D155ax-5 Sebm034801

SEBM034801
MACHINE MODEL SERIAL NUMBER
D155AX-5 76001 and up
• This shop manual may contain attachments and optional equipment that are not
available in your area. Please consult your local Komatsu distributor for those items
you may require.
Materials and specifications are subject to change without notice.
• D155AX-5 mounts the SA6D140E-3 engine.

For details of the engine, see the 140-3 Series Engine Shop Manual.
© 2003
All Rights Reserved
Printed in Japan 12-03 (03)
00-1
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CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
10 STRUCTURE AND FUNCTION ........................................................ 10-1
40 MAINTENANCE STANDARD ........................................................... 40-1
90 OTHERS ............................................................................................ 90-1
00-2 D155AX-5
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions must be taken to these pages according to Q Page to be newly added Add
the list below.
q Page to be replaced Replace
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Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

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00-2-2 D155AX-5
(1)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
}
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume: PAGES next to the CONTENTS page.
Attachments volume: volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
k
date information before you start any work.
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing 3) Do not sling a heavy load with one rope alone,
interference with the part to be removed. but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to the rope, or slipping of the rope from its
the table below: original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
a The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
a Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050 (2 pcs.) container ylene, polyprophylene, tetrafluor-
oethlene and vinyl chloride),
rubber, metal and non-metal.
• Features: Resistance to heat and

Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
790-129-9060 Adhesive: • Used as adhesive or sealant for

(Set of 1 kg metal, glass and plastic.
LT-3 adhesive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined
LT-4 790-129-9040 250 g container holes.
Holtz • Used as heat-resisting sealant for

790-126-9120 75 g Tube repairing engine.
MH 705
• Quick hardening type adhesive

Three bond 790-129-9140 50 g Polyethylene • Cure time: within 5 sec. to 3 min.
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha 790-129-9130 2g Polyethylene ter 30 minutes)
201 container • Used mainly for adhesion of rub-
bers, plastics and metals.
• Resistance to heat, chemicals

Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to
648-50 container high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange sur-
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

1211 790-129-9090 100 g Tube repairing engine.
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 ± 1.4 1.35 ± 0.15

8 13 31 ± 3 3.2 ± 0.3
10 17 66 ± 7 6.7 ± 0.7
12 19 113 ± 10 11.5 ± 1
14 22 177 ± 19 18 ± 2
16 24 279 ± 30 28.5 ± 3
18 27 382 ± 39 39 ± 4
20 30 549 ± 59 56 ± 6
22 32 745 ± 83 76 ± 8.5
24 36 927 ± 103 94.5 ± 10.5
27 41 1320 ± 140 135 ± 15

30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3290 ± 340 335 ± 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2

8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

a In the case of flared nuts for which there is no special instruction,
tighten to the torque given in the table below.
SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

a In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7

12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 34.3 ± 4.9 3.5 ± 0.5

03, 04 20 Varies depending 93.1 ± 9.8 9.5 ± 1
05, 06 24 on type of 142.1 ± 19.6 14.5 ± 2
10, 12 33 connector. 421.4 ± 58.8 43 ± 6
14 42 877.1 ± 132.3 89.5 ± 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

a Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 7.35 ± 1.47 0.75 ± 0.15

10 10 17 11.27 ± 1.47 1.15 ± 0.15
12 12 19 17.64 ± 1.96 1.8 ± 0.2
14 14 22 22.54 ± 1.96 2.3 ± 0.2
16 16 24 29.4 ± 4.9 3 ± 0.5
18 18 27 39.2 ± 4.9 4 ± 0.5
20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7±1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 n 127.4 ± 19.6 13 ± 2
36 36 36 151.9 ± 24.5 15.5 ± 2.5
42 42 n 210.7 ± 29.4 21.5 ± 3
52 52 n 323.4 ± 44.1 33 ± 4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
a Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) inch, Thread series (mm) (Reference)
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary
Color White & Blue — Black & Red Red & Yellow Yellow & Green & Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
GENERAL
01 GENERAL
SPECIFICATION DRAWING ................................................................................................................... 01- 2

SPECIFICATIONS ................................................................................................................................... 01- 4
WEIGHT TABLE ...................................................................................................................................... 01- 10
TABLE OF FUEL, COOLANT AND LUBRICANT .................................................................................... 01- 12
D155AX-5 01-1
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
• Semi U-tiltdozer + variable multi-shank ripper
• U-tiltdozer + variable giant ripper
01-2 D155AX-5
GENERAL SPECIFICATION DRAWING
• Full U-tiltdozer + variable multi-shank ripper
• Full U-tiltdozer + variable giant ripper
D155AX-5 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D155AX-5
Serial number 76001 and up
Bare tractor 29,400

Weight
With semi U-dozer + variable multi-shank kg

ripper + ROPS + cab + air conditioner + 39,500
560mm HD shoe + side cover
Minimum turning radius (F1, center of machine) m 2.1
Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
1st 3.5
Transmission speed ranges
Forward
2nd km/h 6.2
3rd 10.8
1st 4.8
Performance
Reverse
2nd km/h 8.4
3rd 13.9
Bare tractor
With semi U-tiltdozer + variable multi- 80.41 {0.82}
Ground pressure
shank ripper + ROPS + cab + air con-

ditioner + side cover 107.87 {1.10}
kPa {kg/cm2}
With Full U-dozer + variable multi-
shank ripper + ROPS + cab + air con- 109.55 {1.12}
ditioner + 560mm HD shoe + side cov-
er
Bare tractor 4,865
Overall height Overall width Overall length
With semi U-dozer + variable multi- 8,155

shank ripper mm
With Full U-dozer + variable multi- 8,550
shank ripper
Bare tractor 2,695
Dimensions
With semi U-dozer + variable multi- 3,955

shank ripper mm
With Full U-dozer + variable multi- 4,265
shank ripper
To top of exhaust pipe 3,395

mm
To top of cab 2,590
(to top of control lever)
01-4 D155AX-5

Overall height
With cab installed 3,365
With ROPS canopy installed mm 3,500
With canopy installed 3,500

Dimensions
Track gauge 2,100
Length of track on ground 3,210

mm
Track shoe width (Standard) 560
Minimum ground clearance 485

(To bottom surface of undercover)
Name SA6D140E-3
Type of engine 4-cycle, water-cooled, in-line, vertical type,

direct injection, with turbocharger and aftercooler
No. of cylinders - Bore x Stroke mm 6-140 x 165
Piston displacement l {cc} 15.24 {15,240}
Flywheel horsepower kw/rpm{HP/rpm} 231/1,900 {310/1,900}
Max. torque Nm/rpm{kgm/rpm} 1,635/1,250 {167/1,250}

Performance
Engine
Max. speed at no load rpm 2,050
Min. speed at no load rpm 700
Min. fuel consumption ratio g/kwh {g/HPh} —
Starting motor 24V, 11kW
Alternator 24V, 50A
Battery 12V, 170Ah x 2
Radiator core type D-7
3-element, single-stage, single phase

Torque converter
Power train system
(TCS43-17A)
Planetary gear, multiple disc clutch,

hydraulically actuated,
Transmission force-feed lubrication gear pump,
forward 3-speed, reverse 3-speed,
electrically actuated type
D155AX-5 01-5
Variable swash plate type (HPV160)

Max. delivery pressure: 41.2 MPa {420 kg/cm2}
HSS pump
Theoretical delivery: 341 l/min/2,130 rpm
Fixed swash plate type (HMF140)

HSS motor
Max. pressure: 41.2 MPa {420 kg/cm2}
Power train
Bevel gear shaft Spiral bevel gear, force-feed lubrication gear pump
Differential planetary gear, hydraulic motor drive, electric motorized,

HSS steering system
hydraulically actuated
HSS
Wet type, multiple clutch disc, spring boosted,

Master brake
hydraulically actuated, pedal operated
Final drive Spur gear 1-stage, planetary gear 1-stage, splash type lubrication
Suspension Rigid, balancing beam type

Undercarriage
Carrier roller 2 each side
Track roller 6 each side
Track shoe (shoe width: 560 mm) Assembly type, single grouser, 41 each side, pitch: 228.6 mm
Lubrication pump + power train +

Gear type (SAL(3)100+SAL(2)56+SAL(2)25)
torque converter charged (3 tandem)
Scavenging pump (tandem) Gear type (112)
Gear type (71)

HSS, PPC charge pump
Max. delivery pressure: 3.4 MPa {35 kg/cm2}
(tandem with scavenging pump (112))
Theoretical delivery: 135 l/min/1,972 rpm
Gear type (SAR(4)112)

Work equipment hydraulic system
Max. delivery pressure : 20.6 MPa {210 kg/cm2}

Work equipment pump
Theoretical delivery : 255 l/min/2,220 rpm
Type 2+1+1 tandem spool type, hydraulically assisted type

Main control valve
• For blade lift

Ripper tilt + ripper lift + blade lift + blade tilt
• For blade tilt
• For ripper lift
• For ripper tilt
01-6 D155AX-5
Type Reciprocal, piston type
Cylinder bore 120

Dimensions of blade
Piston rod outer diameter 75
Max. piston stroke mm 1,347
Max. distance between pins 3,187
Min. distance between pins 1,836
Cylinder bore 180

Dimensions of blade
Max. piston stroke mm 160

Work equipment hydraulic system
Cylinder bore 200

Dimensions of blade tilt,
Hydraulic cylinder
Cylinder bore 160

Dimensions of ripper
Cylinder bore 160

Dimensions of ripper
Hydraulic tank Box type (control valve externally installed)
D155AX-5 01-7
Type Hydraulic semi U-tilt dozer, hydraulic U-tilt dozer
Blade support method Brace type (right tilt cylinder)
Blade lifting height (from ground level) mm 1,250
Blade lowering depth (from ground level) mm 590

Performance
Max. blade tilt mm 1,000

Semi U-tiltdozer
Blade cutting angle variation deg. ±6
Blade capacity m3 11.7 < SAE 8.8 >
Blade width mm 3,955

Dimensions
Blade height mm 1,720
Blade cutting angle deg. 52
Blade lifting height (from ground level) mm 1,250
Blade lowering depth (from ground level) mm 590

Performance
Work equipment
Max. blade tilt mm 1,080

Full U-dozer
Blade cutting angle variation deg. ±6
Blade capacity m3 13.2 < SAE 11.8 >
Blade width mm 4,265

Dimensions
Blade height mm 1,720
Blade cutting angle deg. 52

Full U-dozer + pitch Semi U-tiltdozer + pitch
Max. tilt mm 1,000

Performance
Max. pitch angle deg. 6
Max. pitch-back angle deg. 6
Max. tilt mm 1,080

Performance
Max. pitch angle deg. 6
Max. pitch-back angle deg. 6
01-8 D155AX-5

Variable multi-shank ripper
Max. digging depth mm 870

Performance
Max. lifting height mm 925
Ripping angle of point deg 34.5 – 60

Dimensions
Max. beam width mm 2,260

Work equipment
Shank positions No. of holes 2
Max. digging depth mm 1,220

Dimensions Performance
Variable giant ripper
Max. lifting height mm 925
Ripping angle of point deg 34.5 – 60
Max. beam width mm 1,535
Shank positions No. of holes 3
D155AX-5 01-9
GENERAL WEIGHT TABLE
WEIGHT TABLE
kThis weight table is for reference in handling or
transporting components.
Unit: kg
Engine, damper assembly 1,864

• Engine assembly 1,726
• Damper assembly 117
• Universal joint 18
• Engine mount parts (wiring) 3
Radiator assembly (including built-in oil cooler) 306

Hydraulic cooler 45 (28 as individual part)
Fuel tank assembly (when empty) 267
Fuel tank assembly (when full) 798
Power train unit assembly 2,318

• Torque converter, PTO assembly 342
• Transmission assembly 645
• HSS assembly 894
• Brake valve assembly 14
• HSSïPPC charge filter assembly 22
• HSSïPPC charge valve assembly 21
• Power train filter assembly 20
• Scavenging pumpïHSSïPPC charge pump 36
• Power train lubrication pump 27
• Work equipment pump 19
• HSS motor 63
• HSS pump 102
Final drive assembly 1,372 x 2

Sprocket teeth (12 x 9) x 2
Hull frame assembly 3,182
Track group assembly (each side) 3,755

• Track frame 1,224
• Idler assembly 410
• Recoil spring assembly 508
• Bogie, track roller assembly 410 x 3
• Track roller assembly (single flange x1) 97 x 3
• Track roller assembly (double flange x1) 109 x 3
• Carrier roller assembly 45 x 2
01-10 D155AX-5
GENERAL WEIGHT TABLE
Unit: kg
Track shoe assembly (560 mm, wet type) 2,558 x 2

Pivot shaft assembly 116 x 2
Equalizer bar 229
Hydraulic tank assembly

95
Hydraulic filter assembly
19
Main control valve
99
(Blade lift + blade tilt + ripper lift + ripper tilt)
Engine underguard 183

Transmission underguard 228
Operatorís seat 51
Semi U-tiltdozer assembly 4,903

• Blade 2,818
• Straight frame 690 x 2
• Tilt brace 98 x 1
• Center brace 92 x 2
• Tilt cylinder assembly 190
Semi U-tilt + pitch dozer assembly 5,007

• Blade 2,818
• Straight frame 690 x 2
• Center brace 92 x 2
• Tilt cylinder assembly 190
• Pitch cylinder assembly 215
Blade lift cylinder assembly 165 x 2
Multi-shank ripper assembly 3,710

• Bracket, beam 2,014
• Shank 266 x 3
• Lift cylinder assembly 119 x 2
• Tilt cylinder assembly 122 x 2
Giant ripper assembly 3,135

• Bracket, beam 1,728
• Shank 333 x 1
• Lift cylinder assembly 119 x 2
• Tilt cylinder assembly 122 x 2
• Pin puller cylinder assembly 7
ROPS assembly 464

Cab 410
ROPS canopy 450
Dashboard (including air conditioner unit) 83
Floor frame 180
Side cover 30
Air conditioner (excluding air conditioner unit) 87
D155AX-5 01-11
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANT
TABLE OF FUEL, COOLANT AND LUBRICANT

Ambient temperature CAPACITY (l)
Refilling position Kind of oil –22 –4 14 32 50 68 86 104 °F
Specified Refilled
–30 –20 –10 0 10 20 30 40 50°C
SAE 30
SAE 10W
Engine oil pan 42 37
SAE 10W-30
SAE 15W-40
Power train case SAE 30 90 45
Final drive case (each side) SAE 10W 58 58
Damper case Engine oil 1.5 1.5
SAE 30
Pivot shaft case (each side) 8.7 8.7
116 87
SAE 10W (w/o
attachment)
126 87
Hydraulic system SAE 10W-30 (with blade,
w/o ripper)
180 87
SAE 15W-40 (with blade,
ripper)
Idler (each) 0.59 0.59
Track roller (each) 0.45 0.45
Gear oil GO 140
Carrier roller (each) 0.68 0.68
Bogie (each) 0.21 – 0.23 0.21 – 0.23
Diesel ASTM D975 No. 2

Fuel tank 625 —
fuel *2
*1
Grease fitting Grease NLGI No.2 — —
Cooling system
Coolant Add antifreeze 107 —
(including reservoir tank)
*1 ASTM D975 No. 1
IMPORTANT *2 use only diesel fuel. (2) When starting the engine in an atmospheric tem-
Use only diesel fuel for this machine. perature of lower than 0°C, be sure to use en-
The engine of this machine is equipped with the gine oil of SAE10W, SAE10W-30 and SAE15W-
electronically controlled high-pressure fuel injection 40 even though an atmospheric temperature
system to attain better fuel consumption characteris- goes up to 10°C more or less in the day time.
tics and better exhaust gas characteristics. Accord- (3) Use API classification CD as engine oil and if
ingly, high accuracy of the parts and high lubrication API classification CC, reduce the engine oil
performance are required. If kerosene, etc. which change interval to half.
has low lubrication performance is used, the durabil- (4) There is no problem if single grade oil is mixed
ity of the engine is lowered remarkably. with multigrade oil (SAE10W-30, 15W-40), but
be sure to add single grade oil that matches the
NOTE: temperature in the table.
(1) When fuel sulphur content is less than 0.5 %, (5) We recommend Komatsu genuine oil which has
change oil in the oil pan every periodic mainte- been specifically formulated and approved for
nance hours described in this manual. use in engine and hydraulic work equipment ap-
Change oil according to the following table if fuel plications.
sulphur content is above 0.5 %.
ASTM: American Society of Testing and Material
Change interval of oil in SAE: Society of Automotive Engineers
Fuel sulphur content API: American Petroleum Institute
engine oil pan
0.5 to 1.0 % 1/2 of regular interval Specified capacity: Total amount of oil including oil
for components and oil in piping.
Above 1.0 % 1/4 of regular interval Refill capacity: Amount of oil needed to refill system
during normal inspection and maintenance.
01-12 D155AX-5
10 STRUCTURE AND FUNCTION
Radiator, oil cooler ...................................... 10- 2 Suspension ................................................. 10-122

Power train system ..................................... 10- 6 Work equipment hydraulic piping diagram .. 10-124
Overall drawing of power train unit ............. 10- 8 PPC control piping diagram ........................ 10-127
Power train hydraulic equipment layout ...... 10- 10 Work equipment control .............................. 10-128
Damper, universal joint ............................... 10- 12 Hydraulic tank and filter ............................... 10-130
Torque converter, PTO ............................... 10- 14 Accumulator ................................................ 10-132
Transmission control ................................... 10- 18 PPC lock valve ............................................ 10-133
Transmission .............................................. 10- 20 PPC valve ................................................... 10-134
Tranmission ecmv ....................................... 10- 30 PCCS lever ................................................. 10-144
Main relief valve .......................................... 10- 35 Piston valve ................................................. 10-147
Lubrication relief valve ................................ 10- 38 Pin puller switch .......................................... 10-148
Scavenging pump strainer .......................... 10- 39 Pin puller solenoid valve ............................. 10-150
Power train pump strainer .......................... 10- 40 Main control valve ....................................... 10-152
Power train oil filter ..................................... 10- 41 Self pressure reducing valve ....................... 10-178
HSS system ................................................ 10- 42 Cylinder stay ............................................... 10-185
HSS pump .................................................. 10- 54 Work equipment .......................................... 10-186
HSS motor .................................................. 10- 70 Cab mount ................................................... 10-190
Cooling fan pump ....................................... 10- 78 Cab .............................................................. 10-191
Cooling fan motor ....................................... 10- 86 Air conditioner ............................................. 10-193
HSS charge filter bypass valve ................... 10- 92 Engine control ............................................. 10-194
HSS oil cooler bypass valve ....................... 10- 93 Engine control system ................................. 10-195
Steering brake control ................................ 10- 94 Cri engine control system ............................ 10-196
Bevel gear shaft, HSS, brake ..................... 10- 96 Monitor system ............................................ 10-198
Brake valve ................................................. 10-110 Monitor panel .............................................. 10-200
Final drive ................................................... 10-114 Sensors ....................................................... 10-203
Track frame ................................................. 10-117 Deceleration potentiometer ......................... 10-207
Track roller bogie ........................................ 10-119 Palm command control system ................... 10-209
Recoil spring ............................................... 10-120
Main frame .................................................. 10-121
D155AX-5 10-1
STRUCTURE AND FUNCTION RADIATOR, OIL COOLER
RADIATOR, OIL COOLER

• RADIATOR
10-2 D155AX-5
1. Outlet hose
2. Reservoir tank
2. Inlet hose
3. Air bleed hose
4. Overflow hose
6. Water filler cap
7. Radiator core assembly
8. Inlet hose (for circulating at low water tempera-
ture)
9. Lower tank (power train oil cooler built-in)
10. Fan
11. Drain plug
12. Cushion
13. Breather cap
14. Valve
Outline
• The reservoir tank is provided for radiator.
• The power train oil cooler is built in the lower
tank of the radiator.
Radiator
Core type D-7
Fin pitch (mm) 4.0
Heat dissipation area (m2) 102.42

Relief
(MPa {kg/cm2}) 0.09 {0.9}
Pressure pressure
valve Vacuum
(MPa {kg/cm2}) 0.005 {0.05}
pressure
D155AX-5 10-3
• OIL COOLER
1. Hydraulic cooler
2. Power train oil cooler
A. Power train oil cooler outlet port

B. Power train oil cooler inlet port
Outline
• The power train oil cooler is built in the lower
tank of the radiator.
Power train Hydraulic

oil cooler cooler
Core type PTO-OL J-4 (4.0P)
Inner fin type TF8-C TF9-P

Built in lower
Cooling method Air cooled
tank
Heat dissipation area 2.47 m2 8.52 m2
10-4 D155AX-5
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
Outline
• The power generated by engine (1) has its tor- • Brake (16) of the HSS is used for braking the
sional vibration dampened by damper (2), and machine. Brake (16) is a wet, multiple disc
then passes through universal joint (3), and is clutch, spring boosted type. If brake (16) on only
transmitted to torque converter (11). 1 side is applied, the machine can carry out pivot
• The power from the engine is transmitted turns. The power sent from brake (16) is trans-
through the oil by torque converter (11) to the mitted to final drive (17).
transmission input shaft (turbine shaft) in accor- • Final drive (17) consists of a single-stage spur
dance with the change in load. gear and a single-stage planetary gear system.
• Transmission (12) uses a combination of a plan- It reduces the speed and rotates sprocket (18) to
etary gear system and hydraulic clutches to re- drive track shoe (19) and move the machine. It
duce the speed and shift the gears (3 forward also rotates fan motor (22) with the oil dis-
gears and 3 reverse gears). It connects 2 sets of charged from fan pump (20) driven with PTO (7).
clutches selected according to the change in
load, and transmits the power to bevel gear (13)
from the bevel pinion at the rear end of the trans-
mission.
• The power transmitted to the bevel gear shaft is
transmitted to HSS (Hydrostatic Steering Sys-
tem) (14). HSS pump (11) is driven by PTO (7),
and output oil of the HSS pump drives HSS mo-
tor (15). The rotation of the pair of the HSS gears
on the right and left is controlled by HSS motor
(15). The steering is carried out by generating a
difference in speed on the right and left. It is also
possible to use the HSS mechanism to rotate the
right and left sides in opposite directions to carry
out pivot turns.
10-6 D155AX-5
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
1. Engine (SDA6D140E-3) 8. Steering lubricating oil pump 14. HSS unit

2. Damper (SAR(3)-100) 15. HSS motor (HMF140)
3. Universal joint 9. Power train pump 16. Brake
4. Scavenging pump (SAL(2)-56) 17. Final drive
5. HSS charge pump 10. Torque converter charge pump 18. Sprocket
6. Work equipment pump (SAL(2)-25) 19. Track shoe
(SAR(4)-112) 11. Torque converter 20. Fan pump (LPV45)
7. PTO 12. Transmission 21. HSS pump (HPV160)
13. Bevel gear 22. Fan motor (LMF55)
D155AX-5 10-7
STRUCTURE AND FUNCTION OVERALL DRAWING OF POWER TRAIN UNIT
OVERALL DRAWING OF POWER TRAIN UNIT
10-8 D155AX-5
STRUCTURE AND FUNCTION OVERALL DRAWING OF POWER TRAIN UNIT
1. Torque converter, PTO (TCS43-17A) 9. Transmission main relief valve

2. Work equipment pump (SAR(4)-112) 10. HSS pump (HPV160)
3. Transmission 11. Steering lubricating oil pump (SAL(3)-100)
4. Brake valve 12. Power train pump (SAL(2)-56)
5. HSS motor (HMF140) 13. Torque converter charge pump (SAL(2)-25)
6. HSS unit 14. PPC, HSS charge pump (71)
7. Cooling fan pump 15. Scavenging pump (112)
8. HSS oil cooler bypass valve 16. Scavenging pump strainer
17. Power train pump strainer
Outline
• The power train unit can be broadly divided into
torque converter (1), transmission unit (3), and
steering unit (6).
• So, after the power train unit has been removed,
it can be disassembled into the torque converter,
transmission unit, ans steering unit.
• HSS unit consists of the bevel pinion unit, bevel
gear shaft, HSS motor, planetary gear and
brake.
D155AX-5 10-9
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC EQUIPMENT LAYOUT
POWER TRAIN HYDRAULIC EQUIPMENT LAYOUT
1. Scavenging pump (112) A. Left brake oil pressure pickup port

2. Torque converter charge pump (SAL(2)-25) B. Transmission main relief oil pressure pickup port
3. Power train pump (SAL(2)-56) C. Forward transmission clutch oil pressure pickup
4. Power train lubrication pump (SAL(3)-100) port
5. Transmission control valve D. Reverse transmission clutch oil pressure pickup
6. Brake control valve port
7. Main relief valve E. 1st transmission clutch oil pressure pickup port
8. Centralized pressure detection port F. 2nd transmission clutch oil pressure pickup port
9. Power train oil strainer G. 3rd transmission clutch oil pressure pickup port
10. Power train oil filter H. Torque converter inlet oil pressure pickup port
11. Power train oil cooler J. Torque converter outlet oil pressure pickup port
(built in radiator lower tank)
10-10 D155AX-5
STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
10-12 D155AX-5
STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
1. Breather
2. Dipstick
3. Drain plug
4. Input shaft
5. Flywheel
6. Outer body
7. Coupling
8. Universal joint
9. Cover
10. Rubber coupling
11. Inner body
Outline
• The damper dampens the torsional vibration
caused by the change in engine torque and the
impact torque generated when accelerating sud-
denly or when carrying out heavy-duty digging.
In this way it acts to protect the torque converter,
transmission, and other parts of the power train.
• This damper has few component parts: it uses a
rubber coupling, so the vibration is absorbed by
the damping effect of the rubber material.
Operation
• The motive force from the engine passes
through flywheel (5) and is transmitted to outer
body (6).
The torsional vibration of the engine is absorbed
by rubber coupling (10), and the power is trans-
mitted to inner body (11). It passes through uni-
versal joint (8), and is then transmitted to the
torque converter and transmission.
D155AX-5 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO
10-14 D155AX-5
D155AX-5 10-15
A. Torque converter oil inlet port Outline

B. To oil cooler • The torque converter is a 3-element, 1-stage, 1-
C. From transmission case (to power train/steering phase type and forms one unit with the transmis-
lubrication pimp) sion.
D. To transmission case (passage) • Pump (14) forms one unit with input coupling (7)
PTO drive gear (8) and drive case (12), and is ro-
tated by the power from the engine.
1. Power train/steering lubrication pump mount • Turbine (13) forms one unit with transmission in-
2. HSS pump mount put shaft (17), and is rotated by the oil from the
3. Scavenging pump mount pump (14).
4. Fan pump mount • Stator (15) forms one unit with stator shaft (16),
5. Work equipment pump mount and is fixed to PTO case (11).
6. PTO lubrication tube • Each pump installed to the PTO case is driven
7. Input coupling with the power transmitted from drive gear (8)
8. PTO drive gear (No. of teeth: 55) through PTO idler gear (10) to pump drive gears
9. PTO idler gear shaft (18), (19), and (20).
10. PTO idler gear (No. of teeth: 74)
11. PTO case
12. Drive case
13. Turbine
14. Pump
15. Stator
16. Stator shaft
17. Transmission input shaft
18. Power train/steering lubrication pump, work
equipment pump drive gear (No. of teeth: 47)
19. HSS pump, fan pump, fan pump drive gear
(No. of teeth: 49)
20. Scavenging pump drive gear (No. of teeth: 53)
21. Sleeve
22. Power train oil strainer
10-16 D155AX-5
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
a For steering operation concerned to operation of a PCCS: Abbreviation for Palm Command Control
the Palm Command Steering Control lever System
(PCCS lever), see STEERING, BRAKE CON-
TROL.
10-18 D155AX-5
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
1. Brake pedal Lever positions

2. Safety lever A. Neutral
3. PCCS lever B. Forward
(Forward-Reverse, Gear shift) C. Reverse
3A. UP switch D. OFF
(Gear is shifted up each E. Shift UP
time this switch is pressed.) F. Shift DOWN
3B. DOWN switch G. Free
(Gear is shifted down each H. Lock
time this switch is pressed.)
4. Transmission neutral safety
switch
5. Cable
6. Transmission control valve
Outline
• The transmission is controlled with PCCS lever
(3).
The PCCS lever is used to select the travel di-
rection and shift the gear.
• Since the safety mechanism is employed, trans-
mission neutral safety switch (4) does not work
and the engine does not start unless safety lever
(2) is in the LOCK position.
D155AX-5 10-19
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
10-20 D155AX-5
A. Transmission 1st clutch pressure pick-up port J. To PTO case

B. Transmission 3rd clutch pressure pick-up port K. To steering case (drain)
C. Transmission R clutch pressure pick-up port L. From steering case
D. Transmission 2nd clutch pressure pick-up port M. Transmission lubrication oil inlet
E. Transmission F clutch pressure pick-up port N. To forward clutch
F. To case P. To reverse clutch
(power train/steering lubrication pump) Q. To 3rd clutch
G. From PTO case R. To 2nd clutch
H. To scavenging pump S. To 1st clutch
D155AX-5 10-21
10-22 D155AX-5
1. Main relief valve Outline

2. Transmission case
• The transmission consists of planetary gear sys-
3. Transmission control valve and valve cover as-
tems and disc clutches and has "3 forward gear
sembly
speeds and 3 reverse gear speeds".
4. Lubricating oil relief valve
• Among the 5 sets of planetary gear system and
5. Input shaft
disc clutch of the transmission, 2 clutches are
6. Reverse clutch sungear (34 teeth)
fixed hydraulically with control valves to select 1
7. Pinion shaft
rotating direction and rotating speed.
8. Ring gear of reverse travel (86 teeth)
• Clutches No. 1, No. 2, No. 3, No. 4, and No. 5 are
9. Planetary pinion for reverse travel (26 teeth)
fixed respectively when the reverse, forward,
10. Disc
3rd, 2nd, and 1st gears are selected.
11. Plate
12. Piston
13. Planetary pinion for forward travel (27 teeth) Number of plates and discs
14. Planetary pinion for 3rd gear speed (36 teeth)
Clutch No. Number of discs Number of plates
15. Ring gear for 3rd gear speed (Number of internal
teeth: 91, Number of external teeth: 109)
No.1 5 4
16. Sun gear for 2nd gear speed (39 teeth) No.2 6 5
17. Planetary pinion for 1st gear speed (21 teeth) No.3 4 3
18. Sun gear for 1st gear speed (49 teeth) No.4 4 3
19. Output shaft (Number of teeth of sun gear for 3rd No.5 3 2
gear speed: 20)
20. Ring gear for 1st gear speed (Number of internal
teeth: 91, Number of external teeth: 105) Gear speeds and operated clutches
21. 1st clutch carrier (90 teeth)
22. Clutch housing for 1st gear speed Gear speed Operated clutches (Turned ON)
23. Clutch housing for 2nd gear speed
Forward 1st No.2·No.5
24. Planetary pinion for 2nd gear speed (26 teeth)
Forward 2nd No.2·No.4
25. Ring gear for 2nd gear speed (Number of inter- Forward 3rd No.2·No.3
nal teeth: 90, Number of external teeth: 105) Neutral 1. No.5
26. Clutch housing for 3rd gear speed Reverse 1st No.1·No.5
27. Carrier for 2nd and 3rd gear speeds Reverse 2nd No.1·No.4
28. Clutch housing for forward travel Reverse 3rd No.1·No.3
29. Sun gear for forward travel (37 teeth)
30. Ring gear for forward travel (Number of internal 1: While the transmission is in neutral, the 1st
teeth: 91, Number of external teeth: 105) clutch is filled with low-pressure oil so that the
31. Carrier for forward travel (86 teeth) machine can start without a time lag, but it is
32. Clutch housing for reverse travel not engaged.
33. Return spring
34. Ring gear for reverse travel (Number of internal
teeth: 90, Number of external teeth: 105)
35. Pin
36. Carrier for reverse travel (90 teeth)
D155AX-5 10-23
Operation
1. Operation of disc clutch
• To lock ring gear (8) a disc clutch is used. The
clutch consists of piston (12), plates (11), discs
(10), pin (35) and piston return springs (33).
The internal teeth of the disc engage with the ex-
ternal teeth of the ring gear.
The teeth on the outside diameter of the plate
engage with pins (35) secured by housing (32).
Clutch engaged (locked)

• Oil from the control valve flows under pressure
through the port in housing (32) to the back of
piston (12).
The piston presses plates (11) and discs (10) to-
gether, and the resulting frictional force stops the
rotation of discs so ring gear (8) meshing with
the internal teeth of the disc is locked.
Clutch disengaged (free)

• When the supply of pressure oil from the control
valve is shut off, piston (12) is returned to its orig-
inal position by the force of piston return spring
(33). This relieves the frictional force between
plates (11) and discs (10), making the ring (8)
free.
10-24 D155AX-5
Oil circuit of 1st clutch

Since the 1st clutch is the farthest from the control
valve and has the longest circuit to the cylinder, it
takes the longest time to fill the circuit.
To solve this problem, the oil is supplied to the 1st
clutch even if the gear shift lever is in the NEUTRAL
position,
Accordingly, when the gear shift lever is shifted from
the NEUTRAL position to the F1 position, the pump
is required to supply oil of only quantity to fill the for-
ward clutch.
When the gear shift switch is changed from the F1 to
F2, the pump is required to supply fill of only quantity
to fill the 2nd clutch since the forward clutch has
been filled with the oil.
The time lag in the gear shifting operation is reduced
by using the oil as explained above.
D155AX-5 10-25
2. Forward 1st
• When the transmission is set to FORWARD 1st, • Carrier (21) is meshed with ring gear (25), and
the No. 2 clutch and No. 5 clutch are engaged. rotates as one unit, so the rotation is transmitted
The motive force from the torque converter to planet pinion (17).
transmitted to input shaft (5) is then transmitted • Ring gear (20) is being held in position by No. 5
to output shaft (19). clutch, so the rotation of planet pinion (17) ro-
• No. 2 clutch is actuated by the hydraulic pres- tates sun gear (18), and this rotates output shaft
sure applied to the clutch piston, and holds ring (19).
gear (30) in position. No. 5 clutch is actuated by
the hydraulic pressure applied to the clutch pis-
ton, and engages ring gear (20).
• The motive force from the torque converter is
transmitted to input shaft (5), and the rotation of
the input shaft passes through sun gear (29) and
is transmitted to planet pinion (13).
• Ring gear (30) is held in position by No. 2 clutch,
so the rotation of planet pinion (13) rotates carri-
er (31), which is on the inside of ring gear (30).
• Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
carrier (31) passes through planet pinion (24)
and is transmitted to ring gear (25).
10-26 D155AX-5
3. Forward 2nd
• When the transmission is set to FORWARD 2nd • Carrier (31) and carrier (27) are joined by a
the No. 2 clutch and No. 4 clutch are engaged. spline, and rotate as one unit, so the rotation is
The motive force from the torque converter transmitted to planet pinion (24).
• No. 2 clutch is actuated by the hydraulic pres- tates sun gear (16), and this rotates output shaft
sure applied to the clutch piston, and holds ring (19).
D155AX-5 10-27
4. Forward 3rd
• When the transmission is set to FORWARD 3rd • Carrier (31) and carrier (27) are joined by a
the No. 2 clutch and No. 3 clutch are engaged. spline, and rotate as one unit, so the rotation is
The motive force from the torque converter transmitted to planet pinion (14).
• No. 2 clutch is actuated by the hydraulic pres- tates output shaft (19).
sure applied to the clutch piston, and holds ring
10-28 D155AX-5
5. Reverse 1st
• When the transmission is set to REVERSE 1st, carrier (31) passes through planet pinion (24)
the No. 1 clutch and No. 5 clutch are engaged. and is transmitted to ring gear (25).
The motive force from the torque converter • Carrier (21) is meshed with ring gear (25), and
transmitted to input shaft (5) is then transmitted rotates as one unit, so the rotation is transmitted
to output shaft (19). to planet pinion (17).
• No. 1 clutch is actuated by the hydraulic pres- • Ring gear (20) is being held in position by No. 5
sure applied to the clutch piston, and holds car- clutch, so the rotation of planet pinion (17) ro-
rier (36) in position. No. 5 clutch is actuated by tates sun gear (18), and this rotates output shaft
the hydraulic pressure applied to the clutch pis- (19).
• Carrier (36) is held in position by No. 1 clutch, so
the rotation of planet pinion (9) rotates ring gear
(8).
Ring gear (8) rotates in the opposite direction
from the input shaft, and rotates carrier (31).
• Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
D155AX-5 10-29
STRUCTURE AND FUNCTION TRANMISSION ECMV
TRANMISSION ECMV
(Electronic Control Modulation Valve)
10-30 D155AX-5
1. Proportional solenoid valve for 3rd clutch ECMV

2. Proportional solenoid valve for 1st clutch ECMV
3. Proportional solenoid valve for R clutch ECMV
4. Proportional solenoid valve for 2nd clutch ECMV
5. Proportional solenoid valve for F clutch ECMV
6. Fill switch for 3rd clutch
7. Fill switch for 2nd clutch
8. Fill switch for 1st clutch
9. Fill switch for R clutch
10. Fill switch for F clutch
11. Connector for 1st proportional solenoid valve
12. Connector for 3rd proportional solenoid valve
13. Connector for R proportional solenoid valve
14. Connector for 2nd proportional solenoid valve
15. Connector for F proportional solenoid valve
16. Connector for 3rd fill switch
17. Connector for 2nd fill switch
18. Connector for 1st fill switch
19. Connector for R fill switch
20. Connector for F fill switch
21. Filter
22. Pressure control valve
23. Oil pressure detection valve
24. Pressure control valve spring
A. 1st clutch operating pressure pick-up port

B. 3rd clutch operating pressure pick-up port
C. R clutch operating pressure pick-up port
D. 2nd clutch operating pressure pick-up port
E. F clutch operating pressure pick-up port
F. To clutch
P. From pump
T. Drain
D155AX-5 10-31
Outline of ECMV
• The ECMV (Electronic Control Modulation
Valve) consists of the following two units, a pres-
sure control valve and fill switch.
• Pressure control valve
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
• Fill switch
Detects that the clutch is filled with oil. It has the
functions below.
1) It outputs a signal (fill signal) to the controller
as soon as the clutch is filled with oil to report
the completion of filling.
2) It outputs a signal (fill signal) to the controller
while an oil pressure is applied to the clutch
to report the presence/absence of oil pres-
sure.
A region: Before gear shift (When draining)
B region: During filling
C region: Voltage regulation
D region: During filling (During trigger)
E region: Filling starts
F region: Filling finishes
a The logic is so designed that the controller will

not recognize completion of filling even if the fill
switch is turned ON during the triggering period
(in the D-region).
ECMV and proportional solenoid

• One proportional solenoid is attached to one EC-
MV. After receiving the command current from
the controller, it produces thrust in the right fig-
ure.
By making the proportional solenoid-produced

thrust act on the pressure control valve spool, it
produces an oil pressure shown in the right fig-
ure. By controlling the amount of command cur-
rent, the thrust is changed to operate the
pressure control valve, controlling the oil flow
and oil pressure.
ECMV and fill switch

• One fill switch is attached to one ECMV. When
the clutch completes filling, the pressure of the
clutch turns "ON" the fill switch. By this signal,
the oil pressure starts build-up.
10-32 D155AX-5
Operation of ECMV
• The ECMV is controlled by the command current
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relation among the proportional solenoid
command current of the ECMV, the clutch input
pressure, and fill switch output signal is as
shown in the figure to the right.
A region: Before gear shift (When draining)

B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling
• The clutch is crimped by the piston when shifting

the gear with the gear shift switch. If a high oil
pressure is applied suddenly, however, the pis-
ton connects to the clutch suddenly, causing the
machine to make a sudden start and give an ex-
cessive shock to the machine.
To prevent them, it is designed so that if you con-
nect the ECMV to shift gears with the gear shift
switch, the oil pressure to the clutch may be
gradually increased up to the specified level. By
this design, the clutch is excited smoothly to
eliminate the shock at the start, improve the du-
rability of the power transfer system, and also
provide operator comfort.
1. Before gear shift (Region A in the diagram)

When a current is not carried to the proportional
solenoid (1), the pressure control valve (2) is
draining the oil at the clutch port A through the
drain port dr.
Since, at that time, no oil pressure acts on the oil
pressure detection valve (3), the fill switch (4) is
OFF.
D155AX-5 10-33
2. When filling (When inputting the trigger com-

mand to the pressure control valve)
(B region in the diagram)
If you supply a current to the proportional sole-
noid (1) with no oil in the clutch, an oil pressure
proportional to the solenoid force acts on the
chamber B, pushing the pressure control valve
(2) rightward. This operation opens the pump
port P and clutch port A to start filling the clutch
with oil. When the clutch is filled with oil, the fill
switch (4) is turned ON.
3. Pressure regulation (C region in the diagram)

If you flow a current to the proportional solenoid
(1), the solenoid produces thrust proportional to
the current. Pressure is regulated by striking a
balance among the thrust of the solenoid, the
thrust of the oil pressure of the clutch port, and
reaction force of the pressure control spring (5).
10-34 D155AX-5
STRUCTURE AND FUNCTION MAIN RELIEF VALVE
MAIN RELIEF VALVE
1. Body Outline
2. Torque converter relief valve 1. Main relief valve
3. Valve spring Main relief valve (6) sets the set pressure of the
4. Piston oil pressure for the transmission, steering clutch,
5. Piston spring and brake.
6. Main relief valve 2. Torque converter relief valve
7. Valve spring Torque converter relief valve (2) acts to protect
8. Piston spring the torque converter from abnormally high pres-
9. Piston sure by relieving the circuit if the torque convert-
er inlet port pressure rises above the set
A. Drain port (for torque converter relief) pressure.
B. Drain port Unit: MPa {kg/cm2}
C. From pump
D. Drain port Set pressure
E. To torque converter Main relief pressure 3.07 {31.33}
P1. Main relief oil pressure detection port
P8. Torque converter relief oil pressure Torque converter relief pressure 0.84 {8.55}
detection port
D155AX-5 10-35
STRUCTURE AND FUNCTION MAIN RELIEF VALVE
Operation of main relief valve

• The oil from the power train pump passes
through the filter, enters port A of the main relief
valve, then passes through orifice a and enters
port B.
When the oil from the pump fills the circuit, the oil
pressure starts to rise.
• As the oil pressure in the circuit rises, the oil en-
tering port B pushes piston (4). The reaction
compresses spring (7), moves main relief valve
(6) to the left in the arrow direction, and opens
ports A and C.
Then, the oil from the pump is relieved from port
A to port C, then flows from port C to the torque
converter.
The oil pressure at port A at this point is 3.07
MPa {31.33 kg/cm2}
Operation of torque converter relief valve

• The oil relieved by the main relief valve flows
from port C to the torque converter, and at the
same time, passes through orifice b and enters
port D.
When the passage to the torque converter is
filled with oil, the oil pressure starts to rise.
• As the oil pressure to the torque converter rises,
the oil entering port D pushes piston (9). The re-
action compresses spring (3), moves relief valve
(2) to the right in the arrow direction, and opens
ports C and E.
Then, the oil from port C is relieved to port E and
is drained to the oil tank.
The oil pressure at port C at this point is 0.84
MPa {8.55 kg/cm2}.
10-36 D155AX-5
STRUCTURE AND FUNCTION LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
1. Forward clutch housing

2. Spring
3. Piston
A. From oil cooler

B. Drain
C. Drain
Outline
• The oil leaving the torque converter passes
through the oil cooler built in the radiator lower Unit: MPa {kg/cm2}
tank. It then goes through the lubrication relief
valve and lubricates the transmission and PTO. Set pressure
Pressure when normal 0.14 ± 0.05 {1.4 ± 0.5}

• The lubrication relief valve is installed to the right
side face of the forward clutch housing, and pre- Cracking pressure 0.30 ± 0.03 {3.0 ± 0.3}
vents any abnormal pressure in the lubricating
oil.
10-38 D155AX-5
STRUCTURE AND FUNCTION SCAVENGING PUMP STRAINER
SCAVENGING PUMP STRAINER
1. Scavenging pump (112) Outline

2. PTO drive gear • Scavenging pump (1) is driven by PTO drive
3. Pump drive gear gear (2). It acts to return the oil accumulated in
4. PTO case the transmission case to the steering case.
5. Strainer • The strainer is made of punched metal with 2-
mm diameter holes.
A. Scavenging pump suction port
B. Scavenging pump delivery port
D155AX-5 10-39
STRUCTURE AND FUNCTION POWER TRAIN PUMP STRAINER
POWER TRAIN PUMP STRAINER
1. Power train lubrication pump (rear)

(SAL(3)-100)
2. Power train pump (front) (SAL(3)-80)
3. Power train pump strainer assembly
3A. Magnet
3B. Strainer
Performance
3C. Shaft
Mesh size (µm) 149
A. From steering case
B. To power train pump Filtering area (cm2) 2,100
a The front pump indicates the pump at the Pressure resistance (MPa {kg/cm2}) 0.2 {2.0}
shaft mount end.
10-40 D155AX-5
STRUCTURE AND FUNCTION POWER TRAIN OIL FILTER
POWER TRAIN OIL FILTER
1. Power train oil filter assembly

1A. Cover
1B. Body
1C. Element
Performance
1D. Valve
1E. Spring Cracking
(MPa {kg/cm2}) 0.103 ± 0.02 {1.05 ± 0.2}
1F. Drain plug pressure
A. To transmission case Mesh size (µm) 30

B. From power train pump Filtering area (cm2) 10,026
Filter flow (l/min}) 169
D155AX-5 10-41
STRUCTURE AND FUNCTION HSS SYSTEM
HSS SYSTEM
10-42 D155AX-5
1. PCCS lever A. FORWORD REVERSE signal

2. Transmission, steering controller B. STEERING signal
3. Servo valve C. Control information
4. HSS pump D. CAN communication network
5. Engine E. Work equipment pressure signal
6. Work equipment pump F. Steering circuit pressure signal A
7. Work equipment control valve G. Steering circuit pressure signal B
8. Sprocket
9. Final drive
10. HSS motor
11. HSS closed circuit
12. Engine controller
Outline
• The HSS system is a hydrostatic system; HSS
stands for Hydrostatic Steering System.
• The HSS system consists of a set of piston pump
and piston motor as shown in the diagram. With
this system, it is possible to turn continuously by
generating a difference in speed between the left
and right tracks. There is no need to reduce
speed.
• The Transmission, steering controller controls
the angle of the swash plate in the HSS pump
according to the angle of operation of the PCCS
lever, and controls the speed and directional of
rotation of the HSS motor.
The HSS motor uses the planetary gear system
of the bevel gear shaft to create a difference in
the speed of the left and right sprockets, and this
turns the machine.
• The Transmission, steering controller detects
the speed of the engine and the hydraulic pres-
sure at all parts, and controls the swash plate an-
gle of the HSS pump to prevent the engine from
stalling.
• The engine control information such as the en-
gine speed is transmitted and received through
the CAN communication network between the
engine controller and transmission and steering
controller.
D155AX-5 10-43
ACTUATION OF HSS SYSTEM

1. PCCS lever at NEUTRAL and machine stopped
10-44 D155AX-5
D155AX-5 10-45
1. Hydraulic tank
2. Charge pump
3. HSS, PPC charge circuit filter
4. Accumulator
5. HSS, PPC charge circuit valve
6. Charge pressure sensor
7. HSS pump
7A. Suction safty valve
7B. Suction safty valve
7C. Charge safty valve
7D. Servo piston
7E. Solenoid B
7F. Solenoid A
7G.Servo valve
8. HSS motor
8A. Flashing shuttle valve
8B. Cooling shuttle valve
9. Pump, motor drain circuit block
9A. Charge relief valve
10. Hydraulic temperature sensor
11. Oil cooler bypass valve
12. Hydraulic oil cooler
13. HSS controller
14. PCCS lever (Steering)
U. To PCC valve
V. LEFT TURN
W. NEUTRAL
X. RIGHT TURN
Actuation when PCCS lever is at NEUTRAL and

machine is stopped
• When PCCS lever (14) is at NEUTRAL, there is • To ensure the suction performance of HSS pump
no electric signal from HMT controller (13) to (7), the charge pressure in the HSS charge cir-
HSS pump solenoids (7E) and (7F). Servo valve cuit is always detected by charge pressure sen-
(7G) and servo piston (7D) are both at neutral, sor (6), and feedback is sent to HSS controller
so the swash plate angle of HSS pump (7) is 0, (13).
and the delivery from ports PA or PB is also 0.
• The pressurized oil from charge pump (2) pass-

es through PPC, HSS charge valve (5) and en-
ters the charge circuit. The pressurized oil
entering port A is set to the maximum pressure
for the charge circuit 3.7MPa {38kg/cm2} by
charge safety valve (7C). When the HSS pump
is at neutral, all the oil flow is relieved from port
D, passes through oil cooler bypass valve (11)
and hydraulic cooler (12), and is drained to hy-
draulic tank (1).
10-46 D155AX-5
1. PCCS lever at FORWARD and left turn
10-47-1 D155AX-5
(1)
D155AX-5 10-47-2
(1)
PCCS lever at FORWARD and left turn

• When PCCS lever (14) is operated to FOR-
WARD and left turn, an electric signal flows from
HSS controller (13) to solenoid B (7E). Servo
valve (7G) and servo piston (7D) move in the di-
rection of the arrow, change the angle of the
swash plate of HSS pump (7) and pressure oil is
discharged from port PB.
• When oil is discharged from PB, the pressure at
port PA is low, so safety-suction valve (7B)
opens, and if there is insufficient oil in the HSS
closed circuit, oil is supplied from (7B).
• The pressure oil leaving PB enters port MB of
HSS motor (8) and rotates the HSS motor. The
return oil flows from port MA to port PA and cir-
culates inside the HSS closed circuit.
At the same time, the pressure oil from port F
moves shuttle valve (8A) in the direction of the
arrow, and low-pressure ports E and G open.
When this happens, the minimum pressure (18
kg/cm2) is maintained at the low-pressure side
by charge relief valve (9A), and the suction per-
formance of the HSS pump is ensured. The ex-
cess pressure oil is relieved from charge relief
valve (9A) to port H, passes through oil cooler
bypass valve (11) and hydraulic oil cooler (12),
and is drained to hydraulic tank (1).
• The relief pressure (11 kg/cm2) of charge relief
valve (9A) is lower than the relief pressure (28
kg/cm2) of charge safety valve (7C). As a result,
the charge pressure oil flowing into the HSS cir-
cuit is relieved from charge relief valve (9A).
10-48 D155AX-5
(1)
3. PCCS lever at travel FORWARD and right turn
10-50 D155AX-5
D155AX-5 10-51
PCCS lever at travel FORWARD and right turn

• When PCCS lever (14) is operated to FOR-
WARD and right turn, an electric signal flows
from HSS controller (13) to solenoid A (7F). Ser-
vo valve (7G) and servo piston (7D) move in the
direction of the arrow, change the angle of the
swash plate of HSS pump (7) and pressure oil is
discharged from port PA.
• When oil is discharged from PA, the pressure at
port PB is low, so safety-suction valve (7A)
opens, and if there is insufficient oil in the HSS
closed circuit, oil is supplied from port B.
• The pressure oil leaving PA enters port MA of
HSS motor (8) and rotates the HSS motor. The
return oil flows from port MB to port PB and cir-
culates inside the HSS closed circuit.
At the same time, the pressure oil from port E
moves shuttle valve (8A) in the direction of the
arrow, and low-pressure ports F and G open.
When this happens, the minimum pressure (18
kg/cm2) is maintained at the low-pressure side
by charge relief valve (9A), and the suction per-
formance of the HSS pump is ensured. The ex-
cess pressure oil is relieved from charge relief
valve (9A) to port H, passes through oil cooler
bypass valve (11) and hydraulic oil cooler (12),
and is drained to hydraulic tank (1).
• The relief pressure (11 kg/cm2) of charge relief
valve (8B) is lower than the relief pressure (28
kg/cm2) of charge safety valve (7C). As a result,
the charge pressure oil flowing into the HSS cir-
cuit is relieved from charge relief valve (9A).
10-52 D155AX-5
STRUCTURE AND FUNCTION HSS PUMP
HSS PUMP
Type: HPV160
1. Servo valve connector 5. Suction safety valve

2. Piston pump 6. Charge safety valve
3. Servo piston 7. Plug for measuring
4. Servo valve (PA and PB pump pressure)
Outline
• The pump is composed of variable displacement
piston pump with swash plate, servo valve, suc-
tion safety valve, and charge safety valve.
10-54 D155AX-5
1. PISTON PUMP
A. PSVO: Servo valve source pressure supply port

B. PD2 : Pump drain port
C. PB : Pump inlet and outlet port
D. PA : Pump inlet and outlet port
E. PC : Charge pressure supply port
F. PCD : Charge safety valve relief port
G. PSVA : Servo valve outlet port
H. PSVB : Servo valve outlet port
J. PSV1 : Servo valve source port
D155AX-5 10-55
1. Shaft 8. Piston
2. Case 9. Cylinder block
3. Cradle 10. Valve plate
4. Rocker cam 11. End cap
5. Servo piston 12. Bearing
6. Slider 13. Spline
7. Shoe 14. Bearing
Outline
• The rotation torque transmitted to the pump shaft • Rocker cam (4) has plane A, and shoe (7) is al-
is converted to hydraulic energy and pressurized ways pressed against this surface as it slides in
oil is discharged according to the load. a circle.
• It is possible to change the delivery amount (nor- Rocker cam (4) sends high pressure oil to the
mal delivery , 0 reverse delivery) by space between cylindrical surface B and cradle
changing the swash plate angle. (3) fixed to the case (2), to form a hydrostatic
bearing and carries out a rocking movement.
Structure • Piston (8) carries out motion relative to the axial
direction inside each cylinder chamber of cylin-
• Cylinder block (9) is supported to shaft (1) by a
der block (9).
spline (13), and shaft (1) is supported by front
• Cylinder block (9) carries out rotation relative to
and rear bearings (12) and (14).
valve plate (10) while sealing the pressurized oil,
• The end of piston (8) has a concave ball shape,
and this surface ensures that the hydraulic bal-
and shoe (7) is caulked to it to form one unit. Pis-
ance is maintained correctly. The oil inside each
ton (8) and shoe (7) form a spherical bearing.
cylinder chamber of cylinder block (9) is sucked
in and discharged through valve plate (10).
10-56 D155AX-5
Operation
1. Operation of pump
• Cylinder block (9) rotates together with shaft (1),
and shoe (7) slides on plane A.
When this happens, angle a of center line X of
rocker cam (4) to the axial direction of cylinder
block (9) changes. This angle a is called the
swash plate angle.
1) With swash plate angle a formed by the an-
gle between center line X of rocker cam (4)
to the axial direction of cylinder block (9),
plane A acts as a cam for shoe (7). In this
way, piston (8) slides inside cylinder block
(9), and as a result, a difference is generated
between volumes E and F inside the cylinder
block. The amount of suction and discharge
is equal to difference F - E.
In other words, cylinder block (9) rotates,
and the volume of chamber F becomes
smaller, so oil is discharged during this pro-
cess. At the same time, the volume of cham-
ber E becomes larger and oil is sucked in as
the volume increases.
2) When center line X of rocker cam (4) is the
same as the axial direction of cylinder block
(9) (swash plate angle = 0), the difference
between volumes E” and F” inside cylinder
block (9) is 0, so no oil flows in or out, and no
pumping is carried out.
3) With swash plate angle a formed by the an-
gle between center line X of rocker cam (4)
to the axial direction of cylinder block (9),
plane A acts as a cam for shoe (7). In this
way, piston (8) slides inside cylinder block
(9), and as a result, a difference is generated
between volumes E” and F” inside the cylin-
der block. The amount of suction and dis-
charge is equal to difference E” - F”.
In other words, cylinder block (9) rotates,
and the volume of chamber E” becomes
smaller, so oil is discharged during this pro-
cess. At the same time, the volume of cham-
ber F” becomes larger and oil is sucked in as
the volume increases. When the swash plate
angle changes, the suction/discharge action
of ports PA and PB is reversed.
D155AX-5 10-57
2. Control of discharge amount

1) If swash plate angle a becomes larger, the
difference between volumes E and F be-
comes larger, and oil delivery Q is increased.
Swash plate angle is changed by servo
piston (5).
Servo piston (5) carries out reciprocal move-
ment in a straight line ( ) according to the
command from the valve. This straight-line
movement is transmitted to rocker cam (4)
through slider (6), and rocker cam (4), which
is supported on the cylindrical surface by
cradle (2) slides on the cylindrical surface
( direction).
In the case of the pump, swash plate angle a
is a maximum of ±20°
10-58 D155AX-5
3. Servo valve
1. Connector 9. Spring
2. Solenoid valve B 10. Lever 2
3. Solenoid valve A 11. Body
4. Connector 12. Screw
5. Shaft 13. Arm
6. Coil 14. Spool
7. Base
8. Lever 1 A. PSV1 : Servo valve source port
B. PSVB : Servo valve output port
C. PSVA : Servo valve output port
D155AX-5 10-59
Actuation
1. When pressurized oil (servo source pressure)
does not enter from the charge pump or when
there is no current flowing to solenoid valve coil
(6), the servo valve and servo piston (15) are not
actuated.
10-60 D155AX-5
2. When the current flows to solenoid valve coil (6)

and coil is excited, solenoid propulsion force f1
is generated and shaft (5) pushes spool (14) to
the right in the direction of the arrow. Lever 2
(10), which is interconnected with spool (14),
uses screw (12) as a fulcrum and rotates clock-
wise while pulling spring (9).
3. When spool (14) moves, the passages between
ports A and B and ports C and D open, and pres-
surized oil from the charge pump passes through
ports A and B and flows to port F of servo piston
(15).
At the same time, the oil at port G passes
through ports D and E, and is drained.
D155AX-5 10-61
4. Servo piston (15) is moved to the right in the di-

rection of the arrow by the pressurized oil enter-
ing port F, and the swash plate angle of the
variable pump becomes larger by an amount
equal to stroke a of the servo piston. At the same
time, arm (13), which is connected to servo pis-
ton (15) rotates arm (13) around screw (12) as a
fulcrum, and lever 1 (8) is moved to the left.
Servo piston (15) stops in a position where sole-
noid propulsion force f1 is balanced with spring
force f2.
10-62 D155AX-5
5. The stroke of the servo piston, which changes

the delivery amount of the variable pump, is con-
trolled by the servo valve.
The relationship between the stroke of the servo
piston and the current of the solenoid valve is as
shown in the diagram.
D155AX-5 10-63
4. Suction safety valve
1. Charge pump 5D. Poppet

2. HSS pump 5E. Valve seat
3. Oil cooler 5F. Spring
4. Charge safety valve 5G.Pressure adjustment screw:
5. Suction safety valve one turn adjusts pressure by approx.
5A. Valve 13.7 MPa {140kg/cm2}
5B. Piston 6. HSS motor
5C. Sleeve
Function
• There are two suction safety valves installed to
the HSS pump, and they have the following func-
tions.
1. High pressure relief valve
The valve restricts the maximum pressure
inside the HSS circuit in order to protect the
HSS circuit and to restrict the maximum
drawbar pull of the machine.
2. Suction safety valve
The valve ensures the flow of charge oil to
the HSS circuit and prevents the charge oil
from flowing into the pump high pressure
side (delivery side).
10-64 D155AX-5
Actuation when acting as high pressure relief

valve
(Valve at piston pump delivery side)
• Port A is connected to the piston pump circuit
and port B is connected to the charge circuit.
The pressurized oil also fills port C through drill
hole a in piston (5B). In addition, poppet (5D) is
in tight contact with valve seat (5E).
• If abnormal pressure is generated in the piston

pump circuit and the oil pressure at port A and C
reaches the pressure set by spring (5F), poppet
(5D) is pushed to the right in the direction of the
arrow, and the oil at port C is relieved from port
D to port B to reduce the oil pressure at port C.
• When the oil pressure at port C goes down, a dif-

ferential pressure is generated between port A
and port C by orifice b in piston (5B). Valve (5A)
is pushed to the right in the direction of the arrow
by the oil pressure at port A, and the oil at port A
is relieved to port B.
In this way, the piston pump circuit is prevented
from reaching any higher pressure.
D155AX-5 10-65
Operation when acting as suction safety valve
1. When HSS pump delivery is 0

• The HSS circuit is closed, and the charge pres-
sure oil does not flow into the HSS circuit.
Therefore, the charge pressure oil from the
charge pump all passes through charge safety
valve (4) and is drained through oil cooler (3) to
the tank.
2. When HSS pump delivery is discharged from

port PA
1) Valve at piston pump delivery side
• When pressure oil is discharged from
port PA of HSS pump (2), port PA be-
comes the high pressure side. This
pressure oil at port PA passes through
drill hole a in piston (5B) and flows to port
A.
When this happens, valve (5A) is pushed
to the left in the direction of the arrow
against sleeve (5C) because of the dif-
ference in area (A1>A2). Therefore, the
pressure oil from charge pump (1) is pre-
vented from flowing into the HSS closed
circuit.
10-66 D155AX-5
2) Valve at piston pump suction side

• Port PB becomes the suction side, so it
becomes the low pressure side. Be-
cause of the difference in area (A1>A2),
valve (5A) is pushed to the right in the di-
rection of the arrow by the charge pres-
sure oil and the seat of sleeve (5C)
opens.
As a result, the charge pressure oil at
port B passes through the gap and flows
to port PB to carry out the charge func-
tion for the HSS circuit.
D155AX-5 10-67
3. Charge safety valve
1. Charge pump 4C. Valve seat

2. HSS pump 4D. Poppet
3. Oil cooler 4E. Spring
4. Charge safety valve 4F. Pressure adjustment screw
4A. Valve 5. Suction safety valve
4B. Spring 6. HSS motor
Function
• The charge safety valve is installed to the HSS
pump between the suction safety valve and the
oil cooler. It acts to restrict the maximum pres-
sure in the charge circuit.
Set pressure: 3.7 MPa {38 kg/cm2} at 204 l/min
10-68 D155AX-5
Operation
• Port A is connected to the charge circuit, and
port B is connected to the tank drain circuit. The
pressure oil passes through orifice a in valve
(4A) and fills C. Poppet (4D) is in tight contact
with valve seat (4C).
• If abnormal pressure is generated in the circuit or

the shuttle valve of the HSS motor is at neutral,
and the pressure oil at ports A and C reaches the
pressure set by spring (4E), poppet (4D) is
pushed to the right in the direction of the arrow,
and the oil at C is relieved to port D to reduce the
pressure of the oil at C.
• When the pressure of the oil at port C goes

down, a differential pressure is created between
ports A and C because of orifice a in valve (4A).
Valve (4A) is pushed to the right in the direction
of the arrow by the oil pressure at port A, and the
oil at port A is relieved to port B.
In this way, the pressure in the charge circuit is
prevented from going any higher.
• Drain port D at the poppet portion is drained to

the HSS pump case, so the back pressure of
drain port B is not added to the charge relief
pressure, and the valve always displays the set
relief characteristics.
D155AX-5 10-69
STRUCTURE AND FUNCTION HSS MOTOR
HSS MOTOR
Type: HMF140
1. PISTON MOTOR
1. HSS motor Outline

2. Flashing shuttle valve • Motor is composed of fixed capacity, fixed swash
3. Bypass valve plate type piston motor, flashing shuttle valve,
4. Charge relief valve bypass valve and charge relief valve.
A. MB : From HSS pump

Specifications
B. MA : From HSS pump
C. T : To hydraulic tank Type HMF140
D. P : From pivot turn solenoid
E. C : From charge pump Theoretical displacement (cm3/rev) 140
F. CB : Pressure sensor mounting port Rated output pressure MPa {kg/cm2} 41.2{420}
G. CD : To hydraulic tank
H. CA : Pressure sensor mounting port Rated speed (rpm) 2,200
10-70 D155AX-5
1. Output shaft 10. Flashing shuttle valve

2. Motor case 11. Bypass valve
3. Swash plate 12. Spool return spring
4. Piston 13. Plug
5. Cylinder block 14. Charge relief valve
6. Valve plate 15. Bearing (rear)
7. End cover 16. Spline
8. Cover 17. Shoe
9. Spool return spring 18. Bearing (front)
Outline
Pressurized oil sent from pump is converted to rota-
tion energy and is transmitted to output shaft.
Structure
• Cylinder block (5) is supported to shaft (1) by a • Cylinder block (5) carries out rotation relative to
spline (16), and shaft (1) is supported by front valve plate (6) while sealing the pressurized oil,
and rear bearings (18) and (15). and this surface ensures that the hydraulic bal-
• The end of piston (4) has a concave ball shape, ance is maintained correctly. The oil inside each
and shoe (17) is caulked to it to form one unit. cylinder chamber of cylinder block (5) is sucked
• Piston (4) and shoe (17) form a spherical bear- in and discharged through valve plate (6).
ing.
• Piston (4) carries out motion relative to the axial
direction inside each cylinder chamber of cylin-
der block (5).
D155AX-5 10-71
Operation
1. Operation of motor
• The pressurized oil sent from the pump en-
ters cylinder block (5) and pushes piston (4)
from the back face.
In the case of the motor, the center line of
plate (3) is always at an angle (swash plate
angle to the axial direction of cylinder
block (5). As a result, if we take the example
of one of pistons (4), oil pressure is applied
to the back face of the right, and piston axial
force FO is generated.
• With shoe (15), which is joined to piston (4)
by the spherical surface, reaction force FR in
a direction at right angles to plane A is gen-
erated. The combined force of FO and FR is
FP, and this becomes the force to rotate cyl-
inder block (5).
• Shaft (1), which is meshed to cylinder block
(5) by spline (14) transmits this rotation
torque to the output side. Cylinder block (5)
rotates, and while the condition changes
from volume E to volume F, pressurized oil
from the pump flows into the cylinder cham-
ber, and pressure P is generated according
to the load. On the other hand, when the
condition goes beyond volume F and chang-
es to volume E, the oil is pushed out and re-
turned to the pump.
2. Rotation speed and torque control

• As flow Q from the HSS pump is increased,
motor speed N is heightened.
Q = qN Q: Total flow
• Since the swash plate angle of the HSS mo-
(q = E – F) q: Flow per 1 turn
tor is fixed ( is constant), torque T is pro-
N: Rotation speed
portional to pressure P. Pq
T = ------- P: Pressure
• Swash plate angle is 19°. 2π
T: Rotating torque
10-72 D155AX-5
3. Flushing shuttle valve

Function
• The shuttle valve acts to switch the shuttle valve
spool according to the pressurized oil in the HSS
high-pressure circuit, and to return the oil in the
HSS low-pressure circuit through the oil cooler to
the tank. The shuttle valve is installed to the HSS
motor assembly.
Operation
1. When HSS pump swash plate angle is at neu-
tral position
• The swash plate angle of the pump is at the neu-
tral position, so the delivery from HSS pump (2)
is 0. When this happens, the same oil pressure
is applied to ports A and B at both ends of shuttle
valve spool (7), so spool (7) remains at the neu-
tral position.
• When this happens, the relationship of the set
pressure of charge relief valve (8) is as follows.
Set pressure of Set pressure of
charge safety valve > charge relief valve
(4) (8)
• As a result, the pressurized oil from charge
pump (1) flows from port C of the motor through
charge relief valve (8), where the set pressure is
lower. It is then relieved and drained from oil
cooler (3) to the tank.
2. When HSS pump is discharging oil from port

PA
• The pressurized oil from HSS pump (2) enters
port MA from port PA, passes through orifice a of
shuttle valve spool (7), then enters port A. Spool
(7) is pushed to the right by the pressurized oil at
port A, so the passage between ports MB and D
is opened and the oil is connected to charge re-
lief valve (8).
pressure of charge relief valve is as follows.
charge safety valve
(4)
> charge relief valve
(8)
pump (1) flows from port D through charge relief
valve (8), where the set pressure is lower.
It is then relieved and is drained from oil cooler
(3) to the tank.
D155AX-5 10-73
3. When HSS pump is discharging oil from port

PB
• The pressurized oil from HSS pump (2) enters
port MB from port PB, passes through orifice b
of shuttle valve spool (7), then enters port B.
Spool (7) is pushed to the left by the pressurized
oil at port B, so the passage between ports MA
and E is opened and the oil is connected to
charge relief valve (8).
pressure of charge relief valve (8) is as follows.
charge safety valve > charge relief valve
(4) (8)
pump (1) flows from port E through charge relief
valve (8), where the set pressure is lower.
It is then relieved and drained from oil cooler (3)
to the tank.
10-74 D155AX-5
4. Charge relief valve
1. Charge pump 8. Charge relief valve

2. HSS pump 8A. Valve
3. Oil cooler 8B. Spring
4. Charge safety valve 8C. Valve seat
5. Suction safety valve 8D. Poppet
6. HSS motor 8E. Spring
7. Shuttle valve 8F. Pressure adjustment screw
8G. Filter
Function
• The charge relief valve is installed to the HSS
motor. It maintains the minimum pressure on the
low pressure side of the circuit to secure the suc-
tion performance of the HSS pump.
a Set pressure:
2.3 MPa {23 kg/cm2} (at 120 l/min)
D155AX-5 10-75
Operation
• While the HSS pump is discharging oil through
port PA or PB, the oil on the low pressure side of
the HSS circuit flows through port MA or MB and
shuttle valve (7) to inlet port A of charge relief
valve (8).
• The oil in port A also fills port C through orifice a

of valve (8A). At this time, poppet (8D) is fitted
to valve seat (8C).
• If the oil pressure in port C rises to the level set

with spring (8E), poppet (8D) is pushed to the left
and the oil in port C is relieved to port D, thus the
oil pressure in port C lowers.
• If the oil pressure in port C lowers, differential

pressure is generated between ports A and C
because of orifice a. As a result, valve (8A) is
pushed to the left and the oil in port A is relieved
to port B.
By this operation, the oil pressure in the charge
circuit is kept at the set pressure of charge relief
valve (8). This charge pressure keeps supplying
the oil to the closed HSS circuit.
• Since drain port D of the puppet is joined to the

drain part of the HSS motor, the back pressure
on drain port B is not added to the charge relief
pressure and the specified relief characteristics
are maintained.
10-76 D155AX-5
STRUCTURE AND FUNCTION COOLING FAN PUMP
COOLING FAN PUMP

Type: LPV45
A. PEPC : EPC valve source pressure inlet port DC: Delivery

B. P1 : Pump discharge port SC: Suction
C. PAEPC : EPC output pressure detection plug
D. TO : Drain port
E. PS : Pump suction port
10-78 D155AX-5
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D155AX-5 10-79
Function
• The rotation and torque of the engine are trans- • Piston (6) in each cylinder of cylinder block (7)
mitted to the shaft of this pump and converted moves relatively in the axial direction.
into hydraulic energy in this pump. This pump • Cylinder block (7) rotates relatively against valve
discharges the pressurized oil according to the plate (8), sealing the pressurized oil, and the hy-
load. draulic balance is maintained properly.
• The discharge of this pump can be changed by • The oil in each cylinder of cylinder block (7) can
changing the swash plate angle in it. be sucked and discharged through valve plate
(8).
Structure
• Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported by the
front and rear bearings.
• The end of piston (6) has a concave ball shape,
and shoe (5) is caulked to it to form one unit. Pis-
ton (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slid circularly.
Rocker cam (4) slides around ball (11).
10-80 D155AX-5
Operation
1. Operation of pump
• Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane A. At this time,
rocker cam (4) tilts around ball (11). As a result,
angle between center line X of rocker cam (4)
and the axis of cylinder block (7) changes. Angle
is called the swash plate angle.
• If angle is made between center line X of
rocker cam (7) and the axis of cylinder block (7),
plane A works as a cam for shoe (5).
• Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between vol-
umes E and F in cylinder block (7). As a result,
each piston (6) sucks and discharges oil by F - E.
• In other words, if cylinder block (7) rotates and
the volume of chamber E is decreased, the oil is
discharged from chamber E. On the other hand,
the volume of chamber F is increased and the oil
is sucked in chamber F. (In the figure, chamber
F is at the end of the suction stroke and chamber
E is at the end of the discharge stroke.)
• If center line X of rocker cam (4) is equal to the
axial of cylinder block (7) (the swash plate angle
is 0), there is not a difference between volumes
E and F in cylinder block (7) and oil is not sucked
or discharged. (The swash plate angle is not set
to 0 actually, however.)
• In short, swash plate angle is in proportion to
the pump discharge.
D155AX-5 10-81
2. Control of discharge
• If swash plate angle is increased, the differ-
ence between volumes E and F is increased, or
discharge Q is increased. Swash plate angle
is changed with servo piston (10).
• Servo piston (10) reciprocates straight according
to the signal pressure of the servo valve. This
straight motion is transmitted to rocker cam (4).
Then, rocker cam (4) supported on ball (11)
slides around ball (11).
10-82 D155AX-5
Servo valve
A. P: EPC valve source pressure port

B. PE: Control piston pressure port
C. PH: Pump discharge port
D. T: Drain port
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D155AX-5 10-83
Function
• The servo valve controls the current input to the • The relationship between the input current to the
EPC valve and the swash plate angle of the EPC valve and the output pressure of the EPC
pump so that they will be related as shown in the valve is as follows.
figure.
10-84 D155AX-5
Operation
• The output pressure of the EPC valve is applied
to the piston chamber to push the piston (6). Pis-
ton (6) pushes spool (5) until it is balanced with
the spring.
• Then, the land of the servo piston pressure pas-
sage is connected to the pump discharge pas-
sages by the cut of spool (5) and the discharge
pressure is led to the servo piston.
• The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
• If spool (5) is pushed back, the pump discharge
circuit and the servo piston circuit are shut off.
The pressure in the servo piston chamber lowers
and the rocker cam returns toward the maximum
swash plate angle.
• These processes are repeated until the swash
plate is fixed to a position where the EPC output
is balanced with the spring force.
• Accordingly as the EPC output pressure is
heightened, the swash plate angle is decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
D155AX-5 10-85
STRUCTURE AND FUNCTION COOLING FAN MOTOR
COOLING FAN MOTOR

Type: LMF55
A. P : From fan pump

B. TC : To tank
C. T : From oil cooler to tank
Specifications
Type: LMF55
Capacity: 55 cm3/rev
Rated speed: 1,200 rpm
Rated flow rate: 66 l/min
Cracking pressure of check valve:
76.5 kPa {0.78 kg/cm2}
10-86 D155AX-5
1. Output shaft 11. Check valve

2. Case 12. Pilot valve
3. Thrust plate 13. Reversible valve spool
4. Shoe 14. Safety valve
5. Piston 15. Reversible valve spring
6. Cylinder block
7. Valve plate
8. End cover
9. Center spring
10. Check valve spring
D155AX-5 10-87
1. Hydraulic motor unit

Function
• This hydraulic motor is called a swash plate-type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
Principle of operation
• The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only 1 side of the Y-Y line
connecting the top dead center and bottom dead
center of the stroke of piston (4).
• The oil sent to 1 side of cylinder block (5) press-
es pistons (4) (4 or 5 pieces) and generates
force F1 (F1 kg = P kg/cm2 x x/4D2 cm2).
• This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of degrees
to the output shaft (1), the force is divided into
components F2 and F3.
• The radial component F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = (F3 x ri)] ro-
tates the cylinder block (5) through the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
revolves to transmit the torque.
10-88 D155AX-5
2. Suction valve
Function
• If the fan pump stops, the hydraulic oil does not
flow into the motor. Since the motor continues
revolution because of the force of inertia, howev-
er, the pressure on the outlet side of the motor
rises.
• When the oil stops flowing in from inlet port P, the
suction valve sucks in the oil on the outlet side
and supplies it to the port MA where there is not
sufficient oil to prevent cavitation.
Operation
1. When pump is started
• If the hydraulic oil from the pump is supplied to
port P and the pressure on the MA side rises and
starting torque is generated in the motor, the mo-
tor starts revolution. The oil on the outlet MB
side of the motor returns through port T to the
tank.
2. When pump is stopped

• If the engine is stopped and the input revolution
of the fan pump lowers to 0 rpm, the hydraulic oil
from the pump is not supplied to port P any
more. As the hydraulic oil is not supplied to the
MA side of the motor, the motor speed lowers
gradually to stop.
• If the motor shaft is revolved by the force of iner-
tia while the oil flow in the port P is reducing, the
oil in port T on the outlet side is sent by the suc-
tion valve to the MA side to prevent cavitation.
D155AX-5 10-89
3. OPERATION OF REVERSIBLE VALVE
1) When ON-OFF solenoid for reversible 2) When ON-OFF solenoid for reversible
valve is turned OFF valve is turned ON
• If ON-OFF solenoid (1) for reversible valve is • If ON-OFF solenoid (1) for reversible valve is
turned "OFF", the hydraulic oil from the turned "ON", ON-OFF reversible valve (2)
pump is blocked by ON-OFF reversible valve changes to let the hydraulic oil from the
(2) and port C is connected to the tank cir- pump flow through port C into spool chamber
cuit. D.
• Accordingly, reversible valve spool (3) is • The hydraulic oil in chamber D pushes re-
pushed by reversible valve spool spring (4) versible valve spool (3) against reversible
to the right to open motor port MA and then valve spool spring (4). As a result, motor port
the hydraulic oil flows in to revolve the motor MB opens and the hydraulic oil flows in to re-
forward (clockwise). volve the motor in reverse (counterclock-
wise).
10-90 D155AX-5
4. Safety valve
Function
• When the engine is started, the pressure in port
P of the fan motor is heightened in some cases.
• Safety valve (1) is installed to protect the fan sys-
tem circuit.
Operation
• If the pressure in port P rises above the cracking
pressure of safety valve (1), valve (2) of safety
valve (1) opens to release the hydraulic oil into
port T.
• By this operation, generation of abnormal pres-
sure in port P is prevented.
D155AX-5 10-91
STRUCTURE AND FUNCTION HSS CHARGE FILTER BYPASS VALVE
HSS CHARGE FILTER BYPASS VALVE
C. To HSS motor, HSS pump Outline

P. Charge filter outlet When the difference between the charge inlet pres-
P1. Charge filter inlet sure and charge outlet pressure is increased, the
T. To hydraulic tank HSS charge filter bypass valve drains the oil into the
tank without sending it to the HSS charge circuit.
(Cracking differential pressure:
490 ± 98 kPa {5 ± 1 kg/cm2})
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between filter bypass size Shaft Hole clearance limit
1
valve and valve body
– 0.035 + 0.013 0.035–
28 0.08
– 0.045 0 0.058
Clearance between filter bypass – 0.020 + 0.018 0.020–
2 15 0.06
valve and piston – 0.030 0 0.048 Replace
Standard size Repair limit
Installed Installed Installed
3 Filter bypass valve spring Free length Free length
length load load
71.15N
70.3 64.3 – –
{7.26kg}
10-92 D155AX-5
STRUCTURE AND FUNCTION HSS OIL COOLER BYPASS VALVE
HSS OIL COOLER BYPASS VALVE
1. Plug A. From charge relief valve

2. Valve B. To hydraulic tank
3. Shim C. From oil cooler
4. Plug D. To oil cooler
5. Spring E. From charge safety valve
6. Body
Outline
• This valve is installed in the circuit between the
HSS pump and HSS motor charge relief valve oil
return circuit and the oil cooler. If any abnormal
pressure is generated in the oil flowing to the oil
cooler, this valve acts to return the oil directly to
the hydraulic tank.
Set pressure
Cracking pressure {MPa (kg/cm2)} 0.42 {4.27}
D155AX-5 10-93
STRUCTURE AND FUNCTION STEERING BRAKE CONTROL
STEERING BRAKE CONTROL

• Regarding the transmission-related description
of the operation of the PCCS lever, see TRANS-
MISSION CONTROL.
• PCCS: Palm Command Control System
10-94 D155AX-5
STRUCTURE AND FUNCTION STEERING BRAKE CONTROL
1. Brake pedal
2. Safety lever
3. Brake valve
4. PCCS lever (Steering)
5. Limit switch
6. Transmission, steering controller
7. Cable
8. Rod (From brake pedal)
9. Potentiometer
Positions of levers and pedals

A. Neutral
B. Forward straight
C. Reverse straight
D. Left turn
E. Right turn
F. Brake OFF
G. Brake ON
H. Free
J. Lock
Outline
• PCCS lever (4) sends electric signals to trans-
mission, steering controller (6). Upon receiving
those signals, transmission, steering controller
(6) sends signals to servo valve of HSS pump to
changes the discharge of the pump to operate
the steering motor.
• Brake pedal (1) operates the brake through rod
(8) and brake valve (3).
• Safety lever (2) is connected to brake valve (3)
and used as the parking brake, too.
D155AX-5 10-95
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, HSS, BRAKE
BEVEL GEAR SHAFT, HSS, BRAKE
10-96 D155AX-5
D155AX-5 10-97
10-98 D155AX-5
1. Cover
2. Output shaft
3. Bearing cage
4. Spring
5. Brake piston
6. Brake plate (4 on each side)
7. Brake disc (5 on each side)
8. Brake outer drum
9. Brake inner drum
10. Nut
11. Bearing A
12. Shim (for adjusting preload of bevel gear)
13. Bevel gear shaft
14. Bevel gear (35 teeth)
15. Bearing B
16. Carrier
17. Ring gear
18. Planet pinion gear
19. Hub
20. Sun gear
21. Shim (for adjusting bevel pinion gear)
22. Bearing cage
23. Bearing
24. Nut (for adjusting preload of bearing)
25. Bevel pinion gear (21 teeth)
26. Gear E (for right sun gear drive)
27. Gear D
28. Shaft
29. HSS motor
30. Pinion gear
31. Gear A
32. Gear C
33. Gear B (for left sun gear drive)
D155AX-5 10-99
Outline Brake
Bevel gear shaft • The brakes are installed to carry out braking of
• With the bevel gear shaft, the power output from the machine, and are interconnected with brake
the transmission has its rotating speed reduced inner drum (9).
and is sent at right angles to the left and right by • The brake is a wet type, multiple disc clutch,
the meshing of the bevel pinion and bevel gear. spring boosted type, and is hydraulically operat-
• The bevel gear shaft system employs spiral bev- ed using pressurized oil from the brake valve,
el gears for the bevel pinion and bevel gear, and which is interconnected with the brake pedal.
employs a forced lubrication system using pres- • The lubrication is a forced lubrication type using
surized oil. oil from the oil power train lubrication pump cir-
• The bevel gear shaft system consists of bevel cuit, which passes through the housing and
gear (14), which is meshed with bevel pinion cage, and is sent to the discs and plates.
(25), bevel gear shaft (13), and bearings (11) • The brake consists of brake inner drum (9)
and (15), which support the bevel gear shaft. (which is interconnected with carrier (16) and
brake outer drum (8)), disc (7), plate (6), brake
HSS outer drum (8), piston (5), spring (4), bearing
cage (3), which support these, brake cover (1),
• The HSS (Hydrostatic Steering System) consists
and output shaft (2).
of a transfer portion, which reverses the direction
Brake outer drum (8) and brake cover (1) are
of the rotation of HSS motor (29) on the left and
fixed to the HSS case.
right and transmits it to sun gear (20), and a
Output shaft (1) is connected to brake inner
planetary gear system, which increases or de-
drum (9) by a spline.
creases the speed of the input, and then outputs
• When the engine stops, the back pressure of the
it.
brake piston drops, so the brake is automatically
The direction of steering of the machine is
applied. However, it is dangerous if the brake is
changed by stopping the rotation of the HSS mo-
released when the engine is started again and
tor or by changing the direction of rotation from
the pressure in the circuit rises, so when the
the normal direction to the reverse direction.
parking the machine, always place the parking
• The transfer portion uses a spur gear reduction
brake at the LOCK position.
mechanism.
• A forced lubrication system using the oil from the
power train lubrication pump is employed for lu-
bricating the transfer.
• A forced lubrication system using the oil from the
power train lubrication pump is employed for lu-
bricating the planetary gear.
• The transfer portion consists of HSS motor pin-
ion (30), gear A (31), gear C (32), shaft (28),
gear D (27), gear E (26), gear B (33), and cover
(1), which supports these.
• The planetary gear consists of sun gear (20),
planet pinion (18), hub (19), and carrier (16)
(which is interconnected with brake inner drum
(9)).
10-100 D155AX-5
Flow of power for HSS
• The power from the transmission passes power from the transmission at the planetary
through bevel pinion gear (25) and bevel gear gear portion, and is transmitted from carrier (16)
(14), and is transmitted to bevel gear shaft (13). to output shaft (2).
It then goes from bevel gear shaft (13) through The power sent to the right is transmitted from
hub (19), ring gear (17), carrier (16), and brake gear A (31) through gear C (32), gear D (27), and
inner drum (9), and is transmitted to left and right gear E (26) to right sun gear (20) in order to re-
output shafts (2). verse the rotation of the power from the HSS mo-
• When the steering is operated, HSS motor (29) tor. (The flow of power beyond this point is the
rotates and the power is transmitted from pinion same as on the left side.)
gear (30) to gear A (31), where it is divided to the • The braking force is applied by braking the rota-
left and right. tion of inner drum (9) (which is interconnected
The power sent to the left is transmitted from with carrier (16)) at brake outer drum (8), which
gear A (31) to gear B (33), sun gear (20), and is fixed to the HSS case.
planet pinion gear (18). It is combined with the
D155AX-5 10-101
OPERATION OF HSS
1. When PCCS lever is at NEUTRAL

Traveling straight forward
Transmission output speed Transmission output speed

Left bevel gear shaft output speed Right bevel gear shaft output speed
a The direction of rotation of the HSS motor and In this condition, the power from bevel gear shaft
gears is as seen from the left side of the ma- (14) is input to hub (20), passes through ring gear
chine. (18) and planet pinion (19), and is transmitted to car-
rier (17). It then passes through brake inner drum
Traveling straight forward (10), which forms one unit with the carrier, and is
When the PCCS lever is at the NEUTRAL position, transmitted to output shaft (2).
HST motor (30), and transfer gear (33) and left and Therefore, the left and right output speeds are the
right sun gears (21) of the planetary gear portion, same and the machine travels in a straight line.
which are interconnected with the HSS motor, are
stopped.
10-102 D155AX-5
• Direction of rotation of HSS motor
Turn Left turn Right turn Neutral

PCCS
lever Travel
Neutral Forward Reverse Neutral Forward Reverse All
direction
Direction of
Counter- Counter- Clock- Clock- Clock- Counter-
rotation of Stopped
clock- clock- wise wise wise clock-
HSS motor
wise wise wise
Counter-rotation turn
D155AX-5 10-103
2. PCCS lever operated to RIGHT TURN

Forward
Transmission output speed Transmission output speed : Transmission power

Acceleration from HSS motor Deceleration from HSS motor : HSS motor power
Left bevel gear shaft output speed Right bevel gear shaft output : Combined power
( + ) speed ( - )
When the machine is traveling forward, bevel gear This rotation acts on the left and right planetary gear
shaft (13) and hub (19), which is connected to it, ro- mechanisms. The speed of carrier (16) on the left is
tate clockwise. accelerated from the speed when traveling in a
If the PCCS lever is operated to the RIGHT TURN straight line by the amount of the power from the
position when the machine is traveling forward, HSS HSS motor. On the other hand, the speed of carrier
motor (29) rotates clockwise, the rotation passes (16) on the right is decelerated from the speed when
through gear A (31), and gear B (33) on the left side traveling in a straight line, so a difference in rotation
of the machine rotates clockwise, while gear E (26) is generated in the output on the left and right. The
on the right side of the machine is rotated counter- output speed on the right is lower, so as a result, the
clockwise by gear C (32). In other words, the rota- machine travels forward and turns to the right.
tion of the HSS motor is transmitted to sun gears
(20) as rotation in opposite directions on the left and
right by the transfer portion.
10-104 D155AX-5
Reverse

( + ) speed ( - )
When the machine is traveling in reverse, bevel gear This rotation acts on the left and right planetary gear
shaft (13) and hub (19), which is connected to it, ro- mechanisms. The speed of carrier (16) on the left is
tate counterclockwise. accelerated from the speed when traveling in a
If the PCCS lever is operated to the RIGHT TURN straight line by the amount of the power from the
position when the machine is traveling in reverse, HSS motor. On the other hand, the speed of carrier
HSS motor (29) is rotated counterclockwise in the (16) on the right is decelerated from the speed when
opposite direction from when traveling forward by traveling in a straight line, so a difference in rotation
the function of the HSS controller. The rotation pass- is generated in the output on the left and right. The
es through gear A (31), and gear B (33) on the left output speed on the right is lower, so as a result, the
side of the machine rotates counter-clockwise, while machine travels in reverse and turns to the right.
gear E (26) on the right side of the machine is rotated
clockwise by gear C (32). In other words, the rotation
of the HSS motor is transmitted to sun gears (20) as
rotation in opposite directions on the left and right by
the transfer portion.
D155AX-5 10-105
3. PCCS lever operated to LEFT TURN

Forward

( + ) speed ( - )
When the machine is traveling forward, bevel gear This rotation acts on the left and right planetary gear
shaft (13) and hub (19), which is connected to it, ro- mechanisms. The speed of carrier (16) on the right
tate clockwise. is accelerated from the speed when traveling in a
If the PCCS lever is operated to the LEFT TURN po- straight line by the amount of the power from the
sition when the machine is traveling forward, HSS HSS motor. On the other hand, the speed of carrier
motor (29) rotates counterclockwise, the rotation (16) on the left is decelerated from the speed when
passes through gear A (31), and gear B (33) on the traveling in a straight line, so a difference in rotation
left side of the machine rotates counterclock-wise, is generated in the output on the left and right. The
while gear E (26) on the right side of the machine is output speed on the left is lower, so as a result, the
rotated clockwise by gear C (32). In other words, the machine travels forward and turns to the left.
rotation of the HSS motor is transmitted to sun gears
(20) as rotation in opposite directions on the left and
right by the transfer portion.
10-106 D155AX-5
Reverse

( + ) speed ( - )
When the machine is traveling in reverse, bevel gear This rotation acts on the left and right planetary gear
shaft (13) and hub (19), which is connected to it, ro- mechanisms. The speed of carrier (16) on the right
tate counterclockwise. is accelerated from the speed when traveling in a
If the PCCS lever is operated to the LEFT TURN po- straight line by the amount of the power from the
sition when the machine is traveling in reverse, HSS HSS motor. On the other hand, the speed of carrier
motor (29) is rotated clockwise in the opposite direc- (16) on the left is decelerated from the speed when
tion from when traveling forward by the function of traveling in a straight line, so a difference in rotation
the HSS controller. The rotation passes through is generated in the output on the left and right. The
gear A (31), and gear B (33) on the left side of the output speed on the left is lower, so as a result, the
machine rotates clockwise, while gear E (26) on the machine travels in reverse and turns to the left.
right side of the machine is rotated counterclockwise
by gear C (32). In other words, the rotation of the
HSS motor is transmitted to sun gears (20) as rota-
tion in opposite directions on the left and right by the
transfer portion.
D155AX-5 10-107
Operation of brake
1. Brake released
When the brake pedal is at the RELEASED po-
sition, the brake valve is also at the NEUTRAL
position, so oil flows to back pressure port A of
brake piston (5).
When the oil pressure rises, the piston is pushed
to the left in the direction of the arrow, compress-
es spring (4), and releases the pressure pushing
disc (7) and plate (6) into tight contact. When
this happens, the power transmitted from bevel
gear shaft (13) through the HSS to brake inner
drum (9) is transmitted to output shaft (2), and is
then transmitted to the final drive.
2. Brake applied (brake pedal depressed)

When the brake pedal is depressed, the brake
valve is switched, and the oil at port A, which
was applying back pressure to piston (5), is con-
nected to the drain circuit.
In this condition, piston (5) is pushed to the right
in the direction of the arrow by the tension of
spring (4), so disc (7) and plate (6) are brought
into tight contact with the stopper of brake outer
drum (8). The brake outer drum is joined to the
HSS case and is locked in position.
Therefore, the rotation of brake inner drum (9) (in
other words, output shaft (2) is braked when the
disc and plate are brought into tight contact.
By adjusting the amount the brake pedal is de-
pressed, it is possible to adjust the hydraulic
pressure applied to piston (5), thereby adjusting
the braking force.
10-108 D155AX-5
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
1. Main brake lever 8. Piston T2: Drain

2. Parking brake lever 9. Spring (small) BR:To brake piston
3. Plug 10. Spring (large) P: From power train pump
4. Body 11. Shaft (main brake) T1: Drain
5. Spring 12. Shaft (parking brake)
6. Seat 13. Spring
7. Brake valve 14. Plug
Outline
• The brake valve is in the circuit between the
power train pump through the main relief valve
and the brake piston inside the HSS unit. It con-
sists of the main brake valve, parking brake
valve, and solenoid valve.
• When the brake pedal is depressed, the pressur-
ized oil flowing to the brake piston is shut off, so
the brake piston pushes the disc and plate into
tight contact because of the force of the spring,
and the brake is applied. In the case of the HSS,
the brake is used only for braking the machine,
so the left and right brakes are actuated at the
same time.
10-110 D155AX-5
Operation
1. Brake released (parking brake OFF, brake pedal RELEASED)
Z: To main relief valve

Y: From power train pump
X: Check valve
W: Brake piston
• When the brake pedal is released (not being de- • If the oil pressure at port E goes above the set
pressed), each valve is pushed to the set posi- pressure, the pressure of the oil entering port A
tion by the tension of the spring. through orifice a also rises. This pushes brake
• Shaft (6) is pushed fully to the right in the direc- valve (3) to the left, throttles the passage be-
tion of the arrow by spring (5). tween ports B and E, and controls the oil pres-
• The pressurized oil from the power train pump sure.
passes through the main relief valve and enters
port B. It then passes through ports E and D,
flows to the back pressure port of the brake pis-
ton, and pushes the piston to the left in the direc-
tion of the arrow to compress the brake spring
and release the brake. The oil pressure at this
point is balanced at 2.7 MPa {28 kg/cm2}, and
this is possible to measure at centralized pres-
sure detection port P.
D155AX-5 10-111
2. Brake actuated (parking brake OFF, brake pedal DEPRESSED)

X: Check valve
W: Brake piston
• When the brake pedal is depressed, shaft (6) is pressurized oil at port B flows to port E. In this
pushed to the left in the direction of the arrow, way, the oil pressure is maintained and the pres-
and compresses spring (5). The reaction force sure beyond port E does not go down any fur-
pushes brake valve (3) to the left in the direction ther.
of the arrow. Therefore, the passage ports B • If the brake pedal is depressed further, the above
and E are closed, and the pressurized oil from operation is repeated, and when the valve reach-
the power train pump stops at port B. Seat (2) is es the end of its stroke, the brake is completely
also pushed to the left in the direction of the ar- applied.
row, and the passage between ports E and G is • The oil pressure beyond port E is determined by
opened. When this happens, the pressurized oil the tension of spring (5), which changes the load
forming the back pressure of the brake piston is according to the amount the brake pedal is de-
pushed back by the force of the brake spring and pressed. Therefore, if the brake pedal is de-
enters port E from port D. Some of the return oil pressed a short distance the oil pressure beyond
passes through ports E and G and is drained port E is set to a high pressure, and the brake is
from port F; the rest of the oil passes from port E partially applied. If the brake pedal is depressed
through orifice a and enters port A. a large distance, the oil pressure is set to a low
• When the pressure at port E goes down, the pressure and the brake is applied.
pressure at port A also goes down, so force of
the spring (1) pushes brake valve (3) back to the
right in the direction of the arrow. The passage
between ports E and G is closed and the pas-
sage between ports B and E is opened, so the
10-112 D155AX-5
3. Parking brake ON (brake pedal RELEASED, safety lever at LOCK)

X: Check valve
W: Brake piston
• The solenoid valve is excited in the same way as • The pressurized oil flowing to the brake piston
in Item 1. In addition, shaft (6) is pushed fully to port and forming the back pressure passes from
the right in the direction of the arrow by spring port D through port C and is drained. Shaft (8)
(5). remains pushed to the left in the direction of the
• If the safety lever is placed at the LOCK position, arrow, so the back pressure of the brake piston
shaft (7) is pushed to the left in the direction of port continues to drop. The brake piston is
the arrow. The passage between ports E and D pushed to the right in the direction of the arrow
is closed, and the passage between ports D and by the brake spring, so the brake is completely
C is opened. Therefore, the pressurized oil from applied, and this condition is maintained.
the power train pump enters port E and stops. • Even when the engine is started again, this con-
dition is maintained.
D155AX-5 10-113
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
Outline
• The final drive is a single stage spur gear, single • Floating seal (4) is installed to the rotating sliding
stage planetary gear reduction type. portion of the sprocket to prevent the entry of dirt
The lubrication is of splash type using the rota- or sand and to prevent leakage of lubricating oil.
tion of the gears.
The final drive can be removed and installed as
a single unit.
10-114 D155AX-5
1. Sun gear (16 teeth) 9. No. 1 pinion (19 teeth)

2. Carrier 10. No. 1 gear (81 teeth)
3. Ring gear (65 teeth) 11. Sprocket hub
4. Floating seal 12. Sprocket teeth
5. Cover 13. Hub
6. Cover 14. Planet pinion (24 teeth)
7. Final drive case 15. Pinion shaft
8. Bearing cage
D155AX-5 10-115
POWER FLOW
• The power from the bevel gear and steering Then, the rotating force of sun gear (1) forms the
clutch is transmitted to No. 1 pinion (9). It then rotating force of carrier (2), which supports the
passes through No. 1 gear (10), which is planet pinion, and is transmitted to sprocket hub
meshed with the No. 1 pinion, and is transmitted (11).
to sun gear (1) to rotate it. The direction of rotation of carrier (2) is the same
The rotation of sun gear (1) is transmitted to as that of sun gear (1).
planet pinion (14), but ring gear (3), which is The rotating force transmitted to sprocket hub
meshed with the planet pinion, is fixed to cover (11) is transmitted to sprocket teeth (12).
(5), so the planet pinion rotates on its own axis
and moves around the sun gear along the ring
gear.
10-116 D155AX-5
TRACK FRAME
Outline Track roller, bogie

• The track rollers are mounted on an X-shaped
Positioning of track roller flange
bogie. This increases the actual ground contact
and bogie
area between the track shoes and the ground on
rough surfaces, and helps increase the drawbar Bogie Inner Outer Outer Inner Inner Outer
pull.
• The X-shaped bogies are equipped with rubber Track roller D S S D D S
pads to absorb the shock from the ground sur-
face. D: Double
S: Single
D155AX-5 10-117
1. Equalizer bar
2. Idler
3. Track frame
4. Carrier roller
5. Sprocket
6. Sprocket guard
7. Bogie assembly
8. Track roller
9. Track roller guiding guard
10. Pivot shaft
10-118 D155AX-5
STRUCTURE AND FUNCTION TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
1. Rubber mount Outline

2. Track roller • One track roller is mounted to each of inner bo-
3. Inner bogie gie (3) and outer bogie (4) to ensure that the
4. Outer bogie track roller and track shoe are always in contact.
5. Cartridge pin • Rubber mount (1) is used to absorb the machine
6. Floating seal vibration caused by contact with the ground.
7. Bushing
8. Plug
9. Bogie mount cap
D155AX-5 10-119
STRUCTURE AND FUNCTION RECOIL SPRING
RECOIL SPRING
1. Yoke Outline
2. Nut • Recoil spring (4) is used to adjust the track ten-
3. Retainer sion by pumping in or releasing grease from lu-
4. Recoil spring br icator ( 11) to move rod (5) for ward or
5. Rod backward. The recoil spring also acts to dampen
6. Spring cylinder any sudden shock brought to bear on the idler.
7. Retainer
8. Piston
9. Grease chamber cylinder
10. Pin
11. Lubricator
(for pumping in and releasing grease)
10-120 D155AX-5
STRUCTURE AND FUNCTION MAIN FRAME
MAIN FRAME
1. Engine mount
2. Power train unit mount
3. ROPS mount
4. Power train underguard
5. Engine underguard
D155AX-5 10-121
STRUCTURE AND FUNCTION SUSPENSION
SUSPENSION
Outline
• The front of the track frame rocks up and down
using the rear pivot shafts (3) and (4) as a ful-
crum.
Equalizer bar (1) rocks using center pin (2) as a
fulcrum. The left and right track frames are con-
nected by side pin (5).
10-122 D155AX-5
STRUCTURE AND FUNCTION SUSPENSION
1. Equalizer bar
2. Center pin
3. Left pivot shaft
4. Right pivot shaft
5. Side pin
6. Spherical bushing
7. Greasing tube
D155AX-5 10-123
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

SEMI U-DOZER
1. Blade tilt cylinder 6. Main control valve

2. R.H. blade lift cylinder 7. Hydraulic filter
3. PPC, HSS charge valve 8. Hydraulic tank
4. Accumulator 9. Work equipment pump (SAR(4)112)
5. PPC, HSS charge filter 10. PPC, HSS charge pump
11. L.H. blade lift cylinder
12. Oil cooler
10-124 D155AX-5
MULTI-SHANK RIPPER
1. Main control valve

2. Divider block
3. Ripper tilt cylinder
4. Ripper lift cylinder
D155AX-5 10-125
GIANT RIPPER
a The diagram shows a machine equipped with a

pin puller cylinder
1. Main control valve

2. Divider block
3. Ripper tilt cylinder (right)
4. Ripper lift cylinder (right)
5. Pin puller cylinder
6. Ripper lift cylinder (left)
7. Ripper tilt cylinder (left)
8. Pin puller solenoid valve
9. Brake valve
a. To steering case
10-126 D155AX-5
STRUCTURE AND FUNCTION PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

BLADE, RIPPER CONTROL
1. PPC, HSS charge valve 6. Ripper control PPC valve

2. Accumulator 7. PPC, HSS charge pump (104)
3. Blade control PPC valve 8. Work equipment pump (SAR(4)112)
4. Main control valve 9. PPC lock valve
5. PPC, HSS charge filter
D155AX-5 10-127
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL
10-128 D155AX-5
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
1. Work equipment safety lever

2. Blade control lever
3. Ripper control lever
4. PPC lock valve
5. Pin puller switch
Lever positions
A : Blade HOLD
B : Blade LOWER
C : Blade FLOAT
D : Blade RAISE
E : Blade LEFT TILT
F: Blade RIGHT TILT
G : Ripper HOLD
H : Ripper RAISE
J : Ripper LOWER
K : Ripper DECREASE TIP ANGLE
L : Ripper INCREASE TIP ANGLE
M : FREE
N : LOCK
Outline
• The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
• Work equipment safety lever (1) is interconected
with PPC lock valve (4), and at the LOCK posi-
tion, the oil in the PPC circuit is stopped.
D155AX-5 10-129
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
10-130 D155AX-5
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
1. Hydraulic filter Specified

2. Oil filler cap value
3. Sight gauge Tank capacity (l) 120
4. Hydraulic tank Hi (l) 85
Hydraulic Level
5. Filter case tank inside Center (l) 82
6. Cover tank Low (l) 79
7. Air bleeding plug
8. Element Cracking 16.7±6.9
(kPa {kg/cm2})
Breather pressure {0.17±0.07}
9. Suction valve
10. Spring cap Vacuum valve actuating 0 – 0.49
pressure (kPa {kg/cm2}) {0 – 0.005}
11. Drain plug for removing dirt
12. Breather cap Cracking (kPa {kg/cm2}) 103.0±19.6
13. Pressure valve pressure {1.05±0.2}
Hydraulic Mesh size (µ m) 30/8
14. Strainer filter
Filtering area (cm2) 10,026
A. From main control valve Filtering oil flow (l/min) 255
B. To hydraulic tank Mesh size (µ m) 105
Strainer
Filtering area (cm2) 2,300
D155AX-5 10-131
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
FOR PPC VALVE
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.1 MPa {32 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
Function
• The accumulator is installed between the PPC
charge pump and the PPC valve. Even if the en-
gine is started with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the main control valve to actuate it
and enable the work equipment to move down
under its own weight.
Operation
• After the engine is stopped, when the PPC valve
is at neutral, chamber A inside the bladder is
compressed by the oil pressure in chamber B.
• When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa {30 kg/
cm2}, and the pressure of the nitrogen gas in
chamber A expands the bladder, so the oil in
chamber B acts as the pilot pressure and actu-
ates the main control valve.
10-132 D155AX-5
STRUCTURE AND FUNCTION PPC LOCK VALVE
PPC LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The PPC lock valve is installed in the PPC circuit
between the PPC, HSS charge valve and PPC
valve. If the work equipment safety lever is
placed at the LOCK position, the PPC lock valve
is actuated together with the work equipment
safety lever. This stops the oil in the PPC circuit
and makes it impossible to operate the work
equipment.
D155AX-5 10-133
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
FOR BLADE LIFT, BLADE TILT
P. From self pressure reducing valve

T. To hydraulic tank
P1. To blade lift valve
P2. To blade lift valve
P3. To blade tilt valve
P4. To blade tilt valve
10-134 D155AX-5
1. Disc
2. Plate
3. Body
D155AX-5 10-135
Operation
1. At neutral
1) PPC value for blade lift
Ports A and B of the blade lift control valve,
and ports P1 and P2 of the PPC valve are
connected to drain chamber D through fine
control hole f in spool (1).
2) PPC valve for blade tilt

Ports A and B of the blade tilt control valve,
and ports P3 and P4 of the PPC valve are
connected to drain chamber D through fine
control hole f in spool (1).
10-136 D155AX-5
2. During fine control (neutral- fine control)

• When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
• When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port P1 to port A.
• When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
• When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with pressure at port P1.
The relationship in the position of the spool (1)
and body (10) (fine control hole f is at a point
midway between drain hole D and pump pres-
sure chamber PP) does not change until retainer
(9) contacts spool (1).
• Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control level, so the pressure at port P1 also ris-
es in proportion to the travel in the control lever.
• In this way the control valve spool moves to a po-
sition where the pressure in chamber A (the
same as the pressure at port P1) and the force
of the control valve spool return spring are bal-
anced.
D155AX-5 10-137
3. During fine control

(when control lever is returned)
• When disc (5) starts to be returned, spool (1) is
pushed up to the force of centering spring (3)
and the pressure at port P1.
• When this happens, fine control hole f is con-
nected to drain chamber D, and the pressure oil
at port P1 is released.
• If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D.
At almost the same time it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
• When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P2 and enters cham-
ber B to fill the chamber with oil.
4. At full stroke
• When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
• Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber A from port P1, and pushes the
control valve spool.
• The oil returning from chamber B from port P2
through fine control hole f' and flows to drain
chamber D.
10-138 D155AX-5
5. Blade operated to FLOAT 6. Blade released from FLOAT

• When piston (4) at port P1 (LOWER side) is • When disc (5) is returned from the FLOAT posi-
pushed by disc (5) and moves down, protrusion tion, it is pushed down by a force greater than
a of the piston contacts ball (11) during the the pressure of the oil in chamber E.
downward stroke. (The detent starts to be actu- • For this reason, chamber E is shut off from pas-
ated.) sage d and is connected to the drain chamber.
• If piston (4) is pushed further, ball (11) pushes up Therefore, the oil pressure inside chamber E is
collar (12), which is being held by detent spring lost, and the FLOAT, position is released.
(13), and moves to the outside, so the ball pass-
es over protrusion a of the piston.
• At this point, piston (4') at the opposite side is
pushed up by the spring (14).
• As a result, the oil inside chamber F flows
through b and c and enters chamber E, and pis-
ton (4') follows disc (5). Passage d is intercon-
nected with port P1, so it is under more or less
the same pressure as port P1.
• Chamber E is normally interconnected with drain
chamber D, but when ball (11) passes over pro-
trusion a of the piston, passage d and chamber
E (which were shut off) are interconnected and
pressurized oil flows.
• At the same time, the control valve also moves
to the FLOAT position, so the blade circuit is set
to the FLOAT condition.
• The pressurized oil inside chamber E pushes up
piston (4'), so even of the lever is released, it is
held at the FLOAT position.
D155AX-5 10-139
FOR RIPPER
P. From self pressure reducing valve

T. To hydraulic tank
P1. To ripper tilt valve
P2. To ripper tilt valve
P3. To ripper lift valve
P4. To ripper lift valve
10-140 D155AX-5
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for lever joint)
D155AX-5 10-141
Operation • Therefore, metering spring (2) is compressed

proportionally to the amount of movement of the
1. At neutral control lever, so the pressure at port P1 also ris-
• Ports A and B of the ripper control valve and es in proportion to the travel in the control lever.
ports P1, P2, P3, and P4 of the PPC valve are • In this way the control valve spool moves to a po-
connected to drain chamber D through fine con- sition where the pressure in chamber A (the
trol hole f of spool (1). same as the pressure at port P1) and the force
of the control valve spool return spring are bal-
anced.
2. During fine control (neutral ý fine control)

• When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
• When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port P1 to Port A.
• When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
• When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P1. The relation-
ship in the position of the spool (1) and body (10)
(fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP)
does not change until retainer (9) contacts spool
(1).
10-142 D155AX-5
3. During fine control 4. At full stroke

(when control lever is returned) • When disc (5) pushes down piston (4), and re-
• When disc (5) starts to be returned, spool (1) is tainer (9) pushes down spool (1), fine control
pushed up by the force of centering spring (3) hole f is shut off from drain chamber D, and is
and the pressure at port P1. connected with pump pressure chamber PP.
• When this happens, fine control hole f is con- • Therefore, the pilot pressure oil from the charg-
nected to drain chamber D and the pressure oil ing pump passes through fine control hole f and
at port P1 is released. flows to chamber A from port P1, and pushes the
• If the pressure at port P1 drops too far, spool (1) control valve spool.
is pushed down by metering spring (2), and fine • The oil returning from chamber B passes from
control hole f is shut off from drain chamber D. At port P2 through fine control hole f' and flows to
almost the same time, it is connected to pump drain chamber D.
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
• When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P2 and enters cham-
ber B to fill the chamber with oil.
D155AX-5 10-143
STRUCTURE AND FUNCTION PCCS LEVER
PCCS LEVER
FOR STEERING
a Do not disassemble. If it is disassembled, the output voltage characteristics and operating effort character-
istics will need to be adjusted.
1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
10-144 D155AX-5
FUNCTION
1. Operating effort characteristics
(1) Operation for forward and reverse travel (2) Operation for steering
• The control lever is held at 3 positions of • Free return(Operating effort characteris-
Forward ,Neutral,and Reverse (Operat- tics chart B).
ing effort characteristics chart A).
D155AX-5 10-145
2. Output voltage characteristics

• The control uniy is installed to the left control
stand and the control lever is installed direct-
lyonto it.
• The operating angle (stroke) of the control
lever is sensed potentiometers and signal
voltages are output to the transmisson,steer-
ing controller.
• A potentiometer is installed in each of longi-
tudinal direction and lateral direction.
Each potentiometer outputs 2 signal voltag-
es which are opposite to each other as
shown in the figure at right.
10-146 D155AX-5
STRUCTURE AND FUNCTION PISTON VALVE
PISTON VALVE
FOR BLADE LIFT CYLINDER
Outline
• The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the
hydraulic pump to reduce the oil pressure being
exerted on the piston.
When the blade is tilted, the blade is subject to a
tortional force owing to the uneven position of
the pistons in the two cylinders; that is the piston
one side is still moving while the piston on the
other side has reached its stroke end.
The piston valves are installed to prevent the tor-
tional force from occurring. When one of the pis-
tons reaches its stroke end, its piston valve
opens to relieve the oil pressure.
In addition the piston valve relieves the shock
which occurs when the piston comes into contact
with the cylinder head or the bottom and serves
to reduce the subsequent surge pressure in the
cylinder by letting the oil escape from the cylin-
der before the piston reaches its stroke end.
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts on
piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction of
the arrow until piston valve seat (4) comes into
snug contact with the tapered section, thereby,
this causing the pressure in the cylinder to rise
and moving piston (2) in the direction of the ar-
row.
2. Piston valve OPEN

Just before piston rod (1) reaches the end of its
stroke, the tip of valve (6) contacts the cylinder
bottom, so valve (6) and piston valve (3) stop at
that position and do not move further. Only pis-
ton (2) moves further.
When this happens, the oil at the cylinder head,
which was sealed by piston valve (3), escapes
from piston valve seats (4) and (5), and the pres-
sure inside the cylinder stops rising.
D155AX-5 10-147
STRUCTURE AND FUNCTION PIN PULLER SWITCH
PIN PULLER SWITCH
1. Connector
2. Wire
3. Switch
4. Knob
Function
• The pin puller solenoid valve is controlled by
turning the pin puller switch ON/OFF. This
changes the oil circuit to the pin puller cylinder
and sets the shank mounting pin to the PUSH IN
or PULL OUT position.
10-148 D155AX-5
STRUCTURE AND FUNCTION PIN PULLER SOLENOID VALVE
PIN PULLER SOLENOID VALVE
1. Plug A. To pin puller cylinder bottom

2. Spring B. To pin puller cylinder head
3. Spring retainer P. From power train pump
4. Valve body T. To HSS case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
10-150 D155AX-5
STRUCTURE AND FUNCTION PIN PULLER SOLENOID VALVE
Operation
1. Pin puller switch at PUSH IN position
When the pin puller switch is set to the PUSH IN
position, no electric current flows to solenoid (9)
and it is deenergized.
Then, ports P and A and ports B and T of spool
(5) open, and the oil from the power train pump
flows from port P to port A, and enters the bot-
tom end of pin puller cylinder (10).
When the oil enters the bottom end of the cylin-
der and the pressure in the circuit starts to rise,
the cylinder extends and pushes shank mount-
ing pin (11) into shank (12).
2. Pin puller switch at PULL OUT position

When the pin puller switch is set to the PULL
OUT position, electricity flows to solenoid (9) and
it is excited.
Then, the solenoid pushes out push pin (8) and
spool (5) moves to the left in the arrow direction.
At this point, ports P and A and ports B and T
close, and ports P and B and ports A and T
open, so the oil from the power train pump flows
from port P to port B and enters the head end of
pin puller cylinder (10).
When the oil enters the cylinder head end and
the pressure in the circuit rises, the cylinder re-
tracts and pulls shank mounting pin (11) out of
shank (12).
D155AX-5 10-151
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE
A1. To blade tilt cylinder head PA4. From ripper PPC valve port P2
A2. To blade lift cylinder head PB1. From blade PPC valve port P2
A3. To ripper lift cylinder head PB2. From blade PPC valve port P3
A4. To ripper tilt cylinder head PB3. From ripper PPC valve port P4
B1. To blade tilt cylinder bottom PB4. From ripper PPC valve port P1
B2. To blade lift cylinder bottom P. Pump port
B3. To ripper lift cylinder bottom T. Drain port
B4. To ripper tilt cylinder bottom a. Pump pressure detection plug
PA1. From blade PPC valve port P1 b. LS pressure detection plug
PA2. From blade PPC valve port P4 c. PPC charge valve pressure port
PA3. From ripper PPC valve port P3
10-152 D155AX-5
D155AX-5 10-153
1. Valve block 11. Cancel piston

2. Ripper tilt spool 12. Cancel spring
3. Ripper lift spool 13. LS check valve
4. Blade lift spool 14. Main relief valve
5. Blade tilt spool 15. Back pressure check valve
6. Valve body 16. Back pressure valve
7. Load check valve 17. Check valve (built-in spool)
8. Orifice 18. Suction valve
9. Unload spring 19. Preset check valve
10. Unload spool 20. LS bypass valve
10-154 D155AX-5
Function Operation
• When the work equipment control levers are at 1. At HOLD (unload valve at low setting)
HOLD, the oil discharged from the pump is all 1) When the work equipment spool is at HOLD, LS
unloaded, and the pressure loss of the valve is circuit pressure LS = seal drain pressure TS (hy-
kept below 0.5 MPa {5 kg/cm2}. draulic leak pressure from valve) = 0 MPa (0 kg/
In this way, the pressure loss when the lever is at cm2), so unload spool (1) is balanced by the dif-
HOLD is small, so the heat loss is also small. ference in load between load F2 of spring (3) and
• Proportional control is carried out by the unload load F1 of spring (2) that is set to oppose pump
valve (1), which controls the amount of oil sent to pressure P which is sent to chamber A1.
the cylinder to an amount that matches the open- In other words, AO x P = F1 – F2 (AO: Area re-
ing of the spool. ceiving pump pressure in chamber A1).
• The unload valve (1) is controlled by the differ- 2) By making F1 – F2 smaller, it is possible to make
ence in pressure on both sides of the spool, so pump pressure P smaller.
there is a little change in the oil flow caused by When this is done, the area of the opening be-
the load pressure. It also provides the function of tween ports A and B is determined, so the loss
pressure compensation. of pressure from A to B (P – T) can be kept more
or less constant regardless of back pressure TP
between ports A and B.
D155AX-5 10-155
2. Control of oil flow (unload valve at high setting)

Blade lift, tilt valve
Ripper lift, tilt valve
1) Meter-in oil flow control

a The diagram shows
the blade tilt valve.
• E PLS = Differential pressure between ports A and J = 1.8 – 2.9 MPa {18 – 30 kg/cm2}
• E PLS' = Differential pressure between ports A and F
(E PLS C E PLS')
10-156 D155AX-5
• Because of the action of the unload valve, an (4) When the oil in chamber F flows and the pres-
amount of oil that matches the opening of the sure rises, the pressures in chamber J and
spool flows to the cylinder. (Proportional control) chamber L both rise at the same time. The pres-
• The unload valve is controlled by the difference sure in chamber L pushes against the spring (5)
in pressure on both sides of the spool, so the and moves piston (4) to the left. Piston (4) is sep-
change in the amount of the oil flow caused by arated from unload spool (3), so the load of
the load pressure is small (pressure compensa- spring (5) does not act on unload spool (3).
tion).
(5) The unload valve is balanced by differential
(1) If the PPC valve output pressure PA1 is sent to pressure EPLS, which is the difference in pres-
the spring (2) chamber of spool (1), spool (1) sure between the pressures of chamber A1 and
pushes against spring (2) and moves to the right chamber J, in other words, meter-in pressure
to a position where it balances with the load of loss (ports A – J) and the load of spring (6). At
the spring. this balanced position, the unload oil flow of the
unload valve is determined.
(2) If spool (1) is actuated, the passage between The portion of the oil discharged from the pump
ports E and F opens, so part of the oil flow dis- which is not unloaded is supplied to the tilt cylin-
charged from the pump flows through ports A, B, der. The meter-in pressure loss is determined by
C, D, E, and F, and then into the cylinder. But in the area of opening of spool (1), so an amount of
this condition, almost all the oil discharged from oil that matches the area of opening of spool (1)
the pump is unloaded. flows to the tilt cylinder, regardless of the load
pressure.
(3) At the same time, the pressure in chamber F
flows into the passage inside the spool from LS
throttle d1, then passes through ports G, H, and
I, and is sent to spring chamber J of the unload
valve. In addition, the pressure in chamber A
(pump pressure) is sent to chamber A1 of the
unload valve, while the pressure in chamber J
passes through LS passage K and is sent to
chamber L.
a Throttle d2 is specially assembled to the tilt valve

to adjust the oil flow.
D155AX-5 10-157
2) Meter-out control using downward movement of blade under own weight

(blade control lever at LOWER)
10-158 D155AX-5
• If the blade moves down under its own weight,

the oil flow of return oil from cylinder is controlled
by the area of the opening of the man spool (1).
• Because of back-pressure valve (3), a back

pressure that matches the oil flow is formed in
drain circuit T1 of the control valve, so oil is sup-
plied to the cylinder bottom from suction valve
(2) to prevent a vacuum from forming in the cir-
cuit.
(1) When the spool port is opened by PPC output

pressure PA2, because of the downward move-
ment of the blade, the oil at the cylinder head
passes through ports A, B, C, and D, and is
drained to the tank. The flow of return oil from the
lift cylinder is throttled by the area of the opening
between ports A and B, so the lowering speed is
controlled.
(2) When the blade moves down under its own

weight, there is no LS pressure, so the back
pressure is formed in chamber C in accordance
with the characteristics of back-pressure valve
(3). The oil flowing from the cylinder head flows
from the drain circuit, passes through suction
valve (2), and is supplied to the bottom end of
the cylinder.
The oil discharged from the pump passes
through pots A1, B1, C1, D1, and E1, and is sup-
plied to the cylinder bottom.
a For details of the vacuum prevention function,

see 5. UNLOAD VALVE PRESET SYSTEM.
D155AX-5 10-159
3) Meter-out control using downward movement of blade under own weight

(blade control lever at FLOAT)
10-160 D155AX-5
• When the lift valve is at FLOAT, the cylinder port

and drain port are connected to put the circuit in
a no-load condition.
• When the lift valve is in the FLOAT condition, the
pump circuit and cylinder ports A2 and B2 are
separated so that the control valve can carry out
other operations.
(1) With the control lever at the FLOAT position,

when pressure PA2 reaches 3.4 MPa {35 kg/
cm 2 }, lift spool (1) is at the maximum stroke
FLOAT position.
(2) In this condition, ports A2 and B2 and LS circuit

O are all connected to the drain circuit, so there
is no load on the lift cylinder.
(3) If the cylinder is driven by the weight of the

blade, the oil passes from port A2 through ports
A, B, F, and G, and the rest of the oil passes
through ports C and D, and is drained.
When this happens, the oil flow is throttled by the
area of opening between ports A and B of the
spool, and the cylinder speed is controlled.
(4) Pump circuit chamber E and ports A2 and B2

are separated, and the pump pressure is formed,
so it is possible to carry out compound opera-
tions with the other control valves.
D155AX-5 10-161
3. At relief
a The diagram shows the tilt cylinder immediately
after it reaches the end of its stroke.
10-162 D155AX-5
1) If spool (1) moves to the right because of PPC

output pressure PA1, the oil discharged from the
pump flows through ports A, B, C, D, E, and F,
and flows to the bottom end of the tilt cylinder.
When this happens, the pressure in chamber F
is sent through LS sensing hole G through ports
H, I, J, K, L, M, and N, and goes to ports M and
N of unload spool (2).
2) If the cylinder reaches the end of its stroke and it

stops, the condition becomes P C P1 C PLS, and
unload spool (2) is pushed completely to the left
by the load of spring (3), so the unload oil flow
becomes 0.
3) In this condition, all the oil discharged by the

pump tries to flow to the cylinder, but the cylinder
piston is stopped, so the pressure in the pump
circuit rises.
4) If the pump pressure reaches the cracking pres-

sure, relief valve (4) is actuated, so the maxi-
mum pressure in the pump circuit is set.
5) Throttle Q of relief valve (4) is used to keep the

peak pressure to the minimum.
D155AX-5 10-163
4. Compound operations
a The diagram shows the lift valve + tilt valve.
10-164 D155AX-5
• It consists of a parallel circuit, so when com-

pound operations are carried out, the oil flow is
divided according to the size of each spool open-
ing.
1) The tilt valve and lift valve spools are actuated by

PPC output pressure PA1, PB2 and each spool
is balanced at a position that matches its pilot
pressure.
2) When pressure P1 Z pressure P2

Lift valve load pressure P2 is sent to the unload
valve M, N chamber through LS passage.
(1) When unload valve does not reach fully

closed position
When the discharge flow of oil from the
pump is greater than the total of the oil flow
demanded by the tilt valve and lift valve, an
oil flow that matches the opening of the spool
flows to both the tilt valve and lift valve.
(2) When unload valve is at fully closed position

(there is no unload oil flow)
When the discharge flow of oil from the
pump is smaller than the total of the oil flow
demanded by the tilt valve and lift valve, the
flow of oil to the tilt valve and lift valve is di-
vided according to P – P1 differential pres-
sure and P – P2 differential pressure. In
other words, more oil flows to P1 where the
load is small.
a In cases where the blade is raised in the air

and the tilt valve and lift valve (for raise) are
operated at the same time, the tilt valve load
pressure is smaller than the lift valve load
pressure, so the flow of oil to the tilt valve is
given priority. In addition, the oil flow de-
manded by the tilt valve is smaller, so the
condition is just as if priority was given to the
oil flow for the tilt valve.
(3) When pressure P1 = pressure P2

P – P1 = P – P2, so an oil flow proportional
to the size of the spool opening is distributed
to each spool.
D155AX-5 10-165
5. Unload valve preset system
1) Lift valve
10-166 D155AX-5
• The response is improved at blade RAISE.
• At blade LOWER, all the oil discharged from the

pump is supplied to the bottom end of the lift cyl-
inder to prevent any vacuum from forming at the
cylinder bottom.
(1) When spool (1) is switched by PPC output pres-

sure PB2, basic pressure P1 of the PPC valve
goes through preset check valve (3) into the LS
passage through ports A, B, C, D, E, and F. (Pre-
set pressure: Min. 3.4 MPa {35 kg/cm2})
(2) Immediately after the spool is switched, pump

pressure P is approx. 0.5 – 1.0 MPa {5 – 10 kg/
cm2}, so unload spool (2) is pushed to the left.
The opening between ports G and L is closed,
and the oil discharged from the pump all flows
through ports G, H, I, J, and K and is supplied to
the lift cylinder, so the response is improved.
(3) When the lift cylinder pressure rises and goes

above the preset pressure, preset check valve
(3) closes, so unload spool (2) returns to the
original EPLS control.
(4) In cases as with blade LOWER where the flow of

oil from the pump cannot keep up with the blade
lowering speed, if the load pressure is not
reached, unload spool (2) is kept in the condition
in Item 2) to make it possible to present a vacu-
um from forming in the cylinder.
D155AX-5 10-167
2) Tilt valve
10-168 D155AX-5
• The response is improved at blade TILT.
(1) When spool (1) is switched by PPC output pres-

sure PA1, basic pressure P1 of the PPC valve
goes through preset check valve (3) into the LS
passage through ports A, B, C, D, E, and F. (Pre-
set pressure: Min. 3.4 MPa {35 kg/cm2})
(2) Immediately after the spool is switched, pump

pressure P is approx. 0.5 – 1.0 MPa {5 – 10 kg/
cm2}, so unload spool (2) is pushed to the left.
The opening between ports G and L is closed,
and the oil discharged from the pump all flows
through ports G, H, I, J, and K and is supplied to
the tilt cylinder, so the response is improved.
(3) When the tilt cylinder pressure rises and goes

above the preset pressure, preset check valve
(3) closes, so unload spool (2) returns to the
original EPLS control.
D155AX-5 10-169
OPERATION OF WORK EQUIPMENT CONTROL CIRCUITBLADE

1. At blade RAISE
10-170 D155AX-5
OPERATION
• When blade control lever (1) is operated to the
RAISE position, the spool of PPC valve (2),
which is directly connected to the lever, is
moved.
When this happens, the pilot pressure entering
PPC valve (2) from PPC pump (3) is sent to port
PB2 of blade lift spool (4).
• This pilot pressure pushes spool (4) to the left,

and connects ports A and B and ports C and D.
The oil at port PA2 passes through PPC valve
(2) and is drained to hydraulic tank (5).
• When this happens, the pressurized oil from hy-

draulic pump (6) enters port P, passes through
unload valve (7) and ports A and B, and goes to
the head end of blade lift cylinders (8) and (9) to
raise blade (10).
At the same time, the oil at the cylinder bottom
passes through ports C, D, and T, and is drained
to hydraulic tank (5).
D155AX-5 10-171
2. At blade LEFT TILT
10-172 D155AX-5
OPERATION
• When blade control lever (1) is operated to the
LEFT TILT position, the spool of PPC valve (2),
moved.
PA1 of blade tilt spool (4).
• This pilot pressure pushes spool (4) to the right,

The oil at port PB1 passes through PPC valve

the bottom end of blade tilt cylinder (8) to tilt
blade (9) to the left.
At the same time, the oil at the cylinder head
D155AX-5 10-173
3. At ripper RAISE
10-174 D155AX-5
OPERATION
• When ripper control lever (1) is operated to the
RAISE position, the spool of PPC valve (2),
moved.
PB3 of ripper lift spool (4).
• This pilot pressure pushes spool (4) to the left,

The oil at port PA3 passes through PPC valve

the head end of ripper lift cylinders (8) to raise
ripper (9).
At the same time, the oil at the cylinder bottom
D155AX-5 10-175
4. At ripper TILT IN
10-176 D155AX-5
OPERATION
• When ripper control lever (1) is operated to the
TILT IN position, the spool of PPC valve (2),
moved.
PA4 of ripper tilt spool (4).
• This pilot pressure pushes spool (4) to the right,

The oil at port PB4 passes through PPC valve

the bottom end of ripper tilt cylinders (8) to tilt in
ripper (9).
At the same time, the oil at the cylinder head
D155AX-5 10-177
STRUCTURE AND FUNCTION SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE
T: To hydraulic tank
P1: From pump
P2: To fan motor
PR:To PPC valve and EPC valve
10-178 D155AX-5
1. Valve (sequence valve) 6. Screw

2. Spring 7. Poppet
3. Valve (pressure reducing valve) 8. Spring (pressure reducing valve pilot)
4. Spring (pressure reducing valve main) 9. Spring (safety valve)
5. Filter 10. Ball
D155AX-5 10-179
Function
The self pressure reducing valves reduces the dis-
charge pressure of the fan pump and supplies it to
the PPC valve, the EPC valve, etc. as the control
pressure.
10-180 D155AX-5
Operation
1. At engine stop (total low pressure)
• The spring (6) pushes the poppet (5) the seat,

and the circuit between the ports PR and T is
closed.
• The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports P1 and
PR is open.
• The spring (3) pushes the valve (2) to the left
side, and the circuit between the ports P1 and P2
is closed.
D155AX-5 10-181
2. When the load pressure P2 is lower than the

output pressure PR of the self pressure re-
ducing valve.
• The spring (3) and the PR pressure (0 MPa {0kg/ • Therefore, there will occur a differential pressure
cm2} at the time of engine stop) pushes the valve around the hold a in the spool (8) and the spool
(2) in the direction to close the circuit between will move in the direction to close the port P1 and
the ports P1 and P2. When the hydraulic oil en- the PR opening. Then, the P1 pressure is re-
ters the P1 port, the expression (P1 pressure C duced and adjusted to a certain pressure (set
Spring (3) force + (ød area x PR pressure)) pressure) with the opening and is supplied as the
holds, and the self pressure reducing valve will PR pressure.
adjust the openings of the ports P1 and P2 so
that the P1 pressure can be maintained higher
than the PR pressure.
• When the PR pressure rises above the set pres-
sure, the poppet (5) will open and the hydraulic
oil flows through the route from the PR port, the
hole a in the spool (8), the poppet (5) opening to
the tank port T.
10-182 D155AX-5
3. At raise of load pressure P2
• When the load pressure P2 rises due to digging • When the PR pressure rises above the set pres-
or other operations, the pump delivery will in- sure, the poppet (5) will open and the hydraulic
crease and the P1 pressure will rise. Then, the oil will flow through the route from the PR port,
expression (P1 pressure > Spring (3) force + (ød the hole a in the spool (8), the poppet (5) open-
area x PR pressure)) will hold, and the valve (2) ing to the tank port T.
will move to the right side till the stroke end. • Therefore, there will occur a differential pressure
As a result, the opening between the ports P1 around the hold a in the spool (8) and the spool
and P2 will increase, the passage resistance will (8) will move in the direction to close the port P1
become smaller to reduce engine loss horse- and the PR opening. Then, the P1 pressure is re-
power. duced and adjusted to a certain pressure (set
pressure) with the opening and is supplied as the
PR pressure.
D155AX-5 10-183
4. At occurrence of abnormal high pressure
• When the PR pressure of the self pressure reduc-

ing valve rises abnormally high, the ball (10) will sep-
arate from the seat against the spring (9) force to
flow the hydraulic oil to the output ports PR o T so
as to reduce the PR pressure. Then, the equipment
(PPC valve, EPC valve, etc.), to which the oil pres-
sure is supplied, is protected from the abnormal high
pressure.
10-184 D155AX-5
STRUCTURE AND FUNCTION CYLINDER STAY
CYLINDER STAY
1. Grease nipple
2. Yoke
3. Oil seal
4. Bushing
5. Bushing
6. Grease nipple
D155AX-5 10-185
STRUCTURE AND FUNCTION WORK EQUIPMENT
WORK EQUIPMENT
SEMI U-DOZER
1. End bit
2. Cutting edge
3. Blade
4. Center brace
5. Tilt cylinder
6. Straight frame
7. Trunnion
8. Brace
10-186 D155AX-5
U-DOZER
1. End bit
2. Cutting edge
3. Blade
4. Center brace
5. Tilt cylinder
6. Straight frame
7. Trunnion
8. Brace
D155AX-5 10-187
MULTI-SHANK RIPPER
1. Mount bracket
2. Tilt cylinder
3. Lift cylinder
4. Beam
5. Shank
6. Protector
7. Ripper point
8. Arm
10-188 D155AX-5
GIANT RIPPER
• Machine equipped with pin puller
1. Bracket
2. Tilt cylinder
3. Lift cylinder
4. Beam
5. Pin puller cylinder
6. Shank
7. Protector
8. Ripper point
9. Arm
D155AX-5 10-189
STRUCTURE AND FUNCTION CAB MOUNT
CAB MOUNT
1. Support Outline
2. Damper mount (front) • Viscous mounts are installed at two places at the
3. Damper mount (rear) front and two places at the rear to secure the
floor frame and cab.
• An oil-filled damper mount is used to absorb the
vibration.
10-190 D155AX-5
STRUCTURE AND FUNCTION CAB
CAB
CAB ASSEMBLY
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D155AX-5 10-191
STRUCTURE AND FUNCTION CAB
ROPS GUARD
1. ROPS guard
10-192 D155AX-5
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Condenser 9. Front window defroster

2. Valve (hot water outlet) 10. Air conditioner unit
3. Hot water pick-up piping 11. Vent
4. Refrigerant piping 12. Blower motor
5. Receiver tank 13. Side window defroster
6. Hot water return piping A. Fresh air
7. Air conditioner compressor B. Recirculated air
8. Valve (hot water inlet) C. Hot air/cold air
D155AX-5 10-193
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
1. Decelerator pedal Outline

2. Decelerator potentiometer • The throttle signals of the fuel control dial and
3. Starter switch decelerator pedal flow in the engine controller,
4. Fuel dial where they are processed together with the 3rd
5. Battery throttle signal from the transmission and steering
6. Battery relay controller. The engine controller controls the en-
7. Transmission, steering controller gine according to the commands.
8. Starter
9. Fuel supply pump
10-194 D155AX-5
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Outline
• The engine controller receives the fuel control • The information of the engine controller is pos-
dial signal of the 1st throttle, decelerator pedal sessed jointly by the other controllers through
signal of the 2nd throttle, and 3rd throttle signal the network and used for the optimum control of
which is the control signal from the steering con- the engine and machine body.
troller, and then controls the fuel supply pump • The auto deceleration is a function of setting the
according to the command signal having the low- engine speed low temporarily when the travel di-
est engine speed. rection is changed from F3, R3, F2, and R2 (to
The control signals of the 3rd throttle are as fol- protect the transmission clutch).
lows. • The neutral deceleration is a function of limiting
(1) Auto deceleration (F3, R3, F2, R2) the high idling speed when the transmission is
(2) Neutral deceleration set in neutral.
• The steering controller calculates a proper en-
gine speed from information items (1), (2), etc.
and sends it as the 3rd throttle signal to the en-
gine controller.
D155AX-5 10-195
STRUCTURE AND FUNCTION CRI ENGINE CONTROL SYSTEM
CRI ENGINE CONTROL SYSTEM

a "CRI" is an abbreviation for Common Rail Injection.
SYSTEM DIAGRAM
Outline
• The signals detected by various sensors are in-
put to the engine controller.
• The input signals are processed by the controller
and output to each actuator to control the fuel in-
jection rate and fuel injection timing.
10-196 D155AX-5
STRUCTURE AND FUNCTION CRI ENGINE CONTROL SYSTEM
1. Fuel tank System configuration

2. Fuel supply pump assembly • The CRI system consists of fuel supply pump
2A. PCV (2), common rail (5), injector (8), engine control-
2B. High pressure pump ler (9)to control them, and sensors.
2C. Priming pump • The fuel supply pump generates fuel pressure in
2D. Feed pump the common rail. The fuel pressure is controlled
2E. Bypass valve by the fuel discharge rate of the supply pump.
2F. G speed sensor The discharge rate is controlled by turning on
3. Fuel filter and off PCV (discharge control valve) (2A) of the
4. Overflow valve fuel supply pump according to the electric sig-
5. Common rail nals from the engine controller.
6. Pressure limiter The common rail receives the pressurized fuel
7. Flow damper from the fuel supply pump and distributes it to
8. Injector assembly the cylinders.
8A. Orifice The fuel pressure is sensed by the common rail
8B. Control chamber fuel pressure sensor installed to the common rail
8C. Hydraulic piston and controlled by the feedback method so that
8D. Injector the actual fuel pressure will match to the com-
8E. Nozzle mand pressure set according to the engine
9. Engine controller speed and the load on the engine.
10. NE speed sensor The fuel pressure in the common rail is applied
to the nozzle (8E) side of the injector and control
chamber (8B) through the fuel injection pipe of
each cylinder.
• The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve). If the TWV is
turned on, the fuel circuit is so changed that the
high-pressure fuel in the control chamber will
flow through orifice (8A). The needle valve is
raised to start fuel injection by the nozzle crack-
ing pressure applied as the high-pressure fuel on
the nozzle side. If the TWV is turned off, the fuel
circuit is so change that the high-pressure fuel
wilt be applied to the control chamber through
the orifice. As a result, the needle valve lowers
and finishes fuel injection. Accordingly, the fuel
injection timing and fuel injection rate are con-
trolled respectively by the timing to turn on the
TWV and the length of the turn-on time of the
TWV.
D155AX-5 10-197
STRUCTURE AND FUNCTION MONITOR SYSTEM
MONITOR SYSTEM
• The monitor system monitors the machine con- • The CPU (Central Processing Unit) in the moni-
dition with the sensors installed to various parts tor panel displays and outputs various informa-
of the machine and processes and displays the tion items processed by the transmission,
obtained information on the panel quickly to no- steering controller. The display unit is LCD (Liq-
tify the operator of the machine condition. uid Crystal Display)
The main display sections and functions of the
panel are as follows.
1) Monitor unit which turns on the alarm when
the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel level,
etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and volt-
age of the sensors and solenoids,
10-198 D155AX-5
STRUCTURE AND FUNCTION MONITOR SYSTEM
Processing in monitor panel (Common to all specifications)

Display of monitor panel
(1) Contents and conditions of processing (2)Method (3) Flow of signals
1) Display of travel direction and gear speed.

F1, R3, etc. are notified by CAN according to information
of transmission and steering controller.
2) Display of gauges of engine speed, engine water tem- CAN

perature, etc.
Controller converts the sensor signals into gauge num-
bers and sends them to the monitor panel by CAN.
3) Display of trouble CAN

When the machine has a trouble, the corresponding fail-
ure code is notified to the monitor panel by CAN. Each sensor/solenoid-controller-
Which one should be turned on, the buzzer or the cau- monitor panel
tion lamp, is notified, too.
(a) In normal state
User code
(b) In trouble history display mode
The service code (6-digit code) and the following
items are displayed
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrences
The monitor panel displays the code on the multi infor-
mation section.
Display of monitoring condition
1) The communication conditions of each sensor, each so- CAN

lenoid, and CAN are displayed.
The item Nos. and device conditions are notified to the
monitor panel by CAN.
The monitor panel displays the items and each value on Each sensor-controller- monitor
its multi-information section. panel
2) Each items is selected by using the cursor switches, se-

lector switches, buzzer cancel switch, and shift UP/
DOWN switches.
Other items
1) Maintenance mode
2) Pm clinic auxiliary mode
3) Adjustment mode
4) Failure code display mode
5) Maintenance interval change mode
6) Electric system failure code display mode — —
7) Mechanical system failure code display mode
8) Adjustment mode
9) Load saving display mode
10) Real time monitoring mode
11) Dual display monitoring mode
a See TESTING AND ADJUSTING, Special functions of monitor panel (EMMS).
D155AX-5 10-199
STRUCTURE AND FUNCTION MONITOR PANEL
MONITOR PANEL
1. Display portion A 8. Hydraulic oil temperature caution lamp

(Speed range display and engine speed) 9. Power train oil temperature caution lamp
2. Charge caution lamp 10. Engine water temperature caution lamp
3. Power train oil temperature gauge 11. Engine oil pressure caution lamp
4. Engine water temperature gauge 12. Maintenance caution lamp
5. Fuel gauge 13. Preheat pilot lamp
6. Hydraulic oil temperature gauge 14. Display portion B (Multi information)
7. HSS charge pressure caution lamp
Outline
• The monitor panel consists of a monitor that is- 2) If the engine is started, the check-before-
sues an alarm when an error occurred in a vehi- starting items go off. (Whether the engine is
cle, a gauge that always displays the state of the running is judged by the signal (CAN) from
vehicle, and the service meter display portion the engine controller.)
etc.
The monitor panel installs a microcomputer and 3. Cautions
processes and displays signals from each sen- Caution items are checked until the engine stops
sor and controller. after the engine starts.
Besides, the items displayed on the monitor por- If an error occurs, the error is displayed by flash-
tion and gauge portion are listed in the table on ing and the alarm lamp synchronously flashes.
the next page. a Further, if an emergency item flashes, the alarm
buzzer also sounds at the same time.
Operation Flashing of the monitor and alarm lamp is re-
1. When the power turns on (When the starter peated. They come on and off for about 0.8 sec-
switch ON) ond.
1) All items of the gauge and monitor portions a The flashing period of the monitor slightly chang-
come on for three seconds. es when atmospheric temperature is low (below
2) The alarm lamp comes on for two seconds. about -10°C), but this case in not abnormal.
2. Check before starting
1) After all lighting of Section 1 is terminated, if
there is an error in a check-before-starting
item, the item may flash and the contents of
the error may be displayed on display portion
B (14).
10-200 D155AX-5
Monitor panel display

Display
Symbol Display item Display range Display method
category
Displays when engine is stopped and

starting switch is ON
Radiator coolant level Below low level
Display when normal: OFF
Display when abnormal: Flashes
Check
When sensor is abnormal

Display when normal: OFF
Engine oil pressure or when wiring harness is
Display when abnormal: ON
disconnected
Battery charge When charge is defective

SAP00522
Below 49.0kPa
Engine oil pressure
{0.5kg/cm2}
When at highest level

Engine coolant tempera- (108°C or above) on
ture engine coolant
temperature gauge
When at highest level

Torque converter oil tem- (130°C or above) on
Caution
Displays when starting switch is ON and

perature engine coolant
engine is running
temperature gauge Display when normal: OFF
Display when abnormal: Flashes
CAUTION lamp flashes
Hydraulic oil temperature 105±3°C or above Alarm buzzer sounds
When HSS charge

HSS charge pressure
pressure is reduced
When replacement time

Maintenance of filter or oil has been
passed
Lights according to required time

determined by engine controller based.
Pilot
Preheating When preheating It also lights at the time of manual pre-

heat by setting starting switch at preheat
position (turning it counterclockwise).
D155AX-5 10-201
Display
Symbol Display item Display range Display method
category
Engine coolant
temperature
Torque converter oil One place lights up to show

temperature applicable level
Gauges
Hydraulic oil temperature
All lamps light up below ap-

Fuel level
plicable level
Multi information
Service meter Actuated when the engine is

From 0 to 99999
(Hours meter) rotating
10-202 D155AX-5
STRUCTURE AND FUNCTION SENSORS
SENSORS
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine coolant temperature Resistance – –

Torque converter
Resistance – –
oil temperature
Hydraulic oil temperature Resistance – –
Fuel level Resistance – –
Engine speed Resistance – –
Bevel gear shaft speed Resistance – –
Pitch angle – – –
Deceleration potentiometer Resistance – –
HSS charge pressure Contact – –
ENGINE OIL PRESSURE SENSOR
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
ENGINE COOLANT TEMPERATURE SENSOR

TORQUE CONVERTER OIL TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
D155AX-5 10-203
ENGINE SPEED SENSOR

BEVEL GEAR SPEED SENSOR
1. Magnet
2. Terminal
3. Case
4. Boots
5. Connector
10-204 D155AX-5
PITCH ANGLE SENSOR
1. Body 3. Wire
2. Tube 4. Connector
• The sensor is filled with electrolyte. If the sensor

leans, the electrolyte surface slants. If the elec-
trolyte surface slants, the contact area of the 2
electrodes installed in the sensor with the elec-
trolyte changes. As a result, the electrostatic ca-
pacity between the 2 electrodes changes. The
change of the electrostatic capacity is output as
the change of the voltage.
• The input and output characteristics of the sen-
sor are shown in the figure at right.
D155AX-5 10-205
FUEL LEVEL SENSOR
1. Connector Function
2. Float • The fuel sensor is installed to the side face of the
3. Arm fuel tank. The float moves up and down accord-
4. Body ing go the fuel level. This movement of the float
5. Spring is transmitted by the arm and actuates a variable
6. Contact resistance. This sends a signal to the monitor
7. Spacer panel to indicate the remaining fuel level.
10-206 D155AX-5
STRUCTURE AND FUNCTION DECELERATION POTENTIOMETER
DECELERATION POTENTIOMETER
1. Connector Outline
2. Lever • The deceleration potentiometer is installed to the
3. Body front lower part of the floor and connected to the
4. Potentiometer decelerator pedal by linkage.
5. Cuppling • If the decelerator pedal is pressed, it rotates the
6. Shaft throttle potentiometer shaft through the linkage
7. Stopper and the potentiometer resistance changes.
Constant voltage is applied between pins A and
C of the potentiometer and a voltage signal is
sent through pin B to the engine controller ac-
cording to the position of the decelerator pedal.
D155AX-5 10-207
STRUCTURE AND FUNCTION DECELERATION POTENTIOMETER
HSS charging pressure sensor
1. Switch
2. Case
3. Wire
4. Connector
10-208 D155AX-5
STRUCTURE AND FUNCTION PALM COMMAND CONTROL SYSTEM
PALM COMMAND CONTROL SYSTEM
1. Monitor panel (Multi-information) 6. Engine speed sensor

2. Preset mode switch 7. Transmission control valve
3. Auto shift-down switch 8. Steering control valve
4. Engine controller 9. Transmission output shaft speed sensor
5. Transmission, steering controller
D155AX-5 10-209
STRUCTURE AND FUNCTION PALM COMMAND CONTROL SYSTEM
• Shift mode function

1. Function
If you shift the PCCS lever to the forward or re-
verse, the gear speed selected from the shift
mode is turned on.
• Shift mode 1: F1/R1
2. Type of Modes
(1) F1-R1
(2) F1-R2
(3) F2-R2
3. Selecting method
Shift the PCCS lever to “N”.
Select a mode with the shift up switch and shift down switch.
Shift up switch ON Shit up switch ON
Shift mode 1 Shift mode 2 Shift mode 3
Shift down switch ON Shift down switch ON
4. Displaying method
The selected mode is displayed on the monitor
panel.
• Auto Shift-down Function
1. Function
This function automatically shifts the gear speed
down if load is increased while the machine is
traveling at 2nd or 3rd speed or while the ma-
chine is in operation.
1) This function turns on the shift-down auto-
matically by calculating the drawbar pull
(load to the machine body) based the engine
speed, transmission speed and throttle infor-
mation from the transmission, steering con-
troller.
2) Once the machine is automatically shifted
down, it is not automatically shifted up again
to the former gear speed (it can be shifted up
with the shift switch, however).
3) This function is available for both the forward
and reverse travel.
2. Selecting method
Turn the auto shift-down switch (1) “N”.
10-210 D155AX-5
MAINTENANCE STANDARD
40 MAINTENANCE STANDARD
Engine mount ............................................... 40- 2

Power train unit mount ................................. 40- 3
Damper, universal joint ................................ 40- 4
Torque converter, PTO ................................ 40- 5
Transmission ............................................... 40- 8
Main relief valve ........................................... 40- 10
Bevel gear shaft, hss, brake (1/2) ................ 40- 12
Bevel gear shaft, hss, brake (2/2) ................ 40- 14
Brake valve ................................................... 40- 16
Scavenging pump, hss, PPC charge pump .. 40- 17
Power train pump, lubrication pump ............. 40- 18
Oil cooler bypass valve ................................. 40- 19
Final drive .................................................... 40- 20
Sprocket ....................................................... 40- 22
Main frame ................................................... 40- 24
Track frame .................................................. 40- 26
Recoil spring ................................................ 40- 27
Track roller bogie ......................................... 40- 28
Idler .............................................................. 40- 30
Track roller ................................................... 40- 32
Carrier roller ................................................. 40- 34
Track shoe ................................................... 40- 35
Suspension .................................................. 40- 42
Work equipment pump ................................. 40- 44
HSS pump ................................................... 40- 45
HSS motor ................................................... 40- 46
Cooling fan pump ......................................... 40- 47
Cooling fan motor ......................................... 40- 49
PPC valve ..................................................... 40- 50
Main control valve ........................................ 40- 52
Self pressure reducing valve ........................ 40- 57
Work equipment cylinder ............................. 40- 58
Quick drop valve ........................................... 40- 62
Cylinder stay ................................................. 40- 63
Work equipment ........................................... 40- 64
D155AX-5 40-1
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between bracket size Shaft Hole clearance limit
1
and cushion
–0.1 +0.046 0.100 –
60 0.4 Replace
–0.3 0 0.346
Standard clearance Clearance limit

Free height of mount
2
rubber
90 88
40-2 D155AX-5
MAINTENANCE STANDARD POWER TRAIN UNIT MOUNT
POWER TRAIN UNIT MOUNT
Unit: mm
Tolerance
Interference between size Shaft Hole clearance limit
1
steering case and bushing
+0.096 +0.046 –0.096 –
204 Max. 0
+0.050 0 –0.004
Clearance between bracket –0.1 +0.046 0.100 – Replace

2 60 0.4
and cushion –0.3 0 0.346

Free height of front mount
3
rubber
90 88
Free height of rear mount
4 43 41
rubber
D155AX-5 40-3
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
Unit: mm
Tolerance
Clearance between size clearance limit
1 flywheel housing Shaft Hole
and cover
–0.022 +0.070 0.022 –
511.18 0.2
–0.092 0 0.162
Replace
Clearance between –0.020 +0.063 0.020 –
2 466.72 0.2
flywheel and damper –0.083 0 0.146
Outer circumference Standard size Tolerance Repair limit

3 of coupling oil seal
0
contact surface 90 89.8
–0.087
40-4 D155AX-5
MAINTENANCE STANDARD TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO
D155AX-5 40-5
40-6 D155AX-5
Unit: mm
Standard size Tolerance Repair limit

1 Outer diameter of input coupling
oil seal contact surface 0
ø 100 ø 99.8 Hard chrome
–0.054 plating or replace
2 Inner diameter of retainer seal ring +0.040

ø 140 ø 140.3
contact surface 0
Width 0
4.45 4.0
3 Wear of stator shaft –0.1
seal ring
Thickness 5.2 ± 0.1 4.7
4 Backlash between PTO drive gear

0.198 – 0.484
and PTO idler gear
Backlash between PTO idler gear

5 and drive gear of power train/ Replace
0.198 – 0.484
steering lubrication pump, work
equipment pump
Backlash between PTO idler gear

6 and drive gear of HSS pump, fan 0.198 – 0.484
pump
Backlash between PTO drive

7 gear and scavenging pump drive 0.198 – 0.484
gear
D155AX-5 40-7
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
40-8 D155AX-5
MAINTENANCE STANDARD TRANSMISSION
Unit: mm

Free length Free length
1 No. 1 clutch spring (x 12) length load load
73.5N 62.8N
81.7 70.2 76.8
{7.5 kg} {6.4 kg}
40.2N 34.3N
2 No. 2 clutch spring (x12) 81.7 75.4 76.8
{4.1 kg} {3.5 kg}
98.1N 83.4N
3 No. 3 clutch spring (x12) 70 50 65.8
{10 kg} {8.5 kg}
93.2N 79.4N
4 No. 4 clutch spring (x12) 70 51 65.8
{9.5 kg} {8.1 kg}
66.7N 56.9N
5 No. 5 clutch spring (x12) 66 51.8 62
{6.8 kg} {5.8 kg}
Clutch disc thickness Standard size Tolerance Repair limit

6
(No. 1 - No. 2 clutch) 5.4 ±0.1 4.9
Clutch disc thickness
7 5.4 ±0.1 4.9
(No. 3 - No. 5 clutch)
Clutch plate thickness
8 5.8 ±0.1 5.2
(No. 1 - No. 5 clutch)
Overall assembled Replace
9 50.2 ±0.3 47.5
thickness of No. 1 clutch
Overall assembled
10 61.4 ±0.3 58.2
Overall assembled
11 39 ±0.3 36.9
Overall assembled
12 39 ±0.3 36.9
Overall assembled
13 27.8 ±0.3 26.2
–0.01
Wear of seal ring of Width 3.0 2.70
–0.03
14 transmission input
shaft Thickness 2.7 ±0.10 2.55
Backlash between sun Standard clearance Clearance limit

gears and planet pinion
15
(FORWARD, REVERSE, 0.14 – 0.35 —
1st - 3rd)
Backlash between planet
pinions and ring gear
16 0.15 – 0.38 —
inner teeth (FORWARD,
REVERSE, 1st, 2nd)
17 pinion and ring gear inner 0.16 – 0.41 —
teeth (3rd)
Backlash between carrier
18 and ring gear inner teeth 0.18 – 0.54 —
(REVERSE)
Backlash between carrier
19 and ring gear inner teeth 0.18 – 0.48 —
(FORWARD, 1st)
D155AX-5 40-9
MAINTENANCE STANDARD MAIN RELIEF VALVE
MAIN RELIEF VALVE
Unit: mm
Standard Tolerance Standard Clearance

Clearance between main size clearance limit
Shaft Hole
1 relief valve and valve
body –0.035 +0.013 0.035 –
28 0.08
–0.045 0 0.058
Clearance between main –0.020 +0.018 0.020 –
2 19 0.07
relief valve and piston –0.030 0 0.048
Clearance between torque
–0.035 +0.013 0.035 –
3 converter relief valve and 22 0.08
–0.046 0 0.068
valve body
Clearance between torque
–0.020 +0.021 0.020 –
4 converter relief valve and 15 0.07
–0.030 0 0.051
piston
Standard size Repair limit Replace
Main relief valve outside Free length Free length
5 length load load
spring
481N 483.5N
128 75.3 124.2
{49kg} {49.3kg}
Main relief vavle inside 401.8N 382.5N
6 108 75.3 104.8
spring {41.0kg} {39.0kg}
Main relief valve piston 7.32N 6.96N
7 30 25 29.1
Torque converter relief 153N 145.1N
8 50 42 48.5
valve spring {15.6kg} {14.8kg}
Torque converter relief 4.87N 4.61N
9 26 20 25.2
valve piton spring {0.497kg} {0.47kg}
40-10 D155AX-5
MAINTENANCE STANDARD BEVEL GEAR SHAFT, HSS, BRAKE (1/2)
BEVEL GEAR SHAFT, HSS, BRAKE (1/2)
40-12 D155AX-5
Unit: mm

Brake plate thickness Replace
2.9 2.6
1
Tolerance Repair limit
Repair
Brake plate distortion
or replace
Within 0.15 0.3

Brake disc thickness Replace
4.5 4.2
2
Tolerance Repair limit
Repair
Brake disc distortion
or replace
Within 0.25 0.4
Overall assembled Standard size Repair limit

3 thickness of brake
plates and discs 34.1 31.4

Backlash between brake
4
disc and brake inner drum
0.4 – 0.7 1.0
Backlash between sun gear
5 0.17 – 0.52 0.60 Replace
and planet gear
6 0.19 – 0.55 0.70
pinion and ring gear
Tolerance
Seal ring contact surface
size Shaft Hole clearance limit
7 at brake piston small-
diameter portion –0.100 +0.072 0.100 –
220 —
–0.172 0 0.244
D155AX-5 40-13
BEVEL GEAR SHAFT, HSS, BRAKE (2/2)
40-14 D155AX-5
Unit: mm

Backlash between gear A
1
and pinion
0.19 – 0.62 0.70
2 0.18 – 0.58 0.70 Replace
and gear C
Backlash between gear D
3 0.19 – 0.61 0.80
and gear E
4 0.20 – 0.67 0.80
and gear B
Backlash between bevel Adjust or
5 0.25 – 0.33 0.50
gear and pinion replace
D155AX-5 40-15
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
Unit: mm
Tolerance
Clearance between brake size clearance limit
1 Shaft Hole
valve and body
–0.020 +0.013 0.020 –
19 0.07
–0.030 0 0.043
Clearance between brake –0.03 +0.015 0.030 –

2 9 0.08
valve and piston –0.04 0 0.055
Clearance between parking –0.034 +0.013 0.034 –

3 19 0.08
brake valve and body –0.043 0 0.056
Replace
4 Free Installed Installed Free Installed

Brake modulating spring
length length load length load
57.23N 54.9N
49.5 34.5 48.0
{5.84kg} {5.6kg}
157.98N 149.9N
5 Brake valve return spring 52.5 35 51
{16.12kg} {15.3kg}
Parking brake valve return 24.30N 23.03N

6 69.5 42 67.4
40-16 D155AX-5
MAINTENANCE STANDARD SCAVENGING PUMP, HSS, PPC CHARGE PUMP
SCAVENGING PUMP, HSS, PPC CHARGE PUMP

112 + 104
Unit: mm
Standard
Type Clearance limit
clearance
1 Side clearance
112 0.10 – 0.14 0.18
104 0.05 – 0.10 0.14
Clearance between plain 112

2 bearing inner diameter and 0.06 – 0.13 0.18 Replace
gear shaft outer diameter 104
Type Standard size Tolerance
3 Pin driving depth 112 0

13
104 –0.5
4 Spline shaft rotation torque 6.86 – 11.77Nm {0.7–1.2kgm}
Delivery Standard Delivery

Type Speed
pressure delivery limit
Delivery
0.3MPa 230 l/min
– 112 210 l/min —
Oil: EO10-CD {3kg/cm2}
Oil temperature: 45 – 50°C 2,200rpm
4.4MPa 215 l/min
104 195 l/min
{45kg/cm2}
D155AX-5 40-17
MAINTENANCE STANDARD POWER TRAIN PUMP, LUBRICATION PUMP
POWER TRAIN PUMP, LUBRICATION PUMP

SAL (3) 80 + 100
Unit: mm
Standard
Type Clearance limit
clearance
1 Side clearance
SAL (3) 80 0.10 – 0.15 0.19
SAL (3) 100 0.13 – 0.18 0.22
Clearance between plain SAL (3) 80

2 bearing inner diameter and 0.060 – 0.149 0.20 Replace
gear shaft outer diameter SAL (3) 100
Type Standard size Tolerance
3 Pin driving depth SAL (3) 80 0

14
SAL (3) 100 –0.5
4 Spline shaft rotation torque 13.7–23.5Nm {1.4–2.4kgm}

Type Speed
Delivery
2.9MPa
– SAL(3) 80 192 l/min 176 l/min —
Oil: EO10-CD {30kg/cm2}
Oil temperature: 45 – 50°C 2,500rpm
2.9MPa
SAL (3) 100 241 l/min 221 l/min
{30kg/cm2}
40-18 D155AX-5
MAINTENANCE STANDARD OIL COOLER BYPASS VALVE
OIL COOLER BYPASS VALVE
Unit: mm
Tolerance
Clearance between oil size Shaft Hole clearance limit
1 cooler bypass valve and
valve body –0.035 +0.013 0.035 –
22 0 0.08
–0.045 0.058
Replace
Installed Installed Free Installed
Free length
2 Spring length load length load
78.5 N 74.6 N
52 49 50
{8.0kg} {7.6kg}
D155AX-5 40-19
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-20 D155AX-5
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

Backlash between No. 1
1
pinion and No. 1 gear
0.28 – 0.93 1.0
Backlash between sun gear
2 0.24 – 0.79 1.0
and planet pinion
3 0.26 – 0.87 1.0
pinion and ring gear
Outer diameter of No. 1 Standard size Repair limit
4 pinion oil seal contact
surface 95 94.9
Replace
Outer diameter of No. 1
5 pinion oil seal contact 95 94.9
surface
Clearance at ball between
6 2.4 —
cover and shaft
Tolerance
Standard Standard Interference
Interference between pinion size Shaft Hole interference limit
7
shaft and carrier
–0.010 –0.009 0.006 –
58 0.006
–0.003 –0.039 0.049
Clearance of No. 1 pinion
8 0 – 0.1 (standard shim thickness: 2) Adjust
bearing in axial direction
D155AX-5 40-21
MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Standard clearance Repair limit

1 Wear of sprocket tooth tip
351 339
2 Wear of sprocket tooth root 23.7 17.5 Rebuid or

replace
3 Wear of width of sprocket tooth tip 83 75
Wear of width of sprocket tooth
4 103 95
root
40-22 D155AX-5
MAINTENANCE STANDARD SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
D155AX-5 40-23
MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
40-24 D155AX-5
MAINTENANCE STANDARD MAIN FRAME
Unit: mm
Tolerance
Clearance between HSS size clearance limit
1 Shaft Hole
case and main frame
–0.015 +0.046 0.015 –
250 0.2
–0.061 0 0.107
Clearance between main
+0.054 +0.154 0.070 – Replace
2 frame and radiator guard 95 1.5
0 +0.124 0.154
bushing
Clearance between main
+0.054 +0.154 0.070 –
3 frame and radiator guard 95 1.5
0 +0.124 0.154
bushing
Clearance between
–0.120 +0.207 0.240 –
4 equalizer bar center pin 85 1.5
–0.174 +0.120 0.381
and bushing
Press-fitting force for
5 radiator guard mount 73.5 – 122.6 kN {7.5 – 12.5 ton}
bushing
6 radiator guard mount 73.5 – 122.6 kN {7.5 – 12.5 ton} —
bushing
7 equalizer bar center pin 63.7 – 132.4 kN {6.5 – 13.5 ton}
bushing
D155AX-5 40-25
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
Unit: mm
Item Repair limit
Curvature Correct or
1 Deformation of track frame 7 (over length of 3000)
Twisting replace
3 (over length of 300)
Dents (pipe portion) 12

Clearance between idler
2 Adjust
and guide
0.5 – 1.0 3
40-26 D155AX-5
MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
Unit: mm

1 Recoil spring Free length Free length
length load load
298.7N 283.7N
1,125 937 1,091
{30,.456kg} {28,930kg}
Tolerance
Standard Standard Clearance Replace
Clearance between inner size clearance limit
2 cylinder and outer cylinder Shaft Hole
bushing
0 +0.277 0.062 –
130 0.7
–0.063 +0.062 0.340
Clearance between inner
+0.039 +0.130 0.061 –
3 cylinder and protrusion of 75 1.0
+0.009 +0.100 0.121
adjustment cylinder
Press-fitting force for outer

4 cylinder bushing (outer 19.6 – 29.4 kN {2 – 3 ton}
cylinder side) —
5 Press-fitting force for 245 kN {2.5 ton}

idler yoke
D155AX-5 40-27
MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
40-28 D155AX-5
MAINTENANCE STANDARD TRACK ROLLER BOGIE
Unit: mm
Tolerance
Clearance between size clearance limit
1 Shaft Hole
cartridge pin and bushing
–0.165 +0.189 0.294 –
80 0.8
–0.195 +0.129 0.384
Clearance between collar +0.203 +0.083 –0.183 –

2 133 — Replace
and outer bogie +0.183 +0.020 –0.100

3 135 —
and outer bogie +0.183 +0.020 –0.100

4 134 —
and inner bogie +0.183 +0.020 –0.100
5 Clearance of collar 1.5

6 0.98 – 18.6 kN {0.1 – 1.9 ton}
bushing
7 2.94 – 5.88 kN {0.3 – 0.6 ton}
washer
8 0.98 – 3.92 kN {0.1 – 0.4 ton}
washer
9 58.8 – 103.9 kN {6.0 – 10.6 ton} —
collar
10 88.3 – 202 kN {9.0 – 20.6 ton}
outer bogie
11 198 – 436 kN {20.2 – 44.5 ton}
inner bogie
12 94 – 206 kN {9.6 – 21.0 ton}
outer bogie
D155AX-5 40-29
MAINTENANCE STANDARD IDLER
IDLER
40-30 D155AX-5
MAINTENANCE STANDARD IDLER
Unit: mm

Outer diameter of
1
protrusion
792 —
2 Outer diameter of tread 750 725 Rebuild or

3 Depth of tread 21 — replace
4 Overall width 240 —
5 Width of tread 58.5 —
Tolerance
Clearance between shaft size Shaft Hole clearance limit Replace
6
and bushing bushing
–0.350 +0.270 0.310–
140 —
–0.413 –0.040 0.683
Tolerance
Interference between idler size Shaft Hole interference limit
7
and bushing
+0.063
150 — — —
–0.100
Rebuild or
8 Shaft flange width 216 — replace
D155AX-5 40-31
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
40-32 D155AX-5
MAINTENANCE STANDARD TRACK ROLLER
Unit: mm

Outer diameter of flange
1
(outside flange)
285 —
Outer diameter of flange
2 275 —
(inside flange)
3 Outer diameter of tread 250 210
4 Thickness of tread 57.5 37.5
5 Overall width 295 —
single flange 113 — Rebuild or

6 Inner width replace
double flange 69 —
Width of tread
7 61 —
(single flange)
Width of tread
8 61 —
(double flange)
Flange width
9 25 —
(outside of double flange)
Flange width
10 22 —
(inside of double flange)
11 Shaft flange width 246 —
Press-fitting dimension
12 — —
for collar
Tolerance
Clearance between shaft size Shaft Hole clearance limit Replace
13
and bushing bushing
–0.350 +0.260 0.360 –
125 —
–0.413 +0.010 0.673
Tolerance
Interference between shaft size Shaft Hole interference limit
14 Replace
and seal guide
—
D155AX-5 40-33
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outer diameter of flange
220 —
2 Outer diameter of tread 190 171 Rebuild or

replace
3 Width of tread 63 —
4 Thickness of tread 37.5 28
5 Width of flange 21 —
Tolerance Standard
Standard Interfer-
interfer-
Interference between size Shaft Hole ence limit
6 ence
bearing and roller
0 –0.024 0.009 –
110 —
–0.015 –0.059 0.059
Replace
Interference between +0.021 0 0.002–
7 60 —
bearing and shaft +0.002 –0.015 0.036

Play of roller in axial
8
direction
0.010 – 0.220 —
40-34 D155AX-5
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
DRY TYPE
a P portion shows the link of bushing press fitting end.
D155AX-5 40-35
Unit: mm

1 Link pitch
231.85 (Heavy-duty areas)
228.85
233.85 (Standard areas)
Reverse or
When turned replace
Standard size
2 Bushing outside diameter Normal load Impact load
81 75.0 77.0

Repair or
3 Link height
replace
144 128
Thickness of link metal
4 45.5
(bushing press-fitting portion)
5 219.8
Replace
6 Shoe bolt pitch 76.2
7 25.4
8 Inside width 122.8

Repair or
9 Link Overall width 61.4
replace
10 Tread width 54.3
11 Protrusion of pin 4.5

Protrusion of regular
12 10.4
bushing
13 Overall length of pin 294 Adjust or
replace
14 Overall length of bushing 202.2
15 Thickness of bushing metal 15.8
16 Thickness of spacer —
17 Bushing 88.2 – 313.6 kN {9 – 32 ton}
18 Press-fitting Regular pin 205.8 – 568.4 kN {21 – 58 ton} —

force
Master pin 107.8 – 274.4 kN {11 – 28 ton}
19
: Dry type track link
40-36 D155AX-5
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
588.4 ± 58.8 {60 ± 6} 120 ± 10
Shoe bolt Retighten
20 Tightening torque Additional tightening Lower limit torque
(Nm {kgm}) angle (deg.) (Nm {kgm})
b. Master link
— — —
No. of shoes (each side) 41 —
Tolerance
Standard
Standard size
Interference between Shaft Hole interference
21
bushing and link
+0.404 +0.074 0.230 –
77.0
+0.304 0 0.404
Interference between +0.584 +0.062 0.272 –

22 48.5
regular pin and link +0.304 0 0.584
Tolerance
Standard
Standard size
Clearance between Shaft Hole clearance
23
regular pin and bushing Adjust or
+0.484 +1.164 0.180 –
48.5 replace
+0.334 +0.664 0.830
Tolerance
Standard
Standard size
24
master pin and link
+0.330 +0.062 0.238 –
48.5
+0.300 0 0.330
Tolerance
Standard
Standard size
Clearance between Shaft Hole clearance
25
master pin and bushing
–0.550 +0.280 0.670 –
49
–0.650 +0.120 0.930
D155AX-5 40-37
SEALED AND LUBRICATED TRACK
a P portion shows the link of bushing press fitting end.
40-38 D155AX-5
Unit: mm

1 Link pitch
231.85 (Heavy-duty areas)
228.85
233.85 (Standard areas)
Reverse or
When turned replace
Standard size
2 Bushing outside diameter Normal load Impact load
81 72.5 75.0

Repair or
3 Link height
replace
144 128
Thickness of link metal
4 45.5
(bushing press-fitting portion)
5 219.8
Replace
6 Shoe bolt pitch 169
7 76.2
8 Inside width 122.8

Repair or
9 Link Overall width 61.4
replace
10 Tread width 54.3
11 Protrusion of pin 4.5

Protrusion of regular
12 3.25
bushing
13 Overall length of pin 291.6 Adjust or
replace
14 Overall length of bushing 187.9
15 Thickness of bushing metal 15.9
16 Thickness of spacer 11.1
17 Bushing 49 – 196 kN {5 – 20 ton}
18 Press-fitting Regular pin 196 – 294 kN {20 – 30 ton} —

force
Master pin —
19
D155AX-5 40-39
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
588.4 ± 58.8 {60 ± 6} 120 ± 10
Shoe bolt Retighten
20 Tightening torque Additional tightening Lower limit torque
(Nm {kgm}) angle (deg.) (Nm {kgm})
b. Master link
588.4 ± 58.8 {60 ± 6} 180 ± 10 882.6 {90}
No. of shoes (each side) 41 —
Tolerance
Standard
Standard size
21
bushing and link
+0.404 +0.074 0.230 –
77.0
+0.304 0 0.404
Interference between +0.484 –0.038 0.372 –

22 48.5
regular pin and link +0.334 –0.100 0.584
Tolerance
Standard Standard
Clearance between size Shaft Hole clearance
23 Adjust or
regular pin and bushing
+0.484 +1.164 0.180 – replace
48.5
+0.334 +0.664 0.830
Tolerance
Standard Standard
Interference between size interference
24 Shaft Hole
master pin and link
— — — —
Tolerance
Standard Standard
Clearance between size clearance
25 Shaft Hole
master pin and bushing
— — — —
40-40 D155AX-5
SINGLE SHOE
Unit: mm

1 Height
80 30
Repair or
2 Thickness 17
replace
3 Length at bottom 33
4 Length at top 15
D155AX-5 40-41
MAINTENANCE STANDARD SUSPENSION
SUSPENSION
40-42 D155AX-5
MAINTENANCE STANDARD SUSPENSION
Unit: mm
Tolerance
Clearance between pivot size clearance limit
1 Shaft Hole
shaft and bushing (inner)
–0.145 +0.125 0.230 –
175 1.0
–0.208 +0.085 0.333
Clearance between pivot –0.145 +0.125 0.230 –

2 148 1.0
shaft and bushing (outer) –0.208 +0.085 0.333 Replace
bushing
Clearance between center –0.120 +0.279 0.310 –
3 85 1.0
pin and bushing –0.174 +0.190 0.453
Clearance between side –0.048 0 0.033 –

4 75 1.0
pin and bushing –0.078 –0.015 0.078
Clearance between side pin

–0.1 +0.3
5 and spherical surface of 82 0.2 – 0.6 1.0
–0.3 +0.1
bushing
Press-fitting force for pivot
6 1.96 – 38.2 kN {0.2 – 3.9 ton}
shaft bushing (inner)
Press-fitting force for pivot
7 0.98 – 33.3 kN {0.1 – 3.4 ton} —
shaft bushing (outer)
Press-fitting force for side
8 43.1 – 213.8 kN {4.4 – 21.8 ton}
pin bushing
D155AX-5 40-43
MAINTENANCE STANDARD WORK EQUIPMENT PUMP
WORK EQUIPMENT PUMP

SAR(4)112
Unit: mm

1 Side clearance
0.11–0.16 0.19
Clearance between plain

2 bearing inner diameter and 0.060–0.140 0.20
gear shaft outer diameter
Replace
Standard size Tolerance
3 Pin driving depth 0
21
–0.5
4 Spline shaft rotation torque 11.8 – 19.6 {1.2 – 2.0}

Delivery Speed
– —
Oil: EO10-CD 20.6 MPa
Oil temperature: 45 – 50°C 2,200 rpm 233 l/min 215 l/min
{210kg/cm2}
40-44 D155AX-5
MAINTENANCE STANDARD HSS PUMP
HSS PUMP
Type: HPV160
D155AX-5 40-45
MAINTENANCE STANDARD HSS MOTOR
HSS MOTOR
Type: HMF140
Unit: mm
Free length Installed Installed Installed

Free length
1 Spool return spring x OD length load load
Replace spring
if damaged
530N 498N
43.5 x 28.7 36.0 — or deformed
{54kg} {50.8kg}
294N 277N
2 Spool return spring 48.5 x 21 41.0 —
{30kg} {28.2kg}
40-46 D155AX-5
MAINTENANCE STANDARD COOLING FAN PUMP
COOLING FAN PUMP

Type: LPV45
D155AX-5 40-47
MAINTENANCE STANDARD COOLING FAN PUMP
1. SERVO VALVE
40-48 D155AX-5
MAINTENANCE STANDARD COOLING FAN MOTOR
COOLING FAN MOTOR

Type: LMF55
Unit: mm
Free length
Installed Installed Installed If damaged or
x Outside Free length
10 Check valve spring length load load deformed,
diameter
replace spring
13.72N 10.29N
16.4 x 8.9 11.5 —
{1.4kg} {1.05kg}
D155AX-5 40-49
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
1. For blade lift, tilt
40-50 D155AX-5
MAINTENANCE STANDARD PPC VALVE
2. For ripper
Unit: mm

Centering spring Free length
1 x OD length load load
(for P3, P4 port)
55.9N 44.7N Replace spring
50.4 x 15.5 34.0 —
{5.7kg} {4.56kg} if damaged
or deformed
Centering spring 71.4N 56.9N
2 50.1 x 15.5 34.0 —
(for P1, P2 port) {7.28kg} {5.8kg}
16.7N 13.3N
3 Metering spring 26.5 x 8.20 24.9 —
{1.70kg} {1.36kg}
D155AX-5 40-51
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

(1/5)
a Precautions when tightening portions marked .
To ensure that the 3 bolts are tightened evenly,
tighten the bolts in three steps as follows.
1st pass: 58.8 ± 9.8 Nm {6 ± 1 kgm}
2nd pass: 137.3 ± 9.8 Nm {14 ± 1 kgm}
3rd pass: 186.3 ± 9.8 Nm {19 ± 1 kgm}
40-52 D155AX-5
(2/5)
D155AX-5 40-53
(3/5)
Unit: mm

Spool return spring Free length
(for blade LIFT only)
223.6N 178.5N
76.3 x 30 68.5 —
{22.8kg} {18.2kg}
140.2N 111.8N
2 Spool return spring 51.7 x 31.3 50 —
{14.3kg} {11.4kg}
Spool return spring 222.6N 268.7N

3 54.7 x 36.5 33.5 —
(for blade LIFT [FLOAT]) {22.7kg} {27.4kg}
12.7N 9.81N Replace spring

4 Load check valve spring 20.8 x 10.2 13.5 —
{1.3kg} {1.0kg} if damaged
or deformed
442.3N 354N
5 Unload spring 87.2 x 26 53.1 —
{45.1kg} {36.1kg}
443.2N 355N
6 Cancel spring 118.4 x 19.5 92.5 —
{45.2kg} {36.2kg}
71.6N 56.9N
7 Back pressure valve spring 99.5 x 14.9 96 —
{7.3kg} {5.8kg}
2.16N 0.98N
8 Relief valve spring 16.3 x 21.3 9 —
{0.22kg} {0.10kg}
1.27N 19.0N
9 Relief valve spring 20 x 7 13.7 —
{0.13kg} {1.94kg}
40-54 D155AX-5
(4/5)
D155AX-5 40-55
(5/5)
Unit: mm

Check valve spring inside Free length
spool
1.96N 1.57N
22 x 5.3 17 —
{0.2kg} {0.16kg} Replace spring
if damaged
62.5N 5.1N
2 Suction valve spring 64.9 x 12.5 56 — or deformed
{6.37kg} {0.52kg}
Check valve spring inside 0.29N 0.20N

3 9.4 x 4.6 8.5 —
spool {0.03kg} {0.02kg}
5.5N 4.4N
4 Suction valve spring 46.8 x 7.5 40.6 —
{0.56kg} {0.45kg}
40-56 D155AX-5
MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE
Unit: mm

Spring Free length
(pressure reduction valve main)
19.6 17.7N
19.2 x 7.20 16.1 — Replace spring if
{2.0kg} {1.80kg}
any damages or
Spring 28N 25.6N deformations are
2 17.8 x 7.20 12.7 —
(pressure reduction valve pilot) {2.90kg} {2.60kg} found
200N 186N
3 Spring 71.0 x 18.0 59.0 —
{20.4kg} {19.0kg}
61.7N 58.8N
4 Spring (safety valve) 16.1 x 7.80 13.4 —
{6.30kg} {6.0kg}
D155AX-5 40-57
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER
• BLADE LIFT CYLINDER
• BLADE TILT CYLINDER
• PIN PULLER CYLINDER
40-58 D155AX-5
Unit: mm
Tolerance
size clearance limit
Shaft Hole
Clearance Blade – 0.030 +0.271 0.105 –

75 0.675
1 between piston LIFT – 0.104 + 0.075 0.375
rod and bushing
Blade – 0.036 +0.270 0.097 –
90 0.673
TILT – 0.123 + 0.061 0.393
Pin –0.065 +0.133 0.072 –

30 0.55
puller –0.117 +0.007 0.250
Clearance between
piston rod spherical Blade –0.200 +0.030 0.200 –
2 85 1.0
surface and blade LIFT –0.300 0 0.330
ball portion Replace
Clearance between
Blade –0.120 +0.054 0.120 –
3 cylinder support shaft 85 0.5
LIFT –0.207 0 0.261
bushing and yoke
Blade –0.200 +0.300 0.200 –
Clearance between 115 —
TILT –0.300 0 0.600
4 piston rod spherical
surface and cap Pin –0.100 +1.300 1.300 –
29 —
puller –0.200 +1.200 1.500
Clearance between
Blade –0.300 +0.174 0.400 –
5 cylinder bottom sup- 60 1.0
TILT –0.500 +0.100 0.674
port shaft and bushing
Clearance between
Pin –1.1 1.0 –
6 cylinder bottom sup- 26 ±0.1 —
puller –1.2 1.3
port shaft and boss
D155AX-5 40-59
• RIPPER LIFT CYLINDER
• RIPPER TILT CYLINDER
40-60 D155AX-5
Unit: mm
Tolerance
size clearance limit
Shaft Hole
Clearance between
1 piston rod and Ripper – 0.030 +0.271 0.091 –
bushing 80 0.675
LIFT – 0.104 + 0.061 0.375
Ripper – 0.030 +0.271 0.091 –

80 0.675
TILT – 0.104 + 0.061 0.375
Ripper –0.036 +0.207 0.156 – Replace

Clearance between 85 1.0
LIFT –0.090 +0.120 0.297
2 piston rod support
shaft and bushing Ripper –0.036 +0.207 0.156 –
85 1.0
TILT –0.090 +0.120 0.297
Clearance between Ripper –0.036 +0.207 0.156 –

85 1.0
cylinder bottom LIFT –0.090 +0.120 0.2970
3
support shaft and Ripper –0.036 +0.207 0.156 –
bushing 85 1.0
TILT –0.090 +0.120 0.297
D155AX-5 40-61
MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE

• FOR BLADE LIFT CYLINDER
Unit: mm
Tolerance
Clearance between spool size clearance limit
1 Shaft Hole
and valve body
–0.011 +0.010 0.011 –
38.0 0.03
–0.016 0 0.026
Replace

Free length Free length
2 Valve spring length load load
136.3N 122.6N
75.2 55.9 67.7
{13.9kg} {12.5kg}
40-62 D155AX-5
MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
Unit: mm
Tolerance
Clearance between cylinder size clearance limit
1 Shaft Hole
yoke and bushing
–0.172 +0.063 0.172 – Replace
125 0.5
–0.235 0 0.298
Clearance between cylinder –0.170 +0.054 0.170 –

2 100 0.5
yoke and bushing –0.224 0 0.278
D155AX-5 40-63
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
SEMI U-DOZER
40-64 D155AX-5
Unit: mm
Tolerance
Clearance between brace size clearance limit
1 Shaft Hole
and pin
–0.3 +0.5 Replace
60 0.6 – 1.0 2
–0.5 +0.3
Clearance between brace –0.3 +0.5

2 60 0.6 – 1.0 2
pin and bracket –0.5 +0.3

3 115 0.2 – 0.6 1
spherical surface and cap –0.3 0
Adjust shims
Clearance between center or replace
–0.2 +0.3
4 brace spherical surface 115 0.2 – 0.6 1
–0.3 0
and cap
Clearance between joint –0.2 +0.5
5 120 0.5 – 1.2 2
and blade bracket –0.7 +0.3

6 120 0.5 – 1.2 2
and frame –0.7 +0.3
Clearance between frame –0.3 +0.3

7 60 0.3 – 0.8 3
pin and joint –0.5 0
Replace
8 60 0.3 – 0.8 3
pin and frame –0.5 0
Clearance between blade –0.3 +0.3

9 60 0.3 – 0.8 3
bracket pin and joint –0.5 0

10 60 0.3 – 0.8 3
bracket pin and bracket –0.5 0
Clearance between center Adjust shims

–0.2 +0.3
–0.3 0 or replace
and cap
Clearance between center –0.3 +0.3

12 85 0.6 – 0.8 2
link pin and center link –0.5 0

13 85 0.2 – 0.6 2
link pin and blade bracket –0.5 –0.1
Replace
14 196 0.3 – 0.6 2
link and blade bracket 0 +0.5
Clearance between trunnion –0.5 +0.5

15 160 0.5 – 1.5 8
and cap spherical surface –1.0 0
D155AX-5 40-65
U-DOZER
40-66 D155AX-5
Unit: mm
Tolerance
Clearance between brace size clearance limit
1 Shaft Hole
and pin
–0.3 +0.5 Replace
60 0.6 – 1.0 2
–0.5 +0.3

2 60 0.6 – 1.0 2
pin and bracket –0.5 +0.3

3 115 0.2 – 0.6 1
spherical surface and cap –0.3 0
Adjust shims
Clearance between center or replace
–0.2 +0.3
–0.3 0
and cap
5 120 0.5 – 1.2 2
and blade bracket –0.7 +0.3

6 120 0.5 – 1.2 2
and frame –0.7 +0.3

7 60 0.3 – 0.8 3
pin and joint –0.5 0
Replace
8 60 0.3 – 0.8 3
pin and frame –0.5 0

9 60 0.3 – 0.8 3
bracket pin and joint –0.5 0

10 60 0.3 – 0.8 3
bracket pin and bracket –0.5 0
Clearance between center Adjust shims

–0.2 +0.3
–0.3 0 or replace
and cap

12 85 0.6 – 0.8 2
link pin and center link –0.5 0

13 85 0.2 – 0.6 2
link pin and blade bracket –0.5 –0.1
Replace
14 196 0.3 – 0.6 2
link and blade bracket 0 +0.5
Clearance between trunnion –0.5 +0.5

15 160 0.5 – 1.5 8
and cap spherical surface –1.0 0
D155AX-5 40-67
CUTTING EDGE, END BIT
Unit: mm

1 Height of outside of end bit
415 300
Replace
2 Width of end bit 662 500
3 Height of inside of end bit 330 260

Turn
4 Height of cutting edge 330 260 (215 to turning)
or replace
40-68 D155AX-5
MULTI-SHANK RIPPER
GIANT RIPPER
D155AX-5 40-69
Unit: mm
Tolerance
Clearance between arm size clearance limit
1 mounting pin and Shaft Hole
mounting bracket
–0.036 +0.207 0.156 –
110 1.5
–0.090 +0.120 0.297
Clearance between arm –0.036 +0.520 0.348 –

2 110 1.5
mounting pin and bushing –0.090 +0.312 0.610
Clearance between arm
–0.036 +0.207 0.156 –
3 mounting pin and beam 110 1.5
–0.090 +0.120 0.297
bracket
Clearance between arm –0.036 +0.520 0.348 –
4 110 1.5 Replace
mounting pin and bushing –0.090 +0.312 0.610
Clearance between shank

Shaft 75 +0.300 +0.300
5 mounting pin and shank 1.4 – 2.6 10.0
Hole 77 –0.300 –0.300
holder
Clearance between shank
Shaft 75 +0.300 +0.100
6 mounting pin and shank 4.6 – 5.4 15.0
Hole 80 –0.300 –0.100
hole

7 Wear of point
335 225
8 Wear of protector 115 90
40-70 D155AX-5
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (1/2) .................................................................................................... 90- 3

HYDRAULIC CIRCUIT DIAGRAM (2/2) .................................................................................................... 90- 5
ELECTRIC CIRCUIT DIAGRAM (1/6) ....................................................................................................... 90- 7
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB .......................................................................................... 90- 19
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER ........................................................................ 90- 21
D155AX-5 90-1
(1)
HYDRAULIC CIRCUIT DIAGRAM (1/2)
D155AX-5 90-3
HYDRAULIC CIRCUIT DIAGRAM (2/2)
D155AX-5 90-5
ELECTRIC CIRCUIT DIAGRAM (1/6)
D155AX-5 90-7
(1)
D155AX-5 90-9
(1)
D155AX-5 90-11
(1)
D155AX-5 90-13
(1)
D155AX-5 90-15
(1)
D155AX-5 90-17
(1)
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB
D155AX-5 90-19
(1)
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER
D155AX-5 90-21
(1)

D155ax-5 Sebm034801

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D155ax-5 Sebm034801

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SEBM034801

MACHINE MODEL SERIAL NUMBER

D155AX-5 76001 and up

• D155AX-5 mounts the SA6D140E-3 engine.

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

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

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

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

q 00- 1 (1) 10- 9 10-56 10-100 10-144

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

a The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

790-129-9060 Adhesive: • Used as adhesive or sealant for

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

• Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 ± 1.4 1.35 ± 0.15

27 41 1320 ± 140 135 ± 15

Thread diameter Width across

6 10 7.85 ± 1.95 0.8 ± 0.2

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

10 14 65.7 ± 6.8 6.7 ± 0.7

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque