SEBM005207

Shop
Manual

D155AX
Super Dozer

SERIAL NUMBERS D155AX=3 - 60001 mdw

This material is proprietary to Komatsu America international Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.

It is our policy to improve our products whenever it is possible and practical to do so. We resew the right to make
changes or add improvemet& at any time without incurring any obligation to install such changes on products sold
previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.

December 1997 Coovriaht 1997 Komatsu America Intemational Comoanv 00-l

0
 CONTENTS

No. of page

01 GENERAL . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . ...~..................................... 01-I

‘IO STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . ...*............. 10-I

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I

30 DISASSEMBLY AND ASSEMBLY . . . . . ...m...................*.......... 30-I

40 MAINTENANCE STANDARD . . . . . . ...n..................................... 40-I

8
5
E;

00-2
0
SAFETY SAFETY NOTICE

SAFETY

r--
SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.

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

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.

2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for weld- ing signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21 When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.

14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity. bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane. rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.

16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.

18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.

00-4
FOREWORD GENERAL

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.

00-5
FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....I is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
volume to cover all REVISIONS
Attachments volume:
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.

FILING METHOD
1. See the page number on the bottom of the Symbol 1 Item Remarks
page. File the pages in correct order.
Special safety precautions are

--LI a
Following examples show how to read the
Safety necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3 or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
TT T Places that require special at-
Unit number (I. Engine) tention for the tightening
Item number (2. Testing and torque during assembly.

Adjusting) Places to be coated with ad-

Consecutive page number for hesives and lubricants, etc.
each item.

@I
Places where oil, water or fuel
Oil, water must be added, and the ca-
Additional pages: Additional pages are indi- pacity.
I
cated by a hyphen (-1 and number after the
Places where oil or water
page number. File as in the example. - : Drain must be drained, and quan-
Example: tity to be drained.

1o-4 12-203

1o-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
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
the part to the relative
2) Check for existence
of all bolts fastening
parts.
of another part caus-
100% 88%
;EB
79% 71% 41%
SAM)0479

3) Do not sling a heavy load with one rope

ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.

A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:

Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
When hoisting a load with two or more
without galvanizing)
ropes, the force subjected to each rope
Rope diameter r Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
IO 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN (2000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 (1000 kg} when two ropes make a 120”

20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN 14000 kg) if they sling
30 98.1 10.0
a 19.6 kN 12000 kg} load at a lifting angle
40 176.5 18.0 of 150”.
AII LY
50 274.6 28.0

60 392.2 40.0

* The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.

I
2) Sling wire ropes from the middle portion
30 60 90 120 150
of the hook. Lifting angle (decree) SAD00480

00-7
FOREWORD COATING MATERIALS

COATING MATERIALS
Ir The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
Ir For coating materials not listed below, use the equivalent of products shown in this list.

Category K omatsu code Part No. o’w Container Main applications, features
-
l Used to prevent rubber gaskets, rubber
LT-IA 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
-
l Used in places requiring an immediately
effective, strong adhesive. Used for plas-
20 9 ‘olyethylene
LT-1 B 790-129-9050 tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
-
l Features: Resistance to heat and chemi-
‘olyethylene cals
LT-2 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.
-
790-129-9060 idhesive: l Used as adhesive or sealant for metal, glass
(Set of adhe- 1 kg and plastic.
LT-3 sive and lardening Can
hardening agent:
agent) 500 g
Adhesives -
‘olyethylens l Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
-
Holtz l Used as heat-resisting sealant for repair-
790-126-9120 75 g Tube
MH 705 ing engine.
-
l Quick hardening type adhesive
Three bond ‘olyethylene l Cure time: within 5 sec. to 3 min.
790-i29-9i4a 50 g Used mainly for adhesion of metals, rub-
1735 container l

bers, plastics and woods.

-
l Quick hardening type adhesive
l Quick cure type (max. strength after 30 min-
Aron-alpha ‘olyethylene
790-129-913a 29 utes)
201 container
l Used mainly for adhesion of rubbers, plas-
tics and metals.
-
l Features: Resistance to heat, chemicals
Loctite ‘olyethylene
79A-129-911f 50 cc l Used at joint portions subject to high tem-
646-50 container
peratures.
-
l Used as adhesive or sealant for gaskets
LG-1 790-129-901a 200 g Tube
and packing of power train case, etc.
-
Features: Resistance to heat
Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant 790-129-907c to prevent seizure.
LG-3 1 kg Can
Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.

00-8
FOREWORD COATING MATERIALS

Category Komatsu code Part No. o’ty Container Main applications, features

l Features: Resistance to water, oil

l Used as sealant for flange surface, thread.

I LG-4
17go-12g-go201 2oo ’ 1 Tube 1
l

l
Also possible to use as sealant for flanges
with large clearance.
Used as sealant for mating surfaces of fi-
nal drive case, transmission case.

l Used as sealant for various threads, pipe

Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container l Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.

l Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.

l Features: Silicon based, quick hardening

type
LG-7 09920-00150 150 g Tube l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.

Three bond l Used as heat-resisting sealant for repairing

1790-129-90901 100 g I Tube I engine.
1211
I I I I I
I

l Used as lubricant for sliding portion (to pre-

LM-G
Molybde- 1 ogg40-ooo51 1 ” 9 1 Can 1 vent from squeaking).
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
I I I I I

SYG2-4OOLl l General purpose type

SYG2-350LI
G2-LI SYG2-4OOLI-A Various Various
SYG2-16OLI
SYGA-16OCNLI

l Used for normal temperature, light load

SYG24OOCA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GP-CA SYGZ-4OOCA-A Various Various
SYG2-16OCA
SYGA-16OCNCA
I I I I
t

1Mf!$Er/ SYG2-400M 1 (r{r ISelows type1

l Used for places with heavy load

00-9
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Use these torques for metric bolts and nuts. (Always use torque wrench).

Thread diameter Width

of bolt across flats

m-
mm mm Nm km

6 10 13.2f 1.4 1.35kO.15

8 13 31f3 3.2kO.3
10 17 66f7 6.7kO.7
12 19 113flO 11.5+1
14 22 177+19 18f2

16 24 279+30 28.5f3
18 27 382f39 39f4
20 30 549f59 56f6
22 32 745f83 76f8.5
24 36 927f103 94.5+ 10.5

27 41 1320f140 135+15
30 46 1720f190 175f20
33 50 2210+240 225f25
36 55 2750f290 280+30
39 60 3290f340 335f35

Thread diameter Width

of bolt across flats

mm mm Nm bm
6 10 7.85f 1.95 0.8kO.2
8 13 18.6f4.9 1.9f0.5
IO 14 40.2f5.9 4.1k0.6
12 27 82.35f7.85 8.4f0.8

TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 19 24.5? 4.9 2.5f0.5
03 18 24 49k19.6 5f2
04 22 27 78.5f 19.6 8f2
05 24 32 137.3k29.4 14f3
06 30 36 176.5f29.4 18f3
10 33 41 196.lf49 20f5
12 36 46 245.2f 49 25+5
14 42 55 294.2* 49 30+5

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
Thread diameter Width across flat Tightening torque

mm mm Nm km

10 14 65.7+ 6.8 6.7f0.7

12 17 112k9.8 11.5fl
16 22 279f29 28.5f3

00-l0
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 34.3k 4.9 3.5kO.5
03,04 20 Varies depending on 93.1 k 9.8 9.5f 1
05,06 24 type of connector. 142.lf 19.6 14.5+2
IO,12 33 421.4+ 58.8 43+6
14 42 877.1f132.3 89.55 13.5

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Thread diameter Width across flat Tighteni 4 J torque

Nominal No.
mm mm Nm kgm
08 8 14 7.35k1.47 0.75kO.15
10 10 17 11.27f 1.47 1.15f0.15
12 12 19 17.6451.96 1.8f0.2
14 14 22 22.54-1:1.96 2.3f 0.2
16 16 24 29.4f 4.9 3f 0.5
18 18 27 39.2+ 4.9 4f0.5
20 20 30 49f 4.9 5f0.5
24 24 32 68.6k9.8 7fl
30 30 32 107.8+_ 14.7 11+ 1.5
33 33 - 127.4f 19.6 13f2
36 36 36 151.9f24.5 15.5f2.5
42 42 - 210.7f29.4 21.5f3
52 52 - 323.4f 44.1 33f 4.5
- - -

TIGHTENING TORQUES OF FLARE NUT

SAW0483
Use these torques for O-ring boss connector

Thread diameter Width across flat Tightening torque

mm mm Nm kgm
I I I

14 19 24.5+4.9 2.5f0.5
18 24 49f 19.6 5+2
22 27 78.5+ 19.6 8f2
24 32 137.3k29.4 14f3
30 36 176.5529.4 18f3
33 41 196.1+49 2055
36 46 245.2f 49 25f5
42 55 294.2+49 30f5

00-l 1
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

Use these torques for metric bolts and nuts of 102 Series Engine.

Thread diameter Tightening torque

mm Nm kgm
6 IO?2 1.02 f 0.20
8 24 + 4 2.45 f 0.41
IO 43 f 6 4.38 + 0.61
12 77 f 12 7.85 + 1.22

TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

Use these torques for metric eye joints of 102 Series Engine.

Thread diameter Tightening torque

mm Nm kgm
6 8f2 0.81 f 0.20
8 10 f2 1.02 + 0.20
10 12 f2 1.22 f 0.20
12 24 f 4 2.45 f 0.41
14 36 f 5 3.67 f 0.51

TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)

Use these torques for inches tapered screws of 102 Series Engine.

Thread diameter Tightening torque

inches Nm kgm
l/16 3fl 0.31 f 0.10
118 8+2 0.81 + 0.20
l/4 12f2 1.22 f 0.20
318 15 f 2 1.53 f 0.41
112 24 f 4 2.45 + 0.41
314 36 f 5 3.67 f 0.51
1 60 i 9 6.12 f 0.92

00-l 2
FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire
rJmlnle~l CaylezjD. Curre;$rating
N~t~a~;aof Dia. ;Ifnstr$nds Cross se4tion rn Applicable circuit
m I I
0.85 11 ~~1 0.88 1 2.4 1 12 1 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1

5 65 0.32 5.23 4.6

15 84 0.45 13.36 7.0 59

I I I I I Starting (Glow plug)

40 85 0.80 42.73 11.4

60 127 0.80 63.84 13.6

100 217 I 0.80 109.1 I 17.6 I 230 I Starting

CLASSIFICATION BY COLOR AND CODE

Circuits

pr- Zlassi-
\
ication
Charging Ground Starting Lighting Instrument Signal Other

pri_ Code W B B R
1
marY t Color White Black Black Red

WR - BW RW
2
White & Red - Black & White Red & White Yellow & Red IGreen & White IBlue & White

WB - BY RB YB I GR I LR
3
White & Black - Black & Yellow Red & Black Yellow & Black Green & Red I I Blue & Red
4ti Code WL - BR RY YG GY LY
4
iary
t Color White & Blue - Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow

I
Code WG - - RG YL GB LB
5
Color Red & Green Yellow & Blue Green & Black Blue & Black

Code RL YW GL -
6
Color - I-I - Red & Blue Yellow&White Green & Blue -

00-l 3
FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.

EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as @, 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 0.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. 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 1 mm = 0.03937 in

0 1 2 3 4 5 ; 6 7 8

0 0 0.039 0.079 0.118 0.157 0.197; 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591; 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 j 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 i 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 i 1.811 1.850 1.890 1.929
@ j
.. . . . . .. . ..1.969
. . ..50 .2.008 .2.047 . 2.087 .2.126 ~2.165 2.205 2.244 2.283 2.323
a-- 60
. .. . . . . . .
I 2.362
. .. . . . . .. .
2.402
.. .. . . .. ..
2.441
. .. . . . . . . .
2.480
.. . . . . .. .
2.520 2.559 2.598 2.638 2.677 2.717
2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-14
FOREWORD CONVERSIONTABLE

Millimeters to Inches
1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

- - - - -

Kilogram to Pound
1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
\

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12

70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17

80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
,
90 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
I

198.42 d 1 1

00-15
FOREWORD CONVERSIONTABLE

Liter to U.S. Gallon

lt = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019

20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661

30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303

40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586

60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228

70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870

80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511

90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon

.._- _._..,.,, . ... . _...

0
I 1
I 2
3 I 4 I 5 I 6 17 I 8I g
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179

20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579

40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978

60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178

70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378

80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577

90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-16
FOREWORD CONVERSIONTABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9
\

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4

20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1

40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8

60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1

70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4

80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7

90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4

110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7

120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1

130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4

140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0

160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4

170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7

180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0

190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-l 7
FOREWORD CONVERSIONTABLE

kg/cm* to lb/in*
1 kg/cm2 = 14.2233 lb/in2
T

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2

20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5

30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2

60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

70 995.6 1010 1024 1038 1053 1067 081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 223 1237 1252 1266

90 1280 1294 1309 1323 1337 1351 365 1380 1394 1408

100 1422 1437 451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 593 1607 1621 1636 1650 1664 1678 1693

120 1707 1721 735 1749 1764 1778 1792 1806 1821 1835

130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977

140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-18
FOREWORD CONVERSION TABLE

Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8”F

“C “F “C “F “C “F “C “F 1
-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 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 66 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-19
01 GENERAL

Specification drawing .................................... Ol- 2

Specifications ................................................. Ol- 4
Weight table .................................................. .Ol-10
Table of fuel, coolant and lubicants ............ .Ol-12

01-l
GENERAL SPECIFICATION DRAWING

SPECIFICATION DRAWING
l Semi U-tiltdozer + giant ripper

- Unit:mm

3210 2510
I . s
8155 :
& f

SD000304

l U-tiltdozer + giant ripper

3210 2510
I-
8550

SDD00305

01-2
GENERAL SPECIFICATION DRAWING

. Semi U-tiltdozer + multi-shank ripper

Unit: mm

G.L

. U-tiltdozer + multi-shank ripper

SDW0378
GENERAL SPECIFICATIONS

SPECIFICATIONS

Machine model D155AX-3

Serial number 60001 - 60279 60280 and up

f
Bare tractor kg 28,400

I
With semi U-dozer + variable multi-shank ripper kg 38,500
+ ROPS + cab + air conditioner + side cover

Minimum turning radius (center of machine) m 1.05

Gradeability deg 30
Stability (front, rear, left, right) deg 35
-
Continuous speed control
e
E Low speed - high speed km/h 0 - 11.2
2
-
Continuous speed control
8
t Low speed - high speed km/h 0 - 13.9
5
CT

Bare tractor kPa{kg/cm*} 77.47{0.79}

With semi U-dozer + variable multi-shank rip- kPa{kg/cm*} 104.92{1.07}
per + ROPS + cab + air conditioner + side
cover
With U-dozer + variable multi-shank ripper + kPa{kg/cm*} 105.90{1.08}
ROPS + cab + air conditioner + side cover

Bare tractor mm 4,975

With semi U-dozer + variable multi-shank rip- mm 8,155

per
With U-dozer + variable multi-shank ripper mm 8,550

Bare tractor mm 2,695

With semi U-dozer + variable multi-shank rip- mm 3,955

per

With U-dozer + variable .multi-shank ripper mm 4,265

To top of exhaust pipe mm 3,395

To top of cab mm 2,555

(to top of control lever)
GENERAL SPEClFldATlONS

Machine model D155AX-3

Serial number 60001 - 60279 60280 and up

With cab installed mm 3,365

With ROPS canopy installed mm 3,500

With canopy installed mm 3,500

Track gauge mm 2,100

Length of track on ground (mm) mm 3,210

Track shoe width (standard) mm 560

Minimum ground clearance mm 485

(To bottom surface of undercover)

Name S6D140-1 SAGD 140-2

I-cycle, watercooled, 4cycle, water-cooled,
Type of engine n-line, vertical type, di- in-line, vertical type, di-
‘ect injection, with tur- rect injection, with tur-
locharger bocharger, aftercooler

No. of cylinders - Bore x Stroke mm 6-140x165 6-140x165

Piston displacement e ICC1 15.24{15,240) 15.24{15,240}

Flywheel horsepower kW/rpm{HP/rpmI 225/l ,900{302/1,9001

t? Max. torque Nm/rpm{kgm/rpmI 1,432/l ,250{146/1,250)

5
E Max. speed at no load rpm 2,050

5 Min. speed at no load rpm 700

Min. fuel consumption ratio g/kWh{g/HPhI 205U531

Starting motor 24V, IlkW

Alternator 24V, 35A

Battery 12V, 170Ahx2

Radiator core type D-7

Planetary gear, multiple disc clutch + hydro-

static transmission,hydraulically actuated
HMT (electrical type), force-feed lubrication
gear pump, forward 3-speed, reverse 3-
speed (automatic transmission)

01-5
a
GENERAL SPECIFICATIONS

Machine model D155AX-3

Serial number 60001 - 60279 60280 and up

I
Variable swash plate type (HPV160)
Max. delivery pressure : 41.2 MPa {420 kg/cm*}
Theoretical delivery : 298 e /min/1,861 rpm

Variable swash plate type (HMV160+160)

Max. pressure: 41.2 MPa (420 kg/cm*}
.E
s Bevel gear shaft Spiral bevel gear, force-feed lubrication gear pump
5
2 Differential planetary gear type, driven by hydraulic mo-
a H HSS steering system tor, manual type, hydraulically actuated
s -
Wet type, multiple clutch disc, spring boosted, hydrauli-
S Master brake
cally actuated, pedal operated

Spur gear l-stage, planetary gear l-stage, splash type

Final drive
lubrication pump

Suspension Rigid, balancing beam type

2 each side

6 each side

Assembly type, single grouser, 41 each side, pitch: 228.6

Track shoe (560 mm)
mm

Power train + lubrication pump (tandem) Gear type (SAL(3)100+80)

Scavenging pump (tandem) Gear type (112)

Gear type (104)

HMT, PPC charge pump (tandem with scavenging
Max. delivery pressure : 4.4 MPa 145 kg/cm*}
pump (112))
Theoretical delivery : 206 e /min/1,982 rpm

Fixed swash plate type (HMF160)

HSS motor Max. pressure: 41.2 MPa I420 kg/cm*}
Rated flow (theoretical value) : 299 e /min

Variable swash plate type (HPVIGO)

CLSS load sensing type
Max. delivery pressure : 36.3 MPa {370 kg/cm3

01-6
@
GENERAL SPECIFICATIONS

Machine model D 155AX-3

Serial number 60001 - 60279 60280 and up

f

Type 3+1+1 tandem, spool type, hydraulically assisted type

. For HSS
. For blade lift HSS + ripper tilt + ripper lift + blade lift + blade tilt
. For blade tilt
. For ripper lift
. For ripper tilt
.
,

Type Reciprocal, piston type

Cylinder bore mm 120

Piston rod outer diameter mm 75

Max. piston stroke mm 1,347

Max. distance between pins mm 3,187

Min. distance between pins mm 1,836

Cylinder bore mm 180

Piston rod outer diameter mm 90

Max. piston stroke mm 160

Max. distance between pins mm 1,468

Min. distance between pins mm 1,308

Cylinder bore mm 200

Piston rod outer diameter mm 90

Max. piston stroke mm 160

Max. distance between pins mm 1,468

Min. distance between pins mm 1,308

Cylinder bore mm 160

Piston rod outer diameter mm 80

Max. piston stroke mm 510

Max. distance between pins mm 1,538

Min. distance between pins mm 1,028

Cylinder bore mm 160

Piston rod outer diameter mm 80

Max. piston stroke mm 350

Max. distance between pins mm 1,545

Min. distance between pins mm 1,195

01-7
a
GENERAL SPECIFICATIONS

Machine model D155AX-3

Serial number 60001 - 60279 60280 and up

I

Hydraulic tank Box type (control valve externally installed)

Type 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 <SAE 8.8>

Blade width mm 3,955

Blade height mm 1,720

Blade cutting angle deg 52

8
5
Blade lifting height (from ground level) mm 1,250
Z
Blade lowering depth (from ground level) mm 590

Max. blade tilt mm 1,080

Blade cutting angle variation deg +6

Blade capacity m3 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 6

Max. pitch-back angle deg 6

Max. tilt mm 1,080

Max. pitch angle deg 6

Max. pitch-back angle deg 6

01-8
@
GENERAL SPECIFICATIONS

Machine model D155AX-3

Serial number 60001 - 60279 60280 and up

- f I
Max. digging depth mm 870

Max. lifting height mm 925

Ripping angle of point deg 34.5 - 60

Max. beam width mm 2,260

Shank positions Jo. of holes 2

5
E
.-Q

i! Max. digging depth mm 1,220

2
P Max. lifting height mm 925

Ripping angle of point deg 34.5 - 60

Max. beam width mm 1,535

Shank positions 40. of holes 3

01-9
8
GENERAL WEIGHT TABLE

WEIGHT TABLE
a This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model D 155AX-3

Serial number 60001 - 60279 60280 and up

Engine, damper assembly 1,340 1,395

l Engine assembly 1,220 1,275

l Damper assembly 117 117

l Universal joint 18 18

l Engine mount parts (wiring) 3 3

Radiator assembly (including built-in oil cooler) 306

Hydraulic cooler 104 (88 as individual part)

Fuel tank assembly (when empty) 235

Fuel tank assembly (when full) 660

. Power train unit assembly 2,705

. HMT assembly (including PTO) 1,164

. HSS assembly 891

. HMT control valve assembly 87

. Brake valve assembly 15

. PPC charge filter assembly 22

. PPC charge valve assembly 21

. Power train filter assembly 20

. Scavenging pump, PPC charge pump 36

. Power train, lubrication pump 27

. Hydraulic, HSS pump 106

. HSS motor 64

. HMT pump 102

. HMT motor 158

Final drive assembly 1,372x2

Sprocket teeth (12X9)x2

Hull frame assembly 3,182

Track group assembly (each side) 3,755

Track frame 1,224

Idler assembly 410

Recoil spring assembly 508

Bogie, track roller assembly 410x3

Track roller assembly (single flange xl) 97x3

Track roller assembly (double flange xl) 109x3

Carrier roller assemb1.y 45x2

01-10
@
 GENERAL WEIGHT TABLE

Unit: kg

Machine model D155AX-3

Serial number 60001 - 60279 60280 and up

Track shoe assembly (560 mm, wet type) 2,558x2

Pivot shaft assembly 116x2

Equalizer bar 229

Hydraulic tank assembly 102

Hydraulic filter assembly 19
Main control valve 112
(HSS + blade lift + blade tilt + ripper lift + ripper tilt)

Engine underguard 183

Transmission underguard 228

Operator’s seat 42

Semi U-tiltdozer assembly 4,903

l Blade 2,818

l Straight frame 690x2

l Tilt brace 98x1

l Center brace 92x2

l Tilt cylinder assembly 190

8 Semi U-tilt + pitch dozer assembly 5,007

c l Blade 2,818
b l Straight frame 690x2
l Center brace 92x2
l Tilt cylinder assembly 190
l Pitch cylinder assembly 215

Blade lift cylinder assembly 165x2

Multi-shank ripper assembly 3,710

l Bracket, beam 2,014

l Shank 266x3

l Lift cylinder assembly 119x2

l Tilt cvlinder assembly 122x2

Giant ripper assembly 3,135

l Bracket, beam 1,728

l Shank 333x1

l Lift cylinder assembly 119x2

l Tilt cylinder assembly 122x2

l Pin puller cylinder assembly 7

ROPS assembly 480

Cab 285

ROPS canopy 698

Canopy 105

Dashboard 83

Floor frame 310

Side cover 130

Air conditioner assembly 110

01-11
8
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS

TABLE OF FUEL, COOLANT AND LUBRICANTS

KIND OF AMBIENT TEMPERATURE I CAPACITY (t,

RESERVOIR
FLUID

Engine oil pan

Power train case

Final drive case (each side) Engine oil

0’“““““l
Hydraulic system

-1 Gear oil

Bogie (each) 1 1 1 / 1 / 1 1 1 0.21 - 0.23 1 0.21 - 0.23 i-

I

Add antifreeze

* AsrMD975No.1
NOTE:
(I) When fuel sulphur content is less than 0.5 %, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than O”C, be sure to
tenance hours described in this manual. use engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table if SAEl5W-40 even though an atmospheric tem-
fuel sulphur content is above 0.5 %. perature goes up to 10°C more or less in the
day time.
(3) Use API classification CD as engine oil and if
Change interval of oil API classification CC, reduce the engine oil
Fuel sulphur content
in engine oil pan change interval to half.
0.5to 1.0% l/2 of regular interval (4) There is no problem if single grade oil is mixed
with multigrade oil (SAEIOW-30, 15W-401, but
Above 1.0 % l/4 of regular interval be sure to add single grade oil that matches the
temperature in the table on the left.
(5) We recommend Komatsu genuine oil which
ASTM: American Society of Testing and Material
has been specifically formulated and ap-
SAE: Society of Automotive Engineers
proved for use in engine and hydraulic work
API: American Petroleum Institute
equipment applications.

Specified capacity:Total amount of oil including oil for components and oil in piping.
Refill capacity:Amount of oil needed to refill system during normal inspection and maintenance.

01-12
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 10 STRUCTURE AND FUNCTION

Radiator ........................................................ IO- 2 Suspension ................................................... IO-144

Oil cooler ...................................................... IO- 4 Work equipment hydraulic piping diagram IO-146
Engine control .............................................. IO- 6 PPC control piping diagram ........................ IO-149
Power train ................................................... IO- 8 Work equipment control ............................. IO-150
Power train system ...................................... IO- 9 Work equipment, HMT and HSS
Power trai unit mount ................................. IO- 10 hydraulic system diagram .................... IO-152
Overall drawing of power train unit ........... IO- 11 Work equipment, HMT and HSS
Power train hydraulic piping diagram.. ...... IO- 12 hydraulic circuit diagram ...................... IO-153
Power train hydraulic system drawing ....... IO- 14 Hydraulic tank and filter.. ............................ IO-160
Power train hydraulic circuit diagram ........ IO- 15 Hydraulic, HSS pump.. ................................ IO-162
Damper, universal joint ............................... IO- 16 Accumulator ................................................. IO-177
HMT system ................................................. IO- 18 EPC solenoid valve ...................................... IO-178
HMT control ................................................. IO- 24 PPC lock valve.. ............................................ IO-181
8
PTO ............................................................... IO- 26 PPC valve ..................................................... IO-182
c
HMT .............................................................. IO- 28 Main control valve ....................................... IO-188
z
‘HMT control valve ....................................... IO- 46 Operation of main control valve.. ............... IO-190
Lubrication relief valve ................................ IO- 58 HSS motor ................................................... IO-212
HMT pump assembly .................................. IO- 60 Operation of steering, work equipment
HMT motor assembly.. ................................ IO- 78 control circuit.. ....................................... IO-218
Operation of HMT system.. ......................... IO- 94 Piston valve .................................................. 1O-228
PPC, EPC, HMT charge filter ....................... IO-100 Quick drop valve .......................................... IO-229
PPC, EPC, HMT charge valve.. .................... IO-101 Cylinder stay ................................................ 1O-230
HMT oil cooler bypas valve ........................ IO-104 Work equipment .......................................... IO-231
Steering, brake control ................................ IO-106 Pin puller switch .......................................... IO-235
Bevel gear shaft, HSS, brake ...................... IO-107 Pin puller solenoid valve.. ........................... IO-236
Operation of HSS.. ....................................... IO-I 12 Tilt/Pitch selector switch .............................. 1O-238
Brake valve.. ................................................. IO-123 Pitch solenoid valve ..................................... 1o-239
Scavenging pump strainer.. ........................ IO-132 Cab mount ................................................... IO-242
Power train pump strainer.. ........................ IO-133 Cab.. .............................................................. IO-243
Power train oil filter.. ................................... IO-134 Air conditioner ............................................. IO-245
Final drive ..................................................... IO-135 Electrical wiring diagram.. ........................... IO-247
Radiator guard ............................................. IO-138 Electrical circuit diagram ......................... .lO-248-2
Main frame, under guard.. .......................... IO-139 Machine monitor system ............................ IO-251
Track frame .................................................. IO-140 Sensors.. ....................................................... IO-255
Recoil spring ................................................ IO-142 Engine control system.. ............................... IO-259
Track roller bogie ......................................... IO-143 HMT control system .................................... IO-266

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8
STRUCTURE AND FUNCTION RADIATOR

RADIATOR

SKCOOOOZ

1. Radiator core assembly 9. Fan

2. Fan guard 10. Outlet hose
3. Reservoir tank 11. Drain plug
4. Lower tank (power train oil cooler built-in) 12. Inlet hose (for circulating at low water
5. Overflow hose temperature)
6. Water filler cap 13. Cushion
7. Air bleed hose 14. Breather cap
8. Inlet hose 15. Valve

1o-2
STRUCTURE AND FUNCTION RADIATOR

A-A

B-B

SKD00003

Outline
Radiator
l The radiator is provided with a reservoir tank
I
to make it easier to check and maintain the
radiator water level.
. The power train oil cooler is built into the
lower tank. *

Relief
(MPa (kg/cm?) 0.09 (0.9)
Pressure pressure
valve Vacuum
pressure (MPa (kg/cm211 0.005 (0.05)

1o-3
STRUCTURE AND FUNCTION OIL COOLER

OIL COOLER

1. Swing hinge
2. Hydraulic cooler
3. Power train oil cooler

A. Power train oil cooler outlet port

6. Power train oil cooler inlet port

Outline
. The power train oil cooler is built into the
lower tank.
Z SKDOOOD5
. The hydraulic cooler can be tilted, so it is easy
to clean.

Cooling method Built into lower Air coo,ed

, tank I

Heat dissipation area 1.829 m2 39.7 mz

1o-4
STRUCTURE AND FUNCTION OIL COOLER

SKD00400

Procedure for tilting hydraulic cooler

1. Remove top pin bolt (3) and nut (2) and bot- 1. Bolt
tom pin bolt (5) from mounting hole A, then 2. Nut
pass them through A and B and install them. 3. Pin bolt
* The diagram- shows the condition of the 4. Hydraulic cooler
pin bolt when tilted. 5. Pin bolt
2. Remove 4 top bolts (I) and 4 bottom bolts (6). 6. Bolt
3. In this condition, use bolts (3) and (5) as the A. Holes used when installing (chassis side, top,
fulcrum and tilt hydraulic cooler (4). bottom: 2 places)
* When installing again, carry out the pro- B. Holes used when tilting (oil cooler side, top,
cedure in the reverse order to removal, bottom: 2 places)
and return the pin bolt to its original po-
sition.

1o-5
STRUCTURE AND FUNCTION ENGINE CONTROL

ENGINE CONTROL

SEW0007

1. Decelerator pedal Outline

2. Fuel control dial . The engine speed is controlled electrically by
3. Engine throttle controller fuel control dial (2) and mechanically by
4. Governor motor decelerator pedal (I).
5. Rod l The operation signal of fuel control dial (2)
6. Fuel injection pump enters engine throttle controller (3). A drive
signal is then sent to governor motor (4) to
control fuel injection pump (6).
Dial, pedal positions
0: LOW IDLING
0: HIGH IDLING
0: HIGH IDLING
0: LOW IDLING

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