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BULLDOZER
D155AX-6
D155AX-6 1
SEN01205-00 50 Disassembly and assembly
Engine and cooling system 3. Remove two fuel tube joint bolts, and remove
fuel main filter head assembly (5). [*1]
Removal and installation of fuel
supply pump assembly
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 795-630-5500 Standard puller 1
A 2 01010-81090 Bolt 2
3 01643-31032 Washer 2
Removal
4. Remove tubes (6) and (7) between fuel supply
Disconnect the negative terminal () of the pump and fuel main filter.
battery.
5. Remove tube (8) between fuel supply pump
1. Open engine hood left cover (1) and remove and priming pump. [*2]
side covers, (2) and (3).
6. Remove oil level gauge guide (9).
2 D155AX-6
50 Disassembly and assembly SEN01205-00
10. Remove stay (20), two covers (21), and two 13. Check that the mounting bolt hole (c) at the top
covers (22), and remove high pressure pipes of cover align to the forcing tap of drive gear.
(23) and (24). [*4] If they are not aligned, rotate crankshaft
If the common rail side sleeve nut for high one more turn.
pressure pipe is hard to loose, loosen the
mounting bolts for gate type frame (25). 14. Remove nut (29). [*5]
Take care not to drop into the case.
D155AX-6 3
SEN01205-00 50 Disassembly and assembly
4 D155AX-6
50 Disassembly and assembly SEN01205-00
[*1]
@ Fuel tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
[*2]
@ Fuel tube sleeve nut:
43 47 Nm {4.4 4.8 kgm}
[*3]
@ Tube (16) common rail side joint bolt:
17.7 22.6 Nm {1.8 2.3 kgm}
@ Tube (16) supply pump side joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}
D155AX-6 5
SEN01205-00 50 Disassembly and assembly
Removal and installation of fuel 5. Remove tube (5) and block (6).
injector assembly
Removal
This section explains the procedure for remov-
ing No.1 fuel injector assembly.
6 D155AX-6
50 Disassembly and assembly SEN01205-00
D155AX-6 7
SEN01205-00 50 Disassembly and assembly
8 D155AX-6
50 Disassembly and assembly SEN01205-00
2. Install high pressure pipe clamp and stay. 3. Install the subsequent procedure in the reverse
1) Temporarily tighten high pressure pipe order of removal.
clamp, stay (16), clamping bolts (38)
through (42), and stay mounting bolt, with [*1]
fingers. @ Joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
2) Tighten permanently high pressure pipe
clamping bolt. [*2]
@ Clamping bolt: @ Clamping bolt (7): 9.8 1 Nm {1 0.1 kgm}
9.8 1 Nm {1 0.1 kgm}
3) Tighten permanently stay mounting bolt. [*3]
4) Temporarily tighten high pressure pipe @ Cylinder head cover mounting bolt:
clamp, stay (15), clamping bolts (44) 29.4 34.3 Nm {3.0 3.5 kgm}
through (48), and stay mounting bolt, with
fingers. [*4]
5) Install cover (11). Install with the notch downward.
Install with the notch toward cylinder
block side. [*5]
6) Install high pressure pipe clamp (10) and When installing rocker arm and rocker shaft
gate type frame (9) temporarily. assembly (22), check the ball portion of adjust-
7) Tighten clamping bolt for high pressure ment screw (25) to be inserted securely into
pipe clamp (10) permanently. socket of push rod (23), and tighten mounting
@ Clamping bolt: bolts.
9.8 1 Nm {1 0.1 kgm} As 3 mounting bolts are different each other,
8) Tighten gate type frame (9) permanently. install them referring to the followings.
9) Tighten high pressure pipe clamp, stay Mounting bolt (19): Stem length 120mm
(15) and clamping bolts (44) through (48), Mounting bolt (20): Stem length 90 mm
permanently. Mounting bolt (21): Stem length 75.2 mm
@ Clamping bolt: @ Mounting bolts (19), (20) and (21):
9.8 1 Nm {1 0.1 kgm} 93 103 Nm {9.5 10.5 kgm}
10) Tighten permanently stay mounting bolt. Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
D155AX-6 9
SEN01205-00 50 Disassembly and assembly
[*6] [*7]
Install wiring harness according to the follow-
ing procedure.
1) Install clip (29).
2) Tighten two capture nuts (30).
Tighten capture nuts alternately.
@ Capture nut:
2 0.2 Nm {0.2 0.02 kgm}
3) Tighten wiring harness clamping bolt (28).
10 D155AX-6
50 Disassembly and assembly SEN01205-00
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
A 4 790-331-1110 Wrench 1
Removal
1. Remove the engine hood referring to the sec-
tion "Removal and installation of engine hood 8. Remove two joint bolts (8), and remove fuel
assembly". main filter head assembly (9). [*1]
2. Drain the coolant. 9. Remove two joint bolts (10), and remove corro-
6 Coolant: 824 sion resistor head assembly (11). [*2]
D155AX-6 11
SEN01205-00 50 Disassembly and assembly
13. Disconnect connector PEVA (19). 19. Remove air intake housing.
1) Remove tube (25) and block (26).
12 D155AX-6
50 Disassembly and assembly SEN01205-00
22. Remove clamp (31). 26. Remove two, upper and lower side, wiring har-
ness clamps (38) at the rear side of intake
23. Remove mounting bolts of bracket (32), and manifold.
move bracket (32) with hose (33).
D155AX-6 13
SEN01205-00 50 Disassembly and assembly
29. Remove stays (43), (44) and (45), for high 32. Remove heat insulation covers, (48), (49) and
pressure pipe clamp. [*8] (50).
30. Remove water tube (46) in front of intake man- 33. Remove muffler (51).
ifold.
Muffler: 55 kg
14 D155AX-6
50 Disassembly and assembly SEN01205-00
35. Remove heat insulation covers (53) and (54), 40. Remove heat insulation cover (62).
and bracket (55) and (56).
41. Remove brackets (63) and (64), and remove
bypass tube (65). [*12]
37. Remove water tube (58). 42. Remove oil tube (66) and water tube (67). [*13]
D155AX-6 15
SEN01205-00 50 Disassembly and assembly
44. Disconnect connectors CN1 (69), CN2 (70), 48. Remove water tube (82). [*19]
CN3 (71), CN4 (72), CN5 (73) and CN6 (74),
and move wiring harnesses (75) and (76). 49. Remove cylinder head cover (83). [*20]
To disconnect the connector, push in the
(X) direction with a flat-head screwdriver
[1] placed at the stepped portion (a) while
pressing stopper (b).
16 D155AX-6
50 Disassembly and assembly SEN01205-00
51. Remove three mounting bolts (84) through 5) Remove mounting bolt (100) of holder
(86), and remove rocker arm and rocker shaft (99). [*25]
assembly (87).
Loosen lock nut (89), and loosen adjust-
ment screw (90) two or three turns to pre-
vent excessive force applied to push rod
(88), when installing rock er arm and
rocker shaft assembly. [*21]
D155AX-6 17
SEN01205-00 50 Disassembly and assembly
18 D155AX-6
50 Disassembly and assembly SEN01205-00
3) Install cylinder head assembly. 2. After installing cross head (103), make adjust-
4) Tighten mounting bolts in order of 1 through ment as follows.
6 as shown in the figure. 1) Loosen lock nut (111), and loosen adjust-
k Mounting bolt: ment screw (112).
Lubricant with molybdenum dis- 2) Lightly push cross head (103) contact sur-
ulfide (LM-P) face (h) with rocker arm, and hold cross
@ Mounting bolt head to contact with push rod (102) side
1st time: valve stem (113).
137 157 Nm {14 16 kgm} 3) Screw slowly adjustment screw (112), and
2nd time: check the position where adjustment
284 294 Nm {29.0 30.0 kgm} screw touches valve stem (114).
3rd time: Retighten 90 (+30/0) with 4) From the above condition, screw adjust-
tool A4. ment screw (112) 20.
When tool A4 is not available, put 5) While holding adjustment screw (112) with
marks (a) and (b) to bolt and cylinder a flat-head screwdriver, tighten locknut
head, and retighten bolt 90 (+30/0). (111).
5) Tighten auxiliary bolt (tightening order: @ Locknut:
7th) with the following torque. 58.7 5.9 Nm {6.0 0.6 kgm}
@ Auxiliary bolt:
66.6 7.4 Nm {6.8 0.8 kgm}
D155AX-6 19
SEN01205-00 50 Disassembly and assembly
[*1] [*2]
@ Joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
[*3]
@ Fuel tube sleeve nut:
43 47 Nm {4.4 4.8 kgm}
[*4] [*10]
When loosened hose clamp, replace clamp
with new one.
Tighten the hose clamp according to the fol-
lowing procedure.
1) Locate the punch mark (f) of bridge (108)
as shown in the figure, and adjust the
position of bridge to be under band (109). [*7] [*8] [*15] [*18]
2) Tighten bolt (110) so that the dimension Install high pressure pipe, clamp, stay and gate
(g) is between 8 and 10 mm. type frame referring to the section, "Removal
k Threaded portion of bolts: and installation of fuel injector assembly".
PANDO 18B from Three Bond [*9]
3) Tighten bolt (110) with the following Tighten intake manifold mounting bolts in the
torque. numerical order shown below.
@ Bolt: 25 5 Nm {2.55 0.5 kgm} @ Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
[*5]
[*11]
Adjust the tension of air compressor belt, refer-
k EGR tube mounting bolt threaded portion:
ring Testing and adjusting section "Testing and
Lubricant with molybdenum disulfide
adjusting of air conditioner compressor belt
(LM-P)
tension".
@ EGR tube mounting bolt, EGR tube and
bracket mounting bolt:
[*6]
44.1 53.9 Nm {4.5 5.5 kgm}
@ Joint bolt (37a):
9.8 12.7 Nm {1.0 1.3 kgm}
[*12]
@ Joint bolt (37b):
k Threads and seat surface of bypass tube
19.6 29.4 Nm {2.0 3.0 kgm}
mounting bolt: Lubricant with molybde-
num disulfide (LM-P)
@ Bypass tube mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
[*13]
@ Oil tube cylinder block side joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
20 D155AX-6
50 Disassembly and assembly SEN01205-00
[*14]
Tighten exhaust manifold mounting bolts in the
numerical order shown below.
k Threads of mounting bolt:
Lubricant with molybdenum disulfide
(LM-P)
@ Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
[*20]
@ Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
[*21]
When installing rocker arm and rocker shaft
assembly (87), check the ball portion of adjust-
ment screw (90) to be inserted securely into
socket of push rod (88), and tighten mounting
bolts.
As three mounting bolts are different each
[*25] [*26]
other, install them referring the followings.
Install the fuel injector assembly referring to
Mounting bolt (84): Stem length 120mm
the section, "Removal and installation of fuel
Mounting bolt (85): Stem length 90mm
injector assembly".
Mounting bolt (86): Stem length 75.2 mm
@ Mounting bolt:
93 103 Nm {9.5 10.5 kgm}
Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
D155AX-6 21
SEN01205-00 50 Disassembly and assembly
22 D155AX-6
50 Disassembly and assembly SEN01205-00
[*1]
Install hoses (5) and (7) with the red circle
paint upward.
k Tube flange: gasket sealant
@ Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
Tighten two parallel clamps for hose (6) with its
bolt location rotated 180 each other.
k Tube flange: gasket sealant
@ Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*2]
Set radiator assembly according to the follow-
ing procedure.
1) Set rubber (13) with its stepped portion (a) 4) Sling the radiator assembly and set it on
downward. the lower tank slowly.
Apply appropriate amount of grease Check visually the installation condi-
to prevent drop down when lifted up. tion from the machine front.
2) Install O-ring (14).
k O-ring periphery: Grease (G2-LI)
D155AX-6 23
SEN01205-00 50 Disassembly and assembly
Removal and installation of 4. Remove four mounting bolts for tube (4). [*2]
aftercooler assembly
5. Remove brackets, (5), (6) and (7).
Removal
Disconnect the negative terminal () of the
battery.
24 D155AX-6
50 Disassembly and assembly SEN01205-00
Installation
Carry out installation in the reverse order of
removal.
[*1] [*2]
When loosened hose clamp, replace clamp
with new one.
Tighten the hose clamp according to the fol-
lowing procedure.
1) Locate punch mark (a) of bridge (9) as
shown in the figure, and adjust the posi-
tion of bridge to be under band (10).
2) Tighten bolt (11) so that dimension (b) is
between 8 and 10 mm.
k Threaded portion of bolts:
PANDO 18B from Three Bond
3) Tighten bolt (11) with the following torque.
@ Bolt: 25 5 Nm {2.55 0.5 kgm}
D155AX-6 25
SEN01205-00 50 Disassembly and assembly
Removal and installation of 7. Remove heat insulation cover (3) and drain
engine assembly tube (4).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Service tool
799-703-1200 1
kit
Vacuum pump
799-703-1100 1
(100 V)
Q Vacuum pump
799-703-1111 1
(220 V)
Vacuum pump
799-703-1121 1
(240 V) 8. Remove muffler (5).
799-703-1401 Gas leak detector 1 Muffler: 50 kg
Removal
Disconnect the negative terminal () of the
battery.
26 D155AX-6
50 Disassembly and assembly SEN01205-00
12. Disconnect ground (8) at engine left side. 15. Remove after cooler tube (11). [*2]
13. Disconnect fuel hose (9) from fuel supply 16. Sling water tube (12) and remove it. [*3]
pump.
D155AX-6 27
SEN01205-00 50 Disassembly and assembly
18. Disconnect two hoses each from air condi- 25. Disconnect hose (26) from radiator lower tank.
tioner condenser (15) and oil cooler (16), and [*4]
remove frame (17).
28 D155AX-6
50 Disassembly and assembly SEN01205-00
[*1] [*2]
When loosened hose clamp, replace clamp
with new one.
Tighten the hose clamp according to the fol-
lowing procedure.
1) Locate punch mark (a) of bridge (31) as
shown in the figure, and adjust the posi-
tion of bridge to be under band (32).
2) Tighten bolt (33) so that dimension (b) is
between 8 and 10 mm.
k Threaded portion of bolts:
PANDO 18B from Three Bond
3) Tighten bolt (33) with the following torque.
@ Bolt: 25 5 Nm {2.55 0.5 kgm}
[*3]
k Engine side tube flange:
Gasket sealant (LG-1)
@ Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*4]
@ Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*5]
@ Universal joint mounting bolt:
98 123 Nm {10 12.5 kgm}
[*6]
@ Engine mount fixing bolt:
823.8 1029.7 Nm {84 105 kgm}
D155AX-6 29
SEN01205-00 50 Disassembly and assembly
30 D155AX-6
50 Disassembly and assembly SEN01205-00
[*1]
@ Pre cleaner duct and exhaust pipe mounting
bolt: 98 123 Nm {10 12.5 kgm}
[*2]
@ Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
D155AX-6 31