D155ax-5 Sebm034805

SEBM034805
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.
© 2004
All Rights Reserved
Printed in Japan 06-04 (02)
00-1
(5)
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1
20 TESTING AND ADJUSTING ............................................................. 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1
40 MAINTENANCE STANDARD ........................................................... 40-1
90 OTHERS ............................................................................................ 90-1
00-2 D155AX-5
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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
( ) Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
q 00- 1 (5) 10- 6 10-52 10- 97 10-141

00- 2 (3) 10- 7 10-54 10- 98 10-142
q 00- 2-1 (5) 10- 8 10-55 10- 99 10-143
q 00- 2-2 (5) 10- 9 (4) 10-56 10-100 (4) 10-144
q 00- 2-3 (5) 10-10 10-57 (4) 10-101 10-145 (4)
q 00- 2-4 (5) 10-12 10-58 (4) 10-102 10-146 (4)
q 00- 2-5 (5) 10-13 (4) 10-59 10-103 10-147 (4)
00- 3 10-14 10-60 10-104 10-148
00- 4 10-15 10-61 10-105 10-150
00- 5 10-16 10-62 10-106 10-151
00- 6 10-18 (4) 10-63 10-107 10-152
00- 7 10-19 10-64 10-108 10-153
00- 8 10-20 10-65 10- 110 10-154
00- 9 10-21 10-66 10- 111 10-155 (4)
00-10 10-22 10-67 (4) 10- 112 (4) 10-156
00-11 10-23 10-68 10- 113 10-157
00-12 10-24 10-69 10- 114 10-158
00-13 10-25 10-70 10- 115 10-159
00-14 10-26 10-71 (4) 10- 116 10-160
00-15 10-27 10-72 (4) 10- 117 10-161 (4)
00-16 10-28 10-73 10- 118 10-162
00-17 10-29 10-74 10- 119 10-163 (4)
00-18 10-30 10-75 10-120 10-164
00-19 10-31 10-76 (4) 10-121 10-165 (4)
00-20 10-32 (4) 10-78 10-122 10-166
00-21 10-33 10-79 10-123 10-167
00-22 10-34 10-80 10-124 10-168
01- 1 10-35 10-81 (4) 10-125 10-169
01- 2 10-36 10-82 (4) 10-126 10-170
01- 3 10-38 10-83 10-127 10-171
01- 4 10-39 10-84 (4) 10-128 10-172
01- 5 10-40 10-85 10-129 10-173
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01- 7 10-42 10-87 10-131 10-175
01- 8 10-43 (4) 10-88 10-132 10-176
01- 9 10-44 10-89 10-133 10-177
01-10 (4) 10-45 10-90 10-134 10-178
01-11 10-46 10-91 10-135 10-179
01-12 10-47-1 (1) 10-92 10-136 (4) 10-180
10- 1 10-47-2 (1) 10-93 10-137 10-181
10- 2 10-48 (1) 10-94 10-138 10-182 (4)
10- 3 (4) 10-50 10-95 10-139 (4) 10-183 (4)
10- 4 10-51 10-96 10-140 10-184
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10-185 20-126 (2) 20-185 (2) 20-321 (2) 20-380 (2)

10-186 20-127 (2) 20-186 (2) 20-322 (2) 20-381 (2)
10-187 20-128 (2) 20-187 (2) 20-323 (2) 20-401 (2)
10-188 20-129 (2) 20-188 (2) 20-324 (2) q 20-402 (5)
10-189 20-130 (2) 20-189 (2) 20-325 (2) q 20-403 (5)
10-190 20-131 (2) 20-190 (2) 20-326 (2) 20-404 (2)
10-191 20-132 (2) 20-191 (2) 20-327 (2) 20-405 (2)
10-192 20-133 (2) 20-192 (2) 20-328 (2) 20-406 (2)
10-193 20-134 (2) 20-193 (2) 20-329 (2) 20-407 (2)
10-194 20-135 (2) 20-194 (2) 20-330 (2) 20-408 (2)
10-195 20-136 (2) 20-195 (2) 20-331 (2) 20-409 (2)
10-196 20-137 (2) 20-196 (2) 20-332 (2) 20-410 (2)
10-197 (4) 20-138 (2) 20-197 (2) 20-333 (2) 20- 411 (2)
10-198 20-139 (2) 20-198 (2) 20-334 (2) 20-412 (2)
10-199 (4) 20-140 (2) 20-199 (2) 20-335 (2) 20-413 (2)
10-200 (4) 20-141 (2) 20-200 (2) 20-336 (2) 20-414 (2)
10-201 20-142 (2) 20-201 (2) 20-337 (2) 20-415 (2)
10-202 20-143 (2) 20-202 (2) 20-338 (2) 20-416 (2)
10-203 20-144 (2) 20-203 (2) 20-339 (2) 20-417 (2)
10-204 20-145 (2) 20-204 (2) 20-340 (2) 20-418 (2)
10-205 (4) 20-146 (2) 20-205 (2) 20-341 (2) q 20-419 (5)
10-206 20-147 (2) 20-206 (2) 20-342 (2) q 20-420 (5)
10-207 20-148 (2) 20-207 (2) 20-343 (2) q 20-421 (5)
10-208 20-149 (2) 20-208 (2) 20-344 (2) q 20-422 (5)
10-209 20-150 (2) 20-209 (2) 20-345 (2) 20-423 (2)
10-210 20-151 (2) 20-210 (2) 20-346 (2) q 20-424 (5)
20- 1 (2) 20-152 (2) 20- 211 (2) 20-347 (2) 20-426 (2)
20- 2 (2) 20-153 (2) 20-212 (2) 20-348 (2) 20-427 (2)
20- 3 (2) 20-154 (2) 20-213 (2) 20-349 (2) 20-428 (2)
20- 4 (2) 20-155 (2) 20-214 (2) 20-350 (2) 20-429 (2)
20- 5 (2) 20-156 (2) 20-215 (2) 20-351 (2) 20-430 (2)
20- 6 (2) 20-157 (2) 20-216 (2) 20-352 (2) 20-431 (2)
20- 7 (2) 20-158 (2) 20-217 (2) 20-353 (2) 20-432 (2)
20- 8 (2) 20-159 (2) 20-218 (2) 20-354 (2) 20-433 (2)
20-101 (2) 20-160 (2) 20-219 (2) 20-355 (2) 20-434 (2)
20-102 (2) 20-161 (2) 20-220 (2) 20-356 (2) 20-435 (2)
20-103 (2) 20-162 (2) 20-221 (2) 20-357 (2) 20-436 (2)
20-104 (2) 20-163 (2) 20-222 (2) 20-358 (2) 20-437 (2)
20-105 (2) 20-164 (2) 20-223 (2) 20-359 (2) 20-438 (2)
20-106 (2) 20-165 (2) 20-301 (2) 20-360 (2) 20-439 (2)
20-107 (2) 20-166 (2) 20-302 (2) 20-361 (2) 20-440 (2)
20-108 (2) 20-167 (2) 20-303 (2) 20-362 (2) 20-442 (2)
20-109 (2) 20-168 (2) 20-304 (2) 20-363 (2) 20-443 (2)
20- 110 (2) 20-169 (2) 20-305 (2) 20-364 (2) 20-444 (2)
20- 111 (2) 20-170 (2) 20-306 (2) 20-365 (2) 20-445 (2)
20- 112 (2) 20-171 (2) 20-307 (2) 20-366 (2) 20-446 (2)
20- 113 (2) 20-172 (2) 20-308 (2) 20-367 (2) 20-447 (2)
20- 114 (2) 20-173 (2) 20-309 (2) 20-368 (2) 20-448 (2)
20- 115 (2) 20-174 (2) 20-310 (2) 20-369 (2) 20-450 (2)
20- 116 (2) 20-175 (2) 20- 311 (2) 20-370 (2) 20-451 (2)
20- 117 (2) 20-176 (2) 20-312 (2) 20-371 (2) 20-452 (2)
20- 118 (2) 20-177 (2) 20-313 (2) 20-372 (2) 20-453 (2)
20- 119 (2) 20-178 (2) 20-314 (2) 20-373 (2) 20-454 (2)
20-120 (2) 20-179 (2) 20-315 (2) 20-374 (2) 20-455 (2)
20-121 (2) 20-180 (2) 20-316 (2) 20-375 (2) 20-456 (2)
20-122 (2) 20-181 (2) 20-317 (2) 20-376 (2) 20-457 (2)
20-123 (2) 20-182 (2) 20-318 (2) 20-377 (2) 20-458 (2)
20-124 (2) 20-183 (2) 20-319 (2) 20-378 (2) 20-459 (2)
20-125 (2) 20-184 (2) 20-320 (2) 20-379 (2) 20-460 (2)
00-2-2 D155AX-5
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20-461 (2) 20-522 (2) 20-582 (2) 20-647 (2) 30- 4 (3)
q 20-462 (5) 20-524 (2) 20-583 (2) 20-648 (2) 30- 5 (3)
20-463 (2) 20-525 (2) 20-584 (2) 20-649 (2) q 30- 6 (5)
q 20-464 (5) 20-526 (2) 20-585 (2) 20-650 (2) q 30- 7 (5)
20-465 (2) 20-527 (2) 20-586 (2) 20-651 (2) q 30- 8 (5)
20-466 (2) 20-528 (2) 20-587 (2) 20-652 (2) q 30- 9 (5)
20-467 (2) 20-529 (2) 20-588 (2) 20-653 (2) q 30-10 (5)
20-468 (2) 20-530 (2) 20-589 (2) 20-655 (2) q 30-11 (5)
20-469 (2) 20-531 (2) 20-590 (2) 20-656 (2) q 30-12 (5)
20-470 (2) 20-532 (2) 20-591 (2) 20-657 (2) q 30-13 (5)
20-471 (2) 20-533 (2) 20-592 (2) 20-658 (2) q 30-14 (5)
20-472 (2) 20-534 (2) 20-593 (2) 20-659 (2) q 30-15 (5)
20-474 (2) 20-535 (2) 20-594 (2) 20-661 (2) q 30-16 (5)
20-475 (2) 20-536 (2) 20-595 (2) 20-662 (2) q 30-17 (5)
20-476 (2) 20-537 (2) 20-601 (2) 20-663 (2) q 30-18 (5)
20-477 (2) 20-538 (2) q 20-602 (5) 20-664 (2) q 30-19 (5)
20-478 (2) 20-539 (2) 20-603 (2) 20-665 (2) q 30-20 (5)
20-479 (2) 20-540 (2) 20-604 (2) 20-701 (2) q 30-21 (5)
20-480 (2) 20-541 (2) 20-605 (2) 20-702 (2) q 30-22 (5)
20-481 (2) 20-542 (2) 20-606 (2) 20-703 (2) q 30-23 (5)
20-482 (2) 20-543 (2) 20-607 (2) 20-704 (2) q 30-24 (5)
20-483 (2) 20-544 (2) 20-608 (2) 20-705 (2) 30-25 (3)
20-484 (2) 20-545 (2) 20-609 (2) 20-706 (2) 30-26 (3)
20-485 (2) 20-546 (2) 20-610 (2) 20-707 (2) 30-27 (3)
20-486 (2) 20-547 (2) 20- 611 (2) 20-708 (2) 30-28 (3)
20-487 (2) 20-548 (2) 20-612 (2) 20-709 (2) q 30-29 (5)
20-488 (2) 20-549 (2) 20-614 (2) 20-710 (2) 30-30 (3)
q 20-489 (5) 20-550 (2) 20-615 (2) 20- 711 (2) 30-31 (3)
20-490 (2) 20-551 (2) 20-616 (2) 20-712 (2) 30-32 (3)
20-491 (2) 20-552 (2) 20-617 (2) 20-713 (2) 30-33 (3)
q 20-492 (5) 20-553 (2) 20-618 (2) 20-714 (2) 30-34 (3)
20-493 (2) 20-554 (2) 20-619 (2) 20-715 (2) 30-35 (3)
20-494 (2) 20-555 (2) 20-620 (2) 20-716 (2) 30-36 (3)
20-496 (2) 20-556 (2) 20-621 (2) 20-751 (2) q 30-37 (5)
20-497 (2) 20-557 (2) 20-622 (2) 20-752 (2) q 30-38 (5)
20-498 (2) 20-558 (2) 20-623 (2) 20-753 (2) 30-39 (3)
20-499 (2) 20-559 (2) 20-624 (2) 20-754 (2) q 30-40 (5)
20-500 (2) 20-560 (2) 20-625 (2) 20-755 (2) q 30-41 (5)
20-501 (2) 20-561 (2) 20-626 (2) 20-756 (2) 30-42 (3)
20-502 (2) 20-562 (2) 20-627 (2) 20-757 (2) q 30-43 (5)
20-503 (2) 20-563 (2) 20-628 (2) 20-758 (2) 30-44 (3)
20-504 (2) 20-564 (2) 20-629 (2) 20-759 (2) q 30-45 (5)
20-505 (2) 20-565 (2) 20-630 (2) 20-760 (2) q 30-46 (5)
20-506 (2) 20-566 (2) 20-631 (2) 20-761 (2) q 30-47 (5)
20-507 (2) 20-567 (2) 20-632 (2) 20-762 (2) 30-48 (3)
20-508 (2) 20-568 (2) 20-633 (2) 20-763 (2) 30-49 (3)
20-509 (2) 20-569 (2) 20-634 (2) 20-764 (2) 30-50 (3)
q 20-510 (5) 20-570 (2) 20-635 (2) 20-765 (2) 30-51 (3)
20- 511 (2) 20-571 (2) 20-636 (2) 20-766 (2) 30-52 (3)
20-512 (2) 20-572 (2) 20-637 (2) 20-767 (2) 30-53 (3)
20-513 (2) 20-573 (2) 20-638 (2) 20-768 (2) 30-54 (3)
20-514 (2) 20-574 (2) 20-639 (2) 20-769 (2) q 30-55 (5)
20-515 (2) 20-575 (2) 20-640 (2) 20-770 (2) q 30-56 (5)
20-516 (2) 20-576 (2) 20-641 (2) 20-771 (2) 30-57 (3)
q 20-517 (5) 20-577 (2) 20-642 (2) 20-772 (2) 30-58 (3)
20-518 (2) 20-578 (2) 20-643 (2) 20-773 (2) q 30-59 (5)
q 20-519 (5) 20-579 (2) 20-644 (2) 30- 1 (3) 30-60 (3)
20-520 (2) 20-580 (2) 20-645 (2) 30- 2 (3) 30-61 (3)
20-521 (2) 20-581 (2) 20-646 (2) 30- 3 (3) 30-62 (3)
D155AX-5 00-2-3
(5)
30- 63 (3) 30-122 (3) 30-181 (3) q 30-240 (5) 30-299 (3)
30- 64 (3) 30-123 (3) 30-182 (3) 30-241 (3) 30-300 (3)
30- 65 (3) 30-124 (3) 30-183 (3) q 30-242 (5) 30-301 (3)
30- 66 (3) q 30-125 (5) 30-184 (3) q 30-243 (5) 30-302 (3)
30- 67 (3) 30-126 (3) 30-185 (3) 30-244 (3) 30-303 (3)
30- 68 (3) q 30-127 (5) 30-186 (3) 30-245 (3) 30-304 (3)
30- 69 (3) q 30-128 (5) 30-187 (3) 30-246 (3) 30-305 (3)
30- 70 (3) 30-129 (3) 30-188 (3) 30-247 (3) 30-306 (3)
30- 71 (3) q 30-130 (5) 30-189 (3) q 30-248 (5) 30-307 (3)
30- 72 (3) 30-131 (3) q 30-190 (5) q 30-249 (5) 30-308 (3)
30- 73 (3) 30-132 (3) 30-191 (3) q 30-250 (5) 30-309 (3)
30- 74 (3) 30-133 (3) 30-192 (3) q 30-251 (5) 30-310 (3)
30- 75 (3) 30-134 (3) 30-193 (3) 30-252 (3) 30- 311 (3)
30- 76 (3) q 30-135 (5) q 30-194 (5) 30-253 (3) q 30-312 (5)
30- 77 (3) 30-136 (3) q 30-195 (5) q 30-254 (5) 30-313 (3)
30- 78 (3) 30-137 (3) 30-196 (3) q 30-255 (5) 30-314 (3)
30- 79 (3) q 30-138 (5) q 30-197 (5) q 30-256 (5) 40- 1
30- 80 (3) 30-139 (3) q 30-198 (5) q 30-257 (5) 40- 2
q 30- 81 (5) 30-140 (3) q 30-199 (5) q 30-258 (5) 40- 3
30- 82 (3) 30-141 (3) 30-200 (3) q 30-259 (5) 40- 4
30- 83 (3) q 30-142 (5) 30-201 (3) q 30-260 (5) 40- 5
30- 84 (3) 30-143 (3) 30-202 (3) 30-261 (3) 40- 6
30- 85 (3) 30-144 (3) q 30-203 (5) 30-262 (3) 40- 7
30- 86 (3) 30-145 (3) q 30-204 (5) 30-263 (3) 40- 8
30- 87 (3) 30-146 (3) 30-205 (3) 30-264 (3) 40- 9
30- 88 (3) 30-147 (3) q 30-206 (5) 30-265 (3) 40- 10
30- 89 (3) 30-148 (3) q 30-207 (5) 30-266 (3) 40- 12
30- 90 (3) q 30-149 (5) q 30-208 (5) 30-267 (3) 40- 13
30- 91 (3) 30-150 (3) q 30-209 (5) 30-268 (3) 40- 14
30- 92 (3) 30-151 (3) 30-210 (3) 30-269 (3) 40- 15
30- 93 (3) 30-152 (3) 30- 211 (3) 30-270 (3) 40- 16
30- 94 (3) 30-153 (3) q 30-212 (5) 30-271 (3) 40- 17
30- 95 (3) 30-154 (3) q 30-213 (5) 30-272 (3) 40- 18
30- 96 (3) 30-155 (3) q 30-214 (5) 30-273 (3) 40- 19
30- 97 (3) 30-156 (3) q 30-215 (5) 30-274 (3) 40- 20
30- 98 (3) 30-157 (3) q 30-216 (5) 30-275 (3) 40- 21
30- 99 (3) 30-158 (3) q 30-217 (5) 30-276 (3) 40- 22
30-100 (3) 30-159 (3) 30-218 (3) 30-277 (3) 40- 23
30-101 (3) 30-160 (3) 30-219 (3) 30-278 (3) 40- 24
30-102 (3) 30-161 (3) q 30-220 (5) 30-279 (3) 40- 25
30-103 (3) 30-162 (3) 30-221 (3) 30-280 (3) 40- 26
30-104 (3) 30-163 (3) q 30-222 (5) 30-281 (3) 40- 27
30-105 (3) 30-164 (3) q 30-223 (5) 30-282 (3) 40- 28
30-106 (3) 30-165 (3) q 30-224 (5) 30-283 (3) 40- 29
30-107 (3) 30-166 (3) 30-225 (3) 30-284 (3) 40- 30
30-108 (3) 30-167 (3) 30-226 (3) q 30-285 (5) 40- 31
30-109 (3) 30-168 (3) 30-227 (3) 30-286 (3) 40- 32
30- 110 (3) q 30-169 (5) q 30-228 (5) 30-287 (3) 40- 33
30- 111 (3) q 30-170 (5) q 30-229 (5) q 30-288 (5) 40- 34
30- 112 (3) q 30-171 (5) 30-230 (3) q 30-289 (5) 40- 35
30- 113 (3) q 30-172 (5) 30-231 (3) q 30-290 (5) 40- 36
30- 114 (3) 30-173 (3) 30-232 (3) 30-291 (3) 40- 37
30- 115 (3) 30-174 (3) q 30-233 (5) 30-292 (3) 40- 38
30- 116 (3) 30-175 (3) q 30-234 (5) 30-293 (3) 40- 39
30- 117 (3) 30-176 (3) 30-235 (3) 30-294 (3) 40- 40
30- 118 (3) q 30-177 (5) 30-236 (3) 30-295 (3) 40- 41
30- 119 (3) 30-178 (3) 30-237 (3) 30-296 (3) 40- 42
30-120 (3) 30-179 (3) 30-238 (3) 30-297 (3) 40- 43
30-121 (3) 30-180 (3) q 30-239 (5) 30-298 (3) 40- 44
00-2-4 D155AX-5
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40-45
40-46
40-47
40-48
40-49
40-50
40-51
40-52
40-53
40-54
40-55
40-56
40-57
40-58
40-59
40-60
40-61
40-62
40-63
40-64
40-65
40-66
40-67
40-68
40-69
40-70
90- 1 (1)
90- 3
90- 5
90- 7 (2)
90- 9 (2)
90-11 (2)
90-13 (2)
90-15 (2)
90-17 (2)
90-19 (2)
90-21 (2)
D155AX-5 00-2-5
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00-2-6 D155AX-5
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
• HSS/PPC charge filter assembly 22
• HSS/PPC charge valve assembly 21
• Power train filter assembly 20
• Scavenging pump HSS/PPC 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
(4)
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. Inlet hose
3. Air bleed hose
4. Overflow hose
5. Reservoir tank
6. Coolant filler cap
7. Radiator core assembly
8. Inlet hose (for circulating at low coolant temper-
ature)
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
(4)
• 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, and steering unit.
• HSS unit consists of the bevel pinion unit, bevel
gear shaft, HSS motor, planetary gear and
brake.
D155AX-5 10-9
(4)
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.
• The 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
(4)
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 of the Palm Command a PCCS: Abbreviation for Palm Command Control
Steering Control lever (PCCS lever), see System
STEERING, BRAKE CONTROL.
10-18 D155AX-5
(4)
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 as shown in the
figure to the right.
By making the proportional solenoid-produced

thrust act on the pressure control valve spool, it
produces an oil pressure as shown in the figure
to the right. By controlling the amount of com-
mand current, 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
(4)
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 direction of ro-
tation 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
(4)
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 performed.
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
(4)
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) performs 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
(4)
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 perform the charge function
for the HSS circuit.
D155AX-5 10-67
(4)
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) performs 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) performs motion relative to the axial
direction inside each cylinder chamber of cylin-
der block (5).
D155AX-5 10-71
(4)
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
(as shown to the right) 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.
• Since the swash plate angle of the HSS mo- Q = qN Q: Total flow
tor is fixed ( is constant), torque T is pro- (q = E – F) q: Flow per 1 turn
portional to pressure P. N: Rotation speed
Pq
• Swash plate angle is 19°. T = ------- P: Pressure
2π
T: Rotating torque
10-72 D155AX-5
(4)
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 poppet 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
(4)
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. (However, the swash plate angle
is actually not set to 0.)
• In short, swash plate angle is in proportion to
the pump discharge.
D155AX-5 10-81
(4)
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
(4)
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 below.
10-84 D155AX-5
(4)
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
outer drum (8), piston (5), spring (4), bearing
HSS
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 parking
the normal direction to the reverse direction.
the machine, always place the parking brake at
• The transfer portion uses a spur gear reduction
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
(4)
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
(4)
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
(4)
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
(4)
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
(4)
2. Output voltage characteristics

• The control unit is installed to the left control
stand and the control lever is installed direct-
ly onto it.
• The operating angle (stroke) of the control
lever is sensed potentiometers and signal
voltages are output to the transmisson,
steering 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 to the right.
10-146 D155AX-5
(4)
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
on 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
(4)
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 performed by unload valve load F1 of spring (2) that is set to oppose pump
(1), which controls the amount of oil sent to the pressure P which is sent to chamber A1.
cylinder to an amount that matches the opening In other words, AO x P = F1 – F2 (AO: Area re-
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
(4)
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 perform
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 perform compound operations
with the other control valves.
D155AX-5 10-161
(4)
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)
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 performed, 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
(4)
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 out-

put pressure PR of the self pressure reduc-
ing valve.
• Spring (3) and the PR pressure (0 MPa {0kg/ • Therefore, there will occur a differential pressure
cm2} at the time of engine stop) pushes valve (2) around the hold a in spool (8) and the spool will
in the direction to close the circuit between ports move in the direction to close port P1 and the PR
P1 and P2. When the hydraulic oil enters the P1 opening. Then, the P1 pressure is reduced and
port, the expression (P1 pressure C Spring (3) adjusted to a certain pressure (set pressure) with
force + (ød area x PR pressure)) holds, and the the opening and is supplied as the PR pressure.
self pressure reducing valve will adjust the open-
ings of 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, poppet (5) will open and the hydraulic oil
flows through the route from the PR port, the
hole a in spool (8), poppet (5) opening to the tank
port T.
10-182 D155AX-5
(4)
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, poppet (5) will open and the hydraulic oil
crease and the P1 pressure will rise. Then, the will flow through the route from the PR port, the
expression (P1 pressure > Spring (3) force + (ød hole a in spool (8), the poppet (5) opening to tank
area x PR pressure)) will hold, and valve (2) will port T.
move to the right side till the stroke end. • Therefore, there will occur a differential pressure
As a result, the opening between ports P1 and around the hold a in spool (8), and spool (8) will
P2 will increase, the passage resistance will be- move in the direction to close port P1 and the PR
come smaller to reduce engine loss horsepower. opening. Then, the P1 pressure is reduced and
adjusted to a certain pressure (set pressure) with
the opening and is supplied as the PR pressure.
D155AX-5 10-183
(4)
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
(4)
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 coolant 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
(4)
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 coolant temperature caution lamp
3. Power train oil temperature gauge 11. Engine oil pressure caution lamp
4. Engine coolant 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
(4)
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 to the right.
D155AX-5 10-205
(4)
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
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES

Standard value table for engine ............... 20- 2
Standard value table for chassis .............. 20- 3
TESTING AND ADJUSTING ...................... 20-101
TROUBLESHOOTING ................................ 20-301
a The following precautions are necessary, when using the standard value tables for testing and adjusting, or
for troubleshooting.
1. The values in the table are for new machines, and are obtained from reference to values when shipping from
the factory. Therefore, they should be used as target values for judging the progress of wear, or when repair-
ing the machine.
2. The standard values for judging failures are based on the results of various tests when shipping the machine
from the factory. These values should be used as reference together with the repair condition and operating
record of the machine to make judgements on failures.
3. The values in the table should not be used for judging claims.
k When carrying out testing, adjusting, or troubleshooting, stop the machine on level ground, install the safety
pins and block the tracks.
k When carrying out work together with other workers, use agreed signals and do not allow unauthorized per-
sons near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan or other rotating parts.
D155AX-5 20-1
(2)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Engine SA6D140E-3
Item Measurement conditions Unit Standard value for Service limit value
new machine
High idling 2,050 ± 50 2,050 ± 50
Speed Low idling rpm 700 ± 50 700 ± 50
Rated speed 1,900 1,900
Intake air pressure
At rated output kPa {mmHg} Min. 113 {850} Min. 93 {700}
(Boost pressure)
Whole speed range
Exhaust temperature ºC Max. 650 Max. 700
(Outside air temperature: 20ºC)
At sudden acceleration Max. 6.0 Max. 7.0
Exhaust gas color Bosch index
At high idling Max. 1.0 Max. 2.0
Valve clearance Air intake valve 0.35 —
mm
(At normal temperature) Exhaust valve 0.57 —
Oil temperature: 40 – 60ºC kPa {kg/cm2} Min. 4.1 {42} Min. 2.8 {29}
Compression pressure
(Engine speed) (rpm) (200 – 250) (200 – 250)
Cooling water temperature:
Blow-by pressure Within operating range kPa {mmH2O} Max. 1.47 {150} Max. 2.94 {300}
At rated output
Cooling water temperature:
Within operating range
At high idling
SAE30 or SAE15W40 oil 0.34 – 0.54 {3.5 – 5.5} Min. 0.21 {2.1}
Oil pressure SAE10W30 oil MPa {kg/cm2} 0.29 – 0.49 {3.0 – 5.0} Min. 0.18 {1.8}
At low idling
SAE30 or SAE15W40 oil 0.12 {1.2} Min. 0.08 {0.8}
SAE10W30 oil 0.10 {1.0} Min. 0.07 {0.7}
Oil temperature Whole speed range (In oil pan) ºC 90 – 110 Max. 120
Deflection under finger pressure
Tension of alternator belt mm 13 – 16 13 – 16
of 98N {10kg}
Tension of air conditioner Deflection under finger pressure
mm 10 10
compressor belt of 58.8N {6kg}
20-2 D155AX-5
(2)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Category Item Measurement conditions Unit Standard value for Service
new machine limit value
Decelerator pedal • Engine water temperature:
Within operating range 850 ± 50 850 ± 50
speed
• Power train oil temperature:
Auto deceleration Within operating range
• Hydraulic oil temperature: 1,900 ± 50 1,900 ± 50
speed
rpm
Torque converter • Decelerator pedal speed: Press pedal.
• Auto deceleration speed: 1,651 ± 50 1,491
stall speed
Set all equipment in neutral.
Torque converter • Torque converter stall speed: F3
stall + Work equip- • Torque converter stall + Work equip- 1,410 ± 60 1,250
ment relief speed ment relief speed: F3 + Ripper RAISE
Neutral o
30 ± 5 30 ± 5
Forward and Forward
reverse Neutral o
30 ± 5 30 ± 5
• Stop engine. Reverse
mm
• Set lever knob to center. Neutral o
40 ± 5 40 ± 5
Left
Steering
Neutral o
40 ± 5 40 ± 5
Right
• Stop engine.
Decelerator pedal mm 45 ± 15 45 ± 15
• Set pedal to center.
All stroke 79 ± 10 79 ± 10
• Engine: Low idling
Brake pedal Stroke to 0 of mm
• Set pedal to center. 55 ± 2 55 ± 2
oil pressure
• Engine: Low idling Neutral – 72 ± 10 72 ± 10
• Hydraulic oil temperature: Raise/Float (Lower: 47 ± 10) (Lower: 47 ± 10)
Blade lever mm
Within operating range Neutral –
• Set lever knob to center. 53 ± 10 53 ± 10
Right/Left tilt
• Engine: Low idling Neutral –
75 ± 10 75 ± 10
• Hydraulic oil temperature: Raise/Lower
Ripper lever mm
Within operating range Neutral –
• Set lever knob to center. 80 ± 10 80 ± 10
Tilt in/out
Neutral o 56.9 ± 6.9 56.9 ± 6.9
Forward and Forward {5.8 ± 0.7} {5.8 ± 0.7}
reverse Neutral o 56.9 ± 6.9 56.9 ± 6.9
• Stop engine. Reverse N {5.8 ± 0.7} {5.8 ± 0.7}
• Set lever knob to center. Neutral o {kg} 24.5 ± 4.9 24.5 ± 4.9
Left {2.5 ± 0.5} {2.5 ± 0.5}
Steering
Neutral o 24.5 ± 4.9 24.5 ± 4.9
Right {2.5 ± 0.5} {2.5 ± 0.5}
• Stop engine. N 49.0 ± 9.8 49.0 ± 9.8
Decelerator pedal
• Set pedal to center. {kg} {5.0 ± 1.0} {5.0 ± 1.0}
• Engine: Low idling N 490.0 ± 49.0 608
Brake pedal
• Set pedal to center. {kg} {47.0 ± 5.0} {62}
Neutral o 39.2 ± 4.9 39.2 ± 4.9
• Engine: Low idling Raise {4.0 ± 0.5} {4.0 ± 0.5}
• Hydraulic oil temperature: Neutral o N 82.4 ± 9.8 82.4 ± 9.8
Blade lever
Within operating range Float {kg} {8.4 ± 1.0} {8.4 ± 1.0}
• Set lever knob to center. Neutral – 28.4 ± 4.9 28.4 ± 4.9
Right/Left tilt {2.9 ± 0.5} {2.9 ± 0.5}
• Engine: Low idling Neutral – 19.6 ± 4.9 19.6 ± 4.9
• Hydraulic oil temperature: Raise/Lower N {2.0 ± 0.5} {2.0 ± 0.5}
Ripper lever
Within operating range Neutral – {kg} 24.5 ± 4.9 24.5 ± 4.9
• Set lever knob to center. Tilt in/out {2.5 ± 0.5} {2.5 ± 0.5}
D155AX-5 20-3
(2)

Engine: 0.1 – 0.49 0.1 – 0.49
Torque converter Low idling {1 – 5} {1 – 5}
inlet pressure • Power train oil Engine: Max. 1.0 Max. 1.0
temperature: High idling MPa {Max. 10} {Max. 10}
Within operating range Engine: {kg/cm2} 0.05 – 0.29 0.05 – 0.29
Torque converter • Transmission: Neutral Low idling {0.5 – 3} {0.5 – 3}
outlet pressure Engine: 0.39 – 0.59 0.39 – 0.59
High idling {4 – 6} {4 – 6}
Engine:
— —
Transmission main Low idling
relief pressure Engine: 3.24 – 3.53 3.09
High idling {33 – 36} {31.5}
Engine: 3.04 – 3.33 2.88
Transmission F Low idling {31 – 34} {29.4}
clutch pressure Engine: 3.24 – 3.53 3.09
High idling {33 – 36} {31.5}
Engine: 3.04 – 3.33 2.88
Transmission R Low idling {31 – 34} {29.4}
clutch pressure • Power train oil Engine: 3.24 – 3.53 3.09
temperature: 65 – 80ºC High idling {33 – 36} {31.5}
• Parking brake lever: Free
Engine: 3.04 – 3.33 2.88
(Without main relief oil MPa
Transmission 1st Low idling {31 – 34} {29.4}
pressure) {kg/cm2}
clutch pressure • Brake pedal: Depressed Engine: 3.24 – 3.53 3.09
(Without main relief oil High idling {33 – 36} {31.5}
pressure) Engine: 3.04 – 3.33 2.88
Transmission 2nd Low idling {31 – 34} {29.4}
High idling {33 – 36} {31.5}
Engine: 3.04 – 3.33 2.88
Transmission 3rd Low idling {31 – 34} {29.4}
High idling {33 – 36} {31.5}
Transmission lubri-
Engine:
cating oil pressure — —
High idling
(For reference)
Engine: 2.75 ± 0.29 2.16
• Power train oil Low idling MPa {28 ± 3} {22}
Brake pressure
temperature: 65 – 80ºC Engine: {kg/cm2} 2.75 ± 0.29 2.16
High idling {28 ± 3} {22}
• Power train oil
Ripper pin puller Engine: MPa Min. 2.45 Min. 2.45
temperature:
operating pressure High idling {kg/cm2} {Min. 25} {Min. 25}
20-4 D155AX-5
(2)

HSS main relief 38.2 – 41.7 38.2 – 41.7
• Hydraulic oil temperature:
pressure MPa {390 – 425} {390 – 425}
HSS charge relief {kg/cm2} Min. 1.96 3.24
• Engine: High idling
pressure {Min. 20} {33}
• Flat road F1 3.5 ± 0.2 3.5 ± 0.2

• Engine coolant
temperature: F2 6.2 ± 0.3 6.2 ± 0.3
• Power train oil F3 10.8 ± 0.6 10.8 ± 0.6
temperature:
Travel speed km/h
• Engine: High idling R1 4.8 ± 0.2 4.8 ± 0.2
• Run up distance:
10 – 30m R2 8.4 ± 0.3 8.4 ± 0.3
• Measuring distance:
20m R3 13.9 ± 0.6 13.9 ± 0.6
Engine:
— —
Low idling
Unload pressure
Engine:
— —
High idling
Engine: 18.63 ± 0.98 18.63 ± 0.98
Blade lift relief Low idling {190 ± 10} {190 ± 10}
pressure • Hydraulic oil Engine: 20.59 ± 0.98 20.59 ± 0.98
temperature: High idling {210 ± 10} {210 ± 10}
Engine: 18.63 ± 0.98 18.63 ± 0.98
• Unload pressure: Low idling MPa {190 ± 10} {190 ± 10}
Blade tilt relief
Set all equipment in
pressure Engine: {kg/cm2} 20.59 ± 0.98 20.59 ± 0.98
neutral.
High idling {210 ± 10} {210 ± 10}
• Relief pressure:
Set cylinder to stroke Engine: 18.63 ± 0.98 18.63 ± 0.98
Ripper lift relief end. Low idling {190 ± 10} {190 ± 10}
pressure Engine: 20.59 ± 0.98 20.59 ± 0.98
High idling {210 ± 10} {210 ± 10}
Engine: 18.63 ± 0.98 18.63 ± 0.98
Ripper tilt relief Low idling {190 ± 10} {190 ± 10}
pressure Engine: 20.59 ± 0.98 20.59 ± 0.98
High idling {210 ± 10} {210 ± 10}
Control circuit main • Hydraulic oil temperature:
3.24 – 3.92 3.24 – 3.92
pressure Within operating range
MPa {33 – 40} {33 – 40}
(HSS, PPC, fan) • Engine: High idling
{kg/cm2}
PPC valve output • PPC valve output pressure: 3.82 – 4.12 3.53
pressure Set lever to stroke end {39 – 42} {36}
D155AX-5 20-5
(2)

Raise 3.0 – 5.0 3.0 – 5.0
Blade lift
• Engine: High idling Lower 1.0 – 1.5 1.0 – 1.5
• Apply no load to blade.
• Between ground level and raising
end of blade
Left tilt 2.7 ± 0.5 3.5
Blade tilt
• Engine: High idling Right tilt 2.3 ± 0.5 3.0
• Apply no load to blade.
• Between left tilt end and right tilt sec
end
Raise 2.5 ± 0.5 4.0
Ripper lift • Hydraulic oil temperature:

• Apply no load to ripper. Lower 3.0 ± 0.5 5.0
• Between ground level and raising
end of ripper
Tilt in 3.5 ± 0.5 4.5
Ripper tilt
• Engine: High idling Tilt out 2.5 ± 0.5 4.0
• Apply no load to ripper.
• Between tilt-in end and tilt-out end
20-6 D155AX-5
(2)

Blade • Move lever to stroke end. Max. 1.7 2.5
• Lower blade from max. raising position and
measure time after blade comes in contact with
ground until idler is lifted.
sec
Ripper • Move lever to stroke end. Max. 1.5 1.5
• Lower ripper from max. raising position and
measure time after ripper comes in contact with
ground until sprocket is lifted.
Hydraulic
drift of lift- Max. 150/15 minutes 200/15 minutes
ed blade
• Engine: Stopped
• Measure reduction of blade bottom height h
(for 15 minutes).
Hydraulic
drift of
machine Max. 50/5 minutes 70/5 minutes
lifted by mm
blade • Hydraulic oil temperature:
• Engine: Stopped
• Measure reduction of idler center height h
(for 5 minutes).
Hydraulic
drift of
machine Max. 50/5 minutes 70/5 minutes
tilted by
blade
• Engine: Stopped
• Measure reduction of idler center height h
(for 5 minutes).
D155AX-5 20-7
(2)

Hydraulic
drift of
machine mm Max. 50/5 minutes 70/5 minutes
lifted by
ripper • Hydraulic oil temperature:
• Engine: Stopped
• Measure reduction of sprocket center height h
(for 5 minutes).
Blade tilt
Max. 3.0 12
cylinder • Hydraulic oil temperature:
Ripper lift
• Engine: High idling cc/min Max. 2.7 11
cylinder
• Relieve cylinder and measure leakage for 1
Ripper tilt minute.
Max. 2.7 11
cylinder
• Fan: 100% speed mode
Min. speed — —
• Engine: Low idling
Fan speed rpm
• Fan: 100% speed mode
Max. speed 1,200 ± 50 1,200 ± 50
Fan pump oil • Fan: 100% speed mode MPa 13.7 13.7
pressure • Engine: High idling {kg/cm2} {140} {140}
20-8 D155AX-5
(2)

Tools for testing, adjusting, and Inspecting wear of sprocket ........................ 20-144
troubleshooting ........................................... 20-102 Adjusting clearance of idler ......................... 20-145
Measuring engine speed ............................ 20-104 Testing and adjusting track shoe tension .... 20-146
Measuring intake air pressure Testing and adjusting work equipment
(Boost pressure) ......................................... 20-107 oil pressure ................................................. 20-147
Measuring exhaust temperature ................. 20-109 Testing and adjusting control circuit
Measuring exhaust gas color ...................... 20-111 main pressure ............................................. 20-150
Adjusting valve clearance ........................... 20-113 Measuring PPC valve output pressure ........ 20-151
Measuring compression pressure .............. 20-114 Adjusting play of PPC valve ........................ 20-153
Measuring blow-by pressure ....................... 20-116 Measuring outlet pressure of
Measuring engine oil pressure ................... 20-117 ripper pin puller solenoid valve .................... 20-154
Handling of fuel system devices ................. 20-118 Testing parts which cause hydraulic drift of
Releasing residual pressure from blade and ripper .......................................... 20-155
fuel system .................................................. 20-118 Measuring internal leakage of
Measuring fuel pressure ............................. 20-119 work equipment cylinder ............................. 20-156
Bleeding air from fuel circuit ....................... 20-120 Releasing residual pressure from
Inspection of fuel circuit for leakage ........... 20-122 work equipment cylinder ............................. 20-157
Testing and adjusting alternator Bleeding air from work equipment cylinder .... 20-157
belt tension ................................................. 20-123 Adjusting safety lock lever ........................... 20-158
Testing and adjusting air conditioner Measuring fan motor speed ........................ 20-159
compressor belt .......................................... 20-124 Measuring fan circuit oil pressure ............... 20-160
Adjusting fuel control dial and Bleeding air from fan pump ......................... 20-161
decelerator pedal ........................................ 20-125 Adjusting blade (SEMI-U tiltdozer) .............. 20-162
Measuring power train oil pressure ............ 20-127 Testing and adjusting of operator’s cab ....... 20-164
Testing and adjusting HSS oil pressure ...... 20-132 Special functions of monitor panel (EMMS) ... 20-168
Adjusting transmission speed sensor ......... 20-137 Handling of high-voltage circuit of
Bleeding air from HSS pump ...................... 20-138 engine controller ......................................... 20-209
Simple method of testing brake Adjustment method of replaced controller .. 20-209
performance ............................................... 20-138 Preparation work for troubleshooting for
Adjusting brake pedal ................................. 20-139 electric system ............................................ 20-211
Adjusting at parking brake lever ................. 20-141 Pm clinic service ......................................... 20-213
Emergency escape method when Undercarriage troubleshooting report ......... 20-220
power train has trouble ............................... 20-142
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safe-
ty pins and blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt, or other rotating parts.
D155AX-5 20-101
(2)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Testing and adjusting item Symbol Part No. Part name Q’ty Remarks
Measuring intake air

A 799-201-2202 Boost gauge kit 1 –101 – 200kPa {–760 – 1,500mmHg}
pressure (boost pressure)
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299ºC
temperature
1 799-201-9000 Handy smoke checker 1 Pollution level: 0 – 70%
Measuring exhaust gas
C (With standard color)
color 2 Purchased Smoke meter 1 (Pollution level x 1/10 C Bosch index)
Adjusting valve clearance D Purchased Filler gauge 1 (Air intake: 0.35mm, Exhaust: 0.57mm)
1 795-502-1590 Compression gauge 1 0 – 6.9MPa {0 – 70kg/cm2}
Measuring compression
E 795-471-1310 Adapter 1
pressure 2 For 140E-3 engine
6217-71-6110 Gasket 1
Measuring blow-by
F 799-201-1504 Blow-by checker 1
pressure
Pressure gauge: 2.5, 5.9, 39.2, 58.8MPa
799-101-5002 Hydraulic tester 1
Measuring engine oil 1 {25, 60, 400, 600kg/cm2}
G
pressure 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8MPa {600kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98MPa {10kg/cm2}
1
Measuring fuel pressure H 790-261-1203 Digital hydraulic tester 1 aSame as G
2 799-401-2320 Hydraulic tester 1
Measuring power train oil 1
J 790-261-1203 Digital hydraulic tester 1 aSame as G
pressure
2 799-401-2320 Hydraulic tester 1
1 aSame as G1
Testing and adjusting HSS 790-261-1203 Digital hydraulic tester 1
K
oil pressure 799-101-5220 Nipple 2
2 Size: 10 x 1.25mm
07002-11023 O-ring 2
19M-06-32820 Switch assembly 1
Emergency escape when 1
L 17M-06-41530 Wiring harness 1
power train has trouble
2 790-190-1600 Pump assembly 1
Testing and adjusting 1 aSame as G1
790-261-1203 Digital hydraulic tester 1
work equipment oil M
pressure 799-101-5220 Nipple 1
2 Size: 10 x 1.25mm
07002-11023 O-ring 1
Testing and adjusting 799-101-5002 Hydraulic tester 1
1 aSame as G1
control circuit basic N 790-261-1203 Digital hydraulic tester 1
pressure 2 799-401-3200 Adapter 1 Size: 02
1 aSame as G1
Measuring PPC valve 790-261-1203 Digital hydraulic tester 1
P
output pressure 799-401-3100 Adapter 1 Size: 02
2
799-401-3200 Adapter 1 Size: 03
Measuring ripper pin 799-101-5002 Hydraulic tester 1
1 aSame as G1
puller solenoid valve outlet Q 790-261-1203 Digital hydraulic tester 1
pressure 2 799-401-3200 Adapter 1 Size: 03
Measuring oil leakage R Purchased Measuring cylinder 1
20-102 D155AX-5
(2)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Testing and adjusting item Symbol Part No. Part name Q’ty Remarks
Measuring fan motor

S 799-205-1100 Multitachometer 1
speed
1 aSame as G1
790-261-1203 Digital hydraulic tester 1
Measuring fan circuit oil
T 2 799-401-3400 Adapter 1 Size: 05
pressure
799-101-5220 Nipple 1 Size: 10 x 1.25mm
3
07002-11023 O-ring 1
Measuring water
temperature and oil — 799-101-1502 Digital thermometer 1 aSame as B
temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294N {0 – 30kg}
—
effort and pressing force 79A-264-0091 Push-pull scale 1 0 – 490N {0 – 50kg}
Measuring stroke and
— Purchased Scale 1
hydraulic drift
Measuring work
— Purchased Stopwatch 1
equipment speed
Measuring voltage and
— Purchased Tester 1
resistance
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connec-
tors and electric circuit diagram of each system.
D155AX-5 20-103
(2)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

a Measure the engine speed under the following 3. Measuring high idling speed
condition. 1) Start the engine and set the fuel control dial
• Engine water temperature: in the high idling position.
Within operating range 2) Set the PCCS lever and work equipment
• Power train oil temperature: control lever in neutral and measure the en-
Within operating range gine speed.
• Hydraulic oil temperature: a The high idling speed measured in the “Mon-
Within operating range itoring mode” or in the “Pm Clinic auxiliary
mode” is the auto-deceleration speed.
1. Preparation work a When measuring the high idling speed of the
Turn the starting switch ON and set the monitor engine, use the “Adjustment mode”.
panel in the “Monitoring mode” to prepare for Adjustment code:
measurement of the engine speed. 0007 (Engine decelerator cut mode)
a For the operating method, see “SPECIAL
FUNCTIONS OF MONITOR PANEL (EMMS)”.
• Monitoring code: 01000 (Engine speed)
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control dial
in the high idling position.
2. Measuring low idling speed 2) Set the PCCS lever and work equipment
1) Start the engine and set the fuel control dial control lever in neutral and press the decel-
in the low idling position. erator pedal and measure the engine speed.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the en-
gine speed.
20-104 D155AX-5
(2)
5. Measuring torque converter stall speed 6. Torque converter stall + Work equipment re-
1) Start the engine and set the fuel control dial lief speed (Full stall speed)
in the low idling position. 1) Start the engine and set the fuel control dial
2) Press the brake pedal securely and set the in the low idling position and raise the ripper
parking brake lever in the FREE position and to the stroke end.
set the PCCS lever in the FORWARD and 2) Keep pressing the brake pedal securely and
3rd gear speed position. set the parking brake lever in the FREE posi-
a Before going to the next step, check that tion and set the PCCS lever in the FOR-
the upper display unit of the monitor pan- WARD and 3rd gear speed position.
el is set in the normal display state and it a Before going to the next step, check that
displays [F3]. the upper display unit of the monitor pan-
a Keep the steering unit in neutral. el is set in the normal display state and it
3) Press the decelerator pedal and set the fuel displays [F3].
control dial in the high idling position. a Set the steering unit in neutral.
4) Return the decelerator pedal slowly to stall 3) Press the decelerator pedal and set the fuel
the torque converter with the engine at high control dial in the high idling position.
idling. 4) Return the decelerator pedal slowly to stall
k Keep pressing the brake pedal securely the torque converter with the engine at high
and keep your right foot on the decelera- idling.
tor pedal for safety until the work is fin- k Keep pressing the brake pedal securely
ished. and keep your right foot on the decelera-
5) Just after the power train oil temperature tor pedal for safety until the work is fin-
gauge reads the top line of the green range, ished.
return the direction of the PCCS lever into 5) Just after the power train oil temperature
neutral. gauge reads the top line of the green range,
return the direction of the PCCS lever into
neutral.
6) Repeat above steps 2) – 5) 3 times.

7) Perform steps 2) – 4) again and measure the
engine speed about 5 seconds after the 6) Repeat above steps 2) – 5) 3 times.
power train oil temperature gauge reads the 7) Perform steps 2) – 4) again and relieve the
top line of the green range. ripper in the raising direction and measure
a After finishing measurement, return the the engine speed about 5 seconds after the
direction of the PCCS lever into neutral power train oil temperature gauge reads the
and lower the power train oil temperature top line of the green range.
with the engine at high idling. a After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the power train oil temperature
with the engine at high idling.
D155AX-5 20-105
(2)
a The engine speed can be measured in the “Pm

Clinic auxiliary mode” of the monitor panel (Mea-
sure the high idling speed of the engine in the
“Adjustment mode”, however).
a For the operating method, see OPERATION
MANUAL.
• Auxiliary code: 01 (Engine speed)
20-106 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

a Measuring instruments for intake air pressure 4. Run the engine at medium or higher speed and
(boost pressure) drain the oil from the hose.
a Insert the joint of the gauge and hose half-
Symbol Part No. Name way and open the self-seal on the hose side
A 799-201-2202 Boost gauge kit repeatedly, and the oil is drained.
a If Pm kit (A) is available, the air bleeding cou-
k When installing and removing the measuring in- pling (790-261-1130) in it may be used.
strument, take care not to touch a hot part. a If any oil is left in the hose, the gauge does
a Measure the intake air pressure (boost pressure) not move. Accordingly, be sure to drain the
under the following condition. oil.
• Engine water temperature:
Within operating range 5. Run the engine at high idling and stall the torque
• Power train oil temperature: converter and measure the intake air pressure
Within operating range (boost pressure) at this time.
• Hydraulic oil temperature: a For the procedure for stalling the torque con-
Within operating range verter, see MEASURING ENGINE SPEED.
a Normally, the intake air pressure (boost
1. Open the right side cover of the engine and left pressure) should be measured while the en-
flame. gine is operated at the rated output. In the
field, however, an approximate value can be
2. Remove boost pressure pick-up plug (1) in front obtained by stalling the torque converter.
of intake manifold.
6. After finishing measurement, remove the mea-

3. Install nipple [1] of boost gauge kit A and con- suring instrument and return the removed parts.
nect gauge [2].
D155AX-5 20-107
(2)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
a The boost pressure can be measured in the “Pm

Clinic auxiliary mode” of the monitor panel.
a For the operating method, see OPERATION
MANUAL.
• Auxiliary code: 02 (Boost pressure)
20-108 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

a Measuring instrument for exhaust temperature 4. Install sensor [1] of digital thermometer B and
connect them to meter [2].
Symbol Part No. Name a Clamp the wiring harness of the digital ther-
B 799-101-1502 Digital thermometer mometer so that it will not touch a hot part
during measurement.
k Install and remove the measuring instrument af-
ter the exhaust manifold is cooled.
a Measure the exhaust temperature under the fol-
lowing condition.
• Torque converter oil temperature:
1. Open the right side cover of the engine and re-

move right flame cover.
5. Procedure for measuring maximum exhaust
2. Remove turbocharger heat insulation cover (1). temperature for troubleshooting.
Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the digital thermom-
eter.
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it by
the following calculation.
• Corrected value [ºC] = Measured value +
2 x (20 – Outside air temperature)
3. Remove exhaust temperature pick-up plug (2).
D155AX-5 20-109
(2)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
6. Procedure for measuring exhaust temperature 3) After the temperature lowers and is stabi-
periodically for preventive maintenance. lized, measure it (Condition c in the figure).
a If the torque converter is stalled simply, the k Just after the torque converter oil tem-
torque converter oil temperature is overheat- perature gauge reads the red range, re-
ed before the exhaust temperature is stabi- turn the direction of the PCCS lever into
lized. Accordingly, measure according to the neutral and lower the torque converter oil
following procedure. temperature.
1) Stall the torque converter fully to raise the
exhaust temperature to about 650ºC accord-
ing to the following procedure (Condition a in
the figure).
i) Start the engine and set the fuel control
dial to the low idling position. Raise the
ripper lift cylinder to the stroke end with
the ripper lever.
ii) Press the brake pedal securely and set
the PCCS lever in the FORWARD 3rd
gear speed position.
iii) Press the decelerator pedal and set the
fuel control dial to the high idling posi-
tion.
iv) Return the decelerator pedal slowly to
stall the torque converter and relieve the
ripper in raising direction with the engine
at high idling.
k Press the brake pedal securely and keep
your right foot on the decelerator pedal
for safety until the work is finished.
2) Stop only relieving the ripper and lower the
exhaust temperature by only stalling the
torque converter (Condition b in the figure).
a If the temperature does not lower but ris-
es, set the temperature in step 1).

suring instrument and return the removed parts.
20-110 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

a Measuring instrument for exhaust gas color 2. Measuring with smoke meter C2
1) Insert probe [1] of smoke meter C2 in the
Symbol Part No. Name outlet of the exhaust pipe and fix it to the ex-
1 799-201-9000 Handy smoke checker haust pipe with a clip.
C
2 Purchased Smoke meter
k When installing and removing the measuring in-

strument, take care not to touch a hot part.
a If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
a Measure the exhaust gas color under the follow-
ing condition.
1. Measuring with handy smoke checker C1 2) Connect the probe hose, receptacle of the
1) Stock a sheet of filter paper to handy smoke accelerator switch, and air hose to smoke
checker C1. meter C2.
2) Insert the exhaust gas intake pipe in the ex- a Limit the supplied air pressure to 1.5MPa
haust pipe. {15kg/cm2}.
3) Start the engine. 3) Connect the power cable to a receptacle of
4) Accelerate the engine suddenly or run it at AC100V power supply.
high idling and operate the handle of handy a Before connecting the cable, check that
smoke checker C1 so that the filter paper will the power switch of the smoke meter is
absorb the exhaust gas. turned off.
4) Before connecting the cable, check that the
power switch of the smoke meter is turned
off.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter C2.
5) Remove the filter paper and compare it with

the attached scale.
6) After finishing measurement, remove the
measuring instrument and return the re-
moved parts.
D155AX-5 20-111
(2)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
6) Start the engine.

7) Accelerate the engine suddenly or run it at
high idling and press the accelerator pedal of
smoke meter C2 and collect the exhaust gas
into the filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated val-
ue.
moved parts.
20-112 D155AX-5
(2)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

a Adjusting instrument for valve clearance 4. Insert filler gauge D in clearance b between
rocker arm (3) and cross head (4) and adjust the
Symbol Part No. Name valve clearance with adjustment screw (5).
D Purchased Filler gauge a Adjust the adjustment screw with the filler
gauge inserted so that the filler gauge can
1. Open the both side cover of the engine and re- be moved lightly.
move both flame cover.
3 Locknut:
5. Fix adjustment screw (5) and tighten locknut (6).
2. Remove all cylinder head covers (1).
53.0 – 64.7Nm {5.4 – 6.6kgm}
a After tightening the locknut, check the valve
clearance again.
3. Rotate the crankshaft forward and set line a of

“1.6TOP” of the damper to pointer (2) to set the
No. 1 cylinder piston to the compression top
dead center.
6. Rotate the crankshaft forward by 120 degrees
a Rotate the hexagonal part of the water pump
and repeat steps 3 – 5 for each cylinder in the fir-
drive shaft end to crank the engine.
ing order.
a When the No. 1 cylinder piston is at the com-
• Firing order: 1 – 5 – 3 – 6 – 2 – 4
pression top dead center, the No. 1 cylinder
rocker arm can be moved with the hand by
7. After finishing adjustment, return the removed
the valve clearance. If the rocker arm does
3 Cylinder head cover mounting bolt:

parts.
not move, the piston is not at the compres-
sion top dead center. In this case, revolve the
crankshaft 1 more turn. 29.4 – 34.3Nm {3.0 – 3.5kgm}
D155AX-5 20-113
(2)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pres- a Pass a wire, etc. under the fuel path project-
sure ed sideways and pull up the injector (Do not
pry the injector top up).
Symbol Part No. Name
1 795-502-1590 Compression gauge
E 795-471-1310 Adapter
2
6217-71-6110 Gasket
a When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
a Measure the compression pressure under the
following condition.
• Engine oil temperature: 40 – 60ºC
1. Open the right and left engine side covers and 5. Install adapter E2 and connect it to compression
remove the right and left frame cover. gauge E1.
3 Mounting bolt:
a Secure the adapter with the injector holder.
2. Remove head cover (1) of the cylinder to mea-
sure the compression pressure. 58.8 – 73.5Nm {6.0 – 7.5kgm}
a Apply a little amount of engine oil to the con-
necting parts of the adapter and gauge so
that air will not leak easily.
6. Install rocker arm assembly (2) and adjust the
3 Mounting bolt:
valve clearance.
93 – 103Nm {9.5 – 10.5kgm}

a See ADJUSTING VALVE CLEARANCE.
3. Remove rocker arm assembly (2).

a Referring to ADJUSTING VALVE CLEAE-
ANCE, set the cylinder to be measured at
the compression top dead center so that you
can work easily.
4. Disconnect fuel high-pressure tube (3) and re-

move the injector wiring harness and injector (4).
a Use a high-pressure pipe ring wrench (on
the market) to disconnect and connect the
fuel high-pressure tube. At this time, loosen
the clamps on the common rail side and at
the intermediate part.
a Disconnect the terminal of the injector wiring
harness on the injector side and the bracket
on the rocker housing side and remove the
injector wiring harness (Loosen the terminal
nuts alternately).
20-114 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
7. Disconnect engine intermediate connectors E21 3) Tighten sleeve nut (14) of the fuel high-pres-
(5) and E22 (6). sure tube to injector (11) lightly.
k If these connectors are not disconnected, a Use a high-pressure pipe ring wrench
the engine may start while your are measur- (on the market) to disconnect and con-
ing, and that is dangerous. Accordingly, be nect the fuel high-pressure tube.
sure to disconnect the connectors. a Tighten the sleeve nut lightly until it is
k Cover the connector on the controller side
stopped by the injector.
3 Mounting bolt:
(body side) with a vinyl sheet, etc. to prevent 4) Tighten mounting bolt (13) securely.
electric leakage and grounding fault.
58.8 – 73.5Nm {6.0 – 7.5kgm}
5) Tighten sleeve nut (14) of the fuel high-pres-
3 Sleeve nut:
sure tube securely.
39.2 – 49.0Nm {4 – 5kgm}

6) Tighten the intermediate clamp of the fuel
high-pressure tube.
7) Install the injector wiring harness.
a Tighten the terminal nuts at the injector
3 Nut: 2 ± 0.2Nm {0.2 ± 0.02kgm}

top alternately.
8. Turn the starting switch ON and prepare for mea-

suring the engine speed with the monitor panel.
a See MEASURING ENGINE SPEED.
9. Crank the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it is
stabilized.
a When measuring the compression pressure,
measure the engine speed, too, and check
that it is in the measurement condition range.
a After installing the rocker arm assembly, ad-
just the valve clearance. For details, see AD-
suring instruments and return the removed
3 Rocker arm assembly mounting bolt:

JJUSTING VALVE CLEARANCE.
parts.
a Install the injector and fuel high-pressure
tube according to the following procedure. 93 – 103Nm {9.5 – 10.5kgm}
1) Assemble injector (11) and holder (12) to-
gether and set them to the mounting position
of the cylinder head.
a When setting the injector, pull the fuel
high-pressure tube to outside of the cyl-
inder head so that the threads of the in-
jector will not interfere with the taper seal
of the fuel high-pressure tube.
2) Tighten mounting bolt (13) temporarily.
a Tighten the mounting bolt to a degree
that you can move the injector.
D155AX-5 20-115
(2)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measuring instrument for blow-by pressure a The blow-by pressure may vary largely with
the engine condition. If the measured value
Symbol Part No. Name is judged abnormal, check for increase of oil
F 799-201-1504 Blow-by checker consumption, bad exhaust gas color, deteri-
oration of oil, high deterioration speed of oil,
a Measure the blow-by pressure under the follow- etc. which are related to the abnormal blow-
ing condition. by pressure.
1. Open the left side cover of the engine and left

flame cover on the top.
2. Install nozzle [1] of blow-by checker F to blow-by

hose (1) and connect them to gauge [2].

3. Run the engine at high idling, stall the torque

converter, and measure the blow-by pressure.
a For the procedure for stalling the torque con-
verter, see MEASURING ENGINE SPEED.
a Normally, the blow-by pressure should be
measured while the engine is operated at the
rated output. In the field, however, an ap-
proximate value can be obtained by stalling
the torque converter.
a If it is impossible to run the engine at the rat-
ed output or stall the torque converter, mea-
sure while the engine is running at high
idling.
The value obtained in this case is about 80%
of the blow-by pressure at the rated output.
20-116 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

a Measuring instruments for engine oil pressure 4. Run the engine at low idling and high idling and
measure the engine oil pressure in each speed.
799-101-5002 Hydraulic tester
1
G 790-261-1203 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a Measure the engine oil pressure under the fol-

lowing condition.
1. Open the left side cover of the engine and re-

move left flame cover.
2. Remove the engine oil pressure of cylinder 5. After finishing measurement, remove the mea-
block. suring instruments and return the removed
parts.
3. Install nipple [1] and [2] of hydraulic tester G1

and connect them to hydraulic tester G2.
D155AX-5 20-117
(2)
HANDLING OF FUEL SYSTEM DEVICES
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE
HANDLING FROM
OF FUEL FUELDEVICES
SYSTEM SYSTEM
HANDLING OF FUEL SYS- RELEASING RESIDUAL PRES-

TEM DEVICES SURE FROM FUEL SYSTEM
a Precautions for testing and adjusting fuel system a Pressure is generated in the low-pressure circuit
The common rail fuel injection system (CRI) con- and high-pressure circuit of the fuel system while
sists of more precise parts than the conventional the engine is running.
fuel injection pump and nozzle. If foreign matter Low-pressure circuit:
enters this system, it can cause a trouble. Feed pump – Fuel filter – Fuel supply pump
When testing and adjusting the fuel system, take High-pressure circuit:
care more than the past. If dust, etc. sticks to any Fuel supply pump – Common rail – Fuel in-
part, wash that part thoroughly with clean fuel. jector
a Precautions for replacing fuel filter capacitor a The pressure in both low-pressure circuit and
Be sure to use Komatsu genuine fuel filter car- high-pressure circuit lowers to a safety level au-
tridge. tomatically 30 seconds after the engine is
Since the common rail fuel injection system stopped.
(CRI) consists of more precise parts than the a Before the fuel circuit is tested and its parts are
conventional fuel injection pump and nozzle, it removed, the residual pressure in the fuel circuit
employs a high-efficiency special filter to prevent must be released completely. Accordingly, ob-
foreign matter from entering it. serve the following.
If a filter other than the genuine one is used, the k Before testing the fuel system or removing its
fuel system may have a trouble. Accordingly, parts, wait at least 30 seconds after stopping the
never use such a filter. engine until the residual pressure in the fuel cir-
cuit is released. (Do not start the work just after
stopping the engine since there is residual pres-
sure.)
20-118 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE

a Measuring instrument for fuel pressure 3. Run the engine at high idling and measure the
fuel pressure.
Symbol Part No. Name a If the fuel pressure is in the following range,
799-101-5002 Hydraulic tester it is normal.
1 0.15 – 0.3MPa {1.5 – 3kg/cm2}
H 790-261-1203 Digital hydraulic tester
a Measure only the fuel pressure in the low-pres-

sure circuit from the feed pump to the fuel filter
and fuel supply pump.
k Since the pressure in the high-pressure circuit
from the fuel supply pump to the common rail
and fuel injector is very high, it cannot be mea-
sured.
1. Open the left side cover of the engine and re-

move fuel pressure pick-up plug (1) of fuel filter.
parts.
2. Install nipple (1) of hydraulic tester H1 and con-

nect hydraulic gauge H2.
D155AX-5 20-119
(2)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
a If fuel is used up or if a fuel circuit device is re-

moved and installed, bleed air from the fuel cir-
cuit according to the following procedure.
a Open the left side cover of the engine.
a The above figure shows the model equipped with
the additional (optional) fuel filter.
1. Remove fuel filter and additional fuel filter (1) and

fill it with fuel and install it again.
a Perform this step only when the additional
fuel filter is installed.
a Fill the fuel filter with clean fuel and take care
that dirt will not enter it.
a Add fuel through inlet ports 1a (8 places) of 2. Loosen air bleed plug (2) of the additional fuel fil-
the filter. Since hole 1b is the outlet port ter and bleed air.
(clean side), do not add fuel through it. a Perform this step only when the additional
a If clean fuel is not available, do not remove fuel filter is installed.
the filter but fill it with the fuel from the fuel a The air bleed plug has a hexagonal head.
tank by operating the priming pump. a Do not operate the priming pump.
a When the fuel flows out of the plug hole, in-
3 Air bleed plug:

stall the plug.
7.8 – 9.8kgm {0.8 – 1.0Nm}
20-120 D155AX-5
(2)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Remove plug (3a) of the fuel filter and operate

priming pump (4).
a Operate the priming pump until the fuel flows
3 Plug: 3.9 – 6.9kgm {0.4 – 0.7Nm}

out of the plug hole, then install the plug.
4. Remove plug (3b) of the fuel filter and operate

priming pump (4).
3 Air bleed plug:

out of the plug hole, then install the plug.
7.8 – 9.8kgm {0.8 – 1.0Nm}
5. Loosen air bleeder (5) of the fuel supply pump

and operate priming pump (4) 90 – 100 times.
out of the air bleeder and tighten the air
bleeder. Then, operate the priming pump
3 Air bleeder:
several times more until it becomes heavy.
4.9 – 6.9kgm {0.5 – 0.7Nm}
6. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled au-
tomatically if the engine is cranked.
a If the engine does not start, there may be still
air in the low-pressure circuit. In this case,
repeat the above steps from 2.
D155AX-5 20-121
(2)
TESTING AND ADJUSTING INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE

k Very high pressure is generated in the high-pres- 8. Run the engine at high idling and apply a load to
sure circuit of the fuel system. If fuel leaks while it.
the engine is running, it is dangerous since it can a Relief the oil by blade raising operation.
catch fire.
After testing the fuel system or removing its 9. Inspect the fuel piping and devices for fuel leak-
parts, inspect it for fuel leakage according to the age.
following procedure. a Inspect around the high-pressure circuit
a Clean and degrease the engine and the parts parts coated with the color checker for fuel
around it in advance so that you can inspect it leakage.
easily for fuel leakage. a If any fuel leakage is detected, repair it and
inspect again from step 2.
1. Spray color checker (developer) over the fuel a If any fuel leakage is not detected, inspection
supply pump, common rail, fuel injector, and is completed.
joints of the high-pressure piping.
2. Run the engine at speed below 1,000rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel leak-

age.
a Inspect around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
a If any fuel leakage is detected, repair it and
4. Run the engine at low idling.

age.
leakage.
6. Run the engine at high idling.

age.
leakage.
20-122 D155AX-5
(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION

Testing procedure Adjustment procedure
1. Open the engine side cover on the right and re- a Adjust the belt according to the following proce-
move the right frame cover. dure when the belt deflection is not normal.
2. Measure the belt deflection (a) when pushing a 1. Loosen 2 cover mounting bolts (1) and remove
point midway between the alternator pulley and the cover.
the drive pulley with the finger.
a Deflection (a) when pressing force is approx. 2. Loosen bolts and nuts (2), (3), and (4).
98N {approx. 10kg}: 13 – 16mm
3. Turn nut (5) to move alternator (6), and adjust the
belt tension.
a Test for breakage of each pulley, friction of V-
ditch, and contact between belt and V-ditch.
a Replace it with new belt if it was too
stretched so that adjustability was lost, or cut
and crack occurred.
a When moving the alternator, do not push it
directly with a bar but put a wood piece be-
tween it and the bar.
4. Tighten bolts and nuts (4), (3), and (2) to fix al-
ternator (6).
5. Install the cover and tighten mounting bolts (1).

a When the belt was replaced, readjust it after
one-hour operation.
D155AX-5 20-123
(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR

BELT
Testing Adjusting
1. Open the engine side cover and remove the left a If the deflection is abnormal, adjust it according
frame cover. to the following procedure.
2. Press the intermediate point between the air 1. Loosen the 4 bolts (1).
conditioner compressor pulley and drive pulley
with a finger and measure deflection (a). 2. Rotate jack bolt (2) to move compressor (6) and
a Deflection (a) when pressing force is approx. adjust the belt tension.
58.8N {approx. 6kg}: 10mm a Test for breakage of each pulley, friction of V-
ditch, and contact between belt and V-ditch.
a Replace it with new belt if it was too
stretched so that adjustability was lost, or cut
and crack occurred.
a When moving the air conditioner compres-
sor, do not push it directly with a bar but put
a wood piece between it and the bar.
a After finishing adjustment, tighten locknut of
the jack bolt.
3. Tighten bolt (1) to fix alternator (6).

a When the belt was replaced, readjust it after
one-hour operation.
20-124 D155AX-5
(2)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL

1. Outline of fuel control system 2. Preparation work
The following signals are input as rotation com- Start the engine, set the monitor panel in the
mand signals to the engine controller. “Adjustment mode”, and prepare for measuring
• Fuel control dial potentiometer signal the engine speed.
• Decelerator pedal potentiometer signal a For the method of operation, see “SPECIAL
• 3rd throttle signal F U N C T I O N S O F M O N I TO R PA N E L
The engine controller controls the fuel control (EMMS)”.
system of the engine (CRI system) according to • Adjustment code:
the one of the above input signals having the 0007 (Engine deceleration cut mode)
lowest engine speed. a The engine speed is displayed in 1rpm.
Adjust the deceleration slow rotation by adjust-
ing the decelerator pedal linkage.
[1] Fuel control dial

[2] Engine controller
[3] Steering and transmission controller
[4] Decelerator pedal
[5] Decelerator pedal potentiometer
[6] Engine (CRI system)
[7] 3rd throttle signal
[8] Rod
D155AX-5 20-125
(2)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
3. Adjusting decelerator pedal engine speed

With the fuel control dial in the high idling posi-
tion, press decelerator pedal (1) to stopper bolt
(2) and check that the decelerator pedal engine
speed is normal.
• Decelerator pedal engine speed:
850 ± 50rpm
a If the decelerator pedal engine speed is ab-
normal, adjust installed dimension a of stop-
per bolt (2).
• Standard installed dimension a of stopper
bolt: 19mm
4. High idling engine speed

Set the fuel control dial in the high idling position
and check that the high idling engine speed is
normal.
• High idling engine speed: 2,050 ± 50rpm
a If the engine speed is abnormal, perform the
following.
• When the engine speed is above 1,950rpm:
Lower the engine speed below 1,900rpm
temporarily with stopper bolt (3) to eliminate
the play of the decelerator pedal, and then
adjust the engine speed to the high idling
speed.
• When the engine speed is below 1,950rpm:
Adjust the engine speed to the high idling
speed with stopper bolt (3).
• Standard installed dimension b of stopper
bolt: 6mm
20-126 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE

a Measuring instrument for power train pressure 1. Measuring torque converter inlet pressure
(IN)
Symbol Part No. Name 1) Connect oil pressure gauge [1] of hydraulic
799-101-5002 Hydraulic tester tester J1 to oil pressure pick-up nipple (1).
1 a Use an oil pressure gauge of 2.5MPa
J 790-261-1203 Digital hydraulic tester
{25kg/cm2}.
k Stop the machine on a level place, lower the

work equipment to the ground, and set the park-
ing brake lever and safety lock lever in the LOCK
position.
a Measure the power train oil pressure under the
following condition.
• Power train oil temperature: 65 – 80 degree
a The centralized power train pressure pick-up
ports are installed inside the inspection cover in
front of the left fender.
a The table of oil pressure measurement posi-

tion and application gauge 2) Start the engine and set the PCCS lever in
the full neutral position.
Gauge 3) Measure the oil pressure while the engine is
No. Mark Measured oil pressure
(MPa {kg/cm2}) running at low idling and high idling.
Torque converter inlet
1 IN 2.5 {25}
pressure
Torque converter outlet
2 OUT 0.98 {10}
pressure
Transmission main relief
3 TM 5.9 {60}
pressure
Transmission forward clutch
4 F 5.9 {60}
pressure
Transmission reverse clutch
5 R 5.9 {60}
pressure
Transmission 1st clutch
6 1ST 5.9 {60}
pressure
Transmission 2nd clutch 4) After finishing measurement, remove the
7 2ND 5.9 {60} measuring instrument and return the re-
pressure
moved parts.
Transmission 3rd clutch
8 3RD 5.9 {60}
pressure
9 BR Steering left brake pressure 5.9 {60}
D155AX-5 20-127
(2)
2. Measuring torque converter outlet pressure 3. Measuring transmission main relief pressure
(OUT) (TM)
1) Connect hydraulic tester J2 to oil pressure 1) Connect oil pressure gauge [1] of hydraulic
pick-up nipple (2). tester J1 to oil pressure pick-up nipple (3).
a Use an oil pressure gauge of 0.98MPa a Use an oil pressure gauge of 5.9MPa
{10kg/cm2}. {60kg/cm2}.
2) Start the engine and set the PCCS lever in 2) Run the engine and set the PCCS lever in
the full neutral position. the full neutral position.
3) Measure the oil pressure while the engine is 3) Measure the oil pressure while the engine is
running at low idling and high idling. running at low idling and high idling.
4) After finishing measurement, remove the 4) After finishing measurement, remove the
measuring instrument and return the re- measuring instrument and return the re-
moved parts. moved parts.
20-128 D155AX-5
(2)
4. Measuring transmission forward clutch pres- 5. Measuring transmission reverse clutch pres-
sure (F) sure (R)
1) Connect oil pressure gauge [1] of hydraulic 1) Connect oil pressure gauge [1] of hydraulic
tester J1 to oil pressure pick-up nipple (4). tester J1 to oil pressure pick-up nipple (5).
{60kg/cm2}. {60kg/cm2}.
2) Run the engine and set the parking brake le- 2) Run the engine and set the parking brake le-
ver in the FREE position. ver in the FREE position.
3) Press the brake pedal and set the PCCS le- 3) Press the brake pedal and set the PCCS le-
ver in the FORWARD and 3rd gear speed ver in the REVERSE 3rd gear speed posi-
position. tion.
running at high idling. running at high idling.
k Since the torque converter will be k Since the torque converter will be
stalled, press the brake pedal securely stalled, press the brake pedal securely
and keep your right foot on the decelera- and keep your right foot on the decelera-
tor pedal for safety until the work is fin- tor pedal for safety until the work is fin-
ished. ished.
D155AX-5 20-129
(2)
6. Measuring transmission 1st clutch pressure 7. Measuring transmission 2nd clutch pressure
(1ST) (2ND)
1) Connect oil pressure gauge [1] of hydraulic 1) Connect oil pressure gauge [1] of hydraulic
tester J1 to oil pressure pick-up nipple (6). tester J1 to oil pressure pick-up nipple (7).
{60kg/cm2}. {60kg/cm2}.
2) Run the engine and set the parking brake le- 2) Run the engine and set the parking brake le-
ver in the FREE position. ver in the FREE position.
3) Press the brake pedal and set the PCCS le- 3) Press the brake pedal and set the PCCS le-
ver in the FORWARD and 1st gear speed po- ver in the FORWARD and 2nd gear speed
sition. position.
running at low idling. running at low idling.
k Since the torque converter will be k Since the torque converter will be
stalled, keep pressing the brake pedal stalled, keep pressing the brake pedal
securely. securely.
k Do not raise the engine speed to high k Do not raise the engine speed to high
idling during measurement. idling during measurement.
20-130 D155AX-5
(2)
8. Measuring transmission 3rd clutch pressure 9. Measuring steering brake pressure (BR)
(3RD) 1) Connect oil pressure gauge [1] of hydraulic
1) Connect oil pressure gauge [1] of hydraulic tester J1 to oil pressure pick-up nipple (9).
tester J1 to oil pressure pick-up nipple (8). a Use an oil pressure gauge of 5.9MPa
a Use an oil pressure gauge of 5.9MPa {60kg/cm2}.
{60kg/cm2}.
2) Run the engine and set the parking brake le-

2) Run the engine and set the parking brake lever in the FREE position.
ver in the FREE position. 3) Measure the oil pressure while the engine is
3) Press the brake pedal and set the PCCS le- running at low idling and high idling.
ver in the FORWARD and 3rd gear speed a Check that the oil pressure lowers to 0
position. when the brake pedal is pressed or the
4) Measure the oil pressure while the engine is parking brake lever is set in the LOCK
running at low idling. position.
k Since the torque converter will be
stalled, keep pressing the brake pedal
securely.
k Do not raise the engine speed to high
idling during measurement.

moved parts.

moved parts.
D155AX-5 20-131
(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING HSS OIL PRESSURE
TESTING AND ADJUSTING HSS OIL PRESSURE

a Testing and adjusting instrument for HSS oil 3) Install nipple K2 and connect oil pressure
pressure gauge [1] of hydraulic tester K1.
a Use an oil pressure gauge of 58.8MPa
Symbol Part No. Name {600kg/cm2}.
1
790-261-1203 Digital hydraulic tester
K
799-101-5220 Nipple (10 x 1.25mm)
2
07002-11023 O-ring
Measuring
position.
a Measure the HSS oil pressure under the follow-
ing condition.
• Hydraulic oil temperature: 4) Run the engine and set the parking brake le-
Within operating range ver in the FREE position and press the brake
pedal.
1. Measuring HSS main relief pressure k Since the steering circuit will be stalled,
1) Remove the inspection cover (with foot rest) keep pressing the brake pedal securely
in center of the floor. and keep your right foot on the decelera-
2) Remove oil pressure pick-up plug (1) or (2). tor pedal for safety until the work is fin-
• (1): For left steering (Port PA) ished.
• (2): For right steering (Port PB) 5) Run the engine at high idling and steer to the
right or left with the PCCS lever. When the
steering circuit is relieved, measure the oil
pressure.
a Since a pivot turn will be made with only
the steering system, set the direction of
the PCCS lever into neutral.

moved parts.
20-132 D155AX-5
(2)
a HSS main relief pressure (A) can be measured a HSS main relief pressure (B) can be measured
in the “Pm Clinic auxiliary mode” of the monitor in the “Pm Clinic auxiliary mode” of the monitor
panel. panel.
a For the operating method, see OPERATION a For the operating method, see OPERATION
MANUAL. MANUAL.
• Auxiliary code: 05 (HSS oil pressure A) • Auxiliary code: 06 (HSS oil pressure B)
D155AX-5 20-133
(2)
2. Measuring HSS charge relief pressure 5) Measure the oil pressure while the engine is
1) Open the right fender inspection cover. running at high idling.
2) Remove oil pressure pick-up plug (3) in the
top of charge filter.

3) Install nipple K2 and connect oil pressure moved parts.
gauge [1] of hydraulic tester K1.
a Use an oil pressure gauge of 5.9MPa 3. Measuring HSS servo charge pressure
{60kg/cm2}. a The control circuit main pressure from the
self-pressure reducing valve of the control
valve is used as the HSS servo charge pres-
sure commonly for work equipment PPC and
fan pump control.
a For the measuring method, see TESTING
AND ADJUSTING CONTROL MAIN PRES-
SURE.
4) Run the engine and set the PCCS lever in

the full neutral position.
20-134 D155AX-5
(2)
Adjusting 2. Adjusting HSS charge relief pressure (when

pressure is low)
1. Adjusting HSS main relief pressure
a If the HSS charge relief pressure is low, ad-
a If the HSS main relief pressure is abnormal,
just the charge relief valve (8) of the HSS
adjust it with main relief valve (4) or (5) of the
motor to heighten the HSS charge relief
HSS pump according to the following proce-
pressure.
dure.
1) Remove the under cover of the fuel tank.
• (4): For left steering (Port PA)
• (5): For right steering (Port PB)
a The diagram shows HSS pump from bottom
view.
1) Open the under cover in front of the main
flame.
2) Fixing adjustment screw (9), loosen locknut

(10).
3) Turn the adjustment screw (9) to adjust the
pressure.
a If the adjustment screw is
2) Fixing adjustment screw (6), loosen locknut • turned to the right, the pressure rises.
(7). • turned to the left, the pressure lowers.
3) Turn the adjustment screw (6) to adjust the a Quantity of adjustment per turn of adjust-
pressure. ment screw: 1MPa {10.4kg/cm2}
a If the adjustment screw is 4) Fixing adjustment screw (9), tighten locknut
3 Locknut:
• turned to the right, the pressure rises. (10).
• turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust- 58.8 – 78.5Nm {6 – 8kgm}
ment screw:
Approx. 13.7MPa {Approx. 140kg/cm2}
4) Fixing adjustment screw (6), tighten locknut
3 Locknut: 29 – 39Nm {3 – 4kgm}

(7).
5) After finishing adjustment, check the oil pres-

sure again according to the procedure for
measurement described above.
5) After finishing measurement, check the oil

pressure according to the above measuring
method.
D155AX-5 20-135
(2)
3. Adjusting HSS charge relief pressure (when 5) After finishing adjustment, check the oil pres-
pressure is high) sure again according to the procedure for
a If the HSS charge relief pressure is high, ad- measurement described above.
just the charge safety valve (11) of the HSS
pump to lower the HSS charge relief pres-
sure.
a The figure is the view from the front side.
1) Remove the under cover in front of the main
flame.

(13).
pressure.
a If the adjustment screw is
• turned to the right, the pressure rises.
a Quantity of adjustment per turn of adjust-
ment screw: 1.55MPa {15.8kg/cm2}
3 Locknut:
(13).
58.8 – 78.5Nm {6 – 8kgm}
20-136 D155AX-5
(2)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR

1. Remove the fuel tank and then remove transmis- 5. After finishing adjustment, set the monitor panel
sion speed sensor (1). in the “Monitoring display mode” and check that
a Before adjusting transmission speed sensor it displays the transmission speed normally.
(1), remove it and check that its tip is free a For the operating method, see “SPECIAL
from steel chips and flaws, then install it FUNCTIONS OF MONITOR PANEL (EMMS)”.
again. a Monitoring code: 31400 (Transmission speed)
2. Tighten sensor (1) until its tip comes in contact
2 Threads of sensor:
with the tooth tip of bevel gear (2).
Gasket sealant (LG-5)
3. Return sensor (1) by the specified angle.

a Returning angle of sensor: 1/2 – 1 turn
a Adjust clearance a between the sensor tip
and gear tooth tip to 0.75 – 1.50mm.
2 Nut: 49.0 – 68.6Nm {5 – 7kgm}

4. Fix sensor (1) with nut (3).
D155AX-5 20-137
(2)
BLEEDING AIR FROM HSS PUMP
TESTING AND ADJUSTING SIMPLE METHOD OF TESTING BRAKE
BLEEDING PERFORMANCE
AIR FROM HSS PUMP
BLEEDING AIR FROM HSS SIMPLE METHOD OF TEST-

PUMP ING BRAKE PERFORMANCE
a If the HSS pump is removed and installed or its a Carry out the simple test of brake performance
piping is disconnected and connected, bleed air under the following condition.
from the pump case according to the following • Power train oil temperature:
procedure. Within operating range
a Before bleeding air, check that the hydraulic oil
level is proper. 1. Set the blade and ripper in the travel position on
a level place.
1. Remove the inspection cover (with foot rest) in
center of the floor.
2. Loosen air bleeder (1) and leave it for 15 min-

utes.
2. Run the engine and set the parking brake lever

in the FREE position.
3. Run the engine at low idling and press the brake

pedal and set the PCCS lever in the FORWARD
3. After 15 minutes, run the engine at low idling. and 2nd gear speed position.
a After starting the engine, do not move the k If this test is carried out in the 1st gear posi-
PCCS lever from the full neutral position. tion, the brake will be overloaded. According-
ly, be sure to carry out in the 2nd gear speed.
4. After oil flows out of air bleeder (1), tighten air a Set the steering unit in neutral.
3 Air bleeder:
bleeder (1).
4. Press the decelerator pedal and set the fuel con-
7.8 – 9.8Nm {0.8 – 1.0kgm} trol dial in the high idling position.
5. Return the decelerator pedal slowly and check

that the machine does not start when the engine
speed reaches the high idling level.
k Since the torque converter will be stalled,
press the brake pedal securely and keep
your right foot on the decelerator pedal for
safety until the work is finished.
20-138 D155AX-5
(2)
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL
ADJUSTING BRAKE PEDAL
1 Tighten the locknuts of the rods and joint secure- 2. Adjust fitting length of brake rod
ly, and bend the cotter pins securely. 1) Adjust fitting dimension c of rod (3) on the
valve side, then connect to brake valve lever
1. Adjudt the stroke of brake pedal (4).
Adjust fitting dimension b of damper (2) so that • Fitting dimension c of rod: 1,245mm
the stroke a of brake pedal (1). 2) Adjust fitting dimension d of rod (6) on the
• Pedal stroke a: 79mm pedal side, then connect to brake pedal (1).
• Fitting dimension b of damper: 39mm • Fitting dimension d of rod: 195mm
3) Lightly push rod (3) on the valve side toward
the rear of the machine, and turn only joint
(7) to connect rods (3) and (6).
a Push rod (3) with a force of about 9.8 –
19.6N {1 – 2kg}.
a Fix joint (5) so that installed dimension c
3 Joint:
of the rod will not change.
34.3 – 58.8Nm {3.5 – 6.0kgm}
D155AX-5 20-139
(2)
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL
4) When brake pedal (1) released, adjust its

play with dimension e between the poins of
rod assembly (8).
• Play of pedal: 1 – 8mm (Center of pedal)
• Dimension e between pins of rod assem-
bly: 1,447mm
a Adjust by turning joints (5) and (7) in the
same direction.
5) With brake pedal (1) released, check that
brake pedal (1) is in contact with damper (2).
3. Checking brake oil pressure

1) Start the engine and set the parking brake le-
ver in the free position.
2) Check that the brake oil pressure is as fol-
lows when the brake pedal is depressed.
a For the method of measuring the brake
oil pressure, see MEASURING POWER
TRAIN OIL PRESSURE.
• Brake oil pressure (While engine is run-
ning at high idling)
Brake pedal Oil pressure

2.75 ± 0.29MPa
Released
{28 ± 3kg/cm2}
Depressed 0MPa {0kg/cm2}
4. Adjusting zero point of brake potentiometer

Adjust the zero point of the brake potentiometer.
For details, see SPECIAL FUNCTIONS OF
MONITOR PANEL (EMMS).
a Use the adjustment mode.
• Adjustment code:
0005 (Brake potentiometer zero point adjust-
ment)
20-140 D155AX-5
(2)
TESTING AND ADJUSTING ADJUSTING AT PARKING BRAKE LEVER
ADJUSTING AT PARKING BRAKE LEVER
1 Tighten the nut and joint of the cable securely, 3. Checking brake oil pressure
and then bend the cotter pin securely. Check that the brake oil pressure is as follows
when the parking brake lever is set in the FREE
1. Assembling and installing lever assembly and LOCK positions.
1) Assemble lever assembly (9) and adjust the a For the method of measuring the brake oil
operation of limit switch (10). pressure, see MEASURING POWER TRAIN
a When assembling the lever assembly, OIL PRESSURE.
disconnect the parking brake cable from • Blake oil pressure (Engine at high idling)
the lever.
• When lever is raised: OFF, lowered: ON Parking lever Oil pressure
• Operation stroke of limit switch: 3mm 2.75 ± 0.29MPa
FREE position
2) Install lever assembly (9). {28 ± 3kg/cm2}
LOCK position 0MPa {0kg/cm2}
2. Adjusting length of parking brake cable
1) Connect parking brake cable (11) to the lever
4. Checking limit switch
and valve and adjust dimensions f and g.
1) Change the monitor panel to the monitoring
• Dimension f of cable: 93mm
display mode.
• Dimension g of cable: 91mm
a For the operating method of the monitor-
2) Operate parking brake lever (12) between
ing display mode, see “SPECIAL FUNC-
the FREE and LOCK positions and adjust
TIONS OF MONITOR PANEL (EMMS)”.
rod end (14) so that spool stroke h of brake
• Monitoring code:
valve (13) will be normal.
40910 (Steering controller related switch
• Spool stroke h: 19mm
input 1)
2) When the parking lever set in the FREE and
LOCK positions, Check that the limit switch
signal is normal.
D155AX-5 20-141
(2)
TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS

TROUBLE
a Devices used for emergency escape a Since the male side of connector PL2 is
kept disconnected, mask it with a vinyl
Symbol Part No. Name sheet, etc.
19M-06-32820 Switch assembly a Put switch assembly [1] in the cab
1 through the cab window.
L 17M-06-41530 Wiring harness
2 790-190-1600 Pump assembly
1. Escape with switch box (Use L1)

a If the machine cannot be moved because of
a trouble in the electric system of the power
train control unit (travel direction, gear
speed, steering), escape according to the
following procedure.
a The engine must be startable for the follow-
ing procedure. If the engine cannot be start-
ed, see EMERGENCY ESCAPE WITH
BRAKE RELEASING DEVICE.
1) Connect switch assembly [1] to wiring har-
ness [2] of emergency escape device L1. 3) Remove cover in the rear of operator seat.
k Set the all gear speed switches of switch
4) Disconnect neutral safety relay (NSF) and
assembly [1] in the OFF position and the connect pins [3] and [5] of the connector on
direction switch in the P position to pre- the wiring harness side.
vent the machine from starting suddenly. a Direct connection circuit:
No. 3 of NSF (female) io No. 5
a If the connector (PL2) is disconnected,
an model selection error is made and the
neutral safety relay is not driven because
of that error. The above work must be
performed to avoid this problem.
k If the engine is started by this method,
the neutral safety function does not work.
Accordingly, before starting the engine,
set the parking brake lever in the LOCK
position and set the PCCS lever in the
full neutral position.
k Start the engine by this method only in
an emergency. If the engine does not
2) Open the left fender inspection cover and
start in another case, be sure to carry out
connect wiring harness [2] to connectors
troubleshooting and repair the trouble.
PL1 (1) and PL2 (2).
• Connector PL1 (1):
Connect to male side and female side.
• Connector PL2 (2):
Connect to female side.
20-142 D155AX-5
(2)
TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
5) Start the engine and set the parking brake le- 2. Escape with brake releasing device (Use L2)
ver in the FREE position. a If the engine cannot be started and the park-
6) Operate switch assembly [1] and move the ing brake cannot be released, escape ac-
machine to a safe place. cording to the following procedure.
a The gear speed switch is so made that 1) Assemble pump assembly L2.
the switch on the lower gear speed will
be operated first.
2) Install volume pump [3] of pump assembly

L2 to the outside of the operator’s cab.
3) Remove the fuel tank under cover.

4) Disconnect hose (4) of supply port (P) of rip-
per pin puller solenoid valve.
D155AX-5 20-143
(2)
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
TESTING AND ADJUSTING INSPECTING WEAR OF SPROCKET
5) Connect end hose of pump assembly L2. INSPECTING WEAR OF

6) Turn the starting switch ON and set the park-
ing brake lever in the FREE position. SPROCKET
7) Operate the vacuum pump to raise the brake
releasing oil pressure to the initial pressure. a As the wear measurement gauge for the sprock-
• Initial pressure: et, use the “Full-scale drawing of sprocket tooth
Approx. 2.74MPa {28kg/cm2} profile” in “STRUCTURE, FUNCTION AND
a Since an accumulator is installed in the MAINTENANCE STANDARD”, “Sprocket”.
circuit, the handle must be operated 30 – a Make a copy of the “Full-scale drawing of sprock-
50 times to raise the oil pressure. et tooth profile” on a transparent sheet and apply
a If the oil pressure does not rise above a it to the sprocket directly to see if the sprocket is
certain level, the relief valve may be set serviceable.
to low pressure. In this case, adjust the
set pressure of the relief valve.
8) Tow the machine to a safe place.
a The brake releasing oil pressure lowers
gradually because of internal leakage
and the brake is applied again about 1
minutes after. Accordingly, work quickly.
a If the brake releasing pressure lowers to
about 1.57MPa {16kg/cm2}, the brake is
applied. In this case, operate the volume
pump again to raise the brake releasing
pressure to the intial pressure.
20-144 D155AX-5
(2)
TESTING AND ADJUSTING ADJUSTING CLEARANCE OF IDLER
ADJUSTING CLEARANCE OF IDLER
a If the lateral guide and vertical guide of the idler 2. Vertical adjustment
are so worn that the idler runs out or slants, ad- 1) Measure clearance b at 2 places between
just the clearance of the idler according to the fol- guide plates (5) and (6).
lowing procedure. 2) If clearance b is wider than 8mm, replace up-
per and lower guide plates (5), (6), (7), and
1. Lateral adjustment (8) with new ones, since no shims are used
1) Drive the machine 1 – 2m on flat ground, and to adjust the height.
then remove the cover (1). (at 2 places) a Guide plates (5), (7), and (8) are welded.
2) Measure clearance a at 2 places between
the track frame and right and left guide plates
(2).
3) If clearance a is larger than 4mm, loosen bolt
(3) and reduce shim (4).
• Standard clearance a on each side:
0.5 – 1.0mm
a Do not loosen the bolt more than 3 turns.
a This part can be adjusted by 6mm on
each side.
D155AX-5 20-145
(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

Testing Adjusting
1. Drive the machine slowly on a level place, then a If the track shoe tension is abnormal, adjust it ac-
stop it. cording to the following procedure.
a Do not apply the brake when stopping.
1. Remove cover (1).
2. Place straight steel bar [1] between the idler and
front carrier roller and measure clearance a be- 2. When the tension is too high
tween the bottom of the steel bar and shoe Loosen plug (2) to discharge the grease.
grouser. k Since the high-pressure grease may spout
a As the steel bar, use an unequal angle steel
3 Plug: 49 ± 2.45Nm {5 ± 0.25kgm}
out, do not loosen the plug more than 1 turn.
bar which bends less.
• Standard clearance a: 20 – 30mm
3. When tension is low
Add grease through grease valve (2).
a If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
a After finishing adjustment, check the tension

again according to the testing procedure
shown above.
20-146 D155AX-5
(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE

a Testing and adjusting instruments for work 4) Run the engine at high idling and set the
equipment oil pressure blade lever and ripper lever in neutral and
measure the oil pressure.
1
M
799-101-5220 Nipple (10 x 1.25mm)
2
07002-11023 O-ring
Measuring
position.
a Measure the work equipment oil pressure under
the following condition. 5) After finishing measurement, remove the
• Hydraulic oil temperature: measuring instrument and return the re-
Within operating range moved parts.
1. Measuring unload pressure

1) Remove the control valve cover on the right
side of the machine.
2) Remove oil pressure pickup plug (1) on the
front side of the control valve.
3) Install nipple M2 and connect oil pressure

gauge [1] of hydraulic tester M1.
{400kg/cm2}.
D155AX-5 20-147
(2)
2. Measuring main relief pressure a The unload pressure and main relief pressure
a Measure the main relief pressure at the can be measured in the “Pm Clinic auxiliary
same point with the unload pressure. mode” of the monitor panel.
a Use an oil pressure gauge of 39.2MPa a For the operating method, see OPERATION
{400kg/cm2}. MANUAL.
• Auxiliary code: 03 (Work equipment oil pressure)
1) Start the engine and set the safety lock lever

in the FREE position.
2) Run the engine at high idling and operate the
blade lever and ripper lever to relieve each
cylinder at a stroke end and measure the oil
pressure.

moved parts.
20-148 D155AX-5
(2)
Adjusting 5) After finishing adjustment, check pressure

again according to the procedure for mea-
a The unload pressure cannot be adjusted.
surement described above.
1. Adjusting main relief pressure
a If the main relief pressure is abnormal, ad-
just main relief valve (2) of the control valve
according to the following procedure.
1) Remove the control valve cover on the right
side of the machine.

(5).
pressure.
a If the adjustment nut is
• turned to the right, the pressure rises.
a Quantity of adjustment per turn of adjust-
ment nut:
Approx. 19.6MPa {Approx. 200kg/cm2}
3 Locknut:
(4).
29.4 – 39.2Nm {3.0 – 4.0kgm}
D155AX-5 20-149
(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN

PRESSURE
a Testing and adjusting instruments for control cir- 4. Install nipple [1] of hydraulic tester N1 and con-
cuit main pressure nect oil pressure gauge [2].
Symbol Part No. Name {400kg/cm2}.
1
N 790-261-1203 Digital hydraulic tester
2 799-401-3100 Adapter (Size 02)
a The control circuit main pressure is the pressure

lowered by the self-pressure reducing valve of
the control valve. It is used commonly for HSS
servo charge, work equipment PPC, and fan
pump control.
Measuring
work equipment to the ground, and set the park- 5. Run the engine at high idling and set the blade
ing brake lever and safety lock lever in the LOCK lever and ripper lever in neutral and measure the
position. oil pressure.
a Measure the control circuit main pressure under
the following condition.
1. Open the right fender control valve cover.
2. Disconnect hose (1).

Adjusting
a The self-pressure reducing valve cannot be ad-
justed.
3. Install oil pressure pickup adapter N2 and con-

nect the disconnected hose again.
20-150 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE

a Measuring instruments for PPC valve output 4. Install nipple [1] of hydraulic tester P1 and con-
pressure nect oil pressure gauge [2].
a Use the oil pressure gauge of 5.9MPa {60kg/
Symbol Part No. Name cm2}.
1
P
799-401-3100 Adapter (Size 02)
2
799-401-3200 Adapter (Size 03)

position.
a Before measuring the PPC valve output pres-
sure, check that the control circuit main pressure
is normal.
a Measure the PPC valve output pressure under 5. Start the engine and set the safety lock lever in
the following condition. the FREE position.
Within operating range 6. Run the engine at high idling and operate the
control lever of the circuit to be measured and
1. Remove the control valve cover on the right side measure the oil pressure.
of the machine. a Measure the oil pressure with the lever at a
stroke end.
2. Disconnect PPC valve outlet hose of measuring a When measuring the blade circuit, operate
circuit. the lever until the blade floats.
a For the circuit to be measured, see the draw-
ing on the next page.
a In the following figure, the blade PPC valve is
on the right side and the ripper PPC valve is
on the left side.

3. Install nipple P2 and connect the disconnected

hose again.
D155AX-5 20-151
(2)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
Connection diagram of PPC circuit
a The connection of the PPC valve is seen from the lever side (upper side).
20-152 D155AX-5
(2)
TESTING AND ADJUSTING ADJUSTING PLAY OF PPC VALVE
ADJUSTING PLAY OF PPC VALVE

a If the end play of the blade lever and ripper lever
is excessive, adjust it with their PPC valves ac-
cording to the following procedure.
a This figure shows the PPC valve for the ripper.
• Standard play a:
0.5 – 3.0mm at 200mm from revolution cen-
ter of lever (in both longitudinal and lateral di-
rections)
1. Remove boot (1).
2. Loosen locknut (2) and turn disc (3) to adjust the

play.
a Do not move the piston at this time.
3 Locknut: 98 – 127Nm {10 – 13kgm}

3. Fix disc (3) and tighten locknut (2).
4. Install boot (1).
D155AX-5 20-153
(2)
MEASURING OUTLET PRESSURE OF RIPPER PIN
TESTING AND ADJUSTING PULLER SOLENOID VALVE
MEASURING OUTLET PRESSURE OF RIPPER PIN

PULLER SOLENOID VALVE
a Measuring instruments for outlet pressure of rip- 3. Install nipple [1] of hydraulic tester Q1 and con-
per pin puller solenoid valve nect oil pressure gauge [2].
a Use an oil pressure gauge of 5.9MPa {60kg/
Symbol Part No. Name cm2}.
1
Q 790-261-1203 Digital hydraulic tester
2 799-401-3200 Adapter (Size 03)

position.
a Measure the outlet pressure of the ripper pin
puller solenoid valve under the following condi-
tion.
4. Run the engine at high idling and operate the rip-
1. Disconnect pin puller cylinder hose (1) or (2). per pin puller switch and measure the oil pres-
sure.
2. Install oil pressure pickup adapter Q2 and con-

nect the disconnected hose again. 5. After finishing measurement, remove the mea-
20-154 D155AX-5
(2)
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT
TESTING AND ADJUSTING OF BLADE AND RIPPER
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT

OF BLADE AND RIPPER
a If the blade or ripper drifts hydraulically, check to 3) Ripper lift cylinder
see if the cause is on the cylinder packing side or Brace the ripper to push up the rear side of
control valve side according to the following pro- the machine body.
cedure.
1. Set the cylinders to be tested in the following po-

sitions and stop the engine.
1) Blade lift cylinder
Brace the blade to raise the front side of the
machine body.
a Since the blade lift cylinder is equipped
with a piston valve, do not extend it to the
stroke end.
2. Extend the cylinder to be tested with the corre-

sponding lever and check its movement.
• If the lowering speed is increased, the cylin-
der packing is defective.
• If the lowering speed does not change, the
control valve is defective.
a If the pressure in the accumulator is lost, run
the engine for about 10 seconds to heighten
the pressure in the accumulator.
2) Blade tilt cylinder [Reference]

Extract the tilt cylinder to the stroke end and Reason why the lowering speed is increased
brace the blade to push up the left side of the when the cylinder packing is the cause of the hy-
machine body. draulic drift:
1) If the machine is set in the above position
(where the holding pressure is applied to the
bottom side), the oil leaks from the bottom
side to the head side. Since the volume on
the head side is less than that on the bottom
side by the volume of the rod, the pressure in
the head side is increased by the oil flowing
in from the bottom side.
2) As the pressure in the head side is in-
creased, it is balanced at a certain level
(which depends on the leakage), then the
lowering speed is lowered.
3) If the circuit on the head side is opened to the
drain circuit by the above operation of the le-
ver (the bottom side is closed by the check
valve at this time), the oil on the head side
flows in the drain circuit. As a result, the
pressure is unbalanced and the lowering
speed is increased.
D155AX-5 20-155
(2)
TESTING AND ADJUSTING MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT

CYLINDER
a Measuring instruments for internal leakage of • (2): Ripper lift cylinder
work equipment cylinder Part for block: 07379-00640 (Flange No. 06)
• (3): Ripper tilt cylinder
Symbol Part No. Name Part for block: 07379-01044 (Flange No. 10)
R Purchased Measuring cylinder
a Measure the internal leakage of work equipment

cylinder under the following condition.
• Hydraulic oil temperature: 45 – 55ºC
a Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be mea-
sured.
1. Extend the cylinder to be measured to the stroke

end and set the machine in the measuring posi-
tion.
1) Blade tilt cylinder
Tilt the blade left to the end.
3. Run the engine at high idling and apply the relief
2) Ripper lift cylinder
pressure to the cylinder bottom side.
Pull out the shank pin and lower the ripper to
• Blade tilt cylinder:
the end.
Operate to extend the cylinder
3) Ripper tilt cylinder
to be measured.
Tilt the ripper forward to the end.
• Ripper lift cylinder:
Operate to lower ripper.
2. Disconnect hoses (1), (2) and (3) on the cylinder
• Ripper tilt cylinder:
head side and block the hose side with a plug or
Operate to tilt ripper forward.
flange for oil stopper.
a Remove the hose cover of the blade tilt cylin-
4. After 30 second, measure leakage in 1 minute.
der.
k Take care not to disconnect the hose on the
bottom side.
• (1): Blade tilt cylinder
Part for block: 07376-50422 (Plug No. 04)
5. After finishing measurement, return the removed

parts.
20-156 D155AX-5
(2)
RELEASINGRELEASING
RESIDUAL RESIDUAL
PRESSUREPRESSURE
FROM WORK
FROM
EQUIPMENT
WORK EQUIPMENT
CYLINDER
TESTING AND ADJUSTING BLEEDING AIR FROM WORK EQUIPMENT CYLINDER
RELEASING RESIDUAL BLEEDING AIR FROM WORK

PRESSURE FROM WORK EQUIPMENT CYLINDER
EQUIPMENT CYLINDER
a When disconnecting the piping between the con- a If the work equipment cylinder is removed and
trol valve and work equipment cylinder, release installed or its piping is disconnected and con-
the residual pressure from the circuit according nected, bleed air from its circuit according to the
to the following procedure. following procedure.
1. Loosen the oil filler cap of the hydraulic tank 1. Run the engine at low idling for about 5 minutes.
gradually to release the residual pressure from
the tank. 2. Running the engine at low idling, extend and re-
tract the cylinder to be bled 4 – 5 times.
2. Set the safety lock lever in the FREE position a Move the piston rod to about 100mm before
and operate the work equipment control lever to the stroke end and never relieve the oil.
each direction.
a If the work equipment control lever is operat- 3. Running the engine at high idling and carry out
ed 2 – 3 times, the residual pressure in the the operation in 2.
accumulator is released.
4. Running the engine at low idling, move the cylin-
3. Run the engine at low idling for about 5 seconds, der to the stroke end to relieve the oil.
then stop it.
4. Repeat steps 2 – 3 above 2 – 3 times.
D155AX-5 20-157
(2)
TESTING AND ADJUSTING ADJUSTING SAFETY LOCK LEVER
ADJUSTING SAFETY LOCK LEVER
1. Adjust dimension a between pins of rod (1).

• Dimension a between pins: 329mm
2. Connect rod (1) to safety lock lever (2) and PPC

lock valve (3).
20-158 D155AX-5
(2)
TESTING AND ADJUSTING MEASURING FAN MOTOR SPEED
MEASURING FAN MOTOR SPEED

a Measuring instruments for fan motor speed 6. Measure the fan motor speed while the engine is
running at high idling and low idling.
S 799-205-1100 Tachometer kit
1. Open the radiator mask and remove the fan net.
2. Stick 1 sheet of reflecting tape [1] to the fan.
3. Set probe [2] with stand [3], matching it to reflec-

tion tape [1], and connect it to tachometer [4].
k Take care that the probe will not interfere
with the fan.

4. Close the radiator mask and set the fan speed

select switch to normal mode.
k Be sure to close the radiator mask before
starting the engine. Do not start the engine
with the radiator mask open.
k If the fan is rotated in reverse, the measuring
instruments may be pulled in. Accordingly,
be sure to rotate the fan forward.
5. Run the engine and set the monitor panel in the

adjustment mode.
a For the method of operating the adjustment
mode, see SPECIAL FUNCTIONS OF
a Adjustment code:
1005 (Fan 100% speed mode)
D155AX-5 20-159
(2)
TESTING AND ADJUSTING MEASURING FAN CIRCUIT OIL PRESSURE
MEASURING FAN CIRCUIT OIL PRESSURE

a Measuring instruments for fan circuit oil pressure 4. Install nipple T3 and connect oil pressure gauge
[1] of hydraulic tester T1.
Symbol Part No. Name a Use an oil pressure gauge of 39.2MPa
799-101-5002 Hydraulic tester {400kg/cm2}.
1
T 2 799-401-3400 Adapter (Size 05)
799-101-5220 Nipple (10 x 1.25mm)
3
07002-11023 O-ring
k Stop the machine on level ground and lower the

work equipment to the ground, then set the park-
ing brake lever and safety lock lever in the lock
position.
a Measure the fan circuit oil pressure under the fol-
lowing condition.
Within operating range 5. Close the radiator mask.
k Be sure to close the radiator mask before
1. Open radiator mask and remove the fan net. starting the engine. Do not start the engine
with the radiator mask open.
2. Disconnect hose (1) on the supply side of the fan
motor. 6. Run the engine and set the monitor panel in the
adjustment mode.
a For the method of operating the adjustment
mode, see SPECIAL FUNCTIONS OF
a Adjustment code:
1005 (Fan 100% speed mode)
7. Measure the fan circuit oil pressure while the en-

gine is running at high idling and low idling.
3. Install adapter T2 and connect the disconnected

hose again.

parts.
20-160 D155AX-5
(2)
TESTING AND ADJUSTING BLEEDING AIR FROM FAN PUMP
BLEEDING AIR FROM FAN PUMP

a If the fan pump is removed and installed or its
piping is disconnected and connected, bleed air
from the pump case according to the following
procedure.
a Before bleeding air, check that the hydraulic oil
level is proper.
1. Remove the inspection cover (with foot rest) in

center of the floor.
2. Loosen air bleeder (1) and leave it for 15 min-

utes.
3. After 15 minutes, run the engine at low idling.
4. After oil flows out of air bleeder, tighten air bleed-
3 Air bleeder:
er (1).
7.8 – 9.8Nm {0.8 – 1.0kgm}
D155AX-5 20-161
(2)
TESTING AND ADJUSTING ADJUSTING BLADE (SEMI-U TILTDOZER)
ADJUSTING BLADE (SEMI-U TILTDOZER)
2 Adjusted point: Grease (G2-LI)

a If the blade is removed and installed or disas- 2) Adjust the shim of center (2).
sembled and reassemble, adjust it according to
the following procedure.
Adjusted Adjusted Standard Standard shim
1. Adjusting shims for assembly point clearance clearance thickness

1) Adjust the shim of tilt (1). 2 b Max. 1mm 4mm

point clearance clearance thickness
1 a Max. 1mm 4mm
TAD00149
a
TAD00131
20-162 D155AX-5
(2)
TESTING AND ADJUSTING ADJUSTING BLADE (SEMI-U TILTDOZER)

3) Adjust the shim of lift (3).

point clearance clearance thickness
3 c Max. 1mm 4mm
TAD00150
2. Adjusting blade tilt distance

1) Adjust dimension d of brace (4) with the han-
dle.
• Dimension d of brace: 1,390mm
2) Measure right and left tilt distances e1 and
e2.
• Right tilt distance e1: 450mm
• Left tilt distance e2: 450mm
3) If both tilt distances are not the same, adjust
dimension d of brace (4) according to the fol-
lowing procedure.
• e1 > e2: Increase dimension d finely.
• e1 < e2: Decrease dimension d finely.
D155AX-5 20-163
(2)
TESTING AND ADJUSTING TESTING AND ADJUSTING OF OPERATOR’S CAB
TESTING AND ADJUSTING OF OPERATOR’S CAB

a If the operator’s cab has been removed and in-
stalled or assembled in the field, test and adjust
it according to the following procedure.
1. Measuring pressure in cab

a Criterion
Criterion: Measured value X 78.5Pa {8mmH2O}
a Measurement conditions
Engine speed: High idling
Fan speed: 100% mode (Refer to the following)
Air condition fan switch: High position
EXTERNAL/INTERNAL air changeover switch:
EXTERNAL
a To set the fan speed in the 100% mode, use the 2. Check of searing performance
user adjustment mode of the monitor panel. 1) Close all the openings (doors and windows)
“04:FAN 100% SPEED” of “4-USER AD- of the cab.
JUST MODE” 2) Splash water around the hatched part of the
a If the criterion is not satisfied, check the cab at the rate of about 19l/min for 10 min-
seals of the through holes for the wiring har- utes.
ness in the cab and those of the mounting • At this time, it is not necessary to splash
holes of optional equipment. pressurized water.
1) Prepare a transparent vinyl hose. 3) Splash water horizontally from a hose over
• Outside diameter: 6mm, Length: 3,000mm sealing surface (4).
2) Secure the inside end of the hose to the top 4) Check around the dashboard carefully.
of the seat back with a tape. a If water leaks, caulk the leaking part and
3) Remove bolt (1) under the left console box. check again.
Pass the other end of the hose through the
bolt hole and take it out of inspection cover
(2) on the left side of the cab.
4) Seal the hole of bolt (1) with tape (3).

5) Pour water in the hose up to about half and
bend the hose in the shape of U.
6) Secure the hose to the outside of the cab
with a tape and set the water level in the
hose out of the cab to that in the cab.
7) Run the engine at high idling and measure
water level difference c.
• [a]: Inside of cab (Pressurized)
• [b]: Out of cab (Atmospheric pressure)
• [c]: Measured value (Internal pressure)
20-164 D155AX-5
(2)
3. Testing and adjusting of door lock

a Close the door and check the relationship
between the operator’s cab and door. If there
is any fault, repair it.
1) Check of condition of damper rubber (There
are 2 pieces on each side. Check all of
them.)
i) Stick a sealing tape [1] to the contact
face of damper rubber (1).
ii) Open and close the door 2 – 3 times.
iii) Check the contact parts of sealing tape
[1] and the cab.
• Normal:
When the door is closed, the damper
rubber comes in contact lightly.
• Abnormal:
When the door is closed, the damper
rubber does not come in contact or
comes in contact so strongly that ad-
hesive tape is removed.
3) Adjusting height of damper rubber

i) Loosen the mounting bolt of damper rub-
ber (1).
a Even if the mounting bolt is not re-
moved, you can remove and install
the shims.
2) Check of latch and striker (Check on both ii) Increase or decrease of shims (5) under
sides.) damper rubber (1) to adjust the height of
Close door (2) and check the engaging con- damper rubber (1) properly.
dition of latch (3) and striker (4).
a Check deviation a of latch center y and
striker center x from each other from the
direction of A.
• Normal:
Error of a must be 0.5mm or less.
D155AX-5 20-165
(2)
4) Adjusting height of latch and striker 2) Check the installed height of stopper rubber
i) Tighten the mounting bolt of striker (4) (There are 2 pieces on each side. Check all
temporarily bolt and close the door 2 – 3 of them.)
times to align latch (3) and striker (4) with i) Lock the door open and shake it in the
each other. forward and reverse directions to see if it
ii) Check the engaging condition of latch (3) has any play.
and striker (4). ii) Check that the operating effort of unlock
iii) Tighten the mounting bolt of striker (4) lever is not heavy.
securely. iii) Check that striker (4) is not leaning from
iv) Open and close the door and check that center d of latch (3).
it is locked and unlocked smoothly. iv) Check that latch (3) is not deviating from
a If the door is not locked and unlocked center e of striker (4).
smoothly (If the knob is heavy), perform • Normal:
the adjustment procedure from the first. Error of e must be 0.5mm or less.
a Operating effort of knob:
49 ± 19.6N {5 ± 2kg}
5) Apply grease
Apply grease to latch (3).
a If latch (3) is not greased, the knob be-
comes heavy. Accordingly, apply grease
2 Latch: Grease (G2-LI)

sufficiently.
4. Testing and adjusting of open lock

a Lock the door open and check the relation-
ship between the operator’s cab and door. If
there is any fault, repair it.
1) Check of condition of open lock latch and 3) Adjusting latch and striker
striker i) Loosen mounting bolt (7) of striker (4).
Check the relationship between open lock ii) Adjust striker (4) upright, and tighten
latch (3) and striker (4) from the direction of mounting bolt (7).
B.
a Move the door in the opening direction to
check the engagement of the latch and
striker.
20-166 D155AX-5
(2)
4) Adjusting installed height of stopper rubber

i) Loosen locknut (10) of stopper rubber (8)
(on the upper side).
ii) Loosen locknut (11) of stopper rubber (9)

(on the lower side).
iii) Adjust the height of stopper rubbers (8)

and (9) to eliminate the trouble.
a If there is any play, project (heighten) the
stopper rubber until the play is eliminat-
ed.
a If the lock is not applied easily or the re-
set lever is heavy to operate, return (low-
er) the stopper rubbers within the range
where the door has not play.
iv) Fixing stopper rubbers (8) and (9), tight-
en locknuts (10) and (11).
D155AX-5 20-167
(2)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Display section of special Operation section 1 of special Operation section 2 of special

functions functions functions
(Basic operation) (Changeover operation)
1. Gear speed display section 3. Service switch (Inside cover) 4. Buzzer cancel switch
2. Multi-information section 5. Information switch
6. Shift-up switch
7. Shift-down switch
a EMMS: Equipment Management Monitoring System
20-168 D155AX-5
(2)
Normal function and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the normal function and special functions and displays information of various
types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed according to the operation of the switches.
1. Normal function: Operation mode
With this function, the operator can display and change the items displayed normally.
2. Special function: Service mode
With this function, a serviceman can display and change the displayed items with special switches for test-
ing, adjusting, and troubleshooting.
Flow of modes and functions
Operator mode
Normal display (Default) 1 Maintenance mode Maintenance item: 12 items

[>] [<]
2 Pm clinic auxiliary mode Auxiliary menu: 6 items
Travel direction/Gear speed [>] [<]
[U]
+
( ) 3 Error code display mode
Shift mode/Service meter
[>] [<]
[t] 4 Adjustment mode Adjustment menu: 5 items
[>] [<]
(Automatic) 1 Maintenance mode
Action code display function
[ON] & [U]( ) [t]
Service mode
Maintenance interval change

5 Maintenance item: 12 items
mode
[>] [<]
Electric system error code
6
display mode
[>] [<]
Mechanical system error code
7
display mode
[>] [<]
8 Adjustment mode
[>] [<]
9 Load memory display mode Display menu: 3 items
[>] [<]
10 Real-time monitoring mode
[>] [<]
11 Dual display monitoring mode [ON]: Service switch
[>] [<] [U]: Buzzer cancel switch (Left)
[ t ]: Buzzer cancel switch (Right)
Maintenance interval change [ > ]: Information switch (Right)
5
mode [ < ]: Information switch (Left)
( ): Min. 2.5 sec
D155AX-5 20-169
(2)
Operation and display in operator mode (Outline)

a In this section, only the outline of the operation
mode is described. For the details of the con-
tents and operation method of each function and
mode, see Operation Manual.
Normal display mode (Default)

The monitor panel displays the following information
normally.
Gear speed display section (1):
• Left side: Travel direction (P·N·F·R)
• Right side: Gear speed (1·2·3)
• Graphics: Engine speed
Multi-information section (2):
a Information is displayed in 2 lines of 16 charac-
ters each.
• Left side:
Gear shift mode (F1-R1·F1-R2·F2-R2)
• Right side:
Service meter (Unit: 0.1h)
1. Maintenance mode
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replacement
of oils and filters is displayed on the multi-infor-
mation section (2) and reset after the replace-
ment.
a Gear speed display section (1) keeps dis-
playing normally.
Order Display Item
1 01:ENG OIL Engine oil
2 02:ENG FILT Engine oil filter
3 03:FUEL FILT Fuel filter
4 04:HYD FILT Hydraulic oil filter
5 05:CORR RES Corrosion resistor
6 06:BYPS FILT Bypass filter *
7 07:DAMP OIL Damper oil
8 08:FNL OIL Final drive oil
9 09:HYD OIL Hydraulic oil
10 10:POWL OIL Power train oil
11 11:POWL FILT Power train oil filter
12 12:HSS FILT HSS charge filter
Note: The items marked with * are displayed but

not used for this machine.
20-170 D155AX-5
(2)
2. Pm clinic auxiliary mode

(2-PM CLINIC MODE)
In this mode, the condition of the machine is dis-
played on multi-information section (2) as an
auxiliary function of the periodic diagnoses such
as the Pm clinic, even if any measuring instru-
ment is not connected.
playing normally.
Order Display Item
1 01-ENG. SPEED Engine speed
2 02-BOOST PRESSURE Boost pressure
Work equipment oil
3 03-HYD. PUMP PRES
pressure
4 04-BATTERY VOLT Battery voltage
5 05-HSS PUMP-A HSS oil pressure A
6 06-HSS PUMP-B HSS oil pressure B
3. Error code display mode

(3-FAULT CODE DISPLAY MODE)
In this mode, the contents of each fault in the ma-
chine are displayed by a 6-character error code
on the multi-information section (2).
When the user or the operator needs to be noti-
fied of the error code of each fault, this mode is
applied.
playing normally.
a When a serviceman needs to check the error
codes for troubleshooting, the Electric sys-
tem error code display mode and the Me-
chanical system error code display mode
should be used for more detailed informa-
tion.
a Method of checking error code:
Turn buzzer cancel switch (4) to the [U] po-
sition on the screen shown at right, and the
all error codes detected currently are dis-
played at the interval of about 2 seconds. (To
finish displaying, turn the buzzer cancel
switch to the [ t ] position.)
a For the details of displayed error codes, see
the errors code table in TROUBLESHOOT-
ING WHEN ERROR CODE IS INDICATED
(ERROR CODE).
D155AX-5 20-171
(2)
4. Adjustment mode (4-USER ADJUST MODE)

In this mode, the display condition of the monitor
panel can be adjusted and the fan speed (for
cleaning the radiator) can be changed on the
multi-information section (2).
playing normally.
Order Display Item
Adjustment of LCD
1 01:LCD BRIGHTNES
brightness
Adjustment of display
2 02:DSP BRIGHTNES
brightness
Adjustment of display
3 03:DSP CONTRAST
contrast
Fan 100% speed
4 04:FAN 100% SPEED mode (For cleaning
radiator)
Non-injection crank-
5 05:NO INJECTION
ing mode
1) Brightness of LCD
This function is used to adjust the brightness
of the back light of the LCD gauge unit (See
the operation manual).
2) Brightness of display
This function is used to adjust the brightness
of the back light of the multi-information unit
(See the operation manual).
3) Contrast of display
This function is used to adjust the contrast of
the LCD of the multi-information unit (See
the operation manual).
4) Fan 100% mode

This function is used to clean the radiator.
20-172 D155AX-5
(2)
5) Non-injection cranking mode

This function is used to stop fuel injection
into all the cylinders of the engine to lubricate
the engine parts before starting the engine
after a long-time stop.
i) Operate the information switch to select
this mode.
ii) Set the buzzer cancel switch in the [U]
position to settle the mode.
iii) Under this condition, set the starting
switch in the START position to perform
non-injection cranking.
iv) Return the starting switch to the ON po-
sition and set the buzzer cancel switch in
the [ t ] position to reset the mode.
k Limit the continuous non-injection crank-
ing to 20 seconds to protect the starting
motor.
k This function set ineffective for safety
while the engine is running.
a If the system gets out of the mode, this
function is ineffective.
D155AX-5 20-173
(2)
Action code display function

If a fault to be notified to the operator occurs during
work, an action code and a phone No. are displayed
on the multi-information section (2).
a Gear speed display section (1) keeps displaying
normally.
a The phone No. is displayed for only important ac-
tion codes. The display shown at right is an ex-
ample. (The form of the displayed phone No.
depends on the form of the input No.)
a If an important action code is displayed, the cau-
tion lamp flashes and the caution buzzer sounds.
<Reference>
An action code is displayed only when a serious fault
occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure to
check for a error code in the “Electric system error
code display mode” and “Mechanical system error
code display mode” of the service mode.
Action codes table

Action
Indication method of fault Example of fault contents Remedy
code
• Automatic function stops or nor-
• Backup alarm does not sound. mal function stops partially but
E01 • Only action code is displayed. • Fan speed is always set to maxi- machine can work.
mum. • Call your Komatsu distributor for
repair.
• Stop engine and start it again,
• Gear is not shifted up or down.
and you can operate machine
• Action code is displayed. • Engine boost pressure is abnor-
without limiting function. You must
E02 • Caution lamp flashes. mal.
take care, however.
• Caution buzzer sounds. • Exhaust gas color is bad when
• Call your Komatsu distributor for
temperature is low.
repair.
• Engine water temperature is de-
fective.
• Usable gear speeds are limited.
• Action code is displayed. • Move machine to safe place.
• Engine speed does not rise fully.
CALL E03 • Caution lamp flashes. • Call your Komatsu distributor for
• Gear shifting shocks become
• Caution buzzer sounds. repair.
large.
• Steering performance lowers.
• Brake shocks become large.
• Action code is displayed. • Engine cannot be controlled. • Stop machine immediately.
CALL E04 • Caution lamp flashes. • Machine cannot travel. • Call your Komatsu distributor for
• Caution buzzer sounds. • Machine stops. repair.
20-174 D155AX-5
(2)
Operation and display in service mode

Method of changing to service mode
a When using the service mode, change the
screen by the following special operation.
1) Special operation of switches

Set the monitor panel in the service mode by op-
erating service switch (3) and buzzer cancel
switch (4).
• Keeping the service switch in the ON posi-
tion, hold the buzzer cancel switch in the [U]
position for 2.5 seconds.
a If the display of multi-information unit (2)
changes, the service mode is selected.
a The gear speed display unit (1) keeps the
normal display until any mode is selected.
a Each time the monitor panel is set in the ser-
vice mode, the “Maintenance inter val
change mode” is displayed first.
2) Selecting and executing mode to be used

Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
• [ > ]: Next mode No.
• [ < ]: Previous mode No.
• [U]: Execute mode.
a For the details of operation in each mode,
see the following pages.
Gear
a When operating each mode, each code is Order speed Service mode display and item
displayed at gear speed display (1) (See the display
table at right). 5-EXCHG, INTVAL. SET MODE

1 1C
Maintenance interval change mode
3) Finishing mode and function 6-ELEC. FAULT CODE MODE
The current mode and function can be finished 2 EE
Electric system fault code display mode
by either of the following method, regardless of
the current mode and hierarchy. 7-MACHINE FAULT CODE MODE
3 bE
i) When continuing the operation in another Mechanical system fault code display mode
mode or function or in the operator mode: 8-SERVICE ADJUST MODE
Return to the mode screen or function 4 Cb
Adjustment mode
screen to be used next by operating buzzer
9-LOAD MEMORY DISPLEY MODE
cancel switch (4). 5 Ld
• [ t ]: Screen returns. Load memory display mode
ii) When finishing the all operation: 10-REAL TIME MONITORING MODE
6 5R
Turn off the starting switch. Real time monitoring mode
11-DUAL DISPLAY MONITORING MODE
7 dR
Dual display monitoring mode
D155AX-5 20-175
(2)
5. Maintenance interval change mode

(5-EXCHG. INTVAL. SET MODE)
In this mode, you can check and set the mainte-
nance interval times of various filters and oils
which are the bases of the maintenance display
function in the operator mode.
1) Selecting and executing mode

i) Select “Maintenance interval change
mode” on the mode selection screen.
a If the mode is selected, the title is
displayed on multi-information sec-
tion (2).
ii) Display the maintenance item selection
screen by operating buzzer cancel
switch (4).
a If the mode is operated, code (1C) is
displayed on gear speed display sec-
tion (1).
2) Selecting and displaying maintenance item

i) Operate information switch (5) on the
maintenance item selection screen to
select a maintenance item.
• [ > ]: Next code
• [ < ]: Previous code
ii) Display the maintenance item selection
screen by operating buzzer cancel
switch (3).
• [U]: Execute item.
3) Contents of information section

The following items are displayed on the in-
formation section.
(a): Code
(b): Maintenance item
(c): Replacement interval time (Set time)
a The items shown at right are examples.
a If the replacement interval does not need
to be changed, finish the operation on
this screen.
a If the replacement interval needs to be
changed, go to step 4).
20-176 D155AX-5
(2)
4) Changing replacement interval time

i) Change the set time by operating infor-
mation switch (5), shift-up switch (6), and
shift-down switch (7).
• [ > ]: Move cursor to right.
• [ < ]: Move cursor to left.
• [UP]: Increase number.
• [DOWN]: Decrease number.
a If you do not use the maintenance

function, set the all times to 0.
ii) If the input time is correct, enter the

change of setting by operating buzzer
cancel switch (4).
• [U]: Enter change.
a If the change is finished normally, the
information display screen appears
after the screen shown at right.
a If the change is not finished normally,

the information display screen before
the change appears after the screen
shown at right. In this case, execute
the above operation again.
D155AX-5 20-177
(2)
Maintenance items table

Replacement interval time
Order Display Item 1st time 2nd time and after
(Cannot be changed) (Can be changed)
1 01:ENG OIL Engine oil 0500h 0500h
2 02:ENG FILT Engine oil filter 0500h 0500h
3 03:FUEL FILT Fuel filter 0500h 0500h
4 04:HYD FILT Hydraulic oil filter 0250h 2000h
5 05:CORR RES Corrosion resistor 1000h 1000h
6 06:BYPS FILT Bypass filter — —
7 07:DAMP OIL Damper oil 2000h 2000h
8 08:FNL OIL Final drive oil 0250h 1000h
9 09:HYD OIL Hydraulic oil 0250h 2000h
10 10:POWL OIL Power train oil 0250h 1000h
11 11:POWL FILT Power train oil filter 0250h 0500h
12 12:HSS FILT HSS charge filter 0250h 1000h
a The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that the
first maintenance has been finished in the maintenance mode of the operator mode, then change the 2nd
and after interval times.
20-178 D155AX-5
(2)
6. Electric system error code display mode

(6-ELEC. ERROR CODE MODE)
In this mode, you can check the past electric sys-
tem error codes.

i) Select “Electric system error code display
mode” on the mode selection screen.
tion (2).
ii) Display the error code display screen by
operating buzzer cancel switch (4).
a If the mode is operated, code (EE) is
tion (1).
2) Display in the case where no codes are re-

corded
If no error codes have been output up to now,
the information section displays as shown at
right.
3) Display in the case where 1 or more codes

are recorded
If any error code has been output up to now,
right.
(a): Record No. (Up to 20)
(b): Error code (Code being output currently
is flashing)
(c): Number of past occurrences
(d): Time measured by service meter after
first occurrence
(e): Time measured by service meter after
last occurrence
a For the details of displayed error codes,
see the errors code table in TROUBLE-
SHOOTING WHEN ERROR CODE IS
INDICATED (ERROR CODE).
D155AX-5 20-179
(2)
a Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output currently.
a Condition for detecting and keeping error
code
If a error code of any item other than
communication is output, it keeps flash-
ing until the starting switch is turned off.
After the starting switch is turn on or the
engine is started again, the error code
keeps lighting until the same fault is de-
tected.
A error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are

recorded.
When multiple codes are recorded, they can
be displayed one by one by operating infor-
mation switch (5).
a The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

While a error code to be deleted, operate
shift-up switch (6) or shift-down switch (7).
• [UP] or [DOWN]: Delete error code.
a A error code which is being output cur-
rently (which is flashing) cannot be delet-
ed.
20-180 D155AX-5
(2)
7. Mechanical system error code display mode

(7-MACHINE ERROR CODE MODE)
In this mode, you can check the past mechanical
system error codes.

i) Select “Mechanical system error code
display mode” on the mode selection
screen.
tion (2).
ii) Display the error code display screen by
operating buzzer cancel switch (4).
a If the mode is operated, code (bE) is
tion (1).
2) Display in the case where no codes are re-

corded
If no error codes have been output up to now,
right.
3) Display in the case where 1 or more codes

are recorded
If any error code has been output up to now,
right.
(a): Record No. (Up to 20)
(b): Error code (Code being output currently
is flashing)
(c): Number of past occurrences
(d): Time measured by service meter after
first occurrence
(e): Time measured by service meter after
last occurrence
a For the details of displayed error codes,
see the errors code table in TROUBLE-
SHOOTING WHEN ERROR CODE IS
INDICATED (ERROR CODE).
D155AX-5 20-181
(2)
a Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output currently.
a Condition for detecting and keeping error
code
If a error code of any item other than
communication is output, it keeps flash-
ing until the starting switch is turned off.
After the starting switch is turn on or the
engine is started again, the error code
keeps lighting until the same fault is de-
tected.
A error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are

recorded.
When multiple codes are recorded, they can
be displayed one by one by operating infor-
mation switch (5).
a The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

The mechanical system error codes cannot
be deleted.
20-182 D155AX-5
(2)
8. Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.

i) Select “Adjustment mode” on the mode
selection screen.
tion (2).
ii) Display the adjustment code input screen
by operating buzzer cancel switch (4).
a If the mode is operated, code (Cb) is
tion (1).
2) Selecting adjustment items

i) On the adjustment code input screen, in-
put the 4-digit code of the item to be ad-
justed by operating information switch
(5), shift-up switch (6), and shift-down
switch (7).
ii) After inputting the code, operate buzzer
cancel switch (4) to execute code.
• [U]: Execute code.
a If an incorrect code is input, the
screen shown at right appears, and
then the adjustment code input
screen appears again. In this case,
execute the input operation again.
D155AX-5 20-183
(2)
3) Contents of display on adjustment screen

(a): Code
(b): Adjustment item
(c): Related information
a For the detailed information and adjust-
ment procedure, see “ADJUSTMENT
MODE TABLE AND ADJUSTMENT
PROCEDURE”.
4) When operating machine in adjustment mode

If the parking brake lever is set in the FREE
position, gear speed display section (1) dis-
plays normally and the machine can be op-
erated normally.
a To select another screen, return the
parking brake lever to the LOCK position
and perform the necessary procedure.
5) Automatic selection of adjustment item (Lim-

ited function)
After one of some adjustment items is select-
ed, if the information switch is operated, the
next adjustment item is selected automati-
cally, even if the code of the next adjustment
item is not input.
• [ > ]: Code is increased
• [ < ]: Code is decreased
a This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Adjustment mode ta-
ble. Those items are selected in the
order of their numbers.
a Note that this operation is not effective
while the parking brake lever is in the
RESET position.
a You may return to the screen for inputting
codes and enter a code without using
this function.
20-184 D155AX-5
(2)
Adjustment mode table and adjustment procedure

Related Disassembly/ Automatic
No. Code Adjustment item information Assembly selection
1 0001 INP TEL NO. Phone No. input mode Figure/Symbol
2 0002 S/T S.CODE Steering controller specification set Code q 1
3 0004 BODY TYPE Machine specification set Code q 2
4 0005 BRAKE BASE Brake potentiometer initial set (Zero-point adjustment) Voltage q 3
5 0006 PUMP N.AJST HSS pump neutral adjustment Pressure q 5
6 0007 ENG.FULL CH Engine deceleration-cut mode Speed 4
7 0008 INJ->123456 Common rail reduced cylinder mode Speed
8 0009 PITCH SENS. Pitch angle sensor initial set Voltage q 6
9 0010 FAN 70%MODE Fan 70% speed mode Adjustment data 7
10 0523 SMR SET Service meter adjustment Time
11 1005 FAN100%MODE Fan 100% speed mode Adjustment data 8
12 1012 S/T N-SET Steering lever neutral set Voltage
13 1013 S/T L-SET Steering lever left set Voltage
14 1014 S/T R-SET Steering lever right set Voltage
15 2222 HSS ADJUST HSS lever initial current set Current
16 9997 HI IDLE SET High idling limit mode Adjustment data
17 9998 SFT INHIBIT Gear speed limit mode Permit
k Items marked with q in the Disassembly/Assembly column of the above table must be adjusted after the
machine is assembled or any controller is replaced.
a The items marked with numbers in the “Sending in order” column can be sent in order with the information
switch.
D155AX-5 20-185
(2)
(1) [0001]: Phone number input mode

• This code inputs or changes a phone number to
be displayed simultaneously with when the user
code is displayed.
• The lower part displays a phone number and
symbols.
• Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ?
• Instructions for use:
By operating the information switch (5), shift up
switch (6), and shift down switch (7), input a
phone number and symbols.
• [ > ]: Moves the cursor rightward.
• [ < ]: Moves the cursor leftward.
• [UP]: Advance the numeric character or
character (in the order of available
characters).
• [DOWN]: Reverse the numeric character or
character (in the reverse order of
available characters).
a Sixteen digits of numeric characters are pro-
vided. To avoid confusion, input symbols oth-
er than numeric characters at digits you will
not use.
a 0 (zero) is input at all places of the lower part
before shipment from our factory.
a The setting is enabled even after ending this
code.
(2) [0002]: Steering and transmission controller

specification set
• This code is used to initialize the specification
codes recognized by the steering controller and
the set values of the memory in the controller.
• The specification code is displayed on the lower
line.
• Adjustment method:
i) Set buzzer cancel switch (4) in the [U] posi-
tion and check that the caution buzzer
sounds.
ii) Check that the displayed specification code
has changed from [4*4] to [444].
a If specification code [444] is not displayed,
the controller wiring harness or the controller
unit may be defective.
a Even if this code is turned off, the setting is
effective.
20-186 D155AX-5
(2)
(3) [0004]: Machine specification set

• This code is used to have the machine specifica-
tion recognized by the controllers which com-
pose the system.
• The machine specification code is displayed on
the lower line.
a Since this code is reset when “Steering and
transmission controller specification set” is
executed, adjust it after that.
i) Select the code of the machine specification
by setting shift up switch (6).
ii) Set buzzer cancel switch (4) in the [U] posi-
No. Specification
sounds.
k If the machine specification is different from
00 Standard specification
the setting in the controller, the machine may 10 Pitch dozer specification
move abnormally or an error may be made. 80 —
Accordingly, be sure to match the setting to 90 —
the machine specification.
effective.
(4) [0005]: Brake potentiometer zero point

adjustment
• This code is used to adjust the zero point of the
potentiometer of the brake pedal.
• The deviation from the standard is displayed by
voltage on the lower line (Display range: –2500 –
2500).
i) Check that the brake pedal is in neutral (it is
not depressed).
ii) With the brake pedal released, set buzzer
cancel switch (4) in the [U] position and
check that the caution buzzer sounds.
a Even if the neutral position of the brake pedal
is adjusted, the display of the lower line does
not change.
effective.
a This adjustment is performed to have the
zero point of the potentiometer recognized
by the controller. It is not performed to adjust
the effect of the brake.
D155AX-5 20-187
(2)
(5) [0006]: HSS pump neutral adjustment

(HSS specification)
• This code is used to solve a problem in the
straight travel performance of the HSS steering.
• The HSS oil pressure is indicated on the lower
line.
• Adjustment method 1 (Check of HSS differential

pressure and deviation direction):
a Before performing this adjustment, check the
differential pressure of the HSS pump to see
if the straight travel performance needs to be
adjusted.
i) Run the engine at high idling with the parking
brake lever in the LOCK position.
ii) Set the monitor panel in the real-time moni-
toring mode (5R) and execute it to the follow-
ing code.
50500 (HSS differential oil pressure)
iii) Check the indicated differential pressure to
see if the straight travel performance needs
to be adjusted.
a If the differential pressure is 2MPa or
lower, the straight travel performance
does not need to be adjusted. In this
case, finish the work.
a If the differential pressure is higher than
2MPa, perform the following adjustment
step.
iv) Run the engine at high idling and tilt the
PCCS lever “to the right end and return it and
measure the differential pressure” and tilt it
“to the left end and return it and measure the
differential pressure”, and then judge the de-
viation direction from the measured differen-
tial pressure.
a The machine deviates during travel in
the lever operation direction in which the
differential pressure is higher.
20-188 D155AX-5
(2)
• Adjustment method 2 (Adjustment of neutral po-

sition of HSS):
k Since the steering circuit will be relieved,
take care of safety around the machine and
keep pressing the brake pedal securely dur-
ing adjustment.
i) Set the monitor panel in the adjustment
mode.
ii) Set the parking brake lever in the FREE po-
sition and keep pressing the brake pedal se-
curely and run the engine at high idling.
iii) Turn the PCCS lever fully in the opposite di-
rection to the deviating direction and keep it
that position.
iv) Set the buzzer cancel switch (4) in the [U]
position and return the PCCS lever to the
neutral position.
a It takes about 1 minutes to complete the
adjustment (The progress of the adjust-
ment is displayed graphically on the en-
gine speed display section of the monitor
panel).
v) When the adjustment is completed, the all
segments of the engine speed display sec-
tion of the monitor panel light up and start
flashing.
• Adjustment procedure 3 (Check of adjustment):

Check that the differential pressure in the HSS
pump is in the normal range according to Adjust-
ment method 1 above.
50500 (HSS differential pressure)
• Normal range: Max. 2MPa {20.4kg/cm2}
effective.
(6) [0007]: Engine deceleration-cut mode

• This code is used to stop the auto-deceleration
function of the engine and check the high idling
speed of the engine singly.
• The engine speed is displayed on the lower line
(Display range: 0 – 3000).
• Using method:
While this code is displayed, its function is turned
on and the auto-deceleration function is turned
off.
a If this code is turned off, its function is turned
off.
D155AX-5 20-189
(2)
(7) [0008]: Common rail reduced cylinder mode

a When the engine common rail system seems to
be faulty, this code is used to stop injecting fuel
into 1 or more cylinders (reduce the number of
effective cylinders) while the engine is running
and find out a faulty cylinder from the change of
the engine speed.
a Since a fault is detected by the difference of the
engine speed in the reduced cylinder mode op-
eration from that in the normal mode operation,
use this function while the engine is running.
• The engine speed is displayed on the lower line
(Display range: 0 – 3000).
• Using method:
Select the cylinders to be turned off for the re-
duced cylinder mode operation by operating in-
formation switch (5) and buzzer cancel switch
(4).
Use this method to turn on the selected cylinders
again, too.
• [U]: Execute or stop reduced cylinder mode
operation.
a The figure at right is an example that No. 2
cylinder is turned off for reduced cylinder
mode operation and turned on again (The
cylinder No. lamp is turned off in the reduced
cylinder mode operation and on in the nor-
mal mode operation).
a Only one or more cylinders can be turned off
for the reduced cylinder mode operation.
a If this code is turned off, its function is turned
off.
20-190 D155AX-5
(2)
(8) [0009]: Pitch angle sensor initial set

• This code is used to adjust the zero point and
correct the installation error of the pitch angle
sensor.
• The deviation from the standard neutral position
is displayed by voltage on the lower line (Display
range: –2500 – 2500).
i) Stop the machine on level ground.
ii) Buzzer cancel switch (4) in the [U] position
and check that the caution buzzer sounds.
a Even after adjustment, the display of the low-
er line does not change.
effective.
(9) [0010]: Fan 70% speed mode

• This code forcedly sets the rpm of cooling fan at
approximately 70% of the maximum speed.
• The lower part displays data for adjustment.
The function is enabled with this code displayed
to control the rpm of cooling fan to approximately
70% of the maximum speed.
a Ending this code disables the function.
(10) [0523]: Service meter adjustment

• This code is used to match the value of a new
service meter to the value of the machine.
k Since this code can only put the service meter
forward and cannot put it back, operate carefully.
• The service meter reading is displayed on the
lower line (Display range: 00000 – 99999).
• Using method:
a If you input a wrong value, do not enter the
setting but cancel this code, then execute the
setting again.
i) Set the service meter reading by operating
information switch (5) and shift-up switch (6).
a The actual service meter displays by the
unit of 0.1h, but this code adjustment by
the unit of 1h.
a Cannot adjust the values lower than cur-
rent service meter.
sounds.
a Even if the adjustment mode is turned off,
the setting is effective.
D155AX-5 20-191
(2)
(11) [1005]: Fan 100% speed mode

• This code forcedly sets the rpm of cooling fan at
approximately 100% of the maximum speed.
• The lower part displays data for adjustment.
a The function is enabled with this code dis-
played to control the rpm of cooling fan to ap-
proximately 100% of the maximum speed.
i) Change the adjustment value of the maxi-
mum speed by operating shift-up switch (6)
and shift-down switch (7).
• [UP]: Increase the adjustment value.
• [DOWN]: Decrease the adjustment val-
ue.
ii) To settle the adjustment value, set buzzer
cancel switch (4) in the [U] position and
check that the alarm buzzer sounds.
a If this code is finished, the function becomes
ineffective but the set adjustment value is ef-
fective.
(12) [1012]: Steering lever neutral set

• This code is used to adjust the steering potenti-
ometer neutral position of the PCCS lever.
• The output signal of steering potentiometer from
displayed by voltage on the lower line (Display
range: 0 – 5000).
i) Shift the PCCS lever in the steering neutral
position.
sounds.
effective.
a This code is not for adjustment of the steer-
ing performance, etc.
20-192 D155AX-5
(2)
(13) [1013]: Steering lever left set

• This code is used to adjust the maximum left
steering potentiometer position of the PCCS le-
ver.
• The output signal of the steering potentiometer
from displayed by voltage on the lower line (Dis-
play range: 0 – 5000).
i) Set the PCCS lever to the left steering stroke
end.
sounds.
effective.
(14) [1014]: Steering lever right set

• This code is used to adjust the maximum right
steering potentiometer position of the PCCS le-
ver.
• The output signal of steering potentiometer from
displayed by voltage on the lower line (Display
range: 0 – 5000).
i) Set the PCCS lever to the right steering
stroke end.
sounds.
effective.
D155AX-5 20-193
(2)
(15) [2222]: HSS lever initial current set

• When the steering start feeling is different by the
steering direction, this code is used to adjust the
turning radius at the start of steering.
• The current to drive the HSS pump EPC sole-
noid is displayed on the lower line [Display
range: –350 (Left end) – 0 – 350 (Right end)].
i) Set the parking lever to FREE position.
ii) Gradually turning the PPC lever to the left or
right, display and keep the current to be set.
• If the lever is turned to the left, the cur-
rent becomes negative.
• If the lever is turned to the right, the cur-
rent becomes positive.
iii) Set buzzer cancel switch (4) in the [U] posi-
sounds.
a As the set current is increased in the positive
or negative direction, the turning radius at
the start of steering is decreased (the ma-
chine turns more quickly).
a The figure at right is an example that the set
current for steering to the left is reduced to
increase the turning radius.
effective.
(16) [9997]: High idling limit mode

• This code is used to limit the use high idling
speed.
• The limited speed (0 – 400) is displayed on the
lower line.
• Limit range: High idling speed – –400rpm
• Using method:
i) Select a limit speed by setting information
switch (5) in the [ > ] position or [ < ] position.
sounds.
a If the high idling speed is limited, the engine
speed is not raised to the normal high idling
level even if the fuel control dial is controlled
so.
effective.
20-194 D155AX-5
(2)
(17) [9998]: Gear speed limit mode

• This code is used to limit the use of the 3 gear
speeds.
• The usable gear speeds are displayed by bits on
the lower line (in the order of the 3rd, 2nd, and
1st from the left).
• Using method:
Limit or allow the use of the maximum gear
speed by operating information switch (5) and
buzzer cancel switch (4).
• [ > ]: Do not prohibit shifting to 3rd gear speed.
• [ < ]: Prohibit shifting to 3rd gear speed.
• [U]: Enter the selection.
• Display on lower line [o]:
Gear speed is effective.
• Display on lower line [_]:
Gear speed is not effective.
a If the use of a gear speed is limited, the
transmission is not shifted to that gear speed
even if the gear shift-up switch is operated.
effective.
D155AX-5 20-195
(2)
9. Load memory display mode

(9-LOAD MEMORY DISPLAY MODE)
In this mode, you can check the load on the ma-
chine, forward odometer, and reverse odometer.

i) Select “Load memory display mode” on
the mode selection screen.
tion (2).
ii) Display the adjustment code input screen
a If the mode is operated, code (Ld) is
tion (1).
2) Changing information screen No. Display Item

Change the information screen by operating
01 01-1000 rpm SMR 1,000rpm service meter
information switch (5).
• [ > ]: Next screen. 02 02-FOWARD ODO Forward odometer
• [ < ]: Previous screen. 03 03-REVERCE ODO Reverse odometer
3) Display of 1,000rpm service meter (01)

This code is used to display the service
meter which integrates the operation hours
only while the engine speed is higher than
1,000rpm.
a The data cannot be reset.
20-196 D155AX-5
(2)
4) Display of forward odometer (02)

On this screen, the integrated forward travel
distance is displayed.
5) Display of reverse odometer (03)

On this screen, the integrated reverse travel
distance is displayed.
6) When operating machine in load memory

display mode
erated normally.
parking brake lever to the LOCK position
D155AX-5 20-197
(2)
10. Real-time monitoring mode

(10-REAL TIME MONITORING MODE)
In this mode, the speeds, oil pressures, oil tem-
peratures, currents, voltages, etc. can be moni-
tored by using the signals from sensors,
switches, and solenoids installed various parts of
the machine.
a This mode is used to monitor 1 item. When
monitoring 2 items simultaneously, use the
“Dual display monitoring mode”.

i) Select “Real-time monitoring mode” on
the mode selection screen.
tion (2).
ii) Display the monitoring code input screen
• [U]: Decide selection.
a If the mode is operated, code (5R) is
tion (1).
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit code of the item to be monitored by
operating information switch (5), shift-up
switch (6), and shift-down switch (7).
ii) After inputting the code, display the mon-

itoring screen by operating buzzer can-
cel switch (4).
• [U]: Enter input code.
a If the input code is correct, the moni-
toring screen shown at right ap-
pears.
20-198 D155AX-5
(2)
a If the input code is not correct, the

code input screen appears again af-
ter the screen shown at right.
3) Contents of display on monitoring screen

(Right figure shows examples)
(a): Code
(b): Monitoring item
(c): Information
(d): Unit (Not displayed for some items)
a For the details, see the “MONITORING
MODE TABLE”.
4) Function of holding monitoring information

If an information item such as the engine
speed is not stabilized and cannot be read
easily in the monitoring mode, it can be held
and released by operating buzzer cancel
switch (4).
• [U]: Hold and release.
a While the monitored item is held, the let-
ter “H” is displayed at the left end of the
lower line.
5) When operating machine in monitoring mode

erated normally.
parking brake lever to the FREE position
D155AX-5 20-199
(2)
6) Automatic selection of monitoring item (Lim-

ited function)
After one of some monitoring items is select-
ed, if the information switch is operated, the
next monitoring item is selected automatical-
ly, even if the code of the next monitoring
item is not input.
• [ > ]: Code is increased
• [ < ]: Code is decreased
a This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Monitoring mode ta-
ble. Those items are selected in the
order of their numbers.
a Note that this operation is not effective
while the parking brake lever is in the
RESET position.
a You may return to the screen for inputting
codes and enter a code without using
this function.
20-200 D155AX-5
(2)
Monitoring mode table

In
No. Code Monitored item Unit Display range order
1 01000 ENG. SPEED Engine speed rpm 0 – 3000 1
2 03000 FUEL DIAL Voltage of fuel control dial mV 0 – 5000 —
3 03001 FUEL DIAL Acceleration ratio % 0 – 100 2
4 03200 BATTERY Battery voltage mV 0 – 30000 34
5 04102 WATER HIGH Engine water temperature (High temperature side) ºC 0 – 150 24
6 04104 WATER LOW Engine water temperature (Low temperature side) ºC –30 – 100 25
7 04200 FUEL SENS Fuel level sensor voltage mV 0 – 5000 27
8 04204 FUEL TEMP. Fuel temperature ºC 0 – 150 —
9 04401 HYD. TEMP. Hydraulic oil temperature ºC 0 – 150 —
10 04402 HYD. TEMP. Hydraulic oil temperature voltage mV 0 – 5000 —
11 10000 FAN REVO. Command speed of cooling fan rpm 0 – 2000 —
12 20000 ENG-MACHIN Engine controller program No. Character — —
13 20200 MON. PROGRM Monitor panel program No. Character — —
14 20202 S/T. PROGRM Steering controller and transmission controller program No. Character — —
15 20203 ENG-PROGRM Engine controller program No. Character — —
16 20300 KOMTRAX KOMTRAX LED display — (See detailed information) 35
17 30100 T/C TEMP. Power train oil temperature ºC 0 – 150 26
18 31400 T/M OUT Transmission speed rpm 0 – 5000 28
19 31520 T/M-FILL Input state of transmission-related fill switch Bit (See detailed information) —
20 31602 1st CLUTCH Output command current of 1st clutch ECMV mA 0 – 1000 —
21 31603 2nd CLUTCH Output command current of 2nd clutch ECMV mA 0 – 1000 —
22 31604 3rd CLUTCH Output command current of 3rd clutch ECMV mA 0 – 1000 —
23 31606 Rev CLUTCH Output command current of reverse clutch ECMV mA 0 – 1000 —
24 31608 Frd CLUTCH Output command current of forward clutch ECMV mA 0 – 1000 —
25 31612 1 CLUTCH F Output FB current of 1st clutch ECMV mA 0 – 1000 21
26 31613 2 CLUTCH F Output FB current of 2nd clutch ECMV mA 0 – 1000 22
27 31614 3 CLUTCH F Output FB current of 3rd clutch ECMV mA 0 – 1000 23
28 31616 R CLUTCH F Output FB current of reverse clutch ECMV mA 0 – 1000 20
29 31622 F CLUTCH F Output FB current of forward clutch ECMV mA 0 – 1000 19
30 31623 FAN PUMP.O Output command current of fan pump solenoid mA 0 – 1000 —
31 31624 FAN PUMP.F Output FB current of fan pump solenoid mA 0 – 1000 —
32 31624 PITCH SOL Drive current of blade pitch solenoid mA 0 – 1000 —
33 32900 BODY ANGLE Body pitch angle º –30 – 30 33
34 36100 Q-INJECTOR Command value of fuel injection rate mm3/st –30 – 600 —
35 36200 CRI. PRESS Command pressure of common rail MPa 0 – 150 —
36 36300 CRI-TIMING Fuel injection timing CA –30.0 – 30.0 —
37 36400 CRI. PRESS Common rail pressure MPa 0 – 200 5
38 36500 BOOST. PRES Boost pressure kPa 0 – 300 6
39 36600 CRI. CONTRL Engine control mode Character — —
40 36700 CRI-TORQUE Converted torque of engine % 0 – 100 —
41 36800 CRI-Q-MOD1 Fuel injection amount adjustment command value 1 Character 0123456789abcdef —
42 36801 CRI-Q-MOD2 Fuel injection amount adjustment command value 2 Character 0123456789abcdef —
43 40001 VEHICLE SP Travel speed (Theoretical value) km/h 0 – 100 31
44 40900 ENG-SW 1 Engine controller input signal 1 Bit (See detailed information) —
45 40901 ENG-SW 2 Engine controller input signal 2 Bit (See detailed information) —
D155AX-5 20-201
(2)
In
No. Code Monitored item Unit Display range order
46 40905 T/M-SW1 Transmission-related controller input signal 1 Bit (See detailed information) —
47 40906 T/M-SW2 Transmission-related controller input signal 2 Bit (See detailed information) —
48 40909 T/M SOL.2 Transmission-related controller output signal Bit (See detailed information) —
49 40910 S/T-SW1 Steering-related controller input signal 1 Bit (See detailed information) —
52 40914 S/T SOL.1 Output signal of steering controller Bit (See detailed information) —
53 50000 DESEL PEDAL Deceleration ratio % 0 – 100 3
54 50001 DESEL PEDAL Voltage of deceleration potentiometer mA 0 – 5000 —
55 50100 SSC 3rd throttle % 0 – 100 4
56 50200 T/M LEVER 1 Voltage of forward-reverse potentiometer 1 mV 0 – 5000 7
57 50201 T/M LEVER 2 Voltage of forward-reverse potentiometer 2 mV 0 – 5000 8
58 50300 S/T LEVER 1 Voltage of steering potentiometer 1 mV 0 – 5000 9
59 50301 S/T LEVER 2 Voltage of steering potentiometer 2 mV 0 – 5000 10
60 50400 BRAKE PEDL Voltage of brake potentiometer mV 0 – 5000 11
61 50500 HSS PUMP D HSS oil differential pressure MPa –50 – 50 12
62 50501 HSS PUMP A HSS oil pressure A MPa 0 – 50 13
63 50502 HSS PUMP B HSS oil pressure B MPa 0 – 50 14
64 50503 HSS PUMP A Voltage of HSS oil pressure A sensor mV 0 – 5000 —
65 50504 HSS PUMP B Voltage of HSS oil pressure B sensor mV 0 – 5000 —
66 50600 HSS L.H.F Output FB current of left HSS solenoid mA 0 – 1000 17
67 50601 HSS R.H.F Output FB current of right HSS solenoid mA 0 – 1000 18
68 50602 HSS L.H.O Output command current of left HSS solenoid mA 0 – 1000 —
69 50603 HSS R.H.O Output command current of right HSS solenoid mA 0 – 1000 —
70 50900 N-SAFETY Drive current of neutral safety relay mV 0 – 30000 30
71 51000 SSC ORDER 3rd throttle command speed rpm 0 – 3000 —
72 60000 TRACTION Traction force (Theoretical value) W 0–0 32
73 60100 BODY ANGLE Body pitch angle sensor voltage mV 0 – 5000 —
74 60600 BR HOLD Drive voltage of battery relay mV 0 – 30000 —
75 60700 S/T MODE Steering state code Character — —
76 60800 FILL MODE Variable for setting fill condition Character — —
77 60909 MOD. MODE Setting of modulation condition Character — —
78 70000 CHG. P. MODE Variable for setting condition of gear shift point Character — —
79 70300 B. KNOB SW Input signal of blade lever knob switch Bit (See detailed information) —
80 70304 T/M SOL.1 Output signal of transmission related controller Bit (See detailed information) —
81 70400 BACK ALARM Drive voltage of back-up alarm relay mV 0 – 30000 —
82 70500 Regulation Reguration speed rpm 0 – 2200 —
83 70700 HYD. PUMP 1 Work equipment oil pressure MPa 0 – 50 —
84 70701 HYD. PUMP 1 Voltage of work equipment oil pressure sensor mV 0 – 5000 —
a The items marked with numbers in the “Sending in order” column can be sent in order with the information
switch.
20-202 D155AX-5
(2)
Detailed information on bit display codes

Examples of display of bit information
a The display position of the bit information in the
“Real-time monitoring mode (Display of only 1
item)” is different from that in the “Dual display
monitoring mode (Simultaneous display of 2
items)”.
a The bit information is displayed by [_] for OFF
and [o] for ON in the places (a) – (h).
a The state of each item shown below is the con-
dition for turning on the bit.
19) 31520: Input state of transmission related fill switch

(a): Forward clutch fill switch: ON
(b): Reverse clutch fill switch: ON
(c): 1st clutch fill switch: ON
(d): 2nd clutch fill switch: ON
(e): 3rd clutch fill switch: ON
( f ): (Unused)
(g): (Unused)
(h): (Unused)
44) 40900: Engine controller input signal 1

(a): Starting switch signal C: Input
(b): (Unused)
(c): (Unused)
(d): Low engine oil pressure switch: ON
(e): High engine oil pressure switch: ON
( f ): (Unused)
(g): (Unused)
(h): Model selection signal 1: ON
45) 40901: Engine controller input signal 2

(a): Model selection signal 2: ON
(b): Model selection signal 3: ON
(c): (Unused)
(d): (Unused)
(e): N-signal 1: ON
( f ): N-signal 2: ON
(g): (Unused)
(h): (Unused)
D155AX-5 20-203
(2)
46) 40905: Transmission related controller input signal 1

(a): Gear shift-up switch: OFF
(b): Gear shift-up switch: ON
(c): Gear shift-down switch: OFF
(d): Gear shift-down switch: ON
(e): (Unused)
( f ): (Unused)
(g): (Unused)
(h): (Unused)
47) 40906: Transmission-related controller input signal 2

(a): Automatic gear shift-down switch: ON
(b): Fan reverse mode: ON
(c): Fan reverse 100% mode: ON
(d): (Unused)
(e): (Unused)
( f ): (Unused)
(g): (Unused)
(h): (Unused)
48) 40909: Transmission related controller output signal

(a): Transmission N-signal: ON
(b): (Unused)
(c): (Unused)
(d): Back-up alarm relay: ON
(e): Neutral safety relay: ON
( f ): (Unused)
(g): (Unused)
(h): (Unused)
49) 40910: Steering related controller input signal 1

(a): (Unused)
(b): (Unused)
(c): (Unused)
(d): (Unused)
(e): Parking brake lever switch: FREE
( f ): Parking brake lever switch: LOCK
(g): (Unused)
(h): (Unused)
20-204 D155AX-5
(2)

(a): Buzzer cancel switch: At U
(b): Buzzer cancel switch: At T
(c): Information switch: At <
(d): Information switch: At >
(e): Service switch: ON
( f ): (Unused)
(g): (Unused)
(h): (Unused)

(a): ACC signal: ON
(b): (Unused)
(c): (Unused)
(d): Motoring signal: ON
(e): (Unused)
( f ): (Unused)
(g): (Unused)
(h): (Unused)
52) 40914: Output signal of steering related controller

(a): (Unused)
(b): (Unused)
(c): Fan reverse solenoid: ON
(d): (Unused)
(e): Battery relay drive: ON
( f ): (Unused)
(g): (Unused)
(h): (Unused)
80) 70300: Blade lever knob switch input signals

(a): (Unused)
(b): (Unused)
(c): Blade lever pitch switch: When OFF
(d): Blade lever pitch switch: When ON
(e): (Unused)
( f ): (Unused)
(g): (Unused)
(h): (Unused)
D155AX-5 20-205
(2)
81) 70304: Transmission-related controller output

signals
(a): (Unused)
(b): Pitch solenoid: When ON
(c): (Unused)
(d): (Unused)
(e): (Unused)
( f ): (Unused)
(g): (Unused)
(h): (Unused)
20-206 D155AX-5
(2)
11. Dual display monitoring mode

(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be displayed
simultaneously.
a Note that only codes and monitoring infor-
mation are displayed in this mode since the
usable display columns are limited. (Item
names and units cannot be displayed.)

i) Select “Dual display monitoring mode”
on the mode selection screen.
tion (2).
ii) Display the monitoring code input screen
a If the mode is operated, code (dR) is
tion (1).
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit codes of the items to be monitored
to the upper and lower lines by operating
information switch (5), shift-up switch (6),
and shift-down switch (7).
ii) After inputting the codes, display the

monitoring screen by operating buzzer
cancel switch (4).
• [U]: Enter input code.
a If the input codes are normal, the
monitoring screen shown at right ap-
pears.
D155AX-5 20-207
(2)
a If the input codes are abnormal, the

code input screen appears again af-
ter the screen shown at right.
3) Contents of display on monitoring screen

(Right figure shows examples)
(a): Code 1
(b): Information 1
(c): Code 2
(d): Information 2
a For the details, see the “MONITORING
MODE TABLE”.
4) When operating machine in monitoring mode

erated normally.
parking brake lever to the FREE position
20-208 D155AX-5
(2)
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
TESTING AND ADJUSTING HANDLING OF
ADJUSTMENT
HIGH-VOLTAGE
METHOD
CIRCUIT
OF REPLACED
OF ENGINE CONTROLLER
HANDLING OF HIGH-VOLT- ADJUSTMENT METHOD OF

AGE CIRCUIT OF ENGINE REPLACED CONTROLLER
CONTROLLER
a After the machine is assembled or steering and
transmission controller is replaced, adjust the
system according to the following procedure.
k If the system is not adjusted, the machine may
not operate normally and may move suddenly.
Accordingly, be sure to adjust it.
a Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. According-
ly, take a record of the next replacement periods
of the oils and filters.
a Precautions for replacing a controller:
k
When replacing a controller, stop the machine in
The engine controller has a high-voltage circuit a safe place and turn the starting switch off.
(110 – 130V) to drive the fuel injector. This circuit
is connected to the wiring harness and connec- 1. Setting system in service mode
tors between the engine controller and fuel injec- Turn the starting switch on and set the monitor
tor. panel in the “Adjustment mode” of the service
a Normally, the engine controller outputs the high mode.
voltage to the fuel injector only while the engine
is running and stops outputting if the engine 2. Adjusting steering and transmission control-
stops. ler
k If you touch the high-voltage circuit directly, you Select steering and transmission controller
may get an electric shock. To avoid this, observe specification set (0002) and adjust the steering
the following precautions. and transmission controller.
1. The following connectors are used in the high-

voltage circuit.
• Engine controller connector: EGC3
• Junction connector: E21
• Injector connectors:
CN1, CN2, CN3, CN4, CN5, CN6
• Injector head terminal (in head cover)
2. When disconnecting or connecting a connector

related to the high-voltage circuit, be sure to turn
off the starting switch.
3. If a T-adapter is inserted in or connected to a

connector related to the high-voltage circuit for
troubleshooting, do not start the engine.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
D155AX-5 20-209
(2)
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
3. Turning power on again 7. Checking error codes

Turn the starting switch off and on, then set the 1) Set the monitor panel in the “Electric system
monitor panel in the “Adjustment mode” of the error code display mode” of the service
service mode again. mode.
2) See if any error code is being output current-
4. Adjusting machine specification ly. If any error code is not being output, de-
Select Machine specification set (0004) and ad- lete the all error codes.
just the machine specification. a If any error code is being output, remove its
cause by troubleshooting and execute steps
6 and 7 again.
a Precautions after replacing controller:

If any controller is replaced, the service meter in
the oil and filter maintenance mode is reset to 0.
As a result, the replacement period displayed on
the monitor panel may be different from the actu-
al operating hours. To solve this problem, deter-
mine the first replacement periods of the oils and
filters after the replacement of the controller ac-
cording to the replacement periods recorded be-
fore the replacement of the controller.
5. Adjusting brake potentiometer
Select Brake potentiometer initial set (0005) and
adjust the brake potentiometer.
6. Turning power on again

Turn the starting switch off and on.
20-210 D155AX-5
(2)
PREPARATION WORK FOR TROUBLESHOOTING
TESTING AND ADJUSTING FOR ELECTRIC SYSTEM

FOR ELECTRIC SYSTEM
a When carrying out troubleshooting for an electric 2. Engine controller
circuit related to the monitor panel, engine con- 1) Remove left console box inspection cover
troller or steering and transmission controller, ex- (3).
pose the related connectors according to the
following procedure.
1. Monitor panel
1) Remove cover (1) above the dashboard.
2) Insert or connect T-adapters in or to connec-

tors EGC1, EGC2, and EGC3 of engine con-
troller (4).
a If the connectors cannot be disconnect-
ed and connected easily, remove the
2) Insert or connect T-adapters in or to connec- controller from the floor frame.
tors S03 and S04 on the back side of monitor a Since the connectors are secured with
panel (2). screws, loosen those screws before dis-
connecting.
a When connecting the connectors again,
tighten their screws to the specified
3 Screw: 2.82Nm {0.288kgm}

torque.
D155AX-5 20-211
(2)
TESTING AND ADJUSTING FOR ELECTRIC SYSTEM
3. Steering and transmission controller

1) Remove engine controller.
a Do not disconnect engine controller con-
nectors (EGC1, EGC2, and EGC3).
2) Insert or connect T-adapters in or to connec-
tors STC1, STC2, and STC3 of steering and
transmission controller (5).
a If the connectors cannot be disconnect-
ed and connected easily, remove the
controller from the floor frame.
a Since the connectors are secured with
screws, loosen those screws before dis-
connecting.
a When connecting the connectors again,
tighten their screws to the specified
3 Screw: 2.82Nm {0.288kgm}

torque.
20-212 D155AX-5
(2)
TESTING AND ADJUSTING PM CLINIC SERVICE
Pm CLINIC SERVICE
Model Serial No. Service meter
D155AX-5 h
User name Date of clinic Serviceman
Specifications
Blade Rear attachment Shoe width
Semi-U blade Multi-shank ripper 560 mm
U-blade Variable giant ripper 610 mm
Dual tilt blade Counterweight kg 660 mm
710 mm
Operating conditions
Quarry, mine Construction Type of soil (specific gravity ) Type of work
Coal Construction, Rock Dozing %
Gold civil engineering Gravel Side cutting %
Limestone Roads Sand Ripping %
Tunnels Clay Travel %
Existence of abnormalities
Oil, water level check
Engine coolant level When necessary
Engine oil level Power train Damper case
Hydraulic oil level Final drive ( )
Engine coolant temperature Max. range Power train oil temperature Max. range Ambient temperature
Max.
Min.
Height above sea level
m
Operator’s opinion
Visual check results
Service code history
E h E h
Content: Content:
E h E h
Content: Content:
D155AX-5 20-213
(2)
Pm-clinic
TESTING AND ADJUSTING measuring points for D155AX-5 (1/3)
PM CLINIC SERVICE
Reference items of measurement procedure (Pages)

1. Engine speed: Measuring engine speed (20-104 – 106 page)
2. Blow-by pressure: Measuring blow-by pressure (20-116 page)
3. Engine oil pressure: Measuring engine oil pressure (20-117 page)
4. Boost pressure: Measuring intake air pressure (boost pressure) (20-107 – 108 page)
5. Exhaust temperature: Measuring exhaust temperature (20-109 – 110 page)
20-214 D155AX-5
(2)
Pm-clinic
PM CLINIC SERVICE

6. Items related to torque converter: Measuring power train oil pressure (20-127 – 131 page)
7. Items related to transmission: Measuring power train oil pressure (20-127 – 131 page)
8. Items related to blake: Measuring power train oil pressure (20-127 – 131 page)
D155AX-5 20-215
(2)
Pm-clinic
PM CLINIC SERVICE

9. Items related to HSS oil pressure: Testing and adjusting HSS oil pressure (20-132 – 136 page)
10. Items related to work equipment: Testing and adjusting work equipment oil pressure, Testing and adjusting control circuit basic pres-
sure (20-147 – 150 page)
11. Items related to fan: Measuring fan motor speed, Measuring fan circuit oil pressure (20-159 – 160 page)
20-216 D155AX-5
(2)
TESTINGPm
ANDCLINIC CHECK
ADJUSTING SHEET PM No.
Serial CLINIC SERVICE
D155AX-5
Work order No. Date Service meter Serviceman
/ / h
Item Measurement conditions Unit Standard value for Service limit value Measurement Pass Fail
new machine results
Low idling 675 – 725 675 – 725
High idling Deceleration pedal depressed 800 – 900 800 – 900
Engine speed High idling (Deceleration cut-off mode) rpm 1850 – 1950 1850 – 1950
Torque converter stall 1601 – 1701 1491
Torque converter stall + work equipment relief 1350 – 1470 1250
kPa Max. 1.47 Min. 2.94
Blow-by pressure Torque converter stall
<mmAq> <Max. 150> <Max. 300>
0.12 Min. 0.8
Engine at low idling
SAE30 <1.2> <Min. 0.8>
SAE10W15 0.34 – 0.54 Min. 0.21
Engine at high idling
MPa <3.5 – 5.0> <Min. 2.1>
Engine oil pressure
<kg/cm2> 0.10 Min. 0.07
<1.0> <Min. 0.7>
SAE10W30
0.29 – 0.49 Min. 0.18
<3.0 – 5.0> <Min. 1.8>
kPa Min. 113 Min. 93
Boost pressure Torque converter stall
<mmHq> <Min. 850> <Min. 700>
Exhaust temperature Torque converter stall ºC Max. 650 Max. 700
new machine results
0.1 – 0.49 0.1 – 0.49
Inlet oil pressure
<1 – 5> <1 – 5>
Transmission: 0.05 – 0.29 0.05 – 0.29
Outlet oil pressure
Neutral MPa <0.5 – 3> <0.5 – 3>
Oil temperature: <kg/cm2> Max. 1 Max. 1
Inlet oil pressure
70 – 90ºC <Max. 10> <Max. 10>
0.39 – 0.59 0.39 – 0.59
Outlet oil pressure
<4 – 6> <4 – 6>
k When measuring the pressure of each transmission clutch, check only with the engine at low idling to ensure safety.
new machine results
Engine at low idling — —

Transmission:
Main relief pressure
Neutral 3.24 – 3.53 3.09
<33 – 36> <31.5>
3.04 – 3.33 2.88
F clutch pressure Transmission: F3 Engine at low idling
<31 – 34> <29.4>
MPa 3.04 – 3.33 2.88
R clutch pressure Transmission: R3 Engine at low idling
<kg/cm2> <31 – 34> <29.4>
3.04 – 3.33 2.88
1st clutch pressure Transmission: F1 Engine at low idling
<31 – 34> <29.4>
3.04 – 3.33 2.88
2nd clutch pressure Transmission: F2 Engine at low idling
<31 – 34> <29.4>
3.04 – 3.33 2.88
3rd clutch pressure Transmission: F3 Engine at low idling
<31 – 34> <29.4>
new machine results
2.46 – 3.04 3.16
Transmission: MPa <25 – 31> <22>
Brake pressure
Neutral <kg/cm2> 2.46 – 3.04 3.16
<25 – 31> <22>
Brake performance Engine at high idling, F2, brake actuated Machine must not move
D155AX-5 20-217
(2)
TESTINGPm
ANDCLINIC CHECK
ADJUSTING SHEET PM No.
D155AX-5
/ / h
new machine results
PCCS lever (for travel) 38.2 – 41.7 38.2 – 41.7
HSS main relief right FULL <390 – 425> <390 – 425>
pressure PCCS lever (for travel) MPa 38.2 – 41.7 38.2 – 41.7
left FULL <kg/cm2> <390 – 425> <390 – 425>
HSS charge relief PCCS lever (for travel) Min. 1.96 3.24
pressure NEUTRAL <Min. 20> <33>
HSS servo charge (Common use with work equipment PPC and fan Measure at control circuit
pressure pump control) basic pressure
new machine results
17.65 – 19.61 17.65 – 19.61
<180 – 200> <180 – 200>
Blade tilt relief
19.61 – 21.57 19.61 – 21.57
<200 – 220> <200 – 220>
Main relief pressure
MPa 17.65 – 19.61 17.65 – 19.61
<kg/cm2> <180 – 200> <180 – 200>
Ripper lift relief
19.61 – 21.57 19.61 – 21.57
<200 – 220> <200 – 220>
Control circuit basic 3.24 – 3.92 3.24 – 3.92
Lever: Neutral Engine at high idling
pressure <33 – 40> <33 – 40>
new machine results
Blade RAISE
Engine at high idling 3–5 3–5
Blade left tilt
Engine at high idling 2.3 – 3 3.5
Sec.
Ripper down
Engine at high idling 2.5 – 3.5 5
Ripper tilt in
Engine at high idling 3–4 4.5
new machine results
Hydraulic oil temperature ºC — —

Engine stopped
Blade lift cylinder Blade lift: For 15 min. Max. 150 200
Ripper lift: For 5 min. mm
Ripper lift cylinder Max. 50 70
new machine results
Engine at low — —
Fan speed rpm
Fan 100%
Engine at high Max. 150 200
speed mode
MPa
Fan oil pressure Engine at high Max. 50 70
<kg/cm2>
new machine results
Visual inspection of drain plug There must be no excessive
Final drive —
Engine stopped metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
20-218 D155AX-5
(2)
TESTINGPm
ANDCLINIC
ADJUSTING PM No.
Serial No
Pm CLINIC
UNDERCARRIAGE CHECK SHEET D155AX-5
D155AX-5
UNDERCARRIAGE CHECK SHEET
/ / h
h
Measure the bushing temperature immediately after operations

Left side of machine
Measurement
results Pass Fail
Right side of machine

Measurement
results Pass Fail
Opening of track link Left track A: Clearance between links

Pin No. 1.4 mm
Right track A: Clearance between links

Pin No. 1.4 mm
D155AX-5 20-219
(2)
TESTING ANDUNDERCARRIAGE
ADJUSTING TROUBLESHOOTING REPORT
UNDERCARRIAGE TROUBLESHOOTING REPORT
(DRY TYPE · NORMAL)
(Program form No.: SELA195001)
20-220 D155AX-5
(2)
(DRY TYPE · IMPACT)
D155AX-5 20-221
(2)
(OIL LUBRICATED TYPE · NORMAL)
20-222 D155AX-5
(2)
(OIL LUBRICATED TYPE · IMPACT)
D155AX-5 20-223
(2)
TESTING AND ADJUSTING UNDERCARRIAGE TROUBLESHOOTING REPORT
20-224 D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING
Points to remember when troubleshooting ..... 20-302
Sequence of events in troubleshooting ....... 20-303
Points to remember when carrying out
maintenance ............................................... 20-304
Checks before troubleshooting .................... 20-312
Classification and procedures of
troubleshooting ............................................ 20-313
Connector allocation drawing and
electrical circuit diagram for each system ... 20-316
Connector arrangement drawing ................. 20-322
Circuit drawing for monitor panel
(M circuit) .................................................... 20-328
Circuit drawing for engine controller system
(E circuit) ..................................................... 20-330
Circuit drawing for steering and
transmission controller system (S circuit) .... 20-332
Connection table for connector
pin numbers ................................................ 20-334
T-branch box and T-branch table ................. 20-357
Parts & service operation tips ..................... 20-359
D155AX-5 20-301
(2)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior in-
vestigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the ma- a The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred because of the failure is not repaired, the same
fore? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-302 D155AX-5
(2)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
D155AX-5 20-303
(2)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic
equipment” (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or ox-
idization of the contact surfaces.
(2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-304 D155AX-5
(2)
(3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering
may be damaged, or the wiring may be bro-
ken.
(4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the connec-
tor, depending on the direction of the water
jet.
As already said, the connector is designed to
prevent water from entering, but at the same
time, if water does enter, it is difficult for it to
be drained. Therefore, if water should get
into the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take other
appropriate action before passing electricity
through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector and
an oil film is formed on the mating surface
between the male and female pins, the oil
will not let the electricity pass, so there will
be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
D155AX-5 20-305
(2)
2) Removing, installing, and drying connectors

and wiring harnesses
(1) Disconnecting connectors

• Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For connec-
tors which have a lock stopper, press down
the stopper with your thumb and pull the con-
nectors apart.
a Never pull with one hand.
• When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and down
or to the left or right, the housing may
break.
• Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or wa-
ter from getting in the connector portion.
a If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-306 D155AX-5
(2)
(2) Connecting connectors

• Check the connector visually.
Check that there is no oil, dirt, or water stuck
to the connector pins (mating portion).
Check that there is no deformation, defective
contact, corrosion, or damage to the connec-
tor pins.
Check that there is no damage or breakage
to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connector,
warm the inside of the wiring with a dry-
er, but be careful not to make it too hot as
this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
• Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in the
connector until the stopper clicks into posi-
tion.
• Correct any protrusion of the boot and any

misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is out
of position, adjust it to its correct position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
• If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
(3) Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them in
until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
D155AX-5 20-307
(2)
(4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in wa-
ter or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
• Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
• Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dry-
er to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
• Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-308 D155AX-5
(2)
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box un-
less necessary.
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
(5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
(6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand)
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
D155AX-5 20-309
(2)
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling or
assembling hydraulic equipment, it is necessary to
be particularly careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or re-
pairing the machine in rain or high winds, or plac-
es where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger or dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt, or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil fill-
er and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
20-310 D155AX-5
(2)
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as possi-
ble of the old hydraulic oil must be drained out.
(Do not drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contami-
nants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to re-
move the contaminants, sludge, and old oil from
the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3µ) particles that the filter built
into the hydraulic equipment cannot remove, so
it is an extremely effective device.
D155AX-5 20-311
(2)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
Value
1. Check fuel level — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
4. Check oil level in damper case — Add oil
5. Check power train oil level — Add oil
6. Check engine oil level (engine oil pan level) — Add oil
7. Check coolant level — Add coolant
8. Check dust indicator for clogging — Clean or replace
9. Check travel of brake pedal — Adjust
10. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
13. Check for abnormal noise, smell — Repair

14. Check for oil leakage — Repair
15. Carry out air bleeding — Bleed air
16. Check battery voltage (engine stopped) 20 – 30V Replace

17. Check battery electrolyte level — Add or replace
18. Check for discolored, burnt, exposed wiring — Replace
19. Check for missing wiring clamps, hanging wire — Repair
20. Check for water leaking on wiring (pay particularly careful attention Disconnect connector
—
to water leaking on connectors or terminals) and dry
21. Check for water on wiring — Replace
After running for
22. Check alternator voltage (engine running at 1/2 throttle or above) several minutes: Replace
27.5 – 29.5V
23. Check operating sound of battery relay (starting switch ON, OFF) — Replace
20-312 D155AX-5
(2)
TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING

Classification of Troubleshooting
Mode Explanation
Error code Troubleshooting when a service code is displayed
E Mode Troubleshooting of the electrical system
H Mode Troubleshooting of the hydraulic and mechanical systems
S Mode Troubleshooting of the engine body
Troubleshooting Procedures
When any phenomenon supposed to be a failure appeared on the machine, select a Troubleshooting No. ac-
cording to the procedures below and proceed to the text of the relevant troubleshooting:
1. Troubleshooting Procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display a error code in the error code display mode
(electrical system, mechanical system) on the monitor display (EMMS).
Execute a troubleshooting of the relevant [Error Code] in accordance with the displayed error code.
a Since a error code flashes when a problem was detected, the failure has not always been corrected even
if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when
the starting switch is set to ON.)
a When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the trou-
bleshooting of the error code.)
2. Troubleshooting Procedures when error codes have been recorded:

When no action code is displayed on the monitor panel, check a error code in the error code display mode
(electrical system, mechanical system) on the monitor panel (EMMS).
When error codes have been recorded, execute a troubleshooting of the relevant [Error Code] in accor-
dance with the error code.
a Since a error code flashes when a problem was detected, the failure has not always been corrected even
if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when
the starting switch is set to ON.)
a When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the trou-
bleshooting of the error code.)
3. Troubleshooting Procedures when no action code is displayed and error codes have not been re-
corded:
When error codes have not been recorded in the monitor panel (EMMS), a failure that the machine cannot
diagnose by itself is supposed to have occurred in the electrical system or the hydraulic/mechanical system.
In this case, check again a phenomenon supposed to be a failure and select the relevant phenomenon out
of the table of “Phenomena supposed to be Failures and Troubleshooting No.” Then, execute the trouble-
shooting in the [E Mode] or [H Mode] related to the phenomenon.
D155AX-5 20-313
(2)
Phenomena supposed to be Failures and Troubleshooting No.
Troubleshooting
No. Phenomenon suppose to be Failure Error
E Mode H Mode S Mode
Code
Phenomenon related to action code/error code
1 An action code is displayed on the monitor panel. Check the error code.
2 A error code is displayed in the error code display mode. q
Phenomenon related to engine
3 The engine does not start smoothly. (Engine starting takes a time all the time.) S-1
4 The engine does not rotate. E-1 S-2 a)
5 The engine does not start. The engine rotates but does not exhaust gas. S-2 b)
6 The engine exhausts gas but does not rotate. S-2 c)
7 The engine does not pick-up smoothly. (Poor follow-up performance) S-3
8 The engine stops during operation. S-4
9 The engine rotates abnormally. (Hunting) S-5
10 Insufficient output or no power S-6
11 Black exhaust (Imperfect combustion) S-7
12 Large oil consumption or blue exhaust S-8
13 Oil is contaminated fast. S-9
14 Large fuel consumption S-10
15 Oil mixes in coolant, spurts or water reduces. S-11
16 Engine oil pressure drops. S-12
17 Oil increases. S-13
18 Water temperature rises too high. (Overheat) S-14
19 An abnormal noise occurs. S-15
20 Large vibration S-16
21 The preheater does not work. (Manual preheating system) E-2
Phenomenon related to power train
22 The power train has no power (no drawbar pull). H-1 S-6
23 The power train does not travel (in case of 2-spool or 3-spool). H-2
24 The power train does not start at all gear speeds. H-3
25 The power train travel forward or in reverse only H-4
26 Large time lag at any gear speed or at forward-reverse shifting H-5
27 Steering is not possible. (Left turn or right turn is impossible.) H-6
28 The steering speed is slow or the steering system has no power. H-7
29 The brake does not work. H-8
30 The power train oil is overheated. H-9
31 Abnormal noise around the HSS and work equipment pump or the HSS motor H-10
Phenomenon related to work equipment
32 All the work equipment operates slowly. H-11
33 All the work equipment does not operate. H-12
34 The blade lift moves slowly or has no power. H-13
35 The blade tilt moves slowly or has no power. H-14
36 The ripper lift moves slowly or has no power. H-15
37 The ripper tilt moves slowly or has no power. H-16
38 Large hydraulic drift of the blade lift H-17
39 Large hydraulic drift of the blade tilt H-18
40 Large hydraulic drift of the ripper lift H-19
20-314 D155AX-5
(2)
Troubleshooting
No. Phenomenon suppose to be Failure Error
E Mode H Mode S Mode
Code
41 Ripper pin puller cylinder does not work. (Giant ripper attachment machine) E-3 H-20
42 Blade pitch does not work. (Pitch dozer attachment machine) H-21
43 Abnormal sound comes out from around work equipment pump. H-22
Phenomenon related to monitor panel (Operator mode: Normal screen)
44 When the starting switch is set to ON, no light on the monitor panel comes on. E-4
45 When the starting switch is set to ON, all the lights on the monitor panel do not go out. E-5
46 While the engine is operating, the caution items flash. E-6
47 While the engine is operating, the emergency warning items flash. E-7
48 While the preheater is operating, the preheating pilot lamp does not come on. E-8
49 Indication of the engine water temperature gauge is abnormal. E-9
50 Indication of the power train oil temperature gauge is abnormal. E-10
51 Indication of the hydraulic oil temperature gauge is abnormal. E-11
52 Indication of the fuel gauge is abnormal. E-12
53 Indications of gear speed and engine speed are abnormal. E-13
54 Indication of the shift mode service meter is abnormal. E-14
55 The warning lamp does not flash or does not go out. E-15
56 The alarm buzzer does not sound or does not stop. E-16
57 Auto shift down is not possible or is not released. E-17
58 The fan rotation select switch does not work. E-18
59 The buzzer cancel switch does not work. E-19
60 The information switch does not work. E-20
Phenomenon related to monitor panel (Service mode: Special function screen)
61 The service switch does not work. E-21
Others
62 The back-up alarm does not sound. E-22
63 The head lamp, night lamp, rear lamp, and ripper point lamp on the panel do not come on. E-23
64 The wiper and window washer malfunctions. E-24
65 The air conditioner does not operate. E-25
D155AX-5 20-315
(2)
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM FOR EACH SYSTEM

CIRCUIT DIAGRAM FOR EACH SYSTEM
TABLE OF CONNECTORS
Address
Connector Type of Number
No. of pins Device name 3-dimen-
connector sional M-circuit E-circuit S-circuit
drawing
101 DT-A 8 Intermediate connector E-7 L-6 B-2

203 DT 2 Left rear lamp K-8 L-8
203 DT 2 Right head lamp A-4 L-8
204 DT 2 Left head lamp A-2 L-8
205 Terminal 1 Horn A-3
214 DT-B 12 Intermediate connector O-3 A-6
215 DT-C 12 Intermediate connector O-2 E-6 D-8
217 DT 2 Caution buzzer O-3 C-8
218 DT-D 12 Intermediate connector O-2
224 DT 2 Pin puller solenoid valve I-2
226 DT 2 Ripper point lamp J-8 J-8
242 DT 2 Right rear lamp I-8 J-8
244 DT 2 Backup alarm K-7 A-1
245 DT 2 Intermediate connector J-8 J-7
250 Terminal 1 Starting switch (B terminal) P-9
255 Terminal 1 Starting switch (R1 terminal) P-8
256 Terminal 1 Starting switch (R2 terminal) P-8
260 Terminal 1 Starting switch (BR terminal) P-8
262 DT 2 Horn switch S-9
263 X 2 Pin puller switch S-9
265 Terminal 1 Horn switch R-9
266 Terminal 1 Horn switch R-9
270 Terminal 1 Starting switch (ACC terminal) P-9
280 Terminal 1 Starting switch (C terminal) P-9
361 M 2 Front windshield washer motor K-3
362 M 2 Left windshield washer motor K-3
363 M 2 Right windshield washer motor J-3
364 M 2 Rear windshield washer motor J-3
406 DT 2 HSS charge oil pressure switch AF-7 H-8
422 DT 2 Intermediate connector J-8 K-7
423 DT 2 Fuel level sensor I-9 K-8
453 DT 2 Power train hydraulic oil temperature sensor AI-2 H-8
810 Plug 1 Intermediate connector (Service power source) T-1
AC1 MIC 17 Air conditioner control panel (Cab) P-6
AC2 AMP 16 Air conditioner control panel (Cab) Q-8
AC3 AMP 12 Air conditioner control panel (Cab) Q-8
A/C DT 2 Air conditioner compressor Y-3
AL/B Terminal 1 Alternator (B terminal) Y-6 G-2
ASD 4 Auto shift-down switch O-6 E-9
20-316 D155AX-5
(2)
a Addresses show approximate positions of these devices in single view layout drawings of connectors and
electrical circuit diagrams of each other.
Address
drawing
8OOF Plug 1 External power supply intermediate terminal X-7

8OOM Plug 1 External power supply intermediate terminal X-7
BKA Relay 5 Backup alarm relay V-8 F-9
BRK DT 3 Brake pedal potentiometer R-1 A-2
BUZ 3 Buzzer cancel switch P-7 F-9
CA1 DT 3 CAN terminating resistor V-1 L-2 E-8 I-2
CA2 DT 3 CAN terminating resistor Q-6 C-8 I-8 A-8
CAN DT-A 12 Intermediate connector V-2 B-8
CB1 — — Circuit breaker (20A) M-7 D-8 J-8 C-9
CB2 — — Circuit breaker (20A) (Cab) M-6
B30L — — Circuit breaker (30A) (Body) X-4 D-1 G-5 E-1
B30S — — Circuit breaker (30A) (Power supply) X-4 E-1 H-5 E-1
B105L — — Circuit breaker (105A) (Body) X-4 D-2 G-6 E-2
B105S — — Circuit breaker (105A) (Power supply) X-4 E-2 H-6 E-2
CN1 DT 2 Engine No. 1 injector Y-7 A-3
CN2 DT 2 Engine No. 2 injector Z-8 A-2
CN3 DT 2 Engine No. 3 injector AA-8 A-2
CN4 DT 2 Engine No. 4 injector AB-8 A-1
CN5 DT 2 Engine No. 5 injector AC-8 A-2
CN6 DT 2 Engine No. 6 injector AC-8 A-2
1 4 Intermediate connector (Cab) H-9
2 2 Rear left speaker (Cab) I-8
4 2 Rear right speaker (Cab) G-9
6 Plug 1 Heat absorbing glass (EU) H-9
7 9 Radio (Cab) B-9
8 2 Accessory 12V power source connector (Cab) B-9
9 3 Heat absorbing glass switch (Cab) B-8
10 2 Additional lamp switch (Cab) B-8
11 2 Wiper intermittent switch (Cab) B-9
12 6 Rear wiper switch (Cab) A-9
13 6 Right wiper switch (Cab) A-9
14 6 Front wiper switch (Cab) A-9
15 6 Left wiper switch (Cab) A-9
16 2 Room lamp (Cab) B-7
17 4 Right door wiper motor (Cab) B-6
18 4 Intermediate connector (Cab) D-7
19 DT 4 Intermediate connector (Cab) C-5
20 DTHD 1 Cab power source connector (Cab) C-6
21 DTHD 1 Cab power source connector (Cab) C-5
23 6 Front wiper motor (Cab) E-8
24 4 Left door wiper motor (Cab) B-6
D155AX-5 20-317
(2)
Address
drawing
25 Relay 4 Lamp relay (Cab) B-8

26 Relay 6 Left wiper intermit relay (Cab) C-8
27 Relay 5 Left wiper intermittent select relay (Cab) C-7
28 Relay 6 Front wiper intermit relay (Cab) C-8
29 Relay 5 Front wiper intermittent select relay (Cab) C-7
30 Relay 6 Right wiper intermit relay (Cab) C-8
31 Relay 5 Right wiper intermittent select relay (Cab) C-7
32 Relay 6 Rear wiper intermit relay (Cab) C-8
33 Relay 5 Rear wiper intermittent select relay (Cab) D-7
34 Relay 4 Heat absorbing glass relay (Cab) C-8
35 4 Converter (Cab) C-9
36 Plug 1 Heat absorbing glass (Cab for EU) H-8
37 4 Rear wiper motor (Cab) H-9
ACC 2 Accessory socket (Cab) C-7
B AMP 2 Blower motor (Air conditioner unit) O-4
BRB Terminal 1 Battery relay (B-terminal) X-4 E-1 H-5 F-1
BRC Terminal 1 Battery relay (C-terminal) X-5 E-1 H-6 F-1
BRE Terminal 1 Battery relay (E-terminal) X-3 F-1 I-6 F-1
CIG 2 Lamp shape power supply (Cab) C-7
FL 2 Additional left front lamp (Cab) H-8
FR 2 Additional right front lamp (Cab) E-8
P SUMITOMO 2 Pressure switch (Air conditioner unit) P-6
R YAZAKI 4 Blower resister (Air conditioner unit) O-5
R1 (RLBM) Relay 4 Blower high relay (Air conditioner unit) O-4
R2 (RLBH) Relay 4 Blower main relay (Air conditioner unit) O-4
R3 (RLBM1) Relay 4 Blower medium 1 relay (Air conditioner unit) O-4
R4 (RLBM2) Relay 4 Blower medium 2 relay (Air conditioner unit) O-3
R5 (RLEC) Relay 4 Compressor clutch relay (Air conditioner unit) O-5
R6 (RLCD) Relay 4 Condenser relay (Air conditioner unit) O-5
RL 2 Additional left rear lamp (Cab) H-8
RR 2 Additional right rear lamp (Cab) G-9
S MIC 4 External/internal air changeover servo motor (Air conditioner unit) Q-6
SW Terminal 1 Battery relay (SW-terminal) X-3 F-1 I-5 F-1
T AMP 2 Thermistor (Air conditioner unit) P-6
W MIC 4 A/M servo motor (Air conditioner unit) P-1
CUR 3 Information switch P-7 E-9
DCL DT 3 Decelerator pedal potentiometer Q-1 K-8
DIAL M 3 Fuel dial W-7 K-8
E21 HD30 31 Intermediate connector D-6 C-3
E22 HD30 31 Intermediate connector E-6 J-3 C-7 I-2
EG1 HD30 31 Intermediate connector S-1 G-5 G-3 G-2
EGC1 DRC-26 24 Engine controller X-2 K-1 A-7 H-1
EGC2 DRC-26 40 Engine controller W-2 K-1 A-6 H-1
20-318 D155AX-5
(2)
Address
drawing
EGC3 DRC-26 40 Engine controller W-2 A-4 I-1

EMS 3 Spare connector N-8 E-9
ENE DT 2 Spare connector AD-5
F1T DT 2 1st clutch ECMV (Fill switch) AH-7 L-3
F2T DT 2 2nd clutch ECMV (Fill switch) AJ-3 L-3
F3T DT 2 3rd clutch ECMV (Fill switch) AG-6 L-2
F32 DTHD 1 Spare switch input X-5 D-1 G-6 D-1
F96 DTHD 1 Spare input V-2 D-2 G-6 D-2
FAC DT 2 Fan pump solenoid valve AI-2 K-7
FAM — 4 Pivot turn switch P-7 D-9
FAR2 DT 2 Reverse fan motor solenoid valve A-1 A-2
FFC DT-A 12 Intermediate connector H-1 J-6 H-4 B-1
FFT DT 2 FWD clutch ECMV (Fill switch) AI-7 L-4
FLS X 4 Engine controller RS232C V-1 B-3
FRT DT 2 REV clutch ECMV (Fill switch) AI-7 L-3
FS1 — — Fuse box 1 W-7 A-1 D-2
FS2 — — Fuse box 2 W-8 A-1 G-6 D-1
FS12 — — Fuse box 1 W-7 A-1 D-2
FS22 — — Fuse box 2 W-8 A-1 G-6 D-1
FSB HD30 31 Intermediate connector X-3
FTU 4 Spare switch input N-8
FWL 4 Front lamp switch O-6 E-8
G DT 2 Engine speed G sensor AB-2 E-8
GND1 Terminal 1 GND (Cab) B-8
GND2 Terminal 1 GND (Cab) B-9
GND3 Terminal 1 GND (Cab) C-7 L-1
GND4 Terminal 1 GND (Cab) H-9
GND02 Terminal 1 GND (Floor) V-2 A-5 K-1 C-1
GND03 Terminal 1 GND (Floor) U-1 L-1
GND05 Terminal 1 GND (Floor) Q-1 A-5 C-1
GND06 Terminal 1 GND (ROPS) H-2
GND07 Terminal 1 GND (ROPS) J-8 C-1
HHP DT 3 Hydraulic oil pressure sensor AF-6 K-5
HSA DT 2 HSS pump solenoid valve (Left) AE-4 K-7
HSB DT 2 HSS pump solenoid valve (Right) AE-4 K-7
HSPA DT 3 HSS oil pressure sensor A AI-7 K-5
HSPB DT 3 HSS oil pressure sensor B AI-7 K-4
HT Terminal 1 Ribbon heater (C-terminal) AD-7
HT/A Terminal 1 Ribbon heater (A-terminal) AD-6 I-1
HT/B Terminal 1 Ribbon heater (B-terminal) AD-5 I-1
M26 6 Air conditioner unit (Cab) P-6
NE DT 2 Engine speed Ne sensor AD-4 E-9
NSF Relay 5 Neutral safety relay U-8 F-6 H-9
D155AX-5 20-319
(2)
Address
drawing
NSW DT 3 Parking lever switch X-6 A-2

P03 DT 6 Intermediate connector Q-8 B-9
PCV1 SUMITOMO 2 Fuel supply pump PCV1 AB-2 A-1
PCV2 SUMITOMO 2 Fuel supply pump PCV2 AB-2 A-1
PFUEL DT 3 Common rail fuel pressure sensor AC-3 A-8
PIM SUMITOMO 3 Boost pressure sensor Y-3 A-9
PL1 HD30 23 Intermediate connector AJ-5 I-4
PL2 HD30 31 Intermediate connector AJ-5 H-7 I-7
PL5 DT-A 12 Intermediate connector AJ-5 G-7 I-5
PPR Relay 5 Fuel pump (engine controller) power relay V-8 G-9
PSEL DT 2 Pitch select solenoid valve AH-2 K-5
PSH Terminal 1 Engine oil pressure sensor (High pressure) AD-3 E-9
PSL Terminal 1 Engine oil pressure sensor (Low pressure) AD-3 E-9
PT1 DT 3 Intermediate connector O-2 B-1
PT2 DT 3 Body pitch angle O-1 A-1
R Terminal 1 Alternator (R-terminal) Y-5 H-2 K-2
RDG DT 8 Intermediate connector A-2 L-7 B-2
RHR Relay 5 Pre-heater relay W-8 E-6 G-9
RWL 4 Rear lamp switch O-7 E-8
S03 AMP070 20 Monitor panel N-9 A-8 I-8
S04 AMP070 12 Monitor panel N-9 B-8 A-9
S13 DT-A 12 Intermediate connector O-3 C-6 J-7 C-8
S1T DT 2 1st clutch ECMV (Solenoid valve) AF-6 L-3
S2T DT 2 2nd clutch ECMV (Solenoid valve) AJ-4 L-3
S24 Terminal 6 Service switch M-6 C-9 D-9
S3T DT 2 3rd clutch ECMV (Solenoid valve) AG-6 L-2
SDS DT 2 HSS oil temperature sensor AJ-6 K-6
SEL DT 4 Engine model select connector (Engine controller) V-1 B-8
SFT DT 2 FWD clutch ECMV (Solenoid valve) AJ-3 L-4
SFTD — 3 Shift-down switch U-9 K-8
SFTU — 3 Shift-up switch U-9 K-8
SRT DT 2 REV clutch ECMV (Solenoid valve) AG-7 L-4
ST DT 2 Starting motor Z-8 H-2
ST/B Terminal 1 Starting motor (B-terminal) AA-8 G-2
STC1 DRC-26 24 Steering and transmission controller X-1 A-4 A-7
STC2 DRC-26 40 Steering and transmission controller X-1 A-3 K-4 A-6
STC3 DRC-26 40 Steering and transmission controller X-1 A-3 A-4
STF X 4 Software writing connector (Steering and transmission controller) X-5 C-8
THL DT 3 Fuel temperature sensor (Low temperature) AC-2 E-8
TL1 HD30 23 Intermediate connector X-6 K-7 I-9
TL2 DT-B 8 FWD/REV and steering potentiometer X-7 K-9
TL3 DT 6 Intermediate connector X-7 K-8
TM1 DT 2 Transmission rotating sensor AJ-6 K-6
20-320 D155AX-5
(2)
Address
drawing
TMV HD30 23 Intermediate connector AH-7 K-4

TWH DT 2 Engine water temperature sensor (High temperature) AB-8 B-9
TWL DT 3 Engine water temperature sensor (Low temperature) AA-8 B-9
WNBL — 3 Blade knob lower switch R-8 A-9
WNBU — 3 Blade knob upper switch R-8 A-9
D155AX-5 20-321
(2)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING
CONNECTOR ARRANGEMENT DRAWING
20-322 D155AX-5
(2)
D155AX-5 20-323
(2)
20-324 D155AX-5
(2)
D155AX-5 20-325
(2)
20-326 D155AX-5
(2)
D155AX-5 20-327
(2)
TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL (M CIRCUIT)
CIRCUIT DRAWING FOR MONITOR PANEL

(M CIRCUIT)
20-328 D155AX-5
(2)
TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL (M CIRCUIT)
a This circuit diagram was drawn by extracting the monitor panel system, starting and filling systems, the light-
ing system and the communication network system from the general electrical circuit diagram.
(The indication of CONNECTOR AND PIN NO. from each branching or merging point shows the destination
of branching or merging point in the same harness parts.)
D155AX-5 20-329
(2)
TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM

(E CIRCUIT)
20-330 D155AX-5
(2)
TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
a This circuit diagram was drawn by extracting the engine controller system from the general electrical circuit
diagram.
(The indication of CONNECTOR AND PIN NO. from each branching or merging point is the destination of
branching or merging point in the same harness parts.)
D155AX-5 20-331
(2)
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION
TROUBLESHOOTING CONTROLLER SYSTEM (S CIRCUIT)

CONTROLLER SYSTEM (S CIRCUIT)
20-332 D155AX-5
(2)
TROUBLESHOOTING CONTROLLER SYSTEM (S CIRCUIT)
a This circuit diagram was drawn by extracting the steering and transmission controller system from the gen-
eral electrical circuit diagram.
(The indication of CONNECTOR AND PIN NO. from each branching or merging point is the destination of
branching or merging point in the same harness parts.)
D155AX-5 20-333
(2)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No. of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-334 D155AX-5
(2)
SWP type connector

No. of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
D155AX-5 20-335
(2)
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-336 D155AX-5
(2)
M type connector
No. of
pins T-adapter
Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
D155AX-5 20-337
(2)
S type connector
No. of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-338 D155AX-5
(2)
S type connector
No. of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
D155AX-5 20-339
(2)
MIC type connector

No. of
pins T-adapter
Part No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-340 D155AX-5
(2)
MIC type connector

No. of
pins T-adapter
Part No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
D155AX-5 20-341
(2)
AMP040 type connector

No. of
pins T-adapter
Part No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
20-342 D155AX-5
(2)
AMP070 type connector

No. of
pins T-adapter
Part No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
D155AX-5 20-343
(2)
L type connector
No. of
pins T-adapter
Part No.
2 —
— —
Connector for PA
No. of
pins T-adapter
Part No.
9 —
— —
Bendix MS connector
No. of
pins T-adapter
Part No.
10 799-601-3460
— —
20-344 D155AX-5
(2)
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.: 08027-10310 Part No.: 08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
D155AX-5 20-345
(2)
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
8 —
08027-10820 (Black) 08027-10870 (Black)
20-346 D155AX-5
(2)
F type connector
No. of
pins T-adapter
Part No.
4 —
— —
D155AX-5 20-347
(2)
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-11201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-348 D155AX-5
(2)

Type
Part No.
799-601-9230
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

799-601-9240
18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
D155AX-5 20-349
(2)

Type
Part No.
799-601-9250
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-350 D155AX-5
(2)

Type
Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202, Part No.: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 08191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202, Part No.: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 08191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
D155AX-5 20-351
(2)

Type
Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
(9) Pin (female terminal) Pin (male terminal)
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-352 D155AX-5
(2)
DT Series connector
No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
D155AX-5 20-353
(2)
DT Series connector
No. of
pins T-adapter
Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820 T (normal type) Part No.: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920 T (normal type) Part No.: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
20-354 D155AX-5
(2)
DTM Series connector

No. of
pins T-adapter
Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No. of
pins T-adapter
Part No.
1 —
Part No.: 08192-31200 (Contact size #12) Part No.: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D155AX-5 20-355
(2)
DRC26 Series connector

No. of
pins T-adapter
Part No.
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
20-356 D155AX-5
(2)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass’y.
Connector type
Part No. No. of pins
or part name
799-601-2600 Measurement box Econo-21P Q Q Q Q Q Q

799-601-3100 Measurement box MS-37P Q
799-601-3200 Measurement box MS-37P Q
799-601-3300 Measurement box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P Q Q
799-601-3420 BENDIX (MS) 24P Q Q
799-601-3430 BENDIX (MS) 17P Q Q
799-601-3440 BENDIX (MS) 17P Q Q
799-601-3450 BENDIX (MS) 5P Q Q
799-601-3460 BENDIX (MS) 10P Q Q
799-601-3510 BENDIX (MS) 5P Q Q
799-601-3520 BENDIX (MS) 14P Q Q
799-601-3530 BENDIX (MS) 19P Q Q
799-601-2910 BENDIX (MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Additional cable Q Q Q
799-601-2850 Case Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
D155AX-5 20-357
(2)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
Connector type
Part No. No. of pins
or part name
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD30 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Measurement box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
799-601-9420 For fuel, boost press. 3P Q
799-601-9430 PVC for solenoid 2P Q
20-358 D155AX-5
(2)
TROUBLESHOOTING PARTS & SERVICE OPERATION TIPS
D155AX-5 20-359
(2)
20-360 D155AX-5
(2)
D155AX-5 20-361
(2)
20-362 D155AX-5
(2)
D155AX-5 20-363
(2)
20-364 D155AX-5
(2)
D155AX-5 20-365
(2)
20-366 D155AX-5
(2)
D155AX-5 20-367
(2)
20-368 D155AX-5
(2)
D155AX-5 20-369
(2)
20-370 D155AX-5
(2)
D155AX-5 20-371
(2)
20-372 D155AX-5
(2)
D155AX-5 20-373
(2)
20-374 D155AX-5
(2)
D155AX-5 20-375
(2)
20-376 D155AX-5
(2)
D155AX-5 20-377
(2)
20-378 D155AX-5
(2)
D155AX-5 20-379
(2)
20-380 D155AX-5
(2)
D155AX-5 20-381
(2)
20-382 D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING WHEN
ERROR CODE IS DISPLAYED
(ERROR CODE)
Error codes table ......................................... 20-402

Information described in
troubleshooting list ...................................... 20-406
Troubleshooting at each error code ............. 20-408
D155AX-5 20-401
(2)
TROUBLESHOOTING ERROR CODES TABLE
ERROR CODES TABLE
Error Control- Action Caution Caution

code
Fault part Fault ler code lamp buzzer
1500L0 Transmission clutch Double engagement S/T·T/M CALL E03 q q
15SAL1 Transmission forward clutch ECMV system Command current is OFF and fill signal is ON S/T·T/M CALL E03 q q
15SALH Transmission forward clutch ECMV system Command current is ON and fill signal is OFF S/T·T/M CALL E03 q q
15SBL1 Transmission reverse clutch ECMV system Command current is OFF and fill signal is ON S/T·T/M CALL E03 q q
15SBLH Transmission reverse clutch ECMV system Command current is ON and fill signal is OFF S/T·T/M CALL E03 q q
15SEL1 Transmission 1st clutch ECMV system Command current is OFF and fill signal is ON S/T·T/M CALL E03 q q
15SELH Transmission 1st clutch ECMV system Command current is ON and fill signal is OFF S/T·T/M CALL E03 q q
15SFL1 Transmission 2nd clutch ECMV system Command current is OFF and fill signal is ON S/T·T/M CALL E03 q q
15SFLH Transmission 2nd clutch ECMV system Command current is ON and fill signal is OFF S/T·T/M CALL E03 q q
15SGL1 Transmission 3rd clutch ECMV system Command current is OFF and fill signal is ON S/T·T/M CALL E03 q q
15SGLH Transmission 3rd clutch ECMV system Command current is ON and fill signal is OFF S/T·T/M CALL E03 q q
A000N1 Engine Engine overrun ENG — — —
AB00MA Alternator Malfunction S/T·T/M — — —
AD00L2 Common rail Abnormal fuel pressure ENG CALL E03 q q
AD00MA Common rail Malfunction ENG CALL E03 q q
AD10L3 Fuel supply pump Uncontrollability ENG E02 q q
AD10MA Fuel supply pump Malfunction ENG CALL E03 q q
AD10MB Fuel supply pump Lowering of function ENG CALL E03 q q
AD11KA Fuel supply pump solenoid 1 Disconnection ENG CALL E03 q q
AD11KB Fuel supply pump solenoid 1 Short circuit ENG CALL E03 q q
AD51KA Fuel supply pump solenoid 2 Disconnection ENG CALL E03 q q
AD51KB Fuel supply pump solenoid 2 Short circuit ENG CALL E03 q q
ADA1KA Injector solenoid No. 1 Disconnection ENG E02 q q
ADAZKB Injector solenoid No. 1, 2, and 3 Short circuit ENG CALL E03 q q
ADB1KA Injector solenoid No. 2 Disconnection ENG E02 q q
ADC1KA Injector solenoid No. 3 Disconnection ENG E02 q q
ADD1KA Injector solenoid No. 4 Disconnection ENG E02 q q
ADDZKB Injector solenoid No. 4, 5, and 6 Short circuit ENG CALL E03 q q
ADE1KA Injector solenoid No. 5 Disconnection ENG E02 q q
ADF1KA Injector solenoid No. 6 Disconnection ENG E02 q q
B@BAZG Engine oil Lowering of oil pressure MACHINE — — —
B@BCNS Engine coolant water Overheating MACHINE — — —
B@BCZK Power train oil Overheating MACHINE — — —
B@CENS HSS charge pressure Lowering of oil pressure MACHINE — — —
B@HANS Hydraulic oil Overheating MACHINE — — —
D110KA Battery relay Disconnection S/T·T/M — — —
D110KB Battery relay Short circuit S/T·T/M — — —
D130KA Neutral safety relay Disconnection S/T·T/M E02 q q
D130KB Neutral safety relay Short circuit S/T·T/M E02 q q
D161KA Back-up alarm relay Disconnection S/T·T/M E01 — —
D161KB Back-up alarm relay Short circuit S/T·T/M E01 — —
20-402 D155AX-5
(5)
Error Control- Action Caution Caution

code
Fault part Fault ler code lamp buzzer
D182KZ Pre-heating relay coil Disconnection or short circuit ENG — q q
D1D0KB Engine controller load power supply Short circuit ENG E02 q q
D5ZFKA Transmission neutral signal Disconnection S/T·T/M E01 — —
D5ZFKB Transmission neutral signal Short circuit S/T·T/M E01 — —
DAFRKR Monitor panel CAN communication Defective communication MON CALL E03 q q
DAQ0KK Steering/transmission controller power supply Lowing of source voltage S/T·T/M CALL E04 q q
DAQ0KT Steering/transmission controller Internal defect of controller S/T·T/M E01 — —
DAQ5KK Steering/transmission controller 5V power supply system Lowing of source voltage S/T·T/M CALL E03 q q
DAQ6KK Steering/transmission controller 24V power supply system Lowing of source voltage S/T·T/M CALL E03 q q
DAQ9KQ Steering/transmission controller machine model selection Disagreement of model selection signals S/T·T/M CALL E04 q q
DAQRKR Steering/transmission controller CAN communication Defective communication S/T·T/M CALL E03 q q
DB20KQ Malfunction of engine controller machine model collection Disagreement of model selection signals ENG CALL E03 q q
DB20KT Engine controller Internal defect of controller ENG CALL E03 q q
DB22KK Engine controller load power supply Lowing of source voltage ENG CALL E04 q q
DB29KQ Engine controller machine model selection Disagreement of model selection signals ENG CALL E03 q q
DB2AMA Engine controller Q-adjustment switch Malfunction ENG E02 q q
DB2RKR Engine controller CAN communication Defective communication S/T·T/M CALL E03 q q
DB2RMC Steering/transmission controller CAN communication Defective communication ENG CALL E03 q q
DB30KK Steering/transmission controller power supply Lowing of source voltage T/M·S/T CALL E04 q q
DB30KT Steering/transmission controller Internal defect of controller S/T·T/M E01 — —
DB35KK Steering/transmission controller 5V power supply system Lowing of source voltage S/T·T/M CALL E03 q q
DB36KK Steering/transmission controller 24V power supply system Lowing of source voltage S/T·T/M CALL E03 q q
DB39KQ Steering/transmission controller machine model selection Disagreement of model selection signals S/T·T/M CALL E04 q q
DB3RKR Steering/transmission controller CAN communication Defective communication S/T·T/M CALL E03 q q
DD11KB Starting switch Short circuit ENG CALL E04 q q
DD12KA Shift-up switch Disconnection S/T·T/M E02 q q
DD12KB Shift-up switch Short circuit S/T·T/M E02 q q
DD13KA Shift-down switch Disconnection S/T·T/M E02 q q
DD13KB Shift-down switch Short circuit S/T·T/M E02 q q
DD14KA Travel lock switch Disconnection S/T·T/M CALL E03 q q
DD14KB Travel lock switch Short circuit S/T·T/M CALL E03 q q
DDE2L6 Engine oil pressure switch Run and stop of engine do not agree with signals ENG — q q
DDN7KA Blade pitch switch Disconnection S/T·T/M E02 q q
DDN7KB Blade pitch switch Short circuit S/T·T/M E02 q q
DDQ2KA Travel lock switch Disconnection S/T·T/M CALL E03 q q
DDQ2KB Travel lock switch Short circuit S/T·T/M CALL E03 q q
DGE2KX Engine water temperature sensor (For high temperature) Out of input signal range ENG — q q
DGE3L6 Engine water temperature sensor (For low temperature) Run and stop of engine do not agree with signals ENG E02 q q
DGE4KX Fuel temperature sensor Out of input signal range ENG — — —
DGS1KX Hydraulic oil temperature sensor Out of input signal range S/T·T/M — — —
DH21KB Hydraulic pump oil pressure sensor Disconnection or short circuit S/T·T/M E01 — —
D155AX-5 20-403
(5)
Error Action Caution Caution

code
Fault part Fault Controller
code lamp buzzer
DH22KA Hydraulic pump oil pressure sensor Disconnection S/T·T/M E01 — —
DH22KB Hydraulic pump oil pressure sensor Short circuit S/T·T/M E01 — —
DH30KX Boost pressure sensor Out of input signal range ENG E02 q q
DH40KX Common rail pressure sensor Out of input signal range ENG CALL E03 q q
DHH3KA HSS pump oil pressure sensor A Disconnection S/T·T/M CALL E03 q q
DHH3KB HSS pump oil pressure sensor A Short circuit S/T·T/M CALL E03 q q
DHH4KA HSS pump oil pressure sensor B Disconnection S/T·T/M CALL E03 q q
DHH4KB HSS pump oil pressure sensor B Short circuit S/T·T/M CALL E03 q q
DK10KX Fuel dial Out of input signal range ENG CALL E03 q q
DK12KX Deceleration pedal potentiometer Out of input signal range ENG CALL E03 q q
DK30KA Steering lever potentiometer 1 Disconnection S/T·T/M CALL E03 q q
DK30KB Steering lever potentiometer 1 Short circuit S/T·T/M CALL E03 q q
DK30KX Steering lever potentiometer Out of input signal range S/T·T/M CALL E04 q q
DK30KZ Steering lever potentiometer Double engagement S/T·T/M CALL E04 q q
DK30L8 Steering lever potentiometer Analog signals do not agree S/T·T/M CALL E03 q q
DK31KA Steering lever potentiometer 2 Disconnection S/T·T/M CALL E03 q q
DK31KB Steering lever potentiometer 2 Short circuit S/T·T/M CALL E03 q q
DK40KA Brake pedal potentiometer Disconnection S/T·T/M E01 — —
DK40KB Brake pedal potentiometer Short circuit S/T·T/M E01 — —
DK55KX Forward-reverse potentiometer Out of input signal range S/T·T/M CALL E04 q q
DK55KZ Forward-reverse potentiometer Double engagement S/T·T/M CALL E04 q q
DK55L8 Forward-reverse potentiometer Analog signals do not agree S/T·T/M CALL E03 q q
DK56KA Forward-reverse potentiometer 1 Disconnection S/T·T/M CALL E03 q q
DK56KB Forward-reverse potentiometer 1 Short circuit S/T·T/M CALL E03 q q
DK57KA Forward-reverse potentiometer 2 Disconnection S/T·T/M CALL E03 q q
DK57KB Forward-reverse potentiometer 2 Short circuit S/T·T/M CALL E03 q q
DKH1KA Machine pitch angle sensor Disconnection S/T·T/M CALL E03 q q
DKH1KB Machine pitch angle sensor Short circuit S/T·T/M CALL E03 q q
DLE3LC Engine Ne speed sensor Malfunction ENG CALL E03 q q
DLF1KA Transmission bevel speed sensor Disconnection S/T·T/M E01 — —
DLH1LC Engine G speed sensor Malfunction ENG CALL E03 q q
DV00KB Caution buzzer Short circuit MON E01 — —
DW5AKA Blade pitch selector solenoid Disconnection S/T·T/M E02 q q
DW5AKB Blade pitch selector solenoid Short circuit S/T·T/M E02 q q
DW7BKA Fan reverse solenoid Disconnection S/T·T/M E01 — —
DW7BKB Fan reverse solenoid Short circuit S/T·T/M E01 — —
DWN1KA HSS pump solenoid B Disconnection S/T·T/M CALL E03 q q
DWN1KB HSS pump solenoid B Short circuit S/T·T/M CALL E03 q q
DWN2KA HSS pump solenoid A Disconnection S/T·T/M CALL E03 q q
DWN2KB HSS pump solenoid A Short circuit S/T·T/M CALL E03 q q
DWN5KA Fan pump solenoid Disconnection S/T·T/M E01 — —
DWN5KB Fan pump solenoid Short circuit S/T·T/M E01 — —
20-404 D155AX-5
(2)
Error Action Caution Caution

code
Fault part Fault Controller
code lamp buzzer
DXH4KA 1st clutch ECMV solenoid Disconnection S/T·T/M CALL E03 q q
DXH4KB 1st clutch ECMV solenoid Short circuit S/T·T/M CALL E03 q q
DXH5KA 2nd clutch ECMV solenoid Disconnection S/T·T/M CALL E03 q q
DXH5KB 2nd clutch ECMV solenoid Short circuit S/T·T/M CALL E03 q q
DXH6KA 3rd clutch ECMV solenoid Disconnection S/T·T/M CALL E03 q q
DXH6KB 3rd clutch ECMV solenoid Short circuit S/T·T/M CALL E03 q q
DXH7KA Reverse clutch ECMV solenoid Disconnection S/T·T/M CALL E03 q q
DXH7KB Reverse clutch ECMV solenoid Short circuit S/T·T/M CALL E03 q q
DXH8KA Forward clutch ECMV solenoid Disconnection S/T·T/M CALL E03 q q
DXH8KB Forward clutch ECMV solenoid Short circuit S/T·T/M CALL E03 q q
a “Controller” in the table indicates classification of the controller in charge of system check, monitor panel,
and code.
MON: Fault code of electric system checked by monitor panel
ENG: Fault code of electric system checked by engine controller
T/M·S/T: Fault code of electric system checked by steering controller and transmission controller
Machine: Fault code of mechanical system
a Even if only 1 system has an abnormality, 2 or more failure codes may be displayed simultaneously.
D155AX-5 20-405
(2)
TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST

a The troubleshooting list and related circuit diagram summarize the following information. Understand their
contents well to advance troubleshooting.
Action code Error code
Trouble Trouble that appeared on machine
Panel display Panel display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of monitor
Action to be taken to protect the system and equipment when the monitor panel or controller detects a
panel or
trouble
controller
Problem that
Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or con-
appears on
troller (above)
machine
Related
Information related to a detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state required to judge the assumed cause
(good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness is dis-
connected.
• Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Defective hot short
2 A harness not connected to the power (24V) circuit comes into con-
tact with the power (24V) circuit.
Possible causes • Defective short
Cause by which a trouble is
and standard A harness of an independent circuit abnormally comes into contact
assumed to be detected
value in normal with one of another circuit.
(The order number indicates
state a serial number, not a <Notes on troubleshooting>
priority sequence.) (1) Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect the T-junction adapter as
3 shown below unless especially specified.
• When “male” or “female” is not indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
both the male and female.
• When “male” or “female” is indicated for a connector number, dis-
connect the connector, and insert the T-junction adapter in only
either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in the
rear.
20-406 D155AX-5
(2)
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model-No. of pins) (Color).
• “Connector No. and pin No.” from each branching/merging point are shown:
End of branch or source of merging within the same wiring harness parts is shown.
• Arrow ( ): Roughly indicates mounting place on machine.
D155AX-5 20-407
(2)
TROUBLESHOOTING ERROR CODE 1500L0
ERROR CODE 1500L0 (TRANSMISSION CLUTCH: DOUBLE ENGAGEMENT)
Action code Error code Transmission clutch: Double engagement

Trouble
CALL E03 1500L0 (Steering and transmission controller system)
• Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Connection error)
(1) Either [DXH4KA] or [DXH4KB]
Contents of
• Of the error codes related to the transmission clutch, the following codes were displayed at the same
trouble
time.
(1) [15SAL1] and [15SBL1]
(2) [15SALH] and [15SBLH]
(3) Two or over of these [15SEL1], [15SFL1], and [15SGL1]
(4) Two or over of these [15SELH], [15SFLH], and [15SGLH]
Action of • Flashes caution lamp and turns on caution buzzer.
controller • Limits operation of engine and transmission.
Problem that • The auto shift down function does not start.
appears on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, running is limited to specific gear speeds.
Related
• Method of reproducing error code: Engine start + Run
information

Possible causes
Confirm the error codes displayed at the same time, then carry out troubleshooting for the codes.
and standard
[15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
value in normal
state [15SGLH]
[DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB]
20-408 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE 15SAL1
ERROR CODE 15SAL1 (FORWARD CLUTCH ECMV: FILL SIGNAL IS ON WHEN

COMMAND CURRENT IS TURNED OFF)
Action code Error code Forward clutch ECMV: Fill signal is ON when command current is
Trouble
CALL E03 15SAL1 turned OFF (Steering and transmission controller system)
Contents of
• The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit.
trouble
• Flashes caution lamp and turns on caution buzzer.
Action of
• Decides that engine speed is neutral (N) at reverse operation. (Prevent double engagement)
controller
• Limits operation of engine and transmission.
Problem that
• Once machine is stopped, engine speed is limited to medium (half).
appears on
• Once machine is stopped, running is limited to F1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
(Code 31520: Transmission fill switch input state)
information
• Method of reproducing error code: Engine start + Neutral running

aPrepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective forward clutch fill FFT (male) PCCS lever Resistance
1
switch (Internal short)
Between (1) – N Min. 1Mz
chassis ground F (Forward) Max. 1z
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness ground- without turning starting switch ON.
Possible causes
2 ing (Contact with ground cir-
and standard Wiring harness between STC2 (female) (35) –
cuit) Resistance Min. 1Mz
value in normal FFT (female) (1) with chassis ground
state aPrepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective steering and STC2 PCCS lever Voltage
3
transmission controller
Between (35) – N 5 – 11V
chassis ground F (Forward) Max. 1V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
4 system is assumed to be abnormal. Carry out the related troubleshoot-
system
ing (H mode).
Circuit diagram related to transmission forward clutch ECMV
D155AX-5 20-409
(2)
TROUBLESHOOTING ERROR CODE 15SALH
ERROR CODE 15SALH (FORWARD CLUTCH ECMV: FILL SIGNAL IS OFF WHEN
COMMAND CURRENT IS TURNED ON)
Action code Error code Forward clutch ECMV: Fill signal is OFF when command current is
Trouble
CALL E03 15SALH turned ON (Steering and transmission controller system)
Contents of
• The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at forward operation. (Prevent double engagement)
controller
Problem that
appears on
• Once machine is stopped, running is limited to R1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start + Forward running

shooting.
Defective forward clutch fill FFT (male) PCCS lever Resistance
1
chassis ground F (Forward) Max. 1z
Disconnection in wiring aPrepare with starting switch OFF, then carry out troubleshooting
Possible causes harness (Disconnection in without turning starting switch ON.
2
and standard wiring or defective contact in Wiring harness between STC2 (female) (35) –
Resistance Max. 1z
value in normal connector) FFT (female) (1)
shooting.
3
Between (35) – N 5 – 11V
chassis ground F (Forward) Max. 1V
system
ing (H mode).
20-410 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE 15SBL1
ERROR CODE 15SBL1 (REVERSE CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND
CURRENT IS TURNED OFF)
Action code Error code Reverse clutch ECMV: Fill signal is ON when command current is
Trouble
CALL E03 15SBL1 turned OFF (Steering and transmission controller system)
Contents of
• The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at forward operation. (Prevent double engagement)
controller
Problem that
appears on
• Once machine is stopped, running is limited to R1.
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective reverse clutch fill FRT (male) PCCS lever Resistance
1
chassis ground R (Reverse) Max. 1z
Possible causes
value in normal FRT (female) (1) with chassis ground
shooting.
3
Between (25) – N 5 – 11V
chassis ground R (Reverse) Max. 1V
system
ing (H mode).
Circuit diagram related to transmission reverse clutch ECMV
D155AX-5 20-411
(2)
TROUBLESHOOTING ERROR CODE 15SBLH
ERROR CODE 15SBLH (REVERSE CLUTCH ECMV: FILL SIGNAL IS OFF WHEN
COMMAND CURRENT IS TURNED ON)
Action code Error code Reverse clutch ECMV: Fill signal is OFF when command current is
Trouble
CALL E03 15SBLH turned ON (Steering and transmission controller system)
Contents of
• The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at reverse operation. (Prevent double engagement)
controller
Problem that
appears on
• Once machine is stopped, running is limited to F1.
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective reverse clutch fill FRT (male) PCCS lever Resistance
1
chassis ground R (Reverse) Max. 1z
2
Resistance Max. 1z
value in normal connector) FRT (female) (1)
shooting.
3
Between (25) – N 5 – 11V
chassis ground R (Reverse) Max. 1V
system
ing (H mode).
20-412 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE 15SEL1
ERROR CODE 15SEL1 (1ST CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND
Action code Error code 1st clutch ECMV: Fill signal is ON when command current is turned
Trouble
CALL E03 15SEL1 OFF (Steering and transmission controller system)
Contents of
• The fill switch signal is not set off at output stop of the transmission 1st clutch solenoid circuit.
trouble
Problem that
appears on
• Once machine is stopped, running is limited to F1 and R1.
machine
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start + F2 or R2 running

shooting.
Defective 1st clutch fill
1 F1T (male) PCCS lever Resistance
Between (1) – Other than F1/N/R1 Min. 1Mz
chassis ground F1·R1 Max. 1z
Possible causes
value in normal F1T (female) (1) with chassis ground
shooting.
Defective steering and
3 STC3 PCCS lever Voltage
Between (19) – Other than F1/N/R1 5 – 11V
chassis ground F1·R1 Max. 1V
system
ing (H mode).
Circuit diagram related to transmission 1st clutch ECMV
D155AX-5 20-413
(2)
TROUBLESHOOTING ERROR CODE 15SELH
ERROR CODE 15SELH (1ST CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND
CURRENT IS TURNED ON)
Action code Error code 1st clutch ECMV: Fill signal is OFF when command current is turned
Trouble
CALL E03 15SELH ON (Steering and transmission controller system)
Contents of
• The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not start.
machine • Once machine is stopped, running is limited to F2 and R2.
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 1st clutch fill
2
Resistance Max. 1z
value in normal connector) F1T (female) (1)
shooting.
system
ing (H mode).
20-414 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE 15SFL1
ERROR CODE 15SFL1 (2ND CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND
Action code Error code 2nd clutch ECMV: Fill signal is ON when command current is turned
Trouble
CALL E03 15SFL1 OFF (Steering and transmission controller system)
Contents of
• The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not operate.
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill
Possible causes
shooting.
system
ing (H mode).
Circuit diagram related to transmission 2nd clutch ECMV
D155AX-5 20-415
(2)
TROUBLESHOOTING ERROR CODE 15SFLH
ERROR CODE 15SFLH (2ND CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND
Action code Error code 2nd clutch ECMV: Fill signal is OFF when command current is turned
Trouble
CALL E03 15SFLH ON (Steering and transmission controller system)
Contents of
• The fill switch signal is not set on at output to the transmission 2nd clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill
2
Resistance Max. 1Mz
shooting.
system
ing (H mode).
20-416 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE 15SGL1
ERROR CODE 15SGL1 (3RD CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND
Action code Error code 3rd clutch ECMV: Fill signal is ON when command current is turned
Trouble
CALL E03 15SGL1 OFF (Steering and transmission controller system)
Contents of
• The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not operate.
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill
Possible causes
shooting.
system
ing (H mode).
Circuit diagram related to transmission 3rd clutch ECMV
D155AX-5 20-417
(2)
TROUBLESHOOTING ERROR CODE 15SGLH
ERROR CODE 15SGLH (3RD CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND
Action code Error code 3rd clutch ECMV: Fill signal is OFF when command current is turned
Trouble
CALL E03 15SGLH ON (Steering and transmission controller system)
Contents of
• The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill
2
Resistance Max. 1z
shooting.
system
ing (H mode).
20-418 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE A000N1
ERROR CODE A000N1 (ENGINE: OVERRUN)

Trouble Engine: Overrun (Engine controller system)
— A000N1
Contents of
• The engine speed exceeded the specified speed.
trouble
Action of • Turn on caution buzzer.
controller • Stops fuel injection until the engine speed lowers below the specified speed.
Problem that
appears on • None in particular.
machine
Related • Engine speed can be checked in monitoring mode (Monitoring mode: 01000).
information • Method of reproducing error code: Turn starting switch ON.

If any other error code is displayed and recorded at the same time, car-
Possible causes 1 Defective related system
ry out troubleshooting for that error code first.
and standard
value in normal As it is suspected that the way of using machine is improper, instruct
2 Improper use
state the using procedure again.
If no problem is found in cause 1 to 2, it is suspected that engine con-
3 Defective engine controller
troller is defective. (Check that engine speed is displayed normally.)
D155AX-5 20-419
(5)
TROUBLESHOOTING ERROR CODE AB00MA, ERROR CODE AD00L2
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION)

Trouble Alternator: Malfunction (Steering and transmission controller system)
— AB00MA
Contents of
• During rotation of engine, charge level caution lamp flashes.
trouble
Action of
• Flashes charge level caution lamp.
controller
Problem that
appears on • If machine is operated as it is, battery may be discharged.
machine
Related • Battery voltage can be checked in monitoring mode. (Code 03200: Battery voltage)
information • Method of reproducing error code: Start engine.

Defective battery charge It is suspected that problem causing defective battery charge is occur-
Possible causes
1 (When system is in normal ring at present or occurred in past. Investigate cause and damage con-
and standard
state) dition, and correct it.
value in normal
state Carry out troubleshooting of charge level caution lamp system in ac-
Defective charge level
2 cordance with “During running of engine, emergency caution item
caution lamp system
flashes” in E mode.
ERROR CODE AD00L2 (COMMON RAIL: ABNORMAL FUEL PRESSURE)

Trouble Common rail: Abnormal fuel pressure (Engine controller system)
CALL E03 AD00L2
Contents of
• The fuel pressure of common rail became high (level 1).
trouble
Action of
controller
Problem that
appears on • Normal drive.
machine
• The fuel state (fuel pressure) of common rail can be checked in monitoring mode.
Related
(Code 36400: Common rail pressure)
information
• Method of reproducing error code: Engine start

Check the displayed error code. If another code is displayed, first carry
1 Defective related system
out troubleshooting for the code.
2 Inappropriate fuel The fuel used may be inappropriate; directly check it.
Defective electric system of
3 common rail pressure Carry out troubleshooting for error code [DH40KX].
Possible causes sensor
and standard
value in normal Defective mechanical
The common rail pressure sensor is assumed to be defective mechan-
4 system of common rail
state ically; directly check it.
pressure sensor
The overflow valve may cause spring damage, sheet abrasion, or ball
5 Defective overflow valve
fixing; directly check it.
6 Clogged overflow pipe The overflow pipe is assumed to be clogged; directly check it.
The pressure limiter is assumed to be defective mechanically; directly
7 Defective pressure limiter
check it.
20-420 D155AX-5
(5)
TROUBLESHOOTING ERROR CODE AD00MA
ERROR CODE AD00MA (COMMON RAIL: MALFUNCTION)

Trouble Common rail: Malfunction (Engine controller system)
CALL E03 AD00MA
Contents of
• The fuel pressure of common rail became high (level 2).
trouble
controller • Limits output and engine speed for operation.
Problem that
appears on • Engine output and speed reduces.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for error code [AD00L2].
state
D155AX-5 20-421
(5)
TROUBLESHOOTING ERROR CODE AD10L3
ERROR CODE AD10L3 (FUEL SUPPLY PUMP: OBJECTIVE PART CANNOT BE

CONTROLLED)
Action code Error code Fuel supply pump: Objective part cannot be controlled
Trouble
E02 AD10L3 (Engine controller system)
Contents of
• Non-pressure transmission (level 1) occurred in fuel supply pump.
trouble
Action of
controller
Problem that
appears on • Normal drive.
machine
• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring
Related
mode. (Code 36400: Common rail pressure)
information

Check the displayed error code. If another code is displayed, first carry
1 Defective related system
out troubleshooting for the code.
2 Inappropriate fuel The fuel used may be inappropriate; directly check it.
Defective low-pressure The low-pressure circuit equipment is assumed to be defective; see
3
circuit equipment Note 1 for troubleshooting.
The filter strainer is assumed to be clogged; see Note 2 for trouble-
Possible causes 4 Clogged filter strainer
shooting.
and standard
value in normal Defective electric system of Carry out troubleshooting for error codes [AD11KA], [AD11KB],
5
fuel supply pump PCV [AD51KA], and [AD51KB].
state
6 Defective fuel supply pump The fuel supply pump is assumed to be defective; directly check it.
Defective common rail The common rail pressure sensor is assumed to be defective; directly
7
pressure sensor check it.
The pressure limiter is assumed to be defective mechanically; directly
8 Defective pressure limiter
check it.
The fuel injector is assumed to be defective; see Note 3 for trouble-
9 Defective fuel injector
shooting.
Note 1: When the low-pressure equipment is defective, check the following points:
1) Remaining fuel quantity
2) Feed pump fixing, abrasion, and filter clogging
3) Leak and clogging of low-pressure fuel pipe
4) Defective bypass valve function or other parts assembled erroneously (See the figure below.)
5) Clogged fuel filter
6) Fuel mix in oil pan (Fuel leak in head cover)
• Fuel low-pressure circuit pressure: 0.15 – 0.3MPa {1.5 – 3.0kg/cm2}
20-422 D155AX-5
(5)
TROUBLESHOOTING ERROR CODE AD10L3
Figure: Overflow valve (1), bypass valve (2), and fuel inlet joint (3) mounting positions
• Overflow valve (1): Spring viewed from both holes
• Bypass valve (2): Spring viewed from nut hole side
• Fuel inlet joint (3): Gauze filter viewed from both holes
Note 2: Follow the procedure below to check, clean, and replace the filter and strainer.
1) Gauze filter: Disassemble and check. If the filter is clogged, clean it.
2) Gauze filter upstream strainer: If the gauze filter is clogged, also clean the upstream strainer.
3) Fuel filter: If abnormality is not yet recovered after steps 1) and 2), replace the fuel filter.
Note 3: When the fuel injector is defective, measure the fuel spill charge for decision.
k The temperature of spill fuel rises extremely (max. 90ºC). Take care not to get burnt.
1) Disconnect the hose connected to the spill tube return set (in the rear of the engine).
2) Connect another hose to the end of the spill tube so that spill fuel can be poured in the container.
3) Start the engine and measure the spill fuel quantity per minute at stall for each engine speed.
a Limit of fuel spill charge (6 cylinders in all)

Engine stall speed (rpm) Spill limit (cc/min.)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
D155AX-5 20-423
(2)
TROUBLESHOOTING ERROR CODE AD10MA, ERROR CODE AD10MB
ERROR CODE AD10MA (FUEL SUPPLY PUMP: MALFUNCTION)

Trouble Fuel supply pump: Malfunction (Engine controller system)
CALL E03 AD10MA
Contents of
• An abnormal pressure occurred in the common rail fuel pressure.
trouble
controller • Runs in normal control state.
Problem that
appears on • Engine output and speed reduces.
machine
Related
information

and standard
state
ERROR CODE AD10MB (FUEL SUPPLY PUMP: PERFORMANCE REDUCTION)

Trouble Fuel supply pump: Performance reduction (Engine controller system)
CALL E03 AD10MB
Contents of
• Non-pressure transmission (level 2) occurred in the fuel supply pump.
trouble
controller • Limits output and engine speed for operation.
Problem that
appears on • Engine output reduces.
machine
• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring
Related
mode. (Code 36400: Common rail pressure)
information

and standard
state
20-424 D155AX-5
(5)
TROUBLESHOOTING ERROR CODE AD10MA, ERROR CODE AD10MB
D155AX-5 20-425
(2)
TROUBLESHOOTING ERROR CODE AD11KA
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN WIRING)
Action code Error code Fuel supply pump solenoid 1: Disconnection in wiring
Trouble
CALL E03 AD11KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in fuel supply pump solenoid 1 (PCV1).
trouble
Action of
• Limits engine and transmission operation.
controller
• Stops output to fuel supply pump solenoid 1 circuit.
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears on • Once machine is stopped, running is limited to F1 and R1.
machine • If codes [AD51KA] and [AD51KB] are displayed at the same time, engine stops.
Related • The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 1.
information • Method of reproducing error code: Engine start

Defective fuel supply pump without turning starting switch ON.
1 solenoid 1 (Internal discon- PCV1 (male) Resistance
nection in wiring) Between (1) – (2) 2.3 – 5.3z
Between (1) – chassis ground Min. 1Mz
Disconnection in wiring without turning starting switch ON.
harness (Disconnection in Wiring harness between EGC3 (female) (12) –
2 Resistance Max. 1z
Possible causes wiring or defective contact in PCV1 (female) (1)
and standard connector) Wiring harness between EGC3 (female) (22) –
Resistance Max. 1z
value in normal PCV1 (female) (2)
state aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness ground-
without turning starting switch ON.
Wiring harness between EGC3 (female) (22) –
PCV1 (female) (2) with chassis ground
EGC3 (male) Resistance
Between (12) – (22) 2.3 – 5.3z
Between (12) (22) –
Min. 1Mz
chassis ground
20-426 D155AX-5
(2)
Circuit diagram related to fuel supply pump solenoid 1
D155AX-5 20-427
(2)
TROUBLESHOOTING ERROR CODE AD11KB
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT)

Trouble Fuel supply pump solenoid 1: Short circuit (Engine controller system)
CALL E03 AD11KB
Contents of
• Overcurrent flowed in fuel supply pump solenoid 1 (PCV1) circuit.
trouble
Action of
controller
appears on • Once machine is stopped, travel is limited to F1 and R1.
machine • When code [AD51KA] and [AD51KB] appear at the same time, engine stops.
Related • For troubleshooting of fuel supply pump solenoid 1, special adaptor (799-601-9430) is required.

1 solenoid 1 (Internal short PCV1 (male) Resistance
circuit) Between (1) – (2) 2.3 – 5.3z
Short circuit with chassis
2 ground in wiring harness
(Contact with ground circuit) Resistance Min. 1Mz
Possible causes aPrepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal Short circuit of wiring harness between EGC3
state Hot short circuit in wiring
(female) (12) – PCV1 (female) (1) with chassis Voltage Max. 1V
3 harness (Contact with 24V
ground
circuit)
Short circuit of wiring harness between EGC3
(female) (22) – PCV1 (female) (2) with chassis Voltage Max. 1V
ground
Between (12) – (22) 2.3 – 5.3z
Between (12) (22) –
Min. 1Mz
chassis ground
20-428 D155AX-5
(2)
D155AX-5 20-429
(2)
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN WIRING)
Action code Error code Fuel supply pump solenoid 2: Disconnection in wiring
Trouble
CALL E03 AD51KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in fuel supply pump solenoid 2 (PCV2).
trouble
Action of
controller

Possible causes wiring or defective contact in PCV2 (female) (1)
and standard connector) Wiring harness between EGC3 (female) (23) –
Resistance Max. 1z
value in normal PCV2 (female) (2)
Between (13) – (23) 2.3 – 5.3z
Between (13) (23) –
Min. 1Mz
chassis ground
20-430 D155AX-5
(2)
D155AX-5 20-431
(2)
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: SHORT CIRCUIT)

Trouble Fuel supply pump solenoid 2: Short circuit (Engine controller system)
CALL E03 AD51KB
Contents of
• Overcurrent occurred in fuel supply pump solenoid 2 (PCV2).
trouble
Action of
controller

Possible causes PCV2 (female) (1)
and standard aPrepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Defective harness hot short Wiring harness between EGC3 (female) (13) –
3 Voltage Max. 1V
(Contact with 24V circuit) PCV2 (female) (1) with chassis ground
Voltage Max. 1V
Between (13) – (23) 2.3 – 5.3z
Between (13) (23) –
Min. 1Mz
chassis ground
20-432 D155AX-5
(2)
D155AX-5 20-433
(2)
TROUBLESHOOTING ERROR CODE ADA1KA
ERROR CODE ADA1KA (NO. 1 INJECTOR SOLENOID: DISCONNECTION IN WIRING)
Action code Error code No. 1 injector solenoid: Disconnection in wiring

Trouble
E02 ADA1KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in the No. 1 injector solenoid (TWV#1) circuit.
trouble
controller • Stops output to the No. 1 injector solenoid circuit.
Problem that
machine
Related
information

Defective No. 1 injector sole- without turning starting switch ON.
1 noid (Internal disconnection
CN1 (male) Resistance
in wiring)
Between (1) and (2) 0.4 – 1.1z
Possible causes
and standard
value in normal 2 Resistance Max. 1z
state wiring or defective contact in CN1 (female) (1)
connector) Wiring harness between EGC3 (female) (24) –
Resistance Max. 1z
CN1 (female) (2)
Between (14) and (24) 0.4 – 1.1z
20-434 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE ADA1KA
Circuit diagram related to No. 1 injector solenoid
D155AX-5 20-435
(2)
TROUBLESHOOTING ERROR CODE ADAZKB
ERROR CODE ADAZKB (NO. 1, 2, AND 3 INJECTOR SOLENOIDS: SHORT CIRCUIT)
Action code Error code No. 1, 2, and 3 injector solenoids: Short circuit
Trouble
CALL E03 ADAZKB (Engine controller system)
Contents of • Overcurrent occurred in the No. 1 injector solenoid (TWV#1), No. 2 injector solenoid (TWV#2), or No. 3
trouble injector solenoid (TWV#3).
Action of
• Limits engine and transmission operations.
controller
• Stops output to the No. 1, 2, and 3 injector solenoid circuits.
machine • Engine output reduces extremely.
Related
information

Defective No. 1 injector
1 CN1 (male) Resistance
solenoid (Internal short)
Between (1) – (2) 0.4 – 1.1z
Between (1) (2) – chassis ground Min. 1Mz
Defective No. 2 injector CN2 (male) Resistance
2
Between (1) – (2) 0.4 – 1.1z
Possible causes Defective No. 3 injector CN3 (male) Resistance
3
and standard solenoid (Internal short)
Between (1) – (2) 0.4 – 1.1z
value in normal
state
Resistance Min. 1Mz
CN1 (female) (1) with chassis ground
Resistance Min. 1Mz
4 ing (Contact with ground cir- Resistance Min. 1Mz
cuit)
Resistance Min. 1Mz
Resistance Min. 1Mz
Resistance Min. 1Mz
20-436 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE ADAZKB

aPrepare with starting switch OFF, then turn starting switch ON for
troubleshooting.
Voltage Max. 1V
Voltage Max. 1V
Defective harness hot short Wiring harness between EGC3 (female) (6) –
5 Voltage Max. 1V
(Contact with 24V circuit) CN2 (female) (1) with chassis ground
Possible causes Voltage Max. 1V
and standard
value in normal Voltage Max. 1V
state
Voltage Max. 1V
EGC3 (female) Resistance
Between (14) – (24) 0.4 – 1.1z
Between (6) – (16) 0.4 – 1.1z
Between (5) – (15) 0.4 – 1.1z
Between (5), (6), (14), (15), (16)
Min. 1Mz
and (24) – chassis ground
Circuit diagram related to No. 1, 2, and 3 injector solenoids
D155AX-5 20-437
(2)
TROUBLESHOOTING ERROR CODE ADB1KA
ERROR CODE ADB1KA (NO. 2 INJECTOR SOLENOID: DISCONNECTION IN WIRING)

Trouble
E02 ADB1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
Between (1) and (2) 0.4 – 1.1z
Possible causes
and standard
Resistance Max. 1z
CN2 (female) (2)
Between (6) and (16) 0.4 – 1.1z
20-438 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE ADC1KA
ERROR CODE ADC1KA (NO. 3 INJECTOR SOLENOID: DISCONNECTION IN WIRING)

Trouble
E02 ADC1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
Between (1) and (2) 0.4 – 1.1z
Possible causes
and standard
Resistance Max. 1z
CN3 (female) (2)
Between (5) and (15) 0.4 – 1.1z
D155AX-5 20-439
(2)
TROUBLESHOOTING ERROR CODE ADD1KA
ERROR CODE ADD1KA (NO. 4 INJECTOR SOLENOID: DISCONNECTION IN WIRING)

Trouble
E02 ADD1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
Between (1) and (2) 0.4 – 1.1z
Possible causes
and standard
Resistance Max. 1z
CN4 (female) (2)
Between (26) and (36) 0.4 – 1.1z
20-440 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE ADD1KA
D155AX-5 20-441
(2)
TROUBLESHOOTING ERROR CODE ADDZKB
ERROR CODE ADDZKB (NO. 4, 5, AND 6 INJECTOR SOLENOIDS: SHORT CIRCUIT)
Action code Error code No. 4, 5, and 6 injector solenoids: Short circuit
Trouble
CALL E03 ADDZKB (Engine controller system)
Contents of • Overcurrent occurred in the No. 4 injector solenoid (TWV#4), No. 5 injector solenoid (TWV#5), or No. 6
trouble injector solenoid (TWV#6).
Action of
• Limits engine and transmission operations.
controller
• Stops output to the No. 4, 5, and 6 injector solenoid circuits.
machine • Engine output reduces extremely.
Related
information

Defective No. 4 injector
1 CN4 (male) Resistance
Between (1) – (2) 0.4 – 1.1z
Defective No. 5 injector CN5 (male) Resistance
2
Between (1) – (2) 0.4 – 1.1z
Possible causes Defective No. 6 injector CN6 (male) Resistance
3
and standard solenoid (Internal short)
Between (1) – (2) 0.4 – 1.1z
value in normal
state
Resistance Min. 1Mz
Resistance Min. 1Mz
4 ing (Contact with ground cir- Resistance Min. 1Mz
cuit)
Resistance Min. 1Mz
Resistance Min. 1Mz
Resistance Min. 1Mz
20-442 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE ADDZKB

aPrepare with starting switch OFF, then turn starting switch ON for
troubleshooting.
Voltage Max. 1V
Voltage Max. 1V
Defective harness hot short Wiring harness between EGC3 (female) (34) –
5 Voltage Max. 1V
(Contact with 24V circuit) CN5 (female) (1) with chassis ground
Possible causes Voltage Max. 1V
and standard
value in normal Voltage Max. 1V
state
Voltage Max. 1V
Between (26) – (36) 0.4 – 1.1z
Between (34) – (33) 0.4 – 1.1z
Between (25) – (35) 0.4 – 1.1z
Between (25), (26), (33), (34), (35)
Min. 1Mz
and (36) – chassis ground
Circuit diagram related to No. 4, 5, and 6 injector solenoids
D155AX-5 20-443
(2)
TROUBLESHOOTING ERROR CODE ADE1KA
ERROR CODE ADE1KA (NO. 5 FUEL INJECTOR SOLENOID: DISCONNECTION IN WIRING)
Action code Error code No. 5 fuel injector solenoid: Disconnection in wiring
Trouble
E02 ADE1KA (Engine controller system)
Contents of
• Disconnection occurred in No. 5 fuel injector solenoid (TWV#5) circuit.
trouble
controller • Stops output to No. 5 fuel injector solenoid circuit.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing error code: Start engine.
information

Defective No. 5 fuel injector without turning starting switch ON.
1 solenoid (Internal discon-
nection)
Between (1) – (2) 0.4 – 1.1z
Possible causes
and standard
Resistance Max. 1z
CN5 (female) (2)
Between (34) – (33) 0.4 – 1.1z
Circuit diagram related to No. 5 fuel injector solenoid
20-444 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE ADF1KA
ERROR CODE ADF1KA (NO. 6 FUEL INJECTOR SOLENOID: DISCONNECTION IN WIRING)
Action code Error code No. 6 fuel injector solenoid: Disconnection in wiring
Trouble
E02 ADF1KA (Engine controller system)
Contents of
• Disconnection occurred in No. 6 fuel injector solenoid (TWV#6) circuit.
trouble
controller • Stops output to No. 6 fuel injector solenoid circuit.
Problem that
appears on • Engine output lowers.
machine
Related
information

Defective No. 6 fuel injector without turning starting switch ON.
1 solenoid (Internal discon-
nection)
Between (1) – (2) 0.4 – 1.1z
Possible causes
and standard
Resistance Max. 1z
CN6 (female) (2)
Between (25) – (35) 0.4 – 1.1z
Circuit diagram related to No. 6 fuel injector solenoid
D155AX-5 20-445
(2)
TROUBLESHOOTING ERROR CODE B@BAZG, ERROR CODE B@BCNS
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION)

Trouble Engine oil: Oil pressure reduction (Mechanical system)
— B@BAZG
Contents of
• During rotation of engine, engine oil pressure caution lamp flashes.
trouble
Action of • Flashes oil pressure caution lamp.
controller • Turns on caution buzzer.
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
Related
information

Engine oil pressure reduc- It is suspected that problem causing engine oil pressure reduction is
Possible causes
1 tion (When system is in nor- occurring at present or occurred in past. Investigate cause and dam-
and standard
mal state) age condition, and correct it.
value in normal
state Carry out troubleshooting of engine oil pressure caution lamp system
Defective engine oil pres-
2 in accordance with “During running of engine, emergency caution item
sure caution lamp system
flashes” in E mode.
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT)

Trouble Radiator coolant: Overheat (Mechanical system)
— B@BCNS
Contents of
• During rotation of engine, engine coolant temperature caution lamp flashes.
trouble
Action of • Flashes engine coolant temperature caution lamp.
controller • Turns on caution buzzer. (Function of monitor panel)
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
Related
information

Engine coolant temperature It is suspected that problem causing engine coolant temperature over-
Possible causes
1 overheat (When system is in heat is occurring at present or occurred in past. Investigate cause and
and standard
normal state) damage condition, and correct it.
value in normal
state Defective engine coolant Carry out troubleshooting of engine coolant temperature caution lamp
2 temperature caution lamp system in accordance with “During running of engine, emergency cau-
system tion item flashes” in E mode.
20-446 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE B@CENS, ERROR CODE B@CHZG
ERROR CODE B@CENS (POWER TRAIN OIL: OVERHEAT)

Trouble Power train oil: Overheat (Mechanical system)
— B@CENS
Contents of
• During rotation of engine, power train oil temperature caution flashes.
trouble
Action of • Flashes power train oil temperature overheat caution lamp.
controller • Turns on caution buzzer. (Function of monitor panel)
Problem that
appears on • If machine is operated as it is, power train may be damaged.
machine
Related
information

Power train oil temperature It is suspected that problem causing power train oil temperature over-
Possible causes
1 overheat (When system is in heat is occurring at present or occurred in past. Investigate cause and
and standard
normal state) damage condition, and correct it.
value in normal
state Defective power train oil Carry out troubleshooting of power train oil temperature caution lamp
2 temperature overheat cau- system in accordance with “During running of engine, emergency cau-
tion lamp system tion item flashes” in E mode.
ERROR CODE B@CHZG (HSS CHARGE PRESSURE: OIL PRESSURE REDUCTION)

Trouble HSS charge pressure: Oil pressure reduction (Mechanical system)
— B@CHZG
Contents of
• During rotation of engine, HSS charge pressure caution lamp flashes.
trouble
Action of • Flashes HSS charge pressure caution lamp.
Problem that
appears on • If machine is operated as it is, HSS pump or motor may be damaged.
machine
Related
information

HSS charge pressure It is suspected that problem causing HSS charge pressure reduction is
Possible causes
1 reduction (When system is occurring at present or occurred in past. Investigate cause and dam-
and standard
in normal state) age condition, and correct it.
value in normal
state Defective HSS charge Carry out troubleshooting of HSS charge pressure caution lamp sys-
2 pressure caution lamp tem in accordance with “During running of engine, emergency caution
system item flashes” in E mode.
D155AX-5 20-447
(2)
TROUBLESHOOTING ERROR CODE B@HANS
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT)

Trouble Hydraulic oil: Overheat (Mechanical system)
— B@HANS
Contents of
• During rotation of engine, hydraulic oil temperature caution lamp flashes.
trouble
Action of • Flashes hydraulic oil temperature caution lamp.
Problem that
appears on • If machine is operated as it is, work equipment circuit units may be damaged.
machine
Related
information

Hydraulic oil temperature It is suspected that problem causing hydraulic oil temperature overheat
Possible causes
1 overheat (When system is in is occurring at present or occurred in past. Investigate cause and dam-
and standard
normal state) age condition, and correct it.
value in normal
state Defective hydraulic oil tem- Carry out troubleshooting of hydraulic oil temperature caution lamp
2 perature caution lamp sys- system in accordance with “During running of engine, emergency cau-
tem tion item flashes” in E mode.
20-448 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE B@HANS
D155AX-5 20-449
(2)
TROUBLESHOOTING ERROR CODE D110KA
ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION IN WIRING)
Action code Error code Battery relay: Disconnection in wiring

Trouble
— D110KA (Steering and transmission controller system)
Contents of
• Current does not flow when outputting it to battery relay circuit.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears on • Problem may occur in data writing to ROM (nonvolatile storage) of each controller.
machine
• Output state (voltage) to battery relay can be checked in monitoring mode.
Related
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing error code: Switch starting switch from ON to OFF.

Defective battery relay without turning starting switch ON.
1
(Internal disconnection) Battery relay Continuity
Between terminals SW – BRE Continue
harness (Disconnection in Wiring harness between STC3 (female) (4) –
wiring or defective contact in battery relay SW terminal
Possible causes connector) Wiring harness between battery relay BRE –
Resistance Max. 1z
and standard chassis ground
value in normal aPrepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Hot short circuit in wiring
3 harness (Contact with 24V Short circuit of wiring harness between STC3
(female) (4) – battery relay terminal SW –
circuit) Voltage Max. 1V
starting switch terminal 260 with chassis
ground
4 STC3 Starting switch Voltage
Between (4) –
OFF Max. 1V
chassis ground
20-450 D155AX-5
(2)
Circuit diagram related to battery relay
D155AX-5 20-451
(2)
TROUBLESHOOTING ERROR CODE D110KB
ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT)
Action code Error code Battery relay: Short circuit

Trouble
— D110KB (Steering and transmission controller system)
Contents of
• Abnormal current flowed to battery relay circuit when outputting it.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears on • Problem may occur in data writing to ROM (nonvolatile storage) of each controller.
machine
• Output state (voltage) to battery relay can be checked in monitoring mode.
Related
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing error code: Switch starting switch from ON to OFF.

Defective battery relay Battery relay Continuity/resistance
1
(Internal short circuit) Between terminals SW – BRE Continue
Between terminal SW –
Min. 1Mz
chassis ground
Possible causes aPrepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Short circuit with chassis
2 ground in wiring harness Short circuit of wiring harness between STC3
state (female) (4) – battery relay terminal SW –
starting switch terminal 260 with chassis
ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
3 STC3 Starting switch Voltage
Between (4) –
ON 20 – 30V
chassis ground
20-452 D155AX-5
(2)
Circuit diagram related to battery relay
D155AX-5 20-453
(2)
ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION IN WIRING)
Action code Error code Neutral safety relay: Disconnection in wiring

Trouble
E02 D130KA (Steering and transmission controller system)
Contents of
• 24V is not generated when ground of neutral safety relay circuit is interrupted.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
appears on • Engine does not start.
machine
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related
• Method of reproducing error code: Turn starting switch ON and operate parking lever (Lock position).
information
• This error code detects abnormality in primary side (coil side) of neutral safety relay, but not in second-
ary side (contact side)

If circuit breaker is tripped, circuit probably has short circuit with
1 Defective fuse FS1-5
ground. (Refer to cause 4)
Defective neutral safety re- without turning starting switch ON.
2
lay (Internal disconnection) NSF (male) Resistance
Between (1) – (2) 200 – 400z
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between STC2 (female) (8) –
tion in wiring or defective NSF (female) (2)
Possible causes contact in connector) Wiring harness between NSF (female) (1) –
and standard Resistance Max. 1z
FS1-5
value in normal
Short circuit with chassis Short circuit of wiring harness between STC2
4 ground in wiring harness (female) (8) – NSF (female) (2) with chassis Resistance Min. 1Mz
(Contact with ground circuit) ground
Short circuit of wiring harness between NSF
Resistance Min. 1Mz
(female) (1) – FS1-5 with chassis ground
5 STC2 Parking lever Voltage
Between (8) – Free position 20 – 30V
chassis ground Lock position Max. 1V
20-454 D155AX-5
(2)
Circuit diagram related to neutral safety relay
D155AX-5 20-455
(2)
ERROR CODE D130KB (NEUTRAL SAFETY RELAY: SHORT CIRCUIT)
Action code Error code Neutral safety relay: Short circuit

Trouble
E02 D130KB (Steering and transmission controller system)
Contents of
• Abnormal current flowed in neutral safety relay circuit at the time of ground output.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
appears on • Engine does not start.
machine
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related
• Method of reproducing error code: Turn starting switch ON and operate parking lever (Free position).
information
• This error code detects abnormality in primary side (coil side) of neutral safety relay, but not in second-
ary side (contact side)

Defective neutral safety without turning starting switch ON.
1
relay (Internal short circuit) NSF (male) Resistance
Between (1) – (2) 200 – 400z
Possible causes
Hot short circuit in wiring carry out troubleshooting.
and standard
value in normal
circuit) (female) (8) – NSF (female) (2) with chassis Voltage Max. 1V
state
ground
Between (8) – Free position 20 – 30V
chassis ground Lock position Max. 1V
20-456 D155AX-5
(2)
Circuit diagram related to neutral safety relay
D155AX-5 20-457
(2)
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION IN WIRING)
Action code Error code Back-up alarm relay: Disconnection in wiring

Trouble
E01 D161KA (Steering and transmission controller system)
Contents of
• 24V is not generated when ground output of neutral safety relay circuit is interrupted.
trouble
Action of
• Stops output to back-up alarm relay circuit.
controller
Problem that
appears on • Back-up alarm is not turned on.
machine
• Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
Related
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse position).
information
• This error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in sec-
ondary side (contact side)

If fuse is burnout, circuit probably has short circuit with chassis ground.
1 Defective fuse FS2-(4)
(Refer to cause 4)
Defective back-up alarm re- without turning starting switch ON.
2
lay (Internal disconnection) BKA (male) Resistance
Between (1) – (2) 200 – 400z
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between STC2 (female) (18) –
tion in wiring or defective BKA (female) (2)
Possible causes contact in connector) Wiring harness between BKA (female) (1) –
FS2-(4)
value in normal
Short circuit with chassis Short circuit of wiring harness between STC2
4 ground in wiring harness (female) (18) – BKA (female) (2) – with chassis Resistance Min. 1Mz
Short circuit of wiring harness between BKA
Resistance Min. 1Mz
(female) (1) – FS2-(4) – with chassis ground
Between (18) – Neutral position 20 – 30V
chassis ground Reverse position Max. 1V
20-458 D155AX-5
(2)
Circuit diagram related to back-up alarm relay
D155AX-5 20-459
(2)
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT)
Action code Error code Back-up alarm relay: Short circuit

Trouble
E01 D161KB (Steering and transmission controller system)
Contents of
• Abnormal current flowed in back-up alarm relay circuit at the time of output.
trouble
Action of
• Stops output to back-up alarm relay circuit.
controller
Problem that
appears on • Back-up alarm is not turned on.
machine
• Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
Related
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse position).
information
• This error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in sec-

Defective back-up alarm without turning starting switch ON.
1
relay (Internal short circuit) BKA (male) Resistance
Between (1) – (2) 200 – 400z
Possible causes
and standard
value in normal
circuit) (female) (18) – BKA (female) (2) – with chassis Voltage Max. 1V
state
ground
Between (18) – Neutral position 20 – 30V
chassis ground Reverse position Max. 1V
20-460 D155AX-5
(2)
Circuit diagram related to back-up alarm relay
D155AX-5 20-461
(2)
TROUBLESHOOTING ERROR CODE D182KZ
ERROR CODE D182KZ (PREHEATER RELAY COIL: DISCONNECTION IN WIRING OR

SHORT CIRCUIT)
Action code Error code Preheater relay coil: Disconnection in wiring or short circuit
Trouble
— D182KZ (Steering and transmission controller system)
Contents of
• The drive circuit of the preheater relay has a trouble of disconnection or short circuit.
trouble
Action of
• Cannot drive the preheater relay.
controller
Problem that
appears on • The engine does not start easily at low temperature.
machine
• Method of reproducing error code: Turn starting switch ON. The preheated relay is driven when the
Related outside temperature is below –5ºC.
information • This error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in sec-

Defective preheater relay without turning starting switch ON.
1 (Internal disconnection or
RHR (male) Resistance
short)
Between (1) – (2) 200 – 400z
wiring or defective contact in RHR (female) (2)
connector) Wiring harness between RHR (female) (1) –
Resistance Max. 1z
270
and standard
value in normal Short circuit of wiring harness between EGC1
state (female) (12) – RHR (female) (2) with chassis Resistance Min. 1Mz
ground
(Contact with ground circuit)
Between wiring harness between RHR (fe-
male) (1) – starting switch terminal 270 – other Resistance Min. 1Mz
related circuit with chassis ground
EGC1 Preheater relay Voltage
When relay is
4 Defective controller 20 – 30V
not driven
Between (12) –
When relay is driven
chassis ground
(Outside temperature: Max. 1V (Note)
Max. –5ºC)
Note: When the outside temperature is below –5ºC, if the starting switch is turned ON, the engine controller
drives the preheated relay for 20 – 40 seconds (The length of the drive time depends on the outside tem-
perature).
20-462 D155AX-5
(5)
TROUBLESHOOTING ERROR CODE D182KZ
Circuit diagram related to preheater relay coil
D155AX-5 20-463
(2)
TROUBLESHOOTING ERROR CODE D1D0KB
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY: SHORT

CIRCUIT)
Action code Error code Engine controller load power supply: Short circuit
Trouble
E02 D1D0KB (Engine controller system)
Contents of
• Voltage is generated in controller load power supply circuit when starting switch is turned OFF.
trouble
controller • Limits operation of engine, transmission, and brake.
Problem that
appears on
• Once machine is stopped, it cannot travel any more.
machine
• Method of reproducing error code: Turn starting switch OFF.
Related
• This error code detects abnormality in secondary side (contact side) of engine controller load power
information
supply relay, but not in primary side (coil side)

Defective engine controller without turning starting switch ON.
1 load power supply relay
PPR (male) Resistance
(Internal short circuit)
Between (3) – (5) Min. 1Mz
Possible causes
and standard
2 harness (Contact with 24V Short circuit of wiring harness between EGC3
value in normal
circuit) (female) (1), (2), (21) – PPR (female) (3) with Voltage Max. 1V
state
chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting with
starting switch OFF or ON.
3 Defective engine controller EGC3 Starting switch Voltage
Between (1), (2), OFF position Max. 1V
(21) – chassis ground ON position 20 – 30V
20-464 D155AX-5
(5)
TROUBLESHOOTING ERROR CODE D1D0KB
Circuit diagram related to engine controller
D155AX-5 20-465
(2)
TROUBLESHOOTING ERROR CODE D5ZFKA
ERROR CODE D5ZFKA (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION IN

WIRING)
Action code Error code Transmission neutral signal: Disconnection in wiring

Trouble
E01 D5ZFKA (Steering and transmission controller system)
Contents of
• The transmission neutral signal output line is disconnected.
trouble
Action of
• Stops outputting the transmission neutral signal.
controller
Problem that
• None in particular. (This signal is used for backing up. Since main signals are transmitted and received
appears on
by CAN communication, the machine is controlled normally with those signals.)
machine
• The state of the transmission neutral signal can be checked in monitoring mode.
Related
(Code 40901: Input signal)
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever in N position.

harness (Disconnection in without turning starting switch ON.
1
wiring or defective contact in Wiring harness between STC2 (female) (19) –
Resistance Max. 1z
connector) EGC3 (female) (7), (17)
Short circuit with chassis without turning starting switch ON.
Possible causes 2 ground in wiring harness Short circuit of wiring harness between STC2
and standard (Contact with ground circuit) (female) (19) – EGC3 (female) (7), (17) with Resistance Min. 1Mz
value in normal chassis ground
state
Defective steering and carry out troubleshooting.
3
transmission controller Between STC2 (male) PCCS lever in N Voltage Max. 1V
(19) – ground PCCS lever in F or R Voltage 20 – 30V
4 Defective engine controller carry out troubleshooting.
Between EGC3 (male) (7), (17) – ground Voltage Approx. 7V
Circuit diagram related to transmission neutral signal
20-466 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE D5ZFKB
ERROR CODE D5ZFKB (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT)
Action code Error code Transmission neutral signal: Short circuit

Trouble
E01 D5ZFKB (Steering and transmission controller system)
Contents of
• The transmission neutral signal output line has a short circuit.
trouble
Action of
• Stops outputting the transmission neutral signal.
controller
Problem that
• None in particular. (This signal is used for backing up. Since main signals are transmitted and received
appears on
by CAN communication, the machine is controlled normally with those signals.)
machine
• The state of the transmission neutral signal can be checked in monitoring mode.
Related
(Code 40901: Input signal)
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever in F or R position.

harness (Disconnection in without turning starting switch ON.
1
Resistance Max. 1z
connector) EGC3 (female) (7), (17)
Short circuit with chassis carry out troubleshooting.
and standard (Contact with ground circuit) (female) (19) – EGC3 (female) (7), (17) with Voltage Max. 1V
value in normal chassis ground
state
3
transmission controller Between STC2 (male) PCCS lever in N Voltage Max. 1V
(19) – ground PCCS lever in F or R Voltage 20 – 30V
4 Defective engine controller carry out troubleshooting.
Between EGC3 (male) (7), (17) – ground Voltage Approx. 7V
Circuit diagram related to transmission neutral signal
D155AX-5 20-467
(2)
TROUBLESHOOTING ERROR CODE DAFRKR
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE

COMMUNICATION)
Action code Error code Monitor panel CAN communication: Defective communication
Trouble
CALL E03 DAFRKR (Monitor panel system)
Contents of
• Monitor panel cannot recognize steering and transmission controller with CAN communication circuit.
trouble
Problem that • System may not operate normally.
machine • Once machine is stopped, travel is limited to F1 and R1.
Related
• Method of reproducing error code: Turn starting switch ON.
information

Wiring harness between S04 (female) (1), (2)
Disconnection in wiring – STC2 (female) (32) – EGC2 (female) (32) –
Resistance Max. 1z
harness (Disconnection in CA1 (female) (A) – CA2 (female) (A) – CAN
1
wiring or defective contact in (male) (3)
connector) Wiring harness between S04 (female) (3), (4)
– STC2 (female) (22) – EGC2 (female) (22) –
Resistance Max. 1z
CA1 (female) (B) – CA2 (female) (B) – CAN
(male) (10)
Short circuit of wiring harness between S04
(female) (1), (2) – STC2 (female) (32) – EGC2
(female) (32) – CA1 (female) (A) – CA2 (fe- Resistance Min. 1Mz
male) (A) – CAN (male) (3) with chassis
ground
Possible causes (female) (3), (4) – STC2 (female) (22) – EGC2
and standard (female) (22) – CA1 (female) (B) – CA2 (fe- Resistance Min. 1Mz
value in normal male) (B) – CAN (male) (7) with chassis
state ground
(female) (32) – CA1 (female) (A) – CA2 (fe- Voltage Max. 1V
ground
circuit)
(female) (22) – CA1 (female) (B) – CA2 (fe- Voltage Max. 1V
male) (B) – CAN (male) (10) with chassis
ground
Defective CAN terminal without turning starting switch ON.
4
resistance CA1 (male), CA2 (male) Resistance
Between (A) – (B) Approx. 120z
Defective monitor panel or If no problem is found in causes 1 to 4, it is suspected that monitor pan-
5 defective steering and el or steering and transmission controller are defective. (Troubleshoot-
transmission controller ing cannot be carried out since it is internal defect.)
20-468 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DAFRKR
Circuit diagram related to CAN communication
D155AX-5 20-469
(2)
TROUBLESHOOTING ERROR CODE DAQ0KK DB30KK
ERROR CODE DAQ0KK DB30KK (STEERING AND TRANSMISSION CONTROLLER

POWER SOURCE: SOURCE VOLTAGE REDUCTION)
Action code Error code Steering and transmission controller power source:
DAQ0KK Trouble Source voltage reduction
CALL E04
DB30KK (Steering and transmission controller system)
Contents of
• Source voltage of steering and transmission controller is below 17V.
trouble
• Monitor panel may not display normally.
Problem that
• Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
• Both of DAQ0KK and DB30KK are displayed and recorded.
Related • Charge level (voltage) of battery can be checked in monitoring mode.
information (Code 03200: Battery voltage)

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with chas-
1
(CB105) sis ground. (Refer to cause 4)
If fusible link is burnout, circuit probably has short circuit with chassis
2 Defective fuse (FS1-(5))
ground. (Refer to cause 4)
Wiring harness between STC3 (female) (1),
Resistance Max. 1z
Disconnection in wiring (2), (11), (12) and (22) – FS1-(5)
harness (Disconnection in Wiring harness between FS12-(5) – battery re-
wiring or defective contact in lay terminal B105L
connector) Wiring harness between B105S – battery relay
Resistance Max. 1z
terminal BRC
Wiring harness between STC3 (female) (21),
Possible causes Resistance Max. 1z
(31), (32) and (33) – chassis ground (GND02)
and standard
Short circuit of wiring harness between STC3
(female) (1), (2), (11), (12) and (22) – FS1-(5) Resistance Min. 1Mz
Short circuit with chassis with chassis ground
4 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) FS12-(5) – battery relay terminal B105L with Resistance Min. 1Mz
chassis ground
Short circuit of wiring harness between B105S
– battery relay terminal BRC with chassis Resistance Min. 1Mz
ground
5 STC3 Voltage
Between (1), (2), (11), (12), (22) –
20 – 30V
(21), (31), (32), (33)
20-470 D155AX-5
(2)
Circuit diagram related to steering and transmission controller power source
D155AX-5 20-471
(2)
TROUBLESHOOTING ERROR CODE DAQ0KT DB30KT
ERROR CODE DAQ0KT DB30KT (STEERING AND TRANSMISSION CONTROLLER:

ABNORMALITY IN CONTROLLER)

Steering and transmission controller:
DAQ0KT Trouble
E01 Abnormality in controller (Steering and transmission controller system)
DB30KT
Contents of
• Information of ROM (nonvolatile storage) of steering and transmission controller is not normal.
trouble
Action of
• Sets default internal adjustment value.
controller
Problem that
• Gear shift feeling of transmission may become worse.
appears on
• Adjustment function may not work normally.
machine
Related • Both of DAQ0KT and DB30KT are displayed and recorded.

It is normal of error code lights on (reset display) after carrying out ad-
Possible causes Adjust defective steering
1 justment mode.
and standard and transmission controller
• Code 0002: S/T·T/M controller specification set
value in normal
state Troubleshooting cannot be carried out since it is internal defect.
2 (It is no problem even if you use controller unless no visible problem ap-
pears on machine.)
20-472 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DAQ0KT DB30KT
D155AX-5 20-473
(2)

SENSOR 5V POWER SUPPLY: SOURCE VOLTAGE REDUCTION)
Action code Error code Steering and transmission controller sensor 5V power supply:
CALL E03
• Voltage of 5V power supply circuit of steering and transmission controller sensor is below 4.5V or above
Contents of
5.5V.
trouble
• Abnormal current flowed in 5V power supply circuit of steering and transmission controller sensor.
Action of
• Stops output to 5V power supply circuit if abnormal voltage flows
controller
Related • Both of DAQ5KK and DB35KK are displayed and recorded.

Defective forward-reverse TL2 (male) Resistance
1 potentiometer (Internal
short circuit) Between (4) – (1) 3.2kz ± 20%
Sensor 1 (FR3)
Between (4) –
Sensor 2 (FR4) Min. 1Mz
chassis ground
Defective steering potenti- TL2 (male) Resistance
2 ometer (Internal short cir-
Between (5) – (8) 3.2kz ± 20%
cuit) Sensor 1 (ST1)
Sensor 2 (ST2) Between (5) –
Min. 1Mz
chassis ground
Possible causes Defective brake potentiome-
3 BRK (male) Resistance
and standard ter (Internal short circuit)
Between (C) – (A) 5kz ± 20%
value in normal
Between (C) – chassis ground Min. 1Mz
state
(female) (22) – TL2 (female) (4), – TL2 (fe-
male) (5), – BRK (female) (C) with chassis
ground
circuit) (female) (22) – TL2 (female) (4), – TL2 (fe-
Voltage Max. 1V
male) (5), – BRK (female) (C) with chassis
ground
6
transmission controller STC1 Voltage
Between (22) – (21) 4.5 – 5.5V
20-474 D155AX-5
(2)
Circuit diagram related to steering and transmission controller sensor 5V power supply
D155AX-5 20-475
(2)

Action code Error code Steering and transmission controller sensor 24V power supply:
CALL E03
• Voltage of 24V power supply circuit of steering and transmission controller sensor is below 17V or
Contents of
above 30V.
trouble
• Abnormal current flowed in 24V power supply circuit of steering and transmission controller sensor.
Action of
• Stops output to 24V power supply circuit if abnormal voltage flows
controller
• System may not operate normally.
Problem that
appears on
• Once machine is stopped, travel is limited to F1 and R1.
machine
• Oil pressure of work equipment cannot be monitored in service mode.
Related • Both of DAQ6KK and DB36KK are displayed and recorded.

aDisconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Work equipment oil
Defective work equipment HHP connector
pressure sensor
oil pressure sensor, HSS oil It is internal defect
HSS oil pressure
1 pressure sensor, and angle error code lights on HSPA connector
sensor A
of inclination sensor (reset display) when
(Internal short circuit) HSS oil pressure
disconnecting right HSPB connector
connector sensor B
Possible causes
Angle of inclination
and standard PT2 connector
sensor
value in normal
(Contact with ground circuit) (female) (16) – HHP (female) (B) – HSPA (fe- Resistance Min. 1Mz
male) (B) – HSPB (female) (B) – PT2 (female)
(C) with chassis ground
3
(16) – (21) 20 – 30V
20-476 D155AX-5
(2)
Circuit diagram related to steering and transmission controller sensor 24V power supply
D155AX-5 20-477
(2)
TROUBLESHOOTING ERROR CODE DAQ9KQ DB39KQ
ERROR CODE DAQ9KQ DB39KQ (STEERING AND TRANSMISSION CONTROLLER TYPE

SELECT: TYPE SELECT SIGNAL INCONSISTENCY)
Action code Error code Steering and transmission controller type select:
DAQ9KQ Trouble Type select signal inconsistency
CALL E04
DB39KQ (Steering and transmission controller system)
Contents of • Internal spec. setting of steering and transmission controller is inconsistent with spec. set signal.
trouble (Steering and transmission controller may not recognize normally.)
Action of
• Stops all outputs to steering and transmission controller.
controller
• Limits operation of engine, transmission, and brake.
Problem that • Machine does not operate at all.
machine • Once machine is stopped, it cannot travel any more.
Related • Both of DAQ9KQ and DB39KQ are displayed and recorded.

Defective steering and It is normal if error code lights on (reset display) after carrying out ad-
1 transmission controller justment mode.
adjustment • Adjustment code: 0002: Steering and transmission controller spec.
aPrepare with starting switch OFF, carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring Short circuit of wiring harness between STC3
harness (Disconnection in (female) (30) – PL2 (female) (10)
and standard 2
wiring or defective contact in Short circuit of wiring harness between PL2
value in normal Resistance Max. 1z
connector) (male) (10) – PL2 (male) (21)
state
Short circuit of wiring harness between PL2
Resistance Max. 1z
(female) (21) – STC3 (21), (31), (32) and (33)
3 STC3 Voltage
Between (30) – (21), (31),
Max. 1V
(32) and (33)
20-478 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DAQ9KQ DB39KQ
Circuit diagram related to steering and transmission controller type select
D155AX-5 20-479
(2)
TROUBLESHOOTING ERROR CODE DAQRKR DB3RKR
ERROR CODE DAQRKR DB3RKR (STEERING AND TRANSMISSION CONTROLLER CAN

COMMUNICATION: DEFECTIVE COMMUNICATION)
Action code Error code Steering and transmission controller CAN communication:
DAQRKR Trouble Defective communication
CALL E03
DB3RKR (Steering and transmission controller system)
Contents of • Steering and transmission controller cannot recognize monitor panel, or engine controller with CAN
trouble communication circuit.
Related • Both of DAQRKR and DB3RKR are displayed and recorded.

Wiring harness between STC2 (female) (32) –
Disconnection in wiring
S04 (female) (1), (2) – EGC2 (female) (32) – CA1 Resistance Max. 1z
harness (Disconnection in
1 (female) (A) – CA2 (female) (A) – CAN (male) (3)
wiring or defective contact in
connector) Wiring harness between STC2 (female) (22) –
S04 (female) (3), (4) – EGC2 (female) (22) – CA1
Resistance Max. 1z
(female) (B) – CA2 (female) (B) – CAN (male)
(10)
Short circuit of wiring harness between STC2 (fe-
male) (32) – S04 (female) (1), (2) – EGC2 (fe-
Short circuit with chassis Resistance Min. 1Mz
male) (32) – CA1 (female) (A) – CA2 (female) (A)
– CAN (male) (3) with chassis ground
Possible causes male) (22) – S04 (female) (3), (4) – EGC2 (fe-
Resistance Min. 1Mz
and standard male) (22) – CA1 (female) (B) – CA2 (female) (B)
value in normal – CAN (male) (10) with chassis ground
state aPrepare with starting switch OFF, then turn starting switch ON and
Hot short circuit in wiring Voltage Max. 1V
circuit)
Voltage Max. 1V
male) (22) – CA1 (female) (B) – CA2 (female) (B)
4
Defective monitor panel,
If no problem is found in causes 1 to 4, it is suspected that monitor pan-
defective engine controller,
5 el, engine controller, or steering and transmission controller are defec-
defective steering and
tive. (Troubleshooting cannot be carried out since it is internal defect.)
20-480 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DAQRKR DB3RKR
D155AX-5 20-481
(2)
TROUBLESHOOTING ERROR CODE DB20KQ
ERROR CODE DB20KQ (MALFUNCTION OF ENGINE CONTROLLER MACHINE MODEL

COLLECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS)
Action code Error code Malfunction of engine controller machine model collection:
Trouble
CALL E03 DB20KQ Disagreement of model selection signals (Engine controller system)
Contents of • The model check code set in the engine controller is not the same as the model check code received
trouble by communication.
Action of
• Control the machine model as the default specified.
controller
• Limits operation of engine.
Related
information

Installation of wrong engine Check the part No. of the engine controller.
1
controller (If the part No. is correct, the inside of the controller may be defective.)
Installation of wrong
Check the part No. of the steering and transmission controller.
2 steering and transmission
(If the part No. is correct, the inside of the controller may be defective.)
controller
Wiring harness between S04 (female) (1), (2) –
STC2 (female) (32) – EGC2 (female) (32) – CA1 Resistance Max. 1z
3 (female) (A) – CA2 (female) (A) – CAN (male) (3)
connector) Wiring harness between S04 (female) (3), (4) –
STC2 (female) (22) – EGC2 (female) (22) – CA1
Resistance Max. 1z
(female) (B) – CA2 (female) (B) – CAN (male)
(10)
Short circuit of wiring harness between S04 (fe-
male) (1), (2) – STC2 (female) (32) – EGC2 (fe-
Short circuit with chassis Resistance Min. 1Mz
Possible causes male) (32) – CA1 (female) (A) – CA2 (female) (A)
and standard – CAN (male) (3) with chassis ground
value in normal Short circuit of wiring harness between S04 (fe-
state male) (3), (4) – STC2 (female) (22) – EGC2 (fe-
Resistance Min. 1Mz
Hot short circuit in wiring Voltage Max. 1V
circuit)
Voltage Max. 1V
6
Defective steering and If no problem is found in causes 1 to 6, it is suspected that steering and
7 transmission controller, transmission controller, engine controller are defective.
defective engine controller (Troubleshooting cannot be carried out since it is internal defect.)
20-482 D155AX-5
(2)
D155AX-5 20-483
(2)
TROUBLESHOOTING ERROR CODE DB20KT
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER)
Action code Error code Engine controller: Abnormality in controller

Trouble
CALL E03 DB20KT (Engine controller system)
Contents of
• Problem occurred in engine controller.
trouble
Action of
• Cannot operate fuel injector solenoid well or stops output.
controller
Problem that • Engine may stop during operation or engine may not start.
Related
information

Possible causes harness (Disconnection in
1 Short circuit of wiring harness between EGC3
and standard wiring or defective contact in
value in normal connector) (female) (11), (31), (32) with chassis ground Resistance Max. 1z
(GND03)
state
If no problem is found in cause 1, it is suspected that engine controller
2 Defective engine controller is defective. (Troubleshooting cannot be carried out since it is internal
defect.)
20-484 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DB20KT
Circuit diagram related to engine controller power supply
D155AX-5 20-485
(2)
TROUBLESHOOTING ERROR CODE DB22KK
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE

VOLTAGE REDUCTION)
Action code Error code Engine controller load power supply: Source voltage reduction
Trouble
CALL E04 DB22KK (Engine controller system)
Contents of
• Load source voltage of engine controller is below 17V.
trouble
Problem that • Engine may stop during operation or engine may not start.
• Charge level (voltage) of battery can be checked in monitoring mode.
(Code 03200: Battery voltage)
Related
information
• This error code defects abnormality in secondary side (contact side) of engine controller load power
supply relay, but not in primary side (coil side).

Defective circuit breaker If circuit breaker is disconnect, circuit probably has short circuit with
1
(CB105) chassis ground. (Refer to cause 5)
If fuse is burnout, circuit probably has short circuit with chassis ground.
(Refer to cause 5)
aPrepare with starting switch OFF, turn starting switch ON and carry
Defective engine controller out troubleshooting.
3 load power supply relay If error code lights on (reset display) by replacing right con-
(Internal disconnection) nector with other relay, engine controller load power supply PPR
relay is defective.
Wiring harness between EGC3 (female) (1),
Resistance Max. 1z
Disconnection in wiring (2), (21) – PPR (female) (3)
harness (Disconnection in Wiring harness between PPR (female) (5) –
wiring or defective contact in FS2-(2)
connector) Wiring harness between FS22-(2) inlet port –
Resistance Max. 1z
Possible causes battery relay terminal B105L
and standard Wiring harness between battery relay terminal
Resistance Max. 1z
value in normal B105S – battery relay terminal BRC
(female) (1), (2), (21) – PPR (female) (3) with Resistance Min. 1Mz
chassis ground
Short circuit with chassis Short circuit of wiring harness between PPR
5 ground in wiring harness (female) (5) – FS2-2 outlet port with chassis Resistance Min. 1Mz
Short circuit of wiring harness between
FS22-(2) – battery relay terminal B105L – with Resistance Min. 1Mz
chassis ground
Wiring harness between battery relay terminal
Resistance Min. 1Mz
B105S – BRC with chassis ground
out troubleshooting.
6 Defective engine controller EGC3 Voltage
Between (1), (2), (21) –
20 – 30V
(11), (31), (32)
20-486 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DB22KK
Circuit diagram related to engine controller power supply
D155AX-5 20-487
(2)
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL
INCONSISTENCY)
Action code Error code Engine controller type select: Type select signal inconsistency
Trouble
CALL E03 DB29KQ (Engine controller system)
Contents of
• Type select signal acquired by engine controller is not normal.
trouble
Action of
• Controls it as default-set type.
controller
Problem that • Machine does not provide normal output.
Related
information

wiring or defective contact in SEL (male) (2)
Resistance Max. 1z
SEL (male) (1)
Possible causes
and standard Short circuit with chassis
(female) (17) – SEL (male) (3) with chassis Resistance Min. 1Mz
value in normal 2 ground in wiring harness
ground
state (Contact with ground circuit)
(female) (23) – SEL (male) (4) with chassis Resistance Min. 1Mz
ground
EGC1, EGC2 Voltage
Between EGC1 (3) – EGC2 (1) Max. 1V
Between EGC1 (17), (23) –
20 – 30V
EGC2 (1)
Circuit diagram related to engine controller type select
20-488 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DB2AMA
ERROR CODE DB2AMA (ENGINE CONTROLLER Q-ADJUSTMENT SWITCH:

MALFUNCTION)
Action code Error code Engine controller Q-adjustment switch: Malfunction

Trouble
E02 DB2AMA (Engine controller system)
Contents of
• Q-adjustment switch is not set at correct position.
trouble
Problem that • Q-adjustment setting cannot be changed.
• Setting condition (letters) of Q-adjustment switch can be checked in monitoring mode.
Related
(Code 36800: Q-adjustment command value 1, Code 36801: Q-adjustment command value 2)
information

Possible causes Defective Q-adjustment If both Q-adjustment switches 1 and 2 are set at [F], Q-adjustment
1
and standard switch setting switch setting is defective.
value in normal If no problem is found in above cause, it is suspected that engine con-
state 2 Defective engine controller troller is defective. (Troubleshooting cannot be carried out since it is in-
ternal defect.)
D155AX-5 20-489
(5)
TROUBLESHOOTING ERROR CODE DB2RKR
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE

COMMUNICATION)
Action code Error code Engine controller CAN communication: Defective communication
Trouble
CALL E03 DB2RKR (Engine controller system)
Contents of • Engine controller cannot recognize steering and transmission controller with CAN communication cir-
trouble cuit.
Related
information

Disconnection in wiring EGC2 (female) (32) – S04 (female) (1), (2) –
Resistance Max. 1z
1
EGC2 (female) (22) – S04 (female) (3), (4) –
Resistance Max. 1z
(male) (10)
(female) (32) – EGC2 (female) (32) – S04 (fe-
male) (1), (2) – CA1 (female) (A) – CA2 (fe- Resistance Min. 1Mz
ground
Possible causes (female) (22) – EGC2 (female) (22) – S04 (fe-
and standard male) (3), (4) – CA1 (female) (B) – CA2 (fe- Resistance Min. 1Mz
state ground
male) (1), (2) – CA1 (female) (A) – CA2 (fe- Voltage Max. 1V
ground
circuit)
male) (3), (4) – CA1 (female) (B) – CA2 (fe- Voltage Max. 1V
ground
4
Defective engine controller, If no problem is found in causes 1 to 4, it is suspected that engine con-
5 defective steering and troller, steering and transmission controller are defective.
transmission controller (Troubleshooting cannot be carried out since it is internal defect.)
20-490 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DB2RKR
D155AX-5 20-491
(2)
TROUBLESHOOTING ERROR CODE DB2RMC
ERROR CODE DB2RMC (STEERING AND TRANSMISSION CONTROLLER CAN

Action code Error code Steering and transmission controller CAN communication:
Trouble
CALL E03 DB2RMC Defective communication (Engine controller system)
Contents of • Steering and transmission controller cannot recognize engine controller with CAN communication cir-
trouble cuit.
Related
information

Disconnection in wiring STC2 (female) (32) – S04 (female) (1), (2) –
Resistance Max. 1z
1
STC2 (female) (22) – S04 (female) (3), (4) –
Resistance Max. 1z
(male) (10)
(female) (32) – STC2 (female) (32) – S04 (fe-
male) (1), (2) – CA1 (female) (A) – CA2 (fe- Resistance Min. 1Mz
ground
Possible causes (female) (22) – STC2 (female) (22) – S04 (fe-
and standard male) (3), (4) – CA1 (female) (B) – CA2 (fe- Resistance Min. 1Mz
state ground
male) (1), (2) – CA1 (female) (A) – CA2 (fe- Voltage Max. 1V
ground
circuit)
male) (3), (4) – CA1 (female) (B) – CA2 (fe- Voltage Max. 1V
ground
4
Defective steering and If no problem is found in causes 1 to 4, it is suspected that steering and
5 transmission controller, transmission controller, engine controller are defective.
defective engine controller (Troubleshooting cannot be carried out since it is internal defect.)
20-492 D155AX-5
(5)
TROUBLESHOOTING ERROR CODE DB2RMC
D155AX-5 20-493
(2)
ERROR CODE DB30KK DAQ0KK, ERROR CODE DB30KT DAQ0KT,
ERROR CODE DB35KK DAQ5KK, ERROR CODE DB36KK DAQ6KK,
TROUBLESHOOTING ERROR CODE DB39KQ DAQ9KQ, ERROR CODE DB3RKR DAQRKR
ERROR CODE DB30KK DAQ0KK (STEERING AND TRANSMISSION CONTROLLER

POWER SOURCE: SOURCE VOLTAGE REDUCTION)
a See DAQ0KK.
ERROR CODE DB30KT DAQ0KT (STEERING AND TRANSMISSION CONTROLLER:

ABNORMALITY IN CONTROLLER)
a See DAQ0KT.

a See DAQ5KK.

a See DAQ6KK.
ERROR CODE DB39KQ DAQ9KQ (STEERING AND TRANSMISSION CONTROLLER TYPE

SELECT: TYPE SELECT SIGNAL INCONSISTENCY)
a See DAQ9KQ.
ERROR CODE DB3RKR DAQRKR (STEERING AND TRANSMISSION CONTROLLER CAN

a See DAQRKR.
20-494 D155AX-5
(2)
ERROR CODE DB30KK DAQ0KK, ERROR CODE DB30KT DAQ0KT,
ERROR CODE DB35KK DAQ5KK, ERROR CODE DB36KK DAQ6KK,
TROUBLESHOOTING ERROR CODE DB39KQ DAQ9KQ, ERROR CODE DB3RKR DAQRKR
D155AX-5 20-495
(2)
TROUBLESHOOTING ERROR CODE DD11KB
ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT)

Trouble Starting switch: Short circuit (Engine controller system)
CALL E04 DD11KB
Contents of
• Signal C of starting switch is input during running of engine.
trouble
Problem that • Machine does not operate at all.
Related
information

aPrepare with starting switch OFF, then carry out troubleshooting with
Defective adjustment of starting switch OFF or START.
1 starting engine (Internal Starting switch Starting switch Resistance
disconnection) Between 250 (B) – When OFF/ON Min. 1Mz
280 (C) START Max. 1z
Possible causes out troubleshooting.
and standard Short circuit of wiring harness between EGC1
value in normal Hot short circuit in wiring
(female) (20) – NSF (female) (5) with chassis Voltage Max. 1V
state 2 harness (Contact with 24V
ground
circuit)
Short circuit of wiring harness between NSF
(female) (3) – starting switch 280 terminal (C) Voltage Max. 1V
with chassis ground
EGC1 Voltage
Between (20) – chassis ground Max. 1V
20-496 D155AX-5
(2)
Circuit diagram related to starting switch signal C
D155AX-5 20-497
(2)
TROUBLESHOOTING ERROR CODE DD12KA
ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION IN WIRING)
Action code Error code Shift up switch: Disconnection in wiring

Trouble
E02 DD12KA (Steering and transmission controller system)
Contents of
• Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
trouble
controller • Recognizes that switch is not pressed.
Problem that
• Shift up is not possible.
appears on
• Auto shift down does not function.
machine
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
Related • Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
information (Code 40905: Steering and transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift up switch.

Shift up switch
SFTU (male)
Defective shift up switch OFF (Release) ON (Press)
1
(Internal disconnection) Resistance between
Max. 1z Min. 1Mz
(2) – (3)
Resistance between
Min. 1Mz Max. 1z
(2) – (1)
Disconnection in wiring Wiring harness between STC1 (female) (12) –
Resistance Max. 1z
harness (Disconnection in SFTU (female) (3)
2
Resistance Max. 1z
connector) SFTU (female) (1)
Possible causes
SFTU (female) (2)
value in normal
state aPrepare with starting switch OFF, turn starting switch ON and carry
(female) (12) – SFTU (female) (3) with chassis Voltage Max. 1V
ground
circuit)
(female) (9) – SFTU (female) (1) with chassis Voltage Max. 1V
ground
Shift up switch
STC1, STC3
Defective steering and OFF (Release) ON (Press)
4
transmission controller Voltage between
Max. 1V 5 – 11V
STC1 (12) – STC1 (4)
Voltage between
5 – 11V Max. 1V
STC3 (9) – STC1 (4)
20-498 D155AX-5
(2)
Circuit diagram related to shift up switch and shift down switch
D155AX-5 20-499
(2)
ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT)
Action code Error code Shift up switch: Short circuit

Trouble
E02 DD12KB (Steering and transmission controller system)
Contents of
• Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
• Shift up is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift up switch can be checked in monitoring mode.

Shift up switch
SFTU (male)
Defective shift up switch OFF (Release) ON (Press)
1
Max. 1z Min. 1Mz
(2) – (3)
Resistance between
Min. 1Mz Max. 1z
(2) – (1)
Possible causes
(female) (12) – SFTU (female) (3) with chassis Resistance Min. 1Mz
state ground
(female) (9) – SFTU (female) (1) with chassis Resistance Min. 1Mz
ground
Shift up switch
STC1, STC3
3
Max. 1V 5 – 11V
STC1 (12) – STC1(4)
Voltage between
5 – 11V Max. 1V
STC3 (9) – STC1(4)
20-500 D155AX-5
(2)
D155AX-5 20-501
(2)
ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION IN WIRING)
Action code Error code Shift down switch: Disconnection in wiring

Trouble
E02 DD13KA (Steering and transmission controller system)
Contents of
• Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
• Shift down is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
• Method of reproducing error code: Turn starting switch ON and operate shift down switch.

Shift down switch
SFTD (female)
Defective shift down switch OFF (Release) ON (Press)
1
Max. 1z Min. 1Mz
(2) – (3)
Resistance between
Min. 1Mz Max. 1z
(2) – (1)
Resistance Max. 1z
harness (Disconnection in SFTD (male) (3)
2
Resistance Max. 1z
connector) SFTD (male) (1)
Possible causes
SFTD (male) (2)
value in normal
state aPrepare with starting switch OFF, turn starting switch ON and carry
(female) (24) – SFTD (male) (3) with chassis Voltage Max. 1V
ground
circuit)
(female) (18) – SFTD (male) (1) with chassis Voltage Max. 1V
ground
Shift down switch
STC1
4
Max. 1V 5 – 11V
STC1 (24) – STC1 (4)
Voltage between
5 – 11V Max. 1V
STC1 (18) – STC1 (4)
20-502 D155AX-5
(2)
D155AX-5 20-503
(2)
ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT)
Action code Error code Shift down switch: Short circuit

Trouble
E02 DD13KB (Steering and transmission controller system)
Contents of
• Signals of two systems of shift down switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
• Shift down is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift down switch can be checked in monitoring mode.

Shift down switch
SFTD (female)
Defective shift down switch OFF (Release) ON (Press)
1
Max. 1z Min. 1Mz
(2) – (3)
Resistance between
Min. 1Mz Max. 1z
(2) – (1)
Possible causes
(female) (24) – SFTD (male) (3) with chassis Resistance Min. 1Mz
state ground
(female) (18) – SFTD (male) (2) with chassis Resistance Min. 1Mz
ground
Shift down switch
STC1
3
Max. 1V 5 – 11V
STC1 (24) – STC1 (4)
Voltage between
5 – 11V Max. 1V
STC1 (18) – STC1 (4)
20-504 D155AX-5
(2)
D155AX-5 20-505
(2)
TROUBLESHOOTING ERROR CODE DD14KA DDQ2KA
ERROR CODE DD14KA DDQ2KA (TRAVEL LOCK SWITCH: DISCONNECTION IN WIRING)
Action code Error code Travel lock switch: Disconnection in wiring

DD14KA Trouble
CALL E03 (Steering and transmission controller system)
DDQ2KA
Contents of
• Signals of two systems of travel lock switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
• Recognizes parking lever is in Free position.
controller
Problem that
appears on
machine
• Both of DD14KA and DDQ2KA are displayed and recorded.
Related
• Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
information
(Code 40905: Steering and transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate parking lever.

Travel lock switch (Internal Parking lever
1 NSW (male)
disconnection) Free position Lock position
Between (A) – (B) Max. 1z Min. 1Mz
Between (A) – (C) Min. 1Mz Max. 1z
Resistance Max. 1z
harness (Disconnection in NSW (female) (C)
2
Resistance Max. 1z
connector) NSW (female) (B)
Possible causes Wiring harness between STC1 (female) (4) –
Resistance Max. 1z
NSW (female) (A)
and standard
value in normal aPrepare with starting switch OFF, turn starting switch ON and carry
state out troubleshooting.
(female) (15) – NSW (female) (C) with chassis Voltage Max. 1V
ground
circuit)
(female) (5) – NSW (female) (B) with chassis Voltage Max. 1V
ground
Parking lever
STC1, STC2
Defective steering and Free position Lock position
4
Max. 1V 5 – 11V
STC2 (5) – STC1 (4)
Voltage between
5 – 11V Max. 1V
STC2 (15) – STC1 (4)
20-506 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DD14KA DDQ2KA
Circuit diagram related to travel lock switch
D155AX-5 20-507
(2)
TROUBLESHOOTING ERROR CODE DD14KB DDQ2KB
ERROR CODE DD14KB DDQ2KB (TRAVEL LOCK SWITCH: SHORT CIRCUIT)
Action code Error code Travel lock switch: Short circuit

DD14KB Trouble
CALL E03 (Steering and transmission controller system)
DDQ2KB
Contents of
• Signals of two systems of travel lock switch circuit were turned ON (CLOSE) at the same time.
trouble
Action of
• Recognizes parking lever is in Free position.
controller
Problem that
appears on
machine
• Both of DD14KB and DDQ2KB are displayed and recorded.
Related
• Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
information
(Code 40905: Steering and transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate parking lever.

Travel lock switch (Internal Parking lever
1 NSW (male)
disconnection) Free position Lock position
Between (A) – (B) Max. 1z Min. 1Mz
Between (A) – (C) Min. 1Mz Max. 1z
Possible causes Short circuit with chassis
2 ground in wiring harness Resistance Min. 1Mz
NSW (female) (C) with chassis ground
value in normal (Contact with ground circuit)
state Wiring harness between STC2 (female) (5) –
Resistance Min. 1Mz
NSW (female) (B) with chassis ground
Parking lever
STC1, STC2
Defective steering and Free position Lock position
3
Max. 1V 5 – 11V
STC2 (5) – STC1 (4)
Voltage between
5 – 11V Max. 1V
STC2 (15) – STC1 (4)
20-508 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DD14KB DDQ2KB
Circuit diagram related to travel lock switch
D155AX-5 20-509
(2)
TROUBLESHOOTING ERROR CODE DDE2L6
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: OPERATION STATE AND
STOP STATE OF ENGINE DO NOT AGREE WITH SIGNALS)
Action code Error code Engine oil pressure switch: Operation state and stop state of engine do
Trouble
— DDE2L6 not agree with signals (Engine controller system)
Contents of
• Signals of engine oil pressure switch are inconsistent with engine state.
trouble
Action of
controller
Problem that
appears on
machine
• Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode.
Related
(Code 40900: Engine controller input signal 1)
information
• Method of reproducing error code: Turn starting switch ON or start engine.

Defective low engine oil without turning starting switch ON or by starting engine.
1 pressure switch (Internal PSL Engine Resistance
disconnection/short circuit) Between terminal – Stop Max. 1z
chassis ground Min. 600rpm Min. 1Mz
Defective high engine oil without turning starting switch ON or by starting engine.
2 pressure switch (Internal PSH Engine Resistance
disconnection/short circuit) Between terminal – Stop Max. 1z
chassis ground Min. 1,300rpm Min. 1Mz
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness (Disconnection in Wiring harness between EGC1 (female) (21) –
value in normal wiring or defective contact in PSL
state connector) Wiring harness between EGC1 (female) (15) –
Resistance Max. 1z
PSH
(female) (21) – PSL with chassis ground
without turning starting switch ON or by starting engine.
EGC1 Engine Voltage
5 Defective engine controller Between (21) – Stop Max. 1V
chassis ground Min. 600rpm 20 – 30V
Between (15) – Stop Max. 1V
chassis ground Min. 1,300rpm 20 – 30V
20-510 D155AX-5
(5)
TROUBLESHOOTING ERROR CODE DDE2L6
Circuit diagram related to low engine oil pressure switch & high engine oil pressure switch
D155AX-5 20-511
(2)
TROUBLESHOOTING ERROR CODE DDN7KA
ERROR CODE DDN7KA (BLADE KNOB PITCH SWITCH: DISCONNECTION IN WIRING)
Action code Error code Blade knob pitch switch: Disconnection in wiring
Trouble
E02 DDN7KA (Steering and transmission controller system)
Contents of
• Signals of two systems of blade knob pitch switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
appears on • Blade pitch does not function. (Operating blade pitch causes tilt operation.)
machine
Related • Input state (ON/OFF) from blade knob pitch switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input signal)
• Method of reproducing error code: Turn starting switch ON (and operate blade knob pitch switch).

Blade pitch upper side switch
Defective blade pitch upper WNBU (male)
OFF (Release) ON (Press)
1 side switch (Internal
disconnection) Resistance between
Max. 1z Min. 1Mz
(2) – (3)
Resistance between
Min. 1Mz Max. 1z
(2) – (1)
Blade pitch lower side switch
Defective blade pitch lower WNBL (female)
Max. 1z Min. 1Mz
(2) – (3)
Resistance between
Min. 1Mz Max. 1z
(2) – (1)
Possible causes without turning starting switch ON.
Resistance Max. 1z
value in normal Disconnection in wiring WNBU (female) (3)
state harness (Disconnection in Wiring harness between STC3 (female) (20) –
wiring or defective contact in WNBU (female) (1) – WNBL (male) (1)
Resistance Max. 1z
WNBL (male) (2)
Wiring harness between WNBU (female) (2) –
Resistance Max. 1z
WNBL (male) (3)
(female) (10) – WNBU (female) (3) with chas- Voltage Max. 1V
sis ground
(female) (20) – WNBU (female) (1) – WNBL Voltage Max. 1V
(male) (1) with chassis ground
circuit)
Short circuit of wiring harness between WNBU
(female) (2) – WNBL (male) (3) with chassis Voltage Max. 1V
ground
Short circuit of wiring harness between WNBL
(male) (2) – STC1 (female) (4) with chassis Voltage Max. 1V
ground
20-512 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DDN7KA

Possible causes
Blade pitch both side switch
and standard STC1, STC3
value in normal Defective steering and OFF (Release) ON (Press)
5
state transmission controller Voltage between
Max. 1V 5 – 11V
STC3 (10) – STC1 (4)
Voltage between
5 – 11V Max. 1V
STC3 (20) – STC1 (4)
Circuit diagram related to blade knob pitch switch
D155AX-5 20-513
(2)
TROUBLESHOOTING ERROR CODE DDN7KB
ERROR CODE DDN7KB (BLADE KNOB PITCH SWITCH: SHORT CIRCUIT)
Action code Error code Blade knob pitch switch: Short circuit
Trouble
E02 DDN7KB (Steering and transmission controller system)
Contents of
• Signals of two systems of blade knob pitch switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
appears on • Blade knob pitch does not function. (Operating blade pitch causes tilt operation.)
machine
Related • Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input signal)
• Method of reproducing error code: Turn starting switch ON (and operate blade knob pitch switch).

Blade pitch upper side switch
Defective blade pitch upper WNBU (male)
Max. 1z Min. 1Mz
(2) – (3)
Resistance between
Min. 1Mz Max. 1z
(2) – (1)
Blade pitch lower side switch
Defective blade pitch lower WNBL (female)
Max. 1z Min. 1Mz
(2) – (3)
Resistance between
Possible causes Min. 1Mz Max. 1z
(2) – (1)
state
(female) (10) – WNBU (female) (3) with chas- Resistance Min. 1Mz
Short circuit with chassis sis ground
(Contact with ground circuit) (female) (20) – WNBU (female) (1) – WNBL Resistance Min. 1Mz
(male) (1) with chassis ground
Short circuit of wiring harness between WNBU
(female) (2) – WNBL (male) (3) with chassis Resistance Min. 1Mz
ground
Blade pitch both side switch
STC1, STC3
4
Max. 1V 5 – 11V
STC3 (10) – STC1 (4)
Voltage between
5 – 11V Max. 1V
STC3 (20) – STC1 (4)
20-514 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DDN7KB
Circuit diagram related to blade knob pitch switch
D155AX-5 20-515
(2)
TROUBLESHOOTING ERROR CODE DDQ2KA DD14KA, ERROR CODE DDQ2KB DD14KB
ERROR CODE DDQ2KA DD14KA (TRAVEL LOCK SWITCH: DISCONNECTION IN WIRING)

a See DD14KA.
ERROR CODE DDQ2KB DD14KB (TRAVEL LOCK SWITCH: SHORT CIRCUIT)

a See DD14KB.
20-516 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DGE2KX
ERROR CODE DGE2KX (ENGINE COOLANT TEMPERATURE SENSOR (FOR HIGH

TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE)
Action code Error code Engine coolant temperature sensor (for high temperature):
Trouble
— DGE2KX Input signal is out of normal range (Engine controller system)
Contents of
• High engine coolant temperature sensor signal is out of normal range.
trouble
Action of • Fixes coolant temperature signal output at 90ºC.
Problem that • Monitor panel does not display engine coolant temperature normally.
• Engine coolant temperature (ºC) can be checked in monitoring mode.
Related
(Code 04102: Engine coolant temperature (High temperature side))
information

Defective high engine without turning starting switch ON.
coolant temperature sensor TWH (male) Resistance
1
(Internal disconnection or
short circuit) Between (1) – (2) 3.5k – 90kz
Between (1), (2) – chassis ground Min. 1Mz
Possible causes 2 Resistance Max. 1z
wiring or defective contact in TWH (female) (1)
and standard connector) Wiring harness between EGC2 (female) (39) – Resistance Max. 1z
value in normal TWH (female) (2)
3 ground in wiring harness Short circuit of wiring harness between EGC2
(Contact with ground circuit) (female) (27) – TWH (female) (1) with chassis Resistance Min. 1Mz
ground
4 Defective engine controller EGC2 (female) Resistance
Between (27) – (39) 3.5k – 90kz
Circuit diagram related to high engine coolant temperature sensor
D155AX-5 20-517
(5)
TROUBLESHOOTING ERROR CODE DGE3L6
ERROR CODE DGE3L6 (ENGINE COOLANT TEMPERATURE SENSOR (FOR LOW

TEMPERATURE): OPERATION STATE AND STOP STATE OF ENGINE DO
NOT AGREE WITH SIGNALS)
Action code Error code Engine coolant temperature sensor (for low temperature):
Trouble Operation state and stop state of engine do not agree with signals
E02 DGE3L6 (Engine controller system)
Contents of
• Low engine coolant temperature sensor signal is out of normal range.
trouble
Action of
controller
Problem that
• Exhaust gas color is bad at low temperature.
appears on
• Engine does not start easily at low temperature.
machine
• Engine coolant temperature (ºC) can be checked in monitoring mode.
Related
(Code 04104: Engine coolant temperature (Low temperature side))
information

Defective low engine coolant without turning starting switch ON.
temperature sensor TWL (male) Resistance
1
short circuit) Between (1) – (2) 0.3k – 9kz
wiring or defective contact in TWL (female) (1)
and standard connector) Wiring harness between EGC2 (female) (39) – Resistance Max. 1z
value in normal TWL (female) (2)
(Contact with ground circuit) (female) (37) – TWL (female) (1) with chassis Resistance Min. 1Mz
ground
Between (37) – (39) 0.3k – 9kz
Circuit diagram related to low engine coolant temperature sensor
20-518 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DGE4KX
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF

NORMAL RANGE)
Action code Error code Fuel temperature sensor: Input signal is out of normal range
Trouble
— DGE4KX (Engine controller system)
Contents of
• Fuel temperature sensor signal is out of normal range.
trouble
Action of
• Operates with normal control.
controller
Problem that
appears on • Engine output lowers a little at low temperature.
machine
Related • Fuel temperature (ºC) can be checked in monitoring mode. (Code 04204: Fuel temperature)
information • Method of reproducing error code: Turn starting switch ON or start engine.

Defective fuel temperature without turning starting switch ON.
1 sensor (Internal disconnec- THL (male) Resistance
tion or short circuit) Between (A) – (B) 0.3k – 9kz
Between (A), (B) – chassis ground Min. 1Mz
wiring or defective contact in THL (female) (A)
Possible causes
THL (female) (B)
value in normal
(Contact with ground circuit) (female) (17) – THL (female) (A) with chassis Resistance Min. 1Mz
ground
Between (17) – (39) 0.3k – 9kz
Between (17), (39) –
Min. 1Mz
chassis ground
Circuit diagram related to fuel temperature sensor
D155AX-5 20-519
(5)
TROUBLESHOOTING ERROR CODE DGS1KX
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS

OUT OF NORMAL RANGE)
Action code Error code Hydraulic oil temperature sensor: Input signal is out of normal range
Trouble
— DGS1KX (Steering and transmission controller system)
Contents of
• Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
• Does not take any particular action.
controller
Problem that
appears on • Hydraulic oil temperature gauge of monitor panel may not display normally.
machine
• Hydraulic oil temperature (ºC) can be checked in monitoring mode.
Related
(Code 04401: Hydraulic oil temperature)
information

Defective hydraulic oil tem- without turning starting switch ON.
perature sensor (Internal
1 SDS (male) Resistance
disconnection or short cir-
Between (1) – (2) 1k – 50z
cuit)
wiring or defective contact in SDS (female) (1)
and standard SDS (female) (2)
state Short circuit with chassis without turning starting switch ON.
(Contact with ground circuit) (female) (9) – SDS (female) (1) with chassis Resistance Min. 1Mz
ground
Short circuit with power out troubleshooting.
4 source in wiring harness Short circuit of wiring harness between STC1
(Contact with 24V circuit) (female) (9) – SDS (female) (1) with chassis Voltage Max. 1V
ground
If no problem is found in causes 1 to 4, it is suspected that engine con-
5 troller, steering and transmission controller are defective. (Trouble-
shooting cannot be carried out since it is internal defect.)
20-520 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DGS1KX
Circuit diagram related to hydraulic oil temperature sensor
D155AX-5 20-521
(2)
TROUBLESHOOTING ERROR CODE DH21KB
ERROR CODE DH21KB (HYDRAULIC PUMP OIL PRESSURE SENSOR: DISCONNECTION

IN WIRING OR SHORT CIRCUIT)
Action code Error code Hydraulic pump oil pressure sensor:

Trouble Disconnection in wiring or short circuit
E01 DH21KB (Steering and transmission controller system)
Contents of • Signal voltage of hydraulic pump oil pressure sensor circuit is below 0.5V.
trouble • Signal voltage of hydraulic pump oil pressure sensor circuit is above 6.0V.
Action of
controller
Problem that
appears on • Hydraulic pump oil pressure cannot be monitored.
machine
• If the trouble of error code [DH22KA] or [DH22KB] occurs, this error code is also displayed and record-
ed.
Related
• Input (Voltage) from hydraulic pump oil pressure sensor can be checked in monitoring mode.
information
(Code 70701: Voltage of hydraulic pump oil pressure sensor)

When error code [DH22KA]
Possible causes
1 is also displayed Carry out troubleshooting for error code [DH22KA].
and standard
(Disconnection)
value in normal
state When error code [DH22KB]
2 is also displayed Carry out troubleshooting for error code [DH22KB].
(Short circuit)
20-522 D155AX-5
(2)
D155AX-5 20-523
(2)
TROUBLESHOOTING ERROR CODE DH22KA
ERROR CODE DH22KA (HYDRAULIC PUMP OIL PRESSURE SENSOR: DISCONNECTION

IN WIRING)
Action code Error code Hydraulic pump oil pressure sensor: Disconnection in wiring
Trouble
E01 DH22KA (Steering and transmission controller system)
Contents of
• Signal voltage of hydraulic pump oil pressure sensor circuit is below 0.5V.
trouble
Action of
controller
Problem that
machine
• When this error happens, both of DH22KA and DH21KB are displayed and recorded.
Related • Input (Voltage) from hydraulic pump oil pressure sensor can be checked in monitoring mode.
information (Code 70701: Voltage of hydraulic pump oil pressure sensor)

Defective 24V power source See if error code [DAQ6KK] or [DB36KK] is displayed. If it is displayed,
1
system carry out troubleshooting for it first.
aPrepare with starting switch OFF, turn starting switch ON or start en-
gine and then carry out troubleshooting.
HHP Voltage
Defective hydraulic pump oil Between (B) – (A) Power source 20 – 30V
2 pressure sensor (Internal Between (C) – (A) Signal 0.5 – 6.0V
trouble) The voltage of the pressure sensor is measured with the wiring har-
ness connected. Accordingly, if the voltage is abnormal, check the wir-
ing harness and controller to confirm that there is not another cause of
the failure before judging the troubleshooting result.
value in normal Disconnection in wiring Wiring harness between STC1 (female) (16) –
state Resistance Max. 1z
harness (Disconnection in HHP (female) (B)
3
Resistance Max. 1z
connector) HHP (female) (A)
Resistance Max. 1z
HHP (female) (C)
(Contact with ground circuit) (female) (1) – HHP (female) (C) with chassis Resistance Min. 1Mz
ground
If no problem is found in causes 1 to 4, it is suspected that engine con-
5 troller, steering and transmission controller are defective. (Trouble-
shooting cannot be carried out since it is internal defect.)
20-524 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DH22KA
Circuit diagram related to hydraulic pump oil pressure sensor
D155AX-5 20-525
(2)
ERROR CODE DH22KB (HYDRAULIC PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT)
Action code Error code Hydraulic pump oil pressure sensor: Short circuit
Trouble
E01 DH22KB (Steering and transmission controller system)
Contents of
• Signal voltage of hydraulic pump oil pressure sensor circuit is below 6.0V.
trouble
Action of
controller
Problem that
machine
• When this error happens, DH21KB is also displayed and recorded.
Related • Input (Voltage) from hydraulic pump oil pressure sensor can be checked in monitoring mode.
information (Code 70701: Voltage of hydraulic pump oil pressure sensor)

1
HHP Voltage
Defective hydraulic pump oil Between (B) – (A) Power source 20 – 30V
2 pressure sensor (Internal Between (C) – (A) Signal 0.5 – 6.0V
Possible causes
and standard ness connected. Accordingly, if the voltage is abnormal, check the wir-
value in normal ing harness and controller to confirm that there is not another cause of
state the failure before judging the troubleshooting result.
Short circuit with power
3 source in wiring harness Voltage Max. 1V
(female) (1) – HHP (female) (C)
(Contact with 24V circuit)
Voltage Max. 1V
(female) (21) – HHP (female) (A)
If no problem is found in causes 1 to 3, it is suspected that steering and
4 transmission controller are defective. (Troubleshooting cannot be car-
ried out since it is internal defect.)
20-526 D155AX-5
(2)
Circuit diagram related to hydraulic pump oil pressure sensor
D155AX-5 20-527
(2)
TROUBLESHOOTING ERROR CODE DH30KX
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL

RANGE)
Action code Error code Boost pressure sensor: Input is out of normal range
Trouble
E02 DH30KX (Engine controller system)
Contents of
• Boost pressure sensor signal is out of normal range.
trouble
Action of
controller
Problem that
appears on • Machine is not affected seriously.
machine
• Special adapter (799-601-9420) is necessary for troubleshooting for boost pressure sensor.
Related
• Boost pressure (pressure) can be checked in monitoring mode. (Code 36500: Boost pressure)
information

PIM Voltage
Between (3) – (1) Power source 4.6 – 5.4V
Defective boost pressure
1 Between (2) – (1) Signal 0.3 – 4.7V
sensor (Internal trouble)
The voltage of the pressure sensor is measured with the wiring har-
Disconnection in wiring Wiring harness between EGC2 (female) (19) –
Resistance Max. 1z
harness (Disconnection in PIM (female) (3)
2
wiring or defective contact in Wiring harness between EGC2 (female) (20) –
Resistance Max. 1z
connector) PIM (female) (2)
Resistance Max. 1z
PIM (female) (1)
(female) (19) – PIM (female) (3) with chassis Resistance Min. 1Mz
state 3 ground in wiring harness
ground
(female) (20) – PIM (female) (2) with chassis Resistance Min. 1Mz
ground
(female) (19) – PIM (female) (3) with chassis Voltage Max. 1V
Short circuit with power ground
4 source in wiring harness Short circuit of wiring harness between EGC2
(Contact with 24V circuit) (female) (20) – PIM (female) (2) with chassis Voltage Max. 1V
ground
(female) (39) – PIM (female) (1) with chassis Voltage Max. 1V
ground
Between (19) – (39) 4.6 – 5.4V
Between (20) – (39) 0.3 – 4.7V
20-528 D155AX-5
(2)
Circuit diagram related to boost presure sensor
D155AX-5 20-529
(2)
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL
RANGE)
Action code Error code Common rail pressure sensor: Input is out of normal range
Trouble
CALL E03 DH40KX (Engine controller system)
Contents of
• Common rail pressure sensor signal is out of normal range.
trouble
Problem that
appears on
machine
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail pressure sensor.
Related • Common rail pressure (pressure) can be checked in monitoring mode.
information (Code 36400: Common rail pressure)

PFUEL Voltage
Defective common rail Between (3) – (1) Power source 4.6 – 5.4V
1 pressure sensor (Internal Between (2) – (3) Signal 0.3 – 4.7V
Resistance Max. 1z
harness (Disconnection in PFUEL (female) (1)
2
Resistance Max. 1z
connector) PFUEL (female) (2)
Resistance Max. 1z
PFUEL (female) (3)
(female) (19) – PFUEL (female) (1) with chas- Resistance Min. 1Mz
state 3 ground in wiring harness
sis ground
(female) (40) – PFUEL (female) (2) with chas- Resistance Min. 1Mz
sis ground
(female) (19) – PFUEL (female) (1) with chas- Voltage Max. 1V
Short circuit with power sis ground
(Contact with 24V circuit) (female) (40) – PFUEL (female) (2) with chas- Voltage Max. 1V
sis ground
(female) (39) – PFUEL (female) (3) with chas- Voltage Max. 1V
sis ground
Between (19) – (39) 4.6 – 5.4V
Between (40) – (39) 0.3 – 4.7V
20-530 D155AX-5
(2)
Circuit diagram related to common rail presure sensor
D155AX-5 20-531
(2)
TROUBLESHOOTING ERROR CODE DHH3KA
ERROR CODE DHH3KA (HSS PUMP OIL PRESSURE SENSOR A: DISCONNECTION IN

WIRING)
Action code Error code HSS pump oil pressure sensor A: Disconnection in wiring
Trouble
CALL E03 DHH3KA (Steering and transmission controller system)
Contents of
• Signal voltage of HSS pump oil pressure sensor A is below 0.5V.
trouble
Action of
controller
Problem that • HSS pump oil pressure (A side) cannot be monitored.
• Input (Voltage) from HSS pump oil pressure sensor A can be checked in monitoring mode.
Related
(Code 50503: Voltage of HSS pump oil pressure sensor A)
information

1
HSPA Voltage
Defective HSS pump oil Between (B) – (A) Power source 20 – 30V
2 pressure sensor A (Internal Between (C) – (A) Signal 0.5 – 6.0V
disconnection) The voltage of the pressure sensor is measured with the wiring har-
Possible causes
and standard Disconnection in wiring Wiring harness between STC1 (female) (16) –
Resistance Max. 1z
value in normal harness (Disconnection in HSPA (female) (B)
3
state wiring or defective contact in Short circuit of wiring harness between STC1
Resistance Max. 1z
connector) (female) (21) – HSPA (female) (A)
Resistance Max. 1z
HSPA (female) (C)
(female) (16) – HSPA (female) (B) with chassis Resistance Min. 1Mz
ground
(female) (20) – HSPA (female) (C) with chassis Resistance Min. 1Mz
ground
20-532 D155AX-5
(2)
Circuit diagram related to HSS pump oil pressure sensor A
D155AX-5 20-533
(2)
TROUBLESHOOTING ERROR CODE DHH3KB
ERROR CODE DHH3KB (HSS PUMP OIL PRESSURE SENSOR A: SHORT CIRCUIT)
Action code Error code HSS pump oil pressure sensor A: Short circuit
Trouble
CALL E03 DHH3KB (Steering and transmission controller system)
Contents of
• Signal voltage of HSS pump oil pressure sensor A is above 6.0V.
trouble
Action of
controller
Problem that • HSS pump oil pressure (A side) cannot be monitored.
• Input (Voltage) from HSS pump oil pressure sensor A can be checked in monitoring mode.
Related
(Code 50503: Voltage of HSS pump oil pressure sensor A)
information

1
HSPA Voltage
2 pressure sensor A (Internal Between (C) – (A) Signal 0.5 – 6.0V
Possible causes
(female) (20) – HSPA (female) (C)
Voltage Max. 1V
(female) (21) – HSPA (female) (A)
20-534 D155AX-5
(2)
Circuit diagram related to HSS pump oil pressure sensor A
D155AX-5 20-535
(2)
ERROR CODE DHH4KA (HSS PUMP OIL PRESSURE SENSOR B: DISCONNECTION IN

WIRING)
Action code Error code HSS pump oil pressure sensor B: Disconnection in wiring
Trouble
CALL E03 DHH4KA (Steering and transmission controller system)
Contents of
• Signal voltage of HSS pump oil pressure sensor B is below 0.5V.
trouble
Action of
controller
Problem that • HSS pump oil pressure (B side) cannot be monitored.
• Input (Voltage) from HSS pump oil pressure sensor B can be checked in monitoring mode.
Related
(Code 50504: Voltage of HSS pump oil pressure sensor B)
information

1
HSPB Voltage
2 pressure sensor B (Internal Between (C) – (A) Signal 0.5 – 6.0V
Possible causes
and standard Disconnection in wiring Wiring harness between STC1 (female) (16) –
Resistance Max. 1z
value in normal harness (Disconnection in HSPB (female) (B)
3
state wiring or defective contact in Short circuit of wiring harness between STC1
Resistance Max. 1z
connector) (female) (21) – HSPB (female) (A)
Resistance Max. 1z
HSPB (female) (C)
(female) (16) – HSPB (female) (B) with chassis Resistance Min. 1Mz
ground
(female) (14) – HSPB (female) (C) with chassis Resistance Min. 1Mz
ground
20-536 D155AX-5
(2)
Circuit diagram related to HSS pump oil pressure sensor B
D155AX-5 20-537
(2)
ERROR CODE DHH4KB (HSS PUMP OIL PRESSURE SENSOR B: SHORT CIRCUIT)
Action code Error code HSS pump oil pressure sensor B: Short circuit
Trouble
CALL E03 DHH4KB (Steering and transmission controller system)
Contents of
• Signal voltage of HSS pump oil pressure sensor B is above 6.0V.
trouble
Action of
controller
Problem that • HSS pump oil pressure (B side) cannot be monitored.
• Input (Voltage) from HSS pump oil pressure sensor B can be checked in monitoring mode.
Related
(Code 50504: Voltage of HSS pump oil pressure sensor B)
information

1
HSPB Voltage
2 pressure sensor B (Internal Between (C) – (A) Signal 0.5 – 6.0V
Possible causes
(female) (14) – HSPB (female) (C)
Voltage Max. 1V
(female) (21) – HSPB (female) (A)
20-538 D155AX-5
(2)
Circuit diagram related to HSS pump oil pressure sensor B
D155AX-5 20-539
(2)
TROUBLESHOOTING ERROR CODE DK10KX
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE)
Action code Error code Fuel control dial: Input is out of normal range
Trouble
CALL E03 DK10KX (Engine controller system)
Contents of
• Signal voltage of fuel control dial is out of normal range.
trouble
Action of
• Continues controlling with signal of decelerator pedal potentiometer.
controller
Problem that
appears on
machine
• Inputting from fuel control dial (Voltage) can be checked in monitoring mode.
Related
(Code 03000: Voltage of fuel control dial)
information

Defective fuel control dial DIAL (male) Resistance
1 (Internal disconnection or
Between (1) – (3) 4.0 – 6.0kz
short circuit)
Between (1) – (2) 0.25 – 7.0kz
Between (2) – (3) 0.25 – 7.0kz
Resistance Max. 1z
harness (Disconnection in DIAL (female) (1)
2
Resistance Max. 1z
connector) DIAL (female) (2)
Resistance Max. 1z
DIAL (female) (3)
Possible causes Short circuit of wiring harness between EGC2
and standard (female) (9) – DIAL (female) (1) with chassis Resistance Min. 1Mz
value in normal ground
state Short circuit of wiring harness between EGC2
(female) (10) – DIAL (female) (2) with chassis Resistance Min. 1Mz
ground
(female) (9) – DIAL (female) (1) with chassis Voltage Max. 1V
(Contact with 24V circuit) (female) (10) – DIAL (female) (2) with chassis Voltage Max. 1V
ground
(female) (29) – DIAL (female) (3) with chassis Voltage Max. 1V
ground
Between (9) – (29) 4.6 – 5.4V
Between (10) – (29) 0.5 – 4.5V
20-540 D155AX-5
(2)
Circuit diagram related to fuel control dial
D155AX-5 20-541
(2)
ERROR CODE DK12KX (DECELERATION PEDAL POTENTIOMETER: INPUT IS OUT OF

NORMAL RANGE)
Action code Error code Deceleration pedal potentiometer: Input is out of normal range
Trouble
CALL E03 DK12KX (Engine controller system)
Contents of
• Signal voltage of deceleration pedal potentiometer is out of normal range.
trouble
Action of
• Continues controlling with signal of fuel control dial.
controller
Problem that
appears on
machine
• Input (Voltage) from deceleration pedal potentiometer can be checked in monitoring mode.
Related
(Code 50001: Voltage of deceleration pedal potentiometer)
information

Defective deceleration pedal without turning starting switch ON.
potentiometer (Internal DCL (male) Resistance
1
disconnection or short Between (A) – (C) 4.0 – 6.0kz
circuit) Between (A) – (B) 0.25 – 7.0kz
Between (B) – (C) 0.25 – 7.0kz
Resistance Max. 1z
harness (Disconnection in DCL (female) (A)
2
Resistance Max. 1z
connector) DCL (female) (B)
Resistance Max. 1z
DCL (female) (C)
Possible causes Short circuit of wiring harness between EGC2
and standard (female) (9) – DCL (female) (A) with chassis Resistance Min. 1Mz
(female) (38) – DCL (female) (B) with chassis Resistance Min. 1Mz
ground
(female) (9) – DCL (female) (A) with chassis Voltage Max. 1V
(Contact with 24V circuit) (female) (38) – DCL (female) (B) with chassis Voltage Max. 1V
ground
(female) (29) – DCL (female) (C) with chassis Voltage Max. 1V
ground
Between (9) – (29) 4.6 – 5.4V
Between (38) – (29) 0.3 – 4.5V
20-542 D155AX-5
(2)
Circuit diagram related to deceleration pedal potentiometer
D155AX-5 20-543
(2)
TROUBLESHOOTING ERROR CODE DK30KA
ERROR CODE DK30KA (STEERING LEVER POTENTIOMETER 1: DISCONNECTION IN

WIRING)
Action code Error code Steering lever potentiometer 1: Disconnection in wiring

Trouble
CALL E03 DK30KA (Steering and transmission controller system)
Contents of
• Signal voltage of steering lever potentiometer 1 system is below 0.5V.
trouble
Action of
• Continues controlling with signal of steering lever potentiometer 2 system.
controller
Problem that
appears on
machine
• Input (Voltage) from steering lever potentiometer 1 can be checked in monitoring mode.
Related
(Code 50300: Voltage of steering lever potentiometer 1)
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).

Defective 5V sensor power See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
1
source system carry out troubleshooting for it first.
Defective steering lever without turning starting switch ON.
potentiometer 1 (Internal TL2 (male) PCCS lever Resistance
2
disconnection or short Between (5) – (8) 3.2kz ± 20%
circuit) Between (5) – (7) Neutral 1.6kz ± 20%
Between (7) – (8) 1.6kz ± 20%
and standard harness (Disconnection in Wiring harness between STC1 (female) (22) –
wiring or defective contact in TL2 (female) (5)
state connector) Wiring harness between STC1 (female) (2) –
Resistance Max. 1z
TL2 (female) (7)
(Contact with ground circuit) (female) (2) – TL2 (female) (7) H with chassis Resistance Min. 1Mz
ground
5
Between (2) – (21) 0.5 – 4.5V
20-544 D155AX-5
(2)
Circuit diagram related to steering lever potentiometer
D155AX-5 20-545
(2)
TROUBLESHOOTING ERROR CODE DK30KB
ERROR CODE DK30KB (STEERING LEVER POTENTIOMETER 1: SHORT CIRCUIT)
Action code Error code Steering lever potentiometer 1: Short circuit

Trouble
CALL E03 DK30KB (Steering and transmission controller system)
Contents of
• Signal voltage of steering lever potentiometer 1 system is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
2
Possible causes circuit) Between (5) – (7) Neutral 1.6kz ± 20%
and standard Between (7) – (8) 1.6kz ± 20%
value in normal aPrepare with starting switch OFF, then turn starting switch ON and
state Short circuit with power carry out troubleshooting.
(Contact with 24V circuit) (female) (2) – TL2 (female) (7) with chassis Voltage Max. 1V
ground
4
Between (2) – (21) 0.5 – 4.5V
20-546 D155AX-5
(2)
D155AX-5 20-547
(2)
TROUBLESHOOTING ERROR CODE DK30KX, ERROR CODE DK30KZ
ERROR CODE DK30KX (STEERING LEVER POTENTIOMETER: INPUT SIGNAL IS OUT OF

NORMAL RANGE)
Action code Error code Steering lever potentiometer: Input signal is out of normal range
Trouble
CALL E04 DK30KX (Steering and transmission controller system)
Contents of • Either of error codes [DK30KA] and [DK30KB] of steering lever potentiometer systems 1 and 2 and er-
trouble ror codes [DK31KA] and [DK31KB] are displayed simultaneously.
Problem that
appears on
machine
• Input (Voltage) from steering lever potentiometers can be checked in monitoring mode.
Related (Code 50300: Voltage of steering lever potentiometer 1)
information (Code 50301: Voltage of steering lever potentiometer 2)

and standard
value in normal Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
state
ERROR CODE DK30KZ (STEERING LEVER POTENTIOMETER: DOUBLE FAILURE)
Action code Error code Steering lever potentiometer: Double failure

Trouble
CALL E04 DK30KZ (Steering and transmission controller system)
• When starting switch is turned ON, either of steering lever potentiometer systems 1 and 2 is abnormal,
Contents of
then either of error codes [DK30KA] and [DK30KB] and error codes [DK31KA] and [DK31KB] are dis-
trouble
played simultaneously.
Problem that
appears on
machine

and standard
state
20-548 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DK30L8
ERROR CODE DK30L8 (STEERING LEVER POTENTIOMETER: ANALOG SIGNALS DO

NOT AGREE WITH EACH OTHER)
Action code Error code Steering lever potentiometer: Analog signals do not agree with each
Trouble
CALL E03 DK30L8 other (Steering and transmission controller system)
Contents of • Total signal voltage of each of steering lever potentiometer 1 system and 2 system is below 4.41V or
trouble above 5.59V.
Action of
• Continues controlling with signal of normal one of steering lever potentiometer 1 system and 2.
controller
Problem that
appears on
machine

and standard
state
D155AX-5 20-549
(2)
ERROR CODE DK31KA (STEERING LEVER POTENTIOMETER 2: DISCONNECTION IN

WIRING)
Action code Error code Steering lever potentiometer 2: Disconnection in wiring

Trouble
Contents of
• Signal voltage of steering lever potentiometer 2 system is below 0.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective sensor power See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
1
2
circuit) Between (5) – (6) Neutral 1.6kz ± 20%
Between (6) – (8) 1.6kz ± 20%
Resistance Max. 1z
TL2 (female) (6)
(Contact with ground circuit) (female) (19) – TL2 (female) (6) with chassis Resistance Min. 1Mz
ground
5
Between (19) – (21) 0.5 – 4.5V
20-550 D155AX-5
(2)
D155AX-5 20-551
(2)
ERROR CODE DK31KB (STEERING LEVER POTENTIOMETER 2: SHORT CIRCUIT)
Action code Error code Steering lever potentiometer 2: Short circuit

Trouble
Contents of
• Signal voltage of steering lever potentiometer 2 system is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective sensor power See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
1
2
Possible causes circuit) Between (5) – (6) Neutral 1.6kz ± 20%
(Contact with 24V circuit) (female) (19) – TL2 (female) (6) with chassis Resistance Max. 1V
ground
4
Between (19) – (21) 0.5 – 4.5V
20-552 D155AX-5
(2)
D155AX-5 20-553
(2)
ERROR CODE DK40KA (BRAKE PEDAL POTENTIOMETER: DISCONNECTION IN WIRING)
Action code Error code Brake pedal potentiometer: Disconnection in wiring

Trouble
E01 DK40KA (Steering and transmission controller system)
Contents of
• Signal voltage of brake pedal potentiometer is below 0.5V.
trouble
Action of
• Cannot recognize location of brake pedal.
controller
Problem that
appears on • Automatic shift-down function does not work normally.
machine
• Input (Voltage) from brake pedal potentiometer can be checked in monitoring mode.
Related
(Code 50400: Voltage of brake pedal potentiometer)
information
• Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake pedal without turning starting switch ON.
potentiometer (Internal BRK (male) Resistance
2
disconnection or short Between (A) – (C) 4.0 – 6.0kz
circuit) Between (A) – (B) 0.25 – 7.0kz
Between (B) – (C) 0.25 – 7.0kz
Resistance Max. 1z
harness (Disconnection in BRK (female) (C)
Possible causes 3
value in normal connector) BRK (female) (B)
state Wiring harness between STC1 (female) (21) –
Resistance Max. 1z
BRK (female) (A)
(female) (22) – BRK (female) (C) with chassis Resistance Min. 1Mz
ground
(female) (3) – BRK (female) (B) with chassis Resistance Min. 1Mz
ground
5
Between (3) – (21) 0.5 – 4.5V
20-554 D155AX-5
(2)
Circuit diagram related to brake pedal potentiometer
D155AX-5 20-555
(2)
ERROR CODE DK40KB (BRAKE PEDAL POTENTIOMETER: SHORT CIRCUIT)
Action code Error code Brake pedal potentiometer: Short circuit

Trouble
E01 DK40KB (Steering and transmission controller system)
Contents of
• Signal voltage of brake pedal potentiometer is above 4.5V.
trouble
Action of
• Cannot recognize location of brake pedal.
controller
Problem that
appears on • Automatic shift-down function does not work normally.
machine
• Input (Voltage) from brake pedal potentiometer can be checked in monitoring mode.
Related
(Code 50400: Voltage of brake pedal potentiometer)
information
• Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake pedal without turning starting switch ON.
potentiometer (Internal BRK (male) Resistance
2
disconnection or short (A) – (C) 4.0 – 6.0kz
circuit) (A) – (B) 0.25 – 7.0kz
(B) – (C) 0.25 – 7.0kz
Possible causes
and standard aPrepare with starting switch OFF, then turn starting switch ON and
value in normal carry out troubleshooting.
state Short circuit of wiring harness between STC1
(female) (3) – BRK (female) (B) with chassis Voltage Max. 1V
3 source in wiring harness
ground
(female) (21) – BRK (female) (A) with chassis Voltage Max. 1V
ground
4
Between (3) – (21) 0.5 – 4.5V
20-556 D155AX-5
(2)
Circuit diagram related to brake pedal potentiometer
D155AX-5 20-557
(2)
TROUBLESHOOTING ERROR CODE DK55KX, ERROR CODE DK55KZ
ERROR CODE DK55KX (FORWARD-REVERSE LEVER POTENTIOMETER: INPUT SIGNAL

IS OUT OF NORMAL RANGE)
Action code Error code Forward-reverse lever potentiometer: Input signal is out of normal
Trouble
CALL E04 DK55KX range (Steering and transmission controller system)
Contents of • Either of error codes [DK56KA] and [DK56KB] of forward-reverse lever potentiometer systems 1 and 2
trouble and either of error codes [DK57KA] and [DK57KB] are displayed simultaneously.
Problem that
appears on
machine
• Input (Voltage) from forward-reverse lever potentiometers can be checked in monitoring mode.
(Code 50300: Voltage of forward-reverse lever potentiometer 1)
Related
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

and standard
state
ERROR CODE DK55KZ (FORWARD-REVERSE LEVER POTENTIOMETER: DOUBLE

FAILURE)
Action code Error code Forward-reverse lever potentiometer: Double failure

Trouble
CALL E04 DK55KZ (Steering and transmission controller system)
• When starting switch is turned ON, either of forward-reverse lever potentiometer systems 1 and 2 is
Contents of
abnormal, then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and
trouble
[DK57KB] are displayed simultaneously.
Problem that
appears on
machine
Related
information
verse travel).

and standard
state
20-558 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DK55L8
ERROR CODE DK55L8 (FORWARD-REVERSE LEVER POTENTIOMETER: ANALOG

SIGNALS DO NOT AGREE WITH EACH OTHER)
Action code Error code Forward-reverse lever potentiometer: Analog signals do not agree with
Trouble
CALL E03 DK55L8 each other (Steering and transmission controller system)
Contents of • Total signal voltage of each of forward-reverse lever potentiometer 1 system and 2 system is below
trouble 4.41V or above 5.59V.
Action of
• Continues controlling with signal of normal one of forward-reverse lever potentiometer 1 system and 2.
controller
Problem that
appears on
machine
Related
information
verse travel).

and standard
state
D155AX-5 20-559
(2)
ERROR CODE DK56KA (FORWARD-REVERSE LEVER POTENTIOMETER 1:

DISCONNECTION IN WIRING)
Action code Error code Forward-reverse lever potentiometer 1: Disconnection in wiring

Trouble
Contents of
• Signal voltage of forward-reverse lever potentiometer 1 system is below 0.5V.
trouble
Action of
• Continues controlling with signal of forward-reverse lever potentiometer 2 system.
controller
Problem that
appears on
machine
• Input (Voltage) from forward-reverse lever potentiometer 1 can be checked in monitoring mode.
Related (Code 50200: Voltage of forward-reverse lever potentiometer 1)
information • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

1
Defective forward-reverse without turning starting switch ON.
lever potentiometer 1 TL2 (male) PCCS lever Resistance
2
(Internal disconnection or Between (4) – (1) 3.2kz ± 20%
short circuit) Between (4) – (3) Neutral 1.6kz ± 20%
Between (3) – (1) 1.6kz ± 20%
Resistance Max. 1z
TL2 (female) (3)
ground
5
Between (13) – (21) 0.5 – 4.5V
20-560 D155AX-5
(2)
Circuit diagram related to forward-reverse lever potentiometer
D155AX-5 20-561
(2)
ERROR CODE DK56KB (FORWARD-REVERSE LEVER POTENTIOMETER 1: SHORT

CIRCUIT)
Action code Error code Forward-reverse lever potentiometer 1: Short circuit

Trouble
Contents of
• Signal voltage of forward-reverse lever potentiometer 1 system is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

Defective 5V sensor power See if error code [DB35KK] [DAQ5KK] is displayed. If it is displayed,
1
2
Possible causes short circuit) Between (4) – (3) Neutral 1.6kz ± 20%
ground
4
Between (13) – (21) 0.5 – 4.5V
20-562 D155AX-5
(2)
D155AX-5 20-563
(2)
ERROR CODE DK57KA (FORWARD-REVERSE LEVER POTENTIOMETER 2:

DISCONNECTION IN WIRING)
Action code Error code Forward-reverse lever potentiometer 2: Disconnection in wiring

Trouble
Contents of
• Signal voltage of forward-reverse lever potentiometer 2 system is below 0.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

Defective 5V sensor power See if error code [DB35KK] [DAQ5KK] is displayed. If it is displayed,
1
2
short circuit) Between (4) – (2) Neutral 1.6kz ± 20%
Between (2) – (1) 1.6kz ± 20%
Resistance Max. 1z
TL2 (female) (2)
ground
5
Between (7) – (21) 0.5 – 4.5V
20-564 D155AX-5
(2)
D155AX-5 20-565
(2)
ERROR CODE DK57KB (FORWARD-REVERSE LEVER POTENTIOMETER 2: SHORT

CIRCUIT)
Action code Error code Forward-reverse lever potentiometer 2: Short circuit

Trouble
Contents of
• Signal voltage of forward-reverse lever potentiometer 2 system is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

harness (Disconnection in See if error code [DB35KK] [DAQ5KK] is displayed. If it is displayed,
1
wiring or defective contact in carry out troubleshooting for it first.
connector)
2
Possible causes (Internal disconnection or Between (4) – (1) 3.2kz ± 20%
and standard short circuit) Between (4) – (2) Neutral 1.6kz ± 20%
value in normal Between (2) – (1) 1.6kz ± 20%
state aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power carry out troubleshooting.
ground
4
Between (7) – (21) 0.5 – 4.5V
20-566 D155AX-5
(2)
D155AX-5 20-567
(2)
TROUBLESHOOTING ERROR CODE DKH1KA
ERROR CODE DKH1KA (BODY PITCH ANGLE SENSOR: DISCONNECTION IN WIRING)
Action code Error code Body pitch angle sensor: Disconnection in wiring
Trouble
CALL E03 DKH1KA (Steering and transmission controller system)
Contents of
• Signal voltage of body pitch angle sensor is below 0.15V.
trouble
Action of
• Cannot recognize body pitch angle.
controller
Problem that • Shocks are made when gear is shifted on slope and when machine is steered on level place.
• Input (Voltage) from body pitch angle sensor can be checked in monitoring mode.
Related
(Code 60100: Voltage of body pitch angle sensor)
information

Defective 24V power source See if error code [DAQ6KK] [DB36KK] is displayed. If it is displayed,
1
PT2 Voltage
Between (C) – (A) Power source 20 – 30V
Defective body pitch angle
2 Between (B) – (A) Signal 0.15 – 4.85V
The voltage of the body pitch angle sensor is measured with the wiring
harness connected. Accordingly, if the voltage is abnormal, check the
wiring harness and controller to confirm that there is not another cause
of the failure before judging the troubleshooting result.
value in normal Disconnection in wiring Wiring harness between STC1 (female) (16) –
harness (Disconnection in PT2 (female) (C)
3
Resistance Max. 1z
connector) PT2 (female) (B)
Resistance Max. 1z
PT2 (female) (A)
(Contact with ground circuit) (female) (8) – PT2 (female) (B) with chassis Resistance Min. 1Mz
ground
20-568 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DKH1KA
Circuit diagram related to body pitch angle sensor
D155AX-5 20-569
(2)
TROUBLESHOOTING ERROR CODE DKH1KB
ERROR CODE DKH1KB (BODY PITCH ANGLE SENSOR: SHORT CIRCUIT)
Action code Error code Body pitch angle sensor: Short circuit
Trouble
CALL E03 DKH1KB (Steering and transmission controller system)
Contents of
• Signal voltage of body pitch angle sensor is above 4.85V.
trouble
Action of
• Cannot recognize body pitch angle.
controller
Problem that • Shocks are made when gear is shifted on slope and when machine is steered on level place.
• Input (Voltage) from body pitch angle sensor can be checked in monitoring mode.
Related
(Code 60100: Voltage of body pitch angle sensor)
information

Defective 24V power source See if error code [DAQ6KK] [DB36KK] is displayed. If it is displayed,
1
PT2 Voltage
Between (C) – (A) Power source 20 – 30V
Defective body pitch angle
2 Between (B) – (A) Signal 0.15 – 4.85V
Possible causes The voltage of the body pitch angle sensor is measured with the wiring
and standard harness connected. Accordingly, if the voltage is abnormal, check the
value in normal wiring harness and controller to confirm that there is not another cause
state of the failure before judging the troubleshooting result.
(Contact with 24V circuit) (female) (8) – PT2 (female) (B) with chassis Voltage Max. 1V
ground
20-570 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DKH1KB
Circuit diagram related to body pitch angle sensor
D155AX-5 20-571
(2)
TROUBLESHOOTING ERROR CODE DLE3LC
ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: MALFUNCTION)

Trouble Engine Ne speed sensor: Malfunction (Engine controller system)
CALL E03 DLE3LC
Contents of
• Engine speed cannot be recognized by signal of engine Ne speed sensor.
trouble
Problem that • Engine speed may become unstable or engine may stop.
Related • Special adapter (799-601-9410) is necessary for troubleshooting for engine Ne speed sensor.

Defective engine Ne speed without turning starting switch ON.
1 sensor (Internal disconnec- NE (male) Resistance
tion or short circuit) Between (1) – (2) 85 – 210z
wiring or defective contact in NE (female) (2)
Resistance Max. 1z
Possible causes NE (female) (1)
(female) (36) – NE (female) (2) with chassis Resistance Min. 1Mz
ground
(female) (26) – NE (female) (1) with chassis Resistance Min. 1Mz
ground
Between (36) – (26) 85 – 210z
Between (26), (36) –
Min. 1Mz
chassis ground
Circuit diagram related to engine Ne speed sensor
20-572 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DLF1KA
ERROR CODE DLF1KA (TRANSMISSION BEVEL SPEED SENSOR: DISCONNECTION IN

WIRING)
Action code Error code Transmission bevel speed sensor: Disconnection in wiring
Trouble
E01 DLF1KA (Steering and transmission controller system)
Contents of
• Signal is not input from transmission bevel speed sensor.
trouble
Action of
• Assumes that transmission bevel speed is 0rpm.
controller
Problem that
• Transmission bevel speed cannot be monitored.
appears on
• Traction force cannot be calculated.
machine
• Transmission output (rpm) can be checked in monitoring mode.
Related
(Code 31400: Transmission speed)
information
• Method of reproducing error code: Start engine and travel machine actually.

Defective transmission bevel carry out troubleshooting.
1 speed sensor (Internal dis- TM1 (male) Resistance
connection or short circuit) Between (1) – (2) 500 – 1,000z
Possible causes harness (Disconnection in Wiring harness between STC2 (female) (30) –
and standard 2 Resistance Max. 1z
wiring or defective contact in TM1 (female) (1)
value in normal connector) Wiring harness between STC2 (female) (29) –
TM1 (female) (2)
(Contact with ground circuit) (female) (30) – TM1 (female) (1) with chassis Resistance Min. 1Mz
ground
Circuit diagram related to transmission bevel speed sensor
D155AX-5 20-573
(2)
TROUBLESHOOTING ERROR CODE DLH1LC
ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: MALFUNCTION)

Trouble Engine G speed sensor: Malfunction (Engine controller system)
CALL E03 DLH1LC
Contents of
• Signal of engine G speed sensor does not match to signal of engine Ne speed sensor.
trouble
Problem that
appears on
machine
Related • Special adapter (799-601-9410) is necessary for troubleshooting for engine G speed sensor.

Defective engine G speed carry out troubleshooting.
1 sensor (Internal disconnec- G (male) Resistance
tion or short circuit) Between (1) – (2) 1.4k – 3.5kz
wiring or defective contact in G (female) (2)
Resistance Max. 1z
Possible causes G (female) (1)
(female) (35) – G (female) (2) with chassis Resistance Min. 1Mz
ground
(female) (25) – G (female) (1) with chassis Resistance Min. 1Mz
ground
Between (35) – (25) 1.4k – 3.5kz
Between (25), (35) –
Min. 1Mz
chassis ground
Circuit diagram related to engine G speed sensor
20-574 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DV00KB
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT)

Trouble Caution buzzer: Short circuit (Monitor panel system)
E01 DV00KB
Contents of
• Abnormal current flowed when caution buzzer circuit output ground signal.
trouble
Action of
• Stops caution buzzer circuit from outputting ground signal.
controller
Problem that
appears on • Caution buzzer does not sound.
machine
Related • Method of reproducing error code: Turn starting switch ON (When it is turned ON, buzzer sounds for 2
information second).

Defective caution buzzer without turning starting switch ON.
1
(Internal short circuit) 217 (male) Resistance
Between (1) – (2) 200z
Possible causes Short circuit with power carry out troubleshooting.
and standard 2 source in wiring harness Short circuit of wiring harness between S03
value in normal (Contact with 24V circuit) (female) (18) – 217 (female) (1) with chassis Voltage Max. 1V
state ground
S03 Caution buzzer Voltage
3 Defective monitor panel
When turned OFF 20 – 30V
Between (18) –
When turned ON
chassis ground Max. 3V
(sounding)
Circuit diagram related to caution buzzer
D155AX-5 20-575
(2)
TROUBLESHOOTING ERROR CODE DW5AKA
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION IN

WIRING)
Action code Error code Blade pitch selector solenoid: Disconnection in wiring
Trouble
E02 DW5AKA (Transmission controller system)
Contents of
• When signal is output to blade pitch selector solenoid circuit, any current does not flow.
trouble
controller • Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
machine
• Output (Current) to blade pitch selector solenoid can be checked in monitoring mode.
Related
(Code 31625: Blade pitch selector solenoid drive current)
information
• Method of reproducing service code: Turn starting switch ON and perform blade pitch switch.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid (Internal short
PSEL (male) Resistance
circuit)
Between (1) – (2) 10 – 40z
wiring or defective contact in PSEL (female) (1)
and standard
Resistance Max. 1z
state PSEL (female) (2)
(Contact with 24V circuit) (female) (28) – PSEL (female) (1) with chassis Voltage Max. 1V
ground
Defective transmission
controller
Circuit diagram related to blade pitch selector solenoid
20-576 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DW5AKB
ERROR CODE DW5AKB (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT)
Action code Error code Blade pitch selector solenoid: Short circuit
Trouble
E02 DW5AKB (Transmission controller system)
Contents of
• When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
trouble
controller • Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
machine
• Output (Current) to blade pitch selector solenoid can be checked in monitoring mode.
Related
(Code 31625: Blade pitch selector solenoid drive current)
information
• Method of reproducing service code: Turn starting switch ON and perform blade pitch switch.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid (Internal short PSEL (male) Resistance
circuit) Between (1) – (2) 10 – 40z
Possible causes Between (1) – chassis ground Min. 1Mz
value in normal Short circuit with chassis without turning starting switch ON.
state 2 ground in wiring harness Short circuit of wiring harness between STC3
(Contact with ground circuit) (female) (28) – PSEL (female) (1) with chassis Resistance Min. 1Mz
ground
Defective transmission
controller
Circuit diagram related to blade pitch selector solenoid
D155AX-5 20-577
(2)
TROUBLESHOOTING ERROR CODE DW7BKA
ERROR CODE DW7BKA (FAN REVERSE SOLENOID: DISCONNECTION IN WIRING)
Action code Error code Fan reverse solenoid: Disconnection in wiring

Trouble
E01 DW7BKA (Steering and transmission controller system)
Contents of
• When signal is output to fan reverse solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to fan reverse solenoid circuit.
controller
Problem that
appears on • The fan reversing function cannot be used.
machine
• Output (Current) to fan reverse solenoid can be checked in monitoring mode.
Related
(Code 40914: Controller output signal related steering)
information
• Method of reproducing service code: Turn starting switch ON and operate fan in reverse.

Defective fan reverse sole- without turning starting switch ON.
1
noid (Internal disconnection) FAR2 (male) Resistance
Between (1) – (2) 34 – 44z
wiring or defective contact in FAR2 (female) (1)
and standard
state FAR2 (female) (2)
(Contact with 24V circuit) (female) (18) – FAR2 (female) (1) with chassis Voltage Max. 1V
ground
Circuit diagram related to fan reverse solenoid
20-578 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DW7BKB
ERROR CODE DW7BKB (FAN REVERSE SOLENOID: SHORT CIRCUIT)
Action code Error code Fan reverse solenoid: Short circuit

Trouble
E01 DW7BKB (Steering and transmission controller system)
Contents of
• When signal was output to fan reverse solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to fan reverse solenoid circuit.
controller
Problem that
appears on • The fan reversing function cannot be used.
machine
• Output (Current) to fan reverse solenoid can be checked in monitoring mode.
Related
(Code 40914: Controller output signal related steering)
information
• Method of reproducing service code: Turn starting switch ON and operate fan in reverse.

Defective fan reverse sole-
1 FAR2 (male) Resistance
noid (Internal short circuit)
Between (1) – (2) 34 – 44z
and standard (Contact with ground circuit) (female) (18) – FAR2 (female) (1) with chassis Resistance Min. 1Mz
state
Short circuit in wiring
3 harness (with another wiring Short circuit in wiring harness between STC3
(female) (18) – FAR2 (female) (1) with wiring
harness) Resistance Min. 1Mz
harness between STC3 (female) (13) – FAR2
(female) (2)
Circuit diagram related to fan reverse solenoid
D155AX-5 20-579
(2)
TROUBLESHOOTING ERROR CODE DWN1KA
ERROR CODE DWN1KA (HSS PUMP SOLENOID B: DISCONNECTION IN WIRING)
Action code Error code HSS pump solenoid B: Disconnection in wiring

Trouble
CALL E03 DWN1KA (Steering and transmission controller system)
Contents of
• When signal is output to HSS pump solenoid B circuit, any current does not flow.
trouble
Action of
• Stops outputting to HSS pump solenoid B circuit.
controller
Problem that
appears on
machine
• Output (Current) to HSS pump solenoid B can be checked in monitoring mode.
Related (Code 50600: Left HSS solenoid output FB current)
information • Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to
left).

Defective HSS pump sole- without turning starting switch ON.
1 noid B (Internal disconnec-
HSA (male) Resistance
tion)
Between (1) – (2) 10 – 20z
and standard wiring or defective contact in HSA (female) (1)
state HSA (female) (2)
(Contact with 24V circuit) (female) (3) – HSA (female) (2) with chassis Voltage Max. 1V
ground
Circuit diagram related to HSS pump solenoid B
20-580 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DWN1KB
ERROR CODE DWN1KB (HSS PUMP SOLENOID B: SHORT CIRCUIT)
Action code Error code HSS pump solenoid B: Short circuit

Trouble
CALL E03 DWN1KB (Steering and transmission controller system)
Contents of
• When signal was output to HSS pump solenoid B circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to HSS pump solenoid B circuit.
controller
Problem that
appears on
machine
• Output (Current) to HSS pump solenoid B can be checked in monitoring mode.
Related (Code 50600: Left HSS solenoid output FB current)
left).

Defective HSS pump sole- HSA (male) Resistance
1
noid B (Internal short circuit)
Between (1) – (2) 10 – 20z
and standard (Contact with ground circuit) (female) (25) – HSA (female) (1) with chassis Resistance Min. 1Mz
state
Short circuit in wiring harness between STC3
3 harness (with another wiring
harness) (female) (25) – HSA (female) (1) with wiring
Resistance Min. 1Mz
harness between STC3 (female) (3) – HSA (fe-
male) (2)
Circuit diagram related to HSS pump solenoid B
D155AX-5 20-581
(2)
ERROR CODE DWN2KA (HSS PUMP SOLENOID A: DISCONNECTION IN WIRING)
Action code Error code HSS pump solenoid A: Disconnection in wiring

Trouble
CALL E03 DWN2KA (Steering and transmission controller system)
Contents of
• When signal is output to HSS pump solenoid A circuit, any current does not flow.
trouble
Action of
• Stops outputting to HSS pump solenoid A circuit.
controller
Problem that
appears on
machine
• Output (Current) to HSS pump solenoid A can be checked in monitoring mode.
Related (Code 50601: Right HSS solenoid output FB current)
right).

Defective HSS pump sole- without turning starting switch ON.
1 noid A (Internal disconnec-
HSB (male) Resistance
tion)
Between (1) – (2) 10 – 20z
and standard wiring or defective contact in HSB (female) (1)
state HSB (female) (2)
(Contact with 24V circuit) (female) (3) – HSB (female) (2) with chassis Voltage Max. 1V
ground
Circuit diagram related to HSS pump solenoid A
20-582 D155AX-5
(2)
ERROR CODE DWN2KB (HSS PUMP SOLENOID A: SHORT CIRCUIT)
Action code Error code HSS pump solenoid A: Short circuit

Trouble
CALL E03 DWN2KB (Steering and transmission controller system)
Contents of
• When signal was output to HSS pump solenoid A circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to HSS pump solenoid A circuit.
controller
Problem that
appears on
machine
• Output (Current) to HSS pump solenoid A can be checked in monitoring mode.
Related (Code 50601: Right HSS solenoid output FB current)
right).

Defective HSS pump sole- HSB (male) Resistance
1
noid A (Internal short circuit)
Between (1) – (2) 10 – 20z
and standard (Contact with ground circuit) (female) (35) – HSB (female) (1) with chassis Resistance Min. 1Mz
state
harness) (female) (35) – HSB (female) (1) with wiring
Resistance Min. 1Mz
harness between STC3 (female) (3) – HSB (fe-
male) (2)
Circuit diagram related to HSS pump solenoid A
D155AX-5 20-583
(2)
ERROR CODE DWN5KA (FAN PUMP SOLENOID: DISCONNECTION IN WIRING)
Action code Error code Fan pump solenoid: Disconnection in wiring

Trouble
E01 DWN5KA (Steering and transmission controller system)
Contents of
• When signal is output to fan pump solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to fan pump solenoid circuit.
controller
Problem that
appears on • Fan speed is kept at maximum level.
machine
• Output (Current) to fan pump solenoid can be checked in monitoring mode.
Related
(Code 31624: Fan solenoid output FB current)
information
• Method of reproducing service code: Turn starting switch ON.

Defective fan pump solenoid without turning starting switch ON.
1
(Internal disconnection) FAC (male) Resistance
Between (1) – (2) 15 – 25z
wiring or defective contact in FAC (female) (2)
and standard
state FAC (female) (1)
(Contact with 24V circuit) (female) (23) – FAC (female) (1) with chassis Voltage Max. 1V
ground
Circuit diagram related to fan pump solenoid
20-584 D155AX-5
(2)
ERROR CODE DWN5KB (FAN PUMP SOLENOID: SHORT CIRCUIT)
Action code Error code Fan pump solenoid: Short circuit

Trouble
E01 DWN5KB (Steering and transmission controller system)
Contents of
• When signal was output to fan pump solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to fan pump solenoid circuit.
controller
Problem that
appears on • Fan speed is kept at maximum level.
machine
• Output (Current) to fan pump solenoid can be checked in monitoring mode.
Related
(Code 31624: Fan solenoid output FB current)
information
• Method of reproducing service code: Turn starting switch ON.

Defective fan pump solenoid
1 FAC (male) Resistance
Between (1) – (2) 15 – 25z
and standard (Contact with ground circuit) (female) (36) – FAC (female) (2) with chassis Resistance Min. 1Mz
state
3 harness (with another wiring Short circuit in wiring harness between STC3
(female) (36) – FAC (female) (2) with wiring
harness between STC3 (female) (23) – FAC
(female) (1)
Circuit diagram related to fan pump solenoid
D155AX-5 20-585
(2)
TROUBLESHOOTING ERROR CODE DXH4KA
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION IN WIRING)
Action code Error code 1st clutch ECMV: Disconnection in wiring

Trouble
CALL E03 DXH4KA (Steering and transmission controller system)
Contents of
• When signal is output to 1st clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 1st clutch solenoid circuit.
controller
Problem that • Automatic shift-down function does not work.
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31612: Output FB current of 1st clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in F1 or R1.

Defective 1st clutch ECMV without turning starting switch ON.
1
(Internal short circuit) S1T (male) Resistance
Between (1) – (2) 5 – 25z
wiring or defective contact in S1T (female) (1)
and standard
Resistance Max. 1z
state S1T (female) (2)
(Contact with 24V circuit) (female) (23) – S1T (female) (2) with chassis Voltage Max. 1V
ground
20-586 D155AX-5
(2)
TROUBLESHOOTING ERROR CODE DXH4KB
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT)
Action code Error code 1st clutch ECMV: Short circuit

Trouble
CALL E03 DXH4KB (Steering and transmission controller system)
Contents of
• When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 1st clutch solenoid circuit.
controller
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31612: Output FB current of 1st clutch ECMV)
information

Defective 1st clutch ECMV
1 S1T (male) Resistance
Between (1) – (2) 5 – 25z
and standard (Contact with ground circuit) (female) (6) – S1T (female) (1) with chassis Resistance Min. 1Mz
state
(female) (6) – S1T (female) (1) with wiring har-
ness between STC3 (female) (23) – S1T (fe-
male) (2)
D155AX-5 20-587
(2)
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION IN WIRING)
Action code Error code 2nd clutch ECMV: Disconnection in wiring

Trouble
Contents of
• When signal is output to 2nd clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 2nd clutch solenoid circuit.
controller
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31613: Output FB current of 2nd clutch ECMV)
information

Defective 2nd clutch ECMV without turning starting switch ON.
1
Between (1) – (2) 5 – 25z
and standard
Resistance Max. 1z
ground
20-588 D155AX-5
(2)
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT)
Action code Error code 2nd clutch ECMV: Short circuit

Trouble
Contents of
• When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 2nd clutch solenoid circuit.
controller
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31613: Output FB current of 2nd clutch ECMV)
information

Defective 2nd clutch ECMV
Between (1) – (2) 5 – 25z
state
(female) (16) – S2T (female) (1) with wiring
harness between STC3 (female) (23) – S2T
(female) (2)
D155AX-5 20-589
(2)
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION IN WIRING)
Action code Error code 3rd clutch ECMV: Disconnection in wiring

Trouble
Contents of
• When signal is output to 3rd clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 3rd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
(Code 31614: Output FB current of 3rd clutch ECMV)
information

Defective 3rd clutch ECMV without turning starting switch ON.
1
Between (1) – (2) 5 – 25z
and standard
Resistance Max. 1z
ground
20-590 D155AX-5
(2)
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT)
Action code Error code 3rd clutch ECMV: Short circuit

Trouble
Contents of
• When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 3rd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
(Code 31614: Output FB current of 3rd clutch ECMV)
information

Defective 3rd clutch ECMV
Between (1) – (2) 5 – 25z
state
(female) (26) – S3T (female) (1) with wiring
harness between STC3 (female) (23) – S3T
(female) (2)
D155AX-5 20-591
(2)
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION IN WIRING)
Action code Error code Reverse clutch ECMV: Disconnection in wiring

Trouble
Contents of
• When signal is output to reverse clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1.
machine
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31616: Output FB current of reverse clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in reverse.

Defective reverse clutch without turning starting switch ON.
1
ECMV (Internal short circuit) SRT (male) Resistance
Between (1) – (2) 5 – 25z
wiring or defective contact in SRT (female) (1)
and standard
Resistance Max. 1z
state SRT (female) (2)
(Contact with 24V circuit) (female) (13) – SRT (female) (2) with chassis Voltage Max. 1V
ground
20-592 D155AX-5
(2)
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT)
Action code Error code Reverse clutch ECMV: Short circuit

Trouble
Contents of
• When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1.
machine
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31616: Output FB current of reverse clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in reverse.

Defective reverse clutch
1 SRT (male) Resistance
ECMV (Internal short circuit)
Between (1) – (2) 5 – 25z
and standard (Contact with ground circuit) (female) (37) – SRT (female) (1) with chassis Resistance Min. 1Mz
state
(female) (37) – SRT (female) (1) with wiring
harness between STC3 (female) (13) – SRT
(female) (2)
D155AX-5 20-593
(2)
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION IN WIRING)
Action code Error code Forward clutch ECMV: Disconnection in wiring

Trouble
Contents of
• When signal is output to forward clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31622: Output FB current of forward clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine forward.

Defective forward clutch without turning starting switch ON.
1
ECMV (Internal short circuit) SFT (male) Resistance
Between (1) – (2) 5 – 25z
wiring or defective contact in SFT (female) (1)
and standard
Resistance Max. 1z
state SFT (female) (2)
(Contact with 24V circuit) (female) (13) – SFT (female) (2) with chassis Voltage Max. 1V
ground
20-594 D155AX-5
(2)
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT)
Action code Error code Forward clutch ECMV: Short circuit

Trouble
Contents of
• When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31622: Output FB current of forward clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine forward.

Defective forward clutch
1 SFT (male) Resistance
ECMV (Internal short circuit)
Between (1) – (2) 5 – 25z
and standard (Contact with ground circuit) (female) (27) – SFT (female) (1) with chassis Resistance Min. 1Mz
state
(female) (27) – SFT (female) (1) with wiring
harness between STC3 (female) (13) – SFT
(female) (2)
D155AX-5 20-595
(2)
20-596 D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E-MODE)
Before carrying out troubleshooting for E-11 The hydraulic oil temperature gauge
electrical system (E-mode) ......................... 20-602 does not indicate normally ................ 20-624
Information described in E-12 Indication of the fuel gauge is
troubleshooting list ...................................... 20-603 abnormal ........................................... 20-625
E- 1 The engine does not start ................. 20-604 E-13 Indications of gear speed and
E- 2 The preheater does not operate engine speed are abnormal .............. 20-626
(Manual preheating function) ............ 20-606 E-14 Indication of the shift mode and
E- 3 The ripper pin puller cylinder service meter are abnormal .............. 20-626
does not operate E-15 The warning lamp does not flash or
(Giant ripper attachment machine) ... 20-608 does not go out .................................. 20-627
E- 4 The monitor panel does not come on E-16 The alarm buzzer does not sound or
at all when the starting switch is does not stop ..................................... 20-628
turned ON ......................................... 20-610 E-17 Auto shift down switch
E- 5 When the starting switch is turned ON, does not work .................................... 20-629
the monitor panel completely remains E-18 The fan rotation select switch
lighted and does not go out .............. 20-612 does not work .................................... 20-630
E- 6 While the engine is operating, E-19 The buzzer cancel switch
the battery charge level caution does not work .................................... 20-632
flashes .............................................. 20-614 E-20 The information switch
E- 7 While the engine is operating, the does not work .................................... 20-634
emergency warning item flashes ...... 20-616 E-21 Cannot enter into service mode ........ 20-636
E- 8 While the preheater is operating, E-22 The back-up alarm does not sound ... 20-638
the preheating pilot lamp does not E-23 The head lamp, panel night lamp,
come on ............................................ 20-620 rear lamp, and ripper point lamp
E- 9 The engine water temperature gauge do not light up .................................... 20-640
does not indicate normally ................ 20-622 E-24 Malfunction of wipers ......................... 20-642
E-10 Indication of the power train oil E-25 Washing water does not come out .... 20-655
temperature gauge is abnormal ........ 20-623 E-26 The air conditioner does not operate .... 20-661
D155AX-5 20-601
(2)
BEFORE CARRYING OUT TROUBLESHOOTING FOR
TROUBLESHOOTING ELECTRICAL SYSTEM (E-MODE)
BEFORE CARRYING OUT TROUBLESHOOTING FOR

ELECTRICAL SYSTEM (E-MODE)
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power constantly, regardless of the position of the starting
switch).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fus-
ible link to see if the power is supplied normally.
Fuse box 1 (FS1)

Type of power supply Fuse No. Fuse capacity Destination of power
1 30A Spare power supply
Heater relay
2 20A
Switch power supply Horn
(Circuit breaker CB105) 3 20A Headlamp
4 20A Rear lamp
5 20A Steering and transmission controller
Fuse box 2 (FS2)

Monitor panel
1 15A
Alarm buzzer
Switch power supply 2 20A Engine controller injection power supply
(Circuit breaker CB105) 3 30A Air conditioner unit (via circuit breaker CB2)
Backup alarm
4 20A
Pin puller solenoid valve
Starting switch (via circuit breaker CB1)
Constant power supply
5 30A Engine controller
(Circuit breaker CB30)
Monitor panel
Fuse box 3 (for cab)

Constant power supply Radio
1 10A
(Circuit breaker CB30) 12-V converter (for accessory socket and 12-V spare power supply)
Room lamp
2 20A Radio
Additional lamp relay and additional lamp
3 20A Heat wire glass relay and heat wire glass
Switch power supply
4 10A Rear wiper and rear windshield washer
(Circuit breaker CB105)
Wiper intermittent relay (Front, rear, left, right)
5 10A
Front wiper and front windshield washer
Left wiper and left windshield washer
6 10A
Right wiper and right windshield washer
20-602 D155AX-5
(5)

a Troubleshooting lists and related circuit diagrams contain the following information all together. Understand
the contents carefully and troubleshoot the machine.
Trouble Problem that appears on the machine.
Related
Information related to problems occurred or troubleshooting
information

<Described contents>
• Standard value in normal state required to judge the assumed cause
(good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness is dis-
connected.
• Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Defective hot short
2 A harness not connected to the power (24V) circuit comes into con-
tact with the power (24V) circuit.
Possible causes • Defective short
Cause by which a trouble is
and standard A harness of an independent circuit abnormally comes into contact
assumed to be detected
with one of another circuit.
value in normal (The order number indicates
state a serial number, not a <Notes on troubleshooting>
priority sequence.) (1) Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect the T-junction adapter as
• When “male” or “female” is not indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
both the male and female.
• When “male” or “female” is indicated for a connector number, dis-
connect the connector, and insert the T-junction adapter in only
either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in the
rear.
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model-No. of pins) (Color).
• “Connector No. and pin No.” from each branching/merging point are shown:
End of branch or source of merging within the same wiring harness parts is shown.
• Arrow ( ): Roughly indicates mounting place on machine.
D155AX-5 20-603
(2)
TROUBLESHOOTING E-1
E-1 THE ENGINE DOES NOT START

Trouble • The engine does not start.
• The engine start circuit has the neutral safety function, and the engine does not start unless the parking
lever is set to the lock position.
Related
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” when
information
the starting switch is set to ON, the main electric power supply system is supposed to be out of order.
So, inspect the main electric power supply system.

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24V Min. 1.26
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective starting switch Starting switch Switch position Resistance
2
(internal disconnection)
Between 250 (B) and OFF Min. 1Mz
280 (C) START Max. 1z
aPrepare with the starting switch OFF, then start the engine and carry
Defective neutral safety re-
3 If the engine starts in accordance with the engine starting arrangement
lay (internal disconnection)
after the neutral safety relay (NSF) is replaced with another one while
the starting switch is set to OFF, the relay is defective.
aPrepare with the starting switch OFF, then turn the starting switch
Defective alternator (internal ON and carry out troubleshooting.
4
short-circuit) Alternator Voltage
Between R terminal and ground Max. 1V
aPrepare with the starting switch OFF, then start the starting switch
and carry out troubleshooting.
Possible causes Starting motor Voltage
and standard Between Terminal
Power source 20 – 30V
value in normal S/T-B and ground
state Detective starting motor Between ST (2) –
5 Charge Max. 1V
(internal defect) ground
Between ST (1) –
Starting 20 – 30V
ground
When the voltages of power source, for charging and starting are nor-
mal but the starting motor does not rotate, the starting motor is defec-
tive.
Disconnection of wiring Wiring harness between 280 (C) – NFS (fe-
Resistance Max. 1z
harness (disconnection in male) (3)
6
wiring or defective contact in Wiring harness between NSF (female) (5) – ST
Resistance Max. 1z
connector) (female) (1)
Wiring harness between NSF (female) (5) –
Resistance Max. 1z
EGC1 (female) (20)
ON and carry out troubleshooting.
Hot short circuit of wiring
7 harness (Contact with 24V Hot short circuit of wiring harness between al-
ternator R terminal – ST (female) (2) – S04 (fe-
male) (9) – STC1 (female) (15) – other related
circuit with ground
20-604 D155AX-5
(2)
TROUBLESHOOTING E-1
Engine start/charge-related circuit diagram
D155AX-5 20-605
(2)
TROUBLESHOOTING E-2
E-2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)

Trouble • The preheater does not operate. (Manual preheating function)
aThis troubleshooting describes the procedures to be followed when the manual preheating function
cannot heat the electrical intake air heater mounting section. (When the preheating lamp only does not
come on, carry out the troubleshooting of “The preheating lamp does not come on.”)
Related • For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are
information available. When either function is performed, the preheating lamp comes on.
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” hen the
starting switch is turned ON, the main electric power supply system supposed to be out of order. So,
inspect the main electric power supply system.

without turning the starting switch ON or set the starting switch to
HEAT.
Defective starting switch Starting switch Switch position Resistance
1
(Internal disconnection) OFF Min. 1Mz
Between 250 (B) – HEAT
255 (R1) (Left side of OFF Max. 1z
position)
aPrepare with the starting switch OFF, then set the starting switch to
HEAT and carry out troubleshooting.
Heater relay Voltage
Between Terminal
Defective heater relay Power source 20 – 30V
2 HT/B (B) – ground
Possible causes (internal defect)
Between Terminal
and standard Signal 20 – 30V
HT (C) – ground
value in normal
state When the both voltages of power source and signal are normal and no
operating sound is caused, the heater relay is defective.
Defective electrical intake air without turning the starting switch ON.
3
heater (internal defect) Electrical intake air heater Continuity
Between terminals Continue
Wiring harness between starting switch 255
Disconnection of wiring Resistance Max. 1z
(R1) – HT (C)
4
wiring or defective contact in Wiring harness between battery relay BRC ter-
minal – starting motor ST/B – heater relay HT/ Resistance Max. 1z
connector)
A (A) terminal
Wiring harness between heater relay HT/B (B)
Resistance Max. 1z
terminal – electrical intake air heater
20-606 D155AX-5
(2)
TROUBLESHOOTING E-2
Engine preheat/start/charge-related circuit diagram
D155AX-5 20-607
(2)
TROUBLESHOOTING E-3
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE (GIANT RIPPER
ATTACHMENT MACHINE)
• The ripper pin puller cylinder does not op- (1) When the switch is pulled out, the cylinder does not retract.
Trouble
erate. (2) When the switch is pushed in, the cylinder does not extend.
Related
information

When the fuse is blown, a ground fault may have possibly occurred to
1 Defective fuse (FS2-4)
the circuit.
Defective pin puller switch without turning the starting switch ON.
2 (Internal disconnection or 263 (male) Switch Resistance
short circuit) Pull Max. 1z
Between (1) – (2)
Press Min. 1Mz
Defective pin puller solenoid without turning the starting switch ON.
3 (Internal disconnection or 224 (male) Resistance
short circuit) Between (1) – (2) 10 – 80z
Between (1) – ground Min. 1Mz
Possible causes aPrepare with the starting switch OFF, then carry out troubleshooting
and standard without turning the starting switch ON.
value in normal Disconnection of wiring Wiring harness between FS2-4 outlet – 263
Resistance Max. 1z
state harness (Disconnection in (female) (1)
4
wiring or defective contact in Wiring harness between 263 (female) (2) –
Resistance Max. 1z
connector) 224 (female) (1)
Wiring harness between 224 (female) (2) –
Resistance Max. 1z
ground (GND07)
Ground fault of wiring har-
Between wiring harness related to FS2-(4) –
5 ness (Contact with ground Resistance Min. 1Mz
263 (female) (1) with ground
circuit)
Between wiring harness (between 263 (fe-
Resistance Min. 1Mz
male) (2) – 224 (female) (1)) with ground
Hot short circuit of wiring ON and carry out troubleshooting.
circuit) Between wiring harness (between 263 (fe-
Voltage Max. 1V
male) (2) – 224 (female) (1)) with ground
20-608 D155AX-5
(2)
TROUBLESHOOTING E-3
Circuit diagram related to ripper pin puller solenoid
D155AX-5 20-609
(2)
TROUBLESHOOTING E-4
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING
SWITCH IS TURNED ON
Trouble • The monitor panel does not come on at all when the starting switch is turned ON.
Related • When the starting switch is turned ON, the gear speed indicator, the multi information section, the
information gauge section and the lamp section come on for approximately 2 sec. and go out.

Defective fuse When the fuse is burning out, the circuit may have possibly been short-
1
(FS2-1, FS2-5) circuited with ground.
Disconnection of wiring Wiring harness between FS2-(1) – S03 (fe-
Resistance Max. 1z
harness (Disconnection in male) (1) (2)
2
wiring or defective contact in Wiring harness between FS2-(5) – S03 (fe-
Resistance Max. 1z
connector) male) (5) (6)
Possible causes Wiring harness between S03 (female) (3) (4) –
Resistance Max. 1z
and standard ground (GND02)
value in normal aPrepare with the starting switch OFF, then carry out troubleshooting
state without turning the starting switch ON.
Short circuit of wiring harness between FS2-
(1) – S03 (female) (1) (2) with ground
circuit)
Resistance Min. 1Mz
(5) – S03 (female) (5) (6) with ground
Defective monitor panel S03 Voltage
4
power supply
Between (1) (2) – (3) (4) 20 – 30V
Between (5) (6) – (3) (4) 20 – 30V
20-610 D155AX-5
(2)
TROUBLESHOOTING E-4
Circuit diagram related to power source of monitor panel
D155AX-5 20-611
(2)
TROUBLESHOOTING E-5
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COM-
PLETELY REMAINS LIGHTED AND DOES NOT GO OUT
• When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
Trouble
out.
Related • When the starting switch is turned ON, the gear speed indicator, the multi information section, the
information gauge section and the lamp section come on for approximately 2 sec. and go out.

and standard
value in normal 1 Defective monitor panel Troubleshooting cannot be carried out since it is internal defect.
state
20-612 D155AX-5
(2)
TROUBLESHOOTING E-5
D155AX-5 20-613
(2)
TROUBLESHOOTING E-6
E-6 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION
FLASHES
Trouble • The battery charge level caution flashes.
Related • When any abnormality is detected during engine operation, the battery charge level caution lamp will
information flash.

aPrepare with the starting switch OFF, then start the engine and carry
Defective alternator (insuffi-
1 Alternator Engine speed Voltage
cient power generation)
Between R terminal – Min. medium speed
20 – 30V
ground (half)
Disconnection of wiring aPrepare with the starting switch OFF, then carry out troubleshooting
harness (Disconnection in without turning the starting switch ON.
2
Possible causes wiring or defective contact in Wiring harness between S04 (female) (9) – al-
Resistance Max. 1z
and standard connector) ternator R terminal
state Ground fault of wiring har- without turning the starting switch ON.
3 ness (Contact with ground Short circuit of wiring harness between S04
circuit) (female) (9) – alternator R terminal – ST (fe- Resistance Min. 1Mz
male) (2) – STC1 (female) (15) with ground
4 Defective monitor panel S04 Engine speed Voltage
Min. medium speed
Between (9) – ground 20 – 30V
(half)
20-614 D155AX-5
(2)
TROUBLESHOOTING E-6
D155AX-5 20-615
(2)
TROUBLESHOOTING E-7
E-7 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM

FLASHES
Trouble (1) The engine oil pressure caution lamp flashes.
• When any abnormality is detected during engine operation, the engine oil pressure caution lamp will
Related flash and sound the alarm buzzer.
information • The engine oil pressure switch signal is sent and received from the engine controller through commu-
nication.

Drop of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is de-
1
(when the system is normal) tected.
The engine oil low pressure without turning the switch ON or after starting the engine.
2 switch is defective (Internal PSL Engine Resistance
short circuit) Between terminal – Stop Max. 1z
ground Min. 600rpm Min. 1Mz
The engine oil high pressure without turning the switch ON or after starting the engine.
3 switch is defective (Internal PSH Engine Resistance
short circuit) Between terminal – Stop Max. 1z
Possible causes ground Min. 1,300rpm Min. 1Mz
and standard
value in normal
state Ground fault of wiring har-
(female) (21) – PSL with ground
circuit)
Resistance Min. 1Mz
(female) (15) – PSH with ground
without turning the switch ON or after starting the engine.
EGC1 Engine Voltage
5 Defective engine controller Stop Max. 1V
Between (21) – ground
Min. 600rpm 20 – 30V
Stop Max. 1V
Min. 1,300rpm 20 – 30V
6 Defective monitor panel Troubleshooting cannot be carried out since it is internal defect.
Circuit diagram related to engine oil low pressure switch and engine oil high pressure switch
20-616 D155AX-5
(2)
TROUBLESHOOTING E-7
Trouble (2) The engine water temperature caution lamp flashes.

• When any abnormality is detected during engine operation, the engine water temperature caution lamp
Related will flash and sound the alarm buzzer.
information • The engine water temperature caution lamp flashes or goes out as it links with indication on the engine
water temperature gauge.

Overheated engine water As overheated engine water was detected, check the engine water
1 temperature (when the temperature. (The water temperature; Over 102ºC: The lamp flashed/
system is normal) Over 108ºC: Lamp flashed and sound the buzzer.)
Check the indication on the engine water temperature gauge. If the in-
dication is abnormal, carry out the troubleshooting of “Indication on the
engine water temperature gauge is abnormal.”
aWater temperatures are guides for selecting
indications.
Possible causes
and standard The engine water tempera-
ture sensor system is defec- Water temperature
value in normal 2
tive (Engine controller gauge
state
system)
White range/
Water temperature Red range
Green range
lamp
Goes out. Flashes.
3 Defective monitor panel el is defective. (Troubleshooting cannot be carried out since it is inter-
nal defect.)
Trouble (3) The power train oil temperature caution lamp flashes.
• When any abnormality is detected during engine operation, the power train oil temperature caution
Related lamp will flash and sound the alarm buzzer.
information • The power train oil temperature caution lamp flashes or goes out as it links with indication on the power
train oil temperature gauge.

As an overheated power train oil temperature was detected, check the
Overheated oil temperature
power train oil temperature. (When the oil temperature is over 120ºC,
1 of power train (when the
the lamp flashes. When the oil temperature is over 130ºC, the lamp
system is normal)
flashes and sound the buzzer.)
Check the indication on the power train oil temperature gauge. If the in-
power train oil temperature gauge is abnormal.”
aOil temperatures are guides for selecting in-
dications.
Possible causes
and standard
value in normal The power train oil tempera-
state 2 ture sensor system is defec- Oil temperature gauge
tive (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
nal defect.)
D155AX-5 20-617
(2)
TROUBLESHOOTING E-7
Trouble (4) The hydraulic oil temperature caution lamp flashes.

• When any abnormality is detected during engine operation, the hydraulic oil temperature caution lamp
Related will flash and sound the alarm buzzer.
information • The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydraulic
oil temperature gauge.

As an overheated hydraulic oil temperature was detected, check the
Overheated hydraulic oil
hydraulic oil temperature. (When the oil temperature is over 100ºC, the
1 temperature (when the
lamp flashes. When the oil temperature is over 110ºC, the lamp flashes
system is normal)
and sound the buzzer.)
Check the indication on the engine water temperature gauge. If the in-
hydraulic oil temperature gauge is abnormal.”
aOil temperatures are guides for selecting in-
dications.
Possible causes
and standard
The hydraulic oil tempera-
value in normal
state 2 ture sensor system is defec- Oil temperature gauge
tive (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
nal defect.)
20-618 D155AX-5
(2)
TROUBLESHOOTING E-7
Trouble (5) HSS charge pressure caution lamp flashes.

Related • When any abnormality is detected during engine operation, the HSS charge pressure caution lamp will
information flash and sound the alarm buzzer.

Drop of HSS charge pres-
Check the HSS charge pressure as the drop of HSS charge pressure
1 sure (When the system is
is detected.
normal)
without turning starting switch ON or start engine.
Defective the HSS charge oil 406 (male) HSS charge pressure Resistance
2 pressure switch (Internal Max. 0.8MPa
disconnection) Min. 1Mz
{Max. 8kg/cm2}
Between (1) – (2)
Min. 1.4MPa
Possible causes Max. 1z
{Min. 14kg/cm2}
and standard
value in normal aPrepare with starting switch OFF, then carry out troubleshooting.
Disconnection of wiring
state Wiring harness between S03 (female) (15) –
harness (Disconnection in Resistance Max. 1z
3 406 (female) (1)
connector) Wiring harness between 406 (female) (2) –
Resistance Max. 1z
ground (GND02)
Hot short circuit of wiring without turning the starting switch ON.
(female) (15) – 406 (female) (1) with ground
nal defect.)
Circuit diagram related to HSS charge oil pressure switch
D155AX-5 20-619
(2)
TROUBLESHOOTING E-8
E-8 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES
NOT COME ON
Trouble • While the preheater is operating, the preheating pilot lamp does not come on.
• This troubleshooting describes the procedures to be followed when the preheating lamp doe not come
on. (When the electrical intake air heater mounting section is not heated, carry out the troubleshooting
Related
of “The preheater does not work.”)
information
• For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are
available. Even when either function is performed, the preheating lamp comes on.

Disconnection of wiring aPrepare with the starting switch OFF, then carry out troubleshooting
harness (Disconnection in without turning the starting switch ON.
1
wiring or defective contact in Wiring harness between S03 (female) (9) –
Resistance Max. 1z
connector) heater relay HT/B (B) terminal
Ground fault of wiring har- without turning the starting switch ON.
Possible causes
2 ness (Contact with ground Short circuit of wiring harness between S03
and standard circuit) (female) (9) – heater relay HT/B (B) terminal Resistance Min. 1Mz
value in normal
with ground
state
S03 Starting switch Voltage
3 Defective monitor panel ON Max. 1V
HEAT
(Left side of OFF 20 – 30V
position)
20-620 D155AX-5
(2)
TROUBLESHOOTING E-8
D155AX-5 20-621
(2)
TROUBLESHOOTING E-9
E-9 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY
Trouble • The engine water temperature gauge does not indicate normally.
• Signals of the engine water high temperature sensor are sent and received from the engine controller
Related through communication.
information • When any abnormality occurred in the engine hot water temperature sensor system, the error code
[DGE2KX] is displayed sometimes.

The engine water high tem- without turning the starting switch ON.
perature sensor is defective
1 TWH (male) Resistance
Between (1) – (2) 3.5k – 90kz
short circuit)
Between (1) (2) – ground Min. 1Mz
Disconnection of wiring without turning the starting switch ON.
wiring or defective contact in TWH (female) (1)
Resistance Max. 1z
TWH (female) (2)
and standard without turning the starting switch ON.
value in normal 3 ness (Contact with ground
state circuit) Resistance Min. 1Mz
(female) (27) – TWH (female) (1) with ground
Hot short circuit of wiring
(female) (27) – TWH (female) (1) with ground
Between (27) – (39) 3.5k – 90kz
Between (27) (39) – ground Min. 1Mz
nal defect.)
Circuit diagram related to engine coolant high temperature sensor
20-622 D155AX-5
(2)
TROUBLESHOOTING E-10
E-10 INDICATION OF THE POWER TRAIN OIL TEMPERATURE GAUGE IS ABNOR-

MAL
Trouble • Indication of the power train oil temperature gauge is abnormal.
Related • The signals of the power train oil temperature sensor are transmitted and received by communication
information through the monitor panel.

The power train oil tempera- without turning the starting switch ON.
ture sensor is defective (In- Power train oil
1 453 (male) Resistance
ternal disconnection or short temperature
circuit) Between (1) – (2) 3.5k – 90kz
10 – 100ºC
harness (Disconnection in Wiring harness between 453 (female) (2) –
Possible causes wiring or defective contact in S03 (female) (3) (4), – ground
and standard connector) Wiring harness between 453 (female) (2) –
ground
state aPrepare with the starting switch OFF, then carry out troubleshooting
3 ness (Contact with ground
circuit) Short circuit of wiring harness between S04
Resistance Min. 1Mz
Voltage Max. 1V
nal defect.)
Circuit diagram related to power train oil temperature sensor
D155AX-5 20-623
(2)
E-11 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NOR-
MALLY
Trouble • The hydraulic oil temperature gauge does not indicate normally.
• The signals of the hydraulic oil temperature sensor are transmitted and received by communication
Related through the steering and transmission controller.
information • When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.

The hydraulic oil tempera- without turning the starting switch ON.
ture sensor is defective (In- SDS (male) Resistance
1
ternal disconnection or short
circuit) Between (1) – (2) 3.5k – 90kz
wiring or defective contact in SDS (female) (1)
Resistance Max. 1z
Possible causes SDS (female) (2)
and standard aPrepare with the starting switch OFF, then carry out troubleshooting
value in normal Ground fault of wiring har- without turning the starting switch ON.
state 3 ness (Contact with ground
circuit) Resistance Min. 1Mz
(female) (14) – SDS (female) (1) with ground
(female) (14) – SDS (female) (1) with ground
5 transmission controller is defective. (Troubleshooting cannot be carried
out since it is internal defect.)
nal defect.)
Circuit diagram related to hydraulic oil temperature sensor
20-624 D155AX-5
(2)
E-12 INDICATION OF THE FUEL GAUGE IS ABNORMAL

Trouble • Indication of the fuel gauge is abnormal.
Related
information

Defective fuel level sensor without turning the starting switch ON.
1 (Internal disconnection or 423 (male) Remained fuel level Resistance
short circuit) Between (1) – (2) Full Approx. 4z
(ground) Empty Approx. 85z
harness (Disconnection in Wiring harness between S04 (female) (10) –
wiring or defective contact in 423 (female) (1)
Possible causes
connector) Wiring harness between 423 (female) (2) –
value in normal S03 (female) (3) (4), – ground
Resistance Min. 1Mz
Voltage Max. 1V
nal defect.)
Circuit diagram related to fuel level sensor
D155AX-5 20-625
(2)
TROUBLESHOOTING E-13, E-14
E-13
E-13 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL

Trouble • Indications of gear speed and engine speed are abnormal.
Related • Signals of gear speed and engine speed are sent and received through communication by the monitor
information panel.

and standard
state
E-14 INDICATION OF THE SHIFT MODE AND SERVICE METER ARE ABNORMAL
Trouble (1) During engine operation, the service meter does not advance.
• The service meter measures time while the monitor panel is receiving engine drive signals (alternator
Related signals).
information • The display data are sent and received through communication by the steering and transmission con-
troller.

Possible causes
When the battery charge level caution lamp flashes during engine op-
and standard Defective alternator signals
1 eration, carry out the troubleshooting of “While the engine is operating,
value in normal system
caution items flash.”
state
2 Defective monitor panel Troubleshooting cannot be carried out since it is internal defect.
Trouble (2) Shift mode and service meter are not display.
Related • The display data are sent and received through communication by the steering and transmission con-
information troller.

and standard
state
20-626 D155AX-5
(2)
E-15 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT
Trouble • The warning lamp does not flash or does not go out.
Related
information

and standard
state
D155AX-5 20-627
(2)
E-16 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP
Trouble • The alarm buzzer does not sound or does not stop.
Related • When a short circuit occurs in the alarm buzzer system, the error code [DV00KB] is displayed some-
information time.

Defective circuit breaker When the fuse FS2-(1) is cut off, a ground fault may have possibly oc-
1
fuse (FS2-(1)) curred in the circuit. (Refer to cause 4.)
Defective alarm buzzer without turning the starting switch ON.
2 (Internal disconnection or 217 (male) Resistance
short circuit) Between (1) – (2) 200z
Between (1), (2) – ground Min. 1Mz
Possible causes harness (Disconnection in Wiring harness between S03 (female) (18) –
and standard wiring or defective contact in 217 (female) (1)
value in normal connector) Wiring harness between 217 (female) (2) –
FS2-1
circuit) Short circuit of wiring harness between FS2-1
Resistance Min. 1Mz
– 217 (female) (2) with ground
S03 Alarm buzzer Voltage
At stop 20 – 30V
Between (12) – ground At operation
Max. 3V
(sounding)
Circuit diagram related to alarm buzzer
20-628 D155AX-5
(2)
E-17 AUTO SHIFT DOWN SWITCH DOES NOT WORK

Trouble • Auto shift down switch does not work.
Related
information

Defective auto shift down without turning the starting switch ON.
1 switch (Internal disconnec- ASD (male) Auto shift down switch Resistance
tion or short circuit) Q (OFF) Min. 1Mz
Between (2) – (3)
(ON) Max. 1z
wiring or defective contact in ASD (female) (2)
Possible causes connector) Wiring harness between ASD (female) (3) –
ground (GND05)
value in normal
Ground steering and fault of without turning the starting switch ON.
3 wiring harness (Contact with
ground circuit) Short circuit of wiring harness between STC2
Resistance Min. 1Mz
(female) (37) – ASD (female) (2) with ground
4 STC2, STC3 Auto shift down switch Voltage
Between STC2 (37) – Q (OFF) Approx. 7V
STC3 (21) (31) (32) (33) (ON) Max. 3V
Restriction of function by When Causes 1 to 4 are not applicable, the steering and transmission
5
controller controller may be restricting the function because of other causes.
Circuit diagram related to auto shift down switch
D155AX-5 20-629
(2)
E-18 THE FAN ROTATION SELECT SWITCH DOES NOT WORK

(1) Fan cannot be shifted to normal mode.
• The fan rotation select switch does not
Trouble (2) Fan cannot be shifted to reverse mode.
work.
(3) Fan cannot be shifted to clean mode (reverse rotation).
Related • The rotation direction of the fan can be changed only while the starting switch is in the ON position
information (while the engine is stopped) for safety.

Fan rotation select
Defective fan rotation select FAM (male) Resistance
switch
1 switch (Internal disconnec-
Q (Normal) Min. 1Mz
tion or short circuit) Between (3) – (4)
REV (Reverse) Max. 1z
Q (Normal) Min. 1Mz
Between (3) – (2)
CLN (Clean) Max. 1z
Disconnection of wiring Wiring harness between STC2 (female) (17) –
Resistance Max. 1z
harness (Disconnection in FAM (female) (4)
2
connector) FAM (female) (2)
and standard
Wiring harness between FAM (female) (3) –
ground
state
3 ground in wiring harness Resistance Min. 1Mz
(female) (17) – FAM (female) (4) with ground
Resistance Min. 1Mz
(female) (7) – FAM (female) (2) with ground
Fan rotation select
STC2, STC3 Voltage
Defective steering and switch
4 Q (Normal) Approx. 7V
transmission controller Between STC2 (17) –
STC3 (21) (31) (32) (33) REV (Reverse) Max. 1V
Between STC2 (7) – Q (Normal) Approx. 7V
STC3 (21) (31) (32) (33) CLN (Clean) Max. 1V
20-630 D155AX-5
(2)
Circuit diagram related to fan rotation select switch
D155AX-5 20-631
(2)
E-19 THE BUZZER CANCEL SWITCH DOES NOT WORK

(1) Alarm buzzer cannot be canceled.
Trouble • The buzzer cancel switch does not work. (2) Operation mode cannot be operated.
(3) Service mode cannot be operated.
Related
information

Defective buzzer cancel BUZ (male) Buzzer cancel switch Resistance
1 switch (Internal disconnec- Center Min. 1Mz
Between (1) – (2)
tion or short circuit) t (CW) Max. 1z
Center Min. 1Mz
Between (1) – (3)
U (CCW) Max. 1z
Disconnection of wiring Wiring harness between STC2 (36) – 212 (fe-
Resistance Max. 1z
harness (Disconnection in male) (2)
2
wiring or defective contact in Wiring harness between STC2 (26) – 212 (fe-
connector) male) (3)
and standard
value in normal Wiring harness between 212 (female) (1) –
Resistance Max. 1z
ground (GND05)
state
(36) – BUZ (female) (2) with ground
circuit)
Resistance Min. 1Mz
(26) – BUZ (female) (3) with ground
ON and carry out the troubleshooting.
STC2, STC3 Buzzer cancel switch Voltage
Defective steering and Center Approx. 7V
4 Between STC2 (36) –
STC3 (21) (31) (32) (33) t (CW) Max. 1V
Between STC2 (26) – Center Approx. 7V
STC3 (21) (31) (32) (33) U (CCW) Max. 1V
20-632 D155AX-5
(2)
Circuit diagram related to buzzer cancel switch
D155AX-5 20-633
(2)
E-20 THE INFORMATION SWITCH DOES NOT WORK

(1) Operation mode cannot be operated.
Trouble • The information switch does not work.
(2) Service mode cannot be operated.
Related
information

Defective information switch CUR (male) Information switch Resistance
1 (Internal short circuit or Center Min. 1Mz
Between (1) – (2)
disconnection) (CW) Max. 1z
Center Min. 1Mz
Between (1) – (3)
(CCW) Max. 1z
Disconnection of wiring Wiring harness between STC2 (16) – CUR (fe-
Resistance Max. 1z
harness (Disconnection in male) (2)
2
wiring or defective contact in Wiring harness between STC2 (6) – CUR (fe-
connector) male) (3)
and standard
Wiring harness between CUR (female) (1) –
state ground (GND05)
(16) – CUR (female) (2) with ground
circuit)
Resistance Min. 1Mz
(6) – CUR (female) (3) with ground
STC2, STC3 Information switch Voltage
Defective steering and Center Approx. 7V
4 Between STC2 (16) –
STC3 (21) (31) (32) (33) (CW) Max. 1V
Between STC2 (6) – Center Approx. 7V
STC3 (21) (31) (32) (33) (CCW) Max. 1V
20-634 D155AX-5
(2)
Circuit diagram related to information switch
D155AX-5 20-635
(2)
E-21 CANNOT ENTER INTO SERVICE MODE

Trouble • Cannot enter into service mode.
Related
information

Defective service switch
1 S24 Service switch Resistance
(Internal disconnection)
Between (1) – (2) OFF (Down side) Min. 1Mz
Between (4) – (5) ON (Up side) Max. 1z
Wiring harness between FS2-5 – S24 (1) Resistance Max. 1z
Disconnection of wiring
Wiring harness between S24 (4) – ground
harness (Disconnection in Resistance Max. 1z
2 (GND05)
connector) Wiring harness between S03 (female) (16) –
Resistance Max. 1z
S24 (2)
Resistance Max. 1z
S24 (5)
and standard
value in normal
Short circuit of wiring harness between FS2-5
state Short circuit with power Resistance Min. 1Mz
– S24 (1), – S03 (female) (5) (6) with ground
3 source in wiring harness
(Contact with 24V circuit) Resistance Min. 1Mz
(female) (16) – S24 (2) with ground
Resistance Min. 1Mz
(female) (6) – S24 (5) with ground
4 Defective monitor panel S03 Service switch Voltage
OFF (Down side) Max. 1V
ON (Up side) 20 – 30V
Defective steering and STC1, STC3 Service switch Voltage
5
Between STC1 (6) – OFF (Down side) Approx. 7V
STC3 (21) (31) (32) (33) ON (Up side) Max. 1V
20-636 D155AX-5
(2)
Circuit diagram related to service switch
D155AX-5 20-637
(2)
E-22 THE BACK-UP ALARM DOES NOT SOUND

Trouble • The back-up alarm does not sound.
Related • When a error occurs on the primary side (coil side) of the back-up alarm relay, a relevant error code is
information displayed, but in case of error on the secondary side (contact side), no error code is displayed.

When the fuse is burning out, a ground fault may have probably oc-
curred in the circuit. (Refer to cause 4.)
Defective back-up relay When the relay is replaced with another relay while the starting switch
2
(internal disconnection) is set to OFF and the alarm sounds after the starting switch is turned
on and the machine is operated in reverse, the back-up alarm relay
(BKA) is defective.
Possible causes
Disconnection of wiring Wiring harness between FS2-(4) – BKA (fe-
harness (Disconnection in male) (1), (3)
value in normal 3
wiring or defective contact in Wiring harness between BKA (female) (5) –
state Resistance Max. 1Mz
connector) BAL+
Wiring harness between BAL– – ground
Resistance Max. 1z
(GND07)
(4) – BKA (female) (1), (3) with ground
circuit)
Short circuit of wiring harness between BKA
Resistance Min. 1Mz
(female) (5) – BAL+ with ground
Defective back-up alarm If no problem is found in causes 1 to 4, it is suspected that back-up
5
(internal defect) alarm is defective.
20-638 D155AX-5
(2)
Circuit diagram related to back-up alarm
D155AX-5 20-639
(2)
E-23 THE HEAD LAMP, PANEL NIGHT LAMP, REAR LAMP, AND RIPPER POINT
LAMP DO NOT LIGHT UP
Trouble (1) The head lamp and panel night lamp do not light up.
Related
• If the monitor panel receives the ON signal of the headlamp switch, its night lamp lights up.
information

If the fuse is broken, the circuit probably has a grounding fault, etc. (Re-
fer to cause 4.)
Defective head lamp switch
2 FWL (male) Switch Resistance
Q (OFF) Min. 1Mz
Between (2) – (3)
(ON) Max. 1z
Wiring harness between FS1-(3) – FWL (fe-
male) (2)
Possible causes harness (Disconnection in
3 Wiring harness between FWL (female) (3) –
and standard wiring or defective contact in
connector) 203 (female) (1) – 204 (female) (1) [Head lamp Resistance Max. 1z
value in normal system]
state Wiring harness between FWL (female) (3) –
Resistance Max. 1z
S03 (female) (8) [Panel night lamp system]
Short circuit with chassis Short circuit of wiring harness between FS1-
Resistance Min. 1Mz
4 ground in wiring harness (3) – FWL (female) (2) with ground
(Contact with ground circuit) Short circuit of wiring harness between FWL
(female) (3) – 203 (female) (1) – 204 (female) Resistance Min. 1Mz
(1) – S03 (female) (8) with ground
Defective headlamp (Broken When only the headlamp does not light up, it may be defective. Check
5
bulb defective ground) the bulb for breakage and check the ground wire for a defect.
When only the panel night lamp does not light up, the monitor panel
may be defective.
Trouble (2) The rear lamp and ripper point lamp do not light up.
Related
information

If the fuse is broken, the circuit probably has a grounding fault, etc. (Re-
fer to cause 4.)
Defective rear lamp switch RWL (male) Switch Resistance
2
Q (OFF) Min. 1Mz
Possible causes Between (2) – (3)
(ON) Max. 1z
and standard
Wiring harness between FS1-(4) – RWL (fe-
male) (2)
3 Wiring harness between RWL (female) (3) –
203 (female) (1) – 242 (female) (1) [Rear lamp Resistance Max. 1z
connector)
system]
Wiring harness between RWL (female) (3) –
Resistance Max. 1z
226 (female) (1) [Ripper point lamp system]
20-640 D155AX-5
(2)

Short circuit with chassis Short circuit of wiring harness between FS1-
Resistance Min. 1Mz
4 ground in wiring harness (4) – RWL (female) (2) with ground
Possible causes
(Contact with ground circuit) Short circuit of wiring harness between RWL
and standard
(female) (3) – 203 (female) (1) – 242 (female) Resistance Min. 1Mz
value in normal
state (1) – 226 (female) (1) with ground
Defective rear lamp (Broken When only the rear lamp does not light up, it may be defective. Check
5
bulb defective ground) the bulb for breakage and check the ground wire for a defect.
Defective ripper point lamp
When only the ripper point lamp does not light up, it may be defective.
6 (Broken bulb defective
Check the bulb for breakage and check the ground wire for a defect.
ground)
Circuit diagram related to headlamp, panel night lamp, rear lamp, and ripper point lamp
D155AX-5 20-641
(2)
E-24 MALFUNCTION OF WIPERS

Trouble (1) The front wiper does not operate (Continuous operation is defective).
• Carry out the following troubleshooting when only the front wiper is defective.
Related • If fuse (5) in the cab is broken, intermittent operation of the all wipers becomes defective.
information • If any wiper does not operate, check the fusible link (96A).
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch ON.

Defective circuit breaker If the circuit breaker is turned OFF, the circuit probably has a grounding
1
(96A) fault, etc.
Since fuse (5) in the cab is used for the front wiper system and inter-
2 Defective fuse (5) in cab mittent switch system, those systems probably have a grounding fault,
etc.
Between CN23 (6) – ground Voltage 20 – 30V
3 Defective front wiper motor aPrepare with starting switch OFF, then carry out troubleshooting
Wiring harness between CN23 (female) (1) –
Resistance Max. 1z
ground
4 Defective front wiper switch CN14 (male) Position of switch Resistance
ON Max. 1z
Between (3) – (4)
OFF Min. 1Mz
• If the trouble is repaired by replacing the relay with relay CN27,
Possible causes CN31, or CN33, the relay is defective.
value in normal Defective front wiper carry out troubleshooting.
5
intermittent selector relay
state Between CN29 (3) – ground Voltage 20 – 30V
CN30, or CN32, the relay is defective.
Defective front wiper carry out troubleshooting.
6
intermittent relay
Disconnection or short cir- Wiring harness between CN14 (female) (4) – Resistance Max. 1z
cuit with chassis ground in CN29 (female) (3)
wiring harness (Disconnec- Contact of wiring harness between CN14 (fe-
7 Resistance Min. 1Mz
tion in wiring or defective male) (4) – CN29 (female) (3) with ground
contact in connector or con- Wiring harness between CN29 (female) (6) –
tact with ground circuit) Resistance Max. 1z
CN28 (female) (4)
Contact of wiring harness between CN29 (fe-
Resistance Min. 1Mz
male) (6) – CN28 (female) (4) with ground
20-642 D155AX-5
(2)

Wiring harness between fuse (5) – CN14 (fe-
male) (2), (3) and between CN23 (female) (3) Resistance Max. 1z
– CN28 (female) (3)
Contact of wiring harness between fuse (5) –
Possible causes Disconnection or short cir- CN14 (female) (2), (3) and between CN23 (fe- Resistance Min. 1Mz
and standard cuit with chassis ground in male) (3) – CN28 (female) (3) with ground
wiring harness (Disconnec- Wiring harness between CN28 (female) (5) – Resistance
value in normal 7 Max. 1z
tion in wiring or defective CN23 (female) (6)
state
contact in connector or con- Contact of wiring harness between CN28 (fe-
Resistance Min. 1Mz
tact with ground circuit) male) (5) – CN23 (female) (6) with ground
Resistance Max. 1z
ground
Resistance Max. 1z
ground
Trouble (2) The front wiper does not operate intermittently.

• Carry out the following troubleshooting when the ordinary operation is normal.
Related
• When carrying out the troubleshooting, turn the wiper switch and intermittent switch ON.
information
• Stop about 5 seconds after the wiper goes and returns once.

• If the ordinary operation is normal and the other wiper do not operate
intermittently either, the intermittent switch is probably defective.
1 Defective intermittent switch without turning starting switch ON.
CN11 (female) Position of switch Voltage
ON Max. 1z
Between (1) – (2)
OFF Min. 1Mz
Defective front wiper aPrepare with starting switch OFF, then turn starting switch ON and
2 carry out troubleshooting.
Possible causes
and standard • If the trouble is repaired by replacing the relay with relay CN26,
value in normal CN30, or CN32, the relay is defective.
Defective front wiper
state 3 aPrepare with starting switch OFF, then turn starting switch ON and
intermittent relay
Resistance Max. 1z
Disconnection or short cir- CN29 (female) (1)
cuit with chassis ground in Contact of wiring harness between CN11 (fe- Resistance
Min. 1Mz
wiring harness (Disconnec- male) (2) – CN29 (female) (1) with ground
4
tion in wiring or defective Wiring harness between CN29 (female) (5) –
Resistance Max. 1z
contact in connector or con- CN28 (female) (2)
tact with ground circuit) Contact of wiring harness between CN29 (fe-
Resistance Min. 1Mz
Resistance Max. 1z
ground
D155AX-5 20-643
(2)
Trouble (3) The rear wiper does not operate (Continuous operation is defective).
• Carry out the following troubleshooting when only the rear wiper is defective.
Related
• If any wiper does not operate, check the fusible link (96A).
information

1
(96A) fault, etc.
Since fuse (4) in the cab is used for only the rear wiper system, this sys-
2 Defective fuse (4) in cab
tem probably has a grounding fault, etc.
3 Defective rear wiper motor aPrepare with starting switch OFF, then carry out troubleshooting
Resistance Max. 1z
ground
4 Defective rear wiper switch CN12 (male) Position of switch Resistance
ON Max. 1z
Between (3) – (4)
OFF Min. 1Mz
Possible causes aPrepare with starting switch OFF, then turn starting switch ON and
and standard Defective rear wiper
value in normal intermittent selector relay
state
Defective rear wiper carry out troubleshooting.
6
intermittent relay
Disconnection or short cir- Wiring harness between CN12 (female) (4) –
Resistance Max. 1z
CN32 (female) (4)
Resistance Min. 1Mz
20-644 D155AX-5
(2)

Resistance Max. 1z
male) (2), (3)
Resistance Min. 1Mz
CN12 (female) (2), (3) with ground
Resistance Max. 1z
male) (3) – CN37 (female) (3)
Disconnection or short cir-
Possible causes Contact of wiring harness between fuse (4) –
and standard cuit with chassis ground in CN32 (female) (3) – CN37 (female) (3) with Resistance Min. 1Mz
wiring harness (Disconnec-
value in normal 7 ground
tion in wiring or defective
state Wiring harness between CN32 (female) (5) –
contact in connector or con- Resistance Max. 1z
tact with ground circuit) CN37 (female) (1)
Resistance Min. 1Mz
Resistance Max. 1z
ground
Resistance Max. 1z
ground
D155AX-5 20-645
(2)
Trouble (4) The rear wiper does not operate intermittently.

Related
information

ON Max. 1z
Between (1) – (2)
OFF Min. 1Mz
Defective rear wiper aPrepare with starting switch OFF, then turn starting switch ON and
Possible causes
Defective rear wiper
intermittent relay
Resistance Max. 1z
Min. 1Mz
4
Resistance Max. 1z
Resistance Min. 1Mz
Resistance Max. 1z
ground
20-646 D155AX-5
(2)
Trouble (5) The right door wiper does not operate (Continuous operation is defective).
• Carry out the following troubleshooting when only the right door wiper is defective. (If fuse (6) in the cab
Related is broken, the left door wiper does not operate either.)

1
(96A) fault, etc.
Since fuse (6) in the cab is used for the right door wiper system and left
2 Defective fuse (6) in cab door wiper system, either of those systems probably has a grounding
fault, etc.
Between connector (3) just before motor –
Voltage 20 – 30V
Defective right door wiper ground
3
motor aPrepare with starting switch OFF, then carry out troubleshooting
Wiring harness between connector (1) just be-
Resistance Max. 1z
fore motor – ground
Defective right door wiper CN13 (male) Position of switch Resistance
4
switch
ON Max. 1z
Between (3) – (4)
OFF Min. 1Mz
value in normal Defective right door wiper
state intermittent selector relay
Defective right door wiper carry out troubleshooting.
6
intermittent relay
CN30 (female) (4)
Resistance Min. 1Mz
D155AX-5 20-647
(2)

male) (2), (3) – CN17 (4) – connector (female) Resistance Max. 1z
(4) just before motor – CN13 (female) (2), (3)
CN13 (female) (2), (3) – CN17 (4) – connector
Resistance Min. 1Mz
(female) (4) just before motor – CN13 (female)
(2), (3) with ground
Disconnection or short cir- male) (3) Resistance Max. 1z
Possible causes
cuit with chassis ground in
and standard Contact of wiring harness between fuse (6) –
wiring harness (Disconnec- CN30 (female) (3) with ground Resistance Min. 1Mz
value in normal 7
tion in wiring or defective
state
contact in connector or con- Wiring harness between connector (female)
(3) just before motor – CN17 (3) – CN30 (fe- Resistance Max. 1z
tact with ground circuit)
male) (5)
Contact of wiring harness between connector
(female) (3) just before motor – CN17 (3) – Resistance Min. 1Mz
CN30 (female) (5) with ground
Resistance Max. 1z
ground
Wiring harness between connector (female)
Resistance Max. 1z
(1) just before motor – CN17 (1) – ground
20-648 D155AX-5
(2)
Trouble (6) The right door wiper does not operate intermittently.
Related
information

ON Max. 1z
Between (1) – (2)
OFF Min. 1Mz
Defective right door wiper aPrepare with starting switch OFF, then turn starting switch ON and
Possible causes
Defective right door wiper
intermittent relay
Resistance Max. 1z
Min. 1Mz
4
Resistance Max. 1z
Resistance Min. 1Mz
Resistance Max. 1z
ground
D155AX-5 20-649
(2)
Trouble (7) The left door wiper does not operate (Continuous operation is defective).
• Carry out the following troubleshooting when only the left door wiper is defective. (If fuse (6) in the cab
Related is broken, the right door wiper does not operate either.)

1
(96A) fault, etc.
Since fuse (6) in the cab is used for the left door wiper system and left
2 Defective fuse (6) in cab door wiper system, either of those systems probably has a grounding
fault, etc.
Between connector (3) just before motor –
Voltage 20 – 30V
Defective left door wiper ground
3
motor aPrepare with starting switch OFF, then carry out troubleshooting
Wiring harness between connector (1) just be-
Resistance Max. 1z
fore motor – ground
Defective left door wiper CN15 (male) Position of switch Resistance
4
switch
ON Max. 1z
Between (3) – (4)
OFF Min. 1Mz
value in normal Defective left door wiper
state intermittent selector relay
Defective left door wiper carry out troubleshooting.
6
intermittent relay
CN26 (female) (4)
Resistance Min. 1Mz
20-650 D155AX-5
(2)

male) (3) – CN24 (4) – connector (female) (4) Resistance Max. 1z
just before motor
CN26 (female) (3) – CN24 (4) – connector (fe- Resistance Min. 1Mz
male) (4) just before motor with ground
Resistance Min. 1Mz
Possible causes Disconnection or short cir- CN15 (female) (2), (3) – ground
cuit with chassis ground in Wiring harness between fuse (6) – CN15 (fe- Resistance
and standard Max. 1z
value in normal wiring harness (Disconnec- male) (2), (3) – ground
7
state tion in wiring or defective Wiring harness between connector (female)
contact in connector or con- (3) just before motor – CN24 (3) – CN26 (fe- Resistance Max. 1z
tact with ground circuit) male) (5)
(3) just before motor – CN24 (3) – CN26 (fe- Resistance Max. 1z
male) (5) – ground
Resistance Max. 1z
ground
Resistance Max. 1z
(1) just before motor – CN24 (1) – ground
D155AX-5 20-651
(2)
Trouble (8) The left door wiper does not operate intermittently.
Related
information

ON Max. 1z
Between (1) – (2)
OFF Min. 1Mz
Defective left door wiper aPrepare with starting switch OFF, then turn starting switch ON and
Possible causes
Defective left door wiper
intermittent relay
Resistance Max. 1z
cuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance
Min. 1Mz
wiring harness (Disconnec- CN27 (female) (1) with ground
4
Resistance Max. 1z
tact with ground circuit) Wiring harness between CN27 (female) (5) –
Resistance Min. 1Mz
CN26 (female) (2) with ground
Resistance Max. 1z
ground
20-652 D155AX-5
(2)
Circuit diagram related to wipers
D155AX-5 20-653
(2)
20-654 D155AX-5
(2)
E-25 WASHING WATER DOES NOT COME OUT

Trouble (1) Washing water of the front washer does not come out.
Related • Carry out the following troubleshooting when the front wiper operates normally. (If the wiper does not
information operate either, carry out troubleshooting in E-24 THE WIPER DOES NOT OPERATE first.

Wiring harness between 362 (male) (2) –
Defective front washer Resistance Max. 1z
1 ground
motor
Between 362 (2) – ground Voltage 20 – 30V
2 Defective front wiper switch CN14 (female) Position of switch Resistance
W/ or W/ Max. 1z
Possible causes Between (2) – (1)
and standard OFF Min. 1Mz
value in normal aDisconnection or short circuit with chassis ground in wiring harness
state (Disconnection in wiring or defective contact in connector or contact
with ground circuit)
Resistance Max. 1z
Disconnection or short cir- male) (2)
cuit with chassis ground in Contact of wiring harness between fuse (5) – Resistance
Min. 1Mz
wiring harness (Disconnec- CN14 (female) (2) with ground
3
Resistance Max. 1z
contact in connector or con- 19 (3) – 362 (female) (1)
male) (6) – 19 (3) – 362 (female) (1) with Resistance Min. 1Mz
ground
Resistance Max. 1z
ground
D155AX-5 20-655
(2)
Trouble (2) Washing water of the rear washer does not come out.
Related • Carry out the following troubleshooting when the rear wiper operates normally. (If the wiper does not
information operate either, carry out troubleshooting in E-24 THE WIPER DOES NOT OPERATE first.

Resistance Max. 1z
1 Defective rear washer motor ground
2 Defective rear wiper switch CN12 (female) Position of switch Resistance
Possible causes W/ or W/ Max. 1z
and standard Between (2) – (1)
OFF Min. 1Mz
Resistance Max. 1z
male) (2)
Disconnection or short cir- Contact of wiring harness between fuse (4) –
cuit with chassis ground in CN12 (female) (2) with ground Resistance Min. 1Mz
3 Wiring harness between CN12 (female) (1) –
tion in wiring or defective Resistance Max. 1z
19 (4) – 364 (female) (1)
contact in connector or con-
ground
Resistance Max. 1z
ground
20-656 D155AX-5
(2)
Trouble (3) Washing water of the left door washer does not come out.
• Carry out the following troubleshooting when the left door wiper operates normally. (If the wiper does
Related not operate either, carry out troubleshooting in E-24 THE WIPER DOES NOT OPERATE first.
information • Since the left door wiper switch and right door wiper switch use fuse (6) jointly, if fuse (6) is broken, both
wipers do not operate.

Defective left door washer Resistance Max. 1z
1 ground
motor
Defective left door wiper
2 CN15 (female) Position of switch Resistance
switch
Between (2) – (1)
Resistance Max. 1z
male) (2)
19 (1) – 361 (female) (1)
ground
Resistance Max. 1z
ground
D155AX-5 20-657
(2)
Trouble (4) Washing water of the right door washer does not come out.
• Carry out the following troubleshooting when the right door wiper operates normally. (If the wiper does
Related not operate either, carry out troubleshooting in E-24 THE WIPER DOES NOT OPERATE first.
information • Since the right door wiper switch and left door wiper switch use fuse (6) jointly, if fuse (6) is broken, both
wipers do not operate.

Defective right door washer Resistance Max. 1z
1 ground
motor
Defective right door wiper
2 CN13 (female) Position of switch Resistance
switch
Between (2) – (1)
Resistance Max. 1z
male) (2)
19 (2) – 363 (female) (1)
ground
Resistance Max. 1z
ground
20-658 D155AX-5
(2)
Circuit diagram related to washing water
D155AX-5 20-659
(2)
20-660 D155AX-5
(2)
E-26 THE AIR CONDITIONER DOES NOT OPERATE

Trouble (1) No air flow.
Related
information

Defective circuit breaker When the circuit breaker is cut off, a ground fault may have possibly oc-
1
(CB2) curred in the circuit.
Defective blower main relay without turning the starting switch ON.
2
(coil side) CN-R1 (male) Resistance
Between (1) and (2) 240 ± 40z
Defective blower main relay ON and carry out troubleshooting.
3
(contact side) CN-R1 (male) Voltage
Between (8C) and ground 20 – 30V
Defective blower Hi relay without turning the starting switch ON.
4
Between (1) and (2) 240 ± 40z
Defective blower Hi relay ON and carry out troubleshooting.
5
(contact side) The relay is in order when the motor rotates after the starting switch is
Possible causes
turned ON and the blower Hi switch is turned on.
and standard
state Defective blower Mi1 relay without turning the starting switch ON.
6
Between (1) and (2) 240 ± 40z
Defective blower Mi1 relay ON and carry out troubleshooting.
7
turned ON and the blower Mi switch is turned on.
Defective blower Mi2 relay without turning the starting switch ON.
8
Between (1) and (2) 240 ± 40z
Defective blower Mi2 relay ON and carry out troubleshooting.
9
turned ON and the blower Mi switch is turned on.
10 Defective blower motor
The motor is in order when it rotates after the starting switch is turned
ON and the blower Lo switch is turned on.
D155AX-5 20-661
(2)

Wiring harness between CN-R4 (female)
(14C), AC1 (female) (14A), CN-R (female)
Resistance Max. 1z
(0D) or CN-R2 (female) (14E) or CN-R3 (fe-
male) (14N) and ground
Wiring harness between CN-B(female) (11B)
Resistance Max. 1z
and CN-R1 (female) (11A)
Wiring harness between CN-B (female) (12A)
and CN-R2 (female) (12B) or CN-R (female) Resistance Max. 1z
Disconnection of wiring (S121)
harness (Disconnection in Wiring harness between M26 (1B) and AC1
11
Possible causes wiring or defective contact in (female) (1A), CN-R1 (female) (1D), CN-R2 Resistance Max. 1z
and standard connector) (female) (1E) or CN-R4 (female) (11H)
value in normal Wiring harness between CN-R1 (female) (2B)
Resistance Max. 1z
state and AC1 (female) (2A)
Wiring harness between CN-R3 (female) (3B)
Resistance Max. 1z
and AC1 (female) (3A)
Resistance Max. 1z
Resistance Max. 1z
When Causes 1 to 9 are not applicable, the control panel is supposed
12 Defective control panel
to be defective.
When any cause cannot be specified, failure phenomenon may have
Different failure phenome-
13 been mistaken. Carry out the troubleshooting of “Cooling is not possi-
non
ble.”
20-662 D155AX-5
(2)
Trouble (2) Cooling is not possible.

Related
information

1 Defective pressure switch CN-P Blower switch Voltage
Between (6B) and
ON 20 – 30V
ground
Defective compressor clutch without turning the starting switch ON.
2
relay (coil side) CN-R5 (male) Resistance
Between (1) and (2) 240 ± 40z
Defective compressor clutch ON and carry out troubleshooting.
3
relay (contact side) CN-R5 (male) Voltage
Between (18A) and ground 20 – 30V
Defective condenser relay ON and carry out troubleshooting.
4
(contact side) CN-R6 Voltage
Between (23A) and ground 20 – 30V
5 Defective thermistor
AC1 (male) Resistance
Possible causes
and standard Between (9A) and (13A) Max. 3,500z
state Defective condenser blower without turning the starting switch ON.
6
resistor Condenser blower resistor Resistance
Between terminals 2.8z ± 5%
aTurn the starting switch on and carry out the troubleshooting.
7 Defective condenser motor The motor is in order if it is rotating when the air conditioner is switched
ON.
aStart the engine and carry out the troubleshooting.
Defective compressor
8 The compressor magnet clutch is supposed to be out of order, so in-
magnet clutch
spect it directly.
aStart the engine and carry out the troubleshooting.
9 Defective compressor
The compressor is supposed to be out of order, so inspect it directly.
Wiring harness between M26 (8A) and CN-R6
(female) (8B) or CN-R5 (female) (8D) or CN- Resistance Max. 1z
Disconnection of wiring R1 (female) (8C)
10 Wiring harness between M26 (18B) and CN-
wiring or defective contact in Resistance Max. 1z
R5 (female) (18A)
connector)
Wiring harness between M26 (1B) and CN-R5
Resistance Max. 1z
(female) (1K)
Wiring harness between CN-T (female) (9B)
Resistance Max. 1z
D155AX-5 20-663
(2)

Possible causes
harness (Disconnection in Wiring harness between CN-P (female) (7B)
and standard 10 Resistance Max. 1z
wiring or defective contact in and CN-R5 (female) (7A)
value in normal
connector) Wiring harness between CN-P (female) (6B)
When Causes 1 to 10 are not applicable, the control panel is supposed
11 Defective control panel
to be defective.
20-664 D155AX-5
(2)
Circuit diagram related to air conditioner
D155AX-5 20-665
(2)
20-666 D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
(H-MODE)
Information described in
troubleshooting list ...................................... 20-702
H- 1 No travel power (No drawbar pull) ..... 20-703
H- 2 Machine does not move
(At 2nd or 3rd speed) ........................ 20-704
H- 3 Machine does not move in
any speed range ................................ 20-705
H- 4 Machine travels only in one
direction forward or in reverse ........... 20-706
H- 5 When gear is shifted or
travel direction is changed,
large time lag is made ....................... 20-707
H- 6 Machine does not turn
(Not turned rightward or leftward) ...... 20-708
H- 7 Steering speed or power is low ......... 20-708
H- 8 Brake does not work .......................... 20-709
H- 9 Overheat of power train
oil temperature .................................. 20-709
H-10 Abnormal sound comes out from
around HSS pump or HSS motor ...... 20-710
H-11 All work equipment speeds are slow .... 20-711
H-12 Work equipment does not move ........ 20-711
H-13 Blade lift speed is slow or
lacks power ........................................ 20-712
H-14 Blade tilt speed is slow or
lacks power ........................................ 20-712
H-15 Ripper lift speed is slow or
lacks power ........................................ 20-713
H-16 Ripper tilt speed is slow or
lacks power ........................................ 20-713
H-17 Excessive hydraulic drift of blade lift .... 20-714
H-18 Excessive hydraulic drift of blade tilt .... 20-714
H-19 Excessive hydraulic drift of ripper lift .... 20-715
H-20 Ripper pin puller cylinder does not work
(Giant ripper attachment machine) .... 20-715
H-21 Blade pitch does not work
(Pitch dozer attachment machine) ..... 20-716
H-22 Abnormal sound comes out from
around work equipment pump ........... 20-716
D155AX-5 20-701
(2)

a Troubleshooting lists contain the following information all together. Understand the contents carefully and
troubleshoot the machine.
Trouble Problem that appears on the machine.
Related
Information related to problems occurred or troubleshooting
information
Possible causes
2 Cause supposed to have
and standard caused failure <Contents>
value in normal (The sequence shows • Standard values in normal state for judging possible causes
state reference numbers and • Remarks for making judgment
3 does not mean priority.)
20-702 D155AX-5
(2)
TROUBLESHOOTING H-1
H-1 NO TRAVEL POWER (NO DRAWBAR PULL)

Trouble • There is no travel power. (No drawbar pull).
Related
• Confirm that the oil quantity on the power train is normal before troubleshooting.
information

aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
1 Defective engine
Measurement conditions Number of engine rotations
F3 stall 1,491rpm
2 Defective power train pump The power train pump is assumed to be defective; directly check it.
Internally defective torque Original pressure of Torque converter
3 PCCS lever
converter torque converter delivery pressure
Max. 1.0MPa 0.39 – 0.59MPa
Full neutral
{Max. 10kg/cm2} {4 – 6kg/cm2}
PCCS lever Transmission main relief pressure
Full neutral Min. 3.09MPa {31.5kg/cm2}
Defective set pressure of aPrepare with the starting switch OFF, then carry out troubleshooting
4 transmission main relief without turning the starting switch ON.
Possible causes valve and internal defect Directly check that the spring free length and the number of shims are
and standard normal and also that the spool rotates smoothly.
value in normal • Free length of large spring: 128mm
state • Free length of small spring: 108mm
• Number of shims: 6
aPrepare with starting switch OFF, then drive the engine in low idling
Transmission clutch Clutch pressure
Defective transmission valve FWD 2.88MPa {29.4kg/cm2}
5
(ECMV) function REV 2.88MPa {29.4kg/cm2}
1ST 2.88MPa {29.4kg/cm2}
2ND 2.88MPa {29.4kg/cm2}
3RD 2.88MPa {29.4kg/cm2}
6 Defective brake valve
Parking lever Brake pressure
Free 2.16MPa {22kg/cm2}
If the result of the troubleshooting in cause 6 is abnormal, the parking
Defective parking lever or
7 lever or brake pedal linkage is not assumed to be adjusted normally.
brake pedal linkage
Directly check it.
Internally defective trans- The transmission is assumed to be defective internally; directly check
8
mission it.
D155AX-5 20-703
(2)
TROUBLESHOOTING H-2
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)

Trouble • Machine does not move. (At 2nd or 3rd speed)
Related • Confirm that the oil quantity on the power train is normal before troubleshooting.
information • Confirm that the transmission main relief pressure is normal before troubleshooting. (See H-1.)

1 PCCS lever
1.0MPa 0.39 – 0.59MPa
Full neutral
{10kg/cm2} {4 – 6kg/cm2}
Possible causes Defective transmission valve
2 Transmission clutch Clutch pressure
and standard (ECMV) function
2ND 2.88MPa {29.4kg/cm2}
value in normal
state 3RD 2.88MPa {29.4kg/cm2}
Internally defective trans- The transmission clutch (2nd or 3rd speed) is assumed to be defective
3
mission clutch internally; directly check it.
Defective parking brake The parking brake function is assumed to be defective (dragged);
4
function (Drag) check the linkage valves.
aMove to a flat place, and start the engine for troubleshooting.
Defective brake function
5 If the machine does not run by low idling + F2 operation, brake drag oc-
(Drag)
curs. (Carry out troubleshooting “Brake does not work.”)
Internally defective trans- The transmission is assumed to be defective internally; directly check
6
mission it.
20-704 D155AX-5
(2)
TROUBLESHOOTING H-3
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE

Trouble • Machine does not move in any speed range.
Related
information

Full neutral 3.09MPa {31.5kg/cm2}
Defective and Internally de- aPrepare with the starting switch OFF, then carry out troubleshooting
2 fective set pressure of trans- without turning the starting switch ON.
mission main relief valve Directly check that the spring free length and the number of shims are
normal and also that the spool rotates smoothly.
• Free length of large spring: 128mm
• Free length of small spring: 108mm
mode for troubleshooting. (Before this, confirm that the transmission
Possible causes main relief pressure is normal.)
and standard Transmission clutch Clutch pressure
value in normal Defective transmission valve
3 FWD 2.88MPa {29.4kg/cm2}
state (ECMV) function
REV 2.88MPa {29.4kg/cm2}
1ST 2.88MPa {29.4kg/cm2}
2ND 2.88MPa {29.4kg/cm2}
3RD 2.88MPa {29.4kg/cm2}
Internally defective trans- The transmission clutch is assumed to be defective internally; directly
4
mission clutch check it.
aMove to a flat place, and drive the engine in high idling mode for trou-
bleshooting. (Before this, confirm that the transmission main relief
pressure is normal.)
Brake hydraulic pressure
Brake pedal
5 Defective brake function (left/right)
Release 0MPa {0kg/cm2}
Pedal 2.16MPa {22kg/cm2}
When the hydraulic pressure is abnormal, carry out troubleshooting
“Brake does not work.”
D155AX-5 20-705
(2)
TROUBLESHOOTING H-4
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE

Trouble • Machine travels only in one direction Forward or in reverse.
Related
information

valve or internal defect Directly check that the spring free length and the number of shims are
normal and also that the spool rotates smoothly.
Possible causes
and standard
value in normal
state
mode for troubleshooting. (Before this, confirm that the transmission
Defective transmission valve main relief pressures is normal.)
3 Transmission clutch Clutch pressure
(ECMV) function
FWD 2.88MPa {29.4kg/cm2}
Defective transmission When the troubleshooting in cause 4 is abnormal, the clutch seal is as-
4
clutch seal sume to be defective; directly check it.
Internally defective trans- The transmission clutch (forward or reverse) is assumed to be defec-
5
mission clutch tive internally; directly check it.
20-706 D155AX-5
(2)
TROUBLESHOOTING H-5
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME

LAG IS MADE
Trouble • Time lag is excessive when shifting gear or changing direction.
Related
information

valve or internal defect Directly check that the spring length and the number of shims are nor-
mal and also that the spool rotates smoothly.
Possible causes aPrepare with starting switch OFF, then drive the engine in low idling
and standard mode for troubleshooting. (Before this, confirm that the transmission
value in normal main relief pressure is normal.)
state
Transmission clutch Clutch pressure
Defective transmission valve FWD 2.88MPa {29.4kg/cm2}
3
(ECMV) function
1ST 2.88MPa {29.4kg/cm2}
2ND 2.88MPa {29.4kg/cm2}
3RD 2.88MPa {29.4kg/cm2}
Defective transmission When the troubleshooting in cause 3 is abnormal, the clutch seal is as-
4
clutch seal sume to be defective; directly check it.
Internally defective trans- The transmission clutch is assumed to be defective internally; directly
5
mission clutch check it.
aMove to a flat place, then start the engine for troubleshooting.
6 If the machine does not run by low idling + F2 operation, brake drag oc-
(Drag)
curs. (Carry out troubleshooting “Brake does not work.”)
D155AX-5 20-707
(2)
TROUBLESHOOTING H-6, H-7
H-6
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD)

Trouble • Machine does not turn. (The machine does not turn leftward or rightward.)
Related
• Confirm that the oil quantity for function is normal before troubleshooting.
information

Defective set pressure or aPrepare with starting the engine, then drive the engine in high idling
defective function of self- mode for troubleshooting.
1 pressure reducing valve
(HSS servo charge pres- PCCS lever Original pressure of control circuit
sure) Neutral 3.24 – 3.92MPa {33 – 40kg/cm2}
defective function of HSS mode for troubleshooting.
2
charge safety valve (pump PCCS lever HSS charge relief pressure
Possible causes side) Neutral 2.65 – 3.43MPa {27 – 35kg/cm2}
and standard Defective set pressure or aPrepare with starting the engine, then drive the engine in high idling
value in normal defective function of HSS mode for troubleshooting.
state 3
charge relief valve (motor PCCS lever HSS charge relief pressure
side) Neutral 2.65 – 3.43MPa {27 – 35kg/cm2}
Defective function of HSS The HSS pump solenoid valve function is assumed to be defective; di-
4
pump solenoid valve rectly check it.
Defective function of HSS The HSS motor bypass valve function is assumed to be defective; di-
5
motor bypass valve rectly check it.
If an abnormal sound occurs in the HSS peripheral equipment, carry
Abnormal sound from HSS
6 out troubleshooting “Abnormal Sound around HSS Pump or HSS Mo-
peripheral equipment
tor.”
H-7 STEERING SPEED OR POWER IS LOW

Trouble • Steering speed or power is insufficient.
Related
information

aPrepare with starting the engine, then drive the engine in high idling
Defective set pressure or mode for troubleshooting.
1 defective function of HSS
PCCS lever HSS main pressure
main relief valve
Left or right stroke end 38.2 – 41.7MPa {390 – 425kg/cm2}
2 pressure reducing valve
(HSS servo charge pres- PCCS lever Original pressure of control circuit
sure) Neutral 3.24 – 3.92MPa {33 – 40kg/cm2}
Possible causes Defective set pressure or aPrepare with starting the engine, then drive the engine in high idling
and standard defective function of HSS mode for troubleshooting.
value in normal 3
state side) Neutral 2.65 – 3.43MPa {27 – 35kg/cm2}
4
5
pump solenoid valve rectly check it.
If an abnormal sound occurs in the HSS peripheral equipment, carry
Abnormal sound from HSS
6 out troubleshooting “Abnormal Sound around HSS Pump or HSS Mo-
peripheral equipment
tor.”
20-708 D155AX-5
(2)
H-8
H-8 BRAKE DOES NOT WORK

Trouble • Brake does not work.
Related • Confirm that the oil quantity on the power train is normal before troubleshooting.
information • Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)

Defective brake valve func-
1 Brake pedal Brake hydraulic pressure
tion
Possible causes At release 0MPa {0kg/cm2}
and standard At pedaling 2.16MPa {22kg/cm2}
value in normal Defective adjustment of If the troubleshooting in cause 1 is abnormal, the adjustment of the
state 2
brake pedal linkage brake pedal linkage is assumed to be defective; directly check it.
If the troubleshooting in cause 1 is abnormal, the brake seal is as-
3 Defective brake seal
sumed to be defective; directly check it.
Slipped or abrasive brake The brake disk plate is assumed to be slipped or abrasive; directly
4
disk plate check it.
H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE

Trouble • The oil temperature of the power train overheats.
• Confirm that the value of the oil temperature of the power train matches the actual oil temperature be-
Related
fore troubleshooting. (If they do not match, carry out troubleshooting “Abnormal Power Train Oil tem-
information
perature.”)
• Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)

The engine cooling system is assumed to be defective or the engine
1 Defective engine system
output is assumed to be increased; see the Shop Manual: Engine.
Defective power train pump aThe power train pump is assumed to be defective or aired from the
2
or air from suction circuit suction circuit; directly check it.
3 PCCS lever
Possible causes
Max. 1.0MPa 0.39 – 0.59MPa
and standard Full neutral
{Max. 10kg/cm2} {4 – 6kg/cm2}
value in normal
state Defective transmission The transmission clutch is assumed to be defective internally (slipped);
4
clutch function (Slip) directly check it.
aPrepare with starting the engine for troubleshooting.
1. Use the blades and ripper to float the machine from the ground.
5 2. Convert the drive position to F3 or R3 while low-idling.
(Drag)
3. If the track shoe does not rotate, brake drag occurs. (Carry out trou-
bleshooting “Brake does not work.”)
aPrepare with starting the engine for troubleshooting.
6 Carry out F3 stall. If the machine does not stop completely, brake slip
(Slip)
occurs.
D155AX-5 20-709
(2)
TROUBLESHOOTING H-10
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS PUMP OR HSS MOTOR
Trouble • Abnormal sound comes out from around HSS pump or HSS motor.
Related
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information

aPrepare with starting the engine, then drive the engine in high idling
1 defective function of HSS PCCS lever HSS main pressure
main relief valve 38.2 – 41.7MPa
Left or right stroke end
{390 – 425kg/cm2}
2 pressure reducing valve PCCS lever Original pressure of control circuit
(HSS servo charge pres- 3.24 – 3.92MPa
sure) Neutral
{33 – 40kg/cm2}
Possible causes mode for troubleshooting.
defective function of HSS
and standard 3
value in normal
state
4
5
charge piping rectly check it.
Internally defective HSS
6 The HSS pump is assumed to be defective internally; directly check it.
pump
Internally defective HSS
7 The HSS motor is assumed to be defective internally; directly check it.
motor
Internally defective work The work equipment pump is assumed to be defective internally; di-
8
equipment pump rectly check it.
20-710 D155AX-5
(2)
H-11
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW

Trouble • All work equipment speeds are slow.
Related
information

Defective PTO (pump drive
The PTO pump drive unit of the work equipment is assumed to be de-
1 unit of HSS and work equip-
fective; directly check it.
ment)
Defective work equipment The pump of work equipment is assumed to be defective; directly
2
pump check it.
Defective unload valve func-
3 The unload valve is assumed to be defective; directly check it.
tion
Possible causes aPrepare with starting switch OFF, then drive the engine in high idling
and standard Defective set pressure or mode for troubleshooting.
value in normal 4 defective function of main Work equipment lever Main relief pressure
state relief valve 20.59 ± 0.98MPa
Stroke end
{210 ± 10kg/cm2}
defective function of self-
5 Work equipment lever Original pressure of control circuit
pressure reducing valve
(PPC original pressure) 3.24 – 3.92MPa
Full neutral
{33 – 40kg/cm2}
Internally defective PPC When the troubleshooting in cause 5 is abnormal, the PPC valve is as-
6
valve sumed to be defective internally; directly check it.
H-12 WORK EQUIPMENT DOES NOT MOVE

Trouble • Work equipment does not move.
Related
information

Defective PTO (Work equip- The PTO pump drive unit of the HSS and work equipment is assumed
1
ment pump drive unit) to be defective; directly check it.
Defective work equipment The work equipment pump is assumed to be defective; directly check
2
pump it.
Defective unload valve func-
3 The unload valve is assumed to be defective; directly check it.
tion
Possible causes aPrepare with starting switch OFF, then drive the engine in high idling
and standard mode for troubleshooting.
value in normal Defective set pressure or
4 defective function of main Work equipment lever Main relief pressure
state
relief valve 20.59 ± 0.98MPa
Stroke end
{210 ± 10kg/cm2}
defective function of self-
5 Work equipment lever Original pressure of control circuit
pressure reducing valve
(PPC original pressure) 3.24 – 3.92MPa
Full neutral
{33 – 40kg/cm2}
D155AX-5 20-711
(2)
H-14
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER

Trouble • Blade lift speed is slow or lacks power.
Related • Confirm whether the blade is remodeled.
information • When the hydraulic drift rate of the blade lift is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Blade Lift.”

Defective PPC valve func- mode for troubleshooting.
1
tion Blade lever PPC valve output pressure
Lift stroke end 3.53MPa {36kg/cm2}
Possible causes
and standard Defective function of blade The spool function of the blade lift operation valve is assumed to be de-
2
value in normal lift operation valve (Spool) fective; directly check it.
state The suction valve function of the blade lift operation valve is assumed
Defective function of blade
to be defective; directly check it.
3 lift operation valve (Suction
aReplace the suction valve in the ripper lift or tilt the suction valve and
valve)
observe how the phenomenon changes.
The blade lift cylinder is assumed to be aired; carry out the air bleed
4 Aired blade lift cylinder
and observe how the phenomenon changes.
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER

Trouble • Blade tilt speed is slow or lacks power.
information • When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Blade Tilt.”

Possible causes 1
tion Blade lever PPC valve output pressure
and standard
Tilt stroke end 3.53MPa {36kg/cm2}
value in normal
state Defective function of blade The spool function of the blade tilt operation valve is assumed to be de-
2
tilt operation valve (Spool) fective; directly check it.
The blade tilt cylinder is assumed to be aired; carry out the air bleed
3 Aired blade tilt cylinder
20-712 D155AX-5
(2)
H-15
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER

Trouble • Ripper lift speed is slow or lacks power.
Related • Confirm whether the ripper is remodeled.
information • When the hydraulic drift rate of the ripper lift is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Ripper Lift.”

1
tion Ripper lever PPC valve output pressure
Lift stroke end 3.53MPa {36kg/cm2}
Possible causes
and standard Defective function of ripper The spool function of the ripper lift operation valve is assumed to be de-
2
value in normal lift operation valve (Spool) fective; directly check it.
state The suction valve of the ripper lift operation valve is assumed to be de-
Defective function of ripper
3 lift operation valve (suction
aReplace the suction valve in the head with one at the bottom, and ob-
valve)
serve how the phenomenon changes.
The ripper lift cylinder is assumed to be aired; carry out the air bleed
4 Aired ripper lift cylinder
H-16 RIPPER TILT SPEED IS SLOW OR LACKS POWER

Trouble • Ripper tilt speed is slow or lacks power.
Related • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information • Confirm whether the ripper is remodeled.

1
tion Ripper lever PPC valve output pressure
Tilt stroke end 3.53MPa {36kg/cm2}
Possible causes
and standard Defective function of ripper The spool function of the ripper tilt operation valve is assumed to be de-
2
value in normal tilt operation valve (Spool) fective; directly check it.
state The suction valve of the ripper tilt operation valve is assumed to be de-
Defective function of ripper
3 tilt operation valve (Suction
aReplace the suction valve in the head with one at the bottom, and ob-
valve)
serve how the phenomenon changes.
The ripper tilt cylinder is assumed to be aired; carry out the air bleed
4 Aired ripper tilt cylinder
D155AX-5 20-713
(2)
H-18
H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT

Trouble • Excessive hydraulic drift of blade lift.
information • Confirm that no oil leaks the circuits in the work equipment before troubleshooting.

aPrepare with starting the engine, then stop the engine for trouble-
shooting.
Follow the procedure below for troubleshooting. If the hydraulic drift
speed becomes high, the spool seal of the blade lift operation valve is
Possible causes
Defective seal of blade lift assumed to be defective.
and standard 1
operation valve (Spool) 1. Prop up the machine using the blade lift, and lift the front of the ma-
value in normal
chine.
state
2. Stop the engine, and release the safety lock lever.
3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of blade lift The seal of the blade lift cylinder is assumed to be defective; directly
2
cylinder check it.
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT

Trouble • Excessive hydraulic drift of blade tilt.

shooting.
speed becomes high, the spool seal of the blade tilt operation valve is
Defective seal of blade tilt assumed to be defective.
Possible causes 1
operation valve (Spool) 1. Prop up the machine using the blade tilt, and lift the right of the ma-
and standard
chine.
value in normal 2. Stop the engine, and release the safety lock lever.
state 3. Set the blade lever to the left tilt side, and confirm how the phenom-
enon changes.
Defective seal of blade tilt mode for troubleshooting.
2
cylinder Blade tilt cylinder Cylinder leak quantity
Left tilt stroke end 12cc/min
20-714 D155AX-5
(2)
H-19
H-19 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT

Trouble • Excessive hydraulic drift of ripper lift.
Related • Confirm whether the ripper is remodeled.

shooting.
speed becomes high, the spool seal of the ripper lift operation valve is
Defective seal of ripper lift assumed to be defective.
Possible causes 1
operation valve (Spool) 1. Prop up the machine using the blade tilt, and lift the rear of the ma-
and standard chine.
value in normal
2. Stop the engine, and release the safety lock lever.
state
3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of ripper lift mode for troubleshooting.
2
cylinder Ripper lift cylinder Cylinder leak quantity
Lowering stroke end 11cc/min
H-20 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACH-
MENT MACHINE)
Trouble • The ripper pin puller cylinder does not work.
Related
• Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)
information

Possible causes Pin puller working
Defective function of pin
and standard 1 Pin puller switch Measurement position
puller solenoid valve pressure
value in normal
Push-in Cylinder bottom side Min. 2.45MPa
state
Pull-in Cylinder head side {Min. 25kg/cm2}
Internally defective pin puller The pin puller cylinder is assumed to be defective internally; directly
2
cylinder check it.
D155AX-5 20-715
(2)
H-22
H-21 BLADE PITCH DOES NOT WORK (PITCH DOZER ATTACHMENT MACHINE)
Trouble • The blade pitch does not work.
Related
information

Defective function of blade
The spool of the blade pitch operation valve is assumed to be defective;
Possible causes 1 pitch selection solenoid
directly check it.
and standard valve
value in normal Defective function of blade The function of the blade pitch cylinder is assumed to be defective; di-
2
state pitch operation valve (Spool) rectly check it.
Defective function of blade The function of the blade pitch selection solenoid valve is assumed to
3
pitch cylinder be defective; directly check it.
H-22 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP
Trouble • Abnormal noise from around work equipment pump.
Related
information

1 Inappropriate oil The oil used is assumed to be inappropriate; directly check it.
Possible causes Clogged hydraulic oil tank The strainer of the hydraulic oil tank is assumed to be clogged; directly
2
and standard strainer check it.
value in normal Air is assumed to be inhaled in the suction circuit of the work machine
state 3 Air inhaled in suction circuit
pump; directly check the pipes.
Internally defective work The work equipment pump is assumed to be defective internally; di-
4
equipment pump rectly check it.
20-716 D155AX-5
(2)
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM

(S-MODE)
Method of using troubleshooting charts ...... 20-752

S- 1 Starting performance is poor
(starting always takes time) ............... 20-756
S- 2 Engine does not start ........................ 20-757
a) Engine does not turn ................... 20-757
b) Engine turns but no exhaust
smoke comes out ........................ 20-758
c) Exhaust smoke comes out
but engine does not start
(Fuel is being injected) ................ 20-759
S- 3 Engine does not pick up smoothly
(follow-up is poor) .............................. 20-760
S- 4 Engine stops during operations ......... 20-761
S- 5 Engine does not rotate smoothly
(hunting) ............................................ 20-762
S- 6 Engine lacks output
(or lacks power) ................................. 20-763
S- 7 Exhaust smoke is black
(incomplete combustion) ................... 20-764
S- 8 Oil consumption is excessive
(or exhaust smoke is blue) ................ 20-765
S- 9 Oil becomes contaminated quickly .... 20-766
S-10 Fuel consumption is excessive .......... 20-767
S-11 Oil is in coolant (or coolant spurts
back, or coolant level goes down) ..... 20-768
S-12 Oil pressure caution lamp lights up
(drop in oil pressure) ......................... 20-769
S-13 Oil level rises (water, fuel in oil) ......... 20-770
S-14 Water temperature becomes
too high (overheating) ....................... 20-771
S-15 Abnormal noise is made .................... 20-772
S-16 Vibration is excessive ........................ 20-773
D155AX-5 20-751
(2)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make fi-
nal confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in (B) are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-752 D155AX-5
(2)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, taking note of the Q or w marks in the chart
for the horizontal lines of symptoms applicable to the
machine. The vertical column (Causes) that has the
highest number of applicable Q or w marks is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
*1. For (Confirm recent repair history) in the

[Questions] Section, ask the user, and mark
the Cause column with E to use as reference
for locating the cause of the fairure. Howev-
er, do not use this when marking calucula-
tions to narrow down causes.
*2. Use the E in the Cause column as reference
for [Degree of use (Operated for long peri-
od)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be in-
cluded if necessary to determine the order
for troubleshooting.
*1
*2
D155AX-5 20-753
(2)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have a causal relationship with this problem: [Exhaust gas gradually became black], [Power gradually be-
came weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited be-
cause an error has occurred in the electrical
system.)
Legend
: Possible causes (judging from Questions and Check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
20-754 D155AX-5
(2)
5 causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the 5
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marked where the
horizontal limes for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cyl. head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element]. Follow
this column down to the troubleshooting area and carry
out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
D155AX-5 20-755
(2)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)

General causes why starting performance is poor
• Defective electrical system
• Insufficient supply of fuel
a With the common rail fuel injection system, the fuel

injection timing is recognized electrically, so even
when the starting operation is carried out, the engine
may not start until the crankshaft has completed two
Wear-out failure inside fuel injector

rotations. However, this does not indicate any abnor-
mality.
When engine warm up like first thing the daytime, the start ability is worse
There is a large amount of the fuel spill (See error code "AD10L3")
20-756 D155AX-5
(2)
TROUBLESHOOTING S-2
S-2 Engine does not start

a) Engine does not turn
General causes why engine does not turn
• Internal parts of engine seized
a See “Engine stops during operations.”
• Defective electrical system
• Failure in power train
a Carry out troubleshooting of the machine.
D155AX-5 20-757
(2)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
20-758 D155AX-5
(2)
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not

start (Fuel is being injected)
General causes why exhaust smoke comes out but
engine does not start
• Lack of rotating force due to defective electrical
system
D155AX-5 20-759
(2)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly
(The injection amount (output) is limited because an
error has occurred in the electrical system.)
20-760 D155AX-5
(2)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops
• Internal part of engine seized
• Failure in power train
a Carry out troubleshooting of the machine.
D155AX-5 20-761
(2)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly
• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
20-762 D155AX-5
(2)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
Carry out troubleshooting for error code"DGE4KX"
D155AX-5 20-763
(2)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
• There is excessive fuel.
20-764 D155AX-5
(2)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive
• Abnormal combustion of oil
• The engine has been run at low or high idling for a
long time continuously (more than 20 minutes contin-
uous operation is not allowed).
• External leakage of oil
• Wear of lubrication system
D155AX-5 20-765
(2)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
20-766 D155AX-5
(2)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
• Leakage of fuel
• Improper condition of fuel injection (injection pressure,
injection timing)
• Excessive injection of fuel
D155AX-5 20-767
(2)
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)
General causes why oil is in coolant
• Internal leakage in lubrication system
• Internal leakage in cooling system
20-768 D155AX-5
(2)
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure drops
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Carry out troubleshooting for error code "DDE2L6"
D155AX-5 20-769
(2)
S-13 Oil level rises (water, fuel in oil)

General causes why oil level rises
• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the cooling water, carry out trouble-

shooting for “Oil is in cooling water.”
20-770 D155AX-5
(2)
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
a Carry out troubleshooting for machine.
D155AX-5 20-771
(2)
S-15 Abnormal noise is made

General causes why abnormal noise is made
• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external

noise.
a If the engine is not thoroughly warmed up, the engine
sound becomes slightly louder because it is operated
in the low temperature mode, but this is not an abnor-
mality.
a When the engine is accelerated, it enters the acceler-
ation mode and the engine noise is higher for 3 sec-
onds, but this is not an abnormality.
20-772 D155AX-5
(2)
S-16 Vibration is excessive

General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
a If there is abnormal noise together with the vibration,

carry out troubleshooting also for “Abnormal noise is
made.”
D155AX-5 20-773
(2)
20-774 D155AX-5
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ...................... 30- 3 FAN DRIVE
PRECAUTIONS WHEN CARRYING Removal and installation........................... 30-68
OUT OPERATION........................................... 30- 4 FAN MOTOR
SPECIAL TOOL LIST...................................... 30- 6 Removal and installation........................... 30-69
SPECIAL TOOL SKETCH............................... 30-16 HYDRAULIC COOLER
STARTING MOTOR Removal and installation........................... 30-70
Removal and Installation ........................... 30-25 ENGINE
ALTERNATOR Removal.................................................... 30-71
Removal and Installation ........................... 30-26 Installation................................................. 30-73
ENGINE OIL COOLER CORE DAMPER
Removal and Installation ........................... 30-27 Removal.................................................... 30-74
FUEL SUPPLY PUMP Installation................................................. 30-75
Removal .................................................... 30-28 Disassembly.............................................. 30-76
Installation ................................................. 30-30 Assembly .................................................. 30-79
WATER PUMP POWER TRAIN UNIT
Removal and Installation ........................... 30-32 Removal.................................................... 30-83
TURBOCHARGER Installation................................................. 30-87
Removal and Installation ........................... 30-33 Separation................................................. 30-88
FUEL INJECTOR POWER TRAIN .............................................. 30-92
Removal .................................................... 30-34 PTO
Installation ................................................. 30-35 Disassembly.............................................. 30-93
NOZZLE TIP Assembly .................................................. 30-97
Removal .................................................... 30-37 TORQUE CONVERTER
Installation ................................................. 30-38 Disassembly............................................ 30-102
ENGINE FRONT SEAL Assembly ................................................ 30-105
Removal .................................................... 30-40 TORQFLOW TRANSMISSION
ENGINE REAR SEAL Assembly .................................................30-117
Removal .................................................... 30-43 HSS CASE
CYLINDER HEAD Assembly ................................................ 30-137
Removal .................................................... 30-48 HYDRAULIC PUMP
Installation ................................................. 30-53 Removal.................................................. 30-150
THERMOSTAT Installation............................................... 30-154
Removal and Installation ........................... 30-57 HSS MOTOR
AIR CONDITIONER COMPRESSOR Removal and Installation......................... 30-155
Removal .................................................... 30-58 POWER TRAIN MAIN RELIEF VALVE
Installation ................................................. 30-59 Removal and Installation......................... 30-156
AIR CONDITIONER CONDENSER POWER TRAIN MAIN RELIEF VALVE
Removal and Installation ........................... 30-60 Disassembly and Assembly .................... 30-157
FUEL TANK ASSEMBLY HSS, PPC CHARGE VALVE
Removal and Installation ........................... 30-61 Removal and Installation......................... 30-158
RADIATOR HSS AND PPC CHARGE VALVE
Removal .................................................... 30-62 Disassembly and assembly .................... 30-159
Installation ................................................. 30-64 TRANSMISSION CONTROL VALVE
RADIATOR, OIL COOLER, GUARD Removal.................................................. 30-160
Removal .................................................... 30-65 Installation............................................... 30-161
Installation ................................................. 30-67
D155AX-5 30-1
(3)
TRANSMISSION CONTROL VALVE EQUALIZER BAR SIDE BUSHING
Disassembly and assembly .....................30-162 Removal and Installation......................... 30-260
BRAKE VALVE SEGMENT TEETH
Removal and Installation .........................30-164 Removal and Installation......................... 30-261
BRAKE VALVE HYDRAULIC TANK
Disassembly and assembly .....................30-165 Removal and Installation......................... 30-262
FINAL DRIVE MAIN CONTROL VALVE
Removal ..................................................30-167 Removal .................................................. 30-263
Installation ...............................................30-169 Installation ............................................... 30-264
FINAL DRIVE Disassembly............................................ 30-265
Disassembly ............................................30-170 Assembly................................................. 30-268
Assembly .................................................30-175 HSS OIL COOLER BYPASS VALVE
TRACK FRAME Removal and Installation......................... 30-272
Removal ..................................................30-181 Disassembly and Assembly .................... 30-273
Installation ...............................................30-183 BLADE PPC VALVE
IDLER Removal .................................................. 30-274
Removal ..................................................30-184 Installation ............................................... 30-275
Installation ...............................................30-185 RIPPER PPC VALVE
IDLER Removal .................................................. 30-276
Disassembly ............................................30-186 Installation ............................................... 30-277
Assembly .................................................30-188 BLADE PPC VALVE
RECOIL SPRING Disassembly............................................ 30-278
Removal and Installation .........................30-191 Assembly................................................. 30-279
RECOIL SPRING BLADE LIFT CYLINDER
Disassembly ............................................30-192 Removal and Installation......................... 30-281
Assembly .................................................30-197 BLADE TILT CYLINDER ASSEMBLY
TRACK ROLLER Removal and Installation......................... 30-282
Removal ..................................................30-201 RIPPER LIFT CYLINDER
Installation ...............................................30-202 Removal and Installation......................... 30-283
TRACK ROLLER RIPPER TILT CYLINDER
Disassembly ............................................30-203 Removal and Installation......................... 30-284
Assembly .................................................30-206 HYDRAULIC CYLINDER
BOGIE Disassembly............................................ 30-285
Removal ..................................................30-209 Assembly................................................. 30-288
Installation ............................................... 30-211 BLADE
BOGIE Removal .................................................. 30-292
Assembly .................................................30-215 Disassembly............................................ 30-294
CARRIER ROLLER Assembly................................................. 30-296
Removal and Installation .........................30-219 MULTI-SHANK RIPPER
CARRIER ROLLER Disassembly............................................ 30-298
Disassembly ............................................30-220 Assembly................................................. 30-300
Assembly .................................................30-222 ROPS GUARD
TRACK SHOE Removal and Installation......................... 30-302
Removal ..................................................30-225 OPERATOR CAB
Installation ...............................................30-227 Removal .................................................. 30-303
Overall Disassembly ...............................30-228 Installation ............................................... 30-304
Overall Assembly.....................................30-233 HOOD
PRESS-FITTING JIG DIMENSION Removal and Installation......................... 30-305
TABLE FOR LINK PRESS ............................30-247 FLOOR FRAME
ONE LINK Removal .................................................. 30-306
Field Disassembly ...................................30-248 Installation ............................................... 30-310
Field Assembly ........................................30-250 DASHBOARD ASSEMBLY
MASTER LINK Removal .................................................. 30-311
Assembly .................................................30-254 MONITOR
PIVOT SHAFT Removal and Installation......................... 30-313
Removal and Installation .........................30-257 HSS CONTROLLER
EQUALIZER BAR Removal and Installation......................... 30-314
Removal ..................................................30-258
Installation ...............................................30-259
30-2 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
[1] When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
[2] Any special techniques applying only to the installation procedure are marked [*1], and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation proce-
dure it applies to.
(Example)
REMOVAL OF QQQQ ASSEMBLY........... Title of operation

k ................................................................ Precautions related to safety when carrying out the operation
1. (1) ............................................ Step in operation
a ............................................................ Technique or important point to remember when removing
(1).
2. EEEE (2) ........................................... [*1] ..........Indicates that a technique is listed for use
during installation
3. T T T T assembly (3)
6 ............................................................ See Lubricant and Coolant Table
INSTALLATION OF QQQQ ASSEMBLY ... Title of operation
• Carry out installation in the reverse order to removal.
[*1] ................................................................ Technique used during installation
a ............................................................ Technique or important point to remember when installing
EEEE (2).
• Adding water, oil .................................... Step in operation
a ............................................................ Point to remember when adding water or oil
5 ......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

[1] For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
D155AX-5 30-3
(3)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal number Plug Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210(Nut), 07222-00210(Plug)
03 07376-50315 07221-20315(Nut), 07222-00312(Plug)
04 07376-50422 07221-20422(Nut), 07222-00414(Plug)
05 07376-50522 07221-20522(Nut), 07222-00515(Plug)
06 07376-50628 07221-20628(Nut), 07222-00616(Plug)
10 07376-51034 07221-21034(Nut), 07222-01018(Plug)
12 07376-51234 07221-21234(Nut), 07222-01219(Plug)
2) Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 100 mm
from the end of its stroke.
3. Operate the steering, bucket, and boom cylinders to the stroke end 3 - 4 times. Stop the engine, loosen
air bleed plug (1) to release the air from the hydraulic tank, and tighten plug (1) again.
4. Increase the engine speed and bleed air according to step 3. Repeat this operation until air does not
come out of the plug any more.
5. After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the hydraulic equipment has been removed for repair, always bleed the air from the system after reassem-
bling the parts. For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
D155AX-5 30-5
(3)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t : Cannot be substituted, should always be prepared (used).
q : Extremely useful if available, can be substituted with commercially available part.
a New/remodel:N .......... Tools with new part numbers, newly developed for this model
R .......... Tools with upgraded part numbers, remodeled from items already available for other
models
Blank.... Tools already available for other models, used without any modification
a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
remodel
Neces-
Sketch
New/
Q’ty
sity
Nature of work Symbol Part No. Part Name Nature of work, remarks
795-471-1700 Remover t 1
795-471-1520 • Block 1
Removal and installation of A Pulling out of drive gear
fuel supply pump assembly
795-471-1530 • Bolt 1
01435-01085 • Bolt 2
Removal and installation of
nozzle tip
B 795T-471-1550 Wrench t 1 Q Fixing of injector assembly
1 795-931-1100 Seal puller t 1 Pulling out of oil seal
795-521-1110 Push tool t 1

engine front seal
C 790-101-5221 Grip t 1
2 Press fitting of oil seal
01010-51225 Bolt t 1
01050-31640 Bolt t 3
1 795-931-1100 Seal puller t 1 Pulling out of oil seal
795-521-1131 Push tool t 1
790-101-5421 Grip t 1
Press fitting of oil seal (Stan-
2
dard type)
01010-51240 Bolt t 1

01050-31625 Bolt t 3
engine rear seal D
795-931-1210 Sleeve jig t 1
795-931-1220 Sleeve jig t 1

Press fitting of oil seal
3
(Sleeve type)
01050-31625 Bolt t 3
01050-31645 Bolt t 3
4 790-331-1110 Wrench q 1 Tightening of flywheel bolt

cylinder head assembly E 790-331-1110 Wrench q 1 Tightening of cylinder head
bolt
791-612-1100 Installer t 1
Disassembly and assembly
of damper assembly
F 790-101-4200 Puller (294 kN {30 ton}) t 1 Press fitting of bearing
790-101-1102 Hydraulic pump t 1

of TORQFLOW transmis- G 799-301-1600 Oil leak tester kit (A) t 1 Check of operation of clutch
piston
sion assembly
791-622-1110 Bracket t 1
of HSS case assembly H 1 01010-31685 Bolt t 1
brake carrier assembly
01017-31620 Bolt t 1
30-6 D155AX-5
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity
790-302-1500 Spanner kit t 1

2
nut (Bevel pinion side)
09003-09200 • Spanner 1
of HSS case assembly H
790-302-1500 Spanner kit t 1
3
nut (Bevel gear side)
09003-08290 • Spanner 1
790-337-1032 Lifting tool t 1
791T-627-1340 Plate t 1 Q
final drive assembly
J 01010-52080 Bolt t 2
final drive assembly
791-627-1320 Shackle t 2
01643-32060 Washer t 2
791T-627-1380 Spacer t 1 Q
790-101-2470 Adapter t 1
791-520-4140 Screw t 1
1 791-101-2540 Washer t 1 Pulling out of pinion shaft
02215-11622 Nut t 1
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-2310 Block t 1
790-101-2550 Leg t 2
790-101-2730 Adapter t 2
790-101-2360 Plate t 2
2 790-101-2560 Nut t 2
Pulling out and press fitting
of sprocket and hub
01643-32060 Washer t 2
of final drive assembly
K 791-650-1130 Bracket t 1
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-2310 Block t 1
791-520-4140 Screw t 1
790-101-2540 Washer t 1
791-112-1180 Nut t 3
02215-11622 Nut t 3
3 Press fitting of bearing
791T-627-1350 Plate t 1 Q
791T-627-1360 Sleeve t 1 Q
01010-82050 Bolt t 5
790-101-2102 Puller (294 kN {30 ton}) t 1
4 791-580-1510 Installer t 1 Installation of floating seal
D155AX-5 30-7
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity
791T-630-1230 Plate t 1 Q
791-630-1220 Rod t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
1 Press fitting of idler bushing
01580-01411 Nut t 2
of idler assembly L
01643-31445 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
3 791-601-1000 Oil pump t 1 Filling with oil
790-101-2800 Bearing puller t 1
790-101-2390 Leg t 2
790-101-2310 Block t 1
790-101-2360 Plate t 4
1 Disconnection of yoke
790-201-2850 Spacer t 1
02215-11622 Nut t 2
790-101-4000 Puller (490 kN {50 ton}) t 1
791-685-8501 Compressor t 1
791T-630-1150 Spacer t 1 Q
791T-630-1160 Spacer t 1 Q
of recoil spring assembly
M 2 791-635-3160 Extension t 1 Compression of recoil spring
04530-01222 Eyebolt t 1
790-101-1600
Cylinder
(686 kN {70 ton}) t 1
790-445-4210 Push tool t 1

3 Press fitting of bushing
790-201-2860 Spacer t 1
790-201-2860 Spacer t 1
790-434-1050 Screw t 1
790-101-2540 Washer t 1
4 Press fitting of yoke
01580-02419 Nut t 1
790-101-4200 Puller (294 kN {30 ton}) t 1
790-101-2680 Adapter t 2
Pulling out of shaft and pull-
of track roller assembly
N 1 790-101-2550 Leg t 2 ing out and press fitting of
seal guide
790-101-2510 Block t 1
30-8 D155AX-5
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity
790-101-2570 Washer t 4
790-101-2560 Nut t 2
790-201-2730 Spacer t 1 Pulling out of shaft and pull-

1 ing out and press fitting of
791T-630-1340 Spacer t 1 Q seal guide
of track roller assembly N 790-101-2102 Puller (294 kN {30 ton}) t 1
2 791T-630-1290 Plate t 1 Q Press fitting of bushing

bogie assembly P 791-630-1420 Fixture t 4 Fixing of bogie
791-630-1500 Remover and installer t 1
791-685-9510 • Frame 1
791-685-9520 • Frame 1
791-685-9530 • Rod 1
791-685-9540 • Rod 1
791-685-9550 • Nut 3
791-685-9560 • Bolt 4
791-126-0150 • Adapter 1
791-630-1430 • Guide 1
791-630-1520 • Nut 2
791-630-1530 • Extension 1
Pulling out and press fitting
1
of pin assembly
791-630-1510 • Shaft 1
791-630-1540 • Adapter 1
Disassembly and assembly Q
of bogie assembly
791-630-1560 • Adapter 1
04530-12030 • Eyebolt 1
04530-11018 • Eyebolt 2
01643-31032 • Washer 4
791-630-1440 • Spacer 1
790-101-4300 Cylinder
(1,470 kN {150 ton}) t 1
791T-630-1580 Bracket t 1 Q
791T-630-1590 Stand t 1 Q
791-685-9510 • Frame 1
2 Pulling out of shaft
791-685-9520 • Frame 1
791-685-9530 • Rod 1
D155AX-5 30-9
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity
791-685-9540 • Rod 1
791-685-9550 • Nut 3
791-685-9560 • Bolt 4
791-630-1510 • Shaft 2
791-630-1520 • Nut 2
791-630-1530 • Extension 1
791-630-1550 • Adapter 1
791-630-1560 • Adapter 1
2 791-685-9620 • Extension 1 Pulling out of shaft
04530-12030 • Eyebolt 1
791-630-1430 • Guide 1
791-630-1440 • Spacer 1
791-630-1450 • Spacer 1
Cylinder
790-101-4300 (1,470 kN {150 ton}) 1
791T-630-1580 Bracket t 1 Q
791T-630-1590 Stand t 1 Q

Q
of bogie assembly
791-685-9510 • Frame 1
791-685-9520 • Frame 1
791-685-9530 • Rod 1
791-685-9540 • Rod 1
791-685-9550 • Nut 3
791-685-9560 • Bolt 4
791-685-9620 • Extension 1
791-630-1510 • Shaft 2
3 791-630-1520 • Nut 2 Press fitting of shaft
791-630-1530 • Extension 1
791-630-1540 • Adapter 1
791-630-1570 • Adapter 1
04530-12030 • Eyebolt 1
791-630-1450 • Spacer 1
791-630-1440 • Spacer 1
790-101-4300
Cylinder
(1,470 kN {150 ton}) t 1
790-101-1102 Hydraulic cylinder t 1
791T-630-1580 Bracket t 1 Q
30-10 D155AX-5
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity

3 791T-630-1590 Stand t 1 Q Press fitting of shaft
Q
of bogie assembly
1 790-102-1891 Nut wrench t 1 Removal and installation of nut

R
of carrier roller assembly
3 791T-630-1350 Spacer t 1 Q Press fitting of ring
790-101-4300 Cylinder
(1,470 kN {150 ton}) t 1
1
of track shoe assembly
790-101-4200 Puller (294 kN {30 ton}) t 1

Overall disassembly and
assembly of track shoe S 2 791-932-1110 Plug push tool t 1 Driving of plug (Small)
assembly
3 791-660-7460 Pin brush t 1 Cleaning of pin
4 791-432-1110 Plug push tool t 1 Driving of plug (Large)
5 791-632-1052 Installer t 1 Insertion of link seal
6 790-701-3000 Seal checker t 1

Filling with oil and check of
airtightness
791-675-9581 Adapter t 1
791-675-9590 Guide t 1
1
01010-52460 Bolt t 2
01010-51440 Bolt t 2
790-101-1102 Pump t 1
2 of 1 link
790-101-4300
Cylinder
(1,470 kN {150 ton}) t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 1
of 1 link in field
T 791-685-9560 Bolt t 1
3 Disassembly 1 link
791-675-9570 Adapter t 1
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder
(1,470 kN{150 ton}) t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9510 Frame t 1
5 791-685-9520 Frame t 1 Disassembly 1 link
791-685-9530 Rod t 1
D155AX-5 30-11
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity
791-685-9550 Nut t 1
791-685-9560 Bolt t 1
791-126-0150 Adapter t 1
791-675-5520 Guide t 1
791-675-5530 Pusher t 1
5 791-675-9570 Adapter t 1 Disassembly 1 link
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
791-685-9620 Extension t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder
(1,470 kN {150 ton}) t 1
790-101-1102 Pump t 1
790-101-4200 Puller (294 kN {30 ton}) t 1
791-675-5542 Adapter t 1
791-675-5571 Adapter t 1
7 Assembly of 1 link
790-101-1102 Pump t 1
790-101-4300
Cylinder
(1,470 kN {150 ton}) t 1

8 791-675-5580 Guide t 1 Assembly of 1 link
T
of 1 link in field
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
9 791-126-0150 Adapter t 1 Assembly of 1 link
01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-675-5542 Adapter t 1
791-675-5571 Adapter t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder
(1,470 kN {150 ton}) t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
10 791-685-9530 Rod t 1 Assembly of 1 link
791-685-9540 Rod t 1
791-685-9550 Nut t 3
30-12 D155AX-5
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-675-5571 Adapter t 1
791-675-9631 Adapter t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder
(1,470 kN {150 ton}) t 1
790-101-1102 Pump t 1
11 Assembly of 1 link
790-101-4200 Puller (294 kN {30 ton}) t 1

Disassembly and assembly T
of 1 link in field
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 1
791-685-9560 Bolt t 1
13 791-126-0150 Adapter t 1 Assembly of 1 link
791-675-5560 Guide t 1
791-675-9570 Adapter t 1
01010-51030 Bolt t 1
791-670-3270 Guide t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder
(1,470 kN {150 ton}) t 1
790-101-1102 Pump t 1
1 Expansion of link
790-101-4200 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
2
of master link
U 790-101-4200 Puller (294 kN {30 ton}) t 1
790-101-4300 Cylinder
(1,470 kN {150 ton}) t 1
3 791-432-1110 Plug push tool t 1 Driving of plug (Large)
4 790-701-3000 Seal checker t 1

Filling with oil and check of
airtightness
5 791-932-1110 Plug push tool t 1 Driving of plug (Small)

791T-650-2110 Sleeve t 1 Q
V Press fitting of ring
pivot shaft assembly
791T-650-2120 Plate t 1 Q
D155AX-5 30-13
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity
790-201-3310 Bolt t 2
790-101-2510 Block t 1

790-101-2570 Washer t 2
V Press fitting of ring
pivot shaft assembly
01580-01613 Nut t 2
790-105-2300 Jack assembly

(196 kN {20 ton}) t 1
791T-650-2130 Sleeve t 1 Q
791-181-1010 Adapter t 1
791-520-4140 Screw t 1
equalizer bar assembly
W 790-101-2540 Washer t 1 Pulling out of center pin
791-112-1180 Nut t 1
790-101-4000 Puller (490 kN {50 ton}) t 1
791-827-1510 Sleeve t 1
791T-650-2210 Sleeve t 1 Q
790-438-1110 Screw t 1
equalizer bar side bushing X 790-101-2540 Washer t 2
assembly
790-112-1180 Nut t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-502-1003 Cylinder repair stand t 1

1
of hydraulic cylinder
2 790-102-3802 Multi-wrench t 1 Installation of round head

(Blade lift)
790-201-1702 Push tool kit t 1 Press fitting of bushing
790-201-1821 • Push tool 1 Blade lift
790-201-1841 • Push tool 1 Blade tilt

3
Ripper lift
790-201-1831 • Push tool 1 Ripper tilt
of hydraulic cylinder assem- Y 790-101-5021 • Grip 1
bly
01010-50816 • Bolt 1
790-201-1500 Push tool kit t 1 Press fitting of dust seal
790-201-1630 • Plate 1 Blade lift
790-201-1650 • Plate 1 Blade tilt

4
Ripper lift
790-201-1640 • Plate 1 Ripper tilt
790-101-5021 • Grip 1
01010-50816 • Bolt 1
30-14 D155AX-5
(5)
remodel
Neces-
Sketch
New/
Q’ty
sity
790-720-1000 Expander t 1 Installation of piston ring
796-720-1670 Ring t 1
Blade lift
07281-01279 Clamp t 1
of hydraulic cylinder assem- Y 5 796-720-1690 Ring t 1
bly Blade tilt
07281-02169 Clamp t 1
796-720-1690 Ring t 1
Ripper lift
Ripper tilt
07281-01919 Clamp t 1
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100 V) t 1

Charging air conditioner
with refrigerant gas
Z 799-703-1110 Vacuum pump (220 V) t 1 Charging with refrigerant gas
790-703-1120 Vacuum pump (240 V) t 1
799-703-1400 Gas leak tester t 1
D155AX-5 30-15
(5)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL SKETCH
SPECIAL TOOL SKETCH

Note: Komatsu cannot accept any responsibility for special
B: Wrench (795T-471-1550) tools manufactured according to these sketches.
Component part of J: Plate (791T-627-1340)
30-16 D155AX-5
(5)
Component part of K1: Spacer (791T-627-1380)
Component part of K3: Plate (791T-627-1350)
D155AX-5 30-17
(5)
Component part of K3: Sleeve (791T-627-1360)
Component part of L1: Plate (791T-630-1230)
30-18 D155AX-5
(5)
Component part of M2: Spacer (791T-630-1150)
Component part of M2: Spacer (791T-630-1160)
D155AX-5 30-19
(5)
Component part of N1: Spacer (791T-630-1340)
10
(Ø69.1)
Ø89.1 DDD00864
HEAT TREATMENT MATERIAL

1223001900 STKM16A
C1 C1
PART NAME QTY
SPACER 1
48.5±0.2
7 9 1T - 6 3 0 - 1 3 4 0
Component part of N2: Plate (791T-630-1290)
30-20 D155AX-5
(5)
Component part of Q1, Q2, and Q3: Bracket (791T-630-1580)
Component part of Q1, Q2, and Q3: Stand (791T-630-1590)
D155AX-5 30-21
(5)
R3: Spacer (791T-630-1350)
Component part of V: Sleeve (791T-650-2110)
30-22 D155AX-5
(5)
Component part of V: Plate (791T-650-2120)
Component part of W: Sleeve (791T-650-2130)
D155AX-5 30-23
(5)
Component part of X: Sleeve (791T-650-2210)
30-24 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open engine right side cover (top) and remove

cover (bottom).
2. Disconnect 3 starting motor wires (1) and 1 wir-

ing connector (2).
3. Remove 3 bolts, then remove starting motor

assembly (3).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
• Carry out installation in the reverse order to
removal.
D155AX-5 30-25
(3)
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
k Disconnect the cable from the negative (–) ter-
1. Open engine right side cover (top) and remove

cover (bottom).
2. Disconnect alternator wiring (1) and (2).
3. Loosen locknut (3), then turn adjustment nut (4)

to loosen tension of V-belt (5).
4. Remove bolts (6) and (7), then remove alternator

assembly (8) together with belt cover. [*1]
a Remove the V-belt from the pulley when
removing the alternator assembly.
INSTALLATION OF
ALTERNATOR ASSEMBLY
removal.
[*1]
a After installing the alternator, adjust the belt
tension. For details, see TESTING AND
ADJUSTING, TESTING AND ADJUSTING
ALTERNATOR BELT TENSION.
30-26 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER CORE ASSEMBLY
a Drain coolant.
6 Coolant: 110 l
1. Remove hose clamp (1).
2. Remove muffler water drain tube (2).
3. Remove adiabatic plate (3).
4. Disconnect turbocharger lubrication tube (4) at

turbocharger end, then move it towards rear.
5. Disconnect connector (5).
6. Remove oil cooler assembly (6).
7. Remove core assembly (8) from cover (7).
INSTALLATION OF ENGINE OIL

COOLER CORE ASSEMBLY
removal.
• Refilling with water

Add water through water filler to the specified
level.
a Run the engine to circulate the water through
the system. Then check the water level
again.
D155AX-5 30-27
(3)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
REMOVAL OF FUEL SUPPLY

PUMP ASSEMBLY
k Disconnect the cable from the negative (-) ter-
1. Open engine side cover (1) and remove left side

cover (2).
2. Close the fuel valve and release the residual

pressure in the fuel system. For details, see
TESTING AND ADJUSTING, Releasing residual
pressure in fuel system.
3. Disconnect air conditioner hose clamp (3) and

move it aside.
4. Disconnect fuel supply pump wiring connectors

PCV1 (4) and PCV2 (5) and engine G speed
sensor wiring connector (6).
5. Disconnect fuel tubes (7) and (8).
6. Remove lubrication tubes (9) and (10).
7. Remove feeler gauge (11).
8. Remove tube clamp (12).
9. Remove fuel high-pressure pipes (13) and (14).
10. Remove bracket (15).
12. Remove nut (23) and washer (24). [*5]

a Take care not to drop the nut and washer into
the engine.
30-28 D155AX-5
(3)
13. Set tool A.
14. Remove the 4 mounting bolts, and then remove

fuel supply pump assembly (30) with tool A.
[*8]
a Take care not to drop key (31).
a Do not remove tool A until you install the fuel

supply pump assembly again. (If tool A is
removed, meshing of the idler gear and fuel
supply pump drive gear may change.)
D155AX-5 30-29
(5)
INSTALLATION OF FUEL
SUPPLY PUMP ASSEMBLY
removal.
3 Joint bolt of fuel tube (15):

[*3]
14.8 – 19.5 Nm {1.5 – 2.0 kgm}

(Supply pump side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Joint bolt of lubrication tube (16):

(Block side)
7.9 – 12.7 Nm {0.8 – 1.3 kgm}

(Supply pump side)
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
(Cylinder block side)
3 Joint bolt of lubrication tube (17):

19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Lubrication tube clamp:

9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3 Mounting nut of fuel supply pump drive

[*5] [*6] [*7] [*8]
gear: 176 – 196 Nm {18 – 20 kgm}
• Procedure for installing fuel supply pump and

tube
1. Install supply pump (30), bracket (29), and

high-pressure pipes (26) and (27) and
tighten them with the fingers.
2. Tighten high-pressure pipes (26) and (27)
3 Sleeve nut:
permanently.
39.2 – 58.8 Nm {4 – 6 kgm} (Common rail)

39.2 – 49 Nm {4 – 5 kgm} (Supply pump side)
3. Tighten supply pump (30) permanently.

a When tightening, apply LOCTITE.
4. Tighten bracket (29) permanently.
5. Install high-pressure pipe clamps (31), (32),

and (33) and upper and lower stays and
tighten them with the fingers.
30-30 D155AX-5
(3)
k The high-pressure pipe clamps are very impor-

tant parts. If they are loosened or their rubber
parts are hardened or they are removed and
the engine is kept operated, the contact parts of
the high-pressure pipes may be worn and the
pipes may be broken by vibration. Accordingly,
be sure to use the genuine high-pressure pipe
clamps and tighten them to the specified
torque.
k Contact of the high-pressure pipes with electric

wiring around them is dangerous. After assem-
bling, check that the distance between the
pipes and the wiring is at least 10 mm. If it is
not, increase it to 10 mm or more by moving the
wiring.
k Do not bend and reuse the high-pressure pipes

or use them for other parts.
6. Tighten upper and lower clamps permanently in

the order of (31), (32), and (33).
3 Clamp bolt: 9.8 ± 1 Nm {1.0 ± 0.1 kgm}

a Before tightening the stays, bend the rubber.
7. Tighten the stays permanently in the installation

order of the upper and lower clamps.
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
fuel circuit.
D155AX-5 30-31
(3)
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.
6 Coolant: 110 l
2. Using an adjustable wrench, push tension pulley

(2) of fan belt (1), and remove fan belt.
3. Loosen locknut (3), then loosen adjustment nut

(4), and remove V-belt (5). [*1]
4. Remove connectors (6) and (7).
5. Remove pulley (8).
6. Remove water pump assembly (9).
INSTALLATION OF WATER
PUMP ASSEMBLY
removal.
[*1]
a After installing the V-belt, adjust the belt ten-
sion. For details, see TESTING AND
ALTERNATOR BELT TENSION.

level.
again.
30-32 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Remove hood assembly.
For details, see REMOVAL OF HOOD ASSEM-
BLY.
2. Remove adiabatic plate (1) and (2).
3. Disconnect tube (3) and hose (4), then lift off air
cleaner assembly (5).
4 Air cleaner assembly: 35 kg
4. Disconnect lubrication hose (6) and drain tube

(7). [*1]
5. Remove turbocharger assembly (8). [*2]
INSTALLATION OF
TURBOCHARGER ASSEMBLY
removal.
[*1]
3 Hose mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
[*2]
3 Turbocharger mounting bolt:
49.0 ± 9.8 Nm {5 ± 1 kgm}
D155AX-5 30-33
(3)
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
REMOVAL OF FUEL
INJECTOR ASSEMBLY
1. Remove hood assembly. For details, see
REMOVAL OF HOOD ASSEMBLY.
2. Remove common rail high-pressure pipe (1). [*1]
3. Disconnect wiring connector (2).

a Insert a flat-head screwdriver in the slit of the
connector to press the stopper and dis-con-
nect the connector.
4. Remove cylinder head cover (3). [*2]

a For Nos. 4 and 5, remove the air cleaner
assembly and air intake connector.
5. Remove mounting bolts and rocker arm (4).

a Loosen locknut (5) and then loosen adjust-
ment screw (6) by 2 – 3 turns so that an
excessive force will not be applied to the
push rod when the rocker arm is installed.
[*3]
6. Remove 2 nuts (7) of solenoid valve above fuel

injector. [*4]
7. Pull out spring clamp (8) and disconnect clamp

(9).
8. Remove mounting bolts (12) of holder (11) of

connector (having an O-ring) (10) and to remove
holder, then insert connector (10) to remove it.
[*4]
30-34 D155AX-5
(3)
9. Remove holder (13) of fuel injector, then remove

injector assembly (14). [*5]
a Do not hold the solenoid of the injector with
priers, etc. to remove the injector.
INJECTOR ASSEMBLY
removal.
[*1]
3 High-pressure pipe sleeve nut:
39.2 – 49 Nm {4.0 – 5.0 kgm}
a If there is any slit b or pit c on the taper seal-

ing part (Part a: The part of 2 mm from the
end) of the high-pressure pipe joint or if part
d (Tape seal end: Part of 2 mm from the end)
has level difference that is felt with a nail (or
if part d is fatigued) and the fuel may leak,
replace the high-pressure pipe.
[*2]
3 Cylinder head mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
[*3]
a When tightening the mounting bolts, check
that the ball of the adjustment screw is fitted
to the socket of the push rod.
3 Rock arm mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details, see

ADJUSTING VALVE CLEARANCE.
D155AX-5 30-35
(3)
[*4]
a Method of installing wiring harness.
1) Fit O-ring (15).
2) Install cap (16).
3) Tighten nut (17).
4) Secure clamp with bolt (18).
3 Terminal nut:
1.8 – 2.2 Nm {0.18 – 0.22 kgm}
a Eliminate the slack of the wiring harness and

press it against the injector body.
[*5]
a Method of installing fuel injector.
1) Install fuel injector assembly (14) and
holder (13) to the cylinder head tempo-
rarily.
2) Tighten mounting bolt (19) of holder (13)
temporarily.
3) Tighten sleeve (20) temporarily.
4) Tighten holder mounting bolt (19) se
curely.
5) Tighten sleeve (20) securely.
a Apply engine oil to the spherical part of the

spherical washer.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
30-36 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY NOZZLE TIP
REMOVAL OF NOZZLE TIP

a [EPA Regulation]
In a country where EPA Regulation is applied,
replace the nozzle of the common rail engine by
the assembly. In a country where EPA Regula-
tion is not applied, however, only the nozzle tip
can be replaced according to the following pro-
cedure.
a All the nozzles shown in the following photos are
for the 125 Series engine. The removal and
installation procedures for them can be applied
as they are, however.
1. Grip tool B with vise [1].

a Do not grip the injector directly with the vise.
2. Set injector assembly (3) to tool B.
3. Using 19-mm deep socket [3], loosen retaining

nut (4).
4. Remove retaining nut (4) from injector assembly

(3).
5. Lift up and remove nozzle assembly (5) verti-

cally.
a Do not remove tip guide (6). (The tip guide
cannot be disassembled.)
a Take care that dirt will not stick to the parts.
D155AX-5 30-37
(5)
INSTALLATION OF NOZZLE
TIP
1. Grip tool B with vise [1].

a Do not hold the injector directly with the vise.
2. Set injector assembly (1) to tool B.
3. Clean the lower body and the threads of retain-

ing nut (2) thoroughly with parts cleaner and
blow air against them.
4. Install new nozzle assembly (3), matching it to

the dowel pin of tip guide (4).
a Take care not to drop the tip.
30-38 D155AX-5
(5)
5. Install nozzle assembly (3) and tighten retaining

nut (2) with the fingers.
6. Set 19-mm deep socket [2] to a torque wrench

and tighten the retaining nut according to the fol-
lowing procedure.
a Apply rust-preventive oil to the nozzle body.
1) Tighten the retaining nut to 88.3 Nm {9.0
kgm}.
2) Make match marks (6) on retaining nut (2)
and lower body (5).
3) Tighten the retaining nut by 45 degrees
(Angle tightening).
D155AX-5 30-39
(3)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
1. Remove the radiator, oil cooler, and guard
assembly. For details, see REMOVAL OF RADI-
ATOR, OIL COOLER, AND GUARD ASSEMBLY.
2. Remove damper (1).
3. Remove front seal (2).
• Removal of standard seal

Hitch the end of tool C1 to the metal ring of seal
(2) and pull out the seal with impacts of a slide
hammer.
a Before pulling out the seal, drive in it a little to
separate it from the housing for the ease of
removal.
a Do not use a drill, etc. since chips may enter
the engine.
• Removal of seal having sleeve

1) Hitch the end of tool C1 to the metal ring of
seal (2) and pull out the seal with impacts of
a slide hammer.
a Before pulling out the seal, drive in it a lit-
tle to separate it from the housing for the
ease of removal.
2) Cut and remove sleeve (3) with a chisel and
a hammer.
a When cutting the sleeve, take care
extremely not to damage the crankshaft.
a Remove all the chips.
30-40 D155AX-5
(5)
INSTALLATION OF ENGINE
FRONT SEAL
1. Installation of front seal (1)
a Before assembling the seal, check that there
are no scratches, burrs, flashes, or rust on
the housing, lip sliding surface, or at the cor-
ner of the end face of the crankshaft.
a When assembling the seal, do not coat the
shaft and seal lip with oil or grease. Wipe off
all oil from the shaft.
a Do not remove the internal plastic tube from
the standard seal until the seal is assembled.
1) Put large inside diameter end of internal

plastic tube (2) in contact with end of crank-
shaft (3).
a Be particularly careful to assemble facing
in the correct direction.
2) Hold metal ring of seal (1) with both hands

and push in with sudden force until it feels
that it has gone over large diameter of inter-
nal plastic cylinder.
3) After pushing seal in, remove internal plastic
tube (2).
a When removing, be particularly careful
not to damage the seal lip.
4) Tighten bolts of tool C2 uniformly until end
face of tool C2 contacts end face of crank-
shaft (3) and press fit seal (1).
a When press fitting the seal, be extremely CDE00231
careful not to damage the lip at the PTO
end when setting the tool in position.
a After press fitting the seal, remove all the
remains of the red sealant on the outside
circumference.
D155AX-5 30-41
(5)
2. Installation of damper assembly

Fit damper assembly (1) and tighten with mount-
ing bolts.
3 Mounting bolt:
245 – 308.7 Nm {25 – 31.5 kgm}
30-42 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL OF ENGINE REAR

SEAL
1. Remove damper assembly.
For details, see REMOVAL OF DAMPER ASSEM-
BLY.
2. Remove 1 mounting bolt of flywheel (1), and

install guide bolt [1].
3. Using eyebolts [2], sling flywheel (1), then

remove remaining mounting bolts.
4. Pull flywheel (1) out and lift off.

k The flywheel pilot portion is shallow, and it
may fall out suddenly, so be careful not to
get your fingers caught.
4 Flywheel: 60 kg
5. Remove rear seal (2).

a Measure the dimension from the end face of
the housing.
• Removing standard seal

Hook tip of tool D1 to metal ring of seal (1), and
use impact force of a slide hammer to pull out.
a Before pulling out, knock the oil seal in
slightly. This separates the seal from the
housing and makes it easier to pull out the
seal.
a Do not use a drill. The metal powder will get
inside the engine.
• Removing seal with sleeve

1) Hook tip of tool D1 to metal ring of seal (1),
and use impact force of a slide hammer to
pull out.
a Before pulling out, knock the oil seal in
slightly. This separates the seal from the
housing and makes it easier to pull out
the seal.
2) Using a chisel and hammer, cut sleeve (2)
and remove.
a Be extremely careful not to damage the
crankshaft when cutting the sleeve.
a Remove all the metal particles that are
produced.
D155AX-5 30-43
(5)
REAR SEAL
a With the Teflon seal (lay-down lip seal), check
the condition of the wear of the shaft, then select
either a standard seal or a seal with a sleeve,
and assemble the seal.
The condition of wear is judged by the smooth-
ness (depth of wear less than 10 µm when
touched with the flat of a finger). If there are no
scratches, assemble a standard seal; in all other
cases, assemble a seal with a sleeve.
1. Procedure for assembling standard seal

shaft and seal lip with oil or grease. Wipe off
all oil from the shaft.
a Do not remove the internal plastic tube from
the standard seal until the seal is assembled.
1) Put large inside diameter end of internal
plastic tube (3) in contact with end of crank-
shaft (4).
a Be particularly careful to assemble facing
in the correct direction.
2) Hold metal ring of seal (1) with both hands

and push in with sudden force.
3) After pushing seal in, remove internal plastic
tube (3).
a When removing, be particularly careful
not to damage the seal lip.
CEE00434
30-44 D155AX-5
(3)
4) Tighten 3 bolts uniformly until end face of

tool D2 (for press fitting seal) contacts end
face of crankshaft (4) and press fit seal (1).
a First, tighten tool D2 (for press fitting
seal) until bolt (45 mm) comes into con-
tact, then tighten with bolt (25 mm).
a When press fitting the seal, be extremely
careful not to damage the lip at the PTO
end when setting the tool in position.
circumference.
2. Assembly procedure for seal with sleeve

shaft and the area between the sleeve and
seal lip with oil or grease. Wipe off all oil
from the crankshaft.
a Always handle the seal and sleeve as a set.
Never disassemble it.
1) Set sleeve/seal (2) to tool D3 (for press fitting
seal with sleeve).
2 Surface of tube inside sleeve :
2) Put sleeve of seal in contact with end face of

crankshaft, then tighten 3 bolts uniformly
until end face of tool D3 contacts end face of
crankshaft (4) to press fit sleeve/seal (2).
a First, tighten tool D3 (for press fitting seal
with sleeve) until bolt (45 mm) comes
into contact, then tighten with bolt (25
mm).
D155AX-5 30-45
(5)
3) Remove tool D3 (for press fitting seal with

sleeve) and install tool D3 (for press fitting
seal).
4) Tighten 3 bolts uniformly until end face of
tool D3 (for press fitting seal) contacts end
face of crankshaft (4) to press fit sleeve/seal
(2).
a First, tighten tool D3 (for press fitting
seal) until bolt (45 mm) comes into con-
tact, then tighten with bolt (25 mm).
circumference.
3. Flywheel
Using eyebolt [4] (12 mm, P=1.75), raise fly-
wheel (1) and tighten to crankshaft with mount-
ing bolts.
2 Coat the thread and seat of the bolt com-
pletely with SAE No. 30 engine oil.
4 Flywheel : 60 kg
a Tighten the flywheel mounting bolts as fol-

lows.
2 Flywheel mounting bolt :
1st step :
Tighten to 112.7 – 122.5 Nm
{11.5 ± 12.5 kgm}
2nd step :1) When using tool D4
Using an angle tightening
wrench (tool D4), tighten bolts
a further 90°+30°
0 in order (1) to
(6).
2) When not using tool A1
Make marks on bolt and fly-
wheel with paint, then tighten
bolts a further 90° +30°
0 in order
(1) to (6).
a After tightening, make one punch mark on

the bolt head to indicate the number of times
it has been tightened.
• If any bolt already has five punch marks,
do not reuse it. Replace it with a new
bolt.
30-46 D155AX-5
(5)
a After installing the flywheel, use dial gauge

[1] to measure the face runout and radial
runout.
a Face runout: Max. 0.30 mm
a Radial runout: Max. 0.30 mm
D155AX-5 30-47
(5)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER
HEAD ASSEMBLY
k Disconnect the cable from the negative (-) termi-
nal of the battery.
1. Drain the coolant.
2. Close the fuel supply valve.
3. Remove the hood assembly. For details, see

REMOVAL OF HOOD ASSEMBLY.
4. Remove engine side covers (right and left).
5. Remove heat insulation covers (1) and (2).
6. Disconnect dust indicator hose (3) and remove

air cleaner tube (4).
7. Remove air cleaner bracket (5).
8. Remove Komaclone hose (6) and air cleaner

assembly (7).
9. Remove water drain tube (10).
10. Remove the mounting bolts of muffler bracket

(11).
a Sling the muffler assembly temporarily
before removing the mounting bolts.
11. Lift off muffler assembly (12).
4 Bracket: 30 kg
30-48 D155AX-5
(3)
12. Disconnect aftercooler tube clamp (13).
13. Disconnect heater hose clamp (14).
14. Disconnect heater hose (15).
17. Disconnect turbocharger lubrication tube inlet

(18) and turbocharger lubrication tube outlet
(19).
18. Remove mounting bolts and exhaust manifold

assembly (20). [*7]
19. Install 2 hanging bolts [1] and 2 guide bolts [2]

and lift off turbocharger and exhaust manifold
assembly (21).
4 Turbocharger and exhaust manifold

assembly: 30 kg
20. Disconnect wiring intermediate connectors E21 •

E22 (18) and 101 (19).
21. Remove damper oil filler tube (20).
D155AX-5 30-49
(3)
22. Remove dust indicator (21).
23. Disconnect engine oil tube clamp (22).
24. Remove engine oil tubes (23) and (24).
25. Disconnect fuel injection wiring (25).
26. Disconnect starting motor wiring (26).
27. Disconnect wiring and wire clamp (27).
28. Disconnect lubrication tube (28).
30 Disconnect aftercooler tube front side (30).
31. Disconnect boost pressure sensor wiring (31).
32. Disconnect aftercooler tube rear side (32).
33. Disconnect corrosion resistor hose (33) and

remove corrosion filter assembly (34) and its
bracket together.
34. Disconnect fuel filter tube (35) and remove fuel

filter assembly (36) and its bracket together.
35. Remove oil level detection pipe (37).
36. Remove fuel hose clamp (38) and disconnect

fuel hose (39) and fuel tube (40).
37. Remove priming pump assembly (41).
38. Remove oil filter (42).
39. Remove engine oil supply pipe (43).
41. Disconnect aeration hose and tube (45).
42. Remove spill tube (46).
30-50 D155AX-5
(3)
a To disconnect fuel injector connector "c",

insert flat-head screwdriver [3] in stepped
part "a" and move it in direction "X", pressing
stopper "b".
b: Fuel injector wiring side
43. Remove the mounting bolts. Using hanging bolt

[4], lift off intake manifold assembly (56). [*13]
4 Intake manifold assembly: 70 kg
44. Remove 5 high-pressure pipe clamps (57). [*14]
45. Remove coolant tube (58) and fuel spill tube

(59). [*15]
46. Remove rubber cap (60) and high-pressure pipe

(61). [*16]
47. Remove head cover (62). [*17]
D155AX-5 30-51
(3)
48. Remove fuel injector assembly (63). For details,

see REMOVAL OF FUEL INJECTOR ASSEM-
BLY.
49. Pull out push rod (64).
50. Remove the mounting bolts and cylinder head

assembly (65). [*18]
30-52 D155AX-5
(3)
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
3 Eye-joint bolt of priming pump hose:
[*8]
removal. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Hose clamp:
[*1] [*6]
3 Eye-joint bolt of fuel filter tube:
[*9]
8.8 ± 0.5 Nm {90 ± 5 kgcm} 14.8 – 19.6 Nm {1.5 – 2.0 kgm}

(Supply pump side)
3 Dust indicator hose mounting nut:

[*2] 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
(Fuel filter side)
17.6 Nm {1.8 kgm}
3 Eye-joint bolt of corrosion resistor tube:

[*10] [*11]
3 Komaclone hose clamp:

[*3]
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
10.8 – 26.5 Nm {1.1 – 2.7 kgm}
3 Coupling bolt of aftercooler tube:

[*12]
3 Band mounting bolt:

[*4]
3 U-clamp nut of aftercooler tube:

14.7 – 18.6 Nm {1.5 – 1.9 kgm}
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
10.8 – 26.5 Nm {1.1 – 2.7 kgm}
3 Water drain tube:

[*5]
[*13]
39.2 – 49 Nm {3 – 4 kgm} Installation procedure for exhaust manifold assembly
1) Fit the gaskets to both sides of the electrical
[*7] intake air heater.
a Install the gasket, then tighten the mounting bolts 2) Install the wiring harness to the electrical
of the exhaust manifold assembly in the order of intake air heater and couple them with the
3 Mounting bolt of exhaust manifold

[1] – [24] as shown below. exhaust manifold.
3) Tighten the mounting bolts of the exhaust
assembly: 59 – 74 Nm {6 – 7.5 kgm} manifold assembly in the order of [1] – [24]
3 Mounting bolt of exhaust manifold

as shown below.
assembly: 59 – 74 Nm {6 – 7.5 kgm}
D155AX-5 30-53
(3)
[*14] [*16] 7. Tighten high-pressure pipe side clamp (57)
3 Clamp bolt:
• Assembly procedure for common rail injec- securely.
tion pipe (Between common rail and injector) 9.8 ± 1 Nm {1 ± 0.1 kgm}
3 Sleeve nut:
1. Install high-pressure pipe (61).
39.2 – 49 Nm {4 – 5 kgm} 8. Tighten stay (69) securely.
a Precautions for installing sleeve nut on
injector side
1) Insert the sleeve nut in the head hole
from outside.
a Check that the O-rings are fitted to both
injector side and sleeve nut side.
2) After sleeve nut catches the threads of
the injector, turn it 2 turns with fingers,
then tighten it with a spanner.
a Control the tightening torque with a
3 Sleeve nut:
torque wrench of spanner type.
39.2 – 49 Nm {4 – 5 kgm}
a If the sleeve nut does not catch the
threads, push its end with a small span-
ner and turn its hexagonal part with the
torque wrench.
a After tightening the sleeve nut, check
that the O-ring is not projected from the
sleeve nut end.
2. Tighten the stay and upper and lower clamps
of high-pressure pipe clamp (57) with fingers.
3. Tighten upper and lower clamps (57)
securely.
3 Clamp bolt:
a Bend the rubber first.
9.8 ± 1 Nm {1 ± 0.1 kgm}
4. Tighten the stay securely.
5. Tighten the stay and upper and lower clamps
of high-pressure pipe side clamp (57) with
fingers.
3 Eye-joint bolt of coolant water tube:
[*15]
6. Install high-pressure pipe clamp (66) and
gate frame (67) temporarily.
3 Eye-joint bolt of fuel spill tube:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
1) Tighten high-pressure pipe clamp (66)
securely first. 8 – 9.8 Nm {0.8 – 1.0 kgm}
2) Install gate frame (67) to special bolt (68)
3 Clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm}

securely.
30-54 D155AX-5
(3)
[*16]
a When installing the high-pressure pipe,
check the paper seal of the joint (Part "a":
Part of 2 mm from the end) for visible length-
wise slit "b" and spot "c" and check part "d"
(End of taper seal: Part of 2 mm from the
end) for stepped-type wear (fatigue) which
your nail can feel. If any of those defects
may cause fuel leakage, replace the high-
pressure pipe.
3 Head cover mounting bolt:

[*17]
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
[*18]
• Before tightening the cylinder head mounting
bolts, check the following matter.
a If the mounting bolts are longer than the fol-
lowing using limits or they have been tight-
ened 5 times (there are 5 punch marks on
them), do not reuse them but replace them.
1) Measure stem length "e" of each mount-
ing bolt and check that the result is less
than the using limit.
2) Using limit of bolt
• Short bolt: Must be shorter than
170.8 mm.
• Long bolt: Must be shorter than
205.8 mm.
2 Mounting bolt:
Lubricant containing molybdenum
disulfide (LM-P)
a A special socket is required to tighten the
3 Cylinder head mounting bolt:

head bolts.
1st time: 137 – 157 Nm {14 – 16 kgm}

2nd time: 284 – 294 Nm {29.0 – 30.0 kgm}
3rd time:
i) When using tool E
Using an angle tightening wrench
(tool E), retighten each bolt by 90° +30°
0
in the order of (1) – (6).
D155AX-5 30-55
(5)
ii) When not using tool E

Make marks on the all bolts and cylin-
der head, then retighten each bolt by
90° +30°
0 in the order of 1) – (6).
a After tightening bolts (1) – (6), tighten
bolt (7) to 66.6 ± 7.4 Nm {6.8 ± 0.8
kgm}.
• Refilling with coolant

Add coolant through the coolant fillers of the
main radiator and sub-radiator to the specified
level. Run the engine to circulate the water
through the system. Then, check the coolant
level again.
5 Coolant: Approx. 110l
30-56 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Drain coolant.
6 Coolant:Below fitting position of thermo-

stat
2. Remove alternator assembly.

For details, see REMOVAL OF ALTERNATOR
ASSEMBLY.
3. Disconnect radiator inlet hose (1).
4. Disconnect bypass tube (2).
6. Remove 2 thermostats (4).
INSTALLATION OF
THERMOSTAT ASSEMBLY
removal.
level.
again.
D155AX-5 30-57
(3)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
k Using tool X, coolect freon gas (R134a).
1. Open engine left side cover (top) and remove

cover (bottom).
2. Remove wiring connector (1).
3. Disconnect hoses (2) and (3). [*1]

a Fit blind plugs to prevent dirt or water from
entering the hoses.
4. Loosen 4 mounting bolts (4).
5. Remove V-belt cover (5).
6. Loosen adjustment bolt (6) and remove.
7. Remove mounting bolts (4), remove V-belt (7)

from pulley, then remove compressor assembly
(8). [*12]
30-58 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
removal.
[*1]
a Install the hoses without twisting or interfer-
ence.
a Install the air conditioner circuit hoses care-
fully to prevent dirt, dust, or water from get-
ting inside the hoses.
a Check that there are O-rings at the piping
connection of the air conditioner hoses
before installing.
Coat the O-rings thoroughly with compressor
3 Tighten the air conditioner gas piping to

oil (Showa Shell Suniso 4G or 5G).
the following tightening torques.
Tightening torque
Thread size Remarks
(Nm {kgm})
16 × 1.5 11.8 – 14.7 {1.2 – 1.5} Liquid
22 × 1.5 19.6 – 24.5 {2.0 – 2.5} Discharge
24 × 1.5 29.4 – 34.3 {3.0 – 3.5} Suction
[*2]
a After installing the V-belt, adjust the belt ten-
sion. For details, see TESTING AND
AIR CONDITIONER COMPRESSOR BELT
TENSION.
• Charging with air conditioner gas

Using tool Z, charge the air conditioner circuit
with air conditioner gas (R134a).
D155AX-5 30-59
(5)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY
k Park the machine on level ground, lower the
work equipment completely to the ground, then
disconnect the cable from the negative (-) ter-
1. Using tool X, collect freon gas (R134a).
2. Open side cover (1) (Left and right).
3. Disconnect hose (2) from receiver tank and hose

(3) from air conditioner compressor. [*1]
a The condenser hose mount breaks easily, so
always use wrenches on both sides.
4. Remove mounting bolts (4), then remove air con-

ditioner condenser assembly (5).
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
removal.
[*1]
ence.
connection of the air conditioner hoses, and
coat the O-rings thoroughly with compressor
oil before connecting.

Using tool X, charge with freon gas (R134a).
30-60 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF FUEL TANK

ASSEMBLY
disconnect the cable from the negative (ÅE ter-
1. Remove cover (1) at bottom of fuel tank.
2. Close lever (2) of fuel valve.
3. Disconnect hose (3) leading to priming pump.
4. Disconnect fuel return hoses (4) and (5).
5. Disconnect fuel level sensor wiring connector (6)

(CN423).
6. Lift off fuel tank assembly (7).

a Sling at three points and use a lever block at
the center to keep the tank horizontal.
a Move the tank to the rear, and when it clears
the floor frame, raise the rear of the tank
slightly with the lever block. (Do this to avoid
interference with the ripper hoses.)
TANK ASSEMBLY
removal.
D155AX-5 30-61
(3)
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
k Lower the work equipment completely to the
ground.
Release the remaining pressure in the circuit.
RELEASING REMAINING PRESSURE IN
HYDRAULIC CIRCUIT. Then loosen the oil
filler cap slowly to release the pressure inside
k Disconnect the cable from the negative (ÅE ter-

the hydraulic tank.
1. Remove hood assembly.

BLY.
2. Drain coolant.
3. Lift opposite side of hinge and gradually open

underguard under engine.
4. Remove radiator top cover (1) and left and right

side plates.
5. Disconnect radiator inlet hose (2), aeration hose

(3), sub tank hose (4), and oil cooler hose (5).
6. Disconnect power train oil cooler hose (6), radia-

tor hose (7), and fan motor hose (8).
7. Disconnect radiator outlet hose (9), power train

oil cooler hose (10).
8. Remove work equipment piping clamp (11) and

fan motor piping clamp (12).
9. Remove oil cooler hose (5).
10. Disconnect oil cooler tube (13).
30-62 D155AX-5
(3)
11. Disconnect head lamp connector (14), then

remove 6 clamps and move wiring towards head
lamp.
12. Disconnect sub-tank hose (15).
13. Remove hose cover (16).
15. Remove the air conditioner condenser assembly.
16. Remove left and right hood mount brackets (19).
18. Open radiator grille (21) and remove the mask.
19. Remove windbreak panels (22) and (23).
20. Remove windbreak panel (24) and lower mount-

ing bracket (25).
21. Remove top mount bolt (26).
22. Lift off main radiator assembly (27).
4 Main Radiator assembly : 310 kg
D155AX-5 30-63
(3)
INSTALLATION OF RADIATOR
ASSEMBLY
removal.
3 Reservoir hose clamp:

[*1]
34 ± 5 Nm {3.4 ± 0.5 kgm}

a Set inserting distance c of hoses a and b as
shown below.
Hoses (12) and (13): Min. 25 mm
Hose (14): 60 mm
a Check that the rubber plates of the windbreak

panels touch the radiator tank securely.
Refilling with water

Add water through the water filler of the main radia-
tor and sub radiator to the specified level. Run the
engine to circulate the water through the piping.
Then, check the water level again.
5 Coolant: Approx. 110 l
30-64 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER, GUARD
REMOVAL OF RADIATOR, OIL

COOLER, GUARD ASSEMBLY
1. Drain coolant.
2. Disconnect blade lift cylinder assembly from

blade, then secure to guard.
For details, see REMOVAL OF BLADE ASSEM-
BLY.
3. Lift engine undercover at opposit end of hinge

and open engine undercover gradually.
4. Disconnect 2 blade lift cylinder hoses (1).
5. Disconnect hydraulic cooler tube (2).
6. Disconnect 2 power train oil cooler hoses (3).
7. Disconnect 2 radiator hoses (4).
8. Disconnect fan motor hose (5).
9. Remove hood assembly (6).

BLY.
10. Remove left and right side covers (7).
11. Remove radiator top cover (8).
12. Disconnect radiator inlet hose (9). [*1]

a Disconnect at the radiator end and move
towards the engine.
13. Disconnect aeration hose (10). [*2]

a Disconnect at the radiator end, then remove
2 clamps and move towards the engine.
14. Remove top fan guard (11).
15. Disconnect head lamp wiring connector (12)

(RDG).
D155AX-5 30-65
(3)
16. Sling radiator, oil cooler, guard assembly (13),

remove lock plate, then remove 4 pins (14), and
lift off radiator, oil cooler, guard assembly (13).
a Be extremely careful not to damage the wir-
ing and hoses when removing.
4 Radiator, oil cooler, guard assembly :

2,050 kg
30-66 D155AX-5
(3)
INSTALLATION OF
RADIATOR, OIL COOLER,
GUARD ASSEMBLY
removal.
3 Radiator inlet hose clamp :

[*1]
882.6 ± 49.0 Nm {90 ± 5 kgcm}
3 Aeration hose clamp :333.4 ± 49.0 Nm

[*2]
{34 ± 5 kgcm}

level.
again.
• Refilling with oil (hydraulic tank, power train

case)
Add engine oil through oil filler to the specified
level.
a Run the engine to circulate the oil through
the system. Then check the oil level again.
D155AX-5 30-67
(3)
DISASSEMBLY AND ASSEMBLY FAN DRIVE
REMOVAL OF FAN DRIVE

ASSEMBLY
1. Drain the hydraulic oil.
6 Hydraulic tank: 87 l
2. Remove the mounting bolt and open fan guard

(1).
3. Disconnect fan motor hoses (2), (3), and (4) and

remove plate (5).
a Plug the disconnected hoses and adapters to
prevent dirt from entering the piping.
a You do not need to remove plate (5), if it is
not an obstacle to removal of the fan drive
assembly.
4. Sling fan drive assembly (6) temporarily and

remove the mounting bolts.
5. Lift off fan drive assembly (6). [*1]
4 Fan drive assembly: 135 kg
INSTALLATION OF FAN
DRIVE ASSEMBLY
removal.
3 Upper mounting bolt:

[*1]
233 – 285 Nm {23.5 – 29.5 kgm}
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank: 87 l
30-68 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY FAN MOTOR
REMOVAL OF FAN MOTOR

ASSEMBLY
1. Remove the fan drive assembly. For details, see
REMOVAL OF FAN DRIVE ASSEMBLY.
2. Remove the mounting bolts and lock plate (1).

[*1]
3. Remove nut (2). [*2]
4. Using puller [1], remove fan (3).
5. Remove the 4 mounting bolts and fan motor

assembly (4). [*3]
4 Fan motor assembly: 40 kg
INSTALLATION OF FAN
MOTOR ASSEMBLY
removal.
[*1]
Be sure to adjust the hole of lock plate (1) by
turning nut (2) in the tightening direction.
3 Mounting nut (2):

[*2]
441 – 539 Nm {45 – 55 kgm}
[*3]
a Wipe the fitting parts of the fan motor and fan
thoroughly, and then degrease them.
D155AX-5 30-69
(3)
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
k Lower the work equipment completely to the
ground. Release the remaining pressure in the
circuit. For details, see TESTING AND ADJUST-
ING, RELEASING REMAINING PRESSURE IN
HYDRAULIC CIRCUIT.
Then loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
1. Remove hood assembly (1) and engine side

cover (2). For details, see REMOVAL OF HOOD
ASSEMBLY.
2. Remove radiator top cover (3).
4. Disconnect reservoir tank hose (5).
5. Remove hose cover (6).
6. Remove cooler hose (7).
7. Disconnect hose (8) and remove tube (9).
INSTALLATION OF
HYDRAULIC COOLER
ASSEMBLY
removal.
• Refilling with oil (hydraulic tank)

level.
30-70 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
a Close the fuel feed valve.
1. Remove radiator and oil cooler and guard
assembly. For details, see REMOVAL OF RADI-
ATOR AND OIL COOLER AND GUARD
ASSEMBLY.
2. Disconnect starting motor wiring (1).
4. Disconnect 2 air conditioner house (3). [*1]

a Loosen the sleeve nut of each hose a little to
discharge the all air conditioner refrigerant
(R134a), then disconnect the hose.
a Plug the hoses to prevent dirt, water, etc.
from entering them.
a Remove the all clamps on the floor frame
and move the hoses toward the engine.
5. Disconnect 2 heater hoese (4).
6. Disconnect head light wiring connector (5).
7. Disconnect fuel hoses (6), (7), and (8).
D155AX-5 30-71
(3)
8. Disconnect ground wire (9).
9. Disconnect universal joint (10) from damper.
10. Remove front mounting bolts (11) and rear

mounting bolts (12). [*2]
11. Moving engine assembly (13) to front of machine

body, lift it off gradually.
a After removing the engine assembly, take
care not to damage the wires, hoses, etc.
4 Engine assembly : 1,750 kg
30-72 D155AX-5
(3)
ASSEMBLY
removal.
[*1]
ence.
connection of the air conditioner hoses
before installing.
Coat the O-rings thoroughly with compressor
3 Tighten the air conditioner gas piping to

oil (Shell Suniso 4G or 5G).
the following tightening torques.
Tightening torque
Thread size Remarks
(Nm {kgm})
16 × 1.5 11.8 – 14.7 {1.2 – 1.5} Liquid
22 × 1.5 19.6 – 24.5 {2.0 – 2.5} Discharge
24 × 1.5 29.4 – 34.3 {3.0 – 3.5} Suction
3 Engine mount bolt:

[*2]
931.7 ± 98.1 Nm {95 ± 10 kgm}
D155AX-5 30-73
(3)
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Drain oil from damper chamber.
6 Damper chamber : 1.5 l
2. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Lift off HMT pump assembly.

For details, see REMOVAL OF HMT PUMP
ASSEMBLY.
4. Disconnect or remove piping and hoses installed

to power train and lubrication pump.
For details, see REMOVAL OF POWER TRAIN,
LUBRICATION PUMP ASSEMBLY.
5. Disconnect breather hose (1) and remove dip-

stick tube (2) together with hose.
6. Lift off universal joint assembly (3), then remove

coupling (4) at torque converter end. [*1]
7. Remove mounting bolts of damper cover assem-

bly (5), then install 2 guide bolts [1] on opposite
sides, and use forcing screws [2] to pull damper
cover (6) out to position where it is possible to
install lifting tool. [*2]
30-74 D155AX-5
(3)
8. Removal of Damper
1) Remove 2 mounting bolts of damper (7),
then set guide bolts [3] in position. [*4]
2) Remove remaining mounting bolts, then use
forcing screws [4] to pull out. [*5]
3) Pull out to position where it is possible to
install eyebolts [5], set lifting tool to damper
(7), then remove.
INSTALLATION OF DAMPER
ASSEMBLY
removal.
2 Universal joint mounting bolt :

[*1]

Thread tightener (LT-2)
110.8 ± 12.7 Nm {11.3 ± 1.3 kgm}
3 Damper cover Mounting bolt :

[*2]
110.8 ± 12.7 Nm {11.3 ± 1.3 kgm}

[*3]
a When installing the damper cover assembly,
remove all oil and grease from the shaft
spline, coat with dry lubricant A, leave for 2
or 3 minutes, then coat with lithium-based
molybdenum disulphide extreme pressure
grease B, and assemble.
Dry type molyb- SUMICO LUB:
A denum disulphide ROCOL DRY SPRAY
lubricant or equivalent
• KYODO YUSHI:
MORILEX NO. 2
Lithium lubricant • SHOWA SHELL:
B grease with molyb- RETINAX AM
denum disulphide • NIPPON OIL:
MORITEX NO. 2
or equivalent
3 Damper Mounting bolt :

[*4] [*5]
110.8 ± 12.7 Nm {11.3 ± 1.3 kgm}
• Refilling with oil
5 Damper chamber : 1.5 l (SAE30CD)
3 Plug : 152.0 ± 24.5 Nm {15.5 ± 2.5 kgm}
D155AX-5 30-75
(3)
DISASSEMBLY OF DAMPER ASSEMBLY
Disassembly of damper cover assembly (1)

1. Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
30-76 D155AX-5
(3)
2. Shaft
1) Set damper cover assembly (1) to block [1],
then tap from output end with a plastic ham-
mer, and pull out shaft (6).
a Remove shaft (6) together with oil seal
(8) and inner race (7-1) of bearing (7).
2) Remove collar (7-2) and O-ring of bearing (7)

from shaft (6), then remove inner race (7-1).
3. Bearing, oil seal

1) Remove oil seal (9) from cover (2), then
remove inner race (7-3) of bearing (7).
2) Remove outer races (7-4) and (7-5) of bear-

ing (7) from cover (2).
D155AX-5 30-77
(3)
Disassembly of damper assembly (10)

4. Remove bolt (11), then remove flange (12).
5. Remove outer body (13), inner body (14), and

cushion (15).
6. Pull out plug (17) from flange (16).

a Only when replacing the plug.
30-78 D155AX-5
(3)
ASSEMBLY OF DAMPER ASSEMBLY
Assembly of damper assembly (10)

1. Align bolt holes of flange (16) and outer body
(13) with cylinder [1], then assemble inner body
2 Mating surface of flange, outer body :

(14).
2 Inside surface of outer body :

2 Cushion contact surface of inner body :

Grease (G2-LI)
Grease (G2-LI)
D155AX-5 30-79
(3)
2. Assemble cushion (15).

a Coat the whole surface of the cushion with
grease (G2-LI).
a After assembling the cushion, fill 30% of the
clearance (16 places) between the inner
body and outer body with grease.
3 Mounting bolt : 66.2 ± 7.4 Nm

3. Assemble flange (12) and tighten with bolt (11).
{6.75 ± 0.75 kgm}
4. Filling with grease

1) Fill inner body [a] with 800 g of grease listed
2 : Grease
below.
Grease Brand name

• KYODO YUSHI:
Lithium lubricant MORILEX NO. 2
grease with • SHOWA SHELL:
molybdenum RETINAX AM
disulphide • NIPPON OIL:
MORITEX NO. 2
or equivalent
Assembly of damper cover assembly (1)

5. Using push tool [2], press fit outer races (7-4)
and (7-5) of bearing (7) to cover (2) with press.
30-80 D155AX-5
(3)
6. Press fit inner race (7-1) of bearing (7) to shaft

(6) with tool F.
7. Assemble collar (7-2) and O-ring to shaft (6).
8. Set cover (2) to shaft (6), and using tool F, press

fit bearing inner race (7-3).
2 Oil seal press-fitting surface :

9. Install oil seals (8) and (9) to cover assembly (2).
2 Lip of oil seal : Grease (G2-LI)

a Coat the oil seal surface thinly with gasket

sealant and wipe off any sealant that is
squeezed out.
D155AX-5 30-81
(5)
10. Coupling
Assemble coupling (5) and holder (4), and
3 Mounting bolt :
tighten bolt (3).
277.5 ± 32.4 Nm {28.3 ± 3.3 kgm}
30-82 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
REMOVAL OF POWER TRAIN

UNIT ASSEMBLY
disconnect the cable from the negative (-) ter-
1. Drain oil
6 Hydraulic tank : Approx. 87 l
6 Power train case: Approx. 45 l
2. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Open cover at bottom of power train unit.
4. Remove cover (1) at bottom of fuel tank.
5. Close lever (2) of fuel valve.
6. Disconnect hose (3) leading to priming pump.
7. Disconnect fuel return hoses (4) and (5).
8. Disconnect fuel level sensor wiring connector (6)

(CN423).
9. Lift off fuel tank assembly (7).

a Sling at three points and use a lever block at
the center to keep the tank horizontal.
a Move the tank to the rear, and when it clears
the floor frame, raise the rear of the tank
slightly with the lever block. (Do this to avoid
interference with the ripper hoses.)
4 Fuel tank assembly (when full) : 800 kg
10. Disconnect engine speed sensor wiring connec-

tor (8).
11. Disconnect 3-unit pump outlet hose (9).
D155AX-5 30-83
(3)
12. Disconnect the clamps and connectors of wiring

(10).
13. Remove top cover of centralized pressure detec-

tion port, then remove centralized pressure
detection block (11) from frame.
14. Disconnect hose (12) between hydraulic pump

and control valve.
15. Disconnect wiring connector (13) (HHP).
16. Remove suction tube (14).
a Be careful not to damage the gasket of the
joint.
17. Disconnect hose (15) between cooler bypass

valve and hydraulic tank.
18. Disconnect hose (16) between charge relief
valve and hydraulic tank.
19. Remove power train oil supply pipe (17).
20. Disconnect power train dipstick tube (18) from
case, and move towards right side of chassis.
30-84 D155AX-5
(3)

22. Disconnect hose (22) between filter case and
transmission.
23. Disconnect hoses (20) and (21) between cooler
bypass valve and oil cooler.
24. Disconnect hose (23) between HSS pump and

charge filter.
25. Disconnect hose (24) between charge + scav-
enging pump and charge filter.
26. Disconnect hose (25) between HSS solenoid
valve and HSS, PPC charge valve at solenoid
valve end.
27. Disconnect hose (26) between oil cooler and

transmission lubrication valve.
a Open the guard (bottom plate) under the
transmission when carrying out the opera-
tion.
28. Disconnect drive shaft (27) at torque converter

end. [*1]
a After disconnecting, push the yoke towards
the torque converter and disconnect com-
pletely.
27
DED00536
D155AX-5 30-85
(3)
29. Remove final drive shaft cover (28), then use bolt
[1] to pull out drive shaft (29) to a point where
spline at steering case end comes out.
a If the shaft does not come out, move the
sprocket (push up the shoe grouser from the
ground surface with a jack) to adjust to a
position where the shaft comes out, then pull
out the shaft.
30. Remove mount caps (30) at both ends of steer-

ing case together with cover. [*2]
31. Loosen coupling clamp (31), and move (open)

seal (32) slightly to outside. [*3]
32. Remove front mount bolt (33). [*4]
33
DBD00541
30-86 D155AX-5
(3)
33. Lift off power train unit assembly (34). [*5]

a Check that the wiring and piping has all been
removed, then lift off the power train unit
assembly.
4 Power train unit assembly : 2,350 kg
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
removal.

[*1]
110.3 ± 22.1 Nm {11.3 ± 2.3 kgm}
3 Mount cap mounting bolt :

[*2]
277.5 ± 32.4 Nm {28.3 ± 3.3 kgm}
[*3]
a Clamp the protruding portion of the coupling
seal, then assemble the clamp thread so
that it is parallel to the cap mount seat sur-
face.
3 Front mount mounting bolt :

[*4]
926.8 ± 103.0 Nm {94.5 ± 10.5 kgm}
[*5]
a When assembling the power train assembly,
be extremely careful not to damage seal
(32).
• Refilling with oil (Hydraulic tank. power train

case.)
level.
5 Power train case : Approx. 45 l
D155AX-5 30-87
(3)
SEPARATION OF POWER
TRAIN UNIT ASSEMBLY
• Drain oil
Before setting the power train unit assembly on
the block, drain the oil from the PTO case.
1. Raise power train unit assembly (1) and set on
block [1].
4 Power train unit assembly : 2,350 kg
2. Disconnect 3 hoses (2) connected to cooler

bypass valve.
3. Disconnect HSS pump connecting hose (3).
4. Remove cooler bypass valve assembly (4)
together with bracket.
5. Disconnect 5 charge relief valve connecting

hoses (5).
6. Disconnect wiring connector (6) (CN406).
7. Remove charge relief valve (7).
8. Disconnect pressure detection hoses (8) and (9),

and remove reducing pressure valve hose (10).
[*1]
a Disconnect the transmission modulation
pressure detection hose.
30-88 D155AX-5
(3)
9. Disconnect pressure detection hose (11). [*1]
10. Remove hydraulic pump assembly (12).
4 Hydraulic pump assembly : 19 kg
a Disconnect the wiring connector (HHP).

11. Remove 2 suction tubes (13) from 3-spool pump
and charge pump.
12. Disconnect PTO lubrication tube (14).
13. Disconnect transmission lubrication tube (15).
[*2]
14. Disconnect 3 HSS pump connecting hoses (16).

15. Disconnect HSS pump solenoid valve wiring
connectors (17) (PUPA-A, B).
16. Disconnect piping (18) and lift off 3-spool pump
assembly (19).
4 3-spool pump assembly : 24 kg
17. Lift off HSS pump assembly (20).
4 HSS pump assembly : 102 kg
D155AX-5 30-89
(3)
18. Remove suction tube (21) and lift off PPC charge
+ scavenging pump assembly (22).
4 Pump assembly : 36 kg
19. Disconnection of steering case [*3]

1) Raise steering case end of power train unit
assembly.
2) Remove mounting bolts at bottom of steering
case (23), and set block [3] under transmis-
sion case.
3) Remove remaining mounting bolts, then
raise steering case assembly (23) and dis-
connect.
4 Steering case assembly : 1,000 kg
20. Set PTO, torque converter, and transmission

assembly (24) on block [4] with PTO facing up.
21. Remove strainer cover (25), then remove spring

(26) and strainer (27). [*4]
30-90 D155AX-5
(3)
22. Remove temperature sensor bracket (28), and

pull out 2 sleeves (29).
23. Remove mounting bolts, then lift off PTO assem-

bly (30).
4 PTO assembly : 200 kg [*5]
24. Sling torque converter assembly (31), and

remove mounting bolts, then use forcing screws
[5] to remove torque converter assembly (31).
4 Torque converter assembly : 130 kg [*6]
D155AX-5 30-91
(3)
DISASSEMBLY AND ASSEMBLY POWER TRAIN
CONNECTION OF POWER
TRAIN ASSEMBLY
• Carry out connection in the reverse order to dis-
connection.
[*1]
• Install the piping of the pressure detection tubes
as shown in the diagram below.
(There are distinguishing color bands installed to
each detection tube.)
Port for measuring pressure

Stamp of block Port for measuring pressure
1 BR Left brack pressure
2 TM T/M main rilief pressure
3 F F T/M cluch pressure
4 R R T/M cluch pressure
5 1st 1st T/M cluch pressure
6 2nd 2nd T/M cluch pressure
7 3rd 3rd T/M cluch pressure
8 In Input pressure of T/C
9 Out Output pressure of T/C
3 Suction tube mounting bolt :

[*2]
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
3 Steering case mounting bolt :

[*3]
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
3 Strainer mounting bolt :

[*4]
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
3 PTO assembly mounting bolt :

[*5]
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
2 Torque converter mounting bolt :

[*6]
3 Torque converter mounting bolt :

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
30-92 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY PTO
DISASSEMBLY OF PTO
ASSEMBLY
1. Lubrication tube
1) Remove shaft lubrication tube (1).
2) Remove pump drive gear lubrication tube (2).
2. HSS pump drive gear, cover assembly

1) Remove mounting bolts, set guide bolt [1] in
position, then use forcing screws [2] to
remove gear and cover assembly (3).
2) Disassemble gear and cover assembly as

follows.
i) Remove cover (4) from gear and bearing
assembly (5).
D155AX-5 30-93
(3)
ii) Remove bearing (6) from gear (7).
3. Cover assembly
1) Remove mounting bolts, then use forcing
screws [3] and guide bolt [4] to remove gear
and cover assembly (8).
2) Remove snap ring (9), then remove spacer

(10).
3) Using puller [5], remove gear assembly (11)
from cover assembly (12).
4) Remove snap ring (13), then remove inner

race (14) from gear assembly (15).
5) Remove snap ring (16), then remove bearing
(17) from cover assembly.
30-94 D155AX-5
(3)
4. Scavenging pump drive gear

1) Remove snap ring (18).
2) Knock out drive gear (19) from snap ring

end.

(21).
5. Idler gear
1) Remove mounting bolts, then remove plate
(22).
D155AX-5 30-95
(3)
2) Remove mounting bolts, set guide bolt [6] in

position, then use forcing screws [7] to
remove shaft (23).
3) Remove bearing (25) and spacer (26) from

gear (24).
a If the parts are to be used again, keep
them as a set with the outer race to pre-
vent the set from being changed.
4) Remove bearing outer race (27) and snap
ring (28) from gear (24).
6. Input shaft outer race

Remove snap ring (29), then remove input shaft
outer race (30).
7. Magnet assembly
1) Remove mounting bolts, then remove cover
(31).
2) Remove spring (32) and magnet assembly
(33).
30-96 D155AX-5
(3)
ASSEMBLY OF PTO
ASSEMBLY
a Clean all parts, and check for dirt or damage.
a After press fitting the bearing, apply 6 cc of
SAE10WCD or SAE30CD in drops, then rotate
about 10 times.
a Check that the snap ring is fitted securely in the
groove.
1. Magnet assembly
1) Assemble magnet assembly (33) and spring
(32).
2) Install cover (31).
2. Input shaft outer race

1) Press fit input shaft outer race (30), and
install snap ring (29).
3. Idler gear
a There are manufacturing numbers and sym-
bols on the bearing and spacer, so form sets
with the same manufacturing number and
symbol when assembling.
1) Fit snap ring (28) to gear (24), and press fit

outer race (27).
D155AX-5 30-97
(3)
2) Using 3 guide bolts [9], insert shaft (23) to

position shown in diagram.
a If shaft (23) is inserted fully, gear (24)
2 O-ring : Grease (G2-LI)

cannot be installed.
3) Install bearing (25) to shaft (23).

4) Install spacer (26).
5) Install gear (24).

6) Fit bearing (25), then tighten plate (22) with
2 Mounting bolt :
bolt and press fit to shaft.
3 Mounting bolt :
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}
2 Mounting bolt :
7) Secure shaft (23) with mounting bolts.
3 Mounting bolt :
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
4. Scavenging pump drive gear

1) Press fit bearing (20) to case, and install
snap ring (37).
30-98 D155AX-5
(3)
2) Hold inner race end of bearing with push tool

[10], and install drive gear (19).
3) Install snap ring (18).
5. Cover assembly
1) Press fit bearing (17) to cover assembly, and
2) Press fit inner race (14) to gear assembly

(15), and install snap ring (13).
3) Using push tool [11], press fit cover (12) to

gear assembly (11).
4) Fit spacer (10), and install snap ring (9).
D155AX-5 30-99
(3)
5) Mesh with idler gear and install cover assem-
2 O-ring : Grease (G2-LI)

bly (8).
2 Mounting bolt :
3 Mounting bolt :
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
6. HSS pump drive gear, cover assembly

1) Assemble gear and cover assembly as fol-
lows.
i) Press fit bearing (6) to gear (7).
ii) Install gear and bearing assembly (5) to

cover (4).
2 Cover O-ring portion :

2) Install gear and cover assembly (3) to case.
3 Mounting bolt :
Grease (G2-LI)
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
30-100 D155AX-5
(3)
7. Lubrication tube
3 Joint bolt :
1) Install lubrication tube (2).
5.0 ± 4.9 Nm {4 ± 0.5 kgm}
3 Joint bolt :
5.0 ± 4.9 Nm {4 ± 0.5 kgm}
D155AX-5 30-101
(3)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Case, turbine assembly
Remove 30 bolts from below, then use eyebolts
[1], and remove case and turbine assembly (1).
2. Input shaft
1) Remove input shaft (2).
2) Remove snap ring (3), then remove inner

race (4).
3. Case
1) Remove snap ring (5).
2) Remove spacer (6).
30-102 D155AX-5
(3)
3) Using puller [2], disconnect case assembly

(7) and turbine (8).
4) Remove bearing (10) from case (9).
4. Stator
Remove snap ring (11), then remove stator (12).
5. Pump assembly
1) Using forcing screws [3] from stator shaft
end, remove pump assembly (13) from stator
shaft (14).
D155AX-5 30-103
(3)
2) Remove seal ring (15) and flange (16) from

stator shaft (14).
3) Remove cage assembly (17) from pump

(18).

(21) from cage (20).
30-104 D155AX-5
(3)
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
a After press fitting the bearing, apply 6 cc of
SAE10WCD or SAE30CD in drops, then rotate
about 10 times.
groove.
a Coat the seal ring with grease (G2-LI) and align
the end gaps.
1. Pump assembly
1) Press fit bearing (21) to cage (20), and install
snap ring (19).
3 Mounting bolt:
2) Install cage assembly (17) to pump (18).
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
3) Install seal ring (15) and flange (16) to stator
2 Mounting bolt:
shaft (14).
4) Using push tool [4], install pump assembly

(13) to stator shaft (14).
a Push the inner race of the bearing to
press fit.
D155AX-5 30-105
(3)
2. Stator
1) Install stator (12).
3. Case
1) Install bearing (10) to case (9).
2) Using push tool [5], push inner race end of

bearing, then install case assembly (7) to
boss portion of turbine (8).

30-106 D155AX-5
(3)
4. Input shaft
1) Press fit inner race (4), and install snap ring
(3).
2 Mounting bolt:
2) Install input shaft (2).
3 Mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
5. Case, turbine assembly

1) Using eyebolts [1], align groove of case with
drain plug, and install case and turbine
2 Mounting bolt:
assembly (1).
3 Mounting bolt:
54.0 ± 4.9 Nm {5.5 ± 0.5 kgm}
3 Drain plug:
2) Install drain plug.
17.2 ± 2.5 Nm {1.75 ± 0.25 kgm}
D155AX-5 30-107
(3)
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DISASSEMBLY OF
TORQFLOW TRANSMISSION
ASSEMBLY
a After removing the discs and plates, keep them
in a flat place to prevent bending or deformation.
1. Relief valve assembly

Remove relief valve assembly (1).
2. Control valve assembly

1) Remove cover assembly (2).
2) Remove sleeve (3) and flanges (4) and (5).
3) Remove control valve assembly (6).
30-108 D155AX-5
(3)
1) Fit a block and set with torque converter side
at top.
2) Remove sleeve (7).
3) Using eyebolts [2], sling transmission case

(8), then remove 13 tie bolts (9) (tightened
together with transmission case), and
remove case (8).
4. Tie bolts
Remove remaining 4 tie bolts (9).
5. Input shaft, front cover, No. 1 carrier assem-

bly
1) Using eyebolts [3], remove input shaft, front
cover, and No. 1 carrier assembly (11).
D155AX-5 30-109
(3)
2) Disassemble input shaft, front cover, and No.

1 carrier assembly as follows.
i) Remove snap ring (12), then remove No.
2 sun gear (13) and snap ring (14).
ii) Remove snap ring (15), then remove No.
1 sun gear (16) and collar (17).
iii) Remove snap ring (18).

iv) Knock input shaft towards torque con-
verter, and remove front cover (19).
v) Remove snap ring (20), then knock input

shaft (21) out towards torque converter
to remove.
vi) Remove snap ring (22), then remove No.

1 ring gear (23).
vii) Pull out shaft (24), then remove thrust
washer (25), gear (26), bearing (27), and
ball (28).
a Be careful not to lose the ball.
30-110 D155AX-5
(3)
6. No. 1 disc, plate, springs

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

1) Using eyebolts [4], remove No. 1 housing
assembly (33).
2) Remove No. 1 piston (34) from housing.
8. Guide pin
Remove guide pin (35).

(39).
10. Remove through bolt guide (40), lubrication relief

valve (41), and spring (120).
D155AX-5 30-111
(3)
11. No. 2 housing, No. 2 carrier assembly

1) Using eyebolts [5], remove No. 2 housing
and No. 2 carrier assembly (42).
2) Remove No. 2 piston (43).
3) Disassemble No. 2 housing and No. 2 carrier

assembly as follows.
i) Remove snap ring (44), then pull out No.
2 carrier assembly (45) from No. 2 hous-
ing (46).
ii) Remove spacer (47) and No. 2 ring gear

(48) from No. 2 carrier assembly (49).
iii) Pull out shaft (50), and remove thrust

ball (54).
iv) Remove snap ring (55), then remove ring

gear (56).
30-112 D155AX-5
(3)
v) Remove seal ring (57) and snap ring (58)

from No. 2 housing (46), then remove
bearing (59).

(63).
13. No. 3 ring gear

Remove No. 3 ring gear (64).
14. No. 3, 4 carrier assembly

1) Remove No. 3 and 4 carrier assembly (65).
D155AX-5 30-113
(3)
2) Disassemble No. 3, 4 carrier assembly as

follows.
i) Remove seal ring (66).
ii) Knock pin (67) into shaft (68).
iii) Knock out shaft (68) from No. 3 carrier
end.
iv) Remove thrust washer (69), No. 4 planet
gear (70), and bearing (71).
a Remove the pin from the shaft.
v) Knock out shaft (72), then remove thrust
washer (73), No. 3 planet gear (74),
bearing (75), and ball (76).
15. No. 3 housing

1) Remove No. 3 housing (77).
16. No. 4 disc, plate, springs, guide pin

2) Remove spring (80), No. 4 disc (81), plate
(82).
3) Remove guide pin (83).
17. No. 5 carrier, No. 4 ring gear assembly

1) Remove mounting bolts (84).
2) Remove No. 5 carrier and No. 4 ring gear
assembly (85).
30-114 D155AX-5
(3)
3) Disassemble No. 5 carrier, No. 4 ring gear

i) Knock out shaft (86), then remove thrust
ball (90).
ii) Remove snap ring (91), then remove No.

4 ring gear (92) from carrier (93).

1) Remove No. 4 housing assembly (94).

2) Remove disc (97), plate (98), and spring
(99).
D155AX-5 30-115
(3)
20. No. 5 ring gear

Remove No. 5 ring gear (100).
21. Collar, No. 4 sun gear, bearing

Remove snap ring (101), then remove collar
(102), No. 4 sun gear (103), and bearing (104).
22. No. 5 sun gear

Remove No. 5 sun gear (105).
23. No. 5 piston

Remove No. 5 piston (106).
24. Shaft, collar

Remove shaft (107) and collar (108) from cover
(109).
25. Bearing cage

1) Remove snap ring (110), then remove bear-
ing (111).
2) Remove snap ring (112), then remove bear-
ing (113).
3) Remove cage (114), then remove seal rings
(115) and (116).
30-116 D155AX-5
(3)
ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
• Precautions when assembling
a Coat the sliding surfaces of all parts with
engine oil before installing.
a Assemble the piston seal rings with the side
receiving the pressure facing the housing as
shown in the diagram.
a When installing metal seal rings, coat with
grease (G2-LI) and install uniformly, taking
care that they do not move to one side.
1. Cage, bearing
1) Install seal rings (116) and (115), then install
cage (114) to cover (109).
2) Press fit bearing (113), and install snap ring
(112).
3) Press fit bearing (111), and install snap ring
(110).
2. Shaft, collar
Install shaft (107) and collar (108) to cover (109).
3. No. 5 sun gear

Install No. 5 sun gear (105).
4. No. 5 ring gear

Install No. 5 ring gear (100).
5. No. 5 piston
Install No. 5 piston (106).
D155AX-5 30-117
(3)
6. Guide pin
Install guide pin (83).

1) Install disc (97), plate (98), and spring (99).
a Discs: 3, Plates: 2
2) Install spring (96).
a Free length of spring: 66 mm

1) Fit seal ring and install No. 4 piston (95).
2) Install No. 4 housing (94).
a Check that the spring is fitted securely in
the groove.
9. No. 5 carrier, No. 4 ring gear assembly

1) Assemble No. 5 carrier and No. 4 ring gear
i) Set No. 4 ring gear (92) to carrier (93),
and install snap ring (91).
ii) Assemble bearing (89) to gear (88), then

put thrust washers (87) in contact on
both sides, and set in carrier.
iii) Fit ball (90) and install shaft (86).
30-118 D155AX-5
(3)
2) Using guide bolts [1], install No. 5 carrier and
3 Mounting bolt:
No. 4 ring gear assembly (85).
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

1) Install No. 4 disc (81), plate (82), and spring
(80).

2) Install No. 3 housing (77).
the groove.
12. No. 3, 4 carrier assembly

1) Assemble No. 3 and 4 carrier assembly as
follows.
i) Press fit bearing (117), and install snap
ring (118).
D155AX-5 30-119
(3)
ii) Assemble bearing (75) to No. 3 planet

gear (74), then put thrust washers (73) in
contact on both sides and set to carrier.
iii) Fit ball (76), then install shaft (72).
iv) Assemble bearing (71) to No. 4 planet
gear (70), then put thrust washers (69) in
contact on both sides and set to carrier.
v) Align shaft pin hole with carrier pin hole
and install shaft (68).
vi) Check that pin holes are aligned, then
knock in pin (67).
vii) Install seal ring (66).
2) Align sun gear and ring gear, then install No.

3 and 4 carrier assembly (65).
a Be careful not to get your fingers caught.
13. No. 3 ring gear

Install No. 3 ring gear (64).
a Install so that the side with the notch in the
outside teeth is facing down.

1) Install disc (62), plate (63), and spring (61).
30-120 D155AX-5
(3)
15. No. 2 housing, No. 2 carrier assembly

1) Assemble No. 2 housing and No. 2 carrier
i) Press fit bearing (59) to No. 2 housing
(46), and install snap ring (58).
ii) Install seal ring (57).
iii) Set ring gear (56) to No. 2 carrier (45),

then install snap ring (55).
iv) Assemble bearing (53) to gear (52), then

both sides, and set to carrier.
v) Fit ball (54) and install shaft (50).
vi) Install seal ring.

vii) Install No. 2 ring gear (48).
viii) Install spacer (47).
a Install so that the side where the
inside is cut is facing the carrier.
D155AX-5 30-121
(3)
ix) Install No. 2 housing (46) to No. 2 carrier

assembly (45).
a Press fit the inner race of the housing
bearing.
x) Install snap ring (44).
2) Install No. 2 piston (43).

3) Using eyebolts [5], install No. 2 housing and
No. 2 carrier assembly (42).
the groove.
16. Install through bolt guide (40), spring (120), and

lubrication relief valve (41).
17. Guide pin

Install guide pin (35).

(37).
a Free length of spring: 81.7 mm
30-122 D155AX-5
(3)

2) Using eyebolts [4], align with No. 2 piston,
then install No. 1 housing assembly (33).
a Push the housing and tap the dowel pin
portion.
20. Input shaft, No. 1 carrier assembly

1) Assemble input shaft and No. 1 carrier
i) Assemble bearing (27) to gear (26), then
ii) Fit ball (28) and install shaft (24).
iii) Set No. 1 ring gear (23) to No. 1 carrier,
and install snap ring (22).
iv) Press fit bearing (117) to input shaft (21).
v) Fit No. 1 carrier assembly (118) to input

shaft (21), then install snap ring (18).
vi) Install collar (17).
vii) Install No. 1 sun gear (16), then install

snap ring (15).
viii) Install snap ring (14).
D155AX-5 30-123
(3)
ix) Install No. 2 sun gear (13), then install

snap ring (12).
2) Raise input shaft, No. 1 carrier assembly

(119), align meshing of No. 2 sun gear and
No. 1 planet gear, then install.

(30).
a Free length of spring: 81.7 mm
22. Front cover

1) Install seal ring (121) to front cover (122).
30-124 D155AX-5
(3)
2) Using eyebolts [6], align front cover (122)

with guide pin and spring, then install.
Press fit inner race end of bearing (123) to
input shaft, then install snap ring (124).
the cover.
23. Tie bolts

Install 4 tie bolts (9). (The 4 bolts marked e in
3 Tie bolt: 166.7 ± 9.8 Nm {17 ± 1 kgm}

the diagram)
24. Operation test of piston

Using tool G, test the operating condition and
stroke of each piston.
Piston Standard stroke (mm)

No. 1 6
No. 2 6
No. 3 5
No. 4 5
No. 5 6

Fit O-ring, then using eyebolts [2], install trans-
mission case (8), and install remaining 13 tie
bolts (9).
2 Tie bolt :Gasket sealant (LG-5)
D155AX-5 30-125
(5)
26. Sleeve
Install sleeve (7).
27. Control valve assembly
3 Mounting bolt:
1) Install control valve assembly (6).
49.1 ± 4.9 Nm {5.0 ± 0.5 kgm}
2) Install flanges (4) and (5), and sleeve (3).
2 Mounting bolt thread portion:

3) Install cover assembly (2).
Gasket sealant (LG-1 or LG-5)
30-126 D155AX-5
(3)
28. Main relief valve assembly
3 Mounting bolt:
Install main relief valve assembly (1).
49.1 ± 4.9 Nm {5.0 ± 0.5 kgm}
D155AX-5 30-127
(5)
DISASSEMBLY AND ASSEMBLY HSS CASE
DISASSEMBLY OF HSS CASE

ASSEMBLY
1. Brake, carrier assembly
1) Angle the HSS case assembly approx. 15°
so that tool H1 is perpendicular to ground
surface.
2) Remove mounting bolts, then using tool H1,
remove brake, carrier assembly (1).
a Do not remove the hexagon socket head
bolt.
a Remove the brake and carrier assembly
on the other side in the same way.
• Disassembly of brake, carrier assembly

1) Remove flange (2) and plate (3).
2) Loosen hexagon socket head bolts uniformly,

then using eyebolts [1], remove brake case
(5).
a The case is being pushed by the brake
spring, so loosen it slowly and uniformly.
a The outside bearing will come out together
with the cover.
3) Remove spacer (6), brake spring (7), piston

(8), and cylinder (9).
30-128 D155AX-5
(5)
4) Remove brake drum (12) together with disc

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

and plate (14) from brake drum.
6) Remove mounting bolts, then remove carrier

assembly (19) from hub (18).
7) Remove gear assembly (20) from hub
assembly (18).
8) Remove ring (21), then remove ring gear

(22) from gear (108).
9) Remove snap ring (23), and pull out shaft
(24).
D155AX-5 30-129
(3)
10) Remove planetary gear (25), bearing (26),

thrust washer (27), shaft (24), and ball (28).
11) Remove snap ring (31), then remove stopper

(32) from hub (18).
2. Bevel pinion assembly

1) Using guide bolts [3] and forcing screws
remove bevel pinion assembly (33) and shim
(34).
a Check the number and thickness of the
shims, and keep in a safe place.
2) Disassembly of bevel pinion assembly

i) Remove bolts (35), plate (36) and pin
(37).
Serial No. 75001 –
ii) Hold with press to prevent pinion from

moving, then use tool H2 to remove lock-
nut (39).
iii) Using push tool [5], remove bevel pinion

(40) from cage (41).
30-130 D155AX-5
(5)
iv) Remove bearing (42).

v) Remove outer races (43) and (107) from
cage (41).
vi) Remove bearing (109) from bevel pinion

(40).
3. Sun gear
Remove sun gear (45).
a Remove the sun gear on the opposite side in
the same way.
4. Gear
1) Remove snap ring (47), then remove spacer
(48).
2) Using gear puller [6], remove gear (49).
D155AX-5 30-131
(3)
a Only inner race (50) of bearing (55) will

remain.
a Remove the gear on the opposite side in the
same way.
5. Valve seat
1) Pull out 3 brake circuit tubes (51) and 2 lubri-
cation tubes (52), then remove.
2) Remove valve seat (53).
6. Lubrication tubes, dipstick tube, suction tube

1) Remove lubrication tubes (52) and (56).
2) Remove lubrication tubes (57) and (58).

3) Remove dipstick tube (59) and suction tube
(60).
30-132 D155AX-5
(3)
7. Motor output gear

1) Remove flange (61) from case (62).
2) Remove flange and gear assembly (63).
3) Remove gear assembly (65) from flange

(64).
4) Remove inner race (67) and bearing (68)

from gear (66).
5) Remove bearing (69) from flange (61).
8. Right carrier drive gear

1) Remove bolt (70), then remove plate (71)
and gear (72).
D155AX-5 30-133
(3)
2) Knock out shaft (73) with a plastic hammer to

remove.
3) Remove inner race (75) from bearing (74).

4) Remove bearing (74).
9. Intermediate gear
1) Remove shaft mounting bolt.
2) Using shock hammer [8], pull out shaft (76),
then remove gear (77) and bearing (78).
10. Bevel gear shaft, bevel gear assembly

1) Remove left retainer mounting bolts (85).
2) Remove right retainer mounting bolts (86).
3) Using eyebolts [7], lift off bevel gear shaft
and bevel gear assembly (87).
shims at the left cage, and keep in a safe
place.
30-134 D155AX-5
(3)
4) Disassembly of bevel gear shaft, bevel gear

assembly
i) Using puller [11], remove inner race (91)
from right shaft (92).
a Remove inner race (91) from the left
shaft (92) in the same way.
ii) Remove right retainer (89) from shaft

(92).
iii) Remove hexagon socket head bolt (95),

then remove plate (93) and shim (94).
iv) Using tool H3, remove nut (96).
D155AX-5 30-135
(5)
v) Using puller [12], pull out left retainer (97)

from shaft (92).
vi) Remove bearing (98) from retainer (97).
vii) Remove nut (99), then remove bevel

gear (100) from shaft (92).
viii) Remove bearing (101) from right retainer

(89).
30-136 D155AX-5
(3)
ASSEMBLY OF HSS CASE

ASSEMBLY
• Precautions when assembling
a Apply drops of engine oil to the rotating portion of
the bearing, then rotate several times.
a Coat the sliding surfaces of all parts with engine
oil before installing.
a Assemble the piston seal rings with the side
receiving the pressure facing the housing, coat
with grease (G2-LI) and install uniformly, taking
care that they do not move to one side.
a Fix the rotation seal ring in position with grease
(G2-LI) and be extremely careful not to get it
caught when assembling.
groove.
1. Bevel gear shaft, bevel gear assembly

1) Assembly of bevel gear shaft, bevel gear
assembly
i) Using push tool, press fit bearings (101)
and (74) to right retainer (89).
ii) Shrink fit inner race (106) to shaft (92).

a Shrink-fitting temperature:
100°C for approx. 30 minutes
iii) Set bevel gear (100) to shaft (92), and
3 Nut : 215.8 – 274.6 Nm

tighten nut (99).
{22.0 – 28.0 kgm}
iv) Install seal ring.
D155AX-5 30-137
(3)
v) Assemble outer race (103), bearing

(104), spacer (105), bearing (104) and
outer race (103) to left retainer (97) in
order.
vi) Fit plate (93), then temporarily tighten
with several hexagon socket head bolts.
vii) Support bevel gear with block [13], then

using push tool [14], press fit retainer
assembly (102) to shaft.
viii) Secure shaft, then using tool H3, tighten
2 Nut : Thread tightener (LT-2)

nut (96).
3 Nut : 735.5 – 902.2 Nm

{75.0 – 92.0 kgm}
a Remove the hexagon socket head
bolts at the portion where the tool
contacts the bolts.
ix) Adjusting shim

Tighten 4 bolts lightly, measure dimen-
sion [a] and dimension [c] to calculate
dimension [b], then decide thickness of
shim [b].
Shim thickness [b] =
([a] - [c]) - (0.1 to 0.2 mm)
x) Assemble selected shim (94), then
tighten bolts (95).
30-138 D155AX-5
(5)
xi) Install right retainer (89) to shaft (92).
xii) Shrink fit inner race (91) to shaft (92).

a Shrink-fitting temperature:
100°C for approx. 20 minutes
2) Install left retainer (88) and guide bolt [9].

3) Using eyebolts [10], raise right retainer, then
align guide bolt with bolt hole, and install
bevel gear shaft and bevel gear assembly
(90) to case.
4) Assemble shim to left retainer, then tighten

mounting bolts (85) and (86) of left and right
retainers.
a There are three types of shims: 0.1, 0.2,
0.5 mm
a The mounting bolts of the left retainer are
loosened when adjusting the backlash
and tooth contact, but tighten them fully
here in order to check the starting torque
of the bevel gear shaft.
D155AX-5 30-139
(3)
5) Push tip of teeth of bevel gear (100) with

push-pull scale [7], and measure starting
torque of bevel gear shaft.
a Starting torque: Max. 3.0 Nm {0.31 kgm}
(At tip of bevel gear teeth:
Max. 19.6 N {2.0 kg})
2. Intermediate gear
1) Assemble snap ring (83) and spacer (84) to
gear (77), then using push tool, press fit
outer race (82).
2) Assemble lower bearing (78), spacer (81),
and upper bearing (78).
3) Assemble gear assembly (79) to case (80),

then align bolt hole and install shaft (76).
a Align the bolt holes of the plate when
installing the shaft.
3. Right carrier drive gear

1) Using push tool, press fit bearing (74) to
case.
2) Using push tool, press fit inner race (75) to
shaft (73).
a Press fit to a point approx. 27 mm from
shaft surface.
a Install to one side only.
30-140 D155AX-5
(3)
3) Align shaft (73) with bearing and install.
4) Using push tool, install inner race (75) to

between shaft and bearing.
a Hold the shaft from the opposite side.
5) Fit gear (72) and plate (71), then tighten bolt
3 Mounting bolt : 98.1 – 122.6 Nm

(70).
{10.0 – 12.5 kgm}
4. Lubrication tubes, dipstick tube, suction tube

1) Install suction tube (60) and dipstick tube
(59).
3 Joint bolt: 7.8 – 9.8 Nm

2) Install lubrication tube (57), (58).
{0.8 – 1.0 kgm}
D155AX-5 30-141
(3)
3 Joint bolt: 7.8 – 9.8 Nm

{0.8 – 1.0 kgm}
5. Bevel pinion assembly

1) Assemble bevel pinion as follows.
i) Using push tool, press fit bearing (109) to
bevel pinion (40).
ii) Using push tool, press fit outer races (43)

and (107) to cage (41).
iii) Put bevel pinion (40) on press stand, and
set cage (41) in position.
iv) Press fit bearing (42) to cage (41) with

press.
v) Hold in press so that pinion does not
move, then use tool H2 and tighten lock-
2 Locknut: Thread tightener (LT-2)

nut (39).
3 Locknut: 696.3 – 863.0 Nm

{71 – 88 kgm}
a Rotate the cage when tightening.
a After tightening the nut, check that
the bevel pinion rotates smoothly.
30-142 D155AX-5
(5)
vi) Turn the nut unit the phase of any one of

the pin insertion holes of the nut (8
places) is matched to that of any one of
the pin insertion holes of the pinion shaft
(5 places). (Returning angle: 0 – 9°)
vii) Insert pin (37) in the above holes. Fit
2 Bolt: Ttread tightener (LT-2)

plate (36) and tighten bolts (35).
3 Bolt: 11.8 – 14.7 Nm

{1.2 – 1.5 kgm}
2) Using guide bolt [3], assemble shim (34) and

install bevel pinion assembly (33).
a There are three types of shim:
0.1, 0.2, 0.5 mm
6. Adjusting tooth contact, backlash

1) Adjusting backlash
Put the probe of dial gauge [6] at right angles
in contact with the tip of the bevel gear teeth.
Hold the bevel pinion in position, and read
the measurement when the bevel gear is
moved forward and backward.
a Standard value for backlash :
0.25 – 0.33 mm
a Measure at least three points on oppo-
site sides.
a If the result of the inspection shows that
the correct backlash is not being obtained,
adjust as follows.
a Adjust the shim thickness at the left
cage.
• If backlash is too small
Loosen mounting bolt of cage and remove
shim.
• If backlash is too large
Loosen mounting bolt of cage and add
shim.
D155AX-5 30-143
(3)
2) Adjusting tooth contact

Testing
i) Coat the tooth face of the bevel pinion
lightly with red lead (minium). Rotate the
bevel gear forward and backward and
inspect the pattern left on the teeth.
ii) Tooth contact should be checked as fol-
lows (from tip of teeth of bevel pinion).
a) Center of tooth contact: 20 - 40 % of
tooth width (from small end)
b) Width of tooth contact: 30 - 50 % of
tooth width
c) Center of tooth contact: 35 - 65 % of
tooth height (from root of tooth)
d) Width of tooth contact: 60 - 80 % of
tooth height
In addition, there should be no strong
contact at the addendum or dedendum
(tip or root of the gear teeth) or at the big
and small ends.
a If the gears are adjusted to this pat-
tern, the tooth contact will be correct
when load is applied.
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line
of bevel gear.
Contact is at the small end of the convex
tooth face of the bevel gear and at the
big end of the concave tooth face.
• Correct the tooth contact as follows.
Adjust the thickness of the shims at the
bevel pinion to move the bevel pinion in
direction A.
Move the bevel gear in direction B, then
check the tooth contact pattern and back-
lash again.
ii) If bevel pinion is too close to center line
of bevel gear.
Contact is at the big end of the convex
tooth face of the bevel gear and the small
end of the concave tooth face.
• Correct the tooth contact as follows.
Adjust the thickness of the shims at the
bevel pinion to move the bevel pinion in
direction B.
Move the bevel gear in direction A, then
check the tooth contact pattern and back-
lash again.
30-144 D155AX-5
(3)
7. Motor output gear

1) Using push tool, press fit bearing (69) to
flange (61).
2) Using push tool, press fit inner race (67) and
bearing (68) to gear (66).
3) Install gear assembly (65) to flange (64).
4) Install flange and gear assembly (63) to case

(62).
5) Install flange (61).
8. Valve seat
D155AX-5 30-145
(3)
2) Align with lubrication tube (52) (installed in

Step 8-1)), then install valve seat (53).
3) Install brake circuit tube (51) and lubrication
tube (52).
9. Gear
1) Install inner bearing (55), snap ring (54), and
outer bearing (55) to gear (49).
2) Align gear (49) with bearing of bevel gear
shaft and install.
3) Using push tool, press fit inner race (50).

4) Fit spacer (48) and install snap ring (47).
10. Sun gear

1) Install thrust washer (46) to sun gear (45).
2) Install sun gear (45).
30-146 D155AX-5
(3)
11. Brake, carrier assembly

a Assemble both sets in the same way.
• Assembly of brake, carrier assembly
1) Assemble stopper (32) to hub (18), then
2) Install bushing (38).
3) Using push tool, press fit inner race (37).
4) Carrier assembly
i) Assemble bearing (26) to gear (25), then
ii) Fit ball (28) and install shaft (24).
iii) Remove snap ring (23).
iv) Install sleeve (36) to carrier (35).
v) Install bushings (29) and (30) to gear

(108).
vi) Set gear (108) to ring gear (22), then fit
ring (21) and install ring gear to gear.
vii) Install gear assembly (20) to hub (18).
3 Mounting bolt :98.1 – 122.6 Nm

viii) Install carrier assembly (19) to hub (18).
{10 – 12.5 kgm}
D155AX-5 30-147
(3)
5) Set brake drum (12) to hub assembly (18).

6) Install discs (15), plates (14) and (13), and
spring (16).
a Discs: 5, Plate (14): 4, Plate (13): 1
7) Hub
hub (9).
ii) Fit seal ring and install hub (9).

9) Install piston (8) and spring (7).
a Install so that the outside circumference
of the spring opens.
10) Brake cover assembly

brake cover (10).
ii) Install guide bolt [2] to hub (9).
30-148 D155AX-5
(3)
iii) Using eyebolts [1], align bolt hole with

hub and brake drum, then install brake
cover assembly (5).
a Tighten the mounting bolts tempo-
rarily.
a The force of the spring is applied, so
tighten the hexagon socket head
bolts uniformly.
iv) Using push tool, press fit inner race (4).
3 Flange:58.8 – 73.6 Nm
v) Install plate (3) and flange (2).
{6 – 7.5 kgm}
vi) Fully tighten bolts temporarily tightened
3 Mounting bolt: 98.1 – 122.6 Nm

in Step iii).
{10 – 12.5 kgm}
• Installation of brake, carrier assembly

1) Angle steering case assembly approx. 15°
so that tool H1 is perpendicular to ground
surface.
2) Using tool H1, install brake, carrier assembly
3 Mounting bolt: 98.1 – 122.6 Nm

(1).
{10 – 12.5 kgm}

a Assemble the brake, carrier assembly on
the opposite side in the same way.
a When cover (109) of the rear surface on

HSS case (107) has been removed,
2 Gasket (apply to both surfaces):

install new gasket (108).
D155AX-5 30-149
(5)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
PUMP ASSEMBLY
disconnect the cable from the negative (–) ter-
1. Drain hydraulic oil and power train oil.
6 Hydraulic oil : Approx. 87 l
2. Remove cab.
For details, see REMOVAL OF CAB ASSEMBLY.
3. Lift off operator’s seat assembly (1).
4 Operator’s seat : 55 kg
4. Remove floor frame left and right side covers (2).
5. Remove floor mat, then remove cover (3).
6. Disconnect brake rod (4).

a Loosen locknut (5), and turn joint (6) to dis-
connect.
Joint (6) has a reverse thread.
7. Remove floor assembly (7).
4 Floor assembly: 26 kg
30-150 D155AX-5
(3)
A. Removal of hydraulic pump assembly

1) Disconnect hose (1) leading to work equip-
ment control valve.
2) Disconnect wiring connector (2) (HHP).
3) Disconnect suction tube joints (3) and (4).
4) Remove 4 mounting bolts (5), then remove
tube (6).
5) Remove mounting bolts, then remove

hydraulic pump assembly (7).
4 Hydraulic pump assembly : 19 kg
B. Removal of 3-spool pump assembly (HSS

lubrication + torque converter, transmission
charge + torque converter charge pump)
1) Remove cover (1).
2) Disconnect HSS motor and brake lubrication

tube (2).
3) Disconnect suction tube (3) from power train
case.
4) Disconnect transmission filter hose (4).
D155AX-5 30-151
(3)
5) Disconnect filter bypass valve hose (5).

a It is difficult to disconnect the hose at the
pump end.
6) Remove mounting bolts, then lift off 3-spool

pump assembly (6).
a Remove together with hose (5).
4 3-spool pump assembly : 24 kg
C. Removal of HSS pump assembly

1) Disconnect HSS and PPC charge valve hose
(1).
2) Disconnect cooler bypass valve hose (2).
3) Disconnect charge filter hose (3).

4) Disconnect solenoid wiring connector (4)
(PUP.A).
5) Disconnect cooler bypass valve hose (5).
6) Disconnect HSS motor hoses (6) and (7).
7) Disconnect charge relief valve hose (8).
30-152 D155AX-5
(3)
8) Disconnect engine speed sensor wiring con-

nector (9) (CN010).
9) Disconnect solenoid wiring connector (10)
(PUP.B).
10) Remove mounting bolts, then lift off HSS

pump assembly (11).
4 HSS pump assembly : 102 kg
D. Removal of charge + scavenging pump

assembly
1) Disconnect charge filter hose (1).
a It is difficult to disconnect the hose at the
pump end.
2) Disconnect power train case suction tube (2).

3) Disconnect suction hydraulic tank tube (3).
D155AX-5 30-153
(3)
4) Lift off charge + scavenging pump assembly

(4).
a Raise, then move slowly towards the
engine, and lower gradually from clear-
ance.
4 Charge + scavenging pump assembly :

30 kg
INSTALLATION OF
HYDRAULIC PUMP
ASSEMBLY
removal.
• Refilling oil
5 Hydraulic oil : Approx. 87 l
• Bleeding air
Bleed the air from the pumps and power train.
BLEEDING AIR.
30-154 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY HSS MOTOR
REMOVAL OF HSS MOTOR

ASSEMBLY
1. Remove fuel tank assembly.

For details, see REMOVAL OF FUEL TANK
ASSEMBLY.
2. Disconnect HSS pump hoses (1) and (2).

3. Disconnect charge relief valve hoses (3), (4),
and (5).
4. Disconnect HSS circuit pressure sensor wiring

connectors (6) and (7) (CNSTAP1.2).
5. Remove mounting bolts, then lift off HSS motor
assembly (8).
4 HSS motor assembly : 65 kg
INSTALLATION OF HSS
MOTOR ASSEMBLY
removal.
D155AX-5 30-155
(3)
DISASSEMBLY AND ASSEMBLY POWER TRAIN MAIN RELIEF VALVE
REMOVAL OF POWER TRAIN

MAIN RELIEF VALVE
ASSEMBLY
1. Remove fuel tank assembly.
For details, see REMOVAL OF FUEL TANK
ASSEMBLY.
3. Disconnect pressure detection hose (2).
4. Remove power train main relief valve assembly

(3). [*1]
INSTALLATION OF POWER
TRAIN MAIN RELIEF VALVE
ASSEMBLY
removal.
[*1]
• Check that there is no damage to the O-ring,
3 Main relief valve mounting bolt:

and assemble securely.
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
30-156 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY POWER TRAIN MAIN RELIEF VALVE
DISASSEMBLY OF POWER
TRAIN MAIN RELIEF VALVE
ASSEMBLY
1. Remove plug (1), then remove valve (2), spring
(3), valve (4), valve (5), shim (6), and springs (7)
and (8) from valve body (9).
2. Remove plug (10).
3. Remove plug (13), then remove guide (14),

spring (15), spool (16), valve (17), spring (18),
and valve (19).
4. Remove plug (20).
ASSEMBLY OF POWER TRAIN

MAIN RELIEF VALVE
ASSEMBLY
Coat the sliding surfaces of all parts with engine
1. Assemble spring (15) and guide (14) to spool

(16).
2. Assemble valve (19), spring (18), and valve (17)

to spool (16), then assemble to valve body (9),
and install plugs (20) and (13).
3. Assemble springs (8) and (7) to plug (10), and

install to valve body (9).
4. Assemble valve (2), spring (3), and valve (4),

then assemble to valve (5) and install shim (6) on
opposite side.
a Check the thickness and number of shims
when assembling.
Standard shim thickness: 0.5 mm
5. Assemble valve (5) to valve body (9), and install

plug (1).
6. Tighten plugs (10) and (1).
D155AX-5 30-157
(3)
DISASSEMBLY AND ASSEMBLY HSS, PPC CHARGE VALVE
REMOVAL OF HSS, PPC

CHARGE VALVE ASSEMBLY
1. Disconnect clamp (1) from filter case.

2. Disconnect PPC lock valve hose (2).
3. Disconnect accumulator hose (3).
4. Disconnect tube (4) coming from charge pump.
5. Remove filter case assembly (5).
6. Disconnect main control valve hose (6).

7. Disconnect drain hose (7).
8. Disconnect charge pressure sensor wiring con-

nector (8) (CN406).
9. Disconnect HSS pump hose (9).
10. Disconnect HSS pump solenoid valve hose (10).
11. Remove mounting bolts, then remove HSS and
PPC charge valve assembly (11).
INSTALLATION OF HSS, PPC

CHARGE VALVE ASSEMBLY
removal.

Add engine oil through the oil filler to the speci-
fied level.
system. Loosen the air bleed plug of the filter
and bleed the air.
After bleeding the air, check the oil level again
with the sight gauge.
30-158 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY HSS AND PPC CHARGE VALVE
DISASSEMBLY AND ASSEMBLY OF HSS AND PPC CHARGE

VALVE ASSEMBLY
1. DISASSEMBLY 2. ASSEMBLY
1) Remove plug (1), shim (2), and spring (3). 1) Install plug (8).
3 Plug: 63.7 ± 14.7 Nm {6.5 ± 1.5 kgm}

a Check the quantity of the shims.
2) Remove plug (8).

2) Install valve (5), spring (6), and valve (7) to
3) Remove spool (4), valve (7), spring (6), and spool (4), and then install spool (4) to body
valve (5). (9).
3) Install spring (3) and shim (2).

a Check the thickness and quantity of the
shim.
Thickness: 0.5 mm
Quantity: 4 pieces
4) Tighten plug (1).
3 Plug: 68.8 ± 9.8 Nm {7 ± 1 kgm}
D155AX-5 30-159
(3)
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF
VALVE ASSEMBLY
k Park the machine on level ground and lower the
work equipment to the ground, and then discon-
nect the cable from the negative (-) terminal of
the battery.
1. Remove the operator's seat and floor plate. For

details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY.

6. Disconnect hose clamp (5) and remove bracket

(6).
7. Disconnect clamp (9) of wires (7) and (8).
8. Disconnect HSS motor hoses (10) and (11), and
then disconnect hose clamp (12).
9. Disconnect 5 clutch hoses (12).

a When removing the hoses, make match
marks on them.
10. Disconnect clamp (13).
12. Disconnect 5 clutch wiring connectors (15).
13. Remove 4 bolts (16) and upper and lower valves

of control valve (17).
30-160 D155AX-5
(3)
INSTALLATION OF
VALVE ASSEMBLY
removal.
[*1]
a Look through the inspection window in the
cover to check that the lever and yoke are
meshed, then tighten the mounting bolts.
a When installing the cover, tap with a plastic
hammer. If the dowel pin portion is not
inserted, remove the cover, correct the
meshing of the lever and yoke, then install
again.
3 Transmission control valve mounting bolt :

[*2]
49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}
D155AX-5 30-161
(3)
DISASSEMBLY OF ASSEMBLY OF
TRANSMISSION CONTROL TRANSMISSION CONTROL
VALVE ASSEMBLY VALVE ASSEMBLY
(ECMV ASSEMBLY) (ECMV ASSEMBLY)
• Disassembly of ECMV assembly 1. Pressure control valve
• Before removing the ECMV assembly from the 1) Install shims (12) and (11) and spring (10) to
transmission assembly, clean around it so that spool (13), and then install the spool to body
dirt will not enter it and transmission assembly. (1).
• Keep the removed parts so that they will not be a When installing the spool, check that it
damaged. moves smoothly.
Standard number of shims: 3
1. Flow control valve Standard shim thickness: 1.5 mm
1) Remove bracket (8) and switch assembly (9) (Thickness of 1 shim: 0.2 mm, 0.5 mm)
from valve body (1). 2) Fit O-ring (14) to valve (15).
2) Remove spring (7), shim (6), and spring seat 3) Put ball (16) in solenoid (17), and then install
(5). solenoid (17).
3) Remove sleeve (2), spring (3), and pin (4).
2. Flow control valve
2. Pressure control valve 1) Install sleeve (2), pin (4), and spring (3) to
1) Remove solenoid (17) from valve body (1). valve body (1).
a Mask the solenoid to prevent dirt from 2) Install shim (6) and spring (7) to spring seat
entering it. (5).
2) Remove valve (15), O-ring (14), and ball 3) Install switch assembly (9) and bracket (8) to
(16). valve body (1).
a Keep the ball so that it will not be lost.
3) Remove spool (13). 3. Testing ECMV oil pressure
a When removing the spool, check that it Check the ECMV oil pressure. For details, see
moves smoothly. TESTING AND ADJUSTING, Testing ECMV oil
4) Remove spring (10) and shims (12) and (11) pressure.
from spool (13).
a Check the quantity of shims (12) and 4. Adjusting ECMV oil pressure
(11). • As a result of testing, if the oil pressure is out
of the standard range, adjust it with shims (5)
and (6).
Quantity of adjustment 0.06MPa

per shim (0.5 mm thick) {Approx. 0.65 kg/cm²}
714-23-15580
Quantity of adjustment 0.025MPa

per shim (0.2 mm thick) {Approx. 0.26 kg/cm²}
714-23-15590
a If the shim is increased, the oil pressure is

heightened. If the former is decreased, the
latter is lowered.
a Install the shims securely and do not drop
them in the valve.
a After adjusting the shim, test the oil pressure
again.
30-162 D155AX-5
(3)
D155AX-5 30-163
(3)
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE

ASSEMBLY
disconnect the cable from the negative (ÅE ter-
1. Disconnect foot brake rod (1).
2. Disconnect parking brake cable (2).
3. Remove bolts (3), then remove bracket (4).

a Do not loosen the lock of the cable.
4. Disconnect HSS case hose (5).
5. Remove mounting bolts, then remove brake

valve assembly (6).
INSTALLATION OF BRAKE
VALVE ASSEMBLY
removal.
30-164 D155AX-5
(3)
DISASSEMBLY OF BRAKE ASSEMBLY OF BRAKE VALVE

VALVE ASSEMBLY ASSEMBLY
1. Remove solenoid valve (1). a Clean all parts, and check for dirt or damage.
2. Remove lever and cover assembly (28). Coat the sliding surfaces of all parts with engine
3. Remove check valve assembly (31) from body oil before installing.
(6). 1. Install shaft (bolt) (7), guide (8), spring (9), guide
4. Remove plug (33), then remove spring (32) and (11), and nuts (14) and (15) as one unit to body
spool (30). (6).
5. Remove plug (2), then remove spring (3), piston 2. Assemble spring (10), and guides (12) and (13),
(4), and valve (5). then install cover (17).
6. Remove cover (29), remove guides (13) and 3. Assemble valve (5), piston (4), and spring (3),
(12), and spring (10), then remove shaft (bolt) then install plug (2).
(7), guide (8), spring (9), guide (11), and nuts 4. Assemble spool (30) and spring (32), then install
(14) and (15) as one unit. plug (33).
7. Disassembly of lever case (26) 5. Install cover (29).
1) Remove levers (18) and (23). 6. Install check valve assembly (31) to body (6).
a Be careful not to lose keys (17) and (24). 7. Install lever and cover assembly (16).
2) Remove lever assemblies (16) and (26). 8. Install solenoid valve (1).
3) Remove seals (19) and (22) from case (25), 9. Assembly of lever case assembly (26)
then remove bearings (20), (21), and (27). 1) Install bearings (20), (21), and (27), and oil
seals (19) and (22) to case (25).
2) Install lever assemblies (16) and (26), then
install levers (18) and (23).
a Install key (17) and (24) securely to
levers (18) and (23).
3) Install lever case (28) to valve body (6) using
cover (29).
D155AX-5 30-165
(3)
30-166 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Remove 8 mounting bolts (2) on inside of final

drive assembly (1). [*1]
3. Jacking up chassis
k 1) Using hydraulic jack (686 kN {70 ton})
and ripper of machine, jack up chassis
and set stands [1] under steering case on
left and right.
2) Set stands [2] on left and right under
main frame at front of chassis.
a After setting stands [1] and [2], set the
hydraulic jack and ripper again to act as
extra support.
4. Lift off guard (3). [*2]
4 Guard : 45 kg
D155AX-5 30-167
(3)
5. Remove 2 segment teeth (4). [*3]
6. Remove drive shaft cover (5).
7. Pull out drive shaft (6).

a Use a forcing screw to pull out the drive shaft
to a point where the spline comes out.
a If the shaft does not come out, move the
sprocket backward and forward to adjust to a
position where the shaft comes out, then pull
out the shaft.
8. Align place where segment teeth were removed

with track frame.
9. Remove mounting bolts on top of final drive

assembly, then install tool J1. [*4]
30-168 D155AX-5
(3)
10. Using tool J, sling final drive assembly (1), and

remove remaining bolts.
kTo prevent the final drive from flying out,
slightly loosen one mounting bolt each on
both sides of the final drive, then loosen
while pulling out the final drive assembly, and
remove.
11. Lift off final drive assembly (1).
4 Final drive assembly : 1400 kg
INSTALLATION OF FINAL
DRIVE ASSEMBLY
removal.
2 Final drive mounting bolt :

[*1] [*4]
3 Final drive mounting bolt :

1323.9 ± 147.1 Nm {135 ± 15 kgm}
2 Guard mounting bolt :

[*2]

745.3 ± 83.4 Nm {76 ± 8.5 kgm}
2 Segment teeth mounting bolt :

[*3]
3 Segment teeth mounting bolt :

1176.8 ± 98.1 Nm {120 ± 10 kgm}
D155AX-5 30-169
(5)
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Carrier assembly
1) Remove cover.
2) Remove mounting bolts, then using eyebolts
[1], remove carrier assembly (1).
3) Remove lock plate (2).
4) Using tool K1, pull out shaft (3).

a Remove all three shafts.
5) Remove gear assembly (4).

a When removing the gear assembly,
press other gears against the outside
wall.
30-170 D155AX-5
(5)
6) Remove bearing (6) from gear (5).

7) Remove outer race (7) from gear (5).
2. Shaft
Using eyebolts [2], remove shaft (9).
3. Holder
Remove holder (10).
4. Ring gear, hub assembly

1) Using wire, remove ring gear and hub
assembly (11).
2) Remove 6 plates (12), then remove ring gear
(14) from hub (13).
5. Sprocket, hub assembly

1) Fit eyebolts, pull out sprocket and hub
assembly (15) with tool K2 and remove.
D155AX-5 30-171
(5)
a Bearing (19) will come out at the same

time.
2) Remove floating seal (16).

a If the floating seal to be used again, be
careful not to damage the seal surface,
and keep it in a safe place.
3) Remove outer race (18).
6. Cover assembly
1) Screw in forcing screws [4], and pull out
cover assembly (21) from case (22), then
use eyebolts [5] to remove.
2) Remove floating seal (16).

a If the floating seal to be used again, be
careful not to damage the seal surface,
and keep it in a safe place.
3) Using bolts [3], knock out spacer (20) and
bearing (19) from cover.
4) Remove bearing (8).
30-172 D155AX-5
(5)
7. Gear
Remove mounting bolts (21), pull out with forcing
screws [6], then using eyebolts [7], remove gear
(24) from hub (25).
a Turn the gear at an angle and remove it.
8. Hub
1) Using eyebolts [8], remove hub (25).
2) Using puller [9], remove inner race (26) from
hub (25).
9. Guide plate
Remove guide plate (37).
10. Pinion assembly

1) Using forcing screws [10], remove cage (27).
D155AX-5 30-173
(3)
2) Remove pinion assembly (29).
3) Remove bearing (31) from pinion (30).
4) Remove outer race (32) and oil seal (33)

from cage (28).
5) Remove outer race (34) from case.
30-174 D155AX-5
(3)
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
a Coat the sliding surfaces of all parts and the
rotating parts of the bearings with engine oil
before installing.
1. Pinion assembly
1) Using push tool [12], install oil seal (33) to
2 Lip of oil seal : Grease (G2-LI)

cage (28).
2) Using push tool, install outer race (32) to

cage (28).
3) Using push tool, press fit oil seal (36) to case

(35).
4) Using push tool, press fit outer race (34) to

case (35).
5) Using push tool, press fit bearing (31) to pin-

ion (30).
6) Install pinion assembly (29) to case.
7) Assemble shim, and install cage (28).

a Be careful not to damage the oil seal.
D155AX-5 30-175
(3)
a Select the shim thickness as follows.

i) Install pinion to cage without assembling
O-ring.
ii) Tighten 4 mounting bolts to specified
3 Mounting bolt : 9.8 Nm {1 kgm}

tightening torque.
iii) Using a clearance gauge, measure clear-

ance a between cage and case at 2
places around circumference, then cal-
culate average value.
iv) Select shim of measured average value
+ (0.05 - 0.1 mm).
a There are four types of shim: 0.15,
0.5, 0.6, 0.7 mm
2. Guide plate
Install guide plate (37).
3. Hub
1) Using push tool, press fit inner race (26) to
hub (25).
2) Using eyebolts [8], install hub (25).
4. Gear
1) Using eyebolts [7], install gear (24) to hub
(25).
a Turn the gear at an angle and insert it.

2) Tighten mounting bolts (21).
{28.25 ± 3.25 kgm}
5. Cover assembly
1) Using push tool, press fit bearing (8) to cover
(38).
30-176 D155AX-5
(3)

3) Using tool K3, press fit bearing (19) to case
(38).
4) Using tool K4, install floating seal (16).
a Remove all oil and grease from the O-
ring and O-ring contact surface, then dry
before installing.
a After installing the floating seal, check
that the angle of the seal is less than 1
mm.
5) Using eyebolts [5], install cover assembly
2 Mounting bolt :
(21) to case (22), and tighten mounting bolts.

{56 ± 6 kgm}
6. Sprocket, hub assembly

1) Install outer race (18) to hub (13).
2) Using tool K4, install floating seal (16).
a Remove all oil and grease from the O-
ring and O-ring contact surface, then dry
before installing.
a After installing the floating seal, check
that the angle of the seal is less than 1
mm.
3) Check that there is no dirt or dust on sliding
surface of floating seal, then coat thinly with
engine oil.
4) Using eyebolts [3], set sprocket and hub

assembly (15) to cover.
D155AX-5 30-177
(5)
5) Using tool J4, rotate sprocket and hub

assembly, and press fit bearing (19).
a Press fit within a range where no preload
is applied.
7. Ring gear, hub assembly

1) Assemble ring gear (14) to hub (13), and
2 Mounting bolt :
tighten plate (12).

{6.75 ± 0.75 kgm}

2) Using wire, install ring gear and hub assem-
bly (11).
8. Holder
2 Mounting bolt :
1) Assemble shim and tighten holder (10).

{56 ± 6 kgm}
2) Select shim thickness as follows.
i) Tighten 4 bolts to specified torque, then
2 Mounting bolt :
settle all parts.
3 Mounting bolts :549.2 ± 58.8 Nm

{56 ± 6 kgm}
ii) Remove bolts, then turn sprocket hub
and check that bearing rotates smoothly.
a At position of carrier assembly
mounting bolts:216 – 265 N
{22 – 27 kg}
iii) Tighten 4 bolts to 34.3 Nm {3.5 kgm},
measure clearance b between holder
and hub at 4 places around circumfer-
ence, calculate average value, then
select shim thickness.
Shim thickness = Average clearance b +
(0 – 0.1 mm)
iv) Finally adjust so that clearance a
between holder and hub is 0.05 – 0.1
mm.
30-178 D155AX-5
(3)
10. Shaft
Using eyebolts [2], install shaft (9).
11. Carrier assembly

1) Using push tool, press fit outer race (7) to
gear.
a Make match marks on the outer race and
bearing.
2) Assemble bearing (6) to gear (5).
3) Set gear assembly (4) to carrier, then align

shaft hole and inner race hole of bearing.
a Insert the gear assembly through the
hole in the center of the carrier, push
against the outside wall, then set the
gear assemblies in the mounting position
after inserting all three gear assemblies.
4) Expand-fit shaft (3) to install.

a Cool in dry ice for approx. 30 minutes.
a When the shaft warms up it will be
impossible to push it in by hand, so align
the notched portion with the hole in the
plate and push in quickly.
2 Mounting bolt :
5) Tighten lock plate (2).

{11.15 ± 1.25 kgm}
D155AX-5 30-179
(3)
6) Using eyebolts [1], install carrier assembly
2 Mounting bolt :
(1).

{56 ± 6 kgm}
7) Install center cover.
30-180 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY TRACK FRAME
REMOVAL OF TRACK FRAME

ASSEMBLY
ASSEMBLY.
2. Jacking up chassis
k1) Using hydraulic jack (686 kN {70 ton})
and ripper of machine, jack up chassis
and set stands [1] under steering case on
left and right.
2) Set stands [2] on left and right under
main frame at front of chassis.
3) Set blocks under front of raised track
frame to ensure safety during operation.
a After setting stand [1] and [2], set the
hydraulic jack and ripper again to act
as extra support.
3. Disconnection of equalizer bar

1) Sling track frame assembly, and remove
cover (1) of equalizer bar, then remove pin
cover (2) and spacer (3).
2) Remove equalizer bar side pin (4) together

with collars (5) and (6).
D155AX-5 30-181
(3)
4. Disconnection of track frame assembly

• Left track frame assembly
Remove cover (7), then remove spacer (8).
• Right track frame assembly

1) Remove cover (9), and disconnect block
(10).
2) Disconnect hose (11) from block (10),

then remove spacer (12).
3) Remove seal (13), then remove washer
(14) and washer (15). [*1]
5. Lift off track frame assembly (16).
4 Track frame assembly : 3,800 kg
30-182 D155AX-5
(3)
INSTALLATION OF TRACK
FRAME ASSEMBLY
removal.
[*1]
a Assemble seal (13) as follows.
1) Keep seal in direction [A] in relation to
pivot shaft.
• Set with the maker’s mark on the out-
side.
2) Turn seal by hand from condition [A] in
direction of arrow to position [B].
• Set with the maker’s mark on the
inside.
3) Coat surface [a] of washer (15) with oil
(EO-30).
4) Keep the seal in condition [B], and
assemble between washer (14) and
washer (15).
a Be careful not to let seal (13) extend outside
surface [b].
• Refilling with oil
5 Pivot chamber oil : Approx. 8.2 l (EO-30)

a The oil level in the pivot chamber will be 25
mm from the end face of the shaft.
D155AX-5 30-183
(3)
DISASSEMBLY AND ASSEMBLY IDLER
REMOVAL OF IDLER
ASSEMBLY
ASSEMBLY.
kTo prevent danger, never stand in front of the
idler assembly.
2. Remove side covers (1).
a Remove one each on the inside and outside.
3. Loosen support mounting bolts, remove shim,

then remove supports (2). [*1]
a Remove one each on the inside and outside.
4. Loosen guide tension bolt (3).

a Loosen two each on the inside and outside.
5. Remove idler guide mounting bolts (4).
6. Raise idler assembly (5), then lift out to front and

remove.
4 Idler assembly: 410 kg
7. Remove spring seat (6), then remove tension

spring (7).
a The above parts are assembled between the
support and track frame.
30-184 D155AX-5
(3)
INSTALLATION OF IDLER
ASSEMBLY
removal.
[*1]
a Set the idler assembly at the center of the
track frame, then adjust clearance a between
the track frame and guide plate with shims.
• Standard clearance a : 0.5 – 1.0 mm
• Standard shim thickness : 6 mm
D155AX-5 30-185
(3)
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove oil drain plug and drain oil.
6 Idler : Approx. 530 – 590 cc
2. Set idler assembly (1) on block [1].
3. Support
1) Remove nut (2), and pull out bolt (3).
2) Remove support (4).
4. Retainer
Remove mounting bolts, then using forcing
screws [2], remove retainer (5).
5. Shaft
1) Turn over idler assembly.
2) Remove nut (6) and bolt (7), then remove
support (8).
3) Using forcing screws [2], remove retainer (9).

4) Lift off shaft (10).
30-186 D155AX-5
(3)
6. Disassembly of support
Remove floating seals (11) from supports (4) and
(8).
7. Disassembly of retainer
Remove floating seals (12) from retainers (5)
and (9).
8. Bushing
Remove bushing (13) from idler (1).
D155AX-5 30-187
(3)
ASSEMBLY OF IDLER
ASSEMBLY
1. Bushing
Set tool L1 to idler (1), and press fit bushing (13).
a When press fitting the bushing, use a plastic
hammer to align the center, then press fit
with a puller.
a Press fit the bushing so that the dimension
from the end face of the idler to the top face
of the bushing is 15 ± 1 mm.
2. Assembly of retainer
Using tool L2, assemble floating seals (12) to
retainers (5) and (9).
a See Fig. [a] for the protrusion of the seal.
a After inserting, check that the angle of the
seal is less than 1 mm.
a When assembling the seal, wash the area
marked by the bold line in Fig. [b] (the O-ring
and O-ring contact surface), remove all oil
and grease, then dry completely.
3. Assembly of support
Using tool L2, assemble floating seals (11) to
supports (8) and (4).
a When assembling the seal, wash the area
marked by the bold line in Fig. [b] (the O-ring
and O-ring contact surface), remove all oil
and grease, then dry completely.
30-188 D155AX-5
(3)
4. Shaft, retainer
1) Set idler [1] on block (1).
2) Install retainer (9).
3) Raise idler (1) and turn over, then set on
block [1].
4) Raise shaft (10) and assemble to idler.

a When assembling, be careful not to dam-
age the retainer mount floating seal at
the bottom.
5. Supports
1) Assemble support (4) to shaft, then fit bolt (3)
and tighten nut (2).
a Before assembling the support, coat the
floating seal mating surface thinly with
engine oil.
2) Turn over idler (1), assemble support (8) to

shaft, then fit bolt (7) and tighten nut (6).
a Before assembling the support, coat the
floating seal mating surface thinly with
engine oil.
D155AX-5 30-189
(3)
6. Refilling with oil

Using tool L3, add oil to specified level and
tighten plug.
5 Idler : Approx. 530 – 590 cc (GO140B)

3 Plug : 205.9 ± 49.0 Nm {21 ± 5 kgm}
a If oil has been added with tool L9, always

angle approx. 10° as shown in the diagram
on the right, and check that the oil level is at
the bottom face of the oil filler port.
30-190 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
REMOVAL OF RECOIL
SPRING ASSEMBLY
1. Remove idler assembly.
For details, see REMOVAL OF IDLER ASSEM-
BLY.
2. Remove cover (1) from track frame.
3. Remove lock plate (2), then remove pin (3).
4. Lift off recoil spring assembly (4).
4 Recoil spring assembly : 510 kg
INSTALLATION OF RECOIL
SPRING ASSEMBLY
removal.
D155AX-5 30-191
(3)
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Disconnection of cover assembly
a Remove cover assembly (2) from recoil
spring case assembly (1) as follows.
1) Set recoil spring assembly (1) on block [1].
a When doing this, check that there is no
damage to the weld of recoil spring case
(1).
2) Loosen mounting bolts (24) of cover (2)

gradually in turn on diagonally opposite
sides.
kTo prevent danger, never stand in front of
the cover assembly or behind the recoil
spring case assembly.
kThe recoil spring inside the recoil spring

case is applying a pushing force of 294
kN {30 tons} on the yoke, so be careful
not to loosen the mounting bolts sud-
denly. Loosen the mounting bolts gradu-
ally until clearance a between the flange
of the recoil spring case and idler yoke
assembly is 10 – 13 mm.
3) When the bolts are loosened, the torque will

suddenly drop. Check that the spring is not
applying any pushing force on the mounting
bolts, then remove all bolts.
a If the torque increases (the pushing force
of the spring is applied) during the loos-
ening operation, stop the loosening oper-
ation and disassemble as follows.
k If the torque does not drop during Steps 2) and

3) described above, and the torque when the
bolts are loosened remains large, there is prob-
ably damage to recoil spring set bolt (18), or nut
(16) at the tip of the shaft has fallen off, so there
is danger that the yoke assembly may fly off to
the front. For this reason, disassemble as fol-
lows.
30-192 D155AX-5
(3)
kWhen disconnecting the cover assembly and

recoil spring case assembly, do not stand in front
of the yoke assembly or behind the recoil spring
case assembly until safety has been confirmed
and the recoil spring assembly has been
removed.
i) Prepare the following parts.

Bolt [1] (x4):791-730-1130
Nut [2] (x4):01580-12016
Washer [3] (x4):01643-32060 (use again)
ii) Remove 4 bolts marked , then install bolts

[1], nuts [2], and washers [3] listed in Step i).
a Check that dimension L is less than 300
mm.
a Screw in bolts [1] until they contact the
bottom of the yoke thread.
iii) Remove remaining 8 bolts (those not marked
).
iv) Hold bolts [1] with a wrench to prevent them

from turning, then loosen 2 nuts [2]simulta-
neously on opposite sides.
a Be careful not to let the load bear on only
one bolt.
v) When recoil spring is fully extended and

torque has completely dropped in loosening
direction of nut [2], remove bolt [1].
a When clearance b is approx. 180 mm,
the spring is fully extended.
4) Sling cover assembly (2), then remove

mounting bolts, and lift off cover assembly.
a The oil inside the spring chamber will
flow out, so set a container under the
cover to catch the oil.
6 Spring chamber : Approx. 12 l
D155AX-5 30-193
(3)
2. Recoil spring assembly

Raise recoil spring assembly (3) and remove
from case.
3. Disconnection of yoke
1) Remove mounting bolts of yoke (4), then
remove spacer (5).
2) Using tool M1, disconnect yoke (4) from

case.
a Disconnection pressure for yoke:
Approx. 147 kN {15 ton}
a Before disconnecting the yoke, make
match marks on the yoke and case.
4. Disassembly of cover assembly

1) Remove cylinder rod (22) from cover assem-
bly (2).
2) Remove bracket, then remove lubricator (6).
30-194 D155AX-5
(5)
3) Remove piston (7) from cylinder rod (22).

a Using an air gun, blow in compressed air
through the lubricator mounting hole to
remove the piston.
4) Remove snap ring (8) from piston (7), then

remove U-packing (9) and wear ring (10).
5) Remove cover (12) from cover (11), then

remove oil seal (13).
6) Remove bushing (14) from cover (11).
5. Disassembly of recoil spring assembly

1) Set recoil spring assembly (3) in tool M2.
kThe spring is under high installed load,
so be careful to set it correctly to tool M2.
a Installed load of spring:
285.8 kN {29,160 kg}
D155AX-5 30-195
(5)
2) Apply hydraulic pressure slowly to compress

spring, then remove lock plate (15) and
remove nut (16).
3) Release hydraulic pressure gradually and

relieve tension of spring.
4) Remove set bolt (18), rear pilot (19), shaft

(20), and pilot (21) from spring (17).
30-196 D155AX-5
(3)
ASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Assembly of recoil spring assembly
1) Assemble pilot (21), shaft (20), rear pilot
(19), and set bolt (18) to spring (17), then set
in tool M2.
kThe spring is under high installed load,
so be careful to set all parts correctly.
2) Apply hydraulic pressure gradually to com-

press spring, and set so that installed length
[a] of spring is standard value. When doing
this, check clearance [b] between shaft (20)
and rear pilot (19).
a Installed load of spring:
285.8 kN {29,160 kg}
a Installed length [a]: 945 mm
a Clearance [b]: 60 mm
3) Install nut (16) and lock plate (15) and tighten
2 Lock bolt: Adhesive (LT-2)

bolt (23).
a When securing nut (16), make a clear-

ance of 0 - 1 mm between lock plate (15)
and nut (16), then bring lock plate (15)
and bolt (18) into tight contact.
a Purpose of making clearance
i) If the nut is screwed in a small amount
and nut (16) protrudes beyond bolt (18),
lock plate (15) may bend and lock bolt
(23) may fall off.
ii) If the nut is screwed in too far, the load of
the spring will always be applied to the
set bolt, and the set bolt will break.
4) Gradually release hydraulic pressure to com-
pletely relieve tension of spring, then remove
spring assembly (3) from tool M1.
D155AX-5 30-197
(5)
2. Assembly of cylinder assembly

1) Using tool M3, press fit bushing (14) to cover
(11).
• Bushing press-fitting force :
19.6 – 29.4 kN {2 – 3 tons}
2) Assemble oil seal (13) to cover (11), install

cover (12) and O-ring.
3) Assemble wear ring (10) and U-packing (9)

to piston (7), then install snap ring (8).
4) Assemble piston (7) to cylinder rod (22) from

U-packing end.
a To prevent air from remaining inside the
cylinder when carrying out the operation
in Step 4) above, fill with grease as fol-
lows, and assemble piston (7).
i) Fill inside of cylinder with approx. 65 cc
of grease.
ii) Set with drain hole in cylinder rod (22)
facing up, then fit lubricator (6), and
loosen.
iii) Push in until piston (7) contacts stopper
face of cylinder rod, and push out all air
and remaining grease.
30-198 D155AX-5
(5)
iv) Tighten lubricator (6), then install
3 Lubricator : 49.0 ± 2.5 Nm

bracket.
{5 ± 0.25 kgm}
5) Assemble cylinder rod (22) to cover assem-

bly (2).
3. Press fitting yoke

1) Align match marks on yoke and case (made
before disconnecting) and assemble.
2) Using tool M4 and spacer (5), press fit yoke
(4) to case.
a Do not coat press-fitting surface [a] with
Molycoat.
• Press-fitting force: 245.2 kN {25 ton}
2 Mounting bolt :
3) Fit spacer (5) and tighten mounting bolts.
4. Raise spring assembly (3) and assemble to

case.
a Before assembling, coat surface [b] of spring
2 Spring assembly surface [b] :

assembly (3) with grease.
Grease (G2-LI)
D155AX-5 30-199
(5)
5. Raise cover assembly (2) and install to case
2 Mounting bolt : Thread tightener (LT-2)

assembly (1).
3 Mounting bolt :
549.2±58.8 Nm {56±6 kgm}

Add oil to spring chamber.
5 Spring chamber : 12 l (SAE30CD)
30-200 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK
ROLLER ASSEMBLY
1. Loosen track shoe tension.
ASSEMBLY.
2. Remove 7 mounting bolts of guard (1), and drop

on top of shoe. [*1]
• Remove guard (1) only for the track roller
assembly at the rear.
3. Remove 4 mounting bolts of track roller assem-

bly (2), and disconnect from bogie (3). [*2]
4. Using work equipment, raise chassis and lift off

guard (1). [*3]
4 Guard : 45 kg
5. Pull out track roller assembly (2) to outside from

top of shoe link.
4 Track roller assembly
[S]: Single flange: 97 kg

[D]: Double flange: 109 kg
• Mounting position of track roller assembly
[S]: Single flange type

[D]: Double flange type
D155AX-5 30-201
(3)
ROLLER ASSEMBLY
removal.

[*1]
3 Guard mounting bolt : 662.0 – 828.7 Nm

{67.5 – 84.5 kgm}
2 Track roller mounting bolt :

[*2]
3 Track roller mounting bolt :

662.0 – 828.7 Nm
{67.5 – 84.5 kgm}
[*3]
a Install the track roller assembly as follows.
1) Install guard (1) temporarily.
2) Lower chassis to a position where track roller
assembly mounting bolts can be assembled,
then install mounting bolts.
3) Tighten guard mounting bolts.
30-202 D155AX-5
(3)
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
1. Remove plug and drain oil.
6 Track roller : Approx. 390 – 450 cc
2. Remove mounting bolts of retainer (2) of track

roller (1).
3. Turn over track roller, and set cylinder [1] or

block so that there is enough space to remove
shaft from bottom.
4. Remove 2 mounting bolts of retainer (3), then set

tool N1 in position and pull out shaft (4) from bot-
tom.
5. Remove seal guide (5), then remove mounting

bolts of retainer (3).
6. Using forcing screws [2], remove retainer (3).
7. Raise roller (6), and pull out from shaft assembly

(7).
D155AX-5 30-203
(5)
8. Set shaft assembly (7) to cylinder [3].
9. Using tool N1, remove retainer (2) and seal

guide (8) from shaft (7).
10. Remove floating seals (9) from seal guides (5)

and (8).
11. Remove floating seals (10) from retainers (2)

and (3), then remove O-ring.
30-204 D155AX-5
(5)
12. Remove 2 coil bushings (11) from roller (6).
D155AX-5 30-205
(3)
ASSEMBLY OF TRACK
ROLLER ASSEMBLY
1. Set roller (6) in press, then use tool N2 to press
fit 2 bushings (11).
a When press fitting the bushing, use a plastic
hammer to align the center, then press fit
with a press.
a Press fit the bushing so that the dimension
from the end face of the roller to the top face
of the bushing is 17 ± 1 mm.
2. Using tool N3, assemble floating seals (10) and

O-ring to retainers (3) and (2).
3. Using tool N3, assemble floating seals (9) to seal

guides (8) and (5).
30-206 D155AX-5
(5)
4. Set roller (6) to cylinder [3], and assemble shaft

(7) to roller.
5. After installing retainer (3), turn over with shaft

assembled to roller and set on cylinder [3].
6. Install retainer (2), assemble seal guide (8) to

shaft, then using tool N1, press fit seal guide (8).
a Press fit the seal guide so that dimension a
from the end face of the shaft to the top sur-
face of the seal guide is 48.5 ± 0.2 mm.
a Turn over the track roller assembly and press
fit seal guide (5) in the same way as above.
a Before assembling, coat the mating surface
of the floating seals at the seal guide end
and retainer end thinly with engine oil.
D155AX-5 30-207
(5)
7. Using tool N4, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
a Standard pressure : 0.1 MPa {1 kg/cm²}
a Method of checking : Hold standard pressure
for 10 seconds. Gauge
indicator must not go
down.
8. Using tool N4, fill track roller assembly with oil.
5 Track roller oil : 390 – 450 cc (GO140)
9. After filling with oil, check that the oil is at speci-

fied level, then tighten plug.
a Checking oil level: Angle track roller approx.
10° and check that oil level is up to bottom
3 Plug : 160.0 – 250.0 Nm

face of oil filler.
{16.0 – 25.0 kgm}
30-208 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY BOGIE
REMOVAL OF BOGIE
ASSEMBLY
1. Loosen track shoe tension.
ASSEMBLY.
2. Remove 7 mounting bolts of guard (1), and drop

on top of shoe. [*1]
3. Sling guard (1), then use work equipment to jack

up chassis, and remove guard (1).
4 Guard : 45 kg
4. Lower chassis, then remove mounting bolts of

bogie guard (2). [*2]
• Bogie guard mounting bolt : 2 each on inside
and outside of track frame
5. Use work equipment to jack up chassis, then use

clearance a between bogie assemblies to
remove bogie guard (2).
6. Using tool P, secure inner bogie (3) and outer

bogie (4).
D155AX-5 30-209
(5)
7. Set steel plate [1] between bogie assembly and

shoe link, then lower chassis and remove mount-
ing bolts of bogie assembly (5). [*3]
a After removing the bogie assembly, set block
[2] between the bogie assemblies to prevent
it from moving.
8. Using work equipment, jack up chassis, fit rope

around bogie assembly (5), then slide on steel
plate [1] and pull to outside. [*4]
4 Bogie assembly : 410 kg
30-210 D155AX-5
(3)
INSTALLATION OF BOGIE
ASSEMBLY
removal.

[*1] [*2]

662.0 – 828.7 Nm {67.5 – 84.5 kgm}
2 Bogie mounting bolt :

[*3]
3 Bogie mounting bolt :

1863.3 – 2353.7 Nm {190.0 – 240.0 kgm}
[*4]
• Procedure for setting bogie assembly on link
1) Set steel plate [1] on top of link as shown
in Fig.
2) Fit wire [3] to bogie bracket (6) of track
frame on opposite side.
3) Fit wire [4] to 2 track rollers of bogie
assembly to be installed, then use lever
block [5] to pull up to top of link.
4) Set bogie assembly in mounting position,
then secure with block so that it does not
move.
5) Using work equipment, gradually lower
chassis to position where bogie mounting
bolts can be assembled, then install
mounting bolts.
6) Lower chassis completely, then tighten
bogie mounting bolts.
7) Raise chassis, then remove steel plate
and install bogie guard (2).
D155AX-5 30-211
(3)
DISASSEMBLY OF BOGIE
ASSEMBLY
a Fixture tool P (used when removing the bogie
assembly) is also used for the disassembly oper-
ation, so leave it installed.
1. Track roller assembly

Turn over bogie assembly, and lift off 2 track
roller assemblies (1). [*1]
a When removing the track roller, check the
mounting positions of the [S] single flange
and [D] double flange.
2. Pulling out pin assembly

1) Set bogie assembly (2) to tool Q1.
a When removing the pin assembly from
the bogie assembly, the pin assembly
must be removed in the correct direction,
so check casting mark [A] (INSERT - )
on the inside of the outer bogie, and set
the bogie assembly correctly in the
direction for removal.
2) Using tool Q1, pull out pin assembly (3) from

bogie assembly (2).
a Removal pressure for pin assembly :
Approx. 800.2 kN {81.6 ton}
30-212 D155AX-5
(5)
3. Pulling out shaft

1) Set pin assembly (3) to tool Q2.
2) Push in shaft (4) with tool Q2, remove collar (5),
then remove spacer (6) and floating seal (7).
a Dimension for pushing in shaft (4):
78.2 mm
a Pressure for pushing in shaft (4):
58.8 – 103.9 kN {6 – 10.6 ton}
3) Turn over pin assembly (3) while still assem-

bled, then set to tool Q2 again.
4) Push in shaft (4) with tool Q2, then remove

collar (8).
a Dimension for pushing in shaft (4):
156.4 mm
a Pressure for pushing in shaft (4):
58.8 – 103.9 kN {6 – 10.6 ton}
D155AX-5 30-213
(5)
5) Remove pin assembly (3) from tool L11, and

pull out spacer (9), ring (10), spacer (11), ring
(12), spacer (13), and ring (14) from shaft
(4).
4. Disassembly of ring
1) Remove floating seals (15) and (16) from
ring (10).
2) Remove floating seals (17) and (18) from
ring (12).
3) Remove floating seal (19) from ring (14).
5. Disassembly of collar
Remove floating seals (20) from collars (5) and
(8).
6. Disconnection of bogie
Remove tool P, and disconnect inner bogie (21)
and outer bogie (22).
30-214 D155AX-5
(5)
ASSEMBLY OF BOGIE
ASSEMBLY
1. Securing bogie
Assemble outer bogie (22) and inner bogie (21),
and secure with tool P.
a After securing with tool P, check that the cen-
ter of the pin assembly hole is showing.
2. Shaft, collar
1) Set collar (8) to tool Q3, and assemble bush-
ing (12) to shaft (4) temporarily, assemble to
spacer, set in position, then press fit.
a When press fitting the shaft, center the
shaft with the collar, then press fit.
a Press-fitting force for collar: 6 - 10.6 ton
2 Collar press-fitting surface of shaft:

a Press-fitting dimension: 78.2 mm
Anti-friction compound (LM-P)

a After press fitting, there must be no
stepped difference at the end face of the
collar and shaft.
2) Remove shaft from spacer, then remove

bushing (12).
3) Using tool Q4, assemble floating seal (20) to

collar (8).
a When assembling the floating seal,
remove all oil and grease from the O-ring
and O-ring contact surface.
a The angle of the floating seal must be
less than 1 mm.
a Protrusion [a] of the seal must be within
5- 7 mm.
D155AX-5 30-215
(5)
3. Assembly of ring, collar

1) Using tool Q4, install floating seals (19), (18),
(17), (16), and (15) to rings (14), (12), and
(10).
a When assembling the floating seals,
remove all oil and grease from the O-ring
and O-ring contact surface.
a The floating seal must be tilted less than
1 mm.
a Protrusion [a] of the seal must be within
5-7 mm.
2) Using tool Q4, assemble floating seal (7) to

collar (5).
a The precautions are the same as the
items marked a for Step 1) above.
4. Assembly of pin assembly

a When assembling the floating seals for each
bushing and collar, coat the seal mating sur-
face thinly with oil (EO-30).
1) Install spacer (6) to shaft (4), then assemble
ring (14).
2) Install spacer (13), then assemble ring (12).
3) Install spacer (11), then assemble ring (10).
30-216 D155AX-5
(5)
5) Set pin assembly (3) to tool Q3, press fit col-

lar (5).
a Press-fitting force for collar: 6 - 10.6 ton
2 Collar press-fitting surface of shaft:

a Press-fitting dimension: 78.2 mm

a Stepped difference at the end face of the
collar and shaft after press fitting:
0 - 2 mm
5. Press fitting pin assembly

1) The bogie and pin assembly must be press
fitted in the correct direction, so check the
press-fitting direction and set tool Q1 in posi-
tion.
i) On the inside of the outer bogie [A], there
is an [INSERT ] casting mark and
arrow, so set the bogie with the letters
and arrow facing the hydraulic cylinder
end of tool Q1.
ii) The pin assembly with the distinguishing
mark machined on the outside circumfer-
ence of the bushing has the larger diam-
eter, so press fit the bushing that has no
distinguishing mark first.
D155AX-5 30-217
(5)
2) Press fit pin assembly (3) to bogie assembly
2 Outside circumference of pin assem

(2).
bly: Anti-friction compound (LM-P)

a Press fit with the [UP] mark on the tip of
the pin at the top.
a Press-fitting force for pin:
Approx. 800.2 kN {81.6 ton}
6. Track roller assembly

Install 2 track roller assemblies (1).
a Check the installation position of the [S] sin-
2 Mounting bolt : Thread tightener (LT-2)

gle flange and [D] double flange, then install.
3 Mounting bolt :
662.0-828.7 Nm {67.5-84.5 kgm}

After assembling, add oil to bogie assembly.
5 Bogie assembly : 210-230 cc (GO140)
30-218 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Remove top cover of track frame, loosen lubrica-
tor (1), then loosen track shoe tension.
kThe recoil spring cylinder is under high inter-

nal pressure, so never loosen lubricator (1)
more than one turn.
a If the track tension is not relieved when the
lubricator is loosened, move the machine
backwards and forwards.
2. Using hydraulic jack [1], raise track shoe.
3. Remove mounting bolts (2).
4. Pass rope [2] through hole in link, wrap around

carrier roller (3), and tighten rope. Gradually
loosen rope to pull out carrier roller (3) from sup-
port (4) and remove it. [*1]
4 Carrier roller : 45 kg
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
removal.
[*1]
a When installing the carrier roller to the sup-
port, leave a clearance as shown in the dia-
2 Support mounting bolt :

gram.
• Adjust the tension of the track shoe assembly.

ADJUSTING TENSION OF TRACK SHOE
ASSEMBLY.
D155AX-5 30-219
(3)
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Remove plug and drain oil.
a Rotate the shaft when draining the oil.
6 Carrier roller : 570 - 680 cc
2. Set carrier roller assembly (1) on block [1].
3. Remove mounting bolts, then remove cover (2).
4. Remove ring (3).
5. Using tool R1, remove nut (4).
6. Using puller [2], remove press-fitting portion of

seal guide, then using eyebolts, remove bearing
(5) and roller (6) as one unit.
7. Remove outer race (7) from roller.
8. Using puller [3], remove seal guide (8) and bear-

ing (9) as one unit.
9. Remove floating seal (10) from seal guide (8).
30-220 D155AX-5
(5)
10. Using push tool [4], remove seal guide (11).
11. Remove floating seal (12) from seal guide (11).
D155AX-5 30-221
(3)
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Using push tool [5], press fit bearing (9).
2. Using push tool [6], press fit outer race (7).
3. Set roller (6) and bearing (5) to shaft.
4. Using push tool [7], press fit bearing (5) to shaft.

a Rotate the roller when press fitting the bear-
ing, and press fit to a position where the rota-
tion of the roller becomes slightly heavier.
5. Using tool R1, tighten nut (4) to 58.8 Nm {6

kgm}.
a After tightening the nut, if the nut hole and
shaft hole are not aligned, turn the nut in the
direction of loosening to align.
6. Install ring (3).
7. Fit O-ring, then fit cover (2) and tighten with

mounting bolts.
a Temporarily tighten the oil filler plug.
30-222 D155AX-5
(5)
8. Turn over roller (6), and add oil between shaft

and roller.
5 Oil : 570 - 680 cc (GO140)
9. Using tool R2, install floating seal (10) to seal

guide (8).
10. Fit O-ring, then align with dowel pin, and install
seal guide (8).
11. Using tool R2, install floating seal (12) to seal

guide (11).
12. Using tool R3, press fit seal guide (11).

a Press fit the seal guide until dimension a
from the end face of the shaft to the top sur-
face of the seal guide is 131.95 ± 0.2 mm.
D155AX-5 30-223
(5)
13. Using tool R4, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
a Standard pressure : 0.1 MPa {1 kg/cm²}
a Method of checking : Hold standard pressure
for 10 seconds. Gauge indicator must not go
down.
14. After checking for air leakage, check again that

level of oil added in Step 8 is at specified level.
a Method of checking oil level
Remove the oil filler plug and tilt the carrier
roller assembly to an angle of approx. 10° to
check the oil level.
3 Plug : 157.0 – 255.0 Nm {16.0 – 26 kgm}

15. Tighten oil filler plug.
30-224 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
CHECKING BEFORE
REMOVAL OF TRACK SHOE
ASSEMBLY
k In some cases, it may be extremely dangerous
to remove the track shoe assembly. To prevent
danger, carry out the following checks before
removing the track shoe assembly.
• Checks before starting
1) Loosen the lubricator at the adjustment cyl-
inder, release the grease, then move the
machine backward and forward a short dis-
tance, and check that the track tension is
relieved. If the track tension is not relieved
and the track shoe assembly remains
tense, there may be an abnormality inside
the track frame (the recoil spring case is bro-
ken, the recoil spring set bolt is broken, or
the nut at the end of the shaft has fallen off).
kNever loosen the lubricator more than
one turn.
2) Check that there is no interference between
the track frame and the guide shown in the
diagram. If there is any interference (when
progress of link pitch elongation is extreme),
there are cases where it is impossible to
know if there is any abnormality inside the
track frame.

ASSEMBLY (NORMAL)
a If CHECKING BEFORE REMOVAL OF TRACK
SHOE ASSEMBLY shows that there is no abnor-
mality, do as follows.
1. Remove blade assembly.

BLY.
2. Loosen lubricator (1) and loosen track shoe ten-
kThe recoil spring cylinder is under high internal

sion. [*1]
pressure, so never loosen lubricator (1) more

than one turn.
If the track tension is not relieved, move the
machine backwards and forwards.
3. Using block [1], adjust position so that master
link is perpendicular.
4. Remove mounting bolts, then remove track shoe
(2). [*2]
D155AX-5 30-225
(3)
5. Disconnect master link (3), guide end of track

link with a crane, move machine slowly in
reverse, and lay out track shoe assembly.

ASSEMBLY
(WHEN THERE IS
ABNORMALITY
INSIDE TRACK FRAME)
a When CHECKING BEFORE REMOVAL OF
TRACK SHOE ASSEMBLY shows any abnor-
mality, do as follows.
kIf there is any abnormality inside the track frame,

there is danger that the track shoe assembly
may spring back when it is removed or that the
idler may spring out when the track shoe assem-
bly is removed. This may lead to serious injury,
kIf there is any interference or abnormal catching

so remove the track shoe assembly as follows.
around the idler assembly, examine carefully and

remove the problem before starting.
1. Remove blade assembly.
BLY.
2. Loosen lubricator (1) of adjustment cylinder, then
move machine backwards and forwards to
release grease. [*1]
kNever loosen the lubricator more than one
turn.
a Check that all the grease has been removed.
30-226 D155AX-5
(3)
3. Drive slowly forward to put track shoe at idler

end in contact with large block [1] or a wall (if
another large bulldozer of the same capacity as
the machine being repaired is available, put in
contact with the blade). Stop machine when
recoil spring bends and slack is formed in track
shoe assembly, then apply brake. When doing
this, set so that master link is between idler and
front carrier roller. For safety reasons, fit a lever
block between carrier roller support and link.
4. Remove idler guide (2).
kAlways remove the idler guide without fail at
this point.
If the track shoe is opened without removing
idler guide (2), it will move to the front when it
opens, and idler guide (2) will be pushed
against the track frame. If the idler guide is
removed in this condition, the idler yoke
assembly will fly out to the front.
5. Remove shoe (4), then disconnect master link
(5). [*2]
kBe extremely careful to ensure safety when
disconnecting the track shoe.
6. Move machine towards rear slowly, and lay out
track shoe assembly.
SHOE ASSEMBLY
removal.
[*1]
a Track shoe tension : 20 - 30 mm
3 Master link mounting bolt :

[*2]
1st step 590.0±60.0 Nm {60.0±6.0 kgm}
2nd step 180°±10°
a When winding on the track, use a bar and

make sure that the link does not come off the
sprocket.
When winding on the track, make sure that
the track tension does not become loose.
a Check that there is no dirt or dust on the mat-
ing surface or thread of the master link.
a Tighten the track shoe bolts in the order [1] -
[4].
D155AX-5 30-227
(3)
OVERALL DISASSEMBLY OF
TRACK SHOE
a This section describes only the procedure for the
lubricated track.
a Use tool S1 for overall disassembly of the track
shoe.
1. Shoe (master link portion)

Set the track assembly on a flat floor with the
shoe facing up, then remove the shoe bolt at the
master link, and remove the shoe.
a Do not use an impact wrench when loosen-
ing the master link bolt.
2. Disassembly into 1/4 parts
Because of the weight of the track assembly, if
the 1/2 assembly is too large and there are prob-
lems with disassembly and assembly work,
divide into 1/4 assemblies.
3. Shoe (regular link portion)
Raise the track assembly and set it on the floor
with the shoe facing up, then use a shoe bolt
impact wrench to remove the shoes.
a When moving the track assembly, be careful
not to damage the master link portion.
a If a gas cutter has to be used to remove the
shoe nut, to prevent deterioration of the seal
due to the heat, keep the temperature of the
seal portion below 80°C, and take action to
prevent welding spatter from entering the
gap between the links.
4. Draining oil
Before disassembling the link assembly, drain
the oil from inside the pin and take precautions
so that the link press does not become dirty with
oil.
a Before disassembling, if it is judged that it is
necessary to rebuild the track as a dry type
track, the following work need not be carried
out.
1) Set the link assembly on a flat floor with the
large plug side facing up, then chamfer the
burrs on the end face of the pin with a
grinder.
a If the track is disassembled with burrs
still at the end face of the pin, the pin
press-fitting hole of the link will be
scratched, and this will cause leakage
from the pin press-fitting portion after
rebuilding.
2) Using a drill (ø0 mm), make a hole in the
large plug, then remove the large plug.
a If any dirt or deteriorated oil is stuck to
the pin hole, drill through with a longer
drill to remove it. When doing this, be
careful not to damage the oil hole.
30-228 D155AX-5
(5)
3) After removing the large plug, use a baby

grinder (angle of grinder tip: 45° - 60°), and
chamfer the pin hole so that the plug is not
damaged when the plug is knocked in.
4) Turn over the link assembly so that the small
plug side is facing up, remove the burrs at
the end face of the pin with a grinder, then
use tool S2 to knock the small plug to the
inside.
a If the small plug hole is blocked with
burrs, grind with a grinder until the hole
can be seen completely.
5) Using a drill (ø0 mm), chamfer the small plug
hole.
6) Blow with compressed air to remove the
metal particles when draining the oil inside
the pin or removing the burrs, then wash the
link assembly with high-pressure water or
steam.
5. Disassembly of link
1) Set the link assembly on a link press, then hit
with a hammer so that the bushing and jaw
are in tight contact.
a If the link tread and outside diameter of
the bushing are worn, adjust the height of
the jaw or guide plate, and center the dis-
assembly jig with the pin and bushing
center to prevent damage to the link hole
when disassembling.
a If the centering is not carried out prop-
erly, the link hole may be damaged, the
pin may break, or the bushing may crack
during disassembly.
2) Operate the left cylinder and remove the left
link and pin and bushing press-fitting portion
at the same time.
a Check the removal force of the pin and
bushing, and use this value as reference
to judge if it is possible to obtain the nec-
essary pin and bushing press-fitting force
when turning and reassembling.
a Do not push the disassembly jig inside
more than is necessary as the spacer
may break.
D155AX-5 30-229
(5)
3) Return the left cylinder, then operate the right

cylinder and remove the right link and pin
and bushing press-fitting portion at the same
time.
4) Return the right cylinder, remove the left and
right links, pins, bushings, and spacers, then
feed the following set for one link assembly
into the jaw.
a To decide if the seal can be used again, carry
out inspection when the seal is still installed
to the link, so do not remove the seal from
the link.
a If oil is remaining, this can be used as a
guideline for reuse of the seal, so mark such
links or seals.
a If the end face of the bushing and seal sur-
face are damaged, it will cause oil leakage,
so be extremely careful when handling.
6. Inspection
Check the following items to determine if the part
can be reused as a lubricated track or as a
grease-filled track. Carry out a comprehensive
check to determine if the link assembly can be
rebuilt as a lubricated track or as a grease-filled
track.
a When making judgments about reuse of
parts, see "Guidance for Reusable Parts,
Undercarriage, Lubricated Track".
1) Check the pins, bushings, links, and spacers
visually for damage, and carry out a color
check or use a flaw detector to check parts
that are suspected of being damaged. Any
part that is cracked must not be used again,
so scrap it.
2) Check the external appearance of the seal
and the end face of the bushing visually to
determine if they can be used again.
a If only the bushing is replaced with a
new part, the worn or damaged part of
the seal lip will contact the end face of
the bushing directly, so it may not be able
to carry out its sealing function. For this
reason, always replace the seal
together with the bushing, or rebuild as a
grease-filled track.
30-230 D155AX-5
(3)
3) Using calipers, measure spacer thickness a

and overall length b of the sliding portion of
the bushing and spacer. Check if it is possi-
ble to obtain the specified seal mounting
dimension when reassembling.
a If the amount of wear of the spacer and
bushing is greater than the specified
amount, the assembly precision of the
seal portion cannot be guaranteed, so
replace with new parts, or rebuild as a
grease-filled track.
4) Using a micrometer, cylinder gauge, and cal-

ipers, measure the outside diameter of the
pin and the inside diameter of the bushing at
the worn portion, and judge if the parts can
be used again.
a If the amount of wear is greater than the
specified amount, there will be play dur-
ing travel, and it will also cause oil leak-
age, so replace with new parts or rebuild
as a grease-filled track.
a For details of the dimensions when mak-
ing judgment, see MAINTENANCE
STANDARDS.
5) Using a micrometer and cylinder gauge,

measure the outside diameter of the pin and
bushing press-fitting portion, and the inside
diameter of the pin and bushing press-fitting
portion of the link to determine if the permit-
ted interference can be obtained. However,
when rebuilding as a lubricated track, check
that the standard interference for the pin and
link can be obtained.
a If the permitted interference can not be
obtained, replace with new parts or
replace with an oversize part.
a For details of the dimensions when mak-
ing judgment, see MAINTENANCE
STANDARDS.
D155AX-5 30-231
(3)
a Precautions for storage

1) To prevent rust of the counterbore portion of
the link, leave the seal installed to the link
and be careful not to damage the seal lip
during storage.
2) Coat the pin and bushing press-fitting por-
tion, shoe mating surface, and master link
mating surface of the link with rust preven-
tion oil to prevent rust.
3) Coat the whole circumference of the pins,
bushings, and spacers with rust prevention
oil to prevent rust, and be particularly careful
not to damage the end face of the bushing
during storage.
30-232 D155AX-5
(3)
OVERALL ASSEMBLY OF
TRACK SHOE
a Use tool S1 for overall assembly of the track
shoe.
When rebuilding as lubricated track

1. Preparatory work
1) Washing seal assembly
• Machines fitted with F3 type seals
Remove the seal assembly from the link,
then separate into the seal ring and load
ring, and clean the parts.
a The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent (trichlene, etc.), so wash
the parts quickly. After cleaning, wipe the
parts with a clean cloth to remove all the
cleaning agent.
• Machines fitted with W7 type seals
For seals that are to be reused, leave the
seal installed to the link, and do not wash it.
2) When reusing the pin, chamfer the corner of

the end face smooth with a grinder. Use a
grinder to remove any protruding parts stuck
to the press-fitting portion.
a If the corner of the end face has become
sharp due to wear, there will be scuffing
at the press-fitting portion and this will
cause oil leakage.
3) Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin
when assembling.
a When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
D155AX-5 30-233
(5)
4) If the link, pin, bushing, or spacer are dirty,

wash them. Remove any protruding parts
stuck to the link and bushing with a grinder.
a These parts easily rust, so wash them
immediately before assembly.
a Use tool S3 to wash the pin hole.
a Do not polish or carry out any other treat-
ment of the end face of the bushing as
this will cause oil leakage.
5) Use tool S4 to knock the large plug into the
pin.
i) Insert the plug into the guide hole
through the plug insertion window.
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
a Dimension a to knock in from end
face of pin: 6 ± 2 mm
a If there is no more place to chamfer
at the pin hole because of wear, use
a baby grinder (angle of grinder tip:
45° - 60°) to carry out chamfering.
a Coat the outside circumference of
the plug with GO90 and knock in the
smaller diameter part first.
6) Installation of seal assembly
• Machines fitted with F3 type seal
Clean the link counterbore, then use tool S5
to push the seal in fully to the bottom.
a If there is oil stuck to the link counterbore
and seal assembly, the seal will rotate and its
sealing performance will drop, so do not coat
with oil. In addition, be careful not to let oil
get into the counterbore portion of the seal
when pushing in.
• Machines fitted with W7 type seal
When reusing the link and replacing the seal
with a new part, clean the link counterbore,
then push the seal in fully to the bottom.
a If there is oil stuck to the link counterbore
and seal assembly, the seal will rotate and its
sealing performance will drop, so do not coat
with oil. In addition, be careful not to let oil
get into the counterbore portion of the seal
when pushing in.
30-234 D155AX-5
(5)
7) In order to keep the protrusion of the pin and

bushing constant and the installation dimen-
sions of the seal within the specified value
during assembly, adjust the press-fitting jig
dimensions of the link press.
a For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
a To leave a small space for the pin when
assembling, ensure that the dimension
(dimension a’) is greater than dimension
a at the pin pushing portion of the left
press-fitting jig.
When assembling in order [1] press fit
ting left link, [2] press fitting right link,
provide the extra space for the pin on the
right press-fitting jig.
a If the end face of the pin (portion P) or
the side face of the link (portions Q, R)
are worn, add the amount of wear to the
standard dimension when adjusting the
dimension of the press-fitting jig so that
the amount of protrusion of the left and
right pin and bushing is uniform.
8) Adjust the relief pressure of the link press to

make sure that the pushing force of the press
does not exceed the specified value.
a If the pushing force is too strong, exces-
sive force will be brought to bear on the
spacer, and it will be pushed against the
bushing. This will cause the spacer to
break or will cause abnormal wear
between the spacer and bushing end
face.
a If the interference at the press-fitting por-
tion is different from when the part is
new, as when reusing a pin or bushing,
measure several of the press-fitting por-
tions, and use the table below to deter-
mine the set pushing force according to
the average interference.
a Pushing force for pin, bushing: 785 kN
{80 ton}
Pushing force C 1.8 x average press-fit-
ting force
(Adjust the relief pressure of the link
press and set the pushing force.)
D155AX-5 30-235
(3)
2. Assembly of link
1) Use a clean brush to coat the area between
the pin and bushing with oil (GO90), set in
position, then set in front of the jaw of the link
press.
a When reusing (turning) the bushing, set
the worn surface on the outside circum-
ference of the bushing facing the shoe
mounting surface of the link (facing up on
the link press).
2) Set the left and right bushing end master link

with the shoe mounting surface facing up,
then press fit to the bushing.
a When doing this, use the pin end master
link as a support.
a Press-fitting force for bushing:
49 – 196 kN {5 – 20 ton}
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between the shoe bolt
holes of the left and right link is the specified
value.
a Use compressed air to remove all metal
particles from burrs caused by press fit-
ting the bushing.
4) Turn over the master link, and check that the

left and right master links have been press
fitted in parallel.
30-236 D155AX-5
(3)
5) Measure the amount of protrusion of the left

and right bushings with a depth gauge.
a Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
6) Feed the master link portion, then set the pin

and bushing in position.
a When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new. If
the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
a Align the large plugs so that they are on
the left side facing the link press when
assembling.
7) To prevent oil from leaking out from scuff

marks on the pin press-fitting portion, coat
the pin press-fitting hole in the link and the
outside diameter of the pin press-fitting por-
tion with gasket sealant (198-32-19890).
8) Set the right link in position and install the

spacer to the pin.
a Check that there is no dirt or dust stuck
to the seal surface and bushing end face,
then use a clean cloth or brush to coat
with oil (GO90).
a Wipe the spacer with a clean cloth, then
install it.
D155AX-5 30-237
(3)
9) Using the right jig as the receiving end and

the left jig as the pushing end, press fit the
pin and bushing at the same time.
a The seal may come off the link due to the
play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit the
seal correctly on the link, then start the
press-fitting operation again.
a Press-fitting force for pin, bushing:
245 – 490 kN {25 – 50 ton}
10) Using a fine adjustment spacer, press fit so

that the end face of the pin is in tight contact
with the bottom of the receiving jig.
a Adjust the depth of the hole in the receiv-
ing jig so that the protrusion of the left
and right pins is uniform.
11) Set the left link in position and install the

spacer to the pin.
a Coat with oil in the same way as when
installing the right link.
12) Using the left jig as the receiving end and the
right jig as the pushing end, press fit the left
link.
a When press fitting, be careful that the left
and right seal and spacer do not come
out of position.
a Provide enough space on the left jig so
that the end face of the pin does not con-
tact the bottom of the jig.
a Press-fitting force for link:
245 – 490 kN {25 – 50 ton}
30-238 D155AX-5
(3)
13) Press fit the link, spacer, and bushing so that

they are each in tight contact.
a It is impossible to check from outside if
they are in tight contact, so control the
hydraulic force of the link press and set
the relief pressure to a constant value.
Then apply hydraulic force and push in
until this pressure is reached.
For details of the setting for the relief
pressure, see "Preparatory work".
a Check that adjacent links swivel freely in
relation to each other.
14) After assembling each link, use a dial gauge
and pinch bar to measure the end play from
the link previously assembled, to check that
the link is assembled within the specified
value.
a If the end play does not come within 0 -
0.13 mm even when applying the push-
ing force until the relief valve is actuated,
raise the relief pressure setting gradually
to adjust.
a Adjust the relief pressure setting carefully
and be sure not to raise the pushing
force of the link press higher than neces-
sary.
15) Using a shoe bolt hole pitch gauge, check
that the distance between the shoe bolt
holes is within the standard value.
a If the distance between the shoe bolt
holes is greater than the specified value,
disassemble and check for any abnor-
mality, then press fit again.
a If the distance between the shoe bolt
holes is smaller than the specified value,
and the shoe cannot be installed, the
wear of the spacer or bushing end face is
probably greater than the repair limit, so
disassemble and replace with a new
part.
a If the end play is too large, the sealing
performance will drop, so set the end
play to a small value.
16) After assembling each link, use tool S6 to
remove the air from inside the pin, and check
the sealing performance.
a Hold the space inside the pin at a vac-
uum of 650 - 700 mmHg for 5 seconds
and check that there is no change in
pressure.
If the pressure changes, disassemble
and check the seal for any abnormality,
then assemble again.
D155AX-5 30-239
(5)
17) Assemble the pin end master link as the final

link.
a Check that the left and right master links
are press fitted in parallel.
3. Filling with oil

After completion of assembly of the link assem-
bly, add oil through the pin hole.
1) Using tool S6, remove the air inside the pin
from the small plug hole, set to a vacuum of
650 - 700 mmHg, then fill with oil (GO90)
until the pressure is 0.2 - 0.3 MPa {2 - 3 kg/
cm²}.
a In cold or extremely cold areas, instead
of GO90, fill with Komatsu genuine oil
(150-09-19270) which has excellent low-
temperature qualities.
a Be careful not to raise the oil pressure
too high as this will have an adverse
effect on the seal.
a To determine the oil amount, set the
small plug end at the top (stand the link
assembly on its side), leave for 30 min-
utes, then fill with oil so that depth L of
the space at the pin hole is within the
specified value below.
Dimension L: 35 - 65 mm
2) After completion of filling with oil, use tool S2

to knock in the small plug to the specified
position.
a Coat the outside circumference of the
small plug with GO90.
a The depth to knock in the plug is as fol-
lows.
Depth from end face: 7.5 ± 1 mm
30-240 D155AX-5
(5)

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
3 Shoe bolt (regular link):

install the shoe.
Initial torque: 588.4 ± 58.8 Nm

{60 ± 6 kgm}
Tightening angle: 120° ± 10°
5. Connecting to make 1/2 assembly

Set two completely assembled portions of track
on a flat surface in a straight line with the shoes
facing up. Pull master link (1) at the pin end to
master link (2) at the bushing end, and set at the
mating surfaces. Then put shoe (3) on top,
check that shoe bolt (4) goes in easily by hand,
2 Shoe bolt:
and connect the two parts with the master bolt.
3 Shoe bolt (master link):


{60.0 ± 6.0 kgm}
a When tightening, tighten in the order [1] - [4].
a Do not use an impact wrench for the master

link.
D155AX-5 30-241
(3)
When rebuilding as grease-filled track
1. Preparatory work
1) Washing seal assembly
• Machines fitted with F3 type seals
Remove the seal assembly from the link,
then separate into the seal ring and load ring,
and clean the parts.
a The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent, so wash the parts
quickly. After cleaning, wipe the parts
with a clean cloth to remove all the clean-
ing agent.
• Machines fitted with W7 type seals

For seals that are to be reused, leave the
seal installed to the link, and do not wash it.
2) When reusing the pin, chamfer the corner of

the end face smooth with a grinder so that
press fitting can be carried out smoothly.
3) Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin
when assembling.
a When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
30-242 D155AX-5
(5)
4) Use tools S4 and S2 to knock the large plug

and small plug into the pin.
i) Insert the plug into the guide hole
through the plug insertion window.
(Coat the plug with oil.)
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
a Dimension a to knock in from end
face of pin:
Small plug: 7.5 ± 1 mm
Large plug: 6 ± 2 mm
a If the plug was not removed from the
pin during disassembly, it can be
used again as it is.
5) Clean any part where outside diameter of the
pin, front face of the spacer, or end face or
inside diameter of the bushing are dirty.
6) Coat the outside diameter of the pin and the
front face of the spacer with grease.
7) Installation of seal assembly
• Machines fitted with F3 type seal
Clean the link counterbore, then use tool S5
to push the seal in fully to the bottom.
a If there is grease stuck to the link coun-
terbore and seal assembly, the seal will
rotate and its sealing performance will
drop, so do not coat with grease.
• Machines fitted with W7 type seal
When reusing the link and replacing the seal
with a new part, clean the link counterbore,
then push the seal in fully to the bottom.
a If there is grease stuck to the link coun-
terbore and seal assembly, the seal will
rotate and its sealing performance will
drop, so do not coat with grease.
8) In order to keep the protrusion of the pin and
bushing constant and the installation dimen-
sions of the seal within the specified value
during assembly, adjust the press-fitting jig
dimensions of the link press.
a For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
a If the end face of the pin (portion P) or
the side face of the link (portions Q, R)
are worn, add the amount of wear to the
standard dimension when adjusting the
dimension of the press-fitting jig so that
the amount of protrusion of the left and
right pin and bushing is uniform.
D155AX-5 30-243
(5)
2. Assembly of link
1) Coat the area between the pin and bushing
with lithium grease (G2-LI), set in position,
then set in front of the jaw of the link press.
a When reusing (turning) the bushing, set
the worn surface on the outside circum-
ference of the bushing facing the shoe
mounting surface of the link (facing up on
the link press).
2) Set the left and right bushing end master link

with the shoe mounting surface facing up,
then press fit to the bushing.
a When doing this, use the pin end master
link as a support.
49 - 196 kN {5 - 20 ton}
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between the shoe bolt
holes of the left and right link is the specified
value.
a Use compressed air to remove all metal
particles from burrs caused by press fit-
ting the bushing.
4) Turn over the master link, and check that the

left and right master links have been press
fitted in parallel.
5) Measure the amount of protrusion of the left

and right bushings with a depth gauge.
a Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
30-244 D155AX-5
(3)
6) Feed the master link portion, then set the pin

and bushing in position.
a When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
a If the outside diameter of the pin is worn,
assemble so that the face that is not
worn is on the pulling side. However, in
this case also assemble so that the side
hole faces the tread surface of the link.
7) Set the left and right links in position, then
operate the left and right pushing jigs to
press fit the pin and bushing at the same
time.
a The seal may come off the link due to the
play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit the
seal correctly on the link, then start the
press-fitting operation again.
a Pushing force for pin, bushing: 785 kN
{80 ton}
Pushing force C 1.8 x average press-fit-
ting force
(Adjust the relief pressure of the link
press and set the pushing force.)
8) Using a shoe bolt hole pitch gauge, measure
the distance between the shoe bolt holes
and stop press fitting when it is within the
standard value.
9) Assemble the pin end master link as the final
link.
a Check that the left and right master links
are press fitted in parallel.

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
3 Shoe bolt (regular link):

install the shoe.

{60 ± 6 kgm}
D155AX-5 30-245
(3)
4. Connecting to make 1/2 assembly

master link (2) at the bushing end, and set at the
mating surfaces. Then put shoe (3) on top,
check that shoe bolt (4) goes in easily by hand,
2 Shoe bolt:
and connect the two parts with the master bolt.

Initial torque:590.0 ± 60.0 Nm

{60.0 ± 6.0 kgm}
a When tightening, tighten in the order [1] - [4].
a Do not use an impact wrench for the master

link.
30-246 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
PRESS-FITTING JIG
DIMENSION TABLE FOR LINK
PRESS
Unit: mm
Jig dimension
a b c
5.7 3.25 50.6
D155AX-5 30-247
(3)
DISASSEMBLY AND ASSEMBLY ONE LINK
FIELD DISASSEMBLY OF ONE

LINK
a This section describes only the procedure for
using the tools. For details of the procedure for
disassembly or assembly, see OVERALL DIS-
ASSEMBLY (or ASSEMBLY) OF TRACK SHOE.
1. Using two bolts (2), install tool T1 (adapter,

guide, bolt) to link (1).
a It is also possible to use two track bolts for
bolt (2).
2. Assemble tool T2 (pump, cylinder 150t) and tool

T3 (frame, rod, adapter, bolt x 1, eyebolt), then
raise the assembly and set on the track.
3. Insert the rod of tool T4 from the cylinder end,

and install with two nuts.
Pass the rod through the hole in link (1) to install.
4. Set tool T5 (adapter, guide, pusher) in position,

then apply hydraulic pressure and remove pin
(3).
When the cylinder reaches the end of its stroke,
insert tool T5 (extension) between the adapter
and guide, and repeat the operation.
30-248 D155AX-5
(5)
5. Set tool T6 (294 kN {30t} puller) and spacer [1] to

the center of the roller tread of the link to be dis-
assembled, then apply hydraulic pressure to the
puller, open the link 5 - 6 mm, and disconnect the
link.
D155AX-5 30-249
(5)
FIELD ASSEMBLY OF ONE

LINK
1. Assemble the link sub-assembly.
1) Set tool T7 to the end face of the link, then
press fit bushing (1).
49 - 196 kN {5 - 20 ton}
2) Set tool T7 to the end face of the link (pin

end), and press fit pin (2).
a Set with the side hole in the pin facing
the link tread.
a Press-fitting force for pin:196 - 294 kN
{20 - 30 ton}
2. Set link sub-assembly (3) on the link to be con-

nected.
3. Set link (4) on the opposite side, and support

with tool T8 (guide).
30-250 D155AX-5
(5)
4. Set tools T9 and T10 in the same way as for the

operation to remove the pin, then use tool T9
(adapter, extension, guide, adapter, bolt) for
press fitting the bushing, and tool T10 (exten-
sion, guide, adapter, bolt) for press fitting the
pin, and press fit in turn.
{20 - 30 ton}
a Press-fitting force for bushing:98 - 196 kN
{10 - 20 ton}
5. Use tool T11 (294 kN {30t} puller) in the same

way as when disassembling, and push open link
(5) at the bushing end.
6. Set link (6) at the pin end to link (5) at the bush-
ing end, connect with tool T12 (guide), then
remove tool T11 (puller).
7. Set tool T5 at pin (7) end, then use tool T13
2 Pin press-fitting hole in link:

(adapter, bolt, guide) to press fit pin (7).
Gasket sealant (198-32-19890)

a Set with the side hole in the pin facing the
link tread.
{40 - 60 ton}
D155AX-5 30-251
(5)
DISASSEMBLY AND ASSEMBLY MASTER LINK
DISASSEMBLY OF MASTER
LINK
1. Removal of track assembly
Remove the track assembly from the track
frame.
ASSEMBLY.
2. Separation of track
Disconnect all master link portions, and divide
into four parts.
3. Removal of master link

• Master pin type
1) Gas cutting of regular link
Gas cut the portion marked WW, and remove
.
Special tool to use: Gas cutter
2) Removal of regular link

Push pin (1) in the direction of the arrow with
a press, remove from link (2), then remove
pin (1) and link (3) at the same time from
bushing (4).
• Master link type

1) Gas cutting, removal of master link at bush-
ing end
Gas cut the portion marked WW, remove
, then move master links (5) and (6) up
or down to remove them. Push pins (8) and
(9) press fitted to regular link (7) with a press
in the direction of the arrows to remove them.
• Special tool to use: Gas cutter
30-252 D155AX-5
(3)
2) Removal of master link at pin end

Gas cut the portion marked WW, remove
, push pin (10) with a press in the direc-
tion of the arrow and remove from link (11),
then remove pin (10) and link (12) at the
same time from bushing (13).
• Special tool to use: Gas cutter
D155AX-5 30-253
(3)
ASSEMBLY OF MASTER LINK

1. Assembly of link at bushing end
1) Using a press, press fit master link (1) at the
bushing end to bushing (2).
a When press fitting the left and right mas-
ter links, be extremely careful to keep
them parallel.
a Be careful not to scratch or damage the
mating surface of the master link and the
end face of the bushing.
Unit: mm
L1 169 ± 0.7
L2 219.8 ± 0.7
D1 27 drill hole
D2 24 × 2.0
2. Installation of link at bushing end

1) Push open the central part of the link tread
with tool U1 as shown in the diagram. (Open
approx. 10 mm at the tip of the link.)
2) Set spacer (3) and seal assembly (4) at the

counterbore of the link at the connection.
30-254 D155AX-5
(5)
3) Align the pin hole and bushing hole, and con-

nect with guide pin [2].
4) Press fit pin (5) with tool U2, and install mas-
2 Pin press-fitting hole in link:

ter link (1) at the bushing end.
Gasket sealant (198-32-19890)

a Set with the side hole in the pin facing
the link tread.
5) Install the shoe to the link at the connection.
6) After knocking in large plug (6) with tool U3,

fill with oil using tool U4, then knock in small
plug (7) with tool U5.
a When press fitting the left and right mas-
ter links, be extremely careful to keep the
left and right links parallel. (Bushing end
and pin end)
a Be careful not to scratch or damage the
mating surface of the master link and the
end face of the bushing.
a End play at connection (play in thrust
direction of links on both sides of pin):
0 - 0.13 mm
a Be extremely careful not to get mud or
dust on the tap hole mating face of the
master link, bushing end face, spacer, or
seal.
D155AX-5 30-255
(5)
3. Assembly of link at pin end

1) Set spacer (3) and seal assembly (4) in the
counterbore of the master link.
2) Pass pin (9) through bushing (8), set pin

master link (10) from the left and right, then
press fit with tool R.
3) After knocking in large plug (11) with tool U3,

fill with oil using tool U4, then knock in small
plug (12) with tool U5.
4. Connecting master link portion

master link (14) at the bushing end, and set at
the mating surfaces. Then put the shoe on top,
and check that the shoe bolt goes in easily by
2 Shoe bolt:
hand.


{60 ± 6 kgm}
30-256 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT
REMOVAL OF PIVOT SHAFT

ASSEMBLY
1. Remove track frame assembly.
For details, see REMOVAL OF TRACK FRAME
ASSEMBLY.
2. Remove seal (1), then remove ring (2). [*1]
3. Sling pivot shaft assembly (3), then remove
mounting bolts, and using forcing screws [1],
raise pivot shaft assembly (3) and pull out. [*2]
4 Pivot shaft assembly : 120 kg
INSTALLATION OF PIVOT
SHAFT ASSEMBLY
removal.
[*1]
a Assemble the seal as follows. (See diagram
on right)
1) Turn over seal so that embossed letters
on seal are on inside.
2) With seal turned over, insert seal on
shaft.
a When inserting the seal, be careful not to
scratch or damage the surface.
a Use tool V to press fit ring (2).
• Press-fitting force : 9.3 - 22.6 kN
{0.95 - 2.3 ton}
2 Pivot shaft mounting bolt :

[*2]
3 Pivot shaft mounting bolt :

823.8 - 1029.7 Nm {84.0 - 105.0 kgm}
D155AX-5 30-257
(5)
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL OF EQUALIZER
BAR ASSEMBLY
1. Remove side pin top cover (1).
2. Set jack (490 kN {50 ton}) under radiator, jack

up, then raise work equipment and set stand [2]
in position.
a Set at a height where the center pin will
come out.
3. Remove equalizer bar side pin cover (2), then

pull out outside bushing (3) and side pin (4), and
remove inside bushing (5). [*1]
a Operate the jack to carry out fine adjustment
of the height, and when the pin is at a point
where it moves easily, tap the pin to remove
it.
4. Sling equalizer bar assembly (6) with crane and

chain block.
5. Remove lock plate (7), then using tool W, pull out

center pin (8). [*2]
kWhen operating the hydraulic system, do not
stand under or in front of the puller. Stand as
far as away as possible when operating it.
6. Operate chain block and crane, and remove

equalizer bar assembly (6).
4 Equalizer bar assembly : 230 kg
kDo not lower the chassis after removing the

equalizer bar assembly.
30-258 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
INSTALLATION OF
EQUALIZER BAR ASSEMBLY
removal.
2 Inside cover : Fill with grease (G2-LI)

[*1]
2 Between equalizer bar side pin portion

and bushing : Fill with grease (G2-LI)
2 Connecting portion of pin and bushing :

[*2]
2 Frame boss portion :

Coat with grease (G2-LI)
Coat with anti-friction compound
2 Between bushing and bushing :

(LM-P)
Fill with grease (G2-LI)
D155AX-5 30-259
(5)
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR SIDE BUSHING
REMOVAL OF EQUALIZER
BAR SIDE BUSHING
1. Remove equalizer bar assembly.
For details, see REMOVAL OF EQUALIZER
BAR ASSEMBLY.
2. Remove seal (1).
3. Remove ring (2).
4. Remove spherical bushing (3) by using tool N2.
INSTALLATION OF
EQUALIZER BAR SIDE
BUSHING
1. Install ring (2) to one side.
2. Press fit spherical bushing (3) by using tool X

with press.
a Press-fitting force : 15.7 kN {1.6 ton}
3. Install ring (2) on opposite side.
2 Between bushing and seal :

4. Install seal (1).
Fill with grease (G2-LI)
5. Install equalizer bar assembly.

For details, see INSTALLATION OF EQUALIZER
BAR ASSEMBLY.
30-260 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY SEGMENT TEETH
REMOVAL OF SEGMENT
TEETH
1. Stop machine at position where it is easy to
remove teeth (between shoe and track frame).
2. Remove mounting bolts, then remove teeth (1).

[*1]
INSTALLATION OF SEGMENT
TEETH
removal.
2 Thread of teeth mounting bolt:

[*1]
3 Teeth mounting nut :1,176.8 ± 98.1 Nm

{120 ± 10 kgm}
D155AX-5 30-261
(3)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
TANK ASSEMBLY
kLower the work equipment completely to the
ground, and release the remaining pressure in
the circuit. For details, see TESTING AND
ADJUSTING, RELEASING REMAINING PRES-
SURE IN HYDRAULIC CIRCUIT. Then loosen
the oil filler cap slowly to release the pressure
inside the hydraulic tank.
1. Drain oil from hydraulic tank.
2. Remove right side cover.

3. Disconnect control valve hose (1) at filter end.
4. Disconnect hydraulic tank tube (2) at joint end,
then remove.
4 Filter case assembly : 24 kg
6. Disconnect work equipment return hose (4).

7. Disconnect cooling drain hose (5).
8. Disconnect suction tube (6) from tank.
9. Remove 4 tank mounting bolts (7).
10. Lift off hydraulic tank assembly (8).
4 Hydraulic tank assembly : 95 kg
INSTALLATION OF
HYDRAULIC TANK
ASSEMBLY
removal.

fied level.
system. Then check the oil level again with the
sight gauge.
• Bleeding air
Bleed the air.
Bleeding air.
30-262 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL OF MAIN
CONTROL VALVE ASSEMBLY
a After disconnecting the pipes and hoses, fit blind
plugs to prevent dirt or dust from entering.
a Make match marks or fit tags to the hoses and
pipes to prevent any mistake in the position
when installing.
1. Drain oil from hydraulic tank.
2. Remove right side cover.

3. Disconnect clamp (1) from filter case.
4. Disconnect charge pump tube (2).
4 Filter case assembly : 24 kg
6. Disconnect clamp (4) of the hose returning to the

hydraulic tank.
7. Remove return filter hose (5).
8. Disconnect PPC hose (6) (green) (blade left tilt).
9. Disconnect PPC hose (7) (colorless) (blade
LOWER).
10. Disconnect PPC hose (8) (black) (ripper DOWN).
11. Disconnect PPC hose (9) (white) (ripper TILT
BACK).
12. Disconnect PPC hose (10) (red) (ripper TILT IN).

13. Disconnect PPC hose (11) (colorless) (ripper
UP).
14. Disconnect PPC hose (12) (black) (blade RAISE).
15. Disconnect PPC hose (13) (yellow) (blade right
tilt).
16. Disconnect hose (14) (ripper TILT BACK).

17. Disconnect hose (15) (ripper TILT IN).
18. Disconnect hose (16) (ripper DOWN).
19. Disconnect hose (17) (ripper UP).
D155AX-5 30-263
(3)
20. Disconnect tube (18) (blade LOWER).

21. Disconnect tube (19) (blade RAISE).
22. Disconnect hose (20) (blade right tilt).

23. Disconnect hose (21) (blade left tilt).
24. Disconnect hose (22) from work equipment
pump.
25. Disconnect PPC hose (23).
26. Disconnect hose (24) returning to the hydraulic
tank.
27. Remove mounting bolts, then lift off main control
valve assembly (25).
4 Main control valve assembly : 100 kg
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
removal.

fied level.
system. Then check the oil level again with the
sight gauge.
• Bleeding air
Bleed the air.
Bleeding air.
30-264 D155AX-5
(3)
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
D155AX-5 30-265
(3)
a This section uses the 4-spool assembly as an

example for the disassembly procedure.
1. Remove bolt (1), and disconnect bodies (2) and

(3) from body (4).
2. Disassembly of ripper (tilt, lift) valve spool

1) Remove case (5) from bodies (2) and (3).
2) Remove case (6), pull out to point where por-
tion [a] of spool assembly (7) comes out,
then hold portion [a] with wrench (width
across flats: 14 mm), and loosen bolt (8).
a If it is possible to carry out work without
scratching or bending the spool, remove
spool assembly (7) and carry out disas-
sembly work.
3) Pull out spool assembly (7) from bodies (2)
and (3).
4) Remove bolt (8), then remove washer (9),
spacer (10), retainer (11), spring (12), and
retainer (13) from spool (14).
5) Remove plug (15), then remove spring (16)
and valve (17).
6) Remove plugs (18) and (20), then remove
check valve (19).
7) Remove check valve (21) and suction valve
(22).
8) Remove plug (23), then remove retainer
(24).
3. Disassembly of blade lift valve spool

1) Remove case (25) from body (4), then
remove spring (26) and retainer (27).
2) Remove case (28), pull out to point where
portion [b] of spool assembly (29) comes out,
then hold portion [b] with wrench (width
sembly work.
3) Pull out spool assembly (29) from body (4).
spacer (32), retainer (33), spring (34), and
retainer (35) from spool (36).
5) Remove plug (37), spring (38), and valve
(39) from spool (36).
30-266 D155AX-5
(3)
4. Disassembly of blade tilt valve spool

1) Remove case (40) from body (4).
2) Remove case (41), pull out to point where
portion [c] of spool assembly (42) comes out,
then hold portion [c] with wrench (width
sembly work.
3) Pull out spool assembly (42) from body (4).
retainer (45), spring (46), and retainer (47).
5) Remove plug (48), and pull out spring (50)
and valve (51) from spool (49).
5. Disassembly of unload valve spool

1) Remove plug (52) from body (4), then
remove spring (53) and retainer (54).
2) Remove plugs (55) and (56), then remove
spring (57), piston (58), and guide (59).
3) Remove bolt (61) from spool (60).
6. Plugs, valves
1) Remove plug (62), then remove spring (63)
and valve (64).
2) Remove plug (65), then remove retainer
(66).
3) Remove plug (67), then remove orifice (68).
4) Remove safety and suction valve (69), suc-
tion valve (70), and valve (71).
5) Remove check valve (72).
6) Remove plugs (73), (74), (75), and (76).
D155AX-5 30-267
(3)
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
30-268 D155AX-5
(3)

Coat the sliding surfaces of all parts with engine
1. Plugs, valves
1) Fit O-rings to plugs (76), (75), (74), and (73)
3 Plug (76):
and install.
3 Plug (75):
29.4 – 39.2 Nm {3.0 – 4.0 kgm}
3 Plug (74):
117.6 – 161.7 Nm {12.0 – 16.5 kgm}
3 Plug (73):
107.8 – 140.7 Nm {11.0 – 15.0 kgm}
176.6 – 196.1 Nm {18.0 – 20.0 kgm}
3 Check valve:
2) Install check valve (72).
58.8 – 78.5 Nm {6.0 – 8.0 kgm}

3) Fit O-rings to valve (71), suction valve (70),
and safety and suction valve (69), then
3 Valve (71):
install.
3 Valve (70):
107.9 – 147.1 Nm {11.0 – 15.0 kgm}
3 Valve (69):
181.4 – 240.3 Nm {18.5 – 24.5 kgm}
137.3 – 156.9 Nm {14.0 – 16.0 kgm}

4) Assemble orifice (68), then fit ring and O-ring
3 Plug (67):
to plug (67) and install.
274.6 – 367.7 Nm {28.0 – 37.5 kgm}

5) Assemble retainer (66), then fit ring and O-
3 Plug (65):
ring to plug (65) and install.
274.6 – 307.7 Nm {28.0 – 37.5 kgm}

6) Assemble valve (64) and spring (63), then fit
3 Plug (62):
O-ring to plug (62) and install.
127.5 – 176.6 Nm {13.0 – 18.0 kgm}
2. Assembly of unload valve spool

1) Assemble guide (59) to spool (60), then
3 Bolt: 5.9 – 8.8 Nm {0.6 – 0.9 kgm}

install bolt (61).
2) Install plug (56), assemble piston (58) and
3 Plug (56):
spring (57), then install plug (55).
3 Plug (55):
181.4 – 240.3 Nm {18.5 – 24.5 kgm}
137.3 – 156.9 Nm {14.0 – 16.0 kgm}

3) Assemble retainer (54) and spring (53) to
3 Plug (52):
body (4), and install plug (52).
372.7 – 465.8 Nm {38.0 – 47.5 kgm}
D155AX-5 30-269
(3)
3. Assembly of blade tilt valve spool

1) Assemble valve (51) and spring (50) to spool
(49), then temporarily tighten plug (48).
2) Assemble retainer (47), spring (46), and
retainer (45) to spool, then fit washer (44) to
bolt (43) and temporarily assemble.
3) Push spool assembly (42) into body to a
point where wrench fits spool portion [c], hold
spool in position with wrench, then tighten
3 Plug (48):
plug (48) and bolt (43), and push into body.
3 Bolt (43):
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
39.2 – 53.9 Nm {4.0 – 5.5 kgm}

4) Fit O-rings to cases (41) and (40), then
3 Case mounting bolt:

assemble to body.
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
4. Assembly of blade lift valve spool

1) Assemble valve (39) and spring (38) to spool
(36), then temporarily tighten plug (37).
2) Assemble retainer (35), spring (34), retainer
(33), and spacer (32) to spool (36), then fit
washer (31) to bolt (30) and temporarily
assemble.
3) Push spool assembly (29) into body to a
point where wrench fits spool portion [b],
hold spool in position with wrench, then
3 Bolt (30):
tighten bolt (30).
58.8 – 73.5 Nm {6.0 – 7.5 kgm}

4) Assemble spool assembly (29) to body (4),

then install case (28).
27.4 – 34.3 Nm {2.8 – 3.5 kgm}

5) Assemble retainer (27) and spring (26) from
opposite side, then fit O-ring to case (25) and

install to body.
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
30-270 D155AX-5
(3)
5. Assembly of ripper (tilt, lift) valve spool

1) Fit O-ring and ring to valve (15), assemble
spring (16) and valve (17), then assemble to
3 Valve (15):
bodies (3) and (2).
127.5 – 176.6 Nm {13.0 – 18.0 kgm}

2) Assemble retainer (24), then fit O-ring and
3 Plug (23):
ring to plug (23) and install to body.
274.6 – 367.7 Nm {28.0 – 37.5 kgm}

3) Install suction valve (22) and check valve
3 Suction valve (22):

(21).
3 Check valve (21):

58.8 – 78.5 Nm {6.0 – 8.0 kgm}
58.8 – 78.5 Nm {6.0 – 8.0 kgm}

4) Install plugs (20) and (18), and check valve
3 Plug (20):
(19).
3 Plug (18):
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
3 Check valve (19):

29.4 – 39.2 Nm {3.0 – 4.0 kgm}
19.6 – 27.5 Nm {2.0 – 2.8 kgm}

5) Assemble retainer (13), spring (12), retainer
(11), and spacer (10) to spool (14), then fit
washer (9) to bolt (8) and temporarily assem-
ble.
6) Push spool assembly (7) into body to a point
where wrench fits spool portion [a], hold
spool in position with wrench, then tighten
3 Bolt (8):
bolt (8).
58.8 – 73.5 Nm {6.0 – 7.5 kgm}

7) Assemble spool assembly to bodies (2) and

(3), and install cases (6) and (5).
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
6. Assemble bodies (2) and (3) to body (4), and
3 Mounting bolt:
tighten mounting bolts (1).
157.0 – 176.7 Nm {16.0 – 18.0 kgm}

a Assemble the O-ring at the body mating sur-
face securely.
D155AX-5 30-271
(3)
DISASSEMBLY AND ASSEMBLY HSS OIL COOLER BYPASS VALVE
REMOVAL OF HSS OIL

COOLER BYPASS VALVE
ASSEMBLY
kPark the machine on level ground, lower the
disconnect the cable from the negative (-) termi-
nal of the battery.
1. Remove operatorís seat and floor plate.

For details, see REMOVAL OF HYDRAULIC
PUMP ASSEMBLY.
2. Disconnect oil cooler hoses (1) and (2).
3. Disconnect hydraulic tank hose (3).
4. Disconnect charge relief valve hose (4).
5. Disconnect HSS pump hose (5).
6. Remove hose bracket (6).
7. Remove mounting bolts, then remove HSS oil

cooler bypass valve assembly (7).
INSTALLATION OF HSS OIL

COOLER BYPASS VALVE
ASSEMBLY
removal.
30-272 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY HSS OIL COOLER BYPASS VALVE
DISASSEMBLY AND ASSEMBLY OF HSS OIL COOLER BYPASS

VALVE ASSEMBLY
DISASSEMBLY ASSEMBLY
1. Remove plug (1), then remove shim (2) from a Clean all parts, and check for dirt or damage.
plug (1). Coat the sliding surfaces of all parts with engine
2. Remove spring (3) and spool (4) from body (5). oil before installing.
3. Remove plug (6). 1. Tighten plug (6).
2. Assemble spool (4) and spring (3) to body (5).
3. Assemble shim (2) to plug (1), and tighten plug
(3).
shims, then assemble.
Shim thickness: 0.5 mm
No. of shims: 2
D155AX-5 30-273
(3)
DISASSEMBLY AND ASSEMBLY BLADE PPC VALVE
REMOVAL OF BLADE PPC

VALVE ASSEMBLY
1. Remove operatorís seat assembly, remove 1

cover on inside right, then remove right side
cover of chassis.
4 Operatorís seat assembly : 55 kg

a Disconnect horn switch connector (CN-262)
at the same time.
4. Loosen lock bolt of lever (3), and pull out lever

(3) together with boot.
5. Disconnect pump hose (4). [*1]
6. Disconnect drain hose (5). [*2]
7. Disconnect PPC hose (6). [*3]
8. Remove blade PPC valve assembly (7). [*4]
30-274 D155AX-5
(3)
INSTALLATION OF BLADE
PPC VALVE ASSEMBLY
removal.
[*1] [*2] [*3]
a The connection position for the pump hose,

drain hose, and PPC hose are distinguished
by color bands at the caulking portion for the
hoses, so check the colors when connecting.
[*4]
a Set the PPC valve in the mounting direction
shown in the diagram on the right when
installing.
(The diagram on the right shows the PPC
valve as seen from the top of the panel.)

level.
D155AX-5 30-275
(3)
DISASSEMBLY AND ASSEMBLY RIPPER PPC VALVE
REMOVAL OF RIPPER PPC

VALVE ASSEMBLY
kFully lower work equipment to the ground.
Release the remaining pressure in the circuit.
HYDRAULIC CIRCUIT. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
1. Remove operator’ seat, remove 1 cover on

inside right, then remove side cover on right side
of chassis.
4 Operator’s seat: 55 kg

a Disconnect the horn switch connector
(CN262) at the same time.
3. Loosen lock bolt of lever (2), and pull out lever

(2) together with boot.
4. Remove lever guide.

Serial No. Only 75001 and up
5. Disconnect pump hose (4). [*1]
6. Disconnect drain hose (5). [*2]
7. Disconnect PPC hose (6). [*3]
8. Remove ripper PPC valve assembly (7). [*4]
30-276 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY RIPPER PPC VALVE
INSTALLATION OF RIPPER
PPC VALVE ASSEMBLY
removal.
[*1] [*2] [*3]
a The connection position for the pump hose,

drain hose, and PPC hose are distinguished
by color bands at the caulking portion for the
hoses, so check the colors when connecting.
[*4]
a Set the PPC valve in the mounting direction
shown in the diagram on the right when
installing.
(The diagram on the right shows the PPC
valve as seen from the top of the panel.)

level.
D155AX-5 30-277
(3)
DISASSEMBLY OF BLADE
PPC VALVE ASSEMBLY
1. Remove nut (1), then remove disc (2) and boot
(3).
2. Remove joint (4), then remove plate (5).
3. Remove seal (6) and collar (7).
4. Remove body (8).
5. Remove plate (9).
6. Remove orifice (10).
7. Remove blade TILT valve.
1) Remove pistons (11) and (12), retainer (13),
springs (14) and (15), and shim (16).
a Check the installation position (oil pres-
sure port) of spring (14), mark the spring
with a tag, and keep it in a safe place.
2) Pull out valve (17) from body (18).
8. Remove blade LOWER valve.
1) Remove piston (19), spacer (20), spring (21),
collar (22), ball (23), retainer (24), shim (25),
piston (26), retainer (27), springs (28) and
(29), and shim (30).
sure port) spring (28), mark the spring
9. Remove blade RAISE valve.
1) Remove piston (32), spring (33), piston (34),
retainer (35), springs (36) and (37), and shim
(38).
sure port) spring (36), mark the spring
30-278 D155AX-5
(3)
ASSEMBLY OF BLADE PPC

VALVE ASSEMBLY
1. Install blade RAISE valve.
1) Assemble valve (39) to body (18).
2) Assemble shim (38) and spring (37) to valve
(39).
a Install spring (37) with the small coiled
seat face (inside diameter) at shim (38)
end.
3) Assemble spring (36), retainer (35), piston
(34), spring (33), and piston (32).
a When assembling piston (34), coat the
outside circumference of the piston and
the inside circumference of the hole in
the body with grease (G2-LI).
inside circumference of the hole in the
body with grease (G2-LI).
2. Install blade LOWER valve.
(31).
end.
3) Assemble spring (28), retainer (27), piston
(26), shim (25), retainer (24), ball (23), collar
(22), spring (21), spacer (20), and piston
(19).
3. Install blade TILT valve.
(17).
end.
D155AX-5 30-279
(3)
3) Assemble spring (14), retainer (13), and pis-

tons (12) and (11).
3 Orifice : 11.8 ± 14.7 Nm {1.2 ± 1.5 kgm}

4. Install orifice (10).
5. Fit O-ring and install plate (9).

6. Fit O-ring and install body (8).
7. Fit O-ring to collar (7), then assemble to body (8)
and install seal (6).
3 Mounting bolt :
8. Install plate (5).
11.8 ± 14.7 Nm {1.2 ± 1.5 kgm}

9. Install joint (4).
a When installing the joint, coat the thread of
3 Joint : 44.1 ± 4.9 Nm {3.5 ± 0.5 kgm}

body (8) with adhesive (LT-2).
a Coat the sliding portion of the joint with

grease (G2- LI).
10. Assemble boot (3) and disc (2), and tighten with
nut (1).
a Coat the contact surface of disc (2) and pis-
3 Nut :
tons (32), (19), and (11) with grease (G2-LI).
112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}
a After installing the disc, adjust the disc

height.
Adjusting PPC valve.
30-280 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY BLADE LIFT CYLINDER
REMOVAL OF BLADE LIFT

CYLINDER ASSEMBLY
ground and stop the engine.
1. Sling head end of lift cylinder assembly, then

remove cap (1). [*1]
kStart the engine and retract piston rod fully,

then tie the piston rod with wire to prevent it

from coming out.
2. Sling lift cylinder assembly, then disconnect hose

(2).
kRelease the remaining pressure inside the
hydraulic circuit. For details, see TESTING
AND ADJUSTING, RELEASING REMAIN-
ING PRESSURE INSIDE HYDRAULIC CIR-
CUIT.
a Fit blind plugs to prevent dirt or dust from
entering the piping.
3. Remove cap (3) and lift off cylinder assembly (4).

[*2]
4 Blade lift cylinder assembly: 170 kg
LIFT CYLINDER ASSEMBLY
removal.
[*1]
a Standard shim thickness: 4 mm
2 Yoke: Grease (G2-LI)

[*2]
• Bleeding air
Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING.

level.
D155AX-5 30-281
(3)
DISASSEMBLY AND ASSEMBLY BLADE TILT CYLINDER
REMOVAL OF BLADE TILT

CYLINDER ASSEMBLY
ground and stop the engine.
1. Remove cylinder protection cover (1) and hose

protection cover (2).
2. Sling tilt cylinder assembly, remove bolt, then

disconnect cap (3) and remove shim. [*1]
kStart the engine and retract piston rod fully,

then tie the piston rod with wire to prevent it

from coming out.
3. Disconnect 2 hoses (4).

hydraulic circuit. For details, see TESTING AND
SURE INSIDE HYDRAULIC CIRCUIT.
a Fit blind plugs to prevent dirt or dust from enter-
ing the piping.
4. Remove lock bolt, then pull out pin (5) and lift off
cylinder assembly (6). [*2]
a Be careful not to damage the hose at the bot-
tom end when lifting off.
4 Blade tilt cylinder assembly: 190 kg
TILT CYLINDER ASSEMBLY
removal.
[*1]
2 Yoke: Grease (G2-LI)

[*2]
• Bleeding air

level.
30-282 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY RIPPER LIFT CYLINDER
REMOVAL OF RIPPER LIFT

CYLINDER ASSEMBLY
1. Sling lift cylinder assembly (1), then remove lock
kStart the engine and retract the piston rod fully.

plate and pull out pin (2) at head end. [*1]
kStop the engine and work equipment control

lever several times to release the pressure inside
the piping. Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank.

3. Remove lock plate, pull out pin (4) at bottom end

and lift off cylinder assembly (1). [*2]
4 Ripper lift cylinder assembly: 120 kg
a One pin (4) is supporting the bottom end of

the lift and tilt cylinders, so pull out the pin
only far enough to remove the lift cylinder.
LIFT CYLINDER ASSEMBLY
removal.
2 Pin: Grease (G2-LI)

[*1]

[*2]
• Bleeding air

level.
D155AX-5 30-283
(3)
DISASSEMBLY AND ASSEMBLY RIPPER TILT CYLINDER
REMOVAL OF RIPPER TILT

CYLINDER ASSEMBLY
1. Sling tilt cylinder assembly (1), then remove lock
kStart the engine and retract the piston rod fully.

plate and pull out pin (2) at head end. [*1]
kStop the engine and work equipment control

lever several times to release the pressure inside
the piping. Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank.

3. Remove lock plate and pull out pin (4). [*2]
4 Ripper tilt cylinder assembly: 125 kg
a One pin (4) is supporting the bottom end of

the lift and tilt cylinders, so when removing
the tilt cylinder assembly, put a block [1]
under lift cylinder (5) to prevent the lift cylin-
der from falling, or pull out the pin gradually
and set a temporary pin in the bottom end of
the lift cylinder.
TILT CYLINDER ASSEMBLY
removal.

[*1]

[*2]
• Bleeding air

level.
30-284 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF
HYDRAULIC CYLINDER
ASSEMBLY
(BLADE LIFT, BLADE TILT, RIPPER LIFT,
RIPPER TILT CYLINDER)
1. Tube
Remove tube.
2. Quick drop valve (blade lift cylinder only)

Remove block (1), and pull out spring (2), spacer
(3), valves (4), (5), and collar (6).
3. Piston rod assembly

• Blade lift cylinder
1) Set cylinder assembly (7) on tool Y1.
2) Using hydraulic pump or power wrench, dis-
connect head assembly (8) with tool Y2.
3) Pull out piston rod assembly (9).
a Place a container under the cylinder to
catch the oil.
• Blade tilt, ripper lift, ripper tilt cylinder

1) Remove mounting bolts, and disconnect
head assembly (10).
Cylinder Width across flats of bolt

Blade tilt 27 mm
Lift
Ripper 24 mm
Tilt
2) Pull out piston rod assembly (11).

a Place a container under the cylinder to
catch the oil.
4. Piston assembly
1) Remove mounting bolts, then remove spacer
(12), and pull out valve (13).
2) Pull out piston assembly (14).
3) Remove backup ring (15) and O-ring (16).
4) Remove retainer (17).
D155AX-5 30-285
(5)
5) Disassembly of piston assembly

i) Remove wear ring (18).
ii) Remove piston ring (19).
a Do not remove seat (20) and valve (21)
from the piston.

1) Remove mounting bolts, then remove spacer
(22).
2) Pull out piston assembly (23).
3) Remove backup ring (24) and O-ring (25).
4) Disassembly of piston assembly

i) Remove wear ring (26).
ii) Remove piston ring (27).
5. Head assembly
1) Remove head assembly (8) or (10).
30-286 D155AX-5
(3)
2) Disassembly of head assembly

i) Remove O-ring (28). (Blade lift cylinder
only)
ii) Remove O-ring (29) and backup ring
(30).
iii) Remove packing (31).
iv) Remove snap ring (32), then remove
dust seal (33).
v) Remove bushing (34).
D155AX-5 30-287
(3)
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
a Coat the sliding surfaces of all parts with engine
oil, and be careful not to scratch or damage the
rod packing, dust seal, or O-ring when installing.
1. Head assembly
1) Assembly of head assembly
i) Using tool Y3, press fit bushing (34).
ii) Using tool Y4, assemble dust seal (33),

and secure with snap ring (32).
iii) Assemble packing (31).
iv) Assemble backup ring (30) and O-ring

(29).
a Do not try to force the backup ring
into position. Warm it in warm water
(50 – 60°C) before fitting it.
v) Assemble O-ring (29). (Blade lift cylinder
only)
30-288 D155AX-5
(5)
2) Assemble head assembly (8) or (10) to pis-

ton rod.
2. Piston assembly
1) Assembly of piston assembly
i) Using tool Y5, expand piston ring (19).
a Set the piston ring on tool Y5 and
turn the handle 8 – 10 times to
expand the ring.
ii) Remove piston ring (19) from tool Y5,
and install to piston.
iii) Using tool Y5, compress piston ring (19).
iv) Assemble wear ring (18).
3) Fit O-ring (16) and install backup ring (15).

a Do not try to force the backup ring into
position. Warm it in warm water (50 –
60°C) before fitting it.
a Coat the O-ring and backup ring with
grease, and secure so that the backup
ring does not open.
4) Install piston assembly (14).
5) Assemble valve (13) to spacer (12), then fit
2 Mounting bolt:
spacer and tighten with mounting bolts.
3 Mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
D155AX-5 30-289
(5)

1) Using tool U3, assemble piston ring (27),
then assemble wear ring (26) in same way
as in Step 2-1) -i) – iv) above.
2) Assemble O-ring (25), backup ring (24), and

piston assembly (23) in same way as in Step
2-3) – 4) above.
3) Secure with spacer (22) and tighten with
2 Mounting bolt:
mounting bolts.
3 Mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
3. Piston rod assembly

1) Set cylinder (7) to tool Y1.
2) Assemble piston rod assembly (9) to cylin-
2 Seal portion: Grease (G2-LI)

der.
a Push the piston rod in to the end of its

stroke.
3 Head assembly:
3) Using tool Y2, tighten head assembly (8).
980.7 ± 98.1 Nm {100 ± 10 kgm}

1) Assemble piston rod assembly (11) to cylin-
2 Seal portion: Grease (G2-LI)

der (7).
a Push the piston rod in to the end of its

stroke.
30-290 D155AX-5
(5)
2) Tighten head assembly (10) with mounting
3 Mounting bolt:
bolts.
Unit: Nm {kgm}
Blade tilt 343.2 ± 34.3 {35 ± 3.5}
Ripper lift 245.2 ± 24.5 {25 ± 2.5}
Ripper tilt 245.2 ± 24.5 {25 ± 2.5}
4. Quick drop valve (blade lift cylinder only)

Assemble collar (6), valves (5), (4), spacer (3),
and spring (2), then fit O-ring and install block
(1).
5. Tube
Fit O-ring and install tube.
D155AX-5 30-291
(3)
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE
ASSEMBLY
ground at a flat place, then set blocks [1]
securely under the left and right straight frame.
1. Remove cap (1) of lift cylinder. [*1]

2. Sling lift cylinder assembly (2), start engine,

retract piston rod fully, then fit cylinder clamp and
secure to radiator guard.
a Tie the piston rod with wire to prevent it from
coming out.
• Disconnect the cylinder from the blade on

the opposite side in the same way.
hydraulic circuit. For details, see TESTING AND

SURE INSIDE HYDRAULIC CIRCUIT. Then
loosen the oil filler cap slowly to release the pres-
sure inside the hydraulic tank.
3. Remove left and right covers (3).

5. Remove left and right trunnion caps (5). [*2]
6. Remove blade assembly (6). [*3]

a Start the engine, drive the machine slowly in
reverse, and disconnect the blade assembly
from the trunnion.
30-292 D155AX-5
(3)
ASSEMBLY
removal.
[*1]
a Adjust with shims so that clearance a at the
cap mating surface is the dimension given
below. Check also that it rotates smoothly.
• Standard clearance a: 0.2 – 0.5 mm
• Standard shim thickness: 4 mm
a After installing the blade, adjust the blade tilt.
ADJUSTING SEMI U-TILTDOZER.
3 Trunnion cap mounting bolt:

[*2]
730.6 ± 98.1 Nm {74.5 ± 10 kgm}
[*3]
a Adjust with blocks [1] so that height b and
width c of the left and right straight frames is
the dimension below.
• Height b at trunnion: Approx. 633.5 mm
• Frame width c: Approx. 2,940 mm

level.
D155AX-5 30-293
(3)
DISASSEMBLY OF BLADE
ASSEMBLY
kPut blocks [1] and hydraulic jack [2] under left
and right straight frame and blade, and set
securely so that the blade is stable.
1. Remove right frame cover (1), and disconnect tilt

cylinder hose (2).
2. Sling tilt cylinder assembly (3), and remove lock

plate, then remove pin (4).
3. Remove mounting bolts, disconnect cap (5), then

lift off tilt cylinder assembly (3).
a There are shims at the cap portion, so check
the number and thickness of the shims, and
keep in a safe place.
4 Tilt cylinder assembly: 190 kg
4. Set block [1] under right center brace (6), and

remove mounting bolts of cap (7) at center frame
end.
30-294 D155AX-5
(3)
5. Sling right straight frame (8) and disconnect right

center brace (6).
6. Remove lock plate, then remove pin (9), and lift
off right straight frame (8).
4 Straight frame: 700 kg
7. Remove left frame cover (10).
8. Sling tilt brace (11), remove lock plate, then

remove pin (12).
9. Remove mounting bolts, disconnect cap (13),

then lift off tilt brace (11).
4 Tilt brace: 100 kg
10. Disconnect left center brace (14) and remove left

straight frame (15) in same way as in Steps 4 – 6
above.
11. Sling center brace (14), remove mounting bolts,

disconnect cap (16), then lift off left and right
center braces (14) and (6).
4 Center brace: 95 kg
12. Raise blade (17), then tip blade over.
4 Blade: 2,850 kg
D155AX-5 30-295
(3)
ASSEMBLY OF BLADE
ASSEMBLY
a Check the number and thickness of the shims
removed from each place during disassembly,
then assemble them again in the same position.
a When carrying out shim adjustment, see TEST-
ING AND ADJUSTING, ADJUSTING SEMI U-
TILTDOZER.
1. Raise blade (17), and insert block and hydraulic

jack under blade, and set securely so that the
blade is stable.
4 Blade: 2,850 kg
2. Raise center brace (14), assemble shim, and

tighten mounting bolts of cap (16).
a Set a block under the center brace to match
the height of the straight frame.
4 Center brace: 95 kg
3. Raise right center frame (8), then install pin (9)

and secure with lock plate.
4 Straight frame: 700 kg
4. Sling right center frame (8), then set spherical

portion of right center brace (6) to right center
frame (8).
5. Assemble shim to cap (7) of right center brace

(6), and tighten mounting bolts.
30-296 D155AX-5
(3)
6. Sling tilt cylinder assembly (3), assemble shim to

cap (5), then tighten mounting bolts.
7. Install pin (4), and secure with lock plate.
8. Connect tilt cylinder hose (2).
9. Install right frame cover (1).
10. Install left straight frame (15) and connect left

center brace (14) in same way as in Steps 3 – 5
above.
11. Sling tilt brace, assemble shim to cap (13), and

tighten mounting bolts.
4 Tilt brace: 100 kg
12. Install pin (12), and secure with lock plate.
13. Install left frame cover.
14. Greasing
After completion of assembly, grease the points
2 Parts of work equipment: Grease (G2-LI)

in the diagram on the right thoroughly.
D155AX-5 30-297
(3)
DISASSEMBLY AND ASSEMBLY MULTI-SHANK RIPPER
DISASSEMBLY OF MULTI-
SHANK RIPPER ASSEMBLY
a After disconnecting the pipes and hoses, cover
with blind plugs to prevent dirt or dust from enter-
ing.
1. Start engine and set ripper to maximum lift and

maximum tilt in.
2. Sling shank (1), remove lock pin, then remove

mounting pin (2), and lower shank (1) slowly to
remove.
4 Shank: 270 kg
3. Set stand [1] under beam and block [2] under

arm, then lower ripper assembly.
4. Sling lift cylinder assembly (3), remove lock

plate, then remove pin (4) at rod end.
a Start the engine, retract the piston rod fully,
then lower on top of the arm.
5. Sling tilt cylinder assembly (5), remove lock

plate, then remove pin (6) at rod end.
a Start the engine, retract the piston rod fully,
then lower on top of the arm.
a The pin is used when removing the beam, so
leave the pin temporarily installed to the
kRelease the remaining pressure in the circuit.

beam.

HYDRAULIC CIRCUIT. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
30-298 D155AX-5
(3)
6. Disconnect lift cylinder hose (7) and tilt cylinder

hose (8) and move towards fuel tank end.
7. Sling lift cylinder assembly (3), remove lock plate

and pull out pin (9), then lift off lift cylinder
assembly (3).
a The pin is the same for the lift cylinder and tilt
cylinder, so pull it out to a position where the
lift cylinder can be removed.
a The mounting bolt for the lock plate of the pin
on the right is also used to tighten the rear
lamp, so remove the rear lamp at the same
time.
4 Lift cylinder assembly: 120 kg
8. Sling tilt cylinder assembly (5), remove pin (9),

then remove tilt cylinder assembly (5).
9. Sling beam (10), remove lock plate, then remove

left and right pins (11), and lift off beam (10).
4 Beam: 1,230 kg
10. Sling arm (12), remove lock plate, then remove

left and right pins (13), and lift off arm (12).
4 Arm: 560 kg
D155AX-5 30-299
(3)
ASSEMBLY OF MULTI-SHANK
RIPPER ASSEMBLY
1. Raise arm (12), install left and right pins (13),
then secure with lock plate.
4 Arm: 470 kg
a Set block [2] under the arm.
2. Raise beam (10), install left and right pins (11),

then secure with lock plate.
4 Beam: 1,200 kg
a Set stand [1] under the beam.
3. Raise tilt cylinder assembly (5), then install pin

(9).
a The same pin is used for the tilt cylinder and
lift cylinder, so push it in to a position where
the tilt cylinder can be installed.

a After installing, lower the rod end on top of
the arm.
4. Raise lift cylinder assembly (3), then install pin

(9), then secure with lock plate.
a The mounting bolt for the lock plate of the pin
on the right is also used to tighten the rear
lamp, so install the rear lamp at the same
time.
4 Lift cylinder assembly: 120 kg

a After installing, lower the rod end on top of
the arm.
5. Connect tilt cylinder hose (8) and lift cylinder

hose (7).
30-300 D155AX-5
(3)
6. Sling tilt cylinder assembly (5), start engine,

extend piston rod, align pin holes, then install pin
(6) and secure with lock plate.
7. Sling lift cylinder assembly (3), start engine,

extend piston rod, align pin holes, then install pin
(4) and secure with lock plate.
8. Start engine and set ripper to maximum lift and

maximum tilt in.
9. Pass wire from shank mounting hole in beam,

raise shank (1), and install, then install pin (2)
and secure with lock pin.
4 Shank: 270 kg
10. Greasing
After finishing assembling, apply sufficient

amount of grease to all the pins.

level.
D155AX-5 30-301
(3)
DISASSEMBLY AND ASSEMBLY ROPS GUARD
REMOVAL OF ROPS GUARD

ASSEMBLY
1. Sling ROPS guard (1) and remove 12 mounting
bolts (2). [*1]
2. Lift off ROPS guard (1).
4 Rops guard: 470 kg
INSTALLATION OF ROPS
GUARD ASSEMBLY
removal.
3 ROPS guard mounting bolt:

[*1]
926.8 ± 103.0 Nm {94.5 ± 10.5 kgm}
30-302 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
REMOVAL OF OPERATOR'S
CAB ASSEMBLY
1. Remove the ROPS guard. For details, see

Removal of ROPS guard.
2. Open cover (1) on the left side of the operator's

cab.
3. Disconnect wiring intermediate connector (2)

(CN-19), washer hose (3), and cab power supply
connectors (4) (CN-20) and (5) (CN-21).
a After disconnecting the connectors, pull out
the wires from inside of the operator's cab.
4. Remove bolt (7) and bracket (6).
5. Remove pedal cap (8).
6. Remove right and left bolts (10) and foot rest (9).
D155AX-5 30-303
(3)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
7. Remove lower mounting bolts (11) of the opera-

tor's cab.
a Remove the bolts on both sides.
8. Remove cigarette lighter (14) and disconnect

accessory socket wiring connector CN-D.
9. Remove garnishes (15), (16), and (17).
10. Remove mounting bolts (18) in the operator's

cab.
a Remove all the bolts at the right, left, and
rear.
11. Lift off operator's cab assembly (19).
4 Operator's cab assembly: 410 kg
INSTALLATION
removal.
[*1]
a Connect the windshield washer hoses
according to their color bands.
Windshield washer hoses

Red ----- Right door
Blue -----Left door
Black ---Rear window
— -------Front window
30-304 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY HOOD
REMOVAL OF HOOD
ASSEMBLY
1. Remove exhaust pipe (1).
2. Remove air cleaner hood (2).
3. Loosen clamp (3) and disconnect connector (4)

from hood end.
4. Lift off hood assembly (5).
4 Hood assembly: 90 kg
INSTALLATION OF HOOD
ASSEMBLY
removal.
D155AX-5 30-305
(3)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
disconnect the cable from the negative (-) termi-
nal of the battery.
1. Remove operator cab assembly.

For details, see REMOVAL OF OPERATOR CAB
ASSEMBLY.
2. Remove the dashboard assembly. For details,

see REMOVAL OF DASHBOARD ASSEMBLY.
3. Lift off operator’s seat (1).
4 Operator’s seat assembly : 55 kg
4. Remove foot rest assembly (2).
6. Remove left armrest (4) and right armrest (5).

7. Remove right side covers (6) and (7).
8. Remove left side covers (8) and (9).
9. Disconnect headlamp wiring connector (10)

(CN-101).
10. Disconnect engine monitor wiring connector (11)
(CN-E22).
11. Disconnect fuel line wiring connector (12)
(CN-E21).
12. Disconnect pitch angle sensor intermediate con-
nector (13).
30-306 D155AX-5
(3)
13. Disconnect wiring connectors (24) (CN-105) and

(25) (CN-104) between battery relay and fuse
box.
14. Disconnect chassis ground (26).
15. Disconnect wiring connectors (27) (CN-153),

(28) (LPL), (29) (CN-451), and (30) (CN-701).
a Disconnect the wiring clamps (2 places).
Tightened together with ground (CN-456).
16. Disconnect window washer motor wiring connec-

tors (31) (CN-361), (32) (CN-362), (33) (CN-
363), and (34) (CN-364).
17. Disconnect wiring clamp (35).
a Gather wiring harnesses together and move
towards floor frame.
18. Disconnect return hoses (36) and (37) coming

from blade and ripper control PPC valves.
D155AX-5 30-307
(3)
19. Disconnect PPC hose (38) (white) (ripper TILT

BACK).
20. Disconnect PPC hose (39) (black) (ripper DOWN).
21. Disconnect PPC hose (40) (colorless) (blade LOWER).
22. Disconnect PPC hose (41) (green) (blade left
tilt). [*2]
23. Disconnect clamp (42).

24. Disconnect hose (43) between lock valve and
charge filter.
25. Disconnect PPC hose (44) (red) (ripper TILT IN).

26. Disconnect PPC hose (45) (colorless) (ripper
UP).
27. Disconnect PPC hose (46) (black) (blade RAISE).
28. Disconnect PPC hose (47) (yellow) (blade right
tilt). [*2]
29. Disconnect parking brake cable (52) from brake

valve, and remove bracket (53) from HSS case.
30. Disconnect brake control rod (54) from brake
valve.
30-308 D155AX-5
(3)
31. Remove 8 front mount bolts (55) left and right.
32. Remove 8 suspension mounting bolts (56).
33. Lift off floor frame assembly (57).
4 Floor frame assembly : 180 kg
a Control with a lever block to avoid interfer-

ence when removing.
D155AX-5 30-309
(3)
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.
[*1]
ence.
a Install the hoses carefully to prevent dirt,
dust, or water from getting inside the hoses.
a Check that the O-ring is fitted to the hose
joint, and then apply compressor oil and con-
nect the hose.
[*2]
a The positions for connecting the PPC hoses
are distinguished by color bands at the quick
coupler, so check the colors when installing.
30-310 D155AX-5
(3)
DISASSEMBLY AND ASSEMBLY DASHBOARD
REMOVAL OF DASHBOARD
ASSEMBLY
disconnect the cable from the negative (–) termi-
nal of the battery.
1. Remove operator’s cab assembly.
For details, see REMOVAL OF OPERATOR’S
CAB ASSEMBLY.
2. Disconnect wiring connectors (1) (214), (2)

(S13), (3) (215), and (4) (216).
3. Disconnect air conditioner hoses (5) and (6).

a Using tool X, collect freon gas (R134a).
4. Remove bracket (7), and move receiver tank

towards outside.
6. Disconnect 2 heater hoses (9).

a Close the heater hose valve at the engine
end.
a After disconnecting, fit with blind plugs.
7. Remove covers (10) and (11).
D155AX-5 30-311
(3)
DISASSEMBLY AND ASSEMBLY DASHBOARD
8. Sling dashboard assembly (13) temporarily and

remove mounting bolts (12).
9. Lift off dashboard assembly (13).
4 Dashboard assembly : 85 kg
INSTALLATION OF
DASHBOARD ASSEMBLY
removal.
[*1]
ence.
connection of the air conditioner hoses, and
coat the O-rings thoroughly with compressor
oil before connecting.

Using tool Z, charge air conditioner circuit with
new freon gas (R134a).
30-312 D155AX-5
(5)
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
ASSEMBLY
kDisconnect the cable from the negative (–) termi-
nal of the battery.
1. Remove mounting bolts and open monitor

assembly (1).
2. Disconnect connectors (2) (S04 and S03), and

remove monitor assembly (1).
INSTALLATION OF MONITOR
ASSEMBLY
removal.
D155AX-5 30-313
(3)
DISASSEMBLY AND ASSEMBLY HSS CONTROLLER
REMOVAL OF HSS
CONTROLLER ASSEMBLY
kDisconnect the cable from the negative (–) termi-
nal of the battery.
1. Remove operator’s seat (1).
2. Remove covers (2) and (3)
3. Remove bolt (4) and controller (5) and discon-

nect the HST controller wiring connectors (CN-
STC1, CN-STCN2, and CN-STC3) and engine
wiring connectors (CN-EGC1, CN-EGC2, and
CN-EGC3).
4. Remove HSS controller assembly.
INSTALLATION OF HSS
CONTROLLER ASSEMBLY
removal.
30-314 D155AX-5
(3)
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
(2)
D155AX-5 90-9
(2)
D155AX-5 90-11
(2)
D155AX-5 90-13
(2)
D155AX-5 90-15
(2)
D155AX-5 90-17
(2)
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB
D155AX-5 90-19
(2)
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER
D155AX-5 90-21
(2)

D155ax-5 Sebm034805

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D155ax-5 Sebm034805

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SEBM034805

MACHINE MODEL SERIAL NUMBER

D155AX-5 76001 and up

• D155AX-5 mounts the SA6D140E-3 engine.

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

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

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

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 (5) 10- 6 10-52 10- 97 10-141

10-185 20-126 (2) 20-185 (2) 20-321 (2) 20-380 (2)

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