. Set tool C on the track shoe and tool B.

REMARK
Set tool B according to the track link height.
7. Operate the blade and ripper to lower the machine up to
the position where the track roller of bogie assembly (1)
contacts tool C.
REMARK
Operate the blade and ripper slowly
Shaft, ring
8. Set tool D.
9. Push shaft (3) by using tool D, and push out ring (4) to-
ward the opposite side.
REMARK
Pushing force (reference): 216 to 402 kN{22 to 41 t}
10. Remove floating seals (5) from end surfaces of rings (4)
and (6).
REMARK
11. Set pulling tool E, and pull out rings (6) and (7).
REMARK
Pulling-out force (reference): 216 to 402 kN{22 to 41 t}
50-486 D155AXI-8

13. Remove spacer (9) and floating seals (10) between rings
(6) and (7).
REMARK
14. Pull out the shaft and ring of the bogie on the opposite side
Bogie assembly
15. Operate the blade and ripper to lift the machine up to the position where bogie assembly (1) can be pulled
out.
NOTICE
Set the blocks between the track roller and track link of the bogie that is not removed to prevent the
machine from lowering.
16. Sling bogie assembly (1), slide it on tool C, and pull it to-
ward outside to remove it.
4 Bogie assembly:
525 kg
METHOD FOR INSTALLING NO. 2, 3, 4 BOGIE ASSEMBLIES

1. Press-fit shaft (3) to ring (4).
REMARK
Shaft (4) press fitting force: 1.96 to 15.68 kN{0.2 to 1.6 t}
D155AXI-8 50-487
2. Install floating seals (5) to rings (6) and (4), and install
floating seals (10) to the opposite side of ring (6) and ring
(7) by using tool F.
REMARK
• When installing floating seals (5) and (10), clean, de-
grease and completely dry the contact faces (hatched
area) of O-ring and floating seals (5) and (10).
• Take care that dirt dose not stick to the contact faces of
floating seals (9) and (14).
• After inserting floating seals (5) and (10), check that
the tilt of the seal is 1 mm or less and the projection di-
mension (a) of the seal is in the range of 3 to 5 mm.
3. Insert spacer (8) and ring (6) to shaft (3) and ring (4).
4. Install spacer (9) to ring (6), and press-fit ring (7) by using
tool G.
REMARK
Press fitting force of ring (7): 3.9 to 48 kN{0.4 to 4.9 t}
Between shaft (3) and ring (7)Molybdenum dioxide lubri-
cant (LM-P)
5. Check the airtightness of the floating seal by using tool H.
50-488 D155AXI-8
Bogie assembly
6. Sling bogie assembly (1), and lower it on tool B and tool C.
7. Hook tool R between the guards of bogie assembly (1) and
the bogie assembly on the opposite side.
8. Slide bogie assembly (1) on tool C by using tool R, and
place it on the mounting position.
9. Operate the blade and ripper to raise the machine.
10. Place tool J and tool K on the rear side of the machine.
11. Place tool L and tool M on the front side of the machine.
12. Lower the machine by using tool K and tool M that are set
on the front and rear side, and install fixing tool A to bogie
assembly (1).
13. Align the track frame with the pin hole of bogie assembly
(1) while adjusting the height by using tool K and tool M
that are set on the front and rear side.
NOTICE
When aligning pin hole position, never insert your fin-
ger into the holes.
D155AXI-8 50-489
REMARK
When pin hole alignment is difficult even by adjusting the front and rear hydraulic jacks, sling the track front
on the opposite side, or set the hydraulic jack to the bogie assembly to align the pin hole.
14. Insert guide tool N into the pin hole.
15. Insert cartridge pin assembly (11) into the pin hole.
REMARK
Insert cartridge pin assembly (11) with arrow (b) of the
edge surface facing upward (installed to the machine).
16. Press-fit cartridge pin assembly (11) by using tool P.
REMARK
• Push in cartridge pin assembly (11) by using cover (2).
• Push in cartridge pin assembly (11) up to machined
surface (c) of the track frame.
• Press-fitting force of cartridge pin assembly: 216 to
402 kN{22 to 41 t}
50-490 D155AXI-8
Refilling with oil

17. Fill the cartridge pin assembly with oil to the specified level
by using tool Q.
REMARK

18. Press-fit cartridge pin assembly (11) on the opposite side
REMARK
Track shoe assembly

BLY”.
21. Adjust the track tension. For details, see TESTING AND ADJUSTING, “TEST AND ADJUST TRACK TEN-
SION”.
D155AXI-8 50-491
DISASSEMBLE AND ASSEMBLE TRACK ROLLER BOGEY ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY
DISASSEMBLE AND ASSEMBLE TRACK ROLLER BOGEY ASSEMBLY

Tools for disassembly and assembly of bogie assembly
New/Redesign
Necessity
Sketch
Q'ty
790-101-2310 Block ■ 1
790-445-4130 Screw ■ 2
796T-470-1130 Plate ■ 1 ○
A 790-101-2360 Plate ■ 2 Press fit of cartridge pin assembly
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN {50 t} ) ■ 1
B 791-601-1000 Oil pump ■ 1 Refilling with oil
METHOD FOR DIS ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY

1. Reverse bogey assembly (1).
2. Remove the roller cap, sling track roller assemblies (2) (2
pieces), and remove them.
REMARK
The dowel pin is inserted. Be careful not to break it.

95 kg

105 kg

4. Remove cartridge pin assembly (4) referring to “REMOVE AND INSTLL BOGIE ASSEMBLY”, “Shaft, ring”.
50-492 D155AXI-8
50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE TRACK ROLLER BOGEY ASSEM-
BLY BLY
5. Disconnect inner bogie (5) and outer bogie (6).
METHOD FOR ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY

1. Assemble cartridge pin assembly (4) referring to “REMOVE AND INSTLL BOGIE ASSEMBLY”, “Cartridge
pin assembly”.
2. Set outer bogie (6) and inner bogie (5).
3. Set tool A.
4. Press-fit cartridge pin assembly (4).

REMARK
• Push in the cartridge pin assembly by using cover (3).
• Insert the cartridge pin assembly with arrow (a) of the
end surface facing upward (installed to the machine).
• Push in the cartridge pin assembly up to the machined
surface of the bogie.
• Press-fitting force of cartridge pin assembly: 215.8 to
402.1 kN{22 to 41 t}
D155AXI-8 50-493
DISASSEMBLE AND ASSEMBLE TRACK ROLLER BOGEY ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY
5. Fill the cartridge pin assembly (4) with oil to the specified
level by using tool B.
REMARK

6. Press-fit cartridge pin assembly (4) on the opposite side
REMARK
After press-fitting the cartridge pin assembly, slide the in-
ner bogie to enable the bogie move lightly.
REMARK
8. Sling track roller assembly (2) (2 pieces), and set on the
bogie.
REMARK
Set the assemblies so that the oil filler port of the track roll-
er assembly faces outside of the machine when installing
the bogie assembly.

95 kg

105 kg
9. Fit the roller cap to track roller assembly (2), and tighten it with the mounting bolt.
REMARK
662 to 829 Nm{67.5 to 84.5 kgm}
50-494 D155AXI-8
BLY REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY

Tools for removal and installation of carrier roller assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Hydraulic jack ■ 2 Support of track shoe assembly

Removal and installation of carrier roller
B - Rope ■ 1
assembly
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY

Track shoe
tor (6), degrease, and loosen the track shoe tension.
k Since the internal pressure of the recoil spring cyl-
inder is high, do not loosen lubricator (6) more than
1 turn.
REMARK
If the track tension is not loosened even by loosening the
lubricator, perform forward and reverse travel of the ma-
chine.
Preparation
2. Raise the track off ground by using tool A.
Carrier roller
4. Pass tool B through the link hole and wind it onto carrier
roller (3). Pull rope B in order to keep carrier roller (3) hori-
zontal and prevent the roller from falling.
5. Loosen tool B gradually while pulling out carrier roller (3)
from support (4) to remove it.
4 Carrier roller (standard type):

48 kg
4 Carrier roller (PLUS type):

55 kg
D155AXI-8 50-495
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY BLY
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY

Carrier roller
1. Raise the track off ground by using tool A.
2. Pass tool B through the link hole and wind it onto carrier
roller (3). Pull tool B until the position where carrier roller
(3) can be pushed into support (4).
3. Loosen tool B gradually while inserting carrier roller (3)

from support (4) to install it.

48 kg

55 kg
REMARK
When installing carrier roller (3) and support (4), provide a
clearance according to the dimension (a) in the figure.
Dimension (a): 1.2 mm
2 Support mounting bolts:
Adhesive (LT-2)
4. Install mounting bolt (2).
5. Remove tool A.
Recovery operation
tor (6) of the cylinder to the original position and inject
grease.
7. Adjust the track shoe tension. For details, see TESTING
AND ADJUSTING, “TEST AND ADJUST TRACK TEN-
SION”.
50-496 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY

Tools for disassembly and assembly of carrier roller assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1 Fixing of carrier roller assembly

B 790-102-1891 Nut wrench ■ 1 Removal and installation of nut
790-101-2501 Push puller ■ 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
C 790-101-2540 • Washer 1
Pulling out of bearing and roller
790-101-2620 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2710 • Adapter 2
C 790-201-1410 Plate ■ 1
D 790-101-3000 Push puller ■ 1 Pulling out of bearing and ring
E 793T-417-1130 Push tool ■ 1 ○ Pulling out of ring
F 793T-417-1210 Push tool ■ 1 ○
G 793T-623-1170 Push tool ■ 1 ○
H 791-651-1510 Installer ■ 1 Installation of floating seal
K 791T-630-1350 Spacer ■ 1 ○ Press-fit of ring
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY

Draining
1. Remove the plug, and drain oil.

570 to 680 cc

860 to 970 cc
D155AXI-8 50-497
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY BLY
Ring
2. Set carrier roller assembly (1) on tool A.
3. Remove the mounting bolt and remove cover (2).
4. Remove ring (3).
Bearing
5. Remove nut (4) by using tool B.
6. Remove the press-fitting portion of the ring (3) by using
tool C, remove bearing (5) and roller (6) as a unit by sling-
ing it with the eyebolt.
4 Bearing (5) and roller (6):

70 kg
7. Remove outer race (7) from roller.

8. Remove ring (8) and inner race of bearing (9) as a unit by
using tool D.
Floating seal
9. Remove floating seal (10) from ring (8).
50-498 D155AXI-8
10. Remove ring (11) by using tool E.

11. Remove floating seal (12) from ring (11).
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY

Bearing
1. Press fit inner race of bearing (9) to shaft by using tool F.
2. Press fit outer race (7) of bearing to roller by using tool G.
3. Set roller (6) and inner race of bearing (5) to shaft.

4. By using tool F, press fit inner race of bearing (5) to shaft.
REMARK
While rotating roller, press fit the bearing until roller move-
ment becomes a little heavy.
5. Tighten nut (4) by using tool B.

3 Nut:
58.8 Nm {6 kgm}
REMARK
After tightening the nut, if the hole of nut is not aligned with
the hole on the shaft, align them in the nut loosening direc-
tion.
6. Install ring (3).
D155AXI-8 50-499
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY BLY
7. Install O-ring, and install cover (2), and tighten the mount-
ing bolt.
REMARK
Tighten lightly oil filler plug.
Refilling with oil

8. Invert roller (6), and add oil between shaft and roller (6).
5 Amount of oil (conventional type):

570 to 680 cc (GO140)
5 Amount of oil (PLUS type):

860 to 970 cc (GO140)
Floating seal
9. By using tool H, install floating seal (10) to ring (8).
10. Install O-ring, align ring (8) with the dowel pin, and install
it.
11. By using tool H, install floating seal (12) to ring (11).
50-500 D155AXI-8
REMARK
• When installing the floating seal, clean, completely de-
grease and dry O-ring and O-ring contact surface
(hatched area).
seal is 1 mm or less and projection dimension (a) of the
seal is in the range of 7 to 11 mm.
• Apply oil to the sliding surface of the floating seal, and
take care to prevent any dirt from sticking.
Ring
12. Press fit ring (11) by using tool K.
REMARK
Press fit the ring so that dimension (a) between the shaft
end surface and upper surface of the ring is
131.95±0.2 mm.
Checking for air leakage

13. By using tool J, apply standard pressure to oil filler port of
carrier roller assembly (1), and check for air leakage of
seal
REMARK
Apply standard pressure for 10 seconds, and check that
pointer of gauge does not drop.
Standard pressure: 0.1 MPa 1 kg/cm2
14. After checking for air leakage, check again that oil which
was filled at step 8. has been refilled to the specified level.
REMARK
Remove oil filler plug, tilt carrier roller assembly approxi-
mately 10 °, and check that oil level reaches to the lower
edge of the oil filler port.
15. Tighten oil filler plug.
3 Oil filler plug:
157 to 255 Nm {16 to 26 kgm}
D155AXI-8 50-501
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY BLY
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY

Tools for removal and installation of pivot shaft assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Forcing screw ■ 2 Removal of pivot shaft assembly

791T-650-2110 Sleeve ■ 1 ○
790-201-2770 Spacer ■ 1
791T-650-2120 Plate ■ 1 ○
792-104-3940 Bolt ■ 2
B 790-101-2510 Block ■ 1 Press fit of ring
790-101-2570 Washer ■ 2
01580-01613 Nut ■ 1
790-105-2300 Jack assembly (196 kN {20 t} ) ■ 1
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY

1. Remove the track frame assembly. For details, see “REMOVE AND INSTALL TRACK FRAME ASSEM-
BLY”.
Pivot shaft assembly
2. Remove seal (1), and remove ring (2).
3. Sling pivot shaft assembly (3), hold it, remove the mount-
ing bolt, and remove pivot shaft assembly (3) while sling-
ing it by using tool A.
REMARK
To easily remove and install the joint parts, adjust it by us-
ing lifting tools so that the joint is kept parallel.
4 Pivot shaft assembly:

135 kg
50-502 D155AXI-8
BLY REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY

Pivot shaft assembly
1. Sling pivot shaft assembly (3), and tighten the mounting
bolt by using tool A.
REMARK
To easily remove and install the joint parts, adjust them by
4 Pivot shaft assembly:

135 kg
2 Pivot shaft mounting bolt:
3 Pivot shaft mounting bolt:
784 to 981 Nm{80 to 100 kgm}
2. Press-fit ring (2) by using tool B.
REMARK
• Press fitting force of ring: 8.8 to 22.5 kN{0.9 to 2.3 t}
• Ring press-fitting dimension: 475.5±1 mm
3. Reverse seal (1) so that the molded character (a) surface

4. Insert seal (1) into the pivot shaft with seal (1) reversed.

5. Install the track shoe assembly. For details, see “REMOVE AND INSTALL TRACK FRAME ASSEMBLY”.
D155AXI-8 50-503
SEPARATION AND CONNECTION OF TRACK ASSEMBLY BLY
SEPARATION AND CONNECTION OF TRACK ASSEMBLY

Tools for separation and connection of track shoe assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1
Separation and connection of track
B - Block ■ 1
shoe assembly
C - Block (large) ● 1
METHOD FOR CHECKING BEFORE SEPARATION OF THE TRACK ASSEMBLY

k Check the following items before the separation of track shoe assembly since the separation of track
shoe assembly is very dangerous.
k Lubricator must not be loosened more than 1 turn and do not remove the lock plate.
k If the grease does not come out sufficiently, move the machine backward and forward.
Track shoe
tor (2) of the cylinder, degrease, and loosen the track shoe
tension.
NOTICE
Since the internal pressure of the recoil spring cylin-
der is high, do not loosen lubricator (2) more than 1
turn.

2. If the track shoe tension is loosened, perform the procedure in “METHOD FOR SEPARATING OF TRACK
ASSEMBLY (NORMAL)”.
3. If the track shoe tension is kept tense and is not loosened even after the preceding work is performed, per-
form the procedure referring to “METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK
FRAME HAS INTERNAL DEFECT)”.
REMARK
• A failure (damages of recoil spring case and recoil spring set bolt, coming off of shaft end nut, etc.) may
occur inside the track frame.
METHOD FOR SEPARATING OF TRACK ASSEMBLY (NORMAL)

REMARK
• If the shoe is loosened when no failure is found in “METHOD FOR CHECKING BEFORE SEPARATION OF
THE TRACK ASSEMBLY”, perform the following procedure.
50-504 D155AXI-8
BLY SEPARATION AND CONNECTION OF TRACK ASSEMBLY
Preparation
1. Align the position of master link (3) with the front of the id-
ler.
REMARK
• Set tools A and B between the front of the idler and
carrier roller so that the mating face of the master link
does not open until the master bolt is pulled out.
Master link
2. Remove track shoe (4), and disconnect master link (3).
REMARK
• Do not remove the mounting bolts (4 pieces) one by
one. Loosen each of them by 1 or 2 turns. Check that
they can be rotated smoothly, and then remove them.
NOTICE
• If a bolt does not turn smoothly and it is unscrewed
forcibly, the threaded part of the bolt and master
link (3) may be damaged.

3. Sling the tip of master link (3), and slowly drive the ma-
chine in the reverse direction to separate track shoe as-
sembly (5).
Length of track shoe: Approximately 10.5 m
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS

INTERNAL DEFECT)
REMARK
If a failure is found in “METHOD FOR CHECKING BEFORE SEPARATION OF THE TRACK ASSEMBLY” and
the shoe is not loosened, perform the following procedure.
NOTICE
If a problem has occurred inside the track frame, the track shoe may spring back when the assembly is
separated. Also, the idler may fly off when the track shoe assembly is separated. This is potentially very
dangerous.
Check
1. Check that lubricator (2) is loosened again.
NOTICE
Do not loosen lubricator (2) 1 turn or more.
D155AXI-8 50-505
2. Drive the machine in the forward and reverse directions to allow the grease to come out sufficiently, and
check that the track tension is kept tense and is not loosened even then.
Blade assembly
3. Remove the blade assembly. For details, see “REMOVE AND INSTALL BLADE ASSEMBLY”.
Master link
4. Slowly drive the machine forward so that the track shoe (4)
on the idler side contacts with tool C or wall (or when large
bulldozer at the same grade as the modification machine is
available, its blade).
5. Adjust master link (3) to the position where it can be dis-
connected easily so that the track shoe (4) contacts with
tool C or wall (blade).
6. Stop the machine with the recoil spring and track shoe (4)
bent, and apply the brake.
7. Remove track shoe (4), and disconnect master link (3).
REMARK
Do not remove the mounting bolts (4 pieces) one by one. Loosen each of them by 1 or 2 turns. Check that
they can be rotated smoothly, and then remove them.
k If a bolt does not turn smoothly and it is unscrewed forcibly, the threaded part of the bolt and
master link (3) may be damaged.
8. Sling the tip of master link (3), and slowly drive the ma-
chine in the reverse direction to separate track shoe as-
sembly (5).
50-506 D155AXI-8
BLY SEPARATION AND CONNECTION OF TRACK ASSEMBLY
METHOD FOR INSTALLING TRACK ASSEMBLY

Track shoe
1. Place track shoe assembly (5) separated with the bottom
of master link (3) facing forward, and place the traveling
part of the machine.
2. Sling the top end of master link (3) at the rear of separated
track shoe assembly (5), and fit it in the sprocket at the
rear of the machine traveling part.
3. Slowly drive the machine forward while slinging the tip of
master link (3), and wind track shoe assembly (5) up to the
idler at the front of the traveling part.
4. Place tool A and tool B between the idler front and carrier
roller.
5. Combine master link (3), and install track shoe (4).

REMARK
• Tighten the shoe mounting bolts for the master link in
the order shown in the following figure.
• Finger-tighten the bolts (4 pieces) until the mating
faces of the master links are fitted.
• If the bolts are tightened forcibly before the master link
mating faces are fitted, the threaded portion of bolts
and master link may be damaged.
2 Shoe mounting bolt (master link):
3 Shoe mounting bolt (1st time):
590±60 Nm {60±6 kgm}
3 Shoe mounting bolt (2nd time):
180±10 ° (retightening)
D155AXI-8 50-507
Recovery work
6. Remove upper cover (1) of the track frame, tighten lubrica-
tor (2) of the cylinder back to the original state, add
grease, and strain the track shoe.
7. Adjust the track tension. For details, see TESTING AND
ADJUSTING, “TEST AND ADJUST TRACK TENSION”.
50-508 D155AXI-8
BLY SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY

k Park the machine on a level ground, and set parking brake lever to LOCK position.
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY

REMARK
The details of separation and connection of PLUS type track shoe assembly are the same as those of the stand-
ard type track shoe. Therefore, see “SEPARATION AND CONNECTION OF TRACK ASSEMBLY”.
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY

Shoe
1. Set the shoe so that master link (1) on the shoe side and
shoe grouser (2) are positioned as shown in the drawing,
and install the shoe.
Shoe bolt
2. Finger-tighten shoe bolts (3) (4 pieces) until the mating
faces of the master link (a) are fitted.
REMARK
If shoe bolts (3) are tightened forcibly when the master link
mating faces (a) are not fitted, the threaded portion of shoe
bolts and master link may be damaged.
3. Apply lubricant to the shoe bolt (master link).
2 Shoe bolt (master link):
4. Tighten shoe bolts (3) (4 pieces) in the order shown in the

drawing.
3 Shoe bolt (master link) initial torque:
490±49 Nm {50±5 kgm}
3 Retightening angle:
180±10 °
D155AXI-8 50-509
DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERAL- 50 DISASSEMBLY AND ASSEM-
LY BLY
DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERALLY

Tools for disassembly and assembly of track shoe assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Jaw ■ 1
791-675-9701 Remover, installer 1
Disassembly and assembly of track
790-101-4300 Cylinder (196 kN 20 t) ■ 1
B shoe assembly
790-101-4200 Cylinder (294 kN 30 t) ■ 1
C 791-932-1110 Plug push tool ■ 1 Driving-in of plug (small)
D 791-660-7460 Pin brush ■ 1 Cleaning of pin
E 791-432-1110 Plug push tool ■ 1 Driving-in of plug (large)
F 791-632-1052 Installer ■ 1 Insertion of link seal
G - Spacer ■ 1 Press-fit of pin and bushing
REMARK
Perform the work referring to “Parts judgment guide, undercarriage, sealed and lubricated track shoe” and
“Parts judgment guide, undercarriage, method for inverting sealed and lubricated track shoe”.
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY

Shoe
1. Sling the shoe assembly, set it on the floor with the shoe
facing upward, and remove the shoe by using a shoe bolt
impact wrench.
REMARK
• If the shoe bolt is not loosened (if its rotational torque is
not reduced to zero) even after it is loosened by 1 turn,
loosen other bolts so that the bolt can be loosened
smoothly.
• If the bolt is rotated forcibly when the torque is not
zero, the bolt and link are deformed and become adhe-
sive, and the maintenance work is required.
• When moving the shoe assembly, be careful not to
damage the master link.
• If the gas cut of the shoe nut is performed to remove it
by necessity, keep the seal temperature 80 °C or less
to prevent seal deterioration due to heat, and take
measures to prevent flame-cutting droplet from enter-
ing the clearance between links.
50-510 D155AXI-8
50 DISASSEMBLY AND ASSEM- DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERAL-
BLY LY
Link
2. Set the link assembly on the link press. Tap it by using a
hammer to make the bushing contact with tool A.
REMARK
• If the link tread and bushing outside diameter are worn,
adjust the height of tool H or guide plate to perform
centering of tool B on the bushing center. Be careful
not to damage the link hole when disassembling.
• If centering is not sufficient, the link hole may be dam-
aged, pin may be broken, or bushing may be cracked
when disassembling.
• Drive in the small plug of the pin towards the inside af-
ter disassembly by using tool C to keep the workplace
clean.
3. Operate the left side cylinder to pull out the left side link
and press-fitting portions of the pin and bushing simultane-
ously.
REMARK
Check the pulling-out force of the pin and bushing to see if
the press-fitting force of them is obtained, that is required
when they are reversed and reassembled.
4. Return the left side cylinder, and operate the right side cyl-
inder to pull out the right side link and press-fitting portions
of the pin and bushing simultaneously.
D155AXI-8 50-511
LY BLY
5. Return the right side cylinder, remove the right and left
links, pins, bushings and spacers, and send the next 1 set
of the link assembly to the jaw.
REMARK
Damage of bushing end surface and seal surface may
cause oil leakage. Handle them carefully.
Maintenance standard
6. Inspect whether the parts can be reused as an oil sealed and lubricated track or grease sealed track ac-
cording to the following procedure, and then comprehensively determine whether to regenerate the parts as
an oil sealed and lubricated track or grease sealed track based on the inspection results.
1) Check the damage conditions of the parts visually, and inspect the doubtful parts by the color check or
by using the magnaflux inspection device. Cracked parts cannot be reused. Discard them.
REMARK
For determination of part regeneration, see “Parts judgment guide, undercarriage, sealed and lubricat-
ed track shoe”.
2) Measure the outside diameter of the press-fitting por-
tions of the pin and bushing by using a micrometer,
and measure the inside diameter of the press-fitting
portions of the pin and bushing in the link by using a
cylinder gauge. Check that the calculated value is
within the range of the standard interference.
REMARK
• Determine the calculated standard interference
value. For details, see MAINTENANCE STAND-
ARD, “Track shoe”.
• If the calculated value is out of the standard inter-
ference range, replace the parts with new ones.
NOTICE
• Do not remove the seal from the link to prevent
rust of the link counterbore. Store it without dam-
aging the seal lip.
• Take rust prevention measures for the bushing
press-fitting portion, shoe mating face, and master
link mating face of the link.
• Take rust prevention measures for the pin, bush-
ing, and spacer (entire circumference) by applying
rust preventive oil, etc. Store it not to damage the
bushing end surface especially.
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY

REMARK
To perform the work, see “Parts judgment guide, undercarriage, method for inverting sealed and lubricated track
shoe”.
50-512 D155AXI-8
BLY LY
Rebuilding for sealed and lubricated track

Preparation
1. Remove the seal assembly from the link, separate seal
ring (1) and load ring (2), and clean them.
REMARK
Clean the seal ring (1) and load ring (2) immediately since
they are easily deteriorated by the detergent. After clean-
ing, wipe off the detergent by using cloth, etc.
2. Smoothly chamfer the end surface corner by using a grind-

er, etc. when reusing the pin. Smooth the protruding mate-
rials at the press-fit area as well.
REMARK
If the end surface corner is sharpened due to wear, scuff-
ing of the press-fit area may occur, and it may cause oil
leakage.
3. Clean the link, pin, bushing and spacer if they are stained.
Smooth the protruding materials on the link and bushing
as well.
REMARK
• Clean them right before the assembly work since they
are easily rusted.
• Do not repair the bushing end surface by grinding, etc.
Otherwise, oil leakage may occur.
4. If larger plug is pulled out, drive in larger plug by using tool
E.
REMARK
Clean the pin hole by using tool D in advance.
1) Insert plug (3) into the hole of the guide through the
plug inserting window.
2) Press the bar with the hand until plug (3) stops.
3) Press plug (3) by using the bar, and press the guide
itself towards pin (4).
REMARK
• If chamfered face of the pin hole is lost due to
wear, chamfer it by using a small-sized grinder
(grindstone end angle: 45 to 60 °) so that plug (3)
is not damaged.
• Apply oil (GO80W90) to the periphery of the plug,
drive in it with the smaller diameter end facing for-
ward.
Driving-in dimension (a) from pin end face: 10±1 mm
D155AXI-8 50-513
LY BLY
5. Clean counterbore of the link, and fully push in the seal by

using tool F to the bottom in order to install the seal as-
sembly.
REMARK
If oil is attached to the link counterbore and seal assembly,
the seal rotates and the sealing performance deteriorates.
Accordingly, do not apply oil to them. Be careful that oil
does not attach to seal when inserting the seal into the
counterbore.
6. Adjust the dimensions of the press-fitting jig of the link

press in order to maintain the protrusion quantity of pins
and bushings constant and keep the seal installation di-
mension within the specified range when assembling.
REMARK
• For the standard dimensions, see “Link press press-fit-
ting jig dimensions” in this section.
• If the pin end face (portion P) or link side faces (por-
tions Q and R) are worn, add the wear reduction to the
standard installed dimensions of the press-fitting jigs so
that the right and left protrusions of the pins and bush-
ings on both sides are even.
7. Adjust the relief pressure of the link press so that the pressing force of the press does not exceed the speci-
fied amount.
REMARK
If the pressing force is excessively strong, excessive force is applied to the spacer and bushing. The spacer
may be damaged or abnormal wear may be occurred between the spacer and bushing end face.
Pushing force of pin and bushing: 862 kN {88 t}
Pushing force ≒ 1.8 x Average press-fitting force (Adjust the relief pressure of the link press to set the
pushing force.)
Link
8. Apply oil (G080W90) to the area between the pin and
bushing by using a clean brush, etc., and set the front side
of the jaw of the link press bushing to the link.
REMARK
When reusing the bushing (invert), set the worn side of the
bushing outer diameter to the shoe mounting surface
(faces upward on the link press) of the link.
50-514 D155AXI-8
BLY LY
9. Press fit bushing to master links on the right and left with
the shoe mounting surface facing upward.
REMARK
Use the master link on the pin side as a support.
10. Use the shoe bolt pitch gauge to press fit until the shoe
bolt hole distance of the right and left link reaches the
specified value.
REMARK
Remove all steel chips such as burr or sharp edge gener-
ated by the press fitting process completely with com-
pressed air.
11. Invert the master link, and check that right and left master
links are press fitted in parallel, etc.
12. Measure the bushing protrusion on the right and left sides
by using the depth gauge.
REMARK
Adjust the press-fitting jig of the link press so that the
bushings on the right and left sides are evenly protruded.
13. Send the master link part, and set the next pin and bush-
ing.
REMARK
• When reusing the pin, set the pin with the side hole
facing the link tread side for assembling in the same
manner as the new one.
• If it is not assembled in the specified direction, its
strength may be lowered. Accordingly, clarify the direc-
tion of side hole (e) on the end surface to avoid assem-
bling in the wrong direction.
D155AXI-8 50-515
LY BLY
14. Set the right side link, and install spacer (5) to the pin.
REMARK
• Check that the seal surfaces and bushing end surfaces
are free from dirt, then apply oil (GO80W90) on them
by using a clean cloth or brush, etc.
• Clean the spacer by using a clean cloth, etc., and then
install it.
15. Set the right side jig on the receiving side and the left side
jig on the pressing side, and press fit the pin and bushing
simultaneously.
REMARK
Smoothly press fit them since the seal may be removed
due to the backlash during press-fit. When the seal is re-
moved from the link, stop the press-fit operation temporari-
ly, reinstall the seal to the link correctly, and then resume
the press-fit work.
Press-fitting force for pin and bushing: 343 to 490 kN {35 to
50 t}
16. Use tool G for minor adjustment to press fit the pin until its
end face reaches the bottom of the receiver jig.
REMARK
Adjust the hole depth of the receiver jig so that the pins on
the right and left side are evenly protruded.
17. Set the left side link, and install the spacer (5) to the pin.
REMARK
Similarly to the right side link, apply oil to them.
50-516 D155AXI-8
BLY LY
18. Set the right side jig on the pressing side and the left side
jig on the receiving side, and press fit the left side link.
REMARK
Press fit the link carefully to avoid removal of right and left
seals and spacers.
Press-fitting force of link: 343 to 490 kN {35 to 50 t}
19. Press fit the link until the link, spacer and bushing closely
contact each other.
REMARK
• You cannot visually check whether the parts are closely
contacted or not. Therefore, manage it by the oil pres-
sure of the link press. Set the relief pressure to the
fixed value, and apply oil pressure up to the specified
pressure. For details of setting of the relief pressure,
see “Preparation” in this section.
• Check that adjacent links are rotated each other.
Testing
20. Check that the distance between the shoe bolt holes is
within the standard range by using the shoe bolt pitch
gauge.
REMARK
• If the shoe bolt hole distance extremely exceeds the
specified value, disassemble it to check for any failure,
and then press fit again.
• If the shoe bolt hole distance is extremely shorter than
the specified value and the shoe cannot be installed,
wear on the spacer, bushing end surface, etc. may ex-
ceed the allowable limit. Therefore, disassemble it to
replace the parts.
21. Remove the air from inside of the pin for each link assem-
bly by using tool H, and check the sealing performance.
REMARK
Hold the space inside the pin at 91 to 95 kPa 680 to
710 mmHg of vacuum for 5 seconds, and check that the
pressure does not change. If the pressure is changed, dis-
assemble the link to check the seal. If no failure is found,
reassemble it.
D155AXI-8 50-517
LY BLY
Refilling with oil

22. By using tool J, fill with oil (GO80W90) until the filling pres-
sure reaches 196 to 294 kPa 2 to 3 kg/cm2.
REMARK
• For cold and extremely cold districts, fill with Komatsu
genuine oil (150-09-19270 for cold district or
195-32-61990 for extremely cold districts) with excel-
lent low-temperature characteristics instead of gear oil
(GO80W90).
• If the oil pressure is raised excessively, it negatively af-
fects the seal.
• Set the link assembly with the smaller plug side facing
upward, leave it for 30 minutes, and then check the oil
level.
• Fill with gear oil (GO80W90) so that pin hole space
depth (L) is within the specified range as shown below.
Dimension (L): 35 to 65 mm
23. After filling with oil, drive in the smaller plug up to the
specified position by using tool C.
REMARK
• Apply oil (GO80W90) to the periphery of the smaller
plug.
• Drive in the plug to the following depth.
Driving-in depth from end surface: 7.5±1 mm
24. Assemble the master link on the pin side as the final link.
REMARK
Check that right and left master links are press fitted in
parallel.
Shoe
25. Set the link assembly on the bed, and install the shoe by
using the shoe bolt impact wrench and torque wrench.
REMARK
2 Shoe bolt:
3 Shoe bolt (regular link) 1st time:
590±60 Nm {60±6 kgm}
3 Shoe bolt (regular link) 2nd time:
26. For the track that has 2 master link joints and consists of 2 track shoe assemblies, place the 2 assemblies
on a level place in a line with the track shoes up.
50-518 D155AXI-8
BLY LY
27. Pull in master link (1) on the roller tread side and master
link (2) on the shoe side, and set them on the mating
faces.
28. Place shoe (3), and fit the link contact surfaces each other
completely.
29. Check that master bolt (4) can be inserted easily by hand, and connect it with the master bolt (4).
2 Master bolt:
3 Master bolt (master link) 1st time:
590±60 Nm {60±6 kgm}
3 Master bolt (master link) (2nd time):
REMARK
Tighten the shoe bolts in the order shown in the figure.
Rebuilding for grease sealed track

Preparation
1. Remove the seal assembly from the link, separate seal
ring (1) and load ring (2), and clean them.
REMARK
Clean seal ring (1) and load ring (2) immediately since
they are easily deteriorated by the detergent. After clean-
ing, wipe off the detergent by using cloth, etc.
D155AXI-8 50-519
LY BLY
2. Smoothly chamfer the end surface corner by using a grind-

er, etc. when reusing the pin.
3. Drive in the large plug and small plug to the pin by using
tools C and E.
1) Insert the plug into the hole of the guide through the
plug inserting window.
REMARK
Apply oil to the plug.
2) Press the bar with the hand until the plug stops.
3) Press the plug with the bar until the guide touches the
pin.
4) Drive in the bar by using a hammer.
REMARK
When the plug is not removed from the pin when dis-
assembling, use it directly.
Driving-in dimension (a) from pin end surface
Small plug: 7.5±1 mm
Large plug: 6.0±2 mm
4. If the pin outside diameter surface, spacer surface, and
bushing end surface and inside diameter surface are
stained, clean them.
5. Apply grease to the pin outside diameter surface and spacer surface.
6. Clean counterbore of the link, and fully push in the seal by
using tool F to the bottom in order to install the seal as-
sembly.
REMARK
If grease is attached to the link counterbore and seal as-
sembly, the seal rotates and the sealing performance dete-
riorates. Accordingly, do not apply grease to them.
50-520 D155AXI-8
BLY LY
7. Adjust the dimensions of the press-fitting jig of the link

press in order to maintain the protrusion quantity of pins
and bushings constant and keep the seal installation di-
mension within the specified range when assembling.
REMARK
• For the standard dimensions, see “Link press press-fit-
ting jig dimensions” in this section.
• If the pin end face (portion P) or link side faces (por-
tions Q and R) are worn, add the wear reduction to the
standard installed dimensions of the press-fitting jigs so
that the right and left protrusions of the pins and bush-
ings on both sides are even.
Link
8. Apply lithium grease (G2-LI) to the area between the pin
and bushing, set the link, and set them on the front side of
the jaw of the link press.
REMARK
When reusing the bushing (invert), set the worn surface of
the bushing outer diameter to the shoe mounting surface
9. For the master links on the right and left bushings, press fit
the bushing with the shoe mounting surface facing upward.
REMARK
Use the master link on the pin side as a support.
10. Use the shoe bolt pitch gauge to press fit until the shoe
bolt hole distance of the right and left link reaches the
specified value.
REMARK
Remove all steel chips such as sharp edge generated by
the press fitting process completely with compressed air.
11. Invert the master link, and check that right and left master
links are press fitted in parallel, etc.
D155AXI-8 50-521
LY BLY
12. Measure the bushing protrusion on the right and left sides
by using the depth gauge.
REMARK
Adjust the press-fitting jig of the link press so that the
bushings on the right and left sides are evenly protruded.
13. Send the master link part, and set the next pin and bush-
ing.
REMARK
• When reusing the pin, set the pin with the side hole
facing the link tread side for assembling in the same
manner as the new one.
• If it is not assembled in the specified direction, its
strength may be lowered. Accordingly,clarify the direc-
tion of side hole on the end surface to avoid assem-
bling in the wrong direction.
• In case of wear around the pin, assemble the link with
the surface free from wear facing the towing side. Also
in this case, assemble it with the side hole facing the
link tread side.
14. Set the right and left links, and operate the right and left
press jigs to press fit the pin and bushing simultaneously.
REMARK
Smoothly press fit them since the seal may be removed
due to the backlash during press-fit. When the seal is re-
moved from the link, stop the press-fit operation temporari-
ly, reinstall the seal to the link correctly, and then resume
the press-fit work.
Pushing pressure for pin and bushing: 343 to 490 kN {35 to
50 t}
Pushing pressure ≒ 1.8 x Average press-fitting force (Ad-
just the relief pressure of the link press to set the pushing pressure.)
15. Check the distance between the shoe bolt holes by using
the shoe bolt pitch gauge. Stop press fitting when the dis-
tance is within the standard range.
16. Assemble the master link on the roller tread side as the fi-
nal link.
REMARK
Check that right and left master links are press fitted in
parallel.
50-522 D155AXI-8
BLY LY
Shoe
17. Set the link assembly on the bed, and install the shoe by
using the impact wrench and torque wrench.
REMARK
2 Shoe bolt:
3 Shoe bolt (regular link) 1st time:
590±60 Nm {60±6 kgm}
3 Shoe bolt (regular link) 2nd time:
19. Pull in master link (1) on the pin side and master link (2) on the bushing side, and set them on the mating
faces.
20. Place shoe (3), and fit the link contact surfaces each other completely.
21. Check that master bolt (4) can be inserted easily by hand,
and connect it with the master bolt (4).
2 Master bolt:
3 Master bolt (master link) 1st time:
590±60 Nm {60±6 kgm}
3 Master bolt (master link) (2nd time):
REMARK
Tighten the shoe bolts in the order shown in the following
figure.
D155AXI-8 50-523
LY BLY
Link press press-fitting jig dimensions

Dimension (a): 4.5 mm
Dimension (b): 3.25 mm
Dimension (c): 50.6 mm
REMARK
• Adjust the press-fitting jig of the link press in order to main-
tain the protrusion quantity of pins and bushings constant
and keep the seal installation dimension within the specified
range when assembling.
• If the pin end face (portion P) or link side faces (portions Q
and R) are worn, add the wear reduction to the standard in-
stalled dimensions of the press-fitting jigs so that the right
and left protrusions of the pins and bushings on both sides
are even.
NOTICE
• Set the link receiving surface of jaw (5) vertically.
• Replaceable wear plate (6) is desirable.
50-524 D155AXI-8
50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY
BLY GENERALLY
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENER-

ALLY
Tools for disassembly and assembly of PLUS type track shoe assembly
New/Redesign
Necessity
Sketch
Q'ty
Installation of track link pin (for small

A 791-932-1110 Push tool ■ 1
plug)
B 790-701-3000 Checker ■ 1 Check of track link airtightness
C 791-601-1000 Oil pump ■ 1 Oil filling of track link
791T-132-1010 • Guide 1 〇
Installation of wedge ring (for large plug
D 791T-132-1020 • Holder 1 〇
side)
793T-B32-1030 • Bar 1 〇
01580-11210 • Nut 1
791T-132-1110 • Guide 1 〇
Installation of wedge ring (for small plug
E 791T-132-1020 • Holder 1 〇
side)
793T-B32-1030 • Bar 1 〇
01580-11210 • Nut 1
F 791T-432-2810 Push tool ■ 1 〇 Press-fit of oil seal
Scattering prevention of wedge ring cut
H - Thick cloth ■ 1
pieces
K - Press jig for pin end ■ 1 Disassembly of pin
L - Jaw ■ 1 Adjustment of link press press-fitting jig
M - Wear plate ■ 1 Adjustment of link press press-fitting jig
Measurement of pin protrusion dimen-
N - Depth gauge ■ 1
sion
Measurement of distance between
P - Pitch gauge for shoe bolt holes ■ 1
shoe bolt holes
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY

REMARK
• For the details of general disassembly of PLUS type track shoe assembly, see “DISASSEMBLY AND AS-
SEMBLY OF TRACK ASSEMBLY GENERALLY (conventional type track shoe)”.
• To perform the disassembly work, judge if the parts are reused or replaced referring to the following materi-
als.
• Parts judgment guide, undercarriage, sealed and lubricated track
• Parts judgment guide, undercarriage, inverting procedure for pin and bushing
D155AXI-8 50-525
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY 50 DISASSEMBLY AND ASSEM-
GENERALLY BLY
NOTICE
• Use the track press which protective cover J is instal-
led.
• When disassembling the pin, wind tool K and wedge

ring (1) around tool H to prevent the cut pieces of
wedge ring (1) from scattering.
• After checking tool H and protective cover J are instal-

led, perform the work.
• Operators and workers for the track press must wear a
helmet, safety eyeglasses, and ear plugs.
• It is normal for the wedge rings to make a “snapping
sound” when cutting them.
• The cut surface of the wedge rings is sharpened and
dangerous. Be sure to wear leather gloves during the
work.
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY

Preparation
1. Install the seal assemblies to the master link counterbore, inner link sub assembly counterbore, outer link
counterbore, and offset link counterbore.
50-526 D155AXI-8
BLY GENERALLY
2. Clean and degrease the portions indicated with heavy line

(a) (counterbore portion of the link and seal assembly),
and push in the seal assembly to the bottom by using tool
F.
REMARK
• If oil is attached to the link counterbore and seal as-
sembly, the seal rotates and the sealing performance is
deteriorated. Accordingly, do not apply oil, grease, etc.
to them.
3. Adjust the press-fitting jig dimensions for the link press.

Dimensions of press jig and installation dimensions
Dimension (b): 4.7 mm
Dimension (c): 122.5 mm
Dimension (d): 122.5 mm
REMARK
• Dimensions listed above are secured to maintain the
protrusion dimensions of the pin and bushing constant
and to keep the seal mounting dimension within the
specified value range when assembling.
• Set the link receiving surface of tool L vertically.
• Replaceable tool M is desirable.
4. Adjust the relief pressure of the link press so that the
pressing force of the press does not exceed the following
specified value.
Specified pressing force: 637 kN {65 t}
REMARK
Excessive strong pressing force may cause the failures
described below.
• If the spacer is pressed by excessive force, spacer
gets damaged.
• Abnormal wear occurs between the spacer and bush-
ing end surface.
D155AXI-8 50-527
GENERALLY BLY
Assembly of link
5. Assemble pin (1), bushing (2), and spacers (3) (2 pieces)
temporarily, and prepare pin sub assemblies (4) (2 pieces).
6. Set pin sub assemblies (4a) and (4b) on tool (L).
7. Direct shoe mounting face (e) upward, and install inner

links (5) to which the seals have already been installed to
the right and left sides of pin sub assemblies (4a) and (4b).
REMARK
Adjust the position so that the spacer and seal are not
caught.
50-528 D155AXI-8
BLY GENERALLY
8. Set spacers (7) on the right and left sides of pin sub as-
sembly (4a) at the front.
9. Direct master link meshing surface (m) upward, and set
master links (13) on roller tread side to which the seals
have already been installed on the positions indicated in
the drawing below.
10. Press fit master links (13) on the roller tread side to pin
sub assembly (4a) at the front.
REMARK
• Perform centering of the link pin hole and pin before
press fitting.
• Install the assemblies so that right and left seals do not
fall off and seal and spacer (7) are not caught.
• Press fit right and left pin sub assemblies (4a) simulta-
neously.
• Check that right and left master links are press fitted in
parallel.
• Take care that the press-fitting force of pin sub assem-
blies, does not exceed the following value.
Press-fitting force: 637 kN {65 t}
• Measure pin protrusion dimension (g) by using tool N,
and adjust the dimension to the following value, and
then press fit the pin.
Protrusion dimension (g): 4.7±0.2 mm
11. Check that the distance between the shoe bolt holes is
within the standard range by using tool P.
• When the distance exceeds the specified value:
Disassemble the assembly, check for any abnormality,
and then assemble them again.
• When the distance is within the specified value range:
Wear of the spacer or bushing end surface may ex-
ceed the allowable limit. Disassemble the assembly
and replace the parts with new ones.
12. Set wedge ring (10) to tool D.
D155AXI-8 50-529
GENERALLY BLY
13. Perform positioning of tool D (larger plug) and pin, and

push in wedge ring (10) until it fits in the pin groove.
REMARK
• Install wedge ring (10) with opening (j) facing shoe
mounting side of the link.
• When wedge ring (10) fits in the pin groove, you can
hear the sound.
14. Install the wedge ring on the opposite side by using tool E
(smaller plug side) according to the same procedure. (See
“SPECIAL TOOLS LIST”.)
15. Press fit the wedge rings at both sides simultaneously by

using tool D and E.
REMARK
Take care that the press-fitting force of pin sub assemblies,
does not exceed the following value.
Press-fitting force: 186 to 284 kN {19 to 29 t}
16. Remove the air from inside of the pin for each link assem-
bly by using tool B, and check the sealing performance.
REMARK
• Hold the space inside the pin at 91 to 95 kPa 680 to
710 mmHg of vacuum for 5 seconds, and check that
the pressure does not change.
• If the pressure is changed, disassemble the link to
check the seal. If no failure is found, reassemble it.
50-530 D155AXI-8
BLY GENERALLY
17. By using tool C, fill with gear oil (GO80W90) until the filling
pressure reaches 196 to 294 kPa 2 to 3 kg/cm2.
REMARK
• If the oil pressure is raised excessively, it negatively af-
fects the seal.
• Set the link assembly with the smaller plug side facing
upward, leave it for 30 minutes, and then check the oil
level.
• Fill with gear oil (GO80W90) so that pin hole space
depth (L) is within the specified range as shown below.
Space depth (L): 35 to 60 mm
18. After filling with oil, drive in the smaller plug to the speci-
fied position by using tool A.
REMARK
Apply gear oil (GO80W90) to the outside perimeter of the
smaller plug, and drive in the plug.
Driving-in depth from pin end surface of smaller plug:
1±1 mm
19. Assemble pin (1), bushing (2), and spacers (3) (2 pieces)
temporarily, and prepare pin sub assemblies (4) (2 pieces).
D155AXI-8 50-531
GENERALLY BLY
20. Send assembled link assembly (11) to the front of the link
press bed.
21. Set pin sub assembly (4d) at the center of the jaw, and set
pin sub assembly (4e) at the front of tool (L).
22. Install inner link (5) with seals having been installed, to the
right and left sides of pin sub assemblies (4d) and (4e) as
directing shoe mounting face (e) upward.
REMARK
Adjust the position so that the spacer and seal are not
caught.
23. Set spacers (7) on the right and left sides of pin sub as-
sembly (4c) at the front and of pin sub assembly (4d) at
the center.
24. Direct shoe mounting face (k) upward, and set outer links
(12) to which the seals have already been installed on the
positions indicated in the figure below.
25. Press fit outer links (12) to pin sub assembly (4c) at the
front and to pin sub assembly (4d) at the center.
REMARK
• Perform centering of the link pin hole and pin before
press-fitting.
• Install the assemblies so that right and left seals do not
fall off and seal and spacer (7) are not caught.
• Press fit pin sub assemblies (4c) and (4d) simultane-
ously.
• Take care that the press-fitting force of pin sub assem-
blies, does not exceed the following value.
Press-fitting force: 637 kN {65 t}
50-532 D155AXI-8
BLY GENERALLY
26. Measure pin protrusion dimension (g) by using tool N, and

adjust the dimension to the following value, and then press
fit the pin.
Protrusion dimension (g): 4.7±0.2 mm
27. Perform the procedures in steps 11 to 18.

28. Perform the procedures in steps 19 to 23.
29. Assemble the master link on the roller tread side as the final link.
REMARK
Check that right and left master links are press fitted in parallel.
D155AXI-8 50-533
GENERALLY BLY
Installation of shoe
30. Set the shoe so that master link (1) on the shoe side and
shoe grouser (2) are positioned as shown in the drawing
below, and install the shoe.
REMARK
• Set the link assembly on the bed of the link press, and
install the shoe by using the shoe bolt impact wrench
and torque wrench.
• Tighten the shoe bolts in the order shown in the figure
below.
2 Shoe bolt (regular link):
3 Shoe bolt (regular link) initial torque:
784±78 Nm {80±8 kgm}
3 Retightening angle:
120±10 °
50-534 D155AXI-8
50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN
BLY FIELD
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD

Tools for disassembly and assembly of 1 link in field
New/Redesign
Necessity
Sketch
Q'ty
791-675-9581 Adapter ■ 1
791-675-9590 Guide ■ 1
A
01010-52465 Bolt ■ 2
01010-51440 Bolt ■ 2
790-101-1102 Pump ■ 1
B
790-101-4300 Cylinder (1470 kN {150 t} ) ■ 1
791-685-9510 Frame ■ 1
791-685-9520 Frame ■ 1
791-685-9530 Rod ■ 1
791-685-9550 Nut ■ 1
791-685-9560 Bolt ■ 1
C
791-675-9570 Adapter ■ 1
04530-12030 Eyebolt ■ 1
01010-51030 Bolt ■ 1
790-101-1102 Pump ■ 1
790-101-4300 Cylinder (1470 kN {150 t} ) ■ 1
791-685-9540 Rod ■ 1 Disassembly of 1 link
D
791-685-9550 Nut ■ 3
791-675-5520 Guide ■ 1
E 791-675-5530 Pusher ■ 1
791-126-0150 Adapter ■ 1
790-101-1102 Pump ■ 1
F
790-101-4200 Puller (294 kN {30 t} ) ■ 1
791-675-5542 Adapter ■ 1
791-675-5571 Adapter ■ 1
G
790-101-1102 Pump ■ 1
790-101-4300 Cylinder (1470 kN {150 t} ) ■ 1
H 791-675-5580 Guide ■ 1
791-126-0150 Adapter ■ 1
791-685-9620 Extension ■ 1
J 791-675-5550 Guide ■ 1
791-675-5542 Adapter ■ 1
01010-51030 Bolt ■ 1
D155AXI-8 50-535
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN 50 DISASSEMBLY AND ASSEM-
FIELD BLY
New/Redesign
Necessity
Sketch
Q'ty
K 791-670-3270 Guide ■ 1
791-126-0150 Adapter ■ 1
791-675-5560 Guide ■ 1
L
791-675-9570 Adapter ■ 1
01010-51030 Bolt ■ 1
791-685-9510 Frame ■ 1
791-685-9520 Frame ■ 1
791-685-9530 Rod ■ 1
791-685-9540 Rod ■ 1
Disassembly of 1 link
791-685-9550 Nut ■ 3
791-685-9560 Bolt ■ 4
M
791-126-0150 Adapter ■ 1
01010-51030 Bolt ■ 1
791-685-9620 Extension ■ 1
791-675-5571 Adapter ■ 1
791-675-5550 Guide ■ 1
791-675-9631 Adapter ■ 1
N - Spacer ■ 1
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD

REMARK
• The following is the explanation only of how to use the tool.
• For details of disassembly and assembly, see “DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY
GENERALLY”.
Adapter, guide, bolt
1. Install tool A (adapter, guide, blade) to link (1) with bolts (2)
(2 pieces).
REMARK
For 2 pieces of bolt (2), the bolts of the track can be used.
50-536 D155AXI-8
BLY FIELD
Pump, cylinder
2. After assembling tool B (pump, cylinder 1470 kN {150 t} )
and tool C (frame, rod, adapter, bolt (1 piece), eyebolt),
sling them as a unit, and set them on the shoe.
Rod
3. Insert the rod of tool D from the cylinder side, and install it
with nut (2 pieces).
Pass the rod through the hole of link (1), and install it.
Adapter, guide, pusher

4. Set tool E (adapter, guide, pusher), apply oil pressure, and
then remove pin (3).
When the cylinder reaches the stroke end, insert tool E
(extension) between the adapter and guide, and repeat the
work.
5. Set tool F (puller 294 kN {30 t} ) and tool E at the center of
the roller tread side of the link to be disassembled, apply
oil pressure to the puller. Open the link 5 to 6 mm to dis-
connect it.
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD

Link sub assembly
1. Set tool G onto end surface of the link, and press fit bush-
ing (1).
D155AXI-8 50-537
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN 50 DISASSEMBLY AND ASSEM-
FIELD BLY
2. Set tool G onto end surface of the link (on the pin side),
and press fit pin (2).
REMARK
Set the tool with side hole (a) of the pin facing link tread
(b).
Pin press-fitting force: 284 to 686 kN {29 to 70 t}
3. Set link sub assembly (3) to the link that will be connected.
Link
4. Set link (4) on the opposite side, and support it by using
tool H (guide).
5. Set tool M and tool J as pin pulling-out work, and press fit
bushing side (d) by using tool M (adapter, extension,
guide, and bolt) and pin side (c) by using tool J (extension,
guide, adapter, and bolt) alternately.
6. By using tool F (puller 294 kN 30 t), open link on bushing

side (5) as disassembling.
50-538 D155AXI-8
BLY FIELD
7. Set link on pin side (6) to link on bushing side (5), connect
them by using tool K (guide), and then remove tool F (pull-
er).
8. Press fit pin (7) by using tool L (adapter, bolt, and guide).
2 Pin press-fitting hole of link (Cylinder: (b), frame
side: (e)):
Liquid gasket (198-32-19890)
REMARK
Set the tool with the side hole of the pin facing the link
tread.
D155AXI-8 50-539
DISASSEMBLE AND ASSEMBLE MASTER LINK BLY
DISASSEMBLE AND ASSEMBLE MASTER LINK

Tools for disassembly and assembly of master link
New/Redesign
Necessity
Sketch
Q'ty
791-675-9701 Remover, installer ■ 1

790-101-1102 Pump ■ 1 Disassembly and assembly of track
A
790-101-4200 Puller (294 kN {30 t} ) ■ 1 shoe
790-101-4300 Cylinder (1470 kN {150 t} ) ■ 1

790-101-1102 Pump ■ 1
B Expansion of link
790-101-4200 Puller (294 kN {30 t} ) ■ 1
C - Guide pin ■ 1 Pin hole alignment of pin and bushing
D 791-432-1110 Plug push tool ■ 1 Driving in of plug (large)
E 790-701-3000 Seal checker ■ 1 Check of floating seal airtightness
F 791-932-1110 Plug push tool ■ 1 Driving in of plug (small)
REMARK
For details of how to use tool B, see “DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN
FIELD”.
METHOD FOR DISASSEMBLING MASTER LINK

1. Remove the track shoe assembly. For details, see “SEPARATION AND CONNECTION OF TRACK AS-
SEMBLY”.
Gas cut
2. Perform the gas cut of portion (a) of the master link on the
bushing side, and remove the hatched area.
3. Move master links (5) and (6) up and down, and remove
them.
4. By using tool A, press pins (8) and (9) press-fitted to regu-
lar link (7) up and down to remove them.
REMARK
For details of how to use tool A, see “DISASSEMBLE AND
ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD”.
50-540 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE MASTER LINK
5. Perform gas cut of portion (b), and remove the hatched

area.
Pin
6. Press pin (10) downward by using tool A, and remove it from link (11).
REMARK
For details of how to use tool A, see “DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN
FIELD”.
Bushing
7. Remove pin (10) and link (12) from bushing (13) simultaneously.
METHOD FOR ASSEMBLING MASTER LINK

Bushing side link
1. Press-fit master link (1) on the bushing side to bushing (2)
by using tool A.
REMARK
• For details of how to use tool A, see “DISASSEMBLE
AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN
FIELD”.
• Take extreme care to press-fit right and left master
links parallel.
• Do not damage the mating face of the master link and
bushing end face.
Dimension (L1): 169±0.7 mm
Dimension (L2): 219.8±0.7 mm
Dimension (D1): ϕ27 mm
Dimension (D2): M24×P2.0 mm
2. Press and expand the link tread center by using tool B as
shown in the following figure. (Expand by 10 mm at the link
end.)
Dimension (a): 5 mm
REMARK
For details of how to use tool B, see “DISASSEMBLE AND
D155AXI-8 50-541
DISASSEMBLE AND ASSEMBLE MASTER LINK BLY
3. Set spacer (3) and seal assembly (4) to the counterbore of

the connection link.
4. Align the pin hole with the bushing hole, and connect them
by using tool C.
5. Press-fit pin (5) by using tool A, and install master link (1)
on the bushing side.
REMARK
• For details of how to use tool A, see “DISASSEMBLE
AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN
FIELD”.
• Direct the side hole of the pin hole toward the link
tread.
2 Link pin hole:
Liquid gasket (198-32-19890)
Shoe
6. Install the shoe to the connection link.
7. Drive in large plug (6) by using tool D, add oil by using tool
E, and drive in small plug (7) by using tool F.
REMARK
• Take extreme care to press-fit right and left master
links so that right and left links are parallel (bushing
side, pin side).
• Do not damage the mating face of the master link and
bushing end face.
• Take extreme care to protect the seal, spacer, bushing
end surface, and master link tap mating face from dirt,
soil or sand.
50-542 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE MASTER LINK
Pin side link

8. Set spacer (3) and seal assembly (4) to the counterbore of
the master link.
9. Pass pin (9) through bushing (8), set master link (10) on
the pin side from both sides, and press-fit it by using tool
A.
REMARK
For details of how to use tool A, see “DISASSEMBLE AND
10. Drive in large plug (11) by using tool D, add oil by using
tool E, and drive in small plug (12) by using tool F.
Connection
12. Pull in master link (13) on the pin side and master link (14)
on the bushing side, and set them on the mating faces.
13. Place the shoe, and fit the link contact surfaces each other
completely.
14. Check that the shoe bolt can be inserted easily by hand,
and connect it with the master bolt.
2 Shoe bolt:
3 Shoe bolt (master link) 1st time:
590±60 Nm {60±6 kgm}
Shoe bolt (master link) 2nd time: 180±10 ° (retightening)
D155AXI-8 50-543
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY BLY
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY

Tools for removal and installation of equalizer bar assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Blocking tool ■ 2
Support of machine
B - Hydraulic jack ■ 2
791T-650-2130 Sleeve ■ 1 ○
790-101-2420 Adapter ■ 1
791-520-4140 Screw ■ 1
C 790-101-2540 Washer ■ 2 Pulling-out of center pin
791-112-1180 Nut ■ 2
790-101-4000 Puller (490 kN {50 t} ) ■ 1
790-101-1102 Pump ■ 1
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY

Underguard
1. Remove the engine underguard and power train under-
guard.
4 Engine underguard:
270 kg
4 Power train underguard:

290 kg
Equalizer bar assembly

2. Place the hydraulic jack to the center of the equalizer bar, and lift the machine. Place tool A and tool B un-
der the radiator guard.
REMARK
It is difficult to remove the pin if the holes of the equalizer bar and track frame are not aligned each other.
Adjust the slinging height on the track frame side for removal.
50-544 D155AXI-8
BLY REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY
4. Remove lock plate (3), and remove side pin (4).

5. Repeat steps 3 and 4 to remove the pin on the opposite
side.
REMARK
If the track frame assembly on the opposite side is lifted
before removing the pin, support it by block, etc.
6. Operate tool B slowly to lower the machine to the position
where the equalizer bar contacts right and left track
frames.
7. Disconnect grease hose (5).
8. Remove lock plate (6).
9. Sling equalizer bar assembly (7) by using the crane and

chain block, and hold it.
REMARK
D155AXI-8 50-545
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY BLY
10. Pull out center pin (8) by using tool C.

k Operate the hydraulic parts remotely. Do not oper-
ate them on the front and bottom side of the puller.
11. Operate the chain block and crane to remove equalizer bar
assembly (7).
4 Equalizer bar assembly:

240 kg
k After removing the equalizer bar assembly, do not
lower the machine.
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY

Equalizer bar assembly
1. Operate the chain block and crane to install equalizer bar
assembly (7).
REMARK
Install the equalizer bar with the greasing nipple side fac-
ing forward.
2. Install center pin (8) by using tool C.

k When aligning pin holes, never insert your finger
into the holes.
k Operate the hydraulic parts remotely. Do not oper-
ate them on the front and bottom sides of the pull-
er.
2 Equalizer bar center bushing:
Grease (G2-LI)
50-546 D155AXI-8
BLY REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY
3. Install lock plate (6).
4. Connect lubrication hose (5).
5. Install side pin (4), and install lock plate (3).

REMARK
Operate the hydraulic jack to adjust the main frame height
before installing the side pin. Align the center of the equal-
izer bar hole with that of the track frame hole.
Install the pin on the opposite side according to the same
procedure described above.
2 Seal lip part:
Grease (G2-LI)
6. Install bolts (1) (2 pieces), and install cover (2).
2 Threaded portion of cover mounting bolt:
3 Cover mounting bolt:
784 to 981 Nm {80 to 100 kgm}
Underguard
7. Place the hydraulic jack to the center of the equalizer bar,
and lift the machine. Remove tool A and tool B that are set
under the radiator guard.
8. Install the engine underguard and power train underguard.
4 Engine underguard:
270 kg
4 Power train underguard:

290 kg
D155AXI-8 50-547
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS BLY
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS

Tools for disassembly and assembly of equalizer bar bushing
New/Redesign
Necessity
Sketch
Q'ty
A 794T-622-1610 Spacer ■ 1 ○ Pulling out of bushing
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS

1. Remove the equalizer bar assembly. For details, see “REMOVE AND INSTALL EQUALIZER BAR ASSEM-
BLY”.
Side bushing
2. Remove seal (1).
3. Remove ring (2).
4. Remove spherical bushing (3) from equalizer bar (4) by

using tool A.
Center bushing
5. Remove center bushing (5) from equalizer bar (4).
50-548 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS

Center bushing
1. Press-fit center bushing (5) to equalizer bar (4) by using
press.
2 Outer periphery of spherical bushing:
Center bushing press-fitting force: 47.1 to 131.4 kN {4.8 to
13.4 t}
Side bushing
2. Install ring (2) to one side of equalizer bar (4).
3. Press-fit spherical bushing (3) to equalizer bar (4) by using
tool A.
2 Outer periphery of spherical bushing:
Spherical bushing press-fitting force: 27.4 to 64.7 kN {2.8
to 6.6 t}
4. Install ring (2) on the opposite side.
5. Press-fit seal (1) by using press.

REMARK
Do not extrude the seal fitting from the equalizer bar end
surface.
Seal press-fitting force: 6.9 to 18.6 kN {0.7 to 1.9 t}
D155AXI-8 50-549
REMOVE AND INSTALL SPROCKET BLY
REMOVE AND INSTALL SPROCKET

METHOD FOR REMOVING SPROCKET

Teeth
1. Stop the machine at the position (midpoint between the shoe and track frame) where teeth (1) is easily re-
moved.
2. Remove the mounting bolt, and remove teeth (1).
METHOD FOR INSTALLING SPROCKET

Teeth
1. Stop the machine at the position (midpoint between the shoe and track frame) where teeth (1) is easily in-
stalled.
2. Tighten the nuts in the order of (a), (b), and (c) in the fol-
lowing figure while pressing teeth (1) toward the center of
sprocket hub (2).
2 Threaded portion pf teeth mounting bolt:
3 Teeth mounting nut:
1176±98 Nm {120±10 kgm}
50-550 D155AXI-8
BLY REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
HYDRAULIC SYSTEM
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
record them.
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY

Draining
1. Drain oil from the hydraulic tank.
Hydraulic tank95 ℓ
SEMBLY”.
Hose, tube
3. Remove hoses (1) and (2).

5. Disconnect suction tube (5).
D155AXI-8 50-551
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY BLY
6. Disconnect tube (6).
Hydraulic tank assembly

7. Remove hydraulic tank lower mounting bolts (4 pieces),
sling hydraulic tank assembly (7), and remove it.
4 Hydraulic tank assembly:

100 kg
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY

Hydraulic tank assembly
1. Sling hydraulic tank assembly (7), install it, and tighten it
with hydraulic tank bottom mounting bolts (4 pieces).
4 Hydraulic tank assembly:

100 kg
Hose, tube
50-552 D155AXI-8
BLY REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY


BLY”.
Refilling with oil
7. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again. (For details, see STRUCTURE
AND FUNCTION, “TABLE OF FUEL, COOLANT, AND LUBRICANTS”.)
5 Hydraulic tank:
95 ℓ
D155AXI-8 50-553
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP 50 DISASSEMBLY AND ASSEM-
ASSEMBLY BLY
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP AS-
SEMBLY
record them.
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND HSS PUMP ASSEM-
BLY
Draining
6 Hydraulic tank:
95 ℓ
2. Remove the operator's cab assembly. For details, see “REMOVE AND INSTALL OPERATOR’S CAB AS-
SEMBLY”.
50-554 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP
BLY ASSEMBLY
3. Remove underguard (1) under the power train.
4 Underguard:
300 kg
Connector

7. Disconnect connectors (5) and (6).
Hose, tube
9. Disconnect hydraulic hoses (8), (9) and (10).
10. Disconnect block (11).
D155AXI-8 50-555
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP 50 DISASSEMBLY AND ASSEM-
ASSEMBLY BLY
11. Disconnect suction tube (12).
Work equipment and HSS pump assembly

12. Disconnect hydraulic hose (13).
13. Remove the mounting bolts, sling work equipment and
HSS pump assembly (14), and remove them.
4 Work equipment and HSS pump assembly (14):

120 kg
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND HSS PUMP ASSEM-
BLY
Work equipment and HSS pump
1. Sling work equipment and HSS pump assembly (14), and
install it.
4 Work equipment and HSS pump assembly (14):

120 kg
2. Install hydraulic hose (13).
Hose, tube
50-556 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP
BLY ASSEMBLY
4. Install block (11).

5. Connect hydraulic hoses (8), (9) and (10).
Connector
7. Connect connectors (5) and (6).

11. Install underguard (1) under the power train.
4 Underguard:
300 kg
12. Install the operator's cab assembly. For details, see “RE-
MOVE AND INSTALL OPERATOR'S CAB ASSEMBLY”.
Refilling with oil

5 Hydraulic tank:
95 ℓ
D155AXI-8 50-557
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LU- 50 DISASSEMBLY AND ASSEM-
BRICATION PUMP ASSEMBLY BLY
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICA-

TION PUMP ASSEMBLY
record them.
METHOD FOR REMOVING POWER TRAIN PUMP AND STEERING LUBRICATION

PUMP ASSEMBLY
Draining
6 Hydraulic tank:
95 ℓ
SEMBLY”.
50-558 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LU-
BLY BRICATION PUMP ASSEMBLY
Underguard
4 Underguard:
300 kg
4. Drain oil from the power train case.
6 Power train case:

90 ℓ
Hose, wiring harness

7. Remove bracket (4) and clamp (5), and move wiring har-
ness (6) aside so that it does not hinder the work.

9. Disconnect tubes (9), (10), and (11).
10. Sling power train pump and steering lubrication pump as-
sembly (12), hold it, remove the mounting bolts (2 pieces),
and remove the assembly.
4 sembly (12):
30 kg
D155AXI-8 50-559
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LU- 50 DISASSEMBLY AND ASSEM-
BRICATION PUMP ASSEMBLY BLY
METHOD FOR INSTALLING POWER TRAIN PUMP AND STEERING LUBRICA-

TION PUMP ASSEMBLY
1. Sling power train pump and steering lubrication pump as-
sembly (12), hold it, tighten the mounting bolts (2 pieces),
and install the assembly.
4 sembly (12):
30 kg
2. Install tubes (11), (10), and (9).
Hose, wiring harness

4. Install wiring harness (6) with bracket (4) and clamp (5).
4 Underguard:
300 kg

BLY”.
50-560 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LU-
BLY BRICATION PUMP ASSEMBLY
Refilling with oil

5 Hydraulic tank:
95 ℓ
10. Refill the power train case with oil to the specified level through the oil filler port. Start the engine to circu-
late the oil through the piping, and check the oil level again. (For details, see STRUCTURE AND FUNC-
TION, “TABLE OF FUEL, COOLANT, AND LUBRICANTS”.)
5 Power train case:

90 ℓ
D155AXI-8 50-561
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY BLY
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY

METHOD FOR REMOVING COOLING FAN PUMP ASSEMBLY

Draining oil
1. Remove plug (1), loosen plug (2) and drain the hydraulic
oil.
6 Hydraulic tank:
95 ℓ
Undercover
2. Remove undercover (3).

3. Remove bolts (4) (4 pieces), and remove suction tube (4).
50-562 D155AXI-8
BLY REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY
4. Remove plates (6) (right and left) and footrests (7) (2

pieces), and remove floor mat (8).
5. Remove floor plate (9).
6. Remove clamps (10) (6 places) from each wiring harness.

7. Disconnect connector FAC (11).
8. Disconnect hoses (13) to (19).
10. Remove cooling fan pump assembly (21).
4 Cooling fan pump assembly:

50 kg
11.
D155AXI-8 50-563
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY BLY
METHOD FOR INSTALLING COOLING FAN PUMP ASSEMBLY

1. Install cooling fan pump assembly (21).
4 Cooling fan pump assembly:

50 kg

4. Install connector FAC (11).
5. Install clamps (10) (6 places) of each wiring harness.
6. Install floor plate (9).
7. Install floor mat (8).

8. Install plates (6) (right and left), and foot rests (7) (2
pieces).
50-564 D155AXI-8
BLY REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY
9. Install suction tube (5) with bolts (4) (4 pieces).
Undercover
10. Install undercover (3).
Refilling with hydraulic oil

11. Install plugs (1) and (2).
12. Refill with oil to the specified level through the oil filler port.
Run the engine to circulate the oil through the system.
Then, check the oil level again.( For details of oil level, see
"TABLE OF FUEL, COOLANT, AND LUBRICANTS".)
6 Hydraulic tank:
95 ℓ
D155AXI-8 50-565
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY BLY
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY

METHOD FOR REMOVING SCAVENGING PUMP ASSEMBLY

Underguard
4 Underguard:
300 kg
Draining
2. Drain oil from the power train case.
6 Power train case:

90 ℓ
4. Disconnect outlet tube (3).
5. Remove the mounting bolts (2 pieces), and remove scav-
enging pump assembly (4).

20 kg
50-566 D155AXI-8
BLY REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY
METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY

1. Install scavenging pump assembly (4) with the mounting
bolts (2 pieces).

20 kg
2. Install outlet tube (3).
Underguard
4 Underguard:
300 kg
Refilling with oil

5. Refill the power train case with oil to the specified level through the oil filler port. Start the engine to circu-
late the oil through the piping, and check the oil level again. (For details, see STRUCTURE AND FUNC-
TION, “TABLE OF FUEL, COOLANT, AND LUBRICANTS”.)
5 Power train case:

90 ℓ
D155AXI-8 50-567
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY BLY
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY

record them.
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY

Control valve cover
1. Remove control valve cover (1).
Connector
2. Disconnect control valve connectors WEP1 (2) to WEP9
(10), WEPA (11), WEPW (12), HSL (13), and HSR (14).
REMARK
Combination of connector No. and related wiring band col-
or
• Connector (2): WEP1 (Green)
• Connector (3): WEP2 (Green/Black)
• Connector (4): WEP3 (Brown)
• Connector (5): WEP4 (Brown/Black)
• Connector (6): WEP5 (Blue)
• Connector (7): WEP6 (Blue/Black)
• Connector (8): WEP7 (Yellow)
• Connector (9): WEP8 (Yellow/Black)
• Connector (10): WEP9 (Red)
• Connector (11): WEPA (Red/Black)
• Connector (12): WEPW (-)
• Connector (13): HSL (Black)
• Connector (14): HSR (N/A)
3. Disconnect power train wiring harness connectors HSS (15) and PUMP (16).
50-568 D155AXI-8
BLY REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
4. Remove wiring harness clamps (17) (2 pieces), and move

the wiring harness assembly so that it does not hinder re-
moval of the control valve assembly.
Hose
5. Disconnect all of hydraulic hoses (18) and (19).
REMARK
In order to prevent oil from flowing out, install the plugs to
Control valve assembly

6. Sling the control valve, hold it, and remove control valve mounting bolts (20) (4 pieces).
7. Sling control valve assembly (21), and remove it.
REMARK
4 before removing.
Check all the wiring and piping are disconnected
Control valve assembly (21):

180 kg
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY

Control valve assembly
1. Sling control valve assembly (21), and install it.
4 Control valve assembly (21):

180 kg
2. Sling the control valve assembly, hold it, and install control
valve mounting bolts (20) (4 pieces).
D155AXI-8 50-569
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY BLY
Hose
3. Remove the plug that was installed to the hose and fitting,
and install all hydraulic hoses (18) and (19).
Connector
4. Install wiring harness clamps (17) (2 pieces).
5. Install power train wiring harness connectors HSS (15) and

PUMP (16).
6. Install control valve connectors WEP1 (2) to WEP9 (10),
WEPA (11), WEPW (12), HSL (13), and HSR (14).
REMARK
Combination of connector No. and related wiring band col-
or
• Connector (2): WEP1 (Green)
• Connector (3): WEP2 (Green/Black)
• Connector (4): WEP3 (Brown)
• Connector (5): WEP4 (Brown/Black)
• Connector (6): WEP5 (Blue)
• Connector (7): WEP6 (Blue/Black)
• Connector (8): WEP7 (Yellow)
• Connector (9): WEP8 (Yellow/Black)
• Connector (10): WEP9 (Red)
• Connector (11): WEPA (Red/Black)
• Connector (12): WEPW (-)
• Connector (13): HSL (Black)
• Connector (14): HSR (N/A)
50-570 D155AXI-8
BLY REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
Control valve cover

7. Install control valve cover (1).
Refilling with oil

D155AXI-8 50-571
REMOVE AND INSTALL BLADE ASSEMBLY BLY
WORK EQUIPMENT
REMOVE AND INSTALL BLADE ASSEMBLY
k Be sure to release the remaining pressure in the piping, and gradually loosen the cap of the hydraul-
ic tank to release the remaining pressure in the tank before disconnecting the hydraulic piping and
hydraulic hose. For details, see TESTING AND ADJUSTING, “RELEASE REMAINING PRESSURE
FROM HYDRAULIC CIRCUIT”.
record them.
k If the wiring and hoses may be damaged or deformed, remove the clips and clamps before discon-
necting them.
METHOD FOR REMOVING BLADE ASSEMBLY

Lift cylinder assembly
1. Lower the work equipment to a level ground, and set tool A
under the right and left I-frames.
2. Remove cap (1) of the lift cylinder.

REMARK
Write down the quantity and thickness of shims.
50-572 D155AXI-8
BLY REMOVE AND INSTALL BLADE ASSEMBLY
3. Sling lift cylinder assembly (2), hold it, start the engine,
fully retract the piston rod, fit the cylinder fixing tool, and fix
the tool on the radiator guard.
NOTICE
Tie the piston rod with wire, etc. so that the piston rod
is not pulled out.
4. Disconnect the lift cylinder assembly on the opposite side
Hose
5. Stop the engine, and release the remaining pressure in the hydraulic hose and hydraulic cylinder.
6. Remove trunnion cover (3).
7. Disconnect hose (4), and remove trunnion cap (5).

REMARK
Plug the piping not to allow dirt to enter.
8. Disconnect the trunnion on the opposite side according to
the same procedure as steps 6 and 7.
Blade assembly
9. Start the engine, slowly drive the machine in the reverse
direction, and disconnect blade assembly (6) from the
trunnion.
D155AXI-8 50-573
METHOD FOR INSTALLING BLADE ASSEMBLY

Blade assembly
1. Adjust blade assembly (b) by using tool A so that trunnion
height (b) of the right and left I-frames and frame width (c)
are adjusted to the following dimensions.
Trunnion height (b): Approximately 636 mm
Frame width (c): Approximately 3016 mm
2. Start the engine, slowly travel the machine forward, and

align blade assembly (6) with the trunnion mounting posi-
tion.
Hose
3. Stop the engine, and release the remaining pressure in the
hydraulic hose and hydraulic cylinder.
REMARK
Connect hose (4) so that it is not twisted.
4. Connect hose (4) from which the plug is removed, and in-
stall trunnion cap (5).
50-574 D155AXI-8
BLY REMOVE AND INSTALL BLADE ASSEMBLY
5. Install trunnion cover (3).

REMARK
Install the trunnion on the opposite side according to the
same procedure as steps 4 and 5.
Lift cylinder assembly

6. Start the engine, sling lift cylinder assembly (2), hold it,
and then remove the cylinder fixing tool and piston rod fix-
ing tool.
7. Slowly extend the lift cylinder, and set it onto the blade
mounting position.
8. Install shims to cap (1), and tighten it with the mounting
bolt (2 places).
REMARK
• Install the shims of the same thickness and quantity as
you wrote down when disassembling to the same posi-
tion as disassembly.
• Adjust clearance (a) between the cap mating faces to
the following dimensions so that the connection
smoothly rotates.
• Standard clearance (a): 0.2 to 1.2 mm
• Standard shim thickness: 4 mm
D155AXI-8 50-575
Adjusting of blade tilt amount (single tilt specifications)

9. Adjust the amount by using handle (8) so that mounting di-
mension (d) of brace (7) is adjusted to the following dimen-
sions.
Dimensions Σ dozer Semi-U dozer Full-U dozer
d 1360 mm 1374 mm 1374 mm
10. Check the dimensions of right and left tilt amounts (e1)
and (e2).
Dimensions Σ dozer Semi-U dozer Full-U dozer
e1 565 mm 570 mm 570 mm
e2 565 mm 570 mm 570 mm
REMARK
• In case of e1 > e2, finely adjust the tilt amount so that
mounting dimension (d) of brace (7) is longer.
• In case of e1 < e2, finely adjust the tilt amount so that
mounting dimension (d) of brace (7) is shorter.
11. Fully grease right and left lift cylinder mounting portions
(e).
2 Lift cylinder mounting portion (e):
Grease (G2-LI)
12. Refill the hydraulic tank with the hydraulic oil. For details, see STRUCTURE AND FUNCTION, “TABLE OF
FUEL, COOLANT, AND LUBRICANTS”.
REMARK
• Refill with oil through the oil filler port of the hydraulic tank to the specified level with the engine stopped.
Run the engine to circulate the oil through the piping.
• After stopping the engine, check the oil level again. If the oil level is lower than the specified level, sup-
ply the oil to the specified level again.
50-576 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE BLADE ASSEMBLY
DISASSEMBLE AND ASSEMBLE BLADE ASSEMBLY
Tools for disassembly and assembly of blade assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 1 Fixing of blade

B - Block ■ 2 Fixing of I-frame
C - Block ■ 1 Fixing of center brace
METHOD FOR DISASSEMBLING BLADE ASSEMBLY

Right tilt cylinder assembly
1. Insert tool A and tool B into and under the right and left I-
frames, and set them so that the blade is securely stabi-
lized.
2. Remove right frame cover (1).

REMARK
Shims are inserted into the bolt mounting portions. Write
down the thickness and quantity, and keep the shims to
prevent from losing.
3. Disconnect right tilt cylinder hose (2).
D155AXI-8 50-577
DISASSEMBLE AND ASSEMBLE BLADE ASSEMBLY BLY
4. Sling right tilt cylinder assembly (3), hold it, remove the
bolt of cap (3a) on the head side, and disconnect it from
the blade.
REMARK
Shims are inserted into the cap. Write down the thickness
and quantity, and keep the shims to prevent from losing.
5. Remove the lock plate, pull out pin (4) on the bottom side,
and remove right tilt cylinder assembly (3).
4 Right tilt cylinder assembly (3):

170 kg
Right I-frame
6. Sling center brace (5), hold it, remove pin (6), and set tool
C under center brace (5).
7. Sling right I-frame (7), hold it, and disconnect center brace
(5) from right I-frame (7).
50-578 D155AXI-8
8. Remove the lock plate, remove pin (9), and remove right I-
frame (7).
4 Right I-frame:
800 kg
Center brace
9. Remove mounting bolt of cap (10), and remove center
brace (11).
4 Center brace:
250 kg
Left tilt cylinder assembly

10. Sling left tilt cylinder (12), and remove it according to the
same procedure as steps 2 to 5.
4 Left tilt cylinder assembly:

170 kg
Left I-frame
11. Remove the lock plate, remove pin (13), sling left I-frame
4 Left I-frame:
500 kg
D155AXI-8 50-579
Blade
12. Sling blade (15), and tilt the blade.
4 Blade:
3700 kg
METHOD FOR ASSEMBLING BLADE ASSEMBLY

Blade
1. Sling blade (15), and place blocks and stands under the
blade to set them so that the blade is securely stabilized.
4 Blade:
3700 kg
Center brace
2. Sling center brace (11), and set it onto the blade mounting
position.
REMARK
Set the block according to the right I-frame height under
the center brace.
4 Center brace:
250 kg
3. Install shims to cap (10), and tighten it with the mounting
bolt.
REMARK
• Standard clearance: Set the play of the ball in the axial
direction of the spherical portion to Max. 1 mm, adjust
the clearance so that the connection rotates smoothly.
• Standard shim thickness: 4.5 mm
50-580 D155AXI-8
Right I-frame
4. Sling right I-frame (7), hold it, and set the pin side of center
brace (5) on the mounting position of right I-frame (7).
4 Right I-frame:
800 kg
5. Align pin (9) with the pin hole, install it, and then fix it with
the lock plate.
6. Sling center brace (5), hold it, align the right I-frame with
the pin hole, and then install pin (6).
Right tilt cylinder assembly

7. Sling right tilt cylinder assembly (3), and set it onto the
blade mounting position.
4 Right tilt cylinder assembly:

170 kg
8. Install shims to cap (3a) on the head side, and tighten it
with the mounting bolt.
REMARK
• Standard clearance: Set the play of the ball in the axial
direction of the spherical portion to Max. 1 mm, adjust
the clearance so that the connection rotates smoothly.
• Standard shim thickness: 4.3 mm
D155AXI-8 50-581
9. Align right tilt cylinder assembly (3) with the right I-frame pin hole, install pin (4), and fix it with the lock
plate.
10. Connect right tilt cylinder hose (2).
11. Install right frame cover (1).
REMARK
Install the shims of the same thickness and quantity as you
wrote down when disassembling to the same position as
disassembly.
Left I-frame
12. Sling left I-frame (14), hold it, align the blade mounting po-
sition with the pin hole, install pin (13), and fix it with the
lock plate.
4 Left I-frame:
500 kg
Left tilt cylinder assembly

13. Install left tilt cylinder assembly (12) according to the same
procedure as steps 7 to 11.
4 Left tilt cylinder assembly:

170 kg
14. After assembling, sufficiently grease the center brace

mounting portion and right and left tilt cylinder mounting
portions.
2 Center brace mounting portion, tilt cylinder mount-
ing portion:
Grease (G2-LI)
50-582 D155AXI-8
50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER AS-
BLY SEMBLY
DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER ASSEM-

BLY
Tools for disassembly and assembly of multi-shank ripper assembly.
New/Redesign
Necessity
Sketch
Q'ty
A - Blocking tool ■ 2 Fixing of beam

B - Block ■ 1 Fixing of arm
FROM HYDRAULIC SYSTEM”.
k Check the connector numbers and installed positions before disconnecting wiring harnesses and
hoses, and record them.
METHOD FOR DISASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY

Shank
1. Adjust the ripper to the maximum raising position and the maximum tilt-in position.
2. Sling shank (1), hold it, remove the lock pin, remove
mounting pin (2), gradually lower shank (1), and remove it.
4 Shank:
300 kg
Lift cylinder assembly, tilt cylinder assembly

3. Set tool A under the beam, set tool B under the arm, and
lower the ripper assembly.
D155AXI-8 50-583
DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER AS- 50 DISASSEMBLY AND ASSEM-
SEMBLY BLY
4. Sling lift cylinder assembly (3), hold it, remove the lock
plate, and remove pin (4) on the rod side.
5. Fully retract the piston rod of lift cylinder assembly (3), and
lower it onto the arm.
6. Sling tilt cylinder assembly (5), hold it, remove the lock
REMARK
The pin is used when removing the beam. Assemble it to
the beam temporarily.
7. Fully retract the piston rod of tilt cylinder assembly (5), and
9. Disconnect lift cylinder hose (7) and tilt cylinder hose (8),
and move them toward the fuel tank side.
plate, remove pin (9), sling lift cylinder assembly (3), and
then remove it.
4 Lift cylinder assembly:

200 kg
11. Sling tilt cylinder assembly (5), hold it, remove pin (9), and
then remove tilt cylinder assembly (5).
4 Tilt cylinder assembly:

270 kg
50-584 D155AXI-8
BLY SEMBLY
Beam, arm
12. Sling beam (10), hold it, remove the lock plate, remove
right and left pins (11), sling beam (10), and then remove
it.
4 Beam:
1100 kg
13. Sling arm (12), hold it, remove the lock plate, remove right
and left pins (13), sling arm (12), and then remove it.
REMARK
4 Arm:
700 kg
METHOD FOR ASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY

Arm, beam
1. Sling arm (12), install right and left pins (13), fix them with
the lock plate, and set tool B under the arm.
4 Arm:
700 kg
2. Sling beam (10), install right and left pins (11), fix them
with the lock plate, and set tool A under the beam.
4 Beam:
1100 kg
D155AXI-8 50-585
DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER AS- 50 DISASSEMBLY AND ASSEM-
SEMBLY BLY
Tilt cylinder assembly, lift cylinder assembly

3. Sling tilt cylinder assembly (5), install pin (9), and lower the
rod side to set it onto the arm.

270 kg
4. Sling lift cylinder assembly (3), push in pin (9), fix the pin
with the lock plate, and lower the rod side to set it onto the
arm.

200 kg
5. Connect tilt cylinder hose (8) and lift cylinder hose (7).
6. Sling tilt cylinder assembly (5), hold it, start the engine, ex-
tend the piston rod, align pin (6) with the pin hole to install
it, and then fix the pin with the lock plate.
7. Sling lift cylinder assembly (3), hold it, extend the piston
rod, align pin (4) with the pin hole to install it, and then fix
the pin with the lock plate.
Shank
8. Adjust the ripper to the maximum raising position and the maximum tilt-in position.
50-586 D155AXI-8
BLY SEMBLY
9. Pass the wire through the shank mounting hole of the

beam, sling shank (1), install the shank with pin (2), and fix
it with the lock pin.
4 Shank:
300 kg
10. After completion of assembling, sufficiently grease all the
pin portions.
2 Pin:
Grease (G2-LI)
11. Refill the hydraulic tank with the hydraulic oil. For details,
see STRUCTURE AND FUNCTION, “TABLE OF FUEL, COOLANT, AND LUBRICANTS”.
REMARK
• Refill with oil through the oil filler port of the hydraulic tank to the specified level with the engine stopped.
Run the engine to circulate the oil through the piping.
• After stopping the engine, check the oil level again. If the oil level is lower than the specified level, sup-
ply the oil to the specified level again.
D155AXI-8 50-587
DISASSEMBLE AND ASSEMBLE GIANT RIPPER ASSEMBLY BLY
DISASSEMBLE AND ASSEMBLE GIANT RIPPER ASSEMBLY

Tools for disassembly and assembly of giant ripper assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Block ■ 2 Fixing of machine

B - Blocking tool ■ 2 Fixing of boom and arm
C - Block ■ 2 Fixing of arm
FROM HYDRAULIC SYSTEM”.
METHOD FOR DISASSEMBLING GIANT RIPPER ASSEMBLY

Shank
1. Place tool A under the track shoe at the rear of the ma-
chine, and lift the rear of the machine.
REMARK
If the rear of the machine is not lifted, you cannot remove
the shank.
2. Adjust the ripper to the maximum raising position and the
maximum tilt-in position.
50-588 D155AXI-8
BLY DISASSEMBLE AND ASSEMBLE GIANT RIPPER ASSEMBLY
3. Sling shank (1), hold it, remove the lock pin, remove
mounting pin (2), gradually lower shank (1), and remove it.
4 Shank:
330 kg
Lift cylinder assembly, tilt cylinder assembly

4. Set tools B under the beam and arm, and lower the ripper
assembly.
5. Sling tilt cylinder assembly (3), hold it, remove the lock
REMARK
The pin is used when removing the beam. Assemble it to
the beam temporarily.
6. Fully retract the piston rod of tilt cylinder assembly (3), and
8. Fully retract the piston rod of lift cylinder assembly (5), and
D155AXI-8 50-589
10. Disconnect lift cylinder hose (7) and tilt cylinder hose (8),
and move them toward the fuel tank side.
plate, remove pin (9) on the bolt side, sling lift cylinder as-
sembly (5), and then remove it.

200 kg
12. Sling tilt cylinder assembly (3), hold it, remove pin (10),
and then remove tilt cylinder assembly (3).

270 kg
Beam, arm
13. Sling beam (11), hold it, remove the lock plate, remove
right and left pins (12), sling beam (11), and then remove
it.
4 Beam:
1100 kg
14. Sling arm (13), hold it, remove the lock plate, remove right
and left pins (14), sling arm (13), and then remove it.
REMARK
4 Arm:
700 kg
50-590 D155AXI-8
METHOD FOR ASSEMBLING GIANT RIPPER ASSEMBLY

Arm, beam
1. Sling arm (13), install right and left pins (14), fix them with
the lock plate, and set tool C under the arm.
4 Arm:
700 kg
2. Sling beam (11), install right and left pins (12), fix them
with the lock plate, and set tool B under the beam.
3. Sling tilt cylinder assembly (3), install pin (10), and lower
the rod side to set it onto the arm.

270 kg
4. Sling lift cylinder assembly (5), push in pin (9), fix the pin
with the lock plate, and lower the rod side to set it onto the
arm.

200 kg
D155AXI-8 50-591
5. Connect tilt cylinder hose (8) and lift cylinder hose (7).
6. Sling lift cylinder assembly (5), hold it, start the engine, ex-
tend the piston rod, align pin (6) with the pin hole to install
it, and then fix the pin with the lock plate.
7. Sling tilt cylinder assembly (3), hold it, extend the piston
rod, align pin (4) with the pin hole to install it, and then fix
the pin with the lock plate.
50-592 D155AXI-8
Shank
8. Adjust the ripper to the maximum raising position and the
maximum tilt-in position.
9. Pass the wire through the shank mounting hole of the beam, sling shank (1), install the shank with pin (2),
and fix it with the lock pin.
4 Shank:
330 kg
REMARK
The direction in which the hose is installed is as shown in
the right figure viewed from the front of machine.
10. After completion of assembling, sufficiently grease all the
pin portions.
2 Pin:
Grease (G2-LI)
11. Refill the hydraulic tank with the hydraulic oil. For details,
see STRUCTURE AND FUNCTION, “TABLE OF FUEL,
COOLANT, AND LUBRICANTS”.
REMARK
• Refill with oil through the oil filler port of the hydraulic
tank to the specified level with the engine stopped. Run
the engine to circulate the oil through the piping.
• After stopping the engine, check the oil level again. If
the oil level is lower than the specified level, supply the
oil to the specified level again.
D155AXI-8 50-593
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER 50 DISASSEMBLY AND ASSEM-
ASSEMBLY BLY
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER AS-

SEMBLY
FROM HYDRAULIC CIRCUIT”.
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEM-

BLY
1. Remove bolts (1) (4 pieces), and remove cap (2).
REMARK
Write down the quantity and thickness of shim (3).
2. Start the engine, and retract the piston rod (4).

REMARK
Tie the piston rod with wire, etc. so that the piston rod (4)
is not pulled out.
3. Fix the cylinder and radiator guard by using plate (5).
50-594 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER
BLY ASSEMBLY

6. Disconnect connector CY41 (9).

NOTICE
Do not disconnect the connecting part (a) of the wir-
ing.
REMARK
Connector number of the right side blade lift cylinder is
CY42.
8. Remove bolts (12) (2 pieces), and remove grip (13).
D155AXI-8 50-595
ASSEMBLY BLY
10. Sling blade lift cylinder assembly (14), and hold it.
11. Remove bolts (15) (4 pieces), and remove cap (16) (2
pieces).
12. Sling blade lift cylinder assembly (14), and remove it from
yoke (18).
4 Blade lift cylinder assembly (14) :

180 kg
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEM-

BLY
1. Sling blade lift cylinder assembly (14), and set it to yoke
(18).
4 Blade lift cylinder assembly (14) :

180 kg
2. Install cap (16) (2 pieces) with bolts (15) (4 pieces).

NOTICE
Install cap (16) aligning the grease fitting hole with
bushing hole (16a).
3. Fix the cylinder and radiator guard by using plate (5).
50-596 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER
BLY ASSEMBLY
4. Install clip (13) with bolts (12) (2 pieces).
5. Connect hoses (10) and (11).
6. Connect connector CY41 (9).

REMARK
Connector number of the right side blade lift cylinder is
CY42.

D155AXI-8 50-597
ASSEMBLY BLY
9. Install plate (5) to its original position.

10. Start the engine, and extend the piston rod.
NOTICE
Be careful not to get your hand caught in between
blade and piston rod when extending the piston rod.
11. Install shim (3).

REMARK
• write down the quantity and thickness of the shim for
setting.
• Standard shim thickness (b):4 mm
12. Install cap (2) with bolts (1) (4 pieces).
50-598 D155AXI-8
50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT
BLY CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLIN-

DER ASSEMBLY
Tools for disassembly and assembly of stroke and reset sensing blade lift cylinder assembly
New/Redesign
Necessity
Sketch
Q'ty

A
B 790-102-3802 Multi wrench ■ 1 Installation of rounded head (blade lift)

C - Rubber hammer ● 1
Removal of stroke sensor
D - Spatula ● 1
790-201-1500 Push tool kit ■ 1
790-201-1630 • Plate 1
E Press-fit of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1702 Push tool kit ■ 1
790-201-1821 • Push tool 1
F Press-fit of bushing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-720-1000 Expander ■ 1
796-720-1660 Ring ■ 1
G 07281-01159 Clamp ■ 1 Installation of piston ring
796-720-1690 Ring ■ 1
07281-01919 Clamp ■ 1
For measurement of sensor installing
H - Digital angle gauge ■ 1
angle
D155AXI-8 50-599
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT 50 DISASSEMBLY AND ASSEM-
CYLINDER ASSEMBLY BLY
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER AS-

SEMBLY
Preparation
1. Set cylinder assembly (1) on tool A.
2. Place an oil container under the cylinder assembly (1).
Tube
3. Remove U-bolts (2) and (3), and remove plate (4).
4. Remove U-bolts (5) and (6), and remove plate (7).
50-600 D155AXI-8
6. Remove tube (9).
Stroke and reset sensor assembly

7. While pressing union (10), loosen sleeve nut (11) of piping
tube (3 places).
NOTICE
Never separate sleeve nut (11) of piping tube.
8. Remove bolts (12) (4 pieces), and remove reset sensor

assembly (13).
D155AXI-8 50-601
9. Remove stroke sensor assembly (15) according to the fol-

lowing procedure.
1) Remove bolts (14) (4 pieces).
2) Insert tool D into clearance between stroke sensor
(18) and housing and plate assembly (16), and re-
move stroke sensor assembly (15).
NOTICE
• When inserting tool D, take care not to damage
wiring and contact surface of O-ring (19) and
stroke sensor assembly (15).
• Material of tool D must be soft material such as
resin, and its edge should not be sharp. Do not
use a stiff and sharp tool such as flat-head
screwdriver, etc.
• If the clearance between stroke sensor assem-
bly (15) and housing and plate assembly (16) is
not enough for the work, tap it lightly with tool
C obliquely upward, and widen the clearance
between stroke sensor assembly (15) and
housing and plate assembly (16).
• When removing stroke sensor assembly (15),
do not remove elbow (17) separately. Remove
them together with stroke sensor assembly
(15) as a unit.
• Cover the hole of housing and plate assembly
(16) from where stroke sensor assembly (15)
has been removed so that dust does not enter
it.
10. Remove stroke and reset sensor assembly (20).
50-602 D155AXI-8
Piston rod assembly

11. Remove bolts (21) (6 pieces), and separate plate (22).
12. Separate housing assembly (23).
REMARK
Secure clearance between housing assembly (23) and cyl-
inder head assembly (24) so as not to disturb removing
cylinder head assembly (24).
Clearance (a) between housing assembly (23) and cylin-
der head assembly (24): 80 to 100 mm
13. Separate cylinder head assembly (24) by using tool B.
14. Draw the piston rod assembly (26) from cylinder tube (25).
REMARK
Place an oil container under the cylinder, and receive oil.
Piston assembly
15. Pull out valve (29) (3 pieces) by removing bolt (27) (6
pieces) and spacer (28).
16. Remove piston assembly (30).
D155AXI-8 50-603
17. Remove magnet holder assembly (31) and pin (55).

REMARK
• Do not remove magnet (40) and retainer (41) from
magnet holder (39).
• Do not bring the magnet part close to magnetically at-
tracted material such as steel work stand since the
magnetic force is strong.
• Do not bring the magnet (40) close to electronic devi-
ces such as mobile phones since the magnetic force of
it is very strong.
• Since magnet holder (39), magnet (40), and retainer
(41) are not fixed, be careful not to drop the parts dur-
ing removal.
18. Remove slider (32).
19. Remove backup ring (33) (2 pieces) and O-ring (34).
Disassembly of piston assembly

20. Remove wear rings (35) (2 pieces).
21. Remove piston ring (36).
REMARK
Do not remove seat (37) and valve (38) from piston.
50-604 D155AXI-8

22. Remove cylinder head assembly (24).
23. Remove housing assembly (23).
Disassembly of head assembly

25. Remove backup ring (42) and O-ring (43), (44), and (45).
26. Remove rod packing (46).
27. Remove buffer ring (47).
28. Remove snap ring (48), and remove bushing (49).
Assembly of housing assembly

29. Remove ring (51) from housing (50).
30. Remove dust seal (52) and (53) from housing (50).
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER AS-

SEMBLY
REMARK
Apply engine oil to the sliding surfaces of each part (for details, see “TABLE OF FUEL, COOLANT, AND LUBRI-
CANTS”) and be careful not to damage rods, packings, dust seals, and O-rings when assembling.
Assembly of housing assembly
1. Press fit dust seal (53) and (52) by using tool E.
D155AXI-8 50-605
Assembly of head assembly

3. Install bushing (49) by using tool F.

5. Install buffer ring (47).
6. Install rod packing (46).
7. Install backup ring (42) and O-ring (43), (44), and (45).

8. Install plate (22).
9. Install housing assembly (23).
10. Install cylinder head assembly (24).
50-606 D155AXI-8
Assembly of piston assembly

11. Expand piston ring (36) by using tool G.
REMARK
Set piston ring to tool G, and rotate the handle 8 to 10
turns to expand it.
12. Remove piston ring (36) from tool G, and install it to piston.
13. Compress piston ring (36) by using tool G.
14. Install wear rings (35) (2 pieces).
Piston assembly
15. Install backup ring (33) (2 pieces) and O-ring (34).
REMARK
• Warm up the backup ring in the hot water at 50 to
60 °C and install it.
• Apply grease on the O-ring and the backup ring, fix
them to prevent the backup ring from opening.
16. Install pins (55) to piston assembly (30).

17. Install it while aligning pin (55) of piston assembly (30) with
the position of (e) portion of magnet holder (31).
D155AXI-8 50-607
Piston rod assembly

18. Install slider (32).
19. Install piston and magnet holder assembly (56).
20. Install valve (29) (3 pieces) to spacer (28).
21. Install spacer (28) with bolts (27) (6 pieces).
2 Bolt (27):
Adhesive (LT-2)
3 Bolt (27):
98 to 123 Nm {10.0 to 12.5 kgm}
22. Insert piston rod assembly (26) into cylinder tube (25).
2 Sealing portion:
Grease (G2-LI)
23. Tighten cylinder head (24) by using tool B.

3 Cylinder head (24):
923±93.0 kNm {95±9.5 kgm}
24. Adjust angle of end surface (f) of housing assembly (23)

and end surface (g) of trunnion pin (57) by using tool H.
Mounting angle (h) made by end surface (f) of housing as-
sembly (23) and end surface (g) of trunnion pin (57): 15 °
±2 °
50-608 D155AXI-8
25. Install housing assembly (23).
26. Install plate (22) with bolts (21) (6 pieces).

NOTICE
Tighten bolts (21) (6 pieces) in the order of 1 to 6, and
tighten it again in the order of 1 to 6.
Bolt hexagonal socket width across flats: 6 mm
3 Bolt (21):
27 to 34 Nm {2.8 to 3.5 kgm}
Stroke and reset sensor assembly

27. Loosen bands (59), (60), and (61).
REMARK
Since adjusting it at the time of positioning, loosen band
until it does not come off.
28. Check the position of band (59), (60), and (61).

(i): Between center of trunnion pin and band (59): 345 mm
(k): Between band (59) and band (60): 301 mm
(m): Between band (60) and band (61): 541.5 mm
(n): Between band (61) and cylinder end: 141.5 mm
D155AXI-8 50-609
30. Drive pins (58) (2 pieces) of housing assembly (23).

REMARK
Replacement of pins (58) is not necessary when reusing
housing assembly (23).
31. Set stroke and reset sensor assembly (20).

NOTICE
• Clean end surface (f) of housing assembly (23) and
end surface (p) of band (60) thoroughly, and suffi-
ciently degrease it.
• Check that sleeve nut of piping tube is loosened.
50-610 D155AXI-8
32. Install stroke sensor assembly (15) with bolts (14) (4

pieces).
NOTICE
• Install it while aligning pin (58) with the hole por-
tion (q) of stroke sensor assembly.
• Take care not to damage roller portion (r).
• Clean mounting bolt thoroughly, and sufficiently
degrease it.
• Tighten mounting bolt diagonally.
Mounting bolt hexagonal socket width across flats: 5 mm
Adhesive (ThreeBond TB1344 or equivalent)
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
33. Install reset sensor assembly (13) according to the follow-

ing procedure.
1) Install reset sensor assembly (13) with bolts (12) (4
pieces).
NOTICE
• Clean mounting bolt thoroughly, and sufficient-
ly degrease it.
• Tighten mounting bolt diagonally.
Mounting bolt hexagonal socket width across flats:
5 mm
Adhesive (ThreeBond TB1344 or equivalent)
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
2) Position band (60), and fasten it lightly by using tool H.
Mounting angle (t) made by end surface (y) of reset
sensor assembly (13) and end surface (g) of trunnion
pin (57): 34 ° ±2 °
Mounting angle (u) made by trunnion pin (57) and
band (60): 35 ° ±2 °
D155AXI-8 50-611
34. Fasten band (59) and (61) to the specified torque.

Mounting angle (v) of band (59): 35 °
Mounting angle (s) of band (61): 20 °
3 Band (59) and (61):
27.4±6.9 Nm {2.8±0.7 kgm}

3 Sleeve nut:
177 to 230 Nm {18 to 23.5 kgm}

3 Clamp (8) mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
50-612 D155AXI-8
37. Temporarily assemble piping with plate (7) and U-bolts (5)
and (6).
38. Temporarily assemble piping with plate (4) and U-bolts (2)
and (3).
Mounting angle (w) of plate (4): 12 °50
D155AXI-8 50-613
39. While pressing union (10), tighten sleeve nut (11) of piping
tube (3 places).
NOTICE
• Lightly tighten it while adjusting the positions of
the reset sensor and piping without applying ex-
cessive force to the piping, check that there are no
problems entirely, and then tighten sleeve nut (11)
to the specified torque.
• Check that union (10) is not loosened.
• Tighten sleeve nut from rod head side in the order
of (11a), (11b), and (11c).
3 Union:
59 to 98 Nm {6.0 to 10.0 kgm}
3 Sleeve nut:
84 to 123 Nm {8.5 to 12.5 kgm}
40. Check again that stroke and reset sensor assembly
mounting bolts are not loosened.
3 Mounting bolts (12) and (14):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
41. Fasten band (60) to the specified torque.

3 Band (60):
59 to 74 Nm {6 to 7.6 kgm}
42. Fasten piping with plate (7) and U-bolts (5) and (6) to the
specified torque.
3 U-bolt (5) and (6):
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
50-614 D155AXI-8
43. Fasten piping with plate (4) and U-bolts (2) and (3) to the
specified torque.
Mounting angle (w) of plate (4): 12 °50
3 U-bolt (2) and (3):
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
44. Remove cylinder assembly (1) from tool A.
D155AXI-8 50-615
METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE TILT 50 DISASSEMBLY AND ASSEM-
METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE TILT CYLIN-

DER ASSEMBLY
Disassembly and assembly tools of blade tilt cylinder assembly
New/Redesign
Necessity
Sketch
Q'ty
790-201-1702 Push tool kit ■ 1

790-201-1841 • Push tool 1
A Press fit of bushing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit ■ 1
790-201-1650 • Push tool 1
B Press fit of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-720-1000 Expander ■ 1
796-720-1660 Ring ■ 1
C 07281-01159 Clamp ■ 1 Installation of piston ring
796-720-1690 Ring ■ 1
07281-01919 Clamp ■ 1
METHOD FOR DISASSEMBLING BLADE TILT CYLINDER ASSEMBLY

Piston rod assembly
1. Place an oil container under the cylinder assembly.
2. Remove mounting bolts and head assembly (1).
3. Pull out piston rod assembly (2).
50-616 D155AXI-8
50 DISASSEMBLY AND ASSEM- METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE TILT
Piston assembly
4. Remove mounting bolts and spacer (3).
5. Pull out piston assembly (4).
6. Remove O-ring (6) and backup ring (5).

7. Remove wear ring (7).
Head assembly
9. Remove head assembly (1).
D155AXI-8 50-617

10. Remove bolt (9), plate (10) and collar (11).
11. Remove ring (12) and dust seal (13) from collar (11).

13. Remove packing (16).
15. Remove dust seal (18).
METHOD FOR ASSEMBLING BLADE TILT CYLINDER ASSEMBLY

REMARK
Apply engine oil to the sliding surfaces of each part (for details, see TABLE OF FUEL, COOLANT, AND LUBRI-
CANTS) and be careful not to damage rods, packings, dust seals, and O-rings when assembling.
1. Press-fit bushing (20) by using tool A.
50-618 D155AXI-8
3. Install dust seal (18) by using tool B.

5. Install packing (16).
6. Install the backup ring (14) and O-ring (15).
7. Install dust seal (13) by using tool B.

D155AXI-8 50-619
9. Install collar (11) and plate (10) with bolts (9).
10. Install head assembly (1) to piston rod.

11. Expand piston ring (8) by using tool C.
REMARK
Set piston ring to tool C, and rotate the handle 8 to 10
turns to expand it.
12. Remove piston ring (8) from tool G, and install it to piston.
13. Compress piston ring (8) by using tool C.
14. Install wear ring (7).

REMARK
• Prevent the backup ring from opening, apply grease on
the O-ring and the backup ring.
50-620 D155AXI-8
16. Install piston assembly (4) and tighten spacer (3) with
mounting bolt.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
Assembly of piston rod assembly

17. Install the cylinder to piston rod assembly (2).
2 Sealing portion:
Grease (G2-LI)
REMARK
Push the piston rod to the stroke end.
18. Install head assembly (1) by tightening mounting bolts.
3 Blade tilt cylinder mounting bolt:
250±24.5 Nm {25.5±2.5 kgm}
D155AXI-8 50-621
METHOD FOR DISASSEMBLING AND ASSEMBLING RIPPER CYLIN- 50 DISASSEMBLY AND ASSEM-
DER ASSEMBLY BLY
METHOD FOR DISASSEMBLING AND ASSEMBLING RIPPER CYLINDER

ASSEMBLY
Disassembly and assembly tools of ripper cylinder assembly
New/Redesign
Necessity
Sketch
Q'ty

A
790-201-1702 Push tool kit ■ 1

790-201-1851 • Push tool ■ 1
B 790-201-1861 • Push tool ■ 1 Press fit of bushing
790-101-5021 • Grip ■ 1
01010-50816 • Bolt ■ 1
790-201-1500 Push tool kit ■ 1
790-201-1660 • Plate ■ 1
C 790-201-1670 • Plate ■ 1 Press fit of dust seal
790-101-5021 • Grip ■ 1
01010-50816 • Grip ■ 1
790-720-1000 Expander ■ 1
796-720-1660 Ring ■ 1
D 07281-01159 Clamp ■ 1 Installation of piston ring
796-720-1690 Ring ■ 1
07281-01919 Clamp ■ 1
790-102-4300 Wrench ■ 1 Removal and installation of screwed-in
E
790-102-4310 Pin ■ 2 piston
METHOD FOR DISASSEMBLING RIPPER CYLINDER ASSEMBLY

Preparation
1. Place an oil container under the cylinder assembly.
50-622 D155AXI-8
50 DISASSEMBLY AND ASSEM- METHOD FOR DISASSEMBLING AND ASSEMBLING RIPPER CYLIN-
BLY DER ASSEMBLY
2. Remove tube (1) from the cylinder assembly.
Piston rod assembly

3. Remove mounting bolts, and remove head assembly (2).
4. Pull out piston rod assembly (3).
Piston assembly
5. Set piston rod assembly (3) on tool A.
6. Remove lock screw (5) of the piston assembly (4).

REMARK
Screw sizeM12x1.75 pitch
REMARK
If screw (5) is punched too firm to remove, tighten it further
once, tap its threaded part, and remove the screw.
D155AXI-8 50-623
DER ASSEMBLY BLY
7. By using tool E, remove piston assembly (4) from piston

rod assembly (3).

8. Remove O-ring (7) and backup ring.
9. Remove wear ring (8).
Head assembly
11. Remove head assembly (2).

13. Remove packing (12).
15. Remove snap ring (14), and remove dust seal (15).
METHOD FOR ASSEMBLING RIPPER CYLINDER ASSEMBLY

REMARK
Apply engine oil to the sliding surfaces of each part (for details, see “TABLE OF FUEL, COOLANT, AND LUBRI-
CANTS”) and be careful not to damage rods, packings, dust seals, and O-rings when assembling.
50-624 D155AXI-8
BLY DER ASSEMBLY

1. Press-fit bushing (17) by using tool B.
3. Install dust seal (15) by using tool C.

6. Install packing (12).
D155AXI-8 50-625
DER ASSEMBLY BLY
8. Install head assembly (2) to piston rod.

9. Expand piston ring (9) by using tool D.
REMARK
Set piston ring to tool D, and rotate the handle 8 to 10
turns to expand it.
10. Remove piston ring (9) from tool D, and install it to piston.
11. Compress piston ring (9) by using tool D.
12. Install wear ring (8).

13. Install the backup ring and O-ring (7).
REMARK
• Prevent the backup ring from opening, apply grease on
the O-ring and the backup ring.
14. By using tool A, install piston assembly (4) to piston rod

assembly (3).
15. When reusing both of piston rod (3) and piston assembly
(4), assemble them according to the following procedure.
REMARK
• Remove burrs and sharp edges from the threaded part
by using a file.
• Clean them thoroughly, and remove all chips and dirt.
1) Screw piston assembly (4) to piston rod (3) by using

tool E and tighten it until the screw hole position
matches with piston assembly (4) position.
50-626 D155AXI-8
BLY DER ASSEMBLY
2) Install screw (5).

REMARK
• Completely degrease and dry the threaded part of
screw before installing it.
• After installing screw, crimp the screw at 4 periph-
eral places.
2 Threaded part of screw:
Adhesive (Loctite No. 262)
3 Screw:
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
REMARK
After tightening screw, crimp the screw at 4 peripheral places.
16. When replacing either or both of piston rod (3) and piston
assembly (4) with new ones, assemble the new ones ac-
1) Remove piston assembly (4) by using tool E.
3 Piston assembly:
294±29.4 Nm {30±3.0 kgm}
2) Make 1 threaded hole to install screw.
REMARK
Drill a hole horizontally in the groove of piston and the
threaded part of piston rod.
Threading dimensions ( mm)
Tap drill hole diameter: 10.3
Depth for drilling tap hole: 27
Tap to use: M12xP1.75
Tapping depth: 20
3) After making the hole, remove all dirt and clean the hole thoroughly.
4) Install screw (5).
REMARK
• Completely degrease and dry the threaded part of
screw before installing it.
• After installing screw, crimp the screw at 4 periph-
eral places.
2 Threaded part of screw:
Adhesive (Loctite No. 262)
3 Screw:
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
D155AXI-8 50-627
DER ASSEMBLY BLY
Assembly of piston rod assembly

17. Install the cylinder to piston rod assembly (3).
2 Sealing portion:
Grease (G2-LI)
REMARK
Push the piston rod to the stroke end.
18. Install head assembly (2) by tightening mounting bolts.
3 Ripper lift mounting bolt:
343±34.3 Nm {35±3.5 kgm}
3 Ripper tilt mounting bolt:
490±49 Nm {50±5.5 kgm}
19. Install tube (1) to the cylinder assembly.
50-628 D155AXI-8
BLY REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY
CAB AND ITS ATTACHMENTS

REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY
Tools for removal and installation of operator's cab assembly
New/Redesign
Necessity
Sketch
Q'ty
A - Oil pan ■ 1 N
B - Valve ■ 1
- Hose ■ 1
D - Funnel ■ 1
E - Hose ■ 1
ue/DEF hose
J 600-919-5050 ■ 1
inch)
refrigerant.
D155AXI-8 50-629
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY BLY
record them.
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY

Cover
2. Disconnect connector (3).


50-630 D155AXI-8
7. Remove control valve cover (8).
10. Remove mudguard covers (12) and (13).
D155AXI-8 50-631
Air conditioner gas

REMARK
Fuel tank assembly
14. Remove the fuel tank assembly. For details, see “REMOVE AND INSTALL FUEL TANK ASSEMBLY”.
17. Place tool C on the track shoe for future used as described
in the subsequent steps.
REMARK
50-632 D155AXI-8
REMARK
B.
tool A.
6 AdBlue/DEF tank:
73 ℓ
NOTICE
REMARK
There is a slit (a) at threaded part of drain plug (20) so that
AdBlue/DEF is not drained too much and splashed.
21. Draining amount decreases in 3 or 4 minutes, and then re-
move drain plug (20).
REMARK
1.8 ℓ.
D155AXI-8 50-633

REMARK
Insert tip of tool D into tool E that is placed on the ground.

25. When tool E is nearly fully filled, securely close valve B1 of
tool B.
creases in approximately 10 seconds. Change tool E to
tool D at the timing of decreasing.
REMARK
0.9 ℓ.
27. When the AdBlue/DEF tank becomes empty, install drain
plug (20) securely.
3 Drain plug: (20):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
50-634 D155AXI-8
Draining coolant
6 Radiator:
103.5 ℓ


32. Disconnect connectors UHA (26) and UHC (27).
33. Disconnect connector DSM (28).

AdBlue/DEF hose (31).
NOTICE
• When handling AdBlue/DEF, be sure to use tool D.
• After disconnecting the AdBlue/DEF hose, install
tool J to the hose side and install tool H to the nip-
ple side to prevent leakage.
D155AXI-8 50-635
39. Disconnect connectors UHV2 (34) and UREA (35).
42. Disconnect coolant inlet port hose (38).
43. Remove mounting bolts (39) (4 pieces), sling AdBlue/DEF

tank assembly (40) and remove it.
4 AdBlue/DEF tank assembly:

45 kg
Wiring, piping
45. Disconnect cooling hose (43a).
46. Remove clamp (41), and disconnect air conditioner tubes

(42a) and (42b).
NOTICE
Plug the hose to prevent dust and water from entering.
50-636 D155AXI-8
47. Remove fresh air duct (44).

NOTICE
Take action to prevent dust and water from entering in-
to the duct.

49. Disconnect connector AC05 (81).
NOTICE
Take action to prevent dust and water from entering in-
to hoses and receiver.
51. Disconnect cab ground cable (45).
52. Disconnect connectors (46), (47), and (48).

54. Disconnect connectors PL1 (50) and PD1 (51).
REMARK
• To remove connectors PL1 (50) and PD1 (51), loosen
hexagonal socket head bolt 4 mm at the center of the
connector.
• To disconnect connectors PL1 (50) and PD1 (51), pull
out them slowly and straight, and check seals for dam-
age, peeling, and sticking foreign materials.
D155AXI-8 50-637
55. Disconnect control valve connectors WEP1 (52) to WEP9

REMARK
Connector No. and related wiring band color are listed as
following.
Connector (52): WEP1 (Green) Connector (61): WEPA (Red/
Black)
Connector (53): WEP2 (Green/ Connector (62): WEPW (-)
Black)
Connector (54): WEP3 (Brown) Connector (63): HSL (Black)
Connector (55): WEP4 (Brown/ Connector (64): HSR (N/A)
Black)
Connector (56): WEP5 (Blue)
Connector (57): WEP6 (Blue/
Black)
Connector (58): WEP7 (Yellow)
Connector (59): WEP8 (Yellow/
Black)
Connector (60): WEP9 (Red)
56. Disconnect connectors HSS (65) and PUMP (66).
58. Remove plates (68) (right and left) and footrests (69) (2
pieces), and remove floor mat (70).
50-638 D155AXI-8
59. Sling the operator's cab assembly, and hold it.

60. Remove bolts, and place cab tipping prevention locks (71)
(1 piece each on right and left sides) to FREE position.
61. Remove front operator's cab mounting bolts (72) (4 pieces

on each of the right and left sides).
62. Remove pin (73) (1 piece each on right and left sides).
63. Remove rear operator's cab mounting bolts (74) (4 pieces
D155AXI-8 50-639
64. Sling operator's cab assembly (75), and remove it.

NOTICE
Check all the wiring and piping are disconnected be-
fore removing.
4 Operator's cab assembly:

1500 kg
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY

1. Sling operator's cab assembly (75), and install it.
NOTICE
Take care not to catch the wiring and piping.
4 Operator's cab assembly:

1500 kg
2. Install rear operator's cab mounting bolts (74) (4 pieces on

each of the right and left sides).
3 Rear operator's cab mounting bolt:
785 to 980 Nm {80 to 100 kgm}
3. Install pins (73) (1 piece each on right and left sides).
3 Pin mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
4. Remove front operator's cab mounting bolts (72) (4 pieces

3 Front operator's cab mounting bolt:
455 to 565 Nm {46.5 to 58.0 kgm}
50-640 D155AXI-8
5. Place cab tipping prevention locks (71) (1 piece each on

right and left sides) to LOCK position.
6. Set floor mat (70).

7. Install plates (68) (right and left), and foot rests (69) (2
pieces).
Wiring, piping
8. Connect control valve connectors WEP1 (52) to WEP9
REMARK
Connector No. and related wiring band color are listed as
following.
Connector (52): WEP1 (Green) Connector (61): WEPA (Red/
Black)
Connector (53): WEP2 (Green/ Connector (62): WEPW (-)
Black)
Connector (54): WEP3 (Brown) Connector (63): HSL (Black)
Connector (55): WEP4 (Brown/ Connector (64): HSR (N/A)
Black)
Connector (56): WEP5 (Blue)
Connector (57): WEP6 (Blue/
Black)
Connector (58): WEP7 (Yellow)
Connector (59): WEP8 (Yellow/
Black)
Connector (60): WEP9 (Red)
D155AXI-8 50-641
9. Connect connectors HSS (65) and PUMP (66).

11. Connect connectors PL1 (50) and PD1 (51).
REMARK
• Check that the seal is installed to the plug correctly.
• Check that the key position is aligned with the groove
on the receptacle side.
• Align the connector on the plug side straight with the
receptacle since the seal is extruded, and slightly fit the
connector while checking the seal for curling.
• Tighten the hexagonal socket head bolt at the center of
the connector 2 or 3 threads.
• Fully fit the connector on the plug side, and adjust the
connector on the plug side so that the clearance be-
tween the aligned receptacle and connector on the
plug side is even when it is viewed from all directions.
3 Hexagonal socket head bolt:
2.8±0.3 Nm {0.28±0.03 kgm}
13. Connect connectors (46), (47), and (48).
14. Connect cab ground cable (45).
50-642 D155AXI-8
15. Connect air conditioner hoses (82) and (83).

NOTICE
ed.
• When connecting air conditioner piping, apply
compressor oil for new refrigerant (R134a) to the
O-rings and threaded portions.
2 O-ring:
3 Air conditioner hose mounting bolt:
8to 12 Nm {0.8to 1.2 kgm}
16. Connect connector AC05 (81).
18. Install fresh air duct (44).
19. Connect air conditioner tubes (42a) and (42b), and install
clamp (41).
NOTICE
ed.
• When connecting air conditioner piping, apply
compressor oil for new refrigerant (R134a) to the
O-rings and threaded portions.
2 Threaded portion of air conditioner tube:
REMARK
When connecting the air conditioner pipes, tighten by using 2 wrenches.
3 Screw size (M22 x 1.5) (width across flats: 24 mm):
20 to 25 Nm {2.04 to 2.55 kgm}
3 Screw size (M16 x 1.5) (width across flats: 19 mm):
12 to 15 Nm {1.22 to 1.53 kgm}
D155AXI-8 50-643
20. Connect coolant hose (43a).


22. Sling AdBlue/DEF tank assembly (40), install it, and tight-
en it with mounting bolts (39) (4 pieces).

45 kg

26. Connect connectors UHV2 (34) and UREA (35).
Check the AdBlue/DEF hose and pin (f) are not damaged.
injector until click sound is heard to install.
REMARK
When it is inserted so that the convex part of pin (f) passes
32. Connect connector DSM (28).
33. Connect connectors UHA (26) and UHC (27).
50-644 D155AXI-8
Fuel tank assembly

38. Install the fuel tank assembly. For details, see “REMOVE AND INSTALL FUEL TANK ASSEMBLY”.
39. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circu-
late the coolant. Then check the coolant level again.
5 Radiator:
103.5 ℓ
Air conditioner gas
REMARK
D155AXI-8 50-645
Cover
44. Install mudguard covers (12) and (13).
46. Close engine left side covers (9) and (10).
50-646 D155AXI-8
47. Install control valve cover (8).


52. Connect connector (3).
53. Close engine right side covers (1) and (2).

54.
D155AXI-8 50-647
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED 50 DISASSEMBLY AND ASSEM-
GLASS) BLY
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)

Tools for removal and installation of operator's cab glass (adhered window glass)
New/Redesign
Necessity
Sketch
Q'ty
A - Seal cutter ■ 1
B - Extra fine wire (piano wire, etc) ■ 1
C - Pliers ■ 1 Removal of window glass.
D - Cutter knife ■ 1
E - Scraper ■ 1
F 793-498-1210 Lifter (suction cup) ■ 2
G - Caulking gun ■ 1
H - Tape ■ 1 Installation of window glass
J - Rubber band ■ 2
K - Styrofoam ■ 2
• Among the glasses on 4 sides of the operator's cab, the adhered window glass is 4 glasses from (3), (4),
(5) and (6) in the figure.
• This section describes the replacement procedure of the adhered window glass.
50-648 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED
BLY GLASS)
Configuration diagram
(1): Door seal

(2): Dam rubber
(3): Front window glass
(4): Rear window glass
(5): Right door glass
(6): Left door glass
D155AXI-8 50-649
GLASS) BLY
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)

Glass
1. Disconnect the adhesive between broken glass (7) and op-
erator's cab (metal sheet) (8) by using tool A.
REMARK
• If the glass is broken in small pieces, it may be re-
moved by using tool D and flat-head screwdriver.
• While widening the cut with a flat-head screwdriver, cut
the adhesive and dam rubber by using tool D.
2. Remove the window glass.
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)

Advance preparation
1. Remove the remaining adhesive and dam rubber from the
sheet metal (adhesion surfaces) of the operator's cab by
using tool D and tool E.
REMARK
• Note that removal of the adhesive and dam rubber left
on the sheet metal surface is sufficient if they become
uninfluential to the bonding effect of new adhesive. You
must avoid damaging the coating surface by excessive
scraping.
• (The right figure shows the operator cab on a wheel
loader.)
2. Remove oil, dust, dirt, etc. from the adhesion surfaces on
cab (7) and glass (8) with white gasoline.
REMARK
• Clean them thoroughly since insufficient cleaning indu-
ces defective adhesion.
• Clean all the black parts on the back of the window
glass.
• After cleaning, leave them for 5 minutes or more for
natural drying.
50-650 D155AXI-8
BLY GLASS)
Dam rubber
3. Attach dam rubber (double-coated adhesion tape) (3)
along the inner edge of mounting surfaces or the front win-
dow glass and right and left door glass.
REMARK
• Do not remove the tape on glass-adhering side of the
dam rubber until installation of the window glass is
started.
• When installing the dam rubber, do not touch the
cleaned surface.
• Take care that the dam rubber is not floated in each
sticking corner.
• Be careful to prevent overlapping in the joining area of
the starting and ending points of dam rubber (3).
• Contact joining ends (a) with each other.
Glass
4. Set the glass to the mounting position by using tool F,
check the clearance between the glass and operator's cab
from all directions, and adjust the glass so that the clear-
ance is even.
REMARK
• Position front window glass (1) from inside of opera-
tor's cab (7), and adjust the front window glass so that
the gaps between black coating (black ceramic) part
and sheet metal of operator cab (7) is even from all di-
rections.
• To position right and left door glasses (2), adjust the
door glasses so that the glass and door sheet metal
are positioned evenly in all directions.
5. After positioning, stick tool F at the area between between
front window glass (1) and operator cab (7), and at 3 posi-
tions of the right, left, and bottom of right and left door
glasses (2) and right and left doors (9). Draw positioning
line (e) on each tape.
6. Cut tool H with tool D etc. among glasses (1), (2) and op-
erator cab (7), and then remove the glass.
REMARK
Do not remove the tapes left on the glasses and the opera-
tor cab until the glasses are installed.
D155AXI-8 50-651
GLASS) BLY
7. Break aluminum dehumidification membrane (11) at the

mouth of adhesive cartridge (10) and attach there the dedi-
cated nozzle.
2 Adhesive:
Sika Japan (Sikaflex 256HV)
REMARK
• Do not use a primer.
• The use limit of adhesive is 6 months after its produc-
tion. Do not use the adhesive after this limit.
• Adhesives must be stored at 25 °C or lower in a dark
and cool place.
• Do not heat the adhesive higher than 30 °C.
• When reusing the adhesive, remove the hardened ad-
hesive at the nozzle tip completely.
8. Cut the tip of adhesive nozzle (12) to dimensions (f) and
(g) as shown in the figure.
Dimension (f): 10 mm
Dimension (g): 15 mm
9. Set adhesive cartridge (10) on tool G.

REMARK
A better workability is obtainable from a power caulking
gun.
10. Remove protective tape (3a) on the glass-bonding side of

dam rubber.
50-652 D155AXI-8
BLY GLASS)
11. Apply adhesive (13) to outside portion of dam rubber (3)

on the operator's cab.
REMARK
• Apply adhesive (13) to dam rubber (3) of operator's
cab (7) according to the dimensions (h) and (j) indicat-
ed in the figure.
• Thickness of applied adhesive (13) must be higher
than that of dam rubber (3).
• Height of applied adhesive must be even.
Dimension (h): 10 mm
Dimension (j): 15 mm
12. Install front window glass (1) to operator's cab (7) by using
tool F while aligning lines (e) of positioning tool H attached
in step 4.
REMARK
• Since the glass cannot be removed and installed again,
install it with utmost caution.
• Glass bonding work must be finished within 5 minutes
from application of adhesive.
13. After installing the glass, press entire circumferential area
until it adheres firmly to the dam rubber.
REMARK
Press the corners of the glass firmly.
D155AXI-8 50-653
GLASS) BLY
14. Install door (9) and right and left glasses (2) by using tool F
while aligning lines (e) of positioning tool H attached in
step 4.
REMARK
• Since the glass cannot be removed and installed again,
install it with utmost caution.
• Glass bonding work must be finished within 5 minutes
from application of adhesive.
15. After installing the glass, press entire circumferential area
until it adheres firmly to the dam rubber.
REMARK
Press the corners of the glass firmly.
16. Fix window glass (9).
REMARK
• Since the front window glass must be adhered com-
pletely, fix it by using tool J and tool K, and cure it.
• Instead of tool J and tool K, you can use the sealing
tape for fixing.
• The following figure shows the operator's cab on the
hydraulic excavator.
17. After installing the glass, remove any excess of the primer
and adhesive on the operator cab and glass.
REMARK
• Wipe off adhesives before it is dried up by using white gasoline.
• When cleaning the glass, be careful not to give an impact to it.
18. Cure the adhered glass.
REMARK
• Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours of curing peri-
od. (Ambient temperature 20 °C / Humidity 65 %)
• Before the machine is operated actually, cure the glass for 24 hours after adhesive is applied.
50-654 D155AXI-8
BLY REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
refrigerant.
record them.
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY

Collecting refrigerant
Refrigerant to be collected: 900 ± 50 g
Draining coolant
2. Drain the coolant.
6 Radiator:
103.5 ℓ
Operator's seat assembly
3. Remove the operator's seat assembly. For details, see “REMOVE AND INSTALL OPERATOR'S SEAT AS-
SEMBLY”.
D155AXI-8 50-655
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY BLY
Cover
4. Remove covers (1), (2), (3), and (4).
5. When removing cover (4), reverse it and disconnect wiring

connectors CBACC-1 (6), CBCIG (7), and AUX terminal
wiring M01B (8).
50-656 D155AXI-8
6. Remove covers (9), (10), and (11).
7. Remove the mounting bolts, and remove filter bracket (12).

REMARK
Take measures to prevent the filter from being damaged
during the work.
D155AXI-8 50-657
Duct
8. Remove the mounting bolts of ducts (13) and (15).
9. Remove mounting clips (2 pieces) of ducts (14) and (15).
10. Remove ducts (13), (14), (15), and (16) in this order.
11. Disconnect wiring connectors ACECU (17), AC01 (18),

and AC02 (19), and disconnect the wiring clamp and band.
Battery cover
50-658 D155AXI-8

16. Remove bolts (26) (2 pieces) and move bracket (27) aside
so that it does not hinder the work.


D155AXI-8 50-659
24. Close cover (22), and remove it from (a) parts (3 places) of
25. Remove fresh air duct (36).
Air conditioner unit assembly

26. Remove bolt (37), ground cables (GND11) (38), (GND12)
(39), clamp (40), and clip (41), and remove ducts (42) and
(43).
REMARK
Remove duct (42) by pulling it upward, and duct (43) by
pulling it forward.
27. Remove inspection cover (44) at the bottom of the opera-

tor's seat.

29. Disconnect heater hose (46).
50-660 D155AXI-8
30. Disconnect heater hose (47).

31. Disconnect air conditioner hose (48).
32. Remove mounting bolts (49) (6 pieces), and remove air

conditioner unit assembly (50).
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY
D155AXI-8 50-661
Air conditioner unit assembly

1. Install air conditioner unit (50) with mounting bolts (49) (6
pieces).
2. Connect air conditioner hose (48).

3. Connect heater hose (47).
4. Connect heater hose (46).

6. Install inspection cover (44) at the bottom of the operator's

seat.
50-662 D155AXI-8
7. Install ducts (42) and (43), install clamp (40), clip (41),
ground cable (GND11) (38), ground cable (GND12) (39)
and bolt (37).
Battery cover
8. Install fresh air duct (36).

REMARK
check the position.
D155AXI-8 50-663




50-664 D155AXI-8
Duct
23. Connect wiring connectors ACECU (17), AC01 (18), and
AC02 (19), and install the wiring clamp and band.
24. Install ducts (16), (15), (14), and (13) in this order.
25. Install the mounting clips (2 pieces) of ducts (14) and (15).
26. Install the mounting bolts of ducts (13) and (15).
Cover
27. Install filter bracket (12) with the mounting bolts.
D155AXI-8 50-665
28. Install covers (9), (10), and (11).
29. When installing cover (4), reverse it and connect wiring

connectors CBACC-1 (6) and CBCIG (7), and AUX termi-
nal wiring M01B (8).
50-666 D155AXI-8
30. Install covers (1), (2), (3), and (4).
Operator's seat assembly

31. Install the operator's seat assembly. For details, see “REMOVE AND INSTALL OPERATOR'S SEAT AS-
SEMBLY”.
32. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circu-
late the coolant. Then check the coolant level again.
5 Radiator:
103.5 ℓ
Air conditioner gas
REMARK
D155AXI-8 50-667
REMOVE AND INSTALL OPERATOR'S SEAT BLY
REMOVE AND INSTALL OPERATOR'S SEAT

METHOD FOR REMOVING OPERATOR'S SEAT

Seat cushion
2. Disconnect connector SBC (2).
3. Remove clamp (3), and disconnect connector HEAT1 (4).
4. Remove bolts (5) (4 pieces), and remove seat cushion (6).
4 Seat cushion:
25 kg
Suspension assembly
5. Remove bolt (7), and remove suspension assembly (8).
4 Suspension assembly:
25 kg
50-668 D155AXI-8
BLY REMOVE AND INSTALL OPERATOR'S SEAT
METHOD FOR INSTALLING OPERATOR'S SEAT

Suspension assembly
1. Install suspension assembly (8) with bolts (7) (4 pieces).
4 Suspension assembly:
25 kg
Seat cushion
2. Install seat cushion (6) with bolts (5) (4 pieces).
4 Seat cushion:
25 kg
3. Connect connector HEAT1 (4).

5. Connect connector SBC (2).

D155AXI-8 50-669
REMOVE AND INSTALL SEAT BELT BLY
REMOVE AND INSTALL SEAT BELT

k Park the machine on a level ground, lower the work equipment to the ground so that it is stable, and
tails, see TESTING AND ADJUSTING, “HANDLING BATTERY DISCONNECT SWITCH”.)
METHOD FOR REMOVING SEAT BELT

2. Disconnect connector SBC (2).
3. Remove the mounting bolts (1 piece each on right and left

sides) of seat belt (4), and remove seat belts (3) and (4).
50-670 D155AXI-8
BLY REMOVE AND INSTALL SEAT BELT
METHOD FOR INSTALLING SEAT BELT

1. Install seat belts (3) and (4) with the seat belt mounting
bolts (1 piece each on right and left sides).
3 Seat belt mounting bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
2. Connect connector SBC (2).

D155AXI-8 50-671
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY BLY
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
refrigerant.
record them.
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY

Cover
1. Open engine side cover (1) on the left side of the machine,
and fix it with the lock.
NOTICE
2. Remove covers (3) and (4) on the bottom of the engine

side cover.
50-672 D155AXI-8
BLY REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
3. Remove cover (5) on the bottom of cover (4).

5. Remove piping clips (8), one each on 2 oil tubes (7).
6. Remove filter head (9) mounting bolts (2 pieces) and cylin-
der block side flange mounting bolts (4 pieces), and re-
move oil tubes (7)(2 pieces) and the flange as a unit.
(9) and oil filter as an assembly.
Engine controller assembly

8. Remove mounting bolts (11) (6 pieces), and remove en-
gine controller cover (10).
REMARK
1 mounting bolt of engine controller cover (10) mounting
bolts (11) is tightened together with clamp (12) of harness.
9. Remove connector cover (13), and remove wiring harness

mounting bolt (with hexagonal socket) (14) and (15).
REMARK
• Remove dust around the engine by using air blow be-
fore the work.
• Always remove wiring harness mounting bolt (14) and
(15) when performing removal of connector lever.
D155AXI-8 50-673
10. Pull up connector lever to (c) direction as pressing hook

(b) part of connector (16).
REMARK
Before starting the work, blow air again to ensure that
there is no dust around the connector and (a) part, to pre-
vent any failure from occurring, and to make removal and
installation work easier.
11. Remove connector (16) by drawing it to your side.
REMARK
Put the masking on the connector part and engine control-
ler having been removed.
12. Remove mounting bolts (18) (4 pieces), and remove en-

gine controller assembly (19) and cover (20).
REMARK
• 1 mounting bolt of engine controller assembly (19)
mounting bolts (20) is tightened together with ground
(17).
• Be careful that engine controller assembly (19) does
not fall when it is being removed.
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY

Engine controller assembly
1. Install engine controller assembly (19) and cover (20) with
mounting bolts (18) (4 pieces)
REMARK
• 1 mounting bolt of engine controller assembly (19)
mounting bolts (20) is tightened together with ground
(17).
• Be careful that engine controller assembly (19) does
not fall when it is being removed.
2. Install harness connector (16).
50-674 D155AXI-8
REMARK
Take care to prevent dust from entering into the clearance between engine controller and connector (16).
3. Tilt connector lever (a) to your side, and fix connector (16).
4. Install wiring harness mounting bolts (14) and (15).

3 Wiring harness connector mounting bolt (hexago-
nal socket head bolt):
8 to 10 Nm {0.81 to 1.02 kgm}
5. Install connector cover (13) according to the following pro-

cedure.
1) Push (d) part, and set protrusion (g) of connector in

hole (h) of cover.
D155AXI-8 50-675
2) Push (e) part, and fit dent part (k) in clearance (j) of
the lever of connector.
3) Push (f) part, set protrusion (m) inside the cover in

clearance (h) of connector.
REMARK
Take care to prevent dust from entering into it when instal-
ling.
6. Install engine controller cover (10) with mounting bolts (11)

(6 pieces).
REMARK
1 mounting bolt of engine controller cover (10) mounting
bolts (11) is tightened together with clamp (12) of harness.

7. Tighten filter head (9) and oil filter with mounting bolts (6
pieces).
8. Install oil tube (7) (2 pieces) and flange according to the
following procedures.
1) Insert oil filter side of oil tube (7) into filter head (9),
and lightly tighten the flange to cylinder block.
2) Tighten mounting bolts on oil filter side to the specified
torque, and tighten flange mounting bolts on cylinder
block side to the specified torque.
REMARK
Set O-ring to the contacting face of cylinder head and
flange.
9. Tighten filter head (9) and oil tube (7) (2 pieces) with mounting bolts (2 pieces).
10. Install piping clips (8) (1 piece each) to oil tubes (7).
11. Install piping clip (6) of fuel return hose.
50-676 D155AXI-8
Cover
14. Unlock the engine side cover (1) and (2), and close them.
D155AXI-8 50-677
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY BLY
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY

METHOD FOR REMOVING POWER TRAIN CONTROLLER ASSEMBLY

Seat
1. Open the right and left doors of the operator's cab, and fix them with the lock.
NOTICE
Check that the lock is securely fixed.
2. Remove seat cushion (1).
4 Seat cushion:
25 kg
3. Remove cover (2) on the left side in the operator's cab.
Power train controller assembly

4. Disconnect wiring harness connectors CN-PTCN1 (3), CN-
PTCN2 (4), and CN-PTCN3 (5).
REMARK
Loosen the hexagonal socket head bolt (4 mm) at the cen-
ter of the connector, and then remove wiring harness con-
nectors CN-PTCN1 (3), CN-PTCN2 (4), and CN-PTCN3
(5).
5. Remove the mounting bolts (4 pieces), and remove power
train controller assembly (6).
50-678 D155AXI-8
BLY REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY
METHOD FOR INSTALLING POWER TRAIN CONTROLLER ASSEMBLY

Power train controller assembly
1. Install power train controller assembly (6) with the mount-
ing bolts (4 pieces).
2. Connect wiring harness connectors CN-PTCN1 (3), CN-
PTCN2 (4), and CN-PTCN3 (5).
REMARK
• Completely remove dirt from the wiring harness con-
nectors of the power train controller assembly before
installation.
• Tighten the hexagonal socket head bolt (4 mm) at the
center of the connector, and then install wiring harness
connectors CN-PTCN1 (3), CN-PTCN2 (4), and CN-
PTCN3 (5).
3 Wiring harness connector mounting bolt (hexagonal socket head bolt):
2.83±028 Nm {0.288±0.028 kgm}
3. Install cover (2) on the left side of inside of the operator's
cab.
Seat
4. Install seat cushion (1).
4 Seat cushion:
25 kg
D155AXI-8 50-679
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY

METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY

Operator's seat assmbly
NOTICE
2. Remove seat cushion (1). For details, see “REMOVE AND
INSTALL OPERATOR SET ASSEMBLY”.
Cover
3. Remove cover (2) on the right side in the operator's cab.
Work equipment controller assembly

4. Disconnect wiring harness connectors CN-WECN1 (3),
CN-WECN2 (4), and CN-WECN3 (5).
REMARK
Loosen the hexagonal socket head bolt (4 mm) at the cen-
ter of the connector, and then remove wiring harness con-
nectors CN-WECN1 (3), CN-WECN2 (4), and CN-WECN3
(5).
5. Remove the mounting bolts (4 pieces), and remove work
equipment controller assembly (6).
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY

Work equipment controller assembly
50-680 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEM-
BLY BLY
NOTICE
2. Install work equipment controller assembly (6) with the
3. Connect wiring harness connectors CN-WECN1 (3), CN-
WECN2 (4), and CN-WECN3 (5).
REMARK
Remove dirt completely from the wiring harness connec-
tors before installation.
Wiring harness connector mounting bolt (hexagonal socket
head bolt (4 mm)) 2.83±0.28 Nm{0.288±0.028 kgm}
Cover
4. Install cover (2) on the right side of inside of the operator's
cab.
Operator seat assmbly

5. Install seat cushion (1). For details, see “REMOVE AND
INSTALL OPERATOR'S SEAT ASSEMBLY”.
D155AXI-8 50-681
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY BLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY

k After lowering the work equipment to the ground, set the work equipment lock lever to LOCK posi-
tion.
k When disconnecting wiring and hoses, be careful not to get damaged or deformed by clips and
clamps. If there is a risk of damaging wiring and hoses, remove clips and clamps in advance.
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY

Monitor cover
1. Remove bottom cover (1).
2. Remove upper cover (2).
Monitor assembly
3. Disconnect wiring connectors FLSW (3), RLSW (4), OPSW
(5), and ADH (6).
4. Disconnect wiring connectors KEY (7), CM01 (8), CM02

(9) and CM04 (10).
REMARK
Be careful not to damage the connectors KEY (7), CM01
(8), CM02 (9) and CM04 (10) as these connectors are too
short to be seen during the disconnection work.
50-682 D155AXI-8
BLY REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
5. Remove monitor assembly (11).
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY

Monitor assembly
1. Install monitor assembly (11).
2. Connect wiring connectors KEY (7), CM01 (8), CM02 (9),

CM04 (10).
REMARK
Be careful not to damage the connectors KEY (7), CM01
(8), CM02 (9) and CM04 (10) as these connectors are too
short to be seen during the connection work.
3. Connect wiring connectors FLSW (3), RLSW (4), OPSW

(5), and ADH (6).
D155AXI-8 50-683
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY BLY
Monitor cover
4. Install upper surface cover (2).
5. Install bottom surface cover (1).
50-684 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SEN-
BLY SOR
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR

METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR

Cover
1. Open engine side covers (1) and (2) on the left side of the
machine, and fix them with the lock.
NOTICE
Mass air flow and temperature sensor assembly

2. Slide the lever (red) of connector MAF (3) in the direction
3. While pressing the knob on the upper portion of the con-
nector, pull out the connector in the direction of the arrow.
D155AXI-8 50-685
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SEN- 50 DISASSEMBLY AND ASSEM-
SOR BLY
4. Remove bolts (4) (2 pieces), and remove mass air flow

and temperature sensor assembly (5).
REMARK
Take care that dirt does not enter into the air cleaner.
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR

Mass air flow and temperature sensor assembly
1. .Install mass air flow and temperature sensor assembly (5)
with bolts (4) (2 pieces).
REMARK
Take care that dirt does not enter into the air cleaner.
3 Mass air flow and temperature sensor assembly
mounting bolt:
0.98 to 1.27 Nm{0.10 to 0.13 kgm}
2. Connect MAF connector (3).

3. Slide the lever (red) of the connector in the direction of the
arrow to lock.
50-686 D155AXI-8
50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SEN-
BLY SOR
Cover
4. Unlock engine side covers (1) and (2) on the left side of
the machine, and close them.
D155AXI-8 50-687
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR BLY
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR

k After the engine is stopped, the parts are very hot. Wait until all parts are cooled down.
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR

Cover
1. Open engine side covers (1) and (2) on the right side of
the machine, and fix them with the lock.
NOTICE
KCCV crankcase pressure sensor

2. Disconnect connector PCCV (3).
3. Remove bolt (4), and remove KCCV crankcase pressure

sensor (5).
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR

KCCV crankcase pressure sensor
REMARK
Use a brand new O-ring.
50-688 D155AXI-8
BLY REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR
2. Install KCCV crankcase pressure sensor (5) with mounting

bolt (4).
3 KCCV crankcase pressure sensor mounting bolt
(hexagonal socket head bolt):
2.03 to 2.48 Nm{0.21 to 0.25 kgm}
3. Install connector PCCV (3).
Cover
4. Unlock and close the engine side covers (1) and (2).
D155AXI-8 50-689
REMOVE AND INSTALL SCR TEMPERATURE SENSOR BLY
REMOVE AND INSTALL SCR TEMPERATURE SENSOR

k Since SCR assembly is heated to 500 °C or above, take care not to get burn injury.
k If SCR assembly is hot, wait until it has cooled down before starting any work.
k Check that no combustible materials (dry leaves, twigs, etc.) accumulated around SCR assembly. If
any dirt or combustible materials are found, remove them.
k SCR is fragile against shock such as falling, handle it with care, and never use damaged part.
METHOD FOR REMOVING SCR TEMPERATURE SENSOR

Engine hood
Temperature sensor
NOTICE
Put the marks on the clamp installation positions.
50-690 D155AXI-8
BLY REMOVE AND INSTALL SCR TEMPERATURE SENSOR
4. Loosen mounting nuts (3) and (4), hold metal portions (a)
of SCR inlet temperature sensor (5) and SCR outlet tem-
perature sensor (6) by hands, and pull out them straight in
the direction of the arrow.
REMARK
• SCR inlet temperature sensor mounting nut (width
• SCR outlet temperature sensor mounting nut (width
5. Disconnect connector E34 (7).

REMARK
For connector E34 (7), slide the lever (yellow) in the direc-
tion of the arrow, release the lock, and then disconnect it.
6. Remove bolts (8) (2 pieces), and remove SCR tempera-
ture sensor (9).
REMARK
D155AXI-8 50-691
REMOVE AND INSTALL SCR TEMPERATURE SENSOR BLY
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR

Temperature sensor
1. Install SCR temperature sensor (9) with bolts (8) (2
pieces).
2 Threaded portion of bolts:
3 Bolt (8):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
REMARK
Mounting bolt (8) (width across flats): 10 mm
2. Install connector E34 (7).
REMARK
Slide the lever (yellow) in the direction of the arrow, insert
connector E34 with the lock released, and slide it in the
opposite direction of the arrow to lock it.
3. Tighten SCR inlet temperature sensor (5) and SCR outlet

temperature sensor (6) with mounting nuts (3) and (4).
3 Mounting nut (3):
35 to 41 Nm {3.6 to 4.2 kgm}
3 Mounting nut (4):
22 to 28 Nm {2.2 to 2.8 kgm}
REMARK
• SCR inlet temperature sensor mounting nut (width
• SCR outlet temperature sensor mounting nut (width
50-692 D155AXI-8
BLY REMOVE AND INSTALL SCR TEMPERATURE SENSOR
4. Install clamps (1) (8 places) to the positions marked during

disassembly.
5. Install clamps (2) (2 places) to the positions marked during
disassembly.
3 Clamps (1), (2) mounting bolt:
10.8 to 26.0 Nm {1.1 to 2.7 kgm}
REMARK
• Clips (1a) (2 pieces each) are tightened together with
spacer (10) respectively.
• For clip fixing position, use the dimensions in the right

figure as a guide.
Engine hood
D155AXI-8 50-693
REMOVE AND INSTALL BATTERY RELAY BLY
REMOVE AND INSTALL BATTERY RELAY
Tools for removal and installation of battery relay
New/Redesign
Necessity
Sketch
Q'ty
A - Oil pan ■ 1 N
B - Valve ■ 1
- Hose ■ 1
D - Funnel ■ 1
E - Hose ■ 1
ue/DEF hose
J 600-919-5050 ■ 1
inch)
k Park 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.
k For details of handling AdBlue/DEF, see Operation and Maintenance Manual, “PRECAUTIONS FOR
AdBlue/DEF”.
k When handling AdBlue/DEF injector by hand, be sure to wear the protective eyeglasses and rubber
gloves.
METHOD FOR REMOVING BATTERY RELAY
50-694 D155AXI-8
BLY REMOVE AND INSTALL BATTERY RELAY
Battery cover



D155AXI-8 50-695
12. Close cover (2), and remove it from (a) parts (3 places) of

in the subsequent steps.
REMARK
50-696 D155AXI-8
REMARK
B.
tool A.
6 AdBlue/DEF tank:
73 ℓ
NOTICE
When handling AdBlue/DEF, use tool G.
REMARK
19. Draining amount decreases in 3 or 4 minutes, and then re-
move drain plug (20).
REMARK
1.8 ℓ.
D155AXI-8 50-697

REMARK
Insert tip of tool D into tool E placed on the ground.

23. When tool E is nearly fully filled, securely close valve B1 of
tool B.
creases in approximately 10 seconds. Change tool E to
tool D at the timing of decreasing.
REMARK
0.9 ℓ.
25. When the AdBlue/DEF tank becomes empty, install drain
plug (20) securely.
3 Drain plug (20):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
50-698 D155AXI-8
Draining coolant
6 Radiator:
103.5 ℓ


30. Disconnect connectors UHA (26) and UHC (27).
31. Disconnect connector DSM (28).

AdBlue/DEF hose (31).
D155AXI-8 50-699
NOTICE
• After disconnecting the AdBlue/DEF hose, install
tool H to the hose side and install tool J to the nip-
ple side to prevent leakage.
37. Disconnect connectors UHV2 (34) and UREA (35).
40. Disconnect coolant inlet port hose (38).
41. Remove mounting bolts (39) (4 pieces), sling AdBlue/DEF
tank assembly (40) and remove it.

45 kg
42. Remove bolts (41) (2 pieces) and move bracket assembly

(42) aside so that it does not hinder the work.
50-700 D155AXI-8
Battery
44. Since 2 batteries are provided, disconnect the wiring from

terminals (44) to (45) of the battery on the downstream
side, and from terminals (46) to (47) of the battery on the
upstream side in the order.
45. Remove bracket (48), sling battery (49) and remove it.
4 Battery (1 piece):
130 kg
Battery relay
46. Remove terminals (50) and (51) on the upper side of the
battery relay.
47. Remove bolts (52) (4 pieces) and move bracket (53) to the
position where you can perform the work easily.
48. Disconnect terminals (54) and (55) on the lower side of the
battery relay.
49. Remove bolts (56) (2 pieces), and remove battery relay
(57).
D155AXI-8 50-701
METHOD FOR INSTALLING BATTERY RELAY

Battery relay
1. Install battery relay (57) with bolts (56) (2 pieces).
3 Mounting bolt:
6.86 to 7.84 Nm {0.7 to 0.8 kgm}
2. Install terminals (54) and (55) on the bottom side of the
battery relay.
4. Install terminals (50) and (51) on the top side of the battery
relay.
Battery
5. Sling battery (49), install it, and fix it with bracket (48).
4 Battery (1 piece):
130 kg
6. Since 2 batteries are provided, install the wiring from termi-
nals (47) to (46) of the battery on the upstream side, and
from terminals (45) to (44) of the battery on the down-
stream side in order.
50-702 D155AXI-8
8. Install bracket assembly (42) with bolts (41) (2 pieces).

9. Sling AdBlue/DEF tank assembly (40), install it, and tight-
en it with mounting bolts (39) (4 pieces).

45 kg

11. Install coolant outlet port hose (37).
13. Connect connectors UHV2 (34) and UREA (35).
Check the AdBlue/DEF hose and pin (f) are not damaged.
injector until click sound is heard to install.
REMARK
When it is inserted so that the convex part of pin (f) passes
19. Connect connector DSM (28).
20. Connect connectors UHA (26) and UHC (27).
D155AXI-8 50-703
Battery cover
REMARK
check the position.
50-704 D155AXI-8




D155AXI-8 50-705


50-706 D155AXI-8
BLY REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY

k After lowering the work equipment to the ground, set the work equipment lock lever to LOCK posi-
tion.
k When disconnecting wiring and hoses, be careful not to get damaged or deformed by clips and
clamps. If there is a risk of damaging wiring and hoses, remove clips and clamps in advance.
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY

Seat cushion
1. Open the left and right doors of the operator cab and fix them with the locks.
NOTICE
2. Remove seat cushion (1). For details, see “REMOVAL
AND INSTALLATION OF OPERATOR'S SEAT”.
4 Seat cushion:
25 kg
Cover
3. Remove covers (2), (3), (4), and (5) from the inside of the
operator cab.
D155AXI-8 50-707
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY BLY
4. Reverse cover (5), and disconnect CBACC (6), CBCIG (7),

and AUX terminal connector M01B (8).
5. Remove covers (9), (10), and (11).
KOMTRAX terminal
6. Remove machine body main harness CK02 (13), CK01
(14), communication antenna wiring (15) and GPS anten-
na wiring (16) from KOMTRAX terminal assembly (17).
7. Remove 4 mounting bolts and remove KOMTRAX terminal
assembly (17).
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY

KOMTRAX terminal
1. Open the left and right doors of the operator cab and fix them with the locks.
NOTICE
2. Install KOMTRAX terminal assembly (17) with mounting
bolts (4 pieces).
3. Connect machine body main harness CK02 (13), CK01
(14), communication antenna wiring (15) and GPS anten-
na wiring (16) to KOMTRAX terminal assembly (17).
50-708 D155AXI-8
BLY REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY
Cover
4. Install covers (9), (10), and (11).
5. Connect CBACC (6), CBCIG (7), and AUX terminal con-

nector M01B (8) to the back side of cover (5).
6. Install covers (2), (3), (4) and (5) in the operator cab.
D155AXI-8 50-709
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY BLY
Seat cushion
7. Install seat cushion (1).
4 Seat cushion:
25 kg
50-710 D155AXI-8
BLY REMOVE AND INSTALL CONTROL BOX
REMOVE AND INSTALL CONTROL BOX

k Turn the power supply of control box to OFF position.
METHOD FOR REMOVING CONTROL BOX

Wiring harness connector
1. Disconnect harness connector MONI (1) from control box
(3).
2. Install the disconnected wiring harness connector MON1
(1) to temporary position (2a) for connector of monitor
bracket (2), and prevent dust entering.
Control box
3. Remove control box (3) by loosening knobs (4) (2 places)
on the right and left sides of control box (3).
D155AXI-8 50-711
REMOVE AND INSTALL CONTROL BOX BLY
METHOD FOR INSTALLING CONTROL BOX

Control box
1. Set the control box (3) to bracket (5).
2. Install control box (3) by tightening knob (4) (2 places) on
the right and left side of control box (3).

3. Disconnect wiring harness connector MONI (1) from tem-
porary position (2a) for the connector, and connect it to
control box (3).
50-712 D155AXI-8
BLY REMOVE AND INSTALL GNSS RECEIVER
REMOVE AND INSTALL GNSS RECEIVER

k Turn the power supply of control box to OFF position.
METHOD FOR REMOVING GNSS RECEIVER

Cover
1. Remove mounting bolts (1) (6 pieces) on the rear left part
inside the cab, and remove cover (2).
GNSS receiver
2. Disconnect wiring harness connectors WAGPSB1 (3),
WAGPSB2 (4),WAGPS1 (8),and MGA1 (5).
NOTICE
• Remove dirt, etc. sticking to each wiring harness
connector, and disconnect them.
• Loosen hexagonal socket head bolts (width across
flat 4mm) at the center of wiring harness connec-
tors WAGPSB1 (3) and WAGPSB2 (4), and discon-
nect them.
3. Remove hexagonal socket head bolt (6) (4 pieces), and re-

move GNSS receiver (7) .
D155AXI-8 50-713
REMOVE AND INSTALL GNSS RECEIVER BLY
METHOD FOR INSTALLING GNSS RECEIVER

GNSS receiver
1. Install GNSS receiver (7) with hexagonal socket head bolt
(6) (4 pieces).
2. Connect wiring harness connectors WAGPSB1 (3),
WAGPSB2 (4).
3 Hexagonal socket head bolt (width across flats
4mm) at center of each wiring harness connector :
2.82 Nm {0.288 kgm}
NOTICE
Remove dirt, etc. sticking to each wiring harness con-
nector, and connect them.
3. Connect wiring harness connector MGA1 (5), WAGPS1
(8).
Cover
4. Install cover (2) with mounting bolts (1) (6 pieces).
50-714 D155AXI-8
BLY REMOVE AND INSTALL GNSS ANTENNA
REMOVE AND INSTALL GNSS ANTENNA

Tools for removal and installation of GNSS antenna
New/Redesign
Necessity
Sketch
Q'ty
Commercially Tightening the wire (made by ESCO,

A Wire twisting pliers ■ 1 N
available equivalent to EA534XC-150)
METHOD FOR REMOVING GNSS ANTENNA

Cover
1. Remove mounting bolts (1) (3 pieces), and remove cover
(2).
(4).
Cable connector
3. Disconnect cable connectors MGA2 (5) and WAGPS2 (6).
4. Remove cable clamp (7).
Bracket
5. Remove bolts (a) (3 places) of bracket (8), and install eye-
bolt.
6. Remove mounting bolts (9) (9 pieces), sling bracket (8),
and remove it.
4 Bracket (8) :
25 kg
D155AXI-8 50-715
REMOVE AND INSTALL GNSS ANTENNA BLY
GNSS antenna
(11).
8. Remove wire (12).

9. Disconnect cable connector (13).
10. Loosen hexagonal socket head bolt (14), and remove
GNSS antenna (15).
METHOD FOR INSTALLING GNSS ANTENNA
50-716 D155AXI-8
GNSS antenna
1. Install GNSS antenna (15) with hexagonal socket head
bolt (14).
3 Hexagonal socket head bolt (14):
14.1±2.4 Nm {1.44±0.24 kgm}
2. Connect cable connector (13) with the following method.
1) Install collar (16) and plate (17) to cable connector
(13), and connect it to GNSS antenna (15).
REMARK
Install it so that cut-out portion (a) of collar (16) fits the
shape of GNSS antenna (15).
2) Tighten cable connector (13) to the following torque.
3 Cable connector (13) :
4.5±0.5 Nm {0.46±0.05 kgm}
3) Provide wire (12) (specification: 0.8 mm austenitic
stainless steel wire, length: 400mm)
4) Pass the wire (12) through the hole on the left hand
side when facing plate (17). (b direction)
5) Pass the wire (12) so that it comes under the crossing,
and hold it with left hand. (c direction)
REMARK
Adjust the wire so that the dimension from the end of
wire (12) held by left hand to the crossing part of the
wire (12) becomes 50 mm.
6) Hold the other end of the wire (12) with right hand,
pass it around the neck of GNSS antenna (15) clock-
wise. (d direction)
7) Pass wire (12) through the hole on the right hand side
when facing the plate (17) over from the other side to
your side. (e direction)
D155AXI-8 50-717
8) Pass wire (12) around the neck of GNSS antenna (15)

again but counterclockwise. (f direction)
9) Hold wires (12) (2 pieces) by using tool A at the place
20 mm away to your side from plate (17).
10) Draw lock slide (18) of tool A toward your side, and fix
it.
11) Pull knob (19) 3 or 4 times, and twist wire (12).
50-718 D155AXI-8
12) Cut the tip of excess wire (12).
Bracket
4. Install eyebolts to the eyebolt mounting position (a) (3 pla-
ces).
4 Bracket (8) :
25 kg
5. Sling bracket (8), and install it with bracket mounting bolts
(9) (9 pieces).
D155AXI-8 50-719
Cable connector
6. Connect cable connectors MGA2 (5), and WAGPS2 (6).
3 Cable connector MGA2 (5) :
4.5±0.5 Nm {0.46±0.05 kgm}
3 Cable connector WAGPS (6) :
1.6 Nm {0.16 kgm}
7. Install cable clamp (7).
Cover
50-720 D155AXI-8
BLY REMOVE AND INSTALL IMU SENSOR
REMOVE AND INSTALL IMU SENSOR

Tools for removal and installation of IMU sensor
New/Redesign
Necessity
Sketch
Q'ty
Commercially Tightening the wire (made by ESCO,

A Wire twisting pliers ■ 1 N
available equivalent to EA534XC-150)
Commercially
B Wrench ■ 1 N
available Tightening the connector
C 791T-606-1110 Hook ■ 1 N
METHOD FOR REMOVING IMU SENSOR

Cover
1. Open side covers (1) and (2) on the right side of the ma-
chine.

D155AXI-8 50-721
REMOVE AND INSTALL IMU SENSOR BLY

4. Remove clamp (5), and disconnect harness connector IMU
(6).
5. Remove inspection cover (7) from the bottom side of the

machine.
IMU sensor
6. Remove mounting bolts (8) (4 pieces), and remove IMU
sensor (9) together with bracket (10) and wiring harness
(11) as a unit.
50-722 D155AXI-8
7. Remove wire (12), and disconnect harness connector IMU

(13).
8. Remove hexagonal socket head bolt (width across flats 5
mm) (14) (3 pieces), and remove IMU sensor (9) from
bracket (10).
METHOD FOR INSTALLING IMU SENSOR

IMU sensor
1. Install IMU sensor (9) with hexagonal socket head bolt
(width across flats 5 mm) (14) (3 pieces) to bracket (10).
REMARK
Assemble IMU sensor (9) with bracket (10), wiring harness
(11) as a sub-assembly before installation to the machine.
2. Connect harness connector IMU1 (13) with the following
method.
1) Tighten wiring harness connector IMU1 (13) by using
tools B and C.
3 Wiring harness connector IMU1 (13):
8.2±0.3 Nm {0.8±0.03 kgm}
D155AXI-8 50-723
2) Provide wire (12) (specification: 0.8 mm austenitic

stainless steel wire, length: 200mm)
3) Pass wire (12) through hole (a) in the * marked angle
(120 °), and pull the bent wire until it becomes the
equal length (approximately 100 mm).
4) Make sure that folding back part (P part) of wire (12) is

attached firmly to connector without any protrusion.
5) Hold wire (12) with tool A at hole (b), draw lock slide
(15) to your side, and fix it.
6) Pull knob (16) 3 or 4 times, and twist wire (12).
7) Pass one of the wires (12) through hole (b).

8) Hold wires (12) (2 pieces) with tool A at dimension (x)
away from hole (b), and fix them. Pull knob (16) twice
again, and twist wire (12).
Dimension (x): 20 mm
9) Leave dimension (y), and cut off the unnecessary part.

Attach protruded wire (12) firmly to the connector sur-
face.
Dimension (y): 10 mm
50-724 D155AXI-8
3. Install IMU sensor (9) together with bracket (10) and wiring
harness (11) as a unit with mounting bolts (8) (4 pieces).

4. Connect wiring harness connector IMU (6).
Cover
8. Close side cover (1) and (2) on the right side of the ma-
chine.
D155AXI-8 50-725
9. Install inspection cover (7) from the bottom side of the ma-
chine.
50-726 D155AXI-8

D155axi-8 Sen06521-02 Disassembly & Assembly

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D155axi-8 Sen06521-02 Disassembly & Assembly

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SEN06521-02

METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...........................................................50-186

METHOD FOR ASSEMBLING DAMPER ASSEMBLY ..................................................................50-314

METHOD FOR ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY.........................................50-493

METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY .................................................50-567

RELATED INFORMATION ON DISASSEMBLY AND AS-

Symbol Item Remark

Reading the unit

COATING MATERIALS LIST

Aron Alpha Polyethy- • Quick-curing type (max. strength is ob-

Polyethy- • Features: Resistance to heat and chemi-

LG-11 • Feature: Can be used together with solid

Molybdenum disulfide lubricant

Seizure prevention compound

For adhered window glass

SPECIAL TOOLS LIST

Tools for removal and installation of supply pump assembly

A - Wrench type torque wrench ■ 1 Tightening of sleeve nut

Tools for removal and installation of injector assembly

Symbol Part No. Part name Remarks

A - Wrench type torque wrench ■ 1 Tightening of sleeve nut

Tools for removal and installation of cylinder head assembly

Symbol Part No. Part name Remarks

A - Wrench type torque wrench ■ 1 Tightening of sleeve nut

Tools for removal and installation of cooling fan drive assembly

Removal and installation of cooling fan

A 790-101-3501 Gear puller ● 1 Removal of cooling fan

Tools for removal and installation of engine front oil seal

Symbol Part No. Part name Remarks

795T-521-1111 Push tool ■ 1 ○

Tools for removal and installation of engine rear oil seal

Symbol Part No. Part name Remarks

A 795-931-1100 Seal puller ■ 1

795T-421-1250 Push tool ■ 1 ○

Tools for removal and installation of AdBlue/DEF tank assembly

Symbol Part No. Part name Remarks

Tools for removal and installation of KDPF assembly

A - Digital angle gauge ● 1 For measurement of KDPF outlet angle

Tools for disassembly and assembly of KDPF assembly New/Redesign

Symbol Part No. Part name Remarks

A - Block ■ 4 Fixing KDPF assembly

Tools for removal and installation of SCR assembly

Symbol Part No. Part name Remarks

A - Digital angle gauge ■ 1 For measurement of SCR inlet angle

Tools for removal and installation of KDPF and SCR assembly

Symbol Part No. Part name Remarks

Disconnection and connection of AdBl-

Tools for removal and installation of AdBlue/DEF mixing tube

Removal and installation of

Tools for removal and installation of AdBlue/DEF injector

Symbol Part No. Part name Remarks

Disconnection and connection of AdBl-

Tools for removal and installation of AdBlue/DEF pump

Tools for disconnection and connection of AdBlue/DEF hose

Tools for removal and installation of damper assembly

Symbol Part No. Part name Remarks

A 790-201-3130 Guide bolt ■ 2 Removal and installation of damper

C 790-201-3120 Guide bolt ■ 2

Tools for disassembly and disassembly of damper assembly

Symbol Part No. Part name Remarks

A - Block ■ 2 Disassembly and assembly of damper

C 793T-623-1170 Push tool ■ 2 ○ Assembly of damper cover assembly