Professional Documents
Culture Documents
155C Shantui
155C Shantui
• 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.
© 2004
All Rights Reserved 00-1
Printed in Japan 10-04 (01)
Contents
No. of page
01 General .......................................................................................................................... 01-1
40 Maintenance standard.........................................................................................40-1
00-2 D155C-1
Safety Safety notice
Safety
Safety notice
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 dangerous situa-
tion 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
Mistakes in operation are extremely dangerous. tools and removed parts. Always keep the tools
Read the Operation and Maintenance Manual care- and parts in their correct places. Always keep
fully BEFORE operating the machine. the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the
1. Before carrying out any greasing or repairs, read areas provided for smoking. Never smoke while
all the precautions given on the decals which working.
are fixed to the machine.
Preparations for work
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose 7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing. the machine on hard, level ground, and block
• Always wear safety glasses when hitting the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Always wear safety glasses when grinding
parts with a grinder, etc. 8. Before starting work, lower blade, ripper, bucket
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
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's Always use the handrails, ladders or steps when
compartment. getting on or off the machine. Never jump on or
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 with
Before disconnecting or removing components
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 carrying
that connecting parts are correctly installed.
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-
ticularly careful to check that they are installed
14. When raising heavy components, use a hoist or
correctly.
crane.
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.
Install the lifting equipment at the correct places.
23. When measuring hydraulic pressure, check that
Use a hoist or crane and operate slowly to pre-
the measuring tool is correctly assembled
vent the component from hitting any other part.
before taking any measurements.
Do not work with any part still raised by the hoist
or crane.
24. Take care when removing or installing the tracks
of track-type machines.
15. When removing covers which are under internal
When removing the track, the track separates
pressure or under pressure from a spring,
suddenly, so never let anyone stand at either
always leave two bolts in position on opposite
end of the track.
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
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.
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 General
k
available. Special safety precautions
Safety are necessary when
performing the work.
Distribution and updating Special technical
Any additions, amendments or other changes will be precautions or other
sent to KOMATSU distributors. Get the most up-to- a Caution precautions for preserving
date information before you start any work. standards are necessary
when performing the work.
Filing method Weight of parts of systems.
1. See the page number on the bottom of the page. Caution necessary when
4
File the pages in correct order. Weight selecting hoisting wire, or
when working posture is
2. Following examples show how to read the page
important, etc.
number.
Places that require special
3
Example 1 (Chassis volume): Tightening
attention for the tightening
torque
10 - 3 torque during assembly.
2
Places to be coated with
Item number Coat adhesives and lubricants,
(10. Structure and Function) etc.
Consecutive page number for
5
each item. Places where oil, water or
Oil, water fuel must be added, and
Example 2 (Engine volume): the capacity.
12 - 5 Places where oil or water
6
Drain must be drained, and
Unit number (1. Engine) quantity to be drained.
Item number
(2. Testing and Adjusting)
Consecutive page number for
each item.
00-6
Foreword Hoisting instructions
Hoisting instructions
Hoisting
Slinging near the edge of the hook may
k
cause the rope to slip off the hook during
Heavy parts (25 kg or more) must be lifted
hoisting, and a serious accident can result.
with a hoist, etc. In the Disassembly and
Hooks have maximum strength at the mid-
assembly section, every part weighing 25
dle portion.
kg or more is indicated clearly with the
symbol 4
interference with the part to be removed. 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
Wire ropes symmetrically wound onto the load.
k
1) Use adequate ropes depending on the
Slinging with one rope may cause
weight of parts to be hoisted, referring to the
turning of the load during hoisting,
table below:
untwisting of the rope, or slipping of the
Wire ropes rope from its original winding position on
(Standard “Z” or “S” twist ropes the load, which can result in a dangerous
without galvanizing) accident.
Rope diameter Allowable load
mm kN tons 4) Do not sling a heavy load with ropes forming
10 9.8 1.0 a wide hanging angle from the hook.
11.5 13.7 1.4 When hoisting a load with two or more
12.5 15.7 1.6 ropes, the force subjected to each rope will
14 21.6 2.2 increase with the hanging angles. The table
16 27.5 2.8 below shows the variation of allowable load
18 35.3 3.6 kN {kg} when hoisting is made with two
20 43.1 4.4 ropes, each of which is allowed to sling up
22.4 54.9 5.6
to 9.8 kN {1000 kg} vertically, at various
30 98.1 10.0
hanging angles.
40 176.5 18.0
50 274.6 28.0 When two ropes sling a load vertically, up to
60 392.2 40.0 19.6 kN {2000 kg} of total weight can be
suspended. This weight becomes 9.8 kN
a The allowable load value is estimated to be {1000 kg} when two ropes make a 120?
one-sixth or one-seventh of the breaking hanging angle. On the other hand, two
strength of the rope used. ropes are subjected to an excessive force
as large as 39.2 kN {4000 kg} if they sling a
2) Sling wire ropes from the middle portion of 19.6 kN {2000 kg} load at a lifting angle of
the hook. 150°.
00-7
Foreword Method of disassembling, connecting push-pull type coupler
Disconnection
1) Release the residual pressure from the
hydraulic tank. For details, see “Testing and
adjusting”, Releasing residual pressure from
hydraulic tank.
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).
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 and push body (2) in straight until sliding
prevention ring (1) contacts contact surface a of prevention 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 lever 2) Hold in the condition in Step 1), and push until
(4) to the right (clockwise). 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 pull 3) Hold in the condition in Steps 1) and 2), and pull
out whole body (2) to disconnect it. out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion and • Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the ring (1) contacts contact surface a of the
hexagonal portion at the male end to connect it. hexagonal portion at the male end to connect 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
00-10
Foreword Coating materials
Category Komatsu code Part No. Q’ty Container Main applications, featuresr
00-11
Foreword Standard tightening torque
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
00-12
Foreword Standard tightening torque
00-13
Foreword Standard tightening torque
2) Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
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.
Thread diameter Tightening torque
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}) Face seal type
Nominal type
Width
size of Nominal thread size
across flats Thread size Root diameter
hose Range Target – Threads per inch,
(mm) (mm) (Reference)
Thread series
9
02 19 34 – 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
16
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 — —
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 1 – 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 — —
00-14
Foreword Electric wire code
Classification by thickness
Copper wire
Norminal Cable O.D. Current rating
Number of Dia. of Cross section Applicable circuit
number (mm) (A)
strands strands (mm2) (mm2)
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
White & White & Red & Rellow & Green & Blue &
Color —
Red Black White Red White White
Code WB — BY RB YB GR LR
3
White & Black & Red & Yellow & Green & Blue &
Color —
Black Yellow Black Black Red Yellow
Code WL — BR RY YG GY LY
4 Auxiliary
White & Black & Red & Yellow & Green & Blue &
Color —
Blue Red Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5
White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6
Yellow & Green &
Color — — — Red & Blue —
White 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.
(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
Foreword Conversion table
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
Foreword Conversion table
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
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
Foreword Conversion table
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
Foreword Conversion table
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
Foreword Conversion table
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centi-
grade 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
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
01 General
D155C-1 01-1
General General assembly drawing
01-2 D155C-1
General Specifications
Specifications
Gradeability deg. 30
Overall
height
Up to top of counterweight
(With counterweight extracted) mm 3,020
D155C-1 01-3
General Specifications
Name SA6D140E-2
Starting motor 24 V, 11 kW
Alternator 24 V, 50 A
Battery 12 V, 170 Ah
01-4 D155C-1
General Specifications
D155C-1 01-5
General Specifications
Equipment
• Wire rope: 20 mm in diameter, having minimum breaking load of 27,600 kg
• Number of wire ropes for the hook: 6
• Number of wire ropes for the boom: 5
• Counterweight pushed out: 9,230 kg
Pulley efficiency is included.
01-6 D155C-1
General Weight table
Weight table
k This weight table is a guide for use when transporting or handling components.
Unit: kg
• Engine 1,750
Universal joint 25
01-8 D155C-1
General Weight table
Unit: kg
Track frame
• Carrier roller 65
Bumper 160
Front: 200
Floor frame assembly
Rear: 430
• Counterweight pump 24
• Transmission pump 21
• Steering pump 26
• Winch pump 29
D155C-1 01-9
General Table of fuel, coolant and lubricants
01-10 D155C-1
General Table of fuel, coolant and lubricants
–50°C Specification
D155C-1 01-11
General Table of fuel, coolant and lubricants
Note
1) When fuel sulphur content is less than 0.5 %,
c h a n g e o i l i n t h e o i l pa n e v e r y p e r i o d i c
maintenance hours described in this manual.
Change oil according to the following table if fuel
sulphur content is above 0.5 %.
Change interval of oil
Fuel sulphur content
in engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
01-12 D155C-1
10 Structure and function
D155C-1 10-1
Structure and function Radiator fan
Radiator fan
10-2 D155C-1
Structure and function Radiator fan
The radiator is composed of three parts, upper tank After its temperature has been lowered, the cooling
(1), radiator core (16) and lower tank (14). water in the lower tank is forced by the water pump
The cooling water passes the engine thermostat and back to the engine cylinder block.
goes to the upper tank where it stays for a short time The upper tank is equipped with a vacuum valve
to remove the air contained in it. The cooling water which keeps the pressure in the upper tank within 74
then flows from the upper tank to the lower tank, kPa {0.75 kg/cm2}. This is to prevent cooling water
passing through the radiator core. Here, heat is dis- from boiling at more than 100°C and forming air bub-
persed by radiation to reduce the temperature of the bles in the cooling water.
cooling water to 85 – 95°C, the most suitable tem- In addition, there is a tube (11) between the upper
perature for the engine. tank and the inlet tube of water pump. The function
The core consists of a number of flat drawn tubes (9) of tube (11) is to supply cooling water from the upper
and fins (10) which increase the heat dispersal effi- tank to prevent the formation of air bubbles at the
ciency. There are two types, D type and G type, inlet of the water pump.
divided according to the arrangement of the tubes. Radiator fan (17) is driven by the V-belts round the
The radiator of the D155C is of the in-line type (D pulleys attached to the engine, and forces air to the
type). core to increase the heat dispersal efficiency of the
core.
The D155C employs the air push-type to send air to
the radiator.
D155C-1 10-3
Structure and function Radiator shutter
Radiator shutter
10-4 D155C-1
Structure and function PTO (Power Take-Off)
D155C-1 10-5
Structure and function Oil cooler
Oil cooler
10-6 D155C-1
Structure and function Power train diagram
10-8 D155C-1
Structure and function Power train diagram
D155C-1 10-9
Structure and function TORQFLOW hydraulic circuit
10-10 D155C-1
Structure and function Hydraulic circuit diagram
D155C-1 10-11
Structure and function Torque converter
Torque converter
10-12 D155C-1
Structure and function Torque converter
D155C-1 10-13
Structure and function Torque converter
1. Transmission of power
The power generated by the engine is transmit-
ted to pump (5). This pump, drive gear (1), and
drive case (2) are made in 1 unit rotated
together.
The power transmitted to the pump rotates tur-
bine (3) with the oil. Accordingly, the power is
transmitted to turbine shaft (10) and coupling (9)
which is made together with the turbine in 1 unit.
The power transmitted to the coupling is trans-
mitted through the universal joint to the input
shaft of the transmission.
2. Flow of oil
The oil pressure is regulated to 0.85 MPa {8.7
kg/cm 2 } by the torque converter relief valve.
Then, the oil flows through port A and the oil
hole in stator shaft (7) into pump (5). Since the
pump is constantly rotated by the engine power,
the oil in it is given centrifugal force and flows in
turbine (3), which is rotated by the centrifugal
force of the oil.
Since the turbine and turbine shaft (10) are
made in 1 unit, the power received by the tur-
bine is transmitted to the transmission.
The oil flowing out of turbine (3) is sent to stator
(12) and flows in pump (5) again. A part of it is
sent from stator shaft (7) through port B to the
oil cooler, however.
10-14 D155C-1
Structure and function Torque converter
Outline
Model D155C is equipped with a three-element, one
stage, single phase torque converter which uses
fluid to carry out automatic torque conversion,
depending upon machine load, while transmitting
power from the engine. The principle components of
the torque converter are pump (5) for converting
mechanical energy from the engine into kinetic
energy of fluid, turbine (3) for reconverting the trans-
mitted kinetic energy into mechanical energy, and
stator (12) for guiding the fluid flow.
When drive gear (1), meshing with the internal teeth
of the flywheel, is rotated by engine starting, pump
(5), constituting a unit with the drive gear and drive
case (2), and mounted on stator shaft (7) with the
bearing, is rotated.
By this rotation, the fluid is thrown outward from the
pump along the pump blades by centrifugal force,
and flows helically to the turbine.
The fluid is impelled with force against the blades of
the turbine and changes its direction toward stator
(12).
The reaction developed at the blades by this action
causes the turbine to rotate, and power is transmit-
ted by turbine shaft (10).
The fluid at the turbine is directed from the central
part of the turbine to the stator where its direction is
changed, and finally returned to the central part of
the pump.
In short, while the fluid flows in the order of pump o
turbine o stator o pump, power is continuously
delivered from the pump to the turbine shaft, from
which it is then transmitted to the universal joint.
The stator used in model D155C is fixed securely on
the stator shaft spline, and does not rotate.
The torque converter (comprising, as already men-
tioned, one pump, one turbine, and one fixed stator)
is referred to as three-element, one stage, single
phase torque converter.
D155C-1 10-15
Structure and function Torque converter
Scavenging pump
Oil oozing out from between contacting faces of
pump, turbine, and stator and PTO lubricating oil is
drained into the torque converter housing after lubri-
cating each sliding part.
Oil collected in the torque converter housing is recir-
culated through strainer (15) to the steering case by
means of scavenging pump (13) which is driven by
gears (14) provided on the back face of the torque
converter pump.
10-16 D155C-1
Structure and function Transmission control
Transmission control
Lever position
N: Neutral
A: Forward 1st
B: Forward 2nd
C: Forward 3rd
D: Reverse 1st
E: Reverse 2nd
F: Reverse 3rd
G: Free
H: Lock
D155C-1 10-17
Structure and function Transmission
Transmission
D155C-1 10-19
Structure and function Transmission
10-20 D155C-1
Structure and function Transmission
D155C-1 10-21
Structure and function Transmission
Outline
Model D155C is equipped with planetary type trans-
mission (F3, R3) and is a combination of planetary
gear system and disc clutch.
For each revolution direction and rpm, two of 5 disc
clutches of the planetary gear system are hydrauli-
cally locked by actuating the control valve.
No. 1 clutch is for Forward, No. 2 for Reverse, No. 3
for 3rd speed, No. 4 for 2nd speed, and No. 5 for 1st
speed.
10-22 D155C-1
Structure and function Transmission
D155C-1 10-23
Structure and function Transmission
10-24 D155C-1
Structure and function Transmission
Operation of transmission
• In the forward 1st speed, No. 1 clutch and No. 5 • When No. 5 clutch is connected, ring gear (22),
clutch are connected, ring gear (14) is fixed and carrier (32), clutch drum (33) and gear (34) are
gear (34) and output shaft (41) are directly con- combined like a unit.
nected to output power. • As the carrier rotates, the power rotates all of
• Power from the torque converter is transmitted ring gear (22), carrier (32), clutch drum (33),
to input coupling (6) and then to input shaft (7), gear (34) and sun gear (26). Output shaft (41)
sun gear (10) and planetary pinion (13). rotates in the same direction with sun gear (10)
• Since ring gear (14) is fixed, planetary pinion to transmit the power.
(13) rotates on its own axis and moves around • The rotation of output shaft (41) is transmitted to
sun gear (10) along ring gear (14). transfer drive gear (42), transfer driven gear (47)
• And carrier (21) transmits power rotating in the and is output from bevel pinion (44) as a rotation
same direction with sun gear (10). in reverse direction from the input direction.
D155C-1 10-25
Structure and function Transmission
10-26 D155C-1
Structure and function Transmission control valve
D155C-1 10-27
Structure and function Transmission control valve
10-28 D155C-1
Structure and function Transmission control valve
1. Upper valve
2. Lower valve
3. Valve set
4. Stopper cover
5. Spring
6. Spring
7. Spring seat
8. Spring
9. Upper valve body
10. Modulating relief valve spool
11. Modulating relief valve sleeve
12. Piston
13. Spring
14. Piston
15. Stopper
16. Cover
17. Quick return valve sleeve
18. Quick return valve
19. Piston
20. Spring
21. Piston
22. Reducing valve
23. Spring
24. Stopper
25. Stopper
26. Directional valve spool
27. Lower valve body
28. Speed valve spool
D155C-1 10-29
Structure and function Transmission control valve
Modulating valve
Outline
• The modulating valve consists of a modulating
relief valve and a quick return valve and is
intended for pressure modulating and main
relief.
• When the gear shift lever is changed over, the
clutch is crimped with the piston. When a high
pressure is applied suddenly, the piston will con-
nect the clutch quickly and the machine will start
immediately or be subjected to an excessive
shock.
So, the modulating valve is installed to rise the
oil pressure applied to the piston slowly to the
set pressure when the gear shift lever is
changed over. It helps to engage the clutch
smoothly without shock at the time of starting, to
improve durability of the power train and to
make the operation comfortable.
Set pressure: 2.26 +0.2 +2
–0.1 MPa {23 –1 kg/cm }
2
10-30 D155C-1
Structure and function Transmission control valve
Operation
1. Right after gear shift
• When the gear shift lever is changed over to
engage the clutch, the passage from the pump
to the clutch piston will open and oil will flow in
the clutch piston. This oil flow moves quick
return valve (18) to the left, and the passage
from chamber A to drain port B opens to release
the back pressure of modulating relief valve
sleeve (11).
Then, the reaction force of springs (5), (6) and
(8) return modulating relief valve spool (10) and
modulating relief valve sleeve (11) to the right
and closes the passage to the torque converter.
D155C-1 10-31
Structure and function Transmission control valve
10-32 D155C-1
Structure and function Transmission control valve
Reducing valve
Outline
• The reducing valve is located in the circuit
between the modulation valve and the speed
valve and reduces the oil pressure applied to the
1st speed clutch below the set pressure of the
modulation valve.
• A rotary clutch is adopted as the 1st speed
clutch of the transmission of a machine on which
the reducing valve is installed.
If the same oil pressure applied to other clutches
is applied to the 1st speed clutch and the clutch
is engaged, an excessive oil pressure much
higher than the clutch capacity will be applied to
the 1st speed clutch. Therefore, the clutch disc
and the clutch plate will be damaged and the
seal ring will be overloaded. As a result, the
clutch will easily come to slip due to oil leak.
So, the reducing valve is installed mainly to pro-
tect the 1st speed clutch (rotary clutch).
Operation
1. Valve "Open"
When oil from the pump fills the whole circuit
and closes the ball check valve of the 1st speed
piston housing, the oil pressure in the whole cir-
cuit including the 1st speed clutch circuit will
start rising.
The modulating valve lets the oil pressure rise
slowly, but the oil passed through orifice "a" of
reducing valve (22) pushes piston (19). As the
oil pressure rises, the reaction force moves
reducing valve (22) gradually to the left and
starts throttling the 1st speed clutch circuit.
2. Valve "Close"
When the modulating valve lets the oil pressure
in the whole circuit rise further, reducing valve
(22) will move more to the left, keep throttling
the 1st speed clutch circuit, come to the stopper
and will not move any more. At the time, the 1st
speed clutch circuit closes the passage from the
modulating valve, and the oil pressure in the cir-
cuit comes not to rise.
When the oil pressure drops due to lubrication of
the transmission or oil leak from the seal ring,
the reaction force of spring (23) will open the 1st
speed clutch circuit, raise the dropped oil pres-
sure to the set pressure of reducing valve (22)
and will maintain the oil pressure at the set pres-
sure.
Set pressure: 1.27 +0.2 +2
–0.1 MPa {13 –1 kg/cm }
2
D155C-1 10-33
Structure and function Transmission lubrication relief valve
10-34 D155C-1
Structure and function Steering and brake control
D155C-1 10-35
Structure and function Axle, steering clutch
10-36 D155C-1
Structure and function Axle, steering clutch
D155C-1 10-37
Structure and function Axle, steering clutch
10-38 D155C-1
Structure and function Steering brake hydraulic piping
D155C-1 10-39
Structure and function Steering and brake hydraulic circuit diagram
10-40 D155C-1
Structure and function Steering and brake hydraulic circuit diagram
Brake
D155C-1 10-41
Structure and function Steering brake
Steering brake
10-42 D155C-1
Structure and function Steering brake
D155C-1 10-43
Structure and function Steering brake
10-44 D155C-1
Structure and function Steering brake
D155C-1 10-45
Structure and function Steering brake
10-46 D155C-1
Structure and function Steering control valve
10-48 D155C-1
Structure and function Steering control valve
D155C-1 10-49
Structure and function Steering control valve
10-50 D155C-1
Structure and function Steering control valve
D155C-1 10-51
Structure and function Steering control valve
10-52 D155C-1
Structure and function Final drive
Final drive
D155C-1 10-53
Structure and function Final drive
10-54 D155C-1
Structure and function Track group
Track group
1. Idler
2. Rod
3. Carrier roller
4. Recoil spring
5. Carrier roller
6. Track roller guard
7. Track roller (D)
8. Track roller (S)
D155C-1 10-55
Structure and function Recoil spring
Recoil spring
10-56 D155C-1
Structure and function Suspension
Suspension
1. Bar
2. Shim
3. Washer
D155C-1 10-57
Structure and function Winch control
Winch control
Winch
Lever position
Winch high-low control lever
N: NEUTRAL
A: LOW
B: HIGH
Hook control lever
C: LOWER
N: NEUTRAL
D: RAISE
E: FREE FALL
Lock lever
F: FREE
L: LOCK
10-58 D155C-1
Structure and function Winch control
Boom
D155C-1 10-59
Structure and function Winch control
10-60 D155C-1
Structure and function Hydraulic circuit diagram for winch
D155C-1 10-61
Structure and function Winch
Winch
10-62 D155C-1
Structure and function Winch
D155C-1 10-63
Structure and function Winch
10-64 D155C-1
Structure and function Winch
Winch clutch
1. Drum
2. Piston
3. Drum (inner)
4. Disc
5. Plate
6. Drum (outer)
7. Plate
8. Drum (outer)
9. Shaft
10. Plate
11. Bolt
D155C-1 10-65
Structure and function Winch
Winch brake
1. Drum (inner)
2. Cover
3. Disc
4. Plate
5. Drum (outer)
6. Piston
7. Cover
8. Shaft
10-66 D155C-1
Structure and function Detailed working circuit diagram for clutch and brake of winch
D155C-1 10-67
Structure and function Detailed working circuit diagram for clutch and brake of winch
Operation
• Oil from oil pump is distributed by flow divider to
two oil circuits: The control circuit which includes
the PPC valve, and the lubrication circuit for var-
ious component parts. Oil distributed to control
circuit flows to individual clutches and brakes.
The direction of oil flow to a clutch or brake is
varied depending on operation of PPC valve.
• When a PPC valve spool is moved to the left, oil
pressure actuates the corresponding clutch pis-
ton to engage clutch. At the same time, oil pres-
sure releases the corresponding brake.
• When clutch piston reaches its stroke end, PPC
valve spool is returned to neutral position, open-
ing the oil drain port, so that oil pressure in cir-
cuit leading to clutch piston is prevented from
increasing further.
Spring-loaded brakes are normally actuated,
clutches are normally disengaged.
• When releasing a brake, it is necessary to push
the brake piston by hydraulic pressure against
return spring force. When engaging a clutch,
clutch disc is compressed by hydraulic pressure.
10-68 D155C-1
Structure and function Power train on winch
Operation
• The PTO input shaft (winch No. 1 shaft) is con-
nected to the Hi-Low clutch first. Since each
lever is in neutral, however, the hydraulic oil
from the PPC valve is drained and the power is
not transmitted.
D155C-1 10-69
Structure and function Power train on winch
Operation
• Since the Hi-Low lever is in the "Low" position,
the hydraulic oil from the PPC valve flows in the
Low clutch.
10-70 D155C-1
Structure and function Power train on winch
Operation
• Since the Hi-Low lever is in the "Hi" position, the
hydraulic oil from the PPC valve flows in the Hi
clutch.
D155C-1 10-71
Structure and function Power train on winch
Operation
• Since the winch Hi-Low lever is in the "Low"
position and the hook lever is in the "Raise"
position, the hydraulic oil from the PPC valve
flows in the hook raise clutch and hook brake to
release the hook drum. Accordingly, the hook
drum rotates.
10-72 D155C-1
Structure and function Power train on winch
5. High position of the Hi-Low lever and boom Raise, hook Lower operation
Operation
• Since the winch Hi-Low lever is in the "Hi" posi-
tion and the boom lever is in the "Raise" position
and the hook lever is in the "Lower" position, the
hydraulic oil from the PPC valve flows in the
hook brake and boom brake to release the hook
drum and boom drum. Accordingly, the hook
drum and boom drum rotate.
D155C-1 10-73
Structure and function Power train on winch
Operation
• The hook lever is in the “Free fall“ position, sole-
noid valve for hook lower clutch stops oil flow to
hook lower clutch, and release the hook brake.
Accordingly, the hook drum rotates.
10-74 D155C-1
Structure and function High-Low valve
High-Low valve
1. Spring Structure
2. Detent ball • High-low selector valve is combined with lubri-
3. Spool (for selector valve) cation valve, cooler bypass valve and pressure
4. Spool (For pressure adjustment valve) adjustment valve.
5. Spool (for cooler bypass valve)
6. Spool (for lubrication valve)
D155C-1 10-75
Structure and function PPC valve
PPC valve
1. Spring Structure
2. Piston • PPC valve consists of six spools which control
3. Spring boom raising clutch, boom brake, boom lower-
4. Shaft ing clutch, hook lowering clutch, hook brake and
raising clutch.
• Each spool is a directional control spool which
changes the direction of oil flow by moving to
right or left.
10-76 D155C-1
Structure and function PPC valve
Operation
• The figure shows PPC valve in neutral where
pressurized oil in a clutch is drained out.
• Spring force in valve is increased according to
stroke of valve spool (1). If spool (1) is moved to
left, drain port C will be closed. At same time,
passage of oil from inlet port A to clutch port B
will be opened, allowing oil to flow into clutch,
which will, in turn, increase the oil pressure.
• Under increased oil pressure, spool will be
moved to right, closing the passage to clutch
port, which will, in turn, result in oil flow from
drain port. In this manner, spring force applied
to spool is dependent on spool stroke.
D155C-1 10-77
Structure and function Flow divider valve
1. Spool Structure
2. Body • Flow divider valve properly distributes oil from
3. Plug an oil pump to two hydraulic systems, and is
operated independently.
A. From winch pump • Oil must be sent at a certain flow ratio to two
B. To high-low valve separate points from a single pipe. This is
C. To high-low valve accomplished by routing oil through a flow
divider containing a free piston which automati-
cally moves back and forth in response to pres-
sure changes, and thus regulates the flow.
• Some flow dividers are used for dividing oil flow
into two circuits at the rate of 1 : 1. (Division of
oil flow can be adjusted as required by changing
the size and number of holes provided in the
flow divider for distributing oil to two circuits.)
10-78 D155C-1
Structure and function Flow divider valve
Operation
• A hollow piston capable of moving left or right is
provided in the valve and its center has holes
drilled sideways. Oil flows from port A into cen-
ter of hollow piston through holes and is divided
into L.H. and R.H. chambers B and C leading to
boosters. The hollow piston forms small and
long hole.
• Effect of orifice
This orifice a was purposed to prevent the chat-
tering of spool by the damping effect of oil kept
in the left side chamber B.
D155C-1 10-79
Structure and function Counterweight hydraulic tank
1. Cap Specification
2. Screen Tank capacity: 47 l
3. Sight gauge (When counterweight is retracted)
4. Counterweight control valve
5. Hydraulic tank
10-80 D155C-1
Structure and function Counterweight piping
Counterweight piping
D155C-1 10-81
Structure and function Counterweight control
Counterweight control
10-82 D155C-1
Structure and function Counterweight hydraulic circuit diagram
1. Hydraulic tank
2. Counterweight pump (PAL063)
3. Main relief valve (Set pressure: 13.7 MPa {140 kg/cm2})
4. Spool
5. Oil filter (Set pressure: 0.22 MPa {2.2 kg/cm2})
6. Slow return valve
7. Counterweight cylinder
D155C-1 10-83
Structure and function Counterweight
Counterweight
10-84 D155C-1
Structure and function Counterweight
Operation
Retraction of counterweight
• The counterweight is retracted by extracting cyl-
inder (7). Spool (4) of the changeover valve is
set to the "RETRACT" position.
• The oil flows through port A and port C of slow
return valve (6) to the cylinder bottom side. The
oil on the cylinder head side returns through the
orifice of port D of the slow return valve. The
counterweight is operated smoothly by this sys-
tem.
D155C-1 10-85
Structure and function Counterweight
Extention of counterweight
• The counterweight is extended by retracting cyl-
inder (7). Spool (4) of the changeover valve is
set to the "EXTEND" position.
• The oil flows through port B and port D of slow
return valve (6) to the cylinder head side. The
oil on the cylinder bottom side returns through
port C of the slow return valve. Since the oil
flow is reduced by port D, the counterweight is
extracted smoothly.
10-86 D155C-1
Structure and function Counterweight control valve
A. To counterweight cylinder
B. To counterweight cylinder
P. From counterweight pump
T. To counterweight tank
D155C-1 10-87
Structure and function Boom
Boom
10-88 D155C-1
Structure and function Safety device
Safety device
Boom kick-out system
• This is a safety device. If boom should collide 1. Boom
against machine body because of overwinding 2. Damper
of wire rope or any other reason, it will cause 3. Shaft
loss of balance or damage to machine body. 4. Spring
Collisions are eliminated by the boom kick-out 5. Rod
system. 6. Boom control lever
• As shown in the figure below, damper spring (4)
is actuated when point A of boom (1) comes into Lever position
contact with point B of shaft (3). A: Boom RAISE
The shock given to the shaft (3) is transmitted to N: NEUTRAL
the rod (5) which automatically moves the boom B: Boom LOWER
control lever (6) from RAISE position to NEU-
TRAL position. As a result, winch is braked by
function of PPC valve.
D155C-1 10-89
Structure and function Safety device
Function
• Switch (5) is turned ON and OFF with the lever.
Normally, since the weight is hanging in the free
state, the switch is kept turned OFF.
• If the hook is wound in more than a certain point,
the weight rises together with hook sheave
block. Then, cable (3) is slackened, switch lever
(4) turns (operates), the switch is turned ON,
and horn (6) sounds.
• If the hook is raised or the boom is lowered, the
positive (+) power of the battery is supplied
through the oil pressure switch to switch (5). If
switch (5) is turned ON at this time, horn (6)
sounds.
If the hook or boom is stopped under this condi-
tion, the oil pressure switch is turned OFF.
Since relay (7) is turned ON, however, the posi-
tive (+) power is supplied through the relay to
switch (5), thus horn (6) keeps sounding.
If the hook or boom is raised and the weight
hangs in the free state, switch (5) is turned OFF
and horn (6) stops sounding.
10-90 D155C-1
Structure and function Safety device
D155C-1 10-91
Structure and function Safety device
Operation
1. When lowering boom
1) Remove elbow (4), install shim (5) and
gasket (6) as shown in the figure, then
install elbow (4) again.
2) Install oil pump (7) and hose (8) as shown in
the figure.
3) Fill pump (7) with engine oil, operate lever
(1) as shown in the figure to generate
hydraulic power. Release the brake and
lower the load.
When doing this, check that valve (2) is in
the CLOSE position.
The lever must be operated 30 to 40 times
to generate hydraulic power. (This is to fill
the brake chamber with oil to make up for
the oil lost during disassembly.)
4) To stop the load, set valve (2) to the OPEN
position to release the hydraulic pressure
and apply the brake.
When valve (2) is set to the OPEN position,
oil will spurt out from drain hose (3).
a Use the same engine oil as used for the
winch.
k Precautions:
Always use engine oil to fill the pump of this
release device. Never use grease, or any pump
which may allow grease to mix with the oil. If
grease gets in, it may become impossible to
operate the winch.
10-92 D155C-1
Structure and function Safety device
Moment limiter
D155C-1 10-93
Structure and function Safety device
10-94 D155C-1
Structure and function Cab
Cab
Cab assembly
1. Door
2. Rear window
3. Top window
4. Right glass
5. Rear glass
6. Rear wiper
7. Front glass
8. Front wiper
D155C-1 10-95
Structure and function Actual electric wiring diagram
10-96 D155C-1
20 Testing and adjusting
a Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use 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.
D155C-1 20-1
Testing and adjusting Standard value table for engine related parts
Engine SA6D140E-2
20-2 D155C-1
Testing and adjusting Standard value table for engine related parts
–50°C spec.
Engine SA6D140E-2
D155C-1 20-3
Testing and adjusting Standard value table for chassis
Permissible
Item Measurement conditions Unit Standard value
value
20-4 D155C-1
Testing and adjusting Standard value table for chassis
Category
Permissible
Item Measurement conditions Unit Standard value
value
78.4 ± 58.8
Engine: Slow o Full
{8 ± 6}
Fuel control lever • Center of lever knob Engine: Full o Slow —
156.9 ± 19.6
Engine: Slow o Stop
{16 ± 2}
Engine: Full o 122.6 ± 24.5
• Engine speed: Deceleration Slow {12.5 ± 2.5}
Decelerator pedal 900 – 950 rpm
• Center of pedal
29.9 ± 4.4
Between gear speeds
• Engine: Stopped {3.05 ± 0.45}
Gearshift lever
• Center of lever knob 31.9 ± 4.4
F R
{3.25 ± 0.45}
Until clutch is disen- 42.2 ± 9.8
• Engine: Slow gaged completely {4.3 ± 1}
Steering lever • Center of lever knob Apply brake and measure 48.1 ± 9.8
Operating effort of control lever
D155C-1 20-5
Testing and adjusting Standard value table for chassis
Category
Permissible
Item Measurement conditions Unit Standard value
value
Torque converter relief • Engine speed: Full 0.8 ± 0.1 0.8 ± 0.1
pressure (Inlet) • Power train oil tempera- {8 ± 1} {8 ± 1}
ture: 70 – 80°C
Torque converter 0.4 ± 0.1 0.4 ± 0.1
outlet pressure {4 ± 1} {4 ± 1}
Transmission 2.2 ± 0.3 2.2 ± 0.3
modulating pressure {22.5 ± 2.5} {22.5 ± 2.5}
Transmission 1.2 ± 0.1 1.2 ± 0.1
reducing pressure {12.5 ± 1} {12.5 ± 1}
Transmission lubricat- 0.1 0.1
ing oil pressure {1.24} {1.24}
Steering clutch 1.4 ± 0.3 1.4 ± 0.3
actuating pressure {14.5 ± 2.5} {14.5 ± 2.5}
Brake actuating 2.5 ± 0.3 2.5 ± 0.3
pressure {25.5 ± 3.5} {25.5 ± 3.5}
13 – 13.7
Engine: Slow {133 – 140} —
Counterweight relief • Hydraulic oil tempera-
pressure ture: 45 – 55°C 13.5 – 14.4
Engine: Full —
{138 – 147}
1.9 – 2.3
Engine: Slow {19 – 23} —
Hydraulic pressure
1.7 – 2.3
Engine: Slow {17 – 23} —
Hook clutch actuating • Hydraulic oil tempera-
pressure ture: 60 – 70°C 1.9 – 2.5
Engine: Full —
{19 – 25}
1.7 – 2.3
Engine: Slow {17 – 23} —
Hook brake actuating • Hydraulic oil tempera-
pressure ture: 60 – 70°C 1.9 – 2.5
Engine: Full {19 – 25} —
20-6 D155C-1
Testing and adjusting Standard value table for chassis
Category
Permissible
Item Measurement conditions Unit Standard value
value
Counterweight
D155C-1 20-7
Testing and adjusting
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use 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.
D155C-1 20-101
Testing and adjusting Tools for testing, adjusting, and troubleshooting
20-102 D155C-1
Testing and adjusting Adjusting valve clearance
Adjusting valve clearance 4. Rotate the crankshaft int the normal cirection by
one revolution and adjust the valve clearance
a Adjusting instrument for valve clearance for the remaining valves marked Q.
a To adjust the valve clearance, loosen lock nut
Symbol Part. No. Name (5) on adjustment screw (4), insert feeler
F Commercially available Feeler gauge gauge F corresponding to the specified
clearance between crosshead (6) and rocker
1. Remove the rocker arm housing cover. arm (7), and adjust the clearance with the
adjustment screw until the thickness gauge
2. Rotate the crankshaft in the normal direction. can slide lightly.
While watching the movement of the intake
valve of the No. 6 cylinder, bring the No. 1 cylin-
der into the top dead center position of the com-
pression stroke and align the "1.6 TOP" mark on
vibration damper (1) with pointer (2).
a When the No. 1 cylinder comes near the top
dead center of the compression stroke, the
No. 6 intake valve will start to move (open).
D155C-1 20-103
Testing and adjusting Measuring compression pressure
Measurement procedure
k While measuring the compression pressure,
take care not burn yourself on the exhaust
manifold or muffler, and be careful not to get
caught in any revolving part of the engine.
a Measure the compression pressure while
the engine is warm. 5. Connect compression gauge D1 to the adapter.
(Oil temperature: 40 – 60°C)
1. Adjust the valve clearance property. For details, 6. Place the fuel control lever in NO INJECTION
see Adjusting valve clearance. position, crank the engine with the starting
motor, and read the gauge when the pointer is
2. Disconnect fuel injection tube (1). stabilized.
a When the No. 1 cylinder comes near the top k If you do not put the fuel control lever in NO
dead center of the compression stroke, the INJECTION position, fuel will blow out.
No. 6 intake valve will start to move (open). a Most compression leakage can be prevented
by applying a small amount of oil to the
mounting section of the adapter.
a For the reference values of the compression
pressure, see Standard value table for en-
gine related parts.
20-104 D155C-1
Testing and adjusting Testing and adjusting fuel injection timing
Testing and adjusting fuel 7. Rotate the crankshaft again slowly in the normal
direction and set to specified dimension c.
injection timing a Specified dimension c: 2.36 +0.2 mm
–0.19
(BTDC: 22°)
a Adjusting instrument for fuel injection timing a Always rotate the crankshaft in the normal
Symbol Part. No. Name direction to align the position.
a Continue to rotate in the normal direction,
AA 795-471-1200 Dial gauge and when the No. 1 cylinder reaches the
TOP (top dead center) position (the indicator
1. Remove No. 1 nozzle holder assembly (1). on the dial gauge rotates in reverse), check
For details, see Removal of nozzel holder assem- that the dial gauge reading is 0 +0.2 mm. If
bly. –0.19
it is not within 0 +0.2
–0.19
mm, carry out Steps 4
and 5 again.
D155C-1 20-105
Testing and adjusting Measuring engine oil pressure
TLD00023
C1
TLD00024
C2
TLD00025
20-106 D155C-1
Testing and adjusting Measuring exhaust color
G2
TLD00140
D155C-1 20-107
Testing and adjusting Measuring exhaust temperature
TLD00030
20-108 D155C-1
Testing and adjusting Testing and adjusting alternator belt tension
TLD00026
2. Adjusting
1) Loosen alternator mount bolt (1).
2) Loosen locknut (2), then turn adjustment nut
(3) and adjust the belt tension.
3) After adjusting the belt tension to the standard
value, tighten lock (2), then tighten alternator
mount bolt (1).
TLD00027
D155C-1 20-109
Testing and adjusting Measuring blow-by
Measuring blow-by 2. Run the engine at near rated output, and mea-
sure the blow-by pressure.
k When measuring, be careful not to touch
a Measuring instruments for blow-by pressure.
any hot parts or rotating parts.
Symbol Part No. Name a The blow-by should be measured with the
1 799-201-1504 Blow-by checker engine running at rated output. However,
E when measuring in the field, a similar value
2 799-201-1590 Gauge can be obtained at torque converter stall
speed.
a Raise the coolant temperature to the operating • If it is impossible to check at rated output or
range before measuring. stall speed, measure at high idling.
In this case, the blow-by value will be about
1. Install blow-by checker E1 to the end of engine 80% of the value at rated output.
breather hose (1), then connect it to gauge E2. a Blow-by varies greatly according to the
condition of the engine. Therefore, if the blow-
by value is considered abnormal, check for
E1 problems connected with defective blow-by,
such as excessive oil consumption, defective
exhaust gas color, and prematurely dirty or
deteriorated oil.
1
TLD00020
E2
TLD00021
20-110 D155C-1
Testing and adjusting Measuring air supply pressure (boost pressure)
Measuring air supply pressure 3. Run the engine at full throttle to stall the torque
conveter, and read the pressure indicated by the
(boost pressure) gauge.
a Measuring instruments for air supply pressure. a The air supply pressure (boost pressure) should
Symbol Part No. Name be measured with the engine running at rated
output. However, when measuring in the field, a
H 799-201-2201 Boost gauge KIT similar value can be obtained at torque conerter
k
stall speed.
Be careful not to touch any hot parts or get
caught in any rotating parts when measuring or
when removing or installing the measuring tools.
1. Remove air supply pressure measurement plug
(1) (PT1/8), then install the coupler inside oil
pressure gauge kit C1.
TLD00033
TLD00034
D155C-1 20-111
Testing and adjusting Measuring engine speed
TLD00010
20-112 D155C-1
Testing and adjusting Measuring torque converter stall speed
1. Install multi-tachometer A.
For details, see Measuring engine speed.
TLD00010
D155C-1 20-113
Testing and adjusting Bleeding air from counterweight cylinder
20-114 D155C-1
Testing and adjusting Adjusting winch control interlock mechanism
1. Adjust the length of the rod so that the center of 1. High-low lever
the interlock spool pin of the control box will be 2. Rod
at 30 mm from the top of the cover when winch 3. Spool
control high-low lever (1) is set in the "N" posi- 4. Cover
tion. 5. PPC valve
a When the high-low valve spool is pushed in, 6. High-low valve
the high-low lever is set in the "N" position.
D155C-1 20-115
Testing and adjusting Measuring oil pressure
20-116 D155C-1
Testing and adjusting Measuring oil pressure
D155C-1 20-117
Testing and adjusting Measuring counterweight oil pressure
20-118 D155C-1
Testing and adjusting Measuring winch oil pressure
D155C-1 20-119
Testing and adjusting Hydraulic circuit diagram for winch
20-120 D155C-1
Testing and adjusting Measuring leakage inside cylinder
1. Measurement posture
• Fully extend the rod of the cylinder and
retract the counterweight.
2. Measuring
1) Disconnect the head piping, and block the
piping at the chassis end with a blind plug.
k Be careful not to disconnect the piping
at the bottom end.
2) Start the engine, run the engine at high
idling, and apply the relief pressure to the
bottom end of the cylinder.
3) Wait for 30 seconds, then measure the
amount of leakage over the next 1 minute.
Disconnect hose
End of stroke
Hose
Relief pressure
TAD00148
D155C-1 20-121
Testing and adjusting Reinstallation (if moment limiter was removed) and adjusting
1. Control box
2. Position of cam dowel pin
3. Matching hole
4. Locknut
5. Connection
6. Fixing (Winch case)
7. Cam control rod
8. Locknut
9. Cam control lever
10. Plate (Cam positioning jig)
20-122 D155C-1
Testing and adjusting Adjustment procedure for moment limiter performance
1. Check
The operation characteristics diagram in the
next page shows the lifting performance curves
of 71 ton-m. The moment limiter operates and
the red lamp on the instruments panel in the
operator's cab lights up according to these
curves.
D155C-1 20-123
Testing and adjusting Adjustment procedure for moment limiter performance
Equipment
• Wire rope: 20 mm in diameter, having minimum breaking load of 27,600 kg
• Number of wire ropes for the hook: 6
• Number of wire ropes for the boom: 5
• Counterweight pushed out: 9,230 kg
Pulley efficiency is included.
20-124 D155C-1
Testing and adjusting Adjustment procedure for moment limiter performance
2. Adjustment method
D155C-1 20-125
Troubleshooting
D155C-1 20-201
Testing and adjusting Points to remember when troubleshooting
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. ex t e r n al l y, s o c h e c k an y i te m th a t i s
If components are disassembled immediately considered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be • Confirm the extent of the failure yourself, and
disassembled. 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
For this reason, when carrying out troubleshoot- me a s ur em e nt t h at m ay m ak e t h e
ing, it is necessary to carry out thorough prior problem worse.
investigation and to carry out troubleshooting in
accordance with the fixed procedure. 5. Troubleshooting
• Use the results of the investigation and
2. Points to ask user or operator inspection in Items 2 – 4 to narrow down the
1) Have any other problems occurred apart causes of failure, then use the
from the problem that has been reported? troubleshooting flowchart to locate the
2) Was there anything strange about the position of the failure exactly.
machine before the failure occurred? a The basic procedure for troubleshooting
3) Did the failure occur suddenly, or were there is as follows.
problems with the machine condition before 1) Start from the simple points.
this? 2) Start from the most likely points.
4) Under what conditions did the failure occur? 3) Investigate other related parts or
5) Had any repairs been carried out before the information.
failure?
When were these repairs carried out? 6. Measures to remove root cause of failure
6) Has the same kind of failure occurred • Even if the failure is repaired, if the root
before? cause of the failure is not repaired, the same
failure will occur again.
3. Check before troubleshooting To prevent this, always investigate why the
1) Check the oil level problem occurred. Then, remove the root
2) Check for any external leakage of oil from cause.
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 D155C-1
Testing and adjusting Sequence of events in troubleshooting
D155C-1 20-203
Testing and adjusting Points to remember when carrying out maintenance
20-204 D155C-1
Testing and adjusting Points to remember when carrying out maintenance
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 solder-
ing may be damaged, or the wiring may be
broken.
D155C-1 20-205
Testing and adjusting Points to remember when carrying out maintenance
• Disconnecting connectors
1) 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 con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
20-206 D155C-1
Testing and adjusting Points to remember when carrying out maintenance
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age 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 dryer, but be careful not to make it
too hot as this will cause short circuits.
a If there is any damage or breakage,
replace the connector.
D155C-1 20-207
Testing and adjusting Points to remember when carrying out maintenance
20-208 D155C-1
Testing and adjusting Points to remember when carrying out maintenance
D155C-1 20-209
Testing and adjusting Points to remember when carrying out maintenance
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.
20-210 D155C-1
Testing and adjusting Points to remember when carrying out maintenance
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove 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,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
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.
D155C-1 20-211
Testing and adjusting Checks before troubleshooting
13. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
14. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
15. Check operation of gauges — Repair or replace
mechanical
equipment
Hydraulic,
20-212 D155C-1
Troubleshooting of engine system
(S mode)
Method of using troubleshooting charts ...................................................................................................... 20-302
S-1 Starting performance is poor (starting always takes time)................................................................ 20-306
S-2 Engine does not start ....................................................................................................................... 20-307
(1) Engine does not turn................................................................................................................... 20-307
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ................................ 20-308
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ............................ 20-309
S-3 Engine does not pick up smoothly (follow-up is poor) ...................................................................... 20-310
S-4 Engine stops during operations........................................................................................................ 20- 311
S-5 Engine does not rotate smoothly (hunting)....................................................................................... 20-312
S-6 Engine lacks output (no power)........................................................................................................ 20-313
S-7 Exhaust smoke is black (incomplete combustion) ........................................................................... 20-314
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-315
S-9 Oil becomes contaminated quickly................................................................................................... 20-316
S-10 Fuel consumption is excessive ........................................................................................................ 20-317
S-11 Oil is in cooling water, or water spurts back, or water level goes down ........................................... 20-318
S-12 Oil pressure caution lamp lights up (drop in oil pressure) ................................................................ 20-319
S-13 Oil level rises (water, fuel in oil)........................................................................................................ 20-320
S-14 Water temperature becomes too high (overheating)........................................................................ 20-321
S-15 Abnormal noise is made................................................................................................................... 20-322
S-16 Vibration is excessive....................................................................................................................... 20-323
D155C-1 20-301
Troubleshooting Method of using troubleshooting charts
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
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 nar-
row 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 proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].
20-302 D155C-1
Troubleshooting Method of using troubleshooting charts
D155C-1 20-303
Troubleshooting Method of using troubleshooting charts
20-304 D155C-1
Troubleshooting Method of using troubleshooting charts
D155C-1 20-305
Troubleshooting S-1
Defective alternator
Defective regulator
–10°C 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the value for the
charging rate of 70% in the above table.
• In cold areas the specific gravity must exceed the value for
the charging rate of 75% in the above table.
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Gradually became worse w w Q Q Q
Ease of starting
Starts when warm w w
Questions
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-306 D155C-1
Troubleshooting S-2
2) When terminal B and terminal C of starting motor are connected, engine starts q
3) When terminal B and terminal C of safety relay are connected, engine starts q
4) When terminal of safety switch and terminal B of starting motor are connected, engine starts q
5) There is no 24V voltage between battery relay terminal b and terminal E q
When ring gear is inspected directly, tooth surface is found to be chipped q
Does not move even when fuel cut solenoid linkage is disconnected q
Does not move even when engine stop motor linkage is disconnected q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy —
D155C-1 20-307
Troubleshooting S-2
General causes why engine turns but no exhaust smoke comes out
• Supply of fuel impossible
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
Causes
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Remedy
Add
20-308 D155C-1
Troubleshooting S-2
(3) Exhaust smoke comes out but engine does not start
(Fuel is being injected)
2) No fuel comes out even when fuel filter air bleed plug is loosened w w Q
There is leakage from fuel piping w
When exhaust manifold is touched immediately after starting engine, temperature of some
w
cylinders is low
When fuel filter is drained, no fuel comes out w
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged q
When air cleaner element is inspected directly, it is found to be clogged q
Heater mount does not become warm q
Either specific gravity of electrolyte or voltage of battery is low q
When feed pump is operated, operation is too light or too heavy q
Speed does not change when operation of certain cylinders is stopped q
When fuel cap is inspected directly, it is found to be clogged q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
D155C-1 20-309
Troubleshooting S-3
a Check that the monitor panel does not display any abnormality in
the governor control system.
General causes why engine does not pick up smoothly
• Insufficient intake of air
• Insufficient supply of fuel
• Improper condition of fuel injection
• Improper fuel used
Causes
High idling speed under no load is normal, but speed suddenly drops when load is applied w w Q
There is hunting from engine (rotation is irregular) Q w Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders
w Q
is low
Blow-by gas is excessive w
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-310 D155C-1
Troubleshooting S-4
Lack of fuel
w : Most probable causes (judging from Questions and Check items)
E : Possible causes due to length of use (used for a long period)
q : Items to confirm the cause
Replace
Replace
Repair
Clean
Clean
Clean
Remedy —
Add
D155C-1 20-311
Troubleshooting S-5
Lack of fuel
w : Most probable causes (judging from Questions and Check items)
E : Possible causes due to length of use (used for a long period)
q : Items to confirm the cause
Confirm recent repair history
Degree of use of machine Operated for long period E E
Occurs at a certain speed range w w w Q
Q w Q Q Q Q
Questions
Clean
Clean
Clean
Remedy
Add
20-312 D155C-1
Troubleshooting S-6
Suddenly w
Power was lost
Gradually Q Q Q Q Q Q
Engine oil must be added more frequently w
Replacement of filters has not been carried out according to Operation Manual w w w
Non-specified fuel is being used w w w w
Dust indicator is red w
Black w
w
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
D155C-1 20-313
Troubleshooting S-7
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
20-314 D155C-1
Troubleshooting S-8
Turbocharger
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
D155C-1 20-315
Troubleshooting S-9
Oil filter caution lamp stays on even when oil pressure rises w Q
When oil filter is inspected, metal particles are found Q w Q
When exhaust pipe is removed, inside is found to be dirty with oil w
Engine oil temperature rises quickly w
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
20-316 D155C-1
Troubleshooting S-10
Causes
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
D155C-1 20-317
Troubleshooting S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
Causes
Remedy
20-318 D155C-1
Troubleshooting S-12
Causes
Sometimes lights up w w Q Q
There is clogging, leakage from hydraulic piping (external) w
Oil level sensor lamp lights up w w
When oil level in oil pan is checked, it is found to be low w
Metal particles are found when oil is drained w
Metal particles are stuck to oil filter element w Q
Oil is cloudy white or smells of diesel oil w
Carry out troubleshooting
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy —
Add
D155C-1 20-319
Troubleshooting S-13
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
20-320 D155C-1
Troubleshooting S-14
Suddenly overheated
Condition of overheating
Always tends to overheat w w Q Q
Rises quickly w Q
Water temperature gauge
Does not go down w
Radiator water level sensor lights up w
Fan belt whines under sudden load w
Cloudy white oil is floating on cooling water w
Cooling water flows out from overflow hose w
Excessive air bubbles inside radiator, water spurts back w
Engine oil level has risen, oil is cloudy white Q w
Check items
When function test is carried out on thermostat, it does not open even at cracking temperature q
When water temperature is measured, it is found to be normal q
When oil cooler is inspected directly, it is found to be clogged q
When measurement is made with radiator cap tester, set pressure is found to be low q
When compression pressure is measured, it is found to be low q
Remove oil pan and inspect directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy —
Add
D155C-1 20-321
Troubleshooting S-15
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q Q
Engine oil must be added more frequently w
Blue under light load w
Color of exhaust gas
Black w Q Q
Metal particles are found in oil filter w w
Blow-by gas is excessive w
Noise of interference is heard from around turbocharger w
Engine pickup is poor and combustion is abnormal w
When exhaust manifold is touched immediately after starting engine, temperature of some
Check items
w Q
cylinders is low
Seal on injection pump has come off w
Abnormal noise is loud when accelerating engine Q Q Q Q Q Q
Clanging sound is heard from around cylinder head w w
Leakage of air between turbocharger and cylinder head, loose clamp w
Vibrating noise is heard from around muffler w
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-322 D155C-1
Troubleshooting S-16
a If there is abnormal noise together with the vibration, carry out trouble-
shooting for "Abnormal noise is made".
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment
• Abnormal combustion
Causes
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q Q
Non-specified oil is being used Q Q
Metal particles are found in oil filter w w
Metal particles are found when oil is drained w w
Oil pressure is low at low idling Q Q
Vibration occurs at mid-range speed Q Q
Check items
Replace
Correct
Correct
Adjust
Remedy
D155C-1 20-323
Troubleshooting of hydraulic,
mechanical system
(H mode)
H-1 Torque converter oil temperature is too high .................................................................................... 20-402
H-2 Machine does not move ................................................................................................................... 20-403
H-3 Machine lacks power or speed......................................................................................................... 20-404
H-4 Machine moves when engine is started ........................................................................................... 20-405
H-5 Excessive time lag when starting machine or shifting gear.............................................................. 20-405
H-6 Excessive shock when starting off or shifting gear........................................................................... 20-406
H-7 Machine moves in only one direction (FORWARD or REVERSE) ................................................... 20-407
H-8 Steering clutch is not disengaged .................................................................................................... 20-408
H-9 Steering clutch slips ......................................................................................................................... 20-409
H-10 Steering brake does not work........................................................................................................... 20-410
H-11 Lack of power, speed when retract counterweight ........................................................................... 20- 411
H-12 Impossible to retract counterweight ................................................................................................. 20-412
H-13 Excessive hydraulic drift of counterweight cylinder .......................................................................... 20-413
H-14 Defective boom RAISE, LOWER (speed, raising force, lowering force) .......................................... 20-414
H-15 Defective hook RAISE, LOWER (speed, raising force, lowering force) ........................................... 20-415
H-16 Excessive hydraulic drift of boom..................................................................................................... 20-416
H-17 Excessive hydraulic drift of hook ...................................................................................................... 20-417
H-18 Play when operating hook ................................................................................................................ 20-418
H-19 Play when operating boom............................................................................................................... 20-419
H-20 Excessive time lag when operating hook ......................................................................................... 20-420
H-21 Excessive time lag when operating boom ........................................................................................ 20-421
H-22 Excessive inching amount................................................................................................................ 20-422
H-23 Winch free fall does not work ........................................................................................................... 20-423
H-24 Winch overheats............................................................................................................................... 20-424
H-25 Excessive noise when operating winch clutch, brake ...................................................................... 20-425
H-26 Control lever is heavy....................................................................................................................... 20-426
H-27 Hook overwind horn does not sound................................................................................................ 20-427
D155C-1 20-401
Troubleshooting H-1
Oil leaking inside torque converter (seal ring defective, plug loose)
Torque converter relief valve malfunction
Air leaking in at suction side of pump
Stainer clogged
Pump defective
Filter clogged
Tank to pump
Scavenging
converter
Torque
pump
a b c d e f g h i
Remedy E E E C
C × × C ×
No. Diagnosis × × × ×
1 Pump makes abnormal noise when oil is cold Q Q
2 High idling, low idling speeds too low Q Q Q
3 Hydraulic pressure at outlet port of torque converter too low Q
4 Hydraulic pressure at inlet port of torque converter too low Q
5 Transmission modulating pressure too low Q Q Q
6 Excessive leakage of oil inside torque converter Q
7 Hydraulic pressure at outlet port of torque converter too high Q
If all checks show no problem,
a The following symbols are used to indicate the action to this is the cause.
be taken when a cause of failure is located.
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-402 D155C-1
Troubleshooting H-2
Stainer clogged
Pump defective
Tank to pump
Transmission
Control valve
a b c d e f g h i j k l m n
Remedy E E E E C
C × C × × × × E ×
No. Diagnosis × × × × ×
1 Pump makes abnormal noise when oil is cold Q Q
2 Machine does not move in any speed range Q Q Q Q Q Q Q Q Q
3 Machine moves normally in certain speed ranges Q Q Q
4 As in item 3; in particuler, machine fails to move only in 1st Q Q Q Q
5 When gear shift lever is in neutral, torque converter output shaft does not rotate Q
6 Output shaft rotates in neutral, but not when gear shift lever is in travel position Q Q
7 Machine will not move when oil temperature rises Q Q Q Q
8 Transmission modulating pressure too Low at every speed range Q Q Q Q Q
9 low Normal at certain speed ranges Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-403
Troubleshooting H-3
Oil leaking inside torque converter (Seal ring defective, plug loose)
• The performance lower than before.
o Some part is probably defective.
Engine defective
Transmission
Other system
Control valve
converter
Torque
a b c d e f g h i j
Remedy E E E
× × × × ×
No. Diagnosis × × ×
1 Speed and power normal in certain speed ranges Q Q Q Q
2 Torque converter stall speed too low Q Q
Low at every speed range Q Q
3 Transmission modulating pressure too low
Normal at certain speed ranges Q
4 Reducing pressure too low Q
Iron or aluminium particles stuck to strainer or drain plug of torque converter
5 Q
case
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-404 D155C-1
Troubleshooting H-4, H-5
1. When engine is started with gear shift lever in NEUTRAL, machine moves.
o Transmission clutch seized.
2. As above, but machine operation returns to normal when engine is warmed up for 10 – 15 minutes.
o Transmission rotated by high viscosity of oil (is proper oil being used?)
Strainer clogged
Pump defective
Tank to pump
Transmission
Control valve
a b c d e f g h i
Remedy E E E
C × × × × ×
No. Diagnosis × × ×
1 Pump makes abnormal noise when oil is cold Q Q
2 Excessive time lag in every speed ranges Q Q Q Q Q Q
3 Machine moves normally in certain speed ranges Q Q Q
As in item 3; in particular, machine fails to move or moves with excessive time
4 Q Q
lag only in 1st speed
5 Transmission modulating pressure too low in every speed range Q Q Q Q Q
6 Torque converter oil temperature is above operating range Q Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-405
Troubleshooting H-6
a b
C C
Remedy
E E
No. Diagnosis
× ×
1 Excessive shock when starting machine or shifting gear Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-406 D155C-1
Troubleshooting H-7
FR valve
a b
Remedy E E
No. Diagnosis × ×
If gear shift lever does not move in F or R
Machine travels in one direction only Q
1 direction
(FORWARD or REVERSE)
If above is normal Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-407
Troubleshooting H-8
Pump defective
Steering clutch
Tank to pump
Control valve
a b c d e f g h i
A A
Remedy E E
C × E × × × E
No. Diagnosis × ×
× ×
1 Oil pressure tool low Q Q Q Q Q Q
2 Pump makes abnormal noise when oil is cold Q Q
3 Clutch does not disengage when oil temperature rises Q Q Q
4 Oil pressure normal, but clutch does not disengage Q
Sometimes disengages, sometimes does not disengage, and sometimes
5 Q
remains disengaged
6 Clutch on one side (left or right) only does not disengage (oil pressure normal) Q Q
7 Turning ability poor on flat surfaces or downhill slopes Q
8 Normal in item 6, but clutch does not disengage with oil temperature rises Q
Oil pressure becomes normal when relief valve is disassembled and cleaned, or
9 Q
shims are added
a In item 7, with cause "i", even if the clutch disengages, the machine will snake on
slopes. If the brakes do not work, the machine will not turn.
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-408 D155C-1
Troubleshooting H-9
Control valve
a b c d
Remedy E
× × ×
No. Diagnosis ×
1 Clutch slips on only one side (L.H. or R.H.) Q Q Q
Sometimes disengages, sometimes does not disengage, and sometimes
2 Q
remains disengaged
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-409
Troubleshooting H-10
Causes
Strainer clogged
Pump defective
Tank to pump
a b c d e f g
A
Remedy E E E
C × E ×
No. Diagnosis × × ×
×
1 Relief pressure too low Q Q Q Q Q
No oil comes out even when plug is removed from pressure pick-up port, and
2 Q
engine is cranked
Pump makes abnormal noise when oil is cold (also may happen with engine at
3 Q Q
full throttle)
4 Brake does not work when oil temperature rises Q
5 Oil pressure normal, but brake does not work Q Q
6 Brake on only side (left or right) does not work Q
Oil pressure becomes normal when relief valve is disassembled and cleaned, or
7 Q
shims are added
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-410 D155C-1
Troubleshooting H-11
Drop in set pressure of pilot relief valve, hole clogged, defective sealing
• Is it normal, that is, there is no leakage of oil from the
piping between the pump and control valve?
• Is it normal, that is, there is no leakage of oil from the
piping between the control valve and the counterweight
cylinder?
Spool stuck
Tank to pump
Control valve
a b c d e f g
A
Remedy E E C
C × C ×
No. Diagnosis × × ×
×
When engine is run at full throttle, relief pressure is tool low when pulling in
1 Q Q Q Q
counterweight
2 When condition is normal with engine is running at low idling Q Q
3 When item 1 is normal Q Q
4 Hydraulic pump makes abnormal noise Q Q
5 When lever is operated, speed is slow but circuit pressure is too high Q
6 Hydraulic drift of counterweight is normal when lever is at HOLD Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-411
Troubleshooting H-12
Oil leakage from piping between control valve and counterweight cylinder head
(From where?)
o Broken part
Drop in set pressure of pilot relief valve, hole clogged, defective sealing
• There was no problem before, such as drop in speed.
o Worn parts, fatigued spring
Spool stuck
Control valve
Control valve
Valve to
cylinder
Pump
a b c d e f g h i j
A
Remedy E E E C C C
× C × ×
No. Diagnosis × × × × × ×
×
1 When pressure pickup plug is removed and engine is cranked, no oil comes out Q
When engine is run at full throttle, pressure at counterweight retract side rises
2 Q Q Q Q Q Q Q Q Q
only a little
When piping at counterweight cylinder head end is removed, then engine is run
3 at low idling and control lever is operated to RETRACT, cylinder does not move Q Q Q
but oil comes out.
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-412 D155C-1
Troubleshooting H-13
Control valve
Valve to
cylinder
a b c d
Remedy E C C
×
No. Diagnosis × × ×
Hydraulic drift is excessive even when blind plug is fitted in piping at
1 Q Q Q
counterweight cylinder bottom
2 When item 1 is normal Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-413
Troubleshooting H-14
H-14 Defective boom RAISE, LOWER (speed, raising force, lowering force)
Causes
connections of piping and valve?
a b c d e f g h i j k
Remedy C E E
A × × × × × × ×
No. Diagnosis A × ×
1 Nothing works (RAISE, LOWER, HI, LOW) Q Q Q Q Q Q Q Q Q
2 Defective actuation of HI or LOW clutch Q Q
3 Defective operation of HI-LOW valve for RAISE, LOWER Q Q Q Q
When boom and hook are operated together, hook speed is far slower than
4 Q Q Q Q Q
when hook is operated independently
Actuating pressures do not rise to relief pressure when engine is run at full
5 Q Q Q Q Q
throttle
6 Excessive drop in pressure from above when engine is run at low idling Q Q Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-414 D155C-1
Troubleshooting H-15
H-15 Defective hook RAISE, LOWER (speed, raising force, lowering force)
Causes
• Is operating force, travel of control lever normal?
a b c d e f g h i j k l
Remedy C E E
A × × × × × × ×
No. Diagnosis A × ×
1 Nothing works (RAISE, LOWER, HI, LOW) Q Q Q Q Q Q Q Q Q
2 Defective actuation of HI or LOW clutch Q Q
3 Defective operation of HI-LOW valve for RAISE, LOWER Q Q Q
When boom and hook are operated together, hook speed is far slower than
4 Q Q Q Q Q
when hook is operated independently
Actuating pressures do not rise to relief pressure when engine is run at full
5 Q Q Q Q Q
throttle
6 Excessive drop in pressure from above when engine is run at low idling Q Q Q Q
7 Defective operation only at LOWER of HI and LOW Q Q Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-415
Troubleshooting H-16
Causes
a b
Remedy
× ×
No. Diagnosis
1 Hydraulic drift occurs when engine is stopped Q
2 Hydraulic drift increases when engine speed is increased Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-416 D155C-1
Troubleshooting H-17
Causes
a b
Remedy
× ×
No. Diagnosis
1 Hydraulic drift occurs when engine is stopped Q
2 Hydraulic drift increases when engine speed is increased Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-417
Troubleshooting H-18
a b c d e f
Remedy C E
× × C ×
No. Diagnosis A ×
1 Problem occurs for both RAISE and LOWER Q Q Q Q Q
2 Problem occurs for only RAISE or LOWER Q Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-418 D155C-1
Troubleshooting H-19
Causes
• Measure actuating pressure of each clutch, brake
a b c d e f
Remedy C E
× × C ×
No. Diagnosis A ×
1 Problem occurs for both RAISE and LOWER Q Q Q Q Q
2 Problem occurs for only RAISE or LOWER Q Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-419
Troubleshooting H-20
a b c d e f g h i j
Remedy E C
A × C C × × × ×
No. Diagnosis × A
1 Excessive for both RAISE and LOWER Q Q Q Q Q Q Q Q Q
2 Excessive for only RAISE or LOWER Q Q Q
3 Time lag excessive when engine is run at low idling Q Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-420 D155C-1
Troubleshooting H-21
a b c d e f g h i j
Remedy E C
A × C C × × × ×
No. Diagnosis × A
1 Excessive for both RAISE and LOWER Q Q Q Q Q Q Q Q Q
2 Excessive for only RAISE or LOWER Q Q Q
3 Time lag excessive when engine is run at low idling Q Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-421
Troubleshooting H-22
a b c d e f g h i
Remedy E C
A × C × × × ×
No. Diagnosis × A
1 Problem occurs for both RAISE and LOWER Q Q Q Q Q Q Q Q
2 Problem occurs for only RAISE or LOWER Q Q
3 Operating pressures do not rise to relief pressure Q Q Q Q Q Q
4 Pressure remaining at each clutch, brake Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-422 D155C-1
Troubleshooting H-23
Causes
Checks for abnormality
Blown fuse
a b c d e
Remedy
× × × E ×
No. Diagnosis
1 When brake actuating pressure normal Q
2 Pressure remains at LOWER clutch Q
3 Solenoid valve pilot lamp lights up Q Q Q Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-423
Troubleshooting H-24
a b c
Remedy
× C C
No. Diagnosis
1 Winch oil cooler oil pressure is high Q Q
2 Winch oil cooler oil pressure is low Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-424 D155C-1
Troubleshooting H-25
Causes
a b c d e f g h i j
Remedy C E E
× × C C × × ×
No. Diagnosis A × ×
1 Excessive noise for all of RAISE, LOWER, HI, LOW Q Q Q
2 Excessive noise when shifting between HI and LOW Q Q Q
3 Excessive noise when operating RAISE, LOWER Q Q Q Q
Excessive difference between condition when engine is at low idling and full
4 Q Q Q Q Q
throttle
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-425
Troubleshooting H-26
a b c d e f
Remedy E E E
× × ×
No. Diagnosis × × ×
1 Becomes heavy when oil pressure is high Q Q
2 Becomes heavy when oil temperature is high Q
3 Always heavy regardless of oil pressure or oil temperature Q Q Q
Does not become lighter even when control lever rod is disconnected at valve
4 Q
end and lever is operated
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
20-426 D155C-1
Troubleshooting H-27
Defective relay
Defective horn
a b c d e f g h
Remedy
× E E × × × × ×
No. Diagnosis
1 Voltage of +24 V is applied to horn terminal. Q
2 Voltage of +24 V is applied to limit switch. Q Q Q
3 Horn sounds when boom is raised but does not sound when hook is raised. Q Q
4 Horn sounds when hook is raised but does not sound when boom is raised. Q Q
Voltage of +24 V is not applied to hook raise oil pressure sensor and boom
5 Q Q
lower oil pressure sensor.
6 When relay is replaced, horn sounds normally. Q
7 When relay is replaced, horn does not sound normally. Q
Legend
A : Adjust
C : Clean
E : Repair
× : Replace
D155C-1 20-427
30 Disassembly and assembly
D155C-1 30-1
Disassembly and assembly
30-2 D155C-1
Disassembly and assembly Method of using manual
Removal of parts
• The removal section contains procedures, pre-
cautions and the amount of oil or water to be
drained.
• Various symbols used in the removal section are
explained and listed below.
D155C-1 30-3
Disassembly and assembly Method of using manual
5
R: Tools with upgraded part numbers,
remodeled from already available tools This mark indicates an amount of oil or
for other models. water to be added.
Blank: Tools already available for other mod-
els, used without any modification. Sketches of special tools
3) Circle mark (Q) in sketch column: 1) Various special tools are illustrated for the
A circle mark means that a sketch of the convenience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T--- xxx
--- xxxx.
Disassembly
• The Disassembly Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the Disassembly Sec-
tion are explained and listed below.
30-4 D155C-1
Disassembly and assembly Precautions when carrying out operation
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
D155C-1 30-5
Disassembly and assembly Precautions when carrying out operation
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 the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) 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.
• 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 piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 D155C-1
Disassembly and assembly Special tool list
New/remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
Removal, installation of
nozzle holder ass’y
1 795-570-1100 Remover assembly t 1 Removal of nozzle holder
Removal, installation of
cylinder head ass’y A
D155C-1 30-7
Disassembly and assembly Special tool list
New/remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
791-575-2003 Installer A 1
791-101-1102 Pump 1
4 Press-fitting sprocket
Cylinder
791-101-1600 1
(686 kN {70 ton})
5 791-575-1520 Installer 1
Installation of floating seal
6 791-580-1510 Installer 1
791-575-3003 Remover 1
790-101-1102 Pump 1 Pulling out second gear hub
7
assembly
Cylinder
790-101-1600 1
(686 kN {70 ton})
791-575-4003 Installer 1
790-101-1102 Pump 1 Press-fitting second gear
8
hub assembly
Puller
Disassembly and assembly 790-101-2102 1
F (294 kN {30 ton})
of final drive assembly
Removal and installation of
9 791-551-1300 Wrench 1
nut (inside body)
791-575-5500 Remover B 1
790-101-1102 Pump 1
10 Pulling out sprocket shaft
Cylinder
790-101-1600 1
(686 kN {70 ton})
791-575-6110 Plug 1
or
791-575-6501 Installer 1
11 Press-fitting sprocket shaft
790-101-1102 Pump 1
Cylinder
790-101-1160 1
(686 kN {70 ton})
Removal and installation of
12 790-401-1800 Lifting tool 1
final cover
Remover and Removal and installation of
1 791-475-6000 1
installer hub nut
791-480-3001 Remover D 1
790-101-1102 Pump 1
2 Pulling out hub
Disassembly and assembly Puller
G 790-101-3800 1
of first pinion assembly (490 kN {50 ton})
791-480-4001 Installer C 1
790-101-1102 Pump 1
3 Press-fitting hub
Puller
790-101-3800 1
(490 kN {50 ton})
791-681-5000 Remover & installer t 1
Removal, installation of 790-101-1102 Pump t 1 Removal, installation of
N
track shoe track shoe
Cylinder
790-101-4300 t 1
(1,471 kN {150 ton})
30-8 D155C-1
Disassembly and assembly Special tool list
New/remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
1 791-685-8000 Compressor t 1
Disassembly, assembly of Cylinder Disassembly, assembly of
J 2 790-101-1300 t 1
recoil spring (981 kN {100 ton}) recoil spring
3 790-101-1102 Pump t 1
4 791-781-1320 Wrench t 1
5 791-781-1000 Compressor t 1 Assembly of winch brake
Disassembly, assembly of 791-100-2200 Installer t 1
M
winch
790-101-1102 Pump t 1
6
Puller
790-101-2102 t 1 Disassembly, assembly of
(294 kN {30 ton})
winch
790-101-1102 Pump t 1
7 Puller
790-101-2102 t 1
(294 kN {30 ton})
D155C-1 30-9
Disassembly and assembly Starting motor
Standard
Installation
–50°C specification
Removal
–50°C specification
Installation
30-10 D155C-1
Disassembly and assembly Alternator
[*1] 3
4 7
a After installing the alternator, adjust the belt DED00004
D155C-1 30-11
Disassembly and assembly Alternator
–50°C specification
Removal
–50°C specification
Installation
[*1]
30-12 D155C-1
Disassembly and assembly Engine oil cooler core
Standard
Installation
D155C-1 30-13
Disassembly and assembly Engine oil cooler core
–50°C specification
Removal
–50°C specification
Installation
DDD00006
• Refilling with coolant
Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
30-14 D155C-1
Disassembly and assembly Fuel injection pump
8 DED00008
10
9 DED00009
11
DED00010
D155C-1 30-15
Disassembly and assembly Fuel injection pump
12
13
DED00011
13 13
DED00012
Installation 16
[*1] 15
a Adjust the linkage. For details, see Testing
and adjusting, Adjusting control linkage.
[*2]
3 Sleeve nut: DED00013
23.5 ± 1.0 Nm {2.4 ± 0.1 kgm}
[*3]
a Install the fuel injection pump according to 18 17
the following procedure.
1) After installing the pump assembly,
accurately match mark (15) on the
damper (I.J) to pointer (16).
2) Loosen the bolt of coupling (18) and set
the match mark (17) on the injection
pump.
DED00014
30-16 D155C-1
Disassembly and assembly Water pump
DED00015 DED00016
Standard
Installation 8
DED00018
[*1]
D155C-1 30-17
Disassembly and assembly Water pump
–50°C specification
Removal
30-18 D155C-1
Disassembly and assembly Water pump
–50°C specification
Installation
[*1]
D155C-1 30-19
Disassembly and assembly Turbocharger
3. Disconnect tube (4) and hose (5) and lift off air
cleaner assembly (6).
4 Air cleaner assembly: 35 kg
Standard
Installation
[*1]
3 Hose mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
7
8
DED00021
9
DED00020
30-20 D155C-1
Disassembly and assembly Turbocharger
–50°C specification
Removal
3. Disconnect tube (4) and hose (5) and lift off air
cleaner assembly (6).
4 Air cleaner assembly: 35 kg
–50°C specification
Installation
[*1]
3 Hose mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
7
8
DED00021
9
DED00020
D155C-1 30-21
Disassembly and assembly Nozzle holder
New/remodel
1
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
2
Remover
A 1 795-570-1100 t 1
assembly
Removal
DBD00413
1. Remove the hood assembly. For details, see
Removal of hood assembly.
Installation
• Carry out installation in the reverse order to
removal.
[*1]
4 Cylinder head cover mounting bolt:
24.5 ± 4.9 Nm {2.5 ± 0.5 kgm}
[*2]
4 Delivery tube sleeve nut:
23.5 ± 1.0 Nm {2.4 ± 0.1 kgm}
[*3]
4 Connector:
31.9 ± 2.5 Nm {3.25 ± 0.25 kgm}
4 Locknut: 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
[*4]
4 Holder mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
[*5]
a When installing the nozzle holder, clean its
mounting part and check that there is no
foreign matter in the sleeve.
Tighten the mounting bolts alternately so that
they will be tightened evenly.
30-22 D155C-1
Disassembly and assembly Cylinder head
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Remover
1 795-570-1100 t 1
assembly
A
Wrench (for angle-
2 790-331-1110 t 1
tightening)
Removal
D155C-1 30-23
Disassembly and assembly Cylinder head
16. Remove oil tube (22), oil filler (23), and boost
pressure compensator tube (44).
30-24 D155C-1
Disassembly and assembly Cylinder head
D155C-1 30-25
Disassembly and assembly Cylinder head
30-26 D155C-1
Disassembly and assembly Cylinder head
D155C-1 30-27
Disassembly and assembly Cylinder head
Installation
[*1]
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
[*2]
a Tighten the bolts in the order of [1] – [3], and
then tighten in the order of [4] – [24] as
shown in the figure at right.
[*3]
3 Joint bolt:
29.4 ± 4.9 Nm {1.15 ± 0.15 kgm}
[*4]
a When installing the hose, take care not to
twist it.
3 Joint bolt: 29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
a Check that the ball of the adjustment screw
is fitted to the socket of the push rod.
[*6] 3 Locknut:
[*10] [*12]
3 Locknut: 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
a When installing the mounting bolts, clean
their oil holes.
30-28 D155C-1
Disassembly and assembly Cylinder head
[*13]
3 Connector:
31.9 ± 2.5 Nm {3.25 ± 0.25 kgm}
[*14]
3 Holder mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
[*15]
a Check that the there is not dirt or foreign
matter on the cylinder head mounting face or
in the cylinder.
a When installing the gasket, check that the
grommet is not removed.
a Thoroughly apply molybdenum disulfide
(LM-P) to the threads and seat of the bolt.
a Tighten the cylinder head mounting bolts in
the order shown in the figure.
2 Mounting bolt:
Anti-friction compound (LM-P)
D155C-1 30-29
Disassembly and assembly Cylinder head
–50°C specification
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Remover
1 795-570-1100 t 1
assembly
A
Wrench (for angle-
2 790-331-1110 t 1
tightening)
Removal
4 Muffler assembly: 45 kg
30-30 D155C-1
Disassembly and assembly Cylinder head
16. Remove oil tube (22), oil filler (23), and boost
pressure compensator tube (44).
D155C-1 30-31
Disassembly and assembly Cylinder head
30-32 D155C-1
Disassembly and assembly Cylinder head
D155C-1 30-33
Disassembly and assembly Cylinder head
30-34 D155C-1
Disassembly and assembly Cylinder head
–50°C specification
Installation
[*1]
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
[*2]
a Tighten the bolts in the order of [1] – [3], and
then tighten in the order of [4] – [24] as
shown in the figure at right.
[*3]
3 Joint bolt:
29.4 ± 4.9 Nm {1.15 ± 0.15 kgm}
[*4]
a When installing the hose, take care not to
twist it. a Check that the ball of the adjustment screw
3 Locknut:
[*9]
3 Head cover mounting bolt: 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}
24.5 ± 9.8 Nm {2.5 ± 1.0 kgm}
[*12]
3 Locknut: 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
[*10]
a When installing the mounting bolts, clean
their oil holes.
D155C-1 30-35
Disassembly and assembly Cylinder head
[*13]
3 Connector:
31.9 ± 2.5 Nm {3.25 ± 0.25 kgm}
[*14]
3 Holder mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
[*15]
a Check that the there is not dirt or foreign
matter on the cylinder head mounting face or
in the cylinder.
a When installing the gasket, check that the
grommet is not removed.
a Thoroughly apply molybdenum disulfide
(LM-P) to the threads and seat of the bolt.
a Tighten the cylinder head mounting bolts in
the order shown in the figure.
2 Mounting bolt:
Anti-friction compound (LM-P)
30-36 D155C-1
Disassembly and assembly Thermostat
Installation
D155C-1 30-37
Disassembly and assembly Radiator
30-38 D155C-1
Disassembly and assembly Radiator
D155C-1 30-39
Disassembly and assembly Radiator
Standard
Installation
1. Radiator assembly
1) Gradually lift up and set radiator assembly
(20) to the mounting position, taking care
that it will not interfere with and break other
parts.
a After positioning the radiator assembly,
lightly tighten the upper mounting bolts
and the bolts to connect the lower
support and shroud.
2) Tighten radiator upper mounting bolts (17).
3) Tighten bolts (18) to connect the radiator
and shroud.
4) Tighten radiator lower supports (19).
3. Rod
Connect radiator shutter rod (15).
a Bend the cotter pin securely.
4. Wiring
Connect side light wire (14).
5. Plate
Install plate (13).
6. Radiator grille
Install radiator grille (12).
30-40 D155C-1
Disassembly and assembly Radiator
7. Plate
Install plate (11)
8. Piping
10. Underguard
Sling underguard (2) and set it to the frame, and
then tighten the mounting bolts.
D155C-1 30-41
Disassembly and assembly Radiator
30-42 D155C-1
Disassembly and assembly Radiator
–50°C specification
Removal
D155C-1 30-43
Disassembly and assembly Radiator
30-44 D155C-1
Disassembly and assembly Radiator
D155C-1 30-45
Disassembly and assembly Radiator
–50°C specification
Installation
1. Radiator assembly
1) Gradually lift up and set radiator assembly
(20) to the mounting position, taking care
that it will not interfere with and break other
parts.
a When installing the radiator assembly, keep
the radiator shutter closed.
a After positioning the radiator assembly,
lightly tighten the upper mounting bolts and
the bolts to connect the lower support and
shroud.
2) Tighten radiator upper mounting bolts (17).
3) Tighten bolts (18) to connect the radiator
and shroud.
4) Tighten radiator lower supports (19).
3. Rod
Connect radiator shutter rod (15).
a Bend the cotter pin securely.
5. Plate
Install plate (13).
6. Radiator grille
Install radiator grille (12).
30-46 D155C-1
Disassembly and assembly Radiator
7. Plate
Install plate (11)
8. Piping
1) Stick the gasket and connect bypass tube
(10).
2 Gasket: Gasket sealant (LG-1)
2) Connect aeration hose (9).
3) Stick the gasket and connect radiator inlet
tube (8).
2 Gasket: Gasket sealant (LG-1)
9. Hood
1) Using sling [1], install hood (7).
D155C-1 30-47
Disassembly and assembly Radiator
11. Underguard
Sling underguard (2) and set it to the frame, and
then tighten the mounting bolts.
30-48 D155C-1
Disassembly and assembly Fuel tank
Standard
Installation
D155C-1 30-49
Disassembly and assembly Fuel tank
–50°C specification
Removal
–50°C specification
Installation
30-50 D155C-1
Disassembly and assembly Torque converter and winch oil cooler
Standard
Installation
D155C-1 30-51
Disassembly and assembly Torque converter and winch oil cooler
–50°C specification
Removal
–50°C specification
Installation
30-52 D155C-1
Disassembly and assembly Engine
D155C-1 30-53
Disassembly and assembly Engine
30-54 D155C-1
Disassembly and assembly Engine
D155C-1 30-55
Disassembly and assembly Engine
Standard
Installation
[*1]
3 Mounting bolt:
98.1 – 121.6 Nm {11.2 – 12.4 kgm}
• Bleeding air
Bleed air from the fuel system. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
30-56 D155C-1
Disassembly and assembly Engine
–50°C specification
Removal
D155C-1 30-57
Disassembly and assembly Engine
30-58 D155C-1
Disassembly and assembly Engine
D155C-1 30-59
Disassembly and assembly Engine
30-60 D155C-1
Disassembly and assembly Engine
–50°C specification
Installation
[*1]
3 Mounting bolt:
98.1 – 121.6 Nm {11.2 – 12.4 kgm}
• Bleeding air
Bleed air from the fuel system. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
D155C-1 30-61
Disassembly and assembly PTO
3. Hoses
1) Disconnect counterweight cylinder hose (3).
2) Disconnect heater hose (4).
4. Piping
1) Disconnect counterweight pump outlet tube
(9).
2) Remove counterweight pump inlet tube (10).
3) Disconnect steering pump outlet hose (11).
4) Remove steering pump inlet tube (12).
30-62 D155C-1
Disassembly and assembly PTO
5. Lubrication tube
Disconnect PTO lubrication tube (13) from en-
gine flange.
6. PTO assembly
Sling PTO assembly (14). Remove 11 bolts (15)
fastening assembly; lift out PTO assembly.
4 PTO assembly: 230 kg
D155C-1 30-63
Disassembly and assembly PTO
Installation
1. PTO assembly
1) Fit O-ring in place and lift PTO assembly
(14) into position so that its splines come
into alignment with those of flywheel hous-
ing.
2. Lubrication tube
With gasket in place, connect lubrication tube
(13).
3. Piping
1) With O-ring in place, install steering pump
inlet tube (12).
2) Connect steering pump outlet hose (11).
3) With O-ring in place, install counterweight
pump inlet tube (10).
4) With O-ring in place, connect counterweight
pump outlet tube (9).
30-64 D155C-1
Disassembly and assembly PTO
4. Hoses
Fit O-ring in place and connect counterweight
cylinder hose (3).
a Make sure hoses are not twisted and do not
interfere with other parts.
6. Oil feeding
1) Tighten hydraulic tank drain plug.
2) Refill hydraulic tank at its oil filler (16) with
engine oil up to the specified level.
5 Hydraulic tank: Approx. 30 l
a Start and run engine to let oil circulate in
hydraulic piping.
Then, check oil level again.
D155C-1 30-65
Disassembly and assembly PTO
1. Lubrication tube
1) Lay down PTO assembly (1) stably with a
block [1] wedged under the assembly.
2) Remove PTO lubrication tube (2).
2. Pumps
1) Turn PTO assembly upside down so that
pumps face upward.
Support PTO assembly on blocks [2] (200
mm high).
2) Remove counterweight pump (3).
3) Remove steering pump (4).
3. Covers
1) Remove flange (5).
2) Remove cover (6).
3) Remove cover (7); take out oil seal cage (8).
30-66 D155C-1
Disassembly and assembly PTO
4. Case assembly
1) Remove mounting bolts.
2) Attach eyebolt [3] (10 mm P = 1.5) to case;
lift out case assembly (12).
D155C-1 30-67
Disassembly and assembly PTO
11. Bearings
1) Remove bearings (27) from casing (26).
2) Remove bearing outer races (29) from cas-
ing (28).
30-68 D155C-1
Disassembly and assembly PTO
Assembly
k Take special care to prevent accidents when tur-
ing PTO assembly upside down.
1. Bearing
Using press-fit tool [6], press-fit bearings (27)
into casing (28).
a Be sure to install snap ring after press-fitting
steering pump drive gear bearings.
D155C-1 30-69
Disassembly and assembly PTO
30-70 D155C-1
Disassembly and assembly PTO
9. Case assembly
1) Set case in press. Press-fit all bearing outer
races (29) using press-fit tool.
a After installing steering pump drive gear
bearing outer race, lock it with snap ring.
a Press-fit PTO drive shaft bearing outer
race after fitting snap ring to case.
10. Cover
1) With O-rings in place, install covers (11),
(10) and (9).
2) Turn PTO assembly upside down and sup-
port it on blocks [2].
D155C-1 30-71
Disassembly and assembly PTO
11. Pumps
1) With O-ring in place, install steering pump
(4).
2) With O-ring in place, install counterweight
pump (3).
30-72 D155C-1
Disassembly and assembly Transmission pump
Installation
• Carry out installation in the reverse order to re-
moval.
D155C-1 30-73
Disassembly and assembly Floor frame
1. Plates
1) Remove floor plates (2), (3) and (4).
a Before removing floor plate (4), discon-
nect decelerator rod.
30-74 D155C-1
Disassembly and assembly Floor frame
5. Wiring
Disconnect cable (17).
D155C-1 30-75
Disassembly and assembly Floor frame
9. Cover
Remove cover (24).
12. Bracket
Disconnect upper and lower pipes (30) and (31).
Remove bracket (32).
a Attach identification tags to disconnected
pipes to prevent their erroneous connection.
13. Bracket
Remove bracket (33) from frame.
30-76 D155C-1
Disassembly and assembly Floor frame
Installation
D155C-1 30-77
Disassembly and assembly Floor frame
2. Bracket
Fit bracket (33) to frame
3. Bracket
Install bracket (32). Connect upper and lower
pipes (31) and (30).
a Be careful not to connect pipes erroneously.
6. Cover
Install cover (24).
30-78 D155C-1
Disassembly and assembly Floor frame
8. Steering/brake rods
Connect 4 rods (21).
a Be sure to bend cotter pins securely.
10. Wiring
Connect cable (17).
D155C-1 30-79
Disassembly and assembly Floor frame
14. Plates
1) Install plates (7), (6) and (5).
30-80 D155C-1
Disassembly and assembly Torque converter
2. Plates
Remove plates (2) and (3).
3. Underguard
Using transmission jack [1], remove torque con-
verter underguard (4).
4 Underguard: 155 kg
D155C-1 30-81
Disassembly and assembly Torque converter
5. Piping
1) Disconnect scavenging pump outlet tube
(6).
6. Wiring
Disconnect torque converter oil temperature
gauge lead (10).
7. Universal joint
Sling universal joint (12), remove mounting
bolts, and lift out the joint.
4 Universal joint: 25 kg
30-82 D155C-1
Disassembly and assembly Torque converter
Installation
D155C-1 30-83
Disassembly and assembly Torque converter
3. Universal joint
1) Lift universal joint (12) into position on cou-
pling.
2) Install and tighten mounting bolts.
2 Mounting bolt:
127.5 ± 3.9 Nm {13 ± 0.4 kgm}
a After installation, apply grease (GLT2-
LI).
4. Wiring
Connect the torque converter oil temperature
gauge lead (10).
5. Piping
1) With O-ring in place, connect torque con-
verter relief valve outlet tube (9) and inlet
tube (8).
2) With O-ring in place, connect torque con-
verter regulating valve outlet tube (7).
30-84 D155C-1
Disassembly and assembly Torque converter
6. Underguard
Using transmission jack [1] install torque con-
verter underguard (4).
k Support center of underguard stably on
transmission jack and install guard carefully
to prevent accidental falling.
7. Plates
Install plates (3) and (2).
8. Oil feeding
1) Tighten steering case drain plug.
2) Refill with engine oil at oil filler (15) up to
specified oil level.
5 Steering, transmission and torque
converter: Approx. 195 l
a Start and run engine to let oil to circulate
in piping. Then, check oil level again.
D155C-1 30-85
Disassembly and assembly Torque converter
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Disassembly
1. Torque converter assembly
1) Set torque converter assembly (1) on tool B.
2) Remove regulator valve assembly (2).
3) Remove relief valve assembly (3).
4) Remove strainer (4).
5) Remove scavenging pump assembly (5).
6) Remove coupling (6).
2. Drain plug
Remove the cover and remove 2 drain plugs (7)
to drain oil in the pump drive case.
4. Pilot
Using an forcing screw, remove pilot (9).
30-86 D155C-1
Disassembly and assembly Torque converter
6. Stator
Remove stator (15).
7. Race
Remove snap ring (16), then remove race (17).
D155C-1 30-87
Disassembly and assembly Torque converter
8. Pump assembly
1) Remove pump assembly (18).
30-88 D155C-1
Disassembly and assembly Torque converter
D155C-1 30-89
Disassembly and assembly Torque converter
30-90 D155C-1
Disassembly and assembly Torque converter
Assembly
a Apply G2-Ll on the O-ring and oil seal.
1. Case
Set case (40) on tool B.
D155C-1 30-91
Disassembly and assembly Torque converter
30-92 D155C-1
Disassembly and assembly Torque converter
4. Pump assembly
1) Fine assembly of pump assembly
i) Using a push tool, press-fit outer race
(21).
ii) Mount gear (20) and tighten it with
mounting bolt (19).
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
D155C-1 30-93
Disassembly and assembly Torque converter
5. Race
Mount race (17) and fix it with snap ring (16).
6. Stator
Mount stator (15).
2 Mounting bolt: Liquid adhesive (LT-2)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
30-94 D155C-1
Disassembly and assembly Torque converter
8. Pilot
Install pilot (9) and fix it with the lock plate.
3 Mounting bolt:
110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
D155C-1 30-95
Disassembly and assembly Torque converter relief valve
Installation
30-96 D155C-1
Disassembly and assembly Torque converter regulating valve
Installation
D155C-1 30-97
Torque converter relief valve
Disassembly and assembly Torque converter regulator valve
Assembly
1. Assemble spool (4), spring (3), shim (2), and
spacer (1) to the valve body, and install the O-
ring to tighten the plug.
Assembly
1. Assemble spool (2) and spring (1) to the valve
body and install the O-ring to tighten the plug.
30-98 D155C-1
Disassembly and assembly Transmission control valve
1. Floor plates
Remove floor plates (1), (2) and (3).
a Before removing floor plate (3), disconnect
decelerator rod.
2. Switch
Remove switch (4).
4. Wiring
Remove intermediate clamp of cable (7).
5. Steering rod
Disconnect steering rod (8).
6. Piping
Disconnect transmission control valve inlet and
outlet tubes (9) and (10).
7. Cover
Remove cover (11).
8. Cover assembly
1) Remove sleeve (12).
2) Loosen inspection plug (13).
a This is to facilitate removal of inspection
plug in the course of reassembly of
transmission control valve.
3) Remove cover assembly (14).
D155C-1 30-99
Disassembly and assembly Transmission control valve
Installation
2. Cover assembly
1) Remove inspection plug (3).
2) With gasket in place, position spool yoke
properly to cover lever, and install cover as-
sembly (14).
a After installing cover assembly, check
inspection plug hole to see that lever is
fitting into yoke.
3) With O-ring in place, install and tighten in-
spection plug (13).
4) With O-ring in place, install sleeve (12).
3. Cover
With gasket in place, install cover (11).
4. Piping
With O-rings in place, connect transmission con-
trol valve inlet and outlet tubes (10) and (9).
30-100 D155C-1
Disassembly and assembly Transmission control valve
5. Steering rod
Connect steering rod (8).
a Be sure to bend cotter pin securely.
6. Piping
Install intermediate clamp of cable (7).
8. Switch
Install switch (4) and connect lead.
9. Floor plates
Install floor plates (3), (2) and (1).
a After installing floor plate (3), connect decel-
erator rod and bend cotter pin securely.
D155C-1 30-101
Disassembly and assembly Transmission control valve
30-102 D155C-1
Disassembly and assembly Transmission control valve
D155C-1 30-103
Disassembly and assembly Transmission control valve
Assembly
30-104 D155C-1
Disassembly and assembly Transmission control valve
3 Lock nut:
• Dimension a: 29 mm
3 Lock nut:
tighten the lock nut.
D155C-1 30-105
Disassembly and assembly Transmission
30-106 D155C-1
Disassembly and assembly Transmission
Installation
• Carry out installation in the reverse order to re-
moval.
[*1] [*2]
a Surely twist the cotter pin.
D155C-1 30-107
Disassembly and assembly TORQFLOW transmission assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Disassembly
a Store removed discs and plates on a flat place so
that they do not bend.
2. Sleeve, cover
1) Remove cover (2).
2) Remove sleeve (3).
3) Remove cover (4).
30-108 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
5. Transmission case
1) Remove mounting bolts (11) and (12).
2) Remove transmission case (13).
6. Coupling
1) Remove holder (14).
2) Using puller [2], remove coupling (15).
D155C-1 30-109
Disassembly and assembly TORQFLOW transmission assembly
8. Shaft assembly
1) Remove spacer (24).
2) Using eyebolt [3], remove shaft assembly
(25).
30-110 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-111
Disassembly and assembly TORQFLOW transmission assembly
14. Plate
Using an eyebolt, remove plate (49).
30-112 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-113
Disassembly and assembly TORQFLOW transmission assembly
24. Plate
Using an eyebolt, remove plate (71).
30-114 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-115
Disassembly and assembly TORQFLOW transmission assembly
30-116 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-117
Disassembly and assembly TORQFLOW transmission assembly
30-118 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
29. Bearing
1) Remove bearing (115).
2) Remove outer race (116).
D155C-1 30-119
Disassembly and assembly TORQFLOW transmission assembly
Assembly
a Apply grease (G2-LI) to seal rings before instal-
lation.
a Install seal ring (a) for the piston with the pres-
sure receiving side (side "b") directed to housing
(c) as shown in the figure.
1. Transfer case
Set transfer case (117) on tool C1.
2. Bearing
1) Using a push tool, press-fit outer race (116).
2) Using a push tool, press-fit bearing (115).
30-120 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
3 Mounting bolt:
vi) Insert the shim and install holder (106).
D155C-1 30-121
Disassembly and assembly TORQFLOW transmission assembly
3 Mounting bolt:
(LT-2)
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
a When tightening the mounting bolts per-
manently after adjusting the backlash
and tooth contact, check that the shim
has not fallen and take care not to drop
them.
a The mounting bolts for the spare trans-
mission assembly are not coated with
adhesive (LT-2). Referring to Assembly
of bevel gear shaft assembly, adjust the
backlash and tooth contact. Then, tight-
en the mounting bolts to the following
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
a Even if the shim on the bevel pinion side
does not need to be adjusted, apply ad-
hesive (LT-2) to the mounting bolts and
tighten them to the tightening torque.
30-122 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-123
Disassembly and assembly TORQFLOW transmission assembly
30-124 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-125
Disassembly and assembly TORQFLOW transmission assembly
6. Guide pin
Install guide pin (72).
7. Plate
Use an eyebolt to install plate (71).
a Using a plastic hammer or other tool, strike in
the dowel pin until there is no more space left
in the contacting face.
30-126 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-127
Disassembly and assembly TORQFLOW transmission assembly
17. Plate
Using an eyebolt, install plate (49).
a Using a plastic hammer or other tool, strike in
the dowel pin until there is no more space in
the contacting face.
30-128 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-129
Disassembly and assembly TORQFLOW transmission assembly
30-130 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-131
Disassembly and assembly TORQFLOW transmission assembly
25. Coupling
1) Install coupling (15).
2) Install the O-ring, then install bolt (14).
3 Mounting bolt:
110.5 ± 12.25 Nm {11.25 ± 1.25 kgm)
(Applicable serial numbers:
50001 to 50900)
384.46 ± 41.65 Nm {39.25 ± 4.25 kgm}
(Applicable serial numbers:
50901 and up)
30-132 D155C-1
Disassembly and assembly TORQFLOW transmission assembly
D155C-1 30-133
Disassembly and assembly Transmission lubrication valve
Installation
30-134 D155C-1
Disassembly and assembly Transmission lubrication valve
Assembly
1. Assemble valve (4), spring (3), and guide (2) to
the valve body.
D155C-1 30-135
Disassembly and assembly Steering control valve
30-136 D155C-1
Disassembly and assembly Steering control valve
Installation
D155C-1 30-137
Disassembly and assembly Steering control valve
1. Piston
Pry snap ring (1) out. Turn in jack bolt [1] (8 mm,
P = 1.25) to stopper (2) and pull jack bolt with
pliers to remove the stopper. Take out piston (3).
2. Relief valve
Pry snap ring (4) out. Turn in jack bolt (8 mm, P
= 1.25) to stopper (5) and pull jack bolt with pli-
ers to remove the stopper. Then, take out spring
(6), valve (7) and piston (8).
1. Cover
Remove cover (1).
30-138 D155C-1
Disassembly and assembly Steering control valve
4. Modulating valve
Remove plate (9) and take out spool (10), valve
(11), piston (12) and spring (13).
D155C-1 30-139
Disassembly and assembly Steering control valve
Assembly
2. Piston
Install piston (3) in housing, fit stopper (2), and
lock with snap ring (1).
a Install piston so that the larger oil hole
faces pipe mounting side.
2. Modulating valve
1) Insert piston (12) into valve (11). Install
spring (13), valve (11) and spool (10), in that
order. in housing.
2) Fit plate (9) to housing.
a Install spool so that longer notch is posi-
tioned on right side as viewed from
housing.
30-140 D155C-1
Disassembly and assembly Steering control valve
5. Cover
With gasket in place, fit cover (1).
D155C-1 30-141
Disassembly and assembly Brake safety valve
Installation
30-142 D155C-1
Disassembly and assembly Brake safety valve
1. Safety valve
1) Remove capnut (1) and take out spring (2)
and plunger (3).
2) Loosen lock nut (4) and remove seat (5).
2. Piston
Pry snap ring (6) out, remove stopper (7), and
take out piston (8).
Assembly
1. Piston
Insert piston (8) into valve body. Install stopper
(7) and lock with snap spring (6).
a Coat piston with engine oil before assembly.
2. Safety valve
1) Install seat (5) in valve body and tighten
locknut (4).
2) Install plunger (3) and spring (2). Tighten
capnut (1).
D155C-1 30-143
Disassembly and assembly Steering pump
Installation
30-144 D155C-1
Disassembly and assembly Steering clutch
D155C-1 30-145
Disassembly and assembly Steering clutch
30-146 D155C-1
Disassembly and assembly Steering clutch
Installation
• Carry out installation in the reverse order to re-
moval.
[*1] [*2]
a Surely bend the cotter pin.
[*3]
3 Mounting bolt:
548.8 ± 58.8 Nm {56.0 ± 6.0 kgm}
[*4]
3 Mounting bolt (14):
382.2 ± 44.1 Nm {39.0 ± 4.5 kgm}
3 Mounting bolt (15):
274.4 ± 34.3 Nm {26.0 ± 3.5 kgm}
[*4]
a Install the brake band with the pin position
facing the body.
• Alignment
a See "Alignment of brake pedal stroke" of
Testing and adjusting for alignment of a brake
pedal stroke.
D155C-1 30-147
Disassembly and assembly Brake booster
Assembly
1. Install the following parts to valve body (2):
1) Build in spool (7) and piston (6).
a Install the spool with the taper seal sur-
face facing the piston.
2) Build in spring (5) and retainer (4), and fix
them with snap ring (3).
30-148 D155C-1
Disassembly and assembly Steering relief valve
Assembly
1. Build piston (5), valve (4), and spring (3) in the
valve body.
D155C-1 30-149
Disassembly and assembly Steering clutch
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-465-5001 Compressor 1
790-101-1102 Pump 1
D
Puller
790-101-2102 1
(294 kN {30 ton})
Disassembly
1. Remove brake band (1).
30-150 D155C-1
Disassembly and assembly Steering clutch
Assembly
1. Install the seal ring on clutch piston (12) and set
the clutch piston on tool D.
D155C-1 30-151
Disassembly and assembly Bevel gear shaft
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Disassembly
1. Steering clutch assembly
See "Removal of steering clutch assembly" for
removal of left and right steering clutch assem-
blies.
4. Nut
Fix the bevel gear through bolt holes on the hub,
then remove nut (2).
5. Hub nut
Remove the lock plate, fix the hub with plate [1],
and use tool E1 to remove left and right hub nuts
(3).
6. Packings
Remove left and right packings (4).
7. Hub
Set tool E2, then remove left and right hubs (5).
30-152 D155C-1
Disassembly and assembly Bevel gear shaft
8. Bearing
1) Temporarily raise the bevel gear shaft as-
sembly and remove mounting bolts, then
use extraction bolts [2] to remove left and
right bearing cages (6).
a Check the number and thickness of
shims assembled in the bearing cage
before storing them.
2) Remove outer races (7) from left and right
bearing cages.
9. Shaft assembly
1) Gently strike the bevel gear to pull out the
faucet joint portion of the shaft, then remove
shaft assembly (8).
a Take out the shaft assembly from the
right clutch housing.
4 Bevel gear shaft assembly : 40 kg
2) Using puller [3], remove left and right bear-
ings (9).
D155C-1 30-153
Disassembly and assembly Bevel gear shaft
Assembly
1. Bevel gear
Set bevel gear (10) in the case.
2. Shaft assembly
1) Using push tool [4], press-fit left and right
bearings (9).
2) Build shaft assembly (8) in the bevel gear.
a Insert the shaft assembly from the right
clutch housing.
3) Temporarily tighten hub nuts on both ends
of the shaft, then raise the shaft to align the
bevel gear to the faucet joint portion of the
shaft.
4) Install the bevel gear mounting bolts, build
the lock plate in, and temporarily tighten the
nut.
3. Bearing cages
1) Using push tool [5], press-fit outer race (7).
30-154 D155C-1
Disassembly and assembly Bevel gear shaft
4. Nuts
Temporarily assemble the hub, install the locks
in bolt holes on the hub, and tighten nuts (21),
then fix the hub with the lock plate.
3 Nut: 230 – 309 Nm {23.5 – 31.5 kgm}
5. Adjusting preload
a When adjusting the preload, remove the
transmission. For details, see Removal of
transmission assembly.
a Revolve the bevel gear shaft by 2 – 3 turns
to fit the bearing, then adjust the preload on
the bearing according to the following proce-
dure.
1) Apply push-pull scale (6) to the outside
tooth tip of the bevel gear shaft assembly
and measure the running torque of the bevel
gear shaft assembly.
• Turning force: 19.6 – 58.8 Nm {2 – 6 kgm}
2) If the turning force is higher or lower than
the standard value, increase or decrease
the shims in 3.
D155C-1 30-155
Disassembly and assembly Bevel gear shaft
30-156 D155C-1
Disassembly and assembly Bevel gear shaft
Adjusting
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
a For adjustment of the shims on the bevel
pinion side, see Assembly of TORQ-
FLOW transmission assembly.
i) When bevel pinion is too far from center
line of bevel gear:
Contact is at the small end of the con-
vex tooth face of the bevel gear and at
the big end of the concave tooth face.
• Adjust the shim thickness at the bevel
pinion end and move the bevel pinion in
direction A.
Or, adjust the shim thickness and move
the bevel gear in direction B.
After adjusting, check the tooth contact
pattern and backlash again.
ii) When 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 as follows:
Adjust the shim thickness at the bevel
pinion end and move the bevel pinion in
direction A.
Or adjust the shim thickness and move
the bevel gear in direction B.
After adjusting, check the tooth contact
pattern and backlash again.
7. Hubs
1) Install the seal ring and align left and right
hubs to the taper serration part to build them
in the bevel gear shaft.
2) Using tool E3, press-fit left and right hubs
(6).
a Press-fitting part: Lubricant containing
molybdenum disulfide (LM-P)
a Press-fitting force: 294 kN {30 ton}
a After press-fitting the hubs, measure di-
mension a between the level difference
on the bevel gear shaft and surface of
the hub.
a Dimension a: 5 to 6.5 mm
D155C-1 30-157
Disassembly and assembly Bevel gear shaft
8. Packing
Build in left and right packings (4).
9. Hub nuts
Fix the hub with plate [1], then use tool E1 to
tighten left and right hub nuts (3) and fix the hub
with the lock plate.
3 Hub nut: 686 ± 49 Nm {70 ± 5 kgm}
a When aligning lock holes of hub nuts, do not
turn any hub nut to the loosening direction
even within the specified torque.
30-158 D155C-1
Disassembly and assembly First pinion
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Remover and
1 791-475-6000 1
installer
791-480-3001 Remover D 1
790-101-1102 Pump 1
2
Puller
G 790-101-3800 1
(490 kN {50 ton})
791-480-4001 Installer C 1
790-101-1102 Pump 1
3
Puller
790-101-3800 1
(490 kN {50 ton})
Disassembly
1. See "Removal of steering clutch assembly" for
removal of the steering clutch assembly.
D155C-1 30-159
Disassembly and assembly First pinion
30-160 D155C-1
Disassembly and assembly First pinion
Assembly
1. Fine assembly of first pinion assembly
1) Using a push tool, press-fit inner race (9).
2) Using a push tool, press-fit inner race (8).
D155C-1 30-161
Disassembly and assembly Final drive
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 791-575-1301 Box 1
791-575-1400 Wrench 1
2 791-108-1370 Guide 1
791-420-6130 Handle 1
791-576-1003 Remover A 1
791-101-1102 Pump 1
3
Cylinder
791-101-1600 1
(686 kN {70 ton})
791-575-2003 Installer A 1
791-101-1102 Pump 1
4
Cylinder
791-101-1600 1
(686 kN {70 ton})
5 791-575-1520 Installer 1
6 791-580-1510 Installer 1
791-575-3003 Remover 1
790-101-1102 Pump 1
7
F Cylinder
790-101-1600 1
(686 kN {70 ton})
791-575-4003 Installer 1
790-101-1102 Pump 1
8
Puller
790-101-2102 1
(294 kN {30 ton})
9 791-551-1300 Wrench 1
791-575-5500 Remover B 1
790-101-1102 Pump 1
10
Cylinder
790-101-1600 1
(686 kN {70 ton})
791-575-6110 Plug 1
or
791-575-6501 Installer 1
11
790-101-1102 Pump 1
Cylinder
790-101-1160 1
(686 kN {70 ton})
12 790-401-1800 Lifting tool 1
Disassembly
1. Track frame assembly
See "Removal of track frame assembly" for re-
moval of the track frame assembly.
2. Drainage of oil
Remove the drain plug and drain oil in the final
drive case and steering case.
6 Steering, transmission case: 149 l
6 Final drive case: 55 l (1 side)
3. Cover
Remove cover (1).
30-162 D155C-1
Disassembly and assembly Final drive
4. Nut
Remove lock plate (2) and use tool F1 to re-
move nut (3).
5. Support
1) Remove washer (4).
2) Remove support (5).
a Store floating seals in a pair.
3) Fine disassembly of support.
Remove bushing (6).
6. Collar, key
1) Remove collar (7).
2) Remove key (8).
7. Sprocket nut
1) Remove lock (9).
2) Using tool F2, remove sprocket nut (10).
8. Retainer
Remove retainer (11).
D155C-1 30-163
Disassembly and assembly Final drive
9. Sprocket assembly
1) Using tool F3, pull out the press-fitted part of
the sprocket assembly and remove sprocket
boss assembly (12)
a Store floating seals in a pair.
4 Sprocket boss assembly: 350 kg
30-164 D155C-1
Disassembly and assembly Final drive
D155C-1 30-165
Disassembly and assembly Final drive
13. Nut
1) Remove snap ring (38), then remove pin
(39).
2) Using tool F9, loosen nut (40).
30-166 D155C-1
Disassembly and assembly Final drive
Assembly
1. Sprocket shaft
Using tool F11, press-fit sprocket shaft (41).
2 Press-fitting part: Lubricant contain-
ing molybdenum disulfide (LM-P)
a Press-fit the shaft with the key groove facing
up.
a Build the nut and snap ring in the shaft during
press-fitting.
a Press-fitting force:
147 to 529.2 kN (15 to 54 t)
2. Nut
1) Using tool F9, tighten nut (40).
a Align the pin hole of the shaft to that of
the nut.
2) Install pin (39) and fix it with snap ring (38).
D155C-1 30-167
Disassembly and assembly Final drive
4) Measurement of backlashes
Measure backlashes of first pinion (42), first
gear (43), second pinion (44), and second
gear (45).
a Standard values of backlashes
1st pinion and 1st gear: 0.27 to 0.68 mm
2nd pinion and 2nd gear:
0.31 to 0.82 mm
30-168 D155C-1
Disassembly and assembly Final drive
6. Sprocket assembly
1) Fine assembly of sprocket assembly
Install the following parts to boss (13):
i) Install teeth (15).
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
1,176 ± 98 Nm {120 ± 10 kgm}
ii) Install cover (14).
3 Mounting bolt:
110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
D155C-1 30-169
Disassembly and assembly Final drive
7. Retainer
Install retainer (11).
3 Mounting bolt:
176.4 ± 19.6 Nm {18 ± 2 kgm}
8. Sprocket nut
1) Install the O-ring to the sprocket, then use
tool F2 to tighten sprocket nut (10).
2) Install lock (9).
9. Collar, key
1) Install key (8).
2) Install collar (7).
a Install the collar with the larger outer di-
ameter facing the body.
30-170 D155C-1
Disassembly and assembly Final drive
10. Support
1) Fine assembly of support
Using a push tool, press-fit bushing (6).
2) Using tool F5, build floating seals in the
sprocket and support.
a Apply oil thinly on surfaces of seals after
building them in.
11. Nut
1) Using tool F1, tighten nut (3) and fix it with
lock plate (2).
3 Nut:
1,715 ± 245 Nm {175 ± 25 kgm}
D155C-1 30-171
Disassembly and assembly Final drive
12. Cover
Install cover (1).
3 Mounting bolt:
276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
30-172 D155C-1
Disassembly and assembly Track
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Removal
1. Boom-and-frame assembly (on the left side)
See Removal of boom-and-frame assembly.
3. Positioning machine
Position machine so that there is enough room
for track to be fully separated. Move machine
back and forth until master link of track is be-
tween idler and carrier roller.
5. Master pin
Set special tools N on machine and remove
master pin (9).
D155C-1 30-173
Disassembly and assembly Track
6. Temporary pin
Remove special tools and insert temporary pin
(5) in master pin hole. Move machine forward
until master link comes near ground. Wedge
block [1] approximately 150 mm high under the
grouser beneath temporary pin and set machine
on it. Pull out temporary pin.
a Setting track on block is to relieve track ten-
sion at temporary pin area.
7. Separating track
Pull out temporary pin and disconnect track. In-
sert bar [2] into hole of last link and sling the bar
from crane. Back machine slowly, allowing track
(6) to ride over carrier rollers and off the sprock-
et.
k To assure safety during track separa-
tion work, be sure to make proper sig-
nals between persons in cooperation
with each other.
Installation
1. Installing track
As machine is moved slowly forward, put bar [2]
into the last link and guide track (6) over sprock-
et, carrier rollers and idler.
k To assure safety during track installa-
tion work, be sure to make proper sig-
nals between persons in cooperation
with each other.
3. Temporary pin
Align holes and install temporary pin (5).
30-174 D155C-1
Disassembly and assembly Track
4. Positioning machine
Back machine until temporary pin is located to
the middle position between idler and carrier
roller.
5. Master pin
Using special tool N, press-fit master pin (4).
a Install master pin so that each end of pin pro-
trudes equally from links.
D155C-1 30-175
Disassembly and assembly Carrier roller
2. Jacking up track
Using jack [1] placed on track frame rear cover,
raise track (5) enough to provide 350 mm or
more of clearance between carrier roller support
and track link.
30-176 D155C-1
Disassembly and assembly Carrier roller
Installation
1. Jacking up track
Using jack [1] placed on track frame rear cover,
raise track (5).
a Jack up track enough to provide approx. 350
mm of clearance between carrier roller sup-
port mounting face and track link.
D155C-1 30-177
Disassembly and assembly Track roller
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Removal
3. Raising machine
To remove any of rear rollers, place block [1] ap-
proximately 300 mm high behind track. Drive
the machine backwards allowing track to climb
up on block just enough to lift roller (6) off track.
k Set parking brake securely. To remove any
of front rollers, drive the machine onto a
block placed ahead of idler.
30-178 D155C-1
Disassembly and assembly Track roller
Installation
D155C-1 30-179
Disassembly and assembly Recoil spring
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 791-685-8000 Compressor t 1
Cylinder
J 2 790-101-1300 t 1
(981 kN {100 ton})
3 790-101-1102 Pump t 1
Disassembly
1. Set recoil spring assembly (1) on tool J.
k Because the installation load of the spring is
large, surely set the spring to avoid danger.
a Spring installation load:
216,580 kN {22,100 kg}
30-180 D155C-1
Disassembly and assembly Recoil spring
Assembly
1. Build pilot (8), bolt (7), shaft (6), and rear pilot
(5) in spring (4), then set the spring on tool H.
k Because the installation load of the spring is
large, surely set the parts to avoid danger.
D155C-1 30-181
Disassembly and assembly Track frame
1. Separating track
See Removal of track assembly.
2. Raising machine
1) Raise the rear end of machine by slinging
the rear end of right and left track frames
and placing block [1] (approximately 90 mm
high) under right and left sides of steering
case.
4. Sprocket cover
1) Remove sprocket cover (2).
2) Remove cover (3).
30-182 D155C-1
Disassembly and assembly Track frame
D155C-1 30-183
Disassembly and assembly Track frame
Installation
2. Sprocket cover
1) Install cover (3).
2) Install sprocket cover (2).
2 Mounting bolt threads:
Adhesive compound (LT-2)
3 Mounting bolt:
274.6 ± 29.4 Nm {28 ± 3 kgm}
30-184 D155C-1
Disassembly and assembly Track frame
4. Lowering machine
1) Sling machine at front end of right and left
track frames. Remove block [2] and lower
front end of machine.
5. Track assembly
See Removal and installation of track assembly.
D155C-1 30-185
Disassembly and assembly Idler
Installation
• Carry out installation in the reverse order to re-
moval.
[*1]
a Standard shim thickness: 6 mm
3 Mounting bolt:
744.8 ± 83.3 Nm {76 ± 8.5 kgm}
[*2]
a Set the idler assembly in the center of the
track frame and align clearance a between
the track frame and guide plate.
a Standard clearance a: 0.5 to 1.0 mm
30-186 D155C-1
Disassembly and assembly Winch control valve
Installation
D155C-1 30-187
Disassembly and assembly Winch control valve
• Valve assembly
1) Remove plug (4) and take out spring (5).
2) Pull out valve (6) and shaft assembly (7)
from the valve body.
3) Remove piston (8) from valve (6).
• Camshaft assembly
1) Separate yoke (17) and rod (18) from cam-
shaft and remove lever assembly (19).
2) Remove lever (20).
a Put a match mark on camshaft and lever
before removing lever.
30-188 D155C-1
Disassembly and assembly Winch control valve
D155C-1 30-189
Disassembly and assembly Winch control valve
Assembly
• Camshaft assembly
1) Reassemble gland assembly using the fol-
lowing procedure:
i) Fit O-ring to gland (35) and install seal
(36).
ii) Install spool (34).
iii) Attach on O-ring and install plug (33).
3 Plug: 68.7 ± 9.8 Nm {7 ± 1 kgm}
30-190 D155C-1
Disassembly and assembly Winch control valve
• Valve assembly
1) Reassemble shaft assembly as follows:
Install retainer (15), spring (14), retainer
(13), spring (12), guide (11) and collar (10)
in that order to shaft (16). Then, lock with
snap ring (9).
D155C-1 30-191
Disassembly and assembly Winch control valve
30-192 D155C-1
Disassembly and assembly High/low speed selector valve
Installation
D155C-1 30-193
Disassembly and assembly High/low speed selector valve
30-194 D155C-1
Disassembly and assembly High/low speed selector valve
D155C-1 30-195
Disassembly and assembly High/low speed selector valve
Assembly
30-196 D155C-1
Disassembly and assembly High/low speed selector valve
D155C-1 30-197
Disassembly and assembly Towing winch pump
Installation
30-198 D155C-1
Disassembly and assembly Counterweight pump
Installation
D155C-1 30-199
Disassembly and assembly Counterweight cylinder
Installation
30-200 D155C-1
Disassembly and assembly Counterweight cylinder
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Disassembly
• Disassembly of piston rod and head assem-
bly
1. Piping
Detach tube (1) and remove elbow (2).
3. Nut
Using special tool K2, remove nut (6).
a Width across flats of nut;
4. Piston assembly
Detach piston assembly (7) from piston rod.
5. Head assembly
Detach head assembly (8) from piston rod.
D155C-1 30-201
Disassembly and assembly Counterweight cylinder
30-202 D155C-1
Disassembly and assembly Counterweight cylinder
Assembly
a Coat sliding surfaces of disassembled parts with
engine oil and make sure that they are free from
dust, scratches, and other defects.
D155C-1 30-203
Disassembly and assembly Counterweight cylinder
3. Head assembly
Set piston rod in special tool K1 and install head
assembly (8).
4. Piston assembly
Install piston rod assembly (7) on piston rod.
5. Nut
Install nut (6) with special tool K2.
3 Nut: 1.77 ± 0.18 kNm {180 ± 18.0 kgm}
7. Piping
1) Attach O-ring and install elbow (2).
2) Attach O-ring and install tube (1).
30-204 D155C-1
Disassembly and assembly Counterweight control valve
Installation
D155C-1 30-205
Disassembly and assembly Counterweight control valve
30-206 D155C-1
Disassembly and assembly Counterweight control valve
D155C-1 30-207
Disassembly and assembly Counterweight control valve
Assembly
30-208 D155C-1
Disassembly and assembly Counterweight control valve
10. Install valve (10), spring (9) and spring seat (8)
in that order into collar (7). Install collar, on
which O-ring is fitted, to housing (39).
D155C-1 30-209
Disassembly and assembly Gate frame
1. Boom/frame
See Removal and installation of boom/frame.
2. Counterweight/frame
See Removal and installation of counterweight/
frame.
5. Piping
Disconnect hoses (5) and (6) between block and
counterweight cylinder from their respective
tubes.
6. Clamp
1) Remove hose clamps (7) and (8).
2) Detach heater hose clamp on the bottom of
gate frame.
30-210 D155C-1
Disassembly and assembly Gate frame
7. Support
Remove oil filler clamp and detach support (9).
8. Bracket
Remove cover (10) and detach winch control
rod bracket (11) from frame.
Installation
2. Bracket
Attach winch control rod bracket (11) to frame
and install cover (10).
3. Support
Install support (9) and attach oil filler clamp.
D155C-1 30-211
Disassembly and assembly Gate frame
4. Clamp
1) Attach heater hose clamp on the bottom of
gate frame.
2) Attach clamp (8) for hose between control
valve and pump. Attach clamp (7) for hose
between control valve and block.
5. Piping
Attach O-rings and install hoses (6) and (5) to
connect counterweight cylinder to block.
8. Counterweight /frame
See Removal and installation of Counterweight /
frame.
9. Boom/frame
See Removal and installation of boom/frame.
30-212 D155C-1
Disassembly and assembly Counterweight/frame
1. Counterweight
Raise counterweight assembly fully. Remove
plates and bolts and lift off the right and lift coun-
terweight (1).
4 Counterweight (one piece): 1600 kg
2. Bracket
1) Sling bracket (2)
2) Pull joint pins (3) until the right and left cylin-
der piston rods can be detached. Set the
right and left cylinder assembly (4) to winch.
3) Pull out joint pins (3) fully to disconnect the
right and lift links (5) from bracket.
3. Link
Sling right or left link (5), pull out joint pin, and lift
off the link. Remove the opposite link in the
same way.
4 Link: 80 kg
D155C-1 30-213
Disassembly and assembly Counterweight/frame
4. Cylinder assembly
k Move control lever two or three times to ex-
pel the remaining pressure from piping.
1) Disconnect cylinder inlet and outlet pipes (7)
and (8).
2) Sling cylinder assembly (4), pull out joint
pin, and lift off cylinder assembly. Remove
the opposite cylinder assembly in the same
way.
4 Cylinder assembly: 62 kg
5. Link
Sling right or left link (6), pull out joint pin, and lift
off the link. Remove the opposite link in the
same way.
4 Link: 700 kg
a Identify the right and left links to prevent con-
fusion.
6. Frame
1) Sling frame (9).
2) Remove upper and lower mounting bolts (1)
and lift off frame.
4 Frame: 590 kg
30-214 D155C-1
Disassembly and assembly Counterweight/frame
Installation
1. Frame
1) Lift frame (9) into position on track frame
and gate frame.
2) Tighten upper and lower mounting bolts
(10).
2. Link
1) Lift link (6) into position to connect it to
frame. Insert the joint pin and install plate to
prevent pin from coming loose.
2) Place link on block [1].
3. Cylinder assembly
1) Lift cylinder assembly (4) into position to
connect it to frame. Insert joint pin and in-
stall plate to prevent pin from coming loose.
2) Attach O-rings and connect cylinder inlet
and outlet hose (7) and (8). Leave cylinder
assembly positioned on winch side.
D155C-1 30-215
Disassembly and assembly Counterweight/frame
4. Link
Lift link (5) into position to connect it to frame. In-
sert joint pin and install plate to prevent pin from
coming loose.
5. Bracket
1) Lift bracket (2) into position to connect it to
link (6). Insert joint pin and install plate to
prevent pin from coming loose.
6. Counterweight
1) Start engine and raise bracket to the end of
its stroke.
2) Lift counterweight (1) into position on brack-
et.
3) Install bolts and plates.
30-216 D155C-1
Disassembly and assembly Boom/frame
4. Sling boom (1), pull out joint pin (3), and lift off
boom.
4 Boom: 1850 kg (7.3 m-Boom)
Installation
D155C-1 30-217
Disassembly and assembly Towing winch
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
L 790-102-1100 Wrench t 1
Removal
Preparation work
• Lower the counterweight completely.
• Wind off wire rope from winch drum.
1. Rod
Detach control rod (1) from towing winch.
2. Piping
1) Remove intermediate clamp (2).
2) Disconnect tubes (3) and (4) leading to cool-
er.
3. Guard
Remove guard (5).
4. Plate
Remove plate (6) and take out shims.
a Check and record the number and thickness
of shims.
30-218 D155C-1
Disassembly and assembly Towing winch
5. Universal joint
1) Remove universal joint under cover.
2) Remove universal joint (7).
D155C-1 30-219
Disassembly and assembly Towing winch
Installation
2. Universal joint
1) Position universal joint (7) on coupling and
tighten mounting bolts.
3 Mounting bolt:
107.9 ± 14.7 Nm {11 ± 1.5 kgm}
2) Install universal joint under cover.
3. Plate
Attach shims and install plate (6).
a Standard shim thickness: 4.6 mm
4. Guard
Install guard (5).
30-220 D155C-1
Disassembly and assembly Towing winch
5. Piping
1) Attach O-rings and connect tubes (4) and
(3) leading to winch control valve from cool-
er.
2) Attach intermediate clamp (2) and fix tubes.
6. Rod
Attach spacer to each end of winch control rod
(1) and install rod.
7. Wire rope
Wind up wire rope onto towing winch.
a Fit the front end of wire rope to winch drum
and sheave securely.
a Be careful not to twist or slacken wire rope
when winding.
D155C-1 30-221
Disassembly and assembly Towing winch
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 791-780-1400 Wrench t 1
2 791-781-1330 Wrench t 1
3 791-781-1310 Wrench t 1
4 791-781-1320 Wrench t 1
5 791-781-1000 Compressor t 1
M 791-100-2200 Installer t 1
790-101-1102 Pump t 1
6
Puller
790-101-2102 t 1
(294kN {30ton})
790-101-1102 Pump t 1
7 Puller
790-101-2102 t 1
(294kN {30ton})
Disassembly (1/2)
1. Draining oil
Drain oil from towing winch case.
6 Towing winch oil: Approx. 100 l
30-222 D155C-1
Disassembly and assembly Towing winch
4. Filter
Remove filter assembly (4).
8. Cover
Remove covers (11), (12), (13), (14), (15), (16),
(17) and (18).
9. Seat
Turn in guide bolts [1] (10 mm, P = 5), remove
mounting bolts, and take out seats (19) and (20).
D155C-1 30-223
Disassembly and assembly Towing winch
10. Collar
Remove collars (21), (22) and (23).
11. Cover
1) Remove covers (24) and (25).
2) Remove level gauge guide (26).
12. Nut
Using special tool M1, loosen right and lift nuts
(27) on drum shaft.
a Temporarily loosening these nuts at this
stage is necessary to facilitate disassembly
work.
13. Case
1) Lift towing winch assembly into position on
blocks (250 mm high) so that winch control
valve faces downward.
k Set blocks stably to prevent winch as-
sembly from overturning.
30-224 D155C-1
Disassembly and assembly Towing winch
14. Pipe
Remove pipe (34).
D155C-1 30-225
Disassembly and assembly Towing winch
30-226 D155C-1
Disassembly and assembly Towing winch
20. Strainer
Remove strainer (48).
21. Cover
Remove covers (49), (50) and (51). Remove
drain plug assembly (52).
22. Seat
Remove seat (53).
23. Case
1) Sling towing winch and turn it upside down
so winch control valve faces upward.
k Support case and drum stably on
blocks to prevent winch from overturn-
ing.
D155C-1 30-227
Disassembly and assembly Towing winch
24. Pipe
Remove pipe (59) and lubrication pipe (60).
30-228 D155C-1
Disassembly and assembly Towing winch
D155C-1 30-229
Disassembly and assembly Towing winch
29. Bracket
Remove bracket (77).
30-230 D155C-1
Disassembly and assembly Towing winch
D155C-1 30-231
Disassembly and assembly Towing winch
30-232 D155C-1
Disassembly and assembly Towing winch
D155C-1 30-233
Disassembly and assembly Towing winch
Disassembly (2/2)
30-234 D155C-1
Disassembly and assembly Towing winch
D155C-1 30-235
Disassembly and assembly Towing winch
30-236 D155C-1
Disassembly and assembly Towing winch
Assembly (1/2)
D155C-1 30-237
Disassembly and assembly Towing winch
30-238 D155C-1
Disassembly and assembly Towing winch
D155C-1 30-239
Disassembly and assembly Towing winch
30-240 D155C-1
Disassembly and assembly Towing winch
Assembly (2/2)
2. Clutch assembly
1) Sling BOOM DOWN/HOOK DOWN clutch
assembly (102) and keep it horizontal by us-
ing a pipe (55 mm I.D.). Set the assembly to
bearing.
a When inserting clutch assembly into
case, be careful not to allow drum teeth
to get out of alignment with disc teeth.
D155C-1 30-241
Disassembly and assembly Towing winch
3. Input shaft
1) Install gear (95) in case.
2) Install collar (96) to shaft (94).
3) Align shaft spline with gear spline and install
shaft in bearing.
30-242 D155C-1
Disassembly and assembly Towing winch
4. Brake shaft
1) Install bearing inner race (111) in bearing.
D155C-1 30-243
Disassembly and assembly Towing winch
5. Drum shaft
Fit collar (114) to shaft (113). Install bearing in-
ner race (115), seal collar (116) and bearing in-
ner race (117) in that order.
6. Hook drum
1) Press-fit bearing (118) into drum and install
snap ring (119).
2) Press-fit oil seal (120).
30-244 D155C-1
Disassembly and assembly Towing winch
8. Gear assembly
1) Using push tool (215 mm O.D.), press-fit
bearing (121) into gear (122).
2) Using push tool (180 mm O.D.), press-fit oil
seal (123) into gear (122).
2Oil seal lip: Fill 40 to 60% of
vacancy with
grease (GLT2-LI)
D155C-1 30-245
Disassembly and assembly Towing winch
10. Bracket
Install bracket (77).
30-246 D155C-1
Disassembly and assembly Towing winch
12. Pipe
Attach O-rings and install pipe (59) and lubrica-
tion pipe (60).
D155C-1 30-247
Disassembly and assembly Towing winch
13. Case
1) Coat fitting surface of case with liquid gas-
ket. Lift case (59) into position using two
eyebolts [33] (12 mm P = 1.75) and one
eyebolt [2] (10 mm, P = 1.5).
2 Fitting surface of case:
Liquid gasket (LG-4)
a Be careful not to damage bearing during
installation.
2) Install mounting bolts.
14. Nut
1) Turn case assembly upside down so that
winch control valve side is placed on a block
(250 mm high).
k Be sure to set the block stably to pre-
vent case assembly from falling down.
2) Using special tools M3 and M4 tighten nuts
(136), (137) and (138).
3 Nut: 137.3 ± 19.6 Nm {14 ± 2 kgm}
a Be sure to bend lock plates securely.
30-248 D155C-1
Disassembly and assembly Towing winch
15. Seat
Attach O-ring and install seat (53).
16. Cover
1) Install seal ring to each shaft
a To facilitate installation of cover, tighten
seal ring with clamp [12].
2) Attach O-rings and install covers (51), (50)
and (49).
a Install covers by hand. Never hammer
them, as it may damage the O-rings.
3) Attach O-ring and install drain plug assem-
bly (52).
17. Strainer
Attach O-ring and install strainer (48).
D155C-1 30-249
Disassembly and assembly Towing winch
30-250 D155C-1
Disassembly and assembly Towing winch
D155C-1 30-251
Disassembly and assembly Towing winch
23. Pipe
Attach O-ring and connect lubrication pipe (34).
24. Case
1) Coat fitting surface of case with liquid gas-
ket. Sling case (33) horizontally using two
eyebolts [2] (10 mm, P = 1.5) and one eye-
bolt [3] (12 mm, P = 1.75). Lift the case into
position.
2 Fitting surface of case:
Liquid gasket (LG-4)
a Be careful not to damage bearing during
installation.
2) Install mounting bolts.
30-252 D155C-1
Disassembly and assembly Towing winch
25. Nut
1) Turn towing winch upside down and place it
on a block (250 mm high).
k Set the block stably to prevent towing
winch from falling down.
D155C-1 30-253
Disassembly and assembly Towing winch
26.
1) Attach O-ring and install oil level gauge
guide (26).
2) Install seal ring to brake shaft, attach O-ring,
and fit cover (25).
3) Attach O-ring and install cover (24).
28. Collar
Attach O-rings and install collars (23), (22) and
(21).
29. Seat
1) Screw in guide bolts [1] (10 mm, P = 1.5) to
case.
2) Attach O-ring to seats (20) and (19).
30-254 D155C-1
Disassembly and assembly Towing winch
30. Cover
Attach O-rings and install collars (18), (17),(16),
(15),(14), (13),(12) and (11).
a Install covers (11), (13), (15) and (16) by
hand. Never hammer them as it may dam-
age O-rings.
34. Filter
Attach O-ring and install filter (4).
D155C-1 30-255
Disassembly and assembly Towing winch
37. Lubrication
Refill towing winch with engine oil through oil fill-
er (160) up to the specified level.
5 Towing winch oil: Approx. 100 l
30-256 D155C-1
Disassembly and assembly Heater
Removal
1. Remove right side covers (1) and (2).
–50°C specification
Installation
D155C-1 30-257
40 Maintenance standard
D155C-1 40-1
Maintenance standard Engine mount
Engine mount
40-2 D155C-1
Maintenance standard PTO
PTO
Unit: mm
D155C-1 40-3
Maintenance standard TORQFLOW transmission
TORQFLOW transmission
(1) Torque converter
40-4 D155C-1
Maintenance standard TORQFLOW transmission
Unit: mm
D155C-1 40-5
Maintenance standard TORQFLOW transmission
Unit: mm
40-6 D155C-1
Maintenance standard Transmission
Transmission
Unit: mm
40-8 D155C-1
Maintenance standard Transmission
Unit: mm
D155C-1 40-9
Maintenance standard Transmission control valve
40-10 D155C-1
Maintenance standard Transmission control valve
Unit: mm
D155C-1 40-11
Maintenance standard Transmission pump
Transmission pump
FAL045
Unit: mm
40-12 D155C-1
Maintenance standard Bevel gear shaft and steering clutch
40-14 D155C-1
Maintenance standard Bevel gear shaft and steering clutch
Unit: mm
D155C-1 40-15
Maintenance standard Bevel gear shaft and steering clutch
40-16 D155C-1
Maintenance standard Bevel gear shaft and steering clutch
Unit: mm
D155C-1 40-17
Maintenance standard Steering brake
Steering brake
40-18 D155C-1
Maintenance standard Steering brake
Unit: mm
D155C-1 40-19
Maintenance standard Steering control valve
40-20 D155C-1
Maintenance standard Steering control valve
Unit: mm
D155C-1 40-21
Maintenance standard Steering pump
Steering pump
FAR100
Unit: mm
40-22 D155C-1
Maintenance standard Final drive
Final drive
(1/2)
40-24 D155C-1
Maintenance standard Final drive
Unit: mm
D155C-1 40-25
Maintenance standard Final drive
(2/2)
40-26 D155C-1
Maintenance standard Final drive
Unit: mm
D155C-1 40-27
Maintenance standard Track frame
Track frame
Unit: mm
40-28 D155C-1
Maintenance standard Recoil spring
Recoil spring
Unit: mm
D155C-1 40-29
Maintenance standard Track
Track
40-30 D155C-1
Maintenance standard Track
Unit: mm
D155C-1 40-31
Maintenance standard Idler
Idler
40-32 D155C-1
Maintenance standard Idler
Unit: mm
4 Width of tead 60 69
5 Total width 245
6 Shaft collar width 20 19
D155C-1 40-33
Maintenance standard Track roller
Track roller
40-34 D155C-1
Maintenance standard Track roller
Unit: mm
D155C-1 40-35
Maintenance standard Carrier roller
Carrier roller
Unit: mm
40-36 D155C-1
Maintenance standard Suspension
Suspension
40-38 D155C-1
Maintenance standard Winch pump
Winch pump
FAL100
Unit: mm
D155C-1 40-39
Maintenance standard Counterweight pump
Counterweight pump
PAL063
Unit: mm
40-40 D155C-1
Maintenance standard Hi-Lo valve
Hi-Lo valve
Unit: mm
D155C-1 40-41
Maintenance standard PPC valve
PPC valve
Unit: mm
40-42 D155C-1
Maintenance standard Flow divider valve
Unit: mm
D155C-1 40-43
Maintenance standard Winch
Winch
40-44 D155C-1
Maintenance standard Winch
Unit: mm
D155C-1 40-45
Maintenance standard Lower clutch
Lower clutch
40-46 D155C-1
Maintenance standard Lower clutch
Unit: mm
D155C-1 40-47
Maintenance standard Raise clutch
Raise clutch
40-48 D155C-1
Maintenance standard Raise clutch
Unit: mm
D155C-1 40-49
Maintenance standard Winch brake
Winch brake
40-50 D155C-1
Maintenance standard Winch brake
Unit: mm
D155C-1 40-51
Maintenance standard Control valve (for counterweight)
Unit: mm
40-52 D155C-1
Maintenance standard Control valve (for counterweight)
Unit: mm
D155C-1 40-53
Maintenance standard Counterweight cylinder
Counterweight cylinder
Unit: mm
40-54 D155C-1
Maintenance standard Slow return valve
Unit: mm
D155C-1 40-55
Maintenance standard Counterweight
Counterweight
40-56 D155C-1
Maintenance standard Counterweight
Unit: mm
D155C-1 40-57
Maintenance standard Boom
Boom
40-58 D155C-1
Maintenance standard Boom
Unit: mm
D155C-1 40-59
90 Others
D155C-1 90-1
Others Electric circuit diagram (STD)
D155C-1 90-3
Others Electric circuit diagram (–50°C spec.)
D155C-1 90-5
Others Cab electric circuit diagram
D155C-1 90-7