D155ax-5 Japan (Eng) Sebd0016205

SEBM016205
MACHINE MODEL
SERIAL NUMBER
D155AX-5
70001 and up
This shop manual may contain attachments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
D155AX-5 mounts the SA6D140E-2 or SA6D140E-3 engine.

For details of the engine, see the 6D140-2 or 140-3 Series Engine Shop Manual.
C 2001 1
All Rights Reserved
Printed in Japan 04-01(03)
D155AX-5
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5
CONTENTS
No. of page
01
GENERAL .............................................................................. 01-1
10
STRUCTURE AND FUNCTION ............................................ 10-1
20
TESTING AND ADJUSTING ................................................ 20-1
30
DISASSEMBLY AND ASSEMBLY ....................................... 30-1
40
MAINTENANCE STANDARD............................................... 40-1
90
OTHERS ................................................................................ 90-1
00-2
1
D155AX-5
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40-59
40-60
40-61
40-62
40-63
40-64
40-66
40-67
40-68
40-69
40-70
40-71
40-72
40-73
40-74
40-75
40-76
40-78
40-79
90- 1
90- 3
90- 5
90- 7
D155AX-5
3
3
3
3
Mark Pages
90- 9
90-11
90-13
90-15
90-17
90-19
Revision
number
Mark Pages
Revision
number
Mark Pages
Revision
number
Mark Pages
Revision
number
3
3
3
3
3
3
3
3
3
3
3
3
3
3
00-2-5
00-7
5
SAFETY
SAFETY
NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper
service
and
repair
is extremely
service and repair techniques

are both effective
designed
manual.
for the specific
injury to workers,
The cautions
by Komatsu
take the necessary
situation
machine
operation.
and described
in this manual
require the use of tools specially
is used to mark safety precautions
these symbols
should
arises or may possibly
always
arise, first consider
Read the Operation

carefully
6. Decide
are extremely
BEFORE operating
Manual
the machine.
out any greasing
read all the precautions

which
dangerous.
and Maintenance
1. Before carrying
a place
in the
repair
the tools
Always
workshop
parts. Always
and parts in their correct
to
keep
places.
keep the work area clean and make
sure that there is no dirt or oil on the floor.
or repairs,
given on the decals
Smoke
only in the areas provided
for smok-
ing. Never smoke while working.
are fixed to the machine.
2. When
carrying
out any operation,
wear safety shoes and helmet.

loose work clothes,
always
. Always
or clothes with buttons
wear
safety glasses when
trained,
7. Before
adding
hitting
oil or making
wear
safety
glasses
repairs are needed,

experienced
when
welder
out welding
gloves,
out the
work,
apron,
al-
hand
shield, cap and other clothes suited for welding work.
or more workers,
always
before
step of the operation.
with two
agree on the operstarting.
form your fellow workers
Always
in-
before starting any
Before starting
work,
REPAIR signs on the controls
in the operators
compartment.
in good condition
the correct way to use them.
the
from moving.
starting
work,
lower
blade,
ripper,
bucket or any other work equipment
to the
If this
equipment
is not possible,
from falling.
In addition,
the
be sure
ing signs on them.
the
machine
with
before starting
10. Remove
or assembling,
blocks,
jacks
support
or stands
work.
all mud and oil from
the steps or
other places used to get on and off the machine. Always

steps when
Never
and learn
insert
to lock all the control levers and hang warn-
9. When disassembling
out any operation
ating procedure
and
safety pin or use blocks to prevent the work
carrying
carrying
to prevent
carry
welding
5. Keep all tools
or tracks
ground.
work. When
hang UNDER
8. Before
repairs,
always have a
ways
wear
grind-
etc.
any
on hard, level ground,
block the wheels

machine
ing parts with a grinder,

3. If welding
FOR WORK
park the machine
parts with a hammer.

. Always
PREPARATIONS
Do not wear
missing.
4. When
care-
safety, and
actions to deal with the situation.
PRECAUTIONS
in operation
in this
be followed
keep tools and removed

Mistakes
The
purpose.
the symbol A
accompanying
fully. If any dangerous
GENERAL
recommended
for safe
and safe. Some of these techniques
by Komatsu
To prevent
important
jump
impossible
use the handrails,
getting
ladders
or
on or off the machine.
on or off the machine.

to use the handrails,
steps, use a stand to provide
If it is
ladders
or
safe footing.
00-3
SAFETY NOTICE
SAFETY
PRECAUTIONS
DURING
19. Be sure to assemble
WORK
original
11 When
or
removing
hydraulic
pressure
loosen them
spurting
the oil filler cap, drain plug
slowly
measuring
to prevent
or removing
of the oil, water
remove
the pressure
or air circuits,
completely
from
first
the
when
and oil in the circuits
the engine
is stopped,
are hot
installing
sure that
high pressure
they
are
installing
Also,
are correctly
for the oil and water
carrying
ful when
circuits.
so be careful
not to get burned.

Wait
20. When
out any work
to cool before
21. When
on the oil or water
13. Before starting work, remove the leads from

Always
remove
the negative
(-1 terminal
check that
the lead from
or installing
14. When raising heavy components,
use a hoist
or parts which
22. When
vibrate
aligning
Check that the wire rope, chains and hooks
fingers
caught
lifting
ample
capacity.
slowly
which
has
equipment
Use a hoist
to prevent
ting any other
or crane
and operate
the component
24. Take care when
tracks of track-type
any
When
covers which
or under
are under in-
always
leave two
bolts in position
sides. Slowly
release the pres-
pressure
from
sure, then slowly loosen the bolts to remove.

removing
17. When
components,
or damage
removing
be careful not
the wiring.
may cause electrical

piping,
Damaged
fires.
stop the fuel or oil
from spilling out. If any fuel or oil drips onto

the floor, wipe it up immediately.
Fuel or oil
on the floor can cause you to slip, or can

even start fires.
18. As a general
rule, do not use gasoline
to
wash parts. In particular,
use only the mini-
mum
washing
parts.
00-4
of gasoline
when
removing
rates suddenly,
pressure
to break
pressure,
tool is correctly
removing
part. Do not work with
removing
wiring
hydraulic
hit-
ternal
16. When
measuring
that the measuring
from
15. When
on opposite
not to get your
in a hole.
check
assem-
at the correct
part still raised by the hoist or crane.
spring,
to check
bled before taking any measurements.
Install the lifting

places.
23. When
equipment
or rotate at
careful
two holes, never insert your
or hand. Be careful
use
When
correctly.
fingers
are free from damage.
parts, always
torques.
violently
be particularly
or crane.
Always
parts
parts such as guards,
that they are installed
first.
connecting
tightening
protective
high speed,
care-
installed.
assembling
installing
Damaged
so be extremely
tubes for high pressure
use the specified
circuits.
the battery.
is be-
hoses, make
not twisted.
tubes are dangerous,
water
be sure
by contact
ing operated.
compo-
circuit.
12. The
hoses and wires,
with other parts when the machine
disconnecting
nents
installing
parts with new parts.
that they will not be damaged
the oil from
out.
Before
Replace any damaged

. When
plugs,
all parts again in their
places.
electrical
or installing
the
machines.
the track, the track
sepa-
so never let anyone stand at
either end of the track.
FOREWORD
GENERAL -
FOREWORD
GENERAL
This
shop
manual
serviceman
has been
an accurate
prepared
as an aid to improve
understanding
repairs and make judgements.
the quality
of the product and by showing
Make sure you understand
of repairs
by giving
the
him the correct way to perform
the contents
of this manual
and use it to full
effect at every opportunity.
This shop manual
mainly
service workshop.
For ease of understanding,
chapters
are further
STRUCTURE
contains
divided
the manual
information
is divided
for operations
performed
into the following
chapters;
in a
these
AND FUNCTION
an understanding
This
technical
into the each main group of components.
This section explains
TESTING
the necessary
the structure
of the structure,
and function
of each component.
but also serves as reference
It serves not only to give
material
for troubleshooting.
AND ADJUSTING
section
adjustments
explains
Troubleshooting
DISASSEMBLY
checks
to be made
to be made at completion
charts correlating
before
and
after
performing
repairs,
as well
as
of the checks and repairs.
Problems
to Causes are also included
in this section.
AND ASSEMBLY
This section
assembling
MAINTENANCE
explains
the order to be followed
each component,
when
as well as precautions
removing,
installing,
disassembling
or
to be taken for these operations.
STANDARD
This section gives the judgement
standards
when
inspecting
disassembled
parts.
NOTICE
The
specifications
time
and without
with
the
latest
contained
any
advance
in this
notice.
shop
manual
Use the
are subject
specifications
to change
given
in the
at any
book
date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES
REVISED EDITION MARK
Shop manuals are issued as a guide to carrying

out repairs. They are divided as follows:
When
Chassis volume:
Engine volume:
pages.
Issued for every machine model

Issued for each engine series
Electrical volume:
Attachments
volume:
I
Each issued as one

volume to cover all
models
These various volumes are designed to avoid

duplicating the same information.
Therefore, to
deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available.
DISTRIBUTION
AND UPDATING
Any additions, amendments

or other changes
will be sent to KOMATSU distributors.
Get the
most up-to-date information before you start any
work.
a manual
(@@@....J
is revised,
is recorded
an edition
on the
bottom
mark
of the
REVISIONS
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS
page.
SYMBOLS
So that the shop manual can be of ample practical use, important safety and quality portions
are marked with the following symbols.
FILING METHOD
Symbol
1. See the page number on the bottom of the

page. File the pages in correct order.
2. Following examples
show how to read the
page number.
Example 1 (Chassis volume):
Item
Safety
Special safety precautions are

necessary
when performing
the work.
Caution
Special technical precautions

or other precautions for preserving standards are necessary when
performing
the
work.
Weight
Weight of parts of systems.

Caution necessary when selecting hoisting wire, or when
working posture is important,
etc.
10 - 3
TT
I
Example
2 (Engine volume):
Unit number (I. Engine)

Item number (2. Testing and
Adjusting)
Consecutive page number for
each item.
3. Additional
cated
pages:
by a hyphen
page number.
Additional
pages are indi-
(-1 and number
after the
File as in the example.
Example:
1o-4
1o-4-1 k
1O-4-2
1o-5
00-6
Item number (IO. Structure

and Function)
Consecutive page number for
each item.
Tightening
Remarks
torque
&
Coat
Places that require special attention

for the tightening
torque during assembly.
Places to be coated with adhesives and lubricants, etc.
Places where oil, water or fuel
nust be added, and the caoacity.
laces
where
oil or water
nust be drained, and quan:ity to be drained.
12-203
Added
pages ---c:~~~~~~~
12-204
HOISTING INSTRUCTIONS
FOREWORD
HOISTING
INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
cause the rope to slip off the hook during
hoisting, and a serious accident can result.
Hooks have maximum
strength at
the middle portion.
Heavy parts (25 kg or more) must be

lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY
section,
every part weighing
25 kg or more is
indicated clearly with the symbol &
If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I)
Check for removal
of all bolts fastening
the part to the relative

2) Check for existence
ing interference
the
part caus-
part to be re-
moved.
adequate
weight
41%
71%
3) Do not sling a heavy load with one rope

alone, but sling with two or more ropes
symmetrically
wound onto the load.
Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping of
the rope from its original winding
position on the load, which can result in a dangerous accident.
WIRE ROPES
I) Use
79%
88%
SAD00479
of another
with
100%
parts.
ropes
depending
of parts to be hoisted,
on the
referring
to
the table below:

4)
Wire ropes
(Standard Z or S twist ropes
without galvanizing)
Rope diameter
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with two or more
ropes, the force subjected to each rope
will increase with the hanging angles. The
table below shows the variation of allowable load kN {kg) when hoisting is made
with two ropes, each of which is allowed
to sling up to 9.8 kN 11000 kg) vertically,
at various hanging angles.
Allowable
load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
to 19.6 kN (2000 kg) of total weight
16
27.5
2.8
suspended.
18
35.3
3.6
(1000
20
43.1
4.4
hanging
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
When two ropes sling a load vertically,

This weight
kg) when
angle.
two
becomes
ropes
make
On the other
ropes are subjected
can be
9.8 kN
a 120
hand,
to an excessive
up
two
force
as large as 39.2 kN (4000 kg) if they sling

a 19.6 kN (2000 kg) load at a lifting angle
of 150.
The allowable
load value is estimated to
be one-sixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle

of the hook.
portion
30
Liftino
60
anole
90
tdeoree)
120
150
SAD00480
00-7
FOREWORD
METHOD
OF DISASSEMBLING,
CONNECTING
PUSH-PULL
TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

* There are 2 types of push-pull type coupler. The method of disassembling and connecting is different, so see the table below when disassembling
and connecting
We 1
1)
Me 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male
end.
1)
CWPO6391
2)
Hold in the condition in Step I), and push

until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
>
E
E
s
:
.?
n
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male
end.
CWPO6392
2)
Hold in the condition in Step I), and turn

lever (4) to the right (clockwise).
CWPO6393
3)
CWPO6394
Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
CWPO6395
00-8
the coupler.
3)
Hold in the condition in Steps I) and 2), and

pull out whole body (2) to disconnect it.
CWP06396
FOREWORD
METHOD OF DISASSEMBLING,
Type 1
l
CONNECTING
PUSH-PULL TYPE COUPLER
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (I) contacts contact surface a of the hexagonal portion at the male
end to connect it.
CWP06391
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (I) contacts contact surface a of the hexagonal portion at the male
end to connect it.
CWP06392
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
*
*
coating materials such as adhesives, gasket sealants and greases

The recommended
disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category
Comatsu code
LT-IA
Part No.
790-129-903c
Qw
150
Container
Tube
Main applications, features

l
LT-1 B
790-129-90x
20 9
(2 pes.)
olyethylens
container
LT-2
0994040030
790-I 29-906C
50 g
olyethylene
container
(Set of adhesive and

hardening
agent)
id hesive
1 kg
lardenint
agent:
500 g
Can
LT-4
790-129-904c
250 g
olyethylenc
container
Holtz
MH 705
790-126-9120
75 g
Tube
50 g
olyethylene
container
LT-3
used for
Used to prevent rubber gaskets, rubber

cushions, and cock plug from coming out.
Used in places requiring an immediately
Used for plaseffective, strong adhesive.
polyprophylene,
tics (except polyethylene,
and vinyl chloride), rubtetrafluoroethlene
ber, metal and non-metal.
Features: Resistance to heat and chemicals
and sealant purUsed for anti-loosening
pose for bolts and plugs.
Used as adhesive or sealant for metal, glass
and plastic.
Adhesives
l
Three bond
1735
790-i29-914a
Aron-alpha
201
790-129-9130
29
olyethylene
container
Loctite
648-50
79A-129-911C
50 cc
olyethylene
container
LG-1
790-129-9010
200 g
Tube
Gasket
790-129-9070
1 kg
Can
l
00-l0
sealant for repair-
Quick hardening type adhesive

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals,
bers, plastics and woods.
rub-
Quick hardening type adhesive

Quick cure type (max. strength after 30 minutes)
Used mainly for adhesion of rubbers, plastics and metals.
Features: Resistance to heat, chemicals

. Used at joint portions subject to high temperatures.
LG-3
Used as heat-resisting
ing engine.
holes.
sealant
Used as sealant for machined
Used as adhesive or sealant for gaskets

and packing of power train case, etc.
Features: Resistance to heat
Used as sealant for flange surfaces and
locations, used
bolts at high temperature
to prevent seizure.
Used as sealant for heat resistance gasket
for high temperature locations such as enexhaust
chamber,
gine precombustion
pipe, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Main applications,
l
LG-4
LG-5
790-129-9080
lkg
p;
l
Gasket
sealant
LG-6
0994040011
Tube
250 g
LG-7
09920-00 150
Tube
150 g
Three bond
1211
Molybdenum
disulphide
lubricant
LM-G
LM-P
l
G2-LI
SYG2-4OOLI
SYG2-35OLI
SYG2-4OOLI-A
SYG2-16OLI
SYGA-IGOCNLI
G2-CA
SYG24OOCA
SYG2-35OCA
SYGZ-4OOCA-A Various
SYG2-16OCA
SYGA-16OCNCI
Grease
Molybdenum
disulphide
lubricant
SYG2-400M
Various
400 g
(IO per
case)
features
Features: Resistance to water, oil

Used as sealant for flange surface, thread.
Also possible to use as sealant for flanges
with large clearance.
Used as sealant for mating surfaces of final drive case, transmission case.
Used as sealant for various threads, pipe
joints, flanges.
Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Features: Silicon based, resistance to heat,
cold
Used as sealant for flange surface, tread.
Used as sealant for oil pan, final drive case,
etc.
Features: Silicon based, quick hardening
type
Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing,
etc.
Used as heat-resisting
engine.
sealant for repairing
Used as lubricant for sliding portion (to prevent from squeaking).

Used to prevent seizure or scuffling of the
thread when press fitting or shrink fitting.
Used as lubricant for linkage, bearings, etc.
General purpose type
Various
I
l
Various
Used for normal temperature,

light load
bearing at places in contact with water or
steam.
Used for places with heavy load
00-l1
FOREWORD
STANDARD
STANDARD TIGHTENING TORQUE
TIGHTENING
TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Ir
In the case of metric

given in the table
nuts and bolts for which there is no special instruction,
tighten
to the torque
below.
Thread diameter
of bolt
Width
across flats
,
mm
mm
Nm
6
8
10
12
14
10
13
17
19
22
13.2k1.4
31f3
66f7
113+10
177f19
16
18
20
22
24
24
27
30
32
36
279f30
382f39
549f59
745+83
927+103
27
30
33
36
39
41
46
50
55
60
1320f140
1720f190
2210+240
2750f290
3290f340
Thread diameter
of bolt
Width
across flats
mm
mm
10
13
14
27
ii
10
12
kcm
1.35f0.15
3.2f0.3
6.7f0.7
11.5fl
18f2
28.5+3
39f4
56f6
76f8.5
94.5f 10.5
135f15
175k20
225f25
280f30
335f35
Nm
kgm
7.85k1.95
18.6f 4.9
40.2f 5.9
82.35f7.85
0.8f0.2
1.9f0.5
4.1kO.6
8.4f0.8
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Sr In the case of flared
instruction,
tighten
nuts for which
to the torque
there
is no special
given in the table below.

SAD0048
Thread
00-l 2
diameter
Width
across flat
l-
Tighteni
3 torque
mm
mm
Nm
km
14
19
24
27
24.5f 4.9
49k19.6
2.5f0.5
18
22
24
30
33
32
36
41
36
42
46
55
78.5f 19.6
137.3f29.4
176.5f29.4
196.lf49
245.2f 49
294.2+49
5f2
8+2
14+3
18f3
2Ok5
25+5
30*5
FOREWORD
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Ir In the case of split flange bolts for which there is no special
instruction,
tighten
to the torque
Thread
diameter
mm
Width
across flat
mm
10
12
16
Tightening
Nm
14
17
22
torque
km
65.7+ 6.8
112f9.8
279f29
6.7rt0.7
11.5fl
28.5f3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

* Unless there are special instructions, tighten the O-ring boss piping joints to the torque
Nominal
No.
Thread
diameter
Width
mm
02
03,04
05,06
IO,12
14
14
20
24
33
42
Tightening
across flat
mm
torque
Nm
knm
Varies depending on
type ofconnector.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

* Unless there are special instructions, tighten the O-ring boss plugs to the torque
Nominal
08
10
12
14
16
18
20
24
30
33
36
42
52
No.
Thread
diameter
below.
Width
across flat
Tightening
below.
torque
mm
mm
Nm
kgm
8
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
-
7.35f1.47
11.27+ 1.47
17.64f1.96
22.54f1.96
29.4f4.9
39.2k4.9
49+ 4.9
68.6f9.8
107.8k14.7
127.4f 19.6
151.9f24.5
210.7f29.4
323.4k44.1
0.75kO.15
1.15f0.15
1.8f0.2
2.3f0.2
3f0.5
4f0.5
5f0.5
7+1
llTk1.5
13+2
15.5k2.5
21.5rt3
33+ 4.5
36
-
00-13
FOREWORD
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques
Thread
for bolts and nuts (unit: mm) of Cummins
diameter
mm
Engine.
Tightening
torque
Nm
6
8
10
12
10
24
43
77
kgm
+2
f 4
f 6
f 12
1.02
2.45
4.38
7.85
f
+
+
f
0.20
0.41
0.61
1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques
Thread
for eye joints (unit: mm) of Cummins
diameter
Engine.
Tightening
mm
Nm
6
8
10
12
14
8k2
10 f2
12 f2
24 f 4
36 ic5
torque
kgm
0.81
1.02
1.22
2.45
3.67
rf:
0.20
iz0.20
+ 0.20
f 0.41
f 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques
Thread
00-14
for tapered
screws (unit: inch) of Cummins
diameter
Engine.
Tightening
inch
Nm
1 /I6
l/8
l/4
318
112
314
1
3+1
8+2
12f2
15f2
24 f 4
36 f 5
60 + 9
torque
kgm
0.31
0.81
1.22
1.53
2.45
3.67
6.12
f 0.10
f 0.20
AI0.20
+ 0.41
+ 0.41
f 0.51
f 0.92
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example:
5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION
Copper wire
N,;.libea,l
N;,naF;sof
0.85
2
BY THICKNESS
Dia. i$str$mds CroT;smezc)tion
11
1
0.32
26
0.88
0.32
2.09
Cay$$D.
Curreykrating
2.4
1
3.1
Applicable
12
20
Starting, lighting, signal etc.
1 Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging
15
84
0.45
13.36
7.0
59
Starting
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
17.6
230
Starting
CLASSIFICATION
109.1
circuit
and signal
(Glow plug)
BY COLOR AND CODE
3
,u+
Color White & Black
Code
WL
Black & Yellow Red & Black Yellow & Black Green & Red
BR
4
arY Color White & Blue
RY
Color White & Green
Code
RL
Color
Red & Blue
WG
GY
LY
Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
Code
5
YG
Blue & Red
RG
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
YW
Yellow&White
GL
Green & Blue
00-l5
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION
The Conversion
details
Table
of the method
TABLE
in this section
is provided
of using the Conversion
to enable
Table,
simple
conversion
see the example
of figures.
For
given below.
EXAMPLE
l
1.
Method
Convert
(I)
of using the Conversion
Table to convert from millimeters
to inches
55 mm into inches.
Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number
5 in the row across the top, take this as @I, then draw a perpendicular
line
down from @.
(3) Take the point where the two lines cross as 0.
from millimeters
2.
to inches.
Therefore,
This point @ gives the value when converting
55 mm = 2.165 inches.
Convert 550 mm into inches.
(I) 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.
Millimeters
to inches
0
10
20
30
40
@-
00-l 6
1 mm = 0.03937
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
,...50
.......,...,..1.969
. . .. . . .. . . .2.126
. . . . . . . . . ?%
. . . . .. . . . ., ..2.008
. . .. . . . .. . ..2.047
. . . . . .. ..a,.... .2.087
.I
60
70
80
90
2.362
2.756
3.150
3.543
..I
2.402
2.795
3.189
3.583
2.441
2.835
3.228
3.622
2.480
2.874
3.268
3.661
2.520
2.913
3.307
3.701
2:953
3.346
3.740
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
in
FOREWORD
CONVERSIONTABLE
Millimeters to Inches
1 mm
= 0.03937
in
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
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-l 7
FOREWORD
CONVERSIONTABLE
Literto U.S. Gallon
If = 0.2642 U.S. Gal

8
1.849
2.113
2.378
4.227
4.491
4.755
5.019
6.604
6.869
7.133
7.397
7.661
8.982
9.246
9.510
9.774
10.039
10.303
11.359
11.624
11.888
12.152
12.416
12.680
12.944
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
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
0.264
0.528
0.793
1.057
1.321
1.585
10
2.642
2.906
3.170
3.434
3.698
3.963
20
5.283
5.548
5.812
6.076
6.340
30
7.925
8.189
8.454
8.718
40
10.567
10.831
11.095
50
13.209
13.473
60
15.850
70
\
0
Literto U.K. Gallon
It = 0.21997 U.K. Gal

1
\
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
CONVERSIONTABLE
FOREWORD
kgm to ft. lb
1 kgm = 7.233 ft. lb
0
\
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
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
10
00-19
FOREWORD
CONVERSIONTABLE
kg/cm* to lb/in2
lkg/cm2 = 14.2233lb/in*
4
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
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
038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
387
2901
2916
2930
2944
2958
!973
210
2987
3001
3015
130
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
456
3470
3485
3499
3513
3527
3542
00-20
CONVERSION TABLE
FOREWORD
Temperature
Fahrenheit-Centigrade
ture reading
These
Conversion
or vice versa
figures
If it is desired
; a simple way to convert
is to enter the accompanying
refer to the temperature

to convert
from
temperatures
and read the corresponding
If it is desired
to convert
from Centigrade
and read the corresponding
in either
Fahrenheit
Fahrenheit
Fahrenheit
to Centigrade
Centigrade
or Centigrade
degrees,
degrees,
temperature
in the center
temperature
to Fahrenheit
temperature
a Fahrenheit
table
into a Centigrade
column
tempera-
of figures.
degrees.
consider
the center
in the column
consider
reading
or boldface
the center
column
as a table
of Fahrenheit
at the left.
column
as a table
of Centigrade
values,
on the right.
1C = 33.8F
-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
46
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9
-20
-4.0
-9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
-28.3
-19
-2.2
-8.9
16
60.8
10.6
51
123.8
30.0
86
186.8
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
-26.7
-16
3.2
-7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
-26.1
-15
5.0
-6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
-25.6
-14
6.8
-6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
-25.0
-13
8.6
-5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
-24.4
-12
10.4
-5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
-23.9
-11
12.2
-4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
-23.3
-10
14.0
-3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
-22.8
-9
15.8
-3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
-22.2
-9
17.6
-2.8
27
80.6
16.7
62
143.6
36.1
97
206.6
-21.7
-7
19.4
-2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
-21.1
-6
21.2
-1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
-20.6
-5
23.0
-1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
-20.0
-4
24.8
-0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
-19.4
-3
26.6
32
89.6
19.4
67
152.6
43.3
110
230.0
-18.9
-2
28.4
0.6
33
91.4
20.0
68
154.4
46.1
115
239.0
-18.3
-1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
-17.2
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
-16.7
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
-16.1
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
-15.6
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
-15.0
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
-14.4
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
-13.9
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
-13.3
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
-12.8
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
-12.2
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
-17.8
00-21
01 GENERAL
Specification
drawing ..................................
Ol- 2
Specifications
...............................................
Ol- 4
Weight table ................................................
.Ol-10
Table of fuel, coolant and Lubricants ....... 01-12
D 155AX-5
01-l
SPECIFICATION
GENERAL
SPECIFICATION
l
Semi
U-tiltdozer
DRAWING
DRAWING
+ giant ripper
Unit: mm
3210
8155
2510
SWD02751
U-tiltdozer
+ giant ripper
SWD02752
01-Z
D 155AX-5
GENERAL
Semi
SPECIFICATION
U-tiltdozer
+ multi-shank
DRAWING
ripper
Unit: mm
G. L
U-tiltdozer
+ multi-shank
3210
81 55
I
SWD02754
D155AX-5
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine
Serial
D155AX-5
model
number
Bare tractor
per + ROPS + cab + air conditioner
turning
radius
(Fl,
center
+ side cover
of machine)
Gradeability
Stability
L
g
!!
%
al
::
.-6
.-ZJ
E
Z
Z
l-
and up
28,400
With semi U-dozer + variable multi-shank rip-
Minimum
70001
(front,
rear, left, right)
kg
38,500
2.1
deg
30
deg
35
3.5
1st
P
E
2nd
6.2
km/h
LL
%
t
3rd
10.8
1st
4.8
km/h
2nd
8.4
CT
13.9
3rd
77.5 IO.791
Bare tractor
With
ripper
semi
U-dozer
+ ROPS
+ variable
+ cab
multi-shank
+ air conditioner
104.9 {I .07}
+
kPa
side cover
With
U-dozer
+ variable
multi-shank
+ ROPS + cab + air conditioner
ripper
Ikghm2)
105.9 f1.081
+ side cover
5
0
-E
=
m
&
6
C
5
.3
=
?
9:
4,975
Bare tractor
With
semi
U-dozer
+ variable
multi-shank
ripper
With
8,155
mm
U-dozer
+ variable
multi-shank
ripper
8,550
2,695
Bare tractor
With
semi
U-dozer
+ variable
multi-shank
ripper
With
3,955
mm
U-dozer
+ variable
multi-shank
ripper
4,265
B
2
.-0
_E
=
m
&
To top of exhaust
To top of cab
(to
top of control
3,395
pipe
mm
2,590
lever)
6
-
01-4
D155AX-5
GENERAL
SPECIFICATIONS
Machine
Serial
With
cab installed
With
ROPS canopy
With
canopy
L-
model
number
D155AX-5
70001
and up
3,365
installed
mm
3,500
installed
3,500
.-0
E? Track gauge
i.- Length of track
n
2,100
on ground
Track shoe width
(standard)
Minimum
clearance
ground
(To bottom
surface
(mm)
3,210
mm
560
485
of undercover)
Name
Type
SAGDI 40-2
4-cycle,
water-cooled,
in-line,
vertical
type, direct injection, with turbocharger
and aftercooler
of engine
No. of cylinders
- Bore x Stroke
Piston displacement
Flywheel
mm
6-140x165
e {cc}
horsepower
k:W/rpmU-lP/rpn
15.24 {I 5.2401
1)
231/1,900
rr]m/rpm(kgm/rpn 1)
{314/1,9001
Max.
torque
Max.
speed
at no load
rpm
2,050
Min. speed
at no load
rpm
700
Min. fuel consumption

Starting
ratio
1,610/1,250
g/kWh(g/HPhI
205 {1531
motor
24V,
Alternator
Torque
11 kW
24V, 35A
Battery
Radiator
{164/1,2501
12V 170Ahx2
core type
converter
D-7
3-element,
single-stage,
single
phase
(TCS43-17A)
Planetary
Transmission
multiple
actuated,
tion
pump,
verse
D155AX-5
gear,
draulically
gear
3-speed,
disc clutch,
force-feed
forward
manual
hy-
lubrica-
3-speed,
mechanical
retype
01-5
SPECIFICATIONS
GENERAL
Serial
D 155AX-5
model
Machine
70001
number
variable
swash
Max. delivery
HSS pump
Theoretical
Max.
HSS steering
Wet type,
Master
plate type
brake
Spur gear
multiple
Track
l-stage,
pump
shoe width:
pump
560 mm)
gear
l-stage,
splash
type
balancing
beam
type
Assembly
type, single grouser,
Gear type
(tandem)
with scavenging
equipment
Gear type
pump
pump
(SAR(4)llZ))
Theoretical
Max.
2+1+1
For blade
lift
For blade tilt
For ripper
lift
For ripper
tilt
: 4.4 MPa 145 kg/cm?

: 206 Umin/1,980
rpm
pressure
delivery
(SAR(4)112)
delivery
tandem
Ripper
(112)
(104)
delivery
Theoretical
Type
(SAL(3)80+100)
Gear type
(tandem)
pump
41 each side, pitch: 228.6
mm
Gear type
01-6
boost pedal oper-
6 each side
Max.
Work
drive,
2 each side
+ lubrication
HSS, PPC charge

(tandem
planetary
roller
Scavenging
motor
actuated
roller
train
gear pump
hydraulicalic
clutch disc, spring
Rigid,
Track shoe (standard
Power
gear,
lubrication
lubrication
Suspension
Carrier
(HMF140)
actuated
ated, hydraulically
Final drive
rpm
: 41.2 MPa {420 kg/cm*)
planetary
hvdraulicallv
%
I
(HPV160)
: 41.2 MPa (420 kg/cm21
bevel gear, force-feed
Differential
system
up
: 341 .Umin/2,130
delivery
pressure
Spiral
Bevel gear shaft
plate type
pressure
Fixed swash
HSS motor
and
: 20.6 MPa 1210 kg/cm21

: 255 .Umin/2,220 rpm
pressure
delivery
spool type,
tilt + ripper
hydraulically
lift + blade
assisted
type
lift + blade tilt
D155AX-5
GENERAL
SPECIFICATIONS
Machine
Serial
model
-I
number
D 155AX-5
Type
70001
Reciprocal,
Cylinder bore
Piston
diameter
Max.
piston
stroke
Max.
distance
between
Min. distance
between
piston type
75
mm
1,347
pins
3,187
pins
1,836
bore
180
Piston rod outer
diameter
Max.
piston stroke
Max.
distance
Min. distance
up
120
rod outer
Cylinder
and
mm
between
between
90
160
pins
1,468
pins
1,308
.
Cylinder
.
- :
Piston
bore
rod outer
Max.
piston
Max.
distance
Cylinder
Piston
between
160
pins
1,468
pins
1,308
bore
Max.
piston
160
Max.
distance
diameter
stroke
Min. distance
I-lydraulic
90
mm
between
rod outer
Cylinder
diameter
stroke
Min. distance
Piston
200
between
between
80
mm
510
pins
1,538
pins
1,028
bore
160
rod outer
diameter
stroke
80
Max.
piston
mm
Max.
distance
between
pins
1,545
Min. distance
between
pins
1,195
350
tank
Box type
(control
valve
externally
installed)
D155AX-5
01-7
GENERAL
SPECIFICATIONS
Serial
l-
model
Machine
number
70001
Type
and up
Hydraulic semi U-tiltdozer, hydraulic U-tiltdozer
Blade support method
Brace type (right tilt cylinder)
Blade lifting height (from ground level)
mm
1,250
Blade lowering depth (from ground level)
mm
590
Max. blade tilt
mm
1,000
Blade cutting angle variation
deg
+6
Blade capacity
m3
11.7 C SAE 8.8 >
Blade width
mm
3,955
Blade height
mm
1,720
Blade cutting angle
deg
52
Blade lifting height (from ground level)
mm
1,250
Blade lowering depth (from ground level)
mm
590
Max. blade tilt
mm
1,080
Blade cutting angle variation
deg
Blade capacity
01-8
D155AX-5
m3
f6
13.2 < SAE 11.8 >
Blade width
mm
4,265
Blade height
mm
1,720
Blade cutting angle
deg
52
Max. tilt
mm
1,000
Max. pitch angle
deg
Max. pitch-back angle
deg
Max. tilt
mm
1,080
Max. pitch angle
deg
Max. pitch-back angle
deg
D155AX-5
GENERAL
SPECIFICATIONS
Machine
Serial
model
D155AX-5
number
70001
and up
Max. digging depth
mm
870
Max. lifting height
mm
925
Ripping angle of point
deg
34.5 - 60
Max. beam width
mm
2,260
No. of holes
Max. digging depth
mm
1,220
Max. lifting height
mm
925
Ripping angle of point
deg
34.5 - 60
Max. beam width
mm
1,535
No. of holes
Shank positions
;
.-i
:
i
Shank positions
D 155AX-5
01-9
WEIGHT TABLE
GENERAL
WEIGHT TABLE
-AThis
weight
table is a guide for use when transporting

Machine
Serial
Engine,
damper
Engine
Damper
Universal
Engine
or handling
D155AX-5
model
70001
number
and up
1,395
assembly
1,275
assembly
117
assembly
18
joint
mount
parts (wiring)
Radiator
assembly
(including
Hydraulic
cooler
3
built-in
oil cooler)
307
77 (47 as individual
Fuel tank assembly
(when
empty)
267
Fuel tank assembly
(when
full)
798
Power
train
. Torque
converter,
342
PTO assembly
645
assembly
HSS assembly
Brake valve
HSSPPC
charge
filter
HSSPPC
charge
valve
Power
Scavenging
pump*HSS*PPC
Power
lubrication
Work equipment
HSS motor
63
HSS pump
102
894
Final drive
Sprocket
14
assembly
train filter
train
22
assembly
21
assembly
20
assembly
charge
pump
19
pump
1,372x2
(12X9)X2
teeth
3,182
assembly
Track group
assembly
3,755
(each side)
1,224
Track frame
410
Idler assembly
Recoil spring
Bogie,
Track
01-10
508
assembly
track roller
410x3
assembly
roller assembly
Track roller assembly

Carrier
36
27
pump
assembly
Hull frame
part)
2,318
unit assembly
. Transmission
Unit: kg
components.
roller assembly
(single
(double
flange
flange
xl)
xl)
97x3
109x3
45x2
D 155AX-5
WEIGHT TABLE
GENERAL
Unit: kg
Machine
Serial
model
number
Track shoe assembly (560 mm, wet type)

Pivot shaft assembly
Equalizer bar
D155AX-5
70001
and up
2,558x2
116x2
229
Hydraulic tank assembly
95
Hydraulic filter assembly
19
Main control valve
99
(Blade lift + blade tilt + ripper lift + ripper tilt)

Engine underguard
183
Transmission underguard
228
Operators seat
Semi U-tiltdozer assembly
l
Blade
51
4,903
2,818
690x2
Straight frame
Tilt brace
98x1
Center brace
92x2
Tilt cylinder assembly
Semi U-tilt + pitch dozer assembly
190
5,007
Blade
2,818
Straight frame
690x2
Center brace
190
Pitch cylinder assembly
215
92x2
Blade lift cylinder assembly
165x2
Multi-shank ripper assembly
3,600
Bracket, beam
2,014
Shank
266x3
Lift cylinder assembly
119x2
122x2
Giant ripper assembly
3,135
1,728
Bracket, beam
Shank
333x1
Lift cylinder assembly
119x2
122x2
Pin puller cylinder assembly
ROPS assembly
480
Cab
285
FLOPScanopy
698
Canopy
105
Dashboard (including air conditioner unit)
83
Floor frame
310
Side cover
130
Air conditioner (excluding air conditioner unit)
D155AX-5
87
01-11
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT
Engine
Power
AMBIENT TEMPERATURE
KIND OF
FLUID
RESERVOIR
AND LUBRICANTS
-22
-4
-10
14
320
50
10
68
20
CAPACITY (J?)
I
86
30
Specified
104F
40~
Refill
0.59
oil pan
train case
EiGcr-4
Final drive case (each side)Engine
oi
Pivot shaft case (each side)
Hydraulic
system
)
Bogie teach)
Fuel tank
11
0.59
1 0.21 - 0.23 i 0.21 - 0.23
Diesel
fuel
Cooling system
(including reservoir
tank)
Add antifreeze
Coolan
99
ASTM D975 No. 1
NOTE:
(I)
When fuel sulphur content is less than 0.5

%, change oil in the oil pan every periodic
maintenance
hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5 %.
Fuel sulphur
content
Change interval of oil

in engine oil pan
0.5 to 1.0 %
l/2 of regular
interval
Above
l/4 of regular
interval
ASTM:
SAE:
API:
1.0 %
American Society of Testing and Material

Society of Automotive
Engineers
American Petroleum Institute
(2) When starting the engine in an atmospheric

temperature
of lower than OT, be sure to
use engine oil of SAEIOW, SAEIOW-30
and
SAE15W-40
even though an atmospheric
temperature
goes up to 10C more or less
in the day time.
CD as engine oil and
(3) Use API classification
if API classification
CC, reduce the engine
oil change interval to half.
(4) There is no problem if single grade oil is mixed
with multigrade oil (SAEIOW-30, 15W-401, but
be sure to add single grade oil that matches the
temperature in the table on the left.
Komatsu genuine oil which
(5) We recommend
has been specifically
formulated
and approved for use in engine and hydraulic work
equipment
applications.
Specified capacity: Total amount of oil including oil for components

Refill capacity: Amount of oil needed to refill system during normal
01-12
and oil in piping.

inspection and maintenance.
D 155AX-5
10 STRUCTURE AND FUNCTION
Engine control ................................................

IO-2
Radiator, oil cooler ........................................
IO-4
Power train .....................................................
IO-8
Power train system ........................................
IO-9
Overall drawing of power train unit ......... IO-10
Power train hydraulic system drawing .... IO-12
Power train hydraulic piping diagram ..... IO-14
Power train hydraulic circuit diagram.. .... IO-15
Damper universal joint.. ..............................
IO-16
Torque converter, PTO ................................
IO-19
Transmission
control ...................................
IO-22
Transmission
................................................
IO-24
Transmission
control valve ........................
1o-34
Main relief valve ..........................................
IO-39
Lubricant relief valve.. .................................
IO-41
Scavenging
pump strainer.. ........................
IO-42
Power train pump strainer.. ........................
IO-43
Power train oil filter.. ...................................
IO-44
HSS system ..................................................
IO-46
HSS pump ....................................................
IO-59
HSS motor ....................................................
IO-75
PPC, HSS charge filter.. ...............................
IO-83
PPC, HSS charge valve ...............................
IO-84
HSS oil cooler bypass valve.. ..................... IO-87
Steering, brake control ................................
IO-88
Bevel gear shaft, HSS brake.. ..................... IO-91
Brake valve .................................................
IO-103
Final drive ...................................................
IO-107
Track frame.. ...............................................
IO-110
Recoil spring ...............................................
IO-I 12
Track roller bogie.. .....................................
IO-I 13
D155AX-5
Main frame .................................................

IO-I 14
Suspension .................................................
1 O-l 16
Work equipment
hydraulic
piping diagram.. .....................................
IO-I 18
PPC control piping diagram ..................... IO-121
Work equipment
control ...........................
IO-122
Work equipment
hydraulic system
and HSS system diagram.. ................... IO-124
Work equipment
hydraulic circuit
and HSS circuit diagram.. ..................... IO-128
Hydraulic tank and filter.. ..........................
IO-130
Accumulator
...............................................
IO-132
PPC lock valve ............................................
IO-133
PPC valve ....................................................
IO-134
Piston valve ................................................
1 O-l 44
Pin puller switch ........................................
IO-I 45
Pin puller solenoid valve ......................... .I O-l 46
Tilt/Pitch selector switch ...........................
IO-148
Pitch solenoid valve ..................................
IO-149
Main control valve .....................................
IO-151
Cylinder stay.. .............................................
IO-178
Work equipment
........................................
IO-179
Cap.. .............................................................
IO-183
Air conditioner
...........................................
IO-185
Electric wiring diagram .............................
IO-186
Electric circuit diagram .............................
IO-190
Monitor system ..........................................
IO-193
Sensors .......................................................
IO-199
Engine starting system .............................
IO-204
HSS electronic control system ................. IO-206
10-l
ENGINE CONTROL
STRUCTURE AND FUNCTION
ENGINE CONTROL
1.
2.
3.
4.
5.
6.
pedal
Decelerator
Fuel control lever
Clutch
Stopper
Rod
Fuel injection pump
Outline
.
The engine speed is controlled
trol lever (2) or decelerator
by fuel conpedal (I).
Lever, pedal positions

0: STOP
0:
0:
0:
0:
LOW
HIGH
HIGH
LOW
1o-2
IDLING
IDLING
IDLING
IDLING
D 155,4X-5
STRUCTURE
AND
RADIATOR,
. RADIATOR
RADIATOR,
FUNCTION
OIL COOLER
6-'?iidH -
1. Radiator core assembly

2. Fan guard
3. Reservoir tank
4.
5.
6.
7.
8.
Lower tank (power

Overflow hose
Water filler cap
Air bleed hose
Inlet hose
1o-4
OIL COOLER
train oil cooler
built-in)
9.
10.
11.
12.
ra
lit-IH
Fan
Outlet hose
Drain plug
Inlet hose (for circulating
temperature)
13. Cushion
14. Breather cap
15. Valve
at low water
D155AX-5
STRUCTURE
RADIATOR,
AND FUNCTION
OIL COOLER
A-A
B-B
11
12
10
SKI290003
Outline
The reservoir
l
Radiator
tank is provided
for radiator.
I
D-7
Core type
Fin pitch
D155AX-5
(mm)
4.0
1o-5
RADIATOR, OIL COOLER
OIL COOLER
I
c
-_
-_
+I
A-A
SJD02746
1O-6
D155AX-5
RADIATOR, OIL COOLER
The hydraulic
cooler can be
Core
inner fin
Cooling method
Heat dissipation area
D155AX-5
PTO-OL
SF-4
TF&C
Built in
lower tank
Air cooled
2.47 m2
20.8 m2
1o-7
POWER TRAIN
POWER TRAIN
SVDO2730
The power generated

by engine (I) has its
torsional vibration dampened by damper (21,
and then passes through universal joint (31,
and is transmitted
to torque converter (IO).
The power from the engine is transmitted
through the oil by torque converter (IO) to
the transmission
input shaft (turbine shaft)
in accordance with the change in load.
Transmission
(11) uses a combination
of a
planetary gear system and hydraulic clutches
to reduce the speed and shift the gears (forward 3 gears, reverse 3 gears). It connects
two sets of clutches selected according to
the change in load, and transmits the power
to bevel gear (12) from the bevel pinion at
the rear end of rhe transmission.
The power transmitted
to the bevel gear
shaft is transmitted
to HSS (Hydrostatic
Steering System (13).
HSS pump (19) is driven by PTO (81, and
output oil of HSS pump drives HSS motor
(14).
1O-8
The rotation of the pair of HSS gears on the

left and right is controlled
by HSS motor
(14).
The steering is carried out by generating
a
difference in speed on the left and right.
It is also possible to use the HSS mechanism
to rotate the left and right sides in opposite
directions to carry out counterrotation
turns.
Brake (15) of the HSS is used only for braking the machine.
Brake (15) is a wet type,
multiple disc clutch, spring boosted type.
The power sent from brake (15) is transmitted to final drive (16).
Final drive (16) consists of a single stage
spur gear and single stage planetary gear
system.
It reduces rhe speed and rotates sprocket
(17) to drive track shoe (18) and move the
machine.
D155AX-5
POWER TRAIN
SYSTEM
POWER TRAIN SYSTEM
i5
1. Engine (SAGDI 40-2)

2. Damper
3. Universal joint
4. PPC, HSS charge pump (104)
5. Scavenging
pump (I 12)
6. Power train lubrication pump (SAL(3)-100)
7. Power train pump (SAL(3)-80)
8. PTO
9. Work equipment
pump (SAR(4)-112)
10. Torque converter
D155AX-5
14
11.
12.
13.
14.
15.
16.
17.
18.
19.
13
I
SVD02729
Transmission
Bevel gear
HSS unit
HSS motor (HMF140)
Brake
Final drive
Sproket
Track shoe
HSS pump (HPVIGO)
1o-9
OVERALL DRAWING
OVERALL DRAWING OF POWER TRAIN UNIT
OF POWER TRAIN UNIT
_____--_-__--(?
n
n
________________y_-.--
(?
SWD02747
10-10
D 155/4X-5
OVERALL DRAWING OF POWER TRAIN UNIT
SJD02748
1.
2.
3.
4.
5.
6.
7.
8.
Work equipment
pump (SAR(4)-112)
Torque converter, PTO
Transmission
Brake valve
HSS motor (HMF140)
HSS unit
Charge relief valve
HSS oil cooler bypass valve
9.
10.
11.
12.
13.
14.
15.
16.
Transmission
main relief valve
HSS pump (HPVIGO)
Power train pump (SAL(3)-80)
Power train lubrication pump (SAL(3klOO)
PPC, HSS charge pump (104)
Scavenging
pump (112)
Scavenging
pump strainer
Power train pump strainer
Outline
The power train unit can be broadly divided
into torque converter (with PTO) (2), transmission unit (31, and steering unit (6).
So, after the power train unit has been removed,
it can be disassembled
into the
torque
converter,
transmission
unit, ans
steering unit.
.
HSS unit consists of the bevel pinion unit,
bevel gear shaft, HSS motor, planetary gear
and brake.
l
D155AX-5
10-11
STRUCTURE
AND FUNCTION
POWER TRAIN
POWER TRAIN HYDRAULIC

(Engine
started,
joystick
at neutral,
SYSTEM
HYDRAULIC
SYSTEM
DRAWING
DRAWING
gear shift lever at 1st)
I
I
L____-__________i
r-___-----_
_________!
i___________________------_
I II I
25 I
DCBA
1
+isJ
I__________________------7_
SWD02749
10-n
D155AX-5
POWER TRAIN HYDRAULIC SYSTEM DRAWING
1. Power train oil pan

IA. Torque converter case
1 B. Transmission
case
IC.
HSS case
2. Oil strainer
3. Power train pump (SAL(3b80)
4. Power train oil filter
5. Main relief valve
6. Transmission
control valve
6A. Modulating
valve
6B. Quick return valve
6C. Speed valve
6D. Directional valve
7. 1st clutch
8. 3rd clutch
9. 2nd clutch
10. REVERSE clutch
11. FORWARD clutch
12. Torque converter relief valve
13. Torque converter
14. Oil cooler
15. Lubrication relief valve
16. Transmission
lubrication
17. PTO lubrication
18. Brake valve
18A. Brake valve
18B. Parking brake valve
19. R.H. brake
20. L.H. brake
21. R.H. brake disc lubrication
22. Bevel gear teeth lubrication
23. L.H. brake disc lubrication
24. Power train lubrication pump (SAL(3)-100)
25. Centralized pressure detection port
26. Oil strainer
27. Scavenging
pump (112)
28. Pin puller solenoid valve
(for giant ripper)
29. Pin puller cylinder
SWD02750
D155AX-5
10-13
STRUCTURE
AND
FUNCTION
POWER TRAIN HYDRAULIC
POWER TRAIN
HYDRAULIC
PIPING
DIAGRAM
PIPING DIAGRAM
SVD02756
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Scavenging
pump (112)
Power train lubrication pump (SAL(3)-100)
Power train pump (SAL(3)-80)
Transmission
control valve
Brake control valve
Main relief valve
Centralized pressure detection port
Power train oil strainer
Power train oil filter
Power train oil cooler
(built in radiator lower tank)
10-14
A.
B.
Brake pressure pickup port

Transmission
modulating
pressure
C.
D.
Port
Torque converter outlet pressure pickup port
Torque converter inlet pressure pickup port
pickup
D155AX-5
converter
Torque
Pressure
ports
converter
Torque
176Q/min_
mesh size 30pm

area 10026cm
Centralized
eletection
Theoretical
rated
flow
Filter
Filter
Filterins
ms_s_ure)
II
__-__2 kg/cm
toiffrencial
case
case
;_
II
c-!
Ie---
i-i-0=0.
1i
case
T-
case
; v
HSS
lubr ,icat
,
I
I
[
/
(
_/
____~~~~~~~~~~__Steering
Transmission
control
valve
___._________________---------~
Transmission
#---w
ion
rake vslve
-__-__-__-
Parking
brake
Hoot
brake
L. H.
brake
R. H.
brake
DAMPER,
DAMPER. UNIVERSAL JOINT
UNIVERSAL
JOINT
B-B
lo
A-A
lo-16
SVD02764
D 155AX-5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
DAMPER, UNIVERSAL JOINT
Breather
Dipstick
Drain plug
Input shaft
Flywheel
Outer body
Coupling
Universal joint
Cover
Rubber coupling
Inner body
Outline
l
The damper dampens the torsional vibration caused by the change in engine torque
and the impact torque generated when accelerating
suddenly or when carrying out
heavy-duty
digging. In this way it acts to
protect the torque converter, transmission,
and other parts of the power train.
This damper has few component
parts: it
uses a rubber coupling, so the vibration is
absorbed by the damping effect of the rubber material.
Operation
l
The motive force from the engine passes

through flywheel
(5) and is transmitted
to
outer body (6).
The torsional vibration of the engine is absorbed by rubber coupling
(IO), and the
power is transmitted
to inner body (I I). It
passes through universal joint (8). and is
then transmitted
to the torque
converter
and transmission.
D155AX-5
10-17
TORQUE CONVERTER, PTO
PTO
TORQUE CONVERTER,
TCS43-17A
L\
AB-
D
SVD02733
D155AX-5
10-19
12
13
I4
15
17
18
B-B
A-A
E-E
SVDO2734
1O-20
D155AX-5
1. Power train, power train lubrication

pump
mount
2. Scavenging
pump mount
3. HSS pump mountin port
4. Power train oil strainer
5. PTO lubrication tube
6. Hydraulic, PPC charge pump mount
7. Input coupling
8. Input shaft
9. PTO drive gear (55 teeth)
10. idler gear shaft
11. Idler gear (66 teeth)
12. PTO case
13. Drive case
14. Turbine
15. Pump
16. Stator
17. Stator shaft
18. Transmission
input shaft
19. HSS pump drive gear (49 teeth)
20. Pump drive gear (47 teeth)
(Hydraulic, power train, power train lubrication pump)
21. Scavenging
pump drive gear (53 teeth)
A.
B.
C.
D.
Torque converter oil inlet port

To oil cooler
To transmission case (from torque converter
case)
From transmission
case (to power train
E.
pump)
To transmission
case (passage)
Outline
Torque
converter
is a 3-element,
single
stage, single phase type, and forms an integrated structure with the transmission.
.
Pump (15) forms one unit with input coupling (71, input shaft (8), and drive case (131,
and is rotated by the motive force from the
engine.
Turbine (14) forms one unit with transmission input shaft (181, and is rotated by the
oil from the pump.
Stator (16) forms one unit with stator shaft
(17), and is held in position by PTO case
(12).
.
The scavenging pump is driven by PTO drive
gear (9), and returns the oil accumulated
in
the transmission
case to the steering case.
l
D155AX-5
10-21
TRANSMISSION
CONTROL
TRANSMISSION
CONTROL
SVDO2787
Lever positions
NEUTRAL
FORWARD
REVERSE
1st
0: 2nd
0: 3rd
0: FREE
@: LOCK
0:
0:
0:
0:
1. Safety lever
2. Joystick
(directional, gear shift)
3. Limit switch
(for safety lever)
4. Cable
control
5. Transmission
valve
Outline
l
.
*
For details of the operation of the joystick

the steering system, see STEERING,
for
BRAKE CONTROL section.
10-22
The
transmission
is controlled
by joystick
(2).
The joystick is used to shift between forward and reverse, and to shift gears.
is equipped with a safety
The transmission
if safety lever (I) is not placed
mechanism:
at the LOCK position, limit switch (3) is not
actuated and the engine cannot be started.
D155AX-5
TRANSMISSION
TRANSMISSION
A
SVDO2757
1 O-24
D 155AX-5
TRANSMISSION
SVD02758
To FORWARD clutch
To REVERSE clutch
To 3rd clutch
To 2nd clutch
To 1st clutch
To torque converter case
(from power train oil strainer)
G. From torque converter case
H. To scavenging pump
J. To torque converter case
K. From scavenging pump
L. From power train pump
M. To steering valve
N. To steering case
P. From steering case
Q. Transmission
lubrication inlet port
A.
8.
C.
D.
E.
F.
D155AX-5
1o-25
TRANSMISSION
No.1
. .
REVERSE
36
35
34
33
32
No.2
_.
31
30
26
29
A-A
1O-26
No.3
3rd
FORWARD
.I,
No.4
.I,
27
No.5
1st
2nd
26
25
24
23
22
21
SDW0027
D155AX-5
STRUCTURE

case
2. Transmission
control valve, valve cover
3. Transmission
assembly
4. Lubrication relief valve
5. Input shaft
6. REVERSE sun gear (34 teeth)
7. Pinion shaft
8. REVERSE ring gear (90 inner teeth,
105 outer teeth)
9. REVERSE planet pinion (26 teeth)
10. Disc
11. Plate
12. Piston
13. FORWARD planet pinion (27 teeth)
14. 3rd planet pinion (36 teeth)
15. 3rd ring gear (91 inner teeth, 105 outer teeth)
16. 2nd sun gear (39 teeth)
17. 1st planet pinion (21 teeth)
18. 1st sun gear (49 teeth)
19. Output shaft (20 teeth at 3rd sun gear
portion)
20. 1st ring gear (91 inner teeth, 105 outer teeth)
21. 1st carrier (90 teeth)
22. 1st clutch housing
23. 2nd clutch housing
24. 2nd planet pinion (26 teeth)
25. 2nd ring gear (90 inner teeth, 105 outer
teeth)
26. 3rd clutch housing
27. 2nd, 3rd carrier
28. FORWARD clutch housing
29. FORWARD sun gear (37 teeth)
30. FORWARD ring gear (91 inner teeth,
105 outer teeth)
31. FORWARD carrier (86 teeth)
32. REVERSE clutch housing
33. Return spring
34. REVERSE ring gear (86 teeth)
35. Pin
36. REVERSE carrier (90 teeth)
D155AX-5
TRANSMISSION
AND FUNCTION
Outline
The transmission
has three forward speeds
and three reverse speeds, and uses a combination of a planetary gear system and disc
clutches.
In the transmission,
two of the clutches of
the 5 sets of planetary
gears and disc
clutches are controlled by the control valve
and are held in position by hydraulic force
to select one rotational
direction and one
speed.
The No. 1 clutch is held in position for reverse, the No. 2 clutch for forward, the No.
3 clutch for 3rd, the No. 4 clutch for 2nd,
and the No. 5 clutch for 1st.
Speed
range and clutches
Speed range
actuated
Clutches used (engaged)

No. 2, No. 5
FORWARD 1st
FORWARD 2nd
No. 2, No. 4
FORWARD 3rd
No. 2, No. 3
Neutral
No. 5
REVERSE 1st
No. 1, No. 5
REVERSE 2nd
No. 1, No. 4
REVERSE 3rd
No. 1, No. 3
No. of plates
Clutch No.
and discs used

No. of discs
No. of plates.
4
No. 1 clutch
No. 2 clutch
No. 3 clutch
No. 4 clutch
No. 5 clutch
1 O-27
STRUCTURE
AND
TRANSMISSION
FUNCTION
Operation
1. Operation
of disc clutch
The disc clutch is installed in order to hold
ring gear (8) in position. It consists of piston
(121, plate (II), disc (IO), pin (351, and piston return spring (33).
The inside disc teeth are meshed with the
outside teeth of the ring gear.
The plate is meshed with pin (35), which is
fixed to housing (32) and the protruding
notched portion on the plate outer diameter.
33
\
35
I.0
?I
j2
32
Clutch engaged (held in position)

The oil from the control
valve
passes
through the port of housing (32) and is forcibly sent to the back of piston (12).
The piston pushes plate (11) against disc
(IO), and the friction stops the disc rotation.
It also holds in position ring gear (81, which
is meshed with the inside teeth.
l
Clutch disengaged
(released)
.
When the oil from the control valve is shut
off, piston (12) is returned
to its original
position by piston return spring (33). The
friction between plate (11) and disc (IO) is
released, and ring gear (8) is placed in neutral.
wl=fa=-
SKD00107
1 O-28
D155AX-5
STRUCTURE
AND FUNCTION
TRANSMISSION
31
30
29
27
A-A
2.
.
Forward 1st
When the transmission
is set to FORWARD
Ist, the No. 2 clutch and No. 5 clutch are
engaged. The motive force from the torque
converter transmitted
to input shaft (5) is
then transmitted
to output shaft (19).
No. 2 clutch is actuated by the hydraulic
pressure applied to the clutch piston, and
holds ring gear (30) in position. No. 5 clutch
is actuated by the hydraulic pressure applied to the clutch piston, and engages ring
gear (20).
The motive force from the torque converter
is transmitted to input shaft (5), and the rotation of the input shaft passes through sun
gear (29) and is transmitted to planet pinion
(13).
D155AX-5
25
24
21
20
SDD00108
Ring gear (30) is held in position by No. 2

clutch, so the rotation of planet pinion (13)
rotates carrier (311, which is on the inside of
ring gear (30).
Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of carrier (31) passes through
planet
pinion (24) and is transmitted
to ring gear
(25).
Carrier (21) is meshed with ring gear (251,
and rotates as one unit, so the rotation is
transmitted
to planet pinion (17).
Ring gear (20) is being held in position by
No. 5 clutch, so the rotation of planet pinion
(17) rotates sun gear (181, and this rotates
output shaft (19).
1 O-29
TRANSMISSION
31
30
29
27
25
24
SWD02802
3. Forward 2nd
l
When the transmission is set FORWARD 2nd

the No. 2 clutch and No. 4 clutch are engaged. The motive force from the torque
then transmitted
is actuated
by the hydraulic pressure applied to the clutch piston, and engages ring
gear (25).
is transmitted
to input shaft (51, and the
rotation of the input shaft passes through
sun gear (29) and is transmitted
to planet
pinion (13).
1O-30

ring gear (30).
spline, and rotate as one unit, so the rotation is transmitted
(24) rotates sun gear (161, and this rotates
output shaft (19).
D 155AX-5
TRANSMISSION
No.
l.,. No.
REVERSE
2_,<No.
FORWARD
3_,.No.
3rd
2nd
4%,No.
1st
31
30
29
27
SWD02803
4. Forward 3rd
l

is set to FORWARD
3rd the No. 2 clutch and No. 3 clutch are
then transmitted
is actuated
by the hydraulic pressure applied to the clutch piston, and engages ring
gear (15).
is transmitted
to planet
pinion (13).
D155AX-5

ring gear (30).
spline, and rotate as one unit, so the rotation is transmitted
(14) rotates output shaft (19).
10-31
STRUCTURE
AND
FUNCTION
36
TRANSMISSION
34
27
3i
A-A
3.
.
Reverse 1st
is set to REVERSE
Ist, the No. 1 clutch and No. 5 clutch are
then transmitted
holds carrier (36) in position. No. 5 clutch is
actuated by the hydraulic pressure applied
to the clutch piston, and engages ring gear
(20).
is transmitted
to planet
pinion (9).
Carrier (36) is held in position by No. 1
1 O-32
25
24
21
20
SDDOOlOS

rotates ring gear (34).
Ring gear (34) rotates in the opposite direction from the input shaft, and rotates carrier
l
(31).
Carrier
spline,
tion of
pinion
(31) and carrier (27) are joined by a

and rotate as one unit, so the rotacarrier (31) passes through
planet
(24) and is transmitted
to ring gear
(25).
Carrier (21) is meshed with ring gear (251,
and rotates as one unit, so the rotation is
transmitted
rotates sun gear (18), and this rotates output shaft (19).
D 155AX-5
TRANSMISSION
TRANSMISSION
CONTROL VALVE
CONTROL VALVE
SJD02739
1o-34
D 155AX-5
TRANSMISSION
A-A
\.
D 155AX-5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
CONTROL VALVE
Quick return valve

Plug
Valve body
Stopper
Speed valve spool
Directional valve spool
Collar
Cover
Stopper
Piston
Piston spring
Modulating
valve spool
Modulating
valve sleeve
Modulating
valve spring
Modulating
valve spring
Modulating
valve spring
Stopper
Cover
(large)
(small)
1o-35
TRANSMISSION
MODULATING
CONTROL VALVE
VALVE
Outline
.
The modulating
valve assembly consists of
the modulating valve and quick return valve,
and has a pressure modulating
function.
.
When the gear shift lever is operated to shift
gear, the clutch is engaged by the piston,
but if high oil pressure is suddenly applied,
the piston will suddenly engage the clutch.
This will cause the machine to start suddenly and will subject the machine to an
excessive shock.
To prevent this, the modulating
valve is installed to raise the pressure applied to the
piston gradually to the set pressure when
the gear shift lever is operated to shift gears.
This engages the clutch smoothly and prevents any starting shock. In this way, it not
only improves the ride for the operator, but
also improves the power train durability.
The graph on the right shows the amount
of time elapsed and the rise in the oil pressure with the modulating
valve.
For example,
when shifting from forward
1st to forward 2nd, the oil from the pump
passes through the speed valve spool and
flows to the 2nd clutch to fill the circuit to
the clutch piston port.
The time taken to fill the circuit to the clutch
piston port is called the filling time. The oil
pressure is 0 to 0.5 MPa (0 to 5 kg/cm*).
The time taken for the oil pressure to rise to
the set pressure after the circuit to the clutch
piston port
is filled is called the build-up
time. The combination
of the filling time
and build-up time is called the modulating
time.
Modulat,ina
time
0. 5
0
Time
t. 0
(set)
SWDO2811
1 O-36
D155AX-5
STRUCTURE
TRANSMISSION
AND FUNCTION
Operation
1. Immediately
after shifting gear
When the gear shift lever is operated and
the clutch is engaged, the passage from the
pump to the clutch cylinder is opened, and
oil flows to the clutch cylinder.
Using the power of this flow, quick return
valve (I) moves to the left, connects ports A
to drain port B, and releases the back pressure of modulating
valve sleeve (13).
When this happens, modulating
valve (12)
and modulating valve sleeve (13) are pushed
back to the right in the arrow direction by
the reaction force of springs (141, (15), and
To
c lutch
CONTROL
VALVE
cylinder
Drain
.A
PUrnP
SWD02938
(16).
2.
Oil pressure starting to rise, while rising

When the oil sent from the pump fills the
circuit to the clutch cylinder, the pressure
starts to rise.
The oil passing through orifice a of quick
return valve (I) moves quick return valve
(I) to the right in the arrow direction, and
closes the passage between port A and drain
port B.
The oil also passes through
orifice b of
modulating
valve (12), flows to port C, and
pushes piston (IO).
When this happens, modulating
valve (12)
uses the reaction force to compress springs
(14) and (15), and moves to the left in the
arrow direction.
The oil passing through the central port of
quick return valve (I) passes through orifice
c and flows to port A. It forms the back
pressure of valve sleeve (131, and moves
valve sleeve (13) to the left in the arrow
direction to compress spring (16).
D 155AX-5
To
Pump
SWD0.2939
1o-37
STRUCTURE
3.
AND FUNCTION
While oil pressure is rising, rise completion

As the oil pressure in the circuit rises, the
back pressure of valve sleeve (13) also rises,
and valve sleeve (13) moves to the left in
the arrow direction.
In addition, as the oil pressure pushing pisvalve (12) moves
ton (IO) rises, modulating
to the left in the arrow direction by reaction
force.
repetition of the above opBy continuous
load of springs (14), (15), and
eration,the
(16) increases, and the oil pressure gradually rises. Finally, valve sleeve (13) contacts
stopper (17) and cannot move any further,
the rise in oil pressure.
thus completing
1 O-38
TRANSMlSSbON
To
clutch
VALVE
CONTROL
cylinder
B
Drain
I5
14
13
Drain
From
Dump
12
10
SWD02940
D 155AX-5
STRUCTURE
AND
MAIN
FUNCTION
RELIEF VALVE
MAIN RELIEF VALVE
Pl
P8
E
D
A-A
1.
2.
3.
4.
5.
6.
7.
8.
9.
A.
B.
C.
D.
E.
PI.
P8.
Body
Torque converter
Valve spring
Piston
Piston spring
Main relief valve
Valve spring
Piston spring
Piston
relief valve
Drain port (for torque converter relief)

Drain port
From pump
Drain port
To torque converter
Main relief oil pressure detection port
Torque converter relief oil pressure
detection port
D155AX-5
Outline
Main relief valve (6) sets the set pressure of
the oil pressure for the transmission,
steering clutch, and brake.
2. Torque converter relief valve
Torque converter relief valve (2) acts to protect the torque converter from abnormally
high pressure by relieving the circuit if the
torque converter
inlet port pressure rises
above the set pressure.
Unit: MPa {kg/cm*}
Set pressure
Main relief pressure
Torque converter relief pressure
2.94 130)
0.87 18.83)
1o-39
STRUCTURE
AND
MAIN
FUNCTION
To torque
converter
*\
Operation
of main relief valve
.
The oil from the power train pump passes
through the filter, enters port A of the main
relief valve, then passes through orifice a
and enters port B.
When the oil from the pump fills the circuit,
the oil pressure starts to rise.
.
As the oil pressure in the circuit rises, the
oil entering port B pushes piston (4). The
reaction compresses spring (71, moves main
relief valve (6) to the left in the arrow direction, and opens ports A and C.
Then, the oil from the pump is relieved from
port A to port C, then flows from port C to
the torque converter.
The oil pressure at port A at this point is
2.94 MPa (30 kg/cm?.
RELIEF VALVE
To oil tank
From pump
To torque
converter
SYD00295
To oil tank
7---lm
I
,
:;
I
Operation
of torque converter relief valve
The oil relieved by the main relief valve
flows from port C to the torque converter,
and at the same time, passes through orifice b and enters port D.
When
the passage to the torque converter
is filled with oil, the oil pressure starts to
rise.
As the oil pressure to the torque converter
rises, the oil entering port D pushes piston
(9). The reaction
compresses
spring (3).
moves relief valve (2) to the right in the
arrow direction, and opens ports C and E.
Then, the oil from port C is relieved to port
E and is drained to the oil tank.
The oil pressure at port C at this point is
0.87 MPa (8.83 kg/cm*).
From pump
To torque
From pump
1O-40
SYD00297
D155AX-5
STRUCTURE
AND
FUNCTION
LUBRICATION
LUBRICATION
RELIEF VALVE
RELIEF VALVE
SDD00028
1. Forward
2. Spring
3. Piston
clutch housing
A. From oil cooler

B. Drain
C. Drain
Outline
.
The oil leaving the torque converter passes
through the oil cooler built in the radiator
lower tank. It then goes through the lubrication relief valve and lubricates the transmission and PTO.
Unit: MPa {kg/cm21
The
lubrication
relief valve is installed to
the right side face of the forward
clutch
housing, and prevents any abnormal
pressure in the lubricating oil.
D 155AX-5
10-41
SCAVENGING
1.
2.
3.
4.
5.
Scavenging
pump
PTO drive gear
Pump drive gear
PTO case
Strainer
SCAVENGING
PUMP STRAINER
(112)
Outline
.
Scavenging
.
A. Scavenging
B. Scavenging
lo-42
PUMP STRAINER
pump suction port

pump delivery port
pump (I) is driven by PTO drive

gear (2). It acts to return the oil accumulated in the transmission
case to the steering case.
The strainer is made of punched metal with
2-mm diameter holes.
D155AX-5
STRUCTURE
POWER TRAIN PUMP STRAINER
AND FUNCTION
POWER TRAIN PUMP STRAINER
3A
38
3c
A-A
SWD07.780
1. Power train lubrication pump (rear)

(SAL(3)-100)
2. Power train pump (front) (SAL(3)-80)
3. Power train pump strainer assembly
3A. Magnet
3B. Strainer
3C. Shaft
Performance
A.
B.
From steering case

To power train pump
*
The front pump indicates
the shaft mount end.
D155AX-5
the pump
at
Mesh size
(u m)
149
Filtering area
Pressure
(cm*)
2,100
resistance
(MPa
{kg/cm*})
0.2 (2.01
o-43
POWER TRAIN OIL FILTER
POWER TRAIN OIL FILTER
1A
18
1D
SKD00040
1.
A.
B.
Power train oil filter assembly

IA. Cover
16. Body
1 C. Element
ID. Valve
IE. Spring
IF. Drain plug
To transmission
case
From power train pump
1o-44
Performance
Cracking
pressure
Mesh
(MPa
size
Filtering
area
Filter flow
{kg/cm*})
0.105 f 0.02 (1.05 f 0.21
(p m)
30
(cm*)
10,026
(Urnin)
169
D155AX-5
HSS SYSTEM
HSS SYSTEM
1
5
//
,,
SVDO2684
1O-46
D155AX-5
STRUCTURE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
AND
HSS SYSTEM
FUNCTION
Joystick
HSS controller
Servo valve
HSS pump
Engine
Hydraulic pump
Work equipment
control
Sprocket
Final drive
HSS motor
HSS closed circuit
valve
A.
B.
C.
D.
E.
F.
G.
Travel REVERSE signal 2

Trave; REVERSE signal 1
Steering signal; I,2
Engine speed signal
Hydraulic pressure signal
Steering circuit pressure signal A
Steering circuit pressure signal B
Outline
The HSS system is a hydrostatic
system;
HSS stands for Hydrostatic
Steering
System.
The HSS system consists of a set of piston
pump and piston motor as shown in the
diagram.
With this system, it is possible to
turn continuously by generating a difference
in speed between the left and right tracks.
There is no need to reduce speed.
The HSS controller controls the angle of the
swash plate in the HSS pump according to
the angle of operation
of the monolever,
and controls the speed and directional
of
rotation of the HSS motor.
The HSS motor uses the planetary gear system of the bevel gear shaft to create a difference in the speed of the left and right
sprockets, and this turns the machine.
The HSS controller detects the speed of the
engine and the hydraulic
pressure
at all
parts, and controls the swash plate angle of
the HSS pump to prevent the engine from
stalling.
Dl %AX-5
1o-47
ACTUATION
1.
ACTUATION
OF HSS SYSTEM
OF HSS SYSTEM
Joystick at NEUTRAL and machine stopped
70 ,,
t
,c
-t
ii
/i
SVDO2685
1 O-48
D155AX-5
ACTUATION OF HSS SYSTEM
-I?
; 7/
14
I3
:-
SVD02666
D155AX-5
1o-49
STRUCTURE
AND
ACTUATION
FUNCTION
OF HSS SYSTEM
1. Hydraulic tank
2. Charge pump
3. HSS, PPC charge circuit filter
4. Accumulator
5. HSS, PPC charge circuit valve
6. Charge pressure sensor
7. HSS pump
7A. Suction safty valve
7B. Suction safty valve
7C. Charge safty valve
7D. Serve piston
7E. Solenoid B
7F. Solenoid A
7G. Servo valve
8. HSS motor
8A. Flashing shuttle valve
88. Cooling shuttle valve
9. Pump, motor drain circuit block
9A. Charge relief valve
sensor
10. Hydraulic temperature
11. Oil cooler bypass valve
12. Hydraulic oil cooler
13. HSS controller
14. Joystick
U. To PCC valve
V. LEFT TURN
W. NEUTRAL
X. RIGHT TURN
Actuation
when joystick is at NEUTRAL
and
machine is stopped
.
When joystick (14) is at NEUTRAL, there is
no electric signal from HMT controller (13)
to HSS pump solenoids (7E) and (7F). Servo
valve (7G) and servo piston (70) are both at
neutral, so the swash plate angle of HSS
pump (7) is 0, and the delivery from ports
PA or PB is also 0.
To ensure the suction performance

of HSS
pump (71, the charge pressure in the HSS
charge circuit is always detected by charge
pressure sensor (6), and feedback is sent to
HSS controller (13).
The pressurized
oil from charge pump (2)
passes through PPC, HSS charge valve (5)
and enters the charge circuit. The pressurized oil entering port A is set to the maximum pressure for the charge circuit 3.7MPa
{38kg/cm*}
by charge
safety valve (7C).
When the HSS pump is at neutral, all the oil
flow is relieved from port D, passes through
oil cooler bypass valve (II) and hydraulic
cooler (12), and is drained to hydraulic tank
(I).
1O-50
D155AX-5
2.
ACTUATION
OF HSS SYSTEM
Joystick at FORWARD and left turn
6
3
,2
;,,,,:
iQ
1
7c,
70 ,,
SVD01667
1o-52
D155AX-5
ACTUATION
OF HSS SYSTEM
4 -__I
14
6
I-
13
m
I
fh
-:
SVD02666
D155AX-5
1o-53
ACTUATION
OF HSS SYSTEM
U. To PCC valve
V. LEFT TURN
W. NEUTRAL
X. RIGHT TURN
Jovstick at FORWARD and left turn

_When monolever
(14) is operated to FORWARD and left turn, an electric signal flows
from HSS controller (13) to solenoid B (7E).
Servo valve (7G) and servo piston (7D) move
in the direction of the arrow, change the
angle of the swash plate of HSS pump (7)
and pressure oil is discharged from port PB.
When oil is discharged from PB, the pressure at port PA is low, so safety-suction
valve (78) opens, and if there is insufficient
oil in the HSS closed circuit, oil is supplied
from (7B).
The pressure oil leaving PB enters port MB
of HSS motor (8) and rotates the HSS motor. The return oil flows from port MA to
port PA and circulates inside the HSS closed
circuit.
At the same time, the pressure oil from port
F moves shuttle valve (8A) in the direction
of the arrow, and low-pressure
ports E and
G open.
When this happens, the minimum pressure
(18 kg/cm*) is maintained
at the low-pressure side by charge relief valve (9A), and
the suction performance
of the HSS pump
is ensured.
The excess pressure oil is relieved from charge relief valve (9A) to port
H, passes through oil cooler bypass valve
(11) and hydraulic
oil cooler (12), and is
drained to hydraulic tank (1).
The relief pressure (II
kg/cm*) of charge
relief valve (9A) is lower than the relief pressure (28 kg/cm*) of charge safety valve (7C).
As a result, the charge pressure oil flowing
into the HSS circuit is relieved from charge
relief valve (9A).
1o-54
D155AX-5
ACTUATION
3.
OF HSS SYSTEM
Joystick at travel FORWARD and right turn
IQ
m
,
y,:
I2
I
C
1/
I,,
I,,
:::
1,111
1,111
nrrrrm,
,,
:::::::::::::::::::::
::::::::::::::::::::
:::::::::::::::::::
I I l,
70 ,,
ii
jj
m-,---7
c-----
I,,
SVD02689
1 O-56
D155AX-5
ACTUATION
OF HSS SYSTEM
4i
;
AA
\
4
14
I-
13
If
f
kl
SVD02690
D155AX-5
1o-57
U.
V.
W.
X.
ACTUATION
OF HSS SYSTEM
To PCC valve
LEFT TURN
NEUTRAL
RIGHT TURN
Joystick at travel FORWARD and right turn

When monolever
(14) is operated to FORWARD and right turn, an electric signal flows
from HSS controller (13) to solenoid B (7F).
Servo valve (7G) and servo piston (7D) move
in the direction of the arrow, change the
angle of the swash plate of HSS pump (7)
and pressure oil is discharged from port PA.
When oil is discharged from PA, the pressure at port PB is low, so safety-suction valve
(7B) opens, and if there is insufficient oil in
the HSS closed circuit, oil is supplied from
(7A).
The pressure oil leaving PA enters port MA
of HSS motor (8) and rotates the HSS motor. The return oil flows from port MB to
port PB and circulates inside the HSS closed
circuit.
At the same time, the pressure oil from port
E moves shuttle valve (8A) in the direction
of the arrow, and low-pressure
ports F and
G open.
When this happens, the minimum
pressure
(18 kg/cm*) is maintained
at the low-pressure side by charge relief valve (9A), and
the suction performance
of the HSS pump
is ensured.
The excess pressure oil is relieved from charge relief valve (9A) to port
H, passes through oil cooler bypass valve
(11) and hydraulic
oil cooler (121, and is
drained to hydraulic tank (1).
The relief pressure (11 kg/cm*) of charge
relief valve (8B) is lower than the relief pressure (28 kg/cm*) of charge safety valve (7C).
As a result, the charge pressure oil flowing
into the HSS circuit is relieved from charge
relief valve (9A).
1O-58
D 155AX-5
HSS PUMP
HSS PUMP
HPVI 60
PC,.PR
1. Servo valve connector
2. Piston pump
3. Servo piston
4. Servo valve
5. Suction safety valve

6. Charge safety valve
7. Plug for measuring
(PA and PB pump pressure)
Outline
l
The pump is composed of variable displacement piston pump with swash plate, servo
valve, suction safety valve, and charge safety
valve.
D155AX-5
1o-59
STRUCTURE
1.
AND
HSS PUMP
FUNCTION
PISTON PUMP
PSVO
I
PSVA
PCS
PSVO
PB
PA
PD2
PR
PSVA
PSVB
PSVI
PC
PC
PSVB
PSVl
SWD02692
: Servo valve source pressure

Pump inlet and outlet port
Pump inlet and outlet port
Pump drain port
Charge safety valve relief pressure
: Servo valve outlet
: Servo valve outlet pressure
: Servo valve source pressure
: Charge pressure
:
:
:
:
1 O-60
D 155AX-5
HSS PUMP
,;
A-A
1. Shaft
2. Case
3. Cradle
4.
5.
6.
7.
Rocker cam
Servo piston
Slider
Shoe
8.
9.
10.
11.
12.
13.
14.
Piston
Cylinder block
Valve plate
End cap
Bearing
Spline
Bearing
Rocker cam (4) has plane A, and shoe (7) is

always pressed against this surface as it
slides in a circle.
Rocker cam (4) sends high pressure oil to
the space between cylindrical surface B and
cradle (3) fixed to the case (21, to form a
hydrostatic bearing and carries out a rocking movement.
Piston (8) carries out motion relative to the
axial direction inside each cylinder chamber
of cylinder block (9).
Cylinder block (9) carries out rotation relative to valve plate (IO) while sealing the
pressurized oil, and this surface ensures that
the hydraulic
balance
is maintained
correctly. The oil inside each cylinder chamber
of cylinder block (9) is sucked in and discharged through valve plate (IO).
Outline
l
The rotation torque transmitted to the pump

shaft is converted to hydraulic energy and
pressurized
oil is discharged
according to
the load.
It is possible to change the delivery amount
(normal delivery 0 reverse delivery) by changing the swash plate angle.
Structure
l
Cylinder block (9) is supported to shaft (I)

by a spline (131, and shaft (I) is supported
by front and rear bearings (12) and (14).
The end of piston (8) has a concave ball
shape, and shoe (7) is caulked to it to form
one unit. Piston (8) and shoe (7) form a
spherical bearing.
D155AX-5
1O-61
STRUCTURE
AND
FUNCTION
Operation
1. Operation of pump
Cylinder block (9) rotates together with shaft
(I), and shoe (7) slides on plane A.
When this happens, angle a of center line X
of rocker cam (4) to the axial direction of
cylinder block (9) changes. This angle c1 is
called the swash plate angle.
I) With swash plate angle 01formed by the
angle between center line X of rocker
cam (4) to the axial direction of cylinder
block (91, plane A acts as a cam for shoe
(7). In this way, piston (8) slides inside
cylinder block (91, and as a result, a difference is generated
between volumes
E and F inside the cylinder block. The
amount of suction and discharge is equal
to difference F - E.
In other words, cylinder block (9) rotates,
and the volume of chamber F becomes
smaller, so oil is discharged during this
process. At the same time, the volume
of chamber E becomes larger and oil is
sucked in as the volume increases.
2) When center line X of rocker cam (4) is
the same as the axial direction of cylinder block (9) (swash plate angle = 01,
the difference between volumes E and
F inside cylinder block (9) is 0, so no oil
flows in or out, and no pumping is carried out.
3) With swash plate angle a formed by the
angle between center line X of rocker
cam (4) to the axial direction of cylinder
block (91, plane A acts as a cam for shoe
(7). In this way, piston (8) slides inside
cylinder block (9), and as a result, a difference is generated
between volumes
E and F inside the cylinder block. The
amount of suction and discharge is equal
to difference E - F.
In other words, cylinder block (9) rotates,
and the volume of chamber E becomes
smaller, so oil is discharged during this
process. At the same time, the volume
of chamber F becomes larger and oil is
sucked in as the volume increases. When
the swash plate angle changes, the suction/discharge
action of ports PA and PB
is reversed.
HSS PUMP
1 O-62
smo120
PA PB
SKD00121
F
SKDO0122
D155AX-5
HSS PUMP
2.
Control of discharge amount

I)
If swash plate angle a becomes larger,

the difference between volumes E and F
becomes
larger, and oil delivery Q is
increased.
Swash
plate angle CL is
changed by servo piston (5).
Servo piston (5) carries out reciprocal
movement
in a straight line (~1 according to the command from the valve. This
straight-line movement is transmitted to
rocker cam (4) through slider (61, and
rocker cam (41, which is supported
on
the cylindrical surface by cradle (2) slides
on the cylindrical surface ( C direction).
In the case of the pump, swash plate
angle a is a maximum
of f20.
A-A
SDD00123
SDD00124
LL_Ll
B-B
D155AX-5
SDD00125
1O-63
HSS PUMP
2.
Servo valve
k-B
PSVl
PSVA
PSVB
A-A
B-0
SWD02694
1.
2.
3.
4.
5.
6.
7.
8.
9.
Connector
Solenoid valve B
Connector
Solenoid valve A
Shaft
Coil
Base
Lever 1
Spring
1 O-64
10.
11.
12.
13.
14.
Lever 2
Body
Screw
Arm
Spool
PSVI : Servo valve source pressure

PSVB : Servo valve output pressure
PSVA : Servo valve output pressure
D155AX-5
HSS PUMP
15
SWD07.695
Actuation
1)
When pressurized oil (servo source pressure)

does not enter from the charge pump or
when there is no current flowing to solenoid valve coil (6), the servo valve and servo
piston (15) are not actuated.
D155AX-5
1O-65
STRUCTURE
2)
3)
AND
FUNCTION
HSS PUMP
When the current flows to solenoid valve

coil (6) and coil is excited, solenoid propuland shaft (5)
sion force fl is generated
pushes spool (14) to the right in the direction of the arrow. Lever 2 (IO), which is
with spool (14), uses screw
interconnected
(12) as a fulcrum and rotates clockwise while
pulling spring (9).
When spool (14) moves, the passages between ports A and B and ports C and D
open, and pressurized oil from the charge
pump passes through ports A and B and
flows to port F of servo piston (15).
At the same time, the oil at port G passes
through ports D and E, and is drained.
1O-66
D155AX-5
STRUCTURE
HSS PUMP
AND FUNCTION
4)
Y--
15
SWD02793
Servo piston (15) is moved to the right in

the direction of the arrow by the pressurized oil entering port F, and the swash plate
angle of the variable pump becomes larger
by an amount equal to stroke a of the servo
piston. At the same time, arm (131, which is
connected to servo piston (15) rotates arm
(13) around screw (12) as a fulcrum,
and
lever 1 (8) is moved to the left.
Servo piston (15) stops in a position where
solenoid propulsion force fl is balanced with
spring force f2.
D 15%X-5
1O-67
HSS PUMP
5) The
stroke
of the servo
piston,
which
changes the delivery amount of the variable
pump, is controlled by the servo valve.
The relationship
between the stroke of the
servo piston and the current of the solenoid
valve is as shown in the diagram.
PSVA
side
solenoid
Current
PSVB
I
1 O-68
side
solenoid
SWD0.2804
D 155AX-5
STRUCTURE
3.
1.
2.
3.
4.
5.
Suction
HSS PUMP
AND FUNCTION
safety valve
Charge pump
HSS pump
Oil cooler
Charge safety valve
Suction safety valve
5A. Valve
5B. Piston
5C. Sleeve
5D.
5E.
5F.
5G.
Poppet
Valve seat
Spring
Pressure adjustment
screw:
one turn adjusts pressure by approx.
13.7 MPa U40kg/cm21
6. HSS motor
Function
.
There are two suction safety valves installed
to the HSS pump, and they have the following functions.
1) High pressure relief valve
The valve restricts the maximum
pressure inside the HSS circuit in order to
protect the HSS circuit and to restrict
the maximum
drawbar pull of the machine.
2) Suction safety valve
The valve ensures the flow of charge oil
to the HSS circuit and prevents
the
charge oil from flowing into the pump
high pressure side (delivery side).
D155AX-5
1 O-69
STRUCTURE
AND
FUNCTION
HSS PUMP
Actuation
when acting as high pressure relief
valve
(Valve at piston pump delivery side)
.
Port A is connected to the piston pump circuit and port B is connected to the charge
circuit. The pressurized oil also fills port C
through drill hole a in piston (5B). In addition, poppet (5D) is in tight contact with
valve seat (5E).
If abnormal pressure is generated in the piston pump circuit and the oil pressure at port
A and C reaches the pressure set by spring
(5F), poppet (5D) is pushed to the right in
the direction of the arrow, and the oil at
port C is relieved from port D to port B to
reduce the oil pressure at port C.
When the oil pressure at port C goes down,

a differential pressure is generated between
port A and port C by orifice b in piston (5B).
Valve (5A) is pushed to the right in the direction of the arrow by the oil pressure at
port A, and the oil at port A is relieved to
port B.
In this way, the piston pump circuit is prevented from reaching any higher pressure.
1O-70
SED00133
5A
5B
D155AX-5
STRUCTURE
AND
HSS PUMP
FUNCTION
Operation when acting as suction safety valve

1) When HSS pump delivery is 0
.
The HSS circuit is closed, and the charge
pressure oil does not flow into the HSS circuit. Therefore, the charge pressure oil from
the charge pump all passes through charge
safety valve (4) and is drained through oil
cooler (3) to the tank.
21 When HSS pump delivery is discharged from

port PA
(I) Valve at piston pump delivery side
.
When pressure oil is discharged from
port PA of HSS pump (21, port PA
becomes
the high pressure
side.
This pressure oil at port PA passes
through drill hole a in piston (5B)
and flows to port A.
When this happens,
valve (5A) is
pushed to the left in the direction of
the arrow against sleeve (5C) because
of the difference
in area
(Al>A2).
Therefore, the pressure oil
from charge pump (I) is prevented
from flowing into the HSS closed circuit.
SWD02943
SED00137
D155AX-5
10-71
STRUCTURE
AND
(2) Valve at piston pump suction side

.
Port PB becomes the suction side,
so it becomes the low pressure side.
Because of the difference
in area
(Al>A2),
valve (5A) is pushed to the
right in the direction of the arrow by
the charge pressure oil and the seat
of sleeve (5C) opens.
As a result, the charge pressure oil
at port B passes through the gap
and flows to port PB to carry out the
charge function for the HSS circuit.
1 O-72
HSS PUMP
FUNCTION
PB+
Ai
Al
SED00138
D155AX-5
STRUCTURE
4.
Charge
1.
2.
3.
4.
AND
HSS PUMP
FUNCTION
safety valve
CA
Charge pump
HSS pump
Oil cooler
Charge safety valve
4A. Valve
4B. Spring
4C. Valve seat

4D. Poppet
4E. Spring
4F. Pressure adjustment
5. Suction safety valve
6. HSS motor
screw
Function
.
The charge safety valve is installed to the
HSS pump between the suction safety valve
and the oil cooler.
It acts to restrict the
maximum
pressure in the charge circuit.
Set pressure: 3.7 MPa I38 kg/cm? at 204 Umin
D155AX-5
1o-73
HSS PUMP
Operation
.
Port A is connected
to the charge circuit,
and port B is connected to the tank drain
4A
4C
4D
circuit. The pressure oil passes through orifice a in valve (4A) and fills C. Poppet (4D)
is in tight contact with valve seat (4C).
&
.
If abnormal pressure is generated in the circuit or the shuttle valve of the HSS motor is
at neutral, and the pressure oil at ports A
and C reaches the pressure set by spring
(4E), poppet (4D) is pushed to the right in
the direction of the arrow, and the oil at C is
relieved to port D to reduce the pressure of
the oil at C.
4D
SED00140
4E
SED00141
When the pressure of the oil at port C goes

down, a differential
pressure is created between ports A and C because of orifice a in
valve (4A). Valve (4A) is pushed to the right
in the direction of the arrow by the oil pressure at port A, and the oil at port A is relieved to port B.
In this way, the pressure in the charge circuit is prevented from going any higher.
Drain port D at the poppet portion is drained
to the HSS pump case, so the back pressure
of drain port B is not added to the charge
relief pressure, and the valve always displays the set relief characteristics.
1o-74
i
SED00142
D 155AX-5
HSS MOTOR
HSS MOTOR
1.
PISTON MOTOR
3
.MB
MA
T
CA
CB
MB
MA
SA
.SB
CA
CB
l--B
1. HSS motor
shuttle valve
2. Flashing
MA : From HSS pump

MB : From HSS pump
PA port
PB port
T
SA
SB
CA
CB
:
:
:
:
:
To hydraulic tank
To charge relief valve
To charge relief valve
Pressure sensor mounting
Pressure sensor mounting
SJD02699
port
port
Outline
.
Motor
is composed of fixed capacity, fixed

swash plate type piston motor, and flashing
shuttle valve, and cooling shuttle valve.
Specifications
D155AX-5
1o-75
STRUCTURE
AND
HSS MOTOR
FUNCTION
If
i4
i3
II
Ii
B-0
A-A
SJD02700
1.
2.
3.
4.
5.
6.
7.
8.
Output shaft
Motor case
Swash plate
Piston
Cylinder block
Valve plate
End cover
Cover
Outline
.
Pressurized oil sent from the pump is converted to rotation energy and is transmitted
to output shaft.
9.
10.
11.
12.
13.
14.
15.
16.
Return spring
Flashing shuttle valve
Plug
Cooling shuttle valve
Bearing
Spline
Shoe
Bearing
Piston (4) carries out motion relative to the

axial direction inside each cylinder chamber
of cylinder block (5).
Cylinder block (5) carries out rotation relative to valve plate (6) while sealing the pressurized oil, and this surface ensures that the
hydraulic
balance is maintained
correctly.
The oil inside each cylinder chamber of cylinder block (5) is sucked in and discharged
through valve plate (6).
.
Structure
.
Cylinder block (5) is supported to shaft (I)
by a spline (141, and shaft (I) is supported
by front and rear bearings (16) and (13).
The end of piston (4) has a concave ball
shape, and shoe (15) is caulked to it to form
one unit.
Piston (8) and shoe (15) form a spherical
bearing.
l
1 O-76
D 155AX-5
STRUCTURE
AND
HSS MOTOR
FUNCTION
Operation
1: Operation of motor
. The pressurized oil sent from the pump enters cylinder block (5) and pushes piston (4)
from the back face.
In the case of the motor, the center line of
plate (3) is always at an angle (swash plate
angle a) to the axial direction of cylinder
block (5). As a result, if we take the example
of one of pistons (41, oil pressure is applied
to the back face of the piston as shown in
the diagram on the right, and piston axial
force FO is generated.
. With shoe (151, which is joined to piston (4)
by the spherical surface, reaction force FR
in a direction at right angles to plane A is
generated.
The combined force of FO and
FR is FP, and this becomes the force to rotate cylinder block (5).
.
Shaft (I), which is meshed to cylinder block
(5) by spline (14) transmits
this rotation
torque to the output side. Cylinder block (5)
rotates, and while the condition
changes
from volume E to volume F, pressurized oil
from the pump flows into the cylinder chamber, and pressure P is generated according
to the load. On the other hand, when the
condition
goes beyond
volume
F and
changes to volume E, the oil is pushed out
and returned to the pump.
2.
Rotation speed and torque control

If flow 0 sent from pump becomes
rotation speed N of motor becomes
larger,
faster.
SWD02701
..
I
0 = qN
(q = E-F)
T=-
Pq
27l
D155AX-5
0
q
N
P
T
14
&DO2702
: Total flow
: Flow per 1 turn

: Rotation speed
: Pressure
: Rotating torque
1o-77
STRUCTURE
AND
FUNCTION
HSS MOTOR
3. Flushing shuttle valve

Function
The shuttle valve acts to switch the shuttle
valve spool according to the pressurized oil
in the HSS high-pressure
circuit, and to return the oil in the HSS low-pressure
circuit
through the oil cooler to the tank. The shuttle valve is installed to the HSS motor assembly.
l
Operation
1) When HSS pump swash plate angle is at
neutral position
. The swash plate angle of the pump is at the
neutral position, so the delivery from HSS
pump (2) is 0. When this happens, the same
oil pressure is applied to ports A and B at
both ends of shuttle valve spool (71, so spool
(7) remains at the neutral position.
. The pressurized oil from charge pump (I)
passes through
charge
safety valve (41,
which is assembled
to the pump, and is
drained from oil cooler (3) to the tank.
21 When
.
HSS pump is discharging

oil from
port PA
The pressurized oil from HSS pump (2) enters port MA from port PA, passes through
orifice a of shuttle valve spool (71, then enters port A. Spool (7) is pushed to the right
in the direction of the arrow by the pressurized oil at port A, so the passage between
ports MB and D is opened and the oil is
connected to charge relief valve (8).
When this happens,
the relationship of the
set pressure of charge relief valve is as follows.
As a result, the pressurized oil from charge

pump (I) flows from port C through charge
relief valve (81, where the set pressure is
lower.
It is then relieved and is drained
from oil cooler (3) to the tank.
SWDO2704
1 O-78
D 155/U-5
STRUCTURE
3)
.
When HSS pump is discharging oil from port

PB
The pressurized oil from HSS pump (2) enters port MB from port PB, passes through
orifice b of shuttle valve spool (71, then enters port B. Spool (7) is pushed to the left in
the direction of the arrow by the pressurized oil at port B, so the passage between
ports MA and C is opened and the oil is
connected to charge relief valve (8).
When this happens, the relationship
of the
set pressure of charge relief valve is as follows.
Set pressure of
charge safety
valve (4)
I
HSS MOTOR
AND FUNCTION
>
Set pressure of
charge relief
I
[ valve (8)
As a result, the pressurized oil from charge

pump (I) flows from port C through charge
relief valve (8), where the set pressure is
lower.
It is then relieved and is drained
from oil cooler (3) to the tank.
t!i!i
D155AX-5
SWD02705
1o-79
STRUCTURE
AND
HSS MOTOR
FUNCTION

Function
The shuttle valve acts to switch the shuttle
valve spool according to the pressurized oil
in the HSS high-pressure
circuit, and to flow
a part of HSS low pressure circuit oil to
HSS motor drain case for cooling oil inside
the case. The cooling shuttle valve is installed to the HSS motor.
l
Operation
1) When HSS pump swash plate angle is at
neutral position
The swash plate angle of the pump is at the
neutral position, so the delivery from HSS
pump (2) is 0. When this happens, the same
oil pressure is applied to ports a and b at
both ends of cooling shuttle valve spool (8D),
so spool (8D) remains at the neutral position, and oil does not flow.
d!
J
/:,
v\
d
2)
l
ED
SWDO2706
When HSS pump is discharging

oil from
port PA
The pressurized oil from HSS pump (2) enters port MA from port PA. Cooled oil in
hydraulic tank flows into MB port through
charge pump (I) and suction safety valve
(5).
High pressure circuit MA is connected with
a of cooling shuttle valve spool (8D). Low
pressure circuit MB is connected with b of
spool (8D).
If difference pressure between MA and MB
exceeds set pressure, spool (8D) moves toward arrow shown in the figure, and oil
flows from MB port through b, orifice c to
motor case (d) to cool.
*
Set pressure: 1.2MPa {12kg/cm2)
When HSS pump discharge
oil from port
MB, spool (8D) moves in opposite side.
SWD02707
1 O-80
D155AX-5
HSS MOTOR
4.
CHARGE RELIEF VALVE
8A
8B
8C
8E
IjF
SWD02708
1.
2.
3.
4.
5.
6.
7.
Charge pump
HSS pump
Oil cooler
Charge safety valve
Suction safety valve
HSS motor
Shuttle valve
8. Charge relief valve

8A. Valve
8B. Spring
8C. Valve seal
80. Poppet
8E. Spring
8F. Pressure adjustment
screw
Function
l
The charge relief valve is installed to the

HSS pump and motor drain block. It acts to
maintain the minimum pressure at the HSS
circuit low-pressure side and ensure the sucof the HSS pump.
tion performance
Set pressure: 1.8MPa I18kg/cm3 at 120 e /min.
D155AX-5
lo-81
HSS MOTOR
Operation
When oil is being discharged from port PA
or port PB of the HSS pump, the oil at the
low-pressure
side flows from port MA or
port MB through shuttle valve (7), port A or
B, and hose and enters inlet port A of charge
relief valve (8).
The pressurized oil entering port A passes

through orifice a in valve (8A) and fills port
C.
Poppet (8D) is in tight contact with valve
seat (80.
SAD00266
If the pressure oil at port C reaches the pressure set by spring (8E), poppet
(8D) is
pushed to the right in the direction of the
arrow, and the oil at port C is relieved to
port D to reduce the pressure of the oil at
port c.
g&j
l
SAD00267
When the pressure of the oil at port C goes

down, a differential
pressure is created between ports A and C because of orifice a in
valve (8A). Valve (8A) is pushed to the right
in the direction of the arrow by the oil pressure at port A, and the oil at port A is relieved to port B.
In this way, the pressure in the charge circuit is maintained
at the set pressure of
charge relief valve (8). This charge pressure
maintains the supply of oil inside the HSS .
closed circuit.
SAD00268
Drain port D at the poppet portion is gathered to the HSS pump and motor block, so
the back pressure of drain port B is not
added to the charge relief pressure, and the
valve always displays the set relief characteristics.
1 O-82
D155AX-5
STRUCTURE
AND
FUNCTION
PPC, HSS CHARGE
FILTER
PPC, HSS CHARGE FILTER
B
B-B
E
6
tB
Z
_-I-I
SAD001 76
A-A
1.
2.
3.
4.
5.
6.
Plug
Cover
Spring
Plate
Element
Case
A. To PPC relief valve

B. To filter bypass valve
C. From charge pump
Performance
Mesh
size
Filtering area
Oil flow
D155AX-5
(pm)
30
km2)
5400
(Q/min)
203
1 O-83
AND
STRUCTURE
VALVE
PPC, HSS CHARGE
FUNCTION
PPC, HSS CHARGE VALVE
A-A
B-B
1.
2.
3.
check valve
Accumulator
Filter bypass valve
PPC, HSS charge valve
D-D
c-c
SWD02709
PI. From charge pump

PC.To HSS charge
T. To tank
Unit: MPa Ikg/cm?
Set pressure
Cl. To main control valve

Cl.To HSS pump, motor servo
C2. To PPC valve
C3. To accumulator
P. From charge filter
1 O-84
PPC, HSS
charge
Filter
valve
valve
bypass
Accumulator
check valve
Cracking
pressure
Set pressure
differenCracking
tial pressure
Cracking
pressure
3.3 134)
4.1 142)
0.63 (6.4)
0.051
(0.521
D 155AX-5
Outline
This valve has the following three valves built
in.
The accumulator
check valve prevents the
pressure
stored in the accumulator
from
flowing anywhere except to PPC valve when
the engine is stopped.
The filter bypass valve acts to keep the differential pressure between the pressures at
the charge filter inlet port and outlet port to
below the set value.
The PPC, HSS charge valve keeps PPC valve
pressure and HSS pump and motor servo
pressure at the specified pressure and relieves any excess oil. The relieved oil flows
to the HSS pump and motor and becomes
the charge pressure for the pump and motor. It also sets the maximum
pressure in
the circuit.
l
Operation
Z: To PPC valve
Y:
X:
W:
V:
U:
Q:
To accumulator
Drain
From charge pump
To HSS servo, main control
Charge filter
To HSS charge
8
Q
valve
SWD0271D

l
The oil from the charge

pump
passes
through the charge filter and enters chamber A. When the pressure of the oil from
chamber A passing through orifice b and
entering chamber C becomes greater than
the set load of spring (21, spool (I) moves
to the right and connects ports A and D.
The oil from the charge pump flows from
chamber A through chamber D and becomes
the charge pressure for the HSS pump and
motor.
If the pressure in chamber A becomes low,
the circuit between A and D is closed and
the pressure in chamber A is maintained.
In this way, the PPC valve pressure, HSS
pump and motor servo pressure are maintained.
D155AX-5
1 O-85
STRUCTURE
AND
FUNCTION
PPC. HSS CHARGE
VALVE
Accumulator
check valve
.
Accumulator
check valve (3) is provided to
prevent the accumulator pressure from dropping when the engine is stopped.
Filter bypass valve

The oil from the charge
pump passing
through the charge filter and entering chamber A passes from chamber A through orifice e and enters chamber
F of the filter
bypass valve.
At the same time, the oil
from the charge pump entering chamber G
of the filter bypass valve directly passes
through orifice h and enters chamber J.
.
If the charge filter becomes clogged and the
oil pressure in chamber F drops, and a differential pressure greater than the set pressure is generated
between chamber F and
chamber J, spool (4) moves to the left, connects ports G and K, and the oil from the
charge pump is drained to the suction piping.
SWD02712
1O-86
D155AX-5
STRUCTURE
AND
HSS OIL COOLER
FUNCTION
BYPASS
VALVE
HSS OIL COOLER BYPASS VALVE
A-A
1. Plug
2. Valve
3. Shim
4. Plug
5. Spring
6. Body
A.
B.
C.
D.
E.
SWD02713
From charge relief valve

To tank
From oil cooler
To oil cooler
From charge safety valve
Outline
This valve is installed in the circuit between
the HSS pump and HSS motor charge relief
valve oil return circuit and the oil cooler. If
any abnormal
pressure is generated
in the
oil flowing to the oil cooler, this valve acts
to return the oil directly to the hydraulic
tank.
l
Set pressure
Cracking pressure (MPa (kg/cm?)
D 155AX-5
0.487
(4.971
1 O-87
t
8
f-l
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
STEERING, BRAKE CONTROL
Pressure sensor for steering circuit A

Pressure sensor for steering circuit I3
Pressure sensor for work equipment
PPC, HSS charge filter
HSS charge pressure sensor
Power train pump
Travel REVERSE sensing switch
Travel REVERSE sensing potentiometer
Steering lever potentiometer
Steering lever
HSS motor
Brake valve
Transmission
HSS pump solenoid valve B
HSS pump solenoid valve A
HSS pump
Engine speed sensor
Flywheel housing
Joystick
Parking limit switch
HSS controller
Outline
.
The electrical signal from joystick (20) passes
.
.
through HSS controller (22) and HSS pump

solenoid valve A (16) and B (15), actuates
HSS motor (12) and operates the steering.
If joystick (20) is moved slightly to the left
when it is being pushed to the FORWARD
position, the machine will turn gradually to
the left. If the joystick is moved fully to the
left, the machine will turn sharply to the
left.
If joystick (20) is moved to the left when it is
at the NEUTRAL position, the machine will
carry out a left counterrotation
turn.
Brake pedal actuates the spool of brake valve
(13) and actuates the left and right brakes at
the same time.
Safety lever (4) is interconnected
with brake
valve (131, and acts also as a parking brake.
When the gear shift is operated, the electric
signal from HSS controller
(20) flows to
brake valve (13) and operates the brake.
D155AX-5
1 O-89
BEVEL GEAR SHAFT, HSS BRAKE
SVD02714
D 155AX-5
10-91
SWD02790
1 O-92
D155AX-5
c-c
22
23
24
26
25
30
29
28
27
SVD02715
D155AX-5
1o-93
1. Cover
2. Output shaft
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Bearing cage
Spring
Brake piston
Plate (I on each side)
Brake plate (4 on each side)
Brake disc (5 on each side)
Brake outer drum
Brake inner drum
Nut
Bearing A
Shim (for adjusting preload of bevel gear)
Bevel gear shaft
Bevel gear (35 teeth)
Bearing B
Carrier
Ring gear
Planet pinion gear
Hub
Sun gear
Shim (for adjusting bevel pinion gear)
Bearing cage
Bearing
Nut (for adjusting preload of bearing)
Bevel pinion gear (21 teeth)
Gear E (for right sun gear drive)
Gear D
Shaft
HSS motor
Pinion gear
Gear A
Gear C
Gear B (for left sun gear drive)
1o-94
D155AX-5
Outline
Bevel gear shaft
With the bevel gear shaft, the power output
from the transmission
has its rotating speed
reduced and is sent at right angles to the
left and right by the meshing of the bevel
pinion and bevel gear.
The bevel gear shaft system employs spiral
bevel gears for the bevel pinion and bevel
gear, and employs a forced lubrication system using pressurized oil.
The bevel gear shaft system consists of
bevel gear (151, which is meshed with bevel
pinion (261, bevel gear shaft (141, and bearings (12) and (161, which support the bevel
gear shaft.
HSS
The HSS (Hydrostatic Steering System) consists of a transfer portion, which reverses
the direction of the rotation of HSS motor
(30) on the left and right and transmits it to
sun gear (211, and a planetary gear system,
which increases or decreases the speed of
the input, and then outputs it.
The direction of steering of the machine is
changed by stopping the rotation of the HSS
motor or by changing the direction of rotation from the normal direction to the reverse direction.
The transfer portion uses a spur gear reduction mechanism.
A forced lubrication
system using the oil
from the power train lubrication
pump is
employed for lubricating the transfer.
A forced lubrication
system using the oil
from the power train lubrication
pump is
employed for lubricating the planetary gear.
The transfer portion consists of HSS motor
pinion (311, gear A (321, gear C (331, shaft
(291, gear D (281, gear E (271, gear B (341,
and cover (I), which supports these.
The planetary gear consists of sun gear (21),
planet pinion (191, hub (201, and carrier (17)
(which is interconnected
with brake inner
drum (IO)).
D 155AX-5
Brake
The brakes are installed to carry out braking
of the machine, and are interconnected
with
brake inner drum (IO).
The brake is a wet type, multiple disc clutch,
spring boosted type, and is hydraulically operated using pressurized oil from the brake
valve, which is interconnected with the brake
pedal.
The lubrication is a forced lubrication type
using oil from the oil power train lubrication pump circuit, which passes through the
housing and cage, and is sent to the discs
and plates.
The brake consists of brake inner drum (IO)
(which is interconnected
with carrier (17)
and brake outer drum (911, disc (81, plate (71,
brake outer drum (91, piston (51, spring (41,
bearing cage (31, which support these, brake
cover (I), and output shaft (2).
Brake outer drum (9) and brake cover (I)
are fixed to the HSS case.
Output shaft (1) is connected to brake innerdrum (IO) by a spline.
When the engine stops, the back pressure
of the brake piston drops, so the brake is
automatically
applied.
However,
it is dangerous if the brake is released when the
engine is started again and the pressure in
the circuit rises, so when the parking the
machine, always place the parking brake at
the LOCK position.
1o-95
STRUCTURE
AND
Flow of Dower
BEVEL GEAR SHAFT,
FUNCTION
for HSS
17
26
18
32
31
30
: Mechanical
: Hydraulic
: Combined
The power from the transmission

passes
through
bevel pinion gear (26) and bevel
gear (15), and is transmitted
to bevel gear
It then goes from bevel gear
shaft (14).
shaft (14) through hub (20), ring gear (18),
carrier (17), and brake inner drum (IO), and
is transmitted
to left and right output shafts
(2).
When the steering is operated, HSS motor
(30) rotates and the power is transmitted
from pinion gear (31) to gear A (32), where
it is divided to the left and right.
The power sent to the left is transmitted
from gear A (32) to gear B (34), sun gear
20
27
28
1 O-96
HSS BRAKE
power
power
power
sK!Joo113
(21), and planet pinion gear (19). It is combined with the power from the transmission
at the planetary gear portion, and is transmitted from carrier (17) to output shaft (2).
The power sent to the right is transmitted
from gear A (32) through gear C (33), gear
D (28), and gear E (27) to right sun gear (21)
in order to reverse the rotation of the power
from the HSS motor.
(The flow of power
beyond this point is the same as on the left
side.)
The braking force is applied by braking the
rotation of inner drum (IO) (which is interconnected with carrier (17)) at brake outer
drum (9), which is fixed to the HSS case.
D155AX-5
STRUCTURE
BEVEL GEAR SHAFT,
AND FUNCTION
HSS BRAKE
OPERATION
OF HSS
1. When joystick is at NEUTRAL
Traveling straight forward
Transmission output speed

@ Right bevel gear shaft output speed
@ Transmission output speed

@ Left bevel gear shaft output speed
SW002716
: Transmission power
The direction of rotation of the HSS motor

and gears is as seen from the left side of
the machine.
Traveling straight forward

When the joystick is at the NEUTRAL position,
HST motor (301, and transfer gear (33) and left
and right sun gears (21) of the planetary gear
portion, which are interconnected
with the HSS
motor, are stopped.
In this condition,
the power from bevel gear
shaft (14) is input to hub (201, passes through
Direction
of rotation
Turn
Joystick
position direction
Travel Neutral
Direction of
rotation of
HSS motor
%
D155AX-5
of HSS motor
Left turn
Forward
z
Counter- r$o;terclockwise
wise
Counterrotation
ring gear (18) and planet pinion (19), and is

transmitted to carrier (17). It then passes through
brake inner drum (IO), which forms one unit
with the carrier, and is transmitted
to output
shaft (2).
Therefore, the left and right output speeds are the
same and the machine travels in a straight line.
Reverse Neutral
Clockwise
Neutral
Right turn
5%
Clockwise
Forward Reverse
Clpckwrse
All
Counter- Stopped
clockwise
turn
1o-97
2.
Joystick operated to RIGHT TURN
Forward
SWD02717

@ Acceleration from HSS motor
lo+@,
@
Forward
When the machine

@ Deceleration from HSS motor
(0 - 0,
is traveling forward, bevel

gear shaft (14) and hub (201, which is connected
to it, rotate clockwise.
If the joystick is operated to the RIGHT TURN
position when the machine is traveling forward,
HSS motor (30) rotates clockwise, the rotation
passes through gear A (32), and gear B (34) on
the left side of the machine rotates clockwise,
while gear E (27) on the right side of the machine is rotated counterclockwise
by gear C (33).
In other words, the rotation of the HSS motor is
transmitted
to sun gears (21) as rotation in opposite directions on the left and right by the
transfer portion.
1 O-98
m
EPZBZZJ: HSS motor power
: Combined power
This rotation acts on the left and right planetary

gear mechanisms.
The speed of carrier (17) on
the left is accelerated
from the speed when
traveling in a straight line by the amount of the
power from the HSS motor. On the other hand,
the speed of carrier (17) on the right is decelerated from the speed when traveling in a straight
line, so a difference in rotation is generated
in
the output on the left and right.
The output
speed on the right is lower, so as a result, the
machine travels forward and turns to the right.
D 15514X-5
STRUCTURE
AND
BEVEL GEAR SHAFT,
FUNCTION
HSS BRAKE
Reverse
I
(0 + 0,
@
@ Transmission
output speed
W
BZZZZZI
: HSS motor power
: Combined power
(O-0,
Reverse
When the machine is traveling in reverse, bevel
to it, rotate counterclockwise.
If the joystick is operated to the RIGHT TURN
position when the machine is traveling
in reverse, HSS motor (30) is rotated counterclockwise
in the opposite direction from when traveling
forward by the function of the HSS controller.
The rotation passes through gear A (321, and
gear B (34) on the left side of the machine rotates counter-clockwise,
while gear E (27) on
the right side of the machine is rotated clockwise by gear C (33). In other words, the rotation
of the HSS motor is transmitted
to sun gears
D155AX-5
SWD02718
(21) as rotation in opposite directions

on the
left and right by the transfer portion.
gear mechanisms.
the left is accelerated
from the speed when
the speed of carrier (17) on the right is decelerated from the speed when traveling in a straight
in
The output
speed on the right is lower, so as a result, the
machine travels in reverse and turns to the right.
10-99
3.
BEVEL GEAR SHAFT. HSS BRAKE
Joystick operated to LEFT TURN
Forward

(0 + 0)

w
EZBZZZY: HSS motor power
: Combined power
(G-0)
Forward
When the machine is traveling forward,
bevel
to it, rotate clockwise.
If the joystick is operated to the LEFT TURN
position when the machine is traveling forward,
HSS motor (30) rotates counterclockwise,
the
rotation passes through gear A (321, and gear B
(34) on the left side of the machine
rotates
counterclock-wise,
while gear E (27) on the right
side of the machine is rotated clockwise by gear
C (33). In other words, the rotation of the HSS
motor is transmitted
to sun gears (21) as rotation in opposite directions on the left and right
10-100
by the transfer portion.

gear mechanisms.
the right is accelerated
from the speed when
the speed of carrier (17) on the left is decelerated from the speed when traveling in a straight
in
The output
speed on the left is lower, so as a result, the
machine travels forward and turns to the left.
D 155AX-5
BEVELGEARSHAFT,HSS
BRAKE
Reverse
i
(0 + 0)

(@-@I
Reverse
When the machine is traveling in reverse, bevel
to it, rotate counterclockwise.
If the joystick is operated to the TURN LEFT
position when the machine is traveling
in reverse, HSS motor (30) is rotated clockwise in
the opposite direction from when traveling forward by the function of the HSS controller.
The
rotation passes through gear A (32), and gear B
(34) on the left side of the machine rotates clockwise, while gear E (27) on the right side of the
machine is rotated counterclockwise
by gear C
(33).
In other words, the rotation of the HSS
D 155AX-5
130
I
SWD02720
EZGZB : Transmission power

EZZZZI : HSS motor power
: Combined power
motor is transmitted
to sun gears (21) as rotation in opposite directions on the left and right
by the transfer portion.
gear mechanisms.
the right is accelerated
from the speed when
the speed of carrier (17) on the left is decelerated from the speed when traveling in a straight
in
The output
speed on the left is lower, so as a result, the
machine travels in reverse and turns to the left.
10-101
STRUCTURE
AND
FUNCTION
BEVEL GEAR SHAFT,
HSS BRAKE
Operation of brake
1. Brake released
When the brake pedal is at the RELEASED
position, the brake valve is also at the NEUTRAL position, so oil flows to back pressure
port A of brake piston (5).
When the oil pressure rises, the piston is
pushed to the left in the direction of the
arrow, compresses
spring (41, and releases
the pressure pushing disc (8) and plate (7)
into tight contact.
When this happens, the
power transmitted from bevel gear shaft (14)
through the HSS to brake inner drum (IO) is
transmitted
to output shaft (21, and is then
transmitted
to the final drive.
2.
SDD00092
Brake applied (brake pedal depressed)

When the brake pedal is depressed,
the
brake valve is switched, and the oil at port
A, which was applying back pressure to piston (51, is connected to the drain circuit.
In this condition, piston (5) is pushed to the
right in the direction of the arrow by the
tension of spring (41, so disc (8) and plate
(7) are brought into tight contact with the
stopper of brake outer drum (9). The brake
outer drum is joined to the HSS case and is
locked in position.
Therefore, the rotation of brake inner drum
(IO) (in other words, output shaft (2)) is
braked when the disc and plate are brought
into tight contact.
By adjusting the amount the brake pedal is
depressed,
it is possible to adjust the hydraulic
pressure
applied
to piston
(51,
thereby adjusting the braking force.
10-102
D 155AX-5
BRAKE VALVE
BRAKE VALVE
14
12
13
A-A
SJD02721
1.
2.
3.
4.
5.
6.
7.
Main brake lever

Parking brake lever
Plug
Body
Spring
Seat
Brake valve
8.
9.
IO.
11.
12.
13.
14.
Piston
Spring (small)
Spring (large)
Shaft (main brake)
Shaft (parking brake)
Spring
Plug
T2: Drain
BR: To brake piston
Tl: Drain
Outline
.
The brake valve is in the circuit between
the
power train pump through the main relief
valve and the brake piston inside the HSS
It consists of the main brake valve,
unit.
parking brake valve, and solenoid valve.
When the brake pedal is depressed, the pressurized oil flowing to the brake piston is
shut off, so the brake piston pushes the disc
and plate into tight contact because of the
force of the spring, and the brake is applied.
In the case of the HSS, the brake is used
so the left
only for braking the machine,
and right brakes are actuated at the same
time.
D 155AX-5
10-103
STRUCTURE
AND
FUNCTION
Operation
1. Brake released
(parking
BRAKE VALVE
brake OFF, brake pedal RELEASED)
SWD0.2722
z:
Y:
x:
w:
To main relief valve

Check valve
Brake piston
When the brake pedal is released (not being

depressed), each valve is pushed to the set
position by the tension of the spring.
Shaft (6) is pushed fully to the right in the
direction of the arrow by spring (5).
The pressurized
oil from the power train
pump passes through the main relief valve
and enters port B. It then passes through
ports E and D, flows to the back pressure
port of the brake piston, and pushes the
piston to the left in the direction of the ar-
10-104
row to compress the brake spring and release the brake.

The oil pressure at this
point is balanced at 2.7 MPa I28 kg/cm?,
and this is possible to measure at centralized pressure detection port P.
If the oil pressure at port E goes above the
set pressure, the pressure of the oil entering port A through orifice a also rises. This
pushes brake valve (3) to the left, throttles
the passage between
ports B and E, and
controls the oil pressure.
D155AX-5
STRUCTURE
2.
AND
Brake actuated
BRAKE VALVE
FUNCTION
iparking
brake OFF, brake pedal depressed)
SVD02724
Z:
Y:

X:
Check valve
Brake piston
W:
When the brake pedal is depressed,

shaft
(6) is pushed to the left in the direction of
the arrow, and compresses spring (5). The
reaction force pushes brake valve (3) to the
left in the direction of the arrow. Therefore,
the passage ports B and E are closed, and
the pressurized
oil from the power train
pump stops at port B.
Seat (2) is also
pushed to the left in the direction of the
arrow, and the passage between
ports E
and G is opened.
When this happens, the
pressurized oil forming the back pressure of
the brake piston is pushed back by the force
of the brake spring and enters port E from
Some of the return oil passes
port D.
through ports E and G and is drained from
port F; the rest of the oil passes from port E
through orifice a and enters port A.
When the pressure at port E goes down, the
pressure at port A also goes down, so force
of the spring (I 1 pushes brake valve (3) back
D155AX-5
to the right in the direction of the arrow.

The passage between ports E and G is closed
and the passage between ports B and E is
opened, so the pressurized oil at port B flows
to port E. In this way, the oil pressure is
maintained
and the pressure beyond port E
does not go down any further.
If the brake pedal is depressed further, the
above operation is repeated, and when the
valve reaches the end of its stroke, the brake
is completely
applied.
The oil pressure beyond port E is determined
by the tension of spring (51, which changes
the load according to the amount the brake
pedal is depressed.
Therefore,
if the brake
pedal is depressed a short distance the oil
pressure beyond port E is set to a high pressure, and the brake is partially applied.
If
the brake pedal is depressed
a large distance, the oil pressure is set to a low pressure and the brake is applied.
10-105
3.
BRAKE VALVE
Parking brake ON (brake pedal RELEASED, safety lever at LOCK)
H-
-D
SVDO2723
z:
Y:
x:
w:

Check valve
Brake piston
The solenoid valve is excited in the same

way as in Item 1. In addition, shaft (6) is
pushed fully to the right in the direction of
the arrow by spring (5).
If the safety lever is placed at the LOCK
position, shaft (7) is pushed to the left in the
direction
of the arrow.
The passage between ports E and D is closed, and the passage between
ports D and C is opened.
Therefore,
the pressurized
oil from the
power train pump enters port E and stops.
The pressurized oil flowing to the brake pis-
lo-106
ton port and forming

the back pressure
passes from port D through port C and is
drained.
Shaft (8) remains pushed to the
left in the direction
of the arrow, so the
back pressure of the brake piston port continues to drop. The brake piston is pushed
to the right in the direction of the arrow by
the brake spring, so the brake is completely
applied, and this condition is maintained.
Even when the engine is started again, this
condition is maintained.
D 155AX-5
STRUCTURE
AND
FUNCTION
FINAL DRIVE
FINAL DRIVE
16
Outline
The final drive is a single stage spur gear,
single stage planetary gear reduction type.
The lubrication is of splash type using the
rotation of the gears.
The final drive can be removed and installed
as a single unit.
SDDOOlO2
D155AX-5
Floating seal (4) is installed to the rotating

sliding portion of the sprocket to prevent
the entry of dirt or sand and to prevent leakage of lubricating oil.
10-107
STRUCTURE
AND
15
1.
2.
3.
4.
5.
6.
7.
8.
FUNCTION
14
Sun gear (16 teeth)

Carrier
Ring gear (65 teeth)
Floating seal
Cover
Cover
Final drive case
Bearing cage
lo-108
FINAL DRIVE
13
12
11
9.
10.
11.
12.
13.
14.
15.
SDD00103
No. 1 pinion (19 teeth)

No. 1 gear (81 teeth)
Sprocket hub
Sprocket teeth
Hub
Planet pinion (24 teeth)
Pinion shaft
D155AX-5
SDD00104
The power from the bevel gear and steering

clutch is transmitted
to No. 1 pinion (9). It
then passes through No. 1 gear (IO), which
is meshed with the No. 1 pinion, and is
transmitted
to sun gear (I) to rotate it.
The rotation of sun gear (I) is transmitted
to planet pinion (14), but ring gear (31, which
is meshed with the planet pinion, is fixed to
cover (51, so the planet pinion rotates on its
own axis and moves around the sun gear
along the ring gear.
D155AX-5
Then, the rotating force of sun gear (I 1forms

the rotating force of carrier (21, which supports the planet pinion, and is transmitted
to sprocket hub (II).
The direction of rotation of carrier (2) is the
same as that of sun gear (I).
The rotating force transmitted
to sprocket
hub (11) is transmitted to sprocket teeth (12).
10-109
STRUCTURE
AND
TRACK
FUNCTION
FRAME
TRACK FRAME
SK000152
Outline
on an XThe track rollers are mounted
the actual
bogie. This increases
shaped
ground contact area between the track shoes
and the ground on rough surfaces, and helps
increase the drawbar pull.
The X-shaped bogies are equipped with rubber pads to absorb the shock from the
Track roller, bogie
Positioning of track roller flange
ground
10-l10
surface.
D: Double
S: Single
D155AX-5
TRACK FRAME
A-A
sKmo153
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Equalizer bar
Idler
Track frame
Carrier roller
Sprocket
Sprocket guard
Bogie assembly
Track roller
Track roller guiding
Pivot shaft
DI 55AX-5
guard
10-111
STRUCTURE
AND
RECOIL SPRING
FUNCTION
A-A
SKD00154
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1 I.
Yoke
Nut
Retainer
Recoil spring
Rod
Spring cylinder
Retainer
Piston
Grease chamber cy1inde.r
Pin
Lubricator
(for pumping in and releasing
10-112
Outline
.
Recoil spring (4) is used to adjust the track
tension by pumping in or releasing grease
from lubricator (11) to move rod (5) forward
or backward. The recoil spring also acts to
dampen any sudden shock brought to bear
on the idler.
grease)
D155AX-5
STRUCTURE
AND
TRACK ROLLER BOGIE
FUNCTION
TRACK ROLLER BOGIE
A-A
4
+A
SWD02762
I.
2.
3.
4.
5.
6.
7.
8.
9.
Rubber mount
Track roller
Inner bogie
Outer bogie
Cartridge pin
Floating seal
Bushing
Plug
Bogie mount cap
Dl ?&AX-5
Outline
.
One track roller is mounted to each of inner
bogie (3) and outer bogie (4) to ensure that
the track roller and track shoe are always in
contact.
.
Rubber mount (I) is used to absorb the machine vibration caused by contact with the
ground.
10-l 13
STRUCTURE
AND
MAIN
FUNCTION
FRAME
MAIN FRAME
A4
A-A
1.
2.
3.
4.
5.
B4
B-B
Engine mount
Power train unit mount
ROPS mount
Power train underguard
Engine underguard
10-114
D155AX-5
SUSPENSION
SUSPENSION
SKDOOl56
Outline
l
lo-116
The front of the track frame rocks

down using the rear pivot shafts (3)
as a fulcrum.
Equalizer bar (I) rocks using center
as a fulcrum. The left and right track
are connected by side pin (5).
up and
and 14)
pin (2)
frames
D155AX-5
STRUCTURE
SUSPENSION
AND FUNCTION
A-A
6
B-B
SK1300157
1.
2.
3.
4.
5.
6.
7.
Equalizer bar
Center pin
Left pivot shaft
Right pivot shaft
Side pin
Spherical bushing
Greasing tube
D 155AX-5
10-117
STRUCTURE
AND
WORK EQUIPMENT
FUNCTION
WORK EQUIPMENT
HYDRAULIC
HYDRAULIC
PIPING DIAGRAM
PIPING DIAGRAM
SEMI U-DOZER
SWD02624
1.
2.
3.
4.
5.
Tilt cylinder
R.H. blade lift cylinder
Accumulator
lo-118
6. Main control valve

7.
8.
9.
10.
11.
12.
Hydraulic filter
Hydraulic tank
Work equipment
pump (SAR(4)112)
PPC, HSS charge pump
L.H. blade lift cylinder
Oil cooler
D 155AX-5
STRUCTURE
AND
FUNCTION
WORK EQUIPMENT
HYDRAULIC
PIPING
DIAGRAM
MULTI-SHANK RIPPER
SED00162
1.
2.
3.
4.
Main control valve

Divider block
Ripper tilt cylinder
Ripper lift cylinder
D 155AX-5
10-119
STRUCTURE
AND
WORK
FUNCTION
EQUIPMENT
HYDRAULIC
PIPING
DIAGRAM
GIANT
*
The diagram
shows a machine
with a pin puller cylinder
equipped
1.
2.
3.
4.
5.
6.
7.
8.
9.
Main control valve

Divider block
Pin puller cylinder
Pin puller solenoid
Brake valve
a. To steering
10-120
(right)
(right)
(left)
(left)
valve
case
D155AX-5
PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

BLADE, RIPPER CONTROL
SVD02626
1.
2.
3.
4.
5.

Accumulator
Blade control PPC valve
Main control valve
D 155AX-5
6.
7.
8.
9.
Ripper control PPC valve

PPC, HSS charge pump (104)
Work equipment
pump (SAR(4)112)
PPC lock valve
10-121
STRUCTURE
AND
FUNCTION
WORK
WORK EQUIPMENT
*
EQUIPMENT
CONTROL
CONTROL
The diagram
shows a machine
equipped
with pitch dozer and pin puller cylinder.
SVDO2627
Lever positions
0: Blade HOLD
0: Blade LOWER
0: Blade FLOAT
0: Blade RAISE
0: Blade LEFT TILT/PITCH
0: Blade RIGHT TILT/PITCH
0: Ripper HOLD
8: Ripper RAISE
@: Ripper LOWER
@: Ripper DIGGING ANGLE
0: Ripper DIGGING ANGLE
0: FREE
0: LOCK
1o-1 22
1. Work equipment
safety lever
2. Blade control lever
3. Ripper control lever
4. Pin puller switch
5. PPC lock valve
DECREASE
INCREASE
Outline
.
The work equipment
control employs a PPC
method which uses a PPC valve to move
each control valve spool.
.
Work equipment safety lever (I) is interconnected with PPC lock valve (61, and at the
LOCK position, the oil in the PPC circuit is
stopped.
D155AX-5
WORK EQUIPMENT HYDRAULIC SYSTEM

AND HSS SYSTEM DIAGRAM
WORK EQUIPMENT
DIAGRAM
I5
HYDRAULIC
SYSTEM
AND HSS SYSTEM
SVDO2725
1. Hydraulic tank
2. Strainer
3. HSS pump assembly
3A.
Servo valve
38.
Servo piston
3C.
Charge safety valve
Setting pressure:
3.7 MPa f38 kg/cm*}
3D.
HSS pump
3E.
Suction-safety
valve
Set pressure:
41.2 MPa 1420 kg/cm*)
lo-124
4.
5.
6.
7.
8.
9.
10.
HSS motor assembly

4A.
Cooling shuttle valve
Set pressure:
1.2 MPa {I2 kg/cm?
4B.
Flushing shuttle valve
4C.
HSS motor
Cooler bypass valve
Oil cooler
Scavenging
pump
PPC, HSS charge pump
Filter bypass valve

Cracking differential
pressure:
0.63 MPa i6.4 kg/cm*}
IOB. PPC, HSS charge valve
Set pressure:
4.12 MPa I42 kg/cm?
IOC. Accumulator check valve
Cracking pressure:
0.05 MPa lo.52 kg/cm*}
11. Accumulator
12. HSS charge pressure sensor
IOA.
Dl SAX-5

SVD02726
13. Hydraulic oil temperature sensor

14. PPC lock valve
15. Blade control PPC valve
15A. For blade lift
15B. For blade tilt
16. Ripper control PPC valve
16A. For ripper tilt
16B. For ripper lift
17. Work equipment pump assembly
18A. Variable unload valve
18B. Back pressure valve
D155AX-5
18C. Back pressure check

valve
18D. Main relief valve
18E. Preset check valve
18F. Load check valve
18G. Blade tilt valve
18H. LS check valve
18J. Blade lift valve
18K. Suction valve
18L. Ripper lift valve
18M. Ripper tilt valve
18N. LS bypass valve
19. Assembly block
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

Set pressure:
1.8 MPa I18 kg/cm?
Quick drop valve
Blade tilt cylinder
R.H. ripper tilt cylinder
R.H. ripper lift cylinder
L.H. ripper lift cylinder
Hydraulic filter
Breather
10-125

Machine equipped with pitch dozer

I5
15AR
Rl5B
I6
16B
IO
SWD02805
1. Hydraulic tank
2. Strainer
3A. Servo valve
3B. Servo piston
3C. Charge safety valve
Set pressure:
3.7 MPa {38 kg/cm*}
3D. HSS pump
3E. Suction safety valve
Set pressure:
41.2 MPa (420 kg/cm21
lo-126
4. HSS motor assembly

4A. Cooling shuttle valve
Set pressure:
1.2 MPa {I2 kg/cm*1
4B. Flushing shuttle valve
4C. HSS motor
5. Cooler bypass valve
6. Oil cooler
7. Scavenging
pump
8. PPC, HSS charge pump
9. PPC, HSS charge filter
10. PPC, HSS charge valve
lOA.Filter
bypass valve
Cracking differential
pressure:
0.63 MPa (6.4 kg/cm*}
IOB. PPC, HSS charge valve
Set pressure:
4.12 MPa (42 kg/cm21
lOC.Accumulator
check valve
Cracking pressure:
0.05 MPa IO.52 kg/cm*)
11. Accumulator
12. HSS charge pressure sensor
13. Hydraulic oil temperature
sensor
D155AX-5

ZZi
@
r---
61
__
SWD02806
14. PPC lock valve

15. Blade control PPC valve
15A. For blade lift
15B. For blade tilt
16. Ripper control PPC valve
16A. For ripper tilt
16B. For ripper lift
17. Work equipment
pump assembly
18A. Variable unload valve
18B. Back pressure valve
18C. Back pressure check valve
D 155AX-5
18D. Main relief valve

18E. Preset check valve
18F. Load check valve
18G. Blade tilt valve
18H. LS check valve
18J. Blade lift valve
18K. Suction valve
18L. Ripper lift valve
18M.Ripper
tilt valve
18N. LS bypass valve
19. Assembly
block
Set pressure:
1.8 MPa {I8 kg/cm21
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Quick drop valve

Blade tilt cylinder
R.H. ripper tilt cylinder
R.H. ripper lift cylinder
L.H. ripper tilt cylinder
Hydraulic filter
Breather
Pitch solenoid valve
Pitch cylinder
1O-l 27
WORK EQUIPMENT HYDRAULIC CIRCUIT

AND HSS CIRCUIT DIAGRAM
WORK EQUIPMENT
DIAGRAM
*
For details
2,.
lo-128
HYDRAULIC
of this page, see Section

- ^
r: z:
:f -I
:I :
CIRCUIT AND HSS CIRCUIT
90.
-2
1:
:
:_
r:
::
_:
:f
D155AX-5
STRUCTURE
.
*
AND
WORK EQUIPMENT
HYDRAULIC CIRCUIT
AND HSS CIRCUIT DIAGRAM
FUNCTION
Machine equipped with pitch dozer

For details of this page, see Section
90.
_________~
r
0
____._-1
SWD02'312
D155AX-5
1O-l 29
HYDRAULIC TANK AND FILTER
HYDRAULIC
TANK AND FILTER
=====*
T====-=
SWD02630
10-130
D155AX-5
HYDRAULIC TANK AND FILTER
11
A-A
E-E
D-D
Tank capacity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Sight gauge
Hydraulic filter
Oil filler cap
Hydraulic tank
Filter case
Cover
Air bleeding plug
Element
Suction valve
Spring
Drain plug for removing
Breather cap
Pressure valve
Strainer
A.
B.
From main control

To hydraulic tank
Hydraulic
tank
Breather
cap
Level
inside
tank
Hydraulic
filter
D155AX-5
85
Center
(.U
82
Low
NJ
79
(kPa Ik9/cm2N
103.0f19.6
(1.05+-0.2)
Mesh size
(,u m)
3018
Filtering area
(cm?
10,026
(Urnin) I
255
(fi m) I
105
(cm21 1
2,300
Filtering oil flow

Mesh size
valve
b?,
Cracking
(kPa {kg/cm211 {d.!&7,1$7]
pressure
Vacuum valve actuating
o-o.49
pressure
(kPa {kg/cr+I)
IO-0.005)
Cracking
pressure
dirt
Hi
Strainer
1Filtering
area
10-l31
STRUCTURE
AND
ACCUMULATOR
FUNCTION
ACCUMULATOR
FOR PPC VALVE
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.1 MPa 132 kg/cm*)
Min. actuation pressure: 1.2 MPa {I2 kg/cm*)
SYD00309
Function
The accumulator
is installed between the
PPC charge pump and the PPC valve. Even
if the engine is started with the work equipment still raised, the pressure of the nitrogen gas compressed
inside the accumulator sends the pilot pressure to the main control valve to actuate it and enable the work
equipment
to move down under its own
weight.
Operation
After the engine is stopped, when the PPC
valve is at neutral, chamber
A inside the
bladder is compressed
by the oil pressure
in chamber B.
.
When the PPC valve is operated, the oil pressure in chamber B goes below 2.9 MPa I30
kg/cm*}, and the pressure of the nitrogen
gas in chamber A expands the bladder, so
the oil in chamber B acts as the pilot pressure and actuates the main control valve.
B
SBD01365
lo-132
D 155AX-5
PPC LOCK VALVE
PPC LOCK VALVE
1.
2.
3.
4.
5.
Lever
End cap
Ball
Seat
Body
SYD00312
Outline
.
The PPC lock valve
is installed in the PPC

circuit between the PPC, HSS charge valve
and PPC valve. If the work equipment safety
lever is placed at the LOCK position, the
PPC lock valve is actuated together with the
work equipment
safety lever. This stops the
oil in the PPC circuit and makes it impossible to operate the work equipment.
D155AX-5
1o-133
PPC VALVE
PPC VALVE
FOR BLADE LIFT, BLADE TILT
SKD01435
P.
T.
P4.
P3.
PI.
P2.
From PPC, HSS charge valve port P

(through
PPC lock valve)
To hydraulic
tank
To blade lift valve (LOWER) port PA2
To blade lift valve (RAISE) port PB2
To blade tilt valve (LEFT TILT) port PA1
To blade tilt valve (RIGHT TILT) port PBI
10-134
D 155AX-5
PPC VALVE
SKD00535
1.
2.
3.
4.
5.
Spool
Metering spring
Centering spring
Pistion
Disc
D 155AX-5
6.
7.
8.
9.
10.
Nut (for lever joint)

Joint
Plate
Retainer
Body
10-135
STRUCTURE
PPC VALVE
AND FUNCTION
Operation
1)
(i)
At neutral
PPC value for blade lift
Ports PA2 and PB2 of the blade lift control
valve, and ports P3 and P4 of the PPC valve
are connected to drain chamber D through
fine control hole f in spool (I).
LIFT CONTROL
VALVE
SAD01547
(ii) PPC valve for blade tilt

Ports PA1 and PBI of the blade tilt control
valve, and ports PI and P2 of the PPC valve
are connected to drain chamber D through
fine control hole f in spool (I).
TILT CONTROL
VALVE
SAD01548
1O-l 36
D155AX-5
STRUCTURE
2)
AND FUNCTION
PPC VALVE
During fine control (neutral- fine control)

When piston (4) starts to be pushed by
disc (51, retainer (9) is pushed; spool (1)
is also pushed by metering spring (2),
and moves down.
When this happens, fine control hole f
is shut off from drain chamber D, and at
almost the same time, it is connected to
pump pressure chamber
PP, so pilot
pressure oil from the charging
pump
passes through fine control hole f and
goes from port P4 to port PA2.
When the pressure at port P4 becomes
higher, spool (I) is pushed back and fine
control hole f is shut off from pump pressure chamber PP.
At almost the same time, it is connected
to drain chamber D to release the pressure at port P4.
When this happens, spool (I) moves up
or down so that the force of metering
spring (2) is balanced with pressure at
port P4.
The relationship
in the position of the
spool (I) and body (IO) (fine control hole
f is at a point midway between
drain
hole D and pump pressure chamber PP)
does not change until retainer (9) contacts spool (I).
Therefore,
metering spring (2) is compressed proportionally.to
the amount of
movement
of the control level, so the
pressure at port P4 also rises in proportion to the travel in the control lever.
In this way the control
valve spool
moves to a position where the pressure
in chamber PA2 (the same as the pressure at port P4) and the force of the
control valve spool return spring are
balanced.
D155AX-5
10-137
STRUCTURE
31
AND
PPC VALUE
FUNCTION
During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool
(I) is pushed up to the force of centering
spring (3) and the pressure at port P4.
When this happens, fine control hole f
is connected to drain chamber D, and
the pressure oil at port P4 is released.
If the pressure at port P4 drops too far,
spool (I) is pushed down by metering
spring (21, and fine control hole f is shut
off from drain chamber
D. At almost
the same time it is connected to pump
pressure chamber
PP, and the pump
pressure is supplied until the pressure
at port P4 recovers to a pressure that
corresponds to the lever position.
When the spool of the control valve returns, oil in drain chamber D flows in
from fine control hole f in the valve on
the side that is not working.
The oil passes through port P3 and enters chamber
PB2 to fill the chamber
with oil.
SAD01550
41
At full stroke
When disc (5) pushes down piston (4),
and retainer (9) pushes down spool (I),
fine control hole f is shut off from drain
chamber D, and is connected with pump
pressure chamber PP.
Therefore, the pilot pressure oil from the
charging pump passes through fine control hole f and flows to chamber
PA2
from port P4, and pushes the control
valve spool.
The oil returning from chamber PB2 from
port P3 through fine control hole f and
flows to drain chamber D.
LIFT CONTROL
lo-138
SAD01551
D 155AX-5
STRUCTURE
5)
6)
AND FUNCTION
Blade operated to FLOAT

When piston (4) at port P4 (LOWER side)
is pushed by disc (5) and moves down,
protrusion a of the piston contacts ball
(11) during the downward
stroke. (The
detent starts to be actuated.)
If piston (4) is pushed further, ball (11)
pushes up collar (12), which is being
held by detent spring (131, and moves
to the outside, so the ball passes over
protrusion a of the piston. At this point,
piston (4) at the opposite side is pushed
up by the spring (14).
As a result, the oil inside chamber
F
flows through b and c and enters chamber E, and piston (4) follows disc (5).
Passage d is interconnected
with port
P4, so it is under more or less the same
pressure as port P4.
Chamber E is normally
interconnected
with drain chamber
D, but when ball
(11) passes over protrusion a of the piston, passage d and chamber
E (which
were shut off) are interconnected
and
pressurized oil flows. At the same time,
the control valve also moves to the
FLOAT position, so the blade circuit is
set to the FLOAT condition. The pressurized oil inside chamber
E pushes up
piston (41, so even of the lever is released, it is held at the FLOAT position.
PPC VALVE
SAD01552
Blade released from FLOAT

When
disc (5) is returned
from the
FLOAT position, it is pushed down by a
force greater than the pressure of the
oil in chamber E.
For this reason, chamber E is shut off
from passage d and is connected to the
drain chamber. Therefore, the oil pressure inside chamber E is lost, and the
FLOAT, position is released.
D155AX-5
1o-1 39
PPC VALUE
FOR RIPPER
-C
-_TT
I
P.
T.
PI.
P2.
P3.
P4.
.P4
From PPC, HSS charge valve pot-t P

(through PPC lock valve)
To hydraulic tank
ANGLE
To ripper tilt valve (DIGGING
CREASE) port PA4
ANGLE
To ripper tilt valve (DIGGING
CREASE) port PB4
To ripper lift valve (LOWE!?) port PA3
To ripper lift valve (RAISE) port PB3
10-140
SKD01448
IN-
DE-
D155AX-5
STRUCTURE
AND FUNCTION
PPC VALVE
A-A
B-B
D-D
E-E
SYD00314
1. Spool
2. Metering
3.
4.
5.
6.
spring
Centering spring
Piston
Disc
Nut (for lever joint)
D 155AX-5
7.
8.
9.
10.
11.
Joint
Plate
Retainer
Body
Filter
10-141
STRUCTURE
AND
PPC VALVE
FUNCTION
Operation
1) At neutral
Ports PA4, PB4, PA3 and PB3 of the ripper
control valve and ports PI, P2, P3, and P4 of
the PPC valve are connected to drain chamber D through fine control hole f of spool
(I).
2)
During fine control (neutral + fine control)

When piston (4) starts to be pushed by disc
(51, retainer (9) is pushed; spool (I) is also
pushed by metering spring (21, and moves
down.
When this happens, fine control hole f is
shut off from drain chamber D, and at almost the same time, it is connected to pump
pressure chamber PP. so pilot pressure oil
from the charging pump passes through fine
control hole f and goes from port PI to Port
PA4.
When the pressure
at port PI becomes
higher, spool (1) is pushed back and fine
control hole f is shut off from pump pressure chamber PP.
At almost the same time, it is connected to
drain chamber D to release the pressure at
port PI.
When this happens, spool (I) moves up or
down so that the force of metering spring
(2) is balanced with the pressure at port PI.
The relationship in the position of the spool
(I) and body (IO) (fine control hole f is at a
point midway
between
drain hole D and
pump
pressure
chamber
PP) does not
change until retainer (9) contacts spool (I).
Therefore, metering spring (2) is compressed
proportionally
to the amount of movement
of the control lever, so the pressure at port
Pl also rises in proportion to the travel in
the control lever.
In this way the control valve spool moves
to a position where the pressure in chamber PA4 (the same as the pressure at port
PI) and the force of the control valve spool
return spring are balanced.
10-142
PA3
(PA41
PB3
(PB4)
SWDO2631
SWD02632
D155AX-5
STRUCTURE
AND FUNCTION
3)
During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool
(I) is pushed up by the force of centering
spring (3) and the pressure at port PI.
When this happens, fine control hole f is
connected to drain chamber D and the pressure oil at port PI is released.
If the pressure at port PI drops too far, spool
(I) is pushed down by metering spring (21,
and fine control hole f is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP,
and the pump pressure is supplied until the
pressure at port PI recovers to a pressure
that corresponds to the lever position.
When the spool of the control valve returns,
oil in drain chamber D flows in from fine
control hole f in the valve on the side that
is not working.
The oil passes through port P2 and enters
chamber PB4 to fill the chamber with oil.
41
At full stroke
When disc (5) pushes down piston (4L and
retainer (9) pushes down spool (I 1, fine control hole f is shut off from drain chamber D,
and is connected with pump pressure chamber PP.
Therefore,
the pilot pressure oil from the
charging pump passes through fine control
hole f and flows to chamber PA4 from port
PI, and pushes the control valve spool.
The oil returning from chamber PB4 passes
from port P2 through fine control hole f
and flows to drain chamber D.
PPC VALVE
SWD02634
D155AX-5
10-143
PISTON
VALVE
PISTON VALVE
FOR BLADE
LIFT CYLINDER
Outline
The piston valve is installed on the piston
in the blade lift cylinder. When the piston
reaches its stroke end, the valve releases
the oil from the hydraulic pump to reduce
the oil pressure being exerted on the piston.
When the blade is tilted, the blade is subject to a tortional force owing to the uneven
position of the pistons in the two cylinders;
that is the piston one side is still moving
while the piston on the other side has
reached its stroke end.
The piston valves are installed to prevent
the tortional force from occurring.
When
one of the pistons reaches its stroke end, its
piston valve opens to relieve the oil pressure.
In addition
the piston valve relieves the
shock which occurs when the piston comes
into contact with the cylinder head or the
bottom and serves to reduce the subsequent
surge pressure in the cylinder by letting the
oil escape from the cylinder before the piston reaches its stroke end.
l
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction of the arrow until piston valve seat (4)
comes into snug contact with the tapered
section, thereby, this causing the pressure
in the cylinder to rise and moving piston (2)
in the direction of the arrow.
4
2.
Piston valve OPEN

Just before piston rod (I) reaches the end
of its stroke, the tip of valve (6) contacts the
cylinder
bottom,
so valve (6) and piston
valve (3) stop at that position and do not
move further. Only piston (2) moves further.
When this happens, the oil at the cylinder
head, which was sealed by piston valve (31,
escapes from piston valve seats (4) and (5L
and the pressure inside the cylinder stops
rising.
10-144
SAD00206
Contact
Dl SAX-5
PIN PULLER SWITCH
PIN PULLER SWITCH
Structure
1.
2.
3.
4.
of
circuit
SED01393
Connector
Wire
Switch
Knob
Function
l
The pin puller solenoid valve is controlled

by turning the pin puller switch ON/OFF.
This changes the oil circuit to the pin puller
cylinder and sets the shank mounting pin to
the PUSH IN or PULL OUT position.
D 155AX-5
10-145
STRUCTURE
AND
FUNCTION
Operation
1. Pin puller switch at PUSH IN position
When the pin puller switch is set to the
PUSH IN position, no electric current flows
to solenoid (9) and it is deenergized.
Then, ports P and A and ports B and P of
spool (5) open, and the oil from the power
train pump flows from port P to port A, and
enters the bottom end of pin puller cylinder
PIN PULLER SOLENOID
From
train
dower
Pump
VALVE
Switch
at
PUSH IN position
(IO).
When the oil enters the bottom end of the
cylinder and the pressure in the circuit starts
to rise, the cylinder extends
and pushes
shank mounting pin (11) into shank (12).
SLD01394
2.
Pin puller switch at PULL OUT position

When the pin puller switch is set to the
PULL OUT position, electricity flows to solenoid (9) and it is excited.
Then, the solenoid pushes out push pin (8)
and spool (5) moves to the left in the arrow
direction.
At this point, ports P and A and ports B and
T close, and ports P and B and ports A and
T open, so the oil from the power train pump
flows from port P to port B and enters the
head end of pin puller cylinder (10).
When the oil enters the cylinder head end
and the pressure in the circuit rises, the cylinder retracts and pulls shank mounting pin
(II) out of shank (12).
From
power
train
Pump
::
I,
/I
::
IO
Switch
at
PULL OUT posit
ion
A0
12
uu
SLD01395
D155AX-5
10-147
TILT/PITCH
TILT/PITCH SELECTOR SWITCH
SELECTOR SWITCH
SDDO0241
1.
2.
3.
4.
Switch
Knob
Wire
Connector
Function
l
The tilt/pitch selector switch is installed to

the blade control lever. When the tilt/pitch
selector switch is turned ON/OFF,
it controls the pitch solenoid valve and opens or
closes the flow of oil to the pitch cylinder.
lo-148
D155AX-5
PITCH SOLENOID
PITCH SOLENOID VALVE
VALVE
From charge pump

_)--_-_
,--,
;--t:____,
L -ml-q&/:
PT
Structure of circuit
SEDWJ242
Outline
l
The pitch solenoid valve is installed between

the pitch cylinder and tilt cylinder. It acts to
open or close the oil pressure circuit to the
pitch cylinder according to the signal from
the tilt/pitch selector switch.
D 155AX-5
1. Main spool assembly

2. Pilot solenoid valve assembly
3. Connector
A.
6.
P.
T.
X.
Y.
To pitch cylinder bottom

To pitch cylinder head
From main control valve
To blade tilt cylinder bottom
From charge pump
To hydraulic tank
10-149
STRUCTURE
AND
Operation
selector switch OFF
Tilt/pitch
.
When tilt/pitch selector switch (I) is not being operated (OFF), no electricity flows to
In
solenoid valve (2), so it is deenergized.
this condition, main spool (3) opens ports P
and T, and closes ports A and B. Therefore,
no oil flows to pitch cylinder (4). Only blade
tilt cylinder (5) moves, and the blade is tilted.
selector switch ON
Tilt/pitch
When tilt/pitch selector switch is operated
(ON), electricity flows to solenoid valve (21,
so it is excited. When this happens, main
spool (3) opens ports P and A, and ports T
circuit is
the hydraulic
and B. Therefore,
connected to the head end of pitch cylinder
(4) and the bottom end of blade tilt cylinder
(5). As a result, when blade tilt cylinder (5)
(4) is also repitch cylinder
is retracted,
tracted, and the blade is pitched.
l
PITCH SOLENOID
FUNCTION
From main control valve
VALVE
To main
control valve
From main _
control valve
SKD00244
10-150
D155AX-5
MAIN CONTROL VALVE
MAIN
CONTROL VALVE
PA4
P04
PA3
PB3
PA2
P02
PA1
PBl
SAD01 553
Al.
A2.
A3.
A4.
Bl.
B2.
B3.
B4.
PAI.
PA2.
PA3.
To blade tilt cylinder head

To blade lift cylinder head
To ripper lift cylinder head
To ripper tilt cylinder head
To blade tilt cylinder bottom
To blade lift cylinder bottom
To ripper lift cylinder bottom
To ripper tilt cylinder bottom
From blade PPC valve port PI
From blade PPC valve port P4
From ripper PPC valve port P3
D155AX-5
PA4.
PBI.
PB2.
PB3.
PB4.
P.
T.
a.
b.
c.

From ripper PPC valve port PI
Pump port
Drain port
Pump pressure detection plug
LS pressure detection plug
PPC charge valve pressure port
10-151
MAIN CONTROL VALVE
-8
A-A
I5
14
13
D-D
c-c
E-E
F-F
SWD02635
10-152
D 155AX-5
MAIN CONTROL VALVE
G-G
K-K
SW02636
J-J
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Valve block
Ripper tilt spool
Ripper lift spool
Blade lift spool
Blade tilt spool
Valve body
Load check valve
Orifice
Unload spring
Unload spool
D155AX-5
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Cancel piston
Cancel spring
LS check valve
Main relief valve
Back pressure check valve
Back pressure valve
Check valve (built-in spool)
Suction valve
Preset check valve
LS bypass valve
10-153
STRUCTURE
AND
FUNCTION
Function
When the work equipment control levers are
at HOLD, the oil discharged from the pump
is all unloaded, and the pressure loss of the
valve is kept below 0.5 MPa (5 kg/cm*}.
In this way, the pressure loss when the lever is at HOLD is small, so the heat loss is
also small.
Proportional
control is carried out by the
unload valve, which controls the amount of
oil sent to the cylinder to an amount that
matches the opening of the spool.
The unload valve is controlled by the difference in pressure on both sides of the spool,
so there is a little change in the oil flow
caused by the load pressure. It also provides the function
of pressure compensation.
10-154
MAIN
CONTROL
VALVE
SAW0184
Operation
1. At HOLD (unload valve at low setting)
I) When the work equipment spool is at HOLD,
LS circuit pressure LS = seal drain pressure
TS (hydraulic leak pressure from valve) i 0
MPa (0 kg/cm2), so unload spool (I) is balanced by the difference in load between load
F2 of spring (3) and load Fl of spring (2)
that is set to oppose pump pressure P which
is sent to chamber Al.
In other words, A0 x P = Fl - F2 (AO: Area
receiving pump pressure in chamber Al).
2) By making Fl - F2 smaller, it is possible to
make pump pressure P smaller.
When this is done, the area of the opening
between
ports A and B is determined,
so
the loss of pressure from A to B (P - T) can
be kept more or less constant regardless of
back pressure TP between ports A and B.
D155AX-5
STRUCTURE
2.
AND
MAIN
FUNCTION
Control of oil flow (unload

Blade lift, tilt valve
II Ripper lift, tilt valve I
(1) Meter-in oil flow control
t
The diagram shows
the blade tilt valve.
CONTROL
VALVE
valve at high setting)
Blade tilt
L. H. tilt
.6
AI
.
.
APLS = Differential
APLS = Differential
(APLS : APLS)
lo-156
pressure between
pressure between
ports A and J = 1.8 - 2.9 MPa I18 - 30 kg/cm?

ports A and F
D155AX-5
STRUCTURE
AND FUNCTION
Because of the action of the unload valve,

an amount of oil that matches the opening
of the spool flows to the cylinder. (Proportional control)
The unload valve is controlled by the difference in pressure on both sides of the spool,
so the change in the amount of the oil flow
caused by the load pressure is small (pressure compensation).
MAIN CONTROL VALVE
4)
When the oil in chamber F flows and the

pressure rises, the pressures in chamber J
and chamber L both rise at the same time.
The pressure in chamber L pushes against
the spring (5) and moves piston (4) to the
left. Piston (4) is separated
from unload
spool (31, so the load of spring (5) does not
act on unload spool (3).
5)
The unload valve is balanced by differential

pressure APLS, which is the difference
in
pressure between the pressures of chamber
Al and chamber J, in other words, meter-in
pressure loss (ports A - J) and the load of
spring (6). At this balanced position, the unload oil flow of the unload valve is determined.
The portion of the oil discharged from the
pump which is not unloaded is supplied to
the tilt cylinder. The meter-in pressure loss
is determined
by the area of opening of
spool (I), so an amount of oil that matches
the area of opening of spool (1) flows to the
tilt cylinder, regardless of the load pressure.
1) If the PPC valve output pressure PA1 is sent

to the spring (2) chamber of spool (I), spool
(1) pushes against spring (2) and moves to
the right to a position where it balances
with the load of the spring.
2)
If spool (I) is actuated, the passage between

ports E and F opens, so part of the oil flow
discharged
from the pump flows through
ports A, 6, C, D, E, and F, and then into the
cylinder.
But in this condition,
almost all
the oil discharged
from the pump is unloaded.
3)
At the same time, the pressure in chamber

F flows into the passage inside the spool
from LS throttle dl, then passes through
ports G, H, and I, and is sent to spring chamber J of the unload valve. In addition, the
pressure in chamber A (pump pressure) is
sent to chamber
Al of the unload valve,
while the pressure
in chamber
J passes
through LS passage K and is sent to chamber L.
APLS
~4 Unloadoilflmv
<
01
Q2 z$%,r
z
Unload
oil flow
(a$scharge
SYD00321
D155AX-5
Throttle d2 is specially assembled

valve to adjust the oil flow.
to the tilt
10-157
STRUCTURE
(2) Meter-out
AND
MAIN
FUNCTION
control using downward

(blade control lever at LOWER)
movement
of blade
CONTROL
VALVE
under own weight
Blade lift
,.
1
,
as
*,
li_
I
,
,
:
.
l,,
5
,
,
.
,
I
2,
: *,,,
.:s : 2
SAD00186
lo-158
D155AX-5
If the blade moves down under its own

weight, the oil flow of return oil from cylinder is controlled by the area of the opening
of the man spool (1).
Because of back-pressure
valve (3), a back
pressure that matches the oil flow is formed
in drain circuit Tl of the control valve, so oil
is supplied to the cylinder bottom from suction valve (2) to prevent a vacuum from
forming in the circuit.
MAIN CONTROL VALVE
I) When the spool port is opened by PPC output pressure PA2, because of the downward
movement
of the blade, the oil at the cylinder head passes through ports A, B, C, and
D, and is drained to the tank. The flow of
return oil from the lift cylinder is throttled
by the area of the opening between ports A
and B, so the lowering speed is controlled.
2) When the blade moves down under its own

weight, there is no LS pressure, so the back
pressure is formed in chamber C in accordance with the characteristics
of back-pressure valve (3). The oil flowing
from the
cylinder head flows from the drain circuit,
passes through suction valve (21, and is supplied to the bottom end of the cylinder.
The oil discharged
from the pump passes
through pots Al, Bl, Cl, Dl, and El, and is
supplied to the cylinder bottom.
For details of the vacuum prevention function, see 5. UNLOAD VALVE PRESET SYSTEM.
D 155/U-5
10-159
STRUCTURE
AND
FUNCTION
control using downward

(3) Meter-out
(blade control lever at FLOAT)
MAIN
movement
of blade
under
CONTROL
VALVE
own weight
Blade lift
WI
Float
\
,**
II
,
,
,
I
,
I
;:
: ,,,
,s,,;,:
sADxm37
lo-160
D155AX-5
MAIN CONTROL VALVE
When the lift valve is at FLOAT, the cylinder

port and drain port are connected to put the
circuit in a no-load condition.
When the lift valve is in the FLOAT condition, the pump circuit and cylinder ports A2
and B2 are separated
so that the control
valve can carry out other operations.
1) With the control
lever at the FLOAT position, when pressure PA2 reaches 3.4 MPa
(35 kg/cm*}, lift spool (I) is at the maximum
stroke FLOAT position.
2)
In this condition,
ports A2 and B2 and LS
circuit 0 are all connected to the drain circuit, so there is no load on the lift cylinder.
3)
If the cylinder is driven by the weight of the

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

B2 are separated, and the pump pressure is
formed, so it is possible to carry out compound operations
with the other control
valves.
D 155/U-5
lo-161
MAIN CONTROL VALVE
3.
*
At relief
The diagram shows the tilt cylinder immediately after it reaches the end of its stroke.
Blade tilt
L. H. tilt F)
2;
5:
:;,
I
,
I
:
;s:=
*,
/,
.,p:>,:;:;
SAD00188
lo-162
D155AX-5
STRUCTURE
(I)
AND
FUNCTION
MAIN
CONTROL
VALVE
If spool (I) moves to the right because of

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

and it stops, the condition
becomes P k PI
% PLS, and unload spool (2) is pushed completely to the left by the load of spring (3),
so the unload oil flow becomes 0.
(3) In this condition,
all the oil discharged
by
the pump tries to flow to the cylinder, but
the cylinder piston is stopped, so the pressure in the pump circuit rises.
(4) If the pump pressure reaches the cracking
pressure, relief valve (4) is actuated, so the
maximum
pressure in the pump circuit is
set.
(5) Throttle Q of relief valve (4) is used to keep
the peak pressure to the minimum.
D 155/,X-5
lo-163
MAIN CONTROL VALVE
4.
*
Compound operations
The diagram
shows the lift valve + tilt valve.

Blade tilt
Blade lift
L. H. tilt
0
P2
0
Pl
SAD00189
lo-164
D155AX-5
STRUCTURE
AND
FUNCTION
MAIN
CONTROL
VALVE
It consists of a parallel circuit, so when compound operations

are carried out, the oil
flow is divided according to the size of each
spool opening.
(1) The tilt valve and lift valve spools are actuated by PPC output pressure PAI, PB2 and
each spool is balanced at a position that
matches its pilot pressure.
(2) When pressure PI I pressure P2
Lift valve load pressure P2 is sent to the
unload valve M, N chamber through LS passage.
I) When unload valve does not reach fully
closed position
When the discharge flow of oil from the
pump is greater than the total of the oil
flow demanded
by the tilt valve and lift
valve, an oil flow that matches the opening of the spool flows to both the tilt
valve and lift valve.
2) When unload valve is at fully closed position (there is no unload oil flow)
When the discharge flow of oil from the
pump is smaller than the total of the oil
flow demanded
by the tilt valve and lift
valve, the flow of oil to the tilt valve and
lift valve is divided according to P - PI
differential pressure and P - P2 differential pressure. In other words, more oil
flows to PI where the load is small.
In cases where the blade is raised in the

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

P - PI = P - P2, so an oil flow proportional
to the size of the spool opening is distributed to each spool.
D 155AX-5
lo-165
STRUCTURE
AND
5.
Unload
(I)
Lift valve
MAIN
FUNCTION
valve preset
CONTROL
VALVE
system
Blade
lift
SAD00190
lo-166
D 155AX-5
The response
is improved
MAIN CONTROL VALVE
at blade RAISE.
At blade LOWER, all the oil discharged from

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

pressure PB2, basic pressure PI of the PPC
valve goes through preset check valve (3)
into the LS passage through ports A, B, C,
D, E, and F. (Preset pressure: Min. 3.4 MPa
(35 kg/cm21)
2)
Immediately
after the spool is switched,
pump pressure P is approx. 0.5 - 1.0 MPa
(5 - 10 kg/cm*), so unload spool (2) is pushed
to the left. The opening between
ports G
and L is closed, and the oil discharged from
the pump all flows through ports G, H, I, J,
and K and is supplied to the lift cylinder, so
the response is improved.
3)
When the lift cylinder pressure rises and

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

flow of oil from the pump cannot keep up
with the blade lowering speed, if the load
pressure is not reached, unload spool (2) is
kept in the condition in Item 2) to make it
possible to present a vacuum from forming
in the cylinder.
D 155AX-5
lo-167
STRUCTURE
AND
FUNCTION
MAIN
CONTROL
VALVE
(2) Tilt valve

Blade tilt
L. H. tilt
I,
I,
iiIil3
,,,
*s
,
:;
I
,
:;
;;;:,
,,,
x::
I,
,p;,2
-B
SAD00191
10-168
D155AX-5
STRUCTURE
I)
MAIN
AND FUNCTION
The response
is improved
CONTROL
VALVE
at blade TILT.
When spool (I) is switched by PPC output

pressure PAI, basic pressure PI of the PPC
valve goes through preset check valve (3)
into the LS passage through ports A, B, C,
D, E, and F. (Preset pressure: Min. 3.4 MPa
135 kg/cm?)
2)
Immediately
after the spool is switched,
pump pressure P is approx. 0.5 - 1.0 MPa
(5 - 10 kg/cm*), so unload spool (2) is pushed
to the left. The opening between
ports G
and L is closed, and the oil discharged from
the pump all flows through ports G, H, I, J,
and K and is supplied to the tilt cylinder, so
the response is improved.
3)
When the tilt cylinder pressure rises and

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

BLADE
At blade RAISE
Blade
lift
Ir
TS
SWD02937
10470
D155AX-5
MAIN CONTROL VALVE
OPERATION
l
::::::::::::::::
When blade control lever (I) is operated to

the RAISE position, the spool of PPC valve
(21, which is directly connected to the lever,
is moved.
When this happens, the pilot pressure entering PPC valve (2) from PPC pump (3) is
sent to port PB2 of blade lift spool (4).
This
left,
and
PPC
tank
pilot pressure pushes spool (4) to the

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

pump (6) enters port P, passes
hydraulic
through unload valve (7) and ports A and B,
and goes to the head end of blade lift cylinders (8) and (9) to raise blade (IO).
At the same time, the oil at the cylinder
bottom passes through ports C, D, and T,
and is drained to hydraulic tank (5).
:/1/,1/,,/,,,,,,,
~::::::::::::::::
111,,,,,,,,,,,,,
SVD02638
D155AX-5
10-171
MAIN CONTROL VALVE
At blade LEFT TILT
BLADE TILT
!\
J
J
6
7
SVDO2639
lo-172
D155AX-5
STRUCTURE
AND
FUNCTION
MAIN
CONTROL
VALVE
OPERATION
When
::
,,
,.
::
::
SVDO2640
D155AX-5
10-173
MAIN CONTROL VALVE
RIPPER
At ripper RAISE
RIPPER LIFT
II
SVD02641
10-174
Dl SAX-5
MAIN CONTROL VALVE
OPERATION
l
When ripper control lever (1) is operated to

the RAISE position, the spool of PPC valve
is moved.
sent to port PB3 of ripper lift spool (4).
This
left,
and
PPC
tank
pilot pressure pushes spool (4) to the

and connects ports A and B and ports C
D. The oil at port PA3 passes through
valve (2) and is drained to hydraulic
(5).

hydraulic
and goes to the head end of ripper lift cylinders (8) to raise ripper (9).
bottom passes through ports C, D, and T,
and is drained to hydraulic tank (5).
SVD02642
Dl MAX-5
10-175
MAIN CONTROL VALVE
At ripper TILT IN
SVD02643
lo-176
D155AX-5
MAIN CONTROL CIRCUIT
OPERATION
.
When ripper control lever (I) is operated
to
the TILT IN position, the spool of PPC valve
is moved.
sent to port PA4 of ripper tilt spool (4).
I2-
This pilot pressure pushes spool (4) to the

right, and connects ports A and B and ports
C and D. The oil at port PB4 passes through
PPC valve (2) and is drained to hydraulic
tank (5).

hydraulic
and goes to the bottom end of ripper tilt
cylinders (8) to tilt in ripper (9).
head passes through ports C, D, and T, and
is drained to hydraulic tank (5).
SVD02644
D155AX-5
10-177
STRUCTURE
AND
FUNCTION
CYLINDER
STAY
CYLINDER STAY
SAD00208
1.
2.
3.
4.
5.
6.
Grease nipple
Yoke
Oil seal
Bushing
Bushing
Grease nipple
lo-178
D155AX-5
STRUCTURE
AND FUNCTION
WORK EQUIPMENT
WORK EQUIPMENT
SEMI U-DOZER
SE000209
1.
2.
3.
4,
5.
6.
7.
8.
End bit
Cutting edge
Blade
Center brace
Tilt cylinder
Straight frame
Trunnion
Brace
D155AX-5
10-179
WORK EQUIPMENT
SED00210
1.
2.
3.
4.
5.
6.
7.
8.
End bit
Cutting edge
Blade
Center brace
Tilt cylinder
Straight frame
Trunnion
Brace
10-180
D155AX-5
WORK EQUIPMENT
MULTI-SHANK RIPPER
SED00212
1.
2.
3.
4.
5.
6.
7.
8.
Mount bracket
Tilt cylinder
Lift cylinder
Beam
Shank
Protector
Ripper point
Arm
D155AX-5
lo-181
GIANT RIPPER
.
Machine equipped
1.
2.
3.
4.
5.
6.
7.
8.
9.
Bracket
Tilt cylinder
Lift cylinder
Beam
Pin puller cylinder
Shank
Protector
Ripper point
Arm
1O-l 82
WORK EQUIPMENT
with pin puller
SED00213
D155AX-5
CAB
CAB
1.
2.
3.
4.
D155AX-5
Front wiper
Front glass
Rear wiper
Door
lo-183
CAB
ROPS GUARD
SDD00247
1. ROPS guard
lo-184
D155AX-5
AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER
PIPING
SWD02645
1. Valve
(hot water inlet)

defroster
Side defroster
Air conditioner
unit
Vent
Blower motor
Valve (hot water outlet)
Hot water pickup piping
Condenser with motor fan
2. Window
3.
4.
5.
6.
7.
8.
9.
lo-185
ELECTRIC WIRING
ELECTRIC WIRING DIAGRAM
DIAGRAM
D155AX-5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Horn
Front lamps
Engine water temperature
sensor
Intake air heater relay
Hydraulic oil pressure sensor
Backup alarm switch
Ripper lamp
Ripper point lamp
HSS oil pressure sensor
HSS drain oil temperature
sensor
Torque converter oil temperature
sensor
HSS pump solenoid A, B
Engine speed sensor
Starting motor
Alternator
D155AX-5
lo-187
OD
-
10-188
Cn
-
D155AX-5
STRUCTURE
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
AND
FUNCTION
ELECTRIC WIRING
DIAGRAM
Monitor panel
Starting switch
Preheating switch
Rear lamp switch
Front lamp switch
Buzzer
Bimetal timer
Radio
Additional
rear working lamp switch
Additional front working lamp switch
Rear window wiper switch
Right door wiper switch
Front window wiper switch
Left door wiper switch
Right door wiper
Horn switch
Pitch switch
Front window wiper
Pin puller switch
Room lamp
Rear window wiper
HSS controller
Cigarette lighter
Fuel level sensor
Rear lamp
Backup alarm
Window washer tank
Batteries
Battery relay
Fuse holder
Steering lever
Left door wiper
D 155AX-5
1O-l 89
ELECTRIC CIRCUIT DIAGRAM

CHASSIS ELECTRIC CIRCUIT DIAGRAM (l/3)
*
For details of this page, see Section 90.
10-190
D155AX-5
P/3)
*
D
c
I
D155AX-5
ELECTRIC CIRCUIT DIAGRAM (3/3)

*
10-l 92
D155AX-5
STRUCTURE
AND
MONITOR
MONITOR
FUNCTION
SYSTEM
SYSTEM
Sensor
Controller
signal
signal
/-Y
L-J
:/
Power
Each
SUPPIY
sensor
i-l
Buzzer
signal
\
Buzzer
Controller
The monitor system uses sensors installed

at various parts of the machine to observe
the machine condition. It processes this information swiftly and displays it on the panel
to keep the operator informed of the machine condition.
The information
displayed on the panel can
be broadly divided into the following
categories.
1.
2.
The monitor group, which informs the

operator when there is an abnormality
in the machine.
The gauge group (coolant temperature,
power train oil temperature,
fuel level),
which always displays the condition of
the machine.
D 155AX-5
Battery
SWD02810
The monitor system consists of the monitor

panel, controller,
sensors, warning
buzzer
and power source.
The monitor
panel and sensors are connected with wiring harnesses, and the power
supply for the monitor panel is taken from
the battery. If any abnormality
occurs in the
machine (detected by the sensor), the monitor and warning lamp flash and the buzzer
sounds to protect the machine. The buzzer
can be stopped temporarily
by operating
the cancel switch.
10-193
STRUCTURE
MONITOR
AND
MONITOR
FUNCTION
PANEL
10
1.
2.
3.
4.
5.
6.
7.
8.
9.
Service meter
Service meter indicator
Engine coolant temperature
Power train oil temperature
Fuel level gauge
Alarm buzzer cancel switch
Warning lamp
10-194
SYSTEM
10. Electronic system caution

(HSS controller)
11. HSS charge pressure caution
12. Engine preheating
indicator
13. Engine oil pressure caution lamp
14. HSS hydraulic oil temperature
caution
15. Battery charge caution lamp
16. Engine coolant temperature
caution lamp
gauge
gauge
indicator
caution
lamp
D155AX-5
MACHINE
Outline
The monitor panel consists of the monitor
group, which gives a warning if any abnormality occurs in the machine, and the service meter and gauge group, which displays
the condition of the machine. The service
meter and fuel level gauge are driven directly by a signal from the machine, but for
the other items, a microcomputer
installed
in the panel processes the signal from various sensors and displays the result.
The items displayed on the indicator type
gauges and monitor portion are as shown
in the table in MONITOR PANEL DISPLAY.
When there is abnormality
in HSS system,
warning
lamp flashes and warning
buzzer
sounds according to the signal sent from
HSS controller.
l
Operation
1. Turning on power (turning starting switch
to ON)
1) All caution monitor items light up for 3
seconds.
2) The warning
lamp lights up for 3 seconds and the alarm buzzer sounds for 1
second.
2.
3.
CAUTION
items
These light up or flash when there is any
abnormality.
The warning
lamp and alarm buzzer flash
or sound together depending
on the item
that is abnormal.
The flashing interval for the monitor and
warning lamp is approx. 0.8 seconds each
repeated ON and OFF.
If any abnormality
is detected
and alarm
buzzer sounds, it is possible to stop the
buzzer temporarily
by pressing the buzzer
cancel switch. In this case, the alarm buzzer
cancel switch indicator lights up. If the cancel switch is pressed again after the buzzer
has been stopped, the buzzer will sound
again and the cancel indicator will go out. If
another abnormality
is detected when the
buzzer has been temporarily
stopped, the
alarm buzzer will sound again and the cancel switch will go out.
D155AX-5
10-195
STRUCTURE
Monitor
AND
MACHINE
FUNCTION
panel display
Meter
(gauge
SYSTEM
group)
Enginecoolanttemparahrre
50-c.
90-c
102-c
Gauge scale
%$L
SYD00338
4.
MONITOR
Fuel level
Powertrain oiltemmperature
SYD00340
SYD00339
Gauge display portion

This consists of analog type meters with an indicator. The coolant temperature
and power train
oil temperature
gauges are driven by a microcomputer,
and the area showing the normal operating range of the machine is made larger to make operations at the limit of the range easier.
The red zone for the water and oil temperature
is a warning area which uses a caution LED,
caution lamp, and caution buzzer.
Connector
terminal
Connector
(signal table)
No.
Connector
Connection
Power
l-l
2-1
supply
No.
Connection
Engine
Torque
water
temperature
converter
oil temperature
l-2
GND
2-2
l-3
2-3
Fuel level
2-4
GND
Battery
l-4
change
Starting
l-5
switch
Preheating
l-6
l-7
Working
l-8
Engine
lamp
(c)
2-5
2-7
switch
oil pressure
2-9
I-IO
2-10
I-II
2-l 1
1-12
2-12
1-13
Model
selection
1-14
Model
selection
Model
selection
1-16
lo-196
Buzzer
output
2-8
oil temperature
2-6
signal
l-9
1-15
HSS hydraulic
System
network
D155AX-5
STRUCTURE
Monitor
AND
panel display
Display
category
MACHINE
FUNCTION
Symbol
(monitor
MONITOR
group)
Display
item
HSS
hydraulic oil
temperature
Buzzer
output
Display
range
Below
Engine
water
temperature
102C
Gone
102C-107C
Flashes
Above
107C
Flashes
Below
120C
Gone
Gone
out
Flashes
Red
Flashes
Gone
out
out
Red
Above
120C
Flashes
Battery
charge
Lighted up
(when engine
is stopped)
Below
SAD00786
HSS charge
pressure
Gone
120C
Lighted
up
Above
Lighted
up
130C
Below
specified
valve
Red
OFF
Flashes
Gone
out
Red
Flashes
I Red
I
up
up
Flashes
Flashes
Lighted
ON
out
Lighted
Flashes
(when engine
is running)
When
defective
electronic
system
When
preheating
Gone
Gone out
(when engine
is stopped)
II
Preheating
out
Flashes
out
12OC-130C
SKD00628
Pilot
Gone
Red
SKDO0627
Electronic
system
4OFF
Flashes
(when engine
is running)
SKD00625
Power train
oil temperature
OFF
Flashes
Lighted up
(when engine
is stopped)
Below
specified
value
out
Red
Flashes
(when engine
is running)
SKD00624
Engine oil
pressure
Gone
-I
ON
Flashes
I
When
defective
charging
(below IOU
Remarks
out
SKDOO623
Warning
SYSTEM
Green
Gone
out
OFF
SKD00629
D155AX-5
10-197
MACHINE MONITOR SYSTEM
T
Display
category
Symbol
Display
item
range
[Ml
Service
meter
0 - 99999.9h
Green
fellow
Time on
the clock
SKD00631
Service
meter
Service
meter
indicator
service
meter
SKD00632
Switches
Buzzer
cancel switcl
indicator
OFF
SKD00633
Switches
Item
Buzzer cancel
Actuation
OFF t)
ON
Symbol
a
@4
CAMCEL
SKDO0634
lo-198
D155AX-5
SENSORS
SENSORS
.
.
The signals from the sensors are input directly to the machine monitor panel.
With the engine oil pressure sensor, if the
contacts are open and the signal wire is
disconnected
from the chassis ground, the
panel judges that the signal is normal.
Display
Caution
Caution,
Type of sensor
category
I
gauge
Engine oil pressure

Engine
coolant
temperature
Sensor
When
method
When
OFF(Open)
Contact
Resistance
normal
abnormal
ON(Closed)
Resistance
Fuel level
Resistance
HMT pump, motor oil temperature
Contact
ONKlosed)
OFF(Open)
Contact
ONKlosed)
OFF(Open)
Gauge
Gauge
Caution
HMT charge
D155AX-5
pressure
10-199
SENSORS
ENGINE OIL PRESSURE SENSOR
234
Structure
of circuit
SYDoo343
1. Plug
2. Contact
ring
3. Contact
4. Diaphragm
5. Spring
6. Thermistor
Function
.
The engine
oil pressure sensor is installed

at the front on the left side of the cylinder
block. When the engine oil pressure is above
the specified value, diaphragm
(4) bends,
so contact (3) and contact ring (2) are separated and the circuit is turned OFF. When
the engine oil pressure goes below the specified pressure, the curve of the diaphragm
becomes smaller, so the contact and contact link come into contact and the circuit is
turned ON. The monitor panel display and
warning
lamp flash, and the alarm buzzer
sounds.
1O-200
D155AX-5
SENSORS
ENGINE COOLANT TEMPERATURE SENSOR

POWER TRAIN OIL TEMPERATURE SENSOR
Structure
of circuit
1. Connector
2. Plug
3. Thermistor
Function
l
The engine coolant temperature

sensor is
installed to the thermostat
housing on the
right side of the engine. It detects the temperature with thermistor
(3) and sends a
signal to the monitor panel.
The monitor panel moves the gauge indicator to the
range that corresponds
to the
signal, and if it is above the specified temperature,
the monitor
panel display and
warning lamp flash, and the buzzer sounds.
The power train oil temperature
sensor is
installed
between
from torque converter
outlet ports to oil cooler, and operates in
the same way as the engine water temperature sensor.
D155AX-5
10-201
SENSORS
FUEL LEVEL SENSOR
6
7
u
A-A
Structure
of circuit
SYD00345
1. Connector
Float
3.
4. Body
5. Spring
Contact
7. Spacer
1O-202
Function
.
The fuel level sensor is installed to the center
of the front face of the fuel tank. Float (2)
moves up and down in accordance with the
level of the remaining fuel.
The movement
of the float passes through
arm (31, which actuates a variable
resistance, and this sends a signal to the monitor
panel to display the level of the remaining
fuel.
D155AX-5
SENSORS
HMT PUMP, MOTOR OIL TEMPERATURE SENSOR
w----J
Structure
of circuit
SYDOO346
Function
l
The HMT pump and motor oil temperature

sensor is installed to the HMT motor drain
outlet block.
The temperature
is detected
by switch (I), and if the oil temperature
goes
above the set value, the switch is turned
OFF. When this happens, the monitor panel
display and warning
lamp flash, and the
alarm buzzer sounds.
1.
2.
3.
4.
Switch
Case
Wire
Connector
HMT CHARGE PRESSURE SENSOR
SE000223
Function
l
This sensor is installed to the PPC, EPC,

HMT charge valve outlet port. If the charge
pressure
drops below the set pressure,
switch (I) is turned OFF. When this happens, the monitor panel display and warning lamp flash, and the alarm buzzer sounds.
D 155AX-5
1.
2.
3.
4.
Switch
Case
Wire
Connector
1 O-203
STRUCTURE
AND
ENGINE
FUNCTION
ENGINE STARTING
STARTING
SYSTEM
SYSTEM
SAD01559
1.
2.
3.
Joystick (directional,
steering lever)
Neutral detection limit switch
Safety lever
1O-204
Outline
.
Neutral detection limit switch (2) is installed
to Joystick (1). If safety lever (3) is not at
the LOCK position, the starting circuit is not
switched
ON and the engine
cannot
be
started.
D155AX-5
HSS ELECTRONIC CONTROL SYSTEM

PARTS LAYOUT
SVD02763
1 O-206
D155AX-5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1 I.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Steering pressure sensor A

Steering pressure sensor B
Hydraulic pressure sensor
Power train pump
Travel REVERSE sensing switch
Travel REVERSE sensing potentiometer
Steering lever potentiometer
Steering lever
HSS motor
Brake valve
Transmission
HSS pump solenoid valve B
HSS pump solenoid valve A
HSS pump
Engine speed sensor
Engine flywheel housing
Joystick
Parking detection switch
HSS controller
D155AX-5
1 O-207
zresros;itch
HSS charge pressure

signal
Limit switch
(ON tj OFF)
Potentiometer
(analog)
Potentiometer
(analog)
Oil pressure sensor

(analog)
Engine speed
signal
Power source
used
Oil pressure sensor

(analog)
Equipment
Electromagnetic
pick-up (pulse)
Reverse speed
position signal
Steering lever
signal 2
Steering lever
signal 1
ilVork equipment
:ircuit oil pressure
signal
Steering circuit B oil

xessure signal
Steering circuit A
oil pressure signal
Name of signal
Signal to detect if oil I

is being
supplied I
correctly
to HSS ,- pump, motor closet I
circuit
Signal to detect actual engine

speed I
and control
swash I- plate angle of HSS
pump
Command signal to
detect reverse speed
position
and determine left or right direction
of steering
when traveling in reverse
Command signal to
determine
left or
right direction
and
size of turning radius
when steering is operated
Command signal to
detect work equipment circuit oil pressure
and control
swash plate of HSS
pump
Command signal to
detect steering
circuit oil pressure and
control swash plate
of HSS pump
Function
HSS
controller
Output signal for sounding alarm to warn of abnormal condition of HSS

controller
Output signal for sounding alarm when HSS

charge pressure is abnormal
Monitor
3utput signal for soundng backup alarm when Backup alarm relay
:raveling in reverse
panel
Relay
(ON t;, OFF)
valve
contra
Equipment used
iSS pump and ad- HSS pump solenoid B solenoid

ust discharge from
)ump
Name of actuator
Iutput
signal
to
Ove swash plate Of HSS pump solenoid A Proportional
Nature of control
STRUCTURE
AND
Explanation
1) Steering
FUNCTION
HSS ELECTRONIC
CONTROL
SYSTEM
of system
system
1 Hydraulic
pressure
sensor
1-y
Potentiometer
Travel
switch
REVERSE sensino
,I
I,
HSS Pump solenoid

I
HSS
controller
,I
I,
HSS charge
Pressure
sensor
I,
I,
Monitor
Panel
I,
Buzzer
II
Steering
lever
SWD02813
Outline
siqnal to determine the left or right direction of

steering when traveling in reverse.
The HSS controller
uses the signal input
from each oil pressure sensor to control the
swash plate angle of the HSS pump and
prevent the engine from stalling.
D155AX-5
lo-209
2)
Warning and other systems
II
Sensors
,I
I,
Actuators
,I
HSS controller
EEI
I,
Monitor panel
Buzzer
HSS PUMP solenoid
7iL
SWD02814
Outline
The HSS pump and motor form a closed
circuit. Oil is supplied to the closed circuit
from the charge pump continuously to compensate for internal leakage.
If this supply
amount becomes low, the pump or motor
may be broken, so a sensor is installed to
detect the charge pressure.
If the charge pressure goes below a certain
pressure, a signal from the HSS charge pressure sensor enters the HSS controller and
uses the alarm buzzer, warning lamp, and
caution lamps on the monitor panel to inform the operator of the condition.
If any abnormality
occurs in the sensors,
actuators (solenoid valves, etc.) or HSS controller, a signal is output through the HSS
controller to the monitor panel warning lamp
and alarm buzzer to warn the operator of
the abnormality.
The nature of the abnormality
is displayed
in numbers and letters on the HSS controller display.
10-210
D 155AX-5
HSS CONTROLLER
3
I
3
CN-1
CN,-2
W-3
SJD02653
1. Display window
2. Connectors
CNI
D 155AX-5
CN2 (CN-2Hl)
CN2 (CN-2H2)
10-211
REVERSE SENSING POTENTIOMETER
SWD02654
1. Connector
2. Lever
Body
4. Potentiometer
5. Coupling
6. Shaft
7. Stopper
REVERSE
When the monolever is operated to forward

or reverse, the potentiometer
shaft is rotated through the link and the resistance
value changes.
A constant voltage is impressed
between
pins (I) and (3) of the potentiometer,
and a
voltage signal matching the position of operation to forward or reverse is sent from
pin (2) to the HSS controller.
10-212
D155AX-5
REVERSE position limit switch
1.
2.
3.
4.
5.
Plunger
Microswitch
Plug
Ball
Bearing
SJD02655
6.
7.
8.
9.
10.
Cap
Railer
Stopper
Diaphragm
Connector
Function
l
The REVERSE position limit switch is installed to the top of the transmission
valve
cover.
When the monolever is operated to the REVERSE position, it pushes the roller of the
limit switch, the circuit is closed, and the
REVERSE position signal is sent to the HSS
controller.
D 155AX-5
lo-213
STRUCTURE
ENGINE
AND
HSS ELECTRONIC
FUNCTION
CONTROL
SYSTEM
SPEED SENSOR
\
5
c
0.
0.75fB
75fG
2,
SWD02815
4. Boot
5. Connector
1. Magnet
2. Terminal
3. Case
Function
The engine speed sensor is installed to the
top left of the engine flywheel.
.
As the engine flywheel gear passes through,
the change in the magnetic field generates
electricity, and the pulse is sent as a pulse
signal to the HSS controller.
BACKUP
ALARM
RELAY
3
1
6
5
Structure of circuit
SED00240
Function
.
The contacts
of the electric
circuit
are
opened and closed by the command
voltage from the HSS controller and sound the
backup alarm.
lo-214
D155AX-5
HSS PRESSURE SENSOR (HSS CHARGE PRESSURE SIGNAL)
SWD02816
1. Switch
2. Case
3. Wire
4. Connector
Function
l
The HSS pressure sensor is installed to the

PPC, HSS charge valve outlet port.
When the charge pressure goes below the
specified pressure, switch (I) is turned OFF,
the monitor panel display and warning lamp
flash, and the alarm buzzer sounds.
STEERING CIRCUIT OIL PRESSURE SENSOR

WORK EQUIPMENT CIRCUIT OIL PRESSURE SENSOR
1. Sensor
2. Connector
Function
l
These sensors
are installed
in steering
closed circuits A and B and in the hydraulic
pump circuit. They convert the oil pressure
at various parts to a voltage and send it to
the HSS controller.
D 155AX-5
10-215
HSS PUMP PROPORTIONAL SOLENOID VALVES A, B
A-A
1. Case
2. Coil
3. Shaft
4. Plunger
\
5
SWD02818
5. Sleeve
6. Filter
7. Connector
Function
l
The HSS pump proportional

solenoid valve
pushes the pilot of the HSS pump servo
valve according
to the command
current
from the HSS controller.
The swash plate
angle of the pump becomes larger in proportion to the electric current which changes
the swash plate angle of the pump, and increases the pump discharge amount.
There
are two proportional
solenoids to discharge
oil from the pump in both the normal and
reverse directions.
lo-216
D155AX-5
STRUCTURE
STEERING
VC
(For
AND
HSS ELECTRONIC
FUNCTION
CONTROL
SYSTEM
LEVER
Vsie
backup)
(For
sienall
A
Lever
stroke
c
7
c-c
4
3
.
fz53
1.
2.
3.
4.
Body
Piston
Lever
Disc
5.
6.
7.
8.
1
2
SWD02819
Retainer
Lever
Potentiometer
Connector
Function
The steering potentiometer
is installed to
the left side part of the floor, and is interconnected by a link to the steering end of
the monolever.
When the monolever is operated in the steering direction, disc (4) is
rotated through the link, pushes piston (2)
down, and rotates potentiometer
(7).
Steering
lever potentiometers
sense lever
angle and output angle signal to HSS controller.
Two potentiometers
are attached to steering lever and they output signal as shown
in the diagram.
D155AX-5
10-217
20
STANDARD
VALUE
TESTING AND ADJUSTING
TABLES
Standard
value table for engine ...................................................................................................
20-
Standard
value table for chassis ..................................................................................................
20-
Standard
value table for electrical
20-
TESTING
.................................................................................................................
AND ADJUSTING
TROUBLESHOOTING
parts .....................................................................................
20-101
............................................................................................................................
The following precautions

troubleshooting
.
are necessary,
when
using the standard
20-201
value tables for testing and adjusting,
or for
The values in the table are for new machines, and are obtained from reference to values when shipping from
the factory. Therefore, they should be used as target values for judging the progress of wear, or when repairing
the machine.
The standard values for judging failures are based on the results of various tests when shipping the machine
from the factory. These values should be used as reference together with the repair condition and operating
record of the machine to make judgements
on failures.
The values in the table should
not be used for judging
When carrying out testing,

pins and block the tracks.
When carrying out work together

persons near the machine.
When checking the water level, always wait for the water to cool down.
the water is still hot, the water will spurt out and cause burns.
Be careful
D 155AX-5
not to get caught
adjusting,
or troubleshooting,
claims.
with
other
workers,
in the fan or other rotating
stop the machine
use agreed
signals
on level ground,
install the safety
and do not allow
If the radiator
unauthorized
cap is removed
when
parts.
20-l
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE

Serial No. 70001 75000
Machine model
D155AX-5
Engine
Item
Measurement conditions
SA6D140E-2
Unit
High idling
Engine speed
Low idling
rpm
At rated output
Exhaust temperature
Whole speed range

(Ambient temperature:
20C)
At sudden acceleration
Exhaust gas color
At high idling
Intake valve
Valve clearance
(at normal temperature)
Exhaust valve
Service limit value
2,050 50
+25
700 0
1,900
kPa
{mmHg}
Min. 85.3
{Min. 640}
67.9
{510}
Max. 680
700
Max. 6.0
8.0
Max. 1.0
2.0
0.43
0.80
Rated speed
Air supply pressure
Standard value
for new machine
Bosch
index
mm
Compression pressure
(SAE15W-40 or SAE30)
Oil temperature:
40 60C
(Engine speed)
MPa
{kg/cm2}
(rpm)
Min. 3.14 {Min.32}

(200 250)
2.16 {22}
(200 250)
Blow-by pressure
At rated output
(Water temperature:
Operating range)
kPa
{mmH2O}
Max. 0.98
{Max. 100}
1.96
{200}
0.29 0.49 {3.0 5.0}

0.25 0.44 {2.5 4.5}
0.20 {2.0}
0.18 {1.8}
Min. 0.1 {Min. 1.0}

Min. 0.1 {Min. 1.0}
0.07 {0.7}
0.07 {0.7}
80 110
120
15 0.5
15 0.5
15
15
10
10
Oil pressure
(Oil temperature:
Min. 80C)
At high idling
SAE15W-40 or SAE30
SAE10W
At low idling
SAE15W-40 or SAE30
SAE10W
Oil temperature
Whole speed range

(inside oil pan)
Fuel injection timing
Before top dead center
MPa
{kg/cm2}
Alternator belt tension
Air conditioner
compressor belt tension
20-2
4
Deflection when pressed

with finger force of
approx. 59 N {6 kg}
mm
D155AX-5
Serial No. 75001 and up

Machine model
D155AX-5
Engine
Item
SA6D140E-3
Unit
High idling
Engine speed
Low idling
rpm
At rated output
Exhaust temperature
Whole speed range

(Ambient temperature:
20C)
At sudden acceleration
Exhaust gas color
At high idling
Intake valve
Valve clearance
(at normal temperature)
Exhaust valve
Service limit value
2,100 50
+25
740 0
1,900
kPa
{mmHg}
Min. 85.3
{Min. 640}
67.9
{510}
Max. 680
700
Max. 4.0
8.0
Max. 1.0
2.0
0.43
0.80
Rated speed
Air supply pressure
Standard value
for new machine
Bosch
index
mm
Oil temperature:
40 60C
(Engine speed)
MPa
{kg/cm2}
(rpm)
Min. 3.14 {Min.32}

(200 250)
2.16 {22}
(200 250)
Blow-by pressure
At rated output
(Water temperature:
Operating range)
kPa
{mmH2O}
Max. 0.98
{Max. 100}
1.96
{200}
0.29 0.49 {3.0 5.0}

0.25 0.44 {2.5 4.5}
0.20 {2.0}
0.18 {1.8}
Min. 0.1 {Min. 1.0}

Min. 0.1 {Min. 1.0}
0.07 {0.7}
0.07 {0.7}
80 110
120
15 0.5
15 0.5
15
15
10
10
Oil pressure
(Oil temperature:
Min. 80C)
At high idling
SAE15W-40 or SAE30
SAE10W
At low idling
SAE15W-40 or SAE30
SAE10W
Oil temperature
Whole speed range

(inside oil pan)
Fuel injection timing
Before top dead center
MPa
{kg/cm2}
Alternator belt tension
Air conditioner
compressor belt tension
D155AX-5
Deflection when pressed

with finger force of
approx. 59 N {6 kg}
mm
20-2-1
4
20-2-2
(Blank page)
D155AX-5
STANDARD VALUE TABLE FOR CHASSIS

Machine model
Engine stall speed
Category
Item
Service limit
value
1,580 100
1,420
1,410 100
1,250
105 20
105 20
60 20
60 20
56 15
56 15
13 5
13 5
13 5
13 5
N FORWARD
45 15
45 15
N REVERSE
45 15
45 15
N Right turn
57 15
63 15
N Left turn
57 15
63 15
Total travel
79 10
79 10
61
61
HOLD RAISE,
FLOAT
80 15
80 15
HOLD LEFT,
RIGHT TILT
60 10
60 10
HOLD RAISE,
LOWER
85 15
85 15
HOLD Digging
angle decrease,
increase
85 15
85 15
98 157
{10 16}
98 177
{10 18}
78 29
{8 3}
216 78
{22 8}
372 78
{38 8}
284 78
{29 8}
186 78
{19 8}
177
{18}
196
{20}
147
{15}
Steering relief +
work equipment raise
stall speed
1
Fuel control lever
Center of lever
knob
Joystick
Gear shift
Control lever travel, pedal travel
Standard value
for new machine
Engine oil pressure:
Within operating range
Engine oil temperature:
Hydraulic oil temperature:
45 55 C
F3
Ripper RAISE stall
Torque converter stall

speed
Decelerator pedal
mm
deg.
Engine at low
idling
Position until
Center of pedal brake oil pressure
becomes 0
Ripper lever
rpm
1st 2nd
Engine stopped
Center of lever 2nd 3rd
knob
Steering
Brake pedal
Engine low idling

High idling
Engine low
idling Stop
Unit
Center of pedal
Directional
Blade lever
Engine at low
idling
Center of
lever knob
Hydraulic oil
temperature:
45 55C
Engine at low
idling
Center of
lever knob
Hydraulic oil
temperature:
45 55C
Fuel control lever

1
Center of lever
knob
Decelerator pedal
Engine stopped
Center of pedal
mm
Engine low idling

High idling
Engine low idling
Stop
N
{kg}
1st 2nd
Joystick
Operating force of
control lever, pedal
D155AX-5
Gear shift
Engine stopped 2nd 3rd

Center of lever
knob
2nd 1st
3rd 2nd
Nm
{kgm}
216
{22
372
{38
284
{29
186
{19
78
8}
78
8}
78
8}
78
8}
1: Serial No. 70001 75000
D155AX-5
20-3
4
Machine model
Item
) Engine stopped N tf FORWARD
.g
2
_)
Directional
I---
bCenter of lever
Steering
Brake pedal
Blade lever
l
Ripper lever
l
Torque converter inlet port

pressure
Torque converter
port pressure
knob
N tf REVERSE
----I
Engine stopped N tf Left turn

Center of lever
knob
N tf Rightturn
Engine at low idling
Center of pedal
Engine at low
idling
Hydraulic oil
t4e5m_p;Fpre:
0
E;&ber of lever
Engine at low
idling
Hydraulic oil
temperature:
45 - 55C
Center of lever
knob
D155AX-5
HOLD tf RAISE,
FLOAT
Unit
Standard value
for new machine
53.9 rf: 19.1
{5.5 f 2.0}
53.9 f 19.1
15.5 zlz2.01
17.6 + 19.1
{I.8 f 2.0)
17.6 f 19.1
t-Egj-+
Service limit
value
78.4
18.01
78.4
18.01
44.1
14.51
. .. .
AA 1
29.4 f 9.8
49.0
13.0 + 1.01
I5.01
29.4 + 9.8
{2.5 f 1.0)
44.1
14.51
HOLD tf RAISE,
LOWER
29.4 rf:9.8
12.5 f 1.01
44.1
(4.51
HOLbDigging
angle decrease,
increase
29.4 + 9.8
12.5 + 1.01
44.1
14.51
H~~G$zf$[~
Power train oil

temperature:
Operating
range
outlet
Transmission main relief

pressure
Transmission modulating
pressure
Brake actuating pressure
HSS main pressure

HSS charge pressure
HSS servo charge pressure
PPC relief pressure
Travel speed
* Measurement
20-4
D 155AX-5
Catf ?-
item
gor Y
Measurement
Hydraulic oil
temperature:
45 - 55C
Blade LIFT relief pressure
Blade TILT relief pressure

-
conditions
20.59 f 0.98
I210 + IO)
20.59 * 0.98
I210 + IO)
Engine at low
idling
18.63 f 0.98
I190 + IO)
18.63 f 0.98
{I90 + IO)
Engine at higt
idling
20.59 f 0.98
1210 I!I 101
20.59 f 0.98
(210 f IO}
at low
18.63 + 0.98
{I90 f 101
18.63 + 0.98
(190 f IO}
20.59 f 0.98
(210 f IO)
20.59 f 0.98
1210 f IO}
at low
18.63 f 0.98
1190 f IO)
18.63 f 0.98
(190 * IO)
Engine at higt
idling
20.59 I?Z0.98
(210 * IO}
20.59 f 0.98
{210 f IO]
at low
18.63 + 0.98
{I90 f 101
18.63 f 0.98
I190 + IO]
20.59 ztz0.98
1210 f IO)
20.59 f 0.98
1210 f IO]
Engine
idling
Engine
idling
pressure
at high
Engine at high
i idling
Enne
PPC valve output pressure

L
Work
equipment
Service limit
value
18.63 f 0.98
{I90 f IO}
Engine
idling
Standard value
of new machinc
18.63 f 0.98
(190 f 10)
Engine at higt
idling
Ripper digging angle

relief
increase
decrease,
pressure
Unit
Engine at low
idling
Engine
idling
Ripper LIFT relief pressure
Load sensing
D155AX-5
model
Machine
at high
g
posture
Blade LIFT drift
MPa
kg/cm
2.94 - 4.4
{30 - 45)
2.94 - 4.4
130 - 451
200
250
150
200
TYDOOOOI
l
l
!E
+3
=r
I
Engine stopped
45 - 55OC
drift at edge of
Hydraulic
blade
Work equipment
-0
posture
Blade TILT drift
D155AX-5
TYD00002
B Engine stopped
mHydraulic oil temperature:
45 - 55C
drift at edge of
- Hydraulic
blade
20-5
STANDARD
VALUE
TABLE
STANDARD
Machine
Cate
Item
gorl I
model
equipment
TABLE FOR CHASSIS
D155AX-5
Measurement
Work
VALUE
conditions
Unit
Standard value
If new machine
Service limit
value
150
200
90
150
posture
ND00003
9 Engine stopped
9 Hydraulic oil temperature:
l
i
Hydraulic
drift
of chassis
45 - 55C
Hydraulic drift at center of idler with
blade pushed to height h against
ground
Work
equipment
posture
mm/
5min.
r--I
l
l
l
TYD00004
Engine stopped
45 - 55C
Hydraulic drift at center of sprocket
with ripper
pushed
to height
h
against-ground
Work
equipment
posture
3-5
3-5
1 - 1.5
l-I.5
2.7 f 0.5
3.5
2.3 ? 0.5
3.0
Blade LIFT
TYD00005
l
l
l
l
Engine at high idling

45 - 55C
Blade: No load
Ground level H Max. height
Work
equipment
sec.
posture
!i
F
t
El
Blade TILT
l-YD00006
l
l
20-6

45 - 55C
Blade: No load
LEFT TILT ti RIGHT TILT
D155AX-5
Machine model
:e-
item
-r
D155AX-5
Unit
Standard value
of new machine
limit
value
Service
Work equipment posture
2.5 + 0.5
4.0
Ripper LIFT
1 Engine
at high idling
1Hydraulic oil temperature:
3.0 +- 1.0
5.0
3.0 -+ 0.5
4.5
TYD00008
45 - 55C
Lowest shank hole
Digging angle decrease ++
increase
2.5 + 0.5
4.0

Hydraulic oil temperature: 45 - 55C
Raise blade to maximum height, then
lower blade and measure time taken
from point where blade contacts
ground to point where idler comes
off ground
1.5 * 0.5
2.5
45 - 55C
1Lowest shank hole

Work equipment posture
sec.
Ripper TILT
.
.
.
.
.
.
.
Blade
.
.
Ripper
.
.
.
.
D155AX-5

Raise ripper to maximum height,
then lower ripper and measure time
taken from point where ripper contacts ground to point where sprocket
comes off ground
Extend piston rod fully and disconnect hose at head end
Measure oil leakage during one
minute of relief
1.5
Max. 3.0
12
c/min i
20-7
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Serial No. 70001 75000
System
Component
Connector Inspection
No.
method
Judgement table
If the condition is as shown in the
table below, it is normal
Measure
resistance
Engine speed
sensor
Between (1) (2)
500 1000
Measurement
condition
1) Turn starting
switch OFF.
2) Disconnect
connector.
Between (1), (2) chassis Min.1 M
CN-ENG
(male)

Measure
voltage
Between (1) (2)
0.5 3.0 V
1) Disconnect
connectors.
2) Engine
running
When using circuit tester, select AC

voltage range.
1) Turn starting
switch ON.
2) Insert Tadapter.
Between (4) (1)
5.0 0.25 V
3) Turn joystick
to steering
Lever Between (3) (1) 4.15 0.25 V
position.
fully at
left
Between (2) (1) 0.85 0.25 V

Steering
potentiometer
CN-STR
Measure
voltage
HSS system
Lever
at N
Between (3) (1) 2.5 0.25 V

Between (2) (1) 2.5 0.25 V
Lever Between (3) (1) 0.85 0.25 V

fully at
right Between (2) (1) 4.15 0.25 V
REVERSE sensing
potentiometer
CN-RSS
Measure
voltage
Between (1) (3)

Lever at N
Lever at
REVERSE
Between
(2) (3)
5.0 0.25 V
Max. 3.5 V
3.5 4.4 V

Steering circuit oil
pressure sensor A
Measure
CN-STHP1 voltage
Between (2) (1)
20 30 V
20-8
4
Measure
CN-STHP2 voltage
1) Turn starting
switch ON.
2) Insert Tadapter.
Between Engine stopped 0.8 1.2 V

(3) (1) Engine running + 4.0 4.6 V
Steering relief

pressure sensor B
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Turn joystick
to directional
position.
Between (2) (1)
20 30 V
1) Turn starting
switch ON.
2) Insert Tadapter.

Steering relief
D155AX-5
Systen
Judgement
Component
Measurement
condition
table
If the condition
is as shown
HSS charge oil
pressure sensor
Between
(1)-(2)
IBetween
Engine stopped
Engine
Max.
Steering neutral
adjusting switch
Backup
switch
(2) - (I)
CN-CSW
(male)
in the
1 20-30
in the
1) Turn starting
switch OFF.
2) Disconnect
connectors.
If the condition
is as shown
in the
1) Turn starting
switch OFF.
2) Disconnect
connectors.
3) Turn joystick
to directional
position.
If the condition
is as shown
in the
1) Turn starting
switch OFF.
2) Disconnect
connectors.
Measure
resistance
alarm
HSS pump
solenoid B
Between
(I)
- (2)
I IO - 20 n
I
(I), (2) -chassis
Between
Between
(I) - (2)
(I), (2) -chassis
relay
Measure
resistance
CN-014
(male)
I- (2)
Between
(I
Between
(3) - (5)
Between
(3) - (6)
in the
IO - 20 R
CN-00
Measure
voltage
Between
(8),(18) -chassis
Between
(8),(18) - (9),(19)
I)
Turn starting
switch OFF.
2) Disconnect
connectors.
Min. 1 MQ
in the
200 - 400 R
I)
Turn starting
switch OFF.
2) Disconnect
connectors.
Min. 1 MR
Max.
If the condition
is as shown
Power supply
for controller
Min. 1 MD
If the condition
is as shown
alarm
1) Turn starting
switch ON.
2) Insert Tadapter.
If the condition
is as shown
If the condition
is as shown
Between
=&
g
E
MQ
HSS pump
solenoid A
3ackup
1 Sz
(I), (2) - chassis.1 Min.1
Between
I) Turn starting
switch OFF.
2) insert Tadapter.
Min. 1 MQ
running
If the condition
is as shown
VVork equipment
circuit oil pressure
sensor
in the
1 R
in the
I)
Turn starting
switch ON.
2) Insert Tadaper.
20 - 30 V
:
~
D 155AX-5
20-9
Syster n
(:onnecto rl nspectiol 7
Component
No.
Judgement
method
Measurement
condition
table
is as shown
If the condition
t,able below, it is normal
Power supply
for solenoids
CN-001
Measure
voltage
System
network
CN-001
1
[
Between
(1),(12) - (9),(19)
krwer
speed
CN-2H2
supply
CN-2Hl
potentiometer
Measure
voltage
Between
[
7t
(4) - (I 2)
When using circuit tester,

voltage range.
II
in the
in the
(IO) - (9)
Measure
voltage
Lever
at N
switch ON.
!) Insert T-
15.0 f 0.25 VI
in the
Lever Between (19) - (9) 4.15 + 0.25 V

fully at
right
Between (20) - (9) 0.85 f 0.25 V
CN-2Hl
Run engine.
Insert Tadaper.
1I) Turn starting

i
Between
I)
!)
select AC
IiF the condition is as shown

t able below, it is normal
Steering
potentiometer
1I) Turn starting

switch ON.
2!I Insert Tadaper.
1 0.5 - 3.0 v 1
If the condition
is as shown
Measure
voltage
in the
1 4 - 8 V
If the condition
is as shown
t ,able below, it is normal
Engine
sensor
ON.
adaper.
20-30V
If the condition is as shown

Measure
voltage
switch
;!) Insert T-
-1
I) Turn starting
in the
Between
(19) - (9) 2.5 f 0.25 V
Between
(20) - (9) 2.5 f 0.25 V
1) Turn starting
switch ON.
2!I Insert Tadapter.
3I) Turn joystick
to steering
position.
Lever Between (19) - (9) 0.85 + 0.25 V

fully at
left
Between (20) - (9) 4.15 + 0.25 V
Travel
REVERSE
iensing
lotentiometer
f the condition is as shown

1,
CN-PHI
CN-2H2
Measure
Joltage
in the
1 ) Turn starting
switch ON.
2!) Insert Tadapter.
3 ) Turn joystick
to directional
position
in the
1 ) Turn starting
switch ON.
2 ) Insert T-
1
C
iteering
circuit
lil pressure
ensor A
is as shown
If the condition
tzrble below, it is normal
ZN-2Hl
ZN-2H2
Jleasure
roltage
Between
C;N_2H2(1j Engine stopped

Engine running +
_I C:N-2H1(9) Steerincl relief
iteering circuit
sil pressure
ensor B
:N-2Hl
:N-2H2
vleasure
foltage
Between
C;N_2H2(9) Engine stopped
Engine running +
CZN-2Hlt9)
Steering relief
adapter.
4.0 _ 4m8 v
is as shown
If the condition
tzable below, it is normal
20-10
0.8 - 1.2 V
in the
0.8 - 1.2 V
1 1 Turn starting
switch ON.
2 1 Insert T-
adapter.
4.0 _ 4.8 v
D 155AX-5
STANDARD
Systen
VALUE
TABLE
Component
HSS charge
oil pressure
sensor
STANDARD
No.
method
CN-2Hl
=t
2
Zf=$
F
g
adjusting
switch
CN-2Hl
CN-2H2
CN-PHI
Judgement
TABLE FOR ELECTRICAL
PARTS
Measurement
condition
table
If the condition
is as shown
in the
1) Turn starting
switch ON.
If the condition
is as shown
in the
1) Turn starting
switch ON.
If the
is as shown
in the
1) Turn starting
switch ON.
If the condition
is as shown
in the
1) Turn starting
switch ON.
If the condition
is as shown
in the
1) Turn starting
switch ON.
Measure
voltage
t
Work
equipment
circuit oil
pressure
sensor
VALUE
Measure
voltage
condition
Measure
voltage
%
I
Ba!zhp
alarm
;ey$w alarm
CN-2Hl
CN_ool
Measure
voltage
Measure
voltage
% Voltage changes 20 - 30 V to below

IV alternatively
every one second.
D155AX-5
20-11
STANDARD
Syster
VALUE
STANDARD
TABLE
Component
(Zonnectol nspectiol
No.
VALUE
Judgement
method
Measurement
condition
table

50c
90 c
102C
01
I)
Turn starting
switch OFF
and insert
dummy resistor, or measure input
resistance.
!) Turn starting
switch ON
and check the
display of
meter.
in the
k&4
Engine water
temperature
meter
KInale,
wleasure
esistancl
loz"c
Approx.
3.7 kQ
120C
Approx.
2.3 kCI
If the condition
is as shown
Transmission
oil temperature meter
Emale)
Measure
-esistanc
Fuel level
meter
Kmale)
1) Turn starting
switch OFF
and insert
resistance.
2) Turn starting
switch ON
and check the
display of
meter.
in the
BVD00518
120C
Approx.
2.3 kR
130C
Approx.
1.8 kR
If the condition
is as shown
I) Turn starting
switch OFF
and insert
resistance.
!) Turn starting
switch ON
and check the
display of
meter.
in the
Measure
,esistancl
BVD00519
I
/
20-12
Between
Fuel level
(3) - chassis
Resistance
1 Approx.
82 kQ
l/10
Approx.
70 kR
Approx.
12 kQ
PARTS
Dl SAX-5
STANDARD
Syster n
VALUE
TABLE
Component
STANDARD
C:onnecto lr Inspeotior
No.
VALUE
Judgement
method
Measurement
condition
table

table
below,
Hydraulic oil
temperature
caution lamp
Vleasure
.esistancc
Yemale)
Ffleasure
IEmale)
r,esistancc
chassis
in the
it is normal
Lamp
goes
out
Be(Te_en At above 3.7 kn

Engine water
temperature
caution lamp
Lamp
flashes
At below 3.7 ka
If the condition
is as shown
Befy_en
At below
1 kQ
chassis
At above
1 MQ
in the
Lamp
goes out
Lamp
flashes
If the condition
is as shown
Battery
lamp
cahrgc
r/leasure
roltage
! I'I
PARTS
in the
21
% Lamp lights up when engine
is
stopped and flashes when engine
is being started.
If the condition
is as shown
in the
Turn starting
switch OFF
and insert
resistance.
2) Turn starting
switch ON
and check the
display of
meter.
I)
1) Turn starting
switch ON, or
run engine.
I) When starting
switch is
turned ON or
engine is running, measure
voltage and
check the display of lamp.
1 When
nAeasure
r esistance
% Lamp lights
stopped
is being
up
is
If the
is
in the
I) Turn
it
2
female)
n
r
At above
kn
At below
kQ
Lamp
or meas-
Lamp
Caution lamp and gauge

signal of 1 sensor.
use same
!) Turn
ON
and
of
lamp.
If
is
in the
it
i\
h
rl
of
t
D 155AX-5
) When starting
switch is
or
engine is run-
Sensor
signal
comes
in
lamp.
20-13
Systen
Component
onnectoi
No.
ispactior
method
Judgement
Vleasurement
condition
table

Preheating
pilot lamp
Pl
in the
) When starting
switch is
turned ON
or PREHEAT,
measure voltage and
check the display of lamp.
in the
) Turn starting
Vleasure
doltage

Power
supply
1
2
Measure
voltage
_I
Between
20 - 30 v
- P1(2),P2(4)1
If the condition
System
network
Measure
voltage
Vlachine
selection
1
imale)
Engine water
temperature
sensor
CN-402
(male)
below,
Between
is as shown
it is normal
(IO) - (4)
oil
sensor
Fuel level sensor
20-14
CN-453
(male)
CN-423
(male)
) Turn starting
switch ON.
9 lnntp:t-
in the
4-8V
If the condition
is as shown
in the
I) Turn starting
switch OFF.
!) Disconnect
conectors.
If the condition
is as shown
in the
1) Turn
Measure
.esistanct 1
starting
switch OFF.
2) Disconnect
conectors.
Measure
resistance 3
(I - 12) E+$;,m-!A,,,,,.
Transmission
temperature
ON.
PI (1) - chassis
Between PI(l)
1[able
switch
52 kQ,
1) Turn
If the condition
is as shown
in the
starting
switch OFF.
2) Disconnect
conectors.
If the condition
is as shown
in the
I) Turn starting
switch OFF.
:?) Disconnect
conectors.
Measure
resistancl e
Measure
resistant
D155AX-5
Systen 1
Component
IEngine
switch
oil pressure
Alternator
(Zonnector
No.
Inspection
method
Judgement
Measurement
condition
table
If the condition
is as shown
table below. it is normal
in the
1) Turn starting
switch OFF.
If the condition
is as shown
in the
1) Run engine.
(half throttle
or above)
CN-403
(male)
CN-112
Measure
voltage
Between terminal R chassis

*
27.5 - 29.5 V
If the battery is old, or after starting in cold area, the voltage may
not rise for some time.
If the condition
is as shown
Neutral
switch
safety
Blade pitch
solenoid
Pin puller
Dl MAX-5
solenoid
CN-152
(male)
CN-454
(male)
CN-246
(male)
Measure
resistance
Between
(1) - (3)
Lever at N or
FORWARD
$&RSE
in the
Min. IM Q
Max.
1 Q
1) Turn starting
switch OFF.
2) Disconnect
connectors.
3) Turn joystick
to directional
position
If the condition
is as shown
in the
1) Turn starting
switch OFF.
If the
in the
1) Turn starting
switch OFF.
Measure
resistance
condition
is as shown
Measure
resistance
20-15

System
Component
No.
method
Judgement table
Measure
resistance
Engine speed
sensor
Between (1) (2)
500 1000
Measurement
condition
1) Turn starting
switch OFF.
2) Disconnect
connector.
Between (1), (2) chassis Min.1 M
CN-E07
(male)

Measure
voltage
Between (1) (2)
0.5 3.0 V
1) Engine
running
2) Insert Tadapter.

voltage range.
1) Turn starting
switch ON.
2) Insert Tadapter.
Between (4) (1)
5.0 0.25 V
3) Turn joystick
to steering
Lever Between (3) (1) 4.15 0.25 V
position.
fully at
left
Between (2) (1) 0.85 0.25 V

Steering
potentiometer
CN-STR
Measure
voltage
Lever
at N
Between (3) (1) 2.5 0.25 V

Between (2) (1) 2.5 0.25 V
HSS system
Lever Between (3) (1) 0.85 0.25 V

fully at
right Between (2) (1) 4.15 0.25 V
REVERSE sensing
potentiometer
CN-RSS
Measure
voltage
Between (1) (3)

Lever at N
Lever at
REVERSE
Between
(2) (3)
5.0 0.25 V
Max. 3.5 V
3.5 4.4 V

pressure sensor A
CN-ST1
Measure
voltage
Between (2) (1)
20 30 V
CN-ST2
Measure
voltage
Between (2) (1)
20 30 V
CN-406
(male)
Measure
resistance
1) Turn starting
switch ON.
2) Insert Tadapter.

Steering relief
HSS charge circuit

oil pressure sensor
1) Turn starting
switch ON.
2) Insert Tadapter.

Steering relief

pressure sensor B
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Turn joystick
to directional
position.
Engine stopped
Between
(1) (2) Engine running
Min. 1 M
1) Turn starting
switch ON.
2) Disconnect
connector.
Max. 1
Between (1), (2) chassis Min. 1 M
20-16
4
D155AX-5
System
Component
No.
method
Measurement
condition
Judgement table
Work equipment
circuit oil pressure
sensor
CN-HHP
Measure
voltage
Between (2) (1)
20 30 V

(3) (1) Engine started + work 2.4 3.0 V
equipment relief
Backup alarm
switch
CN-251
(male)
Lever at N or
Measure
resistance Between FORWARD
(1) (3) Lever
at REVERSE
Min. 1 M
Max. 1

HSS pump
solenoid A
1) Turn starting
switch ON.
2) Insert Tadapter.
CN-PUPA Measure
resistance
Between (1) (2)
10 20
1) Turn starting
switch OFF.
2) Disconnect
connectors.
3) Turn joystick
to directional
position.
1) Turn starting
switch OFF.
2) Disconnect
connectors.

HSS pump
solenoid B
CN-PUPB Measure
resistance
Between (1) (2)
10 20
1) Turn starting
switch OFF.
2) Disconnect
connectors.
HSS system

Backup alarm relay
CN-014
(male)
Measure
resistance
Between (1) (2)
200 400
Between (3) (5)
Min. 1 M
Between (3) (6)
Max. 1

Power supply
for controller
CN-ST1
Measure
voltage
Between (8),(18) chassis
1) Turn starting
switch OFF.
2) Disconnect
connectors.
1) Turn starting
switch ON.
2) Insert Tadaper.
20 30 V
Between (8),(18) (9),(19)
HSS controller

Power supply
for solenoid
CN-ST1
Measure
voltage
Between (17) chassis
1) Turn starting
switch ON.
2) Insert Tadaper.
20 30 V
Between (17) (9),(19)
Net work
(S-NET)
CN-ST1
Measure
voltage

Between (1),(12) (9),(19)
48V

Engine speed
sensor
CN-ST3
Measure
voltage
Between (4) (12)
0.5 3.0 V
1) Turn starting
switch ON.
2) Insert Tadaper.
1) Engine
running
2) Insert Tadaper.

voltage range.
D155AX-5
20-17
4
System
Component
5-V power
supply for
potentiometer
No.
method
CN-ST2
Measure
voltage
Judgement table
Between (10) (9)
5.0 0.25 V

Lever Between (19) (9) 4.15 0.25 V
fully at
right Between (20) (9) 0.85 0.25 V
Steering
potentiometer
CN-ST2
Measure
voltage
Measurement
condition
1) Turn starting
switch ON.
2) Insert Tadaper.
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Turn joystick
to steering
position.
Between (19) (9) 2.5 0.25 V

Lever
at N Between (20) (9)
2.5 0.25 V
Lever Between (19) (9) 0.85 0.25 V
fully at
left Between (20) (9) 4.15 0.25 V
HSS controller
HSS system
Travel
REVERSE
sensing
potentiometer

CN-ST2
CN-ST3
Steering circuit
CN-ST2
oil pressure
CN-ST3
sensor A
Steering circuit
CN-ST2
oil pressure
CN-ST3
sensor B
HSS charge
oil pressure
sensor
Work
equipment
circuit oil
pressure
sensor
Measure
voltage
Between
CN-ST3(10) Lever at N
Lever
CN-ST2(9) at REVERSE
Max. 3.5 V
3.5 4.4 V

Measure
voltage
Between
CN-ST3(1) Engine stopped
Engine running +
CN-ST2(9) Steering relief
0.8 1.2 V
Between
CN-ST3(9) Engine stopped
Engine running +
CN-ST2(9) Steering relief
0.8 1.2 V
Measure
voltage
Between Engine stopped

(8)
chassis Engine running
20 30 V
Measure
voltage
Between
CN-CH2(2) Engine stopped 0.8 1.2 V
Engine running +
CN-CH1(9) Work equipment relief 2.4 3.0 V

Backup alarm
switch
20-18
4
CN-ST2
Measure
voltage
Between
(7)
chassis
Lever at N or
FORWARD
Lever
at REVERSE
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V

CN-ST2
CN-ST3
1) Turn starting
switch ON.
2) Insert Tadapter.
4.0 4.6 V

CN-ST2
1) Turn starting
switch ON.
2) Insert Tadapter.
4.0 4.6 V

Measure
voltage
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Turn joystick
to directional
position
20 30 V
Max. 1 V
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Turn joystick
to directional
position.
D155AX-5
System
Component
No.
method
Judgement table
Backup alarm
relay
CN-ST1
Measure
voltage
Between
(11)
chassis
Lever at N or
FORWARD
Lever
at REVERSE
Max. 1 V
20 30 V()
Voltage changes 20 30 V to below

1V alternatively every one second.
Buzzer cancel
switch 1
CN-ST2
Measure
voltage
Between Switch ON
ST2(6)
chassis Switch OFF
20 30 V
CN-ST2
Measure
voltage
Between Switch ON
ST2(5)
chassis Switch OFF
20 30 V
HSS controller
HSS system
Measure
voltage
Between Switch ON
ST2(18)
chassis Switch OFF
20 30 V
Measure
voltage
Between Switch ON
ST2(17)
chassis Switch OFF
20 30 V
CN-ST2
Measure
voltage
Between Switch ON
ST2(4)
chassis Switch OFF
20 30 V
CN-ST2
Measure
voltage
Between Lever at 3rd or

ST2(13) 2nd
chassis Lever at 1st
20 30 V
Max. 1 V

2nd switch
D155AX-5
CN-ST2
Measure
voltage
Between Lever at 1st or

ST2(14) 2nd
chassis Lever at 3rd
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V

1st switch
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V

Servise switch
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V

Mode selection
CN-ST2
switch 2
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V

Mode selection
CN-ST2
switch 1
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Turn joystick
to directional
position.
Max. 1 V

Buzzer cancel
switch 2
Measurement
condition
20 30 V
Max. 1 V
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Turn joystick
to 3rd or 2nd
position.
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Turn joystick
to 2nd or 1st
position.
20-19
4
System
Component
No.
method
Judgement table
Power train (Torque

converter) oil
temperature sensor
453
(male)
Measure
resistance
When water temperature is 100C

Between When water tem(1) (2) perature is 35C
Approx. 3.8 k
423
(male)
Measure
resistance
Between At full
(1) (2)
At empty
Approx. 29 k
Approx. 52 k
Approx. 80 k
Max.
approx. 12
Approx.
85 110

Alternator
ANB
Measure
voltage
Between terminal R
chassis
1) Turn starting
switch OFF.
2) Disconnect
conectors.
Approx. 4.9 k

Fuel level sensor
Measurement
condition
1) Turn starting
switch OFF.
2) Disconnect
conectors.
1) Run engine.
(half throttle
or above)
27.5 29.5 V
Monitor panel system
Hydraulic oil
temperature
sensor
Monitor panel (Caution module)
S-NET

CN1
CN1
Measure
resistance
Measure
voltage
Between
(5) (2)
When oil temperature

is below 105C
is abouve 105C
Max. 1 V
20 30 V

Between (11) (12) (10)
4.0 10.0 V

Power train
(Torque
converter) oil
temperature
sensor
CN1
(female)
CN2
(female)
Measure
resistance
Oil temperature:
50C (Level 1)
Oil temperature:
90C (Level 2)
Oil temperature:
Between 110C (Level 3)
CN2 (2) Oil temperature:
CN1 (2) 116C (Level 4)
Oil temperature:
120C (Level 5)
Oil temperature:
130C (Level 6)
Approx. 17 k
CN1
(female)
CN2
(female)
Measure
resistance
Between
CN2 (3)
CN1 (2)
20-20
4
1) Turn starting
switch OFF.
2) Disconnect
conectors.
Approx. 2.9 k
Approx. 2.5 k
Approx. 2.3 k
Approx. 2.3 k
Approx. 75 k
Level 3/7
Approx. 50 k
Level 5/7
Approx. 35 k
1) Insert Tadapter.
2) Turn starting
switch ON.
Approx. 5 k

Fuel level
sensor
1) Insert Tadapter.
2) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
conectors.
Approx. 14 k
D155AX-5
System
Component
No.
method
Judgement table
Monitor panel (Caution module)
Preheating
signal
CN1
CN2
Measure
voltage
Between
CN2 (5)
CN1 (2)
When preheater is
turned ON
When preheater is
turned OFF
20 30 V
CN1
CN2
Measure
voltage
Between
CN2 (7)
CN1 (2)
When lamp is
turned ON
When lamp is
turned OFF
Max. 6 V
Measure
voltage
Between
CN2 (8)
CN1 (2)
When buzzer is
turned ON
When buzzer is
turned OFF
Max. 3 V
Monitor pannel system
Backup power
source
CN4
T01
Monitor panel (Tachometer module)
Starting switch
T01
ON signal
Measure
voltage
Measure
voltage
Measure
voltage
Between
(1) (2)
When lamp switch

is turned OFF
When lamp switch
is turned ON
Max. 1 V
20 30 V

Between (1) (2)
20 30 V

Starting switch
T01
STAR signal
Measure
voltage
Between
(3) (2)
When starting switch

is at ON position
is at START position
T01
Measure
voltage
Between
(4) (2)
While engine is
stopped
While engine is
running
S-NET
D155AX-5
T01
T01
Measure
voltage
Measure
voltage
Between
(5) (2)
When switch is
turned OFF
When switch is
turned ON
1) Insert Tadapter.
1) Insert Tadapter.
Max. 1 V
27.5 29.5 V
20 30 V
1) Insert Tadapter.
2) Turn starting
switch ON.
Max. 1 V

Between (9) (10) (8)
1) Insert Tadapter.
2) Turn starting
switch ON.
20 30 V

Service switch
1) Insert Tadapter.
2) Turn starting
switch OFF.
Max. 1 V

Alternator
1) Insert Tadapter.
2) Turn starting
switch ON.
20 30 V

Between (7) (2)
1) Insert Tadapter.
2) Turn starting
switch ON.
20 30 V

Lighting signal
1) Insert Tadapter.
2) Turn starting
switch ON.
20 30 V

CN1
Caution Buzzer CN2
1) Insert Tadapter.
2) Turn starting
switch ON.
Max. 1 V

Caution lamp
Measurement
condition
4.0 10.0 V
1) Insert Tadapter.
2) Turn starting
switch ON.
20-21
4
System
Monitor panel (switch module)
Component
No.
method
Measurement
condition
Judgement table
Between (1) (2)
Power sorce
S01
Measure
voltage
20 30 V

Hydraulic oil temperature sensor
452
(male)
Measure
resistance
Between
(1)
chassis

is below 105C
is abouve 105C
Max. 1
Monitor panel (caution module)
Measure
resistance
Between (1) (2)
OFF
ON
Between (2) (3)
Max.1
Min.1 M
Between (3) (4)
Min.1 M
Max.1
Between (4) (5)
Max.1
Min.1 M
Between (5) (6)
Min.1 M
Max.1

Ribbon heater relay
20-22
X1
Power sorce
HET
(male)
CN1
Measure
resistance
Measure
voltage
Between (1) (2)
200 400
Between (3) (5)
Min.1 M
Between (3) (6)
Max.1

Between (1) (2)
4.0 10.0 V

Starting switch
CN1
START signal
Measure
resistance
Between
(3) (2)

is at ON position
is at START position
CN1
Measure
voltage
Between
(4) (2)
While engine is
stopped
While engine is
running
1) Turn starting
switch OFF.
2) Disconnect
conectors.
1) Turn starting
switch OFF.
2) Disconnect
conectors.
1) Insert Tadapter.
2) Turn starting
switch ON.
1) Insert Tadapter.
Max. 1
20 30 V

Alternator
1) Turn starting
switch OFF.
2) Disconnect
conectors.
Nin. 1 M

Service switch
1) Insert Tadapter.
2) Turn starting
switch ON.
1) Insert Tadapter.
Max. 1 V
27.5 29.5 V
D155AX-5

Tools for testing, adjusting, and troubleshooting ................................................................................ 20-102
Measuring engine speed ........................................................................................................................ 20-103
Measuring intake air pressure (boost pressure) ................................................................................... 20-104
Measuring exhaust temperature ............................................................................................................ 20-105
Measuring exhaust color ........................................................................................................................ 20-106
Adjusting valve clearance ....................................................................................................................... 20-107
Measuring compression pressure ......................................................................................................... 20-108
Measuring blow-by pressure ................................................................................................................. 20-109
Measuring engine oil pressure .............................................................................................................. 20-110
Testing and adjusting fuel injection timing .......................................................................................... 20-111
Handling equipment in fuel circuit ..................................................................................................... 20-111-1
Rereasing remaining pressure in fuel system ................................................................................... 20-111-1
Measuring fuel pressure ...................................................................................................................... 20-111-2
Reduced cylinder mode operation ...................................................................................................... 20-111-3
Bleeding air from fuel system ............................................................................................................. 20-111-5
Check for leakage in fuel system ........................................................................................................ 20-111-6
Testing and adjusting alternator belt tension ....................................................................................... 20-112
Testing and adjusting air conditioner compressor belt tension ...................................................... 20-112-1
Testing and adjusting fun belt tension ............................................................................................... 20-112-2
Adjusting engine speed sensor .............................................................................................................. 20-113
Handling controller high voltage circuit ............................................................................................. 20-113-1
Adjusting fuel control lever and decelerator pedal .............................................................................. 20-114
Measuring torque converter stall speed ............................................................................................... 20-117
Measuring full stall speed ...................................................................................................................... 20-118
Measuring power train oil pressure ...................................................................................................... 20-119
Testing and adjusting HSS main oil pressure ...................................................................................... 20-122
Testing and adjusting HSS charge oil pressure ................................................................................... 20-124
Testing and adjusting HSS servo charge pressure and PPC relief pressure ...................................... 20-126
Bleeding air from HSS pump ................................................................................................................. 20-128
Simple procedure for testing brake performance ................................................................................ 20-129
Adjusting joystick and parking lever ..................................................................................................... 20-130
Testing and adjusting travel reverse sensing potentiometer .............................................................. 20-133
Adjusting travel reverse limit switch ..................................................................................................... 20-134
Adjusting steering neutral position ....................................................................................................... 20-135
Procedure for operating emergency steering switch ........................................................................... 20-139
Adjusting initial current in HSS steering system ............................................................................... 20-140-3
Adjusting brake pedal ............................................................................................................................. 20-141
Adjusting clearance of idler .................................................................................................................... 20-143
Testing wear of sprocket ........................................................................................................................ 20-144
Testing and adjusting track shoe tension ............................................................................................. 20-145
Testing and adjusting hydraulic pressure ............................................................................................. 20-146
Measuring PPC valve output pressure .................................................................................................. 20-148
Adjusting play of PPC valve ................................................................................................................... 20-150
Measuring solenoid valve output pressure .......................................................................................... 20-151
Testing location causing hydraulic drift of blade and ripper ............................................................... 20-152
Measuring leakage inside hydraulic cylinder ....................................................................................... 20-153
Releasing remaining oil pressure in hydraulic cylinder ....................................................................... 20-154
Bleeding air from hydraulic cylinder ..................................................................................................... 20-154
Adjusting work equipment safety lever ................................................................................................ 20-155
Adjusting semi-U tiltdozer ...................................................................................................................... 20-156
D155AX-5
20-101
4
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Check or measurement item Symbol
Engine speed
Air supply pressure

(boost pressure)
Temperature of water, oil ,
and exhaust gas
Exhaust color
799-203-8001
Multi-tachometer
799-201-2202
Boost gauge kit
101 199.9kPa{750 1,500mmHg}
799-101-1502
Digital thermometer
99.9 1299C
799-201-9000
Handy smoke checker
Commercially
available
795-125-1210
Smoke meter
Discoloration 0 70 % (with
standard color)
(Discoloration x 1/10 = Bosch
index)
1
Feeler gauge
SA6D140E-2 Intake valve: 0.43mm,

Exhaust valve: 0.80mm
SA6D140E-3 Intake valve: 0.35mm,
Exhaust valve: 0.57mm
795-502-1205
Compression gauge
0 6.9MPa {0 70kg/cm2}
795-502-1510
Adapter
795-502-1520
Plate
799-201-1504
Blow by checker
0 4.9MPa {0 500mmH2O}
799-101-5002
Hydraulic tester
Pressure gauge: 2.5,5.9,39.2,58.8MPa

{25,60,400,600kg/cm2}
790-261-1203
Digital hydraulic tester
Pressure gauge: 58.8MPa{600kg/cm2}
799-101-5220
Nipple
07002-11023
O-ring
799-401-2320
Hydraulic gauge
791-627-1160
Wear gauge
79A-264-0021
Push-pull scale
0 294N {0 30kg}
0 490N {0 50kg}
Commercially
available
Blow-by pressure
Remarks
Digital display L : 60 2,000rpm
H : 60 19,999rpm
Valve clearance
Part Name
Part No.
1
Oil pressure
2
Wear of sprocket
Operating effort
K
79A-264-0091
Push-pull scale
Scale
Stroke, hydraulic drift
Work equipment speed
Commercially
available
Commercially
available
Measuring voltage and

resistance
79A-264-0211
Tester
Troubleshooting of
wiring harnesses
799-601-8000
T-adapter
P
799-601-7360
Adapter
10 x 1.25
0.98MPa {10kg/cm2}
Stop watch
For 5 pins relay
1: SA6D140E-2 engine
20-102
4
D155AX-5
MEASURING ENGINE SPEED

Serial No. 70001 75000
Be
careful not to touch any hot parts when removing or installing the measuring tools.
Measure the engine speed under the following

conditions.
Coolant temperature: Within operating range
Transmission oil temperature: Within operating range
Hydraulic temperature: 45 55C
1. Remove cap (1) of the speed pickup port.
2. Install sensor 1 of multi-tachometer A to the
speed pickup port, then connect to multi-tachometer A.
3. Start the engine and measure the engine speed
under the following conditions.
1) Measurement at low idling:
i) Set the joystick and work equipment control lever to the neutral position.
ii) Set the fuel control lever to the low idling
position, then measure the engine speed.
2) Measurement at high idling
i) Set the joystick and work equipment control lever to the neutral position.
ii) Set the fuel control lever to the high
idling position, then measure the engine
speed.
When measuring the stall speed of torque converter and speed to stall the torque converter
and relieve the work equipment pump, see the
measurement procedure for them.
TLD00010
D155AX-5
20-103
4

Measure the engine speed in the monitoring
mode and adjusting mode of the monitor panel.
For the general explanation of the monitoring
mode and adjusting mode, see DISPLAY AND
SPECIAL FUNCTIONS OF MONITOR PANEL in
TROUBLESHOOTING.
1. Measuring low idling speed and high idling
speed
1) Remove cover (1).
2) Turn starting switch ON.
3) Turn service switch (2) ON.
The service switch is installed inside the
cover.
4) Turn and hold buzzer cancel switch (3) to
the right for at least 7 seconds to display the
service mode in upper display unit (4).
5) Turn up mode selector switch (5) to display
the monitoring mode.
The mode selector switch is installed inside the cover.
Each time the mode selector switch is
turned up, the mode changes.
If the monitoring mode is selected, round
mark (6) on the left side lights up.
6) Turn buzzer cancel switch (3) to the right to
display "99".
7) Start the engine and read its speed under
the following conditions indicated in lower
display unit (7) of the panel.
The engine speed is indicated by the unit
of rpm.
i) Measuring low idling speed:
Set the joystick and work equipment control lever in neutral and set the fuel control dial in the low idling position.
20-103-1
4
D155AX-5
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
ii) Measuring high idling speed:

Set the joystick and work equipment control lever in neutral and set the fuel control dial in the high idling position.
8) After measuring the engine speed, turn OFF
service switch (2) and set the panel to the
ordinary mode.
9) Install cover (1).
D155AX-5
20-103-2
4

Serial No. 70001 75000
Be
Measure the intake air pressure under the following conditions.

Hydraulic temperature: 45 55 C
1. Remove intake air pressure pickup plug (1) (PT1/
8).
2. Install nipple 1 of oil pressure gauge H1, then
connect to boost gauge B.
3. Start and run the engine at a middle or higher
speed to drain oil from the hoses.
Insert the connecting part of the hose in the
pressure gauge halfway and open the selfsealing part on the hose side repeatedly to
drain the oil.
If Pm kit (A) is available, the air bleeding
coupling (790-261-113) in it may be used.
If any oil remains in the hoses, the gauge
does not operate. Accordingly, drain the oil
without fail.
4. Run the engine at high idling and stall the torque
converter, and measure the intake air pressure
(boost pressure) at this time.
For the procedure to stall the torque converter, see MEASURING TORQUE CONVERTER STALL SPEED.
The normal intake air pressure (boost pressure) must be measured while the machine
is operating at the rated output. An approximate value can be obtained in the field,
however, by measuring when the torque
converter stalls.
20-104
4
D155AX-5
Be
Measure the intake air pressure under the following conditions.

1. Remove intake air pressure pickup plug (1) (PT1/
8).
2. Install nipple 1 of boost gauge kit B, then connect to boost gauge kit.
3. Start and run the engine at a middle or higher
speed to drain oil from the hoses.
Insert the connecting part of the hose in the
pressure gauge halfway and open the selfsealing part on the hose side repeatedly to
drain the oil.
If Pm kit (A) is available, the air bleeding
coupling (790-261-113) in it may be used.
If any oil remains in the hoses, the gauge
does not operate. Accordingly, drain the oil
without fail.
converter, and measure the intake air pressure
(boost pressure) at this time.
The normal intake air pressure (boost pressure) must be measured while the machine
is operating at the rated output. An approximate value can be obtained in the field,
however, by measuring when the torque
converter stalls.
D155AX-5
20-104-1
4
20-104-2
4
(Blank page)
D155AX-5
MEASURING EXHAUST TEMPERATURE

Serial No. 70001 75000
Install
or remove the temperature sensor after

the exhaust manifold is cooled.
Measure the exhaust temperature under the following conditions.

1. Remove the turbocharger heat insulation cover.
TLD00030
2. Remove exhaust temperature pickup plug (1)

(PT1/8).
3. Install sensor 1 of digital thermometer C, then
connect to digital thermometer C.
Clamp the harness of the thermometer so
that it will not touch the hot parts during
measurement.
4. Measure the maximum exhaust temperature

while the machine is actually operating at high
idling.
Use the PEAK mode of the digital thermometer.
The exhaust temperature largely depends on
the ambient air temperature (intake air temperature of the engine). Accordingly, if any
abnormal value is obtained, carry out temperature compensation by the following calculation.
Compensation value [C] = Measured
value + 2 x (20 Ambient air temperature)
D155AX-5
20-105
4
Install
or remove the temperature sensor after

the exhaust manifold is cooled.
Measure the exhaust temperature under the following conditions.

1. Remove the turbocharger heat insulation cover.
2. Remove exhaust temperature pickup plug (1).
3. Install sensor 1 of digital thermometer C, then
connect to digital thermometer C.
Clamp the harness of the thermometer so
that it will not touch the hot parts during
measurement.
4. Measure the maximum exhaust temperature

while the machine is actually operating at high
idling.
Use the PEAK mode of the digital thermometer.
The exhaust temperature largely depends on
the ambient air temperature (intake air temperature of the engine). Accordingly, if any
abnormal value is obtained, carry out temperature compensation by the following calculation.
Compensation value [C] = Measured
value + 2 x (20 Ambient air temperature)
20-105-1
4
D155AX-5
D155AX-5
MEASURING EXHAUST COLOR
(Blank page)
20-105-2
4

Be
When measuring in the field where there is no

air or electric power supply, use Handy Smoke
Checker D1; when recording formal data, use
Smoke Meter D2.
Raise the coolant temperature to the operating range before measuring.
1. Measuring with Handy Smoke Checker D1

1) Install filter paper to Handy Smoke Checker
D1.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle of Handy Smoke
Checker D1 at the same time to collect the
exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
2. Measuring with Smoke Meter D2
1) Insert the probe 1 of Smoke Meter D2 into
the outlet port of the exhaust pipe, and
tighten the clip to secure it to the exhaust
pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter D2.
Keep the pressure of the air supply below 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC100V
socket.
When connecting the cord, check that
the power switch of Smoke Meter D2 is
OFF.
4) Loosen the cap nut of the suction pump,
and fit the filter paper.
Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter D2
ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter D2 at
the same time to collect the exhaust gas
color on the filter.
7) Place the filter paper used to catch the exhaust has color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
20-106
4
D155AX-5
ADJUSTING VALUE CLEARANCE
ADJUSTING VALVE CLEARANCE

Serial No. 70001 75000
1. Remove the cylinder head cover.
For details, see REMOVAL OF CYLINDER
HEAD ASSEMBLY.
2. Rotating the crankshaft in the normal direction
and watching the movement of the valve, align
the 1.6 TOP line (2) on the crank pulley with
pointer (1) to set the No. 1 cylinder to compression top dead center.
When the No. 1 cylinder is at the compression top dead center, the rocker arms on
both intake side and exhaust side can be
moved with the hand. If the rocker arms
cannot be moved, the cylinder is not at the
compression top dead center. In this case,
rotate the crankshaft one more turn and
align the 1.6 TOP line.
Crank the engine with the hexagon shaft of
the water pump pulley.
3.
When No. 1 cylinder is at the compression top

dead center, adjust the valves marked in the
table of locations of valves. Next, rotate crankshaft by 360 in the normal direction and adjust
the valve clearance of the remaining valves
marked .
4. To adjust the clearance, insert feeler gauge E

between rocker arm (3) and crosshead (4), and
adjust with adjustment screw (5), then secure it
with locknut (6).
9 Locknut: 45.1 51.0Nm {4.6 5.2kgm}
After adjusting the No. 1 cylinder at the compression top dead center, it is also possible to
turn the crankshaft 120 each time and adjust
the clearance of the valves of each cylinder according the firing order.
Firing order: 1-5-3-6-2-4
After tightening the locknut, check the clearance again.
D155AX-5
20-107
4
ADJUSTING VALVE CLEARANCE

1. Remove cylinder head cover (1).
See REMOVAL OF CYLINDER HEAD ASSEMBLY in DISASSEMBLY AND ASSEMBLY.
2. Rotate the crankshaft in the normaI direction to
set No. 1 cyIinder at compression top dead
center, and aIign pointer (2) with the [1.6] mark
a on the damper.
Crank the crankshaft with the hexagonaI portion at the tip of the water pump drive shaft.
At compression top dead center, the vaIve
rocker arm can be moved by hand by the
amount of the vaIve clearance. If the rocker
arm does not move, the crankskaft is not at
compression dead center, so rotate it one
more turn.
3. To adjust the valve clearance, insert the feeler
gauge into clearance b between rocker arm (3)
and crosshead (4), and adjust the valve clearance with adjustment screw (5).
IInsert the feeler gauge and turn adjustment
screw (5) until the clearance is a sliding fit.
Valve clearance Intake valve: 0.35 mm
Exhaust valve: 0.57 mm
4. Tighten locknut (6) to hold adjustment screw (5)
in position.
3 Locknut: 53.0 64.7 Nm {5.4 6.6 kgm}
After tightening the locknut, check the clearance again.
5. Turn the crankshaft 120 each time in the normal direction and repeat the procedure in Step
2 to 4 to adjust the valves of each cylinder according to the firing order.
Firing order: 153624
6. After completing the measurement, set to the
original condition.
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
20-107-1
4
D155AX-5
D155AX-5
(Blank page)
20-107-2
4
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

Serial No. 70001 75000
When measuring the compression pressure, be

careful not to touch the exhaust manifold or any
other hot parts or get caught in the fan belt or
any other rotating parts.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine so that the oil temperature
is 40 60C.
3. Remove the nozzle holder assembly from the
cylinder to be measured.
For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
4. Set multi-tachometer A.
For details, see MEASURING ENGINE SPEED.
5. Install adapter 1 of compression gauge F to the
nozzle holder mount, then connect to compression gauge F.
6. Set the fuel control lever to the STOP position.
7. Crank the engine with the starting motor and
measure the compression pressure.
Measure the compression pressure at the
point where the pressure gauge indicator
remains steady.
When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
MEASURING COMPRESSION
PRESSURE
Serial No.: 75001 and up
For the method of measuring the compression
pressure, see the Engine Shop Manual for the
140-3 Series.
20-108
4
D155AX-5
MEASURING BLOW-BY PRESSURE

Serial No. 70001 75000
Measure the blow-by pressure under the following conditions.
1. Install nozzle (1) of blow-by checker G to blowby hose 1.
2. Connect nozzle 1 to blow-by checker G.
converter, and measure the gauge value at this
time.
The normal blow-by pressure must be measured while the machine is operating at the
rated output. An approximate value can be
obtained in the field, however, by measuring when the torque converter stalls.
If it is impossible to check at the rated output or at the torque converter stall speed,
measure with the engine at high idling.
In this case, the blow-by value will be about
80% of the value at the rated output.
Blow-by varies greatly according to the condition of the engine. Therefore, if the blowby value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defective exhaust gas color, and prematurely dirty
or deteriorated oil.
D155AX-5
20-109
4

Measure the blow-by pressure under the following conditions.
1. Remove blow-by tube (1).
If a hose is connected to the end of the
blow-by tube, it does not need to be removed since the blow-by pressure is measured at the end of that hose.
2. Install nozzle 1 of blow-by checker G, then connect it to the blow-by checker.
converter, and measure the gauge value at this
time.
The normal blow-by pressure must be measured while the machine is operating at the
rated output. An approximate value can be
obtained in the field, however, by measuring when the torque converter stalls.
If it is impossible to check at the rated output or at the torque converter stall speed,
measure with the engine at high idling.
In this case, the blow-by value will be about
80% of the value at the rated output.
Blow-by varies greatly according to the condition of the engine. Therefore, if the blowby value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defective exhaust gas color, and prematurely dirty
or deteriorated oil.
20-109-1
4
D155AX-5
D155AX-5
MEASURING ENGINE OIL PRESSURE
(Blank page)
20-109-2

Serial No. 70001 75000
Measure the engine oil pressure under the following conditions.
1. Remove engine oil pressure pickup plug (1) (PT1/

8).
2. Install nipple 1of oil pressure gauge H1, then

connect to oil pressure gauge H2 (0.98MPa
{10kg/cm2}).
3. Start the engine, and measure the oil pressure

with the engine at low idling and high idling.
20-110
4
D155AX-5

Measure the engine oil pressure under the following condition.
Engine water temperature: Within operating
range
1. Remove oil pressure low-pressure switch (1) or
oil pressure high-pressure switch (2).
Wrap the wiring harness of the disconnected
switch with tape to prevent it from touching
the cylinder block.
2. Install nipple 1 of oil pressure gauge H1 and

connect it to the oil pressure gauge H2 (0.98
MPa {10 kg/cm2}).
3. Start the engine and measure the oil pressure
when the engine is running at low idling and
high idling.
4. After completing the measurement, remove the
measurement equipment and set to the original
condition.
3 Oil pressure switch:
2.9 5.9 Nm {0.3 0.6 kgm}
D155AX-5
20-110-1
4
20-110-2
(Blank page)
TESTING AND ADJUSTING FUEL INJECTION TIMING
D155AX-5

Serial No. 70001 75000
Testing
1. Rotate the crankshaft in the normal direction
and align 15 line (2) on the crankshaft pulley
with pointer (1).
At this time, check that line (3) on the coupling is near line (4) on the injection pump
body. If line (3) on the coupling is not seen,
rotate the crankshaft one more turn.
Crank the engine with the hexagon shaft of
the water pump pulley.
2. Remove the lock pin of timing pin (5) and push
in the pin to fix the injection pump drive gear.
If the pin does not go in, turn the crankshaft
forward or backward a little.
3. Under this condition, check that coupling line
(3) is aligned with injection pump line (4).
Adjusting
If the fuel injection timing is not correct, adjust
it according to the following procedure.
1. Loosen the two sets of mounting bolt and nut
(6) in the oblong holes of the coupling and set
bolt (7) to set the coupling free.
2. Turn the coupling to align coupling line (3) with
injection pump line (4).
3. Tighten set bolt (7) and the two sets of mounting bolt and nut (6).
9 Set bolt: 83.8 93.1Nm {8.5 9.5kgm}
Mounting bolt and nut:
58.5 63.7Nm {6.0 6.5kgm}
4. Pull out the pin of timing pin (5) and secure with
the lock pin.
If the injection pump drive system (crank gear injection pump shaft) is disassembled and assembled without removing the engine from the
machine body, the injection timing must be adjusted accurately from the piston stroke. In this
case, see the Engine Shop Manual.
Since the match mark on the timing gear case is
matched to the key way of the supply pump
drive shaft, ADJUSTMENT OF FUEL INJECTION
TIMMING is not necessary.
D155AX-5
20-111
4
HANDLING EQUIPMENT IN FUEL CIRCUIT

RELEASING REMAINING PRESSURE IN FUEL SYSTEM
HANDLING EQUIPMENT IN
FUEL CIRCUIT
RELEASING REMAINING
PRESSURE IN FUEL SYSTEM
Precaution for inspection and maintenance

of fuel system
With the common rail type fuel injection system, more precise equipment is used than
with the conventional fuel injection pump
and nozzle, so problems may occur if dirt or
dust get in.
When carrying out installation and maintenance of the fuel system, pay more attention
than usual to prevent dirt or dust from getting in. If there is any dirt stuck to any part,
use clean fuel to wash it off completely.
Precautions when replacing fuel filter cartrige
Always use a genuine Komatsu part for the
fuel filter cartrige.
With the common rail type fuel injection system, mpre precise equipment is used than
with the conventional fuel injection pump
and nozzle, so a special filter with high efficiency filtering ability is used to prevent dirt
or dust from getting in.
For this reason, if any filter is used as a
substitute for the genuine filter, there is danger that problems will occur with the fuel
system. To prevent this, never use such filters.
When the engine is running, pressure is generated in both the low-pressure circuit and
hifg-pressure circuit of the fuel line.
Low-pressure circuit: Feed pump fuel filter
fuel supply pump
High-pressure circuit: Fuel supply pump common rail fuel injector
For both the low-pressure circuit and highpressure circuit, the pressure automatically
goes down to a safe level 30 seconds after
the engine is stopped.
The ramaining pressure in the fuel system
must be completely released before carrying
out inspection of the fuel system or removal
or installation of the equipment. Always follow the following precautions when carrying
out the operation.
When inspecting the fuel line or removing or
installing equipment, wait for at least 30 seconds after the engine is stopped to release
the remaining pressure in the fuel system
before starting the operation. (There is still
pressure remaining in the circuit, so do not
start operations immediately after the engine
is stopped).
20-111-1
4
D155AX-5
MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE

Measure the fuel pressure only for the low-pressure circuit between the feed pump fuel filter
fuel supply pump.
The high-pressure circuit between the fuel supply pump common rail fuel injector is under
extremely high pressure, so it cannot be measured.
1. Remove fuel pressure measurement plug (1).
2. Fit nipple 1 of pressure test kit A,then connect
to the pressure test kit.
3. Start the engine and measure the fuel pressure
at high idling.
4. After completing the measurement, remove the
measurement equipment and set to the original
condition.
D155AX-5
20-111-2
REDUCED CYLINDER MODE OPERATION

Reduced cylinder mode operation means to run the engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder
which does not output power normally (or, combustion in it is abnormal). (For details, see the
Engine Shop Manual for the 140-3 Series, too.)
Perform the reduced cylinder mode operation by using the setting functions of the "reduced
cylinder mode" of the monitor panel.
For details of the functions of the monitor panel, see DISPLAY AND FUNCTIONS OF MONITOR
PANEL in TROUBLESHOOTING.
1. Selecting of reduced cylinder mode
cover.
the adjustment mode.
If the adjustment mode is selected, round
marks (6) on the right and left sides light
up.
display reduced cylinder mode "E0".
2. Method of performing reduced cylinder mode
operation
1) After adjustment mode "E0" is displayed in
gear speed display unit (4), turn buzzer cancel switch (3) to the left to select an injector
to be disabled.
The flashing bit display unit indicates
each injector No.
1: No. 1 injector
2: No. 2 injector
3: No. 3 injector
4: No. 4 injector
20-111-3
4
D155AX-5
2)
3)
4)
5)
5: No. 5 injector
6: No. 6 injector
The injectors are selected in the order of
1 2 6 1.
After selecting 1 or more injectors to be disabled with buzzer cancel switch (3), turn down
mode selector switch (5).
The flashing speed rises and the selected
injector(s) is (are) disabled and the bit
display unit goes off.
To reset (operate) the disabled injector(s),
turn down mode selector switch (5) again.
The flashing speed becomes normal and
the selected injector(s) start(s) operating
again.
If the system goes out of this mode, the
reduced cylinder mode operation is reset.
Turn OFF service switch (2).
Install cover (1).
D155AX-5
20-111-4
4
BLEEDING AIR FROM FUEL SYSTEM
BLEEDING AIR FROM FUEL SYSTEM

Bleed the air as follows if the engine has run

out of fuel or the fuel circuit equipment has
been removed and installed.
1. Remove fuel filter (1), fill with fuel, then install again.
When filling, use clean fuel and be careful not to let dirt get in.
If clean fuel is not available, do not remove the filter. Operate the priming pump
to fill the inside of the filter with fuel.
2. Remove air bleed plug (2) of the fuel filter
and operate priming pump (3).
Continue operating the priming pump
until fuel flows out from the pump hole.
When fuel comes out, install the plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}
20-111-5
4
3. Loosen air bleeder (4) of the fuel supply pump

and operate priming pump (3) 90 100 times.
Operate the priming pump until fuel flows
out from the bleeder. When the fuel flows
out, tighten the bleeder, then operate the
priming pump several times until the
pump becomes stiff.
3 Air bleeder:
4.9 6.9 Nm {0.5 0.7 kgm}
4. Crank the engine with the starting motor and
start the engine.
When the high-pressure circuit is cranked
with the engine, the air is automatically
bled.
If the engine does not start, the air has
probably not properly bled from the lowpressure circuit, so repeat the procedure
from Step 2.
D155AX-5
CHECK FOR LEAKAGE IN FUEL SYSTEM
CHECK FOR LEAKAGE IN

FUEL SYSTEM
With
the fuel system, the high-pressure circuit is under extremely high pressure, so if
fuel leaks when the engine is running, there
is danger of fire.
Check for fuel leakage as follows when checking the fuel circuit or when equipment has
been removed and installed.
To make it easier to check for fuel leakage,
wipe the engine itself and the surrounding
area clean and remove all oil and grease
before starting the inspection.
9. Check the fuel piping and equipment for fuel

leakage.
Check the high-pressure circuit for fuel
leskage, particularly at the places sprayed
with color checker.
If there is fuel leakage, carry out repairs,
then repeat the check from Step 2.
If no fuel leakage is found, the check is
complete.
1. Spray the fuel supply pump, common rail,

fuel injector, and high-pressure piping connections witha color checker (developing solution).
2. Start the engine, run it at under 1000 rpm,
and when the speed stabilizes, stop the engine.
leakage.
leskage, particularly at the places sprayed
with color checker.
4. Start the engine and run it as low idling.
leakage.
leakage, paticularly at the places sprayed
with color checker.
6. Start the engine and run it at high idling.
leakage.
leakage, particularly at the places sprayed
with color checker.
8. Start the engine, run it at high idling, then
apply load to the engine.
If this inspection is carried out with the
engine mounted on the machine, stall the
torque converter or relieve the hydraulic
pump.
D155AX-5
20-111-6
4
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION

Serial No. 70001 75000
Testing
Measure deflection a of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
alternator pulley and the water pump pulley.
Deflection a of V-belt: approx. 15 mm
Adjusting
If the deflection of the belt is not normal, adjust
1. Loosen mounting bolt and nut (1), mounting
bolt (2) and locknut (3).
2. Turn the adjustment nut and shift alternator (4)

to adjust the belt tension.
3. Tighten locknut (3), mounting bolt (2), and

mounting bolt and nut (1).

1. Inspecting
Measure deflection a when the belt is pressed
with a finger at a point midway between the
alternator pully and drive pully.
Pushing force:
Approx. 98 Nm {approx. 10 kg}
Deflection (one belt): 13 16 mm
2. Adjusting
This makes a clearance of 0.75 1.00 mm
between the tip of the sensor and the tip of
the gear tooth.
If the deflection is not within the specified
range, adjust as follows.
1) Loosen 2 mounting bolts of alternator (1)
and 1 lock bolt of the bar.
2) Loosen locknut (2), move alternator (1) with
adjustment nut (3), adjust the tension of belt
(4).
Deflection (one belt): 13 16 mm
20-112
4
D155AX-5
TESTING AND ADJUSTING AIR CONDITIONER

COMPRESSOR BELT TENSION
3) Tighten locknut (2).

4) Tighten 2 mounting bolts of alternator
(1) and 1 lock bolt of the bar.
After adjusting, check the belt tension
again.
TESTING AND ADJUSTING AIR

CONDITIONER COMPRESSOR
BELT TENSION
Testing
Measure deflection a of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
fan pulley and tension pulley.
Deflection a of V-belt: approx. 10 mm
Adjusting
If the deflection of the belt is not normal, adjust
1. Loosen four mounting bolts (4) and locknut (2).
2. Turn adjustment bolt (3) and shift air conditioner
compressor assembly (4) to adjust the belt tension.
3. Tighten locknut (2) and four mounting bolts (1).
D155AX-5
20-112-1
4
TESTING AND ADJUSTING FUN BELT TENSION
TESTING AND ADJUSTING FUN BELT TENSION

1. Inspection
With the semi auto tension type, there is no
need to inspect untill the belt is replaced.
2. Adjusting
1) Install 2 belts (1).
Loosen the stopper bolt when installing
the belts.
2) Tighten stopper bolt (2) until it contacts
bracket (3).
3) Tighten stopper bolt (2) a futher 2 turns and
hold in position with locknut (4).
3 Locknut:
245.0 308.7 Nm {35.0 31.5 kgm}
20-112-2
4
D155AX-5
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

1. Screw in sensor unit (1) until its end comes in
contact with ring gear (2).
Take care that sensor end will be free from
steel chips and will not be damaged.
8 Threads of sensor:
Gasket sealant (LG-6)
2. Unscrew sensor unit (1) by 1/2 2/3 turns from
the position where it comes in contact with ring
gear (2) to adjust clearance a.
Clearance a: 0.75 1.0mm
3. Tighten locknut (3).

9 Locknut: 69 74Nm {7.0 7.5kgm}
Install the sensor wiring carefully so that an excessive force will not be applied to it.
D155AX-5
20-113
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT
HANDLING CONTROLLER HIGH

VOLTAGE CIRCUIT
With the controller, a high voltage circuit (110

130V) is used for the fuel injector drive.As a result, a high voltage circuit is connected to the
wiring harness and connector from the controller to the fuel injector.
Normally, high voltage is output from the controller to the fuel injector only when the engine
is running. When the engine is stopped, the output stops.
If the high voltage circuit is touched directly,
there is danger of electrocution, so observe the
following precautions when carrying out inspection.
1. The connectors, including these for the high
voltage circuit, are as follows.
Controller connector: CN6, CN7
Intermediate connector: CN-E31, CN-E32, CNE33, CN-E34, CN-E35, CN-E36
Injector connector: IJ1, IJ2, IJ3, IJ4, IJ5, IJ6
Terminal at head of injector (inside head
cover)
2. When disconnecting or connecting the applicable connector, always turn the starting switch
OFF before starting.
3. When a T-adapter has been inserted or connected to the applicable connector to carry out
troubleshooting, never start the engine.
If the starting switch is operated, operate it
only to OFF or ON. Never turn it to the START
position.
20-113-1
4
D155AX-5
D155AX-5
(Blank page)
20-113-2
4
ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL

Serial No. 70001 75000
20-114
4
D155AX-5
1. Outline of fuel control system

The speed signals from the fuel control dial
and the decelerstor pedal potensiometers are
each input to the engine controller.
The engine controller gives priority to the
lower speed of the two input signals and
sends a command to the fuel injection pump.
Adjustment of the engine speed is all carried out by the deceletator pedal linkage.
2. Preparatory work
1) Turn the starting switch on and the monitor
panel to monitoring code [99].
For details, see MEASURING ENGINE
SPEED.
2) Start the engine, set the fuel control dial to
the FULL position, and check that the engine
speed is at least 1000 rpm.
If the engine speed is below 1000
rpm,adjust by extending installation dimension a of rod (1) to make the engine
speed more than 1000 rpm.
D155AX-5
20-115
4
3. Adjusting decelerator pedal speed

Set the fuel control dial at the high idling position, depress decelerator pedal (2) until it contact the stopper, and check that the decelerator
pedal speed is normal.
Decelerator pedal speed: 850 50 rpm
If the engine speed is not correct, adjust
installation dimention a of rod (1).
Installation dimention a: 122 mm
4. Adjusting high idling speed
Set the fuel control dial to the high idling position and check that the high idling speed is
corect.
High idling speed: 2,050 rpm
If engine speed is too low:
Adjust the high idling speed with stopper
bolt (3).
20-116
4
D155AX-5
MEASURING TORQUE CONVERTER STALL SPEED

Serial No. 70001 75000
When
measuring, secure the safety around the

machine.
Measure the torque converter stall speed under
the following conditions.
Transmission oil temperature:
1. Install multi-tachometer A.
2. Start and run the engine at low idling.
3. Depress the brake pedal securely and set the
joystick to the third speed and set the directional lever to the forward position.
4. Depress the decelerator pedal and set the fuel
control lever to the high idling position.
5. Release the decelerator pedal slowly and stall
the torque converter with the engine at high
idling.
Depress the brake pedal securely and keep
your right foot on the decelerator pedal for
safety until the work is finished.
TLD00010
6. If the transmission oil thermometer indicates the

red range, return the joystick immediately to the
neutral position.
7. Repeat above steps 3 through 6 three times.
8. Perform steps 3 through 5 again, and measure
the engine speed just when the transmission oil
thermometer indicates the red range.
After finishing the measurement, return the
joystick to the neutral position immediately,
then lower the transmission oil temperature
with the engine at high idling.
D155AX-5
20-117
4
Make sure that the area around the machine is

safe before starting the operation.
Power train oil temperature: Within operating range
Hydraulic oil temperature: 45 55C
1. Turn the starting switch ON and set the monitor
panel to monitoring code [99].
2. Start the engine and set the fuel control dial to
low idling.
3. Depress the brake pedal firmly, move the full
monolever to 3 and the directional lever to F.
control dial to high idling.
5. Let the decelerator pedal back slowly, run the
engine at high idling, and stall the torque converter.
Depress the brake pedal firmly during operation. For safety reasons, always keep your
right foot on the decelerator pedal until the
completion of the measurement operation.
6. When the power train oil temperature gauge
enters the red gauge, immediately return the
full monolever to neutral.
7. Repeat Steps 3 6 three times.
8. Repeat Steps 3 5 again and measure the engine speed immedeately the power train oil temperature gauge enters the red range.
After completion of the measurement, return the full monolever swiftly to neutral,
and run the engine at high idling to lower
the power train oil temperature.
20-117-1
4
D155AX-5
D155AX-5
(Blank page)
20-117-2
MEASURING FULL STALL SPEED

Serial No. 70001 75000
When measuring, secure the safety around the

machine.
Measure the full stall speed under the following

conditions.
Transmission oil temperature:
1. Install multi-tachometer A.
For details, see MEASURING ENGINE
SPEED.
2. Start and run the engine at low idling. Raise
the ripper lift cylinder to the stroke end.
3. Depress the brake pedal securely and set the
joystick to the third speed and set the directional lever to the forward position.
control lever to the high idling position.
5. Release the decelerator pedal slowly and stall
the torque converter with the engine at high
idling.
Depress the brake pedal securely and keep
your right foot on the decelerator pedal for
safety until the work is finished.
TLD00010
6. If the transmission oil thermometer indicates

the red range, return the joystick immediately
to the neutral position.
7. Repeat above steps 3 through 6 three times.
8. Perform steps 3 through 5 again and raise the
ripper to relieve its cylinder, and measure the
engine speed just when the transmission oil
thermometer indicates the red range.
After finishing the measurement, return the
joystick to the neutral position immediately,
then lower the transmission oil temperature
with the engine at high idling.
20-118
4
D155AX-5
When measuring, confirm the safety around the

machine.
the following condition.
Engine water temperature: Within operating
range
Power train oil temperature: Within operating range
Hydraulic oil temperature: 45 55C
1. Turn on the starting switch and set the monitor
panel to monitoring code "99".
See MEASURING ENGINE SPEED.
2. Start the engine and set the fuel control dial in
the low idling position and raise the ripper lift
cylinder to the stroke end.
3. Press the brake pedal securely and set the joystick to the 3rd gear speed in the forward direction.
4. Press the decelerator pedal and set the fuel control dial in the high idling position.
5. Return the decelerator pedal slowly to stall the
torque converter at high idling.
Press the brake pedal securely and keep your
right foot on the decelerator pedal for safety
until the work is finished.
6. Just after the power train oil temperature gauge
reads the red range, return the joystick into neutral.
7. Repeat above steps 3 6 3 times.
8. Perform above steps 3 5 again and relieve the
ripper by raising it or relieve blade by pitching it
back and measure the engine speed just when
the power train oil temperature gauge reads the
red range.
After finishing measurement, return the joystick into neutral immediately and lower the
power train oil temperature at high idling.
D155AX-5
20-118-1
4
TESTING
MEASURING
A
*
MEASURING
AND ADJUSTING
POWER TRAIN OIL PRESSURE
Stop the machine on level ground and lower

the work equipment
completely to the ground,
then set the parking brake lever and safety lever
to the respective lock positions.
Measure the power train oil pressure under the
following condition.
Transmission
oil temperature:
l
1.
Table of locations of centralized pressure pickup

points for measuring oil pressure and gauges to
use
No.
Measured oil pressure
Transmission main relief pressure
Torque converter
inlet pressure
Torque
outlet
Transmission
converter
modulating
0&$rn2))
5.9 1601
pressure
pressure
.
*
To use the centralized pressure

left-hand the step cover.
2.
Measuring
torque
converter
pickups, remove
inlet pressure
1) Connect
oil pressure gauge H2 (0.98MPa

{10kg/cm21) to oil pressure measuring nipple
(2).
2) Start the engine and set the joystick to the

neutral position.
The transmission
*
speed.
3)
may be set to any gear
Measure the oil pressure with the engine

low idling and high idling.
D155AX-5
at
POWER TRAIN
OIL PRESSURE
3.
3)
OIL PRESSURE
(3).
Start the engine and set the joystick to the
neutral position.
The transmission
*
speed.
Measure the oil pressure with the engine at
low idling and high idling.
main relief pressure

Measuring transmission
pickup plug (I) (IO x
pressure
oil
I) Remove
1.25).
2) Install nipple @ of oil pressure gauge HI
and connect oil pres(5.9MPa {60kg/cm*I),
sure gauge HI.
neutral position.
The transmission
*
4)
5.
POWER TRAIN
Measuring torque converter outlet pressure

I) Connect oil pressure gauge H2 (0.98MPa
(lOkg/cm*I) to oil pressure measuring nipple
2)
4.
MEASURING
AND ADJUSTING
TESTING
speed.
Measure the main relief
engine at high idling.
pressure
with the
pressure
modulation
Measuring transmission
gauge Hi (5.9MPa
oil pressure
I) Connect
{60kg/cm?) to oil pressure pickup nipple (4).
2) Start the engine.
3) Operate the joystick as below with the engine at low idling and high idling, and measpressure at this time.
ure the modulation
the torque converter is stalled by
ASince
steps iv) - VI, depress the brake pedal
securely and keep your right foot on the
decelerator pedal for safety until the work
is finished.
*
Keep the steering wheel at the neutral
position.
Shift the gear to the first speed and the
directional lever to the neutral position,
and measure the oil pressure.
ii) Shift the gear to the second speed and
the directional lever to the neutral position, and measure the oil pressure.
iii) Shift the gear to the third speed and the
directional lever to the neutral position,
i)
zo- 120
D 155AX-5
TESTING
AND ADJUSTING
MEASURING
POWER TRAIN
OIL PRESSURE
iv) Shift the gear to the third speed and the

directional lever to the forward position,
VI Shift the gear to the third speed and the
directional lever to the reverse position,
6.
Measuring brake oil pressure

1) Connect
oil pressure
gauge HI (5.9MPa
{60kg/cm21) to oil pressure pickup nipple (5).
neutral position.
The transmission
*
speed.
3) Run the engine at low or high idling and
operate the parking brake lever and brake
pedal as below, and measure the brake oil
pressure.
i) Set the parking brake lever to the free
position and depress the brake pedal.
ii) Set the parking brake lever to the lock
position and release the brake pedal.
D155AX-5
20-121
TESTING
AND ADJUSTING
TESTING
AND ADJUSTING
HSS MAIN
OIL PRESSURE
1. Loosen locknut (5).

2. Adjust by turning adjustment screw (6).
*
Turn the adjustment screw as follows.
l
To INCREASE
pressure,
turn CLOCKWISE.
l
To DECREASE pressure, turn COUNTERCLOCKWISE.
Ir Amount of adjustment
for one turn of adjustment screw: 13.7MPa {140kg/cm2)
w
Locknut: 29 - 39Nm I3 - 4kgml
*
After completion
pressure
again
shown above.
D 155AX-5
of adjustment,
check the oil
according
to the procedure
II
BVD00496
20-123
TESTING
AND ADJUSTING
HSS CHARGE OIL PRESSURE
HSS CHARGE OIL PRESSURE
Measuring
Stop the
A the
work
machine on level ground and lower

equipment
Measure the HSS charge oil pressure under the

following condition.
.
45 - 55C
1. Remove
the floor inspection
2.
Remove
oil pressure
3.
Install nipple @ of oil pressure gauge HI (5.9MPa

{60kg/cm21), and connect oil pressure gauge HI.
4.
Start the engine and set the joystick and work

equipment
control lever to the respective neutral positions.
5.
Measure the HSS charge

engine at high idling.
cover.
pickup plug (I) (PT1/8).
oil pressure
with the
Adjusting
+ If the HSS charge
oil pressure is not normal,

check that the HSS servo-charge
pressure and
PPC relief pressure are normal, then adjust HSS
charge relief valve (2) according to the following
procedure.
(The main pressure
of the HSS
charge oil pressure is the pressure reduced once
by the HSS servo-charge
pressure and PPC relief circuit.
ZO-124
D155AX-5
TESTING
1.
2.
Loosen locknut (3).

Adjust by turning adjustment
*
Ir
m
*
TESTING
AND ADJUSTING
screw (4).
Turn the adjustment screw as follows.

l
To INCREASE
pressure,
turn CLOCKWISE.
l
To DECREASE pressure, turn COUNTERCLOCKWISE.
Amount of adjustment
for one turn of adjustment screw: 1.55MPa {I 5.8kg/cm21
Locknut: 58.8 - 78.5Nm (6 - 8kgm}
AND ADJUSTING
HSS CHARGE
OIL PRESSURE
I3
BVD00500
After completion
of adjustment,
check the oil
pressure again according to the procedure shown
above.
D155AX-5
ZO-125
TESTING
TESTING
AND ADJUSTING
HSS SERVO CHARGE

AND ADJUSTING
PRESSURE AND PPC RELIEF PRESSURE
TESTING AND ADJUSTING HSS SERVO CHARGE PRESSURE

AND PPC RELIEF PRESSURE
Measuring
the machine on level ground and lower
the work equipment
Astop
Measure the HSS servo charge pressure and

condiPPC relief pressure under the following
tion.
.
45 - 55C
1. Remove
the control
oil pressure
valve cover.
pickup plug (I) (PT1/8).
2.
Remove
3.
Install nipple @ of oil pressure gauge HI (5.9MPa

{60kg/cm*)), and connect oil pressure gauge HI.
4.
Start the engine and set the joystick and work

control lever to the respective neuequipment
tral positions.
5.
Measure the HSS servo charge oil pressure and

PPC relief pressure with the engine at high idling.
Adjusting
If the HSS servo charge oil pressure and PPC
*
relief pressure are not normal, adjust HSS servo
charge valve/PPC relief valve (2) according to
the following procedure.
20-126
D155AX-5
TESTING
TESTING
AND ADJUSTING
HSS SERVO CHARGE

AND ADJUSTING
PRESSURE AND PPC RELIEF PRESSURE
1. Remove plug (3) and springs (4) and (5).

2. Adjust by increasing or decreasing the number
of adjustment shims (6).
Increase or decrease the number of the ad*
justment shims as follows.
.
INCREASE
pressure,
To INCREASE
number of adjustment shims.
DECREASE
pressure,
To DECREASE
number of adjustment shims.
Ir Amount of adjustment for one shim:
0.04MPa 10.4kg/cm21
Plug: 58.8 - 78.4Nm 16 - 8kgml
m
l
After completion
again
pressure
shown above.
D 155AX-5
check the oil

of adjustment,
to the procedure
according
ZO-127
BLEDDING AIR FROM HSS PUMP
BLEDDING AIR FROM HSS PUMP

*
*

45 - 55C
Check that the hydraulic oil is at the specified
level.
* When the HSS pump have been removed or
replaced, or when the hydraulic piping has been
removed, always bleed the air as follows:
1. Loosen air bleed plug (bleeder) (I) at the top of
the HSS pump.
2. Wait for 15 minutes, then start the engine and
run it at idling.
3. When oil comes out from the air bleed plug
hole, tighten the air bleed plug.
20-128
D155AX-5
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE
SIMPLE PROCEDURE FOR TESTING

Ir
BRAKE PERFORMANCE
Carry out the simple procedure for testing brake

under the following condition.
performance
.
Within operoil temperature:
Transmission
ating range
1. Stop the machine on a level surface and set the

blade and ripper to the travel posture.
2. Turn joystick to F2.
Never carry out this test in Fl. If this test is
carried out in Fl, an excessive load will be
brought to bear on the brake.
3. Depress the brake pedal securely at low idling,
turn joystick to FORWARD.
Ir Keep steering on N.
4. Depress the decelerator pedal and pull the fuel
control lever to FULL position.
5. Release the decelerator pedal gradually to raise
the engine speed to the full throttle. Check that
the machine does not start to move.
Because this test is carried out under torque
converter stall, depress the decelerator pedal
securely during the test and keep right foot
on the decelerator pedal until the end of the
test for safety.
TAD00135
D155AX-5
ZO-129
ADJUSTING
ADJUSTING
JOYSTICK AND PARKING LEVER
.23
20- 130
D155AX-5
TESTING
AND ADJUSTING
Tighten the locknuts of the rods and cables

03securely,
and bend the cotter pins securely.
1.
Adjusting directional lever of joystick

I) Remove lever knob (I) and boot (2).
21 Set parking brake lever (3) to the lock
position, then set the direction of joystick (4) to the neutral position.
Ir If parking brake lever (3) is not installed, raise lever (5) with a screwdriver, etc. toward the lock side (upper side).
3) Adjust. distance a between the pins of
rod (6), and connect the rod to joystick
(4) and directional lever (7).
.
Distance a between pins: 68mm
the
4) Adjust fitting distance b between
center of the end of joystick (4) and the
center of the front mounting bolt of the
lever box with rod (6).
.
Fitting distance b: 54 + Imm
5) Set directional lever (8) on the transmission side to the neutral (N) position.
6) Connect cable (9) to directional lever (7)
on the lever stand side and directional
lever (8) on the transmission
side.
7) install boot (2) and lever knob (IL
2.
Adjusting gear speed of joystick

1) Adjust distance c between the pins of
rod (IO), and connect the rod to joystick
(4) and gear speed lever (II).
.
Distance c between pins: 93.5mm
2) Set gear speed lever (12) on the transmission side to the first speed.
3) Connect cable (13) to gear speed lever
(11) on the lever stand side and gear
speed lever (12) on the transmission side.
3.
Adjusting steering system of joystick

1) Adjust distance d between the pins of
rod (14), and connect the rod to intermediate lever (15) and potentiometer
(16).
.
Distance d between pins: 92mm
2) Adjust distance e between the pins of
rod (17), and connect the rod to joystick
(4) and intermediate
lever (15).
.
Distance e between pins: 365mm
3) Adjust rod (17) so that distance f between the center of joystick (4) and left
end of handle (18) will be normal.
.
Distance f: 94mm
* When adjusting
rod (171, set the
steering direction to the neutral.
D155Ax-5
ADJUSTING
4.
JOYSTICK
AND
PARKING
LEVER
General check
I) Install the armrest cover and armrest.
2) Turn the joystick to the forward side and
check that the clearance between the end
of joystick (4) and handle (18) is 50mm.
3) Change the gear speed and check that it
is indicated correctly by the gear speed
indicator.
*
If the gear speed is not indicated correctly, adjust it with the turnbuckle
at the top of cable (9).
4) Check that the steering stroke is 63 +
15mm on each side.
If the machine is equipped with the op5)
erators cab, operate the joystick to the
forward and left steering end, and the
clearance
between the end of joystick
(4) and operators cab is about 70mm.
*
Check that your hand does not touch
the operators cab.
20-l 31
4.
ADJUSTING
Adjusting parking brake lever
1) Adjust distance g between
the pins of rod

(191, and connect the rod to parking brake
lever (3) and intermediate
lever (20).
.
Distance between rod pins: 105mm
2) Adjust distance h between the pins of rod
(211, and connect the rod to intermediate
lever (20) and lock (5).
.
Distance h between rod pins: 91.5mm
3) Set parking brake lever (3) to the free position, and adjust height j of the floor frame
above the end of parking brake lever to the
following value with stopper (21).
.
Lever height j: 424mm
4) Set parking brake lever (3) to the free position.
5) Connect cable 22 to lever (23) and brake
valve lever (24).
6) Set parking brake lever (3) to the lock position, and adjust cable (23) so that brake valve
lever (24) will be at the stroke end.
*
Take care not to pull brake valve lever
(24) more than the stroke end.
7) Operate parking brake lever (3) to the free
position and lock position, and check that
joystick (4) is reset and locked at the respective positions.
8) Set parking brake lever (3) to the lock position.
9) Adjust so that neutral safety switch (25) will
be pushed in and turned on.
.
Push-in stroke: 2.8mm
20-132
D155AX-5
TESTING
TESTING
AND ADJUSTING

POTENTIOMETER
AND ADJUSTING
TRAVEL
REVERSE SENSING
POTENTIOMETER
TRAVEL REVERSE SENSING
-__-__-________
-__-__-__-________
BVDOO521
Testing
1. Insert a T-branch in CN-RSS connector (1) of the
travel reverse sensing potentiometer.
2.
Turn on the starting switch and set the direction of the joystick to the neutral position.
3. Check that the output voltage between pins @
and @ of CN-RSS connector (I) is in the following range.
.
Output voltage: 4.2 f 0.2V
Adjusting
adjust the linkage
*
If the voltage is abnormal,
according to the following procedure.
1. insert a T-branch in CN-RSS connector (I) of the
travel reverse sensing potentiometer.
2. Turn on the starting switch and set the direction
of the joystick to the reverse position.
3. Loosen two locknuts (3) of rod (2), and adjust
the length of rod (2) so that the output voltage
will be in the above range.
.
amount: 2.5 mm per 1 turn of
Adjustment
.
*
rod.
Standard dimension between 2 pins of rod
ends: 168 mm
check voltage again by
After adjustment,
procedure mentioned above.
D155AX-5
20-133
TESTING
AND ADJUSTING
ADJUSTING
ADJUSTING
TRAVEL
REVERSE
LIMIT SWITCH
TRAVEL REVERSE LIMIT SWITCH
BvDoo523
If the travel reverse limit switch is removed,

installed or replaced, adjust its fitting position
according to the following procedure.
1.
Set directional lever (I) of the transmission valve

to the reverse (R) position.
Pressing limit switch (2) against lever (I), secure
it to bracket (3).
l
Stroke a to operate switch: 1.8mm (Max.)
l
Stroke b from operating point of switch to
stopper: 3.0mm (Min.)
Under this condition, turn on the starting switch
and check that the backup buzzer sounds normally.
2.
3.
20- 134
D155AX-5
ADJUSTING STEERING NEUTRAL POSITION

The figure shows for serial No. 70001 75000.
D155AX-5
20-135
4
Serial No. 70001 75000

If the HSS pump or HSS controller is replaced,
adjust the neutral position of the steering system according to the following procedure.
<Reference> Principle of adjustment of neutral position of steering system
If the neutral position of the steering system
is not adjusted, even if the joystick is at the
neutral position, the HSS pump discharges
oil slightly to either PA or PB because of
dispersion of the minimum swash plate angle of the HSS pump.
If the HSS pump discharges oil, the HSS
motor rotates to change the speed of the
track shoes on both sides. Accordingly, the
machine may start or may deviate slightly
while traveling straight even if the lever is at
the neutral position.
To prevent the HSS pump from discharging
oil while the lever is at the neutral position,
the HSS controller controls the current.
The oil discharging condition of the HSS
pump is judged by the differential pressure
between two pressure sensors.
If the HSS pump discharges a large quantity
of oil, the differential pressure becomes
large. If the former does not discharge oil at
all, the latter becomes 0.
The HSS controller controls the current so
that the differential pressure will be kept
below 0.98MPa {10kg/cm2} to minimize the
discharge from the HSS pump when the lever is at the neutral position.
1. Preparation work
Lift up the machine body to raise the track shoes
above the ground by using the blade and ripper.
Set the parking brake lever to the lock position so that the track shoes will not turn
while lifting up the machine body.
If the machine body cannot be lifted up, the
work may be performed without lifting it up.
In this case, if the engine starts, the machine
starts a spin-turn slowly. Secure the safety
around the machine.
After lifting up the machine body, stop the
engine.
2. Setting machine to adjustment mode
1) Remove controller cover (1).
20-136
4
D155AX-5
TESTING
AND ADJUSTING
POSITION
NEUTRAL
STEERING
ADJUSTING
2) Turn the steering neutral position adjustment

3)
3.
4.
switch (2) to the AJUST position.

Pressing and holding buzzer cancel switch
(3) on the monitor panel, turn on the startKeep pressing buzzer cancel
ing switch.
switch (3) further for more than three seconds to set the machine in the adjustment
mode.
If the machine is set in the adjustment
*
mode, caution lamp (4) on the monitor
panel blinks.
Checking travel deviation direction

Sr Check the travel deviation direction by step
2) or 3) below.
I) Start and run the engine at low idling.
Perform all checking work with the en*
gine at low idling.
2) Set the parking brake lever to the free position and see which track shoe moves in reverse to judge the travel deviation direction.
If the left track shoe moves in reverse,
*
the machine deviates to the left. If the
right track shoe moves in reverse, the
machine deviates to the right.
3) Shift the joystick to the right and left to return to the neutral position, and check the
indication of the LED of control (5) each time
to judge the travel deviation direction.
Since the LED of the controller is nor*
mally reflected in the mirror, install the
cover temporarily to reflect it in the mirror.
The LED indicates the pressure (Exam*
ple 1).
The point at the right shoulder of each
figure denotes - (minus) (Example 2).
The point at the left shoulder of each
figure denotes lOOkg/cm* (Example 3).
If the LED indicates a larger figure when
*
the joystick is shifted to either direction
the
to return to the neutral position,
machine deviates in that direction.
4) After checking, lower chassis to the ground
by lifting blade and ripper.
Example
55ks/cm*
/
I
-55kdcm
Example 4
Example 3
Example 2
1 155kdcm'
I-155kdcm'/
I
TWD01017
Setting solenoid valve current

If the LED indicates 10 or less in each direc*
tion in step 3-2) above, the solenoid valve
In
current does not need to be changed.
this case, do not perform steps I) and 2)
below, but perform only step 3).
1) Turn parking lever to LOCK position.
2) Start and run the engine at high idling.
Perform the all setting work with the en*
gine at high idling.
3) Operate the joystick to the stroke end in the
opposite direction to the travel deviation direction confirmed by the above procedure.
D155AX-5
20-137
ADJUSTING
STEERING NEUTRAL POSITION
This operation
is performed
under the
idea that deviation to the left (right) can
be prevented by operating the lever to
the right (left).
Since the track shoes turn at a high
speed, secure the safety around the machine.
With the lever at the stroke end, press buzzer
cancel switch (3) on the monitor panel, then
return the lever to the neutral position.
*
The controller starts calculation and storing of the current. When it finishes, caution lamp (4) stops blinking (About 1
minute)
A
4)
5.
Check of setting
I) Turn parking lever to LOCK position.
2) Start and run the engine at low idling.
*
Perform all checking work with the engine at low idling.
3) Shift the joystick to the right and left to return to the neutral position, and check that
the figure indicated by the LED of control (5)
each time is in the following range.
.
Normal
differential
pressure: 20kg/cm2
max.
6.
Finishing adjustment
1)
2)
mode
Turn steering neutral adjustment

to the OPERATE position.
Install control cover (I).
20-138
switch
(2)
D155AX-5

If the HSS pump or HSS controller is replaced,
adjust the neutral position of the steering system according to the following procedure.
<Reference> Principle of adjustment of neutral position of steering system
If the neutral position of the steering system
is not adjusted, even if the joystick is at the
neutral position, the HSS pump discharges
oil slightly to either PA or PB because of
dispersion of the minimum swash plate angle of the HSS pump.
If the HSS pump discharges oil, the HSS
motor rotates to change the speed of the
track shoes on both sides. Accordingly, the
machine may start or may deviate slightly
while traveling straight even if the lever is at
the neutral position.
To prevent the HSS pump from discharging
oil while the lever is at the neutral position,
the HSS controller controls the current.
The oil discharging condition of the HSS
pump is judged by the differential pressure
between two pressure sensors.
If the HSS pump discharges a large quantity
of oil, the differential pressure becomes
large. If the former does not discharge oil at
all, the latter becomes 0.
The HSS controller controls the current so
that the differential pressure will be kept
below 0.98MPa {10kg/cm2} to minimize the
discharge from the HSS pump when the lever is at the neutral position.
1. Preparation work
Lift up the machine body to raise the track shoes
above the ground by using the blade and ripper.
Set the parking brake lever to the lock position so that the track shoes will not turn
while lifting up the machine body.
If the machine body cannot be lifted up, the
work may be performed without lifting it up.
In this case, if the engine starts, the machine
starts a spin-turn slowly. Secure the safety
around the machine.
After lifting up the machine body, stop the
engine.
D155AX-5
20-138-1
4
2. Selecting HSS neutral adjustment mode

Adjust the steering system in the monitoring mode and adjusting mode of the monitor panel.
For the general explanation of the monitoring mode and adjusting mode, see DISPLAY
AND SPECIAL FUNCTIONS OF MONITOR
2) Turn starting switch ON.
3) Set the engine speed to Hi and turn service
switch (2) ON.
cover.
mark (6) on the right and left side light
up.
display HSS neutral adjustment mode "HN".
3. Operation in HSS neutral adjustment mode
The differential pressure indicated in this
mode is not offset. For confirmation of the
differential pressure after adjustment, select
"J5" in the monitoring mode (See the display functions in the monitoring mode).
1) After adjustment mode "NH" is displayed,
turn the steering lever to the left end
and return it into neutral and measure
value (7) at this time. Similarly, turn the
steering lever to the right end and return
it into neutral and measure value (7) at
this time. Compare these values with
each other.
20-138-2
4
D155AX-5
It can be confirmed that the machine

turns in the direction having the larger
value.
2) Turn the lever in the direction having smaller
value (7) and turn buzzer cancel switch (3)
to the left.
The buzzer makes a pip.
The segments of gauge (8) are turned
on 1 by 1 and all of them are turned on
again when adjustment is finished.
The number of segments of the gauge
is normally 5 - 7.
3) How to clear adjustment value
Set the control lever in neutral and turn
buzzer cancel switch (3) to the left.
4. How to confirm travel deviation direction
How to confirm by movement of track shoe
1) Set the parking brake lever in the free position and check which track shoe moves in
reverse to see the travel deviation direction.
If the left track shoe moves in reverse,
the machine deviates to the left. If the
right track shoe moves in reverse, the
machine deviates to the right.
2) After confirming the travel deviation direction, lower the machine body to the ground
by using the blade and ripper.
5. Finishing adjustment mode
1) Turn service switch (2) OFF.
D155AX-5
20-138-3
4
20-138-4
(Blank page)
D155AX-5
PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH
PROCEDURE FOR OPERATING EMERGENCY STEERING

SWITCH
Serial No. 70001 75000
If the machine cannot be steered because of a trouble in the HSS controller or steering potentiometer,
it can be moved to a safe place by using the emergency steering switch according to the following
procedure.
Since this switch is for the minimum necessary
steering control, use it only for moving to a safe
place.
1. Condition of machine for using switch
1) The machine cannot be steered because of
a trouble in the steering potentiometer.
The LED of the HSS controller indicates
error code [E-62], [E-61], [E-6E], or [E23].
a trouble in the HSS controller.
The LED of the HSS controller indicates
error code [E-57] or nothing.
If the LED indicates nothing, the electric
system of the controller may have trouble. In this case, check the electric system, too.
2. Connection method of switch
1) Turn off the starting switch.
2) Disconnect CN1 connector (1), CN-2H1 connector (2), and CN-2H2 connector (3) from
the HSS controller.
3) Disconnect CN-LPL connector (4) from the
ROPS bracket, then connect the emergency
steering switch (5) to the male connector
and female connector.
D155AX-5
20-139
4
3. Precautions for using switch

1) Before using the switch, insulate it with vinyl tape, etc. to prevent a short circuit between the terminals on its back side and the
machine body.
2) Since the emergency steering switch allows
only ON-OFF operation, unlike the joystick,
keep the engine speed as low as possible
during operation.
If the switch is operated while the engine is running at a high speed, the steering system operates sharply.
3) Note that the machine moves inversely to
the operation of the switch during reverse
travel, unlike when the joystick is used.
Operating directions of switch and steering directions
Position
20-140
Forward
Reverse
Steering to left Steering to right
Steering to right Steering to left
D155AX-5

If the machine cannot be steered because of a trouble in the HSS controller or steering potentiometer,
it can be moved to a safe place by using the emergency steering switch according to the following
procedure.
Since this switch is for the minimum necessary
steering control, use it only for moving to a safe
place.
1. Condition of machine for using switch
a trouble in the steering potentiometer.
The monitor panel indicates error code
[E0730], [E0731], [E0732], [E0733],
[E0734], or [E0735].
a trouble in the HSS controller.
The monitor panel indicates error code
[E0113] or nothing.
If the monitor panel indicates nothing,
the electric system of the controller may
have trouble. In this case, check the electric system, too.
2. Connection method of switch
1) Turn off the starting switch.
2) Disconnect CN-ST1 connector (1), CN-ST3
connector (2), and CN-ST2 connector (3) from
the HSS controller.
3) Disconnect CN-LPL connector (4) from the
ROPS bracket, then connect the emergency
steering switch (5) to the male connector
and female connector.
D155AX-5
20-140-1
4
3. Precautions for using switch

1) Before using the switch, insulate it with vinyl tape, etc. to prevent a short circuit between the terminals on its back side and the
machine body.
2) Since the emergency steering switch allows
only ON-OFF operation, unlike the joystick,
keep the engine speed as low as possible
during operation.
If the switch is operated while the engine is running at a high speed, the steering system operates sharply.
3) Note that the machine moves inversely to
the operation of the switch during reverse
travel, unlike when the joystick is used.
Operating directions of switch and steering directions
Position
20-140-2
4
Forward
Reverse
Steering to left Steering to right
Steering to right Steering to left
D155AX-5
ADJUSTING INITIAL CURRENT IN HSS STEERING SYSTEM
ADJUSTING INITIAL CURRENT

IN HSS STEERING SYSTEM
When the operator steers the machine equipped
with the HSS steering system, he (she) may feel
the steering condition differently between the
steering directions in the initial period of steering. This problem is solved by changing the
initial current in the HSS steering system in the
adjustment mode.
Set the rise current freely in the adjustment
mode and save the data in the non-volatile ROM.
1. Selecting initial current adjustment mode
Adjust the initial current in the monitoring
mode and adjusting mode of the monitor
panel.
For the general explanation of the monitoring mode and adjusting mode, see DISPLAY
AND SPECIAL FUNCTIONS OF MONITOR
cover.
mark (6) on the right and left side light
up.
display initial current adjustment mode "CC".
2. Operation in initial current adjustment mode
1) After adjustment mode "CC" is displayed,
turn the lever in the direction to change the
initial current.
2) Lever current (7) in mV is displayed.
D155AX-5
20-140-3
4
ADJUSTING INITIAL CURRENT IN HSS STEERING SYSTEM
Neutral value: Approx. 2,500 mV

3) After the target current is obtained, turn
buzzer cancel switch (3) to the right to save
the value.
3. Finishing adjustment mode
1) Turn service switch (2) OFF.
20-140-4
4
D155AX-5
TESTING
ADJUSTING
AND ADJUSTING
ADJUSTING
BRAKE PEDAL
BRAKE PEDAL
BVD00684
Tighten the locknuts of the

CB
curely, and bend the cotter
rods and cables sepins securely.
1.
Adjust fitting dimension b of damper (2) so that

the stroke of brake pedal (1) will be dimension
a.
.
Pedal stroke a: 79mm
.
Fitting dimension b of damper: 39mm
2.
Adjust fitting dimension c of rod (3) on the valve

side, then connect to brake valve lever (4).
.
Fitting dimension c of rod: 1,264mm
*
Fully screw joint (5) into the valve side.
3.
Adjust fitting dimension d of rod (6) on the pedal

side, then connect to brake pedal (I).
.
Fitting dimension d of rod: 174mm
4.
Lightly push rod (3) on the valve side toward

the rear of the machine, and turn only joint (7)
to connect rods (3) and (6).
*
Push rod (3) with a force of about 9.8 - 19.6N
{I - 2kg}.
D 155,4X-5
VDOO685
ADJUSTING
Joint: 34.3 - 58.8Nm
13.5 - 6.0kgmI
5.
With brake pedal (I) released, adjust its play

with dimension
e between the pins of rod assembly (8).
.
Play of pedal: 1 - 5mm (Center of pedal)
.
Dimension e between pins of rod assembly:
1,553mm
Ir Adjust by turning joints (5) and (7) in the
same direction.
6.
With brake pedal (I) released, check that brake

pedal (I) is in contact with damper (2).
20-142
BRAKE PEDAL
D 155AX-5
TESTING
AND ADJUSTING
ADJUSTING
CLEARANCE
ADJUSTING
CLEARANCE
OF IDLER
OF IDLER
If the idler side guides, top and buttom guides,

and guide plate wear, and the idler is at an
angle or there is play to the side, adjust as follows.
1.
Adjusting in sideways direction

1) Drive the machine for 1 or 2 m on level
ground, then measure
clearance
a (left,
right, inside, outside: 4 places).
2) If clearance a is more than 4 mm, loosen
bolt (I) and adjust with shim (2) as follows.
*
Clearance on one side: 0.5 - 1.0 mm
*
Do not loosen bolt (I) more than 3 turns.
Ir The maximum
adjustment
amount is 6
mm.
2.
Adjustment
in vertical direction
Shim adjustment cannot be used for adjustment in the vertical direction, so measure
the clearance between the track frame and
guide plate (3). If the clearance is more than
8 mm, replace with a new guide plate (3)
and wear plates (welded) (4), (51, and (6).
l
2;
TAD00132
TAD00133
D155AX-5
20-143
TESTING
AND ADJUSTING
TESTING
WEAR OF SPROCKET
TESTING WEAR OF SPROCKET
Wear
limit
line
TWdOlOl6
1.
Apply wear gauge J to a part where the sprocket

is not meshed with the track shoe.
Match the waved part of the sprocket to that
*
of the wear gauge on the datum line.
2.
Judge the wear of the sprocket.

When the sprocket surface is above the wear
limit line: The sprocket can be used as it is.
When the sprocket surface is below the wear
limit line: Replace the sprocket with new one.
l
20-144
D155AX-5
TRACK SHOE TENSION
TRACK SHOE TENSION
Testing
1. Drive the machine
forward on a level ground,

then stop it.
*
Do not apply the brake when stopping the
machine.
2.
Place a straight steel bar (I) between the idler

and carrier roller, and measure clearance a between the bottom of the steel bar and grouser
of the track shoe.
Standard clearance a: 20 - 30mm
l
Adjusting
*
If the track shoe tension
according
1.
to the following
EVD00532
is abnormal,
procedure.
adjust
it
When tension is too high

Loosen valve (2) to discharge grease.
Since the valve may jump out because of
the internal grease at high pressure, do not
loosen it more than one turn.
2.
When tension is low

Supply grease through valve (2).
Ir If the track shoe is not tensed well, slowly
move the machine forward and backward.
BVD00533
After adjusting the tension, check it again according to the testing procedure shown above.
D 155AX-5
20-145
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING HYDRAULIC PRESSURE

Measuring
the work equipment completely to the ground,
Measure the hydraulic pressure under the following conditions.
1. Measuring main relief pressure

1) Remove the control valve cover.
2) Remove oil pressure pickup plug (1) (10 x
1.25).
3) Install nipple (1) of oil pressure gauge H1
(58.8MPa {600kg/cm2}), and connect oil pressure gauge H1.
The work equipment oil pressure can be
measured in monitoring mode "HA". (See
DISPLAY AND SPECIAL FUNCTIONS OF
MONITOR PANEL.)
4) Start the engine and set the safety lever to

the free position.
5) Run the engine at high idling, and operate
the blade lever and ripper lever to relief each
cylinder at the stroke end, and measure the
oil pressure at this time.
2. Measuring load sensing pressure

1) Remove the control valve cover.
2) Remove oil pressure pickup plug (2) (10 x
1.25).
20-146
4
D155AX-5
3)
4)
5)
HYDRAULIC PRESSURE
Install nipple (I) of oil pressure gauge HI

(58.8MPa (600kg/cm21), and connect oil pressure gauge HI.
Start the engine and set the safety lever to
the free position.
Run the engine at high idling, and operate
the blade lever and ripper lever to relief each
cylinder at the stroke end, and measure the
oil pressure at this time.
Adjusting
*
If the main relief pressure
Ir
1.
2.
is abnormal,
adjust
main relief valve (3) of the control valve.
The load sensing pressure cannot be adjusted.
Loosen locknut (4).

Adjust the main relief pressure by with adjustment screw (5).
Ir Turn the adjustment screw as follows.
To INCREASE
pressure,
turn CLOCKWISE.
turn
pressure,
DECREASE
To
COUNTERCLOCKWISE.
*
Amount of adjustment
for one turn of adjustment screw: 19.6MPa {200kg/cm2)
w
Locknut: 29.4 - 39.2Nm (3 - 4kgm}
l
END00536
After completion
pressure
again
shown above.
D155AX-5
of adjustment,
check the oil
according
to the procedure
20-147
TESTING
MEASURING
AND ADJUSTING
MEASURING
PPC VALVE OUTPUT
PPC VALVE
OUTPUT
PRESSURE
PRESSURE
the machine on level ground and lower

AStop
the work equipment
Measure the PPC valve output pressure

.
45 - 55C
Hydraulic temperature:
1.
Remove
2.
Disconnect
ured.
3.
Install adapter @ and nipple @ of oil pressure

and connect oil
gauge Hl (5.9MPa {60kg/cm*I),
pressure gauge HI.
4.
Start the engine

free position.
5.
Run the engine at high idling, and operate the

control lever of the circuit to be measured, and
measure the oil pressure at this time.
Measure the oil pressure with the control
*
lever at the stroke end.
the oil pressure on the
When measuring
*
blade lowering side, lower the blade until
the machine body is lifted up.
20-148
under
the control valve cover.
the hose (1) of the circuit to be meas-
and set the safety lever to the
D155AX-5
MEASURING
Blade
PPC valve
RiPPer
Safety
lock
(Ripper
disaino
anole
Control
D155AX-5
valve
PPC valve
QPPC
PPC VALVE OUTPUT PRESSURE
connection
is
shown
when
looked
from
lever
side.
increase)
valve
TWD00972
20-149
TESTING
ADJUTING
AND ADJUSTING
ADJUTING
PLAY OF PPC VALVE
Ir
If there is excessive play at the ends of the blade

lever and ripper blade, adjust the PPC valve according to the following procedure.
Standard play a: 1 - 6mm at a point 400mm

from center of rotation of lever (in forward and
backward direction and lateral direction)
The figure
ripper.
1.
Remove
2.
Loosen locknut (2), then turn disc (3) to adjust

the play.
Ir Do not move the piston at this time.
3.
Secure
disc (3) in position
(2).
m
Locknut: 8.07 - 127.49Nm
4.
PLAY OF PPC VALVE
at right shows the PPC valve for the
boot (I).
and tighten
locknut
I10 - 13kgmI
Install boot (I).
20-150
D155AX-5
TESTING
AND ADJUSTING
MEASURING
SOLENOID
MEASURING
VALVE OUTPUT

the work equipment
Measure the solenoid valve output pressure under the following conditions.
.
45 - 55C
The figures at right show the ripper pin-puller
solenoid valve.
SOLENOID
VALVE
OUTPUT
PRESSURE
PRESSURE
1. Measuring output pressure of ripper pin-puller

solenoid valve
I)
Disconnect outlet hoses @ and 0.
2) Install adapter (I) and nipple (2) of oil pressure gauge Hl (5.9MPa {60kg/cm*l), and connect oil pressure gauge HI.
3) Start the engine and relieve the ripper pinpuller cylinder, and measure the oil pressure at this time.
Since the oil pressure for the power train
*
circuit is used for the ripper pin-puller
cylinder, the ripper pin-puller
cylinder
relief pressure is normal if it is the same
as the transmission main relief pressure.
2.
Measuring output pressure of blade pitch solenoid valve

1) Disconnect the outlet hose.
2) Install adapter @ and nipple @ of oil pressure gauge HI (58.8MPa {600kg/cm*I),
and
connect oil pressure gauge HI.
3) Start the engine and relieve the blade pitch
cylinder, and measure the oil pressure at
this time.
*
The blade pitch cylinder relief pressure
is normal if it is the same as the work
equipment
main relief pressure.
D155AX-5
20-151
TESTING LOCATION
AND RIPPER
*
1.
2.
TESTING LOCATION CAUSING HYDRAULIC DRIFT OF

BLADE AND RIPPER
CAUSING
HYDRAULIC
If hydraulic drift occurs in the blade and ripper,

check as follows to see if the cause is in the
cylinder packing or in the control valve.
Set the cylinder to be tested in the following
posture, then stop the engine.
1) Blade lift cylinder
Push the blade against the ground to raise
the front side of the chassis.
Ir Since the cylinder has a piston valve, do
not operate the cylinder to the stroke end.
2) Blade tilt cylinder
Extend the tilt cylinder to the stroke end,
then push the blade further
against the
ground to raise the right side of the chassis.
3) Ripper lift cylinder
Push the blade against the ground to raise
the rear side of the chassis.
Operate the control lever in the direction to extend the cylinder rod.
.
If the downward movement becomes faster,
the packing is defective.
.
If there is no change, the control valve is
defective.
If there is no more pressure in the accumu*
lator, run the engine for about IO seconds to
charge the accumulator
before carrying out
the operation.
Posture
of
testing
DRIFT OF BLADE
lift
cylinder
drift
TWO00973
Posture
of
testing
blade
tilt
cylinder
drift
TWD009
Posture
of
testing
ripper
lift
cylinder
drift
[Reference]
1)
2)
3)
If the cause of the hvdraulic drift is in

the packing, the speed of downward
movement
in the above operation will
become faster for the following reasons.
With the work equipment
in the posture
given above, (holding pressure applied to
the bottom end), the oil will leak from the
bottom end to the head end. However, the
volume at the head end is smaller than at
the bottom end by an amount proportional
to the are of the rod, so if the oil flows in
from the bottom end, the internal pressure
at the head end will rise.
If the internal pressure at the head end rises,
a balance will be made in proportion to this
at a certain pressure (this differs according
to the amount of leakage).
When the pressure becomes balanced, the speed of downward movement
becomes slower.
In this condition, if the lever is operated as
shown above, the circuit at the head end is
connected to the drain circuit (the bottom
end is closed by a check valve), and the oil
at the head end flows to the drain circuit
and the oil pressure is unbalanced
to increase the speed of downward
movement.
20- 152
TWD00975
D155AX-5
TESTING
AND ADJUSTING
MEASURING
MEASURING
LEAKAGE
LEAKAGE INSIDE HYDRAULIC
INSIDE
HYDRAULIC
CYLINDER
CYLINDER
Measure the leakage inside hydraulic cylinder

under the following condition.
.
45 - 55C
Since the blade lift cylinder is equipped with a
piston valve, the leakage inside cannot be measured.
Extend the cylinder to be measured to the stall

end and set it in the measurement
posture.
1) Blade tilt cylinder:
Tilt the blade to the right end.
2) Ripper lift cylinder:
Remove the shank pin and lower the ripper
to the lowest position.
3) Ripper tilt cylinder
Tilt the ripper to the forward end.
2.
Disconnect the head piping of the cylinder, and

block the hose on the chassis side with a blind
plug.
*
Remove the cover of the blade tilt cylinder
hose.
Be careful not to disconnect the hose at the
bottom end.
A
3.
4.
Start and run the engine at high idling, and apply the relief pressure to the bottom side of the
cylinder.
*
Blade lift cylinder: Tilt the blade to the right.
Ripper lift cylinder: Lower the ripper.
Ripper tilt cylinder: Tilt the ripper to forward.
Wait for 30 seconds, then measure

of leakage over next 1 minute.
D155AX-5
Disconnect hose
Stroke end
*b
Hose
the amount
20- 153
TESTING
AND ADJUSTING
RELEASING
CYLINDER
RELEASING
REMAINING
REMAINING
OIL PRESSURE
IN HYDRAULIC
CYLINDER
OIL PRESSURE IN HYDRAULIC
When disconnecting the piping between the work

equipment
cylinder and control valve, release
the remaining oil pressure in the circuit.
1.
Gradually loosen the oil filter cap of the hydraulic tank to release the pressure in the tank.
2.
Operate the work equipment

control lever forward, backward and to the right and left.
*
The pressure in the accumulate
is released
by operating the work equipment control lever two or three times.
3.
Start and run the engine at low idling for about

five seconds, then stop it. Operate the work
equipment control lever forward, backward and
to the right and left two or three times.
*
All remaining oil pressure is released by operating the above operation
two - three
times.
BLEEDING AIR FROM

HYDRAULIC CYLINDER
*
After replacing or installing hydraulic cylinders

or hydraulic piping, bleed the air from the hydraulic cylinders as follows:
1.
Start the engine

minutes.
2.
Run the engine at low idling, and extend and

retract the cylinder to be bled 4 - 5 times.
*
Stop the piston rod about IOOmm from the
stroke end. Never operate it to the relief position.
3.
Run the engine
4.
Run the engine at low idling and operate the

piston rod to the stroke end to relieve the circuit.
20-154
and run at idling for about
at high idling and repeat Step 2.
D155AX-5
ADJUSTING
ADJUSTING
WORK EQUIPMENT
SAFETY LEVER
1.
Adjust distance a between the pins of rod (I),

and connect the rod to PPC lock valve (2) and
safety lever (3).
.
Distance a between pins: 330mm
2.
Adjust distance b between the pins of rod (41,

and connect the rod to lever (5) and safety lever
(3).
.
Distance b between pins: 63.5mm
3.
Set safety lever (3) to the lock position.
4.
Adjust clearance c between levers (5) and (6)

the specified value with rod (4).
l
Clearance c: 0.5 - l.Omm
5.
With blade lever (7) in the lift position, move

safety lever (3) from the free position to the lock
position. Confirm that blade lever (7) returns to
the neutral position at this time.
6.
With safety lever (3) in the lock position, move

blade lever (7).
Confirm that safety lever (3)
does not move to the free position at this time.
D155AX-5
WORK EQUIPMENT SAFETY LEVER
BVD00687
to
20- 155
ADJUSTING
SEMI-U
ADJUSTING
SEMI-U TILTDOZE
TILTDOZER
&000540
If the blade has been removed

adjust it as follows.
or disassembled,
1. Procedure for adjusting with shims when assembling blade

1) Use shims to adjust the clearance at tilt portion (2), center portion (3), and lift portion
(4).
TAD00131
Standard shim thickness:
2)
Max. 4mm
Apply grease to the adjustment locations and

check that the parts rotate smoothly.
&
Each adjustment portion:
Grease (G2-LII
TAD00149
20-156
D 155AX-5
2.
ADJUSTING
SEMI-U TILTDOZE
Adjusting blade tilt

1)
2)
3)
Adjust fitting dimension d of brace (4) with

the handle.
.
Fitting dimension d of brace: 1,390mm
Measure right tilt el and left tilt e2.
.
Right tilt el: 450mm
.
Left tilt e2: 450mm
If the tilt is not the same on the left and right
sides, adjust fitting dimension d of brace (1)
as follows.
.
el > e2: Increase fitting dimension d.
.
el < e2: Decrease fitting dimension d.
D155AX-5
20-157
TROUBLESHOOTING
TROUBLESHOOTING
Points to remember when troubleshooting ........................................................................................ 20-202
Sequence of events in troubleshooting ............................................................................................... 20-203
Points to remember when carrying out maintenance ....................................................................... 20-204
Checks before troubleshooting ............................................................................................................. 20-212
Type of connector and position of installation ................................................................................... 20-214
Connection table for connector pin numbers ..................................................................................... 20-220
Function of electronic control system ................................................................................................. 20-230
Display of HSS controller .......................................................................................................................20-232
Display and special functions of monitor panel .............................................................................. 20-235-1
How to read judgment table ................................................................................................................. 20-236
Judgment table for engine system, hydraulic and mechanical system, and electrical system .... 20-238
Method of using troubleshooting charts ............................................................................................. 20-240
Troubleshooting of network system (N mode) ................................................................................... 20-251
Troubleshooting of engine system (S mode) ..................................................................................... 20-301
Troubleshooting of HSS controller and electrical system (E mode) (Serial No. 70001 75000) ....... 20-401
Troubleshooting of hydraulic and mechanical system (H mode) ..................................................... 20-501
Troubleshooting of monitor system (M mode) (Serial No. 70001 75000) .................................... 20-601
Troubleshooting of monitor system (M mode) (Serial No. 75001 and up) ..................................... 20-701
Troubleshooting of engine controller system (G mode) ................................................................... 20-801
Troubleshooting of HSS controller and electrical system (E mode) (Serial No. 75001 and up) ........ 20-901
D155AX-5
20-201
4
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER
Stop the machine

When
allow
carrying
WHEN TROUBLESHOOTING
in a level place, and check that the safety
out the operation
any unauthorized
with two or more workers,
person to come
If the radiator cap is removed when the

A the
engine to cool down before starting
A
A
A
Be extremely
careful
When
disconnecting
When
removing
the internal
wiring,
always
When
first. When
reoccurrence
carrying
However,
1.
When
the negative
which
measuring
is to pinpoint
and important
that would
are disassembled
produce
immediately
the reported
2)
with
the fail-
4.
3)
when
carrying
to carry
5.
out troubleshoot-
ex-
anything
strange
with the method
operating
Had any repairs
When
about
symptoms,
etc.
to reenact
the
do not carry out
or measurement
that may
worse.
of the investigation
and inspec-
down the causes of
then use the troubleshooting
The
basic
of the failure
procedure
flowchart
to
exactly.
for troubleshooting
is
as follows.
the
ma-
or were there
condition
before
did the failure
occur?
been carried
of operation,
the machine
and
or as
Troubleshooting
Sr
apart from
yourself,
it as a real failure
a problem
failure,
out before
the
1)
Start from the simple
2)
Start from the most likely points.
3)
Investigate
other
points.
related
parts
or infor-
mation.
6.
5)
of the failure
to handle
tion in Items 2 - 4 to narrow
in
occurred?
occur suddenly,
what conditions
extent
whether
locate the position
with the machine
Under
failure
the
Use the results
prior
this?
Measures
to remove
Even if the failure

the failure
root cause of failure
is repaired,
is not repaired,
if the root cause of
the same
failure
will
occur again.
failure?
When
idea
items can be checked
make the problem
out thorough
occurred
before the failure
4)
6)
some
so check any item that is considered
any investigation
that has been reported?
Did the failure
and function.
to form
items.
troubleshooting
with the fixed procedure.
problems
inspection
Confirming
parts, or
and to carry out troubleshooting
there
chine
Other maintenance
Confirm
to find the cause
of manhours,
Have any other problems

Was
Other
of the user or operator.
the problem
and to
symptoms.
ternally,
Points to ask user or operator

1)
swiftly,
the structure
questions
4)
and at the same time, will also lose
ing, it is necessary
accordance
various
3)
any
parts will be disas-
impossible
It will also cause a waste
investigation
release
to be necessary.
become
For this reason,
or air, always
it properly.
to carry out repairs
point is of course to understand
of the failure.
oil or grease,
first.
from oil, water,
be sure to connect
judge
the confidence
parts.
of the battery
is to ask the operator
sembled.
2.
(-1 terminal
equipment,
do not hurry
no connection
ure or other unnecessary

It will
in any rotating
is under pressure
the components.
failure occurs:
.
Parts that have
and do not
may spurt out and cause burns, so wait for
the basic cause of the failure,
troubleshooting
out troubleshooting,
If components
signals,
of the failure.
causes of the failure
carrying
is hot, hot water
disconnect
to disassemble
keep strictly to the agreed
fitted.
troubleshooting.
installing
a short cut to effective
of possible
engine
the plug or cap from a location
pressure
brake are securely
near.
not to touch any hot parts or to get caught
The aim of troubleshooting

prevent
pin, blocks, and parking
were these
Has the
same
repairs
kind
carried
of failure
To prevent this, always
out?
occurred
be-
lem occurred.
Then,
investigate
remove
why the prob-
the root cause.
fore?
3.
Check before troubleshooting

1)
Check for symptoms
of any abnormality
in
the machine.
2)
Check the CHECKS BEFORE STARTING
20-202
items.
D155AX-5
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TROUBLESHOOTING
SEQUENCE
OF EVENTS IN TROUBLESHOOTING
Office, shop
&a
TEW00180
step
1
IExamination,
II
When
confirmation
a request
Jobsite
of symptoms
for repairs
ask the following
2)
TwOO18,
.
.
Name
of customer
Type.
serial number
Details
of jobsite,
Ask questions
is received,
first
points.
of machine
etc.
to gain an outline
of the prob-
lem.
.
Condition
Work being carried
of failure
out at the time of the
failure
.
Operating
Past history,
environment
details
of maintenance,
etc.
TEWOOl83
step 3
Preparation
1)
of troubleshooting
tools
Look at the table
of troubleshooting
the shop manual
and prepare
tools in
the necessary
tools.
.
T-adapter
.
2)
Hydraulic
pressure
gauge
kit, etc.
Look in the parts book and prepare

essary
replacement
the nec1)
parts.
Before
starting
manual,
that
Drive
select
matches
troubleshooting,
a troubleshooting
the symptoms,
and operate
the condition
locate
the
and judge
flowchart
and carry
machine
and
out
to confirm
if there
is really
TEWOO 188
Was there
chine
anything
strange
before the failure
Did the failure
the ma-
occur suddenly?
Had any repairs been carried
D155AX-5
about
occurred?
out before the
20-203
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

Wiring harnesses consist of wiring connecting
one component to another component,
connectors used for connecting and disconnecting
one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration.
Furthermore,
during
inspection and repair operations,
they are frequently removed and installed again, so they
are likely to suffer deformation
or damage. For
this reason, it is necessary to be extremely careful when handling wiring harnesses.
WHEN
HANDLING
TEW00191
Main failures occurring in wiring harness

Defective contact of connectors
(defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector
is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed
or the position is not correctly
aligned, or because there is corrosion
or
oxidization of the contact surfaces.
Improper
insertion
TEW00192
Defective crimping or soldering of connectors

The pins of the male and female connectors
are in contact at the crimped terminal
or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plating at the joint will peel and cause improper
connection or breakage.
TEW00193
20-204
TROUBLESHOOTING
POINTS
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
Disconnections
in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected,
or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering may be damaged, or the wiring may be
broken.
High-pressure
water entering connector
The connector is designed to make it difficult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the connector, depending
on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be shortcircuited by the water, so if any water gets
in, immediately
dry the connector or take
other appropriate action before passing electricity through it.
Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a contact restorer.
*
When wiping the mating portion of the
connector, be careful not to use excessive force or deform the pins.
*
If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before cleanina with comoressed
air.
TEWO0194
TEW00195
TEW00196
D 155AX-5
20-205
TROUBLESHOOTING
2)
Removing, installing,
wiring harnesses
and drying connectors
and
Disconnecting
connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the connectors apart.
*
Never pull with one hand.
When removing from clips
When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
+
If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00485
Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
*
If the machine is left disassembled
for a
long time, it is particularly easy for improper contact to occur, so always cover
the connector.
TEW00198
20-206
D155AX-5
TROUBLESHOOTING
POINTS
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
Connecting connectors
Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating portion).
2) Check that there is no deformation, defective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or breakage to the outside of the connector.
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.
Ir If there is any damage or breakage, replace the connector.
Fix the connector securely.
Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector
until the stopper clicks into
position.
I
TEWCHIZOO
Correct any protrusion of the boot and any

misalignment
of the wiring harness
For connectors fitted with boots, correct any
protrusion
of the boot. In addition,
if the
wiring harness is misaligned,
or the clamp
is out of position, adjust it to its correct position.
If the connector cannot be corrected eas*
ily, remove the clamp and adjust the
position.
If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
D155AX-5
20-207
TROUBLESHOOTING
Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
wawashed in water, do not use high-pressure
ter or steam directly on the wiring harness.
do as
If water gets directly on the connector,
follows.
@ Disconnect the connector and wipe off the
water with a dry cloth.
Ir If the connector is blown dry with compressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the compressed air before blowing with air.
Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
Ir Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
or damage to the connecdeformation
tor.
TEW00202
Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected and carry out a continuity test to
pins
check for any short circuits between
caused by water.
drying the connector,
After completely
*
blow it with contact restorer and reassemble.
T-adapter
TEW00203
20-208
D155AX-5
TROUBLESHOOTING
3)
Handling control box

The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
Do not open the cover of the control box
unless necessary.
TEW00204
Do not place objects on top of the control

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

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors connected to the control box. Fit an arc welding
ground close to the welding point.
II
2.
TEW00206
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting or connect connectors.
2)
Before carrying out troubleshooting,

check that all the related connectors are properly inserted.
*
Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
*
If the power is turned ON with the connectors still disconnected,
unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting
of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
Ir If there is any change, there is probably defective contact in that circuit.
D 155AX-5
20-209
TROUBLESHOOTING
3.
POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment,
it is necessary
to be particularly careful.
1) Be careful of the operating
environment.
Avoid adding hydraulic oil, replacing filters,
repairing the machine in rain or high winds,
places where there is a lot of dust.
or
or
21 Disassembly
and maintenance
work in the field
If disassembly
or maintenance
work is carried
out on hydraulic equipment
in the field, there is
danger of dust entering the equipment.
It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange.
Disassembly and main-tenance
of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance
should be confirmed with special test equipment.
3)
Sealing openings
After any piping or equipment
is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked
with a rag, there is danger of 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,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4)
Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
TEWOO207
TEW00209
20-210
D155AX-5
TROUBLESHOOTING
POINTS
TO REMEMBER
5)
Change hydraulic oil when the temperature

is
high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as possible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants
and sludge in it will mix with
the new oil and will shorten the life of the hydraulic oil.
6)
Flushing operations
After disassembling
and assembling the equipment, 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 secondary flushing is carried out with the specified
hydraulic oil.
WHEN
CARRYING
OUT MAINTENANCE
TEW00210
7)
Cleaning operations
After repairing the hydraulic equipment
(pump,
control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge
or contaminants
in the hydraulic oil circuit.
The oil cleaning equipment
is used to remove
the ultrafine (about 3~) particles that the filter
built into the hydraulic equipment
cannot remove, so it is an extremely effective device.
D 155AX-5
20-211
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Item
Judgement
value
Action
1. Check fuel level, type of fuel
Add fuel
2.
Check for impurities in fuel
Clean, drain
3.
Check hydraulic oil level
Add oil
4.
Check hydraulic strainer
Clean, drain
5.
Check power train oil level
Add oil
6.
Check engine oil level
Add oil
7.
Check coolant level
Add water
8.
Check dust indicator for clogging
Clean or replace
9.
Check power train oil filter
Replace
10. Check hydraulic filter
Replace
11. Check final drive oil level
Add oil
12. Check for looseness, corrosion of battery terminal, wiring

13. Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
Tighten or replace
14. Check for looseness, corrosion of starting motor terminal,

wiring
Tighten or replace
15. Check operation of gauges
Repair or replace
16. Check for abnormal noise, smell
Repair
17. Check for oil leakage
Repair
18. Carry out air bleeding
Bleed air
19. Check battery voltage (engine stopped)
24 - 26 V
Replace
20. Check battery electrolyte level
Add or replace
21. Check for discolored, burnt, exposed wiring
Replace
22. Check for missing wiring clamps, hanging wiring
Repair
23. Check for water leaking on wiring (pay particularly careful

attention to water leaking on connectors or terminals)
Disconnect connector and dry
24. Check for blown, corroded fuses

25. Check alternator voltage (engine running at l/2 throttle
or above)
26. Check operating sound of battery relay (starting switch
ON, OFF)
20-212
After running for

Several minutes:
27.5 - 29.5 V
Replace
Replace
-
D155AX-5
TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION

Serial No. 70001 75000
Connector Connector No. of
type pins
No.
Place of use
Address

type pins
No.
Place of use
Address
CN-1
MIC
21
HSS controller
V-8
CN-111
Alternator terminal B
B-2
CN-1
Single pin
connector
Single pin
connector
Single pin
connector
Additional lamp connector
U-9
CN-112
Alternator terminal R
C-2
Rear speaker (Right)
T-9
CN-152
Neutral safety switch
V-1
T-9
CN-153
SWP
Intermediate connector
L-5
W-2
Rear wiper motor
U-9
CN-201
D-1
Rear speaker (Left)
V-9
CN-203
Right head lamp
C-7
Rear speaker (Left)
V-8
CN-204
Left head lamp
B-4
Horn
B-6
CN-2
CN-3
CN-4
CN-7
Single pin
connector
Single pin
connector
Single pin
connector
Additional lamp connector
Q-8
CN-205
Single pin
connector
CN-8
Single pin
connector
Room lamp
S-9
CN-206
Chassis ground
M-5
CN-9
Front wiper motor
Q-8
CN-211
KES
Rear lamp switch
P-7
CN-10
Radio
M-2
CN-212
KES
Bimetal timer
N-4
CN-11
Left wiper switch
M-2
CN-213
KES
Glow switch
CN-5
CN-6
P-7
CN-12
Front wiper switch
N-3
CN-214
SWP
16
CN-13
Right wiper switch
N-3
CN-215
M-6
Q-1
M-6
P-2
CN-14
Rear wiper switch
N-3
CN-216
KES
Head lamp switch
P-6
CN-15
Cab front lamp switch
O-3
CN-217
Monitor alarm
P-7
Alarm buzzer spare connector
V-8
Alarm buzzer spare connector
V-9
CN-16
Cab rear lamp switch
O-3
CN-217
CN-17
P-5
CN-218
Single pin
connector
Single pin
connector
CN-18
X-7
CN-220
Diode (For starting circuit)
X-6
S-1
CN-223
X-4
S-1
CN-224
Rear lamp
X-6
T-1
CN-243
Ripper lamp
I-9
Backup alarm
X-5
CN-19
CN-21
Single pin
connector
Single pin
connector
CN-22
Single pin
connector
CN-20
Cigarette lighter
W-7
CN-244
Single pin
connector
CN-245
L-6
X-4
CN-101
SWP
12
H-2
P-3
CN-103
Starting motor terminal R/S
C-1
CN-246
Ripper pin-puller solenoid valve
X-5
CN-104
T-1
CN-248
Ripper pin lamp
L-8
CN-105
T-1
CN-250
Starting switch terminal B
CN-106
Starting motor terminal B
E-8
CN-251
Backup alarm switch
L-4
CN-107
Heater relay terminal A
A-9
CN-260
Starting switch terminal BR
CN-108
Heater relay terminal B
C-8
CN-262
V-9
CN-109
Heater relay terminal C
A-9
CN-263
Ripper pin-puller switch
S-9
CN-110
Single pin
connector
D-7
CN-264
SWP
Q-7
20-214
4
D155AX-5
TROUBLESHOOTING
Connector Connector
No. of
type pins
No.
CN-263
I-ICN 264
SWP
II6
Place of use
Ripper pin-puller
Intermediate
Addresl
switch
CN-ARC
CN-C
connector
1 CN-270
1 -
I 1
I Starting switch terminal RI
1 CN-280
I I
I Starting switch terminal C
/ f3l3l~~
iA;{
CN-2H2
AMP040 16
I CN-351 I
I CN-361
:, 1~~~;:,:teminal
I I
XC1
HSS controller
1Air compressor
I KES I 2 I Window
washer
(Front)/
Connector Connector
No. of
type pins
No.
ICN-CRGPI
Place of use
Addres:
Air conditioner condenser
Battery relay
I 2 1HSS chargeoil pressuresensor I
CN-CSW
Steering neutral position

adjustment switch
CN-ENG
Engine rotation
CN-GO1
Diode (For monitor alarm)
CN-H
Battery relay
CN-HHP
Work equipment circuit

oil pressure sensor
CN-LPL
SWP
intermediate
sensor
connector
CN-362
KES
Window
washer
(Left)
ICN-PUPA1
12
CN-363
KES
Window
washer
(Right)
ICN-PUPBI
I 2 1HSS pump solenoid valve B I
ti CN-364
KES
Window
washer (Rear)
I CN-391 I
I 4 1Air conditioner
1CN-392 1
1 2 1Air conditioner
relay
CN-393
CN-394
Air conditioner blower register
1CN-395 1
1 4 1Air conditioner blower switch
I CN-396 I
I 3 I Air conditioner
1CN-397 1
I 2
451
SWP
II 8
switch
Intermediate
~;;~e~~~$rs~~sor
D155AX-5
Steering oil pressure sensor 1
PO1
PO2
IPI
Singlepin ,
connector
Singlepin ,
connector
Blade
pitch
switch
Blade
pitch
switch
12
I Monitor
panel
AMP040 12
Monitor
panel
Chassis
ground
IAMP
connector
12
CN-STHPI
SX8
CN-453
SWP
Reverse travel sensing

potentiometer
Enginec&ant temperahrre
sensor
Hydraulicoil temperaturesensor
CN-701
P2
1 :
Air conditioner clutch relay
I Diode (For air conditioner) 1
CN-452
1 CYZ~~,
CN-RSS
blower motor
Air conditioner thermostat

and pressure switch
I-ICN
1HSS pump solenoid valve A 1
~~;&p~~roieyidvalve~
Intermediate
connector
20-215
TROUBLESHOOTING
TYPE Of CONNECTOR AND POSITION OF INSTALLATION
CN-107
Cl+402
cN-206
D155AX-5
TROUBLESHOOTING
Pl
BVP00642
D155AX-5
TROUBLESHOOTING
cN,-Pl
CN-p2
N-213
CN-206
CN-396
CN-397
cN-&l cN-212
CN-14
CN-13
CN-1
CN-16
CNlol
cN216
(r-Z9A)
CN214
k9A)
BVPOO643
20-218
D155AX-5
TROUBLESHOOTING
CN-6
CN-263
/_
CN-3
CN-2
aN-;N-262
cN-6
cN-244
\
CN-16
D 155AX-5
CN-106
cN-104
CN-21
CN-20
\
CN-c
CN-H
CN-SW
TROUBLESHOOTING

The addresses in the following table refer to the locations of the connectors in the actual view
drawing.
type pins
No.
Place of use
Address

type pins
No.
Place of use
Address
Backup alarm relay
X-7
CN-21
DT
U-1
CN1
AMP
Monitor panel
O-9
CN-211
ML
Headlamp switch
P-7
CN-1
12
1-pin
connector 1
Engine controller
N-1
CN-214
DT
12
M-6
Connector for additional lamp
U-9
CN-215
DT
12
M-7
CN-014
CN-1
CN-10
Radio
M-4
CN-216
ML
Rear lamp switch
P-7
CN-101
G-2
CN-21A
Monitor alarm
W-7
CN-104
T-1
CN-22
DT
1-pin
connector
Cigarette lighter
W-8
CN-105
U-1
CN-220
DT
Diode (For starting circuit)
V-1
CN-106
Starting motor terminal B
P-1
CN-222
DT
12
M-7
CN-107
Heater relay terminal A
D-3
CN-223
X-4
CN-108
Heater relay terminal B
D-2
CN-224
Rear lamp (Left)
X-6
CN-109
Heater relay terminal C
D-3
CN-243
Rear lamp (Right)
I-9
CN-11
KES
M-4
CN-244
DT
Backup alarm
X-5
CN-110
Alternator terminal B
A-3
CN-245
L-6
CN-112
Alternator terminal R
A-3
CN-246
Ripper pin puller solenoid
X-5
CN-12
KES
Front wiper switch
M-4
CN-247
L-9
CN-13
KES
Right wiper switch
N-4
CN-248
Ripper point lamp
L-8
CN-14
KES
Rear wiper switch
N-4
CN-250
Starting switch terminal B
Q-9
CN-15
Cab front lamp switch
N-4
CN-251
Caution lamp
N-9
CN-152
DT
Transmission lock switch
X-3
CN-260
Starting switch terminal BR
P-8
CN-153
DT
12
L-5
CN-262
Horn switch
U-9
CN-16
Cab rear lamp switch
O-4
CN-263
Ripper pin puller switch
S-9
CN-17
KES
Right door wiper motor
P-5
CN-270
Starting switch terminal R1
Q-8
CN-18
KES
Left door wiper motor
W-8
CN-280
Starting switch terminal C
P-9
CN-19
For washer
U-1
CN-290
Starting switch terminal ACC
O-9
CN-1ST
DT
Gear speed switch 1
K-4
CN-2ND
DT
Gear speed switch 2
K-4
AMP
Monitor panel
N-9
CN-3
Engine controller
O-1
1-pin
connector
Rear speaker (Left)
T-9
CN2
wiper switch
Engine controller
O-1
CN-3
CN-2
1-pin
connector
T-9
CN-361
Windshield washer (Front)
X-4
CN-20
DT
T-1
CN-362
Windshield washer (Left)
X-4
CN-201
F-8
CN-363
Windshield washer (Right)
X-3
CN-203
Right headlamp
C-7
CN-364
Windshield washer (Rear)
X-3
CN-204
Left headlamp
E-8
CN-391
ML
Air conditioner relay
N-5
CN-204
X
1-pin
connector
Air conditioner compressor
A-2
CN-392
Air conditioner blower motor
O-6
Air conditioner thermostat &

dual pressure switch
M-8
CN-2
CN-205
20-219-1
4
Horn
B-6
CN-393
ML
D155AX-5
TROUBLESHOOTING

type pins
No.
Place of use
Address

type pins
No.
Place of use
Address
CN-394
ML
Air conditioner resistor
P-6
CN-E41
DT
Supply pump 1
A-1
CN-395
ML
Air conditioner blower switch
M-9
CN-E42
DT
Supply pump 2
B-1
CN-396
ML
Air conditioner switch
M-8
CN-E51
S-1
CN-397
ML
Diode (For air conditioner)
N-5
CN-E51
DT
Ne sensor
D-2
CN-398
ML
Air conditioner clutch relay
M-5
CN-E52
DT
G sensor
C-1
CN4
Monitor panel
M-9
CN-E53
DT
Common rail pressure sensor
C-1
CN-4
20
Engine controller
O-1
CN-E54
DT
Boost pressure sensor
A-2
CN-4
KES
Rear wiper motor
U-9
CN-FCD
DT
Decelerator pedal
S-1
CN-406
DT
HSS charge oil pressure sensor
G-9
CN-FCS
Fuel control dial
W-8
CN-422
X-5
GND1
Chassis ground
M-6
CN-423
Fuel level sensor
X-7
GND2
Chassis ground
T-1
CN-451
DT
12
L-7
CN-H
Battery relay
W-1
CN-452
DT
Hydraulic oil temperature sensor
J-4
CN-HET
Preheater relay
X-6
H-9
HD30 31
CN-453
DT
Transmission oil temperature

sensor
I-3
CN-HHP
DT
Work equipment circuit

pressure sensor
CN-454
Blade pitch solenoid
I-3
CN-LPL
DT
L-6
16
1-pin
connector 1
Engine controller
O-2
CN-M11 HD30
X-6
Rear speaker (Left)
U-9
CN-M2
Starting motor terminals R, S"
A-1
10
1-pin
connector 1
Engine controller
N-2
CN-M22 HD30
X-7
Rear speaker (Left)
U-9
CN-P01
Blade pitch switch
Q-7
CN-5
CN-5
CN-6
CN-6
CN-7
CN-7
CN-701
CN-8
CN-9
DT
14
1-pin
connector 1
Engine controller
N-1
CN-P31
DT
Connector for
additional lamp
Q-7
CN-P7
DT

sensor (Low)
sensor (High)
DT
12
1-pin
connector 1
L-7
CN-P8
Engine oil pressure switch (Low)
D-1
Room lamp
S-9
CN-P9
Engine oil pressure switch (High)
C-1
D-2
D-2
KES
Front wiper motor
Q-8
CN-PUPA
DT
HSS pump solenoid A
H-2
CN-ARC
Air conditioner condenser
W-1
CN-PUPB
DT
HSS pump solenoid B
H-2
CN-BCN
ML
Buzzer cancel switch
P-7
CN-RSS
DT
Reverse sensing potentiometer
X-2
CN-C
Battery relay
V-1
CN-ST1
DT
L-5
CN-CPR
Engine controller relay
W-7
CN-ST2
DT
K-4
CN-E07
DT
Engine speed sensor
D-3
CN-STR
DT
Steering potentiometer
X-2
CN-E21
HD30 31
C-4
CN-SW
Battery relay
V-1
CN-E22
HD30 31
D-4
CN-X1
Service switch
N-5
CN-E31
DT
Injector #1
A-4
CN-X2
Mode selector switch
O-5
CN-E32
DT
Injector #2
B-4
CN-ST1
21
HSS controller
V-8
CN-E33
DT
Injector #3
B-4
CN-ST2
20
HSS controller
V-8
CN-E34
DT
Injector #4
B-4
CN-ST3
16
HSS controller
V-8
CN-E35
DT
Injector #5
C-4
CN-T01
AMP
16
Monitor panel
N-9
CN-E36
DT
Injector #6
D-4
D155AX-5
20-219-2
4
TROUBLESHOOTING
20-219-3
4
D155AX-5
TROUBLESHOOTING
D155AX-5
20-219-4
4
TROUBLESHOOTING
20-219-5
4
D155AX-5
TROUBLESHOOTING
D155AX-5
20-219-6
4
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Ir The terms male and female refer to the pins, while the terms male housing and female
refer to the mating
No.
of
pins
portion
housing
of the housing.
X type connector
Male (female
housing)
Female
(male
housing)
TEWO0221
20-220
TEwoo223
TEW00224
TEW00225
TEW00226
D155AX-5
TROUBLESHOOTING
No.
of
pins
SWP type connector

Male (female
housing)
Female
(male housing)
6
6
TEwoo235
BLF90033
8
TEW00237
12
TEW0023B
12
BLwoO34
11
11
14
io i4
TEWO0239
16
Id
Id i
TEWOO240
_*------____-- .
fE!I
BLPOO036
D155AX-5
13
16
BLFQOO37
20-221
TROUBLESHOOTING
No.
of
pins
M type connector
Male (female housing)
Female (male housing)
M.Paoo36
TEWOO243
TEW00244
4
ZzI
@$
2
2
TEW00246
TEWOO245
6
@
3
TEW00247
TEW00246
8'
.5
BLPWO40
20-222
D 155AX-5
TROUBLESHOOTING
No.
of
pins
CONNECTION
TABLE FOR CONNECTOR
PIN NUMBERS
S type connector
Male (female
housing)
Female
(male
housing)
10
12
io
TEW00251
BLFVW42
12
BLPGoo43
TEWOO2M
ii!%
1
Ii
8
TEW00254
16
D 155,4X-5
16
BLFuO044
TEW00256
20-223
CONNECTION
TROUBLESHOOTING
No.
of
pins
TABLE FOR CONNECTOR PIN NUMBERS
MIC connector
:Jl
BLPOOO45
BLPOO046
BLPOOO46
BLPOoO47
ollouo
0
00
13
13
BLPOCQ49
BLPOOO50
17
17
BLP00051
BLPCO052
21
20-224
TEW00259
TEW00260
D 155AX-5
TROUBLESHOOTING
No.
of
pins
AMP040 type connector


8
BLPooo53
BLFOOO54
12
12
16
16
9
BLPOOO57
TEWO0232
20
11
1
TEW00234
D155AX-5
20-225
CONNECTION TABLE FOR CONNECTOR
TROUBLESHOOTING
No.
of
pins
AMP070
Male (female
type connector
housing)
1
PIN NUMBERS
Female
7
(male
housing)
BLFOOO59
12
%=
8
BLmoo61
20-226
D155AX-5
TROUBLESHOOTING
No.
of
pins
L type type connector

Male (female
al
housing)
Female
(male
housing)
03
IEII
TEW00258
D 155AX-5
20-227
CONNECTION
TROUBLESHOOTING
No.
of
pins
Automobile
Male (female
TABLE FOR CONNECTOR
connector
Female
housing)
PIN NUMBERS
(male
housing)
BLPM)O64
BLpooO63
2
BLPOOo66
BLFWO65
EB
BLPOOO67
BLPOO069
,
fl!r?l
5
'5
20-228
BLPCQ071
8
EiLPOOO72
D155AX-5
TROUBLESHOOTING
No.
of
pins
Relay connector
BLP00073
BLP00074
4
5
BLP00075
D155AX-5
BLP00076
20-229
TROUBLESHOOTING
Type
Shell
size
code
[ ]
18-8
(1)
18-14
(2)
20-229-1
4
HD30 series connector

Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
Pin (male terminal)
Pin (male terminal)
Pin (male terminal)
D155AX-5
TROUBLESHOOTING
Type
Shell
size
code
[ ]
18-20
(3)
18-21
(4)
D155AX-5

Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (male terminal)
Pin (male terminal)
Pin (male terminal)
20-229-2
4
TROUBLESHOOTING
Type
Shell
size
code
[ ]
24-9
(5)
24-16
(6)
20-229-3
4

Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (male terminal)
Pin (male terminal)
Pin (male terminal)
D155AX-5
TROUBLESHOOTING
Type
Shell
size
code
[ ]
24-21
(7)
24-23
(8)
D155AX-5

Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (male terminal)
Pin (male terminal)
Pin (male terminal)
20-229-4
4
TROUBLESHOOTING
Type
Shell
size
code
[ ]
24-31
(9)
20-229-5
4

Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (male terminal)
D155AX-5
TROUBLESHOOTING
[Number is printed on each connector (Wire inserting end).]

No.
of
pins
DT, DT-T series connector

Body (Plug)
Body (Receptacle)
D155AX-5
20-229-6
4
TROUBLESHOOTING

No.
of
pins
DT, DT-T series connector

Body (Plug)
Body (Receptacle)
12
20-229-7
4
D155AX-5
TROUBLESHOOTING

No.
of
pins
DTM series connector

Body (Plug)
Body (Receptacle)
D155AX-5
20-229-8
4
TROUBLESHOOTING
No.
of
pins
DTHD series connector

Body (Plug)
Body (Receptacle)
20-229-9
4
D155AX-5
D155AX-5
(Blank page)
20-229-10
4
FUNCTION OF ELECTRONIC CONTROL SYSTEM

Serial No. 70001 75000
20-230
4
D155AX-5
Functions of HSS system

The HSS system consists of an HSS controller, sensors, switches, solenoid valves, relays, and a monitor panel.
The HSS controller receives input signals
from each sensor and switch, and calculates
them, then sends them to each solenoid
valve and relay to control the HSS system.
At the same time, the HSS controller communicates information with the monitor
panel through the network circuit (S-NET).
The steering potentiometer measures the
quantity of operation of the joystick in the
steering direction, and inputs analog signals
to the HSS controller.
The steering oil pressure sensor senses the
operating pressure of both steering circuit,
and inputs analog signals to the HSS controller.
The work equipment circuit oil pressure sensor senses the operating pressure of the work
equipment circuit, and inputs analog signals
The HSS charge pressure sensor senses the
oil pressure in the HSS charge circuit, and
inputs ON/OFF signals to the HSS controller.
The engine rotation sensor senses engine
rotation, and inputs pulse signals to the HSS
controller.
The travel reverse sensing potentiometer
senses the reverse position of the joystick,
The backup alarm limit switch detects the
reverse position of the directional lever of
the transmission valve, and inputs ON/OFF
signals to the HSS controller.
The steering neutral position adjustment
switch detects changes of the adjustment
mode and working mode, and inputs ON/
OFF signals to the HSS controller.
The HSS pump solenoid valve receives analog signals from the HSS controller, and controls the swash plate angle of the HSS pump.
The backup alarm relay receives ON/OFF signals from the HSS controller, and changes
the backup alarm circuit.
The monitor panel communicates with the
HSS controller through the network circuit
(S-NET). Upon receiving an abnormality signal from the HSS controller, the monitor
panel turns on the electric system caution
lamp and alarm buzzer.
D155AX-5
The emergency steering switch is installed

when the HSS system has trouble. It sends
signals directly to the HSS pump solenoid
valve without passing through the HSS controller to steering the machine in an emergency.
Functions of monitor panel

The monitor panel receives input signals
them, then turns on the gauges and lamps
of itself and sends output signals to the alarm
buzzer to control the monitor panel system.
At the same time, the monitor panel communicates information with the HSS controller through the network circuit (S-NET).
The engine oil pressure switch senses engine oil pressure, and inputs ON/OFF signals to the monitor panel.
The engine coolant temperature sensor
senses the engine coolant temperature, and
inputs analog signals to the monitor panel.
The transmission oil temperature sensor
senses transmission oil temperature, and
The fuel level sensor senses quantity of the
remaining fuel, and input analog signals to
the monitor panel.
If the starting switch is turned to the
preheating position or another position, it
inputs ON/OFF signals to the monitor panel.
The alternator inputs the voltage generated
by itself to the monitor panel.
The alarm buzzer receives ON/OFF signals
from the monitor panel, and turns on and
off itself.
20-231
TROUBLESHOOTING
20-231-1
4
D155AX-5
TROUBLESHOOTING
Functions of HSS system

The HSS system consists of an HSS controller, sensors, switches, solenoid valves, relays, and a monitor panel.
The HSS controller receives input signals
them, then sends them to each solenoid
valve and relay to control the HSS system.
At the same time, the HSS controller communicates information with the monitor
panel through the network circuit (S-NET).
The steering potentiometer measures the
quantity of operation of the joystick in the
steering direction, and inputs analog signals
The steering oil pressure sensor senses the
operating pressure of both steering circuit,
The work equipment circuit oil pressure sensor senses the operating pressure of the work
equipment circuit, and inputs analog signals
The HSS charge pressure sensor senses the
oil pressure in the HSS charge circuit, and
inputs ON/OFF signals to the HSS controller.
The engine rotation sensor senses engine
rotation, and inputs pulse signals to the HSS
controller.
The travel reverse sensing potentiometer
senses the reverse position of the joystick,
The backup alarm limit switch detects the
reverse position of the directional lever of
the transmission valve, and inputs ON/OFF
signals to the HSS controller.
The service switch, mode selector switch,
and buzzer cancel switch are used to input
the data for the monitoring function and
adjustment mode.
The HSS pump solenoid valve receives analog signals from the HSS controller, and controls the swash plate angle of the HSS pump.
The backup alarm relay receives ON/OFF signals from the HSS controller, and changes
the backup alarm circuit.
The monitor panel communicates with the
HSS controller through the network circuit
(S-NET). Upon receiving an abnormality signal from the HSS controller, the monitor
panel turns on the electric system caution
lamp and alarm buzzer.
D155AX-5
The emergency steering switch is installed

when the HSS system has trouble. It sends
signals directly to the HSS pump solenoid
valve without passing through the HSS controller to steering the machine in an emergency.
Functions of monitor panel

The monitor panel receives input signals
them, then turns on the gauges and lamps
of itself and sends output signals to the alarm
buzzer to control the monitor panel system.
At the same time, the monitor panel communicates information with the HSS controller through the network circuit (S-NET).
The engine oil pressure switch senses engine oil pressure, and inputs ON/OFF signals to the monitor panel.
The engine coolant temperature sensor
senses the engine coolant temperature, and
The transmission oil temperature sensor
senses transmission oil temperature, and
The fuel level sensor senses quantity of the
remaining fuel, and input analog signals to
the monitor panel.
If the starting switch is turned to the
preheating position or another position, it
inputs ON/OFF signals to the monitor panel.
The alternator inputs the voltage generated
by itself to the monitor panel.
The alarm buzzer receives ON/OFF signals
from the monitor panel, and turns on and
off itself.
The engine oil pressure and engine water
temperature are input to the engine controller to control the engine and transmitted as
caution information through the communication system to the monitor panel.
20-231-2
4
DISPLAY OF HSS CONTROLLER

Serial No. 70001 75000
20-232
4
D155AX-5
The HSS controller indicates the following system information

and error codes of troubles on the
LED unit.
I) Output current to HSS pump solenoid valve
2) Differential pressure between both HSS steering circuit
3) Error codes of troubles
Since the LED is reflected in the mirror before it is seen, reflect it in a mirror when checking it.
Indication pattern of LED
When P error
(5 sec. )
(When operat
ins
lever)
(0. 5 sec.
and
(3 sec. 1
occured
occured
(0. 5 sec.
/
When P error
E error
(3 sec.
When E error
occured
TWD00978
0
0
0
Co
*
2.
*
Indication of start: If the starting switch is turn to the ON position, [881 is displayed (for 5 minutes).
Indication of information:
If the joystick is operated for steering, the information
is displayed prior
If the joystick is not operated, the information
is not
to all other items (during operation).
displayed and the LED goes off.
P error: All the past error codes stored in the controller are displayed (0.5 seconds + 3 seconds).
E error:. All the error codes currently output are displayed (0.5 seconds + 3 seconds).
All the stored or currently output error codes are displayed once on P error and E error areas, then
the same error codes are displayed from the first one.
Indication of information
The type of the displayed information depends on the condition of the machine and the position of
the steering neutral position adjustment switch.
7) When steering neutral position adjustment switch is at OPERATE position
If the joystick is operated for steering while the starting switch is at the ON or START position,
the current supplied by the HSS controller to the HSS pump solenoid valve is displayed.
*
The unit is IOmA (If 12 is displayed, the current is 120mA).
*
Since the information is displayed prior to all other items, the current can be checked even
while an error code is displayed.
2)
When steering neutral position adjustment switch is at ADJUST position

If the steering neutral position adjustment mode is selected and the joystick is operated
steering, the differential oil pressure between both steering circuit is displayed.
Ir For details, see ADJUSTING
STEERING NEUTRAL POSITION.
D155AX-5
for
20-233
3.
DISPLAY
OF HSS CONTROLLER
Indication of P error and E error

I) Contents of displayed error codes
See the following table of the error codes and troubled systems.
2) Deleting method of error codes
With the buzzer cancel switch on the monitor panel pressed, turn the starting switch to the ON
position and keep the buzzer cancel switch pressed for 3 seconds or longer.
Ir Check that the steering neutral position adjustment
switch is at the OPERATE position.
If
the deleting operation is performed while the steering neutral position adjustment switch
is at the ADJUST position, the steering neutral position adjustment
mode is selected.
3) Using method of error codes
When performing
troubleshooting
after displaying
the error codes, take a note of the all
displayed error codes, then delete them. Then, perform the error code reproducing operation
and troubleshoot
according to the displayed error codes.
*
There may be trouble caused by misoperations
or disconnections
of connectors among the
stored error codes. Avoid unnecessary troubleshooting
work for such trouble.
*
After finishing troubleshooting,
delete the error codes again.
20-234
D 155AX-5
TESTING
DISPLAY
AND ADJUSTING
Error codes and contents

Error
code
of troubles
Troubled
system
19
Short circuit in steering
20
Disconnection
21
1 Short circuit in steering
22
I Disconnection
23
1 Trouble
oil pressure
Disconnection
25
Short circuit in steering
Alarm
buzzer
sensor system A
E+
E+
sensor system A
sensor system
oil pressure
potentiometer
24
Alarm
lamp
oil pressure
in steering
of steering
of trouble
and contents
oil pressure
in steering
in steering
27
1 Short circuit in steering
29
1 Trouble
systems
potentiometer
system
system
Short circuit in travel
52
Disconnection
r~ 53
I Disconnection
1 Short circuit in backup alarm relay system
Ir
54
reverse sensing
in backup alarm
system
potentiometer
system
relay system
Lowering
62
Excessive difference of signal value between

potentiometer
systems 1 and 2 [II
steering
6d
Excessive difference of signal value between

potentiometer
systems 1 and 2 [III
steering
6E
Trouble of either steering potentiometer

deviation of either system from neutral
I Disconnection
S+
65
Short circuit in HSS pump solenoid
66
Disconnection
67
Short circuit in HSS pump solenoid
in HSS pump solenoid
in work equipment
s+
s+
system
point
valve system
s+
s+
s+
s+
s+
1~1~1
B
B
circuit oil pressure sensor system1
s+
s+
E+
E+
71
I Short circuit in work equipment circuit oil pressure sensor system
8d
I S-NET communication
1.1.1
error
Trouble
The
S:
S+:
E:
E+:
symbols
Turn the
Turn the
Start the
Start the
D 155AX-5
of offset current
memory
s+
1 Disconnection
EO
s+
70
Disagreement
of reverse sensing potentiometer
alarm switch signals with each other
1.1.1
valve system A
valve system
and excessive
valve system A
99
s+
s+
of controller
in HSS pump solenoid
E+
txlxl
57
64
of source voltage
Ial.
Id@I
14.1
Id@1
potentiometer
reverse sensing
E+
sensor system
51
Reproducing
operation
1.1.1
system 2
potentiometer
in travel
1 and 2
system
potentiometer
rotation
sensor system
Disconnection
in steering potentiometer
ET----~~~~~~~~
of engine
OF HSS CONTROLLER
and backup
of the reproducing operation denote the following operations.

starting switch to the ON position.
starting switch to the ON position, then operate the concerned
engine.
engine, then operate the concerned switch or lever.
switch
or lever.
20-235
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL

1: Monitoring mode
Sending and returning of items = Buzzer cancel switch
2: Service code mode
E: Error which is occurring currently, P: Error which occurred in past = Code and service meter
reading at time of occurrence of error are displayed alternately.
Sending of items = Buzzer cancel switch, Clearing code (history) = Mode selector switch
3: Adjustment mode
Sending of items = Buzzer cancel switch
20-235-1
4
D155AX-5
TROUBLESHOOTING
Selection of each mode
D155AX-5
20-235-2
4
TROUBLESHOOTING
1. Ordinary display function

Gear speed (1) is displayed in the upper display unit and service meter (2) is displayed in
the lower display unit during ordinary work.
2. Function of displaying user code when error

occurs
If any error to be notified to the operator occurs during work, user code (3) and service
meter (4) are displayed alternately in the lower
display unit.
When a user code of high importance is displayed, the caution lamp flashes and caution
buzzer sounds.
<Reference>
A user code is displayed only when an error of
high importance is detected.
An error may have occurred even if a user
code is not displayed. Accordingly, if you feel
any abnormality, be sure to check for a service
code in the service code display mode.
20-235-3
4
D155AX-5
TROUBLESHOOTING
User codes and abnormal phenomena (Which indicate actions to be taken by operator)
User code
Abnormal phenomenon
Caution lamp
Caution buzzer
E01
Work can be continued with some functions stopped.

Abnormality in backup alarm relay
Abnormality in engine speed sensor of monitor panel
Abnormality in buzzer cancel switch
E02
Some functions, including limiting function, etc.

are stopped (Work can be continued with care).
Abnormality in water temperature sensor
Abnormality in power distribution control
function of HSS
CALL03
Move to a safe place and call a serviceman.

Abnormality in injector
Abnormality in steering position 1 system
Abnormality in forward-reverse travel sensor
CALL
Stop the machine immediately and call a serviceman.

Abnormality in control power source
Abnormality in steering position 2 system
Abnormality in engine pump
D155AX-5
20-235-4
4
TROUBLESHOOTING
3. Function of displaying in monitoring mode

The condition of each part of the machine can
be checked on the monitor panel by the signals from the sensors installed to various parts
of the machine.
Among the monitored information items, the
engine speed, voltage, current, etc. are indicated by values and the other items are indicated by bits as the condition of pressure
switches.
1) Monitoring code (5)
2) Monitoring mode mark (6) (Lamp on the
left side) lights up.
3) Monitor information (7)
20-235-5
4
D155AX-5
TROUBLESHOOTING
Monitoring code Nos. and indicated items

For details of an item, the indication unit of which is bit, see "Details of items indicated by bits".
Code
No.
Monitoring item
Indication
unit
Component
99
Engine speed
rpm
HSS controller
bA
Battery voltage
mV
Monitor panel
HA
Work equipment hydraulic pressure
J5
HSS pump (A-B) differential pressure
kg/cm2
HSS controller
HSS controller
kg/cm
JA
HSS pump A oil pressure
kg/cm
HSS controller
Jb
HSS pump B oil pressure
kg/cm2
HSS controller
PA
HSS pump A output current
mA
HSS controller
CA
HSS pump feedback current
mA
HSS controller
Pb
HSS pump B output current
mA
HSS controller
L1
Steering lever position voltage 1
mV
HSS controller
L2
Steering lever position voltage 2
mV
HSS controller
RU
Reverse travel signal potentiometer voltage
mV
HSS controller
7H
Transmission switch input condition
bit
HSS controller
75
High engine water temperature sensor
Engine controller
76
Low engine water temperature sensor
Engine controller
77
Torque converter oil temperature sensor voltage
Monitor panel
Fd
Fuel control dial voltage
mV
Engine controller
FA
Acceleration percentage
Engine controller
dU
Decelerator voltage
mV
Engine controller
FC
Throttle correction percentage
Engine controller
CP
Common rail pressure
MPa
Engine controller
CO
Common rail command pressure
MPa
Engine controller
bP
Boost pressure
kPa
Engine controller
HE
Transmission switch input condition
bit
HSS controller
EC
Engine control mode
Engine controller
EO
Engine Q regulator command value
Engine controller
C7
Injecting timing command
Engine controller
mm /st
Engine controller
F1
Fuel injection rate command value
FP
Converted torque
Engine controller
67
Fuel temperature
Engine controller
IE
Engine speed
rpm
Engine controller
5N
Indication of condition of S-NET
U1
Engine controller program version
Engine controller
U2
Monitor panel tachometer module program version
Monitor panel
U4
Monitor panel caution module program version
Monitor panel
U5
HSS controller program version
HSS controller
FL
Fuel level sensor voltage
mV
Monitor panel
D155AX-5
bit
Monitor panel
20-235-6
4
TROUBLESHOOTING
Details of items indicated by bits

An example of indication by bit is shown in
the figure at right.
1, 3, and 5 indicate the OFF state.
2, 4, and 6 indicate the ON state.
HE: Transmission switch input condition (Neutral)
1: Neutral stage 1
2: Neutral stage 2
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
The neutral state is shown in the figure at right.
1 and 2 are always in the same state. Difference between them in indication shows an abnormality.
The HSS controller notifies the engine controller whether the transmission is in neutral with
this signal.
7H: Transmission command condition

1: Forward travel command
2: Reverse travel command
3: 1st gear speed command
4: 2nd gear speed command
5: 3rd gear speed command
6: (Unused)
The state of the "forward 1st gear speed" is
shown as an example in the figure at right.
20-235-7
4
D155AX-5
TROUBLESHOOTING
5N: Condition of connection of S-NET

1: Engine controller
2: Monitor panel (Tachometer module)
3: (Unused)
4: HSS controller
5: Monitor panel (Caution module)
6: (Unused)
Indication under the normal condition is shown
in the figure at right. (All are turned ON.)
4. Function of indicating service code

The engine controller, machine controller, or
monitor panel detects abnormalities in the electric system and saves the contents and occurrence time of the abnormalities in he monitor
panel in the order of occurrence.
In this mode, the saved service codes and the
service meter readings at the times when those
codes were output are displayed alternately.
If the letter at the left end of a service code is
E, the abnormality is not corrected yet.
P, the abnormality is corrected.
Up to 20 service codes can be saved.
If any service code is not saved, " " is displayed in the upper display unit.
1) Output error No. is displayed (8).
2) Service code mark (9) lights up.
3) Service code (10).
4) Time when error occurred is displayed (11).
D155AX-5
20-235-8
4
TROUBLESHOOTING
Service codes and abnormal systems

Service
code
Contents of abnormality
Reproduction
method
Troubleshooting
mode
User code
E0101
Abnormality in network system (engine controller system)
N mode
CALL03
E0104
Abnormality in network system (monitor panel system)
N mode
CALL03
E0105
Abnormality in network system (HSS controller system)
N mode
CALL03
E0113
Lowering of HSS controller power source voltage
E mode
CALL03
E0120
Abnormality in monitor panel caution lamp system
M mode
CALL03
E0121
Abnormality in monitor panel caution buzzer system
M mode
CALL03
E0143
Abnormality in HSS controller 5-V power source
E mode
CALL03
E0145
Abnormality in HSS controller sensor power source
E mode
CALL03
E0152
Abnormality in network system (HSS controller system)
N mode
CALL03
E0161
Abnormality in saving of offset current
E mode
CALL03
E0165
Error in network communication
N mode
CALL03
E0211
Abnormality in power train (torque converter) oil temperature
M mode
E0221
Abnormality in gear speed switch system
S+
E mode
E0233
Abnormality in reverse sensing potentiometer system
S+
E mode
CALL03
E0237
Abnormality in transmission neutral signal
S+
E mode
E01
E0272
Nonconformity of reverse sensing potentiometer and backup alarm switch signal
S+
E mode
E02
E0329
Abnormality in HSS oil charging pressure
M mode
E01
E0360
Disconnection in work equipment circuit oil pressure sensor system
E+
E mode
E01
E0361
Short circuit in work equipment circuit oil pressure sensor system
E+
E mode
E01
E0401
Abnormality in engine controller power source
G mode
CALL
E0402
Abnormality in engine controller
G mode
CALL
E0405
Abnormality in fuel control dial system
G mode
CALL03
E0406
Abnormality in decelerator potentiometer system
G mode
CALL03
E0409
Abnormality in engine Ne speed sensor system
G mode
CALL03
E0410
Abnormality in engine G speed sensor system
G mode
CALL03
E0430
Abnormality in engine oil pressure
M mode
CALL
E0432
Abnormality in engine water temperature
M mode
E01
E0436
Abnormality in network system (engine controller)
N mode
CALL03
E0458
Short circuit in fuel injector No. 1/No. 2/No. 3 system
G mode
CALL03
E0459
Short circuit in fuel injector No. 4/No. 5/No. 6 system
G mode
CALL03
E0460
Abnormality in controller drive circuit
G mode
CALL03
E0461
Disconnection in fuel injector No. 1 system
G mode
E02
E0462
G mode
E02
E0463
G mode
E02
E0464
G mode
E02
E0465
G mode
E02
E0466
G mode
E02
E0468
Overcurrent in fuel supply pump PCV1 system
G mode
CALL03
20-235-9
4
D155AX-5
TROUBLESHOOTING
Service
code
Reproduction
method
Troubleshooting
mode
User code
E0469
Disconnection in fuel supply pump PCV1 system
G mode
CALL03
E0470
G mode
CALL03
E0471
G mode
CALL03
E0472
Abnormality in boost pressure sensor system
G mode
E02
E0474
Abnormality in common rail fuel pressure sensor system
G mode
CALL03
E0476
Abnormality in high engine water temperature sensor system
G mode
E01
E0478
Abnormality in low engine water temperature sensor system
G mode
E02
E0480
Abnormality in common rail fuel pressure
G mode
CALL03
E0481
Abnormality in high common rail fuel pressure 1
G mode
CALL03
E0482
Abnormality in high common rail fuel pressure 2
G mode
CALL03
E0483
No-pressure feed by fuel supply pump 1
G mode
CALL03
E0484
No-pressure feed by fuel supply pump 2
G mode
CALL03
E0487
Abnormality in engine oil pressure switch system
G mode
E01
E0488
Abnormality in power source system 1
G mode
CALL
E0489
G mode
E02
E0490
Abnormality in Q regulator switch signal
G mode
E02
E0491
Short circuit in starting switch C system
G mode
CALL
E0493
Abnormality in fuel temperature sensor system
G mode
E01
E0610
Disconnection in backup alarm relay system
S+
E mode
E01
E0611
Short circuit in backup alarm relay system
S+
E mode
E01
E0730
Abnormality in both steering potentiometer systems 1 and 2
E+
E mode
CALL03
E0731
Large difference between signal values of steering potentiometer systems 1 and 2 I
E+
E mode
CALL03
E0732
Abnormality in one steering potentiometer system and large deviation of neutral position of other system
E+
E mode
CALL03
E0733
Abnormality in steering potentiometer system 1
E+
E mode
CALL03
E0734
Abnormality in steering potentiometer system 2
E+
E mode
CALL03
E0735
Large difference between signal values of steering potentiometer systems 1 and 2 II
E+
E mode
CALL03
E0768
Disconnection in steering oil pressure sensor A system
E+
E mode
CALL03
E0769
Short circuit in steering oil pressure sensor A system
E+
E mode
CALL03
E0770
Disconnection in steering oil pressure sensor B system
E+
E mode
CALL03
E0771
Short circuit in steering oil pressure sensor B system
E+
E mode
CALL03
E0772
Disconnection in HSS pump solenoid A system
S+
E mode
CALL03
E0773
Short circuit in HSS pump solenoid A system
S+
E mode
CALL03
E0774
Disconnection in HSS pump solenoid B system
S+
E mode
CALL03
E0775
Short circuit in HSS pump solenoid B system
S+
E mode
CALL03
E0930
Abnormality in engine speed sensor system
E+
E mode
E01
D155AX-5
20-235-10
4
TROUBLESHOOTING
Reproduction method
S: Service code reproduced by turning the starting switch ON
S+: Service code reproduced by turning the starting switch ON and operating the corresponding
switch or lever
E: Service code reproduced by starting the engine
E+: Service code reproduced by starting the engine and operating the corresponding switch or
lever
Troubleshooting mode
N mode: Troubleshooting
G mode: Troubleshooting
E mode: Troubleshooting
M mode: Troubleshooting
of
of
of
of
network system (N mode)

engine controller system (G mode)
HSS controller system and electric system (E mode)
monitor panel system (M mode)
Method of reproducing service codes and confirming resetting of them

Reproduce the service codes and confirm resetting of them after the repair according to the
following procedure.
1) Select the service code display mode and check the displayed service codes.
Record the all service codes.
2) Delete the service codes.
Turn mode selector switch downwards.
3) Reproduce the all service codes which have been displayed.
For the reproduction method, see the above list or the text of troubleshooting.
4) Confirm that the service codes are "displayed" or "not displayed" in the service code display
unit.
20-235-11
4
D155AX-5
TROUBLESHOOTING
5. Display function in adjustment mode

1) Adjustment items (12) are displayed.
2) Adjustment mode marks (13) light up (on
both sides).
3) Adjustment value (14) is displayed.
i) HSS neutral adjustment mode "HN" is
displayed.
ii) HSS initial current adjustment mode
"CC" is displayed.
iii) Reduced cylinder mode (EO) is displayed.
Adjustment code Nos. and adjustment items

Code No.
Adjustment item
Contents
HSS neutral adjustment mode
A machine equipped with the HSS steering system may turn in

either direction while the lever is in neutral because of dispersion of
the pump output, etc. This mode is used to slant the swash plate to
prevent the machine from turning while the lever is in neutral.
(For details of usage of this mode, see TESTING AND ADJUSTING.)
CC
HSS initial current

adjustment mode
When an operator steers a machine equipped with the HSS steering

system, he (she) may feel the steering condition differently between
the steering directions in the initial period of steering. This mode is
used to change the initial current for the period just after steering is
started to solve the above problem.
E0
Reduced cylinder
mode
This mode is used to stop one or more injectors of a common rail

engine to find out an abnormal injector.
HN
D155AX-5
20-235-12
4
HOW TO READ JUDGMENT TABLE
HOW TO READ JUDGMENT TABLE

This judgment table is used to see if each machine trouble is caused by a fault of the engine system,
hydraulic and mechanical system or electrical system, then go to the troubleshooting code (S-, E, H-) matched to the trouble.
Trouble with the monitor panel are not contained in this judgment table.
If the monitor panel has any trouble, go to TROUBLESHOOTING FOR MONITOR PANEL SYSTEM
(M-MODE) directly.
<Using procedure>
1. Specify each machine trouble in the column of Trouble (Trouble code), then go to the right section
of the table.
2. If there is or S in a box of the table, judge by the item in the upper box to determine the moving
direction.
When there is : Referring to INDICATION ON LED OF HSS CONTROLLER, check the error code
displayed by the HSS controller.
When there is S: Insert a T-branch in the blade pitch solenoid valve (CN-454) or ripper pin-puller
solenoid valve (CN-246), and see if the operation of the blade pitch switch or ripper pin-puller
switch and the ON/OFF operation of the solenoid valve input voltage are normal.
3. Go to the trouble code at the bottom of the judgment table according to the judgment result or go
to the right of the table further.
When there is : If the concerned error code is displayed, go to the trouble code at the bottom of
the judgment table.
If the concerned error code is not displayed, go to the right of the table further.
When there is S: If the solenoid valve input voltage is not turned on/off normally, go to the trouble
code at the bottom of the judgment table.
If the solenoid valve input voltage is turned on/off normally, go to the right of the table further.
20-236
D155AX-5
D155AX-5
(Blank page)
20-237
JUDGMENT
TABLE FOR ENGINE SYSTEM, HYDRAULIC AND
MECHANICAL SYSTEM, AND ELECTRICAL SYSTEM
Judgment item
Trouble (Trouble code)
Indication by LED of HSS controller

(Error code)
19
20
21
22
23
24
25
26
27
E-6
E-7
E-8
E-9
Engine does not start easily (It always takes long time to start engine).
Engine does not rotate.
Engine does
Engine rotates but does not discharge exhaust gas.
not start.
Engine discharges exhaust gas but does not start (Fuel is injected).
Engine speed does not rise sharply.
Engine system
Engine stops during operation.

Engine rotation is irregular (hunts).
Output is insufficient or power is low.
Exhaust gas black (Incomplete combustion)
Oil consumption is excessive or exhaust gas is blue.
Oil becomes dirty prematurely.
Fuel consumption is excessive.
Coolant contains oil, blows back or reduces.
Oil pressure caution lamp lights up.
Oil level rises (Oil contains water or fuel).
Coolant temperature rises too high (Overheating).
Abnormal sound is generated.
There is excessive vibration.
Machine does not move or moves slowly at any gear speed in each direction.
Machine does not move or travel power is low in one direction.
Power train system
Machine does not move or moves slowly at specific gear speed.

Long time lag is made in changing travel direction or gear speed.
Travel power (Drawbar pull) is low.
Machine cannot be steered (to one direction).
Steering speed or power is low.
Steering direction is reversed in reverse travel.

Machine steers by itself in neutral position (during travel or at standstill).
If machine is steered, engine stops.
Abnormal sound comes out of HSS pump or HSS motor.

Brake does not work.
Power train oil overheats.
Backup alarm does not sound.
Work equipment system
Work equipment does not work at all.

Work equipment speed or power is low.
Blade lifting speed or power is low.
Blade tilting speed or power is low.
Ripper lifting speed or power is low.
Ripper tilting speed or power is low.
Hydraulic drift is large in blade lifting direction.
Hydraulic drift is large in blade tilting direction.
Hydraulic drift is large in ripper lifting direction.
Blade pitch does not work normally (When equipped with pitch dozer).
Ripper pin puller does not work normally (When equipped with giant ripper).
Abnormal sound comes out of work equipment pump.
Troubleshooting code
20-238
4
E-1
E-2
E-3
E-4
E-5
D155AX-5
29
51
52
53
54
57
62
6d
6E
64
65
66
67
70
71
8d
99
E0
Troubleshooting
code
Indication by LED of HSS controller (Error code)
Measure- Blade pitch

ment of
voltage solenoid valve
Measure- Ripper pin-puller
ment of
voltage solenoid valve
S-1
E-31
S-2
S-3
S-4
S-5
S-6
S-7
S-8
S-9
S-10
S-11
S-12
S-13
S-14
S-15
S-16
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
E-28
H-11
H-12
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-23 E-24 E-25 E-26 E-27 E-29 E-30
D155AX-5
20-239
4
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Serial No. 70001 75000
Component
Troubleshooting code No.

S
Troubleshooting of engine
Troubleshooting of HSS controller and electrical system
Troubleshooting of hydraulic and mechanical system
Troubleshooting of monitor system

Component
Troubleshooting code No.

N
G
E
H
M
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
of
of
of
of
of
network system
engine controller system
HSS controller system and electric system
hydraulic system and mechanical systems
monitor panel system and electric parts system
2. Method of using troubleshooting table for each troubleshooting mode

1 Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code and failure mode (problem with the machine).
2 General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with .
The precautions marked are not given in the
, but must always be followed when
carrying out the check inside the
.
3 Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, a), b)), so go to the appropriate
section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item in the failure mode.
4 Method of following troubleshooting chart
YES
Check or measure the item inside
, and according to the answer follow either

NO
the YES line or the NO line to go to the next

. (Note: The number written at the top
right corner of the
is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column.
Check the cause and take the action given in the Remedy column on the right.
Below the
there are the methods for inspection or measurement, and the judgement values. If the judgement values below the
are correct or the answer to the
question inside the
is YES, follow the YES line; if the judgement value is not
correct, or the answer to the question is NO, follow the NO line.
Below the
is given the preparatory work needed for inspection and measurement,
and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the
equipment may be damaged. Therefore, before starting inspection or measurement,
always read the instructions carefully, and carry out the work in the correct order.
5 Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For
details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6 Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the
connector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
20-240
4
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF NETWORK SYSTEM

(N MODE)
[Serial No. 75001 and up]
Action taken by controller when abnormality occurs and problems on machine ....................... 20-252
N mode system electrical circuit diagram ........................................................................................... 20-254
Service codes of network system ........................................................................................................ 20-255
N-1 [E0101] (Abnormality in network system: engine controller system) is displayed .............. 20-256
N-2 [E0104] (Abnormality in network system: monitor panel system) is displayed ................... 20-257
N-3 [E0105] (Abnormality in network system: HSS controller system) is displayed .................. 20-258
N-4 [E0101], [E0104], and [E0105] (Abnormality in network system) are displayed at same time .... 20-259
N-5 [E0152] (Abnormality in network system: HSS controller system) is displayed .................. 20-260
N-6 [E0165] (Error in network communication) is displayed .......................................................... 20-261
N-7 [E0436] (Abnormality in network system: engine controller) is displayed ............................... 20-262
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been
removed.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
D155AX-5
20-251
4
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN

ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY

OCCURS AND PROBLEMS ON MACHINE
User Service
code code
E0101
E0104
Abnormal system
Abnormality in network
system (engine controller system)
system (monitor panel
system)
When monitor panel detects abnormality in network of engine controller system
When service code E0101 is displayed singly
1. Disconnection or defective contact in wiring harness between monitor panel
T01 (9) - engine controller CN-2 (8), (18)
2. Defective engine controller
When service code E0101 is displayed together with E0104 and E0105
1. Disconnection, defective contact, short circuit with chassis ground, or short
circuit with power source in wiring harness between monitor panel T01 (10) monitor panel CN1 (11), (12) - monitor panel T01 (9) - HSS controller CN-ST1
(1) - HSS controller CN-ST1 (12) - engine controller CN-2 (8), (18)
2. Defective monitor panel (Tachometer module)
When monitor panel detects abnormality in network of monitor panel (caution
module) system
T01 (10) - monitor panel CN1 (11), (12)
2. Defective monitor panel (caution module)
circuit with power source in wiring harness between monitor panel T01 (10) monitor panel CN1 (11), (12) - monitor panel T01 (9) - HSS controller CN-ST1
(1) - HSS controller CN-ST1 (12) - engine controller CN-2 (8), (18)
CALL03
system (HSS controller
system)
When monitor panel detects abnormality in network of HSS controller system

T01 (9) - HSS controller CN-ST1 (1)
2. Defective HSS controller
circuit with power source in wiring harness between monitor panel T01 (9) HSS controller CN-ST1 (1), (12) - engine controller CN-2 (8), (18)
E0152
system
When HSS controller detects abnormality in network

When service code E0152 is displayed together with E0101, E0104, and E0105
Same as each service code
E0165
Error in network communication
1. Defective monitor panel

2. Disconnection, defective contact, or short circuit with chassis ground in wiring
harness between controller CN-ST1 (1) - monitor panel T01 (9)
system
When engine controller detects abnormality in network

When service code E0436 is displayed together with E0101, E0104, and E0105
Same as each service code
E0105
E0436
20-252
4
D155AX-5
TROUBLESHOOTING
Normal condition
(Voltage, current, resistance)

Action taken by controller when

abnormality occurs
Problems on machine
1. Flashes caution lamp.

2. Turns on caution buzzer.


1. Gear speed cannot be displayed.

2. Tachometer is not displayed.
3. Lock-up lamp goes off.

3. Lock-up lamp goes off.

3. Warning lamp and buzzer do not
work.
D155AX-5
20-253
4
TROUBLESHOOTING
N MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
N MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM

Engine controller system
20-254
4
D155AX-5
TROUBLESHOOTING
SERVICE CODES OF NETWORK SYSTEM
SERVICE CODES OF NETWORK SYSTEM

The monitor panel, engine controller, and HSS controller form a network as shown in the "N mode
system electrical circuit diagram".
The monitor panel, engine controller, and HSS controller monitor the communication condition of the
network respectively. If any abnormality occurs, these controllers display the service code corresponding to that abnormality.
1) Monitor panel
The monitor panel monitors the communication condition of the network components and displays the following service codes when an abnormality occurs.
(1) E0101: When abnormality occurs in the engine controller system
(2) E0104: When abnormality occurs in the monitor panel (caution module)
(3) E0105: When abnormality occurs in the HSS controller
2) Engine controller
The engine controller monitors the communication condition of the whole network and displays
the following service codes when an abnormality occurs.
(4) E0152: When abnormality occurs in any system in the whole network (The abnormal system is
not specified)
3) HSS controller
The HSS controller monitors the communication condition of the whole network and displays the
following service codes when an abnormality occurs.
(4) E0436: When abnormality occurs in any system in the whole network (The abnormal system is
not specified)
As the network is monitored by multiple devices as explained above, if any abnormality occurs in the
network system, multiple service codes are displayed simultaneously.
It is important to understand which system each service code indicates by using the monitoring mode,
etc. before starting troubleshooting.
D155AX-5
20-255
4
N-1
TROUBLESHOOTING
N-1 [E0101] (Abnormality in network system: engine controller system)

is displayed
Cause
Remedy
1
Turn starting switch ON.
NO
Are service codes [E0104] and

[E0105] displayed, too?
YES
Go to N-4
2
Turn starting switch OFF.
Disconnect T01 and CN1.
Max. 1
Is resistance between T01 (female) (9)

and CN-ST1 (female) (1), (12) and CN2
(female) (8), (18) normal?
YES
NO
Disconnection or defective contact in

wiring harness between T01 (female) (9) Repair or
- CN-ST1 (female) (1), (12) - CN2 (female) replace
(8), (18)
Defective engine
controller
Replace
N-1. Related electrical circuit diagram
20-256
4
D155AX-5
N-2
TROUBLESHOOTING
N-2 [E0104] (Abnormality in network system: monitor panel

system) is displayed
Cause
Remedy
1
NO

YES
Go to N-4
2
Max. 1
Is resistance between T01 (female)

(10) and T01 (female) (11), (12)
normal?
YES
NO
Disconnection or defective contact

Repair or
in wiring harness between T01
(female) (10) - T01 (female) (11), (12) replace
Defective monitor panel (caution

module)
Replace
D155AX-5
20-257
4
N-3
TROUBLESHOOTING
N-3 [E0105] (Abnormality in network system: HSS controller

Cause
Remedy
1
NO

YES
Go to N-4
2
Max. 1

(9) and CN-ST1 (female) (1) normal?
NO

(female) (9) - ST1 (female) (1)
Repair or
replace
Defective HSS controller
Replace
YES
20-258
4
D155AX-5
N-4
TROUBLESHOOTING
N-4 [E0101], [E0104], and [E0105] (Abnormality in network system) are displayed at same time
Cause
Remedy
1
Disconnect CN1.
NO
When CN1 is disconnected, are all

service codes turned off?
YES

module)
Replace
Replace
Defective engine controller
Replace
Disconnection, defective contact, or short

circuit with chassis ground in wiring harness
between T01 (10) - CN1 (female) (11), (12) or
between T01 (9) - CN-ST1 (female) (1), or
between CN-ST1 (female) (12) - CN-2 (female)
(8), (13)
Repair or
replace
Defective monitor panel (tachometer module)
Replace
2
Disconnect CN-ST1.
NO
When CN-ST1 is disconnected, are

all service codes turned off?
YES
3
Disconnect CN-2.
NO
When CN-2 is disconnected, are all

service codes turned off?
YES
4
Disconnect T01.
Min. 7.5 V
Is voltage between T01 (female) (9)

and chassis ground normal?
NO
YES
D155AX-5
20-259
4
TROUBLESHOOTING
N-5
N-5 [E0152] (Abnormality in network system: HSS controller

Cause
Remedy
1
NO
Are all of service codes [E0101],

[E0104], and [E0105] displayed, too?
YES
Go to N-4
2
Is any one of service codes [E0101],

NO
Replace
YES
Go to N-1, 2, or 3 according to
displayed service code
20-260
4
D155AX-5
TROUBLESHOOTING
N-6
N-6 [E0165] (Error in network communication) is displayed

Cause
Remedy
1
NO
Does monitor panel display

normally?
YES
Defective monitor panel
Replace

wiring harness between T01 (female) (9)
and CN-ST1 (female) (1)
Repair or
replace
Defective HSS
controller
Replace
2
Disconnect T01 and CN-ST1.
Max. 1

(9) and CN-ST1 (female) (1) normal?
YES
NO
D155AX-5
20-261
4
TROUBLESHOOTING
N-7
N-7 [E0436] (Abnormality in network system: engine controller) is

displayed
Cause
Remedy
1
NO
Are all of service codes [E0101],

YES
Go to N-4
2
Is any one of service codes [E0101],

NO
Replace
YES
Go to N-1, 2, or 3 according to
displayed service code
20-262
4
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM

(S MODE)
[Serial No. 70001 75000]
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 turns but exhaust gas does not comes out (fuel is not being injected) ......... 20-307
2 Exhaust gas comes out but engine does not start (fuel is being injected) ................. 20-308
S- 3
Engine does not pick up smoothly (follow-up is poor) ........................................................ 20-309
S- 4
Engine stops during operation ................................................................................................ 20-310
S- 5
Engine does not rotate smoothly (hunting) ........................................................................... 20-311
S- 6
Engine lacks power ................................................................................................................... 20-312
S- 7
Exhaust gas is black (incomplete combustion) ...................................................................... 20-313
S- 8
Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20-314
S- 9
Oil becomes contaminated quickly ......................................................................................... 20-315
S-10
Fuel consumption is excessive ................................................................................................ 20-316
S-11
Oil is in cooling water, or water spurts back, or water level goes down .......................... 20-317
S-12
Oil pressure caution lamp lights up (drop in oil pressure) .................................................. 20-318
S-13
Oil level rises (water or fuel mixed with oil) ......................................................................... 20-319
S-14
Water temperature becomes too high (overheating) ............................................................ 20-320
S-15
Abnormal noise is made .......................................................................................................... 20-321
S-16
Vibration is excessive ............................................................................................................... 20-322
Serial No. 75001 and up: See 140-3 series engine shop manual.
D155AX-5
20-301
4
TROUBLESHOOTING
METHOD
METHOD
OF USING
OF USING TROUBLESHOOTING
TROUBLESHOOTING
CHARTS
CHARTS
This troubleshooting
chart is divided into three
sections: questions, check items, and troubleshooting. The questions
and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection without using troubleshooting
tools.
Next, troubleshooting
tools or direct inspection
are used to check the high probability
causes to
make final confirmation.
[Questions]
Sections @ + @ in the chart on the right correspond to the items where answers can be obtained from the user. The items in @ are items
that can be obtained from the user, depending
on the users level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information
@ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting
is carried out in the order of
probability,
starting with the causes that have
been marked as having the highest probability
from information
gained from [Questions]
and
[Check items].
(a)
(b)
(c)
(d)
20-302
Causes I
0
0
0
0
D155AX-5
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
The basic method of using the troubleshooting

chart
is as follows.
Items listed for [Questions]
and [Check items1 that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high probability are marked with Q.
Check each of the [Questions] and [Check items1 in
turn, taking note of the 0 or Q marks in the chart for
the horizontal lines of symptoms applicable to the
machine. The vertical column (Causes) that has the
highest number of applicable 0 or Q marks is the
most probable cause, so start troubleshooting
for
that item to make final confirmation
of the cause.
%I. For (Confirm
recent repair history) in the
[Questions] Section, ask the user, and mark
the Cause column with A to use as reference
for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes.
332. Use the A in the Cause column as reference
for [Degree of use (Operated for long period)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
D155AX-5
20-303
METHOD
TROUBLESHOOTING
OF USING
TROUBLESHOOTING
CHARTS
Example of troubleshooting
when exhaust gas is black
Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have a causal relationship with this problem: [Exhaust gas gradually became black], [Power
gradually became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with 5
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
s-7
Exhaust gas is black

(incomplete
combustion)
General causes why exhaust gas is black.
.
Insufficient intake of air.
.
Improper condition of fuel injection.
.
Excessive injection of fuel.
Dust indicator is red
Clanging sound is heard from around cylinder head

Exhaust
Muffler
noise is abnormal
is crushed
Air leakagelloose
clamp between turbocharger and cyl. head
>.*
j$ 0
&
k$$i
tiil
When muffler is removed, exhausx gas color retrns to normal
When control rack is pushed, it is found fo be heavy or doer
at retUrn
20-304
D155AX-5
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items1
section and the 5 Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of Oand Omarked where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element:
000
(2) Air leakage between turbocharger
00
and cyl. head:
(3) Clogged, seized injection nozzle:
0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder:
0
Step 3
The calculations in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting
area and carry out the
troubleshooting
item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
D155AX-5
20-305
TROUBLESHOOTING
S-l
Starting
S-l
performance
is poor (starting
Possible causes of the engine not starting

discharged.
.
Electrical system is defective.
.
Fuel supply is insufficient.
.
Air intake is insufficient.
.
improper selection of fuel
(At ambient
temperature
though
exhaust
always takes time)
gas is
or below, use ASTEM D975
of -10C
No. 1)
.
-f
Causes
Batterv
charaina rate
20C
1.28
1.26
1.24
1.23
1.22
0C
1.29
1.27
1.25
1.24
1.23
-10C
1.30
1.28
1.26
1.25
1.24
A battery can be used if the specific gravity shows 70% or

higher charging rate as per the above table.
In cold weather, 75% or higher charging rate is required.
Confirm no abnormality
display of electronic
governor
controller system.
//
Compression pressure measurement found low pressure

Direct inspection of the air cleaner found clogging
1
1 Direct inspection of the fuel fi lter and strainer found clogging
Direct inspection of the feed pump strainer found clogging
I cnr-LB__*__llllll
- ^..^. DcbLIII
^^A:^.. :^ ..-+ !-._%+_A
calm
ID
.g
8
f
z
1=
llL
1-1 , ,
I I.1 I
, , , , , , , I
I I I I I I I.1
IlrmLr
Voltage (26 -30 v) rises between alternator terminals R and E %

No voltage (26 - 30 V) between alternator terminals R and E
Either specific gravity or voltage of the battery is low
Stop fuel injection to one cylinder at a time. If there is no
chanqe in engine speed, that cylinder is not workino.
Checking deliven/ method found deviation in injection timing
When pushed, the control rack is heavy, or does not return
(Remove the blind cover at the rear of the pump. Plunger
control sleeve does not move)
Direct inspection of the fuel cap found clogging
I
% Replacement
permissible.
20-306
of regulator
only is not
Remedy
D 155AX-5
TROUBLESHOOTING
s-2
Engine does not start
s-2
0
Engine runs but exhaust gas does not come out

(fuel is not being injected)
Ir
Confirm that no abnormality of governor controller is displayed on the machine monitor

panel.
Possible causes of no exhaust gas coming out
though engine is running.
.
Fuel is not supplied.
.
Fuel supply is very low.
.
Improper fuel is used. (particularly
in winter)
Fuel selection
standard
In winter, if Class 3 oil is not available, you

may use mixture of Class 2 diesel fuel and
kerosene at the rate of 1 : 1.
CConfirm recent
.-6
v
!z
repair history
C)egree of use
Operated for long perioc
Eixhaust gas suddenly (when starting again) stops coming out
:iltershave not bean replaced accordingto the operation manual
rlud is stucking to fuel tank cap
here is leakage from fuel piping
Jo fuel comes out when draining fuel filter

When the engine is cranked by the starter motor,
1) Injection pump coupling does not rotate
2) Even though the fuel filter air bleeder plug is loosened,
fuel does not come out
3) Even though the injection pipe sleeve nut is loosened,
fuel does not spurt out
Nhen fuel is drained, rust and water come out
D 155AX-5
20-307
s-2
TROUBLESHOOTING
Causes
Exhaust gas comes out but engine does not start

(fuel is being injected)
General causes why exhaust gas comes out but

engine does not start.
.
Lack of rotating force due to defective electrical system.
.
Insufficient supply of fuel.
.
.
Improper selection of fuel.
When fuel lever

contact stopper
a,
C
Y
When
engine
is placed
at FULL position,
it does
not
I loI
is cranked
with
starting
I I I I
I I I I I I
motor,
1) Little fuel comes

nut is loosened
out even when
injection
pump
2) Little fuel comes

is loosened
out even when
fuel filter
air bleed
sleeve
There
is leakage
from
fuel filter
Remove
is drained,
head cover
fuel piping
When exhaust manifold

is touched
immediately
starting engine, temperature
of some cylinders
When
plug
no fuel comes
after
is low
out
and check directly
When control rack is pushed,

does not return
it is found
0
to be heavy,
or
finer are mspacte
20-308
D155AX-5
s-3
TROUBLESHOOTING
S-3
Engine does not pick up smoothly
(follow-up
is poor)
Confirm that no abnormality

of electric governor controller is displayed.
General causes why engine does not pick up
smoothly.
.
.
.
.
Use of improper fuel.
operation
manual
Non-specified
Engine
fuel has been
oil must
Dust indicator
be added
Engine
freauentlv
when
fuel
is red
Rust and water

Interference
used
more
are found
sound
heard
pick-up
suddenly
of exhaust
gas
around
is drained
became
poor
Blue
Color
I I I I I I PI
turbocharger
under
light
load
Black
1 Blow-by
I I I I I
gas is excessive
When air cleaner
is inspected
directly,
it is found to be clogged
iner are inspected
When
control
Turbocharger
rack is pushed,
cannot
it is found
be hand-rotated
When valve clearance

is checked
outside standard value
When
fuel cap is inspected
When feed pump is operated,
directly,
operation
are
to be heavy
or does
it is found
it is found
to be
to be clogged
is too light or tw
heavy
0
c
Remedy
D 155AX-5
I I I I I
smoothly
directly,
directly,
they
I I I
1 101 [ 101 lolo]

1 I I I 1 10
lel
I lol
I lot I I lo
.i
4
4
z
e $
UUO~~~~QUrC~
$8
$
;;
2
c
i
$,
20-309
s-4
TROUBLESHOOTING
S-4
Engine stops during operation
Confirm that fuel gauge on machine monitor indicates certain amount of fuel.
Possible causes of engine stoppage during operation.
l
Seizure of parts inside the engine.
.
Fuel supply amount is insufficient.
.
Overheating.
*
If the engine stops due to overheating,
carry out appropriate troubleshooting.
l
Trouble in the power train.
Ir If the engine stops due to trouble in the
power train, carry out troubleshooting
of the body.
Confirm
recent
Degree
repair
history
Operated
of use
Conditions
stopped
when
the engine
When operating
the feed
operation
is difficult
Mud
pump,
1 Remove
Remove
When
The engine
checked,
Inspection
Inspection
e
k
Engine stopped suddenly

with abnormal
sound
000000
Engine stopped
overheating
00
no response
with
is returned,
00
or
I I I
I I I I I I I
Directly
by
etc.
1.101
when
pump
of the fuel filter

of the feed
+hn mn+.,4
does
not turn
accessories
and strainer
pump
check the feed
c
2
a
2
and the ck directly
the gear train
turns
\A,hnn n, *&3&i
20-310
nn
period
the oil oan and check directly

the head cover
rr
for long
is stuck to fuel tank ca
When turning the engine

hand with a barring tool,
Causes
strainer
found
clogging
! ! ! ! ! ! ! !.!
0
clogging
cx
! ! ! ! 4
I I I!
0
pump
r%.k ic x,0_, h~.\,v
&a
are removed
found
nr rln-
nnt r&l ,r
D155AX-5
TROUBLESHOOTING
S-5
s-5
Engine does not rotate smoothly
(hunting)
Ir
Confirm that no abnormality

of electric governor is displayed.
General
causes why engine does not rotate
smoothlv (hunting).
Air in fuel system.
.
Defective governor mechanism.
.
Defective
electrically
controlled
throttle
mechanism.
(electrically controlled throttle type)
Ir If hunting does not occur when rod connecting governor motor and fuel injection pump is disconnected,
carry out
troubleshooting
for electrical system.
Causes
When feed pump is operated
When feed pump stramer IS mpecte
When fuel filter, strainer are inspected directly, they are

found to be clogged
D155AX-5
20-311
S-6
TROUBLESHOOTING
S-6
Causes
Engine lacks power

/////I/
General causes why engine lacks output.

.
.
.
.
Use of improper fuel.
(if non-specified
fuel is used, output drops)
.
Lack of output due to overheating.
*
If there is overheating
and insufficient
output, carry out troubleshooting
for
overheating.
Power was lost
ration manual
Blow-by gas is excessive

Engine pickup is poor and combustion is irregular
High idling speed under no load is normal, but speed
suddenly drops when load is applied
exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
opfuel
20-312
0
00
I I I I I
00
I I I I
injection to 0
D155AX-5
s-7
TROUBLESHOOTING
S-7
Exhaust gas is black (incomplete
General causes why exhaust gas is black.

.
.
improper condition of fuel injection.
.
s
.I
Color
combustion)
Causes
/////////l
of exhaust gas
Power was lost
D155AX-5
20-313
S-8
TROUBLESHOOTING
S-8
Oil consumption
is excessive (or exhaust gas is blue)
Do not run the engine at idling for more

than 20 minutes continuously. (both low and
high idling)
is excesGe neral causes why oil consumption
siv le.
.
Abnormal combustion
of oil.
.
External leakage of oil.
.
Wear of lubrication system.
Amount of blow-by gas

Area around engine is dirty with oil
There is oil in engine cooling water
When exhaust pipe is removed, inside is found t
20-314
D155AX-5
s-9
TROUBLESHOOTING
S-9
Oil becomes contaminated
quickly
General causes why oil becomes contaminated

quickly.
.
Intake of exhaust gas due to internal wear.
.
Clogging of lubrication passage.
.
Improper combustion.
.
Use of improper oil.
Operation under excessive load.
Causes
Confirm recent repair history

.-s
Degree of use
Engine oil must be added more frequently
Non-specified fuel has been used
Operated for long period
0
Blue under light
Color of exhaust gas

Black
Abnormally exe
Amount of blow-by gas
When compression pressure is measured, it is found to be low

When breather element is inspected directly, it is found to be clogged with
dirty oil, or hose is broken

When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Clogged turbocharger drain tube
Excessive play of turbocharger shaft
E
z
When safety valve is directly inspected, spring is found to be catching or

broken
D 155AX-5
1.1
20-3 15
s-10
TROUBLESHOOTING
S-IO Fuel consumption
is excessive
General causes why fuel consumption

is excessive.
.
Leakage of fuel.
.
.
More
Condition
than for other
machines
of
of fuel consumption
Black
Exhaust
gas color
White
When
exhaust
temperature
manifold
of some
Match
mark
There
is external
on injection
Engine
oil level
Engine
low
lniection
Stop fuel
speed,
injection
When
control
When
check
engine,
IQ/C
fuel
that iniection
amount
at a time.
I
0
engine
of diesel
to one cylinder
00
0
is incorrect
If there
is no change
in engine
is not working.
rack is pushed,
is made
starting
is high
test shows
that cylinder
after
is misaligned
of fuel from
rises and smells

speed
immediately
is low
pump
leakage
idling
oumo
is touched
cylinders
using
it is found
delivery
to be heavy
method,
or does
injection
timing
not return
is found
to be
incorrect
Remove
head cover
and check directly
Remove
feed
pump
and check directly
engine
speed
is measured,
When
low
idling
speed
is found
to be high
Remedy
20-3 16
D 155AX-5
TROUBLESHOOTING
S-II
S-l 1
Oil is in cooling water,

down
or water spurts back, or water level goes
General causes why oil is in cooling water.

.
Internal leakage in lubrication system.
.
Internal leakage in cooling system.
Pressure-tightness
test of oil cooler
Pressure-tightness
test of cylinder
Remove
cylinder
head
Remove
oil pan and check
shows
head
there
shows
is leakage
there
is leakage
and check directly

directly
D 155AX-5
Remedy
20-3 17
s-12
TROUBLESHOOTING
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

Possible causes of the oil pressure caution lamp
lighting up.
.
Leakage, clogging, or wear of the lubricating system.
.
Oil pressure control failure.
.
Use of improper oil. (improper viscosity)
.
Dearadation
of oil due to overheating.
sr Confirm engine oil level is normal before
troubleshooting.
Standard
for engine
-22
-4
oil selection
14
Filters
32
50
have not been
Non-specified
68
replaced
oil has been
as specified
used for long
1 Lights
Leakage
or crushing
in the oil piping
When
the oil is drained,
Metal
chips
attach
Oil is cloudy
white,
in the operation
metal
chips
up once
system
come
in a while
(external)
0
out
to the oil filter
in the relief
20-3 18
or smells
valve
element
like diesel
or regulator
01
1 1 1 1
oil
valve,
or damage
of
D155AX-5
TROUBLESHOOTING
s-13
S-13 Oil level rises (water or fuel mixed with oil)

*
If there is oil in the cooling water, carry out

troubleshooting
for Oil is in cooling water.
Ger leral causes why oil level rises.
.
Water in oil.
.
Fuel in oil. (diluted, and smells of diesel fuel)
D155AX-5
20-3
19
s-14
TROUBLESHOOTING
S-14 Water temperature
becomes too high (overheating)
If coolant level lamp on monitor panel is not

lighted.
If coolant temperature
checked by water
temp. gauge on machine monitor is normal,
refer to Machine monitor troubleshooting
M-mode.
General causes why water temperature becomes
too high.
.
Lack of cooling air. (deformation,
damage of
fan)
.
Drop in heat dissipation efficiency.
.
Defect in cooling circulation system.
Ir Carry out troubleshooting
for chassis.
Confirm
recent
1Degree
repair
CY
Condition
Causes
history
1Operated
of use
for long period
Suddenly
.-6
j;
2
I
lllllllllll/
overheated
of overheating
Always
tends
to overheat
Rises auicklv
Water
temperature
gauge
/
/I Fan belt whines

Cloudy
white
Cooling
water
Excessive
1 Engine
under
sudden
oil is floating
flows
out from
air bubbles
oil level
load
on cooling
inside
has risen,
radiator,
When
light bulb is held behind
Water
is leaking
Belt tension
is found
Temperature
tanks
spurts
back
white
are clogged with dirt or muc
radiator,
of cracks
no light passes through
in hose or loose
clamps
to be slack
difference
between top and bottom
radiator
between
radiator
is excessive
Temperature
tanks
hose
water
oil is cloudy
Radiator shroud, inside of underguard
because
water
overflow
difference
top and bottom
slight
I@I
When
a function
not open
even
test is carried
at the cracking
When water temperature
measurement
pressure
When
is made
is found
to be low
compression
pressure
Remove
directly,
with
it is found to be normal
radiator
cap tester,
I I I I Iel I I I I I I
I I I I I I I.1
I I I I
set
I
it
isfound to
be low
oil pan and check directly
a
$
Remedy
20-320
it is found to be clogged
is measured,
it does
temperature
is measured,
When oil cooler is inspected

When
out on the thermostat,
When water filler port is inspected, the core is found to be clogged
.=
.;
$
0
8
~cccc$drc~$$
.;
$j
{g
LT a:
D 155AX-5
TROUBLESHOOTING
s-15
S-15 Abnormal
noise is made
Causes
Judge if the noise is an internal noise or an

external noise.
General causes why abnormal noise is made.
Abnormality
due to defective parts.
Abnormal combustion
noise.
Air sucked in from intake system.
Engine
oil must
be added
more
frequently
Blue under
Color
of exhaust
light
load
Metal
particles
are found
Vibrating
noise
clamp
is heard
Whencomoression
Turbocharger
When
D 155AX-5
in oil filter
gas is excessive
Air leakage/loose
valve
between
from
turbocharger
around
be hand-rotated
clearance
is checked
and cy~. head
101
1 1 1 I
lol
lol
101 I I I I I I I I
I I I I I I I I I I
1 I
it isfoundto
below
smoothly
directly,
it is found
I lol
I I I I I I I I I I I IG
muffler
oressureismeasured.
cannot
I I I I I I I I I I
I 101 I I I I lol
gas
Black
Blow-by
lol
IO I I I I I I I I I I I
I I.1 I I I I I I I I I
to be
20-321
TROUBLESHOOTING
S-16 Vibration
S-16
is excessive
Ir
If there is abnormal noise together with the

vibration, carry out troubleshooting
for Abnormal noise is made.
General causes why vibration is excessive.
.
Defective parts. (abnormal wear, breakage)
.
Improper alignment.
.
Abnormal combustion.
20-322
7~~
Causes
D155AX-5
TROUBLESHOOTING OF HSS CONTROLLER AND

ELECTRICAL SYSTEM
(E MODE)
Action taken by controller when abnormality

occurs and problems on machine.. ....................... .20-402
Electrical circuit diagram for E mode ..................................................................................................
20-410
20-412
E-l.
[I91 Short circuit in steering oil pressure sensor system A is displayed .............................
E-2.
PO1 Disconnection in steering oil pressure sensor system A is displayed.. ....................... .20-413
E-3.
I211 Short circuit in steering oil pressure sensor system B is displayed.. .......................... .20-414
E-4.
1221 Disconnection in steering oil pressure sensor system B is displayed.. ....................... .20-415
systems 1 and 2 is displayed ................................
-20-416
E-5.
1231 Trouble of steering potentiometer
system 1 is displayed ...................................
20-417
E-6.
1241 Disconnection in steering potentiometer
system 1 is displayed .....................................
.20-418
E-7.
1251 Short circuit in steering potentiometer
system 2 is displayed ..................................
.20-419
E-8.
[261 Disconnection in steering potentiometer
system 2 is displayed ......................................
20-420
E-9.
1251 Short circuit in steering potentiometer
20-421
E-10. [291 Trouble of engine rotation sensor system is displayed .................................................
system is displayed ................ .20-422
E-11. [511 Short circuit in travel reverse sensing potentiometer
in travel reverse sensing potentiometer
system is displayed ............. .20-423
E-12. 1521 Disconnection
in backup alarm relay system is displayed ............................................
20-425
20-426
E-14. I541 Short circuit in backup alarm relay system is displayed ...............................................
20-427
E-15. 1571 Low voltage of controller is displayed .............................................................................
E-16. [621 Excessive difference of signal value between steering potentiometer
systems 1 and 2 is displayed [II .................................................................................
20-428
E-17. [6dl Excessive difference of signal value between steering potentiometer
systems 1 and 2 is displayed [III ................................................................................
20-429
system and excessive deviation
E-18. [6El Trouble of either steering potentiometer
of neutral point signal of either system is indicated.. ..............................................
20-430
in HSS pump solenoid valve system A is displayed.. .......................... .20-431
E-19. [641 Disconnection
.20-432
E-20. I651 Short circuit in HSS pump solenoid valve system A is displayed.. .............................
in HSS pump solenoid valve system B is displayed ............................
.20-433
20-434
E-22. 1671 Short circuit in HSS pump solenoid valve system B is displayed ................................
E-23. I701 Short circuit in work equipment circuit oil pressure sensor system is displayed.. .... .20-435
in work equipment circuit oil pressure sensor system is displayed.. . .20-436
error is displayed .......................................................
20-437
E-25. [8dl System network communication
of reverse sensing potentiometer
and
E-26. 1991 Disagreement
backup alarm switch signals with each other is displayed .....................................
20-438
20-440
E-27. [EOI Trouble of offset current memory is displayed.. .............................................................
20-441
E-28. Backup alarm does not sound ...................................................................................................
E-29. Blade pitch does not work normally (When equipped with pitch dozer) ............................
.20-442
E-30. Ripper pin puller does not work normally (When equipped with giant ripper). ................. .20-444
E-31. Engine does not start (Engine does not rotate). ......................................................................
20-446
D155Ax-5
20-40 1

TROUBLESHOOTING

irror
Abnormal
Lode
system
Nature
Condition
of abnormality
(voltage,
% When signal voltage of oil pressure sensor A exceeds 6.OOOV * Voltage between
Short circuit
in steering oil
19
pressure
sensor system
Disconnection
in steering oil
pressure
sensor
system
Short circuit
in steering oil
21
pressure
sensor
system B
Disconnection
in steering oil
22
pressure
sensor
system
% When signal
6.OOOV
- Voltage
sensor
A exceeds
1. Defective steering oil pressure sensor B

2. Short circuit with power source in wiring harness
between
steering
CN-2H2
system
(1) -CN-2Hl
is in neutral:
0.90 - 1.5ov
When steering system is relieved: 3.95
- 4.6OV (Both sides)
between
steering
CN-2H2
system
(9) - CN-2Hl
is in neutral:
0.90 - 1.5ov
* Voltage between CN-PHI (19) - (9) (System 1)

when steering system is in neutral: 2.4 - 2.6V
When machine is fully steered to left: 4.1 4.3v
When machine is fully steered to right: 0.73 0.89v
* Voltage between CN-2Hl (20) - (9) (System 2)
When steering system is in neutral: 2.4 - 2.6V
When machine is fully steered to I& 0.6 l.lV
. Sum of above signal voltages of systems 1
and 2 ~/SUM)
4.6V t VSUMt 5.4v
signal voltages
1 and 2 lower
of both steering
potentiometer
below 0.5OOV or exceed
sys-
4.5OOV
signal
voltage
of steering
potentiometer
system
(9)
When
between
steering
CN-2H2
system
(9) - CN-2Hl
is in neutral:
0.90 - 1.5ov
1 * Voltage between CN-2Hl (19) - (9)

When steering system is in neutral:
exceeds 4.5OOV
1. Defective steering potentiometer
2. Defective contact, disconnection or short circuit with power
source in wiring harness between controller CN-2Hl (19) -
potentiometer
CN-STR (3)
3. Defective contact or disconnection
in wiring harness between controller CN-2Hl (9) - potentiometer
CN-STR (I)
4. Defective
20-402
between
x When
% When
system
(9)
When
* Voltage
and 2
24
(1) -CN-2Hl
% When signal voltage of oil pressure sensor B lowers below 0.5oov

in wiring harness between fuse 5 - oil pressure sensor STHP2 (2)
3. Defective contact, disconnection
or short circuit with chassis ground in wiring harness between controller CN-2H2
(9) - oil pressure sensor STHP2 (3)
Trouble of
steering
potentiometer
systems 1
Disconnection
in steering
potentiometer
Voltage
(9)
When
controller CN-2H2 (9) - oil pressure sensor STHP2 (3)

in wiring harness between controller CN-2Hl (9) -oil pressure sensor STHP2 (I)
terns
23
of oil pressure
CN-2H2
(1)
% When signal voltage of oil pressure sensor A drops below

0.5oov
1. Defective steering oil pressure sensor A
in wiring harness between fuse 5 - oil pressure sensor STHPl (2)
or short circuit with chassis ground in wiring harness between controller CN-2H2
(1) - oil pressure sensor STHPl (2)
voltage
normal
resistance)
(9)
0.90 - 1.5ov
2. Short circuit with power source in wiring harness between

controller CN-2H2 (1) - oil pressure sensor STHPI (3)
3. Defective contact or disconnection in wiring harness between
controller CN-2Hl (9) - oil pressure sensor STHPl
20
when
current,
2.4 - 2.6V
When machine is fully steered to left:
4.1 - 4.3v
When machine is fully steered to right:
0.73 - 0.89V
HSS controller
D155AX-5

TROUBLESHOOTING
Action
by controller
when abnormality
I. Calculates with steering circuit oil pressure

!. Cannot limit swash plate angle of pump
Problem
is detected
as 0.
when
that appears
on machine
when there is abnormality
steering
1. If machine
is steered
under heavy
2. If machine
is steered
under light load, it operates
load, engine
stalls.
normally
circuit oil pressure is high or steering circuit is relieved.

3. Flashes alarm lamp and turns alarm buzzer on.
1. Calculates with steering circuit oil pressure

2. Cannot limit swash plate angle of pump
as 0.
when
steering
1. If machine
is steered
2. If machine
is steered
under heavy
load, engine
stalls.
normally

I. Calculates with steering circuit oil pressure

!. Cannot limit swash plate angle of pump
as 0.
when
steering
1. If machine
is steered
under heavy
2. If machine
is steered
load, engine
stalls.
normally

I. Calculates with steering circuit oil pressure as 0.

3. Cannot limit swash plate angle of pump when steering
3. Flashes alarm
lamp and turns alarm
1. Controls
with signals of steering
D155AX-5
potentiometer
is steered
under heavy
is steered
load, engine
stalls.
normally
buzzer on.
I. Controls with signals before occurrence of abnormality

til machine stops.
2. Flashes alarm
1. If machine
2. If machine
2.
un-
1. Steering before occurrence of abnormality is continued

machine stops.
2. Once machine stops, it cannot be steered.
1. Machine
can travel
unti
and steer normally.
buzzer on.
20-403

TROUBLESHOOTING
rror
Abnormal
Dde
system
Nature
Condition
of abnormality
(voltage,
3%When
Short circuit
in steering
potentiometer
system
signal voltage of steering potentiometer

system 1
lowers below 0.5OOV
or short circuit with
chassis ground in wiring harness between controller CN2Hl (10) - potentiometer
CN-STR (4)
3. Short circuit with chassis ground in wiring harness between
controller CN9Hl
(19) - potentiometer
% When
signal voltage
exceeds
Disconnection
in steering
potentiometer
system 2
Short circuit
!7
potentiometer
!9
of
rotation
sensor
system
system

between controller CN-
il
sensing
potentiometer
system
Disconnection
in travel
reverse
sensing
potentiometer
system
13
Disconnection
in backup
alarm relay
system
Short circuit
i4
in backup
alarm relay
system
machine
left: 4.1 - 4.3V
When machine
is fully steered
to
is fully steered
right: 0.73 - 0.89V
to
* Voltage between CN-2Hl (20) - (9)

2.4 - 2.6V
When machine is fully steered to
left: 0.6 - l.lV
When machine is fully steered
right: 3.9 - 4.4V
of steering potentiometer
system 2
lowers below 0.5OOV
chassis ground in wiring harness between controller CN2Hl (10) - potentiometer
CN-STR (4)
3. Short circuit with chassis ground in wiring harness between
* Voltage between CN-2Hl (20) - (9)

2.4 - 2.6V
left: 0.6 - l.lV
When machine is fully steered
right: 3.9 - 4.1V
chassis ground in wiring harness between

2H2 (12) - rotation sensor CN-ENG (2)
controller
* Resistance between CN-ENG (male)

(1) - (2): 500 - 1,000 n
* Resistance between CN-ENG
(female) (4) - (12): 500 - 1,000 D
CN-
signal voltage of travel reverse sensing

potentiometer
exceeds 4.7OOV
1. Defective travel reverse sensing potentiometer
controller CN-2Hl (9) - potentiometer CN-RSS (3)
controller CN-2H2 (IO) - potentiometer CN-RSS (2)
* Voltage
.% When signal voltage of travel reverse sensing

potentiometer
lowers below 0.3OOV
1. Defective travel reverse sensing potentiometer
chassis ground in wiring harness between controller CN2H2 (IO) - potentiometer
CN-RSS (2)
chassis ground in wiring harness between controller CN2Hl (IO) - potentiometer
CN-RSS (1)
* Voltage
1. Defective
2. Defective
backup
contact
alarm
relay
or disconnection
in wiring
harness
between controller CNI (11) - relay CN-014 (1)

in wiring harness
between relay CN-014 (2) - CN-SX8 (Chassis ground)
1. Defective backup alarm relay
2. Short circuit with chassis ground
between CNI (11) - relay CN-014
HSS controller
to
CN-STR (2)
1. Defective engine rotation sensor

2. Wrong installation of engine rotation sensor
controller CN-2H2 (4) - rotation sensor CN-ENG (I)
3. Defective
to
HSS controller
signal voltage
% When
Short circuit
in travel
reverse
When
CN-STR (2)
in wiring harness
between controller CN-2Hl (9) - potentiometer
CN-STR
controller CN9Hl
Trouble
engine
* Voltage between CN-2H1 (19) - (9)

2.4 - 2.6V
2Hl
% When
normal
resistance)
CN-STR (3)
4.5OOV

power source in wiring harness
(1)
4. Defective
in steering
potentiometer
system 2
of steering
when
current,
between
harness
(IO) - CN-
is in neutral:
Max.
3.5oov
When joystick
is in reverse
position
3.500 - 4.4oov
between
CN-2H2
(IO) - CN-
2Hl (9)
When joystick
is in neutral: Max.
3.5oov
When joystick is in reverse position:
3.500 - 4.4oov
Voltage
between
ground
When joystick
When
joystick
CN-1 (I I) - chassis
is in neutral: Max. IV
is in reverse position:
20 - 3ov
* Voltage
in wiring
(1)
CN-2H2
2Hl (9)
When joystick
between
ground
When joystick
When
joystick
CN-1 (11) - chassis
is in neutral: Max. 1V
is in reverse position:
20 - 3ov
20-404
D 155AX-5
rROUBLESHOOTlNG
Problem that appears on machine

Action by controller when abnormality is detected
i . Controls
2.
1. Machine
can travel
and steer normally.
i . Controls
2 . Flashes
with signals of steering potentiometer

1.
alarm lamp and turns alarm buzzer on.
1. Machine
can travel
and steer normally.
i . Controls
2 . Flashes
1. Machine
can travel
and steer normally.
alarm
with signals of steering
2 Flashes alarm
potentiometer
with signals
of steering
buzzer on.
potentiometer
i . Calculates with
2 . Cannot control
engine
speed
i . Controls
2 . Flashes
1.
buzzer on.
engine speed as Orpm.

swash plate angle of HSS pump when
is high.
1. Machine can travel and steer normally.

2. If machine is steered frequently on downhills, durability
of HSS motor may be lowered.
3. Neutral position for steering cannot be adjusted.
with signals of backup alarm software

alarm lamp and turns alarm buzzer on.
1. Machine
can travel
and steer normally.
with signals of backup alarm software

2 . Flashes alarm lamp and turns alarm buzzer on.
1. Machine
can travel
and steer normally.
3. Controls
. Takes
no particular
action.
1. Backup alarm
does not sound.
1. Backup alarm
does not sound.
11. Turns
off output
to backup alarm
relay
D155AX-5
20-405

TROUBLESHOOTING
rror
ode
Abnormal
system
x
When
source voltage of controller

contact or disconnection
1. Defective
Dropping
i7
of
source
voltage of
controller
Condition when normal

(voltage, current, resistance)
Nature of abnormality
drops below 17V
in wiring harness
;2
signal value
between
steering
potentiometer
systems 1
and 2 [II
of following range
4.41v < VSUM < 5.59v
id
between
steering
potentiometer
When starting switch is turned on, displayed values are

normal, but sum of signal voltages (VSUM) of steering
potentiometers
1 and 2 is out of following range after a
while
1. Defective
steering
2. Defective
HSS controller
potentiometer
of
iE
system and
excessive
deviation of
neutral point
signal of
either system
Disconnection
in HSS pump
j4
solenoid
valve system
A
Short circuit
55
in HSS pump
solenoid
valve system
A
20-406
Sum (VsuMIof above signal voltages of

systems 1 and 2
4.6V c VSUMt 5.4v
Voltage between CN-2Hl (19) - (9) (System 1

steering sys?emis in neutral: 2.4 - 2.61
machine is fully steered to left: 4.1 4.3v
Voltage between CN-2Hl (20) - (9) (System 1
When
When
When
% When
either
steering
potentiometer
* Voltage between CN-ZHl (19l- (9) (System 1)

- V&age between CN-2Hl (20) - (9) (System 2)
When machine is fully steered to left: 0.6 l.lV
When machine is fully steered to right 3.9 -
systems 1
and 2 [III
Trouble
(81, (18) - (9).
4.4v
I
Excessive
difference of
signal value
CNI
HSS controller
% When starting switch is turned on, sum of signal

voltages (VSVM) of steering potentiometers
1 and 2 is out
of
Voltage between
(19): 20 - 3ov
between controller CNl (81, (18) - fuse 5

in wiring harness
between controller CNl (91, (19) - chassis ground
3. Dropping of battery voltage or defective fuse 5
4. Defective
Excessive
difference
starting
switch is turned
on, either
of following
trouble occurs in both steering potentiometers

1) Defective contact, disconnection
or short circuit in
either system
2) Either system
deviates
from neutral
point excessively
(2.7V t Signal voltage t 2.3V)

1. Defective HSS pump solenoid valve A

chassis ground in wiring harness between controller CN1 (4) - solenoid valve CN-PUPA (I I
in wiring harness
between controller CNI (15) - solenoid valve CN-PUPA
(2)
4. Defective
HSS controller
1. Defective HSS pump solenoid valve A

2. Short circuit with chassis ground in wiring harness
between controller CN-1 (4) - solenoid valve CN-PUPA
(1)
between controller CNl (15) - solenoid valve CN-PUPA
(2)
4. Defective
HSS controller
steering
system
is in neutral:
2.4 - 2.6)
when machine is fully steered to left 0.6 l.lV

when machine is fully steered to right: 3.9 4.4v
Sum (VSVM~of above signal voltages of
systems 1 and 2
4.6V t VSUMt 5.4v
Voltage between CNdHl (19) - 19) (System 1)

steering system is in neutral: 2.4 - 2.6V
+ Voltage between CN-2Hl (20) - (9) (System 2)
when machine is fully steered to left 0.6 l.lV
when machine is fully steered to rigM: 3.9 4.4v
* Sum (VSUM)cf above signal voltages of
q&ems 1 and 2
4.6V t VSUM t 5.4V
When
* Resistance between CN-PUPA (male1

(1) - (2): 10 - 20 n
- Resistance between CNl (female) (41
-(15):
IO-20R
* Indication by LED when starting
switch is turned on (in normal state)
right or left: 93 - 94 (Output current:
930 - 9940mA)
-
Resistance between CN-PUPA (male1

(1) - (2): 10 - 20 n
- Resistance between CNl (female) (41
- (15): 10 - 20 n
930 - 9940mA)
D155AX-5
ACTION
TAKEN
TROUBLESHOOTING
Action
. Turns
by controller
when abnormality
Problem
is detected
off all outputs.
. Controls
BY CONTROLLER WHEN ABNORMALITY

that appears
1. Machine
cannot
1. Steering
before
be steered.
occurrence
of abnormality
with signals before occurrence of abnormality

until machine stops.
I. Flashes alarm lamp and turns alarm buzzer on.

2. Once machine stops, it cannot
. Controls
1. Steering
before
occurrence

. Controls
1. Steering
Since current
does not flow in solenoid
angle of HSS pump becomes 0.

I. Flashes alarm lamp and turns alarm
. Since
output to solenoid
D155AX-5
swash
occurrence
plate
is continued
be steered.
of abnormality
is continued
be steered.
1. Machine cannot
right normally).
be steered
to left (but can be steered
to
1. Machine
be steered
to left (but can be steered
to
buzzer on.
valve is turned

I. Flashes alarm lamp and turns alarm
valve,
before

is continued
be steered.
of abnormality

I_ Flashes alarm lamp and turns alarm buzzer on.

I. Flashes alarm lamp and turns alarm buzzer on.
on machine
off, swash
plate
cannot
right normally).
buzzer on.
20-407

TROUBLESHOOTING
3ror
Abnormal
:ode
system
Disconnection
in HSS pump
66
solenoid
valve system
B
Short circuit
in HSS pump
67
solenoid valve
system B
Nature
70
equipment
circuit oil
pressure
sensor
system
Disconnection
in work
71
8d
equipment
circuit oil
pressure
sensor
system
S-NET
communication error
99
Disagreement
of reverse
sensing
potentiometer
and backup
alarm switch
signals with
each other
1 (5) - solenoid valve CN-PUPB (1)

in wiring harness
between controller CNl (15) - solenoid valve CN-PUPB
(2)
4. Defective
EO
of
offset current
memory
20-408
HSS controller
(1)
between controller CNl (15) - solenoid valve CN-PUPB
HSS controller
Resistance between CN-PUPB (male)

(1) - (2): IO - 20 n
- Resistance between CNI (female) (5)
- (15): 10 - 20 n
930 - 9940mA)
Resistance between CN-PUPB (male)

(1) - (2): 10 - 20 n
* Resistance between CNI (female) (5)
-115): IO-20n
- Indication by LED when starting
930 - 9940mA)
* Voltage
x When signal voltage of work equipment circuit oil

pressure sensor lowers below 0.5OOV
circuit oil pressure sensor
1. Defective work equipment
in wiring harness
between fuse 5 - oil pressure sensor CN-HHP (2)
* Voltage
1. Defective monitor
2. Defective contact,
chassis ground in
(1). (12) - monitor
controller
CN-2H2
(2) - CN-
2.45 - 2.9OV
between
CN-2H2
(2) - CN-
2Hl (9)
is in
When all work equipment
neutral: 0.90 - 1.2OV
When blade is raised and relieved:
2.45 - 2.9OV
CN-
alarm
1. Outputting of error code 1511, 1521

2. Defective backup alarm switch
chassis ground in wiring harness between controller CN2Hl (7) - backup alarm switch CN-251 (3)
in wiring harness
backup alarm
switch
CN-251
(3) - chassis
When joystick is in neutral

Voltage between CN-2H2 (IO) - CN-
2Hl (9): Max. 3.5OOV

Voltage between CN-2Hl (7) - (9):
20 - 3ov
* When joystick is in reverse position
Voltage between CN-2H2 (10) - CN2Hl
(9): 3.5OOV - 4.4OOV
Voltage between
Max. IV
CN-2Hl
(7) - (9):
HSS controller
of neutral
by adjustment
,X When offset current determined
position of steering cannot be stored in non-volatile
memory
1. Defective
between
2Hl (9)
is in
When all work equipment
neutral: 0.90 - 1.2OV
When blade is raised and relieved:
panel
disconnection
wiring harness between controller CN1
panel P2 (IO)
and backup
% When reverse sensing potentiometer
switch signals do not agree with each other
between
normal
resistance)
% When signal voltage of work equipment circuit oil

pressure sensor exceeds 6.OOOV
1. Defective work equipment circuit oil pressure sensor
between controller CN-2H2 (2) - oil pressure sensor CNHHP (3)
in wiring harness
between controller CN-2Hl (9) - oil pressure sensor CNHHP (1)
chassis ground in wiring harness between

2H2 (2) - oil pressure sensor CN-HHP (3)
when
current,
1. Defective HSS pump solenoid valve B

2. Short circuit with chassis ground in wiring harness
between controller CN-1 (5) - solenoid valve CN-PUPB
ground
5. Defective
Trouble
(voltage,
1. Defective HSS pump solenoid valve B

chassis ground in wiring harness between controller CN-
(2)
4. Defective
Short circuit
in work
Condition
of abnormality
* When starting switch is turned to

OFF position, offset current is stored
in non-volatile memory.
HSS controller
D155AX-5

TROUBLESHOOTING
Action
by controller
1. Since current
when abnormality
does not flow in solenoid

2. Flashes alarm lamp and turns alarm
valve,
swash
work
1. Calculates with hydraulic pressure as 0.

2. Cannot limit swash plate angle of pump when
equipment is relieved.
work
with signals
of backup
on machine
1. Machine cannot
left normally).
be steered
to right (but can be steered
to
cannot
alarm
plate
1. Machine
be steered
to right (but can be steered
to
communicate
switch when
cannot
left normally).
1. If machine
1. Calculates with hydraulic pressure as 0.

2. Cannot limit swash plate angle of pump when
equipment
is relieved.
1. Controls
plate
that appears
buzzer on.
1. Since output to solenoid valve is turned off, swash

1. Since S-NET circuit is cut, controller

with monitor panel.
Problem
is detected
is steered
when
engine may stall.

2. Only travel and steering
normally.
work equipment
operation
is relieved,
can be performed
1. If machine is steered when work equipment is relieved,

engine may stall.
2. Only travel and steering operation can be performed
normally.
1. Alarm
lamp and alarm
1. Machine
can travel
1. Machine
may deviate
buzzer do not work.
and steer normally.
trouble [51] and [521 are displayed simultaneously.

2. Controls with signals of travel reverse sensing
potentiometer
played
1. Cannot
when trouble
I511 and 1521 are not dis-
simultaneously.
take any action (Trouble
D 155AX-5
in controller).
during
straight
travel.
20-409
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
FOR E MODE
HSS control system

Sackur
alarm
witch
CN-25I
Engine
speed
Steering
oi I
sureswitch
charle
NSS PU~IP
solenoid
A
CN-PUPS
NSS DUMP
30Ienaid
E
TWD00979
20-410
D 155AX-5
TROUBLESHOOTING
Engine
starting
system
Alternator
With
cab:SOA
P. s6ul
25R
0. L16,
TWDOOSBO
Blade pitch solenoid

Blade
solenoid
and ripper pin puller
solenoid
system
gitch
CN-451
valve
CN0. asp
I53
Pin
Puller
solenoid
CN-246
0. e6
valve
YlT]jX~
A7
CN-456
Blade
Pitch
switch
I I
CN-424
Pin
puller
switch
latterv
elaY
J7
CN-SW
Fender
GND
TWD00981
D 155AX-5
20-411
E-l
TROUBLESHOOTING
E-l.
9%
*
*
*
[I91 Short circuit in steering oil pressure sensor system A is

displayed
This is displayed when the signal voltage from the steering oil pressure sensor A exceeds 6.OOOV.
If the starting switch is turned to the OFF position after trouble occurs, perform the error code
reproducing operation and check that E- is displayed at the head of the error code. (If P- is
displayed, the trouble has been reset.)
Always connect any disconnected
connectors before going
on the next step.
Remedy
Cause
YES
I
YES
1
Is E-19 displayed
when connectors
Is voltage between
CN-2H2 (1) and
CN-2Hl (9) as
shown in following
table?
. Engine at high
idling
-With starting
switch at OFF
position, exchange
connectors.
* Engine at high
idling.
defective HSS controller
R;eplace
Defective contact or
disconnection in wiring
harness between CN-2Hl
(female) (9) - CN-STHPl
(female) (1)
Flepair or
rleplace
2, I
3 YES
Is
CN-2H2 (1) and
_ chassis ground
normal when
NO CN-STHPI is
disconnected?
* Disconnect
CN-STHPI.
. Turn starting
switch ON.
* Max. 1V
NO
Short circuit with power

Flepair or
source in wiring harness
rleplace
between CN-2H2 (female)
(1) - CN-STHPl (female) (31I
Defective steering oil
pressure switch A
rJO
Fleplace
Table
E-l. Related
electrical
CN-70 1
HSS controller
eerlns
circuit diagram
CN-STHP 1
Steering
oil
Pressure
sensor
A
01
TWO00982
20-412
D155AX-5
TROUBLESHOOTING
E-2.
%
*
*
*
*
E-2
[20] Disconnection
displayed
in steering oil pressure sensor system A is
This is displayed when the signal voltage from the steering oil pressure sensor A lowers below
0.5oov.
Check that fuse 5 is not broken. (If it is broken, check the circuits related to it for short circuit with
chassis ground.)
connectors before going on the next step.
61
YE
normalwhenCN-SlHPl
* Engine at high
idling.
CN-STHPl (1) and

N
Rleolace
:
harness between CN-2H2
(female) (1) - CN-STHPI
(female) (3)
(1) - CN-STHPI (female) (3
I *Diinnect I
CN-STHPIand CN-2H2
with oil pressure

*With starting switch
at OFF position,
exchange connectors
* Engine at high
idling.
Remedy
Cause
lepair or
eplace
lepair or
eplace
*Turn starting
switch ON.
*20-30V
lepair or
eplace
roil
leplace
Table
~~
E-2. Related
electrical
circuit diagram
CN-70 1
HSS
controller
Steering
CN-STHP
Steer
in9
oi
Pressure
oil
TWD00982
D155AX-5
20-413
E-3
TROUBLESHOOTING
E-3.
:.
x
Ir
*
*
[21] Short circuit in steering oil pressure sensor system B is

displayed
This is displayed when the signal voltage from the steering oil pressure sensor B exceeds 6.OOOV.
YES
-
lp
Is E-21 displayed
when connectors
are exchanged
with oil pressure
sensor A?
Is voltage between
CN-2H2 (9) and
CN-2H1 (9) es
shown in
following table?
* Engine at high
idling.
3 YES
p
Is voltage between
CN-2H2(9)andchassis
- ground normalwhen NO CN-STHPZis
disconnected?
* Disconnect
NO
CN-STHP2.
-Turn starting switch ON.
* Max. 1 V
*With starting switch

at OFF position,
exchange
NO
connectors.
*Engine at high
idling.
~e~~~eor
(female) (9) - CN-STHPZ
(female) (1)
Repair or
replace
(1) - CN-STHPZ (female) (3)
pressure switch B
Replace
Table
Steering
CN-2H2, CN-2Hl
Between
CN-PHI
CN-2H2
(9) -
(9)
E-3. Related
In neutral
When relieved
electrical
Voltage
0.9-1.5v
3.95 - 4.60 V
circuit diagram
CN-70 1
CN-STHPi
Steering
oil
I
TWD00984
20-414
Dl SAX-5
TROUBLESHOOTING
E-4.
%
*
Ir
Ir
*
E-4
[22] Disconnection
displayed
in steering oil pressure sensor system B is
This is displayed when the signal voltage from the steering oil pressure sensor B lowers below
0.5oov.
reproducing
operation and check that E- is displayed at the head of the error code. (If P- is
chassis ground.)
Cause
Remedy
YEis CN-2H2 (9) and

CN-2Hl (9) as
shown in
1
- Engine
1Is resistanceb&wee: FEr
at high
idling.
with oil pressure
switch ON.
*20-30V
*With starting
switch at OFF
position,
exchange
connectors.
. Engine at high
idling.
NO
(female) (9) - CN-STHP2
(female) (3)
Replace
ilepair or
replace

(9) - CN-STHPP (female) (3)
Repair or
replace
harness between fuse 5 CN-STHP2 (female) (2)
Repair or
replace

pressure switch 5
Replace
Table
E-4. Related
electrical
circuit diagram
CN-70 1
Pressure
sensor
CN-STHPl
Steering
oil
TWD00984
D 155/J-5
20-415
E-5
TROUBLESHOOTING
E-5.
[23] Trouble of steering potentiometer

displayed
systems 1 and 2 is
This is displayed when both signal voltages from the steering potentiometers
lower below 0.5OOV
or exceed 4.5OOV.
reproducing
Remedy
Cause
Go to troubleshooting
error code displayed
simultaneously.
YES
1
*Turn starting
switch ON.
of
leplace
Defective steering
potentiometer
3eplace
Table
E-5. Related
HSS
electrical
circuit diagram
controller
I
CN-LH 1 (040201
Analog
Steering
potentiometer
pJ
GND
Potentiometer
CN-STR (X41
Power
SUPPI
Steering
potentiometer
Steering
Potentiometer
TWD00986
20-4 16
D 155AX-5
E-6
TROUBLESHOOTING
E-6.
%
Ir
*
*
[24] Disconnection
displayed
in steering potentiometer
system 1 is
This is displayed when the signal voltage from steering potentiometer

system 1 exceeds 4.5OOV.
Cause
Replace
4YES
Is voltage between
YES CN-2Hl (19) and
- chassis ground
3
norrnalwhen CN-SIR
is disconnected?
between CH-2Hl
shown in Table l?
Is resistance
between CN-2Hl
* Disconnect CN-STR.
(female) (19) and
*Turn starting switch
CN-STR (female)
ON.
(3) normal?
P
.Max.lV
Turn starting
switch OFF.
NO
Disconnect CN-2Hl
and CN-STR.
Max. 1 Q
YE
. Turn starting
switch ON.
CN-2Hl (1) and (4).

bahvaen(2)and(4).and
* Turn starting
switch OFF.
* Disconnect
CN-STR.
Table
N(
NC1
Remedy
(female) (9) - CN-STR
(female) (I)
Repair or
replace

between CN-2Hl (female)
(19) - CN-STR (female) (3)
Repair or
replace
(female) (3)
Repair or
replace
Defective steering
potentiometer
Replace
Table 2
1
CN-ZH
Steering
When fully
In neutral
Between (19) - (9)
steered
2.4 - 2.6 V
to left
4.1 - 4.3 V
When fully
steered to right
0.73 - 0.89 V
Between (3) - (4)
E-6. Related
HSS controller
electrical
circuit diagram
I
CN-PH 1 (040201
CN-STR (X4)
Steer
in9
potentiometer
TWD00986
D155AX-5
20-417
E-7
TROUBLESHOOTING
E-7.
x
*
*
*
[251 Short circuit in steering potentiometer
system 1 is displayed

system 1 lowers below
0.5oov.
Remedy
Cause
~
ES
between CN-2Hl
Is resistance
between
YES CNZHl(10) and
(female) (4)
- chassisground
3
normalwhen CN-STR
is disconnected?
Is resistancebetween
YES CN-2Hl (femala)(19)
P
- between CN-2Hl (female)
*Turn starting
NO
and chassisground switch OFF.
normalwhen CN-STR
. Disconnect CN-STR
ISdrsmnnected?
Short
circuit with chassis
and CN-2Hl.
* Min. 1 Ma
ground in harness
zN1?fil !lj 1 1 -Turn starting
and f4), between ELI
switch OFF.
NO
NO
* Disconnect
CN-STR and CN9Hl.
* Turn starting
Defective steering
switch OFF.
potentiometer
- Disconnect
CN-STR.
. VFS
.__ I harness
1
CH-ZHl (19) and
(9) as shown in
-Turn starting
switch ON.
Table
Replace
Repair or
replace
Repair or
replace
Repair or
replace
Replace
1
Steering
CN-2H 1
Between (19) - (9)
E-7. Related
HSS
electrical
In neutral
When to
fully
steered
left
When tcfully
steered
right
2.4 - 2.6 V
4.1 - 4.3 v
0.73 - 0.89 V
~~
circuit diagram
controller
I
CN-2H 1 (040201
CN-STR (X4)
Steer
ine
Potentiometer
3
3
3
3
TWO00986
20-418
D155AX-5
E-8
TROUBLESHOOTING
E-8.
[26] Disconnection
displayed
in steering
potentiometer
system 2 is

system 2 exceeds 4.5OOV.
*
-Sr Always connect any disconnected connectors before going on the next step.
+
Cause
4YES
Is voltage between
YES CN-2Hl (20) and
-chassis ground
3_
normalwtwnCNSiR
Is resistance
is disconnected?
* y+;ct
YES between CN-2Hl
NC
- (female) (20) and CN-STR
(female)
* Turn starting
2
(2) normal?
switch ON.
* Max. IV
* Turn starting
between CN-ZHl (1)
switch
OFF.
and(4).between(2)and
NO
* Disconnect
(4).and between(3)and
CN-2Hl and
(4)as showninTableZ?
CN-STR.
. Turn starting
* Max. 1 D
switch OFF.
LIT\
. Disconnect
I
CN-STR.
-Turn starting
switch ON.
Table
Replace
(female) (I)
Repair or
replace

Repair or
replace
(female) (2)
Repair or
replace
Defective steering
potentiometer
Replace
Table 2
CN-STR
Steering
CN-2H1
Between
E-8. Related
I
Remedy
(20) - (9)
electrical
(male)
Resistance
In neutral
When fully
steered
to left
When fully
steered to right
Between (I) - (4)
2.4 - 4.0 R
2.4 - 2.6 V
0.6 - 1.1 V
3.9 - 4.4 v
Between (2) - (4)
5.0 - 8.0 Q
Between
5.0 - 8.0 Q
(3) - (4)
circuit diagram
HSS controller
CN-2H
1 (040201
CN-STR (X4)
Steering
Potentiometer
TWD00986
D 155AX-5
20-419
TROUBLESHOOTING
E-9.
%
*
*
*
E-9
[25] Short circuit in steering potentiometer
system 2 is displayed

system 2 lowers below
0.5oov.
check that all the related connectors are properly inset-ted.
Remedy
Rleplace
4YES
YES CN-2Hl (female) (10)
- and chassis ground 3
normalwhen CN-SIR
is disconnected?
Is resistancebatwxn
YES CN-2Hl (female) (20)
P
NO
*Turn starting
- and chassis ground switch OFF.
normal
when
CNSIR
- Disconnect
2
is disconnected?
CN-STR and CN-2Hl.
Are resistances
* Min. 1 MQ
* Turn starting
between CN-2Hl (1)
- and(4).between(2)and switch OFF.
NO
1 (4).andbetween(3)and
* Disconnect CN-STR
(4)asshowninTable2?
and CN-2Hl.
* Min. 1 MR
*Turn starting
switch OFF.
NO
* Disconnect
CN-STR.
CH-2Hl (20) and

(9) as shown in
. Turn starting
switch ON.
Table
dlsconnectlon m wmng
Rlepair or
neplace
(femae) (4)
Rlepair or
r,eplace
Short circuit with chassis

ground in harness
Flepair or
rfeplace
Defective steering
potentiometer
Fleplace
Table 2
Steering
CN-PHI
In neutral
Between
(19) - (9)
2.4 - 2.6 V
When
steered
fully
to left
0.6 - 1.1 V
When fully
steered to right
3.9 - 4.4 v
Between
E-9. Related
electrical
(3) - (4)
circuit diagram
HSS controller
CN-2H
Analog
1 (04O;O)
CN-STR (X4)
Steer ina
Dotentiometer
GND
Potentiometer
Dower
SUPPI
Steering
potentiometer
Steering
Potentiometer
I
TWO00986
20-420
D155AX-5
E-10
TROUBLESHOOTING
E-10.
*
*
*
*
[29] Trouble of engine rotation
sensor system is displayed

check that the engine rotation sensor has been adjusted
normally.
reproducing
Cause
YES
4 YE:
1r
Is resistance
YES between CN-2H2
Is voltage between
(female) (4) and
CN-2H2 (4) and
3
_
chassis ground
(12) normal?
Is resistance
normal?
* Turn starting
N(
YES between CN-2H2
- (female) (4) and
. Start engine.
switch OFF.
CN-ENG
(female)
. Disconnect CN-2H2
-Taster in AC
2
(1) normal?
and CN-ENG.
range.
Is resistance
*Min. 1 MQ
-Turn
starting
* 0.5 - 3.ov
between CN-ENG
switch OFF.
NO
NO (male) (1) and (2)
* Disconnect
normal?
CN-2H2 and CN-ENG.
* Max. 1 fi
. Turn starting
switch OFF.
NO
- Disconnect
CN-ENG.
-500-1,ooon
E-10. Related
HSS
electrical
[female) (12) - CN-ENG
(female) (2)
ground in harness
(4) - CN-ENG (female) (I)
(female) (4) - CN-ENG
(female) (1)
Defective engine rotation
sensor
Remedy
leplace
lepair or
eplace
lepair or
eplace
lepair or
eplace
leplace
circuit diagram
controller
CN-701
(SWP12)
CN-ENG (X2)
Engine
speed
sensor
JJ
Pulse
input
(-1
-3
TwD009aa
D 155,&t-5
20-42
TROUBLESHOOTING
E-11
E-l 1. 1511 Short circuit in travel reverse sensing potentiometer

is displayed
system
This is displayed when the input signal from the travel reverse sensing potentiometer
exceeds
4.7V.
check that the travel reverse sensing potentiometer
has been
adjusted normally.
Cause
Is voltage
between CN-ZHl
(10) and CN-PHl
(9) as shown in
Table l?
. Turn starting
switch ON.
Table
3 YES
Is voltage between
YES CN-2H2 (10) and
- chassis ground
2
nofmalwhenCN-RSS
is disconnected?
Are resistances
between CN-RSS
NO
. Disconnect
- (male) (1) and (2) and CN-RSS.
NO between (1) and (3)
-Turn starting switch ON.
as shown in Table 2?
.Max. 1 v
I .-.---. Turn starting
NO
switch OFF.* Disconnect
CN-RSS.
Replace
(female) (9) - CN-RSS
(female) (3)
Repair or
replace

(IO) - CN-RSS (female) (2)
Repair or
replace
Defective travel reverse

sensing potentiometer
Replace
Table 2
E-l 1. Related
HSS
! I
Remedy
electrical
circuit diagram
controller
I
Ct+2H 1 (04020)
Analog
Power
SUPPIY
I
CN-2H2
Travel
REVERSE
Potentiometer
20-422
Travel
REVERSE
senslns
Potentiometer
GND
Potentiometer
CN-RSS (X3)
3
3
(040 16)
sensing
TWD00989
D 155AX-5
E-12
TROUBLESHOOTING
E-12.
%
*
*
*
*
[52] Disconnection in travel reverse sensing potentiometer

system is displayed
This is displayed when the input signal from the travel reverse sensing potentiometer
lowers
below 0.3OOV.
check that the travel reverse sensing potentiometer
has been
adjusted normally.
Cause
aYES
reststance
YES between CN-2H2
- (female) (IO) and
3
CN-RSS (female)
(2) normal?
YES CN-2H2 (female) (10)
P
* Turn starting
and chassis ground
Is
Is voltage
between CN-2H2
(IO) and CN-2H1
(9) as shown in
Table I?
* Turn starting
switch ON.
II
lasshown in Table 2? 1 1
Replace
Go to
Replace
A.
(female) (IO) - CN-RSS
(female) (2)
Repair or
replace

ground in harness
(IO) - CN-RSS (female) (2)
Repair or
replace
Defective travel reverse

sensing potentiometer
Replace
harness between CN9Hl
(female) (IO) - CN-RSS
(female) (I)
Repair or
replace

ground in harness
(IO) - CN-RSS (female) (I)
Repair or
replace
k::Fz;. ana
-Turn starting
switch OFF.
- Disconnect
CN-RSS.
Is resistancabetween
CN-PHI (female) (IO)
A - and chassis ground normalwhen CNRSS
is disconnected?
NO
. Turn starting
switch OFF.
* Disconnect CN-RSS
and CN-2Hl.
* Min. 1 MD
Table 1
Remedy
Table 2
D155AX-5
20-423
E-12
TROUBLESHOOTING
E-12. Related
HSS
electrical
controller
Analog
circuit diagram
I
CN-2H 1 (04020)
CN-RSS (X3)
Travel
REVERSE
sensing
Potentiometer
GND
Potentiometer
Power
SuPPI
I
CN-2H2 (04016)
Travel
REVERSE
Potentiometer
sensing
TWD00989
20-424
D155AX-5
TROUBLESHOOTING
E-13.
*
*
*
E-13
[53] Disconnection
in backup alarm relay system is displayed
reproducing
Remedy
Cause
3 YES
n N-014
) (2)and
1
;
((.m$;)
and (2)
* Turn starting
switch OFF.
- Disconnect
CN-014.
.200-400n
E-13. Related
around
normal?
-Turn starting
switch OFF.
* Disconnect
CN-014.
. Max. 1 Q
NO
. Turn starting
switch OFF.
- Disconnect CN-001.
~200-400R
NO
Replace
harness between CNI
(female) (11) - CN-014
female) (1)
Repair or
replace
Iefective contact or
iisconnection in wiring
larness between CN-014
female) (2) - CNSX8
chassis ground)
Defective backup alarm
.elav
40
electrical
Replace
circuit diagram
Backw
alarm
relay
Backup
buzzer
HSS
Repair or
replace
alarm
controller
R&
D155AX-5
20-425
E-14
TROUBLESHOOTING
E-14. [54] Short circuit in backup alarm relay system is displayed

*
*
*
reproducing
Remedy
Cause
2 YES
YES CN-1 (female) (11)
- and chassis ground 1
~_
normal when CN-014
is disconnected?
Is resistance
between CN-014
-Turn starting
NO
(male) (1) and (2) switch OFF.
. Disconnect
normal?
CN-014 and CNI.
* Min. 1M Q
*Turn starting
NO
switch OFF.
. Disconnect
CN-014.
*200-400R
E-14. Related
electrical
Replace

ground in harness
between CNI (female) 11
- CN-014 (female) (I)
Repair or
replace

relay
Replace
circuit diagram
Backup alarm relay
Backup alarm
HSS controller
TWD00990
20-426
D155AX-5
TROUBLESHOOTING
E-15.
%
*
*
*
*
E-15
[57] Low voltage of controller
is displayed
This is displayed when the source voltage of the controller lowers below 17V.
chassis ground.)
Cause
Remedy
Replace
1
Is voltage
between CNl
(8Ml8) and
(9)/(19) normal?
1
* Turn starting
switch ON.
.20-30V
YES
2
Is voltage between
CNl (8M18) and
NO chassis ground
normal?
*Turn starting
switch ON.
-2O-30V
3 YES
Is voltage between
inlet of fuse 5 and
NO chassis ground
normal?
* Remove fuse 5.
. Turn starting
switch ON.
.20-3ov
E-15. Related
electrical
NO
harness between CNl
(female) (9)/(19) - CNSXI
(chassis ground)
Defective fuse or defective
contact or disconnection
in wiring harness
between outlet of fuse 5 CNl (female) (8M18)
Defective power supply
circuit of fuse box or
lowering of battery
voltage
Repair or
replace
Repair or
replace
Repair or
replace
circuit diagram
HSS controller
I
CN-001 (MIC21)
Fuse
box
rffr
CN-SX8
TWD00991
D 155AX-5
20-427
TROUBLESHOOTING
E-16.
%
Ir
*
*
E-16
[62] Excessive difference of signal value between

potentiometer
systems 1 and 2 is displayed [II
steering
This is displayed when the signal voltages of steering potentiometer

systems 1 and 2 are excessively different from each other. (When the starting switch is turned ON, the trouble occurs.)
reproducing
Always connect any disconnected connectors before going on to the next step.
switch ON. _
- See Note.
* 4.41 - 5.59v WSUM)
Note:
Measure the voltage according to the following procedure.

1) Measure the voltage (VI) between CN-2Hl (19) and (9). and that (V2) between
and (9).
2) Add up the two measured voltages (VI, V2) to obtain the total (VSUM).
*
The joystick does not move while the voltage is measured.
E-16. Related
HSS
electrical
(20)
circuit diagram
controller
Fuse
Power
CN-2Hl
lOA@
supply(+)
Power
SUPPIYI-1
Power
supply(+)
Power
SUPPIY(-1
box
Ct+SXS
TWD00991
20-428
D 155AX-5
E-17
TROUBLESHOOTING
E-17.
[6d] Excessive difference of signal value between

potentiometer
systems 1 and 2 is displayed [III
steering
This is displayed when the signal voltages of steering potentiometer

systems 1 and 2 are excessively different from each other. (When the starting switch is turned ON, the systems are normal.)
YES
Is total
of voltage
between CN-2H1
(19) and (9) and
that between (20)
and (9) normal?
Replace
Defective steering
potentiometer
Replace
. Turn starting
switch ON.
* See Note.
* 4.41 - 5.59v PkUM)
Note:
NO
Measure the voltage according to the following procedure.

1) Measure the voltage (VI) between CN-2Hl (19) and (9), and that (V2) between
and (9).
2) Add up the two measured voltages (VI, V2) to obtain the total (VSUM).
t
The joystick does not move while the voltage is measured.
E-17. Related
electrical
HSS controller
CN-001
CN-2H1
(20)
circuit diagram
I
(MIC21)
Fuse
box
TWD00991
D155AX-5
20-429
TROUBLESHOOTING
E-18.
%
*
*
Ir
E-18
[6E] Trouble of either steering potentiometer

system and
excessive deviation of neutral point signal of either system is
indicated
This is displayed when either steering potentiometer

system has trouble and the neutral position
signal of either system is deviated.
Cause
Go to troubleshooting of
error code displayed
simultaneously.
YES
1
Are error codes
24. 25. 26
and 27
displayed
simultaneously?
Remedy
2 YES
Are voltages
between CN-2H109)
NE and (9). and between (20) and (9) as shown
in following table?
* Turn starting
switch ON.
Replace
Defective steering
NO
Table
E-18. Related
HSS
electrical
circuit diagram
controller
Fuse
Power
box
supply(+)
0
$j+
CN-SX8
TWD00991
20-430
D 155AX-5
E-19
TROUBLESHOOTING
E-19.
*
*
*
[64] Disconnection
displayed
in HSS pump solenoid valve system A is
Always connect any disconnected connectors before going on to the next step.
Cause
I Is
_.__
- ..__
mcisttancn
1 112) normal?
zcI between
CNl
Imale) 14) and
-- ._4 (female)
, ,,,,,,ial?
t
a) (1)I I * Turn starting

and (2) and between
nritch OFF.
(2) and chassis
isconnect CNl
and CN-PUPA.
- Max. 1 D
*Turn starting
switch OFF.
. Disconnect
CN-PUPA.
* Turn starting
switch OFF.
. Disconnect CNl
and CN-PUPA
* Max. 1 G
I
4 YE:
CNl (female) (15) and
YES chassis ground
_
3 I- normal when
CN-PUPA is
disconnected?
-Turn starting
N(
-..,:*^I. r-JFF.
,.,,,...lect
1 1 CN-PUPA and CNl.
1 -Min. 1 bVlR
NO
NO

ground in harness
between CNl (female)
(15) - CN-PUPA (female) (2)
harness between CNI
(female) (15) - CN-PUPA
(female) (2)
harness between CNl
(female) (4) - CN-PUPA
(female) (1)
Defective HSS pump
solenoid valve A
NO
Remedy
Fleplace
lepair or
eplace
Flepair or
rieplace
Flepair or
rleplace
Fleplace
Table
CN-PUPA
(male)
Voltage
Between (I) - (2)

B;oF;;n
9
HSS
IO-20R
(2) - chassis
E-19. Related
electrical
Min.
1 MQ
circuit diagram
controller
CN-001 (M&I
\
CN-LPL
(SWP8)
CN-PUPA
(X21
HSS Pump
solenoid
TWD00992
D155AX-5
20-431
E-20
TROUBLESHOOTING
E-20.
*
Ir
*
[65] Short circuit in HSS pump solenoid valve system A is

displayed
reproducing
Remedy
Cause
YES
Replace

between CNI (female)
Repair or
replace
NO
II
nnormal when
Is resstance betw
CN-PUPA (male; ~.,
and (2) and between
(1)and chassis
jj;;~j~;;~yn
in
-
-Turn starting
switch OFF.-

ground in harness
between CNl (female) (4)
- CN-PUPA (female) (I)
Lln
I
Repair or
replace
~f~~_~~f~
-Min.
*Turn starting
switch OFF.
- Disconnect
CN-PUPA.
*Turn startina
Defective HSS pump

solenoid valve A
1 MD
NO
Replace
Table
CN-PUPA
(male)
Between
(I) - (2)
Voltage
10 - 20 a
I
B;oyi;n
9
(1) - chassis
E-20. Related
electrical
Min. 1 ML?
circuit diagram
HSS controller
CN-001 (MI&l)
CN-LPL
(SWPB)
CN-PUPA
(X2)
HSS Pump
solenoid
A
a
p
TWD00992
20-432
D155AX-5
TROUBLESHOOTING
E-21.
*
Ir
Ir
E-21
[66] Disconnection
displayed
in HSS pump solenoid valve system B is
Remedy
(female) (15) and

CN-PUPB (female)
YE
* Turn starting
switch OFF.
* Disconnect CNl
and CN-PUPB.
- Max. 1 R
* Turn starting
switch OFF.
* Disconnect
CN-PUPB.
YES1
Replace

ground in harness
between CNI (female) (151
- CN-PUP6 (female) (2)
Repair or
replace
harness between CNl
(female) (15) CN-PUPB
{female) (2)
I disconnection
in wiring
harness between CNI
(female) (5) - CN-PUPB
(female) (I)
* Turn starting
switch OFF.
* Disconnect CNl
and CN-PUPB
. Max. 1 R
Bepair or
replace
Repair or
replace
3eplace
Table
CN-PUPB (male)
Between
BFoy;;n
9
(I) - (2)
IO-20n
(2) - chassis
E-21. Related
HSS
Voltage
electrical
Min. 1 MR
circuit diagram
controller
CN-001
I
(MIC21)
CN-LPL
(SWP81
CN-PUP6
(X21
HSS Pump
solenoid
TWD00993
D155AX-5
20-433
E-22
TROUBLESHOOTING
E-22.
*
Ir
Ir
[67] Short circuit in HSS pump solenoid valve system B is

displayed.
reproducing
Cause
3 YES
CNl (15) and
YES_ chassis ground
_
normal when
2
p
CN-PUPB is
disconnected?
YES CNl (female) (5)
NO
_ and chassis ground _ - Disconnect
CN-PUPB.
normal when
1
-Turn starting
CN-PUPB is
disconnected?
switch ON.
7s resrstancebetween
CN-PUPB (male1 (1)
.
Max. 1 V
.
Turn
starting
and (2) and between
switch OFF.
(1) and chassis
jr;;ir$ast;kF
in
No
* Min. 1 Ma
* Turn starting
switch OFF.
* Disconnect
CN-PUPB.
NO
Remedy
3efective HSS controller
Replace

between CNl (female) (15)
CN-PUPB (female) (2)
Repair or
replace

ground in harness
between CNI (female) (5)
CN-PUPB (female) (1)
Repair or
replace
Ilefective HSS pump

solenoid valve B
Replace
Table
CN-PUPB (male)
Voltage
Between (I) - (2)
10 - 20 n
B;oet;vnn(1)-chassis
9
Min. 1 MQ
E-22. Related
electrical
circuit diagram
HSS controller
CN-LPL
CN-PUPB
(SWP81
@
(X2)
HSS Pump
solenoid
TWD00993
20-434
D155AX-5
TROUBLESHOOTING
E-23.
E-23
[70] Short circuit in work equipment

system is displayed
This is displayed when the input signal from the work equipment
exceeds 6.OOOV.
3 YES
Replace
Defective work equipment

oil pressure sensor
Replace
(female) (9) - CN-HHP
(female) (1)
(2) - CN-HHP (female) (3)
* Start engine.
- Disconnect
CN-HHP.
* Max. 1 V
and CN-HHP.
* Max. 1 R
NO
Repair or
replace
Repair or
replace
Table
~:
E-23. Related
HSS
electrical
CN-70 1
(SWP 12)
controller
CN-2H
circuit diagram
Hydraulic
Pressure
Hydraulic
oil
1 (04020)
Analog GND
CN-2H2
CN-HHP
(X3)
(04016)
oil
sensor
a\ r
Fuse
-\
t-i-
box
TWD00994
D155AX-5
20-435
E-24
TROUBLESHOOTING
E-24.
%
*
*
*
*
[71] Disconnection in work equipment

system is displayed
This is displayed when the input signal from the work equipment circuit oil pressure sensor lowers
below 0.5OOV.
reproducing
chassis ground.)
Remedy
Cause
ES
4YES
- Start engine.
.-..A..&. ncF,
1 1 . KzEA,d,
CN-HHP (female)
1 (3) normal?
CN-HHP (2) and
* Turn starting
switch ON.
.20-30V
* Turn starting
switch OFF.
NO
* Disconnect CN-2H2
and CN-HHP.
* Max. 1 D
NO
qeplace
Defective work equipmeni

oil pressure sensor
Replace

ground in harness
Repair or
replace
(female) (2) - CN-HHP
(female) (3)
harness between fuse 5 CN-HHP (female) (2)
Repair or
replace
Repair or
replace
Table
E-24. Related
electrical
HSS controller
circuit diagram
CN-2H 1 (04020)
CN-70 1
fSWPl2!
I_,
CN-HHP
(X31
-
,,
HYdraUlic
Pressure
oil
sensor
@
3
CN-2H2
(04016)
3
Fuse
Pressure
box
sensor
I
TWD00994
20-436
D155AX-5
TROUBLESHOOTING
E-25.
E-25
[8d] System network
communication
error is displayed
Cause
YE
1
Does LED of
controller
indicates?
*Turn starting
switch ON.
E-25. Related
HSS
Is resistance
between CN 1
. (female) (1). (12)

and P2 (female)
(10) normal?
* Turn starting
switch OFF.
* Disconnect CNl
and P2.
. Max. 1 R
3 YES
Is resistance
between CNl
YES (female) (I), (12)
_
and chassis ground
2_
normal when P2 is
disconnected?
* Turn starting
NO
switch OFF.
* Disconnect P2
and CNI.
* Min. 1 MQ
NO
eplace

ground in harness
between CNI (female) (11,
(12) - P2 (female) (10)
harness between CNl
(female) (1). (12) - P2
(female) (IO)
Lowering of source
voltage of controller
JO
electrical
Remedy
;epair or
splace
;epair or
splace
;o to A.
circuit diagram
controller
Monitor
CN-2
14 (SWP 16)
Panel
P2 (04016)
system
network
TWD00995
D155AX-5
20-437
E-26
TROUBLESHOOTING
E-26.
z
Ir
+
*
*
[99] Disagreement of reverse sensing potentiometer

alarm switch signals with each other is displayed
and backup
This is displayed when the reverse sensing potentiometer

and backup alarm switch signals do not
agree with each other.
check that the backup alarm switch has been adjusted normally.
reproducing
Cause
C$0 to troubleshooting
-e !rror code displayed
S ,imultaneously.
YES
YES
-c defective
-Turn starting
switch ON.
4 YE! ;
Nc
Is resistance
between CN-251
(male) (1) and (3)
as shown in Table
2?
. Turn starting
switch OFF.
* Disconnect
CN-251.
Is resistance
YES between CN-2Hl
- (female) (7) and
_3
CN-251 (female)
(3) normal?
-
-c ;o to
leplace
A.
Clefective contact or
clisconnection in wiring
rarness between CN-2Hl
female) (7) CN-251
(female) (3)
1:
* Turn starting
NC
switch OFF.
. Disconnect CN-2Hl
and CN-251.
* Max. 1 D
CDefective backup alarm
S;witch
NO
CIefective contact or
dlisconnection in wiring
rarness between CN-251
: female) (1) CN-SX8
chassis ground)
(1
5 YES
CN-2Hl (female1 (7)
A -and chassis ground normal when CN-251
is disconnected?
;epair or
eplace
leplace
;epair or
aplace
s;hort
circuit with chassis

/round in harness
ifretween CN9Hl (female)
17) - CN-251 (female) (3)
NO
* Turn starting
switch OFF.
* Disconnect CN-251
and CN-2Hl.
*Min. 1 MR
20-438
HSS controller
2
Is voltage between
CN-2Hl (7) and
NO chassis ground as
shown in Table l?
of
Are error codes

1511and f521
displayed
simultaneously?
Table
Remedy
epair or
Table 2
D155AX-5
E-26
TROUBLESHOOTING
E-26. Related electrical circuit diagram
-3
CN-SX8
HSS
CN-45 1
(SWPB)
CN-2 5 1
1x31
.a
3
3
Backup
switch
1
1
alarm
A
lWV&
controller
CN-RSS (X31
Travel
REVERSE
sensing
Potentiometer
CN-2H2 (04016)
Travel
REVERSE
Dotentiometer
sensing
TWD00996
D155AX-5
20-439
TROUBLESHOOTING
E-27.
%
Ir
E-27
[EO] Trouble of offset current memory
This is displayed when

controller.
If the starting switch
reproducing operation
displayed, the trouble
is displayed
the offset current cannot be stored in the memory
because of trouble
in the
is turned to the OFF position after trouble occurs, perform the error code
and check that E- is displayed at the head of the error code. (If P- is
has been reset.)
Cause
1 YES
Does machine
deviate during
travel with
steering system in
neutral?
- Start engine.
* On flat ground.
-Travel at forward
first gear speed.

(See Note I).

NO
Replace next time

(See Note 2).
Note 1: If the machine deviates, it must be corrected by performing

ADJUSTMENT
OF NEUTRAL
POSITION OF STEERING SYSTEM. When the steering system is adjusted, however, the offset
current cannot be stored because of this trouble. Accordingly,
replace the HSS controller with
new one before starting adjustment.
Note 2: The machine can be used as it is since the machine does not deviate.
The HSS controller
should be replaced in the first chance, however, as the permanent
countermeasure
against
this trouble.
(If the controller is replaced, be sure to perform ADJUSTMENT
OF NEUTRAL
POSITION OF STEERING SYSTEM.)
20-440
D155AX-5
TROUBLESHOOTING
E-28.
Ir
Ir
*
E-28
Backup alarm does not sound
chassis ground.)
Cause
Remedy
30 to troubleshooting
arror code displayed
simultaneously.
YES
controller indicate
error codes 53
of

relay
Replace
Replace
ES
replacing backup
Is voltage between
CN-014 (3) and
-Turn starting
. Turn starting
switch ON.
.20-30V
E-28. Related
electrical
N0
tlSS controller
Repair or
replace
CN-25 1
(X3)
Backup
switch
alarm
I
CN-2H 1 (04020)
/ Analo;
Repair or
replace
circuit diagram
CN-45 1
(SWP8)
1 Travel
N(
switch OFF.
* Disconnect CN-014
and CN-244.
- Max. 1 Q
harness between CN-014
[female) (6) - CN-244
Ifemale)
harness between fuse 9 CN-014 (female) (3)
REVERSE sianal
CN-RSS (X3)
inPut\q-
GND
Potentiometer
-3
/a~
Power
supply
Travel
REVERSE
sensing
potentiometer
I
CN-2H2
Travel
REVERSE
potentiometer
(04016)
sensing
I
TWDOOg96
D 155AX-5
20-441
TROUBLESHOOTING
E-29.
*
E-29
Blade pitch does not work normally

dozer)
(When equipped
with pitch
*
Jr
chassis ground.)
a)
Blade pitch system
does not work (Solenoid
valve is not excited)
Remedy
2 YES
CN-454 (male) (1)
YE _ and (2) and between _
(1) and chassis
(female) (2) - CN-456
(chassis ground)
Kzz!!G
Replace
* Turn starting
switch OFF.
* Disconnect
CN-454.
1
Is voltagebetween
CN-454 (1) and
chassis ground
1normal?
Repair or
replace
* Turn starting
switch ON.
Repair or
replace
Replace
NO
*20-30V
normal?
I
Repair or
replace
* Disconnect
POl.
. Turn starting
switch ON.
.20-30V
Table
CN-454
Between
B;oF;;n
9
b)
(male)
(1) - (2)
(1) - chassis
Blade tilt system
Voltage
40 - 80 i-l
Min.
MR
does not work (Solenoid
valve is not demagnetized)
Cause
1 YES
Is trouble
corrected by
disconnecting PO1
and PO2?
-Start
engine.
20-442
NO
Remedy
Defective blade pitch

switch
Replace

between 02 (male) CN-454 (female) (1)
Repair or
replace
D 155AX-5
E-29
TROUBLESHOOTING
E-29. Related
Blade
switch
pitch
electrical
PO2
circuit diagram
CN-451
(SWP8)
CN-454
(x2)
Blade
solenoid
pitch
valve
gg
PO1
Fuse
D155AX-5
box
TWD00997
20-443
TROUBLESHOOTING
E-30.
Ir
E-30
Ripper pin puller does not work normally

giant ripper)
(When equipped
with
*
*
chassis ground.)
a)
Pin cannot
be pulled out (Solenoid
valve is not excited)
Cause
YES
YES CN-246 (male) (1)
and (2) and between _
(I) and chassis
round as shown
9ollowing table?
1 1 -Turn starting
switch OFF.
* Disconnect
CN-246.
CN-246 (1) and
No
4 YES
YES
Is resistance
between CN-263
(male) (1) and (2)
normal?
. Turn starting
switch ON.
- Pin puller switch:
PULL
*20-30V
*Turn starting
NO
_
switch OFF.
- Disconnect CN-263.
: PI%&~
switch: PULL
-Turn starting
switch ON.
-2O-30V
NO
Remedy
(female) (2) CN-424
(chassis ground)
qepair or
replace
Defective ripper pin puller

solenoid valve
Replace
(female) (2)- CN-264
(female) (1)
Repair or
replace

switch
Replace
Repair or
replace
Table
CN-246 (male)
Voltage
Between (I) - (2)

I
Between (1) - chassis

ground
b)
Pin cannot
be pushed
1 YES
Is trouble
corrected by
disconnecting
CN-263?
* Start engine.
20-444
NO
40 - 80 Q
Min. 1 MQ
in (Solenoid
valve is not demagnetized)
Defective ripper pin-puller

switch
between CN-263 (female)
(2) - CN-264 (female) (1)
Peplace
Repair or
replace
D155AX-5
TROUBLESHOOTING
E-30. Related
electrical
E-30
circuit diagram
Fuse
;:y+;;
_.. _
ler
box
CN-263
(X2)
(SWPG)
D155AX-5
1
7% CN-424
TWD00998
20-445
TROUBLESHOOTING
E-31.
*
*
*
*
E-31
Engine does not start (Engine does not rotate)
Check that fuse 10 is not broken. (if it is broken, check the circuits related to it for short circuit with
chassis ground.)
When carrying out troubleshooting,
set the parking brake lever to the lock position.
5 YES
YE
4
YE!
1Isconnection
1 I-
of
wiring harness
between starter
and battery relay
normal?
* Check visually.
Is voltage between
CN-103 (2) and
NO
YES
81
. Turn starting
switch ON.
. Max. 1V
Is voltage between
CN103 and chassis
ground normal?
Turn starting
switch ON.
20 - 3ov
Is voltage between
CN-103 (2) and
_ chassis ground
_
normal when
7 YES
NO CN-112 is
Is voltage between
disconnected?
P
CN-103 (2) and
* Disconnect
- chassis ground
alternator
NO normal when CN-220
is disconnected?
terminal FL
* Turn starting
* Disconnect diode. NO
switch ON.
. Turn starting switch ON.
- Max. 1 V
*Max. 1V
_
9
Is resistance
YES between CN-152
n (male)(l) and (3)
normal?
. Turn starting
switch OFF.
. Disconnect
CN-152.
* Max. 1 42
CN-152 (3) and
YE
starting switch is
. Turn starting
switch ON.
*20-30V
* Turn starting
switch
ON .x OFF.
YES
II
n
10 YES
IiFHP
NC
. Turn starting
switch ON.
.20-30V
NO
Are voltage of
1 SN-SW and
-Voltage:Min. 24V
* Specific gravity:
Min. 1.26
YES
* Turn starting
switch ON.
-2O-30V
* Disconnect starting
NO
switch terminals B
and BR.
: zm, slfa$ing switch ON.
NO
20-446
D155AX-5
E-31
TROUBLESHOOTING
Cause
Remedy
Defective starting motor
leplace
Defective connection of
power wiring harness
between starting motor
and battery relay
lepair or
splace
Leplace
Defective diode (CN-220)

between CN-103 (female)
(2) - CNI 12 or between
CN-103 (female) (2) CN220 (female) (2)
(female) (1) - CN-103
(female) (1)
Ieplace
lepair or
eplace
lepair or
eplace
Defective neutral safety

switch
leplace
harness between starting
switch terminal C (CN280) CN-152 (female) (3)
iepair or
eplace
Defective starting switch
teplace
Defective battery relay
switch terminal BR (CN260) - CN-SW
switch terminal B (CN250) -fuse 10 - CNH
Xepair or
eplace
Iepair or
eplace
Defective battery
D 155AX-5
qeplace
TROUBLESHOOTING
E-31
electrical
E-31. Related
circuit diagram
Alternator
Neutral
Battery
C,Ol#l2)
7b
safety
relay
Fender
GND
Battery
Sta;t
ine
sw,i tch
7h
ctq-220
TWD00999
20-448
D 155AX-5
TROUBLESHOOTING OF HYDRAULIC AND

MECHANICAL SYSTEM
(H MODE)
Table of failure
and causes .. . . . . . . .. . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . .. . .. . . . . . .. . . . .. . . . .. .. .. . . . . . . . . .. . . . . 20-502
modes
H- 1.
Machine
does not move or moves
H- 2.
Machine
does not move or travel power
H- 3.
Machine
does not move or moves slowly
H- 4.
Long time lag is made in changing
H- 5.
Travel
power
(Drawbar
slowly
at any gear speed
in each direction..
...... .20-504
is low in one direction .................................
20-506
at specific gear speed ...............................
.20-506
or gear speed.. ...........................
.20-507
travel direction
20-508
pull) is low ..................................................................................
be steered
................................................................
H- 6.
Machine
cannot
(to one direction)
H- 7.
Steering
speed or power
H- 8.
Abnormal
H- 9.
Brake does not work ..........................................................................................................
20-509
20-509
is low ........................................................................................
sound comes out of HSS pump or HSS motor ............................................
20-510
20-512
20-513
...................................................................................................
H-10.
Power train oil overheats
H-II.
Work equipment
does not work at all ..............................................................................
20-514
H-12.
Work equipment
speed or power
is low ..........................................................................
20-515
H-13.
Blade lifting speed or power
is low.. ................................................................................
20-516
H-14.
Blade tilting speed or power
is low.. ................................................................................
20-516
H-15.
Ripper lifting speed or power
is low ................................................................................
20-517
H-16.
Ripper tilting speed or power
is low ................................................................................
20-517
H-17.
Hydraulic
drift is large in blade lifting direction
.............................................................
20-518
.............................................................
20-518
...........................................................
20-519
H-18.
Hydraulic
drift is large in blade tilting
H-19.
Hydraulic
drift is large in ripper lifting direction..
H-20.
Blade pitch does not work normally
H-21.
Ripper pin puller does not work normally
H-22.
D 155AX-5
Abnormal
sound comes
direction
(When
equipped
(When
out of work equipment
with pitch dozer) .....................
equipped
20-519
with giant ripper) ........ ..20-52 0
pump.. ...............................................
20-520
20-50 1
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES

-
2 P
.z
?l
&
3
3
FL 2
Machine does not move or moves slowly at any gear speed in each direction.
Machine does not move or travel power is low in one direction.

Machine
does not move or moves slowly
at specific gear speed.
Long time lag is made in changing travel direction or gear speed.

Travel
power
(Drawbar
Machine
cannot
Steering
speed
Abnormal
pull) is low.
be steered
or power
(to one direction).
is low.
sound comes
out of HSS pump
or HSS motor.
Brake does not work.
-5
-
-6
-6
Power train oil overheats.

Work
equipment
does not work at all.
Work
equipment
speed
or power
-i
is low.
Blade liftina
speed
or power
is low.
Blade tilting
speed
or power
is low.
or power
is low.
SDeed or power
is low.
Ripper
lifting speed
Ripper
tiltins
Hydraulic
drift is large in blade
Hydraulic
drift is large in blade tilting
Hvdraulic
drift is large in ripper
lifting direction.
direction.
lifting direction.
Blade pitch does not work normally (When equipped with pitch dozer).
Ripper pin puller does not work normally (When equipped with giant ripper).
Abnormal
20-502
sound
comes
out of work equipment
pump.
2
P
z
-5
5
-5
-
E
z
6 E
5
.F!
s
T
EE
z s2
m
I=
-5 5
- 6
-3
6
-6 -i
- - - i
- - - - - - - - - -
d
F
m
-
i
-
5
i-
k
ti
E &
m
ii
5 5
i
i
6
5
-5
-
-5
6 -6
- -I,
- - - _
- - - - - - - - - -
D155AX-5
TROUBLESHOOTING
-23
-P
l-
F
or
l-
Control
valve
E
3
Es
z s
- - - - - 6 6
6 -G
-6 - - - - - - - - - - - - - - -
D 155AX-5
z-
E
c?6
- - - - - -
5
-5
-
4z
72
Ei 5
ul
I
-
z
.E
9
-
i
-a -i
5 - -
5
5
5
5
6
-5
-
z
::
=h
ii
$ 2 L = 2 F 2
2 9
5 g
z !z C5 .G
Y
a
a
2 9
-s
5 G5 3
5 G5 i -5 -6 -G -6 - - - - 6
-
3 5 .a
T! .o
ti 5 ii
it u2 +f
9
i%
ti
2 $fn E2
0
2
8
.r
k :
t: 5
2
-
Y
-
z E
3 G Gi ::G
2 m
m z
I? VJ
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - i
-i
-
-r
-
-.s
t
2
b .c 5
-.E
::
Z
v)
%
_)
E
m
-5
-
6
6
-6
- i
- -i
- - - - - - - - - - - - -
P ._
I
F
e
W
i
5
if
H-l
H-2
H-3
H-4
-6
-
H-5
H-6
H-7
H-8
H-9
-5
-
-r
-
H-10
H-l 1
H-12
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
20-503
TROUBLESHOOTING
H-l.
+
H-l
Machine does not move or moves slowly at any gear speed in

each direction
Before carrying
check that the oil level in the power
line is normal.
5 YES
YE
3
Is transmission
YE
2
Is linkage of
joystick (direction,
gear speed)
adjusted normally?
YE
- Engine at high
idling.
-Joystick: Neutral
+ 2.74 MPa
{28kg/cm2)
* Engine at high
idling.
* Joystick: Neutral
- 2.74 MPa
{28kg/cm?
NO
1
YE
6
NC
1
NO
- Engine at high idling.

-Joystick: Neutral
- Inlet pressure: 0.83&0.15MPa {8.5*1.5kg/cm21
* Outlet pressure: 0.44+1.15MPa f4.51!11.5kg/cm*l
Does spool of
main relief valve
) move smoothly?
1
Y
NO
springs and number

of shims in main
relief valve normal?
- Large: 122mm
- Small: 108mm
YES
IO
* Shim: 5 pcs.
pressure normal?
-Engine at high
idlina.
- Parking brake
lever: Free
* 2.16 MPa
(22kg/cm2)
NO
20-504
I
L
NIO
a
YES
Are linkages of
brake pedal and
parking brake lever
adjusted normally?
NO
D155AX-5
TROUBLESHOOTING
c/a*Uive
H-l
~~$creo
/ r3;3ivertorque
1 ,,9a&or
transmission
Defective transmission
modulating valve
Repair or
replace
Defective power train
Repair or
replace
pump
main relief valve spool
Replace
main relief valve
spring/shim
Repair or
replace
Defective adjustment of
joystick linkage
Adjust
_ Defective brake valve
tpfLr
D155AX-5
Repair or
replace
Adjust
20-505
TROUBLESHOOTING
H-2.
*
Machine
H-2, H-3
does not move or travel power is low in one direction

check that the transmission
speed. (If two or more problems have occurred, perform H-l.)
operates
normally
at each gear
Cause
1 YES
Is linkage of
joystick (direction)
adjusted
normally?
NO
H-3.
Ir
Machine
1 YES
II
NO
20-506
Slip of transmission
clutch
Repair or
replace
linkage of joystick
(direction)
Repair or
replace
does not move or moves slowly at specific gear speed

(If two or more problems have occurred, perform H-l.)
Is linkage of
joystick (gear
speed) adjusted
normally?
Remedy
changes
the direction
normally.
clutch
Repair or
replace
linkage of joystick (gear
speed)
Repair or
replace
D155AX-5
TROUBLESHOOTING
H-4.
H-4
Long time lag is made in changing travel direction
Before carrying
Ir

mal, perform H-l.)

check that the speed is normal.
or gear speed
line is normal.
(If the speed is also abnor-
Remedy
Cause
YES
YE
1
joystick (direction,
Dl SAX-5
Repair or
replace
pump
YE
3
I[
IL
NC
Replace
main relief valve
spring/shim
Repair or
replace
springs and number

h
relief valve normal?
- Large: 122mm
* Small: 108mm
- Shim: 5 pcs.
NO
Repair or
replace
4 YES Defective power train
Is transmission
main relief
pressure normal?
Engine at high
idling.
Joystick: Neutral
2.74 MPa
{28kg/cm2)
modulating valve
Defective adjustment
linkage of joystick
of
Repair or
replace
20-507
H-5
TROUBLESHOOTING
H-5.
Travel power (Drawbar
Before carrying

mal, perform H-l.)
pull) is low
check that the speed is normal.
line is normal.
(If the speed is also abnor-
Cause
u-l
4 YES
I
YES
3 -
1
Is transmission
main relief
pressure normal?
I-l
* y&%ck:Operated
. 2.74 MPa
(28kg/cm2)
NO
Defective engine
Go to S mode.
Repair or
replace
Defective torque
converter
Repair or
replace
modulating valve
Repair or
replace
Defective
Repair or
replace
* Engine at high idling. Nc

. Forward + 3rd gear
speed
- 1,420rpm
Is transmission
. Engine at high idling.
. modulating
- * Joystick: Neutral
NO
pressure normal?
* Inlet pressure: 0.83&0.15MPa {8.5~1.5kg/cm21
. - Outlet pressure: 0.44+1.15MPa {4.5+1.5kg/cm
* Engine at high
-
YI
Is inlet pressure
YES and outlet
_
pressure of torque
2
converter normal?
Is torque
converter stall
speed normal?
power train
* Engine at high
idling.
. Joystick: Neutral
. 2.74 Ml%
{28kg/cm)
Replace
* Small: 108mm
- Shim: 5 pcs.
20-508
Remedy
NO
main relief valve
spring/shim
Repair or
replace
D 155AX-5
TROUBLESHOOTING
H-6.
Sr
Machine
Before carrying
H-6, H-7
cannot be steered (to one direction)

check that the hydraulic
oil level is normal.

Cause
Remedy
2 YES
YE
1
30 to H-8.
Is abnormal
sound produced
bv HSS pump
and HSS motor?
Are HSS servo

charge pressure
and PPC relief
NO
H-7.
*
Steering
Before carrying
Defective HSS pump

;olenoid valve
Repair or
replace
HSS servo charge
valve/PPC relief valve
Adjust
Defective HSS servo

charge valve/PPC relief
valve
Repair or
replace
speed or power is low


Cause
Remedy
YES
$0 to H-8.
2
YEIS
s abnormal
;ound produced
,y HSS pump
md HSS motor?
YES
N~
Is HSS main
pressure normal?
*Engine at high
idling.
. All levers: Neutral
-3.53 MPa
{36kg/cm*}
Defective HSS pump

;olenoid valve
tepair or
eplace
Defective HSS main relief

tialve
idjust
Defective HSS main relief

valve
Iepair or
eplace
(415t10kg/cm2)
5 YES
Is oil pressure set to
normal level by
adjusting HSS se~c
HSS servo charge
charge valve/PPC
relief valve?
NO
D155AX-5
4 YE!
Is oil pressure set

. Engine at high
_ to normal level by _
idling.
NO adjusting HSS
main relief valve?
. Steering: Relieved
. 40.7+0.98MPa
NC
charge pressure
I
NO
Defective HSS servo

valve
Repair or
replace
20-509
TROUBLESHOOTING
H-8.
*
H-8
Abnormal
Before carrying
sound comes out of HSS pump or HSS motor

YES
YES
3
YE!
Is oil leakage
from HSS charge
circuit?
* Start engine.
YES
N<

normal level by
adjusting HSS
charge safety valve?
p
YES
5

normal level by
NO replacing HSS
charge safety valve?
6 YES
Is oil pressure set
to normal level by
Ns replacing HSS
charge relief valve?
NO
*Engine at high
idling.
-All levers: Neutral
- 3.53 MPa
(36kg/cm*>
YES

normal level by
adjusting HSS servo
NO charge valve and
PPC relief valve?
YES
17
Is charge filter
clogged?
9 YES
H
NO
Table
Measuring condition
When steering
Low idling
system
neutral
High idling
2.75MPa {Min. 28kg/cm21
is in
When steering
system is
relieved
Note:
HSS charge pressure

Min.
3.43 - 4.12MPa
Low idling
Min.
1.77MPa
High idling
Min. 2.75MPa
(35 - 42kg/cm?
{Min.
18kg/cm*)
{Min. 28kg/cm*I
If the HSS charge pressure is low when the steering system is in neutral, the HSS safety valve
probably has trouble.
If the HSS charge pressure is low when the steering system is relieved, the HSS relieve valve
probably has trouble.
20-510
D155AX-5
H-8
TROUBLESHOOTING
Cause
D 155AX-5
Remedy
Defective HSS pump or

HSS motor
Repair or
replace
Looseness of HSS charge

piping clamp or damage
of O-ring
Repair or
replace
HSS charge safety valve
Adjust
Defective HSS charge

safety valve
Repair or
replace

relief valve
Repair or
replace
Defective HSS pump or

HSS motor
Repair or
replace
HSS servo charge
Adjust
Clogging of hydraulic tank

strainer
Clean or
replace
Clogging of charge filter
Clean or
replace
Defective charge pump
Repair of
replace
20-511
TROUBLESHOOTING
H-9.
Ir
H-9
Brake does not work
Before carrying
check that the oil level in the power train is normal.
Cause
ES
Is brake oil
pressure as
shown in
following table?
2 YES
Is linkage of
brake pedal
adjusted
normally?
Slip of brake disk/plate
3epair or
replace
Defective brake valve
Repair or
replace
linkage of brake pedal
NO
Repair or
Table
Measuring
When brake
pedal is
pressed
When brake
pedal is
released
20-512
condition
Low idling
High idling
Brake oil pressure

OMPa IOkg/cm*I
OMPa {0kg/cm21
Low idling
2.16MPa
122kg/cm21
High idling
2.16MPa
{22kg/cm*I
D155AX-5
TROUBLESHOOTING
H-10
H-10. Power train oil overheats

*
If the temperature
of power train oil exceeds
(when the electric system is normal).
Ir
Before carrying
about 12OC, the lamp on the monitor
check that the oil level in the power train is normal.
YES
3
Is torque
converter stall
speed normal?
YE
4YEI
_
. Engine at high
idling.
s Forward + 3rd
gear speed
* 1,420rpm
2
YES
Is transmission
main relief
pressure normal?
No
Is machine kept
stopped during
_
operation in Step
3?
I:
1
Is brake oil
pressure normal?
-Engine at high
idling.
* Parking brake
YES
S Are free length of springs and
number of shims
in main relief
valve normal?
* Large: 122mm
. Small: 108mm
. Shim: 5 pcs.
YES
Is inlet pressure
and outlet pressure
of torque converter
normal?
NO
*Engine at high
idling.
. Joystick: Neutral
- Inlet pressure: 0.83t0.15MPa {8.5+1.5kg/cm*}
. Outlet pressure: 0.44+1.15MPa (4.5*1.5kg/cm2)
D155AX-5
Remedy
Defective engine cooling

system
Go to S mode.
GotoA
Slip of brake disc/plate
Repair or
replace
NO
Does spool of
main relief valve
move smoothly?
YES
Repair or
replace
pump
-
NC
main relief valve
spring/shim
Repair or
replace
Defective brake valve
Repair or
replace
linkage of brake pedal or
oarking brake lever
Adjust
clutch or too high output
of engine
Repair or
replace
Defective torque
converter
Repair or
replace
NO
A-
Cause
NC
d
* Engine at high
idling.
. Joystick: Neutral
-2.14 MPa
f28kg/cm2)
panel flashes
20-513
H-II
TROUBLESHOOTING
H-l 1. Work equipment

*
Before carrying
does not work at all
1 pressure normal?
Are HSS servo

and PPC relief
- Engine at high
idling.
* Blade tilt:
Relieved
. 20.59+0.98MPa
f210~10kg/cm*~
4
normal level by
- adjusting main relief NO valve of control

valve?
5 YE

normal level by
- replacing main relief NO valve of control
valve?
- Engine at high
idling.
* All levers: Neutral
* 3.53 MPa
{36kg/cm2)
NI
6 YES
Does foreign
- matter come out
NO of charge fitter?
Development work
equipment pump
Repair or
replace
Defective PTO
Repair or
replace
main relief valve of
control valve
Adjust
Defective main relief

valve of control valve
Repair or
replace
Defective unload valve of

control valve
Repair or
replace
Repair or
replace
Defective HSS servo

valve
Repair or
replace
NO
20-514
YES
Cause
D 155AX-5
H-12
TROUBLESHOOTING
H-12. Work equipment

*
Before carrying
speed or power is low
Remedy
YES
2
Is work
YES
_ equipment
YES
relief
Repair cr
replace
main relief valve of
control valve
Adjust
. Engine at high
Development work
equipment pump
adjustingmain relief
. Blade tilt:
Is oil pressureset to
Relieved
20.59+0.98MPa
(210+10kg/cm*)
Are HSS servo

charge pressure
and PPC relief
pressure normal?
- Engine at high
idling.
- All lever: Neutral
- 3.53 MPa
(36kg/cm*)
valve of control valve
replacingmain relief
YES
Defective unload valve of
Repair or
replace
Defective PPC valve
Repair or
replace
Repair or
replace
5
Is oil pressure in
Step 1 set to normal
level by blocking
1
YES
NO
matter come out

of charge filter?
I
7 Ycc
=a
Is conditionset
normal by adjusting
HSS serve charge
NC valve or PPC relief
valve?
_._
l-d
NU
I Defective
adjustment of
HSS servo charge
Adjust
Defective HSS servo

valve
Repair or
replace
Blade
valve
_I HSS
PPC
D155AX-5
Repair or
replace
To
charge
relief
HSS
charge
PPC
Ripper
va I ve
PPC
and
valve
circuit
TWDOlOOO
20-515
TROUBLESHOOTING
H-13, H-14
H-13. Blade lifting speed or power is low

*
Before carrying
Ir

check that the quantity
quantity of hydraulic drift is also abnormal, perform H-17.)

of hydraulic
drift is normal.
Cause
(If the
Remedy
Repair or
replace
YE
1
Repair or
replace
II
Does cylinder
operate
smoothly?
* Engine at high idling.NO

* Blade lever: Operated.
* 3.53MPa
* Start engine.
* Lift blade.
(36kg/cm)
Air in blade lift cylinder
JO
Bleed air
H-14. Blade tilting speed or power is low

Ir
Before carrying


of hydraulic
drift is normal.
Cause
2 YES
II
I
Does cylinder
operate
smoothly?
- Start engine.
- Tilt blade.
20-5 16
YES
1
_
Is output
pressure of PPC
valve normal?
NO
Remedy
Defective operation of
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
Air in blade tilt cylinder
Bleed air
. Engine at high idling.NO

. Blade lever: Operated.
- 3.53MPa {36kg/cm*)
(If the
D155AX-5
H-15, H-16
TROUBLESHOOTING
H-15. Ripper lifting speed or power is low

*
Before carrying


of hydraulic
drift is normal.
Cause
3 YES
Does control
YES_ valve spool
_2
move smoothly?
; Is output
- pressure of PPC
valve normal?
NO
* Engine at high id5ng.L

* Lift ripper.
NO
* 3.53MPa {36kg/cm*)
(If the
Remedy
suction valve of control
valve
Repair or
replace
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
Air in ripper lift cylinder
Bleed air
- Start engine.
* Lift ripper.
H-16. Ripper tilting speed or power is low

Ir
Before carrying
Cause
3 YES
Does control
YES_ valve spool
_2
move smoothly?
YES
1
Does cylinder
operate
smoothly?
. Start engine.
*Tilt ripper.
D155AX-5
Is output
pressure of PPC
valve normal?
NO
suction valve of control
valve
Repair or
replace
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
Air in ripper tilt cylinder
Bleed air
* Engine at high idling.

. Tilt ripper.
NO
* 3.53MPa f36kg/cm*)
Remedy
NO
20-5
17
H-17, H-18
TROUBLESHOOTING
H-l 7. Hydraulic drift is large in blade lifting direction
Cause
1 YES
Is lowering speed
increased by
operating blade
lever in lowerina
direction?
-
- Stop engine.
Defective blade lift

cylinder packing
I-
Remedy
Repair or
replace
NO
Defective oil-tightness of
control valve spool
Repair or
replace
* See TESTING
AND
ADJUSTMENT.
H-18. Hydraulic drift is large in blade tilting
direction
Cause
1 YES
II
Remedy
control valve spool
Repair or
replace
Defective blade tilt

cylinder packing
Repair or
replace
Is leakage in
cylinder normal?
. Engine at high idling. NO

* Blade lift cylinder:
Relieved
- lZcc/min.
20-518
D 155AX-5
TROUBLESHOOTING
H-19, H-20
H-19. Hydraulic drift is large in ripper lifting direction

Remedy
Cause
i1 YES
control valve spool
Repair or
replace
Defective ripper lift

cylinder packing
Repair or
replace
Is leakage in
cylinder normal?
* Engine at high idling. NO

* Ripper lift cylinder: Relieved
- llcc/min.
H-20. Blade pitch does not work normally

dozer)
(When equipped
with pitch
Cause
YES
1
Is output
pressure of blade _
2 YES
pitch valve
normal?
~
Dose blade pitch
- Engine at
- valve spool
high idling.
NO
move smoothly?
- Blade pitch
cylinder: Relieved
NO
* 20.5950.98MPa
{210~10kg/cm*~
D155AX-5
Remedy

cylinder
Repair or
replace

valve solenoid valve
Repair or
replace
Defective main valve of

blade pitch valve
Repair or
replace
20-5 19
H-21, H-22
TROUBLESHOOTING
H-21. Ripper pin puller does not work normally

giant ripper)
*
Before carrying
(When equipped
check that the power train system
1 YES
solenoid valve
normal?
Repair or
replace
u
solenoid valve
I
. Enaine at hiah
II
idlina.NO
- Ripper pin &ller: Relieved
- 2.74MPa 128kg/cm2)
H-22. Abnormal
Ir
is normal.

cylinder
Is outputpressure
of ripperpin puller
with
Before carrying
sound comes out of work equipment
Looseness of suction
YES
Is air sucked in
suction circuit of
Repair or
replace
pump
Cause
YE
piping clamp of pump or

damage of O-ring
YES
Remedy
Repair or
replace
Clogging of hydraulic tan1

strainer
Repair or
replace
Defective work equipmen
Repair or
replace
pump
Is oil used proper?
I
tank?
IL
NC
20-520
Operate for a while, then

check condition for
change.
Inspect again
according to
change of
condition.
Use of improper oil
Replace
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF
MONITOR SYSTEM
(M MODE)
[Serial No. 70001 75000]
Electrical circuit diagram for M mode ............................................................................................ 20-602
M- 1. Monitor lamps do not light up for 3 seconds when starting switch is turned ON ........ 20-603
M- 2. When starting switch is turned ON, monitor lamps
all light up but do not go out ............................................................................................... 20-603
M- 3. Abnormality in preheating monitor lamp ........................................................................... 20-604
M- 4. Abnormality in battery charge lamp .................................................................................... 20-606
M- 5. Abnormality in engine oil pressure caution lamp .............................................................. 20-608
M- 6. Engine water temperature caution lamp flashes ................................................................ 20-610
M- 7. Transmission oil temperature caution lamp flashes .......................................................... 20-610
M- 8. HSS oil temperature caution lamp flashes ......................................................................... 20-611
M- 9. HSS charge oil pressure caution lamp flashes ................................................................... 20-612
M-10. Electronic system caution lamp on monitor panel does not work in accordance
with LED display on HSS controller .................................................................................... 20-613
M-11. Monitor caution lamp on monitor panel does not work in accordance
with each caution lamp ......................................................................................................... 20-613
M-12. Alarm buzzer does not sound or sounds continuously ..................................................... 20-614
M-13. Abnormality in engine water temperature gauge .............................................................. 20-616
M-14. Abnormality in transmission oil temperature gauge ......................................................... 20-618
M-15. Abnormality in fuel level gauge ........................................................................................... 20-620
M-16. Service meter does not work after engine is started ......................................................... 20-622
M-17. Monitor panel night lighting does not light up
when head lamp switch is turned on .................................................................................. 20-623
M-18. Head lamps or rear lamps do not light up ......................................................................... 20-624
M-19. Automatic preheating is not carried out when preheating switch is turned to AUTO .. 20-626
M-20. Window wipers and window washers do not work .......................................................... 20-628
M-21. Air conditioner does not work .............................................................................................. 20-632
D155AX-5
20-601
4
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
FOR M MODE

CN-GDI
Eva ine
-----~------------------------
Alternator
With cab:5DA
Ensine rater
Engine oi
CN-2 I1
Monitor
Heater
caneI
relay
p2
I ___---,--_~_._..~___,__
CN-264
Ill
Binetal
timer
Startino
X
X
CN-206
sr,te.
Toraw converter
oil tewerature
sensor
CN-451
E:
switch
HSS controller
For spare
alarm huller
&
CN-424
&
1
netrorl:
srats.nstwrt
CN-452
NSS oil
temperature
switch
w
CN-SXB
HSS charge
oil ~reszure
switch
TWDOIOOI
20-602
D15SAX-5
M-l,
TROUBLESHOOTING
M-l.
Monitor lamps do not light up for 3 seconds when starting _

switch is turned ON
_
Check that No.3 fuse is not broken.

chassis ground.
Before carrying
Always
any disconnected
connect
If it is broken,
check if the related
check that all the related

connectors
circuit is in contact
connectors
are properly
YES
* Turn starting
switch ON.
*20-30V
Is voltage
between PI (I)
and chassis
ground normal?
* Turn starting
switch ON.
-2O-30V
Related
Monitor
harness between PI
(female) (21, P2 (female) (4)
- CN-SX8 (chassis ground)
harness between fuse 3 PI (female) (1)
2 YES
Ne
electrical
Panel
NO
CN-215
(SWPBI
SUPPIY
Fuse
box
CN-214
(SWP8)
P2 (040121
@
@
CN-SX8
TWD01002
When starting switch is turned ON, monitor

but do not go out
lamps all light up
Cause
D 155AX-5
Replace
@
I
M-2.
Repair or
replace
a-3
GND
GND
Replace
circuit diagram
Pl (04016)
Power
inserted.
Remedy
1
Is voltage
between Pl (1)
and Pl (2). P2 (4)
normal?
with
before going on the next step.

Cause
M-l.
M-2
Remedy
Replace
20-603
TROUBLESHOOTING
M-3.
M-3
Abnormality
in preheating
Ir
Before
mally.
Before carrying
Always
any disconnected
a)
Preheating
monitor
lamp
carrying out troubleshooting,

check that the automatic
preheating
If the automatic preheating system is also abnormal, see M-19.
connect
monitor
check that all the related connectors

connectors
before going
system
are properly
qeplace
harness between Pl
(female) (9) - CN-108
Repair or
replace
monitor
lamp stays lighted
up
Cause
1 YES
Is voltage
between Pl (9)
and chassis
ground normal?
* Turn starting
switch ON.
* Max. 1 V
20-604
Remedy
*Turn starting
NO
switch to PREHEAT.
*20-30V
Preheating
inserted.
lamp does not light up
1 YES
b)
nor-
on the next step.
Cause
Is voltage
between Pl (9)
and chassis
ground normal?
operates
NO
Remedy
Replace
harness between Pl
(female) (9) - CN-108
Repair or
replace
D155AX-5
TROUBLESHOOTING
M-3. Related
M-3
electrical
circuit diagram
Intake
air
heater
CN-101
(SWP12)
Monitor
Panel
Pl (040 16)
IIir::i::
p(
Heater
relay1
h,
CN-2 11
LSWP11
I
TWD01003
D 155AX-5
20405
M-4
TROUBLESHOOTING
M-4.
Abnormality
in battery charge lamp
Before carrying
Always
connect
any disconnected
a)
Battery
charge lamp does not light up when starting

connectors
connectors
are properly
switch
is turned
ON while
engine is stopped
Remedv
Cause
YES
- See
Note.
*Turn starting
switch ON.
* Max. 1 V
NO
Note: When measuring voltage

tor terminal side.
b)
Battery
charge
disconnect
lamp flashes
while
alternator
engine
inserted.
terminal
Replace

supply in wiring harness
between PI (female) (4) CN-220 (female) (2) - CN-11:
- CN-103 (female) (2)
Repair or
replace
Defective alternator
Replace
R, and measure
voltage
on the alterna-
is running
>
between PI (4)
,
between CN-112
Reolace

supply in wiring harness
between Pl (female) (4) CN-112 - CN-103 (female)
(2) - CN220 - CN-SW
Repair or
replace
Replace
1ground normal?
* See
Note.
. Start engine.
*IO-3ov
Note: When measuring voltage

tor terminal side.
20-606
NO
disconnect
alternator
terminal
R, and measure
voltage
on the alterna-
D155AX-5
M-4
TROUBLESHOOTING
M-4. Related
electrical
circuit diagram
Alternator
Battery
relay
TWD01004
D 1554X-5
20-607
TROUBLESHOOTING
M-5.
M-5
Abnormality
in engine oil pressure caution lamp
Before carrying
Ir
Always
connect
any disconnected
a1
Caution
lamp does not light up when

connectors
starting
before going
switch
connectors
YES
Is resrstance
between Pl
(female) (8) and
chassis ground
normal?
p
*Turn starting
switch OFF.
* Disconnect Pl.
- Max. 1 R
IS
between CN-403
- (switch side) and
NO chassis ground
normal?
2 YES
z
is turned
ON while
engine
is stopped
Cause
Remedy
Replace
harness between Pl
(female) (8) CN-403
Repair or
replace
Defective engine oil

pressure sensor
Replace
*Turn starting
NO
switch OFF.
* Disconnect CN-403.
- Max. 1 D
b)
Caution

check that the engine oil pressure is normal.
pressure lowers below about 0.49MPa {0.5kg/cm21, the caution lamp flashes.
lamp flashes
while
engine
is running
If the engine
Cause
YES
1
Is resrstance
between Pl
(female) (81 and
chassis ground
normal?
p
- Disconnect PI.
* Start engine.
. Min. 1 fi
2 YES
IS
between CN-403
- (switch side) and
NO chassis ground
normal?
* Disconnect CN-403N0
- Start engine.
* Min. 1 R
20-608
inserted.
on the next step.
I
1
are properly
oil
Remedy
Replace

ground in harness
between PI (female) (8) CN-403
Repair or
replace

pressure sensor
D155AX-5
M-5
TROUBLESHOOTING
M-5.
Related
Monitor
electrical
Panel
circuit diagram
I
Pl (04016)
CN-214
(SWP 16)
CN-101
SWP 12)
Engine
Pressure
oil
switch
-3
I
TWD01005
D155AX-5
20-609
TROUBLESHOOTING
M-6.
*
M-6,
M-7
caution lamp flashes

check that the engine water is not overheated.
water temperature
exceeds about 102C, the caution lamp flashes.
If the engine
Remedy
1 YES
Is engine water
temperature
gauge in red
r~nlX=??
* Turn starting
switch ON.
M-7.
*
Go to M-13.
Transmission
oil temperature

If the transmission
oil temperature
check that the transmission oil temperature

is not overheated.
exceeds about 120X, the caution lamp flashes.
I
1 YES
. Turn starting
switch ON.
20-610
Replace
NO
Cause
Go to M-14.
Replace
NO
D 155AX-5
M-8
TROUBLESHOOTING
HSS oil temperature
M-8.

check that the HSS oil is not overheated.
temperature
exceeds about 120X, the caution lamp flashes.
Before carrying
Always
any disconnected
connect

connectors
connectors
If the HSS oil
are properly
inserted.
Remedy
Cause
YES
Replace
harness between P2
(female) (5) - CN-452
(female) (1)
Repair or
replace

pressure sensor
NO
-Turn starting
switch OFF.
. Disconnect CN-452.
* Max. 1 !J
M-8. Related
Monitor
electrical
Panel
circuit diagram
I
P2 (040 121
temperature
CN-70 1
(SWP12)
CN-215
(SWP8)
t
HSS drain
temperature
switch
CN-452
(xl 1
oil
TWD01006
D 155AX-5
20-611
M-9
TROUBLESHOOTING
M-9.
HSS charge oil pressure caution lamp flashes

pressure drops below about 0.78MPa
Before carrying
Always
any disconnected
connect
check that the HSS oil pressure is normal.

{8kg/cm2}, the caution lamp flashes.
connectors
connectors
If the HSS oil
are properly

Remedy
Cause
I Isresistance
. Disconnect
CN-2Hl.
- Start engine.
+ Max. 1 R
3 YES
1 : ~liygct
[normal?
. Disconnect
CN-CRGP.
+ Start engine.
* Max. 1 Q
inserted.

or monitor panel
Replace
Defective contact or disconnection in wiring harness

(8) - CN-CRGP (female) (1)
Repair or
replace

between CN-CRGP (female)
(2) - CN-SX8 (Chassis ground
Repair or
replace

pressure sensor
Replace
CN-CRGP.
NO
M-9. Related electrical circuit diagram
HSS
controller
HSS charge
I
PM-7n
Pressure
1 lCWD f 91
fhl-dnfi
(~31
PN-rar,p
(~2)
i I Pressure
switch
0
km
sensor
CN-SX8
TWD01007
20-612
D155AX-5
M-10,
TROUBLESHOOTING
M-10.
M-11
Electronic system caution lamp on monitor panel does not work

in accordance with LED display on HSS controller
Cause
Remedy
Replace
M-l 1. Monitor caution lamp on monitor panel does not work in

accordance with each caution lamp
Cause
D155AX-5
Remedy
Replace
20413
M-12
TROUBLESHOOTING
M-12.
Alarm buzzer does not sound or sounds continuously
Before carrying
Always
any disconnected
a)
Caution
Note that the buzzer may not sound in certain ranges of the coolant temperature
oil temperature
even if their caution lamps flash.
Check that fuse 3 is not broken.

chassis ground.)
connect
lamp flashes
but buzzer
check that ail the related

connectors
connectors
are properly
inserted.
does not sound

and transmission
(If it is broken, check the circuits related to it for short circuit with
Remedy
Cause
YES
Replace
(femaleH2) - P2 (female) (7)
Repair or
replace
Defective alarm buzzer
Replace
Repair or
replace
1
Does buzzer sound
when P2 (7) is
connected to
chassis ground?
p
-Turn starting
switch ON.
YES
2
Does buzzer sound
when CN-217 (2) is
NO connected to
chassis ground?
-Turn starting
switch ON.
3 YES
Is voltage
between CN-217
NO (1) and chassis
ground normal?
+ Remove fuse 5.
NO
*Turn starting switch
ON.
.20-30V
b)
Caution
lamp does not flash but buzzer sounds continuously
I
YES
1
Does buzzer stop
sounding when
P2 is
disconnected?
* Disconnect P2.
* Turn starting
switch ON.
20-614
2 YES
Is resistance
between P2 (female)
_ (71 and chassis
_
NO ground normal
when CN-217 is
disconnected?
NO
* Turn starting
switch OFF.
* Disconnect CN-217
and Pl.
* Min. 1 MR
Cause
Remedy
Replace
Defective alarm buzzer

ground in harness
between P2 (female) (7) CN-217 (female) (2) CN-217 (spare)
Repair or
replace
D155AX-5
TROUBLESHOOTING
M-12. Related
Monitor
electrical
M-12
circuit diagram
CN-215
(iWP8)
Panel
~2p21040;21,
Alarm
CN-264
(iWP6)
output
Qg
,w
Fuse
CN-GO 1
(IN-218
c__
I I
,$-2
spare
alarm
buzzer
17
box
TWD01008
D 155AX-5
20-615
M-13
TROUBLESHOOTING
M-13.
Abnormality
in engine water temperature
Before carrying
Always
any disconnected
connect
a) Coolant temperature
*

connectors
gauge
connectors
are properly
inserted.
gauge stays in C range and does not rise
If the coolant
check that the coolant temperature
is normal.
temperature
rises above about 5OC, the coolant temperature
gauge rises into the white range.
Cause
I Is resistance
* Disconnect
CN-402.
*Turn starting
switch ON.
switch OFF.
NO
* Max. 1 D
temperature
3 YES
I I
Remedy
Defective coolant
temperature gauge
Replace
Replace
Iefective contact or discomection in wiring harness

oetween P2 (female) (1) 3N-402 (female) (1)
Repair or
replace
(female) (2) CN-SX8
(chassis ground)
Repair or
replace
bl
Coolant
gauge stays in H range and does not lower

check that the coolant temperature
is normal.
If the coolant
temperature
rises above about 102C, the coolant temperature
gauge rises into the red range.
Cause
YES
1
Does gauge lower

gradually toward C
side when CN-402
2
YES
Is resistance
is disconnected?
p
between P2 (female)
* Disconnect
_ (1) andchassis
_
NO ground normal
CN-402.
when CN-402 is
*Turn starting
disconnected?
switch ON.
NO
. Turn starting
switch OFF.
. Disconnect CN-402
and P2.
* Min. 1 MD
20-616
Remedy
Defective coolant
temperature gauge
Replace
Replace

ground in harness
between P2 (female) (I) CN-402 (female) (1)
Repair of
replace
D155AX-5
TROUBLESHOOTING
M-13.
Related
Monitor
panel
electrical
M-13
circuit diagram
I
P2 (04Oi2)
CN-214
LsWP161
CN-101
(SWP12)
CN-402
o(2)
Engine
water
temperature
sensor
3
3
TWD01009
D155AX-5
20-617
M-14
TROUBLESHOOTING
M-14.
Abnormality
in transmission
Before carrying
Always
any disconnected
connect
a) Oil temperature
Ir
oil temperature

connectors
gauge
connectors
are properly
inserted.
gauge stays in C range and does not rise

oil temperature
is normal.
If the
transmission
oil temperature
rises above about 50-C, the coolant temperature
gauge rises into the
white range.
Cause
3 YES
oil temperature gauge
Replace
Replace

between P2 (female) (2) CN-453 (female) (1)
Repair or
replace
(female) (2) - CN-SX8
(chassis ground)
Repair or
replace
!II
CN-453 (female) (I)

is connected to (2)?
* Disconnect
CN-453.
-Turn starting
switch ON.
Remedy
_
l-l-
CN-453 (female) (I)
I Is resistance
between CN-453
(female) (2) and
I\
F+.+g
Turn e.Y.
..,
r...;trh WE
NO
lnnect P2 and CN-453

switch OFF.
NO
. Disconnect CN-453.
- Max. 1 Q
b)
Oil temperature
gauge stays in H range and does not lower
sr

oil temperature
is normal.
If the
transmission
oil temperature
rises above about 120X, the coolant temperature
gauge rises into the
red range.
Cause
YES
1
Does gauge lower
gradually toward C
side when CN-453
is disconnected?
* Disconnect
CN-453.
* Turn starting
switch ON.
20-618
YES
Is resiStance
between P2 (female)
_ (2) and chassis
NO ground normal
when CN-453 is
disconnected?
NO
*Turn starting
switch OFF.
- Disconnect CN-453
and P2.
f Min. 1 MD
Remedy
oil temperature gauge
Replace

ground in harness
Repair or
replace
D155AX-5
M-14
TROUBLESHOOTING
M-14.
Related
Monitor
electrical
Panel
circuit diagram
I
P?
,_ (04Oi9l
._._.-.
Transmission
oil
temperature
I
Pl (04016)
GND
CN-214
(SWP 16)
w-45
(SWPBI
CN-453
(x21
Transmission
oil
temperature
sensor
CkSX8
TWDOlOlO
D155AX-5
20-619
M-15
TROUBLESHOOTING
M-15.
Abnormality
in fuel level gauge
Before carrying
Always
any disconnected
a)
Fuel level gauge stays in E
Ir
Before carrying
connect

connectors
connectors
are properly
inserted.
check that there is some fuel in the fuel tank.
Cause
3 YES
Is resistance
-_
Remedy
Defective fuel level sensor
Replace
Replace

between P2 (female) (3) EN-423 (female) (I)
Repair or
replace
(female) (2) - CN-424
(chassis ground)
Repair or
replace
CN-423tfemale) (1)
- ursconnect
CN-423.
-Turn starting
switch ON.
Nq*~y
.$jg:;
switch OFF.
NO
* Max. 1 Q
b)
Fuel level gauge stays in F
Before carrying
2 and CN-423
check that the fuel level in the fuel tank is low.
Cause
YES
1
Does gauge lower
gradually toward E
side when CN-423
is disconnected?
. Disconnect
CN-423.
* Turn starting
switch ON.
20-620
2
YES
Is resistance
between P2 (female)
_ (3) and chassis
_
NO ground normal
when CN-423 is
disconnected?
_
NO
* Turn starting
switch OFF.
. Disconnect CN-423
and P2.
* Min. 1 MQ
Remedy
Defective fuel level

sensor
Replace

ground in harness
Repair or
replace
D 155AX-5
TROUBLESHOOTING
M-15
Monitor
Panel
I
P2 (040201
CN-214
(SWP161
CN- 153
(SWP6)
CN-422
(x21
CN-423
o(2)
Fuel
level
sensor
-J
CN-424
TWDOlOll
D155AX-5
20-621
TROUBLESHOOTING
M-16.
M-16
Service meter does not work after engine is started
Cause
1 YES
Remedy
See M-4
Is battery charge
caution lamp
flashing?
* Start engine.
20-622
Replace
NO
D155AX-5
M-17
TROUBLESHOOTING
M-17.
Monitor panel night lighting does not light up when head lamp
switch is turned on

light up, see M-18.
check that the head lamps light up.
Before carrying
check that all the related connectors
Always
any disconnected
connect
connectors
If the head lamps do not
are properly
Remedy
Cause
1 YES
1Is voltage
between P2 (7) chassis ground
normal?
. Turn starting
switch ON.
*Turn head lamp
switch ON.
*20-30V
M-17.
inserted.
Replace
harness between P2
(female) (7) - CN-216
(female) (2)
Replace
NO
Related
electrical
Monitor
Panel
circuit diagram
Ck215
LSWPB)
Pl (04016)
CR-101
LSWP121
CN-20 1
(x2)
CN-203
(x 1I
Head lamp
(R.H. )
",fl;fo4
Head lamp
(L.H. )
-3
,
;:;;,;amp
_
CN-2 16 (KES4)
1
-TP
TWD01012
D 155AX-5
20-623
M-18
TROUBLESHOOTING
M-18.
Head lamps or rear lamps do not light up
Before carrying
Always
any disconnected
al
Front lamps do not light up

chassis ground.
connect

connectors
connectors
are properly
If it is broken,
YES
M-18 a) Related
Monitor
3
YES
2 PIs voltage between
CN-216 (female)
(3) and chassis
ground normal?
Is resistance
between CN-216
(male) (2) and (3Jnormal?
*Turn starting
switch 0~
Replace
disconnection m wiring
(female) (2) - CN-203
(female) (I) or CN-204
(female) (1)
Repair or
replace
Defective front lamp switch
Replace
Repair or
replace
circuit diagram
Panel
W-215
(SWPB)
pG++
,a
T-
Head lamp
switch
Breakage of front lamp

which does not light up
* Disconnect
CN-216.
. Turn starting
switch ON.
*20-30V
electrical
with
Remedy
Cause
lls voltage between

CN-203/CN-204
(female) (I) and
chassis ground
normal?
* Disconnect
CN-203 and
CN-204.
NE
-Turn starting
switch ON.
-Turn front lamp
switch ON.
*20-30V
inserted.
CN-101
LSWP12)
cl+20
(X21
CN-203
Head lamp
(R. H. 1
:z;fO
Head lamp
(L. H. )
>I-
CN-2 16 (KES4)
l-
TP
TWD01012
20-624
D 155AX-5
M-18
TROUBLESHOOTING
b1 Rear lamps
*
do not light up

chassis ground.
If it is broken,
circuit
is in contact
Cause
YES
voltage oetween
CN-224lCN-243/
CN-243 (female) (1)
H
and chassis
Is
* Disconnect
CN-211.
* Turn starting
switch ON.
-2O-30V
* Turn rear lamp

switch ON.
.20-30V
M-18 b) Related
Rear
lamp
switch
YES
electrical
CN-211
(KES4)
NO
with
Remedy
Breakage of rear lamp

which does not light up
Replace
(female) (2) - CN-224
(female) (1). CN-243 (female)
(1) or CN-248 (female) (1)
Repair or
replace
Defective rear lamp switch
Replace
Repair or
replace
circuit diagram
CN-215
(SWPB)
a.
CN- 153
LSWP6)
CN-223
(x 1)
CN-224
(x 1)
Rear
I amp
CN-24 5
Ripper
I amp
Fuse
box
Ripper
Point
I amp
TWDOlOl3
D155AX-5
20-625
M-19
TROUBLESHOOTING
M-19.
Automatic preheating
is turned to AUTO
Before carrying
Always
any disconnected
connect
is not carried out when preheating

connectors
connectors
are properly
4 YEI
between CN-212
(2) and chassis
ground normal?
-Turn starting
switch ON.
*20-30V
NO
YES
I Is voltage
A-
switch OFF.* Disconnect

CN-212.
between CN-109
and chassis
ground normal?
* Turn starting
switch ON.
.20-30V
20-626
NO
I
NO
Go to
Remedy
A.
between CN-213
(male) (2) and (3)
. Turn starting
NC
switch OFF.
. Max. 1 R
inserted.
Cause
Yf
switch
Defective glow switch
Ieplace
(female) (1) - CN-213
qepair or
.eplace
Defective bimetal timer
qeplace
switch terminal BR CN-212 (female1 (2)
qepair or
,eplace
Defective heater relay
leplace
(female) (2) - CN-109
lepair or
eplace
D155AX-5
M-19
TROUBLESHOOTING
M- 19. Related
electrical
Preheating
circuit diagram
Battery
switch
Intake
CN-213
air
heater
I I
-I
Bimeta
timer
Monitor
Panel
Heater
7%
relay1
CN-214
TWD01003
D 155AX-5
20-627
M-20
TROUBLESHOOTING
M-20.
Window
wipers and window
Before carrying
Sr
Always
any disconnected
a)
All window
connect
wipers
and window
washers do not work

connectors
washers
connectors
are properly
do not work
Cause
harness between CN-C fuse box for cab
b)
Front window
wiper
Defective wiper switch
Does Yviper work

norma Ily when
switch is
replaced?
*Turn starting
switch ON.
20-628
Remedy
Repair or
replace
does not work
Cause
1I
inserted.
Ii-l
Remedy
Replace
4 YES
I Is
resistance
between switch
YES connector (female) _
(4) and motor
3
~
connector (female)
Is resistance
(2)
normal?
YES between switch
Nl
- connector (female) - . Turn starting
switch OFF.
(3) and chassis
2
P
ground normal?
* Disconnect connector
Is voltage between
* Max. 1 Q
*Turn starting
motor connector
switch OFF.
NO
N5 (5) and chassis
- Disconnect connector.
ground normal?
* Max. 1 Q
-Turn starting
I
switch ON.
.20-30V
Defective wioer motor
Replace
harness between switch
connector (female) (4)
motor connector (female) (2)
Repair or
replace
connector (female) (3) chassis ground
Repair or
replace
harness between fuse box
for cab - motor connector
(female) (5)
Repair or
replace
D155AX-5
TROUBLESHOOTING
c)
Right or left window
M-20
wiper
does not work
Cause
YES
Remedy
Iefective wiper switch
Replace
Defective wiper motor
Replace
4 YES
I Is resistance
Itbetween switch
YES connector (female) _
(4) and motor
3
connector (female)
Is resistance
(2)
normal?
YES between switch
- connector (female) - -Turn starting
NC
(3) and chassis
switch OFF.
2
P
ground normal?
. Disconnect connector.
Is voltage between
P
.Max.lR
. Turn starting
switch connector
switch OFF.
NO
N j- (3) and chassis
- Disconnect connector.
ground?
. Max. 1 R
. Turn starting
switch ON.
NO
.20-30V
. Turn starting
switch ON.
d)
Washer
fluid is not sprayed
I
Iefective contact or
:onnector (female) (4) motor connector (female) (2)
harness between fuse box
for cab - motor connector
[female) (3)
harness between motor
connector (female) (3) chassis ground
YES
1
P. Turn starting
switch ON.
-Turn washer
ON.
YES
Repair or
replace
Remedy
Insufficiency of washer
fluid, clogging of nozzle or
defective piping
Supply washer
fluid, repair or
replace
Defective window washer

motor
Replace
Replace
2
Does washer work
when motor
No connector is
replaced?
P
. Turn starting
switch ON.
. Turn washer
ON.
D155AX-5
Repair or
replace
out
Cause
Does motor
produce rotating
sound?
Repair or
replace
YES
3
Does washer work
- when switch is
NO replaced?
_
,, YES disconnection in wiring
Repair or
P
_ harness between switch
replace
Is resistance
connector (female) (1) between motor
motor connector (female) (1)
- connector (female) Defective contact or
NO (2) -chassisground
Repair or
normal?
harness between motor
replace
. Turn starting
No connector (female) (2) switch OFF.
CN-SX8 (chassis ground)
. Disconnect
connector.
I
I
- Max. 1 R
20-629
M-20
TROUBLESHOOTING
M-20.
Related
electrical
circuit diagram
CN-361
Front
window
washer
motor
CN-362
Left
window
washer
motor
CN-363
Right
window
washer
motor
CN-364
1
Washer
Rear
circuit
CN-SX8
Front
wiper
window
washer
CN-18
motor
Left
motor
wiper
Rear
wiper
Front
motor
Right
switch
Rear
switch
wiper
wiper
wiper
Right
wiper
CN-
motor
11
Bat
Fuse
for
terv
c
TWDO
20-630
D155AX-5
TROUBLESHOOTING
M-21.
M-21
Air conditioner
does not work

chassis ground.
Before carrying
Ir
Always
any disconnected
a)
Air does not flow
connect
out.
Blower
If it is broken,

connectors
connectors
are properly
with
inserted.
does not work.
Table
Table 1
YES
6
Is voltage
YES
5
Is resistance
YES between CN-395
- (female) (4) and
chassis ground
4
normal?
YES
3
YEz
Is voltage
between CN-395
(3) and chassis
2
Is resistance
YES between CN-391
_
(male) (I) and (3)
1
normal?
Is voltage
between CN-391
_
(1) (2) and chassis
ground normal?
* Turn starting
switch ON.
-2O-30V
- Turn starting
switch OFF.
- Disconnect
CN-391.
- 240+4OI2
* Turn starting
switch ON.
-2O-30V
between CN-391
(4) and chassis
ground normal?
* Turn starting
-
switch ON
* Set blower switch
to oosition other
NO
Is continuity
* Turn starting
between CN-395
(male) and each
switch OFF.
* Disconnect
terminal as shown
CN-395.
in Table l?
* Max. 1 Q
*Turn starting
switch OFF.
* Disconnect
NO
CN-395.
NO
NO
NO
11
YES
Is resistance
between CN-394
(female) (1) and
CN-395 (female)
(2) normal?
-Turn starting
NO
switch OFF.
- Disconnect CN-394
and CN-395.
* Max. 1 D
20-632
D155AX-5
TROUBLESHOOTING
M-21
Cause
10
YES
YEI
r-----G
of condenser
ground normal?
. Turn starting
switch ON.
. Set blower switch
to position other
than OFF.
*20-30V
1
H
and (3) as shown

in Table 2?
II
1,
1
1
- Turn starting
switch ON.
. Set blower switch No
to position other
than OFF.
JO
. Max. 1 R
* Turn starting
switch OFF.
s Disconnect
CN-394.
Remedy
(female) (3) - chassis
ground
Repair or
replace
Defective blower resistor
Replace
Defective blower motor
Replace
(female) (4) - CN-392
(female) (1)
Repair or
replace
Defective air conditioner

relay
Replace
(female) (4) - CN-204
(Chassis ground)
Repair or
replace
Defective blower switch
Replace
(female) (3) - CN-395
(female) (3)
Repair or
replace
NO

relay
larness between fuse 8 EN391 (female) (1) (2)
Repair or
replace
Go to b).
[female) (1) - CN-395
[female) (2)
D155AX-5
Xepair or
eplace
20-633
M-21
TROUBLESHOOTING
b)
Air does not flow out.
Note:
Air conditioner
does not work.
Measure the voltage with the dual pressure switch and thermostat switch turned on.
Dual pressure switch changing pressure (Refrigerant circuit pressure):
High pressure side: ON (when pressure lowers) at 2.06MPa 121 kg/cm?, OFF (when pressure
rises) at 2.65MPa {27kgc/m*l
Low pressure side: ON (when pressure rises) at 0.23MPa {2.35kg/cm21, OFF (when pressure
lowers) at 0.21 MPa (2.1 kg/cm*)
Thermometer
switch changing temperature
(Evaporator discharge temperature):
ON (when temperature
lowers) at 4.5C or below, OFF (when temperature
rises) at 1C or
higher
l
YES
I--
(male) (1) and (3)

5
YES
., I ICN-395 (female) (3) I
Is resistance
YES between CN-396
_
- (female) (2) and
CN-398 (female)
4
(3) normal?
Is resistance
* Turn starting
between CN-396
_
switch OFF.
. Disconnect
(male) (2) and (3)
CN-396 and CN-391
normal?
-
* Turn starting
switch OFF.
Disconnect
CN-398.
*240+40R
L
NO
r10
I
*
I urn arr
conditioner switch ON.
(male) (1) and (3)

Is voltage
between CN-396
(3) and chassis
ground normal?
* Turn starting
switch ON.
.20-30V
-Max.
* Turn starting
switch OFF.
* Disconnect
NO
CN-396.
-Turn air
conditioner switch ON.
- Max. 1 R
1 fJ
NO
13
YES
Is voltage
YES between CN-ARC
t2 r (2) and chassis
I
A
Same condition
between CN-393
(4) and chassis
NO
___ . ___
.20-30V
20-634
NO
D 15514X-5
M-21
TROUBLESHOOTING
Cause
10 YES
YES
8
Is resistance
between CN-398
(2) and chassis
ground normal?
YEz
7
Is resistance
between CN-398
(female) (1) and
CN-395 (female)
(3) normal?
--
Turn starting
switch ON.
. 2. _ 3oV
-Turn starring
switch OFF
. Disconnect CN-395 NO
and CN-398.
- Max. 1 Q
Is resistance
between CN-398
(4) and chassis
ground normal?
Is voltage
YES_ between CN-393
(1) and chassis
9
ground normal?
. Same condition
under Step 9.
-Turn starring
switch ON.
. Turn air conditioner NO
switch ON.
* Set blower switch to
position other than OFF.
* zo-3ov
NO
NO /
Goto
Remedy
A.
(female) (I) - CN-394
(female) (4)
Repair or
replace
Defective clutch relay
Replace
Repair or
replace
(female) (1) - CN-395
(female) (3)
Repair or
replace
Replace
(female) (2) - CN-398
(female) (3)
Repair or
replace

switch
(female) (I I- CN-395
(female) (3)
Repair or
reolace

switch
Replace
Repair or
replace

fan motor or compressor
Replace
harness betweenCN-215
(male) (7) - CN-ARC
(female) (5)
Repair or
replace
(female) (4) - CN-351
(female) (I)
Defective dual pressure
switch
D155AX-5
Repair or
Replace
20-635
TROUBLESHOOTING
M-21.
Related
M-21
electrical
circuit diagram
Blower
switch
CN391
(KES4)
CN-396 042)
Air
conditioner
Air
conditioner
rritch
condenser
I I I Cllo. I
CN-SX8
Blower
mater
CN-351
(Xl)
CN-101
(SWPlL)
hemostat
I
Air conditioner
CmPreSSOr
20-636
Dus
oressure
switch
TWO01015
D 1594X-5
TROUBLESHOOTING
TROUBLESHOOTING OF MONITOR SYSTEM

(M MODE)
Action taken by controller when abnormality occurs and problems on machine .......................... 20-702
M mode system electrical circuit diagram .......................................................................................... 20-704
M-1. [E0120] (Abnormality in monitor panel caution lamp system) is displayed ......................... 20-706
M-2. [E0121] (Abnormality in monitor panel caution buzzer system) is displayed ...................... 20-707
M-3. [E0211] (Abnormality in oil temperature of power line: torque converter) is displayed ..... 20-708
M-4. [E0329] (Abnormality in HSS oil temperature) is displayed ................................................... 20-708
M-5. [E0430] (Abnormality in engine oil pressure) is displayed ..................................................... 20-709
M-6. [E0432] (Abnormality in engine water temperature) is displayed ......................................... 20-709
M-7 When starting switch is turned ON, all segments of monitor panel do not light up .......... 20-710
M-8. When starting switch is turned ON, all segments of monitor panel light up but
do not go out. ......................................................................................................................20-712
M-9. When starting switch is turned ON (with engine stopped),
caution items (excluding battery charge level and engine oil pressure) flash ............ 20-713
M-10. When engine is started, caution items flash
(daily check items and engine related items are normal) .............................................. 20-715
M-11. HSS charging oil pressure caution lamp flashes ..................................................................... 20-718
M-12. Preheater lamp does not light up or stays lighted up ............................................................ 20-719
M-13. Abnormality in caution buzzer ................................................................................................... 20-720
M-14. Abnormality in CAUTION lamp ................................................................................................. 20-722
M-15. Abnormality in engine water temperature gauge ................................................................... 20-724
M-16. Abnormality in power train (torque converter) oil pressure gauge ....................................... 20-725
M-17. Abnormality in fuel level gauge ................................................................................................ 20-727
M-18. Gear speed display segments indicate [ ], and engine speed is not displayed ............... 20-729
M-19. Service meter does not advance while engine is running ..................................................... 20-729
M-20. Abnormality in service mode display ....................................................................................... 20-730
M-21. Monitor panel lighting does not light up
(though headlamps and working lamps light up) ........................................................... 20-732
M-22. When head lamp switch is turned on, monitor panel lighting does not light up ............... 20-734
M-23. Head lamps or rear lamps do not light up ............................................................................... 20-735
M-24. Electric intake air heater does not work ................................................................................... 20-737
M-25. Windshield wiper or washer does not work ............................................................................ 20-739
M-26. Air conditioner does not work ................................................................................................... 20-742
removed.
D155AX-5
20-701
4
TROUBLESHOOTING


User Service
code code Abnormal system
Abnormality in
E0120 monitor panel caution
lamp system
CALL
03
E0121
E01
Abnormality in
monitor panel caution
buzzer system
Abnormality in power
E0211 train (torque converter)
oil temperature
E0329
Abnormality in HSS
charging oil pressure
When ground output voltage to caution lamp is high
1. Defective caution lamp
2. Short circuit with power source in wiring harness between monitor panel CN2
(7) - caution lamp CN-251 (2)
When ground output voltage to caution buzzer is high

1. Defective caution buzzer
2. Short circuit with power source in wiring harness between monitor panel CN2
(8) - caution buzzer CN-21A (1)
When torque converter oil temperature caution lamp on monitor panel flashes
1. Torque converter oil temperature rises above about 80C
2. Defective torque converter oil temperature sensor
When HSS oil temperature caution lamp on monitor panel flashes

1. HSS oil temperature rises above about 108C
CN1 (5) - sensor 452 (1)
3. Defective HSS oil temperature sensor
When engine oil pressure caution lamp on monitor panel flashes

1. Lowering of engine oil pressure
2. Defective engine oil pressure sensor
CALL
Abnormality in engine
E0430 oil pressure
When engine water temperature caution lamp on monitor panel flashes

1. Defective engine water temperature sensor
E01
Abnormality in engine
E0432 water temperature
20-702
4
D155AX-5
TROUBLESHOOTING
Normal condition
(Voltage, current, resistance)
Voltage between CN2 (7) - chassis
ground: Max. 6 V (When lamp lights
up)

Action taken by controller when

abnormality occurs
Voltage between CN2 (8) - chassis 1. Turns on caution lamp.

ground: Max. 3 V (When buzzer sounds)
Resistance between 453 (1) - (2)

At 100C: Approx. 3.8 k
At 90C: Approx. 4.9 k
At 35C: Approx. 29 k
Problems on machine
1. Caution lamp does not light up.
1. Caution buzzer does not sound.
1. Turns on caution lamp and caution

buzzer.
When voltage sensor between 452 (1) 1. Turns on caution lamp and caution
buzzer.
(CN1 (5)) and chassis ground is turned
ON (hydraulic oil temperature is below about 104C): Max. 1 V
When sensor is turned OFF (hydraulic
oil temperature is above about 108C):
20 - 30 V
Low-pressure switch resistance

When engine is stopped: Max. 1
buzzer.
When engine speed is above about 600
rpm: Min. 1 M
High-pressure switch resistance
When engine speed is above about
1,300 rpm: Min. 1 M
Sensor resistance (10 - 100C)
High-temperature sensor: 90 k - 3.5
buzzer.
Low-temperature sensor: 9 k - 0.3
D155AX-5
20-703
4
TROUBLESHOOTING
M MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM

20-704
4
D155AX-5
TROUBLESHOOTING
D155AX-5
20-705
4
M-1
TROUBLESHOOTING
M-1. [E0120] (Abnormality in monitor panel caution lamp system) is

displayed
Cause
Remedy
1
Disconnect 251.
100 - 400
NO
Is resistance between 251 (male) (1)

and 2 normal?
Defective caution lamp
Replace
Short circuit with power source in

wiring harness between CN2
(female) (7) - 251 (female) (2)
Repair or
replace

module)
Replace
YES
2
Disconnect 251 and CN2.
Max. 1 V
When 251 is disconnected, is

voltage between CN2 (female) (7)
YES
NO
20-706
4
D155AX-5
M-2
TROUBLESHOOTING
M-2. [E0121] (Abnormality in monitor panel caution buzzer system) is

displayed
Cause
Remedy
1
Disconnect 21A.
Min. 200
NO
Is resistance between terminals of

21A (buzzer side) normal?
Replace

(female) (8) - 222 (5) - 21A (female)
(1)
Repair or
replace

module)
Replace
YES
2
Disconnect 21A and CN2.
Max. 1 V
When 21A is disconnected, is

voltage between CN2 (female) (8)
YES
NO
D155AX-5
20-707
4
M-3, M-4
TROUBLESHOOTING
M-3. [E0211] (Abnormality in oil temperature of power line: torque

converter) is displayed
Cause
Remedy
1
NO
Is power train (torque converter) oil

pressure lamp of monitor flashing?
YES
Go to M-10 c)
2
NO
Is [E] is displayed at head of service

code?
YES
See note.

module)
Replace
Note: This means that the power train oil temperature sensor has detected abnormal temperature but
the display of the monitor panel has become normal. Accordingly, inspect the power train and
remove the cause of the abnormal temperature.
M-4. [E0329] (Abnormality in HSS oil temperature) is displayed

Cause
Remedy
1
NO
Is hydraulic oil lamp of monitor

flashing?
YES
Go to M-10 d)
2
code?
YES
NO
Defective HSS hydraulic system
See note.

module)
Replace
Note: This means that the HSS oil temperature sensor has detected abnormal temperature but the
display of the monitor panel has become normal. Accordingly, inspect the HSS oil temperature
system and remove the cause of the abnormal temperature.
20-708
4
D155AX-5
M-5, M-6
TROUBLESHOOTING
M-5. [E0430] (Abnormality in engine oil pressure) is displayed

If an error in N mode is detected, inspect in N mode first.
Cause
Remedy
1
NO
Is engine oil pressure lamp of

monitor flashing?
YES
Go to M-10 b)
2
NO

code?
YES
Defective engine
See note.

module)
Replace
Note: This means that the engine oil pressure sensor has detected abnormal oil pressure but the
display of the monitor panel has become normal. Accordingly, inspect the engine and remove
the cause of the abnormal pressure.
M-6. [E0432] (Abnormality in engine water temperature) is displayed

If an error in N mode is detected, inspect in N mode first.
Cause
Remedy
1
Is engine water temperature lamp of NO
monitor flashing?
YES
Go to M-10 b)
Replace
Defective engine
See note.

module)
Replace
2
code?
YES
NO
Note: This means that the engine water temperature sensor has detected abnormal temperature but
the display of the monitor panel has become normal. Accordingly, inspect the engine and
remove the cause of the abnormal temperature.
D155AX-5
20-709
4
TROUBLESHOOTING
M-7
M-7. When starting switch is turned ON, all segments of monitor panel do not light up
a) The caution module (gauge and lamp display unit) does not light up.
Check that fuse 6 is normal. (If it is broken, check the circuit related to it for short circuit with
chassis ground.)
Cause
Remedy
1
20 - 30 V
NO
Is voltage between CN (1) and (2)

normal?
YES

module)
Replace

wiring harness between CN1 (female) (1)
- fuse 6
Repair or
replace

in wiring harness between CN1
(female) (2) - chassis ground
Repair or
replace
2
20 - 30 V
Is voltage between CN1 (1) and

chassis ground normal?
YES
NO
M-7 a). Related electrical circuit diagram
20-710
4
D155AX-5
TROUBLESHOOTING
M-7
b) The tachometer module (tachometer and service meter display unit) does not light up.
Check that fuses 6 and 10 are normal. (If they are broken, check the circuit related to them for short
circuit with chassis ground.)
Cause
Remedy
1
20 - 30 V
NO
Is voltage between T01 (7) and (2)

normal?
YES
2
20 - 30 V
NO
Is voltage between T01 (1) and (2)

normal?
YES

(female) (1) - fuse 6
Repair or
replace

module)
Replace

(female) (7) - fuse 10
Repair or
replace

Repair or
replace
3
20 - 30 V
Is voltage between T01 (7) and

YES
NO
M-7 b). Related electrical circuit diagram
D155AX-5
20-711
4
TROUBLESHOOTING
M-8
M-8. When starting switch is turned ON, all segments of monitor

panel light up but do not go out.
a) Caution module (Gage and lamp display unit) does not go off.
Cause

module)
Remedy
Replace
b) The tachometer module (tachometer and service meter display unit) does not go off.
Cause

module)
20-712
4
Remedy
Replace
D155AX-5
TROUBLESHOOTING
M-9
M-9. When starting switch is turned ON (with engine stopped),

caution items (excluding battery charge level and engine oil
pressure) flash
Any error in N mode must not be detected at this time.
Inspect both of the engine oil pressure sensor system and alternator system.
a) Engine oil pressure sensor
Cause
Remedy
Is engine oil pressure system

normal?
NO
See troubleshooting of engine

controller.
Repair or
replace
NO
See troubleshooting of engine

controller.
Repair or
replace
Defective monitor panel (Caution

module)
Replace
YES
2
Is N mode normal?
YES
b) Alternator system
Cause
Remedy
1
Disconnect ANR.
Max. 1 V
NO
Is voltage between ANR (alternator

side) and chassis ground normal?
Replace

module)
Replace

module)
Replace
YES
2
Disconnect CN1.
Max. 1 V
NO
Is voltage between CN1 (female) (4)

YES
3
Disconnect T01.
Max. 1 V

NO
YES

Max. 1 V
4
When 220 is disconnected, is voltage NO
between CN1 (female) (4) and

Repair or
(female) (4) - T01 (female) (4) - ANR replace
- M2 (female) (2) - 220 (male) (2)
YES
Defective diode (220)
D155AX-5
Replace
20-713
4
TROUBLESHOOTING
M-9
20-714
4
D155AX-5
TROUBLESHOOTING
M-10
M-10. When engine is started, caution items flash (daily check items
and engine related items are normal)
a) Charge level lamp flashes
Cause
Remedy
1
Disconnect ANR.
Start engine (at medium or
higher speed).
20 - 30 V
NO
Is voltage between ANR (alternator

side) and chassis ground normal?
Replace

module)
Replace
Delta connection CN1 (female) (4) ANR
Repair or
replace
Defective monitor panel (Tachometer module)
Replace
YES
2
Disconnect CN1.
higher speed).
20 - 30 V
Is voltage between CN-1 (female) (4) NO

YES
3
Disconnect T01, CN1.
higher speed).
20 - 30 V
When T01 is disconnected, is voltage

between CN1 (female) (4) and chassis
ground normal?
YES
NO
D155AX-5
20-715
4
TROUBLESHOOTING
M-10
b) Engine oil pressure lamp flashes

Check that the engine oil pressure is normal before troubleshooting.
Cause
Remedy
1
Is oil pressure switch judged
defective by troubleshooting of
engine controller?
NO
YES
Defective engine oil pressure

sensor
Check
according to
standard values
table, then
replace
2
NO
Is N mode normal?
YES
See N mode.

module)
Repair or
replace
c) Power train (Torque converter) oil temperature lamp flashes.

Check that the power train (torque converter) oil temperature is normal before troubleshooting.
Cause
Remedy
1
Start engine.
Does power train oil temperature

gauge indicate level 7 (highest)?
NO

module)
Replace
NO

module)
Replace
Defective power train oil temperature sensor
Check
according to
standard values
table, then
replace
YES
2
Connect short connector
to 453.
Start engine.
When short connector is connected

to 453 (female), does lamp go off?
YES
M-10 c). Related electrical circuit diagram
20-716
4
D155AX-5
TROUBLESHOOTING
M-10
d) HSS oil temperature lamp flashes

Check that the hydraulic oil temperature is normal before troubleshooting.
Cause
Remedy
1
Connect 452 to chassis
ground.
Start engine.
When 452 (female) (1) is connected

to chassis ground, does lamp go
off?
NO
YES
Defective HSS sensor
Check
according to
standard values
table, then
replace

(female) (5) - 452 (female) (1)
Repair or
replace

module)
Replace
2
Disconnect CN1.
Max. 1
Is resistance between CN1 (female)

(5) and chassis ground normal?
YES
NO
M-10 d). Related electrical circuit diagram
D155AX-5
20-717
4
TROUBLESHOOTING
M-11
M-11. HSS charging oil pressure caution lamp flashes

Check that the HSS charge oil pressure is normal before troubleshooting (The caution lamp flashes
when the HSS charge oil pressure lowers below about 0.78 MPa {8 kg/cm2}).
Cause
Remedy
1
Disconnect CN1.
Start engine.
Max. 1
NO

YES
Replace
Defective HSS charge pressure

sensor
Replace

in wiring harness between CN-406
(female) (2) - GND2 (chassis
ground)
Repair or
replace

(female) (8) - CN-406 (female) (1)
Repair or
replace
2
Disconnect CN-406.
Start engine.
Max. 1
Is resistance between CN-406 (male) NO

(1) and (2) normal?
YES
3
Disconnect CN-406.
Max. 1
Is resistance between CN-406

(female) and chassis ground
normal?
YES
NO
20-718
4
D155AX-5
TROUBLESHOOTING
M-12
M-12. Preheater lamp does not light up or stays lighted up

Check that the preheater is normal.
a) The preheater lamp does not light up during the preheating operation
Cause
Remedy
1
Disconnect CN2.
Turn starting switch to
PREHEAT position (See note).
20 - 30 V
NO


(female) (5) - ribbon heater
Repair or
replace

module)
Replace
YES
Note: Turn the starting switch in the opposite direction to the ON position and hold it.
b) The preheater lamp lights up while preheater is turned off
Cause
Remedy
1
Disconnect CN2.
Max. 1 V

YES
NO

(female) (5) - ribbon heater
Repair or
replace

module)
Replace
D155AX-5
20-719
4
TROUBLESHOOTING
M-13
M-13. Abnormality in caution buzzer

Check that any service code is not displayed (If any one is displayed, troubleshoot according to it).
Even if the charge level lamp among the caution items flashes, the caution buzzer does not sound.
a) The buzzer does not sound for 1 second after the starting switch is turned on
chassis ground.)
Cause
Remedy
1
Disconnect CN2 and connect
(female) (8) to chassis ground.
NO
When CN2 (female) (8) is connected

to chassis ground, does buzzer
sound?
YES

module)
Replace
NO

in wiring harness between fuse 6 21A
Repair or
replace
NO

wiring harness between CN2 (female)
(8) - 21A
Repair or
replace
Defective caution buzzer
Replace
2
Disconnect 21A.
20 - 30 V
Is voltage between 21A (power

source side) and chassis ground
normal?
YES
3
Disconnect CN2 and 21A.
Max. 1

(8) and 21A (monitor side) normal?
YES
b) The buzzer sounds while monitor is displaying normally
Cause
Remedy
1
Disconnect CN2.
NO
When CN2 is disconnected, does

buzzer stop sounding?
YES

module)
Replace
Short circuit with chassis ground in

- 21A
Repair or
replace
Defective caution buzzer
Replace
2
Disconnect 21A and CN2.
Max. 1
When 21A (monitor side) is disconnected, is

resistance between CN2 (female) (8) and
NO
YES
20-720
4
D155AX-5
TROUBLESHOOTING
M-13
D155AX-5
20-721
4
TROUBLESHOOTING
M-14
M-14. Abnormality in CAUTION lamp

Check that any service code is not displayed (If any one is displayed, troubleshoot according to it).
a) The lamp does not light up for 2 seconds after the starting switch is turned on or it does not light
up while a caution item is flashing
chassis ground.)
Cause
Remedy
1
Disconnect CN2 and connect
(female) (7) to chassis ground.
When CN2 (female) (7) is connected

to chassis ground, does lamp light
up?
NO
YES

module)
Replace
NO

wiring harness between fuse 6 - 251
(female) (1)
Repair or
replace
NO

- 251 (female)
Repair or
replace
Replace
2
Disconnect 251.
20 - 30 V
Is voltage between 251 (female) (1)

YES
3
Disconnect CN2 and 251.
Max. 1

(7) and 251 (female) normal?
YES
b) The lamp light up while monitor is displaying normally
Cause
Remedy
1
Disconnect CN2.
NO
When CN2 is disconnected, does

lamp go off?
YES

module)
Replace
2
Max. 1 M
When 251 is disconnected, is resistance

ground normal?
NO

wiring harness between CN2 (female) (7) Repair or
replace
- 251 (female) (2)
YES
20-722
4
Replace
D155AX-5
TROUBLESHOOTING
M-14
D155AX-5
20-723
4
TROUBLESHOOTING
M-15
M-15. Abnormality in engine water temperature gauge

Check that the engine water temperature is normal (If it is abnormal, troubleshoot the engine).
The following troubleshooting procedure is prepared on the assumption that the engine controller
is operating normally.
Cause
Remedy
Defective engine water temperature

sensor
Check
according to
standard values
table, then
replace
1
NO
Is water temperature sensor of engine

controller is judged defective by
troubleshooting?
YES
2
Is N mode normal?
YES
20-724
4
NO
Check N mode.

module)
Replace
D155AX-5
M-16
TROUBLESHOOTING
M-16. Abnormality in power train (torque converter) oil pressure gauge

Check that the power train oil temperature is normal (If it is abnormal, troubleshoot the power
train).
a) The power train oil temperature gauge displays abnormally low temperature
Cause
Remedy
Defective power train oil temperature

sensor
Check
according to
standard values
table, then
replace

(female) (2) - 453 (female) (2)
Repair or
replace
Disconnection, defective contact, or

short circuit with power source in
(female) (2) - 453 (female) (1)
Repair or
replace

module)
Replace
1
Connect short connector to
453.
NO

to 453, does displayed value go off?
YES
2
Max. 1
NO

(2) and 453 (female) (1) normal?
YES
3
Disconnect CN2 and 453
Max. 1
NO

YES
b) The power train oil temperature gauge does not display (even 1 bar)
Cause
Remedy
1
Disconnect 453.
NO
When 453 is disconnected, does

gauge display normally?
YES
Defective power train oil temperature sensor
Check
according to
standard values
table, then
replace

(female) (2) - 453 (female) (1)
Repair or
replace

module)
Replace
2
Min. 1 M

ground normal?
NO
YES
D155AX-5
20-725
4
TROUBLESHOOTING
M-2
20-726
4
D155AX-5
M-17
TROUBLESHOOTING
M-17. Abnormality in fuel level gauge

Check that the fuel level is sufficiently high.
a) The fuel level gauge always displays full
Cause
Remedy
1
Disconnect 423.
NO
When 423 is disconnected, does

displayed level go off?
YES
Check
according to
standard values
table, then
replace

(female) (3) - 423 (female) (1)
Repair or
replace

module)
Replace
2
Min. 1 M
NO

ground normal?
YES
b) The fuel level gauge does not display (even 1 bar)
Cause
Remedy
1
Connect short connector to
423.
NO

to 423, does gauge display full?
YES
Check
according to
standard values
table, then
replace

(female) (2) - 423 (female) (2)
Repair or
replace

short circuit with power source in
(female) (3) - 423 (female) (1)
Repair or
replace

module)
Replace
2
Max. 1
NO

YES
3
Max. 1

YES
D155AX-5
NO
20-727
4
TROUBLESHOOTING
M-17
20-728
4
D155AX-5
TROUBLESHOOTING
M-18, M-19
M-18. Gear speed display segments indicate [ ], and engine speed is

not displayed
Cause
Abnormality in network system
Remedy
Go to N-3
M-19. Service meter does not advance while engine is running
Cause
Remedy
1
Start engine.
Is sandglass displayed in service

meter unit?
NO
Go to M10 a)
YES
D155AX-5
Replace
20-729
4
TROUBLESHOOTING
M-20
M-20. Abnormality in service mode display

a) When service switch is turned on, the service mode is not displayed
Cause
Remedy
1
Disconnect T01.
Turn service switch ON.
Max. 1
NO

YES

module)
Replace
Defective service switch
Replace

(female) (5) - X1 (3)
Repair or
replace

in wiring harness between X1 (2) chassis ground
Repair or
replace
2
Max. 1
NO
Is resistance between X1 (2) and (3)

normal?
YES
3
Max. 1
NO

(5) and (3) normal?
YES
b) When the service switch is turned off, the service mode does not change to the normal mode
Cause
Remedy
1
Disconnect T01.
Turn service switch OFF.
Min. 1 M
NO

YES

module)
Replace
Defective service switch
Replace

wiring harness between T01
(female) (5) - X1 (3)
Repair or
replace
2
Turn service switch OFF.
Min. 1 M
Is resistance between X1 (2) and (3)

normal?
YES
20-730
4
NO
D155AX-5
TROUBLESHOOTING
M-20
D155AX-5
20-731
4
TROUBLESHOOTING
M-21
M-21. Monitor panel lighting does not light up (though headlamps and
working lamps light up)
Check that the bulb is not broken (If it is broken, replace it).
chassis ground.)
a) The panel lamp of the tachometer module does not light up
Cause
Disconnect T01.
Turn head-lamp and working lamp
switches ON.
20 - 30 V
Remedy
1
NO
Is voltage between T01 (female) (6)

YES

- 211 (female) (2)
Repair or
replace
Replace
b) The panel lamp of the caution module does not light up
Cause
Remedy
1
Disconnect T01.
Turn headlamp and working lamp
switches ON.
20 - 30 V
NO

YES
Defective lamp or defective contact

of lamp
Replace

- chassis ground
Replace
Disconnection or defective contact in wiring

harness between CN4 (female) (1) - 211
(female) (2)
Repair or
replace
2
Disconnect CN4.
Max. 1

YES
20-732
4
NO
D155AX-5
M-9
TROUBLESHOOTING
D155AX-5
20-733
4
TROUBLESHOOTING
M-22
M-22. When head lamp switch is turned on, monitor panel lighting does
not light up
Check that the headlamp light up normally before troubleshooting (If it does not light up, perform
M-23).
Cause
Remedy
1
Turn headlamp switch ON.
20 - 30 V
Is voltage between T01 (6) and

NO

- CN-211 (female) (2)
Replace
Replace
YES
20-734
4
D155AX-5
TROUBLESHOOTING
M-23
M-23. Head lamps or rear lamps do not light up

a) The headlamp does not light up
chassis ground.)
Cause
Remedy
1
Disconnect CN-203 and CN-204.
20 - 30 V
NO
Is voltage between CN-203, CN-204

(female) (1) and chassis ground normal?
YES
Defective bulb
Replace

in wiring harness between fuse 4 CN-211 (female) (3)
Repair or
replace
Defective headlamp switch
Replace

(female) (2) - CN-203 (female) (1) or
CN-204 (female) (1)
Repair or
replace
2
Disconnect CN-211.
20 - 30 V
NO
Is voltage between CN-211 (female)

YES
Disconnect CN-211.
Max. 1
3
(2) and (3) normal?
YES
D155AX-5
20-735
4
TROUBLESHOOTING
M-23
b) The rear lamp does not light up

chassis ground.)
Cause
Disconnect CN-224, CN-243,
and CN-248.
Turn rear lamp switch ON.
20 - 30 V
Remedy
1
NO
Is voltage between CN-224, CN-243, CN248 (female) (1) and chassis ground
normal?
YES
Defective bulb
Replace

Repair or
replace
Defective rear lamp switch
Replace

(female) (2) - CN-224 (female) (1) or
CN-248 (female) (1)
Repair or
replace
2
Disconnect CN-216.
20 - 30 V
NO

YES
3
Disconnect CN-216.
Turn rear lamp switch ON.
Max. 1
Is resistance between CN-216 (male)

(2) and (3) normal?
YES
NO
20-736
4
D155AX-5
TROUBLESHOOTING
M-24
M-24. Electric intake air heater does not work

The automatic preheater works only when the coolant temperature is low.
In this troubleshooting, only manual preheating with the key switch is inspected.
Cause
Remedy
Turn key switch to left

end.
20 - 30 V
NO
Is voltage between key switch R1

Defective key switch
Replace
NO

wiring harness between key switch R1 CN-109
Repair or
replace
NO

wiring harness between CN-214 (female)
(10) - CN-109
Repair or
replace
Defective heater relay
Replace
YES
2
Disconnect CN-214.
Is there continuity between key

switch R1 and CN-109?
YES
3

20 - 30 V
Is voltage between CN-109 and

YES
D155AX-5
20-737
4
TROUBLESHOOTING
M-24
20-738
4
D155AX-5
TROUBLESHOOTING
M-25
M-25. Windshield wiper or washer does not work

a) All windshield wipers and windshield washers do not operate
Cause
wiring harness between CN-C - cab fuse
box
Remedy
Repair or
replace
b) Front windshield wiper does not operate
Cause
Remedy
When switch is replaced with

another one, does wiper operate
normally?
NO
YES
Replace

in wiring harness between cab fuse
box - motor connector (female) (5)
Repair or
replace

in wiring harness between switch
connector (female) (3) - chassis
ground
Repair or
replace

connector (female) (4) - motor
Repair or
replace
Replace

20 - 30 V
NO
Is voltage between motor connector

YES
3
Disconnect connector.
Max. 1
Is resistance between switch

connector (female) (3) and chassis
ground normal?
NO
YES
4
Max. 1
Is resistance between switch connector

(female) (4) and motor connector (female)
(2) normal?
NO
YES
D155AX-5
20-739
4
TROUBLESHOOTING
M-25
c) The left windshield wiper, right windshield wiper, or

rear wiper does not operate
Cause
Remedy
1

another one, does wiper operate
normally?
NO
YES

20 - 30 V
2
Is voltage between switch connector NO
Replace

in wiring harness between motor
connector (female) (3) - chassis
ground
Repair or
replace

in wiring harness between cab fuse
box - switch connector (female) (3)
Repair or
replace

Repair or
replace
Replace
YES
3
Max. 1
Is resistance between motor

ground normal?
NO
YES
4
Max. 1
Is resistance between switch connector

(female) (4) and motor connector (female)
(2) normal?
NO
YES
d) Washing liquid does not come out of windshield

washer
Cause
Remedy
1
Turn washer ON.
NO
Is motor sound heard?
Supplying
Insufficient washing liquid, clogging washing
liquid, then
of nozzle, or defective piping
repair or
replace
YES
2
Turn washer ON.
When motor connector is replaced

with another one, does washer
operate?
NO
YES
Defective windshield washer motor
Replace
Replace

in wiring harness between motor
connector (female) (2) - CN-SX8
(chassis ground)
Repair or
replace

Repair or
replace
3
Turn washer ON.
NO

another one, does washer operate?
YES
4
Max. 1
Is resistance between motor

ground normal?
YES
20-740
4
NO
D155AX-5
TROUBLESHOOTING
M-25
D155AX-5
20-741
4
TROUBLESHOOTING
M-26
M-26. Air conditioner does not work

chassis ground.)
a) Air does not blow out
Table 1
Table 2
Terminal
Position
0
1
2
3
CN-394 (male)
Resistance
Between (2) (3)
3 0.5
Between (2) (1)
1 0.1
Cause
Remedy
1
20 - 30 V
NO
Is voltage between CN-391 (1), (1)


in wiring harness between fuse 8
and CN-391 (female) (1), (2)
Repair or
replace
Defective air conditioner relay
Replace

Repair or
replace
Defective blower switch
Replace

(female) (4) - CN-206 (chassis
ground)
Repair or
replace
Defective air conditioner relay
Replace
YES
2
Disconnect CN-391.
240 40

(1) and (3) normal?
YES
3
20 - 30 V
NO
Is voltage between CN-395 (3) and

YES
4
Disconnect CN-395.
NO
Is continuity between terminals of CN395 (male) as shown in Table 1?
YES
5
Disconnect CN-395.
Max. 1

(female) (4) and chassis ground
normal?
NO
YES
6
Set blower switch to position other
than OFF.
20 - 30 V

NO
YES
See next
page A
20-742
4
D155AX-5
TROUBLESHOOTING
M-26
Cause
Remedy
7
Set blower switch to position
other than OFF.
20 - 30 V

Repair or
replace
Defective blower motor
Replace
Defective blower register
Replace
NO

Repair or
replace
NO

Repair or
replace
Go to b)
Replace
NO

YES
8
other than OFF.
NO
Is blower motor of condenser

rotating?
YES
9
Disconnect CN-394.
Are resistance between CN-394 (male) (2)

and (3) and that between (2) and (1) as
shown in Table 2?
NO
YES
10
Disconnect CN-394.
Max. 1

normal?
YES
11
Max. 1

(female) (1) and CN-395 (female) (2)
normal?
YES
D155AX-5
20-743
4
TROUBLESHOOTING
M-26
b) b) Air does not blow out (Air conditioner does not operate)
Note: Measure the voltage after the dual pressure switch and thermostat switch are turned ON.
Switching pressure of dual pressure switch (Refrigerant circuit pressure):
High pressure side: Turned ON at 2.06 MPa {21 kg/cm2} (when pressure lowers) and turned
OFF at 2.65 MPa {27 kg/cm2} (when pressure rises)
Low pressure side: Turned ON at 0.23 MPa {2.35 kg/cm2} (when pressure rises) and turned
OFF at 0.21 MPa {2.1 kg/cm2} (when pressure lowers)
Switching temperature of thermostat switch (Evaporator discharge temperature):
Turned ON at 4.5C (when temperature lowers) and turned OFF at 1C (when temperature
rises)
Cause
Remedy
1
20 - 30 V
NO


Repair or
replace
Defective air conditioner switch
Replace

Repair or
replace
Defective air conditioner switch
Replace

Repair or
replace
Replace
YES

Disconnect CN-396.
Turn air conditioner switch
ON.
Max. 1
2
(1) and (3) normal?
YES
3
Max. 1

normal?
NO
YES

Disconnect CN-396.
Turn air conditioner switch
ON.
Max. 1
4
(2) and (3) normal?
YES
5
Turn air conditioner switch ON.
Max. 1

normal?
NO
YES
6
Disconnect CN-398.
240 40

(1) and (3) normal?
YES
See next
page A
20-744
4
D155AX-5
TROUBLESHOOTING
M-26
Cause
Remedy
7
Disconnect CN-398 and
CN395.
Max. 1

normal?
NO

Repair or
replace
NO

in wiring harness between fuse 8
and CN-398 (female) (2)
Repair or
replace
Replace

(female)(1) - CN-398 (female) (4)
Repair or
replace
Defective dual pressure switch
Replace
NO

Repair or
replace
NO

(male) (7) - CN-ARC (female) (2)
Repair or
replace
Defective air conditioner fan motor

or compressor
Replace
YES
8
20 - 30 V
Is resistance between CN-398 (2)

YES

other than OFF.
20 - 30 V
9
NO
Is resistance between CN-398 (4)

YES
10

other than OFF.
20 - 30 V

normal?
For condition, see note.

20 - 30 V

NO
YES
11
NO
YES
12
20 - 30 V

YES
13
20 - 30 V
Is voltage betweenYES
CN-ARC (2) and
YES
D155AX-5
20-745
4
TROUBLESHOOTING
M-26
20-746
4
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE CONTROLLER

(G MODE)
Judgment table for engine controller and engine ............................................................................. 20-810
G mode system electrical circuit diagram ........................................................................................... 20-812
G-1. [E0401] (Abnormality in engine controller power supply) is displayed ................................ 20-814
G-2. [E0402] (Abnormality in engine controller) is displayed ......................................................... 20-815
G-3. [E0405] (Abnormality in fuel control dial system) is displayed ............................................. 20-816
G-4. [E0406] (Abnormality in decelerator potentiometer system) is displayed ............................ 20-817
G-5. [E0409] (Abnormality in Ne speed sensor system) is displayed ............................................ 20-818
G-6. [E0410] (Abnormality in G speed sensor system) is displayed .............................................. 20-819
G-7. [E0458] (Short circuit in fuel injector No. 1, No. 2, No. 3 system) is displayed ................... 20-820
G-8. [E0459] (Short circuit in fuel injector No. 4, No. 5, No. 6 system) is displayed ................... 20-823
G-9. [E0460] (Abnormality in controller chassis ground circuit) is displayed ............................... 20-826
G-10. [E0461] (Disconnection in fuel injector No. 1 system) is displayed ....................................... 20-827
G-16. [E0468] (Overcurrent in fuel supply pump PCV1 system) is displayed ................................. 20-833
G-17. [E0469] (Disconnection in fuel supply pump PCV1 system) is displayed ............................. 20-834
G-18. [E0470] (Overcurrent in fuel supply pump PCV2 system) is displayed ................................. 20-835
G-19. [E0471] (Disconnection in fuel supply pump PCV2 system) is displayed ............................. 20-836
G-20. [E0472] (Abnormality in boost pressure sensor system) is displayed .................................. 20-837
G-21. [E0474] (Abnormality in common rail fuel pressure sensor system) is displayed............... 20-838
G-22. [E0476] (Abnormality in high engine water temperature sensor system) is displayed ....... 20-839
G-23. [E0478] (Abnormality in low engine water temperature sensor system) is displayed ........ 20-840
G-24. [E0480] (Abnormality in common rail fuel pressure system) is displayed ........................... 20-841
G-25. [E0481] (Abnormality in high common rail fuel pressure 1 system) is displayed
[E0482] (Abnormality in high common rail fuel pressure 2 system) is displayed ............... 20-842
G-26. [E0483] (No-pressure feed by fuel supply pump 1) is displayed
[E0484] (No-pressure feed by fuel supply pump 2) is displayed ........................................... 20-843
G-27. [E0487] (Abnormality in engine oil pressure switch system) is displayed ........................... 20-845
G-28. [E0488] (Abnormality in power supply system 1) is displayed .............................................. 20-847
G-29. [E0489] (Abnormality in power supply system 2) is displayed .............................................. 20-849
G-30. [E0490] (Abnormality in Q regulator switch signal) is displayed ........................................... 20-850
G-31. [E0491] (Short circuit in starting switch C system) is displayed ............................................ 20-851
removed.
D155AX-5
20-801
4

TROUBLESHOOTING

Service
code Abnormal system
E0405
E0406
E0409
E0410
Abnormality in fuel
control dial system
1. Disconnection, defective contact, short circuit, or short circuit with chassis ground in
fuel control dial
2. Disconnection, defective contact, or short circuit with chassis ground in wiring harness
between controller CN-1 (4) (power source) - fuel control dial CN-FCS (1)
between controller CN-1 (6) (signal) - fuel control dial CN-FCS (2)
between controller CN-2 (10) (ground) - fuel control dial CN-FCS (3)
Abnormality in
decelerator
potentiometer system
1. Disconnection, defective contact, short circuit, or short circuit with chassis ground in
decelerator potentiometer
between controller CN-1 (4) (power source) - decelerator potentiometer CN-FCD (1)
between controller CN-1 (7) (signal) - decelerator potentiometer CN-FCD (2)
between controller CN-2 (10) (ground) - decelerator potentiometer CN-FCS (3)
Abnormality in Ne
speed sensor system
between Ne speed sensor
between controller CN-1 (5) (+ side) - Ne speed sensor CN-E51 (1)
between controller CN-1 (12) (- side) - Ne speed sensor CN-E51 (2)
Abnormality in G
speed sensor system
between G speed sensor
between controller CN-2 (1) (+ side) - G speed sensor CN-E52 (1)
between controller CN-2 (9) (- side) - G speed sensor CN-E52 (2)
1.
2.
3.
4.
5.
E0458
Short circuit in No. 1,

No. 2, No. 3 fuel
injector system
6.
7.
8.
9.
10.
11.
1.
2.
3.
4.
5.
E0459
Short circuit in No. 4,

No. 5, No. 6 fuel
injector system
6.
7.
8.
9.
10.
11.
20-802
4
Defective fuel injector No. 1

Short circuit with chassis ground or power source in wiring harness between controller
CN-6 (7) (+ side) - injector No. 1 (1)
CN-6 (8) (- side) - injector No. 1 (2)
Disconnection or defective contact in wiring harness between controller CN-7 (5), (13) chassis ground
Disconnection or defective contact in wiring harness between controller CN-7 (5), (13) chassis ground
D155AX-5
TROUBLESHOOTING
Normal condition

Action taken by controller
Problems on machine
Sensor source voltage

1. Holds present voltage until transmis- 1. When fuel control dial is operated,
Between CN-1 (4) - CN-2 (10): 4.6 - 5.4 V
sion is set in "neutral" and lowers
set speed does not change
Sensor signal voltage
speed command value to 1,300 rpm
CN-1 (6) - CN-2 (10): 0.3 - 4.5 V
after transmission is set in "neutral"
1. Holds present voltage until transmis- 1. When decelerator is operated, set

sion is set in "neutral" and lowers
speed does not change
Between CN-1 (4) - CN-2 (10): 4.6 - 5.4 V
speed command value to 1,300 rpm
after transmission is set in "neutral"
CN-1 (7) - CN-2 (10): 0.3 - 4.5 V
Sensor resistance
Between CN-E51 (1) - (2): 85 - 210
1. Operates machine with output lim- 1. Output is lowered.

ited
Sensor resistance
Between CN-E52 (1) - (2): 1 k - 2 k
1. Operates machine with output lim- 1. Output is lowered.

ited
Injector No. 1 resistance

Between CN-E31 (1) - (2): 0.4 - 1.1
Between CN-E32 (1) - (2): 0.4 - 1.1
Between CN-E33 (1) - (2): 0.4 - 1.1
1. Stops outputting to fuel injectors No. 1. Output is lowered largely (When er1, No. 2 and No. 3 (When error is
ror is displayed singly)
displayed singly)
2. Engine stops (When E0459 is also dis2. Stops outputting to fuel supply pump
played)
and all fuel injectors (When E0459 is
also displayed)

Between CN-E34 (1) - (2): 0.4 - 1.1
Between CN-E35 (1) - (2): 0.4 - 1.1
Between CN-E36 (1) - (2): 0.4 - 1.1
1. Stops outputting to fuel injectors No. 1. Output is lowered largely (When error is displayed singly)
4, No. 5 and No. 6 (When error is
2. Engine stops (When E0458 is also disdisplayed singly)"
played)
2. Stops outputting to fuel supply pump
and all fuel injectors (When E0458 is
also displayed)
D155AX-5
20-803
4
TROUBLESHOOTING
Service
E0460
Abnormality in
controller drive circuit

1. Disconnection or defective contact in wiring harness between controller CN-7 (5), (13) chassis ground (When E0458 and E0459 are also displayed)
Disconnection in fuel
injector No. 1 system
1. Defective fuel injector No. 1

2. Short circuit with chassis ground or power source in wiring harness between controller
CN-6 (7) (+ side) - fuel injector No. 1 CN-E31 (1)
CN-6 (8) (- side) - fuel injector No. 1 CN-E31 (2)





Overcurrent in fuel
supply pump PCV1
system
1. Defective fuel supply pump PCV1

CN-7 (10) (+ side) - PCV1 solenoid CN-E41 (1)
3. Short circuit with power source in wiring harness between controller CN-7 (11) (- side) PCV1 solenoid CN-E41 (2)
E0459
supply pump PCV1
system

2. Disconnection or defective contact in wiring harness between controller CN-7 (10) (+
side) - PCV1 solenoid CN-E41 (1)
between controller CN-7 (11) (- side) - PCV1 solenoid CN-E41 (2)
E0470
Overcurrent in fuel
supply pump PCV2
system

CN-7 (4) (+ side) - PCV2 solenoid CN-E42 (1)
3. Short circuit with power source in wiring harness between controller CN-7 (12) (- side) PCV2 solenoid CN-E42 (2)
E0461
E0462
E0463
E0464
E0465
E0466
E0468
20-804
4
D155AX-5
TROUBLESHOOTING
Normal condition

Problems on machine
1. Operates machine with output lim- 1. Engine speed does not rise to high
idling with no load applied
ited
2. If high load is applied, engine stops
3. Engine stops during operation
4. Engine does not start

Between CN-E31 (1) - (2): 0.4 - 1.1
1. Stops outputting to fuel injector No. 1. Output is lowered (When error is displayed singly)
1 (When error is displayed singly)
2. Stops outputting to fuel supply pump 2. Engine stops (When E0462 - E0466
are also displayed)
and all fuel injectors (When E0462 E0466 are also displayed)

Between CN-E32 (1) - (2): 0.4 - 1.1
are also displayed)

Between CN-E33 (1) - (2): 0.4 - 1.1
are also displayed)

Between CN-E34 (1) - (2): 0.4 - 1.1
are also displayed)

Between CN-E35 (1) - (2): 0.4 - 1.1
are also displayed)

Between CN-E36 (1) - (2): 0.4 - 1.1
are also displayed)
Solenoid resistance
Between CN-E41 (1) - (2): 2.3 - 5.3
1. Stops outputting to PCV1 (When er- 1. Machine can be operated normally

(When error is displayed singly)
2. Stops outputting to PCV1 and PCV2 2. Engine stops (When E0470 is also displayed)
(When E0470 is also displayed)
Solenoid resistance
Between CN-E41 (1) - (2): 2.3 - 5.3

Solenoid resistance
Between CN-E42 (1) - (2): 2.3 - 5.3

D155AX-5
20-805
4

TROUBLESHOOTING
Service
2. Disconnection or defective contact in wiring harness between controller CN-7 (7) (+
side) - PCV2 solenoid CN-E42 (1)
between controller CN-7 (12) (- side) - PCV2 solenoid CN-E42 (2)
E0471
supply pump PCV2
system
E0472
1. Defective boost pressure sensor

between controller CN-2 (2) (power source) - boost pressure sensor CN-E54 (1)
Abnormality in boost 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness
between controller CN-1 (3) (signal) - boost pressure sensor CN-E54 (2)"
pressure sensor system
between controller CN-2 (10) (ground) - boost pressure sensor CN-E54 (3)
E0474
1. Defective common rail fuel pressure sensor

between controller CN-2 (2) (power source) - fuel pressure sensor CN-E53 (1)
Abnormality in common
rail fuel pressure sensor 3. Disconnection, defective contact, or short circuit with chassis ground in wiring harness
between controller CN-1 (1) (signal) - fuel pressure sensor CN-E53 (2)
system
between controller CN-2 (10) (ground) - fuel pressure sensor CN-E53 (3)
E0476
1. Defective high water temperature sensor

Abnormality in high wabetween controller CN-2 (4) (signal) - high water temperature sensor CN-P7 (1)
ter temperature sensor 3. Disconnection or defective contact in wiring harness between controller CN-2 (10) (ground)
system
- high water temperature sensor CN-P7 (2)
E0478
E0480
E0481
E0482
E0483
1. Defective low water temperature sensor

Abnormality in low wabetween controller CN-2 (3) (signal) - low water temperature sensor CN-P31 (1)
ter temperature sensor 3. Disconnection or defective contact in wiring harness between controller CN-2 (10) (ground)
system
- low water temperature sensor CN-P31 (2)
Abnormality in com- See E0481 and E0482
mon rail fuel pressure
1.
2.
3.
High common rail fuel 4.
5.
pressure 1
High common rail fuel See E0481

pressure 2
1.
2.
3.
No-pressure feed by 4.
5.
fuel supply pump 1
6.
20-806
4
Fuel viscosity is high (Improper fuel)

Overflow valve
Defective pressure limiter
Defective common rail fuel pressure sensor
Clogging of overflow piping
Defective low-pressure fuel circuit

Defective fuel supply pump PCV
Defective common rail fuel pressure sensor
Defective fuel injector
Leakage from high-pressure fuel piping
D155AX-5
TROUBLESHOOTING
Normal condition

Problems on machine
Solenoid resistance
Between CN-E42 (1) - (2): 2.3 - 5.3


Between CN-E54 (3) - (1): 4.6 - 5.4 V
Between CN-E54 (2) - (1): 0.3 - 4.7 V
1. Operates in normal control mode
1. Machine can be operated normally

Between CN-E53 (3) - (1): 4.6 - 5.4 V
Between CN-E53 (2) - (1): 0.3 - 4.7 V
1. Limits output in open control mode
1. Output is lowered
Sensor resistance (When water tem- 1. Operates in normal control mode

perature is 10 - 100C
Between CN-P7 (1) - (2): 90 k - 3.5
1. Water temperature signal output on

monitor panel is fixed to 90C
Sensor resistance (When water tem- 1. Operates in normal control mode

perature is 10 - 100C
Between CN-P31 (1) - (2): 9 k - 0.3
1. Exhaust gas color is bad when temperature is low

2. Engine does not start easily when
temperature is low
1. Operates machine with output lim- 1. Output is lowered

ited
1. Stops outputting to fuel supply pump 1. Output is lowered

2. Stops outputting to fuel injector
1. Derates engine output
2. Operates machine with output limited
D155AX-5
20-807
4

TROUBLESHOOTING
Service
E0484
E0487
E0488
E0489
E0490
E0491
No-pressure feed by
fuel supply pump 2
See E0483
1. Defective low oil pressure sensor

2. Defective high oil pressure sensor
between controller CN-4 (5) (low pressure) - low oil pressure sensor CN-P8
Abnormality in oil pres4. Disconnection or defective contact in wiring harness between controller CN-4 (6) (high
sure switch system
pressure) - high oil pressure sensor CN-P9
1. Defective power source relay

between starting switch terminal ACC - power source relay CN-CPR (1)
3. Disconnection or defective contact in wiring harness between power source relay CNCPR (2) - chassis ground
Abnormality in power 4. Disconnection, defective contact, or short circuit with chassis ground in wiring harness
supply system 1
between controller CN-7 (6), (14) - power source relay CN-CPR (3)
between battery relay terminal B - power source relay CN-CPR (5)
1 Defective power source relay
2. Short circuit with power source in wiring harness between controller CN-7 (6), (14) Abnormality in power
power source relay CN-CPR (3)
supply system 2
1. Defective setting of Q regulator switch

Abnormality in Q regu- 2. Defective engine controller
lator switch signal
1.
2.
Short circuit in starting
switch C system
3.
20-808
4

Short circuit with power source in wiring harness between controller CN-4 (2) - starting
switch terminal C
D155AX-5
TROUBLESHOOTING
Normal condition

Problems on machine
1. Stops outputting to fuel supply pump 1. Engine stops.

2. Stops outputting to fuel injector
Low-pressure switch resistance
Between CN-P8 - chassis ground
When engine speed is above 600 rpm:
Min. 1 M
High-pressure switch resistance
Between CN-P9 - chassis ground
When engine speed is above 1,300
rpm: Min. 1 M
Source voltage
Between CN-7 (6), (14) - (5), (13)
When starting switch is turned ON:
20 - 30 V
1. Engine stops during operation

2. Engine cannot be started.
Source voltage
Between CN-7 (6), (14) - (5), (13)
When starting switch is turned OFF:
Max. 8 V
Either of Q regulator switches 1 and 2 1. Operates in normal control mode

of controller is set to "F"
1. Setting of Q regulator cannot be

changed

Starting switch C signal voltage
Voltage between CN-4 (2) - chassis
ground
When starting switch is turned ON:
Max. 1 V
When starting switch is turned to
START position: 20 - 30 V
1. Machine can be operated normally 10

seconds after started
D155AX-5
20-809
4
TROUBLESHOOTING
JUDGMENT TABLE FOR ENGINE CONTROLLER AND ENGINE
Abnormality in controller drive circuit
Short circuit in fuel injector No. 4, No. 5, No. 6 system
Short circuit in fuel injector No. 1, No. 2, No. 3 system
Abnormality in G speed sensor system
Abnormality in Ne speed sensor system
E02
Abnormality in fuel control dial system
CALL CALL CALL0 CALL0 CALL0 CALL0 CALL0 CALL0 CALL0 E02
3
3
3
3
3
3
3
Abnormality in engine controller
User
code
Service
code
Abnormality in decelerator potentiometer system
Abnormality in engine controller power supply
Self-diagnosis display
E0401 E0402 E0405 E0406 E0409 E0410 E0458 E0459 E0460 E0461 E0462
Trouble mode
Engine does not start
Exhaust gas is discharged but engine does not

Engine does not start (does not start easily)
start easily
Exhaust gas is not discharged
Engine stops during operation
Output is insufficient
Acceleration is low
Engine speed keeps Exhaust gas is normal

at low idling and
does not follow up
Exhaust gas is very black
fuel control dial
Engine speed
rises to high
idling of itself
Engine speed is not set to low-low idling

Engine speed
cannot be set to
low idling
Engine speed is not set to high-low idling
Much fuel is
consumed
Engine speed rises immediately when error is displayed

Engine speed rises while error is displayed
Exhaust gas is normal

Exhaust gas is very black
10
Engine speed does not rise to high idling

Engine speed
cannot be set to Engine speed rises to high idling but returns to
high idling
low idling
11
Automatic warm-up operation is abnormal
12
Automatic decelerator does not work
13
Engine speed does not change when working mode is changed
14
Engine speed does not lower

Engine does not
Engine keeps running at low idling even after
stop
starting switch is turned off
15
Hunting in engine speed
16
Much oil is consumed or exhaust gas color is bad
17
Oil becomes dirty soon
18
Cooling water contains oil
19
Oil pressure caution lamp lights up
20
Oil level rises
21
Water temperature rises too high
22
Abnormal sound is made
23
Vibration is too high
Troubleshooting G-1 G-2 G-3 G-4 G-5 G-6 G-7 G-8

code
20-810
4
G-9 G-10 G-11
D155AX-5

E02
E02
E02
E02 CALL0 CALL0 CALL0 CALL0 E02 CALL0 E02 CALL0 E02
3
3
3
3
3
3
D155AX-5
Abnormally high common rail fuel pressure 2

No feed by fuel supply pump 1
No feed by fuel supply pump 2
E02
E02
E02
E02 CALL0 CALL CALL CALL0 CALL
3
3
Does starting motor rotate?
Short circuit in starting switch C signal system
Abnormality in Q regulator switch signal
Abnormality in pressure switch system
Abnormally high common rail fuel pressure 1
Abnormality in common rail fuel pressure
Abnormality in low water temperature sensor system
Abnormality in high water temperature sensor system
Abnormality in common rail fuel pressure sensor system
Abnormality in boost pressure sensor system
TROUBLESHOOTING
Self-diagnosis display
Troubleshooting code
displayed
when service
code is not
displayed
E0463 E0464 E0465 E0466 E0468 E0469 E0470 E0471 E0472 E0474 E0476 E0478 E0480 E0481 E0482 E0483 E0484 E0487 E0488 E0489 E0490 E0491
See volume of engine
G-12 G-13 G-14 G-15 G-16 G-17 G-18 G-19 G-20 G-21 G-22 G-23 G-24 G-25 G-25 G-26 G-26 G-27 G-28 G-29 G-30 G-31
20-811
TROUBLESHOOTING
G MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
20-812
4
D155AX-5
TROUBLESHOOTING
D155AX-5
20-813
4
G-1
TROUBLESHOOTING
G-1.
[E0401] (Abnormality in engine controller power supply) is

displayed
Cause
Remedy
1
Disconnect CN-4.
20 - 30 V
Is voltage between CN-4 (female) (7), NO

(18) and (8), (19) normal?
YES
Replace
Defective wiring harness between

CN4 - CN-E51
Replace

CN-E51 (14) - GND2
Repair or
replace

CN-E51 (female) (12) - CN-214
(female) (11)
Repair or
replace
Is voltage between CN-214 (male) (8) NO


CN-214 (8) - battery
Repair or
replace
YES

CN-214 (8) - (11) or defective
starting switch
Repair or
replace
2
Disconnect CN-E51.
20 - 30 V
NO
Is voltage between CN-E51 (female)

(12) and (14) normal?
YES
3
Disconnect CN-E51.
0
NO
Is resistance between CN-E51 (14)

YES
4
Disconnect CN-214.
20 - 30 V
NO
Is voltage between CN-214 (male)

YES
5
Disconnect CN-214.
20 - 30 V
G-1. Related electrical circuit diagram
20-814
4
D155AX-5
G-2
TROUBLESHOOTING
G-2.
[E0402] (Abnormality in engine controller) is displayed
Go to troubleshooting of error code [E0460].
D155AX-5
20-815
4
G-3
TROUBLESHOOTING
G-3.
[E0405] (Abnormality in fuel control dial system) is displayed

Cause
Remedy
1
Insert T-adapter in CN-FCS.
NO
Is voltage between CN-FCS (1) and

(3) 4.6 - 5.4 V?
YES
2
Insert T-adapter in CN-1
and CN-2.
Is voltage between CN-1 (4) and CN-2 NO

(10) 4.6 - 5.4 V?
3
Is resistance between CN-FCS (male) (1) and
(3), between (2) and (3), and between (2)
and chassis ground as shown in Table 1?
Repair or
replace

short circuit with chassis ground in
Repair or
(female) (4) - CN-FCS (female) (1) or replace
between CN-2 (female) (10) - CNFCS (female) (3)
YES

Disconnect CN-FCS.
NO
Defective fuel control dial
Replace

wiring harness between CN-1
(female) (6) - CN-FCS (female) (2)
Repair or
replace
Replace
YES
4
Disconnect CN-1 and
CN-2.
Is resistance between CN-1 (female) (4) and

CN-2 (10), between (6) and (10), and between
(6) and chassis ground as shown in Table 2?
NO
YES
Table 1
Table 2
CN-FCS (male)
Resistance
CN-1, CN-2 (male)
Resistance
Between (1) (3)
4.0 6.0 k
Between CN-1 (4) CN-2 (10)
4.0 6.0 k
Between (2) (3)
0.24 7.0 k
0.24 7.0 k
Between (2) GND
Min. 1M
Between CN-1 (6) GND
Min. 1M
20-816
4
D155AX-5
G-4
TROUBLESHOOTING
G-4.
[E0406] (Abnormality in decelerator potentiometer system) is

displayed
Cause
Remedy
1
Insert T-adapter in TS.
NO
Is voltage between CN-FCD (1) and

(3) 4.6 - 5.4 V?
YES
2
Insert T-adapter in CN-1
and CN-2.
Is voltage between CN-1 (4) and CN- NO

2 (10) 4.6 - 5.4 V?
Repair or
replace

Repair or
(female) (4) - CN-FCD (female) (1) or replace
between CN-2 (female) (10) - CNFCD (female) (3)
YES
3
Disconnect CN-FCD.
Is resistance between CN-FCD (male) (1) and

(3), between (2) and (3), and between (2)
and chassis ground as shown in Table 1?
NO
Defective decelerator potentiometer
Replace

(female) (6) - CN-FCD (female) (2)
Repair or
replace
Replace
YES
4
Disconnect CN-1 and
CN-2.
Is resistance between CN-1 (female) (4)

and CN-2 (10), between (7) and CN-2 (10),
and between CN-1 (7) and chassis ground
NO
YES
Table 1
Table 2
CN-FCD (male)
Resistance
CN-1, CN-2 (male)
Resistance
Between (1) (3)
4.0 6.0 k
4.0 6.0 k
Between (2) (3)
0.24 7.0 k
0.24 7.0 k
Between (2) GND
Min. 1M
Between CN-1 (7) GND
Min. 1M
D155AX-5
20-817
4
TROUBLESHOOTING
G-5.
G-5
[E0409] (Abnormality in Ne speed sensor system) is displayed

Cause

Disconnect CN-E51.
1
Is resistance between CN-E51 (male) NO
(1) and (2) and between (1), (2) and
chassis ground as shown in Table 1?
Remedy
Defective Ne speed sensor
Replace

(female) (5) - CN-E51 (female) (1) or
between CN-1 (female) (12) - CNE51 (female) (2)
Repair or
replace

Repair or
replace
Replace
YES
2

Disconnect CN-1.
NO
Is resistance between CN-1 (female)

(5) and (12) 85 - 210
YES
3

Disconnect CN-1 and
CN-E51.

(5) and (12) above 1 M?
NO
YES
Table 1
CN-E51 (male)
Resistance
Between (1) (2)
85 210
Between (1) (2) GND
Min. 1M
20-818
4
D155AX-5
TROUBLESHOOTING
G-6.
G-6
[E0410] (Abnormality in G speed sensor system) is displayed

Cause
Remedy
1
Disconnect CN-E52.

Defective G speed sensor
Replace

between CN-2 (female) (9) - CN-E52
(female) (2)
Repair or
replace

(female) (2)
Repair or
replace
Replace
YES
2
Disconnect CN-2.
NO

(1) and (9) 1 - 2 k?
YES
3
Disconnect CN-2 and
CN-E52.

(1) and (9) above 1 M?
NO
YES
Table 1
CN-E52 (male)
Resistance
Between (1) (2)
1 2 k
Between (1) (2) GND
Min. 1M
G-6). Related electrical circuit diagram
D155AX-5
20-819
4
TROUBLESHOOTING
G-7.
G-7
[E0458] (Short circuit in fuel injector No. 1, No. 2, No. 3 system)

is displayed
Since high voltage (110 - 130 V) is used for the electric circuit of the fuel injector, take care of an
electric shock and electric leakage, referring to TESTING AND ADJUSTING, "Handling of highvoltage controller circuit".
a) Judgment of abnormal system
Cause
Remedy
Abnormality in fuel injector system

No. 1
Go to
troubleshooting step b)

No. 2
Go to
troubleshooting step c)

No. 3
Go to
troubleshooting step d)

(female) (5), (13) - chassis ground
Repair or
replace
Replace
1
Disconnect CN-6.

NO
YES
2
Disconnect CN-6.

NO
YES
3
Disconnect CN-6.

NO
YES
4
Turn starting switch
OFF.
Disconnect CN-7.
Is resistance between CN-7 (female) (5), NO

(13) and chassis ground below 1 ?
YES
Table 1
CN-6 (female)
CN-6 (female)
CN-6 (female)
Resistance
Between (7) (8)
Between (4) (10)
Between (3) (9)
0.4 1.1
Between (7) (8) GND Between (4) (10) GND Between (3) (9) GND
20-820
4
Min. 1M
D155AX-5
TROUBLESHOOTING
G-7
b) Troubleshooting of fuel injector No. 1 system
Cause
Remedy
1
Disconnect CN-E31.

YES
Replace
Short circuit with chassis ground or

(female) (1) or between CN-6
(female) (8) - CN-E31 (female) (2)
Repair or
replace
Table 2
CN-E31 (female)
Resistance
Between (1) (2)
0.4 1.1
Between (1) (2) GND
Min. 1M
c) Troubleshooting of fuel injector No. 2 system

Cause
Remedy
1
Disconnect CN-E32.

YES
Replace

Repair or
replace
Table 2
CN-E32 (female)
Resistance
Between (1) (2)
0.4 1.1
Between (1) (2) GND
Min. 1M
d) Troubleshooting of fuel injector No. 3 system
Cause
Remedy
1
Disconnect CN-E33.

YES
Replace

Repair or
replace
Table 2
CN-E33 (female)
Resistance
Between (1) (2)
0.4 1.1
Between (1) (2) GND
Min. 1M
D155AX-5
20-821
4
TROUBLESHOOTING
G-7
G-7 a), b). Related electrical circuit diagram
G-7 a), c). Related electrical circuit diagram
G-7 a), d). Related electrical circuit diagram
20-822
4
D155AX-5
TROUBLESHOOTING
G-8.
G-8
[E0459] (Short circuit in fuel injector No. 4, No. 5, No. 6 system)

is displayed
a) Judgment of abnormal system
Cause
Remedy

No. 4
Go to
troubleshooting step b)

No. 5
Go to
troubleshooting step c)

No. 6
Go to
troubleshooting step d)

Repair or
replace
Replace
1
Disconnect CN-7.

NO
YES
2
Disconnect CN-7.

NO
YES
3
Disconnect CN-7.

NO
YES
4
Turn starting switch
OFF.
Disconnect CN-7.
Is resistance between CN-7 (female) (5), NO

YES
Table 1
CN-7 (female)
CN-7 (female)
CN-7 (female)
Resistance
Between (3) (9)
Between (1) (7)
Between (2) (8)
0.4 1.1
Between (3) (9) GND
D155AX-5
Between (1) (7) GND Between (2) (8) GND
Min. 1M
20-823
4
TROUBLESHOOTING
G-8
b) Troubleshooting of fuel injector No. 4 system

Cause
Remedy
1
Disconnect CN-E34.

YES
Table 2
CN-E34 (female)
Resistance
Between (1) (2)
0.4 1.1
Between (1) (2) GND
Min. 1M
Replace

Repair or
replace
c) Troubleshooting of fuel injector No. 5 system

Cause
Remedy
1
Disconnect CN-E35.

YES
Replace

Repair or
replace
Table 3
CN-E35 (female)
Resistance
Between (1) (2)
0.4 1.1
Between (1) (2) GND
Min. 1M
d) Troubleshooting of fuel injector No. 6 system

Cause
Remedy
1
Disconnect CN-E36.

YES
Replace

Repair or
replace
Table 4
CN-E36 (female)
Resistance
Between (1) (2)
0.4 1.1
Between (1) (2) GND
Min. 1M
20-824
4
D155AX-5
TROUBLESHOOTING
G-8
G-8 a), b). Related electrical circuit diagram
G-8 a), c). Related electrical circuit diagram
G-8 a), d). Related electrical circuit diagram
D155AX-5
20-825
4
TROUBLESHOOTING
G-9.
G-9
[E0460] (Abnormality in controller chassis ground circuit) is

displayed
When starting switch is turned on, error codes [E0458] and [E0459] are displayed, too.
Cause
Remedy
1
Disconnect CN-7.
Is resistance between CN7 (female) (5), NO


Repair or
replace
Replace
YES
20-826
4
D155AX-5
G-10
TROUBLESHOOTING
G-10. [E0461] (Disconnection in fuel injector No. 1 system) is displayed

Cause
Remedy

Disconnect CN-E31.

(1) and (2) 0.4 - 1.1 ?
Replace

(female) (2)
Repair or
replace
Replace
YES
2

Disconnect CN-6.

(7) and (8) 0.4 - 1.1 ?
NO
YES
D155AX-5
20-827
4
G-11
TROUBLESHOOTING

Cause
Remedy
1
Disconnect CN-E32.

(1) and (2) 0.4 - 1.1 ?
Replace

Repair or
replace
Replace
YES
2
Disconnect CN-6.

(4) and (10) 0.4 - 1.1 ?
NO
YES
20-828
4
D155AX-5
G-12
TROUBLESHOOTING

Cause
Remedy

Disconnect CN-E33.

(1) and (2) 0.4 - 1.1 ?
Replace

(female) (2)
Repair or
replace
Replace
YES
2

Disconnect CN-6.

(3) and (9) 0.4 - 1.1 ?
NO
YES
D155AX-5
20-829
4
G-13
TROUBLESHOOTING

Cause
Disconnect CN-E34.
1
(1) and (2) 0.4 - 1.1 ?
Remedy
Replace

(female) (2)
Repair or
replace
Replace
YES
2

Disconnect CN-7.

(3) and (9) 0.4 - 1.1 ?
NO
YES
20-830
4
D155AX-5
TROUBLESHOOTING
G-14

Cause
Remedy

Disconnect CN-E35.

(1) and (2) 0.4 - 1.1 ?
Replace

(female) (2)
Repair or
replace
Replace
YES
2

Disconnect CN-7.

(1) and (7) 0.4 - 1.1 ?
NO
YES
D155AX-5
20-831
4
TROUBLESHOOTING
G-15

Cause
Remedy

Disconnect CN-E36.

(1) and (2) 0.4 - 1.1 ?
Replace

(female) (2)
Repair or
replace
Replace
YES
2

Disconnect CN-7.

(2) and (8) 0.4 - 1.1 ?
NO
YES
20-832
4
D155AX-5
TROUBLESHOOTING
G-16
G-16. [E0468] (Overcurrent in fuel supply pump PCV1 system) is

displayed
Cause
Disconnect CN-E41.
1
Remedy
Defective fuel supply pump PCV1
Replace

between CN-7 (female) (10) - CNE41 (female) (1) or between CN-7
Repair or
replace
Replace
YES

Disconnect CN-7.
2
Is resistance between CN-7 (female) (10) NO
and (11) and between (10), (11) and
YES
Table 1
Table 2
CN-E41 (male)
Resistance
CN-7 (male)
Resistance
Between (1) (2)
2.3 5.3
Between (10) (11)
2.3 5.3
Min. 1M
Between (10), (11) chassis ground
Min. 1M
D155AX-5
20-833
4
TROUBLESHOOTING
G-17
G-17. [E0469] (Disconnection in fuel supply pump PCV1 system) is

displayed
Cause
Disconnect CN-E41.
1
(1) and (2) 2.3 - 5.3 ?
Remedy
Replace
YES

Disconnect CN-7.
2
NO
(10) and (11) and between (11) and
YES

Repair or
replace
or between CN-7 (female) (11) - CNE41 (female) (2)
Replace
Table 1
CN-7 (male)
Resistance
Between (10) (11)
2.3 5.3
Between (11) chassis ground
Min. 1M
20-834
4
D155AX-5
G-18
TROUBLESHOOTING
G-18. [E0470] (Overcurrent in fuel supply pump PCV2 system) is

displayed
Cause
Remedy

Disconnect CN-E42.

Replace

Repair or
replace
Replace
YES
2

Disconnect CN-7.

NO
YES
Table 1
Table 2
CN-E42 (male)
Resistance
CN-7 (male)
Resistance
Between (1) (2)
2.3 5.3
Between (4) (12)
2.3 5.3
Min. 1M
Min. 1M
D155AX-5
20-835
4
TROUBLESHOOTING
G-19
G-19. [E0471] (Disconnection in fuel supply pump PCV2 system) is

displayed
Cause
Remedy
1
Disconnect CN-E42.

(1) and (2) 2.3 - 5.3 ?
Replace

Repair or
replace
Replace
YES

Disconnect CN-7.
2
NO
YES
Table 1
CN-7 (male)
Resistance
Between (4) (12)
2.3 5.3
Min. 1M
20-836
4
D155AX-5
TROUBLESHOOTING
G-20
G-20. [E0472] (Abnormality in boost pressure sensor system) is

displayed
Cause
Remedy
1
Connect T-adapter to CN-2.
Is voltage between CN-2 (2) and (10) NO

4.6 - 5.4V?
YES
2
Disconnect CN-E54.
NO
Is voltage between CN-E54 (3) and

(1) 4.6 - 5.4V?
YES

Repair or
replace
Defective boost pressure sensor
Repair
Repair

Repair or
replace
Defective boost pressure sensor
Repair
3
Connect T-adapter to CN-1
and CN-2.

2 (10) 0.3 - 4.7 V?
YES
4
Disconnect CN-1 and CNE54

CN-E54 (female) (2) and between CN-1 (female)
NO
YES
Table 3
CN-1 and CN-E35 (female)
Resistance
Between CN-1 (3) - CN-E54 (2)
Max. 1
CN-1 (3) and chassis ground
Max. 1M
D155AX-5
20-837
4
TROUBLESHOOTING
G-21
G-21. [E0474] (Abnormality in common rail fuel pressure sensor system)

is displayed
Cause
Remedy
1
Is voltage between CN-2 (2) and (10) NO

4.6 - 5.4V?
YES
2
Disconnect CN-E53.
NO
Is voltage between CN-E53 (1) and

(3) 4.6 - 5.4V?
YES

Repair or
replace
Defective common rail fuel

pressure sensor
Repair
Repair

Repair or
replace

pressure sensor
Repair
3
Connect T-adapter to
CN-1 and CN-2.

2 (10) 0.3 - 4.7 V?
YES
4
Disconnect CN-1 and
CN-E53

CN-E53 (female) (2) and between CN-1 (female)
YES
NO
Table 1
CN-1, CN-E53 (female)
Resistance
Between CN-1 (1) CN-E53 (2)
Max. 1
CN-1 (1) and chassis ground
Max 1M
20-838
4
D155AX-5
TROUBLESHOOTING
G-22
G-22. [E0476] (Abnormality in high engine water temperature sensor

Cause
Remedy
1
Disconnect CN-P7.
Water temperature: 10 - 100C
Is resistance between CN-P7 (male)

NO
Defective high water temperature

sensor
Replace

(female) (4) - CN-P7 (female) (1) or
between CN-2 (female) (10) - CN-P7
(female) (2)
Repair or
replace

(female) (4) - CN-P7 (female) (1)
Repair or
replace
Replace
YES
2
Disconnect CN-2.
NO

(4) and (10) 90 k - 3.5 k?
YES
3

Disconnect CN-2 and
CN-P7.

(4) and chassis ground above 1 M?
NO
YES
Table 1
CN-P7 (male)
Resistance
Between (1) (2)
90 k 3.5 k
Min. 1M
D155AX-5
20-839
G-23
TROUBLESHOOTING
G-23. [E0478] (Abnormality in low engine water temperature sensor

Cause
Remedy
1
Disconnect CN-P31.
Is resistance between CN-P31 (male) NO

Defective low water temperature

sensor
Replace

(female) (3) - CN-P31 (female) (1) or
between CN-2 (female) (10) - CNP31 (female) (2)
Repair or
replace

(female) (3) - CN-P31 (female) (1)
Repair or
replace
Replace
YES
2
Disconnect CN-2.
NO

(3) and (10) 9 k - 0.3 k?
YES
3

Disconnect CN-2 and
CN-P31.

(3) and chassis ground above 1 M?
NO
YES
Table 1
CN-P31 (male)
Resistance
Between (1) (2)
9 k 0.3 k
Min. 1M
20-840
D155AX-5
TROUBLESHOOTING
G-24
G-24. [E0480] (Abnormality in common rail fuel pressure system) is

displayed
Go to error code [E0481] and [E0482].
D155AX-5
20-841
4
TROUBLESHOOTING
G-25
G-25. [E0481] (Abnormality in high common rail fuel pressure 1 system) is

displayed
[E0482] (Abnormality in high common rail fuel pressure 2 system) is
displayed
Cause
Remedy
Go to
troubleshooting of
displayed
error code.
1
NO
Is any other error code displayed,

too?
YES
2
NO
Is proper fuel matched to atmospheric temperature used?
Improper fuel
Replace
YES
3
Loosen joint of fuel
supply pump overflow
valve
When priming pump is operated, does NO

fuel leak through joint connector?
YES
4
Disassemble fuel supply
pump overflow valve
Is spring broken or is seat worn or is NO

ball seized in overflow valve?
YES
Go to
troubleshooting No. 7
Defective overflow valve
Replace
Replace
Defective electrical system of

common rail fuel pressure sensor
Repair or
replace
Defective mechanical system of

common rail fuel pressure sensor
Replace
Clogging of overflow pipe
Repair or
replace
5
Loosen joint of common
rail pressure limiter
NO
When engine is started, does fuel

leak through joint connector?
YES
6
Is any trouble in electrical system
detected by troubleshooting of error
code [E0474]?
NO
YES
7
Is overflow pipe clogging?
NO
YES
20-842
4
D155AX-5
TROUBLESHOOTING
G-26
G-26. [E0483] (No-pressure feed by fuel supply pump 1) is displayed

[E0484] (No-pressure feed by fuel supply pump 2) is displayed
Cause
Remedy
Go to
troubleshooting of
displayed
error code.
1
NO
Is any other error code displayed,

too?
YES
2
NO
Is proper fuel matched to atmospheric temperature used?
Improper fuel
Replace
Fuel leakage through high-pressure

circuit
Repair or
replace
Defective low-pressure circuit

devices (See Note 1)
Repair or
replace
Replace
Defective fuel injector
Replace

pressure sensor
Replace
Defective fuel supply pump
Replace
Defective electrical system of fuel

supply pump PCV
Repair or
replace
YES
3
Visually inspect while engine is
stopped, then inspect while
engine is running at low idling.
NO
Does fuel leak through fuel pump, highpressure primary piping, common rail, or
high-pressure secondary piping?
YES
4
Measure fuel pressure (See
TESTING AND ADJUSTING).
Run engine at high idling.
Is pressure in low-pressure fuel circuit NO

0.15 - 0.3 MPa {1.5 - 3.0 kg/cm2}?
YES
Disconnect outlet pipe of
common rail pressure
limiter.
Start engine.
5
NO
Is fuel drainage from pressure

limiter below 10 cc/min?
YES
6
Disconnect either PCV
connector.
Start engine.
When either PCV connector of fuel

pump is disconnected, does engine
stop?
NO
YES
7
Disconnect spill collection hose of injector.
Start engine.
NO
Is spill rate of injector normal (See

Note 2)?
YES
8
Is any trouble in electrical system detected NO
by troubleshooting of error codes [E0468],
[E0469], [E0470], and [E0471]?
YES
D155AX-5
20-843
4
TROUBLESHOOTING
G-26
Note 1: If the equipment in the low-pressre circuit is defective, inspect the following points.
1) Remaining amount of fuel
2) Stuck, worn feed pump, clogged filter
3) Leakage, clogged low-pressure fuel piping
4) Defective actuation of bypass valve, incorrect assembly with other parts (See Fig. 1)
5) Clogged fuel filter
6) Fuel entering oil pan (fuel leakage inside head cover)
Fig. 1 Mounting positions of bypass valve (1), bypass valve (2), fuel inlet port joint
Note 2: Method of measuring amount of fuel spill flow

The fuel in the spill line is at high temperature (up to 90C), so be careful not to burn youself
during the operation.
1) Disconnect the hose connected to the spill tube return collection portion (rear of engine).
2) Connect another hose to the tip of the spill tube, and collect the spill fuel in a container.
3) Start the engine, stall the engine at each speed, and measure the spill fuel amount for 1
minute.
Limits for fuel spill amount (total for 6 cylinders)
Stall speed (rpm)
Spill limit (cc/min)
1,600
720
1,700
765
1,800
810
1,900
855
2.000
900
20-844
4
D155AX-5
TROUBLESHOOTING
G-27
G-27. [E0487] (Abnormality in engine oil pressure switch system) is

displayed
Cause
Remedy
1
Insert T-adapter in CN-4.
NO
YES
2
Disconnect CN-P8.
Is resistance between CN-P8 (switch

side) and chassis ground as shown
in Table 2?
NO
YES
Defective low oil pressure switch
Replace

(female) (5) - CN-P8
Repair or
replace
Replace
Defective high oil pressure switch
Replace

(female) (5) - CN-P9
Repair or
replace
3
Insert T-adapter in CN4.
NO
YES
4
Disconnect CN-P9.
Is resistance between CN-P9 (switch

side) and chassis ground as shown
in Table 4?
NO
YES
Table 1
CN-4 (male)
Between (5)
chassis ground
Table 2
Engine
Voltage
CN-P8
Engine
Resistance
Stopped
Max. 1 V
Stopped
Max. 1
Above 600 rpm
20 30 V
Between CN-P8
(switch) - chassis
ground
Above 600 rpm
Min. 1 M
Table 3
CN-4
Between (6)
chassis ground
D155AX-5
Table 4
Engine
Resistance
CN-P9
Engine
Resistance
Stopped
Max. 1 V
Stopped
Max. 1
Above 600 rpm
20 30 V
Between CN-P9
(switch) - chassis
ground
Above 1,300 rpm
Min. 1 M
20-845
4
TROUBLESHOOTING
G-27
20-846
4
D155AX-5
TROUBLESHOOTING
G-28
G-28. [E0488] (Abnormality in power supply system 1) is displayed

Cause
Remedy
1
NO
Is voltage between CN-7 (6), (14)

and (5), (13) 20 - 30 V?
YES
Replace
Defective power source relay (coil

side)
Replace

wiring harness between starting
switch terminal ACC - CN-CPR
(female) (1)
Repair or
replace

in wiring harness between CN-CPR
Repair or
replace
2
Disconnect CN-CPR.
NO
Is resistance between CN-CPR

(male) (1) and (2) 200 - 400 ?
YES
3
Insert T-adapter in CNCPR.
NO
Is voltage between CN-CPR (1) and

chassis ground 20 - 30 V?
YES
4
Disconnect CN-CPR.
Is resistance between CN-CPR

below 1?
NO
YES
5
NO

Defective battery relay or disconnection, defective contact, or short

circuit with chassis ground in wiring Repair or
replace
harness between terminal B - CNCPR (female) (5)
YES
6

YES
D155AX-5
NO
Defective power source relay

(contact side)
Replace

(female) (6), (14) - CN-CPR (female)
(3)
Repair or
replace
20-847
4
TROUBLESHOOTING
G-28
20-848
4
D155AX-5
TROUBLESHOOTING
G-29
G-29. [E0489] (Abnormality in power supply system 2) is displayed

Caution
Remedy
1
Is voltage between CN-7 (6), (14) and NO

(5), (13) below 8 V?
YES
Replace
Defective power source relay

(contact side)
Replace

(female) (6) (14) - CN-CPR (female)
(5)
Repair or
replace
2
Disconnect CN-CPR.
Is voltage between CN-7 (6), (14) (5), (13) below 8 V?
YES
NO
D155AX-5
20-849
4
TROUBLESHOOTING
G-30
G-30. [E0490] (Abnormality in Q regulator switch signal) is displayed
Caution
Remedy
1
Are both of Q regulator switches 1
and 2 set to "F"?
NO
Replace
Defective setting of Q regulator
Readjust
YES
20-850
4
D155AX-5
G-31
TROUBLESHOOTING
G-31. [E0491] (Short circuit in starting switch C system) is displayed

Caution
Remedy
1
NO

chassis ground below 1 V?
YES
Replace
Replace

(female) (2) - starting switch
terminal C
Repair or
replace
2
Disconnect starting
switch terminal C.
Is voltage between starting switch

terminal C and chassis ground
below 1 V?
YES
NO
D155AX-5
20-851
4
TROUBLESHOOTING
20-852
4
(Blank page)
D155AX-5
TROUBLESHOOTING
TROUBLESHOOTING OF HSS CONTROLLER AND

ELECTRICAL SYSTEM
(E MODE)
Electrical circuit diagram for E mode .................................................................................................. 20-910
E-1. [E0113] (Drop of HSS controller power supply voltage) is displayed ................................... 20-912
E-2. [E0143] (Abnormality in HSS controller 5V power supply voltage) is displayed ................. 20-913
E-3. [E0145] (Abnormality in HSS controller sensor power supply voltage) is displayed .......... 20-914
E-4. [E0161] (Abnormality in HSS controller memory data of offset current) is displayed ........ 20-915
E-5. [E0221] (Abnormality in gear speed switch system) is displayed ......................................... 20-916
E-6. [E0233] (Short circuit in travel REVERSE sensing potentiometer system) is displayed ...... 20-917
E-7. [E0233] (Disconnection in travel REVERSE sensing potentiometer system) is displayed ... 20-918
E-8. [E0237] (Abnormality in transmission NEUTRAL signal) is displayed .................................. 20-920
E-9. [E0272] (Unequality between travel REVERSE sensing potentiometer signal and
backup alarm switch signal) is displayed .................................................................. 20-921
E-10. [E0360] (Disconnection in work equipment oil pressure sensor system) is displayed ........ 20-923
E-11. [E0361] (Short circuit in work equipment oil pressure sensor system) is displayed ........... 20-924
E-12. [E0610] (Disconnection in backup alarm relay system) is displayed ..................................... 20-925
E-13. [E0611] (Short circuit in backup alarm relay system) is displayed ........................................ 20-926
E-14. [E0730] (Abnormality in both steering potentiometer systems 1 and 2) is displayed ........ 20-927
E-15. [E0731] (Large difference between steering potentiometer systems 1 and 2: Case I)
is displayed ...................................................................................................................... 20-928
E-16. (Abnormality in steering potentiometer system on one side and
large deviation of neutral position on one side) is displayed ....................................... 20-929
E-17. [E0733] (Disconnection in steering potentiometer system 1) is displayed ........................... 20-930
E-18. [E0733] (Short circuit in steering potentiometer system 1) is displayed .............................. 20-931
E-19. [E0734] (Disconnection in steering potentiometer system 2) is displayed ........................... 20-932
E-20. [E0734] (Short circuit in steering potentiometer system 2) is displayed .............................. 20-933
E-21. [E0735] (Large difference between steering potentiometer systems 1 and 2: Case II)
is displayed ....................................................................................................................... 20-934
E-22. [E0768] (Disconnection in steering oil pressure sensor A system) is displayed .................. 20-935
E-23. [E0769] (Short circuit in steering oil pressure sensor A system) is displayed ..................... 20-936
E-24. [E0770] (Disconnection in steering oil pressure sensor B system) is displayed .................. 20-937
E-25. [E0771] (Short circuit in steering oil pressure sensor B system) is displayed ..................... 20-938
E-26. [E0772] (Disconnection in HSS pump solenoid A system) is displayed ............................... 20-939
E-27. [E0773] (Short circuit in HSS pump solenoid A system) is displayed .................................. 20-940
E-28. [E0774] (Disconnection in HSS pump solenoid B system) is displayed................................ 20-941
E-29. [E0775] (Short circuit in HSS pump solenoid B system) is displayed ................................... 20-942
E-30. [E0930] (Abnormality in engine speed sensor system) is displayed ..................................... 20-943
E-31. Backup alarm does not sound ................................................................................................... 20-944
E-32. Blade pitch malfunctions (Machine equipped with pitch dozer) ............................................ 20-945
E-33. Ripper pin puller malfunctions (Machine equipped with giant ripper) ................................. 20-947
E-34. Engine does not start (Engine does not rotate) ....................................................................... 20-949
removed.
D155AX-5
20-901
4
TROUBLESHOOTING


Error
code
Abnormal
system
Drop of HSS
E0113 controller
power supply
voltage

When controller power source voltage lowers below 17 V

Voltage between CN-ST1 (8), (18) - (9),
1. Disconnection or defective contact in wiring harness between
(19): 20 - 30 V
controller CN-ST1 (8), (18) - fuse 5
CN-ST1 (9), (19) - chassis ground
3. Lowering of battery voltage or defective fuse 5
When source voltage of 5 V for HSS controller sensor lowers Voltage between CN-ST2 (10) - CN-RSS
below 4.5 V or rises above 5.5 V
(3): 4.5 - 5.5 V
Abnormality in
1. Disconnection or defective contact in wiring harness between Voltage between CN-ST2 (10) - CN-STR
HSS controller
CN-RSS (1) - CN-ST2 (10)
(4): 4.5 - 5.5 V
E0143
5V power
supply
CN-STR (4) - CN-ST2 (10)
When source voltage for HSS controller sensor lowers below Voltage between CN-ST1 (13) - (9), (19):
Abnormality in
17 V
17 - 30 V
E0145 HSS controller 1. Disconnection or defective contact in wiring harness between
sensor power
CN-ST (13) - (9), (19)
supply
Abnormality in When offset current determined by neutral adjustment of steer- When starting switch is turned OFF, offing system cannot be saved in non-volatile memory
set current is saved in non-volatile
E0161 memory data of
memory.
offset current
Abnormality in
E0221 gear speed
switch system
1. Abnormality in signal of switch used to display gear speed on Set joystick in 3rd or 2nd gear speed position.
monitor panel
3rd or 2nd gear speed: 20 - 30 V
Set joystick in 1st or 2nd gear speed position.
1st or 2nd gear speed: 20 - 30 V
When signal voltage of sensing potentiometer rises above Voltage between CN-ST3 (10) - CN-ST2
4.700 V
(9)
Short circuit in
When joystick is in neutral: Max. 3.500 V
travel REVERSE 1. Defective reverse sensing potentiometer
When joystick is in reverse position: 3.500
E0233 sensing
controller CN-ST2 (9) - potentiometer CN-RSS (3)
- 4.400 V
potentiometer
system
controller CN-ST3 (10) - potentiometer CN-RSS (2)
When signal voltage of sensing potentiometer lowers below Voltage between CN-ST3 (10) - CN-ST2
0.300 V
(9)
1. Defective reverse sensing potentiometer
When joystick is in neutral: Max. 3.500 V
2. Disconnection, defective contact, or short circuit with chassis
When joystick is in reverse position: 3.500
ground in wiring harness between controller CN-ST3 (10) - 4.400 V
potentiometer CN-RSS (2)
ground in wiring harness between controller CN-ST2 (10) potentiometer CN-RSS (1)
Voltage between CN-6 (1) - chassis
1.
Abnormality in
ground: 18 - 30 V
transmission
E0237
3. Disconnection or defective contact in wiring harness between Voltage between CN-ST3 (6) - chassis
NEUTRAL signal
ground: 18 - 30 V
CN-6 (1), (5) - CN-ST3 (6), (4)
Disconnection
in travel
E0233 REVERSE
sensing
potentiometer
system
Unequality of
travel REVERSE
sensing
E0272 potentiometer
signal and
backup alarm
switch signal
When reverse sensing potentiometer and backup alarm switch When joystick is in neutral
signal do not conform to each other
Voltage between CN-ST3 (10) - CN-ST2
1. When error code [E0233] is displayed
(9): Max. 3.500 V
2. Defective backup alarm switch
Voltage between CN-ST2 (7) - (9): 20 - 30 V
3. Disconnection, defective contact, or short circuit with chassis When joystick is in reverse position
ground in wiring harness between controller CN-ST2 (7) Voltage between CN-ST3 (10) - CN-ST2
backup alarm switch CN-25 (3)
(9): Max. 3.500 - 4.400 V
Voltage between CN-ST2 (7) - (9): Max. 1 V
backup alarm switch CN-25 (3) - chassis ground
Disconnection
in work
E0360 equipment oil
pressure
sensor system
When signal voltage of work equipment circuit oil pressure Voltage between CN-ST3 (2) - CN-ST2 (9)
sensor lowers below 0.500 V
When all work equipment is in neutral:
0.90 - 1.20 V
When blade is raised to relief: 2.45 - 2.90 V
CN-S51 (13) - oil pressure sensor CN-HHP (2)
ground in wiring harness between CN-ST3 (2) oil pressure
sensor CN-HHP (3)
20-902
4
D155AX-5
TROUBLESHOOTING


1. Stops all outputs.
1. Machine cannot be steered.
1. Cannot repair (Internal trouble of controller).
1. Machine may deviate from straight travel line.
1. Outputs error code and display " " on panel.
1. Gear speed is not displayed on monitor panel.
1. Controls with signal of backup alarm switch.

2. Flashes warning lamp and sounds warning buzzer.
1. Machine can be driven and steered normally.
1. Controls with signal of backup alarm switch.

1. Controls with signal of backup alarm switch, if error code

[E0233] is displayed.
2. Controls with signal of reverse sensing potentiometer, if error
code [E0233] is not displayed.
1. If machine is steered when work equipment is relieved, engine

1. Calculates with work equipment oil pressure at 0.
may stall.
2. Cannot limit inclination angle of HSS pump when work equip2. Only travel and steering operations can be executed normally.
ment is relieved.
D155AX-5
20-903
4
TROUBLESHOOTING
Error
code
Abnormal
system


Short circuit in
work equipE0361 ment oil
pressure
sensor system
When signal voltage of oil pressure sensor B rises above 6.000 V Voltage between CN-ST3 (2) - CN-ST2 (9)
When all work equipment is in neutral:
0.90 - 1.20 V
When blade is raised to relief: 2.45 - 2.90 V
controller CN-ST3 (2) - oil pressure sensor CN-HHP (3)
controller CN-ST2 (9) - oil pressure sensor CN-HHP (1)
Disconnection
in backup
E0610 alarm relay
system

Voltage between CN-ST1 (11) - chassis
ground
controller CN-ST1 (11) - relay CN-014 (1)
When joystick is in neutral: Max. 1 V
When joystick is in reverse position: 20 relay CN-014 (2) - chassis ground
30 V
Short circuit
in backup
E0611 alarm relay
system
Voltage between CN-ST1 (11) - chassis

ground
2. Short circuit with chassis ground in harness between controlWhen joystick is in neutral: Max. 1 V
ler CN-ST (11) - relay CN-014 (1)
When joystick is in reverse position: 20 - 30 V
Abnormality
in both
E0730 steering
potentiometer
systems 1 and
2
When signal voltages of steering potentiometer systems 1 and Voltage between CN-ST2 (19) - (9) (System 1)
When steering system is in neutral: 2.4 - 2.6 V
2 lower to 0.500 V or rise to 4.500 V at same time
When steering system is turned to left end:
4.1 - 4.3 V
When steering system is turned to right end:
0.73 - 0.89 V
Voltage between CN-ST2 (20) - (9) (System 2)
0.6 - 1.1 V
3.9 - 4.4 V
Sum of signal voltages of above systems 1
and 2 (VSUM)
4.6 V < VSUM < 5.4 V
Large
difference
between
E0731 steering
potentiometer
systems 1 and
2I
If both potentiometers are normal when starting switch is Voltage between CN-ST2 (19) - (9) (System 1)
turned ON but sum of signal voltages (VSUM) of potentiometer
system 1 and potentiometer system 2 goes out of following
range afterward
4.1 - 4.3 V
0.73 - 0.89 V
0.6 - 1.1 V
3.9 - 4.4 V
and 2 (VSUM)
4.6 V < VSUM < 5.4 V
Abnormality
in steering
potentiometer
system of one
E0732 side and large
deviation of
neutral
position
If both steering potentiometer systems have following abnor- Voltage between CN-ST2 (19) - (9) (System 1)
malities when starting switch is turned on
1) Disconnection, defective contact, or short circuit in one sys4.1 - 4.3 V
tem
2) Large deviation of neutral position of one system (2.3 V < Signal
0.73 - 0.89 V
voltage < 2.7 V)
2 Defective HSS controller
0.6 - 1.1 V
3.9 - 4.4 V
and 2 (VSUM)
4.6 V < VSUM < 5.4 V
Disconnection
E0733 in steering
potentiometer
system 1
When signal voltage of steering potentiometer 1 rises above Voltage between CN-ST2 (19) - (9)
4.500 V
1. Defective potentiometer
4.1 - 4.3 V
2. Disconnection, defective contact, or short circuit with power
source in wiring harness between controller CN-ST2 (19) 0.73 - 0.89 V
potentiometer CN-STR (3)
controller CN-ST2 (9) - potentiometer CN-STR (1)
20-904
4
D155AX-5
TROUBLESHOOTING


1. If machine is steered when work equipment is relieved, engine

1. Calculates with work equipment oil pressure at 0.
may stall.
2. Cannot limit inclination angle of HSS pump when work equip2. Only travel and steering operations can be executed normally.
ment is relieved.
1. Does not take particular action.
1. Backup alarm does not sound.
1. Stops outputting to backup alarm relay.
1. Backup alarm does not sound.
1. Controls with signal before occurrence of abnormality until 1. Steering operation before occurrence of abnormality is continued until machine is stopped.
machine is stopped.
2. Machine cannot be steered once it is stopped.
machine is stopped.
1. Controls with signal before occurrence of abnormality until ma- 1. Steering operation before occurrence of abnormality is continued
chine is stopped.
until machine is stopped.
1. Controls with signal of steering potentiometer system 2.

D155AX-5
20-905
4
TROUBLESHOOTING
Error
code
Abnormal
system


Short circuit
in steering
E0733 potentiometer
system 1
When signal voltage of steering potentiometer 1 lowers below Voltage between CN-ST2 (19) - (9)
0.500 V
2.4 - 2.6 V
4.1 - 4.3 V
ground in wiring harness between CN-ST2 (10) - potentiometer
CN-STR (4)
0.73 - 0.89 V
3. Short circuit with chassis ground in harness between controller CN-ST2 (19) - potentiometer CN-STR (3)
Disconnection
in steering
E0734 potentiometer
system 2
When signal voltage of steering potentiometer 2 rises above Voltage between CN-ST2 (20) - (9)
4.500 V
2.4 - 2.6 V
2. Disconnection, defective contact, or short circuit with power
source in wiring harness between controller CN-ST2 (20) 0.6 - 1.1 V
potentiometer CN-STR (2)
3.9 - 4.4 V
controller CN-ST2 (9) - potentiometer CN-STR (1)
Short circuit
in steering
E0734 potentiometer
system 2
When signal voltage of steering potentiometer 2 lowers below

0.500 V
ground in wiring harness between CN-ST2 (10) - potentiometer
CN-STR (4)
3. Short circuit with chassis ground in harness between controller CN-ST2 (20) - potentiometer CN-STR (2)
Large
difference
between
signal values
E0735 of steering
potentiometer
systems 1
and 2 II
Voltage between CN-ST2 (20) - (9)

2.4 - 2.6 V
0.6 - 1.1 V
3.9 - 4.4 V
If sum of signal voltages (VSUM) of potentiometer system 1 Voltage between CN-ST2 (19) - (9) (System 1)
and potentiometer system 2 goes out of following range when
starting switch is turned on
4.1 - 4.3 V
4.41 V < VSUM < 5.59 V
0.73 - 0.89 V
0.6 - 1.1 V
3.9 - 4.4 V
and 2 (VSUM)
4.6 V < VSUM < 5.4 V
Disconnection
in steering oil
E0768 pressure
sensor A
system
When signal voltage of oil pressure sensor A lowers below

0.500 V
CN-ST1 (13) - oil pressure sensor CN-ST1 (2)
ground in wiring harness between controller CN-ST3 (1) - oil
pressure sensor CN-ST1 (3)
Short circuit
in steering oil
E0769 pressure
sensor A
system
When signal voltage of oil pressure sensor A rises above Voltage between CN-ST3 (1) - CN-ST2 (9)
6.000 V
0.90 - 1.50 V
When steering system is relieved (on right
controller CN-ST3 (1) - oil pressure sensor CN-ST1 (3)
or left side): 3.95 - 4.60 V
Disconnection
in steering oil
E0770 pressure
sensor B
system
When signal voltage of oil pressure sensor B lowers below Voltage between CN-ST3 (9) - CN-ST2 (9)
0.500 V
0.90 - 1.50 V
CN-ST1 (13) - oil pressure sensor CN-ST2 (2)
or left side): 3.95 - 4.60 V
ground in wiring harness between controller CN-ST3 (9) - oil
pressure sensor CN-ST2 (3)
20-906
4
Voltage between CN-ST3 (1) - CN-ST2 (9)

0.90 - 1.50 V
or left side): 3.95 - 4.60 V
D155AX-5
TROUBLESHOOTING





machine is stopped.
1. Calculates with steering circuit oil pressure at 0.

1. If machine is steered under heavy load, engine may stall.
2. Cannot limit inclination angle of HSS pump when steering 2. Machine is steered normally under light load.
circuit pressure is high or steering circuit is relieved.

2. Cannot limit inclination angle of HSS pump when steering cir- 2. Machine is steered normally under light load.
cuit pressure is high or steering circuit is relieved.

2. Cannot limit inclination angle of HSS pump when steering cir- 2. Machine is steered normally under light load.
cuit pressure is high or steering circuit is relieved.
D155AX-5
20-907
4
TROUBLESHOOTING
Error
code
Abnormal
system


Short circuit in
steering oil
E0771 pressure
sensor B
system
When signal voltage of oil pressure sensor B rises above 6.000 V Voltage between CN-ST3 (9) - CN-ST2 (9)
0.90 - 1.50 V
or left side): 3.95 - 4.60 V
Disconnection
in HSS pump
E0772 solenoid A
system
1. Defective HSS pump solenoid A

controller CN-ST1 (4) - solenoid CN-PUPA (1)
Resistance between CN-PUPA (male) (1)

- (2): 10 - 20
Between CN-ST1 (female) (4) - (15): 10 - 20
Display of LED when starting switch is turned
on (under normal condition)
When machine is steered to right or left end:
93 - 94 (Output current: 930 - 940 mA)
Short circuit in
E0773 HSS pump
solenoid A
system
1. Defective HSS pump solenoid A

2. Short circuit with chassis ground in harness between controller CN-ST1 (4) - solenoid CN-PUPA (1)
Resistance between CN-PUPA (male) (1) (2): 10 - 20

Between CN-ST1 (female) (4) - (15): 10 - 20
Display of LED when starting switch is turned
on (under normal condition)
When machine is steered to right or left end:
93 - 94 (Output current: 930 - 940 mA)
Disconnection
in HSS pump
E0774 solenoid B
system
Resistance between CN-PUPB (male) (1) 1. Defective HSS pump solenoid B

(2): 10 - 20
Between CN-ST1 (female) (4) - (15):
controller CN-ST1 (5) - solenoid CN-PUPB (1)
10 - 20
Display of LED when starting switch is
turned on (under normal condition)
When machine is steered to right or left
end: 93 - 94 (Output current: 930 - 940 mA)
Short circuit in
HSS pump
E0775 solenoid B
system
Abnormality
in engine
E0930 speed sensor
system
20-908
4
1. Defective HSS pump solenoid B

2. Short circuit with chassis ground in harness between controller CN-ST1 (5) - solenoid CN-PUPB (1)
Resistance between CN-PUPB (male) (1) (2): 10 - 20

Between CN-ST1 (female) (4) - (15):
10 - 20
Display of LED when starting switch is
turned on (under normal condition)
When machine is steered to right or left
end: 93 - 94 (Output current: 930 - 940 mA)
1. Abnormality in engine speed sensor

2. Defective installation of engine speed sensor
controller CN-ST3 (4) - speed sensor CN-E07 (1)
ground in wiring harness between controller CN-ST3 (12) speed sensor CN-E07 (2)
Resistance between CN-E07 (male) (1) (2): 500 - 1,000

Resistance between CN-ST3 (female) (4)
- (12): 500 - 1,000
D155AX-5
TROUBLESHOOTING


2. Cannot limit inclination angle of HSS pump when steering
circuit pressure is high or steering circuit is relieved.

2. Machine is steered normally under light load.
1. Since current does not flow in solenoid, inclination angle of 1. Machine cannot be steered to left (can be steered to right norHSS pump becomes 0.
mally, however).
1. Since outputting to solenoid is stopped, inclination angle of

HSS pump becomes 0.
1. Machine cannot be steered to left (can be steered to right normally, however).
1. Since current does not flow in solenoid, inclination angle of 1. Machine cannot be steered to right (can be steered to left norHSS pump becomes 0.
mally, however).
1. Since outputting to solenoid is stopped, inclination angle of 1. Machine cannot be steered to right (can be steered to left norHSS pump becomes 0.
mally, however).
1. Calculates with engine speed at 0 rpm.

2. Cannot control inclination angle of HSS pump when engine 2. If machine is steered frequently while traveling down slope,
speed is high.
durability of HSS motor may be lowered.
3. Neutral position of steering cannot be adjusted.
D155AX-5
20-909
4
TROUBLESHOOTING

HSS control system
20-910
4
D155AX-5
TROUBLESHOOTING
Engine starting system
Blade pitch solenoid and ripper pin puller solenoid system
D155AX-5
20-911
4
TROUBLESHOOTING
E-1.
E-1
[E0113] (Drop of HSS controller power supply voltage) is

displayed
This error code is displayed when the source voltage for the controller lowers below 17 V.
chassis ground.)
Cause
Remedy
1
20 - 30 V
NO
Is voltage between CN-ST1 (8), (18)

and (9), (19) normal?
Replace (Adjust
neutral position
of steering
system)

wiring harness between CN-ST1 (female)
(9), (19) - chassis ground
Repair or
replace
Defective fuse box power source

circuit or lowering of battery
voltage
Repair or
replace
Defective fuse, or disconnection or

defective contact in wiring harness
between outlet of fuse 5 - CN-ST1
(female) (8), (18)
Repair or
replace
YES
2
20 - 30 V
NO
Is voltage between CN-ST1 (8), (18)

YES
3
Remove fuse 5.
20 - 30 V
Is voltage between inlet of fuse 5

YES
NO
20-912
4
D155AX-5
TROUBLESHOOTING
E-2.
E-2
[E0143] (Abnormality in HSS controller 5V power supply voltage)

is displayed
This error code is displayed when the source voltage of 5 V for the controller sensor lowers below
4.5 V or rises above 5.5 V.
Cause
Remedy
1
Disconnect CN-ST2.
4.5 - 5.5 V
Replace (Adjust
neutral position
of steering
system)
NO

wiring harness between CN-RSS (1) CN-ST2 (10)
Repair or
replace
NO

wiring harness between CN-STR (4) CN-ST2 (10)
Repair or
replace
NO
Is voltage between CN-ST2 (9) and

(10) normal?
YES
2
Disconnect CN-RSS.
4.5 - 5.5 V
Is voltage between CN-RSS (1) and

(3) normal?
YES
3
Disconnect CN-STR.
4.5 - 5.5 V
Is voltage between CN-STR (1) and

(4) normal?
YES
Restart and check that error does
not occur.
D155AX-5
20-913
4
TROUBLESHOOTING
E-3.
E-3
[E0145] (Abnormality in HSS controller sensor power supply

voltage) is displayed
This error code is displayed when the source voltage of 5 V for the controller sensor lowers below
4.5 V or rises above 5.5 V.
Cause
Remedy
1
NO
Does HSS controller display error

code [E0113]?
YES
Go to troubleshooting of displayed
error code
2
Disconnect CN-ST1.
17 - 30 V

(9), (19) normal?
NO
Replace (Adjust
neutral position
of steering
system)
YES
Restart and check that error does
not occur.
20-914
4
D155AX-5
TROUBLESHOOTING
E-4.
E-4
[E0161] (Abnormality in HSS controller memory data of offset

current) is displayed
This error code is displayed when the offset current cannot be saved in the memory for an internal
trouble of the controller.
Cause
Remedy
1
Start engine.
On level ground.
Travel at F1.
Does machine deviate while

traveling with steering system in
neutral?
NO
Replace next
time (See
Note 2)
Replace
immediately
(See Note 1)
YES
Note 1: If the machine deviates, it must be corrected by "Adjusting the neutral position of the steering
system". If this error occurs, however, the offset current after adjustment cannot be memorized. Accordingly, replace the HSS controller with new one and carry out adjustment.
Note 2: Since the machine does not deviate, it can be used as it is for the present. Replace the HSS
controller, however, at the earliest chance as a permanent action. (After replacing the controller, be sure to "Adjust the neutral position of the steering system".)
D155AX-5
20-915
4
TROUBLESHOOTING
E-5.
E-5
[E0221] (Abnormality in gear speed switch system) is displayed
This error code is displayed when the information on the limit switches on the power train is
abnormal.
Cause
Remedy
1
NO
Is resistance of each switch as

shown in table?
Replace (Adjust
neutral position
of steering
system)
Limit switches 1st and 3rd are

connected reversely.
Repair or
replace

wiring harness between CN-1ST (3), CN2ND (3) - CN-ST2 (13), (14)
Repair or
replace
Reconnect and check
Repair or
replace
Disconnection in wiring harness

between CN-1ST (3) - CN-2ND (3),
defective installation of limit switch, or
defective limit switch
Repair or
replace
YES
2
Are 1st and 3rd reversed? (Are gear NO

speeds displayed on monitor panel
reversed?)
YES
3
NO
Is resistance of both 1st and 3rd

below 1 respectively?
YES
4
Is resistance of both 1st and 3rd
above 100 respectively?
NO
YES
Table
Location
Between ST2 (13) GND
Between ST2 (14) GND
1st
Max 1
Min. 100
2nd
Min. 100
Min. 100
3rd
Min. 100
Max 1
20-916
4
D155AX-5
TROUBLESHOOTING
E-6.
E-6
[E0233] (Short circuit in travel REVERSE sensing potentiometer

This error code is displayed when the input signal from the reverse sensing potentiometer rises
above 4.7 V.
Check that the reverse sensing potentiometer is adjusted normally before troubleshooting.
Cause
Remedy
1
NO

CN-ST2 (9) as shown in table 1?
Replace
(Adjust
neutral
position of
steering
system)
Defective reverse sensing

potentiometer
Replace
Short circuit with power source in wiring

harness between CN-ST3 (female) (10) CN-RSS (female) (2)
Repair or
replace
YES
2
Disconnect CN-RSS.
Is resistance between CN-RSS (male) NO

(1) and (2) and between (1) and (3)
YES
3
Disconnect CN-RSS.
Max. 1 V
When CN-RSS is disconnected, is

voltage between CN-ST3 (female)
YES
NO

wiring harness between CN-ST2 (female) Repair or
replace
(9) - CN-RSS (3)
Table 2
Table 1
CN-ST3, CN-ST2
Forward/Reverse
Voltage
CN-RSS (male)
Resistance
Between CN-ST3 (10)

CN-ST2 (9)
In neutral
Max. 3.5 V
Between (1) (2)
0.3 5.7 k
Reverse
3.5 4.4 V
Between (2) (3)
4 6 k
D155AX-5
20-917
4
TROUBLESHOOTING
E-7.
E-7
[E0233] (Disconnection in travel REVERSE sensing potentiometer

This error code is displayed when the input signal from the reverse sensing potentiometer lowers
below 0.300 V.
Check that the reverse sensing potentiometer is adjusted normally before troubleshooting.
Cause
Remedy
NO

CN-ST2 (9) as shown in table 1?
Replace
(Adjust
neutral
position of
steering
system)
NO
Defective reverse sensing

potentiometer
Replace
NO

wiring harness between CN-ST3
(female) (10) - CN-RSS (female) (2)
Repair or
replace
NO

(female) (10) - CN-RSS (female) (2)
Repair or
replace
NO

Repair or
replace
(10) - CN-RSS (female) (1)
YES
2
Disconnect CN-RSS.
Is resistance between CN-RSS

(male) (1) and (2) and between (1)
and (3) as shown in Table 2?
YES
3
Disconnect CN-RSS and CN-ST3.
Min. 1 M

resistance between CN-ST3 (female) (10)
YES
4
Max. 1
Is resistance between CN-ST3

(female) (10) and CN-RSS (female)
(2) normal?
YES
5
Min. 1 M

YES
Table 2
Table 1
Between CN-ST3 (10)

CN-ST2 (9)
20-918
4

Repair or
replace
(10) - CN-RSS (female) (1)
Lever position
Voltage
CN-RSS (male)
Resistance
NEUTRAL
Max. 3.5 V
Between (1) (2)
0.3 5.7 k
REVERSE
3.5 4.4 V
Between (2) (3)
4 6 k
D155AX-5
TROUBLESHOOTING
E-7
D155AX-5
20-919
4
TROUBLESHOOTING
E-8.
E-8
[E0237] (Abnormality in transmission NEUTRAL signal) is

displayed
Cause
Remedy
1
Disconnect CN-6.
NO
Are voltage between CN-6 (1) and chassis

ground and that between CN-6 (5) and
chassis ground as shown in table?
YES
Replace
Disconnection or short circuit with chassis

ground in wiring harness between CN-ST3
(6), (16) - CN-6 (1), (5)
Repair or
replace
Replace
2
Disconnect CN-ST3.
18 - 30 V
Are voltage between CN-ST3 (6) and

chassis ground and that between CN-ST3
NO
YES
Table
Transmission F-N
signal
Transmission R-N
signal
When transmission lever

is in F or R
When transmission lever

is in neutral
Between CN-6 (1) - chassis ground
18 30 V
Max. 3 V
Between CN-6 (5) - chassis ground
18 30 V
Max. 3 V
20-920
4
D155AX-5
TROUBLESHOOTING
E-9.
E-9
[E0272] (Unequality between travel REVERSE sensing

potentiometer signal and backup alarm switch signal) is
displayed
This error code is displayed when the reverse sensing potentiometer does not conform to the
input signal of the backup alarm switch.
Check that the backup alarm switch and reverse sensing potentiometer are adjusted normally
before troubleshooting.
Cause
Remedy
NO
Is error code [E0233] displayed?
YES
error code
2
NO
Replace (Adjust
neutral position
of steering
system)
Defective backup alarm switch
Replace
YES

(1) and (3) as shown in Table 2?

Disconnect CN-251.
YES
4
Disconnect CN-ST2 and CN-251.
Max. 1

normal?
NO

Repair or
replace
(7) - CN-251 (female) (3)
NO

(7) - CN-251 (female) (3)
Repair or
replace

(1) - chassis ground
Repair or
replace
YES
5
Disconnect CN-251 and CN-ST2.
Min. 1 M
When CN-251 is disconnected, is

resistance between CN-ST2 (male) (7) and
YES
Table 1
Table 2
CN-ST2
Forward/Reverse
Voltage
CN-251 (male)
Forward/Reverse
Resistance
Between (7)
chassis
In neutral
20 30 V
In neutral
Min. 1 M
Reverse
Max. 1 V
Between (1)
(3) chassis
Reverse
Max. 1
D155AX-5
20-921
4
TROUBLESHOOTING
E-9
20-922
4
D155AX-5
TROUBLESHOOTING
E-10
E-10. [E0360] (Disconnection in work equipment oil pressure sensor

This error code is displayed when the input signal from the work equipment circuit oil pressure
sensor lowers below 0.500 V.
Cause
Remedy
1
Start engine.
NO

CN-ST2 (9) normal?
Replace (Adjust
neutral position
of steering
system)

wiring harness between CN-ST1 (13) CN-HHP (female) (2)
Repair or
replace
YES
2
20 - 30V
NO
Is voltage between CN-HHP (2) and

YES

Disconnect CN-ST3 and CN-HHP.
Max. 1
3
NO
(female) (2) and CN-HHP (female) (3)
normal?

Repair or
replace
YES
4
Min. 1 M
When CN-HHP is disconnected, is

resistance between CN-ST3 (2) and
YES
NO

Repair or
replace
Defective work equipment circuit oil

pressure sensor
Replace
Table
CN-ST3, CN-ST2
Between CN-ST3 (2)
CN-ST2 (9)
Work equipment
circuit
Voltage
In neutral
0.9 1.2 V
When relieved
2.45 2.90 V
D155AX-5
20-923
4
TROUBLESHOOTING
E-11
E-11. [E0361] (Short circuit in work equipment oil pressure sensor

This error code is displayed when the input signal from the work equipment circuit oil pressure
sensor rises above 6.000 V.
Cause
Remedy
1
Start engine.
NO

CN-ST2 (9) normal?
Replace (Adjust
neutral position
of steering
system)

harness between CN-ST3 (female) (2) CN-HHP (female) (3)
Repair or
replace
YES
2
Disconnect CN-HHP.
Max. 1 V
When CN-HHP is disconnected, is

NO
YES
3
Max. 1

NO
(female) (9) and CN-HHP (female) (1)
normal?
YES

Repair or
replace
Defective work equipment circuit oil

Replace
pressure sensor
Table
CN-ST3, CN-ST2
Between CN-ST3 (2)
CN-ST2 (9)
Work equipment
circuit
Voltage
In neutral
0.9 1.2 V
When relieved
2.45 2.90 V
20-924
4
D155AX-5
TROUBLESHOOTING
E-12
E-12. [E0610] (Disconnection in backup alarm relay system) is

displayed
Cause
Remedy
1
Disconnect CN-014.
200 - 400

(1) and (2) normal?
Defective backup alarm relay
Replace
NO

Repair or
replace
NO

(11) - CN-014 (female) (1)
Repair or
replace
Defective HSS
controller
Replace (Adjust
neutral position
of steering
system)
YES
2
Disconnect CN-014.
Max. 1

normal?
YES
3
Disconnect CN-ST1.
200 - 400

(female) and chassis ground
normal?
YES
D155AX-5
20-925
4
TROUBLESHOOTING
E-13
E-13. [E0611] (Short circuit in backup alarm relay system) is displayed
Cause
Remedy
1
Disconnect CN-014.
200 - 400
NO

(female) (1) and (2) normal?
Replace
YES
2
Disconnect CN-014 and CN-ST1.
Min. 1 M

NO

Repair or
replace
(11) - CN-014 (female) (1)
YES
Replace (Adjust
neutral position
of steering
system)
20-926
4
D155AX-5
TROUBLESHOOTING
E-14
E-14. [E0730] (Abnormality in both steering potentiometer systems 1

and 2) is displayed
This error code is displayed when signal voltages from both steering potentiometers are below
0.500 V or above 4.500 V.
Cause
Remedy
1
NO
Are error codes [E0733] and [E0734]

displayed, too?
YES
error code
2
Are voltage between CN-ST2 (19)

and (9) and that between (20) and
(9) as shown in table?
NO
Defective steering potentiometer
Replace
Replace (Adjust
neutral position
of steering
system)
YES
Table
CN-ST2
Steering
Steering
When fully
When fully
steered to left steered to right
Between (19) (9)
2.4 2.6 V
4.1 4.3 V
0.73 0.89 V
Between (20) (9)
2.4 2.6 V
0.6 1.1 V
3.9 4.4 V
D155AX-5
20-927
4
TROUBLESHOOTING
E-15
E-15. [E0731] (Large difference between steering potentiometer

systems 1 and 2: Case I) is displayed
This error code is displayed when the difference between the signal voltages of steering
potentiometer systems 1 and 2 becomes large (If the signal voltages are normal when the starting
switch is turned on).
Cause
Remedy
1
See note.
4.41 - 5.59 V (VSUM)
Is sum of voltage between CN-ST2

(19) and (9) and that between (20)
and (9) normal?
NO
Replace
Replace (Adjust
neutral position
of steering
system)
YES
Note: Measure the voltage according to the following procedure.

1) Measure voltage (V1) between CN-ST2 (19) and (9) and voltage (V2) between CN-ST2 (20)
and (9).
2) Add up 2 voltages (V1 and V2) to obtain the sum (VSUM).
The joystick does not move while the voltage is being measured.
20-928
4
D155AX-5
TROUBLESHOOTING
E-16
E-16. (Abnormality in steering potentiometer system on one side and

large deviation of neutral position on one side) is displayed
This error code is displayed when 1 steering potentiometer system is abnormal and the neutral
position of the other system is deviated.
Cause
Remedy
1
NO
Are error codes [E0733] and [E0734]

displayed, too?
YES
Replace (Adjust
neutral position
of steering
system)
Replace
2
Are voltage between CN-ST2 (19)

and (9) and that between (20) and
(9) as shown in table?
NO
YES
error code
D155AX-5
20-929
4
TROUBLESHOOTING
E-17
E-17. [E0733] (Disconnection in steering potentiometer system 1) is

displayed
This error code is displayed when the signal voltage from steering potentiometer system 1 rises
above 4.500 V.
Cause
Remedy
1
NO

(9) as shown in Table 1?
Defective HSS
controller
Replace (Adjust
neutral position
of steering
system)
Replace
NO

Repair or
replace
NO

harness between CN-ST2 (female) (19) CN-STR (female) (3)
Repair or
replace

Repair or
replace
YES
2
Disconnect CN-STR.
NO
Are resistance between CN-STR (male) (1)

and (4), that between (2) and (4), and that
between (3) and (4) as shown in Table 2?
YES
3
Disconnect CN-ST2 and CN-STR.
Max. 1

(female) (19) and CN-STR (female)
(3) normal?
YES
4
Disconnect CN-STR.
Max. 1 V
When CN-STR is disconnected, is

voltage between CN-ST2 (19) and
YES
Table 1
Table 2
CN-ST2
In neutral
Between (19) (9)
2.4 2.6 V
Steering
When fully
When fully
4.1 4.3 V
0.73 0.89 V
CN-STR (male)
Resistance
Between (1) (4)
2.4 4.0
Between (2) (4)
5.0 8.0
Between (3) (4)
5.0 8.0
20-930
4
D155AX-5
TROUBLESHOOTING
E-18
E-18. [E0733] (Short circuit in steering potentiometer system 1) is

displayed
This error code is displayed when the signal voltage from steering potentiometer system 1 lowers
below 0.500 V.
Cause
Remedy
NO

Replace (Adjust
neutral position
of steering
system)
Replace
NO

Repair or
replace
NO

Repair or
wiring harness between CN-ST2 (female) replace
YES
2
Disconnect CN-STR.
NO

YES
3
Disconnect CN-STR and CN-ST2.
Min. 1 M

YES
4
Min. 1 M

YES

Table 1
Repair or
replace
Table 2
CN-ST2
In neutral
Between (19) (9)
2.4 2.6 V
Steering
When fully
When fully
4.1 4.3 V
0.73 0.89 V
CN-STR (male)
Resistance
Between (1) (4)
2.4 4.0
Between (2) (4)
5.0 8.0
Between (3) (4)
5.0 8.0
D155AX-5
20-931
4
TROUBLESHOOTING
E-19
E-19. [E0734] (Disconnection in steering potentiometer system 2) is

displayed
This error code is displayed when the signal voltage from steering potentiometer system 2 rises
above 4.500 V.
Cause
Remedy
NO

Replace (Adjust
neutral position
of steering
system)
Replace
NO

Repair or
replace
NO

harness between CN-ST2 (female) (20) CN-STR (female) (2)
Repair or
replace

Repair or
replace
YES
2
Disconnect CN-STR.

NO
YES
3
Disconnect CN-ST2 and CN-STR.
Max. 1

(female) (20) and CN-STR (female)
(2) normal?
YES
4
Disconnect CN-STR.
Max. 1 V

voltage between CN-ST2 (20) and
YES
Table 1
Table 2
CN-ST2
In neutral
Between (20) (9)
2.4 2.6 V
Steering
When fully
When fully
0.6 1.1 V
3.9 4.4 V
CN-STR (male)
Resistance
Between (1) (4)
2.4 4.0
Between (2) (4)
5.0 8.0
Between (3) (4)
5.0 8.0
20-932
4
D155AX-5
TROUBLESHOOTING
E-20
E-20. [E0734] (Short circuit in steering potentiometer system 2) is

displayed
This error code is displayed when the signal voltage from steering potentiometer system 2 lowers
below 0.500 V.
Cause
Remedy
1
NO

Replace (Adjust
neutral position
of steering
system)
Replace

Repair or
replace

Repair or
replace
YES
2
Disconnect CN-STR.
NO

YES

Min. 1 M
3
NO
YES
4
Min. 1 M

YES
NO

Repair or
replace
Table 1
Table 2
CN-ST2
In neutral
Between (20) (9)
2.4 2.6 V
Steering
When fully
When fully
0.6 1.1 V
3.9 4.4 V
CN-STR (male)
Resistance
Between (1) (4)
2.4 4.0
Between (2) (4)
5.0 8.0
Between (3) (4)
5.0 8.0
D155AX-5
20-933
4
TROUBLESHOOTING
E-21
E-21. [E0735] (Large difference between steering potentiometer

systems 1 and 2: Case II) is displayed
This error code is displayed when the difference between the signal voltages of steering
potentiometer systems 1 and 2 becomes large (If the signal voltages are normal when the starting
switch is turned on).
Cause
Remedy
1
See note.
4.41 - 5.59 V (VSUM)
Is sum of voltage between CN-ST2

(19) and (9) and that between (20)
and (9) normal?
NO
Replace
Replace (Adjust
neutral position
of steering
system)
YES
Note: Measure the voltage according to the following procedure.

1) Measure voltage (V1) between CN-ST2 (19) and (9) and voltage (V2) between CN-ST2 (20)
and (9).
2) Add up 2 voltages (V1 and V2) to obtain the sum (VSUM).
The joystick does not move while the voltage is being measured.
20-934
4
D155AX-5
TROUBLESHOOTING
E-22
E-22. [E0768] (Disconnection in steering oil pressure sensor A system)

is displayed
This error code is displayed when the signal voltage from steering oil pressure sensor A lowers
below 0.500 V.
Cause
Remedy
1
Turn starting switch OFF

and exchange connectors.
Run engine at high speed.
NO
When connector is exchanged with oil

pressure sensor B, is [E0773] displayed?
Defective steering oil pressure

switch A
Replace
Replace (Adjust
neutral position
of steering
system)

(13) - CN-ST1 (female) (2)
Repair or
replace

(female) (1) - CN-ST1 (female) (3)
Repair or
replace

in wiring harness between CN-ST3
(female) (1) - CN-ST1 (female) (3)
Repair or
replace
YES
2
Run engine at high

speed.
NO

CN-ST2 (9) as shown in table?
YES

20 - 30 V
NO

YES
4
Disconnect CN-ST1 and CN-ST3.
Min. 1 M
When CN-ST1 is disconnected, is

YES
NO
Table
CN-ST3, CN-ST2
Steering
Voltage
Between CN-ST3 (1)

CN-ST2 (9)
In neutral
0.9 1.5 V
When relieved
0.39 4.60 V
D155AX-5
20-935
4
TROUBLESHOOTING
E-23
E-23. [E0769] (Short circuit in steering oil pressure sensor A system) is

displayed
This error code is displayed when the signal voltage from steering oil pressure sensor A rises
above 6.000 V.
Cause
Remedy
1
Turn starting switch OFF and
exchange connectors.
NO

switch A
Replace
Replace (Adjust
neutral position
of steering
system)

NO
voltage between CN-ST3 (female) (1)

harness between CN-ST3 (female) (1) CN-ST1 (female) (3)
Repair or
replace
YES

(9) - CN-ST1 (female) (1)
Repair or
replace

pressure sensor B, is [E0772] displayed?
YES
2
Run engine at high
speed.
NO

YES
3
Disconnect CN-ST1.
Max. 1 V
Table
CN-ST3, CN-ST2
Steering
Voltage
Between CN-ST3 (1)

CN-ST2 (9)
In neutral
0.9 1.5 V
When relieved
3.95 4.60 V
20-936
4
D155AX-5
TROUBLESHOOTING
E-24
E-24. [E0770] (Disconnection in steering oil pressure sensor B system)

is displayed
This error code is displayed when the signal voltage from steering oil pressure sensor B lowers
below 0.500 V.
Cause
Remedy
1

NO

pressure sensor A, is [E0775] displayed?

switch B
Replace
Replace (Adjust
neutral position
of steering
system)
NO
Disconnection, defective contact, or short circuit

with chassis ground in wiring harness between
CN-ST1 (13) - CN-ST2 (female) (2)
Repair or
replace
NO

Repair or
replace
YES
2
Run engine at high

speed.
NO

YES

20 - 30 V

YES
4
Disconnect CN-ST2 and CN-ST3.
Min. 1 M

YES

Repair or
replace
Table
CN-ST3, CN-ST2
Steering
Voltage
Between CN-ST3 (9)

CN-ST2 (9)
In neutral
0.9 1.5 V
When relieved
3.95 4.60 V
D155AX-5
20-937
4
TROUBLESHOOTING
E-25
E-25. [E0771] (Short circuit in steering oil pressure sensor B system) is

displayed
This error code is displayed when the signal voltage from steering oil pressure sensor B rises
above 6.000 V.
Cause
Remedy
1
NO

switch B
Replace
Replace (Adjust
neutral position
of steering
system)

NO

harness between CN-ST3 (female) (9) CN-ST2 (female) (3)
Repair or
replace
YES

Repair or
replace

pressure sensor A, is [E0774] displayed?
YES
2
Run engine at high
speed.
NO

YES
3
Disconnect CN-ST2.
Max. 1 V
Table
CN-ST3, CN-ST2
Steering
Voltage
Between CN-ST3 (9)

CN-ST2 (9)
In neutral
0.9 1.5 V
When relieved
3.95 4.60 V
20-938
4
D155AX-5
TROUBLESHOOTING
E-26
E-26. [E0772] (Disconnection in HSS pump solenoid A system) is

displayed
Cause
Remedy
1
Disconnect CN-PUPA
NO
Are resistance between CN-PUPA (male)

(1) and (2) and that between (1) and
Defective HSS pump solenoid
Replace
YES
2
Disconnect CN-ST1 and CN-PUPA.
Max. 1

(female) (4) and CN-PUPA (female)
(1) normal?
NO

Repair or
replace
NO

NO

Repair or
replace
YES
3
Disconnect CN-ST1 and CN-PUPA.
Max. 1

(female) (15) and CN-PUPA (female)
(2) normal?
Repair or
replace
YES
4
Disconnect CN-PUPA and CN-ST1.
Min. 1 M
When CN-PUPA is disconnected, is

YES
Repair or
replace
Table
CN-PUPA (male)
Resistance
Between (1) (2)
10 20
Between (1) chassis
Min. 1 M
D155AX-5
20-939
4
TROUBLESHOOTING
E-27
E-27. [E0773] (Short circuit in HSS pump solenoid A system) is

displayed
Cause
Remedy
1
Disconnect CN-PUPA.
NO
Are resistance between CN-PUPA (male)

Replace
NO

Repair or
replace
NO

harness between CN-ST1 (female) (15) CN-PUPA (female) (2)
Repair or
replace
Replace (Adjust
neutral position
of steering
system)
YES
2
Disconnect CN-PUPA and CNST1.
Min. 1 M

YES
3
Disconnect CN-PUPA.
Max. 1 V

YES
Table
CN-PUPA (male)
Resistance
Between (1) (2)
10 20
Between (1) chassis
Min. 1 M
20-940
4
D155AX-5
TROUBLESHOOTING
E-28
E-28. [E0774] (Disconnection in HSS pump solenoid B system) is

displayed
Cause
Remedy
1
Disconnect CN-PUPB
NO
Are resistance between CN-PUPB (male)

Replace
YES
2
Disconnect CN-ST1 and CN-PUPB.
Max. 1

(female) (5) and CN-PUPB (female)
(1) normal?
NO

replace
(5) - CN-PUPB (female) (1)
NO

Repair or
replace
NO

replace
YES
3
Disconnect CN-ST1 and CN-PUPB.
Max. 1

(female) (15) and CN-PUPB (female)
(2) normal?
YES
4
Disconnect CN-PUPB and CN-ST1.
Min. 1 M
When CN-PUPB is disconnected, is

YES
Replace (Adjust
neutral position
of steering
system)
Table
CN-PUPB (male)
Resistance
Between (1) (2)
10 20
Between (1) chassis
Min. 1 M
D155AX-5
20-941
4
TROUBLESHOOTING
E-29
E-29. [E0775] (Short circuit in HSS pump solenoid B system) is

displayed
Cause
Remedy
1
Disconnect CN-PUPB
NO
Are resistance between CN-PUPB (male)

Replace
NO

Repair or
replace
NO

harness between CN-ST1 (female) (15) CN-PUPB (female) (2)
Repair or
replace
Replace (Adjust
neutral position
of steering
system)
YES
2
Disconnect CN-PUPB and CN-ST1.
Min. 1 M

YES
3
Disconnect CN-PUPB.
Max. 1 V

YES
Table
CN-PUPB (male)
Resistance
Between (1) (2)
10 20
Between (1) chassis
Min. 1 M
20-942
4
D155AX-5
TROUBLESHOOTING
E-30
E-30. [E0930] (Abnormality in engine speed sensor system) is displayed
Check that the engine speed sensor is adjusted normally before troubleshooting.
Cause
Remedy
1
Start engine.
Measure with tester in AC range.
0.5 - 3.0 V
NO

(12) normal?
Replace (Adjust
neutral position
of steering
system)
Defective engine speed sensor
Replace
NO

(4) - CN-E7 (female) (1)
Repair or
replace
NO

(4) - CN-E7 (female) (1)
Repair or
replace
YES

Disconnect CN-E07.
500 - 1,000
2
(1) and (2) normal?
YES
3
Disconnect CN-ST3 and CN-E07.
Max. 1

(female) (4) and CN-E07 (female) (1)
normal?
YES
4
Disconnect CN-ST3 and CN-E07.
Min. 1 M
When CN-E07 is disconnected, is

YES

Repair or
replace
(12) - CN-E07 (female) (2)
D155AX-5
20-943
4
TROUBLESHOOTING
E-31
E-31. Backup alarm does not sound

chassis ground.)
Cause
Remedy
1
Does HSS controller display error
code [E0610] [E0611]?
YES
error code
2
20 - 30 V
NO


wiring harness between fuse 9 - CN-014
(female) (3)
Repair or
replace
Replace

(5) - CN-244 (female) (2)
Repair or
replace
Replace
YES
3
When backup alarm relay is
replaced, does system become
normal?
NO
YES
4
Max. 1

normal?
NO
YES
20-944
4
D155AX-5
TROUBLESHOOTING
E-32
E-32. Blade pitch malfunctions (Machine equipped with pitch dozer)

chassis ground.)
a) Blade pitch does not work (Solenoid is not turned on)
Cause
Remedy
1
Turn on pitch switch.
20 - 30 V
NO

YES
2
Disconnect CN-454.
NO
Are resistance between CN-454 (female)

YES
Defective blade pitch solenoid
Replace

Repair or
replace

wiring harness between fuse 1 - CN-P01
(female) (1)
Repair or
replace
Defective blade pitch switch
Replace

wiring harness between CN-P01 (female)
(1) - fuse (1)
Repair or
replace
3
Disconnect CN-P01.
20 - 30V
NO
Is voltage between CN-P01 (female)

YES

Disconnect CN-P01.
Turn on pitch switch.
Max. 1
4
NO
Is resistance between CN-P01 (1)

and (2) normal?
YES
Table
CN-454 (male)
Voltage
Between (1) (2)
40 80
Between (1) chassis
Min. 1 M
b) Blade tilt does not work (Solenoid is not turned off)

Cause
Remedy
1
Start engine.
When CN-P01 is disconnected, does

system become normal?
NO

harness between CN-P01 (female) (2) CN-454 (female) (1)
Repair or
replace
Defective blade pitch switch
Replace
YES
D155AX-5
20-945
4
TROUBLESHOOTING
E-32
20-946
4
D155AX-5
TROUBLESHOOTING
E-33
E-33. Ripper pin puller malfunctions (Machine equipped with giant

ripper)
chassis ground.)
a) Pin cannot be pulled out (Solenoid is not turned on)
Cause
Remedy
1
Pin puller switch: PULL OUT
20 - 30 V
NO

YES
2
Disconnect CN-246.
Are resistance between CN-246 (fmale) (1)

and (2) and that between (1) and chassis
ground as shown in table?
NO
YES
Defective ripper pin puller switch
Replace

Repair or
replace

wiring harness between fuse 1 - CN-263
(female) (1)
Repair or
replace
Replace

(2) - CN-246 (female) (1)
Repair or
replace
3
20- 30 V
NO

YES

Disconnect CN-263.
Pin puller switch: PULL OUT
Max. 1
4
(1) and (2) normal?
YES
Table
CN-246 (male)
Voltage
Between (1) (2)
40 80
Between (1) chassis
Min. 1 M
b) Pin cannot be pushed in (Solenoid is not turned off)

Cause
Remedy
1
Start engine.
When CN-263 is disconnected, does

system become normal?
NO
Short circuit with power source in wiring Repair or

harness between CN-263 (female) (2) replace
CN-246 (female) (1)
YES
D155AX-5
Replace
20-947
4
TROUBLESHOOTING
E-33
20-948
4
D155AX-5
TROUBLESHOOTING
E-34
E-34. Engine does not start (Engine does not rotate)

chassis ground.)
When troubleshooting, set the parking brake lever in the lock position.
Check that any error code related to the engine (E mode) is not displayed.
Note: In this section, troubleshooting related to the battery relay will be performed on the assumption
that the engine controller is free from error.
Cause
Remedy
1
Voltage: Min. 24 V
Specific gravity: Min. 1.26
NO
Are battery voltage and specific

gravity of battery fluid normal?
Replace

wiring harness between starting motor battery relay
Repair or
replace
Defective starting motor
Replace
Replace

harness between CN-M2 (female) (2) CN-E22 or between CN-M2 (female) (2) CN-220 (female) (2)
Repair or
replace
Defective diode (CN-220)
Replace
YES
2
When starting switch is operated,
does operating sound of battery
relay come out?
Starting switch ON and

OFF.
NO
YES
3
START position.
20 - 30 V
NO
Is voltage between CN-M2 (1) and

YES
4
Max. 1 V
NO
Is voltage between CN-M2 (2) and

5
NO
Is connection between starting

motor and battery relay normal?
Check visually.
YES
Disconnect alternator
terminal R.
Max. 1 V
NO
When CN-E22 is disconnected, is voltage

between CN-M2 (2) and chassis ground
normal?
YES
7
voltage between CN-M2 (2) and
Disconnect diode.
Max. 1 V
NO
YES
See next
page A
D155AX-5
See next
page B
20-949
4
TROUBLESHOOTING
E-34
Cause
Remedy
8
START position.
20 - 30 V
NO

YES
9
Disconnect CN-252.
Max. 1

START position.
20 - 30 V

(1) and (3) normal?
Defective neutral safety switch and

wrong adjustment of it
Repair or
replace
YES

(female) (1) - CN-M2 (female) (1)
Repair or
replace
Replace
Is voltage between starting motor

terminal C and chassis ground
normal?
10
NO

Repair or
in wiring harness between starting
switch terminal C (CN-280) - CN-152 replace
(female) (3)
YES

20 - 30 V
Is voltage between SN-SW and

11
NO
YES

20 - 30 V
Is voltage between starting switch

terminal BR and chassis ground
normal?

switch terminal BR (CN-260) - CNSW
Repair or
replace
Replace
13
Is resistance between starting switch NO
terminals B and BR normal?
YES
20-950
Replace
12
NO
YES
Disconnect starting switch

terminals B and BR.
Max. 1

Repair or
switch terminal B (CN-260) - fuse 10 replace
- CN-H
D155AX-5
TROUBLESHOOTING
E-34
D155AX-5
20-951
4
30 DISASSEMBLY AND ASSEMBLY

Method of using manual ............................ 30- 3
Precautions when carring out operation ... 30- 5
Special tool list ............................................. 30- 7
Special tool sketch ....................................... 30-17
STARTING MOTOR
Removal and Installation ...................... 30-26
ALTERNATOR
ENGINE OIL COOLER CORE
FUEL INJECTION PUMP
Removal .................................................. 30-29
Installation .............................................. 30-30
WATER PUMP
TURBOCHARGER
NOZZLE HOLDER
FUEL INJECTOR
Removal and Installation ................... 30-33-1
ENGINE FRONT SEAL
Removal .................................................. 30-34
Installation .............................................. 30-35
ENGINE REAR SEAL
Removal .................................................. 30-37
Installation .............................................. 30-38
CYLINDER HEAD
Removal .................................................. 30-42
Installation .............................................. 30-47
THERMOSTAT
AIR CONDITIONER COMPRESSOR
Removal .................................................. 30-50
Installation .............................................. 30-51
AIR CONDITIONER CONDENSER
FUEL TANK
RADIATOR
Removal .................................................. 30-54
Installation .............................................. 30-56
RADIATOR, OIL COOLER, GUARD
Removal .................................................. 30-57
Installation .............................................. 30-59
FAN DRIVE
Removal .................................................. 30-60
Installation .............................................. 30-61
D155AX-5
HYDRAULIC COOLER
ENGINE
Removal .................................................. 30-63
Installation .............................................. 30-65
DAMPER
Removal .................................................. 30-66
Installation .............................................. 30-67
Disassembly ........................................... 30-68
Assembly ................................................ 30-71
POWER TRAIN UNIT
Removal .................................................. 30-75
Installation .............................................. 30-79
Separation .............................................. 30-80
Connection ............................................. 30-84
PTO
Disassembly ........................................... 30-85
Assembly ................................................ 30-89
TORQUE CONVERTER
Disassembly ........................................... 30-94
Assembly ................................................ 30-97
TORQFLOW TRANSMISSION
Disassembly ......................................... 30-100
Assembly .............................................. 30-109
HSS CASE
Disassembly ......................................... 30-120
Assembly .............................................. 30-129
HYDRAULIC PUMP
Removal ................................................ 30-142
Installation ............................................ 30-146
HSS PUMP
Disassembly ...................................... 30-146-1
Assembly ........................................... 30-146-8
HSS MOTOR
Removal and Installation .................... 30-147
POWER TRAIN MAIN RELIEF VALVE
Disassembly and Assembly ............... 30-149
HSS, PPC CHARGE VALVE
HSS, PCC CHARGEING VALVE
Disassembly ......................................... 30-151
Assembly .............................................. 30-152
TRANSMISSION CONTROL VALVE
Removal ................................................ 30-153
Installation ............................................ 30-154
Disassembly and Assembly ............... 30-155
30-1
5
BRAKE VALUE
Removal and installation ....................
Disassembly
and Assembly ...............
FINAL DRIVE
Removal ................................................
Installation ........... . ................................
Disassembly .........................................
Assembly ..............................................
TRACK FRAME
Removal ................................................
Installation ............................................
IDLER ASSEMBLY
Removal ................................................
Installation ............................................
Disassembly .........................................
Assembly ..............................................
RECOIL SPRING
Removal and Installation ....................
Disassembly .........................................
Assembly ..............................................
TRACK ROLLER
Removal ................................................
Installation ............................................
Disassembly .........................................
Assembly ..............................................
BOGIE
Removal ................................................
Installation ............................................
Disassembly .........................................
Assembly ..............................................
CARRIER ROLLER
Removal and Installation.. .................
Disassembly .........................................
Assembly ..............................................
TRACK SHOE
Checking before removal ...................
Removal (normal) ................................
Removal (when there is abnormality inside track frame) .................
Installation ............................................
Overall disassembly ............................
Overall assembly .................................
Press-fitting jig dimention table for
link press ..............................................
ONE LINK
Disassembly .........................................
Assembly ..............................................
MASTER LINK
Disassembly .........................................
Assembly ..............................................
PIVOT SHAFT
EQUALIZER BAR
Removal ................................................
Installation ............................................
EQUALIZER BAR SIDE BUSHING
30-2
0
30-I 57
30-158
30-160
30-162
30-I 63
30-168
30-174
30-176
30-177
30-178
30-179
30-181
30-I 84
30-I 85
30-190
30-194
30-195
30-196
30-199
30-202
30-204
30-205
30-209
30-213
30-214
30-216
30-219
30-219
30-220
30-221
30-222
30-227
30-241
30-242
30-244
30-246
30-248
30-251
30-252
30-253
30-254
SEGMENT TEETH
Removal and Installation . . . . . . .. . . . . . . .. . . .. 30-255
HYDRAULIC TANK
Removal and Installation . . . . . . .. . . .. . . .. . . . . 30-256
MAIN CONTROL VALVE
Removal . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . .. . .. . . . . . 30-257
installation . .. . . . . .. . . . . .. . . .. . . . . . . . . . . . . .. . .. . . .. . . . . 30-258
Disassembly . . . . . . . . . . . . . . .. .. .. . . . . . . . . . . . .. . . .. . . . . 30-259
Assembly . . .. .. . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . .. . . .. . . . . 30-262
Removal and Installation . . . . . . . .. . . .. . . . . .. . 30-266
Disassembly,
assembly of HMT
oil cooler bypass valve .. .. . . .. .. . . . . . . . .. . . . . 30-267
BLADE PPC-VALVE
Removal . . . . . .. . .. . .. . . . . . . .. . .. . . . . . . . . . . . . .. . . . . . . . . . . 30-268
Installation . . . . . . .. . . . . . .. . . . . . . . . . . .. . . . .. . . .. . . .. . . . . 30-269
RIPPER PPC VALVE
Removal . . . . . . . .. . . . . . . . . . . . . . . .. . . . .. . . . . . . . . .. . . .. . . .. 30-270
Installation . .. . . . . . . . . . . . . . . . .. . . . . .. . . .. . . . . . . .. . . . .. . 30-271
BLADE PPC VALVE
Disassembly .. . . . . . . .. . . . .. . .. . . . . . . . . . . . . . .. . . . . . . . . 30-272
Assembly ..,....._..................................
30-273
BLADE LIFT CYLINDER
Removal and Installation . . . . .. . . .. .. . . . . . . . . 30-275
BLADE TILT CYLINDER
Removal and Installation .. . . . .. . . . . . .. . . . . .. 30-276
RIPPER LIFT CYLINDER
Removal and Installation .. . . . . . .. . . . . . .. . . . . 30-277
RIPPER TILT CYLINDER
Removal and Installation . . . . . . . .. . .. . . . . . . . . 30-278
HYDRAULIC CYLINDER
Disassembly .. . . . . . . . . . . . . .. .. . . . . . . . . . . . . .. . . . . . . . . . 30-279
Assembly . . .. . .. . . . . . . . . . . . . .. . . .. . . . . . . . . . . . .. . . . . . . . . 30-282
BLADE
Removal . . . . . . . . .. .. . . . . . . . . . . . .. . .. .. . . . . . . . . .. . . . .. . . . 30-286
Installation . .. . . . . . . . . . . . . . . . . .. . .. .. . . . . . . .. . . .. . . . .. . 30-287
Disassembly . .. . . . .. . . .. .. . . . . .. . . .. .. .. .. . . . . . . .. . . . 30-288
Assembly . . . . . . .. . . . . . .. . . .. . . . . . . .. . . . . .. . . . . . .. . . . . .. 30-290
MULTI-SHANK
RIPPER
Disassembly . . . . . . . . . . . . .. . . .. .. . . . . . . . . . .. . . . . . . . . . . 30-292
Assembly . . . . . . .. .. . . . .. . . .. . . . . . . . .. . . . . .. . . .. . . . . . . . . 30-294
ROPS GUARD
Removal and Installation . . . . . . . . .. .. .. . . . . .. 30-296
OPERATOR CAB
Removal and Installation .. . . . .. . . . . . .. .. . . . . 30-297
HOOD
Removal and Installation .. . . . .. . . . .. . . . . . . . . 30-298
FLOOR FRAME
Removal . . . . . .. . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . .. . . .. . . . . 30-299
Installation . .. . . . . . .. . . .. . . . .. . . . . . . . . . . . . .. . . . .. . . . .. . 30-304
DASHBOARD
Removal . . . . . . . .. . .. . . . . .. . .. . . . . . .. . . . . . . . .. . . . .. . . . . . . 30-305
Installation .,..........................................
30-306
MONITOR
Removal and Installation . . . . . . . .. . . . .. . . . . . . 30-307
HSS CONTROLLER
Removal and Installation . . .. . . .. . . . . . . . . . . . . 30-308
D 155AX-5
DISASSEMBLY
METHOD OF USING MANUAL
AND ASSEMBLY

1.
When removing or installing unit assemblies

@ When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked a,
and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL
ASSEMBLY
.. . . . . . . . . . Title of operation
xxxx(1)
. . . . . . . .. . . . . . . . . .. . . . . . .. . . . .. . .. . .. . .. .. . .. . Step in operation
* .. . . . . .. . . . . .. . . . .. . . . .. . . . . . . . .. . .. . . . . . . . .. . . . . .. . . . .. .. . . Technique or important point to remember when
removing x x x x (1).
. .........Indicates that a technique is listed for use
n n a A(2) . . . . . . .. . . . . . . . . .. . . .. .. . . . . . . . .. . . . .. . . . . . . m
during installation
0 0 0 0 assembly (3)
2.
3.
-
OF 0000
. ........................................ ...... ............. ... . Precautions related to safety when carrying out the operation
a
1.
. . . . . . . . .. . . . . . . . . . . .. .. .l...................................
See Lubricant
and Coolant
Table
INSTALLATION
OF 0000
ASSEMBLY . . Title of operation
Carry out installation in the reverse order to removal.
m
. . . . . . . . .. .. . .. . . . . . . . .. . .. . . . . . . . .. .. . . . . .. . . . . . . . . .. . . . . . . . . .Technique used during installation
* .. .............. .............. .... .......................... Technique or important point to remember when
installing (2).
.
Adding water, oil . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . . . Step in operation
* . . . . . . . .. . . . . . . . . . . . .. .. . . . . . . . . . . . . .. . . .._................. Point to remember when adding water or oil
l
I&
. . .. .. . . .. . . . .. . . .. . .. . .. . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . Quantity
when
filling with oil and water
2.
General precautions when carrying out installation

or removal (disassembly
or assembly) of
units are given together as PRECAUTIONS
WHEN CARRYING OUT OPERATION,
so be sure to
follow these precautions when carrying out the operation.
3.
Listing of special tools

For details of the description, part number, and quantity of any tools (Al, etc.) that appear
in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
Special tools marked * in the table cannot be supplied.
Special tools with part number 790T-000-0000
in the table are prohibited for supply.
Special tools marked 0 in the sketch column are tools introduced
in this manual
in
sketches for special tools.
However, note that Komatsu cannot accept any responsibility
for special tools manufactured according to the sketch.
D 155AX-5
30-3
0
DISASSEMBLY
4.
Ir
General
AND ASSEMBLY
tightening
torque
table
(when
using torque
In the case of metric nut and bolts for which there

Thread
diameter
Width
across flats
0
5.
Ir
wrench)
is no special
instruction,
tighten
SAW281
to the torque
z
SAC03482
mm
mm
kgm
Nm
6
8
10
12
14
10
13
17
19
22
1.3520.15
3.2kO.3
6.7r0.6
11.5~1.0
18.Ok2.0
13.2k1.4
31.4r2.9
65.7k6.8
112k9.8
177+19
16
18
20
22
24
24
27
30
32
36
28.5+3
39+4
56+6
76+8
94.5klO
279229
383239
549258
745+78
927298
27
30
33
36
39
41
46
50
55
60
135k15
175*20
225k25
280+30
335k35
1320+140
1720+190
22105240
27502290
32802340
Table of tightening
torques
for flared
nuts
In the case of flared nuts for which there is no soecial

instruction, tighten to the torque given in thetable
below.
SAW0483
Thread
6.
Ir
Table
diameter
Width
30-4
0
mm
mm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
2.520.5
5kl
8&l
14*3
18*3
20~5
2525
3Ok5
of tightening
torques
In the case of split flange

in the table below.
Thread
across flats
Tightening
diameter
for split flange
Nm
24.5r4.9
49k19.6
78.5k19.6
137.3k29.4
176.5k29.4
196.1*49
245.2*49
294.2249
bolts
bolts for which there is no special instruction,
Width
torque
Tightening
across flats
tighten
to the torque
given
torque
mm
mm
kgm
Nm
14
18
22
14
17
22
6.7r0.7
11.5+1
28.523
65.7k6.8
112-cg.8
279k29
D155AX-5
DISASSEMBLY
METHOD
AND ASSEMBLY
PRECAUTIONS
WHEN CARRYING
OF USING
MANUAL
OUT OPERATION
[When carrying out removal or installation (disassembly

or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.1
1. Precautions when carrvinn out removal work
.
If the coolant contains antifreeze, dispose of it correctly.
.
After disconnecting
hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
.
When draining oil, prepare a container of adequate size to catch the oil.
.
Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling.
.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting
the connectors.
Do not pull the wires.
.
Fit wires and hoses with tags to show their installation
position to prevent any mistake when
installing.
.
Check the number and thickness of the shims, and keep in a safe place.
.
When raising components,
be sure to use lifting equipment
of ample strength.
.
When using forcing screws to remove any components,
tighten the forcing screws uniformly in
turn.
.
Before removing any unit, clean the surrounding
area and fit a cover to prevent any dust or dirt
from entering after removal.
Precautions when handling piping during disassembly
Ir
Fit the following blind plugs into the piping after disconnecting
it during disassembly
operations.
1) Hoses and tubes using sleeve nuts
Nominal
number
02
03
04
05
06
10
12
2) Split flange
Nominal
Flange (hose end)

07379-00400
07379-00500
3) If the part is not under hydraulic
pressure,
02430
27
D155AX-5
nut (elbow end)

Use
07221-20210(Nut),
07221-20315(Nut),
07221_20422(Nut),
07221-20522(Nut),
07221_20628(Nut),
07221-21034(Nut),
07221-21234(Nut),
the two items below

07222-0021O(Plug)
07222-00312(Plug)
07222-00414(Plug)
07222-00515(Plug)
07222-00616(Plug)
07222-01018(Plug)
07222-01219(Plug)
as a set
type hoses and tubes

number
04
05
Sleeve
Plug
07376-50210
07376-50315
07376-50422
07376-50522
07376-50628
07376-51034
07376-51234
07049-02734
1 24
1 27
Sleeve head (tube end)

07378-I 0400
07378-I 0500
the following
1 20
1 22.5
Split flange
07371-30400
07371-30500
corks can be used.
25
28
I 30
1 34
DEW00401
30-5
0
DISASSEMBLY
2. Precautions
AND ASSEMBLY
when
carrying
out installation
work
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation
or deterioration,
screw them in fully, and
align the direction of the hook.
When tightening
split flanges, tighten uniformly in turn to prevent excessive tightening
on one
side.
When operating the hydraulic cylinders for the first time after reassembling
cylinders, pumps and
other hydraulic equipment
removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment
control lever to operate the hydraulic cylinder 4 - 5 times,
stopping 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 -4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
*
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
Then check the water level again.
the engine to circulate the water through the system.
If the hydraulic equipment
has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system.
Then check the oil level again.
If the hydraulic equipment has been removed for repair, always bleed the air from the system after
reassembling
the parts. For details, see TESTING AND ADJUSTING,
Bleeding air.
disulohide arease) to the work eouioment oar&.
Add the soecified amount of arease (molvbdenum
30-6
a
D 155AX-5
DISASSEMBLY
SPECIAL TOOL LIST
AND ASSEMBLY
SPECIAL TOOL LIST

*
Ir
*
Ir
with part number 790T-000-0000

cannot be supplied (they are items to be locally
manufactured).
Necessity:=
: Cannot be substituted, should always be prepared (used).
0 : Extremely useful if available, can be substituted with commercially
available part.
New/remodel:
N . .. . . . .. Tools with new part numbers, newly developed for this model
R . . .. . . . . . Tools with upgraded part numbers, remodeled from items already available
for other models
Blank.. Tools already available for other models, used without any modification
Tools marked
0 in the Sketch column are tools introduced
in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Gil r
Part Name
$2 -2 s$ % Nature of work, remarks
ymbol
Part No.
Nature of work
ZB CY SE rz
Tools
790-331-I 110
Wrench
795-931-1100
Seal puller
795-521-1110
Push tool
Removal, installation of
cylinder head
Removal of engine oil
seal
790-101-5221
Grip
01010-51225
Bolt
01050-31640
Bolt
795-521-1131
Push tool
I
Press fitting of crankshaft front oil seal
I
Press fitting of crankshaft rear oil seal
Disassembly
assembly
and
of engine
795T-473-1110
795-570-I
100
Remover
Disassembly
assembly
and
of damper
assembly
I
Push tool
Press fitting of injection

pump oil seal
1
I
796-514-2110
Wrench
01011-81090
Bolt
791-612-1100
Installer
;;+z~TI
of nozzle
Press fitting
of damper
assembly
Disassembly and assembly
of transmission assembly
clutch brake assembly
Disassembly
assembly
D 155AX-5
and
of HSS
DISASSEMBLY
Nature
SPECIAL TOOL LIST
AND ASSEMBLY
of work
S;ymbol
Part No.
Part Name
i> c
ZGj a
$3 Tj Nature of work, remarks

SE cn
Removal, installation
final drive assembly
Removal
Removal
of
of sprocket
and installa-
tion of final
drive
assembly
Press fitting
Removal
Disassembly
assembly
of planetary
and
of idler, track
Press-fitting
of idler
roller,
roller
carrier
bogie
assembly
30-8
0
of sprocket
D155AX-5
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL LIST
d,
Nature
of work
iymbol
Nut
0 1643-31445
Washer
790-101-2102
Puller (294 kN (30 ton}) n
790-101-1102
Hydraulic
796-670-1020
installer
791T-630-1290
Plate
790-101-2680
Adapter
790-101-2550
Leg
790-101-2510
Block
790-101-2570
Washer
790-101-2560
Nut
790-101-1102
Hydraulic
791-651-1510
assembly
Press fitting
bushing
Id41
roller,
Installer
I Removal
790-102-1891
Nut wrench
791-651-1510
Installer
I3
791T-630-1350
Spacer
!3
791-601-1000
I Oil pump
(n I 1 I
IFilling
Id31
791-685-9550
791-630-1540
Adapter
791-630-1560
Adapter
I=111
04530-I
Eyebolt
04530-11018
Eyebolt
IdI1 I I
I=121 I I
01643-31032
Washer
Id41
Nut
of ring
fitting
of ring
Installation of floating
seal
__-.
carrier roller nut
Installation of floating
seal
Press fitting of carrier
roller ring
bogie assembly
7
Ic
of idler
installation of idler
floating seal
Press fitting of track
roller bushing
I=121 I IPress
pump
remarks
I I
I=111
and
of idler, track
roller carrier
pump
J=
$, -2 $$ g Nature of work,
ZB u SE c/3
01580-01411
1
Disassembly
Part Name
Part No.
with oil
O-
D155AX-5
2030
Removal, press-fitting
pin assembly
of
30-9
0
DISASSEMBLY
Nature
SPECIAL
AND ASSEMBLY
of work
791-630-1440
790-101-4300
10
Part Name
Part No.
;ymbol
(1470kN(150ton)) n
Cylinder
Spacer
s =
& .w
q
ZB a SE
cn
Remover, installer
assembly part No.:
791-630-1500
790-101-1102
Hydraulic pump
Bracket
791T-630-1590
Stand
791-685-9510
Frame
791-685-9520
Frame
791-630-1530
Extension
IWIll
04530-I 2030
Eyebolt
I r-r-i
791-630-1430
Guide
Nature of work, remarks
79lT-630-1580
TOOL LIST
Removal, press-fitting of
pin assembly
Remover, installer
assembly part No.:
791-630-1500
Disassembly and
assembly of idler, track
roller carrier roller,
bogie assembly
1 796101-1102
1 Hydraulic pump
Id11 I I
1n 1 1 I
Assembly of shaft
Remover, installer
assembly part No.:
791-630-1500
12
30-10
a
791-685-9620
Extension
791-630-1510
Shaft
791-630-1520
Nut
791-630-1530
Extension
791-630-1540
Adapter
D 155AX-5
DISASSEMBLY
Nature
AND ASSEMBLY
of work
1s
iymbol
SPECIAL
Part Name
Part No.
l
791-630-1570
TOOL LIST
&_ .+
r z
38 2 Nature of work, remarks
2.5 cf SE UY
Assembly of shaft
Disassembly and
assembly of idler, tracl
roller carrier roller,
bogie assembly
g case cover
recoil spring case
Disassembly and
assembly of recoil
spring assembly
Removal of yoke from

recoil spring case
r.5
L
D155AX-5
791-730-I 130
Bolt
01580-12016
Nut
01643-32060
Washer
Disconnection of yoke
from recoil spring case
30-11
0
SPECIAL TOOL LIST
Part Name
791T-650-2010
Remover assembly
791T-650-2130
Sleeve
791-181-1010
Adapter
791-520-4140
Screw
790-101-2540
Washer
791-112-1180
Nut
790-101-4000
Puller (490 kN {50 ton})
790-101-1102
Hydraulic pump
791T-650-2200
Remover & installer
791-827-1510
Sleeve
791T-650-2210
Sleeve
790-438-1110
Screw
790-101-2540
Washer
790-112-1180
Nut
790-101-2102
790-101-1102
Hydraulic pump
791T-650-2100
Installer assembly
791T-650-2110
Sleeve
791T-650-2120
Plate
790-201-3310
Bolt
790-101-2510
Block
790-101-2570
Washer
01580-01613
Nut
790-105-2300
Jack assembly (196 kN {20 ton})
790-101-1102
Hydraulic pump
790-501-5000
Unit repair stand (for 100V)
790-501-5200
Unit repair stand (for 220V, 240V)
790-901-2110
Bracket
790-901-1343
Plate
790-201-3610
Bolt
795-465-1110
Washer
01643-33080
Washer
01643-32060
Washer
01582-02016
Nut
790-201-2220
Plate
790-201-2750
Spacer
Sketch
Part No.
Qty
Symbol
New/remodel
Nature of work
Necessity
DISASSEMBLY AND ASSEMBLY
fi

Removal of equalizer
bar center pin
Disassembly and
assembly of equalizer
bar assembly
Disassembly and
assembly of pivot
shaft
Removal, press fitting of

equalizer bar side pin
spherical bushing
fi
fi
fi
Press fitting of pivot

shaft ring
1
1
Disassembly and
assembly of HSS pump
assembly
Q
2
30-12
2
Disassembly, assembly
of pump assembly
Disassembly, assembly of
cylinder block assembly
Removal of roller bearing
D155AX-5
SPECIAL TOOL LIST
Qty
790-201-2850
Spacer
790-201-2190
Plate
790-201-2740
Spacer
790-201-2240
Plate
790-201-2750
Spacer
790-101-5001
Push tool kit
790-101-5111
Plate
790-101-5021
Grip
01010-50816
Bolt
796-730-2300
Wrench
795-630-1803
Torque wrench
790-201-2700
Push tool kit
790-201-2740
Plate
791-675-9701
Remover & installer
790-101-4300
Cylinder (1470 kN {150 ton})
790-101-4200
790-101-1102
Hydraulic pump
791-646-7531
Remover
791-660-7460
Pin brush
791-432-1110
Plug push tool
791-932-1110
Plug push tool
791-632-1052
Installer
Insertion of link seal

Filling with oil and
checking air tightness
Symbol
3
Part No.
Part Name
Disassembly and
assembly of HSS pump
assembly
Q
6
790-701-3000
Seal checker
791-675-9581
Adapter
791-675-9590
Guide
01010-52460
Bolt
01010-51440
Bolt
790-101-1102
Pump
790-101-4300
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
10 791-685-9550
Nut
791-685-9560
Bolt
791-675-9570
Adapter
01010-51030
Bolt
R
8
D155AX-5

Removal of roller bearing
Press fitting of roller bearing
Press fitting of shaft assembly
Press fitting of needle

bearing
Inspection of shaft rotating torque
Press fitting of oil seal
Overall disassembly
and assembly of track
shoe assembly
Sketch
Necessity
Nature of work
New/remodel
of track shoe assembly
Removal of pin plug

Cleaning of oil-sealed
track pin
Knocking out pin plug
(large)
Knocking out pin plug
(small)
Disassembly of 1 link
30-13
2
SPECIAL TOOL LIST
Eyebolt
Pump
790-101-4300
791-685-9540
Rod
791-685-9550
Nut
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9550
Nut
791-685-9560
Bolt
791-126-0150
Adapter
791-675-5520
Guide
791-675-5530
Pusher
791-675-9570
Adapter
01010-51030
Bolt
04530-12030
Eyebolt
791-685-9620
Extension
790-101-1102
Pump
790-101-4300
790-101-1102
Pump
790-101-4200
791-675-5542
Adapter
791-675-5571
Adapter
790-101-1102
Pump
790-101-4300
Part No.
04530-12030
10 790-101-1102
Part Name
11
12
Overall disassembly
shoe assembly
13
14
15 791-675-5580
Guide
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9540
Rod
791-685-9550
Nut
791-685-9560
Bolt
791-126-0150
Adapter
01010-51030
Bolt
791-685-9620
Extension
791-675-5542
Adapter
16
30-14
2
Sketch
Qty
Symbol
New/remodel
Nature of work
Necessity
Disassembly of 1 link
Assembly of 1 link
D155AX-5
SPECIAL TOOL LIST
791-675-5571
16 790-101-1102
Part Name
Adapter
Pump
790-101-4300
Cylinder (1470 kN {150 ton}) 1
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9540
Rod
791-685-9550
Nut
791-685-9560
Bolt
791-126-0150
Adapter
01010-51030
Bolt
791-685-9620
Extension
791-675-5550
Guide
791-675-5571
Adapter
791-675-9631
Adapter
790-101-1102
Pump
790-101-4300
17
Overall disassembly
shoe assembly
R 18 791-670-3270
Guide
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9540
Rod
791-685-9550
Nut
791-685-9560
Bolt
Adapter
791-675-5560
Guide
791-675-9570
Adapter
01010-51030
Bolt
791-670-3270
Guide
790-101-1102
Pump
790-101-4300
790-101-1102
Pump
790-101-4200
Puller (294 kN {30 ton}) 1
791-675-9701
Remover & installer 1
19 791-126-0150
20
21 790-101-1102
790-101-4200
D155AX-5
Pump
Sketch
Part No.
Qty
Symbol
New/remodel
Nature of work
Necessity
Assembly of 1 link
Puller (294 kN {30 ton}) 1
Kit for filling with oil

track link
30-15
2
SPECIAL TOOL LIST
21 790-101-4300
790-101-4200
791-646-7900
Push tool kit
Bar
790-434-1210
Guide
791-646-7523
Bar
791-646-7590
Guide
790-502-1003
Cylinder repair stand
790-101-1102
Hydraulic pump
790-102-3802
Multi-wrench
790-720-1000
Expander
Installation of round
head (blade lift cylinder)
Installation of cylinder
piston ring
796-720-1670
Ring
Blade lift cylinder
07281-01279
Clamp
Ripper lift & tilt cylinder
796-720-1690
Ring
07281-01919
Clamp
796-720-1690
Ring
07281-02169
Clamp
790-201-1702
Push tool kit
Press fitting coil bushing
790-201-1821
Push tool
Blade lift cylinder
790-201-1831
Push tool
790-201-1841
Push tool
Blade tilt cylinder
790-101-5021
Clip
01010-50816
Bolt
790-201-1500
Push tool kit
790-201-1630
23 791-434-1220
24
Disassembly and
assembly of hydraulic
cylinder assembly

track link
Pump
790-101-1102
22
Overall disassembly
shoe assembly
Part Name
Sketch
Part No.
Qty
Symbol
New/remodel
Nature of work
Necessity
For large plug
For small plug
of hydraulic cylinder
Blade tilt cylinder
Press fitting dust seal
Plate
Blade lift cylinder
790-201-1640
Plate
790-201-1650
Plate
Blade tilt cylinder
790-101-5021
Grip
01010-50816
Bolt
799-703-1200
Service tool kit
799-703-1100
Vacuum pump (100 V)
799-703-1110
Vacuum pump (220 V)
790-703-1120
Vacuum pump (240 V)
799-703-1400
Gas leak detector
Collection, reuse of
freon gas
30-16
2
Collecting, charging with

freon gas
D155AX-5
DISASSEMBLY
SPECIAL TOOL SKETCH
AND ASSEMBLY
SPECIAL TOOL SKETCH

Note:
Komatsu
sketches.
cannot
accept
any responsibility
for special
tools
manufactured
according
to these
A4 Push tool
100
Unless
be no
otherwise
burrs
or
specified,
flushes
at
the
there
shall
corner.
J-l Plate
-I
s
if?
Cl0
2-22
DRILLS
25
67.5
36.5
I
I
...
PART NAME
PLATE
791T-627-1340
D155AX-5
MATERIAL
HEAT TREATMENT
Ss4ooP
I
an,
1
30-l 7
0
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL SKETCH
J-4 Plate
522 DRILLS
Equally divided around
circumference
HEAT TREATMENT
MATERIAL
I
SS4OOP
WI-Y
1
n
J-4 Sleeve
4
cv
!?
F
791T-627-1360
30-18
0
D155AX-5
DISASSEMBLY
SPECIAL TOOL SKETCH
AND ASSEMBLY
J-5 Spacer
iI
a
co.5
Co.5
__
__
Y
co.5
co.5
__
230
DDwo857
I
I
HEAT TREATMENT
MATERIAL
STKM13A
PART NAME
SPACER
QTY
I
791T-627-1380
L-l Plate
2-14 DRILLS
HEAT TREATMENT
MATERIAL
PART NAME
PLATE
L-4
32
D155AX-5
QN
I
791T-630-1230
30-19
0
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL SKETCH
L-3 Plate
DDlYJJSZ
HEAT TREATMENT
MATERIAL
SS4caP
PART NAME
Q-W
PLATE
791T-630-1290
791T-630-1340
L-4 Spacer
,
C
t-
-g
,
Cl
-3
<
30-20
0
48.5kO.2
Cl
D155AX-5
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL SKETCH
L-8 Spacer
DDD00865
Cl
_
a:+
<
131.9520.2
+
>
791T-630-1350
D155AX-5
30-21
0
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL SKETCH
L-10 Bracket
I-
23 DRILL
280
5v
PLACE
_@40
-I
A-A
LA
The
Paintwork
shall
be PT-9
munsell
8.5845/g.
0
Lo
I
02
BOSS
SS4008
1.75
440
0.17
116
01
PLATE
SS4OOP
SYM.
PART NAME
MATERIAL
DXD0317'
MATERIAL
PART NAME
PTY
SEE DWG
BRACKET
REMARKES
QTYISET "(#
HEAT TREATMENT
----
791T-630-1580
'A
L-10 Stand
,-+-<2PLACES
4-0
0
0
02
24DRIL
4----O
01
15
-I j
-4-c
5
)1580-02016
02
ZPLACES
300
l--A
CWD02536
NUT
SID
--
CHANNEL
SS400A
5. 58
01
PLATE
SS4OOP
SYM.
PART NAME
MATERIAL
30-22
0
A-A
.!A
2.63
QTY/SET "z;;B
---$150, 75. 6. 5
HEAT TREATMENT
MATERIAL
----
SEE DWG
PART NAME
QTY
STAND
116
REMARKES
791T-630-1590
'A
D 155/J-5
DISASSEMBLY
M-l
SPECIAL TOOL SKETCH
AND ASSEMBLY
Spacer
DDW0858
HEAT TREATMENT
MATERIAL
1223w19W
50
M-l
STKM16A
PART NAME
SPACER
QTY
I
791T-630-1150
Spacer
250
12 x 1.75
Cl
500
HEAT TREATMENT
PART NAME
SPACER
791T-630-1160
D155AX-5
MATERIAL
1223301sal
STKMltiA
I
ON
1
30-23
0
DISASSEMBLY
N-l
AND ASSEMBLY
SPECIAL TOOL SKETCH
Sleeve
02
TUBE
5.54
012oxt7
HEAT TREATMENT
MATERIAL
_._
SEE DWG
PART NAME
cm
SLEEVE
01
PLATE
039
SYM.
PART NAME
QlY/SET
Es
t12
791T-650-2130
REMAJKES
N-2 Sleeve
DDDC4870
HEAT TREATMENT
MATERIAL
SEE DEG
02
01
SYM.
30-24
0
TUBE
sTKh416A
I 1.55
I 012oxta
PART NAME
SLEEVE
Q-rf
1
PLATE
PART NAME
MATERIAL
Im/SETI
%?S
REMARKES
791T-650-2210
/\
D155AX-5
DISASSEMBLY
SPECIAL TOOL SKETCH
AND ASSEMBLY
P Sleeve
465.5kO.2
\
02
TUBE
STKMlBA
11.7
DDDWBffi
HEAT TREATMENT
PLATE
SYM.
PART NAME
SrnP
MATERIAL
1
QTY,SET
2.7
MATERIAL
SEE DWG
01sOxt10
PART NAME
SLEEVE
01
ON
1
r22
REMAKES
;F
791T-650-2110
P Plate
2-20 DRILLS
HEAT TREATMENT
MATERIAL
SS4OOP
PART NAME
PLATE
v
D155AX-5
791T-650-2120
QTY
1
30-25
0
REMOVAL OF STARTING
MOTOR ASSEMBLY
STARTING MOTOR
Serial 70001 75000

2
Disconnect
the cable from the negative () terminal of the battery.
1. Open engine right side cover (top) and remove

cover (bottom).
2. Disconnect 3 starting motor wires (1) and 1 wiring connector (2).
3. Remove 3 bolts, then remove starting motor
assembly (3).
1
DED00001
INSTALLATION OF STARTING
MOTOR ASSEMBLY
Carry out installation in the reverse order to

removal.
3
DED00002
30-26
5
D155AX-5
REMOVAL OF ALTERNATOR
ASSEMBLY
ALTERNATOR
Serial No. 70001-75000
Disconnect
1
1. Open engine right side cover (top) and remove
cover (bottom).
2. Disconnect alternator wiring (1) and (2).
2
DED00003

3. Loosen locknut (3), then turn adjustment nut (4)
to loosen tension of V-belt (5).
4. Remove bolts (6) and (7), then remove alternator assembly (8) together with belt cover. 1
e Remove the V-belt from the pulley when removing the alternator assembly.
INSTALLATION OF
ALTERNATOR ASSEMBLY

removal.
1
e
After installing the alternator, adjust the belt

tension. For details, see TESTING AND ADJUSTING, TESTING AND ADJUSTING ALTERNATOR BELT TENSION.
D155AX-5
6
5
3
4
DED00004
30-27
5
5
ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER CORE ASSEMBLY
e
Serial No. 70001 75000

6
Drain coolant.
1. Remove wiring clamp (1).
2. Remove muffler water drain tube (2).

3. Remove adiabatic plate (3).
4. Disconnect turbocharger lubrication tube (4) at

turbocharger end, then move it towards rear.
2
DED00005
5. Disconnect connector (5).

6. Remove oil cooler assembly (6).
7. Remove core assembly (8) from cover (7).
INSTALLATION OF ENGINE OIL

COOLER CORE ASSEMBLY

removal.
Refilling with water

Add water through water filler to the specified
level.
e Run the engine to circulate the water through
the system. Then check the water level again.
DDD00006
30-28
5
D155AX-5
FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
Serial No. 70001 75000
1. Close valve of fuel supply piping.
2. Rotate crankshaft in normal direction and align
match mark of fuel injection pump.
fl This makes it easier to check the compression top dead center position of the No. 1
cylinder when installing the fuel injection
pump.
3. Open engine left side cover (top) and remove
cover (bottom).
4. Disconnect fuel control rod (1), and fuel hoses
(2), (3), (4), and (5).
1
5. Remove boost compensator tube (19).

6. Disconnect fuel hose (6) and tube (7).
7. Remove coupling cover (8).
6
8
DED00008
8. Remove lubrication tubes (9) and (10).
10
9. Disconnect 6 delivery tubes (11).
DED00009
11
DED00010
D155AX-5
30-29
5
5
FUEL INJECTION PUMP
10. Loosen tightening bolt (12) at drive shaft end,

and remove 4 pump mounting bolts (13).
12
13
DED00011
11. Remove fuel injection pump assembly (14) together with coupling.
3
14
13
13
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
DED00012
16
Serial No. 70001 75000

removal.
1
e
15
Adjust the linkage. For details, see TESTING AND ADJUSTING, ADJUSTING FUEL
CONTROL LINKAGE.
DED00013
2
3 Sleeve nut: 123.5 1.0 Nm {2.4 0.1 kgm}
3
e
Install the fuel injection pump as follows.

1) After installing pump assembly, align
damper (I,J) marks (15) and pointer (16)
correctly.
2) Loosen bolt of coupling (18) to align
match mark (17) of injection pump.
18
17
DED00014
30-30
5
D155AX-5
WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.
1
2. Using an adjustable wrench, push tension pulley (2) of fan belt (1), and remove fan belt.
3. Loosen locknut (3), then loosen adjustment nut
(4), and remove V-belt (5).
1
4. Remove connectors (6) and (7).
5. Remove pulley (8).
6. Remove water pump assembly (9).
3
2
4
5
DED00016
DED00015
Serial No. 70001 75000
INSTALLATION OF WATER
PUMP ASSEMBLY

removal.
1
e
After installing the V-belt, adjust the belt tension. For details, see TESTING AND ADJUSTING, TESTING AND ADJUSTING ALTERNATOR BELT TENSION.

level.
e Run the engine to circulate the water through
8
DED00018
D155AX-5
30-31
1
5
TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
Serial No. 70001 - 75000
1. Remove hood assembly.
For details, see REMOVAL OF HOOD ASSEMBLY.
2. Remove adiabatic covers (2) and (3).
3. Disconnect tube (4) and hose (5), then lift off air
cleaner assembly (6).
4 Air cleaner assembly: 35 kg
4. Disconnect lubrication hose (7) and drain tube
(8).
1
5. Remove turbocharger assembly (9).
2
6
4
DBD00026
INSTALLATION OF
Serial No. 70001 75000

removal.
1
3 Hose mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
2
3 Turbocharger mounting bolt:
49.0 9.8 Nm {5 1 kgm}
DED00021
9
DED00020
30-32
5
D155AX-5
TURBOCHARGER
REMOVAL OF
3. Disconnect tube (3) and hose (4), then lift off air
4
Air cleaner assembly: 35 kg
4. Disconnect lubrication hose (6) and drain tube

(7).
1
5. Remove turbocharger assembly (8).
INSTALLATION OF

removal.
1
3
2
3
D155AX-5
Hose mounting bolt:

66.2 7.4 Nm {6.75 0.75 kgm}
Turbocharger mounting bolt:

49.0 9.8 Nm {5 1 kgm}
30-32-1
5
30-32-2
(Blank Page)
D155AX-5
NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
Serial No. 70001 75000
1
e For No. 4 and 5 cylinders, remove the air
cleaner assembly and air supply connector.
3. Disconnect delivery tube (2).
2
DBD00413
4. Loosen locknut (3), and remove connector (4).

3
5. Remove holder (5).
6. Using tool A, remove nozzle holder assembly

(6).
5
3
4
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
DBD00414
Serial No. 70001 75000

removal.
1
3 Cylinder head cover mounting bolt:
24.5 4.9 Nm {2.5 0.5 kgm}
2
3 Delivery tube sleeve nut:
23.5 0.98 Nm {2.4 0.1 kgm}
5
4
3
3 Connector:
31.9 2.5 Nm {3.25 0.25 kgm}
3 Locknut: 39.2 4.9 Nm {4.0 0.5 kgm}
4
3 Holder mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
5
e When assembling the nozzle holder, clean
the nozzle holder mount and check that there
is no dirt or dust inside the sleeve before
assembling.
Tighten the mounting bolts uniformly in turn
to prevent excessive tightening on one side.
DBD00415
DBD00416
D155AX-5
30-33
5
5
FUEL INJECTOR
REMOVAL OF FUEL INJECTOR

ASSEMBLY
1. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY.
2. Remove common rail high-pressure pipe (1).
1
3. Disconnect wiring connector (2).

fl Insert a flat-head screwdriver in the slit of
the connector to press the stopper and disconnect the connector.
2
fl For Nos. 4 and 5, remove the air cleaner
assembly and air intake connector.
5. Remove mounting bolts and rocker arm (4).

fl Loosen locknut (5) and then loosen adjustment screw (6) by 2 - 3 turns so that an
excessive force will not be applied to the
push rod when the rocker arm is installed.
3
6. Remove 2 nuts (7) of solenoid valve above fuel

injector.
4
7. Pull out spring clamp (8) and disconnect clamp
(9).
8. Remove mounting bolts (12) of holder (11) of
connector (having an O-ring) (10) and to remove
holder, then insert connector (10) to remove it.
4
30-33-1
5
D155AX-5
FUEL INJECTOR
9. Remove holder (13) of fuel injector, then remove

injector assembly (14).
5
fl Do not hold the solenoid of the injector with
priers, etc. to remove the injector.
INSTALLATION OF FUEL
INJECTOR ASSEMBLY

removal.
1
3 High-pressure pipe sleeve nut:
39.2 7.4 Nm {4.0 5.0 kgm}
fl If there is any slit "b" or pit "c" on the taper
sealing part (Part "a": The part of 2 mm from
the end) of the high-pressure pipe joint or if
part "d" (Tape seal end: Part of 2 mm from
the end) has level difference that is felt with
a nail (or if part "d" is fatigued) and the fuel
may leak, replace the high-pressure pipe.
2
3 Cylinder head mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
3
fl When tightening the mounting bolts, check
that the ball of the adjustment screw is fitted to the socket of the push rod.
3 Rock arm mounting bolt:
93 103 Nm {9.5 10.5 kgm}
fl Adjust the valve clearance. For details, see
ADJUSTING VALVE CLEARANCE.
D155AX-5
30-33-2
5
ENGINE REAR SEAL
4
fl Method of installing wiring harness.
1) Fit O-ring (15).
2) Install cap (16).
3) Tighten nut (14).
4) Secure clamp with bolt (18).
3 Terminal nut:
1.8 2.2 Nm {0.18 0.22 kgm}
fl Eliminate the slack of the wiring harness and
press it against the injector body.
5
fl Method of installing fuel injector.
1) Install fuel injector assembly (14) and holder
(13) to the cylinder head temporarily.
2) Tighten mounting bolt (19) of holder (13)
temporarily.
3) Tighten sleeve (20) temporarily.
4) Tighten holder mounting bolt (19) se
curely.
5) Tighten sleeve (20) securely.
fl Apply engine oil to the spherical part of the
spherical washer.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
30-33-3
5
D155AX-5
DISASSEMBLY
REMOVAL
SEAL
AND ASSEMBLY
ENGINE FRONT SEAL
OF ENGINE FRONT
1.
Remove radiator, oil cooler, and guard assembly.

For details, see REMOVAL OF RADIATOR,
OIL
COOLER, GUARD ASSEMBLY.
2.
Remove
crankshaft
3.
Remove
rear seal (2).
Removing standard seal

Hook tip of tool A2 to metal ring of seal (2), and
use impact force of a slide hammer to pull out.
Ir Before pulling out, knock the oil seal in
slightly.
This separates the seal from the
housing and makes it easier to pull out the
seal.
*
Do not use a drill. The metal powder will
get inside the engine.
pulley (I).
Tool
Removing seal with sleeve

1) Hook tip of tool A2 to metal ring of seal (21,
and use impact force of a slide hammer to
pull out.
*
Before pulling out, knock the oil seal in
slightly.
This separates the seal from
the housing and makes it easier to pull
out the seal.
2) Using a chisel and hammer, cut sleeve (3)
and remove.
*
Be extremely careful not to damage the
crankshaft when cutting the sleeve.
*
Remove all the metal particles that are
produced.
k?
Slide
hammer
=--===-I
DXD03181
Standard
:iesl
seal
with
sleeve
Flvwheel
houshina
Flywheel
houshino
Metal
ring
of seal
Metal
rina
Crankshaft
DXD03182
30-34
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
FRONT SEAL
1.
ENGINE FRONT SEAL
OF ENGINE
-
Installation of front seal (I)

Before assembling the seal, check that there
are no scratches, burrs, flashes, or rust on
the housing, lip sliding surface, or at the
corner of the end face of the crankshaft.
When assembling the seal, do not coat the
shaft and seal lip with oil or grease.
Wipe
off all oil from the shaft.
Do not remove the internal plastic tube from
the standard seal until the seal is assembled.
Plastic
tube
installation
Smaller
for
end
Put large inside diameter end of internal plastic tube (2) in contact with end of crankshaft
(3).
Ir Be particularly careful to assemble
ing in the correct direction.
fac-
CDE00230
2)
3)
4)
Hold metal ring of seal (I) with both hands

and push in with sudden force until it feels
that it has gone over large diameter of internal plastic cylinder.
After pushing seal in, remove internal plastic tube (2).
*
When removing,
be particularly
careful
not to damage the seal lip.
Tighten bolts of tool A3 uniformly until end
face of tool A3 contacts end face of crankshaft (3) and press fit seal (I).
*
When press fitting the seal, be extremely
careful not to damage the lip at the PTO
end when setting the tool in position.
*
After press fitting the seal, remove all
the remains of the red sealant on the
outside circumference.
CWD02540
D155AX-5
DISASSEMBLY
2.
AND ASSEMBLY
ENGINE FRONT SEAL
Installation of damper pulley assembly

Fit damper pulley assembly (2) and tighten with
mounting bolts (1).
w
Mounting bolt:
245 - 308.7 Nm I25 - 31.5 kgm1
30-36
0
D155AX-5
DISASSEMBLY
REMOVAL
SEAL
ENGINE REAR SEAL
AND ASSEMBLY
OF ENGINE REAR
1. Remove damper assembly.

For details, see REMOVAL OF DAMPER
BLY.
bolt of flywheel
ASSEM-
(I),
2.
Remove 1 mounting
install guide bolt 0.
3.
Using eyebolts 0, sling flywheel

move remaining mounting bolts.
4.
Pull flywheel (I) out and lift off.

The flywheel pilot portion is shallow,
may fall out suddenly, so be careful
get your fingers caught.
&I kg
Flywheel:
(I),
and
then rea
DBCW417
and it
not to
60 kg
m
from the end face of
5.
Remove rear seal (2).

Measure the dimension
*
the housing.
Removing standard seal

Hook tip of tool A2 to metal ring of seal (21, and
use impact force of a slide hammer to pull out.
*
This separates the seal from the
slightly.
housing and makes it easier to pull out the
seal.
Ir Do not use a drill. The metal powder will
DBD00418
Tool
A2
Slide
get inside the engine.
Removing seal with sleeve

I) Hook tip of tool A2 to metal ring of seal (2),
and use impact force of a slide hammer to
pull out.
*
This separates the seal from
slightly.
the housing and makes,it easier to pull
2)
out the seal.

Using a chisel and hammer, cut sleeve (3)
and remove.
Be extremely careful not to damage the
*
crankshaft when cutting the sleeve.
Ir Remove all the metal particles that are
hammer
-,/,
DXD03181
I
Standard
with
sleeve
Flywheel
houshins
Flywheel
houshina
es1
seal
rino
Metal
of seal
produced.
Crankshaft
3
DXD03182
D155AX-5
30-37
0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
REAR SEAL
*
ENGINE
REAR SEAL
OF ENGINE
With the Teflon seal (lay-down lip seal), check

the condition of the wear of the shaft, then
select either astandard seal or a seal with a
sleeve, and assemble the seal.
The condition
of wear is judged
by the
smoothness (depth of wear less than 10 urn
when touched with the flat of a finger).
If
there are no scratches, assemble a standard
seal; in all other cases, assemble a seal with
a sleeve.
Assembly
(Plastic
auide
tube)
Standard
seal
Seal
with
sleeve
DEE00103
1.
Procedure for assembling

standard seal
When assembling the seal, do not coat the
shaft and seal lip with oil or grease.
Wipe
off all oil from the shaft.
Do not remove the internal plastic tube from
the standard seal until the seal is assembled.
Put large inside diameter end of internal plastic tube (3) in contact with end of crankshaft
(4).
Ir Be particularly careful to assemble facing in the correct direction.
Lip
at
engine
end
DEE00104
Lip
at
PTO and
Assembly
(Plastic
Large
inside
diameter
end
guide
tube)
Small
inside
diameter
end
DEE00105
2) Hold metal ring of seal (1) with both hands

3)
and push in with sudden force.

After pushing seal in, remove internal plastic tube (3).
Ir When removing,
be particularly
careful
not to damage the seal lip.
CEE00434
30-38
0
D155AX-5
DISASSEMBLY
4)
2.
AND
ENGINE
ASSEMBLY
Tighten 3 bolts uniformly until end face of

tool A5 (for press fitting seal) contacts end
face of crankshaft (4) and press fit seal (I).
First, tighten tool A5 (for press fitting
seal) until bolt (45 mm) comes into contact, then tighten with bolt (25 mm).
When press fitting the seal, be extremely
careful not to damage the lip at the PTO
end when setting the tool in position.
After press fitting the seal, remove all
Assembly procedure for seal with sleeve

When assembling
the seal, do not coat the
shaft and the area between the sleeve and
seal lip with oil or grease.
Wipe off all oil
from the crankshaft.
Always handle the seal and sleeve as a set.
Never disassemble
it.
Set sleeve/seal (2) to tool A5 (for press fitting seal with sleeve).
&
Surface of tube inside sleeve :
Gasket sealant (LG-71
REAR SEAL
CWD02541
Lip of crankshaft side
DXD03186
DXD03187
2)
Put sleeve of seal in contact with end

face of crankshaft, then tighten 3 bolts
uniformly until end face of tool A5 contacts end face of crankshaft (4) to press
fit sleeve/seal (2).
Ir First, tighten tool A5 (for press fitting seal with sleeve) until bolt (45
mm) comes into contact, then tighten
with bolt (25 mm).
CWDO2543
D155AX-5
DISASSEMBLY
3)
4)
Remove
sleeve)
seal).
Tighten
tool A5
face of
ENGINE REAR SEAL
AND ASSEMBLY
tool A5 (for press fitting seal with

and install tool A5 (for press fitting
3 bolts uniformly until end face of
(for press fitting seal) contacts end
crankshaft (4) to press fit sleeve/seal
(2).
Ir First, tighten tool A5 (for press fitting
seal) until bolt (45 mm) comes into contact, then tighten with bolt (25 mm).
Ir After press fitting the seal, remove all
3.
CWD02544
Flywheel
Using eyebolt @ (12 mm, P=1.75), raise flywheel
(I) and tighten to crankshaft with mounting bolts.
&
Coat the thread and seat of the bolt completely with SAE No. 30 engine oil.
& kg
Ir
Flywheel
: 60 kg
Tighten the flywheel mounting bolts as follows.

&
Flywheel mounting bolt :
1st step :
Tighten to 112.7 - 122.5 Nm Ill.5 - 12.5 kgm1

2nd step : I) When using tool Al
Using
an angle tightening
wrench (tool Al), tighten bolts
a further 90+3$ in order @ to
0.
2) When not using tool Al

Make
wheel
bolts
@ to
marks on bolt and flywith paint, then tighten

a further 90+3to in order
@.
DXD03188
30-40
0
After tightening,
make one punch mark on
the bolt head to indicate the number of times
it has been tightened.
.
If any bolt already has five punch marks,
do not reuse it. Replace it with a new
bolt.
Makemarkson
D155AX-5
DISASSEMBLY
AND ASSEMBLY
ENGINE REAR SEAL
DhDOW46
After installing the flywheel,

use tool CiJ to
measure the face runout and radial runout.
*
Face runout: Max. 0.30 mm
*
Radial runout: Max. 0.30 mm
D155AX-5
30-41
0
CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
Serial No. 70001 75000
Disconnect the cable from the negative (-) terminal of the battery.
1. Drain coolant.
2. Close fuel supply valve.
4. Remove engine side covers (left, right).
6. Disconnect tube (4) and hose (5), and lift off air
6
4 Air cleaner assembly : 35 kg
4
DBD00026
7. Remove tube (7), then lift off muffler assembly

(8).
4 Muffler assembly : 45 kg
7
DBD00027
8. Remove bracket (9).
10
9. Disconnect turbocharger lubrication hose (10)
and return tube (11).
1
11
30-42
5
DBD00028
D155AX-5
DISASSEMBLY
10. Lift off turbocharger

sembly
I+ kg
11. Remove
CYLINDER HEAD
AND ASSEMBLY
and exhaust
(12).
Turbocharger,
bly : 50 kg
aeration
as-
manifold
exhaust
manifold
tube (13).
assem-
hose (14) and tube (151, and remove

corrosion resistor (16) and fuel filter (17) together
a
with bracket.
of the electrical inThe ground connection
*
with the same
take air heater is tightened
bolt.
12. Disconnect
13. Remove engine oil filter (18).

14. Disconnect dust indicator hose (19).
15. Disconnect 4 heater relay wires (20).
+
Make marks when

bracket (21).
disconnecting.
16. Remove
oil tube (22), oil filler (23), and boost

tube (44).
compensator
18. Remove clamp bolts of air conditioner hose (241,
wiring (251, level gauge (261, fuel hose (271, and
m
corrosion hose (28).
the
The bolts are used also for tightening
*
and
length
the
check
so
manifold,
intake
position of installation of the bolts.
17. Remove
Dl!SAX-5
30-43
0
DISASSEMBLY
19. Remove
CYLINDER
AND ASSEMBLY
aftercooler
piping
(451, (46).
45
20. Remove
intake connector
21. Remove
delivery
22. Remove
clamp
of PTO level gauge
CLD02173
(31).
and aftercooler
assemm
spill tube (33).
25. Remove
delivery
jzJ
tube (34).
26. Remove turbocharger lubrication

*
No. 3 cylinder head only
head cover.
46
(30).
24. Remove
27. Remove
CL002172
(29).
tube clamp
23. Remove intake manifold

bly (32).
HEAD
hose (IO). m
m
28. Remove rocker arm assembly (35).
*
Loosen the locknut and turn the adjustment
screw back 2 - 3 turns.
30-44
0
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
29. Remove
crosshead
30. Remove
push rod (37).
CYLINDER HEAD
(36).
31. Loosen locknut (38).

32. Remove
connector
33. Remove
holder
34. Using
tool
(39).
(40).
A, remove
nozzle
holder
assembly
(41).
DEW1246
35. Remove
D155AX-5
housing
(42).
DISASSEMBLY
36. Remove
f?lkg
30-46
0
AND
cylinder
Cylinder
CYLINDER
ASSEMBLY
head assembly
head assembly
(43).
HEAD
: 30 kg (each)
D155AX-5
CYLINDER HEAD
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
Serial No. 70001 75000
removal.
1
3 Mounting bolt : 66.2 7.4 Nm
{6.75 0.75 kgm}
2
fl Tighten the bolts in the order 1 - 3 as
shown in the diagram on the right, then
tighten in the order 4 - N.
3 Exhaust manifold mounting bolt :
1st step : 29.4 4.9 Nm
{3.0 0.5 kgm}
2nd step : 66.2 7.4 Nm
{6.75 0.75 kgm}
3
3 Joint bolt : 29.4 4.9 Nm
{1.15 0.15 kgm)
4
fl Install the hoses without twisting or interference.
{3.0 0.5 kgm}
5
fl Tighten the bolts in the order of 1 - N as
shown in the diagram on the right.
3 Intake manifold mounting bolt :
1st step : 29.4 4.9 Nm
{3.0 0.5 kgm}
2nd step : 66.2 7.4 Nm
{6.75 0.75 kgm}
6
3 Intake connector mounting bolt :
49.0 9.8 Nm {5 1 kgm}
7
{0.9 0.1 kgm}
8
3 Delivery tube sleeve nut :
23.5 1.0 Nm {2.4 0.1 kgm}
9
3 Head cover mounting bolt :
24.5 9.8 Nm {2.5 1.0 kgm}
0
fl Clean the mounting bolt oil holes before installing.
fl Check that the ball of the adjustment screw
is fitted properly into the socket of the push
D155AX-5
i !8
!9 o r!4
u!7
@0 w
q!3
!5 t !0 @2
!6 y
e@1
@3 !1
@4 !2
DBD00041
@2 !8 !4 !0 y w e
@1 !7
!1 !5 !9 @3
!3 o t q r i !2 !6 @0 @4
DAD00042
rod.
fl Adjust the valve clearance.
For details, see TESTING AND ADJUSTING, ADJUSTING VALVE CLEARANCE.
3 Rocker arm assembly :
98 4.9 Nm {10 0.5 kgm}
3 Locknut :
48.0 2.9 Nm {4.9 0.3 kgm}
A
fl Adjust the crosshead as follows.
1) Loosen locknut, then turn adjustment
screw back.
2) Press top of crosshead lightly and
tighten adjustment screw.
3) When adjustment screw contacts
valve stem, screw in a further 20.
4) Tighten locknut to hold in position.
3 Locknut : 58.8 5.9 Nm
{6.0 0.6 kgm}
B
3 Locknut : 39.2 4.9 Nm
{4.0 0.5 kgm}
30-47
5
DISASSEMBLY
CYLINDER HEAD
AND ASSEMBLY
m
w
Connector
Holder
: 31.9 +. 2.5 Nm
(3.25 2 0.25 kgm)
1
mounting
bolt : 66.2 + 7.4 Nm

16.75 t 0.75 kgm}
+
*
*
Check that there is no dirt or dust on the

cylinder head mounting surface or inside the
cylinder.
When installing the gasket, check that the
grommet does not come out.
Coat the bolt thread and seat face completely
with molybdenum
disulphide (LM-PI.
Tighten the cylinder head mounting bolts in
the order given in the diagram.
&
Cylinder head mounting bolt :
Anti-friction
compound (LM-PI
w
Cylinder head mounting bolt :
1st step : Tighten
to 147 r 9.8 Nm
{I5 f 1 kgml
2nd step : Tighten to 215.6 + 4.9 Nm
(22 f 0.5 kgm}
3rd step : 1) When using tool B
.
Using an angle tightening
wrench, tighten bolt 90+3r.
2) When not using tool B
.
Make marks on bolt and flywheel with a felt pen, then
tighten bolt 90.
Make marks on
cylinderhead and bolt
Ir Tighten bolt 0 to 66.2 * 7.4 Nm (6.75 f 0.75

kgm) one time.
* After tightening,
make one punch mark on
the bolt head to indicate the number of times
it has been tightened.
If any bolt already has five punch marks,
do not reuse it. Replace it with a new
bolt.
DAD03345

l
30-48
0
Make mark with punch
Add water through water filler to the specified level.

Run the engine to circulate the water through
Then check the water level
the system.
again.
D155AX-5
DISASSEMBLY
THERMOSTAT
AND ASSEMBLY
REMOVAL OF THERMOSTAT
ASSEMBLY
1.
Drain coolant.
2.
Remove alternator assembly.

For details, see REMOVAL OF ALTERNATOR
SEMBLY.
inlet hose (1).
3.
Disconnect
radiator
4.
Disconnect
bypass tube (2).
5.
Remove
cover (3).
6.
Remove
2 thermostats
INSTALLATION
THERMOSTAT
l
Carry out installation

removal.
AS-
(4).
OF
ASSEMBLY
in the
reverse
order
to

level.
t
Then check the water level
the system.
again.
D155AX-5
DBDW422
30-49
0
REMOVAL OF AIR
ASSEMBLY
Serial No. 70001 75000
1 3
Using tool X, collect freon gas (R134a).
2
1. Open engine left side cover (top) and remove
cover (bottom).
2. Remove wiring connector (1).
3. Disconnect hoses (2) and (3).

1
fl Fit blind plugs to prevent dirt or water from
entering the hoses.
DBD00423
Serial No. 70001 75000

4. Loosen 4 mounting bolts (4).
5. Remove V-belt cover (5).
6
6. Loosen adjustment bolt (6) and remove.
7. Remove mounting bolts (4), remove V-belt (7)
from pulley, then remove compressor assembly
(8).
2
5
DBD00424
Serial No. 70001 75000

4
DBD00425
30-50
5
D155AX-5
DISASSEMBLY
AND ASSEMBLY
INSTALLATION OF AIR
ASSEMBLY
.

removal.
m*
sr
*
in the
reverse
order
to

Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses.
Check that there are O-rings at the piping
connection of the air conditioner
hoses before installing.
Coat the O-rings thoroughly
with compressor oil (Showa Shell Suniso 4G or 5G).
Tighten the air conditioner gas piping to
the following tightening torques.
Thread
size Tightening
torque
(Nm {knmH
Remarks
16 x 1.5
11.8.- 14.7 II.2 - 1.51 Liquid
22 x 1.5
19.6 - 24.5 (2.0 - 2.5) Discharge
24 x 1.5
29.4 - 34.3 (3.0 - 3.51 Suction
p?J
*
After installing the V-belt, adjust the belt tension. For details, see TESTING AND ADJUSTING, TESTING AND ADJUSTING
BELT TENSION.
Charging with air conditioner
gas
Using tool S, charge the air conditioner

with air conditioner gas (R134a).
D155AX-5
circuit
30-5 1
0
DISASSEMBLY
AIR CONDITIONER
AND ASSEMBLY
COMPRESSOR
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY
APark
the
machine on level ground, lower the

completely to the ground, then
disconnect the cable from the negative (-1 terminal of the battery.
work equipment
1. Using tool X, collect freon gas (R134a).
2.
Open side cover (I) and disconnect

nector (2) (CN223).
3.
Remove
& kg
wiring
con-
cover (3).
Cover : 30 kg
4.
Disconnect hose (4) from receiver tank and hose

(5) from air conditioner compressor.
a
Ir The condenser hose mount breaks easily, so
always use wrenches on both sides.
5.
Disconnect
6.
Remove mounting bolts, then remove

tioner condenser assembly (7).
wiring
connector
INSTALLATION
CONDITIONER
ASSEMBLY
l
Carry out
removal.
*
*
*
installation
(6) (ARC).
air condi-
OF AIR
CONDENSER
in the
reverse
order
to

connection of the air conditioner hoses, and
coat the O-rings thoroughly
with compressor oil before connecting.
Charging with air conditioner gas

Using tool X, charge with freon gas (R134a).
30-52
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF FUEL TANK

ASSEMBLY
a
Park the machine on level ground, lower the

work equipment completely to the ground, then
1.
Remove
2.
Close lever (2) of fuel valve.
3.
Disconnect
hose (3) leading
4.
Disconnect
fuel return hoses (4) and (5).
5.
Disconnect fuel
(6) (CN422).
6.
Lift off fuel tank assembly (7).

+
Sling at three points and use a lever block at
the center to keep the tank horizontal.
+
Move the tank to the rear, and when it clears
the floor frame, raise the rear of the tank
slightly with the lever block. (Do this to avoid
interference with the ripper hoses.)
cover (I) at bottom
level sensor
of fuel tank.
to priming
wiring
pump.
connector
INSTALLATION OF FUEL TANK

ASSEMBLY
. Carry out installation in the reverse order to
removal.
D155AX-5
30-53
a
DISASSEMBLY
RADIATOR
AND ASSEMBLY
REMOVAL OF RADIATOR
ASSEMBLY
Lower the
A ground.
work equipment
completely
to the
Release the remaining pressure in the circuit.

For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Disconnect the cable from the negative (-1 terminal of the battery.
A..
_.

2. Drain coolant.
3. Lift opposite side of hinge and gradually open
underguard under engine.
4. Disconnect 2 power train oil cooler hoses (I).
5. Disconnect 2 radiator hoses (2).
6. Disconnect clamp (3) for hydraulic cooler hose
from radiator.
7. Open radiator grill (4).
8. Remove radiator top cover (5) and left and right
side plates.
9. Disconnect hydraulic cooler hose (6) and remove
clamp.
10. Loosen locknuts on locknuts on hydraulic cooler

assembly swing bolts (71, and screw bolts into
both top and bottom swing holes (condition a).
11. Remove 8 bracket mounting bolts (81, and open
hydraulic cooler assembly (9) to front.
30-54
0
D155AX-5
RADIATOR
DISASSEMBLY
AND ASSEMBLY
12. Disconnect
radiator
inlet hose (IO).
13. Disconnect
aeration
hose (1 I).
14. Disconnect
sub-tank
hose (12).
15. Disconnect head lamp connector (13) (CN2011,

then remove 6 clamps and move wiring towards
head lamp.
16. Remove
left and right hood mount brackets (14).
17. Remove
seal (15).
18. Remove
bottom
19. Remove
seal (17).
20. Remove
top mount
mount
bracket (16).
bolt (18).
17
16
21. Lift off radiator assembly (19).

*
Be extremely careful not to damage the seal
or radiator core when removing the radiator.
&l kg
D155AX-5
Radiator
assembly
: 329 kg
30-55
0
DISASSEMBLY
AND ASSEMBLY
RADIATOR
INSTALLATION OF RADIATOR
ASSEMBLY
l

removal.
in the reverse order to
If
*
After installing the hydraulic cooler assembly, remove bolts (7) from both top and bottom swing holes, then fix them at the original positions with the locknuts (condition b).
m
m
Radiator inlet hose clamp :

882.6 + 49.0 Ncm I90 t 5 kgcm)
Aeration hose clamp :

333.4 2 49.0 Ncm (34 + 5 kgcml
Refilling
with
water

level.
*
Refilling
case)
with
oil (hydraulic
tank,
power
train
Add engine oil through oil filler to the specified

level.
*
Run the engine to circulate the oil through
the system. Then check the oil level again.
30-56
0
Dl MAX-5
RADIATOR,
AND ASSEMBLY
DISASSEMBLY
OIL COOLER,
GUARD
REMOVAL OF RADIATOR, OIL

COOLER, GUARD ASSEMBLY
1. Drain coolant.
from
assembly
blade lift cylinder
2. Disconnect
guard.
to
secure
blade, then
For details, see REMOVAL OF BLADE ASSEMBLY.
3. Lift engine undercover at opposit end of hinge
and open engine undercover gradually.
hoses (I).
4. Disconnect
2 blade lift cylinder
5. Disconnect
2 hydraulic
6. Disconnect
2 power train oil cooler hoses (3).
7. Disconnect
2 radiator
cooler hoses (2).
hoses (4).
8. Remove hood assembly (5).

9. Remove
left and right covers (6).
IO. Remove
left and right side covers (7).
11. Remove
radiator
DELM429
B/---T
top cover (8).
If
12. Disconnect radiator inlet hose (9).
move
and
end
at the radiator
Disconnect
*
towards the engine.
@
13. Disconnect aeration hose (IO).
Sr Disconnect at the radiator end, then remove
2 clamps and move towards the engine.
m
hose (II).
14. Disconnect air conditioner
+ Loosen the sleeve nut slightly, and release
gas (R134a) completely
the air conditioner
the hose.
before disconnecting
* Fit blind plugs to prevent dirt or water from
entering
15. Disconnect
(CN201).
D155AX-5
the hoses.
head lamp
wiring
connector
(12)
30-57
DISASSEMBLY
AND ASSEMBLY
RADIATOR, OIL COOLER, GUARD
16. Remove fan guard (13).
17. Push tension

and remove
pulley (141, loosen

fan belt (15).
belt tension,
DElXM4.23
18. Remove
head lamp (16).
I- II
DEW0434
19. Sling radiator,
oil cooler, guard assembly (171,

remove lock plate, then remove 4 pins (181, and
lift off radiator, oil cooler, guard assembly (17).
Ir Be extremely careful not to damage the wiring and hoses when removing.
&I
kg
30-58
0
Radiator,
oil cooler,
guard assembly :
2,050 kg
Dl E&AX-5
DISASSEMBLY
AND ASSEMBLY
RADIATOR,
OIL COOLER,
GUARD
INSTALLATION OF RADIATOR,
OIL COOLER, GUARD
ASSEMBLY
.
Carry out
removal.
installation
Radiator
Aeration
in the
reverse
order
to
inlet hose clamp :

882.6 t 49.10 Ncm I90 z 5 kgcm}
hose clamp
: 333.4 + 49.0 Ncm

64
+. 5 kgcml

level.
Ir Run the engine to circulate the water through
Refilling with oil (hydraulic tank, power train

case)
level.
*
D155AX-5
30-59
0
DISASSEMBLY
FAN DRIVE
AND ASSEMBLY
REMOVAL OF FAN DRIVE

ASSEMBLY
Disconnect the cable
A minal
of the battery.
(-1 ter-
the negative
from
1. Drain coolant.
2. Remove
hood assembly.
For details, see REMOVAL
BLY.
3. Remove
radiator
side plates.
OF HOOD
top cover
left and
and
radiator inlet hose (I)

engine end.
4. Disconnect
towards
5. Disconnect
clamp
aeration
bracket (3).
6. Disconnect
wards
sub-tank
sub-tank end.
7. Disconnect
right
and move
m
it
hose (2) and remove
hose
m
(4) and move
it to-
hose (5).
hose
air conditioner
8. Remove condenser,
ASSEM-
guard, and sub-tank
assem-
bly (6).
+I kg
Condenser,
guard,
sub-tank
assembly :
25 kg
wrench, push tension pulley (8) of fan belt (71, and remove fan belt (7).
9. Using an adjustable
IO. Remove
fan guard
as 3 parts.in
order (91, (IO),
(II).
30-60
0
D155AX-5
DISASSEMBLY
FAN DRIVE
AND ASSEMBLY
head lamp connector (12) (CN201),

then remove 2 clamps and move wiring towards
radiator.
11. Disconnect
12. Remove left and right hood mount brackets (13).

13. Remove
seal (14).
eyebolts 0, sling fan drive and guard

assembly (151, then remove mounting bolts, and
remove assembly.
14. Using
&I kg
Fan drive, guard assembly
: 150 kg
15. Remove guard (17) from fan drive assembly
(16).
16
INSTALLATION
ASSEMBLY
.
Carry out
removal.
installation
OF FAN DRIVE
in the
reverse
order
to
Radiator
inlet hose clamp :

882.6 t 49.0 Ncm I90 +. 5 kgcm}
Aeration
hose clamp :
333.4 + 49.0 Ncm I34 2 5 kgcm1
D155AX-5
30-61
0
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
ALower
the work equipment
completely
to the
ground.
Release the remaining pressure in the
circuit. For details, see TESTING AND ADJUSTING, RELEASING
REMAINING
PRESSURE
IN
HYDRAULIC CIRCUIT.
Then loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.

1.
Open radiator grill (1).
2.
Remove cover (2).
3.
Disconnect hoses (3) and (41, and clamp (5).
4.
Loosen locknuts on hydraulic cooler assembly

swing bolts (61, and screw bolts into both top
and bottom swing holes (condition a).
5.
Remove 8 bracket mounting bolts (7)
6.
Open hydraulic cooler assembly (8) to front.
7.
List off hydraulic cooler assembly (8).

kg
rz+l
Hydraulic cooler assembly : 105 kg
INSTALLATION OF HYDRAULIC
COOLER ASSEMBLY
l

removal.
Refilling with oil (hydraulic tank)

level.
*
30-62
0
D155AX-5
ENGINE
REMOVAL OF ENGINE
ASSEMBLY
Serial No. 70001 75000
Disconnect
fl Close the supply valve of the fuel tank.

1. Remove radiator, oil cooler, guard assembly.
For details, see REMOVAL OF RADIATOR, OIL
COOLER, GUARD ASSEMBLY.
1
DED00436
2. Disconnect starting motor wiring (1).

3. Disconnect engine speed sensor connectors (2)
(CN009, CN010).
DED00437
4. Disconnect wiring connector (3) (CN101).

5. Disconnect 2 air conditioner hoses (4). 1
fl Loosen the sleeve nut slightly, and release
the air conditioner gas (R134a) completely
before disconnecting the hose.
fl Fit blind plugs to prevent dirt or water from
entering the hoses.
fl Disconnect at the air conditioner end, then
remove all the clamps from the floor frame
and move towards the engine.
DED00438
6. Disconnect 2 heater hoses (5).

fl Disconnect at the air conditioner end, then
move towards the engine.
5
DED00439
D155AX-5
30-63
5
DISASSEMBLY
hose (6).
7. Disconnect
fuel supply
8. Disconnect
fuel return hose (7).
9. Disconnect
fuel control
10. Disconnect
ENGINE
AND ASSEMBLY
ground
rod (8).
wiring
(9).
11. Disconnect
universal
12. Remove front mount

bolts (12).
joint (IO) at damper
7 -
DEW0440
end.
bolts (11) and rear mount

m
11
12
(13) towards front of

13. Move engine assembly
machine, and lift off gradually.
Be careful not to damage the wiring or hoses
*
when removing the engine assembly.
&I kg
30-64
0
Engine assembly
: 1,750 kg
D155AX-5
ENGINE
Disconnect
the cable from the negative (-) terminal of the battery.

fl Close the fuel feed valve.
1. Remove radiator and oil cooler and guard assembly. For details, see REMOVAL OF RADIATOR AND OIL COOLER AND GUARD ASSEMBLY.
2. Disconnect starting motor wiring (1).

3. Disconnect wiring connector (2).
4. Disconnect 2 air conditioner house (3).
1
fl Loosen the sleeve nut of each hose a little to
discharge the all air conditioner refrigerant
(R134a), then disconnect the hose.
fl Plug the hoses to prevent dirt, water, etc.
from entering them.
fl Remove the all clamps on the floor frame
and move the hoses toward the engine.
5. Disconnect 2 heater hoese (4).
6. Disconnect air conditioner wiring connector (5).

7. Disconnect fuel hoses (6), (7), and (8).
D155AX-5
30-64-1
5
ENGINE
8. Disconnect ground wire (9).
9. Disconnect universal joint (10) from damper.
10. Remove front mounting bolts (11) and rear

mounting bolts (12).
2
11. Moving engine assembly (13) to front of machine body, lift it off gradually.
fl After removing the engine assembly, take
care not to damage the wires, hoses, etc.
4 Engine assembly : 1,750 kg
30-64-2
5
D155AX-5
DISASSEMBLY
INSTALLATION
ASSEMBLY
l

removal.
*
*
*
ENGINE
AND ASSEMBLY
OF ENGINE
in the
reverse
order
to

connection of the air conditioner
hoses before installing.
Coat the O-rings thoroughly
with compressor oil (Shell Suniso 4G or 5G).
Tighten the air conditioner gas piping to
the following tightening torques.
Thread
size Tightening torque

(Nm Mm))
Remarks
16 x 1.5
11.8 - 14.7 Il.2 - 1.5} Liquid
22 x 1.5
19.6 - 24.5 {2.0 - 2.5) Discharge
24 x 1.5
29.4 - 34.3 13.0 - 3.51 Suction
Engine
mount
bolt:
931.7 + 98.1 Nm I95 t 10 kgm1
D155AX-5
30-65
0
DISASSEMBLY
AND ASSEMBLY
DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1.
Drain oil from damper

-
2.
3.
Damper
chamber.
chamber
: 1.5 1
Remove floor frame assembly.

For details, see REMOVAL OF FLOOR
ASSEMBLY.
FRAME
Lift off HMT pump assembly.

For details, see REMOVAL OF HMT PUMP
SEMBLY.
AS-
4.
Disconnect or
to power train
FOR DETAILS,
LUBRICATION
5.
Disconnect breather hose (I) and remove

stick tube (2) together with hose.
6.
Lift off universal joint assembly (31, then remove

coupling (4) at torque converter end.
m
7.
Remove mounting
bolts of damper cover assembly (5), then install (2) guide bolts @ on
opposite sides, and use forcing screws @ to
pull damper cover (6) out to position where it is
possible to install lifting tool.
/KJ
8.
Lift off damper
cover assembly
(6).
Damper
cover assembly
: 117 kg
kg
rz?l
30-66
0
remove piping and hoses installed

and lubrication pump.
SEE REMOVAL OF POWER TRAIN,
PUMP ASSEMBLY.
dip-
Dl !XAX-5
DISASSEMBLY
9.
DAMPER
AND ASSEMBLY
Removal of Damper
1) Remove 2 mounting bolts of damper (71, then
m
set guide bolts @ in position.
2) Remove remaining mounting bolts, then use
m
forcing screws @I to pull out.
3) Pull out to position where it is possible to
install eyebolts 0, set lifting tool to damper
(7), then remove.
INSTALLATION
ASSEMBLY
l
Carry out
removal.
OF DAMPER
installation
in the
reverse
order
to
a
bolt :
Thread tightener (LT-2)
Universal joint mounting bolt :
110.8 + 12.7 Nm (II.3 +11.3 kgm)
joint mounting
Universal
&
w
Damper cover Mounting bolt :

110.8 = 12.7 Nm Ill.3 F 1.3 kgm)
m
m
*
When installing the damper cover assembly, remove all oil and grease from the shaft
spline, coat with dry lubricant A, leave for 2
or 3 minutes, then coat with lithium-based
pressure
extreme
disulphide
molybdenum
grease B, and assemble.
Level Dlua.
Dry type molybdenum disulphide
SUMICO LUB:
ROCOL DRY SPRAY
Mounting bolt :
110.8 + 12.7 Nm Ill.3
Damper
I 1.3 kgm}
Refilling with oil

chamber
: 1.5 e (SAE30CDl
Damper
Plug : 152.0 + 24.5 Nm 115.5 z 2.5 kgm}
D 155/4X-5
30-67
0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
DAMPER
OF DAMPER ASSEMBLY
16
lXiXJ1208
Disassembly
of damper cover assembly (II
1. Coupling
Remove bolt (3) from cover (21, then remove
holder (4) and coupling (5).
DEEOG3.M
30-68
0
D155AX-5
DISASSEMBLY
2.
DAMPER
AND ASSEMBLY
Shaft
I)
Set damper cover assembly (I) to block 0,

then tap from output end with a plastic hammer, and pull out shaft (6).
* Remove shaft (6) together with oil seal
(8) and inner race (7-I) of bearing (7).
7-l
2)
Remove collar (7-2) and O-ring of bearing

(7) from shaft (61, then remove inner race (7-
7-l
I).
DDiXI1209
7-2
/
O-ring
DEW1210
3.
Bearing, oil seal

1)
Remove oil seal (9) from cover (2), then remove inner race (7-3) of bearing (7).
7-3
I
2)
DDWl211
Remove outer races (7-4) and (7-5) of bearing (7) from cover (2).
7-k
D155AX-5
DDco1212
30-69
DISASSEMBLY
AND ASSEMBLY
DAMPER
Disassembly of damper assembly (101

4. Remove bolt (111, then remove flange
(12).
5.
Remove outer
cushion (15).
(14), and
6.
Pull out plug (17) from flange (16).

Ir Only when replacing the plug.
body
(131, inner
body
16
15
17
14
13
DDDO1213
30-70
0
Dl SAX-5
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
DAMPER
OF DAMPER ASSEMBLY
16
Assembly of damper assembly (101

1. Align bolt holes of flange (16) and outer body
(13) with cylinder 0, then assemble inner body
(14).
&
&
&
surface of flange, outer body :

Gasket sealant (LG-41
Inside surface of outer body :
Grease (G2-LII
Cushion contact surface of inner body :
Grease (G2-LII
14
Mating
13
DDccl1214
D155AX-5
30-71
0
DISASSEMBLY
2.
AND ASSEMBLY
DAMPER
Assemble cushion (15).

Ir Coat the whole surface of the cushion with
grease (G2-LI).
Ir After assembling the cushion, fill 30% of the
clearance (16 places) between the inner body
and outer body with grease.
Cushion
DEDo1215
3.
Assemble flange
-Mounting
(12) and tighten with bolt (11).

bolt : 66.2 = 7.4 Nm
16.75 = 0.75 kgm}
4.
Filling with grease

I) Fill inner body @ with 800 g of grease listed
below.
6
: Grease
Brand name
Grease
KYODO YUSHI:
MORILEX NO. 2
SHOWA SHELL:
RETINAX AM
NIPPON OIL:
MORITEX NO. 2
or equivalent
l
Lithium lubricant
grease with
molybdenum
disulphide
0
a
DOD01217
Assembly of damper cover assembly (1)

5. Using push tool 0, press fit outer races (7-4)
and (7-5) of bearing (7) to cover (2) with press.
30-72
0
D155AX-5
DISASSEMBLY
DAMPER
AND ASSEMBLY
Press fit inner race (7-I) of bearing

(6) with tools Cl and C2.
(7) to shaft
7.
Assemble
collar (7-2) and O-ring to shaft (6).

6
\
7-l
I
7-2
/
/
O-ring
DEW1210
8.
Set cover (2) to shaft (6), and using tool B, press

fit bearing inner race (7-3).
CWD02546
9.
Install oil seals (8) and (9) to cover assembly

&
Oil seal press-fitting surface :
(2).
Gasket sealant (LG-5)

&
*
Lip of oil seal : Grease (G2-LII

Coat the oil seal surface thinly with gasket
sealant and wipe off any sealant that is
squeezed out.
D155AX-5
/Lu
/
//
30-73
0
DISASSEMBLY
DAMPER
AND ASSEMBLY
10. Coupling
Assemble coupling (5) and holder (41, and tighten
bolt (3).
w
Mounting bolt :
277.5 + 32.4 Nm 128.3 + 3.3 kgm}
2
DE!xo504
30-74
0
D155AX-5
POWER TRAIN UNIT
REMOVAL OF POWER TRAIN

UNIT ASSEMBLY
Serial No. 70001 75000
Park
the machine on level ground, lower the

disconnect the cable from the negative (-) terminal of the battery.
1. Drain oil
6 Hydraulic tank : Approx. 97
6 Power train case: Approx. 60
2. Remove floor frame assembly.
For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Open bottom plate at bottom of power train
unit.
4. Remove cover (1) at bottom of fuel tank.
5. Close lever (2) of fuel valve.
6. Disconnect hose (3) leading to priming pump.
7. Disconnect fuel return hoses (4) and (5).
8. Disconnect fuel level sensor wiring connector
(6) (CN422).
9. Lift off fuel tank assembly (7).
fl Sling at three points and use a lever block at
the center to keep the tank horizontal.
fl Move the tank to the rear, and when it clears
the floor frame, raise the rear of the tank
slightly with the lever block. (Do this to
avoid interference with the ripper hoses.)
4 Fuel tank assembly (when full) : 760 kg
10. Disconnect engine speed sensor wiring connector (8).
11. Disconnect suction tube (9) of 3-spool pump
(HSS lubrication, torque converter, transmission
charge).
fl Remove the cover at the top of the pump.
D155AX-5
30-75
5
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN UNIT
12. Remove suspension rod (IO).
13. Remove top cover of centralized pressure detection port, then remove centralized pressure detection block (11) from frame.
14. Disconnect hose (12) between hydraulic pump

and control valve.
15. Disconnect wiring connector (13) (HHP).
16. Remove suction tube (14).
*
Be careful not to damage the gasket of the
joint.
17. Disconnect hose (15) between cooler bypass

valve and hydraulic tank.
18. Disconnect hose (16) between charge relief valve
and hydraulic tank.
19. Remove power train oil supply pipe (17).
20. Disconnect power train dipstick tube (18) from
case, and move towards right side of chassis.
30-76
0
D155AX-5
POWER TRAIN UNIT
DISASSEMBLY
AND ASSEMBLY
21. Disconnect
(19)
between
oil cooler
(22)
between
filter
hose
transmission.
22. Disconnect
hose
transmission.
23. Disconnect hoses
bypass valve and
and
case and
(20) and (21) between

oil cooler.
cooler
24. Disconnect hose (23) between HSS pump and

charge filter.
25. Disconnect
hose (24) between charge + scavenging pump and charge filter.
26. Disconnect
hose (25) between
HSS solenoid
valve and HSS, PPC charge valve at solenoid
valve end.
27. Disconnect
hose (26) between
oil cooler and
transmission
lubrication valve.
*
Open the guard (bottom
plate) under the
transmission
when carrying out the operation.
28. Disconnect drive shaft (27) at torque converter

m
end.
Ir After disconnecting,
push the yoke towards
the torque converter and disconnect completely.
D155AX-5
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN UNIT
Remove final drive shaft cover (281, then use

bolt @ to pull out drive shaft (29) to a point
where spline at steering case end comes out.
Ir If the shaft does not come out, move the
sprocket (push up the shoe grouser from
the ground surface with a jack) to adjust to a
position where the shaft comes out, then
pull out the shaft.
30. Remove mount caps (30) at both ends of steerm

ing case together with cover.
31. Loosen coupling clamp (311, and move (open)

m
seal (32) slightly to outside.
32. Remove front mount bolt (33).
30-78
0
Dl SAX-5
POWER TRAIN UNIT
33. Lift off power train unit assembly (34).

5
fl Check that the wiring and piping has all been
removed, then lift off the power train unit
assembly.
4
Power train unit assembly : 2800 kg
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
Serial No. 70001 75000

removal.
1
3 Universal joint mounting bolt :
110.3 22.1 Nm {11.3 2.3 kgm}
2
3 Mount cap mounting bolt :
277.5 32.4 Nm {28.3 3.3 kgm}
3
fl Clamp the protruding portion of the coupling seal, then assemble the clamp thread
so that it is parallel to the cap mount seat
surface.
4
3 Front mount mounting bolt :
926.8 103.0 Nm {94.5 10.5 kgm}
5
fl When assembling the power train assembly, be extremely careful not to damage seal
(32).
Refilling with oil (Hydraulic tank. power train

case.)
level.
fl Run the engine to circulate the oil through
5
Hydraulic tank : Approx. 97
Power train case : Approx. 60
D155AX-5
30-79
5
1
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN UNIT
SEPARATION OF POWER
TRAIN UNIT ASSEMBLY
.
Drain oil
Before setting the power train unit assembly on
the block, drain the oil from the PTO case.
1. Raise power train unit assembly (I) and set on
block 0.
&I kg
2.
3.
4.
5.
6.
7.
8.
Power train unit assembly : 2800 kg
Disconnect 3 hoses (2) connected to cooler bypass valve.

Disconnect HSS pump connecting hose (3).
Remove cooler bypass valve assembly (4) together with bracket.
Disconnect 5 charge relief valve connecting

hoses (5).
Disconnect wiring connector (6) (CN406).
Remove charge relief valve (7).
Disconnect pressure detection hoses (8) and (9),

and remove reducing pressure valve hose (IO).
m
Ir Disconnect the transmission
modulation
pressure detection hose.
30-80
a
D155AX-5
DISASSEMBLY
9. Disconnect
10. Remove
POWER TRAIN
AND ASSEMBLY
pressure
hydraulic
Hydraulic
hose (11).
detection
pump
assembly
UNIT
(12).
: 19 kg
pump assembly
j,
Disconnect the wiring connector (HHP).
11. Remove 2 suction tubes (13) from S-spool pump
and charge pump.
12. Disconnect PTO lubrication tube (14).
lubrication tube (15).
13. Disconnect transmission
m
14. Disconnect 3 HSS pump connecting hoses (16).

HSS pump solenoid valve wiring
15. Disconnect
connectors (17) (PUPA-A, B).
16. Disconnect piping (18) and lift off 3-spool pump
assembly (19).
&I kg
3-spool
pump assembly
17. Lift off HSS pump assembly

& kg
D155AX-5
HSS pump assembly
: 24 kg
(20).
: 116 kg
30-81
0
DISASSEMBLY
AND ASSEMBLY
POWER TRAIN UNIT
18. Remove suction tube (21) and lift off PPC charge
+ scavenging pump assembly (22).
+I kg
Pump assembly : 36 kg
G-l
19. Disconnection of steerina case
Raise
steering
case
&d
of
power
train
unit
1)
assembly.
2) Remove mounting bolts at bottom of steering case (231, and set block @ under transmission case.
3) Remove remaining mounting bolts, then
raise steering case assembly (23) and disconnect.
A kg
Steering case assembly : JO00 kg
20. Set PTO, torque converter, and transmission assembly (24) on block @ with PTO facing up.
24
21. Remove strainer cover (251, then remove spring

(26) and strainer (27).
m
30-82
0
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
22. Remove
temperature
sensor
pull out 2 sleeves (29).
23. Remove
sembly
mounting
(30).
bolts,
r+ kg
PTO assembly
POWER TRAIN UNIT
bracket
then
(281, and
lift off PTO as-
: 200 kg
24. Sling torque
converter assembly (311, and remove mounting bolts, then use forcing screws
@ to remove torque converter assembly (31).
& kg
D155AX-5
Torque
converter
assembly
: 130 kgm
30-83
0
DISASSEMBLY
POWER TRAIN
AND ASSEMBLY
CONNECTION OF POWER
TRAIN ASSEMBLY
Carry out connection
disconnection.
m
.
Install the piping of the pressure detection

tubes as shown in the diagram below.
(There are distinguishing
color bands installed to each detection tube.)
WHITE
b BLACK
Transmission
Pressure
YELLOW
RED
WHITE
Torque
RED
converter
YELLOW
Brake
Suction tube mounting bolt :

66.2 +. 7.4 Nm 16.75 + 0.75 kgm}
Steering case mounting bolt :

110.3 = 12.3 Nm Ill.25 2 1.25 kgm1
Strainer mounting bolt :

66.2 = 7.4 Nm 16.75 + 0.75 kgm}
converter
Torque
WHITE
I BLACK
Pressure
Torque
Brake
Pressure
converter
inlet
outlet
Torque
WHITE
modurated
converter
Transmission
Pressure
inlet
outlet
modurated
DXD03 189
If
pJ
-PTO
assembly mounting bolt :

110.3 f 12.3 Nm (11.25 + 1.25 kgm}
116
&
m
30-84
0
Torque converter mounting bolt :

Thread tightener (LT-21
Torque converter mounting bolt :
66.2 + 7.4 Nm I6.75 2 0.75 kgm}
D155AX-5
DISASSEMBLY
PTO
AND ASSEMBLY
DISASSEMBLY
OF PTO
ASSEMBLY
1.
Lubrication tube
1) Remove shaft lubrication
2)
Remove
pump
drive
tube (I).
gear
lubrication
tube
(2).
2.
HSS pump drive gear, cover assembly

1) Remove mounting bolts, set guide bolt @ in
position, then use forcing screws @ to remove gear and cover assembly (3).
2)
Disassemble gear and cover assembly as follows.

i)
Remove cover (4) from gear and bearing
assembly (5).
CWD02587
D 155AX-5
30-85
a
DISASSEMBLY
ii)
PTO
AND ASSEMBLY
Remove
bearing
(6) from gear (7).
CWD02589
3.
Cover assembly
bolts, then use forcing
I) Remove mounting
screws @ and guide bolt @ to remove gear
and cover assembly (8).
CWD02591
2)
Remove
3)
(IO).
Using puller 0, remove gear assembly
from cover assembly (12).
snap ring (91, then
remove
spacer
(11)
CWD02592
4)
5)
Remove snap
race (14) from
Remove snap
ing (17) from
ring
gear
ring
cover
(131, then remove

assembly (15).
(161, then remove
assembly.
inner
bear-
30-86
a
CWD02594
D155AX-5
DISASSEMBLY
4.
PTO
AND ASSEMBLY
Scavenging pump drive gear

1) Remove snap ring (18).
2)
Knock
end.
3)
Remove snap ring (20), then

ing (21).
out drive
gear
I/
(19) from
snap
remove
L
18
ring
bear-
CWD02598
5.
idler gear
1) Remove
mounting
bolts, then remove
plate
(22).
CWD02599
D 155AX-5
30-87
0
DISASSEMBLY
2)
Remove mounting bolts, set guide bolt @ in

position, then use forcing screws 0 to remove shaft (23).
3)
Remove bearing (25) and spacer (26) from

gear (24).
*
If the parts are to be used again, keep
them as a set with the outer race to prevent the set from being changed.
Remove bearing outer race (27) and snap
ring (28) from gear (24).
4)
6.
PTO
AND ASSEMBLY
Input shaft outer race

Remove snap ring (291, then remove
outer race (30).
input shaft
CWD02602
7.
Magnet assembly
I) Remove mounting
2)
(31).
Remove
spring
bolts, then remove
(32) and magnet
cover
assembly
(33).
30-88
0
CWD02603
D155AX-5
DISASSEMBLY
ASSEMBLY
ASSEMBLY
Ir
*
1.
OF PTO
Clean all parts, and check for dirt or damage.

After press fitting the bearing, apply 6 cc of
SAEIOWCD
or SAE30CD in drops, then rotate
about 10 times.
Check that the snap ring is fitted securely in the
groove.
Magnet assembly
1) Assemble magnet
2)
2.
PTO
AND ASSEMBLY
assembly
(33) and spring
(32).
Install cover (31).
CWD02603
input shaft outer race

1) Press fit input shaft outer race (301, and install snap ring (29).
CWD02602
3.
idler gear
There are manufacturing
numbers and symbols on the bearing and spacer, so form sets
with the same manufacturing
number and
symbol when assembling.
Fit snap ring (28) to gear (241, and press fit

outer race (27).
24
27
\
1
CWD02606
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
PTO
Using 3 guide bolts (91, insert shaft (23) to

position shown in diagram.
*
If shaft (23) is inserted fully, gear (24)
cannot be .installed.
&
: Grease (G2-LI)
CWD0260Y
L
3)
4)
Install bearing (25) to shaft (23).

Install spacer (26).
5)
6)
Install gear (24).

Fit bearing (25), then tighten plate (22) with
bolt and press fit to shaft.
&
Mounting bolt :
m
Mounting bolt :
277.0 f 31.9 Nm (28.25 i 3.25 kgml
Secure shaft (23) with mounting bolts.
&
Mounting bolt :
m
Mounting bolt :
110.3 z 12.3 Nm Ill.25
+ 1.25 kgm)
7)
7.
CWD02610
Scavenging pump drive gear

I) Press fit bearing (20) to case, and install snap
ring (37).
CWD0259t
30-90
0
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
PTO
Hold inner race end of bearing with

tool @, and install drive gear (19).
push
CWD0'2612
3)
tnstall snap ring (16).
CWDO2596
5.
Cover assembly
1) Press fit bearing (17) to cover assembly,
and
install snap ring (16).
2)
Press fit inner race (14) to gear

(15), and install snap ring (13).
assembly
CWD02594
3)
Using push tool 0,

gear assembly (1 I).
4)
Fit spacer (IO), and install snap ring (9).
press fit cover
(12) to
CWD02592
D155AX-5
30-91
0
DISASSEMBLY
5)
6.
PTO
AND ASSEMBLY
Mesh with idler gear and install cover assembly (8).

&
O-ring : Grease (G2-LII
&
Mounting bolt :
Thread tightener
(LT-2)
w
Mounting bolt :
110.3 + 12.3 Nm 01.25 = 1.25 kgm)
HSS pump drive gear, cover assembly

I) Asserkble gear and cover assembly
lows.
i)
Press fit bearing (6) to gear (7).
as fol-
ii)
Install gear and bearing

cover (4).
assembly
DXD03212
(5) to
CWD02616
2) Install gear and cover assembly

&
m
(3) to case.
Cover O-ring portion : Grease (G2-LI)
Mounting bolt :
110.3 = 12.3 Nm {Il.25
+ 1.25 kgm1
CWDO2617
30-92
0
D155AX-5
7.
PTO
Lubrication tube
1) install lubrication tube (2).
B
Joint bolt :
5.0 L 4.9 Nm I4 = 0.5 kgml
2)
Install lubrication tube (1).

m
Joint bolt :
5.0 z 4.9 Nm I4 2 0.5 kgml
D155AX-5
30-93
0
DISASSEMBLY
TORQUE CONVERTER
AND ASSEMBLY
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1.
Case, turbine assembly

Remove 30 bolts from below, then use eyebolts
0, and remove case and turbine assembly (IL
2.
Input shaft
1)
Remove
2) Remove
input shaft (2).
snap
ring (31, then
remove
inner
race (4).
3.
Case
1)
2)
Remove
Remove
snap ring (5).

spacer (6).
5
DLCOX92
30-94
0
D155AX-5
DISASSEMBLY
4.
TORQUE CONVERTER
AND ASSEMBLY
3)
Using puller 0, disconnect

(7) and turbine (8).
4)
Remove
bearing
case assembly
(IO) from case (9).
Stator
Remove
snap ring (1 I), then remove
stator (12).
11
5.
Pump assembly
1) Using forcing screws @ from stator shaft
end, remove pump assembly (13) from stator
shaft (14).
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
TORQUE CONVERTER
2) Remove seal ring (15) and flange (16) from

stator shaft (14).
3)
Remove
cage assembly
(17) from pump (18).

18
4)
30-96
0
Remove snap ring (191, then

ing (21) from cage (20).
remove
bear20
21
Dl SAX-5
DISASSEMBLY
TORQUE
AND ASSEMBLY
CONVERTER
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
*
*
*
*

After press fitting the bearing, apply 6 cc of
SAEIOWCD
or SAE30CD in drops, then rotate
about 10 times.
groove.
Coat the seal ring with grease (G2-LI) and align
the end gaps.
DKWJlOl
1.
Pump assembly
1) Press fit bearing
snap ring (19).
18
(21) to cage (201, and install
2) Install cage assembly

w
(17) to pump (18).

Mounting bolt:
66.2 t 7.4 Nm I6.75 t 0.75 kgm1
I
3)
Install seal ring (15) and flange (16) to stator

shaft (14).
6
Mounting bolt:
.
4)
Using push tool 0, install pump assembly

(13) to stator shaft (14).
*
Push the inner race of the bearing to
press fit.
DLCOX99
DLEW103
D155AX-5
DISASSEMBLY
2.
TORQUE
AND ASSEMBLY
Stator
1) Install stator (12).
2) Install snap ring (II).
CONVERTER
IL
11
3.
Case
1) Install bearing
2)
(IO) to case (9).
Using push tool 0, push inner race end of

bearing, then install case assembly
(7) to
boss portion of turbine (8).
i3
DUO3104
3)
4)
Install spacer (6).

Install snap ring (5).
5
DlDCQO93
I
30-98
0
DLCW392
I
D155AX-5
DISASSEMBLY
4.
AND ASSEMBLY
TORQUE
CONVERTER
Input shaft
1) Press fit inner race (41, and install snap ring
(3).
DLDCQ391
2)
5.
Install input shaft (2).

&
Mounting bolt:
Thread tightener
(LT-21
m
Mounting bolt:
110.3 t 12.3 Nm (II.25
+ 1.25 kgml
Case, turbine assembly

1) Using eyebolts 0, align groove of case with
drain plug, and install case and turbine assembly (1).
&
Mounting bolt:
Thread tightener
(LT-21
w
Mounting bolt:
54.0 t 4.9 Nm I5.5 = 0.5 kgm}
2) Install drain plug.
w
Drain plug:
17.2 + 2.5 Nm (I.75 + 0.25 kgm1
D155AX-5
30-99
0
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
DISASSEMBLY
TRANSMISSION
OF TORQFLOW
ASSEMBLY
After removing the discs and plates, keep them

in a flat place to prevent bending or deformation.
1.
Relief valve assembly

Remove relief valve assembly
(I).
2.
Control valve assembly

1) Remove cover assembly
sleeve
TRANSMISSION
J-l
DEW0459
(2).
2)
Remove
(3) and flanges
(4) and (5).
3)
Remove control valve assembly (6).

*
Remove the bolt marked %.
DEW0462
30-100
0
D155AX-5
DISASSEMBLY
3.
AND ASSEMBLY
Transmission
case
1) Fit a block and set with
side at top.
2) Remove sleeve (7).
3)
TORQFLOW
torque
TRANSMISSION
converter
Using eyebolts 0, sling transmission

case
(8), then remove 13 tie bolts (9) (tightened
together
with transmission
case), and remove case (8).
8--
DEiY30464
4.
5.
Tie bolts
Remove remaining
4 tie bolts (9).
Input shaft, front cover, No. 1 carrier assembly

I)
Using eyebolts 0, remove input shaft, front
cover, and No. 1 carrier assembly (II).
DEDW466
D155AX-5
30-101
0
DISASSEMBLY
2)
AND ASSEMBLY
Disassemble
input shaft, front cover, and
No. 1 carrier assembly as follows.
Remove snap ring (121, then remove No.
i)
2 sun gear (13) and snap ring (14).
ii) Remove snap ring (151, then remove No.
1 sun gear (16) and collar (17).
iii) Remove snap ring (18).

iv) Knock input shaft towards torque converter, and remove front cover (19).
18
v)
Remove snap ring (201, then knock input

shaft (21) out towards torque converter
to remove.
Remove snap ring (221, then remove No.

1 ring gear (23).
vii) Pull out shaft (241, then remove thrust
washer (251, gear (261, bearing (279, and
ball (28).
*
Be careful not to lose the ball.
vi)
24
23
28
25
26
25
DEW0471
30-102
0
27
WDCO472
D155AX-5
DISASSEMBLY
AND ASSEMBLY
TORQFLOW
TRANSMISSION
6. No. 1 disc, plate, springs

I)
Remove spring (29).
2) Remove spring (301, disc (311, and plate (32).
DECCO473
7. No. 1 housing assembly

1) Using eyebolts 0, remove No. 1 housing
assembly (33).
2) Remove No. 1 piston (34) from housing.
8. Guide pin
Remove guide
pin (35).

1) Remove spring (36).
39
37
36
10. Remove through bolt guide (401, lubrication

lief valve (411, and spring (120).
re-
DDWO476
D155AX-5
DDm477
30-103
0
DISASSEMBLY
AND ASSEMBLY
11. No. 2 housing, No. 2 carrier assembly

1) Using eyebolts 0, remove No. 2 housing
and No. 2 carrier assembly (42).
2) Remove No. 2 piston (43).
43
3)
Disassemble
No. 2 housing and No. 2 carrier assembly as follows.
i) Remove snap ring (441, then pull out No.
2 carrier assembly (45) from No. 2 housing (46).
ii)
46
/
Remove spacer (47) and No. 2 ring gear

(48) from No. 2 carrier assembly (49).
iii) Pull out shaft (501, and remove thrust

washer (511, gear (521, bearing (53), and
ball (54).
*
51
52
53
iv) Remove snap ring (551, then remove

gear (56).
30-104
0
DDCCO481
ring
D155AX-5
DISASSEMBLY
AND ASSEMBLY
VI Remove seal ring (57) and snap ring (58)

from No. 2 housing,
ing (59).
then remove
bear-
59
46
58
DEixoe3

13. No. 3 ring gear

Remove No. 3 ring gear (64).
14. No. 3, 4 carrier assembly

1) Remove No. 3 and 4 carrier assembly
D155AX-5
(65).
.65
DISASSEMBLY
2)
TRANSMISSION
TORQFLOW
AND ASSEMBLY
No. 3, 4 carrier assembly as

Disassemble
follows.
i) Remove seal ring (66).
ii) Knock pin (67) into shaft (68).
iii) Knock out shaft (68) from No. 3 carrier
end.
iv) Remove thrust washer (69), No. 4 planet
gear (701, and bearing (71).
Remove the pin from the shaft.
*
VI Knock out shaft (721, then remove thrust
washer (73). No. 3 planet gear (741, bearing (751, and ball (76).
*
II
76
74
73
72
167
15. No. 3 housing

1) Remove No. 3 housing (77).
DDDW487
/78
-77
DEW0488
16. No. 4 disc, plate, springs, guide pin

I) Remove spring (79).
2) Remove spring (801, No. 4 disc (81),
3)
(82).
Remove
guide
plate
79
pin (83).
81
83
80
82
17. No. 5 carrier, No. 4 ring gear assembly

I) Remove mounting bolts (84).
2) Remove No. 5 carrier and No. 4 ring gear
assembly (85).
DE&O491
30- 106
0
D155Ax-5
DISASSEMBLY
3)
AND ASSEMBLY
TORQFLOW
Disassemble
No. 5 carrier, No. 4 ring gear
assembly as follows.
i)
Knock out shaft (86), then remove thrust
washer (87), gear (88), bearing (89), and
ball (90).
*
90
TRANSMISSION
86
87
88
89
87
93
ii)
Remove snap ring (91), then remove

4 ring gear (92) from carrier (93).

1) Remove No. 4 housing assembly
No.
(94).

2) Remove disc (97), plate (98), and spring
(99).
96
D155AX-5
30-107
0
DISASSEMBLY
AND ASSEMBLY
TORQFLOW
TRANSMISSION
20. No. 5 ring gear

Remove No. 5 ring gear (100);
101
21. Collar, No. 4 sun gear, bearing
Remove snap ring (IOI),
then remove collar
(1021, No. 4 sun gear (1031, and bearing (104).
102
22. No. 5 sun gear

Remove No. 5 sun gear (105).
100
23. No. 5 piston

Remove No. 5 piston (106).
24. Shaft, collar

Remove shaft (107) and collar (108) from cover
(109).
25. Bearing
1)
2)
3)
cage
Remove snap ring (1 IO), then remove bearing (111).

Remove snap ring (1121, then remove bearing (113).
Remove cage (1141, then remove seal rings
(115) and (116).
30-108
0
115
114
112
113
D 155AX-5
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
TRANSMISSION
ASSEMBLY OF TORQFLOW
TRANSMISSION
ASSEMBLY
.
Precautions when assembling

*
*
Coat the sliding surfaces of all parts with
engine oil before installing.
*
Assemble the piston seal rings with the side
receiving the pressure facing the housing as
shown in the diagram.
*
When installing metal seal rings, coat with
grease (G2-LI) and install uniformly, taking
care that they do not move to one side.
1.
Cage, bearing
1) Install seal rings (116) and (1151, then install
cage (114) to cover (109).
2) Press fit bearing (1131, and install snap ring
(112).
3) Press fit bearing (I 1 I), and install snap ring
(I IO).
I
2.
116
111
110
DDDoo498
Shaft, collar
Install shaft (107) and collar (108) to cover (109).
1
-7
3.
No. 5 sun gear

Install No. 5 sun gear (105).
10
4.
No. 5 ring gear

Install No. 5 ring gear (100).
5.
No. 5 piston
Install No. 5 piston (106).
100
106
D155AX-5
30-109
0
DISASSEMBLY
6.
7.
Guide pin
Install guide
AND ASSEMBLY
pin (83).
No. 5 disc, plate, springs

1) Install disc (971, plate (981, and spring
*
Discs: 3, Plates: 2
2) Install spring (96).
*
Free length of spring: 66 mm
(9%
98
DEW0501
I
8.
No. 4 housing assembly

1) Fit seal ring and install No. 4 piston (95).
2) Install No. 4 housing (94).
*
Check that the spring is fitted securely in
the groove.
I
9.
No. 5 carrier, No. 4 ring gear assembly

1) Assemble No. 5 carrier and No. 4 ring gear
i) Set No. 4 ring gear (92) to carrier (931,
and install snap ring (91).
DEW0502
93.
Assemble bearing (89) to gear (881, then

put thrust washers (87) in contact on both
sides, and set in carrier.
iii) Fit ball (90) and install shaft (86).
ii)
89
87
93
30-110
0
D 155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
Using guide bolts 0, install No. 5 carrier

and No. 4 ring gear assembly (85).
w
Mounting bolt:
66.2 t: 7.4 Nm (6.75 = 0.75 kgm}
85

I) Install No. 4 disc (811, plate (821, and spring
(80).
Discs: 4, Plates: 3
*
2)
79.
Install spring (79).

*
80

2) Install No. 3 housing (77).
*
the groove.
12. No. 3, 4 carrier assembly

1) Assemble
No. 3 and 4 carrier assembly as
follows.
Press fit bearing (1171, and install snap
i)
ring (118).
D155AX-5
DISASSEMBLY
AND ASSEMBLY
ii)
Assemble
bearing (75) to No. 3 planet
gear (741, then put thrust washers (73)
in contact on both sides and set to carrier.
iii) Fit ball (761, then install shaft (72).
iv) Assemble
bearing (71) to No. 4 planet
gear (701, then put thrust washers (69)
in contact on both sides and set to carrier.
VI Align shaft pin hole with carrier pin hole
and install shaft (68).
vi) Check that pin holes are aligned, then
knock in pin (67).
vii) Install seal ring (66).
2)
76
74
73
72
67
Dlxc04a7
Align sun gear and ring gear, then install

No. 3 and 4 carrier assembly (65).
*
Be careful not to get your fingers caught.
MDCKM66
13. No. 3 ring gear

Install No. 3 ring gear (64).
*
Install so that the side with the notch in the
outside teeth is facing down.

1) Install disc (621, plate (631, and spring
*
Discs: 4, Plates: 3
2) Install spring,(60).
*
(61).
60\
H-62
63-
DECW46.4
30-112
0
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
15. No. 2 housing, No. 2 carrier assembly

1) Assemble No. 2 housing and No. 2 carrier
Press fit bearing (59) to No. 2 housing
i)
(461, and install snap ring (58).
ii) Install seal ring (57).
iii) Set ring gear (56) to No. 2 carrier

then install snap ring (55).
46-
(451,
56.
DEW0506
iv) Assemble bearing (53) to gear (521, then

sides, and set to carrier.
VI
51
Fit ball (54) and install shaft (50).
52
53
54
vi) Install seal ring.

vii) Install No. 2 ring gear (48).
viii) Install spacer (47).
*
Install so that the side where the inside is cut is facing the carrier.
48
D155AX-5
DEDOO508
30-113
0
DISASSEMBLY
ix)
x)
2)
3)
TORQFLOW
AND ASSEMBLY
TRANSMISSION
Install No. 2 housing (46) to No. 2 carrier assembly (45).

*
Press fit the inner race of the housing bearing.
Install snap ring (44).
Install No. 2 piston (43).

Using eyebolts 0, install No. 2 housing and
No. 2 carrier assembly (42).
*
the groove.
DECO0478
16. Install through bolt guide (401, spring (1201, and

lubrication relief valve (41).
40
17. Guide pin

Install guide pin (35).
I) Install No. 2 disc (381, plate (391, and spring
2)
(37).
*
Discs: 5, Plates: 4
*
Free length of spring: 81.7 mm
30-114
0
39
37
36
D155AX-5
DISASSEMBLY
AND ASSEMBLY

2) Using eyebolts 0, align with No. 2 piston,
then install No. 1 housing assembly (33).
*
Push the housing and tap the dowel pin
portion.
.33
34
20. Input shaft, No. 1 carrier assembly

1) Assemble input shaft and No. 1 carrier assembly as follows.
i) Assemble bearing (27) to gear (261, then
ii) Fit ball (28) and install shaft (24).
iii) Set No. 1 ring gear (23) to No. 1 carrier,
and install snap ring (22).
24
28
22
25
26
25
27
DDcOo472
iv) Press fit bearing

VI
23
/
DEMO471
(117) to input shaft (21).
Fit No. 1 carrier assembly (118) to input

shaft (211, then install snap ring (18).
DEW0510
vi)
Install collar (17).
vii) Install No. 1 sun gear (161, then

snap ring (15).
viiijlnstall
D155AX-5
snap ring (14).
install
16
DISASSEMBLY
ix) Install No 2 sun gear (131, then

snap ring (12).
2)
AND ASSEMBLY
install
Raise input shaft, No. 1 carrier assembly

(11% align meshing of No. 2 sun gear and
No. 1 planet gear, then install.
DEW0514

1) Install No. 1 disc (31), plate (321, and wring
2)
(30).
*
Discs: 5, Plates: 4
*
Free length of spring: 81.7 mm
22. From cover

1) Install seal ring (121) to front cover (122).
DDDoo516
30-116
0
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
TORQFLOW
Using eyebolts @, align front cover (122)

with guide pin and spring, then install.
Press fit inner race end of bearing (123) to
input shaft, then install snap ring (124).
*
the cover.
122
DECO0517
TRANSMISSION
123 124
DDlX0518
23. Tie bolts

Install 4 tie bolts (9). (The 4 bolts marked * in
the diagram)
m
Tie bolt: 166.7 + 9.8 Nm I17 = 1 kgm}
24. Operation test of piston

Using tool C, test the operating
stroke of each piston.
Piston
Standard
condition
and
stroke (mm)
No. 1
No. 5
6.
DEW0520
case
25. Transmission
Fit O-ring, then using eyebolts 0, install transmission case (81, and install remaining
13 tie
bolts (9).
-0
8-
DEDXJ464
D155AX-5
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
26. Sleeve
Install sleeve
TRANSMISSION
(7).
DECYJO463
27. Control valve assembly

1) Install control valve assembly (6).
w
Mounting bolt:
49.1 + 4.9 Nm I5.0 = 0.5 kgm)
2)
Install flanges
3)
&
Install cover assembly (2).

Mounting bolt thread portion:
Gasket sealant (LG-1 or LG-51
30-118
0
(4) and (5), and sleeve (3).
D155AX-5
DISASSEMBLY
AND ASSEMBLY
28. Main relief valve assembly

Install main relief valve assembly
w
Mounting bolt:
(I).
49.1 +. 4.9 Nm 15.0 + 0.5 kgm}
D155AX-5
30-119
0
DISASSEMBLY
AND ASSEMBLY
HSS CASE
DISASSEMBLY OF HSS CASE

ASSEMBLY
1.
Brake, carrier assembly

1) Angie the HSS case assembly approx. 15
so that tool El is perpendicular
to ground
surface.
2) Remove mounting bolts, then using tool El,
remove brake, carrier assembly (1).
*
Do not remove the hexagon socket head
bolt.
Sr Remove the brake and carrier assembly
on the other side in the same way.
DLCOG997
Disassembly
1) Remove
2)
of brake, carrier assembly

flange (2) and plate (3).
Loosen hexagon socket head bolts uniformly,

then using eyebolts 0, remove brake case
(5).
Ir The case is being pushed by the brake
spring, so loosen it slowly and uniformly.
*
The outside bearing will come out together with the cover.
3)
Remove spacer (6), brake spring

(8), and cylinder (9).
G), piston
DKDOlCO3
30-120
0
D155AX-5
DISASSEMBLY
4)
HSS CASE
AND ASSEMBLY
Remove brake drum (12) together

and plate.
with disc
I
5)
Remove plate (131, disc (151, spring (161, and

plate (14) from brake drum.
6)
Remove mounting
bolts, then remove carrier assemblv (19) from hub (18).
Remove gear assembly (20) from hub assembly (18).
7)
DKWlWl
DLCOlCO3
8)
9)
DLDO1004
Remove ring (211, then remove ring gear

(22) from gear (108).
Remove snap ring (231, and pull out shaft
(24).
DLDD1005
D 155AX-5
DLiYJOO6
30-121
0
HSS CASE
10) Remove planetary gear (25), bearing (26),

thrust washer (27), shaft (24), and ball (28).
25
26
24
28
27
DLD01007
11) Remove snap ring (31), then remove stopper (32) from hub (18).
32
31
18
DKD01008
2. Bevel pinion assembly

1) Using guide bolts 3 and forcing screws remove bevel pinion assembly (33) and shim
(34).
fl Check the number and thickness of the
shims, and keep in a safe place.
34
33
r
DLD01009
2) Disassembly of bevel pinion assembly

i) Remove bolts (35), (36) and pin (37).
Serial No. 75001
E2
41
40
ii) Hold with press to prevent pinion from

moving, then use tool E2 to remove
locknut (39).
iii) Using push tool 5, remove bevel pinion
(40) from cage (41).
39
DLD01010
30-122
5
DKD01011
D155AX-5
HSS CASE
iv) Remove bearing (42).

v) Remove outer races (43) and (107) from
cage (41).
42
107
43
41
DLD01013
DLD01012
vi) Remove bearing (109) from bevel pinion

(40).
40
109
DLD01014
3. Sun gear
Remove sun gear (45).
fl Remove the sun gear on the opposite side
in the same way.
45
47
4. Gear
1) Remove snap ring (47), then remove spacer
(48).
48
DLD01016
DLD01015
2) Using gear puller 6, remove gear (49).
49
y
DLD01017
D155AX-5
30-123
5
DISASSEMBLY
AND ASSEMBLY
HSS CASE
Only inner race (50) of bearing (55) will remain.

Remove the gear on the opposite side in the
same way.
DKco1018
5.
Valve seat
1) Pull out 2 brake circuit tubes (51) and 3 lubrication tubes (52), then remove.
2) Remove valve seat (53).
DKW1019
6.
Lubrication tubes, dipstick tube, suction tube

1) Remove lubrication tubes (52) and (56).
2)
3)
Remove
Remove
lubrication tubes (57) and (58).

dipstick tube (59) and suction tube
(60).
30-124
0
D155AX-5
DISASSEMBLY
7.
HSS CASE
AND ASSEMBLY
Motor output gear

1) Remove flange (61) from case (62).
2) Remove flange and gear assembly (63).
3)
Remove gear assembly
(65) from flange (64).

65
64
&
4)
5)
Remove inner race (67) and bearing (68) from

gear (66).
Remove bearing (69) from flange (61).
Ic
69
61
66
8.
Right carrier drive gear

1) Remove bolt (701, then
and gear (72).
remove
plate
DKDO1026
(71)
D155AX-5
DKCO1025
DLCO1027
DUO1028
30-125
0
DISASSEMBLY
HSS CASE
AND ASSEMBLY
2)
Knock out shaft (73) with

to remove.
3)
4)
Remove
Remove
a plastic hammer
inner race (75) from bearing

bearing (74).
(74).
DLDOlOBl
gear
9. Intermediate
1) Remove shaft mounting bolt.
2) Using shock hammer @, pull out shaft (76),
then remove gear (77) and bearing (78).
Bevel gear shaft, bevel gear assembly

1) Remove left retainer mounting bolts (85).
2) Remove right retainer mounting bolts (86).
3) Using eyebolts 0, lift off bevel gear shaft
and bevel gear assembly (87).
Check the number and thickness of the
*
shims at the left cage, and keep in a safe
place.
30-126
0
D 155AX-5
DISASSEMBLY
4)
HSS CASE
AND ASSEMBLY
Disassembly
of bevel gear shaft, bevel gear
assembly
Using puller 0, remove inner race (91)
i)
from right shaft (92).
Remove inner race (91) from the left shaft
*
in the same way.
ii)
Remove
right
retainer
(89) from
shaft
92
(92).
88
L-?--A
DLLWlO?J
iii) Remove hexagon socket head bolt (95),

then remove plate (93) and shim (94).
iv) Using tool E3, remove
D155AX-5
nut (96).
30-127
0
DISASSEMBLY
v)
vi)
HSS CASE
AND ASSEMBLY
Using puller 0, pull out left retainer (97)

from shaft (92).
Remove bearing (98) from retainer (97).
r-l
DLDO1040
DID01041
vii) Remove nut (991, then remove bevel gear

(100) from shaft (92).
viii)Remove
bearing (101) from right retainer
(89).
DLC01043
30-128
0
D155AX-5
DISASSEMBLY
HSS CASE
AND ASSEMBLY
ASSEMBLY
ASSEMBLY
OF HSS CASE
Precautions when assembling

Apply drops of engine oil to the rotating portion
of the bearing, then rotate several times.
Coat the sliding surfaces of all parts with engine
oil before installing.
Assemble
the piston seal rings with the side
receiving the pressure facing the housing, coat
with grease (G2-LI) and install uniformly, taking
care that they do not move to one side.
Fix the rotation seal ring in position with grease
(G2-LI) and be extremely
careful not to get it
caught when assembling.
groove.
Bevel gear shaft, bevel
1) Assembly
of bevel
assembly
i)
Using push tool,
and (74) to right
gear assembly
gear shaft, bevel
press fit bearings
retainer (89).
gear
(101)
L
f
Ii
I
/
9
Piston
DLDYOM
DKtM1045
ii)
1 1
DLt6046
Shrink fit inner race (106) to shaft (92).

*
Shrink-fitting
temperature:
100C for approx. 30 minutes
g2-
DiCQ1047
iii) Set bevel gear (100) to shaft (921, and

tighten nut (99).
m
Nut : 215.8 - 274.6 Nm
(22.0 - 28.0 kgml
iv) Install seal ring.
DLCO1042
D155AX-5
30- 129
0
DISASSEMBLY
AND ASSEMBLY
HSS CASE
VI Assemble
outer race (103), bearing (104),

spacer (105), bearing (104) and outer race
(103) to left retainer (97) in order.
tighten
vi) Fit plate (93), then temporarily
with several hexagon socket head bolts.
DKJXM048
vii) Support bevel gear with block 0, then

using push tool @I, press fit retainer assembly (102) to shaft.
DKW1049
viii)Secure shaft, then using tool E3, tighten

nut (96).
6
Nut : Thread tightener (LT-2)
m
Nut : 735.5 - 902.2 Nm
i75.0 - 92.0 kgml

*
Remove the hexagon

socket head
bolts at the portion where the tool
contacts the bolts.
DLC01050
ix) Adjusting shim

Tighten 4 bolts lightly, measure dimension @ and dimension
@ to calculate
dimension
@, then decide thickness of
shim @.
Shim thickness @ =
(0 - 0) - (0.1 to 0.2 mm)
selected
shim
(941, then
XI Assemble
tighten bolts (95).
30-130
0
D155AX-5
DISASSEMBLY
xi)
HSS CASE
AND ASSEMBLY
Install right retainer
(89) to shaft (92).

92
DLiXlO37
xii) Shrink fit inner race (91) to shaft (92).

j,
Shrink-fitting
temperature:
100C for approx. 20 minutes
DLDO1052
2) Install left retainer (88) and guide bolt @.

3)
Using eyebolts @I, raise right retainer, then

align guide bolt with bolt hole, and install
bevel gear shaft assembly (90) to case.
DLD01054
4)
Assemble shim to left retainer, then tighten

mounting bolts (85) and (86) of left and right
retainers.
*
There are three types of shims: 0.1, 0.2,
0.5 mm
*
The mounting
bolts of the left retainer
are loosened when adjusting the backlash and tooth contact, but tighten them
fully here in order to check the starting
torque of the bevel gear shaft.
D155AX-5
30-131
0
DISASSEMBLY
5)
2.
HSS CASE
AND ASSEMBLY
Push tip of teeth of bevel gear (100) with

starting
scale 0, and measure
push-pull
torque of bevel gear shaft.
Starting torque: Max. 3.0 Nm (0.31 kgm}
*
(At tip of bevel gear teeth:
Max. 19.6 N (2.0 kg})
gear
Intermediate
1) Assemble snap ring (83) and spacer (84) to
gear (771, then using push tool, press fit outer
race (82).
lower bearing (781, spacer (811,
2) Assemble
and upper bearing (78).
77
78
DKDJ1057
3)
gear assembly (79) to case (801,

Assemble
then align bolt hole and install shaft (76).
Align the bolt holes of the plate when
*
installing the shaft.
DLD01059
DLCG1059
3.
Right carrier drive gear

1) Using push tool, press fit bearing (74) to
case.
2) Using push tool, press fit inner race (75) to
shaft (73).
*
Press fit to a point approx. 27 mm from
shaft surface.
*
Install to one side only.
DLKHO&l
30-132
0
73
DL!M1061
D155AX-5
DISASSEMBLY
AND ASSEMBLY
HSS CASE
3)
Align shaft (73) with bearing
4)
Using push tool, install inner race (75) to

between shaft and bearing.
+
Hold the shaft from the opposite side.
5)
and install.
Fit gear (72) and plate (711, then tighten

(70).
w
Mounting
bolt
bolt : 98.1 - 122.6 Nm

IlO.
- 12.5 kgm1
DLC01028
DLDO1027
4.
Lubrication tubes,
1) Install suction
2)
dipstick tube, suction tube

tube (60) and dipstick tube
(59).
Install lubrication tube (57), (58).
w
Joint bolt: 7.8 - 9.8 Nm
IO.8 - 1.0 kgm)
DLC41022
D 155AX-5
DtDO1021
DISASSEMBLY
3)
5.
AND ASSEMBLY
HSS CASE
Install lubrication tube (56).

m
Joint bolt: 7.8 - 9.8 Nm
IO.8 - 1.0 kgm}
Bevel pinion assembly

1) Assemble bevel pinion as follows.
i) Using push tool, press fit bearing
to bevel pinion (40).
(109)
Using push tool, press fit outer races

(43) and (107) to cage (41).
iii) Put bevel pinion (40) on press stand, and
set cage (41) in position.
ii)
iv) Press fit bearing (42) to cage (41) with

press.
VI Hold in press so that pinion does not
move, then use tool E2 and tighten
locknut (39).
&
Locknut: Thread tightener (LT-2)
w
Locknut : 696.3 - 863.0 Nm
*
*
(71 - 88 kgm)
Rotate the cage when tightening.
After tightening
the nut, check that
the bevel pinion rotates smoothly.
30-134
0
DID01067
D155AX-5
HSS CASE
Serial No. 75001

vi) Turn the nut unit the phase of any one
of the pin insertion holes of the nut (8
places) is matched to that of any one of
the pin insertion holes of the pinion shaft
(5 places). (Returning angle: 0 - 9)
vii) Insert pin (37) in the above holes. Fit
plate (36) and tighten bolts (35).
2 Bolt : Thread tightener (LT-2)
3 Bolt : 11.8 - 14.7 Nm
{1.2 - 1.5 kgm}
2) Using guide bolt 3, assemble shim (34) and
install bevel pinion assembly (33).
fl There are three types of shim:
0.1, 0.2, 0.5 mm
y
6. Adjusting tooth contact, backlash
1) Adjusting backlash
Put the probe of dial gauge 6 at right angles in contact with the tip of the bevel gear
teeth. Hold the bevel pinion in position, and
read the measurement when the bevel gear
is moved forward and backward.
fl Standard value for backlash :
0.25 - 0.33 mm
fl Measure at least three points on opposite sides.
If the result of the inspection shows that
the correct backlash is not being obtained, adjust as follows.
fl Adjust the shim thickness at the left cage.
If backlash is too small
Loosen mounting bolt of cage and remove shim.
If backlash is too large
Loosen mounting bolt of cage and add
shim.
DBD00156
Front
DAD00157
Front
DAD00158
D155AX-5
30-135
1
5
DISASSEMBLY
2)
AND ASSEMBLY
Adjusting tooth contact

Testing
i)
Coat the tooth face of the bevel pinion lightly
with red lead (miniurn).
Rotate the bevel
gear forward and backward and inspect the
pattern left on the teeth.
ii) Tooth contact should be checked as follows
(from tip of teeth of bevel pinion).
a) Center of tooth contact: 20 - 40 % of
tooth width (from small end)
b) Width of tooth contact: 30 - 50 % of tooth
width
c) Center of tooth contact: 35 - 65 % of
tooth height (from root of tooth)
d) Width of tooth contact: 60 - 80 % of tooth
height
In addition, there should be no strong contact at the addendum
or dedendum
(tip or
root of the gear teeth) or at the big and
small ends.
*
If the gears are adjusted to this pattern,
the tooth contact will be correct when
load is applied.
HSS CASE
Root of tooth
Tip of tooth
I
I
Small end
DBDOOES
Big
end
-
\
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained, adjust again as follows.
If bevel pinion is too far from center line of
i)
bevel gear.
Contact is at the small end of the convex
tooth face of the bevel gear and at the big
end of the concave tooth face.
.
Correct the tooth contact as follows.
Adjust the thickness of the shims at the bevel
pinion to move the bevel pinion in direction
A.
Move the bevel gear in direction B, then
check the tooth contact pattern and backlash again.
ii) If bevel pinion is too close to center line of
bevel gear.
Contact is at the big end of the convex tooth
face of the bevel gear and the small end of
the concave tooth face.
.
Correct the tooth contact as follows.
Adjust the thickness of the shims at the bevel
pinion to move the bevel pinion in direction
B.
Move the bevel gear in direction A, then
check the tooth contact pattern and backlash again.
30-136
0
DBtXJO160
B*
,:
t
A
DBW0161
BC
3
+
A
DBW0162
D155AX-5
DISASSEMBLY
7.
HSS CASE
AND ASSEMBLY
Motor output gear

1) Using push tool, press fit bearing (69) to
flange (61).
2) Using push tool, press fit inner race (67) and
bearing (68) to gear (66).
f
61
66
3)
Install gear assembly
(65) to flange
DKw1025
(64).
DKD01024
4)
Install flange and gear assembly
5)
(62).
Install flange
(61).
(63) to case
61
KDO1023
8.
Valve seat
1) Install lubrication
D155AX-5
tube (52).
DISASSEMBLY
2)
3)
HSS CASE
AND ASSEMBLY
Align with lubrication tube (52) (installed in

Step 8-111, then install valve seat (53).
Install brake circuit tube (51) and lubrication
tube (52).
52
\
51
9. Gear
1) Install
outer
2) Align
shaft
inner bearing (551, snap ring (54), and

bearing (55) to gear (49).
gear (49) with bearing of bevel gear
and install.
DLDJ1072
3)
4)
Using push tool, press fit inner race (50).

Fit spacer (48) and install snap ring (47).
10. Sun gear

1) Install thrust washer
2)
(46) to sun gear (45).
Install sun gear (45).
457
30-138
0
DKW1073
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
11. Brake, carrier assembly

*
Assemble both sets in
.
Assembly of brake, carrier
1) Assemble stopper (32)
stall snap ring (31).
2) Install bushing (38).
3) Using push tool, press
4)
HSS CASE
the same way.

assembly
to hub (181, then in-
32
fit inner race (37).
Carrier assembly
i) Assemble bearing (26) to gear (251, then
ii) Fit ball (28) and install shaft (24).
iii) Remove snap ring (23).
iv) Install sleeve (36) to carrier (35).
24
35
36
DKCQ1076
v)
vi)
Install bushings
(29) and (30) to gear
(108).
Set gear (108) to ring gear (221, then fit
ring (21) and install ring gear to gear.
vii) Install gear assembly (20) to hub (18).

viiijlnstall carrier assembly (19) to hub (18).
m
Mounting bolt : 98.1 - 122.6 Nm
{IO - 12.5 kgm1
18
DLD8004
D155AX-5
DISASSEMBLY
5)
6)
HSS CASE
AND ASSEMBLY
Set brake drum (12) to hub assembly (18).

Install discs (15), plates (14) and (13), and
spring (16).
*
Discs: 5,
18
13
Plate (14): 4,
Plate (13): 1
14
16
15
DLD01078
7)
8)
9)
Hub
i)
Using push tool, press fit bearing
hub (9).
(17) to
ii) Fit seal ring and install hub (9).

Install spacer (6).
Install piston (8) and spring (7).
*
Install so that the outside circumference
of the spring opens.
DWlOCO
10) Brake cover assembly

i)
Using push tool, press fit bearing
brake cover (IO).
ii) Install guide bolt @ to hub (9).
(I I) to
---1
30-140
0
DKCO1082
D155AX-5
DISASSEMBLY
AND ASSEMBLY
HSS CASE
iii) Using eyebolts 0, align bolt hole with

hub and brake drum, then install brake
cover assembly (5).
Ir Tighten the mounting
bolts temporarily.
*
The force of the spring is applied, so
tighten
the hexagon
socket head
bolts uniformly.
iv) Using push tool, press fit inner race (4.

Install plate (3) and flange (2).
Flange: 58.8 - 73.6 Nm
(6 - 7.5 kgm1
vi) Fully tighten bolts temporarily tightened
in Step iii).
m
Mounting bolt: 98.1 - 122.6 Nm
I10 z 12.5 kgm)
v)
m
4-u
DLEO1255
Installation
of brake, carrier assembly
Angle
steering
case assembly approx. 15
I)
so that tool El is perpendicular
to ground
surface.
2) Using tool El, install brake, carrier assembly
(I).
w
*
Ir
&
Mounting
bolt: 98.1 - 122.6 Nm

{IO - 12.5 kgm}
Assemble the brake, carrier assembly
the opposite side in the same way.
on
When cover (109) of the rear surface on

HSS case (107) has been removed,
install new gasket (108).
Gasket (apply to both surfaces):
Gasket sealant (LG-II
D155AX-5
DAD02453
HYDRAULIC PUMP
PUMP ASSEMBLY
Park

disconnect the cable from the negative () terminal of the battery.
1. Drain hydraulic oil and power train oil.

6 Hydraulic oil : Approx. 97
6 Power train case : Approx. 60
2. Remove cab.
For details, see REMOVAL OF CAB ASSEMBLY.
Serial No. 70001 75000
3. Lift off operators seat assembly (1).

4 Operators seat : 54 kg
4. Remove floor frame left and right side covers
(2).
5. Remove floor mat, then remove cover (3).
30-142
1
5
D155AX-5
HYDRAULIC PUMP
6. Disconnect acceleration rod (4) from yoke.
7. Disconnect deceleration rod (5) from yoke.

8. Disconnect brake rod (6).
fl Loosen locknut (7), and turn joint (8) to disconnect.
Joint (8) has a reverse thread.
9. Remove floor assembly (9).
4 Floor assembly: 26 kg
A. Removal of hydraulic pump assembly

1) Disconnect hose (1) leading to work equipment control valve.
2) Disconnect wiring connector (2) (HHP).
3) Disconnect suction tube joints (3) and (4).
4) Remove 4 mounting bolts (5), then remove
tube (6).
5) Remove mounting bolts, then remove hydraulic pump assembly (7).

4 Hydraulic pump assembly : 19 kg
D155AX-5
30-143
1
5
HYDRAULIC PUMP
B. Removal of 3-spool pump assembly (HSS lubrication + torque converter, transmission charge
+ torque converter charge pump)
2) Disconnect HSS motor and brake lubrication

tube (2).
3) Disconnect suction tube (3) from power train
case.
4) Disconnect transmission filter hose (4).
5) Disconnect filter bypass valve hose (5).

fl It is difficult to disconnect the hose at
the pump end.
6) Remove mounting bolts, then lift off 3-spool

pump assembly (6).
fl Remove together with hose (5).
4 3-spool pump assembly : 24 kg
30-144
1
5
D155AX-5
HYDRAULIC PUMP
C. Removal of HSS pump assembly

1) Disconnect HSS and PPC charge valve hose
(1).
2) Disconnect cooler bypass valve hose (2).
3) Disconnect charge filter hose (3).

4) Disconnect solenoid wiring connector (4)
(PUP.A).
5) Disconnect cooler bypass valve hose (5).
6) Disconnect HSS motor hoses (6) and (7).
7) Disconnect charge relief valve hose (8).
8) Disconnect engine speed sensor wiring connector (9) (CN010).

9) Disconnect solenoid wiring connector (10)
(PUP.B).
10) Remove mounting bolts, then lift off HSS

pump assembly (10).
4 HSS pump assembly : 116 kg
D155AX-5
30-145
1
5
HYDRAULIC PUMP
D. Removal of charge + scavenging pump assembly

1) Disconnect charge filter hose (1).
fl It is difficult to disconnect the hose at
the pump end.
2) Disconnect power train case suction tube (2).

3) Disconnect suction hydraulic tank tube (3).
4) Lift off charge + scavenging pump assembly

(4).
fl Raise, then move slowly towards the engine, and lower gradually from clearance.
4 Charge + scavenging pump assembly :
30 kg
INSTALLATION OF HYDRAULIC
PUMP ASSEMBLY

removal.
Refilling oil
Hydraulic oil : Approx. 97
Power train case : Approx. 60
Bleeding air
Bleed the air from the pumps and power train.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-146
1
5
D155AX-5
HSS PUMP
DISASSEMBLY OF HSS PUMP

ASSEMBLY
HPV160
Set hydraulic pump assembly (1) to tool Q1.
2. Servo valve assembly

Remove 4 mounting bolts, then remove servo
valve assembly (2).
fl Remove the four mounting bolts marked by

hatching in the diagram on the right.
3. Safety-suction valve assemblies

Remove 2 safety-suction valve assemblies (3).
fl It is impossible to adjust the pressure of the
safety- suction valve, so do not disassemble
it.
D155AX-5
30-146-1
2
HSS PUMP
4. Charge relief valve assembly

1) Remove charge relief valve assembly (4).
2) Disassemble charge relief valve assembly as

follows.
fl Measure screwed-in depth a of the adjustment screw before disassembling.
i)
Remove locknut (5), then remove adjustment screw (6) from sleeve (7).
ii) Remove spring (8) and poppet (9).
5. End cap assembly

1) Remove 2 plugs (10) and 3 plugs (11).
30-146-2
2
D155AX-5
HSS PUMP
2) Remove plug (12).
3) Remove 6 mounting bolts, then remove end

cap assembly (13).
4) Disassemble end cap assembly as follows.

i) Remove valve plate (14) from end cap
(15).
ii) Remove needle bearing (16).
D155AX-5
30-146-3
2
HSS PUMP
6. Cylinder block, piston assembly

1) Remove cylinder block and piston assembly
(17).
fl The piston is fitted tightly to the rocker
cam, so check that the cylinder block and
piston come off together as one unit.
2) Disassemble cylinder block and piston assembly as follows.

i) Remove piston assembly (18) from cylinder block assembly (19).
fl Remove the piston and shoe retainer
as one unit.
ii) Remove 9 pistons (20) from shoe retainer
(21).
iii) Remove retainer guide (22).

iv) Remove 3 pins (23).
v) Set tool Q2 to cylinder block assembly

and compress spring.
vi) Remove snap ring (24) from cylinder
block (25).
vii) Remove tool Q2.
viii)Remove seat (26), spring (27), and seat
(28).
30-146-4
2
D155AX-5
HSS PUMP
7. Rocker cam
1) Remove rocker cam (29) together with slider.
2) Remove slider (30) from rocker cam (29).
8. Shaft, cradle assembly

1) Remove 6 mounting bolts, then remove shaft
and cradle assembly (31).
fl Push the input spline end of the shaft to
remove.
2) Disassemble shaft and cradle assembly as

follows.
i) Using press, remove shaft assembly (32)
from cradle (33).
D155AX-5
30-146-5
2
HSS PUMP
ii) Remove snap ring (34) and washer (35)

from shaft (36).
fl The washer is a selected part, so
check the thickness.
iii) Using tool Q3, remove roller bearing (37).
9. Servo piston
1) Remove stopper assemblies (38) and (39).
2) Disassemble stopper assembly as follows.

i) Remove locknut (40).
ii) Remove rod (41) from cap (42).
iii) Remove retainer (43) and spring (44).
3) Remove servo piston (45).
30-146-6
2
D155AX-5
HSS PUMP
10. Oil seal

1) Remove snap ring (46), then remove spacer
(47).
2) Remove oil seal (48).
11. Pump case

Remove 2 plugs (49) from pump case (50).
D155AX-5
30-146-7
2
HSS PUMP
ASSEMBLY OF HSS PUMP

ASSEMBLY
HPV160
fl Clean all parts, remove all burrs, check for dirt
or damage, and be particularly sure to clean the
drill hole oil passage.
fl Coat the rotating and sliding surfaces of all parts
with engine oil (EO-10CD) before assembling.
fl Always check the contact of the following parts
before assembling. For details, see CHECKING
CONTACT BETWEEN PARTS.
1) Cradle and rocker cam
2) Cylinder block and valve plate
3) Valve plate and end cap
1. Pump case
1) Set pump case (50) to tool Q1.
2) Fit O-rings and install 2 plugs (49).
3 Plug: 58.8 - 78.4 Nm {6 - 8 kgm}
2. Servo piston
1) Insert servo piston (45) in pump case.
fl When the slider groove is set facing the
bottom of the case, insert the servo piston so that the part receiving the servo
valve lever faces the mounting surface
of the servo valve.
2) Assemble stopper assembly as follows.
i) Set spring (44) and retainer (43) to cap
(42).
ii) Fit O-ring and install rod (41).
iii) Install locknut (40).
iv) Adjust dimension b from flange surface

of cap (42) to tip of retainer (43), then
tighten locknut (40).
fl Dimension b = 80 0.1 mm
3 Locknut :
265 - 323 Nm {27 - 33 kgm}
fl Adjust the cap assemblies on both sides
to the same dimension.
30-146-8
2
D155AX-5
HSS PUMP
3) Fit O-rings and install cap assemblies (38)

and (39).
3 Mounting bolt:
59 - 74 Nm {6 - 7.5 kgm}
3. Shaft, cradle assembly

1) Assemble shaft and cradle assembly as follows.
i) Using tool Q4 and press, press fit roller
bearing (37) to shaft (36).
2 Press-fitting surface of bearing:
Grease (G2-LI)
ii) Select washer thickness as follows.

Select washer (35) of each thickness and assemble temporarily. Measure dimension c
from top surface of washer to top end of
snap ring groove. Then select washer so that
dimension is within range below.
Dimension c = 1.8 - 2.0 mm
Washer thickness : 3.0, 3.1, 3.2 mm
iii) Fit selected washer (35), and secure with

snap ring (34).
D155AX-5
30-146-9
2
HSS PUMP
iv) Using tool Q5 and press, press fit shaft

assembly (32) to cradle (33).
Grease (G2-LI)
2) Install shaft and cradle assembly (31) to

pump case.
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
4. Rocker cam
1) Install slider (30) to rocker cam (29).
fl Install the slider so that the chamfered
part faces the rocker cam.
2) Install rocker cam (29) to cradle.

fl Check that the sliding portion is fitted
together tightly, and that the slider is
fitted securely in the servo piston groove.
30-146-10
2
D155AX-5
HSS PUMP
5. Cylinder block, piston assembly

1) Assemble cylinder block and piston assembly as follows.
1) Set seat (28), spring (27), and seat (26)
to cylinder block (25).
ii) Set tool Q2 to cylinder block and compress spring.
iii) Install snap ring (24) and remove tool
Q2.
iv) Install 3 pins (23).

v) Install retainer guide (22).
vi) Assemble 9 pistons (20) to shoe retainer

(21).
vii) Assemble piston assembly (18) to cylinder block assembly (19).
2) Assemble rear cylinder block and piston assembly (17).

fl Check that the spline of the cylinder block
and shaft is meshed and that the sliding
portion of the rocker cam and piston
shoe is tightly fitted.
D155AX-5
30-146-11
2
HSS PUMP
6. End cap assembly

1) Assemble end cap assembly as follows.
i) Using tool Q6, press fit needle bearing
(16) to end cap (15).
Grease (G2-LI)
ii) Install valve plate (14) to end cap (15).

fl Align the pin groove of the valve
plate end and the pin of the end cap
end, and check that the valve plate
and end cap are in tight contact.
2) Fit O-ring and install end cap assembly (13).

2 Mating surface of pump case:
Gasket sealant (LG-7 or LG-5)
3 Mounting bolt:
343 - 427 Nm {35 - 43.5 kgm}
3) Measure rotating torque of shaft as follows.

Using tool Q7, measure rotating torque of
input shaft.
fl Rotate shaft at a constant speed (3 - 5
sec/1 turn) and measure rotating torque.
Rotating torque:
Max. 17.6 Nm {Max. 1.8 kgm}
(Torque variation range:
Max. 2.94 Nm {Max. 0.3 kgm})
fl If the rotating torque is not normal, disassemble again and look for the cause.
30-146-12
2
D155AX-5
HSS PUMP
4) Fit O-ring and install plug (12).

3 Plug: 24.5 - 34.3 Nm {2.5 - 3.5 kgm}
5) Fit O-ring and install 3 plugs (11).

3 Plug: 147 - 186 Nm {15 - 19 kgm}
6) Fit O-rings and install 2 plugs (10).
3 Plug : 147 - 186 Nm {15 - 19 kgm}
fl When pressure inspection plug has been
removed
3 Pressure inspection plug:
17.7 - 22.6 Nm {1.8 - 2.3 kgm}
7. Oil seal
1) Using tool Q8, press fit oil seal (48).
2 Oil seal lip: Grease (G2-LI)
2) Fit spacer (47) and secure with snap ring

(46).
D155AX-5
30-146-13
2
HSS PUMP
8. Charge relief valve assembly

1) Assemble charge relief valve assembly as
follows.
i) Assemble poppet (9) and spring (8) to
sleeve (7).
ii) Fit O-ring and install adjustment screw
(6) and locknut (5).
iii) Align with screwed-in dimension a of

adjustment screw measured before disassembly, then tighten locknut.
2) Fit O-ring and install charge relief valve assembly (4).

3 Charge relief valve:
49 - 59 Nm {5 - 6 kgm}
9. Safety-suction valve assembly

Fit O-ring and install 2 safety-suction valve assemblies (3).
3 Safety-suction valve:
216 - 235 Nm {22 - 24 kgm}
30-146-14
2
D155AX-5
HSS PUMP
10. Servo valve assembly

Fit O-ring and install servo valve assembly (2).
2 Mating surface:
Gasket sealant (LG-7 or LG-5)
fl When inserting the arm of the servo valve
into the servo piston, be careful not to cause
any gouging.
fl Gradually tighten the mounting bolts on opposite sides in turn.
3 Mounting bolt:
27.5 - 34.3 Nm {2.8 - 3.5 kgm}
D155AX-5
30-146-15
2
HSS PUMP
CHECKING CONTACT BETWEEN PARTS

fl If either part of the following pairs of sliding
parts has been repaired or replaced with a repair part (new part), check the contact as follows.
There is no need for this check if both parts of
the pair have been repaired or replaced with a
repair part (new part).
1) Cradle and rocker cam
2) Cylinder block and valve plate
3) Valve plate and end cap
1. Cradle and rocker cam
1) Remove all oil and grease from the parts to
be checked.
fl Do not wipe with a cloth.
2) Paint the cradle with inspection paint, then
put the rocker cam on top.
fl Coat thinly with paint.
fl Assemble in the direction shown in the
diagram on the right.
3) Push the rocker cam with a force of 39.2 49.0 N {4 - 5 kg}, and move it from the position where it contacts the stopper to the
maximum swash plate angle. Repeat this
process 2 or 3 times.
4) Remove the rocker cam, transfer the contact
surface to a tape, and check the contact surface.
fl The standard for the contact is as given
below.
(1) Within 36 - 50 mm of center (center
portion): Contact of more than 90%
(2) Range from center portion (36 - 50
mm) to 67 mm: Contact of 50% 90%
(3) Not within width of 67 mm (outside):
Contact of less than 50%
(It is not permitted to have contact
only at the outside and no contact at
the center.)
fl If the contact is defective and lapping is
carried out, it must always be carried
out for both parts together.
30-146-16
2
D155AX-5
HSS PUMP
2. Cylinder block and valve plate

1) Make a centering tool for the cylinder block
and valve plate.
fl The tool can be made from plastic,
bakelite or any other soft material.
be checked.
3) Paint the cylinder block with inspection paint,
then put the tool and valve plate on top.
4) Push the valve plate with a force of 39.2 49.0 N {4 - 5 kg} against the cylinder block,
turn the valve plate 90, then turn it back to
the original position. Repeat this process 2
or 3 times.
5) Remove the valve plate, transfer the contact
fl The standard for the contact is as given
below.
(1) Seal portion (range of 101.5 mm): Contact of more than 80% and no break
around whole circumference
(2) Land portion (range of 101.5 mm - 128
mm): Contact of more than 60% and no
break around whole circumference
3. Valve plate and end cap

be checked.
2) Paint the end cap with inspection paint, then
put the valve plate on top.
3) Push the valve plate with a force of 39.2 49.0 N {4 - 5 kg} against the end cap, turn
the valve plate 90, then turn it back to the
original position. Repeat this process 2 or 3
times.
4) Remove the valve plate, transfer the contact
fl The contact of the mating surface of the
valve plate and end cap must cover at
least 80% without any variation.
fl If the contact is defective, use a surface
plate and correct by lapping.
D155AX-5
30-146-17
2
DISASSEMBLY
HSS MOTOR
AND ASSEMBLY
REMOVAL OF HSS MOTOR

ASSEMBLY

1. Remove fuel tank assembly.

For details, see REMOVAL OF FUEL TANK
SEMBLY.
2.
3.
Disconnect
Disconnect
AS-
HSS pump hoses (I) and (2).

charge relief valve hoses (31, (41, and
(5).
4.
5.
Disconnect HSS circuit pressure sensor wiring

connectors (6) and (7) (CNSTAP1.2).
Remove mounting bolts, then lift off HSS motor
assembly (8).
& kg
HSS motor assembly
: 64 kg
INSTALLATION OF HSS
MOTOR ASSEMBLY
. Carry out installation in the reverse
order
to
removal.
D 155AX-5
30-147
0
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF POWER TRAIN

MAIN RELIEF VALVE
ASSEMBLY
1.
Remove fuel tank assembly.

For details, see REMOVAL OF FUEL TANK ASSEMBLY.
2.
Disconnect hose (I).
3.
Disconnect pressure detection hose (2).
4.
Remove power train main relief valve assembly

a
(3).
INSTALLATION
OF POWER
TRAIN MAIN RELIEF VALVE
ASSEMBLY
l

removal.
.
w
Check that there is no damage to the O-ring,

and assemble securely.
Main relief valve mounting bolt:
44.1 - 53.9 Nm (4.5 - 5.5 kgm)
30-l 48
a
D155AX-5
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY OF POWER
TRAIN MAIN RELIEF VALVE
ASSEMBLY
1.
@@---I
0
Remove plug (I), then remove valve (21, spring

(31, valve (41, valve (51, shim (61, and springs (7)
and (8) from valve body (9).
*
Check the number
and thickness
of the
2.
Remove
3.
Remove
plug (131, then remove
guide
spring (151, spool (161, valve (171, spring
and valve (19).
4.
Remove
0------z
D
Y---3
L4
plug (IO).
(141,
(181,
16
plug (20).
ASSEMBLY OF POWER TRAIN

MAIN RELIEF VALVE
ASSEMBLY
*

1.
Assemble
spring
(i5)
and guide
(14) to spool
(16).
2. Assemble valve (191, spring (181, and valve (17)
to spool (161, then assemble to valve body (91,
and install plugs (20) and (13).
3.
Assemble springs (8) and (7) to plug (IO), and

install to valve body (9).
4.
Assemble
valve (21, spring (31, and valve (41,
then assemble to valve (5) and install shim (6)
on opposite side.
*
Check the thickness and number of shims
when assembling.
Standard shim thickness: 0.5 mm
5.
Assemble
valve (5) to valve body (91, and install
plug (I).
6.
Tighten
D 155AX-5
plugs (IO) and (I).
30-l 49
0
DISASSEMBLY
AND ASSEMBLY
HSS, PPC CHARGE VALVE
REMOVAL OF HSS, PPC

CHARGE VALVE ASSEMBLY
a

1.
2.
3.
4.
5.
Disconnect clamp (I) from filter case.

Disconnect PPC lock valve hose (2).
Disconnect accumulator
hose (3).
Disconnect tube (4) coming from charge
Remove filter case assembly (5).
6. Disconnect
7. Disconnect
pump.
main control valve hose (6).

drain hose (7).
8. Disconnect charge pressure sensor wiring connector (8) (CN406).

9. Disconnect HSS pump hose (9).
10. Disconnect HSS pump solenoid valve hose (IO).
11. Remove mounting bolts, then remove HSS and
PPC charge valve assembly (1 I).
INSTALLATION
OF HSS, PPC
CHARGE VALVE ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
to

Add engine oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Loosen the air bleed plug of the filter
and bleed the air.
After bleeding the air, check the oil level again
with the sight gauge.
30- 150
0
D155AX-5
HSS, PPC CHARGING VALVE
DISASSEMBLY OF HSS, PPC CHARGING VALVE ASSEMBLY

20
14
21
22
1
15
3
17
18
19
16
13
11
12
10
9
8
6
5
23
DKD01197
1. Remove plug (1), then remove springs (3) and

(4) from valve body (2).
2. Remove plug (5), then remove spool assembly
(6).
3. Remove valve (8), spring (9), valve (10), and
shim (11) from spool (7).
4. Remove plug (12), then remove spring (13).
5. Remove plug (14), then remove spool assembly
(15).
6. Remove valve (17), spring (18), and valve (19)
from spool (16).
7. Remove plug (20), then remove spring (21) and
valve (22).
8. Remove plug (23).
D155AX-5
30-151
1
5
HSS, PPC CHARGING VALVE
ASSEMBLY OF HSS, PPC CHARGING VALVE ASSEMBLY

20
14
21
22
1
15
3
17
18
19
16
13
11
12
10
9
8
6
5
fl Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts
with engine oil before installing.
1. Tighten plug (23).
2. Assemble valve (22) and spring (21) to valve
body (2), and tighten plug (20).
3. Assemble valve (19), spring (18), and valve
(17) to spool (16).
4. Assemble spool assembly (15) to valve body
(2), and tighten plug (14).
3 Plug : 63.7 14.7 Nm {6.5 1.5 kgm}
5. Assemble spring (13) and tighten plug (12).
3 Plug : 68.6 9.8 Nm {7 1 kgm}
6. Assemble valve (10), spring (9), valve (8),
and shim (11) to spool (7).
fl Check the number and thickness of the
shims, then assemble.
Shim thickness: 0.5 mm
No. of shims: 4
7. Assemble spool assembly (6) to valve body
(2) and tighten plug (5).
3 Plug : 68.6 9.8 Nm {7 1 kgm}
30-152
1
5
5
23
DKD01197
8. Assemble springs (4) and (3), and tighten

plug (1).
3 Plug : 68.6 9.8 Nm {7 1 kgm}
D155AX-5
TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
Park

1. Remove operators seat and floor plate.

For details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY.
2. Disconnect hose brackets (1) and (2) from transmission case cover.
3. Disconnect speed control cable (3), and remove

bracket from case cover.
fl Do not disconnect the cable from the bracket.
4. Disconnect directional control cable (4), and remove bracket from case cover.
fl Do not disconnect the cable from the bracket.
5. Disconnect transmission modulation pressure
detection hose (5).
6. Disconnect wiring connector of gear speed detection limit switch (5-1).
Serial No. Only 75001 and up
7. Disconnect backup alarm limit switch wiring connector (6) (CN251), and remove limit switch (7).
8. Using forcing screws, remove transmission cover
(8).
1
9. Disconnect hose (9) coming from charge pump,
and remove plate (10).
10. Remove sleeve (11), then remove block (12).
D155AX-5
30-153
1
5
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
CONTROL VALVE
(13) and (14).
10. Remove
sleeves
11. Remove
block (151, then remove sleeve (16).

a
12. Remove
mounting bolts, then remove transmism

sion control valve assembly (17).
INSTALLATION OF
TRANSMISSION
CONTROL
VALVE ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
to
Look through the inspection window in the

cover to check that the lever and yoke are
meshed, then tighten the mounting bolts.
When installing the cover, tap with a plastic
hammer.
If the dowel pin portion is not
inserted, remove the cover, correct the meshing of the lever and yoke, then install again.
&
Sleeve
Transmission
30- 154
0
: Grease (G2-LII
control valve mounting bolt :

49.0 2 4.9 Nm 15.0 = 0.5 kgm)
D155AX-5
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
CONTROL
VALVE
DISASSEMBLY OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
ASSEMBLY OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
1.

Coat the sliding surfaces of all parts
1.
Assembly
of directional
valve, modulation
valve
1) Assemble
valves (29) and (28), spring
(27), and valve (26) to valve (23), then fit
stopper (25) and install snap ring (24).
2) Assemble
valve assembly (23) to body
(I), then assemble springs (19) and (18),
washer (17) and spring (16) from opposite side, assemble spring (16), then install spacer (15).
3) Install shim (14) and cover (13).
Disassembly
of quick return valve
Remove plug (2), then pull out valve
gether with valve (4).
(3) to-
2.
Disassembly
of speed valve
1) Pull out spool assembly (5) from valve
body (1).
2) Loosen nut (6), and disconnect spool (7)
and yoke (8).
3.
Disassembly
of directional
valve, modulation valve
1) Remove snap ring (9), then remove stopper (10).
2) Loosen nut (II), then remove yoke (12).
3) Remove cover (13), shim (14), and spacer
(15), then remove spring (16), washer
(17), and springs (18) and (19).
Remove
cover (20).
4)
5) Remove collar (21) and spool (22).
6) Remove valve assembly (23).
snap ring (24), stopper
(25),
7) Remove
valve (26), spring (27), valve (28), and
valve (29) from valve assembly (23).
Free length of
spring (mm)
83.8 - 84.2
84.3 - 84.7
84.8 - 85.2
No. of standard
shims
4)
5)
6)
Dl SAX-5
Install spool (22) and collar (21) to body

(I), then install cover (20).
Assemble stopper (IO), and install snap
ring (9).
Assemble nut (11) to yoke (12), then install to spool (22).
w
Locknut :
27.5 - 34.3 Nm I2.8 - 3.5 kgm}
*
Installation dimension a of yoke:
29.1 mm
2.
Assembly of speed valve

1) Assemble nut (6) to yoke (8), and install
to spool (7).
w
Locknut :
27.5 - 34.3 Nm 12.8 - 3.5 kgml
2) Install spool assembly (5) to body (1).
3.
Assembly of quick return valve

1) Assemble valve (4) to valve (3), then insert in body and install plug (2).
30-155
0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CONTROL VALVE
2
3
DED01247
30-156
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
BRAKE VALVE
REMOVAL OF BRAKE VALVE

ASSEMBLY

1.
Disconnect
foot brake rod (I).
2.
Disconnect
parking
3.
Remove bolts (31, then remove bracket (4).

Jr Do not loosen the lock of the cable.
4.
Disconnect
5.
Remove
mounting
valve assembly (6).
brake cable (2).
HSS case hose (5).

bolts,
then
remove
brake
INSTALLATION OF BRAKE
VALVE ASSEMBLY
.
Carry out
removal.
D155AX-5
installation
in the
reverse
order
to
30-l 57
0
DISASSEMBLY
DISASSEMBLY OF BRAKE
VALVE ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
Remove
Remove
Remove
(24).
Remove lever assemblies (16) and (26).
Remove seals (19) and (22) from case
(25), then remove bearings (20), (21), and
(27).
30-158
0
ASSEMBLY OF BRAKE
VALVE ASSEMBLY
solenoid valve (1).

lever and cover assembly (28).
check valve assembly
(31) from
body (6).
Remove plug (33), then remove spring (32)
and spool (30).
Remove plug (2), then remove spring (3),
piston (4), and valve (5).
Remove cover (29), remove guides (13) and
(12), and spring (IO), then remove shaft (bolt)
(7), guide (8), spring (9), guide (II), and nuts
(14) and (15) as one unit.
Disassembly
of lever case (26)
1) Remove levers (18) and (23).
*
Be careful not to lose keys (17) and
2)
3)
BRAKE VALVE
AND ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.

Install shaft (bolt) (7), guide (8), spring (9),
guide (II),
and nuts (14) and (15) as one
unit to body (6).
Assemble
spring (IO), and guides (12) and
(13), then install cover (17).
Assemble
valve (5), piston (4), and spring
(3), then install plug (2).
Assemble
spool (30) and spring (32), then
install plug (33).
Install cover (29).
Install check valve assembly
(31) to body
(6).
Install lever and cover assembly (16).
Install solenoid valve (1).
Assemblv of lever case assembly (26)
1) Instail bearings (20), (21), and (27), and
oil seals (19) and (22) to case (25).
2) Install lever assemblies (16) and (26),
then install levers (18) and (23).
*
Install key (17) and (24) securely to
levers (18) and (23).
3) Install lever case (28) to valve body (6)
using cover (29).
Dl SAX-5
DISASSEMBLY
D155AX-5
AND ASSEMBLY
BRAKE VALVE
30-159
0
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Remove 8 mounting
drive assembly (1).
3.
Jacking
&)
2)
*
bolts (2) on inside of final

a
up chassis
Using hydraulic jack (686 kN (70 ton))
and ripper of machine, jack up chassis
and set stands @ under steering case on
left and right.
Set stands @ on left and right under
main frame at front of chassis.
After setting stands @I and 0, set the
hydraulic jack and ripper again to act as
extra support.
DUOX75
0
4.
DLCO3176
Lift off guard (3).

& kg
Guard : 45 kg
30-160
a
Ly
DBDOO726
D155AX-5
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
5.
Remove
2 segment
teeth (4).
6.
Remove
drive shaft cover (5).
7.
Pull out drive shaft (6).

*
Use a forcing screw to pull out the drive
shaft to a point where the spline comes out.
*
If the shaft does not come out, move the
sprocket backward and forward to adjust to
a position where the shaft comes out, then
pull out the shaft.
8.
Align place where

with track frame.
9.
Remove mounting
bolts on top
assembly, then install tool F2.
segment
teeth were removed
of final
drive
m
DBDoo729
D 155AX-5
30-161
0
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
10. Using tool Jl, sling final drive assembly (I), and
remove remaining bolts.
To prevent the final drive from flying out,
slightly loosen one mounting
bolt each on
both sides of the final drive, then loosen
while pulling out the final drive assembly,
and remove.
11. Lift off final drive assembly

E?lkg
(I).
Final drive assembly
: 1500 kg
CWD02648
INSTALLATION
OF FINAL
DRIVE ASSEMBLY
l
Carry out
removal.
&
installation
in the
reverse
order
to
Final drive mounting bolt :

Final drive mounting bolt :
1323.9 + 147.1 Nm I135 t 15 kgm1
bolt :
Guard mounting bolt :
745.3 = 83.4 Nm {76 f 8.5 kgm1
Guard mounting
teeth mounting bolt :

Segment teeth mounting bolt :
1176.8 = 98.1 Nm (120 = 10 kgm}
Segment
30-l 62
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1.
Carrier assembly
1) Remove cover.
2) Remove mounting bolts, then using eyebolts
0, remove carrier assembly (I).
3)
Remove
lock plate (2).
DEW1143
4)
Using tool 55, pull out shaft (3).

*
Remove all three shafts.
CWD02649
5)
Remove gear assembly (4).

*
When removing the gear assembly, push
the gears which are not being removed
against the outside wall, then remove
the gear which is to be removed.
DKDX145
D 1 SAX-5
30-163
0
DISASSEMBLY
6)
7)
Remove
Remove
ASSEMBLY
AND
FINAL DRIVE
bearing (6) from gear (5).

outer race (7) from gear (5).
6
6.
7
DKDO1146
2.
3.
Shaft
Using eyebolts
0,
Holder
Remove
(IO).
holder
remove
shaft (9).
I
4.
Ring gear, hub assembly

gear and hub asI) Using wire, remove-ring
sembly (11).
2) Remove 6 plates (121, then remove ring gear
(14) from hub (13).
5.
Sprocket, hub assembly

Fit eyebolts, pull out sprocket and hub asI)
sembly (15) with tool 52 and remove.
30-164
0
DEW1147
D155AX-5
DISASSEMBLY
2)
3)
6.
AND ASSEMBLY
Bearing
time.
(19) will come
FINAL DRIVE
out at the same
Remove floating seal (16).

Ir If the floating seal to be used again, be
careful not to damage the seal surface,
and keep it in a safe place.
Remove outer race (18).
16
18
Cover assembly
1) Screw in forcing screws 0, and pull out
cover assembly (21) from case (22). then use
eyebolts @ to remove.
22
DEm1154
2)
3)
4)
Remove floating seal (16).

Ir If the floating seal to be used again, be
careful not to damage the seal surface,
Using bolts 0, knock out spacer (20) and
bearing (19) from cover.
Remove bearing (8).
DKD01155
D155AX-5
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
7. Gear
Remove mounting bolts (211, pull out with forcing screws @, then using eyebolts 0, remove
gear (24) from hub (25).
*
Turn the gear at an angle and remove it.
DEW1166
8. Hub
1) Using eyebolts @, remove hub (25).
2) Using puller 0, remove inner race (26) from
hub (25).
DEW1166
26
DECO1169
9. Guide plate
Remove guide
r
plate (37).
10. Pinion assembly

1) Using forcing
screws @, remove
cage (27).
DEDOll61
30-166
0
D155AX-5
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
2)
Remove
pinion assembly
3)
Remove
bearing
(29).
(31) from pinion (30).
ill
3i
DLD31163
DLm1162
4)
Remove outer race (32) and oil seal (33) from

cage (28).
32
5)
Remove
outer race (34) from case.
34
0
39
L_--/
1
DLDJllM
D 155AX-5
DLDO1165
30-167
0
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
ASSEMBLY
ASSEMBLY
OF FINAL DRIVE
*
*

Coat the sliding surfaces of all parts and the
rotating parts of the bearings with engine oil
before installing.
1.
Pinion assembly
1) Using push- tool 0,
install oil seal (33) to

cage (28).
&
Lip of oil seal : Grease (G2-LI)
DKD01166
2) Using push tool, install outer race (32) to

cage (28).
3)
32
\
Using push tool,

case (35).
press fit oil seal
(36) to
!I!
35
DKD01168
DLDY167
4)
Using push tool, press fit outer race (34) to

case (35).
5)
Using
pinion
36
34
push tool,
(30).
press fit bearing
(31) to
,
e
_,
35.
6)
Install pinion
assembly
7)
Assemble shim, and install cage (28).

Ir Be careful not to damage the oil seal.
DLCM1166
(29) to case.
28
DLDJ1171
30- 168
0
DtDOll72
D155AX-5
DISASSEMBLY
2.
3.
AND ASSEMBLY
FINAL DRIVE
Select the shim thickness as follows.

Install pinion to cage without assembling
i)
O-ring.
bolts to specified
ii) Tighten 4 mounting
tightening torque.
w
Mounting bolt : 9.8 Nm 11 kgml
iii) Using a clearance gauge, measure clearance a between cage and case at 2 places
around
circumference,
then calculate
average value.
iv) Select shim of measured average value
+ (0.05 - 0.1 mm).
Ir There are four types of shim: 0.15,
0.5, 0.6, 0.7 mm
Guide plate
Install guide
plate (37).
Hub
1) Using push tool, press fit inner race (26) to
hub (25).
2) Using eyebolts 0, install hub (25).
37
DEW1174
4.
Gear
1) Using
2)
eyebolts
0,
install
gear
(24) to hub
(25).
*
Turn the gear at an angle and insert it.
Tighten mounting bolts (21).
w
Mounting bolt : 277.0 t 31.9 Nm
I28.25 + 3.25 kgml
DEW1153
5.
DED01176
Cover assembly
1) Using push tool, press fit bearing (8) to cover
(38).
DK!M1177
D155AX-5
30-169
0
DISASSEMBLY
2)
3)
4)
FINAL DRIVE
AND ASSEMBLY
Install spacer (20).

Using tool 54, press fit bearing
(19) to case
ilk
(38).
Using tool 53, install floating seal (16).
+
Remove all oil and grease from the Oring and O-ring contact surface, then dry
before installing.
Ir After installing the floating seal, check
that the angle of the seal is less than 1
mm.
54
18
CWD02652
5)
Using eyebolts 0, install cover assembly (21)

to case (221, and tighten mounting bolts.
&
Mounting bolt :
Thread tightener
m
Mounting
(LT-21
bolt : 549.2 2 58.8 Nm

156 t 6 kgm)
DEDO1180
6.
Sprocket, hub assembly
1) Install outer race (18) to hub (13).

2) Using tool J3, install floating seal (16).
*
3)
4)
Remove all oil and grease from the Oring and O-ring contact surface, then dry
before installing.
*
After installing the floating seal, check
that the angle of the seal is less than 1
mm.
Check that there is no dirt or dust on sliding
surface of floating seal, then coat thinly with
engine oil.
Using eyebolts 0, set sprocket

sembly (15) to cover.
30-170
0
CWD02654
and hub as-
D155AX-5
DISASSEMBLY
5)
FINAL DRIVE
AND ASSEMBLY
Using tool J4, rotate sprocket and hub assembly, and press fit bearing (19).
Ir Press fit within a range where no preload
is applied.
CWD02655
7.
Ring gear, hub assembly

ring gear (14) to hub (131, and
1) A&emble
tighten plate (12).
a
Mounting bolt :
Thread tightener
(LT-2)
m
Mounting bolt : 66.2 = 7.4 Nm
16.75 = 0.75 kgm}
2) Using wire, install ring gear and hub assembly (11).
8.
Holder
1) Assemble shim and tighten holder (IO).
&
Mounting bolt :
w
Mounting bolt : 549.2 = 58.8 Nm
I56 + 6 kgm)
2) Select shim thickness as follows.
i) Tighten 4 bolts to specified torque, then
settle all parts.
&
Mounting bolt :
Thread tightener
(LT-2)
w
Mounting bolts : 549.2 + 58.8 Nm
I56 + 6 kgml
ii) Remove bolts, then turn sprocket hub
and check that bearing rotates smoothly.
Ir At position
of carrier
assembly
mounting bolts: 216 - 265 N
(22 - 27 kg)
iii) Tighten 4 bolts to 34.3 Nm (3.5 kgml,
measure clearance b between holder and
hub at 4 places around circumference,
calculate average value, then select shim
thickness.
Shim thickness = Average clearance b +
(0 - 0.1 mm)
iv) Finally adjust so that clearance a between
holder and hub is 0.05 - 0.1 mm.
D 155,4X-5
DEW1148
II
DEco1185
b
$
DK!MllE6
30-171
0
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
10. Shaft
Using eyebolts
0,
install shaft (9).
11. Carrier assemblv
1) Using push tool, press fit outer race (7) to
2)
gear.
*
Make match marks on the outer race and
bearing.
Assemble bearing (6) to gear (5).
3)
5)
DKDOllSO
Set gear assembly (4) to carrier, then align

shaft hole and inner race hole of bearing.
Ir Insert the gear assembly
through
the
hole in the center of the carrier, push
against the outside wall, then set the gear
assemblies in the mounting position after inserting all three gear assemblies.
I
4)
DKD01189
,6
DKDO1145
Expand-fit shaft (3) to install.

*
Cool in dry ice for approx. 30 minutes.
Ir When the shaft warms up it will be impossible to push it in by hand, so align
the notched portion with the hole in the
plate and push in quickly.
Tighten lock plate (2).
6
Mounting bolt :
Thread tightener
(LT-21
w
Mounting bolt : 109.3 2 12.3 Nm
(11.15 + 1.25 kgm}
DEW1192
30-172
0
D155AX-5
DISASSEMBLY
6)
Using
FINAL DRIVE
AND ASSEMBLY
eyebolts
0,
install
carrier
assembly
(1).
&
Mounting
bolt :
Mounting
bolt : 549.2 i 58.8 Nm
Thread tightener
(LT-21
156 f 6 kgml
7)
Install center cover.
DEW1142
D155AX-5
30-173
0
DISASSEMBLY
AND ASSEMBLY
TRACK FRAME
REMOVAL OF TRACK FRAME

ASSEMBLY
1.
Remove track shoe assembly.

2.
Jacking
2)
3)
3.
up chassis
Using hydraulic jack (686 kN 170 ton})

A 1) and
ripper of machine, jack up chassis
and set stands @ under steering case on
left and right.
Set stands @ on left and right under
main frame at front of chassis.
Set blocks under front of raised track
frame to ensure safety during operation.
Ir After setting stand @ and 0, set the
hydraulic jack and ripper again to act
as extra support.
Disconnection
of equalizer bar
1) Sling track frame assembly,
and remove
cover (I) of equalizer bar, then remove pin
cover (2) and spacer (3).
2)
Remove equalizer bar side pin (4) together

with collars (5) and (6).
3 56
4
DKJNO178
30- 174
0
D155AX-5
DISASSEMBLY
4.
TRACK FRAME
AND ASSEMBLY
Disconnection
of track frame assembly
.
Left track frame assembly
Remove cover (71, then remove spacer (8).
I
.
Right track frame assembly

I) Remove cover (91, and disconnect
DLDoo179
1
DL!XOWl
block
(IO).
I
DLCCO182
DLDOO181
2)
3)
5.
Disconnect
hose (I I) from block (IO),
then remove spacer (12).
Remove seal (131, then remove washer
a
(14) and washer (15).
Lift off track frame

r+ kg
Track frame
assembly
assembly
-1
(16).
: 3,960
kg
i6
D155AX-5
OLD20185
30-175
0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
l
Carry out
removal.
installation
TRACK FRAME
OF TRACK
in the reverse
order
to
Makers
Assemble seal (13) as follows.

1) Keep seal in direction @ in relation to
pivot shaft.
Set with the makers mark on the
outside.
2) Turn seal by hand from condition @ in
direction of arrow to position @.
Set with the makers mark on the
inside.
3) Coat surface @ of washer (15) with oil
(EO-30).
4) Keep the seal in condition @I, and assemble between washer (14) and washer
12
DlllCO186
(15).
Be careful not to let seal (13) extend
surface @.
outside
Refilling with oil

Ia
*
Pivot chamber oil : Approx. 8.2 k! (EO-301

The oil level in the pivot chamber will be 25
mm from the end face of the shaft.
30- 176
0
wmia7
D155AX-5
DISASSEMBLY
AND ASSEMBLY
IDLER
REMOVAL OF IDLER
ASSEMBLY
1. Remove track shoe assembly.
OF TRACK SHOE
ASSEMBLY.
To prevent danger, never stand in front of
g
the idler assembly.
2. Remove side covers (I).
Remove one each on the inside and out*
side.
3.
Loosen support mounting bolts, remove shim,

m
then remove supports (2).
of the
and thickness
Check the number
*
Remove one each on the inside and outside.
*
4.
Loosen guide tension bolt (3).

Loosen two each on the inside and outside.
*
5.
Remove
6.
Raise idler assembly

and remove.
&I kg
7.
idler guide mounting
Idler assembly:
(51, then
DLCCOlSS
bolts (4).
lift out to front
341 kg
Remove spring seat (61, then remove tension

spring (7).
The above parts are assembled between the
*
support and track frame.
DLiXOlSl
D155AX-5
30- 177
0
DISASSEMBLY
IDLER
AND ASSEMBLY
INSTALLATION OF IDLER
ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
to
Set the idler assembly at the center of the

track frame, then adjust clearance a between
the track frame and guide plate with shims.
Standard clearance a : 0.5 - 1.0 mm
Standard shim thickness : 6 mm
30- 178
0
D 15514X-5
DISASSEMBLY
AND ASSEMBLY
IDLER
DISASSEMBLY OF IDLER
ASSEMBLY
1.
Remove
-
oil drain plug and drain oil.

idler : Approx.
2.
Set idler assembly
3.
support
I)
2)
4.
5.
Remove
Remove
530 - 590 cc
(I) on block 0.
nut (21, and pull out bolt (3).

support (4).
Retainer
Remove
mounting
screws 0, remove
bolts,
retainer
then
(5).
using
Shaft
1) Turn over idler assembly.
2) Remove nut (6) and bolt (71, then
support (8).
3)
4)
Using forcing screws 0,

Lift off shaft (IO).
D 155AX-5
remove
forcing
remove
retainer (9).
DISASSEMBLY
6.
7.
AND ASSEMBLY
Disassembly
of support
Remove floating seals
and (8).
(11) from
Disassembly
of retainer
Remove floating seals
and (9).
(12) from
IDLER
supports
retainers
(4)
4I,8
11
Bushing
Remove
30-180
0
bushing
59
(5)
Q
DEW0197
8.
12
MIX0199
(13) from idler (I).
D155AX-5
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
ASSEMBLY
OF IDLER
Ir
1.
Bushing
Set tool
Ll to idler
(I),
and press fit bushing
(13).
Ir When press fitting the bushing, use a plastic
hammer to align the center, then press fit
with a puller.
*
Press fit the bushing so that the dimension
from the end face of the idler to the top face
of the bushing is 15 + 1 mm.
2.
IDLER
-13
CWD02656
Assembly of retainer
Using tool L2, assemble floating seals (12) to
retainers (5) and (9).
See Fig. @ for the protrusion of the seal.
After inserting, check that the angle of the
seal is less than 1 mm.
When assembling
the seal, wash the area
marked by the bold line in Fig. @ (the Oring and O-ring contact surface), remove all
oil and grease, then dry completely.
12
CWD02657
3.
Assembly of support
Using tool L2, assemble floating seals (11) to
supports (8) and (4).
*
*
*
When assembling
the seal, wash the area
marked by the bold line in Fig. @J (the Oring and O-ring contact surface), remove all
oil and grease, then dry completely.
-@--
57mm
TJ
L
DEm202
DEDC0203
CWD02656
D155AX-5
30-l 81
0
DISASSEMBLY
4.
IDLER
AND ASSEMBLY
Shaft, retainer
1). Set idler @ on block (I).
2). Install retainer (9).
3). Raise idler (I) and turn
block 0.
over,
then
set on
mm205
4). Raise shaft (IO) and assemble to idler.

*
When assembling, be careful not to damage the retainer mount floating seal at
the bottom.
5)
5.
Install retainer
(5).
supports
1) Assemble
support (4) to shaft, then fit bolt

(3) and tighten nut (2).
*
Before assembling the support, coat the
floating seal mating surface thinly with
engine oil.
2)
Turn over
shaft, then
*
Before
floating
engine
30-182
0
idler (I), assemble support (8) to

fit bolt (7) and tighten nut (6).
assembling the support, coat the
seal mating surface thinly with
oil.
D155AX-5
DISASSEMBLY
6.
AND ASSEMBLY
Refilling with oil

Using tool L9, add oil to specified
IDLER
level
tighten
plug.
Idler : Approx. 530 - 590 cc (G0140B)

Plug : 205.9 + 49.0 Nm I21 = 5 kgm1
and
-)
To vacuum
tank
To oi I
PUIIIP
If oil has been added with tool L9, always

angle approx. IO as shown in the diagram
on the right, and check that the oil level is at
the bottom face of the oil filler port.
D155AX-5
30-183
0
DISASSEMBLY
AND ASSEMBLY
RECOIL SPRING
REMOVAL OF RECOIL SPRING

ASSEMBLY
1.
Remove idler assembly.

BLY.
OF IDLER ASSEM.I
2.
Remove
cover (I) from track frame.
DLDC0210
3.
Remove
lock plate (21, then remove
pin (3).
DLCOOZll
4.
Lift off recoil spring assembly

r+ kg
Recoil spring
assembly
(4).
: 510 kg
DLCGOZ12
INSTALLATION OF RECOIL
SPRING ASSEMBLY
.

removal.
30-184
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
RECOIL SPRING
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1.
Disconnection
of cover assembly
*
Remove
cover assembly
(2) from recoil
spring case assembly (I) as follows.
1) Set recoil spring assembly (I) on block 0.
Ir When doing this, check that there is no
damage to the weld of recoil spring case
(I).
@3l+----
CKD01030
2)
Loosen mounting
bolts (24) of cover (2)
gradually
in turn on diagonally
opposite
sides.
To prevent danger, never stand in front
of the cover assembly or behind the recoil spring case assembly.
CLD01049
AThe
recoil spring inside the recoil spring
case is applying a pushing force of 294
kN (30 tons} on the yoke, so be careful
not to loosen the mounting
bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange
of the recoil spring case and idler yoke
assembly is 10 - 13 mm.
3)
When the bolts are loosened, the torque will

suddenly drop. Check that the spring is not
applying any pushing force. on the mounting bolts, then remove all bolts.
Ir If the torque increases (the pushing force
of the spring is applied) during the loosening operation, stop the loosening operation and disassemble
as follows.
If the torque does not drop during Steps 2) and

3) described above, and the torque when the
bolts are loosened remains large, there is probably damage to recoil spring set bolt (181, or
nut (16) at the tip of the shaft has fallen off, so
there is danger that the yoke assembly may fly
off to the front. For this reason, disassemble as
follows.
Dl MAX-5
CR
18
16
CLDO1051
30-185
0
DISASSEMBLY
RECOIL SPRING
AND ASSEMBLY
AWhen
disconnecting
the cover assembly
and
recoil spring case assembly,
do not stand in
front of the yoke assembly or behind the recoil
spring case assembly until safety has been confirmed and the recoil spring assembly has been
removed.
i)
Prepare the following parts.

791-730-I 130
Bolt @ (x4):
01580-12016
Nut @ (x4):
Washer @ (x4): 01643-32060
(use again)
CLW1052
Remove 4 bolts marked %, then install bolts

0, nuts 0, and washers @ listed in Step i).
Ir Check that dimension L is less than 300
mm.
*
Screw in bolts @ until they contact the
bottom of the yoke thread.
iii) Remove remaining 8 bolts (those not marked
Zc).
ii)
iv)
VI
Hold bolts @ with a wrench to prevent them

from turning, then loosen 2 nuts Qsimultaneously on opposite sides.
*
Be careful not to let the load bear on
only one bolt.
DLD02850
When recoil spring is fully extended

and
torque has completely dropped in loosening
direction of nut 0, remove bolt 0.
*
When clearance b is approx. 180 mm,
the spring is fully extended.
b
CLD01054
4)
Sling cover assembly

(21, then remove
mounting bolts, and lift off cover assembly.
*
The oil inside the spring chamber will
flow out, so set a container
under the
cover to catch the oil.
-
Spring chamber
: Approx.
12 !Z
l3!3JOO214
30-186
0
Dl55AX-5
DISASSEMBLY
2.
3.
Recoil spring assembly

Raise recoil spring assembly
from case.
Disconnection
of yoke
1) Remove mounting
remove spacer (5).
2)
RECOIL SPRING
AND ASSEMBLY
bolts
(3) and
of yoke
remove
(41, then
iC/
is/[
Using tool M4, disconnect yoke (4) from case.

Disconnection
pressure for yoke:
Approx. 147 kN {I 5 ton}
*
Before disconnecting
the yoke, make
match marks on the yoke and case.
4.
Disassembly
1) Remove
bly (2).
2) Remove
D155AX-5
of cover assembly
cylinder rod (22) from cover assem-
.
bracket, then remove
lubricator
(6).
30487
a
DISASSEMBLY
3)
RECOIL SPRING
AND ASSEMBLY
Remove piston (7) from cylinder rod (22).

Sr Using an air gun, blow in compressed
air through the lubricator mounting hole
to remove the piston.
DEW0219
4)
Remove snap ring (8) from piston (71, then

remove U-packing (9) and wear ring (IO).
7
8
DEDOOZO
5)
6)
5.
Remove cover (12) from cover (II), then remove oil seal (13).
Remove bushing (14) from cover (11).
Disassembly of recoil spring assembly

II
Set recoil spring assembly (3) in tool Ml.

spring is under high installed load,
AThe
so be careful to set it correctly to tool
Ml.
Installed load of spring:
*
285.8 kN (29,160 kg}
CWD07.661
30-188
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
RECOIL SPRING
2) Apply hydraulic pressure slowly to compress

spring, then remove
move nut (16).
lock plate (15) and re-15
3)
Release hydraulic pressure gradually

lieve tension of spring.
and re-
DEcccl223
4)
Remove set bolt (18), rear pilot (1%

(20), and pilot (21) from spring (17).
shaft
18
@@
DEDOOZ24
D155AX-5
30-189
0
DISASSEMBLY
AND
ASSEMBLY
ASSEMBLY
1.
ASSEMBLY
RECOIL SPRING
OF RECOIL SPRING
Assembly of recoil spring assembly

1) Assemble pilot (21), shaft (20), rear pilot (19),
and set bolt (18) to spring (17), then set in
tool Ml.
The spring is under high installed load,
so be careful to set all parts correctly.
DElXOZZ4
I
2)
Apply hydraulic pressure gradually to compress spring, and set so that installed length
@ of spring is standard value. When doing
this, check clearance @ between shaft (20)
and rear pilot (19).
Installed load of spring:
*
285.8 kN (29,160 kg)
*
Installed length 0: 945 mm
*
Clearance @: 60 mm
3)
Fit nut (16), then install lock plate (15).

When securing nut (16), make a clear*
ance of 0 - 1 mm between lock plate (15)
and nut (16), then bring lock plate (15)
and bolt (18) into tight contact.
Purpose of making clearance
i)
If the nut is screwed in a small amount
and nut (16) protrudes beyond bolt (18),
lock plate (15) may bend and lock bolt
(23) may fall off.
ii) If the nut is screwed in too far, the load
of the spring will always be applied to
the set bolt, and the set bolt will break.
Gradually release hydraulic pressure to completely relieve tension of spring, then remove
recoil assembly (3) from tool Ml.
4)
30- 190
0
CWD02661
I-
DEW0225
,, Clearance O-l.Omm
OLD02921
D 155AX-5
DISASSEMBLY
2.
RECOIL SPRING
AND ASSEMBLY
Assembly of cylinder assembly

I)
Using tool M2, press fit bushing (14) to cover
(II).
.
Bushing
press-fitting force :
19.6 - 29.4 kN 12 - 3 tons)
2)
Assemble oil seal (13) to cover

cover (12) and O-ring.
(II),
install
3)
Assemble wear ring (IO) and U-packing

to piston (71, then install snap ring (8).
(9)
8
4)
Assemble piston (7) to cylinder rod (5) from

U-packing end.
* To prevent air from remaining inside the
cylinder when
carrying out the operation in Step 4) above, fill with grease as
follows, and assemble piston (7).
i) Fill inside of cylinder with approx. 65 cc
of grease.
ii) Set with drain hole in cylinder rod (22)
facing up, then fit lubricator
(61, and
loosen.
iii) Push in until piston (7) contacts stopper
face of cylinder rod, and push out all air
and remaining grease.
D 155AX-5
DISASSEMBLY
RECOIL SPRING
AND ASSEMBLY
iv) Tighten lubricator (61, then install bracket.

w
Lubricator : 49.0 f 2.5 Nm
I5 t 0.25 kgm}
5)
Assemble
cylinder
22
rod (22) to cover assem-
bly (2).
3.
Press fitting yoke

1) Align match marks on yoke and case (made
2)
before disconnecting)
and assemble.
Using tool M3 and spacer (51, press fit yoke
(4) to case.
*
Do not coat press-fitting surface @ with
Molycoat.
.
Press-fitting force: 245.2 kN 125 ton)
I
3)
Fit spacer (5) and tighten

A
Mounting bolt :
mounting
Thread tightener
4.
CWDO.2663
bolts.
(LT-2)
Raise spring assembly (3) and assemble to case.

*
Before assembling, coat surface @ of spring
assembly (3) with grease.
&
Spring assembly surface
@ :
Grease (G2-LII
CKD01056
30-192
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
RECOIL SPRING
Raise cover assembly (2) and install to case assembly (II.

&
Mounting bolt : Thread tightener
(LT-2)
QFJ
Mounting bolt :
549.2258.8
Nm I56=6 kgml
Refilling with oil

Add oil to spring chamber.
%#
D 155AX-5
Spring
chamber
: 12 4 (SAEBOCDI
30-193
0
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Loosen track shoe tension.
SEMBLY.
OF TRACK SHOE AS-
2.
Remove 7 mounting bolts of guard (I), and drop

m
on top of shoe.
.
Remove guard (I) only for the track roller
assembly at the rear.
3.
Remove 4 mounting bolts of track roller assemm

bly (21, and disconnect from bogie (3).
4.
Using work equipment,

guard (1).
&I kg
raise chassis and lift off

113
Guard : 45 kg
DBDJO732
5.
Pull out track roller assembly

top of shoe link.
(2) to outside from

0: Single flange: 97 kg
@: Double flange: 109 kg
Mounting
position
of track roller assembly
0: Single flange type

@I: Double flange type
30-194
0
D155AX-5
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
INSTALLATION OF TRACK
ROLLER ASSEMBLY
.

removal.
&
&
in the
reverse
order
to
bolt :
Guard mounting bolt : 662.0 - 828.7 Nm
I67.5 - 84.5 kgm}
Guard mounting
bolt :
Thread tightener
Track roller mounting bolt :
Track roller mounting
(LT-2)
662.0 - 828.7 Nm
I67.5 - 84.5 kgml
Install the track roller assembly as follows.

I) Install guard (I) temporarily.
2) Lower chassis to a position where track roller
assembly mounting bolts can be assembled,
then install mounting bolts.
3) Tighten guard mounting bolts.
Dl!SAX-5
30- 195
0
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
1.
Remove
-
plug and drain oil.

Track roller : Approx. 390 - 450 cc
2.
Remove mounting
roller (I 1.
3.
Turn over track roller, and set cylinder @ or

block so that there is enough space to remove
shaft from bottom.
4.
Remove 2 mounting
bolts of retainer (31, then
set tool L4 in position and pull out shaft (4) from
bottom.
bolts of retainer
(2) of track
.4
.3
CWD02664
5.
Remove seal guide (51, then

bolts of retainer (3).
6.
Using forcing
screws
0,
remove
remove
mounting
retainer
(3).
DEDXQ33
7.
DEDoozx
Raise roller (61, and pull out from shaft assembly (7).
DEW0235
30- 196
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
8. Set shaft assembly
TRACK ROLLER
(7) to cylinder
9. Using tool L4, remove

(8) from shaft (7).
0.
retainer (2) and seal guide
CWD0.2665
10. Remove
and (8).
floating
seals (9) from
seal guides
11. Remove floating seals (IO) from

and (3). then remove O-ring.
DI 55AX-5
retainers
(5)
(2)
23
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
O-ring
DE000240
12. Remove 2 coil bushings (11) from roller (6).
'11
DEW0241
30-198
0
D 155AX-5
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
*
1.

Set roller (6) in press, then use tool L3 to press
fit 2 bushings (II).
*
When press fitting the bushing, use a plastic
hammer to align the center, then press fit
with a press.
*
Press fit the bushing so that the dimension
from the end face of the roller to the top
face of the bushing is 17 + 1 mm.
2.
'
CUD02666
Using tool 53, assemble floating seals (IO) to

retainers (3) and (2).
Ir After inserting, check that the angle of the
*
J3
I-~
3.
Fig. @ -
Using tool 53, assemble floating seals (9) to seal

guides (8) and (5).
*
*
D155AX-5
30499
0
DISASSEMBLY
4.
TRACK ROLLER
AND ASSEMBLY
Set roller (6) to cylinder

(7) to roller.
0,
and assemble
shaft
DEW0245
5.
After installing retainer (3), turn over with shaft

assembled to roller and set on block 0.
6.
Install retainer (21, assemble seal guide (8) to

shaft, then using tool L4, press fit seal guide (8).
Press fit the seal guide so that dimension a
*
from the end face of the shaft to the top
surface of the seal guide is 48.5 + 0.2 mm.
Turn over the track roller assembly and press
*
fit seal guide (5) in the same way as above.
coat the mating surface
Before assembling,
*
at the seal guide end
seals
floating
the
of
and retainer end thinly with engine oil.
CWD02667
30-200
0
D155AX-5
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
7.
Using tool L9, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
Ir Standard pressure : 0.1 MPa (1 kg/cm*)
*
Method of checking : Hold standard pressure
for 10 seconds. Gauge
indicator must not go
down.
8.
Using tool L9, fill track roller assembly

Q
9.
with oil.
Track roller oil : 390 - 450 cc (GO1401
After filling with oil, check that the oil is at specified level, then tighten plug.
*
Checking oil level: Angle track roller approx.
IO and check that oil level is up to bottom
face of oil filler.
m
Plug : 160.0 - 250.0 Nm US.0 - 25.0 kgml
D 155AX-5
30-201
0
DISASSEMBLY
AND ASSEMBLY
BOGIE
REMOVAL OF BOGIE
ASSEMBLY
1. Loosen track shoe tension.
2.
Remove 7 mounting
on top of shoe.
3.
Sling guard (I), then use work equipment

jack up chassis, and remove guard (I).
r+ kg
bolts of guard (I), and drop

m
to
Guard : 45 kg
4.
Lower chassis, then remove mounting bolts of

bogie guard (2).
112
.
Bogie guard mounting bolt : 2 each on inside and outside of track frame
5.
Use work equipment

to jack up chassis, then
use clearance a between bogie assemblies
to
remove bogie guard (2).
6.
Using tool L13, secure inner bogie (3) and outer

bogie (4).
30-202
0
CWDO2669
D155AX-5
DISASSEMBLY
AND ASSEMBLY
7.
Set steel plate @) between bogie assembly and

shoe link, then lower chassis and remove mounting bolts of bogie assembly (5).
*
After removing the bogie assembly, set block
@ between the bogie assemblies to prevent
it from moving.
8.
Using work equipment,

jack up chassis, fit rope
around bogie assembly (51, then slide on steel
plate @ and pull to outside.
a
r3 kg
Bogie assembly
BOGIE
: 410 kg
DBCGO740
D155AX-5
30-203
0
DISASSEMBLY
AND
ASSEMBLY
INSTALLATION
ASSEMBLY
.
Carry out
removal.
&
w
&
w
BOGIE
OF BOGIE
installation
in the
reverse
order
to
bolt :
Thread tightener
(LT-2)
Guard mounting bolt :
662.0 - 828.7 Nm (67.5 - 84.5 kgm}
Guard mounting
bolt :
Thread tightener
(LT-2)
Bogie mounting bolt :
1863.3 - 2353.7 Nm I190.0 - 240.0 kgm1
Bogie mounting
Procedure for setting bogie assembly on link

I) Set steel plate @ on top of link as shown in
Fig.
2) Fit wire @to bogie bracket (6) of track frame
on opposite side.
3) Fit wire @I to 2 track rollers of bogie assembly to be installed, then use lever block @ to
pull up to top of link.
in mounting
position,
4) Set bogie assembly
then secure with block so that it does not
move.
5) Using work equipment, gradually lower chassis to position where bogie mounting bolts
can be assembled,
then install mounting
bolts.
then tighten bo6) Lower chassis completely,
gie mounting bolts.
7) Raise chassis, then remove steel plate and
install bogie guard (2).
DAD00741
DAwo742
30-204
0
D 155AX-5
DISASSEMBLY
DISASSEMBLY
ASSEMBLY
OF BOGIE
Fixture tool L13 (used when removing the bogie

assembly) is also used for the disassembly
operation, so leave it installed.
1.

Turn over bogie assembly, and lift off 2 track
a
roller assemblies (I).
*
When removing the track roller, check the
mounting
positions of the @ single flange
and @ double flange.
2.
Pulling out pin assembly

1) Set bogie assembly (2) to tool LIO.
*
When removing the pin assembly from
the bogie assembly, the pin assembly
must be removed in the correct direction, so check casting mark @ (INSERT I)) on the inside of the outer bogie, and
set the bogie assembly correctly in the
direction for removal.
2)
BOGIE
AND ASSEMBLY
a--
Using tool LIO, pull out pin assembly

(3)
from bogie assembly (2).
*
Removal pressure for pin assembly :
Approx. 800.2 kN (81.6 ton1
LlO
CWD02670
D155AX-5
30-205
0
DISASSEMBLY
3.
AND ASSEMBLY
BOGIE
PuWing out shaft

I) Set pin assembly (3) to tool Lll.
2) Push in shaft (4) with tool Lll, remove
collar (51, then remove spacer (6) and floating

seal (7).
Ir Dimension for pushing in shaft (4):
78.2 mm
*
Pressure for pushing in shaft (4):
58.8-103.9 kN (6-10.6 ton)
Lll
CUD02671
3)
Turn over pin assembly

(3) while still assembled, then set to tool Lll again.
I
U
/--
I
CUD02672
4)
Push in shaft (4) with tool Lll, then remove

collar (8).
*
Dimension for pushing in shaft (4):
156.4 mm
*
Pressure for pushing in shaft (4):
58.8 - 103.9 kN 16 - 10.6 ton)
D 155AX-5
30-207
0
DISASSEMBLY
5)
BOGIE
AND ASSEMBLY
Remove pin assembly (3) from tool Lll, and

pull out spacer (91, ring (IO), spacer (II),
ring (121, spacer (131, and ring (14) from shaft
(4).
4.
Disassembly
of ring
1) Remove floating seals (15) and (16) from
ring (IO).
2) Remove floating seals (17) and (18) from
ring (12).
3) Remove floating seal (19) from ring (14).
15,19 IO,14
16
17
18
12
DLW0749
5.
Disassembly
of collar
Remove floating seals (20) from
collars
(5) and
(8).
58
6.
Disconnection
of bogie
Remove tool L13, and disconnect
(21) and outer bogie (22).
inner
DLDCO7SO
bogie
CUD02673
30-208
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
ASSEMBLY
BOGIE
OF BOGIE
1.
Securing bogie
Assemble outer bogie (22) and inner bogie (211,
and secure with tool L13.
*
After securing with tool L13, check that the
center of the pin assembly hole is showing.
2.
Shaft, collar
1) Set collar (8) to tool L12, and assemble bushing (12) to shaft (4) temporarily,
assemble to
spacer, set in position, then press fit.
Ir When press fitting the shaft, center the
shaft with the collar, then press fit.
Ir Press-fitting force for collar: 6 - 10.6 ton
Ir Press-fitting dimension: 78.2 mm
6
Collar press-fitting surface of shaft:
Anti-friction
compound (LM-PI
*
After press fitting, there must be no
stepped difference at the end face of the
collar and shaft.
2)
Remove
bushing
3)
Using tool L14, assemble floating seal (20)

to collar (8).
When assembling
the floating seal, remove all oil and grease from the O-ring
and O-ring contact surface.
The angle of the floating seal must be
less than 1 mm.
Protrusion @ of the seal must be within
5- 7 mm.
shaft
(12).
from
spacer,
then
CWD02673
remove
CWD02674
12
D155AX-5
CWD02675
30-209
0
DISASSEMBLY
3.
AND ASSEMBLY
BOGIE
Assembly of ring, collar

1) Using tool L14, install floating seals (191, (181,
(171, (161, and (15) to rings (14). (121, and
(IO).
Ir When assembling the floating seals, remove all oil and grease from the O-ring
and O-ring contact surface.
Ir The floating seal must be tilted less than
1 mm.
*
Protrusion @ of the seal must be within
5-7 mm.
2)
Using tool L14, assemble floating seal (7) to

collar (5).
Ir The precautions
are the same as the
items marked * for Step 1) above.
I
4.
CWO02678
Assembly of pin assembly

*
When assembling the floating seals for each
bushing and
collar, coat the seal mating
surface thinly with oil (EO-30).
1) Install spacer (6) to shaft (41, then assemble
ring (14).
2) Install spacer (131, then assemble ring (12).
3) Install spacer (II), then assemble ring (IO).
4) Install spacer (9).
30-210
0
D155Ax-5
DISASSEMBLY
5)
AND ASSEMBLY
BOGIE
Set pin assembly (3) to tool L12, press fit

collar (5).
*
Press-fitting force for collar: 6 - 10.6 ton
Ir Press-fitting dimension: 78.2 mm
&
Collar press-fitting surface of shaft:
Anti-friction
compound (LM-P)
*
Stepped difference at the end face of the
collar and shaft after press fitting:
O-2mm
5.
CWD02679
Press fitting pin assembly

1) The bogie and pin assembly must be press
fitted in the correct direction, so check the
press-fitting direction and set tool LIO in position.
i)
On the inside of the outer bogie @, there
is an [INSERT+)
casting mark and arrow, so set the bogie with the letters
and arrow facing the hydraulic cylinder
end of tool LIO.
ii) The pin assembly with the distinguishing mark machined
on the outside circumference of the bushing has the larger
diameter,
so press fit the bushing that
has no distinguishing
mark first.
D155AX-5
30-211
0
DISASSEMBLY
2)
AND ASSEMBLY
BOGIE
Press fit pin assembly (2) to bogie assembly.

6
Outside circumference
of pin assem
bly: Anti-friction
compound
(LM-PI
*
Press fit with the [UP] mark on the tip of
the pin at the top.
*
Press-fitting force for pin:
Approx. 800.2 kN (81.6 ton)
6.

Install 2 track roller assemblies (1).
*
Check the installation position of the @ single flange and @ double flange, then install.
&
Mounting bolt : Thread tightener
(LT-2)
w
Mounting bolt :
662.0-828.7
Nm {67.5-84.5 kgm1
7.
Refilling with oil

After assembling,
%8
30-212
0
add oil to bogie assembly.
Bogie assembly
: 210-230
cc (60140)
D155AX-5
DISASSEMBLY
CARRIER ROLLER
AND ASSEMBLY
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1.
Remove top cover of track frame, loosen lubricator (11, then loosen track shoe tension.
The recoil spring cylinder is under high internal pressure, so never loosen lubricator
(I) more than one turn.
Ir If the track tension is not relieved when the
lubricator
is loosened,
move the machine
backwards and forwards.
2.
Using
3.
Remove
4.
Pass rope @
carrier roller
loosen rope
support and
& kg
hydraulic
jack 0,
mounting
raise track shoe.
bolts (2).
through hole in link, wrap around

(31, and tighten rope.
Gradually
to pull out carrier roller (3) from
a
remove it.
Carrier
roller : 45 kg
DLDW255
INSTALLATION
OF CARRIER
ROLLER ASSEMBLY
.

removal.
in the
reverse
order
to
pJ
*
&
When installing the carrier roller to the support, leave a clearance as shown in the diagram.
Support mounting bolt :
Thread tightener
.
(LT-2)
Adjust the tension of the track shoe assembly.

ADJUSTING
TENSION
OF TRACK SHOE ASSEMBLY.
DLDW257
DI 55AX-5
30-213
0
DISASSEMBLY
CARRIER ROLLER
AND ASSEMBLY
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1.
Remove plug and drain oil.

*
Rotate the shaft when draining
-
Carrier
the oil.
roller : 570 - 680 cc
2.
Set carrier
3.
Remove
mounting
4.
Remove
ring (3).
5.
Using tool L6, remove
6.
Using puller 0, remove press-fitting portion of

seal guide, then using eyebolts, remove bearing
(5) and roller (6) as one unit.
roller assembly
(1) on block 0.
bolts, then remove
cover (2).
nut (4).
CWD02681
7.
Remove
8.
Using puller 0, remove

ing (9) as one unit.
outer race (7) from
roller.
seal guide (8) and bear-
DEW0263
QED00262
9.
Remove
floating
seal (IO) from seal guide (8).

8
30-214
0
10
D155AX-5
DISASSEMBLY
10. Using push tool 0,

11. Remove
D 155,4X-5
CARRIER ROLLER
AND ASSEMBLY
floating
remove
seal guide (II).
seal (12) from seal guide
(II).
30-215
0
DISASSEMBLY
AND ASSEMBLY
CARRIER ROLLER
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
*
1. Using push tool 0,
press fit bearing
(9).
2.
Using push tool @, press fit outer race (7).
3.
Set roller (6) and bearing
4.
Using push tool 0, press fit bearing (5) to shaft.

*
Rotate the roller when press fitting the bearing, and press fit to a position where the
rotation
of the roller
becomes
slightly
heavier.
(5) to shaft.
Mm269
5.
Using
tool
L6, tighten
nut (4) to 58.8
Nm
DEDCXI270
(6
kgm1.
*
After tightening the nut, if the nut hole and
shaft hole are not aligned, turn the nut in
the direction of loosening to align.
6.
Install ring (3).
CWDOZ.682
7.
Fit O-ring, then fit cover (2) and tighten

mounting bolts.
*
Temporarily
tighten the oil filler plug.
30-216
0
with
D155AX-5
DISASSEMBLY
CARRIER ROLLER
AND ASSEMBLY
8. Turn over roller (61, and add oil between
shaft
and roller.
Sk
Oil : 570 - 680 cc (GO1401
9. Using tool L5, install

guide (8).
floating
seal (IO) to seal
10. Fit O-ring, then align with dowel

seal guide (8).
pin, and install
I
11. Using tool L5, install
guide (11).
floating
CWD02683
seal (12) to seal
Q
L8
II
r-t!zk
'CWD02684
12. Using tool L8, press fit seal guide (II).

*
Press fit the seal guide until dimension
a
from the end face of the shaft to the top
surface of the seal guide is 131.95 f 0.2 mm.
D155AX-5
30-217
0
DISASSEMBLY
CARRIER
AND ASSEMBLY
13. Using tool L9, apply standard pressure to

oil filler port, and check for leakage of air
seal.
Ir Standard pressure : 1 kg/cm*
*
Method of checking : Hold standard
sure for 10 seconds.
Gauge indicator
not go down.
ROLLER
roller
from
presmust
14. After checking for air leakage, check again that

level of oil added in Step 8 is at specified level.
*
Method of checking oil level
Remove the oil filler plug and tilt the carrier
roller assembly to an angle of approx. IO to
check the oil level.
15. Tighten oil filler plug.
w
Plug : 157.0 - 255.0 Nm US.0 - 26 kgml
30-218
0
wwo279
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
TRACK SHOE
CHECKING BEFORE REMOVAL

OF TRACK SHOE ASSEMBLY
AIn
some cases, it may be extremely dangerous

to remove the track shoe assembly.
To prevent
danger, carry out the following
checks before
removing the track shoe assembly.
Checks before starting
1) Loosen the lubricator at the adjustment
cylinder, release the grease, then move the

machine backward and forward a short distance, and check that the track tension is
relieved.
If the track tension is not relieved
and the track shoe assembly remains tense,
there may be an abnormality inside the track
frame (the recoil spring case is broken, the
recoil spring set bolt is broken, or the nut at
the end of the shaft has fallen off).
Never loosen the lubricator more than
one turn.
Check that there is no interference between
the track frame and the guide shown in the
diagram.
If there is any interference (when
progress of link pitch elongation is extreme),
there are cases where it is impossible
to
know if there is any abnormality
inside the
track frame.
2)
REMOVAL OF TRACK SHOE

ASSEMBLY (NORMAL)
*
If CHECKING
BEFORE REMOVAL
OF TRACK
SHOE ASSEMBLY shows that there is no abnormality, do as follows.
1.
Remove blade assembly.

2. Loosen lubricator (1) and loosen track shoe tension.
m
AThe
recoil spring cylinder is under high internal
pressure, so never loosen lubricator (1) more
than one turn.
If the track tension is not relieved, move the
machine backwards and forwards.
3. Using block 0, adjust position so that master
link is perpendicular.
4. Remove mounting bolts, then remove track shoe
a
(2).
DLWO280
D 155AX-5
30-2 19
0
DISASSEMBLY
5.
TRACK SHOE
AND ASSEMBLY
Disconnect
master link (31, guide end of track
link with a crane, move machine slowly in reverse, and lay out track shoe assembly.
DLD00281
REMOVAL OF TRACK SHOE

ASSEMBLY
(WHEN THERE IS ABNORMALITY
INSIDE TRACK FRAME)
*
When CHECKING BEFORE REMOVAL OF TRACK

SHOE ASSEMBLY
shows any abnormality,
do
as follows.
If there is any abnormality inside the track frame,

there is danger that the track shoe assembly
may spring back when it is removed or that the
idler may spring out when the track shoe assembly is removed.
This may lead to serious
injury,
so remove the track shoe assembly as
fo-IIOWS.
If there is any interference or abnormal catching
around the idler assembly,
examine
carefully
and remove the problem before starting.
Remove blade assembly.
Loosen lubricator (I) of adjustment cylinder, then
move machine b.ackwards and forwards to release grease.
Never loosen the lubricator more than one
turn.
*
Check that all the grease has been removed.
1.
2.
DLD00254
30-220
0
D155AX-5
DISASSEMBLY
3.
4.
5.
6.
AND
ASSEMBLY
TRACK SHOE
Drive slowly forward to put track shoe at idler

end in contact with large block @ or a wall (if
another large bulldozer of the same capacity as
the machine being repaired is available, put in
contact with the blade).
Stop machine
when
recoil spring bends and slack is formed in track
shoe assembly, then apply brake. When doing
this, set so that master link is between idler and
front carrier roller. For safety reasons, fit a lever block between carrier roller support and link.
Remove idler guide (2).
AAlways
remove the idler guide without fail
at this point.
If the track shoe is opened without removing idler guide (21, it will move to the front
when it opens, and idler guide (2) will be
pushed against the track frame.
If the idler
guide is removed in this condition, the idler
yoke assembly will fly out to the front.
Remove shoe (41, then disconnect master link
m
(5).
Be
extremely
careful
to
ensure
safety
when
a
disconnecting
the track shoe.
Move machine towards rear slowly, and lay out
track shoe assembly.
CLD01058
INSTALLATION
OF TRACK
SHOE ASSEMBLY
order
to
removal.
u
*
Track shoe tension
: 20 - 30 mm
m
w
Master
link mounting
1st step
590.0&60.0
2nd step
180+10
Ir
*
bolt :
Nm {60.0&6.0
kgm}
When winding on the track, use a bar and

make sure that the link does not come off
the sprocket.
When winding on the track, make sure that
the track tension does not become loose.
Check that there is no dirt or dust on the
mating surface or thread of the master link.
Tighten the track shoe bolts in the order 0 0.
D155AX-5
DKD00282
30-221
0
DISASSEMBLY
TRACK SHOE
AND ASSEMBLY
OVERALL DISASSEMBLY
TRACK SHOE
OF
This section describes

the lubricated track.
1.
Shoe (master link portion)

Set the track assembly on a flat floor with the
shoe facing up, then remove the shoe bolt at
the master link, and remove the shoe.
*
Do not use an impact wrench when loosening the master link bolt.
Disassembly
into l/4 parts
Because of the weight of the track assembly, if
the l/2 assembly is too large and there are problems with disassembly
and assembly work, divide into l/4 assemblies.
Shoe (regular link portion)
Raise the track assembly and set it on the floor
with the shoe facing up, then use a shoe bolt
impact wrench to remove the shoes.
*
When moving the track assembly, be careful
not to damage the master link portion.
Ir If a gas cutter has to be used to remove the
shoe nut, to prevent deterioration
of the seal
due to the heat, keep the temperature
of the
seal portion below 8OC, and take action to
prevent welding
spatter from entering the
gap between the links.
Draining oil
Before disassembling
the link assembly, drain
the oil from inside the pin and take precautions
so that the link press does not become dirty
with oil.
*
Before disassembling,
if it is judged that it is
necessary to rebuild the track as a dry type
track, the following
work need not be carried out.
1) Set the link assembly on a flat floor with the
large plug side facing up, then chamfer the
burrs on the end face of the pin with a
grinder.
*
If the track is disassembled
with burrs
still at the end face of the pin, the pin
press-fitting
hole of the link will be
scratched,
and this will cause leakage
from the pin press-fitting
portion after
rebuilding.
2) Using a drill (al0 mm), make a hole in the
large plug, then remove the large plug.
*
If any dirt or deteriorated
oil is stuck to
the pin hole, drill through with a longer
drill to remove it. When doing this, be
careful not to damage the oil hole.
2.
3.
4.
30-222
0
only the procedure
for
Burrs
Chamfer
DLD02923
D155AX-5
DISASSEMBLY
3)
4)
5)
6)
5.
TRACK SHOE
AND ASSEMBLY
After removing the large plug, use a baby

grinder (angle of grinder tip: 45 - SO), and
chamfer the pin hole so that the plug is not
damaged when the plug is knocked in.
Turn over the link assembly so that the small
plug side is facing up, remove the burrs at
the end face of the pin with a grinder, then
use tool R5 to knock the small plug to the
inside.
*
If the small plug hole is blocked with
burrs, grind with a grinder until the hole
can be seen completely.
Using a drill (@IO mm), chamfer the small
plug hole.
Blow with compressed
air to remove the
metal particles when draining the oil inside
the pin or removing the burrs, then wash
the link assembly with high-pressure
water
or steam.
Disassembly of link
1)
2)
Set
hit
jaw
*
the link assembly on a link press, then

with a hammer so that the bushing and
are in tight contact.
If the link tread and outside diameter of
the bushing are worn, adjust the height
of the shoe or guide plate, and center
the disassembly
jig with the pin and
bushing center to prevent damage to the
link hole when disassembling.
Ir If the centering is not carried out properly, the link hole may be damaged, the
pin may break, or the bushing may crack
during disassembly.
Operate the left cylinder and remove the left
link and pin and bushing press-fitting
portion at the same time.
+
Check the removal force of the pin and
bushing, and use this value as reference
to judge if it is possible to obtain the
necessary pin and bushing press-fitting
force when turning and reassembling.
*
Do not push the disassembly
jig inside
more than is necessary as the spacer
may break.
Left
disassembly
Jio
Jaw
Right
disassembly
jio
DLD02924
r)
DLWO29C
D155AX-5
30-223
0
DISASSEMBLY
3)
4)
6.
AND ASSEMBLY
Return the left cylinder, then operate the right

cylinder and remove the right link and pin
and bushing press-fitting portion at the same
time.
Return the right cylinder, remove the left
and right links, pins, bushings, and spacers,
then feed the following set for one link assembly into the jaw.
To decide if the seal can be used again,
carry out inspection when the seal is still
installed to the link, so do not remove
the seal from the link.
If oil is remaining, this can be used as a
guideline for reuse of the seal, so mark
such links or seals.
If the end face of the bushing and seal
surface are damaged,
it will cause oil
leakage, so be extremely
careful when
handling.
Inspection
Check the following
items to determine
if the
part can be reused as a lubricated track or as a
grease-filled
track. Carry out a comprehensive
check to determine
if the link assembly can be
rebuilt as a lubricated track or as a grease-filled
track.
* When making judgments
about reuse of
parts, see Guidance for Reusable Parts, Undercarriage,
Lubricated Track.
1) Check the pins, bushings, links, and spacers
visually for damage, and carry out a color
check or use a flaw detector to check parts
that are suspected of being damaged.
Any
part that is cracked must not be used again,
so scrap it.
2) Check the external appearance of the seal
and the end face of the bushing visually to
determine
if they can be used again.
* If only the bushing is replaced with a new
part, the worn or damaged part of the seal
lip will contact the end face of the bushing
directly, so it may not be able to carry out
its sealing function.
For this reason, always
replace the seal
together with the bushing, or rebuild as a
grease-filled
track.
30-224
0
TRACK SHOE
DLDO0291
DLD00292
D155AX-5
DISASSEMBLY
3)
AND ASSEMBLY
Using calipers, measure spacer thickness a

and overall length b of the sliding portion of
the bushing and spacer. Check if it is possible to obtain the specified seal mounting
dimension when reassembling.
*
If the amount of wear of the spacer and
bushing
is greater than the specified
amount, the assembly precision of the
seal portion cannot be guaranteed,
so
replace with new parts, or rebuild as a
grease-filled track.
TRACK SHOE
DLiXfJ293
4)
5)
Using a micrometer,
cylinder gauge, and
calipers, measure the outside diameter
of
the pin and the inside diameter of the bushing at the worn portion, and judge if the
parts can be used again.
*
If the amount of wear is greater than the
specified amount, there will be play during travel, and it will also cause oil leakage, so replace with new parts or rebuild as a grease-filled
track.
*
For details of the dimensions when making judgment,
see MAINTENANCE
STANDARDS.
Using a micrometer
and cylinder
gauge,
measure the outside diameter of the pin and
bushing press-fitting portion, and the inside
diameter of the pin and bushing press-fitting portion of the link to determine
if the
permitted
interference
can
be obtained.
However,
when rebuilding
as a lubricated
track, check that the standard interference
for the pin and link can be obtained.
*
If the permitted interference
can not be
obtained, replace with new parts or replace with an oversize part.
Ir For details of the dimensions when making judgment,
see MAINTENANCE
STANDARDS.
D155AX-5
DLL%0294
DLBXCS5
DISASSEMBLY
AND ASSEMBLY
TRACK SHOE
Precautions
for storage
rust of the counterbore
portion
of the link, leave the seal installed to the link
and be careful not to damage the seal lip
during storage.
Coat the pin and bushing press-fitting portion, shoe mating surface, and master link
mating surface of the link with rust prevention oil to prevent rust.
Coat the whole circumference
of the pins,
bushings, and spacers with rust prevention
oil to prevent rust, and be particularly careful not to damage the end face of the bushing during storage.
1) To prevent
2)
3)
30-226
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
TRACK SHOE
OVERALL ASSEMBLY
1.
When
1.
Preparatory work
I) Washing seal assembly
.
rebuilding
as lubricated
track
Machines fitted with F3 type seals

Remove the seal assembly from the link,
then separate into the seal ring and load
ring, and clean the parts.
*
The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent (trichlene, etc.), so wash
the parts quickly.
After cleaning, wipe
the parts with a clean cloth to remove
all the cleaning agent.
Machines fitted with W7 type seals
For seals that are to be reused, leave the
seal installed to the link, and do not wash it.
2)
When reusing the pin, chamfer the corner of

the end face smooth with a grinder.
Use a
grinder to remove any protruding parts stuck
to the press-fitting portion.
*
If the corner of the end face has become
sharp due to wear, there will be scuffing
at the press-fitting
portion and this will
cause oil leakage.
3)
Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin
when assembling.
*
When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
Make mark to indicate
DLD32301
D155AX-5
30-227
0
DISASSEMBLY
AND ASSEMBLY
If the link, pin, bushing, or spacer are dirty,

wash them.
Remove any protruding
parts
stuck to the link and bushing with a grinder.
Ir These parts easily rust, so wash them
immediately
before assembly.
*
Use tool R3 to wash the pin hole.
Ir Do not polish or carry out any other treatment of the end face of the bushing as
this will cause oil leakage.
5) Use tool R4 to knock the large plug into the
pin.
i) Insert the plug into the guide hole
through the plug insertion window.
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
*
Dimension
a to knock in from end
face of pin: 6 + 2 mm
*
If there is no more place to chamfer
at the pin hole because of wear, use
a baby grinder (angle of grinder tip:
45 - 60) to carry out chamfering.
*
Coat the outside circumference
of the
plug with GO90 and knock in the
smaller diameter part first.
6) Installation of seal assembly
.
Machines fitted with F3 type seal
Clean the link counterbore, then use tool R6
to push the seal in fully to the bottom.
Ir If there is oil stuck to the link counterbore
and seal assembly, the seal will rotate and
its sealing performance
will drop, so do not
coat with oil. In addition, be careful not to
let oil get into the counterbore
portion of
the seal when pushing in.
.
Machines fitted with W7 type seal
When reusing the link and replacing the seal
with a new part, clean the link counterbore,
then push the seal in fully to the bottom.
*
If there is oil stuck to the link counterbore
and seal assembly, the seal will rotate and
its sealing performance
will drop, so do not
coat with oil. In addition, be careful not to
let oil get into the counterbore
portion of
the seal when pushing in.
TRACK SHOE
4)
30-228
0
CWD02666
Remove oil and

from bold line
ereaee
Direction
of
DXD03191
D155AX-5
DISASSEMBLY
AND ASSEMBLY
7)
In order to keep the protrusion of the pin

and bushing constant and the installation
dimensions
of the seal within the specified
value during assembly, adjust the press-fitting jig dimensions of the link press.
*
For details of the standard dimensions,
see PRESS-FITTING
JIG DIMENSION
TABLE FOR LINK PRESS.
Ir To leave a small space for the pin when
assembling,
ensure that the dimension
(dimension a) is greater than dimension
a at the pin pushing portion of the left
press-fitting jig.
When assembling in order @ press fit
ting left link, @ press fitting right link,
provide the extra space for the pin on
the right press-fitting jig.
*
If the end face of the pin (portion PI or
the side face of the link (portions Q, R)
are worn, add the amount of wear to the
standard dimension when adjusting the
dimension of the press-fitting jig so that
the amount of protrusion of the left and
right pin and bushing is uniform.
8)
Adjust the relief pressure of the link press to

make sure that the pushing force of the press
does not exceed the specified value.
Ir If the pushing force is too strong, excessive force will be brought to bear on the
spacer, and it will be pushed against the
bushing.
This will cause the spacer to
break or will cause abnormal wear between the spacer and bushing end face.
Ir If the interference
at the press-fitting
portion is different from when the part
is new, as when reusing a pin or bushing, measure several of the press-fitting
portions, and use the table below to determine the set pushing force according
to the average interference.
*
Pushing force for pin, bushing: 785 kN
{80 ton1
Pushing force L. 1.8 x average press-fitting force
(Adjust the relief pressure of the link
press and set the pushing force.)
D155AX-5
TRACK SHOE
30-229
0
DISASSEMBLY
2.
AND ASSEMBLY
TRACK SHOE
Assembly of link
1)
Use a clean brush to coat the area between

the pin and bushing with oil (GOgO), set in
position, then set in front of the jaw of the
link Dress.
* When reusing (turning) the bushing, set
the worn surface on the outside circumference of the bushing facing the shoe
mounting surface of the link (facing up
on the link press).
2)
Set
link
up,
Ir
*
3)
the left and right bushing end master

with the shoe mounting surface facing
then press fit to the bushing.
When doing this, use the pin end master
link as a support.
Press-fitting force for bushing:
49 - 196 kN (5 - 20 ton1
Using a shoe bolt hole pitch gauge, press fit

until the distance between
the shoe bolt
holes of the left and right link is the specified value.
Ir Use compressed air to remove all metal
particles from burrs caused by press fitting the bushing.
DLDIO311
4)
30-230
0
Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
D 155AX-5
DISASSEMBLY
5)
Measure the amount of protrusion

of the
left and right bushings with a depth gauge.
*
Adjust the press-fitting
jig for the link
press so that the protrusion of the left
and right bushings is uniform.
6)
Feed the master link portion, then set the

pin and bushing in position.
When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified
direction,
the strength
may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
+ Align the large plugs so that they are on
the left side facing the link press when
assembling.
7)
TRACK SHOE
AND ASSEMBLY
DLD02925
To prevent oil from leaking out from scuff

marks on the pin press-fitting
portion, coat
the pin press-fitting hole in the link and the
outside diameter of the pin press-fitting portion with gasket sealant (198-32-19890).
Coat
whole
circumference)
)
DLD02926
8)
Set the right link in position and install the

spacer to the pin.
*
Check that there is no dirt or dust stuck
to the seal surface and bushing end face,
then use a clean cloth or brush to coat
with oil (G090).
f
Wipe the spacer with a clean cloth, then
install it.
I
D 155,4X-5
DLD00315
30-231
0
DISASSEMBLY
9)
TRACK SHOE
AND ASSEMBLY
Using the right jig as the receiving end and

the left jig as the pushing end, press fit the
pin and bushing at the same time.
*
The seal may come off the link due to
the play when press fitting, so press fit
smoothly.
If the seal comes off the link,
stop the press-fitting
operation
and fit
the seal correctly on the link, then start
the press-fitting operation again.
Jr Press-fitting force for pin, bushing:
25 - 50 ton
I
IO) Using a fine adjustment
spacer, press fit so
that the end face of the pin is in tight contact with the bottom of the receiving jig.
*
Adjust the depth of the hole in the receiving jig so that the protrusion of the
left and right pins is uniform.
DLD00316
Fine a djust,ment,
spacer
11) Set the left link in position and install the

spacer to the pin.
*
Coat with oil in the same way as when
installing the right link.
DLD00318
12) Using the left jig as the receiving end and

the right jig as the pushing end, press fit the
left link.
When press fitting, be careful that the
left and right seal and spacer do not
come out of position.
Provide enough space on the left jig so
that the end face of the pin does not
contact the bottom of the jig.
Press-fitting force for link:
245 - 490 kN 125 - 50 ton)
DLD00319
30-232
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
TRACK SHOE
13) Press fit the link, spacer, and bushing so

that they are each in tight contact.
*
It is impossible to check from outside if
they are in tight contact, so control the
hydraulic force of the link press and set
the relief pressure to a constant value.
Then apply hydraulic force and push in
until this pressure is reached.
For details of the setting for the relief
pressure, see Preparatory
work.
*
Check that adjacent links swivel freely in
relation to each other.
14) After assembling each link, use a dial gauge
and pinch bar to measure the end play from
the link previously assembled, to check that
the link is assembled
within the specified
value.
If the end play does not come within 0 0.13 mm even when applying the pushing force until the relief valve is actuated, raise the relief pressure setting
gradually to adjust.
Adjust the relief pressure setting carefully and be sure not to raise the pushing force of the link press higher than
necessan/.
15) Using a shoe bolt hole pitch gauge, check
that the distance between the shoe bolt holes
is within the standard value.
*
If the distance between
the shoe bolt
holes is greater than the specified value,
disassemble
and check for any abnormality, then press fit again.
*
If the distance between the shoe bolt
holes is smaller than the specified value,
and the shoe cannot be installed, the
wear of the spacer or bushing end face
is probably greater than the repair limit,
so disassemble
and replace with a new
part.
Ir If the end play is too large, the sealing
performance
will drop, so set the end
play to a small value.
16) After assembling
each link, use tool R7 to
remove the air from inside the pin, and check
the sealing performance.
jl
Hold the space inside the pin at a vacuum
of 650 - 700 mmHg for 5 seconds and
check that there is no change in pressure.
If the pressure changes, disassemble and
check the seal for any abnormality,
then
assemble again.
D155AX-5
30-233
0
DISASSEMBLY
TRACK SHOE
AND ASSEMBLY
17) Assemble
the pin end master link as the
final link.
*
Check that the left and right master links
are press fitted in parallel.
3.
Filling with oil

After completion of assembly of the link assembly, add oil through the pin hole.
I) Using tool R7, remove the air inside the pin
from the small plug hole, set to a vacuum of
650 - 700 mmHg, then fill with oil (GO901
until the pressure is 0.2 - 0.3 MPa (2 - 3 kg/
cm*).
*
In cold or extremely cold areas, instead
of G090, fill with Komatsu genuine oil
(150-09-19270)
which has excellent lowtemperature
qualities.
Ir Be careful not to raise the oil pressure
too high as this will have an adverse
effect on the seal.
Ir To determine
the oil amount,
set the
small plug end at the top (stand the link
assembly on its side), leave for 30 minutes, then fill with oil so that depth L of
the space at the pin hole is within the
specified value below.
Dimension L: 35 - 65 mm
IrL
GO90
Oil
level
Pin
+---
2) After completion
of filling with oil, use tool

R5 to knock in the small plug to the specified position.
*
Coat the outside circumference
of the
small plug with G090.
-k The depth to knock in the plug is as follows.
Depth from end face: 7.5 + 1 mm
30-234
0
Large
PIUD
0L00.2929
D155AX-5
DISASSEMBLY
4.
TRACK SHOE
AND ASSEMBLY

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
m
Shoe bolt (regular link):
Initial torque: 588.4 z 58.8 Nm
I60 t 6 kgml
Tightening
5.
angle: 120 + IO
Connecting to make l/2 assembly

Set two completely assembled portions of track
on a flat surface in a straight line with the shoes
facing up. Pull master link (I) at the pin end to
master link (2) at the bushing end, and set at the
mating surfaces. Then put shoe (3) on top, check
that shoe bolt (4) goes in easily by hand, and
connect the two parts with the master bolt.
&
Shoe bolt: Anti-friction compound UVl-PI
w
Initial torque: 590.0 t 60.0 Nm
{SO.0 t. 6.0 kgm)
Tightening angle: 180 + IO
*
When
tightening,
tighten
in the order
DLDBO327
@ -
o-
DLDD3328
Do not use an impact wrench

link.
for the master
DLDO0298
D155AX-5
30-235
0
DISASSEMBLY
AND ASSEMBLY
2.
When
rebuilding
1.
Preparatory work
as grease-filled
TRACK SHOE
track
I) Washing seal assembly

.
Machines fitted with F3 type seals
Remove the seal assembly
from the link,
then separate into the seal ring and load
ring, and clean the parts.
Ir The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent, so wash the parts quickly.
After cleaning,
wipe the parts with a
clean cloth to remove all the cleaning
agent.
Machines fitted with W7 type seals

For seals that are to be reused, leave the
seal installed to the link, and do not wash it.
2) When reusing the pin, chamfer the corner of

the end face smooth with a grinder so that
press fitting can be carried out smoothly.
3)
30-236
0
Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin
when assembling.
*
When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
Dl SAX-5
DISASSEMBLY
TRACK SHOE
AND ASSEMBLY
Use tools R4 and R5 to knock the large plug

and small plug into the pin.
i) Insert the plug into the guide hole
through the plug insertion window.
(Coat the plug with oil.)
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
Dimension
a to knock in from end
face of pin:
Small pin: 7.5 r 1 mm
Large pin: 6 + 2 mm
If the plug was not removed from
the pin during disassembly, it can be
used again as it is.
of
5) Clean any part where outside diameter
the pin, front face of the spacer, or end face
or inside diameter of the bushing are dirty.
6) Coat the outside diameter of the pin and the
front face of the spacer with grease.
7) Installation of seal assembly
.
Machines fitted with F3 type seal
Clean the link counterbore, then use tool R6
to push the seal in fully to the bottom.
If there is grease stuck to the link coun*
terbore andseal assembly, the seal will
rotate and its sealing performance
will
drop, so do not coat with grease.
.
Machines fitted with W7 type seal
When reusing the link and replacing the seal
with a new .part, clean the link counterbore,
then push the seal in fully to the bottom.
*
If there
is grease
stuck to the link
counterbore and seal assembly, the seal
will rotate and its sealing performance
will drop, so do not coat with grease.
of the pin
8) In order to keep the protrusion
and bushing constant and the installation
dimensions
of the seal within the specified
value during assembly, adjust the press-fitting jig dimensions
of the link press.
Ir For details of the standard dimensions,
see PRESS-FITTING
JIG DIMENSION
TABLE FOR LINK PRESS.
If the end face of the pin (portion PI or
*
the side face of the link (portions 0, RI
are worn, add the amount of wear to the
standard dimension when adjusting the
dimension of the press-fitting jig so that
the amount of protrusion of the left and
right pin and bushing is uniform.
4)
D155AX-5
a:
a
-1
DXD031g2
Remove all oil and araase

from
the
Direction
to push in
DXD03193
Remove all o'

from the sha
DLD02932
30-237
0
DISASSEMBLY
2.
AND ASSEMBLY
TRACK SHOE
Assembly of link
1)
Coat the area between the pin and bushing

with lithium grease (G2-LII, set in position,
then set in front of the jaw of the link press.
Ir When reusing (turning) the bushing, set
the worn surface on the outside circumference of the bushing facing the shoe
mounting surface of the link (facing up
on the link press).
2)
Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
* When doing this, use the pin end master
link as a support.
*
49 - 196 kN 15 - 20 ton}
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between
the shoe bolt
holes of the left and right link is the specified value.
*
Use compressed air to remove all metal
particles from burrs caused by press fitting the bushing.
4) Turn over the master
link, and check that

the left and right master links have been
press fitted in parallel.
DLlBI311
5) Measure
the amount of protrusion

of the
left and right bushings with a depth gauge.
Ir Adjust the press-fitting
jig for the link
press so that the protrusion of the left
and right bushings is uniform.
30-238
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
Feed the master link portion, then set the

pin and bushing in position.
Ir When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
Ir If the outside diameter of the pin is worn,
assemble so that the face that is not worn
is on the pulling side. However, in this
case also assemble so that the side hole
faces the tread surface of the link.
7) Set the left and right links in position, then
operate the left and right pushing jigs to
press fit the pin and bushing at the same
time.
* The seal may come off the link due to
the play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again.
*
Pushing force for pin, bushing: 785 kN
180 ton}
Pushing force = 1.8 x average press-fitting force
(Adjust the relief pressure of the link
press and set the pushing force.)
8) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes
and stop press fitting when it is within the
standard value.
9) Assemble the pin end master link as the
final link.
*
Check that the left and right master links
are press fitted in parallel.
TRACK SHOE
6)
OLD00329
DLDOBll
3.

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
w
{SO + 6 kgm}
Tightening angle: 120 + IO
Dl %AX-5
30-239
0
DISASSEMBLY
4.
TRACK SHOE
AND ASSEMBLY
Connecting to make l/2 assembly

facing up. Pull master link (I) at the pin end to
master link (2) at the bushing end, and set at the
mating surfaces. Then put shoe (3) on top, check
that shoe bolt (4) goes in easily by hand, and
connect the two parts with the master bolt.
&
Shoe bolt: Anti-friction compound UVI-PI
w
Shoe bolt (master link):
160.0 + 6.0 kgm1
Tightening
angle: 180 + IO
*
When
tightening,
tighten
in the order
DlJm327
@ -
o-
Do not use an impact wrench

link.
for the master
lJLD00298
30-240
0
D155AX-5
PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS
PRESS-FITTING JIG DIMENSION

TABLE FOR LINK PRESS
-a
DLD00331
Unit: mm
Jig dimension
5.7
D155AX-5
3.25
50.6
30-241
0
ONE LINK
.DISASSEMBLY AND ASSEMBLY
FIELD DISASSEMBLY OF ONE

LINK
-k This section describes only the procedure for
using the tools. For details of the procedure for
disassembly or assembly, see OVERALL DISASSEMBLY (or ASSEMBLY) OF TRACK SHOE.
1.
Using two bolts (21, install tool R8 (adapter,

guide, bolt) to link (1).
*
It is also possible to use two track bolts for
bolt (2).
2.
Assemble tool R9 (pump, cylinder 150t) and tool

RlO (frame, rod, adapter, bolt x 1, eyebolt), then
raise the assembly and set on the track.
3.
Insert the rod of tool RI1 from the cylinder end,

and install with two nuts.
Pass the rod through the hole in link (I) to install.
4.
Set tool RI2 (adapter, guide, pusher) in position, then apply hydraulic pressure and remove
pin (3).
When the cylinder reaches the end of its stroke,
insert tool RI2 (extension) between the adapter
and guide, and repeat the operation.
30-242
0
ii
CWD02696
DISASSEMBLY
5.
AND ASSEMBLY
ONE LINK
Set tool R13 (294 kN {3OtI puller) and spacer @

to the center of the roller tread of the link to be
disassembled, then apply hydraulic pressure to
the puller, open the link 5 - 6 mm, and disconnect the link.
D155AX-5
CWD02700
30-243
0
DISASSEMBLY
AND
ASSEMBLY
FIELD ASSEMBLY
LINK
ONE LINK
OF ONE
Press or remover
1.
Assemble the link sub-assembly.

I) Set tool RI4 to the end face of the link, then
press fit bushing (1).
*
49 - 196 kN (5 - 20 ton]
+
I
yt-L-2)
Set tool RI4 to the end face of the link (pin

end), and press fit bushing (I).
*
Set with the side hole in the pin facing
the link tread.
*
Press-fitting force for pin: 196 - 294 kN
120 - 30 ton1
m
Press or
side
I
/
Set link sub-assembly
rePOVer
Tread
2.
DXD03197
DXD03198
(3) on the link to be con-
netted .
.3
3.
Set link (4) on the opposite

with tool RI5 (guide).
side, and support
:WD02 703
30-244
0
D155AX-5
DISASSEMBLY
4.
5.
AND ASSEMBLY
ONE LINK
Set tools RI6 and RI7 in the same way as for

the operation to remove the pin, then use tool
RI6 (adapter, extension,
guide, adapter,
bolt)
for press fitting the pin, and tool RI7 (extension,
guide, adapter, bolt) for press fitting the bushing, and press fit in turn.
*
(20 - 30 ton1
*
Press-fitting force for bushing: 98 - 196 kN
{IO - 20 ton}
Cylinder at
Use tool R20 (294 kN {30t) puller) in the same

way as when disassembling,
and push open link
(5) at the bushing end.
R20
6.
CWD02705
Set link (6) at the pin end to link (5) at the bushing end, connect with tool RI8 (guide), then remove tool R20 (puller).
CWD02706
7.
Set tool RI2 at pin (7) end, then use tool RI9
(adapter, bolt, guide) to press fit pin (7).
&
Pin press-fitting hole in link:
Gasket sealant (198-32-198901

*
*

link tread.
(40 - 60 ton}
the
$fiTfq
DXD03200
D155AX-5
DISASSEMBLY
MASTER LINK
AND ASSEMBLY
DISASSEMBLY OF MASTER
LINK
1.
Removal of track assembly

Remove the track assembly from the track frame.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2.
Separation of track
Disconnect all master link portions, and divide
into four parts.
3.
.
Removal of master link

Master pin tvpe
1) Gas-cutting of regular link
Gas cut the portion marked W,
move a.
Special tool to use: Gas cutter
and re-
Bushi
OLD02940
2) Removal of regular link

Push pin (1)
with a press,
move pin (1)
from bushing
in the direction of the arrow

remove from link (21, then reand link (3) at the same time
(4).
Master link type
1) Gas cutting, removal of master link at bushing end

Gas cut the portion marked WW, remove @ ,
then move master links (5) and (6) up or
down to remove them. Push pins (8) and (9)
press fitted to regular link (7) with a press in
the direction of the arrows to remove them.
Special tool to use: 1. Gas cutter
2. Tool 01
l
30-246
0
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
MASTER LINK
Removal of master link at pin end

Gas cut the portion marked MAN, remove @ ,
push pin (IO) with a press in the direction of
the arrow and remove from link (111, then
remove pin (IO) and link (12) at the same
time from bushing (13).
Special tool to use: 1. Gas cutter
2. Tool 02
l
D 155,4X-5
30-247
0
DISASSEMBLY
AND
ASSEMBLY
1.
MASTER
ASSEMBLY
OF MASTER
LINK
LINK
Assembly of link at bushing end

I) Using a press, press fit master link (I) at the
bushing end to bushing (2).
*
When press fitting the left and right master links, be extremely
careful to keep
them parallel.
+
Be careful not to scratch or damage the
mating surface of the master link and
the end face of the bushing.
D2
Unit: mm
D2
2.
24 x 2.0
Installation
of link at bushing end
I) Push open the central part of the link tread
with tool R20 as shown in the diagram.
(Open approx. IO mm at the tip of the link.)
DXD03213
2) Set spacer (3) and seal assembly

counterbore
(4) at the
of the link at the connection.
DLD02941
30-248
0
D155AX-5
DISASSEMBLY
MASTER
AND ASSEMBLY
3)
Align the pin hole and bushing

connect with guide pin 0.
4)
Remove tool R20, press fit pin (5) with tool,

and install master link (I) at the bushing
end.
&
Pin press-fitting hole in link:
Gasket sealant (198-32-19890)
*
the link tread.
hole,
LINK
and
+
Press
5)
Install the shoe to the link at the connection.
6)
After knocking in large plug (6) with tool R4,

fill with oil using tool R7, then knock in small
plun (7) with tool R5.
* When press fitting the left and right master links, be extremely
careful to keep
the left and right links parallel. (Bushing
end and pin end)
*
Be careful not to scratch or damage the
mating surface of the master link and
the end face of the bushing.
*
End play at connection
(play in thrust
direction of links on both sides of pin):
0 - 0.13 mm
Ir
Be extremely careful not to get mud or
dust on the tap hole mating face of the
master link, bushing end face, spacer, or
seal.
D 155AX-5
fit
DLD02943
30-249
0
DISASSEMBLY
3.
MASTER
AND ASSEMBLY
Assembly of link at pin end

1) Set spacer (3) and seal assembly
counterbore
of the master link.
LINK
(4) in the
DLD07.941
2) Pass pin (9) through
bushing (81, set pin

master link (10) from the left and right, then
press fit with tool.
3)
After knocking in large plug (I I) with tool

R4, fill with oil using tool R7, then knock in
small plug (12) with tool R5.
I
4.
Connecting
master link portion
facing up. Pull master link (13) at the pin end to
master link (14) at the bushing end, and set at
the mating surfaces. Then put the shoe on top,
and check that the shoe bolt goes in easily by
hand.
&
Shoe bolt: Anti-friction compound (LM-PI
m
Shoe bolt (master link):
{SO t. 6 kgm}
Tightening
angle: 180 t 10
30-250
0
11
DBCOX55
14
DBDCG356
D155AX-5
DISASSEMBLY
AND ASSEMBLY
PIVOT SHAFT
REMOVAL OF PIVOT SHAFT

ASSEMBLY
1.
2.
3.
Remove track frame assembly.

For details, see REMOVAL OF TRACK FRAME
ASSEMBLY.
Remove seal (I), then remove ring (2).
m
Sling pivot shaft assembly
(31, then remove
mounting
bolts, and using forcing screws 0,
raise pivot shaft assembly (3) and pull out.
el
kg
Pivot shaft assembly
: 116 kg
INSTALLATION OF PIVOT
SHAFT ASSEMBLY
l

removal.
in the
reverse
order
to
M
*
*
*
Assemble the seal as follows.

(See diagram
on right)
1) Turn over seal so that embossed letters
on seal are on inside.
2) With seal turned over, insert seal on
shaft.
When inserting the seal, be careful not to
scratch or damage the surface.
Use tool Pl to press fit ring (2).
.
Press-fitting force : 8.8 - 22.6 kN
(0.9 - 2.3 ton)
Ring
Embossed
letter
Seal
-ii!f!d
-
Pivot shaft
(2) Insert
0-J
(lITurn
DLDOLU59
bolt :
&
Pivot shaft mounting
Pivot shaft mounting bolt :

823.8 - 1029.7 Nm I84.0 - 105.0 kgm)
Thread tightener
D155AX-5
(LT-21
30-251
0
DISASSEMBLY
AND ASSEMBLY
EQUALIZER BAR
REMOVAL OF EQUALIZER
ASSEMBLY
BAR
1.
Remove
2.
Set jack (490 kN 150 ton11 under radiator, jack

up, then raise work equipment
and set stand @
in position.
*
Set at a height where the center pin will
come out.
3.
Remove equalizer bar side pin cover (21, then

pull out outside bushing (3) and side pin (41,
and remove inside bushing (5).
a
*
Operate the jack to carry out fine adjustment of the height, and when the pin is at a
point where it moves easily, tap the pin to
remove it.
4.
Sling equalizer
chain block.
5.
Remove lock plate (71, then using tool Nl, pull

out center pin (8).
B
the hydraulic system, do
&A When operating
not stand under or in front of the puller.
Stand as far as away as possible when operating it.
6.
side pin top cover (I).
bar assembly
(6) with crane and
Operate
chain block and crane,
equalizer bar assembly (6).
Equalizer
L&l
Ai
bar assembly
and
DtLW176
remove
: 229 kg
Do not lower the chassis after removing

equalizer bar assembly.
the
DEW0764
235
DEDO0765
30-252
0
D155AX-5
DISASSEMBLY
BAR
EQUALIZER
AND ASSEMBLY
INSTALLATION OF EQUALIZER
BAR ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
to
Inside cover : Fill with grease (G2-LI)

Between equalizer bar side pin portion
and bushing : Fill with grease (G2-LI)
a
&
a
portion of pin and bushing :

Coat with grease (G2-LI)
Frame boss portion :
Coat with anti-friction compound (LM-P)
Between bushing and bushing :
Fill with grease (G2-LI)
Connecting
CWD07.708
I
-
\._
\ /
/
6
DEW0767
D155AX-5
30-253
0
DISASSEMBLY
AND ASSEMBLY
EQUALIZER BAR SIDE BUSHING
REMOVAL OF EQUALIZER
SIDE BUSHING
1.
BAR
Remove equalizer bar assembly.

For details, see REMOVAL OF EQUALIZER
ASSEMBLY.
2.
Remove
seal (I).
3.
Remove
ring (2).
4.
Remove
spherical
bushing
BAR
(3).
INSTALLATION
OF EQUALIZER
BAR SIDE BUSHING
1. Install ring (2) to one side.
2.
Press fit spherical bushing (3) with press.

*
Press-fitting force : 15.7 kN (I.6 ton)
3.
Install ring (2) on opposite
4.
Install seal (1).

&
Between
5.
bushing
side.
and seal :
Fill with grease (G2-LII
Install equalizer bar assembly.

For details, see INSTALLATION
BAR ASSEMBLY.
30-254
0
OF EQUALIZER
D155AX-5
DISASSEMBLY
SEGMENT TEETH
AND ASSEMBLY
REMOVAL
TEETH
OF SEGMENT
1.
Stop machine at position where it is easy to

remove teeth (between shoe and track frame).
2.
Remove
mounting
bolts, then remove
INSTALLATION
TEETH
l
Carry out
removal.
&
installation
Thread
Teeth
OF SEGMENT
in the
reverse
of teeth mounting
mounting
teeth (1).
a
order
to
bolt:

nut : 1176.8 + 98.1 Nm
I120 t: 10 kgml
D155AX-5
30-255
0
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC TANK
TANK ASSEMBLY
a
Lower the work equipment

completely
to the
ground, and release the remaining
pressure in
the circuit. For details, see TESTING AND ADJUSTING,
RELEASING REMAINING
PRESSURE
IN HYDRAULIC CIRCUIT. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
1. Drain oil from hydraulic

-
Hydraulic
tank.
tank : Approx. 97 &?
2. Remove right side cover.

3. Disconnect control valve hose (I) at filter end.
4. Disconnect hydraulic tank tube (2) at joint end,
then remove.
5. Remove filter case assembly (3).
r+ kg
Filter case assembly
: 24 kg
Disconnect charge relief valve hose (4).

Disconnect cooler bypass valve hose (5).
Disconnect suction tube (6) from tank.
Disconnect block (7) from tank.
10. Lift off hydraulic tank assembly (8).
6.
7.
8.
9.
r+lkg
Hydraulic
: 92 kg
tank assembly
INSTALLATION
OF HYDRAULIC
TANK ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
to

system. Then check the oil level again with the
sight gauge.
Bleeding air
Bleed the air.
For details,
see TESTING
Bleeding air.
30-256
a
AND
ADJUSTING,
D155AX-5
DISASSEMBLY
MAIN CONTROL VALVE
AND ASSEMBLY
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
Lower the work equipment completely to the
A ground,
and release the remaining pressure in
the circuit. For details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE
IN HYDRAULIC CIRCUIT. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
After disconnecting the pipes and hoses, fit blind
plugs to prevent dirt or dust from entering.
Make match marks or fit tags to the hoses and
pipes to prevent any mistake in the position
when installing.
1. Drain oil from hydraulic tank.
A
2.
3.
4.
5.
Hydraulic tank : Approx. 97 .t
Remove right side cover.

Disconnect clamp (I) from filter case.
Disconnect charge pump tube (2).
Remove filter case assembly (3).
&l kg
Filter case assembly : 24 kg
Disconnect hydraulic tank return hose (4).

Remove return filter hose (5).
Disconnect PPC hose (6) (green) (blade left tilt).
Disconnect PPC hose (7) (colorless) (blade
LOWER).
10. Disconnect PPC hose (8) (black) (ripper DOWN).
11. Disconnect PPC hose (9) (white) (ripper TILT
BACK).
6.
7.
8.
9.
12.
13.
14.
15.
Disconnect
Disconnect
Disconnect
Disconnect
tilt).
PPC hose (IO) (red) (ripper TILT IN).

PPC hose (11) (colorless) (ripper UP).
PPC hose (12) (black) (blade RAISE).
PPC hose (13) (yellow) (blade right
16.
17.
18.
19.
Disconnect
Disconnect
Disconnect
Disconnect
hose
hose
hose
hose
D155AX-5
(14)
(15)
(16)
(17)
(ripper
(ripper
(ripper
(ripper
TILT BACK).
TILT IN).
DOWN).
UP).
30-257
DISASSEMBLY
AND ASSEMBLY
MAIN CONTROL VALVE
20. Disconnect tube (18) (blade LOWER).

21. Disconnect tube (19) (blade RAISE).
22. Disconnect hose (20) (blade right tilt).
23. Disconnect hose (21) (blade left tilt).
24. Disconnect hose (22) from hydraulic pump.
25. Remove mounting bolts, then lift off main control valve assembly (23).
& kg
Main control valve assembly : 99 kg
INSTALLATION
OF MAIN
CONTROL VALVE ASSEMBLY
l

removal.

system. Then check the oil level again with the
sight gauge.
Bleeding air
Bleed the air.
For details, see TESTING
Bleeding air.
30-258
a
AND ADJUSTING,
D 155AX-5
DISASSEMBLY
AND ASSEMBLY
MAIN CONTROL VALVE
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
23
,
22 nm
-C.-J0
LO
28
72
J
DDcowJ4
30-259
0
DISASSEMBLY
AND ASSEMBLY
This section uses the 4-spool assembly as an

example for the disassembly procedure.
1.
Remove bolt (I), and disconnect bodies (2) and

(3) from body (4).
2.
Disassembly of ripper (tilt, lift1 or scraper (ejector, apron, bowl) valve spool
1) Remove case (5) from bodies (2) and (3).
2) Remove case (6), pull out to point where
portion @ of spool assembly (7) comes out,
then hold portion @ with wrench (width
across flats: 14 mm), and loosen bolt (8).
*
If it is possible to carry out work without
scratching or bending the spool, remove
spool assembly (7) and carry out disassembly work.
3) Pull out spool assembly (7) from bodies (2)
and (3).
4) Remove bolt (81, then remove washer (91,
spacer (IO), retainer (II), spring (121, and
retainer (13) from spool (14).
5) Remove plug (151, then remove spring (16)
and valve (17).
6) Remove plugs (18) and (201, then remove
check valve (19).
7) Remove check valve (21) and suction valve
(22).
8) Remove plug (231, then remove retainer (24).
3.
Disassemblv of blade lift valve spool

1) Remove case (25) from body (41, then remove spring (26) and retainer (27).
2) Remove case (281, pull out to point where
then hold portion (@ with wrench (width
*
3) Pull out spool assembly (29) from body (4).
4) Remove bolt (301, then remove washer (311,
spacer (321, retainer (331, spring (341, and
retainer (35) from spool (36).
5) Remove plug (371, spring (381, and valve (39)
from spool (36).
30-260
0
MAIN CONTROL VALVE
DLZiX1201
DDW1202
D155AX-5
DISASSEMBLY
4.
AND ASSEMBLY
Disassembly
of blade tilt valve spool
1) Remove case (40) from body (4).
2) Remove case (41), pull out to point where
then hold portion @ with wrench
(width
*
3) Pull out spool assembly (42) from body (4).
4) Remove bolt (43), then remove washer (44),
retainer (45), spring (46), and retainer (47).
5) Remove plug (48), and pull out spring (50)
and valve (51) from spool (49).
5.
Disassembly
of unload valve spool
1) Remove plug (52) from body (4), then remove spring (53) and retainer (54).
2) Remove plugs (55) and (56), then remove
spring (57), piston (58), and guide (59).
3) Remove bolt (61) from spool (60).
6.
Plugs, valves
1) Remove plug (62), then remove spring (63)
and valve (64).
2) Remove plug (65), then remove retainer (66).
3) Remove plug (67), then remove orifice (68).
4) Remove safety and suction valve (69), suction valve (70), and valve (71).
5) Remove check valve (72).
6) Remove plugs (73), (74), (75), and (76).
D155AX-5
MAIN
CONTROL
VALVE
DDE01203
30-261
0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
MAIN CONTROL VALVE
OF MAIN CONTROL VALVE ASSEMBLY

21
\
fei-
30-262
0
23
,20
D155AX-5
DISASSEMBLY
AND ASSEMBLY
MAIN CONTROL VALVE

1. Plugs, valves
1) iit O-rings to plugs (761, (751, (741, and (73)
and install.
m
Plug (76):
w
m
29.4 - 39.2 Nm j3.0 - 4.0 kgm1

Plug (75):
117.6 - 161.7 Nm 112.0 - 16.5 kgml
Plug (74):
107.8 - 140.7 Nm ill.0 - 15.0 kgm1
2)
Plug (73):
176.6 - 196.1 Nm I18.0 - 20.0 kgml
Install check valve (72).
w
Check valve:
58.8 - 78.5 Nm (6.0 - 8.0 kgml

3)
4)
5)
6)
2.
Fit O-rings to valve (711, suction valve (70),

and safety and suction valve (691, then install.
w
Valve (71):
107.9 - 147.1 Nm (II.0 - 15.0 kgm1
w
Valve (70):
181.4 - 240.3 Nm 118.5 - 24.5 kgml
m
Valve (69):
137.3 - 156.9 Nm I14.0 - 16.0 kgml
Assemble
orifice (681, then fit ring and Oring to plug (67) and install.
w
Plug (67):
274.6 - 367.7 Nm (28.0 - 37.5 kgml
Assemble retainer (661, then fit ring and Oring to plug (65) and install.
w
Plug (65):
274.6 - 307.7 Nm 128.0 - 37.5 kgml
Assemble valve (64) and spring (631, then fit
O-ring to plug (62) and install.
w
Plug (62):
127.5 - 176.6 Nm I13.0 - 18.0 kgm)
Assembly of unload valve spool
1) Assemble
2)
3)
guide (59) to -spool (601, then install bolt (61).

w
Bolt: 5.9 - 8.8 Nm iO.6 - 0.9 kgm1
Install plug (561, assemble piston (58) and
spring (571, then install plug (55).
w
Plug (56):
181.4 - 240.3 Nm 118.5 - 24.5 kgml
m
Plug (55):
137.3 - 156.9 Nm (14.0 - 16.0 kgml
Assemble
retainer (54) and spring (53) to
body (41, and install plug (52).
m
Plug (52):
372.7 - 465.8 Nm I38.0 - 47.5 kgml
D 1 SSAX-5
30-263
0
DISASSEMBLY
AND ASSEMBLY
3.
Assembly of blade tilt valve spool

1) Assemble valve (51) and spring (50) to spool
(491, then temporarily tighten plug (48).
2) Assemble retainer (471, spring (461, and retainer (45) to spool, then fit washer (44) to
bolt (43) and temporarily assemble.
3) Push spool assembly (42) into body to a
point where wrench fits spool portion 0,
hold spool in position with wrench, then
tighten plug (48) and bolt (431, and push
into body.
m
Plug (48):
58.8 - 73.5 Nm j6.0 - 7.5 kgml
w
Bolt (43):
39.2 - 53.9 Nm t4.0 - 5.5 kgm1
4) Fit O-rings to cases (41) and (401, then assemble to body.
w
Case mounting bolt:
27.4 - 34.3 Nm (2.8 - 3.5 kgm}
4.
Assembly of blade lift valve spool

1) Assemble valve (39) and spring (38) to spool
(361, then temporarily tighten plug (37).
2) Assemble retainer (351, spring (341, retainer
(331, and spacer (32) to spool, then fit washer
(31) to bolt (30) and temporarily assemble.
3) Push spool assembly (29) into body to a
point where wrench fits spool portion @
hold spool in position with wrench, then
tighten bolt (30).
m
Bolt (30):
58.8 - 73.5 Nm 16.0 - 7.5 kgml
4) Assemble spool assembly (29) to body (41,
then install case (28).
w
Case mounting bolt:
27.4 - 34.3 Nm 12.8 - 3.5 kgml
5) Assemble retainer (27) and spring (26) from
opposite side, then fit O-ring to case (25)
and install to body.
w
Case mounting bolt:
27.4 - 34.3 Nm 12.8 - 3.5 kgm}
30-264
0
MAIN CONTROL VALVE
DDw1202
Dl SAX-5
DISASSEMBLY
5.
MAIN
AND ASSEMBLY
CONTROL
VALVE
Assembly of ripper (tilt, lift) or scraper (ejector,

apron, bowl) valve spool
1) Fit O-ring and ring to valve (151, assemble
spring (16) and valve (17). then assemble to
bodies (3) and (2).
w
Valve (15):
127.5 - 176.6 Nm I13.0 - 18.0 kgm}
retainer (24), then fit O-ring and
2) Assemble
ring to plug (23) and install to body.
w
Plug (23):
274.6 - 367.7 Nm (28.0 - 37.5 kgm}
3) Install suction valve (22) and check valve
(21).
w
w
Install
4)
Suction valve (22):

58.8 - 78.5 Nm (6.0 - 8.0 kgm}
Check valve (21):
58.8 - 78.5 Nm (6.0 - 8.0 kgm}
plugs (20) and (181, and check valve
(19).
w
5)
6)
7)
6.
Plug (20):
19.6 - 27.5 Nm I2.0 - 2.8 kgm1
w
Plug (18):
29.4 - 39.2 Nm (3.0 - 4.0 kgm}
w
Check valve (19):
19.6 - 27.5 Nm (2.0 - 2.8 kgm}
Assemble retainer (131, spring (121, retainer
(1 I), and spacer (IO) to spool (141, then fit
washer (9) to bolt (8) and temporarily
assemble.
Push spool assembly (7) into body to a point
where wrench fits spool portion (a), hold
spool in position with wrench, then tighten
bolt (8).
w
Bolt (8):
58.8 - 73.5 Nm IS.0 - 7.5 kgm}
Assemble spool assembly to bodies (2) and
(31, and install cases (6) and (5).
w
Case mounting bolt:
27.4 - 34.3 Nm (2.8 - 3.5 kgm)
Assemble
bodies
tighten mounting
w
Mounting
157.0
*
Assemble the
face securely.
D155AX-5
(2) and (3) to body (4), and

bolts (1).
bolt:
- 176.7 Nm (IS.0 - 18.0 kgm)
O-ring at the body mating sur-
DDDOlZOl
30-265
0
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF HSS OIL

COOLER BYPASS VALVE
ASSEMBLY
a

1.
Remove operators seat and floor plate.

For details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY.
2.
Disconnect oil cooler hoses (I) and (2).
3.
Disconnect
hydraulic
4.
Disconnect
charge
5.
Disconnect
HSS pump hose (5).
6.
Remove mounting
bolts, then remove
cooler bypass valve assembly (6).
tank hose (3).
relief valve hose (4).
HSS oil
INSTALLATION OF HSS OIL

COOLER BYPASS VALVE
ASSEMBLY
. Carry out installation in the reverse order
to
removal.
30-266
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
HMT OIL COOLER BYPASS VALVE
DISASSEMBLY, ASSEMBLY OF HMT OIL COOLER

BYPASS VALVE ASSEMBLY
mDo1200
Disassembly
1. Remove plug (I),
2.
3.
Assembly
then
remove
shim
(2) from
plug (I).
Remove spring (3) and spool (4) from body (5).
Remove plug (6).
2.

Tighten plug (6).
Assemble
spool (4) and spring (3) to body
3.
(5).
Assemble
1.
shim
(2) to plug (I),
and tighten
plug (3).
Ir Check the number and thickness
shims, then assemble.
Shim thickness: 0.5 mm
No. of shims: 2
D 1SSAX-5
of the
30-267
0
DISASSEMBLY
BLADE PPC VALVE
AND ASSEMBLY
REMOVAL OF BLADE PPC

VALVE ASSEMBLY
to the
completely
the work equipment
ALower
pressure in
ground, and release the remaining
the circuit. For details, see TESTING AND ADPRESSURE
RELEASING REMAINING
JUSTING,
the oil filler
loosen
Then
IN HYDRAULIC CIRCUIT.
inside the
pressure
the
release
to
cap slowly
hydraulic tank.
1
remove
right side
seat assembly,
operators
1. Remove
cover on inside right, then remove
cover of chassis.
& kg
2.
Operators
seat assembly
Remove cover (1).

Ir Disconnect horn switch
at the same time.
: 50 kg
connector
(CN-262)
bracket (2).
3.
Remove
4.
Loosen lock bolt of lever (31, and pull out lever

(3) together with boot.
5.
Disconnect
pump
6.
Disconnect
drain hose (5).
7.
Disconnect
PPC hose (6).
8.
Remove
hose (4).
blade PPC valve assembly
(7).
30-268
0
D155AX-5
DISASSEMBLY
BLADE PPC VALVE
AND ASSEMBLY
INSTALLATION
OF BLADE PPC
VALVE ASSEMBLY
.

removal.
in the
reverse
order
to
The connection position for the pump hose,

drain hose, and PPC hose are distinguished
by color bands at the caulking portion for
the hoses, so check the colors when connecting.
P3
alve from above)

DAD00788
pJ
*
Set the PPC valve in the mounting direction

shown in the diagram
on the right when
installing.
(The diagram on the right shows the PPC
valve as seen from the top of the panel.)

level.
*
D155AX-5
30-269
0
RIPPER PPC VALVE
REMOVAL OF RIPPER PPC

VALVE ASSEMBLY
Fully
lower work equipment to the ground. Release the remaining pressure in the circuit. For
details, see TESTING AND ADJUSTING, RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank.
1. Remove operator seat, remove 1 cover on inside right, then remove side cover on right side
of chassis.
4 Operators seat: 50 kg
2. Remove cover (1).
e Disconnect the horn switch connector
(CN262) at the same time.
3. Loosen lock bolt of lever (2), and pull out lever
(2) together with boot.
4. Remove lever guide.
Serial No. Only 75001 and up
5. Disconnect pump hose (4).
6. Disconnect drain hose (5).
7. Disconnect PPC hose (6).
6
6
DBD00791
7. Remove ripper PPC valve assembly (7).
30-270
1
5
D155AX-5
DISASSEMBLY
RIPPER PPC VALVE
AND ASSEMBLY
INSTALLATION OF RIPPER PPC

VALVE ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
to
m
*
The connection position for the pump hose,

drain hose, and PPC hose are distinguished
by color bands at the caulking portion for
the hoses, so check the colors when connecting.
PI
(Viewofvalvetiomabove)
DAwo793
Set the PPC valve in the mounting direction

shown in the diagram
on the right when
installing.
(The diagram on the right shows the PPC
valve as seen from the top of the panel.)

level.
*
the system.
Then check the oil level again.
D155AX-5
30-271
0
DISASSEMBLY
AND ASSEMBLY
BLADE PPC VALVE
DISASSEMBLY OF BLADE PPC

VALVE ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove
nut (I), then remove
disc (2) and boot
(3).
Remove joint (41, then remove plate (5).
Remove seal (6) and collar (7).
Remove body (8).
Remove plate (9).
Remove orifice (IO).
Remove blade TILT valve.
I) Remove pistons (11) and (121, retainer (131,
springs (14) and (151, and shim (16).
Ir Check the installation position (oil pressure port) of spring (141, mark the spring
with a tag, and keep it in a safe place.
2) Pull out valve (17) from body (18).
Remove blade LOWER valve.
1) Remove piston (191, spacer (201, spring (211,
collar (22), ball (23), retainer (241, shim (25),
piston (261, retainer (271, springs (28) and
(291, and shim (30).
+
Check the installation position (oil pressure port) spring (281, mark the spring
with a tag, and keep it in a safe place.
2) Pull out valve (31) from body (18).
Remove blade RAISE valve.
1) Remove piston (32), spring (33), piston (341,
retainer (351, springs (36) and (37), and shim
2)
(38).
*
Check the
sure port)
with a tag,
Pull out valve
installation position (oil presspring (36), mark the spring

(39) from body (18).
CED02 160
30-272
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
BLADE PPC VALVE
INSTALLATION
OF BLADE PPC
VALVE ASSEMBLY
1.
2.
3.
Install blade RAISE valve.

1) Assemble valve (39) to body (18).
2) Assemble shim (38) and spring (37) to valve
(39).
*
Install spring (37) with the small coiled
seat face (inside diameter) at shim (38)
end.
3) Assemble
spring (361, retainer (351, piston
(34), spring (331, and piston (32).
*
When assembling
piston (34), coat the
outside circumference
of the piston and
the inside circumference
of the hole in
the body with grease (G2-LI).
Ir When assembling
piston (321, coat the
inside circumference
of the hole in the
body with grease (G2-LI).
Install blade LOWER valve.
1) Assemble valve (31) to body (18).
(31).
*
seat face (inside diameter)
at shim (30)
end.
3) Assemble
spring (281, retainer (271, piston
(261, shim (251, retainer (241, ball (231, collar
(231, spring (211, spacer (201, and piston (19).
*
When assembling
piston (26), coat the
of the piston and
of the hole in
the body with grease (G2-LI).
+ When assembling
of the hole in the
body with grease (G2-LI).
Install blade TILT valve.
I) Assemble valve (17) to body (18).
(17).
*
seat face (inside diameter)
at shim (16)
end.
D155AX-5
CEDO
30-273
a
DISASSEMBLY
AND ASSEMBLY
BLADE PPC VALVE
3)
4.
5.
6.
7.
8.
9.
10.
Assemble spring (141, retainer (13), and pistons (12) and (11).
Ir When assembling
of the piston and
of the hole in
the body with grease (G2-Lb.
*
When assembling
piston (I I), coat the
of the hole in the
body with grease (G2-Lb.
Install orifice (IO).
m
Orifice : 11.8 f: 14.7 Nm (1.2 z 1.5 kgm1
Fit O-ring and install plate (9).
Fit O-ring and install body (8).
Fit O-ring to collar (71, then assemble to body
(8) and install seal (6).
Install plate (5).
m
Mounting bolt :
11.8 = 14.7 Nm (I.2 = 1.5 kgml
Install joint (4).
*
When installing the joint, coat the thread of
body (8) with adhesive (LT-2).
w
Joint : 44.1 = 4.9 Nm j3.5 z 0.5 kgml
*
Coat the sliding portion of the joint with
grease (G2- Lb.
Assemble boot (3) and disc (21, and tighten with
nut (I).
*
Coat the contact surface of disc (2) and pistons (321, (191, and (11) with grease (G2-LI).
w
Nut : 112.7 + 14.7 Nm Ill.5 + 1.5 kgm}
30-274
0
After installing
the disc, adjust the disc
height.
Adjusting PPC valve.
D155AX-5
DISASSEMBLY
AND
BLADE LIFT CYLINDER
ASSEMBLY
REMOVAL OF BLADE LIFT

CYLINDER ASSEMBLY
Lower the work
A ground
and stop
1.
equipment
the engine.
completely
to the
Sling head end of lift cylinder assembly, then

a
remove cap (I).
*
Check the number
and thickness
of the
Start the engine and retract piston rod fully,
then tie the piston rod with wire to prevent
it from coming out.
A
2.
Sling lift cylinder assembly, then disconnect hose

(2). Release the remaining
pressure inside the
hydraulic circuit. For details, see TESTING
AND ADJUSTING,
RELEASING REMAINING
PRESSURE INSIDE HYDRAULIC CIRCUIT.
*
Fit blind plugs to prevent dirt or dust from
entering the piping.
3.
Remove
cap (3) and lift off cylinder
assembly
m
(4).
& kg
Blade lift cylinder
assembly:
170 kg
INSTALLATION
OF BLADE LIFT
CYLINDER ASSEMBLY
.
Carry out
removal.
installation
Standard
in the
shim thickness:
reverse
order
to
4 mm
m
&
Yoke: Grease
(G2-LI)
Bleeding air
Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING.

level.
*
D155AX-5
30-275
0
DISASSEMBLY
BLADE TILT CYLINDER
AND ASSEMBLY
REMOVAL OF BLADE TILT

CYLINDER ASSEMBLY

ground and stop the engine.
1.
Remove cylinder protection

protection cover (2).
2.
Sling tilt cylinder assembly, remove bolt (I ), then

m
disconnect cap (3) and remove shim.
*
Check the number
and thickness
of the
Start the engine and retract piston rod fully,
then tie the piston rod with wire to prevent
it from coming out.
completely
to the
cover (I) and hose
A
3.
Disconnect 2 hoses (4).

Release the remaining
pressure inside the
hydraulic circuit. For details, see TESTING
AND ADJUSTING,
RELEASING REMAINING
PRESSURE INSIDE HYDRAULIC CIRCUIT.
*
Fit blind plugs to prevent dirt or dust from
4.
Remove lock bolt, then pull out pin (5) and lift
a
off cylinder assembly (6).
*
Be careful not to damage the hose at the
bottom end when lifting off.
& kg
Blade tilt cylinder
assembly:
DEW1112
190 kg
INSTALLATION
OF BLADE TILT
CYLINDER ASSEMBLY
l
Carry out
removal.
installation
Standard
shim thickness:
Y 0 ke : Grease
@!&
in the
reverse
order
to
4 mm
(G2-LII
Bleeding air

level.
*
30-276
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF RIPPER LIFT

CYLINDER ASSEMBLY
1.
Sling lift cylinder assembly (I), then remove lock

plate and pull out pin (2) at head end.
m
AStart
the engine and retract the piston rod fully.
AStop
the engine and operate the control lever
several times to release the pressure inside the
piping. Then loosen the oil filler cap slowly to
2.
3.

*
Fit blind plugs to prevent
dirt or dust from
Remove lock plate, pull out pin (4) at bottom

end and lift off cylinder assembly (I).
112
I+ kg
*
assembly:
120 kg
One pin (4) is supporting the bottom end of

the lift and tilt cylinders, so pull out the pin
only far enough to remove the lift cylinder.
INSTALLATION
OF RIPPER LIFT
CYLINDER ASSEMBLY
removal.
a
&
Pin: Grease
(G2-LI)
Pin: Grease
(G2-LII
@2J
a
Bleeding air

level.
*
D155AX-5
30-277
0
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF RIPPER TILT

CYLINDER ASSEMBLY
1.
Sling tilt cylinder assembly (I), then remove lock

plate and pull out pin (2) at head end.
m
AStart
the engine and retract the piston rod fully.
AStop
the engine and operate the control lever
several times to release the pressure inside the
piping.
Then loosen the oil filler cap slowly to
2.
3.

*
Remove
&I kg
*
dirt or dust from
lock plate and pull out pin (4).

assembly:
130 kg
One pin (4) is supporting the bottom end of

the lift and tilt cylinders, so when removing
the tilt cylinder assembly, put a block @ under lift cylinder (5) to prevent the lift cylinder from falling, or pull out the pin gradually and set a temporary pin in the bottom
end of the lift cylinder.
INSTALLATION
OF RIPPER TILT
CYLINDER ASSEMBLY
removal.
&
Pin: Grease
(G2-LII
Pin: Grease
(G2-LII
Bleeding air

Add engine oil to circulate the oil through
system. Then check the oil level again.
30-278
0
the
Dl!ZAX-5
HYDRAULIC
AND ASSEMBLY
DISASSEMBLY
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(BLADE LIFT, BLADE
TILT CYLINDER)
1.
2.
Tube
Remove
TILT,
RIPPER
LIFT, RIPPER
tube.
Quick drop valve (blade lift cylinder only)

Remove block (I), and pull out spring (21, spacer
(31, valves (4) and (51, and collar (6).
3. Piston rod assembly

.
Blade lift cylinder
1) Set cylinder assembly (7) on tool Ul.
2) Using hydraulic pump or power wrench, disconnect head assembly (8) with tool U2.
3) Pull out piston rod assembly (9).
Place a container under the cylinder to
*
catch the oil.
Blade tilt, ripper lift, ripper tilt cylinder

bolts, and disconnect
mounting
Remove
head assembly (IO).
I)
2)
4.
24 mm
1 Ripper/--$--i
Pull out piston rod assembly (11).

Place a container under the cylinder
*
catch the oil.
to
Piston assembly
Blade lift cylinder
1) Remove mounting bolts, then remove spacer
(121, and pull out valve (13).
2) Pull out piston assembly (14).
3) Remove backup ring (15) and O-ring (16).
4) Remove retainer (17).
D155AX-5
CYLINDER
DISASSEMBLY
5)
HYDRAULIC
AND ASSEMBLY
of piston assembly
Disassembly
ring (18).
wear
Remove
i)
ii) Remove piston ring (19).
Do not remove seat (20) and valve
*
from the piston.
CYLINDER
(21)
18
18
.
I)
2)
3)
DBDW365

Remove mounting bolts, then remove spacer
(22).
Pull out piston assembly (23).
Remove backup ring (24) isnd O-ring (25).
24
4)
Disassembly
Remove
i)
ii) Remove
of piston assembly
wear ring (26).
piston ring (27).
26
27
DBWO375
5.
Head assembly
1) Remove head assembly
(8) or (IO).
Blade lift
Blade tilt
Ripper lift
Ripper tik
30-280
0
D155AX-5
DISASSEMBLY
2)
AND ASSEMBLY
Disassembly
i)
Remove
of head assembly
O-ring (28). (Blade
HYDRAULIC
CYLINDER
lift cylinder
only)
ii) Remove O-ring (29) and backup ring (30).
iii) Remove packing (31).
iv) Remove snap ring (32), then remove dust
seal (33).
v) Remove bushing (34).
32 33
34 31 30
29
Blade tilt
Ripper litl
Rippertilt
D 155AX-5
30-281
a
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
CYLINDER
*
HYDRAULIC
CYLINDER
OF HYDRAULIC

oil, and be careful not to scratch or damage the
rod packing, dust seal, or O-ring when install-
34
32 33
31 20 30
29
DLD02944
1.
Head assembly
1) Assembly of head assembly
i)
Using tool U4, press fit bushing
(34).
34
CWD02728
ii)
Using tool U5, assemble dust seal (33),

and secure with snap ring (32).
iii) Assemble packing (31).
1
31
iv) Assemble
VI
backup
CWD02730
ring (30) and O-ring
(29).
*
Do not try to force the backup ring
into position.
Warm it in warm water (50 - 60C) before fitting it.
Assemble O-ring (28). (Blade lift cylinder
32
32
/
only)
30-282
0
D155AX-5
DISASSEMBLY
2)
2.
Assemble
ton rod.
AND ASSEMBLY
head assembly
HYDRAULIC
CYLINDER
(8) or (IO) to pis-
Piston assembly
.
Blade lift cylinder
1) Assembly of piston assembly
i)
Using tool U3, expand piston ring (19).
*
Set the piston ring on tool U3 and
turn the handle 8 - 10 times to expand the ring.
ii) Remove piston ring (19) from tool U3,
and install to piston.
iii) Using tool U3, compress piston ring (19).
iv) Assemble wear ring (18).
Blade
lift
Blade
Ripper
Ripper
tilt
lift
tilt
u3
19
kh
CWD02732
2)
Install retainer
(17).
18
18
ti
3)
4)
5)
Fit O-ring (16) and install backup ring (15).

*
Do not try to force the backup ring into
position. Warm it in warm water (50 60C) before fitting it.
*
Coat the O-ring and backup ring with
grease, and secure so that the backup
ring does not open.
Install piston assembly (14).
Assemble valve (13) to spacer (121, then fit
spacer and tighten with mounting bolts.
&
Mounting bolt:
Thread tightener
(LT-2)
w
Mounting bolt:
110.3 2 12..3 Nm (II.25
+ 1.25 kgm}
D155AX-5
DBtMo37Q
16
30-283
0
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC
CYLINDER

piston ring (271,
I) Using tool U3, assemble
then assemble wear ring (26) in same way
as in Step 2-I) -i) - iv) above.
26
27
2) Assemble
3)
O-ring (251, backup ring (24), and

piston assembly (23) in same way as in Step
2-3) - 4) above.
Secure with spacer (22) and tighten with
mounting bolts.
&
Mounting bolt:
Thread tightener
(LT-21
m
Mounting bolt:
98.1 - 122.6 Nm I10.0 - 12.5 kgml
24
DBwO366
3.
Piston rod assembly

Blade lift cylinder
I) Set cylinder (7) to tool Ul.
piston rod assembly (9) to
2) Assemble
der.
&
Seal portion: Grease (G2-LI)
It
Push the piston rod in to the end
stroke.
3) Using tool U2, tighten head assembly
m
Head assembly:
980.7 2 98.1 Nm II00 + 10
cylin-
w
thJ2
89
of its
(8).
kgm}
CWDd2727
.
I)
30-284
0

Assemble piston rod assembly (II) to cylinder (7).
6
Seal portion: Grease (G2-LI)
*
Push the piston rod in to the end of its
stroke.
D155AX-5
DISASSEMBLY
2)
HYDRAULIC
AND ASSEMBLY
Tighten head assembly

bolts.
w
Mounting bolt:
(10) with
CYLINDER
mounting
Unit: Nm (kgm)
Blade tilt
343.2 +. 34.3 (35 + 3.5}
Ripper lift 1 245.2 +124.5 (25 f 2.51

Ripper tilt
4.
245.2 + 24.5 I25 z 2.5)
Quick drop valve (blade lift cylinder only)

Assemble
collar (6), valves (5) and (4), spacer
(3), and spring (2), then fit O-ring and install
DEW0361
block (1).
5.
Tube
Fit O-ring
D155AX-5
and install tube.
30-285
0
-I
DISASSEMBLY
BLADE
AND ASSEMBLY
REMOVAL OF BLADE
ASSEMBLY

completely
to the
ground at a flat place, then set blocks @ securely under the left and right straight frame.
1.
Remove cap (I) of lift cylinder.

*
Check the number
and thickness
2.
m
of the
Sling lift cylinder assembly (21, start engine, retract piston rod fully, then fit cylinder clamp and
secure to radiator guard.
*
Tie the piston rod with wire to prevent it
from coming out.
.
Disconnect the cylinder from the blade on
the
opposite side in the same way.
.
Release the remaining
pressure inside the hydraulic circuit.
For details, see TESTING AND
ADJUSTING,
RELEASING
REMAINING
PRESSURE INSIDE HYDRAULIC CIRCUIT. Then loosen
the oil filler cap slowly to release the pressure
inside the hydraulic tank.
DLCQO381
3.
Remove
left and right covers (3).
4.
Disconnect hose (4).

*
caps (5).
5.
Remove
6.
m
Remove plate assembly (6).
t
Start the engine, drive the machine slowly
in reverse, and disconnect the blade assembly from the trunnion.
30-286
left and right trunnion
dirt or dust from
D155AX-5
DISASSEMBLY
AND ASSEMBLY
BLADE
INSTALLATION OF BLADE
ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
to
m
*
Adjust with shims so that clearance a at the

cap mating surface is the dimension
given
below. Check also that it rotates smoothly.
l
Standard clearance a: 0.2 - 0.5 mm
l
Standard shim thickness: 4 mm
After installing the blade, adjust the blade
tilt.
ADJUSTING
SEMI U-TILTDOZER.
Trunnion cap mounting bolt:

730.5 + 98.1 Nm (74.5 + 10 kgml
a
*
Adjust with blocks @I so that height b and

width c of the left and right straight frames
is the dimension below.
.
Height b at trunnion: Approx. 633.5 mm
.
Frame width c: Approx. 2,940 mm

level.
*
D155AX-5
30-287
0
DISASSEMBLY
BLADE
AND ASSEMBLY
DISASSEMBLY
ASSEMBLY
OF BLADE
Put blocks 0 and hydraulic jack @ under left

and right straight frame and blade, and set securely so that the blade is stable.
1.
Remove right frame cover

tilt cylinder hose (2).
(I),
and disconnect
DEW030
2.
Sling tilt cylinder assembly (3), and remove

plate, then remove pin (4).
3.
Remove mounting bolts, disconnect cap (5), then

lift off tilt cylinder assembly (3).
*
There are shims at the cap portion, so check
the number and thickness of the shims, and
keep in a safe place.
I+ kg
4.
Tilt cylinder
assembly:
lock
190 kg
Set block @ under right center brace (61, and

remove mounting bolts of cap (7) at center frame
end.
*
30-288
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
BLADE
5. Sling right straight frame (8) and disconnect right

center brace (6).
6. Remove lock plate, then remove pin (9), and lift
off right straight frame (8).
el
kg
Straight
frame:
900 kg
DECO0393
7. Remove
left frame
6. Sling tilt brace (II),

move pin (12).
cover (IO).
remove
lock plate, then re-
bolts, disconnect
cap (131,
9. Remove mounting
then lift off tilt brace (11).
*
el
kg
Tilt brace: 100 kg
left center brace (14) and remove

10. Disconnect
left straight frame (15) in same way as in Steps
4 - 6 above.
11. Sling center brace (141, remove mounting bolts,
disconnect cap (161, then lift off left and right
center braces (14) and (6).
*
el
kg
Center brace: 95 kg
14
DEW0395
12. Raise blade (171, then tip blade over.

& kg
Blade: 2,900 kg
DEW0396
D155AX-5
DISASSEMBLY
BLADE
AND ASSEMBLY
ASSEMBLY OF BLADE
ASSEMBLY
*
Check the number and thickness of the shims

removed from each place during disassembly,
then assemble them again in the same position.
When carrying out shim adjustment,
see TESTING AND ADJUSTING,
ADJUSTING
SEMI UTILTDOZER.
1. Raise blade (171, and insert block and hydraulic

jack under blade, and set securely so that the
blade is stable.
DEW0396
r3 kg
2.
Blade: 2,900
kg
Raise center brace (141, assemble

shim, and
tighten mounting bolts of cap (16).
*
Set a block under the center brace to match
the height of the straight frame.
*
& kg
Center brace: 95 kg
14
3.
Raise right center frame (81, then install pin (9)

and secure with lock plate.
&I kg
4.
DEW0395
Straight
frame:
900 kg
Sling right center frame (8), then set spherical

portion of right center brace (6) to right center
frame (8).
6
5.
Assemble shim to cap (7) of right center

(6), and tighten mounting bolts.
*
30-290
0
brace
D155AX-5
DISASSEMBLY
BLADE
AND ASSEMBLY
6. Sling tilt cylinder
assembly (31, assemble

to cap (51, then tighten mounting bolts.
*
&I kg
Tilt cylinder
assembly:
shim
190 kg
7. Install pin (41, and secure with lock plate.

8. Connect tilt cylinder
hose (2).
9. Install right frame cover (I).
10. Install left straight
frame (15) and connect left

center brace (14) in same way as in Steps 3 - 5
above.
11. Sling tilt brace, assemble
shim to cap (131, and

tighten mounting bolts.
*
E?lkg
Tilt brace: 100 kg
12. Install pin (121, and secure with lock plate.

13. Install left frame cover.
14. Greasing
After completion of assembly, grease the points
in the diagram on the right thoroughly.
&
Parts of work equipment: Grease (G2-LII
D155AX-5
DISASSEMBLY
AND ASSEMBLY
MULTI-SHANK
RIPPER
DISASSEMBLY OF MULTISHANK RIPPER ASSEMBLY

*
After disconnecting
the pipes and hoses, cover
with blind plugs to prevent dirt or dust from
entering.
1. Start engine and set ripper to maximum

and maximum tilt in.
2.
height
Sling shank (I), remove lock pin, then remove

mounting pin (21, and lower shank (I) slowly to
remove.
el
kg
IX1330398
Shank: 270 kg
3.
Set stand @ under beam and block @ under

arm, then lower ripper assembly.
4.
Sling lift cylinder assembly (3), remove lock plate,

then remove pin (4) at rod end.
*
Start the engine, retract the piston rod fully,
then lower on top of the arm.
5.
Sling tilt cylinder assembly (51, remove lock plate,

then remove pin (6) at rod end.
*
Start the engine, retract the piston rod fully,
then lower on top of the arm.
*
The pin is used when removing the beam,
so leave the pin temporarily
installed to the
beam.
ARelease
the remaining
pressure in the circuit.
RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT. Then loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
30-292
0
DUXQ401
Dl %AX-5
MULTI-SHANK
6. Disconnect
lift cylinder hose (7) and tilt cylinder

hose (8) and move towards fuel tank end.
RIPPER
7. Sling lift cylinder assembly (31, remove lock plate

and pull out pin (91, then lift off lift cylinder
assembly (3).
*
The pin is the same for the lift cylinder and
tilt cylinder, so pull it out to a position where
the lift cylinder can be removed.
*
The mounting bolt for the lock plate of the
pin on the right is also used to tighten the
rear lamp, so remove the rear lamp at the
same time.
el
kg
Lift cylinder
assembly:
130 kg
8. Sling tilt cylinder assembly (51, remove

then remove tilt cylinder assembly (5).
&I kg
Tilt cylinder
assembly:
pin (91,
130 kg
9. Sling beam (IO), remove lock plate, then remove

left and right pins (1 I), and lift off beam (IO).
kg
CE?l
Beam: 1,200 kg
10. Sling arm (12), remove lock plate, then remove

left and right pins (131, and lift off arm (12).
& kg
D 155AX-5
Arm: 470 kg
30-293
DISASSEMBLY
MULTI-SHANK
AND ASSEMBLY
RIPPER
ASSEMBLY OF MULTI-SHANK
RIPPER ASSEMBLY
1.
Raise arm (121, install left and right pins (13L

then secure with lock plate.
Arm: 470 kg
&I kg
*
Set block @ under the arm.
2.
Raise beam (IO), install left and right pins (II),

then secure with lock plate.
Beam: 1,200 kg
f?lkg
*
Set stand @ under the beam.
3.
Raise tilt cylinder assembly (51, then install pin

(9).
*
The same pin is used for the tilt cylinder and
lift cylinder, so push it in to a position where
the tilt cylinder can be installed.
Tilt cylinder assembly: 130 kg
l+l kg
*
After installing, lower the rod end on top of
the arm.
4.
Raise lift cylinder assembly (31, then install

(9).
*
The mounting bolt for the lock plate of
pin on the right is also used to tighten
rear lamp, so install the rear lamp at
same time.
pin
the
the
the
8,
Lift cylinder assembly: 130 kg

&I kg
*
After installing, lower the rod end on top of
the arm.
5.
Connect tilt cylinder

hose (7).
hose
(8) and lift cylinder
30-294
0
D155AX-5
DISASSEMBLY
AND ASSEMBLY
MULTI-SHANK
RIPPER
6. Sling tilt cylinder
assembly (51, start engine, extend piston rod, align pin holes, then install pin
(6) and secure with lock plate.
7. Sling lift cylinder
assembly (31, start engine, extend piston rod, align pin holes, then install pin
(4) and secure with lock plate.
6. Start engine and set ripper to maximum

maximum
9. Pass wire from shank mounting

raise shank (I), and install,
and secure with lock pin.
el
kg
lift and
tilt in.
Shank:
then
hole in beam,
install pin (2)
130 kg
10. Greasing
After completion of assembly, grease points in
diagram on right thoroughly.
&
Pin: Grease (G2-LI)
.

level.
*
D155AX-5
30-295
0
DISASSEMBLY
REMOVAL
1.
2.
AND ASSEMBLY
ROPS GUARD
OF ROPS GUARD
Sling ROPS guard

bolts (12).
(I) and remove
12 mounting
fKJ
Lift off ROPS guard (I).

&l kg
Rops guard: 700 kg
INSTALLATION
OF ROPS
GUARD
order
to
removal.
30-296
0
ROPS guard mounting bolt:

926.8 1. 103.0 Nm t94.5 + 10.5 kgm}
D 15%X-5
OPERATOR CAB
REMOVAL OF OPERATOR CAB

ASSEMBLY
2
Serial No. 70001 75000
Disconnect
3
4
1. Remove ROPS guard.

For details, see REMOVAL OF ROPS GUARD.
2. Open left side cover.

3. Disconnect connectors (1) (CN360), (2) (CNCAB1), and (3) (CN-CAB2).
4. Disconnect 4 washer hoses (4).
DED01132
5. Remove step (5), then remove cover (6).
6. Remove garnishes (7), (8), and (9).

7. Remove 19 mounting bolts, then lift off operator cab assembly (10).
Operator cab assembly: 290 kg
DED01133
INSTALLATION OF OPERATOR
CAB ASSEMBLY
Serial No. 70001 75000

removal.
1
e
Match the color bands and connect the

washer hoses.
DED01134
10
DED01135
D155AX-5
30-297
1
5
HOOD
REMOVAL OF HOOD
ASSEMBLY
1. Remove exhaust pipe (1).
2. Remove partition (2), then remove rubber seal.

3. Loosen clamp (3) and disconnect connector (4)
from hood end.
4. Lift off hood assembly (5).
4
Hood assembly: 90 kg
DED00795
INSTALLATION OF HOOD
ASSEMBLY

removal.
DED00796
4
DED00797
DED00798
30-298
1
D155AX-5
FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
Serial No. 70001 75000
Park

disconnect the cable from the negative (-) terminal of the battery.
1. Remove operator cab assembly.

For details, see REMOVAL OF OPERATOR CAB
ASSEMBLY.
2. Lift off operators seat (1).
4 Operators seat : 54 kg
3. Remove floor plate (2).
4. Disconnect deceleration rod (3).
5. Remove left armrest (4) and right armrest (5).

6. Remove right side covers (6) and (7).
7. Remove left side covers (8) and (9).
8. Disconnect engine wiring connector (10) (CN101).

9. Disconnect monitor wiring connector (11)
(CN214).
10. Disconnect panel lighting wiring connector (12)
(CN215).
D155AX-5
30-299
5
1
DISASSEMBLY
FLOOR FRAME
AND ASSEMBLY
11. Disconnect air conditioner
hoses (13).
(I
*
Using tool X, collect new freon gas (R134a).
12. Remove bracket (74), and move receiver tank
(15) towards outside.
*
Close the heater hose valve at the engine
end.
*
Fit blind plugs after disconnecting.
14. Loosen bellows hose clamp (171, and disconnect bellows hose from engine hood.
15. Remove 2 covers (18).
16. Open cover (19), remove cleaner cover (20) and

filter, then remove cover (19).
17. Remove covers (21) and (221, and install eyebolts.
I/
30-300
0
CWD02747
D155AX-5
DISASSEMBLY
AND ASSEMBLY
18. Remove mounting bolts, then lift off dashboard

assembly (23).
&I kg
Dashboard assembly : 85 kg
19. Disconnect wiring connectors (24) KN-105) and

(25) (CN-104) between battery relay and fuse
box.
20. Disconnect chassis ground (26).
21. Disconnect wiring connectors (27) (CN-153), (28)

(LPL), (29) (CN-4511, and (30) (CN-701).
Ir Disconnect the wiring clamps (2 places).
Tightened together with ground (CN-456).
22. Disconnect window washer motor wiring connectors (31) (CN-3611, (32) (CN-3621, (33) KN3631, and (34) KN-364).
23. Disconnect wiring clamp (35).
*
Gather wiring harnesses together and move
towards floor frame.
D155AX-5
FLOOR FRAME
DISASSEMBLY
FLOOR FRAME
AND ASSEMBLY
24. Disconnect return hoses (36) and (37) coming

from blade and ripper control PPC valves.
25. Disconnect PPC hose (38) (white) (ripper TILT

BACK).
26. , Disconnect PPC hose (39) (black) (ripper DOWN).
27. Disconnect PPC hose (40) (colorless) (blade
LOWER).
28. Disconnect PPC hose (41) (green) (blade left tilt).
m
29. Disconnect clamp (42).

30. Disconnect hose (43) between
charge filter.
31.
32.
33.
34.
Disconnect
Disconnect
Disconnect
Disconnect
30-302
0
lock valve and
PPC hose (44) (red) (ripper TILT IN):

PPC hose (45) (colorless) (ripper UP).
PPC hose (46) (black) (blade RAISE).
PPC hose (47) (yellow) (blade right
D155AX-5
DISASSEMBLY
AND ASSEMBLY
35. Disconnect speed control cable (481, and remove

bracket (49) from transmission case.
36. Disconnect directional selector control cable (501,
and remove bracket (51) from transmission case.
37. Disconnect parking brake cable (52) from brake

valve, and remove bracket (53) from HSS case.
38. Disconnect brake control rod (54) from brake
valve.
Sr After disconnecting the cable and rod, tie
them to the floor frame.
39. Remove 8 front mount bolts (55).
40. Remove 8 suspension mounting bolts (56).
D155AX-5
FLOOR FRAME
FLOOR FRAME
41. Lift off floor frame assembly (57).

4 Floor frame assembly : 230 kg
fl Control with a lever block to avoid interference when removing.
INSTALLATION OF FLOOR
FRAME ASSEMBLY
Serial No. 70001 75000

removal.
1
fl Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses.
fl Check that there are O-rings at the piping
coat the O-rings thoroughly with compressor oil before connecting.
2
fl The positions for connecting the PPC hoses
are distinguished by color bands at the quick
coupler, so check the colors when installing.
30-304
1
5
D155AX-5
DASHBOARD
REMOVAL OF DASHBOARD
ASSEMBLY
Serial No. 70001 75000
Park

1. Remove operators cab assembly.
For details, see REMOVAL OF OPERATORS CAB
ASSEMBLY.
2. Disconnect engine wiring connector (1) (CN101).
3. Disconnect monitor wiring connector (2) (CN214).
4. Disconnect panel lighting wiring connector (3)
(CN215).
5. Disconnect air conditioner hoses (4).
1
fl Using tool X, collect freon gas (R134a).
6. Remove bracket (5), and move receiver tank towards outside.
fl Close the heater hose valve at the engine
end.
fl After disconnecting, fit with blind plugs.
8. Loosen bellows hose clamp (7), and disconnect
bellows hose from engine hood.
9. Remove 2 covers (8).
DED01138
10. Open cover (9), remove cleaner cover (10) and

filter, then remove cover (9).
9
10
DED01139
D155AX-5
30-305
5
1
DASHBOARD
11. Remove covers (11) and (12), and install eyebolts.
11
12
DED01140
12. Remove mounting bolts, then lift off dashboard

assembly (13).
4 Dashboard assembly : 85 kg
13
INSTALLATION OF
DASHBOARD ASSEMBLY
Serial No. 70001 75000
DED01141

removal.
1
fl Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses.
fl Check that there are O-rings at the piping
coat the O-rings thoroughly with compressor oil before connecting.
Charging with air conditioner gas

Using tool X, charge air conditioner circuit with
new freon gas (R134a).
30-306
1
5
D155AX-5
REMOVAL OF MONITOR
ASSEMBLY
MONITOR
Serial No. 70001 75000
Disconnect
1. Remove mounting bolts and open monitor assembly (1).

2. Disconnect connectors (2) (CN-P1 and CN-P2),
and remove monitor assembly (1).
Serial No. 70001 75000
3. Disconnect connectors (T01, CN4, CN1, CN2),
and remove monitor assembly (1).
Serial No. 75001
DED01117
Serial No. 70001 75000
INSTALLATION OF MONITOR
ASSEMBLY

removal.
DED01118
D155AX-5
30-307
1
5
HSS CONTROLLER
REMOVAL OF HSS
CONTROLLER ASSEMBLY
Serial No. 70001 75000
Disconnect
1. Remove cover (1) at rear of operators seat.

2. Disconnect steering neutral adjustment switch
wiring connector (2) (CN-CSW).
3. Disconnect HSS controller wiring connectors (3)
(CN-1), (4) (CN-2H1), and (5) (CN-2H2).
4. Remove mounting bolts, then remove HSS controller assembly (6).
INSTALLATION OF HSS
CONTROLLER ASSEMBLY
Serial No. 70001 75000

removal.
30-308
1
5
D155AX-5
HSS CONTROLLER
REMOVAL OF HSS
CONTROLLER ASSEMBLY
Disconnect
the cable from the negative () terminal of the battery
1. Remove cover (1) from rear of operator's seat.

2. Disconnect HSS controller wiring connector (2)
(CN-ST1), (3) (CN-ST2), and (4) (CN-ST3.)
3. Remove mounting bolts and HSS controller assembly (5).
INSTALLATION OF HSS
CONTROLLER ASSEMBLY
Carry out installation in the reverse order to removal.
D155AX-5
30-309
5
5
40
MAINTENANCE
ANDARD
ST
.40- 2
Engine mount ...............................................
40- 3
Power train unit mount ...............................
40- 4
Damper, universal joint ...............................
40- 6
Torque converter, PTO ................................
.40-10
................................................
Transmission
40-13
control valve .........................
Transmission
.40-14
Main relief valve.. .........................................
40-16
Bevel gear shaft, HSS brake .......................
.40-20
Brake valve ...................................................
pump,
Scavenging
40-21
PPC, HSS charge pump ........................
Power train pump, lubrication pump.. ....... 40-22
40-24
PPC, HSS charge valve.. ..............................
40-26
Oil cooler bypass valve ...............................
Final drive ......................................................
40-28
.40-30
Main frame ...................................................
.40-32
Track frame ...................................................
.40-33
Recoil spring .................................................
.40-34
Track roller bogie .........................................
40-36
Idler.. ...............................................................
.40-38
Track roller.. ..................................................
.40-40
Carrier roller .................................................
.40-42
Track shoe.. ...................................................
.40-50
Suspension ...................................................
40-52
pump ...............................
Work equipment
.40-53
HSS pump.. ...................................................
.40-54
HSS motor ....................................................
.40-56
PPC valve ......................................................
.40-59
Steering lever ...............................................
Main control valve ........................................
40-60
40-66
cylinder.. ..........................
Work equipment
.40-70
Quick drop valve ..........................................
.40-71
Cylinder stay .................................................
.40-72
Work equipment.. .........................................
D155AX-5
40-l
MAINTENANCE
STANDARD
ENGINE MOUNT
ENGINE MOUNT
926.7z102.9Nm
(94.5210.5kgm)
926.7k102.9Nm
(94.5-cl0.5kgm)
A-A
B-B
SAD00410
Unit:
No
Check item
Criteria
mm
Remedy
Clearance
between
and cushion
bracket
Tolerance
Standard
size
60
Shaft
-0.1
-0.3
Standard
Free height
rubber
40-2
size
Hole
+0.046
0
Standard
clearance
Clearance
limit
0.100
0.346
Repair
0.4
Replace
limit
of mount
90
88
D155AX-5
MAINTENANCE
STANDARD
POWER TRAIN UNIT MOUNT
POWER TRAIN UNIT MOUNT
A-A
Unit: mm
No
Check item
Criteria
Remedy
between
Interference
steering case and bushing
Standard
size
204
Clearance between
and cushion
bracket
60
Tolerance
Shaft
Hole
Standard
clearance
+0.096
+0.050
+0.046
0
-0.096 - 0.004
Max.
-0.1
-0.3
+0.046
0
0.100 0.346
0.4
Standard
3
Free height
rubber
of front mount
Free height
rubber
of rear mount
D 155AX-5
size
Repair
90
88
43
41
Clearance
limit
0
Replace
limit
40-3
DAMPER,
MAINTENANCE
STANDARD
DAMPER,
UNIVERSAL
UNIVERSAL
JOINT
JOINT
276.85+31.85Nm
(28.25+3.25kgm)
IlO.O-cl2.ONm
(11.2-cl.2kgm)
66.15+7.35Nm
(6.75-cO.75kgm)
(11.2z1.2kgm)
Unit:
Tolerance
Standard
Clearance between
1
flywheel housing
and cover
Clearance between
flywheel and damper
Outer circumference
of coupling oil seal
contact surface
40-4
Remedy
Criteria
Check item
size
Shaft
511.18
-0.022
-0.092
466.72
-0.020
-0.083
Standard
90
size
Standard
Clearance
Hole
clearance
limit
+0.070
0
0.022 0.162
0.2
+0.063
0.020 -
0
Tolerance
0
-0.087
mm
Replace
0.2
0.146
Repair
limit
89.8
D155AX-5
MAINTENANCE
STANDARD
TORQUE CONVERTER,
PTO
TCS43-17A
40-6
277*319Nm
i2825*325kPml
D 155AX-5
MAINTENANCE
STANDARD
llOr12.3Nm
11.25*1.25kom)
2.3Nm
:1.25bd
SWD02770
D155AX-5
40-7
MAINTENANCE
STANDARD
Unit: mm
No
Check
item
Outer diameter of input

coupling oil seal contact
surface
Inner diameter of retainer

seal ring contact surface
Wear
3
of stator
Width
Criteria
Standard
size
Remedy
Repair
Tolerance
limit
100
0
-0.054
99.8
140
+0.040
0
140.5
4.45
0
-0.1
5.2
+0.1
4.7
Hard chrome
plating or
replace
shaft seal ring

Thickness
Backlash between PTO

drive gear and PTO idler
gear
Standard
clearance
Clearance
0.204 - 0.516
limit

idler gear and HSS pump
drive gear
0.204 - 0.516
Backlash between PTO idler

gear and power train, work
equipment pump drive gear
0.204 - 0.516

drive gear and scavenging
pump drive gear
0.204 - 0.516
40-8
Replace
D155AX-5
MAINTENANCE
TRANSMISSION
STANDARD
TRANSMISSION
P
*9.8Nm
l.OkPml
SWD02771
40-10
D155AX-5
MAINTENANCE
/
I
STANDARD
TRANSMISSION
F7 i I
2
A-A
\
4
5
SW002772
D155AX-5
40-11
MAINTENANCE
STANDARD
TRANSMISSION
Unit: mm
No
Check
item
Criteria
Standard
No. 1 clutch spring
(x12)
size
Repair
limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
81.7
70.2
73.5 N
17.5 kg1
76.8
62.8 N
16.4 kg)
No. 2 clutch spring
(x12)
81.7
75.4
40.2 N
14.1 kg1
76.8
34.3 N
13.5 kg}
No. 3 clutch spring
(x12)
70
50
98.1 N
110 kg}
65.8
83.4 N
18.5 kg}
No. 4 clutch spring
(x12)
No. 5 clutch spring
(x12)
Lubrication
spring
relief valve
7o
Clutch disc thickness

(No. 1 - No. 5 clutch)
51
66
51.8
26
23.6
Standard
7
Remedy
z52k;j
658
66.7 N
16.8 kg1
12.5 N
{I.27 kg]
size
62
56.9 N
15.8 kg)
11.9 N
II.21 kg}
25.2
Tolerance
5.4
;i4k$
Repair
+0.1
4.9
Clutch plate thickness

(No. 1 - No. 5 clutch)
Overall assembled
thickness of No. 1 clutch
50.2
f0.3
47.5
Overall assembled
IO thickness of No. 2 clutch
61.4
+0.3
58.2
5.8
fO.1
limit
5.2
Replace
11
Overall assembled
39
f0.3
36.9
12
Overall assembled
39
+0.3
36.9
13
Overall assembled
27.8
f0.2
26.2
14
Backlash between sun

gears and planet pinion
(FORWARD,
REVERSE,
1st - 3rd)
15
16
Standard
Backlash between planet

pinions and ring gear
inner teeth (FORWARD,
REVERSE, lst, 2nd)
pinion and ring gear inner
teeth (3rd)
Backlash between carrier

and ring gear inner teeth
(REVERSE)
Backlash between carrier
18 and ring gear inner teeth
(FORWARD,
1st)
17
40-12
clearance
Clearance
0.14 - 0.35
0.15 - 0.38
0.16 - 0.41
0.18 - 0.54
0.18 - 0.48
limit
D 155AX-5
MAINTENANCE
TRANSMISSION
STANDARD
TRANSMISSION
CONTROL VALVE
CONTROL VALVE
SJDO2773
E-B
Unit: mm
No
Check
Criteria
item
Tolerance
Standard
size
Clearance between clutch

selector valve and valve
body, and directional valve
valve body
Hole
Standard
clearance
Clearance
limit
-0.035
-0.045
+0.013
0
0.035 0.058
0.08
-0.1
-0.2
+0.033
0
0.1 0.233
0.26
-0.035
-0.045
+O.Oll
0
0.035 0.056
0.08
Shaft
22
Clearance between
modulating
valve and
sleeve
20
-0.035
-0.045
+0.013
0
0.035
0.058
0.08
Clearance between
modulating
valve sleeve
and valve body
30
-0.035
-0.045
+0.013
0
0.035
0.058
0.08
+0.018
0
0.020
0.048
Replace
Clearance between
modulating
valve and
oiston
12
-0.020
-0.030
Standard
I
7
Modulating
spring
valve
IO
Modulating
spring
valve
Modulating
valve
spring
Modulating
spring
valve
piston
D155AX-5
0.07
Repair
size
limit
Installed
length
Installed
load
Free
length
Installed
load
46.6
130 N
1 113.23 kg1
57.2
124 N
112.6 kg}
676
1 ,,:%Nkg]
Free
length
inside
59
Remedy
outer
1
84.5
52
21
26
20
267 N
(27.2 kg}
4.9 N
IO.5 kg}
82
50.4
25.2
1 &?
:gI
253 N
125.8 kg}
4.7 N
(0.48 kg}
40-13
MAINTENANCE
MAIN
MAIN RELIEF VALVE
STANDARD
RELIEF VALVE
I
5
rl
6
n
SJD02774
Unit: mm
No.
Criteria
Clearance between main

relief valve and valve
body
Clearance
between
Main relief valve

spring
main
outside
40-14
D155AX-5
MAINTENANCE
BVEL GEAR SHAFT,
STANDARD
HSS BRAKE
IEVEL GEAR SHAFT, HSS BRAKE (l/2)
I
I
I
I
40-16
II
II
II
,u& --------------------
/ /
I
l.
!!
r---
D155AX-5
MAINTENANCE
STANDARD
Unit:
mm
NC
Brake
plate
thickness
Brake
plate
distortion
Brake
disc thickness
Brake
disc distortion
Within
0.15
Overall assembled
of brake
thickness
Seal ring contact surface

at brake piston smallportion
diameter
D155AX-5
40-17
MAINTENANCE
STANDARD
BVEL GEAR SHAFT, HSS BRAKE
10.0~12.ONm
1.2*1.2kaml
SVD02766
40-18
D155AX-5
MAINTENANCE
STANDARD
Unit: mm
No.
-
Check
item
Criteria
Standard
Backlash between
and pinion
gear A
Backlash between
and gear C
gear A
Backlash between
and gear E
gear D
Backlash between
and
B
geara
gear A
Backlash between
gear and pinion
bevel
clearance
Remedy
Clearance
0.19 - 0.62
0.70
0.18 - 0.58
0.70
0.19 - 0.61
0.80
0.20 - 0.67
0.80
0.25 - 0.33
0.50
D155AX-5
limit
Replace
Adjust or
replace
40-19
MAINTENANCE
STANDARD
BRAKE VALVE
BRAKE VALVE
ml-.lr----Y
m
686+98Nm
(7.0kl.Okgm)
SKD00434
Unit: mm
No
Check
item
Criteria
Remedy
Clearance between
valve and body
Standard
size
brake
Hole
Standard
clearance
Clearance
limit
-0.020
-0.030
+0.021
0
0.020 0.051
0.07
-0.03
-0.04
+0.015
0
0.030 0.055
0.08
19
-0.034
-0.043
+0.013
0
0.034 0.056
0.08
19
Clearance between
valve and piston
brake
Clearance between parking

brake valve and body
Tolerance
Shaft
~~
4
Brake modulating
Brake valve
Parking
spring
40-20
Peplace
spring
return
brake valve
spring
return
52.5
35
157.98 N
f16.12 kg}
51
149.9 N
(15.3 kg}
69.5
42
24.30 N
(2.48 kg}
67.4
23.03 N
(2.35 kg}
155AX-5
MAINTENANCE
STANDARD
SCAVENGING
SCAVENGING
PUMP,
PPC, HSS CHARGE
PUMP
PUMP, PPC, HSS CHARGE PUMP
112 + 104
(16.5-cl.5kgm)
SDDO0438
Unit: mm
No
Criteria
Check item
I
1
1Standard
Twe
Side clearance
Clearance
between plain
inner diameter and
gear shaft outer diameter
Pin driving
1 Clearance
0.10 - 0.14
0.18
104
0.05 - 0.10
0.14
0.06 - 0.13
0.18
depth
Standard
size
Tolerance
112
13
Spline
shaft rotation
torque
6.86 - 11.77Nm
Type
Delivery
Oil temperature:
Oil:
EOIO-CD
45 - 50C
Speed
112
2,200
104
D 155AX-5
Replace
0
-0.5
104
4
limit
104
Tvpe
3
clearance
112
112
2 bearing
Remedy
lo.7 - 1.2 kgm}
Delivery
pressure
Standard
delivery
Delivery
limit
I30.3kg,cm2I
MPa
230 e/min
210 e/min
4.4 MPa
(45 kg/cm*}
215 emin
195 e/min
rpm
40-21
MAINTENANCE
POWER TRAIN
STANDARD
POWER TRAIN PUMP, LUBRICATION
PUMP,
LUBRICATION
PUMP
PUMP
SAL (3) 80 + 100
SAL(3)80
SAL(S) 100
/
&
277.0?32.ONm
(28.5=3.0kgm)
27.0*32.ONm
(28.5*3.0kgm)
SYWO420
Unit: mm
No
Check item
Side clearance
SAL (3) 100
Clearance between plain

bearing inner diameter and
Pin driving
Spline
0.60 - 0.149
0.20
SAL (3) 100

1
Standard
size
Tolerance
depth
shaft rotation
13.7 - 23.5 Nm {I.4 - 2.4 kgm}
torque
Type
Delivery
Oil: EOIO-CD
Oil temperature:
Speed
SAL (3) 80
45 - 50C
SAL (3) 100
40-22
0.22
Replace
SAL (3) 80
Tvoe
3
0.13 - 0.18
2,500
Delivery
pressure
Standard
delivery
Delivery
limit
2.9 MPa
(30 kg/cm*}
lg2 Umin
176 Urnin
I3o
2.9kg,cm2I
MPa
241 Umin
221 Umin
rpm
D 155AX-5
MAINTENANCE
STANDARD
PPC. HSS CHARGE
VALVE
2
B-B
I
c-c
SAD00436
40-24
D155AX-5
MAINTENANCE
STANDARD
PPC. HSS CHARGE
VALVE
Unit: mm
No
Check
item
Criteria
Clearance between charge

valve and valve body
Clearance
between
charge
Clearance
between
filter
Clearance
between
check
Charge
valve spring
(large)
Charge
valve spring
(small)
s
-
D155AX-5
40-25
MAINTENANCE
STANDARD
OIL COOLER BYPASS VALVE
COOLER BYPASS VALVE
-_--_--
A-A
SAD00437
Unit: mm
No
Check item
Criteria
Clearance between oil

1 cooler bypass valve and
valve body
2 Spring
40-26
D155AX-5
MAINTENANCE
FINAL DRIVE
STANDARD
FINAL DRIVE
-m276.85=31.85Nm
(28.25*3.25kgm)
3
40-28
151.9d4.5Nm
(15.5-c2.5kgm)
548.8+58.8Nm
(56.0t6.0kgm)
1;76.8?98.lNm
(120.0+10.0kgm)
;48.8+58.8Nm
(56.0?6.0kgm)
;51.9&24.5Nm
(15.5s2.5kgm)
D 155AX-5
MAINTENANCE
FINAL DRIVE
STANDARD
Unit: mm
No
Check item
Standard
0.28 - 0.93
1.0
Backlash between
and planet pinion
0.24 - 0.79
1.0
0.26 - 0.87
1.0
sun gear

pinion and ring gear
Standard
Outer diameter of No. 1

pinion oil seal contact
surface
94.9
95
Clearance at ball between

cover and shaft
Clearance between
shaft and carrier
pinion
58
Clearance of No. 1 pinion

bearing in axial direction
Wear of dia. of sprocket

tooth tip
-0.010
-0.003
Wear of dia. of sprocket

tooth root
12
Wear
of width
of sprocket
Wear
tooth
of width
root
of sprocket
D 155AX-5
-0.009
-0.039
0.006
0.049
shim thickness:
Tolerance
size
I
Clearance
limit
0.1
Adjust
2)
Repair
limit
1,002
f2
962
909.4
f0.6
895.0
Standard
11
Standard
clearance
0 - 0.1 (standard
Standard
10
Hole
Shaft
Replace
I
Tolerance
Standard
size
limit
limit
94.9
Outer diameter of No. 1

pinion oil seal contact
surface
Repair
size
95
Clearance
clearance
Backlash between No. 1

pinion and No. 1 gear
103
size
Repair
limit
Rebuild
or replace
95
40-29
MAINTENANCE
MAIN
STANDARD
FEAME
MAIN FRAME
D-D
SKD00441
40-30
D155AX-5
MAINTENANCE
STANDARD
MAIN FRAME
Unit: mm
No
-
Remedy
Criteria
Check item
I
ince
Clearance
between
Hole
HSS
1 case and main frame
+0.046
0
Clearance between
frame and radiator
bushing
main
guard
95
+0.054
0
+0.154
+0.124
Clearance between
frame and radiator
bushing
main
guard
95
io.054
0
+o. 154
+0.124
Clearance between
equalizer bar center
and bushing
pin
85
-0.120
-0.174
+0.207
+0.120
Press-fitting force for

radiator guard mount
bushing

6, radiator guard mount
bushing
7
-

equalizer bar center pin
bushing
D 155AX-5
73.5 - 122.6 kN (7.5 - 12.5 ton1
73.5 - 122.6 kN t7.5 - 12.5 ton1
63.7 - 132.4 kN (6.5 - 13.5
I
-
tOnI
40-31
MAINTENANCE
TRACK FRAME
STANDARD
TRACK FRAME
745+83Nm
(76.0&5kgm)
m.
745+83Nm
(76.0+8.5kgm)
745G33Nm
(76.0?8.5kgm)
;45+83Nm
(76.0&5kgm)
A-A
SKD00442
Unit: mm
No.
I
Check item
Item
1 Deformation
of track frame
Curvature
Twisting
Dents (pipe portion)
Standard
2 Clearance between
and guide
40-32
Remedy
Criteria
clearance
Repair
limit
7 (over length
3 (over length
12
Clearance
idler
of 3000)
of 300)
Correct
or replace
limit
Adjust
0.5 - 1.0
D155AX-5
MAINTENANCE
RICOIL SPRING
STANDARD
RECOIL SPRING
A-A
SKD00443
Unit: mm
No
Remedy
Criteria
Check item
limit
Installed
load
Recoil spring
1,125
Clearance between inner

c&i$;rg
and outer cylinder
937
298.7 kN
(30,456 kg]
1,091
283.7 kN
:28,930 kg}
Clearance
limit
Replace
fl
0.7
Clearance between inner

cylinder and protrusion of
adiustment
cvlinder
Press-fitting force for outer
cylinder bushing (outer
cylinder side)
Press-fitting
yoke
D 155AX-5
force for idler
75
+0.039
+0.009
+0.130
+O.lOO
0.061 0.121
1.0
19.6 - 29.4 kN (2 - 3 ton}
245 kN 125 ton)
40-33
MAINTENANCE
TRACK ROLLER BOGIE
STANDARD
TRACK ROLLER BOGIE
2108*245Nm
(215*25taml
\5
9
A-A
40-34
SWD02789
D155AX-5
MAINTENANCE
TRACK ROLLER BOGIE
STANDARD
Unit: mm
Check item
Criteria
Standard
size
Clearance between
cartridge pin and bushing
80
Tolerance
Remedy
Hole
Standard
clearance
Clearance
limit
-0.165
-0.195
+0.189
+0.129
0.294 0.384
0.8
+0.203
+0.183
+0.083
+0.020
-0.183 -0.100
Shaft
Clearance
and outer
between
bogie
collar
133
Clearance
and
outer
between
bogie
collar
135
+0.203
+0.183
+0.083
+0.020
-0.183 -0.100
Clearance
and inner bogie
between
collar
134
+0.203
+O.
183
+0.083
+0.020
-0.183
-0.100
Clearance
Press-fitting
bushing
force for
0.98 - 18.6 kN iO.1 - 1.9 ton}
Press-fitting
washer
force for
2.94 - 5.88 kN (0.3 - 0.6 ton)
Press-fitting
washer
force for
Press-fitting
collar
force for
1o
Press-fitting
outer bogie
force for
11
Press-fitting
Inner bogie
I2
Press-fitting
outer bogie
of collar
--
1.5
I
D155AX-5
force for
0.98 - 3.92 kN IO.1 - 0.4 ton}
force for
Replace
58.8 - 103.9 kN i6.0 - 10.6 ton}
88.3 - 202 kN (9.0 - 20.6 ton}
198 - 436 kN (20.2 - 44.5 ton1
94 - 206 kN 19.6 - 21.0 ton}
40-35
MAINTENANCE
IDLER
STANDARD
IDLER
SWD02767
40-36
D 155AX-5
MAINTENANCE
STANDARD
IDLER
Unit: mm
No
Criteria
Check item
Remedy
Standard
size
of
Outer
diameter
of tread
Depth
of tread
21
Overall
width
240
of tread
58.5
Width
792
750
725
I
6
Clearance between
and bushing
Standard
size
shaft
140
Interference
between
and bushing
idler
Standard
size
Shaft flange
D155AX-5
width
Tolerance
-0.350
-0.413
+0.270
-0.040
0.310 0.683
Standard
interference
Interference
limit
Hole
+0.063
-0.100
216
Rebuild
or replace
Hole
Tolerance
Shaft
limit
Standard
clearance
Shaft
150
Repair
Outer diameter
prorusion
Clearance
limit
Replace
bushing
Rebuild
or replace
40-37
MAINTENANCE
STANDARD
TRACK ROLLER
TRACK ROLLER
-1
d
i
!
j
I
\,I
!i
IO
II
1
I
__
__-..
L-
,k---------__-.--..dI
TT----i
__.__
iL
;
- t
I_
__ --. i
5
SW802776
40-38
D155AX-5
MAINTENANCE
STANDARD
TRACK ROLLER
Unit: mm
No.
-
Check
Criteria
item
Standard
Outer diameter of flange

(outside flange)
Outer diameter
(inside flange)
of flange
Outer
of tread
Thickness
Overall
Inner width
diameter
of tread
width
Repair
size
285
275
250
210
57.5
37.5
295
Remedy
limit
Rebuild
or replace
Replace
single flange
113
double
69
flange
Width of tread
(single flange)
61
Width of tread
(double flange)
61
Flange width
(outside of double
25
22
flange)
10
Flange width
(inside of double
11
Shaft flange
width
12
Press-fitting
for collar
dimension
13
14
flange)
Clearance between
and bushing
Interference
between
and seal guide
246.0
shaft
shaft
Rebuild
or replace
Standard
size
r
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
Hole
Standard
interference
lnterferenct
limit
Tolerance
Shaft
Replace
bushing
Dl SAX-5
40-39
MAINTENANCE
STANDARD
CARRIER ROLLER
CARRIER ROLLER
SWD02777
Unit: mm
Check item
No
Criteria
Standard size
Outer
diameter
Outer diameter
Width
of tread
Thickness
Width
of tread
Interference
between
bearing and shaft
Play of roller in axial

direction
40-40
190
171
63
Standard
size
limit
Rebuild
replace
or
28
21
of flange
interference
between
bearing and roller
220
37.5
Tolerance
Standard
interference
Interference
limit
-0.024
-0.059
0.009 0.059
0
-0.015
0.002 0.036
Shaft
Hole
110
0
-0.015
60
+0.021
+0.002
Standard
8
Repair
of flange
of tread
Remedy
clearance
Clearance
Replace
limit
Dl !ZAX-5
MAINTENANCE
TRACK SHOE
STANDARD
TRACK SHOE
DRY TYPE
12
21
22
16
18
40-42
IL=d+\
ii
shows the link of bushing
press fitting
19
25
I5
SWD02429
I
P portion
II
23.
Ir
Ei
end.
D155AX-5
MAINTENANCE
STANDARD
TRACK SHOE
Unit: mm
No.
Check item
Criteria
Standard
Remedy
size
Repair
Link pitch
231.85
233.85
228.85
When
Standard
2
Bushing
outside
Normal
Reverse
replace
turned
load
Impact
load
81
II
75.0
77.0
I
I
Repair
size
limit
Repair or
replace
Link height
144
128
Thickness of link metal

(bushing press-fitting portion)
--I
45.5
Shoe
or
Standard
3
(Heavy-duty
areas)
(Standard areas)
size
diameter
limit
219.8
Replace
bolt pitch
76.2
25.4
81
9
1Inside width
122.8
Overall
Link
10
Tread
11
Protrusion
of pin
12
Protrusion
bushing
of regular
13
Overall
length
width
Repair or
replace
61.4
width
54.3
4.5
10.4
of pin
294
Adjust or
replace
I4
Overall
15
Thickness
of bushing
16
Thickness
of spacer
length
of bushing
metal
Press-fitting
force
%
19
Regular
Master
15.8
Bushing
,8
202.2
I
pin
pin
88.2 - 313.6
kN (9 - 32 ton)
205.8 - 568.4 kN 121 - 58
107.8 - 274.4
tOnI
I
I
kN 111 - 28 ton1
.x : Dry type track link
D155AX-5
40-43
MAINTENANCE
STANDARD
TRACK SHOE
Unit: mm
l-
NC
-
Check
item
Criteria
Tightening torque
(Nm Ikgm})
a. Regular
link
Remedy
Additional
angle
588.4 f 58.8 160 f 61

2c
Shoe
Retighten
torque
(Nm Ikgm})
b. Master
Additional
angle
No. of shoes (each side)
Interference
between
bushing and link
22
Interference
between
regular pin and link
2:
Clearance between
regular pin and bushing
5%
Interference
between
master pin and link
tightening
(deg.)
Lower limit torque

(Nm {kgm))
link
24
120 + 10
bolt
Tightening
21
tightening
(deg.)
41
Standard
size
Tolerance
Shaft
Hole
Standard
interference
77.0
+0.404
+0.304
+0.074
0
0.230 0.404
48.5
+0.584
+0.434
+0.062
0
0.272 0.584
Adjust or
replace
Standard
size
48.5
Tolerance
Shaft
Hole
Standard
interference
+0.330
-0.300
+0.062
0
0.238 0.330
Clearance between
master pin and bushing
%X: Dry type track link
40-44
D155AX-5
MAINTENANCE
STANDARD
SEALED AND LUBRICATED
TRACK SHOE
TRACK
21
22
II
24
16
13
\
2
\
\23
19
\
25
\
15
SW002430
Ir
P portion
40-46
shows the link of bushing
pres: s fitting
end.
D155AX-5
MAINTENANCE
STANDARD
TRACK SHOE
l-
No
Check
item
Criteria
Remedy
Standard
Repair
size
1 Link pitch
231.85
233.85
228.85
When
Standard
2
outside
(Heavy-duty
areas)
(Standard areas)
Reverse
replace
turned
size
Normal
Bushing
limit
load
Impact
or
load
diameter
81
72.5
75.0
Standard
3
Link height
Thickness of link metal

(bushing press-fitting portion)
Repair
size
144
limit
Repair or
replace
128
45.5
219.8
Replace
Shoe
bolt pitch
169
76.2
1
I
8
IInside
width
I
(
122.8
Overall
Link
width
Repair or
replace
61.4
10
54.3
Trea width
11
Protrusion
of pin
12
Protrusion
bushing
of regular
13
Overall
4.5
length
3.25
291.6
of pin
Adjust or
replace
14
-
Overall
length
of bushing
187.9
_
15
Thickness
of bushing
16
Thickness
of spacer
metal
15.9
11.1
17
Bushing
49 - 196 kN 15 - 20 ton)
18,
x
Press-fitting
force
19
Regular
Master
pin
pin
196 - 294 kN I20 - 30 ton}
% : Dry type track link
D155AX-5
40-47
TRACK SHOE
STANDARD
MAINTENANCE
Unit: mm
NC
Check
link
588.4 f 58.8 160 + 61
20
Shoe
tightening
(deg.)
Additional
angle
torque
Tightening
(Nm {kgm))
a. Regular
Remedy
Criteria
item
120 + IO
Retighten
bolt
Additional tightening
angle (deg.)
Tightening torque
(Nm IkgmI)
b. Master
Lower limit torque

Wm IkgmI)
link
588.4 f 58.8 (60 f 6)
882.6
180 + 10
190)
No. of shoes (each side)
21
Interfere1
bushing
size
------
Che.f=+
I
22
23
between
Interference
regular pin and link
+0.484
+0.434
48.5
Shaft
+0.484
+0.334
48.5
*X
24
between
Interference
master pin and link
25
Clearance between
master pin and bushing
I
Hole
Standard
clearance
+0.664
+O. 164
0.230 0.830
Tolerance
Standard
size
Shaft
Hole
Standard
interference
Tolerance
Standard
size
9%
0.372 0.584
Tolerance
Standard
size
Clearance between
regular pin and bushing
-0.038
-0.100
Shaft
I
Standard
clearance
Hole
I
Adjust or
replace
.X : Dry type track link
40-48
D155AX-5
MAINTENANCE
STANDARD
TRACK SHOE
SINGLE SHOE
SED01627
Unit: mm
Criteria
Check item
No.
Standard
1
Remedy
Repair
size
limit
Height
30
80
2Thiiineri
17
Length
at bottom
33
Length
at top
15
D 155AX-5
Repair
replace
or
MAINTENANCE
SUSPENSION
STANDARD
SUSPENSION
-1
-1
(56?6kgm)
(56+6kgm)
A-A
B-B
SKD00450
40-50
D 155AX-5
MAINTENANCE
STANDARD
SUSPENSION
9275103Nm
(94.5210.5kgm)
\
I\
2
i
C-C
(Left side)
C-C
(Right side)
SKW0451
Unit:
No
-
Check
item
Criteria
Clearance between pivot

shaft and bushing (inner)
Standard
size
Clearance between pivot

shaft and bushing (outer)
Clearance between
pin and bushing
center
Clearance between
pin and bushing
side
Clearance
between side pin

surface of
bushing
Hole
Standard
clearance
+0.125
+0.085
0.2300.333
1.0
148
-0.145
-0.208
+0.125
+0.085
0.230 0.333
1.0
-0.120
-0.174
+0.279
+0.190
0.310 0.453
1.0
75
-0.048
-0.078
0
-0.015
0.033 0.078
1.0
82
-0.1
-0.3
+0.3
+O.l
0.2 - 0.6
1.0
85
Press-fitting force for pivot

shaft bushing (inner)
1.96 - 38.2 kN (0.2 - 3.9 ton1
Press-fitting force for pivot

shaft bushing (outer)
0.98 - 33.3 kN IO.1 - 3.4 ton)
Press-fitting
pin bushing
D155AX-5
force for side
Clearance
limit
-0.145
-0.208
E and spherical
Shaft
Remedy
175
2
Tolerance
mm
43.1 - 213.8 kN 14.4 - 21.8 ton)
Replace
bushing
40-51
MAINTENANCE
WORK EQUIPMENT
STANDARD
WORK EQUIPMENT
PUMP
PUMP
SAR(4)112
1279*29Nm
(28.5~3kml
SWDO2768
Unit: mm
No
Remedy
Criteria
Check item
Standard
clearance
Clearance
Side clearance
Clearance between plain

bearing inner diameter and
0.11 - 0.16
0.19
0.060 - 0.140
0.20
Replace
Standard
3
Pin driving
Tolerance
size
depth
0
-0.5
21
Spline
shaft rotation
temperature:
40-52
11.8 - 19.6 Nm II.2
torque
Speed
Delivery
45 - 50C
limit
2,200
rpm
Delivery
pressure
20.6 MPa
1210 kg/cm*}
- 2.0 kgm)
Standard
delivery
233 .r?/min
I---Delivery
limit
215 L?/min
D 155AX-5
MAINTENANCE
HSS PUMP
STANDARD
HSS PUMP
HPVl60
20.15*2.45Nm
(2.05*0.25kd
SWD02941
D 155AX-5
40-53
MAINTENANCE
STANDARD
HSS MOTOR
HSS MOTOR
373-t49Nm
(38* 5kPml
55002775
Unit: mm
No.
Check item
Criteria
Standard
Spool
40-54
return spring
Remedy
Repair
size
Free length
xOD
Installed
length
Installed
load
Free
length
45.74 x 24
36.0
115.7 N
{I 1.8 kg)
limit
Installed
load
92.6N
19.5 kg1
Replace
spring
if damaged
or deformed
D 155AX-5
MAINTENANCE
PPC VALVE
STANDARD
PPC VALVE
For blade
112.7214.7Nm
(11.511.5kgm)
44.124.9Nm
(4.520.5kgm)
14.4+1.9Nm
(1.47?0.2kgm)
13.2k1.47Nm
(1.3550.15kgm)
-6.37+2.45Nm
(0.65=0.25kgm)
-8.34i2.45Nm
(0.85?0.25kgm)
40-56
7.36?1.47Nm
(0.75k0.15kgm)
SKD00595
D155AX-5
MAINTENANCE
PPC VALVE
STANDARD
Unit: mm
No
-
Standard
Centering
(for P4)
size
Repair
limit
spring
Metering spring
(for P3, P4)
Centering
(for P3)
Remedy
Criteria
Check item
spring
Replace
spiing
if damaged
or deformed
Centering spring
(for PI, P2)
Metering spring
(for PI, P2)
Detent spring
(for P4)
7
Detent spring
(for P3)
D 155AX-5
40-57
MAINTENANCE
PCC VALVE
STANDARD
For ripper
112.8t14.7Nm
(11.5&1.5kgm)
13.2+1.5Nm
(1.35+0.15kgm)
44.1-c4.9Nm
(4.5k0.5kgm)
39.2k4.9Nm
(420.5kgm)
8.5t2.5Nm
(0.85t0.25kgm)
2.
SYWO454
Unit: mm
No
Check item
Standard
Centering spring
(for P3, P4)
Remedy
Criteria
Repair
size
limit
Free length
xOD
Installed
length
Installed
load
Free
length
Installed
load
50.05 x 15.5
34
71.4 N
(7.28 kg)
56.9 N
15.8 kg}
Centering spring
(for PI, P2)
50.35 x 15.5
34
55.9 N
(5.7 kg}
45.1 N
14.6 kg1
Metering
26.53 x 8.15
24.9
16.7 N
il.7 kg}
13.7 N
Il.4 kg1
spring
Replace
spring
if damaged
or deformed
D155AX-5
MAINTENANCE
STEERING
STEERING LEVER
STANDARD
LEVER
SWD02788
Unit: mm
No.
Standard
Spring
Spring
D 155AX-5
Remedy
Criteria
Check item
size
Repair
limit
Installed
load
Free length
x OD
Installed
length
Installed
load
Free
length
45.8 x 75.5
32
73.5 N
17.5 kg}
58.8N
16.0 kg1
49 x 7.0
25
5.88 N
IO.6 kg1
4.7 N
IO.48 kg}
Replace
spring
if damaged
or deformed
40-59
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
MAIN CONTROL VALVE

*
Precautions when tightening

portions
marked -X.
To ensure that the 3 bolts are tightened evenly, tighten the bolts in three
mx
steps as follows.
1st pass: 58.8 + 9.8 Nm (6 f 1 kgm)
2nd pass: 137.3 f 9.8 Nm (14 + 1 kgm}
3rd pass: 186.3 + 9.8 Nm (19 f 1 kgm}
W-C
31.4*2.9Nm
(3.2+0.3koml
34.3*4.9Nm
(3.5*0.5kml
K4
23.5*3.9Nm
12.4*0.4keml
SAD01560
40-60
D155AX-5
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
66.b7.4Nm
(6.75&0.75kgm)
a=
\m
//Llzz&ulL
66.227.4Nm
(6.75+0.75kam)
tEl
46.627.4Nm
(4.75+0.75kgm)
A-A
/
139.7222.1Nm
(14.25k2.25kgm)
m
321.2+46.6Nm
(32.75-c4.75kgm)
a=
152.0k24.5Nm
(15.5+2.5kgm)
@210.8+29.4Nm
(21.5+3.0kgm)
B-B
@147.1-c9.8Nm
(15elkgm)
@419.2+46.6Nm
(42.75=4.75kgm)
7.4-cl.5Nm
(0.75+0.15kgm)
SAD00456
D155AX-5
40-61
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
a=
127.5-cl9.6Nm
(13+2kgm)
186.3+9.8Nm
(19+lkgm)
147.1+9.8Nm
(15-clkgm)
23.523.9Nm
,(2.4=0.4kgm)
\
139.7+22.1Nm
(14.25~2.2 kgm)
K
D-D
SAD00457
Unit: mm
No.
Check item
Spool return spring

(for blade LIFT only)
Spool
Spool return spring

(for blade LIFT [FLOAT])
Load check valve spring
return
spring
or deformed
7
7
Back pressure
Relief valve
Relief valve spring
40-62
valve
spring
spring
(45.1 kg)
118.4 x 19.5
92.5
443.23 N
l45.2 kg1
354.98 N
(36.2 kg1
99.5 x 14.9
96
71.58 N
(7.3 kg}
56.87 N
i5.8 kg1
16.3 x 21.3
2.16N
IO.22 kg}
0.98 N
(0.10 kg1
20 x 7
13.7
1.27 N
IO.13 kg1
19.02 N
II.94 kg1
D155AX-5
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
68.629.8Nm
(7alkgm)
23.5+3.9Nm
(2.4&0.4kgm)
(1.15-cO.15kgm)
J-J
34.3k4.9Nm
(3.5+0.5kgm)
,,,/
K-K
?2=
66.2+7.4Nm
(6.75?0.75kgm)
E-E
SAD004S3
D155AX-5
40-63
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
186.3*9.8Nm
(19*1kml
CsJ
23.5*3.9Nm
(2.4*0.4bm)
F-F
68.6*9.8Nm
(7*lksml
G-G
H-H
SAD01561
Unit: mm
No
-
Remedy
Check valve spring

spool
inside
Replace
spring
if damaged
or deformed
Dl !%AX-5
MAINTENANCE
WORK EQUIPMENT
.
WORK EQUIPMENT CYLINDER
STANDARD
CYLINDER
BLADE LIFT CYLINDER
110.3+12.3Nm
(11.25t1.25kgm)
981+98Nm
(100+10kgm)
SAD00460
BLADE TILT CYLINDER
110.3+12.3Nm
(11.25+1.25kgm)
343234.3Nm
(35+3.5kgm)
SAD00461
PIN PULLER CYLINDER
441244Nm
(45.0+4.5kgm)
40-66
SBD00462
D155AX-5
MAINTENANCE
STANDARD
Unit: mm
NC
Check item
Criteria
Tolerance
Shaft
Clearance
between oiston
rod and bushing
Blade
TILT
g0
1.1;Clearance between
piston rod spherical
surface and blade
ball portion
Clearance between
zylinder support shaft
bushing and yoke
Hole
,.,,
-0.036
-0.123
+0.270
+0.061
0.097 0.393
-0.065
-0.117
+0.133
+0.007
0.072 0.250
-0.200
-0.300
+0.030
0
0.200 0.330
-0.120
-0.207
+0.054
0
0.120 0.261
65
Blade
TILT
115
-0.200
-0.300
+0.300
0
Pin
puller
2g
-0.100
-0.200
+I .300
+I.200
;;;;e
60
-0.300
-0.500
+0.174
+O.lOO
Clearance between
E zylinder bottom sup- lfi,,,
port shaft and boss
26
-1.1
-1.2
fO.l
Clearance between
;+$;r&b~;;;u;;;-g
Clearance
limit
1
0.675
0.673
I
Blade
LlFT
Standard
clearance
+0.27 1
+0.075
65
--I
-0.030
-0.104
Blade
LIFT
Clearance between
piston rod spherical
surface and cap
Remedy
0.55
1.0
Replace
0.5
D 155AX-5
40-67
MAINTENANCE
STANDARD
245+24.5Nm
(25t2.5kgm)
110.3-c12.3Nm
(11.25+1.25kgm)
SAD00463
245+24.5Nm
(25a2.5kgm)
40-68
110.3e.12.3Nm
(11.25s1.25kgm)
SAD00464
D155AX-5
MAINTENANCE
STANDARD
Unit: mm
Remedy
Criteria
Check item
No
-
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
Clearance between
1 piston rod and

bushing
Clearance between
piston rod support
shaft and bushing
$&?;r!ccbrff;~en
support shaft and
bushing
D155AX-5
Ripper
LIFT
80
-0.030
-0.104
+0.271
+0.061
0.091 0.375
0.675
Ripper
TILT
80
-0.030
-0.104
+0.271
+0.061
0.091 0.375
0.675
Ripper
LIFT
85
-0.036
-0.090
+0.207
+0.120
0.156 0.297
1.0
Ripper
TILT
85
-0.036
-0.090
+0.207
+0.120
0.156 0.297
1.0
LIFT
Ripper
85
-0.090
-0.036
+0.120
+0.207
0.156
0.297
1.0
Ripper
TILT
85
-0.036
-0.090
+0.207
+0.120
0.156 0.297
1.0
Replace
40-69
MAINTENANCE
STANDARD
QUICK DROP VALVE
QUICK DROP VALVE

.
FOR BLADE LIFT CYLINDER
SED00465
Unit: mm
No.
Check item
Clearance
and valve
between
body
Criteria
Tolerance
Standard
size
spool
Shaft
38.0
-0.011
-0.016
I
Valve
40-70
spring
Hole
Standard
clearance
+O.OlO
0
0.011 0.026
Standard
Remedy
size
Clearance
limit
0.03
I
Repair
limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
75.2
55.9
136.3 N
(13.9 knl
67.7
122.6N
(12.5 kg}
Replace
D155AX-5
CYLINDER STAY
STANDARD
MAINTENANCE
CYLINDER STAY
SAD00466
Unit: mm
No
-
Check
Clearance
between
1 yoke and bushing
Clearance between
2 yoke
and bushing
D155AX-5
Remedy
Criteria
item
cylinder
cylinder
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
125
-0.172
-0.235
+0.063
0
0.172
0.298
0.5
100
-0.170
-0.224
io.054
0
0.170 0.278
0.5
Replace
40-71
MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
SEMI U-DOZER
10
?4
I
k
A-A
I
D-D
E-E
F-F
G-G
SED00467
40-72
D155AX-5
MAINTENANCE
STANDARD
WORK EQUIPMENT
Unit: mm
No.
Criteria
Check item
Clearance
and pin
between
Tolerance
Standard
size
brace
Shaft
Hole
Remedy
Standard
clearance
Clearance
limit
60
-0.3
-0.5
+0.5
+0.3
0.6 - 1.0
60
-0.3
-0.5
+0.5
+0.3
0.6 - 1.0
3 Clearance between brace

spherical surface and cap
115
-0.2
-0.3
+0.3
0
0.2 - 0.6
Clearance between center

4 brace spherical surface
and cap
115
-0.2
-0.3
+0.3
0
0.2 - 0.6
Clearance between
and blade bracket
joint
120
-0.2
-0.7
+0.5
+0.3
0.5 - 1.2
Clearance between
and frame
joint
120
-0.2
-0.7
+0.5
+0.3
0.5 - 1.2
60
-0.3
-0.5
+0.3
0
0.3 - 0.8
2 Clearance between
pin and bracket
7 Cjearance between
pm and joint
brace
frame
Replace
Adjust shims
or replace
Replace
8
Clearance between
pin and frame
frame
60
-0.3
-0.5
+0.3
0
0.3 - 0.8
Clearance between blade

bracket pin and joint
60
-0.3
-0.5
+0.3
0
0.3 - 0.8
lo

bracket pin and bracket
+;3
1 0.3 - 0.8
-0.2
-0.3
+0.3
0
0.2 - 0.6

and cap
60
115
2:;
3
1
center
link
85
-0.3
-0.5
+0.3
0
0.6 - 0.8
13 Clearance
center
hnk pin andbetween
blade bracket
85
-0.3
-0.5
+O.l
-0.1
0.2 - 0.6
I2
Clearance between
link pin and center
/
Adjust shims
or replace
Replace
l4

link and blade bracket
15 Clearance between trunnion

and cap spherical surface
D155AX-5
196
-0.1
160
-0.5
-1.0
+0.3
+0.5
0.3 - 0.6
+0.5
0
0.5 - 1.5
40-73
MAINTENANCE
STANDARD
WORK EQUIPMENT
U-DOZER
6 10
14
12
13
k
A-A
c-c
7.
D-D
E-E
F-F
G-G
SEW0468
40-74
D 155AX-5
MAINTENANCE
STANDARD
WORK EQUIPMENT
Unit: mm
No.
Check item
I
Criteria
Tolerance
Standard
size
, Clearance between brace

and pm
Remedy
Shaft
60
Hole
-0.3
-0.5
+0.5
+0.3
-0.3
-0.5
+0.5
+0.3
Standard
clearance
Clearance
limit
0.6 - 1.0
Replace
Clearance between brace

2 pin and bracket
60
3 Clearance between brace

spherical surface and cap
0.6 - 1.0
2
1
115
-0.2
-0.3
+0.3
0
0.2 - 0.6

and
cap
115
-0.2
-0.3
+0.3
0
0.2 - 0.6
5 Clearance between joint

and blade bracket
120
-0.2
-0.7
+0.5
+0.3
0.5 - 1.2
and frame between joint

6 Clearance
I
120
-0.2
-0.7
+0.5
+0.3
Adjust shims
or replace
0.5 - 1.2
I
7 Clearance between frame

ptn and joint
60
-0.3
-0.5
+0.3
0
8 Clearance between frame

pin and frame
60
-0.3
-0.5
+0.3
0
0.3 - 0.8
3
Replace
9 Clearance between blade

bracket pin and jornt
I
60
I
-0.3
-0.5
+0.3
0

bracket pin and bracket
0.3 - 0.8
0.3 - 0.8
60
-0.3
-0.5
io.3
0
0.3 - 0.8

and
cap
115
-0.2
-0.3
+0.3
0
0.2 - 0.6

link pin and center link
85
-0.3
-0.5
io.3
0
lo
I2
I
0.6 - 0.8
I
Adjust shims
or replace
2
,
13 Clearance between center

link pin and blade bracket
85

link and blade bracket
196
-0.3
-0.5
+O.l
-0.1
0.2 - 0.6
-0.1
+0.3
+0.5
0.3 - 0.6
-0.5
-1.0
+0.5
0
0.5 - 1.5
Replace
I4
15 Clearance between trunnion

and cap spherical surface
D 155/4X-5
160
40-75
MAINTENANCE
CUlTlNG
WORK EQUIPMENT
STANDARD
EDGE, END BIT
m
,
1495+162Nm
(152.5+16.5kgm)
149Eel62Nm
(152.5+16.5kgm)
SDD00469
Unit: mm
Standard
1
Height
of outside
Remedy
Criteria
Check item
No.
of end bit
size
Repair
415
300
662
500
limit
Replace
2
Width
Height
of inside of end bit
330
260
Height
of cutting
330
260 (215 to turning)
40-76
of end bit
edge
Turn
or replace
Dl PAX-5
MAINTENANCE
STANDARD
WORK EQUIPMENT
MULTI-SHANK RIPPER
GIANT RIPPER
A-A
B-B
SDD00470
40-78
D155AX-5
MAINTENANCE
WORK EQUIPMENT
STANDARD
Unit: mm
No,
Criteria
Check item
Clearance between arm

1 mounting pin and
mounting bracket
Remedy
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
110
-0.036
-0.090
+0.207
+0.120
0.156 0.297
1.5

2 mounting pin and bushing
110
-6.036
-0.090
+0.520
+0.312
0.348 0.610
1.5

3 mounting pin and beam
bracket
110
-0.036
-0.090
+0.207
+0.120
0.156 0.297
1.5

4 mounting pin and bushing
110
-0.036
-0.090
+0.520
+0.312
0.348 0.610
1.5
1.4 - 2.6
10.0
Clearance
5 mounting
holder
Clearance
6 mounting
hole
-
between shank
pin and shank
Shaft
Hole
+0.300
-0.300
75
77
I
between shank
pin and shank
Shaft
Hole
+0.300
-0.300
I
+0.300
-0.300
75
80
+O.lOO
-0.100
4.6 - 5.4
I
Replace
15.0
I
Repair limit
Standard size
7 Wear of point
8 Wear of protector
-
D155AX-5
115
90
40-79
90 OTHERS
Work equipment hydraulic circuit and

HSS circuit diagram ............................. 90- 3
Machine equipped with pitch dozer ...... 90- 5
Electric circuit diagram (1/3)
(Serial No. 70001-75000) ......................... 90- 7
(Serial No. 70001-75000) ......................... 90- 9
(Serial No. 70001-75000) ........................ 90-11
(Serial No. 75001 and up) ...................... 90-13
(Serial No. 75001 and up) ...................... 90-15
(Serial No. 75001 and up) ...................... 90-17
Electric circuit diagram inside cab
(Serial No. 75001 and up) ...................... 90-19
D155AX-5
90-1
3

Serial No. 70001 75000
D155AX-5
90-7
3

Serial No. 70001 75000
D155AX-5
90-9
3

Serial No. 70001 75000
D155AX-5
90-11
3
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB

D155AX-5
90-19
3

D155AX-5
90-13
3

D155AX-5
90-15
3

D155AX-5
90-17
3
Komatsu America international Company

440 North Fairwav Drive
I
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
PROPOSAL
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR

2
NAME OF COMPANY:
PHONE NO:
:
S
DEPARTMENT:
E
R
NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:

D155ax-5 Japan (Eng) Sebd0016205

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SEBM016205

D155AX-5 mounts the SA6D140E-2 or SA6D140E-3 engine.

GENERAL .............................................................................. 01-1

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

TESTING AND ADJUSTING ................................................ 20-1

DISASSEMBLY AND ASSEMBLY ....................................... 30-1

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

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

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

service and repair techniques

for the specific

take the necessary

require the use of tools specially

is used to mark safety precautions

arises or may possibly

arise, first consider

Read the Operation

out any greasing

read all the precautions

and parts in their correct

keep the work area clean and make

sure that there is no dirt or oil on the floor.

given on the decals

only in the areas provided

ing. Never smoke while working.

are fixed to the machine.

out any operation,

wear safety shoes and helmet.

or clothes with buttons

safety glasses when

repairs are needed,

shield, cap and other clothes suited for welding work.

step of the operation.

agree on the operstarting.

form your fellow workers

before starting any

REPAIR signs on the controls

the correct way to use them.

bucket or any other work equipment

ing signs on them.

all mud and oil from

other places used to get on and off the machine. Always

to lock all the control levers and hang warn-

safety pin or use blocks to prevent the work

5. Keep all tools

on hard, level ground,

block the wheels

ing parts with a grinder,

park the machine

parts with a hammer.

actions to deal with the situation.

keep tools and removed

fully. If any dangerous

and safe. Some of these techniques

use the handrails,

on or off the machine.

on or off the machine.

steps, use a stand to provide

19. Be sure to assemble