Komatsu D155A-2 Bulldozer Shop Manual SEBM01750209 – PDF DOWNLOAD 

Description

Komatsu D155A-2 Bulldozer Shop Manual SEBM01750209 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D155A-2 Bulldozer Shop Manual SEBM01750209 – PDF DOWNLOAD 

Language : English
Pages : 520
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu D155A-2 Bulldozer Shop Manual SEBM01750209 – PDF DOWNLOAD 

MACHINE MODEL        SERIAL No.
D155A-2                          50001 and up

COVER 1
CONTENTS 2
10 STRUCTURE AND FUNCTION 24
GENERAL 25
POWER TRAIN HYDRAULIC SYSTEM 27
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 28
TORQUE CONVERTER 29
TORQFLOW TRANSMISSION 35
TRANSMISSION CONTROL 41
TORQFLOW HYDRAULIC CIRCUIT DIAGRAM 42
TRANSMISSION CONTROL VALVE 43
TRANSMISSION LUBRICATION RELIEF VALVE 50
TRANSMISSION PUMP 51
TRANSMISSION AND STEERING OIL STRAINER 52
TRANSMISSION OIL FILTER 53
STEERING OIL FILTER 54
BEVEL GEAR SHAFT AND STEERING CLUTCH 55
STEERING CONTROL 57
STEERING CONTROL (FOR ASSIST BRAKE) 58
STEERING AND BRAKE PIPING 59
STEERING AND BRAKE HYDRAULIC SYSTEM 60
STEERING AND BRAKE HYDRAULIC CIRCUIT DIAGRAM 61
STEERING PUMP 62
STEERING MAIN RELIEF VALVE 63
STEERING AND BRAKE CONTROL VALVE 64
STEERING BRAKE 68
SPRING ASSIST BRAKE SYSTEM 72
FINAL DRIVE 76
PTO (POWER TAKE OFF) 77
TRACK GROUP 78
IDLER CUSHION 79
IDLER 80
TRACK ROLLER AND CARRIER ROLLER 81
TRACK (LUBRICATED TRACK LINK) 82
TRACK (DRY TYPE TRACK LINK) 83
SUSPENSION 84
HYDRAULIC PIPING 85
HYDRAULIC CONTROL 89
HYDRAULIC SYSTEM 91
HYDRAULIC CIRCUIT DIAGRAM 92
HYDRAULIC TANK 93
HYDRAULIC PUMP 94
BLADE LIFT AND RIPPER CONTROL VALVE 95
BLADE TILT CONTROL VALVE 100
RIPPER SELECTOR VALVE AND PILOT CHECK VALVE 101
HYDRAULIC LEVER OPERATION 105
CYLINDER 109
CYLINDER STAY 113
WORK EQUIPMENT CONTROL HYDRAULIC SYSTEM 114
WORK EQUIPMENT CONTROL HYDRAULIC CIRCUIT DIAGRAM 115
PILOT SOLENOID VALVE 116
PIN-PULLER SOLENOID VALVE (FOR GIANT RIPPER) 117
PIN-PULLER CYLINDER (FOR GIANT RIPPER) 119
ROTARY SERVO VALVE 120
STRAIGHT TILT DOZER 124
VARIABLE MULTIPLE SHANK RIPPER 126
VARIABLE GIANT RIPPER 128
ELECTRICAL CIRCUIT DIAGRAM 130
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM) 132
APS (AUTO PRIMING SYSTEM) 138
AIR CONDITIONER 140
20 TESTING AND ADJUSTING 142
TABLE OF STANDARD VALUES FOR ENGINE 143
TABLE OF STANDARD VALUES FOR CHASSIS 144
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE 149
TESTING AND ADJUSTING 151
TESTING AND ADJUSTING TOOL LIST 152
ADJUSTING VALVE CLEARANCE 153
MEASURING COMPRESSION PRESSURE 154
ADJUSTING FUEL INJECTION TIMING 155
MEASURING TORQUE CONVERTER STALL SPEED 156
BLEEDING AIR FROM HYDRAULIC CYLINDER 157
MEASURING OIL PRESSURE 158
ADJUSTING FUEL CONTROL LINKAGE 160
ADJUSTING GEAR SHIFT LEVER LINKAGE 162
ADJUSTING STEERING CLUTCH LINKAGE 164
ADJUSTING TRAVEL OF BRAKE PEDAL 165
ADJUSTING BRAKE PEDAL LINKAGE 166
ADJUSTING SPRING ASSIST BRAKE 167
ADJUSTING BLADE CONTROL LINKAGE 168
ADJUSTING RIPPER CONTROL LINKAGE 170
H-MODE TROUBLESHOOTING 172
PREPARATION FOR TROUBLESHOOTING 173
METHOD OF READING TROUBLESHOOTING TABLE 175
PREVENTING RECURRENCE OF THE SAME TROUBLE 177
TROUBLESHOOTING 178
H-1 TORQUE CONVERTER TEMPERATURE TOO HIGH 178
H-2 MACHINE DOES NOT MOVE 179
H-3 MACHINE LACKS POWER OR SPEED 181
H-4 MACHINE MOVES WHEN ENGINE IS STARTED 182
H-5 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 182
H-6 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 183
H-7 MACHINE TRAVELS IN ONE DIRECTION ONLY (FORWARD OR REVERSE) 183
H-8 STEERING CLUTCH DOES NOT DISENGAGE 184
H-9 STEERING CLUTCH SLIPS 185
H-10 STEERING BRAKE DOES NOT WORK 186
H-11 BLADE LIFT LACKS POWER AND SPEED 187
H-12 BLADE DOES NOT LIFT 188
H-13 THE FRONT OF MACHINE CANNOT BE RAISED OFF GROUND BY THE BLADE 189
H-14 HYDRAULIC DRIFT OF LIFT CYLINDER IS LARGE 190
H-15 BLADE MOVES UNSTEADILY WHEN LEVELING THE GROUND (CONTROL LEVER IN “HOLD”) 191
H-16 BLADE LOWERS UNDER THE FOLLOWING CONDITIONS 191
H-17 TRAVEL OF THE PISTON RODS IN THE RIGHT AND LEFT LIFT CYLINDERS IS DIFFERENT (APPLICABLE TO STRAIGHT-TILT DOZER ONLY) 191
H-18 BLADE TILTING FORCE IS LACK, BLADE TILTING SPEED IS SLOW, THE MACHINE CANNOT BE RAISED OFF GROUND BY BLADE TILTING FORCE 192
H-19 TILT CYLINDER DOES NOT MOVE OFF (TILTING IS IMPOSSIBLE) 193
H-20 HYDRAULIC DRIFT OF TILT CYLINDER IS LARGE 194
H-21 HYDRAULIC DRIFT OF RIPPER CYLINDER IS LARGE 195
H-22 CONTROL LEVER OPERATING FORCE IS HEAVY 196
M-MODE TROUBLESHOOTING 197
CONNECTOR TYPE AND MOUNTING POSITION 198
POSITION OF CONNECTORS FOR TROUBLESHOOTING 199
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 200
PROCEDURE FOR TROUBLESHOOTING 204
CHECKS BEFORE TROUBLESHOOTING 205
METHOD OF USING TROUBLESHOOTING CHART 206
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM) 208
M-1 NO MONITOR PANEL DISPLAY IS GIVEN WHEN STARTING SWITCH IS TURNED ON 209
M-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MONITOR PANEL STAY LIGHTED AND DO NOT GO OUT 209
M-3 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHECK ITEMS FLASH (CHECK ITEM LEVELS ARE AT SPECIFIED LEVEL ) 210
M-4 NO PREHEATING IS BEING CARRIED OUT, BUT PREHEATING DISPLAY LIGHTS UP 211
M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH 212
M-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH 213
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN THE ENGINE OR IN THE CHECK ITEMS) 214
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR ONE SECOND 217
(a) CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND 217
(b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY, BUT BUZZER SOUNDS 217
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), LAMPS DO NOT LIGHT UP FOR 2 SECONDS 218
(a) CAUTION ITEM IS FLASHING BUT WARNING LAMPS DOES NOT FLASH 218
(b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY, BUT LAMPS LIGHT UP 218
M-10 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP 219
M-11 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED 220
M-12 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE 221
M-13 ENGINE WATER TEMPERATURE GAUGE GIVES NO DISPLAY 221
M-14 TORQUE CONVERTER OIL TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE 222
M-15 TORQUE CONVERTER OIL TEMPERATURE GAUGE GIVES NO DISPLAY 222
M-16 FUEL GAUGE ALWAYS DISPLAYS TANK FULL 223
M-17 FUEL GAUGE GIVES NO DISPLAY 223
E-MODE TROUBLESHOOTING FOR ELECTRICAL SYSTEM 224
TABLE OF FAILURE MODES AND CAUSES 225
APS SYSTEM 226
E-1 EVEN WHEN PREHEATING SWITCH IS TURNED ON, APS PILOT LAMP ON MONITOR PANEL DOES NOT LIGHT UP 227
E-2 WHEN PREHEATING SWITCH IS TURNED ON, APS PILOT LAMP ON MONITOR PANEL LIGHT UP, BUT IT DOESN’T GO OUT, OR THE TIME TAKEN FOR IT TO GO OUT IS NOT 60-100 SEC 229
E-3 EVEN WHEN ENGINE IS CRANKED, IT DOES NOT START 231
E-4 APS CONTROL UNIT DOES NOT WORK PROPERLY 234
E-5 PIN PULLER CYLINDER DOES NOT WORK (ONLY FOR MACHINES WITH GIANT RIPPER) 238
30 DISASSEMBLY AND ASSEMBLY 239
METHOD OF USING MANUAL 241
PRECAUTIONS WHEN CARRYING OUT OPERATION 242
SPECIAL TOOL LIST 244
WEIGHT TABLE 249
TABLE OF TIGHTENING TORQUE AND STANDARD VALUE 251
TABLE OF OIL AND COOLANT QUANTITIES 265
STARTING MOTOR 266
REMOVAL 266
INSTALLATION 266
ALTERNATOR 266
REMOVAL 266
INSTALLATION 266
AIR COMPRESSOR 266
REMOVAL 266
INSTALLATION 266
CONDENSER 266
REMOVAL 266
INSTALLATION 266
NOZZLE HOLDER 268
REMOVAL 268
INSTALLATION 268
FUEL INJECTION PUMP 268
REMOVAL 268
INSTALLATION 268
ENGINE OIL COOLER 270
REMOVAL 270
INSTALLATION 270
WATER PUMP 270
REMOVAL 270
INSTALLATION 270
TURBOCHARGER 272
REMOVAL 272
INSTALLATION 272
TORQUE CONVERTER OIL COOLER 272
REMOVAL 272
INSTALLATION 272
CYLINDER HEAD 274
REMOVAL 274
INSTALLATION 278
RADIATOR GUARD 280
REMOVAL 280
INSTALLATION 280
RADIATOR 282
REMOVAL 282
INSTALLATION 282
PTO 282
REMOVAL 282
INSTALLATION 282
DISASSEMBLY 284
ASSEMBLY 286
FUEL TANK 288
REMOVAL 288
INSTALLATION 288
ENGINE 290
REMOVAL 290
INSTALLATION 294
TORQUE CONVERTER 296
REMOVAL 296
INSTALLATION 296
DISASSEMBLY 298
ASSEMBLY 304
TORQUE CONVERTER RELIEF VALVE 310
REMOVAL 310
INSTALLATION 310
DISASSEMBLY 310
ASSEMBLY 310
TORQUE CONVERTER REGULATOR VALVE 310
REMOVAL 310
INSTALLATION 310
DISASSEMBLY 310
ASSEMBLY 310
TRANSMISSION 312
REMOVAL 312
INSTALLATION 312
DISASSEMBLY 314
ASSEMBLY 326
TRANSMISSION CONTROL VALVE 340
REMOVAL 340
INSTALLATION 340
DISASSEMBL 342
ASSEMBLY 344
TRANSMISSION LUBRICATION VALVE 350
REMOVAL 350
INSTALLATION 350
DISASSEMBLY 350
ASSEMBLY 350
BEVEL GEAR AND SHAFT 352
REMOVAL 352
INSTALLATION 354
STEERING CLUTCH 360
REMOVAL 360
INSTALLATION 360
DISASSEMBLY 362
ASSEMBLY 362
STEERING RELIEF VALVE 364
REMOVAL 364
INSTALLATION 364
DISASSEMBLY 364
ASSEMBLY 364
BRAKE BOOSTER 366
DISASSEMBLY 366
ASSEMBLY 366
STEERING AND BRAKE VALVE 366
REMOVAL 366
INSTALLATION 366
DISASSEMBLY 368
ASSEMBLY 368
TRANSMISSION PUMP 370
REMOVAL 370
INSTALLATION 370
STEERING PUMP 370
REMOVAL 370
INSTALLATION 370
ASSIST BRAKE CYLINDER 370
REMOVAL 370
INSTALLATION 370
NO 1 PINION 372
DISASSEMBLY 372
ASSEMBLY 374
FINAL DRIVE 376
DISASSEMBLY 376
ASSEMBLY 380
TRACK FRAME 386
REMOVAL 386
INSTALLATION 386
RECOIL SPRING 388
REMOVAL 388
INSTALLATION 388
DISASSEMBLY 390
ASSEMBLY 390
IDLER 392
REMOVAL 392
INSTALLATION 392
TRACK ROLLER 392
REMOVAL 392
INSTALLATION 392
CARRIER ROLLER 394
REMOVAL 394
INSTALLATION 394
TRACK SHOE 394
REMOVAL 394
INSTALLATION 394
OVERALL DISASSEMBLY 396
OVERALL ASSEMBLY 401
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 415
FIELD DISASSEMBLY OF ONE LINK 416
FIELD ASSEMBLY OF ONE LINK 418
DISASSEMBLY OF MASTER LINK 420
ASSEMBLY OF MASTER LINK 422
HYDRAULIC PUMP 425
REMOVAL 425
INSTALLATION 425
BLADE AND RIPPER CONTROL VALVE 427
REMOVAL 427
INSTALLATION 427
DISASSEMBLY 429
ASSEMBLY 429
BLADE TILT CONTROL VALVE 431
DISASSEMBLY 431
ASSEMBLY 431
SERVO VALVE ASSEMBLY FOR BLADE LIFT 433
REMOVAL 433
INSTALLATION 433
SERVO VALVE ASSEMBLY FOR BLADE TILT 433
REMOVAL 433
INSTALLATION 433
SERVO VALVE ASSEMBLY FOR RIPPER 433
REMOVAL 433
INSTALLATION 433
RIPPER SELECTOR VALVE 435
REMOVAL 435
INSTALLATION 435
DISASSEMBLY 437
ASSEMBLY 437
BLADE LIFT CYLINDER 439
REMOVAL 439
INSTALLATION 439
BLADE TILT CYLINDER 439
REMOVAL 439
INSTALLATION 439
RIPPER LIFT CYLINDER 441
REMOVAL 441
INSTALLATION 441
RIPPER TILT CYLINDER 441
REMOVAL 441
INSTALLATION 441
HYDRAULIC CYLINDER 443
DISASSEMBLY 443
ASSEMBLY 445
PIN-PULLER CYLINDER 447
REMOVAL 447
INSTALLATION 447
DISASSEMBLY 447
ASSEMBLY 447
BLADE 449
REMOVAL 449
INSTALLATION 449
DISASSEMBLY 451
ASSEMBLY 451
RIPPER 453
DISASSEMBLY 453
ASSEMBLY 453
CAB 455
REMOVAL 455
INSTALLATION 455
CAB AND FLOOR FRAME 457
REMOVAL 457
INSTALLATION 457
MONITOR 459
REMOVAL 459
INSTALLATION 459
40 MAINTENANCE STANDARD 461
TORQUE CONVERTER 462
TORQFLOW TRANSMISSION 466
TRANSMISSION CONTROL VALVE 470
TRANSMISSION LUBRICATION VALVE 474
TRANSMISSION PUMP 475
BEVEL GEAR SHAFT 476
STEERING CLUTCH 478
STEERING PUMP 480
STEERING MAIN RELIEF VALVE 481
STEERING AND BRAKE CONTROL VALVE 482
STEERING BRAKE 484
ASSIST BRAKE CYLINDER 486
ASSIST BRAKE AUTOMATIC DRAIN VALVE 487
FINAL DRIVE 488
TRACK FRAME 490
RECOIL SPRING 491
IDLER 492
TRACK ROLLER 494
CARRIER ROLLER 496
TRACK (LUBRICATED TRACK LINK) 497
TRACK (DRY TYPE TRACK LINK) 499
SUSPENSION 501
HYDRAULIC PUMP 502
BLADE LIFT AND RIPPER CONTROL VALVE 503
BLADE TILT CONTROL VALVE 507
RIPPER SELECTOR VALVE AND PILOT CHECK VALVE 508
HYDRAULIC CYLINDER 509
CYLINDER STAY 512
PIN-PULLER CYLINDER (FOR GIANT RIPPER) 513
ROTARY SERVO VALVE (FOR BLADE LIFT) 514
STRAIGHT TILTDOZER 515
VARIABLE MULTI-SHANK RIPPER 517
VARIABLE GIANT RIPPER 519

DESCRIPTION:

Komatsu D155A-2 Bulldozer Shop Manual SEBM01750209 – PDF DOWNLOAD 

MACHINE MODEL        SERIAL No.
D155A-2                          50001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

S.V 24/12/24