Komatsu D155AX-5 Crawler Bulldozer Shop Manual SEBM034807 – PDF DOWNLOAD

Description

Komatsu D155AX-5 Crawler Bulldozer Shop Manual

FILE DETAILS:

Komatsu D155AX-5 Crawler Bulldozer Shop Manual

Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D155AX-5
Serial Number: 76001 and up
Book Code: SEBM034807
Language: English
Pages: 1145
File Format: Portable Document Format (PDF)

DESCRIPTION:

Komatsu D155AX-5 Crawler Bulldozer Shop Manual 

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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
Disassembly and assembly:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
Maintenance standard:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”.
Others:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu D155AX-5 Crawler Bulldozer Shop Manual 

COVER..................................................................................................................   1
CONTENTS...............................................................................................................   2
01 GENERAL.............................................................................................................  28
	SPECIFICATION DRAWING..............................................................................................  29
	SPECIFICATIONS.....................................................................................................  31
	WEIGHT TABLE.......................................................................................................  37
	TABLE OF FUEL, COOLANT AND LUBRICANT...............................................................................  39
10 STRUCTURE AND FUNCTION..............................................................................................  40
	RADIATOR, OLL COOLER...............................................................................................  41
	POWER TRAIN SYSTEM.................................................................................................  44
	OVERALL DRAWING OF POWER TRAIN UNIT ...............................................................................  46
	POWER TRAIN HYDRAULIC EQUIPMENT LAYOUT.............................................................................  48
	DAMPER, UNIVERSAL JOINT............................................................................................  49
	TORQUE CONVERTER, PTO..............................................................................................  51
	TRANSMISSION CONTROL...............................................................................................  54
	TRANSMISSION.......................................................................................................  56
	TRANMISSION ECMV...................................................................................................  66
	MAIN RELIF VALVE...................................................................................................  71
	LUBRICATION FELIEF VALVE...........................................................................................  73
	POWER TRAIN PUMP STARINER..........................................................................................  75
	POWER TRAIN OIL FILTER.............................................................................................  76
	HSS SYSTEM.........................................................................................................  77
	HSS PUMP...........................................................................................................  88
	HSS MOTOR.......................................................................................................... 104
	COOLING FAN PUMP................................................................................................... 111
	COOLING FAN MOTOR.................................................................................................. 119
	HSS CHARGE FILTER BYPASS VALVE..................................................................................... 125
	HSS OIL COOLER BYPASS VALVE........................................................................................ 126
	STEERING BRAKE CONTROL............................................................................................. 127
	BEVEL GEAR SHAFT, HSS, BRAKE....................................................................................... 129
	TRACK FRAME........................................................................................................ 149
	FINAL DRIVE........................................................................................................ 146
	TRACK ROLLER BOGIE................................................................................................. 151
	RECOIL SPRING...................................................................................................... 152
	MAIN FRAME......................................................................................................... 153
	SUSPENSION......................................................................................................... 154
	WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM............................................................................ 156
	PPC CONTROL PIPING DIAGRAM......................................................................................... 159
	WORK EQUIPMENT CONTROL............................................................................................. 160
	HYDRAULIC TANK AND FILTER.......................................................................................... 162
	ACCUMULATOR........................................................................................................ 164
	PPC LOCK VALVE..................................................................................................... 165
	PPC VALVE.......................................................................................................... 166
	PCCS LEVER......................................................................................................... 176
	PISTON VALVE....................................................................................................... 179
	PIN PULLER SWITCH.................................................................................................. 180
	PIN PULLER SOLENOID VALVE.......................................................................................... 181
	MAIN CONTROL VALVE................................................................................................. 183
	SELF PRESSURE REDUCING VALVE....................................................................................... 209
	CYLINDER STAY...................................................................................................... 216
	WORK EQUIPMENT..................................................................................................... 217
	CAB MOUNT.......................................................................................................... 221
	CAB................................................................................................................ 222
	AIR CONDITIONER.................................................................................................... 224
	ENGINE CONTROL..................................................................................................... 225
	ENGINE CONTROL SYSTEM.............................................................................................. 226
	CRI ENGINE CONTROL SYSTEM.......................................................................................... 227
	MONITOR SYSTEM..................................................................................................... 229
	MONITOR PANEL...................................................................................................... 231
	SENSORS............................................................................................................ 234
	DECELERATION POTENTIOMETER......................................................................................... 238
	PALM COMMAND CONTROL SYSTEM ....................................................................................... 240
20 TESTING AND ADJUSTING............................................................................................... 242
	STANDARD VALUE TABLE FOR ENGINE.................................................................................... 243
	STANDARD VALUE TABLE FOR CHASSIS................................................................................... 244
	TESTING AND ADJUSTING ............................................................................................. 250
		TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.............................................................. 251
		MESURING ENGINE SPEED.......................................................................................... 253
		MEASURING INTAKE AIR PRESSURE(BOOST PRESSURE).................................................................. 256
		MEASURING EXHAUST TEMPRATURE................................................................................... 258
		MEASURING EXHAUST GAS COLOR.................................................................................... 260
		ADJUSTING VALVE CLEARANCE...................................................................................... 262
		MEASURING COMPRESSION PRESSURE................................................................................. 263
		MEASURING BLOW-BY PRESSURE..................................................................................... 265
		MEASURING ENGINE OIL PRESSURE.................................................................................. 266
		HANDLING OF FUEL SYSTEM DEVICES................................................................................ 267
		RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM................................................................... 267
		MEASURING FUEL PRESSURE........................................................................................ 268
		BLEEDING AIR FROM FUEL CIRCUIT................................................................................. 269
		INSPECTION OF FUEL CIRCUIT FOR LEAKAGE......................................................................... 271
		TESTING AND ADJUSTING ALTERNATOR BELT TENSION ................................................................. 272
		TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT.......................................................... 273
		ADJUSTNG FUEL CONTROL DIAL AND DECELERATIOR PEDAL.............................................................. 274
		MEASURING POWER TRAIN OIL PRESSURE............................................................................. 276
		TESTING AND ADJUSTING HSS OIL PRESSURE......................................................................... 281
		ADJUSTING TRANSMISSION SPEED SENSOR............................................................................ 286
		BLEEDING AIR FROM HSS PUMP .................................................................................... 287
		SIMPLE METHOD OF TESTING BRAKE PERFORMANCE..................................................................... 287
		ADJUSTING BRAKE PEDAL.......................................................................................... 288
		ADJUSTING AT PARKING BRAKE LEVER .............................................................................. 290
		EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE........................................................... 291
		INSPECTING WEAR OF SPROCKET ................................................................................... 293
		ADJUSTING CLAERANCE OF IDLER................................................................................... 294
		TESTING AND ADJUSTING TRACK SHOE TENSION ...................................................................... 295
		TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE.............................................................. 296
		TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE............................................................ 299
		MEASURING PPC VALVE OUTPUT PRESSURE............................................................................ 300
		ADJUSTING PLAY OF PPC VALVE.................................................................................... 302
		MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE.................................................. 303
		TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER.................................................. 304
		MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER.......................................................... 305
		RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER....................................................... 306
		BLEEDING AIR FROM WORK EQUIPMENT CYLINDER...................................................................... 306
		ADJUSTING WORK EQUIPMENT LOCK LEVER............................................................................ 307
		MEASURING FAN MOTOR SPEED...................................................................................... 308
		MEASURING FAN CIRCUIT OIL PRESSURE............................................................................. 309
		BLEEDING AIR FROM FAN PUMP..................................................................................... 310
		ADJUSTING BLADE (SEMI-U TIL TDOZER)............................................................................ 311
		TESTING AND ADJUSTING OF OPERATOR'S CAB........................................................................ 313
		SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)...................................................................... 317
		HANDLING OF HIGH-VOLT-AGE CIRCUIT OF ENGINE CONTROLLER......................................................... 358
		ADJUSTMENT METHOD OF REPLACED CONTROLLER....................................................................... 358
		PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM....................................................... 360
		PM CLINIC SERVICE.............................................................................................. 362
		UNDERCARRIAGE THROUBLESHOOTING REPORT.......................................................................... 369
	TROUBLESHOOTING.................................................................................................... 373
		POINTS TO REMEMBR WHEN TROUBLESHOOTING ........................................................................ 374
		SEQUENCE OF EVENTS IN TROUBLESHOOTING ......................................................................... 375
		POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .............................................................. 376
		CHECKS BEFORE TROUBLESHOOTING ................................................................................. 384
		CLASSIFICATOIN AND PROCEDURES OF TROUBLESHOOTING .............................................................. 385
		CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM ................................... 388
		CONNECTOR ARRANGEMENT DRAWING ................................................................................. 394
		CIRCUIT DRAWING FOR MONITOR PANEL (M CIRCUIT).................................................................. 400
		CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)....................................................... 402
		CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (S CIRCUIT).................................... 404
		CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................... 406
		T-BRANCH BOX AND T-BRANCH TABLE ............................................................................... 429
		PARTS & SERVICE OPERATION TIPS................................................................................. 431
	CONTENTS........................................................................................................... 432
		3. GENERAL DESCRIPTION OF CONNECTOR............................................................................ 433
			3-1 DT CONNECTOR........................................................................................... 433
			3-2 HD30 CONNECTOR......................................................................................... 433
			3-3 PIN NUMBER ARRANGEMENT................................................................................. 434
				3-3-1 PIN NUMBER ARRANGMENT OF DT CONNECTOR............................................................ 434
				3-3-2 INSERT ARRANGMENT OF HD30 CONNECTOR (VIEWED FROM THE PIN TERMINAL)............................... 435
		4. GENERAL DESCRIPTION OF KIT.................................................................................. 436
			4-1 OUTLINE OF THE KIT .................................................................................... 436
				4-1-1 REPAIR KIT (A)................................................................................... 436
				4-1-2 REPAIR KIT (B)................................................................................... 436
			4-2 TYPES AND IDENTIFICATION OF PINS AND SOCKETS <REFERENCE>............................................... 437
				4-2-1 PIN TERMINAL .................................................................................... 437
				4-2-2 SOCKET TERMINAL ................................................................................. 437
				4-2-3 IDENTIFYING SEALING PLUG......................................................................... 437
		5. LIST OF REPAIR KIT COMPONENTS............................................................................... 438
			5-1 REPAIR KIT (A) COMPONENT LIST (PART NO.: 790-222-4000)................................................. 438
			5-2 REPAIR KIT (B) COMPONENT LIST (PART.: 790-222-4100).................................................... 440
		6. REPLACEMENT OF CONNECTORS AND TERMINALS..................................................................... 441
			6-1 PULLING OUT AND FITTING IN THE CONNECTOR TERMINAL ..................................................... 441
				6-1-1 TOOLS REQUIRED................................................................................... 441
				6-1-2 PULLING OUT THE TERMINAL......................................................................... 442
				6-1-3 FITTING IN THE TERMINAL.......................................................................... 442
			6-2 PULLING OUT AND FITTING IN THE HD30 CONNECTOR TERMINAL................................................. 444
				6-2-1 TOOLS REQUIED ................................................................................... 444
				6-2-2 PULLING OUT THE TERMINAL ........................................................................ 444
				6-2-3 FITTING IN THE TERMINAL ......................................................................... 445
		7. CRIMP OF TERMINAL .......................................................................................... 446
			7-1 TOOLS REQUIED.......................................................................................... 446
			7-2 SELECTING PIN AND SOCKET TERMINALS..................................................................... 446
			7-3 CRIMPING THE TERMINAL ................................................................................. 446
		8. REPLACEMENT OF MACHINE-MOUNTED CONNECTORS WITH DEUTSCH CONNECTORS........................................... 448
		9. PART NO.LIST OF HD30 CONNECTOR BODY ........................................................................ 450
			9-1 PART NO. LIST OF HD30 CONNECTOR BODY (WITHOUT ADAPTOR)................................................. 450
			9-2 PART NO. LIST OF HD30 CONNECTOR BODY (WITH ADAPTOR).................................................... 451
			9-3 CONNECTOR MOUNTING NUT WASHER.......................................................................... 452
	TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE).......................................................... 454
		ERROR CODES TABLE.............................................................................................. 455
		INFORMATION DESCRIBED IN TROUBLESHOOTING LIST.................................................................. 459
		TROUBLESHOOTING AT EACH ERROR CODE............................................................................. 461
	TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...................................................................... 643
		BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)............................................. 644
		INFORMATION DESCRIBED IN TROUBLESHOOTING LIST.................................................................. 645
		E-1 THE ENGINE DOES NOT START ................................................................................. 646
		E-2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)................................................ 648
		E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE (GIANT RIPPER ATTACHMENT MACHINE).......................... 650
		E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON............................ 652
		E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.... 654
		E-6 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION FLASHES.................................... 655
		E-7 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES.......................................... 657
		E-8 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON............................... 661
		E-9 THE ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY............................................ 663
		E-10 INDICATION OF THE POWER OIL TEMPERATURE GAUGE IS ABNORMAL................................................. 664
		E-11 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY............................................ 665
		E-12 INDICATION OF THE FUEL GAUGE IS ABNORMAL.................................................................. 666
		E-13 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL................................................... 667
		E-14 INDICATION OF THE SHIFT MODE AND SERVICE METER ARE ABNORMAL............................................... 667
		E-15 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT ....................................................... 668
		E-16 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.......................................................... 669
		E-17 AUTO SHIFT DOWN SWITCH DOES NOT WORK  .................................................................... 670
		E-18 THE FAN RATATION SELECT SWITCH DOES NOT WORK.............................................................. 671
		E-19 THE BUZZER CANCEL SWITCH DOES NOT WORK.................................................................... 673
		E-20 THE INFORMATOIN SWITCH DOES NOT WORK ..................................................................... 675
		E-21 CANNOT ENTER INTO SERVICE MODE............................................................................ 677
		E-22 THE BACK-UP ALARM DOES NOT SOUND.......................................................................... 679
		E-23 THE HEAD LAMP, PANEL NIGHT LAMP, REAR LAMP, AND RIPPER POINT LAMP DO NOT LIGHT UP......................... 681
		E-24 MALFUNCTION OF WIPERS..................................................................................... 683
		E-25 WASHING WATER DOES NOT COME OUT........................................................................... 695
		E-26 THE AIR CONDITIONER DOES NOT OPERATE...................................................................... 700
	TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)........................................................ 705
		INFORMATION DESCRIBED IN TROUBLESHOOTING LIST.................................................................. 706
		H-1 NO TRAVEL POWER (NO DRAWBAR PULL).......................................................................... 707
		H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)................................................................ 708
		H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE................................................................... 709
		H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE................................................ 710
		H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME IS MADE.................................... 711
		H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD)................................................... 712
		H-7 STEERING SPEED OR POWER IS LOW............................................................................. 712
		H-8 BRAKE DOES NOT WORK........................................................................................ 713
		H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE.................................................................... 713
		H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS PUMP OR HSS MOTOR................................................ 714
		H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW........................................................................ 715
		H-12 WORK EQUIPMENT DOES NOT MOVE.............................................................................. 715
		H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER .................................................................. 716
		H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER................................................................... 716
		H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER.................................................................. 717
		H-16 RIPPER TILT SPEED IS SLOW OR LACKS POWER.................................................................. 717
		H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT................................................................... 718
		H-18 EXCESSIVE HYDRAULIC OF BLADE TILT......................................................................... 718
		H-19 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT.................................................................. 719
		H-20 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE)................................ 719
		H-21 BLADE PITCH DOES NOT WORK (PITCH DOZER ATTACHMENT MACHINE)................................................ 720
		H-22 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP.................................................. 720
	TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE).......................................................................... 721
		MOTHOD OF USING TROUBLESHOOTING CHARTS......................................................................... 722
		S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).................................................. 726
		S-2 ENGINE DOES NOT START...................................................................................... 727
			a) ENGINE DOES NOT TURN ................................................................................... 727
			b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT............................................................. 728
			c) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).............................. 729
		S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)....................................................... 730
		S-4 ENGINE STOPS DURING OPERATIONS............................................................................. 731
		S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................. 732
		S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)....................................................................... 733
		S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................. 734
		S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................... 735
		S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................... 736
		S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................. 737
		S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN).................................... 738
		S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)................................................ 739
		S-13 OIL LEVER RISES (COOLANT, FUEL IN OIL).................................................................... 740
		S-14 COOLANT TEMPERATURE BECOMES TOO HIGHT (OVERHEATING)....................................................... 741
		S-15 ABNORMAL NOISE IS MADE.................................................................................... 742
		S-16 VIBRATION IS ESCESSIVE.................................................................................... 743
30 DISASSEMBLY AND ASSEMBLY............................................................................................ 744
	METHOD OF USING MANUAL............................................................................................. 746
	PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................ 747
	SPECIAT TOOL LIST ................................................................................................. 749
	SPECIAL TOOL SKETCH................................................................................................ 759
	STARTING MOTOR .................................................................................................... 768
		REMOVAL AND INSTALLATION....................................................................................... 768
	ALTERNATOR ........................................................................................................ 769
		REMOVAL AND INSTALLATION....................................................................................... 769
	ENGINE OIL COOLER CORE............................................................................................. 770
		REMOVAL AND INSTALLATION....................................................................................... 770
	FUEL SUPPLY PUMP................................................................................................... 771
		REMOVAL........................................................................................................ 771
		INSTALLATION................................................................................................... 773
	WATER PUMP ........................................................................................................ 775
		REMOVAL AND INSTALLATION....................................................................................... 775
	TURBOCHARGER ...................................................................................................... 776
		REMOVAL AND INSTALLATION....................................................................................... 776
	FUEL INJECTOR...................................................................................................... 777
		REMOVAL........................................................................................................ 777
		INSTALLATION................................................................................................... 778
	NOZZLE TIP......................................................................................................... 780
		REMOVAL........................................................................................................ 780
		INSTALLATION................................................................................................... 781
	ENGINE FRONT SEAL ................................................................................................. 783
		REMOVAL........................................................................................................ 783
		INSTALLATION................................................................................................... 784
	ENGINE REAR SEAL................................................................................................... 786
		REMOVAL ....................................................................................................... 786
		INSTALLATION................................................................................................... 787
	CYLINDER HEAD ..................................................................................................... 791
		REMOVAL........................................................................................................ 791
		INSTALLATION................................................................................................... 796
	THERMOSTAT......................................................................................................... 800
		REMOVAL AND INSTALLATION....................................................................................... 800
	AIR CONDITIONER COMPRESSOR ........................................................................................ 801
		REMOVAL........................................................................................................ 801
		INSTALLATION................................................................................................... 802
	AIR CONDITIONER CONDENSER ......................................................................................... 803
		REMOVAL AND INSTALLATION....................................................................................... 803
	FUEL TANK ......................................................................................................... 804
		REMOVAL AND INSTALLATION....................................................................................... 804
	RADIATOR........................................................................................................... 805
		REMOVAL........................................................................................................ 805
		INSTALLATION................................................................................................... 807
	RADIATOR, OIL COOLER, GUARD........................................................................................ 808
		REMOVAL ....................................................................................................... 808
		INSTALLATION................................................................................................... 810
	FAN DRIVE.......................................................................................................... 811
		REMOVAL AND INSTALLATION....................................................................................... 811
	FAN MOTOR ......................................................................................................... 812
		REMOVAL AND INSTALLATION....................................................................................... 812
	HYDRAULIC COOLER................................................................................................... 813
		REMOVAL AND INSTALLATION....................................................................................... 813
	ENGINE ............................................................................................................ 814
		REMOVAL ....................................................................................................... 814
		INSTALLATION................................................................................................... 816
	DAMPER............................................................................................................. 817
		REMOVAL........................................................................................................ 817
		INSTALLATION................................................................................................... 818
		DISASSEMBLY.................................................................................................... 819
		ASSEMBLY....................................................................................................... 822
	POWER TRAIN UNIT .................................................................................................. 826
		REMOVAL ....................................................................................................... 826
		INSTALLATION................................................................................................... 830
		SEPARATION..................................................................................................... 831
	POWER TRAIN........................................................................................................ 835
		CONNECTION..................................................................................................... 835
	PTO................................................................................................................ 836
		DISASSEMBLY.................................................................................................... 836
		ASSEMBLY....................................................................................................... 840
	TORQUE CONVERTER................................................................................................... 845
		DISASSEMBLY.................................................................................................... 845
		ASSEMBLY ...................................................................................................... 848
	TORQFLOW TRANSMISSION.............................................................................................. 851
		DISASSEMBLY.................................................................................................... 851
		ASSEMBLY....................................................................................................... 860
	HSS CASE .......................................................................................................... 871
		DISASSEMBLY.................................................................................................... 871
		ASSEMBLY....................................................................................................... 880
	HYDRAULIC PUMP..................................................................................................... 893
		REMOVAL........................................................................................................ 893
		INSTALLATION................................................................................................... 897
	HSS MOTOR ......................................................................................................... 898
		REMOVAL AND INSTALLATION....................................................................................... 898
	POWER TRAIN MAIN RELIFF VALVE...................................................................................... 899
		REMOVAL AND INSTALLATION....................................................................................... 899
	POWER TRAIN MAIN RELIFF VALVE...................................................................................... 900
		DISASSEMBLY AND ASSEMBLY....................................................................................... 900
	HSS, PPC CHARGE VALVE.............................................................................................. 901
		REMOVAL AND INSTALLATION....................................................................................... 901
	HSS AND PPC CHARGE VALVE .......................................................................................... 902
		DISASSEMBLY AND ASSEMBLY....................................................................................... 902
	TRANSMISSION CONTROL VALVE......................................................................................... 903
		REMOVAL ....................................................................................................... 903
		INSTALLATION................................................................................................... 904
	TRANSMISSION CONTROL VALVE......................................................................................... 905
		DISASSEMBLY AND ASSEMBLY....................................................................................... 905
	BRAKE VALVE........................................................................................................ 907
		REMOVAL AND INSTALLATION....................................................................................... 907
	BRAKE VALVE........................................................................................................ 908
		DISASSEMBLY AND ASSEMBLY ...................................................................................... 908
	FINAL DRIVE ....................................................................................................... 910
		REMOVAL........................................................................................................ 910
		INSTALLATION................................................................................................... 912
	FINAL DRIVE........................................................................................................ 913
		DISASSEMBLY.................................................................................................... 913
		ASSEMBLY....................................................................................................... 918
	TRACK FRAME........................................................................................................ 924
		REMOVAL........................................................................................................ 924
		INSTALLATION................................................................................................... 926
	IDLER ............................................................................................................. 927
		REMOVAL........................................................................................................ 927
		INSTALLATION................................................................................................... 928
	IDLER.............................................................................................................. 929
		DISASSEMBLY.................................................................................................... 929
		ASSEMBLY ...................................................................................................... 931
	RECOIL SPRING ..................................................................................................... 934
		REMOVAL AND INSTALLATION....................................................................................... 934
	RECOIL SPRING ..................................................................................................... 935
		DISASSEMBLY.................................................................................................... 935
		ASSEMBLY ...................................................................................................... 940
	TRACK ROLLER....................................................................................................... 944
		REMOVAL........................................................................................................ 944
		INSTALLATION................................................................................................... 945
	TRACK ROLLER ...................................................................................................... 946
		DISASSEMBLY.................................................................................................... 946
		ASSEMBLY....................................................................................................... 949
	BOGIE.............................................................................................................. 952
		REMOVAL........................................................................................................ 952
		INSTALLATION................................................................................................... 954
	BOGIE ............................................................................................................. 955
		DISASSEMBLY.................................................................................................... 955
		ASSEMBLY....................................................................................................... 958
	CARRIER ROLLER..................................................................................................... 962
		REMOVAL AND INSTALLATION....................................................................................... 962
	CARRIER ROLLER..................................................................................................... 963
		DISASSEMBLY.................................................................................................... 963
		ASSEMBLY....................................................................................................... 965
	TRACK SHOE......................................................................................................... 968
		REMOVAL........................................................................................................ 968
		INSTALLATION................................................................................................... 970
		OVERALL DISASSEMBLY............................................................................................ 971
		OVERALL ASSEMBLY............................................................................................... 976
	PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS................................................................... 990
	ONE LINK........................................................................................................... 991
		FIELD DISASSEMBLY.............................................................................................. 991
		FIELD ASSEMBLY ................................................................................................ 993
	MASTER LINK........................................................................................................ 995
		DISASSEMBLY.................................................................................................... 995
		ASSEMBLY....................................................................................................... 997
	PIVOT SHAFT........................................................................................................1000
		REMOVAL AND INSTALLATION.......................................................................................1000
	EQUALLZER BAR......................................................................................................1001
		REMOVAL........................................................................................................1001
		INSTALLATION...................................................................................................1002
	EQUALIZER BAR SIDE BUSHING ........................................................................................1003
		REMOVAL AND INSTALLATION.......................................................................................1003
	SEGMENT TEETH .....................................................................................................1004
		REMOVAL AND INSTALLATION.......................................................................................1004
	HYDRAULIC TANK.....................................................................................................1005
		REMOVAL AND INSTALLATION.......................................................................................1005
	MAIN CONTROL VALVE ................................................................................................1006
		REMOVAL........................................................................................................1006
		INSTALLATION...................................................................................................1007
		DISASSEMBLY....................................................................................................1008
		ASSEMBLY.......................................................................................................1011
	HSS OIL COOLER BYPASS VALVE .......................................................................................1015
		REMOVAL AND INSTALLATION.......................................................................................1015
		DISASSEMBLY AND ASSEMBLY.......................................................................................1016
	BLADE PPC VALVE....................................................................................................1017
		REMOVAL........................................................................................................1017
		INSTALLATION...................................................................................................1018
	RIPPER PPC VALVE...................................................................................................1019
		REMOVAL........................................................................................................1019
		INSTALLATION...................................................................................................1020
	BLADE PPC VALVE....................................................................................................1021
		DISASSEMBLY....................................................................................................1021
		ASSEMBLY.......................................................................................................1022
	BLADE LIFT CYINDER ................................................................................................1024
		REMOVAL AND INSTALLATION.......................................................................................1024
	BLADE TILT CYLINDER................................................................................................1025
		REMOVAL AND INSTALLATION.......................................................................................1025
	RIPPER LIFT CYLINDER...............................................................................................1026
		REMOVAL AND INSTALLATION.......................................................................................1026
	RIPPER TILT CYLINDER ..............................................................................................1027
		REMOVAL AND INSTALLATION.......................................................................................1027
	HYDRAULIC CYLINDER.................................................................................................1028
		DISASSEMBLY....................................................................................................1028
		ASSEMBLY.......................................................................................................1031
	BLADE..............................................................................................................1035
		REMOVAL........................................................................................................1035
		INSTALLATION...................................................................................................1036
		DISASSEMBLY....................................................................................................1037
		ASSEMBLY.......................................................................................................1039
	MULTI-SHANK RIPPER ................................................................................................1041
		DISASSEMBLY....................................................................................................1041
		ASSEMBLY ......................................................................................................1043
	ROPS GUARD.........................................................................................................1045
		REMOVAL AND INSTALLATION.......................................................................................1045
	OPERTOR'S CAB......................................................................................................1046
		REMOVAL........................................................................................................1046
		INSTALLATION ..................................................................................................1047
	OPERATOR'S CAB GLASS (STUCK GLASS).................................................................................1048
		REMOVAL AND INSTALLATION.......................................................................................1048
	HOOD...............................................................................................................1057
		REMOVAL AND INSTALLATION.......................................................................................1057
	FLOOR FRAME........................................................................................................1058
		REMOVAL........................................................................................................1058
		INSTALLATION...................................................................................................1061
	DASHBOARD..........................................................................................................1062
		REMOVAL........................................................................................................1062
		INSTALLATION...................................................................................................1063
	MONITOR............................................................................................................1064
		REMOVAL AND INSTALLATION.......................................................................................1064
	HSS CONTROLLER.....................................................................................................1065
		REMOVAL AND INSTALLATION.......................................................................................1065
40 MAINTENANCE STANDARD................................................................................................1066
	ENGINE MOUNT.......................................................................................................1067
	POWER TRAIN UNIT JOINT ............................................................................................1068
	DAMPER, UNIVERSAL JOINT............................................................................................1069
	TORQUE CONVERTER, PTO .............................................................................................1070
	TRANSMISSION.......................................................................................................1073
	MAIN RELIEF VALVE..................................................................................................1075
	BEVEL GEAR SHAFT, HASS, BRAKE (1/2)................................................................................1076
	BEVEL GEAR SHAFT, HASS, BRAKE (2/2)................................................................................1078
	BRAKE VALVE........................................................................................................1080
	SCAVENGING PUMP, HASS, PPC CHARGE PUMP.............................................................................1081
	POWER TRAIN PUMP, LUBRICATION PUMP.................................................................................1082
	OIL COOLER BYPASS VALVE............................................................................................1083
	FINAL DRIVE........................................................................................................1084
	SPROCKET...........................................................................................................1086
	MAIN FRAME.........................................................................................................1088
	TRACK FRAME........................................................................................................1090
	RECOIL SPRING .....................................................................................................1091
	TRACK ROLLER BOGIE.................................................................................................1092
	IDLER..............................................................................................................1094
	TRACK ROLLER.......................................................................................................1096
	CARRIER ROLLER.....................................................................................................1098
	TRACK SHOE.........................................................................................................1099
	SUSPENSION.........................................................................................................1106
	WORK EQUIPMENT PUMP................................................................................................1108
	HSS PUMP...........................................................................................................1109
	HSS MOTOR..........................................................................................................1110
	COOLING FAN PUMP...................................................................................................1111
	COOLING FAN MOTOR .................................................................................................1113
	PPC VALVE..........................................................................................................1114
	MAIN CONTROL VALVE.................................................................................................1116
	SELF PRESSURE REDUCING VALVE.......................................................................................1121
	WORK EQUIPMENT CYLINDER............................................................................................1122
	QUICK DROP VALVE...................................................................................................1126
	CYLIDER STAY.......................................................................................................1127
	WORK EQUIPMENT.....................................................................................................1128
90 OTHERS .............................................................................................................1135
	HYDRAULIC CIRCUIT DIAGRAM (1/2)....................................................................................1136
	HYDRAULIC CIRCUIT DIAGRAM (2/2)....................................................................................1137
	ELECTRIC CIRCUIT DIAGRAM (1/6).....................................................................................1138
	ELECTRIC CIRCUIT DIAGRAM (2/6).....................................................................................1139
	ELECTRIC CIRCUIT DIAGRAM (3/6).....................................................................................1140
	ELECTRIC CIRCUIT DIAGRAM (4/6).....................................................................................1141
	ELECTRIC CIRCUIT DIAGRAM (5/6).....................................................................................1142
	ELECTRIC CIRCUIT DIAGRAM (6/6).....................................................................................1143
	ELECTRIC CIRCUIT DIAGRAM INSIDE CAB................................................................................1144
	ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER........................................................................1145

KOMATSU D155AX-5 CRAWLER BULLDOZER SHOP MANUAL SEBM034807 – PDF DOWNLOAD:

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