Komatsu D155AX-5 Bulldozer Shop Manual SEBM016207 – PDF DOWNLOAD 

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Komatsu D155AX-5 Bulldozer Shop Manual SEBM016207 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D155AX-5 Bulldozer Shop Manual SEBM016207 – PDF DOWNLOAD 

Language : English
Pages : 1184
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu D155AX-5 Bulldozer Shop Manual SEBM016207 – PDF DOWNLOAD 

MACHINE MODEL      SERIAL NO.
D155AX-5                      70001 and up

COVER 1
CONTENTS 2
SAFETY 3
SAFETY NOTICE 3
FOREWORD 5
GENERAL 5
HOW TO READ THE SHOP MANUAL 6
HOISTING INSTRUCTIONS 7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 8
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 15
CONVERSION TABLE 16
01 GENERAL 23
SPECIFICATION DRAWING 24
SPECIFICATIONS 26
WEIGHT TABLE 32
TABLE OF FUEL, COOLANT AND LUBRICANT 34
10 STRUCTURE AND FUNCTION 35
ENGINE CONTROL 36
RADIATOR, OIL COOLER 38
POWER TRAIN 42
POWER TRAIN SYSTEM 43
OVERALL DRAWING OF POWER TRAIN UNIT 44
POWER TRAIN HYDRAULIC SYSTEM DRAWING 46
POWER TRAIN HYDRAULIC PIPING DIAGRAM 48
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 49
DAMPER, UNIVERSAL JOINT 50
TORQUE CONVERTER, PTO 53
TRANSMISSION CONTROL 56
TRANSMISSION 58
TRANSMISSION CONTROL VALVE 68
MAIN RELIEF VALVE 73
LUBRICATION RELIEF VALVE 75
SCAVENGING PUMP STRAINER 76
POWER TRAIN PUMP STRAINER 77
POWER TRAIN OIL FILTER 78
HSS SYSTEM 80
ACTUATION OF HSS SYSTEM 82
HSS PUMP 93
HSS MOTOR 109
PPC, HSS, CHARGE FILTER 117
PPC, HSS, CHARGE VALVE 118
HSS OIL COOLER BYPASS VALVE 121
STEERING BRAKE CONTROL 122
BEVEL GEAR SHAFT, HSS, BRAKE 125
BRAKE VALVE 137
FINAL DRIVE 141
TRACK FRAME 144
RECOIL SPRING 146
TRACK ROLLER BOGIE 147
MAIN FRAME 148
SUSPENSION 150
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 152
PPC CONTROL PIPING DIAGRAM 155
WORK EQUIPMENT CONTROL 156
WORK EQUIPMENT HYDRAULIC SYSTEM AND HSS SYSTEM DIAGRAM 158
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM 162
HYDRAULIC TANK AND FILTER 164
ACCUMULATOR 166
PPC LOCK VALVE 167
PPC VALVE 168
PISTON VALVE 178
PIN PULLER SWITCH 179
PIN PULLER SOLENOID VALVE 180
TILT/PITCH SELECTOR SWITCH 182
PITCH SOLENOID VALVE 183
MAIN CONTROL VALVE 185
CYLINDER STAY 212
WORK EQUIPMENT 213
CAB 217
AIR CONDITIONER 219
ELECTRIC WIRING DIAGRAM 220
ELECTRIC CIRCUIT DIAGRAM 228
MONITOR SYSTEM 231
SENSORS 243
ENGINE STARTING SYSTEM 250
HSS ELECTRONIC CONTROL SYSTEM 254
20 TESTING AND ADJUSTING 271
STANDARD VALUE TABLES 271
STANDARD VALUE TABLE FOR ENGINE 272
STANDARD VALUE TABLE FOR CHASSIS 275
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 280
TESTING AND ADJUSTING 295
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 296
MEASURING ENGINE SPEED 297
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 300
MEASURING EXHAUST TEMPERATURE 303
MEASURING EXHAUST COLOR 306
ADJUSTING VALVE CLEARANCE 307
MEASURING COMPRESSION PRESSURE 310
MEASURING BLOW-BY PRESSURE 311
MEASURING ENGINE OIL PRESSURE 314
TESTING AND ADJUSTING FUEL INJECTION TIMING 317
HANDLING EQUIPMENT IN FUEL CIRCUIT 318
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 318
MEASURING FUEL PRESSURE 319
REDUCED CYLINDER MODE OPERATION 320
BLEEDING AIR FROM FUEL SYSTEM 322
CHECK FOR LEAKAGE IN FUEL SYSTEM 323
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 324
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 325
TESTING AND ADJUSTING FUN BELT TENSION 326
ADJUSTING ENGINE SPEED SENSOR 327
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT 328
ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL 330
MEASURING TORQUE CONVERTER STALL SPEED 333
MEASURING FULL STALL SPEED 336
MEASURING POWER TRAIN OIL PRESSURE 339
TESTING AND ADJUSTING HSS MAIN OIL PRESSURE 342
TESTING AND ADJUSTING HSS CHARGE OIL PRESSURE 344
TESTING AND ADJUSTING HSS SERVO CHARGE PRESSURE AND PPC RELIEF PRESSURE 346
BLEEDING AIR FROM HSS PUMP 348
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE 349
ADJUSTING JOYSTICK AND PARKING LEVER 350
TESTING AND ADJUSTING TRAVEL REVERSE SENSING POTENTIOMETER 353
ADJUSTING TRAVEL REVERSE LIMIT SWITCH 354
ADJUSTING STEERING NEUTRAL POSITION 355
PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH 363
ADJUSTING INITIAL CURRENT IN HSS STEERING SYSTEM 367
ADJUSTING BRAKE PEDAL 369
ADJUSTING CLEARANCE OF IDLER 371
TESTING WEAR OF SPROCKET 372
TESTING AND ADJUSTING TRACK SHOE TENSION 373
TESTING AND ADJUSTING HYDRAULIC PRESSURE 374
MEASURING PPC VALVE OUTPUT PRESSURE 376
ADJUSTING PLAY OF PPC VALVE 378
MEASURING SOLENOID VALVE OUTPUT PRESSURE 379
TESTING LOCATION CAUSING HYDRAULIC DRIFT OF BLADE AND RIPPER 380
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER 381
RELEASING REMAINING OIL PRESSURE IN HYDRAULIC CYLINDER 382
BLEEDING AIR FROM HYDRAULIC CYLINDER 382
ADJUSTING WORK EQUIPMENT SAFETY LEVER 383
ADJUSTING SEMI-U TILTDOZER 384
TROUBLESHOOTING 387
POINTS TO REMEMBER WHEN TROUBLESHOOTING 388
SEQUENCE OF EVENTS IN TROUBLESHOOTING 389
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 390
CHECKS BEFORE TROUBLESHOOTING 398
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 400
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 412
FUNCTION OF ELECTRONIC CONTROL SYSTEM 432
DISPLAY OF HSS CONTROLLER 436
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL 440
HOW TO READ JUDGMENT TABLE 452
JUDGMENT TABLE FOR ENGINE SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM, AND ELECTRICAL SYSTEM 454
METHOD OF USING TROUBLESHOOTING CHARTS 456
TROUBLESHOOTING OF NETWORK SYSTEM (N MODE) 459
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 460
N MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM 462
SERVICE CODES OF NETWORK SYSTEM 463
N-1 E0101 (Abnormality in network system: engine controller system) is displayed 464
N-2 E0104 (Abnormality in network system: monitor panel system) is displayed 465
N-3 E0105 (Abnormality in network system: HSS controller system) is displayed 466
N-4 E0101, E0104, and E0105 (Abnormality in network system) are displayed at same time 467
N-5 E0152 (Abnormality in network system: HSS contoller system) is displayed 468
N-6 E0165 (Error in network communication) is displayed 469
N-7 E0436 (Abnormality in network system: engine controller) is displayed 470
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 471
METHOD OF USING TROUBLESHOOTING CHARTS 472
S-1 Starting performance is poor (starting always takes time) 476
S-2 Engine does not start 477
① Engine runs but exhaust gas does not come out (fuel is not being injected) 477
② Exhaust gas comes out but engine does not start (fuel is being injected) 478
S-3 Engine does not pick up smoothly (follow-up is poor) 479
S-4 Engine stops during operations 480
S-5 Engine does not rotate smoothly (hunting) 481
S-6 Engine lacks power 482
S-7 Exhaust gas is black (incomplete combustion) 483
S-8 Oil consumption is excessive (or exhaust gas is blue) 484
S-9 Oil becomes contaminated quickly 485
S-10 Fuel consumption is excessive 486
S-11 Oil is in cooling water, or water spurts back, or water level goes down 487
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 488
S-13 Oil level rises (water of fuel mixed with oil) 489
S-14 Water temperature becomes too high (overheating) 490
S-15 Abnormal noise is made 491
S-16 Vibration is excessive 492
TROUBLESHOOTING OF HSS CONTROLLER AND ELECTRICAL SYSTEM (E-MODE) [Serial No 70001-75000] 493
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 494
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE 502
E-1 [19] Short circuit in steering oil pressure sensor system A is displayed 504
E-2 [20] Disconnection in steering oil pressure sensor system A is displayed 505
E-3 [21] Short circuit in steering oil pressure sensor system B is displayed 506
E-4 [22] Disconnection in steering oil pressure sensor system B is displayed 507
E-5 [23] Trouble of steering potentiometer systems 1 and 2 is displayed 508
E-6 [24] Disconnection in steering potentiometer system 1 is displayed 509
E-7 [25] Short circuit in steering potentiometer system 1 is displayed 510
E-8 [26] Disconnection in steering potentiometer system 2 is displayed 511
E-9 [25] Short circuit in steering potentiometer system 2 is displayed 512
E-10 [29] Trouble of engine rotation sensor system is displayed 513
E-11 [51] Short circuit in travel reverse sensing potentiometer system is displayed 514
E-12 [52] Disconnection in travel reverse sensing potentiometer system is displayed 515
E-13 [53] Disconnection in backup alarm relay system is displayed 517
E-14 [54] Short circuit in backup alarm relay system is displayed 518
E-15 [57] Low voltage of controller is displayed 519
E-16 [62] Excessive difference of signal value between steering potentiometer systems 1 and 2 is displayed [I] 520
E-17 [6d] Excessive difference of signal value between steering potentiometer systems 1 and 2 is displayed [II] 521
E-18 [6E] Trouble of either abnormality in steering potentiometer system and excessive deviation of neutral point is displayed 522
E-19 [64] Disconnection in HSS pump solenoid valve system A is displayed 523
E-20 [65] Short circuit in HSS pump solenoid valve system A is displayed 524
E-21 [66] Disconnection in HSS pump solenoid valve system B is displayed 525
E-22 [67] Short circuit in HSS pump solenoid valve system B is displayed 526
E-23 [70] Short circuit in work equipment circuit oil pressure sensor system is displayed 527
E-24 [71] Disconnection in work equipment circuit oil pressure sensor system is displayed 528
E-25 [8d] System network communication error is displayed 529
E-26 [99] Disagreement of reverse sensing potentiometer and backup alarm switch signal with each other is displayed 530
E-27 [E0] Trouble of offset current memory is displayed 532
E-28 Backup alarm does not sound 533
E-29 Blade pitch does not work normally (When equipped with pitch dozer) 534
E-30 Ripper pin puller does not work normally (When equipped with giant ripper) 536
E-31 Engine does not start (Engine does not rotate) 538
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 541
TABLE OF FAILURE MODES AND CAUSES 542
H-1 Machine does not move or moves slowly at any gear speed in each direction 544
H-2 Machine does not move or travel power is low in one direction 546
H-3 Machine does not move or moves slowly at specific gear speed 546
H-4 Long time lag is made in changing travel direction or gear speed 547
H-5 Travel power (Drawbar pull) is low 548
H-6 Machine cannot be steered (to one direction) 549
H-7 Steering speed or power is low 549
H-8 Abnormal sound comes out of HSS pump or HSS motor 550
H-9 Brake does not work 552
H-10 Power train oil overheats 553
H-11 Work equipment does not work at all 554
H-12 Work equipment speed or power is low 555
H-13 Blade lifting speed or power is low 556
H-14 Blade tilting speed or power is low 556
H-15 Ripper lifting speed or power is low 557
H-16 Ripper tilting speed or power is low 557
H-17 Hydraulic drift is large in blade lifting direction 558
H-18 Hydraulic drift is large in blade tilting direction 558
H-19 Hydraulic drift is large in ripper lifting direction 559
H-20 Blade pitch does not work normally (When equipped with pitch dozer) 559
H-21 Ripper pin puller does not work normally (When equipped with giant ripper) 560
H-22 Abnormal sound comes out of work equipment pump 560
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE) [Serial No 70001-75000] 561
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE 562
M-1 Monitor lamps do not light up for 3 seconds when starting switch is turned ON 563
M-2 When starting switch is turned ON, monitor lamps all light up but do not go out 563
M-3 Abnormality in preheating monitor lamp 564
M-4 Abnormality in battery charge lamp 566
M-5 Abnormality in engine oil pressure caution lamp 568
M-6 Engine water temperature caution lamp flashes 570
M-7 Transmission oil temperature caution lamp flashes 570
M-8 HSS oil temperature caution lamp flashes 571
M-9 HSS charge oil pressure caution lamp flashes 572
M-10 Electronic system caution lamp on monitor panel does not work in accordance with LED display on HSS controller 573
M-11 Monitor caution lamp on monitor panel does not work in accordance with each caution lamp 573
M-12 Alarm buzzer does not sound or sounds continuously 574
M-13 Abnormality in engine water temperature gauge 576
M-14 Abnormality in transmission oil temperature gauge 578
M-15 Abnormality in fuel level gauge 580
M-16 Service meter does not work after engine is started 582
M-17 Monitor panel night lighting does not light up when head lamp switch is turned on 583
M-18 Head lamps or rear lamps do not light up 584
M-19 Automatic preheating is not carried out when preheating switch is turned to AUTO 586
M-20 Window wipers and window washers do not work 588
M-21 Air conditioner does not work 592
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE) [Serial No 75001 and up] 597
ACTION TAKEN BY CONTROLLRE WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 598
M MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM 600
M-1 [E0120] (Abnormality in monitor panel caution lamp system) is displayed 602
M-2 [E0121] (Abnormality in monitor panel caution buzzer system) is displayed 603
M-3 [E0211] (Abnormality in oil temperature of power line: torque converter) is displayed 604
M-4 [E0329] (Abnormality in HSS oil temperature) is displayed 604
M-5 [E0430] (Abnormality in engine oil pressure) is displayed 605
M-6 [E0432] (Abnormality in engine water temperature) is displayed 605
M-7 When starting switch is turned ON, all segments of monitor panel do not light up 606
M-8 When starting switch is turned ON, all segments of monitor panel light up but do not go out 608
M-9 When starting switch is turned ON (with engine stopped), caution items (excluding battery charge level and engine oil pressure) flash 609
M-10 When engine is started, caution items flash (daily check items and engine related items are normal) 611
M-11 HSS charging oil pressure caution lamp flashes 614
M-12 Preheater lamp does not light up or stays lighted up 615
M-13 Abnormality in caution buzzer 616
M-14 Abnormality in CAUTION lamp 618
M-15 Abnormality in engine water temperature gauge 620
M-16 Abnormality in power train (torque converter) oil pressure gauge 621
M-17 Abnormality in fuel level gauge 623
M-18 Gear speed display segments indicate [- -], and engine speed is not displayed 625
M-19 Service meter does not advance while engine is running 625
M-20 Abnormality in service mode display 626
M-21 Monitor panel lighting does not light up (though headlamps and working lamps light up) 628
M-22 When head lamp switch is turned on, monitor panel lighting does not light up 630
M-23 Head lamps or rear lamps do not light up 631
M-24 Electric intake air heater does not work 633
M-25 Windshield wiper or washer does not work 635
M-26 Air conditioner does not work 638
TROUBLESHOOTING OF ENGINE CONTROLLER (G MODE) 643
ACTION TAKEN BY CONTROLLRE WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 644
JUDGMENT TABLE FOR ENGINE CONTROLLER AND ENGINE 652
G MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM 654
G-1 [E0401] (Abnormality in engine controller power supply) is displayed 656
G-2 [E0402] (Abnormality in engine controller) is displayed 657
G-3 [E0405] (Abnormality in fuel control dial system) is displayed 658
G-4 [E0406] (Abnormality in decelerator potentiometer system) is displayed 659
G-5 [E0409] (Abnormality in Ne speed sensor system) is displayed 660
G-6 [E0410] (Abnormality in G speed sensor system) is displayed 661
G-7 [E0458] (Short circuit in fuel injector No 1, No 2, No 3 system) is displayed 662
G-8 [E0459] (Short circuit in fuel injector No 4, No 5, No 6 system) is displayed 665
G-9 [E0460] (Abnormality in controller chassis ground circuit) is displayed 668
G-10 [E0461] (Disconnection in fuel injector No 1 system) is displayed 669
G-11 [E0462] (Disconnection in fuel injector No 2 system) is displayed 670
G-12 [E0463] (Disconnection in fuel injector No 3 system) is displayed 671
G-13 [E0464] (Disconnection in fuel injector No 4 system) is displayed 672
G-14 [E0465] (Disconnection in fuel injector No 5 system) is displayed 673
G-15 [E0466] (Disconnection in fuel injector No 6 system) is displayed 674
G-16 [E0468] (Overcurrent if fuel supply pump PCV1 system) is displayed 675
G-17 [E0469] (Disconnection if fuel supply pump PCV1 system) is displayed 676
G-18 [E0470] (Overcurrent if fuel supply pump PCV2 system) is displayed 677
G-19 [E0471] (Disconnection if fuel supply pump PCV2 system) is displayed 678
G-20 [E0472] (Abnormality in boost pressure sensor system) is displayed 679
G-21 [E0474] (Abnormality in common rail fuel pressure sensor system) is displayed 680
G-22 [E0476] (Abnormality in high engine water temperature sensor system) is displayed 681
G-23 [E0478] (Abnormality in low engine water temperature sensor system) is displayed 682
G-24 [E0480] (Abnormality in common rail fuel pressure system) is displayed 683
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 684
G-26 [E0483] (No-pressure feed by fuel supply pump 1) is displayed [E0484] (No-pressure feed by fuel supply pump 2) is displayed 685
G-27 [E0487] (Abnormality in engine oil pressure switch system) is displayed 687
G-28 [E0488] (Abnormality in power supply system 1) is displayed 689
G-29 [E0489] (Abnormality in power supply system 2) is displayed 691
G-30 [E0490] (Abnormality in Q regulator switch signal) is displayed 692
G-31 [E0491] (Short circuit in starting switch C system) is displayed 693
TROUBLESHOOTING OF HSS CONTROLLER AND ELECTRICAL SYSTEM (E MODE) [Serial No 75001-75999] 695
ACTION TAKEN BY CONTROLLRE WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 696
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE 704
E-1 [E0113] (Drop of HSS controller power supply voltage) is displayed 706
E-2 [E0143] (Abnormality in HSS controller 5V power supply voltage) is displayed 707
E-3 [E0145] (Abnormality in HSS controller sensor power supply voltage) is displayed 708
E-4 [E0161] (Abnormality in HSS controller memory data of offset current) is displayed 709
E-5 [E0221] (Abnormality in gear speed switch system) is displayed 710
E-6 [E0233] (Short circuit in travel REVERSE sensing potentiometer system) is displayed 711
E-7 [E0233] (Disconnection in travel REVERSE sensing potentiometer system) is displayed 712
E-8 [E0237] (Abnormality in transmission NEUTRAL signal) is displayed 714
E-9 [E0272] (Unequality between travel REVERSE sensing potentiometer signal and backup alarm switch signal) is displayed 715
E-10 [E0360] (Disconnection in work equipment oil pressure sensor system) is displayed 717
E-11 [E0361] (Short circuit in work equipment oil pressure sensor system) is displayed 718
E-12 [E0610] (Disconnection in backup alarm relay system) is displayed 719
E-13 [E0611] (Short circuit in backup alarm relay system) is displayed 720
E-14 [E0730] (Abnormality in both steering potentiometer systems 1 and 2) is displayed 721
E-15 [E0731] (Large difference between steering potentiometer systems 1 and 2: Case I) is displayed 722
E-16 (Abnormality in steering potentiometer system on one side and large deviation of neutral position on one side) is displayed 723
E-17 [E0733] (Disconnection in steering potentiometer system 1) is displayed 724
E-18 [E0733] (Short circuit in steering potentiometer system 1) is displayed 725
E-19 [E0734] (Disconnection in steering potentiometer system 2) is displayed 726
E-20 [E0734] (Short circuit in steering potentiometer system 2) is displayed 727
E-21 [E0735] (Large difference between steering potentiometer systems 1 and 2: Case II) is displayed 728
E-22 [E0768] (Disconnection in steering oil pressure sensor A system) is displayed 729
E-23 [E0769] (Short circuit in steering oil pressure sensor A system) is displayed 730
E-24 [E0770] (Disconnection in steering oil pressure sensor B system) is displayed 731
E-25 [E0771] (Short circuit in steering oil pressure sensor B system) is displayed 732
E-26 [E0774] (Disconnection in HSS pump solenoid A system) is displayed 733
E-27 [E0775] (Short circuit in HSS pump solenoid A system) is displayed 734
E-28 [E0772] (Disconnection in HSS pump solenoid B system) is displayed 735
E-29 [E0773] (Short circuit in HSS pump solenoid B system) is displayed 736
E-30 [E0930] (Abnormality in engine speed sensor system) is displayed 737
E-31 Backup alarm does not sound 738
E-32 Blade pitch malfunctions (Machine equipped with pitch dozer) 739
E-33 Ripper pin puller malfunctions (Machine equipped with giant ripper) 741
E-34 Engine does not start (Engine does not rotate) 743
30 DISASSEMBLY AND ASSEMBLY 747
METHOD OF USING MANUAL 749
PRECAUTIONS WHEN CARRYING OUT OPERATION 751
SPECIAL TOOL LIST 753
SPECIAL TOOL SKETCH 763
STARTINGMOTOR 772
REMOVAL 772
INSTALLATION 772
ALTERNATOR 773
REMOVAL 773
INSTALLATION 773
ENGINE OIL COOLER CORE 774
REMOVAL 774
INSTALLATION 774
FUEL INJECTION PUMP 775
REMOVAL 775
INSTALLATION 776
WATER PUMP 777
REMOVAL 777
INSTALLATION 777
TURBOCHARGER 778
REMOVAL 778
INSTALLATION 778
NOZZLE HOLDER 781
REMOVAL 781
INSTALLATION 781
FUEL INJECTOR 782
REMOVAL 782
INSTALLATION 783
ENGINE FRONT SEAL 786
REMOVAL 786
INSTALLATION 787
ENGINE REAR SEAL 789
REMOVAL 789
INSTALLATION 790
CYLINDER HEAD 794
REMOVAL 794
INSTALLATION 799
THERMOSTAT 801
REMOVAL 801
INSTALLATION 801
AIR CONDITIONER COMPRESSOR 802
REMOVAL 802
INSTALLATION 803
AIR CONDITIONER CONDENSER 804
REMOVAL 804
INSTALLATION 804
FUEL TANK 805
REMOVAL 805
INSTALLATION 805
RADIATOR 806
REMOVAL 806
INSTALLATION 808
RADIATOR, OIL COOLER, GUARD 809
REMOVAL 809
INSTALLATION 811
FAN DRIVE 812
REMOVAL 812
INSTALLATION 813
HYDRAULIC COOLER 814
REMOVAL 814
INSTALLATION 814
ENGINE 815
REMOVAL 815
INSTALLATION 819
DAMPER 820
REMOVAL 820
INSTALLATION 821
DISASSEMBLY 822
ASSEMBLY 825
POWER TRAIN UNIT 829
REMOVAL 829
INSTALLATION 833
SEPARATION 834
POWER TRAIN 838
PTO 839
DISASSEMBLY 839
ASSEMBLY 843
TORQUE CONVERTER 848
DISASSEMBLY 848
ASSEMBLY 851
TORQFLOW TRANSMISSION 854
DISASSEMBLY 854
ASSEMBLY 863
HSS CASE 874
DISASSEMBLY 874
ASSEMBLY 883
HYDRAULIC PUMP 896
REMOVAL 896
INSTALLATION 900
HSS PUMP 901
DISASSEMBLY 901
ASSEMBLY 908
HSS MOTOR 919
REMOVAL 919
INSTALLATION 919
POWER TRAIN MAIN RELIEF VALVE 920
REMOVAL 920
INSTALLATION 920
DISASSEMBLY 921
ASSEMBLY 921
HSS, PPC CHARGE VALVE 922
REMOVAL 922
INSTALLATION 922
HSS, PPC CHARGING VALVE 923
DISASSEMBLY 923
ASSEMBLY 924
TRANSMISSION CONTROL VALVE 925
REMOVAL 925
INSTALLATION 926
DISASSEMBLY 927
ASSEMBLY 927
BRAKE VALVE 929
REMOVAL 929
INSTALLATION 929
DISASSEMBLY 930
ASSEMBLY 930
FINAL DRIVE 932
REMOVAL 932
INSTALLATION 934
DISASSEMBLY 935
ASSEMBLY 940
TRACK FRAME 946
REMOVAL 946
INSTALLATION 948
IDLER 949
REMOVAL 949
INSTALLATION 950
DISASSEMBLY 951
ASSEMBLY 953
RECOIL SPRING 956
REMOVAL 956
INSTALLATION 956
DISASSEMBLY 957
ASSEMBLY 962
TRACK ROLLER 966
REMOVAL 966
INSTALLATION 967
DISASSEMBLY 968
ASSEMBLY 971
BOGIE 974
REMOVAL 974
INSTALLATION 976
DISASSEMBLY 977
ASSEMBLY 981
CARRIER ROLLER 985
REMOVAL 985
INSTALLATION 985
DISASSEMBLY 986
ASSEMBLY 988
TRACK SHOE 991
CHECKING BEFORE REMOVAL 991
REMOVAL (NORMAL) 991
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) 992
INSTALLATION 993
OVERALL DISASSEMBLY 994
OVERALL ASSEMBLY 999
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 1013
ONE LINK 1014
FIELD DISASSEMBLY 1014
FIELD ASSEMBLY 1016
MASTER LINK 1018
DISASSEMBLY 1018
ASSEMBLY 1020
PIVOT SHAFT 1023
REMOVAL 1023
INSTALLATION 1023
EQUALIZER BAR 1024
REMOVAL 1024
INSTALLATION 1025
EQUALIZER BAR SIDE BUSHING 1026
REMOVAL 1026
INSTALLATION 1026
SEGMENT TEETH 1027
REMOVAL 1027
INSTALLATION 1027
HYDRAULIC TANK 1028
REMOVAL 1028
INSTALLATION 1028
MAIN CONTROL VALVE 1029
REMOVAL 1029
INSTALLATION 1030
DISASSEMBLY 1031
ASSEMBLY 1034
HSS OIL COOLER BYPASS VALVE 1038
REMOVAL 1038
INSTALLATION 1038
HMT OIL COOLER BYPASS VALVE 1039
DISASSEMBLY 1039
ASSEMBLY 1039
BLADE PPC VALVE 1040
REMOVAL 1040
INSTALLATION 1041
RIPPER PPC VALVE 1042
REMOVAL 1042
INSTALLATION 1043
BLADE PPC VALVE 1044
DISASSEMBLY 1044
INSTALLATION 1045
BLADE LIFT CYLINDER 1047
REMOVAL 1047
INSTALLATION 1047
BLADE TILT CYLINDER 1048
REMOVAL 1048
INSTALLATION 1048
RIPPER LIFT CYLINDER 1049
REMOVAL 1049
INSTALLATION 1049
RIPPER TILT CYLINDER 1050
REMOVAL 1050
INSTALLATION 1050
HYDRAULIC CYLINDER 1051
DISASSEMBLY 1051
ASSEMBLY 1054
BLADE 1058
REMOVAL 1058
INSTALLATION 1059
DISASSEMBLY 1060
ASSEMBLY 1062
MULTI-SHANK RIPPER 1064
DISASSEMBLY 1064
ASSEMBLY 1066
ROPS GUARD 1068
REMOVAL 1068
INSTALLATION 1068
OPERATOR CAB 1069
REMOVAL 1069
INSTALLATION 1069
HOOD 1070
REMOVAL 1070
INSTALLATION 1070
FLOOR FRAME 1071
REMOVAL 1071
INSTALLATION 1076
DASHBOARD 1077
REMOVAL 1077
INSTALLATION 1078
MONITOR 1079
REMOVAL 1079
INSTALLATION 1079
HSS CONTROLLER 1080
REMOVAL 1080
INSTALLATION 1080
40 MAINTENANCE STANDARD 1083
ENGINE MOUNT 1084
POWER TRAIN UNIT MOUNT 1085
DAMPER, UNIVERSAL JOINT 1086
TORQUE CONVERTER, PTO 1088
TRANSMISSION 1092
TRANSMISSION CONTROL VALVE 1095
MAIN RELIEF VALVE 1096
BEVEL GEAR SHAFT, HSS, BRAKE (1/2) 1098
BEVEL GEAR SHAFT, HSS, BRAKE (2/2) 1100
BRAKE VALVE 1102
SCAVENGING PUMP, PPC, HSS CHARGE PUMP 1103
POWER TRAIN PUMP, LUBRICATION PUMP 1104
PPC, HSS, CHARGE VALVE 1106
OIL COOLER BYPASS VALVE 1108
FINAL DRIVE 1110
SPROCKET 1112
MAIN FRAME 1114
TRACK FRAME 1116
RECOIL SPRING 1117
TRACK ROLLER BOGIE 1118
IDLER 1120
TRACK ROLLER 1122
CARRIER ROLLER 1124
TRACK SHOE 1126
SUSPENSION 1134
WORK EQUIPMENT PUMP 1136
HSS PUMP 1137
HSS MOTOR 1138
PPC VALVE 1140
STEERING LEVER 1143
MAIN CONTROL VALVE 1144
WORK EQUIPMENT CYLINDER 1150
QUICK DROP VALVE 1154
CYLINDER STAY 1155
WORK EQUIPMENT 1156
90 OTHERS 1165
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DAIGRAM 1167
MACHINE EQUIPPED WITH PITCH DOZER 1169
ELECTRIC CIRCUIT DIAGRAM (1/3) (Serial No 70001-75000) 1171
ELECTRIC CIRCUIT DIAGRAM (2/3) (Serial No 70001-75000) 1173
ELECTRIC CIRCUIT DIAGRAM (3/3) (Serial No 70001-75000) 1175
ELECTRIC CIRCUIT DIAGRAM (1/3) (Serial No 75001 and up) 1177
ELECTRIC CIRCUIT DIAGRAM (2/3) (Serial No 75001 and up) 1179
ELECTRIC CIRCUIT DIAGRAM (3/3) (Serial No 75001 and up) 1181
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB (Serial No 75001 and up) 1183

DESCRIPTION:

Komatsu D155AX-5 Bulldozer Shop Manual SEBM016207 – PDF DOWNLOAD 

MACHINE MODEL      SERIAL NO.
D155AX-5                      70001 and up

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

IMAGES PREVIEW OF THE MANUAL:

S.V  25/12/24