Komatsu D155A-2 Dozer Bulldozer Shop Manual SEBM018602 PDF

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Komatsu D155A-2 Dozer Bulldozer Shop Manual SEBM018602 –  PDF DOWNLOAD

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Komatsu D155A-2 Dozer Bulldozer Shop Manual SEBM018602 –  PDF DOWNLOAD

Language : English
Pages : 462
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D155A-2 Dozer Bulldozer Shop Manual SEBM018602 –  PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 25
SPECIFICATION DRAWING 26
SPECIFICATIONS 27
WEIGHT TABLE 32
TABLE OF FUEL,COOLANT AND LUBRICANTS 34
10 STRUCTURE AND FUNCTION 35
ENGINE CONTROL 36
RADIATOR,OIL COOLER 37
PTO 39
POWER TRAIN 41
POWER TRAIN SYSTEM 43
POWER TRAIN HYDRAULIC PIPING DIAGRAM 44
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 45
TORQUE CONVERTER 47
TRANSMISSION CONTROL 52
TRANSMISSION 53
TRANSMISSION CONTROL VALVE 61
TRANSMISSION LUBRICATION RELIEF VALVE 69
STEERING CONTROL 70
BEVEL GEAR SHAFT AND STEERING CLUTCH 71
STEERING MAIN RELIEF VALVE 74
STEERING BRAKE 75
STEERING AND BRAKE CONTROL VALVE 79
SPRING ASSIST BRAKE SYSTEM 84
FINAL DRIVE 89
TRACK FRAME 93
RECOIL SPRING 94
SUSPENSION 95
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 96
WORK EQUIPMENT CONTROL 100
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 102
HYDRAULIC TANK 103
ROTARY SERVO VALVE 104
PISTON VALVE 108
PIN PULLER SWITCH 109
PIN-PULLER SOLENOID VALVE 110
MAIN CONTROL VALVE 112
RIPPER SELECTOR VALVE AND PILOT CHECK VALVE 116
PILOT SOLENOID VALVE 120
CYLINDER STAY 121
WORK EQUIPMENT 122
CAB 125
AIR CONDITIONER 126
ACTUAL ELECTRIC WIRING DIAGRAM 127
MONITOR SYSTEM 129
SENSOR 134
20 TESTING AND ADJUSTING 138
STANDARD VALUE TABLE FOR FUNCTIONS RELEVANT TO THE ENGINE 139
STANDARD VALUE TABLE FOR FUNCTIONS RELEVANT TO THE MACHINE BODY 140
STANDARD VALUE TABLE FOR ELECTRIC EQUIPMENT AND PARTS 144
TESTING AND ADJUSTING 145
LIST OF EQUIPMENT,PARTS AND TOOLS NECESSARY FOR INSPECTIONS,ADJUSTMENTS AND FOR TROUBLESHOOTING 146
MEASURING THE ENGINE REVOLUTION 147
MEASURING THE INTAKE MANIFOLD PRESSURE (BOOST PRESSURE) 148
MEASURING THE EXHAUST TEMPERATURE 149
MEASURING THE EXHAUST GAS COLOR 150
ADJUSTING THE VALVE CLEARANCE 151
MEASURING THE COMPRESSION PRESSURE 152
MEASURING THE BLOWBY PRESSURE 153
MEASURING THE ENGINE OIL PRESSURE 154
INSPECTING AND ADJUSTING THE FUEL INJECTION TIMING 155
INSPECTING AND ADJUSTING THE ALTERNATOR BELT TENSION 156
INSPECTING AND ADJUSTING THE AIR COMPRESSOR BELT TENSION 156
MEASURING THE TORQUE CONVERTER STALLING REVOLUTION RATE 157
MEASURING THE TORQUE CONVERTER STALLING + WORK EQUIPMENT PUMP RELIEVING REVOLUTION RATE (FULL STALL REVOLUTION RATE) 158
MEASURING THE OIL PRESSURE 159
ADJUSTING THE STROKES AND LINKAGES 161
TROUBLESHOOTING 173
POINTS TO REMEMBER WHEN TROUBLESHOOTING 174
SEQUENCE OF EVENTS IN TROUBLESHOOTING 175
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 176
CHECKS BEFORE TROUBLESHOOTING 184
CONNECTOR TYPES AND CONNECTING EQUIPMENT AND PART NAMES 185
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 189
HOW TO FOLLOW THE TROUBLESHOOTING FLOW DIAGRAMS 195
TROUBLESHOOTING FOR ELECTRIC EQUIPMENT (E-MODE) 197
ELECTRIC CIRCUIT DIAGRAM FOR THE E-MODE SYSTEM CIRCUITS 198
E-1 THE ENGINE DOES NOT START (IN CASE THE ENGINE DOES NOT ROTATE) 199
E-2 THE LAMPS DO NOT TURN ON 202
a) HEAD LAMPS 202
b) WORKING LAMP 203
c) REAR LAMP 204
E-3 PRE-HEATING CANNOT BE EFFECTED 205
E-4 THE BACKING ALARM DOES NOT SOUND 206
E-5 THE PIN PULLER CYLINDER CANNOT BE ACTIVATED (WITH MACHINES EQUIPPED WITH THE GIANT RIPPER) 207
a) THE PIN CANNOT BE PULLED OUT (THE SOLENOID CANNOT BE EXCITED ) 207
b) THE PIN CANNOT BE PUSHED IN (THE SOLENOID CANNOT BE DEMAGNETIZED ) 207
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL EQUIPMENT (H-MODE) 209
HOW TO PROCEED WITH THE TROUBLESHOOTING 210
H-1 TORQUE CONVERTER OIL TEMPERATURE IS TOO HIGH 212
H-2 THE MACHINE WOULD NOT START TRAVELING 213
H-3 THE TRACKING FORCE IS TOO WEAK OR THE TRAVELING SPEED IS TOO SLOW 214
H-4 THE MACHINE MOVES FORWARD OR BACKWARD WHEN THE ENGINE IS STARTED 215
H-5 STARTING OR SPEED SHIFTING TIME LAG IS TOO LONG 215
H-6 STARTING OR SPEED SHIFTING SHOCK IS TOO BIG 216
H-7 THE MACHINE TRAVELS ONLY IN THE FORWARD DIRECTION OR IN REVERSE DIRECTION 216
H-8 THE STEERING CLUTCH CANNOT BE DISENGAGED 217
H-9 THE STEERING CLUTCH SLIPS 218
H-10 THE STEERING BRAKE IS NOT EFFECTIVE 219
H-11 THE BLADE LIFTING POWER AND SPEED ARE INSUFFICIENT 220
H-12 THE BLADE CANNOT BE LIFTED 221
H-13 THE MACHINE BODY CANNOT BE RAISED BY USE OF THE BLADE 222
H-14 HYDRAULIC DRIFT OF THE BLADE LIFT CYLINDER IS EXCESSIVE 223
H-15 THE BLADE SHAKES UNSTEADILY UP AND DOWN WHEN MAKING GROUND LEVELING WORKS (WHILE THE CONTROL LEVER IS BEING SET TO THE “HOLD” POSITION) 224
H-16 THE BLADE COMES DOWN 224
1) WHEN THE WORK EQUIPMENT CONTROL LEVER IS SHIFTED FROM THE “HOLD” POSITION TO THE “UP” POSITION: 224
2) THE BLADE COMES DOWN GRADUALLY WHEN THE ENGINE IS STOPPED EVEN WHEN THE WORK EQUIPMENT CONTROL LEVER IS BEING SET TO THE “UP” POSITION: 224
H-17 THE BLADE IS LIFTED WITH ITS LH AND RH END AT UNEVEN ELEVATIONS (WITH THE STRAIGHT-DOZERS ONLY) 224
H-18 THE MACHINE BODY CANNOT BE RAISED BY TILTING OF THE BLADE OWING TO INSUFFICIENT TILTING FORCE AND SPEED 225
H-19 THE BLADE CANNOT BE TILTED 226
H-20 HYDRAULIC DRIFT OF THE BLADE TILT CYLINDER IS EXCESSIVE 227
H-21 HYDRAULIC DRIFT OF THE RIPPER CYLINDER IS EXCESSIVE 228
H-22 THE OPERATING EFFORTS FOR THE CONTROL LEVER ARE TOO HIGH 229
TROUBLESHOOTING FOR MONITOR PANEL AND RELATED PARTS (M-MODE) 230
ELECTRIC CIRCUIT DIAGRAM FOR THE M-MODE SYSTEM CIRCUITS 231
M-1 THE MONITOR PANEL INDICATIONS DO NOT APPEAR EVEN WHEN THE STARTING SWITCH IS TURNED “ON” 232
a) WHEN THE MONITOR PANEL INDICATIONS DO NOT APPEAR TOTALLY: 232
b) WHEN THE MONITOR PANEL INDICATIONS APPEAR ONLY PARTLY: 232
M-2 THE MONITOR PANEL LIGHTS TOTALLY WHEN THE STARTING SWITCH IS TURNED “ON” AND IT CANNOT BE TURNED OFF 232
M-3 THE “EVERYDAY CHECKUP ITEMS” FLASH WHEN THE STARTING SWITCH IS TURNED ON (BUT NOT AS FAR AS STARTING THE ENGINE) 233
M-4 THE (PRE-HEATING INDICATION) APPEARS EVEN THOUGH THE PRE-HEATING OPERATION HAS NOT BEEN MADE 234
M-5 THE “EVERYDAY CHECKUP ITEMS” FLASH WHEN THE STARTING SWITCH IS TURNED ON AND WHEN THE ENGINE IS STARTED 235
a) ALTERNATOR CIRCUITS 235
b) ENGINE OIL PRESSURE CIRCUITS 235
M-6 THE CAUTION ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON (BUT NOT AS FAR AS STARTING THE ENGINE) 236
M-7 THE CAUTION ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON AND WHEN THE ENGINE IS STARTED 237
a) (ENGINE OIL PRESSURE) FLASHES 237
b) (RADIATOR WATER LEVEL) FLASHES 237
c) (ENGINE WATER TEMPERATURE) FLASHES 237
d) (CHARGING LEVEL) FLASHES 238
e) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES 238
M-8 THE BUZZER DOES NOT SOUND FOR ONE SECOND WHEN THE STARTING SWITCH IS TURNED ON (BUT NOT AS FAR AS STARTING THE ENGINE) 240
a) THE BUZZER DOES NOT SOUND EVEN THOUGH THE CAUTION ITEM IS FLASHING 240
b) THE BUZZER SOUNDS EVEN THOUGH NO ALARM IS BEING INDICATED ON THE MONITOR 240
M-9 THE LAMP DOES NOT TURN ON FOR TWO SECONDS WHEN THE STARTING SWITCH IS TURNED ON (BUT NOT AS FAR AS STARTING THE ENGINE) 241
a) THE LAMP DOES NOT FLASH EVEN THOUGH THE CAUTION ITEM IS FLASHING 241
b) THE LAMP LIGHTS EVEN THOUGH NO ALARM IS BEING INDICATED ON THE MONITOR 241
M-10 THE PANEL ILLUMINATION DOES NOT TURN ON (EVEN THOUGH THE LCD INDICATIONS ARE NORMAL ) 242
M-11 THE SERVICE METER DOES NOT WORK EVEN THOUGH THE ENGINE HAS BEEN STARTED 243
M-12 THE ENGINE WATER TEMPERATURE GAUGE IS INDICATING ABNORMALLY LOW TEMPERATURE READING 244
M-13 THE ENGINE WATER TEMPERATURE GAUGE IS UNWORKABLE 244
M-14 THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS INDICATING ABNORMALLY LOW TEMPERATURE READING 245
M-15 THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS UNWORKABLE 245
M-16 THE FUEL GAUGE ALWAYS INDICATE THE FULL TANK STATE 246
M-17 THE FUEL GAUGE DOES NOT MAKE INDICATIONS 246
30 DISASSEMBLY AND ASSEMBLY 247
METHOD OF USING MANUAL 249
PRECAUTIONS WHEN CARRYING OUT OPERATION 251
SPECIAL TOOL LIST 253
FUEL INJECTION PUMP ASSEMBLY 258
REMOVAL 258
INSTALLATION 258
CYLINDER HEAD ASSEMBLY 259
REMOVAL 259
INSTALLATION 263
RADIATOR GUARD ASSEMBLY 266
REMOVAL 266
INSTALLATION 267
RADIATOR,TORQUE CONVERTER OIL COOLER ASSEMBLY 268
REMOVAL 268
INSTALLATION 269
PTO ASSEMBLY 270
DISASSEMBLY 270
ASSEMBLY 271
FUEL TANK ASSEMBLY 273
REMOVAL 273
INSTALLATION 274
ENGINE,TORQUE CONVERTER ASSEMBLY 275
REMOVAL 275
INSTALLATION 278
TORQUE CONVERTER ASSEMBLY 279
REMOVAL 279
INSTALLATION 279
DISASSEMBLY 280
ASSEMBLY 284
TORQUE CONVERTER RELIEF VALVE ASSEMBLY 289
DISASSEMBLY 289
ASSEMBLY 289
TORQUE CONVERTER REGULATOR VALVE 289
DISASSEMBLY 289
ASSEMBLY 289
TRANSMISSION ASSEMBLY 290
REMOVAL 290
INSTALLATION 291
TORQUE FLOW TRANSMISSION ASSEMBLY 292
DISASSEMBLY 292
ASSEMBLY 303
TRANSMISSION CONTROL VALVE ASSEMBLY 318
DISASSEMBLY 318
ASSEMBLY 320
TRANSMISSION LUBRICATION VALVE ASSEMBLY 322
DISASSEMBLY 322
ASSEMBLY 322
BEVEL GEAR SHAFT ASSEMBLY 323
DISASSEMBLY 323
ASSEMBLY 325
STEERING CLUTCH ASSEMBLY 330
REMOVAL 330
INSTALLATION 332
DISASSEMBLY 333
ASSEMBLY 334
BRAKE BOOSTER ASSEMBLY 335
DISASSEMBLY 335
ASSEMBLY 335
STEERING RELIEF VALVE ASSEMBLY 336
DISASSEMBLY 336
ASSEMBLY 336
VALVE ASSEMBLY LINKED TO STEERING,BRAKE 337
DISASSEMBLY 338
ASSEMBLY 338
FIRST PINION ASSEMBLY 339
DISASSEMBLY 339
ASSEMBLY 340
FINAL DRIVE ASSEMBLY 341
DISASSEMBLY 341
ASSEMBLY 345
TRACK FRAME ASSEMBLY 350
REMOVAL 350
INSTALLATION 350
RECOIL SPRING ASSEMBLY 351
REMOVAL 351
INSTALLATION 352
DISASSEMBLY 353
ASSEMBLY 353
IDLER ASSEMBLY 354
REMOVAL 354
INSTALLATION 354
TRACK SHOE ASSEMBLY 355
REMOVAL 355
INSTALLATION 355
ENTIRE DISASSEMBLY 356
ENTIRE ASSEMBLY 361
1 LINK IN FIELD 375
DISASSEMBLY 375
ASSEMBLY 377
MASTER LINK 379
DISASSEMBLY 379
ASSEMBLY 381
BLADE,RIPPER CONTROL VALVE ASSEMBLY 384
DISASSEMBLY 385
ASSEMBLY 385
BLADE TILT CONTROL VAVLE 386
DISASSEMBLY 386
ASSEMBLY 386
RIPPER SELECTOR VALVE ASSEMBLY 387
DISASSEMBLY 388
ASSEMBLY 388
OIL CYLINDER ASSEMBLY 389
DISASSEMBLY 389
ASSEMBLY 391
PIN PULLER CYLINDER ASSEMBLY 393
DISASSEMBLY 393
ASSEMBLY 393
WORK MACHINE ASSEMBLY 394
REMOVAL 394
INSTALLATION 394
DISASSEMBLY 395
ASSEMBLY 396
RIPPER ASSEMBLY 397
DISASSEMBLY 397
ASSEMBLY 398
CABIN ASSEMBLY 399
REMOVAL 399
INSTALLATION 400
CABIN FLOOR FRAME ASSEMBLY 401
REMOVAL 401
INSTALLATION 402
FLOOR FRAME ASSEMBLY 403
REMOVAL 403
INSTALLATION 404
40 MAINTENANCE STANDARD 405
ENGINE MOUNT 406
TORQUE CONVERTER 407
TRANSMISSION 409
TRANSMISSION CONTROL VALVE 411
TRANSMISSION LUBRICATION RELIEF VALVE 413
TRANSMISSION PUMP 414
BEVEL GEAR SHAFT 415
STEERING CLUTCH 417
STEERING PUMP 419
STEERING MAIN RELIEF VALVE 420
STEERING AND BRAKE CONTROL VALVE 421
STEERING BRAKE 423
SPRING ASSIST BRAKE CYLINDER 425
AUTOMATIC DRAIN VALVE 426
FINAL DRIVE 427
TRACK FRAME 429
RECOIL SPRING 430
LDLER 431
TRACK ROLLER 433
CARRIER ROLLER 435
TRACK SHOE (DRY TYPE) 437
TRACK SHOE (SEALED AND LUBRICATED TYPE) 440
SUSPENSION 444
WORK EQUIPMENT PUMP 445
ROTARY SERVO VALVE (FOR BLADE LIFT) 446
MAIN CONTROL VALVE 447
BLADE TILT VALVE 449
RIPPER SELECTOR VALVE AND PILOT CHECK VALVE 450
WORK EQUIPMENT CYLINDER 451
QUICK DROP VALVE 453
CYLINDER STAY 454
WORK EQUIPMENT 455
90 OTHERS 460
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO 57001-57284) 461
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO 57285 AND UP) 462

DESCRIPTION:

Komatsu D155A-2 Dozer Bulldozer Shop Manual SEBM018602 –  PDF DOWNLOAD

G.B 20/12/24